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York YCWL0056SE User Manual

York YCWL0056SE
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YCWL0056 - 0198
WATER-COOLED LIQUID CHILLERS
STYLE A (60 HZ)
50 - 200 TONS
175KW THROUGH 700KW
INSTALLATION, OPERATION, MAINTENANCE
WATER-COOLED LIQUID CHILLERS
HERMETIC SCROLL
Supersedes: 201.26-NM1 (617)
Form 201.26-NM1 (118)
035-21965-101
R410A
Products are produced at a
f a c ilit y whose q u a l ity-
management sys tems are
ISO9001 certified.
Issue Date:
January 19, 2018

Table of Contents

Questions and Answers:

York YCWL0056SE Specifications

General IconGeneral
BrandYork
ModelYCWL0056SE
CategoryChiller
LanguageEnglish

Summary

SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

INTRODUCTION

Overview of YORK YCWL chillers and manual usage instructions.

WARRANTY

Covers equipment and materials defects, limitations, and conditions for warranty coverage.

SAFETY

Standards for safety, including ASHRAE, NEC, and OSHA compliance, and personnel responsibility.

MISUSE OF EQUIPMENT

Guidelines on proper and improper use of the equipment to prevent injury or damage.

SECTION 2 – PRODUCT DESCRIPTION

INTRODUCTION

Overview of YORK YCWL water-cooled liquid chillers.

COMPRESSORS

Details on suction-gas cooled hermetic scroll compressors used in the unit.

REFRIGERANT CIRCUITS

Description of the two independent refrigerant circuits and their components.

EVAPORATOR

Details of the dual-circuit, direct-expansion evaporator design.

CONDENSER

Description of the dual refrigerant circuit water-cooled condenser.

MICROPROCESSOR CONTROL CENTER

Features of the control center, including display, keypad, and functions.

SECTION 3 – TRANSPORTATION, HANDLING AND STORAGE

DELIVERY AND STORAGE

Precautions for unit delivery and storage conditions to ensure quality.

INSPECTION

Procedures for inspecting units upon receiving for transit damage.

MOVING THE UNIT

Guidelines for site suitability and lifting methods, including weights.

SECTION 4 – INSTALLATION

INSTALLATION CHECKLIST

Items to check before placing units in operation.

LOCATION REQUIREMENTS

Site requirements for optimal performance and service access.

UNIT ISOLATION (NOISE SENSITIVE LOCATION)

Recommendations for installations near noise-sensitive areas.

FOUNDATION

Requirements for unit foundation and base frame support.

PIPEWORK CONNECTION

Recommendations for piping to ensure satisfactory operation and avoid damage.

WATER TREATMENT

Guidelines for water treatment to maintain heat exchanger performance and prevent damage.

GLYCOL SOLUTIONS

Recommendations for using glycol solutions for freeze protection below 40°F.

OPTION FLANGES

Describes types of flanges available for customer or local code requirements.

REFRIGERANT RELIEF VALVE PIPING

Recommendations for piping relief valves to the exterior for safety.

ELECTRICAL CONNECTION

Recommendations for safe and satisfactory unit electrical connections.

Flow Switch (SF)

Connection of flow switch for protection against loss of liquid flow.

SECTION 5 – TECHNICAL DATA

OPERATIONAL LIMITATIONS

Specifies temperature and flow limits for unit operation.

VOLTAGE LIMITATIONS

Absolute voltage limits to prevent compressor damage.

EVAPORATOR PRESSURE DROP CHARTS

Graphical data for evaporator pressure drop based on water flow.

CONDENSER PRESSURE DROP CHARTS

Graphical data for condenser pressure drop based on water flow.

ETHYLENE AND PROPOLYNE GLYCOL CORRECTION FACTORS

Factors for pressure drop adjustments when using glycol solutions.

PHYSICAL DATA - STANDARD AND HIGH EFFICIENCY

Table of physical specifications for different models.

SINGLE POINT ELECTRICAL DATA

Electrical parameters for single-point power supply, including MCA, fuses, and lugs.

DUAL POINT ELECTRICAL DATA

Electrical parameters for dual-point power supply, including MCA, fuses, and lugs.

ELECTRICAL DATA

General electrical data including micro panel power and voltage ranges.

ELECTRICAL NOTES AND LEGEND

Explanations of electrical terms, notes, and legends.

GROUND WIRE SIZING

Tables for sizing ground wire based on disconnect switch or circuit breaker options.

SECTION 6 – COMMISSIONING

PREPARATION – POWER OFF

Initial checks before applying power to the unit.

PREPARATION – POWER ON

Steps to follow after applying power for startup checks.

WATER SYSTEM

Verification of chilled liquid system installation and flow.

FLOW SWITCH

Checking flow switch installation and wiring for safety.

TEMPERATURE SENSOR(S)

Ensuring proper installation and coating of leaving liquid temperature sensor.

UNIT OPERATING SEQUENCE

Description of the chiller's operating sequence and compressor staging.

SECTION 7 – UNIT CONTROLS

INTRODUCTION

Overview of the microprocessor control center and its components.

IPU II and I/O BOARDS

Description of the controller and I/O board functions.

DISPLAY

Details of the 40-character Liquid Crystal Display.

KEYPAD

Functionality of the 12-button non-tactile keypad.

BATTERY BACK-UP

Purpose and function of the Real Time Clock battery backup.

TRANSFORMER

Role of the transformer in supplying power to the control center.

SINGLE SYSTEM SELECT AND PROGRAMMING # OF COMPRESSORS

Configuration for single/dual systems and compressor programming.

STATUS KEY

Explanation of status messages displayed on the control panel.

UNIT STATUS

Displays current chiller operating status messages.

GENERAL STATUS MESSAGES

Messages indicating system status, cooling demand, or faults.

FAULT SAFETY STATUS MESSAGES

Displays when safety thresholds are exceeded, causing system shutdown.

SYSTEM SAFETIES

Faults that cause individual systems to shut down.

UNIT SAFETIES

Faults that cause all running compressors to shut down.

DISPLAY/PRINT KEYS

How to use keys to retrieve and print system data.

OPER DATA KEY

Accessing and scrolling through unit operating parameters.

HISTORY DISPLAYS

Accessing and interpreting safety shutdown history.

ENTRY KEYS

Using keys for viewing and changing programmed values.

SETPOINTS KEYS

Navigating and programming cooling setpoints and ranges.

COOLING SETPOINTS

Procedures for setting cooling setpoints and ranges.

LEAVING CHILLED LIQUID CONTROL

Regulating leaving chilled liquid temperature based on setpoint and range.

RETURN CHILLED LIQUID CONTROL

Staging compressors based on return chilled liquid temperature.

REMOTE SETPOINT CONTROL

Displaying remote setpoint and cooling range for unit control.

SCHEDULE/ADVANCE DAY KEY

Programming a seven-day daily schedule and holiday settings.

PROGRAM KEY

Changing programmable operating parameters.

SYSTEM TRIP VOLTS

Programming trip voltages for high current protection.

UNIT TRIP VOLTS

Programming trip voltages for unit high current protection.

UNIT KEYS

Navigating and selecting programmable options.

OPTION 1 – LANGUAGE

Setting the display language for the control interface.

OPTION 4 – CHILLED LIQUID COOLING TYPE

Selecting between water or glycol for chilled liquid cooling.

OPTION 6 – LOCAL/REMOTE CONTROL TYPE

Selecting local or remote control mode for the chiller.

OPTION 9 – LEAD/LAG TYPE (TWO SYSTEM UNITS ONLY)

Configuring automatic or manual lead/lag for systems.

OPTION 12 – CURRENT FEEDBACK OPTIONS INSTALLED

Selecting current sensing method (None, One Per Unit, One Per System).

OPTION 18 – FLASH CARD UPDATE

Procedure for updating chiller operating program via flash card.

CLOCK

Setting and displaying current day, time, and date for scheduling.

SECTION 8 – UNIT OPERATION

CAPACITY CONTROL

Initiation of chiller start sequence and capacity control functions.

SUCTION PRESSURE LIMIT CONTROLS

Controls to prevent reaching low-pressure cutout by limiting loading.

DISCHARGE PRESSURE LIMIT CONTROLS

Controls to unload system before reaching high-pressure safety limits.

LEAVING CHILLED LIQUID CONTROL

Regulating leaving chilled liquid temperature based on setpoint and range.

LEAVING WATER TEMPERATURE CONTROL EXAMPLE

Example illustrating staging based on leaving water temperature.

LEAVING CHILLED LIQUID CONTROL OVERRIDE TO REDUCE CYCLING

Temporary setpoint adjustment to reduce compressor cycling.

LEAVING CHILLED LIQUID SYSTEM LEAD/LAG AND COMPRESSOR SEQUENCING

Strategies for lead/lag and sequencing compressors to equalize run hours.

RETURN CHILLED LIQUID CONTROL

Staging compressors to match cooling load based on return liquid temperature.

ANTI-RECYCLE TIMER

Timer to prevent short cycling and ensure compressor heat dissipation.

ANTI-COINCIDENCE TIMER

Timer to prevent simultaneous starts and excessively high starting current.

EVAPORATOR PUMP CONTROL AND YORK HYDRO KIT PUMP CONTROL

Control of evaporator and hydro kit pumps based on various conditions.

EVAPORATOR HEATER CONTROL

Control of the evaporator heater based on ambient air temperature.

PUMPDOWN CONTROL

Process for pumping down the system upon shutdown.

LOAD LIMITING

Feature to prevent loading beyond desired value by limiting compressor operation.

SECTION 9 – SERVICE AND TROUBLESHOOTING

CLEARING HISTORY BUFFERS

Procedure to clear history buffers, with a caution note.

SERVICE MODE

Steps to enter service mode and manage outputs, configuration, and inputs/outputs.

SERVICE MODE – OUTPUTS

Viewing and modifying digital outputs in service mode.

SERVICE MODE – CHILLER CONFIGURATION

Programming chiller configuration parameters like refrigerant type and valve type.

SERVICE MODE – ANALOG AND DIGITAL INPUTS

Viewing analog and digital inputs to the microboard.

CHECKING INPUTS AND OUTPUTS

Procedures for checking digital inputs and analog temperature/pressure inputs.

DIGITAL INPUTS

Checking ON/OFF status of digital inputs connected to the I/O board.

ANALOG INPUTS – TEMPERATURE

Checking analog inputs representing varying temperatures.

ANALOG INPUTS – PRESSURE

Checking analog inputs representing varying pressures.

MICROBOARD LAYOUT

Diagram showing connections and components on the microboard.

TROUBLESHOOTING

Table of common problems, causes, and solutions.

SECTION 10 – MAINTENANCE

COMPRESSORS

Procedures for checking oil level and performing oil analysis for compressor health.

OPERATING PARAMETERS

Importance of checking system operating temperatures and pressures.

ON-BOARD BATTERY BACK-UP

Function of the Real Time Clock chip and battery backup.

OVERALL UNIT INSPECTION

Periodic inspections for proper equipment operation and anomaly detection.

BACNET AND MODBUS DATA COMMUNICATIONS

Reading and modifying chiller data via serial communication protocols.

ANALOG WRITE POINTS

Reading and modifying analog data points for BACnet/Modbus.

BINARY WRITE POINTS

Reading and modifying binary data points for BACnet/Modbus.

ANALOG READ ONLY POINTS

Reading analog data points that cannot be modified.

BINARY MONITOR ONLY POINTS

Reading binary data points that cannot be modified.

COMMUNICATIONS DATA MAP NOTES:

Notes regarding BACnet and Modbus communication data maps.

YORKTALK 2 COMMUNICATIONS

Procedures for receiving control data and transmitting operational/history data.

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