Model Yt G0 A1 B1 Thru Yt L6 D8 F2 (Style H) HCFC-123 (Cooling Only)

MILLENNIUM
CENTRIFUGAL LIQUID CHILLERS

OPERATING & MAINTENANCE Supersedes: Nothing 1096 FORM 160.48-O1
MODEL YT G0 A1 B1 thru YT L6 D8 F2 (STYLE H)

HCFC-123 (cooling only)
WITH MICROCOMPUTER CONTROL CENTERS

PART #371-01200-002, #371-01200-007 & 371-01200-014
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER &
VARIABLE SPEED DRIVE
26874A
WARNING
SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE.
SERIOUS INJURY COULD RESULT IF PROPER PROCEDURES ARE
NOT FOLLOWED WHEN SERVICING SYSTEM. ALL SERVICE WORK
SHALL BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN IN
ACCORDANCE WITH YORK INSTALLATION/OPERATION MANUAL.
TABLE OF CONTENTS
Section 1: Description of System and Operational Fundamentals .......................... 4
Section 2: MicroComputer Control Center ................................................................. 6

Introduction ................................................................................................... 6
Control Center .............................................................................................. 7
Operation ...................................................................................................... 8
Programming the MicroComputer Control Center ...................................... 13
Service Keys .............................................................................................. 18
Operating Modes ........................................................................................ 20
Compressor Switch .................................................................................... 21
Display Messages ...................................................................................... 21
Section 3: System Operating Procedures ................................................................ 28
Section 4: System Components Description - Compressor/Motor Assembly ...... 35
Section 5: Operational Maintenance ......................................................................... 39

Use of Pump Assisted Turboguard Purge Unit ........................................... 39
Oil Return System ...................................................................................... 42
Charging the Unit With Oil .......................................................................... 44
Section 6: Trouble Shooting ...................................................................................... 46
Section 7: Maintenance .............................................................................................. 52

Renewal Parts ............................................................................................ 52
Checking System for Leaks ....................................................................... 52
Evacuation and Dehydration of Unit ........................................................... 52
Refrigerant Charging .................................................................................. 55
Checking the Refrigerant Charge During Unit Shut Down .......................... 55
Handling Refrigerant for Dismantling and Repairs ..................................... 55
Megging the Motor ...................................................................................... 56
Condensers and Coolers ............................................................................ 56
Compressor ................................................................................................ 59
Electrical Controls ...................................................................................... 59
Section 8: Preventive Maintenance ........................................................................... 59
NOTE: This instruction covers operation of chillers equipped with Electro-Mechanical or Solid State
Starters. If chiller is equipped with Variable Speed Drive, Form 160.00-O1 is to be used in
conjunction with this manual.
REFERENCE LITERATURE
DESCRIPTION FORM NO
INSTALLATION 160.48-N1
OPERATION – VARIABLE SPEED DRIVE 160.00-O1
RENEWAL PARTS – UNIT 160.48-RP5
RENEWAL PARTS – CONTROL PANEL 160.48-RP3
RENEWAL PARTS – B & C COMPRESSOR 160.45-RP2.2
RENEWAL PARTS – E COMPRESSORS 160.48-RP1
RENEWAL PARTS – F COMPRESSORS 160.48-RP2
RENEWAL PARTS – C3 COMPRESSORS 160.48-RP4
WIRING (WITH EM STARTER) 160.48-PA19
WIRING (WITH SOLID STATE STARTER) 160.48-PA20
WIRING (WITH VARIABLE SPEED DRIVE) 160.48-PA21
2 YORK INTERNATIONAL
FORM 160.48-O1
26874A
FIG. 1 - YT CHILLER WITH ELECTRO-MECHANICAL STARTER
28009A
FIG. 2 - YT CHILLER WITH VARIABLE SPEED DRIVE

YORK INTERNATIONAL 3
SECTION 1
DESCRIPTION OF SYSTEM AND OPERATIONAL
FUNDAMENTALS
SYSTEM OPERATION DESCRIPTION
YORK Millenium chillers are commonly applied to large ing through the condenser tubes absorbs heat from
air conditioning systems, but may be used on other ap- the refrigerant vapor, causing it to condense. The con-
plications. The unit consists of an open motor mounted denser water is supplied to the chiller from an external
to a compressor (with integral speed increasing gears) source, usually a cooling tower. The condensed refrig-
condenser with purge unit, sub-cooler, cooler and flow erant drains from the condenser into the flow control
control chamber. chamber, where the flow restrictor meters the flow
of liquid refrigerant to the cooler to complete the
The chiller is controlled by a modern state of the art refrigerant circuit.
MicroComputer Control Center which monitors its
operation. The control center is programmed by the The major components of a chiller are selected to
operator to suit job specifications. Automatic timed start- handle the refrigerant which would be evaporated at
ups and shutdowns are also programmed to suit full load design conditions. However, most systems
nighttime, weekends, and holidays. The operating sta- will be called upon to deliver full load capacity for only
tus, temperatures, pressures, and other information a relatively small part of the time the unit is in opera-
pertinent to operation of the chiller are automatically tion.
displayed and read on a 40 character alphanumeric
message display. Other displays can be observed by CAPACITY CONTROL
pressing the keys as labeled on the control center. The major components of a chiller are selected for full
The chiller with the MicroComputer Control Center is load capacities; therefore, capacity must be controlled
applied with an Electro-Mechanical Starter, a factory to maintain a constant chilled liquid temperature leav-
packaged YORK Solid State Starter or a factory pack- ing the cooler. Prerotation vanes (PRV), located at the
aged Variable Speed Drive that produces even greater entrance to the compressor impeller, compensate for
efficiency and energy savings. variation in load. (See Fig. 3 Detail A)
In operation, a liquid (water or brine) to be chilled flows The position of these vanes is automatically controlled
through the cooler, where refrigerant, boiling at low pres- through a lever arm attached to an electric motor lo-
sure and temperature, absorbs heat from the water. The cated outside the compressor housing. The automatic
chilled liquid is then piped to fan coil units or other air adjustment of the vane position in effect provides the
conditioning terminal units, where it flows through finned performance of many different compressors to match
coils, absorbing heat from the air. The warmed liquid is various load conditions from full load with vanes wide
then returned to the chiller to complete the chilled liquid open to minimum load with vanes completely closed.
circuit.
For Variable Speed Drive units, the capacity is controlled
The refrigerant vapor, which is produced by the boiling by speed modulation as well as prerotation vane con-
action in the cooler, flows to the compressor where the trol. The Variable Speed Drive selects the combination
rotating impeller increases its pressure and tempera- of compressor motor speed and prerotation vane open-
ture and discharges it into the condenser. Water flow- ing for the most efficient operation. (See Form 160.00-O1)
FORM 160.48-O1
7619A(D)
FIG. 3 (DETAIL A) - COMPRESSOR PREROTATION VANES
COMPRESSOR
DISCHARGE
SUCTION
DISCHARGE
BAFFLE
COOLER
CONDENSER
ELIMINATOR
SUB-COOLER
FLOW
CONTROL
CHAMBER
FLOW CONTROL OIL COOLER LD00478A
FIG. 3 - REFRIGERANT FLOW THROUGH CHILLER

28050A
FIG. 4 - MICROCOMPUTER CONTROL CENTER AND KEYPAD LD00457
Section 2
MICROCOMPUTER CONTROL CENTER
NOTE: This instruction covers operation of chillers equipped with Electro-Mechanical or Solid State Starters. If
chiller is equipped with Variable Speed Drive, Form 160.00-O1 is to be used in conjunction with this
manual.
INTRODUCTION
The YORK MicroComputer Control Center is a micro- • CHILLED LIQUID TEMPERATURES - LEAVING AND
processor based control system for centrifugal chill- RETURN
ers. It controls the leaving chilled water temperature • REFRIGERANT PRESSURES - EVAPORATOR AND
via prerotation vane control and has the ability to CONDENSER
limit motor current via control of the prerotation • DIFFERENTIAL OIL PRESSURE
vanes. Fur ther, it is compatible with YORK Solid • CONDENSER LIQUID TEMPERATURES - OPTIONAL
State Starter, Electro-Mechanical Starter and Vari- FIELD INSTALLED - LEAVING AND RETURN
able Speed Drive applications. • OPTIONS
• PRINT
A keypad mounted on the front of the Control Center
• HISTORY PRINT
(see Fig. 4) allows the operator to display system operat-
• MOTOR CURRENT IN % OF FULL LOAD AMPS
ing parameters on a 40 character alphanumeric display
• SATURATION TEMPERATURES - EVAPORATOR
that is part of the keypad. These readings are displayed
AND CONDENSER
via “Display” keypad as follows: In the English mode;
• DISCHARGE TEMPERATURE
temperatures in °F, pressures in (PSIA); in the metric
• OIL TEMPERATURE
mode, temperatures in °C, pressures in (KPa).
• PURGE PRESSURE
• SOLID STATE STARTER MOTOR CURRENT/ VOLTS
FORM 160.48-O1
The system setpoints (see Fig. 4) are operator entered 1. Remote Start
on the front control center “Setpoints” keypad. These 2. Remote Stop
set points can also be displayed on the 40 character
alphanumeric display. The system setpoints are: 3. Remote LCWT Setpoint (Pulse Width Modulated
signal)
• CHILLED LIQUID TEMPERATURE (LCWT)
• % CURRENT LIMIT 4. Remote Current Limit Setpoint (Pulse Width Modu-
• PULLDOWN DEMAND LIMIT lated signal)
• CLOCK (TIME-OF-DAY) 5. A “Remote Mode Ready to Start” Status Contacts
• DAILY SCHEDULE (7 DAY TIME-CLOCK
PROGRAMMING) 6. Safety Shutdown Status Contacts
• HOLIDAY 7. Cycling Shutdown Status Contacts
• REMOTE RESET TEMPERATURE RANGE
• DATA LOGGER As an enhancement to the standard EMS features, an
optional card file with plug-in printed circuit boards is
The cause of all system shutdowns (safety or cycling) available. These optional cards will accept a remote
is preserved (until the system is reset or restarts) in the LCWT 0° to 10°F or 0° to 20°F setpoint offset and/or
microcomputer’s memory for subsequent viewing on the remote current limit setpoint interface from three user
keypad display. The operator is continually advised of input choices:
system operating conditions by various background and
warning messages. The keypad contains special service 1. 4-20 mA
keys for use by the service technician when performing 2. 0-10 VDC
system troubleshooting.
3. contact closures
The MicroComputer Control Center is designed to be
compatible with most energy management systems
(EMS) in use today. The standard design allows for the
following EMS interface:
CONTROL CENTER
The Control Center front panel layout consists of five functions that are only relevant to servicing the chiller.
key groups, one switch, and a 1 line by 40 character Typically, these keys would not be used for daily chiller
alphanumeric vacuum fluorescent display: (See Fig. 4) operation.
CHARACTER DISPLAY - The alphanumeric vacuum ACCESS CODE - Permits operator to access the pro-
fluorescent display is located to the right of the “STA- gram.
TUS” key. All messages, parameters, set points, and data
PROGRAM - Permits operator to program the Control
can be viewed at this location. The main communica-
Center.
tions between the operator or service technician and the
MicroComputer Control Center occurs on this display. MODE - Permits operator to check what mode the Con-
trol Center is presently in (“LOCAL”, “REMOTE” or “SER-
DISPLAY - Provide a direct read-out of each monitored
VICE”).
parameter on the alphanumeric display.
1. Service - allows manual PRV control with visual dis-
ENTRY - These keys are used to enter the values for
play readout of PRV operation.
the operator programmed setpoints. These keys are
used in conjunction with the “SETPOINT” keys while in 2. Local - allows manual compressor start from the
program mode. “COMPRESSOR” switch on control center front.
SETPOINTS - These keys are used as follows: 3. Program - allows operator programming of system
setpoints.
1. To view each setpoint, in any Mode, or
4. Remote - allows remote start, remote stop of com-
2. To select the individual setpoints that are programmed
pressor and remote reset of LCWT and % current
by the operator in “Program” Mode only.
limit.
Pressing the appropriate key enables the operator to
COMPRESSOR - “START”, “RUN”, “STOP/RESET”
program that setpoint pressing the “ENTRY” keys.
SWITCH - This 3 position rocker switch is used to start
SERVICE - Included in this group of keys are those (except in “REMOTE” mode), stop/run/reset the system.
OPERATION
DISPLAYING SYSTEM PARAMETERS

The “Display” keys are used to display selected moni-
To Display CHILLED LIQUID TEMPERATURES:
tored parameters as follows: (Refer to Fig. 4)
Press “CHILLED LIQUID TEMPS” display key as
• Press and release the appropriate “DISPLAY” key -
described above to produce the following alphanumeric
the message will be displayed for 2 seconds.
display message:
- or-
• Press and hold the appropriate “DISPLAY” key - the CHILLED LEAVING = XXX.X °F, RETURN = XXX.X °F
message will be displayed and updated every 0.5
seconds until the “DISPLAY” key is released.
- or -
To Display REFRIGERANT PRESSURE:
• Press and release appropriate “DISPLAY” key, then
Use “REFRIGERANT PRESSURE” display key as de-
press and release the “DISPLAY HOLD” key - the
scribed above to produce the following alphanumeric
message will be displayed and updated every 2
display message:
seconds until the “DISPLAY HOLD” key is again
pressed and released, or 10 minutes have elapsed,
whichever comes first. EVAP = XXXX.X PSIG, COND = XXXX.X PSIG
NOTE: If the display actually displays X’s, then the moni-

tored parameter is out of normal operating range
(Ref. Fig. 5). If the “English/Metric” jumper is in- To Display OIL PRESSURE:
stalled on the Micro Board, all temperatures are Use “OIL PRESSURE” display key as described above
displayed in degrees Fahrenheit (°F) and all to produce the following alphanumeric display mes-
pressures are displayed in pounds per square sage:
inch absolute (PSIA), except oil pressure which
is displayed in pounds per square inch differen- OIL PRESSURE = XXXX.X PSID
tial (PSID). If the “English/Metric’’ jumper is not
installed, all temperatures are displayed in de-
grees Centigrade (°C) and all pressures are dis-
played in Kilo-Pascals (KPa). To Display OPTIONS:
Use the “OPTIONS” key to display and program the op-
tional parameters for “Guardian Service” and “Remote
VARIABLE DISPLAY -> X’S WHEN EPROM VERSion Chiller Communications”. Refer to instruction Form
CONDENSER PRESSURE = < 9.3 PSIA; > 41.6 PSIA (3.B) (3.C) 160.46-NOM 4.1 for operation and programming. If this
= < 10.0 PSIA; > 40.0 PSIA (Later Versions) option is not installed,
= < 5.0 PSIA; > 12.9 PSIA (3.B) (3.C)
EVAPORATOR PRESSURE
= < 4.0 PSIA; > 12.5 PSIA (Later Versions) NO OPTIONS INSTALLED
= < 9.0 PSIA; > 78.2 PSIA (3.B) (3.C) (3.E)
= < 14.7 PSIA OR > 75.0 PSIA (Later Versions) is displayed when this key is pressed.
(Low Pressure Purge Unit)
PURGE PRESSURE
= < 00.0 PSIA or > 100.0 PSIA 031-01097-001
(High Pressure Pump Through -012 Rev.
To Display SSS MOTOR CURRENT/VOLTS: (Solid
Assisted Purge Unit) .10 and higher State Starter Applications Only)
DISCHARGE TEMPERATURE = < 20.3°F; > 226.4°F If chiller is equipped with a YORK Solid State Starter,
use “SSS MOTOR CURRENT/VOLTS” key to display 3-
OIL TEMPERATURE = < 20.3°F; > 226.4°F
phase compressor motor current and 3-phase solid state
LEAVING COND. WATER TEMP. = < 8.4°F; > 114.4°F starter input line voltage. Continuously pressing this key
will display the motor current and line voltage alternately.
ENTERING COND. WATER TEMP. = < 8.4°F; = > 114.4°F
When used with the “DISPLAY HOLD” key, motor cur-
LEAVING EVAP. WATER TEMP. = < 0°F; = > 81.1°F rent and line voltage will alternately be displayed
ENTERING EVAP. WATER TEMP. = < 0.1°F; > 93.0°F each time this key is pressed. The messages are as fol-
lows:
FIG. 5 - SYSTEM PARAMETERS - OUT OF RANGE

READINGS
FORM 160.48-O1
FLA value x 100%.

A AMPS = XXXX; B AMPS = XXXX; C AMPS = XXXX
For Electro-Mechanical Starter Applications
- the % of Motor Current displayed is the high-
V A – B = XXXX; V B – C = XXXX; V C – A = XXXX est of the three line currents converted to ana-
log voltage calibrated to be 9.7 VDC @ 100%
If chiller is not equipped with Solid State Starter, this FLA.
key produces the following message:
SOLID STATE STARTER NOT INSTALLED To Display OPERATING HOURS:

Use the “OPERATING HOURS” key as described on
In program mode, this key is used to display the appli- page 8 to produce the following message:
cable line voltage range (200-208 VAC, 220-240 VAC,
380 VAC, 400 VAC, 415 VAC, 440-480 VAC, 500-600
ACCUMULATED RUN TIME = XXXXX HRS.
VAC, Supply Voltage Range Disabled). The correct line
voltage range is programmed at the YORK factory and
Version 3.E and later EPROM versions provide OP-
is checked by the service technician at start-up. For
ERATING HOURS and STARTS COUNTER:
security reasons, a special access code is required to
program the line voltage range. The line voltage range
is used to determine a low line voltage threshold for OPER. HOURS = XXXXX; START COUNTER = XXXXX
cycling shutdown. Refer to “System Setpoints” below
for Trip/Reset values. SYSTEM SETPOINTS
The system setpoints may be programmed by the sys-
To Display CONDENSER LIQUID TEMPERATURES: tem operator. The “Setpoints” keys are located on the
(Field Installed Option Package) Control Center keypad. To program, see “Programming
System Setpoints” on page 13. The following is a de-
Use “CONDENSER LIQUID TEMPS” display key as
scription of these setpoints (with the English/Metric
described above to produce the following alphanumeric
jumper installed on the Micro Board):
display message:
CHILLED LIQUID TEMP - This key displays the leav-
COND LEAVING = XXX.X °F. RETURN = XXX.X °F ing chilled water temperature (LCWT) setpoint in de-
grees Fahrenheit. If not programmed, the default value
NOTE: If the condenser liquid thermistors are not is 45°F. See “Programming System Setpoints”, page 13.
connected, the display will blank when this key NOTE: If an Energy Management System is interfaced
is pressed. to the Control Center for the purpose of remote
LCWT setpoint reset, then the operator-
programmed chilled liquid temp will be the base
To initiate a PRINT to Printer: or lowest setpoint available to the Energy Man-
Press the “PRINT” key to initiate a printout to an op- agement System (EMS). This chilled liquid
tional printer. When the key is pressed, temp value must also be entered into the EMS.
Further, any subsequent change to this value
PRINT ENABLE must also be entered into the EMS.
% CURRENT LIMIT - This key displays the maximum
is displayed. Refer to “MicroComputer Control Center - value of motor current permitted by its programmed
System Status Printers” instruction (Form 160.48- setting. The value is in terms of percent of Full Load
NO1.2) for details of the optional printers. Amps (FLA). If not programmed, the default value is
100%. See “Programming System Setpoints”, page 13.
To Display MOTOR CURRENT: If chiller is equipped with a YORK Solid State Starter,
the system FLA is also displayed. This value is pro-
Press the “% MOTOR CURRENT” display key as grammed by the factory and should never be changed.
described above to display motor current as a percent The Micro Board uses this value to calculate and dis-
of Full Load Amps (FLA). The message is as follows: play the % Motor Current parameter that is displayed
when the “% MOTOR CURRENT” display key is pressed.
MOTOR CURRENT = XXX % FLA Also, proper current limit control depends on the cor-
rectly programmed FLA value. For security reasons, a
NOTE: For Solid State Starter Applications - the special access code is required to program the FLA value.
% Motor Current displayed is the highest of three It should only be changed by a service technician.
line currents divided by the programmed chiller
PULL DOWN DEMAND - This function is used to probe reset. For example, if the operator programmed chilled
vide energy savings following the chiller start-up. This liquid temp setpoint is programmed with a value of 10°F,
key displays a programmable motor current limit and then the chilled liquid temp setpoint can be remotely re-
programmable period of time. Operation is as follows: set over a range of 46°F to 56°F (46 + 10 = 56). If not
programmed, the default value for this parameter is 20°F.
Whenever the system starts, the Pull Down Demand
For additional information on remote LCWT reset, refer
Limit is maintained for the programmed time, then the
to Form 160.46-PA4.1.
current limit control returns to % Current Limit setpoint.
The maximum permitted motor current is in terms of % NOTE: If an Energy Management System is interfaced
FLA. The duration of time that the current is limited is in to the Control Center for the purpose of remote
terms of minutes (to a maximum of 255). If not pro- LCWT setpoint reset, then the operator pro-
grammed, the default value is 100% FLA for 00 minutes grammed REMOTE RESET TEMP RANGE
(See “Programming System Setpoints”, page 13). Thus, value determines the maximum value of tem-
no pull down demand limit is imposed following system perature reset controlled by the Energy Man-
start, and the % Current Limit setpoint is used. agement System.
CLOCK - This key displays the day of the week, time of DATA LOGGER - This key is used when an optional
day and calendar date. If not programmed, the default printer is connected to the MicroComputer Control Cen-
value is ter. Refer to Form 160.48-NO1.2 for operation instruc-
tions.
SUNDAY 12:00 AM 1/1/89 SSS MOTOR CURRENT/VOLTS - This key is used on
Solid State Starter applications only. Although this is a
(See “Programming System Setpoints”, page 13.) display key, it is also used to program the applicable AC
DAILY SCHEDULE - This key displays the programmed power line voltage range (200-208 VAC, 220-240 VAC,
daily start and stop times, from Sunday through Satur- 380 VAC, 400 VAC, 415 VAC, 440-480 VAC, 550-600
day plus Holiday. If desired, the Control Center can be VAC). The MicroComputer Control Center uses this entry
programmed to automatically start and stop the chiller to determine the undervoltage-shutdown threshold. For
as desired. This schedule will repeat on a 7-day calen- each line voltage category, there are two shutdown
dar basis. If the Daily Schedule is not programmed, the thresholds - a minimum line voltage level required to
default value is 00:00 AM start and stop times tor all start the compressor and a minimum level required af-
days of the week and the holiday. (Note that the system ter the Control Center is in “RUN” mode. In “ RUN” mode,
will not automatically start and stop on a daily basis with the voltage must be less than the run threshold for 20
these default values because 00:00 is an “Impossible” continuous seconds in order to initiate a shutdown. When
time for the Micro Board; see “Programming System the chiller shuts down,
Setpoints”, page 13). Finally, one or more days in the
week can be designated as a holiday (See description MON 10:00 AM LOW LINE VOLTAGE
under “HOLIDAY” setpoint) and the Control Center can
be programmed (using “DAILY SCHEDULE” setpoint) is displayed. This undervoltage protection can be dis-
to automatically start and stop the chiller on those days abled. The selectable supply voltage ranges and their
so designated. The operator can override the time clock shutdown thresholds are as follows:
at any time using the “COMPRESSOR” switch.
Note that if only a start time is entered for a particular supply voltage range TO START RUN
day, the compressor will not automatically stop until a
200-208 VAC 174 VAC 160 VAC
scheduled stop time is encountered on a subsequent 200-240 200 185
day. 380 331 305
400 349 320
HOLIDAY - This key indicates which days in the upcom- 415 362 335
ing week are holidays. On those designated days, the 440-480 400 370
chiller will automatically start and stop via the holiday 550-600 502 460
start and stop times programmed in the “DAILY SCHED- Supply voltage range disabled 0 None
ULE” setpoint. It will do this one time only and the follow-
ing week will revert to the normal daily schedule for that If Control Center is equipped with version 3.E and later
day. EPROM, an overvoltage shutdown threshold is also
checked. If the line voltage exceeds the overvoltage
REMOTE/RESETTEMP RANGE - This key displays the threshold for 20 continuous seconds, the chiller shuts
maximum offset of remote LCWT setpoint reset. This down,
offset is either 10° or 20°F as programmed. When in
the remote mode, this value is added to the operator
programmed chilled liquid temp setpoint and the sum
equals the temperature range in which the LCWT can
FORM 160.48-O1
press and release the “DISPLAY HOLD” key. The mes-

MON XX:XX AM HIGH LINE VOLTAGE sage will be displayed until the “DISPLAY HOLD” key
is again pressed and released, or 10 minutes have
is displayed. The high line voltage check is disabled along elapsed, whichever comes first.
with the low line voltage check if desired. Refer to the
following chart for thresholds.
To Display CHILLED LIQUID TEMP Setpoint:
For security reasons, a special access code is required
Use the “CHILLED LIQUID TEMP” setpoint key as de-
to program the supply voltage range. The supply volt-
scribed on page 8 to produce the following message:
age range is programmed at the factory and should only
be changed by a service technician.
LEAVING SETPOINT = XX.X °F
LOW/HIGH VOLTAGE TRIP/RESET VALUES
NOTE: The value displayed is the actual LCWT setpoint.
low line voltage high line voltage For example, the value displayed in “LOCAL” or
compressor motor
supply voltage
operating point operating point “PROGRAM” modes is that which is operator
cutout-(V) cutin-(V) cutout-(V) cutin-(V) programmed. The value displayed in the “RE-
range - (V) (on fall) (on rise) (on risei) (on fall)
MOTE” mode is that base setpoint with added
200-208 160 174 227 220 temperature reset by an Energy Management
220-240 185 200 262 254 System, via remote LCWT setpoint (PWM sig-
380 305 331 415 402 nal) if a remote reset signal was received within
400 320 349 436 423 30 minutes.
415 335 362 454 440
440-480 370 400 524 508
550-600 460 502 655 635 To Display % CURRENT LIMIT Setpoint:
Supply voltage
None 0 None 0
range disabled Use “% CURRENT LIMIT” setpoint key as described on
page 8 to produce the following message:
PURGE - There is one programmable purge setpoint:
“EXCESS PURGE THRESHOLD”. CURRENT LIMIT = XXX ° FLA
The EXCESS PURGE THRESHOLD is the number of NOTE: The value displayed is the actual % current limit
purge exhausts that are allowed to occur in 1 hour of chiller setpoint. For example; the value displayed in
operating time before an excess purge warning message “LOCAL” or “PROGRAM” mode is that which is
is displayed. If the number of purge exhausts exceed this operator programmed. The value displayed in
value, “WARNING - EXCESS PURGE” is displayed on the “REMOTE” mode is that which has been pro-
the keypad display (Refer to description of this message grammed by the Energy Management System
in “DISPLAY MESSAGES” section of this book). The DIS- via the remote current limit setpoint input.
PLAY DATA key is used to program this setpoint. It is pro-
If chiller is equipped with a YORK Solid State Starter,
grammable from 10 to 30 purge exhausts per hour by op-
the message is:
erating personnel. The default value is 20 purge ex-
hausts per hour. Field service personnel can program this
setpoint over a wider range (Refer to service manual Form CURRENT LIMIT = XXX % FLA; *MTR CUR = 000 FLA
160.48-M2, Section 13). The typical value would be the
default value 20/hour. However, the number can be low- NOTE: On Solid State Starter applications, this value is
ered to detect small leaks. programmed at the YORK factory. A special ac-
cess code is required.
DISPLAYING SYSTEM SETPOINTS
The currently programmed setpoint values can be To Display PULL DOWN DEMAND Setpoint:
viewed at any time (see page 20) in “SERVICE”,
“LOCAL” or “REMOTE” operating mode as follows: Use “PULL DOWN DEMAND” setpoint key as described
on page 8 to produce the following message:
• Press and release the appropriate “Setpoint” key - the
message will be displayed for 2 seconds. SETPOINT = XX MIN @ XX% LOAD, XX MIN LEFT
- or -
• Press and hold the appropriate “Setpoint” key - the
message will be displayed as long as the key is To Display CLOCK Setpoint (Time of Day):
pressed.
- or - Use “CLOCK” setpoint key as described on page 10 to
• Press and release appropriate “Setpoint” key, then
produce the following message:
To Display REMOTE RESET TEMP RANGE Setpoint:
TODAY IS DAY XX:XX AM/PM 1/1/89
Use “REMOTE RESET TEMP RANGE” setpoint key as
described above to produce the following message:
To Display DAILY SCHEDULE Setpoints: REMOTE RESETTEMP RANGE = 10 °F - or -

• Press and hold the “DAILY SCHEDULE” setpoint key.
The chiller start and stop times for each day of the REMOTE RESETTEMP RANGE = 20 °F
week are sequentially displayed, beginning with
Sunday and ending with Holiday. The display will
continuously scroll until the “DAILY SCHEDULE” key To Display DATA LOGGER Setpoints:
is released.
-or- Refer to YORK Form 160.48-NO1.2 for operation of this
• Press and release the “DAILY SCHEDULE” setpoint key.
key. Then press and release the “DISPLAY HOLD” key.
The chiller start and stop times for each day of the To Display UNDERVOLTAGE Setpoints:
week are sequentially displayed beginning with Sun- (Solid State Starter Applications Only)
day and ending with Holiday. The display will con-
tinuously scroll until the “DISPLAY HOLD” key is again Press “SSS MOTOR CURRENT/VOLTS” key in “PRO-
pressed and released, or 10 minutes have elapsed, GRAM” mode to display the selected voltage range. One
which ever comes first. of the following messages will be displayed:
The display message for DAILY SCHEDULE will scroll SUPPLYVOLTAGE RANGE 200 – 208 - or -
in the following sequence:
SUN START = 08:30 AM STOP = 06:00 PM SUPPLYVOLTAGE RANGE 220 – 240 - or -
MON START = 05:00 AM STOP = 07:00 PM SUPPLY VOLTAGE RANGE 380 - or -
TUE START = 05:00 AM STOP = 07:00 PM SUPPLY VOLTAGE RANGE 400 - or -
WED START = 05:00 AM STOP = 07:00 PM SUPPLY VOLTAGE RANGE 415 - or -
THU START = 05:00 AM STOP = 07:00 PM SUPPLYVOLTAGE RANGE 440 – 480 - or -
FRI START = 05:00 AM STOP = 07:00 PM SUPPLYVOLTAGE RANGE 550 – 600 - or -
SAT START = 05:00 AM STOP = 01:00 PM SUPPLY VOLTAGE RANGE DISABLED
A special access code is required to program the Sup-

HOL START = 00:00 AM STOP = 00:00 PM monply
startVoltage
= 05:00Range.
am stopThe
= 07:00 pm Voltage Range is pro-
Supply
grammed at the factory and checked at system start-
up. (Note to service technician: Refer to programming
To Display HOLIDAY Setpoints: instructions in Service Instruction 160.48-M2).
Use “HOLIDAY” setpoint key as described in the begin-

ning of this section to produce the following message: To Display PURGE Setpoint:
Press “DISPLAY DATA” key in “PROGRAM” mode to
S__ M__ T__ W__ T__ F__ S__ HOLIDAY NOTED BY *
display the excess purge threshold. The following is
displayed:
NOTE: On the days that are designated by an *, the
chiller will automatically start and stop per the
holiday schedule established in “DAILY SCHED- MAXIMUM PURGES PER HOUR = XX
ULE” setpoints.
FORM 160.48-O1
PROGRAMMING THE MICROCOMPUTER

CONTROL CENTER
PROGRAMMING SYSTEM SETPOINTS

The system setpoints can be entered at any time . . .
even when the system is running. Proceed as follows to
enter system setpoints. (Refer to Fig. 6)
1. Press “ACCESS CODE” key.
2. This is displayed:
ENTER VALID ACCESS CODE ___ ___ ___ ___
3. Using “Entry” keys, enter 9 6 7 5.

4. As each digit is entered, the characters Y O R K are
displayed.
NOTE: If digits other than 9 6 7 5 are entered,
Y O R K is still displayed.
NOTE: For ease in remembering the code, note that
the letters Y O R K correspond to the digits LD00457
9 6 7 5 on a telephone dial.
5. Press “ENTER” key.
FIG. 6 - KEYPAD - PROGRAMMING SYSTEM
NOTE: If digits other 9 6 7 5 were entered in step
SETPOINTS
No. 4,
INVALID ACCESS CODE
is displayed when the “ENTER” key is 9. Enter setpoints as detailed below. If you make a mis-
pressed. If this occurs, enter the correct take when entering a value, press “CANCEL” key and
access code (9675) and proceed. then “ENTER” key. The display will revert to the de-
fault values and the cursor will return to the first
6. This is displayed:
changeable digit. You can then proceed to enter the
correct values. If the entered value exceeds accept-
ACCESS TO PROGRAM KEY AUTHORIZED able limits,
NOTE: Unless terminated by pressing the “ACCESS

OUT OF RANGE – TRY AGAIN!
CODE” key again, the operator will have ac-
cess to the “PROGRAM” key for 10 minutes.
message will be displayed for 2 seconds, then the
When 10 minutes have elapsed, access to
program key will be automatically disabled
and the operator must return to step No. 1 to PROGRAM MODE. SELECT SETPOINT
gain access.
message will reappear.
7. Press “PROGRAM” key.
10. When all the desired setpoints have been entered,
8. This is displayed: press the “ACCESS CODE” key to exit program mode
and terminate access to program mode.
PROGRAM MODE, SELECT SETPOINT
ACCESS TO PROGRAM MODE DISABLED
is displayed. The Control Center will automatically

return to “LOCAL”, “REMOTE” or “SERVICE”
mode . . . whichever was last selected.
To enter CHILLED LIQUID TEMP Setpoint:
(Refer to Fig. 7)
1. Press and release “CHILLED LIQUIDTEMP” setpoint
key. The following program prompt message will be
displayed:
LEAVING SETPOINT = XX.X °F (BASE)
(BASE) refers to the base or lowest setpoint avail-

able to an Energy Management System. If any En-
ergy Management System is applied, this value must
be entered into the Energy Management System.
Refer to previous explanation or REMOTE/RESET
TEMP RANGE, page 10.
2. Use “ENTRY” keys to enter desired value.
3. Press and release “ENTER” key. This message is LD0457
displayed:
FIG. 7 - KEYPAD - PROGRAMMING “LEAVING

CHILLED WATER TEMP” SETPOINT
To Enter % CURRENT LIMIT Setpoint:

(Electro-Mechanical Starter or VSD)
(Refer to Fig. 8)
1. Press and release “% CURRENT LIMIT” setpoint key.
The following program prompt message is displayed:
CURRENT LIMIT = XXX % FLA
2. Use “ENTRY” keys to enter desired value.

3. Press and release “ENTER” key. This message is
displayed:
(Solid State Starter)

(Refer to Fig. 8) LD0457
1. Press and release “% CURRENT LIMIT” setpoint key.

The following message is displayed:
FIG. 8 - KEYPAD - PROGRAMMING “% CURRENT
CURRENT LIMIT = XXX % FLA MTR CUR = _ _ _ FLA LIMIT” SETPOINT
2. Use “ENTRY” keys to enter desired current limit value.

NOTE: Motor Current FLA value is entered by YORK 3. Press and release “ENTER” key. The following mes-
factory and checked at system start-up. It can- sage is displayed:
not be changed without special access code.
(Note to service technician: refer to Program-
ming Instructions in Service Instruction Form
160.48-M2.)
FORM 160.48-O1
To Enter PULL DOWN DEMAND Setpoint:

(Refer to Fig. 9)
1. Press and release “PULL DOWN DEMAND”
setpoint key. The following program prompt
message is displayed:
SETPOINT = XXX MIN @ XXX % FLA, XX MIN LEFT
2. Use “Entry” keys to enter desired values. For expla-

nation, see PULL DOWN DEMAND, page 10. Note
that ‘XX min left’ is not an operator entered value.
displayed:
LD0457
FIG. 9 - KEYPAD - PROGRAMMING “PULL DOWN
DEMAND” SETPOINT
To Enter CLOCK Setpoint:

(Refer to Fig. 10)
1. Assure Micro Board Program jumper J-57 is in

“CLKON” position.
2. Press and release “CLOCK” setpoint key. The fol-
lowing program prompt message is displayed:
CURRENT LIMIT = XXX % FLA
3. Press “ADVANCE DAY|SCROLL” key until the pro-

per day of week appears on the display.
4. Use “Entry” keys to enter proper time of day.
5. Press “AM/PM” key to change the AM to PM or vice
versa.
6. Use “Entry” keys to enter proper calendar date.
(MONTH/DAY/YR). If month and day are single digit
entries, precede the entry with “0”. For example 02/
04/88.
LD0457
displayed:
FIG. 10 - KEYPAD - PROGRAMMING “CLOCK”
PROGRAM MODE, SELECT SETPOINT SETPOINT
To Enter DAILY SCHEDULE Setpoint:
Press “ADVANCE DAY/SCROLL” key. The display
(Refer to Fig. 11)
will advance to the next consecutive day and the
1. Press and release “DAILY SCHEDULE” setpoint key. previous day will be automatically entered.
The following program prompt message is displayed:
DAY START XX:XX AM/PM STOP XX:XX AM/PM
2. Press “ADVANCE DAY/SCROLL” key until the day

you wish to program appears on the display.
3. Use “Entry” keys to enter desired start time. If you
wish to cancel the scheduled start and stop times
for a particular day, press “CANCEL” key and then
“ENTER” key.
versa. If the desired entry is already displayed, pro-
ceed to enter the stop time. The cursor will auto-
matically move to the stop time.
5. Use “Entry” keys to enter desired stop time.
versa.
7. Press and release “ENTER” key. This message is LD00457
displayed:
PROGRAM MODE, SELECT SETPOINT - or - FIG. 11 - KEYPAD - PROGRAMMING “DAILY

SCHEDULE” SETPOINT
To Enter HOLIDAY Setpoint: (Refer to Fig. 12)

1. Press and release “HOLIDAY” setpoint key. The fol-
S__ M__ T__ W__ T__ F__ S__ HOLIDAY NOTED BY *
2. Press and release “ADVANCE DAY/SCROLL” key to

move cursor to the day that you wish to designate as
a holiday.
3. Press and release “*” entry key. An * will appear next
to the selected day.
4. After you have placed an * next to each of the days
that you wish to designate a holiday, press “ENTER”
key. The following message is displayed:
To cancel all of the designated holidays: perform Step

1, press “CANCEL” key, and then press “ENTER” key. LD00457
This message is displayed:
To cancel one of the designated holidays: perform

Step 1, press “ADVANCE DAY/SCROLL” key until
the cursor appears to the right of the desired day, FIG. 12 - KEYPAD - PROGRAMMING “HOLIDAY”
press the “*” key, then press the “ENTER” key. SETPOINT
FORM 160.48-O1
To Enter REMOTE/RESET TEMP RANGE Setpoint:

(Refer to Fig. 13)
1. Press and release “REMOTE/RESET TEMP
RANGE” setpoint key. The following program prompt
REMOTE/RESET TEMP RANGE = XX °F
2. Use “Entry” keys to enter desired value (10 or 20).

3. Press and release “ENTER” key. The following mes-
sage is displayed.
LD00457
FIG. 13 - KEYPAD - PROGRAMMING “REMOTE

RESET TEMP RANGE” SETPOINT
To Enter DATA LOGGER Setpoint:

Refer to Form 160.48-NO1.2 for operation of this key.
To Enter EXCESS PURGE THRESHOLD Setpoint:

(Refer to Fig. 14)
1. Press and release “DISPLAY DATA” key. The fol-
MAXIMUM PURGES PER HOUR = XX
2. Use “ENTRY” keys to enter desired values.

3. Press and release “ENTER” key. The following mes-
sage is displayed:
LD00457
FIG. 14 - KEYPAD - PROGRAMMING “EXCESS

PURGE THRESHOLD” SETPOINT
SERVICE KEYS
FIG. 15 - KEYPAD - SERVICE KEYS LOCATION LD00457
The “SERVICE” keys are provided for the service is displayed. If chiller is not running,
technician’s use when performing routine maintenance
or when troubleshooting the system. The “WARNING SYS READY TO START – VANES HOLDING
RESET” and “PREROTATIONVANES” keys are enabled
in “SERVICE” mode only. The remainder of the Service is displayed. The vanes will remain stationary until the
keys are enabled in “SERVICE”, “LOCAL” or “REMOTE” “OPEN”, “HOLD” or “AUTO” keys are pressed and re-
mode. leased. (This function applies to non-Variable Speed
Drive applications only.)
PREROTATION VANES KEYS
AUTO - Press and release this key to put the prerotation
OPEN - Press and release this key to drive the prerotation vanes under LCWT control as long as the current limit
vanes open. If the chiller is running, setpoint is not reached, which causes the current limit
function to override the LCWT control. If system is run-
SYSTEM RUN - VANES OPENING ning,
is displayed. If chiller is not running, SYSTEM RUN – AUTO VANES
SYS READY TO START – VANES OPENING is displayed.The actual opening and closing of the vanes
is indicated on the display. When the vanes are opening,
is displayed. The vanes will continue to open until the
“CLOSE”, “HOLD”, or “AUTO” (if temperature error re- SYSTEM RUN – VANES OPENING
quires it) keys are pressed and released. (This function
applies to non-Variable Speed Drive applications only.) is displayed. If the vanes are closing,
HOLD - Press and release this key to hold the prerotation
vanes in their present position. If chiller is running, SYSTEM RUN – VANES CLOSING
SYSTEM RUN – VANES HOLDING is displayed. Whenever the Control Center is in “LO-
CAL”, “REMOTE” or “PROGRAM” mode, the vane con-
FORM 160.48-O1
trol circuitry is automatically placed in “AUTO” mode and No. 3

the vanes operate to control the leaving chilled water
temperature to the programmed setpoint. (This function PURGE PRESSURE = XX.X PSIA
applies to non-Variable Speed Drive applications only.)
No. 4 (See Note below)
CLOSE - Press and release this key to drive the
prerotation vanes closed. If the chiller is running, 60 MINUTE PURGE COUNT BYPASS; XX MIN LEFT
SYSTEM RUN –VANES CLOSING Purge exhausts are not counted during the first 60 min-
utes of chiller operation. Therefore, this message re-
is displayed. If chiller is not running, places the purge count messages below during the first
hour of operation.
SYS READYTO START – VANES CLOSING
PURGES LAST XX MIN = XX, MAX PURGES/HR = XX
is displayed. When the vanes are fully closed,
SYS READYTO START – VANES CLOSED After the first hour of chiller operation has elapsed, purge
exhausts are counted. This message is displayed dur-
is displayed. The vanes will continue to close until the ing the first hour following the initial 1 hour bypass (see
“OPEN”, “HOLD” or “AUTO” keys are pressed. (This func- above), and after the excess purge message is cleared.
tion applies to non-Variable Speed Drive applications The minutes elapsed during this first hour of purge ex-
only.) haust counting are displayed. The purge count is
incremented each time a purge exhaust occurs. Also,
OTHER SERVICE KEYS the excess purge threshold that has been programmed
by the operator or service person is displayed as MAX
WARNING RESET - Press and release this key to reset PURGES/HR. When the minute count reaches 60, this
the excess purge counting circuitry and the excess purge message is replaced with the following message:
display message. Also, any “WARNING” or “STATUS”
message can be reset with this key, unless the condi-
PURGES LAST HOUR = XX; MAX PURGES/HR = XX
tion still exists. To reset any cycling or warning mes-
sage, place the Control Center in “SERVICE” mode and
After the initial 1 hour bypass and the first hour of purge
press “WARNING RESET” key. To reset any safety shut-
exhaust counting has elapsed as explained above (2
down message, press “WARNING RESET” key in “SER-
hours of chiller run time), this message is displayed
VICE” mode with the “COMPRESSOR” switch in the
thereafter. A running total of the number of purge exhausts
“STOP/RESET” position.
that have occurred within the last hour is displayed. The
MANUAL OIL PUMP - This key is operational in any excess purge threshold that has been programmed by
mode. Press and release this key to run the oil pump. the operator or service person is displayed as MAX
Press and release the key again to stop the oil pump. A PURGES/HR.
10-minute maximum is imposed on the running of the
To hold each of the above messages, press and release
oil pump (i.e., the oil pump will automatically shut off
the “DISPLAY DATA” key, then press and release the
after 10 minutes). If a longer running time is desired,
“DISPLAY HOLD” key. Message No. 1 above will be dis-
the key must be pressed again.
played and updated every 2 seconds until the “DISPLAY
DISPLAY DATA - This key is operational in any three of DATA” key is again pressed and released. Message No.
the Control Center modes of operation (“SERVICE”, “LO- 2 is then displayed and updated every 2 seconds until
CAL” or “REMOTE”). It is used to display certain sys- the “DISPLAY DATA” key is again pressed and released.
tem operating parameters that are relevant to trouble- Message No. 3 is then displayed and updated every 2
shooting the chiller system. seconds until either the “DISPLAY DATA” key is again
Press and hold the “DISPLAY DATA” key. The following pressed and released (whereupon message No. 1 is
messages will sequentially scroll on the display. Each displayed), or the “DISPLAY HOLD” key is pressed and
message will be displayed for 2 seconds. released (whereupon the “DISPLAY DATA” messages
are removed from the display.)
No. 1
NOTE: Purge Count - following a 1 hour bypass at start,
SAT TEMPS EVAP = XX.X °F, COND = XX.X °F purge exhausts are counted and displayed in
the above messages while the chiller is running.
No. 2 With the exception of the first hour after the by-
DISCHARGE TEMP = XXX.X °F, OILTEMP = XXX.X °F pass, the value displayed is the number of ex-
hausts that have occurred in the “Last Hour”.
For example, if you walk up to the Micro Panel
at 9:11 AM and press the “DISPLAY DATA” key
and it says that there have been 7 purges in the C. Starting the chiller.
“Last Hour”, that means that there have been 7
The purge count is frozen by the following:
exhausts since 8:11 AM. If you do this at 2:57
PM, it means that there have been 7 exhausts A. When the chiller is not running.
since 1:57 PM, etc.
B. An excess purge message is being dis-
The purge count is reset to zero by: played and at least 1 full hour of purge
exhausts have accumulated.
A. Clearing the excess purge message.
HISTORY PRINT - This key is used to initiate a history
B. Moving the Micro Board program jumper
print to the optional printer. Refer to Form 160.48-NO1.2
J-57 (CLK ON/OFF) from “CLK OFF” to
for operation of this key.
CLOCK ON” position.
OPERATING MODES
The MicroComputer Control Center can be operated in • If the Control Center is in “REMOTE” mode, this is
four different operating modes as follows: displayed:
SERVICE - Enables all the Service keys except “DIS- REMOTE OPERATING MODE IN EFFECT
PLAY DATA”, “MANUAL OIL PUMP”, and “HISTORY
PRINT”, which are enabled in all modes. See “Service • If the Control Center is in “SERVICE” mode, this is
Keys”, page 18. displayed:
LOCAL - This is the normal operating mode. The com- SERVICE OPERATING MODE IN EFFECT
pressor can be started and stopped from the Control
Center. Also, the Display and Setpoints parameters can To change operating mode, proceed as follows:
be displayed.
1. Press “ACCESS CODE” key.
PROGRAM - Allows the operator to program the
2. This message appears:
Setpoints parameters, and change operating modes.
REMOTE - In this mode, the Control Center will accept ENTER VALID ACCESS CODE __ __ __ __
control signals form a remote device (i.e., Energy Man-
agement System) or cycling inputs. The control signal 3. Using “Entry” keys, enter 9 6 7 5.
inputs are:
4. As each digit is entered, the characters Y O R K are
1. Remote Start displayed.
2. Remote Stop NOTE: If digits other than 9 6 7 5 are entered,
Y O R K is still displayed.
3. Remote LCWT Setpoint
5. Press “ENTER” key.
4. Remote Current Limit Setpoint
NOTE: If digits other than 9 6 7 5 were entered in step
NOTE: The compressor can be stopped by the “COM-
No. 4,
PRESSOR” switch, regardless of the operating
mode. The switch must be in “RUN” position to
enable “REMOTE” mode. The operator cannot INVALID ACCESS CODE
locally start the compressor using the “COM-
PRESSOR” switch when in the “REMOTE” is displayed when the “ENTER” key is pressed.
mode. If this occurs, enter the correct access code
(9 6 7 5) and proceed.
To determine which operating mode the Control Center
is presently in, simply press the “MODE” key. 6. This message is displayed:
• If the Control Center is in “LOCAL” mode, this is

ACCESS TO PROGRAM KEY AUTHORIZED
displayed:
LOCAL OPERATING MODE IN EFFECT NOTE: Unless terminated by pressing the “ACCESS
CODE” key again, the operator will have ac-
cess to the “PROGRAM” key for 10 minutes.
FORM 160.48-O1
When 10 minutes have elapsed, access to 11. Press “ADVANCE DAY” key to scroll to desired
“PROGRAM” key will be automatically dis- mode. Each time this key is pressed, a different
abled and the operator must return to step mode is displayed as above:
No. 1 to gain access.
12. When the desired mode is displayed, press “EN-
7. Press “PROGRAM” key. TER” key.
8. This message is displayed: 13. This message is displayed:
PROGRAM MODE, SELECT SETPOINT PROGRAM MODE, SELECT SETPOINT
9. Press “MODE” key. 14. Press “ACCESS CODE key to exit “PROGRAM”
mode and terminate access to “PROGRAM” mode.
10. The mode that has been previously selected will be
displayed as follows: 15. This message is displayed:
LOCAL MODE SELECTED - or - ACCESS TO PROGRAM MODE DISABLED
SERVICE MODE SELECTED - or -
REMOTE MODE SELECTED
COMPRESSOR SWITCH
(Refer to Fig. 15, page 18)
This rocker switch is used to locally operate the com- To STOP compressor:
pressor. It is used to start, run and stop the compressor.
Move switch from “RUN” to “STOP/RESET” position.
Also, it resets the Control Center after a safety shut-
down. To RESET Control Center:
To START* chiller compressor in “LOCAL” mode: Following a safety shutdown, the operator is required
to reset the Control Center prior to restarting the
Move “COMPRESSOR” switch from “STOP/RESET”
system. Move switch from “RUN” to “STOP/RESET”
to “START” position. Switch will spring-return to “RUN”
position.
position.
*NOTE: The operator cannot start the compressor
(using this switch) when the Control Center
is in “REMOTE” mode.
DISPLAY MESSAGES
The following display messages will be automatically enough to allow the current to decrease to a value less
displayed unless the operator is requesting additional than 104% of the operator-programmed “XXX % FLA”
information via the keypad. current limit.
For example:
SYSTEM RUN – CURRENT LIMIT IN EFFECT
With the operator-programmed “% CURRENT LIMIT”
Displayed when the chiller is running, and the motor set at 50% and the FLA of the chiller equal to 200A,
current is equal to or greater than the operator- the current limit circuit would perform as follows:
programmed “XXX % FLA” current limit value. When (100%) (50% x FLA) = Vanes inhibited from open-
the motor current reaches 100% of this value, the ing further
prerotation vanes are not permitted to open further. If (104%) (50% x FLA) = Vanes driven toward close
the current continues to rise to 104% of this value, the position
vanes will be driven closed - not fully closed; only far
Therefore:
SYSTEM RUN – LOW PRESSURE LIMIT IN EFFECT
(100%) (50% x 200) = 100A = Vanes stop opening
(104%) (50% x 200) = 104A = Vanes driven toward Displayed when the chiller is running and the evapora-
close position tor pressure falls to 5.55 PSIA (R11); 4.50 PSIA (R123).
Simultaneously, the prerotation vanes will be prevented
SYSTEM RUN – AUTO VANES from further opening. This action maintains chiller opera-
tion to prevent low-evaporator-pressure shutdown at 5.42
Displayed when the chiller is running, the MicroComputer PSIA (R11); 4.40 PSIA (R123). When the evaporator
Control Center is in “SERVICE” mode, and the vanes pressure rises to 5.65 PSIA (R11); 4.70 PSIA (R123),
are operating in “AUTO” mode. the vanes will be permitted to open. Low pressure limit
feature is not used when program jumper (JP-3) is cut
SYSTEM RUN – VANES OPENING (Brine application).
Displayed when the chiller is running and the Micro- SYSTEM RUN – HIGH PRESSURE LIMIT IN EFFECT
Computer Control Center is in “SERVICE” mode with:
Displayed when the chiller is running and the condenser
• The vanes operating in “AUTO” mode and opening to
pressure rises to 28.8 PSIA. Simultaneously, the prero-
maintain the leaving chilled water temperature
tation vanes will be inhibited from further opening. This
setpoint.
-or- action occurs to prevent system shutdown on high con-
denser pressure at 29.7 PSIA. When the condenser
• The operator has pressed the vanes “OPEN” key on
pressure falls to 28.6 PSIA, the vanes will be permitted
the keypad.
to open.
SYSTEM RUN – VANES CLOSING

SYSTEM RUN – PRESS STATUS
Displayed when the chiller is running and the Micro-
Displayed when the chiller is running. It instructs the
Computer Control Center is in “SERVICE” mode with:
operator to press the “STATUS” key, whereupon the fol-
• The vanes operating in “AUTO” mode and closing to lowing message will be displayed. The following “Warn-
maintain the leaving chilled water temperature ing Messages” are displayed alternately with the fore-
setpoint. ground message. The foreground message is displayed
-or- for 2 seconds, then the warning message is displayed
• The operator has pressed the vanes “CLOSE” key on for 2 seconds, etc. It is not necessary to press the “STA-
the keypad. TUS” key.
SYSTEM RUN – VANES HOLDING WARNING: COND OR EVAP TRANSDUCER ERROR
Displayed when the chiller is running, the Micro- Indicates a probable condenser or evaporator transducer
Computer Control Center is in “SERVICE” mode, and problem, because the output is unreasonable. The mi-
the operator has pressed the vanes “HOLD” key. croprocessor arrives at this conclulsion by subtracting
the evaporator transducer output from the condenser
SYS READY TO START – VANES OPENING transducer output. The result must be zero or some posi-
tive number. If the result is a negative number, it con-
Displayed when the chiller is not running and the opera- cludes that there is a probable condenser or evaporator
tor has pressed the vanes “OPEN” key on the keypad. transducer problem. This function is inhibited for the first
10 minutes of chiller run-time, and is checked every 10
minutes thereafter. Message is reset by pressing the
SYS READY TO START – VANES CLOSING
“WARNING RESET” key in the “SERVICE” mode.
Displayed when the chiller is not running and the opera-
tor has pressed the vanes “CLOSE” key on the keypad. WARNING: PURGE FLOAT SWITCH ERROR
Indicates the microprocessor is receiving conflicting digi-

SYS READY TO START – VANES HOLDING
tal signals from purge top float switch and purge bottom
float switch (i.e., liquid is simultaneously above TFS and
Displayed when the chiller is not running and the opera-
below BFS . . . an impossible condition). Message is
tor has pressed the vanes “HOLD” key on the keypad.
reset by pressing “WARNING RESET” key in the “Ser-
vice” mode.
FORM 160.48-O1
WARNING: HIGH PURGE PRESSURE SYSTEM SHUTDOWN – PRESS STATUS
If the purge transducer output is indicating a pressure Displayed when chiller is shut down on a cycling shut-
greater than 95 PSIA (for 255 continuous sec.) the above down, safety shutdown (operator must move the “COM-
warning message is displayed alternately with the nor- PRESSOR” switch to “STOP/RESET” in order to restart)
mal foreground message. When the pressure decreases or operator-initiated shutdown (within 30 minutes of ini-
to less than 95 PSIA, the message is automatically tial start-up). The status message consists of the day
cleared. and time of shutdown, cause of shutdown, and type of
restart required. Upon pressing “STATUS” key, “System
MON XX:XX WARNING – EXCESS PURGE Shutdown Message” will be displayed for 2 seconds and
then return to
Anytime after the first hour of chiller operation, if the
purge exhaust count equals the programmed “MAX SYSTEM SHUTDOWN – PRESS STATUS
PURGE/HR” threshold, this message is alternately dis-
played with the normal foreground message. The day Display can be held indefinitely by depressing “DISPLAY
and time displayed is the time the excess purge event HOLD” key. For examples of “System Shutdown Mes-
occurred. This message will be displayed until manually sages”, see below.
cleared using the “WARNING RESET” key in the “Ser-
vice” mode. Clearing the message also resets the purge SYSTEM SHUTDOWN MESSAGES
exhaust count to zero and invokes the message Day of Week Time of Day Cause of Shutdown Type of Restart
PURGES.LAST XX MIN = XX; MAX PURGES/HR = XX MON 10:00 AM – LOW WATER TEMP – AUTOSTART
While the excess purge message is displayed, the purge Chiller was shut down Monday at l0:00AM because the
exhaust count will continue to increment until the 1 hour LCWT has decreased to a value that is 4°F below the
period has elapsed. The count is then frozen until the operator-programmed chilled liquid temperature
excess purge message is cleared. This provides a record setpoint. However, if the setpoint is less than 40°F, the
of the total number of purge exhausts that occurred chiller will 20 always shut down at 36°F. Further, if the
within the 1 hour period that the excess purge event chiller is running and the setpoint is changed, the (Low
occurred. Water Temperature) cutout will be 36°F for l0 minutes in
Refer to “DISPLAY DATA” key in SERVICE KEYS sec- order to eliminate nuisance trips. Finally, for brine chill-
tion for complete explanation of purge counting. ing applications, the LWT cutout is always 4°F below
the setpoint (The water jumper on the Micro Board must
NOTE: If the “STATUS” key is arbitrarily pressed, with- be removed for a brine unit).
out the operator being prompted by the
PRESS STATUS MON XX:XX AM – LOW WATER TEMP – VSD – AUTOSTART
message, this message shall be displayed: Variable Speed Drive has shut down the chiller because
the LCWT has decreased to a value that is 4°F below
the operator-programmed chilled liquid temperature
NO MALFUNCTION DETECTED
setpoint. If the chiller is running and the setpoint is in-
creased greater than 4°F, the Variable Speed Drive will
SYSTEM RUN – LEAVING TEMP CONTROL initiate a shutdown. The shutdown is caused by LWT
contact supplied from the Variable Speed Drive.To cause
Displayed while the chiller is running. Indicates that the the Micro Board to monitor the Variable Speed Drive
prerotation vanes are being controlled by the leaving LWT input, the non-Variable Speed Drive jumper on the
chilled water temperature (LCWT). This is the normal Micro Board must be removed.
mode of chiller operation. Thus, if the LCWT is above
the setpoint, but pulling down rapidly, the vanes will pulse MON XX:XX AM – FLOW SWITCH – AUTOSTART
closed as the LCWT nears the setpoint.
Chiller is shut down because a chilled-liquid flow switch
SYSTEM READY TO START has opened. The flow switch must open for a minimum
of 2 seconds in order to cause a shutdown. The flow
Indicates that the system is not running, but will start switch is checked 25 seconds into “Start Sequence Ini-
upon application of a start signal. tiated” and continuously thereafter.
MON XX:XX AM – SYSTEM CYCLING – AUTOSTART SYSTEM RUN – LEAVING TEMP CONTROL
A remote command (computer relay contact or manual If equipped with 3.E or later EPROM. This check is not
switch) connected to the Remote/Local cycling input of performed when Micro Board program jumper JP-4 is
the digital input board has shut down the chiller. removed (Steam Turbine applications).
MON XX:XX AM – MULTI UNIT CYCLING – AUTOSTART MON XX:XX AM – INTERNAL CLOCK – AUTOSTART
Lead/Lag sequence control accessory has shut down The operator-programmed daily stop schedule has shut
the chiller. down the chiller. The chiller will automatically restart
when the operator-programmed daily star t schedule
MON XX:XX AM – POWER FAILURE – AUTOSTART initates a start. It can be overridden by pressing the
“COMPRESSOR” switch to the “START” position.
The chiller is shut down because there has been a power
interruption or failure. The chiller will automatically REMOTE STOP
restart when power is restored. This message will be
displayed if the Micro Board is configured for “AUTO RE- This message will be displayed when a remote device
START AFTER POWER FAILURE”. The Micro Board is (typically an Energy Management System) has com-
factory set for manual restart after power failure. To con- manded the chiller to shut down. The chiller will restart
vert it to auto restart after power failure, remove one of upon application of a separate start signal from the re-
the two-pin program jumpers from the cloth bag lo- mote device. This message will only be displayed when
cated inside the Control Center and place it on the Control Center is in “REMOTE” mode.
terminals labeled “Auto R” (J-60) on the Micro Board.
ANTI-RECYCLE, XX MIN LEFT
MON XX:XX AM – POWER FAILURE
The chiller may not restart more frequently than every
The chiller is shut down because there has been a power 30 minutes. Displayed when chiller is shut down and
interruption or failure. When power is restored, the chiller there is time remaining on the anti-recycle timer. In nor-
can be restarted by pressing the “COMPRESSOR” mal operation, chiller cannot be restarted until
switch to “STOP/RESET” position and then to “START”
position. This message will be displayed if the Micro ANTI-RECYCLE, 00 MIN LEFT
Board is configured for “MANUAL RESTART AFTER
POWER FAILURE”. The Micro Board is factory set for is displayed. However, when servicing the chiller, it may
manual restart after power failure. This has been ac- be desirable to inhibit this 30-minute timer. If so, simply
complished by removing the two-pin jumper from the install a jumper plug in the unmarked terminals of the
terminals fabled “Auto R” (J-60) on the Micro Board. Micro Board directly under Auto Restart jack.
AC UNDERVOLTAGE – AUTOSTART WARNING

Remove this jumper after servicing. Failure to do
The chiller is shut down because the MicroComputer
this voids the Warranty.
Control Center was in “RUN” mode, displaying
SYSTEM RUN – LEAVING TEMP CONTROL MON XX:XX AM – LOW EVAP PRESSURE
but the motor current was less than 10% FLA for 25 con- The chiller is shut down because the evaporator pressure
tinuous seconds. This is indicative of an AC undervoltage has decreased to 5.42 PSIA (R11); 4.40 PSIA (R123).
condition that has caused the start relay (1R) in the The chiller will be allowed to start when the pressure in-
MicroComputer Control Center to de-energize. This con- creased to 5.43 PSIA (R11); 4.41 PSIA (R123). To restart
dition is checked when the MicroComputer Control Cen- chiller, press the “COMPRESSOR” switch to the “STOP/
ter goes into “RUN” mode (after 30 second pre-lube). This START” position and then to the “START” position.
condition can also be caused by failure of any component
that would cause a loss of the start signal from the Con- MON XX:XX AM – LOW EVAP PRESSURE – BRINE
trol Center. In essence, this check assures that the com-
pressor is running when the Control Center is displaying The chiller is shut down because the brine Low Evapo-
FORM 160.48-O1
rator Pressure (LEP, not included with standard Control 2. Solid State Starter - power fault, 110°F start inhibit,
Center) safety contacts have opened. The brine LEP phase rotation/loss, out of lock.
safety is located external to the Control Center. Safety
3. Current Module - power fault.
cutout settings will vary with the brine application. To
restart the chiller, wait until the safety contacts close,
press the “COMPRESSOR” switch to the “STOP/RESET” MON XX:XX AM – POWER FAULT – AUTOSTART
position and then to the “START” position.
The chiller is shut down because of a Solid StateStarter
or current module (CM-2 Electro-Mechanical starter
MON XX:XX AM – LOW OIL PRESSURE
application) “Power Fault” shutdown. The chiller will au-
tomatically restart. This function is sensed by the motor
The chiller is shut down because the oil pressure has
controller input to the digital input board. A power-fault
decreased to 15 PSID while running, or never achieved
shutdown is initiated by the motor controller contacts
20 PSID prior to compressor start during the oil pump
(CM-1) opening and reclosing in one second.
pre-lube run. The chiller will be allowed to restart when
the pressure increases to 20 PSID. Differential pressure
is sensed by two pressure transducers. To restart chiller, MON XX:XX AM HIGH DISCHARGE TEMP
press “COMPRESSOR” switch to “STOP/RESET” posi-
tion and then to the “START” position. The chiller is shut down because the discharge tem-
perature has increased to 220°F. The system will be al-
lowed to restart when the temperature has decreased
MON XX:XX AM – HIGH PRESSURE
to 219°F. Temperature is sensed by a thermistor RT2.
To restart the chiller, press “COMPRESSOR” switch to
The chiller is shut down because condenser pressure
“STOP/RESET” position and then to the “START” posi-
has increased to 15 PSIG (29.7 PSIA). System will be
tion.
allowed to restart when pressure decreases to 9 PSIG
(23.7 PSIA). Pressure is sensed by a High Pressure
(HP) safety control that is located on a mounting bracket MON XX:XX AM HIGH OIL TEMP
above the oil-pump starter located on the condenser
near the purge unit. This message is prompted by the The chiller is shut down because the oil temperature
opening of the HP safety control contacts. To restart has increased to 180°F. The system will be allowed to
chiller, press “COMPRESSOR” switch to the “STOP/ restart when the temperature decreases to 179°F. The
RESET” position and then to the “START” position. temperature is sensed by a thermistor RT3. To restart
the chiller, press “COMPRESSOR” switch to “STOP/
RESET” position and then to the “START” position.
MON XX:XX AM – EVAP TRANS OR PROBE ERROR
The chiller is shut down because the leaving chilled water MON XX:XX AM – OIL PRESSURE TRANSDUCER
temperature minus the evaporator saturation tem-
perature is outside the range of -2.5°F to +25°F con- Chiller is shut down because to oil pressure has in-
tinuously for 10 minutes. To restart the chiller, press creased to 60 PSID. The chiller will be allowed to restart
“COMPRESSOR” switch to “STOP/START” position and when the oil pressure decreases to 59 PSID. Pressure
then to “START” position. On Brine applications (pro- is sensed by two oil-pressure transducers that are sens-
gram jumper JP-3 removed), this check is no longer per- ing low and high sump pressure. This safety shutdown
formed when the evaporator transducer is reading a is provided primarily as a check on the oil pressure trans-
pressure below its “out-of-range” threshold. ducers. Display of this message is generally indicative
of a defective transducer or interface. To restart the
chiller, press “COMPRESSOR” switch to “STOP/RESET”
MON XX:XX AM – MOTOR CONTROLLER – EXT. RESET
position and then to the “START” position.
The chiller is shut down because a current module
(CM-2 Electro-Mechanical starter application), or the VANE MOTOR SWITCH OPEN
YORK Solid State Starter, or Variable Speed Drive initi-
ated a shutdown. To restart system, reset the external Chiller is shut down because a system-start sequence
device that caused the shutdown. The chiller will auto- has been initiated, but the prerotation vanes are not fully
matically restart. closed.
NOTE: The following motor controller shutdowns do not

MON XX:XX AM – STARTER MALFUNCTION DETECTED
require an external reset to restart the chiller.
1. Variable Speed Drive - over-current, repeat trip, over- The chiller is shut down because the Control Center
temperature. has detected a motor-current value greater than 15%
FLA for 10 seconds minimum anytime when the com-
pressor-start signal is not energized. To restart the chiller, SYSTEM COASTDOWN
press “COMPRESSOR” switch to “STOP/RESET” a po-
sition and then to the “START” position. Displayed while motor is decelerating atter a chiller
shut down. The oil pump is running during this period.
The duration of this period is controlled by the “CSTDN”
MON XX:XX AM – PROGRAM INITIATED RESET (JP-4) wire jumper on the Micro Board as follows:
The chiller is shut down because the Micro Board did FUNCTION Jumper Position
not receive a hardware-generated interrupt on sched-
ule. Typical is an Analog/Digital Converter interrupt. This 150 SEC. COASTDOWN INSTALLED
message is indicative of a Micro Board hardware failure
* 6 MIN. COASTDOWN CUT
or electrical noise on Micro Board. The chiller will auto-
matically restart. This message indicates that the watch- * Use on steam turbine applications only.
dog timer-circuit has reset the microprocessor. This oc-
curs when the time needed to step through program is
longer than allowable, thus the software program is ini- MON XX:XX AM – MTR PHASE CURRENT UNBALANCE
tialized at the beginning. (Solid State Starter Applications Only)
The chiller is shut down because the compressor-
SYSTEM READYTO START – PRESS STATUS motor current was unbalanced while the chiller was
running. The current balance is only checked atter the
The chiller was shut down on a safety shutdown and motor has been running for a minimum of 45 seconds
will start upon application of a local or remote start sig- and the motor current is 80% FLA or greater. If the
nal. Since the message states that the chiller is “Ready current in any phase deviates from the average (a+b+c 3 )
to Start”, it means that the condition that caused the current by greater than 30% for a minimum of 45 con-
shutdown no longer exists and the Control Center has secutive seconds, a shutdown is initiated. To restart the
been manually reset. When the “STATUS” key is pressed, system, press the “COMPRESSOR” switch to “STOP/
a message is displayed that describes the reason for RESET” position and then to the “START” position. An
shutdown. The message will be displayed for 2 seconds example of the conditions for shutdown is as follows:
and then return to If
IøA = 200A
SYSTEM READY TO START – PRESS STATUS IøB = 200A
IøC = 118A
Those messages that could be displayed are any of Then
the previously described safety-shutdown messages IAV = 200 + 200 + 118
3
or warning messages. They can be cleared from the IAV = 173A
display by entering “Service” mode and pressing
“WARNING RESET” key. Or, the message will be IACCEPTABLE = 173 ± 30% = 121A or 225A
cleared by initiating a compressor start. Therefore
Since IøC = 118A which is less than the accept-
START SEQUENCE INITIATED able 121A, the chiller would shut down if this un-
balance exists tor 45 consecutive seconds.
Indicates that the Micro Board has received a local or
remote start signal and has initiated the chiller start-up MON XX:XX AM – LOW LINEVOLTAGE
routine. This is the compressor pre-lube period. The
duration of this period is controlled by the “Prerun” (JP-6) (Solid State Starter Applications Only)
wire jumper on the Micro Board as follows: Chiller is shut down because the voltage in any phase
of line voltage has decreased below the under-voltage-
FUNCTION Jumper Position shutdown threshold for 20 consecutive seconds, or failed
to achieve the minimum required starting line-voltage.
30 SEC. OIL PUMP RERUN INSTALLED Refer to explanation under “System Setpoints - SSS
*180 SEC. OIL PUMP RETURN CUT Motor Current/Volts”, page 8. The system will auto-
matically restart when all phases of line voltage in-
* Only used on YDTK 131-144 “F” compressors. crease to the minimum required starting voltage.
FORM 160.48-O1
MON XX:XX AM – HIGH LINEVOLTAGE MON XX:XX AM – AUX SAFETY SHUTDOWN

(Solid State Starter Applications Only)
The system is shut down because an external device,
Chiller is shut down because the voltage in any phase connected to digital input board TB1-31 (Aux Safety
of line voltage has increased above the over-voltage Shutdown Input), has initiated a system shutdown. This
threshold for 20 consecutive seconds. Refer to expla- input is a general purpose input that can be used to
nation under “System Setpoints - SSS Motor Current/ annunciate a user-defined safety shutdown. To restart
Volts”, page 8. The system will automatically restart chiller, press “COMPRESSOR” switch to “STOP/RESET”
when all phases of line voltage decrease to the maxi- position and then to the “START” position.
mum allowable line voltage to start the chiller.
REPLACE RTC, U16 – REPROGRAM SETPOINTS
MON 09:30 AM LOW OIL TEMPERATURE – AUTOSTART
Indicates that the battery located inside the REAL-TIME
Whenever the oil temperature falls below 55°F, or the oil CLOCK IC Chip (U16 on the Micro Board) is defective.
temperature sensor is disconnected from the Micro This battery provides back-up power to the RTC memory
Board, the preceding message will appear. The system (RAM) in the event of a utility AC power failure. This
will automatically restart when the display indicates 71°F. assures the system setpoints will be maintained. If this
message appears, the RTC IC Chip (U16) on the Micro
MON XX:XX AM FAULTY DISCHARGETEMP SENSOR Board must be replaced. If there had been a power failure
while this message is displayed, the setpoints will have
Whenever the discharge temperature falls below 32°F, been lost and must be reprogrammed. Order a replace-
or the discharge temperature sensor is disconnected ment RTC IC Chip (YORK part number 031-00955-000)
from the Micro Board, the preceding message will ap- from the YORK Parts Distribution Center. With AC power
pear. To restart the system when the discharge tem- removed from system, locate RTC Chip U16 on the Micro
perature rises or the sensor has been connected, press Board and remove existing RTC Chip from socket and
the “COMPRESSOR” switch to the “STOP/RESET” po- discard. Observe anti-static precautions and install new
sition and then to the “START” position. RTC Chip in socket. Assure proper IC orientation - orien-
tation notch must be UP. (Refer to Fig. 16)
MICRO BOARD
U16 RTC 1C CHIP

REAL-TIME CLOCK
24673A
FIG. 16 - MICROCOMPUTER CONTROL CENTER - INTERIOR - WITH PANEL OPEN - LOCATION OF REAL TIME
CLOCK U16 RTC IC CHIP
SECTION 3
SYSTEM OPERATING PROCEDURES
28050A
FIG. 17 - MICROCOMPUTER CONTROL CENTER AND KEYPAD LD00457
WARNING
OIL HEATERS CHECKING THE OIL LEVEL
IN THE OIL RESERVOIR
If the oil heater is de-energized during a shut-
down period, it must be energized for 12 hours Proper operating oil level - the middle of the up-
prior to starting compressor, or remove all oil and per sight glass.
recharge compressor with new oil. (See “Oil
If the oil is excessively high after start-up, the
Charging Procedure”, page 44.)
excess oil may be drained from the oil filter drain
NOTE: The oil heater is thermostatically con- valve while the compressor is running.
trolled and remains energized as long as
If oil level is low, oil should be added to the com-
the fused disconnect switch to the starter
pressor. (See “Oil Charging Procedure”, page 44.)
or Variable Speed Drive is energized.
FORM 160.48-O1
START-UP PROCEDURE must be programmed for the proper day and time.
Any setpoints which are desired to be changed may
Pre-Starting be programmed. If not programmed the “default”
value setpoints are as follows:
Prior to starting the chiller observe the MicroComputer
Control Center. Make sure the display reads LCWT = 45°F
% Current Limit = 100% FLA
SYSTEM READY TO START Pulldown Demand = None
Clock = Sun 12:00A.M.
To pre-start the chiller use the following procedure: Daily Schedule = None
Holiday = None
1. OIL HEATER - The oil heater must be energized for Remote Reset Temp. Range = 20°F
12 hours prior to starting the chiller. The unit will not Data Logger = No Operation
start if the oil is less than 71°F. If not possible the
compressor oil should be drained and new oil must Start-Up
be charged into the oil sump. (See “Oil Charging
Procedure”, page 44.) 1. If the chilled water pump is manually operated, start
the pump. The Control Center will not allow the chiller
2. OIL PUMP - To check, press and release the to start unless chilled liquid flow is established
“MANUAL OIL PUMP” key under “Service” on the through the unit. (A field supplied chilled water flow
Control Center. The oil pump will run for 10 minutes switch is required.) If the chilled liquid pump is wired
and shut down. Press and release the “MANUAL OIL to the MicroComputer Control Center the pump will
PUMP” key to stop the operation of the oil pump for automatically start, therefore, this step is not neces-
less than 10 minutes of operation. sary.
3. PREROTATION VANES - To perform this test the 2. To start the chiller, press the “COMPRESSOR
starter interlock terminals 3 and 4 must be jumpered START” switch. This switch will automatically spring
to allow vanes to open (remove the jumper after test). return to the “RUN” position. (If the unit was previ-
Make sure the Control Center is in the “SERVICE” ously started press the “STOP/RESET” side of the
mode, then press the prerotation vanes “OPEN” and “COMPRESSOR” switch and then press the “START”
“CLOSE” keys to observe the operation of the side of the switch to start the chiller.) When the start
prerotation vanes. The Control Center supplies a sig- switch is energized the Control Center is placed in
nal to operate the prerotation vanes. The movement an operating mode and any malfunction will be noted
of the vanes will be displayed on the control center. by messages on the 40 character alphanumeric dis-
The display readout is active whenever power is sup- play. (See Fig. 17)
plied to the control center. Return from the “Service”
mode to “Local”, “Program”, or “Remote” mode to Note: Any malfunctions which occur during “STOP/
suit the method of operation selected for the chiller RESET” are also displayed.
application. On Variable Speed Drive units, the vanes When the chiller is shut down, the prerotation vanes
may be manually controlled by a switch on the ca- will close automatically to prevent loading the com-
pacity board in the logic box. Thus, the keypad vane pressor on start-up. When the prerotation vanes are
control keys are non-functional on Variable Speed fully closed the display will read
Drive units.
4. % CURRENT LIMIT - Press the “% CURRENT SYSTEM READY TO START – VANES CLOSED
LIMIT” setpoint key on the Control Center. The dis-
when in “SERVICE” mode. When the chiller starts to
play should read
operate, the following automatic sequences are ini-
tiated: (Refer to Fig. 18, “Chiller Starting & Shutdown
CURRENT LIMIT = 100% FLA Sequence”.)
On Solid State Starter units only, the display is 1. The MicroComputer Control Center alphanumeric
display message will read
CURRENT LIMIT = 100% FLA, MTR CUR = XXXX FLA
START SEQUENCE INITIATED
if the Control Center was not programmed. If the set- for the first 30 seconds of the starting sequence. (3
point is not 100% and was predetermined for the job min. if Micro Board JP-6 removed)
application the Control Center should be pro-
grammed to that specification. 2. The compressor vent line solenoid valve will open
after the first 5 minutes of unit operation. The sole-
5. All Control Center setpoints should be programmed noid will close automatically after the compressor
before the chiller is started. Prior to start, the clock shuts down.
FIG. 18 - CHILLER STARTING SEQUENCE & SHUTDOWN SEQUENCE LD00465
3. The 1R-1 contacts of the 1R start relay will remain ter the compressor starts. If the chiller shuts down
open for the first 30 seconds of oil pump operation. during this period of time it cannot be started until
These contacts will close, starting the compressor the timer completes the 30 minute cycle.
motor and the condenser water pump at the end of
6. The chilled liquid pump contacts will close, starting
the 30 second period.
the chilled liquid pump to allow liquid flow through
4. The oil pump will start to circulate oil for a 30 sec- the cooler when the “COMPRESSOR” start switch is
ond pre-run to establish oil flow and adequate lubri- energized.
cation to all bearings, gears, and rotating surfaces
7. After the first 30 seconds of operation, the compres-
within the compressor.
sor will start and the Control Center display mes-
The high and low oil pressure transducers (OP) and sage will read
the oil temperature sensor (RT3) will sense any mal-
function in the lubrication system and activate one
SYSTEM RUN – CURRENT LIMIT IN EFFECT
of the following display messages:
while the motor is accelerating to full speed. When
DAY 10:30 AM – LOW OIL PRESSURE the motor reaches full speed and the current falls
below 100% FLA the message will read
DAY 10:30 AM – HIGH OIL PRESSURE
SYSTEM RUN – LEAVING TEMP. CONTROL
DAY 10:30 AM – LOW OIL TEMP – AUTOSTART
Chiller OPERATION
DAY 11:30 AM – OIL PRESSURE TRANSDUCER After the compressor reaches its operating speed the
prerotation vanes will begin to open under the control of
5. The anti-recycle timer software function will operate the micro processor board or the logic section of the
after the 30 seconds of pre-run time. At this time the Variable Speed Drive which senses the leaving chilled
timer will be initiated and will run for 30 minutes af- liquid temperature. The unit capacity will vary to main-
FORM 160.48-O1
tain the leaving chilled liquid temperature setpoint. The

prerotation vanes are modulated by an actuator under
the control of the microprocessor board or logic section
of the Variable Speed Drive. The vane control routine
employs proportional plus derivative (rate) control ac-
tion. A drop in chilled liquid temperature will cause the
actuator to close the prerotation vanes (and also de-
creases the speed of the motor if equipped with a Vari-
able Speed Drive) to decrease chiller capacity. When
the chilled liquid temperature rises, the actuator will open
the prerotation vanes and increase the compressor
motor speed of the chiller (if controlled by the Variable
Speed Drive), to increase the capacity of the unit.
However, the current draw (amperes) by the compres-
sor motor cannot exceed the setting of the “% CUR-
RENT LIMIT” at any time during the unit operation, since
the MicroComputer Control Center 40 to 100% three
phase peak current limit software function, plus the 3
phase 100% solid state overload current limiter (CM-2)
on Electro-Mechanical Starter applications or the solid
state starter current limit function will override the tem-
perature control function (or the logic section of the
Variable Speed Drive) and prevent the prerotation
vanes from opening beyond the “% CURRENT LIMIT”
setting. LD00466
If the load continues to decrease, after the prerotation FIG. 19 - MINIMUM ENTERING CONDENSING
vanes are entirely closed, the chiller will be shut down WATER TEMPERATURE
by the Low Water Temperature control (LWT) function
which is displayed on the Control Center as: chilled water temperature. Cooling tower fan cycling
will normally provide adequate control of the entering
MON 10:30 AM – LOW WATER TEMPERATURE – AUTOSTART condenser water temperature on most installations.
- or - CHECKING OPERATION
During operation, the following conditions should be
MON 03:50 PM – LOW WATER TEMPERATURE –VSD AUTOSTART
periodically checked:
This occurs when the leaving water temperature falls 1. On starting, the prerotation vanes should remain
to 4°F below setpoint or 36°F, whichever is higher. The closed.
LWT is part of the Micro Board or the capacity control
2. Be sure the oil pump is operating while unit is running.
board (part of the logic section of the Variable Speed
Drive). 3. Check Oil Pressure display. A gradual decrease in
bearing oil pressure of 5 to 10 PSI (with constant
NOTE: If the temperature setpoint has been repro-
suction and discharge pressures) may be an indica-
grammed within the last 10 minutes, the LWT
tion of a dirty filter. The filter should be replaced when
cutout is 36°F for 10 minutes.
pressure loss is 30% or more of the original pres-
sure. The actual bearing oil pressure will vary with
Condenser Water Temperature Control
compressor suction and discharge pressures. When
The YORK Millenium chiller is designed to use less a new system is first operated under normal full load
power by taking advantage of lower than design tem- conditions, the bearing oil pressure should be re-
peratures that are naturally produced by cooling towers corded as a reference point with which to compare
throughout the operating year. Exact control of con- subsequent readings.
denser water, such as a cooling tower bypass, is not
necessary for most installations. The chiller requires only OPERATING LOG SHEET
that the minimum condenser water temperature be no
A permanent daily record of system operating condi-
lower than the value determined by referring to Fig. 19.
tions (temperatures and pressures) recorded at regular
At start-up the entering condenser water temperature intervals throughout each 24 hour operating period
may be as much as 25°F colder than the standby return should be kept.
LD00467 23889A
*NOTE: These items can be printed by an electronic printer connected to J-11 of the Micro Board and pressing the
PRINT key on the Micro Board or automatically using the Data Logger feature.
FIG. 20 - LIQUID CHILLER LOG SHEETS - FORM 160.44-F6
An optional status printer is available for this purpose 2. If the compressor is in operation, check the bear-
or Fig. 20 shows a log sheet used by YORK personnel ing oil pressure by pressing “OIL PRESSURE” key
for recording test data on chillers. It is available from to read the display on the Control Center. Also check
the factory in pads of 50 sheets each under Form No. the oil level in the oil reservoir. Drain or add oil if
160.44-F6 and may be obtained through the nearest necessary.
YORK office. Automatic data logging is possible by con-
3. Check entering and leaving condenser water pres-
necting the optional printer and programming the DATA
sure and temperatures for comparison with job de-
LOGGER function; Ref. Form 146.48-NO1.2.
sign conditions. Condenser water temperatures can
An accurate record of readings serves as a valuable be checked by pressing “CONDENSER LIQUIDTEM-
reference for operating the system. Readings taken when PERATURES” display key.
a system is newly installed will establish normal condi- 4. Check the entering and leaving chilled liquid tem-
tions with which to compare later readings. peratures and evaporator pressure for comparison
For example, dirty condenser tubes may be indicated with job design conditions. This can be accomplished
by higher than normal temperature differences between by pressing the “CHILLED LIQUID TEMPS” key and
leaving condenser water and refrigerant leaving the the “Refrigerant Pressures” key.
condenser. 5. Check the condenser saturation temperature (based
upon condenser pressure sensed by the condenser
OPERATING INSPECTIONS (See Section 2) transducer). Press the “DISPLAY DATA” key. This key
By following a regular inspection using the display may be depressed repeatedly after depressing the
readings of the MicroComputer Control Center, and “Display Hold” key to display three different param-
maintenance procedure, the operator will avoid se- eters.
rious operating difficulty. The following list of inspec- 6. Check the compressor discharge temperature.
tions and procedures should be used as a guide. Press “Display Data” key. During normal operation
discharge temperature should not exceed 220°F.
Daily
7. Check the compressor motor voltage and current
1. Check MicroComputer Control Center displays.
FORM 160.48-O1
(amps) at E-M starter (or Variable Speed Drive), or facturer’s instructions.

on the Control Center display for Solid State Starter b. Meg motor windings - See Fig. 30 for details.
units.
c. Relubricate ball bearings.
8. Check for any signs of dirty or fouled condenser CAUTION: Don’t overlook motor drive end bearing
tubes. (The temperature difference between water located in motor support of F1, F2 com-
leaving condenser and liquid refrigerant leaving the pressors.
condenser should not exceed the difference recorded
for a new unit by more than 4°F.) 4. Purge unit.
9. Verify proper water treatment. a. Clean and inspect all valves.

b. Drain and flush purge shell.
10. If the chiller is controlled by a YORK Variable Speed
Drive, check the operating lights on the logic sec- c. Clean orifices.
tion. (Refer to 160.00-O1) 5. Inspect and service electrical components as nec-
essary.
11. Press the “STATUS” key whenever the display indi-
cates so. This allows any warning messages to be 6. Perform chemical analysis of system.
displayed, such as “EXCESS PURGE”, “HIGH
PURGE PRESSURE”, “REPROGRAM SETPOINTS”, Every Two Years
etc.
1. If unit is equipped with SSS or VSD, flush cooling
circuit and replace with new coolant solution, York
Weekly
Part # 013-04129-000.
1. Check the refrigerant charge. (See “Checking the
Refrigerant Charge”, page 55) NEED FOR PURGING THE SYSTEM
To assure satisfactory operation, it is important that these
Quarterly
systems be kept free of moisture laden air and noncon-
1. Change the purge unit dehydrator at least quarterly, densable gases. Air in the system usually collects in the
or more often if required. condenser, blanketing some of the condensing surface,
causing the discharge pressure and temperature to rise,
2. Clean purge foul gas strainer.
resulting in high operating cost, and possibly surging,
3. Perform chemical analysis of oil. or shutdown of system by high pressure cutout. Mois-
ture in the system causes acid formation which is de-
4. Clean water strainer on VSD (if equipped).
structive to internal system parts.
Semi-Annually (or more often as required.) A Turboguard purge unit is furnished and mounted at
the rear of the system (See Fig. 21). The purpose of
1. Change and inspect compressor oil filter element.
2. Oil return system
a. Change dehydrator.
CHECK VALVE
b. Check nozzle of eductor for foreign particles.
3. Check controls and safety cutouts.
4. Check level of coolant if equipped with SSS or VSD.
FLOAT SWITCH ASS’Y.
Annually (more often if necessary.)

1. Drain and replace the oil in the compressor oil sump
(See “Oil Charging Procedure”, page 44).
PUMP
2. Cooler and Condenser

a. Inspect and clean water strainers.
b. Inspect and clean tubes as required.
c. Inspect end sheets.
d. Backflush heat exchanger on VSD (if equipped).
3. Compressor Drive Motor (See motor manufacturer’s
maintenance and service instruction supplied with
unit)
27406A(D)
a. Clean air passages and windings per manu- FIG. 21 - TURBOGUARD PURGE UNIT
this unit is to automatically remove the mixture of not installed on the Micro Board)
noncondensable gases and refrigerant from the top of • Low Evaporator Pressure
the condenser, expel the noncondensables to the at- • Low Oil Pressure
mosphere and return the refrigerant to the system. • High Condenser Pressure
• Evaporator Transducer or Probe Error
• High Discharge Temperature
IMPORTANT • High Oil Temperature
• Oil Pressure Transducer
The purge unit operates continuously when the
• Starter Malfunction Detected
system is in operation.
• Faulty Discharge Temperature
• Sensor Aux. Safety Shutdown
• Motor Phase Current Unbalance (Solid State Starter
The Turboguard purge unit includes a display message
Unit only)
on the control center display. The message reads
• VSD Shutdowns (See Form 160.00-O1)
WARNING: EXCESS PURGE
If the chiller shuts down on a “Cycling” shutdown the
if an excessive air leak is present within the chiller. The display will read:
“WARNING RESET” should be pushed with the Con-
trol Center in “Service” mode to reset the display. Leak SYSTEM SHUTDOWN – PRESS STATUS
check and correct the leak if the display continues to
show this message. Upon pressing the “status” key the day-of-week, time-
of-day and cause of shutdown are displayed. These shut-
NEED FOR MAINTENANCE OR SERVICE downs do not require the operator to manually reset the
Control Center prior to restarting the chiller. The chiller
If the system is malfunctioning in any manner or the
will automatically restart when the cycling condition is
unit is stopped by one of the safety controls, consult
removed.
Table 2, “Operating Analysis Chart” (pages 50 and 51)
of this instruction manual. After consulting this chart, if
CYCLING SHUTDOWNS
you are unable to make the proper repairs or adjust-
ments to start the compressor or the particular trouble • Power Failure (If auto restart programming jumper is
continues to hinder the performance of the unit, please installed on the Micro Board)
call the nearest YORK District Office. Failure to report • Low Water Temperature
constant troubles could damage the unit and increase • Flow Switch
the cost of repairs considerably. • System Cycling
• Multi-Unit Cycling
NORMAL AND SAFETY SYSTEM SHUTDOWNS • Internal Clock
Normal and safety system shutdowns have been built • Anti-Recycle
into the chiller to protect it from damage during certain • Motor Controller (manual reset of the CM-2 module
operating conditions. Therefore, it should be understood on E-M starter units, the logic board of the SSS or
that at certain pressures and temperatures the system VSD may be required)
will be stopped automatically by controls that respond • Power Fault
to high temperatures, low temperatures, and low and • Low Oil Temperature
high pressures, etc. Table 1 is an explanation of each • Program Initiated Reset
specific shutdown. If the chiller shuts down on a “Safety” • AC Undervoltage
shutdown the display will read • Low Line Voltage (Solid State Starter Units only)
• VSD Shutdowns (See Form 160.00-O1 )
SYSTEM SHUTDOWN – PRESS STATUS
STOPPING THE SYSTEM (See Fig. 4)
Upon pressing the “status” key, the day-of-week, time-
of-day and cause of shutdown are displayed. Safety shut- The MicroComputer Control Center can be programmed
downs require the operator to manually reset the Con- to start and stop automatically (maximum, once each
trol Center prior to restarting the chiller. When the dis- day) whenever desired. Refer to Section 2. To stop the
play reads “Start Sequence Initiated” the cause of the chiller proceed as follows:
safety shutdown is automatically cleared from the 1. Push the compressor switch to “STOP/RESET”. The
memory. Control Center display will show
SAFETY SHUTDOWNS
SYSTEM COASTDOWN
• Power Failure (If auto restart programming jumper is
FORM 160.48-O1
for 150 seconds (6 min. if Micro Board jumper JP-4 2. If freezing temperatures are encountered while the
removed). The compressor, condenser water, and system is idle, carefully drain the cooling water from
cooling tower fans will stop automatically. The oil the cooling tower, condenser, condenser pump, and
pump will continue to run for a period of 150 sec- the chilled water system-chilled water pump and
onds. The oil pump will then stop automatically. coils. Open the drains on the cooler and condenser
Once stopped, the liquid heads to assure complete drainage. (If a Vari-
able Speed Drive, drain its water cooling system. If
SYSTEM COASTDOWN Solid State Starter, drain water from starter cooling
loop. Isolate theTurboguard purge unit from the main
display will be replaced by system.)
SYSTEM READY TO START 3. Isolate the Turboguard purge unit from the main sys-
tem.
2. Stop the chilled water pump (if not wired into the 4. Move jumper J-57 on the Micro Board from CLOCK
Microcomputer Control Center, in which case it will ON position (CLKON) to CLOCK OFF position
shut off automatically simultaneously with the oil (CLKOFF) while 115VAC control power is applied.
pump.) (The actual water pump contact operation is This conserves the battery.
dependent upon the position of Micro Board jumper
J-54.) 5. Open the main disconnect switches to the compres-
sor motor, condenser water pump and the chilled
3. Open the switch to the cooling tower fan motors, if water pump. Open the 115 volt circuit to the Control
used. Center.
4. The compressor sump oil heater (thermostatically
controlled) is energized when the unit is stopped. START UP AFTER PROLONGED SHUTDOWN
1. When putting the system into operation after pro-
PROLONGED SHUTDOWN longed shutdown (during the winter), remove all oil
If the chiller is to be shut down for an extended period of from the compressor. Install a new filter element and
time (for example, over the winter season), the follow- charge compressor with fresh oil. Replace purge unit
ing paragraphs outline the procedure to be followed. and oil return filters. Move jumper J-57 on the micro
board from CLOCK OFF position (CLKOFF) to
1. After the system pressure has risen above atmo- CLOCK ON position (CLKON) and reset the clock.
spheric, test all system joints for refrigerant leaks Energize the 115 volt circuit to the Control Center to
with a leak detector. If equipment room is below 70°F, energize the compressor sump oil heater for at least
circulate hot water (not to exceed 100°F) through 12 hours.
the cooler tubes to raise the system pressure. If any
leaks are found, they should be repaired before al- 2. Operate the “Oil Pump” (press and release the
lowing the system to stand for a long period of time. manual oil pump key) until steady oil pressure is es-
tablished. Then press and release the “Oil Pump”
During long idle periods, the tightness of the system key to stop operation of the oil pump. If the water
should be checked periodically. systems were drained fill the condenser water cir-
cuit and chilled liquid circuit.
SECTION 4
SYSTEM COMPONENTS DESCRIPTION -
COMPRESSOR/MOTOR ASSEMBLY
CASING - The casing is accessible with vertical cir- aluminum impeller. The impeller is designed for balanced
cular joints and fabricated of close-grain cast iron. The thrust. The impeller is dynamically balanced to insure
motor assembly is completely removable from the com- vibration free operation and is overspeed tested for safety.
pressor rotor and scroll assembly. Compressor cast-
BEARINGS - Insert type journal and thrust bearings
ings are designed for 15 PSIG working pressure and
are fabricated of aluminum alloy and are precision bored
hydrostatically pressure tested at 50 PSIG.
and axially grooved.
COMPRESSOR - The rotor assembly consists of a heat
INTERNAL GEARS - Single helical gears with crowned
treated alloy steel drive shaft (integral with pinion gear)
teeth are employed so that more than one tooth is in
and a lightweight, high strength, fully shrouded cast
contact at all times to provide even distribution of the
compressor load with quiet operation. Gears are inte- high voltage) in the terminal box. Provisions are fur-
grally assembled in the compressor rotor support and are nished for 208 through 600 volts for three-lead types of
oil film lubricated. Each gear is individually mounted in starting (solid state, across-the-line, and auto trans-
journal bearings with individual thrust bearings to insure former). Motor terminal lugs are furnished with theYORK
proper balance of forces from the impeller and motor. Current Guard Starter and the Variable Speed Drive
mounted in the power section. Overload/overcurrent
LUBRICATION SYSTEM - YORK lubricating oil is force
transformers (CT’s) are furnished as listed below; in
fed to all bearings and filtered by an externally mounted
motor terminal box, as follows:
15 micron replaceable cartridge oil filter equipped with
service valves. An automatic oil recovery system returns
oil to the compressor that has migrated into the refriger- Application #CT’s Furnished in Motor Terminal Box
ant system. Heat is removed from the oil by a refriger- E-M STARTER 3
ant-cooled oil cooler, located in the evaporator. All oil
piping is completely factory-installed and tested. A ther- SS STARTER 0
mostatically controlled heater is supplied in the oil res-
VS DRIVE 0
ervoir to limit the amount of refrigerant absorbed by
the oil when the compressor is not operating.
Oil (under pressure) is supplied from the oil reservoir by COMPRESSOR LUBRICATION SYSTEM
an internally-mounted submersible oil pump. Oil Pump The chiller lubrication system consists of the oil pump,
motors are available in 208 through 600V-3Ph-60/50Hz oil filter, oil cooler and all interconnecting oil piping and
to match the application and are supplied complete with passages. (See Fig. 22) There are seven main points
starter and current sensing overloads for extra protec- within the motor-compressor which must be supplied
tion. The oil reservoir heater is 1000 watts, 115V-1Ph- with forced lubrication as follows:
60/50Hz immersion type. A separate three phase power
supply is required except when ordered with a YORK 1. Compressor Drive Shaft (Low Speed)
Solid State Starter or Variable Speed Drive. A gravity a. Shaft seal.
flow oil reservoir is provided to feed the bearings and
b. Front and rear journal bearings - one on each
gears during coast down in the event of a power failure.
side of driving gear.
CAPACITY REDUCTION - Prerotation vanes (PRV) c. Low speed thrust bearing (forward and reverse).
modulate the unit capacity from 100% to 10% of design,
2. Compressor Driven Shaft (High Speed)
on normal air conditioning jobs. The prerotation vanes
are airfoil-shaped and made of manganese bronze. An a. Forward and reverse high speed thrust bearing.
external, electric PRV operator automatically controls b. Three journal bearings (YDTJ67 through 95 and
the vane position through a simple, reliable linkage. YDTL108 through 126). Two journal bearings
SHAFT SEAL - The compressor drive shaft seal con- (YDTL131 and 144).
sists of a spring-loaded, precision lapped carbon ring, 3. Speed Increasing Gears
high temperature elastomer “O” ring static seal, and
a. Meshing surfaces of drive and pinion gear teeth.
stress-relieved, precision lapped cast iron collar.The seal
features a small face area and low rubbing speed. It To provide the required amount of oil under the neces-
provides an efficient seal under both vacuum and pres- sary pressure to properly lubricate these parts, a motor
sure conditions. The seal is oil-flooded at all times and driven submersible oil pump is located in a remote oil sump.
is pressure-lubricated during compressor operation. Upon pressing of the “Compressor Start” switch on the
OPEN MOTOR - The 3600 RPM open motor is a drip- control center, the oil pump is immediately energized.
proof, squirrel cage, induction type constructed to YORK After a 30 second delay to allow the system oil pressure
design specifications by nationally-known manufactur- to stabilize, the compressor motor will start. The oil pump
ers. Standard low voltage (208 through 600V-3Ph-60/ will continue to run during the entire operation of the
50Hz) motors are available for full-voltage (across-the- compressor, and for 150 seconds during compressor
line) or reduced-voltage (solid state, star delta or auto coastdown.
transformer) starting. Standard high voltage (2300 The submerged oil pump takes suction from the sur-
through 4160V-3Ph60/50Hz) motors are available for full- rounding oil and discharges it to the oil cooler where
voltage (across-the-line) or reduced-voltage (primary re- heat is rejected. The oil flows from the oil cooler to the
actor or auto transformer) starting. Open close coupled oil filter. The oil leaves the filter and flows to the emer-
motors are built with a cast iron adapter flanged be- gency oil reservoir where it is distributed to the
tween the motor and compressor. This unique design compressor bearings. The oil lubricates the compres-
allows the motor to be coupled to the compressor. sor rotating components and is returned to the oil sump.
MOTOR TERMINAL BOX - The casing is fabricated of Since the emergency oil reservoir is at the highest point
heavy gauge steel. There are six terminals (three for in the lubrication system, it provides an oil supply to
FORM 160.48-O1
the various bearings and gears in the event of a sys- TUBES - Individually-replaceable, 3/4" O.D., integral-
tem shutdown due to power failure. The reservoir, lo- finned copper heat exchanger tubes are used in the
cated on the top of the compressor, allows the oil to be cooler and condenser. The tubes are roller-expanded
distributed through the passages by gravity flow, thus into the tube sheets, providing a leak-proof seal.
providing necessary lubrication during the compres-
COMPACT WATER BOXES - Removable water boxes
sor coastdown.
are fabricated of steel. The standard design working
pressure is 150 PSIG and the boxes are tested at 225
OIL PUMP
PSIG. Integral steel water baffles are located and welded
For normal operation the oil pump should operate at all within the water box to provide required 1, 2, or 3-pass
times during the chiller operation. Manual pump opera- arrangements. Water nozzle connections with Victaulic
tion may be used to establish stable oil pressure before grooves are welded to the water boxes. These nozzle
starting. When depressed and released, the “Manual connections are suitable for Victaulic couplings, weld-
Oil Pump” key will operate the oil pump for 10 minutes ing or flanges (300 PSI has flanges). 1/2" coupling and
and then automatically shut off. To stop the oil pump separable well are located in the entering and leaving
sooner, depress the “Manual Oil Pump” key again. chilled liquid nozzles for temperature sensing elements.
Plugged 1/2" or 3/4" drain and vent connections are pro-
On shutdown of the system for any reason, the oil pump
vided in each water box.
operates and continues to run for 150 seconds. The
system cannot restart during that time interval. COOLER - The cooler is a horizontal, flooded, shell-
and-tube type, with a distribution system consisting of a
OIL HEATER distributor trough to give uniform distribution through-
out the shell length and a perforated distributor plate,
During long idle periods, the oil in the compressor oil
located under the entire tube bundle, to equally distribu-
reservoir tends to absorb as much refrigerant as it can
tor refrigerant. Intermediate steel tube supports are
hold, depending upon the temperature of the oil and the
spaced at intervals of less than four feet. Highly effi-
pressure in the reservoir. As the oil temperature is low-
cient, aluminum mesh eliminators are located above the
ered, the amount of refrigerant absorbed will be
tube bundle to prevent liquid refrigerant carryover into
increased. If the quantity of refrigerant in the oil be-
the compressor.
comes excessive, violent oil foaming will result as the
pressure within the system is lowered on starting. This A liquid level sight glass is conveniently located on the
foaming is caused by refrigerant boiling out of the oil as side of the cooler to aid in determining proper refriger-
the pressure is lowered. If this foam reaches the oil pump ant charge.
suction, the bearing oil pressure will fluctuate with pos-
CONDENSER - The condenser is a horizontal, shell-
sible temporary loss of lubrication, causing the oil pres-
and-tube type, with a discharge gas baffle to prevent
sure safety cutout to actuate and stop the system. See
direct high velocity impingement on the tubes. This baffle
Section 2.
is also used to distribute the refrigerant gas flow prop-
To maintain the lowest possible concentration of refrig- erly for most efficient heat transfer. A purge connection
erant in the oil, the compressor oil reservoir is equip- is located in the condenser for efficient elimination of
ped with a 115 volt electric reservoir oil heater. The oil noncondensibles. Intermediate steel tube supports are
heater is thermostatically controlled at all times during spaced at intervals of less than four feet.
compressor shutdown to maintain the sump oil at 135°F
REFRIGERANT FLOW CONTROL - The flow control
to 145°F. If the oil temperature falls below 55°F, the dis-
chamber is welded to the bottom of the condenser to
play will read
allow complete drainage of liquid refrigerant from the
condenser. The chamber contains a single fixed-orifice
SYSTEM SHUTDOWN – PRESS STATUS flow control with no moving parts.
Pressing the “STATUS” key causes the message to read BURSTING DISC - A 2" or 3" frangible carbon bursting
disc relief device is located in the compressor suction
line.
DAY 10:00 AM – LOW OIL TEMP – AUTOSTART
CONTROL CENTER (See Section 2)
The system will be allowed to automatically restart when
oil temp rises to 71°F. A microprocessor based Control Center is factory
mounted, wired and tested on each chiller. The Control
SHELLS - The cooler and condenser shells are rolled
Center enclosure is a NEMA Type 1 and is provided with
carbon steel plate with fusion welded seams. A thick
a hinged door with lock and key. The MicroComputer
tube sheet is welded to each end of the shell and is
Control Center automatically controls the operation of
drilled and reamed to accommodate the tubes. All shells
the unit in meeting system cooling requirements while
have a design working pressure of 15 PSIG and are
minimizing energy use.
pressure-tested at 30 PSIG.
FIG. 22 - SCHEMATIC DRAWING - YT COMPRESSOR LUBRICATION SYSTEM LD00468
FORM 160.48-O1
SOLID STATE STARTER (OPTIONAL) vane position for maximum part load efficiency by ana-
lyzing information fed to it by sensors located through-
The Solid State Starter is a reduced-voltage liquid cooled
out the chiller.
starter that controls and maintains a constant current
flow to the motor during start-up. The starter is mounted
on the chiller. The power wiring from the starter to the
motor and from the starter control transformer to the
Control Center is factory wired and tested. Available for
200-600V-3Ph-60/50Hz power; 2 or 3 barrel lug connec-
tions per phase are provided on the starter. The starter
enclosure is NEMA Type1 and is provided with a hinged
door with lock and key.
VARIABLE SPEED DRIVE (OPTIONAL)

A 460V-3ph-60/50Hz Variable Speed Drive can be fac-
tory packaged with the chiller. It is designed to vary the
compressor motor speed and prerotation vane position
by controlling the frequency and voltage of the electri-
cal power to the motor. Operational information is con-
tained in Form 160.00-O1. The control logic automati-
cally adjusts motor speed and compressor prerotation
SECTION 5
OPERATIONAL MAINTENANCE
USE OF PUMP ASSISTED TURBOGUARD PURGE UNIT
PURGING THE SYSTEM drop from 90 to 80 PSIA. The pump is also used in the
drain portion of the purge cycle to pump out the purge
To assure satisfactory operation, it is impor tant that
tank. This provides for uniform purge cycle duration. The
these systems be kept free of moisture-laden air and
oil supply to the purge tank is taken downstream from
noncondensible gases. Air in the system usually col-
the chiller oil cooler in order to provide cool oil to the
lects in the condenser, blanketing some of the con-
tank and increase refrigerant separation efficiency. If the
densing surface, causing the discharge pressure and
purge air exhaust solenoid valve tails to open at 90 PSIA,
temperature to rise, resulting in high operating costs
the power to the pump will be cut off at 105 PSIA with
and possibly shutdown of the system by the high pres-
the high pressure cutout switch. Manual reset is required
sure cutout. Moisture in the system causes acid for-
in order to re-energize the boost pump.
mation which is destructive to internal system parts.
A purge unit is furnished to automatically remove the START-UP
mixture of noncondensible gases and refrigerant from the
1. Place the control panel in “PROGRAM” operating
top of the condenser, expel the noncondensibles to the
mode as follows:
atmosphere and return the refrigerant to the system.
a. Press "Access Code" key.
b. This is displayed:
IMPORTANT
day ENTER VALID ACCESS CODE
The purge unit operates continuously only when
the system is in operation.
c. Using "Entry" keys enter the special service ac-
cess code. (See Section 2)
d. As each digit is entered, the characters Y O R K
OPERATION are displayed.
Purge operation is as follows: There is a fill and drain NOTE: If digits other than the correct digits are
cycle which is controlled via the action of the tank float entered, Y O R K is still displayed.
switches. The oil boost pump raises the oil supply pres-
e. Press the “ENTER” key.
sure to the purge tank to enable exhaust release at 90
PSIA. When an exhaust is made, the tank pressure will
CHECK VALVE
PURGE TANK
FLOAT SWITCH ASS’Y
FILTER DRIER
PUMP
2626874A(D) 2627046A(D)
FIG. 23 - PUMP ASSISTED TURBOGUARD PURGE UNIT COMPONENTS
NOTE: If digits other than the correct digits were d. Press the “AUTO” prerotation vanes service key
entered in step No. 4, to verify that the following message is displayed:
day INVALID ACCESS CODE da TURBOGUARD BOOST PUMP SELECTED
is displayed when the “ENTER” key is e. Press the “ACCESS CODE” mode key to exit
pressed. If this occurs, enter the correct “PROGRAM” mode.
access code and proceed.
3. All field piping connections should be leak checked.
f. This is displayed:
4. The purge pump motor will be energized when the
chiller compressor is started; the purge pump motor
DAY ACCESS TO PROGRAM KEY AUTHORIZED
fan should be in motion. If the pump motor fails to start,
try resetting the high pressure cutout switch by de-
NOTE: Unless terminated by pressing the “AC-
pressing and releasing the manual reset button. The
CESS CODE” key again, the operator
purge will go through a fill/drain cycle every 8 to 12
will have access to the “PROGRAM”
minutes depending on the amount of air present in
mode key for 10 minutes. When 10 min-
the system. An air exhaust is made if enough
utes have elapsed, access to the “PRO-
noncondensible is present to bring purge condenser
GRAM” mode key will be automatically
pressure to 90 PSIA. Purge cycling can be monitored
disabled and the operator must return to
on the control panel by using the “DISPLAY DATA”
step No. 1 to gain access.
sevice key to purge tank pressure.
g. Press the “PROGRAM” mode key.
h. This is displayed: Excess Purge Threshold
The excess purge threshold can be programmed by the
day PROGRAM MODE, SELECT SETPOINT service person or customer operator personnel. When this
threshold is met, an excess purge message is displayed
2. Select the Turboguard boost pump, as follows: alternately with the normal foreground message. The ser-
a. Press the “AUTO” prerotation vanes service key. vice person, using the special service access code, can
b. Press the “ADVANCE DAY/SCROLL” entry key program the threshold for 1-30 purges per hour. The cus-
repeatedly (if needed) until the following message tomer operator personnel, using access code 9 6 7 5, can
is displayed: program the threshold for 10-30 purges per hour. The
default value is 20. To enter the excess purge threshold:
day TURBOGUARD BOOST PUMP SELECTED 1. Press the “ACCESS CODE” mode key.
c. Press the “ENTER” key and the display will read: 2. The following message is displayed:
day PROGRAM MODE; SELECT SETPOINT ENTER VALID ACCESS CODE
FORM 160.48-O1
3. Using “entry” keys enter the appropriate access No. 2

code per above description.
60 MINUTE PURGE COUNT BYPASS; XX MIN LEFT
4. As each digit is entered, the characters Y O R K
are displayed. Purge exhausts are not counted during the first 60 min-
utes of chiller operation. Therefore, this message re-
NOTE: If digits other than the correct digits are
places the purge count messages below during the first
entered, Y O R K is still displayed.
hour of operation.
5. Press the “ENTER” key.
No. 3
NOTE: If digits other than the correct digits were en-
tered in step No. 4, PURGES LAST XX MIN = XX; MAX PURGES/HR = XX
After the first hour of chiller operation has elapsed, purge

INVALID ACCESS CODE
exhausts are counted. This message is displayed dur-
is displayed when the “ENTER” key is ing the first hour following the initial 1 hour bypass (see
pressed. If this occurs, enter the correct ac- above), and after the excess purge message is cleared.
cess code and proceed. The minutes elapsed during this first hour of purge ex-
haust counting are displayed. The purge count is
6. The following message is displayed: incremented each time a purge exhaust occurs. Also,
the excess purge threshold that has been programmed
ACCESS TO PROGRAM KEY AUTHORIZED by the operator or service person is displayed as “ MAX
PURGES/HR”. When the minute count reaches 60, this
NOTE: Unless terminated by pressing the “ACCESS message is replaced with the following message:
CODE” mode key again, the operator will
No. 4
have access to the “PROGRAM” mode key
for 10 minutes. When 10 minutes have PURGES LAST HOUR = XX; MAX PURGES/HR = XX
elapsed, access to the “PROGRAM” mode
key will be automatically disabled and the After the initial 1 hour bypass and the first hour of purge
operator must return to step No. 1 to gain exhaust counting has elapsed as explained above (2
access. hours of chiller run time), this message is displayed
thereafter. A running total of the number of purge ex-
7. Press the “PROGRAM” mode key. The following
hausts that have occurred within the last hour is dis-
played. The excess purge threshold that has been pro-
grammed by the operator or service person displayed
PROGRAM MODE, SELECT SETPOINT as “MAX PURGES/HR”.
8. Press the “DISPLAY DATA” service key. This mes- Excess Purge
sage is displayed:
Anytime after the first hour of chiller operation, if the
purge exhaust count equals the programmed “MAX
MAXIMUM PURGES PER HOUR = XX
PURGES/HR” threshold,
9. Using the “ENTRY” keys, enter the desired value. Use
DAY < TIME > WARNING – EXCESS PURGE
leading zeroes where necessary (i.e.: 06).
10. Press the “ENTER” key. is alternately displayed with the normal foreground mes-
11. Press the “PROGRAM” mode key to exit “PRO- sage. The day and time displayed is the time the excess
GRAM” mode. purge event occurred. This message will be displayed
until manually cleared using the “WARNING RESET” ser-
Purge Messages vice key in “SERVICE” mode. Clearing the message also
resets the purge exhaust count to zero and invokes the
The purge messages are displayed as part of the message:
scrolled messages using the “DISPLAY DATA” service
key as follows: PURGES LAST XX MIN = XX; MAX PURGES/HR = XX
No. 1
While the excess purge message is displayed, the purge
PURGE PRESSURE = XXX PSIA exhaust count will continue to increment until the 1 hour
period has elapsed. The count is then frozen until the
This message displays the pressure as sensed hy the excess purge message is cleared. This provides a record
purge transducer. of the total number of purge exhausts that occurred within
the 1 hour period that the excess purge event occurred.
Purge Count of greater than 95.0 PSIA for 255 continuous seconds,
the following message is alternately displayed with the
Following a 1 hour bypass at start, purge exhausts are
normal foreground message:
counted and displayed in the above messages while
the chiller is running. With the exception of the first hour
after the bypass, the value displayed is the number of WARNING – HIGH PURGE PRESSURE
exhausts that have occurred in the “Last Hour”. For ex-
ample, if you walk up to the control panel at 9:11 AM When the pressure decreases to less than 95.0 PSIA,
and press the “DISPLAY DATA” service key and it says the message is automatically cleared.
that there have been 7 purges in the “Last Hour”, that
means that there have been 7 exhausts since 8:11 AM. Excess Purge Alarm Contacts
If you do this at 2:57 PM, it means that there have been A set of alarm contacts are provided on relay board P/N
7 exhausts since 1:57 PM, etc. The purge count is reset 031-00932-002 at terminals TB4-55/56. These are dry
to zero by the following: N.O. contacts rated at 2A inductive @ 250 VAC and 5A
1. Clearing the excess purge message. resistive @ 250 VAC.
2. Moving the Micro Board program jumper J-57 (CLK These contacts can be used to annunciate an excess
ON/OFF) from “CLK OFF” to “CLK ON” position. purge condition to a remote location. Anytime an excess
3. Starting the chiller. purge condition occurs, these contacts close and remain
closed until the excess purge warning message is cleared
The purge count is frozen by the following: by pressing the “WARNING RESET” service key in
1. When the chiller is not running. “SERVICE” mode. This causes the contacts to open.
2. An excess purge message is being displayed and at
least 1 full hour of purge exhausts have accumu- MAINTENANCE
lated. In addition to standard Turboguard purge maintenance
requirements, the exhaust orifice should be cleaned and
High Purge Pressure Warning Message checked on a yearly basis.
If the purge transducer output is indicating a pressure
OIL RETURN SYSTEM
OIL RETURN a. Remove connection on the inlet end of dehydrator.

The oil return system continuously maintains the proper b. Place wrenches on the dehydrator outlet and in-
oil level in the compresor oil sump. (See Fig. 25.) let ends and the flare nut. Loosen the flare nut
and unscrew the dehydrator.
High pressure condenser gas flows continuously through
3. Assemble the new filter-drier as follows:
the eductor inducing the low pressure, oil rich liquid to
flow from the evaporator, through the dehydrator to the a. Place the outlet and inlet ends of the dehydrator
compressor sump. between the flare nuts.
b. Tighten the flare nuts.
CHANGING THE DEHYDRATOR
4. Open condenser stop valve and check dehydrator
To change the dehydrator use the following procedure: connections for refrigerant leaks.
1. Shut the stop valves on the condenser gas line, oil 5. Open all the dehydrator stop valves to allow the li-
return line to rotor support and inlet end of dehydrator. quid refrigerant to flow through the dehydrator and
condenser-gas through the eductor.
2. Remove the dehydrator as follows: Refer to Fig. 26.
FORM 160.48-O1
FIG. 24 - SCHEMATIC OPERATIONAL DIAGRAM LD00471
LD00469 22621A(D)
FIG. 25 - OIL RETURN SYSTEM
FIG. 26 - ASSEMBLY OF DEHYDRATOR LD00470
CHARGING THE UNIT WITH OIL
THE OIL CHARGE the pump discharge connection to the oil charging
valve (A) located on the remote oil reservoir cover
The nominal oil charge for the compressor is: 10 gal.
plate. (See Fig. 27) Do not tighten the connection at
“B” and “C” compressor; 15 gal. “E” and “F’ compres-
the charging valve until after the air is forced out by
sor.
pumping a few strokes of the oil pump. This fills the
New oil YORK Refrigeration Type “C” must be used in lines with oil and prevents air from being pumped
the centrifugal compressor. Since oil absorbs moisture into the system.
when exposed to the atmosphere it should be kept tightly
3. Open the oil charging valve and pump oil into the
capped until used.
system until oil level in the compressor oil reservoir
is about midway in the upper sight glass. Then, close
OIL CHARGING PROCEDURE
the charging valve and disconnect the hand oil pump.
The oil should be charged into the oil reservoir using
4. As soon as oil charging is complete, close the power
the YORK Oil Charging Pump - YORK Part No. 070-
supply to the starter or Variable Speed Drive to en-
10654. To charge oil into the oil reservoir proceed as
ergize the oil heater. (See “System Operating Pro-
follows:
cedures”, page 28). This will keep the concentration
1. The unit should be shut down. of refrigerant in the oil to a minimum.
NOTE: If charging oil to restore the correct level, When the oil reservoir is initially charged with oil, the oil
the unit may be kept in operation. pump should manually be started to fill the lines, pas-
sages, oil cooler and oil filter. This will lower the oil level
2. Immerse the suction connection of the oil charging
in the reservoir. It will then be necessary to add oil to
pump in a clean container of new oil and connect
bring the level back to the center of the upper sight glass.
OIL RESERVOIR
20101A LD00472
CONNECT TO OIL CHARGING VALVE A
FIG. 27 - CHARGING OIL RESERVOIR WITH OIL

FORM 160.48-O1
SECTION 6
TROUBLE SHOOTING
TABLE 1 - CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE
MICROCOMPUTER CONTROL CENTER DISPLAY
SHUTDOWN CAUSE
CONTROL CENTER DISPLAY GOVERNING CONTROL FUNCTION
CONTROL CENTER DISPLAY
DAY OF TIME CAUSE OF METHOD OF OPERATING POINT

DESCRIPTION
WEEK OF DAY SHUTDOWN RESTART ON RISE ON FALL
MON. 10:00 AM Low Water Autostart Low Water (LWT) Chilled water 4°F below chilled
Temperature setpoint water setpoint
MON. 10:00 AM Low Water Autostart Low Water (LWT) Chilled water 4°F below chilled
Temperature VSD setpoint water setpoint
MON. 10:00 AM Flow Switch Autostart Flow Switch
MON. 10:00 AM System Cycling Autostart A remote command

(computer relay contact or
manual switch)
MON. 10:00 AM Multi-Unit Cycling Autostart (Optional)
Lead-Lag Sequence Control
MON. 10:00 AM Internal Clock Autostart Internal Clock
MON. 10:00 AM AC Undervoltage Autostart <15% FLA for 25

continuous seconds
MON. 10:00 AM Power Fault Autostart CM-2 Current Module or
Solid State Starter
Remote Stop Energy Management System
MON. Anti-Recycle, Anti-Recycle
20 Min. Left Timer
MON. 10:00 AM Low Evap. Pressure Low Evap. Pressure 5.43 PSIA 5.42 PSIA
Transducer (LEP)
MON. 10:00 AM Low Evap. Pressure LEP external control Set to Job Spec. Set to Job Spec.
Brine (Brine units only)
MON. 10:00 AM Low Oil Low Oil Press. Transducer (OP) 20 PSID 15 PSID
Pressure High Oil Press. Transducer (OP)
MON. 10:00 AM High Pressure High Pressure 15 PSIG 9 PSIG

Safety Control (HP)
MON. 10:00 AM Evap. Transducer Evap. Pressure Transducer

or Probe Error or Leaving Chilled Water
Thermistor (RS1)
MON. 10:00 AM Motor Controller - CM-2 or Solid State Starter or

Ext. Reset Variable Speed Drive
MON. 10:00 AM High Discharge Discharge Temperature 220°F 219°F
Temperature Thermistor (RT2)
MON. 10:00 AM High Oil Oil Temperature 180°F 179°F
MON. 10:00 AM Power Autostart Micro Board undervoltage 8.29 VDC 7.84 VDC
Failure circuit on 5V unregulated
supply
MON. 10:00 AM Power Micro Board undervoltage 8.29 VDC 7.84 VDC
Failure circuit on 5V unregulated
supply
FORM 160.48-O1
MICROCOMPUTER CONTROL CENTER DISPLAY - CONTINUED
PROGRAMMED START-UP OF PROBABLE CAUSE

SETPOINTS SYSTEM AFTER AND SERVICE
BY OPERATOR SHUTDOWN REQUIRED
4°F below chilled water Automatic Restart when water reaches setpoint. System load is less than minimum capacity.
setpoint (If set to 40°F would If system is running and setpoint is increased
be 36°F.) (36°F minimum) 4°F, system will continue to run, as LWT cutout
shifts to a fixed 36°F for 10 minutes.
4°F below chilled water If system is running and setpoint is increased System load is less than minimum capacity.
setpoint (If set to 40°F would 4°, VSD will Initiate Shutdown. Automatic Restart
be 36°F.) (36°F minimum) when water temperature reaches setpoint.
Automatic Restart when water flow is restored to Lack of water flow.

close flow switch. Check operation of chilled water pump.
Automatic Restart upon remote command. Contact - connected to the Remote/Local
cycling input of the Digital Input Board.
Automatic Restart upon remote command. Contact - connected to the Multi-Unit

cycling input of the Digital Input Board.
Daily Schedule programmed Will automatically restart when programmed Pressing Compressor Start Switch
to shut down unit. schedule permits. overrides the program.
Cycling shutdown occurs when motor current is >15%
FLA for 25 seconds during chiller operation.
Will start automatically following coastdown. Motor Controller contacts opening and closing in less
than 3 seconds due to a power fault condition.
Start up by start signal from remote start switch. Remote Stop Contact Closure.
Will not start until 30 minute Will restart when time left = 00 minutes. Minimum time between successive compressor
timer is timed out. starts is 30 minutes.
To restart, press compressor switch from STOP/RESET See OPERATING ANALYSIS, Table 2
to START position. Sympton 2.
To restart, press compressor switch from STOP/RESET See OPERATING ANALYSIS, Table 2
to START position. Sympton 2.
Will restart when pressure increases to 20 PSID. See OPERATING ANALYSIS, Table 2
To restart, press compressor switch from STOP/RESET Symptom 4, 5, 6, 7, 9, 10, 11.
to START position.
Will restart when pressure falls to 9 PSIG. See OPERATING ANALYSIS, Table 2
To restart, press compressor switch from STOP/RESET Symptom 1 - High Discharge Pressure.
to START position.
To restart, press compressor switch from STOP/RESET Defective Evap. Pressure Transducer or Leaving
to START position. Chiller Water thermistor (RS1). LCWT minus saturation
temp. is less than -2.5°F or greater than 25°F. Checked
every 10 minutes following a 10-min. bypass at start-up.
Reset the device that caused the shutdown. Chiller CM-2 or Solid State Starter or Variable Speed
will start automatically. Drive has shut down chiller.
To restart, press compressor switch from STOP/RESET Condenser tubes dirty or scaled or high condenser
to START position. water temperature. See Symptom 1, Table 2.
To restart, press compressor switch from STOP/RESET Dirty oil filter or restricted oil cooler line. Change oil
to START position. filter. See Sympton 9, Table 2.
Optional AUTO Restart Plug Will restart automatically when voltage reaches 8.29VDC. Power Failure.
is installed on Micro Board. An undervoltage circuit on Micro Board monitors the 5VDC
unregulated supply for an undervoltage condition.
Auto restart plug is removed To restart, press compressor switch to STOP/RESET Power Failure.
on Micro Board. position and then to START position.
SHUTDOWN CAUsE CONTROL CENTER DISPLAY GOVERNING CONTROL FUNCTION
DAY OF TIME CAUSE OF METHOD OF OPERATING POINT

DESCRIPTION
WEEK OF DAY SHUTDOWN RESTART ON RISE ON FALL
MON. 10:00 AM Oil Pressure High Oil Pressure 60 PSID 59 PSID

Transducer Error Transducer or Low
Oil Pressure Transducer
Vane Motor Autostart Vane Motor Switch
Switch Open
MON. 10:00 AM Starter Motor Current >15% for 10

Malfunction seconds with Control Center
Detected not calling for motor to run.
MON. 10:00 AM Program Initiated Autostart Micro Board
Reset
Replace RTC-IC Chip RTC-IC Chip
Reprogram Setpoints
MON. 10:00 AM Low Oil Autostart Oil Temperature 71.0°F 55°F
MON. 10:00 AM Faulty Discharge Discharge Temp. Thermistor 30.0°F 29.9°F
Temperature Sensor (RT2) disconnected or faulty (min.
system operating temp. = 32°F)
MON. 10:00 AM Low Line Voltage SSS Logic Board See legend on wiring diagram.
(SSS units only)
MON. 10:00 AM Motor Phase SSS Logic Board See Section 2.
Current Unbalance
(SSS units only)
FORM 160.48-O1
PROGRAMMED START-UP OF PROBABLE CAUSE

SETPOINTS SYSTEM AFTER AND SERVICE
BY OPERATOR SHUTDOWN REQUIRED
Will start at 59 PSID when compressor switch is This Shutdown is provided to check on Oil pressure
placed to STOP/RESET and then START. Transducers for failure in the high state. Replace Oil
Pressure Transducer in oil sump or compressor.
Restart automatically after Vane Motor arm linkage Vanes are set improperly. Reset vane linkage, check
is set properly. Press STOP/RESET and then vane positions using the Service key switch and proper
START switch. keys on the MicroComputer Control Center or switch
of capacity board of Variable Speed Drive.
Press compressor STOP/RESET switch and then Check motor starter operation. Motor current value
START switch. greater than 15%.
Watchdog timer circuit has reset software program.

Chiller will automatically restart.
Reprogram the Control Center Setpoints and Weak Battery.
proceed with Normal Start-up. Replace RTC-IC chip U16.
Press STOP/RESET switch and then START Oil Temperature Thermistor disconnected from Analog
switch. Input Board. Reconnect or replace open sensor.
Press STOP/START switch and then START Faulty Discharge Temperature Thermistor (RT2) or
switch. disconnected from Analog Input Board. Connect or
replace open sensor.
Chiller will automatically restart when all phases of line Low AC Line Voltage
voltage increase to the minimum required starting level.
Press STOP/RESET switch and then START Motor Phase Current Unbalance
switch.
TABLE 2 - OPERATING ANALYSIS CHART
RESULTS POSSIBLE CAUSE REMEDY
1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE
Temperature difference between liquid Air in condenser. Purge unit operates automatically to take
refrigerant out and water off condenser care of this condition. Test for air leaks if
higher than normal. display
reads: WARNING – EXCESS PURGE
High discharge pressure. Condenser tubes dirty or scaled. Clean condenser tubes.
Check water conditioning.
High condenser water temperature. Reduce condenser water inlet temperature.

(Check cooling tower and water circulation.)
Temperature difference between condenser Insufficient condensing water flow. Increase the quantity of water through the
water on and water off higher than normal, condenser to proper value.
with normal cooler pressure.
2. SYMPTOM: ABNOrMALLY LOW SUCTION PRESSURE
Temperature difference between leaving Insufficient charge of refrigerant. Check for leaks and charge refrigerant into
chilled water and refrigerant in cooler system.
greater than normal with high discharge
temperature. Flow orifice blocked. Remove obstruction.
Temperature difference between leaving Cooler tubes dirty or restricted. Clean cooler tubes.
chilled water and refrigerant in the cooler
greater than normal with normal discharge
temperature.
Temperature of chilled water too low with Insufficient load for system capacity. Check prerotation vane motor operation
low motor amperes. and setting of low water temperature cutout.
3. SYMPTOM: HIGH COOLER PRESSURE
High chilled water temperature. Prerotation vanes fail to open. Check the prerotation vane motor
positioning circuit.
System overloaded. Be sure the vanes are wide open

(without overloading the motor) until the
load decreases.
4. SYMPTOM: NO OIL PRESSURE WHEN SYSTEM START BUTTON PUSHED
Low oil pressure displayed on control Oil pump running in wrong direction. Check rotation of oil pump.
center; compressor will not start. (Electrical Connections)
Oil pump not running. Check electrical connecrtions to oil pump

and press manual reset on oil pump starter
(on condenser shell in front of purge unit).
5. SYMPTOM: COMPRESSOR STARTS, NORMAL OIL PRESSURE DEVELOPS, FLUCTUATES FOR SHORT WHILE, THEN
COMPRESSOR STOPS ON OIL PRESSURE CUTOUT
Oil pressure normal, fluctuates, then com- Unusual starting conditions exist, i.e., oil Drain the oil from the compressor and
pressor stops on Oil Pressure Cutout. foaming in reservoir and piping due to charge new oil into the compressor. (See
Display reading: lowered system pressure. “Oil Charging Procedure”, page 44.)
LOW OIL PRESSURE
Burned out oil heater. Replace oil heater.
FORM 160.48-O1
TABLE 2 - OPERATING ANALYSIS CHART - CONTINUED
RESULTS POSSIBLE CAUSE REMEDY
6. SYMPTOM: UNUSUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS
Unusually high oil pressure is displayed High oil pressure. Transducer defective. Replace low or high oil pressure transducer.
when the oil pressure display key is Relief valve is misadjsuted. Adjust external relief valve.
pressed when the oil pump is running.
7. SYMPTOM: OIL PUMP VIBRATES OR IS NOISY
Oil pump vibrates or is extremely noisy Misalignment of pump or piping. Correct condition or replace faulty part.
with some oil pressure when pressing Mounting bolts loose.
“Oil Pressure” display key. Bent shaft.
Worn pump parts.
NOTE: When oil pump is run without an Oil not reaching pump suction inlet in Check oil supply and oil piping.
oil supply it will vibrate and sufficient quantity.
become extremely noisy.
8. SYMPTOM: OIL PRESSURE GRADUALLY DECREASES (NOTED BY OBSERVATION OF DAILY LOG SHEETS)
Oil pressure (noted when pressing “Oil Oil filter is dirty. Change oil filter.
Pressure” display key) drops to 70% of
oil pressure when compressor was Extreme bearing wear. Inspect compressor.
originally started.
9. SYMPTOM: OIL RETURN SYSTEM CEASES TO RETURN AN OIL/REFRIGERANT SAMPLE
Oil refrigerant return not functioning. Filter-drier in oil return system dirty. Replace oil filter-drier with new.
Jet or office of oil return jet clogged. Remove jet, inspect for dirt.
Remove dirt using solvent and replace.
10. SYMPTOM: OIL PUMP FAILS TO DELIVER OIL PRESSURE
No oil pressure registers when pressing “Oil Faulty oil pressure transducer. Replace oil pressure transducer.
Pressure” display key when oil pump runs. Faulty writing/connectors.
11. SYMPTOM: REDUCED OIL PUMP CAPACITY
Oil pump pumping capacity low. Excessive end clearance in pump. Inspect and replace worn parts.
Other worn pump parts.
Partially blocked oil supply inlet. Check oil inlet for blockage.
12. SYMPTOM: IMPROPER PURGE UNIT OPERATION
Purge unit not purging and air is 1. Faulty float switch assembly. Check these components and replace
present in the unit. 2. Faulty three-way oil solenoid valve. where necessary.
3. Faulty exhaust solenoid valve.
4. Faulty pressure transducer.
Purge unit purging air and refrigerant 1. Faulty exhaust solenoid valve. Restore refrigerant liquid cooling supply.
2. Faulty pressure transducer.
3. Lack of cooling.
SECTION 7
MAINTENANCE
RENEWAL PARTS
For any required Renewal Parts refer to Forms listed on page 2.
CHECKING SYSTEM FOR LEAKS

LEAK TESTING DURING OPERATION To test with R-22, proceed as follows:
The refrigerant side of the system is carefully pressure 1. With no pressure in the system, charge R-22 gas
tested and evacuated at the factory. into the system through the charging valve to a pres-
sure of 2 PSIG.
After the system is in operation under load, the high
pressure components should be carefully leak tested 2. Build up the system pressure with dry nitrogen to
with a leak detector to be sure all joints are tight. If a approximately 10 PSIG. To be sure that the concen-
leak exists frequent purging will be required or refriger- tration of refrigerant has reached all parts of the sys-
ant will be lost. tem, slightly open the oil charging valve and test tor
the presence of refrigerant with a leak detector.
If any leaks are indicated, they must be repaired imme-
diately. Usually, leaks can be stopped by tightening flare 3. Test around each joint and factory weld. It is impor-
nuts or flange bolts. However, if it is necessary to repair tant that this test by thoroughly and carefully done,
a welded joint, the refrigerant charge must be removed spending as much time as necessary and using a
(See “Handling Refrigerant for Dismantling and Repairs”, good leak detector.
page 55).
4. To check for refrigerant leaks in the cooler and con-
denser, open the vents in the cooler and condenser
CONDUCTING PRESSURE TEST
heads and test for the presence of refrigerant. If no
With the refrigerant charge removed and all known leaks refrigerant is present, the tubes and tube sheets may
repaired, the system should be charged with a small be considered tight. If refrigerant is detected at the
amount of R-22 mixed with dry nitrogen so that a halide vents, the heads must be removed, the leak located
torch or electronic leak detector can be used to detect (by means of soap test or leak detector) and repaired.
any leaks too small to be tound by the soap test. Do not
5. When absolute tightness of the system has been
use excessive amounts of R-22; use only enough for
established, blow the mixture of nitrogen and refrig-
proper leak detection.
erant through the charging valve.
EVACUATION AND DEHYDRATION OF UNIT

VACUUM TESTING 3. Operate the vacuum pump in accordance with
“Vacuum Dehydration” until a wet bulb temperature
After the pressure test has been completed the vacuum
of +32°F or a pressure of 5mm Hg. is reached. See
test should be conducted as follows:
Table 3 for corresponding values of pressure.
1. Connect a high capacity vacuum pump, with indica-
4. To improve evacuation circulate hot water (not to
tor, to the system charging valve as shown in Fig. 28
exceed 125°F) through the cooler and condenser
and start the pump (see “Vacuum Dehydration”).
tubes to thoroughly dehydrate the shells. If a source
2. Open wide all system valves, including the purge of hot water is not readily available, a portable water
and gauge valves. Be sure all valves to the atmo- heater should be employed. DO NOT USE STEAM.
sphere are closed. A suggested method is to connect a hose between
FORM 160.48-O1
FIG. 28 - EVACUATION OF CHILLER LD00473
TABLE 3 - SYSTEM PRESSURES
*GAUGE ABSOLUTE BOILING

TEMPERATURES
INCHES OF MERCURY (HG) MILLIMETERS OF
PSIA MICRONS OF WATER °F
BELOW ONE STANDARD ATMOSPHERE MERCURY (HG)
0 14.696 760 760,000 212

10.24* 9.629 500 500,000 192
22.05* 3.865 200 200,000 151
25.98* 1.935 100 100,000 124
27.95* .968 50 50,000 101
28.94* .481 25 25,000 78
29.53* .192 10 10,000 52
29.67* .122 6.3 6,300 40
29.72* .099 5 5,000 35 WATER
29.842* .039 2 2,000 15 FREEZES
29.882* .019 1.0 1,000 +1

29.901* .010 .5 500 -11
29.917* .002 .1 100 -38
29.919* .001 .05 50 -50
29.9206* .0002 .01 10 -70
29.921* 0 0 0
* One standard atmosphere = 14.696 PSIA NOTES: PSIG = Lbs. per sq. in. gauge pressure
= 760 mm Hg. absolute pressure at 32°F = Pressure above atmospheric
= 29.921 inches Hg. absolute at 32°F PSIA = Lbs. per sq. in. absolute pressure
= Sum of gauge plus atmospheric pressure
the source of hot water under pressure and the cooler
head drain connection, out the cooler vent connec-
tion, into the condenser head drain and out the con-
denser vent. To avoid the possibility of causing leaks,
the temperature should be brought up slowly so that
the tubes and shell are heated evenly. Close the sys-
tem charging valve and the stop valve between the
vacuum indicator and the vacuum pump. (See Fig.
28) Then disconnect the vacuum pump leaving the
vacuum indicator in place.
6. Hold the vacuum obtained in Step 3 in the system
for 8 hours; the slightest rise in pressure indicates a
leak or the presence of moisture, or both. If, after 8
hours the wet bulb temperature in the vacuum indi-
cator has not risen above 40°F or a pressure of LD00474
6.3mm Hg, the system may be considered tight.

NOTE: Be sure the vacuum indicator is valved off FIG. 29 - SATURATION CURVE
while holding the system vacuum and be
sure to open the valve between the vacuum
indicator and the system when checking the
vacuum after the 8 hour period. pressure as the system, and the distilled water will be
maintained at the same saturation temperature as any
7. If the vacuum does not hold for 8 hours within the free water in the system, and this temperature can be
limits specified in Step 6 above, the leak must be observed on the thermometer.
found and repaired.
If the system has been pressure tested and found to be
VACUUM DEHYDRATION tight prior to evacuation, then the saturation tempera-
ture recordings should follow a curve similar to the typi-
To obtain a sufficiently dry system, the following instruc- cal saturation curve shown as Fig. 29.
tions have been assembled to provide an effective
method for evacuating and dehydrating a system in the The temperature of the water in the test tube will drop
field. Although there are several methods of dehydrat- as the pressure decreases, until the boiling point is
ing a system, we are recommending the following, as it reached, at which point the temperature will level off
produces one of the best results, and affords a means and remain at this level until all of the water in the shell
of obtaining accurate readings as to the extent of dehy- is vaporized. When this final vaporization has taken place
dration. the pressure and temperature will continue to drop until
eventually a temperature of 35°F or a pressure of 5mm
The equipment required to follow this method of dehy- Hg. is reached.
dration consists of a wet bulb indicator or vacuum gauge,
a chart showing the relation between dew point tem- When this point is reached, practically all of the air has
perature and pressure in inches of mercury (vacuum), been evacuated from the system, but there is still a small
(see Table 3) and a vacuum pump capable of pumping amount of moisture left. In order to provide a medium
a suitable vacuum on the system. for carrying this residual moisture to the vacuum pump,
nitrogen should be introduced into the system to bring it
OPERATION to atmospheric pressure and the indicator temperature
will return to approximately ambient temperature. Close
Dehydration of a refrigeration system can be obtained off the system again, and start the second evacuation.
by this method because the water present in the sys-
The relatively small amount of moisture left will be carried
tem reacts much as a refrigerant would. By pulling down
out through the vacuum pump and the temperature or
the pressure in the system to a point where its satura-
pressure shown by the indicator should drop uniformly
tion temperature is considerably below that of room tem-
until it reaches a temperature of 35°F or a pressure of
perature, heat will flow from the room through the walls
5mm Hg.
of the system and vaporize the water, allowing a large
percentage of it to be removed by the vacuum pump. When the vacuum indicator registers this temperature
The length of time necessary for the dehydration of a or pressure it is a positive sign that the system is evacu-
system is dependent on the size or volume of the sys- ated and dehydrated to the recommended limit. If this
tem, the capacity and efficiency of the vacuum pump, level can not be reached, it is evident that there is a leak
the room temperature and the quantity of water present somewhere in the system. Any leaks must be corrected
in the system. By the use of the vacuum indicator as before the indicator can be pulled down to 35°F or 5mm
suggested, the test tube will be evacuated to the same Hg. in the primary evacuation. During the primary pull-
FORM 160.48-O1
down keep a careful watch on the wet bulb indicator tem- will freeze, and the result will be a faulty temperature
perature, and do not let it fall below 35°F. If the tempera- reading.
ture is allowed to fall to 32°F the water in the test tube
REFRIGERANT CHARGING
To avoid the possibility of freezing the liquid within the TABLE 4 - REFRIGERANT CHARGE
cooler tubes when charging an evacuated system, only SHELL CODES
refrigerant vapor from the top of the drum or cylinder
COOLER COMPRESSOR LBS.
must be admitted to the system until the system pres-
sure is raised above the point corresponding to the freez- G0, G1, G3 B 890
ing point of the cooler liquid. For water, the pressure G0, G1, G3 C 890
corresponding to the freezing point is 20.4 in Hg. vacuum H1, H3 ↓ 970
for R-123 (at sea level).
J1, J3 ↓ 1130
While charging, every precaution must be taken to pre- K1, K3 ↓ 1270
vent moisture laden air from entering the system. Make
G0, G1, G3 E 890
up a suitable charging connection from new copper tub-
ing to fit between the system charging valve and the H1, H3 ↓ 970
fitting on the charging drum. This connection should be J1, J3 ↓ 1130
as short as possible but long enough to permit suffi-
K1, K3 ↓ 1270
cient flexibility for changing drums. The charging con-
nection should be purged each time a full container of L1, L3 ↓ 1390
refrigerant is connected and changing containers should K4, K6 F 1390
be done as quickly as possible to minimize the loss of K7, K9 ↓ 1530
refrigerant.
L4, L6 ↓ 1590
Refrigerant may be furnished in drums containing ei-
ther 100, 200 or 650 Ibs. of refrigerant. These drums use if it should ever become necessary to remove re-
are not returnable and they should be stored for future frigerant from the system.
CHECKING THE REFRIGERANT CHARGE DURING UNIT SHUT DOWN

The refrigerant charge is specified for each chiller model hours or more after the compressor and water pumps
(See Table 4). Charge the correct amount of refrigerant are stopped. The level should be at the center of the
and record the level in the cooler sight glass. sight glass ±1/4 inch.
The refrigerant charge should always be checked and Charge the refrigerant in accordance with the method
trimmed when the system is shut down. shown under “Refrigerant Charging” above. The refrig-
erant level should be observed and the level recorded
The refrigerant charge level must be checked after the
after initial charging.
pressure and temperature has equalized between the
condenser and cooler. This would be expected to be 4
HANDLING REFRIGERANT FOR DISMANTLING AND REPAIRS

If it becomes necessary to open any part of the refriger- If the system must remain open for more than a few
ant system for repairs, the following paragraphs outline hours the refrigerant should be drained and stored in
the procedure for handling the refrigerant while the sys- clean drums for the duration of the repair period.
tem is open.
If conditions permit, the system pressure should be as
Since Refrigerant-123 boils at 82°F under atmospheric near as possible to atmospheric before opening the sys-
pressure, it will not be necessary to remove the refrig- tem and the refrigerant charge should be kept as near as
erant if the system it to be open for only a few hours. possible to 82°F to keep either the refrigerant loss or the
Any part of the system which is above the liquid level air intake to a minimum. After the system has been re-
will be accessible without disturbing the refrigerant assembled, the air should be removed by means of the
charge. purge unit. (See “Purging the System”, page 39.)
MEGGING THE MOTOR
While the main disconnect switch and compressor mo- 2. If readings fall to the left of the applicable curve, re-
tor starter and Variable Speed Drive both open, meg the move external leads from the motor and repeat test.
motor as follows:
NOTE: Motor is to be megged with the stator at ambi-
1. Using a megohm meter (megger), meg between ent temperature after 24 hours of idle standby.
phases and each phase to ground (See Fig. 30); these
readings are to be interpreted using the graph shown
in Fig. 31.
FIG. 30 - DIAGRAM, MEGGING MOTOR WINDINGS LD00475
CONDENSERS AND COOLERS

GENERAL ably before the system is installed. A reliable water treat-
ment company can be consulted to determine whether
Maintenance of condenser and cooler shells is impor-
water treatment is necessary, and if so, to furnish the
tant to provide trouble free operation of the chiller. The
proper treatment for the particular water condition.
water side of the tubes in the shell must be kept clean
and free from scale. Proper maintenance such as tube
CLEANING COOLER AND CONDENSER TUBES
cleaning, and testing for leaks, is covered on the follow-
ing pages. Cooler
It is difficult to determine by any particular test whether
CHEMICAL WATER TREATMENT
possible lack of performance of the water cooler is due
Since the mineral content of the water circulated through to fouled tubes alone or due to a combination of troubles.
coolers and condensers varies with almost every source Trouble which may be due to fouled tubes is indicated
of supply, it is possible that the water being used may when, over a period of time, the cooling capacity de-
corrode the tubes or deposit heat resistant scale in them. creases and the split (temperature difference between
Reliable water treatment companies are available in most water leaving the cooler and the refrigerant tempera-
larger cities to supply a water treating process which ture in the cooler) increases. A gradual drop-off in cool-
will greatly reduce the corrosive and scale forming prop- ing capacity can also be caused by a gradual leak of
erties of almost any type of water. refrigerant from the system or by a combination of foul
ed tubes and shortage of refrigerant charge. An exces-
As a preventive measure against scale and corrosion
sive quantity of oil in the cooler can also contribute to
and to prolong the life of cooler and condenser tubes, a
erratic performance.
chemical analysis of the water should be made prefer-
FORM 160.48-O1
FIG. 31 - MOTOR STATOR TEMPERATURE AND INSULATION RESISTANCES LD00476
Condenser condensers. If acid cleaning is required, YORK recom-
mends the use of this type of organization. The Dow
In a condenser, trouble due to fouled tubes is usually
Industries Service Division of the Dow Chemical Com-
indicated by a steady rise in head pressure, over a pe-
pany, Tulsa, Oklahoma, with branches in principal cities
riod of time, accompanied by a steady rise in condens-
is one of the most reliable of these companies.
ing temperature, and noisy operation. These symptoms
may also be due to foul gas buildup. Purging will re-
TESTING FOR COOLER AND CONDENSER TUBE
move the foul gas revealing the effect of fouling.
LEAKS
TUBE FOULING Cooler and condenser tube leaks may result in refriger-
ant leaking into the water circuit, or water leaking into
Fouling of the tubes can be due to deposits of two types
the shell depending on the pressure levels. If refrigerant
as follows:
is leaking into the water it can be detected at the liquid
1. Rust or sludge, which finds its way into the tubes head vents after a period of shutdown. If water is leak-
and accumulates there. This material usually does ing into the refrigerant, frequent purging will be neces-
not build up on the inner tube surfaces as scale, but sary and system capacity and efficiency will drop off
does interfere with heat transfer. Rust or sludge can sharply. If a tube is leaking and water has entered the
generally be removed from the tubes by a thorough system, the cooler and condenser should be valved off
brushing process. trom the rest of the water circuit and drained immedi-
ately to prevent severe rusting and corrosion. If a tube
2. Scale, due to mineral deposits. These deposits, even
leak is indicated, the exact location of the leak may be
though very thin and scarcely detectable upon physi-
determined as follows:
cal inspection, are highly resistant to heat transfer.
They can be removed most effectively by circulating 1. Allow the system to warm up until a substantial pres-
an acid solution through the tubes. sure is reached for testing. Dry nitrogen (pressure
not to exceed 12 PSIG) may be admitted to the unit
TUBE CLEANING PROCEDURES to increase pressure in the shell. Remove the heads
and listen at each section of tubes for a hissing sound
Brush Cleaning of Tube
that would indicate gas leakage. This will assist in
If the tube fouling consists of dirt and sludge, it can usu- locating the section of tubes to be further investi-
ally be removed by means of the brushing process. Drain gated. If the probable location of the leaky tubes has
the water sides of the circuit to be cleaned (cooling wa- been determined, treat that section in the following
ter or chilled water) remove the heads and thoroughly manner (if the location is not definite, all the tubes
clean each tube with a soft bristle bronze brush. DO will require investigation).
NOT USE A STEEL BRISTLE BRUSH. A steel brush
2. Wash off both tube heads and the ends of all tubes
may damage the tubes.
with water.
Improved results can be obtained by admitting water
into the tube during the cleaning process. This can be
NOTE: Do not use carbon tetrachloride for this pur-
done by mounting the brush on a suitable length of 1/8"
pose since its fumes give the same flame
pipe with a few small holes at the brush end and con-
discoloration that the refrigerant does.
necting the other end by means of a hose to the water 3. With nitrogen or dry air blow out the tubes to clear
supply. them of traces of refrigerant laden moisture from the
circulation water. As soon as the tubes are clear, a
The tubes should always be brush cleaned before acid
cork should be driven into each end of the tube. Re-
cleaning.
peat this with all of the other tubes in the suspected
Acid Cleaning of Tubes section or if necessary, with all the tubes in the cooler
or condenser. Allow the cooler or condenser to remain
If the tubes are fouled with a hard scale deposit, they
corked up to 12 to 24 hours before proceeding.
must be acid cleaned. It is important that before acid
Depending upon the amount of leakage, the corks
cleaning, the tubes be cleaned by the brushing process
may blow from the end of a tube, indicating the loca-
described above. If the relatively loose foreign material
tion of the leakage. If not, it will be necessary to make
is removed before the acid cleaning, the acid solution
a very thorough test with the halide torch.
will have less material to dissolve and flush from the
tubes with the result that a more satisfactory cleaning 4. After the tubes have been corked for 12 to 24 hours,
job will be accomplished with a probable saving of time. it is recommended that two men working at both ends
of the cooler carefully test each tube - one man re-
COMMERCIAL ACID CLEANING moving corks at one end and the other at the op-
posite end to remove corks and handle the test torch.
In many major cities, commercial organizations now of-
Start with the top row of tubes in the section being
fer a specialized service of acid cleaning coolers and
investigated, remove the corks at the ends of one
FORM 160.48-O1
tube simultaneously and insert the exploring tube 6. If any of the tube sheet joints are leaking, the leak
for 5 seconds - this should be long enough to draw should be detected by the test torch. If a tube sheet
into the detector any refrigerant gas that might have leak is suspected, its exact location may be found
leaked through the tube walls. A fan placed at the by using a soap solution. A continuous buildup of
end of the cooler opposite the torch will assure that bubbles around a tube indicates a tube sheet leak.
any leakage will travel through the tube to the torch.
5. Mark any leaking tubes for later identification.
COMPRESSOR
Maintenance for the compressor assembly consists of about by restricted oil lines, passages, or dirty oil filters.
checking the operation of the oil return system and If the unit is shutting down on (HOT) High Oil Tempera-
changing the dehydrator, checking and changing the oil, ture or Low Oil Pressure (OP), change the oil filter ele-
checking and changing the oil filters, checking the ment. Examine the oil filter element for the presence of
operation of the oil heater, checking the operation of aluminum particles. If aluminum particles are noticeable
the oil pump, and observing the operation of the com- and the same conditions continue to stop the unit op-
pressor. eration after a new filter element is installed, notify the
nearestYORK office to request the presence of a YORK
Internal wearing of compressor parts could be a seri-
service man.
ous problem caused by improper lubrication, brought
ELECTRICAL CONTROLS
For information covering the MicroComputer Control the Wiring Diagrams. These diagrams also contain a
Center operation, refer to Section 2. The operating points starting and stopping sequence and timing sequence
of the pressure and temperature cut outs are shown in diagram.
SECTION 8
PREVENTIVE MAINTENANCE
It is the responsibility of the owner to provide the neces- 2. Oil Changing - The oil in the compressor must be
sary daily, monthly and yearly maintenance require- changed annually or earlier if it becomes dark or
ments of the system. IMPORTANT: If a unit failure cloudy.
occurs due to improper maintenance during the war-
ranty period; YORK will not be liable for costs incurred COMPRESSOR MOTOR
to return the system to satisfactory operation.
1. Check motor mounting screws frequently to insure
In any operating system it is most important to provide tightness.
a planned maintenance and inspection of its function-
2. Meg motor windings annually to check for deteriora-
ing parts to keep it operating at its peak efficiency. There-
tion of windings.
fore, the following maintenance should be performed
when prescribed.
PRESSURE TESTING
COMPRESSOR The chiller should be pressure tested annually. Any leaks
1. Oil Filter - The oil filter must be changed when the oil found must be repaired immediately. If frequent purg-
pressure drops 30% or semi-annually if not required ing has occurred, the unit must be pressure tested as
earlier. soon as possible to prevent air and moisture from en-
tering the until. Air and moisture are the worst enemies
When the oil filter is changed it should be inspected of the R-123 system and experience has shown that
thoroughly for any aluminum particles which would units which are maintained tight, are systems that will
indicate possible bearing wear. If aluminum particles provide trouble free efficient operation.
are found this should be brought to the attention of
the nearest YORK office for their further investiga-
tion and recommendations.
COOLER AND CONDENSER Annually
The major portion of maintenance on the condenser and 1. Clean and inspect all valves which are part of the
cooler will deal with the maintaining of the water side of purge unit system.
the condenser and cooler in a clean condition.
2. Drain and flush the oil and refrigerant from the purge
The use of untreated water in cooling towers, closed unit shell.
water systems, etc. frequently results in one or more of
a. Before flushing remove the float assembly from
the following:
the purge unit shell.
1. Scale Formation b. Disconnect the oil line from he bottom of the
2. Corrosion or Rusting purge unit shell.
3. Slime and Algae Formation c. To clean - flush refrigerant from the top of the
It is therefore to the benefit of the user to provide for purge unit shell and let the refrigerant drain from
proper water treatment to provide for a longer and more the bottom through the oil line cormection.
economical life of the equipment. The following recom- d. After a complete flushing, replace the float
mendation should be followed in determining the condi- assembly and the oil drain line.
tion of the water side of the condenser and cooler tubes. 3. Clean the following orifice.
1. The condenser tubes should be cleaned annually or a. One (1) orifice in the liquid line feed to the cool-
earlier if conditions warrant. If the temperature dif- ing coil.
ference between the water off the condenser and
b. Purge unit exhaust orifice.
the condenser liquid temperature is more than 4°
greater than the difference recorded on a new unit it 4. Inspect the foul gas inlet check valve.
is a good indication that the condenser tubes require
cleaning. They should be cleaned as instructed on OIL RETURN SYSTEM
pages 58 and 59 of this manual. 1. Change the dehydrator in the oil return system semi-
2. The cooler tubes under normal circumstances will annually or earlier if the oil return system fails to
not require cleaning. If however the temperature dif- operate.
ference between the refrigerant and the chilled wa- 2. When the dehydrator is changed the nozzle of the
ter increases slowly over the operating season, it is eductor should be checked for any foreign particles
an indication that the cooler tubes may be fouling or that may be obstructing the jet.
that there may be a water by-pass in the water box
requiring gasket replacement. ELECTRICAL CONTROLS
PURGE UNIT 1. All electrical controls should be inspected for obvi-

ous malfunctions.
Every Three Months 2. It is important that the factory settings of controls
1. Change the purge unit dehydrator. (operation and safety) not be changed. If the set-
tings are changed without YORK’s approval the war-
a. If the unit is operating; ranty will be jeopardized.
1) When the purge unit is in the drain cycle, close
3. A 5-11 year life battery is part of the RTC-Real Time
the valve in the high pressure oil supply line
Clock. To replace refer to Section 2.
and allow the unit to complete the drain cycle.
2) Close condenser gas and oil return valves and
replace the dehydrator.
3) Open all valves to return the purge unit to
normal operation.
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA
Copyright © by York International Corporation 1996 ALL RIGHTS RESERVED
Form 160.48-01 (1096)
Supersedes: Nothing

Model Yt G0 A1 B1 Thru Yt L6 D8 F2 (Style H) HCFC-123 (Cooling Only)

Uploaded by

Document Informationclick to expand document informationZ

Document Informationclick to expand document information

Copyright:

Available Formats

Model Yt G0 A1 B1 Thru Yt L6 D8 F2 (Style H) HCFC-123 (Cooling Only)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Model Yt G0 A1 B1 Thru Yt L6 D8 F2 (Style H) HCFC-123 (Cooling Only)

Uploaded by

Copyright:

Available Formats

MILLENNIUM

CENTRIFUGAL LIQUID CHILLERS

MODEL YT G0 A1 B1 thru YT L6 D8 F2 (STYLE H)

WITH MICROCOMPUTER CONTROL CENTERS

Section 1: Description of System and Operational Fundamentals .......................... 4

Section 2: MicroComputer Control Center ................................................................. 6

Section 3: System Operating Procedures ................................................................ 28

Section 4: System Components Description - Compressor/Motor Assembly ...... 35

Section 5: Operational Maintenance ......................................................................... 39

Section 6: Trouble Shooting ...................................................................................... 46

Section 7: Maintenance .............................................................................................. 52

FIG. 1 - YT CHILLER WITH ELECTRO-MECHANICAL STARTER

FIG. 2 - YT CHILLER WITH VARIABLE SPEED DRIVE

FLOW CONTROL OIL COOLER LD00478A

FIG. 3 - REFRIGERANT FLOW THROUGH CHILLER

FIG. 4 - MICROCOMPUTER CONTROL CENTER AND KEYPAD LD00457

DISPLAYING SYSTEM PARAMETERS

NOTE: If the display actually displays X’s, then the moni-

FIG. 5 - SYSTEM PARAMETERS - OUT OF RANGE

FLA value x 100%.

SOLID STATE STARTER NOT INSTALLED To Display OPERATING HOURS:

press and release the “DISPLAY HOLD” key. The mes-

To Display DAILY SCHEDULE Setpoints: REMOTE RESETTEMP RANGE = 10 °F - or -

SUN START = 08:30 AM STOP = 06:00 PM SUPPLYVOLTAGE RANGE 220 – 240 - or -

MON START = 05:00 AM STOP = 07:00 PM SUPPLY VOLTAGE RANGE 380 - or -

TUE START = 05:00 AM STOP = 07:00 PM SUPPLY VOLTAGE RANGE 400 - or -

WED START = 05:00 AM STOP = 07:00 PM SUPPLY VOLTAGE RANGE 415 - or -

THU START = 05:00 AM STOP = 07:00 PM SUPPLYVOLTAGE RANGE 440 – 480 - or -

FRI START = 05:00 AM STOP = 07:00 PM SUPPLYVOLTAGE RANGE 550 – 600 - or -

SAT START = 05:00 AM STOP = 01:00 PM SUPPLY VOLTAGE RANGE DISABLED

A special access code is required to program the Sup-

Use “HOLIDAY” setpoint key as described in the begin-

PROGRAMMING THE MICROCOMPUTER

PROGRAMMING SYSTEM SETPOINTS

ENTER VALID ACCESS CODE ___ ___ ___ ___

3. Using “Entry” keys, enter 9 6 7 5.

INVALID ACCESS CODE

NOTE: Unless terminated by pressing the “ACCESS

is displayed. The Control Center will automatically

LEAVING SETPOINT = XX.X °F (BASE)

(BASE) refers to the base or lowest setpoint avail-

FIG. 7 - KEYPAD - PROGRAMMING “LEAVING

To Enter % CURRENT LIMIT Setpoint:

CURRENT LIMIT = XXX % FLA

2. Use “ENTRY” keys to enter desired value.

PROGRAM MODE, SELECT SETPOINT

(Solid State Starter)

1. Press and release “% CURRENT LIMIT” setpoint key.

2. Use “ENTRY” keys to enter desired current limit value.

To Enter PULL DOWN DEMAND Setpoint:

SETPOINT = XXX MIN @ XXX % FLA, XX MIN LEFT

2. Use “Entry” keys to enter desired values. For expla-

To Enter CLOCK Setpoint:

1. Assure Micro Board Program jumper J-57 is in

CURRENT LIMIT = XXX % FLA

3. Press “ADVANCE DAY|SCROLL” key until the pro-

DAY START XX:XX AM/PM STOP XX:XX AM/PM

ENTER VALID ACCESS CODE _ _ _ _

S M T W T F S__ HOLIDAY NOTED BY *