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York MILLENNIUM YK Operating & Maintenance

York MILLENNIUM YK Operating & Maintenance

Centrifugal liquid chillers
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MILLENNIUM
TM
CENTRIFUGAL LIQUID CHILLERS
OPERATING & MAINTENANCE
MODEL YK (STYLE D)
R-134a (COOLING ONLY)
WITH MICROCOMPUTER CONTROL CENTER
PART #371-01200-010, 371-01200-011 & 371-01200-015
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER & VARIABLE SPEED DRIVE
28815A
WARNING
SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE.

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  • Page 1 MILLENNIUM CENTRIFUGAL LIQUID CHILLERS OPERATING & MAINTENANCE MODEL YK (STYLE D) R-134a (COOLING ONLY) WITH MICROCOMPUTER CONTROL CENTER PART #371-01200-010, 371-01200-011 & 371-01200-015 FOR ELECTRO-MECHANICAL STARTER, SOLID STATE STARTER & VARIABLE SPEED DRIVE 28815A WARNING SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE.

  • Page 2: Reference Instructions

    TABLE OF CONTENTS Page REFERENCE INSTRUCTIONS DESCRIPTION FORM NO.
  • Page 3 NOMENCLATURE MOTOR CODE: 60 HZ 50 HZ...

  • Page 4: Section 1 Description Of System And Fundamentals Of Operation

    SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION 28815A FIG. 1 – SYSTEM OPERATION DESCRIPTION (See Fig. 2)

  • Page 5: Capacity Control

    CAPACITY CONTROL 7619A(D) DETAIL A – LD00924 FIG. 2 –...

  • Page 6: Section 2 Microcomputer Control Center

    Responsibility for assuring the satisfactory operation of other equipment included in the same power source as the YORK equipment rests solely with the user. YORK disclaims any liability resulting from any interference or for the correction thereof.
  • Page 7 INTRODUCTION Setpoints...

  • Page 8: Control Center

    CONTROL CENTER CONTROL CENTER SERVICE –  ACCESS CODE –  CHARACTERISTIC DISPLAY –  PROGRAM –  STATUS MODE –  LOCAL, REMOTE SERVICE DISPLAY –  Service –  Local –  ENTRY –  COMPRESSOR Program –  Setpoint PROGRAM Remote –  SETPOINTS –  COMPRESSOR-START, RUN, STOP/RESET PROGRAM SWITCH –  REMOTE Entry OPERATION DISPLAYING SYSTEM PARAMETERS DISPLAY HOLD Display NOTE: If the display actually displays X’s, then the monitored parameter is out of normal operat- Display ing range (refer to Fig.

  • Page 9: Set Pressure

    DISPLAY XX.X READS CONDENSER PRESS. = < 6.8 PSIG, or > 300 PSIG XX.X PSIG EVAPORATOR PRESS. = < 50 PSIG, or > 125 PSIG XX.X PSIG EVAP. PRESS. (BRINE) = < 25 PSIG, or > 100 PSIG XX.X PSIG HOP TRANSDUCER = <...

  • Page 10: System Setpoints

    NOTE: The operating hours and starts counter can be reset to zero. Refer to “Programming the Mi- croComputer Control Center”, page 14. How- ever, the purpose of the OPERATING HOURS key is to display the total accumulated chiller run time. Therefore, the operating hours should not be arbitrarily reset.
  • Page 11 NOTE: If an Energy Management System is interfaced to the Control Center for the purpose of remote CLOCK –  LCWT setpoint reset, then the operator pro- grammed REMOTE RESET TEMP RANGE value determines the maximum value of tem- SUNDAY 12:00 AM 1/1/92 perature reset controlled by the Energy Man- agement System.
  • Page 12 The currently programmed Setpoint CURRENT LIMIT = XXX % FLA; *MTR CUR = 000 FLA SERVICE, LO- REMOTE NOTE: On Solid State Starter applications, this value is programmed at the YORK factory. A special Setpoint access code is required. Setpoint PULL DOWN DEMAND...

  • Page 13: Data Logger

    FRI START = 05:00 AM STOP = 07:00 PM UNDERVOLTAGE SAT START = 05:00 AM STOP = 01:00 PM (Solid State Starter Applications Only) HOL START = 00:00 AM STOP = 00:00 PM SSS MOTOR CURRENT/VOLTS PRO- GRAM HOLIDAY SUPPLY VOLTAGE RANGE 380 HOLIDAY SUPPLY VOLTAGE RANGE 400 S_ M_ T_ W_ T_ F_ S_ HOLIDAY NOTED BY *...
  • Page 14 PROGRAMMING THE MICROCOMPUTER CONTROL CENTER PROGRAMMING SYSTEM SETPOINTS ACCESS CODE ENTER VALID ACCESS CODE _ _ _ _ ENTRY 9 6 7 5 Y O R K NOTE: If digits other than 9 6 7 5 are entered, Y O R K is still displayed. NOTE: For ease in remembering the code, note that the letters Y O R K correspond to the LD00954...
  • Page 15 CURRENT LIMIT = XXX% FLA; MTR CUR = _ _ _ FLA ENTRY LD00956 NOTE: Motor Current FLA value is entered by YORK factory and checked at system start- FIG. 7 – up. It cannot be changed without special access code. (Note to service technician: refer to “Programming Instructions”...
  • Page 16 PULL DOWN DEMAND PULL DOWN DEMAND SETPOINT = XXX MIN @ XXX % FLA, XXX MIN LEFT Entry PULL DOWN DEMAND ENTER PROGRAM MODE, SELECT SETPOINT LD00957 FIG. 8 – CLOCK CLOCK TODAY IS MON 10:30 PM 1/1/92 ADVANCE DAY / SCROLL Entry AM/PM Entry...
  • Page 17 DAILY SCHEDULE ADVANCE DAY / SCROLL DAILY SCHEDULE ENTER SUN START = XX:XX AM, STOP = XX:XX AM PROGRAM MODE, SELECT SETPOINT CANCEL Entry AM/PM Entry AM/PM ADVANCE DAY/SCROLL MON START = XX:XX AM, STOP = XX:XX AM LD00959 ADVANCE DAY/SCROLL REPEAT MON SCHEDULE MON-FRI? YES = 1;...
  • Page 18 HOLIDAY HOLIDAY S_ M_ T_ W_ T_ F_ S_ HOLIDAY NOTED BY * ADVANCE DAY/SCROLL ENTER PROGRAM MODE, SELECT SETPOINT CANCEL ENTER LD00961 PROGRAM MODE, SELECT SETPOINT FIG. 11 – ADVANCE DAY / SCROLL ENTER REMOTE/ RESET TEMP RANGE REMOTE/RESET TEMP RANGE REMOTE TEMP SETPOINT RANGE = XX °F Entry ENTER...
  • Page 19 SERVICE KEYS LD00963 FIG. 13 – Service HOLD –  WARNING RE- SYSTEM RUN – VANES HOLDING PRE-ROTATION VANES SERVICE Service SYS READY TO START – VANES HOLDING SERVICE LOCAL REMOTE OPEN HOLD AUTO PRE-ROTATION VANES KEYS CLOSE –  SYSTEM RUN – VANES CLOSING SYS READY TO START –...
  • Page 20 ING RESET WARNING RESET SERVICE OPEN –  COMPRESSOR STOP/RESET SYSTEM RUN – LEVEL VALVE OPENING MANUAL OIL PUMP –  SYS READY TO START – LEVEL VALVE OPENING CLOSE HOLD AUTO HOLD –  SYSTEM RUN – LEVEL VALVE HOLDING SYS READY TO START – LEVEL VALVE HOLDING DISPLAY DATA – ...
  • Page 21 NO. 4 – DISCHARGE TEMP = XXX.X°F; OIL TEMP = XXX.X°F   NO. 5 – NO. 2 – HOP = XX.X PSIG; LOP = XX.X PSIG PULLDN LEVEL = XXX%; SETP = XXX%; ACTUAL = XXX%  PULLDN LEVEL SETP NO. 6 – ACTUAL ACTUAL POS ACTUAL POS = XX MILS;...

  • Page 22: Operating Modes

    OPERATING MODES OPERATING MODES NOTE: If digits other than 9 6 7 5 are entered, Y O R K is still displayed. ENTER NOTE: If digits other than 9 6 7 5 were entered in SERVICE –  Service keys DIS- step No. 4, is dis- INVALID ACCESS CODE PLAY DATA, MANUAL OIL PUMP, HISTORY...

  • Page 23: Compressor Switch

    COMPRESSOR SWITCH RESET STOP/RESET START* LOCAL *NOTE: The operator cannot start the compressor (us- COMPRESSOR STOP/RESET ing this switch) when the Control Center is in START REMOTE mode. STOP STOP/RESET DISPLAY MESSAGES SERVICE AUTO SYSTEM RUN - CURRENT LIMIT IN EFFECT SYSTEM RUN –...
  • Page 24 SYS READY TO START – VANES OPENING OPEN SYSTEM RUN – HIGH PRESSURE LIMIT IN EFFECT SYS READY TO START – VANES CLOSING CLOSE SYS READY TO START – VANES HOLDING HOLD SYSTEM RUN – PRESSURE STATUS SYSTEM RUN – LEVEL VALVE OPENING STATUS WARNING: COND OR EVAP TRANSDUCER ERROR SERVICE...

  • Page 25: Restart After Power Failure

    SYSTEM READY TO START MON XX:XX AM – SYSTEM CYCLING – AUTOSTART STANDBY LUBE IN PROCESS - XXX.X MIN LEFT MON XX:XX AM – MULTI UNIT CYCLING – AUTOSTART SYSTEM SHUTDOWN – PRESS STATUS MON XX:XX AM – POWER FAILURE – AUTOSTART COM- PRESSOR STOP/RESET...
  • Page 26 SYSTEM RUN – LEAVING TEMP CONTROL COMPRESSOR STOP/ RESET START MON XX:XX AM – OIL PUMP DRIVE – AUTOSTART MON XX:XX AM – INTERNAL CLOCK – AUTOSTART COMPRESSOR START MON XX:XX AM – LOW OIL PRESSURE REMOTE STOP COMPRESSOR STOP/ RESET START REMOTE...
  • Page 27 PRESSOR STOP/RESET START MON XX:XX AM – HIGH OIL TEMP COMPRESSOR STOP/RESET START MON XX:XX AM – HIGH OIL PRESSURE MON XX:XX AM – MOTOR CONTROLLER – EXT. RESET COMPRES- STOP/RESET START MON XX:XX AM – FAULTY COND PRESSURE XDCR NOTE: The following motor controller shutdowns do not require an external reset to restart chiller.
  • Page 28 MON XX:XX AM – PROGRAM INITIATED RESET MON XX:XX AM – MTR PHASE CURRENT UNBALANCE COMPRESSOR STOP/ RESET START SYSTEM READY TO START – PRESS STATUS ∅ ∅ ∅ STATUS SYSTEM READY TO START – PRESS STATUS ∅ Service WARN- ING RESET MON XX:XX AM –...
  • Page 29 MON XX:XX AM – PROX SENSOR SAFETY SHUTDOWN MON XX:XX AM LOW OIL TEMP DIFF – AUTOSTART MON XX:XX AM – LOW OIL TEMP DIFF – AUTOSTART NOTE: With EPROM version C.02F (T).11, if the refer- ence position is < 42 mils, the minimum allowed distance is 22 mils.
  • Page 30 MON XX:XX AM – OPEN DRAIN TEMP THERMOCOUPLE MON XX:XX AM – AUX SAFETY SHUTDOWN COMPRESSOR STOP-RESET START IMPORTANT: REPLACE RTC. U16 – REPROGRAM SETPOINTS REAL-TIME CLOCK MON XX:XX AM – DC UNDERVOLTAGE 24673A FIG. 14 –...

  • Page 31: Section 3 System Operating Procedures

    SECTION 3 SYSTEM OPERATING PROCEDURES WARNING CAUTION: Comply with EPA and Local regulations when removing or disposing of Refrigera- tion System oil! START-UP PROCEDURE SERVICE LOCAL PRO- GRAM REMOTE SYSTEM READY TO START % CURRENT LIMIT CURRENT LIMIT = 100% FLA CURRENT LIMIT = 100% FLA, MTR CUR = XXXX FLA MANUAL OIL PUMP Service...
  • Page 32 DAY 10:30 AM – LOW OIL PRESSURE DAY 10:30 AM – HIGH OIL TEMPERATURE DAY 10:30 AM – LOW OIL TEMP – AUTOSTART DAY 11:30 AM – OIL PRESSURE TRANSDUCER COMPRESSOR START STOP/RESET COMPRESSOR START NOTE: Any malfunctions which occur during STOP/RESET are also displayed.

  • Page 33: Current Limit

    SYSTEM STARTING & SHUTDOWN SEQUENCE OPERATOR INITIATED (NOTE 2) LD00952 FIG. 15 – % CURRENT LIMIT NOTE: If the temperature setpoint has been repro- grammed within the last 10 minutes, the LWT cutout is 36°F (2.2°C) for 10 minutes. % CURRENT LIMIT Condenser Water Temperature Control MON 10:30 AM –...

  • Page 34: Operating Log Sheet

    OPERATING LOG SHEET 15 x % LOAD Min. ECWT = LCHWT—C RANGE + 5 + LD00467 23889A PRINT FIG. 16 –...
  • Page 35 STATUS OPERATING INSPECTIONS – See Section 2 Weekly Daily Quarterly OIL PRESSURE Semi-Annually (or more often as required) CONDENSER LIQUID TEMPERATURES Annually (more often if necessary) CHILLED LIQUID TEMPS REFRIGERANT PRESSURES DISPLAY DATA DISPLAY HOLD DATA DISPLAY...
  • Page 36 NEED FOR MAINTENANCE OR SERVICE SYSTEM SHUTDOWN – PRESS STATUS STATUS CYCLING SHUTDOWNS NORMAL AND SAFETY SYSTEM SHUTDOWNS SYSTEM SHUTDOWN – PRESS STATUS STATUS START SEQUENCE INITIATED SAFETY SHUTDOWNS STOPPING THE SYSTEM (See Fig. 3, page 6) COMPRESSOR STOP/RESET SYSTEM COASTDOWN...

  • Page 37: Prolonged Shutdown

    SYSTEM COASTDOWN SYSTEM READY TO START START-UP AFTER PROLONGED SHUTDOWN PROLONGED SHUTDOWN MAN- UAL OIL PUMP OIL PUMP...

  • Page 38: Section 4 System Components Description

    SECTION 4 SYSTEM COMPONENTS DESCRIPTION 28815A FRONT VIEW 28778A REAR VIEW FIG. 17 –...
  • Page 39 GENERAL COMPRESSOR COMPRESSOR START CAPACITY CONTROL OIL PUMP COMPRESSOR LUBRICATION SYSTEM (See Fig. 18) MANUAL OIL PUMP MANUAL OIL PUMP...
  • Page 40 LD03278 FIG. 18 –...

  • Page 41: Refrigerant Flow Control

    HEAT EXCHANGERS OIL HEATER SYSTEM SHUTDOWN – PRESS STATUS STATUS DAY 10:00 AM – LOW OIL TEMP – AUTO START MOTOR DRIVELINE REFRIGERANT FLOW CONTROL...

  • Page 42: Optional Hot Gas Bypass

    CAUTION: Isolation of the refrigerant in this sytem must be performed by a qualified service technician. OPTIONAL HOT GAS BYPASS PULLDN LEVEL = XXX%; SETP = XXX%; ACTUAL = XXX% DISPLAY DATA NOTE: Changes in chilled water flow will require re- adjsutment of the hot gas control to insure proper operation.

  • Page 43: Section 5 Operational Maintenance

    SECTION 5 OPERATIONAL MAINTENANCE OIL RETURN SYSTEM CHANGING THE DEHYDRATOR LD00950 FIG. 19 –...

  • Page 44: The Oil Charge

    THE OIL CHARGE OIL CHARGING PROCEDURE LD00472 25721A FIG. 20 –...
  • Page 45 TABLE 1 – SHUTDOWN CAUSE GOVERNING CONTROL FUNCTION CONTROL CENTER DISPLAY PROGRAMMED START-UP OF PROBABLE CAUSE OPERATING SETPOINTS SYSTEM AFTER AND SERVICE DAY OF TIME OF CAUSE OF METHOD OF POINT DESCRIPTION BY OPERATOR SHUTDOWN REQUIRED WEEK SHUTDOWN RESTART RISE FALL...
  • Page 46 PSIG (R-134a) PSIG (R-134a) (172.4 kPa) (173 kPa) (172.4 kPa) (103.4 kPa) PSIG (R-134a) PSIG (R-134a) (1241 kPa) (82.7 kPa)
  • Page 47 TABLE 1 (Cont’d) – SHUTDOWN CAUSE GOVERNING CONTROL FUNCTION CONTROL CENTER DISPLAY PROGRAMMED START-UP OF PROBABLE CAUSE OPERATING SETPOINTS SYSTEM AFTER AND SERVICE DAY OF TIME OF CAUSE OF METHOD OF POINT BY OPERATOR SHUTDOWN REQUIRED DESCRIPTION WEEK SHUTDOWN RESTART RISE FALL...
  • Page 48 TABLE 2 – RESULTS POSSIBLE CAUSE REMEDY 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE 2. SYMPTOM: ABNORMALLY LOW SUCTION PRESSURE 3. SYMPTOM: HIGH COOLER PRESSURE 4. SYMPTOM: NO OIL PRESSURE WHEN SYSTEM START BUTTON PUSHED 5. SYMPTOM: COMPRESSOR STARTS, NORMAL OIL PRESSURE DEVELOPS, FLUCTUATES FOR SHORT WHILE, THEN COMPRESSOR STOPS ON OIL PRESSURE CUTOUT LOW OIL PRESSURE...
  • Page 49 TABLE 2 – RESULTS POSSIBLE CAUSE REMEDY 6. SYMPTOM: USUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS 7. SYMPTOM: OIL PUMP VIBRATES OR IS NOISY OIL PRESSURE 8. SYMPTOM: OIL PRESSURE GRADUALLY DECREASES (Noted by Observation of Daily Log Sheets) PRESSURE 9.

  • Page 50: Section 7 Maintenance

    SECTION 7 MAINTENANCE RENEWAL PARTS CHECKING SYSTEM FOR LEAKS LEAK TESTING DURING OPERATION CONDUCTING R-22 PRESSURE TEST EVACUATION AND DEHYDRATION OF UNIT 27385A(D) LD00949 FIG. 21 –...

  • Page 51: Vacuum Testing

    TABLE 3 – SYSTEM PRESSURES *GAUGE ABSOLUTE BOILING INCHES OF TEMPERATURES MERCURY (HG) MILLIMETERS BELOW ONE PSIA OF MERCURY MICRONS WATER STANDARD (HG) °F ATMOSPHERE 14.696 760. 760,000 10.24" 9.629 500. 500,000 22.05" 3.865 200. 200,000 25.98" 1.935 100. 100,000 27.95"...

  • Page 52: Vacuum Dehydration

    VACUUM DEHYDRATION LD00474 FIG. 22 –...

  • Page 53: Refrigerant Charging

    REFRIGERANT CHARGING TABLE 4 – R-134a SHELL CODES LBS. / KG COOLER COND. CHECKING THE REFRIGERANT CHARGE DURING UNIT SHUTDOWN...

  • Page 54: Handling Refrigerant For Dismantling And Repairs

    HANDLING REFRIGERANT FOR DISMANTLING AND REPAIRS MEGGING THE MOTOR NOTE: Motor is to be megged with the starter at ambient temperature after 24 hours of idle standby. LD00475 FIG. 23 –...
  • Page 55 Minimum Insulation Resistance vs. Temperature (per IEEE Std 43) Open Motors MEGOHMS...

  • Page 56: Tube Fouling

    CONDENSERS AND COOLERS GENERAL TUBE FOULING CHEMICAL WATER TREATMENT TUBE CLEANING PROCEDURES CLEANING COOLER AND CONDENSER TUBES WARNING: Acid cleaning should only be performed by an expert. Please consult your local water treatment representative for assistance in removing scale build-up and preventative maintenance programs to eliminate future problems.

  • Page 57: Commercial Acid Cleaning

    COMMERCIAL ACID CLEANING NOTE: Do not use carbon tetrachloride for this pur- pose since its fumes give the same flame discoloration that the refrigerant does. TESTING FOR COOLER AND CONDENSER TUBE LEAKS...
  • Page 58 COMPRESSOR ELECTRICAL CONTROLS...

  • Page 59: Section 8 Preventive Maintenance

    PREVENTIVE MAINTENANCE COOLER AND CONDENSER IMPORTANT – If a unit failure occurs due to improper maintenance during the war- ranty period; YORK will not be liable for costs incurred to return the system to satisfactory operation. COMPRESSOR COMPRESSOR MOTOR OIL RETURN SYSTEM...

  • Page 60: Electrical Controls

    ELECTRICAL CONTROLS 36USC380 P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA Copyright © by York International Corporation 1998 ALL RIGHTS RESERVED Form 160.52-O1 (898) Supersedes: Nothing...

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371-01200-010371-01200-011371-01200-015Yk

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