York YCAS1135EB Series Manuals

Manuals and User Guides for York YCAS1135EB Series. We have 1 York YCAS1135EB Series manual available for free PDF download: Installation Operation & Maintenance

York YCAS1135EB Series Installation Operation & Maintenance (216 pages)

AIR-COOLED SCREW LIQUID CHILLERS

Brand: York | Category: Chiller | Size: 7.97 MB

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
- 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
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

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York YCAS1135EB Series Manuals

York YCAS1135EB Series Installation Operation & Maintenance (216 pages)

Table of Contents

Section 1 - General Chiller Information & Safety

Fig. 1 - Component Locations

Section 2 - Product Description

Fig. 2 - Screw Compressor

Table 1 - Motor Protector Dip Switch Setting

Section 3 - Handling and Storage

Fig. 3 - Unit Rigging

Fig. 4 - Lifting Lugs

Unit Rigging

Section 4 - Installation

Fig. 5 - Compressor Mounting

Fig. 6 - Pipework Arrangement

Fig. 7 - Victaulic Groove

Fig. 8 - Flange Attachments

Fig. 9 - Power Panel Section

Fig. 10 - Option Panel Section

Fig. 11 - Logic Section Layout

Fig. 12 - Logic Section Layout with

Fig. 13 - Customer Connections

Fig. 14 - Customer Connections

Section 5 - Commissioning

Section 6 - Operation

Fig. 15 - Flow Rate and Pressure Drop

Fig. 16 - Glycol Correction Factors

Section 7 - Technical Data

Fig. 17 - Multiple Point Power Supply Connection

Fig. 18 - Multiple Point Power Supply Connection with Individual System Circuit Breakers

Fig. 19 - Optional Single-Point Power Supply Connection with Individual System Circuit Breakers

Table 2 - Compressor Data

Fig. 20 - Elementary Wiring Diagram - Dxst Direct Drive 3 Compressor

Fig. 21 - Elementary Wiring Diagram - Across The-Line Start 3 Compressor

Fig. 22 - Elementary Wiring Diagram - Wye Delta Start 3 Compressor

Fig. 23 - Control Power Transformer Kit

Fig. 24 - Elementary Wiring Diagram Dxst Direct Drive Control Circuit

Fig. 25 - Connection Diagram 3 Compressor

Fig. 26 - Connection Diagram 3 Compressor

Fig. 27 - Connection Diagram 3 Compressor

Fig. 28 - Connection Diagram 3 Compressor

Fig. 29 - Connection Diagram 3 Compressor

Fig. 30 - Elementary Diagram 3 Compressor Dxst Direct Drive Control Circuit

Fig. 31 - Elementary Diagram Dxst Direct Drive - 3 Compressor

Fig. 32 - Connection Diagram System Wiring 3 Compressor

Fig. 33 - Connection Diagram Ststem Wiring

Fig. 34 - Elementary Wiring Diagram - 4 Compressor

Fig. 35 - Elementary Wiring Diagram - Across-The-Line Start

Fig. 36 - Elementary Wiring Diagram - Wye Delta Start

Fig. 37 - Control Power Transformer Kit

Fig. 38 - Elementary Wiring Diagram

Fig. 39 - Connection Diagram 4 Compressor

Fig. 40 - Connection Diagram 4 Compressor

Fig. 41 - Elementary Wiring Diagram

Fig. 42 - Connection Diagram 4 Compressor

Fig. 43 - Connection Diagram 4 Compressor

Fig. 44 - Connection Diagram 4 Compressor

Fig. 45 - Elementary Diagram - Dxst Direct Drive Control Circuit

Fig. 46 - Elementary Diagram - Dxst Direct Drive Control Circuit

Fig. 47 - Connection Diagram System Wiring

Fig. 48 - Connection Diagram System Wiring

Fig. 49 - Compressor Terminal Box, System

Fig. 50 - Model Ycas0685 Dimensions (Si)

Fig. 51 - Model Ycas0775 - 0905 Dimensions (Si)

Fig. 52 - Model Ycas0965 Dimensions (Si)

Fig. 53 - Model Ycas1065 - Ycas1215 (Si)

Fig. 54 - Clearances

Fig. 55 - Cp-2-XX

Fig. 56 - Isolator Details

Fig. 57 - Cp-2-XX

Fig. 58 - Isolator Details

Fig. 59 - Cp-2-XX

Fig. 60 - Isolator Details

Fig. 61 - Cp-2-XX

Fig. 62 - Isolator Details

Fig. 63 - Refrigerant Flow Diagram

Fig. 64 - Process and Instrumentation

Fig. 65 - Component Locations

Fig. 66 - Compressor Components

Fig. 67 - Compressor Components