York Millennium YK M3 M3 G4 THRU YK S6 S4 J2 Operating & Maintenance Manual Download Page 1

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OPERATING & MAINTENANCE

Supersedes: Nothing

Form 160.49-O2 (1296)

MILLENNIUM

CENTRIFUGAL LIQUID CHILLERS

MODEL YK M3 M3 G4 THRU YK S6 S4 J2 (STYLE C)

R-22 (COOLING ONLY)

MODEL YK LB LB G4 THRU YK SE SC J4 (STYLE C)

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

W ARNING

ARNING

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.

27385A

Summary of Contents for Millennium YK M3 M3 G4 THRU YK S6 S4 J2

Page 1: ...R CONTROL CENTER PART 371 01200 010 371 01200 011 371 01200 015 FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER VARIABLE SPEED DRIVE W W W W W ARNING ARNING ARNING ARNING ARNING SYSTEM CONTAINS REF...

Page 2: ...IONS DESCRIPTION FORM NO Solid State Starter Operation Maintenance 160 46 OM3 1 Variable Speed Drive Operation 160 00 O1 Installation 160 49 N5 Installation and Operation of Printers 160 49 N7 Wiring...

Page 3: ...5CK 5DB CR DC 5CL 5DC CS DD 5CM 5DD CT DE 5CN 5DE CU DF 5CO 5OF CV DH 5CP 5OG CW DJ 5CQ 5OH 5CR 5OJ 5CS R 134a YK NB PB H1 CX C DESIGN LEVEL C POWER SUPPLY for 60 HZ 5 for 50 HZ COMPRESSOR CODE G4 H0...

Page 4: ...ter YORK Solid State Starter optional or Variable Speed Drive op tional In operation a liquid water or brine to be chilled flows through the cooler where boiling refrigerant absorbs heat from the wate...

Page 5: ...ted at the en trance to the compressor impeller compensate for varia tion in load See Fig 2 Detail A The position of these vanes is automatically controlled through a lever arm attached to an electric...

Page 6: ...peration of this equip ment 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: ...ORATOR AND CONDENSER DISCHARGE TEMPERATURE OIL TEMPERATURE HIGH LOW OIL PRESSURE TRANSDUCER PRES SURE SOLID STATE STARTER MOTOR CURRENT VOLTS When Supplied CONDENSER REFRIGERANT LEVEL The system setpo...

Page 8: ...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 operator...

Page 9: ...e To Display OPTIONS This key is not used NO OPTIONS INSTALLED is displayed when this key is pressed To Display SSS MOTOR CURRENT VOLTS Solid State Starter Applications Only If chiller is equipped wit...

Page 10: ...Setpoints page 14 The following is a description of these setpoints with the English Metric jumper installed on the Micro Board CHILLED LIQUID TEMP This key displays the leav ing chilled water temper...

Page 11: ...0 or 20 F as programmed When in the REMOTE mode this value is added to the operator pro grammed CHILLED LIQUIDTEMP setpoint and the sum equals the temperature range in which the LCWT can be reset For...

Page 12: ...yed in LOCAL or PROGRAM mode is that which is operator 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...

Page 13: ...y as described above to produce the following mes sage REMOTE RESET TEMP RANGE 10 F or REMOTE RESET TEMP RANGE 20 F To Display DATA LOGGER setpoints Refer toYORK Form 160 49 N7 for operation of this k...

Page 14: ...is displayed NOTE Unless terminated by pressing the ACCESS CODE key again the operator will have ac cess to the PROGRAM key for 10 minutes When 10 minutes have elapsed access to PROGRAM key will be a...

Page 15: ...IT Setpoint Electro Mechanical Starter refer to Fig 7 1 Press and release CURRENT LIMIT setpoint key The following program prompt message is displayed CURRENT LIMIT XXX FLA 2 Use ENTRY keys to enter d...

Page 16: ...nter 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 follow ing program prompt message is displayed TODAY IS MON 1...

Page 17: ...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 XX XX AM STOP XX XX AM 4 Enter the desired start and stop...

Page 18: ...tep 1 press CANCEL key and then press ENTER key PROGRAM MODE SELECT SETPOINT message is displayed To cancel one of the designated holidays perform Step 1 press ADVANCE DAY SCROLL key until the cursor...

Page 19: ...LD 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 displayed If chiller is not running SYS READY TO START VANE...

Page 20: ...ERANT LEVEL control This allows these keys to manually control the refrigerant level con trol variable orifice in Service mode When manual re frigerant level control is selected the pre rotation vanes...

Page 21: ...a remote device i e Energy Management System or cycling input The control sig nal inputs are 1 Remote Start 2 Remote Stop 3 Remote LCWT Setpoint 4 Remove Current Limit Setpoint NOTE The compressor can...

Page 22: ...To RESET Control Center Following a safety shutdown the operator is re quired to reset the Control Center prior to restart ing the system Move switch from RUN to STOP RESET position NOTE The operator...

Page 23: ...manual Form 160 49 M3 and operating in SERVICE mode Indicates an OPEN command is being output to the variable orifice Manual level control should be selected only by a qualified service technician SYS...

Page 24: ...EM SHUTDOWN PRESS STATUS Displayed when chiller is shut down on a cycling shut down safety shutdown operator must move the COM PRESSOR switch to STOP RESET in order to restart or operator initiated sh...

Page 25: ...TE STOP This message will be displayed when a remote device typically an Energy Management System has com manded the chiller to shut down The chiller will restart upon application of a separate start...

Page 26: ...2 Electro Mechanical starter application Power Fault shutdown The chiller will automatically restart This function is sensed by the motor controller input to the digital input board A power fault shu...

Page 27: ...mode and pressing WARN ING RESET key Or the message will be cleared by initiating a compressor start START SEQUENCE INITIATED Indicates that the Micro Board has received a local or remote start signal...

Page 28: ...ERROR Indicates the chiller has shut down because the differ ence between the High Side Oil Pressure Transducer Output and the Low SideTransducer Output was greater than 15 0 PSID during the Transduc...

Page 29: ...ied ser vice technician before the chiller can be restarted This procedure is detailed in Service manual Form 160 49 M3 MON XX XX AM DC UNDERVOLTAGE The Proximity Temperature Sensor module becomes uns...

Page 30: ...the MANUAL OIL PUMP key to stop the operation of the oil pump for less than 10 minutes of operation 3 Pre Rotation Vanes To perform this test the starter interlock terminals 3 and 4 must be jumpered...

Page 31: ...ate oil for a 50 second pre run to establish oil flow and adequate lubrication to all bearings gears and rotating sur faces within the compressor The high and low oil pressure transducers OP and the o...

Page 32: ...on the Control Center as MON 10 30 AM LOW WATER TEMPERATURE AUTOSTART This occurs when the leaving water temperature falls to 4 F below setpoint or 36 F whichever is higher The LWT is part of the Mic...

Page 33: ...ssure of 5 to 10 psi with constant suction and discharge pressures may be an indi cation of a dirty filter The filter should be replaced when pressure loss is 30 or more of the original pressure The a...

Page 34: ...UID TEMPS key and the REFRIGERANT PRESSURES key 5 Check the condenser saturation temperature based upon condenser pressure sensed by the condenser transducer Press the DISPLAY DATA key This key may be...

Page 35: ...ed on the Micro Board Low Evaporator Pressure Low Oil Pressure High Condenser Pressure Evaporator Transducer or Probe Error High Discharge Temp High Oil Temp Oil Pressure Transducer Starter Malfunctio...

Page 36: ...ratures 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 Open the dr...

Page 37: ...7385A FRONT VIEW DUAL RELIEF VALVES MICROCOMPUTER CONTROL CENTER SUCTION DISCHARGE COMPRESSOR ADAPTER MOTOR SUPPORT COVER MOTOR COOLER REFRIGERANT CHARGINGVALVE DEHYDRATOR SIGHT GLASSES FIG 17 SYSTEM...

Page 38: ...m consists of the oil 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 fo...

Page 39: ...YORK INTERNATIONAL 39 FORM 160 49 O2 FIG 18 SCHEMATIC DRAWING YK COMPRESSOR LUBRICATION SYSTEM LD00951...

Page 40: ...en sure controlled alignment of the assembly Motor is mounted with final alignment at start up Motor drive shaft is directly connected to the com pressor shaft with a flexible disc coupling Coupling h...

Page 41: ...ntrolled to the level setpoint However any time the vanes fully close VMS closes normal level control is terminated any refrigerant level setpoint pulldown in effect is cancelled and the outputs to th...

Page 42: ...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 end of...

Page 43: ...he connection at the charging valve until after the air is forced out by pumping a few strokes of the oil pump This fills the lines with oil and prevents air from being pumped into the system 3 Open t...

Page 44: ...ic 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 Unit Autostart Opt...

Page 45: ...is to START position 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...

Page 46: ...k 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 Program A...

Page 47: ...r than 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 setti...

Page 48: ...emely noisy quantity 8 SYMPTOM OIL PRESSURE GRADUALLY DECREASES Noted by Observation of Daily Log Sheets Oil pressure noted when pressing OIL Oil filter is dirty Change oil filter PRESSURE display key...

Page 49: ...de torch or electronic leak detector 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 t...

Page 50: ...Then disconnect 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...

Page 51: ...sure tested and found 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 w...

Page 52: ...turnable and they should be stored for future use if it should ever become nec essary to remove refrigeration from the system TABLE 4 REFRIGERANT CHARGE R 22 SHELL CODES LBS COOLER COND M M 1 425 M N...

Page 53: ...main disconnect switch and compressor motor starter are open meg the motor as follows 1 Using a megohm meter megger meg between phases and each phase to ground see Fig 23 these readings are to be int...

Page 54: ...54 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 55: ...se in head pressure over a period of 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 g...

Page 56: ...e same flame discoloration that the refrigerant does 3 With nitrogen or dry air blow out the tubes to clear them of traces of refrigerant laden moisture from the circulation water As soon as the tubes...

Page 57: ...by restricted oil lines passages or dirty oil fil ters If the unit is shutting down on HOT High Oil Temperature or Low Oil Pressure OP change the oil filter element Examine the oil filter element for...

Page 58: ...intained tight are systems that provide trouble free efficient opera tion COOLER AND CONDENSER The major portion of maintenance on the condenser and cooler will deal with the maintaining the water sid...

Page 59: ...1 All electrical controls should be inspected for obvi ous malfunctions 2 It is important that the factory settings of controls operation and safety not be changed If the set tings are changed withou...

Page 60: ...O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 1997 ALL RIGHTS RESERVED Form 160 49 O2 1296 Supersedes Nothing...

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