York Millennium YCAS 0693 Installation Operation & Maintenance Download

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INSTALLATION, OPERATION & MAINTENANCE

MILLENNIUM

AIR-COOLED SCREW LIQUID CHILLERS

New Release

Form 201.18-NM4 (700)

MILLENNIUM

YCAS AIR COOLED LIQUID CHILLER

YCAS 0693,0773,0783,0873,0953 (3 COMPRESSOR)

YCAS 1063,1093,1163,1263 (4 COMPRESSOR)

STYLE F

50 Hz

00258VIP

YCAS 3 SYSTEM EPROMs

Microprocessor Board

031-01798-002

YCAS 4 SYSTEM EPROMs

Microprocessor Board

I/O Board #2 EPROM

031-01798-002

031-02018-001

I/O Board #2 EPROM

031-02018-001

Summary of Contents for Millennium YCAS 0693

Page 1: ...NNIUM YCAS AIR COOLED LIQUID CHILLER YCAS 0693 0773 0783 0873 0953 3 COMPRESSOR YCAS 1063 1093 1163 1263 4 COMPRESSOR STYLE F 50 Hz 00258VIP YCAS 3 SYSTEM EPROMs Microprocessor Board 031 01798 002 YCA...

Page 2: ...rd 23 Single Point Power Connection with Individual Circuit Protection 23 Single Point Power Connection with Combined Circuit Protection 23 Single Point Power Connection without Circuit Protection 23...

Page 3: ...Start 57 Wiring Diagrams Across the Line Start and Wye Delta Start YCAS0693 YCAS0953 59 Standard 3 Compressor Power Supplies Wye Delta Start 60 Wiring Diagram Across the Line Start 61 Standard Compre...

Page 4: ...1 11 Microprocessor Board Layout 136 1 12 Logic Section Layout 137 1 13 Anti Recycle Timer 138 1 14 Anti Coincidence Timer 138 1 15 Evaporator Pump Control 138 1 16 Compressor Heater Control 138 1 17...

Page 5: ...65 7 3 Set Schedule Holiday Key 166 7 4 Manual Override Key 167 8 PROGRAMKEY 168 8 1 General 168 8 2 Program Key User Programmable Values 168 8 3 Programming Default Values 172 8 4 3 Compressor Conden...

Page 6: ...hat 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...

Page 7: ...is intended for cooling water or 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...

Page 8: ...Use 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 s...

Page 9: ...at R22 does not represent a carcinogenic hazard to humans Occupational Recommended limit 1000 ppm v v 8 hr TWA 1250 ppm v v 12 hr TWA Exposure Limits Stability Unstable Conditions to Avoid Use in pres...

Page 10: ...highly recommended Section 4 PHYSICAL DATA Appearance Clear liquid gray to yellow or light brown tint Boiling Point 650 F Vapor Pressure 0 01 mmHg 20 C Specific Gravity water 1 0 94 0 97 Volatiles Pe...

Page 11: ...atory Protection Use in well ventilated area Ventilation Local exhaust Protective Gloves Strongly recommended especially for prolonged exposure Eye Face Protection Goggles Firefighters should use NIOS...

Page 12: ...5 salt spray conditions shows breakdown of less than 1 8 either side of a scribed line equiva lent to ASTM D1654 rating of 6 All exposed power wiring is be routed through liquid tight non metallic co...

Page 13: ...eparator The pres surized oil is then cooled in the condenser coils and piped back to the compressor for lubrication The com pressor design working pressure is 31 bar 450 PSIG Each chiller receives a...

Page 14: ...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 t...

Page 15: ...ction The power and control sections have separate hinged latched and gasket sealed doors equipped with wind struts Each power compartment contains Compressor and fan starting contactors fan motor ex...

Page 16: ...under current and phase rotation The module mounted in the power panel utilizes a 7 segment display which provides operating status and fault diagnostic information The 7 segment display will display...

Page 17: ...dip switch change is made power must be cycled off and on to the module to reprogram the module to the new valve Thermal Overload Three PTC positive temperature coefficient ther mistors in the motor...

Page 18: ...0 0 1 0 0 0 73 0 1 0 0 1 0 0 1 74 0 1 0 0 1 0 1 0 75 0 1 0 0 1 0 1 1 76 0 1 0 0 1 1 0 0 77 0 1 0 0 1 1 0 1 78 0 1 0 0 1 1 1 0 79 0 1 0 0 1 1 1 1 80 0 1 0 1 0 0 0 0 81 0 1 0 1 0 0 0 1 82 0 1 0 1 0 0 1...

Page 19: ...0 0 1 114 0 1 1 1 0 0 1 0 115 0 1 1 1 0 0 1 1 116 0 1 1 1 0 1 0 0 117 0 1 1 1 0 1 0 1 118 0 1 1 1 0 1 1 0 119 0 1 1 1 0 1 1 1 120 0 1 1 1 1 0 0 0 121 0 1 1 1 1 0 0 1 122 0 1 1 1 1 0 1 0 123 0 1 1 1 1...

Page 20: ...1 1 1 0 0 157 1 0 0 1 1 1 0 1 158 1 0 0 1 1 1 1 0 159 1 0 0 1 1 1 1 1 160 1 0 1 0 0 0 0 0 161 1 0 1 0 0 0 0 1 162 1 0 1 0 0 0 1 0 163 1 0 1 0 0 0 1 1 164 1 0 1 0 0 1 0 0 165 1 0 1 0 0 1 0 1 166 1 0 1...

Page 21: ...1 0 0 197 1 1 0 0 0 1 0 1 198 1 1 0 0 0 1 1 0 199 1 1 0 0 0 1 1 1 200 1 1 0 0 1 0 0 0 201 1 1 0 0 1 0 0 1 202 1 1 0 0 1 0 1 0 203 1 1 0 0 1 0 1 1 204 1 1 0 0 1 1 0 0 205 1 1 0 0 1 1 0 1 206 1 1 0 0 1...

Page 22: ...t 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 interlocki...

Page 23: ...in areas where units may be exposed to acid rain Phenolic coated condenser coils Completed con denser coil assemblies are covered with a cured Phe Entry Used to confirm Set Point changes cancel in put...

Page 24: ...art 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 mo...

Page 25: ...Remote Control Panel Seq Cntrl Automatic Lead Trans MP Multiple Point SP Single Point NF Non Fused TB Terminal Block Ser Service Ind Sys Brkr L Ext Handles Individual System Breaker Lockable External...

Page 26: ...SER FIELD CABINET FIELD NOTES 1 Q DENOTES SPECIAL S Q 2 DENOTES STANDARD 3 X w in OPTIONS FIELD DENOTES NO OPTION SELECTED Wire Full Unit Enc Panels factory Wire Full Unit Enc Panels field Wire Louver...

Page 27: ...person on site It is recommended that the unit is periodically in spected during storage 3 INSPECTION Remove any transit packing and inspect the unit to en sure that all components have been delivere...

Page 28: ...28 YORK INTERNATIONAL UNIT RIGGING Handling and Storage CORRECT WRONG LD05774 FIG 3 UNIT RIGGING CORRECT WRONG LD03515 FIG 4 LIFTING LUGS 2250mm 88...

Page 29: ...s of suitable strength The channels should be spaced at the same centres as the vibration mounting holes in the unit base frame and must be at least 120 mm 4 3 4 wide at the contact points This will a...

Page 30: ...s 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 recommen...

Page 31: ...of 21 watts per meter under the insulation is recommended supplied independently and controlled by an ambient temperature thermostat set to switch on at 21 C 37 F above the freezing tem perature of th...

Page 32: ...re than 1 meter 3 feet of light con struction ductwork should be supported by the unit Where cross winds may occur any ductwork must be supported to prevent side loading on the unit If the ducts from...

Page 33: ...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 supply to be connected to each of the p...

Page 34: ...t Terminals 29 and 30 Figs 11 and 12 pages 39 and 40 close 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...

Page 35: ...35 YORK INTERNATIONAL FORM 201 18 NM4 POWER AND CONTROL PANEL LAYOUTS WYE DELTA TYPICAL FIG 8 POWER PANEL SECTION 00263VIP 4...

Page 36: ...36 YORK INTERNATIONAL FIG 8 POWER PANEL SECTION CONT D OPTIONS PANEL LAYOUT TYPICAL 00246VIP Installation...

Page 37: ...AYOUT LOGIC SECTION LAYOUT 00247VIP ITEM 1 2 3 4 5 6 7 8 9 10 DESCRIPTION Microprocessor Board Back of Keypad Back of Display I O Expansion Board 1 Power Supply Board Relay Output Board 1 Relay Output...

Page 38: ...38 YORK INTERNATIONAL FIG 10 LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT 00248VIP Installation...

Page 39: ...EMERGENCY STOPS TERMINALS 13 19 TERMINALS 23 38 4 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 Al...

Page 40: ...STOMER CONNECTIONS CUSTOMER CONNECTIONS Installation TRANSFORMERS POWER SUPPLY BOARD CIRCUIT BREAKERS RELAY BOARDS I O EXPANSION BOARD CUSTOMER CONNECTIONS Flow Switch Alarm Run etc MICROPROCESSOR CIR...

Page 41: ...ol 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 COMM...

Page 42: ...f 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 micropanel Figs 11 and 12 pages 39 and 40 Temperature sensor s Ensure t...

Page 43: ...replaced 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 un...

Page 44: ...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 rat...

Page 45: ...so 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...

Page 46: ...er as standard TEMPERATURE AND FLOWS SI UNITS Technical Data Excessive flow above the max GPM will damage the evaporator MODEL LEAVING WATER COOLER FLOW AIR ON NUMBER TEMPERATURE C L S 3 CONDENSER C Y...

Page 47: ...7 47 57 47 57 47 57 Number of Rows 3 3 3 3 3 3 3 3 3 Fins per Meter 512 512 512 512 512 512 512 512 512 Condenser Fans Number Ckt 1 Ckt 2 3 3 3 3 4 4 4 4 4 4 5 5 4 4 4 4 4 4 Number Ckt 3 Ckt 4 4 4 4 4...

Page 48: ...E PRESSURE BAR 10 REFRIGERANT SIDE PRESSURE BAR 20 MINIMUM PRIMARY COOLER FLOW MODEL WATER VOLUME LITERS SECOND YCAS LITERS MIN MAX 0693EC 2570 14 50 0773EC 2748 14 50 0783EC 2983 16 50 0873EC 2983 16...

Page 49: ...49 YORK INTERNATIONAL FORM 201 18 NM4 7 This page intentionally left blank...

Page 50: ...1 0 300 2 250 500 161 283 907 140 283 907 8 4 4 17 1 1093 380 436 600 450 500 2 1 0 300 2 250 500 183 283 907 140 283 907 7 4 4 17 1 1163 380 457 600 500 500 2 1 0 300 2 250 500 168 283 907 168 283 90...

Page 51: ...3 380 457 600 500 500 2 1 0 300 2 250 500 168 283 907 168 283 907 8 4 4 17 1 1263 380 494 600 500 600 2 1 0 300 2 250 500 183 283 907 183 283 907 8 4 4 17 1 Over current Wire Range ELECTRICAL SYSTEM 1...

Page 52: ...AD ELEMENT DISCONNECT SUPPLY CURRENT FUSE SIZE SWITCH SIZE 3 or 4 115V 1 30A 30A 30A Non CE 50 60Hz 3 or 4 115V 1 25A 30A 30A CE 50Hz CONTROL POWER SUPPLY UNITS WITH STANDARD CONTROL CIRCUIT TRANSFORM...

Page 53: ...ctual 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...

Page 54: ...TB1 TB2 TB3 TB4 Field Supply 2 Field Supply 1 Suitable for Across the Line Start 3 4 COMPRESSOR POWER CONNECTION OPTIONS FIG 16 MULTIPLE POINT POWER SUPPLY CONNECTION WITH INDIVIDUAL SYSTEM CIRCUIT B...

Page 55: ...AL SINGLE POINT POWER SUPPLY CONNECTION WITH INDIVIDUAL SYSTEM CIRCUIT BREAKERS LD05554 3 4 COMPRESSOR POWER CONNECTION OPTIONS NOTES 1 Dashed Line indicates Field Provided Wiring 2 The above recommen...

Page 56: ...AGE 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...

Page 57: ...57 YORK INTERNATIONAL FORM 201 18 NM4 FIG 18 ELEMENTARY DIAGRAM ACROSS THE LINE START ELEMENTARY DIAGRAM LD04172A 7...

Page 58: ...58 YORK INTERNATIONAL ELEMENTARY DIAGRAM FIG 19 ELEMENTARY DIAGRAM ACROSS THE LINE START LD04172B Technical Data...

Page 59: ...cations Also refer to cautions on page 63A 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 b...

Page 60: ...LLERS NOT PRESENT ON 3 COMPRESSOR CHILLERS PRESENT ON CERTAIN MODEL CHILLERS NOT PRESENT ON 3 COMPRESSOR CHILLERS FIG 21 STANDARD 3 COMPRESSOR POWER SUPPLIES WYE DELTA START STANDARD 3 COMPRESSOR POWE...

Page 61: ...PRESENT ON CERTAIN MODEL CHILLERS NOT PRESENT ON 3 COMPRESSOR CHILLERS PRESENT ON CERTAIN MODEL CHILLERS NOT PRESENT ON 3 COMPRESSOR CHILLERS WIRING DIAGRAM ACROSS THE LINE START LD04173 FIG 22 ELEME...

Page 62: ...62 YORK INTERNATIONAL STANDARD COMPRESSOR POWER SUPPLIES ACROSS THE LINE START WYE DELTA START FIG 23 ELEMENTARY DIAGRAM LD04175 Technical Data...

Page 63: ...closure or connected to power supplies in the control panel Additionally control wiring not connected to the Smart Panel should not be run through the cabinet This could result in nuisance faults CAUT...

Page 64: ...FORM 201 18 NM4 YORK INTERNATIONAL YORK INTERNATIONAL 63B 64 LD04178 CONNECTION DIAGRAM FIG 24 CONNECTION DIAGRAM Technical Data 7...

Page 65: ...65 YORK INTERNATIONAL FORM 201 18 NM4 LD04179 7...

Page 66: ...66 YORK INTERNATIONAL Technical Data CONNECTION DIAGRAM FIG 25 CONNECTION DIAGRAM LD04180 Box Information continued on page 67...

Page 67: ...TIONAL YORK INTERNATIONAL 67 67A FIG 26 CONNECTION DIAGRAM FIG 44 45 LEGEND PAGES 90 91 LD03281 FIG 27 CONNECTION DIAGRAM CONT D LD04181 CONNECTION DIAGRAM ELECTRIC BOX DXST DIRECT DRIVE CONNECTION DI...

Page 68: ...CONNECTION DIAGRAM ELECTRICAL BOX YCAS YCAS0693 0953 STYLE F STANDARD REMOTE EVAP UNITS FIG 28 CONNECTION DIAGRAM LD04182 FIG 29 CONNECTION DIAGRAM CONNECTION DIAGRAM ELECTRICAL BOX YCAS YCAS0693 0953...

Page 69: ...69 YORK INTERNATIONAL FORM 201 18 NM4 ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT FIG 30 ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT LD04177 7...

Page 70: ...70 YORK INTERNATIONAL Technical Data ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT FIG 31 ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT LD04373...

Page 71: ...NM4 ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT FIG 32 ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT DETAIL C SEE INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR JUMPER OF CONDENSER...

Page 72: ...72 YORK INTERNATIONAL Technical Data CONNECTION DIAGRAM SYSTEM WIRING STANDARD REMOTE EVAP UNITS FIG 33 CONNECTION DIAGRAM SYSTEM WIRING LD04184...

Page 73: ...73 YORK INTERNATIONAL FORM 201 18 NM4 LD04185 CONNECTION DIAGRAM SYSTEM WIRING STANDARD REMOTE EVAP UNITS FIG 34 CONNECTION DIAGRAM SYSTEM WIRING 7...

Page 74: ...74 YORK INTERNATIONAL Technical Data FIG 35 ELEMENTARY DIAGRAM ELEMENTARY DIAGRAM DXST DIRECT DRIVE POWER CIRCUIT LD04260A...

Page 75: ...75 YORK INTERNATIONAL FORM 201 18 NM4 ELEMENTARY DIAGRAM DXST DIRECT DRIVE POWER CIRCUIT LD04260B FIG 36 ELEMENTARY DIAGRAM 7...

Page 76: ...er to cautions on the page 85A 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...

Page 77: ...77 YORK INTERNATIONAL FORM 201 18 NM4 FIG 38 STANDARD POWER SUPPLY WYE DELTA START STANDARD 4 COMPRESSOR POWER SUPPLIES WYE DELTA START LD04262 7...

Page 78: ...78 YORK INTERNATIONAL FIG 39 STANDARD POWER SUPPLY ACROSS THE LINE START STANDARD COMPRESSOR POWER SUPPLIES ACROSS THE LINE START YCAS1063 YCAS1263 LD04261 Technical Data...

Page 79: ...79 YORK INTERNATIONAL FORM 201 18 NM4 This page intentionally left blank 7...

Page 80: ...TERNATIONAL Technical Data STANDARD COMPRESSOR POWER SUPPLIES YCAS1063 YCAS1263 ACROSS THE LINE START WYE DELTA START FIG 40 STANDARD COMPRESSOR POWER SUPPLIES ACROSS THE LINE START AND WYE DELTA STAR...

Page 81: ...FORM 201 18 NM4 FORM 201 18 NM4 YORK INTERNATIONAL YORK INTERNATIONAL 81 81A SHLD G ISN RS485 PORT LD04258 FIG 40 STANDARD COMPRESSOR POWER SUPPLIES ACROSS THE LINE AND WYE DELTA START CONT D...

Page 82: ...FORM 201 18 NM4 YORK INTERNATIONAL YORK INTERNATIONAL 81B 82 This page intentionally left blank This page intentionally left blank Technical Data 7...

Page 83: ...83 YORK INTERNATIONAL FORM 201 18 NM4 This page intentionally left blank 7...

Page 84: ...84 YORK INTERNATIONAL Technical Data FIG 41 CONNECTION DIAGRAM WYE DELTA START CONNECTION DIAGRAM SYSTEMS 1 2 LD04265...

Page 85: ...wer supplies in the control panel Additionally control wiring not connected to the Smart Panel should not be run through the cabinet This could result in nui sance faults CAUTION Any inductive devices...

Page 86: ...FORM 201 18 NM4 YORK INTERNATIONAL YORK INTERNATIONAL 85B 86 CONNECTION DIAGRAM SYSTEMS 3 4 FIG 42 CONNECTION DIAGRAM Technical Data LD04267 7...

Page 87: ...87 YORK INTERNATIONAL FORM 201 18 NM4 LD04268 7...

Page 88: ...88 YORK INTERNATIONAL Technical Data CONNECTION DIAGRAM ELECTRICAL BOX YCAS1063 1263 STYLE F STANDARD REMOTE EVAP UNITS FIG 43 CONNECTION DIAGRAM SYSTEM WIRING LD04264...

Page 89: ...89 YORK INTERNATIONAL FORM 201 18 NM4 CONNECTION DIAGRAM ELECTRICAL BOX YCAS1063 1263 STYLE F STANDARD REMOTE EVAP UNITS FIG 44 CONNECTION DIAGRAM LD04272 7...

Page 90: ...90 YORK INTERNATIONAL Technical Data FIG 45 ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT LD04177...

Page 91: ...91 YORK INTERNATIONAL FORM 201 18 NM4 ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT FIG 46 ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT LD04695 7...

Page 92: ...Data DETAIL C SEE INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR NUMBER OF CONDENSER FANS FOR CHILLER MODELS ELEMENTARY DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT FIG 47 ELEMENTARY DIAGRAM DXST DIRE...

Page 93: ...93 YORK INTERNATIONAL FORM 201 18 NM4 CONNECTION DIAGRAM SYSTEM WIRING STANDARD REMOTE EVAP UNITS FIG 48 CONNECTION DIAGRAM SYSTEM WIRING LD04269 7...

Page 94: ...94 YORK INTERNATIONAL FIG 49 CONNECTION DIAGRAM SYSTEM WIRING CONNECTION DIAGRAM SYSTEM WIRING STANDARD REMOTE EVAP UNITS LD04270 Technical Data...

Page 95: ...95 YORK INTERNATIONAL FORM 201 18 NM4 COMPRESSOR TERMINAL BOX SYSTEMS 1 THROUGH 4 LD04271 FIG 50 COMPRESSOR TERMINAL BOX SYSTEMS 1 4 7...

Page 96: ...lting 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 mus...

Page 97: ...RM 201 18 NM4 7 DIMENSIONS YCAS0693 0773 A F E J D I C H B G LD03977 LD03978 CENTER OF GRAVITY Copper YCAS X Y Z 0693 3561 1059 964 0773 3537 1066 1021 CENTER OF GRAVITY Alum YCAS X Y Z 0693 3465 1052...

Page 98: ...ion 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...

Page 99: ...ET 10 WATER OUTLET 2438 16 DIA MOUNTING HOLES TYP A B C D E F G H I J K L POWER ELEMENTS FOR SYS 1 3 POWER ELEMENTS FOR SYS 2 CONTROL PANEL 762 762 2235 ORIGIN 806 1453 1453 1453 1229 1400 32 32 POWER...

Page 100: ...ing 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...

Page 101: ...INTERNATIONAL FORM 201 18 NM4 7 DIMENSIONS YCAS1063 A G H B C D E F I O P J K L M N LD04017 LD04018 CENTER OF GRAVITY Alum YCAS X Y Z 1063 5228 1117 841 CENTER OF GRAVITY Copper YCAS X Y Z 1063 5284 1...

Page 102: ...ing 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...

Page 103: ...RK INTERNATIONAL FORM 201 18 NM4 7 DIMENSIONS YCAS1093 A G M B C D E F H I J K L N LD03993 LD03994 CENTER OF GRAVITY Alum YCAS X Y Z 1093 4667 1117 808 CENTER OF GRAVITY Copper YCAS X Y Z 1093 4718 11...

Page 104: ...ion 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...

Page 105: ...A RIGGING HOLES EACH SIDE A I B J C K D L E M F N G O H P 762 762 2235 ORIGIN 806 Y X 1453 1453 1453 923 1422 1422 1422 32 32 16 DIA MOUNTING HOLES TYP POWER ELEMENTS FOR SYS 1 3 POWER ELEMENTS FOR SY...

Page 106: ...LEARANCES 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 LD05777 FIG 51 CLEARANCES 1 3 m 48 2 m 72 2 m...

Page 107: ...MR 2 552 1900 861 8 2 51 AWMR 2 53 2000 907 2 2 51 AWMR 2 530 2300 1043 3 2 51 AWMR 2 531 2552 1157 6 2 51 AWMR 2 532 3000 1360 8 2 51 Technical Data 7 ALUMINUM FIN COIL WEIGHT DISTRIBUTION BY MODEL K...

Page 108: ...BLACK BLACK RED GREEN BLACK 1093 RED RED RED RED RED GREEN BLACK RED RED RED RED RED GREEN BLACK 1163 RED RED RED BLACK BLACK GREEN RED BLACK RED RED RED BLACK BLACK GREEN RED BLACK 1263 RED RED RED B...

Page 109: ...521 1552 704 0 2 51 AWMR 2 53 2000 907 2 2 51 AWMR 2 530 2300 1043 3 2 51 AWMR 2 531 2552 1157 6 2 51 AWMR 2 532 3000 1360 8 2 51 7 COPPER FIN COIL WEIGHT DISTRIBUTION BY MODEL KGS YCAS A B C D E F G...

Page 110: ...ACK GREEN RED 1093 RED GREEN GREEN RED RED GREEN RED RED GREEN GREEN RED RED GREEN RED RED 1163 RED GREEN GREEN BLACK BLACK GREEN RED RED RED GREEN GREEN BLACK BLACK GREEN RED RED 1263 RED GREEN GREEN...

Page 111: ...B C D E R 3 or RD 3 5 5 3 375 2 875 2 5 0 5 4 125 0 563 0 25 139 7 85 8 73 2 63 5 12 7 104 8 14 4 6 3 R 4 or RD 4 6 25 4 625 2 75 3 0 0 5 5 0 0 563 0 375 158 7 117 6 69 8 76 2 12 7 127 0 14 4 9 6 LD04...

Page 112: ...2974 AWMR 2 XXX 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 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 5...

Page 113: ...ht of the isolator To use the iso lator as blocking for the equipment insert a 10mm 1 4 shim between the upper load plate and ver tical uprights Lower the equipment on the block ing or shimmed isolato...

Page 114: ...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 recirc...

Page 115: ...115 YORK INTERNATIONAL FORM 201 18 NM4 PROCESS AND INSTRUMENTATION DIAGRAM LD03486 FIG 53 PROCESS AND INSTRUMENTATION DIAGRAM Added to some models 7 7...

Page 116: ...L 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 RE...

Page 117: ...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 SEN...

Page 118: ...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...

Page 119: ...119 YORK INTERNATIONAL FORM 201 18 NM4 COMPRESSOR COMPONENTS CONT D FIG 57 COMPRESSOR COMPONENTS LD03669 7...

Page 120: ...120 YORK INTERNATIONAL COMPRESSOR COMPONENTS CONT D FIG 58 COMPRESSOR COMPONENTS LD03670 Technical Data...

Page 121: ...121 YORK INTERNATIONAL FORM 201 18 NM4 COMPRESSOR COMPONENTS CONT D FIG 59 COMPRESSOR COMPONENTS LD03671 7...

Page 122: ...SSOR COMPONENTS CONT D FIG 60 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 SPRIN...

Page 123: ...ST 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 SL...

Page 124: ...ase power requirements of the compressor See chiller nameplate Pages 25 26 12 Assure 115VAC Control Power has 30A mini mum capacity See Fig 12 page 40 13 Be certain all water temp sensors are inserted...

Page 125: ...8 Set the Time and Date 9 Program the Daily Schedule start and stop times Panel Checks Power ON Both System Switches OFF 1 Apply 3 phase power and verify its value See Fig 8 page 35 2 Apply 115VAC and...

Page 126: ...ure chart use entering air temperature 17 C 30 F for normal condensing temperature b The temperature of the liquid refrigerant out of the condenser should be not be more than 8 C 15 F less than the co...

Page 127: ...and superheat of each system below SYS 1 SYS 2 SYS 3 SYS 4 Liq Line Press ____ ____ ____ ____ kPa PSIG Temp ____ ____ ____ ____ C F Liq Line Temp ____ ____ ____ ____ C F Subcooling ____ ____ ____ ___...

Page 128: ...s well 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 opera...

Page 129: ...erant 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 Control Center In addition EMS BAS System conn...

Page 130: ...s 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 approximate...

Page 131: ...operates the mo tor contactors starters solenoid valves and heaters which control system operation The relay boards are located in the logic section of the control panel s The boards convert 0 12VDC...

Page 132: ...stem s motor specifications Internally the on board 3 C T s and internal circuitry allow the Motor Protector Module to protect against high motor current as programmed on the Motor Pro tector dip swit...

Page 133: ...133 YORK INTERNATIONAL FORM 201 18 NM4 FIG 62 MOTOR PROTECTOR SIDE VIEW 29119A 29121A TOP VIEW TOP VIEW SIDE VIEW 29121A 29120A DISPLAY SWITCH PUSHED TO LEFT INDICATES ON ON 8...

Page 134: ...ion 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 inp...

Page 135: ...of 22 C 40 F the temperature offset would equal Reset Temp 4 sec 1 sec X 4 4 F 10 sec Reset Temp 66 7 Csec 10 sec 6 C 12 F To determine the new setpoint add the reset to the setpoint programmed into m...

Page 136: ...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 Sy...

Page 137: ...Z MODEL LOGIC SECTION FIG 64 LOGIC SECTION LAYOUT ITEM 1 2 3 4 5 6 7 8 DESCRIPTION Microprocessor Board Back of Keypad I O Expansion Board 2 I O Expansion Board 1 Power Supply Board Relay Output Board...

Page 138: ...inutes 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 tem perature is equal to or less than 66 C 150 F 1 1...

Page 139: ...ection 8 page 168 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 from happening Factors dete...

Page 140: ...essages 2 6 System Fault Status Messages 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 sage...

Page 141: ...ndicated 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...

Page 142: ...ge 150 The message indicates that saturated suction tem perature on a system has dropped to 2 C 29 F and that any further temperature reduction could cause some icing of the evaporator tubes Saturated...

Page 143: ...ausing the shut down clears Restart will occur only after anti recycle timers are satisfied and cooling demand requires addi tional cooling A reset hysteresis is built into each safety so repetitive f...

Page 144: ...22 models as long as the compressor continues to run the customer are connected in series with the flow switch es YCAS chillers have a single flow switch wired to the control panel If the flow switch...

Page 145: ...cked up 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 10 C 50 F the Low Oil Differ ential Safety is ac...

Page 146: ...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 bel...

Page 147: ...ual 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 b...

Page 148: ...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...

Page 149: ...heat and compressor slide valve position Examples of these displays are as follows where is the appropriate system number The Cooler Inlet Temp display will only appear if the chiller is selected for...

Page 150: ...from 1 to 5 bar 20 to 70 PSIG for R 22 models and 0 3 to 5 bar 5 to 70 PSIG for R 407c models This display shows the average motor current in amps and average compressor motor current as a percentage...

Page 151: ...for models 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 s...

Page 152: ...UNCTION 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 un...

Page 153: ...onal printer 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 compre...

Page 154: ...nd the pro grammed Target temperature The lower message gives the rate of change of the chilled liquid leaving tem perature in degrees per minute A minus sign indi cates falling temperature No sign in...

Page 155: ...IME 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...

Page 156: ...l cause the oldest set of data to be discarded in favor of storing the new shutdown data The Safety Shutdowns are numbered from 1 to 6 with number 1 always being the most recent If a remote printer is...

Page 157: ...T 6 6 C S E T P O I N T 6 7 C R A N G E 1 1 C This message displays the programmed chilled liquid setpoint and deviation control range programmed at the time of the fault This message indicates the o...

Page 158: ...he Safety Shutdown display D I S P L A Y S A F E T Y S H U T D O W N N O 1 1 T O 4 This message indicates the compressor motor current in as a percentage of Full Load Amps This message shows the syste...

Page 159: ...IXED LIQUID TEMP 51 3 DEGF COOLING RANGE 42 0 2 0 DEGF AMBIENT AIR TEMP 74 8 DEGF LEAD SYSTEM SYS 2 EVAPORATOR PUMP ON EVAPORATOR HEATER OFF ACTIVE REMOTE CONTROL NONE SOFTWARE VERSION C ACS 09 00 SYS...

Page 160: ...ey 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...

Page 161: ...tain 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 capaci...

Page 162: ...chillers if the two compressors can not bring the load under control within 10 minutes the micro will maintain the lead compressor fully loaded at S V Step 75 unload the first lag compressor to Step 4...

Page 163: ...d point and it was scheduled to load the micro could split a load signal of 10 steps between system 1 and 2 It could only load SYS 1 2 steps while loading SYS 2 8 Steps Under these circumstances the t...

Page 164: ...d value in memory from a remote device This feature is typically used for demand limiting or ice storage applications Reset is accomplished by timed closure of external contacts for a defined period o...

Page 165: ...y mode in 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...

Page 166: ...ach day are scrolled through by re petitively pressing the or 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 or key...

Page 167: ...an OFF 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...

Page 168: ...n D I S C H A R G E P R E S S U R E C U T O U T 2 7 2 B A R 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 ticip...

Page 169: ...efrigerant 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 compre...

Page 170: ...e pro grammed 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...

Page 171: ...load point The motor current safety 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 again...

Page 172: ...d 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...

Page 173: ...ctivated when the DP rises over 2 0 bar 290 PSIG The system will remain at the highest fan stage reached unless the OFF conditions given in the next paragraph are satisfied Condenser fan OFF condition...

Page 174: ...8 S 2 15 16 2 BAR 11 4 BAR 18 3 C 22M 331 9 Y 3 17 19 17 2 BAR 12 4 BAR 21 1 C 23M 24M 332 10 S 4 13 17 19 18 3 BAR 13 4 BAR 23 9 C 21M 23M 24M 330 332 8 10 5 15 17 19 19 3 BAR 14 5 BAR 26 7 C 22M 23...

Page 175: ...which is activated when the DP rises over 2 0 bar 290 PSIG The system will remain at the highest fan stage reached unless the OFF conditions given in the next paragraph are satisfied Condenser fan OF...

Page 176: ...4M 331 332 9 10 3 6 13 15 17 19 20 0 BAR 15 2 BAR 29 4 C 21M 22M 23M 24M 330 331 332 8 9 10 1 14 15 2 BAR 10 3 BAR 15 6 C 27M 430 8 S 2 16 16 2 BAR 11 4 BAR 18 3 C 28M 431 9 Y 3 18 20 17 2 BAR 12 4 BA...

Page 177: ...ED WITH 4 OR 5 FANS S 2 1 13 15 2 BAR 10 3 BAR 15 6 C 21M 330 8 S 2 15 16 2 BAR 11 4 BAR 18 3 C 22M 331 9 Y 3 17 17 2 BAR 12 4 BAR 21 1 C 23M 332 10 S 4 13 17 18 3 BAR 13 4 BAR 23 9 C 21M 23M 330 332...

Page 178: ...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 a...

Page 179: ...ssure 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 Outle...

Page 180: ...compressor and cooler heaters for operation X Sample compressor oil and replace oil if necessary1 X Leak check the chiller1 X Disconnect power source and lock out Check tightness of power wiring conne...

Page 181: ...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 clean...

Page 182: ...arts 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 u...

Page 183: ...T TEMP 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 a...

Page 184: ...re in open position 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 d...

Page 185: ...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 96 120 248 194...

Page 186: ...ed 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 transport...

Page 187: ...172 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 1...

Page 188: ...York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 2000 ALL RIGHTS RESERVED Form 201 18 NM4 700 New Release Tele 800 851 1001...

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