Johnson Controls York YCAV1039-1909 Manuals

Manuals and User Guides for Johnson Controls York YCAV1039-1909. We have 1 Johnson Controls York YCAV1039-1909 manual available for free PDF download: Installation Operation & Maintenance

Johnson Controls York YCAV1039-1909 Installation Operation & Maintenance (310 pages)

Brand: Johnson Controls | Category: Chiller | Size: 15 MB

Table of Contents
4
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
Section 3 -Rigging, Handling and Storage
26
Delivery and Storage
26
Inspection
26
Lifting Weights
26
Moving the Chiller
27
Unit Rigging
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
Pipework Arrangements
32
Connection Types & Sizes
32
Cooler Connections
32
Option Flanges
32
Fig 3 - Pipework Arrangement
32
Fig 4 - Victaulic Groove
32
Fig 5 - Flange Attachment
32
Refrigerant Relief Valve Piping
33
Ductwork Connection
33
General Requirements
33
Electrical Connection
33
Power Wiring
34
Power Supply 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
Remote Print
35
Optional Remote Setpoint Offset Temp
35
Optional Remote Setpoint Offset Current
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 - Compr. Wiring
47
Fig 6 - Single Point Power Supply Connection
47
W/Circuit Breaker Protection (3 Compr)
47
Fig 7 - Single Point Power Supply Connection
47
W/Terminal Block (3 Compr)
47
Fig 8 - Single Point Power Supply Connection
48
W/Circuit Breaker Protection (4 Compr)
48
Fig 9 - Single Point Power Supply Connection
48
W/Terminal Block (4 Compr)
48
Fig 10 - Multi-Point Power Supply Connection
49
W/Circuit Breaker Protection (4 Compr)
49
Fig 11 - Multi-Point Power Supply Connection
49
W/Terminal Block (4 Compr)
51
Electrical Notes
54
Wiring Diagrams - 3 Compressor
56
Wiring Diagrams - 4 Compressor
68
Dimensions
84
Technical Data (Clearances)
116
Weight Distribution & Isolator Mounting
117
Fig 12 - Sample Printout Supplied in the Isolator
117
Package & Chiller Panel Literature Packet
117
Isolator Mounting Positions
118
Seismic Isolator Installation
123
Neoprene Isolator Position
124
Refrigerant Flow Diagram
127
Fig 13 - Refrigerant Flow Diagram
127
Diagram
128
Fig 14 - Processes and Instrumentation
128
Component Locations
129
Fig 15 - Component Locations
129
Fig 16 - Control and VSD Cabinet Locations
130
Fig 17 - Chiller Control Board, Relay Boards
131
Microgateway, and Optional Circuit Breaker
131
Microgateway
131
Fig 19 - VSD Logic Board
133
Fig 20 - VSD Logic Board
134
Fig 21 - Power Components
135
Fig 22 - Power Components
136
Fig 23 - Fan Contactors
137
Fig 24 - VSD Components
138
Fig 25 - VSD Components
139
Fig 26 - VSD Components
140
Fig 27 - VSD Components
141
Fig 28 - Inverter Power Components
142
Fig 29 - Inverter Power Components
143
Fig 30 - Inverter Power Components
144
Fig 31 - Inverter Power Components
144
Fig 32 - Glycol Pump & Fill Tube Locations
145
Fig 33 - Glycol Piping & Fill Tube Locations
146
Fig 34 - Compressor Components
147
Equipment Start-Up Check Sheet
148
Unit Checks (no Power)
148
Panel Checks
150
(Power ON-Both System Switches OFF)
150
Programmed Values
151
Chilled Liquid Setpoint
151
Date/Time, Daily Schedule, & Clock Jumper
151
Initial Start-Up
152
Check Subcooling & Superheat
152
Leak Checking
153
Chiller Electronic Components
154
Keypad
154
Display
155
Chiller Control Board
156
Relay Output Boards
157
VSD (Variable Speed Drive)
157
AC to DC Rectifier
157
SCR Trigger Board
158
DC Link Filter
158
1L Line Inductor
159
AC to DC Inverter
159
Laminated Bus Structure
159
VSD Logic Board
160
Control Panel to VSD Communications
160
IGBT Gate Driver Boards
161
Current Transformers
161
DV/DT Output Suppression Network
162
Flash Tank Feed/Drain Valve Controller
162
DC Bus Voltage Isolation Board
163
Chiller Circuit Breaker
163
Autotransformer
163
Chiller Configuration Jumpers
164
Number of Compr. Configuration Jumpers
164
Vsd Logic to Chiller Microprocessor
164
Board Rs-485 Communication
164
Configuration Jumpers
164
Table 1 - Compressors and the Appropriate Jumper
164
Positions
164
Table 2 - VSD Logic Board Address Jumper
164
Max Vsd Frequency
165
Table 3 - Maximum Frequency Jumper
165
Section 7 - Operation
166
Operating Controls
166
Basic Operating Sequence
168
Fig 35 - Chiller Control (Cooling) Range
168
Number of Compressors to Start
169
General
169
Standard IPLV
169
Optional Optimized IPLV
169
Fig 36 - Number of Compressors to Start
169
Minimum Vsd Compressor Start/Stop Frequency
170
Minimum VSD Start Frequency
170
Minimum VSD Run Frequency
170
Fig 37 - Minimum VSD Start Frequency
170
Fig 38 - Minimum VSD Run
170
Acceleration/Deceleration Rate
171
Compressors
171
VSD Acceleration/ Deceleration Rates
171
Standard Iplv Capacity Control
172
Fuzzy Logic Control
173
Hot Water Starts
174
Lag Compressor Operation in Load Limiting
174
Table 4 - Fuzzy Logic Loading/Unloading Vs. Error
174
Optional Iplv Capacity Control
175
Fuzzy Logic
176
Hot Water Starts
177
Table 5 - Fuzzy Logic Loading/Unloading Vs. Error
177
Load Limiting Control
178
Table 6 - Current Load Limiting/Unloading
178
Table 7 - Discharge Pressure Load Limiting
178
Unloading
178
Table 8 - Suction Pressure Load Limiting
179
Unloading
179
Table 9 - VSD Internal Ambient Load Limiting
179
Table 10 - VSD Baseplate Temperature Load
180
Limiting/Unloading
180
Controller
181
Valve Controller & Control Algorithm
181
Fig 39 - LED Locations
182
Fig 40 - Power, Comms Led's
183
Led's
183
Economizer Control
184
Condenser Fan Control
184
Table 11 - Fan Stages & Corresponding Outputs
185
Fig 42 - Standard IPLV Fan Control
186
Vsd Temperature Control/Fan Control Operation
187
Fig 43 - High IPLV Fan Control
187
Remote Temperature Reset Control
188
Local Current Limit Control
189
Pulldown Current Limit Setpoint
189
Remote Current Limit Reset
190
Sound Limit Controls
192
Vsd Operation & Controls
194
VSD Cooling and Cooling Loop
196
Table 12 - VSD Operating Display Parameters
199
Vsd Safeties
200
IGBT Gate Driver (Hardware) Fault
203
Power Supply (Hardware) Fault
205
Unit Warnings
208
Unit Safeties
212
System Safeties
214
Table 13 - Low Differential Oil Pressure Cutout
216
Table 14 - Start Inhibit Sensor Thresholds
218
Status Key
220
Unit Data Key
224
System Data Key
226
Table 15 - Sensor Min/Max Outputs
228
Vsd Data Key
230
Operating Hours & Start Keys
232
History Key
233
Unit Data
234
VSD Data
235
System Data
236
Compressor Operating Hours & Starts
238
Chilled Liquid & Cooling Setpoints
238
Options
238
Program Values
239
Setpoints Key
241
Table 16 - Setpoint Limits
242
Program Key
243
Table 17 - Programmable Operating Parameters
245
Options Key
246
Date/Time & Schedule Key
250
Date/Time Key
250
Schedule Key
251
Unit Operating Schedule
252
Sound Limit Schedule
253
Manual Override Key
254
Print Key
255
Table 18 - Printout Types
255
Operating Data Printout
256
History Data Printout
257
Service Key
258
System Switches Key
264
Serial Number Programming
265
Enabling Optimized High Iplv Mode
267
Unit Setup Mode
268
Table 19 - Unit Setup Programmable Values
268
Default Programmable Values
270
Serial Port Connections
271
Table 20 - Serial Port Connections
271
Analog Input Connections
272
Table 21 - Analog Input Connections
272
Digital Input Connections
274
Table 22 - Digital Input Connections
274
Analog Output Connections
276
Table 23 - Analog Output Connections
276
Digital Output Connections
278
Table 24 - Digital Output Connections
278
Isn Communications
280
Transmitted Data
280
Control Data
280
Table 26 - DXST/ISN Transmitted Data
281
Table 27 - Fault Inhibit Codes
285
Table 28 - Operational Status Codes
287
R-134A Conversion Tables
288
Table 29 - R-134A Pressure to Saturated
288
Temperature Conversion
288
Maintenance
289
General Requirements
289
Maintenance Requirements
290
Troubleshooting Guide
292
Evacuating a System
294
Warranty Policy
295
New Equipment
295
Reconditioned or Replacement Materials
295
All Warranties Are VIOD if
295
Chilled Liquid & Suction Temp Sensor Input Voltage Table
296
Table 30 - Temperature Input Voltage Sensor
296
Outside Air Temp Sensor Input Voltage Table
297
Pressure Transducer Output Voltage Table
297
Table 31 - Outside Air Temperature Input Voltage
297
Table 32 - Pressure Transducer Input Voltage
298
Motor Temperature Sensor Resistance Table
299
Compressor Motor Overload Settings & Maximum Vsd Frequency
300
Table 34 - Compressor Motor Overload Settings
300
Max. VSD Frequency
300
Printer Wiring
301
Fig 44 - Print Cable Chiller to Serial Printer
301
Okidata 184
302
Weigh-Tronix IMP Model 2600
302
Seiko
302
Operating Log
303
Site and Chiller Info
303
Programmed Values
303
Currents
304
System Operating Conditions
305
Water System Conditions
306
Condensor Conditions
306
Recommended Spare Parts
307

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