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