Professional Documents
Culture Documents
201 18-NM3
201 18-NM3
MILLENNIUM ®
YCAS AIR COOLED LIQUID CHILLER
YCAS 250, 270, 300, 330 (3 COMPRESSOR)
YCAS 360, 400, 440 (4 COMPRESSOR)
STYLE F
60 Hz
00258VIP
031-01798-002 031-01798-002
031-02018-001 031-02018-001
TABLE OF CONTENTS
SECTION 1 GENERAL CHILLER Multiple Point Power Connection (Standard) ......... 23
INFORMATION & SAFETY Single-Point Power Connection
Introduction ............................................................. 6 with Individual Circuit Protection ........................... 23
Warranty .................................................................. 6 Single-Point Power Connection
Safety ........................................................................ 6 with Combined Circuit Protection ........................... 23
Standards for Safety .................................................. 6 Single-Point Power Connection
without Circuit Protection ....................................... 23
Responsibility for Safety ......................................... 7
Control Circuit Terminal Block ............................... 23
About this Manual ................................................... 7
Building Automation System (BAS) Interface ........ 23
Misuse of Equipment ............................................... 7
Condenser Coil Protection ...................................... 23
Suitability for Application ......................................... 7
DX Cooler Options ................................................ 24
Structural Support ...................................................... 7
300 PSIG (21 bar) Waterside Design Working
Mechanical Strength .................................................. 7
Pressure .................................................................... 24
General Access .......................................................... 7
1-1/2" (38 mm) Insulation ....................................... 24
Pressure Systems ....................................................... 7
Flange Accessory ..................................................... 24
Electrical .................................................................... 7
Remote DX Cooler .................................................. 24
Rotating Parts ............................................................ 8
Flow Switch Accessory ........................................... 24
Sharp Edges ............................................................... 8
Star-Delta Compressor Motor Starter ..................... 24
Refrigerants and Oils ................................................. 8
Unit Enclosures ...................................................... 24
High Temperature and Pressure Cleaning ................. 8
Fans ......................................................................... 24
Emergency Shutdown ............................................. 8
Sound Reduction Options ..................................... 24
Material Safety Data ............................................... 9
Vibration Isolation ................................................. 24
SECTION 2 PRODUCT DESCRIPTION Unit Nomenclature and Nameplate
Engineering Data ................................................... 25
Introduction ........................................................... 12
Basic Part Number ................................................... 25
General Description ................................................. 12
Options Section of Part Number ............................. 25
Compressor .............................................................. 12
Evaporator ............................................................... 13 SECTION 3 HANDLING AND STORAGE
Condenser ................................................................ 13 Delivery and Storage ............................................. 27
Economizer .............................................................. 14 Inspection ............................................................... 27
Oil Separator / System ............................................. 14 Moving the Chiller ................................................ 27
Oil Cooling .............................................................. 15 Lifting Weights ........................................................ 27
Capacity Control ...................................................... 15 Unit Rigging ........................................................... 28
Power and Control Panel ......................................... 15
Microprocessor Controls ......................................... 15 SECTION 4 INSTALLATION
Motor Current Protection ........................................ 15 Location Requirements ......................................... 29
Motor Protector Module .......................................... 16 Outdoor Installations ............................................ 29
Current Overload ..................................................... 16 Indoor Installations ............................................... 29
Thermal Overload .................................................... 17 Location Clearances .............................................. 29
Current Imbalance ................................................... 17 Installation of Vibration Isolators ....................... 30
Improper Phase Sequence ....................................... 17 Installation ............................................................... 30
Motor Protector Dip Switch Settings ...................... 18 Shipping Braces ..................................................... 30
Motor Starting ....................................................... 22 Pipework Connection ............................................ 30
Keypad Controls .................................................... 22 General Requirements ............................................. 30
Display ..................................................................... 22 Water Treatment .................................................... 31
Entry ........................................................................ 23 Pipework Arrangement......................................... 31
Setpoints .................................................................. 23 Connection Types & Sizes ..................................... 32
Clock ........................................................................ 23 Cooler Connections ............................................... 32
Print ......................................................................... 23 Option Flanges ......................................................... 32
Program ................................................................... 23 Refrigerant Relief Valve Piping ........................... 32
Accessories and Options ....................................... 23 Ductwork Connection ........................................... 32
2 YORK INTERNATIONAL
FORM 201.18-NM3
YORK INTERNATIONAL 3
TABLE OF CONTENTS (CONT’D)
Compressor Components .................................... 126
System Startup Checklist .................................... 132
Unit Checks ........................................................... 132
Panel Checks .......................................................... 133
Initial Start-up ..................................................... 134
Checking Subcooling and Superheat ................. 134
Checking Economizer Superheat ....................... 135
Leak Checking ..................................................... 135
4 YORK INTERNATIONAL
FORM 201.18-NM3
This manual and the Microprocessor Operating Instruc- • Only genuine YORK approved spare parts, oils and
tions contain all the information required for correct refrigerants must be used. Recommendations on
installation and commissioning of the unit, together with spare parts can be found on page 189.
operating and maintenance instructions. The manuals
should be read thoroughly before attempting to operate • All the scheduled maintenance operations detailed
or service the unit. in this manual must be performed at the specified
times by suitably trained and qualified personnel.
All procedures detailed in the manuals, including in- See Maintenance Section, page 187.
stallation, commissioning and maintenance tasks must
only be performed by suitably trained and qualified
personnel. • Failure to satisfy any of these conditions will auto-
matically void the warranty. See Warranty Policy,
The manufacturer will not be liable for any injury or page 193.
damage caused by incorrect installation, commission-
ing, operation or maintenance resulting from a failure SAFETY
to follow the procedures and instructions detailed in Standards for Safety
the manuals. YCAS Millennium chillers are designed and built within
an ISO 9002 accredited design and manufacturing or-
WARRANTY ganization. The chillers comply with the applicable sec-
tions of the following Standards and Codes:
York International warrants all equipment and materi-
als against defects in workmanship and materials for a • ANSI/ASHRAE Standard 15, Safety Code for Me-
period of one year from initial start-up, or eighteen chanical Refrigeration
months from delivery (whichever occurs first) unless
extended warranty has been agreed upon as part of the
contract. • ANSI/NFPA Standard 70, National Electrical Code
(N.E.C.)
The warranty is limited to parts only replacement and
shipping of any faulty part, or sub-assembly which has • ASME Boiler and Pressure Vessel Code, Section
failed due to poor quality or manufacturing errors. All VIII Division 1
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 • ARI Standard 550/590-98, Centrifugal and Rotary
specified. Screw Water Chilling Packages
All warranty claims must specify the unit model, serial In addition, the chillers conform to Underwriters Labo-
number, order number and run hours/starts. These de- ratories (U.L.) for construction of chillers and provide
tails are printed on the unit identification plate. U.L./cU.L. listing label.
6 YORK INTERNATIONAL
FORM 201.18-NM3
Every care has been taken in the design and manufac- Suitability for Application 1
ture of the unit to ensure compliance with the safety The unit is intended for cooling water or glycol solu-
requirements listed above. However, the individual op- tions and is not suitable for purposes other than those
erating or working on any machinery is primarily re- specified in these instructions. Any use of the equipment
sponsible for: other than its intended use, or operation of the equip-
ment contrary to the relevant procedures may result in
Personal safety, safety of other personnel, and the ma- injury to the operator, or damage to the equipment.
chinery.
The unit must not be operated outside the design pa-
Correct utilization of the machinery in accordance with rameters specified in this manual.
the procedures detailed in the manuals.
Structural Support
ABOUT THIS MANUAL Structural support of the unit must be provided as indi-
cated in these instructions. Failure to provide proper
The following terms are used in this document to alert support may result in injury to the operator, or damage
the reader to areas of potential hazard. to the equipment and/or building.
YORK INTERNATIONAL 7
General Chiller Information & Safety
ment without first switching OFF, isolating and lock- are, however, recommended when working on the unit.
ing-off the power supply. Work on live equipment must The build up of refrigerant vapor, from a leak for ex-
only be carried out by suitably trained and qualified ample, does pose a risk of asphyxiation in confined or
personnel. No attempt should be made to gain access enclosed spaces and attention should be given to good
to the control panel or electrical enclosures during nor- ventilation. For more comprehensive information on
mal operation of the unit. safety precautions for use of refrigerants and oils, refer
to the Materials Safety Data tables provided on pages 9
through 11.
Rotating Parts
Fan guards must be fitted at all times and not removed High Temperature and Pressure Cleaning
unless the power supply has been isolated. If ductwork High temperature and pressure cleaning methods (e.g.
is to be fitted, requiring the wire fan guards to be re- steam cleaning) should not be used on any part of the
moved, alternative safety measures must be taken to pressure system as this may cause operation of the pres-
protect against the risk of injury from rotating fans. sure relief device(s). Detergents and solvents which may
cause corrosion should also be avoided.
Sharp Edges
EMERGENCY SHUTDOWN
The finning on the air cooled condenser coils has sharp
metal edges. Reasonable care should be taken when
In case of emergency the electrical option panel is fit-
working in contact with the coils to avoid the risk of
ted with an emergency stop switch CB4 (3 System) or
minor abrasions and lacerations. The use of gloves is
CB5 (4 System) located in the bottom right of the Mi-
recommended.
croprocessor Panel. Separate Circuit Breakers, CB1
(System 1), CB2 (System 2), CB3 (System 3), and CB4
Refrigerants and Oils (System 4) can also be used to stop the respective sys-
Refrigerants and oils used in the unit are generally non- tem in an emergency. When operated, it removes the
toxic, non-flammable and non-corrosive, and pose no electrical supply from the control system, thus shutting
special safety hazards. Use of gloves and safety glasses down the unit.
8 YORK INTERNATIONAL
FORM 201.18-NM3
YORK INTERNATIONAL 9
General Chiller Information & Safety
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.
10 YORK INTERNATIONAL
FORM 201.18-NM3
Stability: Stable 1
Hazardous Polymerization: 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.
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.
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.
In Case of Spill: Wear suitable protective equipment, especially goggles. Stop source of spill. Dike spill area. 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.
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. CPI 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.
YORK INTERNATIONAL 11
Product Description
PRODUCT DESCRIPTION
1 System Fans
2 System 1 Power Panel
3 System 2 Power Panel
4 Control Panel
5 Power Entry 1
6 System 2 Compressor
7 Cooler (Evaporator)
8 System 4 Compressor 9
9 System 2 Condenser
10 Option Box
7
8
6
4
2 3 10 5
00258VIP
Refrigerant gas is injected into the void created by the The compressor is lubricated by removing oil from the
unmeshing of the five lobed male and seven lobed fe- refrigerant using an external oil separator. The pres-
male rotor. Further meshing of the rotors closes the ro- surized oil is then cooled in the condenser coils and
tor threads to the suction port and progressively com- piped back to the compressor for lubrication. The com-
presses the gas in an axial direction to the discharge pressor design working pressure is 450 PSIG (31 bar).
port. The gas is compressed in volume and increased in Each chiller receives a 300 PSIG (21 bar) low side and
pressure before exiting at a designed volume at the dis- a 450 PSIG (31 bar) high side factory test. A 350 watt
charge end of the rotor casing. Since the intake and dis- (115-1-60) cartridge heater is located in the compres-
charge cycles overlap, a resulting smooth flow of gas is sor. The heater is temperature activated to prevent re-
maintained. frigerant condensation.
The rotors are housed in a cast iron compressor hous- The following items are also included:
ing precision machined to provide optimal clearances
for the rotors. Contact between the male and female • Internal discharge check valve to prevent rotor back-
rotor is primarily rolling on a contact band on each of spin or shutdown.
the rotor’s pitch circle. This results in virtually no rotor • An acoustically tuned, internal discharge muffler
wear and increased reliability, a trademark of the screw to minimize noise, while operating flow for maxi-
compressor. mum performance.
The compressor incorporates a complete anti-friction • Discharge and suction shutoff valves.
bearing design for reduced power input and increased
• A rain-tight terminal box.
reliability. Four separated, cylindrical, roller bearings
handle radial loads. Angular-contact ball bearings • A suction gas screen and serviceable, 0.5 micron
handle axial loads. Together they maintain accurate full flow oil filter within the compressor housing.
rotor positioning at all pressure ratios, thereby mini- 2
mizing leakage and maintaining efficiency. A springless Evaporator
check valve is installed in the compressor discharge The system uses a high efficiency Shell and Tube type
housing to prevent compressor rotor backspin due to Direct Expansion Evaporator. Each of the refrigerant
system refrigerant pressure gradients during shutdown. circuits (2, 3, 4 circuits) consists of 4 passes with the
chilled liquid circulating back and forth across the tubes
Motor cooling is provided by suction gas from the from one end to the other.
evaporator flowing across the motor. Redundant over-
load protection is provided using both thermistor and The design working pressure of the cooler on the shell
current overload protection. side is 150 PSIG (10 bar), and 350 PSIG (24 bar) for
the tube (refrigerant side). The water baffles are fabri-
cated from galvanized steel to resist corrosion. Remov-
able heads are provided for access to internally en-
hanced, seamless, copper tubes. Water vent and drain
connections are included.
Condenser
The fin and tube condenser coils are manufactured from
seamless, internally enhanced, high condensing coeffi-
LD03674
FIG. 2 – SCREW COMPRESSOR cient, corrosion resistant copper tubes arranged in stag-
YORK INTERNATIONAL 13
Product Description
gered rows and mechanically expanded into corrosion microprocessor. The valve will remain off for the first
resistant aluminum alloy fins with full height fin col- 3 minutes of compressor operation. After 3 minutes of
lars. They have a design working pressure of 450 PSIG operation, the economizer solenoid valve will open if
(31 bar). Each coil is rested to 495 PSIG (34 bar). the slide valve position is > Step 47, and the pressure
ratio (PR) of discharge pressure to suction pressure is
Multiple fans move air through the coils. They are dy- greater than 2.2 using the following formula:
namically and statically balanced, direct drive with cor-
rosion resistant glass fiber reinforced composite blades
molded into low noise, full airfoil cross section, pro- English: PR = DP (PSIG) + 14.7
viding vertical air discharge from extended orifices for SP (PSIG) + 14.7
efficiency and low sound. Each fan is located in a sepa-
rate compartment to prevent cross flow during fan cy-
cling. Guards of heavy gauge, PVC coated galvanized Metric: PR = DP (BAR) + 1
steel are provided. SP (BAR) + 1
The fan motors are high efficiency, direct drive, 6-pole, The economizer valve will be turned off if the pressure
3-phase, Class- “F,” current overload protected, totally ratio drops below 2.0. It will also turn off if slide valve
enclosed (TEAO) type with double sealed, permanently position drops below Step 44. Under these conditions,
lubricated ball bearings. the valve is closed due to the lack of efficiency im-
provement available from the economizer.
Economizer
(Models YCAS 270, 330, 440) Oil Separator/System
A plate and frame heat exchanger (economizer) is fit- The external oil separator, with no moving parts and
ted to both refrigerant circuits on models YCAS 270, designed for minimum oil carry-over, is mounted in the
330, 440. This increases the efficiency of the system discharge line of the compressor. The high pressure dis-
by subcooling the primary refrigerant liquid to the charge gas is forced around a 90 degree bend. Oil is
evaporator. forced to the outside of the separator through centrifu-
gal action and captured on wire mesh where it drains to
The wet vapor to the economizer is supplied by a small the bottom of the oil separator and into the compressor.
15 ton TXV set for 10°F (5.5°C) superheat that flashes
off 10 - 20% of the liquid from the condenser. 10 - 12 The oil (YORK “L” oil – a POE oil used for all refrig-
tons are utilized for subcooling liquid refrigerant. The erant applications), which drains back into the com-
wet vapor is at an intermediate pressure between dis- pressor through a replaceable 0.5 - 3.0 micron oil filter,
charge and suction (1.7 x suction) and therefore little and oil supply solenoid, is at high pressure. This high
energy is required to pump it back through the com- pressure “oil injection” forces the oil into the compres-
pressor to condenser pressure. This results in a very sor where it is gravity fed to the gears and bearings for
small loss to system efficiency. lubrication. After lubricating the gears and bearings, it
is injected through orifices on a closed thread near the
The economizer provides approximately 25°F (14°C) suction end of the rotors. The oil is automatically in-
of additional subcooling to the liquid refrigerant which jected because of the pressure difference between the
flows to the evaporator at 95°F (35°C) ambient, 55°F discharge pressure and the reduced pressure at the suc-
(13°C) RWT, 44°F (7°C) LWT. Subcooling will drop tion end of the rotors. This lubricates the rotors as well
to approximately 0°F below 90°F (32°C) ambient. The as provides an oil seal against leakage around the ro-
subcooled liquid is then fed to the primary TXV in the tors to assure refrigerant compression (volumetric effi-
system. This additional subcooling results in a signifi- ciency). The oil also provides cooling by transferring
cant increase in the efficiency of the system. The de- much of the heat of compression from the gas to the oil
sign working pressure of the economizer is 450 PSIG keeping discharge temperatures down and reducing the
(31 bar). The economizer liquid supply solenoid is ac- chance for oil breakdown. Oil injected into the rotor
tivated on start-up coincident with the liquid line sole- cage flows into the rotors at a point about 1.2x suction.
noid, after pumpdown. This assures that a required minimum differential of at
least 30 PSID exists between discharge and 1.2x suc-
The economizer operation is controlled by the econo- tion, to force oil into rotor case, a minimum of 10 PSID
mizer solenoid valve. This valve is controlled by the (0.6 bar) is all that is required to assure protection of
14 YORK INTERNATIONAL
FORM 201.18-NM3
the compressor. Oil pressure safety is monitored as the pacity control, compressor and fan contactor coils and
difference between suction and the pressure of the oil compressor motor overloads.
entering the rotor case.
The current transformers for the compressor motor over-
Maximum working pressure of the oil separator is 450 loads sense each phase, as an input to the microproces-
PSIG (31 bar). A relief valve is installed in the oil sepa- sor. This protects the compressor motors from damage
rator piping. This will soon be incorporated into the oil due to: low current input, high input current, unbal-
separator. Oil level should be above the midpoint of anced current, single phasing, phase reversal, and com-
the “lower” oil sight glass when the compressor is run- pressor locked rotor.
ning. Oil level should not be above the top of the “up-
per” sight glass. Oil temperature control is provided The control section contains:
through liquid injection activated by the microproces- ON/OFF switch, microcomputer keypad and display,
sor, utilizing a discharge temperature sensor, and a so- microprocessor board, I/O expansion board, relay
lenoid valve. boards and power supply board.
Automatic spring return of the slide valve to the mini- The standard controls shall include: brine chilling, ther-
mum load position will ensure compressor starting at mal storage, automatic pump down, run signal contacts,
minimum motor load. demand load limit from external building automation
system input, remote reset liquid temperature reset in-
Power and Control Panel put, unit alarm contacts, chilled liquid pump control,
All controls and motor starting equipment are factory automatic reset after power failure, automatic system
wired and function tested. The panel enclosures are de- optimization to match operating conditions.
signed to IP55 and are manufactured from powder
painted galvanized steel. The software is stored in non-volatile memory
(EPROM) to eliminate chiller failure due to AC power
The Power and Control Panel are divided into power failure. The Programmed Setpoint is stored in lithium
sections for each compressor and associated fans, a con- battery backed memory.
trol section and an electrical options section. The power
and control sections have separate hinged, latched, and Motor Current Protection
gasket sealed doors equipped with wind struts.
The microprocessor motor protection provides high cur-
rent protection to assure that the motor is not damaged
Each power compartment contains: due to voltage, excess refrigerant, or other problems
Compressor and fan starting contactors, fan motor ex- that could cause excessive motor current. This is ac-
ternal overloads, control circuit serving compressor ca- complished by sending 3-phase current signals propor-
YORK INTERNATIONAL 15
Product Description
tional to motor current from the Motor Protector mod- HAXXX Normal motor OFF display. Sequentially
ule to the Power Supply Board where the signals are sweeps through the motor protection dip
conditioned and routed to the I/O Expansion board to switch setting.
be multiplexed and sent to the Microprocessor Board. 0 Normal - no fault detected (Running)
If the motor current exceeds the 115% FLA trip point Flashing “0” Motor off or unloaded < 5A (Running)
after 3 seconds of operation on either Wye-Delta or AC current level.
ACL starters, the micro will shut the system down and 1 High current fault.
lock it out after one fault. A manual reset of the re- Loaded phase to phase current
2
spective system switch is required to clear the fault imbalance > 17%.
and restart the system. A thorough check of the mo- Unloaded phase to phase current
3
tor, wiring, and refrigerant system should be done be- imbalance > 25%.
fore restarting a system that has faulted on high motor 4 Improper incoming phase rotation.
current. High motor temperature. Trip point =
5
13kW, reset = 3.25kW.
The micro also provides low motor current protection 6 Communication error.
when it senses a motor current less than 10% FLA. The 7 Unload imbalance ( > 50%)
micro will shut the system down whenever low motor 8 Phase Loss (> 60%)
current is sensed and will lock out a system if three E Out of range of RLA calibration.
faults occur in 90 minutes. Low motor current protec- Other symbols Defective module or supply voltage.
tion is activated 4 seconds after start on both Wye-Delta Working voltage 18 - 30 VAC, 224 VAC nominal.
and ACL starters to assure the motor starts, the system Low voltage trip = 15 VAC.
doesn’t run without refrigerant, the motor protector is
not tripped, and the mechanical high pressure cut-out Whenever a motor protector trips, the motor protec-
is not tripped. Once the system is locked out on Low tor contacts wired in series with the motor contacts
Motor Current, it must be manually reset with the sys- opens and the motor contactor de-energizes allowing
tem switch. See also Motor Protector Module section the motor to stop. The micro senses the low motor
on page 16. current and shuts the system down. The micro will try
two more starts before locking the system out. The
The micro senses low motor current whenever a HPCO system locks out because the motor protector is a
or Motor Protector contact opens. This occurs because manual reset device. After the first start the modules’
the MP and HPCO contacts are in series with the motor contacts will be open preventing the motor contactors
contactor. Whenever either of these devices are open, from energizing. Power must be removed and reapplied
the contactor de-energizes and the motor shuts down. to reset the module.
Since the micro is sending a run signal to the contactor,
it senses the low motor current below 10% FLA and Current Overload
shuts the system down. The 2ACE module design uses one integral current
transformer per phase to provide protection against
Motor Protector Module rapid current overload conditions. The module responds
The mechanical motor protector is a Texas Instruments to changes in current and must be calibrated using DIP
2ACE Three Phase Protection Module (Fig. 70, pages switches located on the module. Integral trip curves al-
140 and 141) thermal and current motor overload pro- low for in-rush currents during Wye-Delta, part wind,
tection. This module protects against phase to phase or ACL starts without nuisance tripping.
current imbalance, over current, under current, and
phase rotation. The module, mounted in the power To check the factory setting of the 2ACE module cur-
panel, utilizes a 7 segment display which provides op- rent overload trip value, obtain the RLA from the mo-
erating status and fault diagnostic information. The 7 tor nameplate. The method used to calculate the trip
segment display will display either a stationary or a value will depend on the type of start (Across-The-Line
flashing alphanumeric value which can be decoded by or Wye-Delta) and the number of wires in each phase
the operator. A list of the codes follows: that are routed through the C.T.
16 YORK INTERNATIONAL
FORM 201.18-NM3
YORK INTERNATIONAL 17
Product Description
18 YORK INTERNATIONAL
FORM 201.18-NM3
YORK INTERNATIONAL 19
Product Description
20 YORK INTERNATIONAL
FORM 201.18-NM3
YORK INTERNATIONAL 21
Product Description
Entry – Used to confirm Set Point changes, cancel in- compartment. Factory wiring is provided from the cir-
puts, advance day, and change AM/PM. cuit breaker to factory supplied terminal blocks in the
power compartments.
Setpoints – For setting chilled liquid temperature,
chilled liquid range, remote reset temperature range. Single-Point Power Connection without Circuit
Protection (Not available on 3 and 4 compressor
Clock – Used to set time, daily or holiday start/stop models)
schedule and manual override for servicing. A single-point supply circuit with field provided pro-
tection is connected to a factory provided terminal block
Print – Used to display or print operating data or sys- or non-fused disconnect switch located in the options
tem fault shutdown history for last six faults. (4 in compartment. Factory wiring is provided from the ter-
YCAS 3 Compressor and YCAS 4 Compressor Mod- minal block or disconnect switch to factory supplied
els). Printouts through an RS-232 port via a separate terminal blocks in the power compartments.
printer. Control Circuit Terminal Block
Program A 120V, 20A control circuit power terminal strip lo-
cated in the control panel to accept a field provided
For setting low leaving liquid temperature cutout, 300
control power supply, rather than the standard factory
to 600 second anti-recycle timer, average motor cur-
mounted control circuit transformer. The supply with
rent unload point, liquid temperature setpoint reset sig-
appropriate branch circuit protection in accordance with
nal from YORK ISN or building automation system.
applicable Local codes, provides the unit control cir-
cuit power supply via the panel mounted Emergency
Additional functions (password protected) for program-
Stop Switch.
ming by a qualified service technician:
Building Automation System (BAS) Interface
Cutouts for low and high ambient, low suction pres- Provides a means to reset the leaving chilled liquid tem- 2
sure and high discharge pressure, refrigerant type, high perature or percent full load amps (current limiting)
discharge pressure unload setpoint. from the BAS (Factory Mounted):
nolic coating. Probably the most suitable selection for Louvered panels and wired guards – Louvered pan-
seashore locations where salt spray may come into con- els mounted over the exterior condenser coil faces, and
tact with the fins, and other corrosive applications ex- heavy gauge welded wire mesh guards mounted around
cept: strong alkalis, oxidizers, and wet bromine, chlo- the bottom of the unit (Factory or field mounted).
rine, and fluorine in concentrations greater than 100
PPM. Louvered panels (condenser coils only) – Louvered
panels are mounted over the exterior condenser coil
DX COOLER OPTIONS: faces on the sides of the unit to visually screen and pro-
tect the coils (Factory or field mounted).
300 PSIG (21 bar) Waterside Design Working
Pressure – The DX cooler waterside is designed and
Louvered panels (full unit) enclosure – Louvered
constructed for 300 PSIG (21 bar) working pressure.
panels over condenser coils and around the bottom of
(Factory Mounted)
the unit (Factory or field mounted).
1-1/2" (38 mm) Insulation – Double thickness insula-
tion provided for enhanced efficiency. FANS
Flange Accessory – Consists of raised face flanges to High static fans: Fans and motors suitable for High
convert grooved water nozzles to flanged cooler External Static conditions to 100 Pa.
connections. Includes companion flanges for field
mounting. SOUND REDUCTION OPTIONS
Remote DX Cooler – Includes the main condensing Low speed fans – Reduced RPM fan motors and alter-
unit less the cooler, refrigerant and liquid line devices. native fan selection for low noise applications.
The insulated cooler and field accessory kits per refrig-
erant circuit are supplied separately. The condensing Compressor sound enclosures – Acoustically
unit is shipped with an R-22 holding charge and the treated metal compressor enclosures. Includes a com-
cooler is shipped with a nitrogen holding charge. pressor mounted temperature transducer to prevent
overheating.
Flow Switch Accessory – Johnson Controls model
F61MG-1C Vapor-proof SPDT, NEMA 4X switch, 150
VIBRATION ISOLATION
PSIG (10 bar) DWP, -20°F to 250°F (-29°C to 121°C),
with 1" NPT (IPS) connection for upright mounting in
Neoprene pad isolation – Recommended for normal
horizontal pipe. A flow switch must be field installed
installations. (Field mounted)
with each unit.
1" (25 mm) spring isolators – Level adjustable, spring
Star-Delta Compressor Motor Starter – Provides
and cage type isolators for mounting under the unit base
approximately 65% reduced inrush current compared
rails (Field mounted).
to across-the-line start (Factory Mounted).
2" (51 mm) seismic spring isolators – Restrained
UNIT ENCLOSURES Spring-Flex Mountings incorporate welded steel hous-
ing with vertical and horizontal limit stops. Housings
Wire enclosure – Heavy gauge welded wire mesh designed to withstand a minimum 1.0 g accelerated
guards mounted on the exterior of the unit (Factory or force in all directions to 2" (51 mm). Level adjustable,
field mounted). deflection may vary slightly by application. (Field
mounted).
24 YORK INTERNATIONAL
YORK INTERNATIONAL
YCAS0300EC40YFA
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
UNIT NOMENCLATURE
0360 Y :Wye (Star) Delta
0400 X :Across the Line
0440
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 3637
POWER FIELD CONTROLS FIELD COMPRESSOR / PIPING FIELD
FORM 201.18-NM3
Ind. Sys. Brkr. & L. Ext. Handles = Individual System Breaker & Lockable External Handle
25
2
26
Product Description
NAMEPLATE ENGINEERING DATA
38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
EVAP. FIELD CONDENSER FIELD CABINET FIELD
UNIT NOMENCLATURE
3 : 300 PSIG DWP Waterside X : Aluminum 1 : Wire (Full Unit) Enc. Panels (factory)
D : Double Thick Insulation C :Copper 2 : Wire (Full Unit) Enc. Panels (field)
W : Weld Flange Kit B :BlackFin 3 : Wire/Louvered Enc. Panels (factory)
V : Victaulic Flange Kit P :Phenolic 4 : Wire/Louvered Enc. Panels (field)
S : Flow Switch X :TEAO Fan 5 : Louvered (Cond. Only) Enc. Panels (factory)
M : Multinat’l Vessel & Assoc.Safety Codes Motors 6 : Louvered (Cond. Only) Enc. Panels (field)
A : ASME Pressure Vessel & Associated Codes (American) 7 : Louvered (Full Unit) Enc. Panels (factory)
S : AS 1210 Vessel & Associated Codes (Australian) 8 : Louvered (Full Unit) Enc. Panels (field)
F : French Vessel & Associated Codes (DRIRE) E : Compressor Sound Enclosure
T : German TUV Vessel & Associated Codes (A.D. X : No Option
I Merkblatter) B : Acoustic Sound Blanket
P : Italian Vessel & Associated Codes (ISPESL) L : Low Sound Fans
R : Polish Vessel & Associated Codes H : High Static Fans
X : Remote DX Cooler S : Final Overspray Paint
: No Option 1 : 1" Deflection
NOTES: S : Seismic
1. Q :DENOTES SPECIAL / S.Q. N : Neoprene Pads
2. # :DENOTES STANDARD
3. X :w/in OPTIONS FIELD, DENOTES NO OPTION SELECTED
YORK INTERNATIONAL
FORM 201.18-NM3
If the unit is to be put into storage, prior to installation, Major damage must be reported immediately to your
the following precautions should be observed: local YORK representative.
• Unit must be “blocked” so that the base is not MOVING THE CHILLER
permitted to sag or bow. Prior to moving the unit, ensure that the installation
site is suitable for installing the unit and is capable of
• Ensure that all openings, such as water connections, supporting the weight of the unit and all associated ser-
are securely capped. vices.
• Do not store where exposed to ambient air tem- The units are designed to be lifted using cables. A
peratures exceeding 110°F (43°C). spreader bar or frame 88" (2250 mm) wide should be
• The condensers should be covered to protect the used in order to prevent damage to the unit from the
fins from potential damage and corrosion, particu- lifting chains (See Figure 3 and 4)
larly where building work is in progress. .
Units are provided with lifting eyes extending from the
• The unit should be stored in a location where there sides of the base frame which can be attached to di-
is minimal activity in order to limit the risk of acci- rectly using shackles or safety hooks (See Figure 4).
dental physical damage. 3
The unit must only be lifted by the base frame at
• To prevent inadvertent operation of the pressure the points provided. Never move the unit on rollers,
relief devices the unit must not be steam cleaned. or lift the unit using a fork-lift truck.
• It is recommended that the control panel keys are Care should be taken to avoid damaging the condenser
removed and deposited with a responsible person cooling fins when moving the unit.
on-site.
Lifting Weights
• It is recommended that the unit is periodically in-
For details of weights and weight distribution refer to
spected during storage.
the Technical Data Section.
YORK INTERNATIONAL 27
Handling and Storage
UNIT RIGGING
CORRECT!
WRONG!
LD03514
WRONG!
CORRECT!
LD03515
INSTALLATION
LOCATION REQUIREMENTS points. This will allow vibration isolators to be fitted if
required.
To achieve optimum performance and trouble-free ser-
vice, it is essential that the proposed installation site Any ductwork or attenuators fitted to the unit must not
meets with the location and space requirements for the have a total static pressure resistance, at full unit air-
model being installed. For dimensions, weight and flow, exceeding the capability of the fans installed in
space requirements, including service access details, the unit.
refer to the Technical Data Section.
INDOOR INSTALLATIONS
It is important to ensure that the minimum service ac-
cess space is maintained for cleaning and maintenance The unit can be installed in an enclosed plant room
purposes. providing the floor is level and of suitable strength to
support the full operating weight of the unit. It is es-
OUTDOOR INSTALLATIONS sential that there is adequate clearance for airflow to
the unit. The discharge air from the top of the unit must
The units can be installed at ground level, or on a be ducted away to prevent recirculation of air within
suitable rooftop location. In both cases an adequate the plant room. If common ducts are used for fans, non-
supply of air is required. Avoid locations where the return dampers must be fitted to the outlet from each
sound output and air discharge from the unit may be fan.
objectionable.
The discharge ducting must be properly sized with a
The location should be selected for minimum sun ex- total static pressure loss, together with any intake static
posure and away from boiler flues and other sources of pressure loss, less than the available static pressure ca-
airborne chemicals that could attack the condenser coils pability for the type of fan fitted.
and steel parts of the unit.
The discharge air duct usually rejects outside the build-
If located in an area which is accessible to unautho-
ing through a louver. The outlet must be positioned to
rized persons, steps must be taken to prevent access to
prevent the air being drawn directly back into the air
the unit by means of a protective fence. This will help
intake for the condenser coils, as such recirculation will
to prevent the possibility of vandalism, accidental dam-
affect unit performance.
age, or possible harm caused by unauthorized removal
of protective guards or opening panels to expose rotat-
ing or high voltage components. LOCATION CLEARANCES
4
For ground level locations, the unit must be installed Adequate clearances around the unit(s) are required for
on a suitable flat and level concrete base that extends the unrestricted airflow for the air-cooled condenser
to fully support the two side channels of the unit base coils and to prevent recirculation of warm discharge
frame. A one-piece concrete slab, with footings extend- air back onto the coils. If clearances given are not main-
ing below the frost line is recommended. To avoid noise tained, airflow restriction or recirculation will cause a
and vibration transmission the unit should not be se- loss of unit performance, an increase in power con-
cured to the building foundation. sumption and may cause the unit to malfunction. Con-
sideration should also be given to the possibility of
On rooftop locations, choose a place with adequate down drafts, caused by adjacent buildings, which may
structural strength to safely support the entire operat- cause recirculation or uneven unit airflow.
ing weight of the unit and service personnel. The unit
can be mounted on a concrete slab, similar to ground For locations where significant cross winds are ex-
floor locations, or on steel channels of suitable strength. pected, such as exposed roof tops, an enclosure of solid
The channels should be spaced at the same centres as or louver type is recommended to prevent wind turbu-
the vibration mounting holes in the unit base frame and lence interfering with the unit airflow.
must be at least 4-3/4" (120 mm) wide at the contact
YORK INTERNATIONAL 29
Installation
sion of vibrations to the building. Flexible connections quality of the water in circulation is
must be used if the unit is mounted on anti-vibration adequate, without any dissolved gases
mounts as some movement of the unit can be expected which can cause oxidation of steel
in normal operation. parts within the cooler.
Pipework and fittings immediately next to the cooler
should be readily de-mountable to enable cleaning be- WATER TREATMENT
fore operation, and to facilitate visual inspection of the
exchanger nozzles. The unit performance given in the Design Guide is based
on a fouling factor of 0.00025 ft2hr°F/Btu (0.044m2/hr
The cooler must be protected by a strainer, prefer-
°C/kW). Dirt, scale, grease and certain types of water
ably of 30 mesh, fitted as close as possible to the liq-
treatment will adversely affect the heat exchanger sur-
uid inlet connection, and provided with a means of
faces and therefore unit performance. Foreign matter
local isolation.
in the water system(s) can increase the heat exchanger
The cooler must not be exposed to flushing velocities pressure drop, reducing the flow rate and causing po-
or debris released during flushing. It is recommended tential damage to the heat exchanger tubes.
that a suitably sized by-pass and valve arrangement is
Aerated, brackish or salt water is not recommended for
installed to allow flushing of the pipework system. The
use in the water system(s). YORK recommends that a
by-pass can be used during maintenance to isolate the
water treatment specialist is consulted to determine that
heat exchanger without disrupting flow to other units.
the proposed water composition will not affect the
Thermometer and pressure gauge connections should evaporator materials of carbon steel and copper. The
be provided on the inlet and outlet connections of each pH value of the water flowing through the cooler must
cooler. be kept between 7 and 8.5.
Drain and air vent connections should be provided at
PIPEWORK ARRANGEMENT
all low and high points in the pipework to permit drain-
age of the system and to vent any air in the pipes. The following is a suggested pipework arrangement for
single unit installations. For multiple unit installations,
Liquid systems at risk of freezing, due to low ambient each unit should be piped as shown.
temperatures, should be protected using insulation and
heater tape and/or a suitable glycol solution. The liquid
pump(s) must also be used to ensure liquid is circu-
lated when the ambient temperature approaches freez-
ing point. Insulation should also be installed around the
cooler nozzles. Heater tape of 21 watts per meter under
the insulation is recommended, supplied independently
and controlled by an ambient temperature thermostat
set to switch on at 37°F (21°C) above the freezing tem- 4
perature of the liquid.
The liquid circulation pump must be controlled by the
unit. This will ensure that when the liquid temperature
falls within 3° or 5°F (2° or 3°C) of freezing the pump
will start. LD04739
CONNECTION TYPES & SIZES The size of any pipework attached to a relief valve must
be of sufficient diameter so as not to cause resistance
For connection sizes relevant to individual models re-
to the operation of the valve. Unless otherwise speci-
fer to the Technical Data Section.
fied by local regulations, table internal diameter depends
on the length of pipe required and is given by the fol-
COOLER CONNECTIONS
lowing formula:
Standard chilled liquid connections on all coolers are
of the Victaulic Groove type. D5 = 1.447 x L
Where:
D = minimum pipe internal diameter
L = length of pipe in meters
If relief pipework is common to more than one valve
its cross sectional area must be at least the total required
LD03521 by each valve. Valve types should not be mixed on a
FIG. 6 – VICTAULIC GROOVE common pipe. Precautions should be taken to ensure
that the outlet of relief valves/vent pipe remain clear of
Option Flanges obstructions at all times.
One of two types of flanges may be fitted depending on
the customer or local Pressure Vessel Code require- DUCTWORK CONNECTION
ments. These are Victaulic-Adapter flanges, normally
supplied loose, or weld flanges which may be supplied General Requirements
loose or ready fitted. Victaulic-Adapter and weld flange The following ductwork recommendations are intended
dimensions are to ISO 7005 - NP10. to ensure satisfactory operation of the unit. Failure to
follow these recommendations could cause damage to
the unit, or loss of performance, and may invalidate the
warranty.
32 YORK INTERNATIONAL
FORM 201.18-NM3
tions must be taken to ensure persons cannot be harmed STANDARD UNITS WITH MULTI POINT POWER
or put at risk from rotating fan blades. SUPPLY WIRING
34 YORK INTERNATIONAL
FORM 201.18-NM3
00263VIP
00246VIP
1 4
3
5
2
10
8
00247VIP
4
PHOTOGRAPH OF
60HZ MODEL LOGIC SECTION
ITEM DESCRIPTION
1 Microprocessor Board
2 Back of Keypad
3 Back of Display
4 I/O Expansion Board #1
5 Power Supply Board
6 Relay Output Board #1
7 Relay Output Board #2
8 Flow Switch & Customer Connection Terminals
9 I/O Expansion Board #2
10 Circuit Breakers
00248VIP
CUSTOMER CONNECTIONS
TERMINALS 13-19
TERMINALS 23-38
00249VIP
CONNECTION
POINTS FOR
EMERGENCY
STOPS
LD03502
CUSTOMER CONNECTIONS
TRANSFORMERS
POWER SUPPLY
BOARD
CIRCUIT
BREAKERS
28965A
MICROPROCESSOR CUSTOMER
CIRCUIT BOARD CONNECTIONS
115 VAC SUPPLY
(Flow Switch, Alarm, Run, etc.)
COMMISSIONING
PREPARATION or copper line, but do not tighten the flare nut. Using
clean oil of the correct type (“L” oil), pump oil until all
Commissioning of this unit should air has been purged from the hose then tighten the nut.
only be carried out by YORK Autho- Stroke the oil pump to add oil to the oil system. The oil
rized personnel. level should be between the middle of the lower and
middle of the upper sight glasses of the oil separator.
Approximately 5 gallons is present in the entire chiller
system, with 1-2 gallons in the oil separator.
The Millennium Microcomputer Control System
Operating Instructions must be read in conjunction Fans
with this section. Check that all fans are free to rotate and are not dam-
aged. Ensure blades are at the same height when ro-
PREPARATION – POWER OFF tated. Ensure fan guard is securely fixed.
Check that the tapping used conforms to the site supply should be connected to terminals 13 and 14 in the
voltage. micropanel ( Figs. 11 and 12, pages 39 and 40).
42 YORK INTERNATIONAL
FORM 201.18-NM3
YORK INTERNATIONAL 43
Operation
OPERATION
GENERAL DESCRIPTION NORMAL RUNNING AND CYCLING
Once the unit has been started, all operations are fully
The units are designed to work independently, or in con- automatic. After an initial period at minimum capacity
junction with other equipment via a YORK ISN build- on the lead compressor, the control system will adjust
ing management system or other automated control sys- the unit load depending on the chilled liquid tempera-
tem. When operating, the unit controls monitor the ture and rate of temperature change. If high heat load is
chilled liquid system temperature at the unit and take present, the controller will increase the capacity of the
the appropriate action to maintain this temperature lead compressor and/or start-up the other compressor.
within desired limits. This action will involve running
one or more compressors at a suitable load step to match If very little heat load is present, the lead compressor
the cooling effect of the refrigerating systems to the will continue at minimum capacity or may simply stop
heat load on the liquid system. The heat removed from again to avoid overcooling the liquid. If the latter is the
the chilled liquid is then rejected from the air cooled case, one compressor will restart automatically should
condenser coils. the liquid temperature rise again.
The following sections give an overview of the opera- Once a compressor is running, discharge pressure rises
tion of the unit. For detailed information, reference as refrigerant is pumped into the air cooled condenser
should be made to the Chiller Control Panel Program- coils. This pressure is controlled by stages of fans to
ming and Data Access Operating Instructions for the ensure maximum unit efficiency while maintaining suf-
unit (pages 136-184). ficient pressure for correct operation of the condensers
and expansion valves.
START-UP When a compressor is running the controller monitors
oil pressure, motor current, and various other system
Check the main power supplies to the unit are ‘ON’, all parameters such as discharge pressure, chilled liquid
refrigerant service valves are open (counter-clockwise temperature, etc. Should any problems occur, the con-
one turn short of fully open) and chilled liquid flow has trol system will immediately take appropriate action
been established (unless the unit chilled liquid pump and display the nature of the fault (Section 2, page 148).
start control is being used, in which case just ensure
the pump supply is on). Ensure only the correct system SHUTDOWN
switches (SYS 1-3 or 1-4) on the microprocessor cir-
cuit board are in the ‘ON’ position. The unit can be stopped at any time by switching the
unit ON/OFF switch just below the keypad to the OFF
Press the ‘STATUS’ key on the keypad and then switch position. The compressor and oil separator heaters will
the unit ON/OFF switch below the keypad to the ON energize to prevent refrigerant condensing in the com-
position. pressor rotors and to prevent the compressor oil becom-
ing saturated with refrigerant. If ambient temperatures
The controller will perform a pre-check to ensure that are low, the cooler heater mats will also energize to pre-
the daily/holiday schedule and any remote interlocks vent the possibility of liquid freezing in the vessels. The
will allow the unit to run, all safety cut-outs are satis- mains power to the unit should not normally be switched
fied and that cooling load is required (i.e. that the chilled OFF, even when the unit is not required to run.
liquid temperature is outside the set limits). Any prob- If mains power must be switched OFF, (for extended
lems found by the pre-check will be displayed if present. maintenance or a shutdown period), the compressor
If no problems are present and cooling duty is required suction, discharge and motor cooling service stop valves
the lead compressor will start. should be closed (clockwise) and if there is a possibil-
ity of liquid freezing due to low ambient temperatures,
The display will show the anti-coincidence timer status the coolers should be drained. Valves should be opened
for the lag compressor, followed by ‘NO COOL LOAD’ and power must be switched on for at least 8 Hours (36
until it is called to operate by the control system. Hours if ambient temperature is over 86°F [30°C]) be-
fore the unit is restarted.
44 YORK INTERNATIONAL
FORM 201.18-NM3
TECHNICAL DATA
FLOW RATE AND PRESSURE DROP CHARTS
COOLER WATER PRESSURE DROP COOLER WATER PRESSURE DROP
(ENGLISH UNITS) (SI UNITS)
"C" Cooler Pressure Loss (ft-H2O) = 0.000174 (GPM) ^ 1.81 "C" Cooler Pressure Loss (kPa) = 0.0808 (l/s) ^ 1.81
"D" Cooler Pressure Loss (ft-H2O) = 0.000140 (GPM) ^ 1.81 "D" Cooler Pressure Loss (kPa) = 0.0650 (l/s) ^ 1.81
100 1000
PRESSURE DROP (ft-H2 O)
10
C D
10
C
D
1 1
100.0 1000.0 1 10 100
WATER FLOW (GPM)
WATER FLOW (l/s)
LD05007 LD05008
1.30
When using glycol solutions, pressure drops are higher A 1.25
50%
1.05 10%
-10 -8 -6 -4 -2 0 2 4 6 8
A = Correction Factor B 7
B = Mean Temperature through Cooler
C = Concentration W/W 1.8
PROPYLENE GLYCOL
1.7
1.6
1.3 40%
1.2
C
30%
1.1 20%
10%
1.0
-10 -8 -6 -4 -2 0 2 4 6 8
B
LD03504
NOTES:
1. For leaving brine temperature below 40°F (4.40°C), contact your nearest YORK office for application requirements.
2. For leaving water temperature higher than 55°F (12.8°C) contact the nearest YORK office for application guidelines.
3. The evaporator is protected against freezing to -20°F (-28.8°C) with an electric heater as standard.
46 YORK INTERNATIONAL
FORM 201.18-NM3
PHYSICAL DATA
ENGLISH UNITS
YORK INTERNATIONAL 47
Technical Data
PHYSICAL DATA
SI UNITS
48 YORK INTERNATIONAL
FORM 201.18-NM3
YORK INTERNATIONAL 49
Technical Data
ELECTRICAL DATA
MULTIPLE POINT POWER SUPPLY CONNECTION Suitable for:
Across-The-Line-Start Only
See Note 3
LD04742
NOTES:
1. U.L. is provided on 60 Hz units for these electrical wiring configurations.
2. — — — — — Dashed Line = Field Provided Wiring.
3. The above recommendations are based on the National Electrical Code and using copper connectors only. Field wiring must also
comply with local codes. *Group Rated breaker must be HRCR type for cU.L. machines.
50 YORK INTERNATIONAL
FORM 201.18-NM3
ELECTRICAL DATA
MULTIPLE POINT POWER SUPPLY CONNECTION Suitable for:
WITH OPTIONAL CIRCUIT BREAKER Y - ∆ Start and
Across-The-Line-Start Only
Each of the two field provided power supply circuits to the
unit with individual branch circuit protection. Field connec-
tions to factory provided, Non-Fused Disconnect Switches
(Opt), or Terminal Blocks (Opt) in the Option Box. Factory
connections to each of the Circuit Breakers in each of the
two power panels.
See Note 3
LD04743
YORK INTERNATIONAL 51
Technical Data
ELECTRICAL DATA
OPTIONAL SINGLE-POINT POWER SUPPLY Suitable for:
CONNECTION AND INTERNAL UNIT CIRCUIT Y - ∆ Start and
BREAKERS Across-The-Line-Start
See Note 3
LD04744
OPTIONAL SINGLE-POINT POWER SUPPLY CONNECTION WITH INTERNAL UNIT CIRCUIT BREAKERS
(One Field Provided Power Supply Circuit to the chiller. Field connections to Power Terminal Block (standard) or Non-Fused Disconnect (option)
in ‘Option Panel’. Circuit Breakers in each Motor Control Center
52 YORK INTERNATIONAL
FORM 201.18-NM3
ELECTRICAL DATA
ELECTRICAL SYSTEM #1 FIELD SUPPLIED WIRING ELECTRICAL SYSTEM #2 FIELD SUPPLIED WIRING
COMPRESSOR #1 DATA COMPRESSOR #3 DATA FAN DATA11, 12 COMPRESSOR #2 DATA COMPRESSOR #4 DATA FAN DATA11, 12
RLA ∆ LRA X-LRA
Y-∆ RLA ∆ LRA X-LRA QTY FLA (EA) LRA (EA)
Y-∆ RLA ∆ LRA X-LRA
Y-∆ RLA ∆ LRA X-LRA
Y-∆ QTY FLA (EA) LRA (EA)
155 343 1,093 155 343 1,093 8 4.8 23.0 155 343 1,093 — — — 4 4.8 23.0
128 280 893 128 280 893 8 4.0 19.0 128 280 893 — — — 4 4.0 19.0
103 224 714 103 224 714 8 3.1 15.2 103 224 714 — — — 4 3.1 15.2
155 343 1,093 227 343 1,093 8 4.8 23.0 155 343 1,093 — — — 4 4.8 23.0
128 280 893 184 280 893 8 4.0 19.0 128 280 893 — — — 4 4.0 19.0
103 224 714 147 224 714 8 3.1 15.2 103 224 714 — — — 4 3.1 15.2
181 343 1,093 199 343 1,093 9 4.8 23.0 181 343 1,093 — — — 5 4.8 23.0
149 280 893 164 280 893 9 4.0 19.0 149 280 893 — — — 5 4.0 19.0
119 224 714 131 224 714 9 3.1 15.2 119 224 714 — — — 5 3.1 15.2
197 343 1,093 227 343 1,093 9 4.8 23.0 197 343 1,093 — — — 5 4.8 23.0
163 280 893 184 280 893 9 4.0 19.0 163 280 893 — — — 5 4.0 19.0
130 224 714 147 224 714 9 3.1 15.2 130 224 714 — — — 5 3.1 15.2
199
164
343
280
1,093
893
155
128
343
280
1,093
893
8
8
4.8
4.0
23.0
19.0
199
164
343
280
1,093
893
155
128
343
280
1,093
893
8
8
4.8
4.0
23.0
19.0
7
131 224 714 103 224 714 8 3.1 15.2 131 224 714 103 224 714 8 3.1 15.2
181 343 1,093 199 343 1,093 9 4.8 23.0 181 343 1,093 199 343 1,093 9 4.8 23.0
149 280 893 164 280 893 9 4.0 19.0 149 280 893 164 280 893 9 4.0 19.0
119 224 714 131 224 714 9 3.1 15.2 119 224 714 131 224 714 9 3.1 15.2
197 343 1,093 227 343 1,093 9 4.8 23.0 197 343 1,093 227 343 1,093 9 4.8 23.0
163 280 893 184 280 893 9 4.0 19.0 163 280 893 184 280 893 9 4.0 19.0
130 224 714 147 224 714 9 3.1 15.2 130 224 714 147 224 714 9 3.1 15.2
YORK INTERNATIONAL 53
Technical Data
ELECTRICAL NOTES
NOTES & LEGEND
(for pages 50 - 53)
1. Minimum circuit ampacity (MCA) is based on 125% of the rated load amps for the largest motor plus 100% of the rated load amps for all
other loads included in the circuit, per N.E.C. Article 430-24. If a Factory Mounted Control Transformer is provided, add the following to
the system #1 MCA values in the YCAS Tables: -17, add 15 amps; -28, add 12 amps; -40, add 7 amps; -46, add 6 amps; -58, add 5 amps.
2. The recommended disconnect switch is based on a minimum of 115% of the summation rated load amps of all the loads included in the
circuit, per N.E.C. 440 - 12A1.
3. Minimum fuse size is based on 150% of the largest motor RLA plus 100% of the remaining RLAs (U.L. Standard 1995, Section 36.1).
Minimum fuse rating = (1.5 x largest compressor RLA) + other compressor RLAs + (# fans x each fan motor FLA).
4. Maximum dual element fuse size is based on 225% maximum plus 100% of the rated load amps for all other loads included in the circuit,
per N.E.C. 440-22. Maximum fuse rating = (2.25 x largest compressor RLA) + other compressor RLAs + (# fans x each fan motor FLA).
5. Minimum circuit breaker is 150% maximum plus 100% of rated load amps included in the circuit, per circuit per U.L. 1995 Fig. 36.2.
Minimum circuit breaker rating = (1.5 x largest compressor RLA) + other compressor RLAs + (# fans x each fan motor FLA).
6. Maximum circuit breaker is based on 225% maximum plus 100% of the rated load amps for all loads included in the circuit, per circuit, per
U.L. 1995 Fig. 36.2. Maximum circuit breaker rating = (2.25 x largest compressor RLA) + other compressor RLAs + ( # fans x each fan
motor FLA).
7. The Incoming Wire Range is the minimum and maximum wire size that can be accommodated by unit wiring lugs. The (1), (2), or (3)
indicate the number of termination points or lugs which are available per phase. Actual wire size and number of wires per phase must be
determined based on ampacity and job requirements using N.E.C. wire sizing information. The above recommendations are based on
the National Electric Code and using copper connectors only. Field wiring must also comply with local codes.
8. A ground lug is provided for each compressor system to accommodate field grounding conductor per N.E.C. Article 250-54. A control
circuit grounding lug is also supplied. Incoming ground wire range is #6 - 350 MCM.
9. The field supplied disconnect is a “Disconnecting Means” as defined in N.E.C. 100.B, and is intended for isolating the unit from the
available power supply to perform maintenance and troubleshooting. This disconnect is not intended to be a Load Break Device.
10. Two-compressor machines with Single-Point power connection, and equipped with Star-Delta compressor motor start, must also include
factory provided circuit breakers in each motor control center. All 3 & 4 compressor machines equipped with Star-Delta compressor
motor start must also include factory provided circuit breakers in each motor control center.
11. Consult factory for Electrical Data on units equipped with “High Static Fan” Option. High Static Fans are 3.8 kW each.
12. FLA for “Low Noise Fan” motors: 200V = 8.0A, 230V = 7.8A, 380V = 4.4A, 460V = 3.6A, 575V = 2.9A.
13. Group Rated breaker must be HACR type for cU.L. Machines.
LEGEND
ACR-LINE ACROSS THE LINE START
C.B. CIRCUIT BREAKER
D.E. DUAL ELEMENT FUSE
DISC SW DISCONNECT SWITCH VOLTAGE CODE
FACT CB FACTORY-MOUNTED CIRCUIT BREAKER -17 = 200-3-60
FLA FULL LOAD AMPS -28 = 230-3-60
HZ HERTZ -40 = 380-3-60
MAX MAXIMUM -46 = 460-3-60
MCA MINIMUM CIRCUIT AMPACITY -58 = 575-3-60
MIN MINIMUM
MIN NF MINIMUM NON-FUSED
RLA RUNNING LOAD AMPS
S.P. WIRE SINGLE-POINT WIRING
Y-∆ WYE-DELTA START
X-LRA ACROSS-THE-LINE INRUSH LOCKED ROTOR AMPS
Y-LRA WYE-DELTA INRUSH LOCKED ROTOR AMPS
54 YORK INTERNATIONAL
FORM 201.18-NM3
ELECTRICAL DATA
TABLE 2 – COMPRESSOR DATA
MAXIMUM kW AND AMPERAGE VALUES FOR DXST COMPRESSORS
COMPRESSOR MODEL AND VOLTAGE CODE
DXS45LA – MOTOR CODE A DXS36LA – MOTOR CODE A DXS24LA – MOTOR CODE (TBD)
(B5N, B5E, B6N, B6E) (A5N, A5E, A6N, A6E) (C5N, C5E, C6N, C6E)
VOLTAGE CODE -17 -28 -40 -46 -50 -58 -17 -28 -40 -46 -50 -58 -17 -28 -40 -46 -50 -58
MAX KW 150 150 150 150 113 150 150 150 150 150 113 150 105 105 105 105 80 105
MAX AMPS 492 428 259 214 193 171 492 428 259 214 193 171 338 294 178 147 135 118
YORK INTERNATIONAL 55
Technical Data
ELEMENTARY DIAGRAM
LD04172A
ELEMENTARY DIAGRAM
LD04172B
LD04186
(PRESENT ON CERTAIN
MODEL CHILLERS)
(NOT PRESENT ON
3-COMPRESSOR CHILLERS)
(PRESENT ON CERTAIN
MODEL CHILLERS)
(NOT PRESENT ON
3-COMPRESSOR CHILLERS)
LD04174
WIRING DIAGRAM
ACROSS-THE-LINE START
(PRESENT ON CERTAIN
MODEL CHILLERS)
(NOT PRESENT ON
3-COMPRESSOR CHILLERS)
(PRESENT ON CERTAIN
MODEL CHILLERS)
(NOT PRESENT ON
3-COMPRESSOR CHILLERS)
LD04173
YORK INTERNATIONAL 61
Technical Data
LD04175
CAUTION:
No Controls (relays, etc.) should be
mounted in the Smart Panel
enclosure or connected to power
supplies in the control panel.
Additionally, control wiring not
connected to the Smart Panel should
not be run through the cabinet. This
could result in nuisance faults.
CAUTION:
Any inductive devices (relays) wired
in series with the flow switch for start/
stop, into the Alarm circuitry, or pilot
relays for pump starters wired
through motor contactor auxiliary
contacts must be suppressed with
YORK P/N 031-00808-000
suppressor across the relay/
contactor coil.
CAUTION:
Control wiring connected to the
control panel should never be run in
the same conduit with power wiring.
ISN RS485
SHLD
PORT
LD04176
CONNECTION DIAGRAM
LD04179
YORK INTERNATIONAL 65
Technical Data
CONNECTION DIAGRAM
Box Information continued from page 67
LD04180
FIG. 21 – CONNECTION DIAGRAM
66 YORK INTERNATIONAL
FORM 201.18-MN3 FORM 201.18-NM3
CONNECTION DIAGRAM FIG. 41 & 42 LEGEND (PAGES 90 & 91)
Box Information continued from page 66
LD04181
LD04182
LD04183
STANDARD & REMOTE EVAP. UNITS STANDARD & REMOTE EVAP. UNITS
ELEMENTARY DIAGRAM
DXST DIRECT DRIVE
CONTROL CIRCUIT
LD04177
ELEMENTARY DIAGRAM
DXST DIRECT DRIVE
CONTROL CIRCUIT
LD04373
ELEMENTARY DIAGRAM
DXST DIRECT DRIVE
CONTROL CIRCUIT
DETAIL "C"
SEE INSTALLATION, OPERATION AND MAINTENANCE MANUAL
FOR JUMPER OF CONDENSER FANS FOR CHILLER MODEL
LD04374
LD04184
LD04185
ELEMENTARY DIAGRAM
DXST DIRECT DRIVE
POWER CIRCUIT
LD04260A
ELEMENTARY DIAGRAM
DXST DIRECT DRIVE
POWER CIRCUIT
LD04260B
LD04186
LD04262
LD04261
YORK INTERNATIONAL 79
Technical Data
LD04257
FIG. 36 – STANDARD COMPRESSOR POWER SUPPLIES - ACROSS-THE-LINE START AND WYE-DELTA START
80 YORK INTERNATIONAL
FORM 201.18-NM3 FORM 201.18-NM3
ISN RS485
SHLD
PORT
7
LD04258
FIG. 36 – STANDARD COMPRESSOR POWER SUPPLIES - ACROSS-THE-LINE AND WYE-DELTA START (CONT’D)
YORK INTERNATIONAL 81 YORK INTERNATIONAL 81A
Technical Data
FORM 201.18-NM3
This page intentionally left blank. This page intentionally left blank.
LD04265
YORK INTERNATIONAL 83
Technical Data
CONNECTION DIAGRAM
SYSTEMS 1 & 2
84 YORK INTERNATIONAL
FORM 201.18-NM3 FORM 201.18NM3
ELEMENTARY DIAGRAM
CAUTION:
No Controls (relays, etc.) should
be mounted in the Smart Panel
enclosure or connected to power
supplies in the control panel.
Additionally, control wiring not
connected to the Smart Panel
should not be run through the
cabinet. This could result in nui-
sance faults.
CAUTION:
Any inductive devices (relays)
wired in series with the flow
switch for start/stop, into the
Alarm circuitry, or pilot relays for
pump starters wired through mo-
tor contactor auxiliary contacts
must be suppressed with YORK
P/N 031-00808-000 suppressor
across the relay/contactor coil.
CAUTION:
Control wiring connected to the
control panel should never be run
in the same conduit with power
wiring.
LD04266
LD04267
FIG. 38 – CONNECTION DIAGRAM
85B YORK INTERNATIONAL 86 YORK INTERNATIONAL
FORM 201.18-NM3
LD04268
YORK INTERNATIONAL 87
Technical Data
LD04264
LD04272
ELEMENTARY DIAGRAM
DXST DIRECT DRIVE
CONTROL CIRCUIT
LD04177
ELEMENTARY DIAGRAM
DXST DIRECT DRIVE
CONTROL CIRCUIT
LD04695
ELEMENTARY DIAGRAM
DXST DIRECT DRIVE
CONTROL CIRCUIT
DETAIL "C"
SEE INSTALLATION, OPERATION AND MAINTENANCE MANUAL
FOR NUMBER OF CONDENSER FANS FOR CHILLER MODELS
LD04757
LD04269
LD04270
LD04271
7"
CONTROL
42"
OPENING
28"
2" (9" HIGH)
MICRO-COMPUTER
CONTROL CENTER
B OPTIONS PANEL
B
C
20-1/8"
CONTROL
TRANSFORMER C
POWER OPENING SERVICE SWITCH
(7" WIDE x
21" HIGH)
4-7/16" (EGDE OF
It is recommended that UNIT TO COOLER
power wiring enters CONNECTION)
on the right side. LD05011
If left side entry is used, 91-13/16"
be sure that space is
available for power wire
VIEW A-A
bending radius.
NOTES:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance,
reliable operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpre-
dictable air flow patterns and possible diminished performance. YORK's unit controls will optimize operation without nuisance high
pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center
assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall - 6'; rear to wall - 6'; control
panel end to wall - 4'; top - no obstructions allowed; distance between adjacent units - 10'. No more than one adjacent wall may be higher
than the unit.
5/8" DIA.
MOUNTING
HOLES (TYP.)
1-1/4"
A B C D E F
POWER PANEL
30"
POWER ELEMENTS
FOR SYS. #1 & #3
88"
30" POWER ELEMENTS
FOR SYS. #2
CONTROL PANEL
G H I J K L
1-1/4"
31-3/4" 57-3/16" 57-3/16" 57-3/16" 48-3/8" 55-1/8"
ORIGIN Y
TOP VIEW
X
LD03965
36"
96"
78" 2"
SYS. #1 & #2 SYS. #3
7
7-1/2" POWER OPENING 2-1/4" DIA. RIGGING 10" 10"
(BOTH SIDES) HOLES (EACH SIDE) WATER INLET
A WATER OUTLET
104"
68" 89-11/16" 67-7/16" 63-9/16"
342-1/4"
Z
SIDE VIEW
X
LD03966
YORK INTERNATIONAL 97
Technical Data
CONTROL
OPENING 1067
711
51 (229 HIGH)
CONTROL ENTRY 51
305
(12) 22
120 800
CONDUIT K.O.'S
51 TYP.
POWER
229 OPENING
(533 HIGH)
VIEW B-B
MICRO-COMPUTER
CONTROL CENTER
B OPTIONS PANEL
B
C
511
CONTROL
TRANSFORMER C
POWER OPENING
SERVICE SWITCH
(178 WIDE x
533 HIGH)
112 (EDGE OF
It is recommended that
UNIT TO COOLER
power wiring enters
CONNECTION)
on the right side.
If left side entry is used, 2331
be sure that space is
available for power wire VIEW A-A LD05012
bending radius.
NOTES:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance,
reliable operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpre-
dictable air flow patterns and possible diminished performance. YORK's unit controls will optimize operation without nuisance high pres-
sure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center
assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall - 2m; rear to wall - 2m; control
panel end to wall - 1.2m; top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be
higher than the unit.
A B C D E F
762 POWER PANEL
POWER ELEMENTS
FOR SYS. #1 & #3
2235
POWER ELEMENTS
762
FOR SYS. #2
CONTROL PANEL
G H I J K L
32
806 1453 1453 1453 1229 1400
ORIGIN
TOP VIEW LD03969
914
2438
1981
50
SYS. #1 & #2 SYS. #3
YORK INTERNATIONAL 99
Technical Data
7"
CONTROL
42"
28" OPENING
2" (9" HIGH)
MICRO-COMPUTER
CONTROL CENTER
B OPTIONS PANEL
B
C
20-1/8"
CONTROL
TRANSFORMER C
POWER OPENING SERVICE SWITCH
(7" WIDE x
21" HIGH)
4-7/16" (EDGE OF
It is recommended that UNIT TO COOLER
power wiring enters CONNECTION)
on the right side.
91-13/16"
If left side entry is used, LD05013
be sure that space is VIEW A-A
available for power wire
bending radius.
NOTES:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance,
reliable operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpre-
dictable air flow patterns and possible diminished performance. YORK's unit controls will optimize operation without nuisance high
pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center
assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall - 6'; rear to wall - 6'; control
panel end to wall - 4'; top - no obstructions allowed; distance between adjacent units - 10'. No more than one adjacent wall may be higher
than the unit.
POWER PANEL A B C D E F
30"
POWER ELEMENTS
FOR SYS. #1 & #3
88"
30" POWER ELEMENTS
FOR SYS. #2
CONTROL PANEL
G H I J K L
1-1/4"
31-3/4"
57-3/16" 57-3/16" 57-3/16" 56-5/16" 95-3/16"
ORIGIN Y
TOP VIEW
X LD03981
36"
96"
78" 2"
SYS. #1 & #2 SYS. #3
CONTROL ENTRY 51
305
(12) 22 800
CONDUIT K.O.'S 120
51 TYP. POWER
229 OPENING
(533 HIGH)
VIEW B-B
191
VIEW C-C
LD03984
MICRO-COMPUTER
CONTROL CENTER
B OPTIONS PANEL
B
C
511
CONTROL
TRANSFORMER C
POWER OPENING SERVICE SWITCH
(178 WIDE x
533 HIGH)
112 (EDGE OF
It is recommended that UNIT TO COOLER
power wiring enters CONNECTION)
on the right side. 2331
If left side entry is used,
be sure that space is VIEW A-A
available for power wire LD05014
bending radius.
NOTES:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance,
reliable operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpre-
dictable air flow patterns and possible diminished performance. YORK's unit controls will optimize operation without nuisance high pres-
sure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center
assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall - 2m; rear to wall - 2m; control
panel end to wall - 1.2m; top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be
higher than the unit.
A B C D E F
762 POWER PANEL
POWER ELEMENTS
FOR SYS. #1 & #3
2235 POWER ELEMENTS
762
FOR SYS. #2
CONTROL PANEL
G H I J K L
32
806 1453 1453 1453 1431 2417
Y
ORIGIN POWER PANEL
TOP VIEW LD03985
X
914
2438
1981
50
SYS. #1 & #2 SYS. #3
7"
CONTROL
OPENING
42"
(9" HIGH)
28"
2"
VIEW B-B
VIEW C-C 7 1/2"
LD03996
MICRO-COMPUTER
CONTROL CENTER
B OPTIONS PANEL
B
21-3/8"
CONTROL
TRANSFORMER C
POWER OPENING SERVICE SWITCH
(7" WIDE x
21" HIGH)
25-5/8" (EDGE OF
It is recommended that UNIT TO COOLER
power wiring enters CONNECTION)
on the right side. 91-13/16"
If left side entry is used,
be sure that space is VIEW A-A
available for power wire LD05015
bending radius.
NOTES:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance,
reliable operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpre-
dictable air flow patterns and possible diminished performance. YORK's unit controls will optimize operation without nuisance high
pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center
assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall - 6'; rear to wall - 6'; control
panel end to wall - 4'; top - no obstructions allowed; distance between adjacent units - 10'. No more than one adjacent wall may be higher
than the unit.
1-1/4"
31-3/4" 36-5/16"
57-3/16" 57-3/16" 57-3/16" 56" 56" 56"
ORIGIN Y
TOP VIEW LD03997
X
36"
96"
78" 2" SYS. #1 & #2 SYS. #3 & #4
CONTROL 1067
711 OPENING
51 (229 HIGH)
CONTROL ENTRY 51
305
(12) 22 800
CONDUIT K.O.'S 120
51 TYP.
POWER
229 OPENING
(533 HIGH)
VIEW B-B
LD04000
MICRO-COMPUTER
CONTROL CENTER
B OPTIONS PANEL
B
C
543
CONTROL
TRANSFORMER C
POWER OPENING SERVICE SWITCH
(178 WIDE x
533 HIGH)
651 (EDGE OF
It is recommended that UNIT TO COOLER
power wiring enters CONNECTION)
on the right side.
2331
If left side entry is used,
be sure that space is VIEW A-A
available for power wire LD05016
bending radius.
NOTES:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance,
reliable operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpre-
dictable air flow patterns and possible diminished performance. YORK's unit controls will optimize operation without nuisance high pres-
sure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center
assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall - 2m; rear to wall - 2m; control
panel end to wall - 1.2m; top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be
higher than the unit.
CONTROL PANEL
I J K L M N O P
32
806 1453 1453 1453 923 1422 1422 1422
Y
ORIGIN
X
TOP VIEW
LD04001
914
2438
1981 50
7"
CONTROL
42"
28" OPENING
2" (9" HIGH)
MICRO-COMPUTER
CONTROL CENTER
B B OPTIONS PANEL
21-3/8"
CONTROL
TRANSFORMER C
POWER OPENING SERVICE SWITCH
(7" WIDE x
21" HIGH)
25-5/8" (EDGE OF
It is recommended that UNIT TO COOLER
power wiring enters CONNECTION)
on the right side.
91-13/16"
If left side entry is used,
be sure that space is VIEW A-A LD05017
available for power wire
bending radius.
NOTES:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance,
reliable operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpre-
dictable air flow patterns and possible diminished performance. YORK's unit controls will optimize operation without nuisance high
pressure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center
assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall - 6'; rear to wall - 6'; control
panel end to wall - 4'; top - no obstructions allowed; distance between adjacent units - 10'. No more than one adjacent wall may be higher
than the unit.
CONTROL PANEL
I J K L M N O P
32
806 1453 1453 1453 2142 1422 1422 1422
ORIGIN Y
TOP VIEW
X
LD04005
914
2438
1981 50 SYS. #1 & #2 SYS. #3 & #4
CONTROL
1067
OPENING
711
51 (229 HIGH)
CONTROL ENTRY 51
305
(12) 13 800
CONDUIT K.O.'S 120
51 TYP.
POWER
229
OPENING
(533 HIGH)
VIEW B-B
VIEW C-C 191 LD04008
MICRO-COMPUTER
CONTROL CENTER
B OPTIONS PANEL
B
543
CONTROL
TRANSFORMER C
POWER OPENING SERVICE SWITCH
(178 WIDE x
533 HIGH)
651 (EDGE OF
It is recommended that
UNIT TO COOLER
power wiring enters
CONNECTION)
on the right side.
If left side entry is used, 2331
be sure that space is LD05018
VIEW A-A
available for power wire
bending radius.
NOTES:
1. Placement on a level surface free of obstructions (including snow, for winter operation) or air recirculation ensures rated performance,
reliable operation and ease of maintenance. Site restrictions may compromise minimum clearances indicated below, resulting in unpre-
dictable air flow patterns and possible diminished performance. YORK's unit controls will optimize operation without nuisance high pres-
sure safety cutout; however, the system designer must consider potential performance degradation. Access to the unit control center
assumes the unit is no higher than on spring isolators. Recommended minimum clearances: Side to wall - 2m; rear to wall - 2m; control
panel end to wall - 1.2m; top - no obstructions allowed; distance between adjacent units - 3m. No more than one adjacent wall may be
higher than the unit.
16 DIA.
MOUNTING
HOLES (TYP.)
32
POWER PANEL
A B C D E F G H
762
POWER ELEMENTS
FOR SYS. #1 & #3
2235
762 POWER ELEMENTS
FOR SYS. #2 & #4
CONTROL PANEL
I J K L M N O P
32
806 1453 1453 1453 2142 1422 1422 1422
ORIGIN Y
TOP VIEW LD04009
X
914
2438
1981 50 SYS. #3 & #4
SYS. #1 & #2
CLEARANCES
(2 m)
(1.3 m) (2 m)
(2 m)
LD04841
Notes: No obstructions allowed above the unit.
Only one adjacent wall may be higher than the unit.
Adjacent units should be 10 feet (3 meters) apart.
FIG. 55 – CLEARANCES
A B C D E F
G H I J K L
LD04126
A B C D E F G H
I J K L M N O P
LD04127
60 HERTZ, ALUMINUM FINS, 1" ISOLATOR SELECTIONS – VMC TYPE CP-2 (SEE TABLE BELOW)
YCAS A B C D E F G H I J K L M N O P
0250 27 31 32 26 26 26 27 31 32 26 31 26 –– –– –– ––
0270 27 31 32 26 26 26 27 31 32 26 31 26 –– –– –– ––
0300 27 31 31 27 27 26 27 31 32 26 32 26 –– –– –– ––
0330 27 31 31 27 27 26 27 31 32 26 32 26 –– –– –– ––
0360 28 31 31 27 26 31 31 27 28 31 31 27 26 31 31 27
0400 28 31 31 27 26 31 31 27 28 31 31 27 26 31 31 27
0440 28 31 31 27 26 31 31 27 28 31 31 27 26 31 31 27
ISOLATOR DETAILS
LD01089
FIG. 56 – CP-2-XX
60 HERTZ, ALUMINUM FINS, NEOPRENE MOUNT SELECTIONS – VMC TYPE RD-4 (SEE TABLE BELOW)
YCAS A B C D E F G H I J K L M N O P
0250 BLACK RED RED BLACK BLACK BLACK BLACK RED GREEN BLACK RED BLACK –– –– –– ––
0270 BLACK RED RED BLACK BLACK BLACK BLACK RED GREEN BLACK RED BLACK –– –– –– ––
0300 BLACK RED RED BLACK BLACK BLACK BLACK RED GREEN BLACK GREEN BLACK –– –– –– ––
0330 BLACK RED RED BLACK BLACK BLACK BLACK RED GREEN BLACK GREEN BLACK –– –– –– ––
0360 RED RED RED BLACK BLACK RED RED BLACK BLACK RED RED BLACK BLACK RED RED BLACK
0400 RED RED RED BLACK BLACK RED RED BLACK BLACK RED RED BLACK BLACK RED RED BLACK
0440 RED RED RED BLACK BLACK RED RED BLACK BLACK RED RED BLACK BLACK RED RED BLACK
29518A 29517A
TYPE R OR RD TYPE R OR RD
NO BOLTING IS IF BOLTING IS PREFERRED–
PREFERRED– Type R or RD mountings are
Type R or RD mountings are furnished with a tapped hole in
may be used without bolting the center. This enables the
under machines having no equipment to be bolted securely
lateral or severe vertical to the mounting.
motion.
LD04033 LD04033 7
60 HERTZ, ALUMINUM FINS, SEISMIC ISOLATOR SELECTIONS - VMC MODEL # AWMR - (SEE TABLE BELOW)
YCAS A B C D E F G H I J K L M N O P
0250 -1-532 -1-553 -1-553 -1-531 -1-531 -1-53 -1-532 -1-553 -2-531 -1-53 -1-553 -1-530 –– –– –– ––
0270 -1-532 -1-553 -1-553 -1-531 -1-531 -1-53 -1-532 -1-553 -2-531 -1-53 -1-553 -1-530 –– –– –– ––
0300 -1-532 -2-530 -1-553 -2-521 -1-532 -1-531 -1-532 -1-553 -2-531 -2-520 -2-531 -1-531 –– –– –– ––
0330 -1-532 -2-530 -1-553 -2-521 -1-532 -1-531 -1-532 -1-553 -2-531 -2-520 -2-531 -1-531 –– –– –– ––
0360 -1-551 -1-553 -1-553 -1-532 -2-520 -1-553 -1-553 -2-521 -1-551 -1-553 -1-553 -1-531 -2-520 -1-553 -1-553 -2-521
0400 -1-551 -1-553 -1-553 -2-521 -2-520 -1-553 -1-553 -2-521 -1-551 -1-553 -1-553 -2-521 -2-520 -1-553 -1-553 -2-521
0440 -1-551 -1-553 -1-553 -2-521 -2-520 -1-553 -1-553 -2-521 -1-551 -1-553 -1-553 -2-521 -2-520 -1-553 -1-553 -2-521
LD02973 LD02974
AWMR-1-XXX AWMR-2-XXX
DIMENSIONS - In.
A B C D E F G H I J K L M N/X
AWMR-1 5/8 3/4
10-1/2 6 3 3/4 3-1/2 1-3/4 1/2 9 5/8 8-1/2 4-1/4 10-1/2
50-553 11NC 5/8
AWMR-2 3/4 3/4
15 6 3 1 7-1/2 3-3/4 1/2 9-1/2 5/8 14-1/2 7-1/4 17
50-553 10NC 5/8
A B C D E F
G H I J K L
LD04126
A B C D E F G H
I J K L M N O P
LD04127
60 HERTZ, COPPER FINS, 1" ISOLATOR SELECTIONS – VMC TYPE CP-2 (SEE TABLE BELOW)
YCAS A B C D E F G H I J K L M N O P
0250 28 31 31 27 27 26 27 31 32 26 32 27 — — — —
0270 28 31 31 27 27 26 27 31 32 26 32 27 — — — —
0300 28 31 32 28 28 27 28 32 32 27 32 27 — — — —
0330 28 31 32 28 28 27 28 32 32 27 32 27 — — — —
0360 28 31 31 27 27 32 31 28 28 31 31 27 27 32 31 28
0400 28 31 31 28 27 32 31 31 28 31 31 28 27 32 31 31
0440 28 31 31 28 27 32 31 31 28 31 31 28 27 32 31 31
ISOLATOR DETAILS
LD01089
FIG. 58 – CP-2-XX
60 HERTZ, COPPER FINS, NEOPRENE MOUNT SELECTIONS – VMC TYPE RD-4 (SEE TABLE BELOW)
YCAS A B C D E F G H I J K L M N O P
0250 RED RED RED BLACK BLACK BLACK RED RED GREEN BLACK GREEN BLACK — — — —
0270 RED RED RED BLACK BLACK BLACK RED RED GREEN BLACK GREEN BLACK — — — —
0300 RED RED GREEN RED RED BLACK RED GREEN GREEN BLACK GREEN BLACK — — — —
0330 RED RED GREEN RED RED BLACK RED GREEN GREEN BLACK GREEN BLACK — — — —
0360 RED RED RED BLACK BLACK GREEN RED RED RED RED RED BLACK BLACK GREEN RED RED
0400 RED RED RED RED BLACK GREEN RED RED RED RED RED RED BLACK GREEN RED RED
0440 RED RED RED RED BLACK GREEN RED RED RED RED RED RED BLACK GREEN RED RED
29518A 29517A
TYPE R OR RD TYPE R OR RD
NO BOLTING IS IF BOLTING IS PREFERRED–
PREFERRED– Type R or RD mountings are
Type R or RD mountings are furnished with a tapped hole in
may be used without bolting the center. This enables the
under machines having no equipment to be bolted securely
lateral or severe vertical to the mounting.
motion.
LD04033 LD04033 7
60 HERTZ, COPPER FINS, SEISMIC ISOLATOR SELECTIONS - VMC MODEL # AWMR - (SEE TABLE BELOW)
YCAS A B C D E F G H I J K L M N O P
0250 -1-551 -1-553 -1-553 -1-532 -1-532 -1-531 -1-551 -1-553 -2-531 -1-530 -2-530 -1-532 — — — —
0270 -1-551 -1-553 -1-553 -1-532 -1-532 -1-531 -1-551 -1-553 -2-531 -1-530 -2-530 -1-532 — — — —
0300 -1-551 -1-553 -2-531 -2-53 -1-532 -1-532 -1-551 -2-530 -2-532 -2-521 -2-531 -1-532 — — — —
0330 -1-551 -1-553 -2-531 -2-53 -1-532 -1-532 -1-551 -2-530 -2-532 -2-521 -2-531 -1-532 — — — —
0360 -1-551 -1-553 -1-553 -1-532 -2-520 -2-530 -1-553 -2-53 -1-551 -1-553 -1-553 -1-532 -2-520 -2-530 -1-553 -2-53
0400 -1-552 -1-553 -1-553 -2-53 -2-521 -2-531 -1-553 -2-53 -1-552 -1-553 -1-553 -2-53 -2-521 -2-531 -1-553 -2-53
0440 -1-552 -1-553 -1-553 -2-53 -2-521 -2-531 -1-553 -2-53 -1-552 -1-553 -1-553 -2-53 -2-521 -2-531 -1-553 -2-53
LD02973 LD02973
AWMR-1-XXX AWMR-2-XXX
DIMENSIONS - In.
A B C D E F G H I J K L M N/X
AWMR-1 5/8 3/4
10-1/2 6 3 3/4 3-1/2 1-3/4 1/2 9 5/8 8-1/2 4-1/4 10-1/2
50-553 11NC 5/8
AWMR-2 3/4 3/4
15 6 3 1 7-1/2 3-3/4 1/2 9-1/2 5/8 14-1/2 7-1/4 17
50-553 10NC 5/8
OC
CDR
OS
EC
COMP.
CLR
RC2
CH.W CH.W
IN OUT
Low Pressure Liquid Low Pressure Vapour High Pressure Vapour
COMP - Compressor CDR -Condenser Coil CLR - Cooler EC - Economizer (Added to some models)
OC - Oil Cooler OS - Oil Separator
3
m /s - Air Entering Compressor R-22 - Refrigerant Circuit Number
Relief Valves
LD05019
Low pressure liquid refrigerant enters the cooler and is A small percentage of the of the liquid passes through
evaporated and superheated by the heat energy absorbed an expansion valve, into the other side of the econo-
from the chilled water passing through the cooler shell. mizer where it is evaporated. This low pressure liquid
Low pressure vapor enters the compressor where pres- subcools the major part of the refrigerant. Medium pres-
sure and superheat are increased. High pressure vapor is sure vapor then returns to the compressor. The
passed through the oil separator where compressor oil is subcooled refrigerant then passes through the expan-
removed and recirculated to the compressor via the oil sion valve where pressure is reduced and further cool-
cooler. The high pressure oil-free vapor is fed to the air ing takes place before returning to the cooler.
cooled condenser coil and fans where the heat is removed.
The fully condensed liquid enters the economizer.
LD03486
Control Panel
BAMB
2-BOT 1-BOT
1-BDP
2-BDP
1-BDT
2-BDT
1-BOT
1-BOP
2-BOP
1-YLLSV
2-YLLSV
1-SHPI
2-SHPI
1-ZCPR
2-ZCPR
2-CCCV 1-CCCV
2-ECH 1-ECH
1-XCMTB
2-XCMTB
2-STS
1-STS
1-BSP
2-BSP
2-YELSSV 1-YELSSV
3-YELSSV
3-BOT
3-BDP
1-RFTS
2-RFTS
3-RFTS
3-BDT
3-BOP
3-SHPI
3-ZCPR
3-CCCV
3-ECH
BCRT
3-XCMTB
EEH1
3-STS
3-BSP
3-YELSSV
- BAMB AMBIENT
- BCLT COLD LEAVING TEMPERATURE
EEH1
BCLT
LD05021
Control Panel
BAMB
2-BOT 1-BOT
1-BDP
2-BDP
1-BDT
2-BDT
1-BOT
1-BOP
2-BOP
1-YLLSV
2-YLLSV
1-SHPI
2-SHPI
1-ZCPR
2-ZCPR
2-CCCV 1-CCCV
2-ECH 1-ECH
1-XCMTB
2-XCMTB
2-STS
1-STS
1-BSP
2-BSP
2-YELSSV 1-YELSSV
4-YELSSV 3-YELSSV
4-BOT
3-BOT
4-BDP
3-BDP
4-BDT
3-BDT
4-BOP
3-BOP
4-SHPI
3-SHPI
4-ZCPR
3-ZCPR
4-CCCV
3-CCCV
4-ECH
3-ECH
4-XCMTB
3-XCMTB
4-STS 3-STS
4-BSP
3-BSP
3-YELSSV
4-YELSSV
3-RFTS
1-RFTS
4-RFTS
2-RFTS
BCRT
- BAMB AMBIENT
- BCLT COLD LEAVING TEMPERATURE 7
EEH1
LD05024
COMPRESSOR COMPONENTS
LIFTING LUG
THREADED HOLE
OIL FILTER
BLEED &
EVACUATION
POINT
LIFTING LUG
THREADED
HOLE
OIL
HEATER
ECONOMIZER
GAS IN
DISCHARGE
CASE DISCHARGE GAS OUT
OIL INLET
FROM
CONDENSER LD03668
CODING COIL
LD03669
LD03670
LD03671
MOTOR ROTOR /
MALE ROTOR LOCKING
KEY
O-RING
MALE ROTOR
LD03672
27
26
25
28
21 22 23 24
29
NO. PART NAME
30
1 O-RING
35 34 33 32 31
2 SUCTION COVER
3 SUCTION STRAINER
20
4 ROTOR SCREW
19
15 16 17 18
36
7 ROTOR
37
8 STATOR
38
9 MALE INLET BEARING
10 MALE ROTOR RETAINING RING
11 MALE ROTOR
14
12 ROTOR CASE
39
13 O-RING
13
40
14 DOWEL PIN
12
15 DISCHARGE CASE
41
16 LIP SEAL
17 DISCHARGE RADIAL BEARING
11
18 SPACER SHIM
10
19 THRUST BEARINGS
42
43
34 THRUST BEARINGS
35 SPACER SHIM 7
36 DISCHARGE RADIAL BEARING
6
37 LIP SEAL
38 DOWEL PIN
5
39 SUPPORT RING
4
40 ECONOMIZER PLUG
41 SUPPORT RING
42 FEMALE ROTOR RETAINING RING
3
LD03673
COMPRESSOR #4
MODEL#: ________________________________
SERIAL #: ________________________________
q 7. Check the control panel to assure it is free of
foreign material (wires, metal chips, etc.).
Unit Checks
Check the system 24 hours prior to initial start q 8. Visually inspect wiring (power and control).
(No Power) Wiring MUST meet N.E.C. and local codes. See
Fig. 8, page 35 and 36.
q 1. Inspect the unit for shipping or installation
damage. q 9. Check tightness of power wiring inside the
power panel on both sides of the motor
q 2. Assure that all piping has been completed.
contactors and inside the motor terminal boxes.
q 3. Check that the unit is properly charged and that
q 10.Check for proper size fuses in main and control
there are no piping leaks.
circuits.
q 4. Open each compressor suction service valve,
q 11.Verify that field wiring matches the 3-phase
discharge service valve, economizer service
power requirements of the compressor. See
valve, liquid line stop valve, and oil line ball
chiller nameplate (Pages 25 - 26).
valves.
q 12.Assure 115VAC Control Power has 30A mini-
q 5. The compressor oil level should be maintained
mum capacity. See Fig. 12, page 40.
so that an oil level is visible in either of the two
oil separator sight glasses. In other words, oil q 13.Be certain all water temp sensors are inserted
level should always be maintained, running or completely in their respective wells and are
coated with heat conductive compound.
132 YORK INTERNATIONAL
FORM 201.18-NM3
q 14. Assure that evaporator TXV bulbs are strapped Dip switches 4 through 8 are spares
onto the suction lines at 4 or 8 o’clock posi- and have no function.
tions.
q 15. Assure that 5 ton TXV bulbs are inserted fully
into the wells in the compressors and that the
bulbs are coated with heat conductive com-
pound. q 5. Program the required operating values into the
micro for cut-outs, safeties, etc. and record them
q 16. Assure that the 15 ton economizer TXV bulbs
in the chart below. See Page 176 for details.
are strapped onto the compressor economizer
supply lines at 4 or 8 o’clock positions. If Default Values are desired for programming
convenience, press the PROGRAM key, 6140,
Panel Checks and ENTER. This loads default values. Record
(Power ON – Both System Switches “OFF”) these values in the chart below.
PROGRAMMED VALUES
q 1. Apply 3-phase power and verify its value (See
Fig. 8, page 35). Refrigerant Type = _________________________
q 2. Apply 115VAC and verify its value on the ter- Dischg Press Cut-out = ____________ PSIG (kPa)
minal block in the lower left of the Power Panel.
Make the measurement between terminals 5 and Disch Press Unld = ________________ PSIG (kPa)
2 (See Fig. 12, page 40). The voltage should be Suction Press Cut-out = ____________ PSIG (kPa)
115VAC +/- 10%.
q 3. Assure the heaters on each compressor are on. High Amb Cut-Out = ___________________ °F (°C)
Allow the compressor heaters to remain on a Low Amb Cut-Out = ___________________ °F (°C)
minimum of 24 hours before startup. This is im-
portant to assure that no refrigerant is in the com- Leaving Chilled Liquid Temp Cut-Out = _____ °F (°C)
pressor oil at start-up! High Motor Current Unload = ____________ % FLA
q 4. Program the dip switches on the microproces-
Anti-Recycle Time = ____________________ Secs
sor board for the desired operating requirements.
See Page 159. OPEN = Left side of switch
pushed down. CLOSED = Right side of switch q 6. Program the Chilled Liquid Setpoint/Range and
pushed down. record:
Setpoint = __________________ °F (°C)
SWITCH “OPEN” SWITCH “CLOSED”
SWITCH
SETTING SETTING Range = ________ to ________ °F (°C)
1 Water Cooling Brine Cooling
2 Standard Ambient Low Ambient Keep in mind that the Target temperature dis-
Control Control played by the micro should equal the desired
3 Refrigerant R-407C Refrigerant R-22 leaving water temperature.
q 7. Assure that the CLK jumper J18 on the Micro-
Verify the selections by pressing the OPTIONS processor Board is in the ON position (Top 2 7
Key on the control panel. Check them off. pins).
Damage to the chiller could result if q 8. Set the Time and Date.
switches are improperly programmed. q 9. Program the Daily Schedule start and stop times.
When the refrigerant charge is correct, there will be no The superheat is calculated as the difference between
bubbles in the liquid sight glass with the system oper- the actual temperature of the returned refrigerant gas
ating under full load conditions, and there will be 10 - in the suction line entering the compressor and the tem-
15°F (6 - 8°C) subcooled liquid leaving the condenser. perature corresponding to the suction pressure as shown
An overcharged system should be guarded against. Evi- in a standard pressure/temperature chart.
dences of overcharge are as follows: Example:
a. If a system is overcharged, the discharge pressure Suction Temp = 46°F (8°C)
will be higher than normal. (Normal discharge/con-
minus Suction Press
densing pressure can be found in the refrigerant tem-
perature/pressure chart; use entering air temperature 60 PSIG converted
+30°F (17°C) for normal condensing temperature. to Temp - 34°F (1°C)
b. The temperature of the liquid refrigerant out of the 12°F (7°C)
condenser should be not be more than 15°F (8°C) The suction temperature should be taken 6" (13 mm)
less than the condensing temperature (The tempera- before the compressor suction service valve, and the
ture corresponding to the condensing pressure from suction pressure is taken at the compressor suction ser-
the refrigerant temperature/pressure chart). vice valve.
Normally, the thermal expansion valve need not be ad- Normally, the thermal expansion valve need not be ad-
justed in the field. If, however, adjustment needs to be justed in the field. If however, adjustment needs to be
made, the expansion valve adjusting screw should be made, the expansion valve adjusting screw should be
turned not more than one turn at a time, allowing suffi- turned not more than one turn at a time, allowing suffi-
cient time (approximately 15 minutes) between adjust- cient time (approximately 15 minutes) between adjust-
ments for the system and the thermal expansion valve ments for the system and the thermal expansion valve
to respond and settle out. Assure that superheat is set at to respond and settle out. Assure that superheat is set
10 - 15°F (6 - 8°C). between 10 - 12°F (6 - 7°C).
q 2. Record the suction temperature, suction pres-
sure, suction pressure converted to temperature, q 1. Record the motor gas temperature, economizer
and superheat of each system below: pressure, economizer pressure converted to tem-
SYS 1 SYS 2 SYS 3 SYS 4
perature, and economizer superheat below:
Suction Temp = ____ ____ ____ ____ PSIG (kPa) SYS 1 SYS 2 SYS 3 SYS 4
Suction Press = ____ ____ ____ ____ °F (0°C) Motor Gas Temp = ____ ____ ____ ____ PSIG (kPa)
Temp = ____ ____ ____ ____ °F (0°C) Economizer Press = ____ ____ ____ ____ °F (°C)
Superheat = ____ ____ ____ ____ °F (0°C) Temp = ____ ____ ____ ____ °F (°C)
STATUS DISPLAY
SETPOINTS
CLOCK
DISPLAY
INFORMATION KEYS
29023A
29023A
User interface is via a touch keypad and a liquid crystal An operator keypad allows complete control of the
display allowing access to operating and programmed chiller from a central location. The keypad offers a
data. Information can be displayed in English (Impe- multitude of commands available to access displays,
rial) units or S.I. (Metric) units (Section 8.1). Conver- program setpoints, and initiate system commands. Keys
sion tables are provided at the back of this manual. are grouped and color coded for clarity and ease of use.
A master ON/OFF rocker switch is provided on the A 40 Character Liquid Crystal Display (2 lines of 20
chiller control panel to activate or deactivate the com- characters) is used for displaying system parameters
plete chiller, while switches to activate or deactivate and operator messages. The display has a lighted back-
individual refrigerant systems are provided on the Mi- ground for night viewing as well as a special feature
croprocessor Board(s). which intensifies the display for viewing in direct
sunlight.
External interface is available for control of the chiller
via a YORK ISN System or YORK Remote Control Displays will be updated every two seconds by the mi-
Center. In addition, EMS/BAS System connections are croprocessor.
1.3 UNIT (CHILLER) ON / OFF SWITCH The battery is a 10 year lithium type, but life will de-
pend upon whether the Real Time Clock’s internal clock
A master UNIT (Chiller) ON / OFF switch is located circuit is energized. With the clock OFF, a rated life of
just below the keypad. This switch allows the operator approximately 10 years can be expected. With the clock
to turn the entire chiller OFF, if desired. The switch ON, approximately 5 years. The clock is enabled and
must be placed in the ON position for the chiller to disabled using a jumper on the microprocessor board.
operate. Any time the switch is in the OFF position, a
Status message indication will be displayed. See page If the chiller is shut down or power failure is expected
136 for the location of this switch. for extended periods, it may be desirable to disable the
clock to save battery life. The clock can then be reacti-
1.4 MICROPROCESSOR BOARD vated and reprogrammed when the chiller is returned
to service. This will not affect the maintenance of pro-
The Microprocessor Board(s) controls and makes de-
grammed values and stored data by the backup battery.
cisions for the chiller. Information inputs from trans-
ducers and sensors around the chiller are either con- While a chiller is operating, the clock must be ON (Sec-
nected directly to the Microprocessor Board or are con- tion 1.11, Item 1) or the internal clock on the micropro-
nected to the I/O Expansion Board and multiplexed cessor will not be active and the micro cannot keep track
before being sent to the Microprocessor Board. The Mi- of time, although all other functions will operate nor-
croprocessor Board circuitry multiplexes all of these mally. Failure to turn the Clock ON could result in the
analog inputs, digitizes them, and constantly scans them chiller not starting due to the time "frozen" on the clock
to monitor chiller operating conditions. Based on this falling outside the Start/Stop time programmed in the
information, the Microprocessor issues commands to Daily Schedule, see Section 7.3.
the Relay Boards to activate and deactivate contactors,
solenoids, etc. for chilled liquid, operating control, and
1.5 ANCILLARY CIRCUIT BOARDS
safety control.
Commands are sent from the Microprocessor Board to Power Supply Board
the I/O Expansion Board to control the slide valves for The on-board switching power supply is fuse protected
chilled liquid control. and converts 24VAC from the logic transformer 2T to
+12V REG which is supplied to the Microprocessor
Keypad commands are acted upon by the micro to Board, Relay Output Boards, and the 40 character dis-
change setpoints, cutouts, scheduling, operating require- play to operate the integrated circuitry.
ments, and to provide displays.
24VAC is filtered, but not regulated, to provide unregu-
A +12VDC REG supply voltage from the Power Sup- lated +24VDC to supply the flow switch, PWM remote
ply Board is converted to +5V REG by a voltage regu- temperature reset, PWM remote current reset, lead /
lator located on the Microprocessor Board. This volt- lag select, and remote print circuitry which may be uti-
age is used to operate the integrated circuitry on the lized with user supplied contacts.
board.
24VAC is also filtered and regulated to +24VDC to be
System Switches 1 - 4 used by the optional EMS/BAS Circuit Boards for re-
System Switches for each system are located on the mote temperature or remote current reset.
Microprocessor Board (Section 1.11, Item 5). These
switches allow the operator to selectively turn a given Individual rectifier and filtering circuits are present
system on or off as desired. which receive the Current Transformer signals for each
phase of motor current on each compressor. These cir-
Internal Clock & Memory Backup Battery cuits rectify and filter the signals to variable DC. A
The Microprocessor Board contains a Real Time Clock phase rotation circuit for each compressor is also present
integrated circuit chip (Section 1.11, Item 2) with an to assure that the screw compressors do not run in the
internal battery backup. The battery backup assures that wrong direction. All of these signals are sent to the I/O
any programmed values (setpoints, clock, cutouts, etc.) Expansion Board which multiplexes them and then
are not lost during a power failure or shutdown period feeds them to the Microprocessor Board.
regardless of the time involved.
I/O Expansion Board #1 The relay boards are located in the logic section of the
The I/O Expansion Board provides multiplexing to al- control panel(s). The boards convert 0 - 12VDC logic
low additional inputs to be connected to the Micropro- levels outputs from the Microprocessor Board to
cessor Board via a single data line. The additional in- 115VAC levels used by the contactors, valves, etc.
puts are multiplexed according to the selection made
by the Microprocessor through address lines. The common side of all relays on the Relay Output
Board is connected to +12VDC REG. The open collec-
tor outputs of the Microprocessor Board energize the
Signals routed through the I/O Expansion Board include
DC relays or triacs by pulling the other side of the relay
Discharge Temperature, Current Transformer outputs
coil to 0VDC. When not energized, both sides of the
(motor current signals), and Oil Temperature.
relay coils or triacs will be at +12VDC potential.
8
Included on the I/O Expansion Board are the outputs for 1.6 CIRCUIT BREAKERS
the slide valve control. This control consists of a Digital
to Analog Converter (DAC) and power transistors to Circuit Breakers are provided for the 115VAC controls.
modulate current through the slide valve solenoids.
• CB1, CB2, and CB3 allows removal of control
power from respective System 1, 2, or 3 for control
I/O Expansion Board # 2 system circuitry servicing. Specifically, the 115VAC
The second I/O Expansion Board is used only on 3 and feed to Relay Output Board 1 which energizes
4 compressor YCAS chillers. Due to limited output and contactors and solenoids.
input capabilities of the main Microprocessor Board, • CB4 allows removal of control power to the Mi-
an additional Microprocessor is needed to control a third croprocessor Board, Power Supply Board, I/O Ex-
and fourth compressor. pansion Boards, and Evaporator Heater on 3 Sys-
tem chillers.
The second I/O Expansion Board has processing • CB5 allows removal of control power to the Mi-
carpabilities. It’s job is to monitor inputs from the third croprocessor Board, Power Supply Board, I/O Ex-
and fourth compressor, provide safety control, and pansion Board, and Evaporator Heater on 4 Sys-
shuttle information back to the main Microprocessor tem chillers.
Board. The shuttling of information is done using an
RS-485 communication line to the Microprocessor The Circuit Breakers remove 115VAC
Board. control power only. High voltage cir-
cuitry will still be energized from the
Communication between the Microprocessor Board and high voltage supply.
I/O Board #2 takes place approximately once every sec-
ond. The communications transfer is necessary to en-
REMOVING 115VAC power to or
able the main Microprocessor to display system param-
opening CB4 (3 System chillers) or
eters and command the starting, stopping, loading, and
unloading of System 3 and 4 to control chilled liquid CB5 ( 4 System chillers), removes
temperature. power from the evaporator heaters.
This could cause evaporator freeze-up
The second I/O Expansion Board also controls the out-
in low ambient temperatures.
puts to a Relay Output Board which activates and
de-activates 115VAC control outputs to System 3 and 1.7 CURRENT TRANSFORMERS (C.T.)
4 compressors, solenoids, etc. These outputs are con- C.T.s located internally in the Motor Protector Modules
trolled in response to commands issued by the Micro- on each of the 3 phases of the power wiring of each com-
processor Board. pressor motor send AC signals proportional to motor cur-
rent to the Power Supply Board which rectifies and fil-
Relay Output Boards ters the signals to variable DC Voltage (analog). These
One Relay Output Board per system operates the mo- analog levels are then fed to the Microprocessor Board
tor contactors/starters, solenoid valves, and heaters via the I/O Expansion Board allowing the microproces-
which control system operation. sor to monitor motor currents for low current, high cur-
rent, unbalanced current, and single phasing.
YORK INTERNATIONAL 139
MicroPanel Contents
29119A
SIDE VIEW
29121A
TOP VIEW
DISPLAY
SWITCH
PUSHED TO
LEFT ON
INDICATES
ON
29120A
SIDE VIEW
1.10 EMS/BAS CONTROLS Closing the input contact for a defined period of time
allows reset of the % Current Limit downward. Con-
The microprocessor system can accept remote signals
tact closure of 1 - 11 seconds will allow % Current Lim-
to Start/Stop the chiller, to adjust maximum allowable
iting to be adjusted downward from 105% by a maxi-
running current for each compressor, and to adjust the
mum of 75%, i.e. to a minimum value of 30% FLA.
chilled liquid leaving temperature setpoint. These func-
EMS Current Limiting operates independently of the
tions can easily be controlled by connecting user sup-
High Average Current Unload (See Section 8.2). The
plied “dry” contacts to the customer terminals in the
micro will always look at the two Current Limit
control panel. In addition, Alarm Contacts are provided
Setpoints and choose the lower as the controlling value,
to remotely signal a fault with the chiller.
whenever Remote Current Limiting is utilized. Con-
tact closures of less than 1 second will be ignored. A
Remote Start/Stop
closure of 11 seconds is the maximum allowable clo-
Remote Start/Stop can be accomplished using a time
sure and provides a Current Limit reduction of 75%.
clock, manual contact or other “dry” contact in series
The remote reset current can be calculated as follows;
with the flow switch (Terminals 13 and 14 of TB4) con-
nected to terminals in the logic section of the control REMOTE
panel. The contact must be closed to allow the chiller to RESET = 105% FLA - {(Contact Closed Time -1sec) x (75% FLA)}
run. Any time the contact opens, the chiller will shut CURRENT 10 sec
down and the NO RUN PERM message will be displayed.
The location of the flow switch connection is shown in For example, after a 4 second pulse, the offset would
Section 1.12. equal:
Wiring from remote “dry” contact (for above, if the programmed setpoint = 44°F (7°C), the
reset functions) should not exceed 25 new setpoint after the 4 second contact closure would
ft. (8 m) and should be run in grounded be 44°F (7°C)+ 12°F (6°C) = 56°F (13°C). This new
conduit that does not carry any wiring setpoint can be viewed on the display by Pressing the
other than control wiring or shielded Remote Reset Temperature/Range key.
cable. If an inductive device (relay, To maintain a given offset, the contact closure signal
contactor) is supplying these contacts, must be repeated every 30 seconds - 30 minutes. The
the coil of the device must be sup- refresh is not accepted sooner than 30 seconds from
pressed with a suppressor YORK Part the end of the last PWM signal, but must be refreshed
Number 031-00808-000 (60Hz models) before 30 minutes has elapsed. After 30 minutes, if no
or a standard RC suppressor (50Hz refresh is provided, the setpoint will change back to its 8
models) across the inductive coil. original value.
After an offset signal, the new Remote
Remote Setpoint Reset
Setpoint may be viewed on the Remote
The chilled liquid leaving temperature setpoint pro-
Reset Temperature Range display.
grammed into the micro can be remotely adjusted to a
higher value using repeated timed closure of “dry” con- However, if this display is being viewed
tacts connected to Terminals 13 and 17 of TB4 in the when the reset pulse occurs, the
logic section of the control panel (See Section 1.12). setpoint will not change on the display.
The duration of the contact closure will decide the To view the new offset, first press any
amount of adjustment. This is achieved as follows: other display key on the keypad and
then press the Remote Reset Tempera-
The maximum allowable reset value can be programmed ture Range key. The new setpoint will
from 2°F - 40°F (1°C - 22°C), as appropriate to the then appear.
application - see Section 6.4. Once the maximum reset
is programmed, an input contact closure of 11 seconds
Remote Setpoint Reset will not oper-
provides the maximum reset. Closure for less than 11
ate when a Remote Control Center
seconds will provide a smaller reset. For noise immu-
nity, the micro will ignore closures of less than 1 sec- Option Kit is connected to the Micro.
ond. To compute the necessary contact closure time to The Remote Control Center will al-
provide a required Reset, use the following steps: ways determine the setpoint.
3
2
26001A
60 Hz Models : 6 7
2 4
00262VIP
PHOTOGRAPH OF
60HZ MODEL LOGIC SECTION
ITEM DESCRIPTION
1 Microprocessor Board
2 Back of Keypad
3 I/O Expansion Board # 2
4 I/O Expansion Board # 1
5 Power Supply Board
6 Relay Output Board #1
7 Relay Output Board #2
8 Flow Switch & Customer Connection Terminals (TB4)
The programmable Anti-Recycle Timer allows the user The evaporator heater is controlled by ambient tem-
to select the compressor anti-recycle time to best suit perature. When the ambient temperature drops below
their needs. Motor heating is a result of inrush current 40°F (4°C), the heater is turned on when the compres-
when the motor is started. This heat must be dissipated sors are turned off. When the temperature rises above
before another start takes place or motor damage may 45°F (7°C), the heater is turned off. An undervoltage
result. The anti-recycle timer assures that the motor has condition will keep the heater off until full voltage is
sufficient time to cool before it is restarted. restored to the system. The heater will provide freeze
protection to -20°F.
An adjustable timer allows for the motor cooling, but
gives the user the ability to extend the anti-recycle timer 115VAC power must remain “ON”
to cut down on cycling. In some applications, faster through CB4 (3 System chillers) or
compressor start response is necessary and shorter anti- CB5 (4 System chillers) for freeze pro-
recycle times are required. These needs should be kept tection. Otherwise, the evaporator
in mind but whenever possible the timer should be ad- must be drained.
justed for the longest period of time tolerable. 600 sec-
onds is recommended, although 300 seconds provides 1.18 PUMPDOWN (LLSV) CONTROL
adequate motor cooling time. Longer periods will al-
low more heat dissipation, reduce cycling, and possi- Each compressor undergoes a pump down cycle on start-
bly increase motor life. See Section 8.2, page 179 for up and shutdown. This assures that liquid refrigerant
programming of the anti-recycle timer. does not enter the compressor on start-up, eliminating
the need for recycling pump down, saving energy and
1.14 ANTI-COINCIDENCE TIMER reducing compressor starts and wear.
The Anti-Coincidence Timer assures that 2 systems
On start-up, the controls unload the compressor and the
do not start simultaneously. This assures that inrush
system either pumps down to the low suction pressure
current is kept to a minimum. A 60 second time delay
cutout setting or pumps down for 15 seconds, which-
will always separate motor starts. This timer is not
ever comes first, after which the Liquid Line Solenoid
programmable.
Valve is energized and normal operation commences.
1.15 EVAPORATOR PUMP CONTROL
On shutdown, the microprocessor controls unload the
Dry contacts are provided which transition (close) when compressor and the Liquid Line Solenoid Valve and
the Daily Schedule is calling for chiller operation and Economizer/Motor Cooling Liquid Supply Solenoid
power has been applied to the micropanel for 30 sec- Valve are de-energized. The compressor continues to
onds. If for some reason the evaporator pump contacts operate until it either pumps down to the low suction
have been closed to run the pump and a power loss or pressure cutout setting or for 180 seconds, whichever
Daily Schedule shuts the pump down (contacts open), comes first. Pump down occurs on “normal” shutdowns
the contacts will not reclose for any reason until 30 where cooling demand has been satisfied or when a
seconds has elapsed after power re-application or 30 system switch is turned off, a flow switch opens, run
seconds have elapsed between a Daily Schedule shut- permissive is lost or a Daily Schedule or a Remote Shut-
down and restart. down is called for.
1.16 COMPRESSOR HEATER CONTROL No pumpdown will occur on a safety shutdown. See
page 149 for the pumpdown display message.
Each compressor has its own heater. The heater will be
off whenever the compressor is running. As soon as the 1.19 ALARMS
compressor shuts off, the heater will turn on and stay Internal contacts are provided in the Power Panel (See
on for 5 minutes. After 5 minutes has elapsed, the heater Section 1.12) which can be used to remotely signal a
will shut off if the discharge temperature rises above warning whenever a fault lockout occurs on any sys-
150 °F (66°C) and will turn on when the discharge tem- tem or if power is lost to the control panel. The internal
perature is equal to or less than 150 °F (66°C). contacts are normally open (N.O.) and will close when
control power is applied to the panel, if no fault condi- When AUTO Lead/Lag is utilized, the micro attempts
tions are present. When a fault occurs which locks out to balance run time between the two compressors. A
a system the respective contacts open. If chiller power number of conditions can occur which will prevent this
is lost or a unit fault occurs, such as a Low Water Temp from happening. Factors determining lead/lag selection
fault, contacts for all systems will open. and the resulting lead/lag determination are:
1. The micro automatically defaults the lead to SYS 1
Contacts for SYS 1 are located on the bottom right of
and the lag to SYS 2 if both compressors are ready
the microprocessor panel, terminals 23 and 24. SYS 2
to start (Anti-recycle Timers timed out) and com-
contacts are located on terminals 27 and 28, SYS 3 on
pressors have equal run time.
terminals 37 and 38, and SYS 4 on terminals 41 and
42. See Fig. 11, Page 39 for the location of these termi- 2. In YCAS 3 System models, SYS 2 is assigned first
nals. lag and SYS 3 the second lag. The same lead/lag 8
assignment occurs with YCAS 4 System models
A 28VDC or 120VAC (60Hz models) or up to 240VAC with SYS 4 assigned as the third lag. Individual
(50Hz models) external alarm circuit (supplied by oth- system run status is not present.
ers) may be connected to these contacts. The contacts
are rated at 125VA. 3. If all compressors are ready to start (Anti-recycle
timers timed out), the compressor with the lowest
If any inductive load devices (relay or run hours will start first.
contactor) supplied by the user are in
the electrical circuit connected to the 4. If all compressors are waiting to start (Anti-recycle
timers have not timed out), the micro will assign
dry alarm contacts, the device must be
the lead to the compressor with the shortest anti-
suppressed at the load with a RC sup-
recycle time in a an effort to provide cooling
pressor YORK Part Number 031- quickly.
00808-000 across the inductive coil.
(Typically, several are supplied loose 5. If the lead compressor is locked out, faulted and
with the panel). Failure to install sup- waiting to restart, SYS switch on the microboard is
pressors will result in nuisance faults off, or a run permissive is keeping an individual
system from running, the lag (first lag in YCAS 3
and possible damage to the chiller.
System and YCAS 4 System models) compressor
If the alarm circuit is applied in an ap- is swapped to the lead. This is true regardless of
plication used for critical duty (such whether the lag compressor is ON or OFF.
as process duty or cooling other criti-
cal equipment) and the alarm circuit MANUAL Lead/Lag selection will be automatically
should fail to function, YORK will not overridden by the micro to allow the lag compressor to
automatically become the lead anytime the selected lead
be liable for damages.
compressor shuts down due to a lock-out, lead system
1.20 RUN STATUS (CHILLER) faults and is waiting to restart, lead switch on the micro
board is in the OFF position, or if a run permissive is
Chiller Run Status contacts between Terminal 28 and keeping the lead of the system off. Automatic
29 close whenever one of the systems is running. These switchover in MANUAL mode is provided to try to
contacts are located on the bottom right of the Micro- maintain chilled liquid temperature as close to setpoint
processor Board and are rated (voltage and current) the as possible.
same as the alarm contacts (Section 1.19). Also use a
suppressor, same as alarm contacts (Section 1.19). In- 1.22 3 OR 4 COMPRESSOR
dividual system “Run Status” is not available. CHILLER CONFIGURATION
1.21 LEAD / LAG COMPRESSOR SELECTION
The EPROMs are identical in 3 and 4 compressor units.
The chiller may be set up for AUTO or MANUAL Lead / To place the software in 3 compressor mode, a jumper
Lag. This is accomplished by programming the option must be connected between J4-3 and +24V on the
under the Program Key. Details for programming the microboard. This connection can be made between
Manual/Auto Lead/Lag Selection are discussed in Pro- terinals 13 and 75 on the terminal block. If the jumper is
gram Key Section 8, page 179. not installed, the unit will operate as a 4 compressor unit.
29023A
This message indicates that both refrigerant systems Anticipation controls monitor discharge pressure, mo-
are in a pumpdown cycle. Pumpdown display messages tor current and suction temperature for each compres-
occur on shutdowns where the cooling load has been sor and if maximum limits are approached, the slide
met, or when a system switch is turned OFF. Note that valve loading of the respective compressor will be re-
only one compressor could be pumping down, as shown duced to avoid exceeding the limit.
in the following display:
S Y S 1 P U M P I N G D OWN Displays of anticipation safety control messages and
S Y S 2 C OM P R U N N I N G their meanings are as follows:
See Section 1.18 (page 146) for details of pumpdown Discharge Pressure Limiting:
control.
S Y S # D S C H L I M I T I N G
Incorrect Refrigerant Warning: S Y S # D S C H L I M I T I N G
R E P R O G R A M T Y P E O F
R E F R I G E R A N T T O R U N Discharge Pressure Limiting takes effect when com-
pressor discharge pressure nears the point at which the
The incorrect Refrigerant Warning will occur if the DIP high pressure cutout would shut the system down. When
Switch setting for refrigerant type and the type pro- the above message appears, discharge pressure has ex-
grammed into the micro “at the factory” are not the ceeded the programmable threshold and the compres-
same. This message will be displayed until the non- sor is being unloaded in an effort to prevent shutdown
programmable “factory” programmed refrigerant type on the high pressure cutout. The operation of this safety
and DIP Switch setting agree. is important if condenser coils become dirty, if there is
a problem with the condenser fan operation, or if ex-
Power Failure Warning: treme ambient or load conditions occur (see Section
The Power Failure Warning will only be displayed on 8.2 / High Discharge Pressure Unload Point [page 177]
“power restoration” after a “power loss,” if manual re- for more details).
start on power failure is selected under the PROGRAM
key (page 180). If manual restart on power failure has Compressor Motor Current Limiting:
been selected, the following warning message is dis- S Y S # C U R R L I M I T I N G
played indefinitely on power restoration and the chiller S Y S # C U R R L I M I T I N G
will not run until the UNIT Switch is cycled OFF-and-
on to restart the unit. This safety is available for users The Motor Current Limiting message indicates that a
who desire a chiller lock-out on power failure. compressor motor current has reached a programmable,
Bas, or remote limit and the system is being unloaded
This is typically not a desirable feature. to assure that motor current does not become exces-
sively high causing a fault (see also Section 8.2 / High
Motor Current Unload Point, page 178; Section 3.5,
Motor Current Key, page 157; Section 1.10, page 142).
When this message appears, the chiller will not run and The Suction Temperature Limiting message applies only
the Unit Switch must be cycled OFF and ON to start when the chiller is set for Water Cooling Mode (see page
the unit. 158). The message indicates that saturated suction tem-
perature on a system has dropped to 29°F (-2°C) and
2.4 ANTICIPATION CONTROL STATUS
that any further temperature reduction could cause some
MESSAGES
icing of the evaporator tubes. Saturated suction tempera-
Anticipation controls are built into the software to ture is computed by the micro by converting suction pres-
prevent safety shutdowns by automatically overriding sure to temperature.
the temperature controls, if system conditions approach
safety thresholds. This avoids total loss of cooling For the first 3 minutes that the saturated suction tem-
resulting from a lockout by a safety control. perature is at or below 29°F (-2°C) any further compres-
sor loading is inhibited to allow time for the temperature High Ambient Temperature Cutout:
to rise. If the condition persists for more than 3 minutes,
U N I T F A U L T
a 5 minute timer is started. As this timer counts down to
H I G H A M B I E N T T E M P
zero, a 1 second unload pulse will be sent to the slide
valve of the affected compressor every 5 seconds as long The High Ambient Temperature Safety protects the
as the temperature is below 31°F (-1°C). If the tempera- chiller from running in ambients above 130°F (54°C)
ture rises above 31°F (-1°C), the micro will inhibit load- where potential malfunction of system mechanical and
ing for the remainder of the 5 minute period. electrical components may result. The High Ambient
Cutout is programmable and can be set for lower limit
If after the 5 minute period the saturated suction tem- values if required (see also Section 8.2 / High Ambient
perature is above 29°F (-2°C), the compressor is allowed Temperature Cutout [page 178]). The fault will clear
to reload, if required, to maintain leaving chilled water. when ambient temperature drops 2°F (1°C) below the 8
Otherwise, the micro will reset the 5 minute timer and cut-out.
start the process over again. To assure that leaving
chilled water requirements are satisfied while one com- Low Leaving Chilled Liquid Temperature Cutout:
pressor is under Suction Temperature Limiting control,
U N I T F A U L T
the micro will start or load other compressor(s) as nec-
L OW L I Q U I D T E M P
essary.
The Low Water Temperature Safety assures that the
2.5 UNIT FAULT STATUS MESSAGES evaporator is not damaged from freezing due to improp-
erly set control points. It also attempts to protect the
A Unit Fault will shut the entire chiller down when a chiller from freezing, if the flow switch should fail.
preset safety threshold is exceeded. The chiller will Whenever the chilled liquid temperature drops below
automatically restart after the condition causing the the programmable cutout, the chiller will shut down
shutdown clears. Restart will occur only after anti-re- (see also Section 8.2 / Leaving Water Temperature Cut-
cycle timers are satisfied and cooling demand requires out, page 178). The chiller fault will clear when tem-
additional cooling. A reset hysteresis is built into each perature rises 4°F (2°C) above the cut-out and cooling
safety so repetitive faulting and clearing will not occur demand exists.
in a short time period.
115VAC Under Voltage Cut-Out:
Continuous monitoring by the microprocessor assures
that instantaneous reactions result. When the chiller is U N I T F A U L T
shut down on one of these safeties, a message will ap- 1 1 5 V A C U N D E R V O L T A G E
pear on the Status display informing the operator of the The Under Voltage Safety assures that the system is
problem as shown in the text that follows. not operated at voltages where malfunction of the mi-
croprocessor could result in system damage. Whenever
Any time that a Unit Fault occurs, the shutdown will be the microprocessor senses an on-board control power
logged into the HISTORY BUFFER. supply failure while a compressor is running, the chiller
is shut down. The microprocessor circuitry is capable
Low Ambient Temperature Cutout:
of operating at voltages 10% below the nominal
U N I T F A U L T 115VAC supply to the panel. Auto-restart of the chiller
L OW A M B I E N T T E M P occurs after a 2 minute start-up timer has elapsed from
the time when power is re-applied, if the AUTO RE-
The Low Ambient Temperature Safety protects the START ON POWER FAILURE is enabled. Otherwise
chiller from running in very low temperatures which the chiller must be manually reset. See Section 8.2 (page
could cause damage due to low system pressures. This 180).
feature is programmable and can also be used to shut Flow Switch Open :
down the chiller at a temperature where continued run-
S Y S # N O R U N P E R M
ning of the chiller is not economical compared to the
S Y S # N O R U N P E R M
use of “free” cooling techniques (see also Section 8.2 /
Low Ambient Temperature Cutout [page 178]). The Closure of the flow switch(es) is monitored to check
fault will clear when ambient temperature rises 2°F that flow is present in the evaporator when a compres-
(1°C) above the cut-out. sor is running. Any external cycling devices fitted by
YORK INTERNATIONAL 151
MicroPanel Contents
the customer are connected in series with the flow High Discharge Pressure Cutout:
switch(es). YCAS chillers have a single flow switch
wired to the control panel. If the flow switch opens, all S Y S # H I G H D S C H P R E S
systems controlled by the panel it is connected to will S Y S # H I G H D S C H P R E S
shut down and a NO RUN PERM (Permissive) mes-
sage will be displayed. Closing of the flow switch, when The Discharge Pressure Safety prevents system pres-
flow is present, will cause the message to disappear sure from exceeding safe working limits. This safety is
and auto-restart to occur. a backup for the mechanical High Pressure Cutout in
each system. The Discharge Pressure Safety is program-
Never bypass a flow switch. This will mable for a range of values below the system upper
cause damage to the chiller and void limit (see Section 8.2 / Page 176, High Discharge Pres-
any warranties. sure Cutout for more details).
S Y S # H I G H D S C H T E M P
S Y S # H I G H D S C H T E M P
2.6 SYSTEM FAULT (SAFETY) STATUS
MESSAGES
This safety protects the compressor rotors from dam-
age due to overheating, expansion, and breakdown of
A System Fault will shut the affected system down
the oil film seal between the rotors. It also protects
whenever a preset safety threshold is exceeded for 3
against excessive oil temperature in the discharge oil
seconds. Automatic restart will occur after the first 2
separator.
shutdowns when the anti-recycle timer times out and
temperature demand exists. After any combination of
For the first 4 seconds of operation discharge tempera-
3 Manual Reset Safeties in a 90 minute time period, the
ture is ignored. After 4 seconds of operation the com-
affected system will shut down and lock out on the last
pressor will shut down if the discharge temperature
fault. When one or more systems are shut down on one
exceeds 260°F (127°C).
of these safeties, a message will appear on the Status
display informing the operator of the problem.
High Oil Differential Pressure Cutout:
The High Motor Current Safety is a S Y S # H I G H O I L D I F F
unique safety which will lock out a sys- S Y S # H I G H O I L D I F F
tem after only a single fault.
The High Oil Pressure Differential Safety protects the
compressors against loss of proper lubrication due to
oil return line blockage. The “differential oil pressure”
for this safety is computed by measuring discharge (oil
To reset a locked out system, turn the System Switch
separator) pressure and subtracting oil pressure return-
for the affected system to the OFF position, then back
ing to the compressor (Discharge - Oil = Oil PSID).
to the ON position (see Section 1.11, Fig. 71 for switch
Under normal operation, the oil pressure differential
locations).
display will be less than 25 PSID (1.7 bar), typical 2 -
10 PSID (0.1 to 0.7 bar). If oil pressure at the compres-
Before returning a locked out system sor drops due to filter blockage, the differential pres-
to service, a thorough investigation of sure on the display will increase and when the maxi-
the cause of the fault should be made. mum limit is reached the compressor will be shut down.
Failure to repair the cause of the fault
while manually allowing repetitive re- This safety is activated after 3 minutes of operation.
Oil pressure must be less than 65 PSID (4.4 bar) for
starts may cause further expensive
R22 models as long as the compressor continues to
damage to the system. run.
S Y S # L OW O I L D I F F S Y S # L OW S U C T P R E S S
S Y S # L OW O I L D I F F S Y S # L OW S U C T P R E S S
The Low Oil Pressure Differential Safety assures the The Low Suction Pressure Cutout aids in protecting
compressor receives proper lubrication by monitoring the evaporator from damage due to ice build up caused
the differential between oil pressure returning to the by operation at low refrigerant charge or restricted re-
compressor and suction pressure. Lack of a differential frigerant flow. A number of transient timer features
indicates that the compressor is not pumping and no oil prevent nuisance trips during start-up, compressor load-
is being pumped through the compressor to lubricate ing, etc. The Low Suction Pressure Safety is program-
the bearings and rotors. mable (see Section 8.2 / Page 177, Low Suction Pres- 8
sure Cutout for more details).
This type of oil failure will not be picked up by the
High Oil Differential Safety since no flow will cause The suction pressure cut-out is ignored for the first 45
the differential through the oil piping to drop to zero. seconds of operation. During the next 180 seconds of
running, suction pressure may be lower than the cut-
EXAMPLE: out, but must be greater than:
For ambients above 50°F (10°C), the Low Oil Differ- SP Cutout= Programmed Cutout X (run Time - 25)
ential Safety is activated after 1 minute of compressor 25
operation when the oil pressure differential must be
greater than 10 PSID (.7 bar). After 2 minutes it must This cutout value increases with time until after 225
be greater than 20 PSID (1.4 bar); after 3 minutes, 30 seconds it equals the programmed cutout value. If suc-
PSID (2 bar); after 4 minutes, 40 PSID (2.7 bar); and tion pressure falls below the calculated cutout value
from 5 minutes of operation and onwards, oil pressure before 225 seconds of run time, the system will be shut
must remain higher than 50 PSID (3.4 bar) or the sys- down.
tem will be shut down. For lower ambients, the linear
ramp times are as follows: The following graph shows a typical programmed suc-
tion pressure cutout of 44 PSIG (3 bar) and its change
AMBIENT TEMP RAMP TIME from time = 0 sec of compressor run time to 225 sec-
>50°F (10°C) 5 Minutes onds of compressor run time.
>45°F (7°C) 6 Minutes
>40°F (4°C) 7 Minutes
>35°F (2°C) 8 Minutes
45
>30°F (-1°C) 9 Minutes
Suction Pressure Cutout
40
<=30°F (-1°C) 10 Minutes 35
30
25
20
High Oil Temperature Cutout: 15
10
S Y S # H I G H O I L T E M P 5
S Y S # H I G H O I L T E M P 0
0 30 60 90 120 150 180 210 240 270 310
This safety assures oil temperature does not exceed a Run Time (seconds)
to loading or fan cycling from causing shutdown. If FLA (full load amps) is approximately
suction pressure drops below the cutout point after 225 1.2 x RLA (rated load amps). RLA is
seconds of operation, the transient timer is activated. specified on the motor / chiller name-
While the transient timer is active, suction pressure must plate and is typical current demand un-
not drop below 10% of the cut-out initially programmed
der rated operating conditions in a
and must be greater than:
fully loaded system. When a system is
C.O. = Programmed C.O. X ( Time + .1 ) fully loaded, typical motor currents
33.3 may be at 60 - 85% FLA depending on
operating conditions.
This transient cutout value increases with time until
after 30 seconds it equals the programmed cutout value. Low Motor Current Cutout / Motor Protector (Hi
If the suction pressure falls below the value as calcu- Motor Winding Temp Cutout) / Mechanical High
lated by the formula relative to time, the system will Pressure Cutout / External Motor Overload:
shut down on a low suction pressure fault. If the suc-
tion pressure rises above the programmed cutout value, S Y S # L OW C U R R / M P / H P
the 30 second timer will be reset. S Y S # L OW C U R R / M P / H P
If the Dip Switch on the microprocessor board is set The Low Motor Current Safety prevents a compres-
for “Water Cooling” (see page 158), the cutout is pro- sor motor running with less current than would nor-
grammable between 44 - 70 PSIG (3-5 bar) for both R- mally be expected. This may result from loss of refrig-
22 and R407c models. In this mode, settings of 44 PSIG erant, contactor, or power problems as well as from a
(3 bar) for R22 and R407c are recommended. If the compressor that is not pumping due to a mechanical
Switch is set for “Brine Cooling” (glycol) the cutout is malfunction. Motor current is monitored using 3 Cur-
programmable between 5 - 70 PSIG (0.3 - 5 bar) for R- rent Transformers (CTs) per motor, one on each phase.
22 and R407c models. In this mode, the cutout should
typically be set to the saturated refrigerant pressure Average motor current is monitored after 3 seconds of
equivalent to 18°F (10°C) below the temperature of the compressor operation. From this time the system will
chilled liquid. NOTE: The sludge point of the glycol be shut down if average motor current is less than 10%
MUST be at least 20°F (11°C) below the equivalent of FLA.
cutout temperature. This programmable value is pass-
word protected. Compressor Motor Protection Modules, External
Motor Overloads and Mechanical High Pressure
High Compressor Motor Current Cutout: Cutouts are fitted to each system. All these devices
stop the compressor by removing power from its motor
S Y S # H I G H M T R C U R R contactor coils. This causes the CTs to obviously sense
S Y S # H I G H M T R C U R R a zero current draw by the compressor motor and causes
The High Motor Current Safety protects against exces- a Low Motor Current Fault to be displayed. These de-
sively high motor current and shuts a system down and vices operate as follows:
locks it out after only a single occurrence of a rise in
average motor current above the cutout point. Motor The Motor Protection Module protects against exces-
current is monitored using 3 Current Transformers sive motor winding temperature by monitoring 3 or 6
(CTs) per motor, one on each phase. sensors built into the motor windings. If the tempera-
ture becomes excessive, the module will cause power
Average motor current is monitored after 7 seconds of to be removed from the compressor contactors shutting
compressor operation. The system will be shut down if down the compressor. Auto restart will not occur since
average motor current exceeds 115% FLA. manual reset is required. A fault lockout will automati-
cally occur after the micro attempts 2 more starts with
the MP contacts open. Manual reset is accomplished Low Evaporator Temperature Cutout (R407c Only):
by removing 115VAC control power from the micro
panel after the motor sensors have sufficient time to S Y S 1 L OW E V A P T E M P
cool. Details relating to operation of the Motor Protec- S Y S 2 L OW E V A P T E M P
tion Module can be found on page 16.
The Low Evaporator Temperature Cutout is to pro-
The External Motor Overload is responsive to motor tect the evaporator from freeze-up with R-407c. This
current. When the overload relay senses single phase safety uses the Cooler Inlet Refrigerant Temp Sen-
operation, locked rotor current in excess of 10 seconds, sors to monitor evaporator inlet refrigerant tempera-
or sustained current overloads in excess of 140% of RLA, ture on each system. These sensors are only installed
it will trip. This causes power to be removed from the on R-407c units. If the refrigerant temperature falls
compressor contactors and shuts down the compressor. below 21°F (-6°C) in water cooling mode, the system 8
will be shut down. If the refrigerant temp falls 19°F
Auto-restart will not be permitted since a manual reset (11°C) below the leaving chilled liquid temp in gly-
of the device is required to restart the compressor. Af- col cooling mode, the system will shut down. Also, if
ter the first fault, the micro will try two more restarts, the cooler inlet refrigerant temp sensor reads out of
but with the External Motor Overload Relay tripped, range low, the system will also shut down.
no restart can occur. The micro will then lock out the
system. In addition to manually resetting the External 2.7 PRINTOUT ON FAULT SHUTDOWN
Motor Overload Relay, the fault will also require reset
If an optional printer is installed, the contents of His-
by turning the appropriate system switch OFF, then ON.
tory Buffer 1 will be sent to the printer any time a fault
shutdown occurs. This will allow record keeping of
The OL relay setting should never be altered. If for some
individual faults, even if they do not cause a lockout of
reason the Overload Relay is replaced, the following
the system. This information may be useful to identify
procedure is used for setup.
developing problems and troubleshooting.
A/L Start: Dial Setting = (1.1 x RLA) / 350
The No Run Permissive fault messages will not be
WYE-Delta Start:Dial Setting = (0.64 x RLA) / 350
stored in the History Buffer and will not cause an auto
printout.
The Mechanical High Pressure Cutout protects
against excessive refrigerant discharge pressure and is
Due to extreme operating conditions
set to 405 PSIG (28 bar). Auto-restart will be permitted
after shutdown on discharge pressure, when the pres- or systems where control deficiencies
sure drops below 330 PSIG (23 bar) and the cutout con- are present, occasional faults may
tacts close. A fault lockout will result if safety thresh- occur with the corresponding auto-
olds are exceeded three times in a 90 minute period. matic printout. This is not a cause for
concern.
29023A
S Y S # C O O L E R I N L E T
R E F R I G T E M P = 2 8 . 2 ° F
*Below 9.0°F (13°C), the Suction
Temp. display will disappear. This will
The Cooler Inlet Temp. display will in turn cause the Superheat display to
only appear if the chiller is selected for disappear.
R-407c.
Temperatures and pressures are either measured directly When the Ambient Temperature key is pressed, ambi-
by transducers and temperature sensors, or computed ent air temperature, as measured surrounding the chiller,
from these measurements as follows: is displayed.
A M B I E N T A I R T E M P
Saturated discharge and suction temperatures are com- = 7 1 . 9 ° F
puted by converting measured pressure to temperature.
Display Limits: Minimum -4.6°F (-20.3°C)
Slide Valve Position is computed based on the number Maximum 137.9°F (58.8°C)
of loading steps that the micro has sent to the slide valve
solenoid in the form of a current signal. To the micro- 3.5 MOTOR CURRENT KEY
processor, STEP 0 = fully unloaded and STEP 75 = Pressing the Motor Current key displays compressor
fully loaded. current for each system:
YORK INTERNATIONAL 157
MicroPanel Contents
SWITCH 2: Ambient Temp. Low Limit Dip Switch Physical Location and Setting
Open:
S 1 - 2 A M B I E N T C O N T R O L
S T A N D A R D
Closed:
8
S 1 - 2 A M B I E N T C O N T R O L
L OW A M B I E N T
SWITCH 3: Refrigerant
Open:
S 1 - 3 R E F R I G E R A N T
R - 4 0 7 C
S 1 - 3 R E F R I G E R A N T
LD03511B
“CLOSED” Position:
R - 2 2 Right side of switch
pushed in
The R-22 Mode MUST be selected for models using LD03511A
refrigerant type R-22. Incorrect selection of this switch FIG. 74 – ENLARGED PHOTOGRAPH OF DIP
may cause serious damage to the chiller. SWITCHES ON MICROPROCESSOR
BOARD
4. PRINT KEYS
29023A
4.1 GENERAL Information available using the Operating Data key is de-
scribed in the following sections. In example displays “ # ”
The Print keys provide access to two sets of informa-
is used to indicate system number where appropriate.
tion either locally on the panel display or, if an optional
printer is connected, remotely as hard copy printouts.
4.3 OPERATING DATA -
The Operating Data (Oper Data) key provides a real- LOCAL DISPLAY MESSAGES
time list of system operating data and programmed set-
tings. The History key provides a comprehensive list YCAS 2 SYSTEM MODELS :
of operating data and programmed settings “at the in-
stant of fault” on each of the last six faults (local dis- When the Operating Data key is pressed, the following
play) or three faults (remote printout) which occurred message appears:
on the chiller. O P E R A T I N G D A T A
D I S P L A Y S
4.2 OPER DATA KEY
Repetitively pressing the áâkeys will scroll through
If a remote printer is not connected, pressing the Oper- the following Common (whole chiller) Data and indi-
ating Data key allows the user to scroll through infor- vidual System Data information displays.
mation, on the 40 character display, which is not di-
rectly available from the Display keys on the panel. Common Data:
T E M P E R R O R 0 0 . 5 ° F System Data:
T E M P R A T E - 0 . 9 ° F / M The following sequence of three displays are provided
first for System 1, then for System 2, and then for Sys-
The upper message gives the difference (error) between tems 3 and 4 as applicable.
actual leaving chilled liquid temperature and the pro- S Y S # R U N T I M E
grammed Target temperature. The lower message gives 1 - 3 - 4 8 - 1 7 D - H - M - S
the rate of change of the chilled liquid leaving tem-
perature in degrees per minute. A minus sign (-) indi- This message displays the accumulated Run Time since
cates falling temperature. No sign indicates rising tem- the last start in Days (D), Hours (H), Minutes (M), and
perature. Seconds (S).
S Y S # L L S V I S O N
L E A D S Y S T E M I S
E C O N T X V S O L I S O N
S Y S T E M N U M B E R #
This message indicates the Liquid Line Solenoid Valve
This message advises which system is programmed as and the economizer TXV solenoid valve position: ON =
the lead. Energized/Open, OFF = De-energized/Closed.
S Y S # F A N S T A G E 3
E V A P P U M P I S O F F
C OM P H E A T E R I S O N
E V A P H E A T E R I S O N
This message advises the stage of condenser fan opera-
This message indicates the position of the optional aux- tion on this system and the status of the compressor
iliary contacts for the evaporator water pump and the heater. See Section 8.4 for details of fan staging.
status of the evaporator heater.
Once the System Data sequence has been repeated for
For the evaporator pump contacts, ON = contacts closed, the second system, pressing the áorâkey again will
OFF = contacts open. loop back to the beginning to the Load/Unload Timer
display. To leave the sequence at any point press a key
The Evaporator Heater status is controlled on ambient from another section of the keypad.
temperature as follows: If measured ambient falls be-
low 40°F (4°C) the Evaporator Heater is switched ON. Pressing the “ * ” at any time while in
If measured ambient then rises above 45°F (7°C) the the OPER DATA mode displays the
heater is switched OFF. The evaporator heater prevents EPROM software version being used,
water standing in the evaporator from freezing. as shown below:
A C T I V E R E M O T E C T R L
N O N E
PWM CURR – EMS PWM Current Limiting Enabled 4.4 OPERATING DATA -
REMOTE PRINTOUT
PWM TEMP – EMS PWM Temp. Reset Enabled
The follow text shows a typical example printout ob-
CUR/TEMP – EMS PWM Current Limiting & tained by pressing the Operating Data key with an op-
Temperature Reset Enabled tional printer attached. In this case an example is shown
162 YORK INTERNATIONAL
FORM 201.18-NM3
SYSTEM 1 DATA
If a remote printer is not connected, pressing the His- This message displays the type of chilled liquid selected
tory key allows the operator to locally scroll through (water or glycol) at the time of the fault.
information relating to the stored safety shutdowns on
the control panel display. S 1 - 2 A M B I E N T C O N T R O L
L OW A M B I E N T
If a remote printer is connected, pressing the History
key will cause data from the last 6 shutdowns on a 2 This display indicates whether standard or low ambi-
compressor chiller or 4 shutdowns on a 3 or 4 compres- ent operation was selected at the time of the fault.
sor chiller to be transmitted from the microprocessor to
the remote printer. The printout will begin with the most S 1 - 3 R E F R I G E R A N T
recent fault which occurred. This does not affect the R - 2 2
stored data and as many prints as desired may be taken.
See Section 4.7 for a HISTORY printout sample. This message indicates the type of refrigerant that was
programmed at the time of the fault (R-22 or R-407C).
4.6 FAULT HISTORY DATA –
LOCAL DISPLAY MESSAGES D I S C H A R G E P R E S S U R E
C U T O U T = 3 9 5 . 0 P S I G
YCAS 2 SYSTEM MODELS:
This message indicates the discharge pressure cut-out
When the History key is pressed, the following mes-
programmed at the time of the fault.
sage will appear:
D I S C H A R G E P R E S S U R E
D I S P L A Y S A F E T Y S H U T -
U N L O A D = 3 7 5 . 0 P S I G
D OWN N O . 1 ( 1 T O 6 )
H I G H A M B I E N T T E M P S E T P O I N T = 4 4 . 0 ° F
C U T O U T = 1 3 0 . 0 ° F R A N G E = + / - 2 . 0 ° F
This message indicates the High Ambient Temperature This message displays the programmed chilled liquid
Cutout at the time of the fault. setpoint and deviation (control range) programmed at
the time of the fault.
L OW A M B I E N T T E M P A M B I E N T A I R T E M P
C U T O U T = 2 5 . 0 ° F 7 7 . 6 ° F
This display shows the Low Ambient Cutout pro- This message indicates the outdoor Ambient Air Tem-
grammed at the time of the fault. perature at the time of the fault.
8
L E A V I N G L I Q U I D T E M P L E A D S Y S T E M I S
C U T O U T = 3 6 . 0 ° F S Y S T E M N U M B E R 1
This display shows the Low Leaving Chilled Liquid This message indicates which system was in the lead at
Cutout programmed at the time of the fault. the time of the fault.
E V A P P U M P I S O N
H I G H M O T O R C U R R E N T
E V A P H E A T E R I S O F F
U N L O A D - 1 0 0 % F L A
S Y S # M O T O R C U R R E N T S Y S # L L S V I S O N
7 8 % F L A E C O N T X V S O L I S O F F
UNIT DATA
SYSTEM 1 DATA
5. ENTRY KEYS
29023A
5.1 GENERAL The Enter key is also used to scroll through available
data when using the Program or Set Schedule/Holiday
The Entry keys allow the user to change numerical val-
keys.
ues programmed in as chiller setpoints, cutouts, clock,
etc.
5.4 CANCEL KEY
5.2 NUMERICAL KEYPAD
When the Cancel key is pressed, the cursor will always
The Numerical keypad provides all keys necessary to return to the first character to be programmed in the
program numerical values into the micropanel. display message. This allows the operator to begin re-
programming, if an error is made. When the Cancel
The “*” key is used to designate holidays when pro- key is pressed, the values already keyed in will be erased
gramming special start/stop times for designated holi- and the original or internally programmed default val-
days in the SET SCHEDULE/HOLIDAY program ues will appear. In other instances the display will re-
mode. main the same and the only reaction will be the cursor
returning to the first character.
The “+/-” key allows programming -C setpoints and
cut-outs in the metric display mode. 5.5 áâ KEYS
29023A
uid to the Setpoint Temperature. The amount of load- Slide Valve Position
ing is varied by changing the amount of signal to the A slide valve position (S V STEP), under the keypad
slide valve solenoid of each compressor. system keys, of 75 indicates that the compressor is fully
loaded. However due to the non-exact movement of the
Slide Valve Control mechanism, a position less than 75, possibly 60, could
The slide valve of each compressor can be moved 75 also mean that the compressor is fully loaded. Keep this
steps, where “0” equals minimum capacity and fully potential indicator error in mind when attempting to
loaded equals 75 steps. The amount of movement that determine slide valve position versus actual compres-
occurs when the micro initiates changes may vary ac- sor capacity.
cording to the error or deviation from setpoint and the
COMPRESSOR STARTING & LOADING
rate of change of chilled liquid temperature. Each time
SEQUENCE FOR 2, 3, AND 4 COMPRESSOR
a change is made, the incremental change may vary from YCAS CHILLERS
1 to 10 steps as determined from the micro. In cases
where internal limiting is not in effect due to possible If no compressors are running, the Daily Schedule per-
fault conditions, the micro will load the compressor with mits, all safeties and run permissives are satisfied, the
the lowest number of steps, alternating loading back anti-recycle timers have timed out, and the leaving liq-
and forth between compressors until both are fully uid temperature rises above the upper limit of the Con-
loaded or unloaded. trol Range, the lead compressor will be started. A full
current signal is sent to the compressor slide valve con-
In some cases the micro will be required to make deci- trol solenoid to allow the internal spring to push the
sions regarding loading under conditions where the slide valve to a minimum loading position to assure it
“error” and “rate” conflict. For example, the micro may is fully unloaded at start. For the first 15 seconds of
elect to unload a compressor if the error is “0” (tem- operation, or until pumpdown to cutout occurs, the liq-
perature is at setpoint), while the rate of change of uid line solenoid valve will remain closed. After an ini-
chilled liquid temperature is negative (falling). The tial period of 15 seconds, the micro will begin to load
micro may also elect to hold capacity when error is “+” up the lead compressor to bring the chilled liquid tem-
(temperature is above setpoint) because the rate of perature to setpoint.
change of chilled liquid is “-”. Below is a chart which
illustrates these conditions. After 5 minutes of run time, if Setpoint Temperature is
not met, the micro will start the 1st lag compressor. This
is not dependent on slide valve position which after 5
ERROR
minutes will be fully loaded at a S V Step of “75”. The
lead compressor will be reduced in capacity to a slide
Negative Zero Positive
valve step of 40. The lag compressor will then be loaded
RATE
until it also reaches a slide valve step of 40 while the
lead compressor is maintained at a constant load. At
Negative Unload Unload Hold this point the compressors will be alternately loaded
with loading always occurring on the compressor with
Zero Unload Hold Load the lowest slide valve step until the leaving chilled liq-
uid is satisfied.
Positive Hold Load Load
On 3 compressor chillers, if the two compressors can-
not bring the load under control within 10 minutes, the
micro will maintain the lead compressor fully loaded at
Load Timers S V Step 75, unload the first lag compressor to Step 40,
and bring on the 2nd lag compressor. The second lag
Fixed timers are set to minimize undershoot and over- compressor will load until it reaches Step 40. From this
shoot as a result of slide valve control. point the compressors will be alternately loaded, always
loading the compressor with the least step of loading
Load Timers are always set at 10 seconds first.
between changes.
Unload timers are set at 5 seconds between On 4 compressor chillers, loading will operate the same
changes. as a 3 compressor chiller with another compressor added
170 YORK INTERNATIONAL
FORM 201.18-NM3
to the sequence. If the load cannot be brought under Compressor Unloading and Shutdown Sequence
control in 15 minutes, the 3rd lag compressor (com- Whenever temperature is below the Setpoint, unload-
pressor 4) will be started. Before starting the 3rd lag ing pulses will be sent to open the unloading port on
compressor, the lead and 1st lag compressor will be the control solenoid to relieve oil pressure on the slide
maintained at full load (S V Step 75) and the 2nd lag valve on the compressor with the highest slide valve
compressor will be unloaded to S V Step 40. If load step. Opening of the unloading port on the control so-
continues to rise, the 2nd and 3rd lag compressor will lenoid allows spring pressure to move the slide valve
be alternately loaded until the leaving chilled liquid to decrease capacity. Every 5 seconds, the micro will
temperature is satisfied. decrement the compressor with the highest slide valve
position by 1 - 10 steps according to the error (devia-
Compressor Loading tion from Setpoint) and the rate of change of chilled
The micro loads and unloads individual compressors liquid temperature. 8
by varying current to the Slide Valve solenoid which
controls oil flow to the slide valve. The slide valve load As load drops, the micro will continue to unload the
solenoid applies oil pressure to the slide valve to over- compressor with the highest slide valve step until all
come spring pressure from an internal spring, increas- compressor slide valves are at “0.” At this point, the
ing capacity. The internal spring moves the slide valve last lag compressor will pump down and cycle off, if
in the opposite direction against oil pressure to decrease chilled liquid temperature drops below “Setpoint - Con-
capacity. trol Range/2”. On 3 and 4 compressor chillers, when a
lag compressor cycles off, the micro will set the re-
Whenever chilled liquid leaving temperature is above maining running lag compressors to Slide Valve Posi-
the Setpoint, loading current will increase to allow oil tions of “10” (future EPROM software will set the po-
pressure to move the slide valve to increase capacity. sition to “30”). As load continues to decrease and all
Every 10 seconds, the micro will increment the slide lag compressors cycle off, the lead compressor will con-
valve step from 1 to 10 steps according to error (devia- tinue unload to a slide valve position of “0” and will
tion from setpoint) and rate of change of chilled liquid. pump down and cycle off if the chilled liquid tempera-
ture drops below “Setpoint – Control Range.”
The micro will always choose the compressor with the
lowest slide valve position to load on increasing de- A lag compressor may be shut down
mand, provided the compressor is not pumping down, before it is fully unloaded to avoid a
has run at least 15 seconds, and is not in a “Limiting” Chiller fault on a Low Water Tempera-
condition. ture cut-out under the following con-
ditions: a) if chilled liquid temperature
Loading Limiting
Load limiting will occur if a system safety threshold is falls below the low end of the Control
neared. The anticipatory capability of the micro limits Range (CR) for more than 37 seconds,
loading or unloads a system if the micro anticipates a b) if chilled liquid temperature drops
safety threshold will be exceeded. Under circumstance more than CR/4 below the low limit of
where loading is required and one of the systems is the Control Range.
nearing a threshold, the micro may elect to split the
number of steps that it would normally load a compres- The lead compressor may be shut
sor between more than one compressor. For instance, if down before it is fully unloaded to
system 1 were nearing its motor current unload point avoid a Chiller Fault on Low Water
and it was scheduled to load, the micro could split a
Temperature under the following con-
load signal of 10 steps between system 1 and 2. It could
ditions: a) if chilled liquid temperature
only load SYS 1 “2” steps while loading SYS 2 “8”
Steps. Under these circumstances, the two systems will drops 2°F below the low limit of the
not appear to equalize loading. Control Range (CR), b) if chilled liq-
uid temperature drops more than CR/
2 below the low limit of the Control
Range.
6.3 LOCAL COOLING SETPOINTS KEY 6.4 REMOTE COOLING SETPOINTS KEY
The Local Cooling Setpoints key is used to program Remote Cooling Setpoints key allows resetting the
the required Leaving Chilled Liquid control tempera- setpoint upward from the programmed value in memory
tures for the application. When the key is pressed, the from a remote device. This feature is typically used for
following message will be displayed: demand limiting or ice storage applications. Reset is
accomplished by timed closure of external contacts for
S E T P O I N T = 4 4 . 0 ° F a defined period of time and allows reset of the setpoint
R A N G E = + / - 2 . 0 ° F upward by up to 40°F (22°C) above the setpoint pro-
grammed in memory – see Section 1.7.
Key in the desired Chilled Liquid Setpoint and the al-
lowable deviation (Range). The micro will accept val- The maximum allowable reset must be programmed into
ues from 10.0 - 70.0°F (-12 to 21°C). For values below memory and can be a value of 2 to 40°F (1 to 22°C)
40°F (4°C), Dip Switch S1, Switch #1 on the Micro- depending on user requirements. To program the reset,
processor Board must be properly programmed for press the Remote Reset Temperature Range key. The
Brine Cooling (see Section 3.7). If unacceptable val- following message will appear:
ues are entered, or the switch is incorrectly selected
when setpoints below 40°F (4°C) are entered, the fol- R E M S E T P = 4 4 . 0 ° F
lowing message will be displayed before returning to R A N G E = + / - 2 . 0 ° F
the Control Range message:
The display indicates the Remote Setpoint which is al-
O U T O F R A N G E - ways equal to the chilled liquid setpoint programmed
T R Y A G A I N ! by the Chilled Liquid Temperature/Range key plus the
offset from the remote reset signal. The display will
After the Setpoint is keyed in, the cursor will automati- also show the Range which is the programmed maxi-
cally advance to the first digit of the Range as shown : mum deviation allowed for the application. This dis-
play is not programmable, and will change the setpoint
S E T P O I N T = 4 4 . 0 ° F only through a signal from a remote device.
R A N G E = + / - 2 . 0 ° F
M A X E M S - P WM R E M O T E
This value should be programmed for the maximum T E M P R E S E T = + 4 0 ° F
allowable positive and negative chilled liquid tempera-
ture deviation that is acceptable from setpoint in the Pressing the REM RESET TEMP RANGE Key again
system application. A typical value would be +/- 2.0°F scrolls the display to the MAX EMS-PWM REMOTE
(1°C). The micro will accept a range from 1.5 - 2.5°F TEMP RESET which is programmable. This should be
(- °C). programmed to the maximum offset which is required
for the application. The maximum programmable value
After the Setpoint and Range is keyed in, press the is 40° F (22°C), while the minimum programmable
ENTER Key to store the data in memory. value is 2°F (1°C).
Failure to press the Enter key will The cursor will stop beneath the first digit of the maxi-
cause the newly programmed values mum reset. Key in the maximum reset allowed for the
to be ignored and not entered into application, remembering to use a leading “0” for val-
memory. ues less than 10°F (or 10°C). Press the ENTER Key to
store the new value in memory.
7. CLOCK KEYS
29023A
7.1 GENERAL for times before 10 o’clock. e.g. 08:31. The cursor will
then advance to the AM/PM designation. If necessary
The microprocessor features a continuously running
press the á or â key to change to the opposite time pe-
internal Clock and calendar and can display actual time
riod.
as well as the day of the week and the date. An auto-
matic schedule feature is provided for starting and stop-
Next, key in the day of the month (the cursor will auto-
ping the chiller on individual days of the week, elimi-
matically skip from AM/PM to the first digit of the date
nating the need for an external time clock. Also pro-
when a “number key” is pressed). The cursor will then
vided are a Holiday feature, allowing special start/stop
skip to the first digit of the year. Key in the year. Al-
times to be set for designated holidays, and a Manual
ways use two digits for the day and the year, using a
Override feature to aid servicing. If the automatic sched-
leading “0” for days 1-9 e.g. 02 FEB 99. Finally, change
ule feature is not required, the micro can be programmed
the month as needed by repetitively pressing the áorâ
to run the chiller on demand as long as the Chiller ON/
key until the proper month appears. Once the desired
OFF and System switches are in the ON position.
information is keyed in, it must be stored into memory
by pressing the Enter key.
Programming of the internal clock/calendar and oper-
ating schedule are described below. Any valid time or date will be accepted. If an out of
range value is entered, the following message will be
7.2 SET TIME KEY
displayed for 3 seconds then revert back to the Set Time
When the Set Time key is pressed, a message showing display message for reprogramming:
the day, time and date will be displayed with the cursor
O U T O F R A N G E -
below the first digit of the time as shown:
T R Y A G A I N !
T O D A Y I S M O N 1 1 . 1 2 A M
1 9 F E B 1 9 9 9
Pressing the Set Time key once enters
First press the á or â key until the proper day appears. the “programming” mode in which the
Press ENTER to move on to the hour part of the display. displayed time does not update. Press-
Next, key in the time (hours/minutes) using a leading “0” ing the Set Time key a second time
enters “display” mode in which the
cursor will disappear and the “live”
clock will be displayed.
M O N S T A R T = 0 6 : 0 0 A M
S T O P = 0 5 : 3 0 P M If the chiller is not required to run on a given day, the
Start time should be programmed for 00:00 AM and
The displays for each day are scrolled through by re- the Stop time programmed for 12:00 AM.
petitively pressing the áorâ key. To reprogram any of
Continue to program each day as needed. After SUN
the daily schedules, key in the new Start time then, if
has been entered, the Holiday message will be dis-
necessary, change the associated AM/PM by pressing
played:
the áorâ key.
H O L S T A R T = 0 8 : 3 0 A M
The á or â key can only be pressed S T O P = 1 2 : 0 0 P M
once to change AM/PM. If an error is
made, press Cancel and begin again. The Holiday (HOL) Start / Stop allows a specific day(s)
to be assigned for special requirements. This is pro-
vided so that a day(s) needing special start / stop re-
quirements can be programmed without disturbing the
Next key in the Stop Time (the cursor will automati- normal working schedule. The start / stop times for the
cally skip from AM/PM to the first digit of the date Holiday schedule are programmed just as any other day.
when a “number key” is pressed) and the AM/PM if
necessary. Now press the ENTER key to store the new Only one start/stop time can be pro-
schedule. The display will scroll to the next day. If an
grammed which will apply to each of
unacceptable time is entered, the following message will
the Holiday days selected.
be displayed for 3 seconds then return to the schedule
display:
O U T O F R A N G E
T R Y A G A I N ! After the Enter key is pressed, a display to designate
which days of the week are holidays will appear:
New start/stop times programmed for S * M T W T F S
Monday are automatically used for all H O L I D A Y N O T E D B Y *
of the following days of the week. When the display appears, the cursor will first stop af-
ter Sunday as shown. To designate a day as a holiday,
press the “ * ” key. If a day marked as a holiday is not to
Always use the Set Schedule/Holiday be a holiday, press the “ * ” key. When the “ * ” key is
key, not the Enter key to scroll through pressed, the cursor will advance to the next day. Use
the schedule displays. Pressing the the á or â keys to move back and forth among days.
ENTER key after viewing Monday will After all the holiday days are programmed, press Enter
change times programmed for the re- to store the new data. The display will then return to
mainder of the week to the Monday the beginning of the Daily Schedule (MON).
schedule.
The Holiday Schedule is only per-
If the chiller is not cycled by the Daily Schedule, but is formed once, then erased from
required to run whenever remote cycling devices, sys- memory. This avoids the need for re-
tem switches, and main Chiller ON/OFF switch are in programming after the holiday, as
the ON position, all 00.00s should be programmed into most special Holiday Schedule re-
the daily schedule. This can be done manually for indi- quirements are occur only occasionally.
vidual days or for all days by pressing Cancel and En-
ter for the Monday Start/Stop schedule.
174 YORK INTERNATIONAL
FORM 201.18-NM3
If an error is made while programming or a change is If a Warning - Low Battery fault mes-
required, press Cancel. This will clear the programmed sage appears on the display the inter-
(*) “Holiday” days (the “0” key will not cancel out a nal clock, calendar and program set-
“ * ” and cannot be used for correcting a programming tings cannot be relied on for accuracy.
error).
Default values are loaded into the mi-
7.4 MANUAL OVERRIDE KEY croprocessor memory and the Manual
Override key can be used to zero out
When the Manual Override key is pressed, the Daily the daily schedule and allow unlimited
Schedule programmed into the chiller is ignored and operation regardless of the time on the
the chiller will start up when water temperature is above internal clock. Reprogramming of the
the high limit of the Control Range, the Chiller ON/ setpoints and cutout values may also be 8
OFF switch is ON, remote cycling devices are necessary. When the MANUAL OVER-
CLOSED, and system switches permit.
RIDE key is pressed the low battery
Normally this key is only used for servicing when the message will disappear. If a power fail-
chiller is required to run but the Daily Schedule is in an ure should again occur, the above pro-
OFF period. This key avoids the need to reprogram the cess will again need to be repeated to
Daily Schedule. Once activated, Manual Override is bring the chiller back on line. See also
only active for a period of 30 minutes and the follow- Section 2.5.
ing status message will be observed.
M A N U A L
O V E R R I D E
8. PROGRAM KEY
29023A
Normally, air-cooled chillers such as YCAS chillers After the compressor starts, and the pump down cycle
should have the cutout set at 395 PSIG (27 bar) for R22 is completed (pump down to cutout or 30 seconds,
and R407c models. The micro will, however, accept whichever comes first.), suction pressure is monitored
values between 200 - 399 PSIG (14 - 28 bar). For this as long as the compressor runs. For the first 270 sec-
cutout to be functional, the Discharge Pressure Read- onds of running, suction pressure can be lower than the
out Option must be installed (fitted as standard on 50Hz programmed cutout, but must be greater than:
models). This programmable value is password pro-
Programmed X Run Time/3 + 10
tected.
Cutout 100
To program the Discharge Pressure Cutout, key in the Example: If programmed Cutout = 44 PSIG (3 bar)
desired value and press the Enter key to store the value and Run Time = 60 seconds
into memory and scroll to the next display. 8
60/3 + 10
New Cutout = 44 X = 13.2 PSIG (0.9 bar)
High Discharge Pressure Unload Point 100
Typically the unload point should be set 20 - 25 PSIG This cutout value increases with time, until after 90
(1.4 - 1.7 bar) below the below the discharge pressure seconds, it equals the programmed cutout value. If the
cutout setting. The micro will accept a range of pro- suction pressure rises to more than 5 PSI (0.3 bar) above
grammable values between 200 - 399 PSIG (14 - 28 the programmed cutout value during the 90 second time
bar). This programmable value is password protected. period, the timer will be reset. If the suction pressure
does not rise to more than 5 PSI (0.3 bar) above the
To program the Discharge Pressure Unload, key in the cutout, the timer will remain at zero and if the pressure
required setting and press the Enter key to store the then falls below the cutout again, the system will shut
value into memory and scroll to the next display. down on a low pressure fault.
Low Suction Pressure Cutout If the Dip Switch on the microprocessor board is set
for “Water Cooling” (see Section 3.7), the cutout is pro-
S U C T I O N P R E S S U R E grammable between 44 - 70 PSIG (3-5 bar) for both
C U T O U T = 4 4 . 0 P S I G R22 and R-407c models. In this mode, settings of 44
PSIG (3 bar) for R22 and R-407c are recommended. If
The Low Suction Pressure Cutout protects the evapo- the Switch is set for “Brine Cooling” (glycol) the cut-
rator from damage due to ice build up caused by opera- out is programmable between 5 - 70 PSIG (0.3 bar) for
tion at low refrigerant suction pressure. R22 and R-407c models. In this mode, the cutout should
be set to the saturated refrigerant pressure equivalent lower temperatures. If operation is occasionally needed
to 18°F (10°C) below the lowest temperature of the below 1°F (-17°C), the cutout should be set at 00.0°F.
programmed chilled liquid Control Range (Section 6). This will allow operation at any temperature, as the mi-
This programmable value is password protected. cro will only recognize temperatures above 1°F (-17°C).
Temperatures below 1°F (-17°C) will not be displayed.
To program the Suction Pressure Cutout, key in the re-
quired setting and press the Enter key to store the value To program the Low Ambient Cutout, key in the re-
into memory and scroll the next display. quired setting and press the Enter key to store the value
into memory and scroll to the next display.
High Ambient Temperature Cut-Out
Operation below 1°F (-17°C) may oc-
H I G H A M B I E N T T E M P
casionally cause nuisance low pres-
C U T O U T = 1 3 0 . 0 ° F
sure safety shutdowns. This will gen-
The High Ambient Cutout is used to select the ambient erally not cause a problem provided
temperature above which the chiller may not operate. ambient temperature is not expected
If the ambient temperature rises 1°F (1°C) above this to be below 1°F (-17°C) for more than
point, the chiller will shut down. Restart will occur au- a short time.
tomatically, when temperature falls more than 1°F (1°C)
below the cutout and cooling demand is present. Low Leaving Liquid Temperature Cut-Out
L E A V I N G L I Q U I D T E M P
This cutout is normally set at 130°F (54°C) to allow
C U T O U T = 3 6 . 0 ° F
operation to the absolute maximum temperature capa-
bility of the electromechanical components; however, The Low Leaving Liquid Temperature Cutout protects
values between 100.0 - 130.0°F (38 - 54°C) are accepted. the evaporator from damage due to ice build up caused
This programmable value is password protected. by operation below the chilled liquid freezing point.
To program the High Ambient Cutout, key in the re- If the leaving chilled liquid temperature (water or gly-
quired setting and press the Enter key to store the value col) drops below the cutout point, the chiller will shut
into memory and scroll to the next display. down. The chiller will restart automatically when tem-
perature rises more than 4°F (2°C) above the cutout
Low Ambient Temperature Cut-Out point and cooling demand exists.
L OW A M B I E N T T E M P
If the Dip Switch on the microprocessor board is set for
C U T O U T = 2 5 . 0 ° F
“Water Cooling” (see Section 3.7, page 158) the cutout
The Low Ambient Cutout is used to select the ambient is automatically set at 36°F (2°C) and cannot be repro-
temperature below which the chiller may not operate. grammed. If the Switch is set for “Brine Cooling” (gly-
If the ambient temperature falls 1°F (1°C) below this col) the cutout can be programmed between 08.0 - 36.0°F
point, the chiller will shut down. Restart will occur au- (-13 through -2°C). The cutout should normally be set to
tomatically, when temperature rises more than 1°F (1°C) 4°F (2°C) below the setpoint minus the range, i.e. 34°F
above the cutout and cooling demand is present (see (setpoint) – 2°F (range) - 4°F = 28°F (see Section 6, page
also Section 2.5 page 151). This programmable value 169).
is password protected.
To program the Leaving Liquid Temperature Cutout, key
If the SW1 Dip Switch on the Microprocessor Board in the required setting and press the Enter key to store
is set for “Standard Ambient Control” (see Section the value into memory and scroll to the next display.
3.7) the low ambient cutout is set at 25°F (-4°C) and
is NOT programmable. If the Dip Switch is set for High Motor Current Unload Point
“Low Ambient Control”, programming of the cutout H I G H M O T O R C U R R E N T
between 00.0 - 50.0°F (8 - 10°C) is allowed. This al- U N L O A D = 1 0 5 % F L A
lows higher values than 25° F (-4°C) to be programmed
to shut down the chiller when other cooling methods The Motor Current Unload point is used to avoid a high
become operational. Values below 25°F (-4°C) can be motor current safety shutdown by unloading a compres-
used for applications requiring chiller operation at sor, if current draw approaches the maximum limit cut-
178 YORK INTERNATIONAL
FORM 201.18-NM3
out value. The chiller can then continue to run auto- the longest period acceptable in each application will
matically at reduced capacity until the cause of the ex- reduce cycling and maximize motor life. 600 seconds
cessive current is attended to. is recommended.
The micro will accept between 30 - 105% for the un- The micro will accept a range of programmable values
load point. The motor current safety will shut the com- between 300 - 600 seconds.
pressor down whenever current exceeds 115%.
To program the Anti-Recycle Time, key in the required
If the programmable limit is set between 100% and setting and press the Enter key to store the value into
105% of full load current, this safety will protect against memory and scroll to the next display.
excessive current causing compressor shutdown due to
extremely high ambient, high chilled liquid tempera- Local/Remote Communications 8
ture, and condenser malfunction caused by dirt or fan
problems. L O C A L / R E M O T E M O D E
L O C A L
If the programmable limit is set below 100% of full
load current, this feature can be used for “demand lim- The panel can be programmed for “Local” or “Remote”
iting”. This is important when demand limiting is criti- communications. “Local” mode allows monitoring
cal due to power requirements or limitations in the build- through the RS-485 port only. “Remote,” allows an ex-
ing (See also Section 1.10). ternal device such as an ISN or Remote Control Center
to change setpoints and programming points.
For the first 60 seconds of operation, the unloading
safety is disabled. After this time, if motor current ex- The áâ keys are used to change from Local to Re-
ceeds the programmed limit, the SYS x CRNT LIMIT- mote. The ENTER Key must be pressed to save the
ING message will appear on the display and a 1 second selection in memory.
unload pulse will be sent to the slide valve of the af-
fected compressor every 5 seconds, until the motor cur- Imperial/SI Units Display
rent drops below the programmed limit. The message
will be removed and additional loading will take place D I S P L A Y U N I T S
I M P E R I A L
when motor current drops below 90% of the pro-
grammed threshold.
This allows the operator to select the display messages
to display Imperial Units (PSIG, F, etc.) or SI (Scien-
Typically, this setpoint should be set at 100% for
tific International, Bars, C, etc.).
maximum motor protection. Programming for
100% is recommended. When programming values
The áâ keys are used to change from Imperial to SI
below 100% use of a leading “0” is required, e.g. 085%.
units. The ENTER Key must be pressed to save the
selection in memory.
To program the High Motor Current Unload, key in the
required setting and press the Enter key to store the Automatic/Manual “Lead/Lag”
value into memory and scroll to the next display.
L E A D / L A G C O N T R O L
Anti-Recycle Time A U T OM A T I C
A N T I R E C Y C L E T I M E R
= 6 0 0 S E C S The chiller may be selected for manual lead/lag or au-
tomatic lead/lag. In some cases the operator may want
The Anti-Recycle Timer controls the minimum time to manually select the system that is desired to be the
between starts for each compressor. This is the time lead system. In most cases, automatic lead/lag is se-
available for the heat build up caused by inrush current lected to allow the micro to attempt to balance run time
at start to be dissipated before the next start. Insuffi- between the system. Details of manual and automatic
cient cooling time between starts can cause heat build lead / lag operation are outlined in Section 1.21.
up and motor damage. A fast compressor start response
is needed in some applications and not in others. Al- The áâ keys are used to change from Automatic to
though the minimum setting allowed on this timer will Manual lead/lag. The ENTER key must be pressed to
avoid excessive heat build up, adjusting the timer for save the selection in memory.
YORK INTERNATIONAL 179
MicroPanel Contents
If manual control is desired, press the á or â key. One the code is being keyed in, the digits are not displayed
of the following messages will be displayed: but are shown as “*” as shown:
L E A D / L A G C O N T R O L P R O G R A M MO D E
M A N U A L S Y S 1 L E A D * * * *
8.3 PROGRAMMING "DEFAULT" VALUES A list of the default values entered into memory, if this
program option is selected, is shown below:
Programmable values may be individually programmed
at start-up or any time thereafter. For ease of program-
ming, once the type of refrigerant is programmed in un- 6140
der the Program key, a “defaults password” may be pro- Programmable Value Default
grammed to automatically program default values into Setting
memory. This will preset all programmable values un- Discharge Pressure Cut-Out R22 399 PSIG (28 bar)
der the Program key to values that will allow operation Low Ambient Cut-Out Std. Amb. 25°F (-4°F)
of the chiller under most operating conditions. This al- Low Amb. 25°F (-4°F)
lows quick start-up programming for typical chilled wa- High Ambient Temperature Cut-Out 130°F (38°C)
ter applications. Discharge Pressure Unload R22 375 PSIG (26 bar)
High Motor Current Unload 100%
To program the default values into memory, first press Anti-Recycle Timer 600 sec.
the PROGRAM key followed by the ENTER key, to Leaving Chilled Liquid Temp Cut-Out 36°F (2°C)
program the “refrigerant type.” Press the Program key Suction Pressure Cut-Out R22 44 PSIG (3 bar)
again, key in the numbers “6140”, then press Enter. As
8.4 3 COMPRESSOR main at the highest fan stage reached unless the OFF
CONDENSER FAN CONTROL conditions given in the next paragraph are satisfied.
The chiller is equipped with 12 or 14 condenser fans, Condenser fan OFF conditions are governed by both
with 4 or 5 fans per system as given below. Fan control the DP and OAT. Fan staging will be decreased from
is via Outside Ambient Temperature (OAT) and Dis- the highest stage reached if both the DP and OAT re-
charge Pressure (DP). There are six stages of fan con- quirements are met. For example, if a system is at a fan
trol utilizing 3 outputs per system. The fan stages will stage of 4, and the DP falls under 195 PSIG and the
operate according to Table 4 or Table 5 depending on OAT drops below 75°F, the fan stage will be reduced to
the number of fans/system. There will be a minimum 5 3. The ON/OFF conditions are provided in the next two
second delay between all fan stages. tables.
8
Condenser fan ON conditions are governed solely by The tables below also indicate fan contactors, wire num-
the Discharge Pressure (DP). When the DP rises above bers, and Relay Output Board or I/O Expansion Board
220 PSIG, fan stage 1 is activated. From here, subse- Output numbers relating to fans energized. SYS 1 fan
quent fan stages are activated as the DP rises in incre- contactors are controlled by Relay Output Board # 1.
ments of 15 PSIG, except stage 6, which is activated SYS 2 by Relay Output Board # 2. SYS 3 is controlled
when the DP rises over 290 PSIG. The system will re- by I/O Expansion Board #2.
LD05022
TABLE 5 – CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS
WITH 5 FANS/SYSTEM
ON * OFF * Relay
Fan Fans Conditions Conditions Fan Wire Board
Stage DP DP & OAT Contactor Number Output
S 1 1 >220 PSIG <150 PSIG & <60°F 9M 130 15
Y 2 3, 5 >235 PSIG <165 PSIG & <65°F 10M, 11M 131 14
3 7, 9 >250 PSIG <180 PSIG & <70°F 12M, 13M 132 10
S
4 1, 7, 9 >265 PSIG <195 PSIG & <75°F 9M, 12M, 13M 130, 132 10, 15
1 5 3, 5, 7,9 >280 PSIG <210 PSIG & <80°F 10M, 11M, 12M, 13M 131, 132 10, 14
6 1, 3, 5, 7,9 >290 PSIG <220 PSIG & <85°F 9M, 10M, 11M, 12M, 13M 130, 131, 132 10, 14, 15
S 1 2 >220 PSIG <150 PSIG & <60°F 15M 230 15
Y 2 4,6 >235 PSIG <165 PSIG & <65°F 16M, 17M 231 14
3 8, 10 >250 PSIG <180 PSIG & <70°F 18M, 19M 232 10
S
4 2, 8, 10 >265 PSIG <195 PSIG & <75°F 15M, 18M, 19M 230, 232 10, 15
2 5 4, 6, 8,10 >280 PSIG <210 PSIG & <80°F 16M, 17M, 18M, 19M 231, 232 10, 14
6 2, 4, 6, 8, 10 >290 PSIG <220 PSIG & <85°F 15M, 16M, 17M, 18M, 19M 230, 231, 232 10, 14, 15
S
Y
S SYSTEM 3 IS ALWAYS EQUIPPED WITH 4 FANS.
* Newer versions of EPROMs will have ON and OFF pressures 15 PSIG below the published values shown above.
8.5 4 COMPRESSOR main at the highest fan stage reached unless the OFF
CONDENSER FAN CONTROL conditions given in the next paragraph are satisfied.
The chiller is equipped with 14 or 18 condenser fans, Condenser fan OFF conditions are governed by both
with 3, 4 or 5 fans per system as given below. Fan con- the DP and OAT. Fan staging will be decreased from
trol is via Outside Ambient Temperature (OAT) and Dis- the highest stage reached if both the DP and OAT re-
charge Pressure (DP). There are six stages of fan con- quirements are met. For example, if a system is at a fan
trol utilizing 3 outputs per system. The fan stages will stage of 4, and the DP falls under 195 PSIG and the
work according to Table 2 or Table 3 depending on the OAT drops below 75°F, the fan stage will be reduced to
number of fans/system. There will be a minimum 5 sec- 3. The ON/OFF conditions are provided in the next two
ond delay between all fan stages. tables.
8
Condenser fan ON conditions are governed solely by The tables below also indicate fan contactors, wire num-
the Discharge Pressure (DP). When the DP rises above bers, and Relay Output Board or I/O Expansion Board
220 PSIG, fan stage 1 is activated. From here, subse- Output numbers relating to fans energized. SYS 1 fan
quent fan stages are activated as the DP rises in incre- contactors are controlled by Relay Output Board # 1.
ments of 15 PSIG, except stage 6, which is activated SYS 2 by Relay Output Board # 2. SYS 3 and 4 are
when the DP rises over 290 PSIG. The system will re- controlled by I/O Expansion Board #2.
LD05023
FIG. 76 – CONDENSER FAN CONTROL LAYOUT FOR DXST COMPRESSORS UNITS
TABLE 6 – CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS
WITH 4 FANS/SYSTEM
ON * OFF * Relay
Fan Fans Conditions Conditions Fan Wire Board
Stage DP DP & OAT Contactor Number Output
S 1 1 >220 PSIG <150 PSIG & <60°F 9M 130 15
Y 2 3 >235 PSIG <165 PSIG & <65°F 10M 131 14
3 5, 7 >250 PSIG <180 PSIG & <70°F 11M, 12M 132 10
S
4 1, 5, 7 >265 PSIG <195 PSIG & <75°F 9M, 11M, 12M 130, 132 10, 15
1 5 3, 5, 7 >280 PSIG <210 PSIG & <80°F 10M, 11M, 12M 131, 132 10, 14
6 1, 3, 5, 7 >290 PSIG <220 PSIG & <85°F 9M, 10M, 11M, 12M 130, 131, 132 10, 14, 15
S 1 2 >220 PSIG <150 PSIG & <60°F 15M 230 15
Y 2 4 >235 PSIG <165 PSIG & <65°F 16M 231 14
3 6, 8 >250 PSIG <180 PSIG & <70°F 17M, 18M 232 10
S
4 2, 6, 8 >265 PSIG <195 PSIG & <75°F 15M, 17M, 18M 230, 232 10, 15
2 5 4, 6, 8 >280 PSIG <210 PSIG & <80°F 16M, 17M, 18M 231, 232 10, 14
6 2, 4, 6, 8 >290 PSIG <220 PSIG & <85°F 15M, 16M, 17M, 18M 230, 231, 232 10, 14, 15
ON * OFF * I/O Expansion Board
Fan Fans Conditions Conditions Fan Wire Output
Stage DP DP & OAT Contactor Number (TB3 SYS) (TB4 SYS)
TABLE 7 – CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS
WITH 5 FANS/SYSTEM
ON * OFF * Relay
Fan Fans Conditions Conditions Fan Wire Board
Stage DP DP & OAT Contactor Number Output
S 1 1 >220 PSIG <150 PSIG & <60°F 9M 130 15
2 3, 5 >235 PSIG <165 PSIG & <65°F 10M, 11M 131 14
Y
S 3 7, 9 >250 PSIG <180 PSIG & <70°F 12M, 13M 132 10
4 1, 7, 9 >265 PSIG <195 PSIG & <75°F 9M, 12M, 13M 130, 132 10, 15
5 3, 5, 7, 9 >280 PSIG <210 PSIG & <80°F 10M, 11M, 12M, 13M 131, 132 10, 14
1
6 1, 3, 5, 7, 9 >290 PSIG <220 PSIG & <85°F 9M, 10M, 11M, 12M 130, 131, 132 10, 14, 15
S 1 2 >220 PSIG <150 PSIG & <60°F 15M 230 15
2 4,6 >235 PSIG <165 PSIG & <65°F 16M, 17M 231 14
Y
S 3 8, 10 >250 PSIG <180 PSIG & <70°F 18M, 19M 232 10
4 2, 8, 10 >265 PSIG <195 PSIG & <75°F 15M, 18M, 19M 230, 232 10, 15
5 4, 6, 8,10 >280 PSIG <210 PSIG & <80°F 16M, 17M, 18M, 19M 231, 232 10, 14
2
6 2, 4, 6, 8, 10 >290 PSIG <220 PSIG & <85°F 15M, 16M, 17M, 18M, 19M 230, 231, 232 10, 14, 15
S
Y
S SYSTEM 3 IS ALWAYS EQUIPPED WITH 3 OR 4 FANS.
S
Y
S SYSTEM 4 IS ALWAYS EQUIPPED WITH 3 OR 4 FANS.
* Newer versions of EPROMs will have ON and OFF pressures 15 PSIG below the published values shown above.
TABLE 8 – CONDENSER FAN CONTROL AND FAN CONTACTOR DATA FOR DXST UNITS
WITH 3 FANS/SYSTEM
ON * OFF * I/O Expansion Board
Fan Fans Conditions Conditions Fan Wire Output
Stage DP DP & OAT Contactor Number (TB3 SYS) (TB4 SYS
S
Y
S SYSTEM 1 IS ALWAYS EQUIPPED WITH 4 OR 5 FANS.
S
Y
S SYSTEM 2 IS ALWAYS EQUIPPED WITH 4 OR 5 FANS.
2
1 13 >220 PSIG <150 PSIG & <60°F 21M 330 8
S
Y 2 15 >235 PSIG <165 PSIG & <65°F 22M 331 9
S 3 17 >250 PSIG <180 PSIG & <70°F 23M 332 10
4 13, 17 >265 PSIG <195 PSIG & <75°F 21M, 23M 330, 332 8, 10
3 5 15, 17 >280 PSIG <210 PSIG & <80°F 22M, 23M 331, 332 9, 10
6 13, 15, 17 >290 PSIG <220 PSIG & <85°F 21M, 22M, 23M 330, 331, 332 8, 9, 10
1 14 >220 PSIG <150 PSIG & <60°F 27M 430 8
S
Y 2 16 >235 PSIG <165 PSIG & <65°F 28M 431 9
S 3 18 >250 PSIG <180 PSIG & <70°F 29M 432 10
4 14, 18 >265 PSIG <195 PSIG & <75°F 27M, 29M 430, 432 8, 10
4 5 16, 18 >280 PSIG <210 PSIG & <80°F 28M, 29M 431, 432 9, 10
6 14, 16, 18 >290 PSIG <220 PSIG & <85°F 27M, 28M, 29M 430, 431, 432 8, 9, 10
* Newer versions of EPROMs will have ON and OFF pressures 15 PSIG below the published values shown above.
MAINTENANCE
GENERAL REQUIREMENTS Refrigerant Leaks: Visually check the heat exchang-
ers, compressors and pipework for damage and gas
The units have been designed to operate continuously
leaks.
provided they are regularly maintained and operated
within the limitations given in this manual. Each unit
Airflow obstructions: Check the air cooled condenser
should be included in a routine schedule of daily main-
coil intakes and adjacent areas are clear of foreign ma-
tenance checks by the operator/customer, backed up by
terials or obstructions e.g. paper, leaves, etc.
regular service inspection and maintenance visits by a
suitably qualified Service Engineer.
Operating conditions: Read the operating pressures
and temperatures at the control panel using the display
It is entirely the responsibility of the owner to provide
keys and check that these are within the operating limi-
for these regular maintenance requirements and/or en-
tations given in the MBCS Manual.
ter into a maintenance agreement with a York Interna-
tional service organization to protect the operation of
Compressor oil level: Check the compressor oil level
the unit. If damage or a system failure occurs due to
after the compressor has been operating on ‘FULL
improper maintenance during the warranty period,
LOAD’ for approximately half an hour. The oil level
YORK shall not be liable for costs incurred to return
should be about half way up the upper of the two sight
the unit to satisfactory condition.
glasses. When the compressor is operating at ‘PART
LOAD’, the level may fall as far as half way down the
This maintenance section applies to lower sight glass but should not fall below this level.
the basic unit only and may, on indi- When the compressor returns to full load the level will
vidual contracts, be supplemented by return to the upper sight glass.
additional requirements to cover any
modifications or ancillary equipment Refrigerant charge: When a system starts up, or some-
as applicable. times after a change of capacity, a flow of bubbles will
be seen in the liquid line sight glass. After a few min-
The Safety Section of this manual utes of stable operation, the bubbles should clear leav-
should be read carefully before at- ing just liquid refrigerant showing in the sight glass.
tempting any maintenance operations
on the unit. This section should be Scheduled Maintenance
The maintenance operations detailed in the following
read in conjunction with the MBCS
table should be carried out on a regular basis by a suit-
Manual. ably qualified Service Engineer. It should be noted that
the interval necessary between each ‘minor’ and ‘ma- 9
Daily Maintenance jor’ service can vary depending on, for instance, appli-
The following maintenance checks should be carried cation, site conditions and expected operating sched-
out on a daily basis by the operator/customer. Please ule. Normally a ‘minor’ service should be carried out
note that the units are not generally user serviceable every three to six months and a ‘major’ service once a
and no attempt should be made to rectify faults or prob- year. It is recommended that your local YORK Service
lems found during daily checks unless competent and Center is contacted for recommendations for individual
equipped to do so. If in any doubt, contact your local sites.
YORK Service Agent.
Chiller / Compressor Operating Log
Unit Status: Press the ‘STATUS’ key on the keypad A Chiller/Compressor Operating Log is supplied on the
and ensure no fault messages are displayed (refer to following page for logging compressor and chiller op-
the MBCS Manual for explanation of messages and the erating data.
Trouble Shooting section for courses of action).
Maintenance
Compr. Ser. No. _________________________
Operating Log Unit Ser. No. ___________________________
Refrigerant ____________________________
Date
Time
Hour Meter Reading
Equipment Room Temp./Outdoor Temp. / / / / / / / / / /
Suction Pressure
Suction Superheat
Discharge Pressure
Actual Discharge Temperature
Oil Pressure
Oil Temperature
Operating Log
FLA % (Motor - )
Oil Level (example )
Sep.
Oil
Brine
Outlet Temperature
Pressure Drop
Flow Rate - GPM or l/s
Air On Temperature
Air
Inlet Temperature
Water
Outlet Temperature
Pressure Drop
Flow Rate - GPM or l/s
Leaving Liquid Refrigerant Temperature
YORK INTERNATIONAL
Remarks:
Note: Temperature and Pressure Units in °F and PSIG respectively unless otherwise noted.
YORK INTERNATIONAL
EVERY
PROCEDURE WEEKLY QUARTERLY SEMI-ANNUALLY YEARLY
* HOURS
___
Check oil level in oil separator sight glass X
Check liquid line sight glass / moisture indicator X
Record system operating pressures and temperatures X
Check programmable operating setpoints and safety cut-outs
X
and assure they are correct for particular application.
Check condenser coils for dirt/debris and clean if necessary X
Check compressor superheat on evaporator and economizer
X
TXV’s; Check condenser and economizer subcooling1
Check compressor and cooler heaters for operation X
1
Sample compressor oil and replace oil if necessary X
Leak check the chiller1 X
Disconnect power source and lock out; Check tightness of
X
power wiring connections1
* Reserved for customer use for any special site determined requirements.
1
This procedure must be performed at the specified time interval by an Industry Certified Technician who has been trained and qualified to work on this type of YORK
equipment. A record of this procedure being successfully carried out must be maintained on file by the equipment owner should proof of adequate maintenance be
required at a later date for warranty validation purposes.
FORM 201.18-NM3
187
9
Maintenance
SPARE PARTS
Recommended Spares
It is recommended that the following common spare
parts are held for preventative of corrective maintenance
operations.
Description Item Part Number
Pressure Transducer 200psi (14 bar) BSP 025-29583-000
Pressure Transducer 400psi (28 bar) BDP, BOP 025-29139-001
Sensor High Temperature BOT, BDT 025-30440-000
Sensor Ambient Temperature BAMB 025-28663-001
Sensor Water Temperature BLCT 025-29964-000
Sensor Water Temperature BMLT 025-29964-000
Associated Drawings
Models R22
General Arrangement
Schematic 10
Connection 201.18-W3
Wiring Diagrams
Customer wiring 201.18-W4
Legend