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OPERATION MANUAL

CONTROL CENTER

CENTRIFUGAL LIQUID CHILLERS

Supersedes: Nothing

Form 160.60-O2 (1004)

FLEXLOGIX CONTROL CENTER

MODEL YB & YG

GAS ENGINE LIQUID CHILLER

Design Level B

Summary of Contents for YB

Page 1: ...OPERATION MANUAL CONTROL CENTER CENTRIFUGAL LIQUID CHILLERS Supersedes Nothing Form 160 60 O2 1004 FLEXLOGIX CONTROL CENTER MODEL YB YG GAS ENGINE LIQUID CHILLER Design Level B...

Page 2: ...ly and safely It is essential that prior to performing any task on this equipment this individual shall have read and under stood this document and any referenced materials This individual shall also...

Page 3: ...hange without notice While YORK makes no commitment to update or provide current information automatically to the manual owner that information if applicable can be obtained by contacting the nearest...

Page 4: ...OIL PRESSURE 38 ZAL 140 COMPRESSOR PROX FORWARD J SERIES ONLY 38 ZAL 140 COMPRESSOR PROX REVERSE J SERIES ONLY 38 DISPLAY MESSAGES TABLE OF CONTENTS SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF...

Page 5: ...102 LOW CONDENSER WATER FLOW 39 CHILLER PANEL EMERGENCY STOP 39 ENGINE DIDN T START PURGE ENGINE 39 TSHH 162 ENGINE HIGH WATER JACKET TEMPERATURE 39 TSLL 161 ENGINE LOW OIL PRESSURE 39 ESS ENGINE OVE...

Page 6: ...GENERAL SYSTEM DESCRIPTION TheYORK ModelYG Gas Engine Chiller is commonly applied to large air conditioning systems but may be used on other applications The chiller is completely factory packaged in...

Page 7: ...emperature by first decreasing the speed and closing the compressor pre rotation vanes PRV See Detail A then opening the hot gas bypass valve 7619A D DETAIL A COMPRESSOR PREROTATION VANES The hot gas...

Page 8: ...ls of Operation REFRIGERANT FLOW DIAGRAM LEGEND HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID REFIGERANT LOW PRESSURE LIQUID REFIGERANT LOW PRESSURE VAPOR EVAPORATOR REFRIGERANT DRAIN AND CHARGING ELIMINAT...

Page 9: ...FORM 160 60 O2 1004 9 YORK INTERNATIONAL 1 This page intentionally left blank...

Page 10: ...utdown the system will display vital information available at any time The locations of various chiller parameters are clearly marked and instructions for specific operation are provided on many of th...

Page 11: ...Control System has four access levels VIEW OPERATOR SERVICE and SUPER USER This instruction is intended only as an operator manual As such depicted here are the system parameters availableattheVIEWan...

Page 12: ...enser PRV Position Displays the position of the pre rotation vanes in percent Engine Speed Displays the engine speed in RPM Condenser Flow Switch Indicates that liquid is flowing through the condenser...

Page 13: ...perature of the oil in the compressor oil sump Oil Supply Pressure Displays the pressure of the compressor oil system Chilled Liquid Temperature Entering Leaving 2 SYSTEM SCREEN LD09880 FIG 6 SYSTEM S...

Page 14: ...ator refrigerant Remote Setpoint Displays the remotely set chilled water setpoint Evaporator Flow Switch Indicates that chilled liquid is flowing through the evaporator PROGRAMMABLE Controlled Stop Un...

Page 15: ...er Small Temperature Difference Displays the temperature expressed as the differential between the water entering and the water leaving the condenser Condenser Pressure Displays the current operating...

Page 16: ...ce Displays the temperature expressed as a differential temperature between the water leaving and the water entering the condenser Evaporator Refrigerant Level Graphical Displays the evaporator refrig...

Page 17: ...equency Displays the operating frequency of the variable speed oil pump drive PRV Motor Opening Closing Indicates the status of the pre rotation vane actuator PRV Position Displays the position of the...

Page 18: ...oil sump Oil Supply Pressure Displays the oil supply pressure Oil Pump Frequency Displays the variable speed oil pump drive frequency Oil Pump Run Indicates the operational status of the oil pump Oil...

Page 19: ...ter input with the vanes fully closed Span Value For manual calibration of the PRV corresponds to the raw PRV potentiometer input with the vanes fully open INTERACTIVE F2 Start Calibration Selecting t...

Page 20: ...saturation temperature Compressor Head Displays the pressure expressed as a differential between the compressor suction and compressor discharge pressures Valve Position Displays the position of the v...

Page 21: ...he status of the low oil pressure trip switch Gear High Oil Temperature Trip Switch Indicates that status of the high gear oil temperature trip switch Gear Oil Pump Indicates the operational status of...

Page 22: ...emperature Graphical Displays the water jacket temperature in F Days Run Time Before Maintenance Displays the number of days operational time remaining before scheduled maintenance Clutch Solenoid Out...

Page 23: ...as exceeded safe limits ESS Engine Overspeed Signal Indicates whether or not the engine is in an overspeed condition Engine Emergency Stop Signal Indicates that the emergency stop switch on the engine...

Page 24: ...res provided by the engine manufac turer Do not modify manifold pressure entries without factory consultation DISPLAY Intake Manifold Pressure Displays the current engine intake manifold pressure Perc...

Page 25: ...t evaporator pressure Low Pressure Setpoint Displays the system low evaporator pressure setpoint Condenser Pressure Displays the current condenser pressure High Pressure Setpoint Displays the system h...

Page 26: ...g with their corresponding minimum and maximum allowable anti surge speed setpoints MSP1 MSP2 PRV ANTI SURGE Displays the minimum and maximum head pressure setpoints in the pre rotation vane position...

Page 27: ...fully open to fully closed F3 Pre rotation Vanes Allows the operator to manually adjust the position of the pre rotation vanes from fully open to fully closed F5 Speed Setpoint Allows the operator to...

Page 28: ...arrow keys on the keypad to assign the desired sensor to that Pen When the graph itself is highlighted the F1 and F2 keys allow the user to move along the vertical scale of the graph The F5 and F7 key...

Page 29: ...RE PV Process variable actual sensor reading in F LOC SP Local chilled water setpoint also available on the Evaporator Screen Output Control variable output signal from 0 to 100 LOW PRESSURE OVERRIDE...

Page 30: ...400 0 300 0 500 I 0 060 0 102 0 103 D 0 000 0 000 0 000 Setpoint Ramp Rate 0 5 F sec LOW PRESSURE OVERRIDE Setpoint 28 0 psig P 1 000 I 2 000 D 0 000 ENGINE LOAD LIMITER Setpoint 100 0 P 0 800 I 1 50...

Page 31: ...erat ing point SPEED ANTI SURGE MAP SPD1 is the maximum system head pressure as defined by the entry fields below the Surge Map SPD2 is the minimum system head pressure as defined by the entry fields...

Page 32: ...that the hot gas bypass valve is fully open The oil heater is thermostatically controlled and remains energized as long as the main power disconnect is engaged Under normal circumstances the chiller...

Page 33: ...ts a demand for chilled water Under these circumstances a manual shutdown is initiated by simply pressing the STOP button on the main panel The Control System will then initiate are normal system shut...

Page 34: ...o start from a separate operator interface panel or control system SYSTEM RUNNING Once the engine has finished warm up and ramped to operating speed the clutch engages and the chiller begins to operat...

Page 35: ...purge routine in which the engine is cranked with the ignition system disabled ENGINE MAINTENANCE STANDBY This message indicates that the system has been switched to engine maintenance standby condit...

Page 36: ...ns F1 Ack Alarm Prompts user to acknowledge the alarm F2 Ack All Alarms Prompts user to acknowledge all alarms F3 Silence Alarms Causes alarm to be silenced until the system detects another alarm F4 S...

Page 37: ...MODE If the engine emergency stop switch is activated the system alerts the operator that the engine needs to be purged in order to safely restart TAL 100 LOW LEAVING CHILLED WATER TEMPERATURE If the...

Page 38: ...L 140 COMPRESSOR PROX FORWARD J SERIES ONLY The compressor proximity thrust probe protects the impeller from damage as a result of thrust bearing wear If the proximity probe detects the impeller is to...

Page 39: ...pted without an engine purge the system alerts the operator by faulting the startup attempt The condition is remedied by selected the F14 tab on the Engine Screen TSHH 162 ENGINE HIGH WATER JACKET TEM...

Page 40: ...eed oil pump motor faults the system trips off line POWER FAILURE If the electrical service is interrupted the system will trip off line It will be necessary to initiate an engine purge before the chi...

Page 41: ...he system trips off line ENGINE DIDN T STOP If the system logic commands engine shutdown and the engine does not respond the system trips off line ENGINE STARTER MOTOR ANTIRECYCLE This feature prevent...

Page 42: ...lls through all alarms listed highlighting each in turn F7 Close Closes the alarm window If an alarm occurs during system startup it is almost always accompanied with a system trip that will need to b...

Page 43: ...FORM 160 60 O2 1004 43 YORK INTERNATIONAL 6...

Page 44: ...FLOW RATE GALLONS MINUTE gpm 0 0631 LITERS SECOND L s LENGTH FEET ft 304 8 MILLIMETERS mm INCHES in 25 4 MILLIMETERS mm MILS 0 001 inch 25 4 MICROMETERS m WEIGHT POUNDS lb 0 4536 KILOGRAMS kg VELOCITY...

Page 45: ...e 38 39 Thrust Bearing Switch 40 Compressor Screen 17 Condenser Code 3 Condenser Screen 15 Flow Switch 12 High Pressure Cutout 15 Leaving Condenser Liquid Temperature 12 Leaving Condenser Water Temper...

Page 46: ...d Temperature 14 Small Temperature Difference 14 Temperature Saturation 13 Executing an Engine Purge 42 F Function Keys 11 27 G Gear INDEX CONT D Gearbox Screen 21 High Oil Temperature Trip Switch 21...

Page 47: ...6 Purge is Required 37 PV 29 R R1 Hardwire 38 Ramping to Minimum Speed 34 Ramp to Minimum Speed 33 Remote Lockout 34 Remote Start Denied 37 INDEX CONT D Remote Start Enabled 34 Restarting The Chiller...

Page 48: ...1 www york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 2004 ALL RIGHTS RESERVED Form 160 60 O2 1004 Su...

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