2.2.1 Attachment E 201.24-NM3 (901).pdf

INSTALLATION, OPERATION AND

MAINTENANCE

YCWS

WATER COOLED LIQUID CHILLERS

New Release Form 201.24-NM3 (901)

60 HERTZ

STYLE A

REFRIGERANT TYPE: R-22

00546VIP

YCWS WATER COOLED LIQUID CHILLERS

YCWS0100SC – 0240SC

91 TONS THROUGH 216 TONS

(320kW THROUGH 760kW)

YORK INTERNATIONAL2

FORM 201.24-NM3 (901)

SECTION 1 SUPPLIER INFORMATION

Introduction Warranty Safety

Standards for Safety Responsibility for Safety About this Manual Misuse of Equipment

Suitability for Application Structural Support Mechanical Strength General Access Pressure Systems Electrical Refrigerants and Oils High Temperature and Pressure Cleaning

Emergency Shutdown Material Safety Data

SECTION 2 PRODUCT DESCRIPTION

Introduction Compressor Motor Starting Capacity Control

Oil Separator Oil Cooler Refrigerant Circuits Condenser Cooler Power and Control Panels Microprocessor Controls Motor Current Protection

Motor Protector Module Current Overload Thermal Overload Current Unbalance / Loss of Phase Improper Phase Sequence

Keypad Controls Status Key Display Keys Print Keys Entry Keys Setpoints Keys Clock Keys Program Key

Accessories and Options Alternative Refrigerants

Electrical Options Multiple Point Power Supply Connection (Standard) Single-Point Power Supply Connection

65 Ka High Voltage Protection Building Automation System (BAS) Interface ... 18

Vibration Isolators Neoprene Pad Isolators 1" Spring Isolators 2" Seismic Spring Isolators Flange Kits (150 PSI) Mechanical Gauge Kit Language LCD and Keypad Flow Switch Accessory Printer

Nomenclature Functional Description

SECTION 3 TRANSPORTATION, HANDLING

AND STORAGE

Delivery and Storage

Inspection Moving the Unit

Lifting by Crane / Hoist

Lifting by Fork Lift

Control Panel Removal

Lifting Weights

SECTION 4 INSTALLATION

Location Requirements Installation of Vibration Isolators Pipework Connection

General Requirements Water Treatment

Glycol Solutions Pipework Arrangement

Recommendations of the Building Services Research Association

Connection Types & Sizes Cooler Connections Option Flanges

Refrigerant Relief Valve Piping Condenser Cooling Liquid Systems

Direct Pressure Control Inlet Temperature Control

Electrical Connection Power Wiring

Units with Single-Point Power Supply Wiring ... 27 Units with Multi Point Power Supply Wiring Control Transformer Primary Voltage Tappings 27 Remote Emergency Stop Device

Common Input Section Wiring Chilled Liquid Pump Common Run Signal System Alarm

TABLE OF CONTENTS

3YORK INTERNATIONAL

TABLE OF CONTENTS (CONT’D)

Control Panel Wiring Flow Switch Remote Run / Stop Remote Print (PNT) Remote Setpoint Offset – Temperature Remote Setpoint Offset – Current

Customer Wiring Data Connection Diagram Legend and Notes

SECTION 5 COMMISSIONING

Commissioning Preparation Preparation – Power Off

First Time Start-up

SECTION 6 UNIT OPERATION

Unit Operation General Description

Start-up Normal Running and Cycling Shutdown

SECTION 7 MICROPANEL

1. INTRODUCTION & PHYSICAL DESCRIPTION

1.1 System Switches 1-2

1.2 Internal Clock & Memory Backup Battery

1.3 Power Supply Board

1.4 Input / Output Expansion Board

1.5 Relay Output Board

1.6 Circuit Breakers

1.7 Current Transformers (C.T.)

1.8 Transformers

1.9 Motor Protector Modules

1.10 Logic Section

1.11 Remote Start / Stop

1.12 Remote Current Reset

1.13 Remote Setpoint Reset

1.14 Control Panel

1.15 Remote Emergency Stop Device

1.16 Common Input Power Section Voltage Free Contacts

1.17 Alarm Contacts

1.18 Chilled Liquid Pump Contact

1.19 Run Contact

1.20 Anti-Recycle Timer

1.21 Anti-Coincidence Timer

1.22 Compressor Heater Control

1.23 Pumpdown (LLSV) Control

1.24 Lead / Lag Compressor Selection

2. CONTROL PANEL PROGRAMMING AND DATA ACCESS

2.1 Display and Status Keys

2.2 Program and Setup Keys

3. STATUS KEYS

3.1 General

YORK INTERNATIONAL4

TABLE OF CONTENTS (CONT’D)

3.2 General Status Messages

3.3 Unit Warnings

3.4 Anticipation Control Status Messages

3.5 Unit Fault Status Messages

3.6 System Fault Status Messages

3.7 Printout on Fault Shutdown

4. DISPLAY KEYS

4.1 General

4.2 Chilled Liquid Temps Key

4.3 System Data Keys

4.4 Ambient Temp Key

4.5 Motor Current Key

4.6 Operating Hrs / Start Counter Key

4.7 Options Key and Dip Switch Settings

4.8 DIP Switch Settings

4.9 Function Key

5. PRINT KEYS

5.1 General

5.2 Oper Data Key

5.3 Oper Data – Local Display Messages

5.4 Oper Data – Remote Printout

5.5 History Key

5.6 History – Local Display Messages

5.7 History – Remote Printout

5.8 Local Printer Option

6. ENTRY KEYS

6.1 General

6.2 Numerical Keypad

6.3 Enter Key

6.4 Cancel Key

6.5 �� Keys

7. SETPOINT KEYS AND CHILLED LIQUID CONTROL

7.1 General

7.2 Chilled Liquid Temperature Control

7.3 Slide Valve Control

7.4 Load Timers

7.5 Slide Valve Position

7.6 Compressor Starting and Loading Sequence

7.7 Compressor Loading

7.8 Loading Limiting

7.9 Compressor Unloading and Shutdown Sequence

7.10 Local Cooling Setpoints Key

7.11 Remote Cooling Setpoints Key

5YORK INTERNATIONAL

TABLE OF CONTENTS (CONT’D)

8. CLOCK KEYS

8.1 General

8.2 Set Time / Date Key

8.3 Set Schedule / Holiday Key

8.4 Manual Override Key

9. PROGRAM KEYS

9.1 General

9.2 User Programmable Values

9.3 Input /Output Display Routine

10. EMS / BAS INTERFACE CARD KITS

10.1 EMS / BAS Remote Temperature Reset

10.2 BAS / EMS Remote Temperature Reset Option

SECTION 8 MAINTENANCE

General Requirements Daily Maintenance Scheduled Maintenance Standard Units

Competent Persons Troubleshooting Guide Sensor Calibration Charts Typical Control Panel Wiring

SECTION 9 TECHNICAL DATA

Flow rate and Pressure Drop Graphs Physical Data / Sound Data Electrical Data Dimensions

Isolator Selection Data Isolator Details Sound Data Compressors

SECTION 10 SPARE PARTS

Recommended Spare Parts Recommended Compressor Oils Associated Drawings

SECTION 11 DECOMMISSIONING, DISMANTLING AND DISPOSAL

General

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INTRODUCTION

YORK YCWS chillers are manufactured to the highest design and construction standards to ensure high per-formance, reliability and adaptability to all types of air conditioning installations.

The unit is intended for cooling water or glycol solu-tions and is not suitable for purposes other than those specified in this manual.

This manual contains all the information required for correct installation and commissioning of the unit, to-gether with operating and maintenance instructions.

This manual should be read thoroughly before attempt-ing to operate or service the unit.

All procedures detailed in the manuals, including in-stallation, commissioning and maintenance tasks must only be performed by suitably trained and qualified personnel.

The manufacturer will not be liable for any injury or damage caused by incorrect installation, commission-ing, operation or maintenance resulting from a failure to follow the procedures and instructions detailed in the manuals.

WARRANTY

York International warrants all equipment and materi-als against defects in workmanship and materials for a period of one year from initial start-up, or eighteen months from delivery (whichever occurs first) unless extended warranty has been agreed upon as part of the contract.

The warranty is limited to parts only replacement and shipping of any faulty part, or sub-assembly which has failed due to poor quality or manufacturing errors. All claims must be supported 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 model, serial number, order number and run hours/starts. These de-tails are printed on the unit identification plate.

The unit warranty will be void if any modification to the unit is carried out without prior written approval from York International.

For warranty purposes, the following conditions must be satisfied:

• The initial start of the unit must be carried out by trained personnel from an Authorized YORK Ser-vice Center. See Commissioning, page 33.

• Only genuine YORK approved spare parts, oils and refrigerants must be used.

• All the scheduled maintenance operations detailed in this manual must be performed at the specified times by suitably trained and qualified personnel.

See Maintenance Section, page 81.

• Failure to satisfy any of these conditions will auto-matically void the warranty.

SAFETY

Standards for Safety

YCWS chillers are designed and built within an ISO 9002 accredited design and manufacturing organiza-tion. The chillers comply with the applicable sections of the following Standards and Codes:

• ANSI/ASHRAE Standard 15, Safety Code for Me-chanical Refrigeration

• ANSI/NFPA Standard 70, National Electrical Code (N.E.C.)

• ASME Boiler and Pressure Vessel Code, Section VIII Division 1

• ARI Standard 550/590-98, Centrifugal and Rotary Screw Water Chilling Packages

In addition, the chillers conform to Underwriters Labo-ratories (U.L.) for construction of chillers and provide U.L./cU.L. listing label.

GENERAL CHILLER INFORMATION & SAFETY

General Chiller Information & Safety

7YORK INTERNATIONAL

RESPONSIBILITY FOR SAFETY

Every care has been taken in the design and manufac-ture of the unit to ensure compliance with the safety requirements listed above. However, the individual op-erating or working on any machinery is primarily re-sponsible for:

Personal safety, safety of other personnel, and the machinery.

Correct utilization of the machinery in accordance with the procedures detailed in the manuals.

ABOUT THIS MANUAL

The following terms are used in this document to alert the reader to areas of potential hazard.

A Warning is given in this document to identify a hazard which could lead to per-sonal injury. Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the in-struction.

A Caution identifies a hazard which could lead to damage to the machine, damage to other equipment and/or envi-ronmental pollution. Usually an instruc-tion will be given, together with a brief explanation and the possible result of ig-noring the instruction.

A Note is used to highlight additional infor-mation which may be helpful to you but where there are no special safety implications.

The contents of this manual include suggested best working practices and procedures. These are issued for guidance only, and they do not take precedence over the above stated individual responsibility and/or local safety regulations.

This manual and any other document supplied with the unit, are the property of YORK which reserves all rights.

They may not be reproduced, in whole or in part, with-out prior written authorization from an authorized YORK representative.

MISUSE OF EQUIPMENT

Suitability for Application

The unit is intended for cooling water or glycol solutions and 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 may result in injury to the op-erator, or damage to the equipment.

The unit must not be operated outside the design pa-rameters specified in this manual.

Structural Support

Structural support of the unit must be provided as indi-cated in these instructions. Failure to provide proper support may result in injury to the operator, or damage to the equipment and/or building.

Mechanical Strength

The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or structures. Ad-ditional components must not be mounted on the unit.

Any such extraneous loads may cause structural fail-ure and may result in injury to the operator, or damage to the equipment.

General Access

There are a number of areas and features which may be a hazard and potentially cause injury when working on the unit unless suitable safety precautions are taken.

It is important to ensure access to the unit is restricted to suitably qualified persons who are familiar with the potential hazards and precautions necessary for safe operation and maintenance of equipment containing high temperatures, pressures and voltages.

Pressure Systems

The unit contains refrigerant vapor and liquid under pres-sure, release of which can be a danger and cause injury.

The user should ensure that care is taken during instal-lation, operation and maintenance to avoid damage to the pressure system. No attempt should be made to gain access to the component parts of the pressure system other than by suitably trained and qualified personnel.

Electrical

The unit must be grounded. No installation or mainte-nance work should be attempted on the electrical equip-ment with out first switching OFF, isolating and lock-ing-off the power supply. Work on live equipment must

YORK INTERNATIONAL8

only be carried out by suitably trained and qualified personnel. No attempt should be made to gain access to the control panel or electrical enclosures during nor-mal operation of the unit.

Refrigerants and Oils

Refrigerants and oils used in the unit are generally non-toxic, non-flammable and non-corrosive, and pose no special safety hazards. Use of gloves and safety glasses are, however, recommended when working on the unit.

The build up of refrigerant vapor, from a leak for ex-ample, does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation. For more comprehensive 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 temperature and pressure cleaning methods (e.g.

steam cleaning) should not be used on any part of the pressure system as this may cause operation of the pres-sure relief device(s). Detergents and solvents which may cause corrosion should also be avoided.

EMERGENCY SHUTDOWN

In case of emergency the electrical option panel is fitted with an emergency stop switch CB3 (Circuit Breaker 3). Separate Circuit Breakers, CB1 (System 1) and CB2 (System 2), can also be used to stop the respective sys-tem in an emergency. When operated, it removes the electrical supply from the control system, thus shutting down the unit.

9YORK INTERNATIONAL

MATERIAL SAFETY DATA

SAFETY DATA R-22

Toxicity Low.

Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. R22

In Contact With Skin may be slightly irritant and liquid has a degreasing effect. Thaw affected areas with water. Remove contaminated clothing carefully - may adhere to skin in case of freeze burns. Wash affected areas with plenty of warm water. If symptoms occur (irritation or blistering) obtain medical attention.

In Contact With Eyes Vapor has no effect. Liquid splashes or spray may cause freeze burns. Immediately irrigate with eyewash solution or clean water for at least 10 minutes. Obtain immediate medical attention.

Highly unlikely to occur - but should this occur freeze burn will occur. Do not induce vomiting.

Ingested Provided patient is conscious, wash mouth with water and give about (0.5 pint) 250 ml to drink.

Obtain immediate medical attention.

High levels of vapor concentration initially produce stimulation and then depression of the central nervous system causing headaches and giddiness and may lead to unconsciousness. Can prove suddenly fatal if the exposure has been severe.

Inhalation At higher concentration there is a danger from asphyxiation due to reduced oxygen content of atmosphere. Remove patient to fresh air, keep warm and at rest. Administer oxygen if necessary.

Apply artificial respiration if breathing has ceased or shows signs of failing. In event of cardiac arrest apply external cardiac massage. Obtain immediate medical attention.

Further Symptomatic and supportive theory is indicated. Cardiac sensitization has been described which

Medical Advice may, in the presence of circulating catecholamines such as adrenaline, give rise to cardiac arrythmia and subsequent arrest following exposure to high concentrations.

A lifetime inhalation study in rats and mice gives a small excess in salivary gland tumors in male

Long Term Exposure rats only at 50,000 ppm, 10,000 ppm showed no effect. This information suggests 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 presence of naked flames, red hot surfaces and high moisture levels.

Hazardous Reactions May react violently with sodium, potassium, barium and all other alkali and alkaline earth metals.

Incompatible materials: Magnesium and alloys containing more than 2% magnesium.

Hazardous Decomposition Halogen acids formed by thermal decomposition.

Products

Avoid inhalation of high concentrations of vapors. Atmospheric concentrations should be minimized

General Precautions and kept as low as reasonably practicable below the occupational exposure limit. The vapor is heavier than air and collects at low level and in confined areas. Ventilate by extraction at lowest levels.

Respiratory Protection Where doubt exists on atmospheric concentration, HSE approved breathing apparatus should be worn. This should be self-contained or of the long breather type.

Storage Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources of heat such as radiators. Keep at temperatures not exceeding 113°F (45°C).

Protective Clothing Wear overalls, impervious gloves and goggles/face protection.

Ensure suitable personal protective clothing and respiratory protection is worn. Provided it is safe to do so, isolate the source of the leak. Allow small spillages to evaporate provided there is suitable

Spill / Leak Procedure ventilation. Large spillages: Ventilate area. Contain spillages with sand, earth or any suitable absorbent material. Prevent liquid from entering drains, sewers, basements and work pits since vapor may create a suffocating atmosphere.

Disposal Best to recover and recycle. If this is not possible, destruction is to be in an approved facility which is equipped to absorb and neutralize acids and other toxic processing products.

Fire Extinguishing Data Non-flammable.

Containers Fire exposed containers should be kept cool with water sprays. Containers may burst if overheated.

Fire Fighting

Self contained breathing apparatus and protective clothing must be worn in fire conditions.

Protective Equip.

REFRIGERANT DATA:

YORK INTERNATIONAL10

MATERIAL SAFETY DATA

Section 1 – PRODUCT NAME AND INFORMATION

Product (Trade Name and Synonyms): YORK “L” Oil Chemical Name: Ester Chemical Family: Polyol Ester Formula: Proprietary CAS#: Proprietary

Section 2 – COMPONENTS AND HAZARD STATEMENT

This product is non-hazardous. The product contains no known carcinogens. No special warning labels are required under OSHA 29 CFR 1910.1200.

Section 3 – SAFE HANDLING AND STORAGE

Handling - Do not take internally. Avoid contact with skin, eyes, and clothing. Upon contact with skin, wash with soap and water. Flush eyes with water for 15 minutes and consult physician. Wash contaminated clothing before reuse.

Storage - Keep container tightly sealed when not in use. Product is hygroscopic. Storage under nitrogen 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, Percent by Volume: 0% Odor: Mild, distinct Solubility in Water: Negligible Evaporation Rate (butyl acetate=1): Nil

Section 5 – FIRE AND EXPLOSION HAZARDS

Flash Point (by Cleveland Open Cup): 230-300°C Flammable Limits: Not Established Auto-Ignition Temperature: no data HMIS Ratings:

Health: 0 Flammability: 1 Reactivity: 0

Extinguishing Media: Dry chemical; CO foam; water fog (see below)

Unusual Fire and Explosion Hazards: None Special Fire Fighting Techniques: Burning fluid may evolve irritating/noxious fumes.

Firefighters should use NIOSH/MNSA-approved self-contained breath-ing apparatus. Use water fog to cool fire-exposed containers. USE WATER CAREFULLY NEAR EXPOSED/BURNING LIQUIDS. May cause frothing and splashing of hot materials.

11YORK INTERNATIONAL

Section 6 – REACTIVITY DATA

Stability: Stable Hazardous Polymerization: Will not occur Incompatible Materials: Strong oxidizers, caustic or acidic solutions Conditions to Avoid: Excessive heat Hazardous Decomposition Products: Analogous compounds evolve carbon monoxide, carbon dioxide, and other unidentified fragments when burned. See Section 5.

This product may degrade some paints and rubber materials.

Section 7 – HEALTH HAZARD DATA

Threshold Limit Value: Not established Situations to Avoid: Avoid breathing oil mists First Aid Procedures:

Ingestion: Consult physician at once. May cause nausea and diarrhea.

Inhalation: Product is not toxic by inhalation. If oil mist is inhaled, remove to fresh air and consult physician.

To the best of our knowledge, the toxicological properties of these compounds have not been fully investigated.

Analogous compounds are considered to be essentially non-toxic.

Section 8 – PERSONAL PROTECTION INFORMATION

Respiratory Protection: Use in well ventilated area Ventilation: Local exhaust Protective Gloves: Strongly recommended, especially for prolonged exposure.

Eye/Face Protection: Goggles

Firefighters should use NIOSH/MNSA-approved self-contained breathing apparatus. Use water fog to cool fire-exposed containers. USE WATER CAREFULLY NEAR EXPOSED/BURNING LIQUIDS. May cause frothing and splashing of hot material.

Section 9 – SPILL OR LEAK PROCEDURES

In Case of Spill: Wear suitable protective equipment, especially goggles. Stop source of spill. Dike spill area. Use absorbent materials to soak up fluid (i.e. sand, sawdust, and commercially available materials).

Wash spill area with large amounts of water. Properly dispose of all materials.

Section 10 – WASTE DISPOSAL METHODS

Incinerate this product and all associated wastes in a licensed facility in accordance with Federal, State, and local regulations.

The information in this material safety data sheet should be provided to all who use, handle, store, transport, or are otherwise exposed to this product. YORK believes the information in this document to be reliable and up to date as of the date of publication, but makes no guarantee that it is.

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TO MAINTAIN PAGE FORMAT.

13YORK INTERNATIONAL

INTRODUCTION

YORK YCWS chillers are designed for water or wa-ter-glycol cooling.

All models are designed for indoor installation. The units are completely assembled with all interconnect-ing refrigerant piping and internal wiring, ready for field installation.

The unit consists of 2 screw compressors in a corre-sponding number of separate refrigerant circuits, a shell and tube DX evaporator, a water cooled condenser and oil separators for each circuit.

Before delivery, the unit is pressure tested, evacuated, and fully charged with refrigerant and oil in each of the independent refrigerant circuits. After assembly, an operational test is performed with water flowing through the cooler to ensure that each refrigerant cir-cuit operates correctly.

The unit framework is fabricated using heavy-gauge galvanized steel which is zinc phosphate pre-treated and powder coated to minimize corrosion.

Compressor

Twin helical semi-hermetic screw compressors, are provided to ensure high operational efficiencies and reliable performance. Capacity control is achieved through a single slide valve. The compressor is a posi-tive displacement type characterized by two helically grooved rotors which are manufactured from forged steel. The 60 Hz motor operates at 3600 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-hermetic, rotary twin screw type and includes the following items:

Two screw rotors, with asymmetric profiles, manufac-tured from forged steel.

A cast iron compressor housing precision machined to provide optimal clearance for the rotors.

An internal discharge check valve to prevent rotor back-spin during shutdown.

An acoustically tuned, internal discharge muffler to minimize noise, while optimizing flow for maximum performance.

Discharge and suction shut-off service valves.

A reliable suction gas cooled high efficiency, accessible hermetic motor with redundant overload protection us-ing both thermistor and current overload protection.

A suction gas screen and serviceable, 0.5 micron full flow oil filter within the compressor housing.

Refrigerant gas is injected into the void created by the unmeshing of the five lobed male and seven lobed fe-male rotor. Further meshing of the rotors closes the rotor threads to the suction port and progressively compresses the gas in an axial direction to the discharge port. The

SECTION 2

PRODUCT DESCRIPTION

1 COMPRESSOR

2 COOLER

3 CONDENSER

4 POWER SECTION - SYSTEM 1

5 COMMON INPUT SECTION

6 POWER SECTION - SYSTEM 2

7 CONTROL PANEL

FIG. 1 – YCWS WATER COOLED LIQUID CHILLER

00546VIP

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gas is compressed in volume and increased in pressure before exiting at a designed volume at the discharge end of the rotor casing. Since the intake and discharge cycles overlap, a resulting smooth flow of gas is maintained.

The rotors are housed in a cast iron compressor hous-ing precision machined to provide optimal clearances for the rotors. Contact between the male and female rotor is primarily rolling on a contact band on each of the rotor’s pitch circle. This results in virtually no ro-tor wear and increased reliability.

The compressor incorporates a complete anti-friction bearing design for reduced power input and increased reliability. Four separated, cylindrical, roller bearings handle radial loads. Angular-contact ball bearings handle axial loads. Together they maintain accurate rotor positioning at all pressure ratios, thereby mini-mizing leakage and maintaining efficiency. A springless check valve is installed in the compressor discharge housing to prevent compressor rotor backspin due to system refrigerant pressure gradients during shutdown.

Motor cooling is provided by suction gas from the evaporator flowing across the motor. Redundant over-load protection is provided using both thermistor and current overload protection.

The compressor is lubricated by removing oil from the refrigerant using an external oil separator.

A 350 watt (115V 1 Ø 60 Hz) immersion heater is lo-cated in the compressor. The heater is temperature ac-tivated to prevent refrigerant condensation.

Motor 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 limited to approximately 33% LRA for the first 4 to 10 seconds, with current increasing to normal running current when the Delta connection is completed.

When the microprocessor initiates a start signal to run a compressor, the applicable relays are energized. The transition of the relay contacts enable the ‘Star’ con-nection of the motor start. The ‘Star’ connection of the motor start is enabled for 4 to 10 seconds depending upon motor current as sensed by the microprocessor.

Normally, the transition to Delta takes 10 seconds if current is below 125% FLA. If motor current exceeds 125% FLA, the transition is made to Delta as long as the “Star” has been enabled for at least 4 seconds.

Capacity Control

The compressors will start at the minimum load posi-tion and provide a capacity control range from 10% to 100% per compressor using a continuous function slide valve. The microprocessor controlled output pressure regulating capacity control valve will command com-pressor capacity independent of control valve input pres-sure and balance the compressor capacity with the cool-ing load.

FIG. 2 – SCREW COMPRESSOR

Product Description

LD03668

SUCTION

GAS IN

MOTOR

TERMINALS

LIFTING LUG

THREADED HOLE

OIL

HEATER

ECONOMIZER

GAS IN

DISCHARGE CASE OIL INLET FROM CONDENSER CODING COIL

DISCHARGE

GAS OUT

OIL FILTER BLEED &

EVACUATION POINT

OIL FILTER

COVER PLATE

CAPACITY CONTROL SOLENOID

(CAPACITY CONTROL, 3-WAY VALVE,

IS LOCATED UNDER THE SOLENOID)

LIFTING LUG

THREADED

HOLE

OIL PRESSURE

TRANSDUCER

LOCATION

ROTORSTATOR

LOCKING BOLT

15YORK INTERNATIONAL

The automatic spring return of the capacity control valve to the minimum load position will ensure com-pressor starting at minimum motor load.

OIL SEPARATOR

Each circuit has a high efficiency, augmented gas im-pingement type oil separator to maximize oil extrac-tion without fragile media to break down.

The oil separator, is mounted in the discharge line of the compressor. The high pressure discharge gas is forced around a 90 degree bend. Oil is forced to the outside of the separator through centrifugal action and captured on wire mesh where it drains to the bottom of the oil separator and into the compressor.

The oil drains back into the compressor through a re-placeable 0.5-3.0 micron oil filter, and oil supply sole-noid, is at high pressure. This high pressure “oil injec-tion” forces the oil into the compressor where it is grav-ity fed to the rotors and bearings for lubrication.

After lubricating the rotor and bearings, it is injected through orifices on a closed thread near the suction end of the rotors. The oil is automatically injected because of the pressure difference between the discharge pres-sure and the reduced pressure at the suction end of the rotors. This lubricates the rotors as well as provides an oil seal against leakage around the rotors to assure re-frigerant compression (volumetric efficiency).

The oil also provides cooling by transferring much of the heat of compression from the gas to the oil keeping discharge temperatures down and reducing the chance for oil breakdown.

Oil injected into the rotor cage flows into the rotors at a point about 1.2 x suction. This assures that a required minimum differential of at least 26 psi (1.8 bar) exists between discharge and 1.2 x suction, to force oil into rotor case, a minimum of 9 psi (0.6 bar) is all that is required to assure protection of the compressor. Oil pressure is measured as the difference between dis-charge pressure and the pressure of the oil entering the rotor case.

Maximum working pressure of the oil separator is 31 bar (450 psi). The oil level should be above the mid-point of the “lower” oil sight glass when the compres-sor is running. The oil level should never be above the top of the “upper” sight glass.

Oil temperature control is provided through liquid in-jection activated by the microprocessor, utilizing a tem-perature sensor, and a solenoid valve.

OIL COOLER

Compressor oil cooling is provided by refrigerant liq-uid, which is injected into the rotor suction when the temperature setpoint has been exceeded.

REFRIGERANT CIRCUITS

Each refrigerant circuit uses copper refrigerant pipe formed on computer controlled bending machines to reduce the number of brazed joints resulting in a reli-able and leak resistant system.

Liquid line components include: a manual shut-off valve with charging port, a high absorption removable core filter-drier, a solenoid valve, a sight glass with moisture indicator, and a thermostatic expansion valve.

Suction lines are covered with closed-cell insulation.

CONDENSER

The dual refrigerant circuit water-cooled condenser is a cleanable shell and tube type with seamless external finned 19 mm OD copper tubes rolled into tube sheets.

The design working pressures are 150 psi (10 bar g) on the waterside and 330 PSIG (23 bar) on the refrigerant side which is protected by pressure relief valve(s).

The condenser has removable steel water heads. The water nozzles are provided with grooves for victualic couplings.

COOLER

The 4 pass dual circuit shell and tube type direct ex-pansion (DX) evaporator has chilled liquid circulating across the tubes from one end to the other. The design working pressures of the cooler are 150 psi (10 bar) on the waterside (shell) and 300 psi (20 bar) on the refrig-erant side (tubes) which is protected by pressure relief valve(s).

The water baffles are fabricated from galvanized steel to resist corrosion. Removable heads are provided for access to internally enhanced, seamless, copper tubes.

Water vent and drain connections are included. The cooler is insulated with flexible closed-cell foam.

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The water nozzles are provided with grooves for victualic couplings and should be insulated by the con-tractor after pipe installation.

POWER AND CONTROL PANELS

All controls and motor starting equipment are factory wired and function tested. The panel enclosures are designed to NEMA 1(IP33) and are manufactured from powder painted galvanized steel.

The panel is divided into power sections for each elec-trical system, a control section and a common input section. Each section has separate hinged, latched, and gasket sealed doors.

Each power section contains:

Compressor starting contactors, control circuit serving compressor, compressor contactor coils and compres-sor motor overloads.

The current transformers for the compressor motor overloads sense each phase, as an input to the micro-processor. This protects the compressor motors from damage due to: low input current, high input current, unbalanced current, single phasing, phase reversal, and compressor locked rotor.

The control section contains:

On/Off toggle switch, microcomputer keypad and dis-play, microprocessor board (ARB), I/O expansion board (AIOB), power supply board (APB) and customer ter-minal block (-XTB1).

MICROPROCESSOR CONTROLS

The microprocessor has the following functions and displays:

A liquid crystal 40 character display with text provided on two lines and light emitting diode backlighting for outdoor viewing.

A color coded, 35 button, sealed keypad with sections for Display, Entry, Setpoints, Clock, Print, Program and the unit Auto/Off switch.

The standard functions include: water or glycol cool-ing, automatic pump down, demand load limiting from external building automation system input, remote re-set liquid temperature reset input, unit alarm 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 (EPROM) to eliminate unit failure due to AC power failure. The programmed setpoint is stored in a lithium battery backed memory.

MOTOR CURRENT PROTECTION

The microprocessor motor protection provides high cur-rent protection to assure that the motor is not damaged due to voltage, excess refrigerant, or other problems that could cause excessive motor current.

If the motor current exceeds the 115% FLA trip point after 3 seconds of operation on Star/Delta starter, the microprocessor will shut the system down and lock it out after one fault. A manual reset of the respective system switch is required to clear the fault and restart the system. A thorough check of the motor, wiring, and refrigerant system should be carried out before restart-ing a system that has faulted on high motor current.

The microprocessor also provides low motor current protection when it senses a motor current less than 10% FLA. Low motor current protection is activated 4 seconds after start on Star/Delta to allow the motor to start. The microprocessor will shut the system down whenever low motor current is sensed and will lock out a system if three faults occur in 90 minutes. Once a system is locked out on Low Motor Current, it must be manually reset with the system switch.

The microprocessor also senses low motor current whenever a High Pressure Cutout (HPCO) or Motor Protector (MP) contact opens. The MP and HPCO con-tacts are connected in series with the motor contactor.

Whenever either of these devices are open, the contactor de-energizes and the motor shuts down. Since the mi-croprocessor is sending a run signal to the contactor, it senses the low motor current below 10% FLA and shuts the system down.

Product Description

17YORK INTERNATIONAL

Motor Protector Module

The mechanical motor protector module provides ther-mal and current motor overload protection. This mod-ule protects against phase to phase current imbalance, over current, under current, and phase rotation. The module, mounted in the power panel, utilizes a 7 seg-ment display which provides operating status and fault diagnostic information. The 7 segment display will dis-play either a stationary or a flashing alphanumeric value which can be decoded by the operator:

Whenever a motor protector trips, the motor protector contacts wired in series with the motor contacts, open and the motor contactor de-energizes allowing the mo-tor to stop. The microprocessor senses the low motor current and shuts the system down. The microproces-sor will try two more starts before locking the system out. The system locks out because the motor protector is a manual reset device. After the first start the protec-tor contacts will be open, thus preventing the motor contactors from energizing. Power must be removed and re-applied to reset the module.

Current Overload

The protector module uses integral current transform-ers per phase to provide protection against rapid cur-rent overload conditions. The module responds to changes in current and must be set-up using the DIP switches located on the module (refer to Section 5 for details). Integral trip curves allow for in-rush currents during Star/Delta starting without nuisance tripping.

Thermal Overload

Three PTC (positive temperature coefficient) ther-mistors in the motor windings of each phase provide thermal protection. The sensor resistance stays rela-tively constant at 1 kW until a temperature of 266°F (130°C) is sensed. The sensor experiences a rapid rise in resistance beyond this temperature. Whenever the resistance of one of the sensors reaches 13 kW, the mod-ule 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 Unbalance (Loaded & Unloaded) Loss of Phase

A 2 second delay at start-up allows for any unbalances resulting during normal starting conditions. After this initial delay, the protector module compares the “Op-erating Current” to the measured half line current. The “Operating Current” is given by 0.65 x factory over-load current setting.

An unloaded compressor condition occurs when any measured half line current is less than the “Operating Current.” A current unbalance exceeding an unloaded level of 25% will result in the motor pilot circuit being de-energized.

A loaded compressor condition occurs when any mea-sured half line current is greater than or equal to the “Operating Current.” A current unbalance exceeding a loaded level of 17% will result in the motor pilot cir-cuit being de-energized.

Improper Phase Sequence

The protector module calculates the phase sequence at start-up using the three current transducers to deter-mine whether the three phase sequence on the load side of the main contactor is miswired. Upon detection of a miswired motor load, the module will de-energize the main contactor pilot circuit within 50 millisecond re-sponse time.

KEYPAD CONTROLS

For a detailed description of the keypad controls refer to the Microprocessor Based Control System Operat-ing Section 7.

Status Key

This key provides a display of the current operational and/or fault status of the unit or the individual refriger-

0 NORMAL - NO FAULT DETECTED

FLASHING “0” MOTOR OFF OR UNLOADED < 5A AC

CURRENT LEVEL

1 HIGH CURRENT FAULT

2 LOADED PHASE TO PHASE CURRENT

IMBALANCE > 17%

3 UNLOADED PHASE TO PHASE

CURRENT IMBALANCE > 25%

4 IMPROPER INCOMING PHASE

ROTATION

5 HIGH MOTOR TEMPERATURE

TRIP POINT = 13 KOHM RESET =

3.25 KOHM

6 COMMUNICATION ERROR

E OUT OF RANGE OF RLA CALIBRATION

OTHER DEFECTIVE MODULE OR SUPPLY

SYMBOLS VOLTAGE

TABLE 1 – MOTOR PROTECTOR FAULTS

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ant systems. The display will show the ‘highest prior-ity’ information as determined by the microprocessor.

The main categories of messages are: General Status Messages; Unit Warnings; Anticipation Control Status Messages; Chiller Fault Status Messages; System Fault Status Messages.

Display Keys

Each key provides a real-time display of commonly re-quired information about the chiller and individual re-frigerant system operating conditions and settings. This is particularly useful during commissioning, monitor-ing the operation of the chiller, diagnosing potential future problems and service troubleshooting. Param-eters may be displayed in Imperial (°F and PSIG) or Metric (°C and bar) units.

Print Keys

These keys allow control panel display or remote print-out of both current real-time operating and programmed data as well as fault history data from the most recent six safety shutdowns.

Entry Keys

The numeric and associated keys are used for enter-ing data required for programming the chiller. The ‘ENTER’ and ‘�’ ‘�’ keys are also used for scroll-ing through information available after pressing other keys.

Setpoints Keys

These keys are used for display and programming of the local and remote offset chilled liquid temperature setpoints.

Clock Keys

These keys are used for display and programming of the clock and operating schedule for the chiller.

Program Key

This key is used for display and programming of the chiller operational settings and limits.

ACCESSORIES AND OPTIONS:

Alternative Refrigerants

Contact your nearest YORK office for information and availability on alternative HFC refrigerants.

ELECTRICAL OPTIONS:

MULTIPLE POINT POWER SUPPLY CONNEC-

TION – Standard field power wiring connection on all models is Multiple Point Power Connection to fac-tory-provided Terminal Blocks. Two field- supplied electrical power circuits with appropriate branch cir-cuit protection provide power to each of two motor control center cabinets, located on either side of the Control panel on the front of the chiller. Each cabinet contains starter elements for one compressor.

Optional to the Terminal Blocks for field power con-nection are Non-Fused Disconnects or Circuit Breaker Switches with external, lockable handles.

SINGLE POINT POWER CONNECTION – (Fac-tory-mounted) An optional configuration for field con-nection of a single electrical circuit to: either Termi-nal Block or Non-Fused Disconnect Switch with lock-able external handle (in compliance with Article 440 of N.E.C., to isolate unit power supply for service).

Factory wiring is provided from the Terminal Block or Disconnect Switch to Factory supplied individual system Circuit Breakers, Non-Fused Disconnect switch with external, lockable handle or J Class Fuses/Fuse Block in each of the two compressor motor control cen-ters. (Note: Single Point Non-Fused Disconnect Switch will not be supplied with individual system Non Fused Disconnect Switches with external, lockable handles in each of the two compressor motor control centers).

65 Ka HIGH VOLTAGE PROTECTION – Non- Fused Disconnect Switch with fuses (200 & 575V) or Circuit Breakers (230, 380, & 460V) are used for ap-plications where customers have a requirement for single point wiring with high “fault current” withstand-ing capability. This option provides between 50Ka and 65Ka withstand protection to the equipment.

BUILDING AUTOMATION SYSTEM INTER-

FACE (Factory-mounted) – Provides means to reset the leaving chilled liquid temperature or percent full load amps (current limiting) from the BAS (Factory-mounted):

• Printed circuit board to accept 4 to 20 milliamp, 0 to 10 VDC, or dry contact closure input from the

BAS.

• A YORK ISN Building Automation System can provide a Pulse Width Modulated (PWM) signal direct to the standard control panel via the standard onboard RS485 port.

Product Description

19YORK INTERNATIONAL

FLOW SWITCH – The flow switch or its equivalent must be furnished with each unit. 150 PSIG (10.5 bar) DWP – For standard units. Johnson Controls model F61MG-1C Vapor-proof SPDT, NEMA 4X switch (150 PSIG [10.5 bar] DWP), -20°F to 250°F- (29°C to 121°C), with 1" NPT connection for upright mount-ing in horizontal pipe. (Field-mounted)

DIFFERENTIAL PRESSURE SWITCH – Alterna-tive to the above mentioned Flow Switch. Pretemco Model DPS 300A-P4OPF-82582-S (20.7bar max work-ing pressure). SPDT 5 amp 125/250 VAC switch. Range:

0 - 2.8 bar, deadband: 0.003 - 0.005bar, with 1/4 NPTE pressure connections.

LANGUAGE LCD AND KEYPAD – Standard dis-play language and keypad is in English. Spanish is avail-able as an option.

PRINTER KIT – Printer for obtaining printout of unit operating and history data. (Field-mounted)

MULTIPLE UNIT SEQUENCE CONTROL (Field-mounted) – Sequencing Control with automatic unit sequencing. Necessary items for operation and control of up to eight units with parallel water circuits. Includes software and mixed liquid temperature sensor (inter-connecting wiring by others).

PRESSURE VESSEL CODES – Coolers and con-densers can be supplied in conformance with the fol-lowing pressure codes:

A.S.M.E. (Standard)

CHICAGO CODE RELIEF VALVES (Factory-mounted) – Unit will be provided with relief valves to meet Chicago Code requirements.

ACCESSORIES:

FLANGES (Weld Type) – Consists of 150 PSI (10.5 bar ) standard cooler (150 lb) R.F. flanges to convert to flanged cooler-connections and includes companion flanges. (Field-mounted)

FLANGES (Victaulic Type) – Consists of (2) Flange adapter for grooved end pipe (standard 150 PSI [10.5 bar] cooler).Includes companion flanges.

(Field-mounted)

VIBRATION ISOLATION:

• Neoprene Isolators – Recommended for normal in-stallations. Provides very good performance in most applications for the least cost. (Field- mounted)

• 1" Spring Isolators – Level adjustable, spring and cage type isolators for mounting under the unit base rails. 1" nominal deflection may vary slightly by application. (Field-mounted)

• 2" Seismic Spring Isolators – Restrained Spring- Flex Mountings incorporate a rugged welded steel housing with vertical and horizontal limit stops.

Housings designed to withstand a minimum 1.0g accelerated force in all directions to 2". Level ad-justable, deflection may vary slightly by applica-tion. (Field-mounted)

ALTERNATIVE CHILLED FLUID APPLICATIONS:

Standard water chilling application range is 40°F to 50°F (4.4°C to 10°C) Leaving Chilled Water Tempera-ture. To protect against nuisance safety trips below 40°F (4.4°C) and reduce the possibility of cooler dam-age due to freezing during chiller operation, the unit microprocessor automatically unloads the compressors at abnormally low suction temperature (pressure) con-ditions , prior to safety shutdown.

• Process Brine Option – Process or other applica-tions requiring chilled fluid below 40°F (4.4°C) risk water freezing in the evaporator, typically over-come by using antifreeze. For these applications, the chiller system incorporates brine (ethylene or propylene glycol solution), and the system design Leaving Chilled Fluid Temperature must be pro-vided on the order form to ensure proper factory configuration.

• Thermal Storage Option – Thermal Storage re-quires special capabilities from a chiller, including the ability to ‘charge’ an ice storage tank, then pos-sibly automatically reset for operation at elevated Leaving Chilled Fluid Temperatures as required by automatic building controls. The Thermal Storage Option provides Ice Storage duty Leaving Chilled Fluid setpoints from 25°F to 15°F ( -4°C to -10°C) minimum during charge cycle, with a Reset range of 36°F (20°C) supply fluid temperature.

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FUNCTIONAL DESCRIPTION

NOMENCLATURE

Low pressure liquid refrigerant enters the cooler tubes and is evaporated and superheated by the heat energy absorbed from the chilled liquid passing through the cooler shell. Low pressure vapor enters the compres-sor where pressure and superheat are increased. High pressure vapor is passed through the oil separator where compressor oil is removed and recirculated to the com-pressor. High pressure superheated refrigerant enters the condenser shell where heat is rejected to the con-denser water passing through the tubes. The fully con-densed and subcooled 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 circuit utilizes a refrigerant to refrigerant suction line heat exchanger to maximize chiller capacity and efficiency by subcooling liquid refrigerant delivered to the expansion valve and superheating suction gas delivered to the compressor.

FIG. 3 – FLOW DIAGRAM

Product Description

LD06817

YCWS0140SC46YAA

:Design Series F :Engineering Change or PIN Level

: YORK

: Chiller : Water Cooled : Screw kW Standard Unit

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR REFRIGERANT VOLTAGE/STARTER DESIGN / DEVELOPMENT LEVEL

Y # # # # S C 1 7 A C 2 8 Y A

W 4 0 S 4 6

5 8 : 0100: 0120: 0140 : 0180: 0200: 0220 : 0240

:R-22 :Wye-Delta

21YORK INTERNATIONAL

DELIVERY AND STORAGE

To ensure consistent quality and maximum reliability, all units are tested and inspected before leaving the fac-tory. Units are shipped completely assembled and con-taining refrigerant under pressure. Units are shipped without export crating unless this has been specified on the Sales Order.

If the unit is to be put into storage, before installation, the following precautions should be observed:

Ensure that all openings, such as water connections, are securely capped.

Do not store where exposed to ambient air tempera-tures exceeding 107°F (42°C).

The unit should be stored in a location where there is minimal activity to limit the risk of accidental physical damage.

To prevent inadvertent operation of the pressure relief devices the unit must not be steam cleaned.

It is recommended that the unit is periodically inspected during 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 should be noted on the shipment docu-mentation and a claim entered according to the instruc-tions given.

Major damage must be reported immediately to your local YORK representative.

MOVING THE UNIT

Before moving the unit, ensure that the installation site is suitable for installing the unit and is capable of sup-porting the weight of…