MILLENNIUM ® CENTRIFUGAL LIQUID CHILLERS OPERATING & MAINTENANCE Supersedes: 160.55-O1 (402) Form 160.
FORM 160.
FORM 160.55-O1 (604) 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 160.55-O1 (604) CHANGEABILITY OF THIS DOCUMENT In complying with YORK’s policy for continuous product improvement, the information contained in this document is subject to change without notice. While YORK makes no commitment to update or pro vide current in for ma tion automatically to the manual owner, that information, if applicable, can be obtained by contacting the nearest YORK Applied Systems Service ofÞce.
FORM 160.55-O1 (604) TABLE OF CONTENTS SECTION 1 Description of System and Fundamentals of Operation............................... 7 SECTION 2 OptiView Control Center ............................................................................. 9 SECTION 3 Printers ..................................................................................................... 112 SECTION 4 System Operating Procedures ..................................................................
FORM 160.55-O1 (604) LIST OF FIGURES FIG. 1 – MODEL YT MILLENNIUM CHILLER .................... 7 FIG. 33 – HISTORY SCREEN............................................ 76 FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER ..... 8 FIG. 34 – HISTORY DETAILS SCREEN ............................ 78 DETAIL A – COMPRESSOR PREROTATION VANES.................................................................. 8 FIG. 35 – SECURITY LOG SCREEN................................. 79 FIG. 3 – CONTROL CENTER ....................
FORM 160.55-O1 (604) SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION COMPRESSOR PURGE UNIT CONTROL CENTER 1 MOTOR CONDENSER 29509A FIG. 1 – MODEL YT MILLENNIUM CHILLER SYSTEM OPERATION DESCRIPTION (SEE FIG. 2) The YORK Model YT Millennium Chiller is commonly applied to large air conditioning systems, but may be used on other applications. The chiller consists of an open motor mounted to a compressor (with integral speed increasing gears) condenser, cooler and variable ßow control.
Description of System and Fundamentals of Operation FORM 160.55-O1 (604) able oriÞce meters the ßow of liquid refrigerant to the cooler to complete the refrigerant circuit. The major components of a chiller are selected to handle the refrigerant, which would be evaporated at full load design conditions. However, most systems will be called upon to deliver full load capacity for only a relatively small part of the time the unit is in operation.
FORM 160.55-O1 (604) SECTION 2 OPTIVIEW CONTROL CENTER INTRODUCTION The YORK OptiView Control Center is a microprocessor based control system for R-11 or R123 centrifugal chillers. It controls the leaving chilled liquid temperature via pre-rotation vane controls and has the ability to limit motor current via control of the pre-rotation vanes. It is compatible with YORK Solid State Starter (optional), Variable Speed Drive (optional) and Electro-Mechanical starter applications.
Description of System and Fundamentals of Operation FORM 160.55-O1 (604) version is C.OPT.02.xx.yzz, and is viewable on the DIAGNOSTICS Screen in SERVICE access level. The program can be upgraded by downloading a new program from a Program Card. Program Cards are shirt-pocket-size portable memory storage devices available from YORK. Earlier vintage chillers could be equipped with a later Microboard due to service replacement.
FORM 160.
OptiView Control Center FORM 160.55-O1 (604) CONTROL CENTER FIG. 3 The OptiView Control Center display is highlighted by a full screen graphics display. This display is nested within a standard keypad and is surrounded by “soft” keys which are redeÞned based on the currently displayed screen. Eight buttons are available on the right side of the panel and are primarily used for navigation between the system screens. At the base of the display are 5 additional buttons.
FORM 160.55-O1 (604) INTERFACE CONVENTIONS OVERVIEW The new graphical display on each control panel allows a wide variety of information to be presented to the user. Each screen description in this document will begin with a section entitled Overview which will describe the graphical elements on the screen and give a short summary of the functions available. Each element on the screen will then be categorized into three distinct groups: Display Only, Programmable and Navigation.
OptiView Control Center FORM 160.55-O1 (604) Leading zeroes are not necessary. If a decimal point is necessary, press the ‘•’ key (i.e. 45.0). Pressing the ▲ key, sets the entry value to the default for that setpoint. Pressing the ▼ key, clears the present entry. The ◄ key is a backspace key and causes the entry point to move back one space. If the dialog box begins with “SELECT”, use the ◄ and ► keys to select the desired value.
FORM 160.55-O1 (604) LANGUAGES The Screens can be displayed in various languages. Language selection is done on the USER Screen. The desired language is selected from those available. Not all languages are available. English is the default language. If a language other than English is being displayed, an English-only speaking person should navigate to the USER Screen using the preceding Navigation chart and select English per the USER Screen instructions in this book.
OptiView Control Center FORM 160.55-O1 (604) HOME SCREEN FIG. 4 OVERVIEW When the chiller system is powered on, the above default display appears. The primary values which must be monitored and controlled are shown on this screen. The Home Screen display depicts a visual representation of the chiller itself. Animation indicates chilled liquid ßow. DISPLAY ONLY Chilled Liquid Temperature - Leaving Displays the temperature of the liquid as it leaves the evaporator.
FORM 160.55-O1 (604) Only qualiÞed service personnel utilize this access level. This level provides advanced control over many of the chiller functions and allows calibration of many of the chiller controls. The access levels are listed above in hierarchical order beginning with the lowest level and proceeding to the highest level. Users logged in under higher access levels may perform any actions permitted by lower access levels.
OptiView Control Center FORM 160.55-O1 (604) SYSTEM SCREEN FIG. 5 OVERVIEW This screen gives a general overview of common chiller parameters for both shells. DISPLAY ONLY Discharge Temperature Displays the temperature of the refrigerant in its gaseous state at discharge of the compressor as it travels to the condenser. Chilled Liquid Temperature - Leaving Displays the temperature of the liquid as it leaves the evaporator.
FORM 160.55-O1 (604) Current Limit Displays the current limit value in use. This value could come from a 0-20mA or 4-20mA, 0-10VDC or 2-10VDC input in Analog Remote mode, PWM signal in Digital Remote mode, MicroGateway interface in ISN mode or a locally programmed value. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen.
OptiView Control Center FORM 160.55-O1 (604) EVAPORATOR SCREEN FIG. 6 OVERVIEW This screen displays a cutaway view of the chiller evaporator. All setpoints relating to the evaporator side of the chiller are maintained on this screen. Animation of the evaporation process indicates whether the chiller is presently in a RUN condition. Animation of the liquid ßow indicates chilled liquid ßow. DISPLAY ONLY Chilled Liquid Flow Switch (Open / Closed) Displays whether the liquid ßow is present in the evaporator.
FORM 160.55-O1 (604) PROGRAMMABLE Local Leaving Chilled Liquid Tem per a ture Range Access Level Required: OPERATOR This is the range over which an analog (0-20mA or 420mA, 0-10VDC or 2-10VDC) in Analog Remote Mode or a digital signal (PWM) in Digital remote mode can reset the Leaving Chilled Liquid Temperature setpoint above the operator programmed Base Setpoint (see below).
OptiView Control Center FORM 160.55-O1 (604) CONDENSER SCREEN FIG. 7 00350VIP0 OVERVIEW This screen displays a cutaway view of the chiller condenser. All setpoints relating to the condenser side of the chiller are maintained on this screen. Animation indicates condenser liquid ßow. This screen also serves as a gateway to controlling the Refrigerant Level. DISPLAY ONLY Leaving Condenser Liquid Temperature Displays the water temperature as it leaves the condenser.
FORM 160.55-O1 (604) Refrigerant Level Setpoint Displays the setpoint to which the refrigerant level is being controlled. it must be enabled via this toggle before the system will utilize the new, enhanced resolution input. Service Technicians refer to YORK Service Manual 160.55-M1. Ramp Up Time Remaining Displays the time remaining in the period in which the Refrigerant Level Setpoint is being ramped to the Refrigerant Level Target Setpoint.
OptiView Control Center FORM 160.55-O1 (604) PURGE SCREEN FIG. 8 OVERVIEW This screen displays a cutaway view of the Purge Tank. LED’s depict the state of the Float switches, Oil Valve solenoid and Air Valve solenoid and the purge exhaust count is displayed. All setpoints relating to the purge system are maintained on this screen. The Purge tank oil level, based on the position of the ßoat switches, is depicted through animation.
FORM 160.55-O1 (604) to 60. During this period, purge exhausts are counted and the Exhaust Count displayed is that which has occurred in the last number of minutes displayed in the Exhaust Window. After the Exhaust Window reaches 60, the purge exhausts that occurred in the oldest minute are discarded from the Exhaust Count and exhausts from the most recent minute are shifted in, providing a rolling count of purge exhausts that occurred in the last 60 minutes.
OptiView Control Center FORM 160.55-O1 (604) REFRIGERANT LEVEL CONTROL SCREEN FIG. 9 00303VIP OVERVIEW This screen displays a cutaway view of the chiller condenser, along with the liquid refrigerant level sensor and the ßow control valve. All setpoints relating to the liquid level control are maintained on this screen. Through animation, the variable oriÞce position is displayed. In addition, the refrigerant ßow control valve (variable oriÞce) can be manually operated.
FORM 160.55-O1 (604) [Refrigerant Level Control] Proportional Limit Close Service Technicians refer to YORK Service Manual 160.55-M1. [Refrigerant Level Control] Rate Limit Open Service Technicians refer to YORK Service Manual 160.55-M1. [Refrigerant Level Control] Rate Limit Close Service Technicians refer to YORK Service Manual 160.55-M1. [Refrigerant Level Control] Raise (Manual) This key puts the level control into manual mode and sends a RAISE command to the variable oriÞce.
OptiView Control Center FORM 160.55-O1 (604) COMPRESSOR SCREEN FIG. 10 00483VIP OVERVIEW This screen displays a cutaway view of the chiller compressor, revealing the impeller and shows all conditions associated with the compressor. In addition, with the proper Access Level, the pre-rotation vanes may be manually controlled. Animation of the compressor impeller indicates whether the chiller is presently in a RUN condition.
FORM 160.55-O1 (604) Full Load Amps Access Level Required: SERVICE Displays the motor current as a percentage of the Full Load Amps (FLA) value. Phase A, B, C Current (Solid State Starter only) Access Level Required: SERVICE Displays the 3-phase motor current values being read from the Solid State Starter. PROGRAMMABLE [Pre-Rotation Vanes] Open (Manual) Access Level Required: SERVICE This key puts the vane control into manual mode and sends an OPEN command to the vanes.
OptiView Control Center FORM 160.55-O1 (604) HOT GAS BYPASS SCREEN FIG. 11 OVERVIEW This screen displays a cutaway view of the Hot Gas Bypass Valve. All setpoints relating to Hot Gas Bypass control are maintained on this screen. Also, related Hot Gas Bypass control parameters are displayed for reference. Through animation, the relative valve position is displayed. In addition, the valve can be manually operated. Requires access level of SERVICE. Service Technicians refer to YORK Service Manual 160.
FORM 160.55-O1 (604) in response to surge events detected by the compressor Variable Speed Drive Adaptive Capacity Control Board. Hot Gas Bypass Control Mode Indicates whether the Hot Gas Bypass is under automatic, manual or override control. “Override” is displayed during Minimum Load override conditions or when the Compressor Motor Variable Speed (if equipped) Drive is running at less than maximum speed. PROGRAMMABLE Close Percentage Service technicians refer to YORK Service Manual 160.55-M1.
OptiView Control Center FORM 160.55-O1 (604) SURGE PROTECTION SCREEN FIG. 12 OVERVIEW (This feature applies to Flash Memory Card version C.MLM.02.02.xxx and later) This screen displays a cutaway view of the chiller compressor and all parameters relating to the Surge Protection feature. All setpoints relating to this feature are maintained on this screen. DISPLAY ONLY Delta P/P A parameter that represents the system differential or “Head pressure”.
FORM 160.55-O1 (604) PROGRAMMABLE Shutdown (Enabled/Disabled) Access Level Required: OPERATOR Allows the user to select whether the chiller will shutdown or continue to run when an Excess Surge situation has been detected. If this setpoint is Enabled and the EXTENDED RUN setpoint is Disabled, a safety shutdown is performed when the SURGE WINDOW COUNT exceeds the COUNT LIMIT setpoint.
OptiView Control Center FORM 160.55-O1 (604) if the SURGE WINDOW COUNT is less than or equal to the COUNT LIMIT, this message and load inhibit are automatically cleared. Alternating with this message is “Warning – Excess Surge Detected” that continues after the 10 minute period has elapsed until manually cleared with the Warning Reset key. See Hot Gas Bypass and Variable Speed Drive exception above.
FORM 160.
OptiView Control Center FORM 160.55-O1 (604) PRE-ROTATION VANES CALIBRATION SCREEN FIG. 13 OVERVIEW This screen displays a cutaway view of the chiller compressor, revealing the pre-rotation vanes and provides the capability of calibrating the pre-rotation vanes for either Variable Speed Drive or Hot Gas Bypass applications. Requires a login access level of SERVICE. Service Technicians refer to YORK Service Manual 160.
FORM 160.
OptiView Control Center FORM 160.55-O1 (604) VSD TUNING SCREEN FIG. 14 OVERVIEW This screen displays a cutaway view of the chiller compressor, revealing the pre-rotation vanes and provides the capability of manually controlling the pre-rotation vanes. Animation of the pre-rotation vanes indicates the pre-rotation vane position. In addition, this screen allows manual control of the frequency command being sent to the Variable Speed Drive. Requires a login access level of SERVICE.
FORM 160.55-O1 (604) Output Current – Phase A, B, C (Flash Memory Card version C.MLM.02.02.xxx and later) Displays the phase current measured to the motor. PROGRAMMABLE Set Allows manual programming of the command frequency value. Manually programming this value will put the VSD frequency control into manual mode. Auto Following manual programming of the command frequency, this returns the system to automatic control.
OptiView Control Center FORM 160.55-O1 (604) OIL SUMP SCREEN FIG. 15 00356VIP OVERVIEW This screen displays a close-up of the chiller oil sump. Manual Oil Pump Operation Time Left Displays the time remaining in the 10-minute manual oil pump operation described below. DISPLAY ONLY PROGRAMMABLE Oil Sump Temperature Displays the temperature of the oil in the sump. Manual Pump Access Level Required: OPERATOR This key puts the Oil Pump control in Manual Mode and forces it to RUN.
FORM 160.55-O1 (604) ELECTRO-MECHANICAL STARTER SCREEN 2 FIG. 16 00357VIP OVERVIEW PROGRAMMABLE This screen displays all information pertaining to an Electro-Mechanical Starter. Local Motor Current Limit Access Level Required: OPERATOR Allows the user to specify the maximum allowed motor current (as a percentage of FLA). When the motor current reaches this value, the pre-rotation vanes will not be permitted to open further.
OptiView Control Center FORM 160.55-O1 (604) MOD “A” SOLID STATE STARTER SCREEN FIG. 17 OVERVIEW This screen displays all information pertaining to the Mod “A” Solid State Starter. 0058VIP Voltage - Phase A, B, C Display the 3-phase input line voltage values being read from the Solid State Starter. DISPLAY ONLY Current - Phase A, B, C Display the 3-phase motor current values being read from the Solid State Starter.
FORM 160.55-O1 (604) Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts. Full Load Amps Access Level Required: SERVICE DeÞne the maximum amps at which the motor can operate. This value is viewable when logged in under the Operator or View access level. Service Technicians refer to YORK Service Manual 160.55-M1. threshold for initiating a shutdown. Service Technicians refer to YORK Service Manual 160.55-M1.
OptiView Control Center FORM 160.55-O1 (604) MOD “B” SOLID STATE STARTER SCREEN FIG. 18 OVERVIEW This screen displays all information pertaining to the Mod “B” Solid State Starter. DISPLAY ONLY Motor Run (LED) Indicates whether the digital output from the controls is commanding the motor to RUN. Motor Current % Full Load Amps Displays the motor current as a percentage of the Full Load Amps (FLA) value. Current Limit Setpoint Displays the current limit in use.
FORM 160.55-O1 (604) Pulldown Demand Limit Access Level Required: OPERATOR Allows the user to specify the current limit value (as a percentage of FLA) to which the chiller will be limited during the speciÞed pulldown time. This value will override the Motor Current Limit value during this time period. This function is used to provide energy savings following chiller start.
OptiView Control Center FORM 160.55-O1 (604) VARIABLE SPEED DRIVE SCREEN FIG. 19 OVERVIEW This screen displays information pertaining to a Variable Speed Drive (VSD). 00360VIP Output Frequency Displays the present output frequency to the motor. Output Current - Phase A, B, C Displays the phase current measured to the motor. DISPLAY ONLY Motor Run (LED) Indicates whether the digital output from the controls is commanding the motor to RUN.
FORM 160.55-O1 (604) Supply Current Total Demand Distortion L1, L2, L3 Displays the Total Dynamic Distortion (TDD) for each of the supply current lines as calculated by the Þlter. PROGRAMMABLE Local Motor Current Limit Access Level Required: OPERATOR Allows the user to specify the maximum allowed motor current (as a percentage of FLA). When the motor current reaches this value, the pre-rotation vanes will not be permitted to open further.
OptiView Control Center FORM 160.55-O1 (604) VARIABLE SPEED DRIVE DETAILS SCREEN (STYLE D VSD AND VSD WITH PART NUMBER 371-03789-XXX (503 HP 60 HZ; 410 HP 50 HZ) FIG. 20 OVERVIEW This screen displays more detailed information pertaining to a Variable Speed Drive (VSD). Flash Memory Card version C.MLM.02.04.xxx (and later) is required for VSD part number 371-03789-xxx (503HP 60Hz; 419 HP 50Hz). Service Technicians refer to YORK Service Manual 160.
FORM 160.55-O1 (604) Internal Ambient Temperature Displays the ambient temperature inside the VSD cabinet as reported by the VSD. Converter Heatsink Temperature Displays the heatsink temperature of the converter as reported by the VSD.
OptiView Control Center FORM 160.55-O1 (604) VARIABLE SPEED DRIVE DETAILS SCREEN (APPLICABLE TO VSD WITH PART NUMBER 371-02767-XXX (60 HZ) OR 371-03700-XXX (50 HZ)) FIG. 21 00562VIP OVERVIEW This screen displays more detailed information pertain ing to a Variable Speed Drive (VSD). Service Technicians refer to YORK Service Manual 160.55M1 for operation instructions and explanation of all programmable setpoints and displayed values.
FORM 160.55-O1 (604) Internal Ambient Temperature Displays the ambient temperature inside the VSD cabinet as reported by the VSD. Converter Heatsink Temperature Displays the heatsink temperature of the converter as reported by the VSD. Baseplate Temperature Displays the Baseplate temperature of the 3-phase voltage regulators as reported by the VSD. VSD Model Access Level Required: SERVICE Displays the Horsepower conÞguration of the Variable Speed Drive control.
OptiView Control Center FORM 160.55-O1 (604) ADAPTIVE CAPACITY CONTROL DETAILS SCREEN FIG. 22 OVERVIEW This screen displays more detailed information pertaining to a Adaptive Capacity Control (ACC). Requires a login access level of SERVICE. Service Technicians refer to YORK Service Manual 160.55-M1 for operation instructions and explanation of all programmable setpoints and displayed values.
FORM 160.55-O1 (604) Pulldown Demand Limit Allows the user to specify the current limit value (as a percentage of FLA) to which the chiller will be limited during the speciÞed pulldown limit time. This value will override the Motor Current Limit value during this time period. This function is used to provide energy savings following chiller start-up. Pulldown Demand Time Allows the user to set a period of time for which the pulldown demand limit will be in effect after the chiller starts.
OptiView Control Center FORM 160.55-O1 (604) HARMONIC FILTER DETAILS SCREEN (STYLE D VSD AND VSD WITH PART NUMBER 371-03789-XXX (503 HP 60 HZ; 410 HP 50 HZ FIG. 23 OVERVIEW This screen displays more detailed information pertaining to the IEEE-519 Harmonic Filter. Flash Memory Card version C.MLM.02.04.xxx (and later) is required for VSD part number 371-03789-xxx (503HP 60Hz; 419 HP 50Hz). DISPLAY ONLY Motor Run (LED) Indicates whether the digital output from the controls is commanding the motor to RUN.
FORM 160.55-O1 (604) Heatsink Temperature (Labeled “Baseplate Temperatures” on VSD with part number 371-03789-xxx {503HP 60Hz; 419HP 50Hz}). Displays the temperature of the Harmonic Filter Heatsink. Voltage Peak (N-L1, N-L2, N-L3) Displays the 3-phase peak voltages as measured by the Harmonic Filter (Neutral to Line). RMS Voltage (L1-L2, L2-L3, L3-L1) Displays the 3-phase RMS Voltages across each line.
OptiView Control Center FORM 160.55-O1 (604) HARMONIC FILTER DETAILS SCREEN (VSD WITH PART NUMBER 371-02767-XXX (60 HZ) OR 371-03700-XXX (50 HZ)) FIG. 24 OVERVIEW This screen displays more detailed information pertaining to the IEEE-519 Harmonic Filter. DISPLAY ONLY Motor Run (LED) Indicates whether the digital output from the controls is commanding the motor to RUN. Motor Current % Full Load Amps Displays the motor current as a percentage of the Full Load Amps (FLA) value.
FORM 160.55-O1 (604) Voltage Peak ( N-L1, N-L2, N-L3 ) Displays the 3-phase peak voltages as measured by the Harmonic Filter (Neutral to Line). RMS Voltage ( L1-L2, L2-L3, L3-L1 ) Displays the 3-phase RMS Voltages across each line. Voltage Total Harmonic Distortion ( L1, L2, L3 ) Displays the 3-phase voltage Total Harmonic Distortion (THD) measurements. RMS Filter Current ( L1, L2, L3 ) Displays the 3-phase Filter current values as measured by the Harmonic Filter.
OptiView Control Center FORM 160.55-O1 (604) SETPOINTS SCREEN FIG. 25 OVERVIEW This screen provides a convenient location for programming the most common setpoints involved in the chiller control. This screen also serves as a gateway to a subscreen for deÞning the setup of general system parameters. DISPLAY ONLY Leaving Chilled Liquid Temperature - Setpoint Displays the present setpoint to which the chiller is operating whether controlled remotely or locally.
FORM 160.55-O1 (604) Local Leaving Chilled Liquid Tem per a ture Setpoint Access Level Required: OPERATOR This value allows the user to deÞne the Leaving Chilled Liquid Temperature that is to be maintained by the chiller. It is programmable over the range of 38.0°F to 70.0°F (water) or 10.0°F to 70.0°F (brine). If Smart Freeze is enabled, the range is 36.0°F to 70.0°F (water).
OptiView Control Center FORM 160.55-O1 (604) SETUP SCREEN FIG. 26 OVERVIEW This screen is the top level of the general conÞguration parameters. It allows programming of the time and date, along with speciÞcations as to how the time will be displayed (12 or 24 hour format). In addition, the chiller conÞguration, as determined by the state of the Microboard Program Jumpers and Program Switches is displayed. A qualiÞed Service Technician, following instructions in YORK Service Manual 160.
FORM 160.55-O1 (604) PROGRAMMABLE Set Date Access Level Required: OPERATOR Allows the user to specify the present date. This value is critical to logging system shutdowns accurately and for utilizing the scheduling capabilities. When prompted to enter a date value, the user must enter the day, month and four-digit year (using leading zeroes as necessary). If within range, the value will be accepted. If out of range, the user is prompted for the information again.
OptiView Control Center FORM 160.55-O1 (604) Schedule Access Level Required: VIEW Moves to the subscreen allowing deÞnition of the chiller operation schedule. Diagnostics Access Level Required: SERVICE Moves to the subscreen allowing limited diagnostic capability while operating. Refer to YORK Service Manual 160.55-M1 Comms Access Level Required: VIEW Moves to the subscreen allowing conÞguration of system communications.
FORM 160.
OptiView Control Center FORM 160.55-O1 (604) SCHEDULE SCREEN FIG. 27 OVERVIEW The schedule screen contains more programmable values than a normal display screen. As such, each programmable value is not linked to a speciÞc button. Instead the Select key is used to enable the cursor arrows which are used to highlight the day and the start or stop time the user wishes to modify. At this point the user may press the ‘!’ (ENTER) key to program the Start / Stop times for that day.
FORM 160.55-O1 (604) tion which enforces the scheduled starting and stopping of the chiller. Use ◄ , ► , ▲ or ▼ cursor arrows to place the box around the desired start or stop time for a given day. Repeat Sunday Schedule Access Level Required: OPERATOR Duplicates the schedule deÞned for Sunday for the remainder of the standard weekdays. Print Access Level Required: VIEW Generates a Schedule print report.
OptiView Control Center FORM 160.55-O1 (604) USER SCREEN FIG. 28 OVERVIEW This screen allows deÞnition of custom User ID’s and matching passwords. This allows the building administrator to assign custom passwords to those who are authorized to maintain the chiller. Each Custom User value is not linked to a speciÞc button. Instead, the Change button is pressed which enables the cursor arrows which are used to highlight the Custom User parameter the user wishes to modify.
FORM 160.
OptiView Control Center FORM 160.55-O1 (604) COMMS SCREEN FIG. 29 00478VIP OVERVIEW (Screen shown from Flash Memory Card version C.MLM.02.02.xxx and later. Screen layout from earlier versions slightly different) This screen allows deÞnition of the necessary communications parameters. Refer to PRINTER Section of this book for details of the Printer connections and setup. Presently, there are no COM 2 communications features available.
FORM 160.55-O1 (604) COM 2 Stop Bit(s) DeÞne the number of stop bits at which the panel shall communicate through the modem port. Setup Access Level Required: VIEW Return to the Setup Screen. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen.
OptiView Control Center FORM 160.55-O1 (604) PRINTER SCREEN FIG. 30 OVERVIEW This screen allows deÞnition of the necessary communications parameters for the printer. Refer to PRINTER section of this book for details of the Printer connections and setup. DISPLAY ONLY Time Remaining Until Next Print Displays the time until the next print log will occur, if the function is enabled. PROGRAMMABLE Log Start Time Access Level Required: OPERATOR Set the time at which scheduled print logs will begin.
FORM 160.55-O1 (604) NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen. Setup Access Level Required: VIEW Return to the Setup Screen.
OptiView Control Center FORM 160.55-O1 (604) SALES ORDER SCREEN FIG. 31 OVERVIEW This screen allows deÞnition of the sales order parameters. The Commissioning date is entered by the YORK Service Technician at the time of chiller commissioning. These values should never be changed or entered by anyone other than a qualiÞed Service Technician. Entry instructions are included in the YORK Service Manual 160.55-M1.
FORM 160.
OptiView Control Center FORM 160.55-O1 (604) OPERATIONS SCREEN FIG. 32 OVERVIEW This screen allows deÞnition of general parameters having to do with the operation of the chiller. DISPLAY ONLY Chiller Run Time (Flash memory Card version C.MLM.02.01 or later) Displays the amount of time the chiller has been running since the last start signal was received. Value is reset to zero when the chiller enters Coastdown. It remains at zero while shutdown and during “System Prelube”.
FORM 160.55-O1 (604) NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen. Setup Access Level Required: VIEW Return to the Setup Screen.
OptiView Control Center FORM 160.55-O1 (604) HISTORY SCREEN FIG. 33 OVERVIEW This screen allows the user to browse through the faults. In order to get a more thorough reporting of the system conditions at the time of the recorded shutdown, move to the subscreen HISTORY DETAILS. The user may use the Select Fault button to select the history to view. At this point the View Details button is used to jump to a subscreen containing stored chiller parameters values at the time of the shutdown.
FORM 160.55-O1 (604) Trending Access Level Required: VIEW Causes a move to a subscreen allowing the user to view trending data on selected chiller parameters. Custom View (Flash memory Card version C.MLM.02.01 or later) Access Level required: VIEW Causes a move to a sub-screen allowing the user to view the Custom Setup Screen. YORK INTERNATIONAL Security Log (Flash Memory Card version C.MLM.02.03.
OptiView Control Center FORM 160.55-O1 (604) HISTORY DETAILS SCREEN FIG. 34 OVERVIEW This screen allows the user to see an on-screen printout of all the system parameters at the time of the selected shutdown. Not all screens are shown above. Number of screens required to display all of the data varies according to type of motor starter and options applied. 00566VIP Page Down Access Level Required: VIEW Scroll down in the displayed data (if applicable).
FORM 160.55-O1 (604) SECURITY LOG SCREEN 2 FIG. 35 00563VIP OVERVIEW PROGRAMMABLE (This screen only available with Flash Memory Card version C.MLM.02.03.xxx and later) Log Entry Allows the user to select a particular setpoint change for detail viewing. This screen displays a listing of the last 75 setpoint changes. They are listed and numbered in reverse order in which they were changed, with the most recent listed as number 1. Multiple pages are necessary to display all 75 changes.
OptiView Control Center FORM 160.55-O1 (604) SECURITY LOG DETAILS SCREEN FIG. 36 OVERVIEW (This screen only available with Flash Memory Card version C.MLM.02.03.xxx and later) This screen allows the user to view the details of a logged setpoint change, selected from the list on the Security Log Screen. The date and time the setpoint was changed, the new and old setpoint value and access level and user ID used to make the change are displayed. The data on this screen can be printed.
FORM 160.55-O1 (604) Security Log Access Level Required: SERVICE Causes an instant return to the Security Log Screen. View Details Access Level Required: SERVICE Causes a move to a sub-screen containing the details of the setpoint change selected with the Log Entry key.
OptiView Control Center FORM 160.55-O1 (604) TREND SCREEN FIG. 37 OVERVIEW As many as six Operator selected parameters (Data Points) can be plotted in an X/Y graph format. The XAxis is scaled per the selected Data Collection Interval and displayed in a time of day or elapsed time format, as selected with the X-axis toggle key. The Y-Axis is scaled for each parameter per the selected minimum and maximum value for each parameter.
FORM 160.55-O1 (604) DISPLAY ONLY This screen allows the user to view the graphical trending of the selected parameters and is also a gateway to the graph setup screens. A red screen with the words “TREND MAX MUST BE > TREND MIN” will appear if the Y-Axis minimum has been programmed to a value that is greater than the Y-Axis maximum for any parameter. If this appears, proceed to the Trend Setup Screen to change the values.
OptiView Control Center FORM 160.55-O1 (604) TREND SETUP SCREEN FIG. 38 OVERVIEW This screen is used to conÞgure the trending screen. The parameters to be trended are selected from the Common Slots Screen or Common Slots Master list and entered as Slot Numbers for Data Points 1 through 6. The Y-Axis minimum and maximum values for each parameter are entered as Data Point Min and Data Point Max for Data Points 1 through 6.
FORM 160.55-O1 (604) Select Access Level Required: OPERATOR This key is used to enter the slot numbers and the minimum and maximum Y-Axis values of each parameter to be trended. Pressing this key places a yellow box around Data Point 1 Slot Number. Use the ▲ and ▼ navigation keys to place the box around the value of Data Points 1 through 6 to be changed. With the desired value selected, press the ✓ key. A dialog box is displayed permitting data entry.
OptiView Control Center FORM 160.55-O1 (604) ADVANCED TREND SETUP SCREEN FIG. 39 OVERVIEW (Flash Memory Card version C.MLM.02.02.xxx and later) The desired data collection start/stop triggers are setup on this screen. The trend data collection can be set to start or stop based upon the status of up to two selected Triggers. The Triggers can consist of digital events or analog parameters compared to thresholds. The Triggers can be used individually or in combination.
FORM 160.55-O1 (604) PROGRAMMABLE Primary Trigger Access Level Required: OPERATOR Selects the Þrst parameter to be evaluated. Selection is made from the Slot Numbers listing on the Trend Common Slots Screen or the Master Slot Numbers List in this book. Setting this slot number to zero disables the Primary Trigger. Primary Operator Access Level Required: OPERATOR Selects the comparator for the Primary Trigger’s relationship to the Primary Test.
OptiView Control Center FORM 160.55-O1 (604) COMMON SLOTS SCREEN FIG. 40 00374VIP OVERVIEW PROGRAMMABLE This screen displays the slot numbers of the commonly monitored parameters. The slot numbers for the remainder of the available parameters are listed on the Master Slot Numbers List that follows. Page Down Access Level required: OPERATOR Scroll down in the displayed data. From these lists, select up to six parameters to be trended.
FORM 160.55-O1 (604) CUSTOM VIEW SCREEN 2 FIG. 41 OVERVIEW (Flash memory Card version C.MLM.02.01 or later) This screen allows up to 10 Service Technician selected parameters to be displayed. These parameters are selected from a list on the Custom View Setup Screen. This allows the Service Technician to display parameters pertinent to a particular problem during troubleshooting.
OptiView Control Center FORM 160.55-O1 (604) CUSTOM VIEW SETUP FIG. 42 OVERVIEW (Flash memory Card version C.MLM.02.01 or later) This screen allows the Service technician to select up to 10 parameters for display on the Custom View Screen. Requires a login access level of SERVICE. Service Technicians refer to YORK Ser vice Manual 160.55-M1 for operation instructions and explanation of all programmable setpoints and displayed values.
FORM 160.55-O1 (604) MASTER SLOT NUMBERS LIST FOR USE WITH TREND FEATURE SLOT NO.
OptiView Control Center FORM 160.55-O1 (604) SLOT NO.
FORM 160.55-O1 (604) SLOT NO.
OptiView Control Center FORM 160.55-O1 (604) DISPLAY MESSAGES The Status Bar of the Display contains a Status Line and, beneath it a Details Line. The Status Line contains a message describing the operating state of the chiller; whether it is stopped, running, starting or shutting down. The Details Line displays Warning, Cycling, Safety, Start Inhibit and other messages that provide further details of the Status Bar messages. The Status Messages listed below are displayed on the Status Line.
FORM 160.55-O1 (604) “MOTOR PULLDOWN LIMIT” The Pulldown Demand Limit Setpoint timer is in effect and the Compressor Motor current is > the Pulldown Demand Current Limit Setpoint value. The Pre-rotation vane operation is being inhibited as described in “ MOTOR – HIGH CURRENT LIMIT” message above. START INHIBIT MESSAGES “ANTI-RECYCLE XXMin/Sec” The chiller is inhibited from starting because the 30 minute anti-recycle time has not yet elapsed. Time remaining is displayed.
OptiView Control Center FORM 160.55-O1 (604) ing. This message automatically clears and the Vanes are permitted to open when the Evaporator pressure increases to the reset value. Warning Threshold (PSIA) Water Brine Reset Threshold (PSIA) Water Brine R11 5.5 0.1 >Safety Setpoint 5.6 0.3>Safety Setpoint R123 4.5 0.1 >Safety Setpoint 4.7 0.
FORM 160.55-O1 (604) “WARNING – REFRIGERANT LEVEL OUT OF RANGE” (Flash Memory Card version C.MLM.02.02C.xxx and earlier) The output of the Condenser Refrigerant Level Sensor is > 5.1VDC. This is indicative of a Level Sensor failure. While this condition exists, the Refrigerant Variable OriÞce is driven to the full open position. This message automatically clears when the Refrigerant Level sensor output is within range. “WARNING - EXCESS SURGE DETECTED” (Flash Memory Card version C.MLM.02.02.
OptiView Control Center FORM 160.55-O1 (604) “LEAVING CHILLED LIQUID – LOW TEMPERATURE” The Leaving Chilled Liquid Temperature has decreased to the programmed Shutdown Temperature Setpoint. The chiller will automatically restart when the temperature increases to the programmed Restart Temperature Setpoint. “LEAVING CHILLED LIQUID – FLOW SWITCH OPEN” The Chilled Liquid Flow Switch has remained open for 2 continuous seconds while the chiller was running or failed to close during the System Pre-lube period.
FORM 160.55-O1 (604) “STARTER – HIGH SUPPLY LINE VOLTAGE” (Mod “A” Solid State Starter”) The voltage in any phase of the AC Power Line Voltage supplying the Solid State Starter has increased to the high line voltage threshold for 20 continuous seconds. The chiller will automatically restart when the voltage returns to the restart level.
OptiView Control Center FORM 160.55-O1 (604) taneously; one via the serial communications link and one via the start relay TB6-24 in the OptiView Control Center. If they are not received within 5 seconds of one another, a cycling shutdown is performed and this message is displayed. This is generally indicative of defective wiring.
FORM 160.55-O1 (604) restart when the cycling condition clears. Service and troubleshooting information is contained in YORK Manual 160.00-M1. “VSD SHUTDOWN – REQUESTING FAULT DATA” The VSD has shut down the chiller and the OptiView Control Center has not yet received the cause of the fault from the VSD, via the serial communications link.
OptiView Control Center FORM 160.55-O1 (604) “VSD – HIGH PHASE C INSTANTANEOUS CURRENT” See “High Phase A Instantaneous Current” message above. “VSD – PHASE A GATE DRIVER” A second level of current protection exists on the VSD driver boards themselves. The collector-to-emitter saturation voltage of each IGBT is checked continuously while the device is gated on.
FORM 160.55-O1 (604) • Low Condenser Flow – The VSD system requires 8 feet of pressure drop across the heat exchanger to maintain adequate GPM. If the pressure drop is less than 8 feet, it will be necessary to correct the ßow problem or add a booster pump as is applied on retroÞt chillers. “VSD – INVALID CURRENT SCALE SELECTION” Since the part number of the VSD Logic Board is the same on all horsepower sizes, the position of Program Jumpers tells the Logic Board the size of the VSD employed.
OptiView Control Center FORM 160.55-O1 (604) This is generally indicative of a wiring problem between the OptiView Control Center and the VSD. venting the chiller from starting, the VSD will require service. “VSD – SERIAL COMMUNICATIONS” This message is generated when communications between the Adaptive Capacity Control (ACC) Board and the VSD Logic Board or between the OptiView Control Center Microboard and the VSD Logic Board, is disrupted.
FORM 160.55-O1 (604) in series to achieve a 900VDC capability for the DC link. It is important the voltage is shared equally from the junction of the center or series capacitor connection, to the negative bus and to the positive bus. This center point should be approximately ½ of the total DC link voltage.
OptiView Control Center FORM 160.55-O1 (604) Enabled by a Service Technician (following instructions in Service Manual 160.55-M1) and the Leaving Chilled Liquid temperature Setpoint is <38.0°F. “EVAPORATOR – TRANSDUCER OR LEAVING LIQUID PROBE” A possible defective Evaporator pressure Transducer or Leaving Chilled Liquid temperature Thermistor has been detected. The pressure and temperature that these devices are indicating are not in the correct relationship to each other.
FORM 160.55-O1 (604) “DISCHARGE – HIGH TEMPERATURE” The discharge temperature, as sensed by the Discharge Temperature Thermistor, has increased to > 220.0°F. The chiller can be started after the temperature decreases to < 220.0°F and the COMPRESSOR switch is placed in the Stop-Reset (O) position. “DISCHARGE – LOW TEMPERATURE” The discharge temperature, as sensed by the Discharge Temperature Thermistor, has decreased to < 30.0°F. The chiller can be started after the temperature increases to > 30.
OptiView Control Center FORM 160.55-O1 (604) MOD “B” SOLID STATE STARTER SAFETY SHUTDOWN MESSAGES “LCSSS SHUTDOWN – REQUESTING FAULT DATA...” The Liquid Cooled Solid State Starter Logic/Trigger Board has shut down the chiller but the Control Center has not yet received the cause of the fault from the LCSSS, via the serial communications link.
FORM 160.55-O1 (604) “VSD SHUTDOWN – REQUESTING FAULT DATA” The VSD has shut down the chiller and the control center has not yet received the cause of the fault from the VSD, via the serial communications link. The VSD shuts down the chiller by opening the Motor Controller “VSD Stop Contacts” (located on the VSD Logic Board and connected between TB6-16 and TB6-53 in the Control Center).
OptiView Control Center FORM 160.55-O1 (604) VSD Logic Board is pressed and the COMPRESSOR switch is placed in the Stop-reset (O) position. "VSD – HIGH PHASE C INVERTER BASEPLATE TEMPERATURE” (VSD part number 371-03789-xxx (503HP 60Hz; 419HP 50Hz (Flash Memory Card version C.MLM.02.04.xxx and later) The chiller has shutdown because the baseplate temperature has increased to >158 ºF.
FORM 160.
Printers FORM 160.55-O1 (604) SECTION 3 PRINTERS 23887A OKIDATA MICROLINE 184 WEIGH-TRONIX 23889A 00085VIP SEIKO DPU-414 FIG.
FORM 160.55-O1 (604) A printer can be connected to the Control Center’s Microboard to print the following reports. The screen from which each report can be generated is listed in parenthesis.
Printers FORM 160.55-O1 (604) codes are sent from the Control Center to the printer. For example, Weigh-Tronix printers require a control code to select 40 column width. This same code is interpreted by the Okidata printer as an instruction to print wide characters. In some instances, a printer will ignore a code it cannot interpret. 3. The Control Center requires a busy signal from the printer when the printer receive buffer is full.
FORM 160.
Printers FORM 160.
FORM 160.
Printers FORM 160.55-O1 (604) YORK SETPOINTS CHILLER ID 0 ------------------------------------------------------------------------- © 1997 - 1999 YORK INTERNATIONAL COR PORATION Mon 21 jun 1999 1:27 :39 PM Software Versions ------------------------------------------------------------------------Controls = C.MLM.02.03.102 BIOS = C.MLM.00.03 Kernel = 0.18 GUI = 0.25 SIO = 0.21 GPIC = 0.03 Ext I/O [Skip if Hot Gas Disabled] = 19962021101 VSD [Skip if Motor Type is not VSD] = C.VSD.01.
FORM 160.
Printers FORM 160.
FORM 160.55-O1 (604) YORK HISTORY 1 CHILLER ID 0 --------------------------------------------------------------------------- © 1997 - 1999 YORK INTERNATIONAL CORPORATION MSYSTEM READY TO START LCSSS – LOGIC BOARD POWER SUPPLY [List any warnings that were active at the time of shutdown] Controls C.MLM.02.03.
Printers FORM 160.
FORM 160.
System Operating Procedures FORM 160.55-O1 (604) SECTION 4 SYSTEM OPERATING PROCEDURES OIL HEATERS If the oil heater is de-energized during a shutdown period, it must be energized for 12 hours prior to starting compressor, or remove all oil and recharge compressor with new oil. (See “Oil Charging Procedure”, page 129.) The oil heater is thermostatically controlled and remains energized as long as the fused disconnect switch to the starter or Variable Speed Drive is energized.
FORM 160.55-O1 (604) Any malfunctions which occur during “STOP/ RESET” are also displayed. Variable Speed Drive) to decrease chiller capacity. When the chilled liquid temperature rises, the actuator will open the prerotation vanes and increase the compressor motor speed of the chiller (if controlled by the Variable Speed Drive), to increase the capacity of the unit. When the chiller is shut down, the prerotation vanes will close automatically to prevent loading the compressor on start-up.
System Operating Procedures FORM 160.55-O1 (604) DISPLAY MESSAGE "SYSTEM RUN" ENERGIZE (OPEN) VENT LINE SOLENOID "SYSTEM PRELUBE" (OIL PUMP PRE-RUN) "SYSTEM COASTDOWN" (OIL PUMP POST-RUN) CHECK OIL PRESS. "SYSTEM SHUTDOWN" 150 SEC. (2.5 MIN.) 0 START 25 (0.4) 30 (0.5) 330 (5.5) 1800 (30) RESTART TIME IN SECONDS (MINUTES) FIG.
FORM 160.55-O1 (604) CHECKING OPERATION During operation, the following conditions should be periodically checked: 1. On starting, the prerotation vanes should remain closed. 2. Be sure the oil pump is operating while unit is running. 3. Check Oil Pressure display. A gradual decrease in bearing oil pressure of 5 to 10 PSI (with constant suction and discharge pressures) may be an indication of a dirty Þlter. The Þlter should be replaced when pressure loss is 30% or more of the original pressure.
System Operating Procedures FORM 160.55-O1 (604) An optional status printer is available for this purpose; or, Fig. 48 shows a log sheet used by YORK personnel for recording test data on chillers. It is available from the factory in pads of 50 sheets each under Form No. 160.44-F6 and may be obtained through the nearest YORK ofÞce. Automatic data logging is possible by connecting the optional printer and programming the DATA LOGGER function.
FORM 160.55-O1 (604) 3. Compressor Drive Motor (See motor manufacturer’s maintenance and service instruction supplied with unit) a.Clean air passages and windings per manufacturer’s instructions. b. Meg motor windings - See Fig. 65 for details. c. Relubricate ball bearings. CHECK VALVE FLOAT SWITCH ASS’Y. PUMP Don’t overlook motor drive end bearing located in motor support of F1, F2 compressors. 4. Purge unit. a. Clean and inspect all valves. b. Drain and ßush purge shell. c. Clean oriÞces. 5.
System Operating Procedures FORM 160.55-O1 (604) condenser water, and cooling tower fans will stop automatically. The oil pump will continue to run for a period of 150 seconds. The oil pump will then stop automatically. Once stopped, the “SYSTEM COASTDOWN” display will be replaced by “SYSTEM READY TO START”. 2. Stop the chilled water pump (if not wired into the OptiView Control Center, in which case it will shut off automatically simultaneously with the oil pump.
FORM 160.55-O1 (604) SECTION 5 SYSTEM COMPONENTS DESCRIPTION COMPRESSOR / MOTOR ASSEMBLY CASING - The casing is accessible with vertical circular joints and fabricated of close-grain cast iron. The motor assembly is completely removable from the compressor rotor and scroll assembly. Compressor castings are designed for 15 PSIG working pressure and hydrostatically pressure tested at 50 PSIG.
System Components Description FORM 160.55-O1 (604) FIG.
FORM 160.55-O1 (604) Application #CT’s Furnished in Motor Terminal Box E-M Starter SS Starter VS Drive 3 0 0 COMPRESSOR LUBRICATION SYSTEM The chiller lubrication system consists of the oil pump, oil Þlter, oil cooler and all interconnecting oil piping and passages. (See Fig. 59) There are seven main points within the motor-compressor which must be supplied with forced lubrication as follows: 1. Compressor Drive Shaft (Low Speed) a. Shaft seal. b.
System Components Description FORM 160.55-O1 (604) Victaulic grooves are welded to the water boxes. These nozzle connections are suitable for Victaulic couplings, welding or ßanges (300 PSI has ßanges). 1/2" coupling and separable well are located in the entering and leaving chilled liquid nozzles for temperature sensing elements. Plugged 1/2" or 3/4" drain and vent connections are provided in each water box.
FORM 160.55-O1 (604) SECTION 6 OPERATIONAL MAINTENANCE OIL RETURN SYSTEM OIL RETURN The oil return system continuously maintains the proper oil level in the compressor oil sump. (See Fig. 57.) High pressure condenser gas ßows continuously through the eductor inducing the low pressure, oil rich liquid to ßow from the evaporator, through the dehydrator to the compressor sump. CHANGING THE DEHYDRATOR To change the dehydrator use the following procedure: 1.
Operational Maintenance FORM 160.55-O1 (604) LD00470 FIG.
FORM 160.55-O1 (604) CHARGING THE UNIT WITH OIL The nominal oil charge for the compressor is: 10 gal. “B” and “C” compressor; 15 gal. “E” and “F’ compressor. New oil YORK Refrigeration Type “C” must be used in the centrifugal compressor. Since oil absorbs moisture when exposed to the atmosphere it should be kept tightly capped until used. OIL CHARGING PROCEDURE The oil should be charged into the oil reservoir using the YORK Oil Charging Pump - YORK Part No. 070-10654.
Troubleshooting FORM 160.55-O1 (604) SECTION 7 TROUBLE SHOOTING TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE CONTROL CENTER DISPLAY SHUTDOWN CAUSE CONTROL CENTER DISPLAY CONTROL CENTER DISPLAY METHOD OF RESTART OPERATING POINT ON FALL TIME OF DAY MON. 10:00 AM Low Water Temperature Autostart Low Water (LWT) Chilled water setpoint 4°F below chilled water setpoint MON.
FORM 160.55-O1 (604) TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE CONTROL CENTER DISPLAY - CONTINUED PROGRAMMED SETPOINTS BY OPERATOR START-UP OF SYSTEM AFTER SHUTDOWN PROBABLE CAUSE AND SERVICE REQUIRED 4°F below chilled water setpoint (If set to 40°F would be 36°F.) (36°F minimum) Automatic Restart when water reaches setpoint. If system is running and setpoint is increased 4°F, system will continue to run, as LWT cutout shifts to a fixed 36°F for 10 minutes.
Troubleshooting FORM 160.55-O1 (604) TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE CONTROL CENTER DISPLAY - CONTINUED SHUTDOWN CAUSE CONTROL CENTER DISPLAY DAY OF WEEK TIME OF DAY MON. 10:00 AM CAUSE OF SHUTDOWN METHOD OF RESTART Oil Pressure Transducer Error Vane Motor Switch Open MON. 10:00 AM Starter Malfunction Detected MON.
FORM 160.55-O1 (604) TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE CONTROL CENTER DISPLAY - CONTINUED PROGRAMMED SETPOINTS BY OPERATOR START-UP OF SYSTEM AFTER SHUTDOWN PROBABLE CAUSE AND SERVICE REQUIRED Will start at 59 PSID when compressor switch is placed to STOP/RESET and then START. This Shutdown is provided to check on Oil pressure Transducers for failure in the high state. Replace Oil Pressure Transducer in oil sump or compressor.
Troubleshooting FORM 160.55-O1 (604) TABLE 2 – OPERATING ANALYSIS CHART RESULTS POSSIBLE CAUSE REMEDY 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE Temperature difference between liquid refrigerant out and water off condenser higher than normal. Air in condenser. Purge unit operates automatically to take care of this condition. Test for air leaks if display reads: “WARNING – EXCESS PURGE” High discharge pressure. Condenser tubes dirty or scaled. Clean condenser tubes. Check water conditioning.
FORM 160.55-O1 (604) TABLE 2 – OPERATING ANALYSIS CHART - CONTINUED RESULTS POSSIBLE CAUSE REMEDY 6. SYMPTOM: UNUSUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. High oil pressure. Transducer defective. Relief valve is misadjusted. Replace low or high oil pressure transducer. Adjust external relief valve. 7.
Maintenance FORM 160.55-O1 (604) SECTION 8 MAINTENANCE RENEWAL PARTS For any required Renewal Parts refer to Forms listed on page 4. CHECKING SYSTEM FOR LEAKS LEAK TESTING DURING OPERATION To test with R-22, proceed as follows: The refrigerant side of the system is carefully pressure tested and evacuated at the factory. 1. With no pressure in the system, charge R-22 gas into the system through the charging valve to a pressure of 2 PSIG.
FORM 160.55-O1 (604) *GAUGE INCHES OF MERCURY (HG) BELOW ONE STANDARD ATMOSPHERE 0 ABSOLUTE PSIA MILLIMETERS OF MERCURY (HG) MICRONS BOILING TEMPERATURES OF WATER °F 14.696 760 760,000 212 10.24* 9.629 500 500,000 192 22.05* 3.865 200 200,000 151 25.98* 1.935 100 100,000 124 27.95* .968 50 50,000 101 28.94* .481 25 25,000 78 29.53* .192 10 10,000 52 29.67* .122 6.3 6,300 40 29.72* .099 5 5,000 35 29.842* .039 2 2,000 15 29.882* .019 1.
Maintenance FORM 160.55-O1 (604) EVACUATION AND DEHYDRATION OF UNIT VACUUM TESTING VACUUM DEHYDRATION After the pressure test has been completed theVacuum test should be conducted as follows: 1. Connect a high capacityVacuum pump, with indicator, to the system charging valve as shown in Fig. 63 and start the pump (see “Vacuum Dehydration”). 2. Open wide all system valves, including the purge and gauge valves. Be sure all valves to the atmosphere are closed. 3.
FORM 160.55-O1 (604) it to atmospheric pressure and the indicator temperature will return to approximately ambient temperature. Close off the system again, and start the second evacuation. The relatively small amount of moisture left will be carried out through theVacuum pump and the temperature or pressure shown by the indicator should drop uniformly until it reaches a temperature of 35°F or a pressure of 5mm Hg. LD00474 FIG.
Maintenance FORM 160.55-O1 (604) CHECKING THE REFRIGERANT CHARGE DURING UNIT SHUT DOWN The refrigerant charge is speciÞed for each chiller model (See Table 4). Charge the correct amount of refrigerant and record the level in the cooler sight glass. The refrigerant charge should always be checked and trimmed when the system is shut down. The refrigerant charge level must be checked after the pressure and temperature has equalized between the condenser and cooler.
FORM 160.55-O1 (604) LD00475 FIG. 65 – DIAGRAM, MEGGING MOTOR WINDINGS CONDENSERS AND COOLERS GENERAL Maintenance of condenser and cooler shells is important to provide trouble free operation of the chiller. The water side of the tubes in the shell must be kept clean and free from scale. Proper maintenance such as tube cleaning, and testing for leaks, is covered on the following pages.
Maintenance MEGOHMS Minimum Insulation Resistance vs. Temperature (per IEEE Std 43) Open Motors FORM 160.55-O1 (604) TEMPERATURE – °F LD00476 FIG.
FORM 160.55-O1 (604) TUBE CLEANING PROCEDURES Brush Cleaning of Tube If the tube fouling consists of dirt and sludge, it can usually be removed by means of the brushing process. Drain the water sides of the circuit to be cleaned (cooling water or chilled water) remove the heads and thoroughly clean each tube with a soft bristle bronze brush. DO NOT USE A STEEL BRISTLE BRUSH. A steel brush may damage the tubes. Improved results can be obtained by admitting water into the tube during the cleaning process.
Preventive Maintenance FORM 160.55-O1 (604) COMPRESSOR Maintenance for the compressor assembly consists of checking the operation of the oil return system and changing the dehydrator, checking and changing the oil, checking and changing the oil Þlters, checking the operation of the oil heater, checking the operation of the oil pump and observing the operation of the compressor.
FORM 160.55-O1 (604) COOLER AND CONDENSER The major portion of maintenance on the condenser and cooler will deal with the maintaining of the water side of the condenser and cooler in a clean condition. The use of untreated water in cooling towers, closed water systems, etc. frequently results in one or more of the following: 1. Scale Formation 2. Corrosion or Rusting 3.
FORM 160.55-O1 (604) SECTION 10 OPTISAVE ENERGY ANALYSER FEATURE The OptiSave Energy Analyzer Feature reveals the advantage of a compressor motor variable speed drive. It calculates the amount of energy that has been saved by having a variable speed drive instead of a constant speed drive. The savings are determined by calculating the energy consumption of a constant speed drive and subtracting the measured energy consumption of the variable speed drive. The resulting difference is the energy savings.
FORM 160.
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Copyright © by York International Corporation 2004 Form 160.55-O1 (604) Supersedes: 160.55-O1 (402) 800-861-1001 www.york.com Subject to change without notice.
