York YGWH 115, Installation, Commissioning & Operation

Page 1: ...CHILLERS STYLE A Cooling Capacities 416 kW to 1328 kW 118 to 378 TR YGWH WATER COOLED SCREW CHILLERS Installation Commissioning Operation Maintenance FORM NO 6S6I B01C EOMA EN 0318 TO BE COMPLETED WH...

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Page 3: ...pection 3 2 4 Installation 4 1 Location Requirements 4 1 Installation of Vibration Isolators 4 1 YGWH Floor Layout Diagram 4 3 Piping Connections 4 4 Water Treatment 4 4 Pipework Arrangement 4 5 Conne...

Page 4: ...ter 7 2 Condenser and Evaporator 7 2 Working conditions 7 4 Scheduled Maintenance 7 4 8 Trouble Shooting 8 1 Competent Persons Trouble Shooting Guide 8 1 Safety Faults Cycling Stops and Warnings 8 2 S...

Page 5: ...y claims must specify the unit model serial number order number and run hours starts Model and serial number information is printed on the unit identification plate The unit warranty will be void if a...

Page 6: ...operated outside the design parameters specified in this manual Structural Support Structural support of the unit must be provided as indicated in these instructions Failure to provide proper support...

Page 7: ...own In case of emergency the control panel is fitted with an emergency stop button RED when pressed it removes the electrical supply to the control circuit thus shutting down the unit The button is lo...

Page 8: ...osure to high concentrations Long term exposure A lifetime inhalation study in rats has shown that exposure to 50 000 ppm resulted in benign tumours of the testis This is not considered to be of relev...

Page 9: ...carbon dioxide and other unidentified fragments when burned Burning may evolve irritating noxious fumes Respiratory protection Use in well ventilated areas ventilate locally Protective clothing Goggl...

Page 10: ...1 6 EN Form 6S6I B01C EOMA EN 0318 Page Left Intentionally Blank...

Page 11: ...rigerant vapour is sucked into the void created by the unmeshing of the male and female rotors Further meshing of the rotors closes the rotor threads to the suction port and progressively compresses t...

Page 12: ...ith 19 mm thick flexible closed cell foam Evaporator The evaporator is a shell and tube falling film type heat exchanger equipped with a pressure relief valve set to 20 7 Bar The evaporator is manufac...

Page 13: ...Comfort Cooling A HFC 134a 5 0 380 3 50 A Design Series G GT Compressor 115 145 180 225 D Ice storage dual conditions 5 3 400 3 50 W Water cooled 260 300 330 375 5 5 415 3 50 H High Efficiency YGWH18...

Page 14: ...increased The high pressure and temperature refrigerant vapour enters the condenser and is condensed The fully condensed and subcooled liquid refrigerant then enters the throttling device where press...

Page 15: ...ILS FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH SERIOUS INJURY OR EQUIPMENT DAMAGE Weights and Weight Distribution Refer to the unit nameplate for unit shipping weight Note that weight...

Page 16: ...20 NM9 Form 50 20 CL9 Form 50 20 NM1 Inspection The unit shipment should be checked on arrival to see that all major pieces boxes and crates are received Each unit should be checked on the trailer or...

Page 17: ...835 028W14459 000 YGWH115 YGWH145 YGWH180 YGWH225 YGWH260 YGWH300 YGWH330 YGWH375 4 Installation TheYGWHunitisshippedasasinglefactoryassembled piped wired and refrigerant charged package or nitrogen h...

Page 18: ...to level unit due to an uneven or sloping floor or foundation steel shims ground if necessary must be added beneath the isolator assemblies as necessary After the unit is levelled wedge and shim under...

Page 19: ...115 2731 1670 2937 1718 152 200 YGWH145 2731 1750 2937 1798 152 200 YGWH180 2731 1960 2937 2008 152 200 YGWH225 2731 1970 2937 2018 152 200 YGWH260 4407 1890 4613 1968 152 230 YGWH300 4407 1960 4613 2...

Page 20: ...sited during flushing It is recommended that a suitably sized by pass and valve arrangement be installed to allow flushing of the pipework system The by pass can be used during maintenance to isolate...

Page 21: ...e Corrosion Fouling PH value 25 C 6 5 to 8 0 X Conductivity 25 C s cm 800 X Chloridion mg L 200 X Sulphate ion mg L 200 X Acid wastage mg L 100 X Total Hardness mg L 200 X Calcium Hardness mg L 150 X...

Page 22: ...ditions If these methods are not available or a cooling tower is not the source of cooling water then a three way valve recirculation system can be used with control based on condenser inlet liquid te...

Page 23: ...d 7 5 metres 220 Vac Outputs Water pump starter Terminal 60 provides a 220 Vac output for water pump control Starting and stopping of pump can be achieved by a contactor and the programmed start stop...

Page 24: ...4 8 EN Form 6S6I B01C EOMA EN 0318 Customer Connections...

Page 25: ...otective conductor is properly and tightly connected to the ground Oil heater Verify that the oil heater is powered on If the chiller has not had power applied for more than 15 days the compressor are...

Page 26: ...ssioning period there should be sufficient heat load to run the unit under stable full load operation to enable the unit controls and system operation to be set up correctly and a commissioning log ta...

Page 27: ...roller will perform a pre check to ensure that if there is any the daily holiday schedule or remote interlocks to prohibit the unit to run and all safety cut outs are satisfied and the cooling or heat...

Page 28: ...d to complete mode change The ON OFF key also indicates unit status grey when unit is OFF or green when unit is operating The key will also remain grey when the unit is prevented from starting by safe...

Page 29: ...tion the correct password must be entered for the required level operator or service and the entry confirmed by the enter key to complete the access level change The alternate keypad is selected using...

Page 30: ...meter is selectable and confirmed with the TICK or cancelled with the CROSS Binary parameters e g true or false are changed by clicking the parameter item and pressing Confirm Digital parameters are c...

Page 31: ...sted V O S Evaporator Condenser Compressor System Evaporator Condenser Condenser Level Control Compressor Diagnostic Save History Clear Safeties Clear History Trend Schedule Setting Special Day Displa...

Page 32: ...l Run Hour Leaving Condenser Temp Return Condenser Temp Condenser Pressure Saturation Temp Small Temp Diff Liquid Level Condenser Liquid Flow Switch Liquid Pump Pump Total Run Hour Run Time Total Run...

Page 33: ...rt Range 0 5 to 2 0 C default 1 0 C Db O When the unit is running if the leaving chilled temperature falls below the Leaving Chilled Temp Setpoint D Db then the unit will cycle stop Range 1 0 to 2 5 C...

Page 34: ...essure Display range 0 0 to 2758 0 kPa Run Current O Actual Run Current Display range 0 0 to 1000 0 A Percent FLA O Percentage of actual Run Current divided by the FLA Display range 0 0 to 100 0 Motor...

Page 35: ...ing unit operation The faults are listed sequentially on the page with details of date time type and description of fault For detailed information on Safety Faults Cycling Stops and Warnings refer to...

Page 36: ...iquid Flow Switch 902 Mode Switch 1375 High Pressure Switch 904 Low Oil Level Switch 1376 Motor Internal Protect Power Protect 906 External Interlock 1377 Starter Running Feedback 908 Remote Switch 90...

Page 37: ...terval is set to 60 seconds This can be modified by clicking on the interval and inputting the new value into pup up dialogue range is 1 3000 seconds will start recording the selected parameter trend...

Page 38: ...um To set a new time setting click button to create a default item then click this item and change the time using the up or down buttons use the button to enable startup or shutdown timing and Confirm...

Page 39: ...tting Pages These pages are mainly for service use contact your local Johnson Controls Service Centre for details The operator can only adjust the display set the system date and time and view version...

Page 40: ...6 14 EN Form 6S6I B01C EOMA EN 0318 Page Left Intentionally Blank...

Page 41: ...Refrigerant charging and leak checking Refrigerant leaks checking Periodic refrigerant leak checking must be part of a comprehensive maintenance program Leak check the entire chiller using a calibrat...

Page 42: ...its with Oil Oil Charge YORK L oil is approved for YGWH Units and the quality of oil required is listed in the Physical Data tables YORK OIL TYPE MOISTURE CONTENT ppm Total Acid NO mgKOH ml L W 300ppm...

Page 43: ...Field Service Office for the correct condenser approach temperature Condenser water side tube cleaning procedure Two methods are used for waterside tube cleaning to remove the scale chemical and mech...

Page 44: ...d the split temperature difference between the water leaving the evaporator and the refrigerant temperature in the evaporator increases A gradual drop off in cooling capacity can also be caused by a g...

Page 45: ...ective Check site pumps valves and strainers Increase quantity of water through the condenser to the proper value Condenser water dirty Check tower fan motor blade valve and water circulation Non cond...

Page 46: ...ly reset after Low Oil Level Switch is closed Code 105 Safety Fault SYS1 Compressor Motor Protection If the 1 Motor Internal Protect DI5 is opened for over 0 5 second the 1 unit will be shut down and...

Page 47: ...ection plug is pulled out the unit will shut down and the message will be displayed This fault has to be manually reset after the sensor recovers Code 117 Safety Fault SYS1 Oil Pressure Sensor Fault W...

Page 48: ...emperature falls below 3 C for over 15 minutes the 1 unit will shut down and the message will be displayed This fault has to be manually reset after the 1 unit is stopped Code 128 Safety Fault SYS1 Mo...

Page 49: ...d the unit will cycling start automatically Code 602 Cycling Stop Condenser Liquid Flow Switch Open This cycling stop is checked 20 seconds after the Liquid Pump is running It is set whenever the Cond...

Page 50: ...ature or Return Condenser Temperature is lower than 2 0 C or Leaving Chilled Temperature or Return Chilled Temperature is lower than Low Temp Stop Setpoint and the liquid pump is turned on This warnin...

Page 51: ...the unit stop load or force unload happens This warning releases and capacity is recovered to automatic control after the 1 Motor current is less than the MLA multiplied by Over Current Percent 5 Code...

Page 52: ...71 31 32 28 29 2 5 59 23 17 21 01 1 9 07 17 33 15 77 Temperature C 17 19 21 23 25 27 29 31 33 35 37 Resistance k 14 37 13 1 11 96 10 93 10 9 16 8 4 7 71 7 085 6 517 6 Temperature C 0 3 6 9 12 15 18 21...

Page 53: ...s 11 33 13 38 16 48 20 58 Maximum working pressure barg Refrigerant System High pressure side barg Power supply voltage V System water volume Air Conditioning l Air temperature surrounding unit C Min...

Page 54: ...umber of Passes Connection sizes inch 8 8 8 8 Type Number of Passes Connection sizes inch 8 8 8 8 Length mm 4807 4835 4872 4872 Width mm 1925 1988 2086 2086 Height mm 2156 2174 2156 2156 Shipping kg 7...

Page 55: ...YGWH115 YGWH145 YGWH180 YGWH225 MODEL A B C D E F L W H YGWH115 648 570 190 180 400 435 3118 1710 1739 YGWH145 698 590 195 180 425 450 3131 1797 1796 YGWH180 713 650 230 230 460 520 3156 1975 1932 YG...

Page 56: ...YGWH260 YGWH300 YGWH330 YGWH375 MODEL A B C D E F L W H YGWH260 860 700 195 195 460 485 4807 1925 2156 YGWH300 860 700 195 230 460 520 4835 1988 2174 YGWH330 860 700 197 229 485 545 4872 2086 2156 YG...

Page 57: ...Contact your local Johnson Controls Sales and Service Centre for information and please quote the unit model number and serial number Recommended Compressor Oils The correct type of oil must be used i...

Page 58: ...10 2 EN Form 6S6I B01C EOMA EN 0318 Page Left Intentionally Blank...

Page 59: ...isposed of Isolate the unit heat exchanger from the external water systems and drain the heat exchanger section of the system If no isolation valves are installed it may be necessary to drain the comp...

Page 60: ...EOMA EN 0318 6S6I B01C EOMA EN 1217 Johnson Controls reserve all rights to product design changes without notification Product performance detailed is agreed in the contract this manual is for refere...