Air-condensed water chillers and heat pumps YLCA / YLHA

1 Technical Information
1.1 General Information
1.1.1 Nomenclature
1.1.2 General description of the unit
1.1.3 Models available and capacities
1.1.4 Features and advantages
1.1.5 Technical specifications
1.2 Safety instructions
1.3 Icons used in this document
1.4 Instructions for storage, transport, loading and unloading of the unit
1.4.1 Inspection
1.4.2 Disposal of packaging
1.4.3 Disposal of the unit
1.4.4 Handling
1.5 Selection guide (YLCA/YLHA)
1.5.1 Selection guide with glycol (cooling only units)
1.6 Technical data
1.6.1 Limits of use
1.6.2 Correction Factors
1.6.3 Physical data
1.6.4 Electrical specifications
1.7 Measurements, clearances and accesses
1.7.1 Clearances
1.7.2 Dimensions and hydraulic connections (models YLCA/YLHA 40)
1.7.3 Dimensions and hydraulic connections (models YLCA/YLHA 50 and 60)
1.7.4 Dimensions and hydraulic connections (models YLCA/YLHA 80)
1.7.5 Dimensions and hydraulic connections (models YLCA/YLHA 100, 120 and 150)
1.8 Capacities YLHA
1.8.1 Cooling capacities YLHA 40 ÷ 150
1.8.2 Cooling capacities YLHA 40 ÷ 150 (35% ethylene glycol)
1.8.3 Heating capacities YLHA 40 ÷ 150
1.9 Capacites YLCA
1.9.1 Cooling capacities YLCA 40 ÷ 150
1.9.2 Cooling capacities YLCA 40 ÷ 150 (35% ethylene glycol)
1.10 Cooling operation and hydraulic diagrams
1.10.1 YLCA models: cooling only
1.10.2 YLHA models: heat pump
1.11 Instructions for installation and connection of the unit
1.11.1 Characteristics of the location
1.11.2 Specifications for the foundation or anchoring of the unit
1.11.3 Hydraulic connections
1.11.4 Rotational direction of Scroll compressors
1.11.5 Preparation and connecting to the various utilities
1.12 Unit sound power spectrum data
1.13 Operating instructions
1.13.1 Operating instructions μC2 (YLCA/YLHA 40)
1.13.2 Operating instructions μC2 (YLCA 50, 60 and 80)
1.13.3 Operating instructions μC2 (YLHA 50, 60 and 80)
1.13.4 Operating instructions μC3 (YLCA / YLHA 100, 120 and 150)
1.14 Wiring diagrams
1.14.1 Unit wiring diagrams
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Service Manual EUWA/Y5-30HB/C(Z)

Service Manual EUWA/Y5-30HB/C(Z)
Small air-cooled water chillers

Contents
1 Introduction
1.1 About This Manual
Part 1
System Outline 1-1
1 General Outline
1.1 What Is in This Chapter
1.2 Technical Specifications
1.3 Electrical specifications
1.4 Outlook Drawing
2 Piping Layout
2.1 What Is in This Chapter
2.2 Functional Diagram Refrigeration Circuit for EUWA5-30HB/C(Z)
2.3 Main Parts Refrigeration Circuit for EUWA5-30HB/C(Z)
2.4 Functional Diagram Refrigeration Circuit for EUWY5-30HB/C,
EUWA5-30HB/C with Glycol Application
2.5 Main Parts Refrigeration Circuit EUWY5-30HB/C, EUWA5-30HB/C
with Glycol Application
3 Wiring Layout
3.1 What Is in This Chapter
3.2 Main functions of the chiller
3.3 Wiring Diagrams
3.4 Field Wiring
Part 2
Functional Description 2-1
1 Functional Control
1.1 What Is in This Chapter
1.2 Operation Range
1.3 Operation Flowchart
1.4 Defrost Principle (only for EUWY5-30HB/C(Z))
1.5 Defrost Circuit Control
1.6 Thermostat Control
1.7 Head Pressure Control for EUWA/Y5-10HB(Z)
1.8 Head Pressure Control for EUWA/Y15-30HC(Z)
1.9 Freeze-up Control
2 The Controller for the EUWA/Y5-10HB(Z) Chillers
2.1 What Is in This Chapter
2.2 The EUWA/Y5-10HB(Z) Controller
2.3 Start/Stop, Cool/Heat and Temperature Setting
2.4 What Happens in Case of an Alarm or a Warning
2.5 Settings: Direct and User Parameters
2.6 How to Read or Adjust Parameter Settings: the Programming Procedure
3 The Controller for the EUWA/Y15-30HC(Z) Chillers
3.1 What Is in This Chapter
3.2 The EUWA/Y15-30HC(Z) Controller
3.3 Start/Stop, Cool/Heat and Temperature Setting
3.4 What Happens in Case of an Alarm
3.5 Menu Overview
3.6 How to Read or Adjust Parameter Settings: the Programming Procedure
3.7 Read-out Menu
3.8 Set Points Menu
3.9 User Settings Menu
3.10 Software Timers Menu
3.11 History Menu
3.12 Info Menu
3.13 Input /Output Menu
3.14 Password Menu
Part 3
Troubleshooting 3-1
1 Overview of Inputs and Outputs
1.1 What Is in This Chapter
1.2 Overview of Inputs and Outputs of EUWA/Y5-10HB(Z)
1.3 Overview of Inputs and Outputs of EUWA/Y15-30HC(Z)
2 Overview of Fault Indications and Safeties
2.1 What Is in this Chapter
2.2 Fault Indication EUWA/Y5-10HB(Z)
2.3 Fault Indication EUWA/Y15-30HC(Z)
2.4 Safeties Overview
3 Checking the Inputs and Outputs
3.1 What Is in This Chapter
3.2 Checking the Temperature Sensors
3.3 Checking the Digital Inputs and Outputs
3.4 Checking the Power Supply and Fuses
4 Troubleshooting
4.1 What Is in This Chapter
4.2 Items to Be Checked
4.3 General Repair Procedures
4.4 Unlocking the Keyboard
4.5 Procedure for controller Changing (EUWA/Y5-10HB(Z)
4.6 Procedure for PCB Changing (EUWA/Y15-30HC(Z)
4.7 Procedure to Set the Carell Controller
4.8 Control of function of 4 way valve(EUWY5-30HB/C)
Part 4
Commissioning and Test Run 4-1
1 Pre-Test Run Checks
1.1 What Is in This Chapter
1.2 General Checks
1.3 Water Piping Checks
1.4 Electrical Checks
2 Test Run & Operation Data
Part 5
Maintenance 5-1
Index i
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Trane Rotary Screw Air Cooled Chiller 100 Ton

Trane Rotary Screw Air Cooled Chiller 100 Ton.
• Model RTAA 1004XF01A1COKBDFN
• S/N U96D33776.
• (2) Trane Compressors, Model CHHN050, 84 amp draw, 460 volt each.
• (10) Fans, 2-1/2 hp, 1.5 amp draw, 460 volt.
• Overall Dimensions 87 in. H x 207 in. L x 90 in. W.

Table of Contents
Features and Benefits
Model Number Description
General Data
Selection Procedure
Application Considerations
Performance Adjustment Factors
Performance Data
Electrical Data
Jobsite Connections
Controls
Dimensional Data
Weights
Options
Typical Wiring Diagrams
Features Summary
Mechanical Specifications
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RTHC Helical Rotary Chillers 1000 to 1400 kW

Table of Contents
General Information
Literature Change History
Unit Identification - Nameplates
Unit Inspection
Inspection Checklist
Loose Parts Inventory
Unit Description
Model Number Coding System
Installation Overview
Installation - Mechanical
Storage
Location Requirements
Access Restrictions
Moving and Rigging
Lifting Procedure
Isolation Pads
Shipping items
Unit Leveling
Water Piping
Water Pressure Drop Data
Water Regulating Valve
Water Regulating Valve Adjustment
Water Treatment
Water Pressure Gauges and Thermometers
Water Pressure Relief Valves
Flow Sensing Devices
Refrigerant Pressure Relief Valve Venting
Thermal Insulation
Installation - Electrical
General Recommendations
Power Supply Wiring
Compressor Motor Phase Sequencing
Module and control panel connectors
Interconnecting wiring (Field Wiring Required)
Operating Principles - Mechanical
General
Refrigeration (Cooling) Cycle
Compressor Description
Oil Management System
Oil Filter
Oil Cooler
Operator Interface - Controls
UCP2 Microprocessor Control System
Chiller Module A11
Stepper Module A13
Starter Module A14
Options Module A15
COMM 3 or COMM 4 (Tracer Interface) A19
Printer Interface Module A17
Clear Language Display (CLD) A53
Key Functions
Communications and Settings Storage
Custom Report Group - Programming
Chiller Report
Refrigerant Report
Compressor Report
Operator Settings
Service Settings
Service Tests
Diagnostics
Unit Start-up
Daily Unit Start-Up
Seasonal Unit Start-Up Procedure
Unit Shutdown
Daily Unit Shutdown
Seasonal Unit Shutdown
Periodic Maintenance
Overview
Weekly Maintenance and Checks
Monthly Maintenance and Checks
Annual Maintenance
Scheduling Other Maintenance
Check Sheets
Contractor confirmation check sheet
Start-up test log
RTHC Operating log
RTHC UCP2 log
Maintenance Procedures
Cleaning the Condenser
Cleaning the Evaporator
Compressor Oil
Oil Sump Level Check
Removing Compressor Oil
Oil Charging Procedure
Replacing the Oil Filter
Refrigerant Charging
Freeze Protection
Diagnostics
Unit Wiring
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CENTRIFUGAL LIQUID CHILLER STYLE G

Contents
1 SUPPLIER INFORMATION
1.1 Introduction
1.2 Warranty
1.3 Safety
1.4 Responsibility for Safety
1.5 About this Manual
1.6 Misuse of Equipment
1.8 Safety Labels
1.9 Material Safety Data

2 PRODUCT DESCRIPTION
2.1 General
2.2 Capacity Control
2.3 Compressor
2.4 Compressor Lubrication System
2.6 Graphic Control Centre (OptiView)
2.7 Heat Exchangers
2.8 Refrigerant Flow Control
2.9 Options and Accessories
2.10 Nomenclature
2.11 Range of Models

3 TRANSPORTATION, RIGGING AND STORAGE
3.1 General
3.2 Shipment
3.3 Inspection, Damage and Shortage
3.4 Rigging.

4 INSTALLATION
4.1 Location
4.2 Motors
4.3 Foundation
4.4 Clearances
4.5 Rigging Unit to Final Location
4.6 Locating and Installing Isolator Pads
4.7 Installing Optional Spring Isolators
4.8 Piping Connections
4.9 Evaporator and Condenser Water Piping
4.9.1 Chilled Water Circuit
4.9.2 Condenser Water Circuit
4.10 Stop Valves
4.11 Flow Switches
4.12 Drain and Vent Valves
4.13 Checking Piping Circuits and Venting Air
4.14 Refrigerant Relief Piping
4.15 Unit Piping
4.16 Control Panel Positioning
4.17 Control Wiring
4.18 Power Wiring
4.19 Units with Solid State Starter or Variable Speed Drive
4.20 Thermal Insulation
4.21 Installation Check

5 COMMISSIONING
5.1 Preparation
5.2 First Time Start-up

6 OPERATION
6.1 Oil Heater Operation
6.2 Checking the Oil Level in the Oil Reservoir
6.3 Start-up Procedure
6.4 Chiller Operation
6.5 Operating Log Sheet
6.7 Stopping the System
6.8 Prolonged Shutdown
6.9 Start-up after Prolonged Shutdown

7 MAINTENANCE
7.1 Inspections
7.2 Oil Return System
7.3 Oil Charge
7.4 Refrigerant Charge
7.5 Condenser and Evaporator
7.6 Compressor
7.7 Compressor Motor
7.8 Electrical Controls
7.9 Testing Motor Winding Insulation

8 TROUBLSHOOTING

9 TECHNICAL DATA
9.1 Dimensions
9.2 Dimensions Evaporator Compact Water Boxes
9.3 Nozzle Arrangements Evaporator Compact Water Boxes
9.4 Dimensions Condenser Compact Water Boxes
9.5 Nozzle Arrangements Condenser Compact Water Boxes
9.6 Dimensions Evaporator Marine Water Boxes
9.8 Nozzle Arrangements Evaporator Marine Water Boxes
9.8 Dimensions Condenser Marine Water Boxes
9.8 Nozzle Arrangements Condenser Marine Water Boxes
9.9 Unit Weights
9.10 Process and Instrumentation Diagram

10 SPARE PARTS

11 DE-COMMISSIONING, DISMANTLING AND DISPOSAL
11.1 General

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YORK Model YS Rotary Screw Liquid Chillers Style D R134a

Introduction
York YS 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 units are intended for cooling water or glycol solutions and are not suitable for purposes other than those specified in this manual.
This manual and the Control System Operating Instructions contain all the information required for correct installation and commissioning of the unit, together with operating and maintenance instructions.
The manuals should be read thoroughly before attempting to operate or service the unit.
All procedures detailed in the manuals, including installation, commissioning and maintenance tasks must only be performed by suitably trained and qualified personnel.
The manufacturer will not be liable for any injury or damage caused by incorrect installation, commissioning, operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manuals.


1 SUPPLIER INFORMATION
1.1 Introduction
1.2 Warranty
1.3 Safety
1.4 Responsibility for Safety
1.5 About this Manual
1.6 Misuse of Equipment
1.7 Safety Labels
1.8 Material Safety Data
2 Product Description
2.1 General
2.2 Capacity Control
2.3 Compressor
2.4 Compressor Lubrication System
2.4.1 Oil Pump
2.4.2 Oil Heater
2.5 Compress Motor
2.6 Graphic Control Centre
2.7 Heat Exchangers
2.7.1 Evaporator
2.7.2 Condenser
2.7.3 Water Boxes
2.8 Refrigerant Flow Control
2.9 Options and Accessories
2.9.1 Service Isolation Valves
2.9.2 Hot Gas Bypass
2.9.3 Solid State Starter
2.9.4 Variable Speed Drive
2.10 Nomenclature
2.11 Range of Models
3 TRANSPORTATION, RIGGING AND
STORAGE
3.1 General
3.2 Shipment
3.3 Inspection, Damage and Shortage
3.4 Rigging
4 INSTALLATION
4.1 Location
4.2 Motors
4.3 Foundation
4.4 Clearances
4.5 Rigging Unit to Final Location
4.6 Locating and Installing Isolator Pads
4.7 Installing Optional Spring Isolators
4.8 Piping Connections
4.9 Cooler and Condenser Water Piping
4.9.1 Condenser Water Circuit
4.10 Stop Valves
4.11 Flow Switches (Field Installed)
4.12 Drain and Vent Valves
4.13 Checking Piping Circuits and Venting Air
4.14 Refrigerant Relief Piping
4.15 Unit Piping
4.16 Control Panel Positioning
4.17 Control Wiring
4.18 Power Wiring
4.19 Units with Solid State Starter
or Variable Speed Drive
4.20 Thermal Insulation
4.21 Installation Check
5 COMMISSIONING
5.1 Preparation
6 OPERATION
6.1 Oil Heater Operation
6.2 Checking the Oil Level in the Oil Reservoir
6.3 Start-up Procedure
6.3.1 Pre-Starting
6.3.2 Start-up
6.4 Chiller Operation
6.4.1 Condenser Water Temperature Control
6.5 Operating Log Sheet
6.6 Maintenance and Service
6.6.1 Normal and Safety System Shutdowns
6.6.2 Safety Shutdowns
6.6.3 Cycling Shutdowns
6.7 Stopping the System
6.8 Prolonged Shutdown
6.9 Start-up after Prolonged Shutdown
7 MAINTENANCE
7.1 Inspections
7.1.1 Daily
7.1.2 Weekly
7.1.3 Every 3 Months
7.1.4 Every 6 Months (or more often as required)
7.1.5 Annually (more often if necessary)
7.2 Oil Return System
7.2.1 Changing the Dehydrator
7.3 Oil Charge
7.3.1 Oil Charging Procedure
7.4 Refrigerant Charge
7.4.1 Checking The Refrigerant Charge
7.4.2 Leak Testing
7.4.3 Vacuum Testing
7.4.4 Refrigerant Charging
7.5 Condenser and Cooler
7.5.1 Chemical Water Treatment
7.5.2 Tube Cleaning
7.5.3 Tube Cleaning Procedures
7.5.4 Tube Leaks
7.6 Compressor
7.7 Compressor Motor
7.7.1 Greased Bearings on Reliance Q5800 Motors
7.8 Electrical Controls
7.9 Testing Motor Winding Insulation
8 TROUBLE SHOOTING
9 TECHNICAL DATA
9.1 Dimensions
9.2 Weights
9.3 Compressor Dimensions
9.4 Motor Weights
9.5 Optional Solid State Starter Details
9.6 Process and Instrumentation Diagram
9.7 Water Box Nozzle Arrangements
10 SPARE PARTS
11 DE-COMMISSIONING, DISMANTLING AND
DISPOSAL
11.1 General
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RCUE40AG2-400AG2 RHUE40AG2-240AG2 Service Manual

RCUE40AG2-400AG2
RHUE40AG2-240AG2
Cooling capacity 112 kW - 1030 kW
Cooling capacity 106 kW - 585 kW
Heating capacity 110 kW - 556 kW

Content
1. Product range and specifi cations
1.1. General data for RCUE40~400AG2
1.2. General data for RHUE40~240AG2
2. Test run
2.1. Check before test run
2.2. Test run method and check
2.3. Restart of Test Run
2.4. Instruction at delivery
2.5.Warning & Cautions
3 Electrical Wiring Diagram
3.1. Power Wiring Diagram
3.2. Power Wiring Diagram (FAN)
3.3. Control PCB (PCBc)
3.4. Input / Output PCB (PCBd)
3.5. Power Wiring Diagram (MCB Option)
3.6. Diagram abbreviations descriptions
4. Control system
4.1. List of Main Control Function
4.2. Water control
4.3. Compressor control
4.4. Current limit control
4.5. Reverse protection control
4.6. Restart control after power failure
4.7. Operation error/wrong setting prevention control [40 – 40]
4.8. Forced capacity control
4.9. Second water temperature setting
4.10. Heat storage operation by external order
4.11. Operation by DC24V input (Remote Control)
4.12. Installation of switch for snow measure (Fan manual operation)
4.13. Switch for confi rmation of high pressure cut
4.14 Antifreeze control in winter
4.15. Saving energy priority mode, silence priority mode (night shift), only cooling
4.16. Defrost (only air-cooled heat pump type)
4.17. Thermo off selection function
5. Troubleshooting
5.1. Initial check
5.2. Troubleshooting
5.3. Analysis and countermeasure of abnormal running
5.4. Thermistor characteristics
6. Maintenance
6.1. Maintenance criteria
6.2. Maintenance criteria of Screw Compressor
6.3. Maintenance of Water Quality
6.4. Cleaning of water side heat exchanger
6.5. Check items in daily operation
6.6. Caution on handling of R407C
6.7. Manual at compressor overall check and parts check
6.8. Refrigerant cycle diagrams
6.9. Overhaul work
6.10. Vacuuming Procedure
6.11. Additional refrigerant insertion
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