York Millennium YCAJ150, Installation Operation & Maintenance

Page 1: ...Supersedes See Back Page Form 150 65 NM4 198 MillenniumTM LIQUID CHILLERS AIR COOLED RECIPROCATING HERMETIC 60 HZ MODELS YCAJ150 230 200 230 460 3 60 26810A With EPROM 031 01652 001 Standard Brine Met...

Page 2: ...67 Unit On Off Switch 74 Compressor Capacity Control 80 System Startup Checklist 81 Preventative Maintenance 86 Options 88 Troubleshooting Chart 106 Temperature Conversion Tables 110 GENERAL INFORMATI...

Page 3: ...s are familiar with its potential hazards Shut off power supply to equipment before beginning work and follow lockout procedures When work ing inside equipment with power off take care to discharge ev...

Page 4: ...MICRO PANEL COOLER CONTROL POWER SUPPLY POWER PANEL COMPRESSOR 1 COMPRESSOR 2 CONDENSER COIL S CONDENSER FANS SIGHT GLASSES HOT GAS BYPASS SYSTEM 1 SYSTEM 2 LIQUIDSTOP VALVE SYSTEM 1 FILTER DRIER SYST...

Page 5: ...S COMPRESSOR TERMINAL BOX 8 CYLINDER MODEL J COMPRESSOR 27299A 27599A MOTOR TERMINALS SUPPRESSORS MOTOR PROTECTOR MP DISCHARGE STOP VALVE OILPRESSURE ACCESS CONN SIGHT GLASSES OIL CHARGING VALVE CAPAC...

Page 6: ...rator is protected against freeze up to 20 F with an electrical heater cable as standard CAUTION Excessive flow will cause damage to the cooler Do not exceed max cooler GPM Special care should be take...

Page 7: ...cted against freeze up to 28 9 C with an electrical heater cable as standard CAUTION Excessive flow will cause damage to the cooler Do not exceed max cooler flow Special care should be taken when mul...

Page 8: ...8 NO OF FANS 36 Dia Direct Drive HP kWEach 1140 RPM 3 2 9 3 2 9 3 2 9 3 2 9 5 3 7 5 3 7 5 3 7 AIRFLOW TOTAL CFM 124 000 124 000 124 000 124 000 143 000 143 000 143 000 COOLER DUALCIRCUITED DWP 235PSIG...

Page 9: ...8 8 8 8 8 NO OF FANS 914 mm Dia Direct Drive HP kWEach 1140 RPM 3 2 9 3 2 9 3 2 9 3 2 9 5 3 7 5 3 7 5 3 7 AIRFLOW TOTAL L S 58 522 58 522 58 522 58 522 67 489 67 489 67 489 COOLER DUALCIRCUITED 406mm...

Page 10: ...de 12 walls should be no higher than the unit The area within the clearances and under the unit s must be kept clean of clutter Additional height should be included to allow for snow accumulation for...

Page 11: ...an the unit The area within the clearances and under the unit s must be kept clean of clutter Additional height should be included to allow for snow accumulation for units which are expected to operat...

Page 12: ...2 6 250 131 525 5 0 J150 58 151 200 250 200 200 225 2 6 250 105 420 4 9 151 200 250 200 200 225 2 6 250 105 420 4 9 J160 28 458 600 700 600 600 700 2 1 0 500 328 1278 12 0 376 450 600 400 450 500 2 1...

Page 13: ...182 749 5 9 150 511 5 9 J230 46 578 700 800 600 2 2 600 3 3 0 500 228 936 8 1 228 936 8 1 J230 58 457 600 600 600 2 2 600 1 1 600 or 2 1 250 182 749 5 9 182 749 5 9 5 Wire Range is the minimum and ma...

Page 14: ...801 5 0 300 350 164 801 5 0 J180 58 334 400 450 400 400 450 1 1 600 or 2 1 250 225 300 131 641 4 9 225 300 131 641 4 9 J190 28 894 1000 1200 1000 1000 1200 NA NA NA 376 1278 12 0 NA NA 328 1602 12 0 J...

Page 15: ...CONTROL POWER SUPPLY UNIT PANEL COMPRESSOR POWER SUPPLY BY OTHERS LD01175 SEE NOTE 6 SEE NOTE 5 SINGLE POINT OPTION LD01174 R DISCONNECT OPTION SEE NOTE 5 UNIT PANEL G 2 L 2L3 2L2 2L1 1L1 1L2 1L3 BY...

Page 16: ...Inspect unit for shipping damage 2 Rig unit per Fig 4 Remove unpainted shipping braces after installation 3 Open unit only to install water piping system Do not remove protective covers from water con...

Page 17: ...t ing the unit to its foundation See DIMENSIONS pages 10 and 11 For ground level installations precautions should be taken to protect the unit from tampering by or injury to unau thorized persons Scre...

Page 18: ...CP 2 31 CP 2 31 CP 2 31 CP 2 32 CP 2 31 CP 2 31 CP 2 31 CP 2 32 YCAJ230 CP 2 31 CP 2 31 CP 2 31 CP 2 32 CP 2 31 CP 2 31 CP 2 31 CP 2 32 ISOLATOR LOCATIONS VMC CP 2 X LD01089 NOTE Standard 1 25 4 mm de...

Page 19: ...nd insulated to protect against freeze up during low ambient periods and to prevent forma tion of condensation on lines in warm humid climates 7 A chilled water flow switch either by YORK or oth ers M...

Page 20: ...and 1 Device must have a minimum contact rating of 100VA at 115 volts A C 5 Contacts are rated at 115V 100VA resistive load only and must be suppressed at load by user 6 See installation operation an...

Page 21: ...FORM 150 65 NM4 21 YORK INTERNATIONAL LD02461 FIG 6 ELEMENTARY DIAGRAM Cont d...

Page 22: ...22 YORK INTERNATIONAL ELEMENTARY DIAGRAM...

Page 23: ...ntactor auxiliary contacts must be sup pressed with YORK P N 031 00808 000 suppressor across the relay contactor coil Any contacts con nected to flow switch inputs or BAS inputs on terminals 13 19 or...

Page 24: ...24 YORK INTERNATIONAL CONNECTION DIAGRAM FIG 7 CONNECTION DIAGRAM LD02463...

Page 25: ...FORM 150 65 NM4 25 YORK INTERNATIONAL FIG 7 CONNECTION DIAGRAM Cont d LD02462...

Page 26: ...26 YORK INTERNATIONAL CONNECTION DIAGRAM TERMINAL BOX AND SYSTEM WIRING FIG 8 SYSTEM WIRING LD02464...

Page 27: ...FORM 150 65 NM4 27 YORK INTERNATIONAL CONNECTION DIAGRAM TERMINAL BOX AND SYSTEM WIRING FIG 8 SYSTEM WIRING Cont d LD02649...

Page 28: ...28 YORK INTERNATIONAL CONNECTION DIAGRAM TERMINAL BOX AND SYSTEM WIRING FIG 8 SYSTEM WIRING Cont d LD02650...

Page 29: ...FORM 150 65 NM4 29 YORK INTERNATIONAL CONNECTION DIAGRAM TERMINAL BOX AND SYSTEM WIRING FIG 8 SYSTEM WIRING Cont d LD02651...

Page 30: ...30 YORK INTERNATIONAL FIG 8 SYSTEM WIRING Cont d LD02499...

Page 31: ...oprocessor to main tain leaving water temperatures These decisions are a function of temperature deviation from setpoint and rate of change of temperature MICROPROCESSOR BOARD The Microprocessor Board...

Page 32: ...ay and as safeties CURRENT TRANSFORMER C T A C T on the 3 power wiring of each motor sends AC signals proportional to motor current to the Power Sup ply Board which rectifies and filters the signal to...

Page 33: ...ANEL 28697A KEYPAD MICROPROCESSOR BOARD TB3 LCD DISPLAY BOARD MICROPROCESSOR BOARD UNITON OFF SWITCH POWER SUPPLY BOARD 2T TRANSFORMER RELAY OUTPUT BOARD 1 LOCATION OF OPTIONAL RELAY OUTPUT BOARD 2 TB...

Page 34: ...ressor running times number of compressor starts and option information on the chiller package This data is useful for monitoring chiller operation diagnosing potential future problems troubleshooting...

Page 35: ...of the eight messages depending on the Dip Switch position A detailed explanation of the meaning of each message and a guide to programming the associated switch is provided on page 37 Fig 13 shows t...

Page 36: ...N C O N T R O L S H A R E D C O N D E N S E R F A N C O N T R O L E N G L I S H U N I T S R E A D O U T M E T R I C U N I T S R E A D O U T R E T U R N W A T E R C O N T R O L L E A V I N G W A T E R...

Page 37: ...10 C A low ambient kit MUST be installed if the switch is placed in this position SWITCH 3 OPEN This mode allows a Remote Control Center or an ISN panel to only view chiller operating conditions It wi...

Page 38: ...eri enced See page 93 for fan control sequence NOTE Discharge pressure transducers must be in stalled These are optional Discharge Pressure Read out Option unless a Low Ambient Kit is installed SWITCH...

Page 39: ...operator to de termine current chiller operating status as a whole and as individual systems The messages displayed will include running status cooling demand fault status external cy cling device st...

Page 40: ...ll take place when discharge pressure has dropped 60 PSIG 4 1 bar below the threshold Optional discharge pressure transducers must be in stalled for this feature to operate This is accomplished by add...

Page 41: ...H A M B I E N T T E M P S Y S 1 L O W O I L P R E S S S Y S 2 L O W O I L P R E S S C H I L L E R F A U L T 1 1 5 V A C U N D E R V O L T A G E S Y S 1 H I G H O I L T E M P S Y S 2 H I G H O I L T E...

Page 42: ...ances the day when the SET TIME display is being programmed The day is nor mally advanced to correspond to the current day of the week The day will advance a day at a time each time the key is pressed...

Page 43: ...ut For this cut out to be functional the Discharge Pressure Readout Option must be installed GENERAL Pushing the PROGRAM key allows the user to program 11 system operating limits These limits include...

Page 44: ...he high ambient cut out point If the ambient rises above this point the chiller will shut down Restart can occur when temperature drops below the cut out This only applies to outdoor air cooled chille...

Page 45: ...for 4 F 2 2 C below the desired leaving chilled liquid temperature AVERAGE CURRENT UNLOAD The purpose of AVERAGE CURRENT UNLOAD is to pro vide adequate motor cooling and to prevent the motor from fau...

Page 46: ...ATE CONTROL TEMP RANGE In this range if water temperature is dropping faster than the RATE SENSITIVITY setting the micro will not load any more stages because water temperature is dropping quickly Thi...

Page 47: ...the week is displayed The day will advance each time the key is pressed The cursor will already be below the first digit of the time Key in the new time if required Be sure to key in a 0 before the o...

Page 48: ...hed ule This can be done manually for each day or by press ing CANCEL and ENTER when the MONDAY START STOP schedule appears NOTE This will have no effect on the holiday schedule Continue to program ea...

Page 49: ...dentally the microproces sor will automatically return to the Daily Schedule MANUAL OVERRIDE M A N U A L O V E R R I D E Manual Override When the MANUAL OVERRIDE key is pressed the Daily Schedule prog...

Page 50: ...ability to select the type of chilled liq uid temperature control by choosing either Return or Leaving Temperature Control This provides the ability to fine tune the method of control for comfort coo...

Page 51: ...50 for instructions to reprogram the Mi croprocessor Dip Switch S1 Switch 4 The display will then scroll to a second message hold This message will display the user s Design Leaving Water Temperature...

Page 52: ...5 F 7 2 12 8 C CONTROL RANGE A RATE CONTROL TEMP OF 65 F 18 3 C which is typi cal 10 F 5 5 C above the high end the Control Range is shown temperatures provide a Control Range differential of 54 0 44...

Page 53: ...lt For normal comfort cooling batch or process applica tions select a high RATE SENSITIVITY of 5 F min 2 8 C R A T E C O N T R O L T E M P 1 0 0 F The RATE CONTROL TEMP establishes a temperature range...

Page 54: ...ery high rate to exceed the RATE SENSITIVITY value pro grammed This will assure normal loading will occur 5 F min 2 8 C min also works well in comfort cooling appli cations If unsure of a RATE SENSITI...

Page 55: ...oading and Rate Control will follow PROGRAMMING LEAVING WATER RATE CONTROL Programmable RATE CONTROL is designed to limit com pressor loader cycling thus saving energy and reducing wear on mechanical...

Page 56: ...the ENTER key The new value will be entered into memory and the display will advance to the next user programmable limit than 1X the Rate Sensitivity Otherwise no other loading or unloading will resu...

Page 57: ...1 C below the temperature at which it was loaded assuming unload ing timers and rate control software allows Listed in Fig 17 19 are the loading and unloading se quences for 5 7 and 10 steps of contr...

Page 58: ...between stages increased when miss ing steps are activated or deactivated by the micro NOTES 1 The Lead Comp 2 Steps Lag Comp Off Step is skipped on a temperature drop 2 The micro controls loading and...

Page 59: ...FORM 150 65 NM4 59 YORK INTERNATIONAL 10 STEP OPTIONAL FIG 19 10 STEP LOADING UNLOADING RETURN WATER CONTROL LD02660 NOTE Temperatures in parentheses are Celsius equivalents...

Page 60: ...F 1 LEAD COMP UNLOADED LAG COMP OFF LEAD COMP UNLOADED LAG COMP OFF LEAD COMP OFF LAG COMP OFF LEAD COMP OFF LAG COMP OFF TEMPERATURE FALL 7 STEP OPTIONAL TEMPERATURE RISE LOAD UNLOAD 7 LEAD COMP 2 ST...

Page 61: ...PSIG 2 8 mPa the contacts in the high pressure cut out will open which removes 115VAC from the motor protector mod ule When 115VAC control power is lost to the module the module s MP contacts open bre...

Page 62: ...ection Page 61 Auto restart will be permitted after a shutdown when dis charge pressure drops to below 330 PSIG 2 3 mPa which allows the mechanical high pressure cut out to reset and its contacts to c...

Page 63: ...r in a short time period An ex ample would be if ambient temperature dropped below the cut out temperature would have to rise 5 F 2 8 C above the cut out before the fault lockout would clear and resta...

Page 64: ...lockout on a safety When the chiller is shut down on one of these safeties a message will appear on the STATUS display informing the operator of the problem This is accessible by press ing the STATUS...

Page 65: ...start Even though the Anti recycle timer has timed out a minimum of 2 minutes 2 minute start up timer must always elapse after a compressor stop be fore it may again restart If a power failure occurs...

Page 66: ...ssumes the lead The previous running compressor will now have 120 pumpdowns available S Y S 1 P U M P D O W N F A I L S Y S 2 P U M P D O W N F A I L A pumpdown failure fault will occur if a system pe...

Page 67: ...ased from memory A sample printout is shown in Fig 21 Photo PRINT KEYS FIG 21 OPERATING DATA PRINTOUT YORK INTERNATIONAL CORPORATION RECIPROCATING WATER CHILLERS SYSTEMSTATUS 8 45AM 6 3 98 SYS 1 COMPR...

Page 68: ...UTDOWNNUMBER3 SHUTDOWN 8 47AM 6 3 98 SYS1STATUS NOFAULTS SYS2 MOTORCURRENTSHUTDOWN RETURNWATERTEMP 65 0 DEGF LEAVINGWATERTEMP 54 0 DEGF LOWWATERCUTOUT 36 0 DEGF SETPOINTTEMP 45 0 DEGF OUTSIDEAIRTEMP 7...

Page 69: ...ystem is presently on as a result of com mands from the microprocessor This is a coded number and the steps must be decoded to be meaningful The decoding varies according to the number of stages pro g...

Page 70: ...D E G F M I N L E A D S Y S T E M I S S Y S T E M N U M B E R 1 E V A P O R A T O R W A T E R P U M P S T A T U S O N E V A P O R A T O R H E A T E R S T A T U S O F F C O N D E N S E R W A T E R P U...

Page 71: ...ng the ENTER key will allow the operator to scroll through the information available in the SAFETY SHUTDOWN Buffer In the information that follows a sample message along with an explanation is provide...

Page 72: ...of the fault This message indicated the entering condenser water temperature at the time of the fault A fixed value will be displayed if the optional sensor is not installed This message indicates the...

Page 73: ...E O N S Y S 2 R U N P E R M I S S I V E O N S Y S 2 L O A D I N G S T A G E S 1 S Y S 2 F O R W A R D F A N S O F F S Y S 2 S U C T I O N P R E S S 6 2 P S I G S Y S 2 R E V E R S E F A N S O F F S Y...

Page 74: ...R M ALARM CONTACTS ANNUNCIATION ALARM Dry contacts connected to terminals 23 and 24 Fig 24 are supplied which will transition to function as a warning whenever a fault shutdown occurs on any sys tem o...

Page 75: ...le Timers timed out the compressor with the lowest run hours will start first 3 If both compressors are waiting to start Anti recycle Timers are not timed out the micro will assign the lead to the com...

Page 76: ...or manual lead lag selection is wired into terminals 13 and 19 on the TB3 Terminal block The location of these terminals is shown in Fig 25 FIG 25 LEAD LAG CONTACT CONNECTION LOCATION LD02093 26001A F...

Page 77: ...e the new value in memory S Y S 1 N O R U N P E R M S Y S 2 N O R U N P E R M R E M S E T P O I N T 4 0 0 R E M R A N G E 2 0 D E G F ing requirements In addition the low battery message which is disp...

Page 78: ...sed with a user supplied YORK P N 031 00808 suppressor NOTE Remote Setpoint Reset will not operate when a Remote Control Center Option Kit is connected to the Micro Panel The Remote Control Center wil...

Page 79: ...l turn on 4 seconds after the compressor starts These fans will continue to run until the compressor shuts down These fans are designated as Fans 2 4 on SYS 1 and Fans 6 8 on SYS 2 If the ambient temp...

Page 80: ...to the suction plenum This forces the piston up uncovering the re cessed opening which allows the suction gas to flow through the port and into the cylinders The cylinders are now loaded NOTE 6 cylind...

Page 81: ...t load operating conditions it is not abnormal for the oil level to be in the lower sight glass If it is necessary to add oil con nect a YORK oil pump to the oil charging valve but do not tighten the...

Page 82: ...After several min utes of operation the bubbles will disappear and there will be a solid column of liquid when the unit is operating normally On startup foaming of the oil may be evident in the compre...

Page 83: ...If however an adjustment is to be made the expansion valve adjusting screw should be turned not more than one turn at a time allowing suffi cient time approximately 15 minutes between adjust ments for...

Page 84: ...if cooling demand requires temperature and rate control The lag compressor remains unchanged at the 1st step of loading 15 After 7 minutes of run time the lag compres sor will load to its 2nd step of...

Page 85: ...two steps to its 1st step of 3 loading steps 12 After 10 minutes and 4 seconds of run time the motor current of the lag compressor must be 14 FLA and 115 FLA Oil pressure must be 5 PSID 34 5 kPa If th...

Page 86: ...new appearance for a reasonable length of operating time Discolora tion of the oil either turning darker brown or in some cases lighter is an indication of contamination ba sically due to moisture If...

Page 87: ...lve and pump oil into the crankcase to the proper level It is necessary that the suc tion end of the hand oil pump be kept submerged under the oil level in the container at all times to avoid entrance...

Page 88: ...Connections to this contact can be made on Terminals 21 and 22 of TB1 in the power panel The location of these terminals is shown in Fig 29 This option utilizes a second Relay Output Board and associ...

Page 89: ...ser as required Re verse rotation of the fans is accomplished by the addi tion of reversing contactors Components The Low Ambient Option consists of 3 kits a Low Ambi ent Kit selected from the chart b...

Page 90: ...3 SYS 1 5M 7M or fans 5 7 SYS 2 11M 13M and will operate the corresponding fans in the forward direction whenever discharge pressure ex ceeds 360 PSIG 2 5 mPa These fans will stay on until discharge...

Page 91: ...g valve with an integral solenoid The pilot operated solenoid is controlled by the microprocessor according to water temperature The regulating valve which becomes activated when the solenoid is energ...

Page 92: ...ULCR CR CR 10 Where UCLR Upper Limit of Control Range CR Control Range Differential Example 55 12 8 C 10 10 10 46 F 7 8 C If temperature continues to drop while the Hot Gas is energized the Hot Gas w...

Page 93: ...arge pressure only allows higher discharge pres sures which in turn raises suction pressure by permit ting better operation of the thermal expansion valve To convert to discharge pressure cycling the...

Page 94: ...of the keypad In addition to manual print selection the micro panel will provide an automatic printout whenever a fault occurs An explanation of the keypad use to obtain a print out is discussed in th...

Page 95: ...tout is shown in Fig 21 on page 67 A printout of the fault shutdown history may be obtained by pressing the HISTORY key A printout showing the last 3 faults with all system conditions at the time of t...

Page 96: ...t Before starting installation all of the items in the kit should be identified by comparing with Fig 36 2 All holes for mounting kit parts are provided in both the chiller frame and the added support...

Page 97: ...FORM 150 65 NM4 97 YORK INTERNATIONAL LD02652 FIG 36 WIRE GRILLE INSTALLATION NOTE Notch grilles to suit water connections and wiring harnesses...

Page 98: ...re starting installation all of the items in the kit should be identified by comparing with Fig 37a 37b and 37c 2 All holes for mounting kit parts are provided in both the chiller frame and the added...

Page 99: ...FORM 150 65 NM4 99 YORK INTERNATIONAL FIG 37A GRILLE AND LOUVER INSTALLATION SIDES LD02653 NOTE Notch grilles to suit water connections and wiring harnesses...

Page 100: ...100 YORK INTERNATIONAL LD02654 FIG 37B LOUVER BRACKETS INSTALLATION...

Page 101: ...FORM 150 65 NM4 101 YORK INTERNATIONAL LD02655 FIG 37C GRILLE AND LOUVER INSTALLATION FRONT AND BACK...

Page 102: ...ation Before starting installation all of the items in the kit should be identified by comparing with Figs 39a 39b and 39c and the associated parts lists 2 All holes for mounting kit parts are provide...

Page 103: ...FORM 150 65 NM4 103 YORK INTERNATIONAL LD02656 FIG 39A LOUVER INSTALLATION SIDES...

Page 104: ...104 YORK INTERNATIONAL LD02654 FIG 39B LOUVER BRACKETS INSTALLATION...

Page 105: ...FORM 150 65 NM4 105 YORK INTERNATIONAL LD02657 FIG 39C GRILLE AND LOUVER INSTALLATION FRONT AND BACK...

Page 106: ...ry mounting hardware Installation 1 Refer to Fig 40a and 40b and the associated parts list Before starting installation all of the items in the kit should be identified by comparing with Fig 40a and 4...

Page 107: ...FORM 150 65 NM4 107 YORK INTERNATIONAL FIG 40A CONDENSER COIL LOUVER INSTALLATION SIDES LD02658...

Page 108: ...108 YORK INTERNATIONAL FIG 40B CONDENSER COIL LOUVER INSTALLATION FRONT AND BACK LD02659...

Page 109: ...signal should be connected to the and terminals on the TB3 Terminal Block at the right of the Microprocessor Board Be sure polarity is correct CAUTION THE 0 10VDC INPUT SIGNAL WIRING MUST NOT BE EARTH...

Page 110: ...110 YORK INTERNATIONAL FIG 41 REMOTE RESET BOARD LD02666 P1...

Page 111: ...motor protector wiring and motor problems As sure that motor protector is not tripped due Motor contactor may to external high pressure switch or may not energize 3 Defective relay output board 3 Repl...

Page 112: ...mometer will result is 10 F 5 5 C Chiller Fault High 1 Temperature sensed incorrectly 1 Verify actual ambient temperature at probe Ambient Temp by thermistor 10 F 5 5 C with a thermometer placed Cuts...

Page 113: ...in either sight Level glass at all times Add YORK C oil if Particularly at necessary start up 2 Excessive flood back of liquid 2 Adjust Thermal Expansion Valve TXV or refrigerant replace power elemen...

Page 114: ...ensor vs thermometer of 2 F is not unusual Replace if necessary 7 Defective evaporator or optional 7 Replace transducer after verifying with a discharge transducer gauge Lack of Cooling 1 Fouled evapo...

Page 115: ...43 9 111 231 8 44 4 112 233 6 45 0 113 235 4 45 6 114 237 2 46 1 115 239 0 46 7 116 240 8 47 2 117 242 6 47 8 118 244 4 48 3 119 246 2 48 9 120 248 0 49 4 121 249 8 50 0 122 251 6 50 6 123 253 4 51 1...

Page 116: ...pic Team 36USC380 P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 1998 ALL RIGHTS RESERVED Form 150 65 NM4 198...