York YCAV1039 - User Manual

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MODELS YCAV1039-1909, 50 HZ

STYLE A

(960-1815KW)

E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY

AIR-COOLED SCREW LIQUID CHILLERS

R-134a

Issue Date:

October 2, 2020

AIR-COOLED SCREW

LIQUID CHILLERS

INSTALLATION, OPERATION, MAINTENANCE Supersedes 201.21-NM4 (616) Form 201.21-NM4 (1020)

035-20995-000

Main Page

Table of Contents4
Section 1 - General Chiller Information & Safety9
Introduction9
Warranty9
Safety9
Standards for Safety9
Responsibility for Safety10
About this Manual10
Misuse of Equipment10
Suitability for Application10
Structural Support10
Mechanical Strength10
General Access10
Pressure Systems11
Electrical11
Rotating Parts11
Sharp Edges11
Refrigerant & Oils11
High Temperature & Pressure Cleaning11
Emergency Shutdown11
Section 2 - Product Description12
Introduction12
General System Description12
Compressor13
Evaporator14
Condensor15
Flash Tank Feed / Drain Valve15
Oil Separator/Oil System15
Relief Valves15
Oil Cooling16
Capacity Controls16
Power and Control Panel16
Microprocessor & VSD Controls16
Display17
Keypad17
Unit Switch17
Variable Speed Drive (VSD)18
Fig 1 - PWM Current Waveform18
Fig 2 - PWM Voltage Waveform18
Accessories & Options19
Single Point Circuit Breaker19
Building Automation System (BAS) Interface19
Condensor Coil Protection19
DX Cooler Options20
Service Valve Option20
Unit Enclosures20
Fans20
Sound Reduction Options20
Vibration Isolation20
Unit Nomenclature21
Product Identification Number22
Section 3 -Rigging, Handling and Storage26
Delivery and Storage26
Inspection26
Lifting Weights26
Moving the Chiller27
Unit Rigging28
Section 4 - Installation29
Location Requirements29
Outdoor Installation29
Indoor Installation29
Location Clearances30
Vibration Isolators30
Installation30
Shipping Braces30
Chilled Liquid Piping30
General Requirements30
Water Treatment32
Pipework Arrangements32
Connection Types & Sizes32
Cooler Connections32
Option Flanges32
Fig 3 - Pipework Arrangement32
Fig 4 - Victaulic Groove32
Fig 5 - Flange Attachment32
Refrigerant Relief Valve Piping33
Ductwork Connection33
General Requirements33
Electrical Connection33
Power Wiring34
Power Supply Wiring34
Control Panel Wiring34
Volts Free Contacts35
Chilled Liquid Pump Starter35
Run Contact35
Alarm Contact35
System Inputs35
Flow Switch35
Remote Run/Stop35
Remote Print35
Optional Remote Setpoint Offset Temp35
Optional Remote Setpoint Offset Current35
Section 5 - Commissioning36
Preparation36
Preparation - General36
Inspection36
Refrigerant Charge36
Service and Oil Line Valves36
Compressor Oil36
Fans36
Isolation / Protection36
Control Panel36
Power Connections37
Grounding37
Water System37
Flow Switch37
Temperature Sensor(S)37
Programmed Options37
Programmed Settings37
Date & Time37
Start / Stop37
Setpoint & Remote Offset37
Interlocks38
Unit Switch38
Start-Up38
Oil Pressure38
Refrigerant Flow38
Loading38
Suction Superheat38
Subcooling38
Condensor & Fan Rotation39
General Operation39
Section 6 - Technical Data40
Water Pressure Drop Charts40
Glycol Correction Factors41
Water Temp. and Flows42
Physical Data44
Operating Limitations and46
Sound Power46
Electrical Data - Compr. Wiring47
Fig 6 - Single Point Power Supply Connection47
W/Circuit Breaker Protection (3 Compr)47
Fig 7 - Single Point Power Supply Connection47
W/Terminal Block (3 Compr)47
Fig 8 - Single Point Power Supply Connection48
W/Circuit Breaker Protection (4 Compr)48
Fig 9 - Single Point Power Supply Connection48
W/Terminal Block (4 Compr)48
Fig 10 - Multi-Point Power Supply Connection49
W/Circuit Breaker Protection (4 Compr)49
Fig 11 - Multi-Point Power Supply Connection49
W/Terminal Block (4 Compr)49
Electrical Notes54
Wiring Diagrams - 3 Compressor56
Wiring Diagrams - 4 Compressor68
Dimensions84
Technical Data (Clearances)116
Weight Distribution & Isolator Mounting117
Fig 12 - Sample Printout Supplied in the Isolator117
Package & Chiller Panel Literature Packet117
Isolator Mounting Positions118
Seismic Isolator Installation123
Neoprene Isolator Position124
Refrigerant Flow Diagram127
Fig 13 - Refrigerant Flow Diagram127
Diagram128
Fig 14 - Processes and Instrumentation128
Component Locations129
Fig 15 - Component Locations129
Fig 16 - Control and VSD Cabinet Locations130
Fig 17 - Chiller Control Board, Relay Boards131
Microgateway, and Optional Circuit Breaker131
Microgateway131
Fig 19 - VSD Logic Board133
Fig 20 - VSD Logic Board134
Fig 21 - Power Components135
Fig 22 - Power Components136
Fig 23 - Fan Contactors137
Fig 24 - VSD Components138
Fig 25 - VSD Components139
Fig 26 - VSD Components140
Fig 27 - VSD Components141
Fig 28 - Inverter Power Components142
Fig 29 - Inverter Power Components143
Fig 30 - Inverter Power Components144
Fig 31 - Inverter Power Components144
Fig 32 - Glycol Pump & Fill Tube Locations145
Fig 33 - Glycol Piping & Fill Tube Locations146
Fig 34 - Compressor Components147
Equipment Start-Up Check Sheet148
Unit Checks (no Power)148
Panel Checks150
(Power ON-Both System Switches OFF)150
Programmed Values151
Chilled Liquid Setpoint151
Date/Time, Daily Schedule, & Clock Jumper151
Initial Start-Up152
Check Subcooling & Superheat152
Leak Checking153
Chiller Electronic Components154
Keypad154
Display155
Chiller Control Board156
Relay Output Boards157
VSD (Variable Speed Drive)157
AC to DC Rectifier157
SCR Trigger Board158
DC Link Filter158
1L Line Inductor159
AC to DC Inverter159
Laminated Bus Structure159
VSD Logic Board160
Control Panel to VSD Communications160
IGBT Gate Driver Boards161
Current Transformers161
DV/DT Output Suppression Network162
Flash Tank Feed/Drain Valve Controller162
DC Bus Voltage Isolation Board163
Chiller Circuit Breaker163
Autotransformer163
Chiller Configuration Jumpers164
Number of Compr. Configuration Jumpers164
Vsd Logic to Chiller Microprocessor Board Rs-485 Communication Configuration Jumpers164
Table 1 - Compressors and the Appropriate Jumper164
Positions164
Table 2 - VSD Logic Board Address Jumper164
Max Vsd Frequency165
Table 3 - Maximum Frequency Jumper165
Section 7 - Operation166
Operating Controls166
Basic Operating Sequence168
Fig 35 - Chiller Control (Cooling) Range168
Number of Compressors to Start169
General169
Standard IPLV169
Optional Optimized IPLV169
Fig 36 - Number of Compressors to Start169
Minimum Vsd Compressor Start/Stop Frequency170
Minimum VSD Start Frequency170
Minimum VSD Run Frequency170
Fig 37 - Minimum VSD Start Frequency170
Fig 38 - Minimum VSD Run170
Acceleration/Deceleration Rate171
Compressors171
VSD Acceleration/ Deceleration Rates171
Standard Iplv Capacity Control172
Fuzzy Logic Control173
Hot Water Starts174
Lag Compressor Operation in Load Limiting174
Table 4 - Fuzzy Logic Loading/Unloading Vs. Error174
Optional Iplv Capacity Control175
Fuzzy Logic176
Hot Water Starts177
Table 5 - Fuzzy Logic Loading/Unloading Vs. Error177
Load Limiting Control178
Table 6 - Current Load Limiting/Unloading178
Table 7 - Discharge Pressure Load Limiting178
Unloading178
Table 8 - Suction Pressure Load Limiting179
Unloading179
Table 9 - VSD Internal Ambient Load Limiting179
Table 10 - VSD Baseplate Temperature Load180
Limiting/Unloading180
Controller181
Valve Controller & Control Algorithm181
Fig 39 - LED Locations182
Fig 40 - Power, Comms Led's183
Led's183
Economizer Control184
Condenser Fan Control184
Table 11 - Fan Stages & Corresponding Outputs185
Fig 42 - Standard IPLV Fan Control186
Vsd Temperature Control/Fan Control Operation187
Fig 43 - High IPLV Fan Control187
Remote Temperature Reset Control 1 8188
Local Current Limit Control189
Pulldown Current Limit Setpoint189
Remote Current Limit Reset190
Sound Limit Controls192
Vsd Operation & Controls194
VSD Cooling and Cooling Loop196
Table 12 - VSD Operating Display Parameters199
Vsd Safeties200
IGBT Gate Driver (Hardware) Fault203
Power Supply (Hardware) Fault205
Unit Warnings208
Unit Safeties212
System Safeties214
Table 13 - Low Differential Oil Pressure Cutout216
Table 14 - Start Inhibit Sensor Thresholds218
Status Key220
Unit Data Key224
System Data Key226
Table 15 - Sensor Min/Max Outputs228
Vsd Data Key230
Operating Hours & Start Keys232
History Key233
Unit Data234
VSD Data235
System Data236
Compressor Operating Hours & Starts238
Chilled Liquid & Cooling Setpoints238
Options238
Program Values239
Setpoints Key241
Table 16 - Setpoint Limits242
Program Key243
Table 17 - Programmable Operating Parameters245
Options Key246
Date/Time & Schedule Key250
Date/Time Key250
Schedule Key251
Unit Operating Schedule252
Sound Limit Schedule253
Manual Override Key254
Print Key255
Table 18 - Printout Types255
Operating Data Printout256
History Data Printout257
Service Key258
System Switches Key264
Serial Number Programming265
Enabling Optimized High Iplv Mode267
Unit Setup Mode268
Table 19 - Unit Setup Programmable Values268
Default Programmable Values270
Serial Port Connections271
Table 20 - Serial Port Connections271
Analog Input Connections272
Table 21 - Analog Input Connections272
Digital Input Connections274
Table 22 - Digital Input Connections274
Analog Output Connections276
Table 23 - Analog Output Connections276
Digital Output Connections278
Table 24 - Digital Output Connections278
Isn Communications280
Transmitted Data280
Control Data280
Table 26 - DXST/ISN Transmitted Data281
Table 27 - Fault Inhibit Codes285
Table 28 - Operational Status Codes287
R-134A Conversion Tables288
Table 29 - R-134A Pressure to Saturated288
Temperature Conversion288
Maintenance289
General Requirements289
Maintenance Requirements290
Troubleshooting Guide292
Evacuating a System294
Warranty Policy295
New Equipment295
Reconditioned or Replacement Materials295
All Warranties Are VIOD if295
Chilled Liquid & Suction Temp Sensor Input Voltage Table296
Table 30 - Temperature Input Voltage Sensor296
Outside Air Temp Sensor Input Voltage Table297
Pressure Transducer Output Voltage Table297
Table 31 - Outside Air Temperature Input Voltage297
Table 32 - Pressure Transducer Input Voltage298
Motor Temperature Sensor Resistance Table299
Compressor Motor Overload Settings & Maximum Vsd Frequency300
Table 34 - Compressor Motor Overload Settings300
Max. VSD Frequency300
Printer Wiring301
Fig 44 - Print Cable Chiller to Serial Printer301
Okidata 184302
Weigh-Tronix IMP Model 2600302
Seiko302
Operating Log303
Site and Chiller Info303
Programmed Values303
Currents304
System Operating Conditions305
Water System Conditions306
Condensor Conditions306
Recommended Spare Parts307

York YCAV1039 - User Manual

Table of Contents

York YCAV1039 Specifications

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Brand	York
Model	YCAV1039
Category	Chiller
Language	English