YS ROTARY SCREW LIQUID CHILLER INSTALLATION, COMMISSIONING, OPERATION AND MAINTENANCE IRED U Q E R E R U T IC P YS STYLE: D REFRIGERANT: R134a Effective from 02/00 GB
035L02381-GB0 I- i Table of Contents 1 2 SUPPLIER INFORMATION 3 1.1 Introduction 1.1 1.2 Warranty 1.1 1.3 Safety 1.1 1.4 Responsibility for Safety 1.1 1.5 About this Manual 1.2 1.6 Misuse of Equipment 1.2 1.7 Safety Labels 1.3 1.8 Material Safety Data 1.4 Product Description 2.1 General 2.1 2.2 Capacity Control 2.2 2.3 Compressor 2.3 2.4 Compressor Lubrication System 2.3 2.4.1 Oil Pump 2.4.2 Oil Heater 2.5 Compress Motor 2.5 2.6 Graphic Control Centre 2.5 2.
I-ii 5 5.1 6 035L02381-GB0 7.4 COMMISSIONING Preparation 5.1 OPERATION 6.1 Oil Heater Operation 6.2 Checking the Oil Level in the Oil Reservoir 6.1 6.3 Start-up Procedure 6.4 6.3.1 Pre-Starting 6.3.2 Start-up Chiller Operation 6.4.1 6.1 6.4 Condenser Water Temperature Control 6.5 Operating Log Sheet 6.4 6.6 Maintenance and Service 6.4 6.6.1 Normal and Safety System Shutdowns 6.6.2 Safety Shutdowns 6.6.3 Cycling Shutdowns 6.7 Stopping the System 6.6 6.
035L02381-GB0 1 SUPPLIER INFORMATION 1.1 Introduction York YS chillers are manufactured to the highest design a nd construction 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 035L02381-GB0 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.
035L02381-GB0 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 035L02381-GB0 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.
035L02381-GB0 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 035L02381-GB0 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.
035L02381-GB0 2 2- 1 Product Description MOTOR TERMINAL BOX RUPTURE DISK COMPRESSOR RELIEF VALVE OIL SEPARATOR MOTOR RELIEF VALVE RELIEF VALVE CONDENSER SIGHT GLASS MICROCOMPUTER CONTROL CENTRE COOLER Figure 2.1 YS Rotary Screw Liquid Chiller (Front View) 2.1 General (Figures 2.1 and 2.2) The York YS Millennium™ Rotary Screw Liquid Chiller is primarily used for large air conditioning systems, but may be used on other applications.
2- 2 035L02381-GB0 OIL SEPARATOR MOTOR TERMINAL BOX RELIEF VALVE RELIEF VALVE COOLER CONDENSER ISOLATION VALVE LIQUID LINE ISOLATION VALVE Figure 2.2 YS Centrifugal Liquid Chiller (Rear View) The rotors are manufactured from forged steel and use asymmetric profiles. The compressor incorporates a complete anti-friction bearing design for reduced power and increased reliability. Four separate cylindrical roller bearings handle radial loads. Two 4-point angular contact ball bearings handle axial loads.
035L02381-GB0 2.3 Motor The compressor motor is an open drip-proof, squirrel cage induction type. The motor has a D-flange and cast iron adaptor mounted rigidly to the compressor for accurate alignment of motor and compressor shafts. The motor drive shaft is connected to the compressor shaft with a flexible disc coupling. Coupling has all metal construction with no wearing parts to assure long life, and no lubrication requirements to provide low maintenance.
2- 4 035L02381-GB0 Three sight glasses are provided in the oil separator for monitoring the oil level and verifying performance of the coalescer element. Liquid oil should be visible in the top glass of the oil separator when the chiller is off. During operation, oil may be higher or lower due to system load and operating conditions. A low oil level safety switch is provided in the bottom of the oil separator.
035L02381-GB0 An oil supply line from the manifold at SB-2 is piped to the capacity control directional valve at Port P. The 4-way capacity control solenoid (directional) valve directs oil pressure against one side or the other of the slide valve piston. The opposite side of the slide valve is relieved to suction pressure at compressor port SC-11. The differential pressure between the P port and the suction pressure (Port SC-11) loads or unloads the slide valve to provide capacity control. 2.
2- 6 035L02381-GB0 Figure 2.6 Refrigerant Flow Diagram Figure 2.
035L02381-GB0 2.9 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 57 mm diameter liquid level sight glass is located on the side of the shell to aid in determining proper refrigerant charge. A 25 mm refrigerant charging valve is provided. 2.
2- 8 035L02381-GB0 Figure 2.6 Capacity Control 2.13 Water Boxes 2.14 Control Centre Removable water boxes fabricated from heavy gauge sheet steel are fitted to each end of both heat exchangers. The design working pressure is 10 bar and the boxes are tested at 15 bar. Integral steel water baffles are located and welded within the water boxes to provide required pass arrangements. Stub-out water nozzle connections with Victaulic grooves are welded to the water boxes.
035L02381-GB0 2- 9 The control centre includes unique safety logic to protect the unit from damaging malfunctions. Comprehensive information can be displayed in the event of a unit shutdown including day, time, and reason for shutdown.
2-10 035L02381-GB0 High Water Side Pressure Heat Exchangers VBG 20 Compliance Kit One or both of the evaporator and condenser may be supplied with a water side design pressure of 20 bar (subject to pressure vessel code approval availability). Factory fitted T.Ue.V. approved mechanical high pressure cut-out switches (two) as required to comply with some safety codes.
035L02381-GB0 3 TRANSPORTATION, RIGGING AND STORAGE 3.1 General 3- 1 4. Do not make final power supply connections to the compressor motor, solid state starter or control centre. 5. Do not charge the compressor with oil. 6. Do not charge the unit with refrigerant. Units can also be shipped dismantled when required by rigging conditions, but generally it is more economical to enlarge access openings to accommodate the factory assembled unit.
3- 2 035L02381-GB0 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. Cooler/condenser shells are not skidded. The unit shipment should be checked on arrival to see that all major pieces, boxes and crates are received.
035L02381-GB0 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. Lift only using holes shown.
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035L02381-GB0 4 INSTALLATION 4.1 Location 4.5 4- 1 Rigging Unit to Final Location YS 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 035L02381-GB0 Unit Weights less than 7423 kg 4.7 Installing Optional Spring Isolators When ordered, 4 spring type isolator assemblies will be furnished with the unit (see table below). The 4 assemblies are identical and can be placed at any of the 4 corners of the unit. While the unit is still suspended by the rigging, the isolator mounting brackets should be bolted to the unit . Place the four spring isolators in position.
035L02381-GB0 4- 3 Check for piping alignment – Upon completion of piping, a connection in each line as close to the unit as possible should be opened, by removing the flange bolts or coupling and checked for piping alignment. If any of the bolts are bound in their holes, or if the connection springs are out of alignment, the misalignment must be corrected by properly supporting the piping or by applying heat to anneal the pipe.
4- 4 035L02381-GB0 If pumps discharge through the chiller, the strainer may be located upstream from pumps to protect both pump and chiller. (Piping between strainer, pump and chiller must be very carefully cleaned before start-up.) If pumps are remotely installed from chiller, strainers should be located directly upstream of the chiller. 4.10 Water Treatment The unit performance given in the Design Guide is based on a fouling factor of 0.044 m² °C/kW (0.00025 ft²hr °F/Btu).
035L02381-GB0 4.13 Stop Valves Stop valves may be provided (by others) in the cooler and condenser water piping adjacent to the unit to facilitate maintenance. Thermometer wells and pressure taps should be provided (by others) in the piping as close to the unit as possible to facilitate operating check. 4- 5 Fill the chilled and condenser water circuits, operate the pumps manually and carefully check the cooler and condenser water heads and piping for leaks. Repair leaks as necessary.
4- 6 035L02381-GB0 Figure 4.5 Typical Refrigerant Vent Piping from Rupture Disk Piping should be properly supported to prevent any strain on bursting disk mounting. Be careful not to puncture bursting disk when thread protector is removed.
035L02381-GB0 4.19 Electrical Connection The following connection recommendations are intended to ensure safe and satisfactory operation of the unit. Failure to follow these recommendations could cause harm to persons, or damage to the unit, and may invalidate the warranty. 4- 7 The main 'START/RUN/STOP-RESET' selector switch on the control centre must remain in 'STOP/RESET' position until the unit is commissioned by authorised personnel.
4- 8 035L02381-GB0 DO NOT make final power supply connections to control centre until approved by a YORK representative. To ensure 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. The figure below shows the power wiring for the motor connections. (Refer to wiring labels in motor terminal box for details to suit motor voltage and amperage.
035L02381-GB0 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. Cycling of the unit based on cool i ng demand is accom pl i shed automatically by the control centre. In addi tion, the control centre has a programmable time clock function as a standard feature with holiday capability.
4-10 035L02381-GB0 4.21.4 Multi Unit Sequence Connections (MUS - TB2: Terminals 1 & 9) 4.21.8 Remote Current Limit Setpoint (RCSP - TB2: Terminals 1 & 20) For multiple unit installation applications, Multi Unit Sequence connections are available to start and stop each unit. The maintained closure of remote contacts will permit the unit to operate in all operating modes with the "COMPRESSOR" switch in the "RUN" position. Conversely, an opening of the contacts will inhibit the unit from operating.
035L02381-GB0 4-11 4.22.1 Remote Mode Ready to Start Status (RMR/S - TB4: terminals 26 & 27) 4.23.2 Condenser Water Pump Starter (CPMSS - TB5, Terminals 2 & 24) When closed, these contacts signify the control centre is in "REMOTE" operating mode, allowing the energy management system or the remote start/stop to control the unit. Holding the Remote Stop Contact open, and momentarily closing the Remote Start will now start the unit.
4-12 035L02381-GB0 -AMB -QCSD -QRCD CP LS -AMB -APB -ARB TB2 TB5 TB4 Power Board -QCSD Control Circuit Switch Disconnector Relay Board -QRCD Residual Currant Device C/S Cycling Shutdown R/STP Remote Stop CP Control Panel R/STT Remote Start RCSP Remote Current Limit Set-Point CPWI Chilled Water Flow Interlock CWP Chilled Water Pump EMS Electro-Mechanical Starter TB4 1 8 19 1 20 1 12 13 1 RLCWTSPRCSP CPWI 9 1NB 1N 1NB 8NB 9NB R/LC 9NB N 5NB RLCWTSP Remote LCW
035L02381-GB0 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 035L02381-GB0 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 centre Operating Instructions and Section 6. Interlocks: Verify that water is flowing through the cooler and that heat load is present.
035L02381-GB0 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 When the unit starts, the following automatic sequences are initiated: (Refer to Figure 6.1 Starting & Shutdown Sequence). 1. The control centre display message will read SYSTEM START SEQUENCE INITIATED for the first 30 seconds of the starting sequence. 2.
6- 2 6.4 035L02381-GB0 Normal Operation After the compressor reaches its operating speed the slide valve will begin to load, under the control of the control Centre, based on the leaving chilled liquid temperature. The unit capacity will vary to maintain the leaving chilled liquid temperature at the programmed setpoint. A drop in chilled liquid temperature will cause the slide valve to unload to decrease unit capacity.
035L02381-GB0 6.8 Operating Inspections By following a regular inspection schedule any potential problems with the unit can be identified early and attended to before serious operating difficulties occur. The following list of inspections and procedures should be used as a guide. In all cases the inspections should only be carried out by properly trained personnel. If a problem is identified, no attempt should be made to carry out any repairs unless properly qualified and equipped to do so.
6- 4 035L02381-GB0 Figure 6.1 Start-up, Operation and Shutdown Sequence Figure 6.
035L02381-GB0 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 centre Operation Instruction. The units have been designed to operate continuously provided they are regularly maintained and operated within the limitations given in this manual.
7- 2 7.3 035L02381-GB0 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.
035L02381-GB0 7.4 Oil Filters and Strainers 7- 3 7.4.3 Evaporator Oil Return (Eductors) The oil return system ensures that oil removed from the discharge gas by the oil separator and oil reaching the evaporator are returned to the compressor effectively.
7- 4 3. 4. 035L02381-GB0 Open the oil charging valve and pump oil into the system until oil level in the oil separator is about midway in the upper sight glass. Then, close the charging valve and disconnect the hand oil pump. As soon as oil charging is complete, close the power supply to the starter to energise the oil heater. This will keep the concentration of refrigerant in the oil to a minimum. 7.6.
035L02381-GB0 7.6.4 Refrigerant Charging When opening any part of the refrigerant system for repairs, the refrigerant charge must be removed. If the chiller is equipped with optional valves, the refrigerant can be isolated in either the condenser or evaporator / compressor while making repairs.
7- 6 035L02381-GB0 7.7.2 Tube Cleaning 7.7.3 Tube Cleaning Procedures Cooler Brush Cleaning of Tubes It is difficult to determine by any particular test whether possible lack of performance of the water cooler is due to fouled tubes alone or due to a combination of troubles.
035L02381-GB0 7.7.4 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 cooler 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.
7- 8 7.9 035L02381-GB0 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.
035L02381-GB0 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 035L02381-GB0 Displayed Reason for Shutdown Control Function Possible Cause Recommended Action AC UNDERVOLTAGE Motor current below 10% for more than 25 seconds during RUN mode Low AC voltage at control centre Check power supply Faulty Start Relay Check Relay1R Low motor current Check CT operation and wiring Check motor HIGH LINE VOLTAGE / LOW LINE VOLTAGE (Solid State Starter only) Line Voltage for any phase above/below voltage limit for more than 20 seconds Power supply fault Check ma
035L02381-GB0 8- 3 Displayed Reason for Shutdown Control Function Possible Cause Recommended Action LOW EVAP PRESSURE Evaporator pressure below 172 kPa Blocked / dirty evaporator tubes Clean tubes Insufficient load for compressor capacity Check low water temperature cut-out setting Check slide valve operation Insufficient refrigerant Check charge level Blocked orifice Check orifice LOW EVAP PRESSUREBRINE Evaporator low pressure switch contacts open As for LOW EVAP PRESSURE As for LOW EVAP
8- 4 035L02381-GB0 Oil System Faults Detected During Regular Inspections Fault Possible Cause Recommended Action OIL RESERVOIR LEVEL DROPPING WHILE UNIT SITTING IDLE System cycling without compressor run being achieved Check correct control system and start-up operation Main oil supply line solenoid valve by-passing Repair or replace valve Internal separator reservoir leak Repair or replace oil separator System cycling without compressor running long enough to return oil Do not run unit at very
035L02381-GB0 8- 5 Electrical System Control Centre Initiated Shutdowns - Manual Reset Restart Displayed Reason for Shutdown Control Function Possible Cause Recommended Action MTR PHASE CURRENT UNBALANCE(SSS only) Current in one phase differs from average by more than 30% Loss of supply to one phase Check mains supply Check power connections Motor fault Check fuses Check motor windings MOTOR CONTROLLER EXT RESET Solid state starter or remote starter current module contacts open Fault in motor
8- 6 035L02381-GB0 Other System Faults Detected During Regular Inspections Fault Possible Cause Remedy EXCESSIVE NOISE I VIBRATION Liquid refrigerant entering compressor Check suction superheat Check for load surges Motor / compressor shaft coupling Check for loose coupling Bearing damage or excessive wear Check filters for metal Check bearings SLIDE VALVE MALFUNCTION Hydraulic service valve(s) closed Check valves are all open Failed actuator solenoid valve Check slide valve is free to move
9- 1 035L02381-GB0 9 TECHNICAL DATA 9.
9- 2 035L02381-GB0 Overall Dimensions - S4 and S5 Compressor S4 COMPRESSOR S4 and S5 COMPRESSOR SHELL CODES - (Cooler-Condenser) D-C D-D E-E E-F F-E F-F A - TUBE SHEET WIDTH 1,880 1,880 1,880 1,943 1,994 2,057 A1 - WITH SOLID STATE STARTER 2,080 2,080 2,080 2,143 2,226 2,200 A - OVERALL WIDTH (Less S.S.S.
035L02381-GB0 9.
9- 4 9.3 035L02381-GB0 Motor Weights Motor Code 50 Hz 5 CC 5 CD 5 CE 5 CF 5 CG 5 CH 5 CI 5 CJ 5 CK 5 CL 5 CM 5 CN 5 CO 9.
035L02381-GB0 9.
9- 6 9.6 035L02381-GB0 Water Box Nozzle Arrangements Cooler Code B C D E F COOLER NOZZLE DIMENSIONS Nozzle Size (in) Dimensions (mm) No. of Passes 1 2 3 AA BB CC DD EE 8 6 4 268 313 414 465 510 10 6 6 298 354 425 573 565 12 8 6 325 389 557 592 657 12 8 6 310 373 490 576 640 14 10 8 370 443 564 684 757 FF 127 149 168 191 233 CONDENSER NOZZLE DIMENSIONS Nozzle Size (in) Dimensions (mm) Condenser No.
035L02381-GB0 10 SPARE PARTS It is recommended that the following common spare parts 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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035L02381-GB0 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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Europe YORK YORK INTERNATIONAL LTD. Gardiners Lane South, Basildon, Essex, SS14 3HE, England For further information, please contact your local area Sales Office. Part No.
