Name: York YCAV0569
Brand: York
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R134a

MODELS YCAV0569-0969, 50 HZ

STYLE A

(492-879 KW)

E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY

LD10477

AIR-COOLED SCREW

LIQUID CHILLERS

INSTALLATION, OPERATION, MAINTENANCE Supesedes 201.21-NN2 (315) Form 201.21-NM2 (616)

Issue Date:

June 30, 2016

035-20993-000

Table of Contents5
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
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 Attatchment32
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 Factors41
Water Temp. and Flows42
Physical Data44
Operating Limitations and46
Sound Power46
Electrical Data47
Fig 6 - Single Point Power Supply Connection W/ Field Supplied Circuit Protection47
Fig 7 - Single Point Power Supply Connection W/ Optional Factory Circuit Breaker47
Electrical Notes50
Elementary Wiring Diagram52
Connection Diagram56
Location Label60
Dimensions62
Technical Data (Clearances)90
Weight Distribution & Isolator Mounting92
Fig 8 - Sample Printout Supplied in the Isolator Package & Chiller Panel Literature Packet92
Isolator Mounting Positions93
Seismic Isolator Installation96
Neoprene Isolator Position98
1" Deflection Isolator Installation99
Refrigerant Flow Diagram101
Fig 9 - Refrigerant Flow Diagram101
Diagram102
Fig 10 - Processes and Instrumentation102
Component Locations103
Fig 11 - Component Locations103
Fig 12 - Control and VSD Cabinet Locations104
Fig 13 - Chiller Control Board, Relay Boards, Microgateway, and Optional Circuit Breaker105
Fig 14 - Chiller Control Board, Relay Boards, and Microgateway106
Fig 15 - VSD Logic Board107
Fig 16 - VSD Logic Board108
Fig 17 - Power Components109
Fig 18 - Fan Contactors & 3T Transformers110
Fig 19 - VSD Components111
Fig 20 - VSD Components112
Fig 21 - VSD Components113
Fig 22 - Inverter Power Components114
Fig 23 - Inverter Power Components115
Fig 24 - Inverter Power Components116
Fig 24A - Inverter Power Components116
Fig 25 - Glycol Pump & Fill Tube Locations117
Fig 26 - Glycol Piping & Fill Tube Locations118
Fig 27 - Compressor Components119
Equipment Start-Up Check Sheet120
Unit Checks (no Power)120
Panel Checks122
(Power ON-Both System Switches OFF)122
Programmed Values123
Chilled Liquid Setpoint123
Date/Time, Daily Schedule, & Clock Jumper123
Initial Start-Up124
Check Subcooling & Superheat124
Leak Checking125
Chiller Electronic Components126
Keypad126
Display127
Chiller Control Board128
Relay Output Boards129
VSD (Variable Speed Drive)129
AC to DC Rectifier129
SCR Trigger Board130
DC Link Filter130
1L Line Inductor131
AC to DC Inverter131
Laminated Bus Structure131
VSD Logic Board132
Control Panel to VSD Communications132
IBGT Gate Driver Boards133
Current Transformers133
DV/DT Output Suppression Network134
Flash Tank Feed/Drain Valve Controller134
DC Bus Voltage Isolation Board135
Chiller Circuit Breaker135
Autotransformer135
Chiller Configuration Jumpers136
Number of Compressors Configuration Jumpers136
Vsd Logic to Chiller Microprocessor Board Rs-485 Communication Configuration Jumpers136
Max Vsd Frequency137
Section 7 - Operation138
Operating Controls138
Basic Operating Sequence140
Fig 28 - Chiller Control (Cooling) Range140
Number of Compressors to Start141
General141
Standard IPLV141
Optional Optimized IPLV141
Fig 29 - Number of Compressors to Start141
Minimum Vsd Compressor Start/Stop Frequency142
Minimum VSD Start Frequency142
Minimum VSD Run Frequency142
Fig 30 - Minimum VSD Start Frequency142
Fig 31 - Minimum VSD Run142
Acceleration/Deceleration Rate143
Compressors143
VSD Acceleration/ Deceleration Rates143
Standard Iplv Capacity Control144
Fuzzy Logic Control145
Hot Water Starts146
Lag Compressor Operation in Load Limiting146
Optional Iplv Capacity Control147
Fuzzy Logic148
Hot Water Starts149
Load Limiting Control150
Flash Tank Drain/Feed Valve Controller153
Valve Controller & Control Algorithm153
Fig 32 - LED Locations154
Fig 33 - Power, Comms Led's155
Fig 34 - Power, Comms & System Open/Close Led's155
Economizer Control156
Condenser Fan Control157
Fig 35 - Standard IPLV Fan Control158
Fig 36 - High IPLV Fan Control158
Vsd Temperature Control/Fan Control Operation159
Remote Temperature Reset Control160
Local Current Limit Control161
Pulldown Current Limit Setpoint161
Remote Current Limit Reset162
Sound Limit Controls164
Vsd Operation & Controls166
VSD Cooling and Cooling Loop168
Vsd Safeties172
IBGT Gate Driver (Hardware) Fault175
Power Supply (Hardware) Fault177
Unit Warnings180
Unit Safeties184
System Safeties186
Status Key192
Unit Data Key196
System Data Key198
Vsd Data Key202
Operating Hours & Start Keys204
History Key205
Unit Data207
VSD Data207
System Data208
Compressor Operating Hours & Starts210
Chilled Liquid & Cooling Setpoints210
Options210
Program Values211
Setpoints Key213
Program Key215
Options Key218
Date/Time & Schedule Key222
Date/Time Key222
Schedule Key223
Unit Operating Schedule224
Sound Limit Schedule225
Manual Override Key226
Print Key227
Operating Data Printout228
History Data Printout229
Service Key230
System Switches Key236
Serial Number Programming237
Enabling Optimized High Iplv Mode239
Unit Setup Mode240
Default Programmable Values242
Serial Port Connections243
Analog Input Connections244
Digital Input Connections246
Analog Output Connections248
Digital Output Connections250
Isn Communications252
Transmitted Data252
R-134A Conversion Tables258
Maintenance259
General Requirements259
Maintenance Requirements260
Troubleshooting Guide262
Evacuating a System264
Warranty Policy265
New Equipment265
Reconditioned or Replacement Materials265
All Warranties Are VIOD if265
Chilled Liquid & Suction Temp Sensor Input Voltage Table266
Outside Air Temp Sensor Input Voltage Table266
Pressure Transducer Output Voltage Table268
Motor Temperature Sensor Resistance Table269
Compressor Motor Overload Settings & Maximum Vsd Frequency270
Printer Wiring271
Fig 37 - Print Cable Chiller to Serial Printer271
Okidata 184272
Weigh-Tronix IMP Model 2600272
Seiko272
Operating Log273
Site and Chiller Info273
Programmed Values273
Currents274
System Operating Conditions275
Water System Conditions276
Condensor Conditions276
Recommended Spare Parts277

York YCAV0569 User Manual

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York YCAV0569 Specifications

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Brand	York
Model	YCAV0569
Category	Chiller
Language	English