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