York YCWS0313SC, Installation, Operation And Maintenance Manual

Page 1: ...STALLATION OPERATION AND MAINTENANCE YCWS WATER COOLED LIQUID CHILLERS New Release Form 201 24 NM2 601 50 HERTZ STYLE B REFRIGERANT TYPE R 22 00546VIP YCWS WATER COOLED LIQUID CHILLERS YCWS0313SC 0663...

Page 2: ...ation System BAS Interface 18 Multi Unit Sequence Control 18 Pressure Vessel Codes 18 Vibration Isolators 18 Neoprene Pad Isolators 18 1 25 mm Spring Isolators 18 Flange Kits 150 PSI 19 Mechanical Gau...

Page 3: ...Backup Battery 38 1 3 Power Supply Board 38 1 4 Input Output Expansion Board 38 1 5 Relay Output Board 38 1 6 Circuit Breakers 39 1 7 Current Transformers C T 39 1 8 Transformers 39 1 9 Motor Protecto...

Page 4: ...7 5 1 General 57 5 2 Oper Data Key 57 5 3 Oper Data Local Display Messages 57 5 4 Oper Data Remote Printout 59 5 5 History Key 60 5 6 History Local Display Messages 60 5 7 History Remote Printout 63 5...

Page 5: ...tion 79 SECTION 8 MAINTENANCE 81 General Requirements 81 Daily Maintenance 81 Scheduled Maintenance 81 Standard Units 82 Competent Persons Troubleshooting Guide 83 Sensor Calibration Charts 85 Typical...

Page 6: ...pported by evidence that the failure has occurred within the warranty period and that the unit has been operated within the designed parameters specified All warranty claims must specify the unit mode...

Page 7: ...is not suitable for purposes other than those specified in these instructions Any use of the equipment other than its intended use or operation of the equipment contrary to the relevant procedures ma...

Page 8: ...prehensive information on safety precautions for use of refrigerants and oils refer to the Materials Safety Data tables provided on pages 9 through 11 High Temperature and Pressure Cleaning High tempe...

Page 9: ...that R22 does not represent a carcinogenic hazard to humans Occupational Recommended limit 1000 ppm v v 8 hr TWA 1250 ppm v v 12 hr TWA Exposure Limits Stability Unstable Conditions to Avoid Use in p...

Page 10: ...highly recommended Section 4 PHYSICAL DATA Appearance Clear liquid gray to yellow or light brown tint Boiling Point 650 F Vapor Pressure 0 01 mmHg 20 C Specific Gravity water 1 0 94 0 97 Volatiles Pe...

Page 11: ...atory Protection Use in well ventilated area Ventilation Local exhaust Protective Gloves Strongly recommended especially for prolonged exposure Eye Face Protection Goggles Firefighters should use NIOS...

Page 12: ...YORK INTERNATIONAL 12 THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN PAGE FORMAT...

Page 13: ...nufactured from forged steel The 50 Hz motor operates at 2950 rpm to direct drive the male rotor which in turn drives the female rotor on a light film of oil Each compressor is direct drive semi herme...

Page 14: ...otor Starting Compressor motor starting is Star Delta S D open transition The starter utilizes 3 motor contactors a tran sition delay relay and a start relay The starter allows inrush current to be li...

Page 15: ...ering the rotor case Maximum working pressure of the oil separator is 31 bar 450 psi A relief valve is installed in the oil sepa rator piping The oil level should be above the mid point of the lower o...

Page 16: ...larm and sta tus contacts chilled liquid pump control automatic re set after power failure automatic system optimization to match operating conditions The software is stored in non volatile memory EPR...

Page 17: ...ne of the sensors reaches 13 kW the module trips which ultimately de energizes the motor s pilot circuit Reset is manual after the motor cools and the sensor resistance drops to 3 25 kW Current Unbala...

Page 18: ...ailable with either single point or multi point power supply connections Single Point Power Supply Connection One field provided 400V 3 50 Hz supply to the unit with cir cuit protection Field connecti...

Page 19: ...e LCD and Keypad Standard display language and keypad is English Span ish is available as an option Flow Switch Accessory JohnsonControlsModel F61MG 1CVapor proofSPDT NEMA 4X switch 150 PSIG 10 bar DW...

Page 20: ...d liquid leaves the condenser and enters the expansion valve where pressure reduction and further cooling takes place The low pressure liq uid refrigerant then returns to the cooler Each refrig erant...

Page 21: ...uring storage INSPECTION Remove any transit packing and inspect the unit to en sure that all components have been delivered and that no damage has occurred during transit If any damage is evident it s...

Page 22: ...CTION CABLES 136 137 138 139 DISCONNECT POWER CABLES 101 102 103 104 105 106 E1 DISCONNECT TERMINAL BLOCK CABLES 2 121 122 125 127 129 Lifting by Fork Lift Insert the forks into the lifting slots in t...

Page 23: ...be isolated from walls and ceiling The unit may be bolted to the foundation using 13 mm holes in the base of the framework When lower trans mitted vibration levels are required optional anti vibra tio...

Page 24: ...tape of 21 watts per meter un der the insulation is recommended supplied independently and controlled by an ambient temperature thermostat set to switch on at 3 C above the freez ing temperature of t...

Page 25: ...ions Standard chilled and condenser cooling liquid connec tions are of the Victaulic groove type FIG 6 CHILLED LIQUID SYSTEM FIG 7 CONDENSER COOLING LIQUID SYSTEM FIG 8 PIPEWORK ARRANGEMENT LEGEND FIG...

Page 26: ...iped in conjunction with a cooling tower although in some cases they can be cooled by well water Direct Pressure Control With liquid cooled units it is necessary to control cool ant flow and or temper...

Page 27: ...in the metal gland plate the cables forming each 3 phase power sup ply must enter via the same hole in the gland plate If separate entries for each cable forming the 3 phase supplies are used the met...

Page 28: ...lation Control Transformer Primary Voltage Tappings It is important to check that the correct primary tap ping has been used on the control transformer With the supply to the unit isolated remove the...

Page 29: ...PWMT Timed closure of suitable contacts connected to termi nals 27 and 13 PWM contacts will give remote offset function of the chilled liquid setpoint if required Remote Setpoint Offset Current PWMC T...

Page 30: ...NATIONAL 30 FIG 12 MULTI POINT POWER SUPPLY CONNECTION STANDARD UNIT CONNECTION DIAGRAM FIG 13 SINGLE POINT POWER SUPPLY WITH INTERNAL CIRCUIT BREAKER OR NON FUSED DISCONNECT SWITCH LD06947 LD06948 In...

Page 31: ...RAM NOTES 1 Dashed line indicates field provided wiring 2 The above recommendations are based upon the National Electric Code and the use of copper connectors only Field wiring must comply with local...

Page 32: ...t is opened This common point of isolation is not supplied by YORK The YORK voltage free contacts are rated at 125VA All inductive devices relays switched by the YORK voltage free contacts must have t...

Page 33: ...condenser with the full operating charge as given in Section 9 Valves Open the compressor suction and discharge and liquid line service valves on both systems Compressor oil The compressor oil level m...

Page 34: ...ays be fitted Ensure the cooling liquid temperature sensor is coated with heat conductive compound Part No 013 00890 000 and inserted in the outlet sensor pocket of the condenser Control supply Verify...

Page 35: ...a flow of liquid refrigerant will be seen in the liquid line sight glass Afterseveralminutesoperationandprovidingafullcharge of refrigerant is in the system the bubbles will disappear and be replaced...

Page 36: ...YORK INTERNATIONAL 36 THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN PAGE FORMAT Commissioning...

Page 37: ...e display will show the anti coincidence timer status for the lag compressor NORMAL RUNNING AND CYCLING Once the unit has been started all operations are fully automatic After an initial period at min...

Page 38: ...m the logic transformer 2T to 12VDC REG which is supplied to the AMB board ARB boards and the 40 character display to operate the integrated circuitry The 24VAC is filtered but not regu lated to provi...

Page 39: ...nalogue sig nal proportional to average motor current to AIOB board and on to the AMB board for microprocessor low high current protection and current display This allows the microprocessor to monitor...

Page 40: ...o terminal 13 to feed the two start stop con tacts Then connect No 1 system start stop contact to terminal 24 and No 2 system start stop contact to ter minal 25 With the associated contact open the NO...

Page 41: ...e immunity the micropro cessor will ignore closures of less than 1 second To calculate the necessary contact closure time to pro vide a required Reset use the following steps RESET TEMPERATURE CONTACT...

Page 42: ...ended that the customer wiring to these terminals uses orange wires This will ensure that circuits not switched off by the units supply dis connecting device are distinguished by color so that they ca...

Page 43: ...de energized The compressor continues to operate until it either pumps down to the low suction pressure cutout setting or for 180 seconds whichever comes first Pump down occurs on normal shutdowns whe...

Page 44: ...uts down the entire chiller when placed in the OFF position The switch must be ON for the chiller to operate 2 2 PROGRAM AND SETUP KEYS Entry Keys refer to Section 6 The numeric and associated keys ar...

Page 45: ...t Switch OFF The unit ON OFF switch on the control panel is in the OFF position and the chiller will not run Schedule Shutdown The chiller has been shut down by the DAILY SCHED ULE programmed into the...

Page 46: ...roprocessor will bring the lead system on and or that the loading sequence has not loaded the chiller far enough to bring the lag system on The lag system will display this message until the load ing...

Page 47: ...discharge pressure has ex ceeded the programmable threshold and the compres sor is being unloaded to prevent nuisance shutdown on the high pressure cutout The operation of this safety is important if...

Page 48: ...hanical and electrical components may result The cutout is programmable and can be set for lower limit values if required The fault will clear when ambient temperature drops 1 C below the cutout Low L...

Page 49: ...rs It also protects against excessive oil temperature in the discharge oil separator For the first 4 seconds of operation discharge tempera ture is ignored After 4 seconds of operation the com pressor...

Page 50: ...quals the programmed cutout value If suction pressure falls below the calculated cutout value before 225 seconds of run time the system will be shutdown The following graph shows a typical programmed...

Page 51: ...current is monitored after 3 seconds of compressor operation From this time the system will be shutdown if average motor current is less than 10 of FLA Compressor motor protection modules and mechani...

Page 52: ...below the leav ing chilled liquid temperature in the Glycol Cooling mode the system will shutdown In addition if the cooler inlet refrigerant temperature sen sor reads out of range low the system will...

Page 53: ...outside the ability of the microprocessor to give an actual read ing This is unlikely to occur unless a problem exists in the measuring sensors or during extreme conditions The display keys and the da...

Page 54: ...ir temperature as measured surrounding the chiller is displayed Display Limits Minimum 20 3 C Maximum 58 8 C 4 5 MOTOR CURRENT KEY Pressing the key displays compressor current for each system This dis...

Page 55: ...ection when the OPTIONS key is pressed SWITCH 1 Water Brine Cooling Open Water cooling mode is for water cooling applications and allows the chilled liquid leaving temperature set point to be programm...

Page 56: ...thout the need to press the SYSTEM 1 DATA key to scroll to the next display After scrolling through the data the display returns to the status message The FUNCTION Key can be used to scroll through th...

Page 57: ...s erased from the memory Information available using the OPER DATA key is de scribed in the following sections In example displays is used to indicate system number where appropriate 5 3 OPER DATA LOC...

Page 58: ...t if the unit is controlling a re mote air cooled condenser and the status of the com pressor heater Once the system data sequence has been repeated for the other systems pressing the o r keys again w...

Page 59: ...D H M S MOTOR CURRENT 0 AMPS 00 FLA SUCTION PRESSURE 3 79 BAR DISCHARGE PRESSURE 17 1 BAR OIL PRESSURE 1 1 BAR SUCTION TEMPERATURE 1 1 DEGC DISCHARGE TEMPERATURE 49 6 DEGC OIL TEMPERATURE 55 5 DEGC S...

Page 60: ...hen the HISTORY key is pressed the following message will appear To select a Safety Shutdown press the appropriate key on the numeric key pad then press ENTER Remem ber that the most recent fault info...

Page 61: ...tes that a remote device such as a Remote Control Center an ISN controller or another device sending a PWM signal for temperature or cur rent reset is overriding control points programmed through the...

Page 62: ...L 5 5 5 C S P 1 1 D P 4 9 6 C S Y S C O O L E R I N L E T R E F R I G T E M P 2 5 C S Y S S A T D S C H 5 4 4 C S U C T S H E A T 1 2 5 C S Y S S V S T E P 3 S Y S R U N T I M E 1 3 4 8 1 7 D H M S S...

Page 63: ...COOLING RANGE 7 0 1 0 DEGC AMBIENT AIR TEMP 22 7 DEGC LEAD SYSTEM SYS 2 EVAPORATOR PUMP ON EVAPORATOR HEATER OFF ACTIVE REMOTE CONTROL NONE SOFTWARE VERSION C A14 10 01 SYSTEM 1 DATA COMPRESSORS STAT...

Page 64: ...hillers both air and water cooled with or without options Items may be indicated on the print out which may not be present on the chiller Installation Limitations The following limitations must be adh...

Page 65: ...operating conditions at the instant that the fault occurred Additionally the Status indication that is noted in the printout will note the specific fault that occurred Using Other Printers Control cod...

Page 66: ...key is also used to scroll through avail able data when using the PROGRAM or SET SCHEDULE HOLIDAY keys 6 4 CANCEL KEY When the CANCEL key is pressed the cursor will always return to the first charact...

Page 67: ...desired range of leaving chilled liquid operating temperatures A description of the operation and programming follows 7 2 CHILLED LIQUID TEMPERATURE CONTROL The SETPOINTS keys are used to program the...

Page 68: ...s between changes 7 5 SLIDE VALVE POSITION A slide valve position S V STEP under the keypad SYSTEM DATA keys of 75 indicates that the com pressor is fully loaded However due to the non exact movement...

Page 69: ...ring its motor current unload point and it was scheduled to load the micropro cessor could split a load signal of 10 steps between sys tems 1 and 2 It could only load system 1 2 steps while loading sy...

Page 70: ...of external con tacts for a defined period of time and allows reset of the setpoint upward by up to 22 C above the setpoint programmed in memory The maximum allowable reset must be programmed into mem...

Page 71: ...ext key in the time hours minutes using a leading 0 for times before 10 o clock e g 08 31 The cursor will then advance to the AM PM designa tion If necessary press the or key to change to the opposite...

Page 72: ...ices system switches and the chiller ON OFF switch are in the ON position all 00 00 s should be programmed into the daily schedule This can be done manually for individual days or for all days by pres...

Page 73: ...f the control range the Chiller ON OFF switch is ON remote cycling devices are closed and system switches permit Normally this key is only used for servicing when the chiller is required to run but th...

Page 74: ...y If an unacceptable value is entered at any stage the following message is displayed for a few seconds and the entered value is ignored The following section shows examples of each pro grammable valu...

Page 75: ...and the run time 60 seconds This cutout value increases with time until after 270 seconds it equals the programmed cutout value If suc tion pressure falls below the calculated cutout value before 270...

Page 76: ...rd is set for GLY COL Brine cooling mode the cutout can be pro grammed between 13 3 C and 2 2 C The cutout should normally be set to 2 C below the setpoint minus the range i e 0 C setpoint 1 C range 2...

Page 77: ...time between the systems The or keys are used to change from AUTO MATIC to MANUAL lead lag If MANUAL control is desired press the or key One of the following messages will be displayed System 1 or 2...

Page 78: ...message follows TABLE 6 PROGRAMMED PRESSURE TEMPERATURE SETTINGS SETPOINTS LOCAL COOLING SETPOINT KEY SETPOINT 4 5 TO 21 1 C WATER 12 2 to 21 1 C GLYCOL RANGE 0 9 to 1 4 C REMOTE COOLING SETPOINT KEY...

Page 79: ...ack to the locally programmed value The new chilled liquid setpoint is calculated by the following equations setpoint local chilled liquid setpoint reset reset Contact Closure 1 x Max Reset Value 10 E...

Page 80: ...put is then sup plied to the PWM input on the microboard at CTB 1 ter minals 13 20 To calculate the chilled liquid setpoint for values between 4mA and 20 ma use the following for mula setpoint local c...

Page 81: ...und during daily checks unless competent and equipped to do so If in any doubt contact your local YORK Service Agent Unit Status Press the STATUS key on the keypad and ensure no fault messages are dis...

Page 82: ...water flow Check water pH glycol strength Check water pressure drop Condenser Check water flow Check water pH glycol strength Check water pressure drop Power Control Check panel condition Check all co...

Page 83: ...EMP than the programmed operating ture and confirm that the displayed value is approxi displayed limit mately correct The warning message should clear when the ambient air temperature reaches the prog...

Page 84: ...ure SYS LOW SUCTION Badly adjusted or faulty expansion Check superheat displayed valve Reduced evaporator performance Check for restricted chilled liquid flow Check for fouled tube surfaces Check supe...

Page 85: ...11 35 6530 3 35 40 5327 3 57 TEST POINT Ambient Air BAMB AMB J11 9 6 TABLE 9 TEST POINTS Oil Temperature BOT Refrigerant Circuit 1 AIOB1 J10 7 4 Refrigerant Circuit 2 AIOB1 J10 6 5 Discharge Temperat...

Page 86: ...YORK INTERNATIONAL 86 TYPICAL CONTROL PANEL WIRING Maintenance...

Page 87: ...FORM 201 24 NM2 87 YORK INTERNATIONAL TYPICAL CONTROL PANEL WIRING LD06957 8...

Page 88: ...ER PRESSURE DROP FIG 23 CONDENSER WATER PRESSURE DROP CURVE MODEL D YCWS0313SC 0373SC 0423SC F YCWS0503SC 0563SC H YCWS0613SC 0663SC CURVE MODEL E YCWS0313SC H K M YCWS0373SC 0663SC Review cutoff limi...

Page 89: ...ns pressure drops are higher than with water Spe cial care must be taken not to exceed the maximum allowed Ethylene Glycol Propylene Glycol LCHLT C Concentration Concentration w w w w 6 5 5 4 12 13 2...

Page 90: ...ater Side Pressure barg 10 3 10 3 10 3 10 3 10 3 10 3 10 3 Maximum Refrigerant Side Pressure barg 22 8 22 8 22 8 22 8 22 8 22 8 22 8 Maximum Condenser Water Flow Rate l s 11 7 11 7 11 7 18 0 18 0 18 9...

Page 91: ...FORM 201 24 NM2 91 YORK INTERNATIONAL THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN PAGE FORMAT 9...

Page 92: ...KCM 4 300 KCM YCWS0423SC 50 6 1 0 AWG 4 300 KCM 4 300 KCM 6 1 0 AWG 4 300 KCM 4 300 KCM YCWS0503SC 50 6 1 0 AWG 4 300 KCM 4 300 KCM 6 1 0 AWG 4 300 KCM 4 300 KCM YCWS0563SC 50 6 1 0 AWG 4 300 KCM 4 3...

Page 93: ...125 150 77 241 YCWS0423SC 50 99 100 125 175 79 241 YCWS0503SC 50 123 150 150 200 98 294 YCWS0563SC 50 122 150 150 200 97 294 YCWS0613SC 50 148 150 200 250 118 294 YCWS0663SC 50 147 150 200 250 117 294...

Page 94: ...613SC 50 245 250 300 350 97 294 118 294 YCWS0663SC 50 263 400 300 350 117 294 117 294 SINGLE POINT POWER SUPPLY SEE FIG 13 14 PAGE 30 31 CHILLER MODELS VOLT CODE HZ MIN 1 CIR MCA MIN N F DISC SW MIN D...

Page 95: ...of the rated load amps for all other loads included in the circuit per N E C Article 440 22 5 Circuit breakers supplied by third party vendors must be certified by local electrical standards Maximum...

Page 96: ...m unless otherwise noted 260 Different for every Model LD06952 LD06953 LD06954 FIG 25 MODELS YCWS0313SB YCWS0663SB DIMENSIONS DIMENSIONS MODELS YCWS0313SB 0663SB MODEL DIM YCWS0313SC 552 YCWS0373SC YC...

Page 97: ...1 O 548 560 560 603 603 601 601 P 254 254 254 254 254 254 254 Q 557 645 645 743 743 839 839 R 1038 1038 1038 1038 1038 1038 1038 S 813 813 813 864 864 914 914 T 406 406 406 432 432 457 457 U 394 384 3...

Page 98: ...1 YCWS0423SC 31 31 31 31 YCWS0503SC 32 32 32 32 YCWS0563SC 32 32 32 32 YCWS0613SC 32 32 35 35 YCWS0663SC 32 32 35 35 1 ISOLATOR SELECTIONS VMC TYPE CP 2 X MODEL A B C D YCWS0313SC RED RED RED RED YCWS...

Page 99: ...ILS ISOLATOR DETAILS LD01089 TYPE MAX LOAD DEFL SPRING SIZE LBS KG IN MM COLOR CP 2 28 1800 816 4 1 02 25 9 GREEN CP 2 31 2200 997 9 0 83 21 0 GRAY CP 2 32 2600 1179 3 0 74 18 7 WHITE CP 2 35 3000 136...

Page 100: ...DT DISCHARGE TEMPERATURE ECH CRANK CASE HEATER BECT CHILLED ENTERING TEMPERATURE FHP HIGH PRESSURE CUTOUT BLCT CHILLED LEAVING TEMPERATURE XCMTB COMPRESSOR MOTOR TERMINAL BOX BOP OIL PRESSURE YSV SOLE...

Page 101: ...FORM 201 24 NM2 101 YORK INTERNATIONAL SECTION 10 SPARE PARTS This information will be available at a later date 10...

Page 102: ...exchanger section of the systems If no isolation valves are installed it may be necessary to drain the complete system If glycol or similar solutions have been used in the water system or chemical ad...

Page 103: ...FORM 201 24 NM2 103 YORK INTERNATIONAL NOTES 11...

Page 104: ...1001 www york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 2001 ALL RIGHTS RESERVED Form 201 24 NM2 601...