York YVAG012 Operation & Maintenance Manual
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York YVAG012 Operation & Maintenance Manual

Dc inverter air-cooled chiller and heat pump
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DC INVERTER AIR-COOLED
CHILLER AND HEAT PUMP
FORM NO.:
6U5M-A11M-NB-EN
Installation , Operation & Maintenance Manual
YVAG012~040RSE
Cooke Industries - Phone: +64 9 579 2185
Email: sales@cookeindustries.co.nz
Web: www.cookeindustries.co.nz

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

  • Page 2: Table Of Contents

    FORM NO.: 6U5M-A11M-NB-EN Table of Contents GENERAL SAFETY GUIDELINES ........................... 4 SECTION 1-PRODUCT DESCRIPTION........................... 6 INTRODUCTION ..............................6 BASIC UNIT NOMENCLATURE ..........................6 THE UNIT DIMENSION ............................6 OPERATING RANGE ..............................8 SECTION 2 –INSTALLATION REQUIREMENTS ......................9 INSPECTION ................................9 MOVING THE UNIT ..............................
  • Page 3 FORM NO.: 6U5M-A11M-NB-EN CONDENSER COILS ............................... 46 OPERATING PARAMETERS ........................... 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 JOHNSON CONTROLS Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz...

  • Page 4: General Safety Guidelines

    Pay attention to keep this document and you can requirements could result in serious damage to the acquire it from local authorized YORK service center equipment and the property in which it is situated, as in case it would be lost.
  • Page 5 FORM NO.: 6U5M-A11M-NB-EN CHANGEABILITY OF THIS DOCUMENT lifting, and operating/service personnel should verify In complying with Johnson Controls’ policy for whether the equipment has been modified and if current continuous product improvement, the information literature is available from the owner of the equipment contained in this document is subject to change without prior to performing any work on the chiller.

  • Page 6: Section 1-Product Description

    SECTION 1-PRODUCT DESCRIPTION INTRODUCTION YORK DC Inverter Air-Cooled Chiller and Heat Pump Unit provide chilled water and hot water for all air conditioning applications using central station air handling or terminal units. They are completely self-contained and are designed for outdoor (roof or ground level) installation. Each complete packaged unit includes hermetic rotary compressors, a liquid cooler, air cooled condensers, a charge of refrigerant R410A and a weather resistant microprocessor control center, all mounted in a sheet metal shell.
  • Page 7 FORM NO.: 6U5M-A11M-NB-EN YVAG020-033 DIMENSIONS FIGURE 2 FIGURE 3 YVAG040 DIMENSIONS JOHNSON CONTROLS Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...

  • Page 8: Operating Range

    For applications with temperature below -25℃, please consult YORK company. Applicable Medium The standard design applicable medium of the unit is purified water. Please consult YORK Company for special medium such as glycol antifreeze fluid. Altitude...

  • Page 9: Section 2 -Installation Requirements

    FORM NO.: 6U5M-A11M-NB-EN SECTION 2 –INSTALLATION REQUIREMENTS with a crane, a canvas hammock shall be used to come INSPECTION round the unit base and be fastened. If the packaging Remove any transit packing and inspect the unit to box has been removed, in order to move the machine, ensure that all components have been delivered and that please apply suitable partition to protect the surface and no damage has occurred during transit.

  • Page 10: Inspection Checklist

    To ensure warranty coverage, this equipment must be commissioned and serviced by an authorized YORK service mechanic or a qualified service person experienced in unit installation. Installation must comply with all applicable codes, particularly in regard to electrical wiring and other safety elements such as HP cutout settings, design working pressures, and ventilation requirements consistent with the amount and type of refrigerant charge.

  • Page 11: Location

    20m over the unit (for 20m higher, please consult entire operating weight of the equipment. See YORK Company); PHYSICAL DATA for operating weight. If the unit is In installations where winter operation is intended and...
  • Page 12 YVAG012~033: Φ20mm Φ20mm Φ20mm Φ26mm FIGURE 5-BACKPLANE SCHEMATIC（012~018)

  • Page 13: Install Spacing

    80% and the unpredictable airflow patterns and possible diminished angle of inclination of the grating blades shall be over performance. YORK’s unit control will optimize 20°, and the blade pitch shall be over 100mm INSTALLATION CLEARANCES Units are surrounded by walls or other obstacles, installation spacing, referring to the following figure.
  • Page 14 FORM NO.: 6U5M-A11M-NB-EN YVAG040 Single Install 1） 2） 3） Model Model Model Back wall Back wall, Height unlimited Back wall Front of the Front of the ≥300 ≥300 unit unit Front of the ≥100 unit Front wall Installation in rows 1）...

  • Page 15: Water System Installation

    FORM NO.: 6U5M-A11M-NB-EN The operating flow rate of the unit shall not exceed WATER SYSTEM INSTALLATION 40% of rated flow for each unit type, too large or too Chilled liquid piping specification small water flow rate would affect the normal use of the unit.
  • Page 16 FORM NO.: 6U5M-A11M-NB-EN should be wrapped with supplemental heater cable and For module application, a place for thermometer insulated to protect against freeze-up during low sensor shall be retained on the main outlet pipe of the ambient periods, and to prevent formation of water system so that the leaving water temperature condensation on lines in warm humid locations.
  • Page 17 FORM NO.: 6U5M-A11M-NB-EN Water system Pipework arrangement The following are suggested pipework arrangements for single unit with built-in pump installations. For multiple unit installations, each unit should be piped as shown. Chilled water system for single unit FIGURE 9 – SINGLE UNIT SYSTEM (WITHOUT EXTERNAL PUMP) FIGURE 10 –...
  • Page 18 FORM NO.: 6U5M-A11M-NB-EN Chilled water system for modular unit A u xilia ry E le ctric H e a te r W a te r F ilte r T h e rm o m e te r W a te r T e m p e ra tu re D ra in S e n so r...
  • Page 19 FORM NO.: 6U5M-A11M-NB-EN TABLE 5– COMPONENTS SYMBOL Modular Connections The units are able to be connected in a pipe network for centralized control. The control 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.
  • Page 20 FORM NO.: 6U5M-A11M-NB-EN Notes: 1. The distances between the walls and peripheral units should employ the same rules as shown in Clearance in SECTION 5, if the units are surrounded by walls 2. Installation contractor must include vent and drain accommodations in chilled water piping near the evaporator. 3.

  • Page 21: Unit External Head

    FORM NO.: 6U5M-A11M-NB-EN Regular measurement on water quality should be conducted before unit installation and during in Users shall be at their own risk for any service, and water quality should conform to the loss if it is due to the matter of water requirements in the above table.
  • Page 22 FORM NO.: 6U5M-A11M-NB-EN 012~018 PUMP HEAD CURVE YVAG012 YVAG014 YVAG016/018 WATER FLOW m³/h FIGURE 16 – UNIT EXTERNAL HEAD CURVE（012~018） 020~033 PUMP HEAD CURVE YVAG028-033 YVAG020-025 WATER FLOW m FIGURE 17 – UNIT EXTERNAL HEAD CURVE（020~033） 040 PUMP HEAD CURVE WATER FLOW m3/h FIGURE 18 –...

  • Page 23: Electrical Connection

    “safety precautions” remote cooling/ heating switch, etc. The units YVAG012~040RSE can be connected Alarm Status Contacts only to a power supply with system impedance no more Normally-open contacts are available for each unit.

  • Page 24: Accessory Dimensions

    FORM NO.: 6U5M-A11M-NB-EN to make any repair which may cause damage or electric parts other than control panel in case of personal injury shock. For any maintenance demand, please contact the as there’s electricity in control cabinet before power manufacturer. supply is cutoff.
  • Page 25 FORM NO.: 6U5M-A11M-NB-EN FIGURE 21 – WATER 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 JOHNSON CONTROLS Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...

  • Page 26: Section 3 -Electrical Continuity

    ELECTRICAL CONNECTION be used. The units are shipped with all factory-mounted controls Only designated accessories by YORK can be wired for operation. used, and services of installation and technology Field Wiring – Power wiring must be provided...

  • Page 27: Electrical Diagram

    FORM NO.: 6U5M-A11M-NB-EN ELECTRICAL DIAGRAM All electrical wiring should be carried out in accordance with local regulations. Route properly sized cables to the cable entries in the side of the unit. It is the responsibility of the user to install over current protection devices between the supply conductors and the power supply terminals on the unit.
  • Page 28 3# Modular 4# Modular of Touch Screen Wiring Terminal RS485 BAS Board RS485 BAS Board RS485 BAS Board RS485 BAS Board YORK-DRV-002-HL YORK-DRV-002-HL YORK-DRV-002-HL YORK-DRV-002-HL A B12V A B12V FIGURE 27 – COMMUNICATION WIRING DIAGRAM FOR MODULAR UNIT（012~018） Wire Controller Of...
  • Page 29 1. All the communication cables should be equipped on site as per the above requirement, and any inconformity should be submitted to YORK Company for confirmation in case of unit malfunction. 2. Modular connection and fan coil joint control cannot be applied simultaneously...
  • Page 30 FORM NO.: 6U5M-A11M-NB-EN Unit Power Supply 1. Unit Power Supply TABLE 9 – POWER SUPPLY CABLE SPECIFICATION MODEL TYPE 020/022 028/033 380V /400V 3N~50Hz POWER SUPPLY 220V~50Hz MAXIMUM OPERATING CURRENT RECOMMENDED WIRE DIAMETER 4mm2 6mm2 6mm2 6mm2 4mm2 6mm2 6mm2 6mm2 C 型...
  • Page 31 Specifications of the master breaker and the power supply cable need to be selected according to the total load. Please contact YORK service personnel for professional support. This manual for 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.
  • Page 32 FORM NO.: 6U5M-A11M-NB-EN POWER SULLY 380V/400V ～ 50Hz L1 L2 L3 N PE L1 L2 N1 N2 component description RE C/H 1 # two-way valve Air-conditioning auxiliary electric heating wire controller The total water control for floor heating The total water control of fan coil units Modular water valve control Give an alarm Breaker...
  • Page 33 FORM NO.: 6U5M-A11M-NB-EN In modular system, wirings of external interlocking, remote switch, cooling/heating switch, auxiliary electric heater and solenoid valve for floor heating are all connected to the 1# modular. 012 ~ 018 unit can meet the power input voltage is 220 v and 230 v under the conditions of use, 020 ~ 040unit can meet the power input voltage is 380 v and 400 v under the conditions of use 012~018 020~040...
  • Page 34 FORM NO.: 6U5M-A11M-NB-EN Notes: Live line of fan coil (floor heating) controller means the control line which controls a two-way or three-way valve (normally closed type), and the fan coil linkage controller need to be connected with another power supply. All the controller of air side terminals need to be connected to the fan coil linkage controller.

  • Page 35: Electrical Schematic Diagram

    FORM NO.: 6U5M-A11M-NB-EN JOHNSON CONTROLS Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
  • Page 36 FORM NO.: 6U5M-A11M-NB-EN U YE V GN GNYE W RD GNYE GNYE GNYE GNYE JOHNSON CONTROLS Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
  • Page 37 FORM NO.: 6U5M-A11M-NB-EN JOHNSON CONTROLS Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...
  • Page 38 FORM NO.: 6U5M-A11M-NB-EN DCL1 DCL2 GNYE JOHNSON CONTROLS Cooke Industries - Phone: +64 9 579 2185 Email: sales@cookeindustries.co.nz Web: www.cookeindustries.co.nz...

  • Page 39: Section 4 - Wire Controller Operation

    FORM NO.: 6U5M-A11M-NB-EN SECTION 4 – WIRE CONTROLLER OPERATION Don’t touch the screen with sharp points or edges which may damage the controller. Don’t twist or pull the wires of the controller. Don’t wipe the controller with benzene, diluent or chemical cloth.

  • Page 40: Basic Operations

    FORM NO.: 6U5M-A11M-NB-EN TABLE 10 – FUNCTIONS OF KEYS MEANING MEANING MEANING COOLING FUNCTION FAULT HEATING TIMER PUMP CONFIRM LOCK CANCEL DOWN LOW SOUND BASIC OPERATIONS Start and Stop the Unit Press the button below on the screen to start or stop the unit. Operating Mode Press the key of “COOLING”...
  • Page 41 FORM NO.: 6U5M-A11M-NB-EN and auto switch to the next setting. The setting will terminate if there’s no operation for 5 seconds or “CANCEL” is pressed. Schedule Timer Press the “TIMER” key for 5 seconds to enter Schedule Timer setting screen. The “TIMER”, “SET” and “ON” icons will flicker while the function is activated.
  • Page 42 FORM NO.: 6U5M-A11M-NB-EN AI7 Unit leaving water temperature sensor fault AI8 Coil temperature sensor fault DI1 Water flow switch fault or water pump overload alarm DI3 Over pressure alarm Communication failure ( failure on 1# unit is between principal unit and wire controller while others for principal and subordinate unit.）...
  • Page 43 FORM NO.: 6U5M-A11M-NB-EN TABLE 12– DESCRIPTION OF FAULT CODE（020~040） DESCRIPTION FAULT CODE AI1 Refrigerant inlet accumulator temperature sensor fault AI2 Suction pressure transducer fault AI3 Discharge temperature sensor fault AI4 Ambient temperature sensor fault AI5 System leaving water temperature sensor fault AI6 System return water temperature sensor fault AI7 Unit leaving water temperature sensor fault AI8 Coil temperature sensor fault...
  • Page 44 FORM NO.: 6U5M-A11M-NB-EN Mainboard and Fan2 communication failure Driver hardware overcurrent Compressor driving failure Compressor overcurrent Reserved Sampling failure of compressor current Heat sink/IPM overheating alarm Pre-charge failure DC bus over voltage DC bus under voltage AC input under voltage AC input overcurrent Driver check out failure AC input hardware overcurrent...
  • Page 45 FORM NO.: 6U5M-A11M-NB-EN TABLE 14 – DESCRIPTION OF RUNNING STATUS（020~040） Running status No. Description AI1 Refrigerant temperature inlet accumulator AI2 Saturate temperature of suction pressure AI3 Discharge temperature AI4 Ambient temperature AI5 System leaving water temperature AI6 System return water temperature AI7 Unit leaving water temperature AI8 Coil temperature AI9 Economizer inlet temperature...

  • Page 46: Section 5 - Maintenance

    If system failure occurs due to improper maintenance compressor to start during the warranty period, YORK will not be liable for costs incurred to return the system to satisfactory CONDENSER COILS operation. The following is intended only as a guide Dirt should not be allowed to accumulate on the con- and covers only the unit components.

  • Page 47: Modbus Protocol

    FORM NO.: 6U5M-A11M-NB-EN MODBUS PROTOCOL TABLE 15 - DEFINITIONS ITEM DESCRIPTION Communication Baud rate: 9600bps; 8-N-1: 1 start bit,1 stop bit, check bit-none, 8 data bits; Data Flow Modbus-RTU Protocol; CRC: Cyclic Redundancy Check; Hexadecimal data. Modbus as master; Master - Slave 1# microboard as slave.
  • Page 48 FORM NO.: 6U5M-A11M-NB-EN TABLE 17 – SYSTEM PARAMETERS Register Name Function Code Note Address Chiller ON/OFF 0-OFF, 1-ON System Status 0-Cooling、1-Heating、8-Only Pump bit0: 1-Antifreezing bit1: 1-Defrost Other Status bit2: 1-Low Sound Mode bit3: Pump Status, 1-On, 0-Off bit4: Compressor Status, 1-On, 0-Off HMI Communication status 1-ON, 0-OFF Unit Networks Status...
  • Page 49 FORM NO.: 6U5M-A11M-NB-EN Bit0 Communication Failure Bit0: 1-Fault Unit Bit1 Conflict Setting Of Unit Model Type Bit1: 1-Fault Unit Bit3 Excessive Lower Ambient Temperature For Cooling Mode Bit3: 1-Fault Unit Excessive Lower System Leaving Water Temperature For Bit5 Bit5: 1-Fault System Cooling Mode Excessive Higher system Leaving Water Temperature For...

  • Page 50: Trouble Shooting

    2. Check power supply to microboard and 3. Communication wire detective between the corresponding wiring. wire controller to unit. 3. Check communication wiring. Contact YORK Service before replacing circuit boards! 1. No chilled liquid flow. 1. Check chilled liquid flow.

  • Page 51: Trouble Shooting (Cont'd)

    FORM NO.: 6U5M-A11M-NB-EN TROUBLE SHOOTING (CONT’D) TABLE21 – TROUBLE SHOOTING (CONT’D) PROBLEM CAUSE SOLUTION “Low Leaving Water 1. Improperly adjusted leaving chilled 1. Re-program the leaving chilled liquid Temp” Fault liquid temp. cutout (glycol only). temp. cutout. 2. Micro panel setpoint/range values 2.

  • Page 52: Poisonous And Harmful Substance Content Table Unit

    FORM NO.: 6U5M-A11M-NB-EN POISONOUS AND HARMFUL SUBSTANCE CONTENT TABLE UNIT TABLE22 –POISONOUS AND HARMFUL SUBSTANCE CONTENT TABLE UNIT Contents of toxic and harmful substances hazardous substance or element Part name Cr(VI) PBDE × ○ ○ ○ ○ ○ Compressor Motor ×...
  • 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 YORK Guangzhou Air Conditioning & Refrigeration Co., Ltd. Phone: +86 763 4681111 Fax: +86 763 4681114 © 2019 Johnson Controls, Inc. www.johnsoncontrols.com FROM NO: 6U5M-A11M-NB-EN SUPERSEDES: 6U5M-A11M-NA- EN * Johnson Controls is committed to the continuous product improvement. Please note the product design may change without notification.

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