MILLENNIUM TM ROTARY SCREW LIQUID CHILLERS INSTALLATION, OPERATION & MAINTENANCE Supersedes: Nothing Form 160.
IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. During installation, operation, maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, oils, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death.
FORM 160.
TABLE OF CONTENTS Nomenclature .......................................................................................................................... 3 SECTION 1 INSTALLATION General .................................................................................................................................... 7 Inspection ................................................................................................................................ 8 Data Plate .....................................
FORM 160.80-NOM1 TABLE OF CONTENTS SECTION 3 OPERATION Basic Description .................................................................................................................. 32 Components ........................................................................................................................... 32 Driveline ............................................................................................................................. 32 Oil Separator .............................
LIST OF TABLES 1 2 3 4 5 6 7 8 9 Clearances .................................................................................................................... 8 Weights - English, R-22 and R-134a Units, 50 and 60 Hz ......................................... 10 Weights - SI, R-22 and R-134a Units, 50 and 60 Hz ................................................. 12 Refrigerant Relief Characteristics ..............................................................................
FORM 160.80-NOM1 SECTION 1 – INSTALLATION GENERAL This instruction describes the installation of a Model YS Rotary Screw Liquid Chiller. (See Figure 1.) This unit is shipped as a single factory assembled, piped, wired and nitrogen or refrigerant charged package (Form 1 shipment). This unit requires a minimum of field labor to make chilled water connections, condenser water connections, refrigerant atmospheric relief connections, and electrical power connections.
Installation The YORK Warranty will be voided if the following restrictions are not adhered to: 1. No valves or connections should be opened under any circumstances because such action will result in loss of the factory refrigerant or nitrogen charge. 2. Do not dismantle or open the unit for any reason except under the supervision of a YORK representative. 3.
FORM 160.80-NOM1 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 the overall height.) Each unit has four lifting holes (two on 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 to avoid damage to the unit and its external connections. Lift only using holes shown in Figure 2.
Installation TABLE 2 – WEIGHTS - ENGLISH, R-22 AND R-134A UNITS, 50 AND 60 HZ SHELL CODE COOLER – COND. COMPRESSOR SHIPPING WT. (Lbs.) OPERATING WT. (Lbs.) REFRIGERANT CHARGE (Lbs. R-22) REFRIGERANT CHARGE (Lbs.
FORM 160.80-NOM1 TABLE 2 – WEIGHTS - ENGLISH, R-22 AND R-134A UNITS, 50 AND 60 HZ (CONT’D) SHELL COMCODE PRESCOOLER SOR – COND. SHIPPING WT. (Lbs.) OPERATING WT. (Lbs.) REFRIGERANT CHARGE (Lbs. R-22) REFRIGERANT CHARGE (Lbs.
Installation TABLE 3 – WEIGHTS - SI, R-22 AND R-134A UNITS, 50 AND 60 HZ SHELL CODE COOLER – COND. COMPRESSOR SHIPPING WT. (Kgs.) OPERATING WT. (Kgs.) REFRIGERANT CHARGE (Kgs. R-22) REFRIGERANT CHARGE (Kgs.
FORM 160.80-NOM1 TABLE 3 – WEIGHTS - SI, R-22 AND R-134A UNITS, 50 AND 60 HZ (CONT’D) SHELL COMCODE PRESCOOLER SOR – COND. SHIPPING WT. (Kgs.) OPERATING WT. (Kgs.) REFRIGERANT CHARGE (Kgs. R-22) REFRIGERANT CHARGE (Kgs.
Installation RIGGING (CONT’D) Units shipped dismantled should be assembled under the supervision of a YORK representative. If the cooler is to be field insulated, the insulation should be applied while the unit is in the lift position, before the unit is placed in position. The longitudinal alignment of the unit should be checked by placing a level on the top center of the cooler shell under the compressor/motor assembly.
FORM 160.80-NOM1 1 LD02942 LD02943 LD02944 OPERATING WEIGHT (Lbs. / Kgs.) DETAIL UP TO 16,365 / 7,423 A 16,636 / 7,546 to 28,835 / 13,080 B 28,836 / 13,080 to 53,530 / 24,281 C FIG.
Installation LD00068 S0 and S1 COMPRESSOR DIMENSION S2 COMPRESSOR S2 and S3 COMPRESSOR SHELL CODES (Cooler – Condenser) B-B A – TUBE SHEET WIDTH B-C C-B C-C 4'–2-7/8" B-B B-C A1 – OVERALL WIDTH 4'–6-3/4" 4'–6-1/4" 5'–3-3/4" B – OVERALL HEIGHT3 5'–8-5/8" 5'–11-1/2" 5'–10-1/4" 5'–11-1/2" 5'–11-1/4" 6'–3-1/4" 4'–6-1/4" 4'-6-3/4" C-B C-C 5'–2-1/2" C – COOLER C/L 1'–1-7/8" 1'–5" D – CONDENSER C/L 0'–11-5/8" 1'–2-1/4" C-D D-C D-D 5'–2-1/2" 5'–3-3/4" 6'–3-1/4" 6'–3-1/4" 6'–7-5/8
FORM 160.80-NOM1 1 LD00505 S4 COMPRESSOR DIMENSION D-C A TUBE SHEET WIDTH S4 and S5 COMPRESSOR SHELL CODES (Cooler – Condenser) D-D 6'–2" 6'–2" E-E E-F F-E 6'–2" 6'–4-1/2" 6'–6-1/2" F-F 6'–9" A1 – With SSS 6'–9-7/8" 6'–9-7/8" 6'–9-7/8" 7'–0-3/8" 7'–3-5/8" 7'–2-5/8" A2 – OVERALL WD.
Installation LD00506 S0 and S1 COMPRESSOR DIMENSION S2 COMPRESSOR S2 and S3 COMPRESSOR SHELL CODES (Cooler – Condenser) A – TUBE SHEET WIDTH 1 A – OVERALL WIDTH 3 B-B B-C C-B C-C B-B B-C C-B C-C C-D D-C D-D 1,292 1,292 1,292 1,292 1,588 1,588 1,588 1,588 1,588 1,588 1,588 1,349 1,349 1,349 1,349 1,591 1,591 1,591 1,591 1,591 1,591 1,591 1,816 1,895 1,857 1,899 1,848 1,946 1,946 1,946 2,054 2,102 2,102 C – COOLER C/L 351 351 351 351 432 432 432 432
FORM 160.80-NOM1 1 LD00273A S4 COMPRESSOR DIMENSION S4 and S5 COMPRESSOR SHELL CODES (Cooler – Condenser) D-C D-D E-E E-F F-E F-F 1,880 1,880 1,880 1,943 1,994 2,057 A – WITH SOLID STATE STARTER 2,080 2,080 2,080 2,143 2,226 2,200 A 2 – OVERALL WIDTH (Less S.S.
Installation INSTALLING OPTIONAL SPRING ISOLATORS To install these spring isolators, first remove the bolts and nuts from the spring isolator bracket. Bolt the isolator bracket to the unit foot support before the unit is located on the floor. Place the four spring isolators in position in accordance with the product drawing, Form 160.47-PA1. The threaded adjusting bolts in each isolator should be screwed out of the isolator until the extended head of the screw fits snugly into the isolator bracket hole.
FORM 160.80-NOM1 The adjusting bolts should now be rotated one (1) turn at a time, in sequence, until the unit end sheets are about 7/8 inch (22mm) off the floor or foundation, and the unit is level. Check the level of the unit both longitudinally and transversely. If the adjusting bolts are not long enough to level the unit due to an uneven or sloping floor or foundation, steel shims (grouted, if necessary) must be added beneath the isolator assemblies as necessary.
Installation COOLER AND CONDENSER WATER PIPING System Turnover Rate (STR) = Volume of chilled water system (gallons) YS Chillers have cooler and condenser liquid heads with nozzles that are grooved for the use of victaulic couplings. The nozzles are alos suitable for welding Class 150 PSIG (1034 kPA) flanges. The nozzles and water pass arrangements are furnished in accordance with the job requirements (see Product Drawing, Form 160.47-PA1).
FORM 160.80-NOM1 If pumps discharge through the unit, the strainer may be located upstream from the pumps to protect both pump and unit. (Piping between the strainer, pump and unit must be very carefully cleaned before start-up.) If pumps are remotely installed from the unit, strainers should be located directly upstream. Condenser Water Circuit For proper operation of the unit, condenser refrigerant pressure must be maintained above cooler pressure.
Checking Piping Circuits and Venting Air After the water piping is completed, but before any water box insulation is applied, tighten and torque the nuts on the liquid head flanges (to maintain between 30 and 60 ft. lbs. / 41 and 81 nm). Gasket shrinkage and handling during transit cause nuts to loosen. If water pressure is applied before this is done, the gaskets may be damaged and have to be replaced.
FORM 160.80-NOM1 TABLE 4 – REFRIGERANT RELIEF CHARACTERISTICS OIL SEPARATOR (R-22) RELIEF VALVE RUPTURE DISK COMPRESSOR C Cr DUAL (1) CR SINGLE CODE LBS. AIR PER MIN. OUTLET NPT #AIR/MIN. OUTLET NPT S0, S1 (2) 24.0 35.9 *3/4" 511.0 2" S2, S3 (2) 28.3 35.9 3/4" 764.0 2" S4 (2) 33.3 63.8 1" 1008.0 2-1/2" S5 (2) 33.3 63.8 1" 1275.0 2-1/2" OIL SEPARATOR (R-134a) RELIEF VALVE RUPTURE DISK COMPRESSOR C Cr DUAL (1) CR SINGLE CODE LBS. AIR PER MIN. OUTLET NPT #AIR/MIN. OUTLET NPT S0, S1 (2) 24.0 35.9 *3/4" 511.
Installation POWER WIRING (CONT’D) Remote Electro-Mechanical starters for the YS Unit must be furnished in accordance with YORK Standard R-1079. Each YS unit is furnished for a specific electrical power supply as stamped on the unit data plate, which also details the motor connection diagrams. To insure proper motor rotation, the starter power input and starter to motor connections must be checked with a phase sequence indicator in the presence of the YORK Representative.
FORM 160.80-NOM1 1 LD03301 FIG.
Start-Up LD03305 FIG.
FORM 160.80-NOM1 SECTION 2 – START-UP YS CHILLER COMMISSIONING CHECKLIST This checklist is provided as a guide to the service technician to ensure the YS Chiller is properly commissioned. c This symbol indicates that the feature described is programmable or selectable from Graphic Control Center. Refer to Operational Form 160.80-O1 and the Service Manual Form 160.80-M1 for more information concerning the Graphic Control Center.
Start-Up Low Temperature Brine Chillers % Verify the freeze point of the brine in the evaporator. Use a hand-held optical refractometer or a hydrometer. % Make certain the Brine Low Evaporator Pressure Cutout Threshold* Setpoint (EVAPORATOR screen) is set above the brine freeze point. High Pressure Safety Switch % Verify the setpoint of the high-pressure safety switch. Reconfirm the High Pressure Limit/Warning threshold setpoint (CONDENSER screen).
FORM 160.80-NOM1 Refrigerant Leak Check % Thoroughly leak check the entire chiller for leaks prior to starting. Make certain to include relief valves. This may require removing field-installed relief valve piping. Compressor Oil % Check the compressor oil level. Oil should be visible in the top sight glass on the side of the oil separator. % Make certain that the oil heater has been energized at least 24 hours prior to starting the chiller.
Start-Up Enter appropriate number for Modem, Printer or ISN Remote Application: c Chiller ID (identification) PRINTER SCREEN If printer is connected to Micro Board Serial Ports, enter the following: c Automatic Print Logging ENABLE/DISABLE c Automatic Printer Logging Start Time c Automatic Print Logging Interval c Printer Type c Report Type (Status, Setpoints, Schedule or Sales Order) Graphic Control Center % Recheck the setpoints and programmable functions of the Graphic Control Center.
FORM 160.80-NOM1 SECTION 3 – OPERATION BASIC DESCRIPTION The YORK YS Chiller package uses a refrigerantflooded evaporator and a liquid-cooled condenser. The compressor is a heavy-duty, industrial-rated rotary screw compressor. The YS package consists of four major components - Driveline, Oil Separator, Condenser, and Evaporator. Refer to the Chiller Package Component drawing, Figure 14. COMPONENTS Driveline The driveline is made up of the compressor and a 2-pole industrial induction motor.
Operation 34 Safety Relief Devices Control Panel Compressor Oil Separator "D"-Flange Oil Filter Evaporator Isolation Valve Liquid Line Isolation Valve Fluid OUT Condenser Fluid IN YORK INTERNATIONAL FIG.
YORK INTERNATIONAL Oil Supply to Capacity Control Port "P" Oil Cooler Oil to Compressor Port SB - 2 SB - 2 Oil Manifold Block Refrigerant Gas from OIl Cooler "1 SOL" Solenoid Valve used on ChillerSizes S0 - S3 Only Oil to Compressor Port SB - 3 Hand Isolation Valve WARNING: Do Not Close This Valve Except to Service Filter "OILPRESSURE" Transducer Pressure Release Valve "SEAL OIL PRESSURE" Transducer Liquid Refrigerant to Oil Cooler "FILTER PRESSURE" Transducer (bottom of oil separator) Oil Temp
Pressure Release Valve Oil Filter "1 SOL" Solenoid Valve used on Chiller Sizes S0 - S3 Only 3-Way Hand Isolation Valve Hand Isolation Valve Pressure Release Valve Oil from Oil Separator Oil Filter Hand Isolation Valve LD04900 YORK INTERNATIONAL FIG.
FORM 160.80-NOM1 A baffle is welded into the top of the evaporator to collect oil that falls from the compressor, preventing oil from mixing with the refrigerant charge. The baffle prevents liquid refrigerant from damaging the compressor. CONDENSING WATER TEMPERATURE YS Chillers can be operated with entering condensing water temperature that is less than design conditions. The following formula is used to calculate the minimum entering condensing water temperature.
Operation The oil pressure transducer is located at the SB-2 manifold. The differential pressure is measured as the difference between the Oil Pressure Transducer at SB-2 and the Filter Pressure Transducer located in the oil separator. This value is compared to the limits in the control panel logic. If the oil filter differential reaches 20 PSID, a warning message is displayed by the control panel display. If the oil filter reaches 25 PSID, a safety shutdown is initiated. See Figure 18.
YORK INTERNATIONAL 6 2 1 3 1 4 First Stage of Oil Separation 5 Oil Out Reduction in Velocity Second Stage of Oil Separation Extended Surface Area 1 Third Stage of Oil Separation Oil & Refrigerant Coalescer Element Gas to Eductor LD04302 39 FORM 160.80-NOM1 1. Sight Glass 2. Oil Level Switch 3. Filter Pressure Transducer and Isolation Valve 4. Oil Charging Valve 5. Oil Heater 6. Discharge Temperature Sensor FIG.
Operation lets are collected on the extended surface area of the wire mesh pads where the oil falls by gravity into the oil reservoir. The third and final stage of oil separation is achieved in the oil coalescing element section of the oil separator. The oil mixed with the refrigerant entering the coalescer element is a very fine aerosol mist about the size of cigarette smoke particles.
FORM 160.80-NOM1 OIL EDUCTOR CIRCUIT An oil eductor circuit is provided to properly manage the amount of oil in the refrigerant charge. A small amount of oil is normal in the refrigerant charge and will be found in the evaporator. If not properly managed the oil will accumulate and have adverse consequences regarding chiller performance. The oil eductor circuit consists of three refrigerant and oil filter driers, two “jet pump” eductors and the interconnecting piping. Refer to Figures 21 and 22.
Operation 42 YORK INTERNATIONAL LD04299 FIG.
YORK INTERNATIONAL Inlet Oil Oil Cooler Sub Cooled Liquid Refrigerant Refrigerant Gas to Evaporator Outlet Oil Manual Liquid Refrigerant Metering Valve Refrigerant Gas from Oil Cooler Liquid Refrigerant to Evaporator Refrigerant Charging Valve Metering Orifice Manual Isolation Valve Variable Orifice Solenoid Valve Manual Isolation Valve Manual Throttling Valve 43 FIG. 23 – YS SCREW CHILLER REFRIGERANT SCHEMATIC – DESIGN LEVEL “E” FORM 160.
Operation oil separator and the condenser, allows all of the refrigerant charge to be stored in the condenser. PORT “T” SERVICE ISOLATION VALVE CAP A ½ inch liquid refrigerant supply is piped from the bottom of the liquid line to the refrigerant cooled oil cooler. The refrigerant gas from the oil cooler is piped directly into the evaporator. A liquid refrigerant-charging valve is piped into the liquid line between the evaporator and the metering orifice.
FORM 160.80-NOM1 Compressor Port SC - 1 3 Compressor Port SC - 2 Unload Load Compressor Port SC - 11 Load Unload Supply Oil Pressure from Manifold at SB-2 Load and Unload T A P B 4 - Way Capacity Control Solenoid Valve Sub-Plate LD04300 Service Isolation Valves FIG. 26 – YS SCREW CHILLER CAPACITY CONTROL PIPING SCHEMATIC – DESIGN LEVEL “E” LD04902 FIG.
Maintenance SECTION 4 – MAINTENANCE GENERAL TABLE 7 – COMPRESSOR OIL LIMITS The maintenance requirements for YS Chillers is shown on the following page. The procedure is given in the left- hand column and the frequency required is marked with an “X” shown in the right-hand columns. Refer to the note at the bottom of the form to maintain warranty validation. COMPRESSOR OIL YORK oil types approved for YS Chillers and the quantity of oil required is listed in Table 6.
FORM 160.80-NOM1 amount of oil removed from the oil separator should equal the amount of new oil pumped into the oil separator. Oil Level A visual check is sufficient to verify the oil level. Two sight glasses are part of the oil separator and should be used to determine the proper operating oil level. The upper sight glass should have liquid oil visible in the sight glass with the chiller off and the oil at 105ºF (40ºC) and 115ºF (46ºC).
Maintenance Maintenance MAINTENANCE REQUIREMENTS FOR YORK YS CHILLERS TABLE 8 – MAINTENANCE REQUIREMENTS FOR YORK YS CHILLERS PROCEDURE DAILY Record Operating Pressures and Temperatures X Check Oil and Refrigerant Levels WEEKLY MONTHLY QUARTERLY YEARLY X Check Operation of Oil Heater X Check 3-Phase Voltage and Current Balance X Leak Check and Repair Leaks *** X Calibrate Safety Controls X Check Slide Valve Operation and Calibrate Slide Valve Potentiometer X Lubricate Motor Bearings (per Moto
FORM 160.80-NOM1 FILTER DRIER REPLACEMENT The filter driers should be changed annually or when excessive amount of oil is indicated in the refrigerant charge. When the filter driers require changing the chiller must be shut off. 1. Close the (5) service isolation valves identified in schematic drawing, Figure 23. 2. Carefully remove the insulation on the (2) filter driers located on the eductor block. 3.
Maintenance REFRIGERANT LEAK CHECKING Periodic refrigerant leak checking must be part of a comprehensive maintenance program. Leak check the entire chiller using a calibrated electronic leak detector. Confirm leaks with soap bubbles that are found using the electronic leak detector. Check refrigerant relief valve piping and tube rolled joints as part of the comprehensive refrigerant leak checking program.
FORM 160.80-NOM1 condenser fluids other than water consult with the local YORK Field Service Office for the correct condenser approach. Where: N = L = Number of Condenser Tubes Length of each Tube in inches To covert in3 to gallons, divide the Volume (in3) by 231 in3/gallon. CONDENSER WATER SIDE TUBE CLEANING PROCEDURE Mechanical Cleaning Procedure Two methods are used for waterside tube cleaning to remove the scale; chemical and mechanical cleaning procedures.
Maintenance MEGOHM THE MOTOR Make certain that the motor disconnect switch (circuit breaker) is in the open position. Megohm the motor as follows: 1. Use a megohm meterto verify the minimum motor and wiring insulation resistance. Megohm between phases and each phase to ground, refer to Fig. 30, Diagram, Megohm Motor Windings. Refer to Fig. 31, Motor Stator Temperature and Insulation resistances. 2.
FIG. 31 – MOTOR STATOR TEMPERATURE AND INSULATION RESISTANCES YORK INTERNATIONAL Minimum Insulation Resistance vs. Temperature (per IEEE Std 43) YT CodePak Open Motors 1. Megohm readings should be taken after Megohm voltage has been applied one minute. 2. If insulation resistance lies to the right of the applicable curve, the motor is acceptable for use. 3. If insulation resistance lies to the left of the applicable curve, the motor should not be run.
Maintenance VIBRATION ANALYSIS Vibration analysis performed at yearly intervals is a useful diagnostic that can detect internal damage to rotating machinery and component parts. This service should be performed by a skilled technician trained in the use and operation of the equipment. Fig. 32 is provided to properly locate the transducer measurement points. Locat- ing the transducers at these locations will enable the data to be analyzed against a large database of sound and vibration data.
FORM 160.80-NOM1 SPECTRAL ALARM BANDS FOR 4/6 LOBE TWIN SCREW CHILLERS Reference: Proven method for specifying spectral band alarm levels and frequencies using today’s predictive maintenance software systems James E. Berry, Technical Associates of Charlotte, Inc. OVERALL LEVEL OA 0.500 IN/SEC (0-PK) MTR/MALE RTR RPM MTR 3570 RPM = 4/6 LOBE RATIO LR FEMALE ROTOR IDLE MALE ROTOR LOBES LOB PUMPING FREQUENCY BPF 14280 CPM = 238.0 HZ FREQUENCY MAX FMAX 178500 CPM = 2,975.0 HZ 59.5 HZ 0.
Maintenance OIL RECOVERY YS Chiller Best Practice Oil Recovery Method A skilled service technician can recover oil from the refrigerant charge in the evaporator in less than 60 minutes. Before starting the chiller, print a History print. This will help you determine the reason for the oil loss. The operating conditions are stored in memory in a history buffer file. Connect a printer and press the History print key. 1.
FORM 160.80-NOM1 the compressor DSH be your guide. Moving the slide valve in increments that are too large will only result in the oil recovery process taking longer than necessary. 8. When the slide valve position is at least 40% and the compressor DSH is above 25ºF, the chiller can be placed in the AUTO mode of operation. Press the AUTO key. 9. Press the STATUS key. The message WARNING – EXCESS CHARGE will appear. To clear this message, press the WARNING RESET key. 10.
Maintenance VACUUM DEHYDRATION Should the chiller be opened to the atmosphere for lengthy repair or service, follow the Vacuum Dehydration Guidelines in Form 160.47-N3.1 (1099), Field Re-Assembly for Form 3 & Form 7 Shipment of Model YS Chillers, to ensure that all air, moisture and non-condensable gases are removed prior to placing the chiller into service.
FORM 160.
Proud Sponsor of the 2000 U.S. Olympic Team 36USC380 P.O. Box 1592, York, Pennsylvania USA 17405-1592 Copyright © by York International Corporation 1999 Form 160.80-NOM1 (1199) Supersedes: Nothing Subject to change without notice.
