York YCAS0130 User Manual

AIR-COOLED SCREW LIQUID CHILLERS

INSTALLATION, OPERATION & MAIN TE NANCE

YCAS AIR-COOLED LIQUID CHILLERS

YCAS0130 THROUGH YCAS0230

New Release

STYLE G

Form 201.19-NM1 (204)

035-20319-000

028971-G

60 Hz

YCAS 2 SYSTEM EPROM 031-01798-001 (STANDARD, BRINE & METRIC MODELS COM BINED)

FORM 201.19-NM1 (204)

CHANGEABILITY OF THIS DOCUMENT

In complying with YORK’s policy for continuous prod uct improvement, the information contained in this doc u ment is subject to change without notice. Literature updates that may occur will be printed on the Revision Sheet and included with the Installation, Operation & Maintenance (IOM) man, which is provided with new equipment. If not found with the manual, the current Revision Sheet containing any applicable revisions, and the manual, can be found on the internet at www.york.com. The Renewal Parts (RP) manual and revision sheet for this equipment can also be found at this internet site.

It is the responsibility of installing/operating/service personnel to determine prior to working on the equip ment, that they have all of the applicable literature, that it is current and that the equipment has not been modiﬁ ed since manufacture.

Revision Sheets are available for the IOM and Renewal Parts

Each update will be assigned a sequential Rev. Level with the date it was introduced

The Description/Change will explain the change. If necessary it will refer the reader to an additional supplement or bulletin.

YORK part number for the Revision Sheet to aid manufacturing and distribution

Web address for the Revision Sheet

2

035-XXXXX-XXX

www.york.com

YORK INTERNATIONAL

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

FORM 201.19-NM1 (204)

This equipment is a relatively complicated ap pa ra tus. Dur ing installation, operation, maintenance or service, in di vid u als may be exposed to certain com po nents or conditions in clud ing, but not limited to: re frig er ants, oils, materials un der pressure, rotating com po nents, and both high and low voltage. Each of these items has the po ten tial, if misused or handled im prop er ly, to cause bodi ly injury or death. It is the obligation and re spon si bil i ty of operating/service per son nel to iden ti fy and rec og nize these inherent hazards, protect them selves, and pro ceed safely in completing their tasks. Failure to com ply with any of these requirements could re sult in se ri ous dam age to the equipment and the prop er ty in

which it is sit u at ed, as well as severe personal injury or death to them selves and people at the site.

This document is intended for use by owner-authorized operating/service personnel. It is expected that this in di vid u al possesses independent training that will en able them to perform their assigned tasks properly and safe ly. It is essential that, prior to performing any task on this equipment, this individual shall have read and un der stood this document and any referenced materials. This in di vid u al shall also be familiar with and comply with all ap pli ca ble governmental standards and regulations per tain ing to the task in question.

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to areas of potential hazard:

DANGER indicates an im mi nent ly hazardous situation which, if not avoid ed, will re sult in death or se ri ous injury.

CAUTION identiﬁ es a hazard which could lead to damage to the ma chine, damage to other equip ment and/or en vi ron men tal pollution. Usually an in struc tion will be given, together with a brief ex pla na tion.

WARNING indicates a potentially haz ard ous sit u a tion which, if not avoid ed, could result in death or se ri ous in ju ry.

External wiring, unless speciﬁ ed as an optional connection in the man u fac tur er’s prod uct line, is NOT to be connected inside the micro pan el cab i net. De vic es such as re lays, switch es, transducers and controls may NOT be installed inside the mi cro pan el. NO external wiring is al lowed to be run through the micro panel. All wir ing must be in ac cor dance with 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. Failure to fol low this will void the man u fac tur er’s warranty and cause serious dam age to property or injury to per sons.

YORK INTERNATIONAL

NOTE is used to highlight ad di tion al information which may be helpful to you.

3

TABLE OF CONTENTS

FORM 201.19-NM1 (204)

SECTION 1 - GENERAL CHILLER INFORMATION & SAFETY

INTRODUCTION ...........................................................9

WARRANTY...................................................................9

SAFETY...........................................................................9

Standards for Safety ...............................................9

RESPONSIBILITY FOR SAFETY...............................10

ABOUT THIS MANUAL..............................................10

MISUSE OF EQUIPMENT...........................................10

Suitability for Application.................................... 10

Structural Support ................................................10

Mechanical Strength............................................. 10

General Access .....................................................10

Pressure Systems.................................................. 10

Electrical...............................................................10

Rotating Parts .......................................................11

Sharp Edges.......................................................... 11

Refrigerants and Oils............................................ 11

High Temperature and Pressure Cleaning ............11

Emergency Shutdown...........................................11

SECTION 2 - PRODUCT DESCRIPTION

INTRODUCTION .........................................................12

General Description..............................................12

Compressor...........................................................12

Evaporator ............................................................13

Condenser.............................................................13

Economizer...........................................................14

Oil Separator/System............................................14

Oil Cooling...........................................................14

Capacity Control ..................................................14

Power and Control Panel......................................14

Each power compartment contains: .....................15

The control section contains:................................15

The options sections contain: ...............................15

Microprocessor Controls...................................... 15

Motor Current Protection .....................................15

Motor Protection Modules (2ACE)......................16

Current Overload..................................................16

Thermal Overload ................................................17

Current Imbalance (Loaded & Unloaded)............ 17

Loss of Phase........................................................ 17

Improper Phase Sequence ....................................17

MOTOR STARTING..................................................... 22

KEYPAD CONTROLS.................................................. 22

Display .................................................................22

Program ................................................................23

ACCESSORIES AND OPTIONS .................................23

Multiple Point Power Connection (Standard) ......23

Single-Point Power Connection with Individual

Circuit Protection .................................................23

Single-Point Power Connection with Combined

Circuit Protection ................................................23

Single-Point Power Connection without Circuit

Protection ............................................................23

Control Circuit Terminal Block............................23

Building Automation System (BAS) Interface.....23

Condenser Coil Protection ..................................23

DX EVAPORATOR AND STARTER OPTIONS .........24

UNIT ENCLOSURES OPTIONS .................................24

FAN OPTIONS ..............................................................24

SOUND REDUCTION OPTIONS................................ 24

VIBRATION ISOLATION ...........................................24

UNIT NOMENCLATURE ............................................25

NAMEPLATE ENGINEERING DATA ........................ 25

PRODUCT IDENTIFICATION NUMBER (PIN) ........26

SECTION 3 - HANDLING AND STORAGE

DELIVERY AND STORAGE....................................... 27

INSPECTION ................................................................27

MOVING THE CHILLER ............................................27

Lifting Weights..................................................... 27

UNIT RIGGING ............................................................ 28

SECTION 4 - INSTALLATION

LOCATION REQUIREMENTS.................................... 29

OUTDOOR INSTALLATIONS ....................................29

INDOOR INSTALLATIONS ........................................29

LOCATION CLEARANCES ........................................29

COMPRESSOR FEET BOLT REMOVAL ...................30

VIBRATION ISOLATORS ..........................................31

Installation............................................................31

SHIPPING BRACES.....................................................31

PIPEWORK CONNECTION ........................................ 31

General Requirements.......................................... 31

WATER TREATMENT..................................................32

PIPEWORK ARRANGEMENT....................................33

CONNECTION TYPES & SIZES.................................33

EVAPORATOR CONNECTIONS ................................33

Optional Flanges ..................................................33

REFRIGERANT RELIEF VALVE PIPING.................. 33

DUCTWORK CONNECTION .....................................33

General Requirements.......................................... 33

ELECTRICAL CONNECTION .................................... 34

POWER WIRING.......................................................... 34

STANDARD UNITS WITH MULTI POINT POWER

SUPPLY WIRING .........................................................34

4

YORK INTERNATIONAL

TABLE OF CONTENTS (CONT’D)

FORM 201.19-NM1 (204)

Units with Single-Point Power Supply Wiring ....34

115VAC CONTROL SUPPLY TRANSFORMER........ 34

Remote Emergency Stop Device..........................35

CONTROL PANEL WIRING........................................35

VOLTS FREE CONTACTS ..........................................35

Chilled Liquid Pump Starter ................................35

Run Contact..........................................................35

Alarm Contacts..................................................... 35

SYSTEM INPUTS......................................................... 35

Flow Switch..........................................................35

Remote Run / Stop ...............................................35

Remote Print......................................................... 35

Remote Setpoint Offset – Temperature ................35

Remote Setpoint Offset – Current........................35

SECTION 5 - COMMISSIONING

PREPARATION.............................................................42

PREPARATION – POWER OFF ..................................42

Inspection .............................................................42

Refrigerant Charge ...............................................42

Valves ...................................................................42

Compressor Oil ....................................................42

Fans ......................................................................42

Isolation/Protection ..............................................42

Control Panel........................................................42

Power Connections............................................... 42

Grounding.............................................................42

Overloads .............................................................42

Supply Voltage .....................................................42

Control Transformer............................................. 42

Switch Settings.....................................................43

Crankcase Heaters ................................................ 43

Water System........................................................43

Flow Switch..........................................................43

Temperature Sensor(s)..........................................43

Control Supply .....................................................43

Programmed Options............................................43

Programmed Settings ...........................................43

Date and Time ......................................................43

Start/Stop Schedule ..............................................43

Setpoint and Remote Offset .................................43

FIRST TIME START-UP...............................................44

Interlocks..............................................................44

System Switches................................................... 44

Start-up................................................................. 44

Oil Pressure ..........................................................44

Refrigerant Flow ..................................................44

Fan Rotation .........................................................44

Suction Superheat................................................. 44

Expansion Valve ..................................................44

Economizer Superheat .........................................44

Subcooling............................................................ 44

General Operation ................................................44

SECTION 6 - OPERATION

GENERAL DESCRIPTION..........................................46

START-UP .....................................................................46

NORMAL RUNNING AND CYCLING....................... 46

SHUTDOWN.................................................................46

SECTION 7 - TECHNICAL DATA

FLOW RATE AND PRESSURE DROP CHARTS.......48

GLYCOL CORRECTION FACTORS........................... 48

TEMPERATURE AND FLOWS ...................................49

PHYSICAL DATA......................................................... 51

OPERATING LIMITATIONS AND SOUND POWER

DATA .............................................................................53

Electrical Data ...................................................... 54

Electrical Notes ....................................................62

WIRING DIAGRAM.....................................................64

ELEMENTARY DIAGRAM......................................... 66

CONNECTION DIAGRAM (SYSTEM WIRING) ...... 77

COMPRESSOR TERMINAL BOX ..............................78

DIMENSIONS–YCAS0130-YCAS0180 (ENGLISH) .82

DIMENSIONS–YCAS0130-YCAS0180 (SI)............... 84

DIMENSIONS–YCAS0200-YCAS0230 (ENGLISH) .86

DIMENSIONS–YCAS0200-YCAS0230 (SI)............... 88

TECHNICAL DATA......................................................90

WEIGHT DISTRIBUTION AND ISOLATOR

MOUNTING POSITIONS ............................................91

INSTALLATION INSTRUCTIONS FOR VMC SERIES AWR/AWMR AND CP RESTRAINED

MOUNTINGS..............................................................107

COMPRESSOR COMPONENTS............................... 111

UNIT CHECKS (NO POWER)................................... 117

SYSTEM STARTUP CHECKLIST.............................117

PANEL CHECKS ........................................................118

PROGRAMMED VALUES......................................... 118

INITIAL START-UP.................................................... 119

CHECKING SUBCOOLING AND SUPERHEAT ....119

CHECKING ECONOMIZER SUPERHEAT ............. 120

LEAK CHECKING .....................................................120

YORK INTERNATIONAL

5

TABLE OF CONTENTS (CONT’D)

FORM 201.19-NM1 (204)

SECTION 8 - MICRO PANEL CONTENTS

CHILLERLER CONTROL PANEL

PROGRAMMING AND DATA ACCESS KEYS .......122

DISPLAY AND STATUS INFORMATION KEYS ....122

ON / OFF ROCKER SWITCH.................................... 122

PROGRAM & SETUP KEYS.....................................122

1. INTRODUCTION & PHYSICAL DESCRIPTION123

1.1 General .........................................................123

1.2 Keypad & Display........................................123

1.3 Unit (chiller) ON/OFF Switch......................124

1.4 Microprocessor Board.................................. 124

1.5 Ancillary Circuit Boards...............................124

1.6 Circuit Breakers ...........................................125

1.8 Transformers.................................................125

1.9 Motor Protection Modules ...........................125

1.10 EMS/BAS Controls.................................... 128

1.11 Microprocessor Board Layout.................... 130

1.12 Logic Section Layout .................................131

1.13 Anti-Recycle Timer ....................................132

1.14 Anti-Coincidence Timer .............................132

1.15 Evaporator Pump Control...........................132

1.16 Compressor Heater Control........................ 132

1.17 Evaporator Heater Control .........................132

1.18 Pumpdown (EEV) Control......................... 132

1.19 Alarms ........................................................133

1.20 Run Status (chiller) ....................................133

1.21 Lead / Lag Compressor Selection ..............133

1.22 Economizer Solenoid Control ....................134

2. STATUS KEY: GENERAL STATUS MESSAGES &

FAULT WARNINGS...............................................136

2.1 General .........................................................136

2.2 General Status Messages..............................136

2.3 Unit Warnings............................................... 137

2.4 Anticipation Control Status..........................138

2.5 Unit Fault Status Messages ..........................139

2.6 System Fault (SAFETY) status ................... 140

2.7 Printout on Fault Shutdown..........................143

3. DISPLAY KEYS & OPTION SWITCHES.............144

3.1 General .........................................................144

3.2 Chilled Liquid Temps key ............................144

3.3 System # Data Keys .....................................145

3.4 Ambient Temp Key ......................................145

3.5 % Motor Current key....................................146

3.6 Operating Hrs / Start Counter key................146

3.7 Options key & .............................................146

3.8 Funtion Key..................................................148

4. PRINT KEYS...........................................................149

4.1 General .........................................................149

4.2 Oper Data Key.............................................. 149

4.3 Operating Data – Software Version.............. 149

4.4 Operating Data – Remote Printout............... 151

4.5 History Key ..................................................152

4.6 Fault History Data – Local Display

Messages ......................................................152

4.7 Fault History Data – Remote Printout..........156

5. ENTRY KEYS .........................................................157

5.1 General .........................................................157

5.2 Numerical Keypad........................................157

5.3 Enter Key......................................................157

5.4 Cancel Key ...................................................157

5.5  KEYS ...............................................157

6. SETPOINTS KEYS & CHILLED LIQUID

CONTROL...............................................................158

6.1 General .........................................................158

6.2 Chilled Liquid Temperature Control ............158

6.3 Local Cooling Setpoints Key .......................162

6.4 Remote cooling setpoints Key......................162

7. CLOCK KEYS ........................................................163

7.1 GENERAL ...................................................163

7.2 SET TIME KEY...........................................163

7.3 set schedule / holiday key.............................164

7.4 Manual Override key.................................... 165

8. PROGRAM KEY.....................................................166

8.1 General .........................................................166

8.2 Program Key – User Programmable Value ..166

8.3 Programming "Default" Values.................... 170

8.4 Electronic Expansion Valve..........................172

8.5 EEV Operation .............................................173

8.6 EEV Programming .......................................175

8.7 EEV Troubleshooting ...................................176

8.8 Condenser Fan Control.................................177

8.9 Service Mode: Unit Setup ............................179

8.10 Sensor Calibration Charts...........................185

8.11 Control Inputs/Outputs...............................186

8.12 ISN Control ...............................................189

6

YORK INTERNATIONAL

TABLE OF CONTENTS (CONT’D)

SECTION 9 - MAINTENANCE

GENERAL REQUIREMENTS................................... 194

CONDENSER COILS................................................. 194

Chiller / Compressor Operating Log..................195

Scheduled Maintenance......................................195

ON-BOARD BATTERY BACK-UP ...........................195

OVERALL UNIT INSPECTION................................ 195

COMPRESSOR UNIT OPERATION .........................196

GENERAL PERIODIC MAINTENANCE CHECKS 198

STANDARD UNITS ...................................................198

SECTION 10 - SPARE PARTS

Recommended Spares ........................................199

Recommended Compressor Oils........................199

FORM 201.19-NM1 (204)

SECTION 11 - TROUBLE SHOOTING

TROUBLESHOOTING GUIDE .................................200

LIMITED WARRANTY YORK AMERICAS

ENGINEERED SYSTEMS .........................................202

WARRANTY ON NEW EQUIPMENT......................202

WARRANTY ON RECONDITIONED OR

REPLACEMENT MATERIALS................................. 202

TEMPERATURE CONVERSION CHART................203

TEMPERATURE CONVERSION CHART

ACTUAL TEMPERATURES......................................203

TEMPERATURE CONVERSION CHART

DIFFERENTIAL TEMPERATURES..........................203

PRESSURE CONVERSION CHARRT - GAUGE

OR DIFFERENTIAL................................................... 203

LIST OF TABLES

TABLE 1 – Motor Protector Dip Switch Setting .......... 18

TABLE 2 – Programmable Values Table

(minimum/maximum)............................... 175

TABLE 3 – Condenser Fan Control and Fan Contactor Data for DXST Units with 4

Fans/System ............................................. 178

TABLE 4 – Condenser Fan Control and Fan Contactor Data For DXST Units With 5

Fans/System.. ........................................... 178

TABLE 5 – Service Mode Programmable Values ......179

TABLE 6 – YCAS Style G, Across the Line Start .....180

TABLE 7 – YCAS Style G, Wye Delta Start ............. 182

TABLE 8 - Digital Outputs.......................................... 186

TABLE 9 - Analog Inputs............................................ 187

TABLE 10 - Digital Inputs .......................................... 188

TABLE 11 - Analog Outputs........................................188

TABLE 12 – ISN Received Data .................................189

TABLE 13 – ISN Transmitted Data.............................189

TABLE 14 – ISN Operational and Fault Codes...........192

YORK INTERNATIONAL

7

LIST OF FIGURES

FORM 201.19-NM1 (204)

FIG. 1 – COMPONENT LOCATIONS......................... 12

FIG. 2 – SCREW COMPRESSOR................................13

FIG. 3 – UNIT RIGGING..............................................28

FIG. 4 – LIFTING LUGS .............................................. 28

FIG. 5 – COMPRESSOR MOUNTING........................30

FIG. 7 – VICTAULIC GROOVE ..................................33

FIG. 8 – FLANGE ATTACHMENTS ...........................33

FIG. 9 – POWER PANEL SECTION............................ 36

FIG. 10 – OPTION PANEL SECTION .........................37

FIG. 11 – LOGIC SECTION LAYOUT........................ 38

FIG. 12 – LOGIC SECTION LAYOUT WITH

CONTROL PANEL LAYOUT...................... 39

FIG. 13 – CUSTOMER CONNECTIONS .................... 40

FIG. 14 – CUSTOMER CONNECTIONS .................... 41

FIG. 16 – GLYCOL CORRECTION FACTORS ..........48

FIG. 15 – FLOW RATE AND PRESSURE DROP

CHARTS ........................................................48

FIG. 17 – WIRING DIAGRAM –

ACROSS-THE-LINE START....................... 64

FIG. 18 – WIRING DIAGRAM –

ACROSS-THE-LINE START....................... 65

FIG. 19 – ELEMENTARY DIAGRAM –

ACROSS-THE-LINE START...................... 66

FIG. 20 – WIRING DIAGRAM –

WYE-DELTA START ...................................68

FIG. 21 – ELEMENTARY DIAGRAM –

WYE-DELTA START ...................................69

FIG. 22 – ELEMENTARY DIAGRAM –

WYE-DELTA START ...................................70

FIG. 22A – POWER PANEL (SYSTEM #1)

COMPONENT LOCATIONS.....................72

FIG. 22B – CONTROL PANEL COMPONENT

LOCATION................................................73

FIG. 22C – POWER PANEL (SYSTEM #2)

COMPONENT LOCATIONS.....................74

FIG. 23 – MODEL YCAS0130 - 0180

DIMENSIONS (ENGLISH) ......................... 82

FIG. 25 – MODEL YCAS0200 - YCAS0230

DIMENSIONS (ENGLISH) ......................... 86

FIG. 26 – MODEL YCAS0200 - YCAS0230

DIMENSIONS (SI).......................................88

FIG. 27 – CLEARANCES.............................................90

FIG. 28 – CP-2-XX........................................................ 92

FIG. 29 – ISOLATOR DETAILS .................................93

FIG. 30 – CP-2-XX........................................................ 96

FIG. 31 – ISOLATOR DETAILS .................................97

FIG. 32 – CP-2-XX...................................................... 100

FIG. 33 – ISOLATOR DETAILS ...............................101

FIG. 34 – CP-2-XX...................................................... 104

FIG. 35 – ISOLATOR DETAILS ...............................105

FIG. 36 – REFRIGERANT FLOW DIAGRAM ......... 108

FIG. 37 – PROCESS AND INSTRUMENTATION

DIAGRAM..................................................109

FIG. 38 – COMPONENT LOCATIONS..................... 110

FIG. 39 – COMPRESSOR COMPONENTS .............. 111

FIG. 40 – COMPRESSOR COMPONENTS .............. 112

FIG. 41 – COMPRESSOR COMPONENTS .............. 113

FIG. 42 – COMPRESSOR COMPONENTS .............. 114

FIG. 43 – COMPRESSOR COMPONENTS .............. 115

FIG. 44 – COMPRESSOR COMPONENTS .............. 116

FIG. 45 – MOTOR PROTECTION MODULE...........127

FIG. 46 – COMPONENT LAYOUT ...........................130

FIG. 47 – LOGIC SECTION LAYOUT...................... 131

FIG. 47A – PROCESS AND INSTRUMENTATION

DIAGRAM ............................................... 135

FIG. 48 – SUCTION PRESSURE CUTOUT ............. 141

FIG. 49 – ENLARGED PHOTOGRAPH OF DIP SWITCHES ON MICROPROCESSOR

BOARD.......................................................147

FIG. 50 – ELECTRONIC EXPANSION VALVE .....172

FIG. 51 – CONDENSER FAN LAYOUT FOR

DXST 2 COMPRESSOR UNITS .............177

8

YORK INTERNATIONAL

GENERAL CHILLER INFORMATION & SAFETY

FORM 201.19-NM1 (204)

INTRODUCTION

YORK YCAS chillers are manufactured to the high est design and construction standards to en sure high performance, reliability and adaptability to all types of air conditioning installations.

The unit is intended for cooling water or glycol so lu tions and is not suitable for purposes other than those spec i ﬁ ed in this manual.

This manual and the Microprocessor Operating In struc tions contain all the information required for correct in stal la tion and commissioning of the unit, together with operating and maintenance instructions. The manuals should be read thoroughly before attempting to operate or service the unit.

All procedures detailed in the manuals, including in stal la tion, commissioning and maintenance tasks must only be performed by suitably trained and qualiﬁ ed per son nel.

The manufacturer will not be liable for any injury or dam age caused by incorrect installation, com mis sion ing, op er a tion or maintenance resulting from a failure to fol low the procedures and instructions detailed in the manuals.

1

For warranty purposes, the following conditions must be satisﬁ ed:

• The initial start of the unit should be carried out by trained personnel from an Authorized YORK Ser vice Cen ter. See Commissioning, page 42.

• Only genuine YORK approved spare parts, oils and re frig er ants must be used. Recommendations on spare parts can be found on page 199.

• All the scheduled maintenance operations detailed in this manual must be performed at the speciﬁ ed times by suitably trained and qualiﬁ ed personnel. See Main te nance Section, page 194.

• Failure to satisfy any of these conditions will au to mat i cal ly void the warranty. See Warranty Policy, page 202.

SAFETY

Standards for Safety

YCAS chillers are designed and built with in an ISO 9002 accredited design and manufacturing or ga ni za tion. The chillers comply with the applicable sec tions of the following Standards and Codes:

WARRANTY

York International warrants all equipment and ma te ri als against defects in workmanship and materials for a pe ri od of eighteen months from deliveryunless extended warranty has been agreed upon as part of the contract.

The warranty is limited to parts only replacement and ship ping of any faulty part, or sub-assembly which has failed due to poor quality or manufacturing errors. All claims must be supported by evidence that the failure has oc curred with in the warranty period, and that the unit has been op er at ed within the designed parameters speciﬁ ed.

All warranty claims must specify the unit model, serial number, order number. These de tails are print ed on the unit identiﬁ cation plate.

The unit warranty will be void if any modiﬁ cation to the unit is carried out without prior written approval from York International.

• ANSI/ASHRAE Standard 15, Safety Code for Me chan i cal Refrigeration

• ANSI/NFPA Standard 70, National Electrical Code (N.E.C.)

• ASME Boiler and Pressure Vessel Code, Section VIII Division 1

• ARI Standard 550/590-98, Centrifugal and Rotary Screw Water Chilling Packages

In addition, the chillers conform to Underwriters Lab o ra to ries (U.L.) for construction of chillers and provide U.L./cU.L. listing label.

YORK INTERNATIONAL

9

General Chiller Information & Safety

FORM 201.19-NM1 (204)

RESPONSIBILITY FOR SAFETY

Every care has been taken in the design and man u fac ture of the unit to ensure compliance with the safety requirements listed above. However, the individual op er at ing or working on any machinery is primarily re spon si ble for:

• Personal safety, safety of other personnel, and the ma chin ery.

• Correct utilization of the machinery in accordance with the procedures detailed in the manuals.

ABOUT THIS MANUAL

The following terms are used in this document to alert the reader to areas of potential hazard.

A Warning is given in this document to identify a haz ard which could lead to per son al injury. Usually an in struc tion will be given, to geth er with a brief ex pla na tion and the possible result of ignoring the in struc tion.

A Caution identiﬁ es a hazard which could lead to dam age to the machine, dam age to other equip ment and/or en vi ron men tal pollution. Usu al ly an in struc tion will be given, together with a brief explanation and the pos si ble result of ig nor ing the in struc tion.

A Note is used to highlight additional in for ma tion which may be helpful to you but where there are no special safety im pli ca tions.

MISUSE OF EQUIPMENT

Suitability for Application

The unit is intended for cooling water or glycol so lu tions and is not suitable for purposes other than those spec i ﬁ ed in these instructions. Any use of the equip ment oth er than its intended use, or operation of the equip ment con trary to the relevant procedures may re sult in injury to the op er a tor, or damage to the equip ment.

The unit must not be operated outside the design pa ram e ters speciﬁ ed in this manual.

Structural Support

Structural support of the unit must be provided as in di cat ed in these instructions. Failure to provide proper support may result in injury to the operator, or damage to the equipment and/or building.

Mechanical Strength

The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or structures. Ad di tion al components must not be mounted on the unit. Any such extraneous loads may cause structural fail ure and may result in injury to the operator, or damage to the equipment.

General Access

There are a number of areas and features which may be a hazard and potentially cause injury when working on the unit unless suitable safety precautions are tak en. It is important to ensure access to the unit is restricted to suitably qualiﬁ ed persons who are familiar with the po ten tial hazards and precautions necessary for safe op er a tion and maintenance of equipment containing high temperatures, pressures and voltages.

The contents of this manual include sug gest ed best working practices and pro ce dures. These are issued for guidance only, and they do not take pre ce dence over the above stated individual responsibility and/or local safety regulations.

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.

10

Pressure Systems

The unit contains refrigerant vapor and liquid under pres sure, release of which can be a danger and cause in ju ry. The user should ensure that care is taken during in stal la tion, operation and maintenance to avoid dam age to the pressure system. No attempt should be made to gain ac cess to the component parts of the pressure sys tem other than by suitably trained and qualiﬁ ed per son nel.

Electrical

The unit must be grounded. No in stal la tion or main te nance work should be attempted on the electrical equip ment without ﬁ rst switching OFF, isolating and lock ing-off the power supply. Work on live equipment must only be carried out by suitably trained and qualiﬁ ed

YORK INTERNATIONAL

FORM 201.19-NM1 (204)

per son nel. No attempt should be made to gain access to the con trol panel or electrical enclosures during nor mal op er a tion of the unit.

Rotating Parts

Fan guards must be ﬁ tted at all times and not removed unless the power supply has been isolated. If ductwork is to be ﬁ tted, requiring the wire fan guards to be re moved, alternative safety measures must be taken to protect against the risk of injury from rotating fans.

Sharp Edges

The ﬁ nning on the air cooled con dens er coils has sharp metal edges. Reasonable care should be taken when working in contact with the coils to avoid the risk of mi nor abra sions and lac er a tions. The use of gloves is recommended.

Refrigerants and Oils

Refrigerants and oils used in the unit are generally nontoxic, non-ﬂ ammable and non-corrosive, and pose no spe cial safety hazards. Use of gloves and safety glass es are, however, recommended when working on the unit. The build up of refrigerant vapor, from a leak for ex-

am ple, does pose a risk of asphyxiation in conﬁ ned or enclosed spac es and attention should be given to good ven ti la tion.

High Temperature and Pressure Cleaning

High temperature and pressure cleaning methods (e.g. steam cleaning) should not be used on any part of the pressure system as this may cause operation of the pres sure relief device(s). Detergents and solvents which may cause corrosion should also be avoided.

EMERGENCY SHUTDOWN

In case of emergency the electrical option panel is ﬁ t ted with an emergency stop switch CB3 (Circuit Break er

3). Separate Circuit Break ers, CB1 (Sys tem 1) and CB2 (Sys tem 2), can also be used to stop the re spec tive sys tem in an emer gen cy. When op er at ed, CB3 re moves the elec tri cal supply from the con trol sys tem, thus shut ting down the unit.

1

YORK INTERNATIONAL

11

Product Description

1 System Fans 2 System 1 Power Panel 3 System 2 Power Panel 4 Control Panel 5 Power Entry 6 System 1 Compressor 7 Evaporator 8 System 2 Compressor 9 System 1 Condenser 10 Option Box

9

PRODUCT DESCRIPTION

1

FORM 201.19-NM1 (204)

2

4

3

10

8

7

6

FIG. 1 – COMPONENT LOCATIONS

INTRODUCTION

YORK YCAS chillers are designed for water or wa ter-glycol cooling. All units are designed to be lo cat ed outside on the roof of a building or at ground level.

The units are completely assembled with all in ter con nect ing refrigerant piping and internal wiring, ready for ﬁ eld installation.

Prior to delivery, the unit is pressure tested, evacuated, and fully charged with refrigerant and oil in each of the two independent refrigerant circuits. After assembly, an operational test is performed with water ﬂ owing through the evaporator to ensure that each refrigerant cir cuit operates correctly.

The unit structure is manufactured from heavy gauge, galvanized steel. All external structural parts are coat ed with “Desert Sand” baked-on enamel powder paint. This provides a ﬁ nish which, when subjected to ASTM B117, 500 hour, 5% salt spray conditions, shows breakdown of less than 1/8" either side of a scribed line (equiv a lent to ASTM D1654 rating of “6”).

5

028971-G

All exposed power wiring is be routed through liquidtight, non-metallic conduit.

General Description

The Air Cooled Screw Chiller utilizes many com po nents which are the same or nearly the same as a stan dard reciprocating chiller of a similar size. This in cludes mod u lar frame rails, condenser, fans and evap o ra tor.

The chiller consists of 2 screw compressors in a cor re spond ing number of separate refrigerant circuits, a sin gle shell and tube DX counterﬂ ow evaporator, econ o miz ers, an air cooled condenser, and expansion valves.

Compressor

The semi-hermetic rotary twin-screw compressor is designed for industrial refrigeration applications and ensures high operational efﬁ ciencies and reliable per- for mance. Capacity control is achieved through a sin gle slide valve. The compressor is a positive dis place ment type characterized by two helically grooved rotors which are manufactured from forged steel. The 60 Hz motor operates at 3550 RPM to direct drive the male rotor which in turn drives the female rotor on a light ﬁ lm of oil.

12

YORK INTERNATIONAL

FORM 201.19-NM1 (204)

Refrigerant gas is drawn into the void created by the unmeshing of the ﬁ ve lobed male and seven lobed fe male rotor. Further meshing of the rotors closes the ro tor threads to the suction port and progressively com press es the gas in an axial direction to the discharge port. The gas is compressed in volume and increased in pressure before exiting at a designed volume at the dis charge end of the rotor casing. Since the intake and dis charge cy cles overlap, a resulting smooth ﬂ ow of gas is maintained.

The rotors are housed in a cast iron compressor hous ing precision machined to provide optimal clearances for the rotors. Contact between the male and female rotor is pri ma ri ly rolling on a contact band on each of the rotor’s pitch circle. This results in virtually no rotor wear and in creased reliability, a trademark of the screw com pres sor.

The compressor incorporates a complete anti-friction bearing design for reduced power input and increased reliability. Four separated, cylindrical, roller bearings handle radial loads. Angular-contact ball bearings han dle axial loads. Together they maintain accurate rotor po si tion ing at all pressure ratios, thereby min i miz ing leak age and maintaining efﬁ ciency. A springless check valve is installed in the compressor discharge housing to pre vent compressor rotor backspin due to system re frig er ant pressure gradients during shut down.

The compressor is lubricated by removing oil from the refrigerant using an external oil separator. The pres sur ized oil from the oil separator is then cooled in the condenser coils and piped back to the compressor for lubrication. The com pres sor design working pressure is 450 PSIG (31 bar). Each chill er receives a 300 PSIG (21 bar) low side and a 450 PSIG (31 bar) high side factory test. A 350 watt (115-1-60) cartridge heat er is located in the com pres sor. The heat er is tem per a ture activated to prevent re frig er ant condensation.

The following items are also included:

• An acoustically tuned, internal discharge mufﬂ er to min i mize noise, while maintaining max i mum ﬂ ow and performance.

• Discharge shutoff valve.

• A rain-tight terminal box.

• A suction gas screen and serviceable, 0.5 - 3.0 micron full ﬂ ow oil ﬁ lter within the compressor housing.

Evaporator

The system uses a high efﬁ ciency Shell and Tube type Di rect Ex pan sion Evaporator. Each of the 2 re frig er ant circuits consists of 4 passes with the chilled liq uid cir cu lat ing back and forth across the tubes from one end to the other.

2

Motor cooling is provided by suction gas from the evap o ra tor flowing across the motor. Redundant over load pro tec tion is provided using both thermistor and cur rent over load protection.

00485VIP

FIG. 2 – SCREW COMPRESSOR

The design working pressure of the standard evaporator on the shell side is 150 PSIG (10 bar), and 350 PSIG (24 bar) for the tube (refrigerant side). The water bafﬂ es are fab ri cat ed from galvanized steel to resist corrosion. Re mov able heads are provided for access to internally en hanced, seamless, copper tubes. Water vent and drain con nec tions are included.

The evaporator is equipped with a heater for protection to -20°F (-29°C) ambient and in su lat ed with 3/4" (19 mm) ﬂ exible closed-cell foam.

The water nozzles are provided with grooves for me chan i cal couplings and should be insulated by the con trac tor after pipe installation.

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

YORK INTERNATIONAL

13

Product Description

FORM 201.19-NM1 (204)

stag gered rows and mechanically expanded into cor ro sion resistant aluminum alloy ﬁ ns with full height ﬁ n col lars. They have a design working pressure of 450 PSIG (31 bar). Each coil is rested to 495 PSIG (34 bar).

Multiple fans move air through the coils. They are dy nam i cal ly and statically balanced, direct drive with cor ro sion re sis tant glass ﬁ ber reinforced composite blades mold ed into low noise, full airfoil cross section, pro vid ing vertical air discharge from extended oriﬁ ces for ef ﬁ cien cy and low sound. Each fan is located in a sep a rate com part ment to prevent cross ﬂ ow during fan cy cling. Guards of heavy gauge, PVC coated galvanized steel are pro vid ed.

The fan motors are high efﬁ ciency, direct drive, 6-pole, 3-phase, Class- “F,” current overload protected, totally en closed (TEAO) type with double sealed, per ma nent ly lubricated ball bearings.

Economizer

Economizer is a refrigerant to refrigerant, compact platetype heat exchanger to maximize chiller capacity and efﬁ ciency by subcooling liquid refrigerant delivered to the cooler expansion valve. Constructed of corrosion resistant stainless steel plates formed to induce turbulent ﬂ ow and enhance heat transfer, then oven brazed and pressure tested for reliability. Designed and constructed with ASME and TÜV certiﬁ cation for 31 bar (450 psig). UL/CSA listed.

Oil Separator/System

The external oil separator, with no moving parts and de signed for minimum oil carry-over, is mounted in the dis charge line of the compressor. The high pressure dis charge gas is forced around a 90 degree bend. Oil is forced to the outside of the separator through cen trif u gal action and captured on wire mesh where it drains to the bottom of the oil separator and ﬂ ows to the condenser for cooling before returning to the compressor.

assure re frig er ant compression (volumetric ef ﬁ cien cy). The oil also provides cooling by transferring much of the heat of com pres sion from the gas to the oil keeping dis charge tem per a tures down and reducing the chance for oil breakdown. Oil injected into the rotor cage ﬂ ows into the ro tors at a point about 1.2x suction. This assures that a required minimum differential of at least 30 PSID (2.1 bar) exists between discharge and 1.2x suc tion, to force oil into the rotor case. A minimum of 10 PSID (0.6 bar) is all that is re quired to assure pro tec tion of the compressor. Oil pressure safety is mon i tored as the dif fer ence between suction and the pres sure of the oil en ter ing the ro tor case.

Maximum working pressure of the oil separator is 450 PSIG (31 bar). Oil level should be above the midpoint of the “low er” oil sight glass when the compressor is run ning. Oil level should not be above the top of the “up per” sight glass.

Oil Cooling

Oil cooling is provided by routing oil from the oil sep a ra tor through several of the top rows of the con dens er coils and back to the compressor.

Capacity Control

The compressors will start at the minimum load po si tion and provide a capacity control range from 10% - 100% of the full unit load using a continuous function slide valve. The microprocessor modulates a voltage signal to a 3-way pres sure reg u lat ing capacity control valve which controls com pres sor capacity, in de pen dent of system pressures, and balances the com pres sor ca pac i ty with the cool ing load. Loading is ac com plished by varying pressure through the pressure regulating ca pac i ty control valve to move the slide valve against the spring pressure to promote stable smooth loading.

Automatic spring return of the slide valve to the min i mum load position will ensure compressor start ing at min i mum motor load.

The oil (YORK “L” oil – a POE oil used for all re frig er ant applications), which ﬂ ows back into the com- pres sor through a replaceable 0.5 - 3.0 micron oil ﬁ lter, is at high pressure. This high pres sure “oil injection” forces the oil into the com pres sor where it is fed to the bearings for lubrication. After lubricating the bearings, it is injected through oriﬁ ces on a closed thread near the suction end of the rotors. The oil is automatically in ject ed because of the pressure difference between the discharge pres sure and the reduced pressure at the suc tion end of the rotors. This lubricates the rotors as well as provides an oil seal against leakage around the ro tors to

14

Power and Control Panel

All controls and motor starting equipment are factory wired and function tested. The panel enclosures are de signed to IP55 and are manufactured from powder paint ed galvanized steel.

The Power and Control Panel are divided into power sec tions for each compressor and associated fans, a con trol section and an electrical options section. The pow er and control sections have separate hinged, latched, and gasket sealed doors equipped with wind struts.

YORK INTERNATIONAL

FORM 201.19-NM1 (204)

Each power compartment contains:

Compressor and fan starting contactors, fan motor ex ter nal overloads, control circuit serving compressor ca pac i ty control, compressor and fan contactor coils and compressor motor overloads. (Fig #1, page 12)

Current transformers in the 2ACE module provide compressor motor over load protection and sense each phase. This protects the compressor motors from dam age due to: low current input, high input current, un bal anced current, single phasing, phase reversal, and com pres sor locked rotor.

The control section contains:

ON/OFF switch, microcomputer keypad and display, mi cro pro ces sor board, I/O expansion board, relay boards and power supply board.

The options sections contain:

A control circuit transformer complete with service switch providing 115/1/60 Hz power to the unit con trol system.

Electrical options as described in “Accessories and Options.”

Microprocessor Controls

The microprocessor has the following functions and displays:

• A liquid crystal 40 character display with text pro vid ed on two lines and light emitting diode back light ing out door viewing.

Motor Current Protection

The microprocessor motor protection provides high cur rent protection to assure that the motor is not damaged due to voltage, excess refrigerant, or other problems that could cause excessive motor current. This is ac com plished by sending a current signal pro por tion al to motor current from the Motor Protector mod ule to the I/O Expansion board to be multiplexed and sent to the Microprocessor Board. If the motor cur rent exceeds the 115% FLA trip point after 3 seconds of op er a tion on either Wye-Delta or ACL starters, the mi cro will shut the system down and lock it out after one fault. A manual reset of the re spec tive system switch is re quired to clear the fault and restart the system. A thor ough check of the mo tor, wiring, and refrigerant system should be done be fore restarting a system that has fault ed on high motor current.

The micro also provides low motor current protection when it senses a motor current less than 10% FLA. The micro will shut the system down whenever low motor current is sensed and will lock out a system if three faults occur in 90 minutes. Low motor current pro tec tion is activated 4 seconds after start on both Wye-Delta and ACL starters to assure the motor starts, the sys tem doesn’t run with out refrigerant, the motor protector is not tripped, and the mechanical high pres sure cut-out is not tripped. Once the system is locked out on Low Motor Current, it must be manually reset with the sys tem switch. See also Motor Protection Module section below.

2

• A color coded, 35 button, sealed keypad with sec tions for Display, Entry, Setpoints, Clock, Print, Pro gram and Unit ON/OFF.

The standard controls shall include: brine chilling, ther mal storage, automatic pump down, run signal con tacts, demand load limit from external building automation sys tem input, remote reset liquid temperature reset in put, unit alarm contacts, chilled liquid pump control, au to mat ic reset after power failure, automatic system op ti mi za tion to match operating conditions.

The software is stored in non-volatile memory (EPROM) to eliminate chiller failure due to AC power failure. The Programmed Setpoints are stored in lithium battery backed memory.

YORK INTERNATIONAL

The micro senses low motor current whenever a HPCO or Motor Protector contact opens. This occurs because the MP and HPCO contacts are in series with the mo tor contactor. Whenever either of these devices are open, the contactor de-energizes and the motor shuts down. Since the micro is sending a run signal to the contactor, it senses the low motor current below 10% FLA and shuts the system down.

15

Product Description

FORM 201.19-NM1 (204)

Motor Protection Modules (2ACE)

The mechanical motor protector is a Texas In stru ments 2ACE Three Phase Protection Module (Fig. 45, page

127), provides thermal and cur rent motor overload pro tec tion. This mod ule also pro tects against phase to phase cur rent im bal ance, over cur rent, under current, and phase ro ta tion. The mod ules, mount ed in the power pan els, uti liz es a 7 seg ment display which provides op er at ing sta tus and fault di ag nos tic in for ma tion. The 7 segment dis play will dis play ei ther a sta tion ary or a ﬂ ash ing al- pha nu mer ic value which can be de cod ed by the op er a tor. A list of the codes follows:

HAXXX Normal motor OFF display. Sequentially sweeps through the motor protection dip switch setting.

0 Normal - no fault detected (Running) Flashing “0” Motor off or un load ed < 5A (Running)

AC current lev el.

1 High cur rent fault.

Loaded phase to phase cur rent

2

imbalance >

Unloaded phase to phase cur rent

3

imbalance >

4 Improper in com ing phase ro ta tion.

High motor tem per a ture. Trip point =

5

13kW, re set = 3.25kW. 6 Communication error. 7 Unload imbalance ( > 8 Phase Loss (> 60%) E Out of range of RLA cal i bra tion. Other symbols Defective module or supply volt age.

Working voltage 18 - 30 VAC, 24 VAC nominal. Low volt age trip = 15 VAC.

17%.

25%.

50%)

Whenever a motor protector trips, the motor pro tec tor contacts wired in series with the motor contacts opens and the motor contactor de-energizes causing the mo tor to stop. The micro senses the low motor current and shuts the system down. The micro will try two more starts be fore locking the system out. The system locks out be cause the motor protector is a man u al re set de vice. Af ter the ﬁ rst start, the modules’ contacts

will be open pre vent ing the motor contactors from en er giz ing. Power must be removed and re applied to re set the mod ule. Use CB3 in the Micro Panel to cycle power.

Current Overload

The 2ACE module design uses one integral current trans form er per phase to provide protection against rap id current over load conditions. The module re sponds to changes in current and must be cal i brat ed using DIP switches lo cat ed on the module. Integral trip curves al low for in-rush cur rents dur ing Wye-Delta, part wind, or ACL starts with out nuisance tripping.

To check the factory setting of the 2ACE module cur rent overload trip value. See Table 1 (pages 18 and 21).

For the location of the dip switches and determining the ON side of the switches, refer to Fig ure 45, page 127. As in di cat ed, to place a switch in the ON po si tion re quires push ing the switch to the left.

A switch must be pushed to the left to place the switch in the ON position. The numerical value for the combination of "ON" switches equals the overload setting.

It is recommended that a YORK Ser vice Tech ni cian or the YORK fac to ry be con sult ed before chang ing these settings for any rea son, since dam age to the com pres sor could re sult. Chang es should nev er be made un less it is ver i ﬁ ed that the set tings are in cor rect.

Anytime a dip switch change is made, pow er must be cycled off and on to the module to re pro gram the mod ule to the new value.

16

YORK INTERNATIONAL

FORM 201.19-NM1 (204)

Thermal Overload

Three PTC (positive temperature co ef ﬁ cient) ther mistors in the motor windings provides thermal pro tec tion. The sensor re sis tance stays rel a tive ly con stant at 1k

Ω until

a tem per a ture of 266°F (130°C) is sensed. The sensor ex pe ri enc es a rapid rise in re sis tance be yond this tem per a ture. When ev er the re sis tance of one of the sen sors reach es 13k

Ω, +/− 3kΩ, the 2ACE module trips, which

ul ti mate ly de-energizes the mo tor’s pi lot cir cuit. Re set is manual after the mo tor cools and the sen sor re sis tance drops to 3.25k

Ω, +/− 0.5kΩ.

Current Imbalance (Loaded & Unloaded)/ Loss of Phase

A 2 second delay at start-up allows for any imbalances resulting during normal starting conditions. After this ini tial delay, the 2ACE module compares the “Op er at ing Current” to the measured half line current. The “Op er at ing Current” is given by 0.65 X factory overload cur rent setting.

An unloaded compressor condition occurs when any measured half line current is less than the “Operating

Current.” A current imbalance exceeding an unloaded level of 25% will result in the motor pilot circuit being de-energized.

A loaded compressor condition occurs when any mea- sured half line current is great er than or equal to the “Operating Current.” A cur rent imbalance exceeding a loaded level of 17% will result in the motor pilot cir cuit being de-energized.

Imbalance is deﬁ ned as (High Phase - Low Phase)/High Phase

Improper Phase Sequence

The 2ACE module calculates the phase sequence at start-up using the three cur rent transformers to de ter mine wheth er the three phase sequence on the load side of the main contactor is miswired. Upon de tec tion of a miswired motor load, the mod ule will de-energize the main contactor pi lot circuit within 50 millisecond re sponse time.

Additional information on the 2ACE MP module may be found on page 125.

2

YORK INTERNATIONAL

17

Product Description

TABLE 1 – MOTOR PROTECTOR DIP SWITCH SETTING

YCAS STYLE G, ACROSS-THE-LINE – 60 HZ

FORM 201.19-NM1 (204)

17 246 *2 166 1 0 1 0 0 1 1 0

28 214 2 144 1 0 0 1 0 0 0 0 130 40 130 2 175 1 0 1 0 1 1 1 1 46 107 1 144 1 0 0 1 0 0 0 0 58 86 1 116 0 1 1 1 0 1 0 0 17 267 *4 90 0 1 0 1 1 0 1 0 28 232 *2 157 1 0 0 1 1 1 0 1 140 40 140 2 189 1 0 1 1 1 1 0 1 46 116 1 157 1 0 0 1 1 1 0 1 58 93 1 125 0 1 1 1 1 1 1 0 17 295 *4 99 0 1 1 0 0 0 1 1

0150

SYS. 1 46 128 2 173 1 0 1 0 1 1 0 1

58 103 1 139 1 0 0 0 1 0 1 1 17 265 *4 89 0 1 0 1 1 0 0 1

46 115 1 155 1 0 0 1 1 0 1 1 58 92 1 124 0 1 1 1 1 1 0 0 17 295 *4 99 0 1 1 0 0 0 1 1 28 256 *4 86 0 1 0 1 0 1 1 1

46 128 2 173 1 0 1 0 1 1 0 1 58 103 1 139 1 0 0 0 1 0 1 1 17 321 *4 108 0 1 1 0 1 1 0 0

46 140 2 189 1 0 1 1 1 1 0 1 58 112 1 151 1 0 0 1 0 1 1 1

17 295 *4 99 0 1 1 0 0 0 1 1

46 128 2 173 1 0 1 0 1 1 0 1 58 103 1 139 1 0 0 0 1 0 1 1

MODEL

NO.

28 256 *4 86 0 1 0 1 0 1 1 0

40 155 2 209 1 1 0 1 0 0 0 1

28 230 *2 155 1 0 0 1 1 0 1 1

0150

40 139 2 188 1 0 1 1 1 1 0 0

SYS. 2

40 155 2 209 1 1 0 1 0 0 0 1

0160

28 279 *4 94 0 1 0 1 1 1 1 0

0170

40 169 *2 114 0 1 1 1 0 0 1 0

SYS. 1

28 256 *4 86 0 1 0 1 0 1 1 1

0170

40 155 2 209 1 1 0 1 0 0 0 1

SYS. 2

VOLT

CODE

CHILLER

NAMEPLATE

RLA

NO.

LEADS

MP

PER

DISPLAY

PHASE

HA XXX

128 64 32 16 8 4 2 1

MO TOR PROTECTOR

DIP SWITCH SETTINGS ON MP (“1” INDICATES ON)

* Indicates one lead/phase through motor protector.

18

YORK INTERNATIONAL

TABLE 1 – MOTOR PROTECTOR DIP SWITCH SETTING (CONT’D)

YCAS STYLE G, ACROSS-THE-LINE – 60 HZ

FORM 201.19-NM1 (204)

17 321 *4 108 0 1 1 0 1 1 0 0

180 40 169 *2 114 0 1 1 1 0 0 1 0 46 140 2 189 1 0 1 1 1 1 0 1 58 112 1 151 1 0 0 1 0 1 1 1 17 342 *4 115 0 1 1 1 0 1 0 0 28 298 *4 101 0 1 1 0 0 1 0 1 200 40 181 *2 122 0 1 1 1 1 1 1 0 46 149 2 201 1 1 0 0 1 0 0 1 58 119 1 161 1 0 1 0 0 0 0 1 17 374 *4 126 0 1 1 1 1 1 1 0

46 163 *2 110 0 1 1 0 1 1 1 0 58 130 2 175 1 0 1 0 1 1 1 1 17 342 *4 115 0 1 1 1 0 1 0 0

46 149 2 201 1 1 0 0 1 0 0 1 58 119 1 161 1 0 1 0 0 0 0 1 17 374 *4 126 0 1 1 1 1 1 1 0 28 325 *4 110 0 1 1 0 1 1 1 0 230 40 197 *2 133 1 0 0 0 0 1 0 1 46 163 *2 110 0 1 1 0 1 1 1 0 58 130 2 175 1 0 1 0 1 1 1 1

MODEL

NO.

28 325 *4 110 0 1 1 0 1 1 1 0

210

40 197 *2 133 1 0 0 0 0 1 0 1

SYS. 1

28 298 *4 101 0 1 1 0 0 1 0 1

210

40 181 *2 122 0 1 1 1 1 1 1 0

SYS. 2

CHILLER

VOLT

NAMEPLATE

CODE

28 279 *4 94 0 1 0 1 1 1 1 0

RLA

NO.

LEADS

MP

PER

DISPLAY

PHASE

HA XXX

128 64 32 16 8 4 2 1

MO TOR PROTECTOR

DIP SWITCH SETTINGS ON MP (“1” INDICATES ON)

2

* Indicates one lead/phase through motor protector

YORK INTERNATIONAL

19

Product Description

TABLE 1 – MOTOR PROTECTOR DIP SWITCH SETTING (CONT’D)

YCAS STYLE G, WYE DELTA START – 60 HZ

FORM 201.19-NM1 (204)

17 246 *4 96 0 1 1 0 0 0 0 0

28 214 *2 167 1 0 1 0 0 1 1 1 130 40 130 2 175 1 0 1 0 1 1 1 1 46 107 2 144 1 0 0 1 0 0 0 0 58 86 2 116 0 1 1 1 0 1 0 0 17 267 *4 105 0 1 1 0 1 0 0 1 28 232 *4 91 0 1 0 1 1 0 1 1 140 40 140 2 189 1 0 1 1 1 1 0 1 46 116 2 157 1 0 0 1 1 1 0 1 58 93 2 126 0 1 1 1 1 1 1 0 17 295 *4 115 0 1 1 1 0 0 1 1

0150

SYS. 1 46 128 2 173 1 0 1 0 1 1 0 1

58 103 2 139 1 0 0 0 1 0 1 1 17 265 *4 104 0 1 1 0 1 0 0 0

46 115 2 155 1 0 0 1 1 0 1 1 58 92 2 124 0 1 1 1 1 1 0 0 17 295 *4 115 0 1 1 1 0 0 1 1 28 256 *4 100 0 1 1 0 0 1 0 0

46 128 2 173 1 0 1 0 1 1 0 1 58 103 2 139 1 0 0 0 1 0 1 1 17 321 *4 126 0 1 1 1 1 1 1 0

46 140 2 189 1 0 1 1 1 1 0 1 58 112 2 151 1 0 0 1 0 1 1 1

17 295 *4 115 0 1 1 1 0 0 1 1

46 128 2 173 1 0 1 0 1 1 0 1 58 103 2 139 1 0 0 0 1 0 1 1

MODEL

NO.

28 256 *4 100 0 1 1 0 0 1 0 0

40 155 2 209 1 1 0 1 0 0 0 1

28 230 *4 90 1 1 0 1 1 0 1 0

0150

40 139 2 188 1 0 1 1 1 1 0 0

SYS. 2

40 155 2 209 1 1 0 1 0 0 0 1

0160

28 279 *4 109 0 1 1 0 1 1 0 1

0170

40 169 *2 132 1 0 0 0 0 1 0 0

SYS. 1

28 256 *4 100 0 1 1 0 0 1 0 0

0170

40 155 2 209 1 1 0 1 0 0 0 1

SYS. 2

VOLT

CODE

CHILLER

NAMEPLATE

RLA

NO.

LEADS

MP

PER

DISPLAY

PHASE

HA XXX

128 64 32 16 8 4 2 1

MO TOR PROTECTOR

DIP SWITCH SETTINGS ON MP (“1” INDICATES ON)

* Indicates one lead/phase through motor protector.

20

YORK INTERNATIONAL

TABLE 1 – MOTOR PROTECTOR DIP SWITCH SETTING (CONT’D)

YCAS STYLE G, WYE DELTA START – 60 HZ

FORM 201.19-NM1 (204)

17 321 *4 126 1 0 0 0 0 0 1 0

180 40 169 *2 132 1 0 0 0 0 1 0 0 46 140 2 189 1 0 1 1 1 1 0 1 58 112 2 151 1 0 0 1 0 1 1 1 17 342 *4 134 1 0 0 0 0 1 1 0 28 298 *4 117 0 1 1 1 0 1 0 1 200 40 181 *2 142 1 0 0 0 1 1 1 0 46 149 2 201 1 1 0 0 1 0 0 1 58 119 2 161 1 0 1 0 0 0 0 1 17 374 *4 146 1 0 0 1 0 0 1 0

46 163 *2 128 1 0 0 0 0 0 0 0 58 130 2 175 1 0 1 0 1 1 1 1 17 342 *4 134 1 0 0 0 0 1 1 0

46 149 2 201 1 1 0 0 1 0 0 1 58 119 2 161 1 0 1 0 0 0 0 1 17 374 *4 146 1 0 0 1 0 0 1 0 28 325 *4 127 0 1 1 1 1 1 1 1 230 40 197 *2 154 1 0 0 1 1 0 1 0 46 163 *2 128 1 0 0 0 0 0 0 0 58 130 2 175 1 0 1 0 1 1 1 1

MODEL

NO.

28 325 *4 127 0 1 1 1 1 1 1 1

210

40 197 *2 154 1 0 0 1 1 0 1 0

SYS. 1

28 298 *4 117 0 1 1 1 0 1 0 1

210

40 181 *2 142 1 0 0 0 1 1 1 0

SYS. 2

CHILLER

VOLT

NAMEPLATE

CODE

28 279 *4 109 0 1 1 0 1 1 0 1

RLA

NO.

LEADS

MP

PER

DISPLAY

PHASE

HA XXX

128 64 32 16 8 4 2 1

MO TOR PROTECTOR

DIP SWITCH SETTINGS ON MP (“1” INDICATES ON)

2

* Indicates one lead/phase through motor protector.

YORK INTERNATIONAL

21

Product Description

FORM 201.19-NM1 (204)

MOTOR STARTING

Two types of compressor motor starting are available: Across-the-Line and optional Wye-Delta Open Tran si tion Start er.

Across-the-Line starters will utilize one contactor and one start relay per compressor. The optional Wye-Delta start er utilizes 4 motor contactors, a transition delay re lay, a start relay, and a start-wye relay.

The Wye-Delta start allows inrush current to be limited to approximately 33% LRA for the ﬁ rst 4 to 7 sec onds, with current increasing to normal running cur rent when the Delta connection is completed.

When the micro initiates a start signal at Relay Output Board #1 (SYS 1) Terminal 20 or Relay Output Board #2 (SYS 2) Ter mi nal 20 to run a com pres sor, the 1CR (SYS 1) or 2CR (SYS 2) relay is en er gized. The tran si tion of the 1CR (SYS 1) or 2CR (SYS 2) relay contacts en er giz es the 1S (SYS 1) or 2S (SYS 2) relay approx. 16ms later. The 1S/2S con tacts in turn en er gize the 1M (SYS 1) or 3M (SYS 2) mo tor con tacts 16ms later. This com pletes the “WYE” con nec tion of the motor start. At the same time, the normally closed 1S/2S auxiliary in ter lock con tact opens pre vent ing the 2M and 1 TRX (SYS 1) or 4M and 2 TRX (SYS 2) mo tor contactors from en er giz ing. 2 sets of aux il ia ry con tacts from 1M (SYS 1) or 3M (SYS 2) close, in ter lock ing the 1M (SYS

1) or 3M (SYS 2) contactors, keep ing them en er gized in par al lel with 1S (SYS 1) or 2S (SYS 2).

The “WYE” connection of the motor start is enabled for 4 to 7 seconds depending upon motor current as sensed by the microprocessor. The tran si tion to Delta takes 7 seconds if current is below 110% FLA. If mo tor current exceeds 110% FLA, the transition is made to Delta as long as the WYE has been enabled for at least 4 seconds.

After the “WYE” connection is enabled for 4 to 7 sec onds, the 1TR (SYS 1) or 2TR (SYS 2) transition delay relay is enabled by the microprocessor from Relay Out put Board #1 Terminal 8 (SYS 1) or Relay Out put Board #2 Terminal 6 (SYS 2). The 1TR (SYS 1) or 2TR (SYS 2) contacts open, de-energizing 1S (SYS 1) or 2S (SYS 2). 1M (SYS 1) or 3M (SYS 2) remain energizes through 2 sets of interlocking con tacts 1M (SYS 1) or 3M (SYS 2). Open ing of the 1TR (SYS 1) or 2TR (SYS

2) con tacts deenergizes 1S/2S and clos es the nor mal ly closed 1S (SYS 1) or 2S (SYS 2) con tacts, en er giz ing

1 TRX (SYS 1) or 2 TRX (SYS 2). 1TRX or 2TRX subsequently energizes motor contactor 2M (SYS 1) or 4M (SYS 2), com plet ing the “DELTA” con nec tion of the motor.

1 TR, 1 TRX, 2 TR, and 2 TRX are NOT “tim ing” re lays. These devices are sim ply pilot relays iden ti cal to 1CR and 2CR.

KEYPAD CONTROLS

Display

Parameters are displayed in English (°F and PSIG) or Metric (°C and Bars) units, and for each circuit, the following items can be displayed:

• Return and leaving chilled liquid, and ambient tem per a ture.

• Day, date and time. Daily start/stop times. Holiday and Manual Override status.

• Compressor operating hours and starts. Automatic or manual lead/lag. Lead compressor iden ti ﬁ ca tion.

• Run permissive status. No cooling load condition. Com pres sor run status.

• Anti-recycle timer and anti-coincident start timer sta tus per compressor.

• System suction (and suction superheat), discharge, and oil pressures and temperatures.

• Percent full load compressor motor current per phase and average per phase. Compressor ca pac i ty con trol valve input steps.

• Cutout status and setpoints for: supply ﬂ uid tem- per a ture, low suction pressure, high discharge pres sure and temperature, high oil temperature, low and high am bi ent, phase rotation safety, and low leav ing liq uid tem per a ture.

• Unloading limit setpoints for high discharge pres sure and compressor motor current.

• Status of: evaporator heater, condenser fans, load and unload timers, chilled water pump.

• “Out of range” message.

• Up to 6 fault shut down conditions.

The standard display language is English, with 4 other languages available.

22

YORK INTERNATIONAL

FORM 201.19-NM1 (204)

Entry – Used to conﬁ rm Set Point changes, cancel in puts, advance day, and change AM/PM.

Setpoints – For setting chilled liquid temperature, chilled liquid range, remote reset temperature range.

Clock – Used to set time, daily or holiday start/stop schedule and manual override for servicing.

Print – Used to display or print operating data or sys tem fault shutdown history for last six faults. Printouts through an RS-232 port via a separate print er.

Program

For setting low leaving liquid temperature cutout, 300 to 600 second anti-recycle timer, average motor cur rent unload point, liquid temperature setpoint reset sig nal from YORK ISN or building automation system.

Additional functions (password protected) for pro gram ming by a qualiﬁ ed service technician:

Cutouts for low and high ambient, low suction pres sure and high discharge pressure, refrigerant type, high dis charge pressure unload setpoint.

ACCESSORIES AND OPTIONS

Multiple Point Power Connection (Standard)

Standard ﬁ eld power wiring connection on all models is Multiple Point Power Connection. Field provided pow er supply circuits, with appropriate branch circuit pro tec tion, are connected to factory provided terminal blocks, non-fused disconnect switches or circuit break ers with lockable external handles located in the two power com part ments.

Single-Point Power Connection with Individual Circuit Protection

A single-point supply circuit with ﬁ eld provided pro- tec tion is connected to a factory provided terminal block or non-fused disconnect switch located in the options com part ment. Factory wiring is provided from the ter mi nal block or disconnect switch to factory supplied internal branch circuit breakers with lockable external handles in the power compartments.

Single-Point Power Connection with Combined Cir cuit Protection

A single-point supply circuit with field provided pro tec tion is connected to a factory provided circuit break er with lockable external handle located in the options com part ment. Factory wiring is provided from the cir cuit breaker to factory supplied terminal blocks in the power compartments.

Single-Point Power Connection without Circuit Protection

A single-point supply circuit with ﬁ eld provided pro- tec tion is connected to a factory provided terminal block or non-fused disconnect switch located in the options com part ment. Factory wiring is provided from the ter mi nal block or disconnect switch to factory supplied terminal blocks in the power compartments.

Control Circuit Terminal Block

A 120V, 20A control circuit power terminal strip lo cat ed in the control panel to accept a ﬁ eld provided control power supply, rather than the standard factory mounted control circuit transformer. The supply with appropriate branch circuit protection in accordance with applicable Local codes, provides the unit control cir cuit power sup ply via the panel mounted Emergency Stop Switch.

Building Automation System (BAS) Interface

Provides a means to reset the leaving chilled liquid tem per a ture or percent full load amps (current limiting) from the BAS (Factory-mounted):

Printed circuit board to accept 4 to 20mA, 0 to 10VDC, or dry contact closure input from the BAS.

A YORK ISN Building Automation System can pro vide a Pulse Width Modulated (PWM) signal direct to the standard control panel via the standard on-board RS485 port.

Condenser Coil Protection

The standard condenser coils have Aluminum ﬁ ns, cop- per tubes, and galvanized steel supports for generally adequate corrosion resistance. However, these ma te ri als are not adequate for all environments.

2

YORK INTERNATIONAL

23

Product Description

FORM 201.19-NM1 (204)

The following options provide added protection:

Black ﬁ n condenser coils – Condenser coils con struct ed using black epoxy coated Aluminum ﬁ n stock for cor- ro sion resistance comparable to copper fin coils in typ i cal seashore locations.

Copper ﬁ n condenser coils – Coils constructed with corrosion resistant copper ﬁ ns. Not recommended in areas where units may be exposed to acid rain.

Phenolic coated condenser coils – Completed con dens er coil assemblies are covered with a cured Phe nol ic coating. Probably the most suitable selection for seashore locations where salt spray may come into con tact with the ﬁ ns, and other corrosive applications ex cept: strong alkalis, oxidizers, and wet bromine, chlo rine, and ﬂ uorine in concentrations greater than 100 PPM.

DX EVAPORATOR AND STARTER OPTIONS

300 PSIG (21 bar) Waterside Design Working Pressure – The DX evaporator waterside is designed

and con struct ed for 300 PSIG (21 bar) working pressure. (Factory-mounted)

1-1/2" (38 mm) Insulation – Double thickness in su la tion provided for enhanced efﬁ ciency.

Flange Accessory – Consists of raised face ﬂ anges to convert grooved water nozzles to ﬂ anged evaporator connections. Includes companion flanges for fieldmount ing. (See Page 33.)

UNIT ENCLOSURES OPTIONS

Wire enclosure – Heavy gauge welded wire mesh guards mounted on the exterior of the unit (Factory- or ﬁ eld-mounted).

Louvered panels and wired guards – Louvered pan- els mounted over the exterior condenser coil faces, and heavy gauge welded wire mesh guards mounted around the bottom of the unit (Factory- or ﬁ eld-mounted).

Louvered panels (condenser coils only) – Lou vered panels are mounted over the exterior condenser coil faces on the sides of the unit to visually screen and pro tect the coils (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).

FAN OPTIONS

High static fans: Fans and motors suitable for High External Static conditions to 100 Pa.

SOUND REDUCTION OPTIONS

Low speed fans – Reduced RPM fan motors and al ter - na tive fan selection for low noise applications.

Compressor sound enclosures – Acoustically treated metal compressor enclosures.

Remote DX Evaporator – Includes the main con dens ing unit less the evaporator, re frig er ant and liquid line de vic es. The insulated evaporator and ﬁ eld acces- sory kits per re frig er ant circuit are sup plied separately. The condensing unit is shipped with a nitrogen holding charge and the evaporator is shipped with a ni tro gen hold ing charge.

Flow Switch Accessory – Johnson Controls model F61MG-1C Vapor-proof SPDT, NEMA 4X switch, 150 PSIG (10 bar) DWP, -20°F to 250°F (-29°C to 121°C), with 1" NPT (IPS) con nec tion for upright mounting in horizontal pipe. A ﬂ ow switch must be ﬁ eld installed with each unit. Optional 300 PSIG switch available.

Star-Delta Compressor Motor Starter – Provides approximately 65% reduced inrush current compared to across-the-line start (Factory-mounted).

24

VIBRATION ISOLATION

Neoprene pad isolation – Recommended for normal installations. (Field-mounted)

1" (25 mm) spring isolators – Level adjustable, spring and cage type isolators for mounting under the unit base rails (Field-mounted).

2" (51 mm) seismic spring isolators – Restrained Spring-Flex Mountings incorporate welded steel hous ing with vertical and horizontal limit stops. Housings designed to withstand a minimum 1.0 g accelerated force in all directions to 2" (51 mm). Level ad just able, de ﬂ ec tion may vary slightly by application. (Field- mount ed).

YORK INTERNATIONAL

: Design Series G

: Engineering

Change

or PIN Level

: 200/3/60

: 230/3/60

: 380/3/60

: 460/3/60

: 380/3/50

: 575/3/60

UNIT NOMENCLATURE

NAMEPLATE ENGINEERING DATA

: Leaving Water Temp = Degrees

: Thermal Storage

: Special LWT Requirements

: No Chicago Code Kit Required

: Chicago Code Kit Required

: Service Isolation Valve

: Both Isolation Valve and Chicago Code

: Special Chicago Code Kit Required

: Standard Valves Required

: Special Optional Valves Required

: No Option Required

: Special Quote

: No Option Required

: Special Quote

: No Option Required

: Special Quote

: No Option Required

: Wye (Star) Delta

: Across-the-Line

: Special Quote

: No Option Required

: Special Quote

FORM 201.19-NM1 (204)

YCAS0230EC46YGA

BASIC PART NUMBER

2 3 4 5 6 7 8 9 10 11 12 13 14 15 1

BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN/DEVELOPMENT LEVEL (STYLE)

: R-22

: R-407C

High-Efﬁ ciency

Standard

High Ambient

0373

0403

Tons

0130

0140

: YORK

: Chiller

: Air-Cooled

Y # # # # E B 1 7 G

C S C 2 8 A

0453

0150

: Screw

A G 4 0

0503

0543

0573

0623

0653

0160

0170

0180

0200

0210

0230

S 4 6

5 0

5 8 Y

X

: No Option Required

: Special Quote

: No BAS Reset / Offset Required

: Temp Reset / Offset

: Current Reset / Offset

: Both Temp and Current Reset / Offset

: Special BAS Reset / Offset Required

: English LCD & Keypad Display (std)

: Spanish LCD & Keypad Display

: French LCD & Keypad Display

: German LCD & Keypad Display

: Italian LCD & Keypad Display

: Special LCD & Keypad Display

: No Option Required

: Special Quote

: N. American Safety Code

: European Safety Code

: No Listing

X

: Special Safety Code

: No Option Required

: Special Quote

: No Pump Control Required

: Pump Control Required

: Special Pump Control Required

2

: No Remote Control Panel Required

: Optiview Remote Control Panel Required

: Special Remote Control Panel Required

: No Sequence Kit Required

: Sequence Kit Required

: Special Sequence Kit Required

YORK INTERNATIONAL

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

OPTIONS MODEL NUMBER

POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD

: Standard Power Option

: MP NF Disconnects

: MP Circuit Breakers

: SP NF Disconnects

: SP TB

: SP Circuit Breaker

: SP TB w/ Separate System Circuit Breakers

: SP NF Disconnect w/ Separate System Circuit Breakers

M D Q TS

X X X NUM

M B QQ

S D X X

B X C S

S B B B

D B Q Q

S X T C

: SP Supply w/ Separate Disconnect Switch

: SP w/ Separate Disconnect Switch

: Special Power Option

: Control Circuit Power Terminal Strip (std)

: Special Transformer Required

: No Option Required

: Special Quote

Q Q S X

F Q

C G X

Q I Q

T : Control Transformer Required Q X

X Q

Q X X

Q Q

C S X

C S X Q

L Q

C

MP = Multiple Point

N

Q

X

SP = Single-Point

Q

NF = Non-Fused

TB = Terminal Block

Ser. = Service

TS = Thermal Storage

X

P

Q

X

O

Q

X

S

Ind. Sys. Brkr. & L. Ext. Handles = Individual

System Breaker & Lockable External Handle

Q

25

Product Description

PRODUCT IDENTIFICATION NUMBER (PIN)

: No Refrigerant Warranty

: 1 Year Refrigerant

: 2 Year Refrigerant

: 5 Year Refrigerant

: No option required

: Buy American Act

: Both Buy American Act

: Container Shipping Kit

: Special quote

: No option required

: Special quote

: No option required

: Special quote

: No option required

: Special quote

: Basildon Plant

: Monterrey Plant

FORM 201.19-NM1 (204)

56 57 58 59 60 61

X

1

2

: No Enclosure Panels Required

: Wire Panels (Factory)

: Wire Panels (Field)

: Wire / Louvered Panels (Factory)

5

X

A

B

C

Q

X

Q

X

Q

X

Q

: Wire / Louvered Panels (Field)

: Louvered (Cond. Only) Panels (Factory)

: Louvered (Cond. Only) Panels (Field)

: Louvered (Full Unit) Panels (Factory)

: Louvered (Full Unit) Panels (Field)

: Special Enclosure Panels

: No Sound Enclosure Required

: Acoustical Arrgt. & Silencerb Kit

: Compressor Blanket

: Special Sound Enclosure

: Dual Sound Attenuation

: No Option Required

B

R

: Special Quote

: No Option Required

: Special Quote

: Standard Sound Fans

: Low Sound Fans

: High Static Fans

: Special Sound Fans

: No Final Overspray Paint Required

: Final Overspray Paint

: Special Overspray Paint Required

: No Vibration Isolators

: 1" Vibration Isolators

: Seismic Vibration Isolators

: Neoprene Vibration Isolators

: Special Vibration Isolators

EXAMPLES:

26

: Aluminum

: Pre-Coated

: Copper

: Post-Coated

: Special Coil

: No Option

: Special Quote

: TEAO Fan Motors

NOTES:

1. Q :DENOTES SPECIAL / S.Q.

2. # :DENOTES STANDARD

3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED

4. Agency Files (i.e. U.L. / E.T.L.; CE; ARI; ETC.) will contain info. based on the ﬁ rst 14 characters only.

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

X X X X X X X X L X X X X X X X X X X X X X X X X X A X X X X X X X X X X X X X

S D T C A T S R L X P R S 2 5 C X 1 X X X X 3 D W S A R X B X X 4 B X X L X S D

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

EVAP. FIELD CONDENSER FIELD CABINET FIELD

: 150PSIG DWP

: 300PSIG DWP

: Special DWP

: 3/4" Evaporator Insulation

: 1 1/2" Evaporator Insulation

: Special Evaporator Insulation

3 B 1

X X X

Q C 2

X P 3

D Q 4

Q X 5

: No Flanges Required

: Weld Flanges Required

: Vitaulic Flanges Required

: Special Flanges Required

: No Flow Switch

: Flow Switch

: Differential Pressure Switch

X Q 6

W X 7

V Q : Special Fan Motors 8

Q Q

X X

S P

D B

: Special Flow Switch

: Multinational Pressure Vessel Codes

: ASME Pressure Vessel Codes

: Australian Pressure Vessel Codes

: French Pressure Vessel Codes

: German Pressure Vessel Codes

Q Q

M D

X

A Q

S X

F Q

T X

: Italian Pressure Vessel Codes

: Polish Pressure Vessel Codes

: Sweden SAQ Pressure Codes

: Austian TUV Pressure Vessel Codes

: European "CE" Pressure Vessel Directive

: Dutch Pressure Pressure Vessel Codes

: Special Pressure Vessel Codes

: Standard Evaporator

I L

P H

D Q

O X

E S

U Q

Q X

X 1

: Remote Evaporator

: Special Evaporator Requirements

: No Option Required

: Special Quote

: Standard Warranty

: 1st Year Parts & Labor

X

55

WARRANTY FIELD

R S

Q N

X Q

Q

B

: 2nd Year Parts Only

: 2nd Year Parts & Labor

: 5 Year Compressor Parts Only

: 5 Year Compressor Parts & Labor Only

: 5 Year Units Parts Only

: 5 Year Unit Parts & Labor

C

D

E

F

G

H

YORK INTERNATIONAL

HANDLING AND STORAGE

FORM 201.19-NM1 (204)

DELIVERY AND STORAGE

To ensure consistent quality and maximum reliability, all units are tested and inspected before leaving the fac to ry. Standard units are shipped completely assembled and con tain ing refrigerant under pressure. Units are shipped with out export crating unless this has been speciﬁ ed on the Sales Order.

Units with remote evaporators will have the chiller and remote evaporator charged with nitrogen.

If the unit is to be put into storage, prior to installation, the following precautions should be observed:

• Unit must be “blocked” so that the base is not

per mit ted to sag or bow.

• Ensure that all openings, such as water con nec tions, are securely capped.

• Do not store where exposed to ambient air tem per a tures exceeding 110°F (43°C).

• The condensers should be covered to protect the ﬁ ns from potential damage and corrosion, par tic u lar ly where building work is in progress.

• The unit should be stored in a location where there is minimal activity in order to limit the risk of ac ci den tal physical damage.

INSPECTION

Remove any transit packing and inspect the unit to en sure that all components have been delivered and that no damage has occurred during transit. If any dam age is evident, it should be noted on the carrier's freight bill and a claim entered in accordance with the in struc tions giv en on the advice note.

Major damage must be reported immediately to your lo cal YORK representative.

MOVING THE CHILLER

Prior to moving the unit, ensure that the installation site is suitable for installing the unit and is capable of sup port ing the weight of the unit and all associated ser vic es.

The units are designed to be lifted using ca bles. A spread er bar or frame 88" (2250 mm) wide should be used in order to prevent damage to the unit from the lifting chains (See Figures 3 and 4).

Units are provided with lifting eyes extending from the sides of the base frame which can be attached to di rect ly using shackles or safety hooks (See Figure 4).

The unit must only be lift ed by the base frame at the points provided. Nev er move the unit on roll ers, or lift the unit using a forklift truck.

3

• To prevent inadvertent operation of the pressure relief devices the unit must not be steam cleaned.

• It is recommended that the unit is periodically in spect ed during storage.

YORK INTERNATIONAL

Care should be taken to avoid damaging the con dens er cooling ﬁ ns when moving the unit.

Lifting Weights

For details of weights and weight distribution refer to the Technical Data Section.

27

Handling and Storage

FORM 201.19-NM1 (204)

UNIT RIGGING

CORRECT!

FIG. 3 – UNIT RIGGING

88" (2250mm)

CORRECT!

✓

WRONG!

✗

WRONG!

LD03514

CORRECT!

FIG. 4 – LIFTING LUGS

28

WRONG!

LD03515

YORK INTERNATIONAL

INSTALLATION

LOCATION REQUIREMENTS

To achieve optimum performance and trouble-free ser vice, it is essential that the proposed installation site meets with the location and space requirements for the model being installed. For dimensions, weight and space requirements, including service access, refer to the Technical Data Section.

It is important to ensure that the minimum service ac cess space is maintained for cleaning and main te nance purposes.

OUTDOOR INSTALLATIONS

The units can be installed at ground level, or on a suitable rooftop location. In both cases an adequate sup ply of air is required. Avoid locations where the sound out put and air discharge from the unit may be ob jec tion able.

The location should be selected for minimum sun ex po sure and away from boiler ﬂ ues and other sources of airborne chemicals that could attack the condenser coils and steel parts of the unit.

If located in an area which is accessible to un au tho rized persons, steps must be taken to prevent access to the unit by means of a protective fence. This will help to prevent the possibility of vandalism, accidental dam age, or possible harm caused by unauthorized re mov al of pro tec tive guards or opening panels to expose ro tat ing or high voltage components.

For ground level locations, the unit must be installed on a suitable ﬂ at and level concrete base that extends to fully support the two side channels of the unit base frame. A one-piece concrete slab, with footings ex tend ing be low the frost line is recommended. To avoid noise and vibration transmission the unit should not be se cured to the building foundation.

FORM 201.19-NM1 (204)

Any ductwork or attenuators ﬁ tted to the unit must not have a total static pressure resistance, at full unit air ﬂ ow, exceeding the capability of the fans installed in the unit.

INDOOR INSTALLATIONS

The unit can be installed in an enclosed plant room pro vid ing the ﬂ oor is level and of suitable strength to sup port the full operating weight of the unit. It is es sen tial that there is adequate clearance for airﬂ ow to the unit. The discharge air from the top of the unit must be duct ed away to prevent recirculation of air within the plant room. If common ducts are used for fans, non-return damp ers must be ﬁ tted to the outlet from each fan.

The discharge ducting must be properly sized with a total static pressure loss, together with any intake stat ic pressure loss, less than the available static pressure ca pa bil i ty for the type of fan ﬁ tted.

The discharge air duct usually rejects outside the build ing through a louver. The outlet must be positioned to pre vent the air being drawn directly back into the air in take for the condenser coils, as such recirculation will affect unit performance.

LOCATION CLEARANCES

Adequate clearances around the unit(s) are required for the unrestricted airﬂ ow for the air-cooled con dens er coils and to prevent recirculation of warm discharge air back onto the coils. If clearances given are not main tained, airﬂ ow restriction or recirculation will cause a loss of unit performance, an increase in power con sump tion and may cause the unit to malfunction. Con sid er ation should also be given to the possibility of down drafts, caused by ad ja cent buildings, which may cause recirculation or un even unit airﬂ ow.

4

On rooftop locations, choose a place with adequate struc tur al strength to safely support the entire op er at ing weight of the unit and service personnel. The unit can be mount ed on a concrete slab, similar to ground ﬂ oor locations, or on steel channels of suitable strength. The channels should be spaced at the same centres as the vibration mounting holes in the unit base frame and must be at least 4-3/4" (120 mm) wide at the con tact points. This will allow vibration isolators to be ﬁ tted if required.

YORK INTERNATIONAL

For locations where signiﬁ cant cross winds are ex- pect ed, such as exposed roof tops, an enclosure of sol id or lou ver type is recommended to prevent wind tur bu lence in ter fer ing with the unit airﬂ ow.

When units are installed in an enclosure, the en clo sure height should not exceed the height of the unit on more than one side. If the enclosure is of louvered con struc tion the same requirement of static pres sure loss ap plies as for ducts and at ten u a tors stated above.

29

Installation

FORM 201.19-NM1 (204)

Where accumulation of snow is likely, ad di tion al height must be provided under the unit to ensure normal air ﬂ ow to the unit.

The clearance dimensions given are nec es sary to main tain good airﬂ ow and en sure cor rect unit op er a tion. It is also nec es sary to con sid er access re quire ments for safe op er a tion and maintenance of the unit and power and control pan els. Lo cal health and safe ty reg u la tions, or prac ti cal con sid er ations for ser vice re place ment of large com po nents, may require larg er clear anc es than those given in the Tech ni cal Data Section of this manual, (page 90).

COMPRESSOR FEET BOLT REMOVAL

After the chiller is placed in the ﬁ nal location, remove the four bolts, 1 , attaching the compressor feet to the frame rails. These bolts are only used for shipping purposes. The bolts are screwed into the compressor feet from the bottom side of the frame rail. Refer to Figure 5.

After the four shipping bolts are removed from the compressor feet, the compressor will be held in place by the four corner brackets, 2.

This assembly reduces compressor noise by isolating the compressor from the base rails.

DO NOT remove the four 3/8" bolts, 3, mounting the corner brackets, 2, to the frame rails.

BASE SUPPORT RAIL

COMPRESSOR

2

3

2

3

CHANNEL BASE

FIG. 5 – COMPRESSOR MOUNTING

30

1

LD09131

YORK INTERNATIONAL