约克螺杆机组YEWS操作维护手册

YEWS100SA50D / YEWS170SA50D / YEWS210SA50DSTYLE DWarningRefrigerant with certain pressure is infused into this systemIt is possible to damage the system severely if be with the incorrect operating procedure when in maintaining. All the maintenances should be performed by the maintenance technician of YORK in accordance with the Installation, Operation and Maintenance Manual of YORK.IMPORTANT !Please read carefully before proceeding!General Safety GuidelinesThis equipment is complex, when performing the installation, operation and maintenance, the personnel may be exposed to the following circumstances or dangers caused by components, including but not limited to: refrigerants, engine oil, compressive material, rotation part and high-low voltage, which will result in personal injury or even casualty if in improper handling. The operation/maintenance personnel have the responsibility to confirm these potential dangers to protect him from the injury while work safely. If these safety requirements are not followed, serve damages on the equipment and property will be caused, or even casualty on the personnel concerned.This manual is just for the authorized operation/maintenance personnel, whom are professionally trained to handle the appointed work safely and correctly. Most important of all, please carefully read and master this manual and other references before any operation on this equipment. The operator is required to be familiar with and follow any relevant government standards and criterion.Variability of this DocumentYork inherits the strategy of updating the product continuously, so that the information in this document can be correspondingly updated without prior notice. York is in no promise to provide the latest information to all the owners of this manual; however, the user can acquire these information from the nearest representative office of engineering system service of York.It is the obligation of operation/maintenance personnel to determine the applicability of the corresponding equipment. If any question before operation, they will contact the customer to confirm whether the equipment have been updated and whether there is the latest available document or not.NomenclatureA50Y E WS100S DStylePower supplyRefrigerant A-R134aS-Standard unit100-Unit modelWater cooled screw chillerHigh efficiencyYORKSection 1 Supplier Information Section 2 Product IntroductionSection 3 Transportation, Transferring and Storage Section 4 Installation Section 5 Control Center Section 6 Startup Commissioning Section 7 Operation Section 8 Maintenance Section 9 Trouble Shooting Section 10 Technical Data Section 11 Spare PartsSection 12 Transferring Stop, Removal and HandlingSection 13 Installation Instructions for the HF68 Flow SwitchesTable of Contents149111742448535561626341.1 IntroductionYork YEWS-D water chiller complies with the most rigorous design and manufacture standards, which ensures the high-quality, reliability and flexibility of various air-condition project.This unit can be used for supplying the chilled water, however, be unsuitable for other applications beyond this manual.This manual contains all the necessary information of operation and maintenance guide for correct installation and testing.Please read this manual carefully before operating and overhauling the unit.All the work elaborated in this manual (including installation, testing and maintenance) should be performed by the trained professional personnel.The manufacturer should not burden any responsibility of injury or damage due to improper installation, testing, operation or improper maintenance, or disobeying the process and guidance in this manual.1.2 WarrantyOne year upon the date of startup and commissioning, or 18 months upon the date of shipment (subject to the prior arrival), Y ork guarantees to remedy the defect of the manufacturing process and material of all the equipment and parts, excepted as the guarantee period is extended in the Contract.The warranty is limited to alter and transport any faulty parts or components, if this part is unavailable due to quality or manufacture problem, the compensation must be supported by the evidence, namely the fault occurs in the guarantee period and the unit is run in the specified parameters.Section 1 Supplier InformationAll the compensation for the warranty must show the unit model, series no. and order no., all of which are printed on the tablet of the unit.Before getting the written consent of YORK International Inc., any alteration on the unit shall be prohibited, or the warranty should be invalid.The following clauses should be obeyed to comply with the product warranty: the commissioning of startup should be performed by the authorized personnel of Y ork. Only the parts, lubricant and refrigerant recognized by York can be adopted.In the regulated time, all the operation and maintenance required in this manual should be completed by the eligible trained personnel. The warranty should lost efficacy automatically for disobeying any above-mentioned clause.1.3 SafetyThe safety standards of YEWS-D water-chilling unit designed and manufactured by the factory passed the attestation of ISO 9000, which meet the limitation regulated in this manual and comply with the following standards: JB8654 Safety Requirements of Positive Displacement and Centrifugal Water-chilling (Heat Pump) Packages.1.4 Safety LiabilityWe take the safety liability into account in designing and manufacturing the unit to ensure that it can meet the safety requirements. However, the followings must be placed in the first in operating any equipment: personal safety, other personnel and equipment safety . Please operate this machine correctly according to the processes in this manual.1.5 About This ManualThe following words in this manual are used for1reminding the operating personnel to pay attention to the potential dangers.The WARNING in this manual is used formarking the dangers that may cause thepersonnel accident. The guidance, simpleexplanations and possible aftermath due toneglecting these guidance should generally begiven, which are expressed in black on redlabel.CAUTION signs the dangers that may result inthe damage of machine, destroy of otherequipment, or environment pollution. Theguidance, simple explanations and possibleaftermath due to neglecting these guidanceshould generally be given, which are expressedin black on yellow label.NOTE is used for highlighting the other usefulinformation, which has no special relation withthe safety, and they are expressed in black onwhite label.The contents of this manual contains the optimal operational approach and process recommended by Y ork, however, it is just for guiding, but not overriding the above-mentioned personal responsibility and local safety ordinance.The copyright of this manual and other information presented together with the product will be in the possession of Y ork. The whole or part of them can not be translated without the written consent of representative of York.1.6 Used EquipmentApplicabilityThis unit can be used for supplying the chilled water, however, unsuitable for other applications beyond this manual. It is possible to cause personnel injury or equipment damage if used for other purposes or in misoperation. The design limit appointed in this manual can not be exceeded in the operation.Supporting structureThe solid supporting structure is required to supply for the unit to avoid the personnel injury or equipment damage.Mechanical strengthThe unit shall not burden load or pressure from the neighboring equipment, pipe or structure. The other parts are forbidden installing on the unit, for any external load or pressure may destroy the structure to further injury the operator or damage the machine.General usageThe appropriate safety precautions should be adopted when operating the unit, or some dangers will happen easily and result in the injury. (Make sure that the password of the unit is just mastered by the authorized person, who knows the possible dangers and necessary safety precautions in the operation and maintenance process, and how to maintain the hot temperature, high voltage and electrical equipment much well, which is very important).Pressure systemThe unit contains the refrigerant vapor and liquid with certain pressure, so that the leakage may result in dangers or cause the injury in the running or unused. The user should ensure that the installation, operation and maintenance are very careful to avoid damaging the pressure system. Please do not attempt to close the spare parts of the pressure system except the professional personnel.Electrical SystemThe unit must be earthed; therefore, the installation or maintenance is forbidden before shutting off the main switch, insulating the power of unit and any controlling power, all of which are completed via the special tools by the trained personnel. Please do not attempt to touch the inside of operation board, distribution board or otherCAUTION NOTEWARNING 2electrical cabinet.Refrigerant and lubricantThe refrigerant and lubricant used by the unit are generally non-toxic, nonflammable and no corrosive, which can not cause particular harm to the body, however, the gloves and safety goggles had better to be put on when in working. Taking leakage as an example, the people will suffocate in the limited or closed space, so that please pay attention to keeping good ventilation in the machinery room.Cleaning under high temperature and high pressureDo not clean any parts of pressure system under high temperature and high pressure (such as swash with the vapor), for which may result in pressure relief. The detergent and solution are also forbidden to avoid the corrosion.1.7 Emergency stopOne switch of emergency stop is set on the electrical control cabinet, which is the red button. When the emergency happens, this switch can cut off the power of the controlling system, as well as lock the switch on the place of OFF.1.8 Safety SignsThe following signs are stuck on each unit to show the guidance or the potential danger. The meaning of each sign is as follows:In white on blue. Please read the instructionfirstly to be convenient for operation.In black on yellow. W arning-hot surfaceIn black on yellow. W arning-please cut off allthe powers before dismantling/removing thecover otherwise the fatal danger will happen.In black on yellow, sign for general attention.32.1 IntroductionYork YEWS-D water-chilling unit is used for supplying the chilled water; all the units are designed to be installed in the room (machinery room).2.2 CompressorThe semi-hermetic twin-screw compressor is adopted to ensure the high-efficient and reliable operation. The capacity control can be realized via the slide valve. The compressor is positive displacement with two spiral steel rotors. The motor with 50HZ can drive the male rotor directly with the rotational speed of 2975rpm, while the male rotor drives the female rotor, one flat of slim oil film is between the female and male rotor.Each compressor is direct-driven and semi-closed twin-screw, and including the followings: twin-screw rotor made from the forged steel, while the unit of precision machining compressor is made from the cast iron. The high-efficient oil separator is placed inside the machine.The inner discharge check valve can prevent the rotor from reversing when the machine stops.The high-efficient semi-closed electrical machinery can cool the suction, which also is with the overload protection, thermoelectricity resistance and over-current protection.The suction filter and full-flow oil filter are installed inside the compressor.The refrigerant gas is sucked into the interspaces constituted between the 5 gear male rotors and 7 gear female rotors, and then the rotor further meshes to close the rotor spiral in the suction mouth and unmeshed the compressed gas in the discharge mouth along with the axis direction. Before the designed capacity leaves the rotor exhaust chamber, the steam capacity is compressed,Section 2 Product Introductionwhile the pressure increases. Because the cycle of the suction and discharge is superposed, the airflow can keep stable.The rotor is inside the body of the compressor, while the body is made from the cast iron with precision machining to minimize the interspaces between the shell and rotor. The contact between the male and female rotor is mainly on pitch circle of each rotor, so that the rotor can not be abraded much and the reliability can also be increased. The compressor adopts the wearable bearing to decrease the power waste and strengthen the reliability, while four single cylindrical roller bearings burden the radial load; the angular contact ball bearing burdens the axial load. No matter under any pressure ratio, they can keep the correct orientation of the rotor, which can reduce the leakage and keep the efficiency. One check valve is set in the discharge port, which can be used for preventing the rotor from reversing due to the pressure grads of refrigerant when the unit is stopped.The refrigerant vapor from the evaporator flows with the motor and cools it. The overloading protection includes the over heating protection and over-current protection.The inner oil separator separates the oil from the refrigerant to directly turn back the compressor to lubricate.One inserted heater of 350W is set in the compressor, which is in constant temperature control; therefore, it can prevent the refrigerant from dissolving into the lubricant. Motor startupThe compressor motor adopts the star-shaped/triangle conversion starter, which includes 3 motor contactors and 1 startup relay and can restrict the startup electrical current in 33LRA around in the first 4~10 seconds, after completing the connection of the triangle, the electric current raise to the normal level.4The corresponding relay is electrified when the microprocessor gives out the compressor startup signal. The relay contacts switch to startup and connect the motor starter in the situation of start-shaped and keep 410 seconds.Capacity controlThe compressor should be started up in the minimal loading place, and reach the capacity control in full loading of 25100 via one continuous slide valve.The spring of the capacity adjustment is automatically reset the minimal loading place to ensure the startup of the compressor motor in the minimal loading.2.3 Oil SeparatorThe inside separator separates the majority of the oil and lubricate it directly, while a few of oil is separated to turn back the compressor.The oil can only return the compressor by one oil filter with one removable filter cartridge; the oil is in high pressure, which leads back the oil to compressor to lubricate the bearing and rotor.After that the oil is sprayed to the closed spiral near the suction rotor. The oil spraying is finished automatically due to the differential pressure between the discharge pressure and suction end, which not only lubricates the rotor and used as oil seal, but also reduce the leakage to ensure the compression of the refrigerant (capacity efficiency).When the compressor is running, the oil level must be higher than the visible location of the sight glass, please stop to check the reason once lower than and to inject the oil according to the actual situation, while the oil level can not be higher than the upper sight glass of inner oil separator, please stop to check and determine whether the oil should be discharged or not according to the actual situation once higher.2.4 Circuit of Refrigerant Each unit is with one independent refrigerating circuit, the liquid pipe includes: manual globe valve with infusing nozzle, throttling device and air bypass electromagnetic valve.2.5 CondenserThe condenser is the shell and tube type, which can be washed. The heat exchanging pipe is the 19mm seamless copper tube with outer finned and expansion joints to the tube plate, with one super cooler in the inner.The designed pressure of the water is 10bar. HG20615 flange is set on the water pipe joint to be convenient for connecting with the pipe. The designed pressure of the safety valve of refrigerant is 20. 7 bar, and the condenser is manufactured and inspected in accordance with the State Standards of China GB 151.2.6 EvaporatorThe flooded evaporator is adopted with the water inputs and outputs from the same side. The designed pressure of the safety valve of refrigerant is 20. 7 bar, and the condenser is manufactured and inspected in accordance with the State Standards of China GB 151.The shell is wrapped with the soft aperture-closed heat preservation material in the thickness of 19mm. HG20615 flange is set on the water pipe joint to be convenient for connecting with the pipe.2.7 Distribution Board and Control PanelAll the control and startup components for the unit are wired and completed the performances testing by the factory. The cabinet is designed according to IP23 and manufactured with the steel plate of powder spraying.The distribution board and control panel is divided into the power, control and startup cabinet according to the electrical system. The power and control part are with the individual hinged door, and each door has the lock and sealing pad.Each distribution board includes: compressor startup5contactor, control circuit, compressor contactor coil and components of compressor overloading protection.The overload protection of compressor is running as follows: read the electrical current signal to the control mainboard via CT, and to protect once exceeding the setting value upon comparing with FLA value.The power protection module of compressor provides the protection hyperlow / hyperhigh / phase sequence/phase out of input voltage.The control panel contains: microcomputer keyboard, HMI and microprocessor panel.2.8 Microprocessor ControlThe microprocessor is with the following performances and displays: liquid crystal display with 120 characters, which can display text with 8 lines of Chinese character and English letters or digit code, back lighting with the LED to be convenient for reading. Sealing keyboard with 20 keys, which are divided into function keys and programme keys.The standard controller includes: running signal contact, unit alarming contact, refrigerating pump and cooling pump control, automatic reset after break, system automatically optimization according to the running situation.The software is memorized in the flash memorizer to avoid the faults of the water chilling unit due to breaking of alternating current power. The program set values is saved in EPROM memorizer. The timing clock of controlling system is provided by RTC, and the service life of the backup lithium battery is 5 years at least.2.9 Current protection of motorThe motor protection of microprocessor provides the overcurrent protection to ensure that the motor is free from the damages due to excessive voltage and refrigerant and other overcurrent problems.After 3 seconds upon starting the star-shape/triangle starter, if the current exceeds 115FLA trip point, the microprocessor will stop the system and lock to be the fault. It is required to reset the corresponding system switch to eliminate the fault and restart the system. Please check the motor, circuit and refrigerating system before restarting.With measuring that the current is lower than 10 FLA(full loading), the microprocessor will also provide the under-current protection. The microprocessor will stop the running once under-current. The under-current protection will perform after 4 minutes of triangle starter startup to ensure that the system keeps running under the situations of without refrigerant, connecting of the motor protection components and mechanical high-voltage switch. It is required to reset the system switch once tripping due to under-current.Components of motor protectionThe electronic motor protection components provide the overheating protection, resistance of three phases PTC (Positive Temperature Coefficient) is installed in each phase of motor winding for protection. The resistance value of sensor will keep in 1K within 125. It will trip once coming up to 13K, so that the control circuit is in no electricity. When the motor cools down and the resistance of sensor reduces to 3.25K, the unit can be restarted again.The signal will be output to the mainboard to stop the motor once the protection components trips.2.10 Keyboard ControlDisplayThe parameters can be displayed in Chinese and English, and the following parameters for each circuit will be displayed:Input/output temperature of chilled waterInput/output temperature of cooling waterTime and date, start and stop time at ordinary days, arrangement on holidays and status of access beyond in manual.Compressor running time and startup times Compressor running status6Suction, discharge, oil pressure and discharge temper-ature of the systemPercentage of compressor current in full loading current Cutoff value and setting value: output temperature of chilled water, hyperlow of the suction, overhigh of the discharge and temperature, overhigh current or hyperlow, hyperlow of the chilled waterSetting value of unloading limit for overhigh discharge pressure and compressor currentInformation for exceeding the running limitFaults stop records over 50 timesInputSetting the output temperature and temperature difference of chilled waterClockSetting the time, startup and stop schedule for ordinary days or holidaysProgrammingSetting with the signals from YORK ISN or building automation system: hyperlow breaking value for output temperature of chilled water, restart timer for 180300 seconds, unloading point for average current, reset the setting value for output temperature of chilled water.Additional functions (with password) to be convenient for the professional inspection and maintenance technician to programme.Cutoff value: hyperlow suction pressure, overhigh discharge pressure, overhigh discharge temperature, unloading setting value for overhigh discharge pressure, percentage limit of compressor current.2.11 Accessory and SelectionWith the standard RS485 joint, YORK ISN building automation system can directly provide the commun-ication signal to the standard control panel.Flow switchGate flow switch, the designed working pressure is 10.3bar and applies for the chilled water and cooling the water pipelines.25mm spring shock absorberThe horizontal adjustable spring shock absorber is installed below the ground plate of the unit (on-site installation).2.12 Performance DescriptionLow pressure refrigerant liquid absorbs the hot outside the pipe in the flooded evaporator and evaporate as the refrigerant vapor, after that the low-pressure vapor enters into the compressor, while in the compressor, the pressure and temperature raise as the high temperature and high pressure gas, which separate the mixed lubricant in the outer and inner oil separator, then the lubricant returns back to the compressor for cycling. The oil-free cooling steam in high pressure and high temperature enter into the condenser, while the cooling water absorbs the heat of condensation, the refrigerating vapor cools to be the over-cooling liquid, and then the refrigerant liquid enters into the throttling device and decrease the pressure and temperature to reach the evaporator, then the whole refrigerating cycle is finished.7F i g 2-1 F l o w C h a r tSection 3 Transportation, Transferring and Storage3.1 Delivery and StorageIn order to acquire the stable quality and utmost reliabil-ity, all units have been tested and inspected before leaving the factory. The complete unit is shipped, moreover, the refrigerant YORK L oil with certain pressure is injected. The unit can not be shipped with the export crate, excepted as otherwise are especially marked in the sales order.If the unit needs to be stored before installation, please adopt the followings precautions:Make sure that the unit is free from wind and rain.Make sure that all the opens (such as pipe joint) are with the protective cover or blanking plate.The unit should be stored in the place without many persons to reduce the dangers of accidental mechanical contusion.Don't wash with the steam to avoid operation of relief valve.Please remove the key to the control panel and hand over to the principal. Please inspect the unit periodically in the period of storage.3.2 InspectionPlease remove the transportation package to inspect the unit and confirm that all the parts have been received and without any damage due to transportation. Any obvious broken must be remarked on the waybill of the forwarder, and claim for compensation according to the guidance on the notice.3.3 TransferringBefore transferring the unit, please confirm that the applicable installed device and tools in the installing location, and which can burden the weight of the unit and all accessories.The unit is designed to hoist with the wire rope, one beam showed in the following picture hoist the unit (hoisting hole on tube plate can adopt 6.8shackle), the hoisting component must be long enough for avoiding all the hoisting, also the damages caused by the hoisting chain. The hoisting component must reach the requirement of the unit weight.Do not move the unit on the roller, or hoist theunit by the fork-lift truck.CAUTIONFig 3-1 RiggingThe field for installing the unit must be the floor, mounting pad or foundation, of which the horizontality must be within 6mm and can burden the operation weight of the whole unit.The unit must be placed in the machinery room with the temperature of 4.443.3¡æ, there is enough space around and above the unit for the routine maintenance. The space for cleaning the evaporator and condenser should be retained at one end of the unit, as well as make use of the door opening or other suitable opening. Space for maintenance requirement The space requirement is as follows:Back, side and upper part of the unit-610mm Front of the unit-914 mmPipe removal-See the below table:4.3 Installation of Shock AbsorberThe selected shock absorber can be bulk transported along with the machine.Place the correct installation location upon the Foundation drawing (Refer to Section 10).Fixation-InstallationTwo methods for selection: rubber shock pad, spring shock absorberRubber shock pad: place each pad on its correct location respectively, and then set down the unit carefully on the shock absorber.Spring shock absorber: place each pad on its correct location respectively, and then set down the unit carefully on the shock absorber.Equally distribute the weight of unit on the spring via regulating the adjusting nut on the spring shock absorberSection 4 Installation4.1 SummaryThis manual introduces how to install YEWS-D screw water cooled chiller. The standard unit for usage is generally installed well, and the pipes and circuits are prepared well, and the nitrogen or refrigerants has been infused. When it is installed on the site, it just requires completing the connections of chilled water pipelines, water pipe of condenser, safety pipelines of refrigerant gases and power, etc.The business representative of Y ork will provide the services of installation inspection and initial startup in accordance with the requirements in the contract. If the followings are not obeyed, Y ork shall keep the right to stop the liabilities of Three Guarantees:1. Prohibit to opening any valve or connector under any circumstances, for which will result in the leakage of the nitrogen or refrigerants.2. Excepted that the business representative supervises of York, otherwise no removal or startup of the unit upon any reason.3. No final power connection for the compressor motor or the controlling center.4. No oil injection in the system.5. Do not attempt to startup the system.6. Please do not infuse the hot water or steam (the highest temperature is100F ¡ã, 38¡æ)into the evaporator once the chiller is powered on.4.2 Arrangement RequirementsThe YEWS-D unit is generally located in any plane inside the building because of its low noise and slight vibration the structure of the plane is just required to support the operation weight of the whole unit.In order to reduce the influence on the surroundings from the vibration and noise, it suggests that the unit should be installed in the area, where the vibration and noise is insensitive.ModelSpace for removing the pipe YEWS100SA50D2100mm YEWS130SA50D /170/2102650mm。