York CodePak YK L1 L1 G4, Operation Manual

Page 1: ...ONL R 134a COOLING ONL R 134a COOLING ONL R 134a COOLING ONLY Y Y Y Y WITH MICROCOMPUTER CONTROL CENTER P WITH MICROCOMPUTER CONTROL CENTER P WITH MICROCOMPUTER CONTROL CENTER P WITH MICROCOMPUTER CO...

Page 2: ...er 160 49 PW5 Wiring Diagram With Solid State Starter 160 49 PW6 STYLES A B YK N2 N1 H1 CX A DESIGN LEVEL A or B POWER SUPPLY for 60 Hz 5 for 50 Hz COMPRESSOR CODE G4 H0 H1 H2 J1 J2 J3 J4 CONDENSER CO...

Page 3: ...y packaged YORK Solid State Starter op tional In operation a liquid water or brine to be chilled flows through the CodePak cooler where boiling refrigerant absorbs heat from the water The chilled liqu...

Page 4: ...chilled liquid tempera ture leaving the cooler Prerotation vanes PRV lo cated at the entrance to the compressor impeller com pensate for variation in load See Fig 2 Detail A The position of these vane...

Page 5: ...r action may be required to correct the interference Additionally any electronic equipment can generate EMI electromagnetic interference which depending upon the installation and magnitude may affect...

Page 6: ...r alphanumeric display The system setpoints are CHILLED LIQUID TEMPERATURE LCWT INTRODUCTION CURRENT LIMIT PULLDOWN DEMAND LIMIT CLOCK TIME OF DAY DAILY SCHEDULE 7 DAY TIME CLOCK PROGRAM MING HOLIDAY...

Page 7: ...R 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 o...

Page 8: ...c display message EVAP XXX X PSIG COND XXX X PSIG To Display OIL PRESSURE Use OIL PRESSURE display key as described on page 7 to produce the following alphanumeric dis play message OIL PRESSURE XXXX X...

Page 9: ...tional printers To Display MOTOR CURRENT Press the MOTOR CURRENT display key as described above to display motor current as a per cent of Full Load Amps FLA The message is as follows MOTOR CURRENT XXX...

Page 10: ...liday see description under HOLIDAY setpoint and the Con trol Center can be programmed usually DAILY SCHED ULE setpoint to automatically start and stop the chiller on those days so designated The oper...

Page 11: ...435 415 335 362 454 453 440 480 370 400 524 523 550 600 460 502 655 654 SupplyVoltage NONE 0 NONE 0 Range Disabled NOTE The value displayed is the actual LCWT set point For example the value displayed...

Page 12: ...ribed in the beginning of this section to produce the following message S_ M_ T_ W_ T_ F_ S_ HOLIDAY NOTED BY NOTE On the days that are designated by an the chiller will automatically start and stop p...

Page 13: ...ed by pressing the ACCESS CODE key again the operator will have ac cess to the PROGRAM key for 10 minutes When 10 minutes have elapsed access to PROGRAM key will be automatically dis abled and the ope...

Page 14: ...int Electro Mechanical Starter refer to Fig 7 1 Press and release CURRENT LIMIT setpoint key The following program prompt message is displayed CURRENT LIMIT XXX FLA 2 Use Entry keys to enter desired v...

Page 15: ...INT 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 fol lowing program prompt message is displayed TODAY...

Page 16: ...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 XX XX AM STOP XX XX AM 4 Enter the desired start and stop time pe...

Page 17: ...1 press CANCEL key and then press EN TER key PROGRAM MODE SELECT SETPOINT message is displayed To cancel one of the designated holidays perform Step 1 press ADVANCE DAY SCROLL key until the cursor app...

Page 18: ...se this key to put the pre rotation vanes under LCWT control as long as the cur rent limit setpoint is not reached which causes the current limit function to override the LCWT control If system is run...

Page 19: ...gain pressed and re leased Message No 3 is then displayed and updated every 2 seconds until either the DISPLAY DATA key is again pressed and released whereupon message No 1 is displayed or the DISPLAY...

Page 20: ...10 The mode that has been previously selected will be displayed as follows LOCAL MODE SELECTED or SERVICE MODE SELECTED or REMOTE MODE SELECTED 11 Press ADVANCE DAY key to scroll to desired mode Each...

Page 21: ...ing to maintain the leaving chilled water temperature set point or The operator has pressed the vanes OPEN key on the keypad SYSTEM RUN VANES CLOSING Displayed when the chiller is running the MicroCom...

Page 22: ...that the system is not running but will start upon application of a start signal SYSTEM SHUTDOWN PRESS STATUS Displayed when chiller is shut down on a cycling shut down safety shutdown operator must...

Page 23: ...y pressing the COMPRESSOR switch to the START position REMOTE STOP This message will be displayed when a remote device typically an Energy Management System has com manded the chiller to shut down The...

Page 24: ...y the motor controller con tacts CM 1 opening and reclosing in one second If Solid State Starter application the shutdown could have been caused by any of the following reasons The ap propriate light...

Page 25: ...key Or the message will be cleared by initiating a compressor start START SEQUENCE INITIATED Indicates that the Micro Board has received a local or remote start signal and has initiated the chiller st...

Page 26: ...Auto Zeroing Sequence that occurs 10 seconds after a chiller start is initiated Message is displayed immedi ately after the Auto Zeroing sequence has completed This indicates that one of the transduce...

Page 27: ...voltage in creases to greater than 19 7VDC MON XX XX AM AUX SAFETY SHUTDOWN The system is shut down because an external device connected to digital input boardTB1 31 Auxiliary Safety Shutdown Input h...

Page 28: ...MANUAL OIL PUMP key to stop the operation of the oil pump for less than 10 minutes of operation 3 Pre Rotation Vanes To perform this test the starter interlock terminals 3 and 4 must be jump ered to...

Page 29: ...late oil for a 50 second pre run to establish oil flow and adequate lubrication to all bearings gears and rotating sur faces within the compressor The high and low oil pressure transducers OP and the...

Page 30: ...vent the Pre rotation Vanes from opening beyond the CURRENT LIMIT setting If the load continues to decrease after the Prerotation Vanes are entirely closed the CodePak will be shut down by the Low Wat...

Page 31: ...load require ments 2 Be sure the oil pump is operating while unit is run ning 3 Check Oil Pressure display A gradual decrease in bearing oil pressure of 5 to 10 psi 34 5 to 69 kPa with constant sucti...

Page 32: ...nd leaving chilled liquid tem peratures and evaporator pressure for comparison with job design conditions This can be accomplished by pressing the CHILLED LIQUID TEMPS key and the REFRIGERANT PRESSURE...

Page 33: ...f auto restart programming jumper is not installed on the Micro Board Low Evaporator Pressure Low Oil Pressure High Condenser Pressure Evaporator Transducer or Probe Error High Discharge Temp High Oil...

Page 34: ...lled water system chilled water pump and coils Open the drains on the cooler and condenser liquid heads to assure complete drainage If Solid State Starter drain water from starter cooling loop 3 Move...

Page 35: ...RGE LINE PRE ROTATIONVANE ACTUATOR CONDENSER OIL COOLER OIL RESERVOIR PUMP SUB COOLER OIL PUMP STARTER 27073A 27073A COM PRESSOR ADAPTER MOTOR SUPPORT COVER MOTOR COOLER REFRIGERANT CHARGINGVALVE DEHY...

Page 36: ...d system consists of the oil pump oil filter oil cooler and all interconnecting oil piping and passages There are main points within the motor compressor which must be supplied with forced lubrication...

Page 37: ...or independent of the evaporator shell to en sure controlled alignment of the assembly Motor is mounted with final alignment at start up Motor drive shaft is directly connected to the com pressor shaf...

Page 38: ...38 YORK INTERNATIONAL FIG 18 SCHEMATIC DRAWING YK COMPRESSOR LUBRICATION SYSTEM LD01079...

Page 39: ...or with lock and key Electrical lugs for incoming power wiring are provided SECTION 5 OPERATIONAL MAINTENANCE OIL RETURN SYSTEM The oil return system continuously maintains the proper oil level in the...

Page 40: ...nnection at the charging valve until after the air is forced out by pumping a few strokes of the oil pump This fills the lines with oil and prevents air from being pumped into the system 3 Open the oi...

Page 41: ...of the manual switch Digital input board MON 10 00 AM Multi Unit Autostart Optional Lead Automatic Restart Contact connected to Lag Sequence upon remote the Multi Unit cycling Control command input of...

Page 42: ...start up MON 10 00 AM Motor Con CM2 or Solid Reset the device CM2 or Solid State troller Ext State Starter that caused the shut Starter has shutdown Reset RT2 down Chiller will chiller start automatic...

Page 43: ...tor Current Press compressor 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 mo...

Page 44: ...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 l...

Page 45: ...me extremely noisy quantity 8 SYMPTOM OIL PRESSURE GRADUALLY DECREASES Noted by Observation of Daily Log Sheets Oil pressure noted when pressing OIL Oil filter is dirty Change oil filter PRESSURE disp...

Page 46: ...electronic leak detector 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 t...

Page 47: ...mosphere 14 696 PSIA 760 mm Hg absolute pressure at 32 F 29 921 inches Hg absolute at 32 F NOTES PSIA Lbs per sq in gauge pressure Pressure above atmosphere PSIA Lbs per sq in absolute pressure Sum of...

Page 48: ...c tive method for evacuating and dehydrating a system in the field Although there are several methods of de hydrating a system we are recommending the follow ing as it produces one of the best results...

Page 49: ...of the drum or cylinder must be admitted to the system pressure until the sys tem pressure is raised above the point corresponding to the freezing point of the cooler liquid For water the pressure cor...

Page 50: ...ith the method shown under the Refrigerant Charging on page 49 The refrigerant level should be observed and the level recorded after initial charging HANDLING REFRIGERANT FOR DISMANTLING AND REPAIRS I...

Page 51: ...YORK INTERNATIONAL 51 FORM 160 49 O1 FIG 24 MOTOR STATOR TEMPERATURE AND INSULATION RESISTANCES 110 43 3 100 37 8 90 32 2 80 26 7 70 21 1 60 15 6 50 10 0 40 4 4 TEMPERATURE F C LD01086...

Page 52: ...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 reveali...

Page 53: ...nds 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 air blow out the t...

Page 54: ...icted oil lines passages or dirty oil fil ters If the unit is shutting down on HOT High Oil Temperature or Low Oil Pressure OP change the oil filter element Examine the oil filter element for the pres...

Page 55: ...e maintained tight are systems that provide trouble free efficient opera tion COOLER AND CONDENSER The major portion of maintenance on the condenser and cooler will deal with the maintaining the water...

Page 56: ...y 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 replace refer to page 25 Proud S...