York YCAV0569 Installation Operation & Maintenance Download

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R134a

MODELS YCAV0569-0969, 50 HZ

STYLE A

(492-879 KW)

E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY

LD10477

AIR-COOLED SCREW

LIQUID CHILLERS

INSTALLATION, OPERATION, MAINTENANCE

Supesedes 201.21-NN2 (315)

Form 201.21-NM2 (616)

Issue Date:

June 30, 2016

035-20993-000

Summary of Contents for YCAV0569

Page 1: ...HZ STYLE A 492 879 KW E V HIGH EFFICIENCY AND S P STANDARD EFFICIENCY LD10477 AIR COOLED SCREW LIQUID CHILLERS INSTALLATION OPERATION MAINTENANCE Supesedes 201 21 NN2 315 Form 201 21 NM2 616 Issue Da...

Page 2: ...ment and any referenced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in question SAF...

Page 3: ...products johnsoncontrols com It is the responsibility of rigging lifting and operating service personnel to verify the applicability of these documents to the equipment If there is any question regard...

Page 4: ...ing on the system NEVER short out the DC Bus to discharge the filter capacitors NEVER place loose tools debris or any objects inside the Control Panel VSD Cabinet NEVER allow the Control Panel VSD Cab...

Page 5: ...NCLOSURES 20 FANS 20 SOUND REDUCTION OPTIONS 20 VIBRATION ISOLATION 20 UNIT NOMENCLATURE 21 PRODUCT IDENTIFICATION NUMBER 22 SECTION 3 RIGGING HANDLING STORAGE DELIVERY AND STORAGE 26 INSPECTION 26 MO...

Page 6: ...Initial Start Up 124 Check Subcooling Superheat 124 Leak Checking 125 CHILLER ELECTRONIC COMPONENTS 126 Keypad 126 Display 127 Chiller Control Board 128 Relay Output Boards 129 VSD Variable Speed Driv...

Page 7: ...INT KEY 227 Operating Data Printout 228 History Data Printout 229 SERVICE KEY 230 SYSTEM SWITCHES KEY 236 SERIAL NUMBER PROGRAMMING 237 ENABLING OPTIMIZED HIGH IPLV MODE 239 UNIT SETUP MODE 240 DEFAUL...

Page 8: ...32 Pressure Transducer Input Voltage 268 Table 33 Motor Temperature Sensor Resistance 269 Table 34 Compressor Motor Overload Settings Max VSD Frequency 270 Fig 1 PWM Current Waveform 18 Fig 2 PWM Vol...

Page 9: ...any faulty part or sub assembly which has failed due to poor quality or manufacturing errors All claims must be supported by evidence that the failure has occurred within the warranty period and that...

Page 10: ...ent supplied with the unit are the property ofYORK which reserves all rights They may not be reproduced in whole or in part without prior written authorization from an authorized YORK representative M...

Page 11: ...aken when working in contact with the coils to avoid the risk of minor abrasions and lacerations The use of gloves is recommended Frame rails brakes and other components may also have sharp edges Reas...

Page 12: ...eral System Description The Latitude YCAV Air Cooled Chiller line combines the best of modern screw compressor design with the latest technology in variable speed drives The result is superior control...

Page 13: ...ONTROL SYSTEM INPUTS COMMUNICATIONS OUTPUTS VSD MOTOR CONTROL PANEL Pressure Transducers Temperature Sensors Level Sensor Switches Liquid Flow High Pressure Start Stop Customer Supplied Contacts Chill...

Page 14: ...d insulated with 3 4 19 mm flexible closed cell insulation The water nozzles are provided with grooves for mechanical couplings and should be insulated by the contractor after pipe installation A 300...

Page 15: ...solenoid valve will typically be on most of the time When the economizer solenoid is OFF the liquid level will vary greatly as the Drain and Feed Valves directly affect the level as they open and clo...

Page 16: ...ectrical cabinet Each Power Compartment Contains Incoming single point power is standard utilizing either a lockable circuit breaker or terminal block 115VAC control transformer VSD fan contactors ON...

Page 17: ...r pump Out of range message Up to 10 fault shutdown histories Keypad An operator keypad allows complete control of the system from a central location The keypad utilizes an overlay to allow use in 5 l...

Page 18: ...r while simultaneously providing a large energy reservoir for use by the DC to AC inverter section of the drive In order to achieve the required voltage capability for the capacitor portion of the fil...

Page 19: ...ic board Each IGBT Power Module within the DC toAC inverter section con tains a thermistor heatsink temperature sensor to provide temperature information to the VSD logic board The Bus Isolator board...

Page 20: ...ior condenser coil faces and heavy gauge welded wire mesh guards mounted around the bottom of the unit Factory or field mounted Louvered Panels Condenser Coils Only Louvered panels are mounted over th...

Page 21: ...NUMBER NOMENCLATURE Y C A V 0569 S A 46 YORK CHILLER AIR COOLED VSD DRIVEN SCREW COMPRESSOR MODEL NUMBER UNIT DESIGNATOR E High Efficiency with Standard IPLV S Standard Efficiency with Standard IPLV...

Page 22: ...dard IPLV V High Efficiency High Ambient Unit Optimized IPLV REF Refrigerant PIN 10 A R 134a VOLTS Voltage PIN 11 12 17 200 3 60 28 230 3 60 40 380 3 60 46 460 3 60 50 380 415 3 50 58 575 3 60 STARTER...

Page 23: ...X No Pump Control required Q Special Pump Control required REMOTE Remote Ctrl Panel PIN 27 X No Remote Control Panel required O Optiview Remote Control Panel required Q Special Remote Control Panel re...

Page 24: ...PIN 45 X Aluminum Coils COILS C Copper Fin Coils B Pre Coated Fin Coils P Post Coated Dipped Coils Q Special Coils HEAT Heat Recovery PIN 46 X Partial Heat Recovery not required H Partial Heat Recove...

Page 25: ...Labor G 5 Year Unit Parts Only H 5 Year Unit Parts Labor Q Special Warranty REFRIGERANT WTY Refrigerant Wty PIN 56 X No Refrigerant Warranty required 1 1 Year Refrigerant Warranty 2 2 Year Refrigeran...

Page 26: ...and fins from potential damage and corrosion particularly where building work is in progress The unit should be stored in a location where there is minimal activity in order to limit the risk of ac ci...

Page 27: ...locations are outside of the container Place 4 X 4 blocks of wood un der the base rails of the unit Gently rest the unit on the blocks and remove the chains and lift truck 5 Attach lifting rigging fro...

Page 28: ...mate center of gravity location shown for base unit Any options selected may add weight to the unit and affect the center of gravity Locate the center of gravity through trial lifts to account for pos...

Page 29: ...nding below the frost line is recommended To avoid noise and vibration transmission the unit should not be secured to the building foundation On rooftop locations choose a place with adequate structur...

Page 30: ...nt of large components may require larger clearances than those given in the Technical Data Section Page 90 INSTALLATION OF VIBRATION ISOLATORS Optional sets of vibration isolators can be supplied loo...

Page 31: ...s which can cause oxidation of steel parts within the cooler A flow switch must be installed in the customer pip ing at the outlet of the cooler and wired back to the control panel using shielded cabl...

Page 32: ...a range between 7 and 8 5 PIPEWORK ARRANGEMENT The following is a suggested piping arrangement for single unit installations For multiple unit installations each unit should be piped as shown in FIG 3...

Page 33: ...the fan outlet and straight for at least three feet 1 meter to obtain static regain from the fan Ductwork should be suspended with flexible hangers to prevent noise and vibration being transmitted to...

Page 34: ...hiller 115VAC CONTROL SUPPLY TRANSFORMER A3 wire high voltage to 115VAC supply transformer is standard in the chiller This transformer is mounted in the Cabinet and steps down the high voltage supply...

Page 35: ...each pair of systems 1 3 2 4 These inputs require a dry contact to start and stop the system System 1 3 remote dry contacts are connected between Terminals 2 and 15 of 1TB FIG 17 Page 109 and System 2...

Page 36: ...alves are of the back seat type open them fully counterclockwise then close one turn of the stem to ensure operating pressure is fed to pressure transducers Open the liquid line service valve and oil...

Page 37: ...hielded cable There should be a straight run of at least 5 pipe diam eters on either side of the flow switch The flow switch should be connected to terminals 2 and 13 in the panel Temperature Sensor s...

Page 38: ...ent the controller will increase the speed of the compressor s Condenser and Fan Rotation Once a compressor is running discharge pressure rises as refrigerant is pumped into the air cooled condenser c...

Page 39: ...YS 1 switch on the keypad and repeat the process for each subsequent system When all run correctly stop the unit switch all applicable switches to the ON position and restart the unit Assure all check...

Page 40: ...re Drop Through YCAV Evaporators 0 20 40 60 80 100 120 140 160 180 200 0 5 10 15 20 25 30 35 40 45 50 Water Flow Rate l s Pressure Drop kPa A B C D SI Units LD10498 MODEL NUMBER YCAV COOLER 0569 S P A...

Page 41: ...re higher than with water see correction factors to be applied when using glycol solutions Special care must be taken not to exceed the maximum flow rate allowed A Correction Factor B Mean Temperature...

Page 42: ...39 4 4 15 6 10 1 47 3 17 7 51 7 0679 4 4 15 6 10 1 47 3 17 7 51 7 0719 4 4 15 6 10 1 47 3 17 7 51 7 0739 4 4 15 6 10 1 47 3 17 7 51 7 0819 4 4 15 6 11 4 47 3 17 7 51 7 0889 4 4 15 6 11 4 47 3 17 7 51...

Page 43: ...43 JOHNSON CONTROLS FORM 201 21 NM2 616 This page intentionally left blank 6...

Page 44: ...6 6 Low Sound Fans Fan Motor kw 1 5 1 5 1 5 1 5 1 5 1 5 1 5 Fan Motor Speed revs sec 19 0 19 0 19 0 19 0 19 0 19 0 19 0 Fan Diameter mm 899 899 899 899 899 899 899 Fan Tip Speed m sec 53 7 53 7 53 7 5...

Page 45: ...5 1 5 1 5 1 5 Fan Motor Speed revs sec 19 0 19 0 19 0 19 0 19 0 19 0 19 0 Fan Diameter mm 899 899 899 899 899 899 899 Fan Tip Speed m sec 53 7 53 7 53 7 53 7 53 7 53 7 53 7 Total Chiller Airflow l sec...

Page 46: ...46 JOHNSON CONTROLS FORM 201 21 NM2 616 OPERATING LIMITATIONS AND SOUND DATA Contact Product Application Marketing for Sound Power Data TECHNICAL DATA...

Page 47: ...OWER SUPPLY CONNECTION WITH OPTIONAL FACTORY CIRCUIT BREAKER LD10598a LD10599a ELECTRICAL DATA 6 2 COMPRESSOR POWER WIRING CONNECTIONS VSD SYSTEM TERMINAL BLOCK FAN CONTACTORS STANDARD CONTROL TRANSFO...

Page 48: ...0 198 5 3 4 198 5 3 4 1 8 30KA 65KA 0889 400 50 236 6 3 4 196 5 3 4 1 8 30KA 65KA 0969 400 50 234 6 3 4 234 6 3 4 1 8 30KA 65KA YCAV S P Field Wiring Protection Field Wiring Lugs STD Terminal Block Fi...

Page 49: ...5 3 4 187 5 3 4 1 8 30KA 42KA 0889 400 50 183 6 3 4 183 6 3 4 1 8 30KA 42KA 0969 400 50 237 6 3 4 181 6 3 4 1 8 30KA 42KA YCAV E V Field Wiring Protection Field Wiring Lugs STD Terminal Block Field Wi...

Page 50: ...element fuse size 150 of the largest compressor RLA plus 100 of the remaining compressor RLA s plus the sum of all condenser fan FLA s 6 RLA Rated Load Amps rated in accordance with UL standard 1995...

Page 51: ...51 JOHNSON CONTROLS FORM 201 21 NM2 616 This page intentionally left blank 6...

Page 52: ...52 JOHNSON CONTROLS FORM 201 21 NM2 616 ELECTRICAL WIRING LD12518 ELEMENTARY CONTROL WIRING DIAGRAM TECHNICAL DATA...

Page 53: ...53 JOHNSON CONTROLS FORM 201 21 NM2 616 ELEMENTARY CONTROL WIRING DIAGRAM CON T 6 LD12519...

Page 54: ...54 JOHNSON CONTROLS FORM 201 21 NM2 616 ELEMENTARY POWER WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER TECHNICAL DATA LD12516 T 115VAC T RUN RUN...

Page 55: ...55 JOHNSON CONTROLS FORM 201 21 NM2 616 ELEMENTARY POWER WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER CON T 6 LD12517...

Page 56: ...56 JOHNSON CONTROLS FORM 201 21 NM2 616 LD12514 CONNECTION WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER TECHNICAL DATA...

Page 57: ...57 JOHNSON CONTROLS FORM 201 21 NM2 616 CONNECTION WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER CON T 6 LD12515...

Page 58: ...58 JOHNSON CONTROLS FORM 201 21 NM2 616 CONNECTION WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER TECHNICAL DATA LD12512...

Page 59: ...59 JOHNSON CONTROLS FORM 201 21 NM2 616 CONNECTION WIRING DIAGRAM 2 COMPRESSOR YCAV CHILLER CON T 6 LD12513...

Page 60: ...60 JOHNSON CONTROLS FORM 201 21 NM2 616 LOCATION LABEL LD10519 TECHNICAL DATA...

Page 61: ...61 JOHNSON CONTROLS FORM 201 21 NM2 616 This page intentionally left blank 6...

Page 62: ...ize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher t...

Page 63: ...Z D D CONTROL PANEL 8 WATER OUTLET 8 WATER INLET A A 3 RIGGING HOLES EACH SIDE 114 X 51 292 2169 2562 POWER SINGLE POINT WITH TERMINAL BLOCK 152 2239 357 2 087 2 172 1 472 1 339 2 055 1 797 16 MOUNTI...

Page 64: ...ion without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on spr...

Page 65: ...2 205 2 356 1 624 1 536 2 338 1 928 16 MOUNTING HOLES TYP APPROX OPERATING WEIGHT DISTRIBUTION KG X G C Y G C X Z D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1626 2756 A A 3 R...

Page 66: ...ation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit is no higher than on s...

Page 67: ...378 1 629 1 541 2 347 1 935 16 MOUNTING HOLES TYP APPROX OPERATING WEIGHT DISTRIBUTION KG X G C Y G C X Z Z D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1232 1626 2756 A A 3 RIGGIN...

Page 68: ...ls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit i...

Page 69: ...igh Efficiency SI CON T 1524 6970 2867 2146 2239 2438 1016 357 2219 HOLES TYP D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1626 2160 1714 A A SYS 2 SYS 1 292 2169 3141 ORIGIN 1...

Page 70: ...rols will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit...

Page 71: ...ard Efficiency SI Con t 6 1524 6970 2867 2146 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1626 2160 1714 A A SYS 2 SYS 1 292 2169 3141 ORIGIN 152 95 25...

Page 72: ...ls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit i...

Page 73: ...High Efficiency SI Con t 6 1524 6970 2867 2146 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1626 2160 1714 A A SYS 2 SYS 1 292 2169 3141 ORIGIN 152 95...

Page 74: ...ls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit i...

Page 75: ...h Efficiency SI Con t 6 1524 6970 2851 2174 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1626 2160 1714 A A SYS 2 SYS 1 292 2169 3141 ORIGIN 152 95 254...

Page 76: ...rols will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit...

Page 77: ...Efficiency SI Con t 6 1524 6970 2912 2011 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1661 2048 1791 A A SYS 2 SYS 1 318 2145 3141 ORIGIN 152 95 254 68...

Page 78: ...ls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit i...

Page 79: ...iciency SI Con t 6 1524 8087 2851 2174 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1626 2160 1393 A A SYS 2 SYS 1 292 2169 2024 2235 ORIGIN 152 95 68 2...

Page 80: ...rols will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit...

Page 81: ...ard Efficiency SI Con t 6 1524 6970 2912 2011 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1661 2048 1791 A A SYS 2 SYS 1 318 2145 3141 ORIGIN 152 95 25...

Page 82: ...ls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit i...

Page 83: ...iciency SI Con t 6 1524 8087 2851 2174 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1626 2160 1393 A A SYS 2 SYS 1 292 2169 2024 2235 ORIGIN 152 95 68 2...

Page 84: ...rols will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit...

Page 85: ...fficiency SI Con t 6 1524 8087 2912 2011 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1661 2048 1470 A A SYS 2 SYS 1 318 2169 2024 2235 ORIGIN 152 95 68...

Page 86: ...ls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit i...

Page 87: ...iciency SI Con t 6 1524 8087 2912 2011 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1661 2048 1470 A A SYS 2 SYS 1 318 2169 2024 2235 ORIGIN 152 95 68 2...

Page 88: ...rols will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance degradation Access to the unit control center assumes the unit...

Page 89: ...fficiency SI Con t 6 1524 8087 2912 2011 2239 2438 1016 357 2219 D D VIEW D D CONTROL PANEL 10 WATER OUTLET 10 WATER INLET 26 26 1238 1661 2048 1470 A A SYS 2 SYS 1 318 2169 2024 2235 ORIGIN 152 95 68...

Page 90: ...21 NM2 616 TECHNICAL DATA CLEARANCES 1 3 m 2 m 2 m 2 m NOTES 1 No obstructions allowed above the unit 2 Only one adjacent wall may be higher than the unit 3 Adjacent units should be 3 Meters 10 Feet...

Page 91: ...91 JOHNSON CONTROLS FORM 201 21 NM2 616 This page intentionally left blank 6...

Page 92: ...a drawing and table specifically for each chiller based on the option selection The drawing and table will be similar to the ones shown below in FIG 8 The drawing will show the isolator locations alo...

Page 93: ...ated as X in FIG 8 YCAV0569S P YCAV0569E V and YCAV0639S P YCAV0639E V YCAV0679S P YCAV0679E V and YCAV0719E V L1 L2 L3 L4 R1 R2 R3 R4 3 75 95mm 48 5 1231 9mm 112 5 2857 5mm 224 75 5708 7mm Control Pa...

Page 94: ...YCAV0739E V and YCAV0819E V LD10504 LD10503 L1 L2 L3 L4 R1 R2 R3 R4 L6 R6 3 75 95mm 48 5 1231 9mm 112 5 2857 5mm 197 53 5017 3mm 309 7848 6mm L5 R5 252 38 6410 5mm Control Panel L1 L2 L3 L4 R1 R2 R3 R...

Page 95: ...21 NM2 616 YCAV0889S P YCAV0889E V and YCAV0969S P LD10508 L1 L2 L3 L4 R1 R2 R3 R4 L6 R6 3 75 95mm 48 5 1231 9mm 113 875 2892 4mm 194 5 4940mm 309 7848 6mm L5 R5 252 375 6410 3mm Control Panel ISOLATO...

Page 96: ...gs SLRS 6 C2 has six springs and SLRS 9 C2 has nine springs Value is de rated by 15 PIN 54 S Weight Range lbs Weight Range kg Vendor P N COLOR YORK P N UP TO 358 LBS Up to 162 kg SLRS 2 C2 420 Red 029...

Page 97: ...er 8 Turn adjustment bolt 8 turns on each mount 9 Take one additional complete turn on each adjustment bolt in sequence until the top plate lifts off of the lower restraining nuts Take no additional t...

Page 98: ...x1 1 2 ND D 3 3 8 2 3 4 6 1 4 5 16 4 5 1 2 13x1 1 2 ND DS 3 3 8 2 3 4 6 1 4 5 16 4 5 1 2 13x1 1 2 SI ND C 65 1 69 9 139 7 6 4 58 7 101 9 1 2 13x1 13 ND D 85 7 69 9 158 8 7 9 101 6 127 0 1 2 13x1 13 ND...

Page 99: ...86 to 483 kg CIP B 1250 Gray 029 24583 005 1064 1404 LBS 483 to 637 kg CIP B 1650 Black 029 24583 006 For Units With Any Load Point Above 1404 LBS 637 KG UP TO 851 LBS Up to 386 kg CIP C 1000 Black 02...

Page 100: ...quip ment is raised free of the spacer blocks or shims Remove the blocks or shims 8 Turn the leveling bolt of all mountings in either direction in order to level the installation 9 Tighten the nuts on...

Page 101: ...101 JOHNSON CONTROLS FORM 201 21 NM2 616 RC2 C R R C R 22 R C R R R R R C R C C R C FIG 9 REFRIGERANT FLOW DIAGRAM REFRIGERANT FLOW DIAGRAM 6 LD10505...

Page 102: ...PERATURE CUTOUT LOW PRESSURE CUTOUT CHT DP DFP DV HPL HTC LPC LOW TEMPERATURE CUTOUT HIGH PRESSURE CUTOUT HEATER LTC HPC HTR SOLENOID VALVE BALL VALVE RELIEF VALVE STOP VALVE ANGLE ACCESS PRESSURE SEN...

Page 103: ...CONTROLS FORM 201 21 NM2 616 COMPONENT LOCATIONS FIG 11 COMPONENT LOCATIONS LD10477 CHILLER VSD ELECTRICAL PANEL FANS CONDENSOR COIL COMPRESSOR FILTER DRIER OIL SEPARATORS GLYCOL PUMP KEYPAD DISPLAY P...

Page 104: ...104 JOHNSON CONTROLS FORM 201 21 NM2 616 FIG 12 CONTROL AND VSD CABINET COMPONENTS COMPONENT LOCATIONS CON T LD10578 TECHNICAL DATA...

Page 105: ...ER CONTROL BOARD RELAY BOARDS MICROGATEWAY AND OPTIONAL CIRCUIT BREAKER LD10579 MICROGATEWAY OPTIONAL CHILLER CONTROL BOARD RELAY BOARD 1 RELAY BOARD 2 OPTIONAL CIRCUIT BREAKER Standard Unit will have...

Page 106: ...4 CHILLER CONTROL BOARD RELAY BOARDS AND MICROGATEWAY LD10580 COMPONENT LOCATIONS CON T TECHNICAL DATA CHILLER CONTROL BOARD MICROGATEWAY OPTIONAL RELAY BOARD 1 RELAY BOARD 2 RS 232 485 JUMPER CLOCK J...

Page 107: ...107 JOHNSON CONTROLS FORM 201 21 NM2 616 FIG 15 VSD LOGIC BOARD LD10582 COMPONENT LOCATIONS CON T 6 VSD LOGIC BOARD...

Page 108: ...201 21 NM2 616 FIG 16 VSD LOGIC BOARD LD10590 COMPONENT LOCATIONS CON T TECHNICAL DATA MADE IN THE USA YORK R86 COMPR 4 Over Load Adjust R42 COMPR 3 Over Load Adjust R64 COMPR 2 Over Load Adjust R19...

Page 109: ...ill have terminal blocks FLASH TANK FEED AND DRAIN VALVE CONTROLLER CONTROL AND VSD CABINET COOLING COIL CONTROL AND VSD CABINET COOLING FAN 1TB TERMINAL BLOCK 10T TRANSFORMER INCOMING POWER GROUND LU...

Page 110: ...N CONTROLS FORM 201 21 NM2 616 FIG 18 FAN CONTACTORS AND 3T TRANSFORMER COMPONENT LOCATIONS CON T LD10584 FAN CONTACTORS 4CR 9CR 3T TRANSFORMER 24VAC to SCR Gate Driver Board and VSD Logic Board TECHN...

Page 111: ...ay Board 1 21 FU Relay Board 2 COOLING FAN 4 9 FU FUSES 14 16 FU FUSES 4 6 FU TB 1 3 SCR Trigger Board 7 9 FU Sys 1 Fans 14 16 FU Sys 2 Fans TRANSIENT SUPPRESSOR BOARD 3 Phase Input 1L AC LINE INDUCTO...

Page 112: ...SCR Trigger Board 24 VAC Supply Transformer CURRENT TRANSFORMERS SNUBBER CAPS C7 C12 BUS ISOLATOR BOARD Feeds VSD Logic Board SCR TRIGGER BOARD IGBT MODULES SCR DIODE MODULES 1RES 2RES BUS CAPACITOR...

Page 113: ...6 FIG 21 VSD COMPONENTS LD10587 FAN RELAYS CURRENT TRANSFORMERS C13 C17 COOLING FANS 1L LINE INDUCTOR CABINET COOLING COIL TRANSIENT SUPPRESSOR BOARD W 11FU 12FU 13 FU FUSES 3 Phase Input 10CR FAN PUM...

Page 114: ...A FIG 22 INVERTER POWER COMPONENTS LD10588 COMPONENT LOCATIONS CON T THE LINE INDUCTOR WILL REACH OPERATING TEMPERATURES OF OVER 300 F DO NOT OPEN PANEL DOORS DURING OPERATION ASSURE THE INDUCTOR IS C...

Page 115: ...NTS LD10592 COMPONENT LOCATIONS CON T LD10591 IGBT S IGBT S IGBT S WATER COOLED HEAT SINK SCR DIODE MODULE SCR DIODE MODULES 1RES 2RES BUS CAPACITORS BANK EQUALIZING BLEEDER RESISTORS LAMINATED BUS ST...

Page 116: ...BUS STRUCTURE BUS FILTER CAPACITORS IGBT GATE DRIVER BOARD IGBT WATER COOLED HEAT SINK IGBT S IGBT S SCR DIODE MODULES SCR DIODE MODULES 1RES 2RES BUS CAPACITORS BANK EQUALIZING BLEEDER RESISTORS FIG...

Page 117: ...EE DETAIL B SEE DETAIL C SEE DETAIL B SEE DETAIL A REAR OF VSD PANEL GLYCOL SYSTEM COMPONENTS GLYCOL FILL TUBE GLYCOL PUMP DETAIL A DETAIL C DETAIL B TYPICAL 4 PLACES SEE DETAIL A SEE DETAIL C SEE DET...

Page 118: ...118 JOHNSON CONTROLS FORM 201 21 NM2 616 TECHNICAL DATA LD10597 FIG 26 GLYCOL PIPING AND FILL TUBE LOCATION GLYCOL FILL TUBE GLYCOL SYSTEM COMPONENTS CON T...

Page 119: ...1 NM2 616 6 COMPRESSOR COMPONENTS LD10596 FIG 27 COMPRESSOR COMPONENTS SUCTION STRAINER STATOR KEY ROTOR MOTOR ROTOR HOUSING MALE ROTOR FEMALE ROTOR BEARINGS SHIMS SHIMS BEARINGS DISCHARGE HOUSING OIL...

Page 120: ...unit is properly charged and there are no piping leaks 4 Open each system suction service valve discharge service valve economizer service valve liquid line stop valve and oil line ball valve 5 The oi...

Page 121: ...ssure drop across the cooler Excessive flow may cause catastrophic damage to the evaporator EQUIPMENT START UP CHECK SHEET CON T 7 Check the control panel to ensure it is free of foreign material wire...

Page 122: ...Logic Board are set correctly correct settings are provided on Page 268 Press the VSD DATA key and using the arrow keys scroll to the compressor overload settings Verify the Factory Set overload pote...

Page 123: ...am the required operating values into the micro for cutouts safeties etc and record them in the chart below See Page 213 for details Record these values in the chart below Suction Press Cutout _______...

Page 124: ...iquid line temp 87 F 30 6 C SUBCOOLING 6 F 3 3 C The subcooling should be adjusted to 5 7 F 2 77 3 78 C 14 Place the panel in Service mode and turn on each fan stage one by one Assure the fans rotate...

Page 125: ...pressure as shown in a standard pressure temperature chart SUPERHEAT Example Suction Temp 46 F 8 C minus Suction Press 30 PSIG converted to Temp 35 F 1 C 11 F 6 C The suction temperature should be ta...

Page 126: ...operation and returns the programmed value to the original value before any programming changes were made when an error is made The UP ARROW and DOWN ARROW keys allow scrolling backward and forward t...

Page 127: ...tore the programmed value the ENTER key must be pressed When the ENTER key is pressed the cursor will disappear The data entry mode may also be exited by pressing the X CANCEL key The programmed data...

Page 128: ...analog signals to digital signals which can be read by the onboard microprocessor On a 2 system chiller approximately half of these inputs are utilized Three integrated circuits on the microprocessor...

Page 129: ...heAC to DC rectifier section with precharge circuit a DC link filter section a three phase DC to AC inverter section and an output RC suppression network AC TO DC RECTIFIER TheAC to DC Rectifier circu...

Page 130: ...uctor forms a low pass LC Filter and provides further smoothing filters ripple to the rectified DC Equalizing Bleeder resistors connected across the banks equalize the voltage between the top and bott...

Page 131: ...ific speed Although a common DC Bus links the compressor drive outputs each compressor has it s own inverter output module Each inverter output module consists of 6 IGBT s 3 modules and an IGBT Gate D...

Page 132: ...and Control section Page 166 CONTROL PANEL TO VSD COMMUNICATIONS Communication between the VSD Logic Board and the Chiller Control Board is made via a three wire RS 485 opto coupled data link Communi...

Page 133: ...riginate from the VSD Logic Board and are changed in level by the IGBT Gate Driver Board The IGBT s in the inverter section of the VSD change the DC Link voltage to a variable Voltage and Frequency ou...

Page 134: ...pens and closes the feed valve to control the liquid level of the refrigerant in the Flash Tank based on commands from the Chiller Control Board Superheat is controlled by sequencing a stepper motor v...

Page 135: ...ned to operate at 460VAC on all voltage units Whenever a 208VAC 60 Hz 230VAC 60 Hz 380VAC 60 Hz 400VAC 50 Hz or 575VAC 60 Hz supply is utilized an autotransformer is used to convert the voltage to 460...

Page 136: ...rning message will be displayed in the Status display TABLE 1 shows the chiller number of compressors and the associated location of the jumpers to program the appropriate compressor configuration TAB...

Page 137: ...umper is out or a 1 or high when the wire jumper is inserted between the two pins The jumpers will only be checked once by the Chiller Control Board on power up TABLE 3 shows the Chiller configuration...

Page 138: ...mbient air temperature If no systems are running and the ambient temperature drops below 40 F the heater is turned on If no systems are running and the temperature rises above 45 F the heater is turne...

Page 139: ...in series with each set of UNIT Switch contacts If either fuse is pulled or blown only the system with the good fuse Input is high will run When both inputs are high the entire chiller will be enabled...

Page 140: ...or starts the Feed and Drain Valves on the system will immediately begin to control superheat and the liquid level in the Flash Tank and the Chiller Control Board micro will begin to regulate the spee...

Page 141: ...the all compressors stopped state This routine will try to run all the compressors unless it is determined that less will be needed due to light load The first step in the sequence is for the micro t...

Page 142: ...ve also illustrates the scaled frequency FIG 30 MINIMUM VSD START FREQUENCY LD10627 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 Ambient Temperature F Minimum VSD Frequency Hz NOTE...

Page 143: ...ble up to 200 Hz the frequency speed is limited by the minimum start frequency and the add a compressor frequency calculation performed by the micro when bringing on an additional compressor When dece...

Page 144: ...emperature to within Setpoint CR 2 the chiller control will make a decision to start another compressor At this point the first compressor will decelerate to a frequency of 5 Hz Reducing the frequency...

Page 145: ...wn 1 FUZZY LOGIC CONTROL The fuzzy logic control in software makes decisions to increase or decrease speed according to the error or deviation from Setpoint and the rate of change of chilled liquid te...

Page 146: ...iller Control Board microprocessor may also elect to hold capacity when error is negative temperature is below Setpoint because the rate of change of chilled liquid is positive rising Table 4 illustra...

Page 147: ...ong as leaving chilled liquid temperature is above the Setpoint CR The chiller control board will be make decisions regard ing speed changes under conditions where the error and rate conflict Under th...

Page 148: ...mpressors running 1 Minimum VSD Freq 50 Hz In the example above one compressor will restart at 100 Hz as indicated in the formula below 50Hz x 1 1 100 Hz 1 The load timer will also be set to 30 second...

Page 149: ...nds As the temperature rises toward Setpoint CR the Chiller Control Board microprocessor s fuzzy logic will begin factoring in the rate of change before continuing to unload If the rate of change is r...

Page 150: ...Current Limit Setpoint and the Current Limit Setpoint 5 the system will unload every 2 seconds according to the amount current is ex ceeding the Current Limit Setpoint At the Current limit Setpoint 0...

Page 151: ...sure Cutout 9 PSIG 9 Hz Suction Pressure Cutout 10 PSIG 10 Hz Suction pressure load limiting is active at start up to only prevent loading of the compressors Suction pres sure limit unloading will not...

Page 152: ...n though increased loading is required Between the VSD Base plate Temperature Cutout 4 F and the cutout forced unloading is performed every 2 seconds according to TABLE 10 below TABLE 10 VSD BASEPLATE...

Page 153: ...id flow from the condenser to assure the liquid level in the Flash Tank is maintained at a proper level The Level Sensor is a rod inserted into the reservoir connected to the side of the Flash Tank Th...

Page 154: ...ion line may be warmed by the ambient contributing to inaccurate suc tion superheat measurement at start up To avoid this situation the MOP control utilizes suction pressure control at start up which...

Page 155: ...tem 1 or 3 Feed Valve Close 6 Close System 1 or 3 Drain Valve Close 7 Close System 2 or 4 Feed Valve Close 8 Close System 2 or 4 Drain Valve Close On 3 and 4 compressor chillers a second module will c...

Page 156: ...ction pressure and low oil differential faults by increasing the load At ambients above 40 F once on the Economizer So lenoid will remain energized until the VSD frequency drops below 90 Hz Below 90 H...

Page 157: ...discharge pressure rises and falls is 5 seconds The controller increments or decrements the fan stage by one stage based on discharge pressure and fan delay time TABLE 11 shows the fan staging and th...

Page 158: ...sure PSIG Fan On Press Fan Off Press LD10633 FIG 35 STANDARD IPLV FAN CONTROL Optimized IPLV Fan Control Fan staging on and off points will be determined by the ambient temperature The fan stage will...

Page 159: ...ut a time delay Pre charge Enable 1 from the Chiller Logic Board is ON Pre charge Enable 2 from the Chiller Logic Board is ON VSD Internal Ambient Temp 158 F Cutout 10 F 148 F When the Internal Ambien...

Page 160: ...set is linear and may be adjusted anywhere between the 0 and 100 points The maximum setpoint allowed is the maximum programmable Local Cooling Setpoint and will be capped at this value if the calculat...

Page 161: ...uid tempera tures on hot water starts and maintaining chilled liquid setpoints REMOTE TEMPERATURE RESET CONTROL CON T 7 0 20 mA Reset Input A 0 mA signal produces a 0 F reset A 20 mA signal produces t...

Page 162: ...ent Limit Setpoint A full scale signal input 100 input equates to the minimum current limit setpoint as defined under the PROGRAM key Current Limit Setpoint The current limit value is linear and may b...

Page 163: ...programmed for 2 10 VDC input OPTIONS key and Chiller Control Board jumper JP5 placed in the V position 0 20 mA Reset Input A 0 mA signal sets the current limit to the maximum value A 20 mA signal set...

Page 164: ...ximum value will be used Contact a local YORK ISN Representative for details on ISN controls and capabilities Remote Sound Limit The Sound Limit Setpoint can be set via the Remote Sound Limit analog i...

Page 165: ...to work properly the Remote Sound Limit must be programmed for 2 10 VDC input OPTIONS key and Chiller Control Board jumper JP6 placed in the V position 0 20 mA Reset Input A 0 mA signal produces a 0 s...

Page 166: ...put frequency required based on the operating frequency command from the Chiller Control Board This information will then be sent to the PWM generator located on the VSD Logic Board On start up the ou...

Page 167: ...tage sinusoidal waveform To change the speed of an AC motor the frequency of the AC voltage must be changed When ever frequency is changed the voltage is changed in a linear ratio Maintaining a relati...

Page 168: ...ronics in the cabinet Never run the glycol pump without coolant Running the glycol pump without coolant may damage the pump seals Always fill the system with approved coolant to avoid damage to the pu...

Page 169: ...ompressors are running Service Mode Fan Pump is disabled In some cases the condenser fans may be turned on by the micro when no compressors are running to keep the power components and Control VSD Cab...

Page 170: ...tions are true otherwise it is disabled Daily Schedule is ON Unit Switch is ON System Switch es are ON Run Permissive s are Enabled Flow Switch indicates flow LCHLT Setpoint High Limit Unit not faulte...

Page 171: ...the Chiller Control Board for both display purposes and for current limiting control This parameter is the 105 FLA value VSD OPERATION AND CONTROLS CON T TABLE 12 VSD OPERATING DISPLAY PARAMETERS DATA...

Page 172: ...roproces sor to save a snapshot of system data The VSD Logic Board then transmits the fault data to the Chiller Control Board microprocessor on the next comms between the two boards If the Chiller Con...

Page 173: ...unit fault for 2 or 3 compressor units The Status display fault message is shown below SYS X YYYYYYYY PRECHARGE LOW DC BUS VOLT UNIT YYYYYYYY PRECHARGE DC BUS VOLTAGE IMBALANCE The fault will be a sys...

Page 174: ...r 3 compressor units Below is the Status display fault message The fault will be a system 1 3 or 2 4 fault on 4 com pressor units Two key presses of the STATUS key are required to show the fault on bo...

Page 175: ...boards monitor the saturation voltage drop across each of the six IGBT s while gated on If the IGBT s saturation voltage exceeds the prescribed limit the gate driver will make the determination that a...

Page 176: ...system will be allowed to restart when the inverter power module base plate temperatures drop below this value It is possible for an internal sensor to fail and not sense temperature without causing...

Page 177: ...Y VSD LOGIC BOARD POWER SUPPLY X indicates the system and YYYYYYY indicates the system is in a FAULT condition and will restart when the fault clears or LOCKOUT and will not restart until the operator...

Page 178: ...ry and are transmitted to the panel as the fault data Fault Relay Fault Acknowledge Bit Control of the Fault Relay is from the VSD Logic Board The Fault Relay on the VSD will be closed during a non fa...

Page 179: ...179 JOHNSON CONTROLS FORM 201 21 NM2 616 8 This Page Intentionally Left Blank...

Page 180: ...opedasadirect replacement for the 031 02478 xxx line of microboards No adapter harness is required when replacing a 02478 with the new 03478 The 03478 uses the IPUII processor card and provides some n...

Page 181: ...VDC powers the analog out puts to the EEV valves CONFIGURATION JUMPERS The same configuration jumpers that existed on the 02478 are provided on the 03478 JP4 Remote Temp Reset jumper position Pins 1 t...

Page 182: ...FLASH CARD UPDATE ERROR XXXXX FLASH CARD UPDATE ERROR CODE DEFINITION 0 Okay 10 Flash card not found 11 SOFTWARE BIN file not found 14 SOFTWARE BIN file larger than expected 15 RAM to IPU Flash trans...

Page 183: ...OMPRESSORS SE LECTED Warning will occur after the VSD has been initialized if no Number of Compressors Select jumpers are installed or if more than 1 jumper is in stalled The following warning message...

Page 184: ...n or while the systems were shut down All faults do not store operating data at the time of the fault LD10605 STATUS KEY If a VSD fault occurs during the fault rampdown or while the systems are shut d...

Page 185: ...ed shutdown if the Chiller Control Board loses communications with the VSD Logic Board while the chiller is operating On power up the Chiller Microprocessor Board will attempt to initialize communicat...

Page 186: ...LL FAULT and these faults will be recorded as such under the HIS TORY information stored at the instant of the primary fault In some cases this information may be valuable in troubleshooting the prima...

Page 187: ...keypad Typically the cutout will be set at 24 PSIG for chilled water applications The cutout is ignored for the first 30 seconds of system run time During the next 3 minutes of run time the cutout po...

Page 188: ...120 second anti recycle timer times out or LOCK OUT and will not restart until the operator clears the fault using the keypad The safety is ignored for the first 60 seconds of run time After the firs...

Page 189: ...shutdown If the suction superheat 2 F the discharge super heat 15 F for 10 seconds and the run time is or 5 minutes the system will fault and shutdown with a controlled ramped shutdown If the suction...

Page 190: ...tor temperature sensor to be ignored if it fails The start inhibit thresholds for each sensor are shown in TABLE 14 SYS X YYYYYYYY SENSOR FAILURE ZZZZZZZZZZZZ TABLE 14 START INHIBIT SENSOR THRESHOLDS...

Page 191: ...ad System Control Voltage Cutout Fault The System Control Voltage Cutout alerts the operator the 115VAC Control voltage to one of the systems is missing This could be due to a system fuse that has bee...

Page 192: ...tem 3 4 data There are three types of status data which may appear on the display General Status mes sages Unit Safeties and System Safeties When power is first applied to the control panel the follow...

Page 193: ...e chiller to run There is a 1 second delay on this safety to assure the flow switch did not momentarily open UNIT STATUS FLOW SWITCH SHUTDOWN This message indicates the chiller is shutdown but running...

Page 194: ...S X PULLDOWN MOTOR CURRENT LIMITING SYS X VSD INTERNAL AMBIENT TEMP LIMITING The pulldown motor current limiting message indicates the pulldown motor current load limit or pulldown motor current unloa...

Page 195: ...complete listing of the unit safeties and the corre sponding status messages is provided on Page 184 System Safety Fault Status Messages A complete listing of the system safeties and the cor respondin...

Page 196: ...he UNIT DATA key or the ARROW key displays the ambient air temperature UNIT LOAD TIMER XXX SEC UNLOAD TIMER XXX SEC UNIT OUTSIDE AMBIENT AIR TEMP XXX X F UNIT TEMP ERROR XXX X F RATE XXX X F M The nex...

Page 197: ...e items will be blanked out The types of remote control are listed below NONE No remote control is actively controlling the chiller however remote monitoring by a remote device may still be active RCC...

Page 198: ...ys all of the measured system pressures oil suction and discharge The second key press of the SYSTEM DATAKey or the DOWN ARROW key displays all of the measured system temperatures oil suction and disc...

Page 199: ...er solenoid is either ON or OFF The next key press displays the liquid level in the flash tank and an indicator of the the Flash Tank Feed Valve is open The next key press displays the system suction...

Page 200: ...essure Transducer 0 0 PSIG 275 0 PSIG Discharge Pressure Transducer 0 0 PSIG 275 0 PSIG Flash Tank Level Capacitance 0 0 100 Leaving Chilled Liquid Temp 3Kohm Thermistor 19 1 F 110 2 F Return Chilled...

Page 201: ...201 JOHNSON CONTROLS FORM 201 21 NM2 616 This page intentionally left blank 8...

Page 202: ...ssor FLA and calculated currents in amps for systems 1 and 2 The calculated currents are approximate and some error can be expected Also keep in mind that measuring inverter PWM current is difficult a...

Page 203: ...MP 3 MOTOR OVERLOAD XXX AMPS COMP 4 MOTOR OVERLOAD XXX AMPS VSD COMP 1 MOTOR OVERLOAD XXX AMPS COMP 2 MOTOR OVERLOAD XXX AMPS VSD INTERNAL AMBIENT TEMP XXX X F COOLING SYSTEM STATUS YYY VSD IGBT BASEP...

Page 204: ...starts are displayed with a single key press The maximum value for both hours and starts is 99 999 at which point they will roll over to 0 A single display is available under this key and is displayed...

Page 205: ...selection HISTORY CHOOSE HISTORY TYPE XXXXXXXXXXXXXXXXXXXXXXXXXXXX NORM HIST XX 18 JUN 20004 10 34 58 AM SYS X COOLING DEMAND SHUTDOWN NORM HIST XX 18 JUN 20004 10 34 58 AM YYYYYYYYYYYYYYYYYYYYYYYYYYY...

Page 206: ...lay Listed below is a description of the fault data displays and their meaning Data will be displayed in a specific order starting with the Status Display System Faults only Fault Display All Fault Di...

Page 207: ...Selection and Flow Switch Status This message indicates the designated lead system at the time of the fault and whether the flow switch was ON Closed or OFF Open at the time of the fault UNIT LEAD SY...

Page 208: ...of the fault IGBT Baseplate Temperature VSD INTERNAL AMBIENT TEMP XXX X F COOLING SYSTEM STATUS YYY VSD COMP 1 MOTOR OVERLOAD XXX AMPS COMP 2 MOTOR OVERLOAD XXX AMPS VSD IGBT BASEPLATE TEMPS T1 XXX F...

Page 209: ...me of the fault The economizer status will be indicated as either ON or OFF System 1 Flash Tank Level and Feed Valve Open HISTORY KEY CON T SYS 1 FLASH TANK LEVEL XXX X FEED VALVE PERCENT OPEN XXX X T...

Page 210: ...NG MODE WATER COOLING SETPOINTS REMOTE SETPOINT XXX X F REMOTE CONTROL RANGE X X F This message displays the remote setpoint and control range at the time of the fault Maximum Remote Temperature Setpo...

Page 211: ...OPTIONS REMOTE CURRENT LIMIT INPUT 4 0 TO 20 0 MILLIAMPS OPTIONS REMOTE CURRENT LIMIT INPUT 0 0 TO 20 0 MILLIAMPS OPTIONS REMOTE CURRENT LIMIT INPUT 2 0 TO 10 0 VOLTS DC OPTIONS REMOTE CURRENT LIMIT I...

Page 212: ...time of the fault Suction Superheat Setpoint PROGRAM SUCTION SUPERHEAT SETPOINT XXX X F This message indicates the suction superheat setpoint programmed at the time of the fault Unit ID Number PROGRA...

Page 213: ...essing the SETPOINTS key a second time or the ARROW key will display the leaving chilled liquid control range default and low high limits SETPOINTS DEF XXXXX LO XXXXX HI XXXXX LOCAL CONTROL RANGE X X...

Page 214: ...ue in the display to store the data into memory The ARROW key allows scrolling back through the setpoints displays The minimum maximum and default values allowed under the SETPOINTS key are provided i...

Page 215: ...I The user programmable value is programmed on in the second line of the message When the PROGRAM Key is first pressed the fol lowing display will appear indicating the user is in the program mode Pre...

Page 216: ...Pulldown Current Limit The pulldown current limit FLA is programmable This allows the micro to limit a system on pulldown limiting for the purpose of peak time energy savings Typically the limit point...

Page 217: ...ise during night time hours The sound limit display will only be present if the sound limit option is programmed at the factory Default Values Alisting of the low limits high limits and default values...

Page 218: ...n of each option message is provided below Display Language Selection The display language can be selected for English Dutch German Italian and Chinese The default language will be English OPTIONS DIS...

Page 219: ...Imperial units F PSIG OPTIONS DISPLAY UNITS IMPERIAL OPTIONS LEAD LAG CONTROL MODE AUTOMATIC OPTIONS DISPLAY UNITS SI OPTIONS LEAD LAG CONTROL MODE MANUAL SYS 1 LEAD The default mode is IMPERIAL OPTI...

Page 220: ...nly appear if the remote temp limit option is enabled at the factory Remote Current Limit Input Selection Remote current limit from an external source may be tied directly into the chiller microproces...

Page 221: ...221 JOHNSON CONTROLS FORM 201 21 NM2 616 8 This page intentionally left blank...

Page 222: ...W keys allows scrolling to the next programmed item Pressing the DOWN ARROW key scrolls to the next item that can be pro grammed and the UP ARROW key scrolls to the previous item The day of the week i...

Page 223: ...st be keyed in for minutes 00 09 CLOCK FRI 18 JUN 2004 10 15 33 AM AM PM XX CLOCK FRI 18 JUN 2004 10 15 33 AM TIME FORMAT XXXXXXX CLOCK FRI 18 JUN 2004 10 15 33 AM MINUTE XX Pressing the DOWN ARROW ke...

Page 224: ...00 PM The line under the 0 is the cursor If the start time is wrong it can be changed by keying in the new time from the numeric keypad Once the correct values for the START hour and minute are entere...

Page 225: ...imit Setpoint programmed under the PROGRAM key 0 will cause no speed reduction while 100 only allows running at minimum speed The START Time for a specific day hour and min ute is entered using the sa...

Page 226: ...ule is being ignored and the chiller will start when chilled liquid temperature allows Remote Contacts UNIT switch and SYSTEM switches permitting This is a pri ority message and cannot be overridden b...

Page 227: ...EL PRINTING option The following message is displayed when the PRINT key is pressed PRINT CHOOSE PRINT REPORT XXXXXXXXXXXXXXXXXXXXX After pressing the PRINT key the printout type is select ed by press...

Page 228: ...ORATOR PUMP RUN O N EVAPORATOR HEATER O F F ACTIVE REMOTE CONTROL N O N E O P E R A T I N G H O U R S 1 X X X X X 2 X X X X X 3 XXXXX 3 circuit 3 XXXXX 4 XXXXX START COUNTER 1 XXXXX 2 XXXXX 3 XXXXX 3...

Page 229: ...DATA PRINTOUT History printouts when selected provide stored data relating to all specific system and chiller operating conditions at the time of the fault regardless of whether a lockout occurred His...

Page 230: ...the ENTER key allows view only Service Mode operation All control board I O will be view able in this mode No outputs can be changed For troubleshooting or start up commissioning purposes the Chiller...

Page 231: ...t This will cause the voltage read on the display to be less than the voltage on the board header inputs between TB1 17 and 18 TB1 19 and 20 or TB1 40 and 41 To correct for this when measuring voltage...

Page 232: ...TEMP X X VDC XXX X F SERVICE AI J22 20 SYS2 SUCTION PRESS X X VDC XXX X PSIG SERVICE AI J22 22 SYS2 OIL PRESS X X VDC XXX X PSIG SERVICE AI J22 24 SYS2 DISCHARGE PRESS X X VDC XXX X PSIG SERVICE AI J...

Page 233: ...I J6 3 PRINT STATUS XXX SERVICE DI J6 5 SYS 2 4 RUN PERM STATUS XXX SERVICE DI J6 6 SPARE DIGITAL INPUT 1 STATUS XXX SERVICE DI J7 2 CONFIG INPUT 0 STATUS XXX SERVICE DI J7 4 CONFIG INPUT 1 STATUS XXX...

Page 234: ...T 1 RB1 TB1 6 STATUS XXX SERVICE DO J11 9 SYS 3 COND FAN OUT 2 RB1 TB1 5 STATUS XXX SERVICE DO J11 10 SYS 3 COND FAN OUT 3 RB1 TB1 4 STATUS XXX SERVICE DO J11 11 SYS 3 COMP HEATER RB1 TB1 3 STATUS XXX...

Page 235: ...XX X VDC SERVICE AO J25 1 SYS 1 SPARE XXX X XX X VDC SERVICE AO J25 2 SYS 2 SPARE XXX X XX X VDC SERVICE AO J25 3 SYS 3 SPARE XXX X XX X VDC SERVICE AO J25 4 SYS 4 SPARE XXX X XX X VDC The sixth data...

Page 236: ...r 4 SYSTEM SWITCHES SYS 1 ON OFF RESET XXXXXXXXXXXXXXX SYSTEM SWITCHES SYS 2 ON OFF RESET XXXXXXXXXXXXXXX SYSTEM SWITCHES SYS 3 ON OFF RESET XXXXXXXXXXXXXXX SYSTEM SWITCHES SYS 4 ON OFF RESET XXXXXXXX...

Page 237: ...Factory Technical Support with the version of the Chiller Control Board EPROM The version will be written on the EPROM label and typically will be in the format Version C ACS XX XX After obtaining the...

Page 238: ...PROGRAMMING CON T At this point the letters entered for theYYYYand XXX inputs should now appear in the top line of the display and should match the first 7 characters of the serial number on the unit...

Page 239: ...e following STATUS message If the message above appears immediately contact YORK Product Technical Support or YORK ES Com mercial for a password to enable the High IPLV mode You will need to provide Y...

Page 240: ...uts Service Time 5 Min 60 Min 15 Min Sys 1 Motor Sensor to Ignore See Below None Sys 2 Motor Sensor to Ignore See Below None Sys 3 Motor Sensor to Ignore See Below None Sys 4 Motor Sensor to Ignore Se...

Page 241: ...IMIT OPTION XXXXXXXXXXXXXXXXXXXXXXXX SETUP MODE SOUND LIMIT OPTION XXXXXXXXXXXXXXXXXXXXXXXX The following setup OPTION display is selectable as ENABLED or DISABLED using the and AR ROW keys SETUP MODE...

Page 242: ...s to their default values YES or NO may be selected for XXX using the and ARROW keys to change the selection Following is a list of the operating parameters that will be reset to their default values...

Page 243: ...trol panel TABLE 20 SERIAL PORT CONNECTIONS BOARD HEADER PORT TYPE PORT USE Chiller Control Board TB1 TB2 RS 232 RS 485 Printer RCC and ISN Chiller Control Board J2 J1 RS 485 Control Panel VSD 1 2 VSD...

Page 244: ...ture 1 Chiller Control Board J19 2 Comp 1 Motor Temperature 2 Chiller Control Board J19 3 Comp 1 Motor Temperature 3 Chiller Control Board J19 6 Comp 2 Motor Temperature 1 Chiller Control Board J19 7...

Page 245: ...gic Board J1 5 to J1 6 Comp 1 Phase C Motor Current VSD Logic Board J1 13 to J1 14 Comp 3 Phase A Motor Current VSD Logic Board J1 15 to J1 16 Comp 3 Phase B Motor Current VSD Logic Board J1 17 to J1...

Page 246: ...sor Select VSD Logic Board J1 11 3 Compressor Select VSD Logic Board J1 12 4 Compressor Select VSD Logic Board J5 1 to J5 2 VSD Logic Board J5 3 to J5 4 VSD Logic Board J6 2 Comp 1 Phase A Gate Driver...

Page 247: ...EADER ANALOG OUTPUT VSD Logic Board J11 2 Phase Loss Fault 1 VSD Logic Board J11 6 Phase Loss Fault 2 VSD Logic Board SW1 Test Pushbutton VSD Logic Board J10 5 to J10 6 Comp 1 3 Run from control panel...

Page 248: ...d J15 5 to J15 6 Sys 2 flash Tank Feed Valve Chiller Control Board J15 7 to J15 8 Sys 2 Flash Tank Drain Valve Chiller Control Board J14 1 to J14 6 Sys 3 Flash Tank Feed Valve Chiller Control Board J1...

Page 249: ...249 JOHNSON CONTROLS FORM 201 21 NM2 616 8 This page intentionally left blank...

Page 250: ...lay Board 1 J9 5 TB1 12 and 11 Sys 1 SPARE Chiller Control Relay Board 1 J9 6 TB1 10 and 9 SPARE Chiller Control Relay Board 1 J9 7 TB1 8 and 7 SPARE Chiller Control Relay Board 1 J9 8 TB1 6 Sys 1 Con...

Page 251: ...Board J7 4 Comp 3 Phase C IGBT Gating Signal VSD Logic Board J7 10 Comp 3 Phase A IGBT Gating Signal VSD Logic Board J7 11 Comp 3 Phase B IGBT Gating Signal VSD Logic Board J7 13 Comp 3 Phase C IGBT G...

Page 252: ...munications with a 3 or 4 compressor chiller involves 2 sections of feature 54 to get all the data Control pa rameters from the ISN as well system 1 2 and unit data are handled in the first section Th...

Page 253: ...Analog Sys 2 Discharge Pressure P30 84 87 Analog Sys 2 Compressor Full Load Amps P31 88 91 Analog Sys 2 Total Run Hours P32 92 95 Analog Sys 2 Total Number of Starts P33 96 99 Analog VSD Output Frequ...

Page 254: ...ndensor Fan Stage 0 6 P64 136 Coded Lead System Number P65 137 Coded Sys 1 2 Debug Code P66 138 141 Analog Local Leaving Chilled Liquid Setpoint P67 142 145 Analog Low Leaving Chilled Liquid Temp Cuto...

Page 255: ...ailure 8 Unit VSD Pre charge Low DC Bus Voltage 9 Unit VSD Pre charge DC Bus Voltage Imbalance 10 Unit VSD High DC Bus Voltage 11 Unit VSD Low DC Bus Voltage 12 Unit VSD DC Bus Voltage Imbalance 13 Un...

Page 256: ...tor Current 43 System VSD Motor Current Overload Software 44 System VSD IGBT Gate Driver Fault 45 System VSD High Baseplate Temp 46 System VSD Single Phase Input 47 System VSD VSD Run Signal Fault 48...

Page 257: ...ing Shutdown 70 Unit SPARE 1 71 Unit SPARE 2 72 Unit SPARE 3 73 Unit SPARE 4 74 System Panel No Run Permissive 75 System Panel Anti Recycle Timer Active 76 System Panel System Switch OFF 77 System Pan...

Page 258: ...34 6 165 0 117 6 300 0 160 0 35 0 40 0 170 0 119 6 305 0 161 3 40 0 45 0 175 0 131 5 310 0 162 5 45 0 49 6 180 0 123 3 315 0 163 8 50 0 54 0 185 0 125 2 320 0 165 0 55 0 58 1 190 0 126 9 325 0 166 2...

Page 259: ...pped to do so If in any doubt contact your local YORK Service Agent Unit Status Press the STATUS key on the keypad and ensure no fault messages are displayed Refrigerant Leaks Visually check the heat...

Page 260: ...is and clean as necessary X Check Programmable Operating Setpoints and Safety Cutouts Assure they are correct for the application X Check Compressor and Evaporator Heater operation X Check for dirt in...

Page 261: ...em X VSD Glycol Change X MAINTENANCE REQUIREMENTS FOR YCAV CHILLERS CON T Reserved for customer use for any special site requirements This procedure must be performed at the specific time by an indust...

Page 262: ...ometer reading of ambient temperature Chiller Fault HIGH AMBIENT TEMPERATURE Ambient Temperature is above the maximum operating limit Check outside air temperature Ambient Sensor is defective Check th...

Page 263: ...g High Superheat Drain Feed Valves NOT controlling Isolate cause Motor Sensor reading incorrectly Program panel to ignore a single sensor Economizer Solenoid energized at low speeds Valve is leaking t...

Page 264: ...rent limiting Ambient temperature is high normal response from controller Remore or panel limiting is in effect Normal response Excess charge in system adjust charge Condensor coils dirty Clean conden...

Page 265: ...ses 1 Labor to remove or reinstall any equipment mate rials or components 2 Shipping handling or transportation charges 3 Cost of refrigerant No warranty repairs or replacements will be made until pay...

Page 266: ...1 76 42 7 2 42 63 2 3 09 23 9 1 78 43 3 2 44 63 8 3 11 24 5 1 80 43 9 2 46 64 5 3 13 25 0 1 82 44 4 2 48 65 1 3 14 25 6 1 84 45 0 2 50 65 8 3 16 26 2 1 86 45 6 2 52 66 5 3 18 26 8 1 88 46 2 2 54 67 1...

Page 267: ...44 112 3 3 75 21 2 1 15 64 4 2 47 113 8 3 78 22 3 1 18 65 3 2 50 115 2 3 81 23 4 1 21 66 3 2 52 116 7 3 84 24 4 1 24 67 2 2 55 118 3 3 87 25 5 1 26 68 1 2 58 119 9 3 90 26 6 1 26 69 1 2 61 121 5 3 93...

Page 268: ...62 35 1 01 175 3 05 40 1 78 40 1 08 180 3 12 45 1 94 45 1 15 185 3 19 50 2 10 50 1 23 190 3 26 55 2 26 55 1 30 195 3 34 60 2 42 60 1 37 200 3 41 65 2 58 65 1 45 205 3 48 70 2 74 70 1 52 210 3 55 75 2...

Page 269: ...6 3 00 5 166 5 485 45 4 368 3 25 4 226 4 510 50 3 602 3 50 3 476 3 728 55 2 986 3 75 2 874 3 098 60 2 488 4 00 2 389 2 588 65 2 083 4 25 1 995 2 172 70 1 753 4 50 1 674 1 832 75 1 481 4 75 1 411 1 551...

Page 270: ...SOR 1 OVERLOAD SETTING AMPS COMPRESSOR 2 OVERLOAD SETTING AMPS MAXIMUM VSD FREQUENCY HZ YCAV0569EA VA 400 168 168 186 YCAV0569SA PA 400 184 184 200 YCAV0639EA VA 400 173 185 200 YCAV0639SA PA 400 231...

Page 271: ...manual for the respective printer for set up and wiring Data from the chiller is transmitted at 1200 baud Wir ing diagrams for cables are shown below OKIDATA MICROLINE 184 25 pin RS 232 DB 25P 25 pin...

Page 272: ...t mode 1 7 off SDD pin 11 1 8 on SDD pin 11 2 1 on 1200 baud 2 2 on 1200 baud 2 3 off 1200 baud 2 4 off DSR active 2 5 on Buffer threshold 32 bytes 2 6 on Busy signal 200ms 2 7 on DTR space after powe...

Page 273: ...2 MODEL COMPRESSOR 3 MODEL COMPRESSOR 4 MODEL SERIAL PROGRAMMED VALUES CHILLED LIQUID SETPOINT Setpoint F C Range F C Display Language Chilled Liquid Mode Local Remote Mode Display Units Lead Lag Cont...

Page 274: ...GBT BASEPLATE TEMPS T1 F C T2 F C SYSTEM OPERATING TEMPERATURES PRESSURES CURRENTS SYSTEM PRESSURES SYS 1 SYS 2 SYS 3 SYS 4 Oil PSIG kPa Suction PSIG kPa Discharge PSIG kPa SYSTEM TEMPERATURES SYS 1 S...

Page 275: ...YS 4 Fan Stage COMPRESSOR HEATER ON OFF SYS 1 SYS 2 SYS 3 SYS 4 Comp Heater SYSTEM RUN TIME Days Hours Mins Sec System 1 System 2 System 3 System 4 SYSTEM STARTS STARTS SYSTEM 1 SYSTEM 2 SYSTEM 3 SYST...

Page 276: ...21 NM2 616 WATER SYSTEM CONDITIONS EVAPORATOR FLOW Flow Rate GPM Evap Pressure Drop FT LBS Circle One Glycol Freeze Point F C CONDENSOR CONDITIONS AIR TEMPERATURE Air ON Temperature F C Air OFF Tempe...

Page 277: ...r Type L R 134a 011 00592 000 VSD Logic Board ALL 031 02477 000 EPROM U36 ALL 031 02521 001 EPROM U39 ALL 031 02522 001 Sensor Outside Air Temperature ALL 025 28663 001 Transducer Pressure 0 275 psig...

Page 278: ...ia USA 17405 1592 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2016 www johnsoncontrols com ALL RIGHTS RESERVED Form 201 21 NM2 616 Issue Date June 30 201...

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