York YCAS0200 User Manual

INSTALLATION, OPERATION & MAINTENANCE
AIR-COOLED SCREW LIQUID CHILLERS
Supersedes: 201.18-NM1 (1298)
Form 201.18-NM1 (102)
YCAS AIR-COOLED SCREW LIQUID CHILLERS
YCAS0130 through YCAS0230
YCAS 2 SYSTEM EPROM 031-01798-001 (STANDARD, BRINE & METRIC MODELS COMBINED)
28971AR

York YCAS0200 Specifications

General

Model	YCAS0200
Category	Chiller
Cooling Capacity	200 tons (703 kW)
Refrigerant	R-134a
Number of Circuits	2
Power Supply	460V/3Ph/60Hz
Operating Range	40°F to 60°F

Summary

GENERAL CHILLER INFORMATION AND SAFETY

YORK EQUIPMENT WARRANTY TERMS

York International warranty terms and conditions for equipment and materials.

YCAS CHILLER SAFETY STANDARDS

Safety standards and codes complied with by YCAS chillers.

EQUIPMENT SAFETY AND MISUSE GUIDELINES

OPERATOR SAFETY RESPONSIBILITIES

Defines primary responsibility for safety during operation and maintenance.

EQUIPMENT MISUSE AND HAZARDS

Discusses equipment suitability, structural support, access, pressure, and electrical safety.

EQUIPMENT SAFETY PRECAUTIONS

ROTATING PARTS SAFETY GUIDELINES

Safety precautions regarding rotating fan parts and guards.

PRODUCT DESCRIPTION OVERVIEW

COMPRESSOR DESIGN AND OPERATION

Details the semi-hermetic rotary twin-screw compressor design and operation.

CHILLER COMPONENTS DETAILS

EVAPORATOR SPECIFICATIONS

Describes the high-efficiency Shell and Tube type Direct Expansion Evaporator.

CONDENSER COIL CONSTRUCTION

Details the construction of the fin and tube condenser coils.

CHILLER SYSTEM COMPONENTS

OIL SEPARATOR AND LUBRICATION SYSTEM

Details the external oil separator and oil injection system for compressor lubrication.

CHILLER COMPONENT DETAILS (CONTINUED)

OIL COOLING AND CAPACITY CONTROL MECHANISMS

Explains oil cooling and how capacity is controlled via a slide valve.

POWER, CONTROL PANELS, AND MICROPROCESSOR INTERFACE

Details power/control panels, microprocessor functions, and keypad.

COMPRESSOR MOTOR PROTECTION SYSTEMS

MOTOR CURRENT PROTECTION MECHANISMS

Explains microprocessor-based high and low motor current protection.

MOTOR PROTECTION MODULE FUNCTIONALITY

Describes the Texas Instruments 2ACE module for motor overload and fault diagnostics.

MOTOR PROTECTION FEATURES AND FAULT DETECTION

CURRENT OVERLOAD AND THERMAL PROTECTION

Details current overload and thermal protection mechanisms for motors.

PHASE IMBALANCE AND SEQUENCE PROTECTION

Describes protection against phase imbalance, loss of phase, and improper sequence.

PRODUCT OPERATION AND CONTROL INTERFACE

COMPRESSOR MOTOR STARTING METHODS

Explains the two types of compressor motor starting: Across-the-Line and Wye-Delta.

KEYPAD AND DISPLAY OPERATION

Details the functions and displays available via the keypad and screen.

HANDLING AND STORAGE PROCEDURES

CHILLER MOVING AND LIFTING INSTRUCTIONS

Guidance on safely moving the chiller, including lifting methods.

UNIT RIGGING AND LIFTING

UNIT RIGGING DIAGRAMS

Illustrates correct and incorrect methods for rigging and lifting the unit.

INSTALLATION LOCATION AND CLEARANCES

LOCATION REQUIREMENTS AND INSTALLATION TYPES

Essential site requirements for optimal chiller performance and different installation types.

REQUIRED INSTALLATION CLEARANCES

Specifies required clearances for airflow and preventing recirculation.

INSTALLATION PROCEDURES

PIPEWORK CONNECTION GUIDELINES

General recommendations for piping to ensure satisfactory operation and prevent damage.

PIPING AND WATER TREATMENT REQUIREMENTS

WATER TREATMENT QUALITY GUIDELINES

Discusses water quality requirements and recommendations for water treatment.

ELECTRICAL CONNECTIONS AND WIRING

POWER WIRING AND SUPPLY TYPE GUIDELINES

Guidelines for power wiring installation and details for multi-point and single-point supplies.

CHILLER ELECTRICAL CONNECTIONS AND INPUTS

REMOTE EMERGENCY STOP AND CONTROL PANEL WIRING

Instructions for remote stop device wiring and control panel wiring.

VOLTS FREE CONTACTS AND SYSTEM INPUTS

Details voltage-free contacts and system inputs like flow switch and remote control.

CUSTOMER ELECTRICAL CONNECTIONS

CUSTOMER CONNECTION TERMINAL LAYOUT

Illustrates customer connection terminals and wiring diagrams.

COMMISSIONING PREPARATION STEPS

PREPARATION – POWER OFF CHECKLIST

Lists pre-checks to be done with the unit's power supply switched OFF.

COMPRESSOR OIL AND VALVE CHECK PROCEDURES

Procedures for checking compressor oil level and opening valves.

COMMISSIONING PROCEDURES AND CHECKS

UNIT START-UP AND OPERATIONAL SETTINGS

Detailed steps for starting the unit and programming operational settings.

COMMISSIONING START-UP CHECKS

FIRST TIME START-UP PROCEDURE

Procedure for initial unit start-up and required checks.

SUPERHEAT AND SUBCOOLING ADJUSTMENT

Checking and adjusting superheat, subcooling, and expansion valve.

CHILLER OPERATION MODES

GENERAL OPERATION AND START-UP OVERVIEW

Overview of unit operation, start-up procedures, and automatic control.

NORMAL RUNNING, CYCLING, AND SHUTDOWN PROCESSES

Describes normal operation, cycling, and proper shutdown procedures.

TECHNICAL DATA: FLOW AND GLYCOL CORRECTION

FLOW RATE AND PRESSURE DROP CHARTS

Charts for cooler water pressure drop versus flow rate in English and SI units.

TECHNICAL DATA: TEMPERATURE AND FLOWS

TEMPERATURE AND FLOWS (ENGLISH UNITS)

Table showing leaving water temperature, cooler flow, and air on condenser.

TEMPERATURE AND FLOWS (SI UNITS)

Table showing leaving water temperature, cooler flow, and air on condenser in SI units.

TECHNICAL DATA: PHYSICAL CHARACTERISTICS

PHYSICAL DATA (ENGLISH UNITS)

Detailed physical data including capacity, charge, weight, and fan specifications.

PHYSICAL DATA (SI UNITS)

Detailed physical data in SI units, including capacity, charge, weight, and fan specifications.

TECHNICAL DATA: OPERATING LIMITATIONS AND SOUND

OPERATING LIMITATIONS (ENGLISH & SI UNITS)

Specifies operating limits for chilled liquid temp, water side pressure, and airflow.

ELECTRICAL DATA: MULTIPLE POINT POWER SUPPLY

MULTIPLE POINT POWER SUPPLY CONNECTION DETAILS

Details field-provided power supply wiring for Y-Delta and Across-the-Line starts.

ELECTRICAL DATA: OPTIONAL SINGLE-POINT POWER SUPPLY

OPTIONAL SINGLE-POINT POWER SUPPLY WITH CIRCUIT BREAKERS

Details wiring for optional single-point power supply with circuit breakers.

ELECTRICAL DATA: OPTIONAL SINGLE-POINT POWER SUPPLY WITH FIELD PROTECTION

OPTIONAL SINGLE-POINT POWER SUPPLY WITH FIELD SUPPLIED CIRCUIT PROTECTION

Details wiring for optional single-point supply with field-provided protection.

ELECTRICAL DATA: COMPRESSOR AND FAN SPECIFICATIONS

TABLE 2 – COMPRESSOR DATA SUMMARY

Provides maximum kW and amperage values for DXST compressors.

ELECTRICAL DATA: WIRING DIAGRAMS

WIRING DIAGRAM – ACROSS-THE-LINE START

Illustrates the wiring diagram for Across-the-Line motor starting.

ELECTRICAL DATA: WIRING DIAGRAMS (CONTINUED)

WIRING DIAGRAM – ACROSS-THE-LINE START (CONTINUED)

Continuation of the wiring diagram for Across-the-Line motor starting.

ELECTRICAL DATA: ELEMENTARY DIAGRAMS

ELEMENTARY DIAGRAM – ACROSS-THE-LINE START

Provides the elementary wiring diagram for Across-the-Line starting.

ELECTRICAL DATA: DIAGRAMS AND POWER SUPPLY

ELEMENTARY DIAGRAM – ACROSS-THE-LINE START (CONTINUED)

Continuation of the elementary wiring diagram with cautions.

ELECTRICAL DATA: WYE-DELTA START WIRING DIAGRAMS

WIRING DIAGRAM – WYE-DELTA START

Illustrates the wiring diagram for Wye-Delta motor starting.

ELECTRICAL DATA: WYE-DELTA START WIRING DIAGRAMS (CONTINUED)

WIRING DIAGRAM – WYE-DELTA START (CONTINUED)

Continuation of the wiring diagram for Wye-Delta motor starting.

ELECTRICAL DATA: WYE-DELTA START ELEMENTARY DIAGRAMS

ELEMENTARY DIAGRAM – WYE-DELTA START

Provides the elementary wiring diagram for Wye-Delta starting.

ELECTRICAL DATA: DIAGRAMS AND POWER SUPPLY (WYE-DELTA)

ELEMENTARY DIAGRAM – WYE-DELTA START (CONTINUED)

Continuation of the elementary wiring diagram with cautions.

ELECTRICAL DATA: CONNECTION DIAGRAMS

CONNECTION DIAGRAM FOR DXST DIRECT DRIVE

Illustrates the connection diagram for DXST Direct Drive.

ELECTRICAL DATA: COMPONENT AND WIRING DETAILS

DETAIL “A”: MOTOR CURRENT AND CONNECTIONS

Provides detail on motor current and compressor motor connections.

TECHNICAL DATA: WIRING AND COMPONENT DIAGRAMS

SYSTEM WIRING CONNECTION DIAGRAM

Shows system wiring connections for YCAS chillers.

COMPRESSOR SYSTEMS 1 & 2 DIAGRAMS

Diagrams of compressor components and terminal boxes.

COMPRESSOR TERMINAL BOX LAYOUTS

COMPRESSOR TERMINAL BOX DIAGRAMS

Shows terminal box layouts for Wye-Delta and Across-the-Line starts.

TECHNICAL DATA: DIMENSIONS

DIMENSIONS – YCAS0130 TO 0180 (ENGLISH UNITS)

Provides overall dimensions for YCAS0130-0180 models in English units.

INSTALLATION CLEARANCES REQUIREMENTS

MINIMUM INSTALLATION CLEARANCES GUIDELINES

Specifies minimum clearances for installation, walls, and adjacent units.

SYSTEM STARTUP CHECKLIST

PRE-STARTUP AND INITIAL STARTUP CHECKLIST

Checklist for unit checks before and during initial start-up.

COMMISSIONING: START-UP AND ADJUSTMENT PROCEDURES

INITIAL START-UP SEQUENCE AND CHECKS

Steps for placing the chiller into operation after programming.

SUBCOOLING AND SUPERHEAT ADJUSTMENT

Checking and adjusting subcooling and superheat.

COMMISSIONING: SUPERHEAT AND LEAK CHECKING

ECONOMIZER SUPERHEAT CHECK PROCEDURE

LEAK CHECKING PROCEDURES

Instructions for performing leak checks on compressors, fittings, and piping.

CHILLER CONTROL PANEL KEYS

DISPLAY AND STATUS INFORMATION KEY FUNCTIONS

Explains how to use status keys to view operational and fault status.

PRINT KEY FUNCTIONS

PROGRAM & SETUP KEY FUNCTIONS

Explains the use of Entry, Setpoints, Clock, and Program keys for configuration.

MICRO PANEL CONTENTS: INTRODUCTION

KEYPAD AND DISPLAY INTERFACE DESCRIPTION

Describes the operator keypad and liquid crystal display interface.

MICRO PANEL COMPONENTS

MICROPROCESSOR BOARD FUNCTIONALITY

Explains the function of the microprocessor board and its inputs/outputs.

MICRO PANEL COMPONENTS: MOTOR PROTECTION

MOTOR PROTECTION MODULE FUNCTIONS

Explains the function of the Motor Protection Module for compressor protection.

MOTOR PROTECTION MODULE DETAILS

MOTOR PROTECTION MODULE PHOTOGRAPH AND SETTINGS

Photograph and details of the Motor Protection Module, including dip switch settings.

MICRO PANEL CONTROLS: EMS/BAS AND REMOTE FUNCTIONS

EMS/BAS CONTROL INTEGRATION

Describes how the microprocessor accepts remote signals for control.

REMOTE START/STOP AND CURRENT RESET PROCEDURES

STATUS KEY: GENERAL MESSAGES AND WARNINGS

UNIT FAULT STATUS MESSAGES

UNIT FAULT MESSAGES AND CUTOUTS

Describes fault messages that shut down the chiller when safety thresholds are exceeded.

AMBIENT AND LIQUID TEMPERATURE CUTOUTS

115VAC UNDER VOLTAGE CUTOUT AND FLOW SWITCH STATUS

SYSTEM FAULT (SAFETY) STATUS MESSAGES

SYSTEM FAULT MESSAGES AND LOCKOUTS

Lists system fault messages that trigger shutdowns and potential lockouts.

HIGH DISCHARGE PRESSURE AND TEMPERATURE CUTOUTS

HIGH OIL DIFFERENTIAL PRESSURE CUTOUT

COMPRESSOR SAFETY CUTOUTS AND MONITORING

LOW MOTOR CURRENT CUTOUT AND MOTOR PROTECTION

Describes safety for low motor current and motor protection module functions.

MOTOR PROTECTION MODULES AND HIGH PRESSURE CUTOUTS

Explains how these devices stop the compressor and the resulting faults.

DISPLAY KEYS AND OPTION SWITCHES

CHILLED LIQUID TEMPERATURE DISPLAY KEY

HISTORY KEY AND FAULT DATA DISPLAY

HISTORY KEY FOR ACCESSING SAFETY SHUTDOWNS

Provides a list of operating/programmed settings at the instant of the last 6 safety shutdowns.

FAULT HISTORY DATA LOCAL DISPLAY MESSAGES

FAULT HISTORY DATA: REMOTE PRINTOUT EXAMPLE

REMOTE PRINTOUT OF SAFETY SHUTDOWN DATA

Shows a printout of safety shutdown data, including system status and programmed values.

PROGRAM KEY FOR SETTING OPERATING PARAMETERS

USER PROGRAMMABLE VALUES FOR THE PROGRAM KEY

Details user-programmable values like pressure and temperature cutouts.

TROUBLESHOOTING GUIDE

COMPETENT PERSONS TROUBLESHOOTING GUIDE

Guide for diagnosing and resolving common problems like no display or unit start failure.

TROUBLESHOOTING GUIDE (CONTINUED)

TROUBLESHOOTING HIGH DISCHARGE PRESSURE AND TEMPERATURE

Continued troubleshooting for issues like high discharge pressure, temperature, and low suction.

LIMITED WARRANTY INFORMATION

WARRANTY TERMS FOR NEW EQUIPMENT

Details YORK's warranty terms for new equipment.

WARRANTY FOR RECONDITIONED OR REPLACEMENT MATERIALS

CONDITIONS THAT VOID EQUIPMENT WARRANTY

Lists conditions that will void the equipment warranty.