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York YCAS0130 manual Changeability Of This Document

Models: YCAS0130

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FORM 201.19-NM1 (204)

CHANGEABILITY OF THIS DOCUMENT

In complying with YORK’s policy for continuous product improvement, the information contained in this document is subject to change without notice. Literature updates that may occur will be printed on the Revision Sheet and included with the Installation, Operation & Maintenance (IOM) man, which is provided with new equipment. If not found with the manual, the current Revision Sheet containing any applicable revisions, and the manual, can be found on the internet at www.york.com. The Renewal Parts (RP) manual and revision sheet for this equipment can also be found at this internet site.

It is the responsibility of installing/operating/service personnel to determine prior to working on the equip- ment, that they have all of the applicable literature, that it is current and that the equipment has not been modiﬁed since manufacture.

Revision Sheets are available for the IOM and Renewal Parts

Each update will be assigned a sequential Rev. Level with the date it was introduced

The Description/Change will explain the change. If necessary it will refer the reader to an additional supplement or bulletin.

YORK part number for the Revision Sheet to aid manufacturing and distribution

Web address for the Revision Sheet

035-XXXXX-XXX

www.york.com

2	YORK INTERNATIONAL

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York YCAS0130 manual Changeability Of This Document

Contents

60 Hz AIR-COOLED SCREW LIQUID CHILLERSYCAS AIR-COOLED LIQUID CHILLERS YCAS0130 THROUGH YCAS0230 STYLE G INSTALLATION, OPERATION & MAINTENANCE New ReleaseCHANGEABILITY OF THIS DOCUMENT READ BEFORE PROCEEDING GENERAL SAFETY GUIDELINESSAFETY SYMBOLS SECTION 4 - INSTALLATION TABLE OF CONTENTSINFORMATION & SAFETY SECTION 1 - GENERAL CHILLERSECTION 5 - COMMISSIONING TABLE OF CONTENTS CONT’DSECTION 7 - TECHNICAL DATA SECTION 6 - OPERATIONTABLE OF CONTENTS CONT’D SECTION 8 - MICRO PANEL CONTENTSSECTION 9 - MAINTENANCE LIST OF TABLESTABLE OF CONTENTS CONT’D SECTION 11 - TROUBLE SHOOTINGLIST OF FIGURES GENERAL CHILLER INFORMATION & SAFETY Standards for SafetySuitability for Application General Chiller Information & SafetyGeneral Access Structural SupportSharp Edges High Temperature and Pressure CleaningRotating Parts Refrigerants and OilsGeneral Description PRODUCT DESCRIPTIONProduct Description CompressorEvaporator CondenserEconomizer Power and Control PanelProduct Description Oil Separator/SystemThe options sections contain Each power compartment containsThe control section contains Microprocessor ControlsMotor Protection Modules 2ACE Other symbolsProduct Description Current OverloadThermal Overload Current Imbalance Loaded & Unloaded/ Loss of PhaseImproper Phase Sequence Product Description YCAS STYLE G, ACROSS-THE-LINE - 60 HZTABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING CONT’D YCAS STYLE G, ACROSS-THE-LINE - 60 HZYCAS STYLE G, WYE DELTA START - 60 HZ Product DescriptionTABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING CONT’D YCAS STYLE G, WYE DELTA START - 60 HZProduct Description DisplaySingle-Point Power Connection with Combined Circuit Protection Multiple Point Power Connection StandardSingle-Point Power Connection with Individual Circuit Protection Single-Point Power Connection without Circuit ProtectionProduct Description The following options provide added protectionNAMEPLATE ENGINEERING DATAYCAS0230EC46YGA UNIT NOMENCLATUREEVAP. FIELD PRODUCT IDENTIFICATION NUMBER PINProduct Description CONDENSER FIELDHANDLING AND STORAGE Lifting WeightsCORRECT UNIT RIGGINGHandling and Storage 88 2250mm CORRECTINDOOR INSTALLATIONS INSTALLATIONOUTDOOR INSTALLATIONS LOCATION REQUIREMENTSInstallation COMPRESSOR FEET BOLT REMOVALInstallation General RequirementsFIG. 6 - PIPEWORK ARRANGEMENT InstallationWATER TREATMENT PIPEWORK ARRANGEMENT Optional FlangesGeneral Requirements CONNECTION TYPES & SIZESInstallation Units with Single-Point Power Supply WiringRemote Setpoint Offset - Temperature Alarm ContactsFlow Switch Remote Emergency Stop DeviceOPTIONAL DISCONNECT SWITCH POWER PANEL LAYOUTS TYPICALInstallation OPTIONAL CIRCUIT BREAKER SWITCHFIG. 10 - OPTION PANEL SECTION OPTION PANEL LAYOUT TYPICALLOGIC PANEL OPTION PANEL WITH SINGLE POINT TERMINAL BLOCK OPTIONAL 60 Hz Models LOGIC SECTION LAYOUTInstallation PHOTOGRAPH OFLOGIC SECTION LAYOUT WITH CONTROL PANEL FIG. 12 - LOGIC SECTION LAYOUT WITH CONTROL PANELFIG. 13 - CUSTOMER CONNECTIONS CUSTOMER CONNECTIONSInstallation 115 VAC SUPPLY CUSTOMER CONNECTIONSFIG. 14 - CUSTOMER CONNECTIONS Power Connections COMMISSIONINGCommissioning InspectionTemperature Sensors Switch SettingsFlow Switch Programmed SettingsInterlocks System SwitchesCommissioning Start-upYORK INTERNATIONAL This page intentionally left blankFORM 201.19-NM1 OPERATION OperationYORK INTERNATIONAL This page intentionally left blankFORM 201.19-NM1 GLYCOL CORRECTION FACTORS TECHNICAL DATATechnical Data FLOW RATE AND PRESSURE DROP CHARTSTEMPERATURE AND FLOWS ENGLISH UNITSSI UNITS TEMPERATURE AND FLOWSTechnical Data PHYSICAL DATA ENGLISH UNITS MODEL NUMBER YCASSI UNITS MODEL NUMBER YCAS Technical DataPHYSICAL DATA OPERATING LIMITATIONS - SI UNITS OPERATING LIMITATIONS AND SOUND POWER DATAOPERATING LIMITATIONS - ENGLISH UNITS MULTIPLE POINT POWER SUPPLY CONNECTION Suitable for Y - ∆ Start and ELECTRICAL DATATechnical Data MULTIPLE POINT POWER SUPPLY CONNECTION - 2 COMPRESSOR UNITSELECTRICAL DATA FANS11FACTORY PROVIDED LUGS WIRE RANGE Technical DataFIELD-SUPPLIED WIRING ELECTRICAL DATAYORK INTERNATIONAL ELECTRICAL DATAFORM 201.19-NM1 OPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION - 2 COMPRESSOR UNITS Technical DataOPTIONAL SINGLE-POINT POWER SUPPLY ELECTRICAL DATAYORK INTERNATIONAL ELECTRICAL DATAFORM 201.19-NM1 ELECTRICAL DATA Technical DataOPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION TO FACTORY CIRCUIT BREAKER Suitable forDXS45LA - MOTOR CODE A ELECTRICAL DATAMAXIMUM kW AND AMPERAGE VALUES FOR DXST COMPRESSORS DXS36LA - MOTOR CODE ANOTES & LEGEND ELECTRICAL NOTESTechnical Data YORK INTERNATIONAL This page intentionally left blankFORM 201.19-NM1 Technical Data WIRING DIAGRAMACROSS-THE-LINE START ACROSS-THE-LINE START WIRING DIAGRAMFIG. 18 - WIRING DIAGRAM - ACROSS-THE-LINE START LD09233FIG. 19 - ELEMENTARY DIAGRAM - ACROSS-THE-LINE START ELEMENTARY DIAGRAMTechnical Data SWITCH SIZE ELEMENTARY DIAGRAMCONTROLPOWER SUPPLY NON-FUSEDTechnical Data WYE-DELTA STARTWIRING DIAGRAM FIG. 20 - WIRING DIAGRAM - WYE-DELTA STARTWYE-DELTA START WIRING DIAGRAMFIG. 21 - ELEMENTARY DIAGRAM - WYE-DELTA START LD09236FIG. 22 - ELEMENTARY DIAGRAM - WYE-DELTA START ELEMENTARY DIAGRAMTechnical Data YORK INTERNATIONAL ELEMENTARY DIAGRAMFORM 201.19-NM1 LD09238 Technical DataFIG. 22A - POWER PANEL SYSTEM #1 COMPONENT LOCATIONS FIG. 22B - CONTROL PANEL COMPONENT LOCATION LD09239LD09240 Technical DataFIG. 22C - POWER PANEL SYSTEM #2 COMPONENT LOCATIONS LD09241 FORM 201.19-NM1YORK INTERNATIONAL 2 ACE MOTOR PROTECTOR MODULE Technical DataLD03282 LD03283 LD03284CONNECTION DIAGRAM SYSTEM WIRING LD09242LD09243 COMPRESSOR TERMINAL BOXTechnical Data ELEMENTARY DIAGRAM CONTROL CIRCUIT LD09373#3/#4 ELEMENTARY DIAGRAMTechnical Data #3/#4YORK INTERNATIONAL This page intentionally left blankFORM 201.19-NM1 Technical Data DIMENSIONS - YCAS0130 - YCAS0180 ENGLISH0P0.71 DIMENSIONS - YCAS0130 - YCAS0180 ENGLISH LD03744All dimensions are in mm unless otherwise noted DIMENSIONS - YCAS0130 - YCAS0180 SITechnical Data 46 EDGE OF UNIT TO COOLER CONNECTIONLD03747 DIMENSIONS - YCAS0130 - YCAS0180 SILD03746 SYS.#2 DIMENSIONS - YCAS0200 - YCAS0230 ENGLISHTechnical Data MICRO-COMPUTERLD03750 DIMENSIONS - YCAS0200 - YCAS0230 ENGLISHLD03749 All dimensions are in mm unless otherwise noted DIMENSIONS - YCAS0200 - YCAS0230 SITechnical Data LD03753 DIMENSIONS - YCAS0200 - YCAS0230 SILD03752 CLEARANCES TECHNICAL DATATechnical Data 1.3 mWEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS Aluminium and Black Fin Condenser CoilsAluminium and Black Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data ISOLATOR DETAILSAWMR-1-XXX WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAluminium and Black Fin Condenser Coils AWMR-2-XXXAluminium and Black Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data NEW DESIGN FOR TYPE RD-4WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS Copper Fin Condenser CoilsCopper Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data ISOLATOR DETAILSAWMR-1-XXX WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSCopper Fin Condenser Coils AWMR-2-XXXCopper Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data NEW DESIGN FOR TYPE RD-4WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS Aluminium Fin Condenser Coils with Silencer KitAluminium Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data ISOLATOR DETAILSAWMR-1-XXX WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAluminium Fin Condenser Coils with Silencer Kit AWMR-2-XXXAluminum Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data NEW DESIGN FOR TYPE RD-4WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS Copper Fin Condenser Coils with Silencer KitCopper Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data ISOLATOR DETAILSAWMR-1-XXX WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSCopper Fin Condenser Coils with Silencer Kit AWMR-2-XXXCopper Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data NEW DESIGN FOR TYPE RD-4INSTALLATION INSTRUCTIONS FOR VMC SERIES AWR/AWMR AND CP RESTRAINED MOUNTINGSFIG. 36 - REFRIGERANT FLOW DIAGRAM REFRIGERANT FLOW DIAGRAMTechnical Data SYSTEM COMPONENTS PROCESS AND INSTRUMENTATION DIAGRAMFIG. 37 - PROCESS AND INSTRUMENTATION DIAGRAM MAJOR COMPONENTSControl Panel COMPONENT LOCATIONSTechnical Data COMPRESSOR COMPONENTS FIG. 39 - COMPRESSOR COMPONENTSFIG. 40 - COMPRESSOR COMPONENTS COMPRESSOR COMPONENTS - CONT’DTechnical Data LD03670 COMPRESSOR COMPONENTS - CONT’DFIG. 41 - COMPRESSOR COMPONENTS FIG. 42 - COMPRESSOR COMPONENTS Technical DataCOMPRESSOR COMPONENTS - CONT’D O-RING OIL FILTER MALE ROTOR DISCHARGE CHECK VALVELD03673 COMPRESSOR COMPONENTS - CONT’DFIG. 43 - COMPRESSOR COMPONENTS FIG. 44 - COMPRESSOR COMPONENTS Technical DataCOMPRESSOR COMPONENTS - CONT’D LD03672SYSTEM STARTUP CHECKLIST Excessive ﬂow may cause catastrophic damage to the evaporatorTechnical Data Record programmed values in the chart belowINITIAL START-UP CHECKING SUBCOOLING AND SUPERHEATTechnical Data temperature, and economizer superheat belowYORK INTERNATIONAL This page intentionally left blankFORM 201.19-NM1 Status Key - see Section CHILLER CONTROL PANEL PROGRAMMING AND DATA ACCESS KEYSMicro Panel Contents Display Keys - see Section1. INTRODUCTION & PHYSICAL DESCRIPTION Internal Clock & Memory Backup Battery Micro Panel ContentsSystem Switches 1 Power Supply BoardRelay Output Boards 2T This 75VA transformer supplies the 24VAC to the power supply board4T Supplies 24VAC power to the 2ACE Motor Protector Modules 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 dataSIDE VIEW SIDE VIEWTOP VIEW FIG. 45 - MOTOR PROTECTION MODULERemote Start/Stop Micro Panel ContentsRemote Current Reset Remote Setpoint Temperature Reset FIG. 46 - COMPONENT LAYOUT Micro Panel Contents1.11 MICROPROCESSOR BOARD LAYOUT 60 HZ MODEL LOGIC SECTION Flow Switch & Customer Connection Terminals TB41.12 LOGIC SECTION LAYOUT 60 Hz Models FIG. 47 - LOGIC SECTION LAYOUT1.14 ANTI-COINCIDENCE TIMER Micro Panel Contents1.13 ANTI-RECYCLE TIMER 1.15 EVAPORATOR PUMP CONTROL1.21 LEAD / LAG COMPRESSOR SELECTION 1.19 ALARMS1.20 RUN STATUS CHILLER PR = DP in PSIG+14.7 SP in PSIG+14.7 Micro Panel ContentsThe micro utilizes the formula below to compute pres- sure ratio 1.22 ECONOMIZER SOLENOID CONTROLECONOMIZER HX PROCESS AND INSTRUMENTATION DIAGRAMFIG. 47A - PROCESS AND INSTRUMENTATION DIAGRAM 2.5 Chiller Fault Status Messages 2.6 System Fault Status Messages 2. STATUS KEY GENERAL STATUS MESSAGES & FAULT WARNINGSMicro Panel Contents Unit Switch OFFAnti-Coincidence Timers System Switches OFFAnti-Recycle Timers Low Battery WarningPump Down Micro Panel ContentsPower Failure Warning Incorrect Refrigerant WarningHigh Ambient Temperature Cutout Suction Temperature LimitingLow Ambient Temperature Cutout Low Leaving Chilled Liquid Temperature CutoutHigh Discharge Temperature Cutout Micro Panel ContentsFlow Switch Open High Discharge Pressure CutoutLow Suction Pressure Cutout High Oil Temperature CutoutLow Oil Differential Pressure Cutout The Low Suction Pressure Cutout aids in protecting theMicro Panel Contents FLA full load amps is approximatelyLow Evaporator Temperature Cutout R407C Only 2.7 PRINTOUT ON FAULT SHUTDOWN3. DISPLAY KEYS & OPTION SWITCHES Micro Panel Contentsdisappear SWITCH 2 Ambient Temp. Range Low Ambient Cutout Open Micro Panel ContentsSWITCH 1 Water / Glycol Cooling Open ClosedDip Switch Physical Location and Setting SWITCH 3 Refrigerant OpenSWITCH 4 Unit Type Open SWITCH 5 Motor Current Average option start-up OpenSWITCH 7 Expansion Valve Type Open Micro Panel ContentsSWITCH 6 Heat Recovery Open SWITCH 8 Standard Options OpenCommon Data 4. PRINT KEYSYCAS 2 System Models Micro Panel Contents System DataThis message indicates the EEV preheat % and the suc- tion superheat Micro Panel Contents When the History key is pressed, the following message will appearBE IN YCAS MODE DISABLEDChiller Data will not appear Micro Panel ContentsSystem Data This message indicates the EEV preheat % and the suc- tion superheat An example of the HISTORY Printout is shown be- low Micro Panel Contents4.7 FAULT HISTORY DATA - REMOTE PRINTOUT 5.1 GENERAL 5. ENTRY KEYS5.4 CANCEL KEY 5.2 NUMERICAL KEYPADUser ac 6. SETPOINTS KEYS & CHILLED LIQUID CONTROLMicro Panel Contents ceptableSlide Valve Position Load TimersSlide Valve Control Compressor Starting & Loading SequenceANTICIPATORY LOAD LIMITING CONTROLS Micro Panel ContentsTimer Counts to Percentage of MotorANTICIPATORY UNLOADING CONTROLS DISCHARGE TEMPERATURE ANTICIPATORY SHUTDOWN CONTROLOIL TEMPERATURE ANTICIPATORY SHUTDOWN CONTROL 6.4 REMOTE COOLING SETPOINTS KEY Micro Panel Contents6.3 LOCAL COOLING SETPOINTS KEY 7. CLOCK KEYS First press theMicro Panel Contents key can only be pressed7.4 MANUAL OVERRIDE KEY High Discharge Pressure Cut-Out 8. PROGRAM KEYMicro Panel Contents Programmed X Run Time/3 + Cutout100 High Discharge Pressure Unload PointLow Suction Pressure Cutout 60/3 +Low Ambient Temperature Cutout Micro Panel ContentsHigh Ambient Temperature Cutout Low Leaving Liquid Temperature CutoutImperial/SI Units Display Anti-Recycle TimeLocal/Remote Communications Automatic/Manual “Lead/Lag”Micro Panel Contents Automatic/Manual Power Failure RestartMode DefaultProgram Value Low LimitIN OUT 8.4 ELECTRONIC EXPANSION VALVEMicro Panel Contents VALVE PREHEAT FEATURE 8.5 EEV OPERATIONMOP FEATURE EEV OPERATIONSENSOR FAILURE CUTOUT SAFETY Micro Panel ContentsLOW SUPERHEAT CUTOUT SAFETY OPERATING DATA DISPLAYS8.6 EEV PROGRAMMING The system shuts down on Low Suction Pressure 8.7 EEV TROUBLESHOOTINGMicro Panel Contents The system shuts down on Low Superheat8.8 CONDENSER FAN CONTROL FIG. 51 - CONDENSER FAN LAYOUT FOR DXST 2 COMPRESSOR UNITSMicro Panel Contents TABLE 3 - CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS WITH 4 FANS/SYSTEMThe chiller must always be programmed for YCAS TABLE 6 - YCAS STYLE G, ACROSS THE LINE START - 60 HZ Micro Panel ContentsIndicates one lead/phase through motor protector Indicates one lead/phase through motor protector TABLE 6 - YCAS STYLE G, ACROSS THE LINE START - 60 HZ. CONTDMicro Panel Contents TABLE 7 - YCAS STYLE G, WYE DELTA START - 60 HZIndicates one lead/phase through motor protector TABLE 7 - YCAS STYLE G, WYE DELTA START - 60 HZ. CONTDSERVICE MODE OUTPUT ENABLE Micro Panel ContentsSERVICE MODE VIEWING INPUTS AND OUTPUTS Oil & Discharge Temperature Sensors 8.10 SENSOR CALIBRATION CHARTSAmbient Temperature Sensor Pressure TransducersTABLE 8 - DIGITAL OUTPUTS 8.11 CONTROL INPUTS/OUTPUTSMicro Panel Contents ANALOG INPUTS TABLE 9 - ANALOG INPUTSTABLE 10 - DIGITAL INPUTS Micro Panel ContentsDIGITAL INPUTS ANALOG OUTPUTSTRANSMITTED DATA 8.12 ISN CONTROLRECEIVED DATA CONTROL DATA Micro Panel Contents TABLE 13 - ISN TRANSMITTED DATA CONTDTABLE 13 - ISN TRANSMITTED DATA CONTD Micro Panel Contents TABLE 14 - ISN OPERATIONAL AND FAULT CODESYORK INTERNATIONAL This page intentionally left blankFORM 201.19-NM1 MAINTENANCE MaintenanceChiller / Compressor Operating Log Scheduled MaintenanceON-BOARD BATTERY BACK-UP OVERALL UNIT INSPECTIONOperating CHILLER/COMPRESSOR COMPRESSOR UNIT OPERATIONMaintenance 196 Operating LogMAINTENANCE REQUIREMENTS FOR YORK YCAS SCREW CHILLERS YORKINTERNATIONALSERVICE SCHEDULE GENERAL PERIODIC MAINTENANCE CHECKS STANDARD UNITSMaintenance MINOR SERVICERecommended Spares SPARE PARTSFor Parts, Service, or Sales Call Toll Free 1-866-YORK SRV Recommended Compressor OilsTROUBLESHOOTING GUIDE TroubleshootingPOSSIBLE TROUBLESHOOTING GUIDE - CONT’DPROBLEM ACTIONWARRANTY ON NEW EQUIPMENT LIMITED WARRANTY YORK AMERICAS ENGINEERED SYSTEMSTroubleshooting WARRANTY ON RECONDITIONED OR REPLACEMENT MATERIALSTemperature Conversion Chart Differential Temperatures TEMPERATURE CONVERSION CHARTTemperature Conversion Chart Actual Temperatures Pressure Conversion Chart Gauge or DifferentialSubject to change without notice. Printed in USA Form 201.19-NM1 204 New ReleaseTele ALL RIGHTS RESERVED