York YCWS0313SC Installation and operating instructions

INSTALLATION,OPERATIONAND
MAINTENANCE
YCWS
WATER COOLED LIQUID CHILLERS
New Release Form 201.24-NM2 (601)
50 HERTZ
STYLE B
REFRIGERANT TYPE: R-22
00546VIP
YCWS WATER COOLED LIQUID CHILLERS
YCWS0313SC – 0663SC

YORK INTERNATIONAL
2
SECTION 1SUPPLIER INFORMATION
Introduction ............................................................ 6
Warranty ................................................................. 6
Safety ....................................................................... 6
Standards for Safety.............................................. 6
Responsibility for Safety........................................ 7
About this Manual.................................................. 7
Misuse of Equipment.............................................. 7
Suitability for Application .................................... 7
Structural Support ................................................. 7
Mechanical Strength ............................................. 7
General Access...................................................... 7
Pressure Systems................................................... 7
Electrical ............................................................... 7
Refrigerants and Oils ............................................ 8
High Temperature and Pressure Cleaning ............ 8
Emergency Shutdown ........................................... 8
Material Safety Data ............................................... 9
SECTION 2PRODUCT DESCRIPTION
Introduction ........................................................... 13
Compressor ......................................................... 13
Motor Starting ..................................................... 14
Capacity Control ................................................. 14
Oil Separator.......................................................... 15
Oil Cooler ............................................................... 15
Refrigerant Circuits ............................................. 15
Condenser.............................................................. 15
Cooler...................................................................... 15
Power and Control Panels .................................... 16
Microprocessor Controls ...................................... 16
Motor Current Protection .................................... 16
Motor Protector Module ..................................... 17
Current Overload ................................................ 17
Thermal Overload ............................................... 17
Current Unbalance / Loss of Phase..................... 17
Improper Phase Sequence................................... 17
Keypad Controls................................................... 17
Status Key ........................................................... 17
Display Keys ....................................................... 18
Print Keys............................................................. 18
Entry Keys........................................................... 18
Setpoints Keys .................................................... 18
Clock Keys ......................................................... 18
Program Key ....................................................... 18
Accessories and Options ...................................... 18
Power Supply Options (All Models) .................. 18
Single-Point Power Supply Connection ............. 18
Multiple Point Power Supply Connection
(Standard)............................................................ 18
Building Automation System (BAS) Interface ... 18
Multi-Unit Sequence Control.............................. 18
Pressure Vessel Codes......................................... 18
Vibration Isolators................................................ 18
Neoprene Pad Isolators ....................................... 18
1" (25 mm) Spring Isolators ............................... 18
Flange Kits (150 PSI) ......................................... 19
Mechanical Gauge Kit ........................................ 19
Language LCD and Keypad................................ 19
Flow Switch Accessory........................................ 19
Printer.................................................................. 19
Nomenclature ........................................................ 20
Functional Description......................................... 20
SECTION 3TRANSPORTATION, HANDLING
AND STORAGE
Delivery and Storage............................................ 21
Inspection .............................................................. 21
Moving the Unit .................................................... 21
Lifting by Crane/ Hoist ....................................... 21
Lifting by Fork Lift ............................................. 22
Control Panel Removal ........................................ 22
Lifting Weights...................................................... 22
SECTION 4INSTALLATION
Location Requirements ........................................ 23
Installation of Vibration Isolators ...................... 23
Pipework Connection ........................................... 23
General Requirements......................................... 23
Water Treatment................................................... 24
Glycol Solutions.................................................. 25
Pipework Arrangement........................................ 25
Recommendations of the Building Services
Research Association .......................................... 25
Connection Types & Sizes.................................... 25
Cooler Connections............................................. 25
Option Flanges .................................................... 26
Refrigerant Relief Valve Piping .......................... 26
Condenser Cooling Liquid Systems.................... 26
Direct Pressure Control....................................... 26
Inlet Temperature Control................................... 26
Electrical Connection ........................................... 26
Power Wiring ........................................................ 27
Units with Single-Point Power Supply Wiring ... 27
Units with Multi Point Power Supply Wiring..... 27
Control Transformer Primary Voltage Tappings 28
Remote Emergency Stop Device ........................ 28
Common Input Section Wiring ........................... 28
Chilled Liquid Pump........................................... 28
Common Run Signal ........................................... 28
System Alarm ...................................................... 28
TABLE OF CONTENTS

FORM 201.24-NM2
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YORK INTERNATIONAL
TABLE OF CONTENTS (CONT’D)
Control Panel Wiring ........................................... 28
Flow Switch ........................................................ 28
Remote Run / Stop .............................................. 28
Remote Print (PNT) ............................................. 28
Remote Setpoint Offset – Temperature .............. 29
Remote Setpoint Offset – Current ...................... 29
Connection Diagrams........................................... 30
Connection Diagram Legend and Notes ............ 32
SECTION 5COMMISSIONING
Commissioning ...................................................... 33
Preparation .......................................................... 33
Preparation – Power Off ..................................... 33
First Time Start-up............................................... 34
SECTION 6UNIT OPERATION
Unit Operation ...................................................... 37
General Description ............................................ 37
Start-up.................................................................. 37
Normal Running and Cycling ............................. 37
Shutdown............................................................... 37
SECTION 7MICROPANEL.............................................................................................................. 38
1. INTRODUCTION & PHYSICAL DESCRIPTION ........................................................................ 38
1.1 System Switches 1-2 ....................................................................................................... 38
1.2 Internal Clock & Memory Backup Battery..................................................................... 38
1.3 Power Supply Board ....................................................................................................... 38
1.4 Input / Output Expansion Board ..................................................................................... 38
1.5 Relay Output Board ........................................................................................................ 38
1.6 Circuit Breakers .............................................................................................................. 39
1.7 Current Transformers (C.T.) ........................................................................................... 39
1.8 Transformers ................................................................................................................... 39
1.9 Motor Protector Modules................................................................................................ 39
1.10 Logic Section .................................................................................................................. 39
1.11 Remote Start / Stop ......................................................................................................... 40
1.12 Remote Current Reset ..................................................................................................... 40
1.13 Remote Setpoint Reset .................................................................................................... 41
1.14 Control Panel................................................................................................................... 42
1.15 Remote Emergency Stop Device .................................................................................... 42
1.16 Common Input Power Section Voltage Free Contacts.................................................... 42
1.17 Alarm Contacts................................................................................................................ 42
1.18 Chilled Liquid Pump Contact ......................................................................................... 42
1.19 Run Contact..................................................................................................................... 42
1.20 Anti-Recycle Timer ......................................................................................................... 42
1.21 Anti-Coincidence Timer.................................................................................................. 43
1.22 Compressor Heater Control ............................................................................................ 43
1.23 Pumpdown (LLSV) Control............................................................................................ 43
1.24 Lead / Lag Compressor Selection ................................................................................... 43
2. CONTROL PANEL PROGRAMMING AND DATA ACCESS ................................................... 44
2.1 Display and Status Keys................................................................................................. 44
2.2 Program and Setup Keys................................................................................................ 44
3. STATUS KEYS ..................................................................................................................................... 45
3.1 General ............................................................................................................................ 45

YORK INTERNATIONAL
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TABLE OF CONTENTS (CONT’D)
3.2 General Status Messages................................................................................................. 45
3.3 Unit Warnings ................................................................................................................. 46
3.4 Anticipation Control Status Messages ........................................................................... 47
3.5 Unit Fault Status Messages ............................................................................................. 48
3.6 System Fault Status Messages ....................................................................................... 49
3.7 Printout on Fault Shutdown ............................................................................................ 52
4. DISPLAY KEYS ................................................................................................................................... 53
4.1 General ............................................................................................................................ 53
4.2 Chilled Liquid Temps Key .............................................................................................. 53
4.3 System Data Keys ........................................................................................................... 53
4.4 Ambient Temp Key ......................................................................................................... 54
4.5 Motor Current Key .......................................................................................................... 54
4.6 Operating Hrs / Start Counter Key.................................................................................. 55
4.7 Options Key and Dip Switch Settings............................................................................. 55
4.8 DIP Switch Settings ........................................................................................................ 56
4.9 Function Key ................................................................................................................... 56
5. PRINT KEYS........................................................................................................................................ 57
5.1 General ............................................................................................................................ 57
5.2 Oper Data Key................................................................................................................. 57
5.3 Oper Data – Local Display Messages............................................................................. 57
5.4 Oper Data – Remote Printout.......................................................................................... 59
5.5 History Key ..................................................................................................................... 60
5.6 History – Local Display Messages ................................................................................. 60
5.7 History – Remote Printout .............................................................................................. 63
5.8 Local Printer Option ....................................................................................................... 64
6. ENTRY KEYS ...................................................................................................................................... 66
6.1 General ............................................................................................................................ 66
6.2 Numerical Keypad .......................................................................................................... 66
6.3 Enter Key......................................................................................................................... 66
6.4 Cancel Key ...................................................................................................................... 66
6.5 áâ Keys......................................................................................................................... 66
7. SETPOINT KEYS AND CHILLED LIQUID CONTROL............................................................. 67
7.1 General ............................................................................................................................ 67
7.2 Chilled Liquid Temperature Control............................................................................... 67
7.3 Slide Valve Control ......................................................................................................... 68
7.4 Load Timers .................................................................................................................... 68
7.5 Slide Valve Position ........................................................................................................ 68
7.6 Compressor Starting and Loading Sequence .................................................................. 68
7.7 Compressor Loading ....................................................................................................... 69
7.8 Loading Limiting............................................................................................................. 69
7.9 Compressor Unloading and Shutdown Sequence ........................................................... 69
7.10 Local Cooling Setpoints Key .......................................................................................... 69
7.11 Remote Cooling Setpoints Key ....................................................................................... 70

FORM 201.24-NM2
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YORK INTERNATIONAL
TABLE OF CONTENTS (CONT’D)
8. CLOCK KEYS ..................................................................................................................................... 71
8.1 General ............................................................................................................................ 71
8.2 Set Time / Date Key ........................................................................................................ 71
8.3 Set Schedule / Holiday Key ............................................................................................ 72
8.4 Manual Override Key...................................................................................................... 73
9. PROGRAM KEYS .............................................................................................................................. 74
9.1 General ............................................................................................................................ 74
9.2 User Programmable Values ............................................................................................. 74
9.3 Input /Output Display Routine ........................................................................................ 77
10. EMS / BAS INTERFACE CARD KITS ............................................................................................ 79
10.1 EMS / BAS Remote Temperature Reset ......................................................................... 79
10.2 BAS / EMS Remote Temperature Reset Option............................................................. 79
SECTION 8MAINTENANCE........................................................................................................... 81
General Requirements .......................................................................................................................... 81
Daily Maintenance................................................................................................................................. 81
Scheduled Maintenance ........................................................................................................................ 81
Standard Units ....................................................................................................................................... 82
Competent Persons Troubleshooting Guide ....................................................................................... 83
Sensor Calibration Charts.................................................................................................................... 85
Typical Control Panel Wiring ............................................................................................................... 86
SECTION 9TECHNICAL DATA ..................................................................................................... 88
Flow rate and Pressure Drop Graphs.................................................................................................. 88
Physical Data / Sound Data .................................................................................................................. 90
Electrical Data ....................................................................................................................................... 92
Dimensions.............................................................................................................................................. 96
Isolator Selection Data .......................................................................................................................... 98
Isolator Details ....................................................................................................................................... 99
Compressors ......................................................................................................................................... 100
SECTION 10 SPARE PARTS..............................................................................................................101
Recommended Spare Parts .................................................................................................................... 101
Recommended Compressor Oils ........................................................................................................... 101
Associated Drawings ............................................................................................................................. 101
SECTION 11 DECOMMISSIONING, DISMANTLING AND DISPOSAL..................................102
General................................................................................................................................................... 102

YORK INTERNATIONAL
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INTRODUCTION
YORK YCWS chillers are manufactured to the highest
design and construction standards to ensure high per-
formance, reliability and adaptability to all types of air
conditioning installations.
The unit is intended for cooling water or glycol solu-
tions and is not suitable for purposes other than those
specified in this manual.
This manual contains all the information required for
correct installation and commissioning of the unit, to-
gether with operating and maintenance instructions.
This manual should be read thoroughly before attempt-
ing to operate or service the unit.
All procedures detailed in the manuals, including in-
stallation, commissioning and maintenance tasks must
only be performed by suitably trained and qualified
personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, commission-
ing, operation or maintenance resulting from a failure
to follow the procedures and instructions detailed in
the manuals.
WARRANTY
York International warrants all equipment and materi-
als against defects in workmanship and materials for a
period of one year from initial start-up, or eighteen
months from delivery (whichever occurs first) unless
extended warranty has been agreed upon as part of the
contract.
The warranty is limited to parts only replacement and
shipping of any faulty part, or sub-assembly which has
failed due to poor quality or manufacturing errors. All
claims must be supported by evidence that the failure
has occurred within the warranty period, and that the
unit has been operated within the designed parameters
specified.
All warranty claims must specify the unit model, serial
number, order number and run hours/starts. These de-
tails are printed on the unit identification plate.
The unit warranty will be void if any modification to
the unit is carried out without prior written approval
from York International.
For warranty purposes, the following conditions must
be satisfied:
• The initial start of the unit must be carried out by
trained personnel from an Authorized YORK Ser-
vice Center. See Commissioning, page 33.
• Only genuine YORK approved spare parts, oils and
refrigerants must be used.
• All the scheduled maintenance operations detailed
in this manual must be performed at the specified
times by suitably trained and qualified personnel.
See Maintenance Section, page 81.
• Failure to satisfy any of these conditions will auto-
matically void the warranty.
SAFETY
Standards for Safety
YCWS chillers are designed and built within an ISO
9002 accredited design and manufacturing organiza-
tion. The chillers comply with the applicable sections
of the following Standards and Codes:
• ANSI/ASHRAE Standard 15, Safety Code for Me-
chanical Refrigeration
• ANSI/NFPA Standard 70, National Electrical Code
(N.E.C.)
• ASME Boiler and Pressure Vessel Code, Section
VIII Division 1
• ARI Standard 550/590-98, Centrifugal and Rotary
Screw Water Chilling Packages
In addition, the chillers conform to Underwriters Labo-
ratories (U.L.) for construction of chillers and provide
U.L./cU.L. listing label.
GENERAL CHILLER INFORMATION & SAFETY
General Chiller Information & Safety

FORM 201.24-NM2
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YORK INTERNATIONAL
1
RESPONSIBILITY FOR SAFETY
Every care has been taken in the design and manufac-
ture of the unit to ensure compliance with the safety
requirements listed above. However, the individual op-
erating or working on any machinery is primarily re-
sponsible for:
Personal safety, safety of other personnel, and the
machinery.
Correct utilization of the machinery in accordance with
the procedures detailed in the manuals.
ABOUT THIS MANUAL
The following terms are used in this document to alert
the reader to areas of potential hazard.
A Warning is given in this document to
identify a hazard which could lead to per-
sonal injury. Usually an instruction will be
given, together with a brief explanation
and the possible result of ignoring the in-
struction.
A Caution identifies 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 brief
explanation and the possible result of ig-
noring the instruction.
A Note is used to highlight additional infor-
mation which may be helpful to you but
wheretherearenospecialsafetyimplications.
The contents of this manual include suggested best
working practices and procedures. These are issued for
guidance only, and they do not take precedence over
the above stated individual responsibility and/or local
safety regulations.
This manual and any other document supplied with the
unit,are the property ofYORK whichreserves allrights.
They may not be reproduced, in whole or in part, with-
out prior written authorization from an authorized
YORK representative.
MISUSE OF EQUIPMENT
Suitability for Application
The unit is intended for cooling water or glycol solutions
and is not suitable for purposes other than those specified
intheseinstructions. Any use of the equipmentother than
its intended use, or operation of the equipment contrary
to the relevant procedures may result in injury to the op-
erator, or damage to the equipment.
The unit must not be operated outside the design pa-
rameters specified in this manual.
Structural Support
Structural support of 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
from adjacent equipment, pipework or structures. Ad-
ditional components must not be mounted on the unit.
Any such extraneous loads may cause structural fail-
ure and may result in injury to the operator, or damage
to the equipment.
General Access
There are a number of areas and features which may
be a hazard and potentially cause injury when working
on the unit unless suitable safety precautions are taken.
It is important to ensure access to the unit is restricted
to suitably qualified persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.
Pressure Systems
Theunitcontainsrefrigerantvaporandliquidunderpres-
sure, release of which can be a danger and cause injury.
The user should ensure that care is taken during instal-
lation, operation and maintenance to avoid damage to
the pressure system. No attempt should be made to gain
access to the component parts of the pressure system
other than by suitably trained and qualified personnel.
Electrical
The unit must be grounded. No installation or mainte-
nance work should be attempted on the electricalequip-
ment with out first switching OFF, isolating and lock-
ing-off the power supply. Work on live equipment must

YORK INTERNATIONAL
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only be carried out by suitably trained and qualified
personnel. No attempt should be made to gain access
to the control panel or electrical enclosures during nor-
mal operation of the unit.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally non-
toxic, non-flammable and non-corrosive, and pose no
special safety hazards. Use of gloves and safety glasses
are, however, recommended when working on the unit.
The build up of refrigerant vapor, from a leak for ex-
ample, does pose a risk of asphyxiation in confined or
enclosed spaces and attention should be given to good
ventilation. For more comprehensive information on
safety precautions for use of refrigerants and oils, refer
to the Materials Safety Data tables provided on pages 9
through 11.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the pres-
surerelief device(s). Detergentsand solvents whichmay
cause corrosion should also be avoided.
EMERGENCY SHUTDOWN
In case of emergency the electrical option panel is fitted
with an emergency stop switch CB3 (Circuit Breaker
3). Separate Circuit Breakers, CB1 (System 1) and CB2
(System 2), can also be used to stop the respective sys-
tem in an emergency. When operated, it removes the
electrical supply from the control system, thus shutting
down the unit.
General Chiller Information & Safety

FORM 201.24-NM2
9
YORK INTERNATIONAL
1
MATERIAL SAFETY DATA
SAFETY DATA R-22
Toxicity Low.
Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. R22
In Contact With Skin may be slightly irritant and liquid has a degreasing effect. Thaw affected areas with water. Remove
contaminated clothing carefully - may adhere to skin in case of freeze burns. Wash affected areas
with plenty of warm water. If symptoms occur (irritation or blistering) obtain medical attention.
In Contact With Eyes Vapor has no effect. Liquid splashes or spray may cause freeze burns. Immediately irrigate with
eyewash solution or clean water for at least 10 minutes. Obtain immediate medical attention.
Highly unlikely to occur - but should this occur freeze burn will occur. Do not induce vomiting.
Ingested Provided patient is conscious, wash mouth with water and give about (0.5 pint) 250 ml to drink.
Obtain immediate medical attention.
High levels of vapor concentration initially produce stimulation and then depression of the central
nervous system causing headaches and giddiness and may lead to unconsciousness. Can prove
suddenly fatal if the exposure has been severe.
Inhalation At higher concentration there is a danger from asphyxiation due to reduced oxygen content of
atmosphere. Remove patient to fresh air, keep warm and at rest. Administer oxygen if necessary.
Apply artificial respiration if breathing has ceased or shows signs of failing. In event of cardiac arrest
apply external cardiac massage. Obtain immediate medical attention.
Further Symptomatic and supportive theory is indicated. Cardiac sensitization has been described which
Medical Advice may, in the presence of circulating catecholamines such as adrenaline, give rise to cardiac arrythmia
and subsequent arrest following exposure to high concentrations.
A lifetime inhalation study in rats and mice gives a small excess in salivary gland tumors in male
Long Term Exposure rats only at 50,000 ppm, 10,000 ppm showed no effect. This information suggests that R22 does
not represent a carcinogenic hazard to humans.
Occupational Recommended limit: 1000 ppm v/v - 8 hr TWA 1250 ppm v/v - 12 hr TWA.
Exposure Limits
Stability Unstable.
Conditions to Avoid Use in presence of naked flames, red hot surfaces and high moisture levels.
Hazardous Reactions May react violently with sodium, potassium, barium and all other alkali and alkaline earth metals.
Incompatible materials: Magnesium and alloys containing more than 2% magnesium.
Hazardous
Decomposition Halogen acids formed by thermal decomposition.
Products Avoid inhalation of high concentrations of vapors. Atmospheric concentrations should be minimized
General Precautions and kept as low as reasonably practicable below the occupational exposure limit. The vapor is
heavier than air and collects at low level and in confined areas. Ventilate by extraction at lowest
levels.
Respiratory Protection Where doubt exists on atmospheric concentration, HSE approved breathing apparatus should be
worn. This should be self-contained or of the long breather type.
Storage Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources of heat
such as radiators. Keep at temperatures not exceeding 113°F (45°C).
Protective Clothing Wear overalls, impervious gloves and goggles/face protection.
Ensure suitable personal protective clothing and respiratory protection is worn. Provided it is safe to
do so, isolate the source of the leak. Allow small spillages to evaporate provided there is suitable
Spill / leak Procedure ventilation. Large spillages: Ventilate area. Contain spillages with sand, earth or any suitable
absorbent material. Prevent liquid from entering drains, sewers, basements and work pits since
vapor may create a suffocating atmosphere.
Disposal Best to recover and recycle. If this is not possible, destruction is to be in an approved facility which
is equipped to absorb and neutralize acids and other toxic processing products.
Fire Extinguishing Data Non-flammable.
Containers Fire exposed containers should be kept cool with water sprays. Containers may burst if overheated.
Fire Fighting Self contained breathing apparatus and protective clothing must be worn in fire conditions.
Protective Equip.
REFRIGERANT DATA:

YORK INTERNATIONAL
10
MATERIAL SAFETY DATA
Section 1 – PRODUCT NAME AND INFORMATION
Product (Trade Name and Synonyms): YORK “L” Oil
Chemical Name: Ester
Chemical Family: Polyol Ester
Formula: Proprietary
CAS#: Proprietary
Section 2 – COMPONENTS AND HAZARD STATEMENT
This product is non-hazardous. The product contains no known carcinogens. No special
warning labels are required under OSHA 29 CFR 1910.1200.
Section 3 – SAFE HANDLING AND STORAGE
Handling - Do not take internally. Avoid contact with skin, eyes, and clothing. Upon contact with skin, wash with
soap and water. Flush eyes with water for 15 minutes and consult physician. Wash contaminated
clothing before reuse.
Storage - Keep container tightly sealed when not in use. Product is hygroscopic. Storage under nitrogen
highly recommended.
Section 4 – PHYSICAL DATA
Appearance: Clear liquid, gray to yellow or light brown tint
Boiling Point: > 650°F
Vapor Pressure: <0.01 mmHg @ 20°C
Specific Gravity (water=1): 0.94-0.97
Volatiles, Percent by Volume: 0%
Odor: Mild, distinct
Solubility in Water: Negligible
Evaporation Rate (butyl acetate=1): Nil
Section 5 – FIRE AND EXPLOSION HAZARDS
Flash Point (by Cleveland Open Cup): 230-300°C
Flammable Limits: Not Established
Auto-Ignition Temperature: no data
HMIS Ratings:
Health: 0
Flammability: 1
Reactivity: 0
ExtinguishingMedia: Dry chemical; CO2 foam; water fog (see below)
Unusual Fire and Explosion Hazards: None
Special Fire Fighting Techniques: Burning fluid may evolve irritating/noxious fumes.
Firefighters should use NIOSH/MNSA-approved self-contained breath-
ing apparatus. Use water fog to cool fire-exposed containers. USE
WATER CAREFULLY NEAR EXPOSED/BURNING LIQUIDS. May
cause frothing and splashing of hot materials.
General Chiller Information & Safety

FORM 201.24-NM2
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YORK INTERNATIONAL
Section 6 – REACTIVITY DATA
Stability: Stable
HazardousPolymerization: Will not occur
Incompatible Materials: Strong oxidizers, caustic or acidic solutions
Conditions to Avoid: Excessive heat
Hazardous Decomposition Products: Analogous compounds evolve carbon monoxide, carbon dioxide,
and other unidentified fragments when burned. See Section 5.
This product may degrade some paints and rubber materials.
Section 7 – HEALTH HAZARD DATA
Threshold Limit Value: Not established
Situations to Avoid: Avoid breathing oil mists
First Aid Procedures:
Ingestion: Consult physician at once. May cause nausea and diarrhea.
Inhalation: Product is not toxic by inhalation. If oil mist is inhaled, remove to fresh air and consult
physician.
To the best of our knowledge, the toxicological properties of these compounds have not been fully investigated.
Analogous compounds are considered to be essentially non-toxic.
Section 8 – PERSONAL PROTECTION INFORMATION
RespiratoryProtection: Use in well ventilated area
Ventilation: Local exhaust
Protective Gloves: Strongly recommended, especially for prolonged exposure.
Eye/FaceProtection: Goggles
Firefighters should use NIOSH/MNSA-approved self-contained breathing apparatus. Use water fog to cool
fire-exposed containers. USE WATER CAREFULLY NEAR EXPOSED/BURNING LIQUIDS. May cause frothing
and splashing of hot material.
Section 9 – SPILL OR LEAK PROCEDURES
In Case of Spill: Wearsuitable protectiveequipment, especiallygoggles. Stopsourceof spill.Dike spillarea. Use
absorbent materials to soak up fluid (i.e. sand, sawdust, and commercially available materials).
Wash spill area with large amounts of water. Properly dispose of all materials.
Section 10 – WASTE DISPOSAL METHODS
Incinerate this product and all associated wastes in a licensed facility in accordance with Federal, State,
and local regulations.
The information in this material safety data sheet should be provided to all who use, handle, store, transport, or are
otherwise exposed to this product. YORK believes the information in this document to be reliable and up to date as
of the date of publication, but makes no guarantee that it is.
1

YORK INTERNATIONAL
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FORM 201.24-NM2
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YORK INTERNATIONAL
INTRODUCTION
YORK YCWS chillers are designed for water or wa-
ter-glycol cooling.
All models are designed for indoor installation. The
units are completely assembled with all interconnect-
ingrefrigerant piping and internalwiring, readyfor field
installation.
The unit consists of 2 screw compressors in a corre-
sponding number of separate refrigerant circuits, a shell
and tube DX evaporator, a water cooled condenser and
oil separators for each circuit.
Before delivery, the unit is pressure tested, evacuated,
and fully charged with refrigerant and oil in each of
the independent refrigerant circuits. After assembly, an
operational test is performed with water flowing
through the cooler to ensure that each refrigerant cir-
cuit operates correctly.
The unit framework is fabricated using heavy-gauge
galvanized steel which is zinc phosphate pre-treated
and powder coated to minimize corrosion.
Compressor
Twin helical semi-hermetic screw compressors, are
provided to ensure high operational efficiencies and
reliable performance. Capacity control is achieved
through a single slide valve. The compressor is a posi-
tive displacement type characterized by two helically
grooved rotors which are manufactured from forged
steel. The 50 Hz motor operates at 2950 rpm to direct
drive the male rotor which in turn drives the female
rotor on a light film of oil.
Each compressor is direct drive, semi-hermetic, rotary
twin screw type and includes the following items:
Two screw rotors, with asymmetric profiles, manufac-
tured from forged steel.
A cast iron compressor housing precision machined to
provide optimal clearance for the rotors.
Aninternal discharge checkvalve toprevent rotorback-
spin during shutdown.
An acoustically tuned, internal discharge muffler to
minimize noise, while optimizing flow for maximum
performance.
Discharge and suction shut-off service valves.
A reliable suction gas cooled high efficiency, accessible
hermetic motor with redundant overload protection us-
ing both thermistor and current overload protection.
A suction gas screen and serviceable, 0.5 micron full
flow oil filter within the compressor housing.
Refrigerant gas is injected into the void created by the
unmeshing of the five lobed male and seven lobed fe-
malerotor. Further meshing ofthe rotorscloses therotor
threadsto the suction portand progressively compresses
the gas in an axial direction to the discharge port. The
SECTION 2
PRODUCT DESCRIPTION
1 COMPRESSOR
2 COOLER
3 CONDENSER
4 POWER SECTION - SYSTEM 1
5 COMMON INPUT SECTION
6 POWER SECTION - SYSTEM 2
7 CONTROL PANEL
FIG. 1 – YCWS WATER COOLED LIQUID CHILLER
2
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YORK INTERNATIONAL
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gas is compressed in volume and increased in pressure
before exiting at a designed volume at the discharge end
ofthe rotor casing. Sincethe intake anddischarge cycles
overlap, a resulting smooth flow of gas is maintained.
The rotors are housed in a cast iron compressor hous-
ing precision machined to provide optimal clearances
for the rotors. Contact between the male and female
rotor is primarily rolling on a contact band on each of
the rotor’s pitch circle. This results in virtually no ro-
tor wear and increased reliability.
The compressor incorporates a complete anti-friction
bearing design for reduced power input and increased
reliability. Four separated, cylindrical, roller bearings
handle radial loads. Angular-contact ball bearings
handle axial loads. Together they maintain accurate
rotor positioning at all pressure ratios, thereby mini-
mizingleakage and maintainingefficiency.A springless
check valve is installed in the compressor discharge
housing to prevent compressor rotor backspin due to
system refrigerant pressure gradients during shutdown.
Motor cooling is provided by suction gas from the
evaporator flowing across the motor. Redundant over-
load protection is provided using both thermistor and
current overload protection.
The compressor is lubricated by removing oil from the
refrigerant using an external oil separator.
A 350 watt (115V 1 Ø 50 Hz) immersion heater is lo-
cated in the compressor. The heater is temperature ac-
tivated to prevent refrigerant condensation.
Motor Starting
Compressor motor starting is Star/Delta (S/D) open
transition.The starter utilizes3 motorcontactors, atran-
sition delay relay and a start relay. The starter allows
inrush current to be limited to approximately 33% LRA
for the first 4 to 10 seconds, with current increasing to
normal running current when the Delta connection is
completed.
When the microprocessor initiates a start signal to run
a compressor, the applicable relays are energized. The
transition of the relay contacts enable the ‘Star’ con-
nection of the motor start. The ‘Star’ connection of the
motor start is enabled for 4 to 10 seconds depending
upon motor current as sensed by the microprocessor.
Normally, the transition to Delta takes 10 seconds if
current is below 125% FLA. If motor current exceeds
125% FLA, the transition is made to Delta as long as
the “Star” has been enabled for at least 4 seconds.
Capacity Control
The compressors will start at the minimum load posi-
tion and provide a capacity control range from 10% to
100% per compressor using a continuous function slide
valve. The microprocessor controlled output pressure
regulating capacity control valve will command com-
pressorcapacityindependent of control valve input pres-
sure and balance the compressor capacity with the cool-
ing load.
FIG. 2 – SCREW COMPRESSOR
Product Description
LD03668
SUCTION
GAS IN
MOTOR
TERMINALS
LIFTING LUG
THREADED HOLE
OIL
HEATER ECONOMIZER
GAS IN
DISCHARGE CASE OIL INLET FROM CONDENSER CODING COIL
DISCHARGE
GAS OUT
OIL FILTER BLEED &
EVACUATION POINT
OIL FILTER
COVER PLATE
CAPACITY CONTROL SOLENOID
(CAPACITY CONTROL, 3-WAY VALVE,
IS LOCATED UNDER THE SOLENOID)
LIFTING LUG
THREADED
HOLE
OIL PRESSURE
TRANSDUCER
LOCATION
ROTOR
STATOR
LOCKING BOLT

FORM 201.24-NM2
15
YORK INTERNATIONAL
The automatic spring return of the capacity control
valve to the minimum load position will ensure com-
pressor starting at minimum motor load.
OIL SEPARATOR
Each circuit has a high efficiency, augmented gas im-
pingement type oil separator to maximize oil extrac-
tion without fragile media to break down.
The oil separator, is mounted in the discharge line of
the compressor. The high pressure discharge gas is
forced around a 90 degree bend. Oil is forced to the
outside of the separator through centrifugal action and
captured on wire mesh where it drains to the bottom of
the oil separator and into the compressor.
The oil drains back into the compressor through a re-
placeable 0.5-3.0 micron oil filter, and oil supply sole-
noid, is at high pressure. This high pressure “oil injec-
tion” forces the oil into the compressor where it is grav-
ity fed to the rotors and bearings for lubrication.
After lubricating the rotor and bearings, it is injected
through orifices on a closed thread near the suction end
of the rotors. The oil is automatically injected because
of the pressure difference between the discharge pres-
sure and the reduced pressure at the suction end of the
rotors. This lubricates the rotors as well as provides an
oil seal against leakage around the rotors to assure re-
frigerant compression (volumetric efficiency).
The oil also provides cooling by transferring much of
the heat of compression from the gas to the oil keeping
discharge temperatures down and reducing the chance
for oil breakdown.
Oil injected into the rotor cage flows into the rotors at
a point about 1.2 x suction. This assures that a required
minimum differential of at least 1.8 bar exists between
discharge and 1.2 x suction, to force oil into rotor case,
a minimum of 0.6 bar is all that is required to assure
protection of the compressor. Oil pressure is measured
as the difference between discharge pressure and the
pressure of the oil entering the rotor case.
Maximum working pressure of the oil separator is 31
bar (450 psi). A relief valve is installed in the oil sepa-
rator piping. The oil level should be above the mid-
point of the “lower” oil sight glass when the compres-
sor is running. The oil level should never be above the
top of the “upper” sight glass.
Oil temperature control is provided through liquid in-
jection activated by the microprocessor, utilizing a tem-
perature sensor, and a solenoid valve.
OIL COOLER
Compressor oil cooling is provided by refrigerant liq-
uid, which is injected into the rotor suction when the
temperature setpoint has been exceeded.
REFRIGERANT CIRCUITS
Each refrigerant circuit uses copper refrigerant pipe
formed on computer controlled bending machines to
reduce the number of brazed joints resulting in a reli-
able and leak resistant system.
Liquid line components include: a manual shut-off
valve with charging port, a high absorption removable
core filter-drier, a solenoid valve, a sight glass with
moisture indicator, and a thermostatic expansion valve.
Suction lines are covered with closed-cell insulation.
CONDENSER
The dual refrigerant circuit water-cooled condenser is
a cleanable shell and tube type with seamless external
finned 19 mm OD copper tubes rolled into tube sheets.
The design working pressures are 10 bar g on the wa-
terside and 23 bar (330 PSIG) on the refrigerant side
which is protected by pressure relief valve(s).
The condenser has removable steel water heads. The
water nozzles are provided with grooves for victualic
couplings.
COOLER
The 4 pass dual circuit shell and tube type direct ex-
pansion (DX) evaporator has chilled liquid circulating
back and forth across the tubes from one end to the
other. The design working pressures of the cooler are
10 bar (150 psi) on the waterside (shell) and 20 bar
(300 psi) on the refrigerant side (tubes) which is pro-
tected by pressure relief valve(s).
The water baffles are fabricated from galvanized steel
to resist corrosion. Removable heads are provided for
access to internally enhanced, seamless, copper tubes.
Water vent and drain connections are included. The
cooler is insulated with flexible closed-cell foam.
2

YORK INTERNATIONAL
16
The water nozzles are provided with grooves for
victualic couplings and should be insulated by the con-
tractor after pipe installation.
POWER AND CONTROL PANELS
All controls and motor starting equipment are factory
wired and function tested. The panel enclosures are
designed to IP33 and are manufactured from powder
painted galvanized steel.
The panel is divided into power sections for each elec-
trical system, a control section and a common input
section. Each section has separate hinged, latched, and
gasket sealed doors.
Each power section contains:
Compressor starting contactors, control circuit serving
compressor, compressor contactor coils and compres-
sor motor overloads.
The current transformers for the compressor motor
overloads sense each phase, as an input to the micro-
processor. This protects the compressor motors from
damage due to: low input current, high input current,
unbalanced current, single phasing, phase reversal, and
compressor locked rotor.
The control section contains:
On/Off toggle switch, microcomputer keypad and dis-
play, microprocessorboard (ARB),I/O expansion board
(AIOB), power supply board (APB) and customer ter-
minal block (-XTB1).
MICROPROCESSOR CONTROLS
The microprocessor has the following functions and
displays:
A liquid crystal 40 character display with text provided
on two lines and light emitting diode backlighting for
outdoor viewing.
A color coded, 35 button, sealed keypad with sections
for Display, Entry, Setpoints, Clock, Print, Program and
the unit Auto/Off switch.
The standard functions include: water or glycol cool-
ing, automatic pump down, demand load limiting from
external building automation system input, remote re-
set liquid temperature reset input, unit alarm and sta-
tus contacts, chilled liquid pump control, automatic re-
set after power failure, automatic system optimization
to match operating conditions.
The software is stored in non-volatile memory
(EPROM) to eliminate unit failure due to AC power
failure. The programmed setpoint is stored in a lithium
battery backed memory.
MOTOR CURRENT PROTECTION
Themicroprocessor motor protection provideshigh cur-
rent protection to assure that the motor is not damaged
due to voltage, excess refrigerant, or other problems
that could cause excessive motor current.
If the motor current exceeds the 115% FLA trip point
after3 seconds ofoperation oneither Star/Deltaor DOL
starters, the microprocessor will shut the system down
and lock it out after one fault. A manual reset of the
respective system switch is required to clear the fault
and restart the system. A thorough check of the motor,
wiring, and refrigerant system should be carried out
before restarting a system that has faulted on high mo-
tor current.
The microprocessor also provides low motor current
protection when it senses a motor current less than
10% FLA. Low motor current protection is activated 4
seconds after start on Star/Delta to allow the motor to
start. The microprocessor will shut the system down
whenever low motor current is sensed and will lock
out a system if three faults occur in 90 minutes. Once a
system is locked out on Low Motor Current, it must be
manually reset with the system switch.
The microprocessor also senses low motor current
whenever a High Pressure Cutout (HPCO) or Motor
Protector (MP) contact opens. The MP and HPCO con-
tacts are connected in series with the motor contactor.
Whenevereither of these devicesare open, thecontactor
de-energizes and the motor shuts down. Since the mi-
croprocessor is sending a run signal to the contactor, it
senses the low motor current below 10% FLA and shuts
the system down.
Product Description

FORM 201.24-NM2
17
YORK INTERNATIONAL
Motor Protector Module
The mechanical motor protector module provides ther-
mal and current motor overload protection. This mod-
ule protects against phase to phase current imbalance,
over current, under current, and phase rotation. The
module, mounted in the power panel, utilizes a 7 seg-
ment display which provides operating status and fault
diagnostic information. The 7 segment display will dis-
playeither a stationaryor aflashing alphanumericvalue
which can be decoded by the operator:
Whenever a motor protector trips, the motor protector
contacts wired in series with the motor contacts, open
and the motor contactor de-energizes allowing the mo-
tor to stop. The microprocessor senses the low motor
current and shuts the system down. The microproces-
sor will try two more starts before locking the system
out. The system locks out because the motor protector
is a manual reset device. After the first start the protec-
tor contacts will be open, thus preventing the motor
contactors from energizing. Power must be removed
and re-applied to reset the module.
Current Overload
The protector module uses integral current transform-
ers per phase to provide protection against rapid cur-
rent overload conditions. The module responds to
changes in current and must be set-up using the DIP
switches located on the module (refer to Section 5 for
details). Integral trip curves allow for in-rush currents
during Star/Delta and DOL starting without nuisance
tripping.
Thermal Overload
Three PTC (positive temperature coefficient) ther-
mistors in the motor windings of each phase provide
thermal protection. The sensor resistance stays rela-
tively constant at 1 kW until a temperature of 130°C
(266°F) is sensed. The sensor experiences a rapid rise
in resistance beyond this temperature. Whenever the
resistance of one of the sensors reaches 13 kW, the
module trips, which ultimately de-energizes the motor’s
pilot circuit. Reset is manual after the motor cools and
the sensor resistance drops to 3.25 kW.
Current Unbalance (Loaded & Unloaded)
Loss of Phase
A 2 second delay at start-up allows for any unbalances
resulting during normal starting conditions. After this
initial delay, the protector module compares the “Op-
erating Current” to the measured half line current. The
“Operating Current” is given by 0.65 x factory over-
load current setting.
An unloaded compressor condition occurs when any
measured half line current is less than the “Operating
Current.” A current unbalance exceeding an unloaded
level of 25% will result in the motor pilot circuit being
de-energized.
A loaded compressor condition occurs when any mea-
sured half line current is greater than or equal to the
“Operating Current.” A current unbalance exceeding a
loaded level of 17% will result in the motor pilot cir-
cuit being de-energized.
Improper Phase Sequence
The protector module calculates the phase sequence at
start-up using the three current transducers to deter-
mine whether the three phase sequence on the load side
of the main contactor is miswired. Upon detection of a
miswired motor load, the module will de-energize the
main contactor pilot circuit within 50 millisecond re-
sponse time.
KEYPAD CONTROLS
For a detailed description of the keypad controls refer
to the Microprocessor Based Control System Operat-
ing Section 7.
Status Key
This key provides a display of the current operational
and/or fault status of the unit or the individual refriger-
0 NORMAL - NO FAULT DETECTED
FLASHING “0”MOTOR OFF OR UNLOADED < 5A AC
CURRENT LEVEL
1 HIGH CURRENT FAULT
2 LOADED PHASE TO PHASE CURRENT
IMBALANCE > 17%
3 UNLOADED PHASE TO PHASE
CURRENT IMBALANCE > 25%
4 IMPROPER INCOMING PHASE
ROTATION
5 HIGH MOTOR TEMPERATURE
TRIP POINT = 13 KOHM RESET =
3.25 KOHM
6 COMMUNICATION ERROR
E OUT OF RANGE OF RLA CALIBRATION
OTHER DEFECTIVE MODULE OR SUPPLY
SYMBOLS VOLTAGE
TABLE 1 – MOTOR PROTECTOR FAULTS
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ant systems. The display will show the ‘highest prior-
ity’ information as determined by the microprocessor.
The main categories of messages are: General Status
Messages; Unit Warnings; Anticipation Control Status
Messages; Chiller Fault Status Messages; System Fault
Status Messages.
Display Keys
Each key provides a real-time display of commonly re-
quired information about the chiller and individual re-
frigerant system operating conditions and settings. This
is particularly useful during commissioning, monitor-
ing the operation of the chiller, diagnosing potential
future problems and service troubleshooting. Param-
eters may be displayed in Imperial (°F and PSIG) or
Metric (°C and bar) units.
Print Keys
These keys allow control panel display or remote print-
outof both currentreal-time operatingand programmed
data as well as fault history data from the most recent
six safety shutdowns.
Entry Keys
The numeric and associated keys are used for enter-
ing data required for programming the chiller. The
‘ENTER’ and ‘á’ ‘â’ keys are also used for scroll-
ing through information available after pressing other
keys.
Setpoints Keys
These keys are used for display and programming of
the local and remote offset chilled liquid temperature
setpoints.
Clock Keys
These keys are used for display and programming of
the clock and operating schedule for the chiller.
Program Key
This key is used for display and programming of the
chiller operational settings and limits.
ACCESSORIES AND OPTIONS
Power Supply Options (All Models)
Units are available with either single-point or multi
point power supply connections:
Single-Point Power Supply Connection – One field
provided 400V, 3Ø, 50 Hz supply to the unit with cir-
cuit protection. Field connections to factory provided
terminal block or door interlocked non-fused discon-
nect switch in the common input section. Internal
branch door interlocked circuit breakers or fuses for
each circuit in the two power panels. The control sys-
tem supply is derived internally.
Multi Point Power Supply Connection – Two field
provided 400V, 3Ø, 50 Hz supplies to the unit with
circuit protection. Field connections to factory provided
terminal block or door interlocked circuit breakers in
each of the two NFDS Power Panels.
Building Automation System (BAS) Interface
Provides a means to reset the leaving chilled liquid tem-
perature and/or percent full load amps (current limit-
ing) from the BAS (Factory-mounted):
Printed circuit board to accept 4 to 20mA, 0 to 10VDC,
or dry contact closure input from the BAS.
A YORK ISN Building Automation
System can provide a Pulse Width
Modulated(PWM)signal directtothe
standard control panel via the stan-
dard on-board RS485 port.
Multi-Unit Sequence Control
A factory-mounted Sequencing Control Center to man-
age sequencing control of up to eight chillers in paral-
lel based on mixed liquid temperature (interconnect-
ing wiring by others).
Pressure Vessel Codes
Coolers and condensers can be supplied in conform-
ance with the following pressure vessel codes:
• A.S.M.E. (Standard)
VIBRATION ISOLATION
Neoprene Pad Isolation – Recommended for normal
installations. (Field-mounted)
1"(25 mm)spring isolators–Level adjustable, spring
and cage type isolators for mounting under the unit base
rails. (Field-mounted)
Product Description

FORM 201.24-NM2
19
YORK INTERNATIONAL
Flange Kits (150 PSI)
Factory fitted flanges to convert grooved cooler/con-
denser water nozzles to flanged connections. Available
in weld or victaulic style with companion flanges for
field-mounting.
Language LCD and Keypad
Standarddisplay language andkeypad isEnglish. Span-
ish is available as an option.
Flow Switch Accessory
JohnsonControls Model F61MG-1C Vapor-proofSPDT,
NEMA 4X switch, 150 PSIG (10 bar) DWP, -20°F to
250°F (-29°C to 121°C), with 1" NPT (IPS) connection
for upright mounting in horizontal pipe. A flow switch
must be field installed with each unit.
Printer
Hand held printer for obtaining printout of unit operat-
ing data and history data.
2

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FUNCTIONAL DESCRIPTION
NOMENCLATURE
Low pressure liquid refrigerant enters the cooler tubes
and is evaporated and superheated by the heat energy
absorbed from the chilled liquid passing through the
cooler shell. Low pressure vapor enters the compres-
sor where pressure and superheat are increased. High
pressure vapor is passed through the oil separator where
compressor oil is removed and recirculated to the com-
pressor. High pressure superheated refrigerant enters
the condenser shell where heat is rejected to the con-
denser water passing through the tubes. The fully con-
densed and subcooled liquid leaves the condenser and
enters the expansion valve, where pressure reduction
and further cooling takes place. The low pressure liq-
uid refrigerant then returns to the cooler. Each refrig-
erant circuit utilizes a refrigerant to refrigerant suction
line heat exchanger to maximize chiller capacity and
efficiency by subcooling liquid refrigerant delivered
to the expansion valve and superheating suction gas
delivered to the compressor.
FIG. 3 – FLOW DIAGRAM
Product Description
LD06817
YCWS0313SC50YAA
:Design Series F
:Engineering
Change
or PIN Level
: YORK
: Chiller
: Water Cooled
: Screw
kW Standard Unit
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN / DEVELOPMENT LEVEL
Y #### S C 5 0 A
CYA
WS
: 0313: 0373: 0423
: 0503: 0613: 0563
: 0663
:R-22 :Wye-Delta