York eco2 YCAS0425EB Installation Operation & Maintenance Download

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INSTALLATION, OPERATION, MAINTENANCE

eco

AIR-COOLED SCREW LIQUID CHILLERS

New Release

Form 201.18-NM8 (701)

YCAS AIR-COOLED SCREW LIQUID CHILLER

YCAS0425EB – YCAS0605EB

YCAS 2-SYSTEM With EPROM

(Standard, Brine & Metric Models Combined)

031-01798-001

28971AR

Better ecology,

Better economy.

50 Hz

Summary of Contents for eco2 YCAS0425EB

Page 1: ...IR COOLED SCREW LIQUID CHILLERS New Release Form 201 18 NM8 701 YCAS AIR COOLED SCREW LIQUID CHILLER YCAS0425EB YCAS0605EB YCAS 2 SYSTEM With EPROM Standard Brine Metric Models Combined 031 01798 001 28971AR Better ecology Better economy 50 Hz ...

Page 2: ...enclature Nameplate Engineering Data 24 SECTION 3 HANDLING AND STORAGE Delivery and Storage 27 Inspection 27 Moving the Chiller 27 SECTION 4 INSTALLATION Location Requirements 29 Outdoor Installations 29 Indoor Installations 29 Location Clearances 29 Installation of Vibration Isolators 30 Shipping Braces 30 Pipework Connection 30 Water Treatment 31 Pipework Arrangement 31 Connection Types Sizes 32...

Page 3: ...tion 57 Optional Single Point Power Supply Connection to Factory Circuit Breaker 57 Wiring Diagrams 58 Dimensions 76 YCAS0425EB YCAS0575EB 76 YCAS0605EB 78 Operating Weights Aluminum Black Fin Coils 80 Isolator Selection Aluminum Black Fin Coils 80 Operating Weights Copper Fin Coils Perimeter Sound Enclosure 81 Installation Instructions for VMC Series AWR AWMR and CP Restrained Mountings 82 Isolat...

Page 4: ...nt Temp Key 120 3 5 Motor Current Key 121 3 6 Operating Hours Start Counter Key 121 3 7 Options Key Dip Switch Settings 121 3 8 Function Key 123 4 PRINT KEYS 124 4 1 General 124 4 2 Oper Data Key 124 4 3 Operating Data Local Display Messages 124 4 4 Operating Data Remote Printout 125 4 5 History Key 127 4 6 Fault History Data Local Display Messages 127 4 7 Fault History Data Remote Printout 130 5 ...

Page 5: ... FIG 20 Elementary Diagram Across The Line Start 58 FIG 21 Power Panel Front Inside View Across The Line Start 62 FIG 22 Electronic Panel Front Inside View Across The Line Start 63 FIG 23 Elementary Diagram Wye Delta Start 64 FIG 24 Power Panel Front Inside View Wye Delta Start 68 FIG 25 Electronic Panel Front Inside View Wye Delta Start 69 FIG 26 Connection Diagram 70 FIG 27 Detail A 71 FIG 28 Co...

Page 6: ...This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard CAUTION identifies a hazard which could lead to damage to the machine damage to other equipment and or en vironmental pollution Usually an ...

Page 7: ...pplicability of these documents to the equip ment in question If there is any question in the mind of operating service personnel as to the applicability of these documents then prior to working on the equipment they should verify with the owner whether the equipment has been modified and if current litera ture is available NOMENCLATURE YC A S 0425 S B 50 Y F The Model Number denotes the following...

Page 8: ...evidence that the failure has occurred within the warranty period and that the unit has been operated within design parameters All warranty claims must specify the unit model se rial number order number and run hours starts These details 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 approval from YOR...

Page 9: ...glycol solu tions and 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 ...

Page 10: ...of gloves and safety glasses are 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 For more comprehensive information on safety precautions for use of refrigerants and oils refer to the Materials Safety Data tables provided on pages...

Page 11: ...upational Recommended limit 1000 ppm v v 8 hr TWA exposure limits Stability Not specified Conditions to avoid Use in presence of naked flames red hot surfaces and high moisture levels Hazardous reactions May react violently with sodium potassium barium and other alkali and alkaline earth metals Incompatible materials Magnesium and alloys containing more then 2 magnesium Hazardous Halogen acids by ...

Page 12: ...rning may evolve irritating noxious fumes Respiratory protection Use in well ventilated areas ventilate locally Protective clothing Goggles or face shield should be worn Gloves not necessary but recommended especially for prolonged exposure Spill Leak procedure Wear suitable protective equipment Especially goggles Stop source of spill Use absorbent materials to soak up fluid i e sand sawdust and c...

Page 13: ...pic Storage under nitrogen highly recommended Section 4 PHYSICAL DATA Appearance Clear liquid gray to yellow or light brown tint Boiling Point 650ºF Vapor Pressure 0 01 mmHg 20ºC Specific Gravity water 1 0 94 0 97 Volatiles Percent by Volume 0 Odor Mild distinct Solubility in Water Negligible Evaporation Rate butyl acetate 1 Nil Section 5 FIRE AND EXPLOSION HAZARDS Flash Point by Cleveland Open Cu...

Page 14: ...well ventilated area Ventilation Local exhaust Protective Gloves Strongly recommended especially for prolonged exposure Eye Face Protection Goggles Firefighters should use NIOSH MNSA approved self contained breathing apparatus Use water fog to cool fire exposed containers USE WATER CAREFULLY NEAR EXPOSED BURNING LIQUIDS May cause froth ing and splashing of hot material Section 9 SPILL OR LEAK PROC...

Page 15: ... subjected to ASTM B117 500 hour 5 salt spray conditions shows breakdown of less than 3 mm 1 8 either side of a scribed line equivalent to ASTM D1654 rating of 6 All exposed power wiring is be routed through 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 sim...

Page 16: ...sur ized oil is then cooled in the condenser coils and piped back to the compressor for lubrication The compres sor design working pressure is 31 bar 450 PSIG Each chiller receives a 21 bar 300 PSIG low side and a 31 bar 450 PSIG high side factory test A 350 watt 115 1 50 cartridge heater is located in the compres sor The heater is temperature activated to prevent re frigerant condensation The fol...

Page 17: ...of at least 2 0 bar 30 PSID exists between discharge and 1 2x suction to force oil into rotor case a minimum of 0 6 bar 10 PSID is all that is required to assure pro tection of the compressor Oil pressure is measured as the difference between suction pressure and the pres sure of the oil entering the rotor case Maximum working pressure of the oil separator is 31 bar 450 PSIG A relief valve is inst...

Page 18: ...nd routed to the I O Expan sion board to be multiplexed and sent to the Micro processor Board If the motor current exceeds the 115 FLA trip point after 3 seconds of operation on either Wye Delta or ACL starters the micro will shut the system down and lock it out after one fault A manual reset of the respective system switch is re quired to clear the fault and restart the system A thorough check of...

Page 19: ...d A list of the codes is shown below Normal motor off display Sequentially HAXXX sweeps through the motor protector dip switch setting 0 Normal no fault detected Running Flashing 0 Motor off or unloaded 5A AC current level Running 1 High current fault 2 Loaded phase to phase current imbalance 17 3 Unloaded phase to phase current imbalance 25 4 Improper incoming phase rotation 5 High motor temperat...

Page 20: ...is miswired Upon detec tion of a miswired motor load the module will de energize the main contactor pilot circuit within 50 mil lisecond response time TABLE 1 MOTOR PROTECTOR DIP SWITCH SETTING Indicates one lead phase through motor protector YCAS STYLE F ACROSS THE LINE 50 HZ MODEL VOLT CHILLER NO MOTOR PROTECTOR NO CODE NAMEPLATE LEADS RLA PER MP OL PHASE VALUE DIP SWITCH SETTINGS ON MP 1 INDICA...

Page 21: ...S 2 transition delay relay is enabled by the microprocessor from Relay Output Board 1 Terminal 8 SYS 1 or Relay Output Board 2 Terminal 6 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 remain energizes through interlocking contacts 1M SYS 1 or 3M SYS 2 Open ing of the 1TR SYS 1 or 2TR SYS 2 contacts deenergizes1S 2Sandclosesthenormallyclosed1...

Page 22: ...provided pro tection is connected to a factory provided circuit breaker with lockable external handle located in the options compartment Factory wiring is provided from the cir cuit breaker to factory supplied terminal blocks in the power compartments Single Point Power Connection without Circuit Protection A single point supply circuit with field provided pro tection is connected to a factory pro...

Page 23: ...oximately 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 mounted Louvered panels and wired guards Louvered pan els mounted over the exterior condenser coil faces and heavy gauge welded wire mesh guards mounted around the bottom of the unit Factory or ...

Page 24: ... High Efficiency 200 3 60 230 3 60 380 3 60 460 3 60 575 3 60 Wye Star Delta Across the Line Design Series F Engineering Change or PIN Level BASIC PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE STARTER DESIGN DEVELOPMENT LEVEL Y E C 1 7 F C 2 8 A A 4 0 S 4 6 5 8 Y X R407C Product Description ...

Page 25: ...X M L S D S B B X F X C G X X X X L X C X X B P C R D S E F G H 300 PSIG DWP Waterside Double Thick Insulation Weld Flange Kit Victaulic Flange Kit Flow Switch Multinat l Vessel Assoc Safety Codes ASME Pressure Vessel Associated Codes American AS 1210 Vessel Associated Codes Australian French Vessel Associated Codes DRIRE German TUV Vessel Associated Codes A D Merkblatter Italian Vessel Associated...

Page 26: ...26 YORK INTERNATIONAL This page intentionally left blank Product Description ...

Page 27: ...ded 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 advice note Major damage must be reporte...

Page 28: ...28 YORK INTERNATIONAL UNIT RIGGING 88 2250mm LD03514 FIG 3 UNIT RIGGING CORRECT WRONG LD03515 FIG 4 LIFTING LUGS CORRECT WRONG Handling Storage ...

Page 29: ...ust be at least 120 mm 4 3 4 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 the fans installed in the unit INDOOR INSTALLATIONS The unit can be installed in an enclosed plant room pro viding the floor is level and...

Page 30: ...for the cooler must not be ex ceeded at any time Refer to the Tech nical Data Section for details The liquid must enter the cooler by the inlet connection The inlet connection for the cooler is at the far end of the unit when viewed from the power and control panels A flow switch must be installed in the customer pipework at the outlet of the cooler and wired back to the control panel using shield...

Page 31: ...ontrol system power supply During risk of freezing the control sys tem should be left switched on to provide the freeze protection function unless the liquid systems have been drained Any debris left in the water pipework between the strainer and cooler could cause serious damage to the tubes in the cooler and must be avoided The installer user must also ensure that the quality of the water in cir...

Page 32: ...se speci fied by local regulations table internal diameter depends on the length of pipe required and is given by the fol lowing formula D5 1 447 x L Where D minimum pipe internal diameter L length of pipe in meters If relief pipework is common to more than one valve its cross sectional area must be at least the total required by each valve Valve types should not be mixed on a common pipe Precauti...

Page 33: ...sure 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 WIRING Standard units require two 3 phase separately fused 3 wire supplies plus a ground per refrigerant system One...

Page 34: ...to indicate that a system is running Alarm Contacts Each system has a voltage free change over contact which will operate to signal an alarm condition when ever a system locks out or there is a power failure To obtain system alarm signal connect the alarm circuit to volt free terminals 23 and 24 for No 1 System and to terminals 27 and 28 for No 2 System SYSTEM INPUTS Flow Switch A chilled liquid f...

Page 35: ...35 YORK INTERNATIONAL FORM 201 18 NM8 FIG 8 PANEL LAYOUTS 4 POWER AND CONTROL PANEL LAYOUTS WYE DELTA TYPICAL 00263VIP ...

Page 36: ...36 YORK INTERNATIONAL FIG 9 OPTION PANEL SECTION OPTION PANEL LAYOUT TYPICAL 00246VIP Installation ...

Page 37: ...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 38: ...38 YORK INTERNATIONAL FIG 11 LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT 00248VIP Installation ...

Page 39: ...R 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 40: ...tion FIG 13 CUSTOMER CONNECTIONS CUSTOMER CONNECTIONS TRANSFORMERS POWER SUPPLY BOARD RELAY BOARDS I O EXPANSION BOARD CUSTOMER CONNECTIONS Flow Switch Alarm Run etc MICROPROCESSOR CIRCUIT BOARD 28965A 115VAC SUPPLY CIRCUIT BREAKERS ...

Page 41: ...at the fan overloads settings are correct for the type of fan fitted Supply Voltage Verify that the site voltage supply corresponds to the unit requirement and is within the limits given in the Technical Data Section COMMISSIONING PREPARATION Commissioning of this unit should only be carried out by YORK Autho rized personnel The eco2 Microcomputer Control System Operat ing Instructions must be rea...

Page 42: ...tion outside of these limits is undesirable and could cause damage Flow Switch Verify a chilled water flow switch is correctly fitted in the customer s pipework 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 Temperature Sensor s Ensure the leaving liquid temperature ...

Page 43: ...and be replaced by a solid column of liquid Fan Rotation As discharge pressure rises the condenser fans operate 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 150 mm 6 before the compressor suction ser vice valve Measure...

Page 44: ...erations 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 lead compres...

Page 45: ...th an electrical heater as standard MODEL LEAVING WATER COOLER FLOW AIR ON NUMBER TEMPERATURE C L S 3 CONDENSER C YCAS MIN 1 MAX 2 MIN MAX MIN MAX 0425 5 0 13 0 9 5 37 9 17 7 50 0475 5 0 13 0 10 6 42 3 17 7 50 0515 5 0 13 0 11 7 46 9 17 7 50 0555 5 0 13 0 12 4 48 5 17 7 50 0575 5 0 13 0 13 1 48 5 17 7 50 0605 5 0 13 0 13 6 48 5 17 7 50 WATER PRESSURE DROP 7 PRESSURE DROP kPa 1000 100 10 1 1 10 WAT...

Page 46: ...r 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 Factor B Mean Temperature through Cooler C Concentrat...

Page 47: ...5 CHILLED WATER TEMP DIFFERENCE ºC 3 10 WATER SIDE PRESSURE BAR 10 REFRIGERANT SIDE PRESSURE BAR 20 COOLER FLOW MODEL LITERS SECOND YCAS MIN MAX 0425EB 9 38 0475EB 11 38 0515EB 12 47 0555EB 12 47 0575EB 13 47 0605EB 14 47 AIR STANDARD FANS 18 46 ENTERING HIGH PRESS FANS 18 46 CONDENSER ºC SLOW SPEED FANS 18 46 FAN STANDARD FANS 20 AVAILABLE STATIC HIGH PRESS FANS OPTION 1 85 PRESSURE Pa HIGH PRESS...

Page 48: ... Fans Number Ckt 1 Ckt 2 4 4 4 4 4 4 4 4 4 4 5 5 Standard Fans Fan Motor HP kW 2 1 6 2 1 6 2 1 6 2 1 6 2 1 6 2 1 6 Fan Motor Speed revs sec 15 8 15 8 15 8 15 8 15 8 15 8 Fan Diameter mm 900 900 900 900 900 900 Fan Tip Speed m sec 45 45 45 45 45 45 Total Chiller Airflow l sec 50 213 50 213 50 213 50 213 50 213 62 767 Low Noise Fans Fan Motor HP kW 2 1 7 2 1 7 2 1 7 2 1 7 2 1 7 2 1 7 Fan Motor Speed...

Page 49: ...49 YORK INTERNATIONAL FORM 201 18 NM8 This page intentionally left blank 7 ...

Page 50: ...2 COMPRESSOR UNITS SEE FIG 16 Each of Two Field Provided Power Supply Circuits individually protected with Branch Circuit Protection Field Connections to Factory provided Terminal Block Std Disconnects Opt or Individual System Circuit Breakers Opt in each of the two Motor Control Centers Optional Circuit Breakers are REQUIRED for units with CE mark See page 55 for Electrical Data Notes Model Volts...

Page 51: ... 173 0 267 0 857 0 5 4 8 23 0 173 0 267 0 857 0 5 4 8 23 0 Model Volts MRA1 Min NF Protection13 Factory Provided Lugs Wire Range7 Compressor Fans11 12 YCAS MCA Disc Sw 2 9 Min 3 5 Max 4 6 Standard Terminal Optional NF Optional RLA Y LRA X LRA Qty FLA LRA Block Disc Switch Circuit Breaker Ea Ea Overcurrent ELECTRICAL SYSTEM 2 FIELD SUPPLIED WIRING 0425EB 380 152 150 200 250 2 300 6 350 6 350 106 21...

Page 52: ... 400 0605EB 481 600 500 600 2 1 500 3 2 0 400 OPTIONAL SINGLE POINT POWER SUPPLY CONNECTION TO FACTORY CIRCUIT BREAKER 2 COMPRESSOR UNITS SEE FIG 19 One Field Provided Power Supply Circuit to the chiller Field connection to Circuit Breaker in Option Panel No internal System Circuit Breaker Protection per Motor Control Center10 CHILLER FIELD SUPPLIED WIRING SYSTEM 1 SYSTEM 2 MODEL MRA1 FACTORY SUPP...

Page 53: ...FAN DATA11 12 YCAS RLA X LRA QTY FLA LRA RLA X LRA QTY FLA LRA 0425EB 106 690 4 4 8 23 0 106 690 4 4 8 23 0 0475EB 148 857 4 4 8 23 0 106 690 4 4 8 23 0 0515EB 148 857 4 4 8 23 0 148 857 4 4 8 23 0 0555EB 188 857 4 4 8 23 0 148 857 4 4 8 23 0 0575EB 188 857 4 4 8 23 0 188 857 4 4 8 23 0 0605EB 173 857 5 4 8 23 0 173 857 5 4 8 23 0 7 ...

Page 54: ...OR DATA MAXIMUM KW 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...

Page 55: ... or lugs which are available per phase Actual wire size and number of wires per phase must be determined based on ampacity and job requirements using N E C wire sizing information The above recommendations are based on the National Electric Code and using copper conductors only Field wiring must also comply with local codes 8 A ground lug is provided for each compressor system to accommodate field...

Page 56: ...T FIG 17 OPTIONAL SINGLE POINT POWER SUPPLY CONNECTION WITH INDIVIDUAL SYSTEM CIRCUIT BREAKERS LD04106 See page 57 for notes SEE NOTE 2 Optional Field Provided 115 1Ø MicroPanel Supply Suitable for Y Start and Across The Line Start LD05555 See page 57 for notes SEE NOTE 2 Optional Field Provided 115 1Ø MicroPanel Supply Suitable for Y Start and Across The Line Start ...

Page 57: ... NOTE 2 Optional Field Provided 115 1Ø MicroPanel Supply 7 NOTES 1 Dashed Line indicates Field Provided Wiring 2 The above recommendations are based on the National Electrical Code and using copper conductors only Field wiring must also comply with local codes FIG 19 OPTIONAL SINGLE POINT POWER SUPPLY CONNECTION TO FACTORY CIRCUIT BREAKER LD05557 See page below for notes Suitable for Across The Li...

Page 58: ...utions on page 61 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 100VA at 115 volts A C 6 Alarm contacts are for annunciating alarm unit malfunc tion Contacts are rated at 115V 100VA resistive load only and ...

Page 59: ...59 YORK INTERNATIONAL FORM 201 18 NM8 WIRING DIAGRAM ACROSS THE LINE START 7 LD06967 FIG 20 CONTINUED ...

Page 60: ...60 YORK INTERNATIONAL FIG 20 CONTINUED ELEMENTARY DIAGRAM Technical Data ...

Page 61: ...s wired through motor contactor auxiliary contacts must be suppressed with YORK P N 031 00808 000 suppressor across the relay contactor coil Any contacts connected to flow switch inputs or BAS inputs on ter minals 13 19 or TB3 or any other terminals must be suppressed with a YORK P N 031 00808 000 sup pressor across the relay contactor coil CAUTION Control wiring connected to the control panel sho...

Page 62: ...62 YORK INTERNATIONAL FIG 21 POWER PANEL FRONT INSIDE VIEW ACROSS THE LINE START Technical Data ...

Page 63: ...63 YORK INTERNATIONAL FORM 201 18 NM8 LD03280 FIG 22 ELECTRONIC PANEL FRONT INSIDE VIEW ACROSS THE LINE START 7 ...

Page 64: ...utions on page 67 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 100VA at 115 volts A C 6 Alarm contacts are for annunciating alarm unit malfunc tion Contacts are rated at 115V 100VA resistive load only and ...

Page 65: ...65 YORK INTERNATIONAL FORM 201 18 NM8 WIRING DIAGRAM WYE DELTA START LD03229 FIG 23 CONT D 7 ...

Page 66: ...66 YORK INTERNATIONAL FIG 23 CONTINUED ELEMENTARY DIAGRAM Technical Data ...

Page 67: ...red through motor contactor auxiliary contacts must be suppressed with YORK P N 031 00808 000 suppressor across the relay contactor coil Any contacts connected to flow switch inputs or BAS inputs on ter minals 13 19 or TB3 or any other terminals must be suppressed with a YORK P N 031 00808 000 sup pressor across the relay contactor coil CAUTION Control wiring connected to the control panel should ...

Page 68: ...68 YORK INTERNATIONAL FIG 24 POWER PANEL FRONT INSIDE VIEW WYE DELTA START Technical Data ...

Page 69: ...69 YORK INTERNATIONAL FORM 201 18 NM8 LD03280 FIG 25 ELECTRONIC PANEL FRONT INSIDE VIEW WYE DELTA START 7 ...

Page 70: ...70 YORK INTERNATIONAL LEGEND FIGS 20 THROUGH 25 LD03281 CONNECTION DIAGRAM ELECTRIC BOX DXST DIRECT DRIVE FIG 26 CONNECTION DIAGRAM Technical Data ...

Page 71: ...71 YORK INTERNATIONAL FORM 201 18 NM8 LD03282 LD03283 LD03284 FIG 27 DETAIL A 7 ...

Page 72: ...72 YORK INTERNATIONAL CONNECTION DIAGRAM SYSTEM WIRING LD03230 LD03231 LD03232 FIG 28 CONNECTION DIAGRAM SYSTEM WIRING FIG 29 SENSOR CONNECTION FIG 30 COMPRESSORS SYSTEMS 1 2 Technical Data ...

Page 73: ...73 YORK INTERNATIONAL FORM 201 18 NM8 COMPRESSOR TERMINAL BOX LD03233 FIG 31 COMPRESSOR TERMINAL BOXES 7 ...

Page 74: ...74 YORK INTERNATIONAL FIG 32 DETAIL B Technical Data LD03285 ...

Page 75: ...75 YORK INTERNATIONAL FORM 201 18 NM8 FIG 33 DETAIL C 7 3 4 5 6 7 8 5 6 3 4 7 8 9 10 LD06841 ...

Page 76: ...luding snow for winter operation or air recirculation ensures rated performance reliable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpre dictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pres sure safety cutout however the system designer must con...

Page 77: ... D D 51 BOTH SIDES POWER OPENING 191 A A 2438 X Z G C 953 914 1981 2989 RIGGING HOLES 2 57 DIA SYS 2 SYS 1 8 8 WATER INLET 5718 3419 1624 WATER OUTLET LD04707 CENTER OF GRAVITY Alum YCAS X Y Z 0425 2801 1084 848 0475 2804 1088 847 0515 2796 1093 845 0555 2799 1096 843 0575 2792 1100 841 CENTER OF GRAVITY Copper YCAS X Y Z 0425 2822 1087 925 0475 2826 1091 924 0515 2818 1095 922 0555 2821 1098 920 ...

Page 78: ...ctions including snow for winter operation or air recirculation ensures rated performance reliable operation and ease of maintenance Site restrictions may compromise minimum clearances indicated below resulting in unpre dictable air flow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pres sure safety cutout however the system designe...

Page 79: ... INLET 6937 1900 2184 3419 1624 WATER OUTLET 2438 CONTROL PANEL FOR SYS 1 POWER ELEMENTS FOR SYS 2 POWER ELEMENTS 762 762 32 32 ORIGIN X Y G C 806 1900 1658 1658 VIEW D D POWER PANEL 2235 MOUNTING 16 DIA HOLES TYP A B C D E F G H LD04703 LD04704 CENTER OF GRAVITY Alum YCAS X Y Z 0605 3137 1102 883 CENTER OF GRAVITY Copper YCAS X Y Z 0605 3191 1104 964 7 ...

Page 80: ...575 28 27 27 27 28 28 27 27 YCAS0605 31 28 28 27 31 28 28 27 CP 4 XX ALUMINUM BLACK FINS NEOPRENE MOUNT SELECTIONS VMC TYPE RD 4 MODEL A B C D E F G H I J K L M N O P YCAS0425 Black Black Black Black Red Red Black Black YCAS0475 Black Black Black Black Red Red Black Black YCAS0515 Red Black Black Black Red Red Black Black YCAS0555 Red Black Black Black Red Red Black Black YCAS0575 Red Black Black ...

Page 81: ...AS0555 28 28 28 28 28 28 28 28 YCAS0575 28 28 28 28 28 28 28 28 YCAS0605 31 31 28 28 31 31 28 28 MODEL A B C D E F G H I J K L M N O P YCAS0425 Red Red Red Red Red Red Red Red YCAS0475 Red Red Red Red Red Red Red Red YCAS0515 Red Red Red Red Red Red Red Red YCAS0555 Red Red Red Red Red Red Red Red YCAS0575 Red Red Red Red Red Red Red Red YCAS0605 Red Red Red Red Red Red Red Red COPPER FINS NEOPREN...

Page 82: ...substructure and equipment to isolators when used under out door equipment exposed to wind forces 3 Lubricate threads of adjusting bolt Loosen hold down bolts to allow for isolator adjustment 4 Block the equipment 1 4 higher than the specified free height of the isolator To use the isolator as blocking for the equipment insert a 1 4 shim be tween the upper load plate and vertical uprights Lower th...

Page 83: ...nches TYPE L W HD A B C D E R 3 or RD 3 139 7 85 8 73 2 63 5 12 7 104 8 14 4 6 3 5 5 3 375 2 875 2 5 0 5 4 125 0 563 0 25 R 4 or RD 4 158 7 117 6 69 8 76 2 12 7 127 0 14 4 9 6 6 25 4 625 2 75 3 0 0 5 5 0 0 563 0 375 FIG 34 ISOLATOR DETAILS 7 LD04804 LD04805 R4 RD4 SERIES ...

Page 84: ...2 3 4 1000 1628 11NC 5 8 AWMR 2 17 6 3 3 4 1 7 1 2 3 3 4 1 2 7 1 2 5 8 14 1 2 7 1 4 17 7 8 1000 1628 10NC 3 4 AWMR 4 17 8 4 7 8 1 1 4 7 1 2 3 3 4 3 4 7 3 4 3 4 14 1 2 7 1 4 17 7 8 1000 1628 9NC 7 8 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 AWMR 2 15 6 3 3 4 1 7 1 2 3 3 4 1 2 9 1 2 5 8 14 1 2 7 1 4 17 3 4 50 553 10NC 5 8 AWMR 4 17 8 4 7 8 1 1 4 7 1 2 3 3...

Page 85: ...85 YORK INTERNATIONAL FORM 201 18 NM8 ISOLATOR LOCATIONS 16 mm 5 8 LD06968 FIG 36 ISOLATOR LOCATIONS FOR ALL MODELS 7 ...

Page 86: ... 3 m 48 2 m 72 2 m 72 2 m 72 CLEARANCES NOTES No obstructions allowed above the unit Only one adjacent wall may be higher than the unit Adjacent units should be 3 meters 10 feet apart LD03484 FIG 37 CLEARANCES Technical Data ...

Page 87: ...ve into the other side of the econo mizer where it is evaporated This low pressure liquid subcools the major part of the refrigerant Medium pres sure vapor then returns to the compressor The subcooled refrigerant then passes through the expan sion valve where pressure is reduced and further cool ing takes place before returning to the cooler FIG 38 REFRIGERANT FLOW DIAGRAM Low Pressure Liquid Medi...

Page 88: ...OID VALVE BALL VALVE RELIEF VALVE STOP VALVE ANGLE ACCESS PURGE VALVE PLUG PRESSURE SENSOR TEMPERATURE SENSOR REPLACEABLE CORE FILTER DRYER SIGHT GLASS FLOW SWITCH option PRESSURE SWITCH ELECTRIC HEATER COMP COMPRESSOR CDR CONDENSER COIL CLR COOLER OCLR OIL COOLER COIL OS OIL SEPARATOR CHT CHILLED LIQUID THERMOSTAT DIF DIFFERENTIAL PRESSURE CUTOUT DFP DISCHARGE PRESSURE FAN CONTROL DV DISPLAY VALU...

Page 89: ...URE BOP OIL PRESSURE BOT OIL TEMPERATURE 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 BCRT 1 RFTS 2 RFTS 2 STS 1 STS 2 BOT 2 CCCV 2 ...

Page 90: ...ECONOMIZER GAS IN DISCHARGE CASE OIL INLET FROM CONDENSER CODING COIL DISCHARGE GAS OUT OIL FILTER BLEED EVACUATION POINT OIL FILTER COVER PLATE CAPACITY CONTROL SOLENOID CAPACITY CONTROL 3 WAY VALVE IS LOCATED UNDER THE SOLENOID LIFTING LUG THREADED HOLE OIL PRESSURE TRANSDUCER LOCATION ROTOR CASE STATOR LOCKING BOLT LD03668 Technical Data ...

Page 91: ...91 YORK INTERNATIONAL FORM 201 18 NM8 COMPRESSOR COMPONENTS CONT D FIG 42 COMPRESSOR COMPONENTS LD03669 7 ...

Page 92: ...92 YORK INTERNATIONAL COMPRESSOR COMPONENTS CONT D FIG 43 COMPRESSOR COMPONENTS LD03670 Technical Data ...

Page 93: ...93 YORK INTERNATIONAL FORM 201 18 NM8 COMPRESSOR COMPONENTS CONT D FIG 44 COMPRESSOR COMPONENTS LD03671 7 ...

Page 94: ...ESSOR COMPONENTS CONT D FIG 45 COMPRESSOR COMPONENTS LD03672 O RING MOTOR ROTOR MALE ROTOR LOCKING KEY MALE ROTOR FEMALE ROTOR O RING RELIEF VALVE ECONOMIZER PLUG SUPPORT RINGS SLIDE VALVE SLIDE VALVE RETURN SPRING Technical Data ...

Page 95: ...UST 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 41 ...

Page 96: ...g 12 page 39 G 13 Be certain all water temp sensors are inserted completely in their respective wells and are coated with heat conductive compound G 14 Assure that evaporator TXV bulbs are strapped onto the suction lines at 4 or 8 o clock positions JOB NAME ______________________________ SALES ORDER _________________________ LOCATION _______________________________ SOLD BY ________________________...

Page 97: ... 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 col umn of liquid when the TXV stabilizes After Panel Checks Power ON Both System Switches OFF G 1 Apply 3 phase power and verify its value See Fig 8 page 35 G 2 Apply 115VAC and verify its value on the ter mi...

Page 98: ... lished the leaving water temperature has been pulled down to the required leaving water temperature and the unit is running in a fully loaded condition Correct superheat setting for a system is 6 7 C 10 12 F The superheat is calculated as the difference between the actual temperature of the returned refrigerant gas in the suction line entering the compressor and the tem perature corresponding to ...

Page 99: ...rew should be turned not more than one turn at a time allowing suffi cient time approximately 15 minutes between adjust ments for the system and the thermal expansion valve to respond and settle out Assure that superheat is set between 6 7 C 10 12 F G 1 Record the motor gas temperature economizer pressure economizer pressure converted to tem perature and economizer superheat below This superheat s...

Page 100: ...ll as fault history data from recent safety shut downs 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 á â keys are also used for scrolling through in...

Page 101: ...h have a single split circuit evapora tor serving 2 independent refrigerant systems YCAS 2 system chillers are configured as a single self contained section with a single control panel controlling the two refrigerant systems 1 2 KEYPAD DISPLAY An operator keypad allows complete control of the chiller from a central location The keypad offers a multitude of commands available to access displays pro...

Page 102: ...cessor will not be active and the micro cannot keep track of time although all other functions will operate nor mally Failure to turn the Clock ON could result in the chiller not starting due to the time frozen on the clock falling outside the Start Stop time programmed in the Daily Schedule see Section 7 3 1 5 ANCILLARY CIRCUIT BOARDS Power Supply Board The on board switching power supply is fuse...

Page 103: ... Expansion Board allowing the microproces sor to monitor motor currents for low current high cur rent unbalanced current and single phasing 3 Transformers 2T 3T and 4T are located in the Con trol Panel These transformers convert the 115VAC Control Power Input to 24VAC to operate the micro processor circuitry 2T This 75VA transformer supplies the Microprocessor power supply 3T Supplies the I O Expa...

Page 104: ...104 YORK INTERNATIONAL 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 105: ...ction of the control panel The contact must be closed to allow the chiller to run Any time the contact opens the chiller will shut down and the NO RUN PERM message will be dis played The location of the flow switch connection is shown in Section 1 12 Never bypass a flow switch This will cause damage to the chiller and void any warranties Wiring from remote dry contacts for stop start reset functio...

Page 106: ...emp 4 sec 1 sec X 22 C 10 sec Reset Temp 66 C sec 10 sec 6 C 12 F To determine the new setpoint add the reset to the setpoint programmed into memory In the example pre ceding if the programmed setpoint 7 C 44 F the new setpoint after the 4 second contact closure would be 7 C 44ºF 6 C 12ºF 13 C 56ºF This new setpoint can be viewed on the display by Pressing the Remote Reset Temperature Range key To...

Page 107: ...EPROM S1 S2 to S5 DESCRIPTION Clock 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 3 4 2 5 1 FIG 48 COMPONENT LAYOUT 26001A 9 ...

Page 108: ...GIC SECTION FIG 49 LOGIC SECTION LAYOUT 6 7 5 8 ITEM 1 2 3 4 5 6 7 8 DESCRIPTION Microprocessor Board Back of Keypad Back of Display I O Expansion Board Power Supply Board Relay Output Board 1 Relay Output Board 2 Flow Switch Customer Connection Terminals 4 3 2 1 28965A Micro Panel Contents ...

Page 109: ... 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 66 C 150 F and will turn on when the discharge tempera ture is equal to or less than 66 C 150 F 1 17 EVAPORATOR HEATER CONTROL The evaporator heater is controlled by ambient tem perature When the ambient temperature drops below 4 C 40 F the heater is turned o...

Page 110: ...SOR SELECTION The chiller may be set up for AUTO or MANUAL Lead Lag This is accomplished by programming the option under the Program Key Details for programming the Manual Auto Lead Lag Selection are discussed in Pro gram Key Section 8 page 138 When AUTO Lead Lag is utilized the micro attempts to balance run time between the two compressors A number of conditions can occur which will prevent this ...

Page 111: ...tus The messages dis played include running status cooling demand fault status external cycling device status load limiting and anti recycle timer status The display will show one mes sage relating to the highest priority information as determined by the microprocessor For individual system status or fault messages the dis play shows information for up to two refrigerant sys tems For models with t...

Page 112: ...isplayed and the indicated system will not run 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 sys tem on The lag system will display this message until the loading sequence is ready for the lag system to...

Page 113: ...s monitor discharge pressure mo tor current and suction temperature for each compres sor and if maximum limits are approached the slide valve loading of the respective compressor will be re duced to avoid exceeding the limit Displays of anticipation safety control messages and their meanings are as follows Discharge Pressure Limiting Discharge Pressure Limiting takes effect when com pressor discha...

Page 114: ...ent Temperature Cutout The Low Ambient Temperature Safety protects the chiller from running in very low temperatures which could cause damage due to low system pressures This feature is programmable and can also be used to shut down the chiller at a temperature where continued run ning of the chiller is not economical compared to the use of free cooling techniques see also Section 8 2 Low Ambient ...

Page 115: ... H O I L D I F F the chiller must be manually reset See Section 8 2 page 142 Flow Switch Open Closure of the flow switch es is monitored to check that flow is present in the evaporator when a compressor is running Any external cycling devices fitted by the cus tomer are connected in series with the flow switch es YCAS 2 system chillers have a single flow switch wired to the control panel YCAS 3 sy...

Page 116: ... oil temperature during normal op eration will be approximately 54 66 C 130 150 F The High Oil Temperature Safety is activated after 2 minutes of compressor operation after which if oil tem perature is above 107 C 225 F for more than 3 sec onds the compressor will shut down Low Suction Pressure Cutout The Low Suction Pressure Cutout aids in protecting the evaporator from damage due to ice build up...

Page 117: ...nitored using 3 Current Transformers CTs per motor one on each phase Average motor current is monitored after 7 seconds of compressor operation The system will be shut down if average motor current exceeds 115 FLA FLA full load amps is approximately 1 2 x RLA rated load amps RLA is specified on the motor chiller name plate and is typical current demand under rated operating conditions in a fully l...

Page 118: ...2 more starts with 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 tor Module can be found on page 18 The External Motor Overload is responsive to motor current When the overload relay senses single phase operation locked rotor current in ex...

Page 119: ...d 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 approxi mately every 2...

Page 120: ...als fully unloaded and step 75 equals fully loaded Slide valve position is approximate and should be used for reference only Under actual conditions the compres sor may be fully loaded between step 60 75 and fully unloaded between step 0 40 Superheats are the difference between the respective saturated temperature converted from pressure and the actual Display Limits for the System Pressures and T...

Page 121: ...key will scroll to the next option dip switch setting Three Option Switch Messages S1 1 to S1 3 will then be displayed in sequence At the end of the sequence the display will automatically revert to the first Option Switch message The following is a detailed guide to programming the Dip Switches together with the associated display mes sage provided for each selection when the Options key is press...

Page 122: ...rrect 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 3 R E F R I G E R A N T R 4 0 7 C S 1 3 R E F R I G E R A N T R 2 2 Dip Switch Physical Location and Setting FIG 51 ENLARGED PHOTOGRAPH OF DIP SWITCHES ON MICROPROCESSOR BOA...

Page 123: ... Dip Switches 3 8 FUNCTION KEY Pressing the Function key only displays the same message 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 Section 3 3 without the need to press the S...

Page 124: ...cted 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 If a remote pri...

Page 125: ... 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 cont...

Page 126: ...LOAD SYS 2 COMPRESSOR RUNNING OPTIONS CHILLED LIQUID WATER AMBIENT CONTROL STANDARD REFRIGERANT TYPE R407C PROGRAM VALUES DSCH PRESS CUTOUT 399 PSIG DSCH PRESS UNLOAD 375 PSIG SUCT PRESS CUTOUT 44 PSIG HIGH AMBIENT CUTOUT 130 0 ºF LOW AMBIENT CUTOUT 25 0 ºF LEAVING LIQUID CUTOUT 36 0 ºF MOTOR CURRENT UNLOAD 100 FLA ANTI RECYCLE TIME 600 SECS LOCAL REMOTE MODE REMOTE LEAD LAG CONTROL AUTOMATIC UNIT...

Page 127: ...ppear To select a Safety Shutdown press the appropriate key on the numeric key pad then press Enter Remember that the most recent fault information is stored as shut down No 1 After the ENTER Key is pressed a mes sage indicating the time and date of the Fault Shutdown will appear Repetitively pressing the áâ Keys allows scrolling through the information available in the Safety Shut down buffer Thi...

Page 128: ...t the time of the fault This message indicates the status of both the evapora tor pump signal from the microprocessor and the evapo rator heater This message indicates that a remote device such as a Remote Control Center an ISN controller or another device sending a PWM signal for temperature or cur rent temperature or current reset is overriding control points programmed through the keypad or def...

Page 129: ...ps equals fully loaded This message which is only displayed if the unit is in R 407C mode indicates the refrigerant temperature at the inlet of the cooler This message indicates the Liquid Line Solenoid Valve and the economizer Thermal Expansion Valve Solenoid Valve position ON Energized OFF De Energized OFF at the time of the fault This message indicates the stage of condenser fan op eration on t...

Page 130: ...ISTORY Key with an optional printer installed 2 compressor chillers will provide a history printout on the last 6 faults An example of the HISTORY Printout is shown YORK INTERNATIONAL CORPORATION eco2 SCREW CHILLER SAFETY SHUTDOWN NUMBER 1 SHUTDOWN 3 56 PM 23 SEPT 99 SYS 1 HIGH DSCH PRESS SHUTDOWN SYS 2 NO FAULTS OPTIONS CHILLED LIQUID WATER AMBIENT CONTROL STANDARD REFRIGERANT TYPE R407C PROGRAM ...

Page 131: ...nter 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 and the ori...

Page 132: ...ogrammed 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 from setpoint and the rate of chang...

Page 133: ...loaded Keep this potential indicator error in mind when attempting to determine slide valve position Compressor Starting Loading Sequence For Compressor YCAS Chillers If no compressors are running the Daily Schedule per mits all safeties and run permissives are satisfied the anti recycle timers have timed out and the leaving liq uid temperature rises above the upper limit of the Con trol Range the...

Page 134: ...ad the compressor with the high slide valve step until all compressor slide valves are at 0 At this point the the last lag compressor will pump down and cycle off if chilled liquid temperature drops below Setpoint Control Range 2 When a lag compressor cycles off the micro will set the remaining running compressors at Slide Valve Positions of 10 As load continues to decrease the lead compressor wil...

Page 135: ... of the set point upward by up to 22 C 40 F above the setpoint programmed in memory see Section 1 7 The maximum allowable reset must be programmed into memory and can be a value of 1 to 22 C 2 to 40 F 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 ways equal to ...

Page 136: ...the cursor will disappear and the live clock will be displayed 7 CLOCK KEYS 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 nating the need for an external time cloc...

Page 137: ... by pressing Cancel and En ter for the Monday Start Stop schedule M O N S T A R T 0 6 0 0 A M S T O P 0 5 3 0 P M Programming the DAILY SCHED ULE will not affect on the holiday schedule If the chiller is not required to run on a given day the Start time should be programmed for 00 00 AM and the Stop time programmed for 12 00 AM Continue to program each day as needed After SUN has been entered the ...

Page 138: ... I D E If a Warning Low Battery fault message appears on the display the in ternal clock calendar and program settings cannot be relied on for accu racy Default values are loaded into the microprocessor memory and the Manual Override key can be used to zero out the daily schedule and allow unlimited operation regardless of the time on the internal clock Repro gramming of the setpoints and cutout v...

Page 139: ...the cutout point is exceeded for 3 seconds the system will shut down 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 Mode Press...

Page 140: ...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 141: ... L A be set to the saturated refrigerant pressure equivalent to 10 C 18 F below the temperature of the chilled liquid 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...

Page 142: ... will shut the com pressor down whenever current 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 tem perature and condenser malfunction caused by dirt or fan problems If the programmable limit is set below 100 of full load current th...

Page 143: ...r the Program key a defaults password may be pro grammed to automatically program default values into memory This will preset all programmable values un der the Program key to values that will allow operation of the chiller under most operating conditions This al lows quick start up programming for typical chilled wa ter applications To program the default values into memory first press the PROGRA...

Page 144: ...TABLE 2 CONDENSER FAN CONTROL FAN CONTACTOR DATA FOR DXST UNITS WITH 4 FANS SYSTEM Fan ON OFF Fan Wire Relay Stage Fans Conditions Conditions Contactor Number Board DP DP OAT Output 1 1 15 2 BAR 10 3 BAR 15 6 C 9M 130 15 S 2 3 5 16 2 BAR 11 4 BAR 18 3 C 10M 11M 131 14 Y 3 7 9 17 2 BAR 12 4 BAR 21 1 C 12M 13M 132 10 S 4 1 7 9 18 3 BAR 13 4 BAR 23 9 C 9M 12M 13M 130 132 10 15 5 3 5 7 9 19 3 BAR 14 5...

Page 145: ...g section for courses of action Refrigerant Leaks Visually check the heat exchangers compressors and pipework for damage and gas leaks Airflow Obstructions Check the air cooled condenser coil intakes and adja cent areas are clear of foreign materials or obstructions e g paper leaves etc Operating Conditions Read the operating pressures and temperatures at the control panel using the display keys a...

Page 146: ...tion 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 Remarks Co...

Page 147: ...ng 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 specifi...

Page 148: ...ion 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 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 Check sensor locations Check fan...

Page 149: ...or 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 follow ing oils ASSOCIATED DRAWINGS SPARE PARTS Models R 22 General Arrangement Wiring Diagrams Schematic 201 18 W8 Connection Customer wiring Legend DESCRIPTION ITEM PART NUMBER Pressure T...

Page 150: ...played 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 FAULT HIGH...

Page 151: ...on 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 refri...

Page 152: ... Sensors Temperature Resistance Voltage C F ohms VDC 0 32 163250 0 282 10 50 99500 0 447 20 68 62450 0 676 30 86 40285 0 976 40 104 26635 1 34 50 122 18015 1 76 60 140 12440 2 20 70 158 8760 2 63 80 176 6290 3 04 90 194 4588 3 40 100 212 3400 3 71 110 230 2556 3 96 120 248 1946 4 17 130 266 1504 4 33 140 284 1174 4 46 150 302 926 4 57 Chilled Leaving Water Temperature CLT and Chilled Return Water ...

Page 153: ...ecifically 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 AND...

Page 154: ...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 36 44 24 ...

Page 155: ...155 YORK INTERNATIONAL FORM 201 18 NM8 10 ...

Page 156: ... 1001 www york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 2001 ALL RIGHTS RESERVED Form 201 18 NM8 701 New Release ...

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