York eco YCAS Series User manual

INSTALLATION, OPERATION & MAINTENANCE
eco2
AIR-COOLED SCREW LIQUID CHILLERS
New Release Form 201.18-NM9 (602)
OPTIMIZED R-407C
YCAS AIR-COOLED LIQUID CHILLER
YCAS0218EB  YCAS0418EB 60 HZ)
YCAS0685EB  YCAS1215EB 50 HZ)
STYLE F
00258VIP
YCAS 3 SYSTEM EPROMs
Microprocessor Board
031-01798-002
YCAS 4 SYSTEM EPROMs
Microprocessor Board
I O Board #2 EPROM
031-01798-002
031-02018-001
I O Board #2 EPROM
031-02018-001
60 HZ UNITS
ONLY
Better ecology,
Better economy.

2YORK INTERNATIONAL
FORM 201.18-NM9 (602)
SECTION 1 GENERAL CHILLER INFORMATION & SAFETY
Introduction ............................................................................................................................................. 11
Warranty ................................................................................................................................................. 11
Saf ty ....................................................................................................................................................... 11
Standards for Safety .............................................................................................................................. 11
R sponsibility for Saf ty ........................................................................................................................12
About this Manual ...................................................................................................................................12
Misus of Equipm nt ...............................................................................................................................12
Suitability for Application ..................................................................................................................... 12
Structural Support ................................................................................................................................. 12
Mechanical Strength ............................................................................................................................. 12
General Access ...................................................................................................................................... 12
Pressure Systems .................................................................................................................................. 12
Electrical ................................................................................................................................................ 12
Rotating Parts ........................................................................................................................................ 13
Sharp Edges .......................................................................................................................................... 13
Refrigerants and ils ............................................................................................................................. 13
High Temperature and Pressure Cleaning ............................................................................................. 13
Em rg ncy Shutdown .............................................................................................................................. 13
SECTION 2 PRODUCT DESCRIPTION
Introduction .............................................................................................................................................14
General Description ............................................................................................................................... 14
Compressor ........................................................................................................................................... 14
Evaporator ............................................................................................................................................. 15
Condenser ............................................................................................................................................. 15
il Separator / System ........................................................................................................................... 16
il Cooling ............................................................................................................................................. 16
Capacity Control .................................................................................................................................... 16
Power and Control Panels ..................................................................................................................... 16
Microprocessor Controls ...................................................................................................................... 17
Motor Current Protection ...................................................................................................................... 17
Motor Protector Module ....................................................................................................................... 17
Current verload ................................................................................................................................... 18
Thermal verload .................................................................................................................................. 19
Current Imbalance ................................................................................................................................. 19
Improper Phase Sequence ..................................................................................................................... 19
Motor Protector Dip Switch Settings .................................................................................................... 20
Motor Starting .........................................................................................................................................24
K ypad Controls ...................................................................................................................................... 24
Display ................................................................................................................................................... 24
Entry ...................................................................................................................................................... 25
Setpoints ............................................................................................................................................... 25
Clock ...................................................................................................................................................... 25
Print ....................................................................................................................................................... 25
Program .................................................................................................................................................. 25
Acc ssori s and Options ........................................................................................................................ 25
Multiple Point Power Connection (Standard) ....................................................................................... 25
Single-Point Power Connection with Individual Circuit Protection ...................................................... 25
Single-Point Power Connection with Combined Circuit Protection ...................................................... 25
Single-Point Power Connection without Circuit Protection .................................................................. 25
Control Circuit Terminal Block ............................................................................................................... 25
Building Automation System (BAS) Interface ......................................................................................25
Condenser Coil Protection .................................................................................................................... 25
DX Cool r Options ..................................................................................................................................26
TABLE OF CONTENTS

3
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
TABLE OF CONTENTS CONTD)
300 PSIG (21 bar) Waterside Design Working Pressure ........................................................................ 26
1-1/2" (38 mm) Insulation ...................................................................................................................... 26
Flange Accessory .................................................................................................................................. 26
Remote DX Cooler ................................................................................................................................. 26
Flow Switch Accessory ......................................................................................................................... 26
Star-Delta Compressor Motor Starter .................................................................................................... 26
Unit Enclosur s .......................................................................................................................................26
Fans .........................................................................................................................................................26
Sound R duction Options ........................................................................................................................26
Vibration Isolation .................................................................................................................................. 26
Unit Nom nclatur and Nam plat
Engin ring Data .................................................................................................................................... 27
Basic Part Number ................................................................................................................................. 27
ptions Section of Part Number ............................................................................................................ 27
SECTION 3 HANDLING AND STORAGE
D liv ry and Storag ...............................................................................................................................29
Insp ction ................................................................................................................................................29
Moving th Chill r ..................................................................................................................................29
Lifting Weights ...................................................................................................................................... 29
Unit Rigging ............................................................................................................................................30
SECTION 4 INSTALLATION
Location R quir m nts ...........................................................................................................................31
Outdoor Installations ..............................................................................................................................31
Indoor Installations .................................................................................................................................31
Location Cl aranc s ...............................................................................................................................31
Installation of Vibration Isolators ..........................................................................................................32
Installation ............................................................................................................................................. 32
Shipping Brac s ......................................................................................................................................32
Pip work Conn ction ..............................................................................................................................32
General Requirements ............................................................................................................................ 32
Wat r Tr atm nt .....................................................................................................................................33
Pip work Arrang m nt ........................................................................................................................... 33
Conn ction Typ s & Siz s ...................................................................................................................... 34
Cool r Conn ctions ................................................................................................................................. 34
ption Flanges ...................................................................................................................................... 34
R frig rant R li f Valv Piping ............................................................................................................. 34
Ductwork Conn ction .............................................................................................................................34
General Requirements ............................................................................................................................ 34
El ctrical Conn ction ..............................................................................................................................35
Pow r Wiring .......................................................................................................................................... 35
Standard Units with Multi Point Pow r Supply Wiring ......................................................................... 35
Units with Single-Point Power Supply Wiring ...................................................................................... 35
115VAC Control Supply Transform r .................................................................................................... 35
Remote Emergency Stop Device ........................................................................................................... 36
Control Pan l Wiring ............................................................................................................................. 36
Volts Fr Contacts .................................................................................................................................36
Chilled Liquid Pump Starter ................................................................................................................... 36
Run Contact .......................................................................................................................................... 36
Alarm Contacts ...................................................................................................................................... 36
Syst m Inputs ..........................................................................................................................................36
Flow Switch ........................................................................................................................................... 36
Remote Run / Stop Switch ..................................................................................................................... 36
Remote Print .......................................................................................................................................... 36
Remote Setpoint ffset  Temperature ................................................................................................. 36

4YORK INTERNATIONAL
FORM 201.18-NM9 (602)
TABLE OF CONTENTS CONTD)
Remote Setpoint ffset  Current ......................................................................................................... 36
Pow r and Control Pan l Layouts (Wy -D lta Typical) .........................................................................37
Options Pan l Layout (Typical) ............................................................................................................... 38
Logic S ction Layout ..............................................................................................................................39
Logic S ction Layout with Control Pan l Layout ..................................................................................40
Custom r Conn ctions ........................................................................................................................... 41
SECTION 5 COMMISSIONING
Pr paration .............................................................................................................................................43
Pr paration  Pow r Off ......................................................................................................................... 43
First Tim Start-up ................................................................................................................................. 45
SECTION 6 OPERATION
G n ral D scription ................................................................................................................................46
Start-up .................................................................................................................................................... 46
Normal Running and Cycling ................................................................................................................. 46
Shutdown .................................................................................................................................................46
SECTION 7 TECHNICAL DATA
Flow Rat and Pr ssur Drop Charts ..................................................................................................... 47
T mp ratur and Flows ...........................................................................................................................50
Physical Data (English Units) ................................................................................................................. 52
Physical Data (SI Units) ..........................................................................................................................53
Op rating Limitations & Sound Pow r Data .........................................................................................55
El ctrical Data (60 Hz) ............................................................................................................................58
Multiple Point Power Supply Connection (60 Hz) ................................................................................. 58
ptional Single-Point Power Supply Connection with Individual System Circuit Breakers (60 Hz) ..... 60
El ctrical Not s (60 Hz) ..........................................................................................................................62
Pow r Conn ction Options (60 Hz) ........................................................................................................63
El ctrical Data (50 Hz) ............................................................................................................................66
Multiple Point Power Supply Connection (50 Hz) ................................................................................. 66
ptional Single-Point Power Supply Connection with Individual System Circuit Breakers (50 Hz) ..... 66
El ctrical Not s (50 Hz) ..........................................................................................................................69
Compressor Data ................................................................................................................................... 69
Fan Data ................................................................................................................................................ 69
Pow r Conn ction Options (50 Hz) ........................................................................................................70
El m ntary Diagram ...............................................................................................................................72
Elementary Diagram  Across-the-Line Start ........................................................................................ 72
Wiring DiagramsAcross-th -Lin Start and Wy -D lta Start ...........................................................74
Standard 3 Compr ssor Pow r Suppli s Wy -D lta Start ..................................................................... 75
Wiring Diagram  Across-th Lin Start ..............................................................................................76
Standard Compr ssor Pow r Suppli s  Across-th Lin Start and Wy -D lta Start .........................78
Conn ction Diagram ............................................................................................................................ 79B
Conn ction Diagram  El ctrical Box .................................................................................................... 84
El m ntary Diagram DXST Dir ct Driv Control Circuit .................................................................... 87
Conn ction Diagram Syst m Wiring  Standard and R mot Evap. Units ...........................................90
El m ntary Diagram DXST Dir ct Driv Pow r Circuit ...................................................................... 92
Wiring Diagram Across-th -Lin Start and Wy -D lta Start ...........................................................94
Standard 4 Compr ssor Pow r Suppli s Wy -D lta Start ..................................................................... 95
Standard Compr ssor Pow r Suppli s  Across-th -Lin Start .............................................................96
Standard Compr ssor Pow r Suppli s ...................................................................................................... 98
Conn ction Diagram Syst ms 1 & 2 ................................................................................................... 99B
Conn ction Diagram Syst ms 3 & 4 ................................................................................................... 102
Conn ction Diagram  El ctrical Box ................................................................................................. 104
El m ntary Diagram DXST Dir ct Driv Control Circuit ................................................................. 106
Conn ction Diagram Syst m Wiring  Standard and R mot Evap. Units ........................................ 109

5
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
TABLE OF CONTENTS CONTD)
Compr ssor T rminal Box  Syst ms 1- 4 ........................................................................................... 111
Dim nsions ........................................................................................................................................... 112
YCAS0218EB - 0268EB (English) (60 Hz) ............................................................................................. 112
YCAS0288EB (English) (60 Hz) ........................................................................................................... 114
YCAS0308EB (English) (60 Hz) ........................................................................................................... 116
YCAS0328EB (English) (60 Hz) ........................................................................................................... 118
YCAS0358EB (English) (60 Hz) ........................................................................................................... 120
YCAS0398EB - 0418EB (English) (60 Hz) ............................................................................................. 122
YCAS0218EB - 0268EB (SI) (60 Hz) ..................................................................................................... 124
YCAS0288EB (SI) (60 Hz) .................................................................................................................... 126
YCAS0308EB (SI) (60 Hz) .................................................................................................................... 128
YCAS0328EB (SI) (60 Hz) .................................................................................................................... 130
YCAS0358EB (SI) (60 Hz) .................................................................................................................... 132
YCAS0398EB - 0418EB (SI) (60 Hz) ..................................................................................................... 134
YCAS0685EB (SI) (50 Hz) .................................................................................................................... 136
YCAS0775EB - 0905EB (SI) (50 Hz) ..................................................................................................... 138
YCAS0965EB (SI) (50 Hz) .................................................................................................................... 140
YCAS1065EB - 1215EB (SI) (50 Hz) ..................................................................................................... 142
Cl aranc s ........................................................................................................................................... 144
W ight Distribution and Isolator Mounting Positions (60 Hz) .......................................................... 145
N opr n Isolator D tails .................................................................................................................... 151
1" Isolator D tails ................................................................................................................................ 152
S ismic Isolator D tails ....................................................................................................................... 153
W ight Distribution and Isolator Mounting Positions (50 Hz) .......................................................... 154
Installation Instructions for VMC S ri s AWR/AWMR and CP R strain d Mountings ................. 156
R frig rant Flow Diagram ................................................................................................................... 157
Proc ss and Instrum ntation Diagram ............................................................................................... 158
Compon nt Locations  3 Compr ssor Units ...................................................................................... 159
Compon nt Locations  4 Compr ssor Units ...................................................................................... 160
Compr ssor Compon nts ..................................................................................................................... 161
Syst m Startup Ch cklist .................................................................................................................... 167
Unit Checks ......................................................................................................................................... 167
Panel Checks ....................................................................................................................................... 168
Initial Start-up ...................................................................................................................................... 169
Ch cking Subcooling and Sup rh at .................................................................................................. 169
Ch cking Economiz r Sup rh at ........................................................................................................ 170
L ak Ch cking .................................................................................................................................... 170
SECTION 8MICRO PANEL CONTENTS ......................................................................................... 171
Chill r Control Pan l Programming and Data Acc ss K ys ................................................. 171
Display and Status Information Keys ....................................................................................... 171
N / FF Rocker Switch ............................................................................................................171
Program & Setup Keys ..............................................................................................................171
1. INTRODUCTION & PHYSICAL DESCRIPTION ................................................................................. 172
1.1 General ....................................................................................................................172
1.2 Keypad & Display .................................................................................................. 172
1.3 Unit (Chiller) n / FF Switch ............................................................................... 173
1.4 Microprocessor Board ...........................................................................................173
1.5 Ancillary Circuit Boards .........................................................................................173
1.6 Circuit Breakers ......................................................................................................174
1.7 Current Transformers (C.T.) ................................................................................... 174
1.8 Transformers .......................................................................................................... 175
1.9 Motor Protector Modules ......................................................................................175