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OPERATING & MAINTENANCE

Supersedes: Nothing

Form 160.52-O1 (898)

MODEL YK (STYLE D)

R-134a (COOLING ONLY)

WITH MICROCOMPUTER CONTROL CENTER

PART #371-01200-010, 371-01200-011 & 371-01200-015

FOR ELECTRO-MECHANICAL STARTER,

SOLID STATE STARTER & VARIABLE SPEED DRIVE

WARNING

SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE.

SERIOUS INJURY COULD RESULT IF PROPER PROCEDURES ARE NOT

FOLLOWED WHEN SERVICING SYSTEM. ALL SERVICE WORK SHALL
BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN IN ACCOR-

DANCE WITH YORK INSTALLATION/OPERATION MANUAL.

MILLENNIUM 

TM

CENTRIFUGAL LIQUID CHILLERS

28815A

Summary of Contents for 371-01200-010

Page 1: ...ELECTRO MECHANICAL STARTER SOLID STATE STARTER VARIABLE SPEED DRIVE WARNING SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE SERIOUS INJURY COULD RESULT IF PROPER PROCEDURES ARE NOT FOLLOWED WHEN SERVICING...

Page 2: ...Maintenance 43 SECTION 6 Trouble Shooting 45 SECTION 7 Maintenance 50 SECTION 8 Preventive Maintenance 59 Page REFERENCE INSTRUCTIONS DESCRIPTION FORM NO Solid State Starter Operation Maintenance 160...

Page 3: ...B DC DD EB EC ED FB FC FD GB GC GD HB HC HD JB JC JD TB TC TD VB VC VD COOLER CODE CB CC CD CE DB DC DD DE FB FC FD GB GC GD GF GH HB HC HF HH JF JG JH TF TG TH VF VH WF WH MODEL MOTOR CODE 60 HZ 50 H...

Page 4: ...s applied with an electro mechanical starter YORK Solid State Starter optional or Variable Speed Drive optional In operation a liquid water or brine to be chilled flows through the cooler where boilin...

Page 5: ...r components of a chiller are selected for full load capacities therefore capacity must be controlled to maintain a constant chilled liquid temperature leav ing the cooler Prerotation vanes PRV locate...

Page 6: ...Operation of this equipment in a residential area is likely to cause interference in which case the user at his own expense will be required to take whatever action may be required to correct the inte...

Page 7: ...EVAPORATOR AND CONDENSER DISCHARGE TEMPERATURE OIL TEMPERATURE HIGH LOW OIL PRESSURE TRANSDUCER PRESSURE SOLID STATE STARTER MOTOR CURRENT VOLTS When Supplied CONDENSER REFRIGERANT LEVEL The system s...

Page 8: ...VICE 1 Service allows manual PRV control with visual display readout of PRV operation 2 Local allows manual compressor start from the COMPRESSOR switch on the Control Center front 3 Program allows ope...

Page 9: ...the differential pressure The offset pressure calculation will not be performed if either transducer is out of range The offset value will be taken as 0 PSI in this instance To Display OPTIONS This k...

Page 10: ...mmed by the system operator The Setpoints keys are located on the Control Center keypad see Fig 3 To program see Programming System Setpoints page 14 The following is a description of these setpoints...

Page 11: ...ming week are holidays On those designated days the chiller will automatically start and stop via the holi day start and stop times programmed in the DAILY SCHEDULE setpoint It will do this one time o...

Page 12: ...erator programmed The value displayed in the REMOTE mode is that which has been pro grammed by the Energy Management System via the remote current limit setpoint input If chiller is equipped with a YO...

Page 13: ...age REMOTE RESET TEMP RANGE 10 F or REMOTE RESET TEMP RANGE 20 F To Display DATA LOGGER setpoints Refer to YORK Form 160 49 N2 for operation of this key To Display UNDERVOLTAGE setpoints Solid State S...

Page 14: ...THORIZED is displayed NOTE Unless terminated by pressing the AC CESS CODE key again the operator will have access to the PROGRAM key for 10 minutes When 10 minutes have elapsed access to PROGRAM key w...

Page 15: ...MODE SELECT SETPOINT message is displayed To Enter CURRENT LIMIT Setpoint Electro Mechanical Starter refer to Fig 7 1 Press and release CURRENT LIMIT setpoint key The following program prompt message...

Page 16: ...y PROGRAM MODE SELECT SETPOINT message is displayed To Enter CLOCK Setpoint Refer to Fig 9 1 Assure Micro Board Program jumper J57 is in CLKON position 2 Press and release CLOCK setpoint key The follo...

Page 17: ...desired hours and minutes stop time e If necessary press the AM PM key to change AM to PM or vice versa 3 Press and release ADVANCE DAY SCROLL key The following prompt message is displayed MON START X...

Page 18: ...R key PROGRAM MODE SELECT SETPOINT message is displayed To cancel all of the designated holidays perform Step 1 press CANCEL key and then press ENTER key PROGRAM MODE SELECT SETPOINT message is displa...

Page 19: ...13 KEYPAD SERVICE KEYS LOCATION SERVICE KEYS LD00963 HOLD Press and release this key to hold the pre rotation vanes in their present position If the chiller is running SYSTEM RUN VANES HOLDING is dis...

Page 20: ...o reset any safety shutdown mes sage press WARNING RESET key in SERVICE mode with the COMPRESSOR switch in the STOP RESET position MANUAL OIL PUMP This key is operational in any mode Press and release...

Page 21: ...celled or NO 2 ACTUAL LEVEL XXX LEVEL SETP XXX Displays the actual refrigerant level in the condenser and the refrigerant level setpoint programmed by the service technician This message replaces the...

Page 22: ...MODE IN EFFECT is displayed If the Control Center is in SERVICE mode SERVICE OPERATING MODE IN EFFECT is displayed To change operating mode proceed as follows 1 Press ACCESS CODE key 2 ENTER VALID ACC...

Page 23: ...lue the vanes will be driven closed not fully closed only far enough to allow the current to decrease to a value less than 104 of the operator programmed XXX FLA cur rent limit For example With the op...

Page 24: ...rises to 28 PSIG 193 kPa R 134a the vanes will be per mitted to open Low pressure limit feature is not used when program jumper JP3 is cut Brine application SYSTEM RUN HIGH PRESSURE LIMIT IN EFFECT Di...

Page 25: ...wn The flow switch is checked 25 seconds into Start Sequence Initiated and continuously thereafter MON XX XX AM SYSTEM CYCLING AUTOSTART A remote command computer relay contact or manual switch connec...

Page 26: ...ut out settings will vary with the brine applica tion To restart the chiller wait until the safety contacts close press the COMPRESSOR switch to the STOP RESET position and then to the START position...

Page 27: ...arge tem perature has increased to 220 F 104 C The system will be allowed to restart when the temperature has decreased to 219 F 103 C Temperature is sensed by a thermistor RT2 To restart the chiller...

Page 28: ...r JP4 removed this period is extended to allow for a longer coastdown time EPROM version C 02F T 11 provides a 6 minute coastdown period EPROM version C 02F T 12 or later provides a 10 minute coastdow...

Page 29: ...T position and then to the START position MON XX XX AM PROX SENSOR SAFETY SHUTDOWN The chiller is shut down because the Proximity Tem perature Sensor has detected that the distance be tween the compre...

Page 30: ...orientation orientation notch must be UP Refer to Fig 14 MON XX XX AM OPEN DRAIN TEMP THERMOCOUPLE The chiller is shut down because the Proximity Tem perature Sensor thermocouple or high speed drain...

Page 31: ...not start if the oil is less than 71 F 22 C If not possible the compressor oil should be drained and new oil must be charged into the oil sump See Charging Unit With Oil page 44 2 Oil Pump To check pr...

Page 32: ...for a 50 sec ond pre run to establish oil flow and adequate lu brication to all bearings gears and rotating sur faces within the compressor The high and low oil pressure transducers OP and the oil te...

Page 33: ...he Control Center as MON 10 30 AM LOW WATER TEMPERATURE AUTOSTART This occurs when the leaving water temperature falls to 4 F 2 2 C below setpoint or 36 F 2 2 C whichever is higher The LWT is part of...

Page 34: ...erating condi tions temperatures and pressures recorded at regu lar intervals throughout each 24 hour operating period should be kept An optional status printer is available for this purpose or Fig 16...

Page 35: ...ondenser saturation temperature based upon condenser pressure sensed by the condenser transducer Press the DISPLAY DATA key This key may be depressed repeatedly after depressing the DISPLAY HOLD key t...

Page 36: ...Low Evaporator Pressure Low Oil Pressure High Oil Flow High Condenser Pressure Evaporator Transducer or Probe Error High Discharge Temp High Oil Temp Oil Pressure Transducer Starter Malfunction Detect...

Page 37: ...ng temperatures are encountered while the system is idle carefully drain the cooling water from the cooling tower condenser condenser pump and the chilled water system chilled water pump and coils Ope...

Page 38: ...COOLER OIL RESERVOIR PUMP 28778A FRONT VIEW SIGHT GLASS REFRIGERANT CHARGING VALVE 28815A COOLER MOTOR ADAPTER MOTOR SUPPORT COVER MICROCOMPUTER CONTROL CENTER SUCTION DUAL RELIEF VALVES VARIABLE SPE...

Page 39: ...pump oil filter oil cooler and all interconnecting oil piping and passages There are main points within the motor com pressor which must be supplied with forced lubrication as follows 1 COMPRESSOR DRI...

Page 40: ...40 YORK INTERNATIONAL FIG 18 SCHEMATIC DRAWING YK COMPRESSOR LUBRICATION SYSTEM LD03278...

Page 41: ...HANGERS Evaporator and condenser shells are fabricated from rolled carbon steel plates with fusion welded seams Heat exchanger tubes are internally enhanced type The evaporator is a shell and tube flo...

Page 42: ...ared and normal control is resumed OPTIONAL SERVICE ISOLATION VALVES If your chiller is equipped with optional service isola tion valves on the discharge and liquid line these valves must remain open...

Page 43: ...drator to the compressor sump CHANGING THE DEHYDRATOR To change the dehydrator use the following procedure 1 Shut the stop valves on the condenser gas line oil return line to rotor support and inlet...

Page 44: ...valve A located on the remote oil reservoir cover plate See Fig 20 Do not tighten the connection at the charging valve until after the air is forced out by pumping a few strokes of the oil pump This f...

Page 45: ...remote com Automatic Restart Contact connected to Cycling mand computer upon remote the Remote Local relay contact or command cycling input of the manual switch Digital input board MON 10 00 AM Multi...

Page 46: ...n RS1 LCWT minus satu tor RS1 ration temperature is less than 2 5 F or greater than 25 F Checked every 10 minutes following a 10 min bypass at start up MON 10 00 AM Motor Con CM2 or Solid Reset the de...

Page 47: ...r Check motor starter Malfunction 15 for 10 swc STOP RESET operation Motor current Detected with Control Cen switch and then value greater than 15 ter not calling for FLA motor to run MON 10 00 AM Pro...

Page 48: ...n normal with normal discharge temperature Temperature of chilled water too low with Insufficient load for Check prerotation vane motor opera with low motor amperes system capacity tion and setting of...

Page 49: ...ALLY DECREASES Noted by Observation of Daily Log Sheets Oil pressure noted when pressing OIL Oil filter is dirty Change oil filter PRESSURE display key drops to 70 of oil pressure when compressor was...

Page 50: ...or can be used to detect any leaks too small to be found by the soap test To test with R 22 proceed as follows 1 With no pressure in the system charge R 22 gas into the system through the charging val...

Page 51: ...t the vacuum pump leaving the vacuum indicator in place 6 Hold the vacuum obtained in Step 3 in the system for 8 hours the slightest rise in pressure indicates a leak or the presence of moisture or bo...

Page 52: ...to be tight prior to evacuation then the saturation tem perature recordings should follow a curve similar to the typical saturation curve shown as Fig 22 The temperature of the water in the test tube...

Page 53: ...urnished in cylinders contain ing either 30 50 125 or 1750 lbs 207 345 862 or 12 066 kg of refrigerant TABLE 4 REFRIGERANT CHARGE CHECKING THE REFRIGERANT CHARGE DURING UNIT SHUTDOWN The refrigerant c...

Page 54: ...enser or evaporator compressor while making any necessary repairs While the main disconnect switch and compressor motor starter are open meg the motor as follows 1 Using a megohm meter megger meg betw...

Page 55: ...FORM 160 52 O1 55 YORK INTERNATIONAL FIG 24 MOTOR STATOR TEMPERATURE AND INSULATION RESISTANCES LD00476 TEMPERATURE F MEGOHMS Minimum Insulation Resistance vs Temperature per IEEE Std 43 Open Motors...

Page 56: ...time accompanied by a steady rise in con densing temperature and noisy operation These symp toms may also be due to foul gas buildup Purging will remove the foul gas revealing the effect of fouling TU...

Page 57: ...ube heads and the ends of all tubes with water NOTE Do not use carbon tetrachloride for this pur pose since its fumes give the same flame discoloration that the refrigerant does 3 With nitrogen or dry...

Page 58: ...or Low Oil Pressure OP change the oil filter element Examine the oil filter element for the pres ence of aluminum particles Aluminum gas seal rings can contact the impeller and account for some alumi...

Page 59: ...he unit should be leak tested quarterly Any leaks found must be repaired immediately COOLER AND CONDENSER The major portion of maintenance on the condenser and cooler will deal with the maintaining th...

Page 60: ...controls operation and safety not be changed If the set tings are changed without YORK s approval the warranty will be jeopardized 3 A 5 11 year life battery is part of the RTC Real Time Clock To repl...

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