Page 1 AIR-COOLED SCREW LIQUID CHILLERS New Release Form 201.19-NM8 (804) INSTALLATION, OPERATION & MAIN TE NANCE 035-20886-000 YCAS AIR-COOLED LIQUID CHILLERS YCAS0685EB THROUGH YCAS0965EB (3 COMPRESSOR) YCAS1065EB THROUGH YCAS1215EB (4 COMPRESSOR) STYLE G R407C 50 Hz 00258VIP (YCAS 4 SYSTEM EPROMs) (YCAS 3 SYSTEM EPROMs) MICROPROCESSOR BOARD MICROPROCESSOR BOARD...
Page 2 While YORK makes no com mit ment to update or provide current information au to mat i cal ly to the manual owner, that information, if ap pli ca ble, can be ob tained by con tact ing the nearest YORK Engineered Systems Service ofﬁ...
Page 3 YORK’s pub lished spec i ﬁ ca tions and must be per formed ONLY by qual i ﬁ ed YORK personnel. YORK will not be re spon si ble for dam ag es/problems re sult ing from im prop er con nec tions to the con trols or ap pli ca tion of im prop er con trol sig nals.
Page 4: Table Of Contents
Remote Run / Stop............33 Building Automation System (BAS) Interface....21 Remote Print..............33 Condenser Coil Protection ..........21 Remote Setpoint Offset – Temperature .......33 DX EVAPORATOR AND STARTER OPTIONS ..22 Remote Setpoint Offset – Current .......33 UNIT ENCLOSURE OPTIONS......... 22 YORK INTERNATIONAL...
Page 5 1.9 Motor Protector Modules ........138 PHYSICAL DATA - YCAS R-407C (SI UNITS) ..48 1.10 Ems/bas Controls..........140 OPERATING LIMITATIONS AND SOUND POWER 1.11 Microprocessor Board Layout ......142 DATA................. 49 1.12 Logic Section Layout ........143 ELECTRICAL DATA..........50 1.13 Anti-recycle Timer..........144 YORK INTERNATIONAL...
Page 6 4.6 Fault History Data – Local Display Messages ..164 SECTION 11 - TROUBLESHOOTING 4.7 Fault History Data – Remote Printout ....168 GUIDE ........212 LIMITED WARRANTY YORK AMERICAS 5. ENTRY KEYS............169 ENGINEERED SYSTEMS........214 5.1 General ..............169 WARRANTY ON NEW EQUIPMENT ..... 214 5.2 Numerical Keypad..........169...
Page 7 TABLE 15 - DIGITAL INPUTS........ 199 TABLE 16 - ANALOG OUTPUTS ......199 TABLE 17 – ISN RECEIVED DATA ....... 201 TABLE 18 – ISN TRANSMITTED DATA ....201 TABLE 19 – ISN OPERATIONAL AND FAULT CODES........204 YORK INTERNATIONAL...
Page 8 FIG. 33 – CONNECTION DIAGRAM STSTEM WIRING - FIG. 79 – CONDENSER FAN CONTROL LAYOUT FOR 3 COMPRESSOR..........71 DXST COMPRESSORS UNITS...... 189 FIG. 34 – ELEMENTARY WIRING DIAGRAM - 4 FIG. 80 – CONDENSER FAN CONTROL LAYOUT FOR COMPRESSOR..........72 DXST COMPRESSORS UNITS...... 191 YORK INTERNATIONAL...
Page 9: Section 1 - General Chiller Information & Safety
The unit warranty will be void if any modiﬁ cation to the unit is carried out without prior written approval from YORK YCAS chillers are manufactured to the high est York International. design and construction standards to en sure high per-...
Page 10: Responsibility For Safety
This manual and any other document supplied with the unit, are the property of YORK which reserves all rights. They may not be reproduced, in whole or in part, with out prior written authorization from an authorized YORK representative.
Page 11: Electrical
(Sys tem 4) can also be used to stop the re spec tive sys tem in an emer gen cy. When op er at ed, CB4 re moves the elec tri cal supply from the con trol sys tem, thus shut ting down the unit. YORK INTERNATIONAL...
Page 12: Section 2 - Product Description
INTRODUCTION All exposed power wiring is be routed through liquid- tight, non-metallic conduit. YORK YCAS chillers are designed for water or wa- ter-glycol cooling. All units are designed to be lo cat ed General Description outside on the roof of a building or at ground level.
Page 13: Evaporator
Condenser The ﬁ n and tube condenser coils are manufactured from seamless, internally enhanced, high condensing co ef ﬁ cient, corrosion resistant copper tubes arranged in 00485VIP FIG. 2 – SCREW COMPRESSOR YORK INTERNATIONAL...
Page 14: Economizer
Economizer (Models YCAS 773, 953, 1093 and 1263) The oil (YORK “L” oil – a POE oil used for all A plate and frame heat exchanger (economizer) is ﬁ tted re frig er ant applications), which ﬂ ows back into the to both refrigerant circuits on models YCAS 773, 953, com pres sor through a replaceable 0.5 - 3.0 micron...
Page 15: Capacity Control
ON/OFF switch, microcomputer keypad and display, system that has fault ed on high motor current. mi cro pro ces sor board, I/O expansion board, relay boards and power supply board. YORK INTERNATIONAL...
Page 16: Motor Protection Modules (2Ace)
It is recommended that a YORK imbalance > 17%. Unloaded phase to phase cur rent Ser vice Tech ni cian or the YORK imbalance > 25%. fac to ry be con sult ed before chang ing Improper in com ing phase ro ta tion.
Page 17: Thermal Overload
“Op er at ing Current” to the measured half line current. The “Op er at ing Current” is given by 0.65 X factory Additional information on the 2ACE MP module may overload cur rent setting. be found on page 138. YORK INTERNATIONAL...
Page 18: Table 1 - Motor Protector Dip Switch Setting
Sys 3 0775 0835 Sys 1 0835 Sys 2 & 3 0905 0965 Sys 1 & 2 0965 Sys 3 1065 1135 Sys 1 & 2 1135 Sys 3 & 4 1215 * Indicates one lead/phase through motor protector. YORK INTERNATIONAL...
Page 19 Sys 3 0775 0835 Sys 1 0835 Sys 2 & 3 0905 0965 Sys 1 & 2 0965 Sys 3 1065 1135 Sys 1 & 2 1135 Sys 3 & 4 1215 * Indicates one lead/phase through motor protector. YORK INTERNATIONAL...
Page 20: Motor Starting
• Up to 6 fault shut down conditions. (4 in YCAS 3 closed 1S (SYS 1) or 2S (SYS 2) con tacts, en er giz ing, Compressor and YCAS 4 Compressor). 1TRX (SYS 1) or 2TRX (SYS 2). 1TRX or 2TRX YORK INTERNATIONAL...
Page 21: Program
RS-232 port via a separate print er. or dry contact closure input from the BAS. Program A YORK ISN Building Automation System can pro- For setting low leaving liquid temperature cutout, 300 vide a Pulse Width Modulated (PWM) signal direct to...
Page 22: Dx Evaporator And Starter Options
(Factory- or ﬁ eld-mounted). Louvered panels (full unit) enclosure – Louvered panels over condenser coils and around the bottom of the unit (Factory- or ﬁ eld-mounted). YORK INTERNATIONAL...
Page 23: Unit Nomenclature
5 6 7 8 11 12 13 14 15 BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL (STYLE) : YORK Tons : Design Series G High-EfÞ ciency : R-407C 0685 : Engineering : Chiller Standard : R-22...
Page 24: Product Identification Number (Pin)
EXAMPLES: 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54...
Page 25: Delivery And Storage
Units with remote evaporators will have the chiller and Major damage must be reported immediately to your remote evaporator charged with nitrogen. lo cal YORK representative. MOVING THE CHILLER If the unit is to be put into storage, prior to installation,...
Page 26: Unit Rigging
Handling and Storage FORM 201.19-NM8 (804) UNIT RIGGING ✓ 88" (2250mm) CORRECT! CORRECT! ✗ WRONG! WRONG! LD03514 FIG. 3 – UNIT RIGGING WRONG! CORRECT! LD03515 FIG. 4 – LIFTING LUGS YORK INTERNATIONAL...
Page 27: Section 4 - Installation
4-3/4" (120 mm) wide at the con tact tion the same requirement of static pres sure loss ap plies points. This will allow vibration isolators to be ﬁ tted as for ducts and at ten u a tors stated above. if required. YORK INTERNATIONAL...
Page 28: Compressor Feet Bolt Removal
DO NOT remove the four 3/8" bolts, 3, mounting the in the Tech ni cal Data Section of this corner brackets, 2, to the frame rails. manual, (page 102). COMPRESSOR BASE SUPPORT RAIL CHANNEL BASE LD09131 FIG. 5 – COMPRESSOR MOUNTING YORK INTERNATIONAL...
Page 29: Vibration Isolators
PSIG) working pres sure and hav ing a 1" N.P.T. con- nection can be obtained from YORK as an ac ces so ry PIPEWORK CONNECTION for the unit. Al ter na tive ly a dif fer en tial pres sure switch sited across an oriﬁ...
Page 30: Water Treatment
ﬂ ow to other units. Aerated, brackish or salt water is not recommended for use in the water system(s). YORK recommends that Thermometer and pressure gauge connections should a wa ter treatment specialist is consulted to determine...
Page 31: Pipework Arrangement
No more than 3 feet (1 meter) of light the evaporator to the compressors. con struc tion ductwork should be supported by the unit. Where cross winds may occur, any ductwork must be sup port ed to prevent side loading on the unit. YORK INTERNATIONAL...
Page 32: Electrical Connection
This will prevent re cir - la tion (not sup plied by YORK). cu la tion of air when only one of the fans is running.
Page 33: Remote Emergency Stop Device
Flow Switch If required, a remote emergency stop de vice can be wired A chilled water ﬂ ow switch, (either by YORK or others) into the unit. The device should be wired into ter mi nals MUST be installed in the leaving water piping of the 31 and 32 (Figs.
Page 34: Fig. 9 - Power Panel Section
Installation FORM 201.19-NM8 (804) POWER PANEL LAYOUTS (TYPICAL) (WYE-DELTA - TYPICAL) 00263VIP FIG. 9 – POWER PANEL SECTION YORK INTERNATIONAL...
Page 35: Fig. 10 - Option Panel Section
FORM 201.19-NM8 (804) OPTION PANEL LAYOUT (TYPICAL) 00246VIP FIG. 10 – OPTION PANEL SECTION YORK INTERNATIONAL...
Page 36: Fig. 11 - Logic Section Layout
DESCRIPTION Microprocessor Board I/O Board #2 I/O Expansion Board #1 Power Supply Board Relay Output Board #1 Relay Output Board #2 Flow Switch & Customer Connection Terminals Circuit Breakers CB1 - CB5 FIG. 11 – LOGIC SECTION LAYOUT YORK INTERNATIONAL...
Page 37: Fig. 12 - Logic Section Layout With
FORM 201.19-NM8 (804) LOGIC SECTION LAYOUT WITH CONTROL PANEL 00248VIP FIG. 12 – LOGIC SECTION LAYOUT WITH CONTROL PANEL YORK INTERNATIONAL...
Page 38: Fig. 13 - Customer Connections
Chilled Liquid Circulating Pump Start Temperature System No. 2 Print Alarm Contacts Chiller Run CONNECTION Isolator POINTS FOR Auxiliary EMERGENCY Interlock STOPS System No. 3 Alarm Contacts System No. 4 Alarm Contacts LD09410 FIG. 13 – CUSTOMER CONNECTIONS YORK INTERNATIONAL...
Page 39 FORM 201.19-NM8 (804) CUSTOMER CONNECTIONS RELAY BOARDS I/O EXPANSION BOARD #1 TRANSFORMERS POWER SUPPLY BOARD CIRCUIT BREAKERS (CB1-CB5) 115 VAC SUPPLY MICROPROCESSOR CUSTOMER CIRCUIT BOARD CONNECTIONS (Flow Switch, Alarm, Run, etc.) 00247VIP FIG. 14 – CUSTOMER CONNECTIONS YORK INTERNATIONAL...
Page 40: Section 5 - Commissioning
It is important to check that the correct pri ma ry Compressor Oil tapping has been used: To add oil to a circuit - connect a YORK hand oil pump (Part No. 470-10654-000) to the 1/4" oil charging valve With the supply voltage to the unit turned off, remove on the oil separator piping with a length of clean hose the lid to the transformer box.
Page 41: Switch Settings
(off set) is to be used, the maximum reset must be pro- wired into the control panel correctly using shielded grammed by pressing the ‘Remote Reset Temp’ key. (See Section 6.) YORK INTERNATIONAL...
Page 42: First Time Start-Up
After several min utes operation and providing a full charge of re frig er ant is in the system, the bubbles will disappear and be re placed by a solid column of liquid. YORK INTERNATIONAL...
Page 43 FORM 201.19-NM8 (804) This page intentionally left blank. YORK INTERNATIONAL...
Page 44: Section 6 - Operation
The units are designed to work independently, or in Once the unit has been started, all operations are fully con junc tion with other equipment via a YORK ISN automatic. After an initial period at minimum capacity build ing management system or other automated con- on the lead compressor, the control system will adjust trol sys tem.
Page 45 FORM 201.19-NM8 (804) This page intentionally left blank. YORK INTERNATIONAL...
Page 46: Section 7 - Technical Data
LD03504 • Actual Measured ∆P = 12' H • Corrected ∆P = 12'/1.3 = 9.2' H FIG. 16 – GLYCOL CORRECTION FACTORS • From Flow Rate and Pressure Drop Chart, locate ß ow @ 9.2' ≈ 300 GPM YORK INTERNATIONAL...
Page 47 1215 NOTES: 1. For leaving brine temperature below 5 °C, contact your nearest YORK ofÞ ce for application requirements. 2. For leaving water temperature higher than 13°C, contact the nearest YORK ofÞ ce for application guidelines. 3. The evaporator is protected against freeze-up to -28.8°C with an electrical heater as standard.
Page 48: Physical Data - Ycas R-407C (Si Units)
Minimum Chilled Water Flow Rate, l/s 18.50 21.00 21.00 21.00 21.00 27.20 27.20 27.20 Maximum Chilled Water Flow Rate, l/s 67.64 76.03 76.03 76.03 76.03 101.00 101.00 101.00 Water Connections, inches NOTE: 1. Optional 21 Bar Waterside available. YORK INTERNATIONAL...
Page 49: Operating Limitations And Sound Power Data
LOW NOISE FAN STD FAN 8-POLE MOTOR 8-POLE MOTOR 8-POLE MOTOR MODEL 6-POLE W/COMPRESSOR 8-POLE W/COMPRESSOR W/ PERIMETER KIT MOTOR BLANKET & PERIMETER KIT MOTOR BLANKET (DISCHARGE LINE WRAPPED) (DISCHARGE LINE WRAPPED) 0685EB 0775EB 0835EB 0905EB 0965EB 1065EB 1135SB 1215EB YORK INTERNATIONAL...
Page 50: Electrical Data
(2) 250 - 500 1065EB (2) # 2 - 4/0 (2) 3/0 - 250 1135EB (2) 1/0 - 300 (2) 250 - 500 1215EB (2) 1/0 - 300 (2) 250 - 500 See page 54 for Electrical Data footnotes. YORK INTERNATIONAL...
Page 51: Multiple Point Power Supply Connection
(1) 1/0 - 300 (1) #4 - 300 —- —- —- 1065EB (2) # 2 - 4/0 (2) 3/0 - 250 1135EB (2) 1/0 - 300 (2) 250 - 500 1215EB (2) 1/0 - 300 (2) 250 - 500 YORK INTERNATIONAL...
Page 52: Optional Single Point Power Supply Connection And Individual System Circuit Breakers
0965EB (3) 2/0 - 500 (3) 2/0 - 400 1065EB (3) 2/0 - 500 (4) 4/0 - 500 1135EB 1000 1000 1000 (3) 2/0 - 500 (4) 4/0 - 500 1215EB See page 54 for Electrical Data footnotes. YORK INTERNATIONAL...
Page 53 11, 12 Y-∆ LRA X-LRA Y-∆ LRA X-LRA Qty FLA (ea) LRA (ea) Y-∆ LRA X-LRA RLA Y-∆ LRA X-LRA FLA (ea) (ea) — — — — — — — — — — — — — — — YORK INTERNATIONAL...
Page 54: Electrical Notes
MINIMUM MIN NF MINIMUM NON-FUSED RUNNING LOAD AMPS S.P. WIRE SINGLE-POINT WIRING UNIT MTD SERV SW UNIT-MOUNTED SERVICE (NON-FUSED DIS CON NECT SWITCH) WYE-DELTA WYE-DELTA START XLRA ACROSS-THE-LINE INRUSH LOCKED ROTOR AMPS YLRA WYE-DELTA INRUSH LOCKED ROTOR AMPS YORK INTERNATIONAL...
Page 55: Table 2 - Compressor Data
COMPRESSOR MODEL AND VOLTAGE CODE DXS45LA – MOTOR CODE A DXS36LA – MOTOR CODE A DXS24LA – MOTOR CODE (TBD) (B5N, B5E, B6N, B6E) (A5N, A5E, A6N, A6E) (C5N, C5E, C6N, C6E) VOLTAGE CODE- MAX KW MAX AMPS YORK INTERNATIONAL...
Page 56: Wiring Diagrams
Technical Data FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM YCAS0685 - YCAS0965 (3 COMPRESSOR) 035-15937-103 Rev - A LD09350 FIG. 20 – ELEMENTARY WIRING DIAGRAM – DXST DIRECT DRIVE 3 COMPRESSOR YORK INTERNATIONAL...
Page 57: Fig. 21 - Elementary Wiring Diagram - Across The-Line Start 3 Compressor
FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM YCAS0685 - YCAS0965 (3 COMPRESSOR) ACROSS-THE-LINE START 035-15937-103 Rev - A LD09352 LD09352 FIG. 21 – ELEMENTARY WIRING DIAGRAM – ACROSS-THE-LINE START 3 COMPRESSOR YORK INTERNATIONAL...
Page 58: Fig. 22 - Elementary Wiring Diagram - Wye Delta Start 3 Compressor
Technical Data FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM YCAS0685 - YCAS0965 (3 COMPRESSOR) WYE DELTA START 035-15937-103 Rev - A FIG. 22 – ELEMENTARY WIRING DIAGRAM – WYE DELTA START 3 COMPRESSOR YORK INTERNATIONAL...
Page 59: Fig. 23 - Control Power Transformer Kit
Terminal Block for Customer Low Voltage (Class 2) Connections. See Note 2 2. Contacts must be suitable for switching 24VDC, (Gold Terminal Block for YORK Connections Only contacts recommend). Wiring shall not be run in the same conduit with any line voltage wiring.
Page 60: Fig. 24 - Elementary Wiring Diagram Dxst Direct Drive Control Circuit
Technical Data FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM YCAS0685 - YCAS0965 (3 COMPRESSOR) FIG. 24 – ELEMENTARY WIRING DIAGRAM DXST DIRECT DRIVE CONTROL CIRCUIT LD010031 YORK INTERNATIONAL...
Page 61 Ad- pressed with a YORK P/N 031-00808-000 sup pres sor across the ditionally, con trol wir ing not con nect ed to the Smart Panel should not re lay/con tac tor coil.
Page 62: Fig. 25 - Connection Diagram 3 Compressor
Technical Data FORM 201.19-NM8 (804) CONNECTION DIAGRAM ELEC. BOX (YCAS0685 - YCAS0965) LD010033 FIG. 25 – CONNECTION DIAGRAM 3 COMPRESSOR YORK INTERNATIONAL...
Page 63: Fig. 26 - Connection Diagram 3 Compressor
FORM 201.19-NM8 (804) Power Panel 035-15937-104 Rev E LD010034 FIG. 26 – CONNECTION DIAGRAM 3 COMPRESSOR POWER PANEL YORK INTERNATIONAL...
Page 64: Fig. 27 - Connection Diagram 3 Compressor
Technical Data FORM 201.19-NM8 (804) CONNECTION WIRING DIAGRAM 035-15937-104 Rev E Power Panel LD010035 FIG. 27 – CONNECTION DIAGRAM 3 COMPRESSOR POWER PANEL YORK INTERNATIONAL...
Page 65 FORM 201.19-NM8 (804) Electronic Panel 035-15937-104 Rev E LD010036 LD09359 YORK INTERNATIONAL...
Page 66: Fig. 28 - Connection Diagram 3 Compressor
Technical Data FORM 201.19-NM8 (804) CONNECTION DIAGRAM ELEC. BOX (YCAS0685 - YCAS0965) LD010039 FIG. 28 – CONNECTION DIAGRAM 3 COMPRESSOR POWER PANEL YORK INTERNATIONAL...
Page 67: Fig. 29 - Connection Diagram 3 Compressor
FORM 201.19-NM8 (804) CONNECTION WIRING DIAGRAM 035 15937 105 Rev D Power Panel LD010037 FIG. 29 – CONNECTION DIAGRAM 3 COMPRESSOR ELECTRONIC PANEL YORK INTERNATIONAL...
Page 68: Fig. 30 - Elementary Diagram 3 Compressor Dxst Direct Drive Control Circuit
Technical Data FORM 201.19-NM8 (804) CONNECTION DIAGRAM ELEC. BOX (YCAS0685 - YCAS0965) Electronic Panel 035-15937-105 Rev D LD010038 FIG. 30 – ELEMENTARY DIAGRAM 3 COMPRESSOR DXST DIRECT DRIVE CONTROL CIRCUIT YORK INTERNATIONAL...
Page 69: Fig. 31 - Elementary Diagram Dxst Direct Drive - 3 Compressor
FORM 201.19-NM8 (804) ELEMENTARY DIAGRAM DXST DRIVE CONTROL CIRCUIT LD010040 FIG. 31 – ELEMENTARY DIAGRAM DXST DIRECT DRIVE - 3 COMPRESSOR YORK INTERNATIONAL...
Page 70: Fig. 32 - Connection Diagram System Wiring 3 Compressor
Technical Data FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM (CONT'D) LD010041 FIG. 32 – ELEMENTARY DIAGRAM SYSTEM WIRING 3 COMPRESSOR YORK INTERNATIONAL...
Page 71: Fig. 33 - Connection Diagram Ststem Wiring
FORM 201.19-NM8 (804) CONNECTION DIAGRAM SYSTEM WIRING (YCAS0685 - YCAS0965) 035 17140 106 Rev A LD010042 FIG. 33 – CONNECTION DIAGRAM STSTEM WIRING - 3 COMPRESSOR YORK INTERNATIONAL...
Page 72: Fig. 34 - Elementary Wiring Diagram - 4 Compressor
Technical Data FORM 201.19-NM8 (804) CONNECTION DIAGRAM SYSTEM WIRING 035 17140 106 Rev A LD010043 FIG. 34 – CONNECTION DIAGRAM STSTEM WIRING - 3 COMPRESSOR YORK INTERNATIONAL...
Page 73: Wiring Diagrams
FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM YCAS1065 - YCAS1215 (4 COMPRESSOR) LD09367 FIG. 35 – ELEMENTARY WIRING DIAGRAM - ACROSS-THE-LINE START YORK INTERNATIONAL...
Page 74: Fig. 36 - Elementary Wiring Diagram - Wye Delta Start
FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM YCAS1065 - YCAS1215 (4 COMPRESSOR) 035 16253 103 Rev A 035-16253-103 Rev - A LD09369 FIG. 36 – ELEMENTARY WIRING DIAGRAM - WYE DELTA START YORK INTERNATIONAL...
Page 75: Fig. 37 - Control Power Transformer Kit
FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM YCAS1065 - YCAS1215 (4 COMPRESSOR) 035 16253 103 Rev A 035-16253-10 Rev - A LD09370 FIG. 37 – CONTROL POWER TRANSFORMER KIT YORK INTERNATIONAL...
Page 76: Fig. 38 - Elementary Wiring Diagram
Terminal Block for Customer Low Voltage (Class 2) Connections. See Note 2 2. Contacts must be suitable for switching 24VDC, (Gold Terminal Block for YORK Connections Only contacts recommend). Wiring shall not be run in the same conduit with any line voltage wiring.
Page 77 FORM 201.19-NM8 (804) This page intentionally left blank. YORK INTERNATIONAL...
Page 78: Fig. 39 - Connection Diagram 4 Compressor
FORM 201.19-NM8 (804) ELEMENTARY WIRING DIAGRAM YCAS1065 - YCAS1215 (4 COMPRESSOR) LD010044 FIG. 39 – ELEMENTARY DIAGRAM 4 COMPRESSOR YORK INTERNATIONAL...
Page 79: Fig. 40 - Connection Diagram 4 Compressor
Ad- pressed with a YORK P/N 031-00808-000 sup pres sor across the ditionally, con trol wir ing not con nect ed to the Smart Panel should not re lay/con tac tor coil.
Page 80: Fig. 41 - Elementary Wiring Diagram
FORM 201.19-NM8 (804) CONNECTION DIAGRAM ELEC. BOX (YCAS1065 - YCAS1215) FIG. 41 – CONNECTION WIRING DIAGRAM YORK INTERNATIONAL...
Page 81 FORM 201.19-NM8 (804) Power Panel 035-16253-104 Rev D LD10047 YORK INTERNATIONAL...
Page 82: Fig. 42 - Connection Diagram 4 Compressor
FORM 201.19-NM8 (804) CONNECTION WIRING DIAGRAM 035-16253-104 Rev E Power Panel LD10048 FIG. 42 – CONNECTION DIAGRAM 4 COMPRESSOR YORK INTERNATIONAL...
Page 83: Fig. 43 - Connection Diagram 4 Compressor
FORM 201.19-NM8 (804) CONNECTION WIRING DIAGRAM Electronic Panel 035-16253-104 Rev E FIG. 43 – CONNECTION DIAGRAM 4 COMPRESSOR LD10049 YORK INTERNATIONAL...
Page 84: Fig. 44 - Connection Diagram 4 Compressor
FORM 201.19-NM8 (804) CONNECTION DIAGRAM ELEC. BOX (YCAS1065 - YCAS1215) LD10050 FIG. 44 – CONNECTION DIAGRAM 4 COMPRESSOR YORK INTERNATIONAL...
Page 85 FORM 201.19-NM8 (804) CONNECTION WIRING DIAGRAM Power Panel 035-16253-105 Rev D LD10051 YORK INTERNATIONAL...
Page 86: Fig. 45 - Elementary Diagram - Dxst Direct Drive Control Circuit
FORM 201.19-NM8 (804) CONNECTION WIRING DIAGRAM 035-16253-105 Power Panel Rev D FIG. 45 – CONNECTION DIAGRAM YORK INTERNATIONAL...
Page 87: Fig. 46 - Elementary Diagram - Dxst Direct Drive Control Circuit
FORM 201.19-NM8 (804) CONNECTION WIRING DIAGRAM Electronic Panel 035-16253-105 Rev D LD10053 FIG. 46 – CONNECTION DIAGRAM YORK INTERNATIONAL...
Page 88: Fig. 47 - Connection Diagram System Wiring
FORM 201.19-NM8 (804) ELEMENTARY DIAGRAM DXST STARTER CONTROL CIRCUIT 035-16253-102 Rev D 035-16253 Rev - B 2ACE Motor Protector LD09373 FIG. 47 – CONNECTION DIAGRAM SYSTEM WIRING YORK INTERNATIONAL...
Page 89: Fig. 48 - Connection Diagram System Wiring
FORM 201.19-NM8 (804) ELEMENTARY DIAGRAM DXST FAN CONTROL CIRCUIT 035-16253-102 Rev D 035-16253-102 Rev - B LD09374 FIG. 48 – CONNECTION DIAGRAM SYSTEM WIRING YORK INTERNATIONAL...
Page 90: Fig. 49 - Compressor Terminal Box, System
FORM 201.19-NM8 (804) CONNECTION DIAGRAM SYSTEM WIRING STANDARD AND REMOTE EVAP UNITS 035-19206-106 Rev - 035-19206-106 Rev a LD09383 FIG. 49 – CONNECTION DIAGRAM SYSTEM WIRING YORK INTERNATIONAL...
Page 91 FORM 201.19-NM8 (804) CONNECTION DIAGRAM SYSTEM WIRING STANDARD AND REMOTE EVAP UNITS 035-19206-106 Rev a 035-19206-106 Rev - LD09385 FIG. 49 – CONNECTION DIAGRAM SYSTEM WIRING (CONT'D) YORK INTERNATIONAL...
Page 92 FORM 201.19-NM8 (804) COMPRESSOR TERMINAL BOX SYSTEM 1 THROUGH 4 035-19206-106 Rev a LD10054 YORK INTERNATIONAL...
Page 93 FORM 201.19-NM8 (804) This page intentionally left blank. YORK INTERNATIONAL...
Page 94: Dimensions - Ycas0685 (Si)
Site re stric tions may compromise min i mum clearances indicated below, resulting in un pre dict able air ß ow pat terns and possible di min ished performance. YORK’s unit controls will optimize operation without nui sance high pres sure safety cutout;...
Page 95 FORM 201.19-NM8 (804) DIMENSIONS – YCAS0685 (SI) LD03977 CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Cop per) YCAS YCAS 3689 3711 1008 0685 0685 LD03978 YORK INTERNATIONAL...
Page 96: Dimensions - Ycas0775 - Ycas0905 (Si)
Site re stric tions may compromise min i mum clearances indicated below, resulting in un pre dict able air ß ow pat terns and possible di min ished performance. YORK’s unit controls will optimize operation without nui sance high pres sure safety cutout;...
Page 97 1034 0905 0905 2438 1981 SYS. #3 SYS. #1 & #2 10" POWER OPENING 10" (4) 57 DIA. RIGGING WATER INLET (BOTH SIDES) WATER OUTLET HOLES (EACH SIDE) 3708 2642 1614 1727 2277 1713 8694 SIDE VIEW LD03970 YORK INTERNATIONAL...
Page 98: Dimensions - Ycas0965 (Si)
Site re stric tions may compromise min i mum clearances indicated below, resulting in un pre dict able air ß ow pat terns and possible di min ished performance. YORK’s unit controls will optimize operation without nui sance high pres sure safety cutout;...
Page 99 CENTER OF GRAVITY (Copper) YCAS YCAS 4854 1042 4938 1049 1056 0965 0965 2438 1981 SYS. 1&2 (4) 57 DIA. RIGGING 10" 10" HOLES (EACH SIDE) POWER OPENING WATER INLET WATER OUTLET 3992 3607 1727 2277 1713 1614 8694 LD05588 YORK INTERNATIONAL...
Page 100: Dimensions - Ycas1065 - Ycas1215 (Si)
Site re stric tions may compromise min i mum clearances indicated below, resulting in un pre dict able air ß ow pat terns and possible di min ished performance. YORK’s unit controls will optimize operation without nui sance high pres sure safety cutout;...
Page 101 1135 1135 5632 1128 5627 1127 1010 1215 1215 2438 1981 SYS. 1&2 SYS. 3&4 10" WATER INLET 10" POWER (4) 57 DIA. RIGGING WATER OUTLET HOLES (EACH SIDE) OPENING 7939 3607 1727 2277 4304 2707 12351 LD06136 YORK INTERNATIONAL...
Page 102: Technical Data
(1.3 m) (2 m) LD09409 NOTES: 1. No obstructions allowed above the unit. 2. Only one adjacent wall may be higher than the unit. 3. Adjacent units should be 10 feet (3 meters) apart. FIG. 54 – CLEARANCES YORK INTERNATIONAL...
Page 103: Weight Distribution And Isolator Mounting Positions
1,173 1,076 —- —- —- —- 9,906 YCAS0905 1,046 1,178 1,078 —- —- —- —- 9,986 YCAS0965 1,012 1,124 10,737 YCAS1065 1,080 1,155 1,148 1,155 12,877 YCAS1135 1,080 1,156 1,150 1,156 12,950 YCAS1215 1,081 1,157 1,150 1,157 13,000 YORK INTERNATIONAL...
Page 104: Fig. 55 - Cp-2-Xx
Purple CP-2-27 1,500 680.4 1.06 26.9 Orange CP-2-28 1,800 816.4 1.02 25.9 Green CP-2-31 2,200 997.9 0.83 21.0 Gray CP-2-32 2,600 1,179.3 0.74 18.7 White CP-2-35 3,000 1,360.8 0.70 17.7 Gold ISOLATOR DETAILS LD01089 FIG. 55 – CP-2-XX YORK INTERNATIONAL...
Page 105: Fig. 56 - Isolator Details
AWMR-2-531 2552 1157.6 AWMR-1-552 1900 861.8 AWMR-2-532 3000 1360.8 LD02973 LD02974 AWMR-1-XXX AWMR-2-XXX DIMENSIONS - In. AWMR-1 10-1/2 3-1/2 1-3/4 8-1/2 4-1/4 10-1/2 11NC 50-553 AWMR-2 7-1/2 3-3/4 9-1/2 14-1/2 7-1/4 10NC 50-553 FIG. 56 – ISOLATOR DETAILS YORK INTERNATIONAL...
Page 106 (499.4) (158.7)(117.6) (41.4) (69.8) (76.2) (12.7) (127.0) (14.4) (9.6) RD-4 BLACK 1,500 (681.0) 2,250 (1021.5) 0.25 0.50 * HD dimension applies to double deﬂ ection Type RD mountings only. GREEN 3,000 (1362.0) (6.3) (12.7) RD-4 GRAY 4,000 (1816.0) YORK INTERNATIONAL...
Page 107 1,239 1,141 —- —- —- —- 10,762 YCAS0905 1,121 1,245 1,144 —- —- —- —- 10,842 YCAS0965 1,084 1,188 11,836 YCAS1065 1,148 1,233 1,225 1,233 14,064 YCAS1135 1,149 1,234 1,227 1,234 14,127 YCAS1215 1,149 1,235 1,227 1,235 14,197 YORK INTERNATIONAL...
Page 108: Fig. 57 - Cp-2-Xx
Purple CP-2-27 1,500 680.4 1.06 26.9 Orange CP-2-28 1,800 816.4 1.02 25.9 Green CP-2-31 2,200 997.9 0.83 21.0 Gray CP-2-32 2,600 1,179.3 0.74 18.7 White CP-2-35 3,000 1,360.8 0.70 17.7 Gold ISOLATOR DETAILS LD01089 FIG. 57 – CP-2-XX YORK INTERNATIONAL...
Page 109: Fig. 58 - Isolator Details
AWMR-2-531 2552 1157.6 AWMR-1-552 1900 861.8 AWMR-2-532 3000 1360.8 LD02973 LD02974 AWMR-1-XXX AWMR-2-XXX DIMENSIONS - In. AWMR-1 10-1/2 3-1/2 1-3/4 8-1/2 4-1/4 10-1/2 11NC 50-553 AWMR-2 7-1/2 3-3/4 9-1/2 14-1/2 7-1/4 10NC 50-553 FIG. 58 – ISOLATOR DETAILS YORK INTERNATIONAL...
Page 110 (499.4) (158.7)(117.6) (41.4) (69.8) (76.2) (12.7) (127.0) (14.4) (9.6) RD-4 BLACK 1,500 (681.0) 2,250 (1,021.5) 0.25 0.50 * HD dimension applies to double deﬂ ection Type RD mountings only. GREEN 3,000 (1,362.0) (6.3) (12.7) RD-4 GRAY 4,000 (1,816.0) YORK INTERNATIONAL...
Page 111 1,239 1,141 —- —- —- —- 10,762 YCAS0905 1,121 1,245 1,144 —- —- —- —- 10,842 YCAS0965 1,084 1,188 11,836 YCAS1065 1,148 1,233 1,225 1,233 14,064 YCAS1135 1,149 1,234 1,227 1,234 14,127 YCAS1215 1,149 1,235 1,227 1,235 14,197 YORK INTERNATIONAL...
Page 112: Fig. 59 - Cp-2-Xx
Purple CP-2-27 1,500 680.4 1.06 26.9 Orange CP-2-28 1,800 816.4 1.02 25.9 Green CP-2-31 2,200 997.9 0.83 21.0 Gray CP-2-32 2,600 1,179.3 0.74 18.7 White CP-2-35 3,000 1,360.8 0.70 17.7 Gold ISOLATOR DETAILS LD01089 FIG. 59 – CP-2-XX YORK INTERNATIONAL...
Page 113: Fig. 60 - Isolator Details
AWMR-2-531 2552 1157.6 AWMR-1-552 1900 861.8 AWMR-2-532 3000 1360.8 LD02973 LD02974 AWMR-1-XXX AWMR-2-XXX DIMENSIONS - In. AWMR-1 10-1/2 3-1/2 1-3/4 8-1/2 4-1/4 10-1/2 11NC 50-553 AWMR-2 7-1/2 3-3/4 9-1/2 14-1/2 7-1/4 10NC 50-553 FIG. 60 – ISOLATOR DETAILS YORK INTERNATIONAL...
Page 114 (499.4) (158.7)(117.6) (41.4) (69.8) (76.2) (12.7) (127.0) (14.4) (9.6) RD-4 BLACK 1,500 (681.0) 2,250 (1,021.5) 0.25 0.50 * HD dimension applies to double deﬂ ection Type RD mountings only. GREEN 3,000 (1,362.0) (6.3) (12.7) RD-4 GRAY 4,000 (1,816.0) YORK INTERNATIONAL...
Page 115 —- —- 11,688 YCAS0905 1,024 1,182 1,024 1,300 1,241 —- —- —- —- 11,768 YCAS0965 1,145 1,243 13,034 YCAS1065 1,222 1,355 1,307 1,355 15,218 YCAS1135 1,010 1,224 1,356 1,308 1,356 15,291 YCAS1215 1,009 1,224 1,357 1,309 1,357 15,340 YORK INTERNATIONAL...
Page 116: Fig. 61 - Cp-2-Xx
Purple CP-2-27 1,500 680.4 1.06 26.9 Orange CP-2-28 1,800 816.4 1.02 25.9 Green CP-2-31 2,200 997.9 0.83 21.0 Gray CP-2-32 2,600 1,179.3 0.74 18.7 White CP-2-35 3.000 1,360.8 0.70 17.7 Gold ISOLATOR DETAILS LD01089 FIG. 61 – CP-2-XX YORK INTERNATIONAL...
Page 117: Fig. 62 - Isolator Details
AWMR-2-531 2552 1157.6 AWMR-1-552 1900 861.8 AWMR-2-532 3000 1360.8 LD02974 LD02973 AWMR-1-XXX AWMR-2-XXX DIMENSIONS - In. AWMR-1 10-1/2 3-1/2 1-3/4 8-1/2 4-1/4 10-1/2 11NC 50-553 AWMR-2 7-1/2 3-3/4 9-1/2 14-1/2 7-1/4 10NC 50-553 FIG. 62 – ISOLATOR DETAILS YORK INTERNATIONAL...
Page 118 (499.4) (158.7)(117.6) (41.4) (69.8) (76.2) (12.7) (127.0) (14.4) (9.6) RD-4 BLACK 1,500 (681.0) 2,250 (1,021.5) 0.25 0.50 * HD dimension applies to double deﬂ ection Type RD mountings only. GREEN 3,000 (1,362.0) (6.3) (12.7) RD-4 GRAY 4,000 (1,816.0) YORK INTERNATIONAL...
Page 119: Installation Instructions For Vmc Series Awr/Awmr And Cp Restrained Mountings
1/4" shim be tween the upper load plate and vertical up rights. Lower the equip ment on the blocking or shimmed isolators. Complete piping and ﬁ ll equipment with wa ter, re frig er ant, etc. YORK INTERNATIONAL...
Page 120: Fig. 63 - Refrigerant Flow Diagram
The high pressure oil-free vapor is fed to the ing to the evaporator. air cooled condenser coil where the heat is re moved. On economized models, the fully con densed liquid enters the econ o miz er. YORK INTERNATIONAL...
Page 121: Fig. 64 - Process And Instrumentation
DIFFERENTIAL PRESSURE CUTOUT CONDENSER COIL COOLER DISCHARGE PRESSURE FAN CONTROL DISPLAY VALUE OIL COOLER COIL HIGH PRESSURE LOAD LIMITING OIL SEPARATOR HIGH TEMPERATURE CUTOUT LOW PRESSURE CUTOUT LOW TEMPERATURE CUTOUT LD09429 FIG. 64 – PROCESS AND INSTRUMENTATION DIAGRAM YORK INTERNATIONAL...
Page 122: Fig. 65 - Component Locations
HIGH PRESSURE CUT-OUT - STS SUCTION TEMPERATURE SENSOR - RFTS REFRIGERANT FEED TEMPERATURE SENSOR (R407C only) - XCMTB COMPRESSOR MOTOR TERMINAL BOX - YELSSV ECONOMIZER LIQUID SUPPLY SOLENOID VALVE - ZCPR COMPRESSOR LD05021 FIG. 65 – COMPONENT LOCATIONS YORK INTERNATIONAL...
Page 123 HIGH PRESSURE CUT-OUT - STS SUCTION TEMPERATURE SENSOR - RFTS REFRIGERANT FEED TEMPERATURE SENSOR (R407C only) - XCMTB COMPRESSOR MOTOR TERMINAL BOX - YELSSV ECONOMIZER LIQUID SUPPLY SOLENOID VALVE - ZCPR COMPRESSOR LD05024 FIG. 65 – COMPONENT LOCATIONS (CONT’D) YORK INTERNATIONAL...
Page 124: Compressor Components
OIL FILTER LOCKING BOLT COVER PLATE OIL FILTER BLEED & EVACUATION POINT LIFTING LUG THREADED HOLE HEATER ECONOMIZER GAS IN DISCHARGE CASE DISCHARGE GAS OUT EVACUATION PORT OIL INLET FROM CONDENSER LD03668 COOLING COIL FIG. 66 – COMPRESSOR COMPONENTS YORK INTERNATIONAL...
Page 125: Fig. 67 - Compressor Components
FORM 201.19-NM8 (804) COMPRESSOR COMPONENTS – CONT’D LD03669 FIG. 67 – COMPRESSOR COMPONENTS YORK INTERNATIONAL...
Page 126: Fig. 68 - Compressor Components
Technical Data FORM 201.19-NM8 (804) COMPRESSOR COMPONENTS – CONT’D LD03670 FIG. 68 – COMPRESSOR COMPONENTS YORK INTERNATIONAL...
Page 127: Fig. 69 - Compressor Components
FORM 201.19-NM8 (804) COMPRESSOR COMPONENTS – CONT’D MALE ROTOR DISCHARGE CHECK VALVE LD06079 RELIEF VALVE FIG. 69 – COMPRESSOR COMPONENTS YORK INTERNATIONAL...
Page 128: Fig. 70 - Compressor Components
BEARING CLAMP NUT REVERSE THRUST BEARING THRUST SPACER SHIM THRUST BEARINGS SPACER SHIM DISCHARGE RADIAL BEARING LIP SEAL DOWEL PIN SUPPORT RING ECONOMIZER PLUG SUPPORT RING FEMALE ROTOR RETAINING RING FEMALE INLET BEARING LD03673 FIG. 70 – COMPRESSOR COMPONENTS YORK INTERNATIONAL...
Page 129: Fig. 71 - Compressor Components
FORM 201.19-NM8 (804) COMPRESSOR COMPONENTS – CONT’D MOTOR ROTOR / MALE ROTOR LOCKING KEY O-RING MALE ROTOR SLIDE VALVE RELIEF O-RING RETURN VALVE SPRING FEMALE ROTOR ECONOMIZER SLIDE VALVE SUPPORT PLUG RINGS LD03672 FIG. 71 – COMPRESSOR COMPONENTS YORK INTERNATIONAL...
Page 130: System Startup Checklist
Technical Data FORM 201.19-NM8 (804) SYSTEM STARTUP CHECKLIST If it is necessary to add oil, con nect a YORK oil pump to the charging valve on the oil sep a ra tor, JOB NAME: _____________________________ but do not tight en the ﬂ are nut on the delivery SALES ORDER #: ________________________ tub ing.
Page 131: Panel Checks
Damage to the chiller could Sys #1 100% FLA = _________________________Amps result if switch es are im prop er ly Sys #2 100% FLA = _________________________Amps pro grammed. Sys #3 100% FLA = _________________________Amps Sys #4 100% FLA = _________________________Amps YORK INTERNATIONAL...
Page 132: Initial Start-Up
This Liq Line Temp = ºF (ºC) is due to the com pres sor com ing up to speed and Subcooling = ºF (ºC) lubrication chang ing from liq uid re frig er ant to YORK INTERNATIONAL...
Page 133: Leak Checking
(IF APPLICABLE) (15 TON TXV) load and unload to control water temperature, the chill er is ready to be placed into operation. The economizer superheat should be checked to as sure YORK INTERNATIONAL...
Page 134: Section 8 - Micro Panel Contents
This switch shuts down the entire chiller when placed in the OFF position. The switch must be ON for the chiller to operate. The systems will not pump down at shutdown when the UNIT switch is switched OFF. YORK INTERNATIONAL...
Page 135: Introduction & Physical Description
The YORK Screw Chiller Control Panel is a mi cro pro - ces sor based control system ﬁ tted to YCAS liq uid chill- YCAS chillers each have a single split circuit evap o ra tor ers.
Page 136: 1.3 Unit (Chiller) On / Off Switch
(setpoints, clock, cutouts, etc.) I/O Ex pan sion Board which multiplexes them and then are not lost during a power failure or shutdown period feeds them to the Microprocessor Board. re gard less of the time involved. YORK INTERNATIONAL...
Page 137: Circuit Breakers
Mi cro pro ces sor This could cause evap o ra tor freeze- Board. up in low ambient tem per a tures. Removing 115VAC power to individual circuits also removes power to the compressor heaters, which should also be avoided. YORK INTERNATIONAL...
Page 138: 1.8 Transformers
M1 and M2 contacts, the last 2 faults will show Low CURR/MP/HP, but will have no value for trouble- shooting. The information contained in HISTORY BUFFER #3 will be use- ful on troubleshooting the cause of the Mo tor Pro tec tor fault. YORK INTERNATIONAL...
Page 139: Fig. 72 - Motor Protection Module
SWITCH PUSHED TO THE LEFT SIDE VIEW INDICATES ON (SWITCHES PLACED IN THE ON POSITION ADD TO EQUAL THE OVERLOAD SETTING VALUE. FOR EXAMPLE, IF SWITCH 2 AND 128 ARE ON, THE DISPLAY WILL FLASH HA130) FIG. 72 – MOTOR PROTECTION MODULE YORK INTERNATIONAL...
Page 140: Ems/Bas Controls
Current Limit may be viewed on the the de vice must be sup pressed with a EMS Current Lim it ing Dis play under sup pres sor YORK Part Number 031- the Mo tor Current Key (see Sec tion 00808-000 across the in duc tive coil.
Page 141 For example, with a programmed setpoint of 44°F (7°C), with a sup pres sor YORK Part Num ber after a 4 second pulse and a programmed maximum off set 031-00808-000 across the in duc tive of 40°F (22°C), the temperature offset would equal:...
Page 142: Microprocessor Board Layout
NOTE : Dimple is positioned at top edge (3A) Dip Switch Set (8 switches) System Switches S2 = System 1 S3 = System 2 S2 to S5 S4 = System 3 S5 = System 4 FIG. 73 – COMPONENT LAYOUT YORK INTERNATIONAL...
Page 143: Logic Section Layout
Back of Keypad I/O Expansion Board # 2 I/O Expansion Board # 1 Power Supply Board Relay Output Board #1 Relay Output Board #2 Flow Switch & Customer Connection Terminals (TB4) Circuit Breakers FIG. 74 – LOGIC SECTION LAYOUT YORK INTERNATIONAL...
Page 144: Anti-Recycle Timer
5 minutes. After 5 minutes has elapsed, the heat er will shut off if the discharge temperature rises above 150 °F (66°C) and will turn on when the dis charge tem per a ture is equal to or less than 150 °F (66°C). YORK INTERNATIONAL...
Page 145: Alarms
RC lead to the compressor with the shortest anti-recycle sup pres sor YORK Part Num ber 031- time in a an effort to provide cooling quick ly. 00808-000 across the in duc tive coil.
Page 146: Or 4 Compressor Chiller Configuration
The second timer assures that a minimum of 3 minutes elapses from the time the economizer turns off to the next time it is called to turn on again. YORK INTERNATIONAL...
Page 147 FORM 201.19-NM8 (804) This page intentionally left blank. YORK INTERNATIONAL...
Page 148: Status Key: General Status Messages & Fault Warnings
S Y S C O M P R U N N I N G applicable to represent the system number where mes- sag es apply to individual systems. This message indicates that the respective compressor is running due to demand. YORK INTERNATIONAL...
Page 149: Unit Warnings
Once a low battery condition is detected, the only way to run the chiller is to use the Manual Override key - see Section 8.7.4. This al lows re pro gram ming of setpoints, cutouts, and sched ule. YORK INTERNATIONAL...
Page 150: Anticipation Control Status
Therefore, "Automatic" is typically ambient or load conditions occur. See Anticipatory Un- selected and programmed under the loading Controls Page 173 for detailed operation. PROGRAM key. See page 182. YORK INTERNATIONAL...
Page 151: Unit Fault Status Messages
This the chill er must be manually reset. See Section 8.2 feature is programmable and can also be used to shut (page 182). down the chiller at a temperature where continued run- YORK INTERNATIONAL...
Page 152: System Fault (Safety) Status Messages
Fail ure to repair the cause of the fault while manually al low ing re pet i tive re starts may cause fur ther ex pen sive damage to the system. YORK INTERNATIONAL...
Page 153: Fig. 75 - Suction Pressure Cutout
130 - 150°F (54 - 66°C). The High Oil Temperature Safety is activated after 2 minutes of compressor operation, after which if oil tem per a ture is above 225°F (107°C) for more than 3 sec onds, the compressor will shut down. YORK INTERNATIONAL...
Page 154 This may result from loss of re frig er ant, a de- fective contactor, power problems, or from a compressor that is not pumping due to a mechanical malfunction. YORK INTERNATIONAL...
Page 155: Printout On Fault Shutdown
R-407C. This safety uses the Evaporator Inlet Refrigerant Temp Sen sors to mon i tor evaporator inlet refrigerant tem per a ture on each system. These sensors are only installed on R-407C units. YORK INTERNATIONAL...
Page 156: Display Keys & Option Switches
M C H L T 4 3 . 8 ° the values which are being displayed, but are outside the ability of the micro to give an actual reading. This YORK INTERNATIONAL...
Page 157: System # Data Keys
Display Limits: Minimum - 4.6°F (-20.3°C) valve solenoid in the form of a voltage signal. To the Maximum 137.9°F (58.8°C) mi cro pro ces sor, STEP 0 = fully unloaded and STEP 75 = fully loaded. YORK INTERNATIONAL...
Page 158: Motor Current Key
The Options key provides a display of op tions which are Cutout setting at 25°F (-4°C) and is not ad just able. programmed by the po si tions of the S1 Dip Switch es on the Mi cro pro ces sor Board. Proper pro gram ming of YORK INTERNATIONAL...
Page 159: Fig. 77 - Enlarged Photograph Of Dip Switches On Microprocessor Board
Place the switch in the CLOSED position selects the type of chiller as an air cooled chiller (YCAS). The DO NOT USE THIS POSITION. switch MUST always be in the CLOSED position. Nuisance trips at start-up could result. Incorrect programming may cause damage to the chiller. YORK INTERNATIONAL...
Page 160: Function Key
The following keys can be scrolled using the Function E L E C T R O N I C Key: Chilled Liquid Temps, System # Data, Motor Cur- rent and Options. Placing the switch in the CLOSED position, conﬁ gures YORK INTERNATIONAL...
Page 161: Print Keys
“rate control” and “temperature deviation from setpoint” to de ter mine Information available using the Operating Data key is de- when loading/unloading should occur. YORK INTERNATIONAL...
Page 162 – YorkTalk via ISN or Remote Control Center (remote mode). PWM CURR – EMS PWM Current Limiting Enabled PWM TEMP – EMS PWM Temp. Reset Enabled CUR/TEMP – EMS PWM Current Limiting & Temperature Reset Enabled YORK INTERNATIONAL...
Page 163: Operating Data - Software Version
This message displays the accumulated Run Time since printouts for the appropriate number of systems: the last start in Days (D), Hours (H), Minutes (M), and Seconds (S). YORK INTERNATIONAL CORPORATION MILLENNIUM SCREW CHILLER S Y S L L S V...
Page 164: History Key
No. 1. After the ENTER Key is pressed, a mes sage in- dicating the time and date of the Fault Shut down will appear: S H U T D O W N O C C U R R E D 5 : 5 9 A M N O V YORK INTERNATIONAL...
Page 165 1 0 0 % F L A This message indicates whether heat recovery is dis- abled or enabled. (HEAT RECOVERY MUST BE This message shows the programmed %FLA Motor DISABLED) Current Unload at the time of the fault. YORK INTERNATIONAL...
Page 166 N U M B E R This message indicates the compressor motor current in amps and as a percentage of Full Load Amps. This message indicates which system was in the lead at the time of the fault. YORK INTERNATIONAL...
Page 167 R E F R I G T E M P 2 8 . 2 ° F This message, which is only displayed if the unit is in R-407C mode, indicates the refrigerant temperature at the inlet of the evaporator. YORK INTERNATIONAL...
Page 168: Fault History Data - Remote Printout
ECONOMIZER TXV SOLENOID An example of the HISTORY Printout is shown be- CONDENSER FAN STAGE low: COMPRESSOR HEATER WYE-DELTA RELAY YORK INTERNATIONAL CORPORATION SYSTEM 2 DATA MILLENNIUM SCREW CHILLER COMPRESSORS STATUS SAFETY SHUTDOWN NUMBER 1 RUN TIME 0- 0-15-26 D-H-M-S...
Page 169: Entry Keys
“AM” or “PM” on the display. For ex- original values will be returned. am ple, pressing the " key when the cursor is on “PM” changes it to “AM.” YORK INTERNATIONAL...
Page 170: Setpoints Keys & Chilled Liquid Control
“Control Range” and is best the slide valve solenoid of each compressor. Voltage de scribed as the maximum acceptable + and - deviation increases with load (0 - approximately 9VDC at full from Setpoint. load). YORK INTERNATIONAL...
Page 171 2nd and 3rd lag compressor will of the mechanism, a position less than 75, possibly 60, be alternately loaded until the leaving chilled liquid could also mean that the compressor is fully loaded. A temperature is satisﬁ ed. YORK INTERNATIONAL...
Page 172 Chill er fault on a Low Wa ter Tem- > 80 % per a ture cut-out under the fol low ing > 90 % conditions: a) if chilled liq uid tem- > 95 % per a ture falls below the low end of the YORK INTERNATIONAL...
Page 173 S Y S D S C H / O I L I N H I B > 108 % S Y S D S C H / O I L I N H I B > 115 % YORK INTERNATIONAL...
Page 174: Local Cooling Setpoints Key
“0” for val ues After the Setpoint and Range is keyed in, press the less than 10°F (or 5.6°C). Press the ENTER Key to store ENTER Key to store the data in memory. the new value in memory. YORK INTERNATIONAL...
Page 175: Clock Keys
Press ENTER to move on to the hour part of the display. Next, key in the time (hours/minutes) using a leading Press ing the Set Time key a second time enters “display” mode in which the cursor will dis ap pear and the “live” clock will be dis played. YORK INTERNATIONAL...
Page 176: Set Schedule / Holiday Key
ON position, all 00.00s should be programmed into the oc ca sion al ly. daily schedule. This can be done manually for in di vid u al days or for all days by pressing Cancel and En ter for the Monday Start/Stop schedule. YORK INTERNATIONAL...
Page 177: Manual Override Key
30 min utes and the fol low ing 2.3, page 149. sta tus message will be ob served: M A N U A L O V E R R I D E YORK INTERNATIONAL...
Page 178: Program Key
Enter key is exceeded for 3 seconds, the system will shut down. is pressed and the display will scroll on to the next pro- Normally, air-cooled chillers, such as YCAS chillers, gram ma ble value. YORK INTERNATIONAL...
Page 179 ﬁ rst.), suction pressure is monitored as long 18°F (10°C) below the lowest temperature of the pro- as the compressor runs. For the ﬁ rst 270 sec onds of run- grammed chilled liquid Control Range (Section 6). YORK INTERNATIONAL...
Page 180 Enter key to store the value into lim it ing”. This is important when demand limiting is memory and scroll to the next display. crit i cal due to power requirements or limitations in the build ing (See also Section 1.10). YORK INTERNATIONAL...
Page 181 S E T P O I N T = 1 2 . 0 º F The EEV superheat setpoint is programmable. The setpoint can be programmed for 9.0ºF (5.0ºC) to 15ºF (8.3ºC) with 12.0ºF (6.6ºC) as the default. YORK INTERNATIONAL...
Page 182: Programming "Default" Values
This will preset all programmable values un der the Program key to values that will allow operation of the chiller under most operating conditions. This al lows quick start-up pro gram ming for typical chilled wa ter ap pli ca tions. YORK INTERNATIONAL...
Page 183: Table 3 - Default Values Table
Imperial Lead / Lag Control Mode Automatic Power Failure Restart Mode Automatic Motor Current Averaging Cutout 30% FLA 110% FLa 70 % FLA 9.0 ºF 15.0 ºF 12.0 ºF Suction Superheat Setpoint 5.0 ºC 8.3 ºC 6.6 ºC YORK INTERNATIONAL...
Page 184: 8.4 Electronic Expansion Valve
The purpose of the EEV is to meter a ﬂ ow of liquid refrigerant into the evaporator to maintain a superheat 120 VAC PILOT SOLENOID EXPANSION VALVE 24 VAC HEAT MOTOR LD09132 FIG. 78 – ELECTRONIC EXPANSION VALVE YORK INTERNATIONAL...
Page 185: 8.5 Eev Operation
ﬁ rst. is the PWM per cent age that will be sent to the ETRE heat motor. This PWM output is the percentage of a 1 second pe ri od that the 24VAC heat motor power signal is energized. YORK INTERNATIONAL...
Page 186 S E N S O R F A I L U R E LIQUID LINE SOLENOID ECONOMIZER TXV SOLENOID OFF(YCAS) OIL COOLING SOLENOID OFF(YCWS) HEAT RECOVERY SOLENOID OFF(B HR) DISCHARGE COOLING SOLENOID OFF(EC,LT) CONDENSER FAN STAGE COMPRESSOR HEATER WYE-DELTA RELAY YORK INTERNATIONAL...
Page 187: 8.6 Eev Programming
The Expansion Valve type selection is viewable un der the OP TIONS key. TABLE 4 – PROGRAMMABLE VALUES TABLE (MINIMUM/MAXIMUM) PROGRAM VALUE MODE LOW LIMIT HIGH LIMIT DEFAULT 15.0 12.0 º º º SUPERHEAT SETPOINT (5.0 º º º YORK INTERNATIONAL...
Page 188: 8.7 Eev Troubleshooting
EEV output. · If everything checks out, it is possible that the EEV has failed. If the small charge in the bulb leaks, the valve will not be able to open and the entire EEV must be replaced. YORK INTERNATIONAL...
Page 189: Compressor Condenser Fan Control
13, 15, 17, 19 >295 PSIG <215 PSIG & <85°F 21M, 22M, 23M, 24M 330, 331, 332 8, 9, 10 * At ambients above 85ºF, stages 3, 4, 5, and 6 will all turn on at 240 psig. YORK INTERNATIONAL...
Page 190: Compressor Condenser Fan Control
<215 PSIG & <85°F 15M, 16M, 17M, 18M, 19M 230, 231, 232 10, 14, 15 SYSTEM 3 IS ALWAYS EQUIPPED WITH 4 FANS. * At ambients above 85ºF, stages 3, 4, 5, and 6 will all turn on at 240 psig. YORK INTERNATIONAL...
Page 191: Table 6 - Condenser Fan Control And Fan Contactor Data For Dxst Units
14, 16, 18, 20 >295 PSIG <215 PSIG & <85°F 27M, 28M, 29M, 30M 430, 431, 432 8, 9, 10 * At ambients above 85ºF, stages 3, 4, 5, and 6 will all turn on at 240 psig. YORK INTERNATIONAL...
Page 192: Table 9 - Condenser Fan Control And Fan Contactor Data For Dxst Units
9, 10 14, 16, 18 >295 PSIG <215 PSIG & <85°F 27M, 28M, 29M 430, 431, 432 8, 9, 10 * At ambients above 85ºF, stages 3, 4, 5, and 6 will all turn on at 240 psig. YORK INTERNATIONAL...
Page 193: 8.10 Service Mode: Unit Setup
180 ºF default Oil Cooling Diff 9 to 18 ºF **** 9 ºF default Discharge Cooling On 176.0 to 239.0 ºF 212.0 ºF default Discharge Cooling Diff 7.2 to 27.0 ºF 18 ºF default Data Logging Mode OFF or ON YORK INTERNATIONAL...
Page 194: Table 11 - Ycas Style G, Across The Line Start - 50 Hz
Sys 1 & 2 0783 Sys 3 0873 0953 1063 Sys 1 & 2 1063 Sys 3 & 4 1093 Sys 1 & 2 1093 Sys 3 & 4 1163 1263 * Indicates one lead/phase through motor protector. YORK INTERNATIONAL...
Page 195: Table 12 - Ycas Style G, Wye Delta Start - 50 Hz
Sys 1 & 2 0783 Sys 3 0873 0953 1063 Sys 1 & 2 1063 Sys 3 & 4 1093 Sys 1 & 2 1093 Sys 3 & 4 1163 1263 * Indicates one lead/phase through motor protector. YORK INTERNATIONAL...
Page 196 (ON and OFF). An example is shown below: S Y S L L S V J 7 - 3 O F F YORK INTERNATIONAL...
Page 197: 8.11 Control Inputs/Outputs
SPARE Microboard / Relay Board 2 J8-5 / TB1-6/5 Evaporator Pump Microboard / Relay Board 2 J8-6 / TB1-4/3 Sys 2 Alarm I/O Expansion J13-1 Sys 1 EEV Heat Motor I/O Expansion J13-2 Sys 2 EEV Heat Motor YORK INTERNATIONAL...
Page 198: Table 14 - Analog Inputs
I/O Expansion J9-2 Sys 2 Fan Pressure Transducer (Heat Recovery only) I/O Expansion J10-6 Sys 2 Oil Temp Sensor I/O Expansion J10-7 Sys 1 Oil Temp Sensor I/O Expansion J11-2 Sys 1 Evaporator Inlet Refrigeration Temp Sensor (R-407c only) YORK INTERNATIONAL...
Page 199: Table 15 - Digital Inputs
Hot Flow Switch (Heat Recovery only) ANALOG OUTPUTS Table 16 lists all the analog outputs and what output board they are on. TABLE 16 - ANALOG OUTPUTS I/O Expansion J2-1 Sys 1 Slide Valve I/O Expansion J12-1 Sys 2 Slide Valve YORK INTERNATIONAL...
Page 200: 8.12 Sensor Calibration Charts
TEST POINTS: Suction Pressure: System 1: ............Microboard J13-7/1 System 2: ............Microboard J14-7/1 Oil Pressure: System 1: ............Microboard J13-8/3 System 2: ............Microboard J14-8/3 Discharge Pressure: System 1: ............Microboard J15-8/3 System 2: ............Microboard J15-7/1 YORK INTERNATIONAL...
Page 201: 8.13 Isn Control
44-47 Sys 1 Discharge Pressure 48-51 Sys 1 % Full Load Amps 52-55 Sys 1 Total Run Hours 56-59 Sys 1 Total Number of Stats 60-63 Sys 1 Anti-Recycle Timer 64-67 Anti-Coincident Timer 68-71 Sys 2 Oil Temperature YORK INTERNATIONAL...
Page 202 *Sys 1 Fault Code *Sys 2 Operatioanal Code *Sys 2 Fault Code Sys 1 Slide Valve Step Sys 1 Condenser Fan Stages Running (0-6) Sys 2 Slide Valve Step Sys 2 Condenser Fan Stages Running (0-6) Lead Compressor Number Debug Code YORK INTERNATIONAL...
Page 203 Cooling Range 174-177 Sys 1 Discharge Superheat 178-181 Sys 2 Suction Temperature 182-185 Sys 2 Discharge Temperature 186-189 Sys 2 Suction Superheat 190-193 Sys 2 Discharge Superheat Digital S1-7 Expansion Valve Type: 0=TXV, 1=EEV S1-8 SPARE — — — YORK INTERNATIONAL...
Page 204: Table 19 - Isn Operational And Fault Codes
* The operational and fault codes are deﬁ ned in Table 19. Note that this table of fault and operational codes is for all DX products. The codes that are grayed out are not used on this unit. YORK INTERNATIONAL...
Page 205 FORM 201.19-NM8 (804) This page intentionally left blank. YORK INTERNATIONAL...
Page 206: Section 9 - Maintenance
YORK Service Agent. for these regular maintenance requirements and/or en ter into a maintenance agreement with a York In ter na tion al Unit Status: Press the ‘STATUS’ key on the keypad ser vice organization to protect the operation of the unit.
Page 207: Chiller / Compressor Operating Log
Nor mal ly a ‘minor’ service should be carried out every three to six months and a ‘major’ service once a year. It is recommended that your local YORK Service Cen ter is contacted for recommendations for in di vid u al sites. ON-BOARD BATTERY BACK-UP U17 is the Real Time Clock chip that maintains the date/ time and stores customer programmed setpoints.
Page 208 YORK Order No. ________________________ CHILLER/COMPRESSOR Compr. Ser. No. _________________________ Operating Log Unit Ser. No. ___________________________ Refrigerant_____________________________ Date Time Hour Meter Reading Equipment Room Temp./Outdoor Temp. Suction Pressure Suction Temperature Suction Superheat Discharge Pressure Actual Discharge Temperature Oil Pressure Oil Temperature...
Page 209 * Reserved for customer use for any special site determined requirements. This procedure must be performed at the speciÞ ed time interval by an Industry CertiÞ ed Technician who has been trained and qualiÞ ed to work on this type of YORK equipment.
Page 210: General Periodic Maintenance Checks
Check emergency stop. Check motor protectors. Check overload devices. Microprocessor controls: Check fault history. Check fan control function. Check program settings. Check ambient cut-out function. Check HP / LP cutout functions Check pump-down function. Check load / unload function. YORK INTERNATIONAL...
Page 211: Section 10 - Spare Parts
Other spare parts vary depending on the unit mod el. Review the chiller Renewal Parts Manual or Contact your local YORK Sales and Ser vice Center for in for ma tion (Please quote the unit model num ber and serial number).
Page 212: Section 11 - Troubleshooting
Check that the compressor unloads correctly. Measured temperature is incorrect. Check water temp sensor and wiring. Chiller FAULT: VAC Check main supply is stable and within allowable UNDERVOLTAGE Poor main supply voltage. limits. displayed. Check for voltage dip on compressor start. YORK INTERNATIONAL...
Page 213 Check operation of economizer, TXV, and liquid solenoid valve. SYS # CURR LIMITING High compressor motor current Check if liquid temperature is within operating limits. displayed has activated unloading. Check if ambient air temperature is above operating (Compressor current un- limits. loading.) YORK INTERNATIONAL...
Page 214: Engineered Systems
Except for reciprocating compressors, which YORK war- rants for a period of one year from date of ship ment, YORK in law or in fact, including the war ran ties of warrants reconditioned or re place ment ma te ri als, or start- merchantability and ﬁ...
Page 215: Temperature Conversion Chart
186.8 22.07 16.5 239.3 100.0 190.4 22.76 246.5 102.2 23.45 17.5 253.8 104.4 197.6 24.14 106.7 201.2 24.83 18.5 268.3 108.9 204.8 25.52 275.5 111.1 208.4 26.21 19.5 282.8 113.3 26.9 115.6 215.6 27.59 20.5 297.3 117.8 219.2 YORK INTERNATIONAL...
Page 216 P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA Tele. 800-861-1001 Copyright © by York International Corporation 2004 ALL RIGHTS RESERVED www.york.com Form 201.19-NM8 (804) New Release...

This manual is also suitable for:

Ycas0685eb series Ycas0775eb series Ycas0835eb series Ycas0905eb series Ycas0965eb series Ycas1065eb series ... Show all

York YCAS Series Installation Operation & Maintenance

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

Fig. 68 - Compressor Components

Fig. 69 - Compressor Components