Name: York YCAS
Brand: York
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INSTALLATION, OPERATION & MAIN TE NANCE

AIR-COOLED SCREW LIQUID CHILLERS

New Release

Form 201.19-NM6 (804)

YCAS AIR-COOLED LIQUID CHILLERS

YCAS0693EC THROUGH YCAS0953EC (3 COMPRESSOR)

YCAS1063EC THROUGH YCAS1263EC (4 COMPRESSOR)

STYLE G R-22

50 Hz

I/O BOARD #2 EPROM

031-02018-001

MICROPROCESSOR BOARD

031-01798-002

(YCAS 3 SYSTEM EPROMs)

(YCAS 4 SYSTEM EPROMs)

I/O BOARD #2 EPROM

031-02018-001

MICROPROCESSOR BOARD

031-01798-002

035-20884-000

00258VIP

Table of Contents4
Section 1 - General Chiller Information & Safety9
Introduction9
Warranty9
Safety9
Standards for Safety9
Responsibility for Safety10
About this Manual10
Misuse of Equipment10
Suitability for Application10
Structural Support10
Mechanical Strength10
General Access10
Pressure Systems10
Electrical11
Rotating Parts11
Sharp Edges11
Refrigerants and Oils11
High Temperature and Pressure Cleaning11
Emergency Shutdown11
Section 2 - Product Description12
Introduction12
General Description12
Compressor12
Fig. 1 - Component Locations12
Evaporator13
Condenser13
Fig. 2 - Screw Compressor13
Economizer14
Oil Separator/System14
Capacity Control15
Power and Control Panel15
Microprocessor Controls15
Motor Current Protection15
Motor Protection Modules (2ACE)16
Current Overload16
Thermal Overload17
Current Imbalance (Loaded & Unloaded)17
Loss of Phase17
Improper Phase Sequence17
Table 1 - Motor Protector Dip Switch Setting18
Motor Starting20
Keypad Controls20
Display20
Program21
Accessories and Options21
Multiple Point Power Connection21
Single-Point Power Connection with Individual Circuit Protection21
Control Circuit Terminal Block21
Building Automation System (BAS) Interface21
Condenser Coil Protection21
DX Evaporator and Starter Options22
Unit Enclosure Options22
Fan Options22
Sound Reduction Options22
Vibration Isolation22
Unit Nomenclature23
Nameplate Engineering Data23
Product Identification Number (Pin)24
Delivery and Storage25
Section 3 - Handling and Storage25
Inspection25
Moving the Chiller25
Lifting Weights25
Unit Rigging26
Fig. 3 - Unit Rigging26
Fig. 4 - Lifting Lugs26
Location Requirements27
Outdoor Installations27
Section 4 - Installation27
Indoor Installations27
Location Clearances27
Compressor Feet Bolt Removal28
Fig. 5 - Compressor Mounting28
Vibration Isolators29
Installation29
Shipping Braces29
Pipework Connection29
General Requirements29
Water Treatment30
Fig. 6 - Pipework Arrangement30
Pipework Arrangement31
Connection Types & Sizes31
Evaporator Connections31
Option Flanges31
Refrigerant Relief Valve Piping31
Ductwork Connection31
General Requirements31
Fig. 7 - Victaulic Groove31
Fig. 8 - Flange Attachments31
Electrical Connection32
Power Wiring32
Standard Units with Multi Point Power Supply Wiring32
Units with Single-Point Power Supply Wiring32
115Vac Control Supply Transformer32
Remote Emergency Stop Device33
Control Panel Wiring33
Volts Free Contacts33
Chilled Liquid Pump Starter33
Run Contact33
Alarm Contacts33
System Inputs33
Flow Switch33
Remote Run / Stop33
Remote Print33
Fig. 9 - Power Panel Section34
Fig. 10 - Option Panel Section35
Fig. 11 - Logic Section Layout36
Fig. 12 - Logic Section Layout with37
Fig. 13 - Customer Connections38
Fig. 14 - Customer Connections38
Section 5 - Commissioning40
Preparation40
Preparation - Power off40
Inspection40
Refrigerant Charge40
Valves40
Compressor Oil40
Fans40
Isolation/Protection40
Control Panel40
Switch Settings41
Compressor Heaters41
Water System41
Flow Switch41
Temperature Sensor(S)41
Control Supply41
Programmed Options41
Programmed Settings41
Date and Time41
Start/Stop Schedule41
First Time Start-Up42
Interlocks42
System Switches42
Start-Up42
Oil Pressure42
Refrigerant Flow42
Fan Rotation42
Suction Superheat42
Expansion Valve42
Economizer Superheat42
Section 6 - Operation44
General Description44
Start-Up44
Normal Running and Cycling44
Shutdown44
Flow Rate and Pressure Drop Charts46
Glycol Correction46
Glycol Correction Factors46
Section 7 - Technical Data46
Evaporator Water Pressure Drop46
Fig. 15 - Flow Rate and Pressure Drop46
Fig. 16 - Glycol Correction Factors46
Physical Data - Ycas R-22 (si Units)48
Operating Limitations and Sound Power Data49
Electrical Data50
Multiple Point Power Supply Connection50
Fig. 17 - Multiple Point Power Supply Connection50
Fig. 18 - Multiple Point Power Supply Connection with Individual System Circuit Breakers51
Electrical Data52
Fig. 19 - Optional Single-Point Power Supply Connection with Individual System Circuit Breakers52
Electrical Notes54
Table 2 - Compressor Data55
Elementary Wiring Diagram Ycas0693 - Ycas0953 (3 Compressor)56
Fig. 20 - Elementary Wiring Diagram - Dxst Direct Drive 3 Compressor56
Fig. 21 - Elementary Wiring Diagram - Across-The-Line Start 3 Compressor57
Fig. 22 - Elementary Wiring Diagram - Wye Delta Start 3 Compressor58
Fig. 23 - Control Power Transformer Kit59
Fig. 24 - Elementary Wiring Diagram Dxst Direct Drive Control Circuit60
Connection Diagram Elec. Box Ycas0693 - Ycas095362
Fig. 25 - Connection Diagram 3 Compressor62
Fig. 26 - Connection Diagram 3 Compressor63
Connection Wiring Diagram64
Fig. 27 - Connection Diagram 3 Compressor64
Fig. 28 - Connection Diagram 3 Compressor66
Fig. 29 - Connection Diagram 3 Compressor67
Elementary Diagram Dxst Direct Drive Control Circuit68
Fig. 30 - Elementary Diagram 3 Compressor Dxst Direct Drive Control Circuit68
Elementary Wiring Diagram69
Fig. 31 - Elementary Diagram Dxst Direct Drive - 3 Compressor69
Connection Diagram System Wiring70
Fig. 32 - Connection Diagram System Wiring 3 Compressor70
Fig. 33 - Connection Diagram Ststem Wiring71
Elementary Wiring Diagram Ycas1063 - Ycas1263 (4 Compressor)72
Fig. 34 - Elementary Wiring Diagram - 4 Compressor72
Fig. 35 - Elementary Wiring Diagram - Across-The-Line Start73
Fig. 36 - Elementary Wiring Diagram - Wye Delta74
Fig. 37 - Control Power Transformer Kit75
Fig. 38 - Elementary Wiring Diagram76
Fig. 39 - Connection Diagram 4 Compressor78
Fig. 40 - Connection Diagram 4 Compressor79
Connection Wiring Diagram80
Fig. 41 - Elementary Wiring Diagram80
Fig. 42 - Connection Diagram 4 Compressor82
Fig. 43 - Connection Diagram 4 Compressor83
Fig. 44 - Connection Diagram 4 Compressor84
Elementary Diagram Dxst Direct Drive Control Circuit86
Fig. 45 - Elementary Diagram - Dxst Direct Drive Control Circuit86
Fig. 46 - Elementary Diagram - Dxst Direct Drive Control Circuit87
Connection Diagram System Wiring Standard and Remote Evap Units88
Fig. 47 - Connection Diagram System Wiring88
Fig. 48 - Connection Diagram System Wiring89
Compressor Terminal Box System 1 through 490
Fig. 49 - Compressor Terminal Box90
Dimensions - Ycas0693 - Ycas0773 (Si)92
Fig. 50 - Model Ycas0693 - 0773 Dimensions (Si)92
Dimensions - Ycas0783 - Ycas0953 (Si)94
Fig. 51 - Model Ycas0783 - 0953 Dimensions (Si)94
Dimensions - Ycas1063 (Si)96
Fig. 52 - Model Ycas1063 Dimensions (Si)96
Dimensions - Ycas1093 (Si)98
Fig. 53 - Model Ycas1093 (Si)98
Dimensions - Ycas1163 - Ycas1263 (Si)100
Fig. 54 - Model Ycas1163 - Ycas1263 Dimensions (Si)100
Technical Data102
Fig. 55 - Clearances102
Weight Distribution and Isolator Mounting Positions103
Fig. 56 - Cp-2-XX104
Fig. 57 - Isolator Details105
Fig. 58 - Cp-2-XX108
Fig. 59 - Isolator Details109
Fig. 60 - Cp-2-XX112
Fig. 61 - Isolator Details113
Fig. 62 - Cp-2-XX116
Fig. 63 - Isolator Details117
Installation Instructions for VMC Series Awr/Awmr and Cp Restrained Mountings119
Refrigerant Flow Diagram120
Fig. 64 - Refrigerant Flow Diagram120
Process and Instrumentation Diagram121
Fig. 65 - Process and Instrumentation121
Component Locations - 3 Compressor Units122
Fig. 66 - Component Locations122
Component Locations - 4 Compressor Units123
Compressor Components124
Fig. 67 - Compressor Components124
Fig. 68 - Compressor Components125
Fig. 69 - Compressor Components126
Fig. 70 - Compressor Components127
Fig. 71 - Compressor Components128
Fig. 72 - Compressor Components129
System Startup Checklist130
Unit Checks (no Power)130
Panel Checks131
Switches "Off")131
Programmed Values131
Initial Start-Up132
Checking Subcooling and Superheat132
Checking Economizer Superheat133
Leak Checking133
Section 8 - Micro Panel Contents134
Chiller Control Panel134
Programming and Data Access Keys134
Display and Status Information Keys134
On / off Rocker Switch134
Program & Setup Keys134
Introduction & Physical Description135
1.1 General135
1.2 Keypad & Display135
1.3 Unit (Chiller) on / off Switch136
1.4 Microprocessor Board136
1.5 Ancillary Circuit Boards136
Circuit Breakers137
1.8 Transformers138
Motor Protector Modules138
Fig. 73 - Motor Protection Module139
Ems/Bas Controls140
Microprocessor Board Layout142
Fig. 74 - Component Layout142
Logic Section Layout143
Fig. 75 - Logic Section Layout143
Anti-Recycle Timer144
Anti-Coincidence Timer144
Evaporator Pump Control144
Compressor Heater Control144
Evaporator Heater Control144
Pumpdown (Eev) Control144
Alarms145
Run Status (Chiller)145
Lead / Lag Compressor Selection145
Or 4 Compressor Chiller Configuration146
Economizer Solenoid Control146
Status Key: General Status Messages & Fault Warnings148
General148
General Status Messages148
Unit Warnings149
Anticipation Control Status150
Unit Fault Status Messages151
System Fault (Safety) Status Messages152
Fig. 76 - Suction Pressure Cutout153
Printout on Fault Shutdown155
Display Keys & Option Switches156
General156
Chilled Liquid Temps Key156
System # Data Keys157
Ambient Temp Key157
Motor Current Key158
Operating Hrs / Start Counter Key158
Options Key & Dip Switch Settings158
Fig. 78 - Enlarged Photograph of Dip Switches on Microprocessor Board159
Function Key160
Print Keys161
General161
Oper Data Key161
Operating Data - Software Version163
Operating Data - Remote Printout163
History Key164
Fault History Data - Local Display Messages164
Fault History Data - Remote Printout168
Entry Keys169
General169
Numerical Keypad169
Enter Key169
Cancel Key169
Keys169
Setpoints Keys & Chilled Liquid Control170
6.1 General170
Chilled Liquid Temperature Control170
Local Cooling Setpoints Key174
Remote Cooling Setpoints Key174
Clock Keys175
General175
Set Time Key175
Set Schedule / Holiday Key176
Manual Override Key177
Program Key178
General178
Programming "Default" Values182
Table 3 - Default Values Table183
8.4 Electronic Expansion Valve184
Fig. 79 - Electronic Expansion Valve184
8.5 Eev Operation185
8.6 Eev Programming187
Table 4 - Programmable Values Table (Minimum/Maximum)187
8.7 Eev Troubleshooting188
Compressor Condenser Fan Control189
Table 5 - Condenser Fan Control and Fan Contactor Data for Dxst Units189
Table 8 - Condenser Fan Control and Fan Contactor Data for Dxst Units189
Fig. 80 - Condenser Fan Control Layout for Dxst Compressors Units189
Compressor Condenser Fan Control191
Table 6 - Condenser Fan Control and Fan Contactor Data for Dxst Units191
Table 7 - Condenser Fan Control and Fan Contactor Data for Dxst Units191
Fig. 81 - Condenser Fan Control Layout for Dxst Compressors Units191
Table 9 - Condenser Fan Control and Fan Contactor Data for Dxst Units192
8.10 Service Mode: Unit Setup193
Table 10 - Service Mode Programmable Values193
Table 11 - Ycas Style G, Across the Line Start - 50 Hz194
Table 12 - Ycas Style G, Wye Delta Start - 50 Hz195
8.11 Control Inputs/Outputs197
Table 13 - Digital Outputs197
Table 14 - Analog Inputs198
Table 15 - Digital Inputs199
Table 16 - Analog Outputs199
8.12 Sensor Calibration Charts200
8.13 Isn Control201
Table 17 - Isn Received Data201
Table 18 - Isn Transmitted Data201
Table 19 - Isn Operational and Fault Codes204
Section 9 - Maintenance206
General Requirements206
Condenser Coils206
Chiller / Compressor Operating Log207
Scheduled Maintenance207
On-Board Battery Back-Up207
Overall Unit Inspection207
Compressor Unit Operation208
General Periodic Maintenance Checks Standard Units210
Section 10 - Spare Parts211
Recommended Spares211
Recommended Compressor Oils211
Section 11 - Troubleshooting Guide212
Limited Warranty York Americas Engineered Systems214
Warranty on New Equipment214
Warranty on Reconditioned or Replacement Materials214
Temperature Conversion Chart215
Actual Temperatures215
Temperature Conversion Chart - Differential Temperatures215
Pressure Conversion Chart - Gauge or Differential215

York YCAS User Manual

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Brand	York
Model	YCAS
Category	Chiller
Language	English