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