Johnson Controls York YCSE 040 User manual

YCSE040-YCSE100 & YCRE040-YCRE100
INSTALLATION, COMMISSIONING,
OPERATION & MAINTENANCE
Form 035-21786-100 (0909)
Revision 1
R407C
Aspak
WATER AND REMOTE AIR
COOLED LIQUID CHILLERS
WITH SCREW COMPRESSORS
STYLE B
(YCSE 134-320KW)
(YCRE 127-307KW)
Библиотека СОК 

TABLE OF CONTENTS
1 SUPPLIER INFORMATION
1.1 Introduction 1.1
1.2 Warranty 1.1
1.3 Safety 1.1
1.4 Responsibility for Safety 1.2
1.5 About this Manual 1.2
1.6 Misuse of Equipment 1.2
1.7 Emergency Shutdown 1.3
1.8 Safety Labels 1.3
1.9 Material Safety Data 1.4
2 PRODUCT DESCRIPTION
2.1 Introduction 2.1
2.2 Compressor 2.1
2.3 Refrigerant Circuits 2.1
2.4 Evaporator 2.1
2.5 Condenser 2.1
2.6 Power and Control Panels 2.2
2.7 Accessories and Options 2.2
2.8 Nomenclature 2.3
2.9 Refrigerant Flow Diagram 2.4
3 TRANSPORTATION, HANDLING AND
STORAGE
3.1 Delivery and Storage 3.1
3.2 Inspection 3.1
3.3 Moving the Unit 3.1
3.4 Lifting Weights 3.2
3.5 Weight Distribution & Centre
of Gravity 3.2
4 INSTALLATION
4.1 Location Requirements 4.1
4.2 Installation of Vibration Isolators 4.1
4.3 Pipework Connection 4.1
4.4 Water Treatment 4.2
4.5 Pipework Arrangement 4.3
4.6 Connection Types & Sizes 4.3
4.7 Condenser Cooling Liquid Systems 4.4
4.8 Electrical Connection 4.5
4.9 Remote Refrigerant Condenser
Systems (YCRE models only) 4.5
4.10 Power Wiring 4.8
4.11 Control Wiring 4.8
4.12 Connection Diagram 4.9
5 COMMISSIONING
5.1 Preparation 5.1
5.2 First Time Start-up 5.2
6 UNIT OPERATION
6.1 General Description 6.1
6.2 Operation 6.1
6.3 Normal Running and Cycling 6.1
6.4 Shutdown 6.1
6.5 Control System 6.1
7 MAINTENANCE
7.1 General Requirements 7.1
7.2 Daily Maintenance 7.1
7.3 Scheduled Maintenance 7.1
7.4 Pressure Vessel In-Service
Inspection 7.2
I-i
035-21786-100 Rev. 1 (0909)

8 TROUBLE SHOOTING
8.1 Competent Persons Trouble
Shooting Guide 8.1
9 TECHNICAL DATA
9.1 Flow Rate and Pressure Drop
Graphs 9.1
9.2 Performance Graphs 9.2
9.3 Operating Limitations 9.4
9.4 Physical Data 9.5
9.5 Electrical Data 9.6
9.6 Sound Data 9.7
9.7 Clearances and Foundations 9.8
9.8 Dimensions 9.9
10 SPARE PARTS
10.1 Renewal Parts List 10.1
10.2 Recommended Compressor Oils 10.1
10.3 Associated Drawings 10.1
11 DECOMMISSIONING. DISMANTLING AND
DISPOSAL
11.1 General 11.1
I-ii
035-21786-100 Rev. 1 (0909)

1 SUPPLIER INFORMATION
1.1 Introduction
York YCSE/YCRE chillers are manufactured to the
highest design and construction standards to ensure
high performance, reliability and adaptability to all types
of air conditioning installations.
The units are intended for cooling water or glycol
solutions and are not suitable for purposes other than
those specified in this manual.
This manual contains all the information required for
correct installation and commissioning of the unit,
together with operating and maintenance instructions.
The manuals should be read thoroughly before
attempting to operate or service the unit.
All procedures detailed in the manuals, including
installation, commissioning and maintenance tasks
must only be performed by suitably trained and qualified
personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation,
commissioning, operation or maintenance resulting
from a failure to follow the procedures and instructions
detailed in the manuals..
1.2 Warranty
Johnson Controls warrants all equipment and materials
against defects in workmanship and materials for one
year from initial start-up, or eighteen months from
delivery (whichever occurs first) unless extended
warranty has been agreed as part of the contract.
The warranty is limited to free replacement and shipping
of any faulty part, or sub-assembly which has failed due
to poor quality or manufacturing errors. All claims must
be supported by evidence that the failure has occurred
within the warranty period, and that the unit has been
operated within the designed parameters specified.
All warranty claims must specify the unit model, serial
number and order number. These details are printed on
the unit identification plate, fitted on the outer edge of the
options panel.
The unit warranty will be void if any modification to the
unit is carried out without prior written approval from
Johnson Controls.
For warranty purposes, the following conditions must be
satisfied:
The initial start of the unit must be carried out by trained
personnel from an Authorised York Service Centre.
Only genuine York approved spare parts, oils and
refrigerants must be used.
All the scheduled maintenance operations detailed in
this manual must be performed at the specified times by
suitably trained and qualified personnel.
Failure to satisfy any of these conditions will
automatically void the warranty.
1.3 Safety
Standards for Safety
YCSE/YCRE chillers are designed and built within an
EN ISO 9001 accredited design and manufacturing
organisation and, within the limits specified in this
manual, are in conformity with the essential health and
safety requirements of the following European Union
Directives:
Machinery Directive (98/37/EC)
Low Voltage Directive (2006/95/EC)
EMC Directive (2004/108/EC)
They conform to the applicable and essential safety
requirements of Pressure Equipment Directive
97/23/EC and bear CE marking.
Fluorinated Greenhouse Gases
nThis equipment contains fluorinated greenhouse
gases covered by the Kyoto Protocol.
nThe global warming potential of the refrigerant
(R407C) used in this unit is 1520.
nThe refrigerant quantity is stated in the Physical
Data table in Section 9 of this document.
nThe fluorinated greenhouse gases in this
equipment may not be vented to the atmosphere.
nThis equipment should only be serviced by
qualified technicians.
1-1
035-21786-100 Rev. 1 (0909)

1.4 Responsibility for Safety
Every care has been taken in the design and
manufacture of the units to ensure that they meet the
safety requirements listed in the previous paragraph.
However, the individual operating or working on any
machinery is primarily responsible for:
Personal safety, safety of other personnel, and the
machinery.
Correct utilisation of the machinery in accordance with
the procedures detailed in the manuals.
1.5 About this Manual
The following symbols are used in this document to alert
the reader to areas of potential hazard.
A Warning is given in this document to
identify a hazard which could lead to
personal injury. Usually an instruction will
be given, together with a brief explanation
and the possible result of ignoring the
instruction.
ACaution identifies a hazard which could
lead to damage to the machine, damage to
other equipment and/or environmental
pollution. Usually an instruction will be given,
together with a brief explanation and the
possible result of ignoring the instruction.
ANote is used to highlight additional
information which may be helpful to you but
where there are no special safety
implications.
The contents of this manual include suggested best
working practices and procedures. These are issued for
guidance only, they do not take precedence over the
above stated individual responsibility and/or local safety
regulations.
This manual and any other document supplied with the
unit, are the property of Johnson Controls which
reserves all rights. They may not be reproduced, in
whole or in part, without prior written authorisation from
an Authorised Johnson Controls representative.
1.6 Misuse of Equipment
Suitability for Application
The unit is intended for cooling water or glycol solutions
and is not suitable for purposes other than those
specified in these instructions. Any use of the equipment
other than its intended use, or operation of the
equipment contrary to the relevant procedures may
result in injury to the operator, or damage to the
equipment.
The unit must not be operated outside the design limits
specified in this manual.
Structural Support
Structural support of the unit must be provided as
indicated in these instructions. Failure to provide proper
support may result in injury to the operator, or damage to
the equipment.
Mechanical Strength
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures.
Additional components must not be mounted on the
unit. Any such extraneous loads may cause structural
failure and may result in injury to the operator, or
damage to the equipment.
General Access
There are a number of areas and features which may be
a hazard and potentially cause injury when working with
the unit unless suitable safety precautions are taken. It
is important to ensure access to the unit is restricted to
suitably qualified persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.
Pressure Systems
The unit contains refrigerant vapour and liquid under
pressure, release of which can be a danger and cause
injury. The user should ensure that care is taken during
installation, operation and maintenance to avoid
damage to the pressure system. No attempt should be
made to gain access to the component parts of the
pressure system other than by suitably trained and
qualified personnel.
1-2
035-21786-100 Rev. 1 (0909)

Electrical
The unit must be earthed. No installation or
maintenance work should be attempted on electrical
equipment without first switching off, isolating and
locking-off the power supplies. Work on live equipment
must only be carried-out by suitably trained and
qualified personnel. No attempt should be made to gain
access to inside of the control panel, wiring or other
electrical enclosures during normal operation of the unit.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally
non-toxic, non-flammable and non-corrosive, and pose
no special safety hazards. Use of gloves and safety
glasses are, however, recommended when working on
the unit. Build up of refrigerant vapour, from a leak for
example, does pose a risk of asphyxiation in confined or
enclosed spaces and attention should be given to good
ventilation. For more comprehensive information on
safety precautions for use of refrigerants and oils, refer
to the Materials Safety Data tables provided.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the
pressure relief device(s). Detergents and solvents
which may cause corrosion should also be avoided.
1.7 Emergency Shutdown
In case of emergency the unit can be shut down by
operating the main power switch on the control panel.
1.8 Safety Labels
The following labels are fixed to each unit to give
instruction, or to indicate potential hazards which may
exist.
White symbol on blue background
For safe operation, read the
Instructions first
Black symbol on yellow background
Warning: This machine may start
automatically without prior warning
Black symbol on yellow background
Warning: Hot surface
Black symbol on yellow background
Warning: Safety relief valve may
discharge gas or liquid without prior
warning
Black symbol on yellow background
Warning: Isolate all electrical sources
of supply before opening or removing
the cover, as lethal voltages may exist
Black symbol on yellow background
General attention symbol
1-3
035-21786-100 Rev. 1 (0909)

1.9 Material Safety Data
Refrigerant Data:
Safety Data R407C
Toxicity Low.
In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption.
Thaw affected areas with water. Remove contaminated clothing carefully — may adhere to skin in
case of freeze burns. Wash affected areas with plenty of warm water. If symptoms occur (irritation
or blistering) obtain medical attention.
In contact with eyes Vapour has no effect. Liquid splashes or spray may cause freeze burns. Immediately irrigate with
eyewash solution or clean water for at least 10 minutes. Obtain immediate medical attention.
Ingested Highly unlikely to occur — but should this occur freeze burn will occur. Do not induce vomiting.
Provided patient is conscious, wash mouth with water and give about 250 ml (0.5 pint) to drink.
Obtain immediate medical attention.
Inhalation High atmospheric concentrations may have an anaesthetic effect, including loss of consciousness.
Very high exposures may cause an abnormal heart rhythm and prove suddenly fatal.
At higher concentration there is a danger from asphyxiation due to reduced oxygen content of
atmosphere. Remove patient to fresh air, keep warm and at rest. Administer oxygen if necessary.
Apply artificial respiration if breathing has ceased or shows signs of failing. In event of cardiac
arrest apply external cardiac massage. Obtain immediate medical attention.
Further medical advice Symptomatic and supportive therapy is indicated. Cardiac sensitisation has been described which
may, in the presence of circulating catecholamines such as adrenalin, give rise to cardiac
arrhythmia’s and subsequent arrest following exposure to high concentrations.
Long term exposure A lifetime inhalation study in rats has shown that exposure to 50,000 ppm resulted in benign
tumours of the testis. This is not considered to be of relevance to humans exposed to
concentrations at or below the occupational exposure limit.
Occupational exposure
limits
Recommended limit: 1000 ppm v/v - 8 hr TWA.
Stability Not specified.
Conditions to avoid Use in presence of naked flames, red hot surfaces and high moisture levels.
Hazardous reactions May react violently with sodium, potassium, barium and other alkali and alkaline earth metals.
Incompatible materials: Magnesium and alloys containing more then 2% magnesium.
Hazardous
decomposition
products
Halogen acids by thermal decomposition and hydrolysis.
General precautions Avoid inhalation of high concentrations of vapours. Atmospheric concentrations should be
minimised and kept as low as reasonably practicable below the occupational exposure limit. The
vapour is heavier than air and collects at low level and in confined areas. Ventilate by extraction at
lowest levels.
Respiratory protection Where doubt exists on atmospheric concentration, HSE approved breathing apparatus should be
worn. This should be self contained or of the long breather type.
Storage Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources of heat
such as radiators. Keep at temperatures not exceeding 45 °C.
Protective clothing Wear overalls, impervious gloves and goggles/face protection.
Spill/leak procedure Ensure suitable personal protective clothing and respiratory protection is worn. Provided it is safe
to do so, isolate the source of the leak. Allow small spillage’s to evaporate provided there is
suitable ventilation.
Large spillage’s: Ventilate area. Contain spillage’s with sand, earth or any suitable absorbent
material. Prevent liquid from entering drains, sewers, basements and work pits since vapour may
create a suffocating atmosphere.
Disposal Best to recover and recycle. If this is not possible, destruction is to be in an approved facility which
is equipped to absorb and neutralise acids and other toxic processing products.
Fire extinguishing data Non-flammable at atmospheric conditions.
Containers Fire exposed containers should be kept cool with water sprays. Containers may burst if
overheated.
Fire fighting protective
equipment
Self contained breathing apparatus and protective clothing must be worn in fire conditions.
1-4
035-21786-100 Rev. 1 (0909)

Thermal and Acoustic Materials Data
Health Hazard & First
Aid
Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic. No first aid necessary.
Stability / Reactivity Stable.
Handling / Use /
Disposal
No special handling precautions required. Dispose of according to local laws and regulations
governing non-biodegradable non-hazardous solid wastes.
Fire & Explosion Flammability rating Class 1 to BS 476 pt 7: Non-flammable. If forced to burn, combustion products
are typically over 95% carbon dioxide and carbon monoxide.
Refrigerant Oil Data:
Safety Data York "Y" Oil
Hazardous Ingredients / Identity Information
Hazardous Components (Specific Chemical
Identity, Common Name)
No hazardous materials present.
CHEMICAL NAME: Polyole ester and Lubricating oil additive
COMPONENT : Polyole ester >99mass%
Lubricating oil additive <1mass%
OSHA PEL ACGIH TLV
Physical Characteristics
Boiling Point Not applicable
Vapor Pressure (mmHg) Not applicable
Vapor Density (AIR=1) Not applicable
Appearance and Odor Light yellow, clear mobile liquid
Specific Gravity (H.0=1) 1.0230g/cm³(15)
Melting Point (Pour point) -27.5
Evaporation Rate Not applicable
Fire and Explosion Hazard Data
Flash Point (Method Used) 250 (COC)
Flammable limits No information LEL UEL
Extinguishing Media Foam, dry chemical, carbon dioxide
Special Fire Fighting Procedures No
Unusual Fire and Explosion Hazards Not in particular. Normal protective measures for organic chemical products
with flash points of above 100
Reactivity Data
Stability Stable
Incompatibility (Materials to Avoid) No
Hazardous Decomposition or By-products No
Hazardous Polymerization Will not occur
1-5
035-21786-100 Rev. 1 (0909)

Health Hazard Data
Route(s) of Entry No significant health hazards are identified. Prolonged repeated skin
contact may cause irritation and dermatitis
Health Hazards (Acute and Chronic) No significant health hazards are identified. Prolonged repeated skin
contact may cause irritation and dermatitis
Carcinogenicity NTP: No IARC Monographs: No OSHA Regulated: No
Signs and Symptoms of Exposure No information is available
Medical Conditions Generally Aggravated
by Exposure
No information is available
Skin Contact Wash material off the skin with copious amounts of water and soap
Eyes Contact Immediately flush with plenty of water for at least 15 minutes
Inhalation Remove exposed person to fresh air
Ingestion Do not induce vomiting. Call a physician immediately
Precautions for Safe Handling and Use
Steps to be Taken In Case Material is
Released or Spilled
Prevent spillage from spreading by using sand and absorb the liquid
substance using a suitable inert material. Transfer to a suitably labelled
sealable container. Do not allow liquid to enter open waters or ground
water.
Waste Disposal Method Waste material may be incinerated under conditions which meet all Federal,
state and local environmental control regulations.
Precautions to be Taken in Handling and
Storing
Store in cool, dark and low humidity place.
Other Precautions Avoid repeated skin contact and breathing of mist or vapour.
Control Measures
Respiratory Protection Under normal conditions, respirator is not usually required.
Ventilation Local Exhaust Not required
Mechanical (General) Not required
Special Adequate ventilation should be maintained
when handling heated products
Protective Gloves Rubber gloves
Eye Protection Glasses or goggles
Other Protective Clothing or Equipment Not required
Work/Hygienic Practices Not required
Additional Information
The information contained herein has been compiled from data published in the literature. This data is believed to be
reliable, but certain values may vary from source to source.
This data is not to be construed as absolutely complete. It is the responsibility of the user to determine the best
precautions necessary for his/her application.
This data only refers to the specific material designated and not to any combinations.
1-6
035-21786-100 Rev. 1 (0909)