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FORM 160.52-O1

41

YORK INTERNATIONAL

On shutdown of the system for any reason, the oil pump

operates and continues to run for 150 seconds. The

system cannot restart during that time interval.

OIL HEATER

During long idle periods, the oil in the compressor oil

reservoir tends to absorb as much refrigerant as it can

hold, depending upon the temperature of the oil and

the pressure in the reservoir. As the oil temperature is

lowered, the amount of refrigerant absorbed will be in-

creased. If the quantity of refrigerant in the oil becomes

excessive, violent oil foaming will result as the pres-

sure within the system is lowered on starting. This foam-

ing is caused by refrigerant boiling out of the oil as the

pressure is lowered. If this foam reaches the oil pump

suction, the bearing oil pressure will fluctuate with pos-

sible temporary loss of lubrication, causing the oil pres-

sure safety cutout to actuate and stop the system. See

“Control Center, Section 2”.

If the oil temperature falls below 55°F (12.7°C), the dis-

play will read
 

  

SYSTEM  SHUTDOWN – PRESS  STATUS  

   

.

Pressing the 

STATUS 

key causes the message to read

 

 

 

DAY  10:00 AM – LOW  OIL  TEMP – AUTO  START  

  

.  The sys-

tem will be allowed to automatically restart when oil

temperature rises to 30°F (16.7°C) above condenser

temperature.

MOTOR DRIVELINE

The compressor motor is an open-drip-proof, squirrel

cage, induction type constructed to YORK design speci-

fications. 60 hertz motors operate at 3570 rpm. 50 hertz

motors operate at 2975 rpm.

The open motor is provided with a D-flange, cast iron

adapter mounted to the compressor and supported by

a motor support.

Motor drive shaft is directly connected to the compres-

sor shaft with a flexible disc coupling. This coupling

has all metal construction with no wearing parts to as-

sure long life, and no lubrication requirements to pro-

vide low maintenance.

For units utilizing remote electro-mechanical starters,

a terminal box is provided for field connected conduit.

Motor terminals are brought through the motor casing

into the terminal box. Jumpers are furnished for three-

lead type of starting. Motor terminal lugs are not fur-

nished. Overload/overcurrent transformers are fur-

nished with all units. For units furnished with factory

packaged Solid State Starters, (optional) see right.

HEAT EXCHANGERS

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, flooded type heat

exchanger. A distributor trough provides uniform distri-

bution of refrigerant over the entire shell length. Stain-

less steel mesh eliminators or suction baffles are lo-

cated above the tube bundle to prevent liquid refriger-

ant carryover into the compressor. A 2" liquid level sight

glass is located on the side of the shell to aid in deter-

mining proper refrigerant charge. The evaporator shell

contains dual refrigerant relief valves.

The condenser is a shell and tube type, with a discharge

gas baffle to prevent direct high velocity impingement

on the tubes. A separate subcooler is located in the

condenser to enhance performance. Dual refrigerant

relief valves are located on condenser shells with op-

tional isolation refrigerant isolation valves.

The removable compact water boxes are fabricated of

steel. The design working pressure is 150 psig (1034

kPa) and the boxes are tested at 225 psig (1551 kPa).

Integral steel water baffles provide the required pass

arrangements. Stub-out water nozzle connections with

Victaulic grooves are welded to the water boxes. These

nozzle connections are suitable for Victaulic couplings,

welding or flanges, and are capped for shipment.

Plugged 3/4" drain and vent connections are provided

in each water box.

REFRIGERANT FLOW CONTROL

Refrigerant flow to the evaporator is controlled by a

variable orifice.

A level sensor senses the refrigerant level in the con-

denser and outputs an analog voltage to the Micro

Board that represents this level (0% = empty; 100% =

full). Under program control, the Micro Board modu-

lates a variable orifice to control the condenser refrig-

erant level to a programmed setpoint. Other setpoints

affect the control sensitivity and response. These set-

points must be entered at chiller commissioning by a

qualified service technician. Only a qualified service

technician may modify these settings. Manual opera-

tion of the refrigerant level control can be selected. This

allows the prerotation vanes keypad keys to manually

control the variable orifice. This manual control can also

be used to position the variable orifice in a fixed posi-

tion. Instructions for selecting manual level control and

entering the level control setpoints are contained in the

“Special Setpoints and Programming Procedures” sec-

Содержание 371-01200-010

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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