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York YCAS0098EB Installation Operation & Maintenance

York YCAS0098EB Installation Operation & Maintenance

Air-cooled liquid chillers
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AIR-COOLED SCREW LIQUID CHILLERS
Supersedes: 201.18-NM7 (916)
Form 201.18-NM7 (1020)
INSTALLATION, OPERATION, MAINTENANCE
YCAS AIR-COOLED LIQUID CHILLERS
YCAS0098EB through YCAS0208EB
28971AR
60 Hz
YCAS 2 SYSTEM EPROM
031-01798-001
(STANDARD, BRINE & METRIC MODELS COMBINED)
Issue Date:
October 2, 2020

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  • Page 1 AIR-COOLED SCREW LIQUID CHILLERS Supersedes: 201.18-NM7 (916) Form 201.18-NM7 (1020) INSTALLATION, OPERATION, MAINTENANCE YCAS AIR-COOLED LIQUID CHILLERS YCAS0098EB through YCAS0208EB 28971AR 60 Hz YCAS 2 SYSTEM EPROM 031-01798-001 (STANDARD, BRINE & METRIC MODELS COMBINED) Issue Date: October 2, 2020...
  • Page 2 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or During rigging, installation, operation, maintenance, death to themselves and people at the site. or service, individuals may be exposed to certain com- This document is intended for use by owner-authorized ponents or conditions including, but not limited to: rigging, installation, and operating/service personnel.
  • Page 3 In lieu of the tradition- corrective actions required and data enabled guidance al maintenance program, a Johnson Controls YORK for optimal operation and lifecycle assurance. The pro- Conditioned Based Maintenance (CBM) program can gram will include fault detection diagnostics, operation be substituted.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION GENERAL CHILLER Single-Point Power Connection INFORMATION & SAFETY with Individual Circuit Protection ......23 Introduction ..............7 Single-Point Power Connection Warranty ..............7 with Combined Circuit Protection ......23 Safety ................7 Single-Point Power Connection without Circuit Protection ........23 Standards for Safety ..........
  • Page 5 System Inputs ............34 Compressor Terminal Box ........73 Dimensions ..............76 Flow Switch ............34 Remote Run / Stop ..........34 YCAS0098EB - 0118EB (English) ...... 76 Remote Print ............34 YCAS0098EB - 0118EB (SI) .......78 Remote Setpoint Offset – Temperature....34 YCAS0128EB (English) ........80 Remote Setpoint Offset – Current ......
  • Page 6 TABLE OF CONTENTS (CONT’D) SECTION MICRO PANEL CONTENTS ..................120 Chiller Control Panel Programming and Data Access Keys ............120 Display and Status Information Keys....................120 ON / OFF Rocker Switch ........................120 Program & Setup Keys ........................120 1. INTRODUCTION & PHYSICAL DESCRIPTION ................ 121 General Keypad &...
  • Page 7 FORM 201.18-NM7 TABLE OF CONTENTS (CONT’D) 5. ENTRY KEYS ............................ 152 General Numerical Keypad ........................152 Enter Key 152 Cancel Key 152   Keys ..........................152 6. SETPOINTS KEYS & CHILLED LIQUID CONTROL ..............153 General Chilled Liquid Temperature Control ..................153 Local Cooling Setpoints Key ....................

  • Page 8: Section 1 General Chiller Information & Safety

    Center. See Commissioning, page 41. in this manual. • Only genuine YORK approved spare parts, oils and This manual and the Microprocessor Operating Instruc- refrigerants must be used. Recommendations on tions contain all the information required for correct spare parts can be found on page 173.

  • Page 9: Responsibility For Safety

    This manual and any other document supplied with the unit, are the property of YORK which reserves all Electrical rights. They may not be reproduced, in whole or in part, The unit must be grounded.

  • Page 10: Rotating Parts

    must only be carried out by suitably trained and qualified the unit. The build up of refrigerant vapor, from a leak personnel. No attempt should be made to gain access to for example, does pose a risk of asphyxiation in confined the control panel or electrical enclosures during normal or enclosed spaces and attention should be given to good operation of the unit.

  • Page 11: Material Safety Data

    General Chiller Information & Safety FORM 201.18-NM7 MATERIAL SAFETY DATA REFRIGERANT DATA: SAFETY DATA R407C Toxicity Low. In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorp- tion. Thaw affected areas with water. Remove contaminated clothing carefully – may adhere to skin in case of freeze burns.
  • Page 12 MATERIAL SAFETY DATA REFRIGERANT OIL DATA: YORK “L” OIL SAFETY DATA Classification Non-hazardous In contact with skin Minimally irritating. No first aid necessary. Exercise reasonable personal cleanliness including cleansing exposed skin areas several times daily with soap and water. Launder soiled work clothes at least weekly.
  • Page 13 General Chiller Information & Safety FORM 201.18-NM7 MATERIAL SAFETY DATA Section 1 – PRODUCT NAME AND INFORMATION Product (Trade Name and Synonyms): YORK “L” Oil Chemical Name: Ester Chemical Family: Polyol Ester Formula: Proprietary CAS#: Proprietary Section 2 – COMPONENTS AND HAZARD STATEMENT This product is non-hazardous.
  • Page 14 The information in this material safety data sheet should be provided to all who use, handle, store, transport, or are otherwise exposed to this product. YORK believes the information in this document to be reliable and up to date as of the date of publication, but makes no guarantee that it is.

  • Page 15: Section 2 Product Description

    INTRODUCTION All exposed power wiring is be routed through liq- uid-tight, non-metallic conduit. YORK YCAS chillers are designed for water or wa- ter-glycol cooling. All units are designed to be located General Description outside on the roof of a building or at ground level.

  • Page 16: Evaporator

    Refrigerant gas is injected into the void created by the The compressor is lubricated by removing oil from the unmeshing of the five lobed male and seven lobed fe- refrigerant using an external oil separator. The pressur- male rotor. Further meshing of the rotors closes the rotor ized oil is then cooled in the condenser coils and piped threads to the suction port and progressively compresses back to the compressor for lubrication.

  • Page 17: Oil Separator/System

    The microprocessor modulates the current signal to a 3-way pressure regulating capacity control valve which The oil (YORK “L” oil – a POE oil used for all refriger- controls command compressor capacity, independent of ant applications), which drains back into the compressor system pressures, and balances the compressor capacity through a replaceable 0.5 - 3.0 micron oil filter, and oil...

  • Page 18: Microprocessor Controls

    The Power and Control Panel are divided into power The software is stored in non-volatile memory (EPROM) sections for each compressor and associated fans, a con- to eliminate chiller failure due to AC power failure. trol section and an electrical options section. The power The Programmed Setpoint is stored in lithium battery and control sections have separate hinged, latched, and backed memory.

  • Page 19: Motor Protection Module

    13kW, reset = 3.25kW. Communication error. Unload imbalance ( > 50%) Phase Loss (> 60%) It is recommended that an YORK Out of range of RLA calibration. Service Technician or the YORK Other symbols Defective module or supply voltage. factory be consulted before changing Working voltage 18 - 30 VAC, 224 VAC nominal.

  • Page 20: Thermal Overload

    Thermal Overload Current.” A current imbalance exceeding an unloaded Three PTC (positive temperature coefficient) thermistors level of 25% will result in the motor pilot circuit being in the motor windings of each phase provides thermal de-energized. protection. The sensor resistance stays relatively con- stant at 1k until a temperature of 266°F (130°C) is Ω...
  • Page 21 Product Description FORM 201.18-NM7 TABLE 1 – MOTOR PROTECTOR DIP SWITCH SETTING YCAS STYLE F, ACROSS-THE-LINE – 60 HZ MODEL VOLT CHILLER MOTOR PROTECTOR CODE NAMEPLATE LEADS MP OL DIP SWITCH SETTINGS ON MP (“1” INDICATED ON) PHASE VALUE 0098 0118 SYS 1 0118...
  • Page 22 TABLE 1 – MOTOR PROTECTOR DIP SWITCH SETTING (CONT’D) YCAS STYLE F, WYE-DELTA START– 60 HZ MODEL VOLT CHILLER MOTOR PROTECTOR CODE NAMEPLATE LEADS MP OL DIP SWITCH SETTINGS ON MP (“1” INDICATED ON) PHASE VALUE 0158 SYS 1 0158 SYS 2.

  • Page 23: Motor Starting

    Product Description FORM 201.18-NM7 contactor 2M (SYS 1) or 4M (SYS 2), completing the MOTOR STARTING “DELTA” connection of the motor. Two types of compressor motor starting are available: Across-the-Line and optional Wye-Delta Open Transi- 1 TR and 2TR are NOT “timing” tion Starter.

  • Page 24: Entry

    BAS. with lockable external handles located in the two power A YORK ISN Building Automation System can pro- compartments. vide a Pulse Width Modulated (PWM) signal direct to...

  • Page 25: Dx Cooler Options

    Product Description FORM 201.18-NM7 The following options provide added protection: UNIT ENCLOSURES Wire enclosure – Heavy gauge welded wire mesh Black fin condenser coils – Condenser coils constructed guards mounted on the exterior of the unit (Factory- or using black epoxy coated Aluminum fin stock for corro- field-mounted). sion resistance comparable to copper fin coils in typical seashore locations.

  • Page 26: Unit Nomenclature Nameplate Engineering Data

    UNIT NOMENCLATURE NAMEPLATE ENGINEERING DATA JOHNSON CONTROLS...
  • Page 27 Product Description FORM 201.18-NM7 UNIT NOMENCLATURE NAMEPLATE ENGINEERING DATA JOHNSON CONTROLS...

  • Page 28: Section 3 Handling And Storage

    If the unit is to be put into storage, prior to installation, Major damage must be reported immediately to your the following precautions should be observed: local YORK representative. MOVING THE CHILLER • Unit must be “blocked” so that the base is not permitted to sag or bow.

  • Page 29: Unit Rigging

    Handling and Storage FORM 201.18-NM7 UNIT RIGGING  88" (2250mm) CORRECT! CORRECT!  WRONG! WRONG! LD03514A FIG. 3 – UNIT RIGGING WRONG! CORRECT! LD03515 FIG. 4 – LIFTING LUGS JOHNSON CONTROLS...

  • Page 30: Section 4 Installation

    INSTALLATION be at least 4-3/4” (120 mm) wide at the contact points. LOCATION REQUIREMENTS This will allow vibration isolators to be fitted if required. To achieve optimum performance and trouble-free service, it is essential that the proposed installation site Any ductwork or attenuators fitted to the unit must not meets with the location and space requirements for the have a total static pressure resistance, at full unit airflow, model being installed.

  • Page 31: Installation Of Vibration Isolators

    Place each mount in its correct position and lower the suitable for 150 PSIG (10 bar) working pressure and hav- unit carefully onto the mounts ensuring the mount ing a 1” N.P.T. connection can be obtained from YORK engages in the mounting holes in the unit base frame. as an accessory for the unit. Alternatively a differential...

  • Page 32: Water Treatment

    Aerated, brackish or salt water is not recommended for heat exchanger without disrupting flow to other units. use in the water system(s). YORK recommends that a water treatment specialist is consulted to determine Thermometer and pressure gauge connections should...

  • Page 33: Pipework Arrangement

    Installation FORM 201.18-NM7 It is recommended that a piece of pipe is fitted to each PIPEWORK ARRANGEMENT valve and directed so that when the valve is activated the The following is a suggested pipework arrangement for release of high pressure gas and liquid cannot be a danger single unit installations. For multiple unit installations, or cause injury.

  • Page 34: Electrical Connection

    This will prevent recircula- tion (not supplied by YORK). tion of air when only one of the fans is running. Units are supplied with outlet guards for safety and to prevent damage to the fan blades.

  • Page 35: Remote Emergency Stop Device

    Installation FORM 201.18-NM7 Removing high voltage power to Run Contact Terminals 29 and 30 (Figs. 12 and 13, pages 39 and 40) the chiller will remove the 115VAC close to indicate that a system is running. supply voltage to the microprocessor circuitry and the evaporator heater.

  • Page 36: Power And Control Panel Layouts (Wye-Delta Typical)

    POWER AND CONTROL PANEL LAYOUTS (WYE-DELTA TYPICAL) 00263VIP FIG. 8 – POWER PANEL SECTION JOHNSON CONTROLS...

  • Page 37: Option Panel Layout (Typical)

    Installation FORM 201.18-NM7 OPTION PANEL LAYOUT (TYPICAL) 00246VIP FIG. 9 – OPTION PANEL SECTION JOHNSON CONTROLS...

  • Page 38: Logic Section Layout

    LOGIC SECTION LAYOUT 60 Hz Models: 00247VIP PHOTOGRAPH OF 60 HZ MODEL LOGIC SECTION DESCRIPTION ITEM Microprocessor Board Back of Keypad Back of Display I/O Expansion Board #1 Power Supply Board Relay Output Board #1 Relay Output Board #2 Flow Switch & Customer Connection Terminals Circuit Breakers FIG.

  • Page 39: Logic Section Layout With Control Panel Layout

    Installation FORM 201.18-NM7 LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT 00248VIP FIG. 11 – LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT JOHNSON CONTROLS...

  • Page 40: Customer Connections

    CUSTOMER CONNECTIONS TERMINALS 13-19 00249VIP TERMINALS 23-38 Flow Switch System No. 1 Run System No. 1 Alarm Contacts System No. 2 Run Current Chilled Liquid Circulating Pump Start Temperature System No. 2 Print Alarm Contacts Chiller Run CONNECTION Isolator POINTS FOR Auxiliary EMERGENCY Interlock...
  • Page 41 Installation FORM 201.18-NM7 CUSTOMER CONNECTIONS RELAY BOARDS I/O EXPANSION BOARD TRANSFORMERS POWER SUPPLY BOARD CIRCUIT BREAKERS 28965A CUSTOMER MICROPROCESSOR CONNECTIONS CIRCUIT BOARD 115 VAC SUPPLY (Flow Switch, Alarm, Run, etc.) FIG. 13 – CUSTOMER CONNECTIONS JOHNSON CONTROLS...

  • Page 42: Section 5 Commissioning

    It is important to check that the correct primary Compressor Oil tapping has been used: To add oil to a circuit - connect a YORK hand oil pump With the supply to the unit isolated remove the lid to (Part No. 470-10654-000) to the 1/4” oil charging valve the transformer box.
  • Page 43 Commissioning FORM 201.18-NM7 Check that the tapping used conforms to the site supply either side of the flow switch. The flow switch should voltage. be connected to terminals 13 and 14 in the micro panel (Figs. 12 and 13, pages 39 and 40). Switch Settings Ensure that the unit Auto/OFF switch on the display Temperature sensor(s) door and the micro board system switches S2 and S5 Ensure the leaving liquid temperature sensor is coated...

  • Page 44: First Time Start-Up

    Fan Rotation FIRST TIME START-UP As discharge pressure rises, the condenser fans operate During the commissioning period in stages to control the pressure. Verify that the fan operation is correct for the type of unit. there should be sufficient heat load to run the unit under stable full load Suction Superheat operation to enable the unit controls,...

  • Page 45: Section 6 Operation

    The units are designed to work independently, or in automatic. After an initial period at minimum capacity conjunction with other equipment via a YORK ISN on the lead compressor, the control system will adjust building management system or other automated control the unit load depending on the chilled liquid tempera- system.

  • Page 46: Section 7 Technical Data

    TECHNICAL DATA FLOW RATE AND PRESSURE DROP CHARTS COOLER WATER PRESSURE DROP COOLER WATER PRESSURE DROP (ENGLISH UNITS) (SI UNITS) Water Cooler Pressure Drop COOLER WATER PRESSURE DROP (SI UNITS) 1000 1000 Water Flow (gpm) WATER FLOW (l/s) LD05825A LD05884A MODEL NUMBER YCAS COOLER MODEL NUMBER YCAS...

  • Page 47: Temperature And Flows

    1. For leaving brine temperature below 40°F, contact your nearest YORK office for application requirements. 2. For leaving water temperature higher than 5.5°F, contact the nearest YORK office for application guidelines. 3. The evaporator is protected against freeze-up to -20°F with an electrical heater as standard.
  • Page 48 PHYSICAL DATA ENGLISH UNITS Refrigerant R-407C Optimized MODEL NUMBER YCAS 0098EB 0118EB 0128EB 0138EB 0148EB 0158EB 0178EB 0198EB 0208EB General Unit Data Unit Capacity at 44°F water & 95°F ambient, TR 87.3 106.7 112.1 126.8 130.5 145.5 164.2 178.1 192.8 Number of Independent Refrigerant Circuits Refrigerant Charge, R-407C, Ckt.-1/Ckt.-2, lbs.
  • Page 49 Technical Data FORM 201.18-NM7 PHYSICAL DATA SI UNITS Refrigerant R-407C Optimized MODEL NUMBER YCAS 0098EB 0118EB 0128EB 0138EB 0148EB 0158EB 0178EB 0198EB 0208EB General Unit Data Unit Capacity at 7°C water & 35°C ambient, kW 310 Number of Independent Refrigerant Circuits Refrigerant Charge, R-407C, Ckt.-1/Ckt.-2, kg.
  • Page 50 This page intentionally left blank. JOHNSON CONTROLS...

  • Page 51: Operating Limitations & Sound Power Data

    FORM 201.18-NM7 OPERATING LIMITATIONS AND SOUND POWER DATA OPERATING LIMITATIONS – ENGLISH UNITS OPERATING LIMITATIONS – SI UNITS LEAVING CHILLED LIQUID TEMP ( °F) 40.1 LEAVING CHILLED LIQUID TEMP ( °C) CHILLED WATER TEMP DIFFERENCE ( °F) CHILLED WATER TEMP DIFFERENCE ( °C) WATER SIDE PRESSURE (PSIG) WATER SIDE PRESSURE (BAR) –...

  • Page 52: Electrical Data

    Technical Data ELECTRICAL DATA MULTIPLE POINT POWER SUPPLY CONNECTION Suitable for: Y - ∆ Start and Across-The-Line-Start “Optional Field Provided 115-1Ø MicroPanel Supply Each of the two field provided power supply circuits to the unit with individual branch circuit protection. Field Power Wir- ing connections to factory provided, Non-Fused Disconnect Switches (Opt), or Terminal Blocks (Opt) in the Option Box. SEE NOTE 2 See page 56 for notes.
  • Page 53 FORM 201.18-NM7 ELECTRICAL DATA SYSTEM #2 FIELD-SUPPLIED WIRING FIELD PROVIDED POWER SUPPLY FACTORY PROVIDED (LUGS) WIRE RANGE COMPRESSOR #2 FANS OVER-CURRENT 11, 12 MODEL VOLTS MIN NF PROTECTION YCAS DISC SW STD. TERMINAL OPT. NF. OPT. C.B. RLA Y-D-LRA XL-LRA QTY 2, 9 (EA.) (EA.)

  • Page 54: Optional Single-Point Power Supply Connection And Individual System Circuit Breakers

    Technical Data ELECTRICAL DATA OPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION AND INDIVIDUAL SYSTEM CIRCUIT BREAKERS Optional Field Provided Suitable for: 115-1-60 Y - ∆ Start and Micropanel Supply Across-The-Line-Start One field provided power supply circuit to the unit with circuit protection. Field connections to factory provided Non-Fused Disconnect Switch (Opt), or Terminal Block (Opt) in the Options Panel.
  • Page 55 FORM 201.18-NM7 ELECTRICAL DATA SYSTEM #1 SYSTEM #2 MODEL VOLTS COMPRESSOR #1 FAN DATA COMPRESSOR #2 FAN DATA 11, 12 11, 12 YCAS Y-D-LRA XL-LRA Y-D-LRA XL-LRA (EA) (EA) (EA.) (EA) 1257 33.0 1257 33.0 1103 38.0 1103 38.0 0098EB 23.0 23.0 19.0...

  • Page 56: Optional Single-Point Power Supply Connection With Field Supplied Circuit Protection

    Technical Data ELECTRICAL DATA OPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION WITH FIELD SUPPLIED CIRCUIT PROTECTION Suitable for: Optional Field Y - ∆ Start and Provided 115-1-60 Across-The-Line-Start Micropanel Supply One field provided power supply circuit to the unit with field supplied circuit protection. Field connections to factory provided Non-Fused Disconnect Switch (Opt), or Terminal Block (Opt) in the Options Panel.
  • Page 57 FORM 201.18-NM7 ELECTRICAL DATA SYSTEM #1 SYSTEM #2 MODEL VOLTS COMPRESSOR #1 FAN DATA COMPRESSOR #2 FAN DATA 11, 12 11,12 YCAS XL-LRA XL-LRA (EA) (EA) (EA.) (EA) 23.0 23.0 0098EB 19.0 19.0 15.2 15.2 23.0 23.0 0118EB 19.0 19.0 15.2 15.2 23.0...

  • Page 58: Optional Single-Point Power Supply Connection To Factory Circuit Breaker

    Technical Data Technical Data ELECTRICAL DATA OPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION TO FACTORY CIRCUIT BREAKER Suitable for: Across-The-Line-Start Optional Field Provided 115-1-60 Micropanel Supply One field provided power supply circuit to the unit with circuit protection. Field connections to factory provided Circuit Breaker in the Options Panel. Factory connections to Terminal Blocks in each of the two Power Panels.

  • Page 59: Fan Data

    FORM 201.18-NM7 ELECTRICAL DATA TABLE 2 – COMPRESSOR DATA MAXIMUM kW AND AMPERAGE VALUES FOR DXST COMPRESSORS 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...

  • Page 60: Electrical Notes

    Technical Data ELECTRICAL NOTES NOTES & LEGEND (for pages 50 - 56) LEGEND ACR-LINE ACROSS THE LINE START VOLTAGE CODE C.B. CIRCUIT BREAKER -17 = 200-3-60 D.E. DUAL ELEMENT FUSE -28 = 230-3-60 DISC SW DISCONNECT SWITCH -40 = 380-3-60 FACT CB FACTORY-MOUNTED CIRCUIT BREAKER -46 = 460-3-60...
  • Page 61 FORM 201.18-NM7 This page intentionally left blank. JOHNSON CONTROLS...

  • Page 62: Wiring Diagram Across-The-Line Start

    Transient Voltage Suppression Terminal Block for Customer Connections Terminal Block for Customer Low Voltage (Class 2) Connections. See Note 2 Terminal Block for YORK Connections Only Wiring and Components by YORK Optional Equipment Wiring and/or Components by Others FIG. 16 – WIRING DIAGRAM – ACROSS-THE-LINE START...
  • Page 63 FORM 201.18-NM7 WIRING DIAGRAM ACROSS-THE-LINE START LD06993A FIG. 17 – WIRING DIAGRAM – ACROSS-THE-LINE START JOHNSON CONTROLS...
  • Page 64 Technical Data ELEMENTARY DIAGRAM FIG. 18 – ELEMENTARY DIAGRAM – ACROSS-THE-LINE START JOHNSON CONTROLS...
  • Page 65 Any contacts connected to flow switch inputs or BAS inputs on terminals 13 - 19 or TB3, or any other terminals, must be sup- pressed with a YORK P/N 031- 00808-000 suppressor across the relay/contactor coil. CAUTION: Control wiring connected to the...

  • Page 66: Wiring Diagram Wye-Delta Start

    Transient Voltage Suppression Terminal Block for Customer Connections Terminal Block for Customer Low Voltage (Class 2) Connections. See Note 2 Terminal Block for YORK Connections Only Wiring and Components by YORK Optional Equipment Wiring and/or Components by Others FIG. 19 – WIRING DIAGRAM – WYE-DELTA START...

  • Page 67: Elementary Diagram - Wye-Delta Start

    FORM 201.18-NM7 WIRING DIAGRAM WYE-DELTA START LD06994A FIG. 20 – ELEMENTARY DIAGRAM – WYE-DELTA START JOHNSON CONTROLS...
  • Page 68 Technical Data ELEMENTARY DIAGRAM FIG. 21 – ELEMENTARY DIAGRAM – WYE-DELTA START JOHNSON CONTROLS...
  • Page 69 Any contacts connected to flow switch inputs or BAS inputs on terminals 13 - 19 or TB3, or any other terminals, must be sup- pressed with a YORK P/N 031- 00808-000 suppressor across the relay/contactor coil. CAUTION: Control wiring connected to the...
  • Page 70 Technical Data FIG. 22A – CONTROL PANEL COMPONENT LOCATIONS JOHNSON CONTROLS...
  • Page 71 FORM 201.18-NM7 LD03280 FIG. 22B – POWER PANEL COMPONENT LOCATION JOHNSON CONTROLS...
  • Page 72 Technical Data LEGEND LD03281 JOHNSON CONTROLS...
  • Page 73 FORM 201.18-NM7 LD03282 LD03283 LD03284 JOHNSON CONTROLS...

  • Page 74: Connection Diagram

    Technical Data CONNECTION DIAGRAM (SYSTEM WIRING) LD06256 LD03231 LD03232 JOHNSON CONTROLS...

  • Page 75: Compressor Terminal Box

    FORM 201.18-NM7 COMPRESSOR TERMINAL BOX LD03233 JOHNSON CONTROLS...
  • Page 76 Technical Data LD03285 JOHNSON CONTROLS...
  • Page 77 FORM 201.18-NM7 #3/#4 #3/#4 #5/#6 #5/#6 #7/#8 #3/#4 #5/#6 #7/#8 #9/#10 LD06840A JOHNSON CONTROLS...
  • Page 78 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 79 FORM 201.18-NM7 DIMENSIONS – YCAS0098EB - YCAS0118EB (ENGLISH) 5/8" DIA. MOUNTING HOLES (TYP.) 1 1/4" 30" POWER ELEMENTS FOR SYS.#1 88" POWER ELEMENTS 30" FOR SYS.#2 CONTROL PANEL 1 1/4" 55 13/16" 54 5/16" 31 3/4" ORIGIN VIEW D-D LD06997A CENTER OF GRAVITY (Alum.)

  • Page 80: Dimensions

    Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 81 FORM 201.18-NM7 DIMENSIONS – YCAS0098EB - YCAS0118EB (SI) 16 DIA. MOUNTING HOLES (TYP.) POWER ELEMENTS FOR SYS.#1 2235 POWER ELEMENTS FOR SYS.#2 CONTROL PANEL 1418 1380 ORIGIN VIEW D-D LD05828A CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper) YCAS YCAS...

  • Page 82: Ycas0128Eb (English)

    Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 83 FORM 201.18-NM7 DIMENSIONS – YCAS0128EB (ENGLISH) 16 DIA. MOUNTING HOLES (TYP.) POWER ELEMENTS FOR SYS.#1 2235 POWER ELEMENTS FOR SYS.#2 CONTROL PANEL 1418 1380 ORIGIN VIEW D-D LD07001A CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper) YCAS YCAS 0128 110.0 43.0 33.0 0128...
  • Page 84 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 85 FORM 201.18-NM7 DIMENSIONS – YCAS0128EB (SI) 16 DIA. MOUNTING HOLES (TYP.) POWER ELEMENTS FOR SYS.#1 2235 POWER ELEMENTS FOR SYS.#2 CONTROL PANEL 1368 1368 1368 LD05832A ORIGIN VIEW D-D CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper) YCAS YCAS 0128 2794 1092 0128...
  • Page 86 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 87 FORM 201.18-NM7 DIMENSIONS – YCAS0138EB (ENGLISH) 16 DIA. MOUNTING HOLES (TYP.) POWER ELEMENTS FOR SYS.#1 2235 POWER ELEMENTS FOR SYS.#2 CONTROL PANEL 1368 1368 1368 ORIGIN VIEW D-D LD07003A CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper) YCAS YCAS 0138 109.0 44.0 38.0...
  • Page 88 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 89 FORM 201.18-NM7 DIMENSIONS – YCAS0138EB (SI) 16 DIA. MOUNTING HOLES (TYP.) POWER ELEMENTS FOR SYS.#1 2235 POWER ELEMENTS FOR SYS.#2 CONTROL PANEL 1368 1368 1368 ORIGIN VIEW D-D LD05836A CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper) YCAS YCAS 0138 2769 1118 0138...
  • Page 90 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 91 FORM 201.18-NM7 DIMENSIONS – YCAS0148EB - YCAS0178EB (ENGLISH) 5/8" DIA. MOUNTING HOLES (TYP.) 1 1/4" 30" POWER ELEMENTS FOR SYS.#1 88" POWER ELEMENTS 30" FOR SYS.#2 CONTROL PANEL 1 1/4" 53 7/8" 53 7/8" 53 7/8" 31 3/4" ORIGIN VIEW D-D LD07007A CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper)
  • Page 92 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 93 FORM 201.18-NM7 DIMENSIONS – YCAS0148EB - YCAS0178EB (SI) 16 DIA. MOUNTING HOLES (TYP.) POWER ELEMENTS FOR SYS.#1 2235 POWER ELEMENTS FOR SYS.#2 CONTROL PANEL 1368 1368 1368 ORIGIN VIEW D-D LD05840A CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper) YCAS YCAS 0148 2802...
  • Page 94 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 95 FORM 201.18-NM7 DIMENSIONS – YCAS0198EB - YCAS0208EB (ENGLISH) 5/8" DIA. MOUNTING HOLES (TYP.) 1 1/4" 30" POWER ELEMENTS FOR SYS.#1 88" POWER ELEMENTS 30" FOR SYS.#2 CONTROL PANEL 1 1/4" 65 5/16" 65 5/16" 74 13/16" 31 3/4" ORIGIN LD05663A VIEW D-D CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper)
  • Page 96 Site restrictions may compromise minimum clearances indicated below, resulting in unpredictable air flow patterns and possible diminished performance. YORK’s unit controls will optimize operation without nuisance high pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center assumes the unit is no higher than on spring isolators.
  • Page 97 FORM 201.18-NM7 DIMENSIONS – YCAS0198EB - YCAS0208EB (SI) 16 DIA. MOUNTING HOLES (TYP.) POWER ELEMENTS FOR SYS.#1 2235 POWER ELEMENTS FOR SYS.#2 CONTROL PANEL 1658 1658 1900 ORIGIN VIEW D-D LD05844A CENTER OF GRAVITY (Alum.) CENTER OF GRAVITY (Copper) YCAS YCAS 0198 2799...

  • Page 98: Clearances

    Technical Data TECHNICAL DATA CLEARANCES (2 m) (1.3 m) LD07011A 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. 33 – CLEARANCES JOHNSON CONTROLS...
  • Page 99 FORM 201.18-NM7 OPERATING WEIGHTS – ALUMINUM & BLACK FIN COILS ALUMINUM & BLACK FIN WEIGHT DISTRIBUTION BY MODEL (lbs.) 60 Hz Total YCAS0098 2,070 1,640 1,211 1,986 1,573 1,161 —- —- —- —- —- —- —- —- —- —- 9,641 YCAS0118 2,173 1,701 1,230 2,078 1,627 1,176 —-...
  • Page 100 Technical Data ISOLATOR SELECTION – ALUMINUM & BLACK FIN COILS ALUMINUM & BLACK FIN, 1” ISOLATOR SELECTIONS - VMC TYPE CP-2-XX (See Table 3) 60 Hz YCAS0098 2-31 2-28 2-27 2-31 2-28 2-26 —- —- —- —- —- —- —- —- —- —-...

  • Page 101: Weight Distribution And Isolator Mounting Positions (Alum. Fin & Black Fin Cond. Coils)

    FORM 201.18-NM7 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS Aluminum Fin and Black Fin Condenser Coils ISOLATOR DETAILS LD01089 FIG. 34 – CP-2-XX ISOLATOR MAX LOAD DEFL. SPRING TYPE & SIZE COLOR lbs. CP-2-26 1200 544.3 1.17 29.7 Purple CP-2-27 1500 680.4 1.06 26.9...
  • Page 102 Technical Data WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS Aluminum Fin and Black Fin Condenser Coils 60 HERTZ, ALUMINUM & BLACK FINS, NEOPRENE MOUNT SELECTIONS – VMC TYPE RD-4 YCAS 0090 BLACK BLACK GRAY* RED BLACK GRAY* 0100 BLACK BLACK GRAY* RED BLACK BLACK 0110 RED BLACK BLACK RED BLACK BLACK 0120...
  • Page 103 FORM 201.18-NM7 WEIGHT DISTRIBUTION AND ISOLATOR MOUNTING POSITIONS Aluminum Fin and Black Fin Condenser Coils ISOLATOR MAX LOAD DEFL. TYPE & SIZE lbs. AWMR-1-530 1150 521.6 AWMR-1-531 1276 578.8 AWMR-1-532 1500 680.4 AWMR-1-551 1676 760.2 AWMR-1-552 1900 861.8 AWMR-1-553 2200 997.9 AWMR-2-531 2552...
  • Page 104 Technical Data OPERATING WEIGHTS COPPER FIN COILS (OR ALUMINUM FIN WITH OPTIONAL SILENCER KIT) COPPER FIN (OR ALUMINUM FIN WITH OPTIONAL SILENCER KIT) WEIGHT DISTRIBUTION BY MODEL (lbs.) 60 Hz Total YCAS0098 2,263 1,790 1,318 2,179 1,723 1,268 —- —- —- —- —-...
  • Page 105 FORM 201.18-NM7 ISOLATOR SELECTION COPPER FIN COILS (OR ALUMINUM FIN WITH OPTIONAL SILENCER KIT) COPPER FINS (OR ALUMINUM FIN WITH OPTIONAL SILENCER KIT), 1” ISOLATOR SELECTIONS - VMC TYPE CP-2-XX – (See Table 3) 60 Hz YCAS0098 2-32 2-31 2-28 2-32 2-31 2-27...
  • Page 106 Technical Data OPERATING WEIGHTS COPPER FIN COILS WITH OPTIONAL SILENCER KIT COPPER FIN WITH OPTIONAL SILENCER KIT WEIGHT DISTRIBUTION BY MODEL (lbs.) 60 Hz Total YCAS0098 2,446 1,980 1,515 2,364 1,913 1,463 —- —- —- —- —- —- —- —- —- —- 11,681...
  • Page 107 FORM 201.18-NM7 ISOLATOR SELECTION COPPER FIN COILS WITH OPTIONAL SILENCER KIT COPPER FINS WITH OPTIONAL SILENCER KIT, 1” ISOLATOR SELECTIONS - VMC TYPE CP-2-XX – (See Table 3) 60 Hz YCAS0098 2-32 2-31 2-28 2-32 2-31 2-27 —- —- —- —- —- —-...

  • Page 108: Installation Instructions For Vmc Series Awr/Awmr And Cp Restrained Mountings

    Technical Data INSTALLATION INSTRUCTIONS FOR VMC SERIES AWR/AWMR AND CP RESTRAINED MOUNTINGS Floor should be level and smooth. 5. Complete piping and fill equipment with water, refrigerant, etc. For indoor applications, isolators do not normally require bolting. If necessary, anchor isolators to 6. Turn leveling bolt of first isolator four full revolu- floor through bolt holes in base plate. IMPORT- tions and proceed to each mount in turn.

  • Page 109: Refrigerant Flow Diagram

    FORM 201.18-NM7 REFRIGERANT FLOW DIAGRAM COMP. Low Pressure Vapour High Pressure Vapour Low Pressure Liquid Medium Pressure Vapour High Pressure Liquid COMP - Compressor CDR -Condenser Coil CLR - Cooler EC - Economizer (Added to some models) OC - Oil Cooler OS - Oil Separator m /s - Air Entering Compressor R-22 - Refrigerant Circuit Number...

  • Page 110: Process And Instrumentation Diagram

    Technical Data PROCESS AND INSTRUMENTATION DIAGRAM SYSTEM COMPONENTS EXPANSION VALVE, THERMOSTATIC SOLENOID VALVE BALL VALVE RELIEF VALVE STOP VALVE ANGLE, ACCESS FLOW PURGE VALVE PLUG PRESSURE SENSOR TEMPERATURE SENSOR REPLACEABLE CORE FILTER DRYER COMP SIGHT GLASS FLOW SWITCH (option) PRESSURE SWITCH ELECTRIC HEATER CHILLED WATER FLOW...

  • Page 111: Component Locations

    FORM 201.18-NM7 COMPONENT LOCATIONS Control Panel BAMB 1-BOT 1-BDP 1-BOT 1-BDP 1-BOP 1-SHPI 1-CCCV 1-ECH BCLT 1-STS 1-BSP 2-BOT 3-BDP 3-BDT 3-BOP BCRT 3-SHPI 3-CCCV 3-ECH 2-YELSSV 2-STS 3-BSP 1-YELSSV - BAMB AMBIENT - BCLT COLD LEAVING TEMPERATURE - BCRT COLD RETURN TEMPERATURE - BDP DISCHARGE PRESSURE...

  • Page 112: Compressor Components

    Technical Data COMPRESSOR COMPONENTS LIFTING LUG THREADED HOLE SUCTION GAS MOTOR TERMINALS OIL PRESSURE TRANSDUCER LOCATION CAPACITY CONTROL SOLENOID (CAPACITY CONTROL, 3 WAY VALVE, IS LOCATED UNDER THE SOLENOID) ROTOR CASE STATOR LOCKING BOLT OIL FILTER COVER PLATE OIL FILTER BLEED &...
  • Page 113 FORM 201.18-NM7 COMPRESSOR COMPONENTS – CONT’D LD03669 FIG. 40 – COMPRESSOR COMPONENTS JOHNSON CONTROLS...
  • Page 114 Technical Data COMPRESSOR COMPONENTS – CONT’D LD03670 FIG. 41 – COMPRESSOR COMPONENTS JOHNSON CONTROLS...
  • Page 115 FORM 201.18-NM7 COMPRESSOR COMPONENTS – CONT’D LD05289 LEVEL I (Original) 022-09711-000 MALE ROTOR DISCHARGE CHECK VALVE LD06079 LEVEL II (Improved) RELIEF VALVE FIG. 42 – COMPRESSOR COMPONENTS JOHNSON CONTROLS...
  • Page 116 Technical Data COMPRESSOR COMPONENTS – CONT’D PART NAME O-RING SUCTION COVER SUCTION STRAINER ROTOR SCREW ROTOR LOCK WASHER ROTOR CLAMP WASHER ROTOR STATOR MALE INLET BEARING MALE ROTOR RETAINING RING MALE ROTOR ROTOR CASE O-RING DOWEL PIN DISCHARGE CASE LIP SEAL DISCHARGE RADIAL BEARING SPACER SHIM THRUST BEARINGS...
  • Page 117 FORM 201.18-NM7 COMPRESSOR COMPONENTS – CONT’D MOTOR ROTOR / MALE ROTOR LOCKING KEY O-RING MALE ROTOR SLIDE VALVE RELIEF O-RING RETURN VALVE SPRING SUPPORT ECONOMIZER FEMALE ROTOR SLIDE VALVE RINGS PLUG LD03672 FIG. 44 – COMPRESSOR COMPONENTS JOHNSON CONTROLS...

  • Page 118: System Startup Checklist

    SALES ORDER #: _________________________ and below the top of the upper sight glass. LOCATION: ______________________________ If it is necessary to add oil, connect a YORK oil pump to the charging valve on the oil separator, SOLD BY: ________________________________ but do not tighten the flare nut on the delivery INSTALLING tubing.

  • Page 119: Panel Checks

    FORM 201.18-NM7 5. Program the required operating values into the Panel Checks  micro for cut-outs, safeties, etc. and record them (Power ON – Both System Switches “OFF”) in the chart below. See Page 160 for details. If Default Values are desired for programming 1.

  • Page 120: Initial Start-Up

    Technical Data The subcooling temperature of each system should be INITIAL START-UP calculated by recording the temperature of the liquid After the control panel has been programmed and the line at the outlet of the condenser and subtracting it compressor heater has been on for 24 hours prior to from the recorded liquid line pressure at the liquid stop start-up, the chiller may be placed into operation.

  • Page 121: Checking Economizer Superheat

    FORM 201.18-NM7 Normally, the thermal expansion valve need not be Normally, the thermal expansion valve need not be adjusted in the field. If, however, adjustment needs to adjusted in the field. If however, adjustment needs to be made, the expansion valve adjusting screw should be made, the expansion valve adjusting screw should be turned not more than one turn at a time, allowing be turned not more than one turn at a time, allowing sufficient time (approximately 15 minutes) between sufficient time (approximately 15 minutes) between...

  • Page 122: Chiller Control Panel Programming And Data Access Keys

    Micro Panel Contents CHILLER CONTROL PANEL PROGRAMMING AND DATA ACCESS KEYS STATUS DISPLAY SETPOINTS CLOCK DISPLAY INFORMATION KEYS 29023A ON / OFF PRINT PROGRAM & SETUP KEY DISPLAY AND STATUS INFORMATION KEYS PROGRAM & SETUP KEYS Status Key - see Section 2 Entry Keys - see Section 5 This key provides a display of the current operational The numeric and associated keys are used for entering...

  • Page 123: Introduction & Physical Description

    1.1 GENERAL provided for remote cycling, current limiting, remote temperature setpoint reset and alarm annunciation. The YORK Screw Chiller Control Panel is a micro- processor based control system fitted to YCAS liq- YCAS chillers each have a single split circuit evapora- uid chillers.

  • Page 124: 1.3 Unit (Chiller) On / Off Switch

    Micro Panel Contents The battery is a 10 year lithium type, but life will de- 1.3 UNIT (CHILLER) ON / OFF SWITCH pend upon whether the Real Time Clock’s internal clock A master UNIT (Chiller) ON / OFF switch is located circuit is energized.

  • Page 125: 1.6 Circuit Breakers

    FORM 201.18-NM7 I/O Expansion Board • CB3 allows removal of control power to the Mi- croprocessor Board, Power Supply Board, I/O The I/O Expansion Board provides multiplexing to allow Expansion Board, and Evaporator Heater. additional inputs to be connected to the Microprocessor Board via a single data line.

  • Page 126: 1.9 Motor Protection Modules

    Micro Panel Contents The module also provides phase rotation protection to 1.9 MOTOR PROTECTION MODULES assure the screw compressor does not rotate backwards. A Motor Protection Module for each compressor is lo- A single phase protection circuit located in the module cated in the Control Panel.
  • Page 127 FORM 201.18-NM7 SIDE VIEW 29119A TOP VIEW TOP VIEW 29121A 29121A DISPLAY SWITCH PUSHED TO LEFT INDICATES 29120A SIDE VIEW FIG. 45 – MOTOR PROTECTION MODULE JOHNSON CONTROLS...

  • Page 128: Ems/Bas Controls

    Motor Current Key (see Section must be suppressed with a suppressor 3.5). However, if this display is being YORK Part Number 031‑00808‑000 viewed when the reset pulse occurs, the across the inductive coil. setpoint will not change on the display.
  • Page 129 Reset Temp = 120°Fsec 10 sec cable. If an inductive device (relay, contactor) is supplying these contacts, = 12°F (6°C) the coil of the device must be suppressed with a suppressor YORK Part Number 031‑00808‑000 across the inductive coil. JOHNSON CONTROLS...

  • Page 130: Microprocessor Board Layout

    Micro Panel Contents 1.11 MICROPROCESSOR BOARD LAYOUT 26001A ITEM DESCRIPTION DESIGNATION Clock Enable/Disable Jump Contact RTC (U13) Real Time Clock and Battery Backup I.C. EPROM Microprocessor I.C. (label shows version) NOTE : Dimple is positioned at top edge Dip Switch Set (8 switches) S2 to S5 System Switches S2 = System 1 S3 = System 2...

  • Page 131: Logic Section Layout

    FORM 201.18-NM7 1.12 LOGIC SECTION LAYOUT 60 Hz Models : 00262VIP PHOTOGRAPH OF 60 HZ MODEL LOGIC SECTION ITEM DESCRIPTION Microprocessor Board Back of Keypad I/O Expansion Board # 1 Power Supply Board Relay Output Board #1 Relay Output Board #2 Flow Switch &...

  • Page 132: Anti-Recycle Timer

    Micro Panel Contents 1.13 ANTI-RECYCLE TIMER 1.17 EVAPORATOR HEATER CONTROL The programmable Anti-Recycle Timer allows the user The evaporator heater is controlled by ambient tempera- to select the compressor anti-recycle time to best suit ture. When the ambient temperature drops below 40°F their needs.

  • Page 133: Run Status (Chiller)

    ON or OFF. cal equipment) and the alarm circuit should fail to function, YORK will not MANUAL Lead/Lag selection will be automatically be liable for damages. overridden by the micro to allow the lag compressor to automatically become the lead anytime the selected lead 1.20...

  • Page 134: Status Key: General Status Messages & Fault Warnings

    Micro Panel Contents 2. STATUS KEY: GENERAL STATUS MESSAGES & FAULT WARNINGS 29023A GENERAL GENERAL STATUS MESSAGES Pressing the Status key displays the current chiller or Unit Switch OFF: individual system operational status. The messages displayed include running status, cooling demand, fault U N I T S W I T C H O F F...

  • Page 135: Unit Warnings

    FORM 201.18-NM7 System Switches OFF: System Loading Requirement: S Y S D S C H L I M I T I N G S Y S C O O L L O A D S Y S D S C H L I M I T I N G S Y S C O O L...

  • Page 136: Anticipation Control Status Messages

    Micro Panel Contents Pump Down: ANTICIPATION CONTROL STATUS MESSAGES S Y S P U M P I N G D O W N Anticipation controls are built into the software to S Y S P U M P I N G D O W N prevent safety shutdowns by automatically overriding This message indicates that both refrigerant systems...

  • Page 137: Unit Fault Status Messages

    FORM 201.18-NM7 could cause damage due to low system pressures. This temperature on a system has dropped to 29°F (-2°C) feature is programmable and can also be used to shut and that any further temperature reduction could cause down the chiller at a temperature where continued run- some icing of the evaporator tubes.

  • Page 138: System Fault (Safety) Status Messages

    Micro Panel Contents the chiller must be manually reset. See Section 8.2 Before returning a locked out system (page 162). to service, a thorough investigation of the cause of the fault should be made. Flow Switch Open: Failure to repair the cause of the fault while manually allowing repetitive S Y S R U N...
  • Page 139 FORM 201.18-NM7 (0.1 to 0.7 bar). If oil pressure at the compressor drops lubrication. Typical oil temperature during normal op- due to filter blockage, the differential pressure on the eration will be approximately 130 - 150°F (54 - 66°C). display will increase and when the maximum limit is The High Oil Temperature Safety is activated after 2 reached the compressor will be shut down.
  • Page 140 Micro Panel Contents After 225 seconds of operation with suction pressure Average motor current is monitored after 7 seconds of operating above the cut-out, a 30 second transient timer compressor operation. The system will be shut down if prevents short term fluctuations in suction pressure due average motor current exceeds 115% FLA. to loading or fan cycling from causing shutdown.

  • Page 141: Printout On Fault Shutdown

    FORM 201.18-NM7 removed from the compressor contactors shutting down (-6°C) in water cooling mode, the system will be shut the compressor. Auto restart will not occur since manual down. If the refrigerant temp falls 19°F (11°C) below reset is required. A fault lockout will automatically occur the leaving chilled liquid temp in glycol cooling mode, after the micro attempts 2 more starts with the MP con- the system will shut down.

  • Page 142: Display Keys & Option Switches

    Micro Panel Contents 3. DISPLAY KEYS & OPTION SWITCHES 29023A is unlikely to occur unless a problem exists in the mea- GENERAL suring sensors or during extreme conditions. The Display keys provide direct access to retrieve com- monly required data about the operation of the chiller. The Display keys and the data available from each is This is particularly useful during commissioning, mon- as follows:...

  • Page 143: System # Data Keys

    FORM 201.18-NM7 Slide valve position is APPROXI‑ SYSTEM # DATA KEYS MATE and should be used for ref‑ Pressing one of the System # Data keys a number of erence only. Under actual conditions times scrolls through displays of differential oil pressure the compressor may be fully loaded (OIL), suction pressure (SP) and discharge pressure between step 60 ‑...

  • Page 144: Motor Current Key

    Micro Panel Contents the chiller. The Options key can be used to verify the MOTOR CURRENT KEY Dip Switch positions without looking at or handling the Pressing the Motor Current key displays compressor Microprocessor Board. current for each system: Each press of the key will scroll to the next option/dip C O M P 1 = 6 3 A M P...
  • Page 145 FORM 201.18-NM7 Closed: SWITCH 5: Motor Current Averaging S 1 - 2 A M B I E N T C O N T R O L Open: L O W A M B I E N T S 1 - 5 M O T O R C U R R E N T A V E R A G I N G Low Ambient Mode allows the Low Ambient Cut-Out N O T...

  • Page 146: Function Key

    Micro Panel Contents Dip Switch Physical Location and Setting Summary of Settings The following table gives a summary of Modes (dis- played messages) which can be selected using the Open and Closed positions for each of the eight SW1 Dip Switches.

  • Page 147: Print Keys

    FORM 201.18-NM7 4. PRINT KEYS 29023A GENERAL Information available using the Operating Data key is described in the following sections. In example displays “ The Print keys provide access to two sets of informa- # ” is used to indicate system number where appropriate. tion either locally on the panel display or, if an optional printer is connected, remotely as hard copy printouts.

  • Page 148: Operating Data - Remote Printout

    Micro Panel Contents System Data: T E M P E R R O R 0 0 . 5 ° F T E M P R A T E 0 . 9 ° F / M The following sequence of three displays are provided The upper message gives the difference (error) between first for System 1, then for System 2, and then for Sys- actual leaving chilled liquid temperature and the pro-...
  • Page 149 FORM 201.18-NM7 SYSTEM 2 DATA YORK INTERNATIONAL CORPORATION MILLENNIUM SCREW CHILLER COMPRESSORS STATUS RUN TIME 0- 0-15-26 D-H-M-S UNIT STATUS MOTOR CURRENT 104 AMPS 87 %FLA 2:04PM 10 OCT 98 SUCTION PRESSURE 57 PSIG DISCHARGE PRESSURE 233 PSIG SYS 1...

  • Page 150: History Key

    Micro Panel Contents HISTORY KEY Repetitively pressing the  Keys allows scrolling through the information available in the Safety Shut- If a safety shutdown occurs on the chiller, a compre- down buffer. This is divided into Common (Whole hensive list of operating and programmed settings data Chiller) Data and Individual System Data displays as is stored by the microprocessor.
  • Page 151 FORM 201.18-NM7 S E T P O I N T 4 4 . 0 ° F H I G H A M B I E N T T E M P R A N G E + / - 2 . 0 ° F C U T O U T 1 3 0 .
  • Page 152 Micro Panel Contents S Y S R U N T I M E S Y S S T E P 1 - 3 - 4 8 - 1 7 D - H - M - S This message shows the Run Time logged on the system This message indicates the compressor slide valve po- since the last compressor start, in Days (D), Hours (H), sition at the time of the fault.

  • Page 153: Fault History Data - Remote Printout

    6 faults. COMPRESSOR HEATER WYE-DELTA RELAY An example of the HISTORY Printout is shown below: SYSTEM 2 DATA COMPRESSORS STATUS YORK INTERNATIONAL CORPORATION RUN TIME 0- 0-15-26 D-H-M-S MILLENNIUM SCREW CHILLER MOTOR CURRENT 104 AMPS 87 %FLA SUCTION PRESSURE...

  • Page 154: Entry Keys

    Micro Panel Contents 5. ENTRY KEYS 29023A The Enter key is also used to scroll through available GENERAL data when using the Program or Set Schedule/Holiday The Entry keys allow the user to change numerical keys. values programmed in as chiller setpoints, cutouts, clock, etc.

  • Page 155: Setpoints Keys & Chilled Liquid Control

    FORM 201.18-NM7 6. SETPOINTS KEYS & CHILLED LIQUID CONTROL 29023A described as the maximum acceptable + and - deviation GENERAL from Setpoint. The microprocessor monitors leaving chilled liquid The minimum acceptable temperature is the Lower temperature and adjusts the chiller cooling capacity to Range and is calculated by subtracting the “-”...
  • Page 156 Micro Panel Contents • Load Timers are always set at 10 seconds between to the Setpoint Temperature. The amount of loading is varied by changing the amount of signal to the slide changes. valve solenoid of each compressor. • Unload timers are set at 5 seconds between changes. Slide Valve Control Slide Valve Position The slide valve of each compressor can be moved 75...
  • Page 157 FORM 201.18-NM7 Compressor Loading step. Opening of the unloading port on the control The micro loads and unloads individual compressors solenoid allows spring pressure to move the slide valve by varying current to the Slide Valve solenoid which to decrease capacity. Every 5 seconds, the micro will controls oil flow to the slide valve. The slide valve load decrement the compressor with the highest slide valve solenoid applies oil pressure to the slide valve to over-...

  • Page 158: Local Cooling Setpoints Key

    Micro Panel Contents LOCAL COOLING SETPOINTS KEY REMOTE COOLING SETPOINTS KEY Remote Cooling Setpoints key allows resetting the set- The Local Cooling Setpoints key is used to program the required Leaving Chilled Liquid control temperatures point upward from the programmed value in memory from a remote device.

  • Page 159: Clock Keys

    FORM 201.18-NM7 7. CLOCK KEYS 29023A “0” for times before 10 o’clock. e.g. 08:31. The cursor GENERAL will then advance to the AM/PM designation. If neces- The microprocessor features a continuously running sary press the  or  key to change to the opposite internal Clock and calendar and can display actual time time period.

  • Page 160: Set Schedule / Holiday Key

    Micro Panel Contents SET SCHEDULE / HOLIDAY KEY Programming the DAILY SCHED‑ ULE will not affect on the holiday Messages showing each week day and the holiday start/ schedule. stop schedule, as shown below, can be displayed using the Set Schedule / Holiday key: M O N S T A R T 0 6 : 0 0...

  • Page 161: Manual Override Key

    FORM 201.18-NM7 If an error is made while programming or a change is If a Warning – Low Battery fault required, press Cancel. This will clear the programmed message appears on the display the (*) “Holiday” days (the “0” key will not cancel out a internal clock, calendar and program “...

  • Page 162: Program Key

    Micro Panel Contents 8. PROGRAM KEY 29023A If an unacceptable value is entered at any stage, the GENERAL following message is displayed for a few seconds and The Program key is used to program 12 system operating the entered value is ignored: parameters including cutout points for safeties, antici- patory unload points to avoid faults, and anti-recycle O U T...
  • Page 163 FORM 201.18-NM7 Normally, air-cooled chillers such as YCAS chillers After the compressor starts, and the pump down cycle should have the cutout set at 395 PSIG (27 bar) for R22 is completed (pump down to cutout or 30 seconds, and R407C models. The micro will, however, accept val- whichever comes first.), suction pressure is monitored ues between 200 - 399 PSIG (14 - 28 bar).
  • Page 164 Micro Panel Contents set to the saturated refrigerant pressure equivalent to temperatures. If operation is occasionally needed below 18°F (10°C) below the lowest temperature of the pro- 1°F (-17°C), the cutout should be set at 00.0°F. This will grammed chilled liquid Control Range (Section 6). This allow operation at any temperature, as the micro will only programmable value is password protected.
  • Page 165 FORM 201.18-NM7 limit cutout value. The chiller can then continue to run the longest period acceptable in each application will automatically at reduced capacity until the cause of the reduce cycling and maximize motor life. 600 seconds excessive current is attended to. is recommended.

  • Page 166: Programming "Default" Values

    Micro Panel Contents the code is being keyed in, the digits are not displayed If manual control is desired, press the  or  key. One but are shown as “*” as shown: of the following messages will be displayed: L E A D / L A G C O N T R O L P R O G R A M...

  • Page 167: Condenser Fan Control

    FORM 201.18-NM7 are met. For example, if a system is at fan stage 4, and the CONDENSER FAN CONTROL DP falls below 195 PSIG and the OAT drops below 75 °F, The chiller is equipped with 6 condenser fans, with 3 the fan stage will be reduced to stage 3.
  • Page 168 Micro Panel Contents If discharge pressure drops below 120 PSIG or oil to Table 5 provides a simplified operating graph of the fan suction pressure differential falls below 75 PSID, the staging for this version. micro will turn off a step of fan cycling every 5 seconds: until the discharge pressure rises above 120 PSIG and Fan stages increment identical to the stages shown in oil to suction pressure differential rises above 75 PSID Table 3. in an effort to quickly control the discharge pressure to an acceptable range.
  • Page 169 FORM 201.18-NM7 LOAD / UNLOAD CONTROL CONTINUE COMP ON FANS OFF TIMER = 15 MIN TIMER = 5 SEC CONTINUE CONTROL TIMER TURN ON CONTROL NEXT FAN CONTINUE DP > 285 TIMER = 5 SEC STAGE TURN OFF DP < 120 CONTROL CONTINUE NEXT FAN...
  • Page 170 Micro Panel Contents EPROM Version C.A14.09.03 (A85F), TABLE 5 – CONDENSER FAN CONTROL (EPROM VERSIONS C.A32.09.02 (0483), other .03 versions and higher C.ACS.09.02 (D87E), AND C.A06.09.03 Fan operation is outlined in Table 6. Condenser fan ON (EIOC) conditions are governed solely by the Discharge Pressure (DP).

  • Page 171: Section 9 Maintenance

    It is entirely the responsibility of the owner to provide given in the MBCS Manual. for these regular maintenance requirements and/or enter into a maintenance agreement with a York International Compressor oil level: Check the compressor oil level service organization to protect the operation of the unit.
  • Page 172 Maintenance Operating Log JOHNSON CONTROLS...
  • Page 173 FORM 201.18-NM7 JOHNSON CONTROLS...

  • Page 174: General Periodic Maintenance Checks Standard Units

    Maintenance GENERAL PERIODIC MAINTENANCE CHECKS STANDARD UNITS SERVICE SCHEDULE MINOR SERVICE MAJOR SERVICE All items under Minor Service plus: Unit general: Check thermal insulation. Check main structure. Check vibration isolators. Check paint-work. Refrigerant systems general: Check relief valves. Check solenoid valves. Check fusible plugs.

  • Page 175: Recommended Spares

    BMLT 025-29964-000 Other spare parts vary depending on the unit model. Contact your local YORK Sales and Service Center for information and please quote the unit model number and serial number. When ordering spare parts, we will require the following...

  • Page 176: Section 11 Troubleshooting

    Troubleshooting COMPETENT PERSONS TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE ACTION POSSIBLE CAUSE ACTION No display on panel - Mains supply to control system OFF. Switch on main supply if safe to do so. unit will not start Emergency stop device off. Check if control panel emergency stop switch and any remote emergency stop devices are in the OFF position.
  • Page 177 FORM 201.18-NM7 COMPETENT PERSONS TROUBLESHOOTING GUIDE - CONT’D PROBLEM POSSIBLE CAUSE ACTION POSSIBLE CAUSE ACTION SYS # HIGH DSCH Poor airflow through condenser coils. Check for airflow restrictions caused by blockages displayed (High discharge on intake faces of air coils. pressure trip) Check for damaged fins/return bends.

  • Page 178: Sensor Calibration Charts

    Troubleshooting SENSOR CALIBRATION CHARTS Chilled Leaving Water Temperature (CLT) and Oil & Discharge Temperature Sensors Chilled Return Water Temperature (CRT) Sensors Temperature Resistance Voltage °F (°C) ohms Temperature Resistance Voltage 32° (0°) 163250 0,282 °F (C°) ohms 50° (10°) 99500 0,447 14°...

  • Page 179: Limited Warranty Applied Systems

    YORK. to the exclusions listed below, YORK, at its option, will repair or replace, FOB point of shipment, such YORK ALL WARRANTIES AND GUARANTEES ARE VOID IF: products or components as it finds defective. On materials or components furnished by YORK, but manufactured by 1.

  • Page 180: Temperature Conversion Chart

    Troubleshooting TEMPERATURE CONVERSION CHART Temperature Conversion Chart - Temperature Conversion Chart - Actual Temperatures Differential Temperatures ° F ° C °C °F ° F ° C °C °F -17.8 -0.4 -15.6 -13.3 -11.1 10.4 10.8 -8.9 14.4 -6.7 17.6 11.1 -4.4 21.2 13.3...
  • Page 181 FORM 201.18-NM7 NOTES JOHNSON CONTROLS...
  • Page 182 This page intentionally left blank. JOHNSON CONTROLS...
  • Page 183 FORM 201.18-NM7 This page intentionally left blank. JOHNSON CONTROLS...
  • Page 184 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2020 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 201.18-NM7 (1020) Issue Date: October 2, 2020 Supersedes: 201.18-NM7 (916)

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