York R123 Operating & Maintenance Manual Download

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YORK INTERNATIONAL

FORM 160.55-O1 (604)

LIST OF FIGURES

FIG. 1 – MODEL YT MILLENNIUM CHILLER .................... 7

FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER ..... 8

DETAIL A – COMPRESSOR PREROTATION
VANES.................................................................. 8

FIG. 3 – CONTROL CENTER .......................................... 12

FIG. 4 – HOME SCREEN................................................. 16

FIG. 5 – SYSTEM SCREEN............................................. 18

FIG. 6 – EVAPORATOR SCREEN ................................... 20

FIG. 7 – CONDENSER SCREEN..................................... 22

FIG. 8 – PURGE SCREEN............................................... 24

FIG. 9 – REFRIGERANT LEVEL CONTROL SCREEN ... 26

FIG. 10 – COMPRESSOR SCREEN.................................. 28

FIG. 11 – HOT GAS BYPASS SCREEN ............................ 30

FIG. 12 – SURGE PROTECTION SCREEN ...................... 32

FIG. 13 – PRE-ROTATION VANES CALIBRATION
SCREEN............................................................. 36

FIG. 14 – VSD TUNING SCREEN ..................................... 38

FIG. 15 – OIL SUMP SCREEN........................................... 40

FIG. 16 – ELECTRO-MECHANICAL STARTER SCREEN 41

FIG. 17 – SOLID STATE STARTER
(MOD A) SCREEN.............................................. 42

FIG. 18 – SOLID STATE STARTER
(MOD B) SCREEN ............................................. 44

FIG. 19 – VARIABLE SPEED DRIVE SCREEN ................. 46

FIG. 20 – VARIABLE SPEED DRIVE DETAILS SCREEN

(All VSD except Part Number 371-02767-XXX
(60 Hz) or 371-03700-XXX (50 Hz)) ................... 48

FIG. 21 – VARIABLE SPEED DRIVE DETAILS SCREEN

(VSD with Part Number 371-02767-XXX
(60 Hz) or 371-03700-XXX (50 Hz)) ................... 50

FIG. 22 – ADAPTIVE CAPACITY CONTROL DETAILS

SCREEN............................................................. 52

FIG. 23 – HARMONIC FILTER DETAILS SCREEN

(All VSD except Part Number 371-02767-XXX
(60 Hz) or 371-03700-XXX (50 Hz)) ................... 54

FIG. 24 – HARMONIC FILTER DETAILS SCREEN

(VSD with Part Number 371-02767-XXX (60 Hz)
or 371-03700-XXX (50 Hz))................................ 56

FIG. 25 – SETPOINTS SCREEN ....................................... 58

FIG. 26 – SETUP SCREEN................................................ 60

FIG. 27 – SCHEDULE SCREEN ........................................ 64

FIG. 28 – USER SCREEN.................................................. 66

FIG. 29 – COMMS SCREEN.............................................. 68

FIG. 30 – PRINTER SCREEN............................................ 70

FIG. 31 – SALES ORDER SCREEN .................................. 72

FIG. 32 – OPERATIONS SCREEN .................................... 74

FIG. 33 – HISTORY SCREEN............................................ 76

FIG. 34 – HISTORY DETAILS SCREEN ............................ 78

FIG. 35 – SECURITY LOG SCREEN................................. 79

FIG. 36 – SECURITY LOG DETAILS SCREEN ................. 80

FIG. 37 – TREND SCREEN ............................................... 82

FIG. 38 – TREND SETUP SCREEN .................................. 84

FIG. 39 – ADVANCED TREND SETUP SCREEN.............. 86

FIG. 40 – COMMON SLOTS SCREEN .............................. 88

FIG. 41 – CUSTOM VIEW SCREEN.................................. 89

FIG. 42 – CUSTOM VIEW SETUP SCREEN ..................... 90

FIG. 43 – PRINTERS ........................................................112

FIG. 44 – SAMPLE PRINTOUT (STATUS)........................116

FIG. 45 – SAMPLE PRINTOUT (SETPOINTS) .................110

FIG. 46 – SAMPLE PRINTOUT (SCHEDULE)..................119

FIG. 47 – SAMPLE PRINTOUT (SALES ORDER)........... 120

FIG. 48 – SAMPLE PRINTOUT (HISTORY) .................... 121

FIG. 49 – SAMPLE PRINTOUT (SECURITY LOG).......... 122

FIG. 50 – SAMPLE PRINTOUT (TREND) ........................ 123

FIG. 51 – SAMPLE PRINTOUT

(CUSTOM SCREEN REPORT)........................ 123

FIG. 52 – SAMPLE PRINTOUT

(ADAPTIVE CAPACITY CONTROL NEW MAP
POINT REPORT) ............................................ 123

FIG. 53 – SAMPLE PRINTOUT

(ADAPTIVE CAPACITY CONTROL EXISTING
MAP POINTS REPORT) .................................. 123

   FIG. 54   –   OPERATION SEQUENCE & TIMING
   DIAGRAM (ELECTRO-MECHANICAL
   & SOLID STATE STARTER APPLICATIONS) .. 126

   FIG. 55   –   OPERATION SEQUENCE & TIMING
   DIAGRAM (COMPRESSOR MOTOR
   VARIABLE SPEED DRIVE APPLICATIONS) ... 126

FIG. 56 – MINIMUM ENTERING CONDENSING
WATER TEMPERATURE ................................. 127

FIG. 57 – LIQUID CHILLER LOG SHEETS ..................... 127

FIG. 58 – TURBOGUARD PURGE UNIT......................... 129

FIG. 59 – SCHEMATIC DRAWING (YT) COMPRESSOR
LUBRICATION SYSTEM.................................. 132

FIG. 60 – OIL RETURN SYSTEM .................................... 135

FIG. 61 – ASSEMBLY OF DEHYDRATOR....................... 136

FIG. 62 – CHARGING OIL RESERVOIR WITH OIL ........ 137

FIG. 63 – EVACUATION OF CHILLER ............................ 145

FIG. 64 – SATURATION CURVE ..................................... 147

FIG. 65 – DIAGRAM - MEGGING MOTOR WINDINGS .. 149

FIG. 66 – MOTOR STATOR TEMPERATURE &
INSULATION RESISTANCES .......................... 150

Summary of Contents for R123

Page 1: ...LLENNIUM CENTRIFUGAL LIQUID CHILLERS Supersedes 160 55 O1 402 Form 160 55 O1 604 MODEL YT STYLE J R123 COOLING ONLY WITH OPTIVIEW CONTROL CENTER FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER VARI...

Page 2: ...YORK INTERNATIONAL 2 FORM 160 55 O1 604...

Page 3: ...aterials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are u...

Page 4: ...they should verify with the owner whether the equipment has been modi ed and if current literature is available REFERENCE INSTRUCTIONS DESCRIPTION FORM NO SOLID STATE STARTER MOD A OPERATION MAINTENA...

Page 5: ...Control Center 9 SECTION 3 Printers 112 SECTION 4 System Operating Procedures 124 SECTION 5 System Components Description 131 SECTION 6 Operational Maintenance 135 SECTION 7 Troubleshooting 138 SECTIO...

Page 6: ...CREEN 68 FIG 30 PRINTER SCREEN 70 FIG 31 SALES ORDER SCREEN 72 FIG 32 OPERATIONS SCREEN 74 FIG 33 HISTORY SCREEN 76 FIG 34 HISTORY DETAILS SCREEN 78 FIG 35 SECURITY LOG SCREEN 79 FIG 36 SECURITY LOG D...

Page 7: ...the condenser into the liquid return line where the vari SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION 29509A CONDENSER CONTROL CENTER COMPRESSOR MOTOR COOLER FIG 1 MODEL YT MILLENNIU...

Page 8: ...ACITY CONTROL The major 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 Prerot...

Page 9: ...only They are only displayed when logged in at SERVICE access level or higher The Setpoints and parameters displayed on these screens are explained in detail in YORK Service Manual 160 55 M1 These par...

Page 10: ...the respective revision level increments C Commercial chiller MLM Used on Microboard 031 01730 000 OPT Used on Microboard 031 02430 000 02 YT chiller xx controls revision level 00 01 etc y language p...

Page 11: ...FORM 160 55 O1 604 11 YORK INTERNATIONAL THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT...

Page 12: ...Center display is highlighted by a full screen graphics display This display is nested within a standard keypad and is surrounded by soft keys which are rede ned based on the currently displayed scre...

Page 13: ...s with an Access Level of VIEW This will allow the user to navi gate to most screens and observe the values displayed there However the user will not be allowed to change any values To change any valu...

Page 14: ...NAVIGATION In order to maximize the amount of values which the panel can display to the user and in order to place those values in context multiple screens have been designed to describe the chiller o...

Page 15: ...F 7 2 107 9 C Oil Temperature 19 0 226 3 F 7 2 107 9 C Condenser Pressure 2 5 35 3 PSIA 17 2 243 4 KPAA Condenser Temperature R11 1 4 124 2 F 18 5 51 2 C Condenser Temperature R123 7 2 130 1 F 13 7 5...

Page 16: ...ly if the chiller system is utilizing a Vari able Speed Drive motor controller or Mod B Solid State Starter This displays the total input power used by the system Full Load Amps This displays the perc...

Page 17: ...y Control Details screen Message Clear Access Level Required SERVICE When certain safety or cycling conditions have been detected and the chiller has been shutdown the main status display of the chill...

Page 18: ...a locally programmed value in local mode Evaporator Pressure Displays the present refrigerant pressure in the evaporator Evaporator Saturation Temperature Displays the present saturation temperature i...

Page 19: ...his value could come from a 0 20mAor 4 20mA 0 10VDC or 2 10VDC input in Analog Remote mode PWM signal in Digital Remote mode MicroGateway interface in ISN mode or a locally programmed value PROGRAMMAB...

Page 20: ...rator Evaporator Refrigerant Temperature Displays the temperature of the refrigerant in the evapo rator if the sensor is present Small Temperature Difference Displays the difference between the Leavin...

Page 21: ...F below the setpoint to a minimum cutout of 36 F water 34 F water with Smart Freeze enabled or 6 F brine It establishes the minimum allowable temperature for the Leaving Chilled Liquid Temperature and...

Page 22: ...e The Condenser Refrigerant temperature will be represented by the Condenser Saturation tem perature Drop Leg Refrigerant Temperature Displays the temperature of the refrigerant in the drop leg betwee...

Page 23: ...CE This value allows the user to de ne the condenser pres sure at which the chiller will initiate a warning Drop Leg Enabled Disabled Access Level Required SERVICE When a Drop Leg Refrigerant Sensor h...

Page 24: ...zed at 34 7 PSIA and de energized when the pressure decreases to 29 7 PSIA Top Float Switch LED Illuminated when the Top Float Switch is closed indicating the Purge Tank oil level is less than full Ex...

Page 25: ...PROGRAMMABLE High Efficiency Purge System Enabled Disabled Access Level Required SERVICE Selects the appropriate control and purge exhaust thresholds for the installed purge system High Ef ciency pump...

Page 26: ...w of the condenser When the actual level is 0 to 15 the level is shown about 50 full When the actual level is 16 to 31 the level is shown about 60 full When the actual level is 32 to 47 the level is s...

Page 27: ...key puts the level control into manual mode and sends a RAISE command to the variable ori ce Refrigerant Level Control Lower Manual This key puts the level control into manual mode and sends a LOWER...

Page 28: ...ay eld will show XX X Oil Sump Temperature Displays the temperature of the oil in the sump Discharge Temperature Displays the temperature of the refrigerant in its gaseous state at discharge of the co...

Page 29: ...l Required VIEW Causes an instant return to the Home Screen Pre Rotation Vane Calibration Access Level Required SERVICE Only available if the chiller is stopped and the system uses a Variable Speed Dr...

Page 30: ...an 79 shown as full open Pre rotation Vanes Position Displays the position of the Pre Rotation Vanes over the range of 0 closed to 100 fully open Displayed at XXX until calibration procedure is perfor...

Page 31: ...arlier On SURGE PROTECTION Screen in later Flash Memory Card versions Service technicians refer to YORK Service Manual 160 55 M1 Minimum Load Service technicians refer to YORK Service Manual 160 55 M1...

Page 32: ...oc SURGE PROTECTION SCREEN curred in the last 1 to 5 minutes as programmed with the COUNT WINDOW setpoint If the chiller has been running for less than the COUNTWINDOW minutes it is the number of surg...

Page 33: ...UNT exceeds the COUNT LIMIT at the completion of this period a safety shutdown is performed and Surge Protection Excess Surge is displayed If the Hot Gas Bypassed control is Enabled the Hot Gas Bypass...

Page 34: ...E WINDOW COUNT exceeds the COUNT LIMIT at the completon of the 10 minute extended run period a safety shutdown is performed and Surge Protection Excess Surge is displayed See Hot Gas Bypass andVariabl...

Page 35: ...FORM 160 55 O1 604 35 YORK INTERNATIONAL THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT 2...

Page 36: ...s LED Indicates the calibration sequence is in progress Calibration Messages These are text messages which step the user through the calibration process and indicate its success or failure Hot Gas PRV...

Page 37: ...FORM 160 55 O1 604 37 YORK INTERNATIONAL THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT 2...

Page 38: ...ble Speed Drive Temperature Differential Displays the differential between the Leaving Chilled Liquid Temperature and Setpoint Delta P P Displays a value based on the pressure differential between the...

Page 39: ...control into manual mode and increases the present command frequency by the de ned frequency increment It will not raise the value above the maximum allowed frequency Decrease This key puts the VSD fr...

Page 40: ...Run Output LED Indicates whether the Oil Pump is being commanded to operate Manual Oil Pump Operation Time Left Displays the time remaining in the 10 minute manual oil pump operation described below P...

Page 41: ...non zero PROGRAMMABLE Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed mo tor current as a percentage of FLA When the motor current reaches this...

Page 42: ...Starter Rating and the maximum allowed Full Load Amps Voltage Phase A B C Display the 3 phase input line voltage values being read from the Solid State Starter Current Phase A B C Display the 3 phase...

Page 43: ...cess Level Required SERVICE Allows the user to select a speci c voltage range for volt age checking When not disabled this line voltage range is used to determine a low line and high line voltage thre...

Page 44: ...n period Input Power Displays the Kilowatts measured by the Solid State Starter kW Hours Displays the cumulative amount of kilowatts used over time Starter Model Displays the Solid State Starter model...

Page 45: ...high line volt age threshold for initiating a shutdown Service Techni cians refer to YORK Service Manual 160 55 M1 Starting Current Access Level Required SERVICE De nes the maximum allowed motor star...

Page 46: ...d if the value is non zero Output Voltage Displays the output voltage measured to the motor Output Frequency Displays the present output frequency to the motor Output Current Phase A B C Displays the...

Page 47: ...nergy savings following chiller start up Pulldown Demand Time Access Level Required OPERATOR Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chi...

Page 48: ...value For the Variable Speed Drive this is the data returned by the VSD Logic board Current Limit Setpoint Displays the current limit value in use This value could come from a 0 20mA 4 20mA 0 10VDC or...

Page 49: ...owed mo tor current as a percentage of FLA When the motor current reaches this value the pre rotation vanes will not be permitted to open further If the motor current rises above this value the pre ro...

Page 50: ...by the VSD Logic board Current Limit Setpoint Displays the current limit value in use This value could come from a 0 20mA 4 20mA 0 10VDC or 2 10VDC input in Analog Remote mode PWM signal in Digital Re...

Page 51: ...age of FLA When the motor current reaches this value the pre rotation vanes will not be permitted to open further If the motor current rises above this value the pre rotation vanes will close to reduc...

Page 52: ...tal Remote mode MicroGateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in the programmed pull down period if the value is non zero VSD O...

Page 53: ...gin at which these adjustments will begin to take place Manual Surge Point This key will force the ACC to map a surge detection at the present operating conditions Mapping a point at these conditions...

Page 54: ...rom a 0 20mA 4 20mA 0 10VDC or 2 10VDC input in Analog Remote mode PWM signal in Digital Remote mode MicroGateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays...

Page 55: ...E Local Motor Current Limit Access Level Required OPERATOR Allows the user to specify the maximum allowed mo tor current as a percentage of FLA When the motor current reaches this value the pre rotati...

Page 56: ...ateway interface in ISN mode or a locally programmed value Pulldown Demand Time Left Displays the time remaining in the programmed pull down period if the value is non zero Operating Mode Run Stop Ind...

Page 57: ...the maximum allowed mo tor current as a percentage of FLA When the motor current reaches this value the pre rotation vanes will not be permitted to open further If the motor current rises above this...

Page 58: ...eatwhich the chiller will restart after it has shut down due to over cooling temperature This value is calculated by adding the Leaving Chilled Liquid Temperature Cycling Offset Restart to the Leaving...

Page 59: ...hilled Liquid Temperature Cycling Offset Restart Access Level Required OPERATOR This value allows the user to specify the Leaving Chilled Liquid Temperature at which the chiller will restart after a s...

Page 60: ...o serves as a gateway to more subscreens for de ning general system parameters DISPLAY ONLY 031 01730 000 Microboard Chilled Liquid Pump Operation Displays Standard or Enhanced Motor Type Displays Fix...

Page 61: ...will include the AM and PM modi ers and show the range of time between 1 00 and 12 59 while the 24 Hour time format will show the range of time between 0 00 and 23 59 031 02430 000 Microboard only Cha...

Page 62: ...Moves to the subscreen allowing con guration of system communications Printer Access Level Required VIEW Moves to the subscreen allowing con guration and control of printer functions Sales Order Acce...

Page 63: ...FORM 160 55 O1 604 63 YORK INTERNATIONAL THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT 2...

Page 64: ...p times which are utilized every week The user may then specify exception Start Stop combinations for any day of the week up to 6 weeks in advance At the end of each week the schedule for the next wee...

Page 65: ...red OPERATOR Deletes all programming for exception days within the next 6 weeks Select Access Level Required OPERATOR Places a selection box around a start time for a given day Use or cursor arrows to...

Page 66: ...USER Screen to another Screen English Metric Units Access Level Required OPERATOR De ne the unit system English or Metric used by the chiller display Custom User ID 4 Access Level Required SERVICE Th...

Page 67: ...FORM 160 55 O1 604 67 YORK INTERNATIONAL 2 THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT...

Page 68: ...parameter Use the and keys to place the selection box around the desired parameter to be changed With the selection box around the desired parameter press the ENTER key A dialog box is displayed perm...

Page 69: ...Stop Bit s De ne the number of stop bits at which the panel shall communicate through the modem port NAVIGATION Home Access Level Required VIEW Causes an instant return to the Home Screen Setup Acces...

Page 70: ...l Required SERVICE Only available if the chiller system utilizes a Variable Speed Drive motor controller The chiller monitors the ACC communications and when a surge point is mapped a short report of...

Page 71: ...FORM 160 55 O1 604 71 YORK INTERNATIONAL NAVIGATION Home Access Level Required VIEW Causes an instant return to the Home Screen Setup Access Level Required VIEW Return to the Setup Screen 2...

Page 72: ...Order Number Factory de ned order number under which the chiller was sold System Information Factory de ned conditions for which the chiller was originally rated and sold Condenser and Evaporator Des...

Page 73: ...FORM 160 55 O1 604 73 YORK INTERNATIONAL THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT 2...

Page 74: ...ours Access Level Required ADMIN Displays the total accumulated run time of the chiller This may be reprogrammed to a desired value generally when this value has been reset due to a Microboard re plac...

Page 75: ...FORM 160 55 O1 604 75 YORK INTERNATIONAL 2 NAVIGATION Home Access Level Required VIEW Causes an instant return to the Home Screen Setup Access Level Required VIEW Return to the Setup Screen...

Page 76: ...e Digital Analog or ISN Last Fault While Running This window displays the date and time and the de scription of the last safety or cycling shutdown while the system was running Last Ten Faults This wi...

Page 77: ...parameters Custom View Flash memory Card version C MLM 02 01 or later Access Level required VIEW Causes a move to a sub screen allowing the user to view the Custom Setup Screen Security Log Flash Memo...

Page 78: ...ut This is the on screen printout of the system parame ters PROGRAMMABLE Page Up Access Level Required VIEW Scroll up in the displayed data if applicable Page Down Access Level Required VIEW Scroll do...

Page 79: ...porator condenser etc Setpoint Displays the setpoint that was changed New Value Displays the value that was entered at the time of the setpoint change PROGRAMMABLE Log Entry Allows the user to select...

Page 80: ...login access level of SERVICE DISPLAY ONLY Description Displays the setpoint category that was changed Time Displays the time the setpoint was changed Date Displays the date the setpoint was changed...

Page 81: ...urity Log Access Level Required SERVICE Causes an instant return to the Security Log Screen View Details Access Level Required SERVICE Causes a move to a sub screen containing the details of the setpo...

Page 82: ...the sampled parameter is less than theY Axis label minimum for that parameter the value will be plotted at the minimum value Simi larly if the actual value is greater than the Y Axis label maximum fo...

Page 83: ...display all trended data points simul taneously or select a single trended data point for display hiding the other data points Selections are ALL DATA or DATA POINT X 1 6 Print Flash Memory Card versi...

Page 84: ...the DATA COLLECTION INTERVALor the interval at which the parameter is sampled This interval is programmable over the range of 1 second to 3600 seconds 1 hour in one second increments The selected inte...

Page 85: ...parameter selected for this data point is a digital type on off this value must be set to zero 0 Zero indicates the OFF state Data Point Max 1 6 Access Level Required OPERATOR Only displayed if the as...

Page 86: ...elected Trigger delay per the selected Trigger Action ASecondary Trigger can be evaluated with the Primary Trigger to start stop data collection The Primary to Sec ondary Operator is used to de ne the...

Page 87: ...ter the triggers evaluate as true and the delay timer has elapsed If the Trigger Action is set to Stop data collection will stop after the Triggers evaluate as true and the delay timer has elapsed Pri...

Page 88: ...bers into Data Points 1 through 6 Requires a login access level of OPERATOR or higher DISPLAY ONLY Slot Numbers These are the slot numbers of the most commonly used parameters PROGRAMMABLE Page Down A...

Page 89: ...ing At completion of the service call the display can be cleared or the parameters can be left there for monitor ing by operations personnel DISPLAY ONLY None PROGRAMMABLE Print Access Level Required...

Page 90: ...the number of the parameter s to be displayed Pressing the Select key places a green colored selection box around Custom Slot 1 If it is desired to change an already entered parameter use the 5 and 6...

Page 91: ...re 1538 Oil Pump Control Mode 1539 Oil Pump Is Pump On 1540 Oil Pump Manual Time Left SLOT NO DESCRIPTION 1792 Leaving Chilled Liquid Temperature 1793 Leaving Chilled Liquid Temperature Differential 1...

Page 92: ...5 LcSss Is Serial Communications OK 2586 LcSss Panel to Sss Comm Errors 2587 LcSss Sss to Panel Comm Errors SLOT NO DESCRIPTION 2816 VSD Motor HP 2817 VSD 100 Full Load Amps 2818 VSD Input Power 2819...

Page 93: ...rmonic Distortion 2891 Filter Maximum Total Demand Distortion 2 SLOT NO DESCRIPTION 8205 Refrigerant Level Is Control Enabled 8206 Refrigerant Level Position 8207 Refrigerant Level Is Valve Closing 82...

Page 94: ...r has shut down and the Post run lubrication is being performed On electric motor drive applications the Postlube duration is 150 seconds On Steam Turbine applications it is 15 minutes The actual dura...

Page 95: ...s that which was written to the device it is assumed the BRAM and Real time Clock operation is defective and this message is displayed The BRAM should be replaced by a quali ed Service Technician This...

Page 96: ...de ThiswarningwillnotbedisplayedifthePurgeFloatSwitch Error warning below is in effect WARNING PURGE FLOATSWITCHERROR With the chiller running the Purge Float Switches were in invalid states Typically...

Page 97: ...Digital Remote mode via I O Board TB4 7 8 or in ISN Integrated Systems Network Remote mode via the MicroGateway serial communications LOCAL STOP A local shutdown command has been received by plac ing...

Page 98: ...t CM 2 Module Overload None Overload Phase Rotation Loss Solid State Starter High Temp 212 F High Temp start inhibit 110 F Fault Current Trigger Board Out of Lock MOTOR CONTROLLER LOSS OF CURRENT The...

Page 99: ...s not yet received the cause of the fault from the LCSSS via the serial communications link The LCSSS shuts down the chiller by opening the Motor Controller LCSSS Stop Contacts K1 relay located on the...

Page 100: ...in any phase exceeded the high line voltage threshold continuously for 20 seconds The chiller will automaticallyrestartwhenthevoltageinallphasesreturns to the restart level The thresholds are as follo...

Page 101: ...Serial data communications must be established Refer to VSD Serial Communications fault If communications between the VSD Logic Board Harmonic Filter Logic Board ACC Board and Con trol Center Microbo...

Page 102: ...point we suggest you back ush the heat exchanger by reversing the two rubber hoses which supply condenser water to from the heat exchanger If the rust cannot be back ushed the heat exchanger might hav...

Page 103: ...r371 03789 xxx 503HP60Hz 419HP 50Hz Flash Memory Card version C MLM 02 04 xxx and later The chiller has shutdown because the baseplate tem perature has decreased to 37 F VSD LOW PHASE B INVERTER BASEP...

Page 104: ...er this shutdown and continues to operate properly with the lter operating it is likely the lter tripped due to a sag or surge in the voltage feeding the VSD If this message reoccurs pre venting the c...

Page 105: ...eze feature is not activated If Smart Freeze is activated and has initiated the shutdown Evaporator Low Pressure Smart Freeze is displayed as described next The evaporator pressure as sensed by the Ev...

Page 106: ...or Evapo rator Saturation Temperature is indicating a tem perature of 32 0 F Flash Memory Card version C MLM 02 02 xxx and later The chiller can be started after the temperatures are within 3 0 F of...

Page 107: ...can indicate a Cycling auto restart after power failure or Safety manual restart after power failure shutdown depending upon Control Center con guration It indicates a Cy cling shutdown when displayed...

Page 108: ...e message has been detected by the Liquid Cooled Solid State Starter Logic Trigger Board The voltage across each SCR in monitored to detect the shorted condition The shorted condition must exist conti...

Page 109: ...the primary of the heat exchanger for clogs and silt The chiller can be started after the fault condition clears the RESET button on the VSD Logic Board is pressed and the COMPRESSOR switch is placed...

Page 110: ...d the COMPRESSOR switch is placed in the Stop reset O position HARMONIC FILTER HIGH BASEPLATE TEMPERATURE Applicable to VSD with part number 371 02767 XXX 60 Hz and 371 03700 XXX 50 Hz Requires Flash...

Page 111: ...FORM 160 55 O1 604 111 YORK INTERNATIONAL THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT 2...

Page 112: ...YORK INTERNATIONAL 112 FORM 160 55 O1 604 SECTION 3 PRINTERS FIG 43 PRINTERS 23887A OKIDATA MICROLINE 184 23889A WEIGH TRONIX SEIKO DPU 414 00085VIP Printers...

Page 113: ...similar but print parameters applicable to those devices Figure 44 Status Figure 45 Setpoints Figure 46 Schedule Figure 47 Sales Order Figure 48 History Figure 49 Security Log Flash Memory Card ver si...

Page 114: ...hield Hardware required Cable 18 AWG stranded 50ft maximum length Connectors Microboard None Strip 1 4 insulation from wire and insert into screw terminal block Printers Okidata 25 pin plug DB 25P or...

Page 115: ...on number to the chiller This number will appear at the top of each report Printer Setup Access Level Required OPERATOR or Higher Using the COMMS Screen the Control Center must be con gured to transmi...

Page 116: ...If Drop Leg Sensor enabled Compressor Discharge Temperature 121 6 F Vent Line Solenoid On Oil Sump Oil Pump Run Output On Oil Pressure 30 7 Psid Oil Sump Temperature 137 9 F Skip the following section...

Page 117: ...perature 88 F Converter Heatsink Temperature 102 F Phase A Heatsink Temperature 93 F Phase B Heatsink Temperature 99 F Phase C Heatsink Temperature 97 F Skip the following section if Motor Type is not...

Page 118: ...orator Printers Leaving Chilled Local Setpoint 45 0 F Leaving Chilled ISN Setpoint 45 0 F Leaving Chilled Modem Setpoint 45 0 F Leaving Chilled Analog Setpoint 45 0 F Leaving Chilled Digital Setpoint...

Page 119: ...ge Range Disabled Full Load Amps 215 A Starting Current 1460 A Open SCR Disabled Skip the following section if Motor Type is not VSD Variable Speed Drive Local Motor Current Limit 100 Remote ISN Curre...

Page 120: ...0 00010 Pressure Drop 21 1 Nozzle Arrangement In 2 Nozzle Arrangement Out 3 Leaving Temperature 44 0 Return Temperature 56 0 GPM 1500 0 Tubes 181 Design Load condenser Passes 2 Design Working Pressure...

Page 121: ...ensor enabled Compressor Discharge Temperature 121 6 F Vent Line Solenoid Off Oil Sump Oil Pump Run Output Off Oil Pressure 0 0 Psid Oil Sump Temperature 137 9 F Skip the following section if Hot Gas...

Page 122: ...r Pump Output Off KW Hours 14528 KWH Input Power 150 KW Output Frequency 0 Hz Output Voltage 800 V DC Bus Voltage 600 V DC Inverter Link Current 300 A Phase A Output Current 0 A Phase B Output Current...

Page 123: ...d Active Setpoint 45 0 F Leaving Chilled Liquid Temperature 50 0 F Return Chilled Liquid Temperature 59 3 F Leaving Condenser Liquid Temperature 85 0 F Return Condenser Liquid Temperature 94 9 F Evapo...

Page 124: ...controlled and remains energized as long as the fused disconnect switch to the starter or Variable Speed Drive is energized CHECKING THE OIL LEVEL IN THE OIL RESERVOIR Proper operating oil level the...

Page 125: ...s and also decreases the speed of the motor if equipped with a Variable Speed Drive to decrease chiller capacity When the chilled liquid temperature rises the actuator will open the prerotation vanes...

Page 126: ...EN VENT SOLENOID CHECK OIL PRESS 150 SEC 2 5 MIN SYSTEM SHUTDOWN DISPLAY MESSAGE SYSTEM RUN SYSTEM PRELUBE OIL PUMP PRE RUN SYSTEM COASTDOWN OIL PUMP POST RUN 0 25 30 330 1800 0 4 0 5 5 5 30 START TIM...

Page 127: ...ng oil pressure will vary with compressor suction and discharge pressures When a new system is rst operated under normal full load conditions the bearing oil pressure should be recorded as a reference...

Page 128: ...arison with job design conditions This can be accomplished by pressing the EVAPORATOR key and the RE FRIGERANT PRESSURES key 5 Check the condenser saturation temperature based upon condenser pressure...

Page 129: ...conden sible gases and refrigerant from the top of the condenser expel the noncondensibles to the atmosphere and return the refrigerant to the system IMPORTANT The purge unit operates continuously whe...

Page 130: ...g the system to stand for a long period of time During long idle periods the tightness of the system should be checked periodically 2 If freezing temperatures are encountered while the system is idle...

Page 131: ...ion Overload overcurrent transformers CTs are furnished as listed below in motor terminal box as follows 5 CASING The casing is accessible with vertical circular joints and fabricated of close grain c...

Page 132: ...YORK INTERNATIONAL 132 FORM 160 55 O1 604 FIG 59 SCHEMATIC DRAWING YT COMPRESSOR LUBRICATION SYSTEM LD03278 System Components Description...

Page 133: ...the oil to be distributed through the passages by gravity ow thus providing nec essary lubrication during the compressor coastdown OIL PUMP For normal operation the oil pump should operate at all time...

Page 134: ...or ef cient elimination of noncondensibles Intermediate steel tube supports are spaced at intervals of less than four feet REFRIGERANT FLOW CONTROL The ow con trol chamber is welded to the bottom of t...

Page 135: ...ndenser gas line oil return line to rotor support and inlet end of dehy drator 2 Remove the dehydrator as follows Refer to Fig 58 a Remove connection on the inlet end of dehy drator b Place wrenches o...

Page 136: ...YORK INTERNATIONAL 136 FORM 160 55 O1 604 Operational Maintenance LD00470 FIG 61 ASSEMBLY OF DEHYDRATOR...

Page 137: ...oil cooler and oil lter This will lower the oil level in the reservoir It will then be necessary to add oil to bring the level back to the center of the upper sight glass The nominal oil charge for th...

Page 138: ...Power Fault Autostart CM 2 Current Module or Solid State Starter Remote Stop Energy Management System MON Anti Recycle Anti Recycle 20 Min Left Timer MON 10 00 AM Low Evap Press Low Evap Pressure 5 4...

Page 139: ...Will not start until 30 minute Will restart when time left 00 minutes Minimum time between successive compressor timer is timed out starts is 30 minutes To restart press compressor switch from See OP...

Page 140: ...ch Switch Open MON 10 00 AM Starter Motor Current 15 for 10 Malfunction seconds with Control Center Detected not calling for motor to run MON 10 00 AM Program Initiated Autostart Microboard Reset Repl...

Page 141: ...OptiView Control Center or switch of capacity board of Variable Speed Drive Press compressor STOP RESET switch and then Check motor starter operation Motor current value START switch greater than 15...

Page 142: ...d Clean cooler tubes chilled water and refrigerant in the cooler greater than normal with normal discharge temperature Temperature of chilled water too low with Insufficient load for system capacity C...

Page 143: ...treme bearing wear Inspect compressor originally started 9 SYMPTOM OIL RETURN SYSTEM CEASES TO RETURN AN OIL REFRIGERANT SAMPLE Oil refrigerant return not functioning Filter drier in oil return system...

Page 144: ...any leaks too small to be found by the soap test Do not use excessive amounts of R 22 use only enough for proper leak detection To test with R 22 proceed as follows 1 With no pressure in the system ch...

Page 145: ...122 6 3 6 300 40 29 72 099 5 5 000 35 WATER 29 842 039 2 2 000 15 FREEZES 29 882 019 1 0 1 000 1 29 901 010 5 500 11 29 917 002 1 100 38 29 919 001 05 50 50 29 9206 0002 01 10 70 29 921 0 0 0 One stan...

Page 146: ...YDRATION To obtain a suf ciently dry system the following in structions have been assembled to provide an effective method for evacuating and dehydrating a system in the eld Although there are several...

Page 147: ...e pulled down to 35 F or 5mm Hg in the primary evacuation During the primary pulldown keep a careful watch on the wet bulb indicator temperature and do not let it fall below 35 F If the temperature is...

Page 148: ...rant 123 boils at 82 F under atmospheric pressure it will not be necessary to remove the refrig erant if the system it to be open for only a few hours Any part of the system which is above the liquid...

Page 149: ...ce 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 capacity de creases...

Page 150: ...ERNATIONAL 150 FORM 160 55 O1 604 LD00476 TEMPERATURE F MEGOHMS FIG 66 MOTOR STATOR TEMPERATURE AND INSULATION RESISTANCES Minimum Insulation Resistance vs Temperature per IEEE Std 43 Open Motors Main...

Page 151: ...ting and corrosion If a tube leak is indicated the exact location of the leak may be determined as follows 1 Allow the system to warm up until a substantial pressure is reached for testing Dry nitroge...

Page 152: ...he oil filter should be replaced semi annually or when the operating oil pressure drops 30 from the oil pressure measured at the time of the previous replacement COMPRESSOR MOTOR 1 Check motor mountin...

Page 153: ...Months 1 Change the purge unit dehydrator a If the unit is operating 1 When the purge unit is in the drain cycle close the valve in the high pressure oil sup ply line and allow the unit to complete t...

Page 154: ...the energy consumption of a constant speed drive and subtracting the measured energy consumption of the variable speed drive The resulting difference is the energy savings This data is displayed but d...

Page 155: ...FORM 160 55 O1 604 155 YORK INTERNATIONAL NOTES...

Page 156: ...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 55 O1 604 Supersed...

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York R123, Operating & Maintenance Manual

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