AIR-COOLED SCREW LIQUID CHILLERS INSTALLATION, OPERATION & MAINTENANCE Supersedes: Nothing FORM 201.28-NM1.EN.
Form 201.28-NM1.EN.PED/CE (0211) 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 misused or handled improperly, to cause bodily injury or death.
Form 201.28-NM1.EN.PED/CE (0211) CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous product improvement, the information contained in this document is subject to change without notice. While Johnson Controls 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 Johnson Controls Engineered Systems Service office.
Form 201.28-NM1.EN.PED/CE (0211) TABLE OF CONTENTS SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY .......................................................................... 8 Introduction ....................................................................................................................................................... 8 Warranty ...........................................................................................................................................................
Form 201.28-NM1.EN.PED/CE (0211) SECTION 5 - TECHNICAL DATA ............................................................................................................................ 33 Nomenclature ................................................................................................................................................. 33 DimenSions ....................................................................................................................................................
Form 201.28-NM1.EN.PED/CE (0211) LIST OF FIGURES Figure 1 - YVAA Air-Cooled Screw Liquid Chiller with Variable Speed Drive ................................................................. 13 Figure 2 - Chiller Control System ................................................................................................................................... 14 Figure 3 - View of York Control Center User Interface ................................................................................................
Form 201.28-NM1.EN.PED/CE (0211) LIST OF TABLES Table 1 - Minimum Evaporator Tube Removal Clearance .............................................................................................. 24 Table 2 - Electrical Lug Data........................................................................................................................................... 32 Table 3 - Physical Data .....................................................................................................................
GENERAL CHILLER INFORMATION AND SAFETY Form 201.28-NM1.EN.PED/CE (0211) SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY INTRODUCTION YORK YVAA chillers are manufactured to the highest design and construction standards to ensure high performance, reliability and adaptability to all types of air conditioning installations. The unit is intended for cooling water or glycol solutions and is not suitable for purposes other than those specified in this manual.
Form 201.28-NM1.EN.PED/CE (0211) RESPONSIBILITY FOR SAFETY General Access Every care has been taken in the design and manufacture of the unit to ensure compliance with the safety requirements listed above. However, the individual operating or working on any machinery is primarily responsible for: There are a number of areas and features, which may be a hazard and potentially cause injury when working on the unit unless suitable safety precautions are taken.
GENERAL CHILLER INFORMATION AND SAFETY Form 201.28-NM1.EN.PED/CE (0211) Refrigerants and Oils Refrigerants and oils used in the unit are generally nontoxic, non-flammable and non-corrosive, and pose no special safety hazards. Use of gloves and safety glasses is, however, recommended when working on the unit. The buildup of refrigerant vapor, from a leak for example, does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation.
Form 201.28-NM1.EN.PED/CE (0211) MATERIAL SAFETY DATA Refrigerant Data: Safety Data 1 134a Toxicity Low In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. R134a may be slightly irritant and liquid has a degreasing effect. Thaw affected areas with water. Remove contaminated clothing carefully — may adhere to skin in case of freeze burns. Wash affected areas with plenty of warm water.
GENERAL CHILLER INFORMATION AND SAFETY Form 201.28-NM1.EN.PED/CE (0211) Refrigerant Data: Safety Data 134a Disposal Best to recover and recycle. If this is not possible, destruction is to be in an approved facility which is equipped to absorb and neutralise acids and other toxic processing products. Fire extinguishing data Non-flammable at atmospheric conditions. Containers Fire exposed containers should be kept cool with water sprays. Containers may burst if overheated.
Form 201.28-NM1.EN.PED/CE (0211) SECTION 2 - PRODUCT DESCRIPTION 2 LD15045 FIGURE 1 - YVAA AIR-COOLED SCREW LIQUID CHILLER WITH VARIABLE SPEED DRIVE YORK YVAA R134a chillers are designed for water or glycol cooling. All units are designed to be located outside on the roof of a building or at ground level. The units are completely assembled with all interconnecting refrigerant piping and internal wiring, ready for field installation.
PRODUCT DESCRIPTION Form 201.28-NM1.EN.
Form 201.28-NM1.EN.PED/CE (0211) SEMI-HERMETIC YORK TWIN-SCREW COMPRESSORS Compressors are direct drive, semi-hermetic, rotary twinscrew type, including: muffler, temperature actuated ‘off-cycle’ heater, IP55 terminal board and precision machined cast iron housing. Reliable suction gas cooled, high efficiency, accessible hermetic compressor motor, full suction gas flow through mesh screen filter, with inherent internal thermal overload protection and external current overload on all three phases.
PRODUCT DESCRIPTION Form 201.28-NM1.EN.PED/CE (0211) BUILDING AUTOMATION SYSTEM CAPABILITIES The E-Link Gateway provides an economical and versatile connection between York equipment and open/standard protocols. It efficiently manages the communication protocols currently used by York equipment, exposing the data in a consistent, organized, and defined fashion. The E-Link Gateway is available as a field-installed option on YVAA.
Form 201.28-NM1.EN.PED/CE (0211) Extreme Conditions - During extreme or unusual conditions (i.e. blocked condenser coils, ambient above scheduled maximum, etc.) the chiller control system will avoid shutdown by varying capacity. By monitoring motor current and suction and discharge pressures, the chiller can maintain maximum available cooling output without shutting down.
PRODUCT DESCRIPTION Form 201.28-NM1.EN.PED/CE (0211) EVAPORATOR OPTIONS: GENERAL OPTIONS: 38 mm INSULATION – Double thickness insulation provided. FLANGE KIT – Provides contractor with the couplings best suited to tie into the chilled water piping. All flanges are PN10. FLOW SWITCH ACCESSORY - Vapor proof SPDT, NEMA 3R switch, 10.
Form 201.28-NM1.EN.PED/CE (0211) SECTION 3 - HANDLING AND STORAGE DELIVERY AND STORAGE MOVING THE CHILLER To ensure consistent quality and maximum reliability, all units are tested and inspected before leaving the factory. Units are shipped completely assembled and containing refrigerant under pressure. Units are shipped without export crating unless crating has been specified on the Sales Order.
HANDLING AND STORAGE Form 201.28-NM1.EN.PED/CE (0211) LIFTING UNIT Use spreader bars to avoid lifting chains hitting the chiller. Various methods of spreader bar arrangements may be used; keeping in mind the intent is to keep the unit stable and to keep the chains from hitting the chiller and causing damage. Never lift the chiller using a forklift or by hooking to the top rails. Use only the lifting holes provided. Lifting instructions are placed on a label on the chiller and on the shipping bag.
Form 201.28-NM1.EN.PED/CE (0211) UNIT REMOVAL FROM SHIPPING CONTAINER 1. Place a clevis pin into the holes provided at the end of each base rail on the unit. Attach chains or nylon straps through the clevis pins and hook onto a suitable lift truck for pulling the unit out of the container. (chain shown) 3 2. Slowly place tension on the chains or straps until the unit begins to move and then slowly pull the unit from the container. Be sure to pull straight so the sides do not scrape the container. 3.
HANDLING AND STORAGE Form 201.28-NM1.EN.PED/CE (0211) LIFTING USING LUGS Units are provided with lifting holes in the base frame which accept the accessory lifting lug set (part number 026L00261-000). The lugs (RH and LH) should be inserted into the respective holes in the base frame and turned so that the spring loaded pin engages into the hole and the flanges on the lug lock behind the hole. The lugs should be attached to the cables/chains using shackles or safety hooks.
Form 201.28-NM1.EN.PED/CE (0211) SECTION 4 - INSTALLATION LOCATION REQUIREMENTS LOCATION CLEARANCES For optimum performance and trouble-free service, it is essential that the installation site meet the location and space requirements for the model being installed. Adequate clearances around the unit(s) are required for the unrestricted airflow for the air-cooled condenser coils and to prevent re-circulation of warm discharge air back onto the coils.
INSTALLATION Form 201.28-NM1.EN.PED/CE (0211) VIBRATION ISOLATORS Tube Removal Clearance Area Tube Removal Clearance Area 3 m (10') Minimum 1.8 m (6') Minimum Optional sets of vibration isolators can be supplied loose with each unit. Using the Isolator tables shipped with the unit in the information pack. Identify each mount and its correct location on the unit.
Form 201.28-NM1.EN.PED/CE (0211) There should be a straight run of piping of at least 5 pipe diameters on either side. The flow switch should be wired to Terminals 2 and 13 on the 1TB terminal block. A flow switch is required to prevent damage to the cooler caused by the unit operating without adequate liquid flow. Liquid system lines at risk of freezing, due to low ambient temperatures should be protected using insulation and heater tape and/or a suitable glycol solution.
INSTALLATION Form 201.28-NM1.EN.PED/CE (0211) PIPEWORK ARRANGEMENT The following is a suggested piping arrangement for single unit installations. For multiple unit installations, each unit should be piped as shown below.
Form 201.28-NM1.EN.PED/CE (0211) CONNECTION TYPES AND SIZES For connection sizes relevant to individual models refer to the Section 5 - Technical Data. COOLER CONNECTIONS Standard chilled liquid connections on all coolers are of the Victaulic Groove type.
INSTALLATION Form 201.28-NM1.EN.PED/CE (0211) REFRIGERANT RELIEF VALVE PIPING POWER WIRING The evaporator is protected against internal refrigerant overpressure by refrigerant relief valves. A pressure relief valve is mounted on each of the main refrigerant lines connecting the cooler to the compressors. All electrical wiring should be carried out in accordance with local regulations. Route properly sized cables to cable entries on the unit.
Form 201.28-NM1.EN.PED/CE (0211) CONTROL WIRING SYSTEM INPUTS All control wiring utilizing contact closures to the control panel terminal block is nominal 115VAC and must be run in shielded cable, with the shield grounded at the panel end only, and run in water tight conduit. Run shielded cable separately from mains cable to avoid electrical noise pick-up. Use the control panel cable entry to avoid the power cables.
INSTALLATION Form 201.28-NM1.EN.PED/CE (0211) POWER SUPPLY WIRING VSD CONTROL PANEL INVERTER INVERTER 1 2 STANDARD CONTROL TRANSFORMER UNIT CONTROLS EVAPORATOR HEATER FAN CONTACTORS LINE REACTOR PE CIRCUIT BREAKER SEE NOTE 1 NON FUSED DISCONNECT SWITCH OPTION AVAILABLE FIELD PROVIDED UNIT POWER SUPPLY FIG. 12 – POWER WIRING DIAGRAM NOTES: 1. ------- Dashed Line = Field Provided Wiring 2. The transformer is located in a separate box that is attached to the bottom of the control panel.
Form 201.28-NM1.EN.PED/CE (0211) CUSTOMER CONTROL WIRING CONTROL BOARD RELAY BOARD No. 1 SYS. No. 1 ALARM CONTACTS FLOW SWITCH (-SF) PRINT (PNT) 4 SYS. No. 1 RUN PERM SYS. No. 2 RUN PERM RELAY BOARD No. 2 EVAP. PUMP START SIGNAL SYS. No.
INSTALLATION Form 201.28-NM1.EN.PED/CE (0211) TABLE 2 - ELECTRICAL LUG DATA The data shown in the tables below is applicable to selected typical configurations. Other configurations are available through our configuration/selection software. Please contact your nearest Johnson Controls Sales Office for the chiller configuration that best matches your specific needs.
Form 201.28-NM1.EN.
TECHNICAL DATA Form 201.28-NM1.EN.PED/CE (0211) TABLE 3 - PHYSICAL DATA The data shown in the tables below is applicable to selected typical configurations. Other configurations are available through our configuration/selection software. Please contact your nearest Johnson Controls Sales Office for the chiller configuration that best matches your specific needs. UNIT FRAME CONDENSER CODE EVAPORATOR CODE GENERAL UNIT DATA Number of Independent Refrigerant Circuits Refrigerant Charge, R-134a, Ckt.-1/Ckt.
Form 201.28-NM1.EN.PED/CE (0211) The data shown in the tables below is applicable to selected typical configurations. Other configurations are available through our configuration/selection software. Please contact your nearest Johnson Controls Sales Office for the chiller configuration that best matches your specific needs. UNIT FRAME CONDENSER CODE EVAPORATOR CODE GENERAL UNIT DATA Number of Independent Refrigerant Circuits Refrigerant Charge, R-134a, Ckt.-1/Ckt.-2, kg Oil Charge, Ckt.-1/Ckt.
TECHNICAL DATA Form 201.28-NM1.EN.PED/CE (0211) DIMENSIONS The data shown in this table is applicable to selected typical configurations. Other configurations are available through our configuration/selection software. Please contact your nearest Johnson Controls Sales Office for the chiller configuration that best matches your specific needs. B B 2401 mm 94.5” C B A” PIPE WATER OUTLET 2241 mm 88.3” A” PIPE WATER INLET CONTROL ENTRY 114 mm WIDE X 330 mm HIGH 4.5” WIDE X 13.0” HIGH 102 mm 4.
Form 201.28-NM1.EN.PED/CE (0211) 1120 mm 44.1” 1120 mm 44.1” A VSD / CONTROL PANEL 511 mm 20.1” D 34 mm 1.3” 5 1524 mm 60.0” A 359 mm 14.1” 1204 mm 47.4” E Notes: 1. VSD / Control panel doors extend beyond the end of the unit base by 54 mm (2 1/8"). 2. Standard circuit breaker handle extends beyond the end of the unit base by 102 mm (4").
TECHNICAL DATA Form 201.28-NM1.EN.PED/CE (0211) DURULENE ISOLATOR INSTALLATION TOP BOLT ("B") D TOP WASHER D ("C") CL 1. Read the following instructions before beginning installation. 2. Isolators are shipped fully assembled and are to be positioned in accordance with the submittal drawings or as otherwise reccomended. 3. Set isolators on floor, housekeeping pad or subbase, ensuring that all isolators centrelines match the equipment mounting holes.
Form 201.28-NM1.EN.PED/CE (0211) DURULENE ISOLATOR SPECIFICATIONS DW CD MOLDED DURULENE HF 5 DIA. AD THRU TYP 2 PLACES BT AL W L Mount Type RD3 RD4 L 5.5 6.25 W 3.38 4.63 Dimensions (inches) HF AL AD 2.88 4.13 0.56 2.75 5.00 0.56 Weight Range (kgs)* Up to 375 375 to 766 766 to 1361 *Values de-rated by 25% JOHNSON CONTROLS Type RD3 RD4 RD4 Colour Charcoal Brick Red Charcoal BT 0.25 0.38 CD 1/2-13UNC x 1 1/2-13UNC x 1 DW 2.
TECHNICAL DATA Form 201.28-NM1.EN.PED/CE (0211) 25 MM ISOLATOR INSTALLATION UPPER HOUSING (D) EQUIPMENT BASE POSITIONING PIN (H) 0.25” min - 0.5” max LOWER HOUSING (C) NON-SKID ELASTOMERIC PAD (C) (B) 1. Read the following instructions before beginning installation. 2. Isolators are shipped fully assembled and are to be positioned in accordance with the submittal drawings or as otherwise reccomended. 3.
Form 201.28-NM1.EN.PED/CE (0211) 25 MM ISOLATOR SPECIFICATION 5/8" Ø1/2" H" 5 C" T" B" L" D" W" Mount Type CP C2P W 3 3 D 0.625 0.625 Weight Range (kgs)* Up to 197 197 to 347 347 to 463 463 to 525 525 to 688 Up to 521 521 to 694 694 to 926 926 to 1094 1094 to 1377 *Values de-rated by 15% Dimensions (inches) L B C 7.75 6.5 4.75 10.5 9.25 7.75 Type CP CP CP CP CP C2P C2P C2P C2P C2P Colour Black Dark green Grey White Grey/Red Dark Purple Dark Green Grey White Grey/Red T 0.5 0.5625 H 5.
TECHNICAL DATA Form 201.28-NM1.EN.PED/CE (0211) 50 MM (SEISMIC) ISOLATOR INSTALLATION AND ADJUSTMENT ("A") ("E") CL ("G") ("E") GROMMET ("A") CL 1/4 - 3/8 GAP WASHER EQUIPMENT ("F") ("E") ("F") ("C") ("B") 1. Read the following instructions before beginning installation. 2. Isolators are shipped fully assembled and are to be positioned in accordance with the submittal drawings or as otherwise reccomended. 3.
Form 201.28-NM1.EN.PED/CE (0211) 50 MM (SEISMIC) ISOLATOR SPECIFICATIONS 1-1/8" 5" 5/8" 2-3/4" 2-3/4" 12" 3/8" GAP 5/8-11UNC TYP. (4) Ø3/4" TYP.(4) 5 3/4" 7/8" 14" 12-1/4" 1/2" LIMIT STOP & NUT 8-3/8" OPER.
Form 201.28-NM1.EN.
Form 201.28-NM1.EN.PED/CE (0211) SECTION 6 - COMMISSIONING PREPARATION Commissioning of this unit should only be carried out by Johnson Controls Authorized personnel. Commissioning personnel should be thoroughly familiar with the information contained in this document before starting the unit. Commission the unit using the detailed checks outlined in the Equipment Pre Startup Checklist and Startup Checklist found at the end of this section.
COMMISSIONING Form 201.28-NM1.EN.PED/CE (0211) Avoid levels in either oil separator that are above the middle of the top sight glass. This may cause excessive oil carryover in the system. High oil concentration in the system may cause nuisance trips resulting from incorrect readings on the level sensor and temperature sensors. Temperature sensor errors may result in poor liquid control which will result in liquid overfeed and subsequently damage the compressor.
Form 201.28-NM1.EN.PED/CE (0211) Setpoint and Remote Offset Oil Pressure Set the required leaving chilled liquid temperature setpoint and Control Range under the SETPOINTS key. The chilled liquid temperature control settings need to be set according to the required operating conditions. When a compressor starts, press the relevant “System Pressures” key and verify that oil differential pressure (oil pressure-suction pressure) develops immediately.
Form 201.28-NM1.EN.
Form 201.28-NM1.EN.PED/CE (0211) SECTION 7 - OPERATION OPERATING CONTROLS DISPLAY The keypad also contains keys in the center section for data entry in the various program modes. These keys are listed below: • 0-9 Keys NUMERIC KEYPAD • PERIOD/DECIMAL • +/- PLUS/MINUS • ENTER • CANCEL • ▲ UP ARROW • ▼ DOWN ARROW • ◄ LEFT ARROW 7 • ► RIGHT ARROW The numeric keys allow keying numeric values into memory.
OPERATION Form 201.28-NM1.EN.PED/CE (0211) The ◄ (LEFT ARROW) key allows programming the default value when programming numeric values. For changing numeric values, the ► (RIGHT ARROW) key has no function. The ◄ ► (ARROW) keys also allow scrolling sideways between the same displays on different systems. For example, pressing the ► (RIGHT ARROW) key while viewing the system #1 suction pressure moves the display to system #2 suction pressure. Pressing the ◄ (LEFT ARROW) key moves the opposite direction.
Form 201.28-NM1.EN.PED/CE (0211) Compressor Heater Control Each compressor has its own heater. The purpose of the heater is to assure refrigerant does not condense in the compressor. There is no oil sump, but refrigerant could possibly condense in the rotors or the motor housing. The heater will be OFF whenever the respective compressor is running. As soon as the compressor shuts OFF, the heater will turn ON as long as all motor temperature sensors in the compressor read less than 70°C (158°F).
OPERATION Form 201.28-NM1.EN.PED/CE (0211) UNIT WARNING Invalid Number of Compressors Warning Unit Warning Operation The INVALID NUMBER OF COMPRESSORS SELECTED Warning will occur after the VSD has been initialized, if no ”Number of Compressors Select” jumpers are installed or if more than 1 jumper is installed. The following warning message will be displayed indefinitely. Unit warnings are caused when a condition is present requiring operator intervention to restart the unit.
Form 201.28-NM1.EN.PED/CE (0211) UNIT SAFETIES Low Ambient Temp Fault Unit Safety Operation If the ambient temperature falls below the programmable Low Ambient Temp Cutout the chiller will shut down with a controlled ramped shutdown. This fault will only occur if the Low Ambient Cutout is “ENABLED” under the OPTIONS key. Restart can occur, if demand allows, when temperature rises 1.1°C (2°F) above the cutout. This fault cannot cause a lockout.
OPERATION Form 201.28-NM1.EN.PED/CE (0211) On power-up, the Chiller Microprocessor Board will attempt to initialize communications with the VSD Logic Board. The control panel will request data from the VSD, which includes the number of compressors and the VSD software version. Once these data points have been received by the Chiller Control Board, and have been successfully initialized, the Chiller Control Board will not request them again.
Form 201.28-NM1.EN.PED/CE (0211) Some faults will be unit faults; other faults will be system (specific compressor or compressor pairs) faults, depending upon the number of compressors in the chiller. Most faults will shut down the unit/ system and allow restart once the fault clears and the 120 sec anti-recycle timer times out. These faults will allow up to 3 faults in 90 minutes before locking out the unit/system. Other faults lock out the unit/system after only a single fault.
OPERATION Form 201.28-NM1.EN.PED/CE (0211) Motor Current Overload (Software) Fault The Motor Current Overload will compare the highest of the 3 phases of motor current per compressor to the compressor’s 105 % FLA ADJUST (overload) potentiometer setting on the VSD Logic Board. If the current exceeds the setting continuously for 20 seconds, the compressor will trip. This safety will lock out a system on the 1st fault and shut down with a controlled ramped shutdown.
Form 201.28-NM1.EN.PED/CE (0211) High VSD Internal Ambient Temperature (Software) Fault The VSD Logic board contains a temperature sensor, which monitors the unit’s internal ambient temperature. If the VSD internal ambient temperature rises above the cutout of 70°C (158°F), the unit will fault and shut down with a controlled ramped shutdown. This safety will not cause a lockout. The fault will be a unit fault. Following is the Status display fault message.
OPERATION Form 201.28-NM1.EN.PED/CE (0211) VSD CT Plug (Hardware) Fault Jumpers are installed in each CT plug on the VSD Logic Board to feed back signals to indicate if the plugs are installed or not. If either plug is not installed, a low value is read on the digital input and the unit will immediate shutdown on a fault or will not run if off. This is an auto-restart safety that will restart after the 120 second anti-recylce timer times out and lock out on the 3rd fault in 90 minutes.
Form 201.28-NM1.EN.PED/CE (0211) High Discharge Pressure Cutout (HPCO) (Hardware) Fault The mechanical High Pressure Cutout protects the system from experiencing dangerously high discharge pressure. A system will fault and shut down immediately when the mechanical high pressure cutout contacts open. The fault will occur immediately and not wait 3 seconds, which is typical of most system faults.
OPERATION Form 201.28-NM1.EN.PED/CE (0211) Low Differential Oil Pressure Cutout Fault High Discharge Temperature Cutout Fault The Low Differential Oil Pressure Cutout protects the compressor from low oil flow and insufficient lubrication. A system will fault and shut down with a controlled ramped shutdown when it’s differential between oil and suction pressure falls below the cutout.
Form 201.28-NM1.EN.PED/CE (0211) Sensor Failure Cutout Fault High Motor Temperature Cutout Fault The Sensor Failure Cutout prevents the system from running when a critical sensor (transducer, level sensor, or motor winding temp sensor) is not functioning properly and reading out of range. This safety is checked at startup and will prevent the system from running if one of the sensors has failed. The High Motor Temperature Cutout prevents a compressor from running when its motor temperature is too high.
OPERATION Form 201.28-NM1.EN.PED/CE (0211) Eductor Clog Fault To sense a loss of oil return to the compressor, an eductor clog detection safety is utilized. The safety monitors the temperature of the line between the eductor and the suction line. The control algorithm looks at the eductor line temperature once a second. At start, a clog timer is set at 600 seconds. If the eductor line temperature is less than the saturated suction temperature plus 5.
Form 201.28-NM1.EN.PED/CE (0211) SECTION 8 - MICROPANEL STATUS KEY Examples of the typical Status messages are shown below: General Status Messages UNIT STATUS MANUAL OVERRIDE This message indicates the chiller is operating in MANUAL OVERRIDE mode. This message is a priority message and cannot be overridden by any other STATUS message. When in Manual Override, no other status message will ever be present. Status Key Operation The STATUS key displays the current chiller or system operational status.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) SYS X SYSTEM SWITCH IS OFF SYS X MOTOR CURRENT LIMITING This message indicates the system switch (software via keypad) is turned OFF. The system will not be allowed to run until the system switch is turned ON via the keypad. The motor current limiting message indicates the motor current load limit or motor current unloading is in effect.
Form 201.28-NM1.EN.PED/CE (0211) SYS X ISN SOUND LIMITING The ISN sound limiting message indicates the sound load limit is in effect based on the ISN transmitted sound limit setpoint. The sound limit must be activated for this function to operate. SYS X REMOTE SOUND LIMITING The next key press displays the error in temperature between the actual leaving chilled liquid temperature and the setpoint temperature. The display also shows the rate of change of the chilled liquid temperature.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) SYSTEM DATA KEYS 1 THROUGH 4 The next key press displays discharge temperature, discharge superheat and saturated discharge pressure at the compressor. SYS 1 DISCHARGE SUPERHEAT = XXX.X TEMP = XXX.X °F SAT TEMP = XXX.X °F The next key press displays the System 1 motor thermistor temperatures. SYS 1 MOTOR TEMPS T2 = XXX.X If any motor temp sensor is being ignored, (selectable under Unit Set-up Mode), that sensor’s value will be displayed as XXXXX.
Form 201.28-NM1.EN.PED/CE (0211) The next key press displays the system run time in days, hours, minutes and seconds.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) The next key press displays DC Bus voltage. VSD DATA KEY VSD DC BUS VOLTAGE = XXX VDC The next key press displays the Control Panel/VSD Internal Ambient Temperature and VSD Cooling Pump/ Fan Status. YYY will indicate ON or OFF. VSD INTERNAL AMBIENT TEMP = XXX.X °F COOLING SYSTEM STATUS = YYY The next key press displays the IGBT highest baseplate temperature.
Form 201.28-NM1.EN.PED/CE (0211) The following display will typically be displayed on a normal shutdown due to shutdown on lack of cooling demand.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) Status Fault Type Unit Data SYS X COMPRESSOR RUNNING SYS X FAULT: HIGH DIFF OIL PRESSURE Evaporator Leaving and Entering Chilled Liquid Temperatures This message indicates the type of system fault. This screen is skipped if a UNIT Fault caused the shutdown. UNIT CHILLED LIQUID LEAVING = XXX.X °F ENTERING = XXX.X °F Unit Fault Type This message indicates the leaving and entering chilled liquid temperatures at the time of the fault.
Form 201.28-NM1.EN.PED/CE (0211) Active Remote Control Status UNIT ACTIVE REMOTE CONTROL = XXXXX TYPE: RCC ISN CURR TEMP SOUND This message indicates whether the system was operating under Active Remote Control (RCC, ISN, LOAD, TEMP, or SOUND) or standard control (NONE) at the time of the fault. UNIT SOUND LIMIT ISN = XXX LOCAL = XXX % REMOTE = XXX % This message indicates that sound limiting was in effect, the amount, and whether it was local or remotely limited.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) System # 1 Temperatures Condenser Fans SYS 1 TEMPERATURES SYS 1 This message displays the measured system oil and eductor temperatures at the time of the fault. SYS 1 SYS 1 CONDENSER LIQUID TEMP = XXX.X °F SUBCOOLING= XXX.X SAT TEMP = XXX.X °F This message displays the number of condenser fans ON or the optional VSD fan control speed signal to the inverter and the % of full speed. EDUCTOR = XXX.X °F DISCHARGE = XXX.
Form 201.28-NM1.EN.PED/CE (0211) Chilled Liquid Setpoint Cooling Setpoints Display Units Mode SETPOINTS DEF LO LOCAL COOLING SETPOINT OPTIONS < > DISPLAY UNITS SI This message displays the programmed cooling setpoint at the time of the fault. OPTIONS < > DISPLAY UNITS IMPERIAL SETPOINTS DEF LOCAL CONTROL RANGE This message indicates whether SI (°C, barg) or Imperial units (°F, PSIG) was selected at the time of the fault. LO = HI XX.X °F HI = +/- X.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) Program Values Unit ID Number Suction Pressure Cutout PROGRAM DEF LO REMOTE UNIT ID NUMBER PROGRAM DEF LO SUCTION PRESSURE CUTOUT = HI XX.X PSIG This message indicates the suction pressure cutout programmed at the time of the fault. Low Ambient Cutout PROGRAM DEF LO LOW AMBIENT TEMP CUTOUT = HI XX.X °F This message displays the low ambient temp cutout programmed at the time of the fault.
Form 201.28-NM1.EN.PED/CE (0211) Pressing the SETPOINTS key or the ▼ (ARROW) key a third time will display the remote setpoint and cooling range. This display automatically updates about every 2 seconds. This remote setpoint message is show below: SETPOINTS KEY SETPOINTS REMOTE SETPOINT = XX.X °F REMOTE CONTROL RANGE = +/- X.X °F If there is no remote setpoint being utilized, the remote setpoint value will be displayed as XXXXXX and the remote Control Range will display XXX.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) The cutout is programmable between 1.65 and 2.48 barg (24.0 and 36.0 PSIG) in the Water Cooling mode and 0.34 and 2.48 barg (5.0 and 36.0 PSIG) in the Glycol Cooling mode. The default value for both modes will be 1.65 barg (24.0 PSIG). PROGRAM KEY Low Ambient Cutout PROGRAM DEF LO LOW AMBIENT TEMP CUTOUT = HI XX.
Form 201.28-NM1.EN.PED/CE (0211) Pulldown Current Limit Time Eductor Differential PROGRAM DEF LO HI PULLDOWN CURRENT LIMIT TIME = XXX MIN PROGRAM DEF EDUCTOR DIFFERENTIAL The pulldown current limit time is programmable. This allows the microprocessor to limit a system on pulldown limiting for a defined period of time for the purpose of peak time energy savings. The pulldown limit point is programmable from 0 to 255 with a default of 0 Min.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) TABLE 8 - PROGRAMMABLE OPERATING PARAMETERS PROGRAM VALUE MODE LOW LIMIT HIGH LIMIT DEFAULT Water Cooling 24.0 PSIG 36.0 PSIG 24.0 PSIG 1.65 barg 2.48 barg 1.65 barg Suction Pressure Cutout Glycol Cooling Low Ambient Temp. Cutout Water Cooling Leaving Chilled Liquid Temp. Cutout 5.0 PSIG 36.0 PSIG 24.0 PSIG 0.34 barg 2.48 barg 1.65 barg -2.0°F 50.0°F 25.0°F -18.9°C 10.0°C -3.9°C - - 36.0°F - - 2.2°C Glycol Cooling 11.0°F 36.
Form 201.28-NM1.EN.PED/CE (0211) OPTIONS KEY The default Chilled Liquid Mode will be WATER COOLING. Local / Remote Control Mode Selection Local or Remote Control Mode allows the user to select the chilled liquid temperature control mode. OPTIONS < > Options Key Operation The OPTIONS key provides the user with a display of unit configuration and the capability to modify the configuration. These options can only be viewed under the OPTIONS key. To view the current options settings, press the OPTIONS key.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) Lag selections of individual systems will appear as: OPTIONS < > LEAD / LAG CONTROL MODE MANUAL SYS 1 LEAD OPTIONS < > LEAD / LAG CONTROL MODE MANUAL SYS 2 LEAD Remote Temperature Reset Selection The default setting for Remote Current Reset is DISABLED. This display will only appear if the remote current limit option is enabled under the Unit Setup Mode.
Form 201.28-NM1.EN.PED/CE (0211) DATE/TIME AND SCHEDULE KEYS A “0” must be typed in to select dates for days of the 1st through the 9th. Pressing the ▼ (DOWN ARROW) key again scrolls to month: CLOCK THU MONTH < > Date/Time Key Operation When the DATE/TIME key is pressed, the chiller microprocessor will display the date and the time. This feature is useful and required for using the Daily Schedule.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) Pressing the ▼ (DOWN ARROW) key again scrolls to AM/PM: CLOCK THU AM/PM < > 01-JAN-2010 12:00:00 AM = AM AM/PM can be selected by pressing the ◄ or ► (ARROW) keys. After the meridian is selected, the (ENTER) key must be pressed to store the data. Pressing the ▼ (DOWN ARROW) key again scrolls to the time format selection: CLOCK THU 01-JAN-2010 TIME FORMAT < > 12:00:00 AM = 12 HOUR The time format may be displayed in either a 12 hour or 24 hour format.
Form 201.28-NM1.EN.PED/CE (0211) The Holiday schedule must be programmed weekly. If there is no holiday, the “*” key is also used to delete the “*”. The (ENTER) key is used to accept the holiday schedule for the entire week. To view the schedule without changing it, simply press the SCHEDULE key or the ▼ (DOWN ARROW) key until the desired day is displayed. The ▲ (UP ARROW) key will scroll backwards to the previous screen. The HOLIDAY SCHEDULE is a temporary schedule.
MICROPANEL Form 201.28-NM1.EN.PED/CE (0211) PRINT KEY History Data Printout History printouts, when selected, provide stored data relating to all specific system and chiller operating conditions at the time of the fault, regardless of whether a lockout occurred. History information is stored in battery-backed memory on the Chiller Control Board and is not affected by power failures or resetting of faults.
Form 201.28-NM1.EN.PED/CE (0211) SECTION 9 - MAINTENANCE GENERAL REQUIREMENTS Refrigerant Leaks The units have been designed to operate continuously, provided they are regularly maintained and operated within the limitations given in this manual. Each unit should be included in a routine schedule of daily maintenance checks by the operator/customer, backed up by regular service inspection and maintenance visits by a suitably qualified Service Engineer.
Form 201.28-NM1.EN.PED/CE (0211) MAINTENANCE REFRIGERANT REMOVAL, EVACUATION AND CHARGING Refrigerant Removal The YVAA utilizes a flooded evaporator. Extreme care must be taken when removing refrigerant to prevent damage to the evaporator and the chiller. Carefully review the following caution below before proceeding with the recommended process. Incorrect removal of refrigerant will result in catastrophic freeze damage to the evaporator and possible additional damage to other chiller components.
Form 201.28-NM1.EN.PED/CE (0211) To charge the system with refrigerant, follow the procedure below: Microchannel coils tend to accumulate more dirt on the surface, but less dirt inside the coils, which makes them easier to clean. Follow the three steps below for cleaning the coils: 1.
Form 201.28-NM1.EN.PED/CE (0211) MAINTENANCE MAINTENANCE REQUIREMENTS FOR YVAA CHILLERS PROCEDURE WEEKLY Check Oil Level in Oil Separator Sight Glass. X Check Liquid Line Sight Glass/ Moisture Indicator. X Check refrigerant level in the Evaporator Sight Glass while running full load for 10 to 15 minutes. X Record System Operating Temperatures & Pressures. X Check Condenser Coils for dirt / debris and clean as necessary. X QUARTERLY Check Programmable Operating Setpoints and Safety Cutouts.
Form 201.28-NM1.EN.PED/CE (0211) TABLE 10 - TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE ACTION High Voltage to the Chiller is missing. Supply to the Panel is missing. NO DISPLAY ON CONTROL PANEL. UNIT WILL NOT RUN. LINE FUSE BLOWS. CHILLER FAULT: LOW AMBIENT TEMPERATURE CHILLER FAULT: HIGH AMBIENT TEMPERATURE Check 1FU, 2FU, 4FU, 5FU 17FU, or 19FU. Check 2T or 10T Transformer. Line Fuse is blown. Check Fuses. Chiller Control Board is defective. Replace Chiller Control Board.
Form 201.28-NM1.EN.PED/CE (0211) MAINTENANCE TABLE 10 - TROUBLESHOOTING GUIDE (CONT'D) PROBLEM SYSTEM FAULT: HIGH DISCHARGE PRESSURE POSSIBLE CAUSE ACTION Coils dirty. Check and clean coils. Coils are damaged. Comb out fins. Check fan fuses. Fans NOT operating. Check fan rotation. Check fan motor/blade. SYSTEM FAULT: HIGH DISCHARGE TEMPERATURE System is overcharged. Remove charge and check subcooling. Discharge Temperature Sensor is defective. Check Sensor.
Form 201.28-NM1.EN.PED/CE (0211) TABLE 10 - TROUBLESHOOTING GUIDE (CONT'D) PROBLEM POSSIBLE CAUSE ACTION Ambient temperature is high, normal response from controller SYSTEM STATUS: MOTOR CURRENT LIMITING A high motor current anticipatory control has activated current limiting Remote or panel limiting is in effect, Normal response. Excess charge in system, adjust charge. Condenser coils dirty, Clean condenser. Fans NOT operating. Check fans. VSD FAULT: HIGH BASEPLATE TEMPERATURE Coolant level low.
Form 201.28-NM1.EN.
Form 201.28-NM1.EN.PED/CE (0211) SECTION 10 - DECOMMISSIONING, DISMANTLING AND DISPOSAL Never release refrigerant to the atmosphere when emptying the refrigerating circuits. Suitable retrieval equipment must be used. If reclaimed refrigerant cannot be reused. It must be returned to the manufacturer. Never discard used compressor oil, as it contains refrigerant in solution. Return used oil to the oil manufacturer.
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Copyright © by Johnson Controls 2011 Form 201.28-NM1 (0211) Supersedes: Nothing Tele. 800-861-1001 www.york.com Subject to change without notice.
