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York YCAS0555EB manual available for free PDF download: Installation Operation & Maintenance
York YCAS0555EB Installation Operation & Maintenance (194 pages)
AIR-COOLED SCREW LIQUID CHILLERS
Brand:
York
| Category:
Chiller
| Size: 4.69 MB
Table of Contents
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
20
Display
20
Program
21
Motor Starting
20
Accessories and Options
21
Multiple Point Power Connection (Standard)
21
Single-Point Power Connection with Individual Circuit Protection
21
Single-Point Power Connection with Combined Circuit Protection
21
Single-Point Power Connection Without 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 Enclosures 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
Optional 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
39
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
Crankcase 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
Temperature and Flows
47
Physical Data
48
Operating Limitations and Sound Power Data
49
Electrical Data
50
Electrical Notes
58
Fig. 17 - Wiring Diagram - Across-The-Line Start
60
Wiring Diagram
60
Fig. 18 - Wiring Diagram - Across-The-Line Start
61
Elementary Diagram
62
Fig. 19 - Elementary Diagram - Across-The-Line Start
62
Fig. 20 - Wiring Diagram - Wye-Delta Start
64
Fig. 21 - Elementary Diagram - Wye-Delta Start
65
Fig. 22 - Elementary Diagram - Wye-Delta Start
66
Fig. 23 - Power Panel (System #1)
68
Fig. 24 - Control Panel Component Location
69
Fig. 25 - Power Panel (System #2)
70
Connection Diagram (System Wiring)
73
Compressor Terminal Box
74
Fig. 26 - Dimensions Ycas0295 - 0375
78
Dimensions-Ycas0295-Ycas0375
79
Dimensions-Ycas0425-Ycas0575
80
Fig. 27 - Dimensions Ycas0425- 0575
80
Dimensions-Ycas0605
82
Fig. 28 - Dimensions Ycas0605
82
Fig. 29 - Clearances
84
Technical Data
84
Weight Distribution and Isolator Mounting Positions
85
Fig. 30 - Cp-2-XX
86
Fig. 31 - Isolator Details
87
Fig. 32 - Cp-2-XX
90
Fig. 33 - Isolator Details
91
Fig. 34 - Cp-2-XX
94
Fig. 35 - Isolator Details
95
Fig. 36- Cp-2-XX
98
Fig. 37 - Isolator Details
99
Installation Instructions for VMC Series Awr/Awmr and Cp Restrained Mountings
101
Fig. 38 - Refrigerant Flow Diagram
102
Fig. 39 - Process and Instrumentation Diagram
103
Component Locations
104
Fig. 40 - Component Locations
104
Compressor Components
105
Fig. 41 - Compressor Components
105
Fig. 42 - Compressor Components
106
Fig. 43 - Compressor Components
107
Fig. 44 - Compressor Components
108
Fig. 45 - Compressor Components
109
Fig. 46 - Compressor Components
110
System Startup Checklist
111
Unit Checks (no Power)
111
Panel Checks
112
Programmed Values
112
Checking Subcooling and Superheat
113
Initial Start-Up
113
Checking Economizer Superheat
114
Leak Checking
114
Chiller Control Panel Programming and Data Access Keys
116
Display and Status Information Keys
116
On / off Rocker Switch
116
Program & Setup Keys
116
1 Introduction & Physical Description
117
1.1 General
117
1.2 Keypad & Display
117
1.3 Unit (Chiller) on / off Switch
118
1.4 Microprocessor Board
118
1.5 Ancillary Circuit Boards
118
1.6 Circuit Breakers
119
1.8 Transformers
119
1.9 Motor Protection Modules
119
Fig. 47 - Motor Protection Module
121
EMS/BAS Controls
122
Microprocessor Board Layout
124
Fig. 48 - Component Layout
124
Logic Section Layout
125
Fig. 49 - Logic Section Layout
125
Anti-Recycle Timer
126
Anti-Coincidence Timer
126
Evaporator Pump Control
126
Compressor Heater Control
126
Evaporator Heater Control
126
Pumpdown (EEV) Control
126
Alarms
127
Run Status (Chiller)
127
Lead / Lag Compressor Selection
127
Economizer Solenoid Control
128
Fig. 50 - Process and Instrumentation Diagram
129
2 Status Key: General Status Messages & Fault Warnings
130
General
130
General Status Messages
130
Unit Warnings
131
Anticipation Control Status
132
Unit Fault Status Messages
133
System Fault (SAFETY) Status
134
Fig. 51 - Suction Pressure Cutout
135
Printout on Fault Shutdown
137
3 Display Keys & Option Switches
138
General
138
Chilled Liquid Temps Key
138
System # Data Keys
139
Ambient Temp Key
139
Motor Current Key
140
Operating Hrs / Start Counter Key
140
Options Key
140
Fig. 52 - Enlarged Photograph of Dip Switches on Microprocessor Board
141
Function Key
142
4 Print Keys
143
General
143
Oper Data Key
143
Operating Data - Software Version
143
Operating Data - Remote Printout
145
History Key
146
Fault History Data - Local Display Messages
146
Fault History Data - Remote Printout
150
5 Entry Keys
151
General
151
Numerical Keypad
151
Enter Key
151
Cancel Key
151
Keys
151
6 Setpoints Keys & Chilled Liquid Control
152
General
152
Chilled Liquid Temperature Control
152
Local Cooling Setpoints Key
156
Remote Cooling Setpoints Key
156
7 Clock Keys
157
General
157
Set Time Key
157
Set Schedule / Holiday Key
158
7.4 Manual Override Key
159
8 Program Key
160
General
160
Program Key - User Programmable Value
160
Programming "Default" Values
164
8.4 Electronic Expansion Valve
166
Fig. 53 - Electronic Expansion Valve
166
8.5 Eev Operation
167
8.6 Eev Programming
169
(Minimum/Maximum)
169
TABLE 2 - Programmable Values Table
169
8.7 Eev Troubleshooting
170
8.8 Condenser Fan Control
171
Fig. 54 - Condenser Fan Layout for
171
Data for DXST Units with 4 Fans/System
172
Data for DXST Units with 5 Fans/System
172
TABLE 3 - Condenser Fan Control and Fan Contactor
172
TABLE 4 - Condenser Fan Control and Fan Contactor
172
8.9 Service Mode: Unit Setup
173
TABLE 5 - Service Mode Programmable Values
173
TABLE 6 - YCAS Style G, Across the Line Start
174
TABLE 7 - YCAS Style G, Wye Delta Start
174
8.10 Sensor Calibration Charts
176
8.11 Control Inputs/Outputs
177
TABLE 8 - Digital Outputs
177
TABLE 9 - Analog Inputs
178
TABLE 10 - Digital Inputs
179
TABLE 11 - Analog Outputs
179
8.12 Isn Control
180
TABLE 12 - ISN Received Data
180
TABLE 13 - ISN Transmitted Data
180
TABLE 14 - ISN Operational and Fault Codes
183
Section 9 - Maintenance
184
General Requirements
184
Condenser Coils
184
Chiller / Compressor Operating Log
185
Scheduled Maintenance
185
On-Board Battery Back-Up
185
Overall Unit Inspection
185
General Periodic Maintenance Checks Standard Units
188
Recommended Spares
189
Recommended Compressor Oils
189
Troubleshooting Guide
190
Limited Warranty York Americas Engineered Systems
192
Warranty on New Equipment
192
Warranty on Reconditioned
192
Replacement Materials
192
Temperature Conversion Chart
193
Actual Temperatures
193
Temperature Conversion Chart Differential Temperatures
193
Pressure Conversion Chart - Gauge or Differential
193
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