Name: York YCAV0457P
Brand: York
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MODELS YCAV0267-0527, 60 HZ

STYLE A

(290-515 TONS)

AIR-COOLED SCREW LIQUID CHILLERS

E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY

50075

AIR-COOLED SCREW

LIQUID CHILLERS

INSTALLATION, OPERATION, MAINTENANCE Supersedes 201.21-NM3 (315) Form 201.21-NM3 (616)

035-20994-000

R134a

Issue Date:

June 30, 2016

Table of Contents4
Section 1 - General Chiller Information & Safety9
Introduction9
Warranty9
Safety9
Standards for Safety9
Responsibility for Safety10
About this Manual10
Misuse of Equipment10
Suitability for Application10
Structural Support10
Mechanical Strength10
General Access10
Pressure Systems11
Electrical11
Rotating Parts11
Sharp Edges11
Refrigerant & Oils11
High Temperature & Pressure Cleaning11
Emergency Shutdown11
Section 2 - Product Description12
Introduction12
General System Description12
Compressor13
Evaporator14
Condensor15
Flash Tank Feed / Drain Valve15
Oil Separator/Oil System15
Relief Valves15
Oil Cooling16
Capacity Controls16
Power and Control Panel16
Microprocessor & VSD Controls16
Display17
Keypad17
Unit Switch17
Variable Speed Drive (VSD)18
Fig 1 - PWM Current Waveform18
Fig 2 - PWM Voltage Waveform18
Accessories & Options19
Single Point Circuit Breaker19
Building Automation System (BAS) Interface19
Condensor Coil Protection19
DX Cooler Options20
Service Valve Option20
Unit Enclosures20
Fans20
Sound Reduction Options20
Vibration Isolation20
Unit Nomenclature21
Product Identification Number22
Section 3 - Rigging, Handling and Storage26
Delivery and Storage26
Inspection26
Lifting Weights26
Moving the Chiller27
Unit Rigging28
Section 4 - Installation28
Location Requirements29
Outdoor Installation29
Indoor Installation29
Location Clearances30
Vibration Isolators30
Installation30
Shipping Braces30
Chilled Liquid Piping30
General Requirements30
Water Treatment32
Connection Types & Sizes32
Cooler Connections32
Option Flanges32
Fig 3 - Pipework Arrangement32
Fig 4 - Victaulic Groove32
Fig 5 - Flange Attachment32
Refrigerant Relief Valve Piping33
Ductwork Connection33
General Requirements33
Electrical Connection33
Power Wiring34
Vac Control Supply Transformer34
Control Panel Wiring34
Volts Free Contacts35
Chilled Liquid Pump Starter35
Run Contact35
Alarm Contact35
System Inputs35
Flow Switch35
Remote Run/Stop35
Optional Remote Setpoint Offset Temp35
Optional Remote Setpoint Offset Sound Limit35
Section 5 - Commissioning36
Preparation36
Preparation - General36
Inspection36
Refrigerant Charge36
Service and Oil Line Valves36
Compressor Oil36
Fans36
Isolation / Protection36
Control Panel36
Power Connections37
Grounding37
Water System37
Flow Switch37
Temperature Sensor(S)37
Programmed Options37
Programmed Settings37
Date & Time37
Start / Stop37
Setpoint & Remote Offset37
Interlocks38
Unit Switch38
Start-Up38
Oil Pressure38
Refrigerant Flow38
Loading38
Suction Superheat38
Subcooling38
Condensor & Fan Rotation39
General Operation39
Section 6 - Technical Data40
Water Pressure Drop Charts40
Glycol Correction Factors42
Water Temp. and Flows43
Physical Data44
Operating Limitations and48
Sound Power48
Electrical Data - Compr. Wiring49
Fig 6 - Single Point Power Supply Connection49
W/Circuit Breaker Protection (3 Compr)49
Fig 7 - Single Point Power Supply Connection49
W/Terminal Block (3 Compr)49
W/Circuit Breaker Protection (4 Compr)49
W/Terminal Block (4 Compr)49
Fig 8 - Single Point Power Supply Connection50
W/Circuit Breaker Protection (4 Compr)50
Fig 9 - Single Point Power Supply Connection50
W/Terminal Block (4 Compr)50
Fig 10 - Multi-Point Power Supply Connection51
Fig 11 - Multi-Point Power Supply Connection51
Electrical Notes60
Wiring Diagrams - 3 Compressor62
Wiring Diagrams - 4 Compressor74
Dimensions90
Technical Data (Clearances)156
Fig 12 - Sample Printout Supplied in the Isolator157
Isolator Mounting158
Package & Chiller Panel Literature Packet158
Isolator Mounting Positions159
Seismic Isolator Installation163
Neoprene Isolator Position164
Refrigerant Flow Diagram167
Fig 13 - Refrigerant Flow Diagram167
Diagram168
Fig 14 - Processes and Instrumentation168
Component Locations169
Fig 15 - Component Locations169
Fig 16 - Control and VSD Cabinet Locations170
Fig 17 - Chiller Control Board, Relay Boards171
Microgateway, and Optional Circuit Breaker171
Microgateway171
Fig 19 - VSD Logic Board173
Fig 20 - VSD Logic Board173
Fig 21 - Power Components175
Fig 22 - Power Components175
Fig 23 - Fan Contactors177
Fig 24 - VSD Components178
Fig 25 - VSD Components179
Fig 26 - VSD Components180
Fig 27 - VSD Components181
Fig 28 - Inverter Power Components182
Fig 29 - Inverter Power Components183
Fig 30 - Inverter Power Components184
Fig 31 - Inverter Power Components184
Fig 32 - Glycol Pump & Fill Tube Locations185
Fig 33 - Glycol Piping & Fill Tube Locations186
Fig 34 - Compressor Components187
Equipment Start-Up Check Sheet188
Unit Checks (no Power)188
Panel Checks190
(Power ON-Both System Switches OFF)190
Programmed Values191
Chilled Liquid Setpoint191
Date/Time, Daily Schedule, & Clock Jumper191
Initial Start-Up192
Check Subcooling & Superheat192
Leak Checking193
Chiller Electronic Components194
Keypad194
Display195
Chiller Control Board196
Relay Output Boards197
VSD (Variable Speed Drive)197
AC to DC Rectifier197
SCR Trigger Board198
DC Link Filter198
1L Line Inductor199
AC to DC Inverter199
Laminated Bus Structure199
VSD Logic Board200
Control Panel to VSD Communications200
IGBT Gate Driver Boards201
Current Transformers201
DV/DT Output Suppression Network202
Flash Tank Feed/Drain Valve Controller202
DC Bus Voltage Isolation Board203
Chiller Circuit Breaker203
Autotransformer203
Chiller Configuration Jumpers204
Number of Compr. Configuration Jumpers204
Vsd Logic to Chiller Microprocessor204
Board Rs-485 Communication204
Configuration Jumpers204
Table 1 - Compressors and the Appropriate Jumper204
Positions204
Table 2 - VSD Logic Board Address Jumper204
Max Vsd Frequency205
Table 3 - Maximum Frequency Jumper205
Section 7 - Operation206
Operating Controls206
Basic Operating Sequence208
Fig 35 - Chiller Control (Cooling) Range208
Number of Compressors to Start209
General209
Standard IPLV209
Optional Optimized IPLV209
Fig 36 - Number of Compressors to Start209
Minimum Vsd Compressor Start/Stop Frequency210
Minimum VSD Start Frequency210
Minimum VSD Run Frequency210
Fig 37 - Minimum VSD Start Frequency210
Fig 38 - Minimum VSD Run210
Acceleration/Deceleration Rate211
Compressors211
VSD Acceleration/ Deceleration Rates211
Standard Iplv Capacity Control212
Fuzzy Logic Control213
Hot Water Starts214
Lag Compressor Operation in Load Limiting214
Table 4 - Fuzzy Logic Loading/Unloading Vs. Error214
Optional Iplv Capacity Control215
Fuzzy Logic216
Hot Water Starts217
Table 5 - Fuzzy Logic Loading/Unloading Vs. Error217
Load Limiting Control218
Table 6 - Current Load Limiting/Unloading218
Table 7 - Discharge Pressure Load Limiting218
Unloading218
Table 8 - Suction Pressure Load Limiting219
Unloading219
Table 9 - VSD Internal Ambient Load Limiting219
Table 10 - VSD Baseplate Temperature Load220
Limiting/Unloading220
Controller221
Valve Controller & Control Algorithm221
Fig 39 - LED Locations222
Fig 40 - Power, Comms Led's223
Led's223
Economizer Control224
Condenser Fan Control224
Table 11 - Fan Stages & Corresponding Outputs225
Fig 42 - Standard IPLV Fan Control226
Fig 43 - High IPLV Fan Control226
Vsd Temperature Control/Fan Control Operation227
Remote Temperature Reset Control228
Local Current Limit Control229
Pulldown Current Limit Setpoint229
Remote Current Limit Reset230
Sound Limit Controls232
Vsd Operation & Controls234
VSD Cooling and Cooling Loop236
Table 12 - VSD Operating Display Parameters239
Vsd Safeties240
IGBT Gate Driver (Hardware) Fault243
Power Supply (Hardware) Fault245
Unit Warnings248
Unit Safeties252
System Safeties254
Table 13 - Low Differential Oil Pressure Cutout256
Table 14 - Start Inhibit Sensor Thresholds258
Status Key260
Unit Data Key264
System Data Key266
Table 15 - Sensor Min/Max Outputs268
Vsd Data Key270
Operating Hours & Start Keys272
History Key273
Unit Data274
VSD Data275
System Data276
Compressor Operating Hours & Starts278
Chilled Liquid & Cooling Setpoints278
Options278
Program Values279
Setpoints Key281
Table 16 - Setpoint Limits282
Program Key283
Table 17 - Programmable Operating Parameters285
Options Key286
Date/Time & Schedule Key290
Date/Time Key290
Schedule Key291
Unit Operating Schedule292
Sound Limit Schedule293
Manual Override Key294
Print Key295
Table 18 - Printout Types295
Operating Data Printout296
History Data Printout297
Service Key298
System Switches Key304
Serial Number Programming305
Enabling Optimized High Iplv Mode307
Unit Setup Mode308
Table 19 - Unit Setup Programmable Values308
Default Programmable Values310
Serial Port Connections311
Table 20 - Serial Port Connections311
Analog Input Connections312
Table 21 - Analog Input Connections312
Digital Input Connections314
Table 22 - Digital Input Connections314
Analog Output Connections316
Table 23 - Analog Output Connections316
Digital Output Connections318
Table 24 - Digital Output Connections318
Isn Communications320
Transmitted Data320
Control Data320
Table 26 - DXST/ISN Transmitted Data321
Table 27 - Fault Inhibit Codes325
Table 28 - Operational Status Codes327
R-134A Conversion Tables328
Table 29 - R-134A Pressure to Saturated328
Temperature Conversion328
Maintenance329
General Requirements329
Maintenance Requirements330
Troubleshooting Guide332
Evacuating a System334
Warranty Policy335
New Equipment335
Reconditioned or Replacement Materials335
All Warranties Are VIOD if335
Chilled Liquid & Suction Temp Sensor Input Voltage Table336
Table 30 - Temperature Input Voltage Sensor336
Outside Air Temp Sensor Input Voltage Table337
Table 31 - Outside Air Temperature Input Voltage337
Pressure Transducer Output Voltage Table338
Table 32 - Pressure Transducer Input Voltage338
Motor Temperature Sensor Resistance Table339
Maximum Vsd Frequency340
Table 34 - Compressor Motor Overload Settings340
Max. VSD Frequency340
Printer Wiring341
Fig 44 - Print Cable Chiller to Serial Printer341
Okidata 184342
Weigh-Tronix IMP Model 2600342
Seiko342
Operating Log343
Site and Chiller Info343
Programmed Values343
Currents344
System Operating Conditions345
Water System Conditions346
Condensor Conditions346
Recommended Spare Parts347

York YCAV0457P User Manual

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York YCAV0457P Specifications

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Brand	York
Model	YCAV0457P
Category	Chiller
Language	English