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56

YORK INTERNATIONAL

CONDENSERS AND COOLERS

GENERAL

Maintenance of condenser and cooler shells is impor-

tant to provide trouble free operation of the chiller. The

water side of the tubes in the shell must be kept clean

and free from scale. Proper maintenance such as tube

cleaning, and testing for leaks, is covered on the fol-

lowing pages.

CHEMICAL WATER TREATMENT

Since the mineral content of the water circulated

through coolers and condensers varies with almost

every source of supply, it is possible that the water be-

ing used may corrode the tubes or deposit heat resis-

tant scale in them. Reliable water treatment compa-

nies are available in most larger cities to supply a wa-

ter treating process which will greatly reduce the cor-

rosive and scale forming properties of almost any type

of water.

As a preventive measure against scale and corrosion

and to prolong the life of cooler and condenser tubes,

a chemical analysis of the water should be made pref-

erably before the system is installed. A reliable water

treatment company can be consulted to determine

whether water treatment is necessary, and if so, to fur-

nish the proper treatment for the particular water con-

dition.

CLEANING COOLER AND CONDENSER TUBES

COOLER
It is difficult to determine by any particular test whether

possible lack of performance of the water cooler is due

to fouled tubes alone or due to a combination of

troubles. Trouble which may be due to fouled tubes is

indicated when, over a period of time, the cooling ca-

pacity decreases and the split (temperature difference

between water leaving the cooler and the refrigerant

temperature in the cooler) increases. A gradual drop-

off in cooling capacity can also be caused by a gradual

leak of refrigerant from the system or by a combination

of fouled tubes and shortage of refrigerant charge. An

excessive quantity of oil in the cooler can also contrib-

ute to erratic performance.

CONDENSER
In a condenser, trouble due to fouled tubes is usually

indicated by a steady rise 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 gas revealing the effect of fouling.

TUBE FOULING

Fouling of the tubes can be due to deposits of two types

as follows:

1. Rust or sludge – which finds its way into the tubes

and accumulates there. This material usually does

not build up on the inner tube surfaces as scale,

but does interfere with the heat transfer. Rust or

sludge can generally be removed from the tubes by

a thorough brushing process.

2. Scale – due to mineral deposits. These deposits,

even though very thin and scarcely detectable upon

physical inspection, are highly resistant to heat

transfer. They can be removed most effectively by

circulating an acid solution through the tubes.

TUBE CLEANING PROCEDURES

BRUSH CLEANING OF TUBES
If the tube consists of dirt and sludge, it can usually be

removed by means of the brushing process. Drain the

water sides of the circuit to be cleaned (cooling water

or chilled water) remove the heads and thoroughly clean

each tube with a soft bristle bronze or nylon brush. DO

NOT USE A STEEL BRISTLE BRUSH. A steel brush

may damage the tubes.
Improved results can be obtained by admitting water

into the tube during the cleaning process. This can be

done by mounting the brush on a suitable length of 1/

8" pipe with a few small holes at the brush end and

connecting the other end by means of a hose to the

water supply.

The tubes should always be brush cleaned before acid

cleaning.

ACID CLEANING OF TUBES
If the tubes are fouled with a hard scale deposit, they

may require acid cleaning. It is important that before

acid cleaning, the tubes be cleaned by the brushing

process described above. If the relatively loose foreign

material is removed  before the acid cleaning, the acid

solution will have less material to dissolve and flush

from the tubes with the result that a more satisfactory

cleaning job will be accomplished with a probable sav-

ing of time.

WARNING: Acid cleaning should only be performed by

an expert. Please consult your local water

treatment representative for assistance in

removing scale build-up and preventative

maintenance programs to eliminate future

problems.

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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