Page 2 - DESCRIPTION
2 YORK INTERNATIONAL T T T T TABLE 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 .......................................
Page 3 - NOMENCLATURE
YORK INTERNATIONAL 3 FORM 160.49-O2 R-22 UNITS YK N2 N1 H1 – CX C DESIGN LEVEL (C) POWER SUPPLY – 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,...
Page 4 - SECTION 1; DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION; FIG. 1 – MODEL YK MILLENNIUM CHILLER
4 YORK INTERNATIONAL SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION FIG. 1 – MODEL YK MILLENNIUM CHILLER SYSTEM OPERATION DESCRIPTION (See Fig. 2) The YORK Model YK Millennium Chiller is commonlyapplied to large air conditioning systems, but may beused on other applications. The chill...
Page 6 - SECTION 2; FIG. 3 – MICROCOMPUTER CONTROL CENTER AND KEYPAD; WARNING
6 YORK INTERNATIONAL SECTION 2 MICROCOMPUTER CONTROL CENTER LD00953 26879A FIG. 3 – MICROCOMPUTER CONTROL CENTER AND KEYPAD NOTE: This instruction covers operation of chillers equipped with Electro-Mechanical or Solid State Starters. If chiller is equipped with Variable Speed Drive, Form 160.00-O1 i...
Page 7 - INTRODUCTION
YORK INTERNATIONAL 7 FORM 160.49-O2 INTRODUCTION The YORK MicroComputer Control Center is a micro-processor based control system for R-22 or R134a cen-trifugal chillers. It controls the leaving chilled water tem-perature via pre-rotation vane control and has the abilityto limit motor current via con...
Page 8 - CONTROL CENTER; SETPOINTS – These keys are used as follows:; OPERATION; DISPLAYING SYSTEM PARAMETERS
8 YORK INTERNATIONAL CONTROL CENTER The Control Center front panel layout consists of fivekey groups, one switch and a 1 line by 40 character al-phanumeric vacuum fluorescent display: (see Fig. 3.) CHARACTERISTIC DISPLAY – The alphanumer icvacuum fluorescent display is located to the right of theSTA...
Page 9 - DISPLAY; FIG. 4 – SYSTEM PARAMETERS – OUT OF
YORK INTERNATIONAL 9 FORM 160.49-O2 To Display CHILLED LIQUID TEMPERATURES: Press CHILLED LIQUID TEMPS display key as de-scribed on page 7 to produce the following alphanu-meric display message: CHILLED LEAVING = XXX.X°F, RETURN = XXX.X°F To Display REFRIGERANT PRESSURE: Use REFRIGERANT PRESSURE dis...
Page 10 - SYSTEM SETPOINTS
10 YORK INTERNATIONAL To Display CONDENSER LIQUID TEMPERATURES (Field Installed Option Package): Use CONDENSER LIQUID TEMPS display key asdescribed above to produce the following alphanu-meric display message: COND LEAVING = XXX.X°F; RETURN = XXX.X°F NOTE: If the condenser liquid thermistors are not...
Page 11 - NOTE: If an Energy Management System is interfaced; – or –
YORK INTERNATIONAL 11 FORM 160.49-O2 terms of minutes (to a maximum of 255). If not pro-grammed, the default value is 100% FLA for 00 min-utes. (See “Programming Systems Setpoints”, page 16.)Thus, no pull down demand limit is imposed followingsystem start, and the % current limit setpoint is used. C...
Page 12 - DISPLAYING SYSTEM SETPOINTS
12 YORK INTERNATIONAL DISPLAYING SYSTEM SETPOINTS The currently programmed Setpoint values can beviewed at any time (see page 22) in SERVICE, LOCALor REMOTE operating mode as follows: • Press and release the appropriate Setpoint key – the message will be displayed for 2 seconds. – or – • Press and h...
Page 14 - PROGRAMMING; THE MICROCOMPUTER CONTROL CENTER; FIG. 5 – KEYPAD – PROGRAMMING SYSTEM
14 YORK INTERNATIONAL PROGRAMMING THE MICROCOMPUTER CONTROL CENTER FIG. 5 – KEYPAD – PROGRAMMING SYSTEM SETPOINTS PROGRAMMING SYSTEM SETPOINTS The system setpoints can be entered at any time . . . . .even when the system is running. Proceed as follows toenter system setpoints. (Refer to Fig. 5.) 1. ...
Page 15 - FIG. 6 – KEYPAD – PROGRAMMING “LEAVING; FIG. 7 – KEYPAD – PROGRAMMING “% CURRENT
YORK INTERNATIONAL 15 FORM 160.49-O2 To enter CHILLED LIQUID TEMP Setpoint: (Refer toFig. 6.) 1. Press and release CHILLED LIQUID TEMP setpoint key. The following program prompt message will bedisplayed: LEAVING SETPOINT = XX.X °F (BASE) (BASE) refers to the base or lowest setpoint avail-able to an ...
Page 16 - FIG. 8 – KEYPAD – PROGRAMMING “PULL DOWN; FIG. 9 – KEYPAD – PROGRAMMING “CLOCK”
16 YORK INTERNATIONAL To Enter PULL DOWN DEMAND Setpoint:(Refer to Fig. 8.) 1. Press and release PULL DOWN DEMAND setpoint key. The following program prompt message is dis-played: SETPOINT = XXX MIN @ XXX % FLA, XXX MIN LEFT 2. Use Entry keys to enter desired values. For expla- nation, see PULL DOWN...
Page 17 - FIG. 10 – KEYPAD – PROGRAMMING “DAILY
YORK INTERNATIONAL 17 FORM 160.49-O2 To Enter DAILY SCHEDULE Setpoint:(Refer to Fig. 10.) 1. Press and release DAILY SCHEDULE setpoint key. The following prompt message is displayed: SUN START = XX:XX AM, STOP = XX:XX AM 2. If the displayed start and stop time is not the desired schedule, enter the ...
Page 18 - FIG. 11 – KEYPAD – PROGRAMMING “HOLIDAY”; FIG. 12 – KEYPAD – PROGRAMMING “REMOTE
18 YORK INTERNATIONAL To Enter HOLIDAY Setpoint: (Refer to Fig. 11.) 1. Press and release HOLIDAY setpoint key. The fol- lowing program prompt message is displayed: S_ M_ T_ W_ T_ F_ S_ HOLIDAY NOTED BY r 2. Press and release ADVANCE DAY/SCROLL key to move cursor to the day that you wish to designat...
Page 19 - FIG. 13 – KEYPAD – SERVICE KEYS LOCATION; SERVICE KEYS
YORK INTERNATIONAL 19 FORM 160.49-O2 FIG. 13 – KEYPAD – SERVICE KEYS LOCATION The Service keys are provided for the service techni-cian’s use when performing routine maintenance or whentroubleshooting the system. The WARNING RESET andPRE-ROTATION VANES keys are enabled in SERVICEmode only. The remai...
Page 20 - as
20 YORK INTERNATIONAL OTHER SERVICE KEYS WARNING RESET – Press and release this key to re-set any “WARNING” or “STATUS” message that can bereset with this key, unless the condition still exists. Toreset any cycling or warning message, place the Con-trol Center in SERVICE mode and press WARNINGRESET ...
Page 21 - – ACTUAL POS is; OPERATING MODES
YORK INTERNATIONAL 21 FORM 160.49-O2 NO. 6 ACTUAL POS = XX MILS; REF = YY MILS – ACTUAL POS is the distance between the high speed thrust collar andthe proximity probe that is used to measure the position.REF is the reference position established at time of com-pressor manufacture. NO. 7 HIGH SPEED ...
Page 22 - COMPRESSOR SWITCH
22 YORK INTERNATIONAL 7. Press PROGRAM key. 8. PROGRAM MODE, SELECT SETPOINT is displayed. 9. Press MODE key. 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 ...
Page 24 - message, the following message shall be displayed.; SYSTEM SHUTDOWN MESSAGES; Day of Week
24 YORK INTERNATIONAL at 265 PSIG (R-22); 180 PSIG (R-134a). When the con-denser pressure falls to 245 PSIG (R-22); 160 PSIG(R-134a), the vanes will be permitted to open. SYSTEM RUN – PRESSURE STATUS Displayed when the chiller is running. It instructs theoperator to press the STATUS key, whereupon o...
Page 25 - when Control Center is in REMOTE mode.; The chiller is shut down because condenser pressure
YORK INTERNATIONAL 25 FORM 160.49-O2 will be displayed if the Micro Board is configured forAUTO-RESTART AFTER POWER FAILURE. The Mi-cro Board is factory set for manual restart after powerfailure. To conver t it to auto-restart after power failure,remove one of the two-pin program jumpers from theclo...
Page 26 - • Phase rotation/loss
26 YORK INTERNATIONAL has increased to 265 PSIG (R-22); 180 PSIG (R-134a).System will be allowed 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) safety controlthat is located on a mounting bracket above the oil-pump star ter loc...
Page 27 - jumper on the Micro Board as follows:; FUNCTION; Installed; Since I
YORK INTERNATIONAL 27 FORM 160.49-O2 chiller, press COMPRESSOR switch to STOP/RESETposition and then to START position. VANE MOTOR SWITCH OPEN The chiller is shut down because a system-start se-quence has been initiated, but the pre-rotation vanesare not fully closed. MON XX:XX AM – STARTER MALFUNCT...
Page 30 - SECTION 3; SYSTEM OPERATING PROCEDURES
30 YORK INTERNATIONAL SECTION 3 SYSTEM OPERATING PROCEDURES WARNING OIL HEATERS If the oil heater is de-energized during a shut-down period, they must be energized for 12 hoursprior to starting compressor, or remove all oil andrecharge compressor with new oil. (See “Charg-ing Unit With Oil”, page 43...
Page 31 - CHILLER OPERATION
YORK INTERNATIONAL 31 FORM 160.49-O2 START-UP 1. If the chilled water pump is manually operated, start the pump. The Control Center will not allowthe chiller to start unless chilled liquid flow is es-tablished through the unit. (A field supplied chilledwater flow switch is required.) If the chilled ...
Page 32 - NOTE: If the temperature setpoint has been repro-; Condenser Water Temperature Control; SYSTEM STARTING & SHUTDOWN SEQUENCE; FIG. 15 – CHILLER STARTING SEQUENCE & SHUTDOWN SEQUENCE
32 YORK INTERNATIONAL However, the current draw (amperes) by the compres-sor motor cannot exceed the setting of the % CUR-RENT LIMIT at any time during the unit operation, sincethe MicroComputer Control Center 40 to 100% three-phase peak current limit software function, plus the 3-phase 100% solid s...
Page 33 - ECWT; CHECKING OPERATION; On star ting, the prerotation vanes should remain; OPERATING LOG SHEET
YORK INTERNATIONAL 33 FORM 160.49-O2 be no lower than the value determined by referring tothe 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 ...
Page 34 - OPERATING INSPECTIONS – See Section 2
34 YORK INTERNATIONAL YORK office. Automatic data logging is possible byconnecting the optional printer and programming theDATA LOGGER function; refer to Form 160.49-N7. An accurate record of readings serves as a valuablereference for operating the system. Readings takenwhen a system is newly instal...
Page 35 - NEED FOR MAINTENANCE OR SERVICE; SAFETY SHUTDOWNS; CYCLING SHUTDOWNS
YORK INTERNATIONAL 35 FORM 160.49-O2 4. Inspect and service electrical components as nec- essar y. 5. Perform chemical analysis of system. NEED FOR MAINTENANCE OR SERVICE If the system is malfunctioning in any manner or theunit is stopped by one of the safety controls, consultthe “Operation Analysis...
Page 36 - PROLONGED SHUTDOWN
36 YORK INTERNATIONAL period. EPROM version C.02F(T).12 or later pro-vides a 10 minute coastdown period. The compres-sor, condenser water, and cooling tower fans willstop automatically. The oil pump will continue to runfor coastdown period. The oil pump will then stopautomatically. Once stopped, the...
Page 37 - SECTION 4; SYSTEM COMPONENTS DESCRIPTION; FRONT VIEW; FIG. 17 – SYSTEM COMPONENTS
YORK INTERNATIONAL 37 FORM 160.49-O2 SECTION 4 SYSTEM COMPONENTS DESCRIPTION 2 7 3 8 5 A FRONT VIEW DUAL RELIEFVALVES MICROCOMPUTERCONTROL CENTER SUCTION DISCHARGE COMPRESSOR ADAPTER MOTORSUPPORT & COVER MOTOR COOLER REFRIGERANTCHARGING VALVE DEHYDRATOR SIGHTGLASSES FIG. 17 – SYSTEM COMPONENTS 2...
Page 38 - GENERAL; b. Front and rear journal bearings – one on each; OIL PUMP
38 YORK INTERNATIONAL GENERAL The YORK Model YK Millennium Centrifugal LiquidChiller is completely factory-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 ...
Page 39 - FIG. 18 – SCHEMATIC DRAWING – (YK) COMPRESSOR LUBRICATION SYSTEM
YORK INTERNATIONAL 39 FORM 160.49-O2 FIG. 18 – SCHEMATIC DRAWING – (YK) COMPRESSOR LUBRICATION SYSTEM LD00951
Page 40 - OIL HEATER; Pressing the STATUS key causes the message to read; MOTOR DRIVELINE; Heat exchanger tubes are internally enhanced type.; REFRIGERANT FLOW CONTROL
40 YORK INTERNATIONAL oil pump sooner, depress the MANUAL OIL PUMP keyagain. On shutdown of the system for any reason, the oil pumpoperates and continues to run for 150 seconds. Thesystem cannot restar t during that time interval. OIL HEATER During long idle periods, the oil in the compressor oilres...
Page 41 - is
YORK INTERNATIONAL 41 FORM 160.49-O2 age to the Micro Board that represents this level (0% =empty; 100% = full). Under program control, the MicroBoard modulates a variable orifice to control the con-denser refrigerant level to a programmed setpoint. Othersetpoints affect the control sensitivity and ...
Page 42 - SECTION 5; OPERATIONAL MAINTENANCE; OIL RETURN SYSTEM
42 YORK INTERNATIONAL SECTION 5 OPERATIONAL MAINTENANCE OIL RETURN SYSTEM The oil return system continuously maintains the properoil level in the compressor oil sump. (See Figs. 18 &19.) High pressure condenser gas flows continuouslythrough the eductor inducing the low pressure, oil richliquid t...
Page 43 - THE OIL CHARGE; Immerse the suction connection of the oil charging; FIG. 20 – CHARGING OIL RESERVOIR WITH OIL
YORK INTERNATIONAL 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-134aapplication. New YORK Refrigeration oil must be used in the cen-trifugal compressor. Since oil absorbs moisture whenexposed to the atmosphere, ...
Page 44 - SECTION 6; OUBLESHOO; CENTER DISPLAY
44 Y ORK INTERNA TIONAL SECTION 6 T R OUBLESHOO TING TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE MICROCOMPUTER CONTROL, CENTER DISPLAY SHUTDOWN CAUSE GOVERNING CONTROL FUNCTION CONTROL CENTER DISPLAY OPERATING PROGRAMMED START-UP OF PROBABLE CAUSE DAY OF TIME OF CAU...
Page 47 - TABLE 2 – OPERATING ANALYSIS CHART; RESULTS; SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE; LOW OIL PRESSURE
YORK INTERNATIONAL 47 FORM 160.49-O2 TABLE 2 – OPERATING ANALYSIS CHART RESULTS POSSIBLE CAUSE REMEDY 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE Temperature difference between liquid Air in condenser. refrigerant out and water off condenserhigher than normal. High discharge pressure. Condenser t...
Page 48 - TABLE 2 – OPERATING ANALYSIS CHART (Continued); SYMPTOM: USUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS; OIL PRESSURE display key.; SYMPTOM: OIL PUMP FAILS TO DELIVER OIL PRESSURE; OIL PRESSURE display key when oil; SYMPTOM: REDUCED OIL PUMP CAPACITY
48 YORK INTERNATIONAL TABLE 2 – OPERATING ANALYSIS CHART (Continued) RESULTS POSSIBLE CAUSE REMEDY 6. SYMPTOM: USUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS Unusually high oil pressure is displayed High oil pressure. Trans- Replace low or high oil pressure when the oil pressure display key i...
Page 49 - SECTION 7; MAINTENANCE; RENEWAL PARTS; LEAK TESTING DURING OPERATION; Build up the system pressure with dry nitrogen to; EVACUATION AND DEHYDRATION OF UNIT; FIG. 21 – EVACUATION OF CHILLER
YORK INTERNATIONAL 49 FORM 160.49-O2 SECTION 7 MAINTENANCE RENEWAL PARTS For any required Renewal Par ts, refer to “Parts Lists”shown in “Reference Instructions”, page 2. CHECKING SYSTEM FOR LEAKS LEAK TESTING DURING OPERATION The refrigerant side of the system is carefully pres-sure tested and evac...
Page 50 - VACUUM TESTING; TABLE 3 –
50 YORK INTERNATIONAL VACUUM TESTING After the pressure test has been completed, the vacuumtest should be conducted as follows: 1. Connect a high capacity vacuum pump, with indi- cator, to the system charging valve as shown inFig. 22 and start the pump. (See “Vacuum Dehydra-tion”.) 2. Open wide all ...
Page 51 - VACUUM DEHYDRATION; FIG. 22 – SATURATION CURVE
YORK INTERNATIONAL 51 FORM 160.49-O2 VACUUM DEHYDRATION To obtain a sufficiently dry system, the following in-structions have been assembled to provide an effec-tive method for evacuating and dehydrating a systemin the field. Although there are several methods of de-hydrating a system, we are recomm...
Page 52 - REFRIGERANT CHARGING; TABLE 4 – REFRIGERANT CHARGE; SHELL CODES; CHECKING THE REFRIGERANT CHARGE
52 YORK INTERNATIONAL REFRIGERANT CHARGING To avoid the possibility if freezing liquid within thecooler tubes when charging an evacuated sys-tem, only refrigerant vapor from the top of thedrum or cylinder must be admitted to the systempressure until the system pressure is raised abovethe point corre...
Page 53 - HANDLING REFRIGERANT FOR; If readings fall below shaded area, remove external; FIG. 23 – DIAGRAM, MEGGING MOTOR WINDINGS
YORK INTERNATIONAL 53 FORM 160.49-O2 HANDLING REFRIGERANT FOR DISMANTLING AND REPAIRS MEGGING THE MOTOR If it becomes necessary to open any par t of the refriger-ant system for repairs, it will be necessary to remove thecharge before opening any part of the unit. While the main disconnect switch and...
Page 54 - Minimum Insulation Resistance vs. Temperature (per IEEE Std 43)
54 Y ORK INTERNA TIONAL FIG. 24 – M O T OR ST A T OR TEMPERA TURE AND INSULA TION RESIST ANCES LD00476 TEMPERA TURE – °F MEGOHMS Minimum Insulation Resistance vs. Temperature (per IEEE Std 43) Open Motors
Page 55 - CONDENSERS AND COOLERS; COOLER
YORK INTERNATIONAL 55 FORM 160.49-O2 CONDENSERS AND COOLERS GENERAL Maintenance of condenser and cooler shells is impor-tant to provide trouble free operation of the chiller. Thewater side of the tubes in the shell must be kept cleanand free from scale. Proper maintenance such as tubecleaning, and t...
Page 57 - COMPRESSOR
YORK INTERNATIONAL 57 FORM 160.49-O2 COMPRESSOR ELECTRICAL CONTROLS Maintenance for the compressor assembly consists ofchecking the operation of the oil return system andchanging the dehydrator, checking and changing theoil, checking and changing the oil filters, checking theoperation of the oil hea...
Page 58 - SECTION 8; PREVENTIVE MAINTENANCE
58 YORK INTERNATIONAL SECTION 8 PREVENTIVE MAINTENANCE It is the responsibility of the owner to provide the nec-essary daily, monthy and yearly maintenance require-ments of the system. IMPORTANT – If a unit failure occurs due to improper maintenance during the war-ranty period; YORK will not be liab...
Page 59 - ELECTRICAL CONTROLS; All electrical controls should be inspected for obvi-
YORK INTERNATIONAL 59 FORM 160.49-O2 eductor should be checked for any foreign particlesthat may be obstructing the jet. ELECTRICAL CONTROLS 1. All electrical controls should be inspected for obvi- ous malfunctions. 2. It is important that the factory settings of controls (operation and safety) not ...
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