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

6YORK INTERNATIONAL
FORM 201.18-NM9 (602)
TABLE OF CONTENTS CONTD)
1.10 EMS/BAS Controls ................................................................................................ 177
1.11 Microprocessor Board Layout ............................................................................... 179
1.12 Logic Section Layout ............................................................................................. 180
1.13 Anti-Recycle Timer ................................................................................................181
1.14 Anti-Coincidence Timer .........................................................................................181
1.15 Evaporator Pump Control .......................................................................................181
1.16 Compressor Heater Control ....................................................................................181
1.17 Evaporator Heater Control .....................................................................................181
1.18 Pumpdown (LLSV) Control ....................................................................................181
1.19 Alarms ....................................................................................................................181
1.20 Run Status (Chiller) ................................................................................................182
1.21 Lead / Lag Compressor Selection ...........................................................................182
1.22 3 or 4 Compressor Chiller Configuration ................................................................182
2. STATUS KEY: GENERAL STATUS MESSAGES AND FAULT WARNINGS ........................................ 183
2.1 General ....................................................................................................................183
2.2 General Status Messages .......................................................................................183
2.3 Unit Warnings ........................................................................................................184
2.4 Anticipation Control Status Messages ..................................................................185
2.5 Unit Fault Status Messages ................................................................................... 186
2.6 System Fault (Safety) Status Messages ................................................................187
2.7 Printout on Fault Shutdown ...................................................................................190
3. DISPLAY KEYS & OPTION SWITCHES ........................................................................................... 191
3.1 General ....................................................................................................................191
3.2 Chilled Liquid Temps Key ...................................................................................... 191
3.3 System # Data Keys ............................................................................................... 192
3.4 Ambient Temp Key ................................................................................................192
3.5 Motor Current Key ................................................................................................. 192
3.6 perating HRS / Start Counter Key ....................................................................... 193
3.7 ptions Key & Dip Switch Settings ...................................................................... 193
3.8 Function Key ......................................................................................................... 195
4. PRINT KEYS ............................................................................................................................... 196
4.1 General ....................................................................................................................196
4.2 per Data Key ........................................................................................................ 196
4.3 perating Data  Local Display Messages ............................................................ 196
4.4 perating Data  Remote Printout .........................................................................197
4.5 History Key ............................................................................................................ 199
4.6 Fault History Data  Local Display Messages ......................................................199
4.7 Fault History Data  Remote Printout .................................................................... 202
5. ENTRY KEYS ............................................................................................................................... 203
5.1 General ....................................................................................................................203
5.2 Numerical Keypad ..................................................................................................203
5.3 Enter Key ............................................................................................................... 203
5.4 Cancel Key .............................................................................................................203
5.5 á â Keys ......................................................................................................... 203
6. SETPOINTS KEYS & CHILLED LIQUID CONTROL .......................................................................... 204
6.1 General ....................................................................................................................204
6.2 Chilled Liquid Temperature Control ....................................................................... 204
6.3 Local Cooling Setpoints Key .................................................................................207
6.4 Remote Cooling Setpoints Key ............................................................................. 207

7
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
LIST OF FIGURES
Fig. 1  Component Locations ................................................................................................................................ 14
Fig. 2  Screw Compressor ...................................................................................................................................... 15
Fig. 3  Unit Rigging ................................................................................................................................................ 30
Fig. 4  Lifting Lugs ................................................................................................................................................. 30
Fig. 5  Pipewor Arrangement ............................................................................................................................... 33
Fig. 6  Victaulic Groove .......................................................................................................................................... 34
Fig. 7  Flange Attachments .................................................................................................................................... 34
Fig. 8  Power Panel Section ................................................................................................................................... 37
Fig. 9  Options Panel Layout (Typical) ................................................................................................................ 38
Fig. 10  Logic Section Layout .................................................................................................................................. 39
Fig. 11  Logic Section Layout with Control Panel Layout ..................................................................................... 40
Fig. 12  Customer Connections ............................................................................................................................... 41
Fig. 13  Customer Connections ............................................................................................................................... 42
Fig. 14  Flow Rate and Pressure Drop (English Units, 60 Hz) .............................................................................. 47
Fig. 15  Flow Rate and Pressure Drop (SI Units, 60 Hz) ....................................................................................... 47
Fig. 16  Flow Rate and Pressure Drop (SI Units, 50 Hz) ....................................................................................... 48
Fig. 17  Glycol Correction Factors .......................................................................................................................... 49
Fig. 18  Multiple Point Power Supply Connection ................................................................................................ 63
Fig. 19  Multiple Point Power Supply Connection with Individual System Circuit Brea ers ............................. 63
Fig. 20  Optional Single-Point Power Supply Connection with Individual System Circuit Brea ers .................. 64
SECTION 9MAINTENANCE ............................................................................................................. 222
G n ral R quir m nts ........................................................................................................................... 222
Daily Maintenance ................................................................................................................................... 222
Scheduled Maintenance .......................................................................................................................... 222
Chill r/Compr ssor Op rating Log ..................................................................................................... 222
Compr ssor Unit Op ration .................................................................................................................. 223
Maint nanc R quir m nts ................................................................................................................... 224
G n ral P riodic Maint nanc Ch cks  Standard Units .................................................................... 225
SECTION 10 SPARE PARTS ............................................................................................................... 226
Recommended Spares .............................................................................................................................. 226
Recommended Compressor ils ..............................................................................................................226
Associated Drawings ..............................................................................................................................226
SECTION 11 TROUBLESHOOTING .................................................................................................. 227
Comp t nt P rsons Troubl shooting Guid .......................................................................................... 227
S nsor Calibration Charts .................................................................................................................... 229
Limit d Warranty Appli d Syst ms ....................................................................................................... 230
T mp ratur Conv rsion Chart ............................................................................................................. 231
7. CLOCK KEYS ............................................................................................................................... 208
7.1 General ....................................................................................................................208
7.2 Set Time Key ..........................................................................................................208
7.3 Set Schedule / Holiday Key ................................................................................... 209
7.4 Manual verride Key ............................................................................................. 210
8. PROGRAM KEY ............................................................................................................................... 211
8.1 General ....................................................................................................................211
8.2 Program Key  User Programmable Values ............................................................211
8.3 Programming Default Values ..............................................................................215
8.4 3 Compressor Condenser Fan Control ................................................................... 216
8.5 4 Compressor Condenser Fan Control ................................................................... 219

8YORK INTERNATIONAL
FORM 201.18-NM9 (602)
LIST OF FIGURES CONTD)
Fig. 21  Multiple Point Power Supply Connection (50 Hz) .................................................................................. 70
Fig. 22  Multiple Point Power Supply Connection with Individual System Circuit Brea ers ............................. 70
Fig. 23  Optional Single-Point Power Supply Connection with Individual System Circuit Brea ers .................. 71
Fig. 24  Elementary Diagram  Across-The-Line Start .......................................................................................... 72
Fig. 25  Control Power Transformer Kit ................................................................................................................. 74
Fig. 26  Standard 3-Compressor Power Supplies  Wye-Delta Start ..................................................................... 75
Fig. 27  Elementary Diagram  Across-The-Line Start ........................................................................................... 76
Fig. 28  Elementary Diagram ................................................................................................................................... 78
Fig. 29  Connection Diagram ................................................................................................................................ 79B
Fig. 30  Connection Diagram  Electric Box DXST Direct Drive .......................................................................... 84
Fig. 31  Connection Diagram  Electrical Box ......................................................................................................... 85
Fig. 32  Elementary Diagram  DXST Direct Drive - Control Circuit ................................................................... 87
Fig. 33  Connection Diagram System Wiring .......................................................................................................... 90
Fig. 34  Elementary Diagram  DXST Direct Drive  Power Circuit .................................................................... 92
Fig. 35  Control Power Transformer Kit ................................................................................................................. 94
Fig. 36  Standard 4-Compressor Power Supplies  Wye-Delta Start ..................................................................... 95
Fig. 37  Standard Compressor Power Supplies  Across-The-Line Start .............................................................. 96
Fig. 38  Standard Compressor Power Supplies  Across-The-Line and Wye-Delta Start ..................................... 98
Fig. 39  Connection Diagram  Across-The-Line and Wye-Delta Start, Systems 1 & 2 .................................... 99B
Fig. 40  Connection Diagram  Across-The-Line and Wye-Delta Start, Systems 3 & 4 ..................................... 102
Fig. 41  Connection Diagram  Electrical Box ....................................................................................................... 104
Fig. 42  Elementary Diagram, DXST Direct Drive  Control Circuit .................................................................. 106
Fig. 43  Connection Diagram System Wiring  Standard and Remote Evap. Units ............................................. 109
Fig. 44  Compressor Terminal Box, Systems 1  4 ............................................................................................... 111
Fig. 45  Model YCAS0218EB  0268EB Dimensions (English) .......................................................................... 112
Fig. 46  Model YCAS0288EB Dimensions (English) ........................................................................................... 114
Fig. 47  Model YCAS0308EB Dimensions (English) ........................................................................................... 116
Fig. 48  Model YCAS0328EB Dimensions (English) ........................................................................................... 118
Fig. 49  Model YCAS0358EB Dimensions (English) ........................................................................................... 120
Fig. 50  Model YCAS0398EB  0418EB Dimensions (English) .......................................................................... 122
Fig. 51  Model YCAS0218EB  0268EB Dimensions (SI) .................................................................................. 124
Fig. 52  Model YCAS0288EB Dimensions (SI) .................................................................................................... 126
Fig. 53  Model YCAS0308EB Dimensions (SI) .................................................................................................... 128
Fig. 54  Model YCAS0328EB Dimensions (SI) .................................................................................................... 130
Fig. 55  Model YCAS0358EB Dimensions (SI) .................................................................................................... 132
Fig. 56  Model YCAS0368EB  0418EB Dimensions (SI) .................................................................................. 134
Fig. 57  Model YCAS0685EB Dimensions (SI) .................................................................................................... 136
Fig. 58  Model YCAS0775EB  0905EB Dimensions (SI) .................................................................................. 138
Fig. 59  Model YCAS0965EB Dimensions (SI) .................................................................................................... 140
Fig. 60  Model YCAS1065EB  1215EB Dimensions (SI) .................................................................................. 142
Fig. 61  Clearances ................................................................................................................................................. 144
Fig. 62  Neoprene Isolator Details ......................................................................................................................... 151
Fig. 63  1" Isolator Details ..................................................................................................................................... 152
Fig. 64  Seismic Isolator Details ............................................................................................................................ 153
Fig. 65  Refrigerant Flow Diagram ......................................................................................................................... 157
Fig. 66  Process and Instrumentation Diagram ...................................................................................................... 158
Fig. 67  Component Locations  3-Compressor Units ......................................................................................... 159
Fig. 68  Component Locations  4-Compressor Units ......................................................................................... 160
Fig. 69  Compressor Components ......................................................................................................................... 161
Fig. 70  Motor Protector ........................................................................................................................................ 176
Fig. 71  Component Layout ................................................................................................................................... 179
Fig. 72  Logic Section Layout ................................................................................................................................ 180
Fig. 73  Suction Pressure Cutout ........................................................................................................................... 188
Fig. 74  Enlarged Photograph of Dip Switches on Microprocessor Board .......................................................... 194
Fig. 75  Condenser Fan Control Layout for DXST Compressor Units ............................................................... 216
Fig. 76  Condenser Fan Control Layout for DXST Compressor Units ............................................................... 219

9
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
Table 1  Motor Protector Dip Switch Setting  Across-The-Line Start, 60 Hz ..................................................... 20
Table 2  Motor Protector Dip Switch Setting  Across-The-Line Start, 50 Hz ..................................................... 21
Table 3  Motor Protector Dip Switch Setting  Wye-Delta Start, 60 Hz ............................................................... 22
Table 4  Motor Protector Dip Switch Setting  Wye-Delta Start, 50 Hz ............................................................... 23
Table 5  Temperatures and Flows  English Units, 60 Hz ...................................................................................... 50
Table 6  Temperatures and Flows  SI Units, 60 Hz .............................................................................................. 50
Table 7  Temperatures and Flows  SI Units, 50 Hz .............................................................................................. 51
Table 8  Physical Data  English Units, 60 Hz, R-407c Optimized ....................................................................... 52
Table 9  Physical Data  SI Units, 60 Hz, R-407c Optimized ............................................................................... 53
Table 10  Physical Data  SI, 50 Hz, R-407c Optimized .......................................................................................... 54
Table 11  Operating Limitations  English Units 60 Hz ........................................................................................... 55
Table 12  60 Hz Sound Power Data ........................................................................................................................... 55
Table 13  Operating Limitations  SI Units 60 Hz .................................................................................................... 56
Table 14  60 Hz Sound Power Data ........................................................................................................................... 56
Table 15  Operating Limitations  SI Units 50 Hz .................................................................................................... 57
Table 16  50 Hz Sound Power Data ........................................................................................................................... 57
Table 17  Multiple Point Power Supply Connection  3 & 4 Compressor Units ................................................... 58
Table 18  Optional Single-Point Power Supply Connection with Individual System Circuit Brea ers 
3 & 4 Compressor Units ............................................................................................................................ 60
Table 19  Control Power Supply (Units without Standard Control Circuit Transformers) .................................... 60
Table 20  Control Power Supply (Units with Standard Control Circuit Transformers) .......................................... 61
Table 21  Multiple Point Power Supply Connection  3 & 4 Compressor Units (50 Hz) ..................................... 66
Table 22  Optional Single-Point Power Supply Connection with Individual System Circuit Brea ers 
3 & 4 Compressor Units ............................................................................................................................ 66
Table 23  Control Power Supply (Units without Standard Control Circuit Transformers) .................................... 68
Table 24  Control Power Supply (Units with Standard Control Circuit Transformers) .......................................... 68
Table 25  Compressor Data ........................................................................................................................................ 69
Table 26  Fan Data (-46) ............................................................................................................................................. 69
Table 27  Aluminum Fin Weight Distribution (lbs.) ................................................................................................ 145
Table 28  Aluminum Fin Weight Distribution ( gs.) ............................................................................................... 145
Table 29  Aluminum Fins  Neoprene Mount Selection - VMC Type RD-X ....................................................... 146
Table 30  Aluminum Fins  1" Isolator Selection - VMC Type CP-X-XX ............................................................ 146
Table 31  Aluminum Fins  Seismic Isolator Selections - VMC Model # AWMR-X-XXX .................................. 146
Table 32  Copper Fin Weight Distribution (lbs.) ..................................................................................................... 147
Table 33  Copper Fin Weight Distribution ( gs.) .................................................................................................... 147
Table 34  Copper Fins  Neoprene Mount Selection - VMC Type RD-X ............................................................ 147
Table 35  Copper Fins  1" Isolator Selection - VMC Type CP-X-XX ................................................................ 147
Table 36  Copper Fins  Seismic Isolator Selections - VMC Model # AWMR-X-XXX ...................................... 147
Table 37  Copper Fin w/ Optional Silencer Kit Weight Distribution (lbs.) ............................................................ 147
Table 38  Copper Fin w/ Optional Silencer Kit Weight Distribution ( gs.) ........................................................... 147
Table 39  Copper Fins w/ Optional Silencer Kit  Neoprene Mount Selection - VMC Type RD-X ................... 147
Table 40  Copper Fins w/ Optional Silencer Kit  1" Isolator Selection - VMC Type CP-X-XX ........................ 147
Table 41  Copper Fins w/ Optional Silencer Kit  Seismic Isolator Selections -
VMC Model # AWMR-X-XXX .............................................................................................................. 147
Table 42  Aluminum Fins Weight Distribution ( gs.) by Model ............................................................................ 154
Table 43  Aluminum Fins, Seismic Isolator Selections  VMC Type RD-4 ........................................................... 154
Table 44  Aluminum Fins, 1" Isolator Selections - VMC Type CP-2-XX ............................................................. 154
Table 45  Aluminum Fins, Seismic Isolator Selections - VMC Model # AWMR-X-XXX .................................... 154
Table 46  Copper Fins Weight Distribution ( gs.) by Model ................................................................................. 155
Table 47  Copper Fins, Seismic Isolator Selections  VMC Type RD-4 ............................................................... 155
Table 48  Copper Fins, 1" Isolator Selections - VMC Type CP-2-XX .................................................................. 155
Table 49  Copper Fins, Seismic Isolator Selections - VMC Model # AWMR-X-XXX ........................................ 155
Table 50  Condenser Fan Control and Fan Contactor Data for DXST Units with 3 Fans/System ....................... 217
Table 51  Condenser Fan Control and Fan Contactor Data for DXST Units with 4 Fans/System ....................... 217
Table 52  Condenser Fan Control and Fan Contactor Data for DXST Units with 5 Fans/System ....................... 218
Table 53  Condenser Fan Control and Fan Conatctor Data for DXST Units with 6 Fans/System ....................... 218
Table 54  Condenser Fan Control and Fan Contactor Data for DXST Units with 4 Fans/System ....................... 220
Table 55  Condenser Fan Control and Fan Contactor Data for DXST Units with 5 Fans/System ....................... 221
Table 56  Maintenance requirements for YORK YCAS Screw Chillers ................................................................. 224
Table 57  General Periodic Maintenance Chec s for Standard Units ...................................................................... 225
Table 58  Competent Persons Troubleshooting Guide ........................................................................................... 227
LIST OF TABLES

10 YORK INTERNATIONAL
FORM 201.18-NM9 (602)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: re rigerants,
oils, materials under pressure, rotating components, and
both high and low voltage. Each o these items has the
potential, i misused or handled improperly, to cause
bodily injury or death. It is the obligation and responsi-
bility o operating/service personnel to identi y and rec-
ognize these inherent hazards, protect themselves, and
proceed sa ely in completing their tasks. Failure to com-
ply with any o these requirements could result in seri-
ous damage to the equipment and the property in which
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
it is situated, as well as severe personal injury or death
to themselves and people at the site.
This document is intended or use by owner-authorized
operating/service personnel. It is expected that this in-
dividual possesses independent training that will enable
them to per orm their assigned tasks properly and sa ely.
It is essential that, prior to per orming any task on this
equipment, this individual shall have read and under-
stood this document and any re erenced materials. This
individual shall also be amiliar with and comply with
all applicable governmental standards and regulations
pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or en-
ironmental pollution. Usually an in-
struction will be gi en, together with a
brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
a oided, will result in death or seri-
ous injury.
WARNING indicates a potentially haz-
ardous situation which, if not a oided,
could result in death or serious injury.
External wiring, unless specified as an optional connection in the manufacturers product
line, is NOT to be connected inside the micro panel cabinet. De ices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with YORKs
published specifications and must be performed ONLY by qualified YORK personnel. YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will oid the
manufacturers warranty and cause serious damage to property or injury to persons.

11
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
INTRODUCTION
YORK YCAS eco2 chillers are manu actured to the
highest design and construction standards to ensure high
per ormance, reliability and adaptability to all types o
air conditioning installations.
The unit is intended or cooling water or glycol solu-
tions and is not suitable or purposes other than those
speci ied in this manual.
This manual and the Microprocessor Operating Instruc-
tions contain all the in ormation required or correct
installation and commissioning o the unit, together with
operating and maintenance instructions. The manuals
should be read thoroughly be ore attempting to operate
or service the unit.
All procedures detailed in the manuals, including in-
stallation, commissioning and maintenance tasks, must
only be per ormed by suitably trained and quali ied
personnel.
The manu acturer will not be liable or any injury or
damage caused by incorrect installation, commission-
ing, operation or maintenance resulting rom a ailure
to ollow the procedures and instructions detailed in
the manuals.
WARRANTY
York International warrants all equipment and materi-
als against de ects in workmanship and materials or a
period o one year rom initial start-up, or eighteen
months rom delivery (whichever occurs irst) unless
extended warranty has been agreed upon as part o the
contract.
The warranty is limited to parts-only replacement and
shipping o any aulty part or sub-assembly which has
ailed due to poor quality or manu acturing errors. All
claims must be supported by evidence that the ailure
has occurred within the warranty period, and that the
unit has been operated within the designed parameters
speci ied.
All warranty claims must speci y the unit model, serial
number, order number and run hours/starts. These de-
tails are printed on the unit identi ication plate.
The unit warranty will be void i any modi ication to
the unit is carried out without prior written approval
rom York International.
For warranty purposes, the ollowing conditions must
be satis ied:
 The initial start o the unit must be carried out by
trained personnel rom an Authorized YORK Ser-
vice Center. See Commissioning, page 43.
 Only genuine YORK approved spare parts, oils and
re rigerants must be used. Recommendations on
spare parts can be ound on page 226.
 All the scheduled maintenance operations detailed
in this manual must be per ormed at the speci ied
times by suitably trained and quali ied personnel.
See Maintenance Section, page 222.
 Failure to satis y any o these conditions will auto-
matically void the warranty. See Warranty Policy,
page 230.
SAFETY
Standards for Safety
YCAS eco2 chillers are designed and built within an
ISO 9002 accredited design and manu acturing organi-
zation. The chillers comply with the applicable sections
o the ollowing Standards and Codes:
 ANSI/ASHRAE Standard 15, Sa ety Code or Me-
chanical Re rigeration
 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, Centri ugal and Rotary
Screw Water Chilling Packages
In addition, the chillers con orm to Underwriters Labo-
ratories (U.L.) or construction o chillers and provide
U.L./cU.L. listing label.
SECTION 1  GENERAL CHILLER INFORMATION & SAFETY
1

12 YORK INTERNATIONAL
FORM 201.18-NM9 (602)
RESPONSIBILITY FOR SAFETY
Every care has been taken in the design and manu ac-
ture o the unit to ensure compliance with the sa ety
requirements listed above. However, the individual op-
erating or working on any machinery is primarily re-
sponsible or:
Personal sa ety, sa ety o other personnel, and the
machinery.
Correct utilization o the machinery in accordance with
the procedures detailed in the manuals.
ABOUT THIS MANUAL
The ollowing terms are used in this document to alert
the reader to areas o potential hazard.
A Warning is given in this document to
identi y a hazard which could lead to per-
sonal injury. Usually an instruction will be
given, together with a brie explanation
and the possible result o ignoring the in-
struction.
A Caution identi ies a hazard which
could lead to damage to the machine,
damage to other equipment and/or envi-
ronmental pollution. Usually an instruc-
tion will be given, together with a brie
explanation and the possible result o ig-
noring the instruction.
A Note is used to highlight additional in or-
mation which may be help ul to you but
where there are no special sa ety implications.
The contents o this manual include suggested best
working practices and procedures. These are issued or
guidance only, and they do not take precedence over
the above stated individual responsibility and/or local
sa ety regulations.
This manual and any other document supplied with the
unit are the property o YORK, which reserves all rights.
They may not be reproduced, in whole or in part, with-
out prior written authorization rom an authorized
YORK representative.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended or cooling water or glycol solu-
tions and is not suitable or purposes other than those
speci ied in these instructions. Any use o the equipment
other than its intended use, or operation o the equip-
ment contrary to the relevant procedures, may result in
injury to the operator, or damage to the equipment.
The unit must not be operated outside the design pa-
rameters speci ied in this manual.
Structural Support
Structural support o the unit must be provided as indi-
cated 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
rom adjacent equipment, pipework or structures. Ad-
ditional components must not be mounted on the unit.
Any such extraneous loads may cause structural ail-
ure and may result in injury to the operator, or damage
to the equipment.
General Access
There are a number o areas and eatures which may be
a hazard and potentially cause injury when working on
the unit unless suitable sa ety precautions are taken. It
is important to ensure access to the unit is restricted to
suitably quali ied persons who are amiliar with the po-
tential hazards and precautions necessary or sa e op-
eration and maintenance o equipment containing high
temperatures, pressures and voltages.
Pressure Systems
The unit contains re rigerant vapor and liquid under
pressure, release o which can be a danger and cause
injury. The user should ensure that care is taken during
installation, operation and maintenance to avoid dam-
age to the pressure system. No attempt should be made
to gain access to the component parts o the pressure
system other than by suitably trained and quali ied
personnel.
Electrical
The unit must be grounded. No installation or mainte-
nance work should be attempted on the electrical equip-
General Chiller Information & Safety

13
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
ment without irst switching OFF, isolating and locking-
o the power supply. Work on live equipment must only
be carried out by suitably trained and quali ied person-
nel. No attempt should be made to gain access to the
control panel or electrical enclosures during normal op-
eration o the unit.
Rotating Parts
Fan guards must be itted at all times and not removed
unless the power supply has been isolated. I ductwork
is to be itted, requiring the wire an guards to be re-
moved, alternative sa ety measures must be taken to
protect against the risk o injury rom rotating ans.
Sharp Edges
The inning on the air-cooled condenser coils has sharp
metal edges. Reasonable care should be taken when
working in contact with the coils to avoid the risk o
minor abrasions and lacerations. The use o gloves is
recommended.
Refrigerants and Oils
Re rigerants and oils used in the unit are generally non-
toxic, non- lammable and non-corrosive, and pose no
special sa ety hazards. Use o gloves and sa ety glasses
are, however, recommended when working on the unit.
The build up o re rigerant vapor, rom a leak or ex-
ample, does pose a risk o asphyxiation in con ined or
enclosed spaces and attention should be given to good
ventilation.
igh Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part o the
pressure system as this may cause operation o the pres-
sure relie device(s). Detergents and solvents which may
cause corrosion should also be avoided.
EMER ENCY SHUTDOWN
In case o emergency, the electrical option panel is it-
ted with an emergency stop switch CB4 (3 System) or
CB5 (4 System) located in the bottom right o the Mi-
croprocessor Panel. Separate Circuit Breakers, CB1
(System 1), CB2 (System 2), CB3 (System 3), and CB4
(System 4) can also be used to stop the respective sys-
tem in an emergency. When operated, it removes the
electrical supply rom the control system, thus shutting
down the unit.
1

14 YORK INTERNATIONAL
FORM 201.18-NM9 (602)
1 System Fans
2 System 1 Power Panel
3 System 2 Power Panel
4 Control Panel
Power Entry
6 System 2 Compressor
7 Cooler (Evaporator)
8 System 4 Compressor
9 System 2 Condenser
10 Option Box
INTRODUCTION
YORK YCAS eco2 chillers are designed or water or
water-glycol cooling. All units are designed to be lo-
cated outside on the roo o a building or at ground
level.
The units are completely assembled with all intercon-
necting re rigerant piping and internal wiring, ready or
ield installation.
Prior to delivery, the unit is pressure tested, evacuated,
and ully charged with re rigerant and oil in each o the
two independent re rigerant circuits. A ter assembly,
an operational test is per ormed with water lowing
through the cooler to ensure that each re rigerant cir-
cuit operates correctly.
The unit structure is manu actured rom heavy gauge,
galvanized steel. All external structural parts are coated
with Desert Sand baked-on enamel powder paint. This
provides a inish which, when subjected to ASTM B117,
500 hour, 5% salt spray conditions, shows breakdown
o less than 1/8" either side o a scribed line (equiva-
lent to ASTM D1654 rating o 6).
All exposed power wiring is be routed through liquid-
tight, non-metallic conduit.
General Description
The Air-Cooled Screw Chiller utilizes many compo-
nents which are the same or nearly the same as a stan-
dard reciprocating chiller o a similar size. This includes
modular rame rails, condenser, ans and evaporator.
The chiller consists o 2, 3 or 4 screw compressors in a
corresponding number o separate re rigerant circuits,
a single shell and tube DX evaporator, economizers, an
air-cooled condenser, and expansion valves.
Compressor
The semi-hermetic rotary twin-screw compressor is
designed or industrial re rigeration applications and
ensures high operational e iciencies and reliable per-
ormance. Capacity control is achieved through a single
slide valve. The compressor is a positive displacement
type characterized by two helically grooved rotors
which are manu actured rom orged steel. The 60 Hz
motor operates at 3550 RPM to direct drive the male
rotor which in turn drives the emale rotor on a light
ilm o oil.
SECTION 2  PRODUCT DESCRIPTION
FI . 1  COMPONENT LOCATIONS
Product Description
00258VIP
1
9
23 10 5
4
6
8
7

15
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
Re rigerant gas is injected into the void created by the
unmeshing o the ive lobed male and seven lobed e-
male rotor. Further meshing o the rotors closes the ro-
tor threads to the suction port and progressively com-
presses the gas in an axial direction to the discharge
port. The gas is compressed in volume and increased in
pressure be ore exiting at a designed volume at the dis-
charge end o the rotor casing. Since the intake and dis-
charge cycles overlap, a resulting smooth low o gas is
maintained.
The rotors are housed in a cast iron compressor hous-
ing precision-machined to provide optimal clearances
or the rotors. Contact between the male and emale
rotor is primarily rolling on a contact band on each o
the rotors pitch circle. This results in virtually no rotor
wear and increased reliability, a trademark o the screw
compressor.
The compressor incorporates a complete anti- riction
bearing design or reduced power input and increased
reliability. Four separated, cylindrical, roller bearings
handle radial loads. Angular-contact ball bearings
handle axial loads. Together they maintain accurate rotor
positioning at all pressure ratios, thereby minimizing
leakage and maintaining e iciency. A springless check
valve is installed in the compressor discharge housing
to prevent compressor rotor backspin due to system re-
rigerant pressure gradients during shutdown.
Motor cooling is provided by suction gas rom the
evaporator lowing across the motor. Redundant over-
load protection is provided using both thermistor and
current overload protection.
The compressor is lubricated by removing oil rom the
re rigerant using an external oil separator. The pressur-
ized oil is then cooled in the condenser coils and piped
back to the compressor or lubrication. The compres-
sor design working pressure is 450 PSIG (31 bar). Each
chiller receives a 300 PSIG (21 bar) low side and a 450
PSIG (31 bar) high side actory test. A 350 watt (115-1-
60) cartridge heater is located in the compressor. The
heater is temperature-activated to prevent re rigerant
condensation.
The ollowing items are also included:
 Internal discharge check valve to prevent rotor back-
spin or shutdown.
 An acoustically tuned, internal discharge mu ler
to minimize noise, while operating low or maxi-
mum per ormance.
 Discharge and suction shuto valves.
 A rain-tight terminal box.
 A suction gas screen and serviceable, 0.5 micron
ull low oil ilter within the compressor housing.
Evaporator
The system uses a high-e iciency Shell and Tube type
Direct Expansion Evaporator. Each o the re rigerant
circuits (2, 3, 4 circuits) consists o 4 passes with the
chilled liquid circulating back and orth across the tubes
rom one end to the other.
The design working pressure o the cooler on the shell
side is 150 PSIG (10 bar), and 350 PSIG (24 bar) or
the tube (re rigerant side). The water ba les are abri-
cated rom galvanized steel to resist corrosion. Remov-
able heads are provided or access to internally en-
hanced, seamless, copper tubes. Water vent and drain
connections are included.
The cooler is equipped with a thermostatically con-
trolled heater or protection to -20°F (-29°C) ambient
and insulated with 3/4" (19 mm) lexible closed-cell
oam.
The water nozzles are provided with grooves or me-
chanical couplings and should be insulated by the con-
tractor a ter pipe installation.
Condenser
The in and tube condenser coils are manu actured rom
seamless, internally enhanced, high condensing coe i-
cient, corrosion resistant copper tubes arranged in stag-
FI . 2  SCREW COMPRESSOR
2
00485VIP

16 YORK INTERNATIONAL
FORM 201.18-NM9 (602)
gered rows and mechanically expanded into corrosion
resistant aluminum alloy ins with ull height in col-
lars. They have a design working pressure o 450 PSIG
(31 bar). Each coil is tested to 495 PSIG (34 bar).
Multiple ans move air through the coils. They are dy-
namically and statically balanced, direct drive with cor-
rosion resistant glass iber rein orced composite blades
molded into low noise, ull air oil cross section, pro-
viding vertical air discharge rom extended ori ices or
e iciency and low sound. Each an is located in a sepa-
rate compartment to prevent cross low during an cy-
cling. Guards o heavy gauge, PVC coated galvanized
steel are provided.
The an motors are high-e iciency, direct drive, 6-pole,
3-phase, Class- F, current overload protected, totally
enclosed (TEAO) type with double sealed, permanently
lubricated ball bearings.
Oil Separator/System
The external oil separator, with no moving parts and
designed or minimum oil carry-over, is mounted in the
discharge line o the compressor. The high pressure dis-
charge gas is orced around a 90 degree bend. Oil is
orced to the outside o the separator through centri u-
gal action and captured on wire mesh where it drains to
the bottom o the oil separator and into the compressor.
The oil (YORK L oil  a POE oil used or all re rig-
erant applications), which drains back into the com-
pressor through a replaceable 0.5 - 3.0 micron oil ilter,
and oil supply solenoid, is at high pressure. This high
pressure oil injection orces the oil into the compres-
sor where it is gravity ed to the gears and bearings or
lubrication. A ter lubricating the gears and bearings, it
is injected through ori ices on a closed thread near the
suction end o the rotors. The oil is automatically in-
jected because o the pressure di erence between the
discharge pressure and the reduced pressure at the suc-
tion end o the rotors. This lubricates the rotors as well
as provides an oil seal against leakage around the ro-
tors to assure re rigerant compression (volumetric e i-
ciency). The oil also provides cooling by trans erring
much o the heat o compression rom the gas to the oil
keeping discharge temperatures down and reducing the
chance or oil breakdown. Oil injected into the rotor
cage lows into the rotors at a point about 1.2x suction.
This assures that a required minimum di erential o at
least 30 PSID exists between discharge and 1.2x suc-
tion, to orce oil into rotor case, a minimum o 10 PSID
(0.6 bar) is all that is required to assure protection o
the compressor. Oil pressure sa ety is monitored as the
di erence between suction and the pressure o the oil
entering the rotor case.
Maximum working pressure o the oil separator is 450
PSIG (31 bar). A relie valve is installed in the oil sepa-
rator piping. This will soon be incorporated into the oil
separator. Oil level should be above the midpoint o the
lower oil sight glass when the compressor is running.
Oil level should not be above the top o the upper sight
glass. Oil temperature control is provided through liquid
injection activated by the microprocessor, utilizing a dis-
charge temperature sensor, and a solenoid valve.
Oil Cooling
Oil cooling is provided by routing oil rom the oil sepa-
rator through several o the top rows o the condenser
coils and back to the compressor.
Capacity Control
The compressors will start at the minimum load posi-
tion and provide a capacity control range rom 10% -
100% o the ull unit load using a continuous unction
slide valve. The microprocessor modulates the current
signal to a 3-way pressure regulating capacity control
valve which controls command compressor capacity,
independent o system pressures, and balances the com-
pressor capacity with the cooling load. Loading is ac-
complished by varying pressure through the pressure
regulating capacity control valve to move the slide valve
against the spring pressure to promote stable smooth
loading.
Automatic spring return o the slide valve to the mini-
mum load position will ensure compressor starting at
minimum motor load.
Power and Control Panels
All controls and motor starting equipment are actory
wired and unction tested. The panel enclosures are de-
signed to IP55 and are manu actured rom powder
painted galvanized steel.
The Power and Control Panels are divided into power
sections or each compressor and associated ans, a con-
trol section and an electrical options section. The power
and control sections have separate hinged, latched, and
gasket sealed doors equipped with wind struts.
Each power compartment contains:
Compressor and an starting contactors, an motor ex-
ternal overloads, control circuit serving compressor ca-
pacity control, compressor and an contactor coils and
compressor motor overloads.
Product Description

17
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
The current trans ormers or the compressor motor over-
loads sense each phase, as an input to the microproces-
sor. This protects the compressor motors rom damage
due to: low current input, high input current, unbal-
anced current, single phasing, phase reversal, and com-
pressor locked rotor.
The control section contains:
ON/OFF switch, microcomputer keypad and display,
microprocessor board, I/O expansion board, relay
boards and power supply board.
The options sections contain:
A control circuit trans ormer complete with service
switch providing 115/1/Ø power to the unit control
system.
Electrical options as described in Accessories and
Options.
Microprocessor Controls
The microprocessor has the ollowing unctions and
displays:
 A liquid crystal 40 character display with text pro-
vided on two lines and light-emitting diode back-
lighting outdoor viewing.
 A color coded, 35 button, sealed keypad with sec-
tions or 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 contacts,
demand load limit rom external building automation
system input, remote reset liquid temperature reset in-
put, unit alarm contacts, chilled liquid pump control,
automatic reset a ter power ailure, automatic system
optimization to match operating conditions.
The so tware is stored in non-volatile memory
(EPROM) to eliminate chiller ailure due to AC power
ailure. The Programmed Setpoint is stored in lithium
battery backed memory.
Motor Current Protection
The microprocessor motor protection provides high cur-
rent protection to assure that the motor is not damaged
due to voltage, excess re rigerant, or other problems
that could cause excessive motor current. This is ac-
complished by sending 3-phase current signals propor-
tional to motor current rom the Motor Protector mod-
ule to the Power Supply Board, where the signals are
conditioned and routed to the I/O Expansion board to
be multiplexed and sent to the Microprocessor Board.
I the motor current exceeds the 115% FLA trip point
a ter 3 seconds o operation on either Wye-Delta or
ACL starters, the micro will shut the system down and
lock it out a ter one ault. A manual reset o the re-
spective system switch is required to clear the ault
and restart the system. A thorough check o the motor,
wiring, and re rigerant system should be done be ore
restarting a system that has aulted on high motor cur-
rent.
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 i three
aults occur in 90 minutes. Low motor current protec-
tion is activated 4 seconds a ter start on both Wye-Delta
and ACL starters to assure the motor starts, the system
doesnt run without re rigerant, the motor protector
is not tripped, and the mechanical high pressure cutout
is not tripped. Once the system is locked out on Low
Motor Current, it must be manually reset with the
system switch. See also Motor Protector Module sec-
tion below.
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 motor
contactor. Whenever either o 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.
Motor Protector Module
The mechanical motor protector is a Texas Instruments
2ACE Three Phase Protection Module (Fig. 70, page
176) thermal and current motor overload protection. This
module protects against phase-to-phase current imbal-
ance, over-current, undercurrent, and phase rotation.
The module, mounted in the power panel, utilizes a 7-
segment display which provides operating status and
ault diagnostic in ormation. The 7- segment display will
display either a stationary or a lashing alphanumeric
value which can be decoded by the operator. A list o
the codes ollows:
2

18 YORK INTERNATIONAL
FORM 201.18-NM9 (602)
HAXXX Normal motor OFF display. Sequentially
sweeps through the motor protection dip
switch setting.
0Normal - no fault detected (Running)
Flashing 0 Motor off or unloaded 5A (Running)
AC current level.
1High current fault.
2Loaded phase to phase current
imbalance > 17%.
3Unloaded phase to phase current
imbalance > 25%.
4Improper incoming phase rotation.
5High motor temperature. Trip point =
13kW, reset = 3.25kW.
6Communication error.
7Unload imbalance ( > 50%)
8Phase Loss (> 60%)
EOut of range of RLA calibration.
Other symb ls Defective module or supply voltage.
Working voltage 18 - 30VAC, 24VAC nominal.
Low voltage trip = 15VAC.
Whenever a motor protector trips, the motor protec-
tor contacts wired in series with the motor contacts
open and the motor contactor de-energizes, allowing
the motor to stop. The micro senses the low motor
current and shuts the system down. The micro will try
two more starts be ore locking the system out. The
system locks out because the motor protector is a
manual reset device. A ter the irst start the modules
contacts will be open, preventing the motor contactors
rom energizing. Power must be removed and reapplied
to reset the module.
Current Overload
The 2ACE module design uses one integral current
trans ormer per phase to provide protection against
rapid current overload conditions. The module responds
to changes in current and must be calibrated using DIP
switches located on the module. Integral trip curves al-
low or in-rush currents during Wye-Delta, part wind,
or ACL starts without nuisance tripping.
To check the actory setting o the 2ACE module current
overload trip value, see Tables 1  4 (pages 20 and 23).
For the location o the dip switches and determining the
ON position re er to the Note below and Figure 70.
For the location o the dip switches and determining
the ON side o the switches, re er to Figure 70, page
176. As indicated, to place a switch in the ON position
requires pushing the switch to the le t.
A switch must be pushed to the left to
place the switch in the ON position.
It is recommended that a YORK Ser-
ice Technician or the YORK factory
be consulted before changing these
settings for any reason, since damage
to the compressor could result.
Changes should ne er be made unless
it is erified that the settings are in-
correct.
Anytime a dip switch change is made,
power must be cycled off and on to the
module to reprogram the module to the
new al e.
Product Description

19
YORK INTERNATIONAL
FORM 201.18-NM9 (602)
Thermal Overload
Three PTC (positive temperature coe icient) ther-
mistors in the motor windings o each phase provides
thermal protection. The sensor resistance stays relatively
constant at 1kΩ until a temperature o 266°F (130°C) is
sensed. The sensor experiences a rapid rise in resis-
tance beyond this temperature. Whenever the resistance
o one o the sensors reaches 13kΩ, the 2ACE module
trips, which ultimately de-energizes the motors pilot
circuit. Reset is manual a ter the motor cools and the
sensor resistance drops to 3.25kΩ.
Current Imbalance (Loaded & Unloaded)/
Loss of Phase
A 2 second delay at start-up allows or any imbalances
resulting during normal starting conditions. A ter this
initial delay, the 2ACE module compares the Operat-
ing Current to the measured hal line current. The Op-
erating Current is given by 0.65 X actory overload
current setting.
2
An unloaded compressor condition occurs when any
measured hal line current is less than the Operating
Current. A current imbalance exceeding an unloaded
level o 25% will result in the motor pilot circuit being
de-energized.
A loaded compressor condition occurs when any mea-
sured hal line current is greater than or equal to the
Operating Current. A current imbalance exceeding a
loaded level o 17% will result in the motor pilot cir-
cuit being de-energized.
Imbalance is de ined as
(High Phase - Low Phase)/High Phase
Improper Phase Sequence
The 2ACE module calculates the phase sequence at
start-up using the three current trans ormers to deter-
mine whether the three phase sequence on the load side
o the main contactor is miswired. Upon detection o a
miswired motor load, the module will deenergize the
main contactor pilot circuit within 50 millisecond re-
sponse time.

20 YORK INTERNATIONAL
FORM 201.18-NM9 (602)
Product Description
TABLE 1  MOTOR PROTECTOR DIP SWITCH SETTING  ACROSS-THE-LINE START  60 HZ
YCAS STYLE F, ACROSS-THE-LINE START  60 HZ.
MODEL VOLT CHILLER
NO. MOTOR PROTECTOR
NO. CODE NAMEPLATE
LEADS MP OL
RLA
PER VALUE
PHASE SET DIP SWITCH SETTINGS ON MP (1 INDICATED ON)
THRU MP 128 64 32 16 8 4 2 1
40 121 1 163 1 0 1 0 0 0 1 1
0218 46 100 1 135 1 0 0 0 0 1 1 1
58 80 1 108 0 1 1 0 1 1 0 0
0248 40 121 1 163 1 0 1 0 0 0 1 1
SYS 1 & 2 46 100 1 135 1 0 0 0 0 1 1 1
58 80 1 108 0 1 1 0 1 1 0 0
0248 40 213 *2 144 1 0 0 1 0 0 0 0
SYS 3 46 176 *2 119 0 1 1 1 0 1 1 1
58 141 2 190 1 0 1 1 1 1 1
40 165 *2 111 0 1 1 0 1 1 1 1
0268 46 137 2 185 1 0 1 1 1 0 0 1
58 109 1 147 1 0 0 1 0 0 1 1
0288 40 212 *2 143 1 0 0 0 1 1 1 1
SYS 1 46 176 *2 119 0 1 1 1 0 1 1 1
58 141 2 190 1 0 1 1 1 1 1 0
0288 40 166 *2 112 0 1 1 1 0 0 0 0
SYS 2 & 3 46 137 2 185 1 0 1 1 1 0 0 1
58 109 1 147 1 0 0 1 0 0 1 1
0308 40 195 *2 132 1 0 0 0 0 1 0 0
SYS 1 & 2 46 161 2 217 1 1 0 1 1 0 0 1
58 129 2 174 1 0 1 0 1 1 1 0
0308 40 166 *2 112 0 1 1 1 0 0 0 0
SYS 3 46 140 2 189 1 0 1 1 1 1 0 1
58 109 1 147 1 0 0 1 0 0 1 1
0328 40 195 *2 132 1 0 0 0 0 1 0 0
SYS 1 & 2 46 161 2 217 1 1 0 1 1 0 0 1
58 129 2 174 1 0 1 0 1 1 1 0
0328 40 184 *2 124 0 1 1 1 1 1 0 0
SYS 3 46 152 2 205 1 1 0 0 1 1 0 1
58 122 1 165 1 0 1 0 0 1 0 1
40 166 *2 112 0 1 1 1 0 0 0 0
0358 46 138 2 186 1 0 1 1 1 0 1 0
58 109 1 147 1 0 0 1 0 0 1 1
0398 40 194 *2 131 1 0 0 0 0 0 1 1
SYS 1 & 2 46 162 2 219 1 1 0 1 1 0 1 1
58 129 2 174 1 0 1 0 1 1 1 0
0398 40 166 *2 112 0 1 1 1 0 0 0 0
SYS 3 & 4 46 138 2 186 1 0 1 1 1 0 1 0
58 109 1 147 1 0 0 1 0 0 1 1
0418 40 196 *2 132 1 0 0 0 0 1 0 0
SYS. 1 & 2 46 162 2 219 1 1 0 1 1 0 1 1
58 129 2 174 1 0 1 0 1 1 1 0
0418 40 213 *2 144 1 0 0 1 0 0 0 0
SYS. 3 & 4 46 176 *2 119 0 1 1 1 0 1 1 1
58 141 2 190 1 0 1 1 1 1 1 0
* Indi ates one lead/phase through motor prote tor.