York ZR300 Dokumentacja

1MILLENNIUM® AIR-COOLEDSCROLL CHILLERSYCA50 - YCA11550 - 115 TON175 - 400 kW50Hz / 60HzINSTALLATION, OPERATION, MAINT.

10INSTALLATIONEVAPORATOR PUMP START CONTACTSTerminal block CTB2 - (refer wiring diagram) arenormally open contacts that can be used to switchfield sup

11Power Panel1L11L21L3CTB22L13 14CTB1MicropanelFlow SwitchField Unit Power SupplyField 115-1-50/60 MicropanelPower Supply if controltransformer not su

12VOLTAGE LIMITATIONSWATER FLOW (GPM) AGAINST PRESSURE DROP (FT)The following volatge limitations are absolute andoperation beyond these limitations m

13PHYSICAL DATAYCA Physical Data (R22, 50Hz)Note:1. Nominal info based on LWCT of 44°F and 95°F ambient temperature, Refrigerant R22, Power Supply 380

14PHYSICAL DATAYCA Physical Data (R22, 60Hz)Note:1. Nominal info based on LWCT of 44°F and 95°F ambient temperature, Refrigerant R22, Power Supply 460

15PHYSICAL DATAYCA Physical Data (R407c, 50Hz)Note:1. Nominal info based on LWCT of 44°F and 95°F ambient temperature, Refrigerant R407c, Power Supply

16YCA Physical Data (R407c, 60Hz)Note:1. Nominal info based on LWCT of 44°F and 95°F ambient temperature, Refrigerant R407c, Power Supply 460V/3Ph/60H

17INSTALLATIONPRE-START-UP CHECKLISTJOB NAME: _____________________________SALES ORDER #: ________________________LOCATION: __________________________

18INSTALLATIONPlace the Unit Switch in the control panel to the ONposition. As each compressor cycles on, ensurethat the discharge pressure rises and

19CHECKING SUPERHEAT ANDSUBCOOLINGThe subcooling and superheat should always bechecked when charging the system with refrigerant.When the refrigerant

2IMPORTANT!READ BEFORE PROCEEDING!GENERAL SAFETY GUIDELINESThis equipment is a relatively complicated apparatus. During installation,operation,mainten

20UNIT OPERATING SEQUENCEThe operating sequence described below relates tooperation on a hot water start after power has beenapplied, such as start-up

21INTRODUCTIONThe YORK MicroComputer Control Center is amicroprocessor based control system designed toprovide the entire control for the liquid chill

22PWM remote temperature reset, and demand limitcircuitry which is available to be used with fieldsupplied contacts.The Microprocessor Board energizes

23The following messages are displayed when the“Status” key is pressed. Following each displayedmessage is an explanation pertaining to that particula

24UNIT CONTROLSSys Switch Off tells that the system switch underOPTIONS is turned off. The system will not beallowed to run until the switch is turned

25UNIT CONTROLSWhen this message appears, suction pressurelimiting is in effect. Suction Pressure Limiting is onlyavailable on units that have the suc

26UNIT CONTROLSSYS 1 HIGH DSCH PRESSYS 2 HIGH DSCH PRESThe Discharge Pressure Cutout is a software cutoutin the microprocessor and is backed-up by a m

27UNIT CONTROLSThe Low Ambient Temp Cutout is a safety shutdowndesigned to protect the chiller from operating in a lowambient condition. If the outdoo

28UNIT CONTROLSTABLE 3 - STATUS KEY MESSAGESSTATUS KEY MESSAGESGeneral MessagesUnit Switch OffShutdownSystem SafetiesRemote ControlledShutdownSystem X

29UNIT CONTROLSThe Display / Print keys allow the user to retrievesystem and unit information that is useful for monitoringchiller operation, diagnosi

3SAFETY SYMBOLSThe following symbols are used in this document to alert the reader to areas ofpotential hazard:DANGERDANGER indicates an imminently ha

30SYS X STARTS 1 = XXXXX 2 = XXXXX,3 = XXXXXUNIT CONTROLSThese displays show suction and discharge pressuresfor systems 1 & 2. The discharge p

31UNIT CONTROLSThis display indicates the status of the evaporatorpump contacts and the evaporator heater.The evaporator pump dry contacts are energiz

32UNIT CONTROLSOPER DATA QUICK REFERENCE LISTThe following table is a quick reference list for information available under the OPER DATA key.TABLE 4 -

33UNIT CONTROLSPRINT KeyThe PRINT key allows the operator to obtain a printoutof real-time system operating data or a printout ofsystem data at the “i

34UNIT CONTROLSHISTORY PRINT-OUTPressing the PRINT key and then the HISTORY keyallows the operator to obtain a printout of informationrelating to the

35UNIT CONTROLSThe UP and DOWN arrows are used to scroll forwardsand backwards through the history buffer to displaythe shutdown conditions. Following

36UNIT CONTROLSThe Entry Keys allows the user to view, changeprogrammed values. The ENTRY keys consist of anUP ARROW key, DOWN ARROW key, and anENTER

37UNIT CONTROLSProgramming of the cooling setpoints, daily schedule,and safeties is accomplished by using the keyslocated under the SETPOINTS section.

38UNIT CONTROLSThis message indicates that the cooling setpoint isunder REMOTE control. When under remote control,the cooling setpoint will be determi

39Pressing the COOLING SETPOINTS key a secondtime will display the remote setpoint and cooling range.This display automatically updates about every 2s

4TABLE OF CONTENTS AND TABLESRefrigerant Flow Diagram ...

40UNIT CONTROLSSCHEDULE / ADVANCED DAY KeyThe SCHEDULE is a seven day daily schedule thatallows one start/stop time per day. The schedule canbe progra

41UNIT CONTROLSNOTEThere are some exceptions when thesuction pressure is permitted totemporarily drop below the cutout point.Details are explained und

42UNIT CONTROLSAnother anti-recycle timer is started each time thesystems number one compressor cycles off. Thisanti-recycle time is fixed at 120 seco

43UNIT CONTROLSTable 7 provides a quick reference of the setpoints list for the Setpoint Keys.TABLE 7 - SETPOINTS QUICK REFERENCE LISTSchedule / Advan

44UNIT CONTROLS“UNIT” KEYSOPTIONSCLOCKUnitOPTIONS KeyThere are eleven programmable options under theOPTIONS key. The OPTIONS key is used to scrollthro

45UNIT CONTROLSorThe chilled liquid is glycol. The Cooling Setpoint canbe programmed from 10°F to 70°F (-12.2°C to21.1°C).Option 5 - Ambient Control T

46UNIT CONTROLSOption 8 - Units TypeDisplay messages will show units of measure inImperial units (°F or PSI).orDisplay messages will show units of mea

47UNIT CONTROLSTable 8 provides a quick reference list for the Unit key setpoints.TABLE 8 - UNIT KEYS PROGRAMMING QUICK REFERENCE LISTQuick Reference

48UNIT OPERATIONCAPACITY CONTROLTo initiate the start sequence of the chiller, all runpermissive inputs must be satisfied (flow/remote start/stop swit

49UNIT CONTROLSLWT42.5°F 43.5°F 44.0°F 46.0°F 48.0°(5.8°C) (6.4°C) (6.7°C) (7.8°C) (8.9°)Low Limit Setpoint High limitLeaving Water Temp. Control - Co

5TABLES AND FIGURESTABLES1 Voltages...

50UNIT CONTROLSTABLE 11 - LEAVING CHILLED LIQUID CONTROL FOR 3 COMPRESSORS (SINGLE SYSTEM)*STEP COMP 1 COMP 2 COMP 30 OFF OFF OFF1 ON+HG OFF OFF SEE N

51UNIT CONTROLSRETURN CHILLED LIQUID CONTROL(DUAL SYSTEM 4 AND 6 COMP UNITSONLY)Return chilled liquid control is based on staging thecompressors to ma

52UNIT CONTROLSCOMPRESSOR STAGING FOR RETURN WATER CONTROL - 6 COMPRESSORSCOOLING SETPOINT = 45° F (7.2° C) RANGE = 10° F (5.6° C)TABLE 13 - COMPRESSO

53UNIT CONTROLSEVAPORATIOR PUMP CONTROLThe evaporator pump dry contacts (CTB2 - terminals23 - 24) are energized when any of the followingconditions ar

54UNIT CONTROLSFAN STAGE ON OFF1 OAT > 25°F (-3.9°C) OAT < 20°F(-6.7°C)1 FAN REV OR ANDDP > ctrl_press DP > ctrl_press - diff_press2 OAT &

55UNIT CONTROLSPUMPDOWN (LLSV) CONTROLEach system has a Pumpdown feature upon shut-off.On a non-safety, non-unit switch shutdown, allcompressors but o

56UNIT CONTROLSEMS-PWM REMOTETEMPERATURE RESETEMS-PWM Remote Temperature Reset is a value thatresets the Chilled Liquid Setpoint based on a PWMinput (

57UNIT CONTROLSIf a 4 - 20 ma signal is available, it is applied toterminals A+ and A- and jumpers are applied JU5and JU3 on the reset board. The ma s

58SERVICE AND TROUBLESHOOTINGCLEARING HISTORY BUFFERSThe history buffers may be cleared by pressing theHISTORY key and then repeatedly pressing the UP

59SERVICE AND TROUBLESHOOTINGSERVICE MODE - INPUTSAfter entering the service Mode, all digital and analoginputs to the microboard can be viewed by pre

6REFRIGERANT FLOW DIAGRAMFIG. 1 - REFRIGERANT FLOW DIAGRAM

60SERVICE AND TROUBLESHOOTINGTABLE 21 - MICROBOARD BINARY INPUTS*J9-1 30VDC UNREGULATED SUPPLYJ9-2 UNIT ON/OFF SWITCHJ9-3 PWM TEMP RESET OR LOAD LIMIT

61SERVICE AND TROUBLESHOOTINGFIG. 4 - MICROBOARD LAYOUTTB5TB4TB3TB1 TB2J4J8J6J5J7

62CHECKING INPUTS AND OUTPUTSBINARY INPUTSRefer to the unit wiring diagram. All binary inputs areconnected to J9 of the microboard. The term “binary”r

63Entering Chilled Liquid SensorJ6-6 = +5 VDC regulated supply to sensor.J6-9 = VDC input signal to the microboard. See Table25 for voltage readings t

64ANALOG INPUTS - PRESSURERefer to the unit wiring diagram. Pressure inputs areconected to the microboard on plugs J4 and J7. Theseanalog inputs repre

65SERVICE AND TROUBLESHOOTINGThe suction transducers have a range from 0 to 200psig (13.79 BARG). The output will be linear from.5 vdc to 4.5 vdc over

66KEYPADThe operator keypad is connected to the microboardby a ribbon cable, which is connected to J2 on themicroboard.The integrity of a specific “bu

67OPTIONAL PRINTER INSTALLATIONThe micro panel is capable of supplying a printout ofchiller conditions or fault shutdown information at anygiven time.

68SERVICE AND TROUBLESHOOTINGPROBLEM CAUSE SOLUTIONNO DISPLAY ON PANEL. 1. No 115VAC to 1T. 1 a. Check wiring and fuseUNIT WILL NOT OPERATE. 3FU.b. Ch

69SERVICE AND TROUBLESHOOTINGPROBLEM CAUSE SOLUTION“LOW SUCTION PRESSURE” 4. TXV defective. 4. Replace TXV.FAULT (CONT’D)5. Reduced flow of chilled 5.

7INSTALLATIONINSTALLATION CHECK LISTThe following items, 1 thru 5, must be checked beforeplacing the units in operation.1. Inspect the unit for shippi

70PROBLEM CAUSE SOLUTION“MP/HPCO” FAULT 1. Compressor internal motor 1. Verify refrigerant charge isprotector (MP) open. not low. Verify superheatsett

71It is the responsibility of the equipment owner toprovide maintenance on the system.IMPORTANTIf system failure occurs due to improper maintenancedur

72ISN CONTROLRECEIVED DATA (CONTROL DATA)The middle Market received 8 data values from theISN. The first 4 are analog values and the last 4 aredigital

73ISN PAGE TYPE DATAP61 CODED SYS 1 COND FANS RUNNINGP62 CODED SYS 2 COMP RUNNINGP63 CODED SYS 2 COND FANS RUNNINGP64 CODED -UNIT CONTROL MODE0=LEAVIN

74SERVICE AND TROUBLESHOOTINGTABLE 31 - ISN OPERATIONAL AND FAULT CODESP56/58 OPERATIONAL CODE P57/59 FAULT CODE0 NO ABNORMAL CONDITION 0 NO FAULT1 UN

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76ELECTRICAL DATACircuit Wiring Diagram YCA 50 (DOL 50Hz)

77ELECTRICAL DATA

78ELECTRICAL DATACircuit Wiring Diagram YCA 50 (SOFT STARTER 50Hz)

79ELECTRICAL DATA

8INSTALLATIONFOUNDATIONThe unit should be mounted on a flat and levelfoundation, floor, or rooftop capable of supporting theentire operating weight of

80ELECTRICAL DATACircuit Wiring Diagram YCA 50 (DOL 60Hz)

81ELECTRICAL DATA

82ELECTRICAL DATACircuit Wiring Diagram YCA 50 (SOFT STARTER 60Hz)

83ELECTRICAL DATA

9INSTALLATIONHand stop valves should be installed in all lines tofacilitate servicing.Piping to the inlet and outlet connections of the chillershould