York YCAS0170 Screw Air Chiller Manuals

Manuals and User Guides for York YCAS0170 Screw Air Chiller. We have 2 York YCAS0170 Screw Air Chiller manuals available for free PDF download: Installation, Operation & Maintenance Manual, Installation Operation & Maintenance

York YCAS0170 Installation, Operation & Maintenance Manual (204 pages)

YCAS AIR-COOLED LIQUID CHILLERS STYLE G

Brand: York | Category: Chiller | Size: 6 MB

Changeability of this Document
2
General Safety Guidelines
3
Read before Proceeding
3
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
- Logic Panel
  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
- English Units
  51
- Physical Data
  51
- Operating Limitations and Sound Power Data
  53
  - Electrical Data
    54
  - Compressor Data
    61
  - 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
- Micro-Computer Control Center
  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
- System Components
  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
  - Side View
    127
  - Top View
    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
- Diagram
  135
- Fig. 47A - Process and Instrumentation
  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
  - Function Key
    148
  - Funtion Key
    148
  - Summary of Settings
    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
- Programmable Values Table (Minimum/Maximum)
  175
  - 8.7 Eev Troubleshooting
    176
  - 8.8 Condenser Fan Control
    177
- Dxst 2 Compressor Units
  177
- Fig. 51 - Condenser Fan Layout for
  177
- Condenser Fan Control and Fan Contactor Data for Dxst Units with 4 Fans/System
  178
  - Data for DXST Units with 5 Fans/System
    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
- Received Data (Control 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
- Service Schedule
  198
- General Periodic Maintenance Checks
  198
- Standard Units
  198
  - Major Service
    198
  - Minor Service
    198
  - Recommended Compressor Oils
    199
  - Recommended Spares
    199
  - Spare Parts
    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

York YCAS0170 Installation Operation & Maintenance (168 pages)

AIR-COOLED SCREW LIQUID CHILLERS

Brand: York | Category: Chiller | Size: 6 MB

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

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York YCAS0170 Screw Air Chiller Manuals

York YCAS0170 Installation, Operation & Maintenance Manual (204 pages)

Table of Contents

Section 1 - General Chiller

Section 2 - Product Description

Section 3 - Handling and Storage

Section 4 - Installation

Section 5 - Commissioning

Section 6 - Operation

Section 7 - Technical Data

1 Introduction & Physical Description

2 Status Key: General Status Messages & Fault Warnings

3 Display Keys & Option Switches

4 Print Keys

5 Entry Keys

6 Setpoints Keys & Chilled Liquid Control

7 Clock Keys

8 Program Key

Section 9 - Maintenance

York YCAS0170 Installation Operation & Maintenance (168 pages)

Table of Contents

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