035B40022-000 I-i Table of Contents 1 2 SUPPLIER INFORMATION INSTALLATION 1.1 Introduction 1.1 4.1 Location 4.1 1.2 Warranty 1.1 4.2 Evaporator External Water System 4.1 1.3 Safety 1.1 4.3 Condenser External Water System 4.2 1.4 Emergency Stops/Shutdown 1.2 4.4 Water Connections 4.3 1.5 About this Manual 1.2 4.5 Refrigerant Connections 4.3 1.6 Safety Labels 1.3 4.6 Electrical Supplies 4.4 1.7 Material Safety Data 1.4 4.7 Electrical Connections 4.
I-ii 7 035B40022-000 MAINTENANCE 10 SPARE PARTS 7.1 General Requirements 7.1 10.1 Recommended Spares 10.1 7.2 Daily Maintenance 7.1 10.2 Recommended Compressor Oils 10.1 7.3 Refrigerant Charge 7.2 10.3 Associated Diagrams 10.1 7.4 Compressors 7.2 7.5 Filter Drier 7.2 7.6 Sight Glass 7.2 7.7 Thermostatic Expansion Valve 7.3 7.8 Evaporator(s) 7.3 7.9 Condensers 7.3 8 TROUBLE SHOOTING 9 TECHNICAL DATA 9.1 Pressure Drop Graphs 9.1 9.2 Safety Switch Settings 9.4 9.
035B40022-000 1-1 1 SUPPLIER INFORMATION 1.2 1.1 Introduction The unit is supplied finished, tested and ready to work. The unit warranty will be void if any modification to the unit is carried out without written agreement of York International. York YCWM/YCRM Series chillers are manufactured to the most stringent design and construction standards to ensure high performance, reliability and adaptability to all types of air conditioning installations.
1-2 035B40022-000 The unit contains refrigerant vapour and liquid under pressure within the heat exchangers, compressors and pipework. Release of refrigerant can be a danger and cause injury. It is the responsibility of the user to ensure that the unit is suitable for the conditions of use and that installation and regular maintenance is carried out by personnel with the appropriate skills and in accordance with this manual.
035B40022-000 1.6 Safety Labels Crankcase Heater Warning Label The following labels are fitted to each unit.
1-4 1.7 035B40022-000 Material Safety Data Refrigerant Data: Safety Data R22, R407C Toxicity Low. In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. R22 may be slightly irritant and liquid has a degreasing effect. Thaw affected areas with water. Remove contaminated clothing carefully - may adhere to skin in case of freeze burns. Was affected areas with plenty of warm water.
035B40022-000 Hazardous reactions 1-5 May react violently with sodium, potassium, barium and other alkali and alkaline earth metals. Incompatible materials : Magnesium and alloys containing more then 2% magnesium. Hazardous decomposition products R22: Halogen acids formed by R407C: Halogen acids by thermal thermal decomposition. decomposition and hydrolysis. General precautions Avoid inhalation of high concentrations of vapours.
1-6 035B40022-000 REFRIGERANT OIL DATA Safety Data Oil Classification Non-hazardous In contact with skin Minimally irritating. No first aid necessary. Exercise reasonable personal cleanliness including cleansing exposed skin areas several times daily with soap and water. Launder soiled work clothes at least weekly. In contact with eyes As with most foreign materials flush with plenty of eyewash solution or clean water. Ingested Obtain immediate medical attention.
035B40022-000 1 2 3 4 5 6 2-1 Compressor Compartment Power Compartment Control Compartment Evaporator Condenser Cable Entry 2 3 4 1 1 6 2 PRODUCT DESCRIPTION 2.1 Introduction 5 The following options are available: Option Description The YCWM/YCRM range of twin refrigerant circuit water chillers are designed to be located inside the plant room of a building. Acoustic Kit (170-280) A factory installed kit using acoustically lined compressor enclosure and compressor acoustic covers.
2-2 2.2 035B40022-000 General Specification YCWM/YCRM models are completely assembled with all interconnecting refrigerant piping and wiring ready for field installation. After assembly a full run test is performed, with water flowing through the evaporators, to verify that each refrigerant circuit operates correctly. YCWM units are pressure tested, evacuated and fully charged with refrigerant and include an initial oil charge.
035B40022-000 2.8 Power and Controls 2-3 YCRM Cooling Mode All controls and motor starting equipment necessary for full unit operation are factory wired and tested. The power and control components are separated within the panel, which is designed to IP-53 weather protection. The operation of the YCRM is identical to the YCWM except for the water cooled condenser which is replaced by a remote air cooled condenser.
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035B40022-000 3 3-1 TRANSPORTATION, HANDLING AND STORAGE YCWM/YCRM series chillers are supplied fully assembled. YCWM units are pre-charged with refrigerant and oil in the correct quantity required for operation. YCRM units include a nitrogen holding charge and are pre-charged with oil in the correct quantity required for operation. The refrigerant circuit on YCRM units must be charged before the unit is operated. 3.
3-2 3.3 035B40022-000 Anchorage YCWM/YCRM series chillers are provided with 18 mm diameter holes in the base frame for retaining the unit if required. 3.4 Storage If the unit is to be stored prior to installation, certain precautions should be taken to prevent damage, corrosion or deterioration: n Ensure that all openings, such as water connections, are securely capped or sealed.
4-1 035B40022-000 4 INSTALLATION 4.1 Location Before installing the unit, make sure that the building structure and/or mounting surface can support the unit weight. Overall weights are detailed in Section 9. The unit has been designed for floor mounting in protected indoor locations. The flow switch must be connected in series with other external interlocks. The flow switch should be installed on the pump delivery, upstream of the unit.
4-2 035B40022-000 Before filling the system, ensure that it is free from foreign matter, sand, stones, rust flakes, solder, slag or other materials which could damage the evaporators. It is advisable to by-pass the unit when flushing out the lines. Water used to fill the circuit may have to be treated to ensure that the pH value is correct.
035B40022-000 4.4 Water Connections The water inlet and outlet connections must be connected correctly as shown on the labels fitted next to the fittings. Connect the external water supply lines to the water inlet and outlet fittings on the unit, refer to section 9 for diameters and locations. YCWM 60-150 Heat Pump The YCWM unit can operate as a water to water heat pump by reversing the cycle on the water circuits using three way valves.
4-4 035B40022-000 Refrigerant Connections Units are supplied with a nitrogen holding charge.This should be relieved carefully via the suction service connections and the liquid line service connections. The pipework can be brazed directly onto the welding connections taking care to protect the unit from excess heat which may cause distortion. System Testing All newly installed pipework must be pressure / leak tested to national code requirements (normally 1.
035B40022-000 YCWM-B and YCWM Models 60 to 150 Electrical Connections UNIT TERMINAL BOARD EXTERNAL TERMINAL BOARD L1 L2 EXTERNAL EQUIPMENT TERMINALS LINE 400-3-50 VOLTAGE FREE CONTACT L3 UNIT ELECTRICAL TERMINALS PE 1 2 3 4 35 36 FLOW SWITCH OR EXTERNAL INTERLOCK INTERLOCK (OPTIONAL) CIRC PUMP ETC REMOTE INDICATION VOLTAGE ON 5 (COMMON) 6 (NO) GENERAL ALARM 10 (COMMON) 11 (COOLING) 12 (HEATING) REMOTE ON/OFF CONTROL 37 COMPRESSOR '1' ON 38 39 COMPRESSOR '2' ON 40 24 (COMMON) 25 (CO
4-6 035B40022-000 YCWM-B and YCWM Models 170 to 280 Electrical Connections UNIT TERMINAL BOARD EXTERNAL TERMINAL BOARD L1 L2 EXTERNAL EQUIPMENT TERMINALS LINE 400-3-50 VOLTAGE FREE CONTACT L3 UNIT ELECTRICAL TERMINALS PE 1 2 3 4 35 36 FLOW SWITCH OR EXTERNAL INTERLOCK INTERLOCK (OPTIONAL) CIRC PUMP ETC REMOTE INDICATION VOLTAGE ON 5 (COMMON) 6 (NO) GENERAL ALARM 10 (COMMON) 11 (COOLING) 12 (HEATING) REMOTE ON/OFF CONTROL 37 COMPRESSOR '1' ON 38 39 COMPRESSOR '2' ON 40 41 COMPRESSOR '
035B40022-000 5 COMMISSIONING The unit must be started by trained personnel from an Authorised York Service Centre. Failure to satisfy this requirement will void the warranty. The operations performed by York service personnel are limited to unit starting, and do not include other work on system such as electrical connection, water connection, etc. All other preparatory work, including oil preheating (for at least 12 hours) must be performed by installer. 5.
5-2 035B40022-000 After around 15 minutes of operation, check that no air bubbles are visible through the sight glass on the fluid line. n If air bubbles are visible, the unit has lost part of its charge through one or more leaks. The leaks must be eliminated refer to Section 7. n Repeat the starting procedure after eliminating the leaks. n Where the compressor is provided with a sight glass, check that the oil level is correct. 5.
035B40022-000 6 OPERATION n n Unit capacity control n Compressor startup delay n Anti-freezing protection n External interlock alarm. When the alarm is activated, the control system locks out the unit. Reset is automatic. Alarm management and display n Anti-freezing alarm. This alarm is activated when water temperature at evaporator outlet drops below 3 o C. The control system locks out the associated refrigerating circuit. Alarm is reset manually from the panel.
6-2 6.1 035B40022-000 Control Panel Item Function 8888 Displays operating and fault parameters. + SET POINT + key (increases temperature SET POINT). - SET POINT - key (reduces temperature SET POINT). 6.2 Unit Starting To start the unit proceed as follows: n Set the master switch to the on (l) position to energise the control panel. Check that LED (voltage indicator) goes on. Check that there are no active alarm signals. SET POINT display key.
035B40022-000 6.4 Alarm Display and Reset Alarms are indicated by the associated panel LED’s and by messages on the display. Details of the alarm codes are given below.
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7-1 035B40022-000 Scheduled Maintenance Operation Unless otherwise indicated, the maintenance operations described below can be performed by any properly trained maintenance technician. Check evaporator entering / ● leaving liquid temperature 7.
7-2 7.3 035B40022-000 Refrigerant Charge Never introduce liquid refrigerant in the low pressure side of circuit. Extreme care must be taken to ensure that circuit is correctly charged. An insufficient charge will lead to poor machine performance. In extreme cases, the low pressure switch will cut in and lock the circuit.
035B40022-000 7.7 Thermostatic Expansion Valve YCWM/YCRM refrigerating circuits are provided with a thermostatic expansion valve with an external equaliser. Valves are calibrated at the factory for a 5oC temperature rise. To check the temperature rise: Read the suction pressure using a pressure gauge connected to the charging valve on suction side. Using the pressure gauge temperature scale, determine the saturated suction temperature Tsa corresponding to this pressure.
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035B40022-000 8 8-1 TROUBLE SHOOTING The following table details possible unit faults, their probable cause and suggested remedies. For any other problems not immediately recognisable and/or for technical assistance, call an Authorised York Service Centre. Fault Probable Cause Remedy Differential oil pressure switch cuts Defective differential pressure Check switch operation, replacing if on, break circuit. switch operation. necessary.
8-2 035B40022-000 Fault Probable Cause One or both compressors not Power circuit interrupted. working. Remedy Check power circuit for earth leakage and shorts. Check fuses. High pressure switch activation. Reset pressure switch from panel and re-start unit. Identify and eliminate causes of pressure switch activation. Control circuit fuse blown. Check control circuit for earth leakage and shorts. Change fuses. Loose terminal clamps. Check clamp tightness.
035B40022-000 9 TECHNICAL DATA 9.1 Pressure Drop Graphs YCWM-B and YCRM-B Models 60 to 150 - Evaporators 130 125 75 60 90 100 120 150 75 Pressure Drop kPa 50 45 40 35 30 25 20 15 10 9 8 7 6 5 4 4 5 6 7 8 9 10 15 Flow Rate m³/h Note: Total unit flow rate is shown.
9-2 035B40022-000 YCWM and YCRM Models 60 to 150 - Evaporators 225 200 75 90 175 150 60 120 150 125 100 90 80 70 Pressure Drop kPa 60 50 40 30 20 75 10 9 8 60 7 6 5 4 5 6 7 8 9 10 15 20 25 30 35 40 45 51 Flow Rate m³/h Note: Total unit flow rate is shown.
035B40022-000 YCWM-B and YCWM Models 60 to 150 - Condensers 275 250 225 90 120 150 75 60 200 175 150 125 Pressure Drop kPa 100 75 50 45 40 35 30 25 20 15 14 13 12 11 10 6 7 8 9 10 15 20 25 30 35 40 45 50 55 60 65 Flow Rate m³/h Note: Total unit flow rate is shown. YCWM-B and YCWM Models 170 to 280 - Condensers 90 280 200 80 170 240 70 60 Pressure Drop kPa 50 45 40 35 30 25 20 19 18 17 16 15 20 25 30 35 40 45 Flow Rate m³/h Note: Total unit flow rate is shown.
9-4 9.2 035B40022-000 Safety Switch Settings YCWM/YCRM Low Pressure Switch High Pressure Switch TüV High Pressure Switch Oil Pressure Switch Anti Freezing Thermostat Safety Valve Evaporator Water Differential Pressure Switch 9.3 60 bar bar bar bar °C bar 75 90 120 150 170 200 240 280 0,5 22 28 25 0,8 5 24 50% of Nominal Capacity Operational Limits YCWM/YCRM Chilled Liquid Evaporator Water outlet temperature Flow rate (1) Pressure drop (1) Water outlet Brine outlet Temp.
035B40022-000 9.4 9-5 Physical Data YCWM/YCRM Refrigerant Circuits Refrigerant charge per circuit Compressor Note: x=2 R22 x=7 R407C R 22 R407C Type Theoretical displacement Number No. of cylinders Revs per minute Oil charge per compressor No.
9-6 9.5 035B40022-000 Unit Electrical Data Model Current Input (A) Power Input (KW) 60 30 34 16 20 Nom. Cond. Max. Cond. Nom. Cond. Max. Cond.
035B40022-000 9.7 Sound Power Levels YCWM/ YCRM Model Standard Units R22 R407C Sound Sound Power (dB(A)) Power (dB(A)) 70 67 71 68 71 68 72 69 73 70 97 90 97 90 98 91 99 92 60 75 90 120 150 170 200 240 280 Tolerance ± 2 dB(A) Acoustic Kit supplied as standard on Models 60 to 150 9.
9-8 9.
9-9 035B40022-000 YCWM-B and YCWM Models 170 to 280 A E D F P B O Q M N R L K Q I R K J H G C YCRM Model A B C D E F G H I J K L M N O P R S T 170 2200 1600 800 398 1500 618 368 1570 50 60 1237 147 157 500 114 760 3" 1 1/8" 7/8" 200 2200 1600 800 398 1500 618 368 1570 50 60 1237 147 157 500 114 760 4" 1 1/8" 7/8" 240 2200 1600 800 398 1500 618 368 1570 50 60 1237 147 157 500 114 760 4" 1 3/8" 7/8" 280 2200 16
9-10 035B40022-000 YCRM-B and YCRM Models 170 to 280 A P E D O B N R R G H C YCRM Model A B C D E F G H I J K L M N O P R S T 170 2200 1600 800 398 1500 618 368 1570 50 60 1237 147 157 500 141 760 3" 1 1/8" 7/8" 200 2200 1600 800 398 1500 618 368 1570 50 60 1237 147 157 500 114 760 4" 1 1/8" 7/8" 240 2200 1600 800 398 1500 618 368 1570 50 60 1237 147 157 500 114 760 4" 1 3/8" 7/8" 280 2200 1600 800 398 1500 618
035B40022-000 9.
9-12 035B40022-000 YCWM, YCRM, YCWM-B and YCRM-B Models 170 to 280
035B40022-000 10-1 10 SPARE PARTS 10.1 Recommended Spares The table below lists the recommended spares for one unit for 2 years. Qty. 1 1 1 2 1 2 6 6 1 1 Component HP Switch LP Switch Differential Oil Pressure Switch Gas Filter Thermostatic Valve Auxiliary Relays Compressor Fuses Auxiliary Fuses Compressor Contactor Power Contactor 10.2 Recommended Compressor Oils The table below lists the recommended oil type for each unit.
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035B40022-000 11 D E - C O M M I S S I O N I N G , DISMANTLING AND DISPOSAL Never release refrigerant to the atmosphere when emptying the refrigerating circuits. Suitable retrieval equipment must be used. If reclaimed refrigerant cannot be re-used. It must be returned to the manufacturer. Never discard used compressor oil, as it contains refrigerant in solution. Return used oil to the oil manufacturer.
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Europe YORK Part No.
