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York YCAS Series manuals available for free PDF download: Installation Operation & Maintenance, Wiring Diagram
York YCAS Series Installation Operation & Maintenance (216 pages)
AIR-COOLED SCREW LIQUID CHILLERS
Brand:
York
| Category:
Chiller
| Size: 7.97 MB
Table of Contents
Table of Contents
4
Section 1 - General Chiller Information & Safety
9
Warranty
9
About this Manual
10
Misuse of Equipment
10
Suitability for Application
10
Structural Support
10
Mechanical Strength
10
General Access
10
Pressure Systems
10
Electrical
11
Rotating Parts
11
Sharp Edges
11
Refrigerants and Oils
11
High Temperature and Pressure Cleaning
11
Responsibility for Safety
10
Emergency Shutdown
11
Introduction
9
Safety
9
Standards for Safety
9
Fig. 1 - Component Locations
12
Evaporator
13
Condenser
13
Introduction
12
General Description
12
Compressor
12
Section 2 - Product Description
12
Fig. 2 - Screw Compressor
13
Economizer
14
Oil Separator/System
14
Capacity Control
15
Microprocessor Controls
15
Motor Current Protection
15
Power and Control Panel
15
Current Overload
16
Motor Protection Modules (2ACE)
16
Current Imbalance (Loaded & Unloaded)
17
Improper Phase Sequence
17
Loss of Phase
17
Thermal Overload
17
Table 1 - Motor Protector Dip Switch Setting
18
Keypad Controls
20
Display
20
Program
21
Motor Starting
20
Accessories and Options
21
Multiple Point Power Connection
21
Single-Point Power Connection with Individual Circuit Protection
21
Control Circuit Terminal Block
21
Building Automation System (BAS) Interface
21
Condenser Coil Protection
21
DX Evaporator and Starter Options
22
Fan Options
22
Sound Reduction Options
22
Unit Enclosure Options
22
Vibration Isolation
22
Nameplate Engineering Data
23
Unit Nomenclature
23
Product Identification Number (Pin)
24
Delivery and Storage
25
Inspection
25
Moving the Chiller
25
Lifting Weights
25
Section 3 - Handling and Storage
25
Fig. 3 - Unit Rigging
26
Fig. 4 - Lifting Lugs
26
Unit Rigging
26
Indoor Installations
27
Location Clearances
27
Location Requirements
27
Outdoor Installations
27
Section 4 - Installation
27
Compressor Feet Bolt Removal
28
Fig. 5 - Compressor Mounting
28
Pipework Connection
29
General Requirements
29
Shipping Braces
29
Vibration Isolators
29
Installation
29
Fig. 6 - Pipework Arrangement
30
Water Treatment
30
Connection Types & Sizes
31
Ductwork Connection
31
General Requirements
31
Evaporator Connections
31
Option Flanges
31
Fig. 7 - Victaulic Groove
31
Fig. 8 - Flange Attachments
31
Pipework Arrangement
31
Refrigerant Relief Valve Piping
31
115Vac Control Supply Transformer
32
Remote Emergency Stop Device
33
Electrical Connection
32
Power Wiring
32
Standard Units with Multi Point Power Supply Wiring
32
Units with Single-Point Power Supply Wiring
32
Control Panel Wiring
33
System Inputs
33
Flow Switch
33
Remote Run / Stop
33
Remote Print
33
Volts Free Contacts
33
Chilled Liquid Pump Starter
33
Run Contact
33
Alarm Contacts
33
Fig. 9 - Power Panel Section
34
Fig. 10 - Option Panel Section
35
Fig. 11 - Logic Section Layout
36
Fig. 12 - Logic Section Layout with
37
Fig. 13 - Customer Connections
38
Fig. 14 - Customer Connections
38
Preparation
40
Preparation - Power off
40
Inspection
40
Refrigerant Charge
40
Valves
40
Compressor Oil
40
Fans
40
Isolation/Protection
40
Control Panel
40
Switch Settings
41
Compressor Heaters
41
Water System
41
Flow Switch
41
Temperature Sensor(S)
41
Control Supply
41
Programmed Options
41
Programmed Settings
41
Date and Time
41
Start/Stop Schedule
41
Section 5 - Commissioning
40
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
General Description
44
Normal Running and Cycling
44
Section 6 - Operation
44
Shutdown
44
Start-Up
44
Fig. 15 - Flow Rate and Pressure Drop
46
Fig. 16 - Glycol Correction Factors
46
Flow Rate and Pressure Drop Charts
46
Glycol Correction Factors
46
Section 7 - Technical Data
46
Physical Data - Ycas R-407C (si Units)
48
Operating Limitations and Sound Power Data
49
Electrical Data
50
Fig. 17 - Multiple Point Power Supply Connection
50
Multiple Point Power Supply Connection
50
Fig. 18 - Multiple Point Power Supply Connection with Individual System Circuit Breakers
51
Multiple Point Power Supply Connection
51
Fig. 19 - Optional Single-Point Power Supply Connection with Individual System Circuit Breakers
52
Optional Single Point Power Supply Connection and Individual System Circuit Breakers
52
Electrical Notes
54
Table 2 - Compressor Data
55
Fig. 20 - Elementary Wiring Diagram - Dxst Direct Drive 3 Compressor
56
Wiring Diagrams
56
Fig. 21 - Elementary Wiring Diagram - Across The-Line Start 3 Compressor
57
Fig. 22 - Elementary Wiring Diagram - Wye Delta Start 3 Compressor
58
Fig. 23 - Control Power Transformer Kit
59
Fig. 24 - Elementary Wiring Diagram Dxst Direct Drive Control Circuit
60
Fig. 25 - Connection Diagram 3 Compressor
62
Fig. 26 - Connection Diagram 3 Compressor
63
Fig. 27 - Connection Diagram 3 Compressor
64
Fig. 28 - Connection Diagram 3 Compressor
66
Fig. 29 - Connection Diagram 3 Compressor
67
Fig. 30 - Elementary Diagram 3 Compressor Dxst Direct Drive Control Circuit
68
Fig. 31 - Elementary Diagram Dxst Direct Drive - 3 Compressor
69
Fig. 32 - Connection Diagram System Wiring 3 Compressor
70
Fig. 33 - Connection Diagram Ststem Wiring
71
Fig. 34 - Elementary Wiring Diagram - 4 Compressor
72
Fig. 35 - Elementary Wiring Diagram - Across-The-Line Start
73
Wiring Diagrams
73
Fig. 36 - Elementary Wiring Diagram - Wye Delta Start
74
Fig. 37 - Control Power Transformer Kit
75
Fig. 38 - Elementary Wiring Diagram
76
Fig. 39 - Connection Diagram 4 Compressor
78
Fig. 40 - Connection Diagram 4 Compressor
79
Fig. 41 - Elementary Wiring Diagram
80
Fig. 42 - Connection Diagram 4 Compressor
82
Fig. 43 - Connection Diagram 4 Compressor
83
Fig. 44 - Connection Diagram 4 Compressor
84
Fig. 45 - Elementary Diagram - Dxst Direct Drive Control Circuit
86
Fig. 46 - Elementary Diagram - Dxst Direct Drive Control Circuit
87
Fig. 47 - Connection Diagram System Wiring
88
Fig. 48 - Connection Diagram System Wiring
89
Fig. 49 - Compressor Terminal Box, System
90
Dimensions - Ycas0685 (Si)
94
Fig. 50 - Model Ycas0685 Dimensions (Si)
94
Dimensions - Ycas0775 - Ycas0905 (Si)
96
Fig. 51 - Model Ycas0775 - 0905 Dimensions (Si)
96
Dimensions - Ycas0965 (Si)
98
Fig. 52 - Model Ycas0965 Dimensions (Si)
98
Dimensions - Ycas1065 - Ycas1215 (Si)
100
Fig. 53 - Model Ycas1065 - Ycas1215 (Si)
100
Fig. 54 - Clearances
102
Technical Data
102
Weight Distribution and Isolator Mounting Positions
103
Fig. 55 - Cp-2-XX
104
Fig. 56 - Isolator Details
105
Fig. 57 - Cp-2-XX
108
Fig. 58 - Isolator Details
109
Fig. 59 - Cp-2-XX
112
Fig. 60 - Isolator Details
113
Fig. 61 - Cp-2-XX
116
Fig. 62 - Isolator Details
117
Installation Instructions for VMC Series Awr/Awmr and Cp Restrained Mountings
119
Fig. 63 - Refrigerant Flow Diagram
120
Fig. 64 - Process and Instrumentation
121
Fig. 65 - Component Locations
122
Compressor Components
124
Fig. 66 - Compressor Components
124
Fig. 67 - Compressor Components
125
Fig. 68 - Compressor Components
126
Fig. 69 - Compressor Components
127
Fig. 70 - Compressor Components
128
Fig. 71 - Compressor Components
129
System Startup Checklist
130
Unit Checks (no Power)
130
Panel Checks
131
Switches "Off")
131
Programmed Values
131
Initial Start-Up
132
Checking Subcooling and Superheat
132
Checking Economizer Superheat
132
Leak Checking
133
Chiller Control Panel
134
Display and Status Information Keys
134
On / off Rocker Switch
134
Program & Setup Keys
134
Programming and Data Access Keys
134
Section 8 - Micro Panel Contents
134
1 Introduction & Physical Description
135
1.1 General
135
1.2 Keypad & Display
135
1.3 Unit (Chiller) on / off Switch
136
1.4 Microprocessor Board
136
1.5 Ancillary Circuit Boards
136
Circuit Breakers
137
1.8 Transformers
138
1.9 Motor Protector Modules
138
Fig. 72 - Motor Protection Module
139
Ems/Bas Controls
140
Microprocessor Board Layout
142
Fig. 73 - Component Layout
142
Logic Section Layout
143
Fig. 74 - Logic Section Layout
143
Anti-Recycle Timer
144
Anti-Coincidence Timer
144
Evaporator Pump Control
144
Compressor Heater Control
144
Evaporator Heater Control
144
Pumpdown (Eev) Control
144
Alarms
145
Run Status (Chiller)
145
Lead / Lag Compressor Selection
145
Or 4 Compressor Chiller Configuration
146
Economizer Solenoid Control
146
2 Status Key: General Status Messages & Fault Warnings
148
General
148
General Status Messages
148
Unit Warnings
149
Anticipation Control Status
150
Unit Fault Status Messages
151
System Fault (Safety) Status Messages
152
Fig. 75 - Suction Pressure Cutout
153
Printout on Fault Shutdown
155
3 Display Keys & Option Switches
156
General
156
Chilled Liquid Temps Key
156
System # Data Keys
157
Ambient Temp Key
157
Motor Current Key
158
Operating Hrs / Start Counter Key
158
Options Key & Dip Switch Settings
158
Fig. 77 - Enlarged Photograph of Dip Switches on Microprocessor Board
159
Function Key
160
4 Print Keys
161
General
161
Oper Data Key
161
Operating Data - Software Version
163
Operating Data - Remote Printout
163
History Key
164
Fault History Data - Local Display Messages
164
Fault History Data - Remote Printout
168
5 Entry Keys
169
General
169
Numerical Keypad
169
Enter Key
169
Cancel Key
169
Keys
169
6 Setpoints Keys & Chilled Liquid Control
170
6.1 General
170
Chilled Liquid Temperature Control
170
Local Cooling Setpoints Key
174
Remote Cooling Setpoints Key
174
7 Clock Keys
175
General
175
Set Time Key
175
Set Schedule / Holiday Key
176
Manual Override Key
177
8 Program Key
178
Cut-Out
178
General
178
Programming "Default" Values
182
Table 3 - Default Values Table
183
8.4 Electronic Expansion Valve
184
Fig. 78 - Electronic Expansion Valve
184
8.5 Eev Operation
185
8.6 Eev Programming
187
Table 4 - Programmable Values Table
187
8.7 Eev Troubleshooting
188
Compressor Condenser Fan Control
189
Table 5 - Condenser Fan Control and Fan Contactor Data for Dxst Units
189
Table 8 - Condenser Fan Control and Fan Contactor Data for Dxst Units
189
Fig. 79 - Condenser Fan Control Layout for Dxst Compressors Units
189
Compressor Condenser Fan Control
190
Table 6 - Condenser Fan Control and Fan Contactor Data for Dxst Units
191
Table 7 - Condenser Fan Control and Fan Contactor Data for Dxst Units
191
Fig. 80 - Condenser Fan Control Layout for Dxst Compressors Units
191
Table 9 - Condenser Fan Control and Fan Contactor Data for Dxst Units
192
8.10 Service Mode: Unit Setup
193
Table 10 - Service Mode Programmable Values
193
Table 11 - Ycas Style G, Across the Line Start - 50 Hz
194
Table 12 - Ycas Style G, Wye Delta Start - 50 Hz
195
8.11 Control Inputs/Outputs
197
Table 13 - Digital Outputs
197
Table 14 - Analog Inputs
198
Table 16 - Analog Outputs
199
Table 15 - Digital Inputs
199
8.12 Sensor Calibration Charts
200
8.13 Isn Control
201
Table 17 - Isn Received Data
201
Table 18 - Isn Transmitted Data
201
Table 19 - Isn Operational and Fault Codes
204
Section 9 - Maintenance
206
General Requirements
206
Condenser Coils
206
Chiller / Compressor Operating Log
207
Scheduled Maintenance
207
On-Board Battery Back-Up
207
Overall Unit Inspection
207
Compressor Unit Operation
207
General Periodic Maintenance Checks
210
Standard Units
210
Section 10 - Spare Parts
211
Recommended Spares
211
Recommended Compressor Oils
211
Section 11 - Troubleshooting
212
Guide
212
Engineered Systems
214
Warranty on New Equipment
214
Warranty on Reconditioned or Replacement Materials
214
Temperature Conversion Chart - Differential Temperatures
214
Temperature Conversion Chart
215
Actual Temperatures
215
Pressure Conversion Chart - Gauge or Differential
215
York YCAS Series Installation Operation & Maintenance (168 pages)
AIR-COOLED SCREW LIQUID CHILLERS
Brand:
York
| Category:
Chiller
| Size: 6.08 MB
Table of Contents
Table of Contents
2
General Chiller Information & Safety
6
Introduction
6
Warranty
6
Safety
6
Standards for Safety
6
Responsibility for Safety
7
About this Manual
7
Misuse of Equipment
7
Suitability for Application
7
Structural Support
7
Mechanical Strength
7
General Access
7
Pressure Systems
7
Electrical
7
Rotating Parts
8
Sharp Edges
8
Refrigerants and Oils
8
High Temperature and Pressure Cleaning
8
Emergency Shutdown
8
Section 2 Product Description
9
Introduction
9
General Description
9
Compressor
9
Evaporator
10
Condenser
10
Economizer
11
Suction Line Heat Exchanger
11
Oil Separator / System
11
Oil Cooling
12
Capacity Control
12
Power and Control Panel
12
Microprocessor Controls
12
Motor Current Protection
13
Motor Protection Module
13
Current Overload
14
Thermal Overload
14
Current Imbalance / Loss of Phase
14
Improper Phase Sequence
14
Motor Protector Dip Switch Settings
15
Motor Starting
19
Keypad Controls
19
Display
19
Entry
20
Setpoints
20
Clock
20
Print
20
Program
20
Accessories and Options
20
Multiple Point Power Connection (Standard)
20
Single-Point Power Connection with Individual Circuit Protection
20
Single-Point Power Connection with Combined Circuit Protection
20
Single-Point Power Connection Without Circuit Protection
20
DX Cooler Options
21
300 PSIG (21 Bar) Waterside Design Working
21
Pressure
21
1-1/2" (38 MM) Insulation
21
Flange Accessory
21
Remote DX Cooler
21
Flow Switch Accessory
21
Star-Delta Compressor Motor Starter
21
Unit Enclosures
21
Fans
21
Unit Nomenclature and Nameplate Engineering Data
22
Basic Part Number
22
Options Section of Part Number
22
Section 3 Handling and Storage
23
Delivery and Storage
23
Inspection
23
Moving the Chiller
23
Lifting Weights
23
Unit Rigging
24
Section 4 Installation
25
Location Requirements
25
Outdoor Installations
25
Indoor Installations
25
Location Clearances
25
Installation of Vibration Isolators
26
Installation
26
Shipping Braces
26
Pipework Connection
26
General Requirements
26
Water Treatment
27
Pipework Arrangement
28
Connection Types & Sizes
28
Cooler Connections
28
Option Flanges
28
Refrigerant Relief Valve Piping
28
Ductwork Connection
28
General Requirements
28
Electrical Connection
29
Power Wiring
29
Standard Units with Multi Point Power Supply Wiring
29
Units with Single-Point Power Supply Wiring
29
115VAC Control Supply Transformer
29
Remote Emergency Stop Device
30
Control Panel Wiring
30
Volts Free Contacts
30
Chilled Liquid Pump Starter
30
Run Contact
30
Alarm Contacts
30
System Inputs
30
Flow Switch
30
Remote Run/Stop
30
Remote Print
30
Power and Control Panel Layouts (Wye-Delta Typical)
31
Options Panel Layout (Typical)
32
Logic Section Layout
33
Logic Section Layout with Control Panel Layout
34
Customer Connections
35
Section 5 Commissioning
37
Preparation
37
Preparation - Power off
37
First Time Start-Up
39
Section 6 Operation
40
General Description
40
Start-Up
40
Normal Running and Cycling
40
Shutdown
40
Section 7 Technical Data
41
Flow Rate and Pressure Drop Charts
41
Glycol Correction Factors
41
Temperature and Flows
42
Physical Data (English & si Units)
43
Operating Limitations & Sound Power Data
44
Electrical Data
46
Multiple Point Power Supply Connection
46
Optional Single-Point Power Supply Connection and Individual System Circuit Breakers
48
Optional Single-Point Power Supply Connection with Field Supplied Circuit Protection
50
Optional Single-Point Power Supply Connection to Factory Circuit Breaker
51
Compressor Data
52
Fan Data
52
Electrical Notes
53
Wiring Diagram Across-The-Line Start
54
Elementary Diagram - Across-The-Line Start
56
Panel Component Locations
58
Wiring Diagram Wye-Delta Start
60
Elementary Diagram - Wye-Delta Start
62
Panel Component Locations
64
Connection Diagram
68
Compressor Terminal Box
69
Dimensions
72
YCAS0130 - 0180 (English)
72
Ycas0130 - 0180 (Si)
74
YCAS0200 - 0230 (English)
76
Ycas0200 - 0230 (Si)
78
Clearances
80
Weight Distribution and Isolator Mounting Positions
81
Isolator Installation Instructions for VMC Series AWR/AWMR Isolator and CP Restrained Mountings
89
Refrigerant Flow Diagram
90
Process and Instrumentation Diagram
91
Component Locations
92
Compressor Components
93
System Startup Checklist
99
Unit Checks
99
Panel Checks
100
Initial Start-Up
101
Checking Subcooling and Superheat
101
Checking Economizer Superheat
102
Leak Checking
102
Chiller Control Panel Programming and Data Access Keys
103
Display and Status Information Keys
103
ON / off Rocker Switch
103
Program & Setup Keys
103
Section 8 Micro Panel Contents
104
Introduction & Physical Description
104
1.1 General
104
1.2 Keypad & Display
104
1.3 Unit (Chiller) on / off Switch
105
Microprocessor Board
105
1.5 Ancillary Circuit Boards
105
1.6 Circuit Breakers
106
Current Transformers (C.T.)
106
Transformers
106
Motor Protection Modules
107
Ems/Bas Controls
109
Microprocessor Board Layout
111
Logic Section Layout
112
Anti-Recycle Timer
113
Anti-Coincidence Timer
113
Evaporator Pump Control
113
Compressor Heater Control
113
Evaporator Heater Control
113
Pumpdown (LLSV) Control
113
Alarms
113
Run Status (Chiller)
114
Lead / Lag Compressor Selection
114
Status Key: General Status Messages and Fault Warnings
115
General
115
General Status Messages
115
Unit Warnings
116
Anticipation Control Status Messages
117
Unit Fault Status Messages
118
System Fault (Safety) Status Messages
119
Printout on Fault Shutdown
122
Display Keys & Option Switches
123
General
123
Chilled Liquid Temps Key
123
System # Data Keys
124
Ambient Temp Key
124
Motor Current Key
125
Operating HRS / Start Counter Key
125
Options Key & Dip Switch Settings
125
Function Key
127
Print Keys
128
General
128
Oper Data Key
128
Operating Data - Local Display Messages
128
Operating Data - Remote Printout
129
History Key
131
Fault History Data - Local Display Messages
131
Fault History Data - Remote Printout
134
Entry Keys
135
General
135
Numerical Keypad
135
Enter Key
135
Cancel Key
135
Áâ KEYS
135
Setpoints Keys & Chilled Liquid Control
136
General
136
Chilled Liquid Temperature Control
136
Local Cooling Setpoints Key
139
Remote Cooling Setpoints Key
139
Clock Keys
140
General
140
Set Time Key
140
Set Schedule / Holiday Key
141
Manual Override Key
142
Program Key
143
General
143
Program Key - User Programmable Values
143
Programming "Default" Values
147
Condenser Fan Control
148
Section 9 Maintenance
155
General Requirements
155
Daily Maintenance
155
Scheduled Maintenance
155
Chiller / Compressor Operating Log
155
Compressor Unit Operation
156
Maintenance Requirements
157
General Periodic Maintenance Checks Standard Units
158
Section 10 Spare Parts
159
Recommended Spares
159
Recommended Compressor Oils
159
Associated Drawings
159
Section 11 Troubleshooting
160
Competent Persons Troubleshooting Guide
160
Sensor Calibration Charts
162
Limited Warranty Applied Systems
163
Temperature Conversion Chart
164
YORK Service Offices
165
York YCAS Series Wiring Diagram (32 pages)
AIR-COOLED SCREW LIQUID CHILLERS
Brand:
York
| Category:
Chiller
| Size: 2.74 MB
Table of Contents
Table of Contents
2
Nomenclature
3
Electrical Notes
4
Electrical Data
6
Wiring Diagram
14
Fig. 1 - Wiring Diagram - Across-The-Line Start
14
Fig. 2 - Wiring Diagram - Across-The-Line Start
15
Elementary Diagram
16
Fig. 3 - Elementary Diagram - Across-The-Line Start
16
Wiring Diagram
18
Fig. 4 - Wiring Diagram - Wye-Delta Start
18
Fig. 5 - Elementary Diagram - Wye-Delta Start
19
Elementary Diagram
20
Fig. 6 - Elementary Diagram - Wye-Delta Start
20
Power Panel
22
Fig. 7 - Power Panel (System #1) Component Locations
22
Control Panel
23
Fig. 8 - Control Panel Component Location
23
Power Panel
24
Fig. 9 - Power Panel (System #2) Component Locations
24
Connection Diagram (System Wiring)
27
Fig. 10 - Connection Diagram (System Wiring)
27
Compressor Terminal Box
28
Fig. 11 - Compressor Terminal Box
28
Elementary Diagram Starter Control Circuit
29
Fig. 12 - Elementary Diagram Starter Control Circuit
29
Elementary Diagram Fan Control
30
Fig. 13 - Elementary Diagram Fan Control Circuit
30
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