York Millennium YK M3 M3 G4 THRU YK S6 S4 J2, YK LB LB G4 THRU YK SE SC J4 manual

OPERA TING & MAINTENANCE Supersedes: Nothing F orm 160.49-O2 (1296) MILLENNIUM TM CENTRIFUGAL LIQUID CHILLERS MODEL YK M3 M3 G4 THR U YK S6 S4 J2 (STYLE C) R-22 (COOLING ONL Y) MODEL YK LB LB G4 THRU YK SE SC J4 (STYLE C) R-134a (COOLING ONL Y) WITH MICR OCOMPUTER CONTROL CENTER P AR T #371-01200-010, 371-01200-011 & 371-01200-015 FOR ELECT[...]

2 Y ORK INTERNA TIONAL T T T T T ABLE OF CONTENTS ABLE OF CONTENTS ABLE OF CONTENTS ABLE OF CONTENTS ABLE OF CONTENTS SECTION 1 – Description of System and Fundamentals of Operation ......................................... 4 SECTION 2 – MicroComputer Control Center ...................................... 6 SECTION 3 – System Operating Procedu[...]

Y ORK INTERNA TIONAL 3 FORM 160.49-O2 R-22 UNITS YK N2 N1 H1 – CX C DESIGN LEVEL (C) POWER SUPPL Y – for 60 HZ 5 for 50 HZ COMPRESSOR CODE G4, H0, H1, H2, J1, J2 CONDENSER CODE M3, M4, N3, N4, P3, P4, Q3, Q4, R3, R4, S3, S4 COOLER CODE M3, M4, N3, N4, P3, P4, P5, P6, Q3, Q4, Q5, Q6, R3, R4, R5, R6, S5, S6 MODEL { MO T OR CODE: 60 HZ 50 HZ CH CX[...]

4 Y ORK INTERNA TIONAL SECTION 1 DESCRIPTION OF SYSTEM AND FUND AMENT ALS OF OPERA TION FIG. 1 – MODEL YK MILLENNIUM CHILLER SYSTEM OPERA TION DESCRIPTION (See Fig. 2) The Y ORK Model YK Millennium Chiller is commonly applied to large air conditioning systems, b ut may be used on other applications. The chiller consists of an open motor mounted t[...]

Y ORK INTERNA TIONAL 5 FORM 160.49-O2 7619A(D) DET AIL A – COMPRESSOR PRERO T A TION V ANES design conditions. How ev er , most systems will be called upon to deliver full load capacity f or only a relatively small par t of the time the unit is in operation. CAP A CITY CONTR OL The major components of a chiller are selected f or full load capacit[...]

6 Y ORK INTERNA TIONAL SECTION 2 MICR OCOMPUTER CONTROL CENTER LD00953 26879A FIG. 3 – MICR OCOMPUTER CONTR OL CENTER AND KEYP AD NO TE: This instruction cov ers operation of chillers equipped with Electro-Mechanical or Solid State Star ters. If chiller is equipped with V ariable Speed Drive , Form 160.00-O1 is to be used in conjunction with this[...]

Y ORK INTERNA TIONAL 7 FORM 160.49-O2 INTRODUCTION The Y ORK MicroComputer Control Center is a micro- processor based control system f or R-22 or R134a cen- trifugal chillers. It controls the lea ving chilled water tem- perature via pre-rotation v ane control and has the ability to limit motor current via control of the pre-rotation v anes. Fur the[...]

8 Y ORK INTERNA TIONAL CONTR OL CENTER The Control Center front panel lay out consists of five ke y groups, one s witch and a 1 line by 40 char acter al- phanumeric vacuum fluorescent displa y: (see Fig. 3.) CHARA CTERISTIC DISPLA Y – The alphan umer ic vacuum fluorescent displa y is located to the right of the ST A TUS ke y . All messages, param[...]

Y ORK INTERNA TIONAL 9 FORM 160.49-O2 T o Display CHILLED LIQUID TEMPERA TURES : Press CHILLED LIQUID TEMPS displa y ke y as de- scribed on page 7 to produce the follo wing alphanu- meric display message: CHILLED LEA VING = XXX.X°F , RETURN = XXX.X°F T o Display REFRIGERANT PRESSURE: Use REFRIGERANT PRESSURE display k ey as described on page 7 to[...]

10 Y ORK INTERNA TIONAL T o Display CONDENSER LIQ UID TEMPERA TURES (Field Installed Option P acka g e): Use CONDENSER LIQUID TEMPS displa y ke y as described above to produce the f ollowing alphanu- meric display message: COND LEA VING = XXX.X°F; RETURN = XXX.X°F NO TE: If the condenser liquid ther mistors are not con- nected, or both thermistor[...]

Y ORK INTERNA TIONAL 11 FORM 160.49-O2 terms of minutes (to a maximum of 255). If not pro- grammed, the def ault value is 100% FLA f or 00 min- utes. (See “Programming Systems Setpoints”, page 16.) Thus, no pull down demand limit is imposed f ollowing system star t, and the % current limit setpoint is used. CLOCK – This ke y displays the da y[...]

12 Y ORK INTERNA TIONAL DISPLA YING SYSTEM SETPOINTS The currently programmed Setpoint values can be view ed at any time (see page 22) in SER VICE, LOCAL or REMO TE operating mode as f ollows: • Press and release the appropriate Setpoint key – the message will be displa y ed f or 2 seconds. – or – • Press and hold the appropriate Setpoint[...]

Y ORK INTERNA TIONAL 13 FORM 160.49-O2 TUE ST ART = 05:00 AM ST OP = 07:00 PM WED ST ART = 05:00 AM ST OP = 07:00 PM THU ST AR T = 05:00 AM ST OP = 07:00 PM FRI ST ART = 05:00 AM ST OP = 07:00 PM SA T ST ART = 05:00 AM ST OP = 01:00 PM HOL ST AR T = 00:00 AM ST OP = 00:00 PM T o Display HOLID A Y Setpoints: Use HOLID A Y setpoint ke y as described [...]

14 Y ORK INTERNA TIONAL PR OGRAMMING THE MICROCOMPUTER CONTROL CENTER FIG. 5 – KEYP AD – PROGRAMMING SYSTEM SETPOINTS PROGRAMMING SYSTEM SETPOINTS The system setpoints can be entered at any time . . . . . e ven when the system is running. Proceed as f ollows to enter system setpoints. (Refer to Fig. 5.) 1. Press A CCESS CODE key . 2. ENTER V AL[...]

Y ORK INTERNA TIONAL 15 FORM 160.49-O2 T o enter CHILLED LIQUID TEMP Setpoint: (Refer to Fig. 6.) 1. Press and release CHILLED LIQUID TEMP setpoint ke y . The following prog ram prompt message will be displa yed: LEA VING SETPOINT = XX.X °F (BASE) (BASE) ref ers to the base or lowest setpoint av ail- able to an Energy Management System. If any En-[...]

16 Y ORK INTERNA TIONAL T o Enter PULL DO WN DEMAND Setpoint: (Refer to Fig. 8.) 1. Press and release PULL DO WN DEMAND setpoint ke y . The following prog ram prompt message is dis- pla yed: SETPOINT = XXX MIN @ XXX % FLA, XXX MIN LEFT 2. Use Entr y keys to enter desired v alues. For expla- nation, see PULL DO WN DEMAND , page 12. Note that “XX m[...]

Y ORK INTERNA TIONAL 17 FORM 160.49-O2 T o Enter D AIL Y SCHEDULE Setpoint: (Ref er to Fig. 10.) 1. Press and release D AIL Y SCHEDULE setpoint ke y . The follo wing prompt message is displa y ed: SUN ST ART = XX:XX AM, ST OP = XX:XX AM 2. If the displa yed star t and stop time is not the desired schedule, enter the desired start and stop times as [...]

18 Y ORK INTERNA TIONAL T o Enter HOLIDA Y Setpoint: (Ref er to Fig. 11.) 1. Press and release HOLID A Y setpoint k ey . The fol- lowing progr am prompt message is displa yed: S_ M_ T_ W_ T_ F_ S_ HOLIDA Y NO TED BY r 2. Press and release AD V ANCE D A Y/SCROLL ke y to mov e cursor to the day that y ou wish to designate as a holiday . 3. Press and [...]

Y ORK INTERNA TIONAL 19 FORM 160.49-O2 FIG. 13 – KEYP AD – SER VICE KEYS LOCA TION The Service ke ys are provided for the service techni- cian’ s use when perfor ming routine maintenance or when troubleshooting the system. The W ARNING RESET and PRE-RO T A TION V ANES k eys are enab led in SER VICE mode only . The remainder of the Ser vice k [...]

20 Y ORK INTERNA TIONAL O THER SER VICE KEYS W ARNING RESET – Press and release this ke y to re- set any “W ARNING” or “ST A TUS” message that can be reset with this ke y , unless the condition still exists . T o reset any cycling or w ar ning message, place the Con- trol Center in SER VICE mode and press W ARNING RESET key . T o reset an[...]

Y ORK INTERNA TIONAL 21 FORM 160.49-O2 NO . 6 A CTUAL POS = XX MILS; REF = YY MILS – A CTU AL POS is the distance between the high speed thrust collar and the pro ximity probe that is used to measure the position. REF is the ref erence position established at time of com- pressor manuf acture. NO . 7 HIGH SPEED DRAIN TEMP = XXX.X °F – T empera[...]

22 Y ORK INTERNA TIONAL 7. Press PROGRAM key . 8. PROGRAM MODE, SELECT SETPOINT is displa y ed. 9. Press MODE ke y . 10. The mode that has been previously selected will be display ed as f ollows: LOCAL MODE SELECTED – or – SER VICE MODE SELECTED – or – REMOTE MODE SELECTED 11. Press AD V ANCE D A Y key to scroll to desired mode . Each time [...]

Y ORK INTERNA TIONAL 23 FORM 160.49-O2 Theref ore: (100%) (50% x 200) = 100A = V anes stop open- ing (104%) (50% x 200) = 104A = V anes dr iv en to- ward close position. SYSTEM R UN – A UTO V ANES Displa yed when the chiller is running, the MicroCom- puter Control Center is in SER VICE mode, and the vanes are oper ating in AU T O mode. SYSTEM R U[...]

24 Y ORK INTERNA TIONAL at 265 PSIG (R-22); 180 PSIG (R-134a). When the con- denser pressure f alls to 245 PSIG (R-22); 160 PSIG (R-134a), the vanes will be permitted to open. SYSTEM R UN – PRESSURE ST A TUS Displa yed when the chiller is running. It instr ucts the operator to press the S T A TUS key , whereupon one of the f ollowing messages wil[...]

Y ORK INTERNA TIONAL 25 FORM 160.49-O2 will be display ed if the Micro Board is configured for A UT O-REST ART AFTER PO WER F AILURE . The Mi- cro Board is f actor y set for man ual restar t after power f ailure. T o conv er t it to auto-restar t after po wer failure, remove one of the two-pin program jumpers from the cloth bag located inside the C[...]

26 Y ORK INTERNA TIONAL has increased to 265 PSIG (R-22); 180 PSIG (R-134a). System will be allow ed to restar t when pressure de- creases to 205 PSIG (R-22); 120 PSIG (R-134a). Pres- sure is sensed by a High Pressure (HP) saf ety control that is located on a mounting bracket above the oil- pump star ter located on the condenser . This message is p[...]

Y ORK INTERNA TIONAL 27 FORM 160.49-O2 chiller , press COMPRESSOR s witch to STOP/RESET position and then to ST ART position. V ANE MOT OR SWITCH OPEN The chiller is shut down because a system-start se- quence has been initiated, but the pre-rotation vanes are not fully closed. MON XX:XX AM – ST ARTER MALFUNCTION DETECTED The chiller is shut down[...]

28 Y ORK INTERNA TIONAL or f ailed to achiev e the minimum required star ting line- voltage . Refer to e xplanation under “System Setpoints – SSS Motor Current/V olts”, page 11. The system will automatically restar t when all phases of line voltage increase to the minimum required star ting v oltage. MON XX:XX AM – HIGH LINE V OL T AGE (Sol[...]

Y ORK INTERNA TIONAL 29 FORM 160.49-O2 IMPOR T ANT!!!: Although this message is gener ally indicative of a def ective pro ximity probe, it is possible that the compressor has been damaged. If the high speed thrust bearing is not inspected by a qualified service technician pr ior to star ting the chiller , fur ther se vere compressor damage could re[...]

30 Y ORK INTERNA TIONAL SECTION 3 SYSTEM OPERA TING PR OCEDURES W ARNING OIL HEA TERS If the oil heater is de-energized during a shut- down period, they m ust be energized f or 12 hours prior to star ting compressor , or remove all oil and recharge compressor with new oil. (See “Charg- ing Unit With Oil”, page 43.) NO TE: The oil heater is ther[...]

Y ORK INTERNA TIONAL 31 FORM 160.49-O2 ST ART -UP 1. If the chilled water pump is manually operated, star t the pump . The Control Center will not allow the chiller to star t unless chilled liquid flow is es- tablished through the unit. (A field supplied chilled water flo w switch is required.) If the chilled liquid pump is wired to the MicroComput[...]

32 Y ORK INTERNA TIONAL How ev er , the current draw (amperes) b y the compres- sor motor cannot e xceed the setting of the % CUR- RENT LIMIT at any time during the unit operation, since the MicroComputer Control Center 40 to 100% three- phase peak current limit software function, plus the 3- phase 100% solid state overload current limiter (CM- 2) [...]

Y ORK INTERNA TIONAL 33 FORM 160.49-O2 be no low er than the value deter mined b y referring to the formula below: 100 Min. ECWT = LCHWT—C RANGE + 5 + ( 15 x % LOAD ) where: ECWT = entering condensing water temperature LCHWT = leaving chilled water temperature C RANGE = condensing water temperature range At star t-up , the enter ing condenser wat[...]

34 Y ORK INTERNA TIONAL Y ORK office. A utomatic data logging is possible b y connecting the optional printer and programming the D A T A LOGGER function; ref er to Form 160.49-N7. An accurate record of readings serves as a v aluable ref erence for oper ating the system. Readings taken when a system is newly installed will establish normal conditio[...]

Y ORK INTERNA TIONAL 35 FORM 160.49-O2 4. Inspect and ser vice electrical components as nec- essary . 5. P erform chemical analysis of system. NEED FOR MAINTENANCE OR SER VICE If the system is malfunctioning in any manner or the unit is stopped by one of the saf ety controls, consult the “Operation Analysis Char t”, pages 47 through 48 of this [...]

36 Y ORK INTERNA TIONAL period. EPROM v ersion C .02F(T).12 or later pro- vides a 10 minute coastdown period. The compres- sor , condenser water , and cooling tower f ans will stop automatically . The oil pump will continue to run f or coastdown period. The oil pump will then stop automatically . Once stopped, the SYSTEM COASTDO WN displa y will be[...]

Y ORK INTERNA TIONAL 37 FORM 160.49-O2 SECTION 4 SYSTEM COMPONENTS DESCRIPTION 27385A FRONT VIEW DUAL RELIEF V AL VES MICROCOMPUTER CONTROL CENTER SUCTION DISCHARGE COMPRESSOR AD APTER MOT OR SUPPORT & CO VER MO TOR COOLER REFRIGERANT CHARGING V AL V E DEHYDRA T OR SIGHT GLASSES FIG. 17 – SYSTEM COMPONENTS 27382A OIL PUMP ST ARTER DISCHARGE L[...]

38 Y ORK INTERNA TIONAL GENERAL The Y ORK Model YK Millennium Centrifugal Liquid Chiller is completely f actor y-packaged including cooler , condenser , compressor , motor , lubr ication system, MicroComputer Control Center , and all interconnect- ing unit piping and wiring. The initial charge of refrigerant and oil is supplied for each unit. Oil i[...]

Y ORK INTERNA TIONAL 39 FORM 160.49-O2 FIG. 18 – SCHEMA TIC DRA WING – (YK) COMPRESSOR LUBRICA TION SYSTEM LD00951[...]

40 Y ORK INTERNA TIONAL oil pump sooner , depress the MANU AL OIL PUMP key again. On shutdown of the system f or any reason, the oil pump operates and continues to run f or 150 seconds. The system cannot restar t during that time inter val. OIL HEA TER During long idle periods, the oil in the compressor oil reser v oir tends to absorb as much refr [...]

Y ORK INTERNA TIONAL 41 FORM 160.49-O2 age to the Micro Board that represents this lev el (0% = empty; 100% = full). Under program control, the Micro Board modulates a variable orifice to control the con- denser refrigerant lev el to a programmed setpoint. Other setpoints aff ect the control sensitivity and response. These setpoints must be entered[...]

42 Y ORK INTERNA TIONAL SECTION 5 OPERA TIONAL MAINTENANCE OIL RETURN SYSTEM The oil return system continuously maintains the proper oil le vel in the compressor oil sump . (See Figs. 18 & 19.) High pressure condenser gas flows continuously through the eductor inducing the low pressure, oil rich liquid to flow from the e v apor ator , through t[...]

Y ORK INTERNA TIONAL 43 FORM 160.49-O2 THE OIL CHARGE The nominal oil charge for the compressor is 20 gal., type “F” for R-22 application or type “K” for R-134a application. New Y ORK Refrigeration oil must be used in the cen- trifugal compressor. Since oil absorbs moisture when e xposed to the atmosphere, it should be kept tightly capped u[...]

44 Y ORK INTERNA TIONAL SECTION 6 TROUBLESHOO TING T ABLE 1 – CA USES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORD ANCE WITH THE MICROCOMPUTER CONTROL, CENTER DISPLA Y SHUTDOWN CA USE GO VERNING CONTROL FUNCTION CONTROL CENTER DISPLA Y OPERA TING PROGRAMMED S T ART -UP OF PROB ABLE CAUSE D A Y OF TIME OF CA USE OF METHOD OF DESCRIPTION POINT S[...]

Y ORK INTERNA TIONAL 45 FORM 160.49-O2 MON. 10:00 AM Low Evap. Low Evap. 54.3 54.4 T o restar t, press See OPERA TION Pressure Pressure PSIG (R-22) PSIG (R-22) compressor switch ANAL YSIS T able 2 T ransducer 25 25.1 from ST OP/RESET Symptom 2 (LEP) PSIG (R-134a) PSIG (R-134a) to ST ART position MON. 10:00 AM Low Evap. LEP external Set to Job Set t[...]

46 Y ORK INTERNA TIONAL T ABLE 1 – CA USES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORD ANCE WITH THE MICROCOMPUTER CONTROL, CENTER DISPLA Y SHUTDOWN CA USE GO VERNING CONTROL FUNCTION CONTROL CENTER DISPLA Y OPERA TING PROGRAMMED S T ART -UP OF PROB ABLE CAUSE D A Y OF TIME OF CA USE OF METHOD OF DESCRIPTION POINT SETPOINTS SYSTEM AFTER AND S[...]

Y ORK INTERNA TIONAL 47 FORM 160.49-O2 T ABLE 2 – OPERA TING ANAL YSIS CHART RESUL TS POSSIBLE CA USE REMED Y 1. SYMPTOM: ABNORMALL Y HIGH DISCHARGE PRESSURE T emperature diff erence between liquid Air in condenser . refrigerant out and water off condenser higher than normal. High discharge pressure. Condenser tubes dir ty or . Clean condenser tu[...]

48 Y ORK INTERNA TIONAL T ABLE 2 – OPERA TING ANAL YSIS CHART (Contin ued) RESUL TS POSSIBLE CA USE REMED Y 6. SYMPT OM: USU ALL Y HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS Unusually high oil pressure is displayed High oil pressure. T rans- Replace low or high oil pressure when the oil pressure display key is ducer defective. Relief transduce[...]

Y ORK INTERNA TIONAL 49 FORM 160.49-O2 SECTION 7 MAINTENANCE RENEW AL P AR TS F or any required Renew al Part s, ref er to “P ar ts Lists” shown in “Reference Instructions”, page 2. CHECKING SYSTEM FOR LEAKS LEAK TESTING DURING OPERA TION The refrigerant side of the system is carefully pres- sure tested and e vacuated at the f actor y . Aft[...]

50 Y ORK INTERNA TIONAL V ACUUM TESTING After the pressure test has been completed, the vacuum test should be conducted as f ollows: 1. Connect a high capacity vacuum pump , with indi- cator , to the system charging v alve as sho wn in Fig. 22 and star t the pump. (See “V acuum Dehydra- tion”.) 2. Open wide all system valves, including the purg[...]

Y ORK INTERNA TIONAL 51 FORM 160.49-O2 V ACUUM DEHYDRA TION T o obtain a sufficiently dr y system, the follo wing in- structions hav e been assembled to provide an eff ec- tive method f or ev acuating and dehydrating a system in the field. Although there are sev eral methods of de- h ydrating a system, we are recommending the f ollow- ing, as it pr[...]

52 Y ORK INTERNA TIONAL REFRIGERANT CHARGING T o av oid the possibility if freezing liquid within the cooler tubes when charging an ev acuated sys- tem, only refrigerant vapor from the top of the drum or cylinder must be admitted to the system pressure until the system pressure is raised above the point corresponding to the freezing point of the co[...]

Y ORK INTERNA TIONAL 53 FORM 160.49-O2 HANDLING REFRIGERANT FOR DISMANTLING AND REP AIRS MEGGING THE MO T OR If it becomes necessary to open any par t of the refr iger- ant system f or repairs, it will be necessary to remove the charge bef ore opening any par t of the unit. While the main disconnect s witch and compressor motor star ter are open, m[...]

54 Y ORK INTERNA TIONAL FIG. 24 – MO TOR ST A TOR TEMPERA TURE AND INSULA TION RESIST ANCES LD00476 TEMPERA TURE – °F MEGOHMS Minimum Insulation Resistance vs. T emperature (per IEEE Std 43) Open Motors[...]

Y ORK INTERNA TIONAL 55 FORM 160.49-O2 CONDENSERS AND COOLERS GENERAL Maintenance of condenser and cooler shells is impor- tant to provide troub le free operation of the chiller . The water side of the tubes in the shell must be kept clean and free from scale. Proper maintenance such as tube cleaning, and testing f or leaks, is cov ered on the fol-[...]

56 Y ORK INTERNA TIONAL recommends the use of this type of organization. The Dow Industries Ser vice Division of the Dow Chemical Company , T ulsa, Oklahoma, with branches in principal cities is one of the most reliable of these companies. TESTING FOR COOLER AND CONDENSER TUBE LEAKS Cooler and condenser tube leaks in R-22 or R-134a systems may resu[...]

Y ORK INTERNA TIONAL 57 FORM 160.49-O2 COMPRESSOR ELECTRICAL CONTROLS Maintenance for the compressor assemb ly consists of checking the operation of the oil return system and changing the dehydr ator , checking and changing the oil, checking and changing the oil filters, checking the operation of the oil heater , checking the operation of the oil p[...]

58 Y ORK INTERNA TIONAL SECTION 8 PREVENTIVE MAINTENANCE It is the responsibility of the owner to provide the nec- essary daily , month y and yearly maintenance require- ments of the system. IMPOR T ANT – If a unit f ailure occurs due to improper maintenance during the war- ranty period; Y ORK will not be liable f or costs incurred to return the [...]

Y ORK INTERNA TIONAL 59 FORM 160.49-O2 eductor should be check ed f or an y foreign particles that ma y be obstr ucting the jet. ELECTRICAL CONTROLS 1. All electr ical controls should be inspected for ob vi- ous malfunctions. 2. It is impor tant that the factory settings of controls (operation and saf ety) not be changed. If the set- tings are chan[...]

P .O . Bo x 1592, Y o rk, P ennsylvania USA 17405-1592 Subject to change without notice. Printed in USA Copyright © by Y ork Inter national Corporation 1997 ALL RIGHTS RESERVED Form 160.49-O2 (1296) Supersedes: Nothing[...]