York MILLENNIUM YCAR0645 Liquid Chiller Manuals

Manuals and User Guides for York MILLENNIUM YCAR0645 Liquid Chiller. We have 1 York MILLENNIUM YCAR0645 Liquid Chiller manual available for free PDF download: Installation Operation & Maintenance

York MILLENNIUM YCAR0645 Installation Operation & Maintenance

York MILLENNIUM YCAR0645 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
Section 7 Technical Data

46
Section 8 Start-Up

98
- System Startup Checklist
  98
- Panel Checks
  99
- Initial Start-Up
  99
- Checking Subcooling and Superheat
  100
- Leak Checking
  101
- 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
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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