York YCAS Series

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YORK INTERNATIONAL

FORM 201.19-NM8 (804)

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Main Page

Default Chapter4
- Table of Contents4
Section 1 - General Chiller Information & Safety9
- Warranty9
- About this Manual10
- Misuse of Equipment10
- Responsibility for Safety10
- Emergency Shutdown11
- Introduction9
- Safety9
  - Standards for Safety9
Fig. 1 - Component Locations12
- Evaporator13
- Condenser13
- Introduction12
  - General Description12
  - Compressor12
Section 2 - Product Description12
Fig. 2 - Screw Compressor13
- Economizer14
- Oil Separator/System14
- Capacity Control15
- Microprocessor Controls15
- Motor Current Protection15
- Power and Control Panel15
- Current Overload16
- Motor Protection Modules (2ACE)16
- Current Imbalance (Loaded & Unloaded)17
- Improper Phase Sequence17
- Loss of Phase17
- Thermal Overload17
- Table 1 - Motor Protector Dip Switch Setting18
- Keypad Controls20
  - Display20
  - Program21
- Motor Starting20
- Accessories and Options21
  - Multiple Point Power Connection21
  - Single-Point Power Connection with Individual Circuit Protection21
  - Control Circuit Terminal Block21
  - Building Automation System (BAS) Interface21
  - Condenser Coil Protection21
- DX Evaporator and Starter Options22
- Fan Options22
- Sound Reduction Options22
- Unit Enclosure Options22
- Vibration Isolation22
- Nameplate Engineering Data23
- Unit Nomenclature23
- Product Identification Number (Pin)24
- Delivery and Storage25
- Inspection25
- Moving the Chiller25
  - Lifting Weights25
Section 3 - Handling and Storage25
Fig. 3 - Unit Rigging26
Fig. 4 - Lifting Lugs26
Unit Rigging26
- Indoor Installations27
- Location Clearances27
- Location Requirements27
- Outdoor Installations27
Section 4 - Installation27
- Compressor Feet Bolt Removal28
Fig. 5 - Compressor Mounting28
- Pipework Connection29
  - General Requirements29
- Shipping Braces29
- Vibration Isolators29
  - Installation29
Fig. 6 - Pipework Arrangement30
- Water Treatment30
- Connection Types & Sizes31
- Ductwork Connection31
  - General Requirements31
- Evaporator Connections31
  - Option Flanges31
Fig. 7 - Victaulic Groove31
Fig. 8 - Flange Attachments31
- Pipework Arrangement31
- Refrigerant Relief Valve Piping31
- 115Vac Control Supply Transformer32
  - Remote Emergency Stop Device33
- Electrical Connection32
- Power Wiring32
- Standard Units with Multi Point Power Supply Wiring32
  - Units with Single-Point Power Supply Wiring32
- Control Panel Wiring33
- System Inputs33
- Volts Free Contacts33
Fig. 9 - Power Panel Section34
Fig. 10 - Option Panel Section35
Fig. 11 - Logic Section Layout36
Fig. 12 - Logic Section Layout with37
Fig. 13 - Customer Connections38
Fig. 14 - Customer Connections38
- Preparation40
- Preparation - Power off40
Section 5 - Commissioning40
- First Time Start-Up42
- General Description44
- Normal Running and Cycling44
Section 6 - Operation44
- Shutdown44
- Start-Up44
Fig. 15 - Flow Rate and Pressure Drop46
Fig. 16 - Glycol Correction Factors46
- Flow Rate and Pressure Drop Charts46
- Glycol Correction Factors46
Section 7 - Technical Data46
- Physical Data - Ycas R-407C (si Units)48
- Operating Limitations and Sound Power Data49
- Electrical Data50
Fig. 17 - Multiple Point Power Supply Connection50
- Multiple Point Power Supply Connection50
Fig. 18 - Multiple Point Power Supply Connection with Individual System Circuit Breakers51
- Multiple Point Power Supply Connection51
Fig. 19 - Optional Single-Point Power Supply Connection with Individual System Circuit Breakers52
- Optional Single Point Power Supply Connection and Individual System Circuit Breakers52
- Electrical Notes54
Table 2 - Compressor Data55
Fig. 20 - Elementary Wiring Diagram - Dxst Direct Drive 3 Compressor56
- Wiring Diagrams56
Fig. 21 - Elementary Wiring Diagram - Across The-Line Start 3 Compressor57
Fig. 22 - Elementary Wiring Diagram - Wye Delta Start 3 Compressor58
Fig. 23 - Control Power Transformer Kit59
Fig. 24 - Elementary Wiring Diagram Dxst Direct Drive Control Circuit60
Fig. 25 - Connection Diagram 3 Compressor62
Fig. 26 - Connection Diagram 3 Compressor63
Fig. 27 - Connection Diagram 3 Compressor64
Fig. 28 - Connection Diagram 3 Compressor66
Fig. 29 - Connection Diagram 3 Compressor67
Fig. 30 - Elementary Diagram 3 Compressor Dxst Direct Drive Control Circuit68
Fig. 31 - Elementary Diagram Dxst Direct Drive - 3 Compressor69
Fig. 32 - Connection Diagram System Wiring 3 Compressor70
Fig. 33 - Connection Diagram Ststem Wiring71
Fig. 34 - Elementary Wiring Diagram - 4 Compressor72
Fig. 35 - Elementary Wiring Diagram - Across-The-Line Start73
- Wiring Diagrams73
Fig. 36 - Elementary Wiring Diagram - Wye Delta Start74
Fig. 37 - Control Power Transformer Kit75
Fig. 38 - Elementary Wiring Diagram76
Fig. 39 - Connection Diagram 4 Compressor78
Fig. 40 - Connection Diagram 4 Compressor79
Fig. 41 - Elementary Wiring Diagram80
Fig. 42 - Connection Diagram 4 Compressor82
Fig. 43 - Connection Diagram 4 Compressor83
Fig. 44 - Connection Diagram 4 Compressor84
Fig. 45 - Elementary Diagram - Dxst Direct Drive Control Circuit86
Fig. 46 - Elementary Diagram - Dxst Direct Drive Control Circuit87
Fig. 47 - Connection Diagram System Wiring88
Fig. 48 - Connection Diagram System Wiring89
Fig. 49 - Compressor Terminal Box, System90
- Dimensions - Ycas0685 (Si)94
Fig. 50 - Model Ycas0685 Dimensions (Si)94
- Dimensions - Ycas0775 - Ycas0905 (Si)96
Fig. 51 - Model Ycas0775 - 0905 Dimensions (Si)96
- Dimensions - Ycas0965 (Si)98
Fig. 52 - Model Ycas0965 Dimensions (Si)98
- Dimensions - Ycas1065 - Ycas1215 (Si)100
Fig. 53 - Model Ycas1065 - Ycas1215 (Si)100
Fig. 54 - Clearances102
- Technical Data102
- Weight Distribution and Isolator Mounting Positions103
Fig. 55 - Cp-2-XX104
Fig. 56 - Isolator Details105
Fig. 57 - Cp-2-XX108
Fig. 58 - Isolator Details109
Fig. 59 - Cp-2-XX112
Fig. 60 - Isolator Details113
Fig. 61 - Cp-2-XX116
Fig. 62 - Isolator Details117
- Installation Instructions for VMC Series Awr/Awmr and Cp Restrained Mountings119
Fig. 63 - Refrigerant Flow Diagram120
Fig. 64 - Process and Instrumentation121
Fig. 65 - Component Locations122
- Compressor Components124
Fig. 66 - Compressor Components124
Fig. 67 - Compressor Components125
Fig. 68 - Compressor Components126
Fig. 69 - Compressor Components127
Fig. 70 - Compressor Components128
Fig. 71 - Compressor Components129
- System Startup Checklist130
- Chiller Control Panel134
- Display and Status Information Keys134
- On / off Rocker Switch134
- Program & Setup Keys134
- Programming and Data Access Keys134
Section 8 - Micro Panel Contents134
1 Introduction & Physical Description135
- 1.1 General135
- 1.2 Keypad & Display135
- 1.3 Unit (Chiller) on / off Switch136
- 1.4 Microprocessor Board136
- 1.5 Ancillary Circuit Boards136
- Circuit Breakers137
- 1.8 Transformers138
- 1.9 Motor Protector Modules138
Fig. 72 - Motor Protection Module139
- Ems/Bas Controls140
- Microprocessor Board Layout142
Fig. 73 - Component Layout142
- Logic Section Layout143
Fig. 74 - Logic Section Layout143
- Anti-Recycle Timer144
- Anti-Coincidence Timer144
- Evaporator Pump Control144
- Compressor Heater Control144
- Evaporator Heater Control144
- Pumpdown (Eev) Control144
- Alarms145
- Run Status (Chiller)145
- Lead / Lag Compressor Selection145
- Or 4 Compressor Chiller Configuration146
- Economizer Solenoid Control146
2 Status Key: General Status Messages & Fault Warnings148
- General148
- General Status Messages148
- Unit Warnings149
- Anticipation Control Status150
- Unit Fault Status Messages151
- System Fault (Safety) Status Messages152
Fig. 75 - Suction Pressure Cutout153
- Printout on Fault Shutdown155
3 Display Keys & Option Switches156
- General156
- Chilled Liquid Temps Key156
- System # Data Keys157
- Ambient Temp Key157
- Motor Current Key158
- Operating Hrs / Start Counter Key158
- Options Key & Dip Switch Settings158
Fig. 77 - Enlarged Photograph of Dip Switches on Microprocessor Board159
- Function Key160
4 Print Keys161
- General161
- Oper Data Key161
- Operating Data - Software Version163
- Operating Data - Remote Printout163
- History Key164
- Fault History Data - Local Display Messages164
- Fault History Data - Remote Printout168
5 Entry Keys169
- General169
- Numerical Keypad169
- Enter Key169
- Cancel Key169
- Keys169
6 Setpoints Keys & Chilled Liquid Control170
- 6.1 General170
- Chilled Liquid Temperature Control170
- Local Cooling Setpoints Key174
- Remote Cooling Setpoints Key174
7 Clock Keys175
- General175
- Set Time Key175
- Set Schedule / Holiday Key176
- Manual Override Key177
8 Program Key178
- Cut-Out178
- General178
- Programming "Default" Values182
- Table 3 - Default Values Table183
- 8.4 Electronic Expansion Valve184
Fig. 78 - Electronic Expansion Valve184
- 8.5 Eev Operation185
- 8.6 Eev Programming187
- Table 4 - Programmable Values Table187
- 8.7 Eev Troubleshooting188
- Compressor Condenser Fan Control189
Table 5 - Condenser Fan Control and Fan Contactor Data for Dxst Units189
Table 8 - Condenser Fan Control and Fan Contactor Data for Dxst Units189
Fig. 79 - Condenser Fan Control Layout for Dxst Compressors Units189
- Compressor Condenser Fan Control190
Table 6 - Condenser Fan Control and Fan Contactor Data for Dxst Units191
Table 7 - Condenser Fan Control and Fan Contactor Data for Dxst Units191
Fig. 80 - Condenser Fan Control Layout for Dxst Compressors Units191
- Table 9 - Condenser Fan Control and Fan Contactor Data for Dxst Units192
- 8.10 Service Mode: Unit Setup193
- Table 10 - Service Mode Programmable Values193
- Table 11 - Ycas Style G, Across the Line Start - 50 Hz194
- Table 12 - Ycas Style G, Wye Delta Start - 50 Hz195
- 8.11 Control Inputs/Outputs197
- Table 13 - Digital Outputs197
- Table 14 - Analog Inputs198
- Table 16 - Analog Outputs199
- Table 15 - Digital Inputs199
- 8.12 Sensor Calibration Charts200
- 8.13 Isn Control201
Table 17 - Isn Received Data201
Table 18 - Isn Transmitted Data201
Table 19 - Isn Operational and Fault Codes204
Section 9 - Maintenance206
- General Requirements206
- Condenser Coils206
  - Chiller / Compressor Operating Log207
  - Scheduled Maintenance207
- On-Board Battery Back-Up207
- Overall Unit Inspection207
- Compressor Unit Operation207
- General Periodic Maintenance Checks210
- Standard Units210
Section 10 - Spare Parts211
- Recommended Spares211
- Recommended Compressor Oils211
Section 11 - Troubleshooting212
Guide212
- Engineered Systems214
- Warranty on New Equipment214
- Warranty on Reconditioned or Replacement Materials214
- Temperature Conversion Chart - Differential Temperatures214
- Temperature Conversion Chart215
- Actual Temperatures215
- Pressure Conversion Chart - Gauge or Differential215

York YCAS Series - Page 77

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