York MILLENNIUM YG Series Manual

27704A
OPERATING & MAINTENANCE
MILLENNIUM TM
CENTRIFUGAL LIQUID CHILLERS
Supersedes: 160.60-O1 (1296) Form 160.60-O1 (1197)
MODEL YG & YB
(DESIGN LEVEL A)
YG
YB
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.
28699A

2 YORK INTERNATIONAL
ECP = Engine Control Panel
PLC = Programmable Logic Control
EIS = Electronic Ignition System
ECS = Engine Control Switch
SCM = Status Control Module
ABBREVIATIONS
The abbreviations below are used in this manual.
EMS = Energy Management System
PWM = Pulse Width Modulation
RTC = Real Time Clock
PRV = Prerotation Vane
LWT = Low Water Temperature
HOT = High Oil Temperature
OP = Oil Pressure
LCWT = Leaving Chilled Water Temp.
ECWT = Entering Condensing Water
Temp.
YB MC MC G4  G3406 A
Model Design Level
Cooler Code Engine Size
Condenser Code Power Supply - for 60 Hz
5 for 50 Hz
Compressor Code
NOMENCLATURE
The model number denotes the following characteristics of the unit:
YG NB NB G4  G3408 A
Model Design Level
Cooler Gas Engine Drive Package
Condenser Power Supply - for 60 Hz
Compressor

YORK INTERNATIONAL 3
FORM 160.60-O1
TABLE OF CONTENTS
SECTION 1
Description of System and Fundamentals of Operation ....................................... 10
Capacity Control (Also see page 57) ........................ 11 Quick Shutdowns (Also see page 49) ................... 13
Caterpillar Engine Control Panel ............................... 11 Safety Shutdowns (Also see page 53) .................. 14
SECTION 2
MicroComputer Control Center ......................................................... 17
Introduction .............................................................. 18 Manual Operation ................................................. 34
Micro Panel Control Center ...................................... 19 Fixed Operation .................................................... 34
Operation ................................................................. 19 Manual Speed or Manual Vane Control Selection .. 34
Out of Range Values for R134a (Also see pg 51) ...... 19 Prerotation Vanes and Engine Speed Keys........... 35
Selecting Engine Type .............................................. 20 Calibration Procedures .......................................... 36
System Setpoints .................................................... 23 PRV Motor Wiring Checkout .................................36
Displaying System Setpoints ................................... 24 Operating Modes .................................................. 37
Data Logger Setpoints.............................................. 26 Compressor Switch and Emergency Stop Switch . 38
Programming the MicroComputer Control Center ...... 27 Display Messages ................................................ 38
Programming System Setpoints............................... 27 System Shutdown Messages ............................... 40
Service Keys ............................................................ 32 Engine Related Display Messages .......................44
Automatic Operation ................................................ 32 Engine Related Shutdown Messages .................... 46
SECTION 3
System Operating Procedures ........................................................ 48
Start-Up Procedure (Also see page 50) .................... 48 Chiller Operating Thresholds (Also see page 19) ... 51
Start Sequence (Also see pages 50 & 57)................ 49 Chiller Operation ................................................... 52
Shutdown Sequence ................................................ 49 Safety Shutdowns (Also see page 14) .................. 53
Quick Safety Shutdown (Also see page 13) ............. 49 Cycling Shutdowns ............................................... 54
Timing Chart for System (Also see page 57) ............ 50
SECTION 4
System Components Description........................................................... 55
Photo of YG Components ........................................ 55 Engine Vibration Sensor ....................................... 59
Photo of YB Components ......................................... 56 Gear Oil Temp Switch Connections....................... 60
Start Sequence (Also see pages 49 & 50)................ 57
SECTION 5
Operation Maintenance.............................................................. 61
SECTION 6
Troubleshooting (Problems and Solutions) ................................................ 62
SECTION 7
Maintenance ......................................................................... 66
SECTION 8
Preventative Maintenance ........................................................... 71

4 YORK INTERNATIONAL
QUICK REFERENCE TO FIGURES
FIG. NO. DESCRIPTION PAGE NO.
1YG Gas Engine Drive Chiller ................................................................................... 10
1A YB Gas Engine Drive Chiller ................................................................................... 10
2Engine Speed Control Block Diagram ..................................................................... 11
2A Engine Control Panel .............................................................................................. 15
3Engine Control Panel .............................................................................................. 16
4MicroComputer Control Center and Keypad ............................................................ 17
5System Parameters  Out of Range Readings ........................................................ 19
6Manifold Pressure vs. Engine Speed ....................................................................... 21-23
7Keypad  Programming System Setpoints ............................................................. 27
8Keypad  Programming Leaving Chilled Water Temp Setpoint .............................. 28
9Keypad  Programming Engine Load Limit Setpoint ............................................. 28
10 Keypad  Programming Pulldown Demand Setpoint ............................................. 29
11 Keypad  Programming Clock Setpoint ................................................................ 29
12 Keypad  Programming Daily Schedule Setpoint .................................................. 30
13 Keypad  Programming Holiday Setpoint .............................................................. 31
14 Keypad  Programming Remote Reset Temp Range............................................. 31
15 Keypad  Service Keys Location ............................................................................ 32
16 MicroComputer Control Center  Location of Real Time Clock U16 ......................... 43
17 Chiller Start Sequence & Shutdown Sequence Timing Diagram ............................. 50
18 YG Chiller System Components ............................................................................. 55
18A YB Chiller System Components ............................................................................. 56
19 Saturation Curve ..................................................................................................... 67
QUICK REFERENCE TO TABLES
TABLE NO. DESCRIPTION PAGE NO.
1Operational Thresholds Chart .................................................................................. 51
2Causes of Normal & Safety System Shutdowns in Accordance
with the MicroComputer Control Center ................................................................. 62-63
3Operating Analysis Chart ........................................................................................ 64-65
4System Pressures .................................................................................................. 67
5Refrigerant Charge YB / YG Models........................................................................ 68

YORK INTERNATIONAL 5
FORM 160.60-O1
QUICK REFERENCE  DISPLAY MESSAGES
Following is a list of display messages showing the display and the page it can be found on to help you troubleshoot the
YORK panel faster.
Display Page No.
SYSTEM RUN – LEAVING TEMP CONTROL ...................................................................................................................................................... 38
SYSTEM RUN – ENGINE LOAD LIMIT IN EFFECT ............................................................................................................................................. 38
SYSTEM RUN – AUTO SPEED/AUTO VANES .................................................................................................................................................... 38
SYSTEM RUN – VANES OPENING ....................................................................................................................................................................... 38
SYSTEM RUN – VANES CLOSING ....................................................................................................................................................................... 38
SYSTEM RUN – AUTO SPEED/AUTO VANES .................................................................................................................................................... 38
SYSTEM RUN – VANES HOLDING ....................................................................................................................................................................... 38
SYSTEM RUN – LOW PRESSURE LIMIT IN EFFECT ........................................................................................................................................ 38
SYSTEM RUN – HIGH PRESSURE LIMIT IN EFFECT ........................................................................................................................................ 39
SYSTEM RUN – PRESS STATUS ........................................................................................................................................................................ 39
WARNING: COND OR EVAP TRANSDUCER ERROR ......................................................................................................................................... 39
WARNING – PRV POT OR SWITCH ERROR ....................................................................................................................................................... 39
SYSTEM RUN – LEAVING TEMP CONTROL ...................................................................................................................................................... 39
SYSTEM RUN – SETPOINT OVERRIDE .............................................................................................................................................................. 39
REPLACE RTC , U16 – REPROGRAM SETPOINTS ........................................................................................................................................... 39
SYSTEM READY TO START ................................................................................................................................................................................ 39
SYSTEM SHUTDOWN – PRESS STATUS .......................................................................................................................................................... 39
MACH = X.XX; MACH’S X.XX ............................................................................................................................................................................... 39
ENGINE RPM = XXXX; RPMS = XXXX................................................................................................................................................................. 39
DELTA P OVER P = X.XX; PRV = XXX% ............................................................................................................................................................ 39
COMP. COASTDOWN; ENG SHTDN-PRESS STATUS...................................................................................................................................... 40
COMPR. COASTDN; ENG COOLDN-PRESS STATUS ...................................................................................................................................... 40
COMPR SHUTDOWN – ENGINE COOLDOWN..................................................................................................................................................... 40
MON 10:00 AM – LOW WATER TEMP – AUTOSTART...................................................................................................................................... 40

6 YORK INTERNATIONAL
MON XX:XX AM – FLOW SWITCH........................................................................................................................................................................ 40
MON XX:XX AM – SYSTEM CYCLING – AUTOSTART ..................................................................................................................................... 40
MON XX:XX AM – MULTI UNIT CYCLING – AUTOSTART ............................................................................................................................... 40
MON XX:XX AM – POWER FAILURE.................................................................................................................................................................... 40
MON XX:XX AM – INTERNAL CLOCK – AUTOSTART...................................................................................................................................... 40
REMOTE STOP....................................................................................................................................................................................................... 40
MON XX:XX AM – LOW EVAP PRESSURE ......................................................................................................................................................... 40
MON XX:XX AM – LOW EVAP PRESSURE – BRINE .......................................................................................................................................... 40
MON XX:XX AM – LOW OIL PRESSURE ............................................................................................................................................................. 40
MON XX:XX AM – HIGH PRESSURE .................................................................................................................................................................... 41
MON XX:XX AM – EVAP TRANS OR PROBE ERROR ....................................................................................................................................... 41
MON XX:XX AM – HIGH DISCHARGE TEMP ....................................................................................................................................................... 41
MON XX:XX AM – HIGH OIL TEMP ...................................................................................................................................................................... 41
MON XX:XX AM – HIGH OIL PRESSURE............................................................................................................................................................. 41
MON XX:XX AM – FAULTY COND PRESSURE XDCR....................................................................................................................................... 41
MON XX:XX AM – FAULTY OIL PRESSURE XDCR ........................................................................................................................................... 41
VANE MOTOR SWITCH OPEN ............................................................................................................................................................................. 41
SYSTEM READY TO START – PRESS STATUS............................................................................................................................................... 41
START SEQUENCE INITIATED ............................................................................................................................................................................ 41
START SEQ. INITIATED – COMPRESSOR PRELUBE ...................................................................................................................................... 41
MON 9:30 AM LOW OIL TEMPERATURE – AUTOSTART ................................................................................................................................. 41
MON XX:XXX AM – LOW OIL TEMP DIFF – AUTOSTART ............................................................................................................................... 42
DAY – TIME – OIL PRESSURE XDCR ERROR .................................................................................................................................................... 42
MON XX:XX AM FAULTY DISCHARGE TEMP SENSOR ................................................................................................................................... 42
MON XX:XX AM – PROX SENSOR SAFETY SHUTDOWN................................................................................................................................ 42
FAULTY PROXIMITY PROBE ............................................................................................................................................................................... 42
MON XX:XX AM – HIGH SPEED DRAIN TEMP .................................................................................................................................................... 42
MON XX:XX AM – OPEN DRAIN TEMP THERMOCOUPLE ............................................................................................................................... 42
MON XX:XX AM – DC UNDER VOLTAGE ............................................................................................................................................................ 43
MON XX:XX AM – AUX SAFETY SHUTDOWN ................................................................................................................................................... 43

YORK INTERNATIONAL 7
FORM 160.60-O1
WARNING – PRV POT OR SWITCH ERROR ....................................................................................................................................................... 43
WARNING CONDENSER TRANSDUCER OR PROBE ERROR ........................................................................................................................... 43
REPLACE RTC.U16 – REPROGRAM SETPOINTS .............................................................................................................................................. 43
ENGINE RELATED DISPLAY MESSAGES (Displayed on YORK Micro Panel)
ENGINE START SIGNAL........................................................................................................................................................................................ 44
ENGINE WARMUP ................................................................................................................................................................................................... 44
START SEQ. INITIATED – COMPRESSOR PRELUBE ...................................................................................................................................... 44
SYSTEM RUN; STOP SEQUENCE INITIATED .................................................................................................................................................... 44
WARNING – HIGH ENGINE VIBRATION DETECTED .......................................................................................................................................... 44
WARNING – COMPRESSOR SERVICE TIME ELAPSED .................................................................................................................................... 44
COMPR. COASTDOWN: ENGINE COOLDOWN .................................................................................................................................................. 44
COMPR. SHUTDOWN: ENGINE COOLDOWN ..................................................................................................................................................... 44
MANUAL ENGINE CYCLING................................................................................................................................................................................... 44
COMPRESSOR ROTATION FAULT ..................................................................................................................................................................... 44
COMPR. COASTDN; ENGINE SHTDN – PRESS STATUS ................................................................................................................................ 44
DAY TIME COMPRESSOR ROTATION FAULT .................................................................................................................................................. 44
WARNING – ENGINE SERVICE TIME ELAPSED .................................................................................................................................................. 44
SUN 12:00 AM GENSET OVERRIDE...................................................................................................................................................................... 44
LOW GEAR OIL TEMPERATURE SENSOR ......................................................................................................................................................... 45
SUN 12:00 AM LOW GEAR OIL TEMP – AUTO START ..................................................................................................................................... 45
LOW GEAR OIL TEMP SENSE FAULT................................................................................................................................................................. 45
SUN 12:00 AM LOW GEAR OIL TEMPS SENS FAULT ....................................................................................................................................... 45
ENGINE VIBRATION = X.XX IN/SEC [0.40/0.65/0/60] .......................................................................................................................................... 45
WARNING – HIGH ENGINE VIBRATION DETECTED .......................................................................................................................................... 45
ENGINE VIBRATION LEVEL = X.XX IN/SEC ....................................................................................................................................................... 45
ENGINE VIBRATION SENSOR .............................................................................................................................................................................. 45
GEAR LUBE PUMP.................................................................................................................................................................................................. 45
ENGINE RELATED SHUTDOWN MESSAGES (Displayed on YORK Micro Panel)
COMPRESSOR OVERSPEED................................................................................................................................................................................ 46
SURGE SAFETY...................................................................................................................................................................................................... 46
SURGE SAFETY SHUTDOWN .............................................................................................................................................................................. 46

8 YORK INTERNATIONAL
PLC FAILURE .......................................................................................................................................................................................................... 46
ENGINE OVERSPEED ............................................................................................................................................................................................. 46
ENGINE OVERLOAD ............................................................................................................................................................................................... 46
ENGINE CRANKING FAULT ................................................................................................................................................................................... 46
LOW GEAR OIL TEMPERATURE SWITCH .......................................................................................................................................................... 46
SUN 12:00 AM LOW GEAR OIL TEMP SENS FAULT.......................................................................................................................................... 46
HIGH AFTER COOLER WATER TEMPERATURE................................................................................................................................................ 46
ENGINE FAULT ....................................................................................................................................................................................................... 46
CLUTCH FAILURE .................................................................................................................................................................................................. 46
LOW ENGINE OIL PRESSURE .............................................................................................................................................................................. 47
HIGH ENGINE JACKET TEMP................................................................................................................................................................................ 47
SURFACE SPEED CONTROL: ACTIVE ............................................................................................................................................................... 47
SURFACE SPEED CONTROL: NOT ACTIVE ...................................................................................................................................................... 47
HIGH ENGINE GLYCOL TEMP ............................................................................................................................................................................... 47
COMPR COASTDN; ENGINE SHTDN – PRESS STATUS ................................................................................................................................. 47
DAY TIME HIGH ENGINE GLYCOL TEMP ............................................................................................................................................................ 47
COMPR SHTDN; ENGINE COOLDN – PRESS STATUS .................................................................................................................................... 47
SUN 12:00 AM HIGH ENGINE VIBRATION FAULT .............................................................................................................................................. 47

YORK INTERNATIONAL 9
FORM 160.60-O1
STANDARD DISPLAY MODE KEY MESSAGES
SETPOINT KEY MESSAGE
Chilled Liquid Temp LEAVING SETPOINT = XX.X°F
% Engine Load Limit ENGlNE LOAD LIMIT = XXX%
Pulldown Demand SETPOINT = XXXMIN @ XXX% LOAD, XXX MIN LEFT
Clock TODAY IS SUN 12:00AM XX/XX/XX
Service Interval ENGlNE SETPOINT = XXXX HRS, XXXX HRS REM
COMPRESSOR SETP = XXXX HRS, XXXX HRS REM
Daily Schedule SUN START = 00:00 AM, STOP = 00:00 AM
MON START = 00:00 AM, STOP = 00:00 AM
TUES START = 00:00 AM, STOP = 00:00 AM
WED START = 00:00 AM, STOP = 00:00 AM
THURS START = 00:00 AM, STOP = 00:00 AM
FRI START = 00:00 AM, STOP = 00:00 AM
SAT START = 00:00 AM, STOP = 00:00 AM
HOLIDAY START = 00:00 AM, STOP = 00:00 AM
Holiday S M T W T F S HOLIDAY NOTED BY *
Remote Reset Temp. Range REMOTE TEMP RESET RANGE = 00°F
Data Logger WTO AUTO PRINT INTERVAL = NOT PROGRAMMED
DISPLAY KEY MESSAGE
Chilled Liquid Temps CHILLED LEAVING=XXX.X°F; RETURN=XXX.X°F
Refrigerant Pressures EVAP = XXXX.X PSIG; COND = XXXX.X PSIG
Comp Oil Pressure OIL PRESSURE = XXX.X PSID
Engine Data ENGINE OIL PRESSURE = XXX.X PSIG
ENGINE MANIFOLD PRESSURE = XX.X PSIA
ENGINE JACKET WATER TEMP = XXX.X°F
AC INLET WATER TEMPERATURE = XXX°F
Engine RPM / % Vanes ENGINE SPEED = XXXX RPM; VANES = XXX%
Condenser Liquid Temps COND LEAVING = XXX.X°F; RETURN = XXX.X°F
Print PRINT ENABLE
PRINT REQUEST IN PROGRESS
Chiller Data SAT TEMPS EVAP = XXX .X°F, COND = XXX.X°F
DISCHARGE TEMP = XXX.X°F, OIL TEMP = XXX.X°F
HOP = XXXX.X PSIG; LOP = XXXX.X PSIG
PROXIMITY SENS-POS:XX MILS; REF:XX MILS
HIGH SPEED DRAIN TEMP = XXX.X°F
DELTA P OVER P = X.XX; PRV = XXX%
ENGINE RPM = XXXX; RPMS = XXXX
MACH = X.XX; MACHS = X.XX
REFRIG. LEVEL
Operating Hours/Start Counter OPER. HOURS =XXXXX; START COUNTER = XXXXX
% Engine Load G3516 ENGINE LOADING = XXX%
ENGINE LOAD - > (30 - 39%): XXXX.X HOURS
ENGINE LOAD - > (40 - 49%): XXXX.X HOURS
ENGINE LOAD - > (50 - 59%): XXXX.X HOURS
ENGINE LOAD - > (60 - 69%): XXXX.X HOURS
ENGlNE LOAD - > (70 - 79%): XXXX.X HOURS
ENCilNE LOAD - > (80 - 89%): XXXX.X HOURS
ENGINE LOAD - > (90 - 100%): XXXX.X HOURS

10 YORK INTERNATIONAL
SECTION 1
DESCRIPTION OF SYSTEM AND
FUNDAMENTALS OF OPERATION
FIG. 1  MODEL YG GAS ENGINE DRIVE CHILLER
SYSTEM OPERATING DESCRIPTION (See Fig. 1 or 1A)
The YORK Gas Engine Drive Centrifugal Chiller consists
of two packages; a shell package and a drive line pack-
age. The shell package includes an evaporator and con-
denser with internal subcooler. The drive line package
includes a compressor, compressor lubrication sys-
27704A
GAS ENGINE
ENGINE
CONTROL
PANEL
YORK MICROCOMPUTER
CONTROL CENTER
COMPRESSOR AC DISTRIBUTION
PANEL
OIL SUMP CONDENSER
COOLER
SUCTION
LINE
DISCHARGE
LINE
FIG. 1A  MODEL YB GAS ENGINE DRIVE CHILLER
YORK POWER PANEL
YORK MICRO PANEL
ENGINE JACKET WATER
LOCATION WHEN INSTALLED CATERPILLAR
CONTROL
PANEL
1T 3KVA
TRANSFORMER BATTERY
CHARGER
RT4 LEAVING
COND. WATER
SENSOR
RT5 ENTERING
COND. WATER
SENSOR
RT9 ENTERING
CHILLED
WATER SENSOR
RT1 LEAVING
CHILLED
WATER SENSOR
28699A
tem, natural gas engine, clutch, speed increaser, torsional
vibration reducing coupling, power panel, engine PLC
panel, and chiller control panel.
The YORK Gas Engine Drive Centrifugal Chiller is com-
monly applied to large air conditioning systems, but may
be used on other applications.