YCSE040-YCSE100 & YCRE040-YCRE100

INSTALLATION, COMMISSIONING,OPERATION & MAINTENANCE Form 035-21786-100 (0909)Revision 1

R407C

Aspak

WATER AND REMOTE AIRCOOLED LIQUID CHILLERS

WITH SCREW COMPRESSORSSTYLE B

(YCSE 134-320KW)(YCRE 127-307KW)

TABLE OF CONTENTS

1 SUPPLIER INFORMATION

1.1 Introduction 1.1

1.2 Warranty 1.1

1.3 Safety 1.1

1.4 Responsibility for Safety 1.2

1.5 About this Manual 1.2

1.6 Misuse of Equipment 1.2

1.7 Emergency Shutdown 1.3

1.8 Safety Labels 1.3

1.9 Material Safety Data 1.4

2 PRODUCT DESCRIPTION

2.1 Introduction 2.1

2.2 Compressor 2.1

2.3 Refrigerant Circuits 2.1

2.4 Evaporator 2.1

2.5 Condenser 2.1

2.6 Power and Control Panels 2.2

2.7 Accessories and Options 2.2

2.8 Nomenclature 2.3

2.9 Refrigerant Flow Diagram 2.4

3 TRANSPORTATION, HANDLING ANDSTORAGE

3.1 Delivery and Storage 3.1

3.2 Inspection 3.1

3.3 Moving the Unit 3.1

3.4 Lifting Weights 3.2

3.5 Weight Distribution & Centreof Gravity 3.2

4 INSTALLATION

4.1 Location Requirements 4.1

4.2 Installation of Vibration Isolators 4.1

4.3 Pipework Connection 4.1

4.4 Water Treatment 4.2

4.5 Pipework Arrangement 4.3

4.6 Connection Types & Sizes 4.3

4.7 Condenser Cooling Liquid Systems 4.4

4.8 Electrical Connection 4.5

4.9 Remote Refrigerant CondenserSystems (YCRE models only) 4.5

4.10 Power Wiring 4.8

4.11 Control Wiring 4.8

4.12 Connection Diagram 4.9

5 COMMISSIONING

5.1 Preparation 5.1

5.2 First Time Start-up 5.2

6 UNIT OPERATION

6.1 General Description 6.1

6.2 Operation 6.1

6.3 Normal Running and Cycling 6.1

6.4 Shutdown 6.1

6.5 Control System 6.1

7 MAINTENANCE

7.1 General Requirements 7.1

7.2 Daily Maintenance 7.1

7.3 Scheduled Maintenance 7.1

7.4 Pressure Vessel In-ServiceInspection 7.2

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8 TROUBLE SHOOTING

8.1 Competent Persons TroubleShooting Guide 8.1

9 TECHNICAL DATA

9.1 Flow Rate and Pressure DropGraphs 9.1

9.2 Performance Graphs 9.2

9.3 Operating Limitations 9.4

9.4 Physical Data 9.5

9.5 Electrical Data 9.6

9.6 Sound Data 9.7

9.7 Clearances and Foundations 9.8

9.8 Dimensions 9.9

10 SPARE PARTS

10.1 Renewal Parts List 10.1

10.2 Recommended Compressor Oils 10.1

10.3 Associated Drawings 10.1

11 DECOMMISSIONING. DISMANTLING ANDDISPOSAL

11.1 General 11.1

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1 SUPPLIER INFORMATION

1.1 Introduction

York YCSE/YCRE chillers are manufactured to thehighest design and construction standards to ensurehigh performance, reliability and adaptability to all typesof air conditioning installations.

The units are intended for cooling water or glycolsolutions and are not suitable for purposes other thanthose specified in this manual.

This manual contains all the information required forcorrect installation and commissioning of the unit,together with operating and maintenance instructions.The manuals should be read thoroughly beforeattempting to operate or service the unit.

All procedures detailed in the manuals, includinginstallation, commissioning and maintenance tasksmust only be performed by suitably trained and qualifiedpersonnel.

The manufacturer will not be liable for any injury ordamage caused by incorrect instal lat ion,commissioning, operation or maintenance resultingfrom a failure to follow the procedures and instructionsdetailed in the manuals..

1.2 Warranty

Johnson Controls warrants all equipment and materialsagainst defects in workmanship and materials for oneyear from initial start-up, or eighteen months fromdelivery (whichever occurs first) unless extendedwarranty has been agreed as part of the contract.

The warranty is limited to free replacement and shippingof any faulty part, or sub-assembly which has failed dueto poor quality or manufacturing errors. All claims mustbe supported by evidence that the failure has occurredwithin the warranty period, and that the unit has beenoperated within the designed parameters specified.

All warranty claims must specify the unit model, serialnumber and order number. These details are printed onthe unit identification plate, fitted on the outer edge of theoptions panel.

The unit warranty will be void if any modification to theunit is carried out without prior written approval fromJohnson Controls.

For warranty purposes, the following conditions must besatisfied:

The initial start of the unit must be carried out by trainedpersonnel from an Authorised York Service Centre.

Only genuine York approved spare parts, oils andrefrigerants must be used.

All the scheduled maintenance operations detailed inthis manual must be performed at the specified times bysuitably trained and qualified personnel.

Failure to satisfy any of these conditions willautomatically void the warranty.

1.3 Safety

Standards for Safety

YCSE/YCRE chillers are designed and built within anEN ISO 9001 accredited design and manufacturingorganisation and, within the limits specified in thismanual, are in conformity with the essential health andsafety requirements of the following European UnionDirectives:

Machinery Directive (98/37/EC)

Low Voltage Directive (2006/95/EC)

EMC Directive (2004/108/EC)

They conform to the applicable and essential safetyrequirements of Pressure Equipment Directive97/23/EC and bear CE marking.

Fluorinated Greenhouse Gases

� This equipment contains fluorinated greenhousegases covered by the Kyoto Protocol.

� The global warming potential of the refrigerant(R407C) used in this unit is 1520.

� The refrigerant quantity is stated in the PhysicalData table in Section 9 of this document.

� The fluorinated greenhouse gases in thisequipment may not be vented to the atmosphere.

� This equipment should only be serviced byqualified technicians.

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1.4 Responsibility for Safety

Every care has been taken in the design andmanufacture of the units to ensure that they meet thesafety requirements listed in the previous paragraph.However, the individual operating or working on anymachinery is primarily responsible for:

Personal safety, safety of other personnel, and themachinery.

Correct utilisation of the machinery in accordance withthe procedures detailed in the manuals.

1.5 About this Manual

The following symbols are used in this document to alertthe reader to areas of potential hazard.

A Warning is given in this document toidentify a hazard which could lead topersonal injury. Usually an instruction willbe given, together with a brief explanationand the possible result of ignoring theinstruction.

A Caution identifies a hazard which couldlead to damage to the machine, damage toother equipment and/or environmentalpollution. Usually an instruction will be given,together with a brief explanation and thepossible result of ignoring the instruction.

A Note is used to highlight additionalinformation which may be helpful to you butwhere there are no special safetyimplications.

The contents of this manual include suggested bestworking practices and procedures. These are issued forguidance only, they do not take precedence over theabove stated individual responsibility and/or local safetyregulations.

This manual and any other document supplied with theunit, are the property of Johnson Controls whichreserves all rights. They may not be reproduced, inwhole or in part, without prior written authorisation froman Authorised Johnson Controls representative.

1.6 Misuse of Equipment

Suitability for Application

The unit is intended for cooling water or glycol solutionsand is not suitable for purposes other than thosespecified in these instructions. Any use of the equipmentother than its intended use, or operation of theequipment contrary to the relevant procedures mayresult in injury to the operator, or damage to theequipment.

The unit must not be operated outside the design limitsspecified in this manual.

Structural Support

Structural support of the unit must be provided asindicated in these instructions. Failure to provide propersupport may result in injury to the operator, or damage tothe equipment.

Mechanical Strength

The unit is not designed to withstand loads or stressesfrom adjacent equipment, pipework or structures.Additional components must not be mounted on theunit. Any such extraneous loads may cause structuralfailure and may result in injury to the operator, ordamage to the equipment.

General Access

There are a number of areas and features which may bea hazard and potentially cause injury when working withthe unit unless suitable safety precautions are taken. Itis important to ensure access to the unit is restricted tosuitably qualified persons who are familiar with thepotential hazards and precautions necessary for safeoperation and maintenance of equipment containinghigh temperatures, pressures and voltages.

Pressure Systems

The unit contains refrigerant vapour and liquid underpressure, release of which can be a danger and causeinjury. The user should ensure that care is taken duringinstallation, operation and maintenance to avoiddamage to the pressure system. No attempt should bemade to gain access to the component parts of thepressure system other than by suitably trained andqualified personnel.

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Electrical

The unit must be earthed. No instal lation ormaintenance work should be attempted on electricalequipment without first switching off, isolating andlocking-off the power supplies. Work on live equipmentmust only be carried-out by suitably trained andqualified personnel. No attempt should be made to gainaccess to inside of the control panel, wiring or otherelectrical enclosures during normal operation of the unit.

Refrigerants and Oils

Refrigerants and oils used in the unit are generallynon-toxic, non-flammable and non-corrosive, and poseno special safety hazards. Use of gloves and safetyglasses are, however, recommended when working onthe unit. Build up of refrigerant vapour, from a leak forexample, does pose a risk of asphyxiation in confined orenclosed spaces and attention should be given to goodventilation. For more comprehensive information onsafety precautions for use of refrigerants and oils, referto the Materials Safety Data tables provided.

High Temperature and Pressure Cleaning

High temperature and pressure cleaning methods (e.g.steam cleaning) should not be used on any part of thepressure system as this may cause operation of thepressure relief device(s). Detergents and solventswhich may cause corrosion should also be avoided.

1.7 Emergency Shutdown

In case of emergency the unit can be shut down byoperating the main power switch on the control panel.

1.8 Safety Labels

The following labels are fixed to each unit to giveinstruction, or to indicate potential hazards which mayexist.

White symbol on blue backgroundFor safe operat ion, read theInstructions first

Black symbol on yellow backgroundWarning: This machine may startautomatically without prior warning

Black symbol on yellow backgroundWarning: Hot surface

Black symbol on yellow backgroundWarning: Safety relief valve maydischarge gas or liquid without priorwarning

Black symbol on yellow backgroundWarning: Isolate all electrical sourcesof supply before opening or removingthe cover, as lethal voltages may exist

Black symbol on yellow backgroundGeneral attention symbol

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1.9 Material Safety Data

Refrigerant Data:

Safety Data R407C

Toxicity Low.In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption.

Thaw affected areas with water. Remove contaminated clothing carefully — may adhere to skin incase of freeze burns. Wash affected areas with plenty of warm water. If symptoms occur (irritationor blistering) obtain medical attention.

In contact with eyes Vapour has no effect. Liquid splashes or spray may cause freeze burns. Immediately irrigate witheyewash solution or clean water for at least 10 minutes. Obtain immediate medical attention.

Ingested Highly unlikely to occur — but should this occur freeze burn will occur. Do not induce vomiting.Provided patient is conscious, wash mouth with water and give about 250 ml (0.5 pint) to drink.Obtain immediate medical attention.

Inhalation High atmospheric concentrations may have an anaesthetic effect, including loss of consciousness.Very high exposures may cause an abnormal heart rhythm and prove suddenly fatal.At higher concentration there is a danger from asphyxiation due to reduced oxygen content ofatmosphere. Remove patient to fresh air, keep warm and at rest. Administer oxygen if necessary.Apply artificial respiration if breathing has ceased or shows signs of failing. In event of cardiacarrest apply external cardiac massage. Obtain immediate medical attention.

Further medical advice Symptomatic and supportive therapy is indicated. Cardiac sensitisation has been described whichmay, in the presence of circulating catecholamines such as adrenalin, give rise to cardiacarrhythmia’s and subsequent arrest following exposure to high concentrations.

Long term exposure A lifetime inhalation study in rats has shown that exposure to 50,000 ppm resulted in benigntumours of the testis. This is not considered to be of relevance to humans exposed toconcentrations at or below the occupational exposure limit.

Occupational exposurelimits

Recommended limit: 1000 ppm v/v - 8 hr TWA.

Stability Not specified.Conditions to avoid Use in presence of naked flames, red hot surfaces and high moisture levels.Hazardous reactions May react violently with sodium, potassium, barium and other alkali and alkaline earth metals.

Incompatible materials: Magnesium and alloys containing more then 2% magnesium.Hazardousdecompositionproducts

Halogen acids by thermal decomposition and hydrolysis.

General precautions Avoid inhalation of high concentrations of vapours. Atmospheric concentrations should beminimised and kept as low as reasonably practicable below the occupational exposure limit. Thevapour is heavier than air and collects at low level and in confined areas. Ventilate by extraction atlowest levels.

Respiratory protection Where doubt exists on atmospheric concentration, HSE approved breathing apparatus should beworn. This should be self contained or of the long breather type.

Storage Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources of heatsuch as radiators. Keep at temperatures not exceeding 45 °C.

Protective clothing Wear overalls, impervious gloves and goggles/face protection.Spill/leak procedure Ensure suitable personal protective clothing and respiratory protection is worn. Provided it is safe

to do so, isolate the source of the leak. Allow small spillage’s to evaporate provided there issuitable ventilation.Large spillage’s: Ventilate area. Contain spillage’s with sand, earth or any suitable absorbentmaterial. Prevent liquid from entering drains, sewers, basements and work pits since vapour maycreate a suffocating atmosphere.

Disposal Best to recover and recycle. If this is not possible, destruction is to be in an approved facility whichis equipped to absorb and neutralise acids and other toxic processing products.

Fire extinguishing data Non-flammable at atmospheric conditions.Containers Fire exposed containers should be kept cool with water sprays. Containers may burst if

overheated.Fire fighting protectiveequipment

Self contained breathing apparatus and protective clothing must be worn in fire conditions.

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Thermal and Acoustic Materials Data

Health Hazard & FirstAid

Toxicity Index 99mass%Lubricating oil additive

Health Hazard Data

Route(s) of Entry No significant health hazards are identified. Prolonged repeated skincontact may cause irritation and dermatitis

Health Hazards (Acute and Chronic) No significant health hazards are identified. Prolonged repeated skincontact may cause irritation and dermatitis

Carcinogenicity NTP: No IARC Monographs: No OSHA Regulated: No

Signs and Symptoms of Exposure No information is available

Medical Conditions Generally Aggravatedby Exposure

No information is available

Skin Contact Wash material off the skin with copious amounts of water and soap

Eyes Contact Immediately flush with plenty of water for at least 15 minutes

Inhalation Remove exposed person to fresh air

Ingestion Do not induce vomiting. Call a physician immediately

Precautions for Safe Handling and Use

Steps to be Taken In Case Material isReleased or Spilled

Prevent spillage from spreading by using sand and absorb the liquidsubstance using a suitable inert material. Transfer to a suitably labelledsealable container. Do not allow liquid to enter open waters or groundwater.

Waste Disposal Method Waste material may be incinerated under conditions which meet all Federal,state and local environmental control regulations.

Precautions to be Taken in Handling andStoring

Store in cool, dark and low humidity place.

Other Precautions Avoid repeated skin contact and breathing of mist or vapour.

Control Measures

Respiratory Protection Under normal conditions, respirator is not usually required.

Ventilation Local Exhaust Not requiredMechanical (General) Not requiredSpecial Adequate ventilation should be maintained

when handling heated products

Protective Gloves Rubber gloves

Eye Protection Glasses or goggles

Other Protective Clothing or Equipment Not required

Work/Hygienic Practices Not required

Additional Information

The information contained herein has been compiled from data published in the literature. This data is believed to bereliable, but certain values may vary from source to source.This data is not to be construed as absolutely complete. It is the responsibility of the user to determine the bestprecautions necessary for his/her application.This data only refers to the specific material designated and not to any combinations.

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2 PRODUCT DESCRIPTION

2.1 Introduction

YORK YCSE/YCRE R407C chillers are designed forwater or water-glycol cooling. It is designed for indoorinstallation in a plant room. Units are available with oneor two independent refrigerant circuits with a singleevaporator and, on YCSE models, a single condenser.Units are completely factory assembled with allinterconnecting refrigerant piping and wiring ready forfield installation. The units are pressure tested,evacuated, and fully factory charged with refrigerantR407C and oil in each of the independent refrigerantcircuits. After assembly, an operational test isperformed with water flowing through the evaporatorand condenser (YCSE) to ensure that each refrigerantcircuit operates correctly.

2.2 Compressor

The unit has suction cooled, semi-hermetic screwcompressors. The compressors incorporate twin-screwrotors and solenoid valves for continuous capacitycontrol. The compressors are equipped with a built-in oilseparator, an oil sight glass, a crankcase oil heater anda suction filter. The compressors have a 2-pole motorwith over current and thermostat protection. Start / Deltastarting is provided as standard. All compressors aremounted on isolator pads to reduce transmission ofvibration to the rest of the unit.

Capacity Control

For YCSE/YCRE units, the compressors will start at theminimum load position and provide a capacity controlrange from 15% to 100 % per compressor using acontinuous function slide valve.

2.3 Refrigerant Circuits

Depending on model size, one or two independentrefrigerant circuits are provided on each unit. Eachcircuit uses copper refrigerant pipe formed on computercontrolled bending machines to reduce the number ofbrazed joints resulting in a reliable and leak resistantsystem.

Liquid line components include a service valve, a highabsorption filter dryer, a sight glass with moistureindicator and an electronic expansion valve.

Suction line components include an optional serviceand isolation valve.

Discharge line components include a check valve, anoptional service and isolation valve and a pressure reliefvalve.

2.4 Evaporator

The evaporator is a stainless steel brazed type plateheat exchanger. The waterside design workingpressure is 10 barg. The refrigerant side design workingpressure is 18 bar g. The cooler is thermally insulatedwith flexible closed cell foam. Water connection to theevaporator is via victaulic-grooved connections. Flangeconnections are available as an option.

2.5 Condenser (YCSE Only)

The condenser is a stainless steel brazed type plateheat exchanger. The waterside design workingpressure is 10 barg. The refrigerant side design workingpressure is 30 bar g. Water connection to the condenseris via victaul ic-grooved connect ions. Flangeconnections are available as an option.

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1 Compressor2 Evaporator3 Condenser (YCSE only)4 Power Section5 Control Panel

2.6 Power and Control Panels

All power and controls are contained in an IP2X cabinetwith hinged and gasket sealed outer doors.

The power section includes

A factory mounted non-fused disconnect switch withexternal handle to enable connection of the unit powersupply. The disconnect switch can be used to isolate thepower for servicing.

Factory mounted compressor contactors, fuses andover current relays to provide overload and short circuitprotection.

The control section includes

Four 7-segment LED display

Four push button switches

LED indicators for power, operation and alarm status

Customer terminal block for control inputs and liquidflow switch connection

Microprocessor boards to provide automatic operationand accurate temperature control.

2.7 Accessories and Options

Modbus

To integrate the unit into the building managementsystem. The interface permits the connection of up to 8units using the Modbus communications protocol. Referto HARC Modbus data sheet (035-22384-000).

Lonworks

To integrate the unit into the building managementsystem. The interface permits the connection of up to 8units using the Lon communications protocol. Refer toHARC Lonworks data sheet (035-22383-000).

Multi Unit Sequencer - CSC-5S

Provides individual control and monitoring for up to 8units within the air conditioning system. This allows theunits to be managed remotely from the plant room.

Compressor Circuit Breakers

Circuit breakers to replace the standard fuses forprotection against over current. The breakers providemore precise monitoring than fuses and easy reset afterfault.

Differential Water Pressure Switch (es)

Differential pressure switches between the water inletand outlets to ensure liquid flow during operation.

Flow Switch (es)

Field installed flow switches to ensure liquid flow duringoperation.

Glycol Cooling

Factory set-up for applications requiring water outlettemperatures below 5°C: Category 1: Outlettemperature 0 to 4°C; Category 2: Outlet temperature -1to - 5°C and Category 3: Outlet temperature - 6 to - 10°C.The system must have the correct percentage of glycoladded. (Refer to glycol application factors)

Discharge and/or Suction Stop Valves

Factory fitted valve(s) to allow refrigerant isolationduring servicing.

Compressor Safety Valve(s)

Factory fitted single or dual compressor safety valve(s).

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1 2-Pole Motor2 Built-in Oil Separator3 Twin Screw Rotors4 Oil Sight Glass5 Oil Heater6 Suction Filter

Dual Pressure Relief Valves

Two safety valves in parallel of which one is operationalto assist in valve replacement during maintenance.

Suction Pressure Relief Valves

Additional pressure relief valve on suction side ofcompressor when required.

PN16 Flanges

Welded PN16 flanges and companion flanges on thewater connections with gasket seals.

AVM (Resilient Pads)

Rubber anti-vibration pads underneath the unit to avoidtransmission of vibration to the plant room structure.

2.8 Nomenclature

AVM (Spring Isolators)

Spring and cage type isolators for mounting under theunit base rails to avoid transmission of vibration to theplant room structure (supplied loose with unit for fieldassembly)

Water Filter

Field installed water filter at the cooler inlet to protect theexchanger from excessive fouling.Wooden Crate

Special packing in a wooden crate to protect the chillerfrom damages during transportation

Heat Pump Kit (YCSE only)

Capability to control the chiller based on the condenserleaving water temperature.

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1 2 3 4 5 6 7 7 8 9 10 11BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR / REFRIGERANT DESIGN SERIES

Y : York # # # kW S : Standard Unit 5 0 : 380-415 / 3 / 50 + N

C : Chiller Standard Units B : R407C Refrigerant B : Design Level

S : S = Screw :040 :050 :060: R = Remote Air :080 :100

Cooled Screw

E : European

YCSE100SB50BVOLTAGE

Refigerant Flow Diagram

YCSE

Low-pressure liquid refrigerant enters the cooler and is evaporated and superheated by the heat energy absorbedfrom the chilled liquid passing through the cooler plates. Low-pressure vapour enters the compressors wherepressure and superheat are increased. High pressure superheated refrigerant enters the condenser where heat isrejected to the condenser water passing through the plates. The fully condensed and subcooled liquid leaves thecondenser and enters the expansion valve, where pressure reduction and further cooling takes place. Thelow-pressure liquid refrigerant then returns to the cooler.

YCRE

Low pressure liquid refrigerant enters the cooler and is evaporated and superheated by the heat energy absorbedfrom the chilled water passing through the cooler plates. Low pressure vapour enters the compressor wherepressure and superheat are increased. Heat is rejected by the remote condenser. The fully condensed andsubcooled liquid refrigerant then enters the expansion valve where pressure reduction and further cooling takesplace before returning to the cooler.

2.9 Refrigerant Flow Diagram

YCSE 040, 050, 060, 100 Models

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1 Compressor 16 Compressor Safety Valve (Option)

2 Check Valve 17 Compressor Dual Safety Valve (Option)

3 Pressure Relief Valve 18 Thermistor - Suction

4 Stop Valve (Option) 19 Thermistor - Discharge

5 Condenser 20 Thermistor - Evaporator

6 Stop Valve - Refrigerant Charge Point 21 Thermistor - Evaporator Water Inlet

7 Stop Valve 22 Thermistor - Evaporator Water Oulet

8 Drier 23 Thermistor - Evaporator Water Oulet

9 Sight Glass 24 Thermistor - Condenser Water Inlet (Option)

10 Electronic Expansion Valve 25 Thermistor - Condenser Water Outlet (Option)

11 Evaporator 26 Condenser Water Outlet

12 Stop Valve (Option) 27 Condenser Water Inlet

13 Low Pressure Sensor 28 Evaporator Water Inlet

14 High Pressure Switch 29 Evaporator Water Outlet

15 High Pressure Sensor

YCSE 080 Models

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1 Compressor 18 Pressure Switch

2 Check Valve 19 Solenoid Valve

3 Pressure Relief Valve 20 Capillary Tube

4 Stop Valve (Option) 21 Economiser

5 Condenser 22 Strainer

6 Stop Valve - Refrigerant Charge Point 23 Thermistor - Suction

7 Stop Valve 24 Thermistor - Discharge

8 Drier 25 Thermistor - Evaporator

9 Sight Glass 26 Thermistor - Evaporator Water Inlet

10 Electronic Expansion Valve 27 Thermistor - Evaporator Water Oulet

11 Evaporator 28 Thermistor - Evaporator Water Oulet

12 Stop Valve (Option) 29 Thermistor - Condenser Water Inlet (Option)

13 Low Pressure Sensor 30 Thermistor - Condenser Water Outlet (Option)

14 High Pressure Switch 31 Condenser Water Outlet

15 High Pressure Sensor 32 Condenser Water Inlet

16 Compressor Safety Valve (Option) 33 Evaporator Water Inlet

17 Compressor Dual Safety Valve (Option) 34 Evaporator Water Outlet

YCRE 040, 050, 060, 080, 100 Models

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1 Compressor 15 High Pressure Sensor

2 Stop Valve 16 Compressor Safety Valve (Option)

3 Check Valve 17 Compressor Dual Safety Valve (Option)

4 Pressure Relief Valve (Field Supplied) 18 Thermistor - Suction

5 Remote Condenser (Field Supplied) 19 Thermistor - Discharge

6 Stop Valve 20 Thermistor - Evaporator

7 Drier 21 Thermistor - Evaporator Water Inlet

8 Solenoid Valve 22 Thermistor - Evaporator Water Oulet

9 Sight Glass 23 Thermistor - Evaporator Water Oulet

10 Expansion Valve 24 Evaporator Water Inlet

11 Evaporator 25 Evaporator Water Outlet

12 Stop Valve (Option) 26 YCRE

13 Low Pressure Sensor 27 Field Supplied

14 High Pressure Switch

3 TRANSPORTATION, HANDLING ANDSTORAGE

3.1 Delivery and Storage

To ensure consistent quality and maximum reliability, allunits are tested and inspected before leaving thefactory. Units are shipped completely assembled andcontaining refrigerant under pressure. Units areshipped without export crating unless this has beenspecified on the Sales Order.

If the unit is to be put into storage, before installation, thefollowing precautions should be observed:

Ensure that all openings, such as water connections,are securely capped.

Do not store where exposed to ambient airtemperatures exceeding 42°C.

The unit should be stored in a location where there isminimal activity to limit the risk of accidental physicaldamage.

To prevent inadvertent operation of the pressure reliefdevices the unit must not be steam cleaned.

It is recommended that the unit is periodically inspectedduring storage.

3.2 Inspection

Remove any transit packing and inspect the unit toensure that all components have been delivered andthat no damage has occurred during transit. If anydamage is evident, it should be noted on the shipmentdocumentation and a claim entered according to theinstructions given.

Major damage must be reported immediately to yourlocal Johnson Controls representative.

3.3 Moving the Unit

Before moving the unit, ensure that the installation site issuitable for installing the unit and is capable ofsupporting the weight of the unit and all associatedservices.

The units are designed to be moved using either liftingchains or rollers .

Lifting by Crane/Hoist

Attach the lifting chains to the lifting lugs on each cornerof the unit framework. A spreader frame should be usedto prevent damage to the unit from the lifting chains.

The unit must only be lifted at the pointsprovided.

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1 60° (or more)2 Power Section3 4 x Rigging Bolts4 Spreader Bars

Moving the Unit with Rollers

Use at least 6 equal sized rollers under the base frame.Each roller must support both outer frames. Ensure theunit is balanced evenly on all the rollers.

3.4 Lifting Weights

For details of weights and weight distribution refer toSection 9.

3.5 Weight Distribution & Centre of Gravity

To prevent the unit tipping over do not tilt theunit more than 15°.

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4 INSTALLATION

4.1 Location Requirements

To achieve optimum performance and trouble-freeservice, it is essential that the proposed installation sitemeets with the location and space requirements for themodel being installed. For dimensions, weight andspace requirements, including service access details,refer to Section 9.

The clearances recommended are nominalfor the safe operation and maintenance of theunit and power and control panels. Localhealth and safety regulations, or practicalconsiderations for service replacement oflarge components, may require largerclearances than those given in Section 9.

Units are designed for indoor installation and notintended for wet, corrosive or explosive atmospheres.Installation should allow for water drain, ventilation andsufficient clearance for service.

For installation in equipment rooms near noise-criticalareas, common walls should be of adequate soundattenuating construction, all doors should be tightlygasketed, and the unit should have vibration isolatorsfitted.

The unit must be installed on a suitable flat and levelconcrete base (2) that extends to fully support the unitbase frame.

On basement foundations remove a portion of thebasement floor (3) so that a concrete base can bepoured resting on the ground (1) , with a corkboard (4)installed on both sides, and a waterproof sealingcompound (5).

The concrete base must capable of supporting 150% ofthe operating weight. In case of upper floors, the unitand piping should be isolated from walls and ceiling. Theunit may be bolted to the foundation using 13 mm Øholes in the base of the framework. When lower

transmitted vibration levels are required optionalanti-vibration isolators can be supplied loose for siteinstallation.

4.2 Installation of Vibration Isolators

An optional set of spring and cage or rubber mat typevibration isolators can be supplied loose with each unit.Installation drawings are attached inside the power andcontrol panel.

Only spring and cage or rubber mat typevibration isolators can be installed. Do notinstall both types of vibration isolator together.

4.3 Pipework Connection

General Requirements

The following piping recommendations are intended toensure satisfactory operation of the unit. Failure tofollow these recommendations could cause damage tothe unit, or loss of performance, and may invalidate thewarranty.

The maximum flow rate and pressure drop forthe cooler and condenser must not beexceeded at any time.Refer to Section 9 for details.

� The water must enter the heat exchangers by theinlet connection. Refer to Section 9 for details.

� A flow switch must be installed in the customerpipework at the outlet of the exchangers as shownin the arrangement diagrams, and wired back to thecontrol panel using screened cable. For detailsrefer to “Electrical Connection”. This is to preventdamage to the exchanges caused inadequateliquid flow.

� The flow switch used must have gold platedcontacts for low voltage/current operation. Paddletype flow switches suitable for 10 barg workingpressure can be obtained from Johnson Controlsas an option for the unit.

� The liquid pump(s) installed in the pipeworksystem(s) should discharge directly into the unitheat exchanger section of the system. Thepump(s) require an auto-starter (by others) to bewired to the control panel. For details refer to“Electrical Connection”.

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035-21786-100 Rev. 1 (0909)

150

-20

0m

m

150

-20

0m

m

1 12 23 4 5

� Pipework and fitt ings must be separatelysupported to prevent any loading on the heatexchanger(s) . Flexible connect ions arerecommended which wi l l a lso minimisetransmission of vibrations to the building. Flexibleconnections must be used if the unit is mounted onanti-vibration mounts as some movement of theunit can be expected in normal operation.

� Pipework and fittings immediately next to the heatexchangers should be readily de-mountable toenable cleaning prior to operation, and to facilitatevisual inspection of the exchanger nozzles.

� Each heat exchanger must be protected by a 20mesh strainer, available as an option, fitted asclose as possible to the liquid inlet connection, andprovided with a means of local isolation.

� The heat exchanger(s) must not be exposed toflushing velocities or debris released duringflushing. It is recommended that a suitably sizedby-pass and valve arrangement is installed to allowflushing of the pipework system. The by-pass canbe used during maintenance to isolate the heatexchanger without disrupting flow to other units. Donot exceed heat exchanger design pressuresduring water side pressure tests.

� Thermometer and pressure gauge connectionsshould be provided on the inlet and outletconnections of each heat exchanger.

� Drain and air vent connections should be providedat all low and high points in the pipework to permitdrainage of the system, and to vent any air in thepipes.

� Liquid systems at risk of freezing, due to lowambient temperatures, should be protected usinginsulation and heater tape and/or a suitable glycolsolution. The liquid pump(s) must also be used toensure liquid is circulated when the ambienttemperature approaches freezing point. Insulationshould also be installed around the heat exchangernozzles.

Heater tape of 21 watts per metre under theinsulat ion is recommended, suppl iedindependently and controlled by an ambienttemperature thermostat set to switch on at3°C above the freezing temperature of theliquid.

Any debris left in the water pipework betweenthe strainer and heat exchanger could causeserious damage to the plates in the heatexchanger and must be avoided. Theinstaller/user must also ensure that the qualityof the water in circulation is adequate, withoutany dissolved gasses which can causeoxidation of steel parts within the heatexchanger(s).

4.4 Water Treatment

The unit performance given in the DesignGuide is based on a fouling factor of 0.044m² °C/kW. Dirt, scale, grease and certaintypes of water treatment will adversely affectthe heat exchanger surfaces and thereforeunit performance. Foreign matter in the watersystem(s) can increase the heat exchangerpressure drop, reducing the flow rate andcausing potential damage to the heatexchanger plates.

Aerated, brackish or salt water is not recommended foruse in the water system(s). JCI recommend that a watertreatment specialist is consulted to determine that theproposed water composition will not affect theevaporator materials of stainless steel. The pH value ofthe water flowing through the heat exchangers must bekept between 7 and 8.5. The total installed sytemincluding pumps, cooling coils, pipework, couplings andchiller should be assesed with regards to correct watertreatment. Poor or incorrect water treatment can lead towarranty being avoided.

Glycol Solutions

For unit operation with chilled liquid temperaturesleaving the cooler at below 5°C, glycol solutions shouldbe used to help prevent freezing. Section 9, givesrecommended solution strength with water, as apercentage by weight, for the most common types ofglycol. It is important to check glycol concentrationregularly to ensure adequate concentration and avoidpossible freeze-up in the cooler.

When using glycol solutions, pressure dropsare higher than with water. Special care mustbe taken not to exceed the maximum pressuredrop allowed.

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035-21786-100 Rev. 1 (0909)

4.5 Pipework Arrangement

The following are suggested pipework arrangements forsingle unit installations. For multiple unit installations,each unit should be piped as shown.

Recommendations of the Building ServicesResearch Association

Chilled Liquid System

Condenser Liquid System (YCSE Only)

4.6 Connection Types & Sizes

For connection sizes relevant to individual models referto Section 9.

Refrigerant Relief Valve Piping

The compressor, cooler and condensers are eachprotected against internal refrigerant over-pressure andfire by refrigerant relief valves. The pressure relief valveis set at the design pressure of the system and hasdischarge capacity required by the relevant standard.

It is recommended that each valve should be piped tothe exterior of the building so that when the valve isactivated the release of high pressure gas and liquidcannot be a danger or cause injury.

The size of any pipework attached to a relief valve mustbe of sufficient diameter so as not to cause resistance tothe operation of the valve. For critical or complexinstallations refer to EN13136.

The vent pipe must be installed and completed prior tocommissioning/start-up work commencing.

Unless otherwise specified by local regulations, theinternal diameter depends on the length of pipe requiredand can be estimated with the following formula:

D5=1.447 x L

Where:

D = minimum pipe internal diameter (cm)

L = length of pipe (m).

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035-21786-100 Rev. 1 (0909)

/ Binder Point

If relief pipework is common to more than one valve itscross sectional area must be at least the total requiredby each valve. Valve types should not be mixed on acommon pipe. Precautions should be taken to ensurethat the exit of relief valves/vent pipe remain clear ofobstructions at all times.

4.7 Condenser Cooling Liquid Systems(YCSE Only)

For primary cooling of units, condensers are usuallypiped in conjunction with a cooling tower, well water ordry coolers. Ensure the water is suitable for the stainlesssteel heat exchanger.

With liquid cooled units it is necessary to control coolantflow and / or temperature into the condenser to maintainrefrigerant pressure as constant as possible to ensuresatisfactory operation of the expansion valves.

Direct Pressure Control (By others)

With YCSE units it is possible, if desired, to control thecondenser cooling liquid inlet temperature / flow directlyfrom the unit refrigerant pressure.

The refrigerant pressure can either be used to controlcooling tower / dry cooler effectiveness by controllingfans or dampers on the tower, or to control condenserflow using a three way bypass valve.

The aim is to maintain a stable discharge pressure aslow as possible, but at least 5.0 bar above suctionpressure. This can be done at a fixed value above thehighest expected suction pressure, or by alsomeasuring suction pressure and using differentialcontrol. In either case condenser cooling liquid flow andtemperature limits must also be observed.

Inlet Temperature Control (By others)

For a cooling tower / dry cooler system, the simplestforms of control are to use fan cycling, fan speed control,or air damper control, with the tower having a thermostatin its sump. This will ensure stable condenser coolingliquid temperature sensing at design conditions andshould be adjusted to ensure a condenser cooling liquidentering temperature of not lower than 22°C at lowerambient conditions.

If these methods are not available, or a cooling tower isnot the source of cooling water, then a three way valverecirculation system can be used with control based oncondenser inlet liquid temperature. In this case theobjective is to maintain the inlet cooling liquidtemperature as low as possible, although still observingthe minimum limit of 22°C.

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035-21786-100 Rev. 1 (0909)

4.8 Electrical Connection

The following connection recommendations areintended to ensure safe and satisfactory operation of theunit. Failure to follow these recommendations couldcause harm to persons, or damage to the unit, and mayinvalidate the warranty.

No additional controls (relays, etc.) shouldbe mounted in the control panel. Powerand control wiring not connected to thecontrol panel should not be run throughthe control panel. If these precautions arenot followed it could lead to a risk ofelectrocution. In addition, electrical noisecould cause malfunctions or damage theunit and its controls.

Do not earth earth any portable electricalor welding equipment via the chiller.

After connection do not switch on mainspower to the unit until it has beencommissioned by JCI Authorisedpersonnel. Some internal components arelive when mains is switched on.

The unit ON/OFF switch on the front of the control panelhas been set in the “OFF” position at the factory.

This switch MUST remain in the “OFF” position until theunit is commissioned by JCI Authorised personnel. If theswitch is set to the “ON” position before commissioningthen it must be reported to JCI, otherwise the warrantymay be invalidated.

4.9 Remote Refrigerant Condenser Systems(YCRE models only)

General

For cooling of YCRE units, condensers are usually ofthe remote air-cooled type either roof or ground levelmounted. Refrigerant systems should be designed andinstalled by suitably qualified persons in compliancewith relevant national codes and standards. Thecomplete pipework system and condenser MUST havea Design Working Pressure of at least 27.6 barg.

Suitable controls (e.g. fan cycling) should be included tokeep discharge pressure within the unit operationallimits and at least 4.0 bar above suction pressure.

The condenser should be designed to provide sufficientsubcooling at its outlet to ensure that no 'flashing' willoccur in the liquid line to the unit, or in the filter/drier and

liquid valves on the unit itself. Liquid subcooling shouldbe 4°C to 10°C on arrival at the unit.

It is important to ensure that for each system the remotecondenser and liquid line volume is at least 1.65 timesthe liquid volume of the operating refrigerant charge.

When the unit has been located in its final position, therefrigerant system pipework can be connected.Pipework and fittings MUST be separately supportedand not cause any loading on the unit. Flexibleconnections are recommended and will also minimisetransmission of vibrations to the building. Flexibleconnections MUST be used if the unit is mounted onanti-vibration mounts as some movement of the unit canbe expected in operation.

Pipework Design

The following notes give guidance but should not beconsidered exhaustive:

� Discharge lines MUST be sized for guaranteed oiltransfer at minimum load step on the compressor.P-traps and double risers may be required whenthe condenser is sighted above the unit. Horizontalruns should be inclined slightly towards thecondenser to aid oil transfer.

� Where the condenser is above or level with theunit, the discharge line should rise to at least the topedge of the condenser at some point. This willprevent liquid draining back to the compressorduring the off cycle.

� Elbows, bends and valves should be minimised toreduce pressure drop and prevent loss ofperformance. The liquid line in particular should bedesigned for minimum pressure drop to avoid'flashing' in the liquid line which will cause loss ofperformance and fault conditions to occur.Particular care should be taken where thecondenser is below or level with the unit.

� To avoid the risk of discharge gas pulsation'scausing undesired noise within the building, asuitably sized discharge gas muffler may be fittedin the discharge line near the unit. A slight loss ofperformance may, however, result at full load.

Incorrectly or badly designed and/or installedpipework systems may invalidate unitwarranty.

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035-21786-100 Rev. 1 (0909)

Refrigerant Connections

Units are supplied with a nitrogen holding charge. Donot open the unit stop valves until all preparation for fieldleakage checks has been completed.

The refrigerant piping between the unit and the remotecondenser should be designed in accordance with thefollowing diagram.

Connection pipe sizes are given in the following table.When selecting pipe sizes, pressure drop and velocitymust be considered. If the pipe size is too small prcticalfriction loss is excessive or noise is emitted due to highvelocity. The pipe size should permit sufficient gasspeed to ensure oil return.YCRE units are equipped withan unloader system. The diameter of the dischargepiping must allow sufficient oil to be carried even duringminimum unloader operation. An excessively largediameter must not be selected.

YCRE units are dehydrated and and charged withapproximately 1kg of refrigerant at the factory.

It is possible that air and moisture may enter the systemduring installation. It is essential that that all moisture isremoved from the piping system.

Install the connection piping and accessories withsoldered, brazed or flare connections. Install oil trapsand liquid loops in accordance with the pipingarrangement digrams. Piping length and lift must notexceed the following values.

All horizontal discharge piping should be pitcheddownwards in the direction of the refrigerant flow. Thedischarge line from the compressor should be looped toform a trap so that oil does not train from the dischargepiping to the compresssor head during compressorstoppages.

System Testing

All newly installed pipework must be pressure/leaktested to national code requirements (normally 1.1 xDesign Working Pressure) then fully evacuated beforecharging. Refer to the Section 5 for correct chargingmethods.

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035-21786-100 Rev. 1 (0909)

Maximum EquivalentPiping Length (m)

Maximum Differencein Height (m)

Unit belowRemoteCondenser

30.0 25.0

Unit aboveRemoteCondenser

30.0 5.0

Outer Diameter(mm) Thickness (mm)

Refrigerant Gas 41.3 2.0Refrigerant Liquid 28.6 1.6

Install piping withinlimits of the shaded area

Unit

Unit

RemoteCondenser

RemoteCondenser

0 5L

H

5

0

5

10

15

20

25

10 15 20 25 30

H: Vertical Distance between the Chiller Unit and Remote CondenserL: Horizontal Distance between the Chiller Unit and Remote Condenser

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035-21786-100 Rev. 1 (0909)

Field Supplied

Unit below Remote Condenser

Unit Remote CondenserAbove

Double Riser

Field Supplied

YCREUnit

YCREUnit

YCREUnit

Receiver

ReceiverReceiver

Receiver

Oil Trap Oil Trap

Oil Trap

RemoteCondenser

Liquid Loop Liquid Loop

Liquid Loop

RemoteCondenser

RemoteCondenser

RemoteCondenser

At each10 metres

At each10 metres

At each10 metres

Maximum5 metres

Maximum25 metres

Oil Trap

Oil Trap

Oil Trap

YCRE Refrigerant Piping Arrangements

4.10 Power Wiring

The units are suitable for 380 or 400 V,3 phases + neutral + earth, 50 Hz nominalsupplies only.Minimum allowable 360 V.Maximum allowable 440 V.

All electrical wiring should be carried out in accordancewith local regulations. Route properly sized cables tocable entries on the control panel.

In accordance with EN 60204 it is the responsibility ofthe user to install overcurrent protection devicesbetween the supply conductors and the power supplyterminals on the unit.

To ensure that no eddy currents are set up in the metalgland plate the cables forming each 3 phase powersupply must enter via the same hole in the gland plate.

If separate entries for each cable forming the 3 phasesupplies are used, the metal gland plate must bereplaced by a non-metallic gland plate, with due regardgiven to sealing the panel to IP2X.

All sources of supply to the unit must betaken via a common point of isolation (notsupplied by York). Voltages from externalsources may be present. Refer tooperating limits for unit max/min voltages.

Single Point Power Supply Wiring

All models require one field provided 400 V, 3Ø, + N50 Hz + PE (Protected Earth) supply to the unit withcircuit protection.

Connect the 3 phase supply to the non-fuseddisconnect switch located in the power panel.

Connect the earth wire to the main protective earthterminal located in the power panel.

4.11 Control Wiring

Connect the interlock and control wiring as shown in theunit connection diagram below.

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035-21786-100 Rev. 1 (0909)

Lug Size Max. Cable Capacity

(mm2)YCSE 040 M8 185YCSE 050 M8 185YCSE 060 M8 185YCSE 080 M8 185YCSE 100 M10 240YCRE 040 M8 185YCRE 050 M8 185YCRE 060 M8 185YCRE 080 M10 240YCRE 100 M10 240

4.12 Connection Diagram

YCSE

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035-21786-100 Rev. 1 (0909)

N°° Name

1 In case of remote control operation this wireshall be removed (using item 10).2 R Phase3 Neutral4 Low Voltage / Remote Control5 Run/Stop Signal6 Alarm Signal7 Alarm Lamp (30mA max)8 Pump Interlock9 Pump operation10 Remote Control Switch (RSW-A) (OPTION)11 2 Circuit Units12 Not Fitted

N°° Name13 2 nd. Setting Temperature14 External Thermostat Operation15 Operation Mode (OPTION)

16Only used for:-Diff. Water Pressure switch (OPTION)-Flow Switch (OPTION)

17 Force CompressorLoad Operation

18 Free CoolingOutput signal (Only cycle Nº 1)

19 In case of individual indication without RemoteControl Switch20 Customer wiring21 Force compressor load22 Setting of low voltage control

NOTE:1.All the setting shall be performed before Power ON.

2.Remote / Local Change over Switch on Operation Switch shall be set, to Remote.

3.Terminals 1 ~/21 are for AC220-240V,Terminals A ~D are for DC24V. Terminals E ~F are H-link (Low signal)

N° NameA Main Power/Terminal Board (R,S,T,N)B Electrical BoxC Main Power SwitchD Main Power WiringE Earth Wiring

T he main connection to terminal N is required.

A

B

C

D

E

Remove link between 5 and 6when remote control switch

option is fitted

EVAP

CONDEVAP COND

NOTES:

30mA max

DSW1-4 must be set to ON whenremote control switch option is fitted

SW4 SW5 SW6

YCRE

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035-21786-100 Rev. 1 (0909)

N° Name

1 In case of remote control operation this wiremust be removed (using item 10).

2 S Phase

3 Neutral

4 Low Voltage / Remote Control

5 Run/Stop Signal

6 Alarm Signal

7 Alarm Lamp (30mA max)

8 Pump Interlock

9 Pump operation

10 Remote Control Switch (RSW-A) (OPTION)

11 2 cycles

N° Name

12 2nd. Setting Temperature

13 External Thermostat Operation

14Only used for:- Diff. Water Pressure switch (OPTION)- Flow Switch (OPTION)For Air Cooled: Link 35/36

15 Force CompressorLoad Operation

16 Free CoolingOutput signal (Only cycle Nº 1)

17 In case of individual indication without RemoteControl Switch

18 Customer wiring

19 Force compressor load

20 Setting of low voltage controlNOTE

:1. All the setting must be performed before Power ON.2. Remote / Local Change over Switch on Operation Switch must be set, to Remote3. Terminals 1 ~ 57 are for AC220-240V,Te rminals A ~ D are for DC24V. Terminals E ~ F are H-link (Low signal)

N° Name1 Main Power/Terminal Board (R,S,T,N)2 Electrical Box3 Main Power Switch4 Main Power Wiring5 Earth Wiring

The main connection to terminal N is required.

Remove link between 5 and 6when remote control switch

option is fitted

DSW1-4 must be set to ON whenremote control switch option is fitted

EVAP

NOTES:

30mA max

SW4 SW5 SW6

5 COMMISSIONING

5.1 Preparation

Commissioning of this unit should only becarried out by JCI Authorised personnel whohave attended a YCSE/YCRE training course.

The unit 'ON/OFF' switch on the front of the controlpanel has been set to the 'OFF' position at the factory.This switch must remain in the 'OFF' position,preventing running of the unit until commissioned by JCIAuthorised personnel. If the switch has been set to the'ON' position before commissioning then it must bereported to JCI otherwise the warranty may beinvalidated.

Preparation - Power Off

The following checks should be made with the customersupply/supplies to the unit switched off.

Inspection: Inspect unit for installation damage. Iffound take action and/or repair as appropriate.

Refrigerant charge

Units are normally shipped as standard with a fullrefrigerant operating charge. Check that refrigerantpressure is present in both systems and that no leaksare apparent. If no pressure is present a leak test mustbe undertaken, the leak(s) located and repaired.

Charging from the liquid connection isnecessary on R407C to ensure the correctrefrigerant mix is maintained.

Do not charge liquid refrigerant with static water in thecooler. Care must also be taken to charge liquidrefrigerant slowly to avoid excessive thermal stress atthe charging point. Once the vacuum is broken, chargeinto the condenser with the full operating charge asgiven in Section 9.

The stated operating charge is a guideline only and forboth YCSE and YCRE units the charge should berechecked at full load stable conditions (30minsruntime) for correct suction superheat (6°C), liquidsub-cooling 5.5°C - 9.5°C water cooled, 5.5°C - 9.5°Cair cooled.

Valves: Open the compressor suction valve (option),discharge valve (option) and the liquid line servicevalves on all systems.

Compressor oil: Check the compressor oil for correctlevel at the oil level sight glass. Full at commissionstartup and no less than half full during normaloperation.

Isolation/protection: Verify that all sources of electricalsupply to the unit are taken from point(s) of isolation.

Control panel: Check the panel to see that it is free offoreign materials (wire, metal chips, etc.) and clean out ifrequired.

Power connections: Check the customer powercables are connected correct ly. Ensure thatconnections of power cables within the panels to thecircuit breakers, terminal blocks or switch disconnectorsare tight.

Earthing: Verify that the units protective terminal(s) areproperly connected to a suitable earthing point. Ensurethat all unit internal earth connections are tight.

Supply voltage: Verify that the site voltage supplycorresponds to the unit requirement and is within thelimits given in Section 9.

Switch Settings: Ensure that the unit 'ON/OFF' switchon the control panel is set to 'ON'.

The unit is now live!

Compressor heaters: Verify the compressor heatersare energised. The compressor heaters should be onfor 12 hours before start-up to bring the compressor oilup to the correct operating temperature.

Chilled Liquid System: Verify that the chilled liquidsystem has been installed correctly, and has beencommissioned with the correct direction of water flowthrough the cooler. Purge air from the top of the coolerusing the plugged air vent mounted on the top of thecooler body. Ensure system flushing and watertreatment have been carried out and verify that watermake-up/pressurization units are operating correctly.

Cooling Liquid System: Verify that the cooling liquidsystem has been installed correctly, and has beencommissioned with the correct direction of water flowthrough the condenser. Purge air from the top of thecondenser using the plugged air vent mounted at the topof the condenser water head (YCSE only).

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035-21786-100 Rev. 1 (0909)

Cooler and Condenser flow rates andpressure drops must be within the limits givenin Section 9. Operation outside of these limitsis undesirable and could cause damage.

Flow switch: Verify a chilled liquid flow switch iscorrectly fitted in the customer’s pipework on theevaporator outlet, and wired into the control panelcorrectly. On YCSE units verify a cooling liquid flowswitch is fitted in the customer's pipework on thecondenser outlet, and wired into the control panelcorrectly.

Control supply: Verify the control panel display isilluminated.

HP cut-out reset: Check that the hand resetmechanical high pressure cut-outs mounted on thecompressors are at the correct setting and are reset.

5.2 First Time Start-up

During the commissioning period there shouldbe sufficient heat load to run the unit understable full load operation to enable the unitcontrols, and system operation to be set upcorrectly and a commissioning log taken.

Interlocks: Verify that liquid is flowing through thecooler and that heat load is present. Ensure that anyremote run interlocks are in the run position and that therun schedule requires the unit to run or is overridden.

System configuration: Ensure all DIP switch settingsare correct for system operationand that safety settingsare within the design parameters for the site application.

Start-up: Press the system ON switch SW1 to start theunit. There will be a delay before the compressor starts.See the operating sequence chart in Section 6. Be readywhen the compressor starts to switch off the unitimmediately if any unusual noises or other adverseconditions develop. Use the main ON/OFF switch ifnecessary.

Discharge and suction pressures: Check thedischarge and suction pressures on the control paneldisplay. Refer to Section 6. Check the pressures are inaccordance with the pressure curves given in Section 9.

Superheat temperature: Check the superheattemperature is in accordance with the temperaturecurve given in Section 9.

Sub-cooling temperature: Check the sub-coolingtemperature is in accordance with the temperaturecurve given in Section 9.

Refrigerant flow: When a compressor starts a flow ofliquid refrigerant will be seen in the liquid line sight glass.After several minutes operation and providing a fullcharge of refrigerant is in the system, the bubbles willdisappear and be replaced by a solid column of liquid.Check moisture indicator (if fitted) for correct colourindication.

Control and protective devices: Check that all thecontrol and protective devices operate in accordancewith the operation sequence chart in Section 6.

Thermostat: Check the unit responds correctly tothermostatic demands, remote run demands andshutdown.

General operation: When the checks are complete,stop the unit by pressing the system OFF switch SW2. Ifthe unit is not in remote control mode, restart the unit theunit by pressing the system ON switch SW1. Check thatloading occurs and that general operation is correct.

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035-21786-100 Rev. 1 (0909)

6 UNIT OPERATION

6.1 General Description

The units are designed to work independently, or inconjunction with other equipment via a buildingmanagement system or other automated controlsystem. When operating, the unit controls monitor thechilled liquid system temperature at the unit and take theappropriate action to maintain this temperature withindesired limits. This action will involve running one orboth compressors at a suitable load to match the coolingeffect of the refrigerating systems to the heat load on theliquid system. The heat removed from the chilled liquidis then rejected via the water cooled condenser. Thefollowing sections give an overview of the operation ofthe unit.

6.2 Operation

The operating sequence described below relate tooperation on a cooling demand start after power hasbeen applied, such as start-up commissioning.

The controller will perform a pre-check to ensure thatany remote interlocks will allow the unit to run, all safetycut-outs are satisfied and that cooling load is required(i.e. that the chilled liquid temperature is outside the setlimits). Any problems found by the pre-check will bedisplayed if present. If no problems are present andcooling duty is required the compressor will start.

6.3 Normal Running and Cycling

Once the unit has been started, all operations are fullyautomatic. The display will show one of the normaloperation codes as detailed in the following table.

When a compressor is running the controller monitorsvarious system parameters. Should any problemsoccur, the control system will immediately takeappropriate action and display the nature of the faultRefer to Alarm Codes tables for further details.

6.4 Shutdown

The unit can be stopped manually at any time bypressing the system OFF switch SW2.

To prevent damage to the unit the controlsupply to the compressor heaters should notbe switched off, even when the unit is notrequired to run.

If mains power must be switched off, (for extendedmaintenance or a shutdown period), the compressorsuction, discharge and liquid line service valves on bothsystems should be closed and if there is a possibility ofliquid freezing due to low ambient temperatures, thecooler and condenser should be drained. Fitappropriate valve tags to indicate valve positions andthat systems are drained and isolators. The valvesshould be opened, the cooler and condenser refilledand the power must be switched on for at least 12 hoursbefore the unit is restarted.

6.5 Control System

The control system comprises the operator controlpanel and display on the front of the unit and a controlprinted circuit board located inside the unit on the rear ofthe control panel.

6.5.1 Control Panel

The control panel comprises four push-button switches,a four figure display and three LEDs.

The control panel has four modes of operation:� Normal

� Alarm

� Parameter settings

� Second Water Temperature Setting

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035-21786-100 Rev. 1 (0909)

DisplayLEDs PushButton

Switches

FunctionSW1 Sets system ONSW2 Sets system OFFSW3 Display control UPSW4 Display control DOWNPower LED Displays red when power is presentAlarm LED Display orange when alarm occursDisplay Displays operating or alarm codes

No. 1 Comp. No.2 Comp.C1-88 C2-88 Power supply present, System offC1-Co C2-Co Unit in Cooling modeC1-HE C2-HE Heating mode (heat pump option only)C1-oF C2-oF Unit off - no cooling demand

Pu Pu Pump only operationC1-E0 C2-E0 Initialising Electronic Expansion Valve

Display CodeFunction

The modes are changed by using the display checkswitches SW3 and SW4.

Normal Mode

The display will show one of the normal operation codesas detailed in the following table.

Alarm Mode

When an alarm is activated the orange ALARM LED willbe on. Select the Alarm Mode on the display by pressingand holding SW3� and SW4� simultaneously for 3seconds.

Press SW3� for 3 seconds to enter the alarm historydisplay. The unit can store up to 10 alarm occurences.

Press SW3� or SW4� to scroll through the alarms.The display will automatically toggle (�) between thealarm number and one of the alarm codes as detailed inthe alarm code table.

This example shows that alarm 10 was a system 1 highpressure alarm and alarm 9 was a system 2 highpressure alarm. See Alarm Codes, Pressure/Temperature Settings and Safety and Control DeviceSettings.

Parameter Settings Mode

To change from Normal to Parameter Settings modepress and hold SW3 for 3 seconds. A small LED will lightin the lower right hand section of the display whenParameter Settings mode is selected. To return toNormal mode press and hold SW3 again for 3 seconds.

Press SW3 � or SW4 � to scroll through theparamaeter settings. The display will show theautomatically toggle (�) between the parameter and theparameter value.

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035-21786-100 Rev. 1 (0909)

n o 1 0

C 1 H 1

n o 9

C 2 H 2�

� �

�

No. 1 Comp. No.2 Comp.C1-88 C2-88 Power supply present, System offC1-Co C2-Co Unit in Cooling modeC1-HE C2-HE Heating mode (heat pump option only)C1-oF C2-oF Unit off - no cooling demand

Pu Pu Pump only operationC1-E0 C2-E0 Initialising Electronic Expansion Valve

Display CodeFunction

Normal Operating Mode

AlarmHistory

AlarmMode

ParameterSettingMode

2nd WaterTemperatureSetting Mode

SW3SW3SW4

SW4

SW3

0 0 0 0

C 1 P d � 1 9 2

C 2 P d � 1 9 2

C 1 P S � 0 4 2

C 2 P S � 0 4 2

C 1 t d � 8 2

C 2 t d � 8 2

C 1 t S � - 2

C 2 t S � - 2

� �

Suction Gas Temperature (°C): -2°C

� �

Discharge Gas Temperature (°C): 82°C

� �

Suction Gas Temperature (°C): -2°C

� �

Discharge Gas Temperature (°C): 82°C

� �

Suction Pressure (MPa): 0.42MPa

� �

Suction Pressure (MPa): 0.42MPa

Last Alarm Code (No Alarm)

Discharge Pressure (MPa): 1.92MPa

��

� �

Discharge Pressure (MPa): 1.92MPa

� �

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035-21786-100 Rev. 1 (0909)

C 1 t r � 0 4

C 2 t r � 0 4

C E L � 1 2

C o L � 7

C o L 1 � 7

C o L 1 � 6

t S C � 7

t S H � 7

t S C � 6

t S H � 7

d F � 2� �

Chilled Setting Water Outlet Temp. (Cooling) (°C):7°C

� �

Set Neutral Zone Temperature Difference (°C): 2°C

� �Chilled Water Outlet 2 Temperature (°C): 6°C (YCSEOnly)

� �

Chilled Average Water Outlet Temperature (°C): 7°C

� �Chilled Water Outlet 1 Temperature (°C): 7°C (YCSEOnly)

� �

Chilled Water Inlet Temperature (°C): 12°C

� �

Evaporating Temperature (°C): 4°C

� �

Evaporating Temperature (°C): 4°C

Hot Water Setting Outlet Temp. (Heating) (°C): 7°C(YCSE Heat Pump option only)

� �Chilled 2nd Setting Water Outlet Temperature(Cooling) (°C): 7°C

� �

Hot Water 2nd Setting Outlet Temperature(Heating) (°C): 7°C (YCSE Heat Pump option only)

� �

C 1 L D � U P

C 2 L D � n U

C 2 L D � d O

C 1 P C � C o '

C 2 P C � C o '

C 2 P C � C o -

C 1 t r � - 4

C 1 C o � 7

C 2 C o � 7

C 1 E o � 2 4 0

C 2 E o � 2 4 5

Return to Last Alarm Code�

Compressor Capacity Control (°C) Load up

� �

Compressor Capacity Control (°C) Hold

� �

Compressor Capacity Control (°C) Load down

� �

Control Status Compressor Start Control

� �

Control Status Suction Pressure Control Activated

Evaporating Temperature (°C)

� �

� �

Control Status Discharge Pressure Control Activated(YCSE Only)

� �

Chilled Water Outlet Temperature (°C)

� �

Chilled Water Outlet Temperature (°C)

Expansion Valve Pulse

� �

� �

Expansion Valve Pulse

� �

Second Water Temperature Setting

This temperature setting provides another setting valuefor water temperature. It can be changed by a remotesignal.

Select the Parameter Settings Mode by pressing andholding SW4 for 3 seconds. Press SW4 � to scrollthrough the parameter settings until the second watertemperature setting display is shown:

This shows the setting is 6°C.

The display automatically toggles (�) between theparameter and the parameter value.

Press SW3� or SW4� to switch btween "Hot WaterTemperature Setting" (YCSE heat pump option only)and "Chilled Water Temperature Setting".

Press and hold SW3� and SW4� for 3 seconds toenter the setting mode. Use SW3 � and SW4 � tochange the value.

Press and hold SW3� and SW4� for 3 seconds tosave the setting.

The Chilled Water Temperature is set to 9.5°C. Use thesame procedure to set the Hot Water Temperature(YCSE heat pump option only).

6-4

035-21786-100 Rev. 1 (0909)

t S C � 6

�

t S C d � t S H d�

� 5.5

6� 6.5

t S C d � 9.5

6-5

035-21786-100 Rev. 1 (0909)

No. 1 Comp. No.2 Comp. No. 1 Comp. No.2 Comp.

C1-H1 C2-H2 High Pressure C3-P6 C3-P6

Water Failure for Condenser(Differential Pressure Switch orFlow switch option)(YCSE only)

C1-L1 C2-L2 Low PressureAlarm of Water Failure(Differential Water PressureSwitch Option)

C1-t1 C2-t2Low Suction Gas TemperatureSensor

Activation of AdditionalProtection Device

C1-51 C2-52Activation of Thermal Relay forCompressor Overload

Freezing Protection

C1-71 C2-72Activation of CompressorInternal Thermistor

Phase Abnormally

C1-61 C2-62Activation of Discharge GasTemperature Sensor

No Signal Feedback from WaterPump

C1-91 C2-92Cooler Inlet RefrigerantTemperature Low

Communication Error betweenExpansion Valve PCB andControl PCB

C1-28 C2-28Failure of Suction Gas PressureSensor (Open / Short)

Communication Error betweenChiller and Remote Control (ifCSC-5S connected)

C1-27 C2-27Failure of Discharge GasPressure Sensor (Open / Short)

Excessive High WaterTemperature

C1-26 C2-26Failure of Suction GasThermistor(Open / Short)

Malfunction

C1-21 C2-21Failure of Cooler InletRefrigerant Thermistor(Open/Short)

Failure of Water InletTemperature Thermistor (Open /Short)

C1-23 C2-23Failure of Discharge GasThermistor (Open / Short)

Failure of Water OutletTemperature Thermistor (Open /Short)

C1-24 C2-24Failure of Thermistor set beforeExapansion Valve

C1-25 C1-25Failure of Water OutletTemperature Thermistor incooler site (Open / Short)

Failure of Hot Water InletTemperature Thermistor(Open/Short)(YCSE heat pump option only)

C1-P6 C1-P6 Retry Operation

Failure of Hot Water OutletTemperature Thermistor(Open/Short)(YCSE heat pump option only)

"-" : Flashing Display

13-13

05-05

Alarm Display CodeFunction

6E-6E

AP-AP

32-32

FunctionAlarm Display Code

31-1

40-40

11-11

12-12

5P-5P

EU-EU

03-03

"Pu"-"Pu"

Alarm Codes

6-6

035-21786-100 Rev. 1 (0909)

Water (DSW4-4: OFF)5 to 20 -5 to 5 -10 to -6

ProtectionIf Ps < 3.7bar, starts loadingdown for 10 secs and thenholds slide valve postion

If Ps < 0.9bar, starts loadingdown for 10 secs and thenholds slide valve postion

If Ps < 0.2bar, starts loadingdown for 10 secs and thenholds slide valve postion

Alarm

If Ps < 3.7bar, stopcompressor as thermo-off.Alarm Cn-Ln in this case 3times

AlarmDischarge Gas (Pd) Protection

Alarm CEL/CoL < 2°C CEL/CoL < -8.5°C CEL/CoL < -13.5°C

Protection

If CEL/CoL < 2.5°C startsloading down for 10 secsand then holds slide valvepostion for 30 mins

If CEL/CoL < -8.0°C startsloading down for 10 secsand then holds slide valvepostion for 30 mins

If CEL/CoL < -13.0°C startsloading down for 10 secsand then holds slide valvepostion for 30 mins

Suction Gas Temp (Ts) AlarmIf Ts < 1°C for 10 secs.Alarm Cn-Tn.

If Ts < -10°C for 10 secs.Alarm Cn-Tn.

If Ts < -15°C for 10 secs.Alarm Cn-Tn.

Evaporating Gas Temp. (Te) Thermo-offIf Ts < 3°C for 10 secs stopcompressor as thermo-off

If Ts < -15°C for 10 secsstop compressor as thermo-off

If Ts < -20°C for 10 secsstop compressor as thermo-off

CompressorCoilProtection

Discharge Gas Temp (Ts) Alarm

Leaving Liquid Temp (°C)Cooling Liquid Brine/Glycol (DSW4-4: ON)

Alarm Cn-Ln immediately when Ps 140°C for 3 secs alarm Cn-6n

Starts loading down at 26bar

PressureControl

Suction Gas (Ps)

N/A

FreezeProtection

Water inlet/outlet temp.

Pressure/Temperature Settings

Standard Models YCSE040 YCSE050 YCSE060 YCSE080 YCSE100Compressor HP SwitchCut-out (Mpa)Compressor LP Switch (Pressure Sensor)Cut-out (Mpa)Compressor Internal ThermostatCut-out (°C)Cut-in (°C)Compressor Motor Fuse (A) 100 100 125 125 100Compressor Motor Thermal RelayRating (A) 48 55 70 75 55Compressor Magnetic Circuit Protection (Option)Rating (A) 90 107 127 127 107Oil HeaterRating (W)Discharge Gas (Electronic Control)Cut-out (°C)CCP TimerSetting Time (S)Star-Delta (S)Unloading During Starting (S)Refrigerant Circuit Pressure Relief ValvePressure Setting (Mpa)Freeze Protection ThermostatCut-out (°C)

One for each circuit3.0

One for each evaporator2.0

11593

Manual Reset, Non-Adjustable (One 3 phase set for each compressor motor)

One for each system

2.74Electronic Control

0.05Manual Reset, Non-Adjustable (One switch for each compressor motor)

Manual Reset, Non-Adjustable (One switch for each compressor motor)

Manual Reset, Non-Adjustable (One 3 phase set for each compressor motor)

One heater for each compressor motor)150

140Non-Adjustable (One timer for each compressor motor)

530

180

Safety and Control Device Settings

6-7

035-21786-100 Rev. 1 (0909)

OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF

- OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF

- OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF

- - - ON - - - - - - - - - - - OFF - OFF -

Load Up - - - - - - O O - - - - - - - - - -

Neutral - - - - - - - - O - O - - O O - O -

Load Down - - - - - - - - O - O O - - - - -

Safety Devices Nº 1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS

Power Supply Lamp OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF

Operation Lamp OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF

Alarm Lumpr OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF

Oil Heater CH1 OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON ON ON ON OFF

Motor for Compressor STA DLT DLT DLT DLT DLT DLT DLT DLT DLT

(ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) (ULD) (FLD)

15% 15% 15%-99% 100% 100% 15%-99% 15%-99% 15% 15%-99% 100%

SV11 OFF OFF OFF ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF

SV12 OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF

SV13 OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

3min

5 sec

CLS=Close OPN=Open STA=Star DLT=Delta ULD=Unload FL=Full Load

Controller

Main Power Switch

Chilled Water Pump

MC1

Capacity Control Safety Devices Shut Down

OFF OFF OFF OFF

Minimum 3 mins

30 secTiming Schedule

Solenoid Valve

OFF OFF

Control Devices

Condenser Water Pump

Operation Switch (ON/OFF)

OFF OFF OFF

Starting Control

Control Stage

Standard Operating Sequence - YCSE-040, 050, 060, 080, YCRE-040, 050, 060

OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF- OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF- OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF- - - ON - - - - - - - - - - - - - - OFF - OFF -

Load Up - - - - - - - - O O - - - - - - O O - - - -Neutral - - - - - - - - - - O - - - - O - - - O - -Load Down - - - - - - - - - - - O O O O - - - - - - -Nº 1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN OPN CLS CLS CLS CLSNº 2 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS

Power Supply Lamp OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF

Operation Lamp OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFFAlarm Lamp OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF

CH1 OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON ON ON ON ON OFFCH2 OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF ON ON ON ON OFF

STA DLT STA DLT DLT DLT DLT DLT DLT DLT DLT DLT(ULD) (ULD) (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) (ULD) (FLD)

YCSEYCRE

MC2 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT(ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) (ULD) (ULD) (FLD)

YCSE 15% 15%15%-99% 100% 100%

15%-99%

15%-99% 15%

15%-99%

15%-99% 100%

SV11 OFF OFF OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFFSV12 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFFSV13 OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFFSV21 OFF OFF OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFFSV22 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFFSV23 OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF ON OFF OFF ON OFF OFF OFF OFF OFF

3min5 sec

5 sec

CLS=Close OPN=Open STA=Star DLT=Delta ULD=Unload FL=Full Load

OFF OFF

Motor forCompressor OFF OFF OFF

15% 15% 15% 15%

OFF OFF

OFF

OFF OFF OFF

Controller

MC1

Shut DownSafety Devices

Safety Devices

Oil Heater

OFF OFF OFFOFF

Control Stage

Operation Switch (ON/OFF)

Main Power SwitchChilled Water PumpCondenser Water Pump

Capacity ControlStarting ControlControl Devices

30 secMinimum 3 mins

Timing Schedule 60 sec

Solenoid Valve

OFF OFF OFF

Motor forCompressor OFF OFF OFF

15-99% 100% 100% 15-99% 15-99% 15% 15-99% 100%

Standard Operating Sequence - YCSE-100, YCRE-080, 100

6.5.2 Control Printed Circuit Board

The Control Printed Circuit Board contains various switches for setting the unit control parameters.

6-8

035-21786-100 Rev. 1 (0909)

Switch Function Factory Default

RSW 1 Chilled Water Outlet Temperature Setting Switch 7

RSW 2 Chilled Water Outlet Temperature Setting Switch 0

RSW 3 Hot Water Outlet Temperature Setting Switch (heat pump option only) 5

RSW 4 Hot Water Outlet Temperature Setting Switch (heat pump option only) 4

RSW 5 Not Used N/A

RSW 6 Not Used N/A

RSW 7 Not Used N/A

RSW 8 Neutral Zone Setting Switch. 2 °C is standard. 3

RSW 9 Not Used N/A

SW 6 Local/Remote Changeover Switch. (Up:Local, Down:Remote) Local

SW 7 Local/Remote Pump Operation (Up:Local, Down:Remote) Remote

SW 8 Cooling/ Heating Operation Switch (Up:Cool, Down:Heat) Cool

SW 9 Not Used N/A

SW 10 Not Used N/A

SW 11 Not Used N/A

SW 12 Not Used N/A

cont…

To prevent possible damage to the chiller and/or the control circuit and the warranty becoming void, onlythe following settings and parameters should be applied.

DIP switches must be checked and set before applying control circuit power for the settings to beapplicable. With the exception of the chilled water settings, changing the DIP switch settings with thecontrol circuit power on will have no effect on the unit operation.

6-9

035-21786-100 Rev. 1 (0909)

Switch Function Factory Default

DSW1 Not Used OFF

DSW2-1

DSW2-2Compressor Starting Time Delay

3 Mins

OFF/OFF

DSW3-1

DSW3-2Compressor Isolation for Maintenance ON/ON

DSW3-3 to

DSW3-7Not Used OFF

DSW3-8

DSW3-9

DSW3-10

Sets chiller ID when using more than one chiller with a remote control

systemOFF/OFF/OFF

DSW4-1 Cooling Only (OFF) or Heat Pump Enabled (ON) OFF

DSW4-4 Water (OFF) or Brine/Glycol (ON) OFF

DSW4-2

DSW4-6

DSW4-7

Not Used ON

DSW4-3

DSW4-5

DSW4-8

Not Used OFF

DSW5-1

DSW5-2

Temperature Band for Stop Setting Switch.

1 °C is standard.ON/OFF

DSW5-3

DSW5-4

Temperature Band for Restart Setting Switch.

2 °C is standard.ON/OFF

DSW5-5Differential Temperature of Load-up 2 Mode Setting Switch.

1 °C is standard.ON

DSW5-6Output Signal Time for Load-up 1 Mode Setting Switch.

12 secs is standard.ON

DSW5-7

DSW5-8

Output Signal Time for Load-up 2 and Load-down Mode Setting Switch.

2 secs is standard.ON/ON

DSW5-9

DSW5-10

Interval of Output Signal Time for Load-up 2 and Load-down Mode

Setting Switch. 60 secs is standard.ON/ON

DSW6-1 to

DSW6-4Not Used OFF

DSW7-1

DSW7-2

This switch defines the chilled liquid temperature range

+5°C to -5°C is standard.ON/OFF

DSW7-3 Enables extended minimum capacity control on 2 system chillers. OFF

DSW7-4 Enables H-Link communications between unit and HARC. OFF

Chilled Water Outlet Temperature Setting SwitchRSW1 and RSW2

7°C for chi l led water out let temperature isrecommended. The RSW1 and RSW2 dials are factoryset at 7 and 0. RSW2 should only be set at 0,1 or 2.

Hot Water Outlet Temperature Setting SwitchRSW3 and RSW4 (Heat pump option only)

45°C for hot water out let temperature isrecommended.The RSW3 and RSW4 dials are factoryset at 5 and 4.

Current Limitation: RSW5, RSW6 and RSW7

RSW5, RSW6 and RSW7 are not used.

Neutral Zone Setting Switch: RSW8

2 °C is standard. The RSW8 dial is factory set at 3 = 2 °C.

The settings for RSW8 dial are as follows:

Continuous Capacity Control Setting Switch:DSW5

The figure below the shows the various terms anddefinitions used for capacity control setting.

Temperature Band for Stop Setting SwitchDSW5-1, DSW5-2

1°C degree is factory default: DSW5-1 ON; DSW5-2OFF.

The settings for DSW5-1, DSW5-2 are as follows:

Temperature Band for Restart Setting SwitchDSW5-3, DSW5-4

2°C is factory default: DSW5-3 ON; DSW5-4 OFF.

The settings for DSW5-3, DSW5-4 are as follows:

Differential Temperature of Load-up 2 ModeSetting Switch, DSW5-5

1°C degree is factory default: DSW5-5 ON.

The settings for DSW5-5 are as follows:

Output Signal Time for Load-up 1 Mode SettingSwitch, DSW5-6

12 seconds is factory default: DSW5-6 ON.

The settings for DSW5-6 are as follows:

Output Signal Time for Load-up 2 and Load-downMode Setting Switch, DSW5-7, DSW5-8

2 seconds is factory default: DSW5-7 ON; DSW5-8 ON.

The settings for DSW5-7, DSW5-8 are as follows:

6-10

035-21786-100 Rev. 1 (0909)

RSW 8 0 1 2 3 4 5 6 7 8 9°C 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

DSW5 1 2 1 2 1 2 1 2Setting On On On Off Off On Off Off°C 0.5 1 1.5 2

DSW5 3 4 3 4 3 4 3 4Setting On On On Off Off On Off Off°C 1 2 3 4

DSW5 5 5Setting On Off°C 1 3

DSW5 6 6Setting On OffSecs 12 24

DSW5 7 8 7 8 7 8 7 8Setting On On On Off Off On Off OffSecs 2 4 6 8

Interval of Output Signal Time for Load-up 2 andLoad-down Mode Setting Switch:DSW5-9, DSW5-10

60 seconds is factory default: DSW5-9 ON; DSW5-10ON.

The settings for DSW5-9, DSW5-10 are as follows:

Setting of Compressor Cycling Protection Start:DSW2-1, DSW2-2

This switch sets the compressor starting time delay. Thecompressor will start after this time.

3 minutes is factory default: DSW2-1 OFF; DSW2-2OFF.

The settings for DSW2-1 and DSW2-2 are as follows:

Manual Set Switch A: DSW3-1, DSW3-2,

This switch allows the compressors to be electricallyisolated for maintenance purpoes.

Switches DSW3-1 is for No.1 compressor, "DSW3-2" isfor No.2 compressor. DSW3-3 to DSW3-10 are not usedand should be set to OFF.

The settings for DSW3-1, DSW3-2 are as follows:

Manual Set Switch A: DSW3-8, DSW3-9, DSW3-10

This switch is used to set the chiller ID when using morethan one chiller with a remote control system (HARC,ISN etc.)

Manual Set Switch B: DSW4-1

This switch defines if the unit operates in cooling modeonly or if the optional heat pump mode is enabled.

The setting for DSW4-1 is as follows:

Manual Set Switch B: DSW4-4

This switch defines the unit chilled liquid as either wateror brine/glycol .

The setting for DSW4-4 is as follows:

Manual Set Switch B: DSW4-2, 4-6 and 4-7

These switches must be set to ON.

Manual Set Switch B: DSW4-3, 4-5 and 4-8

These switches must be set to OFF.

Manual Set Switch B: DSW4-9, DSW4