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York YT Millennium Operating & Maintenance

With optiview control center for electro-mechanical starter,solid state starter and variable speed drive
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MILLENNIUM
®
CENTRIFUGAL LIQUID CHILLERS
OPERATING & MAINTENANCE
Supersedes: 160.55-O1 (604)
Form 160.55-O1 (920)
MODEL YT (STYLE J)
R-123 COOLING ONLY
WITH OPTIVIEW
CONTROL CENTER
™
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER and VARIABLE SPEED DRIVE
29509A
Issue Date:
September 18, 2020

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  • Page 1 MILLENNIUM ® CENTRIFUGAL LIQUID CHILLERS OPERATING & MAINTENANCE Supersedes: 160.55-O1 (604) Form 160.55-O1 (920) MODEL YT (STYLE J) R-123 COOLING ONLY WITH OPTIVIEW CONTROL CENTER ™ FOR ELECTRO-MECHANICAL STARTER, SOLID STATE STARTER and VARIABLE SPEED DRIVE 29509A Issue Date: September 18, 2020...
  • Page 2 Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warning will void the manufacturer’s warranty and cause serious damage to property or personal injury. YORK INTERNATIONAL...
  • Page 3 Planned Service Agreement that leverages real time and generalized conditions. In lieu of the tradition- and historical data, delivering performance reporting, al maintenance program, a Johnson Controls YORK corrective actions required and data enabled guidance Conditioned Based Maintenance (CBM) program can for optimal operation and lifecycle assurance.
  • Page 4 FORM 160.55-O1 (920) NOMENCLATURE The model number denotes the following characteristics of the unit — Model Design Level Cooler Code Motor Code Condenser Code Power Supply — for 60 Hz Compressor Code 5 for 50 Hz YORK INTERNATIONAL...

  • Page 5: Table Of Contents

    Printers ..................... 112 SECTION System Operating Procedures ..............124 SECTION System Components Description ............. 131 SECTION Operational Maintenance ................. 135 SECTION Troubleshooting ..................138 SECTION Maintenance ..................... 144 SECTION Preventive Maintenance ................152 SECTION OptiSave Energy Analyser Feature ............154 YORK INTERNATIONAL...
  • Page 6 FORM 160.55-O1 (920) LIST OF FIGURES FIG. 1 – MODEL YT MILLENNIUM CHILLER ....7 FIG. 33 – HISTORY SCREEN .......... 76 FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER . 8 FIG. 34 – HISTORY DETAILS SCREEN ......78 DETAIL A – COMPRESSOR PREROTATION FIG.

  • Page 7: Section 1 Description Of System And Fundamentals Of Operation

    SYSTEM OPERATION DESCRIPTION (SEE FIG. 2) Control Center with a serial communications link. Ear- The YORK Model YT Millennium Chiller is commonly lier vintage chillers, such as those encountered in Control applied to large air conditioning systems, but may be Center retrofit applications are equipped with the Mod used on other applications.

  • Page 8: Fig. 2 - Refrigerant Flow-Through Chiller

    COMPRESSOR PREROTATION VANES (See Detail A) DISCHARGE SUCTION DISCHARGE BAFFLE COOLER CONDENSER ELIMINATOR SUB-COOLER FLOW CONTROL ORIFICE LD00924 OIL COOLER FIG. 2 – REFRIGERANT FLOW-THRU CHILLER YORK INTERNATIONAL...

  • Page 9: Section 2 Optiview Control Center

    FORM 160.55-O1 (920) SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION The YORK OptiView Control Center is a micropro- Advanced Diagnostics and troubleshooting information cessor based control system for R-11 or R123 centrifugal are also for Service Technicians only. Other chiller chillers. It controls the leaving chilled liquid temperature...
  • Page 10 Software version Cards are shirt-pocket-size portable memory stor- C.OPT.02.04B.xxx is of the same controls revision age devices available from YORK. level as C.MLM.02.04.xxx. From this starting point, both receive the same updates at each revision. Soft- Earlier vintage chillers could be equipped with a later ware upgrades should only be performed by a Service Microboard due to service replacement.
  • Page 11 FORM 160.55-O1 (920) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 12: Fig. 3 - Control Center

    The Start/Stop control is operated via a three-position this state to receive a valid remote start signal when rocker switch. When toggled all the way to the right, it is operating under a remote control source. considered in the STOP/RESET position. When in the YORK INTERNATIONAL...
  • Page 13 2. If the dialog box begins with the word “ENTER”, Access Level of VIEW. This will allow the user to navi- use the numeric keys to enter the desired value. YORK INTERNATIONAL...
  • Page 14 Advanced Trend Setup (page 80) for that screen. Following is a layout of all the screens Common Slots (page 82) and how they are connected. Custom View (page 83) Custom Setup (page 84) YORK INTERNATIONAL...
  • Page 15 100.0 PSIA 689.5 KPAA Refrigerant Level (Future) 100.0 100.0 Drop Leg Refrigerant Temperature 121.8 °F -17.7 49.8 °C *Saturation temperatures are calculated values. They will display XXX if the pressure used for the calculation is out of range. YORK INTERNATIONAL...

  • Page 16: Fig. 4 - Home Screen

    10 continuous minutes without a keypress. Motor Run (LED) Is ON when the digital output controlling the Motor SERVICE: In the event that advanced diagnostics are necessary, a SERVICE access level has been provided. Starter contact is on. YORK INTERNATIONAL...
  • Page 17 Using this key, the message can be cleared once the condition has been removed. Warning Reset Access Level Required: OPERATOR Use of this key acknowledges a warning condition and resets the message display associated with it. YORK INTERNATIONAL...

  • Page 18: Fig. 5 - System Screen

    XX.X. mode or a locally programmed value in local mode. % Full Load Amps Evaporator Pressure This displays the percentage of full load amps utilized Displays the present refrigerant pressure in the evaporator. by the system. YORK INTERNATIONAL...
  • Page 19 0-20mA or 4-20mA, 0-10VDC or 2-10VDC Home input in Analog Remote mode, PWM signal in Digital Access Level Required: VIEW Remote mode, MicroGateway interface in ISN mode or Causes an instant return to the Home Screen. a locally programmed value. PROGRAMMABLE None YORK INTERNATIONAL...

  • Page 20: Fig. 6 - Evaporator Screen

    By default, the chiller Leaving Chilled Liquid Temperature will restart at the Leaving Chilled Liquid Temperature Displays the temperature of the liquid as it leaves the Setpoint. evaporator. YORK INTERNATIONAL...
  • Page 21 34°F (water with Smart Freeze enabled) or 6°F (brine). It establishes the minimum allowable temperature for the Leaving Chilled Liquid Temperature and prevents over- cooling of the building. Anytime the Leaving Chilled Liquid Temperature setpoint is increased, the shutdown YORK INTERNATIONAL...

  • Page 22: Fig. 7 - Condenser Screen

    Displays the difference between the Condenser Refrig- erant temperature and the Leaving Condenser Liquid temperature. The Condenser Refrigerant temperature Refrigerant Level Position Displays the present position of the refrigerant level if will be represented by the Condenser Saturation tem- perature. this function is enabled. YORK INTERNATIONAL...
  • Page 23 Drop Leg (Enabled / Disabled) Access Level Required: SERVICE When a Drop Leg Refrigerant Sensor has been installed it must be enabled via this toggle before the system will utilize the new, enhanced resolution input. YORK INTERNATIONAL...

  • Page 24: Fig. 8 - Purge Screen

    Displayed as 0 to 60 minutes. After a 60 minute bypass Illuminated when the Top Float Switch is closed, at chiller start, the Exhaust Window increments from 0 indicating the Purge Tank oil level is less than full. YORK INTERNATIONAL...
  • Page 25 Access Level Required: SERVICE Access Level Required: VIEW Selects the appropriate control and purge exhaust Causes an instant return to the Condenser Screen. thresholds for the installed purge system. High Effi- ciency (pump assisted) purge systems exhaust at >90.0 YORK INTERNATIONAL...

  • Page 26: Fig. 9 - Refrigerant Level Control Screen

    70% full. When the actual level is 48% to 63%, the level is shown about 80% full. When the actual level is 64% to 79%, the level is shown as about 90% full. Actual levels above 79%, shown as 100% full. YORK INTERNATIONAL...
  • Page 27 This key puts the level control into manual mode and sends a LOWER command to the variable orifice. [Refrigerant Level Control] Hold (Manual) This key puts the level control into manual mode and sends a HOLD command to the variable orifice. YORK INTERNATIONAL...

  • Page 28: Fig. 10 - Compressor Screen

    Displays the temperature of the refrigerant in its gaseous This value displays the present position of the pre-ro- state at discharge of the compressor as it travels to the tation vanes as a percentage between 0 and 100%. condenser. YORK INTERNATIONAL...
  • Page 29 Surge Protection feature. sends a HOLD command to the vanes. [Pre-Rotation Vanes] Auto Access Level Required: SERVICE This key returns the vane control to automatic mode. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen. YORK INTERNATIONAL...

  • Page 30: Fig. 11 - Hot Gas Bypass Screen

    When actual position is 60% to 79%, the valve is Surge Detected (LED) shown as 75% open. Positions greater than 79% shown Illuminated for 5 seconds each time a surge is detected as full open. by the Surge Protection feature. It does not illuminate YORK INTERNATIONAL...
  • Page 31 Causes an instant return to the Compressor Screen. earlier. On SURGE PROTECTION Screen in later Flash Memory Card versions) Access Level Required: SERVICE Minimum Load Access Level Required: SERVICE Maximum Open (Flash Memory Card version C.MLM.02.02.xxx and later) Access Level Required: SERVICE YORK INTERNATIONAL...

  • Page 32: Fig. 12 - Surge Protection Screen

    “Warning – Surge Surge Window Count Protection – Excess Surge Limit” is displayed. Refer to Displays the number of surge events that have oc- operation under “Count Limit” below. YORK INTERNATIONAL...
  • Page 33 “Warning – Surge Protection – Excess Surge Limit” provided the SURGE WINDOW COUNT is less than is displayed. When the 10 minutes have elapsed, or equal to the COUNT LIMIT. If the SHUTDOWN YORK INTERNATIONAL...
  • Page 34 Causes an instant return to the Home Screen “Surge Protection – Excess Surge” is displayed. See Hot Gas Bypass and Variable Speed Drive exception Compressor above. Access Level Required: VIEW Causes an instant return to the Compressor Screen. YORK INTERNATIONAL...
  • Page 35 FORM 160.55-O1 (920) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 36: Fig. 13 - Pre-Rotation Vanes Calibration Screen

    Indicates the vanes are closing. Return to the Compressor Screen. Calibration in Progress (LED) Indicates the calibration sequence is in progress. Calibration Messages These are text messages which step the user through the calibration process and indicate its success or failure. YORK INTERNATIONAL...
  • Page 37 FORM 160.55-O1 (920) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 38: Fig. 14 - Vsd Tuning Screen

    Displays the frequency value being sent to the Adaptive Temperature Differential Capacity Control. Displays the differential between the Leaving Chilled Liquid Temperature and Setpoint. [VSD] Frequency Control Mode (Manual / Auto) Displays the present state of the command frequency control. YORK INTERNATIONAL...
  • Page 39 This key puts the VSD frequency control into manual Access Level Required: VIEW mode and increases the present command frequency by Return to the Compressor Screen. the defined frequency increment. It will not raise the value above the maximum allowed frequency. YORK INTERNATIONAL...

  • Page 40: Fig. 15 - Oil Sump Screen

    XX.X. NAVIGATION Oil Pump Run Output (LED) Indicates whether the Oil Pump is being commanded Home to operate. Access Level Required: VIEW Causes an instant return to the Home Screen. YORK INTERNATIONAL...

  • Page 41: Fig. 16 - Electro-Mechanical Starter Screen

    Pulldown Demand Time Left Displays the time remaining in the programmed pull- down period if the value is non-zero. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen. YORK INTERNATIONAL...

  • Page 42: Fig. 17 - Solid State Starter (Mod A) Screen

    This function is used to provide energy savings down period. following chiller start-up. Scale/Model Pulldown Demand Time Display information about the Liquid Cooled-Solid Access Level Required: OPERATOR State Starter Rating and the maximum allowed Full Load Amps. YORK INTERNATIONAL...
  • Page 43 Access Level Required: SERVICE Allows the user to select a specific voltage range for voltage checking. When not disabled, this line voltage range is used to determine a low line and high line volt- age threshold for initiating a shutdown. YORK INTERNATIONAL...

  • Page 44: Fig. 18 - Solid State Starter (Mod B) Screen

    Pre-rotation Vanes will not be Displays the Kilowatts measured by the Solid State permitted to open further. If the motor rises above this Starter. value, the Pre-rotation Vanes will close to reduce the current to this value. YORK INTERNATIONAL...
  • Page 45 Starter Shorted SCR safety detection. This must never Allows the user to set a period of time for which the be disabled unless under advisement of the York Factory. pulldown demand limit will be in effect after the chiller kWH Reset starts.

  • Page 46: Fig. 19 - Variable Speed Drive Screen

    Supply kVA. Output Voltage Displays the output voltage measured to the motor. Voltage Total Harmonic Distortion - L1, L2, L3 Displays the Total Harmonic Distortion (THD) for each of the voltage lines as calculated by the filter. YORK INTERNATIONAL...
  • Page 47 Allows the user to set a period of time for which the Access Level Required: VIEW pulldown demand limit will be in effect after the chiller Moves to the subscreen which provides more infor- starts. mation about the Harmonic Filter. YORK INTERNATIONAL...
  • Page 48 Analog Remote mode, PWM signal in Digital Internal Ambient Temperature Remote mode, MicroGateway interface in ISN mode or Displays the ambient temperature inside the VSD cab- a locally programmed value. inet as reported by the VSD. YORK INTERNATIONAL...
  • Page 49 (as a percentage of FLA). When the motor current reaches this value, the pre-rotation vanes will not be permitted to open further. If the motor current rises above this value, the pre-rotation vanes will close to reduce the current to this value. YORK INTERNATIONAL...

  • Page 50: Fig. 21

    0-20mA, 4-20mA, 0-10VDC or 2-10VDC DC Inverter Link Current input in Analog Remote mode, PWM signal in Digital Displays the DC Inverter link current as reported by Remote mode, MicroGateway interface in ISN mode or the VSD. a locally programmed value. YORK INTERNATIONAL...
  • Page 51 Allows the user to specify the maximum allowed mo- Access Level Required: VIEW tor current (as a percentage of FLA). When the motor Returns to the VSD Screen. current reaches this value, the pre-rotation vanes will not be permitted to open further. If the motor current YORK INTERNATIONAL...

  • Page 52: Fig. 22 - Adaptive Capacity Control Details Screen

    Remote mode, MicroGateway interface in ISN mode or not be permitted to open further. If the motor current a locally programmed value. rises above this value, the pre-rotation vanes will close to reduce the current to this value. YORK INTERNATIONAL...
  • Page 53 Mapping a point at these conditions will cause the ACC to make adjust- ments to the command frequency in the future in order to prevent the chiller from operating at the conditions mapped. USE WITH CAUTION. YORK INTERNATIONAL...
  • Page 54 Remote mode, MicroGateway interface in ISN mode Total Supply kVA or a locally programmed value. Displays the total supply KiloVolt-Amps measured by the Harmonic Filter. Pulldown Demand Time Left Displays the time remaining in the programmed pull- down period if the value is non-zero. YORK INTERNATIONAL...
  • Page 55 RMS Supply Current (L1, L2, L3) Displays the 3-phase RMS Voltages across each line. Access Level Required: VIEW PROGRAMMABLE Returns to the VSD Screen. Local Motor Current Limit Access Level Required: OPERATOR Allows the user to specify the maximum allowed mo- YORK INTERNATIONAL...
  • Page 56 Displays the time remaining in the programmed pull- Baseplate Temperature down period if the value is non-zero. Displays the temperature of the Harmonic Filter Base- plate. Operating Mode (Run / Stop) Indicates whether the Harmonic Filter is operating. YORK INTERNATIONAL...
  • Page 57 Causes an instant return to the Home Screen. Local Motor Current Limit Access Level Required: OPERATOR Allows the user to specify the maximum allowed mo- Access Level Required: VIEW tor current (as a percentage of FLA). When the motor Returns to the VSD Screen. YORK INTERNATIONAL...

  • Page 58: Fig. 25 - Setpoints Screen

    Leaving Chilled Liquid Temperature Cycling – Re- the operator programmed value is 45°F, then the remote start device can set the Leaving Chilled Liquid Temperature Displays the Leaving Chilled Liquid Temperature at which setpoint over the range 45.0° - 55.0°F. YORK INTERNATIONAL...
  • Page 59 Leaving Chilled Liquid Access Level Required: VIEW Temperature setpoint. It is programmable over a range Moves to the subscreen allowing setup of general system of 0°F to 70°F above the setpoint, to a maximum restart parameters. YORK INTERNATIONAL...

  • Page 60: Fig. 26 - Setup Screen

    Chilled Liquid Pump Operation: Displays Standard or Enhanced 031-02430-000 Microboard Refrigerant Selection Motor Type: Displays R11 or R123 Displays Fixed Speed or Variable Speed Liquid Type Refrigerant Selection: Displays R-11 or R123 Displays Water or Brine Anti-Recycle: Displays Disabled or Enabled YORK INTERNATIONAL...
  • Page 61 Used to enter the following setpoints. Pressing this key Schedule places a green selection box around the first changeable Access Level Required: VIEW setpoint. The access level determines which setpoints Moves to the subscreen allowing definition of the chiller operation schedule. YORK INTERNATIONAL...
  • Page 62 Moves to the subscreen displaying operating parameters communications. of the chiller system. Printer User Access Level Required: VIEW Access Level Required: VIEW Moves to the subscreen allowing configuration and Moves to the subscreen allowing configuration of user control of printer functions. preferences. YORK INTERNATIONAL...
  • Page 63 FORM 160.55-O1 (920) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 64: Fig. 27 - Schedule Screen

    Schedule (Enabled / Disabled) of each week the schedule for the next week is created Access Level Required: OPERATOR by combining the standard week definition and the next Allows the user to enable or disable the monitoring func- YORK INTERNATIONAL...
  • Page 65 6 weeks. Causes an instant return to the Home Screen. Select Setup Access Level Required: OPERATOR Access Level Required: VIEW Places a selection box around a start time for a given day. Return to the previous setup screen. YORK INTERNATIONAL...

  • Page 66: Fig. 28 - User Screen

    Setup navigates from the USER Screen to another Screen. Access Level Required: VIEW Return to the Setup Screen. English / Metric Units Access Level Required: OPERATOR Define the unit system (English or Metric) used by the chiller display. YORK INTERNATIONAL...
  • Page 67 FORM 160.55-O1 (920) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 68: Fig. 29 - Comms Screen

    Define the number of parity bits at which the panel shall to be changed. With the selection box around the de- communicate through the modem port. sired parameter, press the ENTER key. A dialog box is displayed permitting data entry. YORK INTERNATIONAL...
  • Page 69 Define the number of stop bits at which the panel shall Access Level Required: VIEW communicate through the modem port. Return to the Setup Screen. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen. YORK INTERNATIONAL...

  • Page 70: Fig. 30 - Printer Screen

    Print All Histories the interval defined above. Access Level Required: OPERATOR Printer Type Generate a report of the system data at the time of all Access Level Required: OPERATOR stored shutdowns. Define the printer type connected to the chiller system. YORK INTERNATIONAL...
  • Page 71 FORM 160.55-O1 (920) NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen. Setup Access Level Required: VIEW Return to the Setup Screen. YORK INTERNATIONAL...

  • Page 72: Fig. 31 - Sales Order Screen

    Commissioning Date other than a qualified Service Technician. The remainder Access Level Required: SERVICE of the values are entered at the YORK Factory during the Define the date at which the chiller was commis- manufacturing of the chiller. sioned.
  • Page 73 FORM 160.55-O1 (920) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 74: Fig. 32 - Operations Screen

    Number of Starts Although the label and number can be changed appro- Access Level Required: ADMIN priately, the default for this entry is “York Intl North Displays the number of the starts the chiller has initiated. American Toll Free Number 1-800-861-1001”. The...
  • Page 75 FORM 160.55-O1 (920) NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen. Setup Access Level Required: VIEW Return to the Setup Screen. YORK INTERNATIONAL...

  • Page 76: Fig. 33 - History Screen

    This window displays the date and time and the de- Access Level Required: VIEW scription of the last safety or cycling shutdown while Causes a move to a subscreen containing the value of the system was running. select chiller parameters at the time of the associated shutdown. YORK INTERNATIONAL...
  • Page 77 Causes a move to a sub-screen allowing the user to view Custom View a record of the last 75 setpoint changes. (Flash memory Card version C.MLM.02.01 or later) Access Level required: VIEW Causes a move to a sub-screen allowing the user to view the Custom Setup Screen. YORK INTERNATIONAL...

  • Page 78: Fig. 34 - History Details Screen

    Access Level Required: VIEW ters. Causes an instant return to the Home Screen. PROGRAMMABLE History Access Level Required: VIEW Page Up Causes a return to the History Screen. Access Level Required: VIEW Scroll up in the displayed data (if applicable). YORK INTERNATIONAL...

  • Page 79: Fig. 35 - Security Log Screen

    New Value Access Level Required: SERVICE Displays the value that was entered at the time of the Causes a move to a sub-screen containing the details of setpoint change. the setpoint change selected with the Log Entry key. YORK INTERNATIONAL...

  • Page 80: Fig. 36 - Security Log Details Screen

    Description Displays the setpoint/category that was changed. NAVIGATION Time Home Displays the time the setpoint was changed. Access Level Required: SERVICE Causes an instant return to the Home Screen. Date Displays the date the setpoint was changed. YORK INTERNATIONAL...
  • Page 81 Access Level Required: SERVICE Causes an instant return to the Security Log Screen. View Details Access Level Required: SERVICE Causes a move to a sub-screen containing the details of the setpoint change selected with the Log Entry key. YORK INTERNATIONAL...

  • Page 82: Fig. 37 - Trend Screen

    The START key must be pressed the X-Axis. If the actual value of the sampled parameter to initiate a new trend screen. is less than the Y-Axis label minimum for that parameter, the value will be plotted at the minimum value. Simi- YORK INTERNATIONAL...
  • Page 83 Only displayed if the trending is stopped. Causes a jump taneously or select a single trended data point for display, to a subscreen for configuring the trending display. hiding the other data points. Selections are ALL DATA or DATA POINT X (1-6). YORK INTERNATIONAL...

  • Page 84: Fig. 38 - Trend Setup Screen

    3. Decide if the resultant sample interval and full screen Selects the interval at which the parameters are sampled. display meet the requirements. If not, select a dif- There are 450 data points displayed across the X-Axis ferent sample interval. YORK INTERNATIONAL...
  • Page 85 (0). Zero indicates the OFF state. played if TRIGGERED has been selected as Chart Data Point Max (1-6) Type. Access Level Required: OPERATOR Only displayed if the associated slot number is not zero. This is the maximum value displayed for the Y-Axis. YORK INTERNATIONAL...

  • Page 86: Fig. 39 - Advanced Trend Setup Screen

    Trigger to start/stop data collection. The Primary to Sec- DISPLAY ONLY ondary Operator is used to define the Trigger combina- tions required to be true to start/stop data collection. The None Secondary Trigger is setup and evaluated the same as the Primary Trigger. YORK INTERNATIONAL...
  • Page 87 If the Trigger Action is set to Stop, data collection will Causes an instant return to the Home Screen. stop after the Triggers evaluate as true and the delay timer has elapsed. TREND SETUP Causes an instant return to the Trend Setup Screen. YORK INTERNATIONAL...

  • Page 88: Fig. 40 - Common Slots Screen

    Generates a list of the slot numbers of the available parameters. NAVIGATION Home DISPLAY ONLY Causes an instant return to the Home Screen. Slot Numbers Trend Setup These are the slot numbers of the most commonly used Causes a return to the Trend Setup Screen. parameters. YORK INTERNATIONAL...

  • Page 89: Fig. 41 - Custom View Screen

    Access Level required: VIEW DISPLAY ONLY Causes an instant return to the History Screen. None Setup PROGRAMMABLE Access Level required: SERVICE Causes a jump to the sub-screen that allows selection of Print the parameters to be displayed. Access Level Required: VIEW YORK INTERNATIONAL...

  • Page 90: Fig. 42 - Custom View Setup Screen

    Scroll down through list of available parameters. Custom View Access Level Required: SERVICE Select Causes a return to the Custom View Screen. First use the Page Up and Page Down keys to scroll through the Slot Numbers list and note the number of YORK INTERNATIONAL...
  • Page 91 Condenser: Saturation Temperature 1537 Oil: Sump Temperature 2054 Condenser: Small Temperature Difference 1538 Oil Pump: Control Mode 2057 Condenser: Is High Pressure Switch Closed 1539 Oil Pump: Is Pump On 2058 Condenser: High Pressure Warning Threshold 1540 Oil Pump: Manual Time Left YORK INTERNATIONAL...
  • Page 92 2584 LcSss: Starting Current 2868 Filter: Supply KVA 2585 LcSss: Is Serial Communications OK 2869 Filter: Total Power Factor 2586 LcSss: Panel to Sss Comm Errors 2870 Filter: DC Bus Voltage 2587 LcSss: Sss to Panel Comm Errors YORK INTERNATIONAL...
  • Page 93 Filter: L3 Total Demand Distortion 12292 Purge: Is Top Float Switch Closed 2890 Filter: Maximum Total Harmonic Distortion 12293 Purge: Exhaust Count 2891 Filter: Maximum Total Demand Distortion 12294 Purge: Window Time 12295 Purge: Is High Efficiency Enabled 12296 Purge: Maximum Purges Per Hour YORK INTERNATIONAL...
  • Page 94 The chiller is running, controlling the Leaving Chilled “SYSTEM RUN” Liquid to the Leaving Chilled Liquid Temperature The chiller is running under the condition described in Setpoint. There are no system conditions inhibiting the Details Line of the Status Bar. this operation. YORK INTERNATIONAL...
  • Page 95 Brine solution and is determined by is then read from the BRAM and compared to the test the YORK Factory. While this condition is in effect, data. If the read data is not the same as that which was...
  • Page 96 WARNING RESET key is pressed on least 20 seconds. Message automatically clears when the HOME Screen is OPERATOR (or higher) access mode. communications are restored. This warning will not be displayed if the Purge Float Switch Error warning (below) is in effect. YORK INTERNATIONAL...
  • Page 97 “REMOTE STOP” manual restart after power failure by a qualified Service A shutdown command has been received from a re- Technician. mote device. Remote Stop commands can be received in Digital Remote mode via I/O Board TB4-7/8 or in YORK INTERNATIONAL...
  • Page 98 Run”. The chiller will automatically restart when the LED on the respective device illuminates to identify the flow switch closes. specific fault that has occurred. Refer to YORK Manual 160.46-OM3.1 for details of Mod “A” Solid State Start- “MOTOR CONTROLLER –...
  • Page 99 The Liquid Cooled State Starter Logic/Trigger Board The Liquid Cooled Solid State Starter receives two has shut down the chiller but the OptiView Control start signals from the OptiView Control Center simul- Center has not yet received the cause of the fault from YORK INTERNATIONAL...
  • Page 100 33L-215 to 1050A. The chiller will be permitted to communications are restored. start when the jumpers are configured correctly. Refer to YORK Starter service manual 160.00-O2 for valid “LCSSS - PHASE LOSS” jumper configurations. (Flash Memory Card version C.MLM.02.01 or later) “LCSSS –...
  • Page 101 Center Microboard does not take place during INSTANTANEOUS CURRENT” initialization, this message will be generated. The See “High Phase A Instantaneous Current” message Serial communications can be verified by selecting above. the VSD DETAILS screen from the MOTOR screen YORK INTERNATIONAL...
  • Page 102 120VAC control power transformer. This message usu- strainer plugs frequently, the heat-exchanger may ally means the power to the VSD has been removed. eventually plug or become restricted to the point of reduced flow. At this point, we suggest you back- YORK INTERNATIONAL...
  • Page 103 In most cases, lem occurs between the two microprocessors on the the problem will be an open thermistor or broken wir- VSD Logic Board. ing to the thermistor. The normal thermistor resistance is 10K ohms at 77ºF. YORK INTERNATIONAL...
  • Page 104 This setpoint logic board. The preset limits are as follows: is set to the peak of the sensed input line-to-line voltage plus 32 volts, not to exceed 760 volts and it varies with YORK INTERNATIONAL...
  • Page 105 The Brine shutdown threshold is programmed at a given threshold for 7 seconds, a chiller shutdown is the YORK Factory. It should not be changed by anyone performed and this message is displayed. The maximum other than a qualified Service Technician. The chiller...
  • Page 106 PSIA and the COMPRESSOR switch is placed in the enabled by a Service technician using instructions Stop-Reset (O) position. in YORK Service Manual 160.55.M1 • Not in Brine cooling mode “AUXILIARY SAFETY – CONTACTS CLOSED” • Smart Freeze is enabled (Flash Memory Card ver- The Auxiliary Safety shutdown contacts, connected sion C.MLM.02.02.xxx and later)
  • Page 107 Extended Run period. The chiller can be started after the Stop-reset (O) position. This message can indicate the COMPRESSOR Switch is placed in the Stop-Reset a Cycling (auto-restart after power failure) or Safety (O) position. (manual restart after power failure) shutdown, depend- YORK INTERNATIONAL...
  • Page 108 “LCSSS – PHASE X SHORTED SCR” after manual resets are performed as detailed below. A shorted Silicon Controlled Rectifier (SCR) in phase A, B or C (designated as X in the message) has been detected by the Liquid Cooled Solid State Starter YORK INTERNATIONAL...
  • Page 109 (Style D VSD) and later) See Phase A message above. The chiller has shutdown because the baseplate tempera- ture has increased to >158 ºF. The chiller can be stated after the fault condition clears, the RESET button on the YORK INTERNATIONAL...

  • Page 110: Fig. 45 - Sample Printout (Setpoints)

    (15 or 30 min demand)”. In the any heatsink exceeds 167°F, the unit will shut down. Filter option supplied by YORK, the displayed TDD is This message is usually an indication of a low cool- the total RMS value of all the harmonic current supplied ant level in the VSD cooling loop.
  • Page 111 FORM 160.55-O1 (920) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 112: Section 3 Printers

    Printers FORM 160.55-O1 (920) SECTION 3 PRINTERS 23887A OKIDATA MICROLINE 184 23889A WEIGH-TRONIX 00085VIP SEIKO DPU-414 FIG. 43 – PRINTERS YORK INTERNATIONAL...
  • Page 113 C.MLM.02.03.xxx and later) ations. • Figure 50 - Trend (Flash Memory Card version 2. Primary differences between printers involve the for- C.MLM.02.02.xxx and later) matting control codes required by the printer. These • Figure 51 - Custom Screen YORK INTERNATIONAL...
  • Page 114 • WEIGH-TRONIX Printer alent; Shell DB-C2-J9 or equivalent. Weigh-Tronix - IMP-24 Model 2600 - Same as Okidata. Cable assembly available from SW1 - off 1200 Baud* Weigh-Tronix. Seiko - 9-Pin D-type Subminiature 2 - on 1200 Baud* (DB-9 pin male). YORK INTERNATIONAL...
  • Page 115 • Log Start Time - Enter the time the first print is 3-3 = on Parity condition - odd desired. 3-4 = on Busy control - H/W busy • Output Interval - Enter the desired interval between 3-5 = on Baud rate select - 1200* prints. YORK INTERNATIONAL...

  • Page 116: Fig. 44 - Sample Printout (Status)

    = 15 % CHILLER ID Pre-Rotation Vanes Position = 75 % YORK Update Chiller ID Surge ------------------------------------------------------------------------- ------------------------------------------------------------------------- (c) 1997 – 2001 YORK INTERNATIONAL Total Surge Count = 127 Surge Window Time = 1 Min CORPORATION Surge Window Count SYSTEM RUN...
  • Page 117 L3 RMS Filter Current = 150 A L1 RMS Supply Current = 152 A L2 RMS Supply Current = 152 A L3 RMS Supply Current = 152 A L1 Voltage Total Harmonic Distortion = 1.5 % FIG. 44 – CONTINUED YORK INTERNATIONAL...
  • Page 118 CHILLER ID Leaving Chilled Modem Setpoint 45.0 ~F Leaving Chilled Analog Setpoint 45.0 ~F ------------------------------------------------------------------------- Leaving Chilled Digital Setpoint 45.0 ~F © 1997 - 1999 YORK INTERNATIONAL CORPO- Remote Range 10.0 ~F RATION Sensitivity Normal Restart Offset 0.0 ~F Restart Setpoint 45.0 ~F...

  • Page 119: Fig. 46 - Sample Printout (Schedule)

    CHILLER ID Pulldown Demand Limit 100 % Pulldown Demand Time 0 Min © 1997 - 1999 YORK international corporation mon 21 jun 1999 1:28:25 pm [Skip the following section if Motor Type is not Mod A SSS] Liquid-Cooled Solid State Starter...

  • Page 120: Fig. 47 - Sample Printout (Sales Order)

    Printers FORM 160.55-O1 (920) YORK SALES ORDER Nameplate Information CHILLER ID --------------------------------------------------------------------------- © 1997 - 1999 YORK INTERNATIONAL CORPORATION Motor Code Mon 21 jun 1999 1:28:46 PM Power (Volts) Phases Order Information Frequency (Hz) --------------------------------------------------------------------------- Looked Rotor Amps 4400 Commissioning date...

  • Page 121: Fig. 48 - Sample Printout (History)

    = 0 % CHILLER ID Pre-Rotation Vanes Position = 0 % Surge --------------------------------------------------------------------------- --------------------------------------------------------------------------- © 1997 - 1999 YORK INTERNATIONAL CORPORATION Total Surge Count = 127 Surge Window Time = 1 Min Surge Window Count MSYSTEM READY TO START LCSSS – LOGIC BOARD POWER SUPPLY...

  • Page 122: Fig. 49 - Sample Printout (Security Log)

    [Skip the following section if Motor Type is not VSD] YORK SETPOINT CHANGE LOG Variable Speed Drive CHILLER ID 163 -------------------------------------------------------------------------- © 1997 – 2000 YORK INTERNATIONAL CORPORATION Motor Run = Off Mon 09 Oct 2000 3:33:47 PM % Full Load Amps...

  • Page 123: Fig. 50 - Sample Printout (Trend)

    YORK TREND YORK CUSTOM VIEW CHILLER ID 0 CHILLER ID 163 (c) 1997 – 2001 YORK INTERNATIONAL CORPORATION © 1997 – 2000 YORK INTERNATIONAL CORPORATION Mon 21 Jun 1999 1:28:25 PM Mon 09 Oct 2000 3:33:47 PM Data 1: Leaving Chilled Liquid Temperature Leaving Chilled Liquid Temperature 45.0 ~F...

  • Page 124: Section 4 System Operating Procedures

    When the start switch is energized the Control Center be programmed. If not programmed the “default” is placed in an operating mode and any malfunction value setpoints are as follows: will be noted by messages on the OptiView Control Center. (See Fig. 3) YORK INTERNATIONAL...
  • Page 125 “SYSTEM RUN”. Condenser Water Temperature Control Chiller Operation The YORK Millennium chiller is designed to use less power by taking advantage of lower than design After the compressor reaches its operating speed the temperatures that are naturally produced by cooling prerotation vanes will begin to open under the control towers throughout the operating year.
  • Page 126 START (0.4) (0.5) (5.5) (30) RESTART (ONLY TIME IN SECONDS (MINUTES) RESTART (IF AFTER THE FIFTH FIVE SUCCESSIVE SUCCESSIVE RESTART) RESTARTS HAVE NOT OCCURRED) LD04644 FIG. 55 – OPERATION SEQUENCE TIMING DIAGRAM (COMPRESSOR MOTOR VARIABLE SPEED DRIVE APPLICATIONS) YORK INTERNATIONAL...

  • Page 127: Fig. 56 - Minimum Entering Condensing Water Temperature

    23889A LD00467 *NOTE: These items can be printed by an electronic printer connected to the Microboard and pressing the PRINT key on the Keypad or automatically using the Data Logger feature. FIG. 57 – LIQUID CHILLER LOG SHEETS YORK INTERNATIONAL...
  • Page 128 An optional status printer is available for this purpose; 7. Check the compressor motor voltage and current or, Fig. 48 shows a log sheet used by YORK personnel (amps) at E-M starter (or Variable Speed Drive), or for recording test data on chillers. It is available from on the OptiView Control Center motor display for the factory in pads of 50 sheets each under Form No.

  • Page 129: Fig. 58 - Turboguard Purge Unit

    1. If unit is equipped with SSS or VSD, flush cooling Center in “SERVICE” mode to reset the display. Leak check and correct the leak if the display continues to circuit and replace with new coolant solution, YORK Part # 013-02987-000. show this message.
  • Page 130 If the water During long idle periods, the tightness of the system systems were drained, fill the condenser water circuit should be checked periodically. and chilled liquid circuit. YORK INTERNATIONAL...

  • Page 131: Section 5 System Components Description

    Hz immersion type. A separate three phase power sup- joints and fabricated of close-grain cast iron. The motor ply is required except when ordered with a YORK Solid assembly is completely removable from the compressor State Starter or Variable Speed Drive. A gravity flow oil rotor and scroll assembly.

  • Page 132: Fig. 59 - Schematic Drawing (Yt) Compressor Lubrication System

    System Components Description FORM 160.55-O1 (920) FIG. 59 – SCHEMATIC DRAWING – (YT) COMPRESSOR LUBRICATION SYSTEM LD03278 YORK INTERNATIONAL...
  • Page 133 1, 2, the various bearings and gears in the event of a system or 3-pass arrangements. Water nozzle connections with shutdown due to power failure. The reservoir, located on YORK INTERNATIONAL...
  • Page 134 Intermediate steel tube supports are adjusts motor speed and compressor prerotation vane spaced at intervals of less than four feet. position for maximum part load efficiency by analyzing information fed to it by sensors located throughout the chiller. YORK INTERNATIONAL...

  • Page 135: Section 6 Operational Maintenance

    5. Open all the dehydrator stop valves to allow the liq- drator. uid refrigerant to flow through the dehydrator and condenser-gas through the eductor. 22621A(D) LD00469 FIG. 60 – OIL RETURN SYSTEM YORK INTERNATIONAL...

  • Page 136: Fig. 61 - Assembly Of Dehydrator

    Operational Maintenance FORM 160.55-O1 (920) LD00470 FIG. 61 – ASSEMBLY OF DEHYDRATOR YORK INTERNATIONAL...

  • Page 137: Fig. 62 - Charging Oil Reservoir With Oil

    This fills and “C” compressor; 15 gal. “E” and “F’ compressor. the lines with oil and prevents air from being pumped New oil YORK Refrigeration Type “C” must be used in into the system. the centrifugal compressor. Since oil absorbs moisture 3.

  • Page 138: Section 7 Troubleshooting

    High Oil Oil Temperature 180°F 179°F Temperature Thermistor (RT3) MON. 10:00 AM Power Autostart Microboard undervoltage 8.29VDC 7.84VDC Failure circuit on 5V unregulated supply MON. 10:00 AM Power Microboard undervoltage 8.29VDC 7.84VDC Failure circuit on 5V unregulated supply YORK INTERNATIONAL...
  • Page 139 8.29VDC. An undervoltage circuit on Microboard monitors the 5VDC unregulated supply for an undervoltage condition. Auto restart plug is removed To restart, press compressor switch to STOP/ Power Failure. on Microboard. RESET position and then to START position. YORK INTERNATIONAL...
  • Page 140 (min. system operating temp. = 32°F) MON. 10:00 AM Low Line Voltage SSS Logic Board See legend on (SSS units only) wiring diagram. MON. 10:00 AM Motor Phase SSS Logic Board See Section 2. Current Unbalance (SSS units only) YORK INTERNATIONAL...
  • Page 141 Analog Input Board. Connect or replace open sensor. Chiller will automatically restart when all phases of line Low AC Line Voltage voltage increase to the minimum required starting level. Press STOP/RESET switch and then START Motor Phase Current Unbalance switch. YORK INTERNATIONAL...
  • Page 142 Oil Pressure Cutout. foaming in reservoir and piping due to charge new oil into the compressor. (See Display reading: “LOW OIL PRESSURE” lowered system pressure. “Oil Charging Procedure”, page 129.) Burned out oil heater. Replace oil heater. YORK INTERNATIONAL...
  • Page 143 2. Faulty three-way oil solenoid valve. where necessary. 3. Faulty exhaust solenoid valve. 4. Faulty pressure transducer. Purge unit purging air and refrigerant 1. Faulty exhaust solenoid valve. Restore refrigerant liquid cooling supply. 2. Faulty pressure transducer. 3. Lack of cooling. YORK INTERNATIONAL...

  • Page 144: Section 8 Maintenance

    5. When absolute tightness of the system has been es- Do not use excessive amounts of R-22; use only enough tablished, blow the mixture of nitrogen and refrig- for proper leak detection. erant through the charging valve. YORK INTERNATIONAL...

  • Page 145: Fig. 63 - Evacuation Of Chiller

    = Pressure above atmospheric = 29.921 inches Hg. absolute at 32°F PSIA = Lbs. per sq. in. absolute pressure = Sum of gauge plus atmospheric pressure TABLE 3 – SYSTEM PRESSURES LD00473 FIG. 63 – EVACUATION OF CHILLER YORK INTERNATIONAL...
  • Page 146 When this final vaporization has taken place the limits specified in Step 5 above, the leak must be pressure and temperature will continue to drop until found and repaired. eventually a temperature of 35°F or a pressure of 5mm Hg. is reached. YORK INTERNATIONAL...

  • Page 147: Fig. 64 - Saturation Curve

    Refrigerant may be furnished in drums containing either 100, 200 or 650 lbs. of refrigerant. These drums are not returnable and they should be stored for future use if it should ever become necessary to remove refrigerant from the system. YORK INTERNATIONAL...
  • Page 148 1. Using a megohm meter (megger), meg between at ambient temperature after 24 hours phases and each phase to ground (see Fig. 65); these of idle standby. readings are to be interpreted using the graph shown in Fig. 66. YORK INTERNATIONAL...

  • Page 149: Fig. 65 - Diagram, Megging Motor Windings

    They can be removed most effectively by circulating to fouled tubes alone or due to a combination of troubles. an acid solution through the tubes. Trouble which may be due to fouled tubes is indicated YORK INTERNATIONAL...

  • Page 150: Fig. 66 - Motor Stator Temperature

    Maintenance FORM 160.55-O1 (920) LD00476 TEMPERATURE – °F FIG. 66 – MOTOR STATOR TEMPERATURE AND INSULATION RESISTANCES YORK INTERNATIONAL...
  • Page 151 4. After the tubes have been corked for 12 to 24 hours, and condensers. If acid cleaning is required, YORK it is recommended that two men working at both recommends the use of this type of organization. The...

  • Page 152: Section 9 Preventive Maintenance

    YORK office to request the presence of a by restricted oil lines, passages or dirty oil filters. If the YORK Service Technician.
  • Page 153 2. It is important that the factory settings of controls (operation and safety) not be changed. If the settings 1. Change the purge unit dehydrator. are changed without YORK’s approval the warranty a. If the unit is operating; will be jeopardized.

  • Page 154: Section 10 Optisave Energy Analyser Feature

    YORK Service Information variable speed drive. The resulting difference is the Letter SI0068.
  • Page 155 FORM 160.55-O1 (920) NOTES YORK INTERNATIONAL...
  • Page 156 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2020 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.55-O1 (920) Issue Date: September 18, 2020 Supersedes: 160.55-O1 (604)

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