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York eco YCAS1215EB manual available for free PDF download: Manual
York eco YCAS1215EB Manual (232 pages)
OPTIMIZED R-407C AIR-COOLED LIQUID CHILLER
Brand:
York
| Category:
Chiller
| Size: 8.64 MB
Table of Contents
Table of Contents
2
Section 1 General Chiller Information & Safety
11
Introduction
11
Warranty
11
Safety
11
Standards for Safety
11
Responsibility for Safety
12
About this Manual
12
Misuse of Equipment
12
Suitability for Application
12
Structural Support
12
Mechanical Strength
12
General Access
12
Pressure Systems
12
Electrical
12
Rotating Parts
13
Sharp Edges
13
Refrigerants and Oils
13
High Temperature and Pressure Cleaning
13
Emergency Shutdown
13
Section 2 Product Description
14
Introduction
14
General Description
14
Compressor
14
Fig. 1 – Component Locations
14
Evaporator
15
Condenser
15
Fig. 2 – Screw Compressor
15
Oil Separator/System
16
Oil Cooling
16
Capacity Control
16
Power and Control Panels
16
Microprocessor Controls
17
Motor Current Protection
17
Motor Protector Module
17
Current Overload
18
Thermal Overload
19
Current Imbalance
19
Improper Phase Sequence
19
Motor Protector Dip Switch Settings
20
Table 1 – Motor Protector Dip Switch Setting – Across-The-Line Start, 60 Hz
20
Table 2 – Motor Protector Dip Switch Setting – Across-The-Line Start, 50 Hz
21
Table 3 – Motor Protector Dip Switch Setting – Wye-Delta Start, 60 Hz
22
Table 4 – Motor Protector Dip Switch Setting – Wye-Delta Start, 50 Hz
23
Motor Starting
24
Keypad Controls
24
Display
24
Entry
25
Setpoints
25
Clock
25
Print
25
Program
25
Accessories and Options
25
Multiple Point Power Connection (Standard)
25
Single-Point Power Connection with Individual Circuit Protection
25
Single-Point Power Connection with Combined Circuit Protection
25
Single-Point Power Connection Without Circuit Protection
25
Unit Enclosures
26
Fans
26
Sound Reduction Options
26
DX Cooler Options
26
PSIG (21 Bar) Waterside Design Working Pressure
26
1-1/2" (38 MM) Insulation
26
Flange Accessory
26
Remote DX Cooler
26
Flow Switch Accessory
26
Star-Delta Compressor Motor Starter
26
Unit Nomenclature and Nameplate Engineering Data
27
Basic Part Number
27
Options Section of Part Number
27
Section 3 Handling and Storage
29
Delivery and Storage
29
Inspection
29
Moving the Chiller
29
Lifting Weights
29
Unit Rigging
30
Fig. 3 – Unit Rigging
30
Fig. 4 – Lifting Lugs
30
Section 4 Installation
31
Location Requirements
31
Outdoor Installations
31
Indoor Installations
31
Location Clearances
31
Installation of Vibration Isolators
32
Installation
32
Shipping Braces
32
Pipework Connection
32
General Requirements
32
Water Treatment
33
Pipework Arrangement
33
Fig. 5 – Pipework Arrangement
33
Connection Types & Sizes
34
Cooler Connections
34
Option Flanges
34
Refrigerant Relief Valve Piping
34
Ductwork Connection
34
General Requirements
34
Fig. 6 – Victaulic Groove
34
Fig. 7 – Flange Attachments
34
Electrical Connection
35
Power Wiring
35
Standard Units with Multi Point Power Supply Wiring
35
Units with Single-Point Power Supply Wiring
35
115VAC Control Supply Transformer
35
Remote Emergency Stop Device
36
Control Panel Wiring
36
Volts Free Contacts
36
Chilled Liquid Pump Starter
36
Run Contact
36
Alarm Contacts
36
System Inputs
36
Flow Switch
36
Remote Run / Stop Switch
36
Remote Print
36
Power and Control Panel Layouts (Wye-Delta Typical)
37
Fig. 8 – Power Panel Section
37
Options Panel Layout (Typical)
38
Fig. 9 – Options Panel Layout (Typical)
38
Logic Section Layout
39
Fig. 10 – Logic Section Layout
39
Logic Section Layout with Control Panel Layout
40
Fig. 11 – Logic Section Layout with Control Panel Layout
40
Customer Connections
41
Fig. 12 – Customer Connections
41
FIG.13 – CUSTOMER CONNECTIONS
42
Section 5 Commissioning
43
Preparation
43
Preparation – Power off
43
First Time Start-Up
45
Section 6 Operation
46
General Description
46
Start-Up
46
Normal Running and Cycling
46
Shutdown
46
Section 7 Technical Data
47
Flow Rate and Pressure Drop Charts
47
Fig. 14 – Flow Rate and Pressure Drop (English Units, 60 Hz)
47
Fig. 15 – Flow Rate and Pressure Drop (si Units, 60 Hz)
47
Fig. 16 – Flow Rate and Pressure Drop (si Units, 50 Hz)
48
Fig. 17 – Glycol Correction Factors
49
Temperature and Flows
50
Table 5 – Temperatures and Flows – English Units, 60 Hz
50
Table 6 – Temperatures and Flows – si Units, 60 Hz
50
Table 7 – Temperatures and Flows – si Units, 50 Hz
51
Physical Data (English Units)
52
Table 8 – Physical Data – English Units, 60 Hz, R-407C Optimized
52
Physical Data (si Units)
53
Table 9 – Physical Data – si Units, 60 Hz, R-407C Optimized
53
Table 10 – Physical Data – SI, 50 Hz, R-407C Optimized
54
Operating Limitations & Sound Power Data
55
Table 11 – Operating Limitations – English Units 60 Hz
55
Table 12 – 60 Hz Sound Power Data
55
Table 13 – Operating Limitations – si Units 60 Hz
56
Table 14 – 60 Hz Sound Power Data
56
Table 15 – Operating Limitations – si Units 50 Hz
57
Table 16 – 50 Hz Sound Power Data
57
Electrical Data (60 Hz)
58
Multiple Point Power Supply Connection (60 Hz)
58
Table 17 – Multiple Point Power Supply Connection – 3 & 4 Compressor Units
58
Optional Single-Point Power Supply Connection with Individual System Circuit Breakers (60 Hz)
60
Table 18 – Optional Single-Point Power Supply Connection with Individual System Circuit Breakers – 3 & 4 Compressor Units
60
Table 19 – Control Power Supply (Units Without Standard Control Circuit Transformers)
60
Table 20 – Control Power Supply (Units with Standard Control Circuit Transformers)
61
Electrical Notes (60 Hz)
62
Power Connection Options (60 Hz)
63
Fig. 18 – Multiple Point Power Supply Connection
63
Fig. 19 – Multiple Point Power Supply Connection with Individual System Circuit Breakers
63
Fig. 20 – Optional Single-Point Power Supply Connection with Individual System Circuit Breakers
64
Electrical Data (50 Hz)
66
Multiple Point Power Supply Connection (50 Hz)
66
Optional Single-Point Power Supply Connection with Individual System Circuit Breakers (50 Hz)
66
Table 21 – Multiple Point Power Supply Connection – 3 & 4 Compressor Units (50 Hz)
66
Table 22 – Optional Single-Point Power Supply Connection with Individual System Circuit Breakers –
66
Table 23 – Control Power Supply (Units Without Standard Control Circuit Transformers)
68
Table 24 – Control Power Supply (Units with Standard Control Circuit Transformers)
68
Electrical Notes (50 Hz)
69
Compressor Data
69
Fan Data
69
Table 25 – Compressor Data
69
Table 26 – Fan Data (-46)
69
Power Connection Options (50 Hz)
70
Fig. 21 – Multiple Point Power Supply Connection (50 Hz)
70
Fig. 22 – Multiple Point Power Supply Connection with Individual System Circuit Breakers
70
Fig. 23 – Optional Single-Point Power Supply Connection with Individual System Circuit Breakers
71
Elementary Diagram
72
Elementary Diagram – Across-The-Line Start
72
Fig. 24 – Elementary Diagram – Across-The-Line Start
72
Wiring Diagrams–Across-The-Line Start and Wye-Delta Start
74
Fig. 25 – Control Power Transformer Kit
74
Standard 3 Compressor Power Supplies Wye-Delta Start
75
Fig. 26 – Standard 3-Compressor Power Supplies – Wye-Delta Start
75
Wiring Diagram – Across-The Line Start
76
Fig. 27 – Elementary Diagram – Across-The-Line Start
76
Standard Compressor Power Supplies – Across-The Line Start and Wye-Delta Start
78
Fig. 28 – Elementary Diagram
78
Connection Diagram
82
Fig. 29 – Connection Diagram
82
Connection Diagram – Electrical Box
84
Fig. 30 – Connection Diagram – Electric Box DXST Direct Drive
84
Fig. 31 – Connection Diagram – Electrical Box
85
Elementary Diagram DXST Direct Drive Control Circuit
87
Fig. 32 – Elementary Diagram – DXST Direct Drive - Control Circuit
87
Connection Diagram System Wiring – Standard and Remote Evap. Units
90
Fig. 33 – Connection Diagram System Wiring
90
Elementary Diagram DXST Direct Drive Power Circuit
92
Fig. 34 – Elementary Diagram – DXST Direct Drive – Power Circuit
92
Wiring Diagram –Across-The -Line Start and Wye-Delta Start
94
Fig. 35 – Control Power Transformer Kit
94
Standard 4 Compressor Power Supplies Wye-Delta Start
95
Fig. 36 – Standard 4-Compressor Power Supplies – Wye-Delta Start
95
Standard Compressor Power Supplies – Across-The-Line Start
96
Fig. 37 – Standard Compressor Power Supplies – Across-The-Line Start
96
Standard Compressor Power Supplies
98
Fig. 38 – Standard Compressor Power Supplies – Across-The-Line and Wye-Delta Start
98
Connection Diagram Systems 1 & 2
102
Connection Diagram Systems 3 & 4
102
Fig. 40 – Connection Diagram – Across-The-Line and Wye-Delta Start, Systems 3 & 4
102
Connection Diagram – Electrical Box
104
Fig. 41 – Connection Diagram – Electrical Box
104
Elementary Diagram DXST Direct Drive Control Circuit
106
Fig. 42 – Elementary Diagram, DXST Direct Drive – Control Circuit
106
Connection Diagram System Wiring – Standard and Remote Evap. Units
109
Fig. 43 – Connection Diagram System Wiring – Standard and Remote Evap. Units
109
Compressor Terminal Box – Systems 1- 4
111
Fig. 44 – Compressor Terminal Box, Systems 1 – 4
111
Dimensions
112
Fig. 45 – Model YCAS0218EB – 0268EB Dimensions (English)
112
YCAS0288EB (English) (60 Hz)
114
YCAS0218EB - 0268EB (English) (60 Hz)
112
Fig. 46 – Model YCAS0288EB Dimensions (English)
114
YCAS0308EB (English) (60 Hz)
116
Fig. 47 – Model YCAS0308EB Dimensions (English)
116
YCAS0328EB (English) (60 Hz)
118
Fig. 48 – Model YCAS0328EB Dimensions (English)
118
YCAS0358EB (English) (60 Hz)
120
Fig. 49 – Model YCAS0358EB Dimensions (English)
120
YCAS0398EB - 0418EB (English) (60 Hz)
122
Fig. 50 – Model YCAS0398EB – 0418EB Dimensions (English)
122
YCAS0218EB - 0268EB (SI) (60 Hz)
124
Fig. 51 – Model YCAS0218EB – 0268EB Dimensions (SI)
124
YCAS0288EB (SI) (60 Hz)
126
Fig. 52 – Model YCAS0288EB Dimensions (SI)
126
YCAS0308EB (SI) (60 Hz)
128
Fig. 53 – Model YCAS0308EB Dimensions (SI)
128
YCAS0328EB (SI) (60 Hz)
130
Fig. 54 – Model YCAS0328EB Dimensions (SI)
130
YCAS0358EB (SI) (60 Hz)
132
Fig. 55 – Model YCAS0358EB Dimensions (SI)
132
YCAS0398EB - 0418EB (SI) (60 Hz)
134
Fig. 56 – Model YCAS0368EB – 0418EB Dimensions (SI)
134
YCAS0685EB (SI) (50 Hz)
136
Fig. 57 – Model YCAS0685EB Dimensions (SI)
136
YCAS0775EB - 0905EB (SI) (50 Hz)
138
Fig. 58 – Model YCAS0775EB – 0905EB Dimensions (SI)
138
YCAS0965EB (SI) (50 Hz)
140
Fig. 59 – Model YCAS0965EB Dimensions (SI)
140
YCAS1065EB - 1215EB (SI) (50 Hz)
142
Fig. 60 – Model YCAS1065EB – 1215EB Dimensions (SI)
142
Clearances
144
Fig. 61 – Clearances
144
Weight Distribution and Isolator Mounting Positions (60 Hz)
145
Table 27 – Aluminum Fin Weight Distribution (Lbs.)
145
Table 28 – Aluminum Fin Weight Distribution (Kgs.)
145
Table 29 – Aluminum Fins – Neoprene Mount Selection - VMC Type RD-X
146
Table 30 – Aluminum Fins – 1" Isolator Selection - VMC Type CP-X-XX
146
Table 31 – Aluminum Fins – Seismic Isolator Selections - VMC Model # AWMR-X-XXX
146
Table 32 – Copper Fin Weight Distribution (Lbs.)
147
Table 34 – Copper Fins – Neoprene Mount Selection - VMC Type RD-X
147
Table 35 – Copper Fins – 1" Isolator Selection - VMC Type CP-X-XX
147
Table 36 – Copper Fins – Seismic Isolator Selections - VMC Model # AWMR-X-XXX
147
Table 37 – Copper Fin W/ Optional Silencer Kit Weight Distribution (Lbs.)
147
Table 38 – Copper Fin W/ Optional Silencer Kit Weight Distribution (Kgs.)
147
Table 39 – Copper Fins W/ Optional Silencer Kit – Neoprene Mount Selection - VMC Type RD-X
147
Table 40 – Copper Fins W/ Optional Silencer Kit – 1" Isolator Selection - VMC Type CP-X-XX
147
Table 41 – Copper Fins W/ Optional Silencer Kit – Seismic Isolator Selections - VMC Model # AWMR-X-XXX
147
Fig. 62 – Neoprene Isolator Details
151
Neoprene Isolator Details
151
Fig. 63 – 1" Isolator Details
152
1" Isolator Details
152
Seismic Isolator Details
153
Fig. 64 – Seismic Isolator Details
153
Weight Distribution and Isolator Mounting Positions (50 Hz)
154
Table 42 – Aluminum Fins Weight Distribution (Kgs.) by Model
154
Table 43 – Aluminum Fins, Seismic Isolator Selections – VMC Type RD-4
154
Table 44 – Aluminum Fins, 1" Isolator Selections - VMC Type CP-2-XX
154
Table 45 – Aluminum Fins, Seismic Isolator Selections - VMC Model # AWMR-X-XXX
154
Table 33 – Copper Fin Weight Distribution (Kgs.)
155
Table 46 – Copper Fins Weight Distribution (Kgs.) by Model
155
Table 47 – Copper Fins, Seismic Isolator Selections – VMC Type RD-4
155
Table 48 – Copper Fins, 1" Isolator Selections - VMC Type CP-2-XX
155
Table 49 – Copper Fins, Seismic Isolator Selections - VMC Model # AWMR-X-XXX
155
Installation Instructions for VMC Series AWR/AWMR and CP Restrained Mountings
156
Fig. 65 – Refrigerant Flow Diagram
157
Refrigerant Flow Diagram
157
Fig. 66 – Process and Instrumentation Diagram
158
Process and Instrumentation Diagram
158
Component Locations – 3 Compressor Units
159
Fig. 67 – Component Locations – 3-Compressor Units
159
Component Locations – 4 Compressor Units
160
Fig. 68 – Component Locations – 4-Compressor Units
160
Compressor Components
161
Fig. 69 – Compressor Components
161
System Startup Checklist
167
Unit Checks
167
Panel Checks
168
Initial Start-Up
169
Checking Subcooling and Superheat
169
Checking Economizer Superheat
170
Leak Checking
170
Section 8 Micro Panel Contents
171
Chiller Control Panel Programming and Data Access Keys
171
Display and Status Information Keys
171
ON / off Rocker Switch
171
Program & Setup Keys
171
Introduction & Physical Description
172
1.1 General
172
1.2 Keypad & Display
172
1.3 Unit (Chiller) on / off Switch
173
1.4 Microprocessor Board
173
1.5 Ancillary Circuit Boards
173
1.6 Circuit Breakers
174
Current Transformers (C.T.)
174
Transformers
175
Motor Protector Modules
175
Fig. 70 – Motor Protector
176
EMS/BAS Controls
177
Microprocessor Board Layout
179
Fig. 71 – Component Layout
179
Logic Section Layout
180
Fig. 72 – Logic Section Layout
180
Anti-Recycle Timer
181
Anti-Coincidence Timer
181
Evaporator Pump Control
181
Compressor Heater Control
181
Evaporator Heater Control
181
Pumpdown (LLSV) Control
181
Alarms
181
Run Status (Chiller)
182
Lead / Lag Compressor Selection
182
Or 4 Compressor Chiller Configuration
182
Status Key: General Status Messages and Fault Warnings
183
General
183
General Status Messages
183
Unit Warnings
184
Anticipation Control Status Messages
185
Unit Fault Status Messages
186
System Fault (Safety) Status Messages
187
Fig. 73 – Suction Pressure Cutout
188
Printout on Fault Shutdown
190
Display Keys & Option Switches
191
General
191
Chilled Liquid Temps Key
191
System # Data Keys
192
Ambient Temp Key
192
Motor Current Key
192
Operating HRS / Start Counter Key
193
Options Key & Dip Switch Settings
193
Fig. 74 – Enlarged Photograph of Dip Switches on Microprocessor Board
194
Function Key
195
Print Keys
196
General
196
Oper Data Key
196
Operating Data – Local Display Messages
196
Operating Data – Remote Printout
197
History Key
199
Fault History Data – Local Display Messages
199
4.7 FAULT HISTORY DATA – REMOTE PRINTOUT
202
Entry Keys
203
General
203
Numerical Keypad
203
Enter Key
203
Cancel Key
203
Setpoints Keys & Chilled Liquid Control
204
General
204
Chilled Liquid Temperature Control
204
Local Cooling Setpoints Key
207
Remote Cooling Setpoints Key
207
Clock Keys
208
General
208
Set Time Key
208
Set Schedule / Holiday Key
209
Manual Override Key
210
Program Key
211
General
211
Program Key – User Programmable Values
211
Programming “Default” Values
215
Compressor Condenser Fan Control
216
Fig. 75 – Condenser Fan Control Layout for DXST Compressor Units
216
Table 50 – Condenser Fan Control and Fan Contactor Data for DXST Units with 3 Fans/System
217
Table 51 – Condenser Fan Control and Fan Contactor Data for DXST Units with 4 Fans/System
217
Table 52 – Condenser Fan Control and Fan Contactor Data for DXST Units with 5 Fans/System
218
Table 53 – Condenser Fan Control and Fan Conatctor Data for DXST Units with 6 Fans/System
218
Compressor Condenser Fan Control
219
Fig. 76 – Condenser Fan Control Layout for DXST Compressor Units
219
Table 54 – Condenser Fan Control and Fan Contactor Data for DXST Units with 4 Fans/System
220
Table 55 – Condenser Fan Control and Fan Contactor Data for DXST Units with 5 Fans/System
221
Section 9 Maintenance
222
General Requirements
222
Daily Maintenance
222
Scheduled Maintenance
222
Chiller/Compressor Operating Log
222
Compressor Unit Operation
223
Maintenance Requirements
224
Table 56 – Maintenance Requirements for YORK YCAS Screw Chillers
224
General Periodic Maintenance Checks – Standard Units
225
Table 57 – General Periodic Maintenance Checks for Standard Units
225
Section 10 Spare Parts
226
Recommended Spares
226
Recommended Compressor Oils
226
Associated Drawings
226
Section 11 Troubleshooting
227
Competent Persons Troubleshooting Guide
227
Table 58 – Competent Person’S Troubleshooting Guide
227
Sensor Calibration Charts
229
Limited Warranty Applied Systems
230
Temperature Conversion Chart
231
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