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York YCAS0140 Installation, Operation & Maintenance Manual

York YCAS0140 Installation, Operation & Maintenance Manual (204 pages)

YCAS AIR-COOLED LIQUID CHILLERS STYLE G

Brand: York | Category: Chiller | Size: 6.17 MB

Table of Contents

Safety Symbols
3
Table of Contents
4
Section 1 - General Chiller

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
    10
  - Rotating Parts
    11
  - Sharp Edges
    11
  - Refrigerants and Oils
    11
  - High Temperature and Pressure Cleaning
    11
  - Emergency Shutdown
    11
- Responsibility for Safety
  10
- Fig. 1 - Component Locations
  12
  - Evaporator
    13
  - Condenser
    13
- Introduction
  12
  - General Description
    12
  - Compressor
    12
- Introduction
  9
- Safety
  9
  - Standards for Safety
    9
Section 2 - Product Description

12
- Fig. 2 - Screw Compressor
  13
  - Economizer
    14
  - Oil Separator/System
    14
  - Oil Cooling
    14
  - Capacity Control
    14
  - Power and Control Panel
    14
  - Each Power Compartment Contains
    15
  - The Control Section Contains
    15
  - The Options Sections Contain
    15
  - Microprocessor Controls
    15
  - Motor Current Protection
    15
  - Motor Protection Modules (2ACE)
    16
  - Current Overload
    16
  - Thermal Overload
    17
  - Current Imbalance (Loaded & Unloaded)
    17
  - Loss of Phase
    17
  - Improper Phase Sequence
    17
  - TABLE 1 - Motor Protector Dip Switch Setting
    18
- Keypad Controls
  22
  - Display
    22
  - Program
    23
- Motor Starting
  22
- Accessories and Options
  23
- DX Evaporator and Starter Options
  24
- Fan Options
  24
- Sound Reduction Options
  24
- Unit Enclosures Options
  24
- Vibration Isolation
  24
- Nameplate Engineering Data
  25
- Unit Nomenclature
  25
- Product Identification Number (Pin)
  26
- Delivery and Storage
  27
- Inspection
  27
- Moving the Chiller
  27
  - Lifting Weights
    27
Section 3 - Handling and Storage

27
- Fig. 3 - Unit Rigging
  28
- Fig. 4 - Lifting Lugs
  28
- Unit Rigging
  28
- Indoor Installations
  29
- Location Clearances
  29
- Location Requirements
  29
- Outdoor Installations
  29
Section 4 - Installation

29
- Compressor Feet Bolt Removal
  30
- Fig. 5 - Compressor Mounting
  30
- Pipework Connection
  31
  - General Requirements
    31
- Shipping Braces
  31
- Vibration Isolators
  31
  - Installation
    31
- Water Treatment
  32
- Connection Types & Sizes
  33
- Ductwork Connection
  33
  - General Requirements
    33
- Evaporator Connections
  33
  - Optional Flanges
    33
- Fig. 7 - Victaulic Groove
  33
- Fig. 8 - Flange Attachments
  33
- Pipework Arrangement
  33
- Refrigerant Relief Valve Piping
  33
- 115Vac Control Supply Transformer
  34
  - Remote Emergency Stop Device
    35
- Electrical Connection
  34
- Power Wiring
  34
- Standard Units with Multi Point Power Supply Wiring
  34
  - Units with Single-Point Power Supply Wiring
    34
- Control Panel Wiring
  35
- System Inputs
  35
  - Flow Switch
    35
  - Remote Run / Stop
    35
  - Remote Print
    35
- Volts Free Contacts
  35
  - Chilled Liquid Pump Starter
    35
  - Run Contact
    35
  - Alarm Contacts
    35
- Fig. 9 - Power Panel Section
  36
- Fig. 10 - Option Panel Section
  37
- Fig. 11 - Logic Section Layout
  38
- Fig. 12 - Logic Section Layout with
  39
- Fig. 13 - Customer Connections
  40
- Fig. 14 - Customer Connections
  41
- Preparation
  42
- Preparation - Power off
  42
  - Inspection
    42
  - Refrigerant Charge
    42
  - Valves
    42
  - Compressor Oil
    42
  - Fans
    42
  - Isolation/Protection
    42
  - Control Panel
    42
  - Switch Settings
    43
  - Crankcase Heaters
    43
  - Water System
    43
  - Flow Switch
    43
  - Temperature Sensor(S)
    43
  - Control Supply
    43
  - Programmed Options
    43
  - Programmed Settings
    43
  - Date and Time
    43
  - Start/Stop Schedule
    43
Section 5 - Commissioning

42
- First Time Start-Up
  44
  - Interlocks
    44
  - System Switches
    44
  - Start-Up
    44
  - Oil Pressure
    44
  - Refrigerant Flow
    44
  - Fan Rotation
    44
  - Suction Superheat
    44
  - Expansion Valve
    44
- General Description
  46
- Normal Running and Cycling
  46
Section 6 - Operation

46
- Shutdown
  46
- Start-Up
  46
- Fig. 15 - Flow Rate and Pressure Drop Charts
  48
- Fig. 16 - Glycol Correction Factors
  48
- Flow Rate and Pressure Drop Charts
  48
- Glycol Correction Factors
  48
Section 7 - Technical Data

48
- Temperature and Flows
  49
- Physical Data
  51
- Operating Limitations and Sound Power Data
  53
  - Electrical Data
    54
  - Electrical Notes
    62
- Fig. 17 - Wiring Diagram - Across-The-Line Start
  64
- Wiring Diagram
  64
- Fig. 18 - Wiring Diagram - Across-The-Line Start
  65
- Elementary Diagram
  66
- Fig. 19 - Elementary Diagram - Across-The-Line Start
  66
- Fig. 20 - Wiring Diagram - Wye-Delta Start
  68
- Fig. 21 - Elementary Diagram - Wye-Delta Start
  69
- Fig. 22 - Elementary Diagram - Wye-Delta Start
  70
- Fig. 22A - Power Panel (System #1)
  72
- Fig. 22B - Control Panel Component
  73
- Fig. 22C - Power Panel (System #2)
  74
- Connection Diagram (System Wiring)
  77
- Compressor Terminal Box
  78
- Dimensions-Ycas0130-Ycas0180 (English)
  82
- Fig. 23 - Model Ycas0130 - 0180 Dimensions (English)
  82
- Dimensions-Ycas0130-Ycas0180 (Si)
  84
- Dimensions-Ycas0200-Ycas0230 (English)
  86
- Fig. 25 - Model Ycas0200 - Ycas0230 Dimensions (English)
  86
- Dimensions-Ycas0200-Ycas0230 (Si)
  88
- Fig. 26 - Model Ycas0200 - Ycas0230 Dimensions (Si)
  88
- Fig. 27 - Clearances
  90
- Technical Data
  90
- Weight Distribution and Isolator Mounting Positions
  91
- Fig. 28 - Cp-2-XX
  92
- Isolator Details
  92
- Fig. 29 - Isolator Details
  93
- Fig. 30 - Cp-2-XX
  96
- Fig. 31 - Isolator Details
  97
- Fig. 32 - Cp-2-XX
  100
- Fig. 33 - Isolator Details
  101
- Fig. 34 - Cp-2-XX
  104
- Fig. 35 - Isolator Details
  105
- Installation Instructions for VMC Series Awr/Awmr and Cp Restrained Mountings
  107
- Fig. 36 - Refrigerant Flow Diagram
  108
- Fig. 37 - Process and Instrumentation Diagram
  109
- Component Locations
  110
- Control Panel
  110
- Fig. 38 - Component Locations
  110
- Compressor Components
  111
- Fig. 39 - Compressor Components
  111
- Fig. 40 - Compressor Components
  112
- Fig. 41 - Compressor Components
  113
- Fig. 42 - Compressor Components
  114
- Fig. 43 - Compressor Components
  115
- Fig. 44 - Compressor Components
  116
- System Startup Checklist
  117
- Unit Checks (no Power)
  117
- Panel Checks
  118
- Programmed Values
  118
- Checking Subcooling and Superheat
  119
- Initial Start-Up
  119
- Checking Economizer Superheat
  120
- Leak Checking
  120
- Display and Status Information Keys
  122
- On / off Rocker Switch
  122
- Program & Setup Keys
  122
- Programming and Data Access Keys
  122
1 Introduction & Physical Description

123
- 1.1 General
  123
- 1.2 Keypad & Display
  123
- 1.3 Unit (Chiller) on / off Switch
  124
- 1.4 Microprocessor Board
  124
- 1.5 Ancillary Circuit Boards
  124
- 1.6 Circuit Breakers
  125
- 1.8 Transformers
  125
- 1.9 Motor Protection Modules
  125
- Fig. 45 - Motor Protection Module
  127
  - EMS/BAS Controls
    128
  - Microprocessor Board Layout
    130
- Fig. 46 - Component Layout
  130
  - Logic Section Layout
    131
- Fig. 47 - Logic Section Layout
  131
  - Anti-Recycle Timer
    132
  - Anti-Coincidence Timer
    132
  - Evaporator Pump Control
    132
  - Compressor Heater Control
    132
  - Evaporator Heater Control
    132
  - Pumpdown (EEV) Control
    132
  - Alarms
    133
  - Run Status (Chiller)
    133
  - Lead / Lag Compressor Selection
    133
  - Economizer Solenoid Control
    134
- Fig. 47A - Process and Instrumentation
  135
- Diagram
  135
2 Status Key: General Status Messages & Fault Warnings

136
- General
  136
- General Status Messages
  136
- Unit Warnings
  137
- Anticipation Control Status
  138
- Unit Fault Status Messages
  139
- System Fault (SAFETY) Status
  140
- Fig. 48 - Suction Pressure Cutout
  141
  - Printout on Fault Shutdown
    143
3 Display Keys & Option Switches

144
- General
  144
- Chilled Liquid Temps Key
  144
- System # Data Keys
  145
- Ambient Temp Key
  145
- Motor Current Key
  146
- Operating Hrs / Start Counter Key
  146
- Options Key
  146
- Fig. 49 - Enlarged Photograph of Dip Switches on Microprocessor Board
  147
  - Funtion Key
    148
4 Print Keys

149
- General
  149
- Oper Data Key
  149
- Operating Data - Software Version
  149
- Operating Data - Remote Printout
  151
- History Key
  152
- Fault History Data - Local Display Messages
  152
- Fault History Data - Remote Printout
  156
5 Entry Keys

157
- General
  157
- Numerical Keypad
  157
- Enter Key
  157
- Cancel Key
  157
- Keys
  157
6 Setpoints Keys & Chilled Liquid Control

158
- General
  158
- Chilled Liquid Temperature Control
  158
- Local Cooling Setpoints Key
  162
- Remote Cooling Setpoints Key
  162
7 Clock Keys

163
- General
  163
- Set Time Key
  163
- Set Schedule / Holiday Key
  164
- 7.4 Manual Override Key
  165
8 Program Key

166
- General
  166
- Program Key - User Programmable Value
  166
- Programming "Default" Values
  170
- 8.4 Electronic Expansion Valve
  172
- Fig. 50 - Electronic Expansion Valve
  172
  - 8.5 Eev Operation
    173
  - 8.6 Eev Programming
    175
  - TABLE 2 - Programmable Values Table
    175
  - (Minimum/Maximum)
    175
  - 8.7 Eev Troubleshooting
    176
  - 8.8 Condenser Fan Control
    177
- Fig. 51 - Condenser Fan Layout for
  177
- Dxst 2 Compressor Units
  177
  - Data for DXST Units with 4 Fans/System
    178
  - Data for DXST Units with 5 Fans/System
    178
  - TABLE 3 - Condenser Fan Control and Fan Contactor
    178
  - TABLE 4 - Condenser Fan Control and Fan Contactor
    178
  - 8.9 Service Mode: Unit Setup
    179
  - TABLE 5 - Service Mode Programmable Values
    179
  - TABLE 6 - YCAS Style G, Across the Line Start
    180
  - TABLE 7 - YCAS Style G, Wye Delta Start
    182
  - 8.10 Sensor Calibration Charts
    185
  - 8.11 Control Inputs/Outputs
    186
  - TABLE 8 - Digital Outputs
    186
  - TABLE 9 - Analog Inputs
    187
  - TABLE 10 - Digital Inputs
    188
  - TABLE 11 - Analog Outputs
    188
  - 8.12 Isn Control
    189
  - TABLE 12 - ISN Received Data
    189
  - TABLE 13 - ISN Transmitted Data
    189
  - TABLE 14 - ISN Operational and Fault Codes
    192
Section 9 - Maintenance

194
- General Requirements
  194
- Condenser Coils
  194
  - Chiller / Compressor Operating Log
    195
  - Scheduled Maintenance
    195
- On-Board Battery Back-Up
  195
- Overall Unit Inspection
  195
- Compressor Unit Operation
  196
- General Periodic Maintenance Checks
  198
- Standard Units
  198
  - Recommended Spares
    199
  - Recommended Compressor Oils
    199
- Troubleshooting Guide
  200
- Limited Warranty York Americas Engineered Systems
  202
- Warranty on New Equipment
  202
- Warranty on Reconditioned or Replacement Materials
  202
- Temperature Conversion Chart
  203
- Actual Temperatures
  203
- Temperature Conversion Chart Differential Temperatures
  203
- Pressure Conversion Charrt - Gauge or Differential
  203

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