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York YCAQ10 Manual

Packaged liquid chillers air cooled – reciprocating hermetic
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PACKAGED LIQUID CHILLERS
AIR COOLED – RECIPROCATING HERMETIC
INSTALL., OPER., MAIN.
Supersedes: 150.40-NM20 (587)
Form 150.40-NM20 (597)
MODELS YCAQ10, YCAM12, YCAK14, YCAKI16, YCAG18
YCAR11, YCAN13, YCAL15, YCAJ17 & YCAH19
ALSO
MODELS YCH100, 120, 150, 175, & 200
STYLE C*
00004TG
*WITH MICROPROCESSOR CONTROL PANEL
WITH G.E. II. 4 EPROM (MODEL YCHA100)
WITH G.E. II. 3 EPROM (MODELS YCHA120 THRU 200)
WITH G.E. II. 5 EPROM (MODELS YCHA120 THRU 200)
(See page 2 for further clarifications)

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  • Page 1 PACKAGED LIQUID CHILLERS AIR COOLED – RECIPROCATING HERMETIC INSTALL., OPER., MAIN. Supersedes: 150.40-NM20 (587) Form 150.40-NM20 (597) MODELS YCAQ10, YCAM12, YCAK14, YCAKI16, YCAG18 YCAR11, YCAN13, YCAL15, YCAJ17 & YCAH19 ALSO MODELS YCH100, 120, 150, 175, & 200 STYLE C* 00004TG *WITH MICROPROCESSOR CONTROL PANEL WITH G.E.

  • Page 2: Table Of Contents

    Preventive Maintenance ..........Trouble-Shooting Chart ............ Service Bulletins .............. UNIT IDENTIFICATION Effective May 1, 1987, YORK introduced a new method CROSS REFERENCE CHART of unit identification (nomenclature). The new method NOMENCLATURE of identification does not reflect any change in unit de-...

  • Page 3: General Information

    28 = 230-3-60 40 = 380-3-60 46 = 460-3-60 LD01773 50 = 380/415-3-50 64 = 346-3-50 FIG. 1 – COOLER WATER PRESSURE DROP Motor Manufacturer (A = A.O. Smith, G = G.E.) J S 4 3 E M -17 G YORK INTERNATIONAL...

  • Page 4: Dimensions

    DIMENSIONS YCHA100 LD01774 NOTES: 1. Clearances – Minimum YORK required clearances to prevent condenser air recirculation and faulty operation of units are as follows: Side to wall 8'–0"* Rear to wall 8'–0"* Control Panel End to wall 5'–0"* Top 50'–0"* Distance Between Adjacent units 12'–0"...
  • Page 5 DIMENSIONS YCHA120, 150, 175, 200 LD01775 NOTES: 1. Clearances – Minimum York required clearances to prevent condenser air recirculation and faulty operation of units are as follows: Side to wall 8'–0"* Rear to wall 8'–0"* Control Panel End to wall 5'–0"* Top 50'–0"...

  • Page 6: Electrical Data

    SINGLE POINT POWER WIRING (OPTIONAL) NON-FUSED MAX. DUAL MIN. CIR. DISCONNECT INCOMING MODEL VOLTS-PH-Hz ELEM. FUSE AMPACITY SWITCH WIRE RANGE 380-3-60 YCHA120 460-3-60 380/415-3-50 380-3-60 YCHA150 460-3-60 (1) #1/0-600MCM 380/415-3-50 380-3-60 (2) #1/0-250MCM YCHA175 460-3-60 CU/AL 380/415-3-50 380-3-60 YCHA200 460-3-60 380/415-3-50 YORK INTERNATIONAL...
  • Page 7 The above recommendations are based on the National Electrical Code. Field wiring must also comply with local codes. Current Overload Setting – Protects motor by stopping unit if compressor motor current exceeds values shown. LEGEND Amps AMP. = Ampacity Hertz Horsepower Phase Volts Running Load Amps Full Load Amps Part Wind YORK INTERNATIONAL...

  • Page 8: Physical Data

    NOTE: Ratings are in accordance with ARI Standard 590 based upon nominal conditions of 44°F leaving chilled water temperature, 95°F ambient air temperature on condenser, 10 degree chilled water range and a 0.0005 fouling factor in the cooler. YORK INTERNATIONAL...

  • Page 9: Installation

    Mason Industries should be selected for minimum sun exposure and to or Vibration Mounting & Controls, Inc. insure an adequate supply of fresh air for the condenser. *Four (4) on YCHA100 (See CLEARANCES, pages 4 & 5.) Avoid locations YORK INTERNATIONAL...
  • Page 10 YCHA175 402 407 406 406 402 407 406 402 YCHA175 2-27 2-32 2-31 2-27 2-32 2-31 2-31 2-27 YCHA200 402 407 407 403 405 407 407 402 YCHA200 2-27 2-32 4-28 2-31 2-28 2-32 4-27 2-28 YCHA100 YCHA120, 150, 175, & 200 LD01776 YORK INTERNATIONAL...
  • Page 11 CHILLED LIQUID PIPING 7. A chilled water flow switch, (either by YORK or oth- ers) must be installed in the leaving water piping of General – When the unit has been located in its final the cooler.

  • Page 12: Unit Controls And Operation

    UNIT CONTROLS AND OPERATION (YCHA100) INTRODUCTION The YORK YCHA100 MicroComputer Control Panel is Concise, step-by-step instructions are printed on the a microprocessor based control system. The micropro- control panel to guide you through each control and cessor monitors return water temperature and controls monitoring procedcure.
  • Page 13 0-11. This num- are 6.0°F, 7.0°F, 8.0°F, 9.0°F, 10.0°F, 11.0°F, 12.0°F, ber can be translated by comparing the number to and 14.0°F, corresponding to setting 0-7 respectively. the “Fault Code” listing on the right side of the panel. YORK INTERNATIONAL...

  • Page 14: Start-Up

    2 min.) Spare ex. Power failure has occured: Spare Restart can occur 2 min. after the return of power High ambient temperature (Anti-recycle time less than 2 min.) Low ambient temperature Low water temperature FIG. 5 – DATA DISPLAY YORK INTERNATIONAL...
  • Page 15 No display (“F” Code) will be indi- to the Analog Input Board allowing the Micro Logic Board cated during the first two faults except for a letter code to monitor motor current. telling the operator the anti-recycle timer is in effect. YORK INTERNATIONAL...
  • Page 16 14FU - INTERIOR 115VAC POWER FUSES 115VAC POWER INPUT CURRENT C.T.s UNDER FAN WIRING MOTOR CURRENT BOARD (MCB) IS MOUNTED UNDER FAN CONTACTORS CONDENSER FAN MOTOR CONTACTORS AND FUSES FIG. 8 – YCHA100 POWER PANEL MOTOR CONTACTORS 00007TG YORK INTERNATIONAL...
  • Page 17 LWT Freeze Safety will cause the system to shut down and * These controls are not furnished as part of the standard unit. A 10K ohm resistor is used in place of them. lock out on a single fault. YORK INTERNATIONAL...
  • Page 18 For example: A setpoint of 51° on the panel and a con- will automatically reload when suction pressure drops tact closure of 4.33 sec. will result in an offset of +5°. below 95 PSIG. This raises the RWT setpoint to 56°F. YORK INTERNATIONAL...
  • Page 19 (by others) must be wired into vice personnel or the customer to obtain system pa- the YORK supplied alarm circuit. If the alarm circuit is rameters on a periodic basis. * applied to chillers used for critical duty (such as pro- cess duty, or cooling other critical equipment) and the A print example is shown below.
  • Page 20 (YCHA100) FIG. 9 – WIRING DIAGRAM YCHA100 LD01779 YORK INTERNATIONAL...
  • Page 21 FORM 150.40-NM20 (YCHA100) LD01779(D) YORK INTERNATIONAL...
  • Page 22 (YCHA100) FIG. 9 – (Continued) LD01780(L) YORK INTERNATIONAL...
  • Page 23 FORM 150.40-NM20 (YCHA100) LD01780(R) YORK INTERNATIONAL...
  • Page 24 (YCHA100) FIG. 9 – Continued LD01781 YORK INTERNATIONAL...
  • Page 25 FORM 150.40-NM20 (YCHA100) LD01782 YORK INTERNATIONAL...
  • Page 26 If it the cutouts as ordered by the customer. Deviation is necessary to add oil, connect a YORK oil pump from these could be due to a defective board or to the oil charging valve, but do not tighten the tampering with the Analog Input Board pots.

  • Page 27: Operating Sequence

    15°F less than is not running. the condensing temperature. (The temperature When the System Power Switch is applied, the corresponding to the condensing pressure from unit will start a 2 minute start-up timer. refrigerant temperature/pressure chart.) YORK INTERNATIONAL...
  • Page 28 The CHILLER NO. OF CYLINDERS gas, drawn into the unloaded cylinders on the down MODEL 60 Hz 50 Hz stroke of the piston, is pumped back into the suction YCHA100 chamber of the compressor housing, without compres- YORK INTERNATIONAL...
  • Page 29 YORK INTERNATIONAL...
  • Page 30 Loader Stage 4 Setpoint plus 2.0°F Setpoint plus 1.0°F SWITCH = 7 Loader Stage 3 Setpoint plus 1.0°F Setpoint COOLING RANGE Loader Stage 2 Setpoint Setpoint minus 1.0°F OF + 2.0°F Compressor Stage 1 Setpoint minus 1.0°F Setpoint minus 2.0°F YORK INTERNATIONAL...
  • Page 31 An explanation of the Jumpers/Switches on the Micro Logic Board is provided on this page and page 32. OUT: RWT Control LWT Control See Figure below for J8, J9, and J10 location. 00008TG FIG. 11 – MICRO LOGIC BOARD JUMPERS (REV. “B” BOARD) YORK INTERNATIONAL...
  • Page 32 * Refer to above sketch to identify “OFF” and “ON” positions. The “dot” can be misleading when identifying switch position. See the “Side View” drawings for recommended position verification. 00009TG FIG. 12 – MICRO LOGIC BOARD DIP SWITCHES (REV. “C” BOARD) YORK INTERNATIONAL...

  • Page 33: Preventive Maintenance

    H. If the oil is clean and free of metal particles, refill the 4. Operating Pressures and Temperatures – Check to compressor with YORK oil “C”. To add oil or to fill the see that operating pressures and temperatures are compressor crankcase, connect the delivery tube of within the LIMITATIONS shown in this book.

  • Page 34: Trouble-Shooting Chart

    16. Suction pressure cutout setting _______ PSIG Problems beyond the scope of this manual should be 17. Optional – Not used on YCHA 100 referred to the local YORK Service Representative. 18. Fault code (if any) see page 14 GENERAL...
  • Page 35 F2 Fault Code 1. Low Oil Charge 1. Oil level should be visible in either sight Low Oil Pressure Fault glass at all times. Add YORK “C” oil if necessary. 2. Too much refrigerant in oil, 2. Check Crankcase Oil heater operation.
  • Page 36 5. Defective Relay Output Board 5. Replace Relay Output Board (Contact NOTE: If external H.P. the local YORK service representative.) Cut-out Switch trips 6. Defective Analog Input Board 6. Replace Analog Input Board (Contact the Fault Code will be the local YORK service representative.)
  • Page 37 Low Compressor Oil 1. Low Oil Charge 1. Oil level should be visible in either Level (Particularly on sight glass at all times. Add YORK “C” Start-Up) oil if necessary. 2. Excessive Flood back of Liquid 2. Adjust Thermal Expansion Valve (TXV) Refrigerant or replace Power Element.
  • Page 38 (YCHA120, 150, 175 & 200) INTRODUCTION Concise, step-by-step instructions are printed on the The YORK YCHA120-200 MicroComputer Control control panel to guide you through each control and Panel is a microprocessor based control system. The monitoring procedure. The control panel is also com-...
  • Page 39 LWT control is absolutely necessary. Control via LWT is best obtained using optional 10. “SELECT DATA DISPLAY” Switches additional steps of loading. Contact YORK Sales These switches can be used to display 18 Test Points for this option. for troubleshooting and data recording. This is done 2.
  • Page 40 8. Micro detected high pressure cutout ex. Anti-recycle timer has timed out at shutdown: 9. High ambient temperature Restart can occur in 2 min. (Anti-recycle time less than 10. Low ambient temperature 2 min.) 11. Low water temperature ex. Power failure has occurred: YORK INTERNATIONAL...
  • Page 41 C.T.’s on the 3φ power wiring of each motor send AC fault and restarted within the last 90 minutes. signals proportional to motor current to the Motor Cur- This insures that the system will not shut down YORK INTERNATIONAL...
  • Page 42 MOTOR CURRENT BOARDS (MCCs) ARE MOUNTED UNDER CENTER FAN CONTACTORS SYSTEM 2 SYSTEM 1 CONDENSER CONDENSER FAN CONTACTORS FAN CONTACTORS AND FUSES AND FUSES SYSTEM 1 SYSTEM 2 MOTOR CONTACTOR MOTOR CONTACTOR FIG. 15 – POWER PANEL 00010TG YORK INTERNATIONAL...
  • Page 43 These controls are not furnished as part of the standard unit. A 10K ohm resistor is used in place of them. This does not apply to item #4 (LWT Freeze Safety). A fault on the LWT Freeze Safety will cause the system to shut down and lock out on a single fault. YORK INTERNATIONAL...
  • Page 44 12 must be closed for a period between 1 and 1 time of fault, and also if the H.P. and motor protector seconds Closure for a period shorter than 1 second.will contacts are open. YORK INTERNATIONAL...
  • Page 45 RWT setpoint back to the fail to function, YORK will not be liable for damages. Any original setpoint of 51° on the Control Panel.
  • Page 46 LD01787 YORK INTERNATIONAL...
  • Page 47 FORM 150.40-NM20 LD01788 YORK INTERNATIONAL...
  • Page 48 LD01789 YORK INTERNATIONAL...
  • Page 49 FORM 150.40-NM20 LD01790 YORK INTERNATIONAL...
  • Page 50 LD01791 YORK INTERNATIONAL...
  • Page 51 FORM 150.40-NM20 LD01792 YORK INTERNATIONAL...
  • Page 52 If it pering with the Analog Input Board pots. is necessary to add oil, connect a York oil pump to Checking the R.P. Relay Remove the wire on ter- the oil charging valve, but do not tighten the flare minal 3 &...
  • Page 53 15°F less than the condensing temperature. (The temperature cor- 3. When the System Power Switch is applied, the unit responding to the condensing pressure from refrig- will start a 2 minute start-up timer. erant temperature/ pressure chart.) YORK INTERNATIONAL...
  • Page 54 10 minute anti- LD01793 FANS DISCHARGE PRESSURE TO CYCLE FANS SYSTEM CONTACTOR CONTROLLED “ON” “OFF” E, F 260 LBS. 190 LBS. G, H 280 LBS. 210 LBS. C, D 260 LBS. 190 LBS. A, B 280 LBS. 210 LBS. YORK INTERNATIONAL...
  • Page 55 All cylinders equipped with unloaders will remain unloaded on start-up until the oil pressure has built up to normal. On each compressor, certain cylinders do not unload. (See Fig. 19.) LD01794 YORK INTERNATIONAL...
  • Page 56 If optional 6 stage loading/unloading is included, Stage 4 loading and unloading is not included on either compressor. Therefore, in the example above, no system response will take place on loading at 50°F and 55°F and no system response will take place on unloading at 53.75°F and 48.75°F. YORK INTERNATIONAL...
  • Page 57 If optional 6 stage loading/unloading is included, stage 4 loading and unloading is not included on either compressor. Therefore, in the examples above, no system response will take place at the temperatures where stage 4 is to be activated or deactivated. YORK INTERNATIONAL...
  • Page 58 * If optional 6 stage loading/unloading is included, Stage 4 loading and unloading is not included on either compressor. Therefore, in the examples above, no system response will take place at the temperatures where Stage 4 is to be activated or deactivated. YORK INTERNATIONAL...
  • Page 59 Setpoint plus 1.0°F SWITCH = 7 Lag Compressor Stage 1 Setpoint plus 1.0°F Setpoint COOLING RANGE Lead Compr. Loader Stage 2 Setpoint Setpoint minus 1.0°F OF + 2.0°F Lead Compressor Stage 1 Setpoint minus 1.0°F Setpoint minus 2.0°F YORK INTERNATIONAL...
  • Page 60 Micro Logic Board is provided on this page and page 61. stages of unloading is IN: LWT Control present. See Figure below for J8, J9, and J10 location. 00011TG FIG. 20 – MICRO LOGIC BOARD JUMPERS (REV. “B” BOARD) YORK INTERNATIONAL...
  • Page 61 * Refer to above sketch to identify “OFF” and “ON” positions. The “dot” can be misleading when identify- Shipped) ing switch position. See the “Side View” drawings for recommended position verification. 00012TG FIG. 21 – MICRO LOGIC BOARD DIP SWITCHES (REV. “C” BOARD) YORK INTERNATIONAL...
  • Page 62 H. If the oil is clean and free of metal particles, refill the to see that operating pressures and temperatures compressor with YORK oil “C”. To add oil or to fill the are within the LIMITATIONS shown in this book.
  • Page 63 16. Suction pressure cutout setting ____ PSIG Problems beyond the scope of this manual should be 17. Optional – Not used referred to the local YORK Service Representative. 18. Fault code (if any) see page 40 GENERAL Using test equipment that is calibrated accurately (pres-...
  • Page 64 F2 or F6 Fault Code 1. Low Oil Charge 1. Oil level should be visible in either sight Low Oil Pressure Fault glass at all times. Add YORK “C” oil if necessary. 2. Too much refrigerant in oil, 2. Check Crankcase Oil heater operation.
  • Page 65 NOTE: If external H.P. 5. Defective Relay Output Board 5. Replace Relay Output Board (Contact Cut-out Switch trips the local YORK service representative.) the Fault Code will be an F1 or F5. 6. Defective Analog Input Board 6. Replace Analog Input Board (Contact the local YORK service representative.)
  • Page 66 Low Compressor Oil 1. Low Oil Charge 1. Oil level should be visible in either Level (Particularly on sight glass at all times. Add YORK Start-up.) “C” oil if necessary. 2. Excessive Flood back of Liquid 2. Adjust Thermal Expansion Valve (TXV) Refrigerant or Replace Power Element.

  • Page 67: Service Bulletins

    In general, the Rev. 1 Brine EPROM functions the same as the Rev. 0 except for fan cycling. Even fan cycling remains much the same except that the wiring has changed on U.L. air cooled chillers and requires the Rev. 1 EPROM. Detailed operation of the new software is contained in FORM 150.24-NM25 and 150.40-NM25. YORK INTERNATIONAL...
  • Page 68 In general, the REV. 2 EPROM functions the same as the REV. 0 and REV. 1 except for fan cycling. Even fan cycling remains much the same except that the wiring has changed on U.L. air cooled chillers and requires the REV. 2 EPROM. Detailed operation of the new software is contained in FORM 150.24-NM25 and 150.40-NM25. YORK INTERNATIONAL...
  • Page 69 WARRANTY PARTS PROCUREMENT PROCEDURE RECIPROCATING CHILLER MICRO PANELS The District office is to take out an S.D. number before calling in a parts order to YORK Baltimore Parts; 9003 Yellow Brick Rd.; P. O. Box #72229; Baltimore, MD 21237-2229. (Phone #1-301-574-0400) All new printed circuit boards will be accompanied with a failure report tag which must be completed in detail on the defective component.
  • Page 70 Panel. This option will provide individual NC dry contacts which will transition when the respective system faults (“F” Code on the display). Order the Alarm Kit using York Part Number 025-27199. Be sure the Microboard & EPROM conforms to the follow- ing guidelines:...
  • Page 71 MICROPROCESSOR PLUG ON WIRING FROM BOARD POWER SUPPLY BOARD Printed Circuit Board Wiring CORRECT MATING OF JACK AND PLUG NOTE CORRECT POSITION OF LOCKING TABS INCORRECT MATING OF JACK AND PLUG NOTE INCORRECT POSITION OF LOCKING TABS LD01898 YORK INTERNATIONAL...
  • Page 72 No line number indicates a -000 and 02 indicates a -002. This is a deviation from normal YORK standards. The small size of the board does not allow the full three digit number to be stamped behind the part number.
  • Page 73 Display. This display indicates the temperature sensed by the OAT sensor located outside on the back side of the Logic section of the control panel. It should coincide with a thermometer located in the same location ± 10°F. YORK INTERNATIONAL...
  • Page 74 TRANSDUCER WARRANTY REQUIREMENTS RECIP. SMART PANEL YORK has made an agreement with Kavlico for reimbursement of parts cost plus reasonable labor for all Kavlico transducers which fail within the chiller warranty period. This will mean considerable savings for YORK as long as certain guidelines are followed.
  • Page 75 FORM 150.40-NM20 MODELS YCAQ10, YCAM12, YCAK14, YCAI16, YCAG18 YCAR11, YCAN13, YCAL15, YCAJ17 & YCAH19 ALSO MODELS YCHA100, 120, 150, 175, & 200 STYLE C CORRECTION TO FORM 150.40-NM20 CODED 587 The Weight Distribution shown on page 4, and the Weights shown in the PHYSICAL DATA table on page 8 of this form have been revised.
  • Page 76 Proud Sponsor of the 1998 U.S. Olympic Team 36USC380 P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA Copyright © by York International Corporation 1997 ALL RIGHTS RESERVED Form 150.40-NM20 (597) Supersedes: 150.40-NM20 (587)

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