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York YCIV0207
Johnson Controls York YCIV0207 User Manual
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R134A
YCIV STYLE
A
MODELS
YCIV0157-0397, 60 HZ
(150-260 TONS)
AIR-COOLED SCREW LIQUID CHILLERS
E/V HIGH
EFFICIENCY
AND S/P
ST
ANDARD EFFICIENCY
AIR-COOLED SCREW LIQUID CHILLERS
INST
ALLA
TION, OPERA
TION, MAINTENANCE
Supersedes: 201.23-NM2 (610)
Form 201.23-NM2 (315)
035-21506-101
Issue Date:
March 9, 2015
2
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1 - General Chiller Information and Safety
19
Introduction
19
Warranty
19
Safety
19
Standards for Safety
19
Responsibility for Safety
20
About this Manual
20
Misuse of Equipment
20
Suitability for Application
20
Structural Support
20
Mechanical Strength
20
General Access
20
Pressure Systems
21
Electrical
21
Rotating Parts
21
Sharp Edges
21
Refrigerants and Oils
21
High Temperature and Pressure Cleaning
21
Emergency Shutdown
21
Section 2 - Product Description
23
Introduction
23
General System Description
23
Compressor
24
FIGURE 1 - Chiller Control System
24
FIGURE 2 - Compressor
24
Evaporator
25
Condenser
25
Flash Tank Feed Valve/Drain Valves
26
Oil Separator/Oil System
26
Relief Valves
26
Oil Cooling
27
Capacity Control
27
Power and Control Panel
27
Each Power Compartment Contains
27
Microprocessor and VSD Controls
27
Display
27
Keypad
28
Unit Switch
28
Variable Speed Drive (VSD)
29
FIGURE 3 - PWM Current Waveform
29
FIGURE 4 - PWM Voltage Waveform
29
Accessories and Options
30
Sound Reduction Options
30
Condenser Coil Protection
31
Protective Chiller Panels
31
Evaporator Options
32
General Options
32
Vibration Isolation
32
Complete Pin Number Description
34
Section 3 - Rigging, Handling and Storage
39
Lifting Weights
39
Delivery and Storage
39
Inspection
39
Moving the Chiller
40
Unit Removal from Shipping Container
40
Lifting Using Lugs
40
Lifting Using Shackles
40
Section 4 - Installation
43
Location Requirements
43
Outdoor Installations
43
Indoor Installations
43
Location Clearances
43
Vibration Isolators
44
Installation
44
Shipping Braces
44
Chilled Liquid Piping
44
General Requirements
44
Water Treatment
45
Pipework Arrangement
46
Connection Types and Sizes
46
Cooler Connections
46
Option Flanges
46
Refrigerant Relief Valve Piping
46
FIGURE 5 - Pipework Arrangement
46
FIGURE 6 - Victaulic Groove
46
FIGURE 7 - Flange Attachment
46
Ductwork Connection
47
General Requirements
47
Electrical Connection
47
Power Wiring
48
Power Supply Wiring
48
115VAC Control Supply Transformer
48
Control Panel Wiring
48
Volts Free Contacts
49
Chilled Liquid Pump Starter
49
Run Contact
49
Alarm Contacts
49
System Inputs
49
Flow Switch
49
Remote Run / Stop
49
Remote Print
49
Optional Remote Setpoint Offset - Temperature
49
Optional Remote Setpoint Offset - Current
49
Section 6 - Technical Data
61
Water Pressure Drop Charts
61
Glycol Correction Factors
65
Water Temperature and Flows
66
Physical Data (English - Standard Efficiency)
68
Physical Data (English - High Efficiency)
70
Physical Data (si - Standard Efficiency)
72
Physical Data (si - High Efficiency)
74
Electrical Data
76
Compressor Power Wiring Connections
76
FIGURE 8 - Two Compressor Wiring Diagram with Circuit Breaker
76
FIGURE 9 - Two Compressor Wiring Diagram with Terminal Block
76
Compressor Power Wiring Connections
77
FIGURE 10 - Three Compressor Wiring Diagram with Circuit Breaker - Single Point
77
FIGURE 11 - Three Compressor Wiring Diagram with Terminal Block - Single Point
77
Standard Efficiency 2-Compressor Units
78
High Efficiency 2-Compressor Units
82
Standard Efficiency 3-Compressor Units
86
High Efficiency 3-Compressor Units
88
Electrical Notes
90
Electrical Wiring Diagrams - 2 Compressor Models
92
FIGURE 12 - Elementary Control Wiring Diagram 2 Compressor Models
92
Elementary Power Wiring Diagram
94
FIGURE 13 - Elementary Power Wiring Diagram - YCIV0157-0267 2 Compressor Models
94
Power Wiring Connection Diagram
96
FIGURE 14 - Power Wiring Connection Diagram - YCIV0157-0267 2 Compressor Models
96
Control Wiring Connection Diagram
98
FIGURE 15 - Control Wiring Connection Diagram - YCIV0157-0267 2 Compressor Models
98
Power Elementary Wiring Diagram
101
FIGURE 16 - Power Elementary Wiring Diagram - YCIV0157-0267 2 Compressor Models
101
Location Label - 2 Compressor Models
103
Panel Layout - 2 Compressor Models
104
Electrical Wiring Diagrams - 3 Compressor Models
106
FIGURE 17 - Control Elementary Diagram - YCIV0257-0397 3 Compressor Models
106
Power Elementary Diagram
110
FIGURE 18 - Power Elementary Diagram - YCIV0257-0397 3 Compressor Models
110
Control Wiring Connection Diagram
112
FIGURE 19 - Control Wiring Connection Diagram - YCIV0257-0397 3 Compressor Models
112
Power Wiring Connection Diagram
116
FIGURE 20 - Power Wiring Connection Diagram - YCIV1050-1500 3 Compressor Models
116
Power Elementary Diagram
120
FIGURE 21 - Power Elementary Diagram - YCIV0257-0397 3 Compressor Models
120
Location Label - 3 Compressor Models
122
Panel Layout - 3 Compressor Models
123
Dimensions - 2 and 3 Compressor si
124
Technical Data - Clearances
144
Isolator Selection and Mounting
145
Isolator Information for Units Shipped on or after June 15, 2008
145
One Inch Deflection Spring Isolators Cross-Reference
162
One Inch Deflection Spring Isolators Installation Instructions
163
Durulene Isolator Cross-Reference
164
Installation of Durulene Vibration Isolators
165
Seismic Isolator Cross-Reference
166
Seismic Isolator Installation and Adjustment
167
Isolator Information for Units Shipped before June 15, 2008
168
SLRS Seismic Isolator Specifications
168
SLRS Seismic Isolator Installation and Adjustment
169
To Install and Adjust Mounts
169
ND-X Neoprene Isolator Specifications
170
Installation of Neoprene Mounts
170
CIP 1" Deflection Restrained Mounting Specifications
171
Installation of 1" Deflection Mounts
172
Refrigerant Flow Diagram
173
FIGURE 22 - Refrigerant Flow Diagram
173
Process and Instrumentation Diagram
174
FIGURE 23 - Process and Instrumentation Diagram
174
Component Locations
175
FIGURE 24 - Component Locations
175
FIGURE 25 - Control and VSD Cabinet Components
176
FIGURE 26 - Chiller Control Board, Relay Boards, Microgateway, and Optional Circuit Breaker
177
FIGURE 27 - Chiller Control Board, Relay Boards, and Microgateway, 2 Compressor
178
FIGURE 28 - Chiller Control Board, Relay Boards, and Microgateway, 3 Compressor
179
FIGURE 29 - VSD Logic Board
180
FIGURE 30 - VSD Logic Board (Original - Obsolete), P/N 031-02477-000
181
FIGURE 31 - VSD Logic Board (New), P/N 031-02507-XXX
182
FIGURE 32 - Power Components, 2 Compressor
183
FIGURE 33 - Power Components, 3 Compressor
184
FIGURE 34 - Fan Contactors and 3T Transformer, 2 Compressor
185
FIGURE 35 - Fan Contactors, 3 Compressor
186
FIGURE 36 - VSD Components
187
FIGURE 37 - VSD Components, 2 Compressor
188
FIGURE 38 - VSD Components, 3 Compressor
189
FIGURE 39 - VSD Components, 2 Compressor
190
FIGURE 40 - VSD Components, 3 Compressor
191
FIGURE 41 - Inverter Power Components, 2 Compressor
192
FIGURE 42 - Inverter Power Components, 3 Compressor
193
FIGURE 43 - Inverter Power Components
194
Glycol System Components
196
FIGURE 44 - Glycol Pump and Fill Tube Locations
196
FIGURE 45 - Glycol Piping and Fill Tube Location
197
Compressor Components
198
FIGURE 46 - Compressor Components
198
Chiller Electronic Components
199
Keypad
199
Keypad Data Entry Mode
200
Display
200
Relay Output Boards
201
VSD (Variable Speed Drive)
202
AC to DC Rectifier
202
SCR Trigger Board
202
DC Link Filter
202
1L Line Inductor
203
DC to AC Inverter
203
Laminated Bus Structure
204
VSD Logic Board
204
FIGURE 47 - New Board P/N 031-02507-000
204
FIGURE 48 - Obsolete Board P/N 031-02477-000
204
Control Panel to VSD Communications
205
IGBT Gate Driver Boards
205
Current Transformers
206
DV/DT Output Suppression Network
206
Flash Tank Feed and Drain Valve Controller
206
DC Bus Voltage Isolation Board
207
Chiller Circuit Breaker
207
Chiller Configuration Jumpers
207
Number of Compressors Configuration Jumper
207
TABLE 1 - Compressors and the Appropriate Jumper Positions
207
VSD Logic to Chiller Microprocessor Board RS-485 Communication Configuration Jumpers
208
Maximum VSD Frequency/Model Designator
208
TABLE 2 - VSD Logic Board Address Jumper
208
TABLE 3 - Maximum Frequency / Model Designator Jumper
208
Section 7 - Operation
209
Operating Controls
209
Anti-Recycle Timer
209
Evaporator Pump Control
209
Evaporator Heater Control
209
Pumpdown Control
209
Compressor Heater Control
209
Alarms
209
Chiller Run Contact
209
Unit Switch
210
Basic Operating Sequence
210
Start Sequence and Loading
210
Number of Compressors to Start
211
General
211
Standard IPLV
211
Optional Optimized High IPLV
211
FIGURE 49 - Chiller Control (Cooling) Range
211
Minimum VSD Compressor Start / Run Frequency
212
Minimum VSD Start Frequency
212
Minimum VSD Run Frequency
212
FIGURE 50 - Number of Compressors to Start
212
FIGURE 51 - Minimum VSD Start Frequency
212
Acceleration / Deceleration Rate When Starting / Stopping Compressors
213
VSD Acceleration and Deceleration Rates
213
Standard IPLV Capacity Control
213
FIGURE 52 - Minimum VSD Run Frequency
213
Fuzzy Logic Control
214
Hot Water Starts
215
Lag Compressor Operation in Load Limiting
215
Optional High IPLV Capacity Control
215
TABLE 4 - Fuzzy Logic Loading/Unloading Vs. Error
215
Fuzzy Logic Control
217
TABLE 5 - Fuzzy Logic Loading/Unloading Vs. Error
217
Hot Water Starts
218
Load Limiting Control
218
Load Limiting
218
Motor Current Load Limiting/Unloading
218
Discharge Pressure Load Limiting/Unloading
218
TABLE 6 - Current Limit Load Limiting/Unloading
218
Suction Pressure Load Limiting/Unloading
219
VSD Internal Ambient Temperature Load Limiting
219
VSD Baseplate Temperature Load Limiting
219
TABLE 7 - Discharge Pressure Load Limiting/Unloading
219
TABLE 8 - Suction Pressure Load Limiting/Unloading
219
TABLE 9 - VSD Internal Ambient Load Limiting/Unloading
219
Flash Tank Drain and Feed Valve Controller
220
Valve Controller and Control Algorithm Operation
220
FIGURE 53 - Flash Tank Drain and Feed Valve Controller
220
TABLE 10 - VSD Baseplate Temperature Load Limiting/Unloading
220
MOP Setpoint Control for Hot Water Starts
221
Moderate to High Ambient MOP Setpoint Control
221
Low Ambient MOP Setpoint Control
221
Actual MOP Setpoint
221
Valve Controller Led's
222
FIGURE 54 - LED Locations
222
FIGURE 55 - Power and Comms Led's
222
FIGURE 56 - Power, Comms and System Open/Close Led's
222
Economizer Control
223
Condenser Fan Control
224
FIGURE 57 - Condenser Fan Locations
224
TABLE 11 - Fan Stages and Corresponding Outputs
224
Standard IPLV Fan Control
225
Optimized IPLV Fan Control
225
High VSD Cabinet Ambient Temperature Fan Operation
225
VSD Temperature Control, Operation of the Coolant Pump, and VSD Cabinet Cooling Fans
225
FIGURE 58 - Standard IPLV Fan Control
225
FIGURE 59 - High IPLV Fan Control
225
Remote Temperature Reset Control
226
Temperature Reset Control
226
Remote ISN Setpoint Control
226
Remote Temperature Reset
226
Local Current Limit Control
227
Pulldown Current Limit Setpoint
227
Remote Current Limit Reset Control
227
Remote ISN Current Limit Setpoint
228
Remote Current Limit Reset
228
Sound Limit Control
229
Sound Limiting and Local Sound Limit Setpoint
229
ISN Sound Limit Setpoint
229
Remote Sound Limit
229
Section 8 - Micropanel
231
VSD Operation and Controls
231
VSD Logic Board
231
VSD Start/Run Initiation
231
PWM Generator Type and Carrier Frequency
231
Short Circuit Protection Minimum Output Pulse Width and Interlock Delay
231
Modulating Frequency
231
Maximum VSD Frequency
232
VSD % Modulation
232
VSD Cooling and Cooling Loop
232
IGBT Module Baseplate Temperature Sensing
233
VSD Internal Ambient Temperature Sensing
234
Pre-Charge
234
Run Mode / Unit Restart
234
DC Bus Voltage Sensing and Scaling
235
Current Sensing and Scaling
235
VSD Transmitted Operating Parameters
235
VSD Safeties (Faults)
235
TABLE 12 - VSD Operating Display Parameters
235
Pre-Charge Low DC Bus Voltage (Software) Fault
236
Pre-Charge DC Bus Voltage Imbalance (Software) Fault
237
High DC Bus Voltage (Hardware) Fault
237
Low DC Bus Voltage (Software) Fault
237
DC Bus Voltage Imbalance (Software) Fault
237
High Motor Current (Hardware) Fault
238
Motor Current Overload (Software) Fault
238
Motor Current Overload (Hardware) Fault
238
IGBT Gate Driver (Hardware) Fault
238
High Baseplate Temperature (Software) Fault
239
High VSD Internal Ambient Temperature (Software) Fault
239
Single Phase Input (Hardware) Fault
239
Power Supply (Hardware) Fault
240
Run Relay (Software) Fault
240
VSD Logic Board Failure (Software) Fault
240
VSD CT Plug (Hardware) Fault
240
VSD Fault Data
240
Fault Relay/Fault Acknowledge Bit
241
VSD Fault Compressor Start Inhibit
241
Unit Warnings
241
Unit Warning Operation
241
Low Battery Warning
241
Invalid Number of Compressors Warning
242
Invalid Serial Number Warning
242
Optimized Efficiency Disabled
242
Unit Safeties
243
Unit Safety Operation
243
High Ambient Temp Fault
243
Low Ambient Temp Fault
243
Low Leaving Chilled Liquid Temp Fault
243
VSD Communications Failure Fault
244
System Safeties (Faults)
244
System Safety (Fault) Operation
244
High Discharge Pressure Cutout (Software) Fault
245
High Discharge Pressure Cutout (HPCO) (Hardware) Fault
245
Low Suction Pressure Cutout (Software) Fault
245
Low Motor Current Cutout Fault
245
High Differential Oil Pressure Cutout Fault
246
Low Differential Oil Pressure Cutout Fault
246
High Discharge Temperature Cutout Fault
246
High Oil Temperature Cutout Fault
246
TABLE 13 - Low Differential Oil Pressure Cutout
246
Low Suction Superheat Cutout Fault
247
Low Discharge Superheat Cutout Fault
247
Sensor Failure Cutout Fault
247
High Motor Temperature Cutout Fault
248
High Flash Tank Level Cutout Fault
248
System Control Voltage Cutout Fault
248
TABLE 14 - Start Inhibit Sensor Thresholds
248
Status Key
249
Status Key Operation
249
General Status Messages
250
Unit Safety (Fault) Status Messages
251
System Safety (Fault) Status Messages
251
VSD Safety (Fault) Status Messages
251
Unit Warning Messages
251
Unit Data Key
252
General
252
Unit Data Key Operation
252
System Data Keys 1 through 4
254
General
254
System 1 Data Key Operation
254
System 2 through 4 Data Key Operation
255
Sensor Displays
256
TABLE 15 - Sensor Min/Max Outputs
256
VSD Data Key
257
General
257
VSD Data Key Operation
257
Operating Hours / Start Counter Key
259
History Key
260
History Key Operation
260
Normal Shutdowns History
260
Fault Shutdowns History
261
Status Fault Type
261
Unit Fault Type
261
All Fault Data
261
Unit Data
262
VSD Data
262
System Data
263
Compressor Operating Hours and Starts
264
Chilled Liquid Setpoint Cooling Setpoints
265
Options
265
Remote Temperature Reset
265
Program Values
266
Pulldown Current Limit
266
Setpoints Key
267
Setpoints Key Operation
267
TABLE 16 - Setpoint Limits
268
Program Key
269
Program Key Operation
269
Suction Pressure Cutout
269
Low Ambient Cutout
270
Low Leaving Liquid Temp Cutout
270
Motor Current Limit
270
Pulldown Current Limit
270
Pulldown Current Limit Time
270
Suction Superheat Setpoint
270
Unit ID Number
270
Sound Limit Setpoint
271
Default Values
271
TABLE 17 - Programmable Operating Parameters
271
Options Key
272
Options Key Operation
272
Display Language Selection
272
Chilled Liquid Cooling Mode Selection
272
Local / Remote Control Mode Selection
273
Display Units Selection
273
System Lead/Lag Control Mode Selection
273
Remote Temperature Reset Selection
274
Remote Current Limit Input Selection
274
Remote Sound Limit Selection
274
Low Ambient Cutout Enable/Disable
274
Date / Time and Schedule Keys
275
Date/Time Key Operation
275
Schedule Key Operation
276
Unit Operating Schedule
277
Sound Limit Schedule
278
Manual Override Key
279
Manual Overrride Key Operation
279
Print Key
280
Print Key Operation
280
TABLE 18 - Printout Types
280
Operating Data Printout
281
History Data Printout
282
Service Key
283
Service Key Operation
283
System Switches Key
289
System Switches Key Operation
289
Serial Number Programming
290
Enabling Optimized High IPLV Mode
291
Unit Setup Mode
292
TABLE 19 - Unit Setup Programmable Values
292
Default Programmable Values
293
Serial Port Connections
293
Analog Input Connections
294
TABLE 20 - Serial Port Connections
294
TABLE 21 - Analog Input Connections
294
Digital Intput Connections
296
TABLE 22 - Digital Input Connections
296
Analog Output Connections
297
TABLE 23 - Analog Output Connections
297
Digital Output Connections
298
TABLE 24 - Digital Output Connections
298
BACNET, MODBUS and YORKTALK 2 Communications
300
FIGURE 60 - Control Board Connections
301
TABLE 25 - Minimum, Maximum and Default Values
301
TABLE 26 - Values Required for BAS Communication
302
TABLE 27 - Real Time Error Numbers
302
Bacnet and Modbus Communications
303
Communications Data Map Notes
303
TABLE 28 - Bacnet and Modbus Communications Data Map
304
Yorktalk 2 Communications
309
TABLE 29 - Yorktalk 2 Communications Data Map
310
Section 9 - Maintenance
313
General Requirements
313
Daily Maintenance
313
Unit Status
313
Refrigerant Leaks
313
Operating Conditions
313
Compressor Oil Level
313
Refrigerant Charge
313
Scheduled Maintenance
313
Chiller / Compressor Operating Log
313
R-134A Conversion Tables
314
TABLE 30 - R-134A Pressure to Saturated Temperature Conversion
314
Maintenance Requirements for YCIV Chillers
315
Troubleshooting Guide
316
Limited Warranty
318
Warranty on New Equipment
318
Warranty on Reconditioned or Replacement Materials
318
Chilled Liquid and Suction Temperature Sensor Input Voltage
319
TABLE 31 - Temperature Input Voltage Sensor (Measured Signal to Shield at the Sensor)
319
TABLE 32 - Outside Air Temperature Sensor Input Voltage (Measured Signal to Shield at the Sensor)
320
TABLE 33 - Pressure Transducer Output Voltage (Measured Signal to Return at the Transducer)
321
TABLE 34 - Motor Temperature Sensor Resistance (Check at the Motor)
322
TABLE 35 - Compressor Motor Overload Settings and Max. VSD Frequency
323
Printer Wiring
326
FIGURE 61 - Print Cable - Chiller to Serial Printer
326
Printer Cables
327
Printer Setup
327
Okidata 184
327
Weigh-Tronix IMP 24 Model 2600
327
Seiko
327
Operating Log Sheet
328
Site and Chiller Information
328
Programmed Values
328
System Operating Conditions
330
Water System Conditions
331
Condenser Conditions
331
Recommended Spare Parts
332
4
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Johnson Controls York YCIV0207 Specifications
General
Brand
Johnson Controls
Model
York YCIV0207
Category
Chiller
Language
English
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