York MILLENNIUM YCAR0315 Installation Operation & Maintenance Download Page 1

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MILLENNIUM

AIR-COOLED RECIPROCATING LIQUID CHILLERS

EPROM

031-02013-001

28971AR

YCAR0315 – YCAR0685 MODELS

50 HZ

STYLE A

90 - 225 TONS
(315 - 685 kW)

INSTALLATION, OPERATION, MAINTENANCE

MILLENNIUM

AIR-COOLED RECIPROCATING

LIQUID CHILLERS

New Release

Form 150.52-NM2 (1001)

Summary of Contents for MILLENNIUM YCAR0315

Page 1: ...TING LIQUID CHILLERS EPROM 031 02013 001 28971AR YCAR0315 YCAR0685 MODELS 50 HZ STYLE A 90 225 TONS 315 685 kW INSTALLATION OPERATION MAINTENANCE MILLENNIUM AIR COOLED RECIPROCATING LIQUID CHILLERS Ne...

Page 2: ...pressor Start 23 Control Circuit Terminal Strip 23 Building Automation System BAS Interface 23 Condenser Coil Protection Options 23 DX Cooler Options 23 Unit Enclosure Options 24 High Static Fan Optio...

Page 3: ...onnection with Internal Unit Circuit Breakers 56 Power Connection Options 58 Wiring Diagrams 60 Dimensions 78 Clearances 90 Isolator Dimensions 91 Weight Distribution Aluminum Fin Coils 92 Isolator Se...

Page 4: ...DISPLAY KEYS and OPTION SWITCHES 122 3 1 General 122 3 2 Chilled Liquid Temps Key 122 3 3 System Data Keys 122 3 4 Ambient Temp Key 123 3 5 Motor Current Key 123 3 6 Operating Hours Start Counter Key...

Page 5: ...152 Maintenance Requirements for YORK J K and P Reciprocating Compressors 153 General Periodic Maintenance Checks Standard Units 154 SPARE PARTS 155 Recommended Spares 155 Recommended Compressor Oils...

Page 6: ...Electrical Box 68 FIG 24 Connection Diagram System Wiring Across the Line Start 70 FIG 25 Connection Diagram System Wiring Part Wind Start 71 FIG 26 Connection Diagram Electrical Box 72 FIG 27 Connec...

Page 7: ...wiring must be in accordance with YORK s published specifications and must be performed ONLY by qualified YORK personnel YORK will not be responsible for damages problems resulting from improper conn...

Page 8: ...serial number order number and run hours starts These de tails are printed on the unit identification plate The unit warranty will be void if any modification to the unit is carried out without prior...

Page 9: ...tions necessary for safe operation and maintenance of equipment containing high temperatures pressures and voltages Pressure Systems The unit contains refrigerant vapor and liquid under pressure relea...

Page 10: ...h may cause corrosion should also be avoided General Chiller Information and Safety EMERGENCY SHUTDOWN In case of emergency the electrical option panel is fit ted with an emergency stop switch CB3 Cir...

Page 11: ...ts that R 22 does not represent a carcinogenic hazard to humans Occupational Recommended limit 1000 ppm v v 8 hr TWA 1250 ppm v v 12 hr TWA Exposure Limits Stability Unstable Conditions to Avoid Use i...

Page 12: ...d when not in use Section 4 PHYSICAL DATA Appearance Colorless liquid Boiling Point 260 C 500 F Vapor Pressure 0 1 mmHg 20 C Specific Gravity water 1 0 89 0 905 Volatiles Percent by Volume 0 Odor Slig...

Page 13: ...not been fully investigated Analogous compounds are considered to be essentially non toxic Section 8 PERSONAL PROTECTION INFORMATION Respiratory Protection Use in well ventilated area Ventilation Loca...

Page 14: ...tection Use in well ventilated areas ventilate locally Protective Clothing Not necessary but goggles or face shield recommended Protective boots and apron may also be worn Act promptly to protect envi...

Page 15: ...are covered with architec turally neutral Desert Sand Munsell 10YR6 2 baked on enamel powder paint This provides a finish which when subjected to ASTM B117 500 hour 5 salt spray conditions shows brea...

Page 16: ...rol is provided by microprocessor oper ated solenoid actuated capacity control valves The electrical solenoid unloading coils are energized to route high pressure fluid to the compressor blocked suc t...

Page 17: ...each compressor and associated fans a control section and an electrical options section Power and control panels are housed in NEMA 3R 12 IP55 rain dust tight powder painted steel cabinets with hinge...

Page 18: ...tor Module section The micro senses low motor current whenever an HPCO or Motor Protector contact opens This occurs because the MP and HPCO contacts are in series with the mo tor contactor Whenever ei...

Page 19: ...whether the three phase sequence on the load side of the main contactor is miswired Upon detec tion of a miswired motor load the module will de en ergize the main contactor pilot circuit within 50 mil...

Page 20: ...ND 2 380 50 117 127 1 1 157 10011101 YCAR0385 SYS 1 380 50 131 142 1 1 176 10110000 SYS 2 380 50 117 127 1 1 157 10011101 YCAR0415 SYS 1 AND 2 380 50 131 142 1 1 176 10110000 YCAR0435 SYS 1 380 50 164...

Page 21: ...0 117 127 1 2 157 10011101 YCAR0385 SYS 1 380 50 131 142 1 1 88 01011000 SYS 2 380 50 131 142 1 1 88 01011000 YCAR0415 SYS 1 and 2 380 50 131 142 1 1 88 01011000 YCAR0435 SYS 1 380 50 164 177 1 1 110...

Page 22: ...er by others Program Used for setting low leaving liquid temperature cutout 300 600 second anti recycle timer lag compressor start time delay average motor cur rent unload point liquid temperature set...

Page 23: ...illed liquid tem perature or percent full load amps current limiting from the BAS Factory mounted Printed circuit board to accept 4 20 mA 0 10VDC or dry contact closure input from the BAS A YORK ISN B...

Page 24: ...tory mounted Louvered Panels Full Unit Enclosure Lou vered panels over coils and around the bottom of the unit These protect the condenser coils provide a visual screen and prevent unauthorized access...

Page 25: ...lity to charge an ice storage tank then pos sibly automatically reset for operation at elevated Leaving Chilled Fluid Temperatures as required by automatic building controls The Thermal Storage Option...

Page 26: ...al Overspray Paint 1 Deflection Seismic X B C D E F G H 1st Yr Parts Only 1st Yr Parts and Labor 2nd Yr Parts Only 2nd Yr Parts and Labor 5 Yr Comp Parts Only 5 Yr Comp Parts and Labor 5 Yr Unit Parts...

Page 27: ...a responsible person on site It is recommended that the unit is periodically in spected during storage INSPECTION Remove any transit packing and inspect the unit to en sure that all components have be...

Page 28: ...28 YORK INTERNATIONAL FORM 150 52 NM2 1001 CORRECT WRONG LD03515 FIG 4 LIFTING LUGS 88 2250mm WRONG LD03514 FIG 3 UNIT RIGGING CORRECT Handling and Storage...

Page 29: ...cured to the building foundation Mounting holes16 mm 5 8 are provided in the base rails for bolting the unit to its foundation See Dimensions for location of the mounting holes On rooftop locations c...

Page 30: ...hose given in the Technical Data Section INSTALLATION OF VIBRATION ISOLATORS Optional sets of vibration isolators can be supplied loose with each unit Using the Isolator tables pages 92 95 in the Tech...

Page 31: ...that a suitably sized by pass and valve arrangement is in stalled to allow flushing of the pipework system The by pass can be used during maintenance to isolate the heat exchanger without disrupting...

Page 32: ...the proposed water composition will not affect the evapo rator materials of carbon steel and copper The pH value of the water flowing through the cooler must be kept between 7 and 8 5 PIPEWORK ARRANG...

Page 33: ...by the unit Where cross winds may occur any ductwork must be supported to prevent side loading on the unit If the ducts from two or more fans are to be combined into a common duct back flow dampers s...

Page 34: ...nsformer It is important to check that the cor rect primary tapping has been used and that it conforms to the site high voltage supply Removing high voltage power to the chiller will remove the 115VAC...

Page 35: ...m SYSTEM INPUTS Flow Switch A chilled liquid flow switch of suitable type must be connected to terminals 13 and 14 Figures 11 and 12 to provide adequate protection against loss of liquid flow Remote R...

Page 36: ...36 YORK INTERNATIONAL FORM 150 52 NM2 1001 Installation POWER AND CONTROL PANEL LAYOUTS FIG 8 POWER PANEL SECTION OPTIONS PANEL WITH TRANSFORMER 00416VIP...

Page 37: ...37 YORK INTERNATIONAL FORM 150 52 NM2 1001 OPTIONS PANEL LAYOUT TYPICAL FIG 8 POWER PANEL SECTION OPTIONS PANEL WITH TRANSFORMER CONTINUED 4 00413VIP...

Page 38: ...n PHOTOGRAPH OF 60 HZ MODEL LOGIC SECTION ITEM 1 2 3 4 5 6 7 8 9 DESCRIPTION Microprocessor Board Back of Keypad Back of Display I O Expansion Board 1 Power Supply Board Relay Output Board 1 Relay Out...

Page 39: ...39 YORK INTERNATIONAL FORM 150 52 NM2 1001 LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT FIG 10 LOGIC SECTION LAYOUT WITH CONTROL PANEL LAYOUT 4 00415VIP...

Page 40: ...ystem No 2 Run 13 13 13 13 13 14 15 16 17 18 19 23 24 25 26 27 28 29 30 System No 1 Alarm Contacts Chilled Liquid Circulating Pump Start System No 2 Alarm Contacts Chiller Run Isolator Auxiliary Inter...

Page 41: ...M2 1001 CUSTOMER CONNECTIONS FIG 12 CUSTOMER CONNECTIONS 4 TRANSFORMERS POWERSUPPLY BOARD CIRCUIT BREAKERS RELAY BOARDS I O EXPANSION BOARD CUSTOMER CONNECTIONS Flow Switch Alarm Run etc MICROPROCESSO...

Page 42: ...properly connected to a suitable grounding point Ensure that all unit internal ground connections are tight Overloads Ensure that the fan overloads settings are correct for the type of fan fitted SEC...

Page 43: ...sing the plugged air vent mounted on the top of the cooler body Flow rates and pressure drops must be within the limits given in the Technical Data Section Operation outside of these limits is undesir...

Page 44: ...Refrigerant Flow When a compressor starts a flow of liquid refrigerant will be seen in the liquid line sightglass After several minutes operation and providing a full charge of refrig erant is in the...

Page 45: ...NG Once the unit has been started all operations are fully automatic After an initial period at minimum capacity on the lead compressor the control system will adjust the unit load depending on the ch...

Page 46: ...S LD07255 Cooler pressure drops are approxi mate A Flow Meter should be used to verify flow 1 00 10 00 100 00 100 1000 Flow GPM Press Drop Ft H 2 O A B Water Cooler Pressure Drops 1 00 10 00 100 00 10...

Page 47: ...on factors to be applied when using glycol solutions Special care must be taken not to exceed the maximum allowed A Correction Factor B Mean Temperature Through Cooler C Concentration W W Excessive fl...

Page 48: ...PROCATING Quantity per Chiller 2 2 2 2 2 Nominal kW Ckt 1 194 211 211 246 246 Nominal kW Ckt 2 194 194 211 211 246 CONDENSERS HIGH EFFICIENCY FIN TUBE WITH INTEGRAL SUBCOOLER Total Chiller Coil Face A...

Page 49: ...6 286 6 308 6 510 6 621 7 027 6 399 6 857 6 880 7 082 7 199 7 718 2 2 2 2 2 2 246 299 299 352 423 423 246 246 299 352 423 423 17 84 23 78 23 78 23 78 23 78 29 73 3 3 3 3 3 3 512 512 512 512 512 512 4...

Page 50: ...RMETIC RECIPROCATING Quantity per Chiller 2 2 2 2 2 Nominal Tons Ckt 1 55 60 60 70 70 Nominal Tons Ckt 2 55 55 60 60 70 CONDENSERS HIGH EFFICIENCY FIN TUBE WITH INTEGRAL SUBCOOLER Total Chiller Coil F...

Page 51: ...858 13 908 14 353 14 598 15 491 14 095 15 118 15 168 15 613 15 858 17 015 2 2 2 2 2 2 70 85 85 100 120 120 70 70 85 100 120 120 256 256 256 256 256 320 3 3 3 3 3 3 13 13 13 13 13 13 4 4 4 4 4 4 4 4 4...

Page 52: ...55 135 600 0 125 0365SC 40 55 144 600 0 125 0385SC 40 55 156 600 0 125 0415SC 40 55 180 600 0 125 0435SC 40 55 195 600 0 125 0485SC 40 55 213 747 0 125 0525SC 40 55 224 747 0 125 0575SC 40 55 247 747...

Page 53: ...ampacity and job requirements using N E C wire sizing information The above recommendations are based on the National Electric Code and using copper conductors only Field wiring must also comply with...

Page 54: ...5 3 3 8 19 0 YCAR0365 380 158 1 200 200 250 2 AWG to 4 0 AWG 1 4 300KCM 1 4AWG 300KCM 117 461 585 3 3 8 19 0 YCAR0385 380 175 6 200 225 300 2 AWG to 4 0 AWG 1 6 350KCM 1 4AWG 300KCM 131 519 641 3 3 8...

Page 55: ...WG to 4 0 AWG 1 4 300KCM 1 4AWG 300KCM 117 461 585 3 3 8 19 0 YCAR0415 380 179 4 200 225 300 2 AWG to 4 0 AWG 1 6 350KCM 1 4AWG 300KCM 131 519 641 4 3 8 19 0 YCAR0435 380 179 4 200 225 300 2 AWG to 4...

Page 56: ...NT PROTECTION13 STANDARD OPTIONAL NF MCA1 DISC SW2 MIN 3 5 MAX 4 6 TERMINAL BLOCK DISC SWITCH YCAR0315 380 230 3 250 300 300 2AWG 300KCM 6AWG 350KCM YCAR0345 380 261 5 400 300 350 1 0 500KCM 2 3 0 250...

Page 57: ...463 3 3 8 19 YCAR0365 380 117 461 585 3 3 8 19 117 461 585 3 3 8 19 YCAR0385 380 131 519 641 3 3 8 19 117 461 585 3 3 8 19 YCAR0415 380 131 519 641 4 3 8 19 131 519 641 4 3 8 19 YCAR0435 380 164 639...

Page 58: ...nect Switches Opt or Terminal Blocks Opt in each of the two Power Panels FIG 14 MULTIPLE POINT POWER SUPPLY CONNECTION LD04921 FIG 15 OPTIONAL SIGNLE POINT POWER SUPPLY WITH INTERNAL CIRCUIT BREAKERS...

Page 59: ...IT PROTECTION STYLE A POWER WIRING CONNECTIONS LD04923 Optional Field Provided 115 1 60 Micro panel Supply One field provided power sup ply circuit to the unit with circuit protection Field connection...

Page 60: ...fer to Pipework Connection General Requirements on pages 30 and 31 5 To stop unit Emergency Stop with contacts other than those shown install the stop contact between 5 and 1 If a stop device is not i...

Page 61: ...Also refer to Pipework Connection General Requirements on pages 30 and 31 5 To stop unit Emergency Stop with contacts other than those shown install the stop contact between 5 and 1 If a stop device i...

Page 62: ...starters wired through motor contactor auxiliary contacts must be suppressed with YORK P N 031 00808 000 sup pressor across the relay contactor coil Any contacts connected to flow switch inputs or BA...

Page 63: ...s 4 To stop unit Emergency Stop with contacts other than those shown install the stop contact between terminals 5 and 1 If a stop device is not installed a jumper must be connected between terminals 5...

Page 64: ...64 YORK INTERNATIONAL FORM 150 52 NM2 1001 Technical Data YCAR0315 YCAR0685 WIRING DIAGRAM CONNECTION DIAGRAM CONTROL CIRCUIT FIG 19 YCAR0315 YCAR0685 WIRING DIAGRAM CONNECTION DIAGRAM CONTROL CIRCUIT...

Page 65: ...65 YORK INTERNATIONAL FORM 150 52 NM2 1001 LD04928 7...

Page 66: ...150 52 NM2 1001 Technical Data YCAR0315 YCAR0685 WIRING DIAGRAM CONTROL CIRCUIT FIG 20 CONTROL CIRCUIT DETAIL B ACROSS THE LINE START ACROSS THE LINE START PART WIND START LD04927 FIG 21 CONTROL CIRCU...

Page 67: ...67 YORK INTERNATIONAL FORM 150 52 NM2 1001 FIG 22 CONTROL CIRCUIT DETAIL C LD04947 YCAR0315 YCAR0685 WIRING DIAGRAM CONTROL CIRCUIT YCAR0315 YCAR0385 YCAR0415 YCAR0525 YCAR0575 YCAR0685 7...

Page 68: ...68 YORK INTERNATIONAL FORM 150 52 NM2 1001 Technical Data YCAR0315 YCAR0685 WIRING DIAGRAM CONNECTION DIAGRAM ELECTRICAL BOX FIG 23 YCAR0315 YCAR0685 WIRING DIAGRAM CONNECTION DIAGRAM ELECTRICAL BOX...

Page 69: ...69 YORK INTERNATIONAL FORM 150 52 NM2 1001 LD06170 7...

Page 70: ...150 52 NM2 1001 Technical Data YCAR0315 0685 WIRING DIAGRAM CONNECTION DIAGRAM SYSTEM WIRING ACROSS THE LINE START FIG 24 CONNECTION DIAGRAM SYSTEM WIRING ACROSS THE LINE START LD04942 LD04943 LD0494...

Page 71: ...NATIONAL FORM 150 52 NM2 1001 YCAR0315 0685 WIRING DIAGRAM CONNECTION DIAGRAM SYSTEM WIRING PART WIND START FIG 25 CONNECTION DIAGRAM SYSTEM WIRING PART WIND START LD04929 LD04931 LD04930 LD04932 LD04...

Page 72: ...72 YORK INTERNATIONAL FORM 150 52 NM2 1001 Technical Data YCAR0315 0685 WIRING DIAGRAM CONNECTION DIAGRAM ELECTRICAL BOX FIG 26 CONNECTION DIAGRAM ELECTRICAL BOX LD04953...

Page 73: ...ERNATIONAL FORM 150 52 NM2 1001 315 385 415 525 575 685 YCAR0315 0685 WIRING DIAGRAM CONNECTION DIAGRAM SYSTEM WIRING ACROSS THE LINE START FIG 27 CONNECTION DIAGRAM SYSTEM WIRING ACROSS THE LINE STAR...

Page 74: ...RNATIONAL FORM 150 52 NM2 1001 315 385 415 525 575 685 Technical Data YCAR0315 0685 WIRING DIAGRAM CONNECTION DIAGRAM SYSTEM WIRING PART WIND START FIG 28 CONNECTION DIAGRAM SYSTEM WIRING PART WIND ST...

Page 75: ...INTERNATIONAL FORM 150 52 NM2 1001 YCAR0315 0685 ELEMENTARY DIAGRAM STANDARD AND REMOTE EVAPORATOR UNITS POWER CIRCUIT FIG 29 ELEMENTARY DIAGRAM POWER CIRCUIT STANDARD AND REMOTE EVAPORATOR UNITS LD0...

Page 76: ...6 YORK INTERNATIONAL FORM 150 52 NM2 1001 Technical Data YCAR0315 0685 ELEMENTARY DIAGRAM STANDARD AND REMOTE EVAPORATOR UNITS CONTROL POWER TRANSFORMER KIT FIG 30 CONTROL POWER TRANSFORMER KIT LD0494...

Page 77: ...77 YORK INTERNATIONAL FORM 150 52 NM2 1001 YCAR0315 0685 WIRING DIAGRAM CONTROL CIRCUIT LD04926 FIG 31 CONTROL CIRCUIT DETAIL A 7...

Page 78: ...n 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 pat...

Page 79: ...POWER ELEMENTS FOR SYS 2 TOP VIEW CONTROL PANEL ORIGIN 806 1418 1380 32 A B C D E F 32 2235 762 762 POWER PANEL 16 DIA MOUNTING HOLES TYP LD03545 LD03546 CENTER OF GRAVITY Alum YCAR X Y Z 0315 2161 1...

Page 80: ...rculation 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 pos...

Page 81: ...VIEW ORIGIN 31 3 4 55 13 16 54 5 16 1 1 4 A B C D E F 5 8 DIA MOUNTING HOLES TYP 1 1 4 88 30 30 POWER ELEMENTS FOR SYS 1 POWER ELEMENTS FOR SYS 2 CONTROL PANEL POWER PANEL LD03542 LD03541 CENTER OF G...

Page 82: ...now 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 unpr...

Page 83: ...WER ELEMENTS FOR SYS 1 POWER ELEMENTS FOR SYS 2 CONTROL PANEL TOP VIEW 806 1368 1368 1368 32 32 ORIGIN 2235 762 762 16 DIA MOUNTING HOLES TYP POWER PANEL LD07033 LD03561 CENTER OF GRAVITY Alum YCAR X...

Page 84: ...n 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 pat...

Page 85: ...TOP VIEW ORIGIN 31 3 4 53 7 8 53 7 8 53 7 8 1 1 4 1 1 4 POWER ELEMENTS FOR SYS 1 POWER ELEMENTS FOR SYS 2 CONTROL PANEL 88 30 30 POWER PANEL 5 8 DIA MOUNTING HOLES TYP A B C D E F G H LD07034 LD03549...

Page 86: ...rculation 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 pos...

Page 87: ...3 57 DIA RIGGING HOLES EACH SIDE 2438 SIDE VIEW TOP VIEW ORIGIN 806 1658 1658 1900 A B C D E F G H CONTROL PANEL POWER ELEMENTS FOR SYS 2 POWER ELEMENTS FOR SYS 1 2235 762 762 POWER PANEL 16 DIA MOUNT...

Page 88: ...n 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 di...

Page 89: ...YS 2 CONTROL PANEL POWER PANEL 5 8 DIA MOUNTING HOLES TYP 1 1 4 1 1 4 TOP VIEW LD03565 LD03566 54 7 16 37 1 2 86 8 WATER OUTLET 107 273 1 8 8 WATER INLET 74 13 16 7 1 4 78 36 2 A A POWER OPENING FAR S...

Page 90: ...old down bolts to allow for isolator adjustment 4 Block the equipment 10 mm 1 4 higher than the specified free height of the isolator To use the iso lator as blocking for the equipment insert a 20 mm...

Page 91: ...1 3 4 1 2 7 5 8 8 1 2 4 1 4 10 1 2 3 4 1000 1628 11NC 5 8 AWMR 2 17 6 3 3 4 1 7 1 2 3 3 4 1 2 7 1 2 5 8 14 1 2 7 1 4 17 7 8 1000 1628 10NC 3 4 AWMR 4 17 8 4 7 8 1 1 4 7 1 2 3 3 4 3 4 7 3 4 3 4 14 1 2...

Page 92: ...599 1 486 1 374 11 618 YCAR0575 1 872 1 643 1 415 1 186 2 077 1 823 1 570 1 316 12 901 YCAR0645 1 874 1 646 1 418 1 189 2 079 1 826 1 573 1 319 12 925 YCAR0685 1 882 1 654 1 426 1 198 2 087 1 834 1 5...

Page 93: ...27 26 31 31 28 27 0685 31 28 27 26 31 31 28 27 TYPE SIZE MAX LOAD DEFL SPRING lbs kg in mm COLOR CP 2 26 1200 544 3 1 17 29 7 Purple CP 2 27 1500 680 4 1 06 26 9 Orange CP 2 28 1800 816 4 1 02 25 9 G...

Page 94: ...733 1 668 1 603 12 884 YCAR0575 2 001 1 818 1 635 1 452 2 196 1 995 1 794 1 593 14 483 YCAR0645 2 004 1 821 1 638 1 455 2 198 1 997 1 797 1 596 14 507 YCAR0685 2 012 1 829 1 646 1 464 2 206 2 005 1 8...

Page 95: ...551 1 552 1 551 1 552 1 553 0415 1 551 1 532 1 532 1 532 1 552 1 551 1 532 1 532 0435 1 551 1 532 1 532 1 532 1 552 1 551 1 532 1 532 0485 1 551 1 551 1 551 1 532 1 552 1 552 1 551 1 551 0525 1 551 1...

Page 96: ...nd fans where the heat is removed The fully condensed liquid enters the economizer The subcooled refrigerant then passes through the expansion valve where pressure is reduced and further cooling takes...

Page 97: ...97 YORK INTERNATIONAL FORM 150 52 NM2 1001 PROCESS AND INSTRUMENTATION DIAGRAM FIG 34 PROCESS AND INSTRUMENTATION DIAGRAM 7 LD06386...

Page 98: ...115VAC Control Power to TB1 has 20A minimum capacity See Fig 8 page 36 q 13 Be certain all water temp sensors are inserted completely in their respective wells and are coated with heat conductive comp...

Page 99: ...uperheat should not drop below 10 C 50 F clear oil in the compressor crankcase solid liquid refriger ant in the liquid indicator and usually no more than 13 8 kPa 2 PSIG variation in suction pres sure...

Page 100: ...1 C 87 F SUBCOOLING 8 C 15 F The subcooling should be adjusted to 7 8 C 12 15 F Add charge as needed to increase subcooling and re move charge as necessary to reduce subcooling When ever removing char...

Page 101: ...C F Superheat ____ ____ ____ ____ C F Proper subcooling and superheat will assure optimum performance and reliability of the system Checks should always be made when commissioning a chiller and on a y...

Page 102: ...OCKER SWITCH This switch shuts down the entire chiller when placed in the OFF position The switch must be ON for the chiller to operate PROGRAM AND SETUP KEYS Entry Keys see Section 5 The numeric and...

Page 103: ...ture setpoint reset and alarm annunciation YCAR chillers each have a single split circuit evapora tor serving 2 independent refrigerant systems YCAR 2 system chillers are configured as a single self c...

Page 104: ...ler is operating the clock must be ON Sec tion 9 1 11 Item 1 or the internal clock on the micro processor will not be active and the micro cannot keep track of time although all other functions will o...

Page 105: ...ing 1 8 TRANSFORMERS 2 Transformers 2T and 3T are located in the Control Panel These transformers convert the 115VAC Con trol Power Input to 24VAC to operate the microproces sor circuitry 2T This 75VA...

Page 106: ...106 YORK INTERNATIONAL FORM 150 52 NM2 1001 FIG 35 MOTOR PROTECTOR SIDE VIEW 29119A 29121A TOP VIEW TOP VIEW SIDE VIEW 29121A 29120A DISPLAY SWITCH PUSHED TO LEFT INDICATES ON ON Micro Panel...

Page 107: ...be closed to allow the chiller to run Any time the contact opens the chiller will shut down and the NO RUN PERM message will be dis played The location of the flow switch connection is shown in Sectio...

Page 108: ...ax Reset Offset 10 sec For example with a programmed setpoint of 7 C 44 F after a 4 second pulse and a programmed maximum offset of 22 C 40 F the temperature offset would equal Reset Temp 4 sec 1 sec...

Page 109: ...3 EPROM S1 S2 to S5 DESCRIPTION Clock Enable Disable Jump Contact Real Time Clock and Battery Backup I C Microprocessor I C label shows version NOTE Dimple is positioned at top edge Dip Switch Set 8 s...

Page 110: ...CTION LAYOUT ITEM 1 2 3 4 5 6 7 8 9 DESCRIPTION Microprocessor Board Back of Keypad Back of Display I O Expansion Board 1 Power Supply Board Relay Output Board 1 Relay Output Board 2 Flow Switch and C...

Page 111: ...e contacts will also close if a Low Water Temp Fault occurs 1 16 COMPRESSOR HEATER CONTROL Each compressor has its own heater The heater will be off whenever the compressor is running 1 17 EVAPORATOR...

Page 112: ...Panel See Section 9 1 12 which can be used to remotely signal a warning whenever a fault lockout occurs on any sys tem or if power is lost to the control panel The inter nal contacts are normally open...

Page 113: ...rst 4 If all compressors are waiting to start Anti recycle timers have not timed out the micro will assign the lead to the compressor with the shortest anti recycle time in an effort to provide coolin...

Page 114: ...ssages 2 3 Unit Warnings 2 4 Anticipation Control Status Messages 2 5 Chiller Fault Status Messages 2 6 System Fault Status Messages These messages are described in detail in this section with example...

Page 115: ...display indicates that an external cycling contact and or the flow switch connected to terminals 13 and 14 in the Logic Section s of the control panel s is are open Whenever the contact s is are open...

Page 116: ...ct Refrigerant Warning will occur if the DIP Switch setting for refrigerant type and the type pro grammed into the micro at the factory are not the same This message will be displayed until the non pr...

Page 117: ...perature on a system has dropped to 4 4 C 24 F and that any further tempera ture reduction could cause some icing of the evaporator tubes Saturated suction temperature is computed by the micro by conv...

Page 118: ...d result in system damage Whenever the microprocessor senses an on board control power supply failure while a compressor is running the chiller is shut down The microprocessor circuitry is capable of...

Page 119: ...igation of the cause of the fault should be made Failure to repair the cause of the fault while manually allowing repetitive re starts may cause further expensive damage to the system High Discharge P...

Page 120: ...ximately 1 2 x RLA rated load amps RLA is specified on the motor chiller name plate and is typical current demand under rated operating conditions in a fully loaded system When a system is fully loade...

Page 121: ...h Pressure Cutout External Motor Overload The Low Motor Current Safety prevents a compres sor motor running with less current than would normally be expected This may result from loss of refrigerant c...

Page 122: ...GENERAL The Display keys provide direct access to retrieve com monly required data about the operation of the chiller This is particularly useful during commissioning moni toring the operation of the...

Page 123: ...ad Stage 0 2 Minimum and maximum values may change as software EPROM revi sions are made 3 4 AMBIENT TEMP KEY When the Ambient Temperature Key is pressed ambi ent air temperature as measured surroundi...

Page 124: ...ammed from 4 4 to 11 1 C 40 to 52 F Selecting this mode also auto programs the Low Chilled Liquid Cutout at 2 C 36 F and the Suction Pressure Cutout at 3 bar 44 PSIG Closed Brine Cooling Mode is for b...

Page 125: ...OPROCESSOR BOARD LD03511A LD03511B OPEN Position Left side of switch pushed in CLOSED Position Right side of switch pushed in 3 8 FUNCTION KEY Pressing the Function key only displays the same message...

Page 126: ...ional printer is connected remotely as hard copy printouts The Operating Data Oper Data key provides a real time list of system operating data and programmed set tings The History key provides a compr...

Page 127: ...gives the rate of change of the chilled liquid leaving tempera ture in degrees per minute A minus sign indicates falling temperature No sign indicates rising temperature This message advises which sys...

Page 128: ...TYPE R 22 PROGRAM VALUES DSCH PRESS CUTOUT 399 PSIG DSCH PRESS UNLOAD 375 PSIG SUCT PRESS CUTOUT 44 PSIG HIGH AMBIENT CUTOUT 130 0 F LOW AMBIENT CUTOUT 25 0 F LEAVING LIQUID CUTOUT 36 0 F MOTOR CURREN...

Page 129: ...rouble shoot a system problem This data reflects the system conditions at the instant the fault occurred and often reveals other system conditions which actually caused the safety threshold to be exce...

Page 130: ...e device such as a Remote Control Center an ISN controller or another device sending a PWM signal for temperature or cur rent temperature or current reset is overriding control points programmed throu...

Page 131: ...tdown No 1 An example of the HISTORY Printout is shown on the following page This message shows the system differential oil pres sure at the time of the fault This message indicates the system oil lin...

Page 132: ...ATOR HEATER OFF ACTIVE REMOTE CONTROL NONE SOFTWARE VERSION C RCP 09 00 SYSTEM 1 DATA COMPRESSORS STATUS OFF RUN TIME 0 0 0 0 D H M S MOTOR CURRENT 0 AMPS 0 FLA SUCTION PRESSURE 125 PSIG DISCHARGE PRE...

Page 133: ...e returned The Enter key is also used to scroll through available data when using the Program or Set Schedule Holiday keys 5 4 CANCELKEY When the Cancel key is pressed the cursor will always return to...

Page 134: ...ity is controlled by switching compressors on or off by varying the number of cylinders loaded on each compressor and by controlling the hot gas valve The microprocessor controls chilled liquid temper...

Page 135: ...Reset is ac complished by timed closure of external contacts for a defined period of time and allows reset of the setpoint upward by up to 22 C 40 F above the setpoint pro grammed in memory see Secti...

Page 136: ...d compressor now loads to Stage 1 The Load Timer will reset to 60 seconds and the Unload Timer to 30 seconds After 2 minutes of operation and the load timer has counted down to 0 and if the chilled li...

Page 137: ...g demand requires it If saturated suction temperature is less than 110 101 of the internal limit of 4 C 24 F for water chill ing or setpoint 6 C 11 F for brine chilling the respective system will not...

Page 138: ...d does not damage the motor If Saturated Suction temperature drops below 24 F chilled liquid applications or setpoint minus 11 brine applications the micro will unload the respective sys tem by 1 stag...

Page 139: ...ng 0 for times before 10 o clock e g 08 31 The cursor will then advance to the AM PM designation If necessary press the or key to change to the oppo site time period Press ENTER to advance to the day...

Page 140: ...nd the ENTER key four times while viewing the Monday Start Stop schedule Programming the DAILY SCHED ULE will not affect on the holiday schedule If the chiller is not required to run on a given day th...

Page 141: ...e activated Manual Override is only active for a period of 30 minutes and will automatically disengage after 30 minutes The following status mes sage will be observed when in the Manual Override Mode...

Page 142: ...ailure to properly program these values may cause damage to the Chiller or operating problems 8 PROGRAM KEY 8 1 GENERAL The Program key is used to program 12 system operat ing parameters including cut...

Page 143: ...scharge pressure has dropped 4 bar 60 PSIG below the threshold Typically the unload point should be set 1 4 to 1 7 bar 20 25 PSIG below the discharge pressure cutout set ting The micro will accept a r...

Page 144: ...ith time until after 30 sec onds it equals the programmed cutout value If the suc tion pressure rises to above the programmed cutout value during the 30 second time period the timer will be reset If t...

Page 145: ...build up adjusting the timer for the longest period acceptable in each appli cation will reduce cycling and maximize motor life 600 seconds is recommended Low Leaving Liquid Temperature Cutout The Lo...

Page 146: ...em Details of manual and automatic lead lag operation are outlined in Section 9 1 21 The keys are used to change from Automatic to Manual lead lag The ENTER key must be pressed to save the selection i...

Page 147: ...ter to store the selection into memory If individual programming is selected the display will now return to the Status display If a default setpoints have been selected the display will momentarily d...

Page 148: ...st fan stage reached unless the OFF conditions given in the next paragraph are satisfied FIG 40 CONDENSER FAN LAYOUT FOR DXRT 2 COMPRESSOR UNITS Condenser fan OFF conditions are governed by both the D...

Page 149: ...3 C 10M 131 14 Y 3 5 17 2 BAR 12 4 BAR and 21 1 C 11M 132 10 S 4 1 5 18 3 BAR 13 4 BAR and 23 9 C 9M 11M 130 132 10 15 5 3 5 19 3 BAR 14 5 BAR and 26 7 C 10M 11M 131 132 10 14 1 6 1 3 5 20 0 BAR 15 2...

Page 150: ...ion for courses of action Refrigerant Leaks Visually check the heat exchangers compressors and pipework for damage and gas leaks Airflow Obstructions Check the air cooled condenser coil intakes and ad...

Page 151: ...on Pressure Suction Temperature Suction Superheat Discharge Pressure Actual Discharge Temperature Oil Pressure Oil Temperature FLA Motor Oil Level example Oil Added gallons or liters Inlet Temperature...

Page 152: ...d lock out Check tightness of X power wiring connections 1 Perform a top head maintenance 1 Note 2 Note 2 MAINTENANCE REQUIREMENTS FOR YORK YCAR RECIP CHILLERS 1 This procedure must be performed at th...

Page 153: ...of maintenance fulfillment may be required for warranty validation purposes Reserved for any special site determined requirements as determined by end user 1 For all models maintain oil level no highe...

Page 154: ...oler Check water flow Check water pH glycol strength Check water pressure drop Check heater mats Air Cooled condensers Check for airflow obstructions Brush fins Check fins Check fan motor bearings Che...

Page 155: ...the parts required All requests for parts should be made to your local YORK Sales and Service Center Recommended Compressor Oils The correct type of oil must be used in the unit as shown on the unit d...

Page 156: ...splayed value is limit approximately correct The warning message should clear when the ambient air temperature rises above the programmed operating limit Check the programmed settings are correct for...

Page 157: ...sured pressure incorrect Check suction pressure transducer calibration and wiring SYS LOW CURR MP HP Compressor current too low Check compressor mains supply fuses contactors displayed and wiring Chec...

Page 158: ...ature Sensor Temperature Resistance Voltage C F ohms Vdc 0 32 163250 0 282 10 50 99500 0 447 20 68 62450 0 676 30 86 40285 0 976 40 104 26635 1 34 50 122 18015 1 76 60 140 12440 2 20 70 158 8760 2 63...

Page 159: ...pecifically agreed to in the con tract documents this warranty does not include the fol lowing costs and expenses 1 Labor to remove or reinstall any equipment materi als or components 2 Shipping handl...

Page 160: ...77 8 68 154 4 176 80 0 70 158 180 82 2 72 161 6 184 84 4 74 165 2 188 86 7 76 168 8 192 88 9 78 172 4 196 91 1 80 176 200 93 3 82 179 6 204 95 6 84 183 2 208 97 8 86 186 8 212 100 0 88 190 4 216 102...

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York MILLENNIUM YCAR0315, Installation Operation & Maintenance

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