Centrifugal Liquid Chillers: Operating & Maintenance

CENTRIFUGAL LIQUID CHILLERS
OPERATING & MAINTENANCE Supersedes: 160.49-O1 (894) Form 160.49-O1 (197)
MODEL YK L1 L1 G4 THRU YK S2 S2 J4 (STYLES A & B)

R-22 AND R-134a (COOLING ONL Y)
ONLY)
AND
MODEL YK LB LB G4 THRU YK SE SC J2 (STYLE C)
R-134a (COOLING ONLY)
ONLY)
WITH MICROCOMPUTER CONTROL CENTER P AR

PART #371-01200-004
ART
FOR ELECTRO-MECHANICAL STAR
STAR TER & SOLID ST
ARTER ATE ST
STA AR
STAR TER
ARTER
27073A
25789A
STYLES A & B
27385A
STYLE C
WARNING
SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE.
SERIOUS INJURY COULD RESULT IF PROPER PROCEDURES ARE
NOT FOLLOWED WHEN SERVICING SYSTEM. ALL SERVICE WORK
SHALL BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN IN
ACCORDANCE WITH YORK INSTALLATION/OPERATION MANUAL.
TABLE OF CONTENTS REFERENCE INSTRUCTIONS
SECTION 1 – Description of System and DESCRIPTION FORM NO.
Fundamentals of Operation ......... 3 Solid State Starter – Operation & Maintenance 160.46-OM3.1
SECTION 2 – MicroComputer Control Center ... 5 Installation 160.49-N1
SECTION 3 – System Operating Procedures .... 28 Installation and Operation of Printers 160.49-N2
Wiring Diagram – Use with Electro-Mechanical Starter 160.49-PW1
SECTION 4 – System Component Description . 35
Wiring Diagram – Field Connections (E-M Starter) 160.49-PW2
SECTION 5 – Operational Maintenance ............ 39
Wiring Diagram – Field Control Modifications 160.49-PW3
SECTION 6 – Trouble Shooting ......................... 41 Wiring Diagram – Control Center with SS Starter 160.49-PW4
SECTION 7 – Maintenance ............................... 46 Wiring Diagram – Field Connections (SS Starter) 160.49-PW5
SECTION 8 – Preventive Maintenance ............. 55 Wiring Diagram – With Solid State Starter 160.49-PW6
NOMENCLATURE
STYLES A & B
YK N2 N1 H1 – CX A
DESIGN LEVEL (A or B) } MOTOR CODE:

60 Hz 50 Hz
POWER SUPPLY CH CX 5CE 5CT
– for 60 Hz CJ CY 5CF 5CU
5 for 50 Hz CK CZ 5CG 5CV
CL CA 5CH 5CW
CM CB 5CI 5CX
COMPRESSOR CODE CN DA 5CJ 5DA
G4,H0,H1,H2,J1,J2,J3,J4 CP DB 5CK 5DB
CR DC 5CL 5DC
CONDENSER CODE CS DD 5CM 5DD
L1,L2,M1,M2,N1,N2,P1,P2,Q1,Q2,R1,R2,S1,S2 CT DE 5CN 5DE
CU DF 5CO 5OF
CV DH 5CP 5OG
COOLER CODE CW OJ 5CQ 5OH
L1,L2,M1,M2,N1,N2,P1,P2,Q1,Q2,R1,R2,S1,S2 5CR 5OJ
5CS
MODEL
STYLE C
YK NB PB H1 – CX C
DESIGN LEVEL (C) } MOTOR CODE:

60 Hz 50 Hz
POWER SUPPLY CH CX 5CE 5CT
– for 60 Hz CJ CY 5CF 5CU
5 for 50 Hz CK CZ 5CG 5CV
CL CA 5CH 5CW
CM CB 5CI 5CX
COMPRESSOR CODE CN DA 5CJ 5DA
G4,H0,H1,H2,J1,J2 CP DB 5CK 5DB
CR DC 5CL 5DC
CONDENSER CODE CS DD 5CM 5DD
LB,LC,MB,MC,NB,NC,PB,PC,QB,QE,RB,RC,SB,SC CT DE 5CN 5DE
CU DF 5CO 5DF
CV DH 5CP 5DG
COOLER CODE CW DJ 5CQ 5DH
LB,LC,MB,MC,NB,NC,PB,PC,PD,PE,QB,QC,QD,QE, 5CR 5OJ
RB,RC,RD,RE,SD,SE 5C
MODEL
2 YORK INTERNATIONAL
FORM 160.49-O1
SECTION 1
DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
COMPRESSOR
CONTROL
CENTER
MOTOR
DISCHARGE LINE
PRE-ROTATION
27073A VANE
ACTUATOR
COOLER
OIL PUMP
STARTER
25717A
SUB COOLER
OIL RESERVOIR/
PUMP OIL CONDENSER
FIG. 1 – MODEL YK CODEPAK CHILLER COOLER
SYSTEM OPERATION DESCRIPTION (See Fig. 2) In operation, a liquid (water or brine to be chilled) flows
through the CodePak cooler, where boiling refrigerant
The YORK CodePak is commonly applied to large air absorbs heat from the water. The chilled liquid is then
conditioning systems, but may be used on other appli- piped to fan coil units or other air conditioning terminal
cations. The CodePak consists of an open motor moun- units, where it flows through finned coils, absorbing
ted to a compressor (with integral speed increasing heat from the air. The warmed liquid is then returned to
gears) condenser, cooler and flow control chamber. the CodePak to complete the chilled liquid circuit.
The CodePak is controlled by a modern state of the art The refrigerant vapor, which is produced by the boiling
MicroComputer Control Center which monitors its op- action in the CodePak cooler, flows to the compressor
eration. The Control Center is programmed by the op- where the rotating impeller increases its pressure and
erator to suit job specifications. Automatic timed start- temperature and discharges it into the condenser. Wa-
ups and shutdowns are also programmed to suit ter flowing through the condenser tubes absorbs heat
nighttime, weekends, and holidays. The operating sta- from the refrigerant vapor, causing it to condense. The
tus, temperatures, pressures, and other information condenser water is supplied to the CodePak from an
pertinent to operation of the CodePak Chiller are auto- external source, usually a cooling tower. The condensed
matically displayed and read on a 40 character al- refrigerant drains from the condenser into the flow con-
phanumeric message display. Other displays can be trol chamber, where the flow restrictor meters the flow
observed by pressing the keys as labeled on the Con- of liquid refrigerant to the cooler to complete the refrig-
trol Center. The CodePak with the MicroComputer Con- erant circuit.
trol Center is applied with an electro-mechanical starter
or a factory packaged YORK Solid State Starter (op- The major components of a CodePak are selected to
tional). handle the refrigerant which would be evaporated at
YORK INTERNATIONAL 3
full load design conditions. However, most systems
will be called upon to deliver full load capacity for only
a relatively small part of the time the unit is in opera-
tion.
CAPACITY CONTROL
The major components of a CodePak are selected for
full load capacities, therefore capacity must be con-
trolled to maintain a constant chilled liquid tempera-
ture leaving the cooler. Prerotation vanes (PRV), lo-
cated at the entrance to the compressor impeller, com-
pensate for variation in load (See Fig. 2. Detail A).
The position of these vanes is automatically controlled

through a lever arm attached to an electric motor lo-
cated outside the compressor housing. The automatic
7619A(D) adjustment of the vane position in effect provides the
performance of many different compressors to match
DETAIL A – COMPRESSOR PREROTATION VANES various load conditions from full load with vanes wide
open to minimum load with vanes completely closed.
LD01066
FIG. 2 – REFRIGERANT FLOW-THRU CODEPAK
FORM 160.49-O1
SECTION 2
MICROCOMPUTER CONTROL CENTER
28455A
FIG. 3 – MICROCOMPUTER CONTROL CENTER AND KEYPAD LD01067
WARNING
This equipment generates, uses and can radiate radio frequency energy and if not installed and used in
accordance with the instructions manual, may cause interference to radio communications. Operation of this
equipment in a residential area is likely to cause interference in which case the user at his own expense will be
required to take whatever action may be required to correct the interference.
Additionally, any electronic equipment can generate EMI (electromagnetic interference) which, depending upon
the installation and magnitude, may affect other electronic equipment. The amount of EMI generated is deter-
mined by the source inductance, load inductance, and circuit impedances. Responsibility for assuring the
satisfactory operation of other equipment included in the same power source as the YORK equipment rests
solely with the user. YORK disclaims any liability resulting from any interference or for the correction thereof.
INTRODUCTION
The YORK MicroComputer Control Center is a micro- • % CURRENT LIMIT

processor based control system for R-22 or R134a • PULLDOWN DEMAND LIMIT
centrifugal chillers. It controls the leaving chilled water • CLOCK (TIME-OF-DAY)
temperature via pre-rotation vane control and has the • DAILY SCHEDULE (7 DAY TIME-CLOCK PROGRAM-
ability to limit motor current via control of the pre-rota- MING)
tion vanes. Further, it is compatible with YORK Solid
• HOLIDAY
State Starter (optional) and electro-mechanical starter
• REMOTE RESET TEMPERATURE RANGE
applications.
• DATA LOGGER
A keypad mounted on the front of the Control Center
(see Fig. 3) allows the operator to display system op- The cause of all system shutdowns (safety or cycling)
erating parameters on a 40 character alphanumeric is preserved (until the system is reset or restarts) in
display that is part of the keypad. These readings are the microcomputer’s memory for subsequent viewing
displayed via “Display” keypad as follows: (In the En- on the keypad display. The operator is continually ad-
glish mode; temperatures in °F, pressures in (PSIG) vised of system operating conditions by various back-
(in the metric mode, temperatures in °C, Pressures in ground and warning messages. The keypad contains
kPa). special service keys for use by the service technician
when performing system troubleshooting.
• CHILLED LIQUID TEMPERATURES – LEAVING AND
RETURN The MicroComputer Control Center is designed to be
• REFRIGERANT PRESSURES – EVAPORATOR AND compatible with most Energy Management Systems
CONDENSER (EMS) in use today. The standard design allows for the
following EMS interface:
• DIFFERENTIAL OIL PRESSURE
• CONDENSER LIQUID TEMPERATURES – 1. Remote Start
OPTIONAL FIELD INSTALLED – LEAVING AND
2. Remote Stop
RETURN
• OPTIONS 3. Remote LCWT Setpoint (Pulse Width Modulated sig-
• PRINT * nal)
• HISTORY PRINT * 4. Remote Current Limit Setpoint (Pulse Width Modulated
• MOTOR CURRENT IN % OF FULL LOAD AMPS signal)
• SATURATION TEMPERATURES – EVAPORATOR 5. A “Remote Mode Ready to Start” Status Contacts
AND CONDENSER
6. Safety Shutdown Status Contacts
• DISCHARGE TEMPERATURE
• OIL TEMPERATURE 7. Cycling Shutdown Status Contacts
• HIGH & LOW OIL PRESSURE TRANSDUCER PRES-
SURE As an enhancement to the standard EMS features, an
• SOLID STATE STARTER MOTOR CURRENT / VOLTS
optional card file with plug-in printed circuit boards is
(When Supplied) available. These optional cards will accept a remote
LCWT 0 to 10°F or 0 to 20°F (0 to 5.56°C or 0 to
11.1°C) setpoint offset and/or remote current limit
The system setpoints (see Fig. 3) are operator entered setpoint interface from three user input choices:
on the front control center Setpoints keypad. These
setpoints can also be displayed on the 40 character 1. 4-20mA
alphanumeric display. The system setpoints are:
2. 0-10VDC
• CHILLED LIQUID TEMPERATURE (LCWT) 3. Contact Closures
* These keys provide a print-out when the customer connects a compatible printer to
the Micro Board RS-232 serial port. (See Form 160.49-N2.)
FORM 160.49-O1
CONTROL CENTER
The Control Center front panel layout consists of five SERVICE – Included in this group of keys are those
key groups, one switch and a 1 line by 40 character al- functions that are only relevant to servicing the chiller.
phanumeric vacuum fluorescent display: (see Fig. 3.) Typically, these keys would not be used for daily chiller
operation.
CHARACTERISTIC DISPLAY – The alphanumeric
vacuum fluorescent display is located to the right of ACCESS CODE – Permits operator to access the pro-
the STATUS key. All messages, parameters, set points, gram.
and data can be viewed at this location. The main com-
munications between the operator or service techni- PROGRAM – Permits operator to program the Control
cian and the MicroComputer Control Center occurs on Center.
this display.
MODE – Permits operator to check what mode the Con-
trol Center is presently in (LOCAL, REMOTE or SER-
DISPLAY – Provide a direct readout of each monitored VICE).
parameter on the alphanumeric display.
1. Service – allows manual PRV control with visual
ENTRY – These keys are used to enter the values for display readout of PRV operation.
the operator programmed setpoints. These keys are 2. Local – allows manual compressor start from the
used in conjunction with the Setpoint keys while in COMPRESSOR switch on the Control Center front.
PROGRAM mode.
3. Program – allows operator programming of system
setpoints.
SETPOINTS – These keys are used as follows:
4. Remote – allows remote start, remote stop of com-
1. To view each setpoint, in any mode, or pressor and remote reset of LCWT and % current
limit.
2. To select the individual setpoints that are pro-
grammed by the operator in PROGRAM mode only. COMPRESSOR-START, RUN, STOP/RESET
SWITCH – This 3-position rocker switch is used to start
Pressing the appropriate key enables the operator to (except in REMOTE mode), stop/run/reset the system.
program that setpoint pressing the Entry keys.
OPERATION
DISPLAYING SYSTEM PARAMETERS message will be displayed and updated every 2 sec-
onds until the DISPLAY HOLD key is again pressed
The Display key are used to display selected moni- and released, or 10 minutes have elapsed, which-
tored parameters as follows: (Refer to Fig. 3.) ever comes first.
• Press and release the appropriate Display key – NOTE: If the display actually displays X’s, then the
the message will be displayed for 2 seconds. monitored parameter is out of normal operat-
ing range (refer to Fig. 4). If the “English/Met-
– or – ric” jumper is installed on the Micro Board, all
temperatures are displayed in degrees Fahr-
• Press and hold the appropriate Display key – the
enheit (°F) and all pressures are displayed in
message will be displayed and updated every 0.5
pounds per sq. inch gauge (PSIG) except oil
seconds until the Display key is released.
pressure which is displayed in pounds per sq.
– or – inch differential (PSID). If the “English/Metric”
jumper is not installed, all temperatures are
• Press and release appropriate Display key, then displayed in degrees Centigrade (°C) and all
press and release the DISPLAY HOLD key – the pressures are displayed in Kilo-Pascals (kPa).
DISPLAY DISPLAY
READS READS
CONDENSER PRESS. = < 6.8 PSIG, or > 300 PSIG XX.X PSIG CONDENSER PRESS. = <46.8 kPa, or > 2068 kPa XX.X kPa
EVAPORATOR PRESS. = < 50 PSIG, or > 125 PSIG XX.X PSIG EVAPORATOR PRESS. = < 345 kPA, or > 862 kPa XX.X kPa
EVAP. PRESS. (BRINE) = < 25 PSIG, or > 100 PSIG XX.X PSIG EVAP. PRESS. (BRINE) = < 172 kPa, or > 690 kPa XX.X kPa
HOP TRANSDUCER = < 59.1 PSIG, or > 314.9 PSIG XX.X PSIG HOP TRANSDUCER = < 407 kPa, or > 2171 kPa XX.X kPa
LOP TRANSDUCER = < 23.2 PSIG, or > 271.8 PSIG XX.X PSIG LOP TRANSDUCER = < 160 kPa, or > 1874 kPa XX.X kPa
DISCHARGE TEMP. = < 20.3°F; > 226.4°F XXX.X°F DISCHARGE TEMP. = < –6.5°C; >108°C XXX.X°C
OIL TEMP. = < 20.3°F; > 226.4°F XXX.X°F OIL TEMP. = < –6.5°C; > 108°C XXX.X°C
LEAVING CONDENSER LEAVING CONDENSER
WATER TEMP. = < 8.4°F; > 134.1°F XXX.X°F WATER TEMP. = < –13.1°C; > 56.8°C XXX.X°C
ENTERING CONDENSER ENTERING CONDENSER
WATER TEMP. = < 8.4°F; > 134.1°F XXX.X°F WATER TEMP. = <–13.1°C ; > 56.8°C XXX.X°C
LEAVING EVAPORATOR = < 0°F XX.X°F LEAVING EVAPORATOR = < –17.8°C XX.X°C
WATER TEMP. = > 81.1°F XX.X°F WATER TEMP. = > 27.3°C XX.X°C
ENTERING EVAPORATOR = < .1°F XX.X°F ENTERING EVAPORATOR = < –17.7°C XX.X°C
WATER TEMP. = > 93°F XX.X°F WATER TEMP. = > 33.9°C XX.X°C
FIG. 4 – SYSTEM PARAMETERS – OUT OF FIG. 4A – SYSTEM PARAMETERS – OUT OF

RANGE READINGS (STANDARD) RANGE READINGS (METRIC)
To Display CHILLED LIQUID TEMPERATURES: ______ PSID = (HOP – LP) – OFFSET PRESSURE
Press CHILLED LIQUID TEMPS display key as OFFSET PRESSURE: Pressure differential between
described on page 7 to produce the following al- the HOP transducer and LOP transducer outputs dur-
phanumeric display message: ing a 3 second period beginning 10 seconds after the
CHILLED LEAVING = XXX.X°F, RETURN = XXX.X°F start of “START SEQUENCE INITIATED”. During this
time, the transducers will be sensing the same pres-
sure and their outputs should indicate the same pres-
To Display REFRIGERANT PRESSURE: sure. However, due to accuracy tolerances in trans-
ducer design, differences can exist. Therefore, to com-
Use REFRIGERANT PRESSURE display key as pensate for differences between transducers and as-
described on page 7 to produce the following al- sure differential pressure sensing accuracy, the OFF-
phanumeric display message: SET PRESSURE is subtracted algebraically from the
differential pressure. The offset pressure calculation
EVAP = XXX.X PSIG; COND = XXX.X PSIG will not be performed if either transducer is out-of-range.
The offset value will be taken as 0 PSI (0 kPa) in this
instance.
To Display OIL PRESSURE:

To Display OPTIONS:
Use OIL PRESSURE display key as described on
page 7 to produce the following alphanumeric dis- This key is not used.
play message:
NO OPTIONS INSTALLED
OIL PRESSURE = XXXX.X PSID
is displayed when this key is pressed.
The differential pressure displayed is the pressure dif-
ference between the high side oil pressure transducer
To Display SSS MOTOR CURRENT / VOLTS:
(output of oil filter) and the low side oil pressure trans-
(Solid State Starter Applications Only)
ducer (compressor housing). Displayed value includes
offset pressure derived from auto-zeroing during “START If chiller is equipped with a YORK Solid State Starter,
SEQUENCE INITIATED”. If either transducer is out- use SSS MOTOR CURRENT / VOLTS key to dis-
of-range, XX.X is displayed. Oil pressure is calcu- play 3-phase compressor motor current and 3-
lated as follows: phase Solid State Starter input line voltage.
FORM 160.49-O1
Continuously pressing this key will display the mo- described above to display motor current as a per-
tor current and line voltage alternately. When used cent of Full Load Amps (FLA). The message is as
with the DISPLAY HOLD key, motor current and follows:
line voltage will alternately be displayed each time
MOTOR CURRENT = XXX% FLA
this key is pressed. The messages are as follows:
A AMPS = XXXX; B AMPS = XXXX; C AMPS = XXXX NOTE: • Liquid-Cooled Solid State Starter Applica-
tions – the % Motor Current displayed is the
V A-B = XXXX; V B-C = XXXX; V C-A = XXXX highest of three line currents divided by the
programmed chiller FLA value x 100%.
If chiller is not equipped with a Solid State Starter, • Electro-Mechanical Starter Applications –
this key produces the following message: the % Motor Current displayed is the highest
SOLID STATE STARTER NOT INSTALLED of the three line currents.
In PROGRAM mode, this key is used to display

the applicable line voltage range (200-208VAC, 220-
240VAC, 380VAC, 400VAC, 415VAC, 440-480VAC, To Display OPERATING HOURS and STARTS
500-600VAC, Supply Voltage Range Disabled). The COUNTER:
correct line voltage range is programmed at the
YORK factory and is checked by the service tech- Use the OPERATING HOURS key as described
nician at start-up. For security reasons, a special on page 7, to produce the following message:
access code is required to program the line volt- OPER. HOURS = XXXXX; START COUNTER = XXXXX
age range. The line voltage range is used to deter-
mine a low line voltage threshold for cycling shut- NOTE: The operating hours and starts counter can be
down. Refer to “System Setpoints” for Trip/Reset reset to zero. Refer to “Programming the Mi-
values. croComputer Control Center”, page 13. How-
ever, the purpose of the OPERATING HOURS
key is to display the total accumulated chiller
To Display CONDENSER LIQUID TEMPERATURES run time. Therefore, the operating hours should
(Field Installed Option Package): not be arbitrarily reset.
Use CONDENSER LIQUID TEMPS display key as

described above to produce the following alphanu-
meric display message: SYSTEM SETPOINTS
COND LEAVING = XXX.X°F; RETURN = XXX.X°F The system setpoints may be programmed by the sys-
– or – tem operator. The Setpoint keys are located on the
COND LEAVING = XXX.X°C; RETURN = XXX.X°C Control Center keypad (see Fig. 3). To program, see
“Programming System Setpoints”, page 13. The fol-
NOTE: If the condenser liquid thermistors are not con- lowing is a description of these setpoints (with the En-
nected, or both thermistors are “out of range”, glish/Metric jumper installed on the Micro Board):
the display will blank when this key is pressed.
CHILLED LIQUID TEMP – This key displays the leav-
ing chilled water temperature (LCWT) setpoint in de-
To Initiate a PRINT to Printer: grees Fahrenheit. If not programmed, the default value
is 45°F (17.2°C). See “Programming System Setpoints”,
Press the PRINT key to initiate a printout to an page 14).
optional printer. When the key is pressed,
PRINT ENABLE is displayed. NOTE: If an Energy Management System is interfaced
to the Control Center for the purpose of re-
Refer to “MicroComputer Control Center – System mote LCWT setpoint reset, then the operator-
Status Printers” instruction, Form 160.49-N2 for de- programmed chilled liquid temperature will be
tails of the optional printers. the base or lowest setpoint available to the
Energy Management System (EMS). This
chilled liquid temperature value must also be
To Display MOTOR CURRENT: entered into the EMS. Further, any subsequent
change to this value must also be entered into
Press the % MOTOR CURRENT display key as the EMS.
% CURRENT LIMIT – This key displays the maximum Note that if only a start time is entered for a particular
value of motor current permitted by its programmed day, the compressor will not automatically stop until a
setting. The value is in terms of percent of Full Load scheduled stop time is encountered on a subsequent
Amps (FLA). If not programmed, the default value is day.
100%. (See “Programming System Setpoints”, page 14.)
HOLIDAY – This key indicates which days in the up-
If chiller is equipped with a YORK Solid State Starter, coming week are holidays. On those designated days,
the system FLA is also displayed. This value is pro- the chiller will automatically start and stop via the holi-
grammed by the factory and should never be changed. day start and stop times programmed in the DAILY
The Micro Board uses this value to calculate and dis- SCHEDULE setpoint. It will do this one time only and
play the % motor current parameter that is displayed the following week will revert to the normal daily sched-
when the % MOTOR CURRENT display key is pressed. ule for that day.
Also, proper current limit control depends on the cor-
rectly programmed FLA value. For security reasons, a
special access code is required to program the FLA REMOTE / RESET TEMP RANGE – This key displays
value. It should only be changed by a service techni- the maximum offset of remote LCWT setpoint reset.
cian. This offset is either 10° or 20°F (5.5° to 11.1°C) as
programmed. When in the REMOTE mode, this value
is added to the operator programmed CHILLED LIQ-
PULL DOWN DEMAND – This function is used to pro- UID TEMP setpoint and the sum equals the tempera-
vide energy savings following the chiller start-up. This ture range in which the LCWT can be reset. For ex-
key displays a programmable motor current limit and a ample, if the operator programmed CHILLED LIQUID
programmable period of time. Operation is as follows: TEMP setpoint is programmed with a value of 46°F
Whenever the system starts, the Pull Down Demand (7.8°C) and the remote/reset temperature range is set
Limit is maintained for the programmed time, then the at 10°F (5.5°C), then the CHILLED LIQUID TEMP
current limit control returns to % current limit setpoint. setpoint can be remotely reset over a range of 46°F
The maximum permitted motor current is in terms of (7.8°C) to 56°F (13.3°C) (46 + 10 = 56) or (7.8 + 5.5 =
% FLA. The duration of time that the current is limited 13.2). If not programmed, the default value for this pa-
is in terms of minutes (to a maximum of 255). If not rameter is 20°F (6.7°C).
programmed, the default value is 100% FLA for 00 min-
utes. (See “Programming Systems Setpoints”, page 15.) For additional information on remote LCWT reset, refer
Thus, no pull down demand limit is imposed following to Form 160.49-PW3.
system start, and the % current limit setpoint is used.
NOTE: If an Energy Management System is interfaced
to the Control Center for the purpose of re-
CLOCK – This key displays the day of the week, time
mote LCWT setpoint reset, then the operator
of day and calendar date. If not programmed, the de-
programmed REMOTE RESET TEMP RANGE
fault value is SUNDAY 12:00 AM 1/1/92 .
value determines the maximum value of tem-
(See “Programming System Setpoints”, page 15.)
perature reset controlled by the Energy Man-
agement System.
DAILY SCHEDULE – This key displays the pro-
grammed daily start and stop times, from Sunday thru
DATA LOGGER – This key is used when an optional
Saturday plus Holiday. If desired, the Control Center
printer is connected to the MicroComputer Control Cen-
can be programmed to automatically start and stop
ter. Refer to Form 160.49-N2 for operation instructions.
the chiller as desired. This schedule will repeat on a 7-
day calendar basis. If the Daily Schedule is not pro-
grammed, the default value is 00:00 AM start and stop SSS MOTOR CURRENT/VOLTS – This key is used on
times for all days of the week and the holiday. (Note Solid State Starter applications only. Although this is a
that the system will not automatically start and stop on display key, it is used to program the applicable AC
a daily basis with these default values because 00:00 power line voltage range (380VAC, 400VAC, 415VAC,
is an “Impossible” time for the Micro Board. See “Pro- 440-480VAC, 550-600VAC). The MicroComputer Con-
gramming System Setpoints”, page 16.) Finally, one or trol Center uses this entry to determine the undervol-
more days in the week can be designated as a holiday tage and overvoltage shutdown threshold. For each line
(see description under HOLIDAY setpoint) and the Con- voltage category there is an undervoltage and over-
trol Center can be programmed (usually DAILY SCHED- voltage shutdown threshold. If the AC power line volt-
ULE setpoint) to automatically start and stop the chiller age exceeds these thresholds for 20 continuous sec-
on those days so designated. The operator can over- onds, the chiller shuts down and displays
ride the time clock at any time using the COMPRES- MON 10:00 AM LOW LINE VOLTAGE
SOR switch.
FORM 160.49-O1
– or – NOTE: The value displayed is the actual LCWT set-

point. For example, the value displayed in LO-
MON 10:00 AM HIGH LINE VOLTAGE CAL or PROGRAM mode is that which is op-
erator programmed. The value displayed in
This overvoltage and undervoltage protection can be the REMOTE mode is that base setpoint with
disabled. Refer to chart below: added temperature reset by an Energy Man-
agement System, via remote LCWT setpoint
LOW / HIGH LINE VOLTAGE TRIP / RESET VALUES (PWM signal) if a remote reset signal was re-
ceived within 30 minutes.
COMPRESSOR LOW LINE VOLTAGE HIGH LINE VOLTAGE
MOTOR OPERATING POINT OPERATING POINT
SUPPLY VOLTAGE CUTOUT-(V) CUTIN-(V) CUTOUT-(V) CUTIN-(V)
RANGE – (V) (ON FALL) (ON RISE) (ON RISE) (ON FALL) To Display % CURRENT LIMIT Setpoint:
380 305 331 415 414
400 320 349 436 435 Use % CURRENT LIMIT setpoint key as described
415 335 362 454 453 above to produce the following message:
440-480 370 400 524 523 CURRENT LIMIT = XXX % FLA
550-600 460 502 655 654
Supply Voltage NOTE: The value displayed is the actual % current
Range Disabled NONE 0 NONE 0
limit setpoint. For example, the value displayed
in LOCAL or PROGRAM mode is that which
is operator programmed. The value displayed
For security reasons, a special access code is required
in the REMOTE mode is that which has been
to program the supply voltage range. The supply volt-
programmed by the Energy Management Sys-
age range is programmed at the factory and should
tem via the remote current limit setpoint input.
only be changed by a service technician.
If chiller is equipped with a YORK Solid State Starter,
DISPLAYING SYSTEM SETPOINTS the message is:
CURRENT LIMIT = XXX % FLA; *MTR CUR = 000 FLA
The currently programmed Setpoint values can be
viewed at any time (see page 21) in SERVICE, LOCAL NOTE: On Solid State Starter applications, this value
or REMOTE operating mode as follows: is programmed at the YORK factory. A special
access code is required.
• Press and release the appropriate Setpoint key –
the message will be displayed for 2 seconds.
– or –
To Display PULL DOWN DEMAND Setpoint:
• Press and hold the appropriate Setpoint key – the
message will be displayed as long as the key is Use PULL DOWN DEMAND setpoint key as de-
pressed. scribed on page 10 to produce the following mes-
sage:
– or –
SETPOINT = XXX MIN @ XX % FLA XXX MIN LEFT
• Press and release the appropriate Setpoint key, then
press and release the DISPLAY HOLD key. The mes-
sage will be displayed until the DISPLAY HOLD key
is again pressed and released, or 10 minutes have
To Display CLOCK Setpoint (Time of Day):
elapsed, whichever comes first.
Use CLOCK setpoint key as described above to
produce the following message:
To Display CHILLED LIQUID TEMP Setpoint: TODAY IS DAY XX:XX AM/PM 1/1/92
Use CHILLED LIQUID TEMP setpoint key as de-

scribed on page 9 to produce the following mes-
sage: To Display DAILY SCHEDULE Setpoints:
LEAVING SETPOINT = XX.X °F
• Press and hold the DAILY SCHEDULE setpoint key.
The chiller start and stop times for each day of the as described above to produce the following mes-
week are sequentially displayed, beginning with Sun- sage:
day and ending with Holiday. The display will continu-
REMOTE RESET TEMP RANGE = 10°F (5.5°C)
ously scroll until the DAILY SCHEDULE key is re-
leased. – or –
– or –
REMOTE RESET TEMP RANGE = 20°F (11.1°C)
• Press and release the DAILY SCHEDULE setpoint
key. Then press and release the DISPLAY HOLD
key. The chiller start and stop times for each day of
the week are sequentially displayed beginning with To Display DATA LOGGER setpoints:
Sunday and ending with Holiday. The display will con-
tinuously scroll until the DISPLAY HOLD key is again Refer to YORK, Form 160.49-N2 for operation of
pressed and released, or 10 minutes have elapsed, this key.
whichever comes first.
To Display UNDERVOLTAGE setpoints:

The display message for DAILY SCHEDULE will scroll (Solid State Starter Applications Only)
in the following sequence:
Press SSS MOTOR CURRENT/VOLTS key in
SUN START = 08:30 AM STOP = 06:00 PM PROGRAM mode to display the selected voltage
MON START = 05:00 AM STOP = 07:00 PM range. One of the following messages will be dis-
played.
TUE START = 05:00 AM STOP = 07:00 PM
WED START = 05:00 AM STOP = 07:00 PM
SUPPLY VOLTAGE RANGE 380
THU START = 05:00 AM STOP = 07:00 PM
FRI START = 05:00 AM STOP = 07:00 PM – or –
SAT START = 05:00 AM STOP = 01:00 PM SUPPLY VOLTAGE RANGE 400
HOL START = 00:00 AM STOP = 00:00 PM
– or –
SUPPLY VOLTAGE RANGE 415
To Display HOLIDAY Setpoints: – or –

SUPPLY VOLTAGE RANGE 440-480
Use HOLIDAY setpoint key as described in the
beginning of this section to produce the following
message: – or –
S_ M_ T_ W_ T_ F_ S_ HOLIDAY NOTED BY * SUPPLY VOLTAGE RANGE 550-600
NOTE: On the days that are designated by an *, the – or –

chiller will automatically start and stop per the SUPPLY VOLTAGE RANGE DISABLED
holiday schedule established in DAILY SCHED-
ULE setpoints.
A special access code is required to program the Sup-
ply Voltage Range. The Supply Voltage Range is pro-
grammed at the factory and checked at system start-
To Display REMOTE RESET TEMP RANGE Setpoint: up. (Note to service technician: Refer to programming
instructions in Service Instruction, Form 160.49-M2.)
Use REMOTE RESET TEMP RANGE setpoint key
FORM 160.49-O1
PROGRAMMING
THE MICROCOMPUTER CONTROL CENTER
PROGRAMMING SYSTEM SETPOINTS
The system setpoints can be entered at any time . . . .

even when the system is running. Proceed as follows
to enter system setpoints. (Refer to Fig. 5.)
1. Press ACCESS CODE key.
2. ENTER VALID ACCESS CODE _ _ _ _ is displayed.
3. Using ENTRY keys, enter 9 6 7 5.
4. As each digit is entered, the characters Y O R K

are displayed.
NOTE: If digits other than 9 6 7 5 are entered,
Y O R K is still displayed.
LD01068
NOTE: For ease in remembering the code, note that
the letters Y O R K correspond to the dig-
its 9 6 7 5 on a telephone dial. FIG. 5 – KEYPAD – PROGRAMMING SYSTEM
SETPOINTS
5. Press ENTER key.
NOTE: If digits other than 9 6 7 5 were entered in

step No. 4, INVALID ACCESS CODE is dis- 9. Enter setpoints as detailed below. If you make a
played when the ENTER key is pressed. If mistake when entering a value, press CANCEL key
this occurs, enter the correct access code and then ENTER key. The display will revert to the
(9675) and proceed. default values and the cursor will return to the first
changeable digit. You can then proceed to enter the
6. ACCESS TO PROGRAM KEY AUTHORIZED is displayed. correct values. If the entered value exceeds ac-
ceptable limits, OUT OF RANGE – TRY AGAIN!
NOTE: Unless terminated by pressing the ACCESS message will be displayed for 2 seconds, then the
CODE key again, the operator will have ac- PROGRAM MODE, SELECT SETPOINT message will re-
cess to the PROGRAM key for 10 minutes. appear.
When 10 minutes have elapsed, access to
PROGRAM key will be automatically dis- 10. When all the desired setpoints have been entered,
abled and the operator must return to step press the ACCESS CODE key to exit PROGRAM
No. 1 to gain access. mode and terminate access to PROGRAM mode.
ACCESS TO PROGRAM MODE DISABLED is displayed.
7. Press PROGRAM key. The Control Center will automatically return to LO-
CAL, REMOTE or SERVICE mode . . . . whichever
8. PROGRAM MODE, SELECT SETPOINT is displayed. was last selected.
To enter CHILLED LIQUID TEMP Setpoint: (Refer to
Fig. 6.)
1. Press and release CHILLED LIQUID TEMP setpoint

key. The following program prompt message will be
displayed:
LEAVING SETPOINT = XX.X °F (BASE)
(BASE) refers to the base or lowest setpoint avail-

able to an Energy Management System. If any En-
ergy Management System is applied, this value
must be entered into the Energy Management Sys-
tem. Refer to previous explanation or REMOTE/
RESET TEMP RANGE, page 10.
2. Use Entry keys to enter desired value.

LD01069
3. Press and release ENTER key.
PROGRAM MODE, SELECT SETPOINT FIG. 6 – KEYPAD – PROGRAMMING “LEAVING
message is displayed. CHILLED WATER TEMP” SETPOINT
To Enter % CURRENT LIMIT Setpoint: 3. Press and release ENTER key.

(Electro-Mechanical Starter, refer to Fig. 7)
PROGRAM MODE, SELECT SETPOINT
1. Press and release % CURRENT LIMIT setpoint key. message is displayed.

The following program prompt message is displayed:
CURRENT LIMIT = XXX% FLA

message is displayed.
(Solid State Starter, refer to Fig. 7)
1. Press and release % CURRENT LIMIT setpoint

key.
The following program prompt message is displayed:
CURRENT LIMIT = XXX% FLA; MTR CUR = _ _ _ FLA

LD01070
NOTE: Motor Current FLA value is entered by YORK
factory and checked at system start-up. It
cannot be changed without special access
code. (Note to service technician: refer to FIG. 7 – KEYPAD – PROGRAMMING “% CURRENT
“Programming Instructions” in Service in- LIMIT” SETPOINT
struction, Form 160.49-M2.
FORM 160.49-O1
To Enter PULL DOWN DEMAND Setpoint:

(Refer to Fig. 8.)
1. Press and release PULL DOWN DEMAND setpoint

key. The following program prompt message is dis-
played:
SETPOINT = XXX MIN @ XXX % FLA, XXX MIN LEFT
2. Use Entry keys to enter desired values. For expla-

nation, see PULL DOWN DEMAND, page 10. Note
that “XX min left” is not an operator entered value.

LD01071
FIG. 8 – KEYPAD – PROGRAMMING “PULL DOWN

DEMAND” SETPOINT
To Enter CLOCK Setpoint: (Refer to Fig. 9.)
1. Assure Micro Board Program jumper J57 is in

“CLKON” position.
2. Press and release CLOCK setpoint key. The fol-

lowing program prompt message is displayed:
TODAY IS MON 10:30 PM 1/1/92
3. Press ADVANCE DAY / SCROLL key until the pro-

gram per day of week appears on the display.
4. Use Entry keys to enter proper time of day.
5. Press AM/PM key to change the AM to PM or vice

versa.
6. Use Entry keys to enter proper calendar date, LD01072

(MONTH/DAY/YR). If month and day are single digit
entries, precede the entry with “0”. For example,
02/04/88.
FIG. 9 – KEYPAD – PROGRAMMING “CLOCK”
SETPOINT
To Enter DAILY SCHEDULE Setpoint: 6. Use the ADVANCE DAY / SCROLL key with proce-
(Refer to Fig. 10.) dure in Step 2. To enter start and stop times for
remainder of the week plus a holiday schedule if
1. Press and release DAILY SCHEDULE setpoint key. required.
The following prompt message is displayed:
7. Press the ENTER key.
SUN START = XX:XX AM, STOP = XX:XX AM
PROGRAM MODE, SELECT SETPOINT is displayed.
2. If the displayed start and stop time is not the de-
sired schedule, enter the desired start and stop
times as follows:
a. If you do not want the chiller to automatically
start and stop on this day, press CANCEL key.
b. Use the Entry keys to enter desired hours and
minutes start time.
c. If necessary, press the AM/PM key to change
“AM” to “PM” or vice versa.
d. Use the Entry keys to enter desired hours and
minutes stop time.
e. If necessary, press the AM/PM key to change
“AM” to “PM” or vice versa.
3. Press and release ADVANCE DAY/SCROLL key.

MON START = XX:XX AM, STOP = XX:XX AM
4. Enter the desired start and stop time per Step 2.
5. Press and release ADVANCE DAY/SCROLL key. LD01073

REPEAT MON SCHEDULE MON-FRI? YES = 1; NO = 0
FIG. 10 – KEYPAD – PROGRAMMING “DAILY
a. If you press the 1 Entry key, Monday’s start and SCHEDULE” SETPOINT
stop time will be automatically entered for Tues-
day through Friday.
– or –
b. If you press the 0 Entry key, Tuesday through
Friday can be programmed with different start
and stop times.
FORM 160.49-O1
To Enter HOLIDAY Setpoint: (Refer to Fig. 11.)
1. Press and release HOLIDAY setpoint key. The fol-

lowing program prompt message is displayed:
S_ M_ T_ W_ T_ F_ S_ HOLIDAY NOTED BY r
2. Press and release ADVANCE DAY/SCROLL key

to move cursor to the day that you wish to desig-
nate as a holiday.
3. Press and release r Entry key. An r will appear

next to the selected day.
4. After you have placed an r next to each of the

days that you wish to designate a holiday, press
ENTER key PROGRAM MODE, SELECT SETPOINT
To cancel all of the designated holidays: perform

Step 1, press CANCEL key, and then press EN-
TER key.
LD01074
To cancel one of the designated holidays: perform

Step 1, press ADVANCE DAY / SCROLL key until
the cursor appears to the right of the desired day, FIG. 11 – KEYPAD – PROGRAMMING “HOLIDAY”
press the r key, then press the ENTER key. SETPOINT
To Enter REMOTE/ RESET TEMP RANGE Setpoint:

(Refer to Fig. 12.)
1. Press and release REMOTE/RESET TEMP RANGE

setpoint key. The following program prompt mes-
sage is displayed:
REMOTE TEMP SETPOINT RANGE = XX °F (°C)
2. Use Entry keys desired value (10° or 20°F) or (5.5°

or 11.1°C).

LD01075
FIG. 12 – KEYPAD – PROGRAMMING “REMOTE

RESET” TEMP RANGE
To Enter DATA LOGGER Setpoint:
Refer to Form 160.49-N2 for operation of this key.
SERVICE KEYS
LD01076
FIG. 13 – KEYPAD – SERVICE KEYS LOCATION
The Service keys are provided for the service techni- rent limit setpoint is not reached, which causes the
cian’s use when performing routine maintenance or when current limit function to override the LCWT control. If
troubleshooting the system. The WARNING RESET system is running, SYSTEM RUN – AUTO VANES is dis-
and PRE-ROTATION VANES keys are enabled in SER- played. The actual opening and closing of the vanes is
VICE mode only. The remainder of the Service keys indicated on the display. When the vanes are opening,
are enabled in SERVICE, LOCAL or REMOTE mode. SYSTEM RUN – VANES OPENING is displayed. If the vanes
are closing, SYSTEM RUN – VANES CLOSING is displayed.
Whenever the Control Center is in LOCAL, REMOTE
PRE-ROTATION VANES KEYS
or PROGRAM mode, the vane control circuitry is au-
tomatically placed in AUTO mode and the vanes oper-
OPEN – Press and release this key to drive the pre- ate to control the leaving chilled water temperature to
rotation vanes open. If the chiller is running, the programmed setpoint.
SYSTEM RUN – VANES OPENING is displayed. If chiller is
not running, SYS READY TO START – VANES OPENING is
CLOSE – Press and release this key to drive the pre-
displayed. The vanes will continue to open until the
rotation vanes closed. If the chiller is running,
CLOSE, HOLD, or AUTO (if temperature error requires
SYSTEM RUN – VANES CLOSING is displayed. If chiller is
it) keys are pressed and released.
not running, SYS READY TO START – VANES CLOSING is
displayed. When the vanes are full closed,
HOLD – Press and release this key to hold the pre- SYS READY TO START – VANES CLOSED is displayed. The
rotation vanes in their present position. If the chiller is vanes will continue to close until the OPEN, HOLD, or
running, SYSTEM RUN – VANES HOLDING is displayed. AUTO keys are pressed.
If chiller is not running,
SYS READY TO START – VANES HOLDING is displayed. The
vanes will remain stationary until the OPEN, HOLD, or OTHER SERVICE KEYS
AUTO keys are pressed and released. WARNING RESET – Press and release this key to
reset any “WARNING” or “STATUS” message that can
AUTO – Press and release this key to put the pre- be reset with this key, unless the condition still exists.
rotation vanes under LCWT control as long as the cur- To reset any cycling or warning message, place the
FORM 160.49-O1
Control Center in SERVICE mode and press WARN- No. 2

ING RESET key. To reset any safety shutdown mes-
DISCHARGE TEMP = XXX.X°F, OIL TEMP = XXX.X°F
sage, press WARNING RESET key in SERVICE mode
with the COMPRESSOR switch in the STOP/RESET
No. 3
position.
HOP = XX.X PSIG; LOP = XX.X PSIG
MANUAL OIL PUMP – This key is operational in any
mode. Press and release this key to run the oil pump.
Press and release the key again to stop the oil pump.
To hold each of the above messages, press and re-
A 10-minute maximum is imposed on the running of
lease the DISPLAY DATA key, then press and release
the oil pump (i.e., the oil pump will automatically shut
the DISPLAY HOLD key. Message No. 1 above will be
off after 10 minutes). If a longer running time is de-
displayed and updated every 2 seconds until the DIS-
sired, the key must be pressed again. The manual oil
PLAY DATA key is pressed and released. Message
pump feature is disabled during “START SEQUENCE
No. 2 is then displayed and updated every 2 seconds
INITIATED” to allow for auto-zeroing of oil pressure
until the DISPLAY DATA key is again pressed and re-
transducers.
leased. Message No. 3 is then displayed and updated
every 2 seconds until either the DISPLAY DATA key is
DISPLAY DATA – This key is operational in any three
again pressed and released (whereupon message No.
of the Control Center modes of operation (SERVICE,
1 is displayed), or the DISPLAY HOLD key is pressed
LOCAL or REMOTE). It is used to display certain sys-
and released (whereupon the DISPLAY DATA mes-
tem operating parameters that are relevant to trouble-
sages are removed from the display.)
shooting the chiller system.
Press and the DISPLAY DATA key. The following mes-

sages will sequentially scroll on the display. Each mes- HISTORY PRINT – This key is used to initiate a his-
sage will be displayed for 2 seconds. tory print to the optional printer. Refer to Form 160.49-
N2 for operation of this key.
No. 1
SAT TEMPS EVAP = XX.X°F, COND = XX.X°F
OPERATING MODES
The MicroComputer Control Center can be operated in 2. Remote Stop

four different operating modes as follows:
3. Remote LCWT Setpoint
SERVICE – enables all the Service keys except DIS-
PLAY DATA, MANUAL OIL PUMP, and HISTORY 4. Remove Current Limit Setpoint
PRINT, which are enabled in all modes. See “Service
Keys”, page 18. NOTE: The compressor can be stopped by the COM-
PRESSOR switch, regardless of the operating
LOCAL – This is the normal operating mode. The com- mode. The switch must be in RUN position to
pressor can be started and stopped from the Control enable REMOTE mode. The operator cannot
Center. Also, the Display and Setpoint parameters can locally start the compressor using the COM-
be displayed. PRESSOR switch when in the REMOTE mode.
PROGRAM – Allows the operator to program the Set- To determine which operating mode the Control Center
point parameters, and change operating modes. is presently in, simply press the MODE key.
REMOTE – In this mode, the Control Center will ac- • If the Control Center is in LOCAL mode,
cept control signals from a remote device (i.e., Energy LOCAL OPERATING MODE IN EFFECT is displayed.
Management System) or cycling input. The control sig-
nal inputs are: • If the Control Center is in REMOTE mode,
REMOTE OPERATING MODE IN EFFECT is displayed.
1. Remote Start
• If the Control Center is in SERVICE mode, 7. Press PROGRAM key.
SERVICE OPERATING MODE IN EFFECT is displayed.
8. PROGRAM MODE, SELECT SETPOINT is displayed.
To change operating mode, proceed as follows:
9. Press MODE key.
1. Press ACCESS CODE key.
10. The mode that has been previously selected will be
2. ENTER VALID ACCESS CODE _ _ _ _ is displayed. displayed as follows:
3. Using Entry keys, enter 9 6 7 5. LOCAL MODE SELECTED
– or –
4. As each digit is entered, the characters Y O R K
are displayed. SERVICE MODE SELECTED
NOTE: If digits other than 9 6 7 5 are entered, – or –
Y O R K is still displayed.
REMOTE MODE SELECTED
5. Press ENTER key.
11. Press ADVANCE DAY key to scroll to desired mode.
NOTE: If digits other than 9 6 7 5 were entered in Each time this key is pressed, a different mode is
step No. 4, INVALID ACCESS CODE is dis- displayed as above:
played when the ENTER key is pressed. If
this occurs, enter the correct access code 12. When the desired mode is displayed, press EN-
(9675) and proceed. TER key.
6. ACCESS TO PROGRAM KEY AUTHORIZED is displayed. 13. PROGRAM MODE, SELECT SETPOINT is displayed.
NOTE: Unless terminated by pressing the ACCESS
CODE key again, the operator will have ac- 14. Press ACCESS CODE key to exit PROGRAM mode
cess to the PROGRAM key for 10 minutes. and terminate access to PROGRAM mode.
When 10 minutes have elapsed, access to
PROGRAM key will be automatically dis- 15. ACCESS TO PROGRAM MODE DISABLED is displayed.
abled and the operator must return to step
No. 1 to gain access.
COMPRESSOR SWITCH
(See Fig. 13, page 18.) Move switch from RUN to STOP/RESET position.
This rocker switch is used to locally operate the com-
pressor. It is used to start, run and stop the compres-
To RESET Control Center:
sor. Also, it resets the Control Center after a safety
shutdown.
Following a safety shutdown, the operator is re-
quired to reset the Control Center prior to restart-
To START* chiller compressor in LOCAL mode:
ing the system. Move switch from RUN to STOP/
Move COMPRESSOR switch from STOP/RESET RESET position.
to START position. Switch will spring-return to RUN
position. NOTE: The operator cannot start the compressor (us-
ing this switch) when the Control Center is in
To STOP compressor: REMOTE mode.
FORM 160.49-O1
DISPLAY MESSAGES
The following displayed messages will be automatically • The operator has pressed the vanes OPEN key on
displayed unless the operator is requesting additional the keypad.
information via the keypad.
SYSTEM RUN – VANES CLOSING
SYSTEM RUN – CURRENT LIMIT IN EFFECT
Displayed when the chiller is running, the MicroCom-
Displayed when the chiller is running, and the motor puter Control Center is in SERVICE mode with:
current is equal-to or greater-than the operator-pro-
grammed “XXX % FLA” current limit value. When the • The vanes operating in AUTO mode and closing to
motor current reaches 100% of this value, the pre- maintain the leaving chilled water temperature
rotation vanes are not permitted to open further. If the setpoint.
current continues to rise to 104% of this value, the – or –
vanes will be driven closed – not fully closed; only far
enough to allow the current to decrease to a value less • The operator has pressed the vanes CLOSE key on
than 104% of the operator-programmed “XXX % FLA” the keypad.
current limit.
SYSTEM RUN – VANES HOLDING
For example:
With the operator-programmed “% CURRENT LIMIT” puter Control Center is in SERVICE mode, and the
set at 50% and the FLA of the chiller equal to 200A, the operator has pressed the vanes HOLD key.
current limit circuit would perform as follows:
(100%) (50% x FLA) = Vanes inhibited from open- SYS READY TO START – VANES OPENING
ing further.
Displayed when the chiller is running and the operator
(104%) (50% x FLA) = Vanes driven toward close has pressed the vanes OPEN key on the keypad.
position.
SYS READY TO START – VANES CLOSING
Therefore:
Displayed when the chiller is not running and the op-
(100%) (50% x 200) = 100A = Vanes stop open- erator has pressed the vanes CLOSE key on the key-
ing pad.
(104%) (50% x 200) = 104A = Vanes driven to-
ward close position. SYS READY TO START – VANES HOLDING
SYSTEM RUN – AUTO VANES

Displayed when the chiller is running and the operator
has pressed the vanes HOLD key on the keypad.
puter Control Center is in SERVICE mode, and the SYSTEM RUN – LOW PRESSURE LIMIT IN EFFECT
vanes are operating in AUTO mode.
Displayed when the chiller is running and the evapora-
SYSTEM RUN – VANES OPENING
tor pressure falls to 56.2 PSIG, 387.5 kPa (R-22); 27
PSIG, 186.1 kPa (R134a). Simultaneously, the pre-ro-
Displayed when the chiller is running, the MicroCom- tation vanes will be prevented from further opening.
puter Control Center is in SERVICE mode with: The action maintains chiller operation to prevent low-
evaporator-pressure shutdown at 54.3 PSIG, 374.0 kPa
• The vanes operating in AUTO mode and opening to (R-22); 25 PSIG, 172.4 kPa (R-134a). When the evapo-
maintain the leaving chilled water temperature set- rator pressure rises to 57.5 PSIG, 396.5 kPa (R-22);
point. 28 PSIG, 193 kPa (R-134a), the vanes will be permit-
– or – ted to open. Low pressure limit feature is not used when
program jumper (JP3) is cut (Brine application).
down, safety shutdown (operator must move the COM-
SYSTEM RUN – HIGH PRESSURE LIMIT IN EFFECT
PRESSOR switch to STOP/RESET in order to restart)
or operator-initiated shutdown (within 30 minutes of
Displayed when the chiller is running and the condenser
initial start-up). The status message consists of the
pressure rises to 246.3 PSIG, 1698.2 kPa (R-22); 162.5
day and time of shutdown, cause of shutdown, and
PSIG, 1120.4 kPa (R-134a). Simultaneously, the pre-
type of restart required. Upon pressing STATUS key,
rotation vanes will be inhibited from further opening.
System Shutdown Message will be displayed for 2 sec-
This action occurs to prevent system shutdown on high
onds and then return to
condenser pressure at 265 PSIG, 1827.2 kPa (R-22);
180 PSIG, 1241.1 kPa (R-134a). When the condenser SYSTEM SHUTDOWN – PRESS STATUS
pressure falls to 245 PSIG, 1689.3 kPa (R-22); 160 Display can be held indefinitely by depressing DIS-
PSIG, 1103.2 kPa (R-134a), the vanes will be permit- PLAY HOLD key. For examples of System Shutdown
ted to open. Messages, see below.
SYSTEM RUN – PRESS STATUS

SYSTEM SHUTDOWN MESSAGES
Displayed when the chiller is running. It instructs the
operator to press the STATUS key, whereupon one of Day of Week Cause of Shutdown
the following messages will be displayed: Time of Day Type of Restart
• WARNING: COND OR EVAP TRANSDUCER ERROR
MON 10:00 AM – LOW WATER TEMP – AUTOSTART
Indicates a probable condenser or evaporator trans-
ducer problem, because the output is unreasonable. Chiller was shut down on Monday at 10:00 AM be-
The microprocessor arrives at this conclusion by cause the LCWT has decreased to a value that is 4°F
subtracting the evaporator transducer output from (2.2°C) below the operator-programmed chilled liquid
the condenser transducer output. The result must be temperature setpoint. However, if the setpoint is less
zero or some positive number. If the result is a nega- than 40°F (4.4°C), the chiller will always shut down at
tive number, it concludes that there is a probable 36°F (2.2°C). Further, if the chiller is running and the
condenser or evaporator transducer problem. This setpoint is changed, the (Low Water Temperature) cut-
function is inhibited for the first 10 minutes of chiller out will be 36°F (2.2°C) for 10 minutes in order to elimi-
run-time, and is checked every 10 minutes thereaf- nate nuisance trips. Finally, for brine chilling applica-
ter. Message is reset by pressing the WARNING RE- tions, the LWT cutout is always 4°F (2.2°C) below the
SET key in the Service mode. setpoint. (The water jumper on the Micro Board must
be removed for a brine unit.)
NOTE: If the STATUS key is arbitrarily pressed, with-
out the operator being prompted by the
MON XX:XX AM – FLOW SWITCH – AUTOSTART
PRESS STATUS message, the following mes-
sage shall be displayed. Chiller is shut down because a chilled-liquid flow switch
NO MALFUNCTION DETECTED has opened. The flow switch must open for a minimum
of 2 seconds in order to cause a shutdown. The flow
switch is checked 25 seconds into “Start Sequence
SYSTEM RUN – LEAVING TEMP CONTROL
Initiated” and continuously thereafter.
Displayed while the chiller is running. Indicates that
the pre-rotation vanes are being controlled by the leaving MON XX:XX AM – SYSTEM CYCLING – AUTOSTART
chilled water temperature (LCWT). This is the normal
mode of chiller operation. Thus, if the LCWT is above A remote command (computer relay contact or manual
the setpoint, but pulling down rapidly, the vanes will switch) connected to the Remote/Local cycling input
pulse closed as the LCWT nears the setpoint. of the digital input board has shut down the chiller.
SYSTEM READY TO START MON XX:XX AM – MULTI UNIT CYCLING – AUTOSTART
Indicates that the system is not running, but will start Lead/Lag sequence control accessory has shut down
upon application of a start signal. the chiller.
SYSTEM SHUTDOWN – PRESS STATUS MON XX:XX AM – POWER FAILURE – AUTOSTART
Displayed when chiller is shut down on a cycling shut- The chiller is shut down because there has been a
FORM 160.49-O1
power interruption or failure. The chiller will automati- upon application of a separate start signal from the
cally restart when power is restored. This message remote device. This message will only be displayed
will be displayed if the Micro Board is configured for when Control Center is in REMOTE mode.
AUTO-RESTART AFTER POWER FAILURE. The Mi-
cro Board is factory set for manual restart after power
ANTI-RECYCLE, XX MIN LEFT
failure. To convert it to auto-restart after power failure,
remove one of the two-pin program jumpers from the
The chiller may not restart more frequently than every
cloth bag located inside the Control Center and place it
30 minutes. Displayed when chiller is shut down and
on the terminals labeled “Auto R” (J60) on the Micro
there is time remaining on the anti-recycle timer. In
Board.
normal operation, chiller cannot be restarted until
ANTI-RECYCLE, 00 MIN LEFT is displayed. However, when
MON XX:XX AM – POWER FAILURE servicing the chiller, it may be desirable to inhibit this
30-minute timer. If so, simply install a jumper plug in
The chiller is shut down because there has been a the unmarked terminals of the Micro Board directly
power interruption or failure. When power is restored, under Auto-Restart jack.
the chiller can be restarted by pressing the COMPRES-
This feature eliminated when program jumper JP4 is
SOR switch to STOP/RESET position and then to
removed (Steam Turbine applications).
START position. This message will be displayed if the
Micro Board is configured for MANUAL RESTART AF-
TER POWER FAILURE. The Micro Board is factory WARNING: Remove this jumper after servicing.
set for manual restart after power failure. This has been Failure to do this voids the Warranty.
accomplished by removing the two-pin jumper from
the terminals labeled “Auto R” (J60) on the Micro Board.
MON XX:XX AM – LOW EVAP PRESSURE

AC UNDERVOLTAGE – AUTOSTART
The chiller is shut down because the evaporator pres-
The chiller is shut down because the MicroComputer sure has decreased to 54.3 PSIG, 374.4 kPa (R-22);
Control Center was in RUN mode, displaying 25.0 PSIG, 172.4 kPa (R-134a). The chiller will be al-
SYSTEM RUN – LEAVING TEMP CONTROL , but the motor
lowed to start when the pressure increases to 54.4
current was less than 10% FLA for 25 continuous sec- PSIG, 375.1 kPa (R-22); 25.1 PSIG, 173.1 kPa (R-134a).
onds. This is indicative of an AC undervoltage condi- To restart chiller, press the COMPRESSOR switch to
tion that has caused the start relay (1R) in the Micro- the STOP/RESET position and then to the START po-
Computer Control Center to de-energize. This condi- sition.
tion is checked when the MicroComputer Control Cen-
ter goes into RUN mode (after 30 second pre-lube).
This condition can also be caused by failure of any MON XX:XX AM – LOW EVAP PRESSURE – BRINE
component that would cause a loss of the start signal
from the Control Center. In essence, this check as- The chiller is shut down because the brine Low Evapo-
sures that the compressor is running when the Control rator Pressure (LEP, not included with standard Con-
Center is displaying trol Center) safety contacts have opened. The brine
SYSTEM RUN – LEAVING TEMP CONTROL . LEP safety is located external to the Control Center.
Safety cut-out settings will vary with the brine applica-
This check is not performed when program jumper JP4
tion. To restart the chiller, wait until the safety contacts
is removed (Steam Turbine applications).
close, press the COMPRESSOR switch to the STOP/
RESET position and then to the START position.
MON XX:XX AM – INTERNAL CLOCK – AUTOSTART
The operator-programmed daily stop schedule has shut MON XX:XX AM – LOW OIL PRESSURE
down the chiller. The chiller will automatically restart
when the operator-programmed daily start schedule The chiller is shut down because the oil pressure has
indicates a start. It can be overriddden by pressing the decreased to 15 PSID (103.4 kPa) while running, or
COMPRESSOR switch to the START position. never achieved 25 PSID, (172.4 kPa) prior to compres-
sor start during the oil pump pre-lube run. The chiller
will be allowed to restart when the pressure increases
REMOTE STOP
to 25 PSID, (172.4 kPa). Differential pressure is sensed
This message will be displayed when a remote device by two pressure transducers. To restart chiller, press
(typically an Energy Management System) has com- COMPRESSOR switch to STOP/RESET position and
manded the chiller to shut down. The chiller will restart then to the START position.
MON XX:XX AM – HIGH PRESSURE • Phase rotation/loss
• Trigger Board out of lock (OOL)
The chiller is shut down because condenser pressure • Power Fault
has increased to 265 PSIG, 1827.2 kPa (R-22); 180 • Half Phase
PSIG, 1241.4 kPa (R-134a). System will be allowed to
restart when pressure decreases to 205 PSIG, 1413.5
kPa (R-22); 120 PSIG, 8274 kPa (R-134a). Pressure is MON XX:XX AM – HIGH DISCHARGE TEMP
sensed by a High Pressure (HP) safety control that is
located on a mounting bracket above the oil-pump The chiller is shut down because the discharge tem-
starter located on the condenser. This message is perature has increased to 220°F (104.5°C). The sys-
prompted by the opening of the HP safety control con- tem will be allowed to restart when the temperature
tacts. To restart chiller, press COMPRESSOR switch has decreased to 219°F (104.0°C). Temperature is
to the STOP/RESET position and then to the START sensed by a thermistor RT2. To restart the chiller, press
position. COMPRESSOR switch to STOP/RESET position and
then to the START position.
MON XX:XX AM – EVAP TRANS OR PROBE ERROR

MON XX:XX AM – HIGH OIL TEMP
The chiller is shut down because the leaving chilled
water temperature minus the evaporator saturation tem- The chiller is shut down because the oil temperature
perature is outside the range of –2.5°F (–19.2°C) to has increased to 180°F (82.3°C). The system will be
+25°F (–3.9°C) continuously for 10 minutes. To restart allowed to restart when the temperature decreases to
the chiller, press COMPRESSOR switch to STOP/RE- 179°F (81.7°C). The temperature is sensed by ther-
SET switch to STOP/RESET position and then to START mistor RT3. To restart the chiller, press COMPRES-
position. On Brine applications (program jumper JP3 SOR switch to STOP/RESET position and then to the
removed), this check is not performed when the evapo- START position.
rator transducer is reading a pressure below its “out-
of-range” threshold. MON XX:XX AM – OIL PRESSURE TRANSDUCER
The chiller is shut down because the oil pressure has

MON XX:XX AM – MOTOR CONTROLLER – EXT. RESET
increased to 125 PSID, 861.8 kPa (during the first 7
The chiller is shut down because a current module minutes of compressor operation) 60 PSID, 413.7 kPa
(CM-2 Electro-Mechanical starter application), or the (after the first 7 minutes of compressor operation). The
YORK Solid State Starter initiated a shutdown. To re- chiller will be allowed to restart when the oil pressure
start system, reset the external device that caused the decreases to 59 PSID, 406.8 kPa. To restart the chiller,
shutdown. The chiller will then automatically restart. press COMPRESSOR switch to STOP/RESET posi-
tion and then to the START position.
NOTE: The following motor controller shutdowns do
not require an external reset to restart chiller. MON XX:XX AM – FAULTY COND PRESSURE XDCR
Solid State Starter 110°F (43.4°C) start inhibit. Any- The chiller is shut down because the condenser trans-
time the chiller has been shut down for any reason, ducer is indicating a pressure of less than 24.2 PSIG,
this message will be displayed until the SCR heatsink 166.9 kPa (R-22), 6.8 PSIG, 46.9 kPa (R-134a); or a
temperatures decrease to below 110°F (43.4°C). pressure greater than 300 PSIG, 2069 kPa (R-22 or
R-134a). This is generally indicative of a defective con-
denser transducer or the transducer has been discon-
MON XX:XX AM – POWER FAULT – AUTOSTART
nected. After the problem has been corrected, the
The chiller is shut down because of a Solid State Starter chiller can be restarted. To restart, press COMPRES-
or current module (CM-2 Electro-Mechanical starter SOR switch to STOP/RESET position and then to
application) “Power Fault” shutdown. The chiller will START position.
automatically restart. This function is sensed by the
motor controller input to the digital input board. A power- MON XX:XX AM – FAULTY OIL PRESSURE XDCR
fault shutdown is initiated by the motor controller con-
tacts (CM-1) opening and reclosing in one second. If The chiller is shut down because either the high side
Solid State Starter application, the shutdown could have or low side oil pressure transducer was out-of-range
been caused by any of the following reasons. The ap- (displaying x’s) while chiller was running. To restart
propriate light on the Solid State Starter Logic Board chiller, press COMPRESSOR switch to STOP/RESET
will be illuminated. position and then to START position.
FORM 160.49-O1
VANE MOTOR SWITCH OPEN FUNCTION JUMPER POSITION

50 Sec. Oil Pump Prerun Installed
The chiller is shut down because a system-start se- 180 Sec. Oil Pump Prerun Cut
quence has been initiated, but the pre-rotation vanes
are not fully closed.
SYSTEM COASTDOWN
MON XX:XX AM – STARTER MALFUNCTION DETECTED Displayed while motor is decelerating after a chiller
shutdown. The oil pump is running during this period.
The chiller is shut down because the Control Center The duration of this period is 150 seconds.
has detected a motor-current value greater than 15%
FLA for 10 seconds minimum anytime when the com-
pressor-start signal is not energized. To restart the MON XX:XX AM – MTR PHASE CURRENT UNBALANCE
chiller, press COMPRESSOR switch to STOP/RESET (Solid State Starter applications only)
position and then to the START position.
The chiller is shut down because the compressor-motor
current was unbalanced while the chiller was running.
MON XX:XX AM – PROGRAM INITIATED RESET
The current balance is only checked after the motor
The chiller is shut down because Micro Board did not has been running for a minimum of 45 seconds and the
receive a hardware-generated interrupt on schedule. motor current is 80% FLA or greater. If the current in
Typical is an Analog/Digital Converter interrupt. This any phase deviates from the average (a + b3+ c ) current
message is indicative of a Micro Board hardware fail- by greater than 30% for a minimum of 45 consecutive
ure or electrical noise on Micro Board. The chiller will seconds, a shutdown is initiated. To restart the sys-
automatically restart. This message indicates that the tem, press the COMPRESSOR switch to STOP/RE-
watchdog timer-circuit has reset the microprocessor. SET position and then to the START position. An ex-
This occurs when the time needed to step through pro- ample of the conditions for shutdown is as follows:
gram is longer than allowable, thus the software pro-
IF:
gram is initialized at its beginning.
I ∅A = 200A
I ∅B = 200A
SYSTEM READY TO START – PRESS STATUS I ∅C = 118A
The chiller was shut down on a safety shutdown and
THEN:
will start upon application of a local or remote start
signal. Since the message states that the chiller is IAV = 200 + 200 + 118
“Ready to Start”, it means that the shutdown no longer 3
exists and the Control Center has been manually re-
IAV = 173A
set. When the STATUS key is pressed, a message is
displayed that describes the reason for shutdown. The IACCEPTABLE = 173 ± 30% = 121A or 225A
message will be displayed for 2 seconds and then re-
turn to SYSTEM READY TO START – PRESS STATUS . THEREFORE:
Those messages that could be displayed are any of
Since I∅C = 118A which is less than the accept-
the previously described safety-shutdown messages
able 121A, the chiller would shut down if this
or warning messages. They can be cleared from the
unbalance exists for 45 consecutive seconds.
display by entering Service mode and pressing WARN-
ING RESET key. Or, the message will be cleared by
initiating a compressor start. MON XX:XX AM – LOW LINE VOLTAGE
(Solid State Starter applications only)
START SEQUENCE INITIATED
Chiller is shut down because the voltage in any phase
Indicates that the Micro Board has received a local or of line voltage has decreased below the under-volt-
remote start signal and has initiated the chiller start- age-shutdown threshold for 20 consecutive seconds,
up routine. or failed to achieve the minimum required starting line-
voltage. Refer to explanation under “System Setpoints
This is the compressor pre-lube period. The duration – SSS Motor Current/Volts”, page 10. The system will
of this period is controlled by the “Prerun” (JP6) wire automatically restart when all phases of line voltage
jumper on the Micro Board as follows: increase to the minimum required starting voltage.
MON XX:XX AM – HIGH LINE VOLTAGE Output and the Low Side Transducer Output was greater
than 15.0 PSID (103.4 kPa) during the “Transducer Auto-
(Solid State Starter applications only)
Zeroing Sequence” that occurs 10 seconds after a
chiller start is initiated. Message is displayed immedi-
Chiller is shut down because the voltage in any phase
ately after the Auto-Zeroing sequence has completed.
of line voltage has increased above the over-voltage
This indicates that one of the transducer outputs is
threshold for 20 consecutive seconds. Refer to expla-
incorrect, possibly due to an incorrect or defective trans-
nation under “System Setpoints – SSS Motor Current/
ducer. To restart the chiller, press COMPRESSOR
Volts”, page 10. The system will automatically restart
switch to STOP/RESET position and then to START
when all phases of line voltage decrease to the maxi-
position.
mum allowable line voltage to start the chiller.
MON XX:XX AM – FAULTY DISCHARGE TEMP SENSOR

MON 09:30 AM – LOW OIL TEMPERATURE – AUTOSTART
Whenever the discharge temperature falls below 30°F
The chiller is running and the oil temperature (as indi-
(–1.1°C), or the discharge temperature sensor is dis-
cated by thermistor RT3) falls below 55°F (12.8°C) the
connected from the Micro Board, the preceding mes-
chiller will shut down and display this message. The
sage will appear. To restart the system when the dis-
chiller will automatically restart when the oil tempera-
charge temperature rises or the sensor has been con-
ture increases to >71°F (21.7°C) AND is greater than
nected, press the COMPRESSOR switch to the STOP/
the condenser saturated temperature by 20°F (11.1°C)
RESET position and then to the START position.
or 30°F (16.7°C) depending upon how long the chiller
was shut down. Refer to the message “MON XX:XX AM LOW
OIL TEMP DIFF – AUTOSTART”. MON XX:XX AM – PROX SENSOR SAFETY SHUTDOWN
The chiller is shut down because the “Proximity/Tem-

MON XX:XX AM – LOW OIL TEMP DIFF – AUTOSTART
perature Sensor” has detected that the distance be-
tween the compressor high speed thrust collar and the
Indicates the chiller is shut down for one of the follow-
sensor probe has increased > 10 mils or decreased
ing reasons:
> 20 mils from the “Reference Position”.
1. The chiller has been shut down for 30 minutes or
NOTE: If the reference position is < 42 mils, the mini-
less and the oil temperature minus the condenser
mum allowed distance is 22 mils.
saturation temperature is less than 30°F (16.7°C).
– or – IMPORTANT: If the chiller has shut down displaying
this message, it cannot be restarted until a qualified
2. The chiller has been shut down for more than 30 service technician performs a visual inspection of the
minutes and the oil temperature minus the con- high speed thrust bearing and performs a special reset
denser saturation temperature is less than 40°F procedure. This special reset procedure is detailed in
(22.2°C). YORK Service manual, Form 160.49-M2. Failure to per-
– or – form the visual inspection prior to restarting the chiller
could result in severe compressor damage!!!
3. Following a power failure, the oil temperature mi-
nus the condenser saturation temperature is less
than 40°F (22.2°C). MON XX:XX AM – HIGH SPEED DRAIN TEMP
The chiller will restart automatically after the condition The chiller has shut down because the “Proximity/Tem-
clears if the COMPRESSOR switch is in the RUN po- perature Sensor” has detected the temperature of the
sition. high speed drain line has reached 250.0°F (121.2°C)
or greater.
NOTE: This check is made only when the chiller is
shut down. It is not checked when the chiller is IMPORTANT: If the chiller has shut down displaying
running or in “Start Sequence Initiated”. this message, it cannot be restarted until a qualified
service technician performs visual inspection of the
high speed thrust bearing and performs a special reset
DAY – TIME – OIL PRESSURE XDCR ERROR procedure. This special reset procedure is detailed in
YORK Service manual, Form 160.49-M2. Failure to per-
Indicates the chiller has shut down because the differ- form the visual inspection prior to restarting the chiller
ence between the High Side Oil Pressure Transducer could result in severe compressor damage!!!
FORM 160.49-O1
MON XX:XX AM – OPEN DRAIN TEMP THERMOCOUPLE defective. This battery provides back-up power to the
RTC memory (RAM) in the event of a utility AC power
The chiller is shut down because the “Proximity/Tem- failure. This assures the system setpoints will be main-
perature Sensor” thermocouple or high speed drain tem- tained. If this message appears, the RTC IC chip (U16)
perature wiring between the “Proximity/Temperature on the Micro Board must be replaced. If there had been
Sensor” module and the MicroComputer Control Cen- a power failure while this message is displayed, the
ter has been disconnected or has a poor electrical con- setpoints will have been lost and must be repro-
nection. grammed. Order a replacement RTC IC chip (YORK
part number 031-00955-000) from the YORK Parts Dis-
IMPORTANT: Open thermocouple shutdowns would tribution Center. With AC power removed from system,
typically indicate hardware or wiring defects and should locate RTC chip U16 on the Micro Board and remove
not result in any damage to the compressor high speed existing RTC chip from socket and discard. Observe
thrust bearing. Therefore, a bearing inspection is not anti-static precautions and install new RTC chip in
required. However, due to the critical nature of these socket. Assure proper IC orientation – orientation notch
circuits, anytime this shutdown occurs, a special re- must be UP. (Refer to Fig. 14.)
set procedure must be performed by a qualified ser-
vice technician before the chiller can be restarted.
This procedure is detailed in Service manual, Form
160.49-M2.
MON XX:XX AM – DC UNDERVOLTAGE
The “Proximity/Temperature Sensor” module becomes MICRO BOARD

unstable in operation when the +24VDC supply de-
creases to +17VDC. Therefore, the Micro Board moni-
tors the +24VDC supply and when it decreases to
+19VDC, it shuts down the chiller and displays this
message, preventing invalid “Proximity Sensor Safety”
or “High Speed Drain Temp” safety shutdowns. The
chiller will automatically restart when the voltage in- U16 RTC
creases to greater than +19.7VDC. IC CHIP
REAL
TIME
CLOCK
MON XX:XX AM – AUX SAFETY SHUTDOWN
The system is shut down because an external device,

connected to digital input board TB1-31 (Auxiliary Safety
Shutdown Input), has initiated a system shutdown. This
input is a general purpose input that can be used to
annunciate a user-defined safety shutdown. To restart
chiller, press COMPRESSOR switch to STOP-RESET
position and then to START position.
24673A
REPLACE RTC. U16 – REPROGRAM SETPOINTS
FIG. 14 – MICROCOMPUTER CONTROL CENTER
Indicates that the battery located inside the REAL- LOCATION OF REAL TIME CLOCK U16
TIME CLOCK IC chip (U16 on the Micro Board) is RTC IC CHIP
SECTION 3
SYSTEM OPERATING PROCEDURES
WARNING
OIL HEATERS CHECKING THE OIL LEVEL IN THE OIL

RESERVOIR
If the oil heater is de-energized during a shut-
down period, they must be energized for 12 hours
Proper operating oil level – the middle of the up-
prior to starting compressor, or remove all oil and
per sight glass.
recharge compressor, with new oil. (See “Charg-
ing Unit With Oil”, page 40.)
If the oil is excessively high after start-up, the
excess oil may be drained from the oil filter drain
NOTE: The oil heater is thermostatically controlled valve while the compressor is running.
and remains energized as long as the
fused disconnect switch to the starter or If oil level is low, oil should be added to the com-
turbo-modulator is energized. pressor. (See “Charging Unit With Oil”, page 40.)
START-UP PROCEDURE the Control Center. The display readout is active

whenever power is supplied to the Control Center.
PRE-STARTING Return from the SERVICE mode to LOCAL, PRO-
GRAM, or REMOTE mode to suit the method of
Prior to starting the CodePak, observe the MicroCom- operation selected for the chiller application. Re-
puter Control Center. Make sure the display reads fer to “Section 2”.
SYSTEM READY TO START .
4. % Current Limit – Press the % CURRENT LIMIT
setpoint key on the Control Center. The “Display”
To pre-start the CodePak, use the following procedure: should read CURRENT LIMIT = 100% FLA on (Solid
State Starter units only, the display is
1. Oil Heater – The oil heater must be energized for CURRENT LIMIT = 100% FLA, MTR CUR = XXXX FLA )
12 hours prior to starting the CodePak. The unit
if the Control Center was not programmed. If the
will not start if the oil is less than 71°F (21.7°C). If
setpoint is not 100% and was predetermined for
not possible the compressor oil should be drained
the job application the Control Center should be
and new oil must be charged into the oil sump.
programmed to that specification. To program, re-
(See “Charging Unit With Oil”, page 40.)
fer to “Section 2”.
2. Oil Pump – To check, press and release the
5. All Control Center setpoints should be programmed
MANUAL OIL PUMP key under Service on the
before the CodePak is started. (Refer to “Section
Control Center. The oil pump will run for 10 min-
2”.) Prior to start, the clock must be programmed
utes and shut down. Press and release the
for the proper day and time. Any setpoints which
MANUAL OIL PUMP key to stop the operation of
are desired to be changed may be programmed. If
the oil pump for less than 10 minutes of operation.
not programmed the “default” value setpoints are
as follows:
3. Pre-Rotation Vanes – To perform this test the
starter interlock terminals 3 and 4 must be jump- LCWT = 45°F (7.2°C)
ered to allow vanes to open (remove the jumper % Current Limit = 100% FLA
after test). Make sure the Control Center is in the Pulldown Demand = None
SERVICE mode, then press the prerotation vanes Clock = Sun 12:00 A.M.
OPEN and CLOSE keys to observe the operation Daily Schedule = None
of the prerotation vanes. The Control Center sup- Holiday = None
plies a signal to operate the prerotation vanes. Remote Reset Temp. Range = 20°F (11.1°C)
The movement of the vanes will be displayed on Data Logger = No operation
FORM 160.49-O1
START-UP The high and low oil pressure transducers (OP)

and the oil temperature sensor (RT3) will sense
1. If the chilled water pump is manually operated, any malfunction in the lubrication system and ac-
start the pump. The Control Center will not allow tivate one of the following display messages:
the CodePak to start unless chilled liquid flow is
established through the unit. (A field supplied DAY 10:30 AM – LOW OIL PRESSURE
chilled water flow switch is required.) If the chilled
liquid pump is wired to the MicroComputer Con- DAY 10:30 AM – HIGH OIL TEMPERATURE
trol Center the pump will automatically start, there-
fore, this step is not necessary. DAY 10:30 AM – LOW OIL TEMP – AUTOSTART
2. To start the CodePak, press the COMPRESSOR DAY 11:30 AM – OIL PRESSURE TRANSDUCER
START switch. This switch will automatically spring
return to the RUN position. (If the unit was previ- 5. The anti-recycle timer software function will oper-
ously started, press the STOP/RESET side of the ate after the 50 seconds of pre-run time. At this
COMPRESSOR switch and then press the START time, the timer will be initiated and will run for 30
side of the switch to start the CodePak.) When minutes after the compressor starts. If the Code
the start switch is energized, the Control Center Pak shuts down during this period of time, it can-
is placed in an operating mode and any malfunc- not be started until the timer completes the 30
tion will be noted by messages on the 40 charac- minute cycle.
ter alphanumeric display. (See Fig. 3.)
6. The chilled liquid pump contacts will close start-
NOTE: Any malfunctions which occur during ing the chilled liquid pump to allow liquid flow
STOP/RESET are also displayed. through the cooler when the COMPRESSOR start
switch is energized.
When the CodePak is shut down, the prerotation
vanes will close automatically to prevent loading 7. After the first 50 seconds of operation, the com-
the compressor on start-up. When the prerotation pressor will start and the Control Center display
vanes are fully closed the “Display” will read message will read
SYSTEM READY TO START – VANES CLOSED SYSTEM RUN – CURRENT LIMIT IN EFFECT while the
when in SERVICE mode. motor is accelerating to full speed. When the mo-
tor reaches full speed and the current falls below
When the CodePak starts to operate, the following au- 100% FLA the message will read
tomatic sequences are initiated: (Refer to Fig. 15, SYSTEM RUN – LEAVING TEMP. CONTROL
“Chiller Starting & Shutdown Sequence Chart”.)
8. For additional display messages and information
1. The MicroComputer Control Center alphanumeric pertaining to the operation of the MicroComputer
display message will read Control Center, refer to “Section 2”.
START SEQUENCE INITIATED
for the first 50 seconds of the starting sequence, 9. Low Oil Temp. Differential.
(3 minutes if Micro Board JP6 removed).
CODEPAK OPERATION
2. The compressor vent line solenoid valve will open
after the first 5.83 minutes of operation. The sole- After the compressor reaches its operating speed, the
noid will close automatically after the compressor Prerotation Vanes will begin to open under the control
shuts down. of the Microprocessor Board which senses the leaving
chilled liquid temperature. The unit capacity will vary
3. The 1R-1 contacts of the 1R start relay will re- to maintain the leaving CHILLED LIQUID TEMPERA-
main open for the first 50 seconds of oil pump TURE setpoint. The Prerotation Vanes are modulated
operation. These contacts will close, starting the by an actuator under the control of the Microprocessor
compressor motor and the condenser water pump Board. The vane control routine employs proportional
at the end of the 50 second period. plus derivative (rate) control action. A drop in chilled
liquid temperature will cause the actuator to close the
4. The oil pump will start to circulate oil for a 50 Prerotation Vanes to decrease CodePak capacity. When
second pre-run to establish oil flow and adequate the chilled liquid temperature rises, the actuator will
lubrication to all bearings, gears, and rotating sur- open the Prerotation Vanes to increase the capacity of
faces within the compressor. the unit.
SYSTEM STARTING & SHUTDOWN SEQUENCE
OPERATOR INITIATED
LD01077
FIG. 15 – CODEPAK CHILLER STARTING SEQUENCE & SHUTDOWN SEQUENCE
However, the current draw (amperes) by the compres- MON 10:30 AM – LOW WATER TEMPERATURE – AUTOSTART
sor motor cannot exceed the setting of the % CUR-
RENT LIMIT at any time during the unit operation, since This occurs when the leaving water temperature falls
the MicroComputer Control Center 40 to 100% three- to 4°F (2.2°C) below setpoint or 36°F (2.2°C), which-
phase peak current limit software function, plus the 3- ever is higher. The LWT is part of the Micro Board.
phase 100% solid state overload current limiter (CM-
2) on Electro-Mechanical Starter applications or the NOTE: If the temperature setpoint has been repro-
Solid State Starter current limit function will override grammed within the last 10 minutes, the LWT
the temperature control function and prevent the Pre- cutout is 36°F (2.2°C) for 10 minutes.
rotation Vanes from opening beyond the % CURRENT
LIMIT setting.
Condenser Water Temperature Control
If the load continues to decrease, after the Prerotation
Vanes are entirely closed, the CodePak will be shut The YORK CodePak is designed to use less power by
down by the Low Water Temperature control (LWT) taking advantage of lower than design temperatures
function which is displayed on the Control Center as: that are naturally produced by cooling towers through-
FORM 160.49-O1
out the operating year. Exact control of condenser wa- cause the vanes to modulate with load require-
ter such as a cooling tower bypass, is not necessary ments.
for most installations. The CodePak requires only that
the minimum condenser water temperature be no lower 2. Be sure the oil pump is operating while unit is run-
than the value determined by referring to the formula ning.
below:
3. Check Oil Pressure display. A gradual decrease in
Min. ECWT = LCHWT—C RANGE + 5 + (15 x 100
% LOAD
) bearing oil pressure of 5 to 10 psi (34.5 to 69 kPa)
(with constant suction and discharge pressures)
where:
may be an indication of a dirty filter. The filter should
ECWT = entering condensing water temperature
be replaced when pressure loss is 30% or more of
LCHWT = leaving chilled water temperature
the original pressure. The actual bearing oil pres-
C RANGE = condensing water temperature range
sure will vary with compressor suction and dis-
charge pressures. When a new system is first op-
At start-up, the entering condenser water temperature
erated under normal full load conditions, the bear-
may be as much as 25°F (13.9°C) colder than the stand-
ing oil pressure should be recorded as a reference
by return chilled water temperature. Cooling tower
point with which to compare subsequent readings.
fan cycling will normally provide adequate control of
the entering condenser water temperature on most in-
stallations. OPERATING LOG SHEET
A permanent daily record of system operating condi-

CHECKING OPERATION
tions (temperatures and pressures) recorded at regu-
lar intervals throughout each 24 hour operating period
During operation, the following conditions should be
should be kept.
periodically checked:
1. On starting, the prerotation vanes should remain An optional status printer is available for this purpose
closed until the compressor motor is up to speed or Fig. 16 shows a log sheet used by YORK Personnel
on the on the run winding; then the vane motor should for recording test data on CodePak systems. It is avail-
LD01078 23889A
*NOTE: These items can be printed by an electronic printer connected to J11 of the Micro Board and pressing the PRINT key on the
Micro Board or automatically using the Data Logger feature.
FIG. 16 – LIQUID CHILLER LOG SHEETS – FORM 160.44-F6
able from the factory in pads of 50 sheets each under 6. Check the compressor discharge temperature.
Form 160.44-F6 and may be obtained through the nearest Press DATA DISPLAY key. During normal opera-
YORK office. Automatic data logging is possible by tion discharge temperature should not exceed 220°F
connecting the optional printer and programming the (104.5°C).
DATA LOGGER function; refer to Form 160.49-N2.
7. Check the compressor motor voltage and current
An accurate record of readings serves as a valuable (amps) at E-M starter (or Turbo-Modulator), or on
reference for operating the system. Readings taken the Control Center display for Solid State Starter
when a system is newly installed will establish normal units.
conditions with which to compare later readings.
8. Check for any signs of dirty or fouled condenser
For example, dirty condenser tubes may be indicated tubes. (The temperature difference between water
by higher than normal temperature differences between leaving condenser and liquid refrigerant leaving the
leaving condenser water and refrigerant leaving the condenser should not exceed the difference re-
condenser. corded for a new unit by more than 4°F (2.2°C.)
9. Verify proper water treatment.

OPERATING INSPECTIONS – See Section 2
10. Press the STATUS key whenever the display indi-
By following a regular inspection using the display read- cates so. This allows any warning messages to be
ings of the MicroComputer Control Center, and main- displayed.
tenance procedure, the operator will avoid serious op-
erating difficulty. The following list of inspections and
procedures should be used as a guide. Weekly
1. Check the refrigerant charge. (See “Checking The

Daily Refrigerant Charge”, page 50.)
1. Check MicroComputer Control Center displays.

Quarterly
2. If the compressor is in operation, check the bear-
ing oil pressure by pressing OIL PRESSURE key 1. Perform chemical analysis of oil.
to read the display on the Control Center. Also check
the oil level in the oil reservoir. Drain or add oil if Semi-Annually (or more often as required)
necessary.
1. Change and inspect compressor oil filter element.
3. Check entering and leaving condenser water pres-
sure and temperatures for comparison with job de- 2. Oil return system.
sign conditions. Condenser water temperatures can a. Change dehydrator.
be checked by pressing CONDENSER LIQUID
TEMPERATURES display key if the optional con- b. Check nozzle of eductor for foreign particles.
denser water temperature sensor kit has been in- 3. Check controls and safety cutouts.
stalled on the condenser entering and leaving wa-
ter piping connections. If not, then conventional
methods may be used. Annually (more often if necessary)
4. Check the entering and leaving chilled liquid tem- 1. Drain and replace the oil in the compressor oil
peratures and evaporator pressure for comparison sump. (See “Charging The Unit With Oil”, page 40.)
with job design conditions. This can be accomplished
by pressing the CHILLED LIQUID TEMPS key and 2. Cooler and Condenser.
the REFRIGERANT PRESSURES key. a. Inspect and clean water strainers.
5. Check the condenser saturation temperature (based b. Inspect and clean tubes as required.
upon condenser pressure sensed by the condenser c. Inspect end sheets.
transducer). Press the DISPLAY DATA key. This
key may be depressed repeatedly after depressing 3. Compressor Drive Motor (See motor manufactur-
the DISPLAY HOLD key to display three different ers maintenance and service instruction supplied
parameters. with unit)
FORM 160.49-O1
a. Clean air passages and windings per manufac- • Faulty Discharge Temp Sensor
turers instructions. • Aux. Safety Shutdown
b. Meg motor windings – See Fig. 23 for details. • Motor Phase Current Unbalance (Solid State Starter
Unit only)
c. Re-lubricate ball bearings.
If the CodePak shuts down on a “Cycling” shutdown
4. Inspect and service electrical components as nec- the display will read SYSTEM SHUTDOWN – PRESS STATUS .
essary.
Upon pressing the STATUS key, the day-of-week, time-
5. Perform chemical analysis of system. of-day and cause of shutdown are displayed. These
shutdowns do not require the operator to manually re-
NEED FOR MAINTENANCE OR SERVICE set the Control Center prior to re-starting the CodePak.
The CodePak will automatically restart when the cy-
If the system is malfunctioning in any manner or the cling condition is removed.
unit is stopped by one of the safety controls, consult
the “Operation Analysis Chart”, pages 44 through 45 CYCLING SHUTDOWNS
of this instruction. After consulting this chart, if you
are unable to make the proper repairs or adjustments • Power Failure (If auto re-start programming jumper
to start the compressor or the particular trouble con- is installed on the Micro Board)
tinues to hinder the performance of the unit, please
• Low Water Temp
call the nearest YORK District Office. Failure to report
constant troubles could damage the unit and increase • Flow Switch
the cost of repairs considerably. • System Cycling
• Multi-Unit Cycling
NORMAL AND SAFETY SYSTEM SHUTDOWNS • Internal Clock
• Anti-Recycle
Normal and safety system shutdowns have been built • Motor Controller (Manual reset of the CM-2 module
into the CodePak to protect it from damage during cer- on E-M starter units; the logic board of the Solid
tain operating conditions. Therefore, it should be un- State Starter may be required)
derstood that at certain pressures and temperatures • Power Fault
the system will be stopped automatically by controls • Program Initiated Reset
that respond to high temperatures, low temperatures,
• Low Oil Temp
and low and high pressures, etc. Table 1 is an explana-
tion of each specific shutdown. If the CodePak shuts • AC Undervoltage
down on a “Safety” shutdown, the display will read • Low Line Voltage (Solid State Starter units only)
SYSTEM SHUTDOWN – PRESS STATUS • High Line Voltage (So2lid State Starter units only)
Upon pressing the STATUS key, the day-of-week, time- • Low Oil Temp. Differential
of-day and cause of shutdown is displayed. Safety shut-
downs require the operator to manually reset the Con-
STOPPING THE SYSTEM (See Fig. 3, page 5)
trol Center prior to restarting the CodePak. When the
display reads START SEQUENCE INITIATED , the cause of
The CodePak MicroComputer Control Center can be
the safety shutdown is automatically cleared from the
programmed to start and stop automatically (maximum,
memory.
once each day) whenever desired. Refer to “Section 2”.
To stop the CodePak, proceed as follows:
SAFETY SHUTDOWNS
1. Push the COMPRESSOR STOP/RESET switch. The
• Power Failure (If auto restart programming jumper is
Control Center display will show
not installed on the Micro Board)
SYSTEM COASTDOWN for 150 seconds, (6 min. if
• Low Evaporator Pressure
Micro Board Jumper JP4 removed). The compres-
• Low Oil Pressure sor, condenser water, and cooling tower fans will
• High Condenser Pressure stop automatically. The oil pump will continue to run
• Evaporator Transducer or Probe Error for a period of 150 seconds. The oil pump will then
• High Discharge Temp stop automatically. Once stopped, the
• High Oil Temp SYSTEM COASTDOWN display will be replaced by
• Oil Pressure Transducer SYSTEM READY TO START .
• Starter Malfunction Detected
2. Stop the chilled water pump (if not wired into the Open the drains on the cooler and condenser liquid
MicroComputer Control Center, in which case it will heads to assure complete drainage. (If Solid State
shut off automatically simultaneously with the oil Starter, drain water from starter cooling loop.)
pump.) (The actual water pump contact operation
is dependent upon the postion of Micro Board jumper 3. Move jumper J-57 on the Micro Board from CLOCK
J54.) ON position (CLKON) to CLOCK OFF position
(CLKOFF) while 115VAC control power is applied.
3. Open the switch to the cooling tower fan motors, if This conserves the battery.
used.
4. Open the main disconnect switches to the com-
4. The compressor sump oil heater (thermostatically pressor motor, condenser water pump and the chilled
controlled) is energized when the unit is stopped. water pump. Open the 115 volt circuit to the Control
Center.
PROLONGED SHUTDOWN
START-UP AFTER PROLONGED SHUTDOWN
If the CodePak is to be shut down for an extended
period of time (for example, over the winter season), 1. When putting the system into operation after pro-
the following paragraphs outline the procedure to be longed shutdown (during the winter), remove all oil
followed. from the compressor. Install a new filter element
and charge compressor with fresh oil. Move jumper
1. Test all system joints for refrigerant leaks with a J-57 on the Micro Board from CLOCK OFF position
leak detector. If any leaks are found, they should (CLKOFF) to CLOCK ON position (CLKON) and re-
be repaired before allowing the system to stand for set the clock. Energize the 115 volt circuit to the
a long period of time. Control Center to energize the compressor sump
oil heater for at least 12 hours.
During long idle periods, the tightness of the sys-
tem should be checked periodically. 2. Operate the Oil Pump (press and release the MAN-
UAL OIL PUMP key) until steady oil pressure is
2. If freezing temperatures are encountered while the established. Then press and release the OIL PUMP
system is idle, carefully drain the cooling water from key to stop operation of the oil pump. If the water
the cooling tower, condenser, condenser pump, and systems were drained, fill the condenser water cir-
the chilled water system-chilled water pump and cuit and chilled liquid circuit.
coils.
FORM 160.49-O1
SECTION 4
SYSTEM COMPONENTS DESCRIPTION
DISCHARGE ADAPTER MOTOR
COM PRESSOR
SUCTION SUPPORT & COVER
MICROCOMPUTER
CONTROL CENTER
DUAL RELIEF
VALVES
MOTOR
COOLER
27073A
27073A
DEHYDRATOR REFRIGERANT
CHARGING VALVE
REFRIGERANT
SIGHT GLASSES LINE
FRONT VIEW
DISCHARGE LINE
PRE-ROTATION VANE ACTUATOR
OIL PUMP
STARTER
SUB-COOLER
25717A
OIL RESERVOIR/
PUMP
CONDENSER
OIL COOLER
FIG. 17 – SYSTEM COMPONENTS
GENERAL piping and passages. There are main points within the
motor-compressor which must be supplied with forced
The YORK CodePak Centrifugal Liquid Chiller is com- lubrication as follows:
pletely factory-packaged including cooler, condenser,
sub-cooler, compressor, motor, lubrication system, Mi- 1. COMPRESSOR DRIVE SHAFT (Low Speed)
croComputer Control Center, and all interconnecting a. Shaft seal.
unit piping and wiring.
b. Front and rear journal bearings – one on each
The initial charge of refrigerant and oil is supplied for side of driving gear.
each unit. Oil is shipped in containers with the chiller. c. Low speed thrust bearing (forward and reverse).
Refrigerant is shipped to the jobsite in cylinders at the
time of installation. 2. COMPRESSOR DRIVEN SHAFT (High Speed)
The services of a YORK factory-trained, field service a. Forward and reverse high speed thrust bearing.
representative are included to supervise the final leak b. Two journal bearings.
testing, charging and the initial start-up and concur-
rent operator instructions. 3. SPEED INCREASING GEARS
a. Meshing surfaces of drive and pinion gear teeth.
COMPRESSOR
To provide the required amount of oil under the neces-
The compressor is a single-stage centrifugal type pow- sary pressure to properly lubricate these parts, a mo-
ered by an open-drive electric motor. tor driven submersible oil pump is located in a remote
oil sump.
The rotor assembly consists of a heat-treated alloy
steel drive shaft and impeller shaft with a cast alumi- Upon pressing of the COMPRESSOR START switch
num, fully shrouded impeller. The impeller is designed on the Control Center, the oil pump is immediately en-
for balanced thrust and is dynamically balanced and ergized. After a 50 second delay to allow the system
over-speed tested. oil pressure to stabilize, the compressor motor will start.
The oil pump will continue to run during the entire op-
The inserted type journal and thrust bearings are fabri- eration of the compressor, and for 150 seconds during
cated of aluminum alloy. Single helical gears with compressor coastdown.
crowned teeth are designed so that more than one tooth
is in contact at all times. Gears are integrally as- The submerged oil pump takes suction from the sur-
sembled in the compressor rotor support and are film rounding oil and discharges it to the oil cooler where
lubricated. Each gear is individually mounted in its own heat is rejected. The oil flows from the oil cooler to the
journal and thrust bearings. oil filter. The oil leaves the filter and flows to the emer-
gency oil reservoir where it is distributed to the com-
The open-drive compressor shaft seal consists of a pressor bearings. The oil lubricates the compressor
spring-loaded, precision carbon ring, high temperature rotating components and is returned to the oil sump.
elastomer “O” ring static seal, and stress-relieved, pre-
cision lapped collars. The seal is oil-flooded at all times Since the emergency oil reservoir is at the highest
and is pressure-lubricated during compressor opera- point in the lubrication system, it provides an oil sup-
tion. ply to the various bearings and gears in the event of a
system shutdown due to power failure. The reservoir,
CAPACITY CONTROL located on the top of the compressor, allows the oil to
be distributed through the passages by gravity flow,
Prerotation vanes (PRV) modulate chiller capacity from thus providing necessary lubrication during the com-
100% to as low as 15% of design for normal air condi- pressor coastdown.
tioning applications. Operation is by an external, elec-
tric PRV actuator which automatically controls the vane
OIL PUMP
position to maintain a constant leaving chilled liquid
temperature.
For normal operation, the oil pump should operate at
all times during CodePak operation. Manual pump op-
COMPRESSOR LUBRICATION SYSTEM (See Fig. 18) eration may be used to establish stable oil pressure
before starting. When depressed and released, the
The CodePak lubricated system consists of the oil MANUAL OIL PUMP key will operate the oil pump for
pump, oil filter, oil cooler and all interconnecting oil 10 minutes and then automatically shut off. To stop the
FORM 160.49-O1
oil pump sooner, depress the MANUAL OIL PUMP key Motor drive shaft is directly connected to the com-
again. pressor shaft with a flexible disc coupling. Coupling
has all metal construction with no wearing parts to
On shutdown of the system for any reason, the oil pump assure long life, and no lubrication requirements to pro-
operates and continues to run for 150 seconds. The vide low maintenance.
system cannot restart during that time interval.
For units utilizing remote electro-mechanical starters,
a terminal box is provided for field connected conduit.
OIL HEATER
Motor terminals are brought through the motor casing
into the terminal box. Jumpers are furnished for three-
During long idle periods, the oil in the compressor oil
lead type of starting. Motor terminal lugs are not fur-
reservoir tends to absorb as much refrigerant as it can
nished. Overload/overcurrent transformers are fur-
hold, depending upon the temperature of the oil and
nished with all units. For units furnished with factory
the pressure in the reservoir. As the oil temperature is
packaged Solid State Starters, (optional) see right.
lowered, the amount of refrigerant absorbed will be in-
creased. If the quantity of refrigerant in the oil becomes
excessive, violent oil foaming will result as the pres- HEAT EXCHANGERS
sure within the system is lowered on starting. This foam-
ing is caused by refrigerant boiling out of the oil as the Evaporator and condenser shells are fabricated from
pressure is lowered. If this foam reaches the oil pump rolled carbon steel plates with fusion welded seams.
suction, the bearing oil pressure will fluctuate with pos- The refrigerant side of each shell is designed for 265
sible temporary loss of lubrication, causing the oil pres- PSIG (1827 kPa) design working pressure, tested at
sure safety cutout to actuate and stop the system. See 400 PSIG (2758 kPa).
“Control Center, Section 2”.
Heat exchanger tubes are internally enhanced type.
To maintain the lowest possible concentration of re-
frigerant in the oil, the compressor oil reservoir is The evaporator is a shell and tube, flooded type heat
equipped with a 115 volt electric reservoir oil heater. exchanger. A distributor trough provides uniform distri-
The oil heater is thermostatically controlled at all times bution of refrigerant over the entire shell length. Alumi-
during compressor shutdown to maintain the sump oil num mesh eliminators are located above the tube bundle
at 135°F (57.3°C) to 145°F (62.8°C). If the oil tempera- to prevent liquid refrigerant carryover into the com-
ture falls below 55°F (12.8°C), the display will read pressor. Two 1-1/2" liquid level sight glasses are lo-
SYSTEM SHUTDOWN – PRESS STATUS . cated on the side of the shell to aid in determining
Pressing the STATUS key causes the message to read proper refrigerant charge. The evaporator shell con-
DAY 10:00 AM – LOW OIL TEMP – AUTO START . The system tains a dual refrigerant relief valve set at 265 PSIG
will be allowed to automatically restart when oil tem- (1827 kPa).
perature rises to 30°F (16.7°C) above condenser tem-
perature. The condenser is a shell and tube type, with a dis-
charge gas baffle to prevent direct high velocity im-
pingement on the tubes. A separate subcooler is lo-
MOTOR DRIVELINE cated below the condenser.
The compressor motor is an open-drip-proof, squirrel The removable compact water boxes are fabricated of
cage, induction type constructed to YORK design speci- steel. The design working pressure is 150 PSIG (1034
fications. 60 hertz motors operate at 3570 rpm. 50 hertz kPa) and the boxes are tested at 225 PSIG (1551 kPa).
motors operate at 2975 rpm. Integral steel water baffles provide the required pass
arrangements. Stub-out water nozzle connections with
(For 60 hertz motors 1750 HP and smaller; and 50 Victaulic grooves are welded to the water boxes. These
hertz motors 1400 HP and smaller) . . . the open motor nozzle connections are suitable for Victaulic couplings,
is provided with a D-flange, factory mounted to a cast welding or flanges, and are capped for shipment.
iron adapter mounted on the compressor. Plugged 3/4" drain and vent connections are provided
in each water box.
(For 2000 HP 60 hertz motors; and 50 hertz motors
above 1400 HP) . . . a separate structural steel base is
furnished to provide rigid mounting of the compressor REFRIGERANT FLOW CONTROL
and motor, independent of the evaporator shell, to en-
sure controlled alignment of the assembly. Motor is Refrigerant flow to the evaporator is controlled by a
mounted with final alignment at start-up. single fixed-orifice with no moving parts.
LD01079
FIG. 18 – SCHEMATIC DRAWING – (YK) COMPRESSOR LUBRICATION SYSTEM
FORM 160.49-O1
MICROCOMPUTER CONTROL CENTER SOLID STATE STARTER (Optional)

(See Section 2)
The Solid State Starter is a reduced voltage starter
The MicroComputer Control Center is factory mounted, that controls and maintains a constant current flow to
wired and tested. The electronic panel automatically the motor during start-up. It is mounted on the chiller.
controls the operation of the unit in meeting system Power and control wiring between the starter and chiller
cooling requirements while minimizing energy usage. are factory installed. Available for 380-600 volts, the
For detailed information on the Control Center, refer to starter enclosure is NEMA-1 with a hinged access door
“Section 2” of this manual. with lock and key. Electrical lugs for incoming power
wiring are provided.
SECTION 5
OPERATIONAL MAINTENANCE
OIL RETURN SYSTEM
The oil return system continuously maintains the proper return line to rotor support and inlet end of the de-
oil level in the compressor oil sump. (See Figs. 18 & hydrator.
19.)
2. Remove the dehydrator. Refer to Fig. 19.
High pressure condenser gas flows continuously
3. Assemble the new filter-drier.
through the eductor inducing the low pressure, oil rich
liquid to flow from the evaporator, through the dehydra- 4. Open condenser stop valve and check dehydrator
tor to the compressor sump. connections for refrigerant leaks.
5. Open all the dehydrator stop valves to allow the
CHANGING THE DEHYDRATOR
liquid refrigerant to flow through the dehydrator and
To change the dehydrator, use the following procedure: condenser-gas through the eductor.
1. Shut the stop valves on the condenser gas line, oil
LD01080
FIG. 19 – OIL RETURN SYSTEM
THE OIL CHARGE plate. (See Fig. 20.) Do not tighten the connection
at the charging valve until after the air is forced out
The nominal oil charge for the compressor is 20 gal. by pumping a few strokes of the oil pump. This fills
(75.7L), type “F” for R-22 application or type “K” for R- the lines with oil and prevents air from being pumped
134a application. into the system.
New YORK Refrigeration oil must be used in the cen- 3. Open the oil charging valve and pump oil into the
trifugal compressor. Since oil absorbs moisture when system until oil level in the compressor oil reser-
exposed to the atmosphere, it should be kept tightly voir is about midway in the upper sight glass. Then,
capped until used. close the charging valve and disconnect the hand
oil pump.
OIL CHARGING PROCEDURE
4. As soon as oil charging is complete, close the power
supply to the starter to energize the oil heater. (See
The oil should be charged into the oil reservoir using
“Section 3, System Operating Procedures”.) This
the YORK Oil Charging Pump – YORK Part No. 070-
will keep the concentration of refrigerant in the oil
10654. To charge oil into the oil reservoir, proceed as
to a minimum.
follows:
When the oil reservoir is initially charged with oil, the
1. The unit must be shut down.
oil pump should be started manually to fill the lines,
2. Immerse the suction connection of the oil charging passages, oil cooler and oil filter. This will lower the oil
pump in a clean container of new oil and connect level in the reservoir. It will then be necessary to add
the pump discharge connection to the oil charging oil to bring the level back to the center of the upper
valve (A) located on the remote oil reservoir cover sight glass.
25721A LD01081
OIL CHARGING
VALVE
FIG. 20 – CHARGING OIL RESERVOIR WITH OIL
TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE MICROCOMPUTER CONTROL, CENTER DISPLAY
YORK INTERNATIONAL
SHUTDOWN CAUSE
GOVERNING CONTROL FUNCTION
CONTROL CENTER DISPLAY
PROGRAMMED START-UP OF PROBABLE CAUSE
OPERATING
SETPOINTS SYSTEM AFTER AND SERVICE
DAY OF TIME OF CAUSE OF METHOD OF POINT
DESCRIPTION BY OPERATOR SHUTDOWN REQUIRED
WEEK DAY SHUTDOWN RESTART ON ON
RISE FALL
MON. 10:00 AM Low Water Autostart Low Water Chilled 4°F (2.2°C) 4°F (2.2°C) be- Automatic Restart System load is less
Temp. (LWT) water below low chilled water when water reaches than minimum capacity
setpoint chiller setpoint (If set setpoint; if system is
water to 40°F (4.4°C) running and setpoint
setpoint would be 36°F is increased 4°F, sys-
(2.2°C)) (36°F tem will continue to
(2.2°C) mini- run, as LWT cutout
mum) shifts to a fixed 36°F
for 10 minutes.
MON. 10:00 AM Flow Switch Autostart Flow Switch Automatic Restart Lack of water flow.
when water flow is Check operation of
Restored to close chilled water pump
TROUBLESHOOTING
flow switch.
MON. 10:00 AM System Autostart A remote com- Automatic Restart Contact-connected to
Cycling mand (computer upon remote the Remote/Local
SECTION 6
relay contact or command. cycling input of the
manual switch) Digital input board
MON. 10:00 AM Multi-Unit Autostart (Optional) Lead- Automatic Restart Contact-connected to
Lag Sequence upon remote the Multi-Unit cycling
Control command. input of the Digital
input board
MON. 10:00 AM Internal Autostart Internal Clock Daily Schedule Will automatically Pressing Compressor
Clock Programmed to restart when pro- Start Switch over-
Shutdown Unit grammed schedule rides the program
permits
MON. 10:00 AM AC under- Autostart <15% FLA for Cycling shutdown occurs
voltage 25 continuous when motor current is
seconds >15% FLA for 25 seconds
during chiller operation
MON. 10:00 AM Power Fault Autostart CM-2 Current Will start automatic- Motor Controller contacts
Module or tically following opening and closing in
Solid State coastdown less than 3 seconds due to
Starter a power fault condition
Remote Stop Energy manage- Start up by start Remote Stop Contact
ment System signal from remote Closure
start switch
MON. Anti-Recycle, Anti-Recycle Will not start Will restart when Min. Time between
20 Min. Left timer until 30 Min. time left = 00 Min. successive compres-
timer is timed sor starts is 30 min.
FORM 160.49-O1
MON. 10:00 AM Low Evap. Low Evap. 54..3 PSIG 54.4 PSIG To restart press com- See OPERATION
Pressure Pressure (374.4 kPa) (375 kPa) pressor switch from ANALYSIS TABLE 2
Transducer (R-22) (R-22) STOP/RESET to Symptom 2.
(LEP) 25 PSIG 25.1 PSIG START position.
(172.4 kPa) (173 kPa)
41
(R-134a) (R-134a)
(Continued on Page 42)
TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE MICROCOMPUTER CONTROL CENTER DISPLAY
42
SHUTDOWN CAUSE
GOVERNING CONTROL FUNCTION
CONTROL CENTER DISPLAY
PROGRAMMED START-UP OF PROBABLE CAUSE
OPERATING
SETPOINTS SYSTEM AFTER AND SERVICE
DAY OF TIME OF CAUSE OF METHOD OF POINT
DESCRIPTION BY OPERATOR SHUTDOWN REQUIRED
WEEK DAY SHUTDOWN RESTART ON ON
RISE FALL
MON. 10:00 AM Low Evap. LEP external Set to Job Set to Job To restart, press See OPERATION
Pressure control (Brine Spec. Spec. compressor switch ANALYSIS Table 2
Brine units only) from STOP/RESET Symptom 2.
to START position
MON. 10:00 AM Low Oil Low Oil 25 PSID 15 PSID Will restart when Refer to OPERATION
Pressure Pressure (172.4 kPa) (103.4 kPa) pressure increases ANALYSIS Table 2
Transducer to 25 PSID. To Symptoms 4, 5, 6, 7,
(OP) restart, press com- 9, 10, 11
pressor switch from
STOP/RESTART to
START position.
MON. 10:00 AM High High Pressure 265 PSIG 205 PSIG Will restart when See Operational
Pressure Safety Control (1827.2 kPa) (1413.5 kPa) pressure falls to Analysis Table 2
(HP) (R-22) (R-22) 205 PSIG. To restart Symptom 1 High
180 PSIG 120 PSIG press compressor Discharge Pressure
(1241.1 kPa) (827.4 kPa) switch from STOP/
(R-134a) (R-134a) RESET to START
position
MON. 10:00 AM Evap. Trans. Evap. Pressure To restart press Defective Evap. Pressure
or Probe Transducer or compressor switch Transducer or Leaving Chilled
Error Leaving Chilled from STOP/RESET Water thermistor (RS1).
Water Thermis- to START position LCWT minus saturation tem-
tor (RS1) perature is less than –2.5°F
(–1.4°C) or greater than 25°F
(13.9°C). Checked every 10
minutes following a 10 min.
bypass at start-up.
MON. 10:00 AM Motor Con- CM2 or Solid Reset the device CM2, or Solid State
troller – Ext. State Starter that caused the shut- Starter has shutdown
Reset (RT2) down. Chiller will chiller
start automatically.
MON. 10:00 AM High Discharge Temp. 220°F 219°F To restart press Condenser tubes dirty or
Discharge Thermistor (104.5°C) (103.9°C) compressor switch scaled or high condenser
Temp. (RT2) from STOP/RESET water temperature. (See
to START position. Symptom 1, Table 1.)
MON. 10:00 AM High Oil Oil Temperature 170°F 169°F To restart press Dirty oil filter or restricted
YORK INTERNATIONAL
Temp. Thermistor (76.7°C) (76.2°C) compressor switch oil cooler line. Change oil
(RT3) from STOP/RESET filter. Refer to OPERATION
to START position ANALYSIS Table 2,
Symptom 9.
MON. 10:00 AM Power Auto-Restart Micro Board 8.29VDC 7.84VDC Optional AUTO Will restart automa- Power Failure.
Failure undervoltage Restart Plug is tically when voltage
circuit on 5V installed on reaches 8.29VDC.
unregulated Micro Board An undervoltage
supply circuit on the Micro
Board monitors the
5VC unregulated
supply for an under-
voltage condition.
YORK INTERNATIONAL
MON. 10:00 AM Power Micro Board 8.29VDC 7.84 Auto restart plug To restart, press Power Failure
Failure undervoltage VDC is removed on compressor switch
circuit on 5V Micro Board to STOP-RESET
unregulated Position and then to
supply START position
MON. 10:00 AM Oil Pressure High Oil Press. 100 PSID (689.5 59 Will start at 59 PSID This Shutdown is provided
Transducer Transducer kPa D) (During1st PSID, (406.8 kPa D) when to check on Oil Pressure
Error 7 min. of Compr. 406.8 compr. switch is placed Transducers for failure in
Oper.) 60 PSID kPa D to STOP/RESET and the high state. Replace
(413.7 kPa D) then START Oil Press. Transducer in
(After first 7 min. oil sump or compressor
of Compr. Oper.)
Vane Motor Autostart Vane Motor Restart automatically Vanes are set improperly,
Switch Open Switch after Vane Motor arm reset vane linkage check
linkage is set pro- vane positions using
perly. Press STOP/ the SERVICE key switch
RESET and then and proper keys on the
START switch MicroComputer Control
Center
MON. 10:00 AM Starter Motor Current > Press compressor Check motor starter
Malfunction 15% for 10 swc. STOP/RESET operation. Motor current
Detected with Control Cen- switch and then value greater than 15%
ter not calling for FLA
motor to run
MON. 10:00 AM Program Autostart Micro Board Watchdog timer circuit
Initiated has reset software pro-
Reset gram – Chiller will
automatically restart.
Replace RTC RTC-IC chip Reprogram the Con- Weak battery
IC chip trol Center Setponts Replace RTC-IC chip
Reprogram & proceed with U16
Setpoints Normal Start-up
MON. 10:00 AM Low Oil Autostart Oil Temp. 71.0°F 55°F Press STOP/ Oil Temp. Thermistor
Temperature Thermistor (21.7°C) (12.8°C) RESET switch & disconnected from
(RT3) then START Analog Input Board.
switch Reconnect or replace
open sensor.
MON. 10:00 AM Faulty Dis- Discharge Temp. 30.0°F 29.9°F Press STOP/ Faulty Discharge Temp.
charge Temp. Thermistor (–1.1°C) (–1.2°C) START switch & Thermistor (RT2) or dis-
Sensor (RT2) discon- then START connected from Analog
nected or faulty switch Input Board. Connect or
operating temp. replace open sensor.
= 32°F
MON. 10.00 AM Low Line SSS Logic See legend on wiring Chiller will automa- Low AC Line Voltage
Voltage (SSS Board diagram tically restart when
Units only) all phases of line vol-
FORM 160.49-O1
tage increase to the
minimum required
43
TABLE 2 – OPERATING ANALYSIS CHART
RESULTS POSSIBLE CAUSE REMEDY
1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE
Temperature difference between liquid Air in condenser.

refrigerant out and water off condenser
higher than normal.
High discharge pressure. Condenser tubes dirty or . Clean condenser tubes. Check water
scaled conditioning.
High condenser water Reduce condenser water inlet
temperature. temperature. (Check cooling tower
and water circulation.)
Temperature difference between conden- Insufficient condensing Increase the quantity of water through
ser water on and water off higher than water flow. the condenser to proper value.
normal, with normal cooler pressure.
2. SYMPTOM: ABNORMALLY LOW SUCTION PRESSURE
Temperature difference between leaving Insufficient charge of Check for leaks and charge
chilled water and refrigerant in cooler refrigerant. refrigerant into system.
greater than normal with high discharge
Flow orifice blocked. Remove obstruction.
temperature.
Temperature difference between leaving Cooler tubes dirty or Clean cooler tubes.
chilled water and refrigerant in the cooler restricted.
greater than normal with normal discharge
temperature.
Temperature of chilled water too low with Insufficient load for Check prerotation vane motor opera-
with low motor amperes. system capacity. tion and setting of low water temper-
ature cutout.
3. SYMPTOM: HIGH COOLER PRESSURE
High chilled water temperature. Prerotation vanes fail to Check the prerotation vane motor
open. positioning circuit.
System overload. Be sure the vanes are wide open
(without overloading the motor) until
the load decreases.
4. SYMPTOM: NO OIL PRESSURE WHEN SYSTEM START BUTTON PUSHED
Low oil pressure displayed on control Oil pump running in wrong Check rotation of oil pump
center; compressor will not start. direction. (Electrical Connections).
Oil pump not running. Check electrical connections to oil
pump and press manual reset on oil
pump starter mounted on condenser
shell.
5. SYMPTOM: COMPRESSOR STARTS, NORMAL OIL PRESSURE DEVELOPS, FLUCTUATES FOR

SHORT WHILE, THEN COMPRESSOR STOPS ON OIL PRESSURE CUTOUT
Oil pressure normal, fluctuates then Unusual starting conditions Drain the oil from the compressor and
compressor stops on Oil Pressure exist, i.e., oil foaming in charge new oil into the compressor.
Cutout. Display reading resevoir and piping due to (Refer to “Charging The System With
LOW OIL PRESSURE . lowered system pressure. Oil”, page 48.)
Burned out oil heater. Replace oil heater.
FORM 160.49-O1
TABLE 2 – OPERATING ANALYSIS CHART (Continued)
RESULTS POSSIBLE CAUSE REMEDY
6. SYMPTOM: USUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS
Unusually high oil pressure is displayed High oil pressure. Trans- Replace low or high oil pressure
when the oil pressure display key is ducer defective. Relief transducer. Adjust external relief
pressed when the oil pump is running. valve is misadjusted. valve.
7. SYMPTOM: OIL PUMP VIBRATES OR IS NOISY
Oil pump vibrates or is extremely noisy Misalignment of pump or Correct condition or replace faulty
with some oil pressure when pressing Mounting bolts loose. part.
OIL PRESSURE display key. Bent shaft.
Worn pump parts.
NOTE: When oil pump is run without Oil not reaching pump Check oil supply and oil piping.
an oil supply it will vibrate and suction inlet in sufficient
become extremely noisy. quantity.
8. SYMPTOM: OIL PRESSURE GRADUALLY DECREASES (Noted by Observation of Daily Log Sheets)
Oil pressure (noted when pressing OIL Oil filter is dirty. Change oil filter.
PRESSURE display key) drops to 70%
of oil pressure when compressor was Extreme bearing wear. Inspect compressor.
originally started.
9. SYMPTOM: OIL PRESSURE SYSTEM CEASES TO RETURN AN OIL/REFRIGERANT SAMPLE
Oil refrigerant return not functioning. Filter-drier in oil return Replace old filter-drier with new.
system dirty.
Jet or orifice of oil return Remove jet, inspect for dirt. Remove
jet clogged. dirt using solvent and replace.
10. SYMPTOM: OIL PUMP FAILS TO DELIVER OIL PRESSURE
No oil pressure registers when pressing Faulty oil pressure Replace oil pressure transducer.
OIL PRESSURE display key when oil transducer
pump runs. Faulty wiring/connectors.
11. SYMPTOM: REDUCED OIL PUMP CAPACITY
Oil pump pumping capacity. Excessive end clearance Inspect and replace worn parts.
pump.
Other worn pump parts.
Partially blocked oil supply Check oil inlet for blockage.
inlet.
SECTION 7
MAINTENANCE
RENEWAL PARTS lide torch or electronic leak detector can be used to
detect any leaks too small to be found by the soap
For any required Renewal Parts, refer to “Parts Lists” test.
shown in “Reference Instructions”, page 2.
To test with R-22, proceed as follows:
1. With no pressure in the system, charge R-22 gas

CHECKING SYSTEM FOR LEAKS into the system through the charging valve to a
pressure of 2 PSIG (13.8 kPa).
LEAK TESTING DURING OPERATION
2. Build up the system pressure with dry nitrogen to
The refrigerant side of the system is carefully pres- approximately 10 PSIG (6.9 kPa). To be sure that
sure tested and evacuated at the factory. the concentration of refrigerant has reached all parts
of the system, slightly open the oil charging valve
After the system is in operation under load, the high and test for the presence of refrigerant with a leak
pressure components should be carefully leak tested detector.
with a leak detector to be sure all joints are tight.
3. Test around each joint and factory weld. It is impor-
If any leaks are indicated, they must be repaired im- tant that this test be thoroughly and carefully done,
mediately. Usually, leaks can be stopped by tightening spending as much time as necessary and using a
flare nuts or flange bolts. However, if it is necessary to good leak detector.
repair a welded joint, the refrigerant charge must be
removed. (See “Handling Refrigerant for Dismantling 4. To check for refrigerant leaks in the cooler and con-
and Repair”, page 55.) denser, open the vents in the cooler and condenser
heads and test for the presence of refrigerant. If no
CONDUCTING R-22 PRESSURE TEST refrigerant is present, the tubes and tube sheets
may be considered tight. If refrigerant is detected
With the R-22 charge removed and all known leaks at the vents, the heads must be removed, the leak
repaired, the system should be charged with a small located (by means of soap test or leak detector)
amount of R-22 mixed with dry nitrogen so that a ha- and repaired.
EVACUATION AND DEHYDRATION OF UNIT
LD01082
FIG. 21 – EVACUATION OF CODEPAK
FORM 160.49-O1
TABLE 3 – SYSTEM PRESSURES (STANDARD)
*GAUGE ABSOLUTE
BOILING
INCHES OF TEMPERATURES
MERCURY (HG) MILLIMETERS OF
BELOW ONE PSIA OF MERCURY MICRONS WATER
STANDARD (HG) °F
ATMOSPHERE
0 14.696 760. 760,000 212
10.24" 9.629 500. 500,000 192
22.05" 3.865 200. 200,000 151
25.98" 1.935 100. 100,000 124
27.95" .968 50. 50,000 101
28.94" .481 25. 25,000 78
29.53" .192 10. 10,000 52
29.67" .122 6.3 6,300 40
29.72" .099 5. 5,000 35
29.842" .039 2. 2,000 15
29.882" .019 1.0 1,000 +1
29.901" .010 .5 500 –11
29.917" .002 .1 100 –38
29.919" .001 .05 50 –50
29.9206" .0002 .01 10 –70
29.921" 0 0 0
*One standard atmosphere = 14.696 PSIA NOTES: PSIA = Lbs. per sq. in. gauge pressure
= 760 mm Hg. absolute pressure at 32°F = Pressure above atmosphere
= 29.921 inches Hg. absolute at 32°F PSIA = Lbs. per sq. in. absolute pressure
= Sum of gauge plus atmospheric pressure
TABLE 3A – SYSTEM PRESSURES (METRIC)
GAUGE ABSOLUTE
BOILING
TEMPERATURES
KILOPASCALS MILLIBARS OF
BELOW ONE KILOPASCALS OF MERCURY MICRONS WATER
STANDARD (HG) °C
ATMOSPHERE
0 101.3 1013.1 760,000 100.0

34.7 66.4 666.5 500,000 88.9
74.7 26.6 266.6 200,000 66.1
88.0 13.3 133.3 100,000 51.1
94.6 6.7 66.7 50,000 38.3
98.0 3.3 33.3 25,000 25.6
100.0 1.3 13.3 10,000 11.1
100.5 .84 8.4 6,300 4.4
100.6 .68 6.7 5,000 1.7
101.1 .27 2.7 2,000 –9.4
101.2 .13 1.3 1,000 –17.2
101.3 .069 .67 500 –23.9
101.3 .014 .13 100 –38.9
101.3 .007 .07 50 –45.6
101.3 .0014 .013 10 –56.7
101.3 0 0 0
VACUUM TESTING VACUUM DEHYDRATION
After the pressure test has been completed, the vacuum To obtain a sufficiently dry system, the following in-
test should be conducted as follows: structions have been assembled to provide an effec-
tive method for evacuating and dehydrating a system
1. Connect a high capacity vacuum pump, with indi- in the field. Although there are several methods of de-
cator, to the system charging valve as shown in hydrating a system, we are recommending the follow-
Fig. 22 and start the pump. (See “Vacuum Dehydra- ing, as it produces one of the best results, and affords
tion”.) a means of obtaining accurate readings as to the ex-
tent of dehydration.
2. Open wide all system valves, including the purge
and gauge valves. Be sure all valves to the atmo- The equipment required to follow this method of dehy-
sphere are closed. dration consists of a wet bulb indicator or vacuum
gauge, a chart showing the relation between dew point
3. Operate the vacuum pump in accordance with temperature and pressure in inches of mercury (vac-
VACUUM DEHYDRATION until a wet bulb tempera- uum), (see Table 3) and a vacuum pump capable of
ture of +32°F (0°C) or a pressure of 5 mm Hg is pumping a suitable vacuum on the system.
reached. See Table 3 for corresponding values of
pressure. OPERATION
4. To improve evacuation circulate hot water (not to Dehydration of a refrigerant system can be obtained
exceed 125°F, 51.7°C) through the cooler and con- by this method because the water present in the sys-
denser tubes to thoroughly dehydrate the shells. If tem reacts much as a refrigerant would. By pulling down
a source of hot water is not readily available, a the pressure in the system to a point where its satura-
portable water heater should be employed. DO NOT tion temperature is considerably below that of room
USE STEAM. A suggested method is to connect a temperature, heat will flow from the room through the
hose between the source of hot water under pres- walls of the system and vaporize the water, allowing a
sure and the cooler head drain connection, out the large percentage of it to be removed by the vacuum
cooler vent connection, into the condenser head pump. The length of time necessary for the dehydra-
drain and out the condenser vent. To avoid the postion of a system is dependent on the size or volume of
sibility of causing leaks, the temperature should be the system, the capacity and efficiency of the vacuum
brought up slowly so that the tubes and shell are pump, the room temperature and the quantity of water
heated evenly. present in the system. By the use of the vacuum indi-
cator as suggested, the test tube will be evacuated to
5. Close the system charging valve and the stop valve the same pressure as the system, and the distilled
between the vacuum indicator and the vacuum water will be maintained at the same saturation tem-
pump. Then disconnect the vacuum pump leaving perature as any free water in the system, and this tem-
the vacuum indicator in place. perature can be observed on the thermometer.
6. Hold the vacuum obtained in Step 3 in the system If the system has been pressure tested and found to
for 8 hours; the slightest rise in pressure indicates be tight prior to evacuation, then the saturation tem-
a leak or the presence of moisture, or both. If, after perature recordings should follow a curve similar to
8 hours the wet bulb temperature in the vacuum the typical saturation curve shown as Fig. 22.
indicator has not risen above 40°F (4.4°C) or a pres-
sure of 6.3 mm Hg, the system may be considered The temperature of the water in the test tube will drop
tight. as the pressure decreases, until the boiling point is
reached, at which point the temperature will level off
NOTE: Be sure the vacuum indicator is valved off and remain at this level until all of the water in the shell
while holding the system vacuum and be is vaporized. When this final vaporization has taken
sure to open the valve between the vacuum place the pressure and temperature will continue to
indicator and the system when checking drop until eventually a temperature of 35°F (1.7°C) or
the vacuum after the 8 hour period. a pressure of 5 mm Hg. is reached.
7. If the vacuum does not hold for 8 hours within the When this point is reached, practically all of the air
limits specified in Step 6 above, the leak must be has been evacuated from the system, but there is still
found and repaired. a small amount of moisture left. In order to provide a
FORM 160.49-O1
bient temperature. Close off the system again, and start

the second evacuation.
The relatively small amount of moisture left will be car-

ried out through the vacuum pump and the tempera-
ture or pressure shown by the indicator should drop
uniformly until it reaches a temperature of 35°F (1.7°C)
or a pressure of 5 mm Hg.
When the vacuum indicator registers this temperature

or pressure, it is a positive sign that the system is
evacuated and dehydrated to the recommended limit.
If this level cannot be reached, it is evident that there
is a leak somewhere in the system. Any leaks must be
LD01084 corrected before the indicator can be pulled down to
FIG. 22 – SATURATION CURVE 35°F (1.7°C) or 5 mm Hg. in the primary evacuation.
During the primary pulldown, keep a careful watch on

medium for carrying this residual moisture to the the wet bulb indicator temperature, and do not let it fall
vacuum pump, nitrogen should be introduced into the below 35°F (1.7°C). If the temperature is allowed to fall
system to bring it to atmospheric pressure and the to 32°F (0°C), the water in the test tube will freeze,
indicator temperature will return to approximately am- and the result will be a faulty temperature reading.
REFRIGERANT CHARGING
To avoid the possibility if freezing liquid within the cooler TABLE 4 – REFRIGERANT CHARGE
tubes when charging an evacuated system, only re-
frigerant vapor from the top of the drum or cylinder SHELL CODES R-22 R-134a R-22 R-134a
must be admitted to the system pressure until the sys-
tem pressure is raised above the point corresponding Con-
Cooler (Lbs.) (Kg.)
to the freezing point of the cooler liquid. For water, the denser
pressure corresponding to the freezing point is 57.5
L L 1350 1340 612 608
PSIG (396.5 kPa) for R-22 or 8.54 PSIG (58.9 kPa) for
R-134a (at sea level). L M 1475 1465 669 665
M L 1525 1525 691 691
While charging, every precaution must be taken to pre-
M M 1625 1625 737 737
vent moisture laden air from entering the system. Make
up a suitable charging connection from new copper M N 1850 1840 839 835
tubing to fit between the system charging valve and N M 1900 1905 861 864
the fitting on the charging drum. This connection should
N N 2125 2125 964 964
be as short as possible but long enough to permit suf-
ficient flexibility for changing drums. The charging con- N P 2125 2125 964 964
nection should be purged each time a full container of P N 2175 2185 987 991
refrigerant is connected and changing containers should
P P 2175 2185 987 991
be done as quickly as possible to minimize the loss of
refrigerant. P Q 2500 2530 1134 1147
Q P 2550 2560 1157 1161
Refrigerant may be furnished in drums containing ei-
Q Q 2925 2905 1327 1318
ther 30, 50, 125 or 1750 lbs. (13.6, 22.7, 56.7 or 793.8
kg) of refrigerant. These drums are not returnable and Q R 3250 3250 1474 1465
they should be stored for future use if it should ever R Q 3500 3500 1588 1588
become necessary to remove refrigeration from the
R R 3850 3840 1746 1742
system.
CHECKING THE REFRIGERANT CHARGE
DURING UNIT SHUTDOWN
The refrigerant charge is specified for each CodePak condenser and cooler. This would be expected to be 4
model (see Table 4). Charge the correct amount of re- hours or more after the compressor and water pumps
frigerant and record the level in the cooler sight glass. are stopped. The level should be at the center of the
sight glass + 1/4 inch (6.35 mm).
The refrigerant charge should always be checked and
trimmed when the system is shut down. Charge the refrigerant in accordance with the method
shown under the “Refrigerant Charging”, on page 49.
The refrigerant charge level must be checked after the The refrigerant level should be observed and the level
pressure and temperature have equalized between the recorded after initial charging.
HANDLING REFRIGERANT FOR

DISMANTLING AND REPAIRS
If it becomes necessary to open any part of the refrigerant system for repairs, it
will be necessary to remove the charge before opening any part of the unit.
MEGGING THE MOTOR

While the main disconnect switch and compressor 2. If readings fall below shaded area, remove external
motor starter are open, meg the motor as follows: leads from motor and repeat test.
1. Using a megohm meter (megger), meg between NOTE: Motor is to be megged with the starter at
phases and each phase to ground (see Fig. 23); ambient temperature after 24 hours of idle
these readings are to be interpreted using the graph standby.
shown in Fig. 24.
LD01085
FIG. 23 – DIAGRAM, MEGGING MOTOR WINDINGS
FORM 160.49-O1
50 (10.0)
70 (21.1)
110 (43.3)
100 (37.8)
40 (4.4)
80 (26.7)
60 (15.6)
90 (32.2)
TEMPERATURE – °F (°C) LD01086
FIG. 24 – MOTOR STATOR TEMPERATURE AND INSULATION RESISTANCES
CONDENSERS AND COOLERS
GENERAL TUBE FOULING
Maintenance of condenser and cooler shells is impor- Fouling of the tubes can be due to deposits of two
tant to provide trouble free operation of the CodePak types as follows:
unit. The water side of the tubes in the shell must be
kept clean and free from scale. Proper maintenance 1. Rust or sludge – which finds its way into the tubes
such as tube cleaning, and testing for leaks, is cov- and accumulates there. This material usually does
ered on the following pages. not build up on the inner tube surfaces as scale,
but does interfere with the heat transfer. Rust or
sludge can generally be removed from the tubes by
CHEMICAL WATER TREATMENT
a thorough brushing process.
Since the mineral content of the water circulated 2. Scale – due to mineral deposits. These deposits,
through coolers and condensers varies with almost even though very thin and scarcely detectable upon
every source of supply, it is possible that the water physical inspection, are highly resistant to heat
being used may corrode the tubes or deposit heat re- transfer. They can be removed most effectively by
sistant scale in them. Reliable water treatment compa- circulating an acid solution through the tubes.
nies are available in most larger cities to supply a wa-
ter treating process which will greatly reduce the cor-
TUBE CLEANING PROCEDURES
rosive and scale forming properties of almost any type
of water.
BRUSH CLEANING OF TUBES
As a preventive measure against scale and corrosion If the tube fouling consists of dirt and sludge, it can
and to prolong the life of cooler and condenser tubes, a usually be removed by means of the brushing process.
chemical analysis of the water should be made prefer- Drain the water sides of the circuit to be cleaned (cool-
ably before the system is installed. A reliable water ing water or chilled water) remove the heads and thor-
treatment company can be consulted to determine oughly clean each tube with a soft bristle bronze brush.
whether water treatment is necessary, and if so, to DO NOT USE A STEEL BRISTLE BRUSH. A steel brush
furnish the proper treatment for the particular water may damage the tubes.
condition.
Improved results can be obtained by admitting water
into the tube during the cleaning process. This can be
CLEANING COOLER AND CONDENSER TUBES done by mounting the brush on a suitable length of 1/8"
pipe with a few small holes at the brush end and con-
COOLER necting the other end by means of a hose to the water
supply.
It is difficult to determine by any particular test whether
possible lack of performance of the water cooler is due
The tubes should always be brush cleaned before acid
to fouled tubes alone or due to a combination of
cleaning.
troubles. Trouble which may be due to fouled tubes is
indicated when, over a period of time, the cooling ca-
ACID CLEANING OF TUBES
pacity decreases and the split (temperature difference
between water leaving the cooler and the refrigerant If the tubes are fouled with a hard scale deposit, they
temperature in the cooler) increases. A gradual drop- must be acid cleaned. It is important that before acid
off in cooling capacity can also be caused by a gradual cleaning, the tubes be cleaned by the brushing pro-
leak of refrigerant from the system or by a combina- cess described above. If the relatively loose foreign
tion of fouled tubes and shortage of refrigerant charge. material is removed before the acid cleaning, the acid
An excessive quantity of oil in the cooler can also con- solution will have less material to dissolve and flush
tribute to erratic performance. from the tubes with the result that a more satisfactory
cleaning job will be accomplished with a probable sav-
CONDENSER ing of time.
In a condenser, trouble due to fouled tubes is usually
indicated by a steady rise in head pressure, over a COMMERCIAL ACID CLEANING
period of time, accompanied by a steady rise in con-
densing temperature, and noisy operation. These symp- In many major cities, commercial organizations now
toms may also be due to foul gas buildup. Purging will offer a specialized service of acid cleaning coolers
remove the foul gas revealing the effect of fouling. and condensers. If acid cleaning is required, YORK
FORM 160.49-O1
recommends the use of this type of organization. The pose since its fumes give the same flame
Dow Industries Service Division of the Dow Chemical discoloration that the refrigerant does.
Company, Tulsa, Oklahoma, with branches in principal
cities is one of the most reliable of these companies. 3. With nitrogen or dry air, blow out the tubes to clear
them of traces of refrigerant laden moisture from
the circulation water. As soon as the tubes are clear,
TESTING FOR COOLER AND CONDENSER
a cork should be driven into each end of the tube.
TUBE LEAKS
Repeat this with all of the other tubes in the sus-
pected section or if necessary, with all the tubes in
Cooler and condenser tube leaks in R-22 or R-134a
the cooler or condenser. Allow the cooler or con-
systems may result in refrigerant leaking into the wa-
denser to remain corked up to 12 to 24 hours be-
ter circuit, or water leaking into the shell depending on
fore proceeding. Depending upon the amount of leak-
the pressure levels. If refrigerant is leaking into the
age, the corks may blow from the end of a tube,
water, it can be detected at the liquid head vents after
indicating the location of the leakage. If not, if will
a period of shutdown. If water is leaking into the refrig-
be necessary to make a very thorough test with
erant, system capacity and efficiency will drop off
the leak detector.
sharply. If a tube is leaking and water has entered the
system, the cooler and condenser should be valved
4. After the tubes have been corked for 12 to 24 hours,
off from the rest of the water circuit and drained imme-
it is recommended that two men working at both
diately to prevent severe rusting and corrosion. If a
ends of the cooler carefully test each tube – one
tube leak is indicated, the exact location of the leak
man removing corks at one end and the other at
may be determined as follows:
the opposite end to remove corks and handle the
leak detector. Start with the top row of tubes in the
1. Allow the system to warm up until a substantial
section being investigated, remove the corks at the
pressure is reached for testing. Dry nitrogen (pres-
ends of one tube simultaneously and insert the ex-
sure not to exceed 12 PSIG, 82.7 kPa) may be ad-
ploring tube for 5 seconds – this should be long
mitted to the unit to increase pressure in the shell.
enough to draw into the detector any refrigerant
Remove the heads and listen at each section of
gas that might have leaked through the tube walls.
tubes for a hissing sound that would indicate gas
A fan placed at the end of the cooler opposite the
leakage. This will assist in locating the section of
detector will assure that any leakage will travel
tubes to be further investigated. If the probable lo-
through the tube to the detector.
cation of the leaky tubes has been determined, treat
that section in the following manner (if the location
5. Mark any leaking tubes for later identification.
is not definite, all the tubes will require investiga-
tions).
6. If any of the tube sheet joints are leaking, the leak
should be indicated by the detector. If a tube sheet
2. Wash off both tube heads and the ends of all tubes
leak is suspected, its exact location may be found
with water.
by using a soap solution. A continuous buildup of
NOTE: Do not use carbon tetrachloride for this pur- bubbles around a tube indicates a tube sheet leak.
COMPRESSOR
Maintenance for the compressor assembly consists of about by restricted oil lines, passages, or dirty oil fil-
checking the operation of the oil return system and ters. If the unit is shutting down on (HOT) High Oil
changing the dehydrator, checking and changing the Temperature or Low Oil Pressure (OP), change the oil
oil, checking and changing the oil filters, checking the filter element. Examine the oil filter element for the pres-
operation of the oil heater, checking the operation of ence of aluminum particles. If aluminum particles are
the oil pump, and observing the operation of the com- noticeable and the same conditions continue to stop
pressor. the unit operation after a new filter element is installed,
notify the nearest YORK office to request the presence
Internal wearing of compressor parts could be a seri-
of a YORK Service man.
ous problem caused by improper lubrication, brought
ELECTRICAL CONTROLS
The operating points of the pressure and temperature

For information covering the MicroComputer Control cut outs are shown in the Wiring Diagrams. These dia-
Center operation, refer to “Section 2”. grams also contain a starting and stopping sequence
diagram.
FORM 160.49-O1
SECTION 8
PREVENTIVE MAINTENANCE
It is the responsibility of the owner to provide the nec- COOLER AND CONDENSER
essary daily, monthy and yearly maintenance require-
ments of the system. IMPORTANT – If a unit failure The major portion of maintenance on the condenser
occurs due to improper maintenance during the war- and cooler will deal with the maintaining the water side
ranty period; YORK will not be liable for costs incurred of the condenser and cooler in a clean condition.
to return the system to satisfactory operation.
The use of untreated water in cooling towers, closed
In any operating system it is most important to provide water systems, etc. frequently results in one or more
a planned maintenance and inspection of its function- of the following:
ing parts to keep it operating at its peak efficiency.
Therefore, the following maintenance should be per- 1. Scale Formation.
formed when prescribed. 2. Corrosion or Rusting.
3. Slime and Algae Formation.
COMPRESSOR
It is therefore to the benefit of the user to provide for
1. Oil Filter – The oil filter must be changed when the proper water treatment to provide for a longer and more
oil pressure drops 30% or semi-annually if not re- economical life of the equipment. The following recom-
quired earlier. mendation should be followed in determining the con-
dition of the water side of the condenser and cooler
When the oil filter is changed, it should be inspected tubes.
thoroughly for any aluminum particles which would
indicate possible bearing wear. If aluminum particles 1. The condenser tubes should be cleaned annually
are found this should be brought to the attention of or earlier if conditions warrant. If the temperature
the nearest YORK office for their further investiga- difference between the water off the condenser and
tion and recommendations. the condenser liquid temperature is more than 4°F
(2.2°C) greater than the difference recorded on a
2. Oil Changing – The oil in the compressor must be new unit, it is a good indication that the condenser
changed annually or earlier if it becomes dark or tubes require cleaning. They should be cleaned as
cloudy. instructed on pages 36 to 37 of this manual.
COMPRESSOR MOTOR 2. The cooler tubes under normal circumstances will

not require cleaning. If however the temperature dif-
1. Check motor mounting screws frequently to insure ference between the refrigerant and the chilled wa-
tightness. ter increases slowly over the operating season, it
is an indication that the cooler tubes may be fouling
2. Meg motor windings annually to check for deterio- or that there may be a water by-pass in the water
ration of windings. box requiring gasket relacement or refrigerant may
have leaked from the chiller.
PRESSURE TESTING
OIL RETURN SYSTEM
The unit should be pressure tested annually. Any leaks
found must be repaired immediately. Air and moisture 1. Change the dehydrator in the oil return system semi-
are the worst enemies of these systems and experi- annually or earlier if the oil return system fails to
ence has shown that units which are maintained tight, operate.
are systems that provide trouble free efficient opera-
tion. 2. When the dehydrator is changed, the nozzle of the
eductor should be checked for any foreign particles 2. It is important that the factory settings of controls
that may be obstructing the jet. (operation and safety) not be changed. If the set-
tings are changed without YORK’s approval, the
ELECTRICAL CONTROLS warranty will be jeopardized.
1. All electrical controls should be inspected for obvi- 3. A 5-11 year life battery is part of the RTC-Real
ous malfunctions. Time Clock. To replace, refer to page 25.
Proud Sponsor
of the 1998
U.S. Olympic Team
36USC380
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA
Copyright © by York International Corporation 1997 ALL RIGHTS RESERVED
Form 160.49-O1 (197)
Supersedes: 160.49-O1 (894)

Centrifugal Liquid Chillers: Operating & Maintenance

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What are the main components of a centrifugal chiller system?

What are the main components of a centrifugal chiller system?

What are the main sections covered in the manual?

What are the main sections covered in the manual?

CENTRIFUGAL LIQUID CHILLERS

OPERATING & MAINTENANCE Supersedes: 160.49-O1 (894) Form 160.49-O1 (197)

MODEL YK L1 L1 G4 THRU YK S2 S2 J4 (STYLES A & B)

WITH MICROCOMPUTER CONTROL CENTER P AR

DESIGN LEVEL (A or B) } MOTOR CODE:

DESIGN LEVEL (C) } MOTOR CODE:

The position of these vanes is automatically controlled

FIG. 2 – REFRIGERANT FLOW-THRU CODEPAK

FIG. 3 – MICROCOMPUTER CONTROL CENTER AND KEYPAD LD01067

The YORK MicroComputer Control Center is a micro- • % CURRENT LIMIT

FIG. 4 – SYSTEM PARAMETERS – OUT OF FIG. 4A – SYSTEM PARAMETERS – OUT OF

To Display OIL PRESSURE:

In PROGRAM mode, this key is used to display

Use CONDENSER LIQUID TEMPS display key as

– or – NOTE: The value displayed is the actual LCWT set-

Use CHILLED LIQUID TEMP setpoint key as de-

To Display UNDERVOLTAGE setpoints:

To Display HOLIDAY Setpoints: – or –

S_ M_ T_ W_ T_ F_ S_ HOLIDAY NOTED BY * SUPPLY VOLTAGE RANGE 550-600

NOTE: On the days that are designated by an *, the – or –

PROGRAMMING SYSTEM SETPOINTS

The system setpoints can be entered at any time . . . .

1. Press ACCESS CODE key.

2. ENTER VALID ACCESS CODE _ _ _ _ is displayed.

3. Using ENTRY keys, enter 9 6 7 5.

4. As each digit is entered, the characters Y O R K

NOTE: If digits other than 9 6 7 5 were entered in

1. Press and release CHILLED LIQUID TEMP setpoint

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

2. Use Entry keys to enter desired value.

To Enter % CURRENT LIMIT Setpoint: 3. Press and release ENTER key.

1. Press and release % CURRENT LIMIT setpoint key. message is displayed.

2. Use Entry keys to enter desired value.

3. Press and release ENTER key.

(Solid State Starter, refer to Fig. 7)

1. Press and release % CURRENT LIMIT setpoint

2. Use Entry keys to enter desired value.

To Enter PULL DOWN DEMAND Setpoint:

1. Press and release PULL DOWN DEMAND setpoint

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

3. Press and release ENTER key.

FIG. 8 – KEYPAD – PROGRAMMING “PULL DOWN

To Enter CLOCK Setpoint: (Refer to Fig. 9.)

1. Assure Micro Board Program jumper J57 is in

2. Press and release CLOCK setpoint key. The fol-

3. Press ADVANCE DAY / SCROLL key until the pro-

4. Use Entry keys to enter proper time of day.

5. Press AM/PM key to change the AM to PM or vice

6. Use Entry keys to enter proper calendar date, LD01072

3. Press and release ADVANCE DAY/SCROLL key.

4. Enter the desired start and stop time per Step 2.

5. Press and release ADVANCE DAY/SCROLL key. LD01073

The following prompt message is displayed:

To Enter HOLIDAY Setpoint: (Refer to Fig. 11.)

1. Press and release HOLIDAY setpoint key. The fol-