ATTACHMENT_J-7.pdf

Operation and Maintenance Manual

York Air Cooled YVAA Chiller

Kayenta Hospital

EQUIPMENT: A\C Chillers

UNIT TAGS: CH-1, CH-2

QUANTITY: 2

Chiller Equipment: Johnson Controls Inc.

2032 w. 4th Street Tempe, AZ 85281

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ATTACHMENT J-7

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AIR-COOLED SCREW

LIQUID CHILLERS

INSTALLATION, OPERATION, MAINTENANCE Supersedes: 201.28-NM1.1 (114) Form 201.28-NM1.1 (514)

Issue Date:

May 30, 2014

HFC-134A

LD15045

150 - 500 TONS

525 - 1750 KW

2 COMPRESSOR

50 AND 60 HZ

MODEL YVAA STYLE A

AIR-COOLED SCREW LIQUID CHILLERS WITH

VARIABLE SPEED DRIVE

FRAME SIZES 015 - 052

035-23219-100

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ATTACHMENT J-7

JOHNSON CONTROLS2

FORM 201.28-NM1.1

ISSUE DATE: 5/30/2014

This equipment is a relatively complicated apparatus.

During installation, operation maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and respon-sibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

which it is situated, as well as severe personal injury or death to themselves and people at the site.

This document is intended for use by owner-authorized operating/service personnel. It is expected that these individuals possess independent training that will en-able them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood this document and any referenced mate-rials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question.

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to specific situations:

Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken.

Indicates a potentially hazardous situa-tion which will result in possible injuries or damage to equipment if proper care is not taken.

Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollu-tion if proper care is not taken or instruc-tions and are not followed.

Highlights additional information useful to the technician in completing the work being performed properly.

External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accor-dance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warn-ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

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In complying with Johnson Controls’ policy for con-tinuous product improvement, the information con-tained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office.

Operating/service personnel maintain responsibility for the applicability of these documents to the equipment.

If there is any question regarding the applicability of

The Control/VSD Cabinet contains lethal high AC and DC voltages. Before per-forming service inside the cabinet, remove the AC supply feeding the chiller and verify using a non-contact voltage sensor.

The DC voltage on the VSD DC Bus will take 5 minutes to bleed off, after AC power is removed. Always check the DC Bus Voltage with a Voltmeter to assure the capacitor charge has bled off before working on the system.

NEVER short out the DC Bus to dis-charge the filter capacitors.

NEVER place loose tools, debris, or any objects inside the Control Panel/VSD Cabinet.

NEVER allow the Control Panel VSD Cabinet doors to remain open if there is a potential for rain to enter the panel.

Keep doors closed and assure all latches are engaged on each door unless the unit is being serviced.

ALWAYS lockout the disconnect supply-ing AC to the chiller.

The 1L Line Inductor will reach operating temperatures of over 150°C (300°F.) DO NOT open panel doors during operation.

Assure the inductor is cool whenever working near the inductor with power

OFF.

these documents, the technician should verify whether the equipment has been modified and if current litera-ture is available from the owner of the equipment prior to performing any work on the chiller.

CHANGE BARS

Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made. These revisions are to technical in-formation and any other changes in spelling, grammar or formatting are not included.

CHANGEABILITY OF THIS DOCUMENT

ASSOCIATED LITERATURE

MANUAL DESCRIPTION FORM NUMBER

Equipment Pre-Startup and Startup Checklist 201.28-CL2

YVAA Frame Size 015 - 027, 2 Compressor 60 Hz (150-275 Tons) YVAA Frame Size 054 - 098, 2 Compressor 50 Hz (525-950 KW)

201.28-RP1

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TABLE OF CONTENTS

SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY

Introduction Warranty Quality Assurance and Safety Fluorinated Greenhouse Gases 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

SECTION 2 - PRODUCT DESCRIPTION

General System Description Semi-Hermetic YORK Twin-Screw Compressors Evaporator Condenser Refrigerant Circuit Electrical Building Automation System Capabilities Microcomputer Control Center

Display Data Programmable Setpoints

Accessories and Options Sound Attenuation

Fan Options Condenser Coils

Condenser Coil Protection Protective Chiller Panels Evaporator Options Controls Options General Options Vibration Isolation

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TABLE OF CONTENTS (CONT'D)

SECTION 3 - HANDLING AND STORAGE

Delivery and Storage Inspection Moving the Chiller Lifting Weights Lifting Unit Unit Removal From Shipping Container Lifting Using Lugs Lifting Using Shackles

SECTION 4 - INSTALLATION

Location Requirements Outdoor Installations Location Clearances

Recommended Minimum Clearances Vibration Isolators

Installation Shipping Braces Chilled Liquid Piping

General Requirements Water Treatment Pipework Arrangement Minimum Water Volume Leaving Water Temperature Out of Range Flow Rate Out of Range Thermal Storage Variable Primary Flow Connection Types and Sizes Evaporator Connections

Option Flanges Refrigerant Relief Valve Piping Electrical Connection Power Wiring Power Supply Wiring 115VAC Control Supply Transformer Control 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

Power Supply Wiring Voltage Utilization Range

Customer Control Wiring

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TABLE OF CONTENTS (CONT'D)

SECTION 5 - TECHNICAL DATA

Nomenclature Elastometric Isolator Installation Elastometric Isolator Specifications One Inch Deflection Isolator Installation One Inch Deflection Spring Isolator Specifications Two Inch Deflection Isolator Installation And Adjustment Two Inch Deflection, Restrained Spring Isolator Specifications Elastometric Isolator Installation (GB Certified Units) Elastometric Isolator Specifications (GB Certified Units) Specifications One Inch Deflection Isolator Installation (GB Certified Units) One Inch Deflection Isolator Installation (GB Certified Units) Specifications Two Inch Deflection Isolator Installation And Adjustment Two Inch Deflection, Restrained Spring Isolator Specifications

SECTION 6 - COMMISSIONING

Preparation

Inspection Refrigerant Charge Correct System Refrigerant Charge Service and Oil Line Valves Compressor Oil Fans Isolation / Protection Control Panel Power Connections Grounding Water System Flow Switch Temperature Sensor(s) Programmed Options Programmed Settings Date and Time Start/Stop Schedule Setpoint and Remote Offset

First Time Start Up Interlocks Unit Switch Startup Oil Pressure Loading Condenser and Fan Rotation System Charge General Operation

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SECTION 7 - OPERATION

Operating Controls

Unit Switch Keypad Keypad Data Entry Mode Display Anti-recycle Timer Evaporator Pump Control Evaporator Heater Control Alarms Chiller Run Contact Flow Switch Control Remote Run / Stop

Basic Operating Sequence Start Sequence and Loading

Unit Warning Unit Warning Operation Low Battery Warning Invalid Number of Compressors Warning Invalid Serial Number Warning

Unit Safeties Unit Safety Operation High Ambient Temp Fault Low Ambient Temp Fault Low Leaving Chilled Liquid Temp Fault VSD Communications Failure Fault

System Safeties (Faults) System Safety (Fault) Operation High Discharge Pressure Cutout (Software) Fault High Discharge Pressure Cutout (HPCO) (Hardware) Fault Low Suction Pressure Cutout (Software) Fault Low Motor Current Cutout Fault High Differential Oil Pressure Cutout Fault Low Differential Oil Pressure Cutout Fault High Discharge Temperature Cutout Fault Low Discharge Superheat Cutout Fault Sensor Failure Cutout Fault High Motor Temperature Cutout Fault System Control Voltage Cutout Fault Eductor Clog Fault

TABLE OF CONTENTS (CONT'D)

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SECTION 8 - MICROPANEL

Unit Data Key System Data Keys 1 Through 4 VSD Data Key Operating Hours / Start Counter Key History Key Setpoints Key Program Key Options Key Date/Time and Schedule Keys Manual Override Key Print Key System Switches Key

SECTION 9 - MAINTENANCE

General Requirements

Weekly Maintenance Unit Status Refrigerant Leaks Operating Conditions Compressor Oil Level Refrigerant Charge Adding Charge to a System

Refrigerant Removal, Evacuation and Charging a YVAA Chiller Refrigerant Removal Evacuating a System Charging Refrigerant into a System

Microchannel Coil Cleaning Scheduled Maintenance

Maintenance Requirements for YVAA Chillers

SECTION 10 - DECOMMISSIONING, DISMANTLING AND DISPOSAL

NOTES

Temperature

TABLE OF CONTENTS (CONT'D)

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ATTACHMENT J-7

JOHNSON CONTROLS10

ISSUE DATE: 5/30/2014

LIST OF FIGURES

FIGURE 1 - YVAA Air-Cooled Screw Liquid Chiller with Variable Speed Drive FIGURE 2 - Chiller Control System FIGURE 3 - View of York Control Center User Interface FIGURE 4 - Proper Lifting of YVAA Chiller FIGURE 5 - Acceptable Minimum Clearances Around/Between Unit(s) FIGURE 6 - Pipework Arrangement FIGURE 7 - Leaving Water Temperature Out of Range Suggested Layout FIGURE 8 - Suggested Layout For Applications With A Flow Rate Less Than The Evaporator Minimum Allowable

Flow Rate FIGURE 9 - Suggested Layout For Applications With A Flow Rate Less Than The Evaporator Minimum Allowable

Flow Rate FIGURE 10 - Victaulic Groove FIGURE 11 - Flange For GB Vessels FIGURE 12 - Flange Attachment FIGURE 13 - Power Wiring - 2 Compressor Connections FIGURE 14 - Customer Control Connections FIGURE 15 - YVAA Dimensions FIGURE 16 - Keyboard and Display

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LIST OF TABLES

TABLE 1 - Minimum Evaporator Tube Removal Clearance TABLE 2 - Evaporator Connections Dimensions TABLE 3 - Electrical Lug Data TABLE 4 - Physical Data - Microchannel Coil TABLE 5 - Physical Data - Round Tube coil TABLE 6 - Unit Rigging TABLE 7 - Isolator Selection and Mounting Locations TABLE 8 - Low Differential Oil Pressure Cutout TABLE 9 - Start Inhibit Sensor Thresholds TABLE 10 - Sensor Min/Max Outputs TABLE 11 - Setpoint Limits TABLE 12 - Programmable Operating Parameters TABLE 13 - Printout Types TABLE 14 - Troubleshooting Guide TABLE 15 - Temperature Input Voltage Sensor (Measured Signal To Shield At The Sensor) TABLE 16 - Outside Air Temperature Sensor Input Voltage (Measured Signal To Shield At The Sensor) TABLE 17 - Pressure Transducer Output Voltage (Measured Signal To Return At The Transducer) TABLE 18 - Motor Temperature Sensor Resistance (Check At The Motor) TABLE 19 - SI Metric Conversion

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1SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY

INTRODUCTION

YORK YVAA chillers are manufactured to the highest design and construction standards to ensure high per-formance, reliability and adaptability to all types of air conditioning installations.

The unit is intended for cooling water or glycol solu-tions and is not suitable for purposes other than those specified in this manual.

This manual contains all the information required for correct installation and commissioning of the unit, to-gether with operating and maintenance instructions.

The manual should be read thoroughly before attempt-ing to operate or service the unit.

All procedures detailed in the manual, including in-stallation, 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, commission-ing, operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manual.

WARRANTY

Johnson Controls warrants YVAA chillers in accor-dance with the "Limited Warranty Engineered Systems Equipment" procedure, Form 50.05-NM2.

Johnson Controls warrants all equipment and materi-als against defects in workmanship and materials for a period of eighteen months from date of shipment or 12 months from date of startup, whichever comes first, unless labor or extended warranty has been purchased as part of the contract.

The warranty is limited to parts only replacement and shipping of any faulty part, or sub-assembly, which has failed due to poor quality or manufacturing errors. All claims must be supported by evidence that the failure has occurred within the warranty period, and that the unit has been operated within the designed parameters specified.

All warranty claims must specify the unit model, serial number, order number and run hours/starts. Model and serial number information is printed on the unit identi-fication plate.

The unit warranty will be void if any modification to the unit is carried out without prior written approval from Johnson Controls.

For warranty purposes, the following conditions must be satisfied:

• The initial start of the unit must be carried out by trained personnel from an authorized Johnson Controls Service Center. Refer to SECTION 6 - COMMISSIONING for more information.

• Only genuine YORK approved spare parts, oils, coolants, and refrigerants must be used.

• All the scheduled maintenance operations detailed in this manual must be performed at the specified times by suitably trained and qualified personnel.

See SECTION 9 - MAINTENANCE for more in-formation.

• Failure to satisfy any of these conditions will automatically void the warranty. Refer to Form 50.05-NM2 for complete details.

QUALITY ASSURANCE AND SAFETY

YVAA chillers are designed within EN ISO 9001 and built within an EN ISO 9002 accredited manufacturing organization.

Units conform with the following European Directives:

• Machinery Directive (2006/42/EC)

• EMC Directive (2004/108/EC)

• Pressure Equipment Directive (97/23/EC)

• Low Voltage Directive (2006/95/EC)

• Safety Code for Mechanical Refrigeration

(EN378-2(2008))

CE/PED marked units conform to the following stan-dards:

• Machinery Directive (2006/42/EC).

• EMC Directive (2004/108/EC).

• Pressure Equipment Directive (97/23/EC).

• Low Voltage Directive (2006/95/EC).

• Safety Code for Mechanical Refrigeration

(EN378-2(2008)).

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SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY

FORM 201.28-NM1.1

ISSUE DATE: 5/30/2014

ETL/ASME marked units conform to the following standards:

• ANSI/ASHRAE 15 – Safety Code for Mechanical Refrigeration.

• ANSI/ASHRAE 34 – Number Designation and Safety Classification of Refrigerants.

• ANSI/NFPA 70 – National Electrical Code (N.E.C.).

• ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.

GB marked units conform to the following standards:

• GB5226.1 Safety of machinery- Electrical equip-ment of machines – Part 1: General requirements.

• GB25131 Safety requirements for water chiller (heat pump) using the vapor compression cycle.

FLUORINATED GREENHOUSE GASES

• This equipment contains fluorinated greenhouse gases covered by the Kyoto Protocol.

• The global warming potential of the refrigerant (HFC-134a) used in this unit is 1300.

• The refrigerant quantity is stated in Table 4 on Page 52 of this document.

• The fluorinated greenhouse gases in this equip-ment may not be vented to the atmosphere.

• This equipment should only be serviced by quali-fied technicians.

RESPONSIBILITY FOR SAFETY

Every care has been taken in the design and manufac-ture of the unit to ensure compliance with the safety requirements listed above. However, the individual operating or working on any machinery is primarily responsible for:

• Personal safety, safety of other personnel, and the machinery.

• Correct utilization of the machinery in accordance with the procedures detailed in the manual.

ABOUT THIS MANUAL

The contents of this manual include suggested best working practices and procedures. These are issued for guidance only, and they do not take precedence over the above stated individual responsibility and/or local safety regulations.

This manual and any other document supplied with the unit are the property of Johnson Controls which re-serves all rights. They may not be reproduced, in whole or in part, without prior written authorization from an authorized Johnson Controls representative.

MISUSE OF EQUIPMENT

Suitability for Application The unit is intended for cooling water or glycol solu-tions and is not suitable for purposes other than those specified in these instructions. Any use of the equip-ment other than its intended use, or operation of the equipment contrary to the relevant procedures may re-sult in injury to the operator, or damage to the equip-ment.

The unit must not be operated outside the design pa-rameters specified in this manual.

Structural Support Structural support of the unit must be provided as in-dicated in these instructions. Failure to provide proper support may result in injury to the operator, or damage to the equipment and/or building.

Mechanical Strength The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or structures. Ad-ditional components must not be mounted on the unit.

Any such extraneous loads may cause structural failure and may result in injury to the operator, or damage to the equipment.

General Access There are a number of areas and features, which may be a hazard and potentially cause injury when working on the unit unless suitable safety precautions are taken.

It is important to ensure access to the unit is restricted to suitably qualified persons who are familiar with the potential hazards and precautions necessary for safe operation and maintenance of equipment containing high temperatures, pressures and voltages.

Pressure Systems The unit contains refrigerant vapor and liquid under pres-sure, release of which can be a danger and cause injury.

The user should ensure that care is taken during installa-tion, operation and maintenance to avoid damage to the pressure system. No attempt should be made to gain ac-cess to the component parts of the pressure system other than by suitably trained and qualified personnel.

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FORM 201.28-NM1.1

ISSUE DATE: 5/30/2014

1Electrical The unit must be grounded. No installation or main-tenance work should be attempted on the electrical equipment without first switching power OFF, isolat-ing and locking-off the power supply. Servicing and maintenance on live equipment must not be attempted.

No attempt should be made to gain access to the con-trol panel or electrical enclosures during normal opera-tion of the unit.

Caution:

This equipment (Class A, Group 1) is designed and manufactured for use in an industrial environment, in accordance with EN 61000-6-2:2005 and EN 61000-6 4:2007 (with EN 55011:2007 limits). It is not intended to be used on a low-voltage public network which sup-plies domestic premises. Radio frequency interference may occur if it is used on a lowvoltage public network.

This equipment equipped with VSD, may generate conducted and radiated disturbances, which may inter-fere with or damage susceptible connected apparatus.

Generally accepted engineering standards and practic-es should be followed to ensure trouble-free and EMC compliant electrical installation. Installations must be supervised or completed by a competent person in ac-cordance with EN 13313.

Special considerations depending on the application:

• Industry standard grounding or “earthing” prac-tices for the equipment and installation

• Use of shielded or special cables (power and/or control)

• Use of metallic conduit and/or cable trays for power and control cables connected to equipment

• Cable segregation (in order to avoid the risk of crosstalk or cross interference to signal cables, the power cables shall be segregated from signal cables)

• Dedicated isolation transformer

• Use of additional EMC fi lters

It is the responsibility of a designated System Integra-tor to take proper steps assuring the Electromagnetic Compatibility of both equipment and installation as a system.

Rotating Parts Fan guards must be fitted at all times and not removed unless the power supply has been isolated. If ductwork is to be fitted, requiring the wire fan guards to be re-moved, alternative safety measures must be taken to protect against the risk of injury from rotating fans.

Sharp Edges The fins on the air-cooled condenser coils have sharp metal edges. Reasonable care should be taken when working in contact with the coils to avoid the risk of minor abrasions and lacerations. The use of gloves is recommended.

Frame rails, brakes, and other components may also have sharp edges. Reasonable care should be taken when working in contact with any components to avoid risk of minor abrasions and lacerations.

Refrigerants and Oils Refrigerants and oils used in the unit are generally non-toxic, non-flammable and non-corrosive, and pose no special safety hazards. Use of gloves and safety glasses is, however, recommended when working on the unit.

The buildup of refrigerant vapor, from a leak for ex-ample, does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation.

High Temperature and Pressure Cleaning High temperature and pressure cleaning methods (e.g. steam cleaning) should not be used on any part of the pressure system as this may cause operation of the pressure relief device(s). Detergents and solvents, which may cause corrosion, should also be avoided.

Emergency Shutdown In case of emergency , the control panel is fitted with an incoming supply circuit breaker with a red and yel-low handle which can be used as the emergency stop device. When operated it removes the electrical supply to the inverter, fans, and control circuit thus shutting down the unit.

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FORM 201.28-NM1.1

ISSUE DATE: 5/30/2014

Safety Labels White symbol on blue background.

For safe operation, read the Instructions first.

Black symbol on yellow background.

Warning: This machine may start auto-matically without prior warning

Black symbol on yellow background.

Warning: Hot surface.

Black symbol on yellow background.

Warning: Safety relief valve may dis-charge gas or liquid without prior warning.

Black symbol on yellow background.

Warning: Isolate all electrical sources of supply before opening or removing the cover, as lethal voltages may exist.

Black symbol on yellow background.

General attention symbol.

Black symbol on yellow background.

Warning: On isolating the supply it may take up to 300 seconds for the capacitor voltage to fall below 50 volts.

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SECTION 2 - PRODUCT DESCRIPTION

YORK YVAA HFC-134a chillers are designed for wa-ter or glycol cooling. All units are designed to be locat-ed outside on the roof of a building or at ground level.

The units are completely assembled with all intercon-necting refrigerant piping and internal wiring, ready for field installation.

Prior to delivery, the unit is pressure tested, evacuated, and fully charged with refrigerant and oil in each of the two independent refrigerant circuits. After assembly, an operational test is performed with water flowing through the evaporator to ensure that each refrigerant circuit operates correctly.

The unit structure is manufactured from heavy gauge, galvanized steel. Many external structural parts are coated with “Champagne” baked-on enamel powder paint.

All exposed power wiring is routed through liquid-tight, non-metallic conduit.

GENERAL SYSTEM DESCRIPTION

The YVAA Chiller combines the best of modern screw compressor design with the latest technology in vari-able speed drives. The result is superior control and efficiency in real world conditions. The VSD enables slowing the speed of the compressor to match the load on the system resulting in precise chilled liquid con-trol, minimized sound, maximum energy efficiency, and reduced cost of ownership. The VSD also provides soft starts with no electrical inrush. The lack of heat build-up on start also enables required off time be-tween starts to be reduced to a period of two minutes.

The YVAA Air-Cooled Screw Chiller utilizes many components, which are the same or nearly the same as a standard screw chiller of a similar size. This includes modular frame rails, condenser, fans, compressors and evaporator.

The chiller consists of two screw compressors in a cor-responding number of separate refrigerant circuits, a hybrid falling film evaporator, an air-cooled condenser, receiver/flash tanks, feed valves, oil separators, and compressor mufflers. Oil separators utilize no moving parts. Oil cooling is accomplished by refrigerant leav-ing the eductor flashing in the suction line which cools the oil, motor and compressor.

FIGURE 1 - YVAA AIR-COOLED SCREW LIQUID CHILLER WITH VARIABLE SPEED DRIVE

LD15045

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SECTION 2 - PRODUCT DESCRIPTION

FORM 201.28-NM1.1

ISSUE DATE: 5/30/2014

An integral liquid cooled, transistorized, PWM, Vari-able Speed Drive (VSD) is controlled by the chiller microprocessor control panel to start/stop, select com-pressors to run, and select compressor speed. Displace-ment Power Factor is 0. 95 at part or full load.

The chiller microprocessor communicates with the VSD Logic Board via a 3-wire RS-485 opto coupled data link. The VSD Logic Board runs the number of compressors required to meet the load and the com-pressors to the speed requested by the chiller micro-processor.

The basic system control and VSD system architec-ture is shown in Figure 2 on Page 18.

SEMI-HERMETIC YORK TWIN-SCREW

COMPRESSORS

Compressors are direct drive, semi-hermetic, rotary twin-screw type, including: muffler, temperature ac-tuated ‘off-cycle’ heater, IP55 terminal board and pre-cision machined cast iron housing.

Reliable suction gas cooled, high efficiency, accessi-ble hermetic compressor motor, full suction gas flow

FIGURE 2 - CHILLER CONTROL SYSTEM

LD15028

INPUTS

Pressure Transducers Temperature Sensors Switches

Liquid Flow High Pressure Start/Stop Level

Customer Supplied Contacts

CONTROL

PANEL

Chiller Control Board)

Microprocessor User Interface Display and

Keypad

DISPLAY KEYPAD MOTOR

OUTPUTS

Relay Output Board)

Solenoids Contactors

Alarm Pump

Compressor Heater Run Status

Evaporator Heater

VSD

VSD Logic Board

SCR Trigger Board Power Components

PWM (Speed Control)

COMMUNICATIONS

Building Automation

Printer Modem

LD15158

3 Phase Power Line

AC/DC Rectifier Power Driver

IGBT Gate Driver

VSD Logic Board

Inverter

PWM Signal

Signal From Main Control Panel

Rectifier

Compressor 1

Compressor 2

Rectifier Controller SCR Trigger Board

(IGBT)

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FORM 201.28-NM1.1

ISSUE DATE: 5/30/2014

through mesh screen filter, with inherent internal ther-mal overload protection and external current overload on all three phases.

Continuous function, microprocessor controlled, Vari-able Speed Drive (VSD) shall provide valve-less, smooth capacity control from 100% down to 10% of chiller capacity.

In addition, elimination of the slide valve and associ-ated unloading components has resulted in a 50% re-duction in compressor moving parts.

EVAPORATOR

The evaporator is a shell and tube, hybrid falling film type heat exchanger. It contains a balance of flooded and falling film technology to optimize efficiency, min-imize refrigerant charge, and maintain reliable control.

A specifically designed distribution system provides uniform refrigerant flow for optimum performance.

CONDENSER

The YVAA introduces micro-channel coil to the York screw compressor chiller line. The micro-channel max-imizes condenser heat transfer, resulting in a smaller footprint, and reduces refrigerant charge by as much as 50%.

Each condenser coil is a single piece all aluminum construction including headers, tubes and fins to avoid galvanic corrosion due to dissimilar metals. Coils and headers are brazed as one piece. Integral sub-cooling is included. The design working pressure is 25.9 barg.

Multiple, standard low sound, high efficiency, TEAO motor driven fans move air through the coils. They are dynamically and statically balanced, direct drive with corrosion-resistant glass fiber reinforced composite blades molded into low-noise, full airfoil cross sec-tions, providing vertical air discharge from extended orifices for efficiency and low sound.

Fan motors are Totally Enclosed Air-Over (TEAO), squirrel-cage type and current protected. The direct drive motors feature double-sealed and permanently lubricated ball bearings, cutting down on maintenance cost over the life of the unit.

REFRIGERANT CIRCUIT

An independent refrigerant circuit is provided per compressor. Each circuit uses copper refrigerant pipe formed on computer controlled bending machines to reduce the number of brazed joints resulting in a reli-able and leak resistant system.

• Discharge lines are provided with a manual com-pressor shutoff service valve (See Accessories and Options on Page 21 for suction line service valve).

• The external oil separators, with no moving parts and designed for minimum oil carry-over, are mounted in the discharge line of the compressor.

• Liquid line components include: high absorp-tion removable core filter-drier, sight glasses with moisture indicators, manual shut-off valve with charging port, orifice and electronic expansion valve.

• An economizer (flash) tank is located in each re-frigerant circuit to increase the system efficiency.

ELECTRICAL

Johnson Controls has over 25 years of experience de-signing variable -speed drives specifically for chiller applications. The result is an extremely reliable air-cooled chiller system that offers industry leading ef-ficiency at real world operating conditions, valve-less compressor loading/unloading, excellent capacity con-trol, high power factor and soft start..

Incoming single point power is standard utilizing a lockable circuit breaker, 115VACcontrol transformer, VSD, fan contactors, ON/OFF unit switch, microcom-puter keypad and display, Chiller Control and VSD Logic boards, and relay boards.

Standard design includes IP55 rating, powder painted steel cabinet with hinged, latched, and gasket sealed outer doors equipped with wind struts for safer servic-ing. The panel includes a control display access door so that display and control features can be accessed with-out opening main cabinet doors.

All exposed power wiring is routed through liquid-tight, UV-stabilized, non-metallic conduit.

BUILDING AUTOMATION SYSTEM

CAPABILITIES

The E-Link Gateway provides an economical and ver-satile connection between York equipment and open/ standard protocols. It efficiently manages the commu-nication protocols currently used by York equipment, exposing the data in a consistent, organized, and de-fined fashion. The E-Link Gateway is available as a

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field-installed option on YVAA. A simple switch se-lection allows configuration of the required equipment profile and output protocol, which reduces equipment connectivity startup time.

MICROCOMPUTER CONTROL CENTER

The microcomputer control center (see Figure 3 on Page 20) provides automatic control of chiller op-eration including compressor start/ stop and load/ unload anti-recycle timers, condenser fans, evapora-tor pump, evaporator heater, unit alarm contacts and run signal contacts. The microcomputer control center comes online as soon as the main power switch on the unit is switched on; immediately, the microcomputer control center will begin to check all variables with a frequency ranging from 30 seconds to almost continu-ous monitoring.

The microprocessor controls the unit’s capacity by matching the actual leaving chilled water tempera-ture (LCWT) to the user-defined setpoint. Factors that may cause the system’s actual LCWT to fluctuate are changes in ambient temperature, loop flow rate, load, and loop volume. The control system reacts to such changes by adjusting the number of compressors that are on and the loading of each compressor in order to keep the LCWT at the setpoint.

The control system logic monitors the rate at which the LCWT is approaching the setpoint to ramp up or down compressor capacity as required. The variable frequen-cy drive allows the compressor capacity to match the load.

Display Data

• Leaving Chilled Liquid Temperature

• Returning Liquid Temperature

• Ambient Temperature

• Lead System

• Compressor Capacity (% of Full Load Amps)

• VSD Output Frequency / Compressor Speed

• Compressor Run Hours

• Compressor Number of Starts

• Oil Pressure and Temperature (per Compressor)

• Evaporator Pump Status

• Evaporator Heater Status

• History Data for Last Twenty Normal Shutdowns

• History Data for Last Ten Shutdown Faults

Programmable Setpoints

• Chiller On/Off

• Chilled Liquid (Water or Glycol)

• Local or Remote Control

• Units of Measure (Imperial or SI)

• System Lead / Lag

• Remote Temperature Reset

• Remote Current Limit

• Leaving Chilled Liquid Temperature Setpoint and Range

Johnson Controls’ systems or another vendor’s systems can incorporate these setpoints and data outputs to give the customer a complete understanding of how the sys-tem is running through a Building Automation System.

Extreme Conditions - During extreme or unusual con-ditions (i.e. blocked condenser coils, ambient above scheduled maximum, etc.) the chiller control system will avoid shutdown by varying capacity. By monitor-ing motor current and suction and discharge pressures, the chiller can maintain maximum available cooling output without shutting down.

FIGURE 3 - VIEW OF YORK CONTROL CENTER

USER INTERFACE

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Unit Safeties are provided for the chiller to perform auto-reset shut down for the following conditions:

• Ambient temperature above or below allowable range

• Out of range leaving chilled liquid temperature

• Under voltage

• Flow switch operation

ACCESSORIES AND OPTIONS

All options factory mounted unless otherwise noted.

Sound Attenuation Low Noise Kits – The standard chiller configuration is equipped with low sound fans and acoustic treatments on the refrig erant lines and compressors. There are several sound attenuation options available to further reduce sound at its source thereby meeting local sound level regulations.

SilentNight™ - Due to time of day based sound regula-tions in some locations it may be desirable to force the chiller to a lower sound level on demand. The Silent- Night control option provides a control input to limit sound output of the chiller based on time of day. This feature is programmable at the chiller panel or can be controlled remotely via a signal (4-20mA or 0-10VDC) from a BAS system.

FAN OPTIONS

Ultra Quiet Fans – The chiller is equipped with spe-cially designed fans and motors to provide lower sound levels yet retain appropriate airflow. The result is re-duced fan generated sound with minimal effect on the chiller capacity or efficiency.

High Static Fans - The chiller is equipped with con-denser fans with higher power motors suitable for high external static pressure, up to 100 Pa (0.4 in. water), across condenser coils. This option should be selected if additional airflow resistance may be present due to flow restrictions such as field installed ducts, filters, sound enclosures etc. Please contact your local JCI representative for more information.

High Airflow Fans - The chiller is equipped with con-denser fans with airfoil type blades and high power mo-tors providing extra airflow across coils. In some chiller configurations, this option can provide an increase in chiller capacity at high ambient. The high airflow fans are also available with variable speed control. Please contact your local JCI representative for more information.

CONDENSER COILS

Fin and tub condenser coilds of seamless, internally-enhanced, high-condensing-coefficient, corrosion re-sistant copper tubes are arranged in staggered rows.

The tubes are mechanically expanded into aluminum fins. Integral subcooling is included. The design work-ing pressure of the coils is 350 PSIG (24 barg).

Condenser Coil Protection The aluminum alloys used in the YVAA micro-chan-nel condenser have been carefully selected and tested for high corrosion resistance. However, all metals can corrode in harsh conditions. Consider protecting coils from corrosive environments such as coastal, marine, urban and industrial.

Post-Coated Epoxy Dipped Condenser - Micro-channel condenser coils applied with electro-deposited and baked flexible epoxy coating that is finished with a polyurethane UV resistant top-coat suitable for highly corrosive applications.

Protective Chiller Panels Wire Panels – UV stabilized black polyvinyl chloride coated, heavy gauge, welded wire mesh guards mounted on the exterior of the full unit. Protects condenser coil faces and prevents unauthorized access to refrigerant components (compressors, pipes, evaporator, etc.), yet provides free air flow. This can cut installation cost by eliminating the need for separate, expensive fencing.

Louvered Panels – Louvered panels, painted the same color as the unit, enclose the unit to visually screen and protect the coils as well as preventing unauthor-ized access to internal components. Also available as a condenser-only option.

Louvered/Wire Panels Combination - Louvered pan-els, painted the same color as the unit, are mounted on external condenser coil faces. Heavy gauge, welded wire-mesh panels, coated to resist corrosion, are mounted around base of machine to restrict unauthorized access.

End Hail Guard – Louvered panels, painted the same color as the unit, are installed on the rear of the unit (opposite end of the control panel) to protect the ex-posed condenser from flying debris or hail.

V-Guard Panels – Solid panels, painted the same col-or as the unit, are installed along the sides of the units to cover exposed piping within the condenser section without impacting airflow. These guard panels can be combined with End Hail Guard option for additional protection from debris.

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Evaporator Options 38 mm insulation – Double thickness insulation pro-vided.

Flange Kit – Provides contractor with the couplings best suited to tie into the chilled water piping. All flanges are PN10.

Connection Location - The standard unit configura-tion is available with fluid inlet connections at rear (op-posite control panel end) of unit. Option available for front fluid inlet on select configurations.

Water Box Heater - The standard unit comes with freeze protection on the evaporator down to -17.8°C (0°F).The waterbox heater option provides additional freeze protection down to -28°C(-20°F). Field wired.

Controls Options High Ambient Operation – This provides special control logic coupled with high airflow fans to permit high ambient up to 52°C (125°F) operation. Fans are airfoil type blades with high power motors. This option may also allow for increased machine capacity, allow-ing the selection of a smaller chassis to meet specific capacity requirements.

Building Automation System Interface (Tempera-ture) - Factory installed option to accept a 4 to 20mA or a 0 to 10VDC input to allow remote reset of the Leaving Chilled Liquid Temperature Setpoint. The setpoint can be positively offset upwards up to 22.2°C (40°F). This option is useful for ice storage or process applications or for periods where higher chilled liquid temperatures are adequate for low loads. Available alone or in combination with BAS Load Limit.

Building Automation System Interface (Load Lim-

it) - Factory installed option to accept a 4 to 20mA or a 0 to 10VDC input to allow remote reset of the Load Limit Setpoint. The setpoint can limit system demand from 30-100%. Available alone or in combination with BAS Temperature Reset.

E-Link – The optional E-Link gateway provides com-munication between the equipment and Building Auto-mation Systems, including BACnet (MS/TP), Modbus, LON and N2.

Thermal Storage – Provides special control logic and modifications to produce leaving chilled brine tem-peratures below 4.4°C (40°F) primarily at times of low ambient temperatures (night time). Option can be used to produce ice to supplement cooling and significantly decrease energy costs. The capability of the chiller is enhanced by using both ice and chilled water simultane-ously during times of peak cooling needs.

General Options Flow Switch Accessory - Vapor proof SPDT, NEMA 3R switch, 10.3 barg (150 psig) DWP, -29°C to 121°C (-20°F to 250°F) with 1" NPT (IPS) connection for upright mount-ing in horizontal pipe. This flow switch or equivalent must be furnished with each unit. Field mounted.

Differential Pressure Switch – This 0.2-3 barg (3-45 psig) range switch, with 1/4" NPTE pressure connec-tions, is an alternative to the paddle-type flow switch.

Field mounted.

Service Isolation Valve – Service suction isolation valve added to unit for each refrigerant circuit.

Dual Pressure Relief Valve – Two safety relief valves are mounted in parallel; one is always operational to assist in valve replacement during maintenance.

Terminal Block [not available for CE marked units]

– Terminal Block connections shall be provided at the point of incoming single point connection for field connection and interconnecting wiring to the compressors. Separate external protection must be supplied, by others, in the incoming power wiring, which must comply with local codes.

Circuit Breaker – A unit-mounted circuit breaker with external lockable handle will be supplied to isolate the single point power voltage for servicing. The circuit breaker is sized to provide motor branch circuit protec-tion, short circuit protection and ground fault protec-tion for the motor branch-circuit conductors, the motor control apparatus and the motors.

Non-Fused Disconnect Switch – Unit-mounted dis-connect switch with external lockable handle can be supplied to isolate the unit power voltage for servicing.

Separate external fusing must be supplied by the power wiring, which must comply with local codes.

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Vibration Isolation Elastomeric Isolation – This option is recommended for normal installations. It provides very good perfor-mance in most applications for the least cost. Field mounted.

25 mm (1") Spring Isolators – Spring and cage type isolators for mounting under the unit base rails are available to support unit. They are level adjustable. 25 mm (1") nominal deflection may vary slightly by ap-plic ation. Field mounted.

50 mm (2") Restrained Spring Isolators – Restrained Spring-Flex Mounting isolators incorporate a rugged welded steel housing with vertical and horizontal limit stops. Housings designed to withstand a minimum 1.0g accelerated force in all directions up to 51 mm (2").

The deflection may vary slightly by application. They are level adjustable. Field mounted.

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SECTION 3 - HANDLING AND STORAGE

DELIVERY AND STORAGE

To ensure consistent quality and maximum reliability, all units are tested and inspected before leaving the fac-tory. Units are shipped completely assembled and con-taining refrigerant under pressure. Units are shipped without export crating unless crating has been speci-fied on the Sales Order.

If the unit is to be put into storage, prior to installation, the following precautions should be observed:

• The chiller must be “blocked” so that the base is not permitted to sag or bow.

• Ensure that all openings, such as water connec-tions, are securely capped.

• Do not store where exposed to ambient air tem-peratures exceeding 43°C (110°F).

• The condensers should be covered to protect the coils and fins from potential damage and corrosion, particularly where building work is in progress.

• The unit should be stored in a location where there is minimal activity in order to limit the risk of ac-cidental physical damage.

• To prevent inadvertent operation of the pressure relief devices the unit must not be steam cleaned.

• It is recommended that the unit is periodically in-spected during storage.

INSPECTION

Remove any transit packing and inspect the unit to en-sure that all components have been delivered and that no damage has occurred during transit. If any damage is evident, it should be noted on the carrier’s freight bill and a claim entered in accordance with the instructions given on the advice note.

Major damage must be reported immediately to your local Johnson Controls representative.

MOVING THE CHILLER

Prior to moving the unit, ensure that the installation site is suitable for installing the unit and is easily ca-pable of supporting the weight of the unit and all as-sociated services.

The units are designed to be lifted using shackles or safety hooks. A spreader bar or frame should be used in order to prevent damage to the unit from the lifting chains. (Refer to Figure 4 on Page 26 for hooks.)

Units are provided with lifting eyes in the sides of the base frame, which can be attached directly using con-tainer lugs, shackles or safety hooks (see Figure 4 on Page 26 for proper lifting illustration).

The unit must only be lifted by the base frame at the points provided. Never move the unit on rollers, or lift the unit using a forklift truck.

Care should be taken to avoid damaging the condenser cooling fins when moving the unit.

LIFTING WEIGHTS

For details of weights and weight distribution, refer to the data shipped in the chiller information packet and unit nameplate.

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LIFTING UNIT

Container lugs should be inserted into the holes pro-vided in the bottom of the frame rail.

Use spreader bars to avoid lifting chains hitting the chiller. Various methods of spreader bar arrangements may be used; keeping in mind the intent is to keep the unit stable and to keep the chains from hitting the chill-er and causing damage.

Never lift the chiller using a forklift or by hooking to the top rails. Use only the lift-ing holes provided.

Lifting instructions are placed on a label on the chiller and on the shipping bag.

FIGURE 4 - PROPER LIFTING OF YVAA CHILLER

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UNIT REMOVAL FROM SHIPPING

CONTAINER

1. Place a clevis pin into the holes provided at the end of each base rail on the unit. Attach chains or nylon straps through the clevis pins and hook onto a suitable lift truck for pulling the unit out of the container.(chain shown)

2. Slowly place tension on the chains or straps until the unit begins to move and then slowly pull the unit from the container. Be sure to pull straight so the sides do not scrape the container.

3. Place a lifting fixture on the forks of the lift truck and reattach the chain or strap. Slightly lift the front of the unit to remove some weight from the floor of the container. Continue pulling the unit with an operator on each side to guide the lift truck operator.

4. Pull the unit until the lifting locations are outside of the container. Place 4 X 4 blocks of wood under the base rails of the unit. Gently rest the unit on the blocks and remove the chains and lift truck.

5. Attach lifting rigging from the crane and slowly complete the removal from the container then lift up and away.

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LIFTING USING LUGS

Units are provided with lifting holes in…