YK MAXE CHILLER
MEP-10100 SM Blvd
GENERAL
Furnish YORK MaxE Centrifugal Liquid Chilling-Unit(s) as indicated on the drawings.
Each unit shall produce a capacity of 750 tons, cooling 1199 gpm of WATER from 58.00 to 43.00 F when supplied with 2250 gpm
of condenser water at 85.00F. Power input shall not exceed 405 KW with an NPLV of 0.366. The cooler shall be selected for
0.00010 fouling factor and a maximum liquid pressure drop of 12.1 ft. Water side shall be designed for 150 psig working pressure.
The condenser shall be selected for 0.00025 fouling factor and maximum liquid pressure drop of 15.3 ft. Water side shall be
designed for 150 psig working pressure. Power shall be supplied to the compressor motor at 460 volts 3 phase - 60 Hertz and
controls at 115 volts 1-phase - 60 Hertz. The chiller shall use R-134A.
Each unit will be completely factory-packaged including evaporator, unit mounted starter, condenser, sub-cooler, compressor, open
motor, lubrication system, Optiview control center. and all interconnecting unit piping and wiring. The chiller will be painted prior to
shipment.
Performance will be certified in accordance with ARI Standard 550/590. Only chillers that are listed in the ARI Certification
Program for Centrifugal and Rotary Screw Water Chillers are acceptable.
The initial charge of refrigerant and oil will be supplied, shipped in containers and cylinders for field installation or factory charged
in the chiller.
COMPRESSOR
The compressor will be a single-stage centrifugal type powered by an open-drive electric motor. The housing will be fully accessible
with vertical circular joints, with the complete operating assembly removable from the compressor and scroll housing. Compressor
castings will be designed for 235 psig working pressure and hydrostatically pressure tested at 355 psig for R-134A units. The rotor
assembly will consist of a heat-treated alloy steel drive shaft and impeller shaft with a cast aluminum, fully shrouded impeller. The
impeller will be designed for balanced thrust, dynamically balanced and overspeed tested for smooth, vibration-free operation.
Insert-type journal and thrust bearings will be fabricated of aluminum alloy, precision bored and axially grooved.
Internal single helical gears with crowned teeth will be designed so that more than one tooth is in contact at all times to provide even
load distribution and quiet operation. Each gear will be individually mounted in its own journal and thrust bearings to isolate it from
impeller and motor forces. Shaft seal shall be provided in double bellows, double-seal, cartridge type. A gravity-fed oil reservoir will
be built into the top of the compressor to provide lubrication during coastdown in the event of a power failure.
Capacity control will be achieved by use of prerotation vanes to provide fully modulating control from maximum to minimum load.
The unit will be capable of operating with lower temperature cooling tower water during part-load operation in accordance with ARI
Standard 550/590. Prerotation vane position will be automatically controlled by an external electric actuator to maintain constant
leaving chilled water temperature.
LUBRICATION SYSTEM
Lubrication oil shall be force-fed to all compressor bearings, gears, and rotating surfaces by an external variable speed oil pump. The
oil pump shall vary oil flow to the compressor based on operating and stand-by conditions, ensuring adequate lubrication at all times.
The oil pump shall operate prior to start-up, during compressor operation and during coastdown. Compressor shall have an auxiliary
reservoir to provide lubrication during coastdown in the event of a power failure.
An oil reservoir, separate from the compressor, shall contain the submersible 2 HP oil pump and a 3000 watt oil heater,
thermostatically controlled to remove refrigerant from the oil. The oil reservoir shall be designed and stamped in accordance with
ASME or applicable pressure vessel code. A non-code reservoir is not acceptable.
Oil shall be filtered by an externally mounted micron replaceable cartridge oil filter equipped with service valves. Oil cooling
shall be done via a refrigerant cooled oil cooler, with all piping factory installed. Oil side of the oil cooler shall be provided with
service valves. An automatic oil return system to recover any oil that may have migrated to the evaporator shall be provided. Oil
piping shall be completely factory installed and tested.
Printed: 3/19/2010 at 10:51
Filename: 287691162
Reference: 160.73-EG1
Page 1 of 7
YK MAXE CHILLER
MEP-10100 SM Blvd
MOTOR DRIVELINE
The compressor motor will be an open drip-proof, squirrel cage, induction type operating at 3570 RPM.
The open motor shall be provided with a D-flange, bolted to a cast iron adapter mounted on the compressor to allow the motor to be
rigidly coupled to the compressor to provide factory alignment of motor and compressor shafts.
Motor drive shaft will be directly connected to the compressor shaft with a flexible disc coupling. Coupling will have all metal
construction with no wearing parts to assure long life, and no lubrication requirements to provide low maintenance.
For units utilizing remote electro-mechanical starters, a large steel terminal box with gasketed front access cover will be provided for
field connected conduit. Overload/overcurrent transformers will be furnished with all units. (For units furnished with factory
packaged Solid State Starters, refer to the options section.)
EVAPORATOR
Evaporator will be of the shell-and-tube, flooded type designed for 180 psig working pressure on the refrigerant side. Shell will be
fabricated from rolled carbon steel plate with fusion welded seams; have carbon steel tube sheets, drilled and reamed to
accommodate the tubes; and intermediate tube supports spaced no more than four feet apart. The refrigerant side will be designed,
tested and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII- Division 1. Tubes shall be highefficiency, internally and externally enhanced type having plain copper lands at all intermediate tube supports to provide maximum
tube wall thickness at the support area. Each tube will be roller expanded into the tube sheets providing a leak-proof seal, and be
individually replaceable. Water velocity through the tubes will not exceed 12 fps. Two liquid level sight glasses will be located on
the side of the shell to aid in determining proper refrigerant charge. Aluminum mesh eliminators will be located above the tube
bundle to prevent liquid refrigerant carryover to the compressor. The evaporator will have a refrigerant relief device sized to meet
the requirements of ASHRAE 15 Safety Code for Mechanical Refrigeration.
Water boxes will be removable to permit tube cleaning and replacement. Stubout water connections having victaulic grooves will be
provided. Vent and drain connections with plugs will be provided on each water box.
CONDENSER
Condenser will be of the shell-and-tube type, designed for 235 psig working pressure on the refrigerant side. Shell will be fabricated
from rolled carbon steel plate with fusion welded seams; have carbon steel tube sheets, drilled and reamed to accommodate the tubes;
and intermediate tube supports spaced no more than four feet apart. The refrigerant side will be designed, tested and stamped in
accordance with ASME Boiler and Pressure Vessel Code, Section VIII- Division 1. Tubes shall be high-efficiency, internally and
externally enhanced type having plain copper lands at all intermediate tube supports to provide maximum tube wall thickness at the
support area. Each tube will be roller expanded into the tube sheets providing a leak-proof seal, and be individually replaceable.
Water velocity through the tubes will not exceed 12 fps.
Water boxes will be removable to permit tube cleaning and replacement. Stubout water connections having victaulic grooves will be
provided. Vent and drain connections with plugs will be provided on each water box.
REFRIGERANT FLOW CONTROL
Refrigerant flow to the evaporator will be controlled by a variable orifice for improving unloading capabilities.
GRAPHIC CONTROL CENTER
General: The chiller shall be controlled by a stand-alone microprocessor based control center. The chiller control panel shall
provide control of chiller operation and monitoring of chiller sensors, actuators, relays and switches.
Control panel: The control panel shall include a 10.4 in. diagonal color liquid crystal display (LCD) surrounded by soft keys
which are redefined based on the screen displayed at that time. This shall be mounted in the middle of a keypad interface and
installed in a locked enclosure. The screen shall detail all operations and parameters, using a graphical representation of the
chiller and its major components. Panel verbiage shall be available in other languages as an option with English always available.
Data shall be displayed in either English or Metric units. Smart Freeze Point Protection shall run the chiller at 36.00F leaving
Printed: 3/19/2010 at 10:51
Filename: 287691162
Reference: 160.73-EG1
Page 2 of 7
YK MAXE CHILLER
MEP-10100 SM Blvd
chilled water temperature, and not have nuisance trips on low water temperature. The sophisticated program and sensor shall
monitor the chiller water temperature to prevent freeze up. When needed Hot Gas Bypass is available as an option. The panel
shall display countdown timer messages so the operator knows when functions are starting and stopping. Every programmable
point shall have a pop-up screen with the allowable ranges, so that the chiller can not be programmed to operate outside of its
design limits.
The chiller control panel shall also provide:
1. System operating information including:
a. return and leaving chilled water temperature
b. return and leaving condenser water temperature
c. evaporator and condenser saturation temperature
d. differential oil pressure
e. percent motor current
f. evaporator and condenser saturation temperature
g. compressor discharge temperature
h. oil reservoir temperature
i. compressor thrust bearing positioning and oil temperature
j. operating hours
k. number of compressor starts
2. Digital programming of setpoints through the universal keypad including:
a. leaving chilled water temperature
b. percent current limit
c. pull-down demand limiting
d. six-week schedule for starting and stopping the chiller, pumps and tower
e. remote reset temperature range
3. Status messages indicating:
a. system ready to start
b. system running
c. system coastdown
d. system safety shutdown-manual restart
e. system cycling shutdown-auto restart
f. system prelube
g. start inhibit
4. The text displayed within the system status and system details field shall be displayed as a color coded
message to indicate severity: red for safety fault, orange for cycling faults, yellow for warnings, and green
for normal messages.
5. Safety shutdowns enunciated through the display and the status bar, and consist of system status, system
details, day, time, cause of shutdown, and type of restart required. Safety shutdowns with a fixed speed
drive shall include:
a. evaporator low pressure
b. evaporator transducer or leaving liquid probe
c. evaporator transducer or temperature sensor
d. condenser high pressure contacts open
e. condenser high pressure
f. condenser pressure transducer out of range
Printed: 3/19/2010 at 10:51
Filename: 287691162
Reference: 160.73-EG1
Page 3 of 7
YK MAXE CHILLER
MEP-10100 SM Blvd
g. auxiliary safety contacts closed
h. discharge high temperature
i. discharge low temperature
j. oil high temperature
k. oil low differential pressure
l. oil high differential pressure
m. oil sump pressure transducer out of range
n. oil differential pressure calibration
o. oil variable speed pump pressure setpoint not achieved
p. control panel power failure
q. motor or starter current imbalance
r. thrust bearing proximity probe clearance
s. thrust bearing - proximity probe out of range
t. thrust bearing high oil temperature
u. thrust bearing oil temperature sensor
v. watchdog software reboot
5.1 Safety shutdowns with a VSD Shall include:
a. VSD shutdown requesting fault data
b. VSD stop contacts open
c. VSD 105% motor current overload
d. VSD high phase A, B,C inverter heatsink temp.
e. VSD high converter heatsink temperature
6. Cycling shutdowns enunciated through the display and the status bar, and consists of system status,
system details, day, time, cause of shutdown, and type of restart required. Cycling shutdowns with a fixed
speed drive shall include:
a. multiunit cycling contacts open
b. system cycling - contacts open
c. oil - low temperature differential
d. oil low temperature
e. control panel - power failure
f. leaving chilled liquid - low temperature
g. leaving chilled liquid - flow switch open
h. motor controller contacts open
i. motor controller loss of current
j. power fault
k. control panel - schedule
l. starter low supply line voltage
m. starter low supply line voltage
n. proximity probe low supply voltage
o. oil - variable speed pump - drive contacts open
6.1 Cycling shutdowns with a VSD shall include:
a. VSD shutdown requesting fault data
b. VSD stop contacts open
c. VSD initialization failed
d. VSD - high phase A,B,C instantaneous current
e. VSD phase A,B,C gate driver
f. VSD single phase input power
Printed: 3/19/2010 at 10:51
Filename: 287691162
Reference: 160.73-EG1
Page 4 of 7
YK MAXE CHILLER
MEP-10100 SM Blvd
g. VSD high DC bus voltage
h. VSD pre charge DC bus voltage imbalance
i. VSD high internal ambient temperature
j. VSD invalid current scale selection
k. VSD low phase A, B, C inverter heatsink temp.
l. VSD low converter heatsink temperature
m. VSD pre-charge - low DC bus voltage
n. VSD logic board processor
o. VSD run signal
p. VSD serial communications
7. Security access to prevent unauthorized change of setpoints, to allow local or remote control of the chiller,
and to allow manual operation of the prerotation vanes and oil pump. Access shall be through ID and
password recognition, which is defined by three different levels of user competence: view, operator, and
service.
8. Trending data with the ability to customize points of once every second to once every hour. The panel
shall trend up to 6 different parameters from a list of over 140, without the need of an external monitoring
system.
9. The operating program stored in non-volatile memory (EPROM) to eliminate reprogramming the chiller due
to AC power failure or battery discharge. Programmed setpoints shall be retained in lithium battery-backed
RTC memory for a minimum of 11 years with power removed from the system.
10. A fused connection through a transformer in the compressor motor starter to provide individual overcurrent protected power for all controls.
11. A numbered terminal strip for all required field interlock wiring.
12. An RS-232 port to output all system operating data, shutdown / cycling message, and a record of the last
10 cycling or safety shutdowns to a field-supplied printer. Data logs to a printer at a set programmable
interval. This data can be preprogrammed to print from 1minute to 1day.
13. The capability to interface with a building automation system to provide:
a. remote chiller start and stop
b. remote leaving chiller liquid temperature adjust
c. remote current limit setpoint adjust
d. remote ready to start contacts
e. safety shutdown contacts
f. cycling shutdown contacts
g. run contacts
STARTUP AND OPERATOR TRAINING
The services of a factory trained, field service representative will be provided to supervise the final leak testing, charging and the
initial startup and conduct concurrent operator instruction.
FACTORY INSULATION
Factory-applied, anti-sweat insulation will be attached to the cooler shell, flow chamber, tube sheets, suction connection, and (as
necessary) to the auxiliary tubing. The insulation will be a flexible, closed-cell plastic type, 3/4 inch thick, applied with vaporproof cement. The insulation will normally prevent sweating in environments with relative humidities up to 75% and dry bulb
temperatures ranging from 50 to 90 F.
Printed: 3/19/2010 at 10:51
Filename: 287691162
Reference: 160.73-EG1
Page 5 of 7
YK MAXE CHILLER
MEP-10100 SM Blvd
ISOLATION MOUNTING
Included with the unit are four vibration isolation mounts, consisting of 1" thick neoprene isolation pads, for field mounting. The
pads are to be mounted under the steel mounting pads on the tube sheets. Suitable for ground floor installation.
SHIPMENT FORM #1
The unit shall be completely assembled, with all main, auxiliary, and control piping installed, controls wired, leak tests completed,
air run tests completed, and refrigerant and oil charge in place. Other miscellaneous materials shall be packed separately.
COMPRESSOR MOTOR STARTER
A variable speed drive will be factory installed on the chiller. It will vary the compressor motor speed by controlling the
frequency and voltage of the electrical power to the motor. The adaptive capacity control logic shall automatically adjust motor
speed and compressor pre-rotation vane position independently for maximum part-load efficiency by analyzing information fed to
it by sensors located throughout the chiller.
Drive will be PWM type utilizing IGBTs with a power factor of 0.95 or better at all loads and speeds.
The variable speed drive will be unit mounted in a NEMA 1 enclosure with all power and control wiring between the drive and
chiller factory installed, including power to the chiller oil pump. Field power wiring shall be a single point connection and
electrical lugs for incoming power wiring will be provided. The entire chiller package will be UL listed.
The following features will be provided:
Door interlocked circuit breaker capable of being padlocked.
UL listed ground fault protection.
Over voltage and under voltage protection.
3-phase sensing motor over current protection.
Single phase protection.
Insensitive to phase rotation.
Over temperature protection.
Digital readout at the chiller unit control panel of output frequency, output voltage, 3-phase
output current, input Kilowatts and Kilowatt-hours, self-diagnostic service parameters. Separate
meters for this information will not be acceptable.
KW Meter - The units input power consumption will be measured and displayed digitally via the
units control panel. The KW meter accuracy is typically +/- 3% of reading. KW meter scale is 0 788 KW
KWh Meter The units cumulative input power consumption is measured and displayed digitally
via the units control panel. The KWh meter is resetable and its accuracy is typically +/- 3% of
reading. KWh meter scale is 0 999,999 kWh.
Ammeter Simultaneous three-phase true RMS digital readout via the unit control panel. Three
current transformers provide isolated sensing. The ammeter accuracy is typically +/- 3% of
readming. Ammeter scale is 0 - 545 A RMS .
Printed: 3/19/2010 at 10:51
Filename: 287691162
Reference: 160.73-EG1
Page 6 of 7
YK MAXE CHILLER
MEP-10100 SM Blvd
Voltmeter Simultaneous three-phase true RMS digital readout via the unit control panel. The voltmeter accuracy is
typically +/- 3% of reading. Voltmeter scale is 0 670 VAC.
Elapsed Time Meter Digital readout of the units elapsed running time (0 876,600 hours,
resetable) is displayed via the unit control panel.
Printed: 3/19/2010 at 10:51
Filename: 287691162
Reference: 160.73-EG1
Page 7 of 7
