| Вид документа | Інструкція |
|---|---|
| Виробник | JCI |
| Моделі | YK, K1-K7 |
| Група обладнання | other |
| Мова документа | англійська |
| Розмір файлу | 2.8 МБ |
Про документ
Factory-packaged single-stage centrifugal liquid chiller for cooling water or glycol solutions, primarily used in large air conditioning systems. The unit includes evaporator, condenser, compressor with open-drive motor, lubrication system and the OptiView graphic microprocessor control centre; refrigerant R134a and oil charges are supplied with the unit. Capacity is controlled by prerotation vanes at the impeller inlet, with optional Solid State Starter or Variable Speed Drive.
Ключові дані
| Refrigerant | R134a |
|---|---|
| Design working pressure water side | 1034 kPa DWP (water boxes tested at 1551 kPa) |
| Motor speed (50 Hz) | 2975 rpm |
| Nominal compressor oil charge | 75.7 litres of York "K" oil |
| Control panel supply | 115 V, 1 Ø, 50 Hz, 15 A (control transformer 2 kVA) |
| Solid State Starter voltage range | 380-600 volts, enclosure IP54 |
| Variable Speed Drive | 400V – 3-Ph – 60/50Hz |
| Indoor ambient range for location | 4.4°C to 43.3°C |
Застосування
- Cooling water or glycol solutions for air conditioning installations
- Large air conditioning systems; other applications per manual specification
Особливості
- OptiView graphic control centre with programmable timed start-ups/shutdowns and automatic displays
- Variable orifice refrigerant flow control with level sensor and microprocessor level setpoint control
- Emergency oil reservoir providing gravity lubrication during power failure shutdown
- Optional hot gas bypass to eliminate compressor surge
- Optional service isolation valves allowing refrigerant charge isolation in evaporator or condenser
- Compact or marine water box options; one-, two-, three-pass nozzle arrangements
- Factory anti-sweat thermal insulation available
Технічні дані
| Parameter | Value |
|---|---|
| Compressor type | Single-stage centrifugal, open-drive electric motor |
| Impeller | Cast aluminum, fully shrouded, dynamically balanced and over-speed tested |
| Shaft seal | Double bellows cartridge style with ceramic internal and atmospheric seal faces |
| Evaporator | Shell and tube, flooded type |
| Condenser | Shell and tube type with separate subcooler |
| Heat exchanger shells | Rolled carbon steel plates, fusion welded seams; internally enhanced tubes |
| Water box design working pressure | 1034 kPa (tested at 1551 kPa) |
| Drain/vent connections | Plugged ¾" in each water box |
| Refrigerant flow control | Variable orifice with condenser level sensor |
| Oil pump pre-lube period | 50 seconds before compressor start; runs 150 s after shutdown |
| Anti-recycle timer | 30 minutes after compressor starts |
| Oil heater control target | Oil temperature 27.7 °C above condenser saturation temperature (defaults 43.3–71 °C) |
| Oil heater thermostat cutout | Opens at 82°C |
| Discharge temperature limit (normal operation) | Should not exceed 104 °C |
| Current limit software function | 40% to 100% three-phase peak current limit |
| Refrigerant relief valves | Dual on evaporator shell and condenser shell |
| Vent line sizing standard | EN13136 or local code |
| Liquid head flange nut torque | Between 41 and 82 Nm |
| Clearances rear and above / front | 610 mm / 910 mm |
| Tube removal clearance | 4300 mm (4900–6700 mm depending on shell codes) |
| Unit levelling tolerance | Within 6 mm end to end and front to rear |
| Isolator pad deflection | Approximately 4 mm |
| Vacuum test criterion | Wet bulb ≤ 4.4°C or pressure ≤ 6.3 mm Hg after 8 hours hold |
| Evacuation endpoint | 0°C wet bulb or 5 mm Hg absolute |
| Freezing point pressure for R134a (water) | 58.9 kPa at sea level |
| Tube leak test pressure | 350 to 690 kPag nitrogen |
| Refrigerant occupational exposure limit | 1000 ppm v/v - 8 hr TWA |
| Refrigerant storage temperature | Not exceeding 45°C |
| Oil flash point | Over 300°C |
| Thermal/acoustic materials toxicity index | <10 to NES713 Issue 3 (1991): non-hazardous, non-toxic |
| Flammability rating (thermal/acoustic materials) | Class 1 to BS 476 pt 7 |
Допуски та стандарти
- EN ISO 9001 accredited design and manufacturing organisation
- Machinery Directive (98/37/EEC)
- Low Voltage Directive (2006/95/EC)
- EMC Directive (2004/108/EC)
- Pressure Equipment Directive (97/23/EEC)
- EN 60204 (service platform height conformity)
- EN13136 (refrigerant relief vent line sizing)
- NES713 Issue 3 (1991) toxicity index
Текст документа
YK - ALL MODELS
INSTALLATION, COMMISSIONING, REVISION 2 035-19569-101 (0109)
OPERATION AND MAINTENANCE
CENTRIFUGAL LIQUID CHILLER
STYLE G
R134A
035-19569-101 (0109)
Table of Contents
1 SUPPLIER INFORMATION 1-1 4 INSTALLATION 4-1
1.1 Introduction 1-1 4.1 Location 4-1
1.2 Warranty 1-1 4.2 Motors 4-1
1.3 Safety 1-1 4.3 Foundation 4-1
1.4 Responsibility for Safety 1-1 4.4 Clearances 4-1
1.5 About this Manual 1-2 4.5 Rigging Unit to Final Location 4-1
1.6 Misuse of Equipment 1-2 4.6 Locating and Installing Isolator Pads 4-1
1.8 Safety Labels 1-3 4.7 Installing Optional Spring Isolators 4-2
1.9 Material Safety Data 1-4 4.8 Piping Connections 4-2
4.9 Evaporator and Condenser Water Piping 4-2
2 PRODUCT DESCRIPTION 2-1
4.9.1 Chilled Water Circuit 4-5
2.1 General 2-1
4.9.2 Condenser Water Circuit 4-5
2.2 Capacity Control 2-2
4.10 Stop Valves 4-6
2.3 Compressor 2-3
4.11 Flow Switches 4-6
2.4 Compressor Lubrication System 2-3
4.12 Drain and Vent Valves 4-6
2.6 Graphic Control Centre (OptiView) 2-5
4.13 Checking Piping Circuits and Venting Air 4-6
2.7 Heat Exchangers 2-5
4.14 Refrigerant Relief Piping 4-6
2.8 Refrigerant Flow Control 2-6
4.15 Unit Piping 4-7
2.9 Options and Accessories 2-6
4.16 Control Panel Positioning 4-7
2.10 Nomenclature 2-7
4.17 Control Wiring 4-7
2.11 Range of Models 2-8
4.18 Power Wiring 4-7
4.19 Units with Solid State Starter or
3 TRANSPORTATION, RIGGING AND STORAGE 3-1 Variable Speed Drive 4-8
3.1 General 3-1 4.20 Thermal Insulation 4-8
3.2 Shipment 3-1 4.21 Installation Check 4-8
3.3 Inspection, Damage and Shortage 3-2
5 COMMISSIONING 5-1
3.4 Rigging 3-3
5.1 Preparation 5-1
5.2 First Time Start-up 5-2
GB I-i
035-19569-101 (0109)
6 OPERATION 6-1 9 TECHNICAL DATA 9-1
6.1 Oil Heater Operation 6-1 9.1 Dimensions 9-1
6.2 Checking the Oil Level in the Oil Reservoir 6-1 9.2 Dimensions -
Evaporator Compact Water Boxes 9-4
6.3 Start-up Procedure 6-1
9.3 Nozzle Arrangements -
6.4 Chiller Operation 6-4 Evaporator Compact Water Boxes 9-5
6.5 Operating Log Sheet 6-4 9.4 Dimensions -
Condenser Compact Water Boxes 9-7
6.7 Stopping the System 6-7
9.5 Nozzle Arrangements -
6.8 Prolonged Shutdown 6-7
Condenser Compact Water Boxes 9-8
6.9 Start-up after Prolonged Shutdown 6-7
9.6 Dimensions -
Evaporator Marine Water Boxes 9-9
7 MAINTENANCE 7-1 9.8 Nozzle Arrangements -
Evaporator Marine Water Boxes 9-10
7.1 Inspections 7-1
9.8 Dimensions -
7.2 Oil Return System 7-2 Condenser Marine Water Boxes 9-11
7.3 Oil Charge 7-3 9.8 Nozzle Arrangements -
Condenser Marine Water Boxes 9-12
7.4 Refrigerant Charge 7-3
9.9 Unit Weights 9-13
7.5 Condenser and Evaporator 7-5
9.10 Process and Instrumentation Diagram 9-15
7.6 Compressor 7-7
7.7 Compressor Motor 7-7
10 SPARE PARTS 10-1
7.8 Electrical Controls 7-8
7.9 Testing Motor Winding Insulation 7-8 11 DE-COMMISSIONING, DISMANTLING AND
DISPOSAL 11-1
8 TROUBLSHOOTING 8-1 11.1 General 11-1
I-ii GB
035-19569-101 (0109)
1 SUPPLIER INFORMATION
1.1 Introduction For warranty purposes, the following conditions must
be satisfied:
York YK chillers are manufactured to the highest design
and construction standards to ensure high performance, The initial start of the unit must be carried out by trained
reliability and adaptability to all types of air conditioning personnel from an Authorised York Service Centre.
installations.
Only genuine York approved spare parts, oils and
The units are intended for cooling water or glycol refrigerants must be used.
solutions and are not suitable for purposes other than
those specified in this manual. All the scheduled maintenance operations detailed in
this manual must be performed at the specified times
This manual and the Control System Operating by suitably trained and qualified personnel.
Instructions contain all the information required for correct
installation and commissioning of the unit, together with Failure to satisfy any of these conditions will automatically
operating and maintenance instructions. The manuals void the warranty.
should be read thoroughly before attempting to operate
or service the unit. 1.3 Safety
All procedures detailed in the manuals, including Standards for Safety
installation, commissioning and maintenance tasks
YK chillers are designed and built within an EN ISO 9001
must only be performed by suitably trained and qualified
accredited design and manufacturing organisation and,
personnel.
within the limits specified in this manual, are in conformity
with the essential health and safety requirements of the
The manufacturer will not be liable for any injury or
following European Union Directives:
damage caused by incorrect installation, commissioning,
operation or maintenance resulting from a failure to
Machinery Directive (98/37/EEC)
follow the procedures and instructions detailed in the
manuals.
Low Voltage Directive (2006/95/EC)
1.2 Warranty EMC Directive (2004/108/EC)
York International warrants all equipment and materials Pressure Equipment Directive (97/23/EEC)
against defects in workmanship and materials for one
year from initial start-up, or eighteen months from delivery 1.4 Responsibility for Safety
(whichever occurs first) unless extended warranty has
been agreed as part of the contract. Every care has been taken in the design and manufacture
of the units to ensure that they meet the safety
The warranty is limited to free replacement and shipping requirements listed in the previous paragraph. However,
of any faulty part, or sub-assembly which has failed due the individual operating or working on any machinery is
to poor quality or manufacturing errors. All claims must primarily responsible for:
be supported by evidence that the failure has occurred
within the warranty period, and that the unit has been ■ Personal safety, safety of other personnel, and the
operated within the designed parameters specified. machinery.
All warranty claims must specify the unit model, serial ■ Correct utilisation of the machinery in accordance
number and order number. with the procedures detailed in the manuals.
The unit warranty will be void if any modification to the The owner must comply with the Governmental
unit is carried out without prior written approval from Standards and Regulations for the commissioning and
York International. in-service inspections of the unit, in particular those
relating to pressure equipments.
GB 1-1
035-19569-101 (0109)
1.5 About this Manual Mechanical Strength
The unit is not designed to withstand loads or stresses
The following symbols are used in this document to alert
from adjacent equipment, pipework or structures.
the reader to areas of potential hazard.
Additional components must not be mounted on the unit.
Any such extraneous loads may cause structural failure
A Warning is given in this document to
and 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
WARNING be given, together with a brief explanation
and the possible result of ignoring the General Access
instruction. There are a number of areas and features which may
be a hazard and potentially cause injury when working
A Caution identifies a hazard which could lead with the unit unless suitable safety precautions are taken.
to damage to the machine, damage to other It is important to ensure access to the unit is restricted
equipment and/or environmental pollution. to suitably qualified persons who are familiar with the
CAUTION Usually an instruction will be given, together potential hazards and precautions necessary for safe
with a brief explanation and the possible result operation and maintenance of equipment containing
of ignoring the instruction. high temperatures, pressures and voltages.
A Note is used to highlight additional information Pressure Systems
which may be helpful to you but where there
are no special safety implications. The unit contains refrigerant vapour and liquid under
NOTE pressure, release of which can be a danger and cause
injury. The user should ensure that care is taken during
installation, operation and maintenance to avoid damage
The contents of this manual include suggested best to the pressure system. No attempt should be made
working practices and procedures. These are issued to gain access to the component parts of the pressure
for guidance only, they do not take precedence over system other than by suitably trained and qualified
the above stated individual responsibility and/or local personnel.
safety regulations.
Electrical
This manual and any other document supplied with
the unit, are the property of York which reserves all The unit must be earthed. No installation or maintenance
rights. They may not be reproduced, in whole or in part, work should be attempted on electrical equipment
without prior written authorisation from an Authorised without first switching off, isolating and locking-off the
York representative. power supplies. Work on live equipment must only be
carried-out by suitably trained and qualified personnel.
1.6 Misuse of Equipment No attempt should be made to gain access to inside of
the control panel, wiring or other electrical enclosures
Suitability for Application during normal operation of the unit.
The unit is intended for cooling water or glycol solutions
Rotating Parts
and is not suitable for purposes other than those
specified in these instructions. Any use of the equipment Motor air vent guards and drive coupling guards must
other than its intended use, or operation of the equipment be fitted at all times and not removed unless the main
contrary to the relevant procedures may result in injury power supply has been isolated.
to the operator, or damage to the equipment.
Refrigerants and Oils
The unit must not be operated outside the design limits
Refrigerants and oils used in the unit are generally
specified in this manual.
non-toxic, non-flammable and non-corrosive, and pose
no special safety hazards. Use of gloves and safety
Structural Support glasses are, however, recommended when working on
Structural support of the unit must be provided as the unit. Build up of refrigerant vapour, from a leak for
indicated in these instructions. Failure to provide proper example, does pose a risk of asphyxiation in confined or
support may result in injury to the operator, or damage enclosed spaces and attention should be given to good
to the equipment. ventilation. For more comprehensive information on
safety precautions for use of refrigerants and oils, refer
to the Materials Safety Data tables provided.
1-2 GB
035-19569-101 (0109)
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the
pressure relief device(s). Detergents and solvents which
may cause corrosion should also be avoided.
1.8 Safety Labels
The following labels are fixed to each unit to give
instruction, or to indicate potential hazards which may
exist.
White symbol on blue background
For safe operation, read the Instructions
first
Black symbol on yellow background
Warning: This machine may start
automatically without prior warning
Black symbol on yellow background
Warning: Hot surface
Black symbol on yellow background
Warning: Safety relief valve may discharge
gas or liquid without prior warning
Black symbol on yellow background
Warning: Isolate all electrical sources of
supply before opening or removing the
cover, as lethal voltages may exist
Black symbol on yellow background
General attention symbol
GB 1-3
035-19569-101 (0109)
1.9 Material Safety Data
Refrigerant Data:
Safety Data R134a
Toxicity Low.
In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous
by skin absorption. Thaw affected areas with water. Remove contaminated
clothing carefully — may adhere to skin in case of freeze burns. Wash
affected areas with plenty of warm water. If symptoms occur (irritation or
blistering) obtain medical attention.
In contact with eyes Vapour has no effect. 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 limits Recommended limit: 1000 ppm v/v - 8 hr TWA.
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 decomposition products Halogen acids by thermal decomposition and hydrolysis.
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, 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.
1-4 GB
035-19569-101 (0109)
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 equipment Self contained breathing apparatus and protective clothing must be worn
in fire conditions.
Refrigerant Oil Data
Safety Data York "K" Oil
Classification Non-hazardous
In contact with skin Minimally irritating. No first aid necessary. Exercise reasonable personal
cleanliness including cleansing exposed skin areas several times daily with
soap and water. Launder soiled work clothes at least weekly.
In contact with eyes Flush eyes with eyewash solution or clean water for 15 minutes and consult
a physician.
Ingested May cause nausea and diahorrhea. Obtain immediate medical attention.
Inhalation If oil mist is inhaled, remove to fresh air and consult a physician.
Occupational exposure limits Not determined.
Stability Stable but hygroscopic - store in sealed containers.
Conditions to avoid Strong oxidisers, caustic or acid solutions, excessive heat. May degrade
some paints and rubber materials.
Hazardous decomposition Not fully, Analogous compounds evolve carbon monoxide, carbon dioxide
and other unidentified fragments when burned. Burning may evolve irritating/
noxious fumes.
Respiratory protection Use in well ventilated areas - ventilate locally.
Protective clothing Goggles or face shield should be worn. Gloves not necessary, but
recommended, especially for prolonged exposure.
Spill / Leak procedure Wear suitable protective equipment. Especially goggles. Stop source of
spill. Use absorbent materials to soak up fluid (i.e. sand, sawdust and
commercially available materials).
Disposal Incinerate the oil and all associated wastes in an approved facility in
accordance with local laws and regulations governing oily wastes.
Fire extinguishing data Flash point over 300°C. Use dry chemical, carbon dioxide or foam. Spraying
water on hot or burning liquid may cause frothing or splashing.
If a leak or spill has not ignited use water spray to disperse the vapours and
to provided protection for persons attempting to stop the leak.
Containers Fire exposed containers should be kept cool with water sprays.
Fire fighting protective equipment Self contained breathing apparatus should be worn in fire conditions.
GB 1-5
035-19569-101 (0109)
Thermal & Acoustic Materials Data
Health Hazard & First Aid Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic.
No first aid necessary.
Stability / Reactivity Stable.
Handling / Use / Disposal No special handling precautions required. Dispose of according to local
laws and regulations governing non-biodegradable non-hazardous solid
wastes.
Fire & Explosion Flammability rating Class 1 to BS 476 pt 7: Non-flammable. If forced to
burn, combustion products are typically over 95% carbon dioxide and
carbon monoxide.
1-6 GB
035-19569-101 (0109)
2 PRODUCT DESCRIPTION
Figure 2.1 YK Centrifugal Liquid Chiller (Front View)
2.1 General (Figures 2.1 and 2.2) In operation, a liquid (water or brine to be chilled) flows
through the evaporator, where boiling refrigerant absorbs
The York YK Millennium™ Centrifugal Liquid Chiller is heat from the liquid. The chilled liquid is then piped to fan
primarily used for large air conditioning systems, but may coil units or other air conditioning terminal units, where
be used on other applications. The chiller is completely it flows through finned coils, absorbing heat from the
factory-packaged including evaporator, condenser, air. The warmed liquid is then returned to the chiller to
compressor, motor, lubrication system, graphic control complete the chilled liquid circuit.
centre (OptiView), and all interconnecting unit piping
and wiring. The initial charge of refrigerant and oil is The refrigerant vapour, which is produced by the boiling
supplied for each unit. action in the evaporator, flows to the compressor
where the rotating impeller increases its pressure and
The chiller is controlled by a modern state of the art temperature and discharges it into the condenser.
microprocessor control centre that monitors its operation. Water flowing through the condenser tubes absorbs
The control centre is programmed by the operator to suit heat from the refrigerant vapour, causing it to condense.
job specifications. Automatic timed start-ups and shut- The condenser water is supplied to the chiller from an
downs are also programmable to suit nighttime, week- external source, usually a cooling tower. The condensed
ends, and holidays. The operating status, temperatures, refrigerant drains from the condenser into the liquid
pressures, and other information pertinent to operation return line, where the variable orifice meters the flow
of the chiller are automatically displayed and read on of liquid refrigerant to the evaporator to complete the
a graphic display. Other displays can be observed by refrigerant circuit.
pressing the keys as labelled on the control centre.
The chiller with the graphic control centre (OptiView) is The major components of a chiller are selected to handle
compatible with an electro-mechanical starter, YORK the refrigerant, which would be evaporated at full load
Solid State Starter (optional), or Variable Speed Drive design conditions. However, most systems will be called
(optional). upon to deliver full load capacity for only a relatively small
part of the time the unit is in operation.
GB 2-1
035-19569-101 (0109)
2.2 Capacity Control (Figure 2.2)
The major components of a chiller are selected for full
load capacities, therefore capacity must be controlled
to maintain a constant chilled liquid temperature leaving
the evaporator. Prerotation vanes (PRV), located at the
entrance to the compressor impeller, compensate for
variation in load (See Detail A).
The position of these vanes is automatically controlled
through a lever arm attached to an electric motor
located outside the compressor housing. The automatic
adjustment of the vane position in effect provides the
performance of many different compressors to match
various load conditions from full load with vanes wide
open to minimum load with vanes completely closed.
Figure 2.2 YK Refrigerant Flow Diagram
2-2 GB
035-19569-101 (0109)
Figure 2.3 YK Centrifugal Liquid Chiller (Rear View)
2.3 Compressor 2.4 Compressor Lubrication System
(Figure 2.4)
The compressor is a single-stage centrifugal type
powered by an open-drive electric motor. The chiller lubrication system consists of the oil pump,
oil filter, oil cooler and all interconnecting oil piping and
The rotor assembly consists of a heat-treated alloy steel passages. The main points within the compressor which
drive shaft and impeller shaft with a cast aluminum, must be supplied with forced lubrication:
fully shrouded impeller. The impeller is designed for
balanced thrust and is dynamically balanced and over- 1. Compressor Drive Shaft (Low Speed)
speed tested.
a. Shaft seal.
The inserted type journal and thrust bearings are b. Front and rear journal bearings –
fabricated of aluminum alloy. Single helical gears with one on each side of driving gear.
crowned teeth are designed so that more than one tooth c. Low speed thrust bearing
is in contact at all times. Gears are integrally assembled (forward and reverse).
in the compressor rotor support and are film lubricated.
Each gear is individually mounted in its own journal and 2. Compressor Driven Shaft (High Speed)
thrust bearings.
a. Forward and reverse high speed thrust
The open-drive compressor shaft seal is a double bellows bearing.
cartridge style with ceramic internal and atmospheric
b. Two journal bearings.
seal faces. The seal is oil-flooded at all times and is
pressure-lubricated during operation.
3. Speed Increasing Gears
a. Meshing surfaces of drive and pinion gear
teeth.
GB 2-3
035-19569-101 (0109)
Figure 2.4 Compressor Lubrication System
2-4 GB
035-19569-101 (0109)
To provide the required amount of oil under the necessary a motor support.
pressure to properly lubricate these parts, a motor driven
submersible oil pump is located in a remote oil sump. Motor drive shaft is directly connected to the compressor
shaft with a flexible disc coupling. This coupling has
Upon pressing of the COMPRESSOR START switch on all metal construction with no wearing parts to assure
the control panel, the oil pump is immediately energized. long life, and no lubrication requirements to provide low
After a 50 second pre-lube period, the compressor motor maintenance.
will start. The oil pump will continue to run during the
entire operation of the compressor, and for 150 seconds For units utilising remote electro-mechanical starters,
during compressor shutdown. a terminal box is provided for field connected conduit.
Motor terminals are brought through the motor casing into
The submerged oil pump takes suction from the the terminal box. Jumpers are furnished for three-lead
surrounding oil and discharges it to the oil cooler where type of starting. Motor terminal lugs are not furnished.
heat is rejected. The oil flows from the oil cooler to the oil Overload/overcurrent transformers are furnished with
filter. The oil leaves the filter and flows to the emergency all units.
oil reservoir where it is distributed to the compressor
bearings. The oil lubricates the compressor rotating For units furnished with factory packaged Solid State
components and is returned to the oil sump. Starters, (optional) see Options Section.
There is an emergency oil reservoir located at the 2.6 Graphic Control Centre (OptiView)
highest point in the lubrication system internally in the
compressor. It provides an oil supply to the various The graphic control centre is factory-mounted, wired
bearings and gears in the event of a system shutdown and tested. The electronic panel automatically controls
due to power failure. The reservoir, located on the top of the operation of the unit in meeting system cooling
the compressor, allows the oil to be distributed through requirements while minimizing energy usage. For
the passages by gravity flow, thus providing necessary detailed information on the Graphic Control Centre, refer
lubrication during the compressor shutdown. to Form 160.54-O1
2.4.1 Oil Pump 2.7 Heat Exchangers
For normal operation, the oil pump should operate at all
Evaporator and condenser shells are fabricated from
times during chiller operation.
rolled carbon steel plates with fusion welded seams.
Heat exchanger tubes are internally enhanced type.
On shutdown of the system for any reason, the oil pump
operates and continues to run for 150 seconds. The
system cannot restart during that time interval.
2.7.1 Evaporator
The evaporator is a shell and tube, flooded type heat
2.4.2 Oil Heater exchanger. A distributor trough provides uniform
distribution of refrigerant over the entire shell length.
During long idle periods, the oil in the compressor oil
Stainless steel mesh eliminators or suction baffles
reservoir tends to absorb as much refrigerant as it can
are located above the tube bundle to prevent liquid
hold, depending upon the temperature of the oil and
refrigerant carryover into the compressor. A 2" liquid
the pressure in the reservoir. As the oil temperature
level sight glass is located on the side of the shell to aid
is lowered, the amount of refrigerant absorbed will be
in determining proper refrigerant charge. The evaporator
increased. If the quantity of refrigerant in the oil becomes
shell contains dual refrigerant relief valves.
excessive, violent oil foaming will result as the pressure
within the system is lowered on starting. This foaming is
caused by refrigerant boiling out of the oil as the pressure
2.7.2 Condenser
is lowered. If this foam reaches the oil pump suction, the The condenser is a shell and tube type, with a discharge
bearing oil pressure will fluctuate with possible temporary gas baffle to prevent direct high velocity impingement
loss of lubrication, causing the oil pressure safety cutout on the tubes. A separate subcooler is located in the
to actuate and stop the system (Refer to Control Centre condenser to enhance performance. Dual refrigerant
Manual 160.54.OI). relief valves are located on condenser shells with
optional isolation refrigerant isolation valves.
2.5 Compressor Motor
The compressor motor is an open-drip-proof, squirrel
2.7.3 Water Boxes
cage, induction type constructed to York design The removable compact water boxes are fabricated of
specifications, 50 hertz motors operate at 2975 rpm. steel. The design working pressure is 1034 kPa and the
boxes are tested at 1551 kPa. Integral steel water baffles
The open motor is provided with a D-flange, cast iron provide the required pass arrangements.
adapter mounted to the compressor and supported by
GB 2-5
035-19569-101 (0109)
Stub-out water nozzle connections with Victaulic grooves 2.9 Options and Accessories
are welded to the water boxes. These nozzle connections
are suitable for Victaulic couplings, welding or flanges, 2.9.1 Service Isolation Valves
and are capped for shipment. Plugged ¾" drain and vent
If the chiller is equipped with optional service isolation
connections are provided in each water box.
valves on the discharge and liquid line, these valves
must remain open during operation. These valves are
2.8 Refrigerant Flow Control
used for isolating the refrigerant charge in either the
evaporator or condenser to allow service access to the
Refrigerant flow to the evaporator is controlled by a
system. A refrigerant pump-out unit will be required to
variable orifice.
isolate the refrigerant.
A level sensor senses the refrigerant level in the condenser
Isolation of the refrigerant in this system must be
and outputs an analog voltage to the microprocessor
performed by a qualified service technician.
that represents this level (0% = empty; 100% = full).
Under program control, the microprocessor modulates
2.9.2 Hot Gas Bypass
a variable orifice to control the condenser refrigerant
level to a programmed setpoint. Other setpoints affect Hot gas bypass is optional and is used to eliminate
the control sensitivity and response. These setpoints compressor surge during light load or high head
must be entered at chiller commissioning by a qualified operation. The control panel will automatically modulate
service technician. Only a qualified service technician the hot gas valve open and closed as required.
may modify these settings. Adjustment of the hot gas control valve must be
performed by a qualified service technician following
While the chiller is shut down, the orifice will be in the Hot Gas Set-up procedure.
the fully open position causing the sensed level to be
approximately 0%. When the chiller is started, after the Changes in chilled water flow will require re-adjustment
vane motor end switch (VMS) opens when entering of the hot gas control to insure proper operation.
SYSTEM RUN, if actual level is less than the level
setpoint, a linearly increasing ramp is applied to the 2.9.3 Solid State Starter
level setpoint. This ramp causes the setpoint to go from
The optional Solid State Starter is a reduced voltage
the initial refrigerant level (approximately 0%) to the
starter that controls and maintains a constant current
programmed setpoint over a period of 15 minutes.
flow to the motor during start-up. It is mounted on the
chiller. Power and control wiring between the starter and
If the actual level is greater than the setpoint when the
chiller are factory installed. Available for 380-600 volts,
VMS opens, there is no pulldown period, it immediately
the starter enclosure is IP54 with a hinged access door
begins to control to the programmed setpoint.
with lock and key. Electrical lugs for incoming power
wiring are provided.
While the chiller is running, the refrigerant level is
normally controlled to the level setpoint. However,
anytime the vanes fully close (VMS closes), normal
2.9.4 Variable Speed Drive
level control is terminated, any refrigerant level setpoint An optional 400V – 3-Ph – 60/50Hz Variable Speed Drive
pulldown in effect is cancelled and the outputs to the level can be factory packaged with the chiller. It is designed to
control will be opposite that which is supplied to the vane vary the compressor motor speed and pre-rotation vane
motor (i.e., when a close pulse is applied to the vane position by controlling the frequency and voltage of the
motor, an open pulse is applied to the level control, etc.). electrical power to the motor. Operational information
When the VMS opens, if the refrigerant level is less than is contained in Form 160.00-O1 (VSD 658 HP and 900
the level setpoint, a refrigerant level setpoint pulldown HP) or 160.00-O4 (VSD OptiSpeed 292 HP and 419
is initiated as described above. Otherwise, the level is HP). The control logic automatically adjusts motor speed
controlled to the programmed setpoint. and compressor pre-rotation vane position for maximum
part load efficiency by analysing information fed to it by
sensors located throughout the chiller.
The VSD eliminates the need for a starter and has a
soft starting characteristic that never exceeds 100%
full load amps. It also provides automatic power factor
correction.
An optional harmonic filter limits electrical power supply
distortion from the variable speed drive and further
improves power factor correction.
2-6 GB
035-19569-101 (0109)
2.10 Nomenclature
YK ER ER Q7 5 CS G S
Model Special Modifications
Evaporator Code Design Level
Condenser Code Motor Code
Compressor Code Power Supply (5 for 50 Hz)
GB 2-7
035-19569-101 (0109)
2.11 Range of Models
COMPRESSOR EVAPORATOR CONDENSER
MOTOR CODES
CODE CODE CODE
Q3 AP to AS AP to AS
CP to CS CP to CS
Q3, Q4 5CC-5CO
DP to DS DP to DS
Q4 EP to ET EP to ET
CP to CS CP to CS
Q5
DP to DS DP to DS
5CE-5CO
EP to ET EP to ET
Q5, Q6, Q7
FQ to FT FQ to FT
EP to ET EP to ET
P7 5CP-5CU
FQ to FT FQ to FT
P8 GQ to GS EV to EX
HQ to HS FV to FX
5CE-5CU
P8, P9 JP to JS JP to JS
LQ to LS LQ to LS
KP to KS, K2 to K4 KP to KS, K2 to K4
H9 5CK-5CW
MQ to MS, M2 to M4 MQ to MS, M2 to M4
K1 KT to KX, K5 to K7 KP to KS, K2 to K4
MQ to MS, M2 to M4 MQ to MS, M2 to M4
NQ to NS, N2 to N4 NP to NS, N2 to N4 5CN-5DC
K1, K2
PQ to PS, P2 to P4 PQ to PS, P2 to P4
QQ to QS, Q2 to Q4 QQ to QS, Q2 to Q4
NQ to NS, N2 to N4 NP to NS, N2 to N4
K3 QQ to QS, Q2 to Q4 QQ to QS, Q2 to Q4 5DA-5DH
RQ, RS, RV, R3, R5, R7 RQ to RS, R2 to R4
RP, RR, RT, R2, R4, R6 RQ to RS, R2 to R4
SQ to SS, S2 to S4
SQ, SS, SV, S3, S5, S7
K4 VP to VS, V2 to V5 5DA-5DJ
TP to TS, T2 to T5
XQ to XS, X2 to X4
XQ to XS, X2 to X4
WP to WT, W2, W4, W6 WQ to WS, W1 to W4
K7 5DD-5DL
ZQ to ZS, Z1 to Z4 ZQ to ZS, Z1 to Z4
2-8 GB
035-19569-101 (0109)
3 TRANSPORTATION, RIGGING AND STORAGE
3.1 General 8. Do not run hot water (40°C maximum.) or steam
through the evaporator or condenser at any time.
YK units are shipped as a single factory assembled,
piped, wired package, requiring minimum installation 3.2 Shipment
to make chilled water connections, condenser water
connections, refrigerant atmospheric relief connections, The chiller may be ordered and shipped in any of the
and electrical power connections. following forms:
Refrigerant and oil charges are shipped separately Form 1 – Factory Assembled Unit (complete with
(unless optional condenser isolation valves are motor, refrigerant and oil charges)
ordered).
1. The motor/compressor assembly mounted, with
Chillers can also be shipped dismantled when required all necessary interconnecting piping assembled.
by rigging conditions, but generally it is more economical Graphic control centre (OptiView) is mounted on the
to enlarge access openings to accommodate the factory unit. Complete unit factory leak tested, evacuated
assembled unit. Chillers shipped dismantled MUST and charged with R134a.
be field assembled under the supervision of a York
representative. An optional Solid State Starter or Variable Speed
Drive can be factory mounted and wired.
FIELD ASSEMBLED UNITS ONLY
2. Miscellaneous material – Four (4) vibration isolation
Use Form 160.73-N3 in conjunction with this manual. pads (or optional spring isolators and brackets).
This instruction will be furnished with all units that are to
be field assembled. Extra copies may be ordered from Form 2 – Factory Assembled Unit (complete with
the York Publication Distribution Centre. motor, refrigerant and oil charges shipped separately).
A York authorised representative must check the 1. The motor/compressor assembly mounted, with
installation, supervise the initial start-up and operation all necessary interconnecting piping assembled.
of all newly installed chillers. Graphic control centre (OptiView) is mounted on the
unit. Complete unit factory leak tested, evacuated
The York Warranty may be voided if the and charged with holding charge of nitrogen.
following restrictions are not adhered to:
An optional Solid State Starter or Variable Speed
CAUTION Drive can be factory mounted and wired.
2. Miscellaneous material – Four (4) vibration isolation
1. No valves or connections should be opened under
pads (or optional spring isolators and brackets).
any circumstances because such action will result in
loss of the factory nitrogen charge.
Form 3 – Driveline Separate From Shells
2. Do not dismantle or open the chiller for any
Shipped as three major assemblies. Unit first
reason except under the supervision of a York
factory assembled, refrigerant piped, wired and leak
representative.
tested; then dismantled for shipment. Compressor/
motor assembly removed from shells and skidded.
3. When units are shipped dismantled, notify the nearest
Evaporator/condenser shells are not skidded.
York office in ample time for a York representative
to supervise rigging the unit to its operating position
All compressor wiring attached, and all conduit is left
and the assembly of components.
on shell. All openings on compressor, oil separator,
and shell are closed and charged with dry nitrogen
4. Do not make final power supply connections to the
(1.4 to 2 kPag).
compressor motor or control centre.
Miscellaneous packaging of control centre, tubing,
5. Do not charge the compressor with oil.
water temperature controls, wiring, oil, isolators, solid
state starter (option), etc.; refrigerant charge shipped
6. Do not charge the unit with refrigerant.
separately.
7. Do not attempt to start the system.
GB 3-1
035-19569-101 (0109)
Units shipped dismantled MUST be re- 3.3 Inspection, Damage and Shortage
assembled by, or under the supervision of, a
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