Installation Operation Maintenance Voyager

Installation Operation Maintenance Voyager™
Commercial 12.5 to 50 Ton 60 Hz Commercial 22.9 to 41.7 Ton 50 Hz CV or VAV Rooftop Air Conditioners with ReliaTel™ Controls

Model Number
"Y" and later Design Sequence
TC*, TE*, YC*330A, 360A, 420A, 480A, 600A (60 Hz/3 phase)
TC*, TE*, YC*275A, 305A, 350A, 400A, 500A (50 Hz/3 phase)

This booklet describes the proper installation, start-up, operation, and maintenance procedures
for TC_, TE_, and YC_27.5 to 50 Ton CV (Constant Volume) and VAV (Variable Air Volume)
applications. Refer to the table of contents for a listing specific topics. Refer to the "System
Troubleshooting" section at the end of this manual for troubleshooting information.
By carefully reviewing the information within this manual and following the instructions, the risk
of improper operation and/or component damage will be minimized.
It is important that periodic maintenance be performed to help assure trouble free operation. A
maintenance schedule is provided at the end of this manual. Should equipment failure occur,
contact a qualified service organization with qualified, experienced HVAC technicians to properly
diagnose and repair this equipment.

Table of Contents
Literature Change History
Overview of Manual
Model Number Description
60 Hz Description
50 Hz Description
General Information
Commonly Used Acronyms/Abbreviations
About the Unit
Precautionary Measures
First Aid Measures
Unit Inspection
Storage
Pre-Installation
General Unit Requirements
Downflow Models Only:
All Units:.
Electrical Requirements
Field Installed Control Wiring
Gas Heat Requirements
Unit Dimensions and Weights
Recommended Clearances
Roof Curb and Ductwork
Horizontal Ductwork
Unit Rigging and Placement.
Installation General Requirements
Condensate Drain Connection
O/A Sensor & Tubing Installation
Installation Electrical
Disconnect Switch External Handle
Factory Mounted Option)
Main Power Wiring
Thru-the-Base Electrical
(Optional Accessory)
Electrical Wire Sizing and Protection Device Equations
Low Voltage Wiring
Control Power Transformer
Field Installed AC Control Wiring
Field Installed DC Control Wiring
Remote Panels and Sensors
Constant Volume Control Options
Variable Air Volume Control Options
Installation Piping
Connecting the Gas Supply Line to the Furnace Gas Train
Start-Up
Unit Control Modules
System Operation
Microelectronic Control Features
Variable Air Volume Applications
Constant Volume or Variable Air Volume Applications
 Preparing the Unit for Operation
Electrical Phasing
Voltage Supply and Voltage Imbalance
Starting the Unit
Test Modes
Verifying Proper Fan Rotation
Verifying Proper Air Flow (CFM)
Exhaust Fan Operation
Economizer Damper Adjustment
Economizer (O/A) Dampers
Manual Fresh Air Damper
Starting the Compressor
Starting 27.5 - 35 Ton units
Starting 40 to 50 Ton units
Compressor Oil
Scroll Compressor Operational Noises
At Low Ambient Start-Up
During Normal Operation
Compressor Crankcase Heaters
Charging by Subcooling
Measuring Subcooling
Gas Heat Units
Electric Heat Units
Final Unit Checkout
For Constant Volume Units;
For Variable Air Volume Units;
Sequence of Operation
Mechanical Cooling Sequence Of Operation
Units without an Economizer
Economizer operation based on Dry Bulb
Economizer operation based on Reference Enthalpy
Economizer Operation based on Comparative Enthalpy
Gas Heat Sequence Of Operation
Electric Heat Sequence Of Operation
Maintenance
Fan Belt Adjustment
Monthly Maintenance
Filters
Cooling Season
Heating Season
Coil Cleaning
Refrigerant Coils
Diagnostics
System Status/Diagnostics
Terminal locations
Diagnostics (CV units only)
Diagnostics (VAV only)
Resetting Cooling and Ignition Lockouts
Zone Temperature Sensor (ZSM) Service Indicator
RTRM Zone Sensor Module (ZSM) Test
Test 1
Test 2
Test 3
Test 4
Programmable & Digital Zone Sensor Test
Rooftop Refrigerator Module (RTRM)
Test 1
Test 2
ReliaTel Air Module (RTAM) Test
Test 1
Test 2
Test 3
Test 5
VFD Programming Parameters
Unit Wiring Diagram Numbers
Warranty and Liability Clause
COMMERCIAL EQUIPMENT RATED 20 TONS AND LARGER AND RELATED ACCESSORIES
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CVHE, CVHF, CVHG Water-Cooled CenTraVac Chillers

Installation, Operation, and Maintenance Guide
CVHE, CVHF, CVHG Water-Cooled CenTraVac™ Chillers
With Tracer AdaptiView™ Control

The unit nameplate is located on the left side of the control panel. A typical unit nameplate is illustrated below and contains the following information.
• Unit model and size descriptor
• Unit electrical requirements
• Correct operating charge and refrigerant type
• Unit test pressures and maximum operating pressures
• Unit literature
Serial Number - The unit serial number provides the specific chiller identity. Always provide this serial number when calling for service or during parts identification.
Service Model Number - The service model represents the unit as built for service purposes. It identifies the selections of variable unit features required when ordering replacements parts or requesting service.
Note: Unit-mounted starters are identified by a separate number found on the starter.
Product Description Block - The CenTraVac models are defined and built using the Product Definition and Selection (PDS) system. This system describes the product offerings using a product coding block which is made up of feature categories and codes that identifies all characteristics of a unit.

Table of Contents
Copyright
Trademarks
Warnings and Cautions
Model Number Description
Pre-Installation
ASHRAE Standard 15 Compliance
Unit Shipment
Installation requirements and Contractor responsibilities
Storage Requirements for chillers not yet installed
Unit Components
Unit Dimensions and Weights
Recommended Unit Clearances
Installation Mechanical
Operating Environment
Foundation Requirements
Rigging
Unit Isolation
Isolation Pads
Spring Isolators
Unit Leveling
Installation Water Piping
Overview
Water Treatment
Pressure Gauges
Valves
Strainers
Flow-Sensing Devices
Evaporator and Condenser Water Piping
Water Box Locations
Water Piping Connections
Grooved Pipe Coupling
Flange-Connection Adapters
Victaulic Gasket Installation
Bolt-Tightening Sequence for Water Piping Connections
Pressure Testing Waterside Piping
Purge Piping
EarthWise Purge Requirements - Purge Installation
Vent Piping
Refrigerant Vent-Line
Vent-line Installation
Insulation
Unit Insulation Requirements
Insulation Thickness Requirements
Installation Controls
Specifications
Installing the AdaptiView display
Adjusting the AdaptiView display arm
Electrical information
Installation Requirements
Electrical Requirements
Trane supplied starter wiring
Customer supplied remote starter wiring
Current transformer and Potential transformer wire sizing
Power Supply Wiring
Circuit Breakers and Fused Disconnects
Power Factor Correction Capacitors (optional)
Interconnecting Wiring
Starter to Motor Wiring (Remote-Mounted Starters Only)
Starter to control panel wiring
10kv-13.8kv Medium Voltage Installation
Motor Supply Wiring
System Control Circuit Wiring
Temperature Sensor Circuits
Unit Start-Up
Starter Module Configuration
Schematic Wiring Drawings
Operating Principles
General Requirements
Cooling Cycle
Oil and Refrigerant Pump
Motor Cooling System
AdaptiView Display
Tracer TU Chiller Service Tool
Start-up and Shut Down
Sequence Of Operation
Ice Machine Control
Free Cooling Cycle
Hot Gas Bypass
Hot Water control
Heat Recovery Cycle
Auxiliary Condensers
Control Panel Devices and Unit Mounted Devices
Unit Start-Up and Shut-down Procedures
Maintenance
Compressor Oil Change
Oil Change Procedure
Oil Filter
General Lubrication
Cleaning the Evaporator
Purge System
Long Term Unit Storage
Refrigerant Charge
Waterbox Removal and Installation
Discussion
Procedure
Connection Devices Information
Forms
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Operation Maintenance Water Cooled CenTraVac With CH530

Warnings and Cautions
Notice that warnings and cautions appear at appropriate intervals throughout this manual. Warnings are provided to alert installing contractors to potential hazards that could result in personal injury or death, while cautions are designed to alert personnel to conditions that could result in equipment damage.
Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

Contents
Warnings and Cautions
General Information
Unit Control Panel (UCP)
Operator Interface
Chilled Water Setpoint
Inter Processor Communication (IPC)
Control System Components
Controls Sequence of Operation
Machine Protection and Adaptive Control
Unit Startup
Unit Shutdown
Periodic Maintenance
Oil Maintenance
Maintenance
Forms
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200-Series MicroTech Control Panel Operating Manual

Operating Manual
200-Series MicroTech Control Panel
For Centrifugal Chillers

Table of Contents
Introduction
General Description
General Description
Control Panel Layout
Component Description
Keypad/Display Operation
Menu Structure
MicroTech Status Menus
Control Menu Description
Alarm Menus Description
Master/Slave Setup
Alarms
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Control Panel McQuay

Control Panel
Air-Cooled Screw Chillers
AWS
50 Hertz
R-134a

Table of Contents
INTRODUCTION
OPERATING LIMITS
CONTROLLER FEATURES
GENERAL DESCRIPTION
CONTROL PANEL LAYOUT
POWER PANEL LAYOUT
ECONOMIZER COMPONENTS
CONTROLLER DESCRIPTION
HARDWARE STRUCTURE
SYSTEM ARCHITECTURE
SEQUENCE OF OPERATION
CONTROLLER OPERATION
MICROTECH III INPUTS/OUTPUTS
EXTENSION I/O COMPRESSOR #1 TO #3
I/O EXV CIRCUIT #1 TO #3
EXTENSION I/O FAN MODULE CIRCUIT #1 & 2
EXTENSION I/O FAN MODULE CIRCUIT #3
EXTENSION I/O UNIT ALARM & LIMITING (POL)
SETPOINTS
UNIT FUNCTIONS
CALCULATIONS
UNIT ENABLE
UNIT MODE SELECTION
UNIT CONTROL STATES
UNIT STATUS
ICE MODE START DELAY
EVAPORATOR PUMP CONTROL
NOISE REDUCTION
LEAVING WATER TEMPERATURE (LWT) RESET
UNIT CAPACITY CONTROL
UNIT CAPACITY OVERRIDES
CIRCUIT FUNCTIONS
CALCULATIONS
CIRCUIT CONTROL LOGIC
CIRCUIT STATUS
COMPRESSOR CONTROL
CONDENSER FAN CONTROL
EXV CONTROL
ECONOMIZER CONTROL
LIQUID INJECTION
ALARMS AND EVENTS
SIGNALING ALARMS
CLEARING ALARMS
DESCRIPTION OF ALARMS
UNIT EVENTS
CIRCUIT STOP ALARMS
CIRCUIT EVENTS
ALARM LOGGING
USING THE CONTROLLER
NAVIGATING
OPTIONAL REMOTE USER INTERFACE
START-UP AND SHUTDOWN
TEMPORARY SHUTDOWN
EXTENDED (SEASONAL) SHUTDOWN
FIELD WIRING DIAGRAM
SYSTEM MAINTENANCE
PREVENTATIVE MAINTENANCE SCHEDULE
APPENDIX
DEFINITIONS
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McQuay MicroTech II Service Manual

MCQUAY MicroTech II Control
pLAN+Driver
for Modular Chillers
McQuay ALS / WHS / PFS
With screw compressors, 1 to 4 circuits
Release of the Manual: 1.0 - 01/05/2001

Contents
APPLICATIONS AND FUNCTIONS CARRIED OUT BY THE SYSTEM
MASTER/SLAVE SYSTEM ARCHITECTURE
INPUT/OUTPUT LIST
AIR/WATER UNIT WITH MAX. 4 SCREW COMPRESSORS MCQUAY ALS / WHS
WATER/WATER UNIT WITH MAX. 2 SCREW COMPRESSORS, MCQUAY PFS
REGULATION
OUTLET TEMPERATURE REGULATION
CONTINUOUS UNLOADING
Principles of working:
Forced Unloading
START-UP OF A SINGLE COMPRESSOR
Description of the logic :
START OF THE COMPRESSOR MOTOR
Description of the Logic:
LIMITATIONS AT COMPRESSOR START
PUMPDOWN
COMPRESSOR ROTATION
CONDENSATION REGULATION
CONDENSATION CONTROL WITH CUT ENABLING
MicroTech II Reference
Description
ANTIFREEZE REGULATION
ELECTRO-VALVE MANAGEMENT
Working Description
WATER PRESSURE CONTROL FOR PFS UNITS
CONTROL LOGIC OF THE COOLING TOWER FOR PFS
PFS with single compressor
PFS with two Compressors
CONTROL LOGIC OF THE 3-WAY VALVE FOR PFS UNITS
ALARMS
GENERAL DESCRIPTION
ALARM HISTORICAL
ALARM TABLE
DRIVER ALARMS
PLAN NETWORK
I/O card address
Terminal address
TERMINAL MANAGEMENT
Terminal configuration procedure
Display of the terminal connection state
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30RA010-055 AquaSnap® Air-Cooled Chillers

Controls, Start-Up, Operation, Service, and Troubleshooting

CONTENTS
SAFETY CONSIDERATIONS.
GENERAL
MAJOR SYSTEM COMPONENTS
General
Main Base Board (MBB)
Scrolling Marquee Display
Energy Management Module (EMM)
Enable/Off/Remote Contact Switch
Emergency On/Off Switch
Board Addresses
Control Module Communication
Carrier Comfort Network Interface
OPERATING DATA
Sensors
• T1 — COOLER LEAVING FLUID SENSOR
• T2 — COOLER ENTERING FLUID SENSOR
• T7,T8 — COMPRESSOR RETURN GAS TEMPERATURE SENSOR (ACCESSORY)
• T9 — OUTDOOR-AIR TEMPERATURE SENSOR
• T10 — REMOTE SPACE TEMPERATURE SENSOR OR
DUAL LEAVING WATER TEMPERATURE SENSOR
Energy Management Module
Loss-of-Cooler Flow Protection
Thermostatic Expansion Valves (TXV)
Capacity Control
• MINUTES LEFT FOR START
• MINUTES OFF TIME
• LEAD/LAG DETERMINATION
• CAPACITY CONTROL OVERRIDES
Head Pressure Control
Operation of Machine Based on Control Method and Cooling Set Point Selection Settings
Cooling Set Point Select
Marquee Display Usage
Service Test.
Optional Factory-Installed Hydronic Package
Cooler Pump Control
Cooler Pump Sequence of Operation
Configuring and Operating Dual Chiller Control
Temperature Reset
Demand Limit
• DEMAND LIMIT (2-Stage Switch Controlled)
• EXTERNALLY POWERED DEMAND LIMIT
(4 to 20 mA Controlled)
• DEMAND LIMIT (CCN Loadshed Controlled)
Cooling Set Point (4 to 20 mA)
TROUBLESHOOTING
Complete Unit Stoppage and Restart
• GENERAL POWER FAILURE
• UNIT ENABLE-OFF-REMOTE CONTACT SWITCH ISOFF
• CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN
• OPEN HIGH-PRESSURE SWITCH(ES)
• OPEN COMPRESSOR INTERNAL THERMAL PROTECTION
• OPEN 24-V CONTROL CIRCUIT BREAKERS
• COOLING LOAD SATISFIED
• THERMISTOR FAILURE
• LOW SATURATED SUCTION
Alarms and Alerts
SERVICE
Electronic Components
• CONTROL COMPONENTS
Compressor Replacement
Cooler
• BRAZED-PLATE COOLER HEAT EXCHANGER REPLACEMENT
• BRAZED-PLATE COOLER HEAT EXCHANGER CLEANING
Check Oil Charge Condenser Section and Coils
• COIL CLEANING
• CLEANING E-COATED COILS
• CONDENSER SECTION
Check Refrigerant Feed Components
• THERMOSTATIC EXPANSION VALVE (TXV)
• FILTER DRIER
• MOISTURE-LIQUID INDICATOR
• MINIMUM LOAD VALVE
• PRESSURE RELIEF DEVICES
Compressor and Unit Protective Devices
• MANUAL STARTER
• COMPRESSOR INTERNAL THERMAL PROTECTION
Check Unit Safeties
• HIGH-PRESSURE SWITCH
• PRESSURE TRANSDUCERS
• COOLER FREEZE-UP PROTECTION
• HEATER CABLE
• WINTER SHUTDOWN
Thermistors
Pressure Transducers
Flow Sensor
Strainer
Motormaster® V Controller
• GENERAL OPERATION
• SET POINTS
• INSTALLATION
• PROGRAMMING
• EPM CHIP
• LIQUID LINE PRESSURE SET POINT ADJUSTMENT
• LOSS OF CCN COMMUNICATIONS
• REPLACING DEFECTIVE MODULES
Hydronic Package
MAINTENANCE
Recommended Maintenance Schedule
PRE-START-UP
System Check
START-UP AND OPERATION
Actual Start-Up
Check Refrigerant Charge
Operating Limitations
• TEMPERATURES
• LOW AMBIENT OPERATION
• VOLTAGE — ALL UNITS
OPERATION SEQUENCE
APPENDIX A — CCN TABLES
APPENDIX B — FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMP AND MANUAL STARTERS
APPENDIX C — BUILDING INTERFACE
START-UP CHECKLIST FOR 30RA LIQUID CHILLER.
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30HR, HS070-160 (Model D) Reciprocating Liquid Chillers

30HR, HS070-160 (Model D)
Reciprocating Liquid Chillers
CONTENS
Safety Considerations
Installation
Inspect Shipment
Rig and Place Unit
- Rigging
- Placement
Check Compressor Mounting and Connections
Make Piping Connections
- Condensor Description
- Condenser Piping
- Cooler Description
- Cooler Piping
- Check Valves
- Flow Switch
Brine Units
Make Electrical Connections
- Electrical Box, Control Section
- Electrical Box, Power Section
- Power Supply
- Umbalanced 3-Phase Supply Voltage
- Control Circuit Wiring
Before Start-Up
Initial Check
Leak Test and Dehydration
Refrigerant Charging
- Liquid Charging Method
Check Oil Charge
Start-Up
Operation Checks
Check Refrigerant Feed Components
- Thermostatic Expansion Valve (TXV)
- Filter Drier
- Moisture-Liquid Indicator
- Liquid Line Solenoid Valves
- Liqid Line Service Valves
- Pressure Relief Devices
- Check Valves
Check Compressor Protection Devices
- Circuit Breakers
- Crankcase Heater
- Oil Pressure Safety Switch (OPSS)
Check Unit Safety Devices
- High-Pressure Switch
- Low-Pressure Switch
- Safety Thermostat
Unit Operation
Control Power
Control Sequence
- Capacity Control
- Chilled Water Temperature Controller
- Complete Unit Stoppage
- Single-Circuit Stoppage
- Restart Procedure
Service
Compressor Replacement
Circuit Breakers
Servicing the Cooler
- Tube Plugging
- Retubing
- Cooler Head Bolt Tightening
Start -Up Checklist
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30GX 082-358 30HXC 080-375

30GX 082-358
30HXC 080-375
Screw Compressor Water-Cooled
Liquid Chillers and
Air-Cooled Liquid Chillers
Nominal cooling capacity 30HXC: 286-1300 kW
Nominal cooling capacity 30GX: 282-1203 kW
50 Hz

LIST OF CONTENTS
1 - INTRODUCTION
1.1 - Installation safety considerations
1.2 - Equipment and components under pressure
1.3 - Maintenance safety considerations
1.4 - Repair safety considerations
2 - PRELIMINARY CHECKS
2.1 - Check equipment received
2.2 - Moving and siting the unit
3 - DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION
3.1 - 30HXC 080-190
3.2 - 30HXC 200-375
3.3 - 30GX 082-182
3.4 - 30GX 207-358
3.5 - Multiple chiller installation
4 - PHYSICAL AND ELECTRICAL DATA FOR 30HXC UNITS
4.1 - Physical data 30HXC
4.2 - Electrical data 30HXC
4.3 - Electrical data, 30HXC compressors
4.4 - Electrical data for 30HXC units with high condensing temperatures (option 150/150A)
4.5 - Unit characteristics 30HXC units with very low temperature option (option 6)
5 - PHYSICAL AND ELECTRICAL DATA FOR UNITS 30GX
5.1 - Physical data 30GX
5.2 - Electrical data 30GX
5.3 - Electrical data, 30GX and 30HXC compressors, option 150 + 150A
6 - APPLICATION DATA
6.1 - Unit operating range
6.2 - Minimum chilled water flow
6.3 - Maximum chilled water flow
6.4 - Variable flow evaporator
6.5 - System minimum water volume
6.6 - Cooler flow rate (l/s)
6.7 - Condenser flow rate (l/s)
6.8 - Evaporator pressure drop curve
6.9 - Condenser pressure drop curve
7 - ELECTRICAL CONNECTION
7.1 - Electrical connections 30HXC units
7.2 - Electrical connections 30GX units
7.3 - Power supply
7.4 - Voltage phase imbalance (%)
7.5 - Recommended wire sections
8 - WATER CONNECTIONS
8.1 - Operating precautions
8.2 - Water connections
8.3 - Flow control
8.4 - Evaporator (and condenser for the 30HXC) water box bolt tightening
8.5 - Frost protection
8.6 - Operation of two units in master/slave mode
9 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA
9.1 - Geared twin screw compressor
9.2 - Pressure vessels
9.3 - Electronic expansion device (EXV)
9.4 - Economizer
9.5 - Oil pumps
9.6 - Motor cooling valves
9.7 - Sensors
10 - MAIN OPTIONS AND ACCESSORIES
10.1 - Compressor suction valves (option 92)
10.2 - Compressor and evaporator noise insulation (30GX - option 14A)
10.3 - Low-noise 30GX units equipped with acoustic panels (option 15)
10.4 - Evaporator frost protection (30GX - option 41A
10.5 - Year-round operation of 30GX units (option 28)
10.6 - Soft Start for 3- and 4-compressor 30HXC and 30GX units (option 25)
10.7 - Electric protection level of the 30HXC control boxes to IP44C (option 20)
10.8 - Tropicalised control box for 30HXC and 30GX units (option 22)
10.9 - Brine units for low-temperature evaporator leaving applications (option 5)
10.10 - Disassembled 30HXC units (option 52)
10.11 - Available fan pressure of 150 Pa for 30GX units (option 12)
11 - MAINTENANCE
11.1 - Maintenance instructions
11.2 - Soldering and welding
11.3 - Refrigerant charging - adding charge
11.4 - Indication of low charge on a 30HXC system
11.5 - Electrical maintenance
11.6 - Pressure transducers
11.7 - Oil charging - low oil recharging
11.8 - Integral oil filter change
11.9 - Filter change-out schedule
11.10 - Filter change-out procedure
11.11 - Compressor replacement
11.12 - Corrosion control
11.13 - Condenser coil
12 - START-UP CKECKLIST FOR 30HXC/GX LIQUID CHILLERS (USE FOR JOB FILE)
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30XA Air-Cooled Liquid Chillers

30XA
Air-Cooled Liquid Chillers
Nominal cooling capacity: 270-1670 kW
50 Hz

Contents
1 - INTRODUCTION
1.1 - Installation safety considerations
1.2 - Equipment and components under pressure
1.3 - Maintenance safety considerations
1.4 - Repair safety considerations
2 - Preliminary checks
2.1 - Check equipment received
2.2 - Moving and siting the unit
3 - dimensions, clearances
3.1 - 30XA 252-352 (standard) and 252-302 (option 254/255)
3.2 - 30XA 402-452 (standard) and 352-452 (option 254/255)
3.3 - 30XA 502 (standard and option 254/255)
3.4 - 30XA 602-802 (standard) and 602-702 (option 254/255)
3.5 - 30XA 852-902 (standard) and 752-852 (option 254/255)
3.6 - 30XA 1002 (standard) and 902-1002 (option 254/255)
3.7 - 30XA 1102-1352 (standard and option 254/255)
3.8 - 30XA 1402-1502 module 1 (standard and option 254/255)
3.9 - 30XA 1402-1502 module 2 (standard and option 254/255)
3.10 - 30XA 1702 module 1 (standard and option 254/255)
3.11 - 30XA 1702 module 2 (standard and option 254/255)
3.12 - Multiple chiller installation
4 - Physical and electrical data for 30XA units
4.1 - Physical data 30XA - Standard units and option 119***
4.2 - Physical data 30XA - Units with option 254 and 255***
4.3 - Sound levels
4.4 - Short-circuit stability current for all units
4.5 - Electrical data 30XA - Standard unit (including option 81)
4.6 - Electrical data 30XA - Option 119 (including option 81)
4.7 - Electrical data 30XA - Option 254/255 (including option 81)
4.8 - Electrical data 30XA - Option 254/255 with option 119 (including option 81)
4.9 - Compressor electrical data
4.10 - Compressor usage per circuit (A, B, C, D)
4.11 - Electrical data, optional hydronic module
5 - ELECTRICAL CONNECTION
5.1 - Power supply
5.2 - Voltage phase imbalance (%)
5.3 - Power connection/disconnect switch
5.4 - Recommended wire sections
5.5 - Power cable entry
5.6 - Field control wiring
6 - Application data
6.1 - Operating limits
6.2 - Minimum chilled water flow (units without hydronic module)
6.3 - Maximum chilled water flow (units without hydronic module)
6.4 - Variable flow evaporator
6.5 - System minimum water volume
6.6 - Maximum system water volume
6.7 - Evaporator water flow rate
6.8 - Evaporator pressure drop curve
7 - WATER CONNECTIONS
7.1 - Operating precautions
7.2 - Victaulic water connections
7.3 - Flow control
7.4 - Evaporator water box bolt tightening
7.5 - Frost protection
7.6 - Operation of two units in master/slave mode
7.7 - Pump pressure/flow rate curves
7.8 - Available static system pressure
8 - FREE-COOLING OPTION
8.1 - Characteristics
8.2 - Operating limits
8.3 - Operation
9 - Heat reclaim condenser option
9.1 - Technical data, 30XA units with heat reclaim condenser option
9.2 - Dimensions, clearances
9.3 - Condenser location
9.4 - Condenser water connections
9.5 - Operating limits for stable operation (no mode changeover)
9.6 - Operating limits for changeover between modes
9.7 - Flow control
9.8 - Heat reclaim operation
9.9 - Condenser pump selection
9.10 - Frost protection
10 - Major system co mpon ent s and op eration data
10.1 - Direct-drive twin-screw compressor with variable capacity slide valve
10.2 - Pressure vessels
10.3 - High-pressure safety switch
10.4 - Condensers
10.5 - Fans
10.6 - Electronic expansion valve (EXV)
10.7 - Moisture indicator
10.8 - Filter drier
10.9 - Sensors
11 - Options and accessories
12 - STANDARD MAINTENANCE
12.1 - Level 1 maintenance
12.2 - Level 2 maintenance
12.3 - Level 3 (or higher) maintenance
12.4 - Tightening torques for the main electrical connections
12.5 - Tightening torques for the main bolts and screws
12.6 - Condenser coil
12.7 - Evaporator maintenance
12.8 - Compressor maintenance
12.9 - Precaution for compresssor power supply bus bar connection
13 - start -up cHecklist for 30XA Liquid chillers (use for job file)
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AIR-COOLED SCREW LIQUID CHILLERS STYLE A (513 - 1355 KW)

YCIV0600SE-YCIV1500SE & YCIV0590HE-YCIV1380HE
AIR-COOLED SCREW LIQUID CHILLERS STYLE A (513 - 1355 KW)
SE - STANDARD EFFICIENCY & HE - HIGH EFFICIENCY
Symphony
R134a

1 - GENERAL CHILLER INFORMATION &
SAFETY
INTRODUCTION
WARRANTY
SAFETY
Standards for Safety
RESPONSIBILITY FOR SAFETY
ABOUT THIS MANUAL
MISUSE OF EQUIPMENT
Suitability for Application
Structural Support
Mechanical Strength
General Access
Pressure Systems
Electrical
Rotating Parts
Sharp Edges
Refrigerants and Oils
High Temperature and Pressure Cleaning
Emergency Shutdown
Safety Labels
2 -PRODUCT DESCRIPTION
INTRODUCTION
GENERAL SYSTEM DESCRIPTION
Compressor
Evaporator
Condenser
Flash Tank Feed Valve/Drain Valves
Oil Separator/Oil System
Relief Valves
Oil Cooling
Capacity Control
Power and Control Panel
Microprocessor and VSD Controls
Display
Keypad
Unit Switch
Variable Speed Drive (VSD)
ACCESSORIES AND OPTIONS
Power Supply Options
Acoustic Options
Energy Effi ciency Option
Condenser Coil Protection
Heat Recovery Options
Unit Protective Panels
Evaporator Options
Building Automation System (BAS) Interface
Vibration Isolation
Dual Pressure Relief Valves
Low Temperature Brine
NOMENCLATURE
3 - HANDLING AND STORAGE
DELIVERY AND STORAGE
INSPECTION
MOVING THE CHILLER
UNIT RIGGING
LIFTING WEIGHTS
UNIT REMOVAL FROM SHIPPING CONTAINER
4 - INSTALLATION
LOCATION REQUIREMENTS
OUTDOOR INSTALLATIONS
INDOOR INSTALLATIONS
OPERATING IN LOW AMBIENT
CONDITIONS
LOCATION CLEARANCES
INSTALLATION OF VIBRATION ISOLATORS
Installation
SHIPPING BRACES
CHILLED LIQUID PIPING
General Requirements
WATER TREATMENT
PIPEWORK ARRANGEMENT
CONNECTION TYPES & SIZES
COOLER CONNECTIONS
Option Flanges
REFRIGERANT RELIEF VALVE PIPING
DUCTWORK CONNECTION
General Requirements
ELECTRICAL CONNECTION
POWER WIRING
POWER SUPPLY WIRING
115 VAC CONTROL SUPPLY TRANSFORMER
CONTROL PANEL WIRING
VOLTS FREE CONTACTS
Chilled Liquid Pump Starter
Run Contact
Alarm Contacts
SYSTEM INPUTS
Flow Switch
Remote Run / Stop
Remote Print
Optional Remote Setpoint Offset – Temperature
Optional Remote Setpoint Offset – Current
Optional Remote Setpoint Offset – Sound Limiting
CONNECTION DATA
5 - COMMISSIONING
PREPARATION
PREPARATION – GENERAL
Inspection
Refrigerant Charge
Service and Oil Line Valves
Compressor Oil
Fans
Isolation / Protection
Control Panel
Power Connections
Protecting Bonding
Water System
Flow Switch
Temperature Sensor(s)
Programmed Options
Programmed Settings
Date and Time
Start/Stop Schedule
Setpoint and Remote Offset
Interlocks
Unit Switch
Start-up
Oil Pressure
Refrigerant Flow
Loading
Condenser and Fan Rotation
Suction Superheat
Subcooling
General Operation
6 - TECHNICAL DATA
WATER PRESSURE DROP
GLYCOL CORRECTION FACTORS
OPERATING LIMITATIONS
PHYSICAL DATA
UNIT ELECTRICAL DATA
SYSTEM ELECTRICAL DATA
UNIT CIRCUIT BREAKER - CURRENT / TIME TRIP CURVE
UNIT CIRCUIT BREAKER - GROUND FAULT PROTECTION CURRENT / TIME TRIP CURVE
DIMENSIONS ELECTRICAL CABLE ENTRY
DESUPERHEATER OPTION PRESSURE DROP
DESUPERHEATER OPTION CONNECTIONS
ISOLATOR POSITIONS -
UNIT CLEARANCES
PROCESS AND INSTRUMENTATION DIAGRAM COMPONENT LOCATIONS
EQUIPMENT START-UP CHECK SHEET
7 - MAINTENANCE
GENERAL REQUIREMENTS
Daily Maintenance
Unit Status
Refrigerant Leaks
Operating Conditions
Compressor Oil Level
Refrigerant Charge
Scheduled Maintenance
Chiller / Compressor Operating Log
MAINTENANCE REQUIREMENTS FOR YCIV CHILLERS.
TROUBLESHOOTING GUIDE
EVACUATING A SYSTEM
WARRANTY
CHILLED LIQUID AND SUCTION TEMPERATURE SENSOR INPUT VOLTAGE
OUTSIDE AIR TEMPERATURE SENSOR INPUT VOLTAGE
PRESSURE TRANDUCER OUTPUT VOLTAGE
MOTOR TEMPERATURE SENSOR RESISTANCE
COMPRESSOR MOTOR OVERLOAD & MAX.VSD FREQUENCY
OPERATING LOG SHEET
R-134A CONVERSION TABLES
DECOMMISSIONING, DISMANTLING AND DISPOSAL
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YPC TWO-STAGE DIRECT-FIRED AND STEAM ABSORPTION CHILLER/HEATERS

YPC TWO-STAGE
DIRECT-FIRED AND STEAM ABSORPTION
CHILLER/HEATERS

MODELS
DIRECT-FIRED
YPC-FA-12SC THROUGH YPC-FZ-19S
YPC-FD-19G THROUGH YPC-FD-20G
STEAM-FIRED
YPC-ST-14SC – YPC-ST-19S
YPC-ST-19G THROUGH YPC-ST-22GL
UNITS SHOWN:
DIRECT-FIRED “S” MODEL
STEAM-FIRED “G” MODEL


SECTION 1 INTRODUCTION
Introduction
Comparison Of Cycles
How It Works
Cooling Cycle
Heating Cycle (without Optional Hot Water Heat Exchanger - Standard Heating)
Heating Cycle (with Optional Hot Water Heat Exchanger - High-Temperature Heating)
Simultaneous Heating And Cooling
Description Of Major Components and Subsystems Control Descriptions
SECTION 2 CRYSTALLIZATION
Dilution Cycle and Crystallization
Fluctuating Tower Water Temperature
Measures To Prevent Crystallization
How To Tell If A Unit is Crystallized
SECTION 3 PURGING AND NON-CONDENSABLES
Non-Condensables
Non-Condensable Quantities
Continuous Internal Purging While
Unit Is Operating
Purge Components
Purge Pump
Purge Tank
Purge Eductor
Gas Separator
Valves
Oil Separator
Absolute Pressure Gauge
Purging Frequency
When To Purge The Purge Tank
When To Purge The Absorber
When To Purge The Hot Water Heater
SmartPurgeTM
SECTION 4 PUMPS
Purge Pump Operation
Cleanliness
Types Of Lubricants
Purge Pump Piping and Operating Valves
The Principle Of Gas Ballast
Oil Level Determination
Bubble Leak Test Procedure
Purge Pump Maintenance
Vacuum Problems
Oil Changes And Oil Level
Shaft Seal Replacement
Repairing Oil Leaks
Drive Problems
Buffalo Pumps
Introduction
Troubleshooting
Pump Overhaul
SECTION 5 BURNERS
Model Identification
Gas Trains
Burners
Burner with Full Modulation Fuel/Air Control (Gas Operation)
Burner with Full Modulation Fuel/Air Control (Oil Operation)
Flame Safeguard Controls
R4140L
RM7840L
SECTION 6 STEAM CONTROL VALVES
Valve Performance
Valve Flow Characteristics
Valve Actuation
SECTION 7 STEAM HEAD GASKET REPLACEMENT
Replacement Procedure
SECTION 8 CHANGEOVER PROCEDURES
Heating/Cooling Changeover Procedure
Cooling/Heating Changeover Procedure
Cooling/Simultaneous Heating/Cooling Operation Changeover Procedure
SECTION 9 REFRIGERANT BLOWDOWN
Refrigerant Blowdown
Refrigerant Blowdown Procedure
SECTION 10 SOLUTION CHEMISTRY MAINTENANCE
Alcohol
SECTION 11 STEAM AND WATER QUALITY CONTROL
Water Quality
Steam/Condensate Quality
Tube Cleaning
SECTION 12 OPERATIONAL & MAINTENANCE RECOMMEDATIONS
Daily Operation Logs and Inspection
General
Preventative Maintenance Schedule
SECTION 13 PARAFLOW GLOSSARY
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YPC Two-Stage Direct-Fired Absorption Chiller-Heaters Style A

YPC Two-Stage Direct-Fired Absorption Chiller-Heaters Style A
Models YPC-DF-12SC through YPC-DF-19S
200 through 675 Tons
703 kW through 2372 kW

TABLE OF CONTENTS
How It Works
Ratings
Control System
Mechanical Specifications
Application Data
Dimensions
Electrical Data
Nozzle Arrangements
Guide Specifications
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Air-Cooled Screw Liquid Chillers with Variable Speed Drive Style A

Air-Cooled Screw Liquid Chillers with Variable Speed Drive Style A
150 - 385 TONS
(527 - 1354 kWi)
2 and 3 Compressor
50 and 60 Hz
ASHRAE 90.1 Compliant
HFC-134a

Table of Contents
FORM 201.23-EG1 (209)
Introduction
Specifications
Accessories and Options
Nomenclature
Temperatures and Flows
Water Pressure Drop
Standard Efficiency Ratings - English - 460V/60Hz
High Efficiency Ratings - English - 460V/60Hz
Standard Efficiency Ratings - SI - 460V/60Hz
High Efficiency Ratings - SI - 460V/60Hz
Standard Efficiency Ratings - SI - 400V/50Hz
High Efficiency Ratings - SI - 400V/50Hz
Standard Efficiency Ratings - English - 380V/60Hz
High Efficiency Ratings - English - 380V/60Hz
Standard Efficiency Ratings - SI - 380V/60Hz
High Efficiency Ratings - SI - 380V/60Hz
Physical Data (English - Standard Efficiency)
Physical Data (English - High Efficiency)
Physical Data (SI - Standard Efficiency)
Physical Data (SI - High Efficiency)
Dimensions - English
Dimensions - SI
Isolator Locations - English
Isolator Locations - SI
Isolator Details
Electrical Data - 2 Comp Standard Efficiency
Electrical Data - 2 Comp High Efficiency
Electrical Data - 3 Comp Standard Efficiency
Electrical Data - 3 Comp High Efficiency
Electrical Notes
Power Wiring
Typical Control Wiring - Two Compressor
Typical Control Wiring - Three Compressor
Application Data
Guide Specifications
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YLAA Air-Cooled Scroll Chillers Style A

Model YLAA Air-Cooled Scroll Chillers Style A
70 – 175 TON
246 – 527 kW
60 Hz
R-410A
Table of Contents
Form 150.62-EG3 (409)
Introduction
Specifications
Microcomputer Control Center
Accessories and Options
Design Parameters
Water Pressure Drop
Selection Criteria and Procedures
Pump Selection Criteria
Pump Pressure Drop Curves
Single Pump Curves
Dual Pump Curves
Ratings - 60 Hz
Part Load Ratings - Standard Efficiency
Part Load Ratings - High Efficiency
Physical Data - English
Dimensions - Four Fan Units
Dimensions - Five Fan Units
Dimensions - Six Fan Units
Dimensions - Eight Fan Units
Dimensions - Ten Fan Units
Isolator Locations
Isolator Details
Electrical Notes
Electrical Data w/o Pumps
Wiring Lugs
Electrical Data w/ Pumps
Wiring Diagram
Elementary Wiring
Condenser Fan Mapping and Sequencing
Compressor Wiring
Power Options Connection Diagram
Power Panel
Dual Pump Wiring
Wiring
MicroPanel Connections
Application Data
Guide Specifications
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YPC ParaFlow Two-Stage Direct-Fired Absorption Chiller-Heaters

Model YPC ParaFlow Two-Stage Direct-Fired Absorption
Chiller-Heaters
Style A
Models YPC‑DF‑12SC through YPC‑DF‑19S
200 through 675 Tons
703 kW through 2372 kW

Table of Contents
FORM 155.17-EG4 (1108)
Introduction
How It Works
Ratings
MicroComputer Control Center
Mechanical Specifications
Application Data
Dimensions
Electrical Data
Nozzle Arrangements: 12SC - 14SC
Nozzle Arrangements: 15SL and Larger
Guide Specifications
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YIA Single-Effect Absorption Chillers Steam

YIA Single-Effect Absorption Chillers Steam And Hot Water Chillers
Style A
120-1377 TONS
(420 - 4840 kW)

Table of Contents
FORM 155.16-EG1 (1008)
Nomenclature
Introduction
Reliability Features
How It Works
MicroComputer Control Center
Mechanical Specifications
Optional Features
Application Data
Ratings
Nozzle Arrangements
Physical Data
Electrical Data
Guide Specifications
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YORK RecipPak LIQUID CHILLERS

YORK RecipPak LIQUID CHILLERS
AIR COOLED - RECIPROCATING HERMETIC
Model 60 HZ
YEAZ88DR6
YEAJ44DR6
YEAJ44HT6
YEAJ54ES6
YEAJ55HT8
YEAJ65HT8
YEAJ66MT8
Model 50 HZ
YEAJ44DR7
YEAJ55DR7
YEAJ55HT7
YEAJ65ES7
YEAJ66HT9
YEAJ76HT9
YEAJ77MT9
STYLE A*

Table of Contents
General Information
Nomenclature
Operational Limitations
Dimensions
Physical Data
Installation
Wiring Diagram
Unit Controls and Operation
Compressor Capacity Control
System Start-up and Operation
Preventative Maintenance
Options
Troubleshooting Chart
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YK-EP Energy Plus Centrifugal Liquid Chillers Style A

Model YK-EP Energy Plus Centrifugal Liquid Chillers Style A
2500 THROUGH 3500 TONS
(8800 through 12300 kW)
Utilizing R-134a

Table of Contents
FORM 160.77-EG1 (512)
Introduction
Sustainability Focus
Unit Components
System Flow Diagram
Equipment Overview
Accessories and Modifications
Application Data
Dimensions (Ft. - In.) - Unit
Dimensions (Ft. - In.) - Nozzle Arrangements
Weights - English
Dimensions (mm) - Unit
Dimensions (mm) - Nozzle Arrangements
Weights - SI
Guide Specifications
SI Metric Conversion
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YCAV Air-Cooled Screw Compressor Liquid Chillers Style A

Model YCAV Air-Cooled Screw Compressor Liquid Chillers Style A
150-385 TONS
527-1354 kW
60 Hz
385-515 TONS
1354-1804 kW
50 & 60 Hz
ASHRAE90.1 Compliant

Table of Contents
FORM 201.21-EG1 (711)
Introduction
Specifications
Accessories and Options
Nomenclature
Temperatures and Flows
Water Pressure Drop
Efficiency
Standard Efficiency Ratings - English - 60Hz
High Efficiency Ratings - English - 60Hz
Standard Efficiency Ratings - SI - 60Hz
High Efficiency Ratings - SI - 60Hz
Standard Efficiency Ratings - SI - 50Hz
Standard Efficiency Ratings - SI - 50Hz - continued
Standard Efficiency Ratings - SI - 50Hz - continued
High Efficiency Ratings - SI - 50Hz
High Efficiency Ratings - SI - 50Hz - continued
High Efficiency Ratings - SI - 50Hz - continued
Physical Data (English - Standard Efficiency)
Physical Data (English - High Efficiency)
Physical Data (SI - Standard Efficiency)
Physical Data (SI - High Efficiency)
Dimensions - English
Dimensions - SI
Isolator Details
Electrical Data - 2 Comp - 60Hz
Electrical Data - 3 Comp - 60Hz
Electrical Data - 4 Comp - 60Hz
Electrical Data - 4 Comp - 50Hz
Electrical Notes
Power Wiring
Typical Control Wiring - Two Compressor
Typical Control Wiring - Three Compressor
Typical Control Wiring - Four Compressor
Application Data
Guide Specifications
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TurboChill Air Cooled Chiller 200 kW - 1100 kW R134a

 Technical, Installation and Maintenance Manual
Contents
Warranty, Commissioning & Maintenance
HEALTH AND SAFETY
GENERAL DESCRIPTION
Nomenclature
Introduction
ENVIRONMENTAL CONSIDERATIONS
Freeze Protection
Environmental Policy
STANDARD FEATURES
Standard Features - Energy Saving
Turbocor Compressor
SPECIFIERS GUIDE
Standard Features
Construction
Water Connections
Condenser
Dual Pressure Relief Valve
R134a Leak Detection System
Maintainable Dual Pressure Relief Valve
Evaporator Differential Pressure Sensor
Refrigeration
Controls
Electrical Components
Standard Features - Energy Saving
Electronically Commutated (EC) Fan Motor
Evaporator
OPTIONAL FEATURES
Optional Extras - Energy Saving
Chiller Sequence Manager
Energy Manager
Economiser Circuit for Increased Part Load Efficiency
Corrosion Resistant Coated Coils
Coil Guards
Anti Vibration Mounts (Spring Type)
Anti Vibration Mounts
(Pad Type)
Discharge Air Plenum - Condenser Fan
Extended Discharge Air Plenum - Condenser Fan
R134a Leak Detection System
Flow Switch
Remote Set-point Adjust
BMS Interface Card
Extended water connections
CONTROLS STANDARD FEATURES
Display/ keypad
Temperature Control
Monitoring
Alarm Handling
Unit Remote ON/OFF
Compressor Anti Cycle Control
Compressor Load Limit
Pump(s) Remote ON/OFF
Remote Setback Temperature Set-point Switch
Compressor Hours Run
Password Protection
Interactive head pressure setpoint management
CONTROLS OPTIONAL FEATURES
BMS Interface Card
Modbus / Carel BMS Connection
Lon BMS Connection
pCOWeb
UPS battery backup
DESIGN FEATURES & INFORMATION
Refrigeration schematic
Minimum system water volume calculations
Typical Part Load Characteristics
Performance effects of glycol
Sound Data
Base Correction Values - Global dB
PERFORMANCE
Global Sound Power Data
Capacity and Mechanical Data Quiet model (TTC … 95)
Capacity and Mechanical Data Super Quiet model (TTC … 70)
Waterside Pressure Drop, all Models
Electrical Data Quiet Model (TTC … 95)
Electrical Data Super Quiet model (TTC … 70)
INSTALLATION
Dimensional Data 8 - 12 Fan Units (mm)
Dimensional Data 12 - 20 Fan Units (mm)
Masses, Point Loadings & Centre of Gravity (C of G)
Lifting Dimensions
Positioning
Airflow & Maintenance Clearances
Anti Vibration Mount, Spring and Pad type.
Anti Vibration Mount allocation
Standard Recommended Installation
Water System
Recommended Requirements
Pump Statement
Interlocks & Protection
Electrical
Interconnecting Wiring
CONTROLS
Use of Display Keypad Buttons
Enabling the Unit
Liquid Level Sensor
Alarm interrogation
COMMISSIONING PROCEDURE
Pre Commissioning Checklist
Refrigerant standing pressure
Electrical
Liquid level Transmitter
Uninterrupted power Supply
Waterside
General water pipework
Differential pressure sensor
Controls
Refrigeration
OPERATIONAL MAINTENANCE CHECKS
Owners Responsibility
Unit Inspection
Refrigeration
Water
Controls
MAINTENANCE ADVICE
Compressor Refrigerant Recovery
Compressor Non Return Valve
Pressure Relief Valve
Evaporator Cleaning
UPS Function
TROUBLESHOOTING
General
Refrigeration
Condenser
Waterside
Unit Alarms
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YORK AIR-COOLED LIQUID CHILLERS HERMETIC SCROLL

MODELS YCAL 0041, 0045, 0051, 0055, 0061, AND YCAL0065E
STYLE "D"

40 - 70 TON
35 - 246 Kw
50Hz and 60Hz

200-3-60
230-3-60
315-3-60
380/415-50
460-3-60
575-3-60
MODELS ONLY

TABLE OF CONTENTS
UNIT NOMENCLATURE NAMEPLATE ENGINEERING DATA
EVAPORATOR
HEAT EXCHANGER AND RELATED COMPONENTS
CONDENSER COILS
CONDENSER COIL COMPONENTS
FAN
FAN COMPONENTS
PIPING
REFRIGERANT PIPING COMPONENTS
COMPRESOR
COMPRESSOR
CONTROL AND POWER PANEL
CONTROL PANEL AND POWER PANEL CONFIGURATIONS
CONTROL PANEL AND POWER PANEL COMPONENTS
CONTROL WIRING HARNESSES
SENSOR WIRING HARNESSES
TEMPERATURE SENSORS AND TRANSDUCERS
TRANSDUCER AND THERMISTOR WIRE HARNESS CONNECTORS
ENCLOSURE
UNIT ENCLOSURE COMPONENTS
CHILLER OPTIONS
VIBRATOR ISOLATORS
CHILLER OPTIONS
ENCLOSURE KIT OPTIONS
OPTIVIEW REMOTE CONTROL CENTER
REMOTE CURRENT/TEMPERATURE RESET PARTS BREAKDOWN
RECOMMENDED SPARE PARTS
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YORK Model YS Rotary Screw Liquid Chillers

Model YS Rotary Screw Liquid Chillers
Design Level E
100 THRU 675 TONS
(315 THRU 2375 KW)
R134A

Contents
Introduction
Ratings
OptiView Control Center
Mechanical Specifications
Accessories and Modifications
Unit Components
Application Data
Dimensions - Std
Dimensions - Std
Weights - Std
Dimensions - Metric
Guide Specifications
Metric Conversion Tables
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YORK Millenniun Centrifugal Liquid Chillers

MODEL YT (STYLE J)
R123 COOLING ONLY
WITH OPTIVIEW™ CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER & VARIABLE SPEED DRIVE

TABLE OF CONTENTS
SECTION 1 Description of System and Fundamentals of Operation
SECTION 2 OptiView Control Center
SECTION 3 Printers
SECTION 4 System Operating Procedures
SECTION 5 System Components Description
SECTION 6 Operational Maintenance
SECTION 7 Troubleshooting
SECTION 8 Maintenance
SECTION 9 Preventive Maintenance

LIST OF FIGURES
FIG. 1 – MODEL YT MILLENNIUM CHILLER
FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER
DETAIL A – COMPRESSOR PREROTATION VANES
FIG. 3 – CONTROL CENTER
FIG. 4 – HOME SCREEN
FIG. 5 – SYSTEM SCREEN
FIG. 6 – EVAPORATOR SCREEN
FIG. 7 – CONDENSER SCREEN
FIG. 8 – PURGE SCREEN
FIG. 9 – REFRIGERANT LEVEL CONTROL SCREEN
FIG. 10 – COMPRESSOR SCREEN
FIG. 11 – HOT GAS BYPASS SCREEN
FIG. 12 – SURGE PROTECTION SCREEN
FIG. 13 – PRE-ROTATION VANES CALIBRATION SCREEN
FIG. 14 – VSD TUNING SCREEN
FIG. 15 – OIL SUMP SCREEN
FIG. 16 – ELECTRO-MECHANICAL STARTER SCREEN
FIG. 17 – SOLID STATE STARTER (MOD A) SCREEN
FIG. 18 – SOLID STATE STARTER (MOD B) SCREEN
FIG. 19 – VARIABLE SPEED DRIVE SCREEN
FIG. 20 – VARIABLE SPEED DRIVE DETAILS SCREEN (All VSD except Part Number 371-02767-XXX (60 Hz) or 371-03700-XXX (50 Hz))
FIG. 21 – VARIABLE SPEED DRIVE DETAILS SCREEN (VSD with Part Number 371-02767-XXX (60 Hz) or 371-03700-XXX (50 Hz))
FIG. 22 – ADAPTIVE CAPACITY CONTROL DETAILS SCREEN
FIG. 23 – HARMONIC FILTER DETAILS SCREEN (All VSD except Part Number 371-02767-XXX (60 Hz) or 371-03700-XXX (50 Hz))
FIG. 24 – HARMONIC FILTER DETAILS SCREEN (VSD with Part Number 371-02767-XXX (60 Hz) or 371-03700-XXX (50 Hz))
FIG. 25 – SETPOINTS SCREEN
FIG. 26 – SETUP SCREEN
FIG. 27 – SCHEDULE SCREEN
FIG. 28 – USER SCREEN
FIG. 29 – COMMS SCREEN
FIG. 30 – PRINTER SCREEN
FIG. 31 – SALES ORDER SCREEN
FIG. 32 – OPERATIONS SCREEN
FIG. 33 – HISTORY SCREEN
FIG. 34 – HISTORY DETAILS SCREEN
FIG. 35 – SECURITY LOG SCREEN
FIG. 36 – SECURITY LOG DETAILS SCREEN
FIG. 37 – TREND SCREEN
FIG. 38 – TREND SETUP SCREEN
FIG. 39 – ADVANCED TREND SETUP SCREEN
FIG. 40 – COMMON SLOTS SCREEN
FIG. 41 – CUSTOM VIEW SCREEN
FIG. 42 – CUSTOM VIEW SETUP SCREEN
FIG. 43 – PRINTERS
FIG. 44 – SAMPLE PRINTOUT (STATUS)
FIG. 45 – SAMPLE PRINTOUT (SETPOINTS)
FIG. 46 – SAMPLE PRINTOUT (SCHEDULE)
FIG. 47 – SAMPLE PRINTOUT (SALES ORDER)
FIG. 48 – SAMPLE PRINTOUT (HISTORY)
FIG. 49 – SAMPLE PRINTOUT (SECURITY LOG)
FIG. 50 – SAMPLE PRINTOUT (TREND)
FIG. 51 – SAMPLE PRINTOUT (CUSTOM SCREEN REPORT)
FIG. 52 – SAMPLE PRINTOUT (ADAPTIVE CAPACITY CONTROL NEW MAP POINT REPORT)
FIG. 53 – SAMPLE PRINTOUT (ADAPTIVE CAPACITY CONTROL EXISTING MAP POINTS REPORT)
FIG. 54 – OPERATION SEQUENCE & TIMING DIAGRAM (ELECTRO-MECHANICAL & SOLID STATE STARTER APPLICATIONS)
FIG. 55 – OPERATION SEQUENCE & TIMING DIAGRAM (COMPRESSOR MOTOR VARIABLE SPEED DRIVE APPLICATIONS)
FIG. 56 – MINIMUM ENTERING CONDENSING WATER TEMPERATURE
FIG. 57 – LIQUID CHILLER LOG SHEETS
FIG. 58 – TURBOGUARD PURGE UNIT
FIG. 59 – SCHEMATIC DRAWING (YT) COMPRESSOR LUBRICATION SYSTEM
FIG. 60 – OIL RETURN SYSTEM
FIG. 61 – ASSEMBLY OF DEHYDRATOR
FIG. 62 – CHARGING OIL RESERVOIR WITH OIL
FIG. 63 – EVACUATION OF CHILLER
FIG. 64 – SATURATION CURVE
FIG. 65 – DIAGRAM - MEGGING MOTOR WINDINGS
FIG. 66 – MOTOR STATOR TEMPERATURE & INSULATION RESISTANCES
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Model YK Centrifugal Liquid Chillers Style G
250 THROUGH 3000 TONS
(879 through 10,500 kW)
Utilizing R-134a
Heat Recovery
Flooded Evaporator & Hybrid Falling Film Evaporator

Table of Contents


FORM 160.75-EG1 (512
Introduction
Ratings
Sustainability Focus
OptiView Control Center
Equipment Overview
Accessories and Modifications
Application Data
Dimensions (Ft. - In.) - Unit
Dimensions (Ft. - In.) - Nozzle Arrangements
Weights - English
Dimensions (mm) - Unit
Dimensions (mm) - Nozzle Arrangements
Weights - SI
Guide Specifications
SI Metric Conversion
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AUX SERVICE MANUAL Modular Chiller (R22 50HZ)

Table of Contents
1. Overview
1.1 Naming rule
1.2 Technical data
1.3 System principle drawing
1.3.1 Systematic schematic diagrams for smart series
1.4 Outline Dimension
1.5 Electric Philosophy Disgram
2. Design guide for Air-Cooling Cold (Hot) Water Module-Model Unit
2.1 Determination of design parameter
2.1.1 Outdoor design parameter
2.1.2 Indoor Design Parameter
2.2 Principle of Loading Calculation and Selection
2.2.1 Determine indoor air conditioner area
2.2.2 Determine cold load index for unit area
2.2.3 Determination of cofficient of simultaneous use
2.2.4 Determination and air conditioner and main model selective
2.2.5 Selective ancillary electric heater
2.3 Design principle of water system
2.3.1 As balanceble as possible for hydraulic force
2.3.2 Avoid large flow rate but small difference in temperature
2.3.3 Expansion supplement water and drainage and exhaust in water system
2.3.4 Water treatment and filtering in water system
2.4 Heat stability of water system
2.4.1 Heat stability of water system
2.4.2 Calculation of system water capacity
2.4.3 Thermal stability requirement of system
2.4.4 Minimum capacity of requirement of system
2.5 Installation manner of water system
2.5.1 Closed type cold and hot water system
2.5.2 Cold and hot water system of open expansion watertank
2.6 Water conduit design
2.6.1 Basic requirement of water conduit design
2.6.2 Design the circulation conduit system subject to building structure
2.7 Design and select and configuration of the pipe, pipe material and pipe caliber
2.7.1 Pipe design
2.7.2 Select and seal connection for pipe material
2.7.3 Determination of caliber
2.8 Design and installation of expansion water tank
2.8.1 Type selective and design of expansion water tank
2.8.2 Installation of expansion water tank
2.9 Design of condesating water discharge system
2.9.1 Condesating water discharge system
2.9.2 Determination of pipe material and pipe caliber for condesating water
2.9.3 Arrangement of condesating water pipe
2.9.4 Concentration drainage tubing and connection
2.9.5 Bracket pitch of condesating water pipe
2.10 Constitution of construction program
3. Installation Manual for Air-Cooled Cold (Hot) Water Unit of Mudular Type
3.1 Installation of main unit
3.1.1 Preparation before installation
3.1.2 Location selection requirement
3.1.3 Lifting and hailing of the unit
3.1.4 Requirements and points for attention while unit installation
3.2 Installation of the circulation conduit
3.3 Electric standard requirement
3.3.1 Electric standard requirement:
3.3.2 Electric correlative standard requirement
3.3.3 Standard requirement of switch electric appliance
3.3.4 Standard requirement of line distribution
3.3.5 Standard requirement for wiring
3.3.6 Earthing requirement
3.3.7 Control layout
3.3.8 Selection of the conduit
3.3.9 Conduit requirement
3.3.10 Fixing spacing of conduit (see the table as followed)
3.3.11 Minimum spacing between electric line and other pipes (see the table as followed)
3.4 Hydraulic test and heat preservation of pipe
3.4.1 Hydraulic test
3.4.2 Heat insulation of pipe
3.5 Injection and commissioning of cold medium water
3.5.1 System cleanout and injection of cold medium water
3.5.2 Inspection before commmissioning
3.5.3 Commissioning
3.5.4 Examination of protection and temperature control
3.5.5 Unit operation condition
3.5.6 Unit normal operation
3.6 Project acceptance and maintenance
3.6.1 Project acceptance
3.6.2 Maintenance
4.Instruction of controller for module-type air cool cold (hot) water unit
4.1 Instruction of bi-system controller for module-type unit
4.1.1 System description
4.1.2 Parameter set
4.1.3 Parameters for system operation temperature
4.1.4 Parameters of system operation time
4.1.5 Protection temperature parameters
4.1.6 Time protection parameters
4.1.7 Frost parameter
4.1.8 Failure protection under cold generation work
4.1.9 Failure protection under heat generation condition
4.1.10 Unfreezing operation
4.1.11 System failure protection and code
4.2 Instruction of quadri-system controller for module-type unit
4.2.1 System description
4.2.2 Parameter set
4.2.3 Failure protection under cold generation
4.2.4 Failure protection under heat generation
4.2.5 Unfreezing operation
4.2.6 System failure protection and code
4.3 Instruction of expansion module controller for electronic expansion valve
4.3.1 Interface description of electronic expansion controller
4.3.2 Parameter set
4.3.3 Frost unfreezing
4.3.4 Orientation
4.3.5 Malfunction
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OptiChill Air Cooled Screw Chiller 500 kW - 1100 kW

Contents
Warranty
HEALTH AND SAFETY
ENVIRONMENTAL CONSIDERATIONS
Freeze Protection
Environmental Policy
GENERAL DESCRIPTION
Unit identification
Introduction
Features
Standard Features
Optional extras
DESIGN FEATURES & INFORMATION 17
Pipework design
Refrigeration schematic
Economiser
Pumps options
Electronic expansion valves (EEV)
Star/delta starting of 3 phase compressors
Minimum system water volume calculations
CONTROLS
General description
Temperature control
Monitoring
Alarm handling
PERFORMANCE DATA
Operating limits
Typical part load characteristics
ESEER calculations
Capacity data - high efficiency
Capacity data - high efficiency plus
Glycol data
Waterside pressure drop (kPa)
Pump packages (optional extras)
SOUND DATA
Measurement of sound data
Global chiller sound level values - high efficiency
Global chiller sound level values - high efficiency plus
GENERAL SPECIFICATION
Mechanical data - high efficiency
Mechanical data - high efficiency plus
Electrical data - high efficiency
Electrical data - high efficiency plus
DIMENSIONAL DATA
Standard Units
Units fitted with optional pump package
Plenum options
INSTALLATION DATA 61
Weights, point loadings & centre of gravity (C of G) - no pumps
Weights - with optional pumps (guidance)
Unit Lifting
Positioning
Anti vibration mounting (optional)
Water system
Standard recommended installation
Electrical
Interconnecting wiring
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Service Manual MINI-CHILLER EWA(Y)Q005~007A*V3

Table of Contents
1 Introduction
1.1 About This Manual
Part 1
System Outline
1 General Outline: Mini-chiller
1.1 What Is in This Chapter?
1.2 EWA(Y)Q005~007A*V3: Outlook and Dimensions
1.3 EWA(Y)Q005~007A*V3: Installation and Service Space
2 Specifications
2.1 What Is in This Chapter?
2.2 EWA(Y)Q005~007A*V3
3 Functional Diagrams
3.1 What Is in This Chapter?
3.2 Pipe Connection Diameters
4 Piping Diagrams
4.1 What Is in This Chapter?
4.2 EWA(Y)Q005~007A*V3
5 Switch Box Layout
5.1 What Is in This Chapter?
5.2 EWA(Y)Q005~007A*V3 (Outdoor)
5.3 EWA(Y)Q005~007A*V3 (Hydro-kit)
6 Wiring Diagrams
6.1 What Is in This Chapter?
6.2 EWA(Y)Q005~007A*V3
7 PCB Layout
7.1 What Is in This Chapter?
7.2 EWA(Y)Q005~007A*V3 (Outdoor)
7.3 EWA(Y)Q005~007A*V3 (Hydro-kit)
Part 2
Functional Description
1 General Functionality
1.1 What Is in This Chapter?
1.2 Preheating Operation
1.3 Four Way Valve Switching
1.4 Freeze-up Protection Control
2 Hydro-kit Functional Concept
2.1 What Is in This Chapter?
2.2 Defrost Control
2.3 Forced Operation Model
3 Outdoor Unit Functional Concept
3.1 What Is in This Chapter?
3.2 Frequency Principle
3.3 Frequency Control
3.4 Controls at Mode Changing / Start-up
3.5 Discharge Pipe Temperature Control
3.6 Input Current Control
3.7 Heating Peak-cut Control
3.8 Fan Control
3.9 Liquid Compression Protection Function 2
3.10 Low Hz High Pressure Limit
3.11 Electronic Expansion Valve Controll
3.12 Malfunctions
Part 3
Troubleshooting
1 Troubleshooting
1.1 What Is in This Chapter?
1.2 Procedure of Self-Diagnosis by Remote Controller
1.3 Fault-diagnosis by Remote Controller
1.4 Overview of Error Codes
2 Error Codes: Hydro-kit
2.1 What Is in This Chapter?
2.2 “A1” Hydro-kit PCB Abnormality
2.3 “A5” Freeze-up Protection Control or High Pressure Control
2.4 “C4, 81, 80” Thermistor or Related Abnormality (Hydro-kit)
3 Error Codes: Outdoor Units
3.1 What Is in This Chapter?
3.2 “E1” Outdoor Unit PCB Abnormality
3.3 “E5” OL Activation (Compressor Overload)
3.4 “E6” Compressor Lock
3.5 “E7” DC Fan Lock
3.6 “E8” Input Over Current Detection
3.7 “EA” Four Way Valve Abnormality
3.8 “F3” Discharge Pipe Temperature Control
3.9 “F6” High Pressure Control in Cooling
3.10 “H0” Compressor Sensor System Abnormality
3.11 “H6” Compressor Startup Failure
3.12 “H8” CT or Related Abnormality
3.13 “P4, J3, J6, H9” Thermistor or Related Abnormality (Outdoor Unit)
3.14 “L3” Switch Box Temperature Rise
3.15 “L4” Radiation Fin Temperature Rise
3.16 “L5” Output Over Current Detection
4 Error Codes: System Malfunctions
4.1 What Is in This Chapter?
4.2 “U0” Insufficient Gas
4.3 “U2” Low-voltage Detection or Over-voltage Detection
4.4 “U4” Signal Transmission Error (between Hydro-kit and Outdoor Units)
4.5 “U7” Malfunction of Transmission between Remote Controller and Control box
5 Additional Checks for Troubleshooting
5.1 What Is in This Chapter?
5.2 Fan Motor Connector Output Check
5.3 Electronic Expansion Valve Check
5.4 Four Way Valve Performance Check
5.5 Thermistor Resistance Check
5.6 Installation Condition Check
5.7 Discharge Pressure Check
5.8 Outdoor Unit Fan System Check (With DC Motor)
5.9 Power Supply Waveforms Check
5.10 Inverter Units Refrigerant System Check
5.11 Capacitor Voltage Check
5.12 Power Transistor Check
5.13 Main Circuit Electrolytic Capacitor Check
5.14 Turning Speed Pulse Input on the Outdoor Unit PCB Check
5.15 “Inverter Checker” Check
Part 4
Commissioning and Test Run
1 Pre-Test Run Checks
1.1 What Is in This Chapter?
1.2 Test Run Checks for Water Pipework
1.3 General Test Run Checks
2 Field settings
2.1 What Is in This Chapter?
2.2 How to Change the Field Settings with the Wired Remote Controller
2.3 Overview of the Field Settings by Remote Control
2.4 Field Setting by Dip Switches from Hydro-kit
3 Operation Range and Test Operation
3.1 Operation Range
3.2 Test Operation
3.3 External Static Pressure Chart
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