160.81-EG1, MAXE Model YR Twin-Screw Compressor Liquid Chillers Design Level A · 2016. 10. 21. · YORK INTERNATIONAL 3 FORM 160.81-EG1 Introduction The YORK M AXE YR Chiller offers

FORM 160.81-EG1 (502)

Model YRTwin-Screw Compressor Liquid Chillers

Design Level A

200 through 430 tons (60 Hz)700 through 1500 kW (50 Hz)170 through 365 tons (50 Hz)600 through 1280 kW (50 Hz)

Utilizing HFC-134aMetric Conversions

mRated in Accordance with the latest edition of ARI

STANDARD 550/590

00562VIP

ASHRAE90.1

COMPLIANT

2 YORK INTERNATIONAL

FORM 160.81-EG1

INTRODUCTION.......................................................... 3

RATINGS ..................................................................... 4

OPTIVIEW CONTROL CENTER ................................. 5

MECHANICAL SPECIFICATIONS ............................... 13

ACCESSORIES & MODIFICATIONS .......................... 17

SI METRIC CONVERSION .......................................... 18

APPLICATION DATA.................................................... 19DIMENSIONS – STD. .................................................. 26

Evaporator, Condenser & Water Boxes ................... 26Evaporators, Compact Water Boxes (ft.-in.) ............ 28Evaporators, Compact Water Boxes (mm) .............. 29Condensers, Compact Water Boxes (ft.-in.) ............ 30Condensers, Compact Water Boxes (mm) .............. 31

Floor Layout, Neoprene Isolators (In.) ..................... 32

Floor Layout, Neoprene Isolators (mm) ................... 33

Floor Layout, Spring Isolators (In. and mm) ............ 34

WEIGHTS – Std. and Metric ........................................ 35

GUIDE SPECIFICATIONS ........................................... 36

NOMENCLATURE

The model number denotes the following characteristics of the unit:

YR TD TD T0 – 46 A S

Model

Evaporator Code Design Level

Power Supply:– for 60 Hz5 for 50 Hz

Condenser Code

Compressor Code

Motor Code

Special Features

PAGE

LIST OF TABLES

1 Water Flow Rate Limits ................ 19

2 Motor Voltage Variations .............. 22

3 60 Hz Electrical Data .................... 23

4 Motor Starters ............................... 24

5 50 Hz Electrical Data .................... 24

6 Available Compressor/Shell/Motor Combinations ..................... 24

PAGETABLE

NO.

Table of Contents

3YORK INTERNATIONAL

FORM 160.81-EG1

Introduction

The YORK MAXE YR Chiller offers a complete combina-tion of features for total owner satisfaction.

MATCHED COMPONENTS MAXIMIZE EFFICIENCY

Actual chiller efficiency cannot be determined by ana-lyzing the theoretical efficiency of any one chiller com-ponent. It requires a specific combination of heat ex-changer, compressor, and motor performance to achievethe lowest system IPLV/NPLV. YORK MAXE chiller tech-nology matches chiller system components to providemaximum chiller efficiency under actual – not just theo-retical – operating conditions.

REAL-WORLD ENERGY PERFORMANCE

YORK pioneered the term “Real-World Energy” to il-lustrate the energy-saving potential of focusing on chillerperformance during off-design conditions. Off-designis not only part-load, but full-load operation as well, withreduced entering condenser water temperatures(ECWTs). This is where chillers operate 99% of the time,and where operating costs add up.

The YR MAXE chillers are the only chillers designed tooperate on a continuous basis with cold ECWT and fullcondenser flow at all load points, taking full advantageof Real-World conditions. This type of operation benefitsthe cooling tower as well; reducing cycling of the fanmotor and ensuring good coverage of the cooling fill.

YORK MAXE chillers offer the most efficient Real-Worldoperation of any chiller, meaning lower operating costsand an excellent return on your chiller investment.

HIGH-EFFICIENCY OIL SEPARATOR

MAXE YR Screw Chillers utilize high-efficiency oil sepa-ration, limiting oil carry-over to less than 500 ppm. Oilis vital in screw compressors for lubrication, rotor seal-ing and cooling. However, oil in the evaporator can leadto reduced heat transfer and reduced system perfor-mance. The high-efficiency oil separator keeps the oilin the lube circuit and maximizes heat transfer efficiency.

HIGH-EFFICIENCY HEAT EXCHANGERS

MAXE chiller heat exchangers offer the latest technologyin heat transfer surface design to give you maximumefficiency and compact design. Waterside andrefrigerant-side design enhancements minimize both en-ergy consumption and tube fouling. The “skip-fin” designat all intermediate tube supports provides maximum tubewall thickness at the support area to extend tube life.

FACTORY PACKAGINGREDUCES FIELD LABOR COSTS

YORK MAXE screw chillers are designed to keep instal-lation costs low. Where installation access is not aproblem, the unit can be shipped completely packaged,requiring minimal piping and wiring to complete theinstallation.

For those units utilizing a factory installed Solid-StateStarter, the three power leads provide all power to thechiller and its auxiliaries.

TAKE ADVANTAGE OF COLDER COOLING TOWERWATER TEMPERATURES

YORK MAXE screw chillers are designed to take full ad-vantage of colder cooling tower water temperatures,which are naturally available during most operatinghours. Considerable energy savings are available byletting tower water temperature drop, rather than artifi-cially holding it above 75°F (23.9°C), especially at lowload, as some chillers require.

U.L. ACCEPTANCE – YOUR ASSURANCEOF RELIABILITY

YORK MAXE screw chillers are approved for listing byUnderwriter’s Laboratories for the United States andCanada. Recognition of safety and reliability is your as-surance of trouble-free performance in day-to-day build-ing operation.


FORM 160.81-EG1

Ratings

ARI CERTIFICATION PROGRAM

The performance of YORK MAXE chillers is certifiedto the Air Conditioning and Refrigeration Institute (ARI)complying with the certification sections of the latestissue of ARI Standard 550/590. Under this CertificationProgram, chillers are regularly tested in strict compli-ance with this Standard. This provides an independent,third-party verification of chiller performance.

YORK YR screw chillers are designed to comply withASHRAE Standard 90.1-1999 and 90.1-2001. The su-perior part-load performance of the YORK YR chillersfar exceeds the IPLV/NPLV requirements of ASHRAE90.1, providing superior Real World Energy savingsfor efficiency conscious owners.

COMPUTERIZED PERFORMANCE RATINGS

Each chiller is custom-matched to meet the individualbuilding load and energy requirements. A large num-ber of standard heat exchangers and pass arrange-ments are available to provide the best possible match.

It is not practical to provide tabulated performance foreach combination, as the energy requirements at both

full- and part-load vary significantly with each heat ex-changer and pass arrangement. Computerized ratingsare available through each YORK sales office. Theseratings can be tailored to specific job requirements,and are part of the ARI Certification Program.

OFF-DESIGN PERFORMANCE

Since the vast majority of its operating hours are spentat off-design conditions, a chiller should be chosen notonly to meet the full-load design, but also for its abilityto perform efficiently at lower loads and lower towerwater temperatures. It is not uncommon for chillers withthe same full-load kW/TON to have an operating costdifference of over 10% due to part-load operation.

Part-load information can be easily and accurately gen-erated by computer. And because it is so important toan owner’s operating budget, this information is nowstandard within the ARI Certification Program in theform of an Integrated Part-Load Value (IPLV), and Non-Standard Part-Load Value (NPLV).

The IPLV / NPLV formulas from ARI Standard 550/590closely track chiller operations, and provide a more ac-curate indication of chiller performance than the previ-ous IPLV / APLV formula. A more detailed analysis musttake into account actual building load profiles, and lo-cal weather data. Part-load performance data shouldbe obtained for each job using its own design criteria.

Rated in accordance with the latestissue of ARI Standard 550/590.

5YORK INTERNATIONAL

FORM 160.81-EG1

OptiView Control Center

OPTIVIEW CONTROL CENTER

The YORK OptiView Control Center, furnished as stan-dard on each chiller, provides the ultimate in efficiency,monitoring, data recording, chiller protection and oper-ating ease. The control center is a factory-mounted,wired and tested state-of-the-art microprocessor basedcontrol system for R-134a screw chillers. The panel isconfigured with a 10.4 inch diagonal color Liquid Crys-tal Display (LCD) surrounded by “soft” keys, which areredefined with one keystroke based on the screen dis-play at that time. This revolutionary development makeschiller operation quicker and easier than ever before.Instead of requiring keystroke after keystroke to huntfor information on a small monochrome LCD screen, asingle button reveals a wide array of information on alarge, full-color illustration of the appropriate compo-nent, which makes information easier to interpret. Thisis all mounted in the middle of a keypad interface andinstalled in a locked enclosure.

The LCD display allows graphic animated display ofthe chiller, chiller sub-systems and system parameters;this allows the presentation of several operating param-eters at once. In addition, the operator may view agraphical representation of the historical operation ofthe chiller as well as the present operation. A StatusBar is displayed at all times on all screens. It containsthe System - Status Line and Details Line, the ControlSource, Access Level, Date and Time.

During the Start Sequence and System Lockout Delay,the system status will include a countdown timer indi-cating the time remaining. The control panel is com-patible with the YORK Solid State Starter (optional),Electro-mechanical (E-M) starter, or any customer sup-plied E-M starter that complies with the YORK R-1131standard. The locations of various chiller parametersare clearly marked and instructions for specific opera-tions are provided. The panel verbiage is available inother languages as an option, with English always avail-able. Data can be displayed in either English or Metricunits, plus keypad entry setpoints of 0.1 increments.

Security access is provided to prevent unauthorizedchange of setpoints. This is accomplished with three dif-ferent levels of access and passwords for each level.There are screens, displayed values, programmablesetpoints and manual controls only available with ser-vice level access to the chiller. They are only displayedwhen logged in at the service access level. The AdvancedDiagnostics and troubleshooting information for the chillerand the panel is also included at this access level.

The panel is fused through a 1-1/2 KVA transformer inthe compressor motor starter to provide individual over-current protected power for all controls. Numbered ter-minal strips for wiring such as Remote Start/Stop, FlowSwitch, Chilled Water Pump and Local or Remote Cy-cling Device are provided. The Panel also provides fieldinterlocks that indicate the chiller status. These con-

00550VIP


FORM 160.81-EG1

OptiView Control Center (continued)

tacts include a Remote Mode Ready To Start, a Cy-cling Shutdown, a Safety Shutdown and a chiller RunContact. Pressure transducers sense system pressuresand thermistors sense system temperatures. The out-put of each transducer is a DC voltage that is analo-gous to the pressure input. The output of each ther-mistor is a DC voltage that is analogous to the tem-perature it is sensing.

Setpoints can be changed from a remote location via0-10VDC, 4-20mA, contact closures or through serialcommunications. The adjustable remote reset range [upto 20°F (11.1°C)] provides flexible, efficient use of re-mote signal depending on reset needs. Serial data inter-face to the YORK ISN Building Automation System (BAS)is through the General Protocol Interface Card (GPIC),which can be mounted inside the Control Center.

This printed circuit board requests the required data fromthe Micro Board and makes it available for the YORKISN network. This optional board is available throughthe YORK BAS group. The operating program is storedin non-volatile memory (EPROM) to eliminate chillerfailure due to AC power failure/battery discharge. Pro-grammed setpoints are retained in lithium battery-backed RTC memory for 11 years minimum.

Smart Freeze Point Protection can operate the chilleras low as 36°F (2.22°C) leaving chilled water tempera-ture, without nuisance trips on Low Water Temperature.The sophisticated program and sensor monitors thechiller water temperature to prevent freeze-up. Eachprogrammable point has a pop-up screen with the al-lowable ranges, so the chiller cannot be programmedto operate outside of its design limits.

Thermal ice storage systems are based on the conceptof using off-peak, lower cost electricity to build ice forhandling the cooling load during peak hours. The mostefficient way to build ice is to maximize chiller load andminimize run time. Standard chiller control systems arenot designed for this operating mode. In a typical appli-cation, chillers will load and unload to maintain a leavingchilled liquid setpoint. When the YORK YR chiller oper-ates in the thermal storage control mode, the unit willremain at 100% load until the setpoint shutdown tem-perature is reached. To add greater operating flexibilityand eliminate unnecessary chiller cycling, two differentLow Water (Liquid) Temperature Restart Thresholds canbe programmed, one for the ice mode and one for thestandard cooling mode. This control enhancement is stan-dard on all YR chillers. The chiller can also be left in thestandard control mode for temperatures ranging between20 and 70°F (-6.7 and 21.1°C), for applications involvinga process or comfort cooling duty that requires leavingchilled liquid temperature setpoint control.

When power is applied to the chiller, the HOME screen isdisplayed. This screen displays a visual representation ofthe chiller and a collection of data detailing important op-erations and parameters. When the chiller is running, theflow of chilled liquid is animated by the alternating shadesof color moving in and out of the pipe nozzles. The pri-mary values that need to be monitored and controlled areshown on this screen. They are as follows:

Display Only:• Chilled Liquid Temperature – Leaving

• Chilled Liquid Temperature – Return

• Condenser Liquid Temperature – Return

• Condenser Liquid Temperature – Leaving

• Motor Run (LED)

• % Full-load Amps

• Operating Hours

With the “soft” keys the operator is only one touch awayfrom the 8 main screens that allow access to the majorinformation and components of the chiller. The 8 screensare the SYSTEM, EVAPORATOR, CONDENSER, COM-PRESSOR, OIL SUMP, MOTOR, SETPOINTS, and theHISTORY. Also on the Home Screen is the ability to LogIN, Log OUT and Print. Log In and Log Out is the meansby which different security levels are accessed.

The SYSTEM screen gives a general overview of com-mon chiller parameters for both shells. This is an endview of the chiller with a 3-D cutaway of both the shells.The following can be viewed from this screen:

Display Only:• Discharge Temperature

• Chilled Liquid Temperature – Leaving

• Chilled Liquid Temperature – Return

• Chilled Liquid Temperature – Setpoint

• Evaporator Pressure

• Evaporator Saturation Temperature

• Condenser Liquid Temperature – Leaving

• Condenser Liquid Temperature – Return

• Condenser Pressure

• Condenser Saturation Temperature

• Oil Temperature

• Differential Oil Pressure

• % Full-load Amps

• Current Limit

• Slide Valve Position

7YORK INTERNATIONAL

FORM 160.81-EG1

The EVAPORATOR screen displays a cutaway view ofthe chiller evaporator. All setpoints relating to the evapo-rator side of the chiller are maintained on this screen.Animation of the evaporation process indicates whetherthe chiller is presently in RUN condition (bubbling) andliquid flow in the pipes is indicated by alternating shadesof color moving in and out of the pipes. Adjustable lim-its on the low water temperature setpoints allow thechiller to cycle on and off for greater efficiency and lesschiller cycling. The chiller cycles off when the leavingchilled water temperature is below setpoint and is ad-justable from 1°F (0.55°C) below to a minimum of 36°F(2.22°C). Restart is adjustable from setpoint up to amax. of 80°F (26.6°C). The Panel will check for flow toavoid freeze-up of the tubes. If flow is interrupted, shut-down will occur after a minimum of two seconds. Thefollowing can also be performed through this screen:

Display Only:• Chilled Liquid Flow Switch (Open/Closed)

• Chilled Liquid Pump (Run/Stop)


• Evaporator Saturation Temperature

• Return Chilled Liquid Temperature

• Leaving Chilled Liquid Temperature

• Evaporator Refrigerant Temperature

• Small Temperature Difference

• Leaving Chilled Liquid Temperature Setpoints –Setpoint

• Leaving Chilled Liquid Temperature Setpoints –Remote Range

• Leaving Chilled Liquid Temperature Setpoints –Shutdown

• Leaving Chilled Liquid Temperature Setpoints –Shutdown Offset

• Leaving Chilled Liquid Temperature Setpoints –Restart

• Leaving Chilled Liquid Temperature Setpoints –Restart Offset

• Ice Storage Active (LED)

Programmable:• Local Leaving Chilled Liquid Temperature – Range

• Local Leaving Chilled Liquid Temperature – Setpoint

• Leaving Chilled Liquid Temperature Cycling Offset –Shutdown

• Leaving Chilled Liquid Temperature Cycling Offset –Restart

The CONDENSER screen displays a cutaway view ofthe chiller condenser. The liquid flow is animated to in-dicate flow through the condenser. All setpoints relat-ing to the condenser side of the chiller are maintainedon this screen. With the proper access level this screenalso serves as a gateway to controlling the RefrigerantLevel. The following can also be viewed through thisscreen:

Display Only:• Leaving Condenser Liquid Temperature

• Return Condenser Liquid Temperature


• Condenser Saturation Temperature

• Small Temperature Difference

• High Pressure Switch (Open/Closed)

• Condenser Liquid Flow Switch

• Condenser Liquid Pump (Run/Stop)

Programmable:• High Pressure Warning Threshold

• Freeze Warning (Enabled/Disabled)

• Freeze Time

The COMPRESSOR screen displays a cutaway viewof the chiller compressor, revealing the rotary screw,and shows all conditions associated with the compres-sor. The slide valve positioning is animated and withthe proper Access level, it can be manually controlled.Animation of the compressor rotors indicates whetherthe chiller is presently in a RUN condition. This screenalso serves as a gateway to sub-screens for calibratingthe slide valve or configuring the optional Hot Gas By-pass. From this screen you can view the following:

Display Only:• Differential Oil Pressure

• Oil Temperature

• Discharge Temperature

• Discharge Superheat

• Slide Valve Position

• Oil Return Solenoid (LED)

• Full-load Amps (E.M. Starter Only)

• Phase A, B, C Current (SSS Only)

Programmable:• Slide Valve Load (Manual)

• Slide Valve Hold (Manual)


FORM 160.81-EG1


• Slide Valve Unload (Manual)

• Slide Valve Auto

• Max. Load Temperature

• Minimum Load FLA

• Minimum Load Control Source

The HOT GAS BYPASS screen, accessed from theCOMPRESSOR screen, displays a pictorial of the by-pass line and solenoid valve location on the chiller. TheHot Gas ON and OFF Setpoints are programmed onthis screen and system parameters pertinent to Hot GasBypass operation are displayed. An LED illuminateswhen the Hot Gas solenoid is ON. If the chiller isequipped with the Hot Gas Bypass option, operationmust be enabled on the OPERATIONS screen. Fromthis screen you can perform the following:

Display Only:• Slide Valve Position

• Return Chilled Liquid Temperature

• Leaving Chilled Liquid Temperature

• Hot Gas Solenoid (LED)

Programmable:• On Setpoint

• Off Setpoint

The SLIDE VALVE CALIBRATION screen displays acutaway view of the chiller compressor, revealing therotary screw and slide valve and provides the capabil-ity of calibrating the slide valve. From this screen, youcan perform the following:

Display Only:• Slide Valve Loading (LED)

• Slide Valve Unloading (LED)

• Calibration Message

Programmable:• Start Calibration

• Cancel Calibration

The OIL SEPARATOR screen displays a close-up viewof the chiller oil separator/sump.

Display Only:• Discharge Temperature

• Discharge Superheat

• Oil Pressure

• Discharge Pressure

• Differential Oil Pressure

• Differential Filter Pressure

• Oil Return Solenoid (LED)



• Condenser Saturation

1. The MOTOR “soft” key on the HOME screen, whenpressed, shows a picture of either a YORK Electro-Mechanical Starter or a Solid State Starter, depend-ing on chiller configuration. The Programmablepulldown demand to automatically limit motor load-ing can be used to minimize building demandcharges. Pulldown time period control over fourhours, and verification of time remaining in pulldowncycle from display readout. Separate digital setpointfor current limiting between 30 and 100%.

The ELECTRO-MECHANICAL STARTER (E–M)screen displays a picture of the starter and the follow-ing values. The ones below are common among bothofferings and the values will be displayed on both typesof starter screens. From this screen you can performthe following:

Display Only:• Motor Run (LED)

• Motor Current % Full-load Amps

• Current Limit Setpoints

• Pulldown Demand Time Left

Programmable:• Local Motor Current Limit

• Pulldown Demand Limit

• Pulldown Demand Time

The SOLID STATE STARTER (SSS) screen displays apicture of the starter and the following values, which aredisplayed in addition to the common ones listed above.From this screen, you can perform the following:

Display Only:• Input Power kW

• kW Hours

• Starter Model

• Voltage – Phase A, B, C

• Current – Phase A, B, C

• Temperature – Phase A, B, C

9YORK INTERNATIONAL

FORM 160.81-EG1

Programmable:• Full-load Amps

• Voltage Range

• Starting Current

• Open SCR

• Shorted SCR

• kWH Reset

The SETPOINTS screen provides a convenient loca-tion for programming the most common setpoints in-volved in the chiller control. The Setpoints are shownon other individual screens, but to cut down on need-less searching, they can all be found on this screen.This screen also serves as a gateway to a sub-screenfor defining the setup of general system parameters.From this screen you can perform the following:

Display Only:• Leaving Chilled Liquid Temperature – Setpoint

• Leaving Chilled Liquid Temperature Cycling –

Shutdown

• Leaving Chilled Liquid Temperature Cycling –

Restart

• Current Limit Setpoint

Programmable:• Local Leaving Chilled Liquid Temperature – Range

• Local Leaving Chilled Liquid Temperature – Setpoint

• Leaving Chilled Liquid Temperature Cycling Offset –

Shutdown

• Leaving Chilled Liquid Temperature Cycling Offset –

Restart

• Remote Analog Input Range

• Local Motor Current Limit



• Print

The SETUP is the top level of the general configura-tion parameters. It allows programming of the time anddate, along with specifications as to how the time willbe displayed. In addition, the chiller configuration asdetermined by the Micro Board program jumpers andprogram switches is displayed. From this screen youcan perform the following:

Display Only:• Chilled Liquid Pump Operation (Displays Standard

or Enhanced)

• Anti-Recycle (Displays Disabled or Enabled)

• Power Failure Restart (Displays Manual or Automatic)

• Liquid Type (Displays Water or Brine)

Programmable:• Set Date

• Set Time

• Clock (Enabled/Disabled)

• 12/24 Hour

The following six subscreens can be accessed fromthe SETUP screen:

The SCHEDULE screen contains more programmablevalues than a normal display screen. Each program-mable value is not linked to a specific button; instead,the select key is used to enable the cursor arrows andcheck key to program the Start/Stop times for any dayof the week up to 6 weeks in advance. The user hasthe ability to define a standard set of Start/Stop timesthat are utilized every week or specify exceptions tocreate a special week.

Programmable:• Exception Start/Stop Times

• Schedule (Enable/Disable)

• Repeat Sunday Schedule

• Standard Week Start/Stop Times

• Reset All Exception Days

• Select

• Print


FORM 160.81-EG1


The USER screen allows definition of the language forthe chiller to display and defines the unit of measure.

Programmable:• System Language

• English/Metric Units

The COMMS screen allows the user to define commu-nications parameters.

Programmable:• Chiller ID

• COM 2 Baud Rate

• COM 2 Data Bit(s)

• COM 2 Parity Bit(s)

• COM 2 Stop Bit(s)

• Printer Baud Rate

• Printer Data Bit(s)

• Printer Parity Bit(s)

• Printer Stop Bit(s)

The PRINTER screen permits the user to define com-munications Parameters for the Printer.Display Only• Time Remaining Until Next Print

Programmable• Log Start Time

• Output Interval

• Automatic Printer Logging (Enabled/Disabled)

• Print Type

• Print Report

• Print All Histories

The SALES ORDER screen allows definition of the or-der parameters. Note: This information is loaded at thefactory or by the installation service technician.

Display Only• Model Number

• Panel Serial Number

• Chiller Serial Number

• YORK Order Number

• System Information

• Condenser and Evaporator Design Load Information

• Nameplate Information

The OPERATIONS screen permits definition of param-eters pertaining to operation of the chiller. What is de-fined is whether the control of the chiller will be Local,Digital Remote, Analog Remote, Modem Remote or ISNRemote.

Programmable• Control Source

The HISTORY screen allows the user to browse throughthe last ten faults; either safety or cycling shutdownswith the conditions, while the chiller is running orstopped. The faults are color coded for ease in deter-mining the severity at a glance, recording the date, timeand description. (See Display Messages for Color Codemeanings.)

Display Only• Last Normal Shutdown

• Last Fault While Running

• Last Ten Faults

Programmable:• Print History

• Print All Histories

By pressing the VIEW DETAILS key you will move tothe HISTORY DETAILS screen. From these screensyou are able to see an on-screen printout of all the sys-tem parameters at the time of the selected shutdown.

Display Only:• History Printout

Programmable:• Page Up

• Page Down

• Print History

Also under the HISTORY screen is the TRENDINGscreen, accessible by the key marked the same. Onthis screen, up to six operator-selected parameters, se-lected from a list of over 140, can be plotted in an X/Ygraph format. The graph can be customized to recordpoints once every second up to once every hour. Thereare two types of charts that can be created: singlescreen, or continuous screen. The single screen col-lects data for one screen width (450 data points acrossthe X-axis), then stops. The continuous screen keeps

11YORK INTERNATIONAL

FORM 160.81-EG1

collecting the data, but the oldest data drops off thegraph from left to right at the next data collection inter-val. For ease of identification, each plotted parameter,title and associated Y-axis labeling is color coordinated.

Display Only:• This screen allows the user to view the graphical

trending of the selected parameters and is a gate-way to the graph setup screens.

Programmable:• Start

• Stop

• y-axis

• x-axis

The TREND SETUP screen is used to configure thetrending screen. The parameters to be trended are se-lected from the Trend Common Slots screen, accessedfrom the Slot Numbers button or the Master Slot Num-bers List found in the Operating Manual. The interval atwhich all the parameters are sampled is selected underthe Collection Interval button. The data point minimumand maximum values may be adjusted closer to in-crease viewing resolution.

Programmable:• Chart Type (select continuous or one screen)

• Collection Interval

• Select

• Data Point Slot Number (1 - 6)

• Data Point Min. (1 - 6)

• Data Point Max (1 - 6)

The TREND COMMON SLOTS screen displays theMaster Slot Numbers List of the monitored parameters.

Display Only:• Slot Numbers

Programmable:• Page Up

• Page Down

• Print

DISPLAY MESSAGES

The Control Center continuously monitors the operat-ing system, displaying and recording the cause of anyshutdowns (Safety, Cycling or Normal). The conditionof the chiller is displayed at the System Status line thatcontains a message describing the operating state ofthe chiller; whether it is stopped, running, starting orshutting down. A System Details Line displays Warn-ing, Cycling, Safety, Start Inhibit and other messagesthat provide further details of the Status Bar messages.Messages are color-coded: Green – Normal Operations;Yellow – Warnings; Orange – Cycling Shutdowns; andRed – Safety Shutdowns to aid in identifying problemsquickly.

Status messages include:

• System Ready To Start

• Cycling Shutdown – Auto Restart

• Safety Shutdown – Manual Restart

• Start Sequence Initiated

• System Run (with countdown timers)

• Start Inhibit

• Slide Valve Closing Before Shutdown

• System Lockout Delay

Run Messages include:

• Leaving Chilled Liquid Control

• Motor Pulldown Limit

• Motor – High Current Limit

Start Inhibit Messages include:

• Anti-Recycle XX min/sec.

• Slide Valve – Position >30%

• Motor Current >15% FLA

• LCSSS – High-Temperature Phase X - Stopped

Warning Messages include:

• Real Time Clock Failure

• Setpoint Override

• Condenser – High Pressure Limit

• Evaporator – Low Pressure Limit

• Freeze Threat From Operating Chiller

• Freeze Threat, Condenser Flow Switch Open

• Low Discharge Superheat Limit


FORM 160.81-EG1

• Low Discharge Superheat Detected

• Maximum Load – Load Limit

• Minimum Load – Load Limit

• Oil – Dirty Filter

• Oil – High Temperature

• Slide Valve Uncalibrated

Routine Shutdown Messages Include:

• Remote Stop

• Local Stop

• Place Compressor Switch In Run Position

Cycling Shutdown Messages Include:

• Multiunit Cycling – Contacts Open

• System Cycling – Contacts Open

• Control Panel – Power Failure

• Leaving Chilled Liquid – Low Temperature

• Leaving Chilled Liquid – Flow Switch Open

• Condenser – Flow Switch Open

• Motor Controller – Contacts Open

• Motor Controller – Loss of Current

• Power Fault

• Control Panel – Schedule

Solid State Starter Only (LCSSS)• Initialization Failed

• Serial Communications

• Requesting Fault Data

• Stop Contacts Open

• Power Fault

• Low Phase (X) Temperature Sensor

• Run Signal

• Invalid Current Scale Selection

• Phase Locked Loop

• Low Supply Line Voltage

• High Supply Line Voltage

• Logic Board Processor

• Logic Board Power Supply

• Phase Loss

Safety Shutdown Messages include:

• Evaporator – Low Pressure

• Evaporator – Low Pressure – Smart Freeze

• Evaporator – Transducer or Leaving Liquid Probe

• Evaporator – Transducer or Temperature Sensor

• Condenser – High Pressure Contacts Open

• Condenser – High Pressure

• Condenser – Pressure Transducer Out of Range

• Auxiliary Safety – Contacts Closed

• Discharge – High Temperature

• Discharge – Low Temperature

• Oil – Low Differential Pressure

• Oil or Condenser Transducer Error

• Oil – Clogged Filter

• Oil – High Pressure

• Control Panel – Power Failure

• Watchdog – Software Reboot

Solid State Starter Only (LCSSS)

• Shutdown – Requesting Fault Data . . .

• High Instantaneous Current

• High Phase (X) Heatsink Temperature – Running

• 105% Motor Current Overload

• Motor or Starter – Current Imbalance

• Open SCR

• Phase Rotation



FORM 160.81-EG1

Mechanical Specifications

GENERAL

Each YORK MAXE YR Screw Chiller will be completelyfactory-packaged including evaporator, condenser, com-pressor, motor, OptiView control center and all inter-connecting unit piping and wiring. The chiller will bepainted prior to shipment and will be packaged to pro-tect the unit during shipment.

Performance will be certified in accordance with ARIStandard 550/590.

The initial charge of refrigerant and oil will be suppliedfor each unit.

DRIVELINE

The compressor will be twin-screw, rotary-screw type.The compressor housing will be of cast iron, precisionmachined to provide minimal clearance for the rotors.The rotors will be manufactured from forged steel anduse asymmetric profiles operating at a maximum speedof 3570 RPM (60 Hz) or 2975 RPM (50 Hz). The com-pressor will incorporate a complete anti-friction bearingdesign to reduce power and increase reliability; cylin-drical roller bearings to handle radial loads; and 4 pointangular contact ball bearings to handle axial loads. Thecompressor will have an internal oil reservoir to assurea constant supply of oil to the bearings at all times. Acheck valve will be incorporated in the compressor hous-ing to prevent rotor backspin during shutdown.

Capacity control will be achieved by use of a slide valveto provide fully modulating control from 100% to 20%of full-load. The slide valve will be actuated by systemdifferential pressure, controlled by external solenoidvalves through the OptiView control center. The unitwill be capable of operating with off-design cooling towerwater during part-load operation in accordance with ARIStandard 550/590.

The motor will be 2-pole, continuous-duty, cage-induc-tion type, and will utilize suction gas cooling (semi-her-metic design). Motor full-load amperes at design condi-tions will not exceed chiller nameplate (FLA). Motor willbe designed for use with the type starter specified.

LUBRICATION SYSTEM

An adequate supply of oil will be available to the com-pressor at all times. During operation, oil will be deliv-ered by positive system pressure differential.

An immersion oil heater will be provided, (temperatureactuated), to effectively remove refrigerant from the oilduring the chiller off-cycle. An external, replaceable car-tridge, oil filter will be provided, along with manual isola-

tion stop valves for ease of servicing. An oil eductor willbe provided to automatically remove oil which may havemigrated to the evaporator, and return it to the compres-sor. The oil separator will be of a vertical design with nomoving parts, and will provide high-efficiency oil separa-tion before the refrigerant enters the heat exchangers.The oil separator will be designed, tested, and stampedin accordance with the ASME Boiler and Pressure Ves-sel Code, Section VIII Division 1. Liquid refrigerant in-jection will be provided to maintain satisfactory oil tem-peratures and allow operation of the chiller over the fullrange of conditions.

EVAPORATOR

Evaporator will be of the shell-and-tube, flooded typedesigned for 235 PSIG (1620 kPa) working pressure onthe refrigerant side, and will be tested in accordance withASME code. The shell will be fabricated from rolled car-bon steel plate with fusion welded seams or carbon steelpipe; have carbon steel tube sheets, drilled and reamedto accommodate the tubes; and intermediate tube sup-ports spaced no more than four feet apart. The refriger-ant side will be designed, tested and stamped in accor-dance with the ASME Boiler and Pressure Vessel Code,Section VIII Division 1. Tubes shall be high-efficiency,internally and externally enhanced type having plain cop-per lands at all intermediate tube supports to providemaximum tube wall thickness at the support area. Eachtube will be roller expanded into the tube sheets provid-ing a leak-proof seal, and be individually replaceable.Water velocity through the tubes will not exceed 12 fps.A liquid level sight glass will be located on the side of theshell to aid in determining proper refrigerant charge. Theevaporator will have a refrigerant relief device to meetthe requirements of the ASHRAE 15 Safety Code forMechanical Refrigeration.

Water boxes will be removable to permit tube cleaningand replacement. Stubout water connections havingvictaulic grooves will be provided. Vent and drain con-nections with plugs will be provided on each water box.

CONDENSER

Condenser will be of the shell-and-tube type, designedfor 235 psig (1620 kPa) working pressure on the refrig-erant side, and be tested in accordance with ASME code.The shell will be fabricated from rolled carbon steel platewith fusion welded seams or carbon steel pipe; havecarbon steel tube sheets, drilled and reamed to accom-modate the tubes; and intermediate tube supportsspaced no more than four feet apart. A refrigerantsubcooler will be provided for improved cycle efficiency.The refrigerant side will be designed, tested andstamped in accordance with the ASME Boiler and Pres-


FORM 160.81-EG1

Mechanical Specifications (continued)

sure Vessel Code, Section VIII, Division 1. Tubes shallbe high-efficiency, internally and externally enhancedtype having plain copper lands at all intermediate tubesupports to provide maximum tube wall thickness atthe support area. Each tube will be roller expanded intothe tube sheets providing a leak proof seal, and be indi-vidually replaceable. Water velocity through the tubeswill not exceed 12 fps. The condenser will have refrig-erant relief devices to meet the requirements of theASHRAE 15 Safety Code for Mechanical Refrigeration.

Water boxes will be removable to permit tube cleaningand replacement. Stubout water connections havingvictaulic grooves will be provided. Vent and drain con-nections with plugs will be provided on each water box.

REFRIGERANT SYSTEM

A modulating variable orifice controlled by the OptiViewControl Center to accommodate varying head condi-tions will meter refrigerant flow to the evaporator.

The condenser shell will be capable of storing the en-tire system refrigerant charge during servicing. Servicevalves will be provided to facilitate removal of refriger-ant charge from the system.

The unit will be equipped with a suction strainer to pre-vent any foreign debris introduced to the system duringmaintenance or service to be allowed into the motorhousing. Motors cooled by refrigerant must be protectedby means of filter or strainer to protect the motor andprolong motor life.


General

The chiller will be controlled by a stand-alone micro-processor based control center. The chiller control panelwill provide control of chiller operation and monitoringof chiller sensors, actuators, relays and switches.

Control Panel

The control panel will include a 10.4 inch diagonal colorliquid crystal display (LCD) surrounded by “soft “ keyswhich are redefined based on the screen displayed atthat time. It will be mounted in the middle of a keypadinterface and installed in a locked enclosure. The screenwill detail all operations and parameters, using a graphi-cal representation of the chiller and its major compo-nents. Panel verbiage is available in other languagesas an option with English always available. Data can bedisplayed in either English or Metric units. Smart FreezePoint Protection will run the chiller at 36 °F (2.2°C) leav-

ing chilled water temperature, and not have nuisancetrips on low water temperature. The sophisticated pro-gram and sensor will monitor the chiller water tempera-ture to prevent freeze up. When needed, Hot Gas By-pass is available as an option. The panel displays count-down timer messages so the operator knows when func-tions are starting and stopping. Every programmablepoint will have a pop-up screen with the allowableranges, so that the chiller can not be programmed tooperate outside of its design limits.

The control panel is provided with a thermal ice stor-age control mode to enhance system performance dur-ing ice building operation. In the thermal storage con-trol mode, the chiller will stay at 100% load until thesetpoint shutdown temperature is reached. To addgreater operating flexibility and eliminate unnecessarychiller cycling, two different Low Water (Liquid) Tem-perature Restart Thresholds are programmable, one forthe ice mode and one for the standard cooling mode.The chiller has the capability to remain in the standardcontrol mode for temperatures between 20 to 70°F (-6.6 to 21.1°C) for applications involving a process orcomfort cooling duty that requires leaving chilled liquidtemperature setpoint control.

The chiller control panel also provides:

1. System operating information including:

a. return and leaving chilled liquid temperature

b. return and leaving condenser liquidtemperature

c. evaporator and condenser saturationtemperature

d. oil pressure at compressor and oil filterdifferential

e. percent motor current

f. evaporator and condenser saturationtemperature

g. compressor discharge temperature

h. oil temperature

i. percent slide valve position

j. operating hours

k. number of unit starts

2. Digital programming of setpoints through the uni-versal keypad including:

a. leaving chilled liquid temperature

b. percent current limit

c. pull-down demand limiting

d. six-week schedule for starting and stopping thechiller, pumps and tower

e. remote reset temperature range


FORM 160.81-EG1

3. Status messages indicating:

a. system ready to start

b. system running

c. system coastdown

d. system safety shutdown-manual restart

e. system cycling shutdown-auto restart

f. start sequence initiated

g. start inhibit

4. The text displayed within the system status andsystem details field will be displayed as a colorcoded message to indicate severity: red for safetyfault, orange for cycling faults, yellow for warnings,and green for normal messages.

5. Safety shutdowns enunciated through the displayand the status bar, and consist of system status,system details, day, time, cause of shutdown, andtype of restart required. Safety shutdowns with afixed speed drive will include:

a. evaporator – low pressure

b. evaporator – low pressure – smart freeze

c. evaporator – transducer or leaving liquid probe

d. evaporator – transducer or temperature sensor

e. condenser – high pressure contacts open

f. condenser – high pressure

g. condenser – pressure transducer out of range

h. auxiliary safety – contacts closed

i. discharge – high temperature

j. discharge – low temperature

k. oil – low differential pressure

l. oil or condenser transducer error

m. oil – clogged filter

n. oil – high pressure

o. control panel – power failure

p. watchdog – software reboot

5.1. Safety shutdowns with a Solid State Starter(LCSSS) will include:

a. shutdown – requesting fault data…

b. high instantaneous current

c. high phase (X) heatsink temperature - running

d. 105% motor current overload

e. motor or starter – current imbalance

f. phase (X) shorted SCR

g. open SCR

h. phase rotation

6. Cycling shutdowns enunciated through the displayand the status bar, and consists of system status,system details, day, time, cause of shutdown, and

type of restart required. Cycling shutdowns with afixed speed drive will include:

a. multiunit cycling – contacts open

b. system cycling - contacts open

c. control panel - power failure

d. leaving chilled liquid - low temperature

e. leaving chilled liquid - flow switch open

f. condenser – flow switch open

g. motor controller – contacts open

h. motor controller – loss of current

i. power fault

j. control panel - schedule

6.1. Cycling shutdowns with a Solid State Starter(LCSSS) will include:

a. initialization failed

b. serial communications

c. requesting fault data

d. stop contacts open

e. power fault

f. low phase (X) temperature sensor

g. run signal

h. invalid current scale selection

i. phase locked loop

j. low supply line voltage

k. high supply line voltage

l. logic board processor

m. logic board power supply

n. phase loss

7. Security access to prevent unauthorized changeof setpoints, to allow local or remote control of thechiller, and to allow manual operation of the slidevalve. Access is through ID and password recog-nition, which is defined by three different levels ofuser competence: view, operator, and service.

8. Trending data with the ability to customize pointsof once every second to once every hour. The panelshall trend up to 6 different parameters from a listof over 140, without the need of an external moni-toring system.

9. The operating program stored in non-volatilememory (EPROM) to eliminate reprogramming thechiller due to AC power failure or battery discharge.Programmed setpoints will be retained in lithiumbattery-backed RTC memory for a minimum of 11years with power removed from the system.

10. A fused connection through a transformer in thecompressor motor starter to provide individualover-current protected power for all controls.


FORM 160.81-EG1

Mechanical Specifications (continued)

11. A numbered terminal strip for all required field in-terlock wiring.

12. An RS-232 port to output all system operating data,shutdown / cycling message, and a record of thelast 10 cycling or safety shutdowns to a field-sup-plied printer. Data logs to a printer at a set pro-grammable interval. This data can bepreprogrammed to print from 1 minute to 1 day.

13. The capability to interface with a building automa-tion system to provide:

a. remote chiller start and stop

b. remote leaving chiller liquid temperature adjust

c. remote current limit setpoint adjust

d. remote ready to start contacts

e. safety shutdown contacts

f. cycling shutdown contacts

g. run contacts

STARTUP AND OPERATOR TRAINING

The services of a factory-trained, field service repre-sentative will be provided to supervise the initial startupand conduct concurrent operator instruction.

CODES AND STANDARDS• ASME Boiler and Pressure Vessel Code – Section

Vlll Division 1.

• ARI Standard 550/590

• c/U.L. – Underwriters Laboratory

• ASHRAE 15 – Safety Code for Mechanical Refrig-eration

• ASHRAE Guideline 3 – Reducing Emission of Ha-logenated Refrigerants in Refrigeration and Air-Con-ditioning Equipment and Systems

• NEC – National Electrical Code

• OSHA – Occupational Safety and Health Act

ISOLATION MOUNTING

The unit is provided with four vibration isolation mountsconsisting of 1" (25.4 mm) thick neoprene isolation padsfor field mounting under the steel mounting pads lo-cated on the tube sheets.

REFRIGERANT CONTAINMENT

The standard unit has been designed as a completeand compact factory packaged chiller. As such, it hasminimum joints from which refrigerant can leak. Theentire assembly has been thoroughly leak tested atthe factory prior to shipment. The YORK chiller in-cludes service valves conveniently located to facili-tate transfer of refrigerant to a remote refrigerant stor-age/recycling system. Optional condenser isolationvalves permit storage of the charge in the condenser.

PAINT

Exterior surfaces are protected with one coat of Carib-bean blue, durable alkyd-modified, vinyl enamel, ma-chinery paint.

SHIPMENT

The unit shall be completely assembled, with all main,auxiliary, and control piping installed, controls wired,leak tests completed, functional run tests completed,and refrigerant charge in place. The oil charge, reliefdevice and other miscellaneous materials shall bepacked separately.

Protective covering is furnished on the Control Centerand unit-mounted controls. The entire unit is then shrink-wrapped with high-quality reinforced plastic to providemaximum protection during transit. Water nozzles arecapped with fitted plastic enclosures.


FORM 160.81-EG1

Accessories and Modifications

SOLID STATE STARTER

The Solid State Starter is a reduced voltage starter thatcontrols and maintains a constant current flow to themotor during startup. It is compact and mounted on thechiller at the motor terminals. Power and control wiringis factory supplied. Available for 200-600 volts, thestarter enclosure is NEMA-1 with a hinged access doorwith lock and key. Electrical lugs for incoming powerwiring are provided.

Standard features include: digital readout at the OptiV-iew Control Center of the following:

Display Only:• 3-phase voltage A, B, C

• 3-phase current A, B, C

• Input power (kW)

• kW Hours

• Starter Model

• Motor Run (LED)







Other features include: low line voltage; 115-volt con-trol transformer; three-leg sensing overloads; phase ro-tation and single-phase failure protection; high tempera-ture safety protection; motor current imbalance andundervoltage safeties; open and close SCR protection;momentary power interruption protection. The LCSSSis cooled by a closed-loop, fresh water circuit consist-ing of a water-to-water heat exchanger and 1/25 HPcirculating pump. All interconnecting water piping isfactory installed and rated for 150 PSIG working pres-sure. Optional unit-mounted circuit breaker includesground fault protection and provides 65,000 amp short-circuit withstand rating in accordance with UL Standard508. A non-fused disconnect switch is also available.Both options are padlockable.

BAS REMOTE CONTROL

A communication interface permitting complete ex-change of chiller data with any BAS system is availablewith optional ISN translator. ISN translator also allowsBAS system to issue commands to the chiller to controlits operation. ISN translators come in two models, con-trolling up to four chillers and eight chillers respectively.

FACTORY INSULATION OF EVAPORATOR

Factory-applied thermal insulation of the flexible, closed-cell plastic type, 3/4" (19mm) thick is attached with va-por-proof cement to the evaporator shell, flow cham-ber, evaporator tube sheets, suction connection, and(as necessary) to the auxiliary tubing. Not included isthe insulation of water boxes and nozzles. This insula-tion will normally prevent condensation in environmentswith relative humidities up to 75% and dry bulb tem-peratures ranging from 50° to 90°F (10° to 32°C). 1-1/2" (38mm) thick insulation is also available for relativehumidities up to 90% and dry bulb temperatures rang-ing from 50° to 90°F (10° to 32°C).

WATER FLANGES

Four 150 Ib. ANSI raised-face flanges, for condenserand evaporator water connections, are factory weldedto water nozzles. Companion flanges, bolts, nuts andgaskets are not included.

SPRING ISOLATION MOUNTING

Spring Isolation mounting is available instead of stan-dard isolation mounting pads when desired. Four level-adjusting/spring-type vibration isolator assemblies withnon-skid pads are provided with mounting brackets forfield installation. Isolators are designed for one-inch(25.4 mm) deflection.

WATER FLOW SWITCHES

Paddle-type, vapor-proof water flow switches suitablefor 150 psig (1034 kPa) DWP for chilled and condenserwater circuits. Switch for 115V-1-50/60 Hz service. Achilled water flow switch is required. Condenser waterflow switch is optional.

SEQUENCE CONTROL KIT

For two, three or four units with chilled water circuitsconnected in series or parallel, the kit consists of returnwater thermostat, lead-lag selector switch for sequencestarting, and time delay relay, with NEMA-1 enclosures,designed for 115V-1-50/60 Hz.

STARTER – FIELD INSTALLED

A field installed, electro-mechanical compressor motorstarter is available, selected for proper size and typefor job requirements and in accordance with YORK En-gineering Standard R-1131 for Starters.


FORM 160.81-EG1

MARINE WATER BOXES

Marine water boxes allow service access for cleaningof the heat exchanger tubes without the need to breakthe water piping. Bolted-on covers are arranged for con-venient access. Victaulic nozzle connections are stan-dard; flanges are optional. Marine water boxes are avail-able for condenser and/or evaporator.

KNOCK-DOWN SHIPMENT

The chiller can be shipped knocked-down into majorassemblies (evaporator, condenser, driveline, etc.) as

required to rig into tight spaces. This is particularly con-venient for existing buildings where equipment roomaccess does not allow rigging a factory packaged chiller.

REFRIGERANT STORAGE/RECYCLING SYSTEM

A refrigerant storage/recycling system is a self-containedpackage consisting of a refrigerant compressor with oilseparator, storage receiver, water-cooled condenser, fil-ter drier and necessary valves and hoses to remove,replace and distill refrigerant. All necessary controls andsafety devices are a permanent part of the system. Typi-cally not required if unit isolation valves are provided.

Accessories and Modifications (continued)

SI Metric ConversionThe following factors can be used to convert from English to the most common Sl Metric values.

MEASUREMENT MULTIPLY THIS BY TO OBTAIN THISENGLISH VALUE METRIC VALUE

CAPACITY TONS REFRIGERANT EFFECT (ton) 3.516 KILOWATTS (kW)

POWER KILOWATTS (kW) NO CHANGE KILOWATTS (kW)

HORSEPOWER (hp) 0.7457 KILOWATTS (kW)

FLOW RATE GALLONS / MINUTE (gpm) 0.0631 LITERS / SECOND (L/s)

LENGTH FEET (ft) 304.8 MILLIMETERS (mm)

INCHES (in) 25.4 MILLIMETERS (mm)

WEIGHT POUNDS (lb) 0.4536 KILOGRAMS (kg)

VELOCITY FEET / SECOND (fps) 0.3048 METERS / SECOND (m/s)

PRESSURE DROP FEET OF WATER (ft) 2.989 KILOPASCALS (k Pa)

POUNDS / SQ. INCH (psi) 6.895 KILOPASCALS (k Pa)

Integrated Part Load Value (IPLV)

In the English I-P system, IPLV is calculated by the fol-lowing formula. A full explanation is shown on page 4:

1 IPLV*= 0.01

+0.42

+0.45

+ 0.12A B C D

Where: A = kW / ton at 100% Load @ 85°F ECFTB = kW / ton at 75% Load @ 75°F ECFTC = kW / ton at 50% Load @ 65°F ECFTD = kW / ton at 25% Load @ 65°F ECFT

In SI Metric, the formula is:

IPLV* = 0.01A + 0.42B + 0.45C + 0.12D

Where: A = COP at 100% Load @ 29.4°C ECFTB = COP at 75% Load @ 23.9°C ECFTC = COP at 50% Load @ 18.3°C ECFTD = COP at 25% Load @ 18.3°C ECFT

NOTE:* The Non-Standard Part-Load Value (NPLV) uses the IPLV formula

with the following exceptions: the ECFT for part-load points varieslinearly from the selected EFT to 65°F (18.3°C) from 100% to 50%loads, and fixed at 65°F (18.3°C) for 50% to 0% loads.


FORM 160.81-EG1

The following is a user’s guide in the application andinstallation of MAXE Chillers, and will ensure the reli-ability and trouble-free life for which this equipment wasdesigned. While this guide is directed towards normal,water-chilling applications, the YORK sales represen-tatives can provide complete recommendations on othertypes of applications.

Location

MAXE Chillers are virtually vibration-free and generallycan be located at any level in a building where the con-struction will support the total system operating weight.

The unit site must be a floor, mounting pad or founda-tion which is level within 1/4" (6.4 mm) and capable ofsupporting the operating weight of the chiller.

Sufficient clearance to permit normal service and main-tenance work should be provided all around and abovethe unit. Additional space should be provided at oneend of the unit to permit cleaning of evaporator andcondenser tubes as required. A doorway or other prop-erly located opening may be used.

The chiller should be installed in an indoor location wheretemperatures range from 40°F to 110°F (4.4°C to 43.3°C).

Water Circuits

Flow Rate – For normal water chilling duty, evaporatorflow rates are permitted at water velocity levels in the heatexchangers tubes of between 3 ft./second and 12 ft./sec-ond (0.91 m/s and 3.66 m/s). Condenser flow rates arepermitted between 3.33 ft./sec. and 12 ft./sec. (1.01 m/sand 3.66 m/s). Variable flow applications are possible, andinitial chiller selections should be made accordingly topermit proper range of flow while maintaining the mini-

Application Data

mum velocity noted above. Variable flow in the condenseris not recommended, as it generally raises the energy con-sumption of the system by keeping the condenser pres-sure high in the chiller. Additionally, the rate of fouling inthe condenser will increase at lower water velocities asso-ciated with variable flow, raising system maintenance costs.Cooling towers typically have narrow ranges of operationwith respect to flow rates, and will be more effective withfull design flow. Ref. Table 1 for flow limits.

Temperature Ranges – For normal water chilling duty,leaving chilled water temperatures may be selected be-tween 38°F (3.3°C) [36°F (2.2°C) with Smart Freeze en-abled) and 70°F (21.1°C) for water temperature rangesbetween 3°F and 30°F (1.7°C and 16.7°C).

Water Quality – The practical and economical applicationof liquid chillers requires that the quality of the water supplyfor the condenser and evaporator be analyzed by a watertreatment specialist. Water quality may affect the perfor-mance of any chiller through corrosion, deposition of heat-resistant scale, or sedimentation or organic growth. Thesewill degrade chiller performance and increase operating andmaintenance costs. Normally, performance may be main-tained by corrective water treatment and periodic cleaningof tubes. If water conditions exist which cannot be correctedby proper water treatment, it may be necessary to provide alarger allowance for fouling, and/or to specify special mate-rials of construction.

General Piping – All chilled water and condenser waterpiping should be designed and installed in accordancewith accepted piping practice. Chilled water and condenserwater pumps should be located to discharge through thechiller to assure positive pressure and flow through theunit. Piping should include offsets to provide flexibility andshould be arranged to prevent drainage of water from the

1 383 (24.2) 1525 (96.2) 613 (38.7) 2204 (139.1)2 192 (12.1) 762 (48.1) 307 (19.4) 1102 (69.5)3 128 (8.1) 508 (32.1) 205 (12.9) 734 (46.3)1 468 (29.5) 1866 (118.0) 683 (43.1) 2455 (154.9)2 234 (14.8) 932 (58.8) 342 (21.6) 1227 (77.4)3 157 (9.9) 621 (39.2) 228 (14.4) 818 (51.6)1 570 (36.0) 2277 (143.7) 771 (48.7) 2774 (175.0)2 286 (18.0) 1138 (71.8) 386 (24.4) 1386 (87.5)3 ––– ––– ––– ––– ––– ––– ––– –––1 693 (43.7) 2771 (174.9) 866 (54.6) 3462 (218.5)2 346 (21.8) 1385 (87.4) 433 (27.3) 1731 (109.2)3 231 (14.6) 924 (58.3) 289 (18.2) 1154 (72.8)1 822 (51.9) 3287 (207.4) 1082 (68.3) 4328 (273.1)2 411 (25.9) 1644 (103.7) 541 (34.1) 2164 (136.5)3 274 (17.3) 1096 (69.2) 361 (22.8) 1443 (91.1)1 986 (62.2) 3945 (248.9) 1350 (85.2) 5400 (340.1)2 493 (31.1) 1972 (124.4) 675 (42.6) 2700 (170.0)3 ––– ––– ––– ––– ––– ––– ––– –––

TB, VB

TC, VC

TD, VD

WB, XB

WC, XC

WD, XD

SHELLCODE PASS EVAPORATOR CONDENSER

MINIMUM MAXIMUM MINIMUM MAXIMUM

TABLE 1 – WATER FLOW RATE LIMITS – GPM (L/s)


FORM 160.81-EG1

Application Data (continued)

evaporator and condenser when the pumps are shut off.Piping should be adequately supported and braced inde-pendently of the chiller to avoid the imposition of strain onchiller components. Hangers must allow for alignment ofthe pipe. Isolators in the piping and in the hangers arehighly desirable in achieving sound and vibration control.

Convenience Considerations – To facilitate the perfor-mance of routine maintenance work, some or all of thefollowing steps may be taken by the purchaser. Evapora-tor and condenser water boxes are equipped with pluggedvent and drain connections. If desired, vent and drainvalves may be installed with or without piping to an opendrain. Pressure gauges with stop cocks, and stop valves,may be installed in the inlets and outlets of the condenserand chilled water line as close as possible to the chiller.An overhead monorail or beam may be used to facilitateservicing.

Connections – The standard chiller is designed for 150psig (1034 kPa) design working pressure in both thechilled water and condenser water circuits. The con-nections (water nozzles) to these circuits are furnishedwith grooves for Victaulic couplings. Piping should bearranged for ease of disassembly at the unit for tubecleaning. All water piping should be thoroughly cleanedof all dirt and debris before final connections are madeto the chiller.

Chilled Water – A flow switch must be installed in thechilled water line of every unit. The switch must be lo-cated in the horizontal piping close to the unit, where thestraight horizontal runs on each side of the flow switchare at least five pipe diameters in length. The switchmust be electrically connected to the chilled water inter-lock position in the unit control center. A water strainer ofmaximum 1/8" (3.2 mm) perforated holes must be field-installed in the chilled water inlet line as close as pos-sible to the chiller. If located close enough to the chiller,the chilled water pump may be protected by the samestrainer. The flow switch and strainer assure chilled wa-ter flow during unit operation. The loss or severe reduc-tion of water flow could seriously impair the chiller per-formance or even result in tube freeze-up.

Condenser Water – The chiller is engineered for maxi-mum efficiency at both design and part-load operationby taking advantage of the colder cooling tower watertemperatures which naturally occur during the wintermonths. Appreciable power savings are realized fromthese reduced heads.

The minimum entering condenser water temperaturefor other full and part-load conditions is provided by thefollowing equation:

°F Min ECWT = LCHWT + 16 + [(% load/100) x(10 - full-load condenser water ∆ T)]

°C Min ECWT = LCHWT + 8.9 + [(% load/100) x(5.6 - full-load condenser water ∆ T)]

Where: ECWT = entering condenser water temperatureLCHWT = leaving chilled water temperature

MULTIPLE UNITS

Selection – Many applications require multiple units tomeet the total capacity requirements as well as to pro-vide flexibility and some degree of protection againstequipment shutdown. There are several common unitarrangements for this type of application. The MAXEchiller has been designed to be readily adapted to therequirements of these various arrangements.

Parallel Arrangement (Refer to Fig. 1) – Chillers maybe applied in multiples with chilled and condenser wa-ter circuits connected in parallel between the units. Fig.1 represents a parallel arrangement with two chillers.Parallel chiller arrangements may consist of equally orunequally sized units. When multiple units are in op-eration, they will load and unload at equal percentagesof design full-load for the chiller.

Depending on the number of units and operating char-acteristics of the units, loading and unloading schemesshould be designed to optimize the overall efficiency ofthe chiller plant. It is recommended to use an evaporatorbypass piping arrangement to bypass fluid around evapo-rator of any unit which has cycled off at reduced loadconditions. It is also recommended to alternate the chillercycling order to equalize chiller starts and run hours.

FIG. 1 – PARALLEL EVAPORATORSPARALLEL CONDENSERS

LD00507

Series Arrangement (Refer to Fig. 2) – The chillersmay be applied in pairs with chilled water circuits con-


FORM 160.81-EG1

nected in series and condenser water circuits connectedin parallel. All of the chilled water flows through both cool-ers with each unit handling approximately one-half of thetotal load. When the load decreases to a customer se-lected load value, one of the units will be shut down by asequence control. Since all water is flowing through theoperating unit, that unit will cool the water to the de-sired temperature.

FIG. 2 – SERIES EVAPORATORSPARALLEL CONDENSERS

LD00508

BRINE APPLICATIONS

The YR Screw Chiller, utilizing the Frick Refrigeration com-pressor, is a good match for the high head requirementsof low temperature brine applications. This is particularlytrue of thermal ice storage systems, typically requiring 22°F(–5.6°C) to 24°F (–4.4°C) leaving brine temperatures. Thisperformance is enhanced with the standard thermal stor-age control mode described on page 6.

Particular attention must be paid to the application oftwo or more chillers with evaporators in parallel or se-ries when the brine temperature is below 32°F (0°C).The brine MUST NOT flow through the evaporator ofthe idle chiller, because it can cause the condenser wa-ter to freeze. A bypass or other type of arrangement isrequired that shuts off flow to the idle evaporator. Whenunits are applied in series with lead/lag capability, theunits should be identical.

REFRIGERANT RELIEF PIPING

Each chiller is equipped with pressure relief devices.The purpose of the relief devices is to quickly relieveexcess pressure of the refrigerant charge to atmosphere,as a safety precaution in the event of an emergencysuch as a fire. They are set to relieve at an internalpressure of 235 psig (1620 kPa) and are located on thecondenser, evaporator and oil separator; and are pro-vided in accordance with ASHRAE 15 Safety Code andASME or applicable pressure vessel code. Under thesecircumstances the relief devices may be relief valves,

overflow valves or type tested Safety Pressure switchesor a combination of these devices.

Sized to the requirements of applicable codes, a ventline must run from the relief device to the outside of thebuilding. This refrigerant relief piping must include acleanable, vertical-leg dirt trap to catch vent-stack con-densation. Vent piping must be arranged to avoid im-posing a strain on the relief connections and shouldinclude one flexible connection.

SOUND AND VIBRATION CONSIDERATIONS

A MAXE chiller is not a source of objectionable soundand vibration in normal air conditioning applications. Neo-prene isolation mounts are furnished as standard witheach unit. Optional level-adjusting spring isolator assem-blies designed for 1" static deflection are available.

MAXE chiller sound pressure level ratings will be fur-nished upon request.

Control of sound and vibration transmission must be takeninto account in the equipment room construction as wellas in the selection and installation of the equipment.

THERMAL INSULATION

No appreciable operating economy can be achievedby thermally insulating the chiller. However, the chiller’scold surfaces should be insulated with a vapor barrierinsulation sufficient to prevent condensation. A chillercan be factory insulated with 3/4" (19mm) or 1-1/2"(38mm) thick insulation, as an option. This insulationwill normally prevent condensation in environmentswith dry bulb temperatures of 50°F to 90°F (10°C to32°C) and relative humidities up to 75% [3/4" (19mm)thickness] or 90% [1-1/2" (38mm) thickness]. The in-sulation is painted and the surface is flexible and rea-sonably resistant to wear. It is intended for a chillerinstalled indoors and, therefore, no protective cover-ing of the insulation is usually required. If insulation isapplied to the water boxes at the job site, it must beremovable to permit access to the tubes for routinemaintenance.

VENTILATION

The ASHRAE Standard 15 Safety Code for Mechani-cal Refrigeration requires that all machinery rooms bevented to the outdoors utilizing mechanical ventilationby one or more power-driven fans. This standard, plusNational Fire Protection Association Standard 90A,state, local and other related codes should be reviewedfor specific requirements.


FORM 160.81-EG1

Application Data (continued)In addition, the ASHRAE Standard 15 requires a refriger-ant vapor detector to be employed for all refrigerants. It isto be located in area where refrigerant from a leak wouldbe likely to concentrate. An alarm is to be activated andthe mechanical ventilation started at a value no greaterthan the TLV (Threshold Limit Value) of the refrigerant.

ELECTRICAL CONSIDERATIONS

Motor Voltage – Low voltage motors (200 - 600 volts)are furnished with six leads. Motor circuit conductor sizemust be in accordance with the National Electrical Code(NEC), or other applicable codes, for the motor full-load amperes (FLA). Flexible conduit should be usedfor the last several feet to the chiller in order to providevibration isolation. Table 2 lists the allowable variationin voltage supplied to the chiller motor. The unit name-plate is stamped with the specific motor voltage and fre-quency for the appropriate motor.

Power Factor Correction Capacitors – Capacitors canbe applied to a chiller for the purpose of power factorcorrection. For remote-Mounted Electro-MechanicalStarters, the capacitors should be located on the loadside of the starter. For YORK SSS, the capacitors mustbe located on the line side of the starter. The capacitorsmust be sized and installed to meet the National Elec-trical Code (NEC) and be verified by YORK.

Ampacity on Load Side of Starter – Electrical powerwire size to the chiller is based on the minimum unitampacity. For YORK SSS, this wiring is done at thefactory. For remote starters, the National Electrical Codedefines the calculation of ampacity, as summarized be-low. More specific information on actual amperage rat-ings will be supplied with the submittal drawings.

• Six-lead type of starting (Star-Delta)

Minimum circuit ampacity per conductor (1 of 6): Ampacity = .721 x compressor motor amps.

• Three-lead type of starting(Across-the-Line, Autotransformer andPrimary Reactor)

Minimum circuit ampacity per conductor (1 of 3): Ampacity = 1.25 x compressor motor amps.

Ampacity on Line Side of Starter –The only additional load on the circuit for the chillerwould be the control transformer, unless it is suppliedby a separate source.

125% of compr. +

FLA of all otherMin. Circuit Ampacity =

motor amps loads on the circuit

Branch Circuit Overcurrent Protection – The branchcircuit overcurrent protection device(s) should be a time-delay type, with a minimum rating equal to the next stan-dard fuse/breaker rating above the calculated value. It iscalculated taking into account the compressor motoramps and may also include control transformer. Referto submittal drawings for the specific calculations for eachapplication.

MOTOR ELECTRICAL DATA

The full-load amperes (FLA) listed in Tables 3 and 4are maximum values and correspond to the maximummotor kW listed. When the Input power (kW) is lessthan maximum motor kW, the FLA should be reducedusing the following equation:

Starters – The chiller is available with a factory-mountedand wired YORK Solid State Starter for 200 - 600 voltapplications. Other types of remote mounted startersare available. These electro-mechanical starters mustbe furnished in accordance with YORK Standard R-1131. Specification. This will ensure that starter com-ponents, controls, circuits, and terminal markings willbe suitable for required overall system performance.

Controls – A 115 volt, single phase, 60 or 50 Hertz(4.5 kVa) power supply must be furnished to the chillerfrom a separate, fused disconnect or from a controltransformer included as an option with electro-mechani-cal starters. No field control wiring is required, whenthe YORK SSS is supplied.

Copper Conductors – Only copper conductors shouldbe connected to compressor motors and starters. Alu-minum conductors have proven to be unsatisfactorywhen connected to copper lugs. Aluminum oxide andthe difference in thermal conductivity between copperand aluminum cannot guarantee the required tight con-nection over a long period of time.

TABLE 2 – MOTOR VOLTAGE VARIATIONS

200 200/208 180 220230 220/240 208 254380 380 342 415460 440/460/480 414 508575 575/600 520 635380 380/400 342 423415 415 374 440

60 HZ

50 HZ

FREQ. RATEDVOLTAGE

NAMEPLATEVOLTAGE MIN. MAX.

OPERATING VOLTAGE


FORM 160.81-EG1

FLA =Motor kW

x Max. Motor FLAMax. Motor kW

The benefit from the FLA correction is the possible useof smaller power wiring and/or starter size.

The locked rotor amperes (LRA) are read directly fromTables 3 and 4 for specific Motor Code and voltage. Thisis because the LRA is dependent only on motor size andvoltage and is independent of input power (kW).

Inrush amperes (IRA) depend on LRA and the type ofstarter applied. The inrush can be calculated using apercentage of LRA shown in Table 5.

TABLE 3 – 60 HZ ELECTRICAL DATA

NAME- AMP MOTOR DATACOMP. PLATE (MAX) 100% 90% 80% 70% 60% 50% 40% 30% 20% MAX.

VOLT. FLA LRA PF EFF PF EFF PF EFF PF EFF PF EFF PF EFF PF EFF PF EFF PF EFF KW (hp)200 850 3634 88.2 94.8 87.8 95.2 87.3 95.5 85.8 95.7 84.3 95.9 80.4 96.0 76.5 96.0 65.8 95.2 55.1 94.4

208 825 3779 86.6 95.0 85.6 95.3 84.6 95.5 82.6 95.7 80.5 95.9 75.5 95.8 70.5 95.7 59.0 94.8 47.4 93.8

230 725 2901 89.2 94.5 89.1 95.0 89.0 95.4 88.2 95.7 87.3 96.0 84.5 96.1 81.6 96.2 72.4 95.6 63.1 94.9

240 695 3027 88.2 94.9 87.7 95.2 87.2 95.5 85.8 95.8 84.3 96.0 80.4 96.0 76.5 96.0 65.8 95.2 55.0 94.4

T0/T1 380 438 1727 89.3 94.6 89.3 95.0 89.2 95.4 88.5 95.7 87.8 96.0 85.1 96.1 82.4 96.2 73.5 95.6 64.6 95.0 251.6

440 370 1390 89.6 94.2 89.8 94.7 90.0 95.2 89.6 95.6 89.2 95.9 87.2 96.1 85.2 96.3 77.7 95.9 70.1 95.4 (321)

460 354 1453 89.2 94.6 89.1 95.0 88.9 95.4 88.1 95.7 87.3 96.0 84.5 96.1 81.6 96.2 72.4 95.6 63.1 94.9

480 339 1516 88.2 94.9 87.7 95.2 87.2 95.5 85.8 95.8 84.3 96.0 80.4 96.0 76.5 96.0 65.8 95.2 55.0 94.4

575 300 1162 89.2 94.6 89.1 95.0 88.9 95.4 88.1 95.7 87.3 96.0 84.4 96.1 81.5 96.2 72.3 95.6 93.1 95.0

600 288 1213 88.2 94.9 87.7 95.3 87.2 95.6 85.8 95.8 84.3 96.0 80.4 96.0 76.5 96.0 65.8 95.3 55.0 94.5

200 882 4048 90.4 94.8 90.2 95.2 90.0 95.5 89.2 95.8 88.3 96.0 85.6 96.0 82.9 96.0 73.8 95.3 64.7 94.6

208 860 4210 89.1 95.0 88.5 95.3 87.8 95.6 86.4 95.8 94.9 96.0 81.3 96.0 77.6 95.9 67.1 95.0 56.5 94.1

230 760 3520 90.5 94.7 90.4 95.1 90.2 95.4 89.5 95.7 88.7 95.9 86.2 96.0 83.7 96.0 75.0 95.4 66.3 94.7

240 737 3673 89.3 95.0 88.8 95.3 88.3 95.5 86.9 95.7 85.4 95.9 81.9 95.9 78.3 95.9 67.9 95.0 57.5 94.1

T2/T3 380 464 2130 90.3 94.8 90.1 95.2 89.9 95.5 89.1 95.8 88.2 96.0 85.6 96.0 82.9 96.0 73.8 95.3 64.7 94.6 275.9

440 400 1603 91.0 94.4 91.2 94.9 91.4 95.3 91.1 95.6 90.8 95.9 89.3 96.1 87.7 96.2 80.9 95.7 74.0 95.1 (351)

460 383 1676 90.5 94.7 90.4 95.1 90.2 95.5 89.5 95.8 88.7 96.0 86.2 96.1 83.7 96.1 75.0 95.4 66.2 94.7

480 372 1749 89.3 95.0 88.8 95.3 88.2 95.6 86.8 95.8 85.4 96.0 81.8 96.0 78.2 95.9 67.9 95.0 57.5 94.1

575 305 1408 90.7 94.7 90.7 95.1 90.6 95.5 90.0 95.8 89.4 96.0 87.2 96.1 85.0 96.2 77.0 95.5 68.9 94.8

600 293 1469 89.9 95.0 89.5 95.3 89.1 95.6 88.0 95.8 86.9 96.0 83.8 96.0 80.7 96.0 71.0 95.2 61.2 94.4

NOTE: FLA = Full-load Amps; LRA = Locked Rotor Amps; PF = Power Factor; EFF = Motor Efficiency100% Loading is Percentage of Maximum Motor Load; not of Specific Application


FORM 160.81-EG1

TYPESTARTER

SOLIDSTATE

STARTERSTAR DELTA AUTO TRANSFORMER ACROSS

THE LINE

60HZ50 HZ

TRANSITION% TAP

INRUSHAS A % OF LRA

200-600380-415

NONE—45

200-600380-415

CLOSED—33

200-600380-415

OPEN—33

200-600380-415

CLOSED57.733

200-600380-415

CLOSED65

42.3

200-600380-415

CLOSED8064

200-600380-415

——

100

TABLE 5 – MOTOR STARTERS

TABLE 4 – 50 HZ ELECTRICAL DATA

NAME- AMP MOTOR DATACOMP. PLATE (MAX) 100% 90% 80% 70% 60% 50% 40% 30% 20% MAX.

VOLT. FLA LRA PF EFF PF EFF PF EFF PF EFF PF EFF PF EFF PF EFF PF EFF PF EFF KW (hp)380 364 1414 89.3 93.7 89.2 94.3 89.1 94.8 88.4 95.2 87.7 95.6 84.9 95.8 82.1 95.9 73.3 95.3 64.5 94.7

T0/T1 400 348 1488 88.2 94.1 87.7 94.6 87.2 95.0 85.9 95.3 84.5 95.6 80.4 95.7 76.3 95.7 65.6 94.9 54.9 94.1210.2

415 333 1544 89.2 93.8 89.1 94.4 88.9 94.9 88.1 95.3 87.3 95.6 84.3 95.8 81.3 95.9 72.2 95.3 93.1 94.6(267)

380 390 1639 90.4 94.0 90.3 94.5 90.1 94.9 89.4 95.3 88.6 95.6 86.2 95.8 83.7 96.0 75.2 95.4 66.6 94.8

T2/T3 400 371 1725 89.6 94.4 89.1 94.8 88.6 95.2 87.3 95.5 85.9 95.7 82.4 95.8 78.9 95.8 68.5 95.1 58.1 94.3231.9

415 354 1790 90.4 94.0 90.3 94.5 90.1 94.9 89.3 95.3 88.5 95.6 86.1 95.8 83.6 95.9 75.1 95.4 66.5 94.8(292)

TABLE 6 – AVAILABLE COMPRESSOR/SHELL COMBINATIONS

COMPRESSOR EVAPORATOR CONDENSERCODE SHELL SHELL

T0, T1TB, TC, TD TB, TC, TD

VB, VC, VD VB, VC, VD

T1 WB, WC, WD WB, WC, WD

T2/T3WB, WC, WD WB, WC, WD

XB, XC, XD XB, XC, XD

NOTE: FLA = Full-load Amps; LRA = Locked Rotor Amps; PF = Power Factor; EFF = Motor Efficiency100% Loading is Percentage of Maximum Motor Load; not of Specific Application


FORM 160.81-EG1

00562VIP

CONDENSERSIGHT GLASS

LIQUID LINEVARIABLE ORIFICE

OPTIVIEW GRAPHICCONTROL CENTER

MOTOR END COMPRESSOREND

OPTIONALUNIT MOUNTEDSOLIDSTATESTARTER

2-STAGE HIGHEFFICIENCYOIL SEPARATOR


FORM 160.81-EG1

TOP VIEW8-1/2"

(216 mm)

M

RELIEF VALVES (SEE TABLE)

JAK

2' - 3-1/2"(698 mm)

2' - 6-1/4"(768 mm)

3'-8-3/4 "(1136.7 mm)

OIL SEPARATOR

SOLID STATE STARTER(OPTIONAL)

OPTIVIEWCONTROL PANEL

L

F

CD E

G

B

SECTION A - A

CONDENSER EVAPORATOR

RELIEF VALVENOTE: ONLY SUPPLIED ON UNITS WITH OPTIONAL ISOLATION VALVES

ISOLATION VALVENOTE: OPTIONAL

H

RELIEF VALVE(SEE TABLE)

ISOLATION VALVENOTE: OPTIONAL

FRONT OF UNIT

MOTOR COMPRESSORMOTOR

ENDCOMPRESSOR

END

MOTOREND

COMPRESSOREND

B

C

U

P

Dimensions

LD07981

FIG. 3 – T0 & T3 COMPRESSORS – EVAPORATOR, CONDENSER AND WATER BOXES DIMENSIONS

RELIEF VALVES* LOCATION WITH ISOLATION WITHOUT ISOLATION

VALVES VALVESEVAPORATOR 1" SINGLE 1" DUAL

CONDENSER 1" DUAL 1" SINGLE

DISCHARGE1-1/4" SINGLE NONE

LINE*All are NPT female


FORM 160.81-EG1

WATER BOX DIMENSIONS (FT. - IN)

DIM.EVAPORATORS W & X CONDENSER W & X

1 PASS 2 PASS 3 PASS 1 PASS 2 PASS 3 PASSH 1'–2-1/4" 1'–2-1/4" 1'–2-1/4" — — —

J — — — 1'–2-1/4" 1'–2-1/4" 1'–2-1/4"

DIM. REAR HEAD 2 PASS REAR HEAD 2 PASSK 5-5/8" 5-5/8"

WATER BOX DIMENSIONS (mm)

DIM.EVAPORATORS W & X CONDENSER W & X

1 PASS 2 PASS 3 PASS 1 PASS 2 PASS 3 PASSH 362 362 362 — — —

J — — — 362 362 362

DIM. REAR HEAD 2 PASS REAR HEAD 2 PASSK 143 143

WATER BOX DIMENSIONS (FT. - IN)

DIM.EVAPORATORS T & V CONDENSER T & V

1 PASS 2 PASS 3 PASS 1 PASS 2 PASS 3 PASSH 1'–2-3/4" 1'–1-1/2" 1'–1-1/2" — — —

J — — — 1'–2-3/4" 1'–0-1/2" 1'–0-1/2"

DIM. REAR HEAD 2 PASS REAR HEAD 2 PASSK 8-3/4" 7-5/8"

WATER BOX DIMENSIONS (mm)

DIM.EVAPORATORS T & V CONDENSER T & V

1 PASS 2 PASS 3 PASS 1 PASS 2 PASS 3 PASSH 375 343 343 — — —

J — — — 375 318 318

DIM. REAR HEAD 2 PASS REAR HEAD 2 PASSK 222 194

EVAPORATOR – CONDENSER SHELL CODESDIM. T0 & T1 COMPRESSORS T1 COMPRESSORS T2 & T3 COMPRESSORS

T - T V - V T - T V - V W - W W - W W - W X - X W - W X - XA 10'–0" 14'–0" 3048 mm 4267 mm 12'–0" 3657 mm 12'–0" 16'-0" 3658 mm 4877 mm

B 7'–5-1/8" 7'–5-1/8" 2264 mm 2264 mm 7'–9-3/4" 2381 mm 8'–10-7/8" 8'–10-7/8" 2715 mm 2715 mm

C 5'–1" 5'–1" 1550 mm 1550 mm 5'–6" 1676 mm 5'–6" 5'–6" 1676 mm 1676 mm

D 2'–6" 2'–6" 762 mm 762 mm 2'–7" 787 mm 2'–7" 2'–7" 787 mm 787 mm

E 2'–7" 2'–7" 787 mm 787 mm 2'–11" 889 mm 2'–11" 2'–11" 889 mm 889 mm

F 1'–3" 1'–3" 381 mm 381 mm 1'–3-1/2" 114 mm 1'–3-1/2" 1'–3-1/2" 394 mm 394 mm

G 1'–3-1/2" 1'–3-1/2" 394 mm 394 mm 1'–5-1/2" 165 mm 1'–5-1/2" 1'–5-1/2" 445 mm 445 mm

L 2-3/4" 2'– 2-3/4" 70 mm 679 mm 2-3/4" 70 mm 2-3/4" 2'–2-3/4" 70 mm 679 mm

M 1'–3" 3'–3" 381 mm 991 mm 1'–3" 381 mm 1'–3" 3'–3" 381 mm 991 mm


FORM 160.81-EG1

Dimensions (Ft.-In.) – Nozzle Arrangements

EVAPORATORS – COMPACT WATER BOXES

1-PASS

2-PASS

3-PASS

EVAPORATOR

EVAPORATOR EVAPORATOR


EVAPORATOR

MOTOR END COMPRESSOR END


MOTOR END COMPRESSOR ENDFLOOR LINE

FLOOR LINE

FLOOR LINE

1"

1" 1"

1"

1" 1"

GG GG

GG GG

GG GG

CC CC

DD

BB

DD

BB

DD

BB

DD

BB

A H

B J

C K

F N

G P

REAR OF UNIT

REAR OF UNIT

REAR OF UNIT

REAR OF UNIT

REAR OF UNIT

REAR OF UNIT

NOZZLEARRANGEMENTS

NO. OF EVAP.PASSES IN OUT

1A H

H A

NOZZLEARRANGEMENTS


2C B

K J

NOTE: Water must enterthrough bottom connection toachieve rated performance.

NOZZLEARRANGEMENTS


3G N

P F


LD07615

NOTES:1. Standard water nozzles are furnished as welding stub-outs with Victaulic grooves, allowing the option of welding, flanges, or use of

Victaulic couplings. Factory installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1/16" raised face), water flangednozzles are optional (add 1/2" to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished.

2. Add 1" for isolators as shown.

3. One-, two- and three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzlesmay be used in combination with any pair of condenser nozzles.

4. Connected piping should allow for removal of compact water boxes for tube access and cleaning.

5. Rear of unit is defined as side of chiller opposite control center.

EVAPORATOREVAPORATOR NOZZLE PIPE SIZE NOZZLE DIMENSIONS

SHELL NO. OF PASSES 1-PASS 2-PASS 3-PASS CODE 1 2 3 CC2 G G BB2 DD2 G G BB2 D D G G

T, V 8" 6" 4" 1'–10-3/4" 1'–3-1/2" 1'–3" 2'–6-1/2" 1'–3-1/2" 1'–3" 2'–6-1/2" 1'–3-1/2"

W, X 10" 8" 6" 2'–0-3/4" 1'–5-1/2" 1'–4-3/4" 2'–8-3/4" 1'–5-1/2" 1'–4-3/4" 2'–8-3/4" 1'–5-1/2"


FORM 160.81-EG1

Dimensions (mm) – Nozzle Arrangements

EVAPORATORS – COMPACT WATER BOXES

1-PASS

2-PASS

3-PASS

EVAPORATOR



EVAPORATOR



MOTOR END COMPRESSOR ENDFLOOR LINE

FLOOR LINE

FLOOR LINE

1"

1" 1"

1"

1" 1"

GG GG

GG GG

GG GG

CC CC

DD

BB

DD

BB

DD

BB

DD

BB

A H

B J

C K

F N

G P

REAR OF UNIT

REAR OF UNIT

REAR OF UNIT

REAR OF UNIT

REAR OF UNIT

REAR OF UNIT

NOZZLEARRANGEMENTS


1A H

H A

NOZZLEARRANGEMENTS


2C B

K J


NOZZLEARRANGEMENTS


3G N

P F


LD07615




3. One-, two- and three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzlesmay be used in combination with any pair of condenser nozzles.


5. Rear of unit is defined as side of chiller opposite control center.

EVAPORATOREVAPORATOR NOZZLE PIPE SIZE NOZZLE DIMENSIONS

SHELL NO. OF PASSES 1-PASS 2-PASS 3-PASS CODE 1 2 3 CC2 G G BB2 DD2 G G BB2 D D G G

T, V 8" 6" 4" 578 343 330 775 343 330 775 394

W, X 10" 8" 6" 629 445 425 832 445 425 832 445


FORM 160.81-EG1

Dimensions (Ft.-In.) – Nozzle Arrangements

CONDENSERS – COMPACT WATER BOXES




3. One-, two- and three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of condenser nozzlesmay be used in combination with any pair of evaporator nozzles.


5. Front of unit is defined as side of chiller where control center is mounted.

NOZZLEARRANGEMENTS

NO. OF COND.PASSES IN OUT

1P Q

Q P

NOZZLEARRANGEMENTS


2R S

T U

NOTE: Water must enterthrough bottom connection toachieve rated performance

NOZZLEARRANGEMENTS


3V Y

X W


LD07982

CONDENSERCONDENSER NOZZLE PIPE SIZE NOZZLE DIMENSIONS

SHELL NO. OF PASSES 1-PASS 2-PASS 3-PASSCODE 1 2 3 CC2 G G BB2 DD2 G G BB2 D D2 G G

T, V 10" 6" 6" 2'–4-3/4" 1'–3" 1'–9-3/4" 2'–11-3/4" 1'–3" 1'–9-3/4" 2'–11-3/4" 1'–3"

W, X 12" 8" 6" 2'–6-3/4" 1'–3-1/2" 1'–11" 3'–2-1/2" 1'–3-1/2" 1'–11" 3'–2-1/2" 1'–3-1/2"

1-PASS

2-PASS

3-PASS

MOTOR END

MOTOR END

MOTOR END

COMPRESSOR END

COMPRESSOR END

COMPRESSOR ENDFLOOR LINE

FLOOR LINE

FLOOR LINE

Q P

U S

T R

Y W

X V

FRONTOF UNIT

FRONT OF UNIT

FRONTOF UNIT

FRONTOF UNIT

FRONTOF UNIT

FRONT OF UNIT

1"

1"

1"

GG

GG

GG

CC

DD

BB

DD

BB

1"

1"

1"

GG

GG

GG

CC

DD

BB

DD

BB

CONDENSER CONDENSER

CONDENSER CONDENSER

CONDENSER CONDENSER


FORM 160.81-EG1

Dimensions (mm) – Nozzle Arrangements

CONDENSERS – COMPACT WATER BOXES


Victaulic couplings. Factory installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.59 mm raised face), waterflanged nozzles are optional (add 12.7 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished.

2. Add 25.4 mm for isolators as shown.

3. One-, two- and three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of condenser nozzlesmay be used in combination with any pair of evaporator nozzles.


5. Front of unit is defined as side of chiller where control center is mounted.

NOZZLEARRANGEMENTS


1P Q

Q P

NOZZLEARRANGEMENTS


2R S

T U


NOZZLEARRANGEMENTS


3V Y

X W


LD07983

CONDENSERCONDENSER NOZZLE PIPE SIZE NOZZLE DIMENSIONS

SHELL NO. OF PASSES 1-PASS 2-PASS 3-PASSCODE 1 2 3 CC2 G G BB2 DD2 G G BB2 D D2 G GT, V 10" 6" 6" 730 381 553 908 381 553 908 381

W, X 12" 8" 6" 781 394 584 978 394 584 978 394

1-PASS

2-PASS

3-PASS

MOTOR END

MOTOR END

MOTOR END

COMPRESSOR END

COMPRESSOR END

COMPRESSOR ENDFLOOR LINE

FLOOR LINE

FLOOR LINE

1"

1" 1"

1"

1" 1"

GG GG

GG GG

GG GG

CC CC

DD

BB

DD

BB

DD

BB

DD

BB

Q P

U S

T R

Y W

X V

FRONTOF UNIT

FRONT OF UNIT

FRONTOF UNIT

FRONTOF UNIT

FRONTOF UNIT

FRONT OF UNIT

CONDENSER CONDENSER

CONDENSER CONDENSER

CONDENSER CONDENSER


FORM 160.81-EG1

Dimensions (In.) – Floor Layout

NEOPRENE ISOLATORS

LD07610

6"

8"

CL

CL

CL

CONDENSER

EVAPORATOR

END SHEETSHELLS

END SHEET

FLOOR LAYOUT

SUPPORT FOOT

DIMENSIONS ARE TYPICAL ALL 4 CORNERS

1"

3"

3"

7/8" DIA.HOLE

DIMENSION "A"From Fig. 3 (pgs. 26 & 27)

5-1/2"

4-1/2"

4-1/2"

5-1/2"

3/8" STEEL PLATE

1" DEFLECTED HEIGHT

1/2"

UNIT WEIGHT UP TO 16,365 LBS.

ISOLATOR TO BE CENTERED UNDER SUPPORT FOOT 7"

6"

4-1/2"

5-1/2"

1/2"

1/2"

3/8" STEEL PLATE

1" DEFLECTED HEIGHT

DIMENSION "C"From Fig. 3 (pgs. 26 & 27)

UNIT WEIGHT 16,366 TO 28,835 LBS.


FORM 160.81-EG1

Dimensions (mm) – Floor Layout

NEOPRENE ISOLATORS

LD07611

152.4

203.2

CL

CL

CL

CONDENSER

EVAPORATOR

END SHEETSHELLS

END SHEET

FLOOR LAYOUT

SUPPORT FOOT

DIMENSIONS ARE TYPICAL ALL 4 CORNERS

25

76.2

22 mm DIA.HOLE

140

114

114

140

13 mm STEEL PLATE

25 mm DEFLECTED HEIGHT

13

UNIT WEIGHT UP TO 7,423 KGS.

ISOLATOR TO BE CENTERED UNDER SUPPORT FOOT

76.2

178152

114

140

13

13

13 mm STEEL PLATE

25 mm DEFLECTED HEIGHT

DIMENSION "A"From Fig. 3 (pgs. 26 & 27)

DIMENSION "C"From Fig. 3 (pgs. 26 & 27)

UNIT WEIGHT 7,423 TO 13,107 KGS.


FORM 160.81-EG1

Dimensions – Floor Layout

SPRING ISOLATORS

ALL DIMENSIONS ARE IN INCHES

ALL DIMENSIONS ARE IN MILLIMETERS

LD07378

LD07379

(Pgs. 26 & 27)

(Pgs. 26 & 27)

(Pgs. 26 & 27)

(Pgs. 26 & 27)


FORM 160.81-EG1

Weights

SOLID STATE STARTER WEIGHT

SIZE LBS KGS

7L, 14L 200 91

26L, 33L 300 136

SHIPPING OPERATING REFRIGERANT LOADING PER COMP. SHELLS WEIGHT WEIGHT CHARGE ISOLATOR

(LBS) (KG) (LBS) (KG) (LBS) (KG) (LBS) (KG)TBTB 11,860 5,380 13,110 5,948 650 295 3,278 1,485TBTC 11,910 5,400 13,200 5,988 650 295 3,303 1,495TBTD 12,010 5,450 13,350 6,053 650 295 3,338 1,515TCTB 11,960 5,425 13,250 6,013 650 295 3,313 1,500TCTC 12,010 5,450 13,340 6,053 650 295 3,338 1,515TCTD 12,110 5,495 13,490 6,123 650 295 3,373 1,530TDTB 12,070 5,475 13,410 6,083 650 295 3,353 1,520TDTC 12,120 5,500 13,500 6,123 650 295 3,378 1,530

T0/T1 TDTD 12,220 5,540 13,650 6,193 650 295 3,413 1,545VBVB 12,680 5,750 14,320 6,495 900 408 3,580 1,625VBVC 12,750 5,785 14,450 6,555 900 408 3,615 1,640VBVD 12,890 5,845 14,660 6,649 900 408 3,665 1,665VCVB 12,820 5,815 14,520 6,586 900 408 3,630 1,645VCVC 12,900 5,850 14,650 6,645 900 408 3,665 1,665VCVD 13,030 5,910 14,850 6,735 900 408 3,715 1,685VDVB 12,990 5,890 14,750 6,690 900 408 3,690 1,675VDVC 13,070 5,930 14,890 6,755 900 408 3,725 1,690VDVD 13,200 5,990 15,090 6,845 900 408 3,775 1,710WBWB 14,660 6,650 17,160 7,784 1,250 567 4,290 1,946WBWC 14,930 6,772 17,550 7,961 1,250 567 4,388 1,990WBWD 15,520 7,040 18,020 8,174 1,250 567 4,505 2,043WCWB 14,840 6,731 17,410 7,897 1,250 567 4,353 1,975

T1 WCWC 15,110 6,854 17,800 8,074 1,250 567 4,450 2,019WCWD 15,440 7,004 18,280 8,292 1,250 567 4,570 2,073WDWB 15,070 6,836 17,730 8,042 1,250 567 4,433 2,011WDWC 15,340 6,958 18,120 8,219 1,250 567 4,530 2,055WDWD 15,670 7,108 18,600 8,437 1,250 567 4,650 2,109WBWB 17,810 8,079 20,310 9,213 1,250 567 5,078 2,303WBWC 18,070 8,197 20,690 9,384 1,250 567 5,172 2,346WBWD 18,400 8,346 21,170 9,603 1,250 567 5,293 2,400WCWB 17,990 8,160 20,560 9,326 1,250 567 5,140 2,331WCWC 18,260 8,283 20,950 9,503 1,250 567 5,238 2,375WCWD 18,580 8,428 21,420 9,716 1,250 567 5,355 2,429WDWB 18,220 8,265 20,880 9,471 1,250 567 5,220 2,367WDWC 18,490 8,387 21,270 9,648 1,250 567 5,318 2,412

T2/T3 WDWD 18,810 8,532 21,740 9,861 1,250 567 5,435 2,465XBXB 19,110 8,669 22,200 10,070 1,550 703 5,550 2,518XBXC 19,370 8,786 22,620 10,260 1,550 703 5,655 2,565XBXD 19,700 8,935 23,150 10,500 1,550 703 5,788 2,625XCXB 19,360 8,782 22,540 10,224 1,550 703 5,635 2,556XCXC 19,620 8,900 22,960 10,415 1,550 703 5,740 2,603XCXD 19,950 9,049 23,490 10,655 1,550 703 5,873 2,664XDXB 19,670 8,922 22,970 10,419 1,550 703 5,743 2,605XDXC 19,940 9,045 23,400 10,614 1,550 703 5,850 2,654XDXD 20,260 9,190 23,920 18,850 1,550 703 5,980 2,713

UNIT WEIGHTS


FORM 160.81-EG1

GENERAL

Furnish and install where indicated on the drawingsYORK MAXE Rotary Screw Liquid Chilling Unit(s). Eachunit shall produce a capacity of tons, coolingGPM of from °F to °F when suppliedwith _____ GPM of condenser water at°F. Power input shall not exceed kW with an IPLV(NPLV) of _____. The evaporator shall beselected for ft2 °F hr/BTU fouling factor and amaximum liquid pressure drop of ft. Water sideshall be designed for 150 or 300 psig working pressure.The condenser shall be selected for foulingfactor and maximum liquid pressure drop of ____ ft.Water side shall be designed for 150 or 300 psig work-ing pressure. Power shall be supplied to the compres-sor motor at volts – 3-phase – (60)(50) Hertz andcontrols at 115 volts –1-phase – (60)(50) Hertz.

– (or) –

Furnish and install where indicated on the drawingsYORK MAXE Rotary Screw Liquid Chilling Unit(s). Eachunit shall produce a capacity of kW, cooling L/Sof from °C to °C when supplied with____ L/S of condenser water at °C. Power inputshall not exceed kW with an IPLV (NPLV) of____. The evaporator shall be selected for M2 °C/Wfouling factor and a maximum liquid pressure drop of___ kPa. Water side shall be designed for 1034 or 2068kPa working pressure. The condenser shall be selectedfor M2 °C/W fouling factor and maximum liquidpressure drop of kPa. Water side shall be designedfor 1034 or 2068 kPa working pressure. Power shall besupplied to the compressor motor at volts – 3-phase– 50 Hz and controls at 115 volts – 1-phase – 50 Hz.

Performance shall be certified or rated in accordancewith the latest edition of ARI Standard 550/590-98 asapplicable. Only chillers that are listed in the ARI Certi-fication Program for Water Chilling Packages using thevapor compression cycle are acceptable.

Each unit shall be completely factory packaged includ-ing evaporator, condenser, subcooler, oil separator, com-pressor/motor, lubrication system, OptiView ControlCenter, Solid State Starter (optional), refrigerant isola-tion valves (optional) and all interconnecting piping andwiring. The factory package shall consist of a “Leaktight”

Guide Specifications

design, with no pipe thread connections that can loosenand leak over time. All units shall ship with a full chargeof refrigerant HFC-134a and oil. Alternatively, the chillershall be shipped with the compressor, control panel andoil separator removed (Form 3) or also with the shellsseparated (Form 7) to allow rigging into the equipmentroom. All units that ship disassembled shall be assembledand factory run tested prior to disassembly and shipment).

Compressor

The compressor shall be a rotary-screw type. The com-pressor housing shall be of cast iron, precision machinedto provide minimal clearance for the rotors. The rotorsshall be manufactured from forged steel and use asym-metric profiles operating at a maximum speed of (3570RPM/60 Hz) (2975 RPM/50 Hz). The compressor shallincorporate a complete anti-friction bearing design to re-duce power and increase reliability; four separate cylin-drical roller bearings to handle radial loads; and two 4-point angular contact ball bearings to handle axial loads.A check valve shall be incorporated in the compressorhousing to prevent rotor backspin during shutdown.

Capacity control shall be achieved by use of a slidevalve to provide fully modulating control from 100% to20% of full-load. The slide valve shall be actuated bysystem differential pressure, controlled by external so-lenoid valves through the OptiView Control Center. Theunit shall be capable of operating with lower tempera-ture cooling tower water during part-load operation inaccordance with ARI Standard 550/590.

Lubrication System

An adequate supply of oil shall be available to the com-pressor at all times. During start-up and coastdown, thisshall be achieved by oil reservoirs in the compressor.During operation, oil shall be delivered by positive sys-tem pressure differential.

All chillers shall be provided with a single oil filter hous-ing with isolation valves. An optional dual filter is avail-able which allows immediate switching from one filterto the other, eliminating downtime during filter changes.The off-line oil filter must be capable of being changedduring chiller operation. The chiller shall ship with a 3micron absolute oil filter, (two filters for dual filter op-tion) maintaining a clean oil system and ensuring supe-rior compressor life.


FORM 160.81-EG1

A 500W immersion oil heater shall be provided andtemperature actuated to effectively remove refrigerantfrom the oil. Power wiring to the Control Center shall befactory installed. An oil eductor shall be provided to au-tomatically remove oil which may have migrated to theevaporator and return it to the compressor. The oil sepa-rator shall be of a vertical design with no moving parts,and shall provide high-efficiency oil separation beforethe refrigerant enters the heat exchangers. The oil sepa-rator shall be designed, tested and stamped in accor-dance with ASME Boiler and Pressure Vessel Code,Section VIII – Division 1.

Motor

The motor shall be 2-pole, continuous duty, cage induc-tion type, and shall utilize suction gas cooling (semi-her-metic design). Motor full-load amperes at design condi-tions shall not exceed motor nameplate (FLA). Motor shallbe designed for use with the type starter specified.

For units utilizing remote electromechanical starters, alarge steel terminal box with gasketed front access covershall be provided for field connected conduit. Overload/overcurrent transformers shall be furnished with all units.(For units furnished with factory packaged Solid StateStarters, refer to the “Options” section.)

Evaporator

Evaporator shall be of the shell-and-tube, flooded typedesigned for 235 psig (1620 kPa) working pressure onthe refrigerant side. Shell shall be fabricated from rolledcarbon steel plate with fusion welded seams or carbonsteel pipe; have carbon steel tube sheets, drilled andreamed to accommodate the tubes; and intermediatetube supports spaced no more than four feet apart. Therefrigerant side shall be designed, tested and stampedin accordance with ASME Boiler and Pressure VesselCode, Section VIII – Division 1. Tubes shall be high-efficiency, internally enhanced type. Each tube shall beroller expanded into the tube sheets providing a leak-proof seal, and be individually replaceable. Water ve-locity through the tubes shall not exceed 12 FPS (3.6m/s). Liquid level sight glass shall be located on theside of the shell to aid in determining proper refrigerantcharge. The evaporator shall have a refrigerant reliefdevice to meet the requirements of ASHRAE 15 SafetyCode for Mechanical Refrigeration.

Water boxes shall be removable to permit tube clean-ing and replacement. Stubout water connections hav-ing Victaulic grooves shall be provided. Water boxesshall be designed for 150 psig (1034 kPa) design work-ing pressure. Vent and drain connections with plugs shallbe provided on each water box.

Condenser

Condenser shall be of the shell-and-tube type, designedfor 235 psig (1620 kPa) working pressure on the refrig-erant side. Shell shall be fabricated from rolled carbonsteel plate with fusion welded seams or carbon steelpipe; have carbon steel tube sheets, drilled and reamedto accommodate the tubes; and intermediate tube sup-ports spaced no more than four feet apart. A refrigerantsubcooler shall be provided for improved cycle effi-ciency. The refrigerant side shall be designed, testedand stamped in accordance with ASME Boiler and Pres-sure Vessel Code, Section VIII – Division 1. Tubes shallbe high-efficiency, internally enhanced type. Each tubeshall be roller expanded into the tube sheets providinga leak-proof seal, and be individually replaceable. Wa-ter velocity through the tubes shall not exceed 12 FPS.The condenser shall have refrigerant relief device tomeet the requirements of ASHRAE 15 Safety Code forMechanical Refrigeration.

Water boxes shall be removable to permit tube clean-ing and replacement. Stubout water connections hav-ing Victaulic grooves shall be provided. Water Boxesshall be designed for 150 psig (1034 kPa) design work-ing pressure. Vent and drain connections with plugs shallbe provided on each water box.

Refrigerant System

The YR chiller is equipped with a refrigerant meteringdevice consisting of a fully modulating variable orificecontrolled via the OptiView Control Center. This controlensures proper refrigerant flow to the evaporator over awide range of operating conditions, including thermal stor-age applications and chilled water reset. Valve operationis programmable and can be customized for a specificapplication via the OptiView Control Center keypad.

The condenser shell shall be capable of storing the en-tire system refrigerant charge during servicing. Isola-tion from the rest of the system shall be by manually


FORM 160.81-EG1


operated isolation valves located at the inlet to the oilseparator and outlet of the condenser (isolation valvesoptional). Additional valves shall be provided to facili-tate removal of refrigerant charge from the system.


General – The chiller shall be controlled by a stand-alonemicroprocessor based control center. The chiller controlpanel shall provide control of chiller operation and moni-toring of chiller sensors, actuators, relays and switches.

Control Panel – The control panel shall include a 10.4-in. diagonal color liquid crystal display (LCD) surroundedby "soft " keys which are redefined based on the screendisplayed at that time. This shall be mounted in the middleof a keypad interface and installed in a locked enclosure.The screen shall detail all operations and parameters,using a graphical representation of the chiller and its ma-jor components. Panel verbiage shall be available in otherlanguages as an option with English always available.Data shall be displayed in either English or Metric units.Smart Freeze Point Protection shall run the chiller at 36°F(2.22°C) leaving chilled water temperature, and not havenuisance trips on low water temperature. The sophisti-cated program and sensor shall monitor the chiller watertemperature to prevent freeze-up. When needed, Hot GasBypass is available as an option. The panel shall displaycountdown timer messages so the operator knows whenfunctions are starting and stopping. Every programmablepoint shall have a pop-up screen with the allowableranges, so that the chiller can not be programmed tooperate outside of its design limits.

The control panel shall be provided with a thermal icestorage control mode to enhance system performanceduring ice building operation. In the thermal storage con-trol mode, the chiller shall stay at 100% load until thesetpoint shutdown temperature is reached. To addgreater operating flexibility and eliminate unnecessarychiller cycling, two different Low Water (Liquid) Tem-perature Restart Thresholds shall be programmable, onefor the ice mode and one for the standard cooling mode.The chiller shall have the capability to remain in thestandard control mode for temperatures between 20 to70°F (-6.7 to 21.1°C) for applications involving a pro-cess cooling duty that requires leaving chilled liquid tem-perature setpoint control.

The chiller control panel shall also provide:

1. System operating information including:

a. Return and leaving chilled water temperature

b. Return and leaving condenser water temp.

c. Evaporator and condenser saturation temp.

d. Oil pressure at compressor and oil filterdifferential

e. Percent motor current

f. Evaporator and condenser saturation temp.

g. Compressor discharge temperature

h. Percent slide valve position

i. Operating hours

j. Number of unit starts

2. Digital programming of setpoints through the uni-versal keypad including:

a. Leaving chilled water temperature

b. Percent current limit

c. Pull-down demand limiting

d. Six-week schedule for starting and stopping thechiller, pumps and tower

e. Remote reset temperature range

3. Status messages indicating:

a. System ready to start

b. System running

c. System lockout

d. System safety shutdown-manual restart

e. System cycling shutdown-auto restart

f. System startup

g. Start inhibit

4. The text displayed within the system status andsystem details field shall be displayed as a colorcoded message to indicate severity: red for safetyfault, orange for cycling faults, yellow for warnings,and green for normal messages.

5. Safety shutdowns enunciated through the displayand the status bar, and consist of system status,system details, day, time, cause of shutdown,and type of restart required. Safety shutdowns shallinclude:

a. Evaporator - low pressure

b. Evaporator - low pressure - smart freeze

c. Evaporator - transducer or leaving liquid probe

d. Evaporator - transducer or temperature sensor

e. Condenser - high pressure contacts open

f. Condenser - high pressure

g. Condenser - pressure transducer out of range

h. Auxiliary safety - contacts closed

i. Discharge - high temperature

j. Discharge - low temperature

k. Oil - low differential pressure

l. Oil or condenser transducer error

m.Oil - clogged filter


FORM 160.81-EG1

n. Oil - high pressure

o. Control panel - power failure

p. Watchdog - software reboot

5.1. Safety shutdowns with a Solid State Starter(LCSSS) shall include:

a. Shutdown - requesting fault data...

b. High instantaneous current

c. High phase (X) heatsink temperature - running

d. 105% motor current overload

e. Motor or starter - current imbalance

f. Phase (X) shorted SCR

g. Open SCR

h. Phase rotation

6. Cycling shutdowns enunciated through the displayand the status bar, and consisting of system sta-tus, system details, day, time, cause of shutdown,and type of restart required.

Cycling shutdowns shall include:

a. Multiunit cycling - contacts open

b. System cycling - contacts open

c. Control panel - power failure

d. Leaving chilled liquid - low temperature

e. Leaving chilled liquid - flow switch open

f. Condenser - flow switch open

g. Motor controller - contacts open

h. Motor controller - loss of current

i. Power fault

j. Control panel - schedule

6.1 Cycling shutdowns with a Solid State Starter(LCSSS) shall include:

a. Initialization failed

b. Serial communications

c. Requesting fault data

d. Stop contacts open

e. Power fault

f. Low phase (X) temperature sensor

g. Run signal

h. Invalid current scale selection

i. Phase locked loop

j. Low supply line voltage

k. High supply line voltage

l. Logic board processor

m.Logic board power supply

n. Phase loss

7. Security access to prevent unauthorized changeof setpoints, to allow local or remote control ofthe chiller, and to allow manual operation of thevariable orifice and slide valve position. Accessshall be through ID and password recognition,which is defined by three different levels of usercompetence: view, operator, and service.

8. Trending data with the ability to customize pointsof once every second to once every hour. The panelshall trend up to 6 different parameters from a listof over 140, without the need of an external moni-toring system.

9. The operating program stored in non-volatilememory (EPROM) to eliminate reprogramming thechiller due to AC power failure or battery discharge.Programmed setpoints shall be retained in lithiumbattery-backed RTC memory for a minimum of 11years with power removed from the system.

10. A fused connection through a transformer in thecompressor motor starter to provide individualover-current protected power for all controls.

11. A numbered terminal strip for all required field in-terlock wiring.

12. An RS-232 port to output all system operating data,shutdown/cycling message, and a record of the last10 cycling or safety shutdowns to a field-suppliedprinter. Data logs to a printer at a set program-mable interval. This data can be preprogrammedto print from 1 minute to 1 day.

13. The capability to interface with a building automa-tion system to provide:

a. Remote chiller start and stop

b. Remote leaving chiller liquid temperature adjust

c. Remote current limit setpoint adjust

d. Remote ready to start contacts

e. Safety shutdown contacts

f. Cycling shutdown contacts

g. Run contacts

COMPRESSOR MOTOR STARTER(OPTION, 200 - 600V)

The chiller manufacturer shall furnish a reduced-volt-age Solid State Starter for the compressor motor. Startershall be factory-mounted and wired on the chiller. Thestarter shall provide, through the use of silicon controlledrectifiers, a smooth acceleration of the motor withoutcurrent transitions or transients. The starter enclosureshall be NEMA 1, with a hinged access door with lockand key. Electrical lugs for incoming power wiring shallbe provided.

Standard features include: digital readout at the OptiV-iew Control Center of the following:

Display Only:• 3-phase voltage A, B, C

• 3-phase current A, B, C

• Input power (kW)

• kW Hours

• Starter Model

• Motor Run (LED)







Other features include: low-line voltage, 115-volt con-trol transformer; three-leg sensing overloads; phase ro-tation and single-phase failure protection; high tempera-ture safety protection, motor current imbalance andundervoltage safeties; open and close SCR protection;momentary power interruption protection. The LCSSSis cooled by a closed loop, fresh water circuit consist-ing of a water-to-water heat exchanger and 1/25 HPcirculating pump. All interconnecting water piping isfactory installed and rated for 150 PSIG working pres-sure. Optional unit-mounted circuit breaker includes


ground fault protection and provides 65,000 amp. Shortcircuit withstand rating in accordance with UL Standard508. A non-fused disconnect switch is also available.Both options are padlockable.

REMOTE ELECTRO-MECHANICAL COMPRES-SOR MOTOR STARTER (OPTIONAL)

A remote electro-mechanical starter of the R-1131 typeshall be furnished for each compressor motor. Thestarter shall be furnished in accordance with the chillermanufacturer’s starter specifications and as specifiedelsewhere in these specifications.

PORTABLE REFRIGERANT STORAGE/RECY-CLING SYSTEM

A portable, self-contained refrigerant storage/recyclingsystem shall be provided consisting of a refrigerant com-pressor with oil separator, storage receiver, water cooledcondenser, filter drier and necessary valves and hosesto remove, replace and distill refrigerant. All necessarycontrols and safety devices shall be a permanent partof the system.

START-UP AND OPERATOR TRAINING

The chiller manufacturer shall include the services of afactory-trained, field service representative to super-vise the final leak testing, charging and the initial start-up and concurrent operator instruction.

Tele. 800-861-1001www.york.com

P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USACopyright © by York International Corporation 2002 ALL RIGHTS RESERVED

Form 160.81-EG1 (502)Supersedes 160.81-EG1 (302)

Documents

160.81-EG1, MAXE Model YR Twin-Screw Compressor Liquid Chillers Design Level A · 2016. 10. 21. · YORK INTERNATIONAL 3 FORM 160.81-EG1 Introduction The YORK M AXE YR Chiller offers