York Millennium YDAS 410 Owner's manual

00064VIP
INSTALLATION, OPERATION, & MAINTENANCE
Millennium ®
AIR COOLED SCREW LIQUID CHILLERS
AIR COOLED SCREW HERMETIC
Supersedes: Nothing Form 201.10-NM4 (1298)
YDAJ 4 SYSTEM With EPROM +(Standard, Brine & Metric Models Combined)
031-01714-105 031-01714-105
MASTER SUBORDINATE
®
M
A
N
U
F
A
C
T
U
R
E
R
C
E
R
T
I
F
I
E
D
T
O
A
R
I
A
S
C
O
M
P
L
Y
I
N
G
W
I
T
H
A
R
I
S
T
A
N
D
A
R
D
5
5
0
C
E
N
T
R
A
L
S
T
A
T
I
O
N
A
I
R
-
H
A
N
D
L
I
N
G
U
N
I
T
S
••
YDAS 410 - 490
STYLE D

YORK INTERNATIONAL
2
TABLE OF CONTENTS
GENERAL CHILLER INFORMATION
Fig. 1  YDAS Chiller............................................ 5
UNIT NOMENCLATURE ............................................. 6
NAMEPLATE ENGINEERING DATA .......................... 7
OPERATIONAL LIMITATIONS ................................... 8
Fig. 2A  Cooler Water Pressure Drop,
Total (English) ...................................... 8
Fig. 2B  Cooler Water Press. Drop, Total (Si) .... 9
PHYSICAL DATA (English) ...................................... 10
PHYSICAL DATA (SI) ................................................11
DIMENSIONS ............................................................ 12
Models YDAS 410 - 490 (English) ....................... 12
Models YDAS 410 - 490 (SI) ............................... 14
ELECTRICAL DATA.................................................. 16
YDAS 410-490 CHILLER COMPONENTS ............... 24
Fig. 7  YDAS 410 - 490 Chiller Components ..... 24
Fig. 8  YDAS 410 - 490 Chiller Typical
Cooler Components ............................. 25
Fig. 9  YDAS 410 - 490 Chiller Components ..... 26
Fig. 10  YDAS 410 - 490 Chiller Components ... 27
Fig. 11  YDAS 410 - 490 Chiller Components ... 28
Fig. 12  YDAS 410 - 490 Chiller Components ... 29
YDAS 410-490 COMPRESSOR COMPONENTS ..... 30
Fig. 13  YDAS 410 - 490 Compressor Compnts 30
Fig. 14  YDAS 410 - 490 Compressor Compnts 31
Fig. 15  Compressor Gas Flow Diagram .......... 32
Fig. 16  Screw Chiller Refrigerant Flow Dia...... 33
GENERAL ................................................................. 34
Fig. 17  Compressor Rotors............................. 34
Fig. 18  Power Panel (w/ Wye-Delta Starting) ... 36
INSTALLATION ......................................................... 37
Fig. 19  Rigging The Chiller Module .................. 37
Fig. 20  Compressor Vibration Isolator .............. 38
WGHT. DISTBTN. & ISOLATOR LCTN (English) .... 40
WGHT. DIST. & ISOLATOR LOCATION (SI) ............ 41
YDAS 410 - 490 SYS 1 AND 2 WIRING DIAGRAM
Wye-Delta Start ................................................... 42
Fig. 22  Elementary Diagram ............................. 42
YDAS 410 - 490 SYS 1 & 2 CONNECTION DIAGRAM
Wye-Delta Start ................................................... 44
Fig. 23  Connection Diagram............................. 44
Fig. 24  Wye-Delta Closed Start ........................ 46
Fig. 25  Compressor Terminal Box .................... 47
YDAS 410 - 490 SYS 3 AND 4 WIRING DIAGRAM
Wye-Delta Start ................................................... 48
Fig. 26  Elementary Diagram ............................. 49
YDAS 410 - 490 SYS 3 AND 4 CONNECTION DIA.50
Wye-Delta Start ................................................... 50
Fig. 27  Connection Diagram............................. 50
Fig. 28  Wye-Delta Closed Transition Start ....... 52
YDAS 410 - 490 SYS. 3 & 4 COMPRESSOR TERM. BOX
Fig. 29  YDAS 410 - 490 Sys. 3 & 4 Compressor
Terminal Box (Wye-delta Start) ............ 53
YDAS 410 - 490 SYS. 1 & 2 WIRING DIAGRAM
Fig. 30  Across-the-line Start ............................. 54
YDAS 410 - 490 SYS. 1 & 2 CONNECTION DIAGRAM
Fig. 31  Across-the-line Start ............................. 56
YDAS 410 - 490 SYS. 1 & 2 (SYSTEM WIRING)
Fig. 32  Across-The-Line Start ......................... 58
YDAS 410 - 490 SYS. 1 & 2 COMPRESSOR TERM. BOX
Fig. 33  (Across-the-line Start) .......................... 59
YDAS 410 - 490 SYS. 3 & 4 WIRING DIAGRAM
Fig. 34  Elementary Diagram ............................. 60
YDAS 410 - 490 SYS. 3 & 4 CONNECTION DIAGRAM
Fig. 35  Across-The-Line Start ......................... 62
YDAS 410 - 490 SYS. 3 & 4 SYSTEM WIRING
Fig. 36  Across-the-line Start ............................. 64
YDAS 410 - 490 SYS. 3 & 4 COMPRESSOR TERM. BOX
Fig. 37  Across-the-line Start ............................. 65

FORM 201.10-NM4
3
YORK INTERNATIONAL
TABLE OF CONTENTS
CHILLER CONTROL PANEL
DISPLAY & STATUS INFORMATION KEYS ....... 66
PROGRAM & SETUP KEYS ............................... 66
1. INTRODUCTION AND PHYSICAL DESCRIPTION
1.1 General ............................................................... 67
1.2 Keypad & Display ............................................... 67
1.3 Unit (Chiller) On (Auto) / Off Switch.................... 68
1.4 Microprocessor Board(s) .................................... 68
1.5 Ancillary Circuit Boards ...................................... 68
1.6 Current Transformers (C.t.) ................................ 69
1.7 Ems/Bas Connections ........................................ 69
1.8 Microprocessor Board Layout ............................ 71
Fig. 38  Microprocessor Board Layout .............. 71
1.8 Microcomputer Control Center ........................... 72
Fig. 39  Microcomputer Control Center ............. 72
1.9 Wye-Delta Start Power Panel............................. 73
Fig. 40  Wye-Delta Start Power Panel .............. 73
1.10 Compressor Heater .......................................... 74
1.11 Evaporator Heater ............................................ 74
1.12 Lead Lag Compressor Selection ...................... 74
Fig. 41  TB4 Location Manual Lead Lag ........... 74
2. STATUS KEY AND FAULT MESSAGES
2.1 General ............................................................... 76
2.2 General Status Messages .................................. 76
2.3 Anticipation Control Status Messages ............... 78
2.4 Chiller Fault Status Messages ............................ 79
2.5 System Fault Status Messages .......................... 80
2.6 Printout On Fault Shutdown ............................... 83
3. DISPLAY KEYS AND OPTION SWITCHES
3.1 General ................................................................ 84
3.2 Chilled Liquid Temps Key .................................... 84
3.3 Ambient Temp Key .............................................. 85
3.4 System Press / Temp Keys.................................. 85
3.5 % Motor Current Ke ............................................. 85
3.6 Operating Hrs / Start Counter Key ...................... 86
3.7 Options Key & Dip Switch Settings ..................... 86
Fig. 42  Dip Switch Phys. Location & Setting .... 89
4. PRINT KEYS
4.1 General ............................................................... 90
4.2 Operating Data Key ............................................ 90
4.3 Operating Data - Local Display Messages ......... 90
4.4 Operating Data  Remote Printout ..................... 94
4.5 History Key ......................................................... 95
4.6 Fault History Data (Local Display Messages) .... 95
4.7 Fault History Data  Remote Printout............... 100
5. ENTRY KEYS
5.1 General ............................................................. 103
5.2 Numerical Keypad ............................................ 103
5.3 Enter Key .......................................................... 103
5.4 Cancel Key ....................................................... 103
5.5 AM / PM Key ..................................................... 103
5.6 Advance Day Key ............................................. 103

YORK INTERNATIONAL
4
TABLE OF CONTENTS
6. SETPOINTS KEYS6104
6.1 General ............................................................. 104
6.2 Chilled Liquid Temperature Control .................. 104
6.3 Chilled Liquid Temp/Range Key ....................... 108
6.4 Remote Reset Temp/Range Key ...................... 109
7. CLOCK KEYS
7.1 General ..............................................................110
7.2 Set Time Key .....................................................110
7.3 Set Schedule / Holiday Key ...............................110
7.4 Manual Override Key ......................................... 111
8. PROGRAM KEY
8.1 General ..............................................................112
8.2 Program Key  User Programmable Values .....113
8.3 Programming Default Values .........................119
8.4 Compressor Motor Full Load Amps Data ......... 121
8.5 System Design Condensing Temperature Data 122
YDAS 410 - 490 FAN CONTROL STRATEGY ....... 123
Fig. 43  Fan Location/Operation ...................... 123
SYSTEM STARTUP CHECKLIST ............................. 124
Checking The System 24 Hours Prior ..................... 124
Panel Cheks ............................................................ 125
Initial Start-Up .......................................................... 126
Checking Superheat & Subcooling ......................... 126
Checking Economizer Superheat ............................ 127
Leak Checking ......................................................... 127
TROUBLESHOOTING............................................... 128
TEMPERATURE CONVERSION TABLES ................ 134

FORM 201.10-NM4
5
YORK INTERNATIONAL
The 410-490 Millennium Air Cooled Screw liquid chiller
is completely assembled with all interconnecting refrig-
erant piping and internal wiring, ready for field installa-
tion. The unit is pressure-tested, evacuated, and fully
charged with Refrigerant-22, and includes an initial oil
charge. After assembly, an operational test is performed
with water flowing through the coolers to check that each
refrigeration circuit operates correctly.
GENERAL CHILLER INFORMATION
The unit structure is heavy gauge, galvanized steel,
covered with a baked-on enamel. Base rails are of
formed double thickness, painted plate steel. Units are
designed in accordance with ARI 550, NFPA 70 (Na-
tional Electrical Code), ASHRAE/ANSI 15 Safety code
for mechanical refrigeration, ASME, and U.L. (200, 230,
460 and 575-3-60 models). Units are rated in accor-
dance with ARI Standard 550.
FIG. 1  YDAS CHILLER
00064VIP

YORK INTERNATIONAL
6
UNIT NOMENCLATURE
The model number denotes the following characteristics of the unit:
YD A S 410 X - 46 Y D
YORK Dual Chiller Design Series
Air Cooled
Type Start
Y = WYE-Delta
X = Across-the-Line
Compressor Design Series
S = Screw
Unit Model Voltage Code:
17 = 200-3-60
28 = 230-3-60
Class 46 = 460-3-60
Blank = Standard Efficiency 58 = 575-3-60
X = High Efficiency

FORM 201.10-NM4
7
YORK INTERNATIONAL
4M2A3HL6A
2 Compressor “W” Chiller Refrigerant Code
Configuration containing A = R-22
4 Fans & 8 Coils per Module B = R-134a
1 = 50 Hz, Economized, 1 Module
2 = 60 Hz, Economized, 1 Module
3 = 50 Hz, Economized, 1.5 Module
4 = 60 Hz, Economized, 1.5 Module Condenser Fan Code
5 = 50 Hz, Economized, 2 Module 6, 7, A, or B
6 = 60 Hz, Economized, 2 Module
7 = 50 Hz, Economized, 2.5 Module Condenser Code
8 = 60 Hz, Economized, 2.5 Module L = 32" x 83"
9 = 50 Hz, Economized, 3 Module 3 row deep coils
10 = 60 Hz, Economized, 3 Module in both systems
M =32" x 83"
4 row deep coils
Gear in System #1 XHS 120 Compressor in System #1
(A, M, F, H, P or S) 3 row deep coils
in System #2
N =32" x 83"
4 row deep coils
in both systems
Motor in 60 Hz
System#1 Compressor Max. KW
0 = 101 Frame, 7" Long N/A
1 = 101 Frame, 8" Long 85 Cooler Code
2 = 101 Frame, 9" Long 105 H = 16" Cooler
3 = 101 Frame, 9.5" Long N/A K = 18" Cooler
4 = 101 Frame, 10" Long 126 N = 20" Cooler
5 = 101 Frame, 10.75" Long 150
6 = 124 Frame, 9.5" Long (G) 184
7 = 124 Frame, 9.5" Long (K) 219
8 = 124 Frame, 10.75" Long (P) 263 Motor in System #2 Compressor
9 = 124 Frame, 10.75" Long (M) N/A (See System #1 motor list)
Gear in System #2 XHS 120 Compressor
(A, M, F, H, P or S)
NAMEPLATE ENGINEERING DATA
Engineering Data (stamped on unit nameplate) denotes the following characteristics of the components of the unit:

YORK INTERNATIONAL
8
OPERATIONAL LIMITATIONS
(English)
LD03801
FIG. 2A – COOLER WATER PRESSURE DROP,TOTAL (ENGLISH)
VOLTAGE LIMITATIONS
The following voltage limitations are ab-
solute and operation beyond these limita-
tions may cause serious damage to the
compressor.
TEMPERATURES AND FLOWS
410  490 TONS
MODEL LEAVING WATER COOLER FLOW AIR ON
NUMBER TEMPERATURE (°F) (GPM)3CONDENSER (°F)
YCAS & YDAS MIN.1MAX.2MIN. MAX. MIN. MAX.4
410 40 52 5005160650 130
440 40 52 5005160650 130
470 40 52 5005160650 130
490 40 52 5005160650 130
NOTES:
1. For leaving brine temperature below 40°F, contact your nearest YORK office for application requirements.
2. For leaving water temperature higher than 52°F, contact your nearest YORK office for application guidelines.
3. The evaporator is protected against freeze-up to -20°F with an electrical heater as standard.
4. Operation above 115°F requires the Optional High Ambient Kit.
5. YDAS Units have two coolers in parallel.
VOLTAGES
UNIT POWER MIN. MAX.
200-3-60 180 220
230-3-60 207 253
460-3-60 414 506
575-3-60 517 633
MODEL YDAS COOLER CODE
410, 440, 470, 490 4

FORM 201.10-NM4
9
YORK INTERNATIONAL
LD03802
TEMPERATURES AND FLOWS
1440 - 1722 kW
NOTES:
1. For leaving brine temperature below 4.4°C, contact your nearest YORK office for application requirements.
2. For leaving water temperature higher than 11°C, contact your nearest YORK office for application guidelines.
3. The evaporator is protected against freeze-up to -28.8°F with an electrical heater as standard.
4. Operation above 46.1°C requires the Optional High Ambient Kit.
5. YDAS Units have two coolers in parallel.
FIG. 2B – COOLER WATER PRESSURE DROP, TOTAL (SI)
OPERATIONAL LIMITATIONS
(SI)
VOLTAGE LIMITATIONS
The following voltage limitations are ab-
solute and operation beyond these limita-
tions may cause serious damage to the
compressor.
VOLTAGES
UNIT POWER MIN. MAX.
200-3-60 180 220
230-3-60 207 253
460-3-60 414 506
575-3-60 517 633
MODEL LEAVING WATER COOLER FLOW AIR ON
NUMBER TEMPERATURE (°C) (L/S)3CONDENSER (°C)
YCAS & YDAS MIN.1MAX.2MIN. MAX. MIN. MAX.4
410 4.4 11.1 31.55101.35-17.7 54.4
440 4.4 11.1 31.55101.35-17.7 54.4
470 4.4 11.1 31.55101.35-17.7 54.4
490 4.4 11.1 31.55101.35-17.7 54.4
MODELYDAS COOLER CODE
410, 440, 470, 490 4

YORK INTERNATIONAL
10
PHYSICAL DATA
(English)
MODEL YDAS 410 440 470 490
NOMINAL CAPACITY (TONS) 396.8 431.7 461.9 478.5
NO. OF REFRIG CIRCUITS 4444
COMPRESSOR Sys. 1 120CP*Q 120CP*Q 120CP*Q 120CP*Q
MODEL XHS Sys. 2 120CH*N 120CH*N 120CP*Q 120CS*Q
Sys. 3 120CH*N 120CP*Q 120CP*Q 120CS*Q
Sys. 4 120BF*L 120CH*N 120CP*Q 120CS*Q
DIAMETER x LENGTH (in.) (2) 20 x 96 (2) 20 x 96 (2) 20 x 96 (2) 20 x 96
VOLUME (GAL.) 108 108 108 108
COOLER
FLOW (GPM) MIN 500 500 500 500
MAX 1606 1606 1606 1606
CONDENSER Sys. 1 4444
ROWS Sys. 2 4444
Sys. 3 4444
Sys. 4 4444
CONDENSER FACE AREA (FT.2)590 590 590 590
NO. 16 16 16 16
CONDENSER HP/KW 3/2.8 3/2.8 3/2.8 3/2.8
FANS NO. OF BLADES 6666
AIRFLOW CFM 268,000 268,000 268,000 268,000
SHIPPING Al. FIN 30,664 30,664 30,664 30,664
WEIGHT Cu. FIN 35,196 35,196 35,196 35,196
(LBS.) OPERATING Al. FIN 31,444 31,444 31,444 31,444
Cu. FIN 35,996 35,996 35,996 35,996
REFRIGERANT CHARGE Sys. 1 210 210 210 210
(LBS. R-22) Sys. 2 235 235 235 235
Sys. 3 210 210 210 210
Sys. 4 235 235 235 235