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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