AIR-COOLED SCREW LIQUID CHILLERS
YCAS AIR-COOLED LIQUID CHILLERS YCAS0130 THROUGH YCAS0230 STYLE G
60 Hz
INSTALLATION, OPERATION & MAINTENANCE New Release
CHANGEABILITY OF THIS DOCUMENT
SAFETY SYMBOLS
GENERAL SAFETY GUIDELINES
READ BEFORE PROCEEDING
TABLE OF CONTENTS
INFORMATION & SAFETY
SECTION 4 - INSTALLATION
SECTION 1 - GENERAL CHILLER
TABLE OF CONTENTS CONT’D
SECTION 7 - TECHNICAL DATA
SECTION 5 - COMMISSIONING
SECTION 6 - OPERATION
TABLE OF CONTENTS CONT’D
SECTION 8 - MICRO PANEL CONTENTS
LIST OF TABLES
TABLE OF CONTENTS CONT’D
SECTION 9 - MAINTENANCE
SECTION 11 - TROUBLE SHOOTING
LIST OF FIGURES
GENERAL CHILLER INFORMATION & SAFETY
Standards for Safety
General Chiller Information & Safety
General Access
Suitability for Application
Structural Support
High Temperature and Pressure Cleaning
Rotating Parts
Sharp Edges
Refrigerants and Oils
PRODUCT DESCRIPTION
Product Description
General Description
Compressor
Evaporator
Condenser
Power and Control Panel
Product Description
Economizer
Oil Separator/System
Each power compartment contains
The control section contains
The options sections contain
Microprocessor Controls
Other symbols
Product Description
Motor Protection Modules 2ACE
Current Overload
Improper Phase Sequence
Current Imbalance Loaded & Unloaded/ Loss of Phase
Thermal Overload
TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING
YCAS STYLE G, ACROSS-THE-LINE - 60 HZ
Product Description
TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING CONT’D
YCAS STYLE G, ACROSS-THE-LINE - 60 HZ
YCAS STYLE G, WYE DELTA START - 60 HZ
Product Description
TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING CONT’D
YCAS STYLE G, WYE DELTA START - 60 HZ
Product Description
Display
Multiple Point Power Connection Standard
Single-Point Power Connection with Individual Circuit Protection
Single-Point Power Connection with Combined Circuit Protection
Single-Point Power Connection without Circuit Protection
Product Description
The following options provide added protection
DATA
YCAS0230EC46YGA
NAMEPLATE ENGINEERING
UNIT NOMENCLATURE
PRODUCT IDENTIFICATION NUMBER PIN
Product Description
EVAP. FIELD
CONDENSER FIELD
HANDLING AND STORAGE
Lifting Weights
UNIT RIGGING
Handling and Storage
CORRECT
88 2250mm CORRECT
INSTALLATION
OUTDOOR INSTALLATIONS
INDOOR INSTALLATIONS
LOCATION REQUIREMENTS
Installation
COMPRESSOR FEET BOLT REMOVAL
Installation
General Requirements
WATER TREATMENT
Installation
FIG. 6 - PIPEWORK ARRANGEMENT
Optional Flanges
General Requirements
PIPEWORK ARRANGEMENT
CONNECTION TYPES & SIZES
Installation
Units with Single-Point Power Supply Wiring
Alarm Contacts
Flow Switch
Remote Setpoint Offset - Temperature
Remote Emergency Stop Device
POWER PANEL LAYOUTS TYPICAL
Installation
OPTIONAL DISCONNECT SWITCH
OPTIONAL CIRCUIT BREAKER SWITCH
LOGIC PANEL OPTION PANEL WITH SINGLE POINT TERMINAL BLOCK OPTIONAL
OPTION PANEL LAYOUT TYPICAL
FIG. 10 - OPTION PANEL SECTION
LOGIC SECTION LAYOUT
Installation
60 Hz Models
PHOTOGRAPH OF
LOGIC SECTION LAYOUT WITH CONTROL PANEL
FIG. 12 - LOGIC SECTION LAYOUT WITH CONTROL PANEL
Installation
CUSTOMER CONNECTIONS
FIG. 13 - CUSTOMER CONNECTIONS
FIG. 14 - CUSTOMER CONNECTIONS
CUSTOMER CONNECTIONS
115 VAC SUPPLY
COMMISSIONING
Commissioning
Power Connections
Inspection
Switch Settings
Flow Switch
Temperature Sensors
Programmed Settings
System Switches
Commissioning
Interlocks
Start-up
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YORK INTERNATIONAL
OPERATION
Operation
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YORK INTERNATIONAL
TECHNICAL DATA
Technical Data
GLYCOL CORRECTION FACTORS
FLOW RATE AND PRESSURE DROP CHARTS
TEMPERATURE AND FLOWS
ENGLISH UNITS
Technical Data
TEMPERATURE AND FLOWS
SI UNITS
PHYSICAL DATA
ENGLISH UNITS MODEL NUMBER YCAS
PHYSICAL DATA
Technical Data
SI UNITS MODEL NUMBER YCAS
OPERATING LIMITATIONS - ENGLISH UNITS
OPERATING LIMITATIONS AND SOUND POWER DATA
OPERATING LIMITATIONS - SI UNITS
ELECTRICAL DATA
Technical Data
MULTIPLE POINT POWER SUPPLY CONNECTION Suitable for Y - ∆ Start and
MULTIPLE POINT POWER SUPPLY CONNECTION - 2 COMPRESSOR UNITS
ELECTRICAL DATA
FANS11
Technical Data
FIELD-SUPPLIED WIRING
FACTORY PROVIDED LUGS WIRE RANGE
ELECTRICAL DATA
FORM 201.19-NM1
ELECTRICAL DATA
YORK INTERNATIONAL
Technical Data
OPTIONAL SINGLE-POINT POWER SUPPLY
OPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION - 2 COMPRESSOR UNITS
ELECTRICAL DATA
FORM 201.19-NM1
ELECTRICAL DATA
YORK INTERNATIONAL
Technical Data
OPTIONAL SINGLE-POINT POWER SUPPLY
ELECTRICAL DATA
CONNECTION TO FACTORY CIRCUIT BREAKER Suitable for
ELECTRICAL DATA
MAXIMUM kW AND AMPERAGE VALUES FOR DXST COMPRESSORS
DXS45LA - MOTOR CODE A
DXS36LA - MOTOR CODE A
Technical Data
ELECTRICAL NOTES
NOTES & LEGEND
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YORK INTERNATIONAL
ACROSS-THE-LINE START
WIRING DIAGRAM
Technical Data
WIRING DIAGRAM
FIG. 18 - WIRING DIAGRAM - ACROSS-THE-LINE START
ACROSS-THE-LINE START
LD09233
Technical Data
ELEMENTARY DIAGRAM
FIG. 19 - ELEMENTARY DIAGRAM - ACROSS-THE-LINE START
ELEMENTARY DIAGRAM
CONTROLPOWER SUPPLY
SWITCH SIZE
NON-FUSED
WYE-DELTA START
WIRING DIAGRAM
Technical Data
FIG. 20 - WIRING DIAGRAM - WYE-DELTA START
WIRING DIAGRAM
FIG. 21 - ELEMENTARY DIAGRAM - WYE-DELTA START
WYE-DELTA START
LD09236
Technical Data
ELEMENTARY DIAGRAM
FIG. 22 - ELEMENTARY DIAGRAM - WYE-DELTA START
FORM 201.19-NM1
ELEMENTARY DIAGRAM
YORK INTERNATIONAL
FIG. 22A - POWER PANEL SYSTEM #1 COMPONENT LOCATIONS
Technical Data
LD09238
FIG. 22B - CONTROL PANEL COMPONENT LOCATION
LD09239
FIG. 22C - POWER PANEL SYSTEM #2 COMPONENT LOCATIONS
Technical Data
LD09240
YORK INTERNATIONAL
FORM 201.19-NM1
LD09241
Technical Data
LD03282 LD03283
2 ACE MOTOR PROTECTOR MODULE
LD03284
CONNECTION DIAGRAM SYSTEM WIRING
LD09242
Technical Data
COMPRESSOR TERMINAL BOX
LD09243
ELEMENTARY DIAGRAM CONTROL CIRCUIT
LD09373
ELEMENTARY DIAGRAM
Technical Data
#3/#4
#3/#4
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YORK INTERNATIONAL
0P0.71
DIMENSIONS - YCAS0130 - YCAS0180 ENGLISH
Technical Data
DIMENSIONS - YCAS0130 - YCAS0180 ENGLISH
LD03744
DIMENSIONS - YCAS0130 - YCAS0180 SI
Technical Data
All dimensions are in mm unless otherwise noted
46 EDGE OF UNIT TO COOLER CONNECTION
LD03746
DIMENSIONS - YCAS0130 - YCAS0180 SI
LD03747
DIMENSIONS - YCAS0200 - YCAS0230 ENGLISH
Technical Data
SYS.#2
MICRO-COMPUTER
LD03749
DIMENSIONS - YCAS0200 - YCAS0230 ENGLISH
LD03750
Technical Data
DIMENSIONS - YCAS0200 - YCAS0230 SI
All dimensions are in mm unless otherwise noted
LD03752
DIMENSIONS - YCAS0200 - YCAS0230 SI
LD03753
TECHNICAL DATA
Technical Data
CLEARANCES
1.3 m
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Aluminium and Black Fin Condenser Coils
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Technical Data
Aluminium and Black Fin Condenser Coils
ISOLATOR DETAILS
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Aluminium and Black Fin Condenser Coils
AWMR-1-XXX
AWMR-2-XXX
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Technical Data
Aluminium and Black Fin Condenser Coils
NEW DESIGN FOR TYPE RD-4
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Copper Fin Condenser Coils
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Technical Data
Copper Fin Condenser Coils
ISOLATOR DETAILS
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Copper Fin Condenser Coils
AWMR-1-XXX
AWMR-2-XXX
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Technical Data
Copper Fin Condenser Coils
NEW DESIGN FOR TYPE RD-4
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Aluminium Fin Condenser Coils with Silencer Kit
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Technical Data
Aluminium Fin Condenser Coils with Silencer Kit
ISOLATOR DETAILS
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Aluminium Fin Condenser Coils with Silencer Kit
AWMR-1-XXX
AWMR-2-XXX
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Technical Data
Aluminum Fin Condenser Coils
NEW DESIGN FOR TYPE RD-4
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Copper Fin Condenser Coils with Silencer Kit
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Technical Data
Copper Fin Condenser Coils with Silencer Kit
ISOLATOR DETAILS
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Copper Fin Condenser Coils with Silencer Kit
AWMR-1-XXX
AWMR-2-XXX
WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS
Technical Data
Copper Fin Condenser Coils with Silencer Kit
NEW DESIGN FOR TYPE RD-4
INSTALLATION INSTRUCTIONS FOR VMC SERIES AWR/AWMR AND CP
RESTRAINED MOUNTINGS
Technical Data
REFRIGERANT FLOW DIAGRAM
FIG. 36 - REFRIGERANT FLOW DIAGRAM
PROCESS AND INSTRUMENTATION DIAGRAM
FIG. 37 - PROCESS AND INSTRUMENTATION DIAGRAM
SYSTEM COMPONENTS
MAJOR COMPONENTS
Technical Data
COMPONENT LOCATIONS
Control Panel
COMPRESSOR COMPONENTS
FIG. 39 - COMPRESSOR COMPONENTS
Technical Data
COMPRESSOR COMPONENTS - CONT’D
FIG. 40 - COMPRESSOR COMPONENTS
FIG. 41 - COMPRESSOR COMPONENTS
COMPRESSOR COMPONENTS - CONT’D
LD03670
Technical Data
COMPRESSOR COMPONENTS - CONT’D
FIG. 42 - COMPRESSOR COMPONENTS
O-RING OIL FILTER MALE ROTOR DISCHARGE CHECK VALVE
FIG. 43 - COMPRESSOR COMPONENTS
COMPRESSOR COMPONENTS - CONT’D
LD03673
Technical Data
COMPRESSOR COMPONENTS - CONT’D
FIG. 44 - COMPRESSOR COMPONENTS
LD03672
SYSTEM STARTUP CHECKLIST
Excessive flow may cause catastrophic damage to the evaporator
Technical Data
Record programmed values in the chart below
INITIAL START-UP
CHECKING SUBCOOLING AND SUPERHEAT
Technical Data
temperature, and economizer superheat below
FORM 201.19-NM1
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YORK INTERNATIONAL
CHILLER CONTROL PANEL PROGRAMMING AND DATA ACCESS KEYS
Micro Panel Contents
Status Key - see Section
Display Keys - see Section
1. INTRODUCTION & PHYSICAL DESCRIPTION
Micro Panel Contents
System Switches 1
Internal Clock & Memory Backup Battery
Power Supply Board
4T Supplies 24VAC power to the 2ACE Motor Protector Modules
2T This 75VA transformer supplies the 24VAC to the power supply board
Relay Output Boards
Micro Panel Contents
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
SIDE VIEW
TOP VIEW
SIDE VIEW
FIG. 45 - MOTOR PROTECTION MODULE
Remote Current Reset
Micro Panel Contents
Remote Start/Stop
Remote Setpoint Temperature Reset
1.11 MICROPROCESSOR BOARD LAYOUT
Micro Panel Contents
FIG. 46 - COMPONENT LAYOUT
Flow Switch & Customer Connection Terminals TB4
1.12 LOGIC SECTION LAYOUT 60 Hz Models
60 HZ MODEL LOGIC SECTION
FIG. 47 - LOGIC SECTION LAYOUT
Micro Panel Contents
1.13 ANTI-RECYCLE TIMER
1.14 ANTI-COINCIDENCE TIMER
1.15 EVAPORATOR PUMP CONTROL
1.20 RUN STATUS CHILLER
1.19 ALARMS
1.21 LEAD / LAG COMPRESSOR SELECTION
Micro Panel Contents
The micro utilizes the formula below to compute pres- sure ratio
PR = DP in PSIG+14.7 SP in PSIG+14.7
1.22 ECONOMIZER SOLENOID CONTROL
FIG. 47A - PROCESS AND INSTRUMENTATION DIAGRAM
PROCESS AND INSTRUMENTATION DIAGRAM
ECONOMIZER HX
2. STATUS KEY GENERAL STATUS MESSAGES & FAULT WARNINGS
Micro Panel Contents
2.5 Chiller Fault Status Messages 2.6 System Fault Status Messages
Unit Switch OFF
System Switches OFF
Anti-Recycle Timers
Anti-Coincidence Timers
Low Battery Warning
Micro Panel Contents
Power Failure Warning
Pump Down
Incorrect Refrigerant Warning
Suction Temperature Limiting
Low Ambient Temperature Cutout
High Ambient Temperature Cutout
Low Leaving Chilled Liquid Temperature Cutout
Micro Panel Contents
Flow Switch Open
High Discharge Temperature Cutout
High Discharge Pressure Cutout
High Oil Temperature Cutout
Low Oil Differential Pressure Cutout
Low Suction Pressure Cutout
The Low Suction Pressure Cutout aids in protecting the
Micro Panel Contents
FLA full load amps is approximately
Low Evaporator Temperature Cutout R407C Only
2.7 PRINTOUT ON FAULT SHUTDOWN
3. DISPLAY KEYS & OPTION SWITCHES
Micro Panel Contents
disappear
Micro Panel Contents
SWITCH 1 Water / Glycol Cooling Open
SWITCH 2 Ambient Temp. Range Low Ambient Cutout Open
Closed
SWITCH 3 Refrigerant Open
SWITCH 4 Unit Type Open
Dip Switch Physical Location and Setting
SWITCH 5 Motor Current Average option start-up Open
Micro Panel Contents
SWITCH 6 Heat Recovery Open
SWITCH 7 Expansion Valve Type Open
SWITCH 8 Standard Options Open
YCAS 2 System Models
4. PRINT KEYS
Common Data
Micro Panel Contents
System Data
This message indicates the EEV preheat % and the suc- tion superheat
Micro Panel Contents
When the History key is pressed, the following message will appear
Chiller Data
DISABLED
BE IN YCAS MODE
System Data
Micro Panel Contents
will not appear
This message indicates the EEV preheat % and the suc- tion superheat
4.7 FAULT HISTORY DATA - REMOTE PRINTOUT
Micro Panel Contents
An example of the HISTORY Printout is shown be- low
5. ENTRY KEYS
5.4 CANCEL KEY
5.1 GENERAL
5.2 NUMERICAL KEYPAD
6. SETPOINTS KEYS & CHILLED LIQUID CONTROL
Micro Panel Contents
User ac
ceptable
Load Timers
Slide Valve Control
Slide Valve Position
Compressor Starting & Loading Sequence
Micro Panel Contents
Timer Counts to
ANTICIPATORY LOAD LIMITING CONTROLS
Percentage of Motor
OIL TEMPERATURE ANTICIPATORY SHUTDOWN CONTROL
DISCHARGE TEMPERATURE ANTICIPATORY SHUTDOWN CONTROL
ANTICIPATORY UNLOADING CONTROLS
6.3 LOCAL COOLING SETPOINTS KEY
Micro Panel Contents
6.4 REMOTE COOLING SETPOINTS KEY
7. CLOCK KEYS
First press the
Micro Panel Contents
key can only be pressed
7.4 MANUAL OVERRIDE KEY
Micro Panel Contents
8. PROGRAM KEY
High Discharge Pressure Cut-Out
High Discharge Pressure Unload Point
Low Suction Pressure Cutout
Programmed X Run Time/3 + Cutout100
60/3 +
Micro Panel Contents
High Ambient Temperature Cutout
Low Ambient Temperature Cutout
Low Leaving Liquid Temperature Cutout
Anti-Recycle Time
Local/Remote Communications
Imperial/SI Units Display
Automatic/Manual “Lead/Lag”
Micro Panel Contents
Automatic/Manual Power Failure Restart
Default
Program Value
Mode
Low Limit
Micro Panel Contents
8.4 ELECTRONIC EXPANSION VALVE
IN OUT
8.5 EEV OPERATION
MOP FEATURE
VALVE PREHEAT FEATURE
EEV OPERATION
Micro Panel Contents
LOW SUPERHEAT CUTOUT SAFETY
SENSOR FAILURE CUTOUT SAFETY
OPERATING DATA DISPLAYS
8.6 EEV PROGRAMMING
8.7 EEV TROUBLESHOOTING
Micro Panel Contents
The system shuts down on Low Suction Pressure
The system shuts down on Low Superheat
8.8 CONDENSER FAN CONTROL
FIG. 51 - CONDENSER FAN LAYOUT FOR DXST 2 COMPRESSOR UNITS
Micro Panel Contents
TABLE 3 - CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS WITH 4 FANS/SYSTEM
The chiller must always be programmed for YCAS
Indicates one lead/phase through motor protector
Micro Panel Contents
TABLE 6 - YCAS STYLE G, ACROSS THE LINE START - 60 HZ
Indicates one lead/phase through motor protector
TABLE 6 - YCAS STYLE G, ACROSS THE LINE START - 60 HZ. CONTD
Micro Panel Contents
TABLE 7 - YCAS STYLE G, WYE DELTA START - 60 HZ
Indicates one lead/phase through motor protector
TABLE 7 - YCAS STYLE G, WYE DELTA START - 60 HZ. CONTD
SERVICE MODE VIEWING INPUTS AND OUTPUTS
Micro Panel Contents
SERVICE MODE OUTPUT ENABLE
8.10 SENSOR CALIBRATION CHARTS
Ambient Temperature Sensor
Oil & Discharge Temperature Sensors
Pressure Transducers
Micro Panel Contents
8.11 CONTROL INPUTS/OUTPUTS
TABLE 8 - DIGITAL OUTPUTS
ANALOG INPUTS
TABLE 9 - ANALOG INPUTS
Micro Panel Contents
DIGITAL INPUTS
TABLE 10 - DIGITAL INPUTS
ANALOG OUTPUTS
RECEIVED DATA CONTROL DATA
8.12 ISN CONTROL
TRANSMITTED DATA
Micro Panel Contents
TABLE 13 - ISN TRANSMITTED DATA CONTD
TABLE 13 - ISN TRANSMITTED DATA CONTD
Micro Panel Contents
TABLE 14 - ISN OPERATIONAL AND FAULT CODES
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YORK INTERNATIONAL
MAINTENANCE
Maintenance
Scheduled Maintenance
ON-BOARD BATTERY BACK-UP
Chiller / Compressor Operating Log
OVERALL UNIT INSPECTION
COMPRESSOR UNIT OPERATION
Maintenance
Operating CHILLER/COMPRESSOR
196 Operating Log
MAINTENANCE REQUIREMENTS FOR YORK YCAS SCREW CHILLERS
YORKINTERNATIONAL
GENERAL PERIODIC MAINTENANCE CHECKS STANDARD UNITS
Maintenance
SERVICE SCHEDULE
MINOR SERVICE
SPARE PARTS
For Parts, Service, or Sales Call Toll Free 1-866-YORK SRV
Recommended Spares
Recommended Compressor Oils
TROUBLESHOOTING GUIDE
Troubleshooting
TROUBLESHOOTING GUIDE - CONT’D
PROBLEM
POSSIBLE
ACTION
LIMITED WARRANTY YORK AMERICAS ENGINEERED SYSTEMS
Troubleshooting
WARRANTY ON NEW EQUIPMENT
WARRANTY ON RECONDITIONED OR REPLACEMENT MATERIALS
TEMPERATURE CONVERSION CHART
Temperature Conversion Chart Actual Temperatures
Temperature Conversion Chart Differential Temperatures
Pressure Conversion Chart Gauge or Differential
Form 201.19-NM1 204 New Release
Tele
Subject to change without notice. Printed in USA
ALL RIGHTS RESERVED