YORK MILLENNIUM YPC Two-Stage Steam-Fired Absorption Chiller

The YORK Millennium YPC Two-Stage Absorption Steam Chiller represents the world’s most efficient commercially available absorption technology. The unique Two-Stage design requires a remarkably low steam input rate of 9.8 Ibs. per ton-hour (1.26 kg per kW-hour), which equates to a COP of approximately 1.19. With today’s energy and environmental considerations, the YORK YPC Two-Stage Steam Absorption Chiller is the ideal choice for a wide range of applications.
U.S. made YPC Steam Chillers come equipped with the same sophisticated microprocessor controls found throughout YORK’s line of centrifugals, making the YPC Steam Chiller the smartest and most efficient absorber on the market today.
With its high efficiency, “smart controls,” proven reliability and guaranteed quality, U.S. made YPC units are the ideal choice for today’s demanding specifications.

Table of Contents
How It Works
Ratings
Control System
Mechanical Specifications
Application Data
Dimensions
Nozzle Arrangements
Guide Specifications
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Duplex CDHF, CDHG Water Cooled CenTraVac With CH530

Warnings and Cautions
General Information
Unit Control Panel (UCP)
Operator Interface
Chilled Water Setpoint
Inter Processor Communication (IPC)
Control System Components
Controls Sequence of Operation
Machine Protection and Adaptive Control
Unit Startup
Unit Shutdown
Periodic Maintenance
Oil Maintenance
Maintenance
Forms
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YORK MILLENNIUM YIA Single-Effect Absorption Chillers

TABLE OF CONTENTS
INTRODUCTION
RELIABILITY FEATURES
HOW IT WORKS
CONTROL SYSTEM
MECHANICAL SPECIFICATIONS
OPTIONAL FEATURES
APPLICATION DATA
RATINGS
NOZZLE ARRANGEMENTS
PHYSICAL DATA
ELECTRICAL DATA
GUIDE SPECIFICATIONS
LIST OF ILLUSTRATIONS
FIG. PAGE
1 Millennium Single-Stage Absorption Chiller Features
2 Standard Steam / Hot Water Cycle Diagram
3 Millennium Control Center
4 Typical Steam Piping
5 System 1: Atmospheric Condensate Return System
6 System 2: Vacuum Condensate Return System
7 System 3: Vacuum Condensate Return System with Steam Inlet
and Condensate Outlet Under Vacuum
8 Typical Hot Water Piping
9 Typical Part Load Steam Consumption – Std. Unit
10 Typical Chiller Start-Up Performance
11 Typical Chiller Cooling Capacity for Required LCHWT
12 Typical Chiller Cooling Capacity for Avail. Steam Inlet Press.
13 Typical Chiller Steam Consumption for LCHWT
14 Steam Chiller Nozzle Arrangements
15 Hot Water Chiller Nozzle Arrangements
16 Unit Dimensions
LIST OF TABLES
TABLE PAGE
1 Enthalpy Values
2 YIA Chiller Shell and Tube Volumes
3 Generator Heat Loss (English)
4 Generator Heat Loss (Metric)
5 Approx. Insulation for Hot and Cold Surfaces (English)
6 Approx. Insulation for Hot and Cold Surfaces (Metric)
7 Nominal Ratings, Steam Machines (English)
8 Nominal Ratings, Steam Machines (Metric)
9 IPLV Analysis
10 Fouling Factor
11 Evaporator Pass Arrangements
12 Absorber / Condenser Arrangements
13 Hot Water Generator Nozzle Arrangements
14 Electrical Ratings
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SINGLE COMPRESSOR CENTRIFUGAL CHILLERS PEH/PHH 050,063,079,087,100,126

INTRODUCTION
G e n e r a l D e s c r i p t i o n
A p p l i c a t i o n
OPERATION
Operator Responsibilities
N o m e n c l a t u r e
O p e r a t i n g S e q u e n c e
C o n t r o l S y s t e m
O p e r a t i n g C o n t r o l s
Control Component Summary
P r o t e c t i v e C o n t r o l s
S a f e t y C o n t r o l R e s e t
C o n t r o l C e n t e r
T e m p e r a t u r e S e c t i o n
R e l a y S e c t i o n
S w i t c h S e c t i o n
C o n t r o l M o d u l e
Capacity Control System
V a n e O p e r a t i o n
M e t e r i n g V a l v e s
O i l S y s t e m
Hot Gas Bypass System
O p e r a t i n g t h e C h i l l e r
P r e l i m i n a r y C h e c k s
S t a r t i n g t h e C h i l l e r
O p e r a t i n g C h e c k s
S h u t d o w n
MAINTENANCE
R o u t i n e M a i n t e n a n c e
L u b r i c a t i o n
Changing Oil Filter
Refrigerant Cycle
Electrical System
Cleaning and Preserving
Seasonal Servicing
Annual Shutdown
Annual Start-up
Repair of System
Pumping Down
Pressure Testing
Leak Testing
Evacuation
Refrigeration Charging
Pressure Relief Valve Replacement
Equipment Warranty
Refrigerant Charts
ADJUSTMENTS
Current Limit Calibration
Temperature Calibration
Ramp-Up Calibration
Pulse Rate Calibration
Current Transformer Signal
Vane Speed Adjustment. ........
Load Recycling Thermostat Setting
Low Oil Temperature Thermostat
T R O U B L E S H O O T I N G G U I D E
McQUAY CENTRIFUGAL OPERATING LOG
M c Q U A Y S E R V I C E P R O G R A M S
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Mini Chiller Service Manual T1/R22/50Hz

CONTENTS
PRODUCT INTRODUCTION
1 MODELS LIST
1.1 Split Type
1.2 Integral Type
2 NOMENCLATURE
1.1 Split Type
1.2 Integral Type
3 FUNCTION
4 PRODUCT DATA
4.1 Product Data at Rated Condition
4.2 Operation Range
4.3 Pressure-loss Conversion Chart
4.4 Electrical Data
5 PIPING DIAGRAM
UNITS CONTROL
1 OPERATION FLOWCHART
1.1 Cooling Operation
1.2 Heating Operation
2 MAIN LOGIC
3 WIRED CONTROLLER
4 CONTROL WIRING DESIGN
UNITS INSTALLATION
1 UNITS INSTALLING
1.1 Installation Positions
1.2 Matters need Attention
1.3 DIMENSION DATA
1.2 INSTALLATION CLEARANCE DATA
2 WATER PIPING WORK
2.1 Installation Procedure
2.2 Matters of Attention
2.3 Antifreeze
3 ELECTRIC WIRING WORK
3.1 Wiring Principle
3.2 Electric Wiring Design
3.3 SPECIFICATION OF POWER CORD & AIR SWITCH
3.4 CIRCUIT DIAGRAM
3.4.1 Circuit Diagram-Split Type
3.4.2 Circuit Diagram- Integral Type
UNITS MAINTENANCE
1 ERROR CODE LIST
2 FLOW CHART OF TROUBLESHOOTING
3 DISASSEMBLY AND ASSEMBLY PROCEDURE OF MAIN PARTS
3.1 Split Type
3.2 Integral Type
4 EXPLODED VIEWS AND PART LIST
4.1 Exploded Views and Parts List- Split Type
4.2 Exploded Views and Parts List- Integral Type
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19XR,XRV Hermetic Centrifugal Liquid Chillers 50/60 Hz

Contents
SAFETY CONSIDERATIONS
INTRODUCTION
ABBREVIATIONS AND EXPLANATIONS
CHILLER FAMILIARIZATION
Chiller Information Nameplate
System Components
Cooler
Condenser
Motor-Compressor
Control Panel
Factory-Mounted Starter or Variable Frequency Drive (Optional)
Storage Vessel (Optional)
REFRIGERATION CYCLE
MOTOR AND LUBRICATING OIL COOLING CYCLE
VFD COOLING CYCLE
LUBRICATION CYCLE
Summary
Details.
Oil Reclaim System
• PRIMARY OIL RECOVERY MODE
• SECONDARY OIL RECOVERY METHOD
STARTING EQUIPMENT
Unit-Mounted Solid-State Starter (Optional)
Unit-Mounted Wye-Delta Starter (Optional)
Unit-Mounted VFD (Optional)
CONTROLS.
Definitions
• ANALOG SIGNAL
• DISCRETE SIGNAL
General
PIC II System Components
• CHILLER VISUAL CONTROLLER (CVC)
• INTERNATIONAL CHILLER VISUAL CONTROLLER (ICVC)
• INTEGRATED STARTER MODULE (ISM)
• CHILLER CONTROL MODULE (CCM)
• OIL HEATER CONTACTOR (1C)
• OIL PUMP CONTACTOR (2C)
• HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)
• CONTROL TRANSFORMERS (T1, T2)
• OPTIONAL TRANSFORMER (T3)
CVC/ICVC Operation and Menus
• GENERAL
• ALARMS AND ALERTS
• CVC/ICVC MENU ITEMS
• BASIC CVC/ICVC OPERATIONS (Using the Softkeys)
• TO VIEW STATUS
• OVERRIDE OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC II System Functions
• CAPACITY CONTROL FIXED SPEED
• CAPACITY CONTROL VFD
• ECW CONTROL OPTION
• CONTROL POINT DEADBAND
• DIFFUSER CONTROL
• PROPORTIONAL BANDS AND GAIN
• DEMAND LIMITING
• CHILLER TIMERS
• OCCUPANCY SCHEDULE
Safety Controls
Shunt Trip (Option)
Default Screen Freeze
Ramp Loading
Capacity Override
High Discharge Temperature Control
Oil Sump Temperature Control
Oil Cooler
Remote Start/Stop Controls
Spare Safety Inputs
Alarm (Trip) Output Contacts
Refrigerant Leak Detector
Kilowatt Output
Remote Reset of Alarms
Condenser Pump Control
Condenser Freeze Prevention
Evaporator Freeze Protection (ICVC Only)
Tower Fan Relay Low and High
Auto. Restart After Power Failure
Water/Brine Reset
• RESET TYPE 1
• RESET TYPE 2
• RESET TYPE 3
Demand Limit Control Option
Surge Prevention Algorithm (Fixed Speed Chiller)
Surge Prevention Algorithm with VFD
Surge Protection VFD Units
Surge Protection (Fixed Speed Chiller)
• HEAD PRESSURE REFERENCE OUTPUT
Lead/Lag Control
• COMMON POINT SENSOR INSTALLATION
• CHILLER COMMUNICATION WIRING
• LEAD/LAG OPERATION
• FAULTED CHILLER OPERATION
• LOAD BALANCING
• AUTO. RESTART AFTER POWER FAILURE
Ice Build Control
• ICE BUILD INITIATION
• START-UP/RECYCLE OPERATION
• TEMPERATURE CONTROL DURING ICE BUILD
• TERMINATION OF ICE BUILD
• RETURN TO NON-ICE BUILD OPERATIONS
Attach to Network Device Control
• ATTACHING TO OTHER CCN MODULES
Service Operation
• TO ACCESS THE SERVICE SCREENS
• TO LOG OUT OF NETWORK DEVICE
• HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE SEQUENCE
Local Start-Up
Shutdown Sequence
Automatic Soft Stop Amps Threshold
Chilled Water Recycle Mode
Safety Shutdown
BEFORE INITIAL START-UP
Job Data Required
Equipment Required
Using the Optional Storage Tank
and Pumpout System
Remove Shipping Packaging
Open Oil Circuit Valves
Tighten All Gasketed Joints and Guide Vane Shaft Packing
Check Chiller Tightness
Refrigerant Tracer
Leak Test Chiller
Standing Vacuum Test
Chiller Dehydration
Inspect Water Piping
Check Optional Pumpout Compressor Water Piping
Check Relief Valves
Inspect Wiring.
Carrier Comfort Network Interface Check Starter
• MECHANICAL STARTER
• BENSHAW, INC. RediStart MICRO™
SOLID-STATE STARTER
• VFD STARTER
Oil Charge
Power Up the Controls and Check the Oil Heater
• SOFTWARE VERSION
Software Configuration
Input the Design Set Points
Input the Local Occupied Schedule (OCCPC01S)
Input Service Configurations
• PASSWORD
• INPUT TIME AND DATE
• CHANGE CVC/ICVC CONFIGURATION IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE CVC/ICVC DISPLAY FROM ENGLISH TO METRIC UNITS
• CHANGE LANGUAGE (ICVC ONLY)
• MODIFY CONTROLLER IDENTIFICATION IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY
• CHANGE THE BENSHAW, INC., RediStart MICRO SOFTWARE CONFIGURATION IF NECESSARY
• VERIFY VFD CONFIGURATION AND CHANGE PARAMETERS IF NECESSARY
• VFD CHILLER FIELD SET UP AND VERIFICATION
• VFD CONTROL VERIFICATION (Non-Running)
• VFD CONTROL VERIFICATION (Running)
• CONFIGURE DIFFUSER CONTROL IF NECESSARY
• MODIFY EQUIPMENT CONFIGURATION IF NECESSARY
Perform a Control Test
• COOLER CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION
Check Optional Pumpout System Controls and Compressor
High Altitude Locations
Charge Refrigerant Into Chiller
• CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT
• CHILLER EQUALIZATION WITH PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP.
Preparation
Dry Run to Test Start-Up Sequence
Check Motor Rotation
Check Oil Pressure and Compressor Stop
To Prevent Accidental Start-Up
Check Chiller Operating Condition
Instruct the Customer Operator
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL
OPERATING INSTRUCTIONS
Operator Duties
Prepare the Chiller for Start-Up
To Start the Chiller
Check the Running System
To Stop the Chiller
After Limited Shutdown
Preparation for Extended Shutdown
After Extended Shutdown
Cold Weather Operation
Manual Guide Vane Operation
Refrigeration Log
PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES
Preparation
Operating the Optional Pumpout Unit
• TO READ REFRIGERANT PRESSURES
Chillers with Storage Tanks
• TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM CHILLER TO PUMPOUT STORAGE TANK
Chillers with Isolation Valves
• TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL
• TRANSFER ALL REFRIGERANT TO CHILLER COOLER VESSEL
• RETURN CHILLER TO NORMAL OPERATING CONDITIONS
GENERAL MAINTENANCE
Refrigerant Properties
Adding Refrigerant
Removing Refrigerant.
Adjusting the Refrigerant Charge
Refrigerant Leak Testing
Leak Rate
Test After Service, Repair, or Major Leak
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply Standing Vacuum Test
Checking Guide Vane Linkage
Trim Refrigerant Charge.
WEEKLY MAINTENANCE
Check the Lubrication System
SCHEDULED MAINTENANCE
Service Ontime.
Inspect the Control Panel
Check Safety and Operating Controls Monthly
Changing Oil Filter
Oil Specification
Oil Changes.
• TO CHANGE THE OIL
Refrigerant Filter
Oil Reclaim Filter
Inspect Refrigerant Float System Inspect Relief Valves and Piping
Compressor Bearing and Gear Maintenance
Inspect the Heat Exchanger Tubes and Flow Devices
• COOLER AND FLOW DEVICES
• CONDENSER AND FLOW DEVICES
Water Leaks
Water Treatment
Inspect the Starting Equipment.
Check Pressure Transducers
Optional Pumpout System Maintenance
• OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE
• OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
Ordering Replacement Chiller Parts
TROUBLESHOOTING GUIDE
Overview
Checking Display Messages.
Checking Temperature Sensors
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers
• UNITS EQUIPPED WITH CVC
• UNITS EQUIPPED WITH ICVC
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure
Control Test
Control Modules
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation
Chiller Control Module (CCM)
• INPUTS
• OUTPUTS
Integrated Starter Module
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules
• INSTALLATION
Solid-State Starters.
• TESTING SILICON CONTROL RECTIFIERS IN BENSHAW, INC. SOLID-STATE STARTERS
• SCR REMOVAL/INSTALLATION
Physical Data
INDEX
INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER
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Standard R Series Process Water Chillers

CONTENTS
1. Safety
1.1 Marking
1.2 Safety Instructions
1.3 Handling Refrigerants
1.4 Environmental Regulations
2. Warranty
3. Technical Data
4. Transport / Storage
5. Installation
5.1 Inspection
5.2 Positioning
5.3 Plumbing
5.4 Water Treatment
5.5 Electrical connections
6. Commissioning
6.1 Procedure
6.2 Check sheet
6.3 Decommissioning
7. Operation
7.1 Control Panel
7.2 Thermostat setting and parameter adjustment
7.3 Starting the chiller
7.4 Fault lights signals
8. Maintenance
8.1 Cleaning the Condenser
8.2 Refrigerant Circuit
8.3 Water Circuit
9. Troubleshooting
10. Chiller Options
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