YR ROTARY SCREW LIQUID CHILLER INSTALLATION, COMMISSIONING, OPERATION AND MAINTENANCE STYLE: A REFRIGERANT: R134a 160.
160.81-ICOM-GB0 (01/02) I- i Table of Contents 1 2 SUPPLIER INFORMATION 4 INSTALLATION 1.1 Introduction 1.1 4.1 Location 4.1 1.2 Warranty 1.1 4.2 Foundation 4.1 1.3 Safety 1.1 4.3 Clearances 4.1 1.4 Responsibility for Safety 1.1 4.4 Rigging Unit to Final Location 4.1 1.5 About this Manual 1.2 4.5 Locating and Installing Isolator Pads 4.1 1.6 Misuse of Equipment 1.2 4.6 Installing Optional Spring Isolators 4.2 1.7 Emergency Shutdown 1.3 4.7 Piping Connections 4.2 1.
I-ii 4.21 160.81-ICOM-GB0 (01/02) Status Connections 4.8 7.5 4.21.1 Remote Mode - Ready to Start 7.5.1 4.21.2 Run Contacts 7.6 4.21.3 Anticipatory Alarm 4.22 Checking The Refrigerant Charge 4.21.5 Safety Shutdown 7.6.2 Leak Testing 7.6.3 Vacuum Testing 7.6.4 Refrigerant Charging 4.9 7.7 4.22.2 Cooling Liquid Pump 4.24 5 Refrigerant Charge 7.6.1 Pump Control Connections Thermal Insulation Installation Check 4.9 4.9 COMMISSIONING 7.5 Oil charging procedure 4.21.
160.81-ICOM-GB0 (01/02) 1 SUPPLIER INFORMATION 1.1 Introduction York YR chillers are manufactured to the highest design a nd constr uction standards to ensu r e hi gh performance, reliability and adaptability to all types of air conditioning installations. The units are intended for cooling water or glycol solutions and are not suitable for purposes other than those specified in this manual.
1- 2 1.5 160.81-ICOM-GB0 (01/02) About this Manual The following symbols are used in this document to alert the reader to areas of potential hazard. A Warning is given in this document to identify a hazard which could lead to personal injury. Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the instruction. A Caution identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution.
160.81-ICOM-GB0 (01/02) 1- 3 Refrigerants and Oils 1.8 Refrigerants and oils used in the unit are generally non-toxic, non-flammable and non-corrosive, and pose no special safety hazards. Use of gloves and safety glasses are, however, recommended when working on the unit. Build up of refrigerant vapour, from a leak for example, does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation.
1- 4 1.9 160.81-ICOM-GB0 (01/02) Material Safety Data Refrigerant Data: Safety Data R134a Toxicity Low. In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. Thaw affected areas with water. Remove contaminated clothing carefully — may adhere to skin in case of freeze burns. Wash affected areas with plenty of warm water. If symptoms occur (irritation or blistering) obtain medical attention. In contact with eyes Vapour has no effect.
160.81-ICOM-GB0 (01/02) 1- 5 Spill/leak procedure Ensure suitable personal protective clothing and respiratory protection is worn. Provided it is safe to do so, isolate the source of the leak. Allow small spillage’s to evaporate provided there is suitable ventilation. Large spillage’s: Ventilate area. Contain spillage’s with sand, earth or any suitable absorbent material. Prevent liquid from entering drains, sewers, basements and work pits since vapour may create a suffocating atmosphere.
1- 6 160.81-ICOM-GB0 (01/02) Thermal & Acoustic Materials Data Health Hazard & First Aid Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic. No first aid necessary. Stability / Reactivity Stable. Handling / Use / Disposal No special handling precautions required. Dispose of according to local laws and regulations governing non-biodegradable non-hazardous solid wastes. Fire & Explosion Flammability rating Class 1 to BS 476 pt 7: Non-flammable.
160.81-ICOM-GB0 (01/02) 2 2- 1 Product Description OPTIVIEW CONTROL PANEL SOLID STATE STARTER OIL SEPARATOR COMPRESSOR EVAPORATOR SIGHT GLASS CONDENSER VARIABLE ORIFICE Figure 2.1 YR Rotary Screw Liquid Chiller (Front View) 2.1 General (Figure 2.1) The York YR Rotary Screw Liquid Chiller is primarily used for large air conditioning systems, but may be used on other applications.
2- 2 160.81-ICOM-GB0 (01/02) Oil is injected into the compressor by differential pressure to lubricate the bearings, seal the rotors and remove the heat of compression. The injected oil mixes with the compressed gas and is separated from the refrigerant gas in the oil separator. The compressor has an oil reservoir located at the rotor bearings to provide lubrication during start-up and during coast-down even in the event of a power failure.
160.81-ICOM-GB0 (01/02) In the first stage of oil separation, high velocity oil and refrigerant gas in the compressor discharge line undergoes a rapid reduction in velocity as it enters the large diameter oil separator. Most of the oil drops out of the refrigerant gas stream due to the reduction in velocity. The oil falls by gravity into the oil reservoir located in the bottom of the oil separator. The second stage of oil separation is achieved in the oil coalescing element section of the oil separator.
2- 4 2.9 160.81-ICOM-GB0 (01/02) Evaporator The evaporator is a shell and tube, flooded type, heat exchanger with a distributor trough providing uniform distribution of refrigerant over the entire shell length to ensure optimum heat transfer. A liquid level sight glass is located on the side of the shell to aid in determining proper refrigerant charge. A refrigerant charging valve is provided. 2.
160.81-ICOM-GB0 (01/02) 2- 5 2.15 Options and Accessories Hot Gas By-pass System Model 'B' Solid State Starter A hot gas bypass system can be factory installed to allow unit operation down to virtually zero load if required. The liquid cooled solid state starter is a reduced voltage soft starter that controls and maintains a constant current flow to the motor during start-up. It is compact and mounted on the unit adjacent to the motor terminals. Power and control wiring is factory supplied.
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160.81-ICOM-GB0 (01/02) 3 TRANSPORTATION, RIGGING AND STORAGE 3.1 General 3.2 3- 1 Shipment YR units are shipped as a single factory assembled, piped, wired package, requiring minimum installation to make chilled water connections, condenser water connections, refrigerant atmospheric relief connections, and electrical power connections.
3- 2 160.81-ICOM-GB0 (01/02) Form 3 – Motor/Compressor Separate From Shells 3.3 Inspection, Damage and Shortage Shipped as three major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Compressor/motor assembly removed from shells and skidded. Evaporator/condenser shells are not skidded. The unit shipment should be checked on arrival to see that all major pieces, boxes and crates are received.
160.81-ICOM-GB0 (01/02) 3.4 Rigging The complete standard unit is shipped without skids. (When optional skids are used it may be necessary to remove the skids so riggers skates can be used under the unit end sheets to reduce overall height.) Each unit has four (4) lifting holes (two in each end) in the end sheets which should be used to lift the unit. Care should be taken at all times during rigging and handling of the chiller to avoid damage to the unit and its external connections.
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160.81-ICOM-GB0 (01/02) 4 INSTALLATION 4.1 Location 4.4 4- 1 Rigging Unit to Final Location YR units are furnished with vibration isolator mounts for basement or ground level installations. Units may be located on upper floor levels providing the floor is capable of supporting the total unit operating weight and optional spring isolators are used.
4- 2 160.81-ICOM-GB0 (01/02) Checking the Isolator Pad Deflection All isolator pads should be checked for the proper deflection while checking to see if the unit is level. Each pad should be deflected approximately 4 mm. If an isolation pad is under-deflected, shims should be placed between the unit tube sheet and the top of the pad to equally deflect all pads.
160.81-ICOM-GB0 (01/02) 4.8 Evaporator and Condenser Water Piping The evaporator and condenser liquid heads have nozzles which are grooved, suitable for welding 10.6 bar DWP flanges or the use of Victaulic couplings. Factory mounted flanges are optional. The nozzles and water pass arrangements are delivered in accordance with the job requirements (see Product Drawings delivered with the job and Section 9). Standard units are designed for 10.6 bar DWP on the water side.
4- 4 160.81-ICOM-GB0 (01/02) 4.10 Glycol Solutions 4.15 Checking Piping Circuits and Venting Air For unit operation with chilled liquid temperatures leaving the evaporator at below 4°C, glycol solutions should be used to help prevent freezing. Section 9 gives recommended solution strength with water, as a percentage by weight, for the most common types of glycol. It is important to check glycol concentration regularly to ensure adequate concentration and avoid possible freeze-up in the evaporator.
160.81-ICOM-GB0 (01/02) 4.17 Unit Piping Compressor lubricant piping and system external piping are factory installed on all units shipped assembled. On units shipped dismantled, the lubricant piping to oil sump and oil cooler and system oil return connections should be completed, under the supervision of the York representative, using material furnished. 4.18 Electrical Connection The following connection recommendations are intended to ensure safe and satisfactory operation of the unit.
4- 6 160.81-ICOM-GB0 (01/02) Route the cables forming the 3 phase power supply via the same hole in the motor terminal box gland plate, using a suitable cable gland, to ensure that no eddy currents are set up in the metal gland plate. If separate entries for each cable forming the 3 phase supplies are used, the metal gland plate must be replaced by a non-metallic gland plate. 4.19.
160.81-ICOM-GB0 (01/02) 4.20 Control Connections Customer voltage free contacts must be suitable for device contact rating to be 5 mA at 115 Vac. If the voltage free contacts form part of a relay or contactor, the coil of the device MUST be suppressed using a standard R/C suppressor to avoid electrical noise which could cause a malfunction or damage to the unit. To avoid the possibility of motor failure due to excessive start cycles, the unit should not normally be cycled using the remote connections.
4- 8 160.81-ICOM-GB0 (01/02) 4.20.8 Remote Current Limit Setpoint - PWM (TB4 terminals 1 & 20) 4.21 Status Connections The motor current limit setpoint can be adjusted remotely by a 1 to 11 second timed closure of remote contacts connected to these terminals. The input signal will only be accepted when the control panel is in the digital 'REMOTE' operating mode. Wiring to the status volt free contacts requires a supply provided by the customer.
160.81-ICOM-GB0 (01/02) 4.21.5 Safety Shutdown (TB2 terminals 42 & 43) 4- 9 4.23 Thermal Insulation (See Product Drawings Form 160.81-PA1) When closed, these contacts signify the unit is not permitted to start due to one or more safety controls. A closure of the safety shutdown contacts means that the operator must manually reset and restart the unit. Safety shutdown contacts function in all operating modes. 4.
4-10 160.81-ICOM-GB0 (01/02) J22 1 REMOTE CURRENT LIMIT SETPOINT (0-10 Vdc / 2-10 Vdc) 2 REMOTE CURRENT LIMIT SETPOINT (0-20 mA / 4-20 mA) 3 REMOTE LEAVING CHILLED LIQUID TEMPERATURE SETPOINT (0-10 Vdc / 2-10 Vdc) 4 REMOTE LEAVING CHILLED LIQUID TEMPERATURE SETPOINT (0-20 mA / 4-20 mA) 5 COMMON OPTIVIEW CONTROL PANEL J22 TB2 45 151 COOLING LIQUID PUMP MICROBOARD Note jumpers ( ) should be removed when these contacts are used. Figure 4.
160.81-ICOM-GB0 (01/02) 5 COMMISSIONING 5.1 Preparation Commissioning of this unit should only be carried out by York authorised personnel. 5- 1 Supply voltage: Verify that the site voltage supply corresponds to the unit requirement and is within the limits given on the unit data plate. The customers disconnection devices can now be set to ON. The Operating Instruction manual must be read in conjunction with this section.
5- 2 5.2 160.81-ICOM-GB0 (01/02) First Time Start-up During the commissioning period there should be sufficient heat load to run the unit under stable full load operation to enable the unit controls, and system operation to be set up correctly and a commissioning log taken. Read the following section in conjunction with the control panel Operating Instructions and Section 6. Interlocks: Verify that water is flowing through the evaporator and that heat load is present.
160.81-ICOM-GB0 (01/02) 6 OPERATION If the oil heater is de-energised during a shutdown period, it must be energized for 24 hours prior to starting the compressor. 6.1 6.3 1. General YR chillers are designed to work independently, or in conjunction with other equipment via a York ISN building management system or other automated control system. The compressor can be started and loaded as required using a range or input signals to achieve the desired cooling effect.
6- 2 3. 160.81-ICOM-GB0 (01/02) The chilled liquid pump contacts close starting the chilled liquid pump to allow liquid flow through the evaporator. The chilled water flow switch is bypassed until the last 5 seconds of the start sequence. 4. After T seconds of start sequence operation, the compressor will start. 5. When the motor reaches full speed and the current falls below 100% FLA the message will read: LEAVING CHILLED LIQUID CONTROL. 6.
160.81-ICOM-GB0 (01/02) 6.7 Prolonged Shutdowns 6- 3 2. Check Oil Pressure Display: The oil and oil filter transducers are compared during compressor operation. If the differential filter pressure exceeds 138 kPa for 8 seconds, the message WARNING OIL - DIRTY FILTER is displayed. If the differential filter pressure exceeds 172.5 kPa for 8 seconds, the unit shuts down and the displayed message is OIL - CLOGGED FILTER.
6- 4 6.9 160.81-ICOM-GB0 (01/02) Operating Log Sheet An accurate record of system operating conditions (temperatures and pressures) recorded at regular intervals throughout each 24 hour operating period should be kept. An optional status printer is available for this purpose using automatic data logging. The record of readings serves as a valuable reference for operating the system. Readings taken when a system is newly installed will establish normal conditions with which to compare later readings.
160.81-ICOM-GB0 (01/02) 7 MAINTENANCE The Safety Section of this manual should be read carefully before attempting any maintenance operations on the unit. This section should be read in conjunction with the control panel Operation Instruction. The units have been designed to operate continuously provided they are regularly maintained and operated within the limitations given in this manual.
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160.81-ICOM-GB0 (01/02) 7.3 7- 3 Regular Maintenance Operations Service Schedule MINOR SERVICE ( 3 - 6 monthly ) * MAJOR SERVICE ( 6 - 12 monthly ) * All items under Minor Service plus: General Check thermal insulation Check vibration isolators Check main structure Check paint-work Check vibration levels Refrigerant Systems Check relief valves Check for pipework damage Check for leaks Check operating temps./press.
7- 4 7.4 160.81-ICOM-GB0 (01/02) Connect a refrigeration pressure hose to the pressure access port and drain the oil and refrigerant into a suitable refrigerant recovery container. Oil Filters and Driers 3. Position a container to collect the oil (less than 1.9 litres). Loosen and remove the drain nut at the bottom of the oil filter housing; drain the oil into the container. 4. Unscrew the oil filter bowl locking nut. 5. Remove the oil filter element. 6. Install a new element. 7.
160.81-ICOM-GB0 (01/02) ® 4. Loosen the Rota-Lock Nuts at each end of the filter driers. Remove the filter driers. 5. Teflon® seal washers are used to seal the filter drier connections. These washers must be replaced when the filter driers are replaced. 6. Tighten the Rota-Lock® Nuts at each end of the three filter driers to a torque of 60 ft.-lb. 7. Evacuate the air from the oil filter to 500 microns PSIG. 8. Open the five hand isolation valves.
7- 6 7.6.3 160.81-ICOM-GB0 (01/02) Vacuum Testing 7.6.4 Vacuum testing should be conducted as follows: 1. Connect a high capacity vacuum pump, with indicator, to the system charging valve and start the pump. 2. Open wide all system valves. Be sure all valves to the atmosphere are closed. 3. Operate the vacuum pump until a wet bulb temperature of 0°C or a pressure of 5 mm Hg (absolute) is reached. 4.
160.81-ICOM-GB0 (01/02) 7.7.1 Chemical Water Treatment Since the mineral content of the water circulated through the evaporator and condenser varies with almost every source of supply, it is possible that the water being used may corrode the tubes or deposit heat resistant scale in them. Reliable water treatment will greatly reduce the corrosive and scale forming properties of almost any type of water. 2. 7.7.3 7- 7 Scale - due to mineral deposits.
7- 8 7.7.4 160.81-ICOM-GB0 (01/02) Tube Leaks 4. After the tubes have been corked for 12 to 24 hours, it is recommended that two men working at both ends of the evaporator carefully test each tube – one man removing corks at one end and the other at the opposite end to remove corks and handle the leak detector. Start with the top row of tubes in the section being investigated.
160.81-ICOM-GB0 (01/02) 7.9 Testing Motor Winding Insulation With the main disconnect switch and compressor motor starter open, test the motor as follows: 1. Test the insulation, using a megohm meter (megger), between phases and each phase and ground as shown; these readings are to be interpreted using the graph shown in below. 2. If readings fall below shaded area, remove external leads from motor and repeat test.
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160.81-ICOM-GB0 (01/02) 8 TROUBLE SHOOTING 8.1 General Requirements Units are not generally user serviceable and no attempt should be made to rectify any faults found with the unit unless suitably qualified and equipped to do so. If in any doubt, contact your local York Agent. To avoid personal injury or possible damage to the unit, the trouble shooting information given in the following section must only be used by competent service personnel using correct procedures and equipment. 8.
8- 2 160.81-ICOM-GB0 (01/02) Fault Possible Cause Remedy Temperature of chilled water too low with low motor current. Insufficient load for system capacity. Check slide valve operation and setting of low water temperature cut-out. Slide valves fail to open. Check the slide valve solenoid valve. System overload. Be sure that the slide valve is fully open (without overloading the motor) until the load decreases. High Evaporator Pressure High chilled water temperature.
160.81-ICOM-GB0 (01/02) 9 TECHNICAL DATA 9.1 Dimensions 9- 1 Overall Dimensions - T0 and T1 Compressor T0 and T1 COMPRESSOR SHELL CODES - (Evaporator-Condenser) DIM. T-T V-V A 3,048 4,267 B 2,445 2,445 C 1,550 1,550 D 762 762 E 787 787 F 381 381 G 394 394 L 70 190 Dimensions in mm EVAPORATOR CODES T & V CONDENSER CODES T & V DIM.
9- 2 9.2 160.81-ICOM-GB0 (01/02) Solid State Starter Details (Optional) POWER WIRING ENTRANCE COVER WITH 22 mm Ø KNOCKOUTS USED AS LEAD HOLES FOR POWER WIRING CONDUIT CONNECTIONS MOTOR/COMPRESSOR OPTIVIEW CONTROL PANEL B SOLID STATE STARTER c F E A D C L OF POWER FRONT VIEW Model/Dim. A 7LK & 14LK 864 26LK & 33LK 889 9.
160.81-ICOM-GB0 (01/02) 9.
9- 4 9.5 160.81-ICOM-GB0 (01/02) Water Box Nozzle Arrangements A A CC CC EVAPORATOR EVAPORATOR GG 25.4 mm MOTOR END FLOOR LINE GG 25.4 mm COMPRESSOR END J B K C DD DD BB BB GG FLOOR LINE 25.4 mm COMPRESSOR END N F P G DD DD BB BB EVAPORATOR EVAPORATOR GG 25.4 mm MOTOR END Evaporator Shell Code T V 2-PASS Nozzle Arrangements No. of Evaporator In Out Passes C B 2 K J NOTE: Water must enter through bottom connection to achieve rated performance EVAPORATOR EVAPORATOR GG 25.
160.81-ICOM-GB0 (01/02) FRONT OF UNIT FRONT OF UNIT P Q CC CC 1-PASS Nozzle Arrangements No. of Condenser In Out Passes P Q 1 Q P CONDENSER CONDENSER GG 25.4 mm COMPRESSOR END 9- 5 GG FLOOR LINE 25.4 mm MOTOR END FRONT OF UNIT FRONT OF UNIT S U R T DD DD BB BB GG 25.4 mm COMPRESSOR END NOTE: Water must enter through bottom connection to achieve rated performance CONDENSER CONDENSER 2-PASS Nozzle Arrangements No. of Condenser In Out Passes R S 2 T U GG 25.
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160.81-ICOM-GB0 (01/02) 10 SPARE PARTS It is recommended that the following common spare par ts are held for preventative of corrective maintenance operations. Part Qty. Information Required Other spare parts vary depending on the unit model. Contact your local York Sales and Service Centre for information and please quote the unit model number and serial number.
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160.81-ICOM-GB0 (01/02) 11 11-1 DE-COMMISSIONING, DISMANTLING AND DISPOSAL N ever release refrigerant t o t h e atm osphere w hen emptyin g t h e 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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YORK Service and Parts Contact Addresses Austria YORK Austria Central & Eastern Europe Headquarters Zetschegasse 3 A 1232 Wien Austria Tel: ++43 1 66 136 195 Fax: ++43 1 66 136 86 Azerbaijan YORK International AO 90 M.Mansurov Str. AZ-370004 Baku Republic of Azerbaijan Tel.
