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MILLENNIUM YCAR0345
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York MILLENNIUM YCAR0345 manual available for free PDF download: Installation Operation & Maintenance
York MILLENNIUM YCAR0345 Installation Operation & Maintenance (160 pages)
AIR-COOLED RECIPROCATING LIQUID CHILLERS
Brand:
York
| Category:
Chiller
| Size: 2.89 MB
Table of Contents
Table of Contents
2
General Safety Guidelines
6
Changeability of this Document
6
Safety Symbols
7
SECTION 1 GENERAL CHILLER INFORMATION and SAFETY
8
Introduction
8
Warranty
8
Safety
8
Responsibility for Safety
8
About this Manual
9
Misuse of Equipment
9
Emergency Shutdown
10
Material Safety Data
11
Section 2 Product Description
15
Introduction
15
General Description
15
Compressor
15
FIG. 1 - Component Locations
15
Evaporator (Cooler)
16
FIG. 2 - Reciprocating Compressor
16
Condenser
17
Power and Control Panels
17
Microprocessor Controls
17
Motor Current Protection
18
Motor Protection Module
18
Current Overload
19
Thermal Overload
19
TABLE 1 - Motor Protector Dip Switch Settings
20
Keypad Controls
22
Accessories and Options
22
Part-Wind Compressor Start
23
Control Circuit Terminal Strip
23
Building Automation System (BAS) Interface
23
Condenser Coil Protection Options
23
DX Cooler Options
23
Unit Enclosure Options
24
High Static Fan Option
24
Sound Reduction Options
24
Hot Gas Bypass
24
Vibration Isolation Options
24
Alternative Chilled Fluid Application Options
24
Unit Nomenclature Nameplate Engineering Data
25
Section 3 Handling and Storage
27
Delivery and Storage
27
Inspection
27
Moving the Chiller
27
FIG. 3 - Unit Rigging
28
FIG. 4 - Lifting Lugs
28
Section 4 Installation
29
Location Requirements
29
Outdoor Installations
29
Indoor Installations
29
Location Clearances
30
Installation of Vibration Isolators
30
Shipping Braces
30
Pipework Connection
30
Water Treatment
31
Pipework Arrangement
32
Connection Types and Sizes
32
Cooler Connections
32
Refrigerant Relief Valve Piping
32
FIG. 5 - Pipework Arrangement
32
FIG. 6 - Victaulic Groove
32
FIG. 7 - Flange Attachments
32
Ductwork Connection
33
Electrical Connection
33
Power Wiring
33
115VAC Control Supply Transformer
34
Control Panel Wiring (Terminals 13 - 19)
34
Volts Free Contacts
35
System Inputs
35
FIG. 8 - Power Panel Section Options
36
FIG. 9 - Logic Section Layout
38
FIG. 10 - Logic Section Layout W/Control Panel
39
FIG. 11 - Customer Connections
40
FIG. 12 - Customer Connections
40
Section 5 Commissioning
42
Preparation
42
Preparation - Power off
42
First Time Start-Up
44
Section 6 Operation
45
General Description
45
Start-Up
45
Normal Running and Cycling
45
Shutdown
45
FIG. 13 - Flow Rate and Pressure Drop Charts
46
Glycol Correction Factors
47
Physical Data
48
Temperatures and Flows
52
Control Power Supply
53
Electrical Legend
53
Electrical Notes
53
Multiple Point Power Supply Connection
54
Optional Single-Point Power Supply Connection with Internal Unit Circuit Breakers
56
Power Connection Options
58
Section 7 Technical Data
46
Flow Rate and Pressure Drop Charts
46
FIG. 14 - Multiple Point Power Supply Connection
58
FIG. 15 - Optional Single-Point Power Supply W/Internal Circuit Breakers
58
FIG. 16 - Optional Single-Point Power Supply W/Field Supplied Circuit Protection
59
Wiring Diagrams
60
FIG. 17 - Standard Dual Compressor Power Supplies - Across-The-Line Start
60
FIG. 18 - Standard Dual Compressor Power Supplies - Part-Wind Start
61
FIG. 20 - Control Circuit - Detail "B
66
FIG. 21 - Control Circuit - Detail "B
66
Fig. 22 - Control Circuit, Detail "C
67
FIG. 23 - YCAR0315 - YCAR0685 Wiring Diagram
68
FIG. 24 - Connection Diagram, System Wiring
70
FIG. 25 - Connection Diagram, System Wiring Part-Wind Start
71
FIG. 26 - Connection Diagram, Electrical Box
72
FIG. 27 - Connection Diagram, System Wiring
73
FIG. 28 - Connection Diagram, System Wiring Part-Wind Start
74
FIG. 29 - Elementary Diagram, Power Circuit
75
FIG. 30 - Control Power Transformer Kit
76
FIG. 31 - Control Circuit - Detail "A
77
Dimensions
78
Clearances
90
FIG. 32 - Clearances
90
Isolator Dimensions
91
Weight Distribution - Aluminum Fin Coils
92
Isolator Selection - Aluminum Fin Coils
93
Weight Distribution - Copper Fin Coils
94
Isolator Selection - Copper Fin Coils
95
Refrigerant Flow Diagram
96
FIG. 33 - Refrigerant Flow Diagram
96
Process and Instrumentation Diagram
97
FIG. 34 - Process and Instrumentation Diagram
97
Section 8 Start-Up
98
System Startup Checklist
98
Panel Checks
99
Initial Start-Up
99
Checking Subcooling and Superheat
100
Leak Checking
101
Chiller Control Panel Programming and Data Access
102
Display and Status Information Keys
102
On / off Rocker Switch
102
Program and Setup Keys
102
1 INTRODUCTION and PHYSICAL DESCRIPTION
103
General
103
Keypad and Display
103
Microprocessor Board
103
Unit (Chiller) on / off Switch
103
Ancillary Circuit Boards
104
Circuit Breakers
105
Current Transformers (Ct)
105
Motor Protection Modules
105
Transformers
105
FIG. 35 - Motor Protector
106
EMS/BAS Controls
107
Microprocessor Board Layout
109
FIG. 36 - Component Layout
109
Logic Section Layout
110
FIG. 37 - Logic Section Layout
110
Anti-Coincidence Timer
111
Anti-Recycle Timer
111
Compressor Heater Control
111
Evaporator Heater Control
111
Evaporator Pump Control
111
Pumpdown Controls
111
Alarms
112
Run Status (Chiller)
112
Compressor Heater
113
Lead / Lag Compressor Selection
113
2 STATUS KEY and FAULT MESSAGES
114
General
114
General Status Messages
114
Unit Warnings
116
Anticipation Control Status Messages
116
Unit Fault Status Messages
117
Individual Start Inhibit Safeties
118
System Fault (Safety) Status Messages (Manual Reset)
119
FIG. 38 - Suction Pressure Cutout
120
Printout on Fault Shutdown
121
3 DISPLAY KEYS and OPTION SWITCHES
122
General
122
Chilled Liquid Temps Key
122
System Data Keys
122
Ambient Temp Key
123
Motor Current Key
123
Operating Hours / Start Counter Key
123
Options Key and Dip Switch Settings
124
Function Key
125
FIG. 39 - Dipswitches on Microprocessor Board
125
4 Print Keys
126
General
126
Oper Data Key
126
Operating Data - Local Display Messages
126
Operating Data - Remote Printout
128
History Key
128
Fault History Data - Local Display Messages
129
Fault History Data - Remote Printout
131
5 Entry Keys
133
General
133
Numerical Keypad
133
Enter Key
133
Cancel Key
133
Keys
133
6 Setpoints Keys and Chilled Liquid Control
134
General
134
Chilled Liquid Temperature Control
134
Local Cooling Setpoints Key
135
Remote Cooling Setpoints Key
135
Chilled Liquid Temperature Control
135
Compressor Capacity Loading Sequence
136
Fuzzy Logic" "Loading" Anticipatory Control
137
Load Limiting" Anticipatory Control
137
Compressor Unloading and Shutdown Sequence
137
Fuzzy Logic" "Unloading" Anticipatory Control
138
Unloading Limiting
138
Optional Hot Gas Bypass Operation
138
7 Clock Keys
139
General
139
Set Schedule / Holiday Key
139
Set Time Key
139
Manual Override Key
141
8 Program Key
142
General
142
Program Key - User Programmable Values
143
Programming "Default" Values
147
TABLE 2 - Program Defaults and Limits
147
Condenser Fan Control
148
FIG. 40 - Condenser Fan Layout for DXRT
148
TABLE 3 - Condenser Fan Control and Fan Contactor Data for DXRT Units with 3 Fans / System
149
TABLE 4 - Condenser Fan Control and Fan Contactor Data for DXRT Units with 4 Fans / System
149
TABLE 5 - Condenser Fan Control and Fan Contactor Data for DXRT Units with 5 Fans / System
149
Section 10 Maintenance
150
General Requirements
150
Daily Maintenance
150
Scheduled Maintenance
150
Chiller/Compressor Operating Log
151
FIG. 41 - Operating Log
151
Maintenance Requirements
152
Maintenance Requirements for YORK J,K and P Reciprocating Compressors
153
General Periodic Maintenance Checks Standard Units
154
Spare Parts
155
Associated Drawings
155
Recommended Compressor Oils
155
Recommended Spares
155
Competent Persons Troubleshooting Guide
156
Troubleshooting
156
Sensor Calibration Charts
158
Limited Warranty
159
Temperature Conversion Chart
160
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