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York YCAS0130 manual Introduction & Physical Description

Models: YCAS0130

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FORM 201.19-NM1 (204)

1. INTRODUCTION & PHYSICAL DESCRIPTION

8

29023A

1.1 GENERAL

The YORK Screw Chiller Control Panel is a micropro- cessor based control system ﬁtted to YCAS liquid chill- ers. It is capable of multi-refrigerant system control to maintain chilled liquid temperature within programmed limits and to provide safety control of the chiller. The microprocessor monitors leaving chilled liquid tempera- ture deviation from setpoint and the rate of change of this temperature to start, stop, load and unload compressors as required.

User interface is via a touch keypad and a liquid crystal display allowing access to operating and programmed data. Information can be displayed in English (Imperial) units or SI (Metric) units (Section 8.1). Conversion tables are provided at the back of this manual.

A master ON/OFF rocker switch is provided on the chiller control panel to activate or deactivate the com- plete chiller, while switches to activate or deactivate individual refrigerant systems are provided on the Mi- croprocessor Board.

External interface is available for control of the chiller via a YORK ISN System or YORK Remote Control Center. In addition, EMS/BAS System connections are

provided for remote cycling, current limiting, remote temperature setpoint reset and alarm annunciation.

YCAS chillers each have a single split circuit evapo- rator serving 2 independent refrigerant systems. YCAS 2 system chillers are conﬁgured as a single self contained section with a single control panel controlling the two refrigerant systems.

1.2 KEYPAD & DISPLAY

An operator keypad allows complete control of the chiller from a central location. The keypad offers a multitude of commands available to access displays, program setpoints, and initiate system commands. Keys are grouped and color coded for clarity and ease of use.

A 40 Character Liquid Crystal Display (2 lines of 20 characters) is used for displaying system parameters and operator messages. The display has a lighted back- ground for night viewing as well as a special feature which intensiﬁes the display for viewing in direct sunlight.

Displays will be updated every two seconds by the microprocessor.

YORK INTERNATIONAL

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York YCAS0130 manual Introduction & Physical Description

Contents

INSTALLATION, OPERATION & MAINTENANCE New Release AIR-COOLED SCREW LIQUID CHILLERSYCAS AIR-COOLED LIQUID CHILLERS YCAS0130 THROUGH YCAS0230 STYLE G 60 HzCHANGEABILITY OF THIS DOCUMENT GENERAL SAFETY GUIDELINES SAFETY SYMBOLSREAD BEFORE PROCEEDING SECTION 1 - GENERAL CHILLER TABLE OF CONTENTSINFORMATION & SAFETY SECTION 4 - INSTALLATIONSECTION 6 - OPERATION TABLE OF CONTENTS CONT’DSECTION 7 - TECHNICAL DATA SECTION 5 - COMMISSIONINGSECTION 8 - MICRO PANEL CONTENTS TABLE OF CONTENTS CONT’DSECTION 11 - TROUBLE SHOOTING LIST OF TABLESTABLE OF CONTENTS CONT’D SECTION 9 - MAINTENANCELIST OF FIGURES Standards for Safety GENERAL CHILLER INFORMATION & SAFETYStructural Support General Chiller Information & SafetyGeneral Access Suitability for ApplicationRefrigerants and Oils High Temperature and Pressure CleaningRotating Parts Sharp EdgesCompressor PRODUCT DESCRIPTIONProduct Description General DescriptionCondenser EvaporatorOil Separator/System Power and Control PanelProduct Description EconomizerMicroprocessor Controls Each power compartment containsThe control section contains The options sections containCurrent Overload Other symbolsProduct Description Motor Protection Modules 2ACECurrent Imbalance Loaded & Unloaded/ Loss of Phase Improper Phase SequenceThermal Overload YCAS STYLE G, ACROSS-THE-LINE - 60 HZ TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTINGProduct Description YCAS STYLE G, ACROSS-THE-LINE - 60 HZ TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING CONT’DProduct Description YCAS STYLE G, WYE DELTA START - 60 HZYCAS STYLE G, WYE DELTA START - 60 HZ TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING CONT’DDisplay Product DescriptionSingle-Point Power Connection without Circuit Protection Multiple Point Power Connection StandardSingle-Point Power Connection with Individual Circuit Protection Single-Point Power Connection with Combined Circuit ProtectionThe following options provide added protection Product DescriptionUNIT NOMENCLATURE DATAYCAS0230EC46YGA NAMEPLATE ENGINEERINGCONDENSER FIELD PRODUCT IDENTIFICATION NUMBER PINProduct Description EVAP. FIELDLifting Weights HANDLING AND STORAGE88 2250mm CORRECT UNIT RIGGINGHandling and Storage CORRECTLOCATION REQUIREMENTS INSTALLATIONOUTDOOR INSTALLATIONS INDOOR INSTALLATIONSCOMPRESSOR FEET BOLT REMOVAL InstallationGeneral Requirements InstallationInstallation WATER TREATMENTFIG. 6 - PIPEWORK ARRANGEMENT CONNECTION TYPES & SIZES Optional FlangesGeneral Requirements PIPEWORK ARRANGEMENTUnits with Single-Point Power Supply Wiring InstallationRemote Emergency Stop Device Alarm ContactsFlow Switch Remote Setpoint Offset - TemperatureOPTIONAL CIRCUIT BREAKER SWITCH POWER PANEL LAYOUTS TYPICALInstallation OPTIONAL DISCONNECT SWITCHOPTION PANEL LAYOUT TYPICAL LOGIC PANEL OPTION PANEL WITH SINGLE POINT TERMINAL BLOCK OPTIONALFIG. 10 - OPTION PANEL SECTION PHOTOGRAPH OF LOGIC SECTION LAYOUTInstallation 60 Hz ModelsFIG. 12 - LOGIC SECTION LAYOUT WITH CONTROL PANEL LOGIC SECTION LAYOUT WITH CONTROL PANELCUSTOMER CONNECTIONS InstallationFIG. 13 - CUSTOMER CONNECTIONS CUSTOMER CONNECTIONS FIG. 14 - CUSTOMER CONNECTIONS115 VAC SUPPLY Inspection COMMISSIONINGCommissioning Power ConnectionsProgrammed Settings Switch SettingsFlow Switch Temperature SensorsStart-up System SwitchesCommissioning InterlocksThis page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL Operation OPERATIONThis page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL FLOW RATE AND PRESSURE DROP CHARTS TECHNICAL DATATechnical Data GLYCOL CORRECTION FACTORSENGLISH UNITS TEMPERATURE AND FLOWSTEMPERATURE AND FLOWS Technical DataSI UNITS ENGLISH UNITS MODEL NUMBER YCAS PHYSICAL DATATechnical Data PHYSICAL DATASI UNITS MODEL NUMBER YCAS OPERATING LIMITATIONS AND SOUND POWER DATA OPERATING LIMITATIONS - ENGLISH UNITSOPERATING LIMITATIONS - SI UNITS MULTIPLE POINT POWER SUPPLY CONNECTION - 2 COMPRESSOR UNITS ELECTRICAL DATATechnical Data MULTIPLE POINT POWER SUPPLY CONNECTION Suitable for Y - ∆ Start andFANS11 ELECTRICAL DATAELECTRICAL DATA Technical DataFIELD-SUPPLIED WIRING FACTORY PROVIDED LUGS WIRE RANGEELECTRICAL DATA FORM 201.19-NM1YORK INTERNATIONAL ELECTRICAL DATA Technical DataOPTIONAL SINGLE-POINT POWER SUPPLY OPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION - 2 COMPRESSOR UNITSELECTRICAL DATA FORM 201.19-NM1YORK INTERNATIONAL CONNECTION TO FACTORY CIRCUIT BREAKER Suitable for Technical DataOPTIONAL SINGLE-POINT POWER SUPPLY ELECTRICAL DATADXS36LA - MOTOR CODE A ELECTRICAL DATAMAXIMUM kW AND AMPERAGE VALUES FOR DXST COMPRESSORS DXS45LA - MOTOR CODE AELECTRICAL NOTES Technical DataNOTES & LEGEND This page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL WIRING DIAGRAM ACROSS-THE-LINE STARTTechnical Data LD09233 WIRING DIAGRAMFIG. 18 - WIRING DIAGRAM - ACROSS-THE-LINE START ACROSS-THE-LINE STARTELEMENTARY DIAGRAM Technical DataFIG. 19 - ELEMENTARY DIAGRAM - ACROSS-THE-LINE START NON-FUSED ELEMENTARY DIAGRAMCONTROLPOWER SUPPLY SWITCH SIZEFIG. 20 - WIRING DIAGRAM - WYE-DELTA START WYE-DELTA STARTWIRING DIAGRAM Technical DataLD09236 WIRING DIAGRAMFIG. 21 - ELEMENTARY DIAGRAM - WYE-DELTA START WYE-DELTA STARTELEMENTARY DIAGRAM Technical DataFIG. 22 - ELEMENTARY DIAGRAM - WYE-DELTA START ELEMENTARY DIAGRAM FORM 201.19-NM1YORK INTERNATIONAL Technical Data FIG. 22A - POWER PANEL SYSTEM #1 COMPONENT LOCATIONSLD09238 LD09239 FIG. 22B - CONTROL PANEL COMPONENT LOCATIONTechnical Data FIG. 22C - POWER PANEL SYSTEM #2 COMPONENT LOCATIONSLD09240 FORM 201.19-NM1 YORK INTERNATIONALLD09241 LD03284 Technical DataLD03282 LD03283 2 ACE MOTOR PROTECTOR MODULELD09242 CONNECTION DIAGRAM SYSTEM WIRINGCOMPRESSOR TERMINAL BOX Technical DataLD09243 LD09373 ELEMENTARY DIAGRAM CONTROL CIRCUIT#3/#4 ELEMENTARY DIAGRAMTechnical Data #3/#4This page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL DIMENSIONS - YCAS0130 - YCAS0180 ENGLISH 0P0.71Technical Data LD03744 DIMENSIONS - YCAS0130 - YCAS0180 ENGLISH46 EDGE OF UNIT TO COOLER CONNECTION DIMENSIONS - YCAS0130 - YCAS0180 SITechnical Data All dimensions are in mm unless otherwise notedDIMENSIONS - YCAS0130 - YCAS0180 SI LD03746LD03747 MICRO-COMPUTER DIMENSIONS - YCAS0200 - YCAS0230 ENGLISHTechnical Data SYS.#2DIMENSIONS - YCAS0200 - YCAS0230 ENGLISH LD03749LD03750 DIMENSIONS - YCAS0200 - YCAS0230 SI Technical DataAll dimensions are in mm unless otherwise noted DIMENSIONS - YCAS0200 - YCAS0230 SI LD03752LD03753 1.3 m TECHNICAL DATATechnical Data CLEARANCESAluminium and Black Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSISOLATOR DETAILS WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data Aluminium and Black Fin Condenser CoilsAWMR-2-XXX WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAluminium and Black Fin Condenser Coils AWMR-1-XXXNEW DESIGN FOR TYPE RD-4 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data Aluminium and Black Fin Condenser CoilsCopper Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSISOLATOR DETAILS WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data Copper Fin Condenser CoilsAWMR-2-XXX WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSCopper Fin Condenser Coils AWMR-1-XXXNEW DESIGN FOR TYPE RD-4 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data Copper Fin Condenser CoilsAluminium Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSISOLATOR DETAILS WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data Aluminium Fin Condenser Coils with Silencer KitAWMR-2-XXX WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAluminium Fin Condenser Coils with Silencer Kit AWMR-1-XXXNEW DESIGN FOR TYPE RD-4 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data Aluminum Fin Condenser CoilsCopper Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSISOLATOR DETAILS WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data Copper Fin Condenser Coils with Silencer KitAWMR-2-XXX WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSCopper Fin Condenser Coils with Silencer Kit AWMR-1-XXXNEW DESIGN FOR TYPE RD-4 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data Copper Fin Condenser Coils with Silencer KitRESTRAINED MOUNTINGS INSTALLATION INSTRUCTIONS FOR VMC SERIES AWR/AWMR AND CPREFRIGERANT FLOW DIAGRAM Technical DataFIG. 36 - REFRIGERANT FLOW DIAGRAM MAJOR COMPONENTS PROCESS AND INSTRUMENTATION DIAGRAMFIG. 37 - PROCESS AND INSTRUMENTATION DIAGRAM SYSTEM COMPONENTSCOMPONENT LOCATIONS Technical DataControl Panel FIG. 39 - COMPRESSOR COMPONENTS COMPRESSOR COMPONENTSCOMPRESSOR COMPONENTS - CONT’D Technical DataFIG. 40 - COMPRESSOR COMPONENTS COMPRESSOR COMPONENTS - CONT’D FIG. 41 - COMPRESSOR COMPONENTSLD03670 O-RING OIL FILTER MALE ROTOR DISCHARGE CHECK VALVE Technical DataCOMPRESSOR COMPONENTS - CONT’D FIG. 42 - COMPRESSOR COMPONENTSCOMPRESSOR COMPONENTS - CONT’D FIG. 43 - COMPRESSOR COMPONENTSLD03673 LD03672 Technical DataCOMPRESSOR COMPONENTS - CONT’D FIG. 44 - COMPRESSOR COMPONENTSExcessive ﬂow may cause catastrophic damage to the evaporator SYSTEM STARTUP CHECKLISTRecord programmed values in the chart below Technical DataCHECKING SUBCOOLING AND SUPERHEAT INITIAL START-UPtemperature, and economizer superheat below Technical DataThis page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL Display Keys - see Section CHILLER CONTROL PANEL PROGRAMMING AND DATA ACCESS KEYSMicro Panel Contents Status Key - see Section1. INTRODUCTION & PHYSICAL DESCRIPTION Power Supply Board Micro Panel ContentsSystem Switches 1 Internal Clock & Memory Backup Battery2T This 75VA transformer supplies the 24VAC to the power supply board 4T Supplies 24VAC power to the 2ACE Motor Protector ModulesRelay Output Boards Always review the data in the history buffer when faults occur. Since the Micro attempts to restart 2 more times and fails to restart with the M1-M2 contacts open, the Micro will record the last 2 faults of Low Curr/MP/ HP. Hence, the third 3rd history buffer will show data related to the true cause. See page 142 for additional fault data Micro Panel ContentsFIG. 45 - MOTOR PROTECTION MODULE SIDE VIEWTOP VIEW SIDE VIEWMicro Panel Contents Remote Current ResetRemote Start/Stop Remote Setpoint Temperature Reset Micro Panel Contents 1.11 MICROPROCESSOR BOARD LAYOUTFIG. 46 - COMPONENT LAYOUT FIG. 47 - LOGIC SECTION LAYOUT Flow Switch & Customer Connection Terminals TB41.12 LOGIC SECTION LAYOUT 60 Hz Models 60 HZ MODEL LOGIC SECTION1.15 EVAPORATOR PUMP CONTROL Micro Panel Contents1.13 ANTI-RECYCLE TIMER 1.14 ANTI-COINCIDENCE TIMER1.19 ALARMS 1.20 RUN STATUS CHILLER1.21 LEAD / LAG COMPRESSOR SELECTION 1.22 ECONOMIZER SOLENOID CONTROL Micro Panel ContentsThe micro utilizes the formula below to compute pres- sure ratio PR = DP in PSIG+14.7 SP in PSIG+14.7PROCESS AND INSTRUMENTATION DIAGRAM FIG. 47A - PROCESS AND INSTRUMENTATION DIAGRAMECONOMIZER HX Unit Switch OFF 2. STATUS KEY GENERAL STATUS MESSAGES & FAULT WARNINGSMicro Panel Contents 2.5 Chiller Fault Status Messages 2.6 System Fault Status MessagesLow Battery Warning System Switches OFFAnti-Recycle Timers Anti-Coincidence TimersIncorrect Refrigerant Warning Micro Panel ContentsPower Failure Warning Pump DownLow Leaving Chilled Liquid Temperature Cutout Suction Temperature LimitingLow Ambient Temperature Cutout High Ambient Temperature CutoutHigh Discharge Pressure Cutout Micro Panel ContentsFlow Switch Open High Discharge Temperature CutoutThe Low Suction Pressure Cutout aids in protecting the High Oil Temperature CutoutLow Oil Differential Pressure Cutout Low Suction Pressure CutoutFLA full load amps is approximately Micro Panel Contents2.7 PRINTOUT ON FAULT SHUTDOWN Low Evaporator Temperature Cutout R407C OnlyMicro Panel Contents 3. DISPLAY KEYS & OPTION SWITCHESdisappear Closed Micro Panel ContentsSWITCH 1 Water / Glycol Cooling Open SWITCH 2 Ambient Temp. Range Low Ambient Cutout OpenSWITCH 5 Motor Current Average option start-up Open SWITCH 3 Refrigerant OpenSWITCH 4 Unit Type Open Dip Switch Physical Location and SettingSWITCH 8 Standard Options Open Micro Panel ContentsSWITCH 6 Heat Recovery Open SWITCH 7 Expansion Valve Type Open4. PRINT KEYS YCAS 2 System ModelsCommon Data System Data Micro Panel ContentsThis message indicates the EEV preheat % and the suc- tion superheat When the History key is pressed, the following message will appear Micro Panel ContentsDISABLED Chiller DataBE IN YCAS MODE Micro Panel Contents System Datawill not appear This message indicates the EEV preheat % and the suc- tion superheat Micro Panel Contents 4.7 FAULT HISTORY DATA - REMOTE PRINTOUTAn example of the HISTORY Printout is shown be- low 5.2 NUMERICAL KEYPAD 5. ENTRY KEYS5.4 CANCEL KEY 5.1 GENERALceptable 6. SETPOINTS KEYS & CHILLED LIQUID CONTROLMicro Panel Contents User acCompressor Starting & Loading Sequence Load TimersSlide Valve Control Slide Valve PositionPercentage of Motor Micro Panel ContentsTimer Counts to ANTICIPATORY LOAD LIMITING CONTROLSDISCHARGE TEMPERATURE ANTICIPATORY SHUTDOWN CONTROL OIL TEMPERATURE ANTICIPATORY SHUTDOWN CONTROLANTICIPATORY UNLOADING CONTROLS Micro Panel Contents 6.3 LOCAL COOLING SETPOINTS KEY6.4 REMOTE COOLING SETPOINTS KEY First press the 7. CLOCK KEYSkey can only be pressed Micro Panel Contents7.4 MANUAL OVERRIDE KEY 8. PROGRAM KEY Micro Panel ContentsHigh Discharge Pressure Cut-Out 60/3 + High Discharge Pressure Unload PointLow Suction Pressure Cutout Programmed X Run Time/3 + Cutout100Low Leaving Liquid Temperature Cutout Micro Panel ContentsHigh Ambient Temperature Cutout Low Ambient Temperature CutoutAutomatic/Manual “Lead/Lag” Anti-Recycle TimeLocal/Remote Communications Imperial/SI Units DisplayAutomatic/Manual Power Failure Restart Micro Panel ContentsLow Limit DefaultProgram Value Mode8.4 ELECTRONIC EXPANSION VALVE Micro Panel ContentsIN OUT EEV OPERATION 8.5 EEV OPERATIONMOP FEATURE VALVE PREHEAT FEATUREOPERATING DATA DISPLAYS Micro Panel ContentsLOW SUPERHEAT CUTOUT SAFETY SENSOR FAILURE CUTOUT SAFETY8.6 EEV PROGRAMMING The system shuts down on Low Superheat 8.7 EEV TROUBLESHOOTINGMicro Panel Contents The system shuts down on Low Suction PressureFIG. 51 - CONDENSER FAN LAYOUT FOR DXST 2 COMPRESSOR UNITS 8.8 CONDENSER FAN CONTROLTABLE 3 - CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS WITH 4 FANS/SYSTEM Micro Panel ContentsThe chiller must always be programmed for YCAS Micro Panel Contents Indicates one lead/phase through motor protectorTABLE 6 - YCAS STYLE G, ACROSS THE LINE START - 60 HZ TABLE 6 - YCAS STYLE G, ACROSS THE LINE START - 60 HZ. CONTD Indicates one lead/phase through motor protectorTABLE 7 - YCAS STYLE G, WYE DELTA START - 60 HZ Micro Panel ContentsTABLE 7 - YCAS STYLE G, WYE DELTA START - 60 HZ. CONTD Indicates one lead/phase through motor protectorMicro Panel Contents SERVICE MODE VIEWING INPUTS AND OUTPUTSSERVICE MODE OUTPUT ENABLE Pressure Transducers 8.10 SENSOR CALIBRATION CHARTSAmbient Temperature Sensor Oil & Discharge Temperature Sensors8.11 CONTROL INPUTS/OUTPUTS Micro Panel ContentsTABLE 8 - DIGITAL OUTPUTS TABLE 9 - ANALOG INPUTS ANALOG INPUTSANALOG OUTPUTS Micro Panel ContentsDIGITAL INPUTS TABLE 10 - DIGITAL INPUTS8.12 ISN CONTROL RECEIVED DATA CONTROL DATATRANSMITTED DATA TABLE 13 - ISN TRANSMITTED DATA CONTD Micro Panel ContentsTABLE 13 - ISN TRANSMITTED DATA CONTD TABLE 14 - ISN OPERATIONAL AND FAULT CODES Micro Panel ContentsThis page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL Maintenance MAINTENANCEOVERALL UNIT INSPECTION Scheduled MaintenanceON-BOARD BATTERY BACK-UP Chiller / Compressor Operating Log196 Operating Log COMPRESSOR UNIT OPERATIONMaintenance Operating CHILLER/COMPRESSORYORKINTERNATIONAL MAINTENANCE REQUIREMENTS FOR YORK YCAS SCREW CHILLERSMINOR SERVICE GENERAL PERIODIC MAINTENANCE CHECKS STANDARD UNITSMaintenance SERVICE SCHEDULERecommended Compressor Oils SPARE PARTSFor Parts, Service, or Sales Call Toll Free 1-866-YORK SRV Recommended SparesTroubleshooting TROUBLESHOOTING GUIDEACTION TROUBLESHOOTING GUIDE - CONT’DPROBLEM POSSIBLEWARRANTY ON RECONDITIONED OR REPLACEMENT MATERIALS LIMITED WARRANTY YORK AMERICAS ENGINEERED SYSTEMSTroubleshooting WARRANTY ON NEW EQUIPMENTPressure Conversion Chart Gauge or Differential TEMPERATURE CONVERSION CHARTTemperature Conversion Chart Actual Temperatures Temperature Conversion Chart Differential TemperaturesALL RIGHTS RESERVED Form 201.19-NM1 204 New ReleaseTele Subject to change without notice. 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