| Вид документа | Інструкція |
|---|---|
| Виробник | JCI |
| Моделі | YCSE040, YCSE050, YCSE060, YCSE080, YCSE100, YCRE040, YCRE050, YCRE060 |
| Група обладнання | other |
| Мова документа | англійська |
| Розмір файлу | 3.6 МБ |
Про документ
YORK YCSE/YCRE R407C chillers are designed for water or water-glycol cooling, intended for indoor installation in a plant room. Units have one or two independent refrigerant circuits with a single evaporator and, on YCSE models, a single water-cooled condenser; YCRE models use a field-supplied remote air-cooled condenser. They are factory assembled, pressure tested, evacuated and fully charged with refrigerant R407C and oil.
Ключові дані
| Cooling capacity range YCSE | 134–320 kW |
|---|---|
| Cooling capacity range YCRE | 127–307 kW |
| Refrigerant | R407C (GWP 1520) |
| Power supply | 400 V, 3 ~, 50 Hz (nominal); allowable 360 to 440 V |
| Compressor type | Semi-hermetic Screw, capacity control 15-100 % |
| Evaporator design working pressure (water side) | 10 barg |
| Maximum refrigerant side pressure | 30 bar |
| Ambient air temperature range | 5 °C min to 46 °C max |
Застосування
- Cooling water or glycol solutions for air conditioning installations
- Glycol cooling options for water outlet temperatures below 5 °C (Category 1: 0 to 4 °C; Category 2: -1 to -5 °C; Category 3: -6 to -10 °C)
- Heat pump operation on YCSE units (option)
Особливості
- Suction-cooled semi-hermetic twin-screw compressors with continuous slide valve capacity control (15% to 100% per compressor; 7.5, 15-100 % on two-circuit models)
- Stainless steel brazed plate heat exchangers with victaulic-grooved connections (flange connections optional)
- Electronic expansion valve, filter dryer, sight glass with moisture indicator
- IP2X power/control cabinet with non-fused disconnect switch
- Options: Modbus or Lonworks BMS interface (HARC), CSC-5S multi unit sequencer (up to 8 units), compressor circuit breakers, differential water pressure switches, flow switches, PN16 flanges, spring isolators or resilient pads, heat pump kit (YCSE only)
- Factory operational test performed before dispatch
Технічні дані
| Parameter | Value |
|---|---|
| Refrigerant | R407C |
| Refrigerant GWP | 1520 |
| Compressor type | Semi-hermetic Screw |
| Capacity control | 15-100 % per compressor |
| Evaporator type | Brazed PHE |
| Evaporator waterside design working pressure | 10 barg |
| Evaporator refrigerant side design working pressure | 18 bar g |
| Condenser (YCSE) refrigerant side design working pressure | 30 bar g |
| Condenser (YCSE) waterside design working pressure | 10 barg |
| Number of refrigerant circuits | 1 (040-080) / 2 (100) |
| Refrigerant charge per circuit | 12 / 14 / 16 / 18 kg; 14 / 14 kg (model 100) |
| Oil charge per circuit | 6 litre |
| Power supply | 400V, 3 ~, 50 Hz (nominal); allowable 360 to 440 V |
| Control terminals voltage | AC220-240V (terminals 1~21/57), DC24V (terminals A~D), H-link low signal (E~F) |
| Cabinet ingress protection | IP2X |
| Liquid outlet temperature (water) | 5 to 15 °C |
| Liquid outlet temperature (glycol) | -10 to 15 °C |
| Minimum / maximum ambient air temperature | 5 °C / 46 °C |
| Recommended minimum system water volume | 420 / 510 / 610 / 730 / 1010 litres (by model size) |
| Fouling factor (design basis) | 0.044 m² °C/kW |
| Required water pH | 7 to 8.5 |
| YCSE dimensions (L × W × H) | 850 × 1105 × 1520 mm (040-080); 1465 × 1105 × 1700 mm (100) |
| YCSE operating weight | 780 / 800 / 875 / 1000 / 1655 kg |
| YCRE dimensions (L × W × H) | 885 × 1045 × 1562 mm (040/050); 885 × 1104 × 1562 mm (060); 1471 × 1104 × 1720 mm (080/100) |
| YCRE operating weight | 650 / 710 / 760 / 1250 / 1370 kg |
| Remote condenser system Design Working Pressure (min.) | at least 27.6 barg |
| YCRE refrigerant gas connection pipe | Outer Diameter 41.3 mm, Thickness 2.0 mm |
| YCRE refrigerant liquid connection pipe | Outer Diameter 28.6 mm, Thickness 1.6 mm |
| Max. piping length to remote condenser | 30.0 m |
| Max. height difference (unit below remote condenser) | 25.0 m |
| Max. height difference (unit above remote condenser) | 5.0 m |
| Nominal running amps YCSE (at 400 V, kW by model) | 34 A (040), 40 A (050), 49 A (060), 55 A (080), 80 A (100) |
| Nominal running amps YCRE | 34 A (040), 42 A (050), 52 A (060), 68 A (080), 84 A (100) |
| Sound power LWA (EN 292-1991 SPL) | YCSE/YCRE: 68 / 69 / 71 / 71 / 72 dB(A) by model size |
| Compressor HP switch cut-out | 2.74 MPa (manual reset, non-adjustable) |
| Compressor LP switch (pressure sensor) cut-out | 0.05 MPa |
| Compressor internal thermostat | Cut-out 115 °C, Cut-in 93 °C |
| Discharge gas cut-out | 140 °C |
| Refrigerant circuit pressure relief valve setting | 3.0 MPa |
| Freeze protection thermostat cut-out | 2.0 °C |
| Oil heater rating | 150 W |
Варіанти замовлення
Nomenclature example: YCSE100SB50B — Y = York, C = Chiller, S = Screw, E = European; capacity :040 :050 :060 :080 :100; S = Standard Unit; B = R407C Refrigerant; 50 = 380-415 / 3 / 50 + N; B = Design Level. Accessories/options referenced in the document: Modbus (HARC-MODBUS), Lonworks (HARC-LONWORKS), Multi Unit Sequencer CSC-5S, compressor circuit breakers, differential water pressure switches, flow switches, glycol cooling categories 1–3, discharge/suction stop valves, compressor safety valve(s), dual pressure relief valves, suction pressure relief valves, PN16 flanges, AVM resilient pads, AVM spring isolators, water filter, wooden crate, heat pump kit (YCSE only).
Допуски та стандарти
- EN ISO 9001 accredited design and manufacturing organisation
- Machinery Directive (98/37/EC)
- Low Voltage Directive (2006/95/EC)
- EMC Directive (2004/108/EC)
- Pressure Equipment Directive 97/23/EC, CE marking
- EN13136 (relief pipework sizing reference)
- EN 60204 (overcurrent protection responsibility)
- NES713 Issue 3 (1991) toxicity index of thermal/acoustic materials
- BS 476 pt 7 Class 1 flammability rating (thermal/acoustic materials)
- Sound data per Eurovent specification and EN 292-1991
Текст документа
Библиотека СОК
YCSE040-YCSE100 & YCRE040-YCRE100
INSTALLATION, COMMISSIONING,
OPERATION & MAINTENANCE
Revision 1 Form 035-21786-100 (0909)
WATER AND REMOTE AIR
COOLED LIQUID CHILLERS
WITH SCREW COMPRESSORS
STYLE B
(YCSE 134-320KW)
(YCRE 127-307KW)
Aspak
R407C
035-21786-100 Rev. 1 (0909)
TABLE OF CONTENTS
1 SUPPLIER INFORMATION 4 INSTALLATION
1.1 Introduction 1.1 4.1 Location Requirements 4.1
1.2 Warranty 1.1 4.2 Installation of Vibration Isolators 4.1
1.3 Safety 1.1 4.3 Pipework Connection 4.1
1.4 Responsibility for Safety 1.2 4.4 Water Treatment 4.2
1.5 About this Manual 1.2 4.5 Pipework Arrangement 4.3
1.6 Misuse of Equipment 1.2 4.6 Connection Types & Sizes 4.3
1.7 Emergency Shutdown 1.3 4.7 Condenser Cooling Liquid Systems 4.4
1.8 Safety Labels 1.3 4.8 Electrical Connection 4.5
1.9 Material Safety Data 1.4 4.9 Remote Refrigerant Condenser
Systems (YCRE models only) 4.5
2 PRODUCT DESCRIPTION
4.10 Power Wiring 4.8
2.1 Introduction 2.1
4.11 Control Wiring 4.8
2.2 Compressor 2.1
4.12 Connection Diagram 4.9
2.3 Refrigerant Circuits 2.1
5 COMMISSIONING
2.4 Evaporator 2.1
5.1 Preparation 5.1
2.5 Condenser 2.1
5.2 First Time Start-up 5.2
2.6 Power and Control Panels 2.2
6 UNIT OPERATION
2.7 Accessories and Options 2.2
6.1 General Description 6.1
2.8 Nomenclature 2.3
6.2 Operation 6.1
2.9 Refrigerant Flow Diagram 2.4
6.3 Normal Running and Cycling 6.1
3 TRANSPORTATION, HANDLING AND
STORAGE 6.4 Shutdown 6.1
3.1 Delivery and Storage 3.1 6.5 Control System 6.1
3.2 Inspection 3.1 7 MAINTENANCE
3.3 Moving the Unit 3.1 7.1 General Requirements 7.1
3.4 Lifting Weights 3.2 7.2 Daily Maintenance 7.1
3.5 Weight Distribution & Centre 7.3 Scheduled Maintenance 7.1
of Gravity 3.2
7.4 Pressure Vessel In-Service
Inspection 7.2
I-i
035-21786-100 Rev. 1 (0909)
8 TROUBLE SHOOTING
8.1 Competent Persons Trouble
Shooting Guide 8.1
9 TECHNICAL DATA
9.1 Flow Rate and Pressure Drop
Graphs 9.1
9.2 Performance Graphs 9.2
9.3 Operating Limitations 9.4
9.4 Physical Data 9.5
9.5 Electrical Data 9.6
9.6 Sound Data 9.7
9.7 Clearances and Foundations 9.8
9.8 Dimensions 9.9
10 SPARE PARTS
10.1 Renewal Parts List 10.1
10.2 Recommended Compressor Oils 10.1
10.3 Associated Drawings 10.1
11 DECOMMISSIONING. DISMANTLING AND
DISPOSAL
11.1 General 11.1
I-ii
035-21786-100 Rev. 1 (0909)
1 SUPPLIER INFORMATION For warranty purposes, the following conditions must be
satisfied:
1.1 Introduction
The initial start of the unit must be carried out by trained
York YCSE/YCRE chillers are manufactured to the personnel from an Authorised York Service Centre.
highest design and construction standards to ensure
high performance, reliability and adaptability to all types Only genuine York approved spare parts, oils and
of air conditioning installations. refrigerants must be used.
The units are intended for cooling water or glycol All the scheduled maintenance operations detailed in
solutions and are not suitable for purposes other than this manual must be performed at the specified times by
those specified in this manual. suitably trained and qualified personnel.
This manual contains all the information required for Failure to satisfy any of these conditions will
correct installation and commissioning of the unit, automatically void the warranty.
together with operating and maintenance instructions.
The manuals should be read thoroughly before 1.3 Safety
attempting to operate or service the unit.
Standards for Safety
All procedures detailed in the manuals, including
installation, commissioning and maintenance tasks YCSE/YCRE chillers are designed and built within an
must only be performed by suitably trained and qualified EN ISO 9001 accredited design and manufacturing
personnel. organisation and, within the limits specified in this
manual, are in conformity with the essential health and
The manufacturer will not be liable for any injury or safety requirements of the following European Union
damage caused by incorrect installation, Directives:
commissioning, operation or maintenance resulting
from a failure to follow the procedures and instructions Machinery Directive (98/37/EC)
detailed in the manuals..
Low Voltage Directive (2006/95/EC)
1.2 Warranty
EMC Directive (2004/108/EC)
Johnson Controls warrants all equipment and materials
against defects in workmanship and materials for one They conform to the applicable and essential safety
year from initial start-up, or eighteen months from requirements of Pressure Equipment Directive
delivery (whichever occurs first) unless extended 97/23/EC and bear CE marking.
warranty has been agreed as part of the contract.
Fluorinated Greenhouse Gases
The warranty is limited to free replacement and shipping
of any faulty part, or sub-assembly which has failed due n This equipment contains fluorinated greenhouse
to poor quality or manufacturing errors. All claims must gases covered by the Kyoto Protocol.
be supported by evidence that the failure has occurred
within the warranty period, and that the unit has been n The global warming potential of the refrigerant
operated within the designed parameters specified. (R407C) used in this unit is 1520.
All warranty claims must specify the unit model, serial n The refrigerant quantity is stated in the Physical
number and order number. These details are printed on Data table in Section 9 of this document.
the unit identification plate, fitted on the outer edge of the
options panel. n The fluorinated greenhouse gases in this
equipment may not be vented to the atmosphere.
The unit warranty will be void if any modification to the
unit is carried out without prior written approval from n This equipment should only be serviced by
Johnson Controls. qualified technicians.
1-1
035-21786-100 Rev. 1 (0909)
1.4 Responsibility for Safety 1.6 Misuse of Equipment
Every care has been taken in the design and Suitability for Application
manufacture of the units to ensure that they meet the
safety requirements listed in the previous paragraph. The unit is intended for cooling water or glycol solutions
However, the individual operating or working on any and is not suitable for purposes other than those
machinery is primarily responsible for: specified in these instructions. Any use of the equipment
other than its intended use, or operation of the
Personal safety, safety of other personnel, and the equipment contrary to the relevant procedures may
machinery. result in injury to the operator, or damage to the
equipment.
Correct utilisation of the machinery in accordance with
the procedures detailed in the manuals. The unit must not be operated outside the design limits
specified in this manual.
1.5 About this Manual
Structural Support
The following symbols are used in this document to alert
the reader to areas of potential hazard. Structural support of the unit must be provided as
indicated in these instructions. Failure to provide proper
A Warning is given in this document to support may result in injury to the operator, or damage to
identify a hazard which could lead to the equipment.
personal injury. Usually an instruction will
be given, together with a brief explanation Mechanical Strength
and the possible result of ignoring the
instruction. The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures.
A Caution identifies a hazard which could Additional components must not be mounted on the
lead to damage to the machine, damage to unit. Any such extraneous loads may cause structural
other equipment and/or environmental failure and may result in injury to the operator, or
pollution. Usually an instruction will be given, damage to the equipment.
together with a brief explanation and the
possible result of ignoring the instruction. General Access
A Note is used to highlight additional There are a number of areas and features which may be
information which may be helpful to you but a hazard and potentially cause injury when working with
w h e r e th e r e a r e n o s p e c i a l s a f e t y the unit unless suitable safety precautions are taken. It
implications. is important to ensure access to the unit is restricted to
suitably qualified persons who are familiar with the
potential hazards and precautions necessary for safe
The contents of this manual include suggested best operation and maintenance of equipment containing
working practices and procedures. These are issued for high temperatures, pressures and voltages.
guidance only, they do not take precedence over the
above stated individual responsibility and/or local safety Pressure Systems
regulations.
The unit contains refrigerant vapour and liquid under
This manual and any other document supplied with the pressure, release of which can be a danger and cause
unit, are the property of Johnson Controls which injury. The user should ensure that care is taken during
reserves all rights. They may not be reproduced, in installation, operation and maintenance to avoid
whole or in part, without prior written authorisation from damage to the pressure system. No attempt should be
an Authorised Johnson Controls representative. made to gain access to the component parts of the
pressure system other than by suitably trained and
qualified personnel.
1-2
035-21786-100 Rev. 1 (0909)
Electrical 1.8 Safety Labels
The unit must be earthed. No installation or The following labels are fixed to each unit to give
maintenance work should be attempted on electrical instruction, or to indicate potential hazards which may
equipment without first switching off, isolating and exist.
locking-off the power supplies. Work on live equipment
must only be carried-out by suitably trained and White symbol on blue background
qualified personnel. No attempt should be made to gain For safe operation, read the
access to inside of the control panel, wiring or other Instructions first
electrical enclosures during normal operation of the unit.
Refrigerants and Oils
Black symbol on yellow background
Refrigerants and oils used in the unit are generally Warning: This machine may start
non-toxic, non-flammable and non-corrosive, and pose automatically without prior warning
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 Black symbol on yellow background
example, does pose a risk of asphyxiation in confined or Warning: Hot surface
enclosed spaces and attention should be given to good
ventilation. For more comprehensive information on
safety precautions for use of refrigerants and oils, refer
to the Materials Safety Data tables provided.
Black symbol on yellow background
High Temperature and Pressure Cleaning Warning: Safety relief valve may
discharge gas or liquid without prior
High temperature and pressure cleaning methods (e.g. warning
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the Black symbol on yellow background
pressure relief device(s). Detergents and solvents Warning: Isolate all electrical sources
which may cause corrosion should also be avoided. of supply before opening or removing
the cover, as lethal voltages may exist
1.7 Emergency Shutdown
In case of emergency the unit can be shut down by Black symbol on yellow background
operating the main power switch on the control panel. General attention symbol
1-3
035-21786-100 Rev. 1 (0909)
1.9 Material Safety Data
Refrigerant Data:
Safety Data R407C
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. Liquid splashes or spray may cause freeze burns. Immediately irrigate with
eyewash solution or clean water for at least 10 minutes. Obtain immediate medical attention.
Ingested Highly unlikely to occur — but should this occur freeze burn will occur. Do not induce vomiting.
Provided patient is conscious, wash mouth with water and give about 250 ml (0.5 pint) to drink.
Obtain immediate medical attention.
Inhalation High atmospheric concentrations may have an anaesthetic effect, including loss of consciousness.
Very high exposures may cause an abnormal heart rhythm and prove suddenly fatal.
At higher concentration there is a danger from asphyxiation due to reduced oxygen content of
atmosphere. Remove patient to fresh air, keep warm and at rest. Administer oxygen if necessary.
Apply artificial respiration if breathing has ceased or shows signs of failing. In event of cardiac
arrest apply external cardiac massage. Obtain immediate medical attention.
Further medical advice Symptomatic and supportive therapy is indicated. Cardiac sensitisation has been described which
may, in the presence of circulating catecholamines such as adrenalin, give rise to cardiac
arrhythmia’s and subsequent arrest following exposure to high concentrations.
Long term exposure A lifetime inhalation study in rats has shown that exposure to 50,000 ppm resulted in benign
tumours of the testis. This is not considered to be of relevance to humans exposed to
concentrations at or below the occupational exposure limit.
Occupational exposure Recommended limit: 1000 ppm v/v - 8 hr TWA.
limits
Stability Not specified.
Conditions to avoid Use in presence of naked flames, red hot surfaces and high moisture levels.
Hazardous reactions May react violently with sodium, potassium, barium and other alkali and alkaline earth metals.
Incompatible materials: Magnesium and alloys containing more then 2% magnesium.
Hazardous Halogen acids by thermal decomposition and hydrolysis.
decomposition
products
General precautions Avoid inhalation of high concentrations of vapours. Atmospheric concentrations should be
minimised and kept as low as reasonably practicable below the occupational exposure limit. The
vapour is heavier than air and collects at low level and in confined areas. Ventilate by extraction at
lowest levels.
Respiratory protection Where doubt exists on atmospheric concentration, HSE approved breathing apparatus should be
worn. This should be self contained or of the long breather type.
Storage Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources of heat
such as radiators. Keep at temperatures not exceeding 45 °C.
Protective clothing Wear overalls, impervious gloves and goggles/face protection.
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.
Disposal Best to recover and recycle. If this is not possible, destruction is to be in an approved facility which
is equipped to absorb and neutralise acids and other toxic processing products.
Fire extinguishing data Non-flammable at atmospheric conditions.
Containers Fire exposed containers should be kept cool with water sprays. Containers may burst if
overheated.
Fire fighting protective Self contained breathing apparatus and protective clothing must be worn in fire conditions.
equipment
1-4
035-21786-100 Rev. 1 (0909)
Thermal and Acoustic Materials Data
Health Hazard & First Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic. No first aid necessary.
Aid
Stability / Reactivity Stable.
Handling / Use / No special handling precautions required. Dispose of according to local laws and regulations
Disposal governing non-biodegradable non-hazardous solid wastes.
Fire & Explosion Flammability rating Class 1 to BS 476 pt 7: Non-flammable. If forced to burn, combustion products
are typically over 95% carbon dioxide and carbon monoxide.
Refrigerant Oil Data:
Safety Data York "Y" Oil
Hazardous Ingredients / Identity Information
Hazardous Components (Specific Chemical No hazardous materials present.
Identity, Common Name) CHEMICAL NAME: Polyole ester and Lubricating oil additive
COMPONENT : Polyole ester >99mass%
Lubricating oil additive <1mass%
OSHA PEL ACGIH TLV
Physical Characteristics
Boiling Point Not applicable
Vapor Pressure (mmHg) Not applicable
Vapor Density (AIR=1) Not applicable
Appearance and Odor Light yellow, clear mobile liquid
Specific Gravity (H.0=1) 1.0230g/cm³(15)
Melting Point (Pour point) -27.5
Evaporation Rate Not applicable
Fire and Explosion Hazard Data
Flash Point (Method Used) 250 (COC)
Flammable limits No information LEL UEL
Extinguishing Media Foam, dry chemical, carbon dioxide
Special Fire Fighting Procedures No
Unusual Fire and Explosion Hazards Not in particular. Normal protective measures for organic chemical products
with flash points of above 100
Reactivity Data
Stability Stable
Incompatibility (Materials to Avoid) No
Hazardous Decomposition or By-products No
Hazardous Polymerization Will not occur
1-5
035-21786-100 Rev. 1 (0909)
Health Hazard Data
Route(s) of Entry No significant health hazards are identified. Prolonged repeated skin
contact may cause irritation and dermatitis
Health Hazards (Acute and Chronic) No significant health hazards are identified. Prolonged repeated skin
contact may cause irritation and dermatitis
Carcinogenicity NTP: No IARC Monographs: No OSHA Regulated: No
Signs and Symptoms of Exposure No information is available
Medical Conditions Generally Aggravated No information is available
by Exposure
Skin Contact Wash material off the skin with copious amounts of water and soap
Eyes Contact Immediately flush with plenty of water for at least 15 minutes
Inhalation Remove exposed person to fresh air
Ingestion Do not induce vomiting. Call a physician immediately
Precautions for Safe Handling and Use
Steps to be Taken In Case Material is Prevent spillage from spreading by using sand and absorb the liquid
Released or Spilled substance using a suitable inert material. Transfer to a suitably labelled
sealable container. Do not allow liquid to enter open waters or ground
water.
Waste Disposal Method Waste material may be incinerated under conditions which meet all Federal,
state and local environmental control regulations.
Precautions to be Taken in Handling and Store in cool, dark and low humidity place.
Storing
Other Precautions Avoid repeated skin contact and breathing of mist or vapour.
Control Measures
Respiratory Protection Under normal conditions, respirator is not usually required.
Ventilation Local Exhaust Not required
Mechanical (General) Not required
Special Adequate ventilation should be maintained
when handling heated products
Protective Gloves Rubber gloves
Eye Protection Glasses or goggles
Other Protective Clothing or Equipment Not required
Work/Hygienic Practices Not required
Additional Information
The information contained herein has been compiled from data published in the literature. This data is believed to be
reliable, but certain values may vary from source to source.
This data is not to be construed as absolutely complete. It is the responsibility of the user to determine the best
precautions necessary for his/her application.
This data only refers to the specific material designated and not to any combinations.
1-6
035-21786-100 Rev. 1 (0909)
4
5
1
2
1 Compressor
2 Evaporator
3 Condenser (YCSE only)
4 Power Section
3
5 Control Panel
2.3 Refrigerant Circuits
2 PRODUCT DESCRIPTION
Depending on model size, one or two independent
2.1 Introduction refrigerant circuits are provided on each unit. Each
circuit uses copper refrigerant pipe formed on computer
YORK YCSE/YCRE R407C chillers are designed for controlled bending machines to reduce the number of
water or water-glycol cooling. It is designed for indoor brazed joints resulting in a reliable and leak resistant
installation in a plant room. Units are available with one system.
or two independent refrigerant circuits with a single
evaporator and, on YCSE models, a single condenser. Liquid line components include a service valve, a high
Units are completely factory assembled with all absorption filter dryer, a sight glass with moisture
interconnecting refrigerant piping and wiring ready for indicator and an electronic expansion valve.
field installation. The units are pressure tested,
evacuated, and fully factory charged with refrigerant Suction line components include an optional service
R407C and oil in each of the independent refrigerant and isolation valve.
circuits. After assembly, an operational test is
performed with water flowing through the evaporator Discharge line components include a check valve, an
and condenser (YCSE) to ensure that each refrigerant optional service and isolation valve and a pressure relief
circuit operates correctly. valve.
2.2 Compressor 2.4 Evaporator
The unit has suction cooled, semi-hermetic screw The evaporator is a stainless steel brazed type plate
compressors. The compressors incorporate twin-screw heat exchanger. The waterside design working
rotors and solenoid valves for continuous capacity pressure is 10 barg. The refrigerant side design working
control. The compressors are equipped with a built-in oil pressure is 18 bar g. The cooler is thermally insulated
separator, an oil sight glass, a crankcase oil heater and with flexible closed cell foam. Water connection to the
a suction filter. The compressors have a 2-pole motor evaporator is via victaulic-grooved connections. Flange
with over current and thermostat protection. Start / Delta connections are available as an option.
starting is provided as standard. All compressors are
mounted on isolator pads to reduce transmission of 2.5 Condenser (YCSE Only)
vibration to the rest of the unit.
The condenser is a stainless steel brazed type plate
Capacity Control heat exchanger. The waterside design working
pressure is 10 barg. The refrigerant side design working
For YCSE/YCRE units, the compressors will start at the pressure is 30 bar g. Water connection to the condenser
minimum load position and provide a capacity control is via victaulic-grooved connections. Flange
range from 15% to 100 % per compressor using a connections are available as an option.
continuous function slide valve.
2-1
035-21786-100 Rev. 1 (0909)
2.7 Accessories and Options
Modbus
1 2-Pole Motor
2 Built-in Oil Separator To integrate the unit into the building management
3 Twin Screw Rotors system. The interface permits the connection of up to 8
4 Oil Sight Glass units using the Modbus communications protocol. Refer
5 Oil Heater
to HARC Modbus data sheet (035-22384-000).
6 Suction Filter
Lonworks
2
To integrate the unit into the building management
system. The interface permits the connection of up to 8
units using the Lon communications protocol. Refer to
1
HARC Lonworks data sheet (035-22383-000).
Multi Unit Sequencer - CSC-5S
Provides individual control and monitoring for up to 8
3
units within the air conditioning system. This allows the
units to be managed remotely from the plant room.
4
6
5 Compressor Circuit Breakers
Circuit breakers to replace the standard fuses for
protection against over current. The breakers provide
more precise monitoring than fuses and easy reset after
fault.
2.6 Power and Control Panels
Differential Water Pressure Switch (es)
All power and controls are contained in an IP2X cabinet
with hinged and gasket sealed outer doors. Differential pressure switches between the water inlet
and outlets to ensure liquid flow during operation.
The power section includes
Flow Switch (es)
A factory mounted non-fused disconnect switch with
external handle to enable connection of the unit power Field installed flow switches to ensure liquid flow during
supply. The disconnect switch can be used to isolate the operation.
power for servicing.
Glycol Cooling
Factory mounted compressor contactors, fuses and
over current relays to provide overload and short circuit Factory set-up for applications requiring water outlet
protection. temperatures below 5°C: Category 1: Outlet
temperature 0 to 4°C; Category 2: Outlet temperature -1
The control section includes to - 5°C and Category 3: Outlet temperature - 6 to - 10°C.
The system must have the correct percentage of glycol
Four 7-segment LED display added. (Refer to glycol application factors)
Four push button switches Discharge and/or Suction Stop Valves
LED indicators for power, operation and alarm status Factory fitted valve(s) to allow refrigerant isolation
during servicing.
Customer terminal block for control inputs and liquid
flow switch connection Compressor Safety Valve(s)
Microprocessor boards to provide automatic operation Factory fitted single or dual compressor safety valve(s).
and accurate temperature control.
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035-21786-100 Rev. 1 (0909)
Dual Pressure Relief Valves AVM (Spring Isolators)
Two safety valves in parallel of which one is operational Spring and cage type isolators for mounting under the
to assist in valve replacement during maintenance. unit base rails to avoid transmission of vibration to the
plant room structure (supplied loose with unit for field
Suction Pressure Relief Valves assembly)
Additional pressure relief valve on suction side of Water Filter
compressor when required.
Field installed water filter at the cooler inlet to protect the
PN16 Flanges exchanger from excessive fouling.Wooden Crate
Welded PN16 flanges and companion flanges on the Special packing in a wooden crate to protect the chiller
water connections with gasket seals. from damages during transportation
AVM (Resilient Pads) Heat Pump Kit (YCSE only)
Rubber anti-vibration pads underneath the unit to avoid Capability to control the chiller based on the condenser
transmission of vibration to the plant room structure. leaving water temperature.
2.8 Nomenclature
YCSE100SB50B
1 2 3 4 5 6 7 7 8 9 10 11
BASE PRODUCT TYPE NOMINAL CAPACITY UNIT DESIGNATOR / REFRIGERANT VOLTAGE DESIGN SERIES
Y : York # # # kW S : Standard Unit 5 0 : 380-415 / 3 / 50 + N
C : Chiller Standard Units B : R407C Refrigerant B : Design Level
S : S = Screw :040 :050 :060
: R = Remote Air :080 :100
Cooled Screw
E : European
Refigerant Flow Diagram
YCSE
Low-pressure liquid refrigerant enters the cooler and is evaporated and superheated by the heat energy absorbed
from the chilled liquid passing through the cooler plates. Low-pressure vapour enters the compressors where
pressure and superheat are increased. High pressure superheated refrigerant enters the condenser where heat is
rejected to the condenser water passing through the plates. The fully condensed and subcooled liquid leaves the
condenser and enters the expansion valve, where pressure reduction and further cooling takes place. The
low-pressure liquid refrigerant then returns to the cooler.
YCRE
Low pressure liquid refrigerant enters the cooler and is evaporated and superheated by the heat energy absorbed
from the chilled water passing through the cooler plates. Low pressure vapour enters the compressor where
pressure and superheat are increased. Heat is rejected by the remote condenser. The fully condensed and
subcooled liquid refrigerant then enters the expansion valve where pressure reduction and further cooling takes
place before returning to the cooler.
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035-21786-100 Rev. 1 (0909)
2.9 Refrigerant Flow Diagram
YCSE 040, 050, 060, 100 Models
1 Compressor 16 Compressor Safety Valve (Option)
2 Check Valve 17 Compressor Dual Safety Valve (Option)
3 Pressure Relief Valve 18 Thermistor - Suction
4 Stop Valve (Option) 19 Thermistor - Discharge
5 Condenser 20 Thermistor - Evaporator
6 Stop Valve - Refrigerant Charge Point 21 Thermistor - Evaporator Water Inlet
7 Stop Valve 22 Thermistor - Evaporator Water Oulet
8 Drier 23 Thermistor - Evaporator Water Oulet
9 Sight Glass 24 Thermistor - Condenser Water Inlet (Option)
10 Electronic Expansion Valve 25 Thermistor - Condenser Water Outlet (Option)
11 Evaporator 26 Condenser Water Outlet
12 Stop Valve (Option) 27 Condenser Water Inlet
13 Low Pressure Sensor 28 Evaporator Water Inlet
14 High Pressure Switch 29 Evaporator Water Outlet
15 High Pressure Sensor
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035-21786-100 Rev. 1 (0909)
YCSE 080 Models
1 Compressor 18 Pressure Switch
2 Check Valve 19 Solenoid Valve
3 Pressure Relief Valve 20 Capillary Tube
4 Stop Valve (Option) 21 Economiser
5 Condenser 22 Strainer
6 Stop Valve - Refrigerant Charge Point 23 Thermistor - Suction
7 Stop Valve 24 Thermistor - Discharge
8 Drier 25 Thermistor - Evaporator
9 Sight Glass 26 Thermistor - Evaporator Water Inlet
10 Electronic Expansion Valve 27 Thermistor - Evaporator Water Oulet
11 Evaporator 28 Thermistor - Evaporator Water Oulet
12 Stop Valve (Option) 29 Thermistor - Condenser Water Inlet (Option)
13 Low Pressure Sensor 30 Thermistor - Condenser Water Outlet (Option)
14 High Pressure Switch 31 Condenser Water Outlet
15 High Pressure Sensor 32 Condenser Water Inlet
16 Compressor Safety Valve (Option) 33 Evaporator Water Inlet
17 Compressor Dual Safety Valve (Option) 34 Evaporator Water Outlet
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035-21786-100 Rev. 1 (0909)
YCRE 040, 050, 060, 080, 100 Models
1 Compressor 15 High Pressure Sensor
2 Stop Valve 16 Compressor Safety Valve (Option)
3 Check Valve 17 Compressor Dual Safety Valve (Option)
4 Pressure Relief Valve (Field Supplied) 18 Thermistor - Suction
5 Remote Condenser (Field Supplied) 19 Thermistor - Discharge
6 Stop Valve 20 Thermistor - Evaporator
7 Drier 21 Thermistor - Evaporator Water Inlet
8 Solenoid Valve 22 Thermistor - Evaporator Water Oulet
9 Sight Glass 23 Thermistor - Evaporator Water Oulet
10 Expansion Valve 24 Evaporator Water Inlet
11 Evaporator 25 Evaporator Water Outlet
12 Stop Valve (Option) 26 YCRE
13 Low Pressure Sensor 27 Field Supplied
14 High Pressure Switch
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035-21786-100 Rev. 1 (0909)
3 TRANSPORTATION, HANDLING AND 3.2 Inspection
STORAGE
Remove any transit packing and inspect the unit to
ensure that all components have been delivered and
3.1 Delivery and Storage that no damage has occurred during transit. If any
damage is evident, it should be noted on the shipment
To ensure consistent quality and maximum reliability, all documentation and a claim entered according to the
units are tested and inspected before leaving the instructions given.
factory. Units are shipped completely assembled and
containing refrigerant under pressure. Units are Major damage must be reported immediately to your
shipped without export crating unless this has been local Johnson Controls representative.
specified on the Sales Order.
3.3 Moving the Unit
If the unit is to be put into storage, before installation, the
following precautions should be observed: Before moving the unit, ensure that the installation site is
suitable for installing the unit and is capable of
Ensure that all openings, such as water connections, supporting the weight of the unit and all associated
are securely capped. services.
Do not store where exposed to ambient air The units are designed to be moved using either lifting
temperatures exceeding 42°C. chains or rollers .
The unit should be stored in a location where there is Lifting by Crane/Hoist
minimal activity to limit the risk of accidental physical
damage. Attach the lifting chains to the lifting lugs on each corner
of the unit framework. A spreader frame should be used
To prevent inadvertent operation of the pressure relief to prevent damage to the unit from the lifting chains.
devices the unit must not be steam cleaned.
The unit must only be lifted at the points
It is recommended that the unit is periodically inspected provided.
during storage.
1 60° (or more)
2 Power Section
3 4 x Rigging Bolts
4 Spreader Bars
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035-21786-100 Rev. 1 (0909)
Moving the Unit with Rollers To prevent the unit tipping over do not tilt the
unit more than 15°.
Use at least 6 equal sized rollers under the base frame.
Each roller must support both outer frames. Ensure the
unit is balanced evenly on all the rollers.
<15°
3.4 Lifting Weights
For details of weights and weight distribution refer to
Section 9.
3.5 Weight Distribution & Centre of Gravity
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035-21786-100 Rev. 1 (0909)
4 INSTALLATION transmitted vibration levels are required optional
anti-vibration isolators can be supplied loose for site
4.1 Location Requirements installation.
To achieve optimum performance and trouble-free 4.2 Installation of Vibration Isolators
service, it is essential that the proposed installation site
meets with the location and space requirements for the An optional set of spring and cage or rubber mat type
model being installed. For dimensions, weight and vibration isolators can be supplied loose with each unit.
space requirements, including service access details, Installation drawings are attached inside the power and
refer to Section 9. control panel.
The clearances recommended are nominal Only spring and cage or rubber mat type
for the safe operation and maintenance of the vibration isolators can be installed. Do not
unit and power and control panels. Local install both types of vibration isolator together.
health and safety regulations, or practical
considerations for service replacement of
large components, may require larger 4.3 Pipework Connection
clearances than those given in Section 9.
General Requirements
Units are designed for indoor installation and not
intended for wet, corrosive or explosive atmospheres. The following piping recommendations are intended to
Installation should allow for water drain, ventilation and ensure satisfactory operation of the unit. Failure to
sufficient clearance for service. follow these recommendations could cause damage to
the unit, or loss of performance, and may invalidate the
For installation in equipment rooms near noise-critical warranty.
areas, common walls should be of adequate sound
attenuating construction, all doors should be tightly The maximum flow rate and pressure drop for
gasketed, and the unit should have vibration isolators the cooler and condenser must not be
fitted. exceeded at any time.
Refer to Section 9 for details.
n The water must enter the heat exchangers by the
inlet connection. Refer to Section 9 for details.
n A flow switch must be installed in the customer
pipework at the outlet of the exchangers as shown
in the arrangement diagrams, and wired back to the
150 - 200 mm 150 - 200 mm
control panel using screened cable. For details
refer to “Electrical Connection”. This is to prevent
damage to the exchanges caused inadequate
liquid flow.
3 4 5 2 1 2 1
n The flow switch used must have gold plated
The unit must be installed on a suitable flat and level contacts for low voltage/current operation. Paddle
concrete base (2) that extends to fully support the unit type flow switches suitable for 10 barg working
base frame. pressure can be obtained from Johnson Controls
as an option for the unit.
On basement foundations remove a portion of the
basement floor (3) so that a concrete base can be n The liquid pump(s) installed in the pipework
poured resting on the ground (1) , with a corkboard (4) system(s) should discharge directly into the unit
installed on both sides, and a waterproof sealing heat exchanger section of the system. The
compound (5). pump(s) require an auto-starter (by others) to be
wired to the control panel. For details refer to
The concrete base must capable of supporting 150% of “Electrical Connection”.
the operating weight. In case of upper floors, the unit
and piping should be isolated from walls and ceiling. The
unit may be bolted to the foundation using 13 mm Ø
holes in the base of the framework. When lower
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035-21786-100 Rev. 1 (0909)
n Pipework and fittings must be separately Any debris left in the water pipework between
supported to prevent any loading on the heat the strainer and heat exchanger could cause
exchanger(s). Flexible connections are serious damage to the plates in the heat
recommended which will also minimise exchanger and must be avoided. The
transmission of vibrations to the building. Flexible installer/user must also ensure that the quality
connections must be used if the unit is mounted on of the water in circulation is adequate, without
anti-vibration mounts as some movement of the any dissolved gasses which can cause
unit can be expected in normal operation. oxidation of steel parts within the heat
exchanger(s).
n Pipework and fittings immediately next to the heat
exchangers should be readily de-mountable to 4.4 Water Treatment
enable cleaning prior to operation, and to facilitate
visual inspection of the exchanger nozzles. The unit performance given in the Design
Guide is based on a fouling factor of 0.044
n Each heat exchanger must be protected by a 20 m² °C/kW. Dirt, scale, grease and certain
mesh strainer, available as an option, fitted as types of water treatment will adversely affect
close as possible to the liquid inlet connection, and the heat exchanger surfaces and therefore
provided with a means of local isolation. unit performance. Foreign matter in the water
system(s) can increase the heat exchanger
n The heat exchanger(s) must not be exposed to pressure drop, reducing the flow rate and
flushing velocities or debris released during causing potential damage to the heat
flushing. It is recommended that a suitably sized exchanger plates.
by-pass and valve arrangement is installed to allow
flushing of the pipework system. The by-pass can Aerated, brackish or salt water is not recommended for
be used during maintenance to isolate the heat use in the water system(s). JCI recommend that a water
exchanger without disrupting flow to other units. Do treatment specialist is consulted to determine that the
not exceed heat exchanger design pressures proposed water composition will not affect the
during water side pressure tests. evaporator materials of stainless steel. The pH value of
the water flowing through the heat exchangers must be
n Thermometer and pressure gauge connections kept between 7 and 8.5. The total installed sytem
should be provided on the inlet and outlet including pumps, cooling coils, pipework, couplings and
connections of each heat exchanger. chiller should be assesed with regards to correct water
treatment. Poor or incorrect water treatment can lead to
n Drain and air vent connections should be provided warranty being avoided.
at all low and high points in the pipework to permit
drainage of the system, and to vent any air in the Glycol Solutions
pipes.
For unit operation with chilled liquid temperatures
n Liquid systems at risk of freezing, due to low leaving the cooler at below 5°C, glycol solutions should
ambient temperatures, should be protected using be used to help prevent freezing. Section 9, gives
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