York YCAS0210 - Page 168

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P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA

Form 201.18-NM1 (102)

Supersedes: 201.18-NM1 (1298)

201.18-NM1 (1098)

Main Page

Table of Contents2
General Chiller Information & Safety6
Introduction6
Warranty6
Safety6
Standards for Safety6
Responsibility for Safety7
About this Manual7
Misuse of Equipment7
Suitability for Application7
Structural Support7
Mechanical Strength7
General Access7
Pressure Systems7
Electrical7
Rotating Parts8
Sharp Edges8
Refrigerants and Oils8
High Temperature and Pressure Cleaning8
Emergency Shutdown8
Section 2 Product Description9
Introduction9
General Description9
Compressor9
Evaporator10
Condenser10
Economizer11
Suction Line Heat Exchanger11
Oil Separator / System11
Oil Cooling12
Capacity Control12
Power and Control Panel12
Microprocessor Controls12
Motor Current Protection13
Motor Protection Module13
Current Overload14
Thermal Overload14
Current Imbalance / Loss of Phase14
Improper Phase Sequence14
Motor Protector Dip Switch Settings15
Motor Starting19
Keypad Controls19
Display19
Entry20
Setpoints20
Clock20
Print20
Program20
Accessories and Options20
Multiple Point Power Connection (Standard)20
Single-Point Power Connection with Individual Circuit Protection20
Single-Point Power Connection with Combined Circuit Protection20
Single-Point Power Connection Without Circuit Protection20
DX Cooler Options21
300 PSIG (21 Bar) Waterside Design Working21
Pressure21
1-1/2" (38 MM) Insulation21
Flange Accessory21
Remote DX Cooler21
Flow Switch Accessory21
Star-Delta Compressor Motor Starter21
Unit Enclosures21
Fans21
Unit Nomenclature and Nameplate Engineering Data22
Basic Part Number22
Options Section of Part Number22
Section 3 Handling and Storage23
Delivery and Storage23
Inspection23
Moving the Chiller23
Lifting Weights23
Unit Rigging24
Section 4 Installation25
Location Requirements25
Outdoor Installations25
Indoor Installations25
Location Clearances25
Installation of Vibration Isolators26
Installation26
Shipping Braces26
Pipework Connection26
General Requirements26
Water Treatment27
Pipework Arrangement28
Connection Types & Sizes28
Cooler Connections28
Option Flanges28
Refrigerant Relief Valve Piping28
Ductwork Connection28
General Requirements28
Electrical Connection29
Power Wiring29
Standard Units with Multi Point Power Supply Wiring29
Units with Single-Point Power Supply Wiring29
115VAC Control Supply Transformer29
Remote Emergency Stop Device30
Control Panel Wiring30
Volts Free Contacts30
Chilled Liquid Pump Starter30
Run Contact30
Alarm Contacts30
System Inputs30
Flow Switch30
Remote Run/Stop30
Remote Print30
Power and Control Panel Layouts (Wye-Delta Typical)31
Options Panel Layout (Typical)32
Logic Section Layout33
Logic Section Layout with Control Panel Layout34
Customer Connections35
Section 5 Commissioning37
Preparation37
Preparation - Power off37
First Time Start-Up39
Section 6 Operation40
General Description40
Start-Up40
Normal Running and Cycling40
Shutdown40
Section 7 Technical Data41
Flow Rate and Pressure Drop Charts41
Glycol Correction Factors41
Temperature and Flows42
Physical Data (English & si Units)43
Operating Limitations & Sound Power Data44
Electrical Data46
Multiple Point Power Supply Connection46
Optional Single-Point Power Supply Connection and Individual System Circuit Breakers48
Optional Single-Point Power Supply Connection with Field Supplied Circuit Protection50
Optional Single-Point Power Supply Connection to Factory Circuit Breaker51
Compressor Data52
Fan Data52
Electrical Notes53
Wiring Diagram Across-The-Line Start54
Elementary Diagram - Across-The-Line Start56
Panel Component Locations58
Wiring Diagram Wye-Delta Start60
Elementary Diagram - Wye-Delta Start62
Panel Component Locations64
Connection Diagram68
Compressor Terminal Box69
Dimensions72
YCAS0130 - 0180 (English)72
Ycas0130 - 0180 (Si)74
YCAS0200 - 0230 (English)76
Ycas0200 - 0230 (Si)78
Clearances80
Weight Distribution and Isolator Mounting Positions81
Isolator Installation Instructions for VMC Series AWR/AWMR Isolator and CP Restrained Mountings89
Refrigerant Flow Diagram90
Process and Instrumentation Diagram91
Component Locations92
Compressor Components93
System Startup Checklist99
Unit Checks99
Panel Checks100
Initial Start-Up101
Checking Subcooling and Superheat101
Checking Economizer Superheat102
Leak Checking102
Chiller Control Panel Programming and Data Access Keys103
Display and Status Information Keys103
ON / off Rocker Switch103
Program & Setup Keys103
Section 8 Micro Panel Contents104
Introduction & Physical Description104
1.1 General104
1.2 Keypad & Display104
1.3 Unit (Chiller) on / off Switch105
Microprocessor Board105
1.5 Ancillary Circuit Boards105
1.6 Circuit Breakers106
Current Transformers (C.T.)106
Transformers106
Motor Protection Modules107
Ems/Bas Controls109
Microprocessor Board Layout111
Logic Section Layout112
Anti-Recycle Timer113
Anti-Coincidence Timer113
Evaporator Pump Control113
Compressor Heater Control113
Evaporator Heater Control113
Pumpdown (LLSV) Control113
Alarms113
Run Status (Chiller)114
Lead / Lag Compressor Selection114
Status Key: General Status Messages and Fault Warnings115
General115
General Status Messages115
Unit Warnings116
Anticipation Control Status Messages117
Unit Fault Status Messages118
System Fault (Safety) Status Messages119
Printout on Fault Shutdown122
Display Keys & Option Switches123
General123
Chilled Liquid Temps Key123
System # Data Keys124
Ambient Temp Key124
Motor Current Key125
Operating HRS / Start Counter Key125
Options Key & Dip Switch Settings125
Function Key127
Print Keys128
General128
Oper Data Key128
Operating Data - Local Display Messages128
Operating Data - Remote Printout129
History Key131
Fault History Data - Local Display Messages131
Fault History Data - Remote Printout134
Entry Keys135
General135
Numerical Keypad135
Enter Key135
Cancel Key135
Áâ KEYS135
Setpoints Keys & Chilled Liquid Control136
General136
Chilled Liquid Temperature Control136
Local Cooling Setpoints Key139
Remote Cooling Setpoints Key139
Clock Keys140
General140
Set Time Key140
Set Schedule / Holiday Key141
Manual Override Key142
Program Key143
General143
Program Key - User Programmable Values143
Programming "Default" Values147
Condenser Fan Control148
Section 9 Maintenance155
General Requirements155
Daily Maintenance155
Scheduled Maintenance155
Chiller / Compressor Operating Log155
Compressor Unit Operation156
Maintenance Requirements157
General Periodic Maintenance Checks Standard Units158
Section 10 Spare Parts159
Recommended Spares159
Recommended Compressor Oils159
Associated Drawings159
Section 11 Troubleshooting160
Competent Persons Troubleshooting Guide160
Sensor Calibration Charts162
Limited Warranty Applied Systems163
Temperature Conversion Chart164
YORK Service Offices165

York YCAS0210 - Page 168

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