York YR Service Manual

YRSTYLE:REFRIGERANT:AR134aROTARY SCREW LIQUID CHILLERGBINSTALLATION, COMMISSIONING,OPERATION AND MAINTENANCE160.81-ICOM-GB0 (01/02)

Thermal & Acoustic Materials DataHealth Hazard & First Aid Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic. No firsta

2 Product Description2.1 General (Figure 2.1)The York YR Rotary Screw Liquid Chiller is primarilyused for large air conditioning systems, but may be u

Oil is injected into the compressor by differentialpressure to lubricate the bearings, seal the rotors andremove the heat of compression. The injected

In the first stage of oil separation, high velocity oil andrefrigerant gas in the compressor discharge lineundergoes a rapid reduction in velocity as

2.9 EvaporatorThe evaporator is a shell and tube, flooded type, heatexchanger with a distributor trough providing uniformdistribution of refrigerant o

2.15 Options and AccessoriesModel 'B' Solid State StarterThe liquid cooled solid state starter is a reduced voltagesoft starter that control

2.16 Nomenclature2-6 160.81-ICOM-GB0 (01/02)Evaporator CodeTB, TC, TD, VB, VC, VDCondenser Code Motor CodeTB, TC, TD, VB, VC, VD 50 = 380/400-3-50 55

3 TRANSPORTATION, RIGGING AND STORAGE3.1 GeneralYR units are shipped as a single factory assembled,piped, wired package, requiring minimum installatio

Form 3 – Motor/Compressor Separate From ShellsShipped as three major assemblies. Unit firstfactory assembled, refrigerant piped, wired andleak tested;

3.4 RiggingThe complete standard unit is shipped without skids.(When optional skids are used it may be necessary toremove the skids so riggers skates

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4 INSTALLATION4.1 LocationYR units are furnished with vibration isolator mounts forbasement or ground level installations. Units may belocated on uppe

Checking the Isolator Pad DeflectionAll isolator pads should be checked for the properdeflection while checking to see if the unit is level. Eachpad s

4.8 Evaporator and Condenser Water PipingThe evaporator and condenser liquid heads havenozzles which are grooved, suitable for welding 10.6 barDWP fla

4.10 Glycol SolutionsFor unit operation with chilled liquid temperaturesleaving the evaporator at below 4°C, glycol solutionsshould be used to help pr

4.17 Unit PipingCompressor lubricant piping and system external pipingare factory installed on all units shipped assembled. Onunits shipped dismantled

Route the cables forming the 3 phase power supply viathe same hole in the motor terminal box gland plate,using a suitable cable gland, to ensure that

4.20 Control ConnectionsCustomer voltage free contacts must besuitable for device contact rating to be 5 mA at115 Vac. If the voltage free contacts fo

4.20.8 Remote Current Limit Setpoint - PWM(TB4 terminals 1 & 20)The motor current limit setpoint can be adjustedremotely bya1to11second timed clos

4.21.5 Safety Shutdown(TB2 terminals 42 & 43)When closed, these contacts signify the unit is notpermitted to start due to one or more safety contr

Table of Contents1 SUPPLIER INFORMATION1.1 Introduction 1.11.2 Warranty 1.11.3 Safety 1.11.4 Responsibility for Safety 1.11.5 About this Manual 1.21.6

4-10 160.81-ICOM-GB0 (01/02)SFSFTB4COOLINGLIQUIDCOOLINGLIQUID PUMPCHILLEDLIQUID PUMPREMOTE/LOCALCYCLINGMULTI UNITSEQUENCEAUXILIARY SAFETYSHUTDOWNREMOT

5 COMMISSIONING5.1 PreparationCommissioning of this unit should only becarried out by York authorised personnel.The Operating Instruction manual must

5.2 First Time Start-upDuring the commissioning period there shouldbe sufficient heat load to run the unit understable full load operation to enable t

6 OPERATIONIf the oil heater is de-energised during ashutdown period, it must be energized for 24hours prior to starting the compressor.6.1 GeneralYR

3. The chilled liquid pump contacts close starting thechilled liquid pump to allow liquid flow through theevaporator. The chilled water flow switch is

6.7 Prolonged ShutdownsIf the unit is to be shut down for an extended period oftime (for example, over the winter season), the followingprocedure shou

6.9 Operating Log SheetAn accurate record of system operating conditions(temperatures and pressures) recorded at regularintervals throughout each 24 h

7 MAINTENANCEThe Safety Section of this manual shouldbe read carefully before attempting anymaintenance operations on the unit. Thissection should be

7.2 Special Maintenance RequirementsIn addition to the regular maintenance schedule, thereare some further special requirements for maintenanceof the

7.3 Regular Maintenance OperationsService Schedule MINOR SERVICE( 3 - 6 monthly ) *MAJOR SERVICE ( 6 - 12 monthly ) *All items under Minor Service plu

4.21 Status Connections 4.84.21.1 Remote Mode - Ready to Start4.21.2 Run Contacts4.21.3 Anticipatory Alarm4.21.4 Cycling Shutdown4.21.5 Safety Shutdow

7.4 Oil Filters and DriersA single oil filter is provided as standard equipment anddual oil filter arrangements are available as optionalequipment. Th

4. Loosen the Rota-Lock®Nuts at each end of the filterdriers. Remove the filter driers.5. Teflon®seal washers are used to seal the filter drierconnect

7.6.3 Vacuum TestingVacuum testing should be conducted as follows:1. Connect a high capacity vacuum pump, withindicator, to the system charging valve

7.7.1 Chemical Water TreatmentSince the mineral content of the water circulated throughthe evaporator and condenser varies with almost everysource of

7.7.4 Tube LeaksEvaporator and condenser tube leaks may result inrefrigerant leaking into the water circuit, or water leakinginto the shell depending

7.9 Testing Motor Winding InsulationWith the main disconnect switch and compressor motorstarter open, test the motor as follows:1. Test the insulation

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8 TROUBLE SHOOTING8.1 General RequirementsUnits are not generally user serviceable and no attemptshould be made to rectify any faults found with the u

8-2 160.81-ICOM-GB0 (01/02)Fault Possible Cause RemedyTemperature of chilled water too lowwith low motor current.Insufficient load for system capacity

9 TECHNICAL DATA9.1 DimensionsNotes1. Unit height includes steel mounting plates under tube sheets. To determine overall installed height,add 22 mm fo

1 SUPPLIER INFORMATION1.1 IntroductionYork YR chillers are manufactured to the highest designand construction standards to ensure highperformance, rel

9.2 Solid State Starter Details (Optional)9.3 Weights9-2 160.81-ICOM-GB0 (01/02)TOP VIEWMOTOR/COMPRESSORPOWER WIRING ENTRANCE COVER WITH22 mm Ø KNOCKO

9.4 Process and Instrumentation Diagram160.81-ICOM-GB0 (01/02)9-3

9.5 Water Box Nozzle Arrangements9-4 160.81-ICOM-GB0 (01/02)In OutAHHA11-PASSNozzle ArrangementsNo. ofPassesEvaporatorIn OutCBKJ2NOTE: Water must ente

160.81-ICOM-GB0 (01/02) 9-5CCDDDDBBBBBBBBDDDDPSWYVXURTQCCGGGGGG GGGGGG25.4 mm25.4 mm25.4 mm25.4 mm25.4 mm25.4 mmCONDENSERCONDENSERCONDENSERMOTOR ENDMO

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10 SPARE PARTSIt is recommended that the following common spareparts are held for preventative of correctivemaintenance operations.Other spare parts v

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11 DE-COMMISSIONING, DISMANTLING AND DISPOSALNever release refrigerant to theatmosphere when emptying therefrigerating circuits. Suitable retrievalequ

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1.5 About this ManualThe following symbols are used in this document to alertthe reader to areas of potential hazard.A Warning is given in this docume

Subject to change without noticeALL RIGHTS RESERVEDPart No. 160.81-ICOM-GB0 (01/02)YORKEuropeYORK INTERNATIONALZ.I. 14 rue de Bel Air, B.P.44473 Carqu

Refrigerants and OilsRefrigerants and oils used in the unit are generallynon-toxic, non-flammable and non-corrosive, and poseno special safety hazards

1.9 Material Safety DataRefrigerant Data:Safety Data R134aToxicity Low.In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely

Spill/leak procedure Ensure suitable personal protective clothing and respiratory protection is worn.Provided it is safe to do so, isolate the source