York YDAJ87HU7, Manual

Page 1: ...NM2 196 60 HZ MODELS YDAJ87KU6 YDAJ88MU6 YDAJ99MW6 50 HZ MODELS YDAJ87HU7 YDAJ97KU7 YDAJ98MU7 YDAJ99MU7 YDAJ99MW9 STYLE A 370 450 TONS 00022TG With EPROM s 031 01096 009 031 01300 002 Standard Brine M...

Page 2: ...power and control wiring They are designed primarily for central station air conditioning applications with normal instal lations being on roof tops or at ground level beside the building The chiller...

Page 3: ...m 2 or 4 Compressor Code 40 380 3 60 7 8 9 See PHYSICAL DATA 46 460 3 60 50 380 415 3 50 Cooler Code 58 575 3 60 H K M 64 346 3 50 Fan Code 6 7 8 9 Condenser Code U W Compressor Series Compressor Styl...

Page 4: ...YORK INTERNATIONAL 4 FIG 1 UNIT COMPONENTS Typical on each of the two modules 00023TG 00024TG...

Page 5: ...FORM 150 75 NM2 5 YORK INTERNATIONAL FIG 1 UNIT COMPONENTS Cont d LD01910 00025TG...

Page 6: ...TORPROTECTOR MP DISCHARGE STOP VALVE SUCTIONPRESSURE CONNECTION CAPACITY CONTROL SOLENOIDS RAINTIGHT TERMINAL BOX SUCTION STOP VALVE SIGHT GLASSES 2 OIL CHARGING VALVE OIL PRESSURE ACCESS CONNECTION C...

Page 7: ...ne temperatures down to 20 F by resetting standard control 2 Operation below 25 F requires the Optional Low Ambient kit 3 Operation above 115 F requires Optional High Ambient kit 4 The evaporator is p...

Page 8: ...Drive 16 16 16 16 16 HP KW Each 1140 RPM 60 HZ 3 2 4 3 2 4 3 2 4 3 2 4 950 RPM 50 HZ 3 2 2 3 2 2 3 2 2 3 2 2 3 2 2 CFM Total 60 HZ 248 000 248 000 248 000 50 HZ 238 400 238 400 238 400 238 400 238 400...

Page 9: ...are expected additional unit height must be provided to insure full air flow 2 Cooler liquid connection sizes inlet and outlet 8 victaulic for the YDAJ87KU6 YDAJ99MW9 3 Dimensions are in inches Drawin...

Page 10: ...BKR WIRE RANGE MCA1 ELEMENT DISC SW CKT BKR WIRE RANGE CODE FUSESIZE MIN SIZE4 HACR TYPE5 CU ONLY 6 FUSESIZE MIN SIZE4 HACR TYPE5 CU ONLY 6 MIN2 MAX3 MIN2 MAX3 J87HU7 50 237 250 400 400 400 1 2 4 250M...

Page 11: ...CM or 2 wires up to 250MCM Actual wire size and number of wires per phase must be determined based on ampacity and job requirements using N E C wire sizing information The above recommendations are ba...

Page 12: ...ins See Fig 4 INSPECTION Immediately upon receiving the unit it should be in spected for possible damage which may have occurred during transit If damage is evident it should be noted on the carrier s...

Page 13: ...Control Panels One of two installation procedures will be required depend ing upon when the chiller was manufactured Please read the note below before proceeding NOTES In the fall winter of 1995 a de...

Page 14: ...that the shield jumper and 180 ohm resistor are installed in the Slave Panel LTP board as shown in Fig 8 MIXED WATER TEMP SENSOR INSTALLATION A Mixed Leaving Water Temperature Sensor MUST be installed...

Page 15: ...SYS 1 2 PRESSURES and SYS 3 4 PRES SURES labels must be installed to indicate dual pur pose keys SYS 1 2 PRESSURES label should be applied over the SYS 1 PRESSURES label and SYS 3 4 PRESSURES should...

Page 16: ...TOR AL CU AL CU AL CU AL CU AL CU AL CU AL CU AL CU YDAJ87KU6 1954 2261 1995 2301 2013 2319 2287 2594 1956 2262 2141 2447 2159 2465 2236 2543 VMC CP 2 31 CP 2 32 CP 2 31 CP 2 32 CP 2 31 CP 2 32 CP 2 3...

Page 17: ...ission of water pump vibration This is optional and the necessary components must be obtained in the field Drain connections should be provided at all low points to permite complete drainage of liquid...

Page 18: ...ust the flow switch paddle to the size of pipe in which it is to be installed See manufactuer s instructions furnished with switch The switches are to be wired to terminals in the respective control p...

Page 19: ...e made as shown on the WIRING DIAGRAM If the Dual Point Wiring Option Fig 14 is installed tow power feeds are required A single feed to the Master Module and a single feed to the Slave Module This dif...

Page 20: ...t be run in the same conduit with any line voltage wiring 4 To cycle unit on and off automatically with contact shown install a cycling device in series with the flow switch FLSW See Note 3 for contac...

Page 21: ...pump starters wired through motor contactor auxiliary contacts must be suppressed with YORK P N 031 00808 000 sup pressor across the relay contact coil which acti vates the contacts Any contacts conne...

Page 22: ...YORK INTERNATIONAL 22 MASTER MODULE WIRING DIAGRAM CONNECTION DIAGRAM MASTER MODULE CONDENSER FANS COOLER COMPRESSORS SYSTEM NO 1 AND NO 2 FIG 16 MASTER MODULE SYSTEM WIRING LD01931 LD01930 LD01929...

Page 23: ...FORM 150 75 NM2 23 YORK INTERNATIONAL MASTER MODULE WIRING DIAGRAM FIG 16 MASTER MODULE SYSTEM WIRING Cont d LD01932...

Page 24: ...YORK INTERNATIONAL 24 MASTER MODULE WIRING DIAGRAM LD01933 FIG 17 MASTER MODULE CONNECTION DIAGRAM...

Page 25: ...FORM 150 75 NM2 25 YORK INTERNATIONAL MASTER MODULE WIRING DIAGRAM LD01934 FIG 17 MASTER MODULE CONNECTION DIAGRAM Cont d...

Page 26: ...suitable for switching 24VDC Gold contacts recommended Wiring shall not be run in the same conduit with any line voltage wiring 4 To cycle unit on and off automatically with contact shown install a c...

Page 27: ...p starters wired through motor contactor auxiliary contacts must be suppressed with YORK P N 031 00808 000 sup pressor across the relay contactor coil which acti vates the contacts Any contacts connec...

Page 28: ...YORK INTERNATIONAL 28 SLAVE MODULE WIRING DIAGRAM CONNECTION DIAGRAM SLAVE MODULE CONDENSER FANS COOLER COMPRESSORS SYSTEM NO 1 AND NO 2 FIG 19 SLAVE MODULE SYSTEM WIRING LD01937 LD01938 LD01939...

Page 29: ...FORM 150 75 NM2 29 YORK INTERNATIONAL SLAVE MODULE WIRING DIAGRAM LD01940 FIG 19 SLAVE MODULE SYSTEM WIRING Cont d...

Page 30: ...YORK INTERNATIONAL 30 SLAVE MODULE WIRING DIAGRAM FIG 20 SLAVE MODULE CONNECTION DIAGRAM LD01941...

Page 31: ...FORM 150 75 NM2 31 YORK INTERNATIONAL SLAVE MODULE WIRING DIAGRAM FIG 20 SLAVE MODULE CONNECTION DIAGRAM Cont d LD01942...

Page 32: ...loading unloading decisions are performed by the Microprocessor to main tain leaving water temperature These decisions are a function of temperature deviation from setpoint and rate of change of temp...

Page 33: ...h the Master and Slave Panel CURRENT TRANSFORMER C T A C T on the 3f power wiring of each motor sends AC signals proportional to motor current to Power Supply Board which recitifies and filters the si...

Page 34: ...OARD MICROPROCESSOR BOARD UNITON OFF SWITCH 2TTRANSFORMER RELAY OUTPUT BOARD 1 TB3 CONNECTIONS FOR FLOW SWITCH AUXILIARY CYCLING LEAD LAG SELECTOR AND EMS BAS CONTROLS LOCATION OF OPTIONAL RELAY OUTPU...

Page 35: ...nding message will be displayed for the Slave Module or the other system NOTE The AMBIENT TEMP OPTIONS and WATER TEMPERATURE keys will not display a sec ond set of data Display Messages may show chara...

Page 36: ...yed The counters for an individual system count to a total of 99 999 hours before rollover Accumulated starts on each compressor are also displayed A total of 99 999 starts can be logged on a system b...

Page 37: ...itions in the order they appear Two possible messages may appear for each of the eight messages depending on the Dip Switch position A detailed explanation of the meaning of each mes sage and a guide...

Page 38: ...EPROM LOCATION 26001A DIMPLEATTOP MASTER EPROM SLAVE EPROM RTC S1 031 01096 009 031 01300 002 VER 0 0 TOPVIEW TOP SIDE LD01943 LD01944 SIDEVIEW OPEN POSITION LEFT SIDE OF SWITCH IS PUSHED DOWN CLOSED...

Page 39: ...ill be from leaving water temperature This MUST be selected SWITCH 5 OPEN Display messages will show units of measure in En glish units F PSI etc CLOSED Display messages will show units of measure in...

Page 40: ...is mode maximum chiller efficiency will be achieved If the Low Ambient option is installed the fan control will automatically change to pressure control at temperatures below 25 F See page 76 for fan...

Page 41: ...ages will both be displayed and may be different X s in the sample displays indicate numerical values will appear in actual displays This message informs the operator that the UNIT switch on the Contr...

Page 42: ...high pres sure cut out will shut the system down causing total loss of cooling When this message appears discharge pres sure has exceeded the user programmable threshold and the micro is unloading the...

Page 43: ...L E R F A U L T L O W A M B I E N T T E M P S Y S 1 H I G H D S C H C H I L L E R F A U L T L O W W A T E R T E M P S Y S 2 H I G H D S C H C H I L L E R F A U L T H I G H A M B I E N T T E M P S Y S...

Page 44: ...ta after any one of the following keys is pressed PROGRAM SET SCHEDULE HOLIDAY OPER DATA HISTORY Cancel Key The CANCEL key allows the user to change errors in the data being programmed into memory Whe...

Page 45: ...HARGE CUT OUT The DISCHARGE CUT OUT is a microprocessor back up for the mechanical high pressure cut out located in each refrigerant circuit Typically chillers with air cooled condensers should have t...

Page 46: ...the high ambient cut out point If the ambient rises above this point the chiller will shut down Restart can occur when temperature drops below the cut out This only applies to outdoor air cooled chil...

Page 47: ...eating is a result of inrush current when the motor is started This heat must be dissipated be fore another start takes place or motor damage may result The anti recycle timer assures the motor has su...

Page 48: ...e RATE SENSITIVITY establishes the rate of change of return or leaving water temperature where the micro will over ride the normal 30 150 seconds per stage load ing rate which is based on error betwee...

Page 49: ...will be dis played when the SET TIME key is pressed To program the day time and date first press the AD VANCE DAY key until the appropriate day of the week is displayed The day will advance each time...

Page 50: ...view times programmed use the ADVANCE DAY KEY not the ENTER KEY This will assure that after viewing MONDAY that the ENTER KEY is not pressed changing times programmed for the rest of the week If the...

Page 51: ...ay will tell the user whether LEAVING WATER CONTROL is programmed The chiller is designed to provide a stable desired mixed leaving water temperature as required by the user and is suitable for all ty...

Page 52: ...E M P C O N T R O L If this message is incorrect see the CHILLED LIQUID CONTROL Section Page 51 for instructions to repro gram the Microprocessor Dip Switch S1 Switch 4 The display will then scroll t...

Page 53: ...ion Typically 2 F above the Low Limit Water Temperature is appro priate The micro will accept a value 1 5 F above the LWT for this value 2 F above the LWT is the default value Key in the upper limit o...

Page 54: ...rise where the chiller does not load and pull temperature down select 0 1 F To program the RATE CONTROL TEMP first press the PROGRAM key Repetitively press the ENTER key un til the display below appea...

Page 55: ...ations 5 0 F min is suggested If unsure of a RATE SENSITIVITY selection use 5 0 F min To program the RATE SENSITIVITY first press the PROGRAM key Repetitively press the ENTER key un til the display be...

Page 56: ...LAG COMP 3 STEPS_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 19 SLAVE LEAD COMP 3 STEPS LAG COMP 2 STEPS_ _ _ SLAVE LEAD COMP 3 STEPS LAG COMP 2 STEPS 18 SLAVE LEAD COMP 2...

Page 57: ...micro begins monitoring motor current after 3 sec onds of operation If motor current is exceeding 120 FLA at the 3 second point the compressor will shut down After 4 seconds of operation motor current...

Page 58: ...tor Three internal temperature sensors are built into the motor stator These sensors are wired into the motor protector module located inside the Motor terminal box As the motor windings heat and cool...

Page 59: ...ture Safety The High Ambient Temperature Safety assures that the chiller does not run in ambients above 130 F where po tential malfunction of system mechanical and electrical components may result Whe...

Page 60: ...e of tripping the relief valve due to a very high rate of rise in pressure resulting from a controls problem which would cause condenser water flow to be interrupted In this case the pressure rise is...

Page 61: ...ard In some cases depending upon tim ing a delay will be noted before the start of the print out These delays should be no cause for concern REMOTE PRINT OUT Oper Data The OPER DATA key allows the ope...

Page 62: ...ATIONAL CORPORATION RECIPROCATING WATER CHILLERS SYSTEMSTATUS 5 24AM 1 02 95 SYS1 COMPRESSORRUNNING SYS2 COMPRESSORRUNNING SYS3 COMPRESSORRUNNING SYS4 ANTI RECYCYLE TIMER 119 SEC RETURN WATER TEMP 1 8...

Page 63: ...117 PSID LIQUID LINE SOLENOID ON RUN PERMISSIVE ON STAGES OF LOADING 4 FORWARD FANS 2 REVERSE FANS OFF HOT GAS BYPASS VALVE OFF SYSTEM 2 DATA COMPRESSOR STATUS ON MOTOR AMPS 65 FLA SUCTION PRESSURE 6...

Page 64: ...d to be meaningful This indication of loading may be different from the actualy loading due to loading unloading timers that are not satisfied and preventing any action or actual mixed leaving water t...

Page 65: ...lenoid is ON or OFF The micro will activate the Hot Gas signal regardless of whether or not this option is installed OFF SYS 2 Liquid Line Solenoid De energized Closed ON SYS 2 Liquid Line Solenoid En...

Page 66: ...for all available mes sages This message informs the operator of the time and date of the fault This message informs the operator of the nature of the fault which occurred if it is on the MASTER Modul...

Page 67: ...ime of the fault This message indicates the Leaving Water Tempera ture from the MASTER Module at the time of the fault This message indicates the Leaving Water Tempera ture from the SLAVE Module at th...

Page 68: ...ressure Read out is installed This display shows the oil pressure of SYS 1 at the time of the fault This display informs the operator whether SYS 1 liquid line solenoid was energized ON or de energize...

Page 69: ...at the time of the fault This display indicates the number of fans on SYS 2 which were running forward at the time of the fault This message indicates the number of fans on SYS 2 which were running in...

Page 70: ...ge indicates whether Compressor 4 was ON or OFF at the time of the fault This message indicates SYS 4 motor current at the time of the fault This display shows the suction pressure of SYS 4 at the tim...

Page 71: ...TUS display indicating the condition will be displayed indicating that the system does not have a Run Permis sive signal A sample of this message follows NOTE This message will not appear if Anti recy...

Page 72: ...ssignment is made whenever both com pressors shut down The respective micro will assign the lead to one of the two compressors it directly con trols with the shortest anti recycle time This will tend...

Page 73: ...ctive and the micro cannot keep track of time although all other functions will op erate normally This could result in the chiller not start ing due to the time frozen on the clock falling outside the...

Page 74: ...can be converted from PSI to kPa using the formula PSI x 6 89 kPa To obtain panel displays in metric Switch 5 of Dip Switch S1 on BOTH Microprocessor Boards must be placed in the OPEN position Page 39...

Page 75: ...2 F 56 F This new setpoint can be viewed on the display by pressing the REMOTE RESET TEMP RANGE key To maintain a given offset the micro must be refreshed every 30 seconds 30 minutes with a contact cl...

Page 76: ...reset 2 Terminal 13 17 contact should always be opened before or simultaneous with those on 13 16 when loading is de sired Otherwise the microprocessor may mistake the closed contacts on 13 17 as a si...

Page 77: ...andard unloading scheme The loading solenoid on these cylinders is connected to additional electronics for optional extra steps of unloading Cylinders 3 4 have no loading solenoids and are truly perma...

Page 78: ...l wires metal chips etc 11 Visually inspect wiring power control Must meet NEC and all local codes See Figs 22 and 24 12 Check for proper size fuses in main and control power circuits 13 Verify that f...

Page 79: ...ill start and a flow of liquid should be noted in the liquid indicator After several min utes of operation the bubbles will disappear and there will be a solid column of liquid when the unit is operat...

Page 80: ...nning fully loaded Correct superheat setting is 12 15 F The superheat is the difference between the actual tem perature of the returned refrigerant gas entering the compressor and the temperature corr...

Page 81: ...ead compressor will shut down 6 After 30 seconds of run time the oil pressure of the lead compressor must be a minimum of 20 PSID and the suction pressure must be a minimum of 50 of cut out 7 After 60...

Page 82: ...oil refer to item 3 under the ANNUAL MAINTENANCE section 3 Check the refrigerant circuit for leaks 4 Operating Pressures and Temperatures Check to see that operating pressures and temperatures are wi...

Page 83: ...ate for long periods of time J Be sure both discharge and suction stop valves are open before operating the unit 4 Suction and Discharge Valves The condition of the suction and discharge valves should...

Page 84: ...inductive devices contactor relay coil con nected to these contacts must be suppressed with YORK P N 031 00808 supplied by others Otherwise nuisance faults may occur 0 F LOW AMBIENT OPTION The standa...

Page 85: ...e sys tem falls below 120 PSIG the ambient temperature exceeds 35 F or discharge pressure of the system rises above 340 PSIG NOTE The corresponding compressor must be on for a minimum of 4 sec before...

Page 86: ...ressure reaches 360 PSIG and com pressor run time has exceeded 30 seconds fans 1 3 SYS 1 5M 7M fans 5 7 SYS 2 11M 13M fans 9 11 SYS 3 5M 7M or fans 13 15 SYS 4 11M 13M will energize turning the fans i...

Page 87: ...Gas Operation The hot gas solenoid is energized if the compressor is on its minimum stage of loading and the return water temperature falls below the following point ULCR CR CR 20 Where ULCR Upper Lim...

Page 88: ...on valve To convert to discharge pressure cycling the micro panel must be programmed for DISCHARGE PRESSURE FAN CONTROL See Page 40 Fan cycling will oper ate as indicated in Table 3 The kit consists o...

Page 89: ...ed at most stationery stores Shown in Fig 40 and 33 is the WEIGH TRONIX printer and a typical sample print out 23889A YORK INTERNATIONAL CORPORATION RECIPROCATING WATER CHILLERS SYSTEMSTATUS 5 24AM 1...

Page 90: ...between the printer and the microprocessor board is 25 feet Twisted pair shielded cable is required 3 The printer must be supplied a 115 VAC source 4 The printer may be left connected to the micro pa...

Page 91: ...ap shot of sys tem operating conditions at the instant that the fault oc curred Additionally the Status indication that is noted in the print out will note the specific fault that occurred Delays may...

Page 92: ...l holes 3 Install grilles using the proper hardware and supports Refer to Fig 44 and the Parts List for placement of the grilles and the proper hardware required 4 Notch grilles to suit water connecti...

Page 93: ...lles pan els and the proper hardware required Discard ex isting grilles to attach the louvered panels where necessary FIG 45 LOUVER AND GRILLE INSTALLATION FOR EACH KIT 4 Notch grilles to suit water c...

Page 94: ...exposed metal parts to prevent rust FIG 47 LOUVER INSTALLATION FOR EACH KIT PART ITEM QTY DESCRIPTION 075 02563 001 1 6 PANEL LOUVERS SIDE BTM 075 02563 002 2 8 PANEL LOUVERS SIDE TOP 075 02563 016 3...

Page 95: ...l be offset linearly according to the voltage 0 10 VDC ap plied The 0 10 VDC signal should be connected to the and terminals on the TB3 Terminal Block at the right of the microprocessor board Be sure...

Page 96: ...e supply 2 Defective contactor contacts and contactor 2 Check contacts and contactor 3 Faulty high voltage wiring 3 Check wiring 4 High motor current stored in memory 4 Loose calibration resistors in...

Page 97: ...em exists LOW AMBIENT TEMP 2 Temperature sensed incorrectly by thermistor 2 Verify actual ambient temperature immediately Cuts out on low ambient at probe with thermometer temperature 3 Check low ambi...

Page 98: ...pressure programmed unload point or 1 Excessive load Check OPERATING LIMITATIONS Solenoid valve de energizes operating limitations have been exceeded Check programmed unloading point to load compress...

Page 99: ...FORM 150 75 NM2 99 YORK INTERNATIONAL...

Page 100: ...4 103 217 4 40 0 104 219 2 40 6 105 221 0 41 1 106 222 8 41 7 107 224 6 42 2 108 226 4 42 8 109 228 2 43 3 110 230 0 43 9 111 231 8 44 4 112 233 6 45 0 113 235 4 45 6 114 237 2 46 1 115 239 0 46 7 116...