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8

YORK INTERNATIONAL

FORM 201.18-NM1 (102)

only be carried out by suitably trained and qualified per-
sonnel. No attempt should be made to gain access to
the control panel or electrical enclosures during normal
operation of the unit.

Rotating Parts
Fan guards must be fitted at all times and not removed
unless the power supply has been isolated. If ductwork
is to be fitted, requiring the wire fan guards to be re-
moved, alternative safety measures must be taken to
protect against the risk of injury from rotating fans.

Sharp Edges
The finning on the air-cooled condenser coils has sharp
metal edges. Reasonable care should be taken when
working in contact with the coils to avoid the risk of
minor abrasions and lacerations. The use of gloves is
recommended.

Refrigerants and Oils
Refrigerants and oils used in the unit are generally non-
toxic, non-flammable and non-corrosive, and pose no

special safety hazards. Use of gloves and safety glasses
is, however, recommended when working on the unit.
The build up of refrigerant vapor, from a leak for ex-
ample, does pose a risk of asphyxiation in confined or
enclosed spaces and attention should be given to good
ventilation.

High Temperature and Pressure Cleaning

High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the pres-
sure relief device(s). Detergents and solvents which may
cause corrosion should also be avoided.

EMERGENCY SHUTDOWN

In case of emergency the electrical option panel is fit-
ted with an emergency stop switch CB3 (Circuit Breaker
3). Separate Circuit Breakers, CB1 (System 1) and CB2
(System 2), can also be used to stop the respective sys-
tem in an emergency. When operated, it removes the
electrical supply from the control system, thus shutting
down the unit.

General Chiller Information & Safety

Summary of Contents for MILLENNIUM YCAS0230

Page 1: ...ENANCE 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 ...

Page 2: ...tandard 20 Single Point Power Connection with Individual Circuit Protection 20 Single Point Power Connection with Combined Circuit Protection 20 Single Point Power Connection without Circuit Protection 20 Control Circuit Terminal Block 20 Building Automation System BAS Interface 20 Condenser Coil Protection 20 DX Cooler Options 21 300 PSIG 21 bar Waterside Design Working Pressure 21 1 1 2 38 mm In...

Page 3: ...h SI Units 43 Operating Limitations Sound Power Data 44 Electrical Data 46 Multiple Point Power Supply Connection 46 Optional Single Point Power Supply Connection and Individual System Circuit Breakers 48 Optional Single Point Power Supply Connection with Field Supplied Circuit Protection 50 Optional Single Point Power Supply Connection to Factory Circuit Breaker 51 Compressor Data 52 Fan Data 52 ...

Page 4: ...113 1 17 Evaporator Heater Control 113 1 18 Pumpdown LLSV Control 113 1 19 Alarms 113 1 20 Run Status Chiller 114 1 21 Lead Lag Compressor Selection 114 2 STATUS KEY GENERAL STATUS MESSAGES AND FAULT WARNINGS 115 2 1 General 115 2 2 General Status Messages 115 2 3 Unit Warnings 116 2 4 Anticipation Control Status Messages 117 2 5 Unit Fault Status Messages 118 2 6 System Fault Safety Status Messag...

Page 5: ...ogram Key User Programmable Values 143 8 3 Programming Default Values 147 8 4 4 Condenser Fan Control 148 SECTION 9 MAINTENANCE 155 General Requirements 155 Daily Maintenance 155 Scheduled Maintenance 155 Chiller Compressor Operating Log 155 Compressor Unit Operation 156 Maintenance Requirements 157 General Periodic Maintenance Checks Standard Units 168 SECTION 10 SPARE PARTS 159 Recommended Spare...

Page 6: ...y evidence that the failure has occurred within the warranty period and that the unit has been operated within the designed parameters specified All warranty claims must specify the unit model serial number order number and run hours starts These de tails are printed on the unit identification plate The unit warranty will be void if any modification to the unit is carried out without prior written...

Page 7: ... is not suitable for purposes other than those specified in these instructions Any use of the equipment other than its intended use or operation of the equip ment contrary to the relevant procedures may result in injury to the operator or damage to the equipment The unit must not be operated outside the design pa rameters specified in this manual Structural Support Structural support of the unit m...

Page 8: ...enerally non toxic non flammable and non corrosive and pose no special safety hazards Use of gloves and safety glasses is however recommended when working on the unit The build up of refrigerant vapor from a leak for ex ample does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation High Temperature and Pressure Cleaning High temperature and ...

Page 9: ...rough liquid tight non metallic conduit General Description The Air Cooled Screw Chiller utilizes many compo nents which are the same or nearly the same as a stan dard reciprocating chiller of a similar size This includes modular frame rails condenser fans and evaporator The chiller consists of 2 screw compressors in a corre sponding number of separate refrigerant circuits a single shell and tube ...

Page 10: ...ator The pressur ized oil is then cooled in the condenser coils and piped back to the compressor for lubrication The compres sor design working pressure is 450 PSIG 31 bar Each chiller receives a 300 PSIG 21 bar low side and a 450 PSIG 31 bar high side factory test A 350 watt 115 1 60 cartridge heater is located in the compressor The heater is temperature activated to prevent refrigerant condensat...

Page 11: ...id supply solenoid is ac tivated on start up coincident with the liquid line sole noid after pumpdown The economizer operation is controlled by the econo mizer solenoid valve This valve is controlled by the microprocessor The valve will remain off for the first 3 minutes of compressor operation After 3 minutes of operation the economizer solenoid valve will open if the slide valve position is Step...

Page 12: ...oth loading Automatic spring return of the slide valve to the mini mum load position will ensure compressor starting at minimum motor load Power and Control Panel All controls and motor starting equipment are factory wired and function tested The panel enclosures are de signed to IP32 and are manufactured from powder painted galvanized steel The Power and Control Panels are divided into power sect...

Page 13: ...Protector contact opens This occurs because the MP and HPCO contacts are in series with the motor contactor Whenever either of these devices are open the contactor de energizes and the motor shuts down Since the micro is sending a run signal to the contactor it senses the low motor current below 10 FLA and shuts the system down Motor Protection Module The mechanical motor protector is a Texas Inst...

Page 14: ... at 1kΩ until a temperature of 266 F 130 C is sensed The sensor experiences a rapid rise in resistance beyond this temperature Whenever the resistance of one of the sensors reaches 13kΩ the 2ACE module trips which ultimately de energizes the motor s pilot circuit Reset is manual after the motor cools and the sensor resistance drops to 3 25kΩ Current Imbalance Loaded Unloaded Loss of Phase A 2 seco...

Page 15: ... 1 1 0 0 0 1 1 SYS 1 28 256 4 86 0 1 0 1 0 1 1 1 40 155 2 209 1 1 0 1 0 0 0 1 46 128 2 173 1 0 1 0 1 1 0 1 58 103 1 139 1 0 0 0 1 0 1 1 0150 17 265 4 89 0 1 0 1 1 0 0 1 SYS 2 28 230 2 78 0 1 0 0 1 1 1 0 40 139 2 188 1 0 1 1 1 1 0 0 46 115 1 155 1 0 0 1 1 0 1 1 58 92 1 124 0 1 1 1 1 1 0 0 0160 17 295 4 99 0 1 1 0 0 0 1 1 28 256 4 86 0 1 0 1 0 1 1 1 40 155 2 209 1 1 0 1 0 0 0 1 46 128 2 173 1 0 1 0 ...

Page 16: ...89 1 0 1 1 1 1 0 1 58 112 1 151 1 0 0 1 0 1 1 1 0200 17 342 4 115 0 1 1 1 0 1 0 0 28 298 4 101 0 1 1 0 0 1 0 1 40 181 2 122 0 1 1 1 1 1 1 0 46 149 2 201 1 1 0 0 1 0 0 1 58 119 1 161 1 0 1 0 0 0 0 1 0210 17 374 4 126 0 1 1 1 1 1 1 0 SYS 1 28 325 4 110 0 1 1 0 1 1 1 0 40 197 2 133 1 0 0 0 0 1 0 1 46 163 2 110 0 1 1 0 1 1 1 0 58 130 2 175 1 0 1 0 1 1 1 1 0210 17 342 4 115 0 1 1 1 0 1 0 0 SYS 2 28 298...

Page 17: ...116 2 157 1 0 0 1 1 1 0 1 58 93 2 126 0 1 1 1 1 1 1 0 0150 17 295 4 115 0 1 1 1 0 0 1 1 SYS 1 28 256 4 100 0 1 1 0 0 1 0 0 40 155 2 209 1 1 0 1 0 0 0 1 46 128 2 173 1 0 1 0 1 1 0 1 58 103 2 139 1 0 0 0 1 0 1 1 0150 17 265 4 104 0 1 1 0 1 0 0 0 SYS 2 28 230 4 90 0 1 0 1 1 0 1 0 40 139 2 188 1 0 1 1 1 1 0 0 46 115 2 155 1 0 0 1 1 0 1 1 58 92 2 124 0 1 1 1 1 1 0 0 0170 17 321 4 126 1 0 0 0 0 0 1 0 SY...

Page 18: ... 17 342 4 134 1 0 0 0 0 1 1 0 28 298 4 117 0 1 1 1 0 1 0 1 40 181 2 142 1 0 0 0 1 1 1 0 46 149 2 201 1 1 0 0 1 0 0 1 58 119 2 161 1 0 1 0 0 0 0 1 0210 17 374 4 146 1 0 0 1 0 0 1 0 SYS 1 28 325 4 127 0 1 1 1 1 1 1 1 40 197 2 154 1 0 0 1 1 0 1 0 46 163 2 128 1 0 0 0 0 0 0 0 58 130 2 175 1 0 1 0 1 1 1 1 0210 17 342 4 134 1 0 0 0 0 1 1 0 SYS 2 28 298 4 117 0 1 1 1 0 1 0 1 40 181 2 142 1 0 0 0 1 1 1 0 ...

Page 19: ...ansition delay relay is enabled by the microprocessor from Relay Output Board 1 Terminal 8 SYS 1 or Relay Output Board 2 Terminal 8 SYS 2 The 1TR SYS 1 or 2TR SYS 2 contacts open de energizing 1S SYS 1 or 2S SYS 2 1M SYS 1 or 3M SYS 2 remains energized through interlocking contacts 1M SYS 1 or 3M SYS 2 Open ing of the 1TR SYS 1 or 2TR SYS 2 contacts de ener gizes 1S 2S and closes the normally clos...

Page 20: ... fins cop per tubes and galvanized steel supports for generally adequate corrosion resistance However these materi als are not adequate for all environments Entry Used to confirm Setpoint changes cancel in puts advance day and change AM PM Setpoints For setting chilled liquid temperature chilled liquid range remote reset temperature range Clock Used to set time daily or holiday start stop schedule...

Page 21: ...o 250 F 29 C to 121 C with 1 NPT IPS connection for upright mounting in horizontal pipe A flow switch must be field installed with each unit Star Delta Compressor Motor Starter Provides approximately 65 reduced inrush current compared to across the line start Factory mounted UNIT ENCLOSURES Wire Enclosure Heavy gauge welded wire mesh guards mounted on the exterior of the unit Factory or field moun...

Page 22: ... Ext Handles Individual System Breaker Lockable External Handle 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 3631 POWER FIELD CONTROLS FIELD COMPRESSOR PIPING FIELD M D X M B Y T S S B C C D B B D S X M L S D S B B X F X C G X X X X L X C X X C P R S EVAP FIELD CONDENSER FIELD CABINET FIELD Wire Full Unit Enc Panels factory Wire Full Unit Enc Panels field Wire Louvered Enc Panels fa...

Page 23: ...sponsible person on site It is recommended that the unit is periodically in spected during storage INSPECTION Remove any transit packing and inspect the unit to en sure that all components have been delivered and that no damage has occurred during transit If any damage is evident it should be noted on the carrier s freight bill and a claim entered in accordance with the instructions given on the a...

Page 24: ...24 YORK INTERNATIONAL FORM 201 18 NM1 102 UNIT RIGGING 88 2250mm CORRECT WRONG LD03514 FIG 3 UNIT RIGGING CORRECT WRONG LD03515 FIG 4 LIFTING LUGS Handling and Storage ...

Page 25: ...nnels of suitable strength The channels should be spaced at the same centers as the vibration mounting holes in the unit base frame and must be at least 4 3 4 120 mm wide at the contact points This will allow vibration isolators to be fitted if required Any ductwork or attenuators fitted to the unit must not have a total static pressure resistance at full unit air flow exceeding the capability of ...

Page 26: ...truc tion is provided on page 89 SHIPPING BRACES The chiller s modular design does not require shipping braces PIPEWORK CONNECTION General Requirements The following piping recommendations are intended to ensure satisfactory operation of the unit s Failure to follow these recommendations could cause damage to the unit or loss of performance and may invalidate the warranty The maximum flow rate and...

Page 27: ...sed to ensure liquid is circu lated when the ambient temperature approaches freez ing point Insulation should also be installed around the cooler nozzles Heater tape of 21 watts per meter under the insulation is recommended supplied independently and controlled by an ambient temperature thermostat set to switch on at 37 F 21 C above the freezing tem perature of the liquid The liquid circulation pu...

Page 28: ...on pipe Precautions should be taken to ensure that the outlet of relief valves vent pipe remain clear of obstructions at all times DUCTWORK CONNECTION General Requirements The following ductwork recommendations are intended to ensure satisfactory operation of the unit Failure to follow these recommendations could cause damage to the unit or loss of performance and may invalidate the warranty When ...

Page 29: ...nstall overcurrent protection devices between the supply conductors and the power supply terminals on the unit To ensure that no eddy currents are set up in the power panel the cables forming each 3 phase power supply must enter via the same cable entry All sources of supply to the unit must be taken via a common point of isola tion not supplied by YORK STANDARD UNITS WITH MULTI POINT POWER SUPPLY...

Page 30: ...pages 35 and 36 close to start the chilled liquid pump This contact can be used as a master start stop for the pump in conjunc tion with the daily start stop schedule Run Contact Terminals 29 and 30 Figs 12 and 13 pages 35 and 36 close to indicate that a system is running Alarm Contacts Each system has a voltage free changeover contact which will operate to signal an alarm condition when ever a sy...

Page 31: ...31 YORK INTERNATIONAL FORM 201 18 NM1 102 POWER AND CONTROL PANEL LAYOUTS WYE DELTA TYPICAL FIG 8 POWER PANEL SECTION 00263VIP 4 ...

Page 32: ...32 YORK INTERNATIONAL FORM 201 18 NM1 102 FIG 9 OPTION PANEL SECTION OPTIONS PANEL LAYOUT TYPICAL 00246VIP Installation ...

Page 33: ...0 LOGIC SECTION LAYOUT LOGIC SECTION LAYOUT 00247VIP ITEM 1 2 3 4 5 6 7 8 9 DESCRIPTION Microprocessor Board Back of Keypad Back of Display I O Expansion Board 1 Power Supply Board Relay Output Board 1 Relay Output Board 2 Flow Switch Customer Connection Terminals Circuit Breakers 6 7 1 3 2 8 9 5 4 4 ...

Page 34: ...34 YORK INTERNATIONAL FORM 201 18 NM1 102 FIG 11 LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT 00248VIP Installation ...

Page 35: ...FOR EMERGENCY STOPS TERMINALS 13 19 TERMINALS 23 38 Print Temperature PWM Current PWM Flow Switch System No 1 Run System No 2 Run 13 13 13 13 13 14 15 16 17 18 19 23 24 25 26 27 28 29 30 System No 1 Alarm Contacts Chilled Liquid Circulating Pump Start System No 2 Alarm Contacts Chiller Run Isolator Auxiliary Interlock 31 32 4 ...

Page 36: ...2 FIG 13 CUSTOMER CONNECTIONS CUSTOMER CONNECTIONS TRANSFORMERS POWER SUPPLY BOARD CIRCUIT BREAKERS RELAY BOARDS I O EXPANSION BOARD CUSTOMER CONNECTIONS Flow Switch Alarm Run etc MICROPROCESSOR CIRCUIT BOARD 28965A 115VAC SUPPLY Installation ...

Page 37: ...ntrol transformer is mounted in the op tions panel It is important to check that the correct pri mary tapping has been used With the supply to the unit isolated remove the lid to the transformer box COMMISSIONING PREPARATION Commissioning of this unit should only be carried out by YORK Autho rized personnel The Millennium Microcomputer Control System Operating Instructions must be read in conjunct...

Page 38: ...ipework on the cooler outlet and wired into the control panel correctly using shielded cable There should be a straight run of at least 5 pipe diam eters on either side of the flow switch The flow switch should be connected to terminals 13 and 14 in the micro panel Figs 12 and 13 pages 35 and 36 Temperature sensor s Ensure the leaving liquid temperature sensor is coated with heat conductive compou...

Page 39: ...placed by a solid column of liquid Fan Rotation As discharge pressure rises the condenser fans oper ate in stages to control the pressure Verify that the fan operation is correct for the type of unit Suction Superheat Check suction superheat at steady full compressor load only Measure suction temperature on the copper line about 6 150 mm before the compressor suction ser vice valve Measure suction...

Page 40: ...tarted all operations are fully automatic After an initial period at minimum capacity on the lead compressor the control system will adjust the unit load depending on the chilled liquid tempera ture and rate of temperature change If high heat load is present the controller will increase the capacity of the lead compressor and or start up the other compressor If very little heat load is present the...

Page 41: ...ned in accordance with ARI 590 92 which allows for an increase in pressure drop of up to 15 above the design value given above Debris in the water may also cause additional pressure drop When using glycol solutions pressure drops are higher than with water see correction factors to be applied when using glycol solutions Special care must be taken not to exceed the maximum allowed A Correction Fact...

Page 42: ...ERATURE C L S 3 CONDENSER C YCAS MIN 1 MAX 2 MIN MAX MIN MAX 0130EC 4 4 12 8 9 3 37 8 17 7 51 7 0140EC 4 4 12 8 10 7 37 8 17 7 51 7 0150EC 4 4 12 8 11 5 44 2 17 7 51 7 0160EC 4 4 12 8 11 9 47 1 17 7 51 7 0170EC 4 4 12 8 12 8 47 1 17 7 51 7 0180EC 4 4 12 8 13 8 47 1 17 7 51 7 0200EC 4 4 12 8 14 4 47 1 17 7 51 7 0210EC 4 4 12 8 15 6 47 1 17 7 51 7 0230EC 4 4 12 8 17 2 47 1 17 7 51 7 MODEL LEAVING WA...

Page 43: ...w Rate gpm 147 170 182 188 203 218 228 246 272 Maximum Chilled Water Flow Rate gpm 600 600 747 747 747 747 747 747 747 Water Connections inches 8 8 8 8 8 8 8 8 8 1 Optional 300psig Waterside available 2 See page 37 MODEL NUMBER YCAS 0130EC 0140EC 0150EC 0160EC 0170EC 0180EC 0200EC 0210EC 0230EC General Unit Data Unit Capacity at 6 7 C water 35 C ambient kW 435 473 520 551 576 601 665 695 746 Numbe...

Page 44: ...FANS 0 115 FAN STANDARD FANS 20 AVAILABLE STATIC HIGH PRESS FANS OPTION 1 85 PRESSURE Pa HIGH PRESS FANS OPTION 2 150 SLOW SPEED FANS 10 ELECTRICAL THREE PHASE 60 Hz V 200 230 380 460 575 440 OPERATING LIMITATIONS SI UNITS Maximum Ambient w High Ambient Kit is 52 C MIN MAX LEAVING CHILLED LIQUID TEMP C 4 5 15 CHILLED WATER TEMP DIFFERENCE C 3 10 WATER SIDE PRESSURE BAR 10 REFRIGERANT SIDE PRESSURE...

Page 45: ...45 YORK INTERNATIONAL FORM 201 18 NM1 102 This page intentionally left blank 7 ...

Page 46: ... 700 2 2 300 2 3 0 250 3 2 0 400 256 571 1712 7 8 0160EC 380 213 250 300 400 300 400 1 500 6 AWG 350 2 3 0 250 155 360 1081 4 8 460 176 200 225 350 225 350 2 300 6 AWG 350 6 AWG 350 128 285 856 4 0 575 141 150 175 250 175 250 2 4 0 6 AWG 350 6 AWG 350 103 238 715 3 1 200 434 600 600 800 600 800 2 1 500 3 2 0 400 3 2 0 400 321 656 1969 8 2 230 380 400 450 700 450 700 2 1 500 2 3 0 250 3 2 0 400 279...

Page 47: ...85 856 4 0 575 141 150 175 250 175 250 2 4 0 6 AWG 350 6 AWG 350 103 238 715 3 1 200 402 400 500 700 500 700 2 1 500 2 3 0 250 3 2 0 400 295 656 1969 8 2 230 351 400 450 700 450 700 2 2 300 2 3 0 250 3 2 0 400 256 571 1712 7 8 0170EC 380 213 200 300 400 300 400 1 500 6 AWG 350 2 3 0 250 155 360 1081 4 8 460 176 200 225 350 225 350 2 300 6 AWG 350 6 AWG 350 128 285 856 4 0 575 141 150 175 250 175 2...

Page 48: ...00 380 2 3 0 250 400 200 729 800 1000 1200 1000 1200 3 1 500 1140 3 2 0 400 800 230 638 800 800 1000 800 1000 3 1 500 1140 3 2 0 400 800 0160EC 380 387 600 450 600 450 600 2 1 500 760 3 2 0 400 630 460 320 400 400 450 400 450 2 2 300 550 2 3 0 250 400 575 257 400 300 400 300 400 1 500 380 2 3 0 250 400 200 762 800 1000 1200 1000 1200 3 1 500 1140 3 2 0 400 800 230 667 800 800 1000 800 1000 3 1 500...

Page 49: ...60 250 128 285 856 4 0 250 128 285 856 4 0 575 250 103 238 715 3 1 250 103 238 715 3 1 200 630 321 656 1969 8 2 630 295 656 1969 8 2 230 630 279 571 1712 7 8 630 256 571 1712 7 8 0170EC 380 400 169 360 1081 4 8 400 155 360 1081 4 8 460 250 140 285 856 4 0 250 128 285 856 4 0 575 250 112 238 715 3 1 250 103 238 715 3 1 200 630 321 656 1969 8 2 630 321 656 1969 8 2 230 630 279 571 1712 7 8 630 279 5...

Page 50: ... 86 463 3 1 0140EC 460 293 400 350 450 2 2 300 400 2 3 0 250 116 579 4 0 116 579 4 0 575 234 250 300 350 1 500 250 6 AWG 350 93 463 2 3 1 93 463 3 1 0150EC 460 307 400 350 450 2 2 300 400 2 3 0 250 128 856 4 0 115 579 4 0 575 246 400 300 350 1 500 250 6 AWG 350 103 715 3 1 92 463 3 1 0160EC 460 320 400 400 450 2 2 300 400 2 3 0 250 128 856 4 0 128 856 4 0 575 257 400 300 400 1 500 400 2 3 0 250 10...

Page 51: ...5 400 2 3 0 250 140 856 4 0 128 856 4 0 575 268 400 2 3 0 250 112 715 3 1 103 715 3 1 0180EC 460 347 400 2 3 0 250 140 856 4 0 140 856 4 0 575 277 400 2 3 0 250 112 715 3 1 112 715 3 1 0200EC 460 375 630 3 2 0 400 149 856 4 0 149 856 4 0 575 299 400 2 3 0 250 119 715 3 1 119 715 3 1 0210EC 460 393 630 3 2 0 400 163 856 4 0 149 856 4 0 575 313 400 2 3 0 250 130 715 3 1 119 715 3 1 0230EC 460 407 63...

Page 52: ...W AND AMPERAGE VALUES FOR DXST COMPRESSORS COMPRESSOR MODEL AND VOLTAGE CODE DXS45LA MOTOR CODE A DXS36LA MOTOR CODE A DXS24LA MOTOR CODE TBD B5N B5E B6N B6E A5N A5E A6N A6E C5N C5E C6N C6E VOLTAGE CODE 17 28 40 46 50 58 17 28 40 46 50 58 17 28 40 46 50 58 MAX kW 150 150 150 150 113 150 150 150 150 150 113 150 105 105 105 105 80 105 MAX AMPS 492 428 259 214 193 171 492 428 259 214 193 171 338 294 ...

Page 53: ...ity and job requirements using N E C wire sizing information The above recommendations are based on the National Electric Code and using copper connectors only Field wiring must also comply with local codes 8 A ground lug is provided for each compressor system to accommodate field grounding conductor per N E C Article 250 54 A control circuit grounding lug is also supplied Incoming ground wire ran...

Page 54: ...ontact shown install a cycling device in series with the flow switch FSLW See Note 3 for contact rating and wir ing specifications Also refer to cautions on page 57 5 To stop unit Emergency Stop with contacts other than those shown install the stop contact between 5 and 1 If a stop device is not installed a jumper must be connected between terminals 5 and 1 Device must have a minimum contact ratin...

Page 55: ...55 YORK INTERNATIONAL FORM 201 18 NM1 102 WIRING DIAGRAM ACROSS THE LINE START FIG 17 WIRING DIAGRAM ACROSS THE LINE START LD03228 7 ...

Page 56: ...56 YORK INTERNATIONAL FORM 201 18 NM1 102 ELEMENTARY DIAGRAM Technical Data FIG 18 ELEMENTARY DIAGRAM ACROSS THE LINE START ...

Page 57: ...actor coil Any contacts connected to flow switch inputs or BAS in puts on terminals 13 19 or TB3 or any other terminals must be suppressed with a YORK P N 031 00808 000 sup pressor across the relay con tactor coil CAUTION Control wiring connected to the control panel should never be run in the same conduit with power wiring UNIT CONTROL MIN MAX DUAL NON FUSED VOLTAGE POWER CIRCUIT ELEMENT DISC SUP...

Page 58: ...58 YORK INTERNATIONAL FORM 201 18 NM1 102 FIG 19 POWER PANEL FRONT INSIDE VIEW ACROSS THE LINE START Technical Data PANEL COMPONENT LOCATIONS ...

Page 59: ...59 YORK INTERNATIONAL FORM 201 18 NM1 102 LD03280 FIG 20 ELECTRONIC PANEL FRONT INSIDE VIEW ACROSS THE LINE START PANEL COMPONENT LOCATIONS 7 ...

Page 60: ...t shown install a cycling device in series with the flow switch FSLW See Note 3 for contact rating and wiring specifications Also refer to cautions on page 63 5 To stop unit Emergency Stop with contacts other than those shown install the stop contact between 5 and 1 If a stop device is not installed a jumper must be connected between terminals 5 and 1 Device must have a minimum contact rating of 1...

Page 61: ...61 YORK INTERNATIONAL FORM 201 18 NM1 102 WIRING DIAGRAM WYE DELTA START FIG 21 CONT D LD03229 7 ...

Page 62: ...62 YORK INTERNATIONAL FORM 201 18 NM1 102 Technical Data Technical Data Technical Data FIG 22 ELEMENTARY DIAGRAM WYE DELTA START ELEMENTARY DIAGRAM ...

Page 63: ... relay contactor coil Any contacts connected to flow switch inputs or BAS in puts on terminals 13 19 or TB3 or any other terminals must be suppressed with a YORK P N 031 00808 000 sup pressor across the relay con tactor coil CAUTION Control wiring connected to the control panel should never be run in the same conduit with power wiring UNIT CONTROL MIN MAX DUAL NON FUSED VOLTAGE POWER CIRCUIT ELEME...

Page 64: ...64 YORK INTERNATIONAL FORM 201 18 NM1 102 Technical Data PANEL COMPONENT LOCATIONS FIG 23A POWER PANEL FRONT INSIDE VIEW WYE DELTA START ...

Page 65: ...65 YORK INTERNATIONAL FORM 201 18 NM1 102 FIG 23B ELECTRONIC PANEL FRONT INSIDE VIEW WYE DELTA START LD03280 PANEL COMPONENT LOCATIONS 7 ...

Page 66: ...66 YORK INTERNATIONAL FORM 201 18 NM1 102 LEGEND FIG 24 25 Technical Data LD03281 CONNECTION DIAGRAM ELECTRIC BOX DXST DIRECT DRIVE FIG 24 CONNECTION DIAGRAM ...

Page 67: ...67 YORK INTERNATIONAL FORM 201 18 NM1 102 LD03282 LD03283 LD03284 FIG 25 DETAIL A see pages 56 57 7 ...

Page 68: ...ORK INTERNATIONAL FORM 201 18 NM1 102 Technical Data CONNECTION DIAGRAM SYSTEM WIRING LD07413 LD03231 LD03232 FIG 26 CONNECTION DIAGRAM SYSTEM WIRING FIG 27 SENSOR CONNECTION FIG 28 COMPRESSORS SYSTEMS 1 2 ...

Page 69: ...69 YORK INTERNATIONAL FORM 201 18 NM1 102 COMPRESSOR TERMINAL BOX LD03233 FIG 29 COMPRESSOR TERMINAL BOXES 7 ...

Page 70: ...70 YORK INTERNATIONAL FORM 201 18 NM1 102 Technical Data FIG 30 DETAIL B LD03285 ...

Page 71: ...71 YORK INTERNATIONAL FORM 201 18 NM1 102 3 4 5 6 3 4 5 6 7 8 5 6 3 4 7 8 9 10 11 12 9 10 7 8 5 6 3 4 FIG 31 DETAIL C LD03286 7 ...

Page 72: ...ance reliable operation and ease of maintenance Site re strictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider po tential performance degradation Access to the unit Micro Panel assu...

Page 73: ...OWER OPENING FAR SIDE 8 WATER OUTLET 83 FOR 130 140 107 FOR 150 180 117 5 8 226 1 8 56 3 8 37 1 2 8 WATER INLET 2 2 1 4 DIA RIGGING HOLES EACH SIDE SIDE VIEW 96 LD02989 LD02990 CENTER OF GRAVITY Copper YCAS X Y Z 0130 103 5 44 4 40 7 0140 103 5 44 4 40 7 0150 108 2 43 0 39 2 0160 108 4 43 1 39 1 0170 108 4 43 1 39 1 0180 108 4 43 1 39 1 CENTER OF GRAVITY Alum YCAS X Y Z 0130 101 3 44 4 37 8 0140 1...

Page 74: ...inter operation or air recirculation ensures rated performance reliable operation and ease of maintenance Site re strictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider po tential p...

Page 75: ... 1033 8 0140 2628 9 1127 8 1033 8 0150 2748 3 1092 2 995 7 0160 2753 4 1094 7 993 1 0170 2753 4 1094 7 993 1 0180 2753 4 1094 7 993 1 CENTER OF GRAVITY Alum YCAS X Y Z 0130 2573 0 1127 8 960 1 0140 2573 0 1127 8 960 1 0150 2710 2 1087 1 919 5 0160 2717 8 1092 2 919 5 0170 2717 8 1092 2 919 5 0180 2717 8 1092 2 919 5 7 ...

Page 76: ...including snow for winter operation or air recirculation ensures rated performance reliable operation and ease of maintenance Site re strictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must c...

Page 77: ...99 LD03000 APPROX OPERATING WEIGHT DISTRIBUTION LBS CENTER OF GRAVITY Copper YCAS X Y Z 0200 122 3 43 3 41 0 0210 122 3 43 3 41 0 0230 122 3 43 3 41 0 CENTER OF GRAVITY Alum YCAS X Y Z 0200 119 4 43 2 38 0 0210 119 4 43 2 38 0 0230 119 4 43 2 38 0 7 ...

Page 78: ...1 LD03002 LD03003 NOTES 1 Placement on a level surface free of obstructions including snow for winter operation or air recirculation ensures rated performance reliable operation and ease of maintenance Site re strictions may compromise minimum clearances indicated below resulting in unpredictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation wit...

Page 79: ...APPROX OPERATING WEIGHT DISTRIBUTION KGS CENTER OF GRAVITY Copper YCAS X Y Z 200 3106 4 1099 8 1041 4 210 3106 4 1099 8 1041 4 230 3106 4 1099 8 1041 4 CENTER OF GRAVITY Alum YCAS X Y Z 200 3032 8 1097 3 965 2 210 3032 8 1097 3 965 2 230 3032 8 1097 3 965 2 7 ...

Page 80: ... 18 NM1 102 CLEARANCES Notes 1 No obstructions allowed above the unit 2 Only one adjacent wall may be higher than the unit 3 Adjacent units should be 10 feet 3 meters apart 1 3 m 2 m 2 m 2 m LD03484 FIG 36 CLEARANCES Technical Data ...

Page 81: ...0200 1 551 1 552 1 552 1 553 1 551 1 552 1 552 1 553 YCAS0210 1 551 1 552 1 552 1 553 1 551 1 552 1 552 1 553 YCAS0230 1 551 1 552 1 552 1 553 1 551 1 552 1 552 1 553 7 60 HERTZ WEIGHT DISTRIBUTION BY MODEL LBS 60 HZ A B C D E F G H TOTAL YCAS0130 1 956 1 633 1 309 986 1 908 1 593 1 277 962 11 625 YCAS0140 1 963 1 638 1 313 989 1 931 1 612 1 292 973 11 711 YCAS0150 1 868 1 648 1 428 1 208 1 958 1 ...

Page 82: ...1 YCAS0210 2 28 2 28 2 28 2 31 2 28 2 28 2 31 2 31 YCAS0230 2 28 2 28 2 28 2 31 2 28 2 28 2 31 2 31 ALUMINIUM OR BLACK FIN CONDENSER COILS 60 HERTZ NEOPRENE MOUNT SELECTION VMC TYPE RD 60 HZ A B C D E F G H YCAS0130 4 Red 4 Red 4 Blk 3 Gray 4 Red 4 Red 4 Blk 3 Gray YCAS0140 4 Red 4 Red 4 Blk 3 Gray 4 Red 4 Red 4 Blk 3 Gray YCAS0150 4 Red 4 Red 4 Blk 4 Blk 4 Red 4 Red 4 Blk 4 Blk YCAS0160 4 Red 4 R...

Page 83: ...52 YCAS0200 1 551 1 552 1 553 2 531 1 551 1 552 2 530 2 531 YCAS0210 1 551 1 552 1 553 2 531 1 551 1 552 2 530 2 531 YCAS0230 1 551 1 552 1 553 2 531 1 551 1 552 2 530 2 531 YCAS 60 HERTZ WEIGHT DISTRIBUTION BY MODEL LBS 60 HZ A B C D E F G H TOTAL YCAS0130 2 066 1 774 1 483 1 192 2 020 1 735 1 450 1 165 12 885 YCAS0140 2 072 1 779 1 487 1 194 2 043 1 754 1 465 1 177 12 971 YCAS0150 1 980 1 790 1 ...

Page 84: ...AS0200 2 28 2 31 2 31 2 32 2 28 2 31 2 31 2 32 YCAS0210 2 28 2 31 2 31 2 32 2 28 2 31 2 31 2 32 YCAS0230 2 28 2 31 2 31 2 32 2 28 2 31 2 31 2 32 60 HERTZ CU FINS NEOPRENE MOUNT SELECTION VMC TYPE RD 60 HZ A B C D E F G H YCAS0130 4 Red 4 Red 4 Blk 4 Blk 4 Red 4 Red 4 Red 4 Blk YCAS0140 4 Red 4 Red 4 Blk 4 Blk 4 Red 4 Red 4 Red 4 Blk YCAS0150 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red YCAS0160...

Page 85: ... 553 YCAS0200 1 551 1 553 2 531 2 532 1 551 1 553 2 531 2 532 YCAS0210 1 551 1 553 2 531 2 532 1 551 1 553 2 531 2 532 YCAS0230 1 551 1 553 2 531 2 532 1 551 1 553 2 531 2 532 7 60 HERTZ WEIGHT DISTRIBUTION BY MODEL LBS 60 HZ A B C D E F G H TOTAL YCAS0130 1 966 1 861 1 756 1 651 1 927 1 824 1 721 1 618 14 325 YCAS0140 1 974 1 867 1 759 1 652 1 949 1 843 1 737 1 631 14 411 YCAS0150 1 886 1 879 1 8...

Page 86: ...0210 2 28 2 31 2 32 2 35 2 28 2 31 2 32 2 35 YCAS0230 2 28 2 31 2 32 2 35 2 28 2 31 2 32 2 35 COPPER FIN CONDENSER COILS WITH SILENCER KITS 60 HERTZ CU R 22 FINS WITH SILENCER KIT NEOPRENE MOUNT SELECTION VMC TYPE RD 60 HZ A B C D E F G H YCAS0130 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red YCAS0140 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red YCAS0150 4 Red 4 Red 4 Red 4 Red 4 Red 4 Red 4 ...

Page 87: ...YPE SIZE MAX LOAD DEFL lbs kg in mm AWMR 1 53 1000 453 6 2 51 AWMR 1 530 1150 521 6 2 51 AWMR 1 531 1276 578 8 2 51 AWMR 1 532 1500 680 4 2 51 AWMR 1 551 1676 760 2 2 51 AWMR 1 552 1900 861 8 2 51 AWMR 1 553 2200 997 9 2 51 AWMR 2 531 2552 1157 6 2 51 AWMR 2 532 3000 1360 8 2 51 A B C D E F G H I J K L M N X AWMR 1 10 1 2 6 3 5 8 3 4 3 1 2 1 3 4 1 2 9 5 8 8 1 2 4 1 4 10 1 2 3 4 50 553 11NC 5 8 AWM...

Page 88: ...OPRENE MOUNTINGS TYPE RD 3 LD04033 Aluminum Fin and Black Fin Condenser Coils 29518A DEFLECTION COLOR MAX LOAD ins mm TYPE CODE lbs kg R RD R 3 BLACK 250 113 5 0 25 0 50 OR RED 525 238 3 6 3 12 7 RD 3 GREEN 750 340 5 GRAY 1100 499 4 R 4 BLACK 1500 681 0 0 25 0 50 OR RED 2250 1021 5 6 3 12 7 RD 4 GREEN 3000 1362 0 GRAY 4000 1816 0 TYPE L W H HD A B C D E R 3 5 1 2 3 3 8 1 3 4 2 7 8 2 1 2 1 2 4 1 8 ...

Page 89: ...e height of the isolator To use the isolator as blocking for the equipment insert a 1 4 shim between the upper load plate and vertical uprights Lower the equipment on the blocking or shimmed isolators 5 Complete piping and fill equipment with water re frigerant etc 6 Turn leveling bolt of first isolator four full revolu tions and proceed to each mount in turn 7 Continue turning leveling bolts unti...

Page 90: ...g through the cooler shell Low pressure vapor enters the compressor where pres sure and superheat are increased High pressure vapor is passed through the oil separator where compressor oil is removed and recirculated to the compressor via the oil cooler The high pressure oil free vapor is fed to the air cooled condenser coil and fans where the heat is removed The fully condensed liquid enters the ...

Page 91: ...91 YORK INTERNATIONAL FORM 201 18 NM1 102 PROCESS AND INSTRUMENTATION DIAGRAM LD03486 FIG 39 PROCESS AND INSTRUMENTATION DIAGRAM Added to some models 7 ...

Page 92: ...URE BSP SUCTION PRESSURE CCCV COMPRESSOR CAPACITY CONTROL VALVE ECH CRANK CASE HEATER EEH EVAPORATOR HEATER SHPI HIGH PRESSURE CUT OUT STS SUCTION TEMPERATURE SENSOR RFTS REFRIGERANT FEED TEMPERATURE SENSOR R407C only XCMTB COMPRESSOR MOTOR TERMINAL BOX YELSSV ECONOMIZER LIQUID SUPPLY SOLENOID VALVE ZCPR COMPRESSOR BCLT 1 RFTS 1 STS 2 BOT 3 CCCV 3 ECH 3 BDP 3 BDT 3 BOP 3 SHPI 3 XCMTB 3 ZCPR 3 BSP ...

Page 93: ...EADEDHOLE OIL HEATER ECONOMIZER GAS IN DISCHARGE CASE OILINLET FROMCONDENSER CODINGCOIL DISCHARGE GAS OUT OILFILTER BLEED EVACUATION POINT OILFILTER COVER PLATE CAPACITY CONTROL SOLENOID CAPACITY CONTROL 3 WAY VALVE IS LOCATED UNDER THE SOLENOID LIFTINGLUG THREADEDHOLE OILPRESSURE TRANSDUCER LOCATION ROTOR CASE STATOR LOCKING BOLT LD03668 ...

Page 94: ... 4 Pole Reliance Motor Stack Diameter Code A 10 1 8 Dia x 10 75 Stack B C etc TBA Economizer Utilization E Economized N Non economized Voltage and Frequency 17 200 3 60 28 230 3 60 40 380 3 60 46 460 3 60 50 380 415 3 50 58 575 3 60 COMPRESSOR WEIGHTS mm SIZE WEIGHT LBS Kg 145 1310 594 136 1250 567 124 1175 533 112 760 345 LESS SERVICE VALUES Compressor Isolator Pad Kit Reduces sound and vibration...

Page 95: ...95 YORK INTERNATIONAL FORM 201 18 NM1 102 COMPRESSOR COMPONENTS CONT D FIG 43 COMPRESSOR COMPONENTS LD03670 7 ...

Page 96: ...96 YORK INTERNATIONAL FORM 201 18 NM1 102 COMPRESSOR COMPONENTS CONT D FIG 44 COMPRESSOR COMPONENTS LD03671 Technical Data ...

Page 97: ...HRUST BEARING 22 BEARING CLAMP NUT 23 BEARING SPACER SLEEVE 24 BEARING PRELOAD SPRING 25 O RING 26 BEARING BORE PLUG 27 DISCHARGE COVER 28 BEARING BORE PLUG 29 BEARING PRELOAD SPRING 30 BEARING SPACER SLEEVE 31 BEARING CLAMP NUT 32 REVERSE THRUST BEARING 33 THRUST SPACER SHIM 34 THRUST BEARINGS 35 SPACER SHIM 36 DISCHARGE RADIAL BEARING 37 LIP SEAL 38 DOWEL PIN 39 SUPPORT RING 40 ECONOMIZER PLUG 4...

Page 98: ... 102 COMPRESSOR COMPONENTS CONT D FIG 46 COMPRESSOR COMPONENTS O RING MOTOR ROTOR MALE ROTOR LOCKING KEY MALE ROTOR FEMALE ROTOR O RING RELIEF VALVE ECONOMIZER PLUG SUPPORT RINGS LD03672 SLIDE VALVE RETURN SPRING SLIDE VALVE Technical Data ...

Page 99: ..._______________________ SOLD BY ________________________________ INSTALLING CONTRACTOR ___________________________ START UP TECHNICIAN COMPANY _______________________________ START UP DATE _________________________ CHILLER MODEL _______________________ SERIAL ________________________________ COMPRESSOR 1 MODEL ________________________________ SERIAL ________________________________ COMPRESSOR 2 MO...

Page 100: ...or Board is in the ON position Top 2 pins q 8 Set the Time and Date q 9 Program the Daily Schedule start and stop times Panel Checks Power ON Both System Switches OFF q 1 Apply 3 phase power and verify its value See Fig 8 and 9 pages 31 and 32 q 2 Apply 115VAC and verify its value on the ter minal block in the lower left of the Power Panel Make the measurement between terminals 5 and 2 See Fig 13 ...

Page 101: ...laced into operation q 1 Place the System Switches on the Micropro cessor Board to the ON position q 2 The compressor will start and a flow of refrig erant will be noted in the sight glass After sev eral minutes of operation the bubbles in the sight glass will disappear and there will be a solid column of liquid when the TXV stabilizes After the water temperature stabilizes at desired operating co...

Page 102: ...d the suction temperature suction pres sure suction pressure converted to temperature and superheat of each system below Normally the thermal expansion valve need not be ad justed in the field If however adjustment needs to be made the expansion valve adjusting screw should be turned not more than one turn at a time allowing suffi cient time approximately 15 minutes between adjust ments for the sy...

Page 103: ...d programmed data as well as fault history data from recent safety shutdowns ON OFF ROCKER SWITCH This switch shuts down the entire chiller when placed in the OFF position The switch must be ON for the chiller to operate PROGRAM SETUP KEYS Entry Keys see Section 5 The numeric and associated keys are used for entering data required for programming the chiller The ENTER and áâkeys are also used for ...

Page 104: ...refrigerant systems are provided on the Mi croprocessor Board s External interface is available for control of the chiller via a YORK ISN System or YORK Remote Micro Panel In addition EMS BAS System connections are provided for remote cycling current limiting remote tem perature setpoint reset and alarm annunciation YCAS chillers each have a single split circuit evapora tor serving 2 independent r...

Page 105: ...down period regardless of the time involved The battery is a 10 year lithium type but life will depend upon whether the Real Time Clock s internal clock cir cuit is energized With the clock OFF a rated life of approximately 10 years can be expected With the clock ON approximately 5 years The clock is enabled and disabled using a jumper on the microprocessor board If the chiller is shut down or pow...

Page 106: ...re spective System 1 for control system circuitry servicing Specifically the 115VAC feed to Re lay Output Board 1 which energizes contactors and solenoids CB2 allows removal of control power from re spective System 2 for control system circuitry servicing Specifically the 115VAC feed to Re lay Output Board 2 which energizes contactors and solenoids CB3 allows removal of control power to the Mi cro...

Page 107: ...tor dip switches These switches are set at the fac tory according to motor specifications The module also provides phase rotation protection to ensure the screw compressor does not rotate back wards A single phase protection circuit located in the module also monitors for a phase imbalance If current imbal ance exceeds 17 of the average motor current in one of the phases the Motor Protector will r...

Page 108: ...8 YORK INTERNATIONAL FORM 201 18 NM1 102 FIG 47 MOTOR PROTECTION MODULE SIDE VIEW 29119A 29121A TOP VIEW TOP VIEW SIDE VIEW 29121A 29120A DISPLAY SWITCH PUSHED TO LEFT INDICATES ON ON Micro Panel Contents ...

Page 109: ...of the control panel The duration of the contact clo sure will determine the amount of adjustment Gener ally this input is used for purposes of demand limit and operates as follows Closing the input contact for a defined period of time allows reset of the Current Limit downward Con tact closure of 1 11 seconds will allow Current Lim iting to be adjusted downward from 105 by a maxi mum of 75 i e to...

Page 110: ...et would equal Reset Temp 4 sec 1 sec X 40 F 10 sec Reset Temp 120 Fsec 10 sec 12 F 6 C To determine the new setpoint add the reset to the setpoint programmed into memory In the example above if the programmed setpoint 44 F 7 C the new setpoint after the 4 second contact closure would be 44 F 7 C 12 F 6 C 56 F 13 C This new setpoint can be viewed on the display by Pressing the Remote Reset Tempera...

Page 111: ...lock Enable Disable Jump Contact Real Time Clock and Battery Backup I C Microprocessor I C label shows version NOTE Dimple is positioned at top edge Dip Switch Set 8 switches System Switches S2 System 1 S3 System 2 S4 System 3 S5 System 4 1 11 MICROPROCESSOR BOARD LAYOUT FIG 48 COMPONENT LAYOUT 2 5 1 26001A 4 3 8 ...

Page 112: ...F 60 HZ MODEL LOGIC SECTION FIG 49 LOGIC SECTION LAYOUT ITEM 1 2 3 4 5 6 7 DESCRIPTION Microprocessor Board Back of Keypad I O Expansion Board 1 Power Supply Board Relay Output Board 1 Relay Output Board 2 Flow Switch Customer Connection Terminals TB4 00262VIP 1 2 5 6 4 3 7 Micro Panel Contents ...

Page 113: ...f the heater will turn on and stay on for 5 minutes After 5 minutes has elapsed the heater will shut off if the discharge temperature rises above 150 F 66 C and will turn on when the discharge tem perature is equal to or less than 150 F 66 C 1 17 EVAPORATOR HEATER CONTROL The evaporator heater is controlled by ambient tem perature When the ambient temperature drops below 40 F 4 C the heater is tur...

Page 114: ...ystem Run Status is not available 1 21 LEAD LAG COMPRESSOR SELECTION The chiller may be set up for AUTO or MANUAL Lead Lag This is accomplished by programming the option un dertheProgramKey DetailsforprogrammingtheManual Auto Lead Lag Selection are discussed in Program Key Section 8 page 146 When AUTO Lead Lag is utilized the micro attempts to balance run time between the two compressors A number ...

Page 115: ...essages These messages are described in detail below with ex amples of each display In each example is used as applicable to represent the system number where mes sages apply to individual systems 2 2 GENERAL STATUS MESSAGES Unit Switch OFF This message indicates that the Chiller ON OFF Switch on the Control Panel is in the OFF position which will not allow the chiller to run Schedule Shutdown Thi...

Page 116: ...System Loading Requirement This message indicates that chilled liquid temperature is below the point where the microprocessor will bring the lead system on and or that the loading sequence has not loaded the chiller far enough to bring the lag system on The lag system will display this message until the load ing sequence is ready for the lag system to start 2 3 UNIT WARNINGS Unit Warnings are ofte...

Page 117: ...on 3 5 Motor Current Key page 125 Remote Current Reset Section 1 10 page 109 Suction Temperature Limiting The Suction Temperature Limiting message applies only when the chiller is set for Water Cooling Mode see page 126 The message indicates that saturated suction tem perature on a system has dropped to 29 F 2 C and that any further temperature reduction could cause some icing of the evaporator tu...

Page 118: ...ecycle timers are satisfied and cooling demand requires addi tional cooling A reset hysteresis is built into each safety so repetitive faulting and clearing will not occur in a short time period Continuous monitoring by the microprocessor ensures that instantaneous reactions result When the chiller is shut down on one of these safeties a message will ap pear on the Status display informing the ope...

Page 119: ... less than 65 PSID 4 4 bar for R 22 models as long as the compressor continues to run the customer are connected in series with the flow switch es YCAS 2 System chillers have a single flow switch wired to the control panel If the flow switch opens all systems will shut down and a NO RUN PERM Permissive message will be displayed Closing of the flow switch when flow is present will cause the mes sag...

Page 120: ... by the High Oil Differential Safety since no flow will cause the differential through the oil piping to drop to zero EXAMPLE For ambients above 50 F 10 C the Low Oil Differ ential Safety is activated after 1 minute of compressor operation when the oil pressure differential must be greater than 10 PSID 7 bar After 2 minutes it must be greater than 20 PSID 1 4 bar after 3 minutes 30 PSID 2 bar afte...

Page 121: ... below 10 of the cutout initially programmed and must be greater than C O Programmed C O X Time 1 33 3 This transient cutout value increases with time until after 30 seconds it equals the programmed cutout value If the suction pressure falls below the value as calcu lated by the formula relative to time the system will shut down on a low suction pressure fault If the suc tion pressure rises above ...

Page 122: ...ith the corresponding auto matic printout This is not a cause for concern the MP contacts open Manual reset is accomplished by removing 115VAC control power from the micro panel after the motor sensors have sufficient time to cool Details relating to operation of the Motor Protec tion Module can be found on page 13 The Mechanical High Pressure Cutout protects against excessive refrigerant discharg...

Page 123: ...om monly required data about the operation of the chiller This is particularly useful during commissioning moni toring the operation of the chiller diagnosing potential future problems and service troubleshooting When a Display key is pressed the corresponding mes sage will be displayed and will remain on the display until another key is pressed Displayed data is in real time and is updated approx...

Page 124: ...splays are as follows where is the appropriate system number The Cooler Inlet Temp display will only appear if the chiller is selected for R 407C Temperatures and pressures are either measured directly by transducers and temperature sensors or computed from these measurements as follows Saturated discharge and suction temperatures are com puted by converting measured pressure to temperature Slide ...

Page 125: ... Low Chilled Liq uid Cutout can be programmed from 8 to 36 F 13 to 2 C and the Suction Pressure Cutout programmed from 20 to 70 PSIG 1 to 5 bar for R 22 models and 5 to 70 PSIG 0 3 to 5 bar for R 407C models 3 5 MOTOR CURRENT KEY Pressing the Motor Current key displays compressor current for each system This display shows the average motor current in amps and average compressor motor current as a ...

Page 126: ...ls us ing refrigerant R 407C Incorrect selection of this switch may cause serious damage to the chiller Closed The R 22 Mode MUST be selected for models using refrigerant type R 22 Incorrect selection of this switch may cause serious damage to the chiller S 1 2 A M B I E N T C O N T R O L S T A N D A R D S 1 2 A M B I E N T C O N T R O L L O W A M B I E N T S 1 3 R E F R I G E R A N T R 4 0 7 C S ...

Page 127: ...e 8 Spare Spare 3 8 FUNCTION KEY Pressing the Function key only displays the same mes sage as pressing the Status key Pressing the Function key followed by another display key will scroll through all the data available under that key once E g pressing the Function key followed by the System 1 Data key will result in scrolling through the 5 displays shown in Sec tion 3 3 without the need to press t...

Page 128: ...rinter is connected remotely as hard copy printouts The Operating Data Oper Data key provides a real time list of system operating data and programmed set tings The History key provides a comprehensive list of operating data and programmed settings at the in stant of fault on each of the last six faults local dis play or three faults remote printout which occurred on the chiller 4 2 OPER DATA KEY ...

Page 129: ...es per minute A minus sign indicates falling temperature No sign indicates rising temperature This message advises which system is programmed as the lead This message indicates the position of the optional aux iliary contacts for the evaporator water pump and the status of the evaporator heater For the evaporator pump contacts ON contacts closed OFF contacts open The Evaporator Heater status is co...

Page 130: ...SCHARGE PRESSURE 131 PSIG OIL PRESSURE 130 PSIG SUCTION TEMPERATURE 68 4 DEGF DISCHARGE TEMPERATURE 68 8 DEGF OIL TEMPERATURE 68 8 DEGF SAT SUCTION TEMP 71 8 DEGF SUCTION SUPERHEAT 3 4 DEGF SAT DISCHARGE TEMP 74 5 DEGF DISCHARGE SUPERHEAT 6 3 DEGF SLIDE VALVE STEP 0 COOLER INLET REFRIG 44 6 DEGF LIQUID LINE SOLENOID OFF ECONOMIZER TXV SOLENOID OFF CONDENSER FAN STAGE OFF COMPRESSOR HEATER ON WYE D...

Page 131: ...eached a further shutdown will cause the oldest set of data to be discarded in favor of storing the new shutdown data The Safety Shut downs are numbered from 1 to 6 with number 1 always being the most recent If a remote printer is not connected pressing the His tory key allows the operator to locally scroll through information relating to the stored safety shutdowns on the control panel display If...

Page 132: ...L A G C O N T R O L A U T O M A T I C L C H L T 4 4 1 F R C H L T 5 2 9 F M C H L T 4 3 8 F S E T P O I N T 4 4 0 F R A N G E 2 0 F This message displays the programmed chilled liquid setpoint and deviation control range programmed at the time of the fault This message indicates the outdoor Ambient Air Tem perature at the time of the fault This message indicates which system was in the lead at the...

Page 133: ...tart in Days D Hours H Minutes M and Seconds S This message indicates the compressor motor current in as a percentage of Full Load Amps This message shows the system differential oil pressure at the time of the fault This message indicates the system oil line temperature at the time of the fault These messages indicate compressor suction gas satu ration temperature and superheat at the time of the...

Page 134: ... 8 DEGF LEAD SYSTEM SYS 2 EVAPORATOR PUMP ON EVAPORATOR HEATER OFF ACTIVE REMOTE CONTROL NONE SOFTWARE VERSION C ACS 09 00 SYSTEM 1 DATA COMPRESSORS STATUS OFF RUN TIME 0 0 0 0 D H M S MOTOR CURRENT 0 AMPS 0 FLA SUCTION PRESSURE 125 PSIG DISCHARGE PRESSURE 131 PSIG OIL PRESSURE 130 PSIG SUCTION TEMPERATURE 68 4 DEGF DISCHARGE TEMPERATURE 68 8 DEGF OIL TEMPERATURE 68 8 DEGF SAT SUCTION TEMP 71 8 DE...

Page 135: ...ned The Enter key is also used to scroll through available data when using the Program or Set Schedule Holiday keys 5 4 CANCEL KEY When the Cancel key is pressed the cursor will always return to the first character to be programmed in the display message This allows the operator to begin re programming if an error is made When the Cancel key is pressed the values already keyed in will be erased an...

Page 136: ...ain this temperature within a programmed range The capacity is controlled by switching compressors on or off and by varying a load unload current to each com pressor slide valve to adjust the capacity of the com pressors The microprocessor controls chilled liquid temperature through a combination of Fuzzy Logic con trol and internal timers Fuzzy logic enables the micro to analyze the deviation fro...

Page 137: ...e position S V STEP under the keypad system keys of 75 indicates that the compressor is fully loaded However due to the non exact movement of the mechanism a position less than 75 possibly 60 could also mean that the compressor is fully loaded Keep this potential indicator error in mind when attempting to de termine slide valve position versus actual compressor capacity Compressor Starting Loading...

Page 138: ...ircumstances the two systems will not appear to equalize loading Compressor Unloading and Shutdown Sequence Whenever temperature is below the Setpoint unload ing pulses will be sent to open the unloading port on the control solenoid to relieve oil pressure on the slide valve on the compressor with the highest slide valve step Opening of the unloading port on the control so lenoid allows spring pre...

Page 139: ...llows reset of the setpoint upward by up to 40 F 22 C above the setpoint pro grammed in memory see Section 1 7 The maximum allowable reset must be programmed into memory and can be a value of 2 to 40 F 1 to 22 C depending on user requirements To program the reset press the Remote Reset Temperature Range key The following message will appear The display indicates the Remote Setpoint which is al way...

Page 140: ...which the cursor will disappear and the live clock will be displayed 7 CLOCK KEYS O U T O F R A N G E T R Y A G A I N 7 1 GENERAL The microprocessor features a continuously running in ternal Clock and calendar and can display actual time as well as the day of the week and the date An auto matic schedule feature is provided for starting and stop ping the chiller on individual days of the week elimi...

Page 141: ...he displays for each day are scrolled through by re petitively pressing the áorâ key To reprogram any of the daily schedules key in the new Start time then if necessary change the associated AM PM by pressing the áorâ key The á or â key can only be pressed once to change AM PM If an error is made press Cancel and begin again Next key in the Stop Time the cursor will automati cally skip from AM PM ...

Page 142: ...period This key avoids the need to reprogram the Daily Schedule Once activated Manual Override is only active for a period of 30 minutes and the follow ing status message will be observed M A N U A L O V E R R I D E If a Warning Low Battery fault mes sage appears on the display the inter nal clock calendar and program set tings cannot be relied on for accuracy Default values are loaded into the mi...

Page 143: ...m will shut down D I S C H A R G E P R E S S U R E C U T O U T 3 9 5 0 P S I G 8 PROGRAM KEY 8 1 GENERAL The Program key is used to program 12 system operat ing parameters including cutout points for safeties an ticipatory unload points to avoid faults and anti recycle timer duration When the Program key is pressed the following mes sage will be displayed to indicate the display is in the Program ...

Page 144: ...gerant suction pressure After the compressor starts and the pump down cycle is completed pump down to cutout or 30 seconds whichever comes first suction pressure is monitored as long as the compressor runs For the first 270 sec onds of running suction pressure can be lower than the programmed cutout but must be greater than This cutout value increases with time until after 270 seconds it equals th...

Page 145: ... 18 F 10 C below the lowest temperature of the programmed chilled liquid Control Range Section 6 This programmable value is password protected To program the Suction Pressure Cutout key in the re quired setting and press the Enter key to store the value into memory and scroll the next display High Ambient Temperature Cutout The High Ambient Cutout is used to select the ambient temperature above wh...

Page 146: ...t exceeds 115 If the programmable limit is set between 100 and 105 of full load current this safety will protect against excessive current causing compressor shutdown due to extremely high ambient high chilled liquid tempera ture and condenser malfunction caused by dirt or fan problems If the programmable limit is set below 100 of full load current this feature can be used for demand lim iting Thi...

Page 147: ...RAM key followed by the ENTER key to program the refrigerant type Press the Program key again key in the numbers 6140 then press Enter As P R O G R A M M O D E D E F A U L T S E T P O I N T S 1 Y E S 0 N O 1 P R O G R A M O P T I O N S S E T T O D E F A U L T V A L U E S If manual control is desired press the á or â key One of the following messages will be displayed System 1 2 3 or 4 can be selec...

Page 148: ...at the highest fan stage reached unless the OFF conditions outlined in the next paragraph are satisfied Condenser fan OFF conditions are governed by both the DP and OAT Fan staging will be decreased from the high est fan stage reached if both the DP and OAT require ments are met For example if a system is at fan stage 4 and the DP falls below 195 PSIG and the OAT drops be low 75 F the fan stage wi...

Page 149: ...3 5 235 PSIG 165 PSIG 65 F 10M 11M 131 14 Y 3 7 9 250 PSIG 180 PSIG 70 F 12M 13M 132 10 S 4 1 7 9 265 PSIG 195 PSIG 75 F 9M 12M 13M 130 132 10 15 5 3 5 7 9 280 PSIG 210 PSIG 80 F 10M 11M 12M 13M 131 132 10 14 1 6 1 3 5 7 9 290 PSIG 220 PSIG 85 F 9M 10M 11M 12M 13M 130 131 132 10 14 15 1 2 220 PSIG 150 PSIG 60 F 15M 230 15 S 2 4 6 235 PSIG 165 PSIG 65 F 16M 17M 231 14 Y 3 8 10 250 PSIG 180 PSIG 70 ...

Page 150: ...M 17M 18M 231 232 10 14 2 6 2 4 6 8 275 PSIG 205 PSIG 85 F 15M 16M 17M 18M 230 231 232 10 14 15 TABLE 7 CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS WITH 5 FANS SYSTEM EPROM VERSION C A17 09 02 5320 Sys 1 Outputs are on Relay Board 1 Sys 2 Outputs are on Relay Output Board 2 Fan ON OFF Fan Wire Relay Stage Fans Conditions Conditions Contactor Number Board DP DP OAT Output 1 1 205 PS...

Page 151: ...ONTINUE CONTINUE CONTINUE CONTINUE CONTINUE CONTINUE CONTINUE DP 285 FANS OFF FAN LOAD UNLOAD TIMER 15 MIN FAN CONTROL TIMER 5 SEC TURN ON NEXT FAN STAGE FAN CONTROL TIMER 5 SEC FAN CONTROL TIMER 5 SEC TURN ON NEXT FAN STAGE TURN OFF NEXT FAN STAGE TURN OFF NEXT FAN STAGE FAN LOAD UNLOAD TIMER 15 MIN FAN CONTROL TIMER 5 SEC FAN LOAD UNLOAD TIMER 15 MIN FAN CONTROL TIMER 5 SEC DP 120 OR OIL SUCT DI...

Page 152: ...Turn off Fan Stage every 15 min 120 PSIG Turn off a Fan Stage every 5 sec 0 PSIG Note A Low Oil Suction Differential Pressure less than 75 PSID will cause the micro to turn a fan stage Off every 5 sec This will override pressure control of the fans TABLE 8 CONDENSER FAN CONTROL EPROM VERSIONS C A32 09 02 0483 C ACS 09 02 D87E AND C A06 09 03 EIOC Micro Panel Contents ...

Page 153: ... 180 PSIG 75 F 9M 11M 12M 130 132 10 15 5 3 5 7 265 PSIG 195 PSIG 80 F 10M 11M 12M 131 132 10 14 1 6 1 3 5 7 275 PSIG 205 PSIG 85 F 9M 10M 11M 12M 130 131 132 10 14 15 1 2 205 PSIG 135 PSIG 60 F 15M 230 15 S 2 4 220 PSIG 150 PSIG 65 F 16M 231 14 Y 3 6 8 235 PSIG 165 PSIG 70 F 17M 18M 232 10 S 4 2 6 8 250 PSIG 180 PSIG 75 F 15M 17M 18M 230 232 10 15 5 4 6 8 265 PSIG 190 PSIG 80 F 16M 17M 18M 231 23...

Page 154: ...1M 12M 132 10 S 4 1 5 7 265 PSIG 195 PSIG 75 F 9M 11M 12M 130 132 10 15 5 3 5 7 275 PSIG 200 PSIG 80 F 10M 11M 12M 131 132 10 14 1 6 1 3 5 7 285 PSIG 205 PSIG 85 F 9M 10M 11M 12M 130 131 132 10 14 15 1 2 205 PSIG 135 PSIG 60 F 15M 230 15 S 2 4 230 PSIG 160 PSIG 65 F 16M 231 14 Y 3 6 8 250 PSIG 180 PSIG 70 F 17M 18M 232 10 S 4 2 6 8 265 PSIG 195 PSIG 75 F 15M 17M 18M 230 232 10 15 5 4 6 8 275 PSIG ...

Page 155: ...ing section for courses of action Refrigerant Leaks Visually check the heat exchang ers compressors and pipework for damage and gas leaks Airflow obstructions Check the air cooled condenser coil intakes and adjacent areas are clear of foreign ma terials or obstructions e g paper leaves etc Operating conditions Read the operating pressures and temperatures at the control panel using the display key...

Page 156: ...ure Suction Temperature Suction Superheat Discharge Pressure Actual Discharge Temperature Oil Pressure Oil Temperature FLA Motor Oil Level example Oil Added gallons or liters Inlet Temperature Outlet Temperature Pressure Drop Flow Rate GPM or l s Air On Temperature Air Off Temperature Inlet Temperature Outlet Temperature Pressure Drop Flow Rate GPM or l s Leaving Liquid Refrigerant Temperature Rem...

Page 157: ...ling 1 X Check compressor and cooler heaters for operation X Sample compressor oil and replace oil if necessary 1 X Leak check the chiller 1 X Disconnect power source and lock out Check tightness of power wiring connections 1 X MAINTENANCE REQUIREMENTS FOR YORK YCAS SCREW CHILLERS Reserved for customer use for any special site determined requirements 1 This procedure must be performed at the speci...

Page 158: ...n of oil Cooler Check water flow Check water pH glycol strength Check water pressure drop Check heater mats Air cooled condensers Check for airflow obstructions Brush fins Clean with mild low pH cleaner Check fins Check fan motor bearings Check fans and fan guards Power Control system general Check panel condition Check all connections Check mains and control wiring Check compressor contactors Che...

Page 159: ...arts required All requests for parts should be made to your local YORK Sales and Service Center Recommended Compressor Oils The correct type of oil must be used in the unit as shown on the unit data plate and labels Standard units use the following oils Associated Drawings Models R 22 General Arrangement Wiring Diagrams Schematic Connection 201 18 NM5 Customer wiring Legend REFRIGERANT COMPRESSOR ...

Page 160: ...MP displayed than the programmed operating temperature and confirm that the displayed value is limit approximately correct The warning message should clear when the ambient air temperature rises above the programmed operating limit Check the programmed settings are correct for the options fitted to the unit Measured temperature is incorrect Check sensor calibration location and wiring Chiller FAUL...

Page 161: ...ion DIFF is displayed High oil differential pressure Dirty blocked oil filter Check and change oil filter cartridge SYS LOW SUCTION Badly adjusted or faulty expansion Check superheat displayed valve Reduced evaporator performance Check for restricted chilled liquid flow Check for fouled tube surfaces Check superheat Low refrigerant charge Check subcooling is correct Check for leaks Restricted refr...

Page 162: ...emperature Sensors Temperature Resistance Voltage F C ohms VDC 32 0 163250 0 282 50 10 99500 0 447 68 20 62450 0 676 86 30 40285 0 976 104 40 26635 1 34 122 50 18015 1 76 140 60 12440 2 20 158 70 8760 2 63 176 80 6290 3 04 194 90 4588 3 40 212 100 3400 3 71 230 110 2556 3 96 248 120 1946 4 17 266 130 1504 4 33 284 140 1174 4 46 302 150 926 4 57 Chilled Leaving Water Temperature CLT and Chilled Ret...

Page 163: ... specifically agreed to in the con tract documents this warranty does not include the fol lowing costs and expenses 1 Labor to remove or reinstall any equipment mate rials or components 2 Shipping handling or transportation charges 3 Cost of refrigerant No warranty repairs or replacements will be made until payment for all equipment materials or components has been received by YORK ALL WARRANTIES ...

Page 164: ...2 4 196 91 1 80 176 200 93 3 82 179 6 204 95 6 84 183 2 208 97 8 86 186 8 212 100 0 88 190 4 216 102 2 90 194 220 104 4 92 197 6 224 106 7 94 201 2 228 108 9 96 204 8 232 111 1 98 208 4 236 113 3 100 212 240 115 6 102 215 6 244 117 8 104 219 2 F C C F 0 0 0 0 4 2 2 2 3 6 8 4 4 4 7 2 12 6 7 6 10 8 16 8 9 8 14 4 20 11 1 10 18 24 13 3 12 21 6 28 15 6 14 25 2 32 17 8 16 28 8 36 20 18 32 4 40 22 2 20 3...

Page 165: ...ernational Corp 732 225 0606 NEVADA Las Vegas York International Corp 702 873 2200 NEW YORK Rochester York International Corp 716 426 0260 New York York International Corp 212 843 1602 NORTH CAROLINA Charlotte York International Corp 704 598 0000 Greensboro York International Corp 336 299 9675 Raleigh York International Corp 919 431 9675 OHIO Cincinnati York International Corp 513 489 8871 Clevela...

Page 166: ...166 YORK INTERNATIONAL FORM 201 18 NM1 102 ...

Page 167: ...167 YORK INTERNATIONAL FORM 201 18 NM1 102 ...

Page 168: ...com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 2002 ALL RIGHTS RESERVED Form 201 18 NM1 102 Supersedes 201 18 NM1 1298 201 18 NM1 1098 ...

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