York YCAV0639 Manuals

Manuals and User Guides for York YCAV0639. We have 1 York YCAV0639 manual available for free PDF download: Installation Operation & Maintenance

York YCAV0639 Installation Operation & Maintenance (278 pages)

AIR-COOLED SCREW LIQUID CHILLERS

Brand: York | Category: Chiller | Size: 8.27 MB

Table of Contents
5
Section 1 - General Chiller Information & Safety
9
Introduction
9
Warranty
9
Safety
9
Standards for Safety
9
Responsibility for Safety
10
About this Manual
10
Misuse of Equipment
10
Suitability for Application
10
Structural Support
10
Mechanical Strength
10
General Access
10
Pressure Systems
11
Electrical
11
Rotating Parts
11
Sharp Edges
11
Refrigerant & Oils
11
High Temperature & Pressure Cleaning
11
Emergency Shutdown
11
Section 2 - Product Description
12
Introduction
12
General System Description
12
Compressor
13
Evaporator
14
Condensor
15
Flash Tank Feed / Drain Valve
15
Oil Separator/Oil System
15
Relief Valves
15
Oil Cooling
16
Capacity Controls
16
Power and Control Panel
16
Microprocessor & VSD Controls
16
Display
17
Keypad
17
Unit Switch
17
Variable Speed Drive (VSD)
18
Fig 1 - PWM Current Waveform
18
Fig 2 - PWM Voltage Waveform
18
Accessories & Options
19
Single Point Circuit Breaker
19
Building Automation System (BAS) Interface
19
Condensor Coil Protection
19
DX Cooler Options
20
Service Valve Option
20
Unit Enclosures
20
Fans
20
Sound Reduction Options
20
Vibration Isolation
20
Unit Nomenclature
21
Product Identification Number
22
Delivery and Storage
26
Inspection
26
Lifting Weights
26
Moving the Chiller
27
Unit Rigging
28
Section 4 - Installation
28
Location Requirements
29
Outdoor Installation
29
Indoor Installation
29
Location Clearances
30
Vibration Isolators
30
Installation
30
Shipping Braces
30
Chilled Liquid Piping
30
General Requirements
30
Water Treatment
32
Connection Types & Sizes
32
Cooler Connections
32
Option Flanges
32
Fig 3 - Pipework Arrangement
32
Fig 4 - Victaulic Groove
32
Fig 5 - Flange Attatchment
32
Refrigerant Relief Valve Piping
33
Ductwork Connection
33
General Requirements
33
Electrical Connection
33
Power Wiring
34
Vac Control Supply Transformer
34
Control Panel Wiring
34
Volts Free Contacts
35
Chilled Liquid Pump Starter
35
Run Contact
35
Alarm Contact
35
System Inputs
35
Flow Switch
35
Remote Run/Stop
35
Optional Remote Setpoint Offset Temp
35
Optional Remote Setpoint Offset Sound Limit
35
Section 5 - Commissioning
36
Preparation
36
Preparation - General
36
Inspection
36
Refrigerant Charge
36
Service and Oil Line Valves
36
Compressor Oil
36
Fans
36
Isolation / Protection
36
Control Panel
36
Power Connections
37
Grounding
37
Water System
37
Flow Switch
37
Temperature Sensor(S)
37
Programmed Options
37
Programmed Settings
37
Date & Time
37
Start / Stop
37
Setpoint & Remote Offset
37
Interlocks
38
Unit Switch
38
Start-Up
38
Oil Pressure
38
Refrigerant Flow
38
Loading
38
Suction Superheat
38
Subcooling
38
Condensor & Fan Rotation
39
General Operation
39
Section 6 - Technical Data
40
Water Pressure Drop Charts
40
Glycol Correction Factors
41
Water Temp. and Flows
42
Physical Data
44
Operating Limitations and
46
Sound Power
46
Electrical Data
47
Fig 6 - Single Point Power Supply Connection W/ Field Supplied Circuit Protection
47
Fig 7 - Single Point Power Supply Connection W/ Optional Factory Circuit Breaker
47
Electrical Notes
50
Elementary Wiring Diagram
52
Connection Diagram
56
Location Label
60
Dimensions
62
Technical Data (Clearances)
90
Weight Distribution & Isolator Mounting
92
Fig 8 - Sample Printout Supplied in the Isolator Package & Chiller Panel Literature Packet
92
Isolator Mounting Positions
93
Seismic Isolator Installation
96
Neoprene Isolator Position
98
1" Deflection Isolator Installation
99
Refrigerant Flow Diagram
101
Fig 9 - Refrigerant Flow Diagram
101
Diagram
102
Fig 10 - Processes and Instrumentation
102
Component Locations
103
Fig 11 - Component Locations
103
Fig 12 - Control and VSD Cabinet Locations
104
Fig 13 - Chiller Control Board, Relay Boards, Microgateway, and Optional Circuit Breaker
105
Fig 14 - Chiller Control Board, Relay Boards, and Microgateway
106
Fig 15 - VSD Logic Board
107
Fig 16 - VSD Logic Board
108
Fig 17 - Power Components
109
Fig 18 - Fan Contactors & 3T Transformers
110
Fig 19 - VSD Components
111
Fig 20 - VSD Components
112
Fig 21 - VSD Components
113
Fig 22 - Inverter Power Components
114
Fig 23 - Inverter Power Components
115
Fig 24 - Inverter Power Components
116
Fig 24A - Inverter Power Components
116
Fig 25 - Glycol Pump & Fill Tube Locations
117
Fig 26 - Glycol Piping & Fill Tube Locations
118
Fig 27 - Compressor Components
119
Equipment Start-Up Check Sheet
120
Unit Checks (no Power)
120
Panel Checks
122
(Power ON-Both System Switches OFF)
122
Programmed Values
123
Chilled Liquid Setpoint
123
Date/Time, Daily Schedule, & Clock Jumper
123
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 Drive)
129
AC to DC Rectifier
129
SCR Trigger Board
130
DC Link Filter
130
1L Line Inductor
131
AC to DC Inverter
131
Laminated Bus Structure
131
VSD Logic Board
132
Control Panel to VSD Communications
132
IBGT Gate Driver Boards
133
Current Transformers
133
DV/DT Output Suppression Network
134
Flash Tank Feed/Drain Valve Controller
134
DC Bus Voltage Isolation Board
135
Chiller Circuit Breaker
135
Autotransformer
135
Chiller Configuration Jumpers
136
Number of Compressors Configuration Jumpers
136
Vsd Logic to Chiller Microprocessor Board Rs-485 Communication Configuration Jumpers
136
Max Vsd Frequency
137
Section 7 - Operation
138
Operating Controls
138
Basic Operating Sequence
140
Fig 28 - Chiller Control (Cooling) Range
140
Number of Compressors to Start
141
General
141
Standard IPLV
141
Optional Optimized IPLV
141
Fig 29 - Number of Compressors to Start
141
Minimum Vsd Compressor Start/Stop Frequency
142
Minimum VSD Start Frequency
142
Minimum VSD Run Frequency
142
Fig 30 - Minimum VSD Start Frequency
142
Fig 31 - Minimum VSD Run
142
Acceleration/Deceleration Rate
143
Compressors
143
VSD Acceleration/ Deceleration Rates
143
Standard Iplv Capacity Control
144
Fuzzy Logic Control
145
Hot Water Starts
146
Lag Compressor Operation in Load Limiting
146
Optional Iplv Capacity Control
147
Fuzzy Logic
148
Hot Water Starts
149
Load Limiting Control
150
Flash Tank Drain/Feed Valve Controller
153
Valve Controller & Control Algorithm
153
Fig 32 - LED Locations
154
Fig 33 - Power, Comms Led's
155
Fig 34 - Power, Comms & System Open/Close Led's
155
Economizer Control
156
Condenser Fan Control
157
Fig 35 - Standard IPLV Fan Control
158
Fig 36 - High IPLV Fan Control
158
Vsd Temperature Control/Fan Control Operation
159
Remote Temperature Reset Control
160
Local Current Limit Control
161
Pulldown Current Limit Setpoint
161
Remote Current Limit Reset
162
Sound Limit Controls
164
Vsd Operation & Controls
166
VSD Cooling and Cooling Loop
168
Vsd Safeties
172
IBGT Gate Driver (Hardware) Fault
175
Power Supply (Hardware) Fault
177
Unit Warnings
180
Unit Safeties
184
System Safeties
186
Status Key
192
Unit Data Key
196
System Data Key
198
Vsd Data Key
202
Operating Hours & Start Keys
204
History Key
205
Unit Data
207
VSD Data
207
System Data
208
Compressor Operating Hours & Starts
210
Chilled Liquid & Cooling Setpoints
210
Options
210
Program Values
211
Setpoints Key
213
Program Key
215
Options Key
218
Date/Time & Schedule Key
222
Date/Time Key
222
Schedule Key
223
Unit Operating Schedule
224
Sound Limit Schedule
225
Manual Override Key
226
Print 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
Default Programmable Values
242
Serial Port Connections
243
Analog Input Connections
244
Digital Input Connections
246
Analog Output Connections
248
Digital Output Connections
250
Isn Communications
252
Transmitted Data
252
R-134A Conversion Tables
258
Maintenance
259
General Requirements
259
Maintenance Requirements
260
Troubleshooting Guide
262
Evacuating a System
264
Warranty Policy
265
New Equipment
265
Reconditioned or Replacement Materials
265
All Warranties Are VIOD if
265
Chilled Liquid & Suction Temp Sensor Input Voltage Table
266
Outside Air Temp Sensor Input Voltage Table
266
Pressure Transducer Output Voltage Table
268
Motor Temperature Sensor Resistance Table
269
Compressor Motor Overload Settings & Maximum Vsd Frequency
270
Printer Wiring
271
Fig 37 - Print Cable Chiller to Serial Printer
271
Okidata 184
272
Weigh-Tronix IMP Model 2600
272
Seiko
272
Operating Log
273
Site and Chiller Info
273
Programmed Values
273
Currents
274
System Operating Conditions
275
Water System Conditions
276
Condensor Conditions
276
Recommended Spare Parts
277

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York YCAV0639 Installation Operation & Maintenance (278 pages)

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