York Ycal0014Sc Users Manual Form 150.62 NM1 (700), Millennium Air Cooled Liquid Chillers Hermetic Scroll, Installation, Operation, Maintenance
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2015-02-02
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MILLENNIUM ® AIR-COOLED LIQUID CHILLERS HERMETIC SCROLL INSTALLATION, OPERATION, MAINT. Supersedes: 150.62-NM1 (899) Form 150.62-NM1 (700) YCAL0014SC - YCAL0080SC 29224(R)A 200-3-60 230-3-60 380-3-60 460-3-60 575-3-60 MODELS ONLY Standard, Glycol & Metric Models, Combined IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. During installation, operation, maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, oils, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if mis-used or handled improperly, to cause bodily injury or death. It is the obligation and responsibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated, as well as severe personal injury or death to themselves and people at the site. This document is intended for use by owner-authorized operating/service personnel. It is expected that this individual possesses independent training that will enable them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood this document and any referenced materials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question. SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard: DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. 2 YORK INTERNATIONAL FORM 150.62-NM1 CAUTION identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation. NOTE is used to highlight additional information which may be helpful to you. CHANGEABILITY OF THIS DOCUMENT In complying with YORK’s policy for continuous product improvement, the information contained in this document is subject to change without notice. While YORK makes no commitment to update or provide current information automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest YORK Engineered Systems Service office. It is the responsibility of operating/service personnel to verify the applicability of these documents to the equipment in question. If there is any question in the mind of operating/service personnel as to the applicability of these documents, then prior to working on the equipment, they should verify with the owner whether the equipment has been modified and if current literature is available. YORK INTERNATIONAL 3 TABLE OF CONTENTS AND TABLES PAGE PRODUCT IDENTIFICATION NUMBER .......................................................... 7 REFRIGERANT FLOW DIAGRAM ................................................................... 9 SECTION 1 INSTALLATION .......................................................................... 10 ELECTRICAL DATA ....................................................................................... 20 OPERATIONAL LIMITATIONS ....................................................................... 30 PHYSICAL DATA ............................................................................................ 34 DIMENSIONS & CLEARANCES .................................................................... 38 PRE-STARTUP CHECKLIST ......................................................................... 54 INITIAL STARTUP .......................................................................................... 55 UNIT OPERATING SEQUENCE .................................................................... 57 SECTION 2 UNIT CONTROLS ...................................................................... 58 STATUS KEY .................................................................................................. 60 DISPLAY/PRINT KEYS .................................................................................. 66 ENTRY KEYS ................................................................................................. 73 SETPOINTS KEY ........................................................................................... 74 UNIT KEYS .................................................................................................... 81 UNIT OPERATION ......................................................................................... 85 SECTION 3 SERVICE AND TROUBLESHOOTING ...................................... 95 OPTIONAL PRINTER INSTALLATION ......................................................... 104 TROUBLESHOOTING CHARTS .................................................................. 105 MAINTENANCE ........................................................................................... 108 ISN CONTROL ............................................................................................. 109 SECTION 4 WIRING DIAGRAMS ............................................................... 112 SECTION 5 APPENDIX 1 – ISOLATORS .................................................... 128 YORK APPLIED SYSTEMS FIELD OFFICE LISTING ................................. 134 TABLES 4 1 MICROPANEL POWER SUPPLY ............................................................ 20 2 STANDARD SINGLE POINT POWER ..................................................... 21 3 STANDARD DUAL POINT POWER ................................................ 22 – 23 4 OPTIONAL SINGLE POINT POWER .............................................. 24 – 25 5 OPTIONAL SINGLE POINT POWER .............................................. 26 – 27 6 OPTIONAL SINGLE POINT POWER .............................................. 28 – 29 7 TEMPERATURES AND FLOWS (ENGLISH) .......................................... 30 8 VOLTAGE LIMITATIONS (ENGLISH) ....................................................... 30 9 COOLER PRESSURE DROPS (ENGLISH) ............................................. 31 10 ETHYLENE GLYCOL CORRECTION FACTORS .................................... 31 11 TEMPERATURES AND FLOWS (METRIC) ............................................ 32 12 VOLTAGE LIMITATIONS (METRIC) ........................................................ 32 YORK INTERNATIONAL FORM 150.62-NM1 TABLES AND FIGURES PAGE TABLES 13 COOLER PRESSURE DROPS (METRIC)............................................. 33 14 ETHYLENE GLYCOL CORRECTION FACTORS .................................. 33 15 PHYSICAL DATA (ENGLISH) ........................................................ 34 – 35 16 PHYSICAL DATA (METRIC) .......................................................... 36 – 37 17 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (ENGLISH) ............. 39 18 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (ENGLISH) ............. 41 19 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (ENGLISH) ............. 43 20 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (ENGLISH) ............. 45 21 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (METRIC) ............... 47 22 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (METRIC) ............... 49 23 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (METRIC) ............... 51 24 WEIGHT DISTRIBUTION/CENTER OF GRAVITY (METRIC) ............... 53 25 SETPOINT ENTRY LIST ....................................................................... 54 26 STATUS KEY MESSAGES .................................................................... 65 27 OPERATOR DATA QUICK REFERENCE .............................................. 69 28 COOLING SETPOINTS PROGRAMMABLE LIMITS & DEFAULTS ....... 76 29 PROGRAM KEY LIMITS & DEFAULTS ................................................. 79 30 SETPOINTS KEY QUICK REFERENCE ............................................... 80 31 UNIT KEYS QUICK REFERENCE ......................................................... 84 32 LEAVING CHILLED LIQUID CONTROL – 6 COMPRESSORS ............. 86 33 LEAVING CHILLED LIQUID CONTROL – 4 COMPRESSORS ............. 86 34 LEAVING CHILLED LIQUID CONTROL – 3 COMPRESSORS ............. 87 35 LEAVING CHILLED LIQUID CONTROL – 2 COMPRESSORS ............. 87 36 COMPRESSOR STAGING FOR RETURN WATER CONTROL ............ 89 37 RETURN CHILLED LIQUID CONTROL – 6 COMPRESSORS .............. 89 38 RETURN CHILLED LIQUID CONTROL – 4 COMPRESSORS .............. 89 39 CONDENSER FAN CONTROL USING OUTDOOR AMBIENT TEMPERATURE AND DISCHARGE ..................................................... 90 40 CONDENSER FAN CONTROL USING DISCHARGE ONLY ................. 90 41 LOW AMBIENT CONDENSER FAN CONTROL – AMBIENT TEMPERATURE AND DISCHARGE PRESSURE CONTROL ............. 91 42 LOW AMBIENT CONDENSER FAN CONTROL – DISCHARGE PRESSURE CONTROL ....................................................................... 91 43 COMPRESSOR OPERATION – LOAD LIMITING ................................. 92 44 MICROBOARD BINARY INPUTS .......................................................... 97 45 MICROBOARD ANALOG INPUTS ........................................................ 97 46 MICROBOARD OUTPUTS .................................................................... 97 47 OUTDOOR AIR SENSOR VALUES ....................................................... 99 YORK INTERNATIONAL 5 TABLES/FIGURES PAGE TABLES 48 ENTERING & LEAVING CHILLED LIQUID TEMPERATURE SENSOR VALUES ............................................................................ 100 49 KEYPAD PIN ASSIGNMENT MATRIX ................................................. 103 50 TROUBLESHOOTING CHARTS ............................................... 105 – 107 51 ISN RECEIVED DATA .......................................................................... 109 52 ISN TRANSMITTED DATA .................................................................. 109 53 ISN TRANSMITTED DATA .................................................................. 110 54 ISN OPERATIONAL & FAULT CODES ................................................. 111 FIGURES 1 REFRIGERANT FLOW DIAGRAM .......................................................... 9 2 STANDARD POWER SUPPLY WIRING ................................................ 14 3 OPTIONAL SINGLE POINT POWER SUPPLY WIRING ....................... 15 4 OPTIONAL SINGLE POINT POWER SUPPLY WIRING – N-F DISC SW OR CIRC BKR ............................................................. 16 5 CONTROL WIRING .............................................................................. 17 6 LEAVING WATER TEMPERATURE CONTROL – COMPRESSOR STAGING .................................................................. 86 7 FIELD & FACTORY ELECTRICAL CONNECTIONS – REMOTE TEMPERATURE RESET BOARD ....................................... 94 6 8 MICROBOARD LAYOUT ....................................................................... 98 9 MICROBOARD RELAY CONTACTS ARCHITECTURE ....................... 103 10 PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS ........... 104 11 ELEMENTARY DIAGRAM ................................................................... 112 12 ELEMENTARY DIAGRAM – POWER CIRCUIT .................................. 114 13 ELEMENTARY DIAGRAM ................................................................... 116 14 ELEMENTARY DIAGRAM – POWER CIRCUIT .................................. 118 15 ELEMENTARY DIAGRAM ................................................................... 120 16 ELEMENTARY DIAGRAM – POWER CIRCUIT .................................. 122 17 ELEMENTARY DIAGRAM ................................................................... 124 18 ELEMENTARY DIAGRAM – POWER CIRCUIT .................................. 126 19 TYPE CP 1 ........................................................................................... 130 20 TYPE CP 2 ........................................................................................... 130 21 R SPRING SEISMIC ISOLATOR ......................................................... 131 22 TYPE CP MOUNTING ......................................................................... 132 23 “AEQM” SPRING-FLEX MOUNTING ................................................... 133 YORK INTERNATIONAL FORM 150.62-NM1 PRODUCT IDENTIFICATION NUMBER (PIN) EXAMPLES: 1 2 3 4 5 6 7 8 9 Y C A S 1 3 8 5 E 10 11 12 13 14 15 A 5 0 Y F A Y C A L 0 0 8 0 S C 4 6 X A A BASIC MODEL NUMBER YCAL0080SC46xAA 1 2 3 4 BASE PRODUCT TYPE Y C A U 5 6 7 8 NOMINAL CAPACITY 9 UNIT DESIGNATOR 0 # # # S : Standard Unit : YORK 1 # # # : Chiller : Air-Cooled Even Number: 60 HZ Nominal Tons : Condensing Odd Number: 50 HZ Nominal kW Unit L : Scroll YORK INTERNATIONAL 10 REFRIGERANT C : R-22 11 12 13 14 15 VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL 1 2 4 4 5 5 7 8 0 6 0 8 : 200 / 3/ 60 A : 230 / 3 / 60 : 380 / 3 / 60 : 460 / 3 / 60 : 380-415 / 3 / 50 : 575 / 3 / 60 X : Across the Line : Design Series A A : Engineering Change or PIN Level 7 OPTIONS MODEL NUMBER X S X 2 X 5 X C X X X 1 X X X X X X X X X 3 X D X W X S X A A R X X X B X X X X X 4 X B X X X X X L X X X S X D X : Low Sound Fans NOTES: 1. Q :DENOTES SPECIAL / S.Q. 2. # :DENOTES STANDARD 3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED 4. Agency Files (i.e. U.L. / E.T.L.; C.E.; ARI; ETC.) will contain info. based on the first 14 characters only. PRODUCT IDENTIFICATION NUMBER (PIN) R E :Hot Gas By-Pass (# circuits) :Compressor External Overload 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 P X 1 55 EXTENDED FIELD YORK INTERNATIONAL X :Leaving Supply Temp. :Chicago Relief Code C 1 : 1" Deflection S : Seismic N : Neoprene Pads X : 1st Year Parts Only B : 1st Year Parts & Labor C : 2nd Year Parts Only D : 2nd Year Parts & Labor E : 5 Year Compressor Parts Only F : 5 Year Compressor Parts & Labor Only G : 5 Year Units Parts Only H : 5 Year Unit Parts & Labor X L L B L R # : Wire Condenser Headers Only (factory) : Wire (Full Unit) Enc. Panels (factory) : Wire (Full Unit) Enc. Panels (field) : Wire/Louvered Enc. Panels (factory) : Wire/Louvered Enc. Panels (field) : Louvered (Cond. Only) Enc. Panels (factory) : Louvered (Cond. Only) Enc. Panels (field) : Louvered (Full Unit) Enc. Panels (factory) : Louvered (Full Unit) Enc. Panels (field) : Acoustic Sound Blanket x 1 2 3 4 5 6 7 8 X A : Aluminum : Copper : Black Fin : Phenolic X : TEAO Fan Motors R S X C B P S W V : 300 PSIG DWP Waterside : Double Thick Insulation : Weld Flange Kit : Victaulic Flange Kit : Flow Switch : ASME Pressure Vessel & Associated Codes : Remote DX Cooler CABINET FIELD X D 48 49 50 51 52 53 54 T 3 45 46 47 CONDENSER FIELD X EVAP. FIELD R A 38 39 40 41 42 43 44 L N C X MP = Multiple Point SP = Single Point NF = Non-Fused TB = Terminal Block Ser. = Service Ind. Sys. Brkr. & L. Ext. Handles = Individual System Breaker & Lockable External Handle X R S B C : Control Transformer (factory) C : Power Factor Capacitor T S F G I X T # : Low Ambient Kit (factory) : High Ambient Kit (factory) : Both Low / High Ambient (factory) : BAS/EMS Temp. Reset / Offset : Spanish LCD & Keypad Display : French LCD & Keypad Display : German LCD & Keypad Display : Discharge Pressure Transducers/ Readout Kit : Suction Pressure Transducers / Readout Kit : Both Discharge & Suction Pressure Transducers / Readout : N. American Safety Code (cU.L./cE.T.L.) : No Listing (typically 50 HZ non-C.E., non-U.L. : Remote Control Panel S : Sequence Control & Automatic Lead Transfer X T L H A D : SP Supply TB : MP Supply TB : SP Supply TB : SP NF Disconnect Switch : SP Circuit Breaker w/ Lockable Handle X X X D X 29 30 31 32 33 34 35 36 37 COMPRESSOR / PIPING FIELD X X X S S B CONTROLS FIELD S 20 21 22 23 24 25 26 27 28 POWER FIELD EXAMPLES: 8 16 17 18 19 FORM 150.62-NM1 REFRIGERANT FLOW DIAGRAM AIR COOLED CONDENSERS YCAL REFRIGERANT FLOW DIAGRAM (INCLUDING TEMPERATURE SENSORS & PRESSURE TRANSDUCERS) NOTE: YCAL0040-0080 HAVE TWO REFRIGERANT SYSTEMS AND ONE DX COOLER. * HOT GAS OPTION - SYSTEM 1 ONLY SIGHT GLASS / MOISTURE INDICATOR LIQUID LINE FILTER / DRIER LIQUID LINE SERVICE VALVE LIQUID LINE SOLENOID VALVE HOT DISCHARGE GAS LINE DISCHARGE LINE BALL VALVE * SOLENOID OPERATED HOT GAS BY PASS VALVE OPTIONAL DISCHARGE PRESSURE TRANSDUCER TXV EQUALIZER LINE SERVICE VALVE HIGH PRESSURE CUTOUT SWITCH SUCTION LINE BALL VALVE RELIEF VALVE 300 PSIG (20.68 BARG) SERVICE VALVE DX COOLER LOW PRESSURE SWITCH OR SUCTION PRESSURE TRANSDUCER RETURN WATER TEMP. SENSOR LEAVING CHILLED WATER LEAVING CHILLED WATER TEMP. SENSOR ENTERING CHILLED WATER OIL EQUALIZING LINE 2 OR 3 COMPRESSORS PER SYSTEM LD03844 FIG. 1 – REFRIGERANT FLOW DIAGRAM YORK INTERNATIONAL 9 Installation INSTALLATION To ensure warranty coverage, this equipment must be commissioned and serviced by an authorized YORK service mechanic or a qualified service person experienced in chiller installation. Installation must comply with all applicable codes, particularly in regard to electrical wiring and other safety elements such as relief valves, HP cut-out settings, design working pressures, and ventilation requirements consistent with the amount and type of refrigerant charge. The unit should be lifted by inserting hooks through the holes provided in unit base rails. Spreader bars should be used to avoid crushing the unit frame rails with the lifting chains. See below. Lethal voltages exist within the control panels. Before servicing, open and tag all disconnect switches. 29224(RIG)A INSPECTION INSTALLATION CHECK LIST The following items, 1 thru 5, must be checked before placing the units in operation. 1. Inspect the unit for shipping damage. 2. Rig unit using spreader bars. 3. Open the unit only to install water piping system. Do not remove protective covers from water connections until piping is ready for attachment. Check water piping to insure cleanliness. 4. Pipe unit using good piping practice (see ASHRAE handbook section 215 and 195. 5. Check to see that the unit is installed and operated within limitations (Refer to LIMITATIONS). The following pages outline detailed procedures to be followed to install and start-up the chiller. HANDLING These units are shipped as completely assembled units containing full operating charge, and care should be taken to avoid damage due to rough handling. 10 Immediately upon receiving the unit, it should be inspected for possible damage which may have occurred during transit. If damage is evident, it should be noted in the carrier’s freight bill. A written request for inspection by the carrier’s agent should be made at once. See “Instruction” manual, Form 50.15-NM for more information and details. LOCATION AND CLEARANCES These units are designed for outdoor installations on ground level, rooftop, or beside a building. Location should be selected for minimum sun exposure and to insure adequate supply of fresh air for the condenser. The units must be installed with sufficient clearances for air entrance to the condenser coil, for air discharge away from the condenser, and for servicing access. In installations where winter operation is intended and snow accumulations are expected, additional height must be provided to insure normal condenser air flow. Clearances are listed under “Notes” in the “DIMENSIONS” section. YORK INTERNATIONAL FORM 150.62-NM1 FOUNDATION SPRING ISOLATORS (OPTIONAL) The unit should be mounted on a flat and level foundation, floor, or rooftop capable of supporting the entire operating weight of the equipment. See PHYSICAL DATA for operating weight. If the unit is elevated beyond the normal reach of service personnel, a suitable catwalk must be capable of supporting service personnel, their equipment, and the compressors. When ordered, four (4) isolators will be furnished. GROUND LEVEL LOCATIONS It is important that the units be installed on a substantial base that will not settle. A one piece concrete slab with footers extended below the frost line is highly recommended. Additionally, the slab should not be tied to the main building foundations as noise and vibration may be transmitted. Mounting holes are provided in the steel channel for bolting the unit to its foundation. (See DIMENSIONS.) For ground level installations, precautions should be taken to protect the unit from tampering by or injury to unauthorized persons. Screws and/or latches on access panels will prevent casual tampering. However, further safety precautions such as a fenced-in enclosure or locking devices on the panels may be advisable. ROOFTOP LOCATIONS Choose a spot with adequate structural strength to safely support the entire weight of the unit and service personnel. Care must be taken not to damage the roof. Consult the building contractor or architect if the roof is bonded. Roof installations should have wooden beams (treated to reduce deterioration), cork, rubber, or vibration isolators under the base to minimize vibration. NOISE SENSITIVE LOCATIONS Efforts should be made to assure that the chiller is not located next to occupied spaces or noise sensitive areas where chiller noise level would be a problem. Chiller noise is a result of compressor and fan operation. Considerations should be made utilizing noise levels published in the YORK Engineering Guide for the specific chiller model. Sound blankets for the compressors and low sound fans are available. YORK INTERNATIONAL Identify the isolator, and locate at the proper mounting point, and adjust per instructions. See Appendix 1. 1 COMPRESSOR MOUNTING The compressors are mounted on four (4) rubber isolators. The mounting bolts should not be loosened or adjusted at installation of the chiller. REMOTE COOLER OPTION For units using remote cooler option, refer to instructions included with miscellaneous cooler parts kit. The unit is shipped with a 6 lb. (2.7 kg) holding charge. The remainder of the charge must be weighed-in according to the operating charge listed under Physical Data. Additional charge must also be added for the refrigerant lines. CHILLED WATER PIPING General – When the unit has been located in its final position, the unit water piping may be connected. Normal installation precautions should be observed in order to receive maximum operating efficiencies. Piping should be kept free of all foreign matter. All chilled water evaporator piping must comply in all respects with local plumbing codes and ordinances. Since elbows, tees and valves decrease pump capacity, all piping should be kept as straight and as simple as possible possible. All piping must be supported independent of the chiller. Consideration should be given to compressor access when laying out water piping. Routing the water piping too close to the unit could make compressor servicing/replacement difficult. 11 Installation Hand stop valves should be installed in all lines to facilitate servicing. Piping to the inlet and outlet connections of the chiller should include high-pressure rubber hose or piping loops to insure against transmission of water pump vibration. The necessary components must be obtained in the field. Drain connections should be provided at all low points to permit complete drainage of the cooler and system water piping. A small valve or valves should be installed at the highest point or points in the chilled water piping to allow any trapped air to be purged. Vent and drain connections should be extended beyond the insulation to make them accessible. ter lines. 6. The chilled water lines that are exposed to outdoor ambients should be wrapped with supplemental heater cable and insulated to protect against freezeup during low ambient periods, and to prevent formation of condensation on lines in warm humid locations. 7. A chilled water flow switch, (either by YORK or others) MUST be installed in the leaving water piping of the cooler. There should be a straight horizontal run of at least 5 diameters on each side of the switch. Adjust the flow switch paddle to the size of the pipe in which it is to be installed. (See manufacturer’s instructions furnished with the switch.) The switch is to be wired to terminals 13 – 14 of CTB1 located in the control panel, as shown on the unit wiring diagram. The piping to and from the cooler must be designed to suit the individual installation. It is important that the following considerations be observed: 1. The chilled liquid piping system should be laid out so that the circulating pump discharges directly into the cooler. The suction for this pump should be taken from the piping system return line and not the cooler. This piping scheme is recommended, but is not mandatory. 2. The inlet and outlet cooler connection sizes are 3" (YCAL0014 - 0030), 4" (YCAL0034 - 0060), or 6" (YCAL0064 - 0080). 3. A strainer, preferably 40 mesh, must be installed in the cooler inlet line just ahead of the cooler. This is important to protect the cooler from entrance of large particles which could cause damage to the evaporator. 4. All chilled liquid piping should be thoroughly flushed to free it from foreign material before the system is placed into operation. Use care not to flush any foreign material into or through the cooler. 5. As an aid to servicing, thermometers and pressure gauges should be installed in the inlet and outlet wa- 12 The Flow Switch MUST NOT be used to start and stop the chiller (i.e. starting and stopping the chilled water pump). It is intended only as a safety switch. WIRING Liquid Chillers are shipped with all factory mounted controls wired for operation. Field Wiring – Power wiring must be provided through a fused disconnect switch to the unit terminals (or optional molded disconnect switch) in accordance with N.E.C. or local code requirements. Minimum circuit ampacity and maximum dual element fuse size are given in the Tables 2 – 6. A 120-1-60, 15 amp source must be supplied for the control panel through a fused disconnect when a control panel transformer (optional) is not provided. Refer to Table 1 and Figures 2 - 4. See Figures 2 - 5 and unit wiring diagrams for field and power wiring connections, chilled water pump starter contacts, alarm contacts, compressor run status contacts, PWM input, and load limit input. Refer to section on UNIT OPERATION for a detailed description of operation concerning aforementioned contacts and inputs. YORK INTERNATIONAL FORM 150.62-NM1 EVAPORATOR PUMP START CONTACTS REMOTE EMERGENCY CUTOFF Terminal block CTB2 - terminals 23 to 24, are normally open contacts that can be used to switch field supplied power to provide a start signal to the evaporator pump contactor. The contacts will be closed when any of the following conditions occur: Immediate shutdown of the chiller can be accomplished by opening a field installed dry contact to break the electrical circuit between terminals 5 to L on terminal block CTB2. The unit is shipped with a factory jumper installed between terminals 5 to L, which must be removed if emergency shutdown contacts are installed. Refer to Figure 5 and unit wiring diagram. 1. Low Leaving Chilled Liquid Fault 2. Any compressor is running. 3. Daily schedule is not programmed OFF and the Unit Switch is ON. PWM INPUT The pump will not run if the micropanel has been powered up for less than 30 seconds, or if the pump has run in the last 30 seconds, to prevent pump motor overheating. Refer to figure 5 and unit wiring diagram. The PWM input allows reset of the chilled liquid setpoint by supplying a “timed” contact closure. Field wiring should be connected to CTB1 - terminals 13 to 20. A detailed explanation is provided in the Unit Control section. Refer to Figure 5 and unit wiring diagram. SYSTEM RUN CONTACTS LOAD LIMIT INPUT Contacts are available to monitor system status. Normally-open auxiliary contacts from each compressor contactor are wired in parallel with CTB2 - terminals 25 to 26 for system 1, and CTB2 - terminals 27 to 28 for system 2 (YCAL0040 - YCAL0080). Refer to Figure 5 and unit wiring diagram. Load limiting is a feature that prevents the unit from loading beyond a desired value. The unit can be “load limited” either 33%, 50%, or 66%, depending on the number of compressors on unit. The field connections are wired to CTB1 - terminals 13 to 21, and work in conjunction with the PWM inputs. A detailed explanation is provided in the Unit Control section. Refer to figure 5 and unit wiring diagram. ALARM STATUS CONTACTS Normally-open contacts are available for each refrigerant system. These normally-open contacts close when the system if functionally normally. The respective contacts will open when the unit is shut down on a unit fault, or locked out on a system fault. Field connections are at CTB2 terminals 29 to 30 (system 1), and terminals 31 to 32 (system 2 YCAL0040 - YCAL0080). When using the Load Limit feature, the PWM feature will not function SIMULTANEOUS OPERATION OF LOAD LIMITING AND TEMPERATURE RESET (PWM INPUT) CANNOT BE DONE. REMOTE START/STOP CONTACTS FLOW SWITCH INPUT To remotely start and stop the chiller, dry contacts can be wired in series with the flow switch and CTB1 - terminals 13 to 14. Refer to Figure 5 and unit wiring diagram. YORK INTERNATIONAL The flow switch is field wired to CTB1 terminals 13 - 14. See Figure 5 and unit wiring diagram. 13 1 Installation STANDARD POWER SUPPLY WIRING – (0014 - 0080) Control Panel Power Panel 2 L GRD 2L3 2L2 2L1 GRD 1L3 1L2 1L1 Circuit # 1 *Circuit # 2 Micropanel Flow Switch CTB2 13 14 CTB1 Field 120-1-60 Micropanel Power Supply if control transformer not supplied Field Unit Power Supply See electrical note 9 LD04483 IT IS POSSIBLE THAT MULTIPLE SOURCES OF POWER CAN BE SUPPLYING THE UNIT POWER PANEL. TO PREVENT SERIOUS INJURY OR DEATH, THE TECHNICIAN SHOULD VERIFY THAT NO LETHAL VOLTAGES ARE PRESENT INSIDE THE PANEL AFTER DISCONNECTING POWER, PRIOR TO WORKING ON EQUIPMENT. THE UNIT EVAPORATOR HEATER USES 120 VAC. DISCONNECTING 120 VAC POWER FROM THE UNIT, AT OR BELOW FREEZING TEMPERATURES, CAN RESULT IN DAMAGE TO THE EVAPORATOR AND UNIT AS A RESULT OF THE CHILLED LIQUID FREEZING. Electrical Notes and Legend located on Page 18 and 19. FIG. 2 – MULTI POINT POWER SUPPLY WIRING 14 YORK INTERNATIONAL FORM 150.62-NM1 OPTIONAL SINGLE POINT POWER SUPPLY WIRING – (0040 - 0080) Control Panel Power Panel 1 2 L 1L3 GRD 1L1 1L2 Micropanel CTB2 Flow Switch 13 14 CTB1 Field 120-1-60 Micropanel Power Supply if control transformer not supplied Field Unit Power Supply See electrical note 9 LD04484 IT IS POSSIBLE THAT MULTIPLE SOURCES OF POWER CAN BE SUPPLYING THE UNIT POWER PANEL. TO PREVENT SERIOUS INJURY OR DEATH, THE TECHNICIAN SHOULD VERIFY THAT NO LETHAL VOLTAGES ARE PRESENT INSIDE THE PANEL AFTER DISCONNECTING POWER, PRIOR TO WORKING ON EQUIPMENT. THE UNIT EVAPORATOR HEATER USES 120 VAC. DISCONNECTING 120 VAC POWER FROM THE UNIT, AT OR BELOW FREEZING TEMPERATURES, CAN RESULT IN DAMAGE TO THE EVAPORATOR AND UNIT AS A RESULT OF THE CHILLED LIQUID FREEZING. Electrical Notes and Legend located on Page 18 and 19. FIG. 3 – OPTIONAL SINGLE POINT POWER SUPPLY WIRING YORK INTERNATIONAL 15 Installation OPTIONAL SINGLE-POINT POWER SUPPLY WIRING N-F DISC SW OR CIRC BKR (0014 - 0080) Control Panel Power Panel 2 L N-F Disconnect Sw. OR Molded Case Circuit Bkr. 1L1 1L2 1L3 GRD Micropanel Flow Switch CTB2 13 14 CTB1 Field 120-1-60 Micropanel Power Supply if control transformer not supplied Field Unit Power Supply See electrical note 9 LD04485 IT IS POSSIBLE THAT MULTIPLE SOURCES OF POWER CAN BE SUPPLYING THE UNIT POWER PANEL. TO PREVENT SERIOUS INJURY OR DEATH, THE TECHNICIAN SHOULD VERIFY THAT NO LETHAL VOLTAGES ARE PRESENT INSIDE THE PANEL AFTER DISCONNECTING POWER, PRIOR TO WORKING ON EQUIPMENT. THE UNIT EVAPORATOR HEATER USES 120 VAC. DISCONNECTING 120 VAC POWER FROM THE UNIT, AT OR BELOW FREEZING TEMPERATURES, CAN RESULT IN DAMAGE TO THE EVAPORATOR AND UNIT AS A RESULT OF THE CHILLED LIQUID FREEZING. Electrical Notes and Legend located on Page 18 and 19. FIG. 4 – OPTIONAL SINGLE POINT POWER WIRING 16 YORK INTERNATIONAL FORM 150.62-NM1 CONTROL WIRING FLOW SW REMOTE START/STOP 13 1 14 13 20 13 PWM INPUT LOAD LIMIT INPUT 21 CTB1 LD03819 * * Factory wired with optional transformer. LD03611 IT IS POSSIBLE THAT MULTIPLE SOURCES OF POWER CAN BE SUPPLYING THE UNIT POWER PANEL. TO PREVENT SERIOUS INJURY OR DEATH, THE TECHNICIAN SHOULD VERIFY THAT NO LETHAL VOLTAGES ARE PRESENT INSIDE THE PANEL AFTER DISCONNECTING POWER, PRIOR TO WORKING ON EQUIPMENT. THE UNIT EVAPORATOR HEATER USES 120 VAC. DISCONNECTING 120 VAC POWER FROM THE UNIT, AT OR BELOW FREEZING TEMPERATURES, CAN RESULT IN DAMAGE TO THE EVAPORATOR AND UNIT AS A RESULT OF THE CHILLED LIQUID FREEZING. FIG. 5 – CONTROL WIRING YORK INTERNATIONAL 17 Installation ELECTRICAL NOTES NOTES: 1. Minimum Circuit Ampacity (MCA) is based on 125% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit, per N.E.C. Article 430-24. If the Factory Mounted Control Transformer is provided, add the following to the system MCA values in the electrical tables for the system supplying power to the optional transformer. -17, add 2.5 amps; -28, add 2.3 amps; -40, add 1.5 amps, 46, add 1.3 amps; -58, add 1 amp. 2. The minimum recommended disconnect switch is based on 115% of the rated load amps for all loads included in the circuit, per N.E.C. Article 440. 3. Minimum fuse size is based upon 150% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit to avoid nuisance trips at start-up due to lock rotor amps. It is not recommended in applications where brown outs, frequent starting and stopping of the unit, and/or operation at ambient temperatures in excess of 95 °F is anticipated. 4. Maximum fuse size is based upon 225% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit, per N.E.C. Article 440-22. 5. Circuit breakers must be U.L. listed and CSA certified and maximum size is based on 225% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit. Exception: YCA0014 and YCAL0020 must have the optional factory overloads installed to use a standard circuit breaker. Otherwise, an HACR-type circuit breakers must be used. Maximum HACR circuit breaker rating is based on 225% of the rated load amps for the largest motor plus 100% of the rated load amps for all other loads included in the circuit. 6. The “INCOMING WIRE RANGE” is the minimum and maximum wire size that can be accommodated by the unit wiring lugs. The (2) preceding the wire range indicates the number of termination points available per phase of the wire range specified. Actual wire size and number of wires per phase must be determined based on the National Electrical Code, using copper connectors only. Field wiring must also comply with local codes. 7. A ground lug is provided for each compressor system to accommodate a field grounding conductor per N.E.C. Table 250-95. A control circuit grounding lug is also supplied. 8. The supplied disconnect is a “Disconnecting Means” as defined in the N.E.C. 100, and is intended for isolating the unit for the available power supply to perform maintenance and troubleshooting. This disconnect is not intended to be a Load Break Device. 9. Field Wiring by others which complies to the National Electrical Code and Local Codes. 18 YORK INTERNATIONAL FORM 150.62-NM1 ELECTRICAL NOTES LEGEND ACR-LINE C.B. D.E. DISC SW FACT MOUNT CB FLA HZ MAX MCA MIN MIN NF RLA S.P. WIRE UNIT MTD SERV SW LRA 1 ACROSS THE LINE START CIRCUIT BREAKER DUAL ELEMENT FUSE DISCONNECT SWITCH FACTORY MOUNTED CIRCUIT BREAKER FULL LOAD AMPS HERTZ MAXIMUM MINIMUM CIRCUIT AMPACITY MINIMUM MINIMUM NON FUSED RATED LOAD AMPS SINGLE POINT WIRING UNIT MOUNTED SERVICE (NON-FUSED DISCONNECT SWITCH) LOCKED ROTOR AMPS VOLTAGE CODE -17 = 200-3-60 -28 = 230-3-60 -40 = 380-3-60 -46 = 460-3-60 -58 = 575-3-60 LEGEND: Field Wiring Factory Wiring YORK INTERNATIONAL 19 Installation ELECTRICAL DATA TABLE 1 – MICROPANEL POWER SUPPLY UNIT VOLTAGE UNIT VOLTAGE CONTROL POWER MCA NOTE A MODELS w/o CONTROL TRANS MODELS w/ CONTROL TRANS -17 -28 -40 -46 -58 OVER CURRENT PROTECTION, SEE NOTE B MIN MAX NF DISC Sw 115-1-60/50 15A 10A 15A 30 A / 240V 200-1-60 230-1-60 380-1-60 460-1-60 575-1-60 15A 15A 15A 15A 15A 10A 10A 10A 10A 10A 15A 15A 15A 15A 15A 30 A / 240V 30 A / 240V 30 A / 480V 30 A / 480V 30 A / 600V A. Minimum #14 AWG, 75°C, Copper Recommended B. Minimum and Maximum Over Current Protection, Dual Element Fuse or Circuit Breaker IT IS POSSIBLE THAT MULTIPLE SOURCES OF POWER CAN BE SUPPLYING THE UNIT POWER PANEL. TO PREVENT SERIOUS INJURY OR DEATH, THE TECHNICIAN SHOULD VERIFY THAT NO LETHAL VOLTAGES ARE PRESENT INSIDE THE PANEL AFTER DISCONNECTING POWER, PRIOR TO WORKING ON EQUIPMENT. THE UNIT EVAPORATOR HEATER USES 120 VAC. DISCONNECTING 120 VAC POWER FROM THE UNIT, AT OR BELOW FREEZING TEMPERATURES, CAN RESULT IN DAMAGE TO THE EVAPORATOR AND UNIT AS A RESULT OF THE CHILLED LIQUID FREEZING. 20 YORK INTERNATIONAL FORM 150.62-NM1 ELECTRICAL DATA – STANDARD SINGLE POINT POWER YCAL0014SC - YCAL0034SC TABLE 2 – STANDARD SINGLE POINT POWER SINGLE POINT FIELD SUPPLIED WIRING MODEL MIN N/F VOLT HZ MCA1 YCAL DISC SW2 0014SC 0020SC 0024SC 0030SC 0034SC 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 75 70 42 34 27 100 93 52 45 36 127 118 76 57 46 140 130 75 62 50 183 170 103 81 65 100 100 60 60 30 150 100 60 60 60 150 150 100 60 60 150 150 100 100 60 200 200 150 100 100 D.E. FUSE MIN3 MAX4 90 100 80 90 45 50 40 40 30 35 110 125 110 125 60 60 50 60 40 45 150 175 150 150 90 100 70 70 50 60 175 175 150 175 90 100 70 80 60 60 200 225 200 200 110 125 90 100 70 80 SYSTEM #1 COMPRESSOR & FAN CKT. BKR.5 MIN 90 80 45 40 30 110 110 60 50 40 150 150 90 70 50 175 150 90 70 60 200 200 110 90 70 MAX 100 90 50 40 35 125 125 60 60 45 175 150 100 70 60 175 175 100 80 60 225 200 125 100 80 INCOMING WIRE RANGE6 #4-#1 #4-#1 #8-#4 # 10 - # 6 # 10 - # 6 # 2 - 1/0 # 2 - 1/0 #6-#2 #8-#4 #8-#4 # 1 - 2/0 # 1 - 2/0 #4-#1 #6-#2 #8-#4 1/0 - 3/0 1/0 - 3/0 #4-#1 #6-#2 #6-#2 3/0 - 250 2/0 - 4/0 # 2 - 1/0 #4-#1 #4-#1 COMPR. #1 RLA 26.0 24.1 14.0 11.5 9.2 37.0 34.3 18.5 16.3 13.1 49.1 45.5 29.5 21.7 17.3 54.7 50.7 28.7 24.1 19.3 51.2 47.4 28.7 22.6 18 LRA 195 195 113 98 80 237 237 154 130 85 298 298 235 170 140 420 420 235 175 140 298 298 235 175 140 COMPR. #2 COMPR. #3 RLA 26.0 24.1 14.0 11.5 9.2 37.0 34.3 18.5 16.3 13.1 49.1 45.5 29.5 21.7 17.3 54.7 50.7 28.7 24.1 19.3 51.2 47.4 28.7 22.6 18 RLA — — — — — — — — — — — — — — — — — — — — 51.2 47.4 28.7 22.6 18 LRA 195 195 113 98 80 237 237 154 130 85 298 298 235 170 140 420 420 235 175 140 298 298 235 175 140 1 FANS LRA QTY FLA (EA) — 2 8.2 — 2 7.8 — 2 4.8 — 2 3.8 — 2 3.1 — 2 8.2 — 2 7.8 — 2 4.8 — 2 3.8 — 2 3.1 — 2 8.2 — 2 7.8 — 2 4.8 — 2 3.8 — 2 3.1 — 2 8.2 — 2 7.8 — 2 4.8 — 2 3.8 — 2 3.1 298 2 8.2 298 2 7.8 235 2 4.8 175 2 3.8 140 2 3.1 See notes and legend on pages 18 and 19. YORK INTERNATIONAL 21 Installation ELECTRICAL DATA – STANDARD DUAL POINT POWER YCAL0040SC - YCAL0080SC TABLE 3 – STANDARD DUAL POINT POWER SYSTEM #1 FIELD SUPPLIED WIRING MODEL VOLT HZ MCA1 MIN N/F YCAL DISC SW2 200 60 91 100 230 60 85 100 0040SC 380 60 54 60 460 60 41 60 575 60 33 60 200 60 130 150 230 60 121 150 0044SC 380 60 73 100 460 60 58 60 575 60 47 60 200 60 146 200 230 60 136 150 0050SC 380 60 79 100 460 60 65 100 575 60 52 60 200 60 141 150 230 60 131 150 0060SC 380 60 77 100 460 60 63 100 575 60 50 60 200 60 187 200 230 60 174 200 0064SC 380 60 105 150 460 60 83 100 575 60 67 100 200 60 185 200 230 60 172 200 0070SC 380 60 104 150 460 60 82 100 575 60 66 100 200 60 208 250 230 60 193 250 0074SC 380 60 113 150 460 60 92 100 575 60 74 100 200 60 207 250 230 60 192 250 0080SC 380 60 112 150 460 60 92 100 575 60 74 100 D.E. FUSE CKT. BKR.5 MIN3 MAX4 100 110 100 110 60 70 45 50 40 40 150 175 150 150 80 100 70 70 60 60 175 200 150 175 90 100 80 80 60 70 175 175 150 175 90 100 70 80 60 60 200 225 200 200 125 125 90 100 80 80 200 225 200 200 125 125 90 100 80 80 225 250 225 225 125 125 100 110 80 90 225 250 225 225 125 125 100 110 80 90 MIN MAX 100 110 100 110 60 70 45 50 40 40 150 175 150 150 80 100 70 70 60 60 175 200 150 175 90 100 80 80 60 70 175 175 150 175 90 100 70 80 60 60 200 225 200 200 125 125 90 100 80 80 200 225 200 200 125 125 90 100 80 80 225 250 225 225 125 125 100 110 80 90 225 250 225 225 125 125 100 110 80 90 SYSTEM #1 COMPRESSOR & FAN INCOMING WIRE RANGE6 # 2 - 1/0 #4-#1 #6-#2 #8-#4 # 10 - # 6 # 1 - 2/0 # 1 - 2/0 #4-#1 #6-#2 #8-#4 1/0 - 3/0 1/0 - 3/0 #4-#1 #4-#1 #6-#2 1/0 - 3/0 1/0 - 3/0 #4-#1 #6-#2 #6-#2 3/0 - 250 2/0 - 4/0 # 2 - 1/0 #4-#1 #4-#1 3/0 - 250 2/0 - 4/0 # 2 - 1/0 #4-#1 #4-#1 4/0 - 300 3/0 - 250 # 2 - 1/0 # 2 - 1/0 #4-#1 4/0 - 300 3/0 - 250 # 2 - 1/0 # 2 - 1/0 #4-#1 COMPR. #1 RLA 32.9 30.5 19.4 14.5 11.6 50.2 46.5 28.1 22.1 17.7 57.4 53.1 30.8 25.3 20.2 55.0 50.9 29.6 24.2 19.4 52.4 48.6 29.3 23.1 18.5 51.8 48.0 29.0 22.9 18.3 58.9 54.5 31.6 26.0 20.8 58.6 54.2 31.5 25.8 20.7 LRA 265 265 155 120 80 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 COMPR. #2 COMPR. #3 FANS RLA 32.9 30.5 19.4 14.5 11.6 50.2 46.5 28.1 22.1 17.7 57.4 53.1 30.8 25.3 20.2 55.0 50.9 29.6 24.2 19.4 52.4 48.6 29.3 23.1 18.5 51.8 48.0 29.0 22.9 18.3 58.9 54.5 31.6 26.0 20.8 58.6 54.2 31.5 25.8 20.7 RLA LRA — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 52.4 298 48.6 298 29.3 235 23.1 170 18.5 140 51.8 298 48.0 298 29.0 235 22.9 170 18.3 140 58.9 420 54.5 420 31.6 235 26.0 175 20.8 140 58.6 420 54.2 420 31.5 235 25.8 175 20.7 140 QTY FLA (EA) 2 8.2 2 7.8 2 4.8 2 3.8 2 3.1 2 8.2 2 7.8 2 4.8 2 3.8 2 3.1 2 8.2 2 7.8 2 4.8 2 3.8 2 3.1 2 8.2 2 7.8 2 4.8 2 3.8 2 3.1 2 8.2 2 7.8 2 4.8 2 3.8 2 3.1 2 8.2 2 7.8 2 4.8 2 3.8 2 3.1 2 8.2 2 7.8 2 4.8 2 3.8 2 3.1 2 8.2 2 7.8 2 4.8 2 3.8 2 3.1 LRA 265 265 155 120 80 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 See notes and legend on pages 18 and 19. 22 YORK INTERNATIONAL FORM 150.62-NM1 ELECTRICAL DATA – STANDARD DUAL POINT POWER YCAL0040SC - YCAL0080SC SYSTEM #2 FIELD SUPPLIED WIRING MCA1 MIN N/F D.E. FUSE DISC SW2 MIN3 91 85 54 41 33 130 121 73 58 47 130 121 73 58 47 141 131 77 63 50 128 119 76 57 46 185 172 104 82 66 181 168 102 80 65 207 192 112 92 74 100 100 60 60 60 150 150 100 60 60 150 150 100 60 60 150 150 100 100 60 150 150 100 100 60 200 200 150 100 100 200 200 150 100 100 250 250 150 100 100 100 100 60 45 40 150 150 80 70 60 150 150 80 70 60 175 150 90 70 60 150 150 90 70 50 200 200 125 90 80 200 200 110 90 70 225 225 125 100 80 YORK INTERNATIONAL CKT. BRK.5 MAX4 MIN MAX 110 110 70 50 40 175 150 100 70 60 175 150 100 70 60 175 175 100 80 60 150 150 90 70 50 225 200 125 100 80 225 200 125 100 80 250 225 125 110 90 100 100 60 45 40 150 150 80 70 60 150 150 80 70 60 175 150 90 70 60 150 150 90 70 50 200 200 125 90 80 200 200 110 90 70 225 225 125 100 80 110 110 70 50 40 175 150 100 70 60 175 150 100 70 60 175 175 100 80 60 150 150 90 70 50 225 200 125 100 80 225 200 125 100 80 250 225 125 110 90 SYSTEM #2 COMPRESSOR & FAN INCOMING WIRE RANGE6 # 2 - 1/0 #4-#1 #6-#2 #8-#4 # 10 - # 6 # 1 - 2/0 # 1 - 2/0 #4-#1 #6-#2 #8-#4 # 1 - 2/0 # 1 - 2/0 #4-#1 #6-#2 #8-#4 1/0 - 3/0 1/0 - 3/0 #4-#1 #6-#2 #6-#2 # 1 - 2/0 # 1 - 2/0 #4-#1 # 6-#2 #8-#4 3/0 - 250 2/0 - 4/0 # 2 - 1/0 #4-#1 #4-#1 3/0 - 250 2/0 - 4/0 # 2 - 1/0 #4-#1 #6-#2 4/0 - 300 3/0 - 250 # 2 - 1/0 # 2 - 1/0 #4-#1 COMPR. #1 RLA 32.9 30.5 19.4 14.5 11.6 50.2 46.5 28.1 22.1 17.7 49.5 45.9 27.8 21.8 17.5 55.0 50.9 29.6 24.2 19.4 34.2 31.6 20.2 15.1 12.0 51.8 48.0 29.0 22.9 18.3 50.5 46.8 28.3 22.3 17.8 58.6 54.2 31.5 25.8 20.7 LRA 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 COMPR. #2 RLA 32.9 30.5 19.4 14.5 11.6 50.2 46.5 28.1 22.1 17.7 49.5 45.9 27.8 21.8 17.5 55.0 50.9 29.6 24.2 19.4 34.2 31.6 20.2 15.1 12.0 51.8 48.0 29.0 22.9 18.3 50.5 46.8 28.3 22.3 17.8 58.6 54.2 31.5 25.8 20.7 LRA 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 COMPR. #3 RLA — — — — — — — — — — — — — — — — — — — — 34.2 31.6 20.2 15.1 12.0 51.8 48.0 29.0 22.9 18.3 50.5 46.8 28.3 22.3 17.8 58.6 54.2 31.5 25.8 20.7 1 FANS LRA QTY FLA (EA) — 2 8.2 — 2 7.8 — 2 4.8 — 2 3.8 — 2 3.1 — 2 8.2 — 2 7.8 — 2 4.8 — 2 3.8 — 2 3.1 — 2 8.2 — 2 7.8 — 2 4.8 – 2 3.8 — 2 3.1 — 2 8.2 — 2 7.8 — 2 4.8 — 2 3.8 — 2 3.1 265 2 8.2 265 2 7.8 155 2 4.8 120 2 3.8 80 2 3.1 298 2 8.2 298 2 7.8 235 2 4.8 170 2 3.8 140 2 3.1 298 2 8.2 298 2 7.8 235 2 4.8 170 2 3.8 140 2 3.1 420 2 8.2 420 2 7.8 235 2 4.8 175 2 3.8 140 2 3.1 23 Installation ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER YCAL0014SC - YCAL0034SC TABLE 4 – OPTIONAL SINGLE POINT POWER SINGLE POINT FIELD SUPPLIED WIRING MODEL YCAL 0014SC 0020SC 0024SC 0030SC 0034SC VOLT 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 HZ 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 1 MCA MIN N/F DISC SW2 75 70 42 34 27 100 93 52 45 36 127 118 76 57 46 140 130 75 62 50 183 170 103 81 65 100 100 60 60 30 150 100 60 60 60 150 150 100 60 60 150 150 100 100 60 200 200 150 100 100 D.E. FUSE MIN3 90 80 45 40 30 110 110 60 50 40 150 150 90 70 50 175 150 90 70 60 200 200 110 90 70 MAX4 100 90 50 40 35 125 125 60 60 45 175 150 100 70 60 175 175 100 80 60 225 200 125 100 80 CKT. BKR.5 MIN 90 80 45 40 30 110 110 60 50 40 150 150 90 70 50 175 150 90 70 60 200 200 110 90 70 MAX 100 90 50 40 35 125 125 60 60 45 175 150 100 70 60 175 175 100 80 60 225 200 125 100 80 INCOMING WIRE RANGE6 FACTORY SUPPLIED OPTIONAL DISCONNECT BREAKER #4-#1 #4-#1 #4-#1 #4-#1 #8-#4 #8-#4 # 10 - # 6 # 10 - # 6 # 10 - # 6 # 10 - # 6 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 #6-#2 #6-#2 #8-#4 #8-#4 #8-#4 #8-#4 # 1 - 2/0 # 1 - 2/0 # 1 - 2/0 # 1 - 2/0 #4-#1 #4-#1 #6-#2 #6-#2 #8-#4 #8-#4 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 #4-#1 #4-#1 #6-#2 #6-#2 #6-#2 #6-#2 3/0 - 250 3/0 - 250 2/0 - 4/0 2/0 - 4/0 # 2 - 1/0 # 2 - 1/0 #4-#1 #4-#1 #4-#1 #4-#1 See notes and legend on pages 18 and 19. 24 YORK INTERNATIONAL FORM 150.62-NM1 ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER YCAL0014SC - YCAL0034SC SYSTEM #1 COMPRESSOR & FAN COMPR. #1 RLA LRA 26.0 195 24.1 195 14.0 113 11.5 98 9.2 80 37.0 237 34.3 237 18.5 154 16.3 130 13.1 85 49.1 298 45.5 298 29.5 235 21.7 170 17.3 140 54.7 420 50.7 420 28.7 235 24.1 175 19.3 140 51.2 298 47.4 298 28.7 235 22.6 175 18 140 COMPR. #2 RLA LRA 26.0 195 24.1 195 14.0 113 11.5 98 9.2 80 37.0 237 34.3 237 18.5 154 16.3 130 13.1 85 49.1 298 45.5 298 29.5 235 21.7 170 17.3 140 54.7 420 50.7 420 28.7 235 24.1 175 19.3 140 51.2 298 47.4 298 28.7 235 22.6 175 18 140 YORK INTERNATIONAL COMPR. #3 RLA LRA — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 51.2 298 47.4 298 28.7 235 22.6 175 18 140 QTY 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 FANS FLA (EA) 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 25 Installation ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER YCAL0040SC - YCAL0060SC TABLE 5 – OPTIONAL SINGLE POINT POWER SINGLE POINT FIELD SUPPLIED WIRING MODEL YCAL 0040SC 0044SC 0050SC 0060SC VOLT 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 HZ 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 1 MCA 173 161 102 77 62 247 229 139 110 88 261 243 145 116 93 267 248 145 119 95 MIN N/F DISC SW2 200 200 150 100 100 400 250 200 150 100 400 400 200 150 150 400 400 200 150 150 D.E. FUSE MIN3 200 175 110 90 70 300 250 150 125 100 300 300 175 125 100 300 300 175 125 100 MAX4 200 175 110 90 70 300 250 150 125 100 300 300 175 125 110 300 300 175 125 110 CKT. BKR.5 MIN 200 175 110 90 70 300 250 150 125 100 300 300 175 125 100 300 300 175 125 100 MAX 200 175 110 90 70 300 250 150 125 100 300 300 175 125 110 300 300 175 125 110 INCOMING WIRE RANGE6 FACTORY SUPPLIED OPTIONAL SINGLE POINT DISCONNECT BREAKER 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 #4-#1 #4-#1 #4-#1 #6-#2 #6-#2 #6-#2 250 - 350 250 - 350 250 - 350 4/0 - 300 4/0 - 300 4/0 - 300 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 300 - 400 300 - 400 300 - 400 250 - 350 250 - 350 250 - 350 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 # 1 - 2/0 # 1 - 2/0 # 1 - 2/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 300 - 400 300 - 400 300 - 400 250 - 350 250 - 350 250 - 350 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 # 1 - 2/0 # 1 - 2/0 # 1 - 2/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 See notes and legend on pages 18 and 19. 26 YORK INTERNATIONAL FORM 150.62-NM1 ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER YCAL0040SC - YCAL0060SC SYSTEM #1 COMPRESSOR & FAN COMPR. #1 RLA 32.9 30.5 19.4 14.5 11.6 50.2 46.5 28.1 22.1 17.7 57.4 53.1 30.8 25.3 20.2 55.0 50.9 29.6 24.2 19.4 LRA 265 265 155 120 80 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 COMPR. #2 RLA 32.9 30.5 19.4 14.5 11.6 50.2 46.5 28.1 22.1 17.7 57.4 53.1 30.8 25.3 20.2 55.0 50.9 29.6 24.2 19.4 YORK INTERNATIONAL LRA 265 265 155 120 80 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 SYSTEM #2 COMPRESSOR & FAN COMPR. #3 RLA — — — — — — — — — — — — — — — — — — — — LRA — — — — — — — — — — — — — — — — — — — — FANS QTY 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 FLA (EA) 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 COMPR. #1 RLA 32.9 30.5 19.4 14.5 11.6 50.2 46.5 28.1 22.1 17.7 49.5 45.9 27.8 21.8 17.5 55.0 50.9 29.6 24.2 19.4 LRA 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 COMPR. #2 RLA 32.9 30.5 19.4 14.5 11.6 50.2 46.5 28.1 22.1 17.7 49.5 45.9 27.8 21.8 17.5 55.0 50.9 29.6 24.2 19.4 LRA 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 COMPR. #3 RLA — — — — — — — — — — — — — — — — — — — — LRA — — — — — — — — — — — — — — — — — — — — 1 FANS QTY 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 FLA (EA) 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 27 Installation ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER YCAL0064SC - YCAL0080SC TABLE 6 – OPTIONAL SINGLE POINT POWER SINGLE POINT FIELD SUPPLIED WIRING MODEL YCAL 0064SC 0070SC 0074SC 0080SC VOLT 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 200 230 380 460 575 HZ 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 1 MCA MIN N/F DISC SW2 306 284 175 136 109 357 332 201 159 127 376 349 207 167 134 399 371 216 177 142 400 400 200 150 150 400 400 250 200 150 600 400 250 200 150 600 600 250 200 200 D.E. FUSE MIN3 350 300 200 150 125 400 350 225 175 150 400 400 225 175 150 450 400 225 200 150 MAX4 350 300 200 150 125 400 350 225 175 150 400 400 225 175 150 450 400 225 200 150 CKT. BKR.5 MIN 350 300 200 150 125 400 350 225 175 150 400 400 225 175 150 450 400 225 200 150 MAX 350 300 200 150 125 400 350 225 175 150 400 400 225 175 150 450 400 225 200 150 INCOMING WIRE RANGE6 FACTORY SUPPLIED OPTIONAL SINGLE POINT DISCONNECT BREAKER 350 - 500 350 - 500 350 - 500 300 - 400 300 - 400 300 - 400 3/0 - 250 3/0 - 250 3/0 - 250 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 # 2 - 1/0 # 2 - 1/0 # 2 - 1/0 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0 400 - 600 400 - 600 400 - 600 4/0 - 300 4/0 - 300 4/0 - 300 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 # 1 - 2/0 # 1 - 2/0 # 1 - 2/0 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0 4/0 - 300 4/0 - 300 4/0 - 300 2/0 - 4/0 2/0 - 4/0 2/0 - 4/0 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 600 - (2) 250 600 - (2) 250 600 - (2) 250 500 - (2) 4/0 500 - (2) 4/0 500 - (2) 4/0 4/0 - 300 4/0 - 300 4/0 - 300 3/0 - 250 3/0 - 250 3/0 - 250 1/0 - 3/0 1/0 - 3/0 1/0 - 3/0 See notes and legend on pages 18 and 19. 28 YORK INTERNATIONAL FORM 150.62-NM1 ELECTRICAL DATA – OPTIONAL SINGLE POINT POWER YCAL0064SC - YCAL0080SC SYSTEM #1 COMPRESSOR & FAN COMPR. #1 RLA 52.4 48.6 29.3 23.1 18.5 51.8 48.0 29.0 22.9 18.3 58.9 54.5 31.6 26.0 20.8 58.6 54.2 31.5 25.8 20.7 LRA 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 COMPR. #2 COMPR. #3 RLA 52.4 48.6 29.3 23.1 18.5 51.8 48.0 29.0 22.9 18.3 58.9 54.5 31.6 26.0 20.8 58.6 54.2 31.5 25.8 20.7 RLA 52.4 48.6 29.3 23.1 18.5 51.8 48.0 29.0 22.9 18.3 58.9 54.5 31.6 26.0 20.8 58.6 54.2 31.5 25.8 20.7 YORK INTERNATIONAL LRA 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 LRA 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 420 420 235 175 140 SYSTEM #2 COMPRESSOR & FAN FANS QTY 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 FLA (EA) 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 COMPR. #1 RLA 34.2 31.6 20.2 15.1 12.0 51.8 48.0 29.0 22.9 18.3 50.5 46.8 28.3 22.3 17.8 58.6 54.2 31.5 25.8 20.7 LRA 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 COMPR. #2 RLA 34.2 31.6 20.2 15.1 12.0 51.8 48.0 29.0 22.9 18.3 50.5 46.8 28.3 22.3 17.8 58.6 54.2 31.5 25.8 20.7 LRA 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 COMPR. #3 RLA 34.2 31.6 20.2 15.1 12.0 51.8 48.0 29.0 22.9 18.3 50.5 46.8 28.3 22.3 17.8 58.6 54.2 31.5 25.8 20.7 LRA 265 265 155 120 80 298 298 235 170 140 298 298 235 170 140 420 420 235 175 140 1 FANS QTY 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 FLA (EA) 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 8.2 7.8 4.8 3.8 3.1 29 Installation OPERATIONAL LIMITATIONS (ENGLISH) TABLE 7 – TEMPERATURES AND FLOWS YCAL00 14SC 20SC 24SC 30SC 34SC 40SC 44SC 50SC 60SC 64SC 70SC 74SC 80SC LEAVING WATER TEMPERATURE (°F ) MAX2 MIN1 40 55 40 55 40 55 40 55 40 55 40 55 40 55 40 55 40 55 40 55 40 55 40 55 40 55 COOLER FLOW (GPM3) MIN 30 30 35 45 75 75 75 75 75 130 130 130 120 MIN4 25 25 25 25 25 25 25 25 25 25 25 25 25 MAX 60 60 70 75 110 250 250 250 250 390 390 390 430 VOLTAGE LIMITATIONS The following voltage limitations are absolute and operation beyond these limitations may cause serious damage to the compressor. AIR ON CONDENSER (°F) MAX5 125 125 125 125 125 125 125 125 125 125 125 125 125 Excessive flow will cause damage to the cooler. Do not exceed max. cooler flow. Special care should be taken when multiple chillers are fed by a single pump. TABLE 8 – VOLTAGES UNIT POWER 200-3-60 230-3-60 380-3-60 460-3-60 575-3-60 MIN. 180 207 355 414 517 MAX. 220 253 415 506 633 NOTES: 1. Standard units cannot be operated below 40°F leaving chilled water temperature. 2. For leaving water temperature higher than 55°F, contact the nearest YORK Office for application guidelines. 3. The evaporator is protected against freeze-up to -20.0°F with an electrical heater as standard. 4. Operation below 25°F requires Optional Low Ambient Kit for operation to 0°F. 5. Operation above 115°F requires Optional High Ambient Kit for operation to 125°F. 30 YORK INTERNATIONAL FORM 150.62-NM1 OPERATIONAL LIMITATIONS (ENGLISH) Cooler Pressure Drop YCAL0030 1 60.00 Press. Drop, Ft. H2O 50.00 40.00 30.00 20.00 10.00 0.00 10 20 30 50 40 60 90 80 70 100 110 120 130 140 150 Flow, GPM LD04966 Cooler Pressure Drop YCAL0034 Press. Drop, Ft. H2O 40.00 30.00 20.00 10.00 0.00 10 20 30 40 50 60 70 90 80 100 110 120 130 150 140 Flow, GPM TABLE 9 – COOLER PRESSURE DROP CURVES MODEL YCAL00 14SC, 20SC, 24SC 30SC 34SC 40SC, 44SC, 50SC, 60SC 64SC, 70SC, 74SC 80SC YORK INTERNATIONAL COOLER CURVE A B NEW NEW C D E LD04967 TABLE 10 – ETHYLENE GLYCOL CORRECTION FACTORS % WT ETHYLENE GLYCOL TONS 10 20 30 40 50 .994 .986 .979 .970 .959 FACTORS COMPR. kW .997 .993 .990 .985 .980 DELTA P 1.03 1.06 1.09 1.13 1.16 GPM/° F/ TON 24.1 24.9 25.9 27.3 29.0 FREEZE POINT (° F) 26 16 5 -10 -32 31 Installation OPERATIONAL LIMITATIONS (METRIC) TABLE 11 – TEMPERATURES AND FLOWS YCAL00 14SC 20SC 24SC 30SC 34SC 40SC 44SC 50SC 60SC 64SC 70SC 74SC 80SC LEAVING WATER TEMPERATURE (°C) MAX2 MIN1 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 4.4 12.8 COOLER FLOW (L/S) MIN 1.9 1.9 2.2 2.8 4.7 4.7 4.7 4.7 4.7 8.2 8.2 8.2 7.6 AIR ON CONDENSER (°C) MIN4 -3.9 -3.9 -3.9 -3.9 -3.9 -3.9 -3.9 -3.9 -3.9 -3.9 -3.9 -3.9 -3.9 MAX 3.8 3.8 4.4 4.7 6.9 15.8 15.8 15.8 15.8 24.6 24.6 24.6 27.1 VOLTAGE LIMITATIONS The following voltage limitations are absolute and operation beyond these limitations may cause serious damage to the compressor. MAX5 51.7 51.7 51.7 51.7 51.7 51.7 51.7 51.7 51.7 51.7 51.7 51.7 51.7 Excessive flow will cause damage to the cooler. Do not exceed max. cooler flow. Special care should be taken when multiple chillers are fed by a single pump. TABLE 12 – VOLTAGES UNIT POWER 200-3-60 230-3-60 380-3-60 460-3-60 575-3-60 MIN. 180 207 355 414 517 MAX. 220 253 415 506 633 NOTES: 1. Standard units cannot be operated below 4.4°C leaving chilled water temperature. 2. For leaving water temperature higher than 12.8°C, contact the nearest YORK Office for application guidelines. 3. The evaporator is protected against freeze-up to -28.9°C with an electrical heater as standard. 4. Operation below -3.9°C requires Optional Low Ambient Kit for operation to -17.8 °C. 5. Operation above 46.1°C requires Optional High Ambient Kit for operation to 51.7°C. 32 YORK INTERNATIONAL 1 FORM 150.62-NM1 OPERATIONAL LIMITATIONS (METRIC) Cooler Press. Drop YCAL0030 180 160 Press. Drop, kPa 140 120 100 80 60 40 20 0 0 10 5 Flow l/s LD04968 Cooler Pressure Drop YCAL0034 100 90 Press. Drop, kPa 80 70 60 50 40 30 20 10 3 4 5 6 9 8 7 10 Flow l/s LD04969 TABLE 13 – COOLER PRESSURE DROP CURVES MODEL YCAL00 14SC, 20SC, 24SC, 30SC 34SC 40SC, 44SC, 50SC, 60SC 64SC, 70SC, 74SC, 80SC YORK INTERNATIONAL COOLER CURVE A B C D E TABLE 14 – ETHYLENE GLYCOL CORRECTION FACTORS % WT ETHYLENE GLYCOL 10 20 30 40 50 FACTORS TONS .994 .986 .979 .970 .959 COMPR. kW .997 .993 .990 .985 .980 DELTA P 1.03 1.06 1.09 1.13 1.16 GPM/° F/ TON 24.1 24.9 25.9 27.3 29.0 FREEZE POINT (° C) -3 -9 -15 -23 -36 33 Installation PHYSICAL DATA (ENGLISH) YCAL0014SC - YCAL0080SC TABLE 15 – PHYSICAL DATA (ENGLISH) Model YCAL00 Nominal Tons Number of Refrigerant Circuits Compressors per circuit Compressors per unit Condenser Total Face Area ft2 Number of Rows Fins per Inch Condenser Fans Number of Fans total Fan hp/kw Fan RPM Number of Blades Total Chiller CFM Evaporator, Direct Expansion Diameter x Length Water Volume, gallons Maximum Water Side Pressure, PSIG Maximum Refrigerant Side Pressure, PSIG Minimum Chiller Water Flow Rate, gpm Maximum Chiller Water Flow Rate, gpm Water Connections, inches Shipping Weight Aluminum Fin Coils, lbs Copper Fin Coils, lbs Operating Weight Aluminum Fin Coils, lbs Copper Fin Coils, lbs Refrigerant Charge, R22, ckt1 / ckt2, lbs Oil Charge, ckt1 / ckt2, gallons 34 14SC 13.6 1 2 2 20SC 17.9 1 2 2 24SC 23.3 1 2 2 30SC 27.1 1 2 2 34SC 34.7 1 3 3 40SC 38.2 2 2 4 44SC 47.4 2 2 4 47.2 2 14 47.2 2 14 66.1 2 14 66.1 3 14 66.1 3 14 128.0 2 14 128.0 2 14 2 2 / 1.4 1140 3 16257 2 2 / 1.4 1140 3 16257 2 2 / 1.4 1140 3 23500 2 2 / 1.4 1140 3 23500 2 2 / 1.4 1140 3 23500 4 2 / 1.4 1140 3 47360 4 2 / 1.4 1140 3 47360 8"x6' 9.6 150 300 30 60 3 8"x6' 9.6 150 300 30 60 3 8"x6.5' 9.6 150 300 35 70 3 8"x7' 10.8 150 300 45 75 3 10"x7' 12 150 300 75 110 4 11"x8' 24 150 300 75 250 4 11"x8' 24 150 300 75 250 4 2152 2319 2168 2329 2356 2540 2560 2860 3007 3358 4123 4510 4222 4610 2225 2392 32 1.7 2241 2402 38 1.7 2435 2619 58 2.1 2647 2947 65 3.5 3117 3468 69 3.2 4363 4750 45/45 2.0/2.0 4462 4850 54/54 2.1/2.1 YORK INTERNATIONAL FORM 150.62-NM1 PHYSICAL DATA (ENGLISH) YCAL0014SC - YCAL0080SC 50SC 49.9 2 2 4 60SC 54.0 2 2 4 64SC 62.4 2 3 6 70SC 69.4 2 3 6 74SC 74.0 2 3 6 80SC 79.1 2 3 6 128.0 2 14 128.0 3 14 149.3 2 14 149.3 2 16 149.3 3 12 149.3 3 14 4 2 / 1.4 1140 3 47360 4 2 / 1.4 1140 3 46080 4 2 / 1.7 1140 3 55253 4 2 / 1.7 1140 3 55253 4 2 / 1.7 1140 3 54550 4 2 / 1.7 1140 3 53760 11"x8' 24 150 300 75 250 4 11"x8' 24 150 300 75 250 4 14"x8' 41 150 300 130 390 6 14"x8' 41 150 300 130 390 6 14"x8' 41 150 300 130 390 6 14"x8' 38 150 300 120 430 6 4300 4688 4596 5275 5207 5735 5322 5925 5569 6247 5819 6611 4540 4928 60/54 3.5/2.1 4836 5515 72/72 3.5/3.5 5501 6029 75/62 3.2/3.0 5616 6219 75/75 3.2/3.2 5863 6541 92/83 5.2/3.2 6128 6919 100/100 5.2/5.2 YORK INTERNATIONAL 1 35 Installation PHYSICAL DATA (METRIC) YCAL0014SC - YCAL0080SC TABLE 16 – PHYSICAL DATA (METRIC) Model YCAL00 Nominal kW Number of Refrigerant Circuits Compressors per circuit Compressors per unit Condenser Total Face Area meters2 Number of Rows Fins per mm Condenser Fans Number of Fans total Fan hp/kw Fan RPM Number of Blades Total Chiller Airflow l/s Evaporator, Direct Expansion Diameter x Length Water Volume, liters Maximum Water Side Pressure, bar Maximum Refrigerant Side Pressure, bar Minimum Chiller Water Flow Rate, l/s Maximum Chiller Water Flow Rate, l/s Water Connections, inches Shipping Weight Aluminum Fin Coils, kg Copper Fin Coils, kg Operating Weight Aluminum Fin Coils, kg Copper Fin Coils, kg Refrigerant Charge, R22, ckt1 / ckt2, kg Oil Charge, ckt1 / ckt2, liters 36 14SC 46.8 1 2 2 20SC 63.0 1 2 2 24SC 82.0 1 2 2 30SC 95.3 1 2 2 34SC 121.9 1 3 3 40SC 135.6 2 2 4 44SC 168.0 2 2 4 4 2 518 4 2 518 6 2 518 6 3 518 6 3 518 12 2 518 12 2 518 2 2 / 1.4 1140 3 7672 2 2 / 1.4 1140 3 7672 2 2 / 1.4 1140 3 11091 2 2 / 1.4 1140 3 11091 2 2 / 1.4 1140 3 11091 4 2 / 1.4 1140 3 22351 4 2 / 1.4 1140 3 22351 203x1829 36 10 21 2 4 3 203x1830 36 10 21 2 4 3 203x1981 36 10 21 2 4 3 203x2134 41 10 21 3 5 3 254x2134 45 10 21 5 7 4 279x2438 91 10 21 5 16 4 279x2438 91 10 21 5 16 4 976 1052 983 1057 1069 1152 1161 1297 1364 1523 1870 2046 1915 2091 1009 1085 15 6 1016 1090 17 6 1104 1188 24 8 1201 1337 30 13 1414 1573 31 12 1979 2155 21/21 8.0/8.0 2024 2200 25/25 8.0/8.0 YORK INTERNATIONAL FORM 150.62-NM1 PHYSICAL DATA (METRIC) YCAL0014SC - YCAL0080SC 50SC 177.1 2 2 4 60SC 191.6 2 2 4 64SC 221.3 2 3 6 70SC 246.0 2 3 6 74SC 262.6 2 3 6 80SC 278.1 2 3 6 12 2 518 12 3 518 14 2 518 14 2 518 14 3 518 14 3 518 4 2 / 1.4 1140 3 22351 4 2 / 1.4 1140 3 21747 4 2 / 1.7 1140 3 26076 4 2 / 1.7 1140 3 26076 4 2 / 1.7 1140 3 25744 4 2 / 1.7 1140 3 25371 279x2438 91 10 21 5 16 4 279x2438 91 10 21 5 16 4 356x2438 155 10 21 8 25 6 356x2438 155 10 21 8 25 6 356x2438 155 10 21 8 25 6 356x2438 144 10 21 8 27 6 1950 2126 2085 2393 2362 2601 2414 2687 2526 2834 2640 2999 2059 2235 27/25 13/8 2194 2502 33/33 13/13 2495 2735 34/28 12/11.4 2547 2821 34/34 12.0/12.0 2659 2967 42/38 20/12 2780 3138 46/46 20/20 YORK INTERNATIONAL 1 37 Installation DIMENSIONS (ENGLISH) YCAL0014SC - YCAL0020SC LD03848 Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'0; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 38 YORK INTERNATIONAL FORM 150.62-NM1 DIMENSIONS (ENGLISH) YCAL0014SC - YCAL0020SC 1 LD03847 TABLE 17 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY MODEL YCAL00 14SC 20SC A 587 591 YORK INTERNATIONAL B 525 529 WEIGHT DISTRIBUTION C D 587 525 591 529 TOTAL 2225 2241 X 50.1 50.2 CENTER OF GRAVITY Y Z 25.8 23.3 25.9 23.2 39 Installation DIMENSIONS (ENGLISH) YCAL0024SC - YCAL0034SC LD03846 * Refers to Model YCAL0030SC ** Refers to Model YCAL0034SC Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 40 YORK INTERNATIONAL FORM 150.62-NM1 DIMENSIONS (ENGLISH) YCAL0024SC - YCAL0034SC 1 LD03845 TABLE 18 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY MODEL YCAL00 24SC 30SC 34SC A 636 692 868 YORK INTERNATIONAL B 581 632 690 WEIGHT DISTRIBUTION C D 636 581 692 632 868 690 TOTAL 2435 2647 3129 X 50.6 50.6 48.0 CENTER OF GRAVITY Y Z 25.9 28.5 25.8 28.9 25.4 26.9 41 Installation DIMENSIONS (ENGLISH) YCAL0040SC - YCAL0060SC LD03850 Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 42 YORK INTERNATIONAL FORM 150.62-NM1 DIMENSIONS (ENGLISH) YCAL0040SC - YCAL0060SC 1 LD03849 TABLE 19 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY MODEL YCAL00 40SC 44SC 50SC 60SC A 1110 1133 1151 1217 YORK INTERNATIONAL B 1071 1098 1119 1201 WEIGHT DISTRIBUTION C D 1110 1071 1133 1098 1151 1119 1217 1201 TOTAL 4363 4462 4540 4836 X 58.6 58.7 58.8 59.2 CENTER OF GRAVITY Y Z 40.3 28.9 40.3 28.6 40.5 28.4 40.3 29.9 43 Installation DIMENSIONS (ENGLISH) YCAL0064SC - YCAL0080SC LD03852 Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 6'; rear to wall – 6'; control panel to end wall – 4'; top – no obstructions allowed; distance between adjacent units – 10'. No more than one adjacent wall may be higher than the unit. 44 YORK INTERNATIONAL FORM 150.62-NM1 DIMENSIONS (ENGLISH) YCAL0064SC - YCAL0080SC 1 LD03851 TABLE 20 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY MODEL YCAL00 64SC 70SC 74SC 80SC A 1463 1492 1551 1620 YORK INTERNATIONAL B 1288 1315 1380 1444 WEIGHT DISTRIBUTION C D 1463 1288 1492 1315 1551 1380 1620 1444 TOTAL 5501 5616 5863 6128 X 56.3 56.3 56.5 56.6 CENTER OF GRAVITY Y Z 46.0 30.1 45.6 30.1 45.9 31.0 45.6 30.8 45 Installation DIMENSIONS (METRIC) YCAL0014SC - YCAL0020SC LD03854 All dimensions in millimeters unless otherwise noted. Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 46 YORK INTERNATIONAL FORM 150.62-NM1 DIMENSIONS (METRIC) YCAL0014SC - YCAL0020SC 1 LD03853 All dimensions in millimeters unless otherwise noted. TABLE 21 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY MODEL YCAL00 14SC 20SC A 266 268 YORK INTERNATIONAL WEIGHT DISTRIBUTION (kg) B C D 238 266 238 240 268 240 TOTAL 1009 1016 CENTER OF GRAVITY (mm) X Y Z 1273 655 592 1275 658 589 47 Installation DIMENSIONS (METRIC) YCAL0024SC - YCAL0034SC LD03856 All dimensions in millimeters unless otherwise noted. Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 48 YORK INTERNATIONAL FORM 150.62-NM1 DIMENSIONS (METRIC) YCAL0024SC - YCAL0034SC 1 LD03855 All dimensions in millimeters unless otherwise noted. TABLE 22 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY MODEL YCAL00 24SC 30SC 34SC A 288 314 390 YORK INTERNATIONAL B 264 287 317 WEIGHT DISTRIBUTION C D 288 264 314 287 390 317 TOTAL 1104 1201 1414 X 1285 1285 1219 CENTER OF GRAVITY Y Z 658 724 655 734 645 683 49 Installation DIMENSIONS (METRIC) YCAL0040SC - YCAL0060SC LD03858 All dimensions in millimeters unless otherwise noted. Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m'; rear to wall – 2m'; control panel to end wall – 1.2m'; top – no obstructions allowed; distance between adjacent units – 3m'. No more than one adjacent wall may be higher than the unit. 50 YORK INTERNATIONAL FORM 150.62-NM1 DIMENSIONS (METRIC) YCAL0040SC - YCAL0060SC 1 LD03857 All dimensions in millimeters unless otherwise noted. TABLE 23 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY MODEL YCAL00 40SC 44SC 50SC 60SC A 503 514 522 552 YORK INTERNATIONAL B 486 498 508 545 WEIGHT DISTRIBUTION C D 503 486 514 498 522 508 552 545 TOTAL 1979 2024 2059 2194 X 1488 1491 1494 1504 CENTER OF GRAVITY Y Z 1024 734 1024 726 1029 721 1024 759 51 Installation DIMENSIONS (METRIC) YCAL0064SC - YCAL0080SC LD03860 All dimensions in millimeters unless otherwise noted. Placement on a level surface of free of obstructions (including snow, for winter operation) or air circulation ensures rated performance, reliable operation, and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable airflow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high-pressure safety cutouts; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall – 2m; rear to wall – 2m; control panel to end wall – 1.2m; top – no obstructions allowed; distance between adjacent units – 3m. No more than one adjacent wall may be higher than the unit. 52 YORK INTERNATIONAL FORM 150.62-NM1 DIMENSIONS (METRIC) YCAL0064SC - YCAL0080SC 1 LD03859 All dimensions in millimeters unless otherwise noted. TABLE 24 – WEIGHT DISTRIBUTION/CENTER OF GRAVITY MODEL YCAL00 64SC 70SC 74SC 80SC A 664 677 704 735 YORK INTERNATIONAL B 584 596 626 655 WEIGHT DISTRIBUTION C D 664 584 677 596 704 626 735 655 TOTAL 2495 2547 2659 2780 X 1430 1430 1435 1438 CENTER OF GRAVITY Y Z 1168 765 1158 765 1166 787 1158 782 53 Installation PRE-STARTUP CHECKLIST JOB NAME: ______________________________ SALES ORDER #: _________________________ LOCATION: _______________________________ SOLD BY: ________________________________ INSTALLING CONTRACTOR: ___________________________ START-UP TECHNICIAN/ COMPANY: _______________________________ START-UP DATE : _________________________ CHILLER MODEL #: _______________________ SERIAL #: ________________________________ CHECKING THE SYSTEM PRIOR TO INITIAL START (NO POWER) Unit Checks G 1. Inspect the unit for shipping or installation damage. G 2. Assure that all piping has been completed. G 3. Visually check for refrigerant piping leaks. G 4. Open suction line ball valve, discharge line ballvalve, and liquid line valve for each system. G 5.The compressor oil level should be maintained so that an oil level is visible in the sight glass.The oil level can only be tested when the compressor is running in stabilized conditions, guaranteeing that there is no liquid refrigerant in the lower shell of the compressor. In this case, the oil should be between 1/4 and 3/4 in the sight glass. At shutdown, the oil level can fall to the bottom limit of the oil sight glass. G 6. Assure water pumps are on. Check and adjust water pump flow rate and pressure drop across the cooler (see LIMITATIONS). Verify flow switch operation. Excessive flow may cause catastrophic damage to the evaporator. G 7. Check the control panel to assure it is free of foreign material (wires, metal chips, etc.). 54 G 8. Visually inspect wiring (power and control). Wiring MUST meet N.E.C. and local codes. See Figures 2- 5, pages 14 - 17. G 9. Check tightness of power wiring inside the power panel on both sides of the motor contactors and overloads. G10. Check for proper size fuses in main and control circuits, and verify overload setting corresponds with RLA and FLA values in electrical tables. G11. Assure 120VAC Control Power to CTB2 has 15 AMP minimum capacity. See Table 1, page 20. G12. Be certain all water temp sensors are inserted completely in their respective wells and are coated with heat conductive compound. G13. Assure that evaporator TXV bulbs are strapped onto the suction lines at 4 or 8 o’clock positions. PANEL CHECKS (POWER ON – BOTH UNIT SWITCH OFF) G 1. Apply 3-phase power and verify its value. Voltage imbalance should be no more than 2% of the average voltage. G 2. Apply 120VAC and verify its value on the terminal block in the Power Panel. Make the measurement between terminals 5 and 2 of CTB2. The voltage should be 120VAC +/- 10%. TABLE 25 – SETPOINTS OPTIONS Display Language Sys 1 Switch Sys 2 Switch Unit Type Chilled Liquid Ambient Control Local/ Remote Mode Control Mode Display Units Lead/Lag Control Fan Control Manual Override COOLING SETPOINTS Cooling Setpoint Range EMS-PWM Max. Setpoint PROGRAM Discharge Pressure Cutout Suct. Pressure Cutout Low Amb. Temp. Cutout Leaving Liquid Temp. Cutout Anti-Recycle Time Fan Control On-Pressure Fan Differential Off-Pressure Total # of Compressors YORK INTERNATIONAL FORM 150.62-NM1 G 3. Program/verify the Cooling Setpoints, Program Setpoints, and unit Options. Record the values below (see sections on Setpoints and Unit keys for programming instruction). G 4. Put the unit into Service Mode (as described under the Control Service And Troubleshooting section) and cycle each condenser fan to ensure proper rotation. G 5. Prior to this step, turn system 2 off (if applicable refer to Option 2 under “Unit Keys” section for more information on system switches.) Connect a manifold gauge to system 1 suction and discharge service valves. Place the Unit Switch in the control panel to the ON position. As each compressor cycles on, ensure that the discharge pressure rises and the suction pressure decreases. If this does not occur, the compressor being tested is operating in the reverse direction and must be corrected. After verifying proper compressor rotation, turn the Unit Switch to “OFF.” The chilled liquid setpoint may need to be temporarily lowered to ensure all compressors cycle “on.” This unit uses scroll compressors which can only operate in one direction. Failure to observe these steps could lead to compressor failure. G 6. YCAL0040 - YCAL0080 units only – Turn system 1 off and system 2 on (refer to Option 2 under “Unit Keys” section for more information on system switches.) Place the Unit Switch in the control panel to the ON position. As each compressor cycles “on,” ensure that the discharge pressure rises and the suction pressure decreases. If this does not occur, the compressor being tested is operating in the reverse direction and must be corrected. After verifying proper compressor rotation, turn the Unit Switch to “OFF.” YORK INTERNATIONAL The chilled liquid setpoint may need to be temporarily lowered to ensure all compressors cycle “on.” G 7. After verifying compressor rotation, return the Unit Switch to the off position and ensure that both Systems are programmed for “ON” (refer to Option 2 under “Unit Keys” section for more information on system switches). INITIAL START-UP After the preceding checks have been completed and the control panel has been programmed as required in the pre-startup checklist, the chiller may be placed into operation. G 1. Place the Unit Switch in the control panel to the ON position. G 2. The first compressor will start and a flow of refrigerant will be noted in the sight glass. After several minutes of operation, the vapor in the sight glass will clear and there should be a solid column of liquid when the TXV stabilizes. G 3. Allow the compressor to run a short time, being ready to stop it immediately if any unusual noise or adverse conditions develop. G 4. Check the system operating parameters. Do this by selecting various displays such as pressures and temperatures and comparing these readings to pressures and temperatures taken with manifold gauges and temperature sensors. G 5. With an ammeter, verify that each phase of the condenser fans and compressors are within the RLA as listed under Electrical Data. CHECKING SUPERHEAT AND SUBCOOLING The subcooling and superheat should always be checked when charging the system with refrigerant. When the refrigerant charge is correct, there will be no vapor in the liquid sight glass with the system operating under full load conditions, and there will be 15°F (8.34°C) subcooled liquid leaving the condenser. An overcharged system should be guarded against. The temperature of the liquid refrigerant out of the condenser should be no more than 15°F (8.34°C) subcooled at design conditions. 55 1 Installation The subcooling temperature of each system can be calculated by recording the temperature of the liquid line at the outlet of the condenser and subtracting it from the liquid line saturation temperature at the liquid stop valve (liquid line saturation temp. is converted from a temperature/pressure chart). Example: Example: Liquid line pressure = 202 PSIG converted to minus liquid line temp. SUBCOOLING = When adjusting the expansion valve, the adjusting screw should be turned not more than one turn at a time, allowing sufficient time (approximately 15 minutes) between adjustments for the system and the thermal expansion valve to respond and stabilize. 102°F - 87°F 15°F The subcooling should be adjusted to 15°F at design conditions. G 1. Record the liquid line pressure and its corresponding temperature, liquid line temperature and subcooling below: Liq Line Press = Saturated Temp = Liq Line Temp = Subcooling = SYS 1 _______ _______ _______ _______ SYS 2 _______ PSIG _______ °F _______ °F _______ °F After the subcooling is verified, the suction superheat should be checked. The superheat should be checked only after steady state operation of the chiller has been established, the leaving water temperature has been pulled down to the required leaving water temperature, and the unit is running in a fully loaded condition. Correct superheat setting for a system is 10°F (5.56°C) 18" (46 cm) from the cooler. The superheat is calculated as the difference between the actual temperature of the returned refrigerant gas in the suction line entering the compressor and the temperature corresponding to the suction pressure as shown in a standard pressure/temperature chart. 56 Suction Temp = minus Suction Press 60 PSIG converted to Temp Superheat = 46°F - 34°F 12°F Assure that superheat is set at 10°F (5.56°C). G 2. Record the suction temperature, suction pressure, suction saturation temperature, and superheat of each system below: Suction temp = Suction Pressure = Saturation Temp = Superheat = SYS 1 _______ _______ _______ _______ SYS 2 _______ °F _______ PSIG _______ °F _______ °F LEAK CHECKING G 1. Leak check compressors, fittings, and piping to assure no leaks. If the unit is functioning satisfactorily during the initial operating period, no safeties trip and the compressors cycle to control water temperature to setpoint, the chiller is ready to be placed into operation. YORK INTERNATIONAL FORM 150.62-NM1 UNIT OPERATING SEQUENCE The operating sequence described below relates to operation on a hot water start after power has been applied, such as start-up commissioning. When a compressor starts, internal timers limit the minimum time before another compressor can start to 1 minute. door air temperature > 25°F (-4°C)). See the section on Operating Controls for details concerning condenser fan cycling. 1 1. For the chiller system to run, the Flow Switch must be closed, any remote cycling contacts must be closed, the Daily Schedule must not be scheduling the chiller off, and temperature demand must be present. 5. After 1 minutes of compressor run time, the next compressor in sequence will start when a system has to load. This compressor will be the one with the least run time that is currently not running in that system. Additional compressors will be started at 60 second intervals as needed to satisfy temperature setpoint. 2. When power is applied to the system, the microprocessor will start a 2 minute timer. This is the same timer that prevents an instantaneous start after a power failure. 6. If demand requires, the lag system will cycle on with the same timing sequences as the lead system. Refer to the section on Capacity Control for a detailed explanation of system and compressor staging. 3. At the end of the 2 minute timer, the microprocessor will check for cooling demand. If all conditions allow for start, the first compressor on the lead system will start and the liquid line solenoid will open. The compressor with the least run time in that system will be the first to start. Coincident with the start, the anticoincident timer will be set and begin counting downward from “60” seconds to “0” seconds. 7. As the load decreases below setpoint, the compressors will be shut down in sequence. This will occur at intervals of either 60, 30, or 20 seconds based on water temperature as compared to setpoint, and control mode. See the section on Capacity Control for a detailed explanation. If the unit is programmed for Auto Lead/Lag, the system with the shortest average run-time of the compressors will be assigned as the “lead” system. A new lead/lag assignment is made whenever all systems shut down. 4. Several seconds after the compressor starts, that systems first condenser fan will be cycled on (out- YORK INTERNATIONAL 8. When the last compressor in a “system” (two or three compressors per system), is to be cycled off, the system will initiate a pump-down. Each “system” has a pump-down feature upon shut-off. On a non-safety, non-unit switch shutdown, the LLSV will be turned off, and the last compressor will be allowed to run until the suction pressure falls below the suction pressure cutout or for 180 seconds, which ever comes first. 57 Unit Controls UNIT CONTROLS YORK MILLENNIUM CONTROL CENTER 00065VIP INTRODUCTION MICROPROCESSOR BOARD The YORK MicroComputer Control Center is a microprocessor based control system designed to provide the entire control for the liquid chiller. The control logic embedded in the microprocessor based control system will provide control for the chilled liquid temperatures, as well as sequencing, system safeties, displaying status, and daily schedules. The MicroComputer Control Center consists of four basic components, 1) microprocessor board, 2) transformer, 3) display and 4) keypad. The keypad allows programming and accessing setpoints, pressures, temperatures, cutouts, daily schedule, options, and fault information. The Microprocessor Board is the controller and decision maker in the control panel. System inputs such as pressure transducers and temperature sensors are connected directly to the Microprocessor Board. The Microprocessor Board circuitry multiplexes the analog inputs, digitizes them, and scans them to keep a constant watch on the chiller operating conditions. From this information, the Microprocessor then issues commands to the Relay Outputs to control contactors, solenoids, etc. for Chilled Liquid Temperature Control and to react to safety conditions. Remote cycling, demand limiting and chilled liquid temperature reset can be accomplished by field supplied contacts. Compressor starting/stopping and loading/unloading decisions are performed by the Microprocessor to maintain leaving or return chilled liquid temperature. These decisions are a function of temperature deviation from setpoint. A Master ON/Off switch is available to activate or deactivate the unit. 58 Keypad commands are acted upon by the micro to change setpoints, cutouts, scheduling, operating requirements, and to provide displays. The on-board power supply converts 24VAC from the 1T transformer to a +12VDC and +5VDC regulated supply located on the Microprocessor Board. This voltage is used to operate integrated circuitry on the board. The 40 character display and unit sensors are supplied power from the micro board 5VDC supply. 24VAC is rectified and filtered to provide unregulated +30 VDC to supply the flow switch, PWM remote temperature reset, and demand limit circuitry which is available to be used with field supplied contacts. YORK INTERNATIONAL FORM 150.62-NM1 The Microprocessor Board energizes on-board relays to output 120VAC to motor contactors, solenoid valves, etc. to control system operation. UNIT SWITCH A UNIT ON/OFF switch is just underneath the keypad. This switch allows the operator to turn the entire unit OFF if desired. The switch must be placed in the ON position for the chiller to operate. DISPLAY The 40 Character Display (2 lines of 20 characters) is a liquid crystal display used for displaying system parameters and operator messages. The display in conjunction with the keypad, allows the operator to display system operating parameters as well as access programmed information already in memory. The display has a lighted background for night viewing and for viewing in direct sunlight. When a key is pressed, such as the OPER DATA key, system parameters will be displayed and will remain on the display until another key is pressed. The system parameters can be scrolled with the use of the up and down arrow keys. The display will update all information at a rate of about 2 seconds. Display Messages may show characters indicating “greater than” (>) or “less than” (<). These characters indicate the actual values are greater than or less than the limit values which are being displayed. YORK INTERNATIONAL KEYPAD The 12 button non-tactile keypad allows the user to retrieve vitals system parameters such as system pressures, temperatures, compressor running times and starts, option information on the chiller, and system setpoints. This data is useful for monitoring chiller operation, diagnosing potential problems, troubleshooting, and commissioning the chiller. It is essential the user become familiar with the use of the keypad and display. This will allow the user to make full use of the capabilities and diagnostic features available. BATTERY BACK-UP The Microprocessor Board contains a Real Time Clock integrated circuit chip with an internal battery back-up. The purpose of this battery back-up is to assure any programmed values (setpoints, clock, cutouts, etc.) are not lost during a power failure regardless of the time involved in a power cut or shutdown period. UNIT STATUS Pressing the STATUS key will enable the operator to determine current chiller operating status. The messages displayed will include running status, cooling demand, fault status, external cycling device status, load limiting and anti-recycle/coincident timer status. The display will be a single message relating to the highest priority message as determined by the micro. Status messages fall into the categories of General Status and Fault Status. 59 2 Unit Controls “STATUS” KEY 00066VIP The following messages are displayed when the “Status” key is pressed. Following each displayed message is an explanation pertaining to that particular display. GENERAL STATUS MESSAGES In the case of messages which apply to individual systems, SYS 1 and, SYS 2 messages will both be displayed and may be different. In the case of single system units, all SYS 2 messages will be blank. U N I T SW I T C H S H U T D OWN O F F This message informs the operator that the UNIT switch on the control panel is in the OFF position which will not allow the unit to run. R E M O T E C O N T R O L L E D S H U T D OWN The REMOTE CONTROLLED SHUTDOWN message indicates that either an ISN or BAS system has turned the unit off, not allowing it to run. D A I L Y S C H E D U L E S H U T D OWN The DAILY SCHEDULE SHUTDOWN message indicates that the daily/holiday schedule programmed is keeping the unit from running. F L OW SW I T C H / R E M S T O P N O R U N P E R M I S S I V E NO RUN PERM shows that either the flow switch is open or a remote start/stop contact is open in series with the flow switch. 60 YORK INTERNATIONAL FORM 150.62-NM1 S Y S S Y S 1 2 S Y S S Y S SW I T C H SW I T C H O F F O F F Sys Switch Off tells that the system switch under OPTIONS is turned off. The system will not be allowed to run until the switch is turned back on. S Y S S Y S 1 2 N O N O C O O L C O O L L O A D L O A D These messages inform the operator that the chilled liquid temperature is below the point (determined by the setpoint and control range) that the micro will bring on a system or that the micro has not loaded the lead system far enough into the loading sequence to be ready to bring the lag system ON. The lag system will display this message until the loading sequence is ready for the lag system to start. S Y S S Y S 1 2 C OM P S C OM P S R U N R U N X X The COMPS RUNNING message indicates that the respective system is running due to demand. The “X” will be replaced with the number of compressors in that system that are running. S Y S S Y S 1 2 A R A R T I M E R T I M E R X X X X S S The anti-recycle timer message shows the amount of time left on the respective systems anti-recycle timer. This message is displayed when the system is unable to start due the anti-recycle timer being active. YORK INTERNATIONAL S Y S S Y S 1 2 A C A C T I M E R T I M E R X X X X S S The anti-coincident timer is a software feature that guards against 2 systems starting simultaneously. This assures instantaneous starting current does not become excessively high due to simultaneous starts. The micro limits the time between compressor starts to 1 minute regardless of demand or the anti-recycle timer being timed out. The anti-coincident timer is only present on two system units. S Y S S Y S 1 2 D S C H D S C H L I M I T I N G L I M I T I N G When this message appears, discharge pressure limiting is in effect. The Discharge Pressure Limiting feature is integral to the standard software control; however the discharge transducer is optional. Therefore, it is important to keep in mind that this control will not function unless the optional discharge transducer is installed in the system. The limiting pressure is a factory set limit to keep the system from faulting on the high discharge pressure cutout due to high load or pull down conditions. When the unload point is reached, the micro will automatically unload the affected system by deenergizing one compressor. The discharge pressure unload will occur when the discharge pressure gets within 15 PSIG of the programmed discharge pressure cutout. This will only happen if the system is fully loaded and will shut only one compressor off. If the system is not fully loaded, discharge limiting will not go into effect. Reloading the affected system will occur when the discharge pressure drops to 85% of the unload pressure and 10 minutes have elapsed. 61 2 Unit Controls S Y S S Y S 1 2 S U C T S U C T L I M I T I N G L I M I T I N G When this message appears, suction pressure limiting is in effect. Suction Pressure Limiting is only available on units that have the suction pressure transducer installed. If a low pressure switch is installed instead, suction pressure limiting will not function. The suction pressure limit is a control point that limits the loading of a system when the suction pressure drops to within 15% above the suction pressure cutout. On a standard system programmed for 44 PSIG/3.0 Bar suction pressure cutout, the micro would inhibit loading of the affected system with the suction pressure less than or equal to 1.15 * 44 PSIG/3.0 Bar = 50 PSIG/3.5 Bar. The system will be allowed to load after 60 seconds and after the suction pressure rises above the suction pressure limit point. expect to see any other STATUS messages when in the MANUAL OVERRIDE mode. MANUAL OVERRIDE is to only be used in emergencies or for servicing. Manual override mode automatically disables itself after 30 minutes. S Y S S Y S 1 2 P U M P I N G P U M P I N G D OWN D OWN The PUMPING DOWN message indicates that a compressor in the respective system is presently in the process of pumping the system down. When pumpdown is initiated, the liquid line solenoid will close and a compressor will continue to run. When the suction pressure decreases to the suction pressure cutout setpoint, the compressor will cycle off. If pump down cannot be achieved three minutes after the liquid line solenoid closes, the compressor will cycle off. FAULT STATUS MESSAGES S Y S S Y S 1 2 L O A D L O A D L I M I T L I M I T X X % X X % This message indicates that load limiting is in effect and the percentage of the limiting in effect. This limiting could be due to the load limit/pwm input or an ISN controller could be sending a load limit command. M A N U A L O V E R R I D E If MANUAL OVERRIDE mode is selected, the STATUS display will display this message. This will indicate that the Daily Schedule is being ignored and the chiller will start-up when chilled liquid temperature allows, Remote Contacts, UNIT switch and SYSTEM switches permitting. This is a priority message and cannot be overridden by anti-recycle messages, fault messages, etc. when in the STATUS display mode. Therefore, do not 62 Safeties are divided into two categories - system safeties and unit safeties. System safeties are faults that cause the individual system to be shut down. Unit safeties are faults that cause all running compressors to be shut down. Following are display messages and explanations. SYSTEM SAFETIES System safeties are faults that cause individual systems to be shut down if a safety threshold is exceeded for 3 seconds. They are auto reset faults in that the system will be allowed to restart automatically after the fault condition is no longer present. However, if 3 faults on the same system occur within 90 minutes, that system will be locked out on the last fault. This condition is then a manual reset. The system switch (under OPTIONS key) must be turned off and then back on to clear the lockout fault. YORK INTERNATIONAL FORM 150.62-NM1 S Y S S Y S 1 2 H I G H H I G H D S C H D S C H P R E S P R E S The Discharge Pressure Cutout is a software cutout in the microprocessor and is backed-up by a mechanical high pressure cutout switch located in the refrigerant circuit. It assures that the system pressure does not exceed safe working limits. The system will shutdown when the programmable cutout is exceeded and will be allowed to restart when the discharge pressure falls below the cutout. Discharge transducers must be installed for this function to operate. S Y S S Y S 1 2 L OW L OW S U C T S U C T P R E S S P R E S S The Suction Pressure Cutout is a software cutout that protects the chiller from an evaporator freeze-up should the system attempt to run with a low refrigerant charge or a restriction in the refrigerant circuit. At system start, the cutout is set to 10% of programmed value. During the next 3 minutes the cutout point is ramped up to the programmed cutout point. If at any time during this 3 minutes the suction pressure falls below the ramped cutout point, the system will stop. This cutout is ignored for the first 90 seconds of system run time to avoid nuisance shutdowns, especially on units that utilize a low pressure switch in place of the suction pressure transducer. After the first 3 minutes, if the suction pressure falls below the programmed cutout setting, a “transient protection routine” is activated. This sets the cutout at 10% YORK INTERNATIONAL of the programmed value and ramps up the cutout over the next 30 seconds. If at any time during this 30 seconds the suction pressure falls below the ramped cutout, the system will stop. This transient protection scheme only works if the suction pressure transducer is installed. When using the mechanical LP switch, the operating points of the LP switch are: opens at 23 PSIG +/- 5 PSIG (1.59 barg +/- .34 barg), and closes at 35 PSIG +/- 5 PSIG (2.62 barg +/- .34 barg). S Y S S Y S 1 2 M P / H P C O M P / H P C O F A U L T F A U L T The Motor Protector/Mechanical High Pressure Cutout protect the compressor motor from overheating or the system from experiencing dangerously high discharge pressure. This fault condition is present when CR1 (SYS 1) or CR2 (SYS 2) relays de-energize due to the HP switch or the motor protector opening. This causes the respective CR contacts to open causing 0 VDC to be read on the inputs to the microboard. The fault condition is cleared when a 30 VDC signal is restored to the input. The internal motor protector opens at 185°F - 248°F (85°C - 120°C) and auto resets. The mechanical HP switch opens at 405 PSIG +/- 10 PSIG (27.92 barg +/.69 barg) and closes at 330 PSIG +/- 25 PSIG (22.75 barg +/- 1.72 barg). UNIT SAFETIES Unit safeties are faults that cause all running compressors to be shut down. Unit faults are auto reset faults in that the unit will be allowed to restart automatically after the fault condition is no longer present. 63 2 Unit Controls U N I T F A U L T : L OW A M B I E N T T E M P The Low Ambient Temp Cutout is a safety shutdown designed to protect the chiller from operating in a low ambient condition. If the outdoor ambient temperature falls below the programmable cutout, the chiller will shut down. Restart can occur when temperature rises 2°F above the cutoff. U N I T F A U L T : L OW L I Q U I D T E M P Restart is allowed after the unit is fully powered again and the anti-recycle timers have finished counting down. UNIT WARNING The following message is not a unit safety and will not be logged to the history buffer. It is a unit warning and will not auto-restart. Operator intervention is required to allow a re-start of the chiller. ! ! L OW B A T T E R Y ! ! C H E C K P R O G / S E T P / O P T N U N I T F A U L T : 1 1 5 V A C U N D E R V O L T A G E The Low Battery Warning can only occur at unit powerup. On micro panel power-up, the RTC battery is checked. If a low battery is found, all programmed setpoints, program values, options, time, schedule, and history buffers will be lost. These values will all be reset to their default values which may not be the desired operating values. Once a faulty battery is detected, the unit will be prevented from running until the PROGRAM key is pressed. Once PROGRAM is pressed the antirecycle timers will be set to the programmed anti-recycle time to allow the operator time to check setpoints, program values, and options. The Under Voltage Safety assures that the system is not operated at voltages where malfunction of the microprocessor could result in system damage. When the115VAC to the micro panel drops below a certain level, a unit fault is initiated to safely shut down the unit. If a low battery is detected, it should be replaced as soon as possible. The programmed values will all be lost and the unit will be prevented from running on the next power interruption. The RTC/battery is located at U17 on the microboard. The Low Leaving Chilled Liquid Temp Cutout protects the chiller form an evaporator freeze-up should the chilled liquid temperature drop below the freeze point. This situation could occur under low flow conditions or if the micro panel setpoint values are improperly programmed. Anytime the leaving chilled liquid temperature (water or glycol) drops below the cutout point, the chiller will shutdown. Restart can occur when chilled liquid temperature rises 2°F above the cutout. 64 YORK INTERNATIONAL FORM 150.62-NM1 STATUS KEY MESSAGES TABLE 26 – STATUS KEY MESSAGES STATUS KEY MESSAGES General Messages Fault Messages Unit Switch Off Shutdown System Safeties Unit Safeties Remote Controlled Shutdown System X High Disch Pressure Low Ambient Temp Daily Schedule Shutdown System X Low Suct Pressure Low Liquid Temp Flow Switch/Rem Stop No Run Permissive System X MP/HPCO Fault 115 VAC Undervoltage System X Switch Off 2 Low Battery Check Prog/Step/Optn (Unit Warning Message) System X No Cooling load System X Comps Run System X AR Timer System X AC Timer System X Disch Limiting System X Suction Limiting System X Percentage Load Limiting Manual Overide Status LD04144 System X Pumping Down (on shutdown) YORK INTERNATIONAL 65 Unit Controls DISPLAY/PRINT KEYS 00067VIP The Display/Print keys allow the user to retrieve system and unit information that is useful for monitoring chiller operation, diagnosing potential problems, troubleshooting, and commissioning the chiller. System and unit information, unit options, setpoints, and scheduling can also be printed out with the use of a printer. Both real-time and history information are available. OPER DATA Key The OPER DATA key gives the user access to unit and system operating parameters. When the OPER DATA key is pressed, system parameters will be displayed and remain on the display until another key is pressed. After pressing the OPER DATA key, the various operating data screens can be scrolled through by using the UP and DOWN arrow keys located under the “ENTRY” section. 66 With the “UNIT TYPE” programmed as a liquid chiller (under the Options key), the following is a list of operating data screens in the order that they are displayed: L C H L T R C H L T = = 4 6 . 2 ° F 5 7 . 4 ° F ° This display shows chilled leaving and return liquid temperatures. The minimum limit on the display for these parameters are 9.2°F (-12.7°C). The maximum limit on the display is 85.4°F (29.7°C). A M B I E N T A I R = 8 7 . 5 ° F T E M P This display shows the ambient air temperature. The minimum limit on the display is 0.4°F (-17.6°C).The maximum limit on the display is 131.2°F (55.1°C). YORK INTERNATIONAL FORM 150.62-NM1 S Y S 1 S P D P = 7 2 . 1 = 2 2 7 . 0 P S I G P S I G S Y S 2 S P D P = 7 3 . 6 = 2 1 9 . 8 P S I G P S I G These displays show suction and discharge pressures for systems 1 & 2. The discharge pressure transducer is optional on all models If the optional discharge transducer is not installed, the discharge pressure would display 0 PSIG (0 barg). Some models come factory wired with a low pressure switch in place of the suction transducer. In this case, the suction pressure would only be displayed as the maximum suction pressure reading of >200 PSIG (13.79 barg) when closed, or < 0 PSIG (0 barg) when open. The minimum limits for the display are: Suction Pressure: 0 PSIG (0 barg) Discharge Pressure: 0 PSIG (0 barg) The maximum limits for the display are: Suction Pressure: 200 PSIG (13.79 barg) Discharge Pressure: 400 PSIG (27.58 barg) S Y S S Y S X H O U R S 1 = X X X X X 2 = X X X X X, 3 = X X X X X X S T A R T S 1 = X X X X X 2 = X X X X X, 3 = X X X X X The above two messages will appear sequentially for each system. The first display shows accumulated running hours of each compressor for the specific system. The second message shows the number of starts for each compressor on each system. YORK INTERNATIONAL L O A D T I M E R = 5 8 U N L O A D T I M E R = 0 S E C S E C This display of the load and unload timers indicate the time in seconds until the unit can load or unload. Whether the systems loads or unloads is determined by how far the actual liquid temperature is from setpoint. A detailed description of unit loading and unloading is covered under the topic of Capacity Control. C O O L I N G 2 O F 8 D E M A N D S T E P S The display of COOLING DEMAND indicates the current “step” in the capacity control scheme. The number of available steps are determined by how many compressors are in the unit. In the above display, the “2” does not mean that two compressor are running but only indicates that the capacity control scheme is on step 2 of 8. Capacity Control is covered in more detail in this publication which provides specific information on compressor staging. L E A D S Y S T E M I S S Y S T E M N U M B E R 2 This display indicates the current LEAD system. In this example system 2 is the LEAD system, making system 1 the LAG compressor. The LEAD system can be manually selected or automatic. Refer to the programming under the “Options” key. A unit utilizing hot gas bypass should be programmed for MANUAL with system 1 as the lead system. Failure to do so will prevent hot gas operation if system 2 switches to the lead system when programmed for AUTOMATIC LEAD/LAG. 67 2 Unit Controls E V A P P U M P I S E V A P H E A T E R I S O N O F F This display indicates the status of the evaporator pump contacts and the evaporator heater. The evaporator pump dry contacts are energized when any compressor is running, or the unit is not OFF on the daily schedule and the unit switch is on, or the unit has shutdown on a Low Leaving Chilled Liquid fault. However, even if one of above is true, the pump will not run if the micro panel has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump motor overheating. The evaporator heater is controlled by ambient air temperature. When the ambient temperature drops below 40°F the heater is turned on. When the temperature rises above 45°F the heater is turned off. An under voltage condition will keep the heater off until full voltage is restored to the system. A C T I V E R E M O T E N O N E C T R L There are several types of remote systems that can be used to control or monitor the unit. The following messages indicate the type of remote control mode active: NONE – no remote control active. Remote monitoring may be via ISN ISN – YorkTalk via ISN (Remote Mode) *LOAD LIM – load limiting enabled. Can be either stage 1 or stage 2 of limiting. *PWM TEMP – EMS-PWM temperature reset S Y S X N U M B E R C OM P S R U N N I N G O F X S Y S X R U N T I M E X X - X X - X X - X X D - H - M - S S Y S H O T S Y S X L L S V I S O N G A S S O L I S O F F X F A N S T A G E 3 The above four message will appear sequentially, first for system 1, then for system 2. The first message indicates the system and number of compressors that are being commanded on by the micro board. The second message indicates the system run time in days – hours – minutes – seconds. Please note that this is not accumulated run time but pertains only to the current system cycle. The third message indicates the system, and whether the liquid line solenoid and hot gas solenoid are being commanded on by the micro board. Please note that hot gas in not available for system 2, so there is no message pertaining to the hot gas solenoid when system 2 message is displayed. The fourth message indicates what stage of condenser fan operation is active. Unless a low ambient kit is added, only stages 1 and 2 will be used to cycle the condenser fans. However, stage 3 may be shown in this display without a low ambient kit added, but it has no effect. See the section on Condenser Fan Control in the Unit Operation section. *Refer to the section on Operating Controls 68 YORK INTERNATIONAL FORM 150.62-NM1 OPER DATA Quick Reference List The following table is a quick reference list for information available under the OPER DATA key. TABLE 27 – OPERATION DATA Oper Data Key Leaving & Chilled Liquid Temps Ambient Air Temperature 2 System 1 Discharge & Suction Pressure System 2 Discharge & Suction Pressure *System X Accumulated Run Times *System X Accumulated Starts Load and Unload Timers Cooling Demand Steps Lead System Indicator Evaporator Pump Contacts & Heater Status Remote Control Active? *System X Number of Comp. Running *System X Run Time Sys 1 LLSV & HGSV Status LD03684 *System X Condenser Fan Staging * Block of information repeats for each system YORK INTERNATIONAL 69 Unit Controls PRINT Key OPERATING DATA PRINTOUT The PRINT key allows the operator to obtain a printout of real-time system operating data or a printout of system data at the “instant of the fault” on the last six faults which occurred on the unit. An optional printer is required for the printout. Pressing the PRINT key and then OPER DATA key allows the operator to obtain a printout of current systemoperating parameters. When the OPER DATA key is pressed, a snapshot will be taken of system operating conditions and panel programming selections. This data will be temporarily stored in memory and transmission of this data will begin to the printer. A sample Oper Data printout is shown below. SYSTEM 1 DATA YORK INTERNATIONAL CORPORATION MILLENNIUM LIQUID CHILLER UNIT STATUS 2:04PM 01 JAN 99 SYS 1 NO COOLING LOAD SYS 2 COMPRESSORS RUNNING 2 OPTIONS CHILLED LIQUID WATER AMBIENT CONTROL STANDARD LOCAL/REMOTE MODE REMOTE CONTROL MODE LEAVING LIQUID LEAD/LAG CONTROL AUTOMATIC FAN CONTROL AMB & DSCH PRESS PROGRAM VALUES DSCH PRESS CUTOUT 395 PSIG SUCT PRESS CUTOUT 44 PSIG LOW AMBIENT CUTOUT 25.0 DEGF LEAVING LIQUID CUTOUT 25.0 DEGF ANTI RECYCLE TIME 600 SECS FAN CONTROL ON PRESS 230 PSIG FAN DIFF OFF PRESS 80 PSIG NUMBER OF COMPRESSORS 6 UNIT DATA RETURN LIQUID TEMP 58.2 DEGF LEAVING LIQUID TEMP 53.0 DEGF DISCHARGE AIR TEMP 55.3 DEGF COOLING RANGE 42.0 +/- 2.0 DEGF SYS 1 SETPOINT 70 +/- 3 PSIG SYS 2 SETPOINT 70 +/-3 PSIG AMBIENT AIR TEMP 74.8 DEGF LEAD SYSTEM SYS 2 EVAPORATOR PUMP ON EVAPORATOR HEATER OFF ACTIVE REMOTE CONTROL NONE SOFTWARE VERSION C.M02.01.00 70 COMPRESSORS STATUS OFF RUN TIME 0- 0- 0- 0 D-H-M-S SUCTION PRESSURE 66 PSIG DISCHARGE PRESSURE 219 PSIG SUCTION TEMPERATURE 52.8 DEGF LIQUID LINE SOLENOID OFF HOT GAS BYPASS VALVE OFF CONDENSER FAN STAGES OFF SYSTEM 2 DATA COMPRESSORS STATUS 2 RUN TIME 0- 0- 1-46 D-H-M-S SUCTION PRESSURE 51 PSIG DISCHARGE PRESSURE 157 PSIG LIQUID LINE SOLENOID ON CONDENSER FAN STAGES 3 DAILY SCHEDULE S M MON TUE WED THU FRI SAT HOL T W T F S START=00:00AM START=00:00AM START=00:00AM START=00:00AM START=00:00AM START=00:00AM START=00:00AM *=HOLIDAY STOP=00:00AM STOP=00:00AM STOP=00:00AM STOP=00:00AM STOP=00:00AM STOP=00:00AM STOP=00:00AM See Service And Troubleshooting section for Printer Installation information. YORK INTERNATIONAL FORM 150.62-NM1 HISTORY PRINTOUT Pressing the PRINT key and then the HISTORY key allows the operator to obtain a printout of information relating to the last 6 Safety Shutdowns which occurred. The information is stored at the instant of the fault, regardless of whether the fault caused a lockout to occur. The information is also not affected by power failures (long term internal memory battery back-up is built into the circuit board) or manual resetting of a fault lock-out. When the HISTORY key is pressed, a printout is transmitted of all system operating conditions which were stored at the “instant the fault occurred” for each of the 6 Safety Shutdowns buffers. The printout will begin with the most recent fault which occurred. The most recent fault will always be stored as Safety Shutdown No. 1. Identically formatted fault information will then be printed for the remaining safety shutdowns. Information contained in the Safety Shutdown buffers is very important when attempting to troubleshoot a system problem. This data reflects the system conditions at the instant the fault occurred and often reveals other system conditions which actually caused the safety threshold to be exceeded. The history printout is similar to the operational data printout shown in the previous section. The differences are in the header and the schedule information. The daily schedule is not printed in a history print. One example history buffer printout is shown below. The data part of the printout will be exactly the same as the operational data print so it is not repeated here. The difference is that the Daily Schedule is not printed in the history print and the header will be as shown below. YORK INTERNATIONAL YORK INTERNATIONAL CORPORATION MILLENNIUM LIQUID CHILLER SAFETY SHUTDOWN NUMBER 1 SHUTDOWN @ 3:56PM 29 JAN 99 SYS 1 SYS 2 HIGH DSCH PRESS SHUTDOWN NO FAULTS HISTORY DISPLAYS The HISTORY key gives the user access to many unit and system operating parameters at the time of a unit or system safety shutdown. When the HISTORY key is pressed the following message is displayed. D I S P L A Y S A F E T Y S H U TD OWN N O . 1 ( 1 TO 6 ) While this message is displayed, the UP or DOWN arrow keys can be used to select any of the six history buffers. Buffer number 1 is the most recent, and buffer number 6 is the oldest safety shutdown that was saved. After selecting the shutdown number, pressing the ENTER key displays the following message which shows when the shutdown occurred. S H U T D OWN O C C U R R E D 1 1 : 2 3 P M 2 9 M A Y 9 8 71 2 Unit Controls The UP and DOWN arrows are used to scroll forwards and backwards through the history buffer to display the shutdown conditions. Following is a list of displayed history data screens in the order that they are displayed: U N I T F A U L T : L OW L I Q U I D T E M P U N I T L I Q U I D T Y P E C H I L L E R C H I L L E D L I Q U I D X X X X X A M B I E N T C O N T R O L X X X X X X X X X X F A N C O N T R O L O N P R E S S U R E = X X X P S I G F A N D I F F E R E N T I A L P R E S S U R E = PS I G L C H L T R C H L T L E A D / L A G C O N T R O L X X X X X X X X F A N CO N T R O L D I S C H A R G E PR E S S U R E M A N U A L O V E R R I D E X X X X X X X X X S U C T I O N P R E S S U R E C U T O U T = X X X X P S I G L OW A M B I E N T T E M P C U T O U T = X X X . X ° F 72 ° F ° F A M B I E N T A I R = X X X . X ° F T E M P ° F L E A D S Y S T E M I S S Y S T E M N U M B E R X E V A P P U M P I S X X X E V A P H E A T E R I S X X X A C T I V E R E MO T E X X X X C T R L S Y S X C OM P S N U M B E R O F R U N N I N G X M O D E D I S C H A R G E P R E S S U R E C U T O U T = X X X X P S I G L E A V I N G C U T O U T X X X . X X X X . X S E T P O I N T = X X . X R A N G E = + / - ° F L O C A L / RE M O T E MO D E X X X X X X X X X C O N T R O L MO D E L E A V I N G L I Q U I D = = OFF L I Q U I D T E M P = X X X . X ° F S Y S X R U N X X - X X - X X - X X S Y S X S Y S H O T S Y S S P D P = = X X X X X X X X X L L S V G A S S O L X F A N T I M E D - H - M - S P S I G P S I G I S I S X X X X X X S T A G E X X X Explanation of the above displays are covered under the STATUS, DISPLAY/PRINT, SETPOINTS, or UNIT keys. YORK INTERNATIONAL FORM 150.62-NM1 “ENTRY” KEYS 2 00068VIP The Entry Keys allows the user to view, change programmed values. The ENTRY keys consist of an UP ARROW key, DOWN ARROW key, and an ENTER/ADV key. UP AND DOWN ARROW KEYS Used in conjunction with the OPER DATA and HISTORY keys, the UP and DOWN arrow keys allow the user to scroll through the various data screens. Refer to the section on “Display/Print” keys for specific information on the displayed information and specific use of the UP and DOWN arrow keys. The UP and DOWN arrow keys are also used for programming the control panel such as changing cooling YORK INTERNATIONAL setpoints, setting the daily schedule, changing safety setpoints, chiller options, and setting the clock. ENTER/ADV key The ENTER key must be pushed after any change is made to the cooling setpoints, daily schedule, safety setpoints, chiller options, and the clock. Pressing this key “enters” the new values into memory. If the ENTER key is not pressed after a value is changed, the changes will not be “entered” and the original values will be used to control the chiller. Programming and a description on the use of the UP and DOWN arrow and ENTER/ADV keys are covered in detail under the SETPOINTS, and UNIT keys. 73 Unit Controls “SETPOINTS” KEYS 00069IP Unit must first be programmed for “Unit Type” Liquid Chiller under Option S key to allow programming of appropriate setpoints. Programming of the cooling setpoints, daily schedule, and safeties is accomplished by using the keys located under the SETPOINTS section. The three keys involved are labeled COOLING SETPOINTS, SCHEDULE/ADVANCE DAY, and PROGRAM. Following are instructions for programming the respective setpoints. The same instruction should be used to view the setpoints with the exception that the setpoint will not be changed. COOLING SETPOINTS The Cooling setpoint and Range can be programmed by pressing the COOLING SETPOINTS key. After pressing the COOLING SETPOINTS key, the Cooling Mode (leaving chilled liquid or return chilled liquid) will 74 be displayed for a few seconds, and then the setpoint entry screen will be displayed. Following are the four possible messages that can be displayed after pressing the COOLING SETPOINT key, indicating the cooling mode: L O C A L L E A V I N G WA T E R T E M P C O N T R O L This message indicates that the cooling setpoint is under LOCAL control. That is, the cooling setpoint is controlling to the locally programmed setpoint. The message also indicates that the control point is based on LEAVING water temperature out of the evaporator. L O C A L R E T U R N WA T E R T E M P C O N T R O L This message indicates that the cooling setpoint is under LOCAL control (the cooling setpoint is controlling to the locally programmed cooling setpoint). However, unlike the previous message, it is now indicating that the control point is based on RETURN water temperature into the evaporator. YORK INTERNATIONAL FORM 150.62-NM1 R E M 0 T E L E A V I N G WA T E R T E M P C O N T R O L This message indicates that the cooling setpoint is under REMOTE control. When under remote control, the cooling setpoint will be determined by a remote device such as an ISN control. The message also indicates that the control point is based on LEAVING water temperature out of the evaporator. R E M O T E R E T U R N WA T E R T E M P C O N T R O L This message indicates that the cooling setpoint is under REMOTE control. When under remote control, the cooling setpoint will be determined by a remote device such as an ISN control. This message also indicates that the control point is based on RETURN water temperature into the evaporator. Immediately after the control mode message is displayed, the COOLING SETPOINT entry screen will be displayed. If the unit is programmed for LEAVING liquid control the following message will be displayed: S E T P O I N T R A N G E = = +/- 4 5 . 0 ° F 2 . 0 ° F (leaving chilled water control) The above message shows the current chilled water temperature SETPOINT at 45.0°F (notice the cursor positioned under the number 5). Pressing either the UP or DOWN arrow will change the setpoint in .5°F increments. YORK INTERNATIONAL After using the UP and DOWN arrows to adjust to the desired setpoint, the ENTER/ADV key must be pressed to enter this number into memory and advance to the RANGE SETPOINT. This will be indicated by the cursor moving under the current RANGE setpoint. The UP and DOWN arrow keys are used to set the RANGE, in .5 °F increments, to the desired RANGE setpoint. After adjusting the setpoint, the ENTER/ADV key must be pressed to enter the data into memory. Notice that the RANGE was programmed for +/- X.X° F. This indicates the SETPOINT to be in the center of the control range. If the control mode has been programmed for RETURN LIQUID control, the message below would be displayed in place of the previous message. 2 S E T P O I N T R A N G E = = 4 5 . 0 ° F + 2 . 0 ° F (return chilled liquid control) Notice that the range no longer has a +/- X.X °F, but only a + X.X °F RANGE setpoint. This indicates that the setpoint is not centered within the RANGE but could be described as the bottom of the control range A listing of the limits and the programmable values for the COOLING SETPOINTS are shown in Table 27. The SETPOINT and RANGE displays just described were based on LOCAL control. If the unit was programmed for REMOTE control (under the OPTIONS key), the above programmed setpoints would have no effect. Both LEAVING and RETURN control are described in detail under the section on Capacity Control. 75 Unit Controls Pressing the COOLING SETPOINTS key a second time will display the remote setpoint and cooling range. This display automatically updates about every 2 seconds. Notice that these setpoints are not “locally” programmable, but are controlled by a remote device such as an ISN control. These setpoints would only be valid if the unit was operating in the REMOTE mode. Pressing the COOLING SETPOINTS a third time will bring up the display that allows the Maximum EMSPWM Temperature Reset to be programmed. This message is shown below. The messages below illustrate both leaving chilled liquid control and return chilled liquid control respectively The Temp Reset value is the maximum allowable reset of the temperature setpoint. The setpoint can be reset upwards by the use of a contact closure on the PWM Temp Reset input (CTB1 terminals 13 - 20)). See the section on Operating Controls for a detailed explanation of this feature. R E M S E T P R A N G E = = 4 4 . 0 ° F + / - 2 . 0 ° F As with the other setpoints, the Up Arrow and Down Arrow keys are used to change the Temp Reset value. After using the UP and DOWN ARROWS to adjust to the desired setpoint, the ENTER/ADV key must be pressed to enter this number into memory. (leaving chilled liquid control) R E M S E T P R A N G E = = M A X E M S - P WM R E M O T E T E M P R E S E T = + 2 0 ° F 4 4 . 0 ° F 1 0 . 0 ° F (return chilled liquid control) The low limit, high limit, and default values for the keys under “SETPOINTS” are listed in Table 28. TABLE 28 – COOLING SETPOINTS PROGRAMMABLE LIMITS AND DEFAULTS SETPOINT KEY MODEL WATER COOLING LEAVING CHILLED LIQUID SETPOINT GLYCOL COOLING LEAVING CHILLED LIQUID CONTROL RANGE — WATER COOLING RETURNED CHILLED LIQUID SETPOINT GLYCOL COOLING RETURN CHILLED LIQUID CONTROL RANGE MAX EMS-PWM REMOTE TEMPERATURE RESET — — LOW LIMIT 40.0°F 4.4°C *10.0°F -12.2°C 1.5°F 0.8°C 40.0°F 4.4°C 10.0°F -12.2°C 4.0°F 2.2°C 2°F 1.0°C HIGH LIMIT **70.0°F 21.1°C **70.0°F 21.1°C 2.5°F DEFAULT 44.0°F 6.7°C 44.0°F 6.7°C 2.0°F 1.4°C 1.1°C 70.0°F 21.1°C 70.0°F 21.1°C 20.0°F 11.1°C 40°F 22.0°C 44.0°F 6.7°C 44.0°F 6.7°C 10.0°F 5.6°C 20°F 11.0°C * Refer to Engineering Guide for operation below 30°F (-1.1°C). Alternate thermal expansion valves must be used below 30°F (-1.1°C). * When using glycol, Leaving Chilled Liquid Setpoint should not be set below 20°F (-6.7°C). ** Do not exceed 55°F (12.8°C) setpoint before contacting the nearest York Office for application guidelines. 76 YORK INTERNATIONAL FORM 150.62-NM1 SCHEDULE/ADVANCE DAY key The SCHEDULE is a seven day daily schedule that allows one start/stop time per day. The schedule can be programmed Monday through Sunday with an alternate holiday schedule available. If no start/stop times are programmed, the unit will run on demand, providing the chiller is not shut off on a unit or system shutdown. The daily schedule is considered “not programmed” when the times in the schedule are all zeros (00:00 AM). To set the schedule, press the SCHEDULE/ADVANCE DAY key. The display will immediately show the following display. M O N S T A R T S T O P = = 0 0 : 0 0 0 0 : 0 0 A M A M The line under the 0 is the cursor. If the value is wrong, it may be changed by using the UP and DOWN arrow keys until correct. Pressing the ENTER/ADV key will enter the times and then move the cursor to the minute box. The operation is then repeated if necessary. This process may be followed until the hour, minutes, and meridian (AM or PM) of both the START and STOP points are set. After changing the meridian of the stop time, pressing the ENTER/ADV key will advance the schedule to the next day. Whenever the daily schedule is changed for Monday, all the other days will change to the new Monday schedule. This means if the Monday times are not applicable for the whole week then the exceptional days would need to be reprogrammed to the desired schedule. YORK INTERNATIONAL To page to a specific day press the SCHEDULE/ADVANCE DAY key. The start and stop time of each day may be programmed differently using the UP and DOWN arrow, and ENTER/ADV keys. After SUN (Sunday) schedule appears on the display a subsequent press of the SCHEDULE/ADVANCE DAY key will display the Holiday schedule. This is a two part display. The first reads: H O L S T A R T S T O P = = 0 0 : 0 0 0 0 : 0 0 A M A M The times may be set using the same procedure as described above for the days of the week. After changing the meridian of the stop time, pressing the ENTER/ ADV key will advance the schedule to the following display: S _ M T W T F S H O L I D A Y N O T E D B Y * The line below the empty space next to the S is the cursor and will move to the next empty space when the ENTER/ADV key is pressed. To set the Holiday, the cursor is moved to the space following the day of the week of the holiday and the UP arrow key is pressed. An * will appear in the space signifying that day as a holiday. The * can be removed by pressing the DOWN arrow key. The Holiday schedule must be programmed weeklyonce the holiday schedule runs , it will revert to the normal daily schedule. 77 2 Unit Controls PROGRAM key There are six operating parameters under the PROGRAM key that are programmable. These setpoints can be changed by pressing the PROGRAM key, and then the ENTER/ADV key to enter Program Mode. Continuing to press the ENTER/ADV key will display each operating parameter. While a particular parameter is being displayed, the UP and DOWN arrow keys can be used to change the value. After the value is changed, the ENTER/ADV key must be pressed to enter the data into memory. Table 29 shows the programmable limits and default values for each operating parameter. Following are the displays for the programmable values in the order they appear: @ D I S C H A R G E C U T O U T = P R E S S U R E 3 9 5 P S I G DISCHARGE PRESSURE CUTOUT is the discharge pressure at which the system will shutdown as monitored by the optional discharge transducer. This is a software shutdown that acts as a backup for the mechanical high pressure switch located in the refrigerant circuit. The system can restart when the discharge pressure drops 40 PSIG (2.76 BARG) below the cutout point. If the optional discharge pressure transducer is not installed, this programmable safety would not apply. It should be noted that every system has a mechanical high pressure cutout that protects against excessive high discharge pressure regardless of whether or not the optional discharge pressure is installed. S U C T I O N C U T O U T = P R E S S U R E 4 4 . 0 P S I G The SUCTION PRESSURE CUTOUT protects the chiller from an evaporator freeze-up. If the suction pressure drops below the cutout point, the system will shut down. 78 There are some exceptions when the suction pressure is permitted to temporarily drop below the cutout point. Details are explained under the topic of System Safeties. L OW A M B I E N T T E M P C U T O U T = 2 5 . 0 ° F The LOW AMBIENT TEMP CUTOUT allows the user to select the chiller outside ambient temperature cutout point. If the ambient falls below this point, the chiller will shut down. Restart can occur when temperature rises 2°F (1.11°C) above the cutout setpoint. L E A V I N G L I Q U I D T E M P C U T O U T = 3 6 . 0 ° F The LEAVING LIQUID TEMP CUTOUT protects the chiller from an evaporator freeze-up. Anytime the leaving chilled liquid temperature drops to the cutout point, the chiller shuts down. Restart will be permitted when the leaving chilled liquid temperature rises 2°F (1.11°C) above the cutout setpoint. When water cooling mode is programmed (Options key), the value is fixed at 36.0°F (2.22°C) and cannot be changed. Glycol cooling mode can be programmed to values listed in Table 28. A N T I = R E C Y C L E 6 0 0 S E C T I M E The anti-recycle timer message shows the amount of time left on the respective systems anti-recycle timer. The programmed ANTI RECYCLE TIME will start to count down at the start of the systems number one compressor. In effect, this is the minimum time start-to-start on the respective systems number one compressor. YORK INTERNATIONAL FORM 150.62-NM1 Another anti-recycle timer is started each time the systems number one compressor cycles off. This anti-recycle time is fixed at 120 seconds and starts to countdown when the systems number one compressor cycles off. The anti-recycle message is displayed when the system is unable to start due to either of the anti-recycle timers being active (counting down). The actual time displayed will be the longer of the two timers, start-tostart or stop-to-start. F A N C O N T R O L O N P R E S S U R E = XX X P S I G The Fan Control On Pressure is the programmed pressure value that is used to stage the condenser fans on, in relation to discharge pressure. Refer to Condenser Fan Control in the UNIT OPERATION section and Tables 38, 39, and 40, 41. F A N D I F F E R E N T I A L O F F P R E S S U R E = X X X PS I G The Fan Differential Off Pressure is the programmed differential pressure value that is used to stage the condenser fans off, in relation to discharge pressure. Refer to Condenser Fan Control in the UNIT OPERATION section and Tables 38, 39 and 40, 41. T O T A L N U M B E R O F C OM P R E S S O R S = 6 The TOTAL NUMBER OF COMPRESSORS are the amount of compressors in the chiller, and determines the stages of cooling available. Notice in Table 29 the chiller is a single or dual refrigerant circuit. This must be programmed correctly to assure proper chiller operation. TABLE 29 – PROGRAM KEY LIMITS AND DEFAULTS PROGRAM VALUE DISCHARGE PRESSURE CUTOUT MODEL — WATER COOLING SUCTION PRESSURE CUTOUT GLYCOL COOLING STANDARD AMBIENT LOW AMBIENT TEMP. CUTOUT LOW AMBIENT LEAVING CHILLED LIQUID TEMP. CUTOUT WATER COOLING GLYCOL COOLING ANTI-RECYCLE TIMER — FAN CONTROL ON-PRESSURE — FAN DIFFERENTIAL OFF-PRESSURE — TOTAL NUMBER OF COMPRESSORS SINGLE SYSTEM TWO SYSTEMS YORK INTERNATIONAL LOW LIMIT 200 PSIG 13.8 BARS 44.0 PSIG 3.03 BARS 20.0 PSIG 1.38 BARS 25.0°F -3.9°C 0°F -17.8°C HIGH LIMIT 399 PSIG 27.5 BARS 70.0 PSIG 4.83 BARS 70.0 PSIG 4.83 BARS 60.0°F 15.6°C 60.0°F 15.6°C — — 8.0°F -13.3°C 300 SEC. 225 PSIG 15.5 BARS 50 PSIG 3.45 BARS 2 4 36.0°F 2.2°C 600 SEC. 300 PSIG 20.7 BARS 150 PSIG 10.3 BARS 3 6 DEFAULT 395 PSIG 27.2 BARS 44.0 PSIG 3.03 BARS 44.0 PSIG 3.03 BAR 25.0°F -3.9°C 25.0°F -3.9°C 36°F 2.2°C 36.0°F 2.2°C 600 SEC. 230 PSIG 15.9 BARS 80 PSIG 5.52 BARS 3 6 79 2 Unit Controls Table 30 provides a quick reference of the setpoints list for the Setpoints Keys. TABLE 30 – SETPOINTS QUICK REFERENCE LIST Quick Reference Programming Chart Setpoints Section Cooling Setpoints Key (press key to adv.) Schedule/ Advance Day Key Program Mode (press enter to adv.) Local Leaving Water Temp Control (Display Only) Mon. – Sun. & Holiday Schedule Discharge Pressure Cutout Chilled Liquid Setpoint & Range Suction Pressure Cutout Remote Setpoint & Range (Display Only) Low Ambient Temp. Cutout EMS - PWM Remote Temp Reset Setpoint Leaving Liquid Temperature Cutout Anti-Recycle Timer Fan Control On-Pressure Fan Differential Off-Pressure Total Numbers of Compressors LD03685 80 YORK INTERNATIONAL FORM 150.62-NM1 “UNIT” KEYS 2 00070VIP OPTIONS key This keeps system 2 off There are eleven programmable options (nine for units with a single refrigerant system) under the OPTIONS key. The OPTIONS key is used to scroll through the list of options by repeatedly pressing the OPTIONS key . After the selected option has been displayed, the UP and DOWN arrow keys are then used to change that particular option. After the option is changed, the ENTER/ADV key must be pressed to enter the data into memory. Table 31 shows the programmable options. Following are the displays in the order they appear: or S Y S S Y S 1 2 SW I T C H SW I T C H O F F O N This keeps system 1 off Option 3 – Unit Type U N I T T Y P E L I Q U I D C H I L L E R Option 1 – Language D I S P L A Y L A N G U A G E E N G L I S H selected for YCAL Chillers or Option 2 – System Switches (two system units only) S Y S S Y S 1 2 SW I T C H SW I T C H O N O N U N I T T Y P E C O N D E N S I N G U N I T selected for YCUL Condensing units. This allows both systems to run Option 4 – Chilled Liquid Cooling Type or S Y S S Y S 1 2 SW I T C H SW I T C H O N O F F C H I L L E D L I Q U I D WA T E R The chilled liquid is water. The Cooling Setpoint can be programmed from 40°F to 70°F (4.4°C to 21.1°C) YORK INTERNATIONAL 81 Unit Controls or A B C D E FI G J K L N O C H L H L EI D L M I Q U PI Q D R S T 1 2 3 4 5 6 7 G 8 L 9 Y 0 C ° O , L. / % - ( ) * X ate on locally programmed values and ignore all commands from the remote devices. The chiller will communicate and send data to the remote monitoring devices. or The chilled liquid is glycol. The Cooling Setpoint can be programmed from 10°F to 70°F (-12.2°C to 21.1°C). Option 5 – Ambient Control Type A B C D B E FI G L M P Q A M E H N TI J K C O N N T O R O L R S T 1 2 3 4 5 6 S 7 T 8 A 9 N 0 D ° A, R. D/ % - ( ) * X The low ambient cutout is adjustable from 25°F to 60°F (-3.9°C to 15.6°C). L O C A L / R E M O T E R E M O T E MO D E This mode should be selected when an ISN or RCC control is to be used to control the chiller. This mode will allow the ISN to control the following items: Remote Start/Stop, Cooling Setpoint, Load Limit, and History Buffer Request. If the unit receives no valid ISN transmission for 5 minutes, it will revert back to the locally programmed values. Option 7 – Unit Control Mode or A M B I E N T C O N T R O L L OW A M B I E N T The low ambient cutout is programmable down to 0°F (-17.8°C). A low ambient kit MUST be installed for this option to be chosen. C O N T R O L M O D E R E T U R N L I Q U I D Unit control is based on return chilled liquid temp. It can only be selected on units that have 4 or 6 compressors (dual system units). or Option 6 – Local/Remote Control Type L O C A L / R E M O T E L O C A L M O D E L C O N T R O L M O D E L E A V I N G L I Q U I D Unit control is based on leaving chilled liquid temp. When programmed for LOCAL, an ISN or RCC control can be used to monitor only. The micro panel will oper- 82 Refer to section on Capacity Control for details on loading and unloading sequences. YORK INTERNATIONAL FORM 150.62-NM1 Option 8 – Units Type D I S P L A Y U N I T S I M P E R I A L Display messages will show units of measure in Imperial units (°F or PSI). or Condenser fans are controlled by ambient temperature and discharge pressure. This mode must be chosen if the discharge pressure transducers are not installed, or if the fan cycling is a concern. Option 11 – Manual Override Mode M A N U A L D I S P L A Y U N I T S S I O V E R R I D E D I S A B L E D M O D E This option allows overriding of the daily schedule that Display messages will show units of measure in SI units (°C or Bar). is programmed. MANUAL OVERRIDE MODE-DISABLED indicates that override mode has no effect. or Option 9 – Lead/Lag Type (two systems only) M A N U A L L E A D / L A G C O N T R O L M A N U A L S Y S 1 L E A D SYS 1 selected as lead compressor. or L E A D / L A G C O N T R O L M A N U A L S Y S 2 L E A D SYS 2 selected as lead compressor. or L E A D / L A G C O N T R O L A U T OM A T I C In this mode the micro determines which system is assigned to the lead and lag. A new lead/lag assignment is made whenever all compressors shut down. The micro will then assign the “lead” to the compressor with the shortest average run time. Option 10 – Condensed Fan Control Mode Condenser fans are controlled by discharge pressure only. This mode may only be chosen when discharge pressure transducers are installed, or if fan cycling is not a concern. or F A N A M B I E N T YORK INTERNATIONAL C O N T R O L & D S C H P R E S S M O D E 2 Manual Override Mode is enabled. This is a service function and when enabled, will allow the unit to start when shut down on the daily schedule. It will automatically be disabled after 30 minutes. CLOCK The CLOCK display shows the current day, time, and date. Pressing the CLOCK key will show the current day, time, and date. It is important that the date and time be correct, otherwise the daily schedule will not function as desired if programmed. In addition, for ease of troubleshooting via the History printouts, the day, time, and date should be correct. To change the day, time, and date press the CLOCK key. The display will show something similar to the following: T O D A Y 1 F A N C O N T R O L D I S C H A R G E PR E S S U R E O V E R R I D E E N A B L E D I S F R I 0 8 : 5 1 A M M A Y 9 8 The line under the F is the cursor. If the day is correct, press the ENTER/ADV key. The cursor will move under the 0 in 08 hours. If the day is incorrect, press the UP or DOWN arrow keys until the desired day is displayed and then press the ENTER/ADV key at which time the day will be accepted and the cursor will move under the 0. In a similar manner, the hour, minute, meridian, month, day, and year may be programmed, whenever the cursor is under the first letter/numeral of the item. Jumper J11 on the microboard must be set to the “CLKON” position to turn on the clock. If this is not done the clock will not function. 83 Unit Controls Table 31 provides a quick reference list for the Unit key setpoints. TABLE 31 – UNIT KEYS PROGRAMMING QUICK REFERENCE LIST Quick Reference Programming Chart Unit Keys Section Options Key (press key to adv.) Clock Display Language Day – Time – Date System Switches on/off Unit Type (Chiller or Condensing Unit) Chilled Liquid Type (water or glycol) Ambient Control (standard or low) Local/Remote Mode Unit Control Mode (Based on Unit Type) Display Units (English or Metric) Lead/Lag Control Fan Control Mode Override Mode LD03686 84 YORK INTERNATIONAL FORM 150.62-NM1 UNIT OPERATION CAPACITY CONTROL To initiate the start sequence of the chiller, all run permissive inputs must be satisfied (flow/remote start/stop switch), and no chiller or system faults exist. The first phase of the start sequence is initiated by the Daily Schedule Start or a Remote Cycling Device. If the unit is shut down on the daily schedule, the chilled water pump microboard contacts (TB5 3-4) will close when the daily schedule start time has been reached. Once flow has been established and the flow switch closes, capacity control functions are initiated. If unit cycling is accomplished with a remote cycling device wired in series with the flow switch, the chilled water pump contacts will always be energized as long as the unit switch is turned on. When the flow switch and remote cycling contacts are closed, the capacity control functions will be initiated. It should be noted that the chilled water pump contacts (TB5 3-4) are not required to be used to cycle the chilled water pump. However, in all cases the flow switch must be closed to allow unit operation. The control system will evaluate the need for cooling by comparing the actual leaving or return chilled liquid temperature to the desired setpoint, and regulate the leaving or return chilled liquid temperature to meet that desired setpoint. LEAVING CHILLED LIQUID CONTROL The setpoint, when programmed for Leaving Chilled Liquid Control, is the temperature the unit will control to within +/- the cooling range. The Setpoint High Limit is the Setpoint plus the Cooling Range. The Setpoint Low Limit is the Setpoint minus the Cooling Range. See Figure 6. YORK INTERNATIONAL If the leaving chilled liquid temperature is above the Setpoint High Limit, the lead compressor on the lead system will be energized along with the liquid line solenoid. Upon energizing any compressor, the 60 second Anti-Coincidence timer will be initiated. If after 60 seconds of run-time the leaving chilled liquid temperature is still above the Setpoint High Limit, the next compressor in sequence will be energized. Additional loading stages are energized at a rate of once every 60 seconds if the chilled liquid temperature remains above the Setpoint High Limit. In this case, the load timer will be 60 seconds. 2 If the chilled liquid temperature falls below the Setpoint High Limit but is greater than the Setpoint Low Limit, loading and unloading do not occur. This area of control is called the control range. If the chilled liquid temperature drops to less than 0.5°F (.28°C) below the Setpoint Low Limit, unloading occurs at a rate of 60 seconds. If the chilled liquid temperature falls to a value greater than 0.5°F (.28°C) below the Setpoint Low Limit but not greater than 1.5°F (.83°C) below the Setpoint Low Limit, unloading occurs at a rate of 30 seconds. If the chilled liquid temperature falls to a value greater than 1.5°F (.83°C) below the Setpoint Low Limit, unloading occurs at a rate of 20 seconds. The leaving chilled liquid setpoint is programmable from 40°F to 70°F (4.4°C to 21.1°C) in water chilling mode and from 10°F to 70°F (-12.2°C to 21.1°C) in glycol chilling mode. In both modes, the cooling range can be from +/-1.5°F to +/-2.5°F (+/-.83°C to 1.39°C). The sequences of Capacity Control (compressor staging) for loading and unloading are shown in Table 32 through Table 35. 85 Unit Controls 20 sec. unloading LWT 30 sec. unloading 42.5°F (5.8°C) 60 sec. unloading 43.5°F (6.4°C) control range (no compressor staging) 44.0°F (6.7°C) Low Limit 46.0°F (7.8°C) Setpoint 60 sec. loading 48.0° (8.9°C) High limit Leaving Water Temp. Control – Compressor Staging Setpoint = 46.0°F (7.8°C) Range = +/- 2°F(1.1°C) FIG. 6 – LEAVING WATER TEMPERATURE CONTROL TABLE 32 – LEAVING CHILLED LIQUID CONTROL FOR 6 COMPRESSORS (8 STEPS) *STEP 0 1 2 3 4 5 6 7 8 LEAD SYSTEM COMP 1 COMP 2 OFF OFF ON+HG OFF ON OFF ON OFF ON ON ON ON ON ON ON ON ON ON COMP 3 OFF OFF OFF OFF OFF OFF OFF ON ON SEE NOTE 1 SEE NOTE 2 SEE NOTE 3 COMP 1 OFF OFF OFF ON OFF ON ON ON ON LAG SYSTEM COMP 2 COMP 3 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF ON ON TABLE 33 – LEAVING CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) *STEP 0 1 2 3 4 5 6 LEAD SYSTEM COMP 1 OFF ON+HG ON ON ON ON ON COMP 2 OFF OFF OFF OFF ON ON ON SEE NOTE 1 SEE NOTE 2 SEE NOTE 3 COMP 1 OFF OFF OFF ON OFF ON ON LAG SYSTEM COMP 2 OFF OFF OFF OFF OFF OFF ON * STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND. 86 YORK INTERNATIONAL FORM 150.62-NM1 TABLE 34 – LEAVING CHILLED LIQUID CONTROL FOR 3 COMPRESSORS (SINGLE SYSTEM) *STEP 0 1 2 3 4 COMP 1 OFF ON+HG ON ON ON COMP 2 OFF OFF OFF ON ON COMP 3 OFF OFF OFF OFF ON SEE NOTE 1 TABLE 35 – LEAVING CHILLED LIQUID CONTROL FOR 2 COMPRESSORS (SINGLE SYSTEM) *STEP 0 1 2 3 COMP 1 OFF ON+HG ON ON COMP 2 OFF OFF OFF ON SEE NOTE 1 2 Notes: 1. Step 1 is Hot Gas Bypass and is skipped when loading occurs. Hot Gas Bypass operation is inhibited during Pumpdown. For Leaving Chilled Liquid Control the Hot Gas Bypass solenoid is energized only when the lead compressor is running and the LWT < SP, the Hot Gas Bypass solenoid is turned off when the LWT > SP + CR/2 2. Step 3 is skipped when loading occurs. 3. Step 4 is skipped when unloading occurs. * STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND. YORK INTERNATIONAL 87 Unit Controls RETURN CHILLED LIQUID CONTROL (DUAL SYSTEM 4 AND 6 COMP UNITS ONLY) Return chilled liquid control is based on staging the compressors to match the cooling load. The chiller will be fully loaded when the return water temperature is equal to the Cooling Setpoint plus the Range Setpoint. The chiller will be totally unloaded (all compressors off) when the return water temperature is equal to the Cooling Setpoint. At return water temperatures between the Cooling Setpoint, and Cooling Setpoint plus Range Setpoint, compressor loading and unloading will be determined by the formulas in Table 37 or Table 38. determining the separation between segments. Note also that the Cooling Setpoint is the point at which all compressors are off, and Cooling Setpoint plus Range Setpoint is the point all compressors are on. Specifically, if the return water temperature is 55°F (12.8°C), then all compressors will be on, providing full capacity. At nominal gpm, this would provide approximately 45°F (7.2°C) leaving water temperature out of the evaporator. Normal loading will occur at intervals of 60 seconds according to the temperatures determined by the formulas. Unloading will occur at a rate of 30 seconds according the temperatures determined in the formulas. If the return water temperature drops to 53.3°F (11.8°C), one compressor would cycle off leaving five compressors running. The compressors would continue to cycle off approximately every 1.7°F (.94°C), with the exception of hot gas bypass. Notice that the hot gas bypass would be available when the return water temperature dropped to 46.25°F (7.9°C). At this point one compressor would be running. The return chilled liquid setpoint is programmable from 40°F to 70°F (4.4°C to 21.1°C) in water chilling mode and from 10°F to 70°F (-12.2°C to 21.1°C) in glycol chilling mode. In both modes, the cooling range can be from 4°F to 20°F (2.2° to 11.1°C). Should the return water temperature rise from this point to 46.7°F (8.2°C), the hot gas bypass would shut off, still leaving one compressor running. As the load increased, the compressors would stage on every 1.7°F (.94°C). As an example of compressor staging (refer to Table 36 and Table 37), a chiller with six compressors using a Cooling Setpoint programmed for 45°F (7.20°C) and a Range Setpoint of 10°F (5.56°C). Using the formulas in Table 37, the control range will be split up into six (seven including hot gas) segments, with the Control Range Also notice that Tables 37 and 38 not only provide the formulas for the loading (ON POINT) and unloading (OFF POINT) of the system, the “STEP” is also shown in the tables. The “STEP” is that sequence in the capacity control scheme that can be viewed under the OPER DATA key. Please refer to the section on the DISPLAY/PRINT keys for specific information on the OPER DATA key. 88 YORK INTERNATIONAL FORM 150.62-NM1 Compressor Staging for Return Water Control – 6 Compressors Cooling Setpoint = 45° F (7.2° C) Range = 10° F (5.6° C) TABLE 36 – COMPRESSOR STAGING FOR RETURN WATER CONTROL # OF COMP ON RWT 0 45°F (7.2°C) *1+HG 46.25°F (7.9°C) 1 46.7°F (8.2°C) 2 48.3°F (9.1°C) 3 50.0°F (10.0°C) 4 51.7°F (11.0°C) 5 53.4°F (11.9°C) 6 55.0°F (12.8°C) *Unloading only TABLE 37 – RETURN CHILLED LIQUID CONTROL FOR 6 COMPRESSORS (8 STEPS) *STEP 0 1 2 3 4 5 6 7 8 COMPRESSOR ON POINT COMPRESSOR OFF POINT SP + CR/6 SP + 2*CR/6 SP + 2*CR/6 SP + 3*CR/6 SP + 4*CR/6 SP + 5*CR/6 SP + CR SETPOINT SP + CR/8 SP + CR/6 SP + CR/6 SP + 2*CR/6 SP + 3*CR/6 SP + 4*CR/6 SP + 5*CR/6 2 SEE NOTE 1 SEE NOTE 2 SEE NOTE 3 TABLE 38 – RETURN CHILLED LIQUID CONTROL FOR 4 COMPRESSORS (6 STEPS) *STEP 0 1 2 3 4 5 6 COMPRESSOR ON POINT COMPRESSOR OFF POINT SP + CR/4 SP + 2*CR/4 SP + 2*CR/4 SP + 3*CR/4 SP + CR SETPOINT SP + CR/8 SP + CR/4 SP + CR/4 SP + 2*CR/4 SP + 3*CR/4 SEE NOTE 1 SEE NOTE 2 SEE NOTE 3 Notes: 1. Step 1 is Hot Gas Bypass and is skipped when loading occurs. Hot Gas Bypass operation is inhibited during Pumpdown. 2. Step 3 is skipped when loading occurs. 3. Step 4 is skipped when unloading occurs. * STEP can be viewed using the OPER DATA key and scrolling to COOLING DEMAND. YORK INTERNATIONAL 89 Unit Controls EVAPORATOR PUMP CONTROL CONDENSER FAN CONTROL The evaporator pump dry contacts (CTB2 - terminals 23 - 24) are energized when any of the following conditions are true: 1. Low Leaving Chilled Liquid Fault 2. Any compressor is running 3. Daily Schedule is not programmed OFF and Unit Switch is ON. Condenser fan operation must be programmed with the Options key under “Fan Control.” Condenser fan control can be selected for Ambient Temp. and Disch. Pressure, or Discharge Pressure Only. The pump will not run if the micro panel has been powered up for less than 30 seconds or if the pump has run in the last 30 seconds to prevent pump motor overheating. EVAPORATOR HEATER CONTROL The evaporator heater is controlled by ambient air temperature. When the ambient temperature drops below 40°F (4.4°C) the heater is turned on. When the temperature rises above 45°F (7.2°C) the heater is turned off. An under voltage condition will keep the heater off until full voltage is restored to the system. TABLE 39 – The condenser fan control by “Ambient Temperature and Discharge Pressure” is a feature that is integral to the standard software control. If the optional discharge transducer is not installed, the condenser fans will operate based on outdoor ambient temperature only. See Table 39. The condenser fan control by “Discharge Pressure” is a feature that can be selected if the discharge pressure transducer is installed and fan recycling is not a concern. Fan control by discharge pressure will work according to Table 40. The fan control on-pressure (ctrl_press) and fan differential off-pressure (diff_press) are programmable under the PROGRAM key. CONDENSER FAN CONTROL USING OUTDOOR AMBIENT TEMPERATURE AND DISCHARGE PRESSURE FAN STAGE 1 1 FAN FWD 2 2 FANS FWD ON OAT >25° F (-3.9°C) OR DP > ctrl_press OAT >45° F (7.2°C) OR DP > ctrl_press + 20 PSIG (1.38 Bars) OFF OAT < 20° F (-6.7°C) AND DP < ctrl_press - diff_press OAT < 40° F (4.4°C) AND DP < ctrl_press - diff_press + 20 PSIG (1.38 Bars) TABLE 40 – CONDENSER FAN CONTROL USING DISCHARGE PRESSURE ONLY FAN STAGE 1 1 FAN FWD 2 2 FANS FWD 90 ON DP > ctrl_press OFF DP < ctrl_press - diff_press DP > ctrl_press + 20 PSIG (1.38 Bars) DP < ctrl_press - diff_press + 20 PSIG (1.38 Bars) YORK INTERNATIONAL FORM 150.62-NM1 LOW AMBIENT CONDENSER FAN CONTROL For unit operation below 25°F (-3.9°C) a low ambient kit is required. The kit consists of a discharge pressure transducer(s) and reversing contactors. With the low ambient kit installed and the unit programmed for low ambient operation, the condenser fans will operate as shown in Tables 41 and 42. Again, notice that condenser fan operation can be programmed for either “temperature and discharge pressure control,” or “discharge pressure control only” as described under Condenser Fan Control. The fan control on-pressure (ctrl_press) and the fan deferential off-pressure (diff_press) are programmable under the PROGRAM key. TABLE 41 – LOW AMBIENT CONDENSER FAN CONTROL – AMBIENT TEMPERATURE AND DISCHARGE PRESSURE CONTROL FAN STAGE 1 1 FAN REV 2 1 FAN FWD 3 2 FANS FWD ON OAT >25° F (-3.9°C) OR DP > ctrl_press OAT >45°F (7.2°C) OR DP > ctrl_press + 20 PSIG (1.38 Bars) OAT > 65°F (18.3°C) OR DP > ctrl_press + 40 PSIG (2.76 Bars) OFF OAT < 20° F (-6.7°C) AND DP < ctrl_press - diff_press OAT < 40°F (-4.40°C) AND DP < ctrl_press - diff_press + 20 PSIG (1.38 Bars) OAT < 60°F (15.6°C) AND DP < ctrl_press - diff_press + 40 PSIG (2.76 Bars) TABLE 42 – LOW AMBIENT CONDENSER FAN CONTROL – DISCHARGE PRESSURE CONTROL FAN STAGE 1 1 FAN REV 2 1 FAN FWD 3 2 FANS FWD YORK INTERNATIONAL ON OFF DP > ctrl_press DP < ctrl_press - diff_press DP > ctrl_press + 20 PSIG (1.38 Bars) DP < ctrl_press - diff_press + 20 PSIG (1.38 Bars) DP > ctrl_press + 40 PSIG (2.76 Bars) DP < ctrl_press - diff_press + 40 PSIG (2.76 Bars) 91 2 Unit Controls PUMPDOWN (LLSV) CONTROL Each system has a Pumpdown feature upon shut-off. On a non-safety, non-unit switch shutdown, all compressors but one in the system will be shut off. The LLSV will also be turned off. The final compressor will be allowed to run until the suction pressure falls below the cutout or for 180 seconds, which ever comes first. Manual pumpdown from the keypad is not possible. LOAD LIMITING Load Limiting is a feature that prevents the unit from loading beyond the desired value. 2 and 4 compressor units can be load limited to 50%. This would allow only 1 compressor per system to run. 3 and 6 compressor units can be load limited to 33% or 66%. The 66% limit would allow up to 2 compressors per system to run, and the 33% limit would allow only 1 compressor per system to run. No other values of limiting are available. There are two ways to load limit the unit. The first is through remote communication via an ISN. A second way to load limit the unit is through closing contacts connected to the Load Limit (CTB1-Terminals 13-21) and PWM inputs (CTB1-Terminals 13-20). Stage 1 of load limiting involves closing the Load Limit input. Stage 2 of load limiting involves closing both the Load Limit and PWM inputs. The first stage of limiting is either 66% or 50%, depending on the number of compressors on the unit. The second stage of limiting is 33% and is only available on 3 and 6 compressor units. Table 43 shows the load limiting permitted for the various number of compressors. NOTE: Simultaneous operation of Load Limiting and EMS-PWM Temperature Reset (described on following pages) cannot occur. COMPRESSOR RUN STATUS Compressor run status is indicated by closure of contacts at CTB2 – terminals 25 to 26 for system 1 and CTB2 – terminals 27 to 28 for system 2. ALARM STATUS System or unit shutdown is indicated by normally-open alarm contacts opening whenever the unit shuts down on a unit fault, or locks out on a system fault. System 1 alarm contacts are located at CTB2 - terminals 29 to 30. System 2 alarm contacts are located at CTB2 - terminals 31 to 32. The alarm contacts will close when conditions allow the unit to operate. COMPRESSOR SEQUENCING The unit control will attempt to equalize the total run hours on individual compressors within a system. When a system is about to start, the compressor with the least run time in that system will be the first to start. When the system has to load, the next compressor to start will be the one with the least run time that is currently not running in that system. TABLE 43 – COMPRESSOR OPERATION – LOAD LIMITING COMPRESSORS IN UNIT 2 3 4 6 92 STAGE 1 50% 66% 50% 66% STAGE 2 – 33% – 33% YORK INTERNATIONAL FORM 150.62-NM1 EMS-PWM REMOTE TEMPERATURE RESET BAS/EMS TEMPERATURE RESET OPTION EMS-PWM Remote Temperature Reset is a value that resets the Chilled Liquid Setpoint based on a PWM input (timed contact closure) to the microboard. This PWM input would typically be supplied by an Energy Management System. The Remote Reset Option allows the Control Center of the unit to reset the chilled liquid setpoint using a 0 - 10 VDC input, a 4-20mA input, or a contact closure input. The Remote Reset circuit board converts the signals mentioned above into pulse width modulated (PWM) signals which the microprocessor can understand. Whenever a reset is called for, the change may be noted by pressing the Cooling Setpoints key twice. The new value will be displayed as “REM SETP = XXX°F” A contact closure on the PWM Temp Reset input at CTB 1 terminals 13 - 20, will reset the chilled liquid setpoint based on the length of time the contacts remain closed. The maximum temperature reset is achieved at a contact closure of 11 seconds. This is the longest contact closure time allowed. One second is the shortest time allowed and causes the Chilled Liquid Setpoint to revert back to the Local programmed value. The reset value is always added to the Chilled Liquid Setpoint, meaning that this function never lowers the Chilled Liquid Setpoint below the locally programmed value, it can only reset to a higher value. The microboard must be refreshed between 30 seconds and 30 minutes. Any contact closure occurring sooner than 30 seconds will be ignored. If more than 30 minutes elapse before the next contact closure, the setpoint will revert back to the locally programmed value. The new chilled liquid setpoint is calculated by the following equations: setpoint = local chilled liquid setpoint + °reset °reset = (Contact Closure - 1) x (*Max. Reset Value) 10 Example: Local Chilled Liquid Setpoint = 45°F (7.22°C). *Max Reset Value = 10°F (5.56°C) Contact Closure Time = 6 Seconds. (English) (6 sec. - 1) (10°F/10) = 5°F Reset So...the new chilled liquid setpoint = 45°F + 5°F= 50°F. This can be viewed by pressing the Cooling Setpoints key twice. The new value will be displayed as “REM SETP = 50.0°F.” (Metric) (6 sec - 1) * (5.56°C/10) = 2.78°C Reset Cooling Setpoint = 7.22°C + 2.78°C = 10.0°C So...the new reset Cooling Setpoint = 7.22 °C + 2.78°C = 10°C. This can be viewed by pressing the Cooling Setpoints key twice. The new value will be displayed as “REM SETP = 10.0°C.” The optional Remote Reset option would be used when reset of the chilled liquid setpoint is required and a PWM signal (timed contact closure) cannot be supplied by an Energy Management System. The Remote Temp. Reset Board will convert a voltage, current, or contact signal that is available from an EMS to a PWM signal, and every 80 seconds provide a PWM input to the microboard. Figure 3 shows a diagram of the field and factory electrical connections. If a 0 - 10VDC signal is available, it is applied to terminals A+ and A-, and jumpers are applied to JU4 and JU2 on the reset board. This dc signal is conditioned to a 1 - 11 second PWM output and supplied to the PWM input on the microboard at CTB 1 terminals 13 - 20. To calculate the reset chilled liquid setpoint for values between 0VDC and 10VDC use the following formula: setpoint = local chilled liquid setpoint + °reset °reset = (dc voltage signal) x (*Max Reset Value) 10 Example: Local Chilled Liquid Setpoint = 45°F (7.22°C) *Max Reset Value = 20°F (11.11°C) Input Signal = 6 VDC (English) °reset = 6VDC x 20°F = 12°F reset 10 setpoint = 45 °F + 12 °F = 57°F (Metric) °reset = 6VDC x 11. 11°C = 6.67°C reset 10 setpoint = 7.22°C + 6.67°C = 13.89°C * Max Reset Value is the “Max EMS-PWM Remote Temp. Reset” setpoint value described in the programming section under Cooling Setpoints. Programmable values are from 2°F to 40°F (1.11°C to 22.22°C). YORK INTERNATIONAL 93 2 Unit Controls + – 035-15961-000 035-15961-000 LD03875 FIG. 7 – FIELD AND FACTORY ELECTRICAL CONNECTIONS OPTIONAL REMOTE TEMPERATURE RESET BOARD If a 4-20mA signal is available, it is applied to terminals A+ and A- and jumpers are applied to JU5 and JU3 on the reset board. The mA signal is conditioned to a 1-11 second PWM output. The PWM output is then supplied to the PWM input on the microboard at CTB 1 terminals 13 - 20. To calculate the chilled liquid setpoint for values between 4mA and 20 ma use the following formula: setpoint = local chilled liquid setpoint + °reset °reset = (mA signal - 4) x (*Max Reset Value) 16 Example: Local Chilled Liquid Setpoint = 45° (7.22°C) *Max Reset Value = 10°F (5.56°C) Input Signal = 12 mA A 240-24 Volt Ratio Transformer (T3) is used to derive nominal 12 volt output from the 120 volt supply. If the Contact Closure input is used. The connections are made to terminals C and D and only jumper JUI must be in place on the reset board. This input is used when a single reset value is needed. When the contacts are closed, the remote temperature reset board will convert this contact closure to a PWM signal that is applied to CTB 1 terminals 13 - 20. (English) °reset = 8mA x 10°F = 5°F reset 16 setpoint = 45°F + 5°F = 50°F To set the PWM output, the contacts must be closed on inputs C - D, and potentiometer R11 (located on the front edge of the PC board) is adjusted to 10VDC as measured at TP3 to terminal 10 on the circuit board. The reset value will be the “Max EMS-PWM Remote Temp. Reset” setpoint value programmed in the SETPOINTS section under the Cooling Setpoints key. (Metric) °reset = 8mA x 5.56°C = 2.78°C reset 16 setpoint = 7.22°C + 2.78°C = 10.0°C NOTE: The coil of any added relay used for reset must be suppressed to prevent possible component damage. Use YORK PN031-00808-000 suppressor. * Max Reset Value is the “Max EMS-PWM Remote Temp. Reset” setpoint value described in the programming section under Cooling Setpoints. Programmable values are from 2°F to 40°F (1.11°C to 11.11°C). 94 YORK INTERNATIONAL FORM 150.62-NM1 SERVICE AND TROUBLESHOOTING CLEARING HISTORY BUFFERS The history buffers may be cleared by pressing the HISTORY key and then repeatedly pressing the UP arrow key until you scroll past the last history buffer choice. The following message will be displayed: 1 I N I T I A L I Z E E N T E R = H I S T O R Y Y E S Pressing the ENTER/ADV key at this display will cause the history buffers to be cleared. Pressing any other key will cancel the operation. SOFTWARE VERSION The software version may be viewed by pressing the HISTORY key and then repeatedly pressing the DOWN arrow key until you scroll past the first history buffer choice. The following message is an example of what will be displayed: S O F T WA R E V E R S I O N C . MM C . 0 1 . 0 1 Following is the order of digital outputs that will appear as the ENTER/ADV key is pressed:\ SYS 1 COMPRESSOR 1 SYS 1 LIQUID LINE SOLENOID VALVE SYS 1 COMPRESSOR 2 SYS 1 COMPRESSOR 3 SYS 1 HOT GAS BYPASS SOLENOID VALVE SYS 2 COMPRESSOR 1 SYS 2 LIQUID LINE SOLENOID VALVE SYS 2 COMPRESSOR 2 SYS 2 COMPRESSOR 3 SYS 1 FAN STAGE 1 SYS 1 FAN STAGE 2 SYS 1 FAN STAGE 3 SYS 2 FAN STAGE 1 SYS 2 FAN STAGE 2 SYS 2 FAN STAGE 3 EVAPORATOR HEATER SYS 1 ALARM SYS 2 ALARM EVAPORATOR PUMP SYS 1 & 2 ACCUM RUN TIME/STARTS 3 SERVICE MODE Service Mode is a mode that allows the user to view all the inputs to the microboard and enable or disable all of the outputs (except compressors) on the unit. Some internal timers and counters will be viewable and modifiable as well. To enter Service Mode, turn the unit switch off and press the following keys in the sequence shown; PROGRAM, UP ARROW, UP ARROW, DOWN ARROW, DOWN ARROW, ENTER. SERVICE MODE - DIGITAL OUTPUTS After pressing the key sequence as described, the control will enter the Service Mode permitting the digital outputs (except compressors), operating hours, and start counters to be viewed/modified. The ENTER/ADV key is used to advance through the digital outputs. Using the UP/DOWN ARROW keys will turn the respective digital output on/off. YORK INTERNATIONAL Each display will also show the output connection on the microboard for the respective digital output status shown. For example: S Y S 1 L L S V T B 3 - 2 I S S T A T U S O F F This display indicates that the system 1 liquid line solenoid valve is OFF, and the output connection from the microboard is coming from terminal block 3 - pin 2. Pressing the UP Arrow key will energize the liquid line solenoid valve and OFF will change to ON in the display as the LLSV is energized. The last display shown on the above list is for the accumulated run and start timers for each system. These values can also be changed using the UP and Down ARROW keys, but under normal circumstances would not be advised. 95 Service and Troubleshooting SERVICE MODE - INPUTS After entering the Service Mode, all digital and analog inputs to the microboard can be viewed by pressing the OPER DATA key. After pressing the OPER DATA key, the UP ARROW and DOWN ARROW keys are used to scroll through the analog and digital inputs. Following is the order of analog and digital inputs that will appear when sequenced with the ARROW keys: (analog inputs) SYS 1 *SUCT PRESSURE SYS 1 SPARE SYS 1 **DISCH PRESSURE SYS 1 SUCT TEMP (YCUL ONLY) SYS 2 SUCT TEMP (YCUL ONLY) SPARE SPARE AMBIENT AIR LEAVING LIQUID RETURN LIQUID SYS 2 *SUCTION PRESSURE SYS 2 SPARE SYS 2 **DISCH PRESSURE SYS 1 GRND FLT SYS 2 GRND FLT (binary inputs) PWM TEMP RESET INPUT LOAD LIMIT INPUT FLOW SW / REM START SYS 2 ZONE THERM (YCUL ONLY) SINGLE SYSTEM SELECT SYS 1 MP / HPCO INPUT SYS 2 MP / HPCO INPUT * The analog inputs will display the input connection, the temperature or pressure, and corresponding input voltage such as: S Y S 1 S U C T 2 . 1 V D C = P R 8 1 J 4 - 1 0 P S I G This example indicates that the system 1 suction pressure input is connected to plug 4 - pin 10 (J4-10) on the microboard. It indicates that the voltage is 2.1 volts dc which corresponds to 81 PSIG (5.6 bars) suction pressure. The digital inputs will display the input connection and ON/OFF status such as: F L OW SW / R E M J 9 - 5 I S S T A R T O N This indicates that the flow switch/remote start input is connected to plug 9- pin 5 (J9-5) on the microboard, and is ON (ON = +30 VDC unregulated input, OFF = O VDC input on digital inputs). CONTROL INPUTS/OUTPUTS Tables 44 and 45 are a quick reference list providing the connection points and a description of the binary and analog inputs respectively. Table 46 lists the connection points for the outputs. All input and output connections pertain to the connections at the microboard. Figure 8 illustrates the physical connections on the microboard. The suction pressure transducer is optional on YCAL0014 - YCAL0060. A low pressure switch is standard on these models in place of the suction transducer. ** The discharge pressure transducer is optional on all models. 96 YORK INTERNATIONAL FORM 150.62-NM1 TABLE 44 – MICROBOARD BINARY INPUTS *J9-1 30VDC UNREGULATED SUPPLY J9-2 UNIT ON/OFF SWITCH J9-3 PWM TEMP RESET OR LOAD LIMIT STAGE 2 ON 3 & 6 COMP UNITS J9-4 LOAD LIMIT STAGE 1 J9-5 FLOW SWITCH AND REMOTE START / STOP (SYS 1 ZONE THERMOSTAT - YCUL ONLY) J9-6 SYSTEM 2 ZONE THERMOSTAT - YCUL ONLY J9-7 SINGLE SYSTEM SELECT (JUMPER = SINGLE SYS, NO JUMPER=TWO SYS) J9-8 CR1 (SYS 1 MOTOR PROTECTOR / HIGH PRESS CUTOUT) J9-9 CR2 (SYS 2 MOTOR PROTECTOR / HIGH PRESS CUTOUT) TABLE 45 – MICROBOARD ANALOG INPUTS TABLE 46 – MICROBOARD OUTPUTS TB3-2 TB3-3 TB3-4 TB3-5 TB3-6 TB3-8 TB3-9 TB3-10 TB4-1 TB4-2 TB4-4 TB4-5 TB4-6 TB4-8 TB4-9 TB4-10 TB5-1 TB5-2 TB5-3 SYSTEM 1 COMPRESSOR 1 SYS 1 LIQUID LINE SOLENOID VALVE SYSTEM 1 COMPRESSOR 2 SYSTEM 1 COMPRESSOR 3 SYSTEM 1 HOT GAS BYPASS VALVE SYSTEM 2 COMPRESSOR 1 SYS 2 LIQUID LINE SOLENOID VALVE SYSTEM 2 COMPRESSOR 2 SYSTEM 2 COMPRESSOR 3 SYS 1 CONDENSER FAN STAGE 1 SYS 1 CONDENSER FAN STAGE 2 SYS 1 CONDENSER FAN STAGE 3 SYS 2 CONDENSER FAN STAGE 1 SYS 2 CONDENSER FAN STAGE 2 SYS 2 CONDENSER FAN STAGE 3 EVAPORATOR HEATER SYSTEM 1 ALARM SYSTEM 2 ALARM EVAPORATOR PUMP STARTER J4-10 Sys 1 Suction Press Transducer or Sys 1 Low Press Switch J4-11 SPARE J4-12 Sys 1 Discharge Pressure Transducer (optional) 3 J5-12 Sys 1 Suction Temp Sensor - YCUL Option J5-13 Sys 2 Suction Temp Sensor - YCUL Option J5-14 SPARE J5-15 SPARE J6-7 J6-8 Ambient Air Temperature Sensor Leaving Chilled Liquid Temperature Sensor J6-9 Return Chilled Liquid Temperature Sensor or Discharge Air Temp Sensor - YCUL Only J7-10 Sys 2 Suct Press Transducer or Sys 2 Low Press Switch J7-11 SPARE J7-12 Sys 2 Discharge Pressure Transducer (optional) J8-5 Sys 1 Ground Fault Circuit J8-6 * Sys 2 Ground Fault Circuit The 30 dc unregulated supply is not an input. This voltage originates on the microboard and is used to supply the contacts for the binary inputs. YORK INTERNATIONAL 97 Service and Troubleshooting TB1 TB2 TB5 J4 TB4 J8 CLOCK J6 ON/OFF JUMPER J5 TB3 J7 J9 00071VIP FIG. 8 – MICROBOARD LAYOUT 98 YORK INTERNATIONAL FORM 150.62-NM1 CHECKING INPUTS AND OUTPUTS BINARY INPUTS Refer to the unit wiring diagram. All binary inputs are connected to J9 of the microboard. The term “binary” refers to two states –- either on or off. As an example, when the flow switch is closed, 30 volts dc will be applied to J9, pin 5 (J9-5) of the microboard. If the flow switch is open, 0 volts dc will then be present at J9-5. Pin 1 of J9 is an unregulated 30VDC that is the dc voltage source used to supply the dc voltage to the various contacts, unit switch, flow switch, etc. This dc source is factory wired to CTB1, terminal 13. Any switch or contact used as a binary input would be connected to this terminal, with the other end connecting to it’s respective binary input on the microboard. Anytime a switch or contact is closed, 30VDC would be applied to that particular binary input. Anytime a switch or contact is open, 0VDC would be applied to that particular binary input. Typically, as high as 34VDC could be measured for the dc voltage on the binary inputs. This voltage is in reference to ground. The unit case should be sufficient as a reference point when measuring binary input voltages. ANALOG INPUTS – Temperature Refer to the unit wiring diagram. Temperature inputs are connected to the microboard on plug J6. These analog inputs represent varying dc signals corresponding to varying temperatures. All voltages are in reference to the unit case (ground). Following are the connections for the temperature sensing inputs: TABLE 47 – OUTDOOR AIR SENSOR TEMPERATURE/VOLTAGE/ RESISTANCE CORRELATION TEMP °F 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 VOLTAGE 0.7 0.8 0.9 1.0 1.1 1.2 1.4 1.5 1.7 1.8 2.0 2.2 2.3 2.5 2.6 2.8 2.9 3.1 3.2 3.4 3.5 3.6 3.7 3.8 3.9 4.0 4.1 RESISTANCE 85398 72950 62495 53685 46240 39929 34565 29998 26099 22673 19900 17453 15309 13472 11881 10501 9298 8250 7332 6530 5827 5209 4665 4184 3759 3382 3048 TEMP C° -18 -15 -12 -9 -7 -4 -1 2 4 7 10 13 16 18 21 24 27 29 32 35 38 41 43 46 49 52 54 Outside Air Sensor J6-4 = +5VDC regulated supply to sensor. J6-7 = VDC input signal to the microboard. See Table 47 for voltage readings that correspond to specific outdoor temperatures. J6-1 = drain (shield connection = 0VDC) YORK INTERNATIONAL 99 3 Service and Troubleshooting TABLE 48 – ENTERING AND LEAVING CHILLED LIQUID TEMP. SENSOR TEMPERATURE/VOLTAGE/ RESISTANCE CORRELATION TEMP °F 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 100 VOLTAGE 1.71 1.78 1.85 1.93 2.00 2.07 2.15 2.22 2.30 2.37 2.45 2.52 2.59 2.67 2.74 2.81 2.88 2.95 3.02 3.08 3.15 3.21 3.27 3.33 3.39 3.45 3.51 3.56 3.61 3.67 3.72 3.76 3.81 3.86 3.90 3.94 3.98 4.02 4.06 4.10 4.13 RESISTANCE 25619 24046 22580 21214 19939 18749 17637 16599 15629 14721 13872 13077 12333 11636 10982 10370 9795 9256 8750 8276 7830 7411 7017 6647 6298 5970 5661 5370 5096 4837 4593 4363 4145 3941 3747 3564 3392 3228 3074 2928 2790 TEMP °C -18 -17 -16 -14 -13 -12 -11 -10 -9 -8 -7 -6 -4 -3 -2 -1 0 1 2 3 4 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 26 27 Entering Chilled Liquid Sensor J6-6 = +5VDC regulated supply to sensor. J6-9 = VDC input signal to the microboard. See Table 48 for voltage readings that correspond to specific liquid temperatures. J6-3 = drain (shield connection = 0VDC) Leaving Chilled Liquid Temp. Sensor J6-5 = +5VDC regulated supply to sensor. J6-8 = VDC input signal to the microboard. See Table 48 for voltage readings that correspond to specific liquid temperatures. J6-2 = drain (shield connection = 0VDC) YORK INTERNATIONAL FORM 150.62-NM1 ANALOG INPUTS – Pressure Refer to the unit wiring diagram. Pressure inputs are connected to the microboard on plugs J4 and J7. These analog inputs represent varying dc signals corresponding to varying pressures. All voltages are in reference to the unit case (ground). System 1 discharge and suction pressures will be connected to J4 of the microboard. System 2 discharge and suction pressure transducers will be connected to J7 of the microboard. The discharge transducers are optional on all units. If the discharge transducers are not installed, no connections are made to the microboard and the discharge pressure readout on the display would be zero. The suction pressure transducers are optional on YCAL0014 - YCAL0060. If the suction transducers are not installed, a mechanical low pressure switch will be installed in its place, and the suction pressure readout on the display will be 0 PSIG when the LP switch is open, and 200 PSIG (13.79 BARG) when the LP switch is closed. The discharge transducers have a range from 0 to 400 PSIG. The output will be linear from .5VDC to 4.5VDC over the 400 PSIG (27.5 BARG) range. Following is the formula that can be used to verify the voltage output of the transducer. All voltage reading are in reference to ground (unit case). YORK INTERNATIONAL V = (Pressure in PSIG x .01) + .5 or V = (Pressure in BARG x .145) + .5 where V = dc voltage output Pressure = pressure sensed by transducer The microboard connections for the Discharge Transducers: System 1 Discharge Transducer J4-7 = +5VDC regulated supply to transducer. J4-12 = VDC input signal to the microboard. See the formula above for voltage readings that correspond to specific discharge pressures. J4-8 = +5VDC return J4-9 = drain (shield connection = 0VDC) System 2 Discharge Transducer J7-7 = +5VDC regulated supply to transducer. J7-12 = VDC input signal to the microboard. See the formula above for voltage readings that correspond to specific discharge pressures. J7-8 = +5VDC return J7-9 = drain (shield connection = 0VDC) 101 3 Service and Troubleshooting The suction transducers have a range from 0 to 200 PSIG (13.79 BARG). The output will be linear from .5 VDC to 4.5 VDC over the 200 PSIG (13.79 BARG) range. Following is a formula that can be used to verify the voltage output of the transducer. All voltage reading are in reference to ground (unit case). V = (Pressure in PSIG x .02) + .5 or V = (Pressure in BARG x .29) + .5 where V = dc voltage input to micro Pressure = pressure sensed by transducer Following are the microboard connections for the Suction Transducer: System 1 Suction Transducer J4-5 = +5VDC regulated supply to transducer. J4-10 = VDC input signal to the microboard. See the formula above for voltage readings that correspond to specific suction pressures. J4-1 = +5VDC return J4-2 = drain (shield connection = 0VDC) If the optional Suction Transducer is not used on the YCAL0014 - YCAL0060, a Low Pressure switch will be used. Following are the microboard connections for the Low Pressure switch. System 1 Low Pressure Switch J4-5 = +5VDC regulated supply to LP switch. J4-10 = input signal to the microboard. 0VDC = open switch / +5 VDC = closed switch. J4-2 = drain (shield connection = 0VDC) System 2 Low Pressure Switch J7-5 = +5VDC regulated supply to LP switch. J7-10 = input signal to the microboard. 0VDC = open switch / +5VDC = closed switch. J7-2 = drain (shield connection = 0VDC) DIGITAL OUTPUTS Refer to the unit wiring diagram and Table 46. The digital outputs are located on TB3, TB4, and TB5 of the microboard. ALL OUTPUTS ARE 120VAC with the exception of TB5-3 to TB5-4. TB5-3 to TB5-4 are the contacts that can be used for an evaporator pump start signal. The voltage applied to either of these terminals would be determined by field wiring. System 2 Suction Transducer J7-5 = +5VDC regulated supply to transducer. J7-10 = VDC input signal to the microboard. See the formula above for voltage readings that correspond to specific suction pressures. J7-1 = +5VDC return J7-2 = drain (shield connection = 0VDC) 102 Each output is controlled by the microprocessor by switching 120VAC to the respective output connection energizing contactors, evap. heater, and solenoids according to the operating sequence. 120 vac is supplied to the microboard via connections at TB3-1, TB3-7, TB4-3, and TB4-7. Figure 9 illustrates the relay contact architecture on the microboard. YORK INTERNATIONAL FORM 150.62-NM1 .points (or pins), that represent one of twelve “buttons” on the keypad. Table 49 lists the key/pin assignments for the keypad. Power to the microboard must be turned off, and the ribbon cable disconnected from the microboard prior to conducting the tests, or component damage may result. After the ribbon cable is disconnected from microboard, ohmmeter leads are connected to the pins representing the specific “button” to be tested. After connecting the meter leads, the “button” being checked is pressed and a reading of zero ohms should be observed. After releasing the “button”, the resistance value should be infinite (open circuit). Pin 1 is usually identified by a stripe on the ribbon cable 3 LD03842 FIG. 9 – MICROBOARD RELAY CONTACT ARCHITECTURE KEYPAD The operator keypad is connected to the microboard by a ribbon cable, which is connected to J2 on the microboard. The integrity of a specific “button” on the keypad can be verified by doing a continuity check across two specific YORK INTERNATIONAL TABLE 49 – KEYPAD PIN ASSIGNMENT MATRIX KEYPAD STATUS OPER DATA PRINT HISTORY UP ARROW DOWN ARROW ENTER/ADV COOLING SETPOINTS SCHEDULE/ADVANCE DAY PROGRAM OPTIONS CLOCK PIN CONNECTIONS 1 TO 5 1 TO 7 1 TO 6 1 TO 8 2 TO 5 2 TO 7 2 TO 6 2 TO 8 3 TO 5 3 TO 7 3 TO 6 3 TO 8 103 Service and Troubleshooting OPTIONAL PRINTER INSTALLATION The micro panel is capable of supplying a printout of chiller conditions or fault shutdown information at any given time. This allows operator and service personnel to obtain data and system status with the touch of the keypad. In addition to manual print selection, the micro panel will provide an automatic printout whenever a fault occurs. Detailed explanation of the print function is given under “Print Key” located in the Keypad and Display section. YORK recommends the field tested WEIGH-TRONIX model 1220 printer (or former IMP 24). This is a compact low cost printer that is ideal for service work and data logging. The WEIGH-TRONIX printer can be obtained by contacting WEIGH-TRONIX for purchase information at: WEIGH-TRONIX 2320 Airport Blvd. Santa Rosa, CA 95402 Phone: 1-800-982-6622 or 1-707-527-5555 (International Orders Only) The part number for the printer that is packaged specifically for YORK is P/N 950915576. The cable to connect the printer can either be locally assembled from the parts listed, or ordered directly from WEIGH-TRONIX under part number 287-040018. Parts The following parts are required: 1. WEIGH-TRONIX model 1220 printer. 2. 2.25" (5.7cm) wide desk top calculator paper. 3. 25 ft. (7.62m) maximum length of Twisted Pair Shielded Cable (minimum 3 conductor), #18 AWG stranded, 300V minimum insulation. 4. One 25 pin Cannon connector and shell. Connector: Cannon P/N DB-25P or equivalent. Shell: Cannon P/N DB-C2-J9. Assembly and Wiring All components should be assembled and wired as shown in Figure 10. Strip the outside insulation back several inches and individual wires about 3/8” (9.5 mm) to connect the cable at the Microboard. Do not connect the shield at the printer-end of the cable. Obtaining a Printout A printout is obtained by pressing the “PRINT” key on the keypad and then pressing either the “OPER DATA” key or “HISTORY” key. LD03843 FIG. 10 – PRINTER TO MICROBOARD ELECTRICAL CONNECTIONS 104 YORK INTERNATIONAL FORM 150.62-NM1 TROUBLESHOOTING TABLE 50 – TROUBLESHOOTING PROBLEM No display on panel. Unit will not operate. CAUSE 1. No 115VAC to 1T. SOLUTION 1a. Check wiring and fuse 3FU b. Check wiring emergency stop contacts 5 to L of CTB2 Terminal Block. c. Replace 1T 2. No 24VAC to Microboard 2. Check wiring 1T to Microboard. 3. 1T defective, no 24VAC output. 3. Replace 1T 4. Short in wire to temp. sensors or pressure transducers. 4. Unplug connections at Microboard to isolate. 5. Defective Microboard or Display board. 5. Replace Microboard. NOTE: Contact YORK Service before Replacing circuit Boards! “FLOW SWITCH/REM STOP NO RUN PERMISSIVE” “LOW SUCTION PRESSURE” FAULT 1. No chilled liquid flow. 1. Check chilled liquid flow. 2. Flow switch improperly installed. 2. Check that the flow switch is installed according to manufacturer’s instructions. 3. Defective flow switch. 3. Replace flow switch. 4. Remote cycling device open. 4. Check cycling devices connected to terminals 13 & 14 of the CTB1 Terminal Block. 1. Improper suction pressure cut-outs adjustments. 1. Adjust per recommended settings. 2. Low refrigerant charge. 2. Repair leak if necessary and add refrigerant. 3. Fouled filter dryer. 3. Change dryer/core. CONT’D YORK INTERNATIONAL 105 3 Service and Troubleshooting PROBLEM “LOW SUCTION PRESSURE” FAULT (CONT’D) “HIGH DISCHARGE PRESSURE” FAULT “LOW LIQUID TEMP” FAULT CAUSE SOL 4. TXV defective. 4. Replace TXV. 5. Reduced flow of chilled liquid through the cooler. 5. Check GPM (See “Limitations” in Installation section). Check operation of pump, clean pump strainer, purge chilled liquid system of air. 6. Defective suction pressure transducer/low pressure switch or wiring 6. Replace transducer/low pressure switch or faulty wiring. Refer to “Service” section for pressure/voltage formula. 7. LLSV defective 7. Replace LLSV 1. Condenser fans not operating or operating backwards. 1. Check fan motor, fuses, and contactors. Assure fan blows air upward. 2. Too much refrigerant. 2. Remove refrigerant. 3. Air in refrigerant system. 3. Evacuate and recharge system. 4. Defective discharge pressure transducer. 4. Replace discharge pressure transducer. Refer to Service section for pressure/voltage formula. 1. Improperly adjusted leaving chilled liquid temp cut-out (glycol only). 1. Re-program the leaving chilled liquid temp. cut-out. 2. Micropanel setpoint/range values improperly programmed. 2. Re-adjust setpoint/range. 3. Chilled liquid flow too low. 3. Increase chilled liquid flow – refer to Limitations in Installation section. 4. Defective LWT or RWT sensor. (assure the sensor is properly installed in the bottom of the well with a generous amount of heat conductive compound) 4. Compare sensor against a known good temperature sensing device. Refer to Service section for temp/ voltage table. CONT’D 106 YORK INTERNATIONAL FORM 150.62-NM1 PROBLEM “MP / HPCO” FAULT COMPRESSOR(S) WON’T START LACK OF COOLING EFFECT YORK INTERNATIONAL CAUSE SOLUTION 1. Compressor internal motor protector (MP) open. 1. Verify refrigerant charge is not low. Verify superheat setting of °10 - 15°F (5.6° 8.3°C). Verify correct compressor rotation. Verify compressor is not over loaded. 2. External overload tripped. 2. Determine cause and reset. 3. HPCO switch open 3. See “High Press. Disch.” Fault 4. Defective HPCO switch 4. Replace HPCO switch 5. Defective CR relay 5. Replace relay 1. Demand not great enough. 1. No problem. Consult “Installation” Manual to aid in understanding compressor operation and capacity control. 3 2. Defective water temperature sensor. 2. Compare the display with a thermometer. Should be within +/- 2 degrees. Refer to Service section for RWT/ LWT temp./voltage table. 3. Contactor/Overload failure 3. Replace defective part. 4. Compressor failure 4. Diagnose cause of failure and replace. 1. Fouled evaporator surface. Low suction pressure will be observed. 1. Contact the local YORK service representative. 2. Improper flow through the evaporator. 2. Reduce flow to within chiller design specs. See Limitations in Installation section. 3. Low refrigerant charge. Low suction pressure will be observed. 3. Check subcooling and add charge as needed. 107 Service and Troubleshooting MAINTENANCE It is the responsibility of the equipment owner to provide maintenance on the system. CONDENSER COILS IMPORTANT Dirt should not be allowed to accumulate on the condenser coil surfaces. Cleaning should be as often as necessary to keep coil clean. If system failure occurs due to improper maintenance during the warranty period, YORK will not be liable for costs incurred to return the system to satisfactory operation. The following is intended only as a guide and covers only the chiller unit components. It does not cover other related system components which may or may not be furnished by YORK. System components should be maintained according to the individual manufacture’s recommendations as their operation will affect the operation of the chiller. COMPRESSORS Oil Level check: The oil level can only be tested when the compressor is running in stabilized conditions, to ensure that there is no liquid refrigerant in the lower shell of the compressor. When the compressor is running at stabilized conditions, the oil level must be between 1/4 and 3/4 in the oil sight glass. Note: at shutdown, the oil level can fall to the bottom limit of the oil sight glass. Use YORK “F” oil when adding oil. Oil Analysis: The oil used in these compressors is pale yellow in color (mineral oil). If the oil color darkens or exhibits a change in color, this may be an indication of contaminants in the refrigerant system. If this occurs, an oil sample should be taken and analyzed. If contaminants are present, the system must be cleaned to prevent compressor failure. Never use the scroll compressor to pump the refrigerant system down into a vacuum. Doing so will cause internal arcing of the compressor motor which will result in failure of compressor. CONDENSER FAN MOTORS Exercise care when cleaning the coil so that the coil fins are not damaged. OPERATING PARAMETERS Regular checks of the system should be preformed to ensure that operating temperatures and pressures are within limitations, and that the operating controls are set within proper limits. Refer to the Operation, StartUp, and Installation sections of this manual. ON-BOARD BATTERY BACK-UP U17 is the Real Time Clock chip that maintains the date/ time and stores customer programmed setpoints. Anytime the chiller is to be off (no power to the microboard) for an extended time (weeks/months), the clock should be turned off to conserve power of the on-board battery. To accomplish this, the J11 jumper on the microboard must be moved to the “CLKOFF” position while power is still supplied to the microboard. THE UNIT EVAPORATOR HEATER IS 120 VAC. DISCONNECTING 120VAC POWER FROM THE UNIT, AT OR BELOW FREEZING TEMPERATURES, CAN RESULT IN DAMAGE TO THE EVAPORATOR AND UNIT AS A RESULT OF THE CHILLED LIQUID FREEZING. OVERALL UNIT INSPECTION In addition to the checks listed on this page, periodic overall inspections of the unit should be accomplished to ensure proper equipment operation. Items such as loose hardware, component operation, refrigerant leaks, unusual noises, etc. should be investigated and corrected immediately. Condenser fan motors are permanently lubricated and require no maintenance. 108 YORK INTERNATIONAL FORM 150.62-NM1 ISN CONTROL RECEIVED DATA (CONTROL DATA) The Middle Market receives 8 data values from the ISN. The first 4 are analog values and the last 4 are digital values. These 8 data values are used as control parameters when in REMOTE mode. When the unit is in LOCAL mode, these 8 values are ignored. If the unit receives no valid ISN transmission for 5 minutes it will revert back to all local control values. Table 51 lists the 5 control parameters. These values are found under feature 54 on the ISN. TABLE 51 – ISN RECEIVED DATA ISN PAGE P03 P04 P05 P06 P07 P08 P09 P10 CONTROL DATA SETPOINT LOAD LIMIT STAGE (0,1, 2) COOLING RANGE (DAT MODE ONLY) — START/STOP COMMAND — — HISTORY BUFFER REQUEST TRANSMITTED DATA After receiving a valid transmission from the ISN, the unit will transmit either operational data or history buffer data depending on the “History Buffer Request” in page 10. Data must be transmitted for every ISN page under feature 54. If there is no value to be sent to a particular page, a zero will be sent. Tables 52 - 53 show the data values and page listings for this unit. YORK INTERNATIONAL TABLE 52 – ISN TRANSMITTED DATA ISN PAGE P11 P12 P13 P14 P15 P16 P17 P18 P20 P21 P22 P23 P24 P25 P27 P28 P29 P33 P35 P36 P37 P38 P39 P40 P41 TYPE ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG ANALOG DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DATA LEAVING CHILLED LIQUID TEMP. RETURN CHILLED LIQUID TEMP. MIXED CHILLED LIQUID TEMP. DISCHARGE AIR TEMP. — AMBIENT AIR TEMP. — SYS 1 RUN TIME (SECONDS) SYS 1 DISCHARGE PRESSURE — — — SYS 1 ANTI-RECYCLE TIMER ANTI-COINCIDENT TIMER SYS 2 RUN TIME (SECONDS) SYS 2 SUCTION PRESSURE SYS 2 DISCHARGE PRESSURE SYS 2 ANTI-RECYCLE TIMER NUMBER OF COMPRESSORS SYS 1 ALARM SYS 2 ALARM EVAPORATOR HEATER STATUS EVAPORATOR PUMP STATUS — — 109 3 Service and Troubleshooting TABLE 53 – ISN TRANSMITTED DATA ISN PAGE * TYPE P42 DIGITAL P43 P44 P45 DIGITAL DIGITAL DIGITAL P46 DIGITAL P47 P48 P49 DIGITAL DIGITAL DIGITAL P50 DIGITAL P51 DIGITAL P52 DIGITAL P53 DIGITAL P54 DIGITAL P55 P56 P57 P58 P59 P60 DIGITAL CODED CODED CODED CODED CODED DATA SYS 1 LIQUID LINE SOLENOID VALVE SYS HOT GAS BYPASS VALVE — — SYS 2 LIQUID LINE SOLENOID VALVE LEAD SYSTEM (0=SYS 1, 1 SYS 2) — — CHILLED LIQUID TYPE (0=WATER, 1=GLYCOL) AMBIENT CONTROL MODE (0=STD, 1 = AMB) LOCAL / REMOTE CONTROL MODE (0=LOCAL, 1=REMOTE) UNITS (0=IMPERIAL, 1=SI) LEAD/LAG CONTROL MODE (0=MANUAL, 1=AUTO) — *SYS 1 OPERATIONAL CODE *SYS 1 FAULT CODE *SYS 2 OPERATIONAL CODE *SYS 2 FAULT CODE SYS 1 COMP RUNNING ISN PAGE P61 P62 P63 P64 TYPE CODED CODED CODED CODED P65 ANALOG P66 ANALOG P67 ANALOG P68 P69 P70 ANALOG ANALOG ANALOG P71 ANALOG P72 P73 ANALOG ANALOG P74 ANALOG P75-P84 — DATA SYS 1 COND FANS RUNNING SYS 2 COMP RUNNING SYS 2 COND FANS RUNNING — UNIT CONTROL MODE 0=LEAVING WATER, 1=RETURN WATER 2=DISCHARGE AIR, 3= SUCTION PRESSURE ANTI-RECYCLE TIME (PROGRAMMED) LEAVING CHILLED LIQUID TEMP CUTOUT LOW AMBIENT TEMP CUTOUT — LOW SUCTION PRESS CUTOUT HIGH DISCHARGE PRESS CUTOUT SETPOINT COOLING RANGE SETPOINT 2 (SP CONTROL) NO DATA ALL ZEROS The operational and fault codes sent to pages 56 through 59 are defined in Table 54. Note that this table of fault and op codes is for all DX products. The codes that are grayed out are not used on this unit. 110 YORK INTERNATIONAL FORM 150.62-NM1 TABLE 54 – ISN OPERATIONAL AND FAULT CODES P56/58 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 OPERATIONAL CODE NO ABNORMAL CONDITION UNIT SWITCH OFF SYSTEM SWITCH OFF LOCK-OUT UNIT FAULT SYSTEM FAULT REMOTE SHUTDOWN DAILY SCHEDULE SHUTDOWN NO RUN PERMISSIVE NO COOL LOAD ANTI-COINCIDENCE TIMER ACTIVE ANTI-RECYCLE TIMER ACTIVE MANUAL OVERRIDE SUCTION LIMITING DISCHARGE LIMITING CURRENT LIMITING LOAD LIMITING COMPRESSOR(S) RUNNING P57/59 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 21 21 22 23 22 23 YORK INTERNATIONAL FAULT CODE NO FAULT VAC UNDERVOLTAGE LOW AMBIENT TEMPERATURE HIGH AMBIENT TEMPERATURE LOW LEAVING CHILLED LIQUID TEMP HIGH DISCHARGE PRESSURE HIGH DIFFERENTIAL OIL PRESSURE LOW SUCTION PRESSURE HIGH MOTOR CURRENT LLSV NOT ON LOW BATTERY WARNING HIGH OIL TEMPERATURE HIGH DISCHARGE TEMPERATE IMPROPER PHASE ROTATION LOW MOTOR CURRENT /MP / HPCO MOTOR CURRENT UNBALANCED LOW DIFFERENTIAL OIL PRESSURE GROUND FAULT MP /HPCO LOW EVAPORATOR TEMPERATURE INCORRECT REFRIGERANT PROGRAMMED POWER FAILURE, MANUAL RESET REQUIRED I/O BOARD FAILURE OIL TEMP INHIBIT (LOW OIL TEMP) 111 3 Wiring Diagrams ELEMENTARY DIAGRAM YCAL0014SC – YCAL0030SC FIG. 11 – ELEMENTARY DIAGRAM 112 YORK INTERNATIONAL FORM 150.62-NM1 20 LD03531 ELEMENTARY DIAGRAM YCAL0014SC – YCAL0030SC 4 FIG. 11 – ELEMENTARY DIAGRAM (Cont’d) YORK INTERNATIONAL 113 Wiring Diagrams ELEMENTARY DIAGRAM YCAL0014SC – YCAL0030SC LD03532 FIG. 12 – ELEMENTARY DIAGRAM 114 YORK INTERNATIONAL FORM 150.62-NM1 This page intentionally left blank. 4 YORK INTERNATIONAL 115 Wiring Diagrams ELEMENTARY DIAGRAM YCAL0034SC FIG. 13 – ELEMENTARY DIAGRAM 116 YORK INTERNATIONAL FORM 150.62-NM1 LD03533 ELEMENTARY DIAGRAM YCAL0034SC 4 FIG. 13 – ELEMENTARY DIAGRAM (Cont’d) YORK INTERNATIONAL 117 Wiring Diagrams ELEMENTARY DIAGRAM YCAL0034SC LD03534 FIG. 14 – ELEMENTARY DIAGRAM 118 YORK INTERNATIONAL FORM 150.62-NM1 This page intentionally left blank. 4 YORK INTERNATIONAL 119 Wiring Diagrams ELEMENTARY DIAGRAM YCAL0040SC – YCAL0060SC FIG. 15 – ELEMENTARY DIAGRAM 120 YORK INTERNATIONAL FORM 150.62-NM1 LD03535 ELEMENTARY DIAGRAM YCAL0040SC – YCAL0060SC 4 FIG. 15 – ELEMENTARY DIAGRAM (Cont’d) YORK INTERNATIONAL 121 Wiring Diagrams ELEMENTARY DIAGRAM YCAL0040SC – YCAL0060SC FIG. 16 – ELEMENTARY DIAGRAM 122 YORK INTERNATIONAL FORM 150.62-NM1 LD03536 ELEMENTARY DIAGRAM YCAL0040SC – YCAL0060SC 4 FIG. 16 – ELEMENTARY DIAGRAM (Cont’d) YORK INTERNATIONAL 123 Wiring Diagrams ELEMENTARY DIAGRAM YCAL0064SC – YCAL0080SC FIG. 17 – ELEMENTARY DIAGRAM 124 YORK INTERNATIONAL FORM 150.62-NM1 LD03537 ELEMENTARY DIAGRAM YCAL0064SC – YCAL0080SC 4 FIG. 17 – ELEMENTARY DIAGRAM (Cont’d) YORK INTERNATIONAL 125 Wiring Diagrams ELEMENTARY DIAGRAM YCAL0064SC – YCAL0080SC FIG. 18 – ELEMENTARY DIAGRAM 126 YORK INTERNATIONAL FORM 150.62-NM1 LD03538 ELEMENTARY DIAGRAM YCAL0064SC – YCAL0080SC 4 FIG. 18 – ELEMENTARY DIAGRAM (Cont’d) YORK INTERNATIONAL 127 Appendix 1 – Isolators APPENDIX 1 (ALUMINUM FINS) 1" DEFLECTION – WEIGHT DISTRIBUTION POINT SPRING LOCATION MODEL # YCAL0014 YCAL0020 YCAL0024 YCAL0030 YCAL0034 YCAL0040 YCAL0044 YCAL0050 YCAL0060 YCAL0064 YCAL0070 YCAL0074 YCAL0080 A CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-2-27 CP-2-27 CP-2-27 CP-2-27 CP-2-28 CP-2-28 CP-2-31 CP-2-31 B CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-2-27 CP-2-27 CP-2-27 CP-2-27 CP-2-28 CP-2-28 CP-2-28 CP-2-28 C CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-2-27 CP-2-27 CP-2-27 CP-2-27 CP-2-28 CP-2-28 CP-2-31 CP-2-31 D CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-2-27 CP-2-27 CP-2-27 CP-2-27 CP-2-28 CP-2-28 CP-2-28 CP2-28 Refer to Dimensions for Weight Distribution Point Location A – D SEISMIC WEIGHT DISTRIBUTION POINT SPRING LOCATION MODEL # YCAL0014 YCAL0020 YCAL0024 YCAL0030 YCAL0034 YCAL0040 YCAL0044 YCAL0050 YCAL0060 YCAL0064 YCAL0070 YCAL0074 YCAL0080 A AEQM-97 AEQM-97 AEQM-97 AEQM-98 AEQM-98 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1625 AEQM-1625 AEQM-1625 AEQM-1625 B AEQM-97 AEQM-97 AEQM-97 AEQM-97 AEQM-98 AEQM-1300 AEQM-1300 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1625 AEQM-1625 C AEQM-97 AEQM-97 AEQM-97 AEQM-98 AEQM-98 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1625 AEQM-1625 AEQM-1625 AEQM-1625 D AEQM-97 AEQM-97 AEQM-97 AEQM-97 AEQM-98 AEQM-1300 AEQM-1300 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1625 AEQM-1625 Refer to Dimensions for Weight Distribution Point Location A – D ISOLATOR SPRING IDENTIFICATION TABLE MODEL CP-1-27 CP-1-28 CP-1-31 CP-1-27 CP-2-28 CP-2-31 128 1" DEFLECTION PART- # 308439-27 308439-28 308439-31 308692-27 308692-28 308692-31 COLOR ORANGE GREEN GRAY ORANGE GREEN GRAY MODEL AEQM-97 AEQM-98 AEQM-1300 AEQM-1600 AEQM-1625 SEISMIC PART # 301055-97 301055-98 301060-1300 301060-1600 301060-1625 COLOR WHITE GRAY YELLOW GRAY RED YORK INTERNATIONAL FORM 150.62-NM1 APPENDIX 1 (COPPER FINS) 1" DEFLECTION – WEIGHT DISTRIBUTION POINT SPRING LOCATION MODEL # YCAL0014 YCAL0020 YCAL0024 YCAL0030 YCAL0034 YCAL0040 YCAL0044 YCAL0050 YCAL0060 YCAL0064 YCAL0070 YCAL0074 YCAL0080 A CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-2-27 CP-2-27 CP-2-27 CP-2-28 CP-2-31 CP-2-31 CP-2-31 CP-2-31 B CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-1-28 CP-2-27 CP-2-27 CP-2-27 CP-2-28 CP-2-28 CP-2-28 CP-2-31 CP-2-31 C CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-2-27 CP-2-27 CP-2-27 CP-2-28 CP-2-31 CP-2-31 CP-2-31 CP-2-31 D CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-1-28 CP-2-27 CP-2-27 CP-2-27 CP-2-28 CP-2-28 CP-2-28 CP-2-31 CP-2-31 Refer to Dimensions for Weight Distribution Point Location A – D SEISMIC WEIGHT DISTRIBUTION POINT SPRING LOCATION MODEL # YCAL0014 YCAL0020 YCAL0024 YCAL0030 YCAL0034 YCAL0040 YCAL0044 YCAL0050 YCAL0060 YCAL0064 YCAL0070 YCAL0074 YCAL0080 A AEQM-97 AEQM-97 AEQM-97 AEQM-98 AEQM-98 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1625 AEQM-1628 AEQM-1628 AEQM-1628 AEQM-1628 B AEQM-97 AEQM-97 AEQM-97 AEQM-98 AEQM-98 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1625 AEQM-1625 AEQM-1625 AEQM-1628 AEQM-1628 C AEQM-97 AEQM-97 AEQM-97 AEQM-98 AEQM-98 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1625 AEQM-1628 AEQM-1628 AEQM-1628 AEQM-1628 D AEQM-97 AEQM-97 AEQM-97 AEQM-98 AEQM-98 AEQM-1600 AEQM-1600 AEQM-1600 AEQM-1625 AEQM-1625 AEQM-1625 AEQM-1628 AEQM-1628 5 Refer to Dimensions for Weight Distribution Point Location A – D ISOLATOR SPRING IDENTIFICATION TABLE MODEL CP-1-27 CP-1-28 CP-2-27 CP-2-28 CP-2-31 YORK INTERNATIONAL 1" DEFLECTION PART- # 308439-27 308439-28 308692-27 308692-28 308692-31 COLOR ORANGE GREEN ORANGE GREEN GRAY MODEL AEQM-97 AEQM-98 AEQM-1600 AEQM-1625 AEQM-1628 SEISMIC PART # 301055-97 301055-98 301060-1625 301060-1625 301060-1628 COLOR WHITE GRAY GRAY RED GRAY/GREEN 129 Appendix 1 – Isolators APPENDIX 1 (DIMENSIONS) LD03839 FIG. 19 – TYPE CP 1 LD03840 FIG. 20 – TYPE CP 2 APPENDIX 1 (DIMENSIONS) MODEL # AEQM-97 AEQM-98 AEQM-99 AEQM-1000 AEQM-1300 AEQM-1600 AEQM-1625 AEQM-1628 A 7 7 7 8-½ 8-½ 8-½ 8-½ 8-½ B 5-½ 5-½ 5-½ 6-½ 6-½ 6-½ 6-½ 6-½ C 4-½ 4-½ 4-½ 6 6 6 6 6 D 2-½ 2-½ 2-½ 4-½ 4-½ 4-½ 4-½ 4-½ E A A A ¾ ¾ ¾ ¾ ¾ F ! ! ! @ @ @ @ @ G 7-! 7-! 7-! 8-@ 8-@ 8-@ 8-@ 8-@ H A A A B B B B B J @ @ @ ½ ½ ½ ½ ½ 5 LD04045 FIG. 21 – R SPRING SEISMIC ISOLATORS Appendix 1 – Isolators APPENDIX 1 INSTALLATION AND ADJUSTING INSTALLATIONS TYPE CP MOUNTING Mountings are shipped completely assembled, ready to install. 1. Locate mountings under equipment at positions shown on tags or on VM layout drawings, or as indicated on packing slip or correspondence. 2. Set mountings on subbase, shimming or grouting where required to provide flat and level surface at the same elevation for all mountings (1/4" maximum difference in elevation can be tolerated). Support the full underside of the base plate - do not straddle gaps or small shims. 3. Unless specified, mountings need not be fastened to floor in any way. If required, bolt mountings to floor through slots. of the mount to go down, possibly resting on the lower housing. 5. If clearance “X” is less than 1/4" on any mounting, with wrench turn up one complete turn on the adjusting bolt of each mounting. Repeat this procedure until 1/4”, clearance at “X” is obtained on one or more mountings. 6. Take additional turns on all mountings having less than 1/4” clearance, until all mountings have at least this clearance. 7. Level the machine by taking additional turns on all mounts at the low side. Clearance should not exceed 1/2" - greater clearance indicates that mountings were not all installed at the same elevation, and shims are required. This completes adjustment. 4. Set the machine or base on the mountings. The weight of the machine will cause the upper housing LD03837 FIG. 22 – TYPE CP MOUNTING 132 YORK INTERNATIONAL FORM 150.62-NM1 APPENDIX 1 “AEQM” SPRING-FLEX MOUNTING INSTALLATION AND ADJUSTMENT INSTRUCTIONS 1. Isolators are shipped fully assembled and are to be spaced and located in accordance with installation drawings or as otherwise recommended. 5. Remove cap screw “C” and save. Gently place machine or machine base on top of bolt “B”. Install cap screw “C” but DO NOT tighten. 1a. Locate spring port facing outward from equipment or base so that spring is visible. 6. The weight of the machine will cause the spring and thus bolt “B” to descend. 2. To facilitate installation, prior to installing, VMC recommends turning adjusting bolt “B” so that the “Operating Clearance” marked “*” is approximately 1" to 1-1/2" for 1" deflection units, 1-1/2" to 2" for 1-1/2" deflection units, and 2" to 2-1/2" for 2" deflection units. 7. Adjust all isolators by turning bolt “B” so that the operating clearance “*” is approximately 1/4". NOTE: It may be necessary to adjust rebound plate “D” for clearance. 3. Locate isolators on floor or subbase as required, ensuring that the isolator centerline matches the equipment or equipment base mounting holes. Shim and/ or grout as required to level all isolator base plates “A”. A 1/4" maximum difference in elevation can be tolerated. 6. Check equipment level and fine adjust isolators to level equipment. 9. Adjust rebound plate “D” so that the operating clearance “**” is no more than 1/4". 10. Tighten cap screw “C”. Adjustment is complete. 4. Anchor all isolators to floor or subbase as required. For installing on concrete VMC recommends HILTI type HSL heavy duty anchors or equal. 5 LD03838 FIG. 23 – “AEQM” SPRING-FLEX MOUNTING YORK INTERNATIONAL 133 ALABAMA Birmingham YORK International Corp. (205) 987-0458 LOUISIANA New Orleans YORK International Corp. (504) 464-6941 ARIZONA Phoenix YORK International Corp. (602) 220-9400 MARYLAND Baltimore/Washington YORK International Corp. (410) 720-6383 CALIFORNIA Los Angeles YORK International Corp. (714) 897-0997 San Francisco YORK International Corp. (510) 426-1166 MASSACHUSETTS Boston YORK International Corp. (781) 769-7950 COLORADO Denver YORK International Corp. (303) 649-1500 CONNECTICUT Danbury YORK International Corp. (203) 730-8100 FLORIDA Miami YORK International Corp. (305) 389-9675 Tampa YORK International Corp. (381) 621-1323 Orlando YORK International Corp. (407) 444-2261 GEORGIA Atlanta YORK International Corp. (404) 925-0346 HAWAII Honolulu YORK International Corp. (808) 596-0761 ILLINOIS Chicago YORK International Corp. (708) 520-1910 INDIANA Indianapolis YORK International Corp. (317) 595-3050 KENTUCKY Louisville YORK International Corp. (502) 499-6020 CANADA Ottawa, Ontario (613) 596-9111 MICHIGAN Detroit YORK International Corp. (810) 689-7277 MINNESOTA Minneapolis YORK International Corp. (612) 780-4446 MISSOURI Kansas City YORK International Corp. (816) 221-9675 St. Louis YORK International Corp. (314) 770-0909 NEW JERSEY Newark YORK International Corp. (908) 225-0606 NEVADA Las Vegas YORK International Corp. (702) 873-2200 NEW YORK Buffalo YORK International Corp. (716) 633-2172 New York YORK International Corp. (212) 843-1602 NORTH CAROLINA Charlotte YORK International Corp. (704) 598-0000 Greensboro YORK International Corp. (336) 299-9675 Raleigh YORK International Corp. (919) 829-1700 Toronto, Ontario (905) 890-6812 Laval, Quebec (514) 387-6000 OHIO Cincinnati YORK International Corp. (513) 489-8871 Cleveland YORK International Corp. (216) 447-0696 Columbus YORK International Corp. (614) 841-5242 PENNSYLVANIA Philadelphia YORK International Corp. (610) 640-2320 Pittsburgh YORK International Corp. (412) 364-6600 York (HQ) YORK International Corp. (717) 771-6561 SOUTH CAROLINA Greenville YORK International Corp. (803) 297-4822 TENNESSEE Kingsport YORK International Corp. (615) 349-2450 Nashville YORK International Corp. (615) 833-9675 TEXAS Austin YORK International Corp. (512) 458-4575 Dallas YORK International Corp. (214) 241-1219 Houston YORK International Corp. (713) 782-5200 San Antonio YORK International Corp. (210) 496-6631 UTAH Salt Lake City YORK International Corp. (801) 261-1200 VIRGINIA Richmond YORK International Corp. (804) 359-2600 Newport News YORK International Corp. (804) 873-0362 WASHINGTON Seattle YORK International Corp. (206) 251-9145 YORK Applied Systems field office listing subject to change. See us on the web at http://www.york.com for additional information. 134 YORK INTERNATIONAL FORM 150.62-NM1 This page intentionally left blank. YORK INTERNATIONAL 135 P.O. Box 1592, York, Pennsylvania USA 17405-1592 Copyright © by York International Corporation 2000 Form 150.62-NM1 (700) Supersedes: 150.62-NM1 (899) 150.62-NM1 (399) Tele. 800-851-1001 www.york.com Subject to change without notice. Printed in USA ALL RIGHTS RESERVED
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : Yes Page Count : 136 Page Mode : UseOutlines Page Layout : SinglePage XMP Toolkit : XMP toolkit 2.9.1-13, framework 1.6 About : uuid:5ac1225f-cadb-4dd7-92a8-9f221c735a77 Producer : Acrobat Distiller 4.0 for Windows Keywords : Form 150.62-NM1 (700), Millennium Air-Cooled Liquid Chillers Hermetic Scroll, Installation, Operation, Maintenance Create Date : 2000:06:15 13:33:40Z Modify Date : 2003:06:30 13:57:05-04:00 Metadata Date : 2003:06:30 13:57:05-04:00 Document ID : uuid:e775b8c7-2303-4bfc-b7f5-ce6320b7b28c Format : application/pdf Title : Form 150.62-NM1 (700), Millennium Air-Cooled Liquid Chillers Hermetic Scroll, Installation, Operation, Maintenance Description : Form 150.62-NM1 (700), Millennium Air-Cooled Liquid Chillers Hermetic Scroll, Installation, Operation, Maintenance Creator : York International Corporation Author : York International Corporation Subject : Form 150.62-NM1 (700), Millennium Air-Cooled Liquid Chillers Hermetic Scroll, Installation, Operation, MaintenanceEXIF Metadata provided by EXIF.tools