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Contents

YCAS AIR-COOLED LIQUID CHILLERS YCAS0130 THROUGH YCAS0230 STYLE G AIR-COOLED SCREW LIQUID CHILLERS60 Hz INSTALLATION, OPERATION & MAINTENANCE New ReleaseCHANGEABILITY OF THIS DOCUMENT GENERAL SAFETY GUIDELINES SAFETY SYMBOLSREAD BEFORE PROCEEDING INFORMATION & SAFETY TABLE OF CONTENTSSECTION 4 - INSTALLATION SECTION 1 - GENERAL CHILLERSECTION 7 - TECHNICAL DATA TABLE OF CONTENTS CONT’DSECTION 5 - COMMISSIONING SECTION 6 - OPERATIONSECTION 8 - MICRO PANEL CONTENTS TABLE OF CONTENTS CONT’DTABLE OF CONTENTS CONT’D LIST OF TABLESSECTION 9 - MAINTENANCE SECTION 11 - TROUBLE SHOOTINGLIST OF FIGURES Standards for Safety GENERAL CHILLER INFORMATION & SAFETYGeneral Access General Chiller Information & SafetySuitability for Application Structural SupportRotating Parts High Temperature and Pressure CleaningSharp Edges Refrigerants and OilsProduct Description PRODUCT DESCRIPTIONGeneral Description CompressorCondenser EvaporatorProduct Description Power and Control PanelEconomizer Oil Separator/SystemThe control section contains Each power compartment containsThe options sections contain Microprocessor ControlsProduct Description Other symbolsMotor Protection Modules 2ACE Current OverloadCurrent Imbalance Loaded & Unloaded/ Loss of Phase Improper Phase SequenceThermal Overload YCAS STYLE G, ACROSS-THE-LINE - 60 HZ TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTINGProduct Description YCAS STYLE G, ACROSS-THE-LINE - 60 HZ TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING CONT’DProduct Description YCAS STYLE G, WYE DELTA START - 60 HZYCAS STYLE G, WYE DELTA START - 60 HZ TABLE 1 - MOTOR PROTECTOR DIP SWITCH SETTING CONT’DDisplay Product DescriptionSingle-Point Power Connection with Individual Circuit Protection Multiple Point Power Connection StandardSingle-Point Power Connection with Combined Circuit Protection Single-Point Power Connection without Circuit ProtectionThe following options provide added protection Product DescriptionYCAS0230EC46YGA DATANAMEPLATE ENGINEERING UNIT NOMENCLATUREProduct Description PRODUCT IDENTIFICATION NUMBER PINEVAP. FIELD CONDENSER FIELDLifting Weights HANDLING AND STORAGEHandling and Storage UNIT RIGGINGCORRECT 88 2250mm CORRECTOUTDOOR INSTALLATIONS INSTALLATIONINDOOR INSTALLATIONS LOCATION REQUIREMENTSCOMPRESSOR FEET BOLT REMOVAL InstallationGeneral Requirements InstallationInstallation WATER TREATMENTFIG. 6 - PIPEWORK ARRANGEMENT General Requirements Optional FlangesPIPEWORK ARRANGEMENT CONNECTION TYPES & SIZESUnits with Single-Point Power Supply Wiring InstallationFlow Switch Alarm ContactsRemote Setpoint Offset - Temperature Remote Emergency Stop DeviceInstallation POWER PANEL LAYOUTS TYPICALOPTIONAL DISCONNECT SWITCH OPTIONAL CIRCUIT BREAKER SWITCHOPTION PANEL LAYOUT TYPICAL LOGIC PANEL OPTION PANEL WITH SINGLE POINT TERMINAL BLOCK OPTIONALFIG. 10 - OPTION PANEL SECTION Installation LOGIC SECTION LAYOUT60 Hz Models PHOTOGRAPH OFFIG. 12 - LOGIC SECTION LAYOUT WITH CONTROL PANEL LOGIC SECTION LAYOUT WITH CONTROL PANELCUSTOMER CONNECTIONS InstallationFIG. 13 - CUSTOMER CONNECTIONS CUSTOMER CONNECTIONS FIG. 14 - CUSTOMER CONNECTIONS115 VAC SUPPLY Commissioning COMMISSIONINGPower Connections InspectionFlow Switch Switch SettingsTemperature Sensors Programmed SettingsCommissioning System SwitchesInterlocks Start-upThis page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL Operation OPERATIONThis page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL Technical Data TECHNICAL DATAGLYCOL CORRECTION FACTORS FLOW RATE AND PRESSURE DROP CHARTSENGLISH UNITS TEMPERATURE AND FLOWSTEMPERATURE AND FLOWS Technical DataSI UNITS ENGLISH UNITS MODEL NUMBER YCAS PHYSICAL DATATechnical Data PHYSICAL DATASI UNITS MODEL NUMBER YCAS OPERATING LIMITATIONS AND SOUND POWER DATA OPERATING LIMITATIONS - ENGLISH UNITSOPERATING LIMITATIONS - SI UNITS Technical Data ELECTRICAL DATAMULTIPLE POINT POWER SUPPLY CONNECTION Suitable for Y - ∆ Start and MULTIPLE POINT POWER SUPPLY CONNECTION - 2 COMPRESSOR UNITSFANS11 ELECTRICAL DATAFIELD-SUPPLIED WIRING Technical DataFACTORY PROVIDED LUGS WIRE RANGE ELECTRICAL DATAELECTRICAL DATA FORM 201.19-NM1YORK INTERNATIONAL OPTIONAL SINGLE-POINT POWER SUPPLY Technical DataOPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION - 2 COMPRESSOR UNITS ELECTRICAL DATAELECTRICAL DATA FORM 201.19-NM1YORK INTERNATIONAL OPTIONAL SINGLE-POINT POWER SUPPLY Technical DataELECTRICAL DATA CONNECTION TO FACTORY CIRCUIT BREAKER Suitable forMAXIMUM kW AND AMPERAGE VALUES FOR DXST COMPRESSORS ELECTRICAL DATADXS45LA - MOTOR CODE A DXS36LA - MOTOR CODE AELECTRICAL NOTES Technical DataNOTES & LEGEND This page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL WIRING DIAGRAM ACROSS-THE-LINE STARTTechnical Data FIG. 18 - WIRING DIAGRAM - ACROSS-THE-LINE START WIRING DIAGRAMACROSS-THE-LINE START LD09233ELEMENTARY DIAGRAM Technical DataFIG. 19 - ELEMENTARY DIAGRAM - ACROSS-THE-LINE START CONTROLPOWER SUPPLY ELEMENTARY DIAGRAMSWITCH SIZE NON-FUSEDWIRING DIAGRAM WYE-DELTA STARTTechnical Data FIG. 20 - WIRING DIAGRAM - WYE-DELTA STARTFIG. 21 - ELEMENTARY DIAGRAM - WYE-DELTA START WIRING DIAGRAMWYE-DELTA START LD09236ELEMENTARY DIAGRAM Technical DataFIG. 22 - ELEMENTARY DIAGRAM - WYE-DELTA START ELEMENTARY DIAGRAM FORM 201.19-NM1YORK INTERNATIONAL Technical Data FIG. 22A - POWER PANEL SYSTEM #1 COMPONENT LOCATIONSLD09238 LD09239 FIG. 22B - CONTROL PANEL COMPONENT LOCATIONTechnical Data FIG. 22C - POWER PANEL SYSTEM #2 COMPONENT LOCATIONSLD09240 FORM 201.19-NM1 YORK INTERNATIONALLD09241 LD03282 LD03283 Technical Data2 ACE MOTOR PROTECTOR MODULE LD03284LD09242 CONNECTION DIAGRAM SYSTEM WIRINGCOMPRESSOR TERMINAL BOX Technical DataLD09243 LD09373 ELEMENTARY DIAGRAM CONTROL CIRCUITTechnical Data ELEMENTARY DIAGRAM#3/#4 #3/#4This page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL DIMENSIONS - YCAS0130 - YCAS0180 ENGLISH 0P0.71Technical Data LD03744 DIMENSIONS - YCAS0130 - YCAS0180 ENGLISHTechnical Data DIMENSIONS - YCAS0130 - YCAS0180 SIAll dimensions are in mm unless otherwise noted 46 EDGE OF UNIT TO COOLER CONNECTIONDIMENSIONS - YCAS0130 - YCAS0180 SI LD03746LD03747 Technical Data DIMENSIONS - YCAS0200 - YCAS0230 ENGLISHSYS.#2 MICRO-COMPUTERDIMENSIONS - YCAS0200 - YCAS0230 ENGLISH LD03749LD03750 DIMENSIONS - YCAS0200 - YCAS0230 SI Technical DataAll dimensions are in mm unless otherwise noted DIMENSIONS - YCAS0200 - YCAS0230 SI LD03752LD03753 Technical Data TECHNICAL DATACLEARANCES 1.3 mAluminium and Black Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAluminium and Black Fin Condenser Coils ISOLATOR DETAILSAluminium and Black Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAWMR-1-XXX AWMR-2-XXXTechnical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAluminium and Black Fin Condenser Coils NEW DESIGN FOR TYPE RD-4Copper Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSCopper Fin Condenser Coils ISOLATOR DETAILSCopper Fin Condenser Coils WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAWMR-1-XXX AWMR-2-XXXTechnical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSCopper Fin Condenser Coils NEW DESIGN FOR TYPE RD-4Aluminium Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAluminium Fin Condenser Coils with Silencer Kit ISOLATOR DETAILSAluminium Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAWMR-1-XXX AWMR-2-XXXTechnical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAluminum Fin Condenser Coils NEW DESIGN FOR TYPE RD-4Copper Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSTechnical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSCopper Fin Condenser Coils with Silencer Kit ISOLATOR DETAILSCopper Fin Condenser Coils with Silencer Kit WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSAWMR-1-XXX AWMR-2-XXXTechnical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONSCopper Fin Condenser Coils with Silencer Kit NEW DESIGN FOR TYPE RD-4RESTRAINED MOUNTINGS INSTALLATION INSTRUCTIONS FOR VMC SERIES AWR/AWMR AND CPREFRIGERANT FLOW DIAGRAM Technical DataFIG. 36 - REFRIGERANT FLOW DIAGRAM FIG. 37 - PROCESS AND INSTRUMENTATION DIAGRAM PROCESS AND INSTRUMENTATION DIAGRAMSYSTEM COMPONENTS MAJOR COMPONENTSCOMPONENT LOCATIONS Technical DataControl Panel FIG. 39 - COMPRESSOR COMPONENTS COMPRESSOR COMPONENTSCOMPRESSOR COMPONENTS - CONT’D Technical DataFIG. 40 - COMPRESSOR COMPONENTS COMPRESSOR COMPONENTS - CONT’D FIG. 41 - COMPRESSOR COMPONENTSLD03670 COMPRESSOR COMPONENTS - CONT’D Technical DataFIG. 42 - COMPRESSOR COMPONENTS O-RING OIL FILTER MALE ROTOR DISCHARGE CHECK VALVECOMPRESSOR COMPONENTS - CONT’D FIG. 43 - COMPRESSOR COMPONENTSLD03673 COMPRESSOR COMPONENTS - CONT’D Technical DataFIG. 44 - COMPRESSOR COMPONENTS LD03672Excessive ﬂow may cause catastrophic damage to the evaporator SYSTEM STARTUP CHECKLISTRecord programmed values in the chart below Technical DataCHECKING SUBCOOLING AND SUPERHEAT INITIAL START-UPtemperature, and economizer superheat below Technical DataThis page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL Micro Panel Contents CHILLER CONTROL PANEL PROGRAMMING AND DATA ACCESS KEYSStatus Key - see Section Display Keys - see Section1. INTRODUCTION & PHYSICAL DESCRIPTION System Switches 1 Micro Panel ContentsInternal Clock & Memory Backup Battery Power Supply Board2T This 75VA transformer supplies the 24VAC to the power supply board 4T Supplies 24VAC power to the 2ACE Motor Protector ModulesRelay 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 ContentsTOP VIEW SIDE VIEWSIDE VIEW FIG. 45 - MOTOR PROTECTION MODULEMicro Panel Contents Remote Current ResetRemote Start/Stop Remote Setpoint Temperature Reset Micro Panel Contents 1.11 MICROPROCESSOR BOARD LAYOUTFIG. 46 - COMPONENT LAYOUT 1.12 LOGIC SECTION LAYOUT 60 Hz Models Flow Switch & Customer Connection Terminals TB460 HZ MODEL LOGIC SECTION FIG. 47 - LOGIC SECTION LAYOUT1.13 ANTI-RECYCLE TIMER Micro Panel Contents1.14 ANTI-COINCIDENCE TIMER 1.15 EVAPORATOR PUMP CONTROL1.19 ALARMS 1.20 RUN STATUS CHILLER1.21 LEAD / LAG COMPRESSOR SELECTION The micro utilizes the formula below to compute pres- sure ratio Micro Panel ContentsPR = DP in PSIG+14.7 SP in PSIG+14.7 1.22 ECONOMIZER SOLENOID CONTROLPROCESS AND INSTRUMENTATION DIAGRAM FIG. 47A - PROCESS AND INSTRUMENTATION DIAGRAMECONOMIZER HX Micro Panel Contents 2. STATUS KEY GENERAL STATUS MESSAGES & FAULT WARNINGS2.5 Chiller Fault Status Messages 2.6 System Fault Status Messages Unit Switch OFFAnti-Recycle Timers System Switches OFFAnti-Coincidence Timers Low Battery WarningPower Failure Warning Micro Panel ContentsPump Down Incorrect Refrigerant WarningLow Ambient Temperature Cutout Suction Temperature LimitingHigh Ambient Temperature Cutout Low Leaving Chilled Liquid Temperature CutoutFlow Switch Open Micro Panel ContentsHigh Discharge Temperature Cutout High Discharge Pressure CutoutLow Oil Differential Pressure Cutout High Oil Temperature CutoutLow Suction Pressure Cutout The Low Suction Pressure Cutout aids in protecting theFLA full load amps is approximately Micro Panel Contents2.7 PRINTOUT ON FAULT SHUTDOWN Low Evaporator Temperature Cutout R407C OnlyMicro Panel Contents 3. DISPLAY KEYS & OPTION SWITCHESdisappear SWITCH 1 Water / Glycol Cooling Open Micro Panel ContentsSWITCH 2 Ambient Temp. Range Low Ambient Cutout Open ClosedSWITCH 4 Unit Type Open SWITCH 3 Refrigerant OpenDip Switch Physical Location and Setting SWITCH 5 Motor Current Average option start-up OpenSWITCH 6 Heat Recovery Open Micro Panel ContentsSWITCH 7 Expansion Valve Type Open SWITCH 8 Standard Options Open4. PRINT KEYS YCAS 2 System ModelsCommon Data System Data Micro Panel ContentsThis message indicates the EEV preheat % and the suc- tion superheat When the History key is pressed, the following message will appear Micro Panel ContentsDISABLED Chiller DataBE IN YCAS MODE Micro Panel Contents System Datawill not appear This message indicates the EEV preheat % and the suc- tion superheat Micro Panel Contents 4.7 FAULT HISTORY DATA - REMOTE PRINTOUTAn example of the HISTORY Printout is shown be- low 5.4 CANCEL KEY 5. ENTRY KEYS5.1 GENERAL 5.2 NUMERICAL KEYPADMicro Panel Contents 6. SETPOINTS KEYS & CHILLED LIQUID CONTROLUser ac ceptableSlide Valve Control Load TimersSlide Valve Position Compressor Starting & Loading SequenceTimer Counts to Micro Panel ContentsANTICIPATORY LOAD LIMITING CONTROLS Percentage of MotorDISCHARGE TEMPERATURE ANTICIPATORY SHUTDOWN CONTROL OIL TEMPERATURE ANTICIPATORY SHUTDOWN CONTROLANTICIPATORY UNLOADING CONTROLS Micro Panel Contents 6.3 LOCAL COOLING SETPOINTS KEY6.4 REMOTE COOLING SETPOINTS KEY First press the 7. CLOCK KEYSkey can only be pressed Micro Panel Contents7.4 MANUAL OVERRIDE KEY 8. PROGRAM KEY Micro Panel ContentsHigh Discharge Pressure Cut-Out Low Suction Pressure Cutout High Discharge Pressure Unload PointProgrammed X Run Time/3 + Cutout100 60/3 +High Ambient Temperature Cutout Micro Panel ContentsLow Ambient Temperature Cutout Low Leaving Liquid Temperature CutoutLocal/Remote Communications Anti-Recycle TimeImperial/SI Units Display Automatic/Manual “Lead/Lag”Automatic/Manual Power Failure Restart Micro Panel ContentsProgram Value DefaultMode Low Limit8.4 ELECTRONIC EXPANSION VALVE Micro Panel ContentsIN OUT MOP FEATURE 8.5 EEV OPERATIONVALVE PREHEAT FEATURE EEV OPERATIONLOW SUPERHEAT CUTOUT SAFETY Micro Panel ContentsSENSOR FAILURE CUTOUT SAFETY OPERATING DATA DISPLAYS8.6 EEV PROGRAMMING Micro Panel Contents 8.7 EEV TROUBLESHOOTINGThe system shuts down on Low Suction Pressure The system shuts down on Low SuperheatFIG. 51 - CONDENSER FAN LAYOUT FOR DXST 2 COMPRESSOR UNITS 8.8 CONDENSER FAN CONTROLTABLE 3 - CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS WITH 4 FANS/SYSTEM Micro Panel ContentsThe chiller must always be programmed for YCAS Micro Panel Contents Indicates one lead/phase through motor protectorTABLE 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 protectorTABLE 7 - YCAS STYLE G, WYE DELTA START - 60 HZ Micro Panel ContentsTABLE 7 - YCAS STYLE G, WYE DELTA START - 60 HZ. CONTD Indicates one lead/phase through motor protectorMicro Panel Contents SERVICE MODE VIEWING INPUTS AND OUTPUTSSERVICE MODE OUTPUT ENABLE Ambient Temperature Sensor 8.10 SENSOR CALIBRATION CHARTSOil & Discharge Temperature Sensors Pressure Transducers8.11 CONTROL INPUTS/OUTPUTS Micro Panel ContentsTABLE 8 - DIGITAL OUTPUTS TABLE 9 - ANALOG INPUTS ANALOG INPUTSDIGITAL INPUTS Micro Panel ContentsTABLE 10 - DIGITAL INPUTS ANALOG OUTPUTS8.12 ISN CONTROL RECEIVED DATA CONTROL DATATRANSMITTED DATA TABLE 13 - ISN TRANSMITTED DATA CONTD Micro Panel ContentsTABLE 13 - ISN TRANSMITTED DATA CONTD TABLE 14 - ISN OPERATIONAL AND FAULT CODES Micro Panel ContentsThis page intentionally left blank FORM 201.19-NM1YORK INTERNATIONAL Maintenance MAINTENANCEON-BOARD BATTERY BACK-UP Scheduled MaintenanceChiller / Compressor Operating Log OVERALL UNIT INSPECTIONMaintenance COMPRESSOR UNIT OPERATIONOperating CHILLER/COMPRESSOR 196 Operating LogYORKINTERNATIONAL MAINTENANCE REQUIREMENTS FOR YORK YCAS SCREW CHILLERSMaintenance GENERAL PERIODIC MAINTENANCE CHECKS STANDARD UNITSSERVICE SCHEDULE MINOR SERVICEFor Parts, Service, or Sales Call Toll Free 1-866-YORK SRV SPARE PARTSRecommended Spares Recommended Compressor OilsTroubleshooting TROUBLESHOOTING GUIDEPROBLEM TROUBLESHOOTING GUIDE - CONT’DPOSSIBLE ACTIONTroubleshooting LIMITED WARRANTY YORK AMERICAS ENGINEERED SYSTEMSWARRANTY ON NEW EQUIPMENT WARRANTY ON RECONDITIONED OR REPLACEMENT MATERIALSTemperature Conversion Chart Actual Temperatures TEMPERATURE CONVERSION CHARTTemperature Conversion Chart Differential Temperatures Pressure Conversion Chart Gauge or DifferentialTele Form 201.19-NM1 204 New ReleaseSubject to change without notice. Printed in USA ALL RIGHTS RESERVED

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Models: YCAS0130