York YCAS0295EB, Installation Operation & Maintenance

Page 1: ...COOLED SCREW LIQUID CHILLERS New Release Form 201 19 NM7 804 YCAS AIR COOLED LIQUID CHILLERS YCAS0295EB THROUGH YCAS0605EB STYLE G R 407C 50 HZ YCAS 2 SYSTEM EPROM 031 01798 001 STANDARD BRINE METRIC...

Page 2: ...l owner that information if applicable can be obtained by contacting the nearest YORK Engineered Systems Service office It is the responsibility of operating service personnel to verify the applicabil...

Page 3: ...aterials 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 u...

Page 4: ...CCESSORIES AND OPTIONS 21 Multiple Point Power Connection Standard 21 Single Point Power Connection with Individual Circuit Protection 21 Single Point Power Connection with Combined Circuit Protection...

Page 5: ...fset 41 FIRST TIME START UP 42 Interlocks 42 System Switches 42 Start up 42 Oil Pressure 42 Refrigerant Flow 42 Fan Rotation 42 Suction Superheat 42 Expansion Valve 42 Economizer Superheat 42 Subcooli...

Page 6: ...lt SAFETY status 134 2 7 Printout on Fault Shutdown 137 3 DISPLAY KEYS OPTION SWITCHES 138 3 1 General 138 3 2 Chilled Liquid Temps key 138 3 3 System Data Keys 139 3 4 Ambient Temp Key 139 3 5 Motor...

Page 7: ...0 TABLE 13 ISN Transmitted Data 180 TABLE 14 ISN Operational and Fault Codes 183 SECTION 9 MAINTENANCE GENERAL REQUIREMENTS 184 CONDENSER COILS 184 Chiller Compressor Operating Log 185 Scheduled Maint...

Page 8: ...UTOUT 135 FIG 52 ENLARGED PHOTOGRAPH OF DIP SWITCHES ON MICROPROCESSOR BOARD 141 FIG 53 ELECTRONIC EXPANSION VALVE 166 FIG 54 CONDENSER FAN LAYOUT FOR DXST 2 COMPRESSOR UNITS 171 FIG 1 COMPONENT LOCAT...

Page 9: ...dence that the failure has occurred within the warranty period and that the unit has been operated within the designed parameters specified All warranty claims must specify the unit model serial numbe...

Page 10: ...than those specified in these instructions Any use of the equipment other than its intended use or operation of the equipment contrary to the relevant procedures may result in injury to the operator o...

Page 11: ...toxic non flammable and non corrosive and pose no special safety hazards Use of gloves and safety glasses are however recommended when working on the unit The build up of refrigerant vapor from a lea...

Page 12: ...t non metallic conduit General Description TheAir Cooled Screw Chiller utilizes many components which are the same or nearly the same as a standard reciprocating chiller of a similar size This include...

Page 13: ...rom the refrigerant using an external oil separator The pressurized oil from the oil separator is then cooled in the condenser coils and piped back to the compressor for lubrication The compressor des...

Page 14: ...e between the discharge pressure and the reduced pressure at the suc tion end of the rotors This lubricates the rotors as well as provides an oil seal against leakage around the rotors to assure refri...

Page 15: ...stored in lithium battery backed memory Motor Current Protection The microprocessor motor protection provides high current protection to assure that the motor is not damaged due to voltage excess ref...

Page 16: ...the low motor current and shuts the system down The micro will try two more starts before locking the system out The system locks out because the motor protector is a manual reset device After the fi...

Page 17: ...t The Operating Current is given by 0 65 X factory overload current setting An unloaded compressor condition occurs when any measured half line current is less than the Operating Current A current imb...

Page 18: ...Settings on MP 128 64 32 16 8 4 2 1 0295 50 79 1 107 0 1 1 0 1 0 1 1 0335 Sys 1 50 115 1 155 1 0 0 1 1 0 1 1 0335 Sys 2 50 79 1 107 0 1 1 0 1 0 1 1 0375 50 115 1 155 1 0 0 1 1 0 1 1 0425 50 106 1 143...

Page 19: ...on MP 128 64 32 16 8 4 2 1 0295 50 79 2 107 0 1 1 0 1 0 1 1 0335 Sys 1 50 115 2 155 1 0 0 1 1 0 1 1 0335 Sys 2 50 79 2 107 0 1 1 0 1 0 1 1 0375 50 115 2 155 1 0 0 1 1 0 1 1 0425 50 106 2 143 1 0 0 0...

Page 20: ...ition 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 o...

Page 21: ...uminum fins cop per tubes and galvanized steel supports for generally adequate corrosion resistance However these materials are not adequate for all environments Entry Used to confirm Set Point change...

Page 22: ...itch 150 PSIG 10 bar DWP 20 F to 250 F 29 C to 121 C with 1 NPT IPS connection for upright mounting in horizontal pipe A flow switch must be field installed with each unit Optional 300 PSIG switch ava...

Page 23: ...fset Current Reset Offset Both Temp and Current Reset Offset Special BAS Reset Offset Required English LCD Keypad Display std Spanish LCD Keypad Display French LCD Keypad Display German LCD Keypad Dis...

Page 24: ...und Fans Low Sound Fans High Static Fans Special Sound Fans No Final Overspray Paint Required Final Overspray Paint Special Overspray Paint Required No Vibration Isolators 1 Vibration Isolators Seismi...

Page 25: ...be steam cleaned It is recommended that the unit is periodically in spected during storage INSPECTION Remove any transit packing and inspect the unit to en sure that all components have been delivered...

Page 26: ...26 YORK INTERNATIONAL FORM 201 19 NM7 804 88 2250mm UNIT RIGGING CORRECT WRONG LD03514 FIG 3 UNIT RIGGING CORRECT WRONG LD03515 FIG 4 LIFTING LUGS CORRECT WRONG Handling and Storage...

Page 27: ...st be at least 4 3 4 120 mm wide at the contact points This will allow vibration isolators to be fitted if required Any ductwork or attenuators fitted to the unit must not have a total static pressure...

Page 28: ...r from the base rails DO NOT remove the four 3 8 bolts 3 mounting the corner brackets 2 to the frame rails 1 2 2 COMPRESSOR CHANNEL BASE BASE SUPPORT RAIL 3 3 LD09131 FIG 5 COMPRESSOR MOUNTING Where a...

Page 29: ...ust not be exceeded at any time Refer to the Technical Data Section for details The liquid must enter the evaporator at the inlet connection The inlet con nection for the evaporator is at the far end...

Page 30: ...der the insulation is recommended supplied inde pendently and controlled by an ambient temperature thermostat set to switch on at 37 F 21 C above the freezing temperature of the liquid The liquid circ...

Page 31: ...sure that the outlet of relief valves vent pipe remain clear of obstructions at all times DUCTWORK CONNECTION General Requirements The following ductwork recommendations are intended to ensure satisfa...

Page 32: ...install overcurrent protection devices between the supply conductors and the power supply terminals on the unit To ensure that no eddy currents are set up in the power panel the cables forming each 3...

Page 33: ...ee Section 8 1 15 Run Contact Terminals 29 and 30 Figs 13 and 14 pages 38 and 39 close to indicate that a system is running Alarm Contacts Each system has a voltage free change over contact which will...

Page 34: ...ATIONAL FORM 201 19 NM7 804 POWER PANEL LAYOUTS TYPICAL FIG 9 POWER PANEL SECTION 028972 G Installation WYE DELTA TYPICAL ACROSS THE LINE TYPICAL 028973 G OPTIONAL DISCONNECT SWITCH OPTIONAL CIRCUIT B...

Page 35: ...35 YORK INTERNATIONAL FORM 201 19 NM7 804 4 FIG 10 OPTION PANEL SECTION OPTION PANEL LAYOUT TYPICAL 00246VIP LOGIC PANEL OPTION PANEL WITH SINGLE POINT TERMINAL BLOCK OPTIONAL...

Page 36: ...TION FIG 11 LOGIC SECTION LAYOUT LOGIC SECTION LAYOUT 028975 G ITEM 1 2 3 4 5 6 7 8 DESCRIPTION Microprocessor Board Back of Display I O Expansion Board 1 Power Supply Board Relay Output Board 1 Relay...

Page 37: ...37 YORK INTERNATIONAL FORM 201 19 NM7 804 4 FIG 12 LOGIC SECTION LAYOUT WITH CONTROL PANEL LOGIC SECTION LAYOUT WITH CONTROL PANEL 028976 G...

Page 38: ...OINTS FOR EMERGENCY STOPS TERMINALS 13 34 028977 G Print Temperature PWM Current PWM Flow Switch System No 1 Run System No 2 Run 14 15 16 17 18 19 23 24 25 26 27 28 29 30 System No 1 Alarm Contacts Ch...

Page 39: ...4 FIG 14 CUSTOMER CONNECTIONS CUSTOMER CONNECTIONS 2028978 G CIRCUIT BREAKERS CB1 CB2 CB3 CUSTOMER CONNECTIONS FLOW SWITCH ALARM RUN ETC 115 VAC SUPPLY MICROPROCESSOR CIRCUIT BOARD RELAY BOARDS I O EX...

Page 40: ...xternal to the panel It is important to check that the correct primary tapping has been used With the supply voltage to the unit turned off remove the lid to the transformer box COMMISSIONING PREPARAT...

Page 41: ...itted in the customer s pipework on the evaporator outlet and wired into the control panel correctly using shielded cable There should be a straight run of at least 5 pipe diameters on either side of...

Page 42: ...a full charge of refrig erant is in the system the bubbles will disappear and be replaced by a solid column of liquid Fan Rotation As discharge pressure rises the condenser fans operate in stages to c...

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Page 44: ...rations 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 temperature and rate of temp...

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Page 46: ...ATE AND PRESSURE DROP CHART Excessive flow above the max GPM will damage the evaporator GLYCOL CORRECTION FACTORS Technical Data MODEL NUMBER YCAS EVAPORATOR 0295 0335 0375 C1 0425 0475 0515 0575 0605...

Page 47: ...pplication guidelines 3 The evaporator is protected against freeze up to 28 8 C with an electrical heater as standard MODEL NUMBER YCAS LEAVING WATER TEMPERATURE C COOLER FLOW L S 3 AIR ON CONDENSER C...

Page 48: ...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 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 15 8 15 8 15 8 Fan Diameter mm 900 900 900...

Page 49: ...PRESSURE BAR 10 REFRIGERANT SIDE PRESSURE BAR 20 EVAPORATOR FLOW MODEL LITERS SECOND YCAS MIN MAX 0295EB 6 9 25 4 0335EB 7 7 25 4 0375EB 8 6 25 4 0425EB 9 5 37 9 0475EB 10 6 42 3 0515EB 11 7 46 9 055...

Page 50: ...OPTIONAL CONTROL TRANSFORMER FITTED OPTIONAL CONTROL TRANSFORMER SEE NOTE 3 SEE NOTE 3 Optional Circuit Breakers are REQUIRED for units with CE mark See page 58 for Electrical Data Notes Model Volts M...

Page 51: ...4 300 79 183 552 3 4 8 23 0 0335EB 380 114 150 150 175 2 4 0 4 300 4 300 79 183 552 3 4 8 23 0 0375EB 380 159 150 200 250 2 300 4 300 6 350 115 217 690 3 4 8 23 0 0425EB 380 152 150 200 250 2 300 6 3...

Page 52: ...he chiller Field connections to Factory Provided Terminal Block standard or Non Fused Disconnect option Individual System Circuit Breakers in each Motor Control Center10 LD05549 See page 58 for Electr...

Page 53: ...EB 115 0 217 0 690 0 3 4 8 23 0 79 0 183 0 552 0 3 4 8 23 0 0375EB 115 0 217 0 690 0 3 4 8 23 0 115 0 217 0 690 0 3 4 8 23 0 0425EB 106 0 217 0 690 0 4 4 8 23 0 106 0 217 0 690 0 4 4 8 23 0 0475EB 148...

Page 54: ...ernal Branch Circuit Protection Breakers per Motor Control Center10 See page 62 for Electrical Data footnotes See page 58 for notes Technical Data LD05550 Option NOT available for units with CE mark S...

Page 55: ...95EB 79 552 3 4 8 23 0 79 552 3 4 8 23 0 0335EB 115 690 3 4 8 23 0 79 552 3 4 8 23 0 0375EB 115 690 3 4 8 23 0 115 690 3 4 8 23 0 0425EB 106 690 4 4 8 23 0 106 690 4 4 8 23 0 0475EB 148 857 4 4 8 23 0...

Page 56: ...Field wiring must also comply with local codes See page 58 for notes Technical Data LD05551 CHILLER FIELD SUPPLIED WIRING SYSTEM 1 SYSTEM 2 MODEL MRA1 FACTORY SUPPLIED BREAKER COMPRESSOR FANS 11 12 CO...

Page 57: ...E 50 50 50 MAX kW 113 113 80 MAX AMPS 193 193 135 7 CONTROL POWER SUPPLY UNITS WITHOUT STANDARD CONTROL CIRCUIT TRANSFORMERS NO OF CONTROL MCA MAX DUAL NON FUSED COMPRESSORS POWER MAX LOAD ELEMENT DIS...

Page 58: ...0 of rated load amps included in the circuit Minimum circuit breaker rating 1 5 x largest compressor RLA other compressor RLAs fans x each fan motor FLA 6 Maximum circuit breaker is based on 225 maxim...

Page 59: ...59 YORK INTERNATIONAL FORM 201 19 NM7 804 This page intentionally left blank 7...

Page 60: ...o refer to cautions on page 63 5 To stop unit Emergency Stop with contacts other than those shown install the stop contact between 5 and 1 If a stop device is not installed a jumper must be connected...

Page 61: ...61 YORK INTERNATIONAL FORM 201 19 NM7 804 LD09233 WIRING DIAGRAM ACROSS THE LINE START FIG 18 WIRING DIAGRAM ACROSS THE LINE START 7 035 15164 103 Rev F...

Page 62: ...62 YORK INTERNATIONAL FORM 201 19 NM7 804 Technical Data ELEMENTARY DIAGRAM FIG 19 ELEMENTARY DIAGRAM ACROSS THE LINE START LD09234...

Page 63: ...the flow switch for start stop into the Alarm circuitry or pilot relays for pump starters wired through motor contactor auxiliary con tacts must be suppressed with YORK P N 031 00808 000 suppressor ac...

Page 64: ...a cycling device in series with the flow switch FSLW See Note 3 for contact rating and wiring specifications Also refer to cautions on page 67 5 To stop unit Emergency Stop with contacts other than th...

Page 65: ...65 YORK INTERNATIONAL FORM 201 19 NM7 804 WIRING DIAGRAM WYE DELTA START FIG 21 ELEMENTARY DIAGRAM WYE DELTA START 7 LD09236...

Page 66: ...66 YORK INTERNATIONAL FORM 201 19 NM7 804 Technical Data ELEMENTARY DIAGRAM FIG 22 ELEMENTARY DIAGRAM WYE DELTA START LD09234...

Page 67: ...flow switch for start stop into the Alarm circuitry or pilot relays for pump starters wired through motor contactor auxiliary con tacts must be suppressed with YORK P N 031 00808 000 suppressor acros...

Page 68: ...68 YORK INTERNATIONAL FORM 201 19 NM7 804 Technical Data FIG 23 POWER PANEL SYSTEM 1 COMPONENT LOCATIONS LD09238 035 18672 104 Rev E...

Page 69: ...69 YORK INTERNATIONAL FORM 201 19 NM7 804 LD010026 FIG 24 CONTROL PANEL COMPONENT LOCATION 7 035 18672 104 Rev E...

Page 70: ...70 YORK INTERNATIONAL FORM 201 19 NM7 804 Technical Data FIG 25 POWER PANEL SYSTEM 2 COMPONENT LOCATIONS LD09240 035 18672 104 Rev E...

Page 71: ...71 YORK INTERNATIONAL FORM 201 19 NM7 804 7 LEGEND LD09241 YCAS0295 YCAS0605...

Page 72: ...72 YORK INTERNATIONAL FORM 201 19 NM7 804 Technical Data LD03282 LD03283 LD03284 035 15164 102 Rev E...

Page 73: ...73 YORK INTERNATIONAL FORM 201 19 NM7 804 7 CONNECTION DIAGRAM SYSTEM WIRING LD010030...

Page 74: ...74 YORK INTERNATIONAL FORM 201 19 NM7 804 Technical Data COMPRESSOR TERMINAL BOX LD10029...

Page 75: ...75 YORK INTERNATIONAL FORM 201 19 NM7 804 7 LD10028 ELEMENTARY DIAGRAM STARTER CONTROL CIRCUIT 035 15164 102 Rev E...

Page 76: ...76 YORK INTERNATIONAL FORM 201 19 NM7 804 Technical Data 3 4 5 6 3 4 5 6 7 8 5 6 3 4 7 8 9 10 LD06840 ELEMENTARY DIAGRAM 035 15164 102 Rev E...

Page 77: ...77 YORK INTERNATIONAL FORM 201 19 NM7 804 7 This page intentionally left blank...

Page 78: ...w patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must consider potential performance...

Page 79: ...IMENSIONS YCAS0295 YCAS0375 7 LD05829A LD05828A 648 648 CENTER OF GRAVITY Alum YCAS X Y Z 0295 1945 1144 987 0335 1974 1145 975 0375 1964 1153 969 CENTER OF GRAVITY Copper YCAS X Y Z 0295 1955 1142 10...

Page 80: ...clearances indicated below resulting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout how...

Page 81: ...05832a LD05833a CENTER OF GRAVITY Alum YCAS X Y Z 0425 2694 1090 937 0475 2704 1088 930 0515 2700 1091 929 0555 2703 1094 926 0575 2698 1097 923 CENTER OF GRAVITY Copper YCAS X Y Z 0425 2732 1092 974...

Page 82: ...lting in unpredictable air ow patterns and possible diminished performance YORK s unit controls will optimize operation without nuisance high pressure safety cutout however the system designer must co...

Page 83: ...83 YORK INTERNATIONAL FORM 201 19 NM7 804 DIMENSIONS YCAS0605 LD05840a LD05841a CENTER OF GRAVITY Alum YCAS X Y Z 0605 3370 1101 973 CENTER OF GRAVITY Copper YCAS X Y Z 0605 3402 1102 1010...

Page 84: ...804 1 3 m 2 m 2 m 2 m TECHNICAL DATA CLEARANCES NOTES 1 No obstructions allowed above the unit 2 Only one adjacent wall may be higher than the unit 3 Adjacent units should be 10 feet 3 meters apart LD...

Page 85: ...06 4 349 YCAS0335 975 777 579 929 740 552 4 551 YCAS0375 1 017 803 590 955 755 554 4 674 YCAS0425 828 758 689 619 870 797 723 650 5 933 YCAS0475 831 765 699 632 877 807 737 667 6 015 YCAS0515 847 778...

Page 86: ...74 18 7 White CP 2 35 3 000 1 360 8 0 70 17 7 Gold FIG 30 CP 2 XX ISOLATOR DETAILS LD01089 ALUMINUM FINS 1 ISOLATOR SELECTIONS VMC TYPE CP 2 XX MODEL A B C D E F G H YCAS0295 2 31 2 28 2 27 2 31 2 28...

Page 87: ...2 2 51 AWMR 1 552 1 900 861 8 2 51 AWMR 1 553 2 200 997 9 2 51 AWMR 2 520 1 300 589 7 2 51 AWMR 2 521 1 552 704 0 2 51 AWMR 2 53 2 000 907 2 2 51 AWMR 1 530 2 300 1 043 3 2 51 AWMR 2 531 2 552 1 157...

Page 88: ...GREEN 3 000 1 362 0 GRAY 4 000 1 816 0 TYPE L W H HD A B C D E R 3 5 1 2 3 3 8 1 3 4 2 7 8 2 1 2 1 2 4 1 8 9 16 1 4 OR 139 7 85 8 44 4 73 2 63 5 12 7 104 8 14 4 6 3 RD 3 R 4 6 1 4 4 5 8 1 5 8 2 3 4 3...

Page 89: ...7 YCAS0335 1 054 845 636 1 008 808 608 4 960 YCAS0375 1 096 871 647 1 034 823 611 5 083 YCAS0425 884 824 765 706 924 862 800 738 6 505 YCAS0475 887 831 775 719 932 873 814 755 6 587 YCAS0515 903 844 7...

Page 90: ...2 600 1179 3 0 74 18 7 White CP 2 35 3 000 1360 8 0 70 17 7 Gold ISOLATOR DETAILS LD01089 1 ISOLATOR SELECTIONS VMC TYPE CP 2 XX MODEL A B C D E F G H YCAS0295 2 32 2 31 2 27 2 32 2 31 2 27 YCAS0335...

Page 91: ...1 552 1 900 861 8 2 51 AWMR 1 553 2 200 997 9 2 51 AWMR 2 520 1 300 589 7 2 51 AWMR 2 521 1 552 704 0 2 51 AWMR 2 53 2 000 907 2 2 51 AWMR 1 530 2 300 1 043 3 2 51 AWMR 2 531 2 552 1 157 6 2 51 AWMR 2...

Page 92: ...ESIGN FOR TYPE RD 4 NEOPRENE MOUNTINGS TYPE RD 3 LD04033 29518A 29517A TYPE L W H HD A B C D E R 3 5 1 2 3 3 8 1 3 4 2 7 8 2 1 2 1 2 4 1 8 9 16 1 4 OR 139 7 85 8 44 4 73 2 63 5 12 7 104 8 14 4 6 3 RD...

Page 93: ...YCAS0335 1 054 845 636 1 008 808 608 4 960 YCAS0375 1 096 871 647 1 034 823 611 5 083 YCAS0425 884 824 765 706 924 862 800 738 6 505 YCAS0475 887 831 775 719 932 873 814 755 6 587 YCAS0515 903 844 785...

Page 94: ...0 1179 3 0 74 18 7 White CP 2 35 3 000 1360 8 0 70 17 7 Gold FIG 34 CP 2 XX ISOLATOR DETAILS LD01089 1 ISOLATOR SELECTIONS VMC TYPE CP 2 XX MODEL A B C D E F G H YCAS0295 2 32 2 31 2 27 2 32 2 31 2 27...

Page 95: ...1 500 680 4 2 51 AWMR 1 551 1 676 760 2 2 51 AWMR 1 552 1 900 861 8 2 51 AWMR 1 553 2 200 997 9 2 51 AWMR 2 520 1 300 589 7 2 51 AWMR 2 521 1 552 704 0 2 51 AWMR 2 53 2 000 907 2 2 51 AWMR 1 530 2 300...

Page 96: ...vertical motion NEW DESIGN FOR TYPE RD 4 NEOPRENE MOUNTINGS TYPE RD 3 LD04033 29518A 29517A TYPE L W H HD A B C D E R 3 5 1 2 3 3 8 1 3 4 2 7 8 2 1 2 1 2 4 1 8 9 16 1 4 OR 139 7 85 8 44 4 73 2 63 5 12...

Page 97: ...A B C D E F G H Total YCAS0295 1 115 896 677 1 073 862 651 5 274 YCAS0335 1 137 931 726 1 092 894 697 5 477 YCAS0375 1 178 958 737 1 119 909 699 5 600 YCAS0425 915 889 864 838 953 926 899 873 7 158 YC...

Page 98: ...y CP 2 32 2 600 1179 3 0 74 18 7 White CP 2 35 3 000 1360 8 0 70 17 7 Gold ISOLATOR DETAILS LD01089 1 ISOLATOR SELECTIONS VMC TYPE CP 2 XX MODEL A B C D E F G H YCAS0295 2 32 2 31 2 28 2 32 2 31 2 28...

Page 99: ...200 997 9 2 51 AWMR 2 520 1 300 589 7 2 51 AWMR 2 521 1 552 704 0 2 51 AWMR 2 53 2 000 907 2 2 51 AWMR 1 530 2 300 1043 3 2 51 AWMR 2 531 2 552 1157 6 2 51 AWMR 2 532 3 000 1360 8 2 51 DIMENSIONS In...

Page 100: ...tion NEW DESIGN FOR TYPE RD 4 NEOPRENE MOUNTINGS TYPE RD 3 LD04033 29518A 29517A TYPE L W H HD A B C D E R 3 5 1 2 3 3 8 1 3 4 2 7 8 2 1 2 1 2 4 1 8 9 16 1 4 OR 139 7 85 8 44 4 73 2 63 5 12 7 104 8 14...

Page 101: ...e height of the isolator To use the isolator as blocking for the equipment insert a 1 4 shim between the upper load plate and vertical uprights Lower the equipment on the blocking or shimmed isolators...

Page 102: ...Asmall percentage of the of the liquid passes through an expansion valve into the other side of the economizer where it is evaporated This low pressure liquid subcools the major part of the refrigeran...

Page 103: ...LVE THERMOSTATIC SOLENOID 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 PRESSUR...

Page 104: ...ATURE 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 SE...

Page 105: ...HEATER ECONOMIZER GAS IN DISCHARGE CASE OIL INLET FROM CONDENSER COOLING COIL DISCHARGE GAS OUT OIL FILTER BLEED EVACUATION POINT OIL FILTER COVER PLATE CAPACITY CONTROL SOLENOID CAPACITY CONTROL 3 W...

Page 106: ...106 YORK INTERNATIONAL FORM 201 19 NM7 804 COMPRESSOR COMPONENTS CONT D FIG 42 COMPRESSOR COMPONENTS LD03669 Technical Data...

Page 107: ...107 YORK INTERNATIONAL FORM 201 19 NM7 804 COMPRESSOR COMPONENTS CONT D FIG 43 COMPRESSOR COMPONENTS LD03670 7...

Page 108: ...108 YORK INTERNATIONAL FORM 201 19 NM7 804 COMPRESSOR COMPONENTS CONT D FIG 44 COMPRESSOR COMPONENTS Technical Data LD06079 MALE ROTOR RELIEF VALVE DISCHARGE CHECK VALVE OIL FILTER OIL FILTER O RING...

Page 109: ...RUST 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...

Page 110: ...804 COMPRESSOR COMPONENTS CONT D FIG 46 COMPRESSOR COMPONENTS O RING MOTOR ROTOR MALE ROTOR LOCKING KEY MALE ROTOR FEMALE ROTOR O RING RELIEF VALVE ECONOMIZER PLUG SUPPORT RINGS LD03672 SLIDE VALVE RE...

Page 111: ..._________________________ LOCATION _______________________________ SOLD BY ________________________________ INSTALLING CONTRACTOR ___________________________ START UP TECHNICIAN COMPANY ______________...

Page 112: ...R407C Chiller Type ________________________ Unit Type _______________________________ 16 Assure that the Flow Switch is properly in stalled wired correctly and working 17 Assure bolts through compres...

Page 113: ...ure and subcooling below SYS 1 SYS 2 Liq Line Press PSIG kPa Temp F C Liq Line Temp F C Subcooling F C Heat Recovery ___________________________ Sys 1 100 FLA ____________________ Amps Sys 2 100 FLA _...

Page 114: ...tion and motor cooling Correct superheat setting is approx 10 12 F 6 7 C The superheat is calculated as the difference between the pressure at the Economizer Service Valve on the compressor converted...

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Page 116: ...om recent safety shutdowns ON OFF ROCKER SWITCH This switch shuts down the entire chiller when placed in the OFF position The switch must be ON for the chiller to operate The systems will not pump dow...

Page 117: ...l refrigerant systems are provided on the Mi croprocessor Board External interface is available for control of the chiller via a YORK ISN System or YORK Remote Control Center In addition EMS BAS Syste...

Page 118: ...iod regardless of the time involved The battery is a 10 year lithium type but life will depend upon whether the Real Time Clock s internal clock circuit is energized With the clock OFF a rated life of...

Page 119: ...wer only High voltage cir cuitry will still be energized from the high voltage supply REMOVING 115VAC power to CB3 or opening CB3 removes power from the evaporator heaters This could cause evaporator...

Page 120: ...path from the Relay Output Board to the motor contactor is broken by the Motor Protection Module contacts it will lock the system out after 3 faults The Motor Protection Module must then be reset by...

Page 121: ...HA _ _ _ WHEN IDLE AND FLASHING CIRCLE WHEN SYSTEM IS RUNNING ON NUMERICAL VALUES 29121A TOP VIEW TOP VIEW 29121A INTEGRAL C T S 3 SWITCH PUSHED TO LEFT INDICATES ON SWITCHES PLACED IN THE ON POSITION...

Page 122: ...input is used for purposes of demand limit and operates as follows Closing the input contact for a defined period of time allows reset of the Current Limit downward Contact closure of 1 11 seconds wil...

Page 123: ...eset Temp 4 sec 1 sec X 40 F 10 sec Reset Temp 120 Fsec 10 sec 12 F 6 C To determine the new setpoint add the reset to the setpoint programmed into memory In the example above if the programmed setpoi...

Page 124: ...sable Jump Contact Real Time Clock and Battery Backup I C Microprocessor I C label shows version NOTE Dimple is positioned at top edge 3A Dip Switch Set 8 switches System Switches S2 System 1 S3 Syste...

Page 125: ...IC SECTION LAYOUT 028980 G 1 2 5 6 4 3 7 8 LOGIC SECTION ITEM 1 2 3 4 5 6 7 8 DESCRIPTION Microprocessor Board Back of Keypad I O Expansion Board 1 Power Supply Board Relay Output Board 1 Relay Output...

Page 126: ...until 30 seconds has elapsed after power re application or 30 seconds have elapsed between a Daily Schedule shutdown and restart If the Daily Schedule is not used On Off times equal 00 00 the contacts...

Page 127: ...iller If the alarm circuit is applied in an application used for critical duty such as process duty or cooling other crit ical equipment and the alarm circuit should fail to function YORK will not be...

Page 128: ...itional 20 F to 25 F 11 1 C to 13 8 C often making the total subcooling at the TXV over 40 F 4 4 C This should not be confused with subcooling at the liquid valve which should generally be 12 Fto 15 F...

Page 129: ...129 YORK INTERNATIONAL FORM 201 19 NM7 804 PROCESS AND INSTRUMENTATION DIAGRAM FIG 50 PROCESS AND INSTRUMENTATION DIAGRAM LD03486 8 ECONOMIZER HX...

Page 130: ...hese messages are described in detail below with ex amples of each display In each example is used as applicable to represent the system number where mes sages apply to individual systems 2 2 GENERAL...

Page 131: ...rature is below the point where the microprocessor will bring the lead system on and or that the loading sequence has not loaded the chiller far enough to bring the lag system on The lag system will d...

Page 132: ...charge pressure nears the point at which the high pressure cutout would shut the system down When the above message appears discharge pressure has exceeded the programmable threshold and the compresso...

Page 133: ...START ON POWER FAILURE is enabled Otherwise the chiller must be manually reset See Section 8 2 page 164 2 5 UNIT FAULT STATUS MESSAGES A Unit Fault will shut the entire chiller down when a preset saf...

Page 134: ...nitored to check that flow is present in the evaporator when a compressor is running Any external cycling devices fitted by the customer are connected in series with the flow switch YCAS 2 System chil...

Page 135: ...not be picked up by the High Oil Differential Safety since no flow will cause the dif ferential through the oil piping to drop to zero During normal operation differential oil pressure must be greater...

Page 136: ...when the pilot solenoid is closed 10 times in 2 minutes due to low superheat S Y S H I G H M T R C U R R S Y S H I G H M T R C U R R The High Motor Current Safety protects against exces sively high m...

Page 137: ...after 4 seconds of compressor operation From this time the system will be shut down if average motor current is less than 10 of FLA Compressor Motor Protection Modules and Me chanical High Pressure Cu...

Page 138: ...required data about the operation of the chiller This is particularly useful during commissioning mon itoring the operation of the chiller diagnosing potential future problems and service troubleshoot...

Page 139: ...E M P 2 8 2 F S Y S O I L 1 7 6 P S I G S P 6 4 D P 1 9 5 P S I G S Y S O I L 1 5 7 4 F S T 3 1 0 D T 1 2 3 2 F S S A T S U C T 3 2 9 F S U C T S H E A T 1 5 0 F SlidevalvepositionisAPPROXIMATE and sh...

Page 140: ...to programstheLowAmbient Cutout setting at 25 F 4 C and is not adjustable S 1 2 A M B I E N T C O N T R O L S T A N D A R D 3 5 MOTOR CURRENT KEY Pressing the Motor Current key displays compressor cur...

Page 141: ...TION Incorrect programming may cause damage to the chiller Closed Place the switch in the CLOSED position selects the type of chiller as an air cooled chiller YCAS The switch MUST always be in the CLO...

Page 142: ...le gives a summary of Modes dis played messages which can be selected using the Open and Closed positions for each of the eight SW1 Dip Switches SWITCH SWITCH OPEN SETTING SWITCH CLOSED SETTING 1 Wate...

Page 143: ...r locally on the panel display or if an optional 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...

Page 144: ...or 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 controlled on ambient temperature as follows...

Page 145: ...by pressing the Operating Data key with an optional printer attached In this case an example is shown for a YCAS 2 System Chiller YORK INTERNATIONAL CORPORATION MILLENNIUM SCREW CHILLER UNIT STATUS 2...

Page 146: ...is stored by the microprocessor The information is stored at the instant of the fault regardless of whether the fault caused a lockout to occur This information is not affected by power failures or ma...

Page 147: ...3 9 5 0 P S I G D I S C H A R G E P R E S S U R E U N L O A D 3 7 5 0 P S I G S U C T I O N P R E S S U R E C U T O U T 4 4 0 P S I G S Y S 1 N O F A U L T S S Y S 2 H I G H M T R C U R R S 1 4 Y C A...

Page 148: ...A N G E 2 0 F This message indicates the status of both the evaporator pump signal from the microprocessor and the evapo rator heater This message indicates that a remote device such as a Remote Contr...

Page 149: ...S I G S P 6 2 D P 2 7 1 P S I G S S A T S U C T 3 4 7 F S U C T S H E A T 1 0 5 F S S A T D S C H 1 2 9 F D S C H S H E A T 6 2 8 F S Y S S V S T E P 4 0 S Y S C O O L E R I N L E T R E F R I G T E M...

Page 150: ...D ON CONDENSER FAN STAGE 3 COMPRESSOR HEATER OFF WYE DELTA RELAY ON DAILY SCHEDULE S M T W T F S HOLIDAY MON START 00 00AM STOP 00 00AM TUE START 00 00AM STOP 00 00AM WED START 00 00AM STOP 00 00AM TH...

Page 151: ...e returned The Enter key is also used to scroll through available data when using the Program or Set Schedule Holiday keys 5 4 CANCEL KEY When the Cancel key is pressed the cursor will always return t...

Page 152: ...ller cooling capacity to maintain this temperature within a programmed range The capacity is controlled by switching compressors on or off and by varying a load unload voltage to each compressor slide...

Page 153: ...or is fully loaded A compressor may also be fully unloaded at step 35 and below Keep this potential indicator error in mind when attempting to determine slide valve position versus actual compressor c...

Page 154: ...fault on a Low Water Tem perature cut out under the following conditions a if chilled liquid tem perature falls below the low end of the Control Range CR for more than 37 seconds b if chilled liquid t...

Page 155: ...s to 0 100 1 102 2 104 3 106 4 108 5 115 10 In the case of Saturated suction temperature the unload ing is based on saturated suction temperature dropping below the internally programmed unload thresh...

Page 156: ...period of time and allows reset of the setpoint upward by up to 40 F 22 C above the setpoint pro grammed in memory see Section 1 7 The maximum allowable reset must be programmed into memory and can b...

Page 157: ...isplay 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 t...

Page 158: ...are scrolled through by re petitively pressing the set Schedule Holiday key To re program any of the daily schedules key in the new Start time then if necessary change the associated AM PM by pressin...

Page 159: ...is in 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 following status message will be observed...

Page 160: ...hillers such as YCAS chillers D I S C H A R G E P R E S S U R E C U T O U T 3 9 5 0 P S I G 8 PROGRAM KEY 8 1 GENERAL The Program key is used to program system operating parameters including cutout po...

Page 161: ...tion pressure is monitored as long as the compressor runs For the first 270 seconds of run ning suction pressure can be lower than the programmed cutout but must be greater than This cutout value incr...

Page 162: ...he saturated refrigerant pressure equivalent to 18 F 10 C below the lowest temperature of the pro grammed chilled liquid Control Range Section 6 To program the Suction Pressure Cutout key in the re qu...

Page 163: ...ion the unloading control is disabled After this time if motor current exceeds the programmed limit the SYS X CURR LIMITING message will appear on the display and a 1 second unload pulse will be sent...

Page 164: ...will allow operation of the chiller under most operating conditions This allows quick start up programming for typical chilled water applications To program the default values into memory first press...

Page 165: ...rature Cutout Standard 25 0 F Ambient 3 9 Low 0 F 50 0 F 25 0 F Ambient 17 8 C 10 0 C 3 9 C Leaving Chilled Liquid Temp Cutout Water Cooling 36 0 2 2 Glycol Cooling 8 0 F 36 0 F 36 0 F 13 3 C 2 2 C 2...

Page 166: ...or software The superheat setpoint can be programmed on the control panel The purpose of the EEV is to meter a flow of liquid refrigerant into the evaporator to maintain a superheat FIG 53 ELECTRONIC...

Page 167: ...that the 24VAC heat motor power signal is energized MOP FEATURE The controller also has an MOPfeature Maximum Op erating Pressure that overrides superheat control when the MOP setpoint is exceeded Th...

Page 168: ...This safety will lock out a system the first time and will not allow automatic restart ing Following are the messages for all systems OPERATING DATA DISPLAYS The following display relating to EEVoper...

Page 169: ...EV output will be set to 0 When the expansion valve type is set to electronic by closing DIP switch 7 the EEV controller low superheat safety device low superheat safety and the sensor failure safety...

Page 170: ...out it is possible that the EEV has failed If the small charge in the bulb leaks the valve will not be able to open and the entire EEV must be replaced The system shuts down on Low Superheat Verify th...

Page 171: ...Pressure DP When the DPrises above 230 PSIG fan stage 1 is activated From here subsequent fan stages are activated as the DP rises in increments of 10 20 PSIG The system will remain at the highest fan...

Page 172: ...Sys 2 Outputs are on Relay Output Board 2 TABLE 4 CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS WITH 5 FANS SYSTEM Sys 1 Outputs are on Relay Board 1 At ambients above 85 F Stages 3 4 a...

Page 173: ...r Drop in Unit Type YCAS or YCWS Heat Recovery Unit Enabled or Disabled Sys 1 100 Full Load Amps 75 to 500 Amps Sys 2 100 Full Load Amps 75 to 500 Amps Sys 1 Motor Protector Input 1 0 to 5 0 volts Sys...

Page 174: ...88 2 203 2 82 0555 SYS 2 50 148 2 160 4 44 0575 50 188 2 203 2 82 0605 50 173 2 187 2 60 Indicates one lead phase through motor protector TABLE 7 YCAS STYLE G WYE DELTA START 50 HZ Indicates one lead...

Page 175: ...own below SERVICE MODE OUTPUT ENABLE The Service Mode allows the user to enable and disable the outputs except compressor To enter the Service Mode turn the UNIT switch off and press PROGRAM 9675 ENTE...

Page 176: ...69 25 3 9 1 80 28 2 2 1 93 32 0 0 2 05 36 2 2 2 17 39 3 9 2 30 43 6 1 2 42 46 7 8 2 54 50 10 2 66 68 20 3 22 86 30 3 69 104 40 4 05 TEST POINT Test Point Microboard J11 9 3 8 10 SENSOR CALIBRATION CH...

Page 177: ...ay Board 1 J9 3 TB1 8 Sys 1 Wye Delta Relay Microboard Relay Board 1 J9 4 TB1 7 SPARE Microboard Relay Board 1 J9 5 TB1 6 5 Evaporator Heater Microboard Relay Board 1 J9 6 TB1 4 3 Sys 1 Alarm Microboa...

Page 178: ...board J15 8 Sys 1 Discharge Pressure Transducer Microboard J16 4 Sys 2 Suction Temp Sensor Microboard J16 6 Sys 1 Suction Temp Sensor Microboard J17 9 Input from I O Expansion Board Microboard J17 10...

Page 179: ...board they are on TABLE 11 ANALOG OUTPUTS Microboard J4 1 Unit Switch Microboard J4 2 PWM Current Limit Microboard J4 3 SPARE Flow Switch Euro CAT only Microboard J4 4 PWM Temp Reset Microboard J4 5 S...

Page 180: ...page a zero will be sent Tables 13 and 14 show the data values and page listings for this unit 8 12 ISN CONTROL TABLE 12 ISN RECEIVED DATA ISN CONTROL DATA PAGE P03 SETPOINT P04 ISN Current Limit P05...

Page 181: ...s 1 Heat Recovery Solenoid Status Heat Recovery P44 116 D Sys 1 Wye Delta P45 117 D Sys 2 Spare Sys 2 Discharge Cooling Solenoid Status Euro CAT Low Temp P46 118 D Sys 2 Liquid Line Solenoid Valve Sta...

Page 182: ...out P71 158 161 A High Discharge Pressure Cutout P72 162 165 A Remote Leaving Chilled Liquid Setpoint P73 166 169 A Sys 1 Suction Superheat P74 170 173 A Cooling Range P75 174 177 A Sys 1 Discharge Su...

Page 183: ...rning 11 Anti Recycle Timer Active 11 High Oil Temperature 12 Manual Override 12 High Discharge Temperature 13 Suction Limiting 13 Improper Phase Rotation 14 Discharge Limiting 14 Low Motor Current MP...

Page 184: ...ifications or ancillary equipment as applicable The Safety Section of this manual should be read carefully before at tempting any maintenance operations on the unit Daily Weekly Maintenance The follow...

Page 185: ...ry between each minor and major service can vary depending on for instance application site conditions and expected operating schedule Normally a minor service should be carried out every three to six...

Page 186: ...re Suction Temperature Suction Superheat Discharge Pressure Actual Discharge Temperature Oil Pressure Oil Temperature FLA Motor Oil Level example Oil Added gallons or liters Inlet Temperature Outlet T...

Page 187: ...ooling1 X Check compressor and evaporator 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 o...

Page 188: ...condition of oil Check discharge superheat Evaporator Check water ow Check water pH glycol strength Check water pressure drop Check heater Air cooled condensers Check for air ow obstructions Brush ns...

Page 189: ...les and Service Center for information Please quote the unit model number and serial number When ordering spare parts we will require the following information to ensure the correct parts are supplied...

Page 190: ...layed 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 th...

Page 191: ...OIL PRESS DIFF is displyed High oil differential pressure Ball valve in oil circuit closed Dirty blocked oil lter Check ball valves are open position Check and change oil lter cartridge SYS LOW SUCTI...

Page 192: ...following costs and expenses 1 Labor to remove or reinstall any equipment materials or components 2 Shipping handling or transportation charges 3 Cost of refrigerant No warranty repairs or replacemen...

Page 193: ...9 78 172 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 11...

Page 194: ...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 2004 ALL RIGHTS RESERVED Form 201 19 NM7 804...