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    YAEP - Manuals

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    YAEP HIGH AMBIENT AIR COOLED LIQUID CHILLER INSTALLATION, COMMISSIONING, OPERATION AND MAINTENANCE STYLE A REFRIGERANT TYPE: R22, R407C MODELS: 50 Hz SOFTWARE: 2 Refrigerant Circuit Models - V4-2 REV 7 and V4C-2 REV 7 and Higher 4 Refrigerant Circuit Models - V4-4 REV 7 and V4C-4 REV 7 and Higher i YORK EMEA [stern YORK INTERNATIONAL (02/04) (GB 1 SUPPLIER INFORMATION 14 12 13 14 15 16 17 18 19 Introduction Warranty Satety Responsibilty for Safety ‘About this Manual Misuse of Equipment Emergency Shutdown Safoty Labols Matorial Safoty Data 2 PRODUCT DESCRIPTION 2a 22 23 24 25 26 27 28 29 Introduction Compressors Coolers) ‘Air Cooled Condensers Refrigerant Circuits Power and Control Panels ‘Options and Accessories Functional Description Nomenclature 3 TRANSPORTATION, HANDLING AND STORAGE 34 32 33 34 35 (2108 Delivery and Storage Inspection on Arial at Site Moving the Chiller Liting Weights Shipping Protection YORK 1 14 14 12 12 12 13 14 18 24 22 22 22 22 22 23 25 26 34 34 34 a2 a2 4 Table of Contents 0351.02537-100 Rev. 0 INSTALLATION 4.1 Location Requirements, 4a 42. Location Clearances 42 43. Vibration Isolator Installation & Dimensions. 4.2 44 Pipework Connection 42 45 Water Treatment 43 46 Pipework Arrangement 4a 47 Connection Types & Sizes 4a 48 Rottigorant Roliot Valve Piping 48 49 Ductwork Connection 48 4.10 Electrical Connection 46 4.11 Power Wiring 46 4.12 Control Section - Output Signals. 47 4.19 Control Section - Input Connections 4a COMMISSIONING 5.1. Preparation 5A 5.2. First Time Start-up 53 UNIT OPERATION 6.1 General Description et 62 Start-up et 63 Normal Running and Cycling et 6.4 Compressor Capacity Control 62 65. Discharge Pressure Fan Control 62 66 Shutdown 62 ce ii osstozss71o0Rev0 «6g YORK" 7 MAINTENANCE 10. SPARE PARTS 71 General Requirements 74 10.1 Recommended Spares 10.4 7.2 Dally Maintenance 71 102 Compressor Top Head Rebuild Kit 102 7.3 Scheduled Maintonanco 72 103 Assoctatod Drawings 102 74 "Wessels in-Sorvica Inspacton 72 41 DE-COMMISSIONING, DISMANTLING 8 TROUBLE SHOOTING AND DISPOSAL 81 Compotont Persons Troublo Th General ms Shooting Guide 84 82 Compressor Components 83 83 Sensor Calibration Charts aa 9 TECHNICAL DATA ot Flow Rate/Pressure Drop Charts ou 9.2 Operating Limitations ou 9:3 Physical Data - R22 Modols 92 9.4 Physical Data - RA07C Modols as 9.5 Electrical Data - R22 Modols a4 9.6 Electrical Data - R407C Models 94 9.7 Control Circuit Electrical Data 95 9.8 Compressor Electrical Data - R22 Models 9s 9.9 Compressor Electrical Data - RAO7C Models 05 9.40 Fan Data 05 9.11 Fuse Ratings and Lug Sizes 96 9.12 Clearances o7 9.18Dimensions9.8 GBD (2104) YORK 1 SUPPLIER INFORMATION 1.1 Introduction High ambient YAEP models will be built to good engineering practices and are completely assembled with all interconnecting refrigerant piping and internal wiring, ready for field installation. Four circuit units are shipped in two sections and require the installation of a two wire communication link between control panels and a mixed leaving liquid temperature sensor. ‘The YAEP range of chillers are designed for water chilling. All units are designed to be located outside on the roof of a building or at ground level and are not suitable for purposes other than those specified in this ‘manual. This manual and the Operating Instructions for the micro based control system contain all the information required for correct installation and commissioning of the unit, together with operating and maintenance instructions. The manuals should be read thoroughly before attempting to operate or service the unit. All procedures detailed in the manuals, including installation, commissioning and maintenance tasks must only be performed by suitably trained and qualified personnel. The manufacturer will not be liable for any injury or damage caused by incorrect installation, commissioning, operation or maintenance resulting from a failure to follow the procedures and instructions detailedin the manuals. All data in this manuals subject to change without notice. 1.2. Warranty York International Limited warrants all equipment and materials against defects in workmanship and materials for a period of one year from initia start-up, or eighteen months from delivery (whichever occurs first) unless extended warranty has been agreed as part of the contract, ‘The warranty is limited to free replacement and shipping of any faulty part, or sub-assembly which has failed due to poor quality or manufacturing errors. All claims must be supported by evidence that the failure has occurred within the warranty period, and that the unit has been operated within the designed parameters specified. All warranty claims must specify the unit model, serial number and order number. These details are printed on the unit identification plate. (2108 14 0351.02537-100 Rev. 0 The unit warranty will be void if any modification to the Unit is carried out without prior written approval from York International For warranty purposes, the following conditions must be satisfied ‘The initial start of the unit must be cartied out by trained personnel from an Authorised York Service Centre. Only genuine York approved spare parts, oils and refrigerants must be used. To obtain York spare parts ‘contact your local York office, Details of York offices are iven on the rear cover of this manual All the scheduled maintenance operations detailed in this manual must be performed at the specified times by suitably trained and qualified personne. Failure to satisty any of these conditions will automatically void the warranty. 13° Safety Standards for Safety YAEP units are designed and built within an EN ISO 9001 accredited design and manufacturing organisation, Units will conform to the applicable essential safety requirements of Pressure Equipment Directive 97/23/EC and bear CE marking and are in conformity with the essential health and safety requirements of the following European Union Directives: Machinery Directive (89/392/EEC) Low Voltage Directive (78/23/EEC) EMC Directive (89/336/EEC) Unless otherwise stated for cortain options. a 1-2 0351.02537-100 Rev. 0 1.4 Responsibility for Safety Every care has been taken in the design and manufacture of York Chillers to ensure that they meet the safety requirements listed in the previous paragraph. However, the individual operating or working on any machinery is primarily responsible for: Personal safety, safety of other personnel, and the machinery Correct utilisation of the machinery in accordance with the procedures detailed in this manual 4.5. About this Manual The following symbols are used in this documentto alert the reader to areas of potential hazard, ‘A Waring is given in this document to identify a hazard which could lead to personal injury, Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the instruction. is ‘A Caution identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation and the possible result of ignoring the instruction, ae] A Note is used to highlight additional information which may be helpful to you but where there are no safety implications. WS) The contents of this manual include suggested best working practices and procedures. These are issued for guidance only, they do not take precedence over the above stated individual responsibility and/or local safety regulations. This manual and any other document supplied with the unit, are the property of YORK which reserves all rights They may not be reproduced, in whole or in part, without prior written authorisation from an authorised YORK representative. YORK 1.6 Misuse of Equipment ‘Suitability for Application ‘The unit is intended for cooling water ands not suitable for purposes other than those specified in these instructions. Any use of the equipment other than its intended use, or operation of the equipment contrary to the relevant ‘procedures may result in injury to the ‘operator, or damage to the equipment. The unit must not be operated outside the design parameters specified in this manual. Structural Support Structural support of the unit must be provided as indicated in these instructions. Failure to provide proper ‘support may result in injury to the operator, or damage to the equipment. Mechanical Strength The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or structures. ‘Additional components must not be mounted on the unit. ‘Any such extraneous loads may cause structural failure and may resultin injury to the operator, or damage to the ‘equipment. The unit should only be lifted in accordance with the instructions given in Section 3 of this manual General Access ‘There are a number of areas and features which may be hazard and potentially cause injury when working with the unitunless suitable safety precautions are taken. itis 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 operation and maintenance of equipment containing high and low temperatures, pressures and voltages. Pressure Systems Each unit has two, three or four independent pressure systems comprising the compressor, air cooled condenser coils, cooler vessel and interconnecting copper pipework. Each system contains refrigerant vapour and liquid under 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 to the pressure system. No attempt should be made to gain access to the ‘component parts of the pressure system other than by suitably trained and qualified personnel. (2108) YORK Electrical The unit must be earthed. No installation or maintenance work should be attempted on electrical equipment without first switching off, isolating and locking-off the main power supply and any control supplies. Work on live equipment must only be carried-out by suitably trained and qualified personnel. No attempt should be made to gain access to internals ‘of the control panel, wiring or other electrical enclosures during normal operation of the ut Rotating Parts Fan guards must be fited at all times and not removed unless the main power supply has been isolated. If ductwork is to be fitted, requiring the wire fan guards to be removed, alternative safety measures must be taken to protect against the risk of injury from rotating fans, Sharp Edges The finning on the air cooled condenser coils has sharp metal edges. Reasonable care should be taken when working in contact with the coils to avoid the risk of minor abrasions and lacerations. The use of gloves is recommended. Refrigerants and Oils Refrigerants and oils used in the unit are generally non-toxic, non-flammable and non-corrosive, and pose no special safety hazards. Use of gloves and safety glasses are, however, recommended when working on the unit. Build up of refrigerant vapour, from a leak for example, does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good ventilation. For more comprehensive information on safety precautions for use of refrigerants and oils, refer to the Materials Safety Data tables provided. 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. (2108 o3sL02537-100Rev.0 1-3 1.7 Emergency Shutdown In case of emergency the control panel is fited with an emergency stop switch which, when operated, removes the electrical supply from the control system and the microprocessor controller. A facility is available to connect a remote emergency stop device for the same purpose, The emergency stop switch can be pad-locked in the off position. PADLOCK Four circuit units have a main panel and a auxiliary panel. In case of emergency each panel, main and auxiliary has its own emergency stop switch which can be identified as red in colour and sited on a yellow back-plate. Both emergency stop switches can be pad-locked in the off position. The device on the main panel when operated, stops systems 1 and 2 only. 1&2V 3&4x Fabio AA facility is available in the main panel to connect a remote emergency stop device to stop systems 1 and2, a 1-4 0351.02537-100 Rev. 0 g@YORK The device on the auxiliary panel when operated, stops Black symbol on yellow systems 3 and 4 only. background Warning: Safety relief valve may discharge gas or liquid without prior waming 1&2x Black symbol on yellow BRAY background puto Waring: Isolate all electrical Feo sources of supply before ‘opening or removing the cover, as lethal voltages may exist A facility is available in the auxiliary panel to connect a ses may remote emergency stop device to stop systems and 4, 1.8 Safety Labels Black symbol on yellow background The following labels are fixed to each unit to give instruction, or to indicate potential hazards which may General attention symbol 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 Warming: Hot surface >>O CGB) (02/04) 15 YORK 0351.02537-100 Rev. 0 1.9 Material Safety Data Refrigerant Data: Safety Data R22 Rao7¢ Toxicity Low. In contact with skin In contact with eyes Ingested Inhalation Further medical advice Long term exposure Occupational exposure limits Stability Liquid splashes or spray may cause freeze bums. Unlikely to be hazardous by skin absorption. R22 may be slightly irritant and liquid has a degreasing effect. Thaw affected areas with water. Remove contaminated clothing carefully - may adhere to skin in case of freeze bums. Wash affected areas with plenty of warm water. If symptoms occur (initation or blistering) obtain medical attention. Vapour has no effect. Liquid splashes or spray may cause freeze bums. Immediately irrigate with eyewash solution or clean water for at least 10 minutes. Obtain immediate medical attention. Highly unlikely to occur-but should this occur freeze burn will occur. Do notinduce vomiting. Provided patient is conscious, wash mouth with water and give about 250 mi (0.5 pint) to drink. Obtain immediate medical attention. R407C High —_ atmospheric concentrations may lead anaesthetic R22 High levels of vapour concentration initially produce stimulation and then depression of the central nervous system causing headaches and giddiness and may lead to unconsciousness. Can prove suddenly effect, including loss of consciousness. Very high exposures may cause an abnormal heart rhythm and prove suddenly fatal. fatal if the exposure has been severe. Athigher concentration there is a danger from asphyxiation due toreduced 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. ‘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 arhythmias and subsequent arrest following exposure to high concentrations. R22 A lifetime inhalation study in rats and mice give a small excess in salivary gland tumours in male rats only at 50,000 ppm. 10,000 ppm showed no effect. This information suggests that R22 does not represent a carcinogenic hazard to humans. R22 Recommended limit : 1000 ppm viv = 8 hr TWA 1250 ppm viv - 12 hr TWA. R22 Unstable. R407C A lifetime inhalation study in rats has shown that exposure to 50,000 ppm resulted in benign tumours of the testis. This isnot considered to be of relevance tohumans exposed to concentrations at or below the occupational exposure limit. R407¢ Recommended limit: 1000 ppm viv 8hr TWA. R407C Not specified Conditions to avoid Hazardous reactions Use in presence of naked flames, red hot surfaces and high moisture levels. May react violently with sodium, potassium, barium and other alkali and alkaline earth metals. Incompatible materials : Magnesium andalloys containing more then 2% magnesium. (2108 a 1-6 035L02537-100 Rev. 0 iMYORK Hazardous decomposition products General precautions R22 Halogen acids formed by thermal | R407C Halogen acids by thermal | decomposition. decomposition and hydrolysis. 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 vapours 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 wom. This should be seff contained or of the long breather | pe Storage Protective clothing Spillleak procedure Disposal Fire extinguishing data Containers @ fighting protective equipment Refrigerant Oil Data Safety Data Classitication In contact with skin 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. | Wear overalls, impervious gloves and goggles/face protection, Ensure suitable personal protective clothing and respiratory protection is worn Provided itis safe to do so, isolate the source of the leak. Allow small spillages to evaporate provided there is suitable ventilation, Large spillages : Ventilate area. Contain spillages 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. 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. R22 Non-flammable R407C Non-flammable at atmospheric conditions. Fire exposed containers should be kept cool with water sprays. Containers may burst if overheated. Self contained breathing apparatus and protective clothing must be worn in fire conditions. [York “C” Oil York “H” Oil Non-hazardous 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: Ingested Inhalation Occupational exposure limits As with most foreign materials flush with | Flush eyes with eyewash solution or plenty of eyewash solution or clean | clean water for 15 minutes and consulta water. physician, Non-toxic. No first aid considered | May cause nausea and diahorrhea necessary. Obtain immediate medical attention. If oil mist is inhaled, remove to fresh air and consult a physician. Recommended imit : 5 mg/cubic metre | Not determined, of oil mist in air for 8 hr daily exposure. (2104) Stability Conditions to avoid Hazardous decomposition Respiratory protection Protective clothing Spill / Leak procedure Disposal Fire extinguishing data Containers GIYORK —cxsicassz-toonevo0 = 1-7 Stable. Stable but hygroscopic -store in sealed | containers. None Specified. Strong oxidisers, caustic or acid solutions, excessive heat. May degrade some paints and rubber materials. Oxides of carbon, aldehydes and | Notfully. Analogous compounds evolve ketones, combustion products of carbon monoxide, carbon dioxide and nitrogen, sulphur. other unidentified fragments when burned, Burning fluid may evolve initatingnoxious fumes. Use in well ventilated areas. Use in well ventilated areas - ventilate locally Not necessary but goggles or face Goggles or face shield should be worn. shield recommended. Gloves not necessary, but recommended, especially forprolonged exposure. 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) Incinerate the oil and all associated wastes in an approved facilty in accordance With local laws and regulations governing olly wastes. Flash point over 180°C. Use water | Flash point over 300°C. Use dry spray, dry chemical, carbon dioxide or | chemical, carbon dioxide or foam. alcohol foam. Water or foam may cause | Spraying water on hot or burning liquid, frothing may cause frothing or splashing, If a leak or spill has not ignited use water spray to disperse the vapours and to provide protection for persons attempting to stop the leak. Fire exposed contair rs should be kept cool with water sprays. Fire fighting protective equipment Self contained breathing apparatus should be worn in fire conditions, Thermal & Acoustic Materials Data Health Hazard & First Aid Toxicity Index <10 to NES719 Issue 3 (1991) : Non-hazardous, non-toxic. No first aid necessary. Stability / Reactivity Handling / Use / Disposal Fire & Explosion Stable. 'No special handling precautions required. Dispose of according to local laws and regulations governing non-biodegradable non-hazardous solid wastes, 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. (2108 @ 1-8 | osstozss7-1o0Rev.0 =x YORK’ Page Lett Intentionally Blank (2104) ZIYORK ss 35102537-100 Rev. 0 2 PRODUCT DESCRIPTION 2.1 Introduction York YAEP high ambient air cooled liquid chillers are designed for water cooling. Units are available with one, two or four refrigerant circuits. ‘One and two refrigerant circuit units have one and two compressors and a cooler mounted on a single base with a single power and control panel mounted at the end of the unit Four refrigerant circuit units are constructed in two sections each having two compressors and a cooler. Four circuit units have a main power and control panel ‘mounted at one end of the unit and an auxiliary power and control panel mounted at the other end of the unit. Four circuit units require the installation of a two wire communication fink between control panels anda mixed leaving liquid temperature sensor. a4 All models are designed to be located outside on the roof of a building or at ground level. All models are delivered completely assembled with allinterconnecting refrigerant piping and internal wiring, ready for field installation Prior to delivery each unit is pressure tested, evacuated and fully charged with refrigerant, and includes an initial oil charge. After assembly a full run test is performed with water flowing through the cooler to verify that each refrigeration circuit operates correctly The unit base and framework are fabricated using heavy-gauge galvanised steel which is zinc phosphate pre-treated and powder coated to minimise corrosion. ‘Sorap view of unit with optional Acoustic Enclosure ‘and optional Sun Shield kt fitted KEY 1 Condenser Fan 5 Compressor 2 Condonsor 6 Powor and Control Panel 3 Cooler ‘(with optional Sun Shiold Kit ited) 4 Filter Drier (2108 22 (0351.02537-100 Rev. 0 2.2 Compressors Each unit is fitted with one, two or four semi-hermetic, reciprocating compressors. The compressor motors are refrigerant gas cooled, with integral temperature sensing solid state overload protection in each phase. The motor terminal boxes are manufactured to prevent ingress of dust and water to IPS4. Starting is by part-winding Compressor Hou 1g The compressor housing is cast iron. It contains: removable cylinder heads with internal muffling, discharge service valve, optional suction service valve (when ordered), crankcase sight glass and heater, oil and suction strainers, and internal relief valve conforming to ASHRAE/ANSI Standard 15 Safety Code. Compressor Lubrication The lubrication is force-fed by a reversible oil pump which supplies oil to all crankshaft and bearing surfaces through a fine mesh stainless stee! filter. Capacity Control Capacity control is provided by solenoid-actuated capacity control valves, controlled by the Micro Based Control System. 2.3. Cooler(s) The single/multi-circuit cooler is the direct- expansion type, with the refrigerant in the tubes and chilled liquid flowing through the battled shell The design working pressure of the shell is 10.3 bar g, and 16.2 bar g for the tube side. The refrigerant side is constructed and tested in accordance with CE/PED pressure vessel code requirements. ASME pressure vessels are available on two and four refrigerant circuit models. The water battles are constructed of galvanised steel to resist corrosion. The removable heads allow access to the internally enhanced, seamless, copper tubes. Vent and drain connections are included. Standard cooler connections are Vietaulic nozzles, The cooler is covered with 19mm flexible, closed-cell, UV stable, colour co-ordinated foam insulation. Each Circuit is protected by a relief valve. YORK 2.4 Air Cooled Condensers Coils The condenser coils are manufactured from seamless copper tubes arranged in staggered rows, mechanically expanded into fins. Integral subcooling is included. Fans ‘The condenser fans are UV. stable polypropylene, high efficiency, airfoil'type fan blades directly driven by independent motors, and positioned for vertical air discharge. The fan guards are constructed of heavy-gauge wire hot dipped galvanized coated steel. After construction the fan deck and cow! are hot dipped galvanized prior to assembly. (Colour co-ordinated paint finish is available as an extra). All blades are dynamically and statically balanced for vibration-free operation, The fan motors are fully enclosed. The motor bearings are double sealed and are permanently lubricated. 2.5 Refrigerant Circuits Unit piping is ACR copper with brazed joints. The liquid line includes: a shut off valve with charging port, sightglass with moisture-indicator, thermal expansion valve (direct acting, max-operating pressure). solenoid valve, and filer drier. The entire suction line, the liquid line between the expansion valve and the cooler, are insulated with flexible, closed-cell, foam insulation. ‘Compressor low, high and oil pressure transducers plus manual high pressure cut-outs are located on the ‘compressor and system pipework. Transducers and cut-outs have Econoseal all weather electrical connections. 2.6 Power and Control Panels All controls and motor starting equipment necessary for {ull unit operation are factory wired and function tested ‘Components are mounted on galvanised steel back plates, and enclosed in the relevant power, common input or control sections of the galvanised steel enclosure. Separate doors are provided for each section. All doors are hinged, lockable with door stays and are designed to IP55 weather protection. Enclosure and doors are finished in zinc phosphate pre-treated baked enamel coloured Desert Sand Four circuit units have a main and auxiliary power and control panel mounted at each end of the unit. (2104) YORK Each Power Section Contains: Partwind compressor starting contactors, system fuses, fan contactors, fan ‘manual motor starters and control interface relays (CE Compliant), The Common Input Section Contains: Non-fused disconnect switch for customer single point power supply connection. Transformer and wiring to allow contol voltage tobe internally derived (CE Compliant). The Control Section Contains: microprocessor board, power supply board and relay board. The relay board contains the control circuit serving compressor solenoids, crankcase heaters and compressor and fan contactor ot Controls ‘The microprocessor based control system is capable of multi-circuit control to maintain chilled liquid temperature. Compressor starting/stopping and loading/ unloading decisions are performed by the microprocessor to maintain leaving water temperature. ‘These decisions are a function of temperature deviation from setpoint and rate of change of temperature. The 40 character display (2 lines of 20 characters) allows the operator to display system operating parameters as well as access programmed information already in memory. ‘The keypad is provided for programming and accessing setpoints, pressures, temperatures, motor current, cut-outs, daily schedule, options and fault information. Remote cycling, unloading and chilled water temperature reset can be accomplished by voltage tree customer contacts, (2108 23 0351.02537-100 Rev. 0 2.7 Options and Accessories Single Point Power Supply Option - Per Panel Customer single point power supply connection to factory fitted terminal block. Internal wiring to fuses in each power section (Not CE Compliant). Multi Point Power Supply Terminal Block Option - Per Circuit Customer supply connection to terminal block in power section. A separate control supply is required to the control circuit switch disconnect (Not CE Compliant). Multi Point Power Supply Fuse Block Option - Per Circuit Customer supply connection to terminal block in power section. A separate control supply is required to the control circuit switch disconnect (Not CE Compliant). Cable Spreader Box To separate cores of large multi-core cable before connection to non-fused disconnect switch’terminal block when Single Point Power Supply is specified. Multi-unit Sequence Control A separate sequencing control centre to manage sequencing control of up to eight chillers in parallel based on mixed leaving liquid temperature (mounting {and interconnection/wiring by others). (Cannot be fitted when a (BAS) Interface is fitted). See separate York documentation, Building Automation System (BAS) / Energy Management System (EMS) Interface Provides a means to reset the leaving chilled liquid temperature from a BAS/EMS. Consists of a factory mounted PCB to accept 4to20mA, 0 to 10 Vde, or dry contact closure input from the BAS/EMS. (Cannot be fitted when a Multi-unit Sequence Control is fitted) Micro Gateway Interface to enable communication with building control systems using BACnet and MODBUS protocols. See separate York documentation. York Talk Translator Provides central communication with third party BMS for monitoring and control of all chillers in the system. See separate York documentation. a 24 (0351.02537-100 Rev. 0 Condenser Coil Fin Protection Gold Epoxy Coated Aluminium Condenser Fins Offers corrosion resistance in mild coastal locations (ASTM 287" Test, after 1500 hours 7% weight loss). Copper Fin Condenser Ci Condenser coils are constructed with copper fins (ASTM 287" Test, after 1500 hours 17% weight loss). * ASTM 287 tests are based on Industrial / Coastal locations. Wire Panel Enclosure Consists of welded-wire-mesh guards mounted on the exterior of the unit. Prevents unauthorized access, yet provides free air flow. Fan Deck Paint Finish Paint finish for fan cowl and fan deck in Desert Sand (RAL1019). Cooler Coolers constructed in accordance with ASME pressure code requirements are available. This option includes a single relief valve, Not available for single refrigerant circuit models, Handed Evaporator ‘Simplifies unit layout and water connection enabling the chillers to be placed in the best orientation to suite the site compound. Double Thickness Insulation The cooler is covered with 38 mm flexible, UV-stable colour co-ordinated closed-cell, foam insulation for added frost protection. Cooler Flange Factory fitted flanges on cooler water connections to 1,S.0. R2084-NP10. Available in Weld or Victaulic Adaptor. Companion Flange Kit Weld/Victaulic Adaptor flanges to match cooler flange kit ISO 7005-1 PN10 supplied loose for field installation by contractor. Includes all necessary nuts, bolts, gaskets, etc. YORK Flow Switch Switch with 1 inch IPS thread suitable for 10 bar g DWP. and having gold contacts for low voltage/ current, to protect unit from loss of water flow. flow switch must be furnished with each unit for field installation by contractor. Added Compressor Capacity Step (Units with 6 and 8 cylinder compressors only) ‘The compressor control system is programmed with an additional capacity step to improve part load performance. This option includes compressor liquid injection cooling. Low Ambient Kit This accessory is factory fitted and includes all necessary components to allow chiller operation down to -18°C condenser intake ait. ‘Sun Shield Kit Sun shield kit to provide shade / air gap around the power and control panels to prevent overheating due to solar gain on applications above 38°C ambient, Unit Aesthetic Panels Non acoustically lined infill panels manufactured trom powder painted galvanised steel to cover the ends of the ‘condenser coil on the opposite end to the control panel. Acoustic Enclosure A four sided acoustically treated enclosure fitted around the compressors and refrigerant pipework below the condenser coils to reduce sound emissions, ‘Suction Service Valves ‘One ball valve per compressor in the low pressure (Suction) pipework. Mechanical Gauge Kit Factory fitted mechanical dial gauges for discharge, suction and oil pressure indication in addition to transducer pressure display, Anti-Vibration Mounts ‘Open spring isolator mounts with levelling screws and fixing down holes, supplied loose for field installation by contractor. Lifting Lug kit ‘One set of ISO Mk5 cam locs to enable safe and easy unit handling, (2108) HIYORK: 3 sioossriconevo | 25 2.8 Functional Description Condenser Coil Refrigerant Circuit No 2 Condenser Coil Refrigerant Circuit No 1 High Pressure + superheated vapour Compressor Fusible Optional Plug) High presoure ssub-cooled liquid | Fitter Drier Low pressure sub-cooled liquid/vapour 4 Refrigerant Circuit No 2 Low pressure liquid/vapour refrigerant enters the cooler and is evaporated and superheated by the heat energy absorbed from the chilled water passing through the cooler shell. Low pressure vapour enters the compressor where pressure and superheat are increased. Heat is rejected via the air cooled condenser coil and fans. 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. (2108 2.6 | ossiozss7-toonev.0 ©6=s/] YORK” 2.9 Nomenclature YAEPOOXDEBSOPA 12 10 Typical Unit Label MODEL YAEPS@XO7A50PA SERIALNo. [#e eee e ORDER No. [##¥e** UNIT DESIGN HIGH [450] Psig LOW [295] Psig REFRIGERANT A- [9070] WORKING PRESS. 37] Bar g ez] Berg — VOLTS PHASE Hz WIRE UNIT SUPPLY asora00 [3 ][s0} Ls VOLTAGE LIMIT ATTERMINALS Max [40] win [342 VOLTS-PHASE-Hz AMPS MAX FUSE SIZE MAX OPERATING MAX UNIT CONTROL SUPPLY : = - FUSE CHARGE SYSTEM NOMINAL MAXIMUM Siz kg AMPS SYSTEM COMPRESSOR = Kw AMPS = KW. AMps__| PW JINRUSH @34av 1 PCBET 113 | [20006 | [135 ] [28527 eearas | 365 ][ 65ka | [265 2 PoasT 113] [_ 2007196] [195] [~ 2asre07 0072s |{ 266 |[ eka | [205 EACH FAN MOTOR 22 | 8758 [zs.1/25.q)LRA TOTAL No. OF MOTORS |_@ COMMON SUPPLY INPUT. == MAX AMPS@342v capacity contro. [16 INTERNATIONAL umm (2104) YORK 3 TRANSPORTATION, HANDLING AND STORAGE 3.1 Deli ry and Storage To ensure consistent quality and maximum reliability, each YAEP is tested and inspected before leaving the factory. Two and three refrigerant circuit units are shipped as completely assembled units containing refrigerant under pressure. Four refrigerant circuit units ate shipped in two parts. It the chiller is to be put into storage, prior to installation, the following precautions should be observed: Ensure that all openings, such as water connections, are securely capped. Do not store where exposed to ambient air temperatures exceeding §2°C The finned heat exchangers should be covered to protect the fins from potential damage and corrosion, Particularly where building work is in progress. The unit should be stored in a location where there is minimal activity in order to limit the risk of accidental physical damage. To prevent inadvertent operation of the pressure relief devices the unit must not be steam cleaned. It is recommended that the control panel keys are removed and deposited with a responsible person on-site. Itis recommended that the unitis periodically inspected during storage to ensure refrigerant pressures are present and to identify any damage that may have ‘occurred and repair as necessary. 3.2 Inspection on Arrival at Site Inspect the unitto ensure that all components have been delivered and that no damage has occurred during transit. f any damage is evident, it should be noted on the carrier's freight bill and a claim entered in accordance with the instructions given on the advice note. Major damage must immediately be reported to your local York representative. (2108 3-4 0351.02537-100 Rev. 0 3.3. Moving the Chiller Units are designed to be lifted using lifting lugs and cables. A spreader bar or frame 2.4 metres wide should be used in order to prevent damage to the unit from the lifting chains: 3.2 (0351.02537-100 Rev. 0 ‘CORRECT INCORRECT 9 LUPTING HOLE wer FLANGE, LOCKING PIN LUFTING HOLE = LOCKING PIV IN BASE FRANE Locking PIN FLANGE ‘The unit must only be lifted by the base frame at the points provided. Never move the unit on rollers, or lift the unit, using a forklift truck, Care should be taken to avoid damaging the ‘condenser cooling fins when moving the unit OE) WE! We Prior to moving the chiller ensure that the installation site is suitable for installing the unit, and is capable of supporting the weight of the unit and all associated services. YORK 3.4 Lifting Weights For details of weights and weight distribution refer to section 9. 3.5 Shipping Protection When commissioning the unit remove the wooden condenser coil protection panels which are hung off the top of the unit and secured by self-tapping bolts along the base. To prevent condenser coil damage York recommend that the condenser coil protection panels are refitted after commissioning until the units ready for operation. Ensure the condenser coil protection panels, are removed prior to operation. A cures (2104) YORK 4 INSTALLATION 4.1 Location Requirements To achieve optimum performance and trouble-free service, itis essential that the proposed installation site ‘meets with the location and space requirements for the model being installed. For dimensions, weight and space requirements, including service access details, refer to Section 9. It is important to ensure that the minimum service access space is maintained for cleaning and ‘maintenance purposes. The unit should not be installed directly on flammable materials, such as wooden structures or roof's. (DE Outdoor Installations Units can be installed at ground level, or on a suitable rooftop location. In both cases an adequate supply of air is required. Avoid locations where the sound output and air discharge from the unit may be objectionable. The location should be selected for minimum sun exposure and away from boiler flues and other sources of aitborne chemicals that could attack the condenser coils and steel parts of the unit. Itlocated in an area which is accessible to unauthorised persons, steps must be taken to prevent access to the Unit by means of a protective fence. This will help to prevent the possibilty of vandalism, accidental damage, or possible harm caused by unauthorised removal of protective guards or opening panels to expose rotating jh voltage components. For ground locations, the unit must be installed on a suitable flat and level concrete base that extends to fully support the two side channels of the unit base frame. A ‘one-piece conorete slab, with footings extending below the frost line is recommended. (2108 44 0351.02537-100 Rev. 0 On rooftop locations, choose a place with adequate structural strength to safely support the entire operating ‘weight of the unit and service personnel. The unit canbe mounted on a concrete slab, similar to ground floor locations, or on steel channels of suitable strength. To avoid noise and vibration transmission the unit should not be secured to the building foundation. Channels should be spaced at the same centres as the vibration mounting holes in the unit base frame and must be at least 120 mm wide at the contact points. This will allow vibration isolators to be fited if required. Standard units are fitted with multi-blade cooling fans. Any ductwork or attenuators fitted to the unit must not have a total static pressure resistance, at full unit airflow, exceeding the capability of the fans installed in the unit. Refer to Section 9. Indoor Installations The unit can be installed in an enclosed plant room providing the floor is level and of suitable strength to support the full operating weight of the unit and service Personnel. It is essential that there is adequate clearance for airflow to the unit. The discharge air from the top of the unit must be ducted away to prevent recirculation of air within the plant room. If common ducts are used for fans, non-return dampers must be fitted to the outlet from each fan. Common ducts should not be used on a four fan unit fited with the optional low ambient kit as these units use fans in the reverse direction in some modes of operation ‘The discharge ducting must be properly sized with a {otal static pressure loss, together with any intake static pressure loss, less than the available static pressure ‘capability for the type of fan fitted. For details referto the details provided in "Outdoor Installations" and Section 9. The discharge air duct usually rejects outside the building through a louvre. The outlet must be positioned to prevent the air being drawn directly back into the air intake for the condenser coils as such recirculation will affect unit performance. a 42 (0351.02537-100 Rev. 0 4.2 Location Clearances (refer to Section 9) Clearances around the unit(s) are required for the unrestricted access of airflow onto the air-cooled condenser coils and to prevent recirculation of warm discharge air back onto the coils. If clearance dimensions are not maintained, airflow restriction or recirculation will cause a loss of unit performance, an increase in power consumption and may cause the unit to malfunction. Consideration should also be given to the possibility of down draughts, caused by adjacent buildings, which may cause recirculation or uneven unit airflow. For locations where significant cross winds are expected, such as exposed roof tops, an enclosure of solid or louvre type is recommended to prevent wind turbulence interfering with the unit airflow. When units are installed in an enclosure, the enclosure height should not exceed the height of the unit. If the enclosure is of louvred construction the same requirement of static pressure loss applies as for ducts and attenuators stated in Section 9. Where accumulation of snow is likely, additional height mustbe provided under the unit to ensure normal airiow to the unit. YD je The clearance dimensions given are necessary to maintain good airflow and ensure correct unit operation. It is also necessary to consider access requirements for safe operation and maintenance of the unit and control panel (600 mm wide doors). Local health and safety regulations, ot practical considerations for service replacement of large components, may require larger clearances than those given below. Dimension to louvred wall assumes 60% imum free area. For louvres of less free area use dimensions for solid walls. D & Pressure drop through louvred walls must not exceed available extemal static pressure capability for the type of fans fitted. YORK 4.3 Vibration Isolator Installation & Dimensions. When ordered, an optional set of spring type vibration isolators will be supplied loose with each unit. = Using the Isolator tables (in Section 9), identity ‘each mount and its correct location on the unit. = Place each mount in its correct position and lower the unit carefully onto the mounts ensuring the locating pin on top of each mount engages in the mounting holes in the unit base frame. m= Transfer the unit weight evenly to the springs by turing the mount adjusting nuts (located just below the top plate of the mount) ‘counter-clockwise to raise and clockwise to lower, This should be done two tums ata time unti the top plates of all mounts are between 6 mm and 13 mm clear of top of their housing and the unit base is level 4.4 Pipework Connection General Requirements ‘The following piping recommendations are intended to ensure satisfactory operation of the unit(s). Failure to follow these recommendations could cause damage to the unit, or loss of performance, and may invalidate the warranty. A coe m= The water must enter the heat exchanger(s) by the inlet connection. The inlet connection for the cooler is at the same end as the refrigerant pipework connections. ‘The maximum flow rate and pressure drop for the cooler must not be exceeded at any time. Reter to Section 9 for details. = A flow switch must be installed in the customer pipework at the outlet of the heat exchanger(s) as shown in the arrangement diagrams, and wired back to the control panel using screened cable. For details refer to “Electrical Connection”. This is to prevent damage to the heat exchanger(s) caused by the unit operating without adequate liquid flow. The flow switch used must have gold plated contacts for low voltage/current operation. Paddle type flow switches suitable for 10 barg working pressure and having 1" N.P.T. connection can be ‘obtained from York as an accessory for the unit, Altematively a differential pressure switch sited across an orifice plate may be used, preferably of the highvlow limit type. (2104) YORK The liquid pump(s) installed in the pipework system(s) should discharge directly into the unit heat exchanger section of the system. The pump(s) may be controlled external to the unit- but an override must be wired to the control panel so that the unit can start the pump in the event that the liquid or ambient temperature falls below the ‘minimum setting. This ensures that the optional heater mat and low temperature pump circulation is ‘enabled. When the unit is not operational, power supplies should be maintained to the unit to allow the automatic frost protection to operate. In addition, the poweris used to ensure the automatic pumpdown system is functioning. For details refer to “Electrical Connection” = Pipework and fittings must be separately supported to prevent any loading on the heat exchanger(s). Flexible connections are recommended which will also minimise transmission of vibrations to the building. Flexible connections must be used ifthe unit is mounted on anti-vibration mounts as some movement of the Unit can be expected in normal operation. = Pipework and fittings immediately adjacent to the heat exchangers should be readily de-mountable to enable cleaning prior to operation, and to facilitate visual inspection of the exchanger nozzles. = Each heat exchanger must be protected by a strainer, preferably of 30 mesh, fitted as close as possible tothe liquidinlet connection, and provided with a means of local isolation. = The heat exchanger(s) must not be exposed to flushing velocities or debris released during flushing. It is recommended that a suitably sized by-pass and valve arrangement is installed to allow ‘lushing of the pipework system. The by-pass can be used during maintenance to isolate the heat ‘exchanger without disrupting flow to other units. = Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each heat exchanger. Drain and air vent connections should be provided at all low and high points in the pipework to permit drainage of the system, and to vent any air in the pipes. (2108 43 0351.02537-100 Rev. 0 m= Liquid systems at risk of freezing, due to low ambient temperatures, should be protected using insulation and heater tape and/or a suitable glycol solution. The liquid pump(s) must also be used to ensure liquid is circulated when the ambient temperature approaches freezing point. Insulation should also be installed around the heat exchanger nozzles. Heater tape of 21 watts per metre under the insulation is recommended, supplied independently and controlled by an ambient temperature thermostat set to switch on at 3°C above the freezing temperature of the liquid = The chilled liquid circulation pump must be controlled to ensure that when the liquid temperature falls within 2 or 3°C of freezing the pump will start ‘Any debris left in the water pipework between the strainer and heat exchanger could cause serious damage to the tubes in the heat exchanger and must be avoided. The installer/user must also ensure that the quality, of the water in circulation is adequate, without any dissolved gasses which can cause oxidation of steel parts within the heat exchanger(s).. A 4.5 Water Treatment Tho unit porformance given in the Design Guido is based on a fouling factor of 0.044 m* °C/KWW (0.00025 ‘fthrF/Btu). Dirt, scale, grease and certain types of water treatment will adversely affect the heat exchanger surfaces and therefore unitperformance. Foreign matter in the water system(s) can increase the heat exchanger pressure drop, reducing the flow rate and causing potential damage to the heat exchanger tubes. ‘Aerated, brackish or salt water is not recommended for use in the water system(s). York recommend that a water treatment specialist is consulted to determine that the proposed water composition will not affect the evaporator materials of carbon steel and copper. The pH value of the water flowing through the heat exchangers must be kept between 7 and 8.5 a 44 (035L02537-100 Rev. 0 4.6 Pipework Arrangement The following are suggested pipework arrangements for single unit installations. For multiple unit installations, each unit should be piped as shown, Recommendations of the Building Services Research Association Chilled Water System - 2 Circuit Units D Chilled Water System - Four Circuit Units Oye a ii $f mp ler 2) (Cooler 1 Cc eel, KEY Isolating Valve - 4 conmallyopen > tt sare: " leatingVabe= Opes tapping Flow regulating valve 1 Fiow swich Flow measurement 4} Flanged connection Mixed Leaving Water Temperature Sensor & YORK 4.7 Connection Types & Sizes For connection and nozzle sizes relevant to individual units, refer to the product drawings in Section 9, Cooler Connections ‘Standard chilled liquid connections on all coolers are of the Vietaulic Groove type. Standard Victaulic A.B if joo _ c L T Optionally, one of two types of flanges may be fitted depending on the customer or local Pressure Vessel Code requirements. These are Vic-Adapter flanges, normally supplied loose, or weld flanges which may be supplied loose or ready fitted. Vic-Adapter and weld flange dimensions are to ISO R2084 NP10. Dimensions are as follows: Optional Flanges N S ale at le WELD FLANGE VIC-ADAPTOR FLANGE eso “a0 fee was enon) = aber wed (2104) YORK 4.8 Refrigerant Relief Valve Piping Coolers are protected against internal refrigerant overpressure and fire by refrigerant relief valves. The pressure relief valve is set at design pressure of the system and has discharge capacity required by relevant standard. For coolers, a pressure relief valve is mounted on each of the main refrigerant lines connecting the cooler to the compressors. York fit a piace of pipe to each valve and direct it so that when the valve is activated the release of high pressure {gas and liquid cannot be a danger or cause injury. For indoor installations pressure relief valves should be piped to the exterior of the building, The size of any pipework attached to a relief valve must be of sufficient diameter so as notto cause resistance to the operation of the valve, Unless otherwise specified by local regulations, the minimum allowable internal diameter depends on the length of pipe required and is given by the following formula: DP= 1.487 xL Where: D = minimum pipe internal diameter in centimetres L= length of pipe in metres Precautions should be taken to ensure the exit of relief valves/vent pipe remain clear of obstructions at all times. 4.9 Ductwork Connection General Requirements The following ductwork recommendations are intended to ensure satisfactory operation of the unit(s). Failure to follow these recommendations could cause damage to the unit, or loss of performance, and may invalidate the warranty. | When ductingis to be fitted to the fan discharge itis recommended that the duct should be the same ‘ross sectional area as the fan outlet and straight foratleast one metre in order to obtain static regain from the fan. = Ductwork should be suspended with flexible hangers to prevent noise and vibration being transmitted to the structure. A flexible joint is also recommended between the duct attached to the fan and the next section for the same reason. Flexible connectors should not be allowed to concertina. (2108 45 0351.02537-100 Rev. 0 = The unit is not designed to take structural loading, No significant amount of weight should be allowed torest on the fan outlet flange, deck assemblies or ‘condenser coil module(s). No more than one metre of ight construction ductwork should be supported by the unit. Where cross winds may occur, any ductwork must be supported to prevent side loading on the unit. Fan discharge ducts should be secured together with tie rods to prevent excessive movement. mI the ducts from two or more fans are to be ‘combined into a common duct, back-flow dampers should be fitted in the individual fan duets. This will prevent recirculation of air when only one of the fans is running. Common ducts should not be used ona four fan unit fitted with the optional low ambient kitas these units use fans inthe reverse direction in some modes of operation. = Units are supplied with outlet side guards for safety and to prevent damage to the fan blades. If these guards are removed to fit ductwork, adequate alternative precautions must be taken to ensure persons cannot be harmed or put at risk from rotating fan blades. Connection Details and Dimensions Fan Code 7 ‘pp rimge Fan Code 9 Tepringe ia —a=esS Z 7) anny A Mion @ 46 (0351.02537-100 Rev. 0 4.10. Electrical Connection The following connection recommendations are intended to ensure safe and satisfactory operation of the unit(s). Failure to follow these recommendations could cause harm to persons, or damage to the unit, and may invalidate the warranty. No additional controls (relays, etc.) should be mounted in any section of the control panel. Power and control wiring not connected to the Control Panel should not, be run through the Control Panel. ifthe: precautions are not followed it could lead to a risk of electrocution. In addition, electrical noise could cause malfunctions, ‘or damage the unit and its controls. After connection do not switch on mains power to the unit, Some internal ‘components are live as soon as mains is, ‘switched on, and this mustonly bedone by authorised persons. for = The unit OFFION switch on the front of the control panel has been sealed in the OFF position at the factory. This seal must remain in place preventing running of the unit until commissioned by authorised personnel. If the seal has been removed before commissioning then it must be reported to the Basildon Factory Quality Manager otherwise warranty may be invalidated 4.11, Power Wiring A cama) All electrical wiring should be carried out in accordance with local regulations. Route properly sized cables (based on installation conditions and currents given in electrical data tables) to site drilled holes in the Control Panel gland plate as specified below. ‘YAEP units require an electrical power supply of 380 V, 400 V or 415 V, 30, 50 Hz Minimum allowable voltage 342 V. Maximum allowable voltage 440 V. In accordance with EN 60204 it is the responsibilty of the user to install overcurrent protection devices between the supply conductors and the customer input supply terminals on the unit YORK To ensure that no eddy currents are set up in the metal gland plate the cables forming each 3 phase power supply must enter via the same hole in the gland plate. If separate entries for each cable forming the 3 phase supplies are used, the metal gland plate must be replaced by a non-metallic gland plate, with due regard iven to sealing the panel to IPSS. A (cs Single Point Power Supply - Disconnect Switch (CE) ‘or Terminal Block Option (Non CE) (Refer to Power Supply Connection Diagram) All sources of supply to the unit must be taken via a common point of isolation (not supplied by York). Each panel (master and auxiliary, if fitted) requires a 3 phase separately fused supply plus earth to be ‘connected to the common input section of the power and control panel. The cables should enter the common input section via the site drilled gland plate on the bottom of the section. Connect each phase to the disconnect switch/terminal block located in the common input section using the lug sizes detailed in Section 9, Connect the earth wire to the main protective earth terminal located in the common input section of the control panel using an M10 lug. Multi Point Power Supply Option (Non CE) (Refer to Power Supply Connection Diagram) Each refrigerant system requires a 3 phase separately fused supply plus earth to be connected to each power section of the power and control panel. A separate fused 2 phase control transformer supply plus earth is required for the main and auxiliary (4 Circuit Units) panels. Each set of supply cables per system should enter via the site drilled gland plate in the bottom of the applicable power section. The supplies can then be routed to their respective input terminals on the compressor contactors. Connect each phase to the compressor contactors using the lug sizes detailed in Section 9. Connect the earth wire to the main protective earth terminal of the applicable power section, using an M4 lug Connect the two phase control transformer supply to the input of the emergency stopisolation device in the applicable common input section with bare wire ends of maximum cable size 4 mm, Also connect an earth wire {o the protective earth terminal using an M4 lug. (2108) YORK Units with Optional Cable Spreader Box Under the common input section of the control panelis a cable spreader box which should be used to separate the cores of large multi-core cable prior to connection to the terminal block/disconnect switch. Remote Emergency Stop Device If required, a remote emergency stop device can be wired to terminals 9 and 4 in the main and auxiliary control panels (located in the common input section). The existing link must first be removed. This device should be rated at 10 amps, 230V, AC-16. Terminals 3 and 4 are in a circuit protected by a 10 amp class gG fuse 4.12. Control Section - Output Signals (Refer to Control Connection Diagram) All wiring to the control section (relay board) output contacts requires a supply, maximum 254 V, provided by the customer. The customer must take particular care deriving the supplies for the output terminals with regard to1acommon point of isolation, These circuits when used must be fed via the common point of isolation so that the voltage is removed when the common point of isolation to the unit is opened, In accordance with EN 60204 it is recommended that the customer wiring to these terminals uses orange wires. This will ensure that circuits not switched off by the YAEP supply disconnecting device are distinguished by colour, so that they can easily be identified as live even when the YAEP disconnecting device is off The YAEP output contacts are rated at 125 VA. All inductive devices (relays) switched by the YAEP output contacts must have their coil suppressed using standard RC suppressors. Chilled Liquid Pump Starter Terminals 33 and 34 in the main panel only close to start chilled liquid pump. This contact can be used as a master startstop for the pump in conjunction with the daily start/stop schedule. If no schedule is set, and the customer has master control of the pump, the YAEP contact must be used to override the customer master start/stop so that the York contact can start the pump in the event of a low temperature liquid condition. (2108 47 0351.02537-100 Rev. 0 Run Contact Terminals 35 and 36 close to indicate that a system is running. Alarm Contacts Each system has a voltage-tree change over contact which will operate to signal an alarm condition whenever ‘system locks out, or there is a power failure, To obtain system alarm signal, connect alarm circuit to volt free terminals as follows: 2c Uni System 1 Terminals 31 and 32 (close on alarm) oF 30 and 32 open on alarm), System 2: ‘Terminals 38 and 39 (close on alarm) or 37 and 39 (open on alarm). 4c Uni Main Panel - System 1: Terminals 31 and 32 (close on alarm) or 30 and 32 (open on alarm). Main Panel - System 2: Terminals 38 and 39 (close on alarm) or 37 and 39(0pen on alarm), Auxiliary Panel - System 3: Terminals 31 and 32 (close on alarm) or 30 and 32 (open on alarm). Auxiliary Panel - System 4: ‘Terminals 38 and 39 (close on alarm) or 37 and 39 (open on alarm). a 48 (0351.02537-100 Rev. 0 4.13. Control Section - Input Connections (Reter to Control Connection Diagram) AAll wiring to the input connections (relay board) is nominal 30 Vde and must be run in screened cable, with the screen earthed at the panel end only. Run screened cable separately from mains cable to avoid electrical noise pick-up. The voltage free contacts must be suitable for 30 Vde (gold contacts recommended). If the voltage free Contacts form part of a relay or contactor, the coil of the device must be suppressed using a standard RC suppressor. The above precautions must be taken to avoid electrical noise which could cause a malfunction or damage to the unit and its controls. Flow Switeh(es) A chilled liquid flow switch (per cooler) of suitable type must be connected to terminals 10 and 13 to provide adequate protection against loss of liquid flow. Remote Run/Stop Remove the link from main panel terminals 11 and 14 (system 1) and terminals 12 and 15 (system 2) and connect remote switch(es) to provide system remote rur’stop control if required. Auxiliary Panel (3 and 4 Circuit units): Remove the link from terminals 11 and 14 (System 3) and terminals 12 and 15 (System 4) and connect remote switch(es) to provide system remote run/stop control it required. Remote Print Closure of suitable contacts connected to terminals 18 and 13 will cause a hard copy printout of Operating Data/Fault History to be made if an optional printer is connected to the RS 232 port. YORK Remote Lead/Lag 2 Circuit Units Ht manual lead/lag control is required, closure of suitable contacts connected to terminals 13 and 19 in the Main Panel will cause System 2 to operate as the lead system ofthe main group. Open contacts will cause System 1 to be in lead. 4 Circuit Units Closure of a suitable contact connected to terminals 13 and 19 in the auxiliary panel will cause System 4 to operate as the lead system of the slave group. Open contact will cause System 3 to be in the lead. Remote Set Point Offset Timed closure of suitable contacts connected to terminals 13 and 17 (PWM contacts) will give remote offset function of the chilled liquid set point if required (terminals located in main control panel). This function cannot be used if*Remote Unload” functionis required, Remote Unloading ‘The Micro Based Control System is capable of remote unloading (or pull-down demand limiting) in two steps. The first step of unloading is achieved by closing suitable contacts connected to terminals 16 and 13 (terminals located in main control panel). The second step of unloading is achieved by closing suitable contacts connected to terminals 17 and 13. The first step contacts must be closed before the second step contacts are closed For details of compressor load steps given by these contacts, refer to the Micro Based Control System Manual. This function cannot be used if “Remote Set point Offset” is required. (2104) YORK 49 0351.02537-100 Rev. 0 Power Supply Connection - (Main Panel and Auxiliary Panel when fitted) YAEP oa ool ae YAEP 44.77% 8 58858-7777 set = fet, Bt Power Section Conon Input "Section Control Cait Switch Disconnect Emergency ‘Step Device Non-Fused Disconnest Switch orTermina BIS patos Systom Fuses, Proectve forforminal Bleck — Ear standard Single Pint Power Suppy (CE) | Sraury pepe! omc et oS Ssconnact sich SS (xCS180) win aap! dao oes consol eee {Promised deconed onc (OCSOES0) deed ena a6 we Ses 2 — Pee if Single Point Power Supply (Non CE} Option oct ewteh (QCSDIESD) derived itera. 1P\. os — Bee Be fall (2108 SupBY par panal oa commen tormina lock (QCSITB) with power dstrinuon fuses, control supply to non od ‘Mult Point Power Supply (Non CE) Options: ‘One supply per terigerant ult to tusterminal look with coparate contol supply to non used disconnect ‘Swich (GCSDIESD), 13 2Ps @ 4.10 — 035L02537-100 Rev. 0 YORK Control Connections - (Main Panel and Auxiliary Panel when fitted) YAEP 001-091 YAEP AAUL-TTX & 55855-7777 ‘YAEP 60X-99% 8 0096%-9999% Seon Sam Soon ca = a Control Section Communes une (Grane ony) } omes ia rar st } oars System ort J exon - ae / F } conan am] 72 women ny) | \ [tes reson vo | — Sa uERerRooR ETO TEESE Es ‘ha — falco Slee Soro $s feamorne cro \ ie — enero Commons Line Cae ‘Sing talanon {EYEE remote Leadtag ETT) Renate ot i Panto) = Ramat Sapsin ase sn Penal ni Tt Remots Urioad TS System No.2 Remete Sinn yer 412 Rami St S06 I 6 hae Lig Pow Sch Not 1:Ftinbetvasn terme ana end comet vgs ras cmt tinal 11 ant ‘Rreombned Honete Stipa ysis 4/2 (eres us) ad syste! (Corea Un (2104) YORK 5 COMMISSIONING 5.1 Preparation Commissioning of this unit should only be cartied out by York authorised personnel AN ‘The Control System Manual must be read in conjunction with this section ‘The unit switch on the front of the control panel has been sealed in the off position at the factory. This seal must remain in place preventing running of the unit until commissioned by authorised personnel. If the seal has been removed before commissioning then it must be reported to the Basildon Factory Quality Manager otherwise the warranty may be invalidated. Preparation - Power Off The following checks should be made with the customer supply/supplies to the unit switched off Inspection: Inspect unit for installation damage. Ifound take action and/or repair as appropriate. Refrigerant charge: Units are normally shipped as standard with a full refrigerant operating charge. Check that refrigerant pressure is present in both systems and that no leaks are apparent. If no pressure is present a leak test must be undertaken, the leak(s) located and repaired. Repaired systems and units supplied with a nitrogen holding charge must be evacuated with a suitable vacuurn pump/recovery unit as appropriate to below 100 microns. Check the unit data plate or unit labels for the type of refrigerantintended for use with the unit and break vacuum from bottle connection for liquid and raise system pressure to 4.6 barg, ® Cos) Do not liquid charge with static water in any of the heat exchangers. Care must also be taken to liquid charge slowly to avoid excessive thermal stress at the charging point. Once the vacuum is broken, charge into the condenser coils with the full operating charge as given on the unit data plate and the Physical Data section of this manual Charging from the liquid connection on the cylinder is necessary on R407C to ensure the ‘correct refrigerant mix is maintained. (2108 5-1 0351.02537-100 Rev. 0 Valves: Open the compressor suction valves and the liquid line service valves on both systems (CCW). Compressor oil: Compressor lubrication systems must be primed prior to first time start-up. Only the YORK Type H oil must be used as given by unit data plate/labels and is as follows for YAEP standard units: To prime each compressor - connect a York hand oil pump (partno. 470-10654-000) tothe 4" compressor oil priming valve with a length of clean hose or copper line, but do not tighten the flare nut. Using clean oil of the correct type, pump oil until all air has been purged from the hose then tighten the nut. Stroke the oil pump 10 times (delivering approximately 1,5 lites) to prime the oil system, The oil evel should be between the middle of the lower and middle of the upper sight glasses. If itis necessary to add oil, continue to stroke the pump until the correct level is achieved Fans: Check that all fans are free to rotate and are not damaged, Ensure blades are at the same height when rotated. Ensure fan guard is securely fixed. Isolation/protection: Verify thatall sources of electrical supply to the unit are taken from a single point of isolation. For units not fitted with a switch disconnector fuse check that the maximum recommended fuse sizos given in the Technical Data section have not been exceeded, Control panel: Check panel to see that it is free of foreign materials (wire, metal chips, ete.) and clean outit required Power connections: Check the customer power cables fare connected to the unit incoming terminals. Ensure that connections of power cables within the panel to contactors, terminal blocks or switch disconnector, and external connection to compressors are tight. Earthing: Verify that the units protective terminal(s) are properly connected to a suitable earthing point. Ensure that all unit internal earth connections are tight. Overloads: Ensure that the fan overloads setting ‘correspond to the current drawn value shown on the unit data plate for the type of fan fitted Supply voltage: Verify that the site voltage supply ‘corresponds to the unit requirement and is within the limits given on the unit data plate / Operating Limitations section. Control Transformer: The 3-wire control transformer is mounted on the unit framework below the control panel, @ 5.2 (0351.02537-100 Rev. 0 Itis important to check that the correct primary tapping has been used: = With the supply to the unitisolated remove the lid to the transformer box. Check that the tapping used conforms to the site supply voltage: 50 Hertz Models The two tappings are 342 - 424 V and 360 - 440 V. 60 Hertz Models The two tappings are 342 - 418 V and 414 - 506 V. ‘Switch Settings: Ensure that the black handled unit switch on the display door and the micro board system switches S2 and $3 in the logic section are set to "0" (OFF). Set the ted handled control circuit switch disconnector/emergency stop device on the lower centre section door to "1" (ON). For units fitted with switch disconnector fuse devices the two power section doors must be closed and the devices set to “1” (ON). The customers disconnection devices can now be set to ON. A Crankcase heaters: Verify the compressor crankcase heaters are energised. If the ambient temperature is above 30°C the compressor crankcase heaters must be on for at least 24 HOURS prior to start-up to ensure all refrigerant liquid is driven out of the oil. If the ambient temperature is below 30°C then allow 8 hours. The machine is now live! YORK Water system(s): Verity that the chilled water system has been installed correctly, and has been commissioned with the correct direction of water flow through the cooler. Inlet should be at the refrigerant pipework connection end of the cooler, Purge ai from the top of the cooler using the plugged air vent mounted ‘on the top of the cooler body. Flow switch(es): Verify a chilled water flow switch is correctly fitted in the customer's pipework on the cooler outlet, and wired into the control panel logic section Opto-isolator board terminals 10 and 13 using screened cable. Temperature sensor(s): Ensure the leaving water temperature sensor is coated with heat conductive ‘compound (part no. 013-00890-000) and is inserted in the bottom of the water outlet sensor pocket of the cooler. This sensor also acts as the freeze protection thermostat sensor and must always be in the water ‘OUTLET sensor pocket. Mixed leaving temperature sensor (4 Circuit Units) ‘Apocket is provided for field mounting in the customers mixed pipework. The pocket has a 0.5" NPT thread and is" long. The mixedleaving sensor is connected to plug 4J17 on the main micro board and the 10m lead is coiled up waiting field running to the location of the field mounted pocket provided ‘A communication link cable is wired into the auxiliary panel micto board TB7 to be field run and connected to the main panel micro board TB7 (refer to Control Connections in Section 4). Run cable away from other power cables. Control supply: Verify the control centre display is illuminated, HP cut-outs (on units with hand reset): Check that the hand reset mechanical high pressure cut-outs mounted on the unit are reset. (2108) YORK Programmed options: Verity that the options factory programmed into the Microprocessor Control Centre are in accordance with the customers order requirements by pressing the ‘Options’ key on the keypad and reading the settings from the display. Refer also to the Micro Based Control System Manual for notes and explanation of messages. Programmed settings: Ensure the system cut-out and operational settings are in accordance with the instructions given in the Microprocessor Control Centre ‘Manual and with operational requirements by pressing the ‘Program’ key. The chilled liquid temperature control settings need to be set according to the unit model and required operating conditions. The following table gives suggested settings. (Unit Capacity Steps a a = [at through cooler at fal loa 1-c [Rate Control temp. °C Rate Sensitivity “C/ min [Control Range °C [Anti-Recycle timer S66. 00 [Unit Capacity Steps Te [at through cooler at fall load /

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