MODEL YB (DESIGN LEVEL A) - docs.johnsoncontrols.com

INSTALLATION INSTRUCTIONS

MILLENNIUM TM

GAS-ENGINE-DRIVE CHILLERS

Supersedes: Nothing Form 160.66-N1 (1297)

MODEL YB(DESIGN LEVEL A)

NOMENCLATURE

The model number denotes the following characteristics of the unit:

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

mMetric Conversions

28699

YORK INTERNATIONAL2

FIG. 1 � UNIT COMPONENTS

POWER PANEL YORK MICRO PANELENGINE JACKET WATERLOCATION WHEN INSTALLED

CATERPILLARCONTROLPANEL

1T 3KVATRANSFORMER

BATTERYCHARGER

RT4 LEAVINGCOND. WATERSENSOR

RT5 ENTERINGCOND. WATERSENSOR

RT9 ENTERINGCHILLEDWATER SENSOR

RT1 LEAVINGCHILLEDWATER SENSOR

28699A

FORM 160.66-N1

3YORK INTERNATIONAL

PAGE

DIMENSIONS & WEIGHTS........................................................................................ 4, 5

INSTALLATION RESPONSIBILITIES ................................................................................ 6

INTRODUCTION ................................................................................................................. 7

GENERAL .................................................................................................................. 7

INSPECTION - DAMAGE - SHORTAGE .................................................................... 7

LONG TERM STORAGE OF EQUIPMENT & PANELS ............................................. 7

UNIT DATA PLATES................................................................................................... 7

RIGGING .................................................................................................................... 8

LOCATION ................................................................................................................. 8

FOUNDATION ............................................................................................................ 8

CLEARANCES ........................................................................................................... 8

LEVELING / MOUNTING ISOLATORS ...................................................................... 8

COMBUSTION AIR REQUIREMENTS ...................................................................... 8

ENGINE ROOM VENTILATION ................................................................................. 9

EXHAUST SYSTEM ................................................................................................... 9

CRANKCASE VENTILATION ..................................................................................... 14

STARTING SYSTEMS................................................................................................ 17

COMPRESSOR CLUTCH .......................................................................................... 17

COOLING SYSTEMS ................................................................................................. 18

PIPING ....................................................................................................................... 18

WATER AND REFRIGERANT RELIEF PIPING ......................................................... 19

COOLER AND CONDENSER WATER PIPING ......................................................... 19

REFRIGERANT RELIEF PIPING ............................................................................... 21

SOUND ENCLOSURE ........................................................................................................ 22

POWER AND CONTROL WIRING .................................................................................... 22

POWER WIRING........................................................................................................ 22

CONTROL WIRING.................................................................................................... 22

PRESSURE / LEAK CHECK ...................................................................................... 24

INSULATION ...................................................................................................................... 26

COUPLING ALIGNMENT ................................................................................................... 26

SERVICE DURING WARRANTY ....................................................................................... 27

REPORTING PROBLEMS ......................................................................................... 27

SERVICE CALL INFORMATION FORM .................................................................... 29

START-UP INFORMATION FORM ............................................................................ 31

LOG SHEET ............................................................................................................... 33

ENGINE GAUGE RANGES........................................................................................ 34

INSTALLATION CHECK LIST .................................................................................... 35

TABLE OF CONTENTS

YO

RK

INT

ER

NA

TIO

NA

L4

FIG. 2 � UNIT DIMENSIONS (STD DIMENSIONS)

RIGGING WEIGHT = 31,000 LBS.OPERATING WEIGHT = 36,000 LBS.

LD02141(ft)

FO

RM

16

0.6

6-N

15Y

OR

K IN

TE

RN

AT

ION

AL

FIG. 3 � UNIT DIMENSIONS (METRIC DIMENSIONS)

RIGGING WEIGHT = 14,060 KGSOPERATING WEIGHT = 16,330 KGS

LD02141(mm)

All dimensions are in mm.

YORK INTERNATIONAL6

INSTALLATION RESPONSIBILITIES

INTRODUCTION

The �YB� Chiller is a smaller version of the �YG� (YCAT)Chiller. The �YB� is a side-by-side shell assembly witha skid mounted driveline mounted on top of the shells.The driveline consists of:

� Compressor, HA31, (G4) R-134a Refrigerant withPOE Oil

� Single Helical Gear Box

� Caterpillar 3406 inline 6-cylinder natural gas drivenengine

� Electric magneto start (24VDC)

� Eaton Pneumatic Clutch assembly

� Auxiliary Plate & Frame Heat Exchanger (Alfa Laval)

Following are lists of items that must be completed forthe proper installation of a YORK Millennium YB Chiller.These lists are arranged to show who is responsiblefor a particular function:

YORK Service

Caterpillar Service

Mechanical Contractor

Electrical Contractor

Insulating Contractor

These lists are not intended to be the final word onwhat each is expected to do. It is only a guideline as towhat has to be done and you may choose to have someof it done by others. For this reason, you will see thatsome of the tasks appear on more than one list.

The most important part of a successful installation isthat everyone knows ahead of time what is expectedof them and when it is expected to be completed.

Get the Literature out early so questions can be notedand answered in a timely fashion. This alone eliminatesa lot of confusion later.

IMPORTANT:

Overall responsibility for the proper installation ofthe chiller remains with YORK Service.

INSTALLATION (CONTRACTOR REQUIREMENTS)

Mechanical:

1. Install unit on isolators and level.

2. Install condenser and evaporator water lines.

3. Install air compressor and air supply line for pneu-matic clutch and air starter if applicable.

4. Install refrigerant relief piping.

5. Install natural gas line from city supply to engine pres-sure regulator. Verify gas pressure does not exceed5 PSI.

6. Install engine exhaust piping.

Electrical:

1. Supply 480V to the YORK Power Panel.

2. Wire flow switches.

Insulation:

1. Insulate chilled water line and water boxes.

2. Engine exhaust piping.

Caterpillar Dealer:

1. Add Glycol solution to engine.

2. Add oil as required.

3. Adjust engine manifold gas pressure.

4. Perform engine tests as required.

5. Check engine operation and performance after it isstarted.

YORK District Office:

1. Final alignment check of the gearbox to compressorand the gearbox to the engine.

2. Install dowel pins in engine, gearbox, and compres-sor.

3. Check rotation of oil pump.

4. Check and add oil as required to gear box, engine,and compressor.

5. Check all keys on keypad.

6. Verify all information in control is correct.

7. Stroke inlet vanes for calibration.

8. Stroke variable orifice valve for calibration open andclosed.

9. Verify that unit is level.

FORM 160.66-N1

7YORK INTERNATIONAL

GENERAL

This instruction describes the installation of the ModelYB Gas Engine Driven Chiller package. This unit isshipped from the factory in York, PA fully assembledand factory tested. This unit consists of side by sidecooler, condenser with an internal subcooler, a driv-eline consisting of a YORK �YK� Centrifugal compres-sor using the new Ozone friendly refrigerant R-134a, aPhiladelphia gear box (speed increaser) and a CAT-ERPILLAR Model 3406A natural gas fired engine, com-pressor lubrication systems, pneumatic clutch, torsionalvibration reducing coupling and all control panels andrelated electrical components, mounted on a skid andattached to the top side of the shells. The package alsoincludes a factory mounted battery charger for the24VDC circuit backup and starting (electric start mod-els), air pressure and gas pressure regulators and aux-iliary oil reservoir for the engine.

The initial charge of refrigerant (R-134a) and oil (YORK�K� oil) for the compressor is supplied, shipped in con-tainers and cylinders for field installation by YORK.

Installation and assembly will be under the supervisionof YORK factory trained service personnel. All pipingand wiring to complete the installation will be completedin the field. A YORK factory trained Service Technicianwill perform or supervise the final leak testing, pres-sure testing, evacuation and charging the unit with re-frigerant and the initial start-up. The complete installa-tion will be checked for procedural and operational com-pliance by a factory trained Service Technician fromYORK. YORK will retain factory trained service repre-sentatives of the engine manufacturer to provide start-up service and operator instruction for the gas engine.

CAUTION: The YORK Warranty will be voided if thefollowing restrictions are not adhered to:(prior to unit final assembly.)

� No valves or connections should beopened under any circumstances be-cause such action will result in loss ofthe factory nitrogen charge.

� Do not dismantle or open the chiller forany reason except under the direct su-pervision of a YORK representative.

� Do not charge the compressor with oil.

� Do not charge the compressor with re-frigerant.

� DO NOT ATTEMPT TO START THESYSTEM.

� Do not run hot water (110°F/43.3°C max.)or steam through the cooler or condenserat any time.

INSPECTION-DAMAGE-SHORTAGE

The unit shipment should be checked on arrival to seethat all the major pieces, boxes, crates and oil are re-ceived. Each unit should be checked on the trailer orrail car when received, before unloading, for any vis-ible signs of damage. Any damage or signs of possibledamage must be reported to the transportation com-pany immediately for their inspection.

YORK WILL NOT BE RESPONSIBLE FOR ANY DAM-AGE IN SHIPMENT OR AT THE JOB SITE OR ANYLOSS OF PARTS. (Refer to Shipping Damage Claims,Form 50.15-NM.)

When received at the job site, all containers should beopened and the contents checked against the packinglist by the YORK Service Technician. Any material short-age should be reported to YORK immediately. (Referto Shipping Damage Claims, Form 50.15-NM.)

STORAGE (CHILLER & MICRO-PANEL)

Upon delivery the unit should immediately be movedand stored indoors. If it is necessary to store the unitoutdoors, it must be protected from the elements andadverse weather conditions. When exposed to tem-perature changes and/or outdoor weather conditions,it is possible for moisture to find its way into internalareas where it can cause rust. It is the responsibility ofthe installing contractor to see that the equipment isfree of ALL rust at the time of installation. If the equip-ment is to be stored for a period exceeding six (6)months or longer, refer to Forms 50.20-NM1 and 50.20-NM2 (Long Term Storage) for procedures for unit andcontrol panels. See CATERPILLAR Form SEHS9031-02 for long term storage procedures for the engine.

UNIT DATA PLATES

A unit data plate is mounted on the condenser of eachunit. This data plate contains the unit model number,unit part number, unit serial number, refrigerant designworking pressure, liquid design working pressure, num-ber of water passes, shell test pressure, type of andamount (in pounds) of refrigerant, type of YORK oil, elec-trical data and the compressor model & serial number

INTRODUCTION

YORK INTERNATIONAL8

and gear code. The cooler and condenser will each havea National Board Certification data plate. The YORKcontrol panel will have a data plate with its model, serialand part number; and the CATERPILLAR engine willhave a data plate containing the model number, serialnumber and arrangement number. (All correspondencewith CATERPILLAR pertaining to the engine must con-tain the CATERPILLAR engine data plate information.)The information on these data plates should be recordedon the YORK Start-up Form (found in the back of thismanual) for distribution and record retention.

RIGGING

Each chiller has four (4) lifting holes, two (2) on eachside as shown in Figs. 2 or 3. Use care when lifting toavoid damage to any of the unit�s components. Use ofa spreader bar is recommended. Rigging weights areshown in Figs. 2 or 3.

NOTE: Do not remove the rigging until the isolatorsare installed.

LOCATION

The Gas Engine Driven Chiller operating weight shouldbe considered when choosing the unit location. In se-lecting a site, consider structural support, access forservice, and tube pull area.

The chiller should be installed in an indoor locationwhere the temperatures range from 50° to 110°F (10°to 43°C).

FOUNDATION

A LEVEL floor, mounting pad or foundation MUST beprovided by others, capable of supporting the operat-ing weight of the unit. (See Figs. 2 and 3).

CLEARANCES

Sides � 3 ft. (915 mm)

Top � 3 ft. (915 mm)

Ends � 3 ft. (915 mm) for the Driveline

Tube Removal Distance For The Shells � 14 ft.(4267 mm) either end, from outside of the waterbox).

LEVELING / MOUNTING ISOLATORS

Four (4) spring-type isolators are furnished with the unit.They are part of the shipped loose items and shouldbe located and identified upon arrival of the unit. One(1) isolator goes under each corner of the shell pack-

age. The spring isolators (York P/N 029 22351-000)that are furnished are as follows:

� 2 each � GREY OUTTER SPRING W/BLACK IN-NER SPRING GO UNDER THE COMPRESSOREND OF THE UNIT.

� 2 each � GREY OUTTER SPRING W/RED INNERSPRING GO UNDER THE ENGINE END OF THEUNIT.

Each spring isolator has six (6) double springs in themounting.

While the unit is still suspended by the rigging, the iso-lators should be bolted to the unit by inserting the capscrew(s) through the hole(s) in the mounting bracketinto the tapped hole in the top of the isolator levelingbolt(s). The unit can now be lowered to the floor.

The leveling bolts should now be rotated one (1) turnat a time, in sequence, until the unit end sheets areabout 1-3/4" off the floor or foundation, and the unit islevel. Check that the unit is level, both longitudinallyand transversely. If the leveling bolts are not longenough to level the unit due to an uneven or slopingfloor foundation, steel shims (grouted, if necessary)must be added beneath the isolator assemblies asnecessary.

After the unit is leveled, wedge and shim under eachcorner to solidly support the unit in this position whilepiping connections are being made, pipe hangars ad-justed and connections checked for alignment. All wa-ter piping is to be completed per instructions beginningon page 19. Pressure test and leak check all water pip-ing.

The unit should now be filled with water and checkedfor leaks. The leveling bolts should now be adjusteduntil the wedges and shims can be removed. The unitshould now be in correct level position, clear of the flooror foundation and without any effect from the weight ofthe piping. When the unit is properly supported, springisolator installed height should be 6" to 6-1/4".

COMBUSTION AIR REQUIREMENTS

The following factors apply to combustion air require-ments:

1. Supply an airflow of 540 SCFM (255 L/s).

2. Engines must be derated for air temperatures above110°F (43.3°C).

3. Locate the intake away from contaminated airsources.

FORM 160.66-N1

9YORK INTERNATIONAL

4. Air cleaners must be easily inspected (indicators areavailable) and maintained.

For more information on Combustion Air Requirements,refer to Form 160.60-AD1.

ENGINE ROOM VENTILATION

The ASHRAE Standard 15 Safety Code for Mechani-cal Refrigeration requires that all machinery rooms bevented to the outdoors utilizing mechanical ventilationby one or more power-driven fans. This standard, plusNational Fire Protection Association Standard 90A,state, local and other codes should be checked for spe-cific requirements. These requirements should be com-pared to the requirements for engine ventilation to en-sure the equipment is properly ventilated.

A 15° to 20°F (8° to 11°C) temperature rise is a rea-sonable target for engine rooms. In cold climates, dis-comfort may be caused by the flow of cold air. Restrictflow only if engine combustion air is available.

Correct routing of ventilation air is vital. Without it, air-flow will not adequately maintain comfortable engineroom temperatures. Engine room temperature shouldnot exceed 110°F (43.3°C).

Openings for intake air should be low, and positionedto admit the coolest, cleanest air possible. Position out-lets high on the opposite wall or roof. If automatic damp-ers are required to admit cooling and combustion air,the control logic should open the dampers immediatelyon engine start-up.

Examples of good ventilation systems are shown in Figs. 4and 5. Both systems bring the air in low across the engineand remove the heated air from above the engine(s).

The system shown in Fig. 6 is an example of very poorventilation. This system provides little air flow across

the engine and does not circulate air throughout theengine room.

Intake and exhaust ventilators may have movable orfixed louvers for weather protection. If movable, actu-ate by pneumatic, electric, or hydraulic motors. Neverdepend on air pressure developed by a fan to movethe vanes.

The primary reason for cooling an engine room is toprotect various components from excessive tempera-tures. Items that require cooling are:

� Electrical components such as magnetos, interfacebox timing control, and control panels.

� Cool air to the air cleaner inlet.

� Avoid engine pre-ignition/detonation.

� Cool air to cool the torsional damper.

� Habitable temperatures for the engine operator orservice personnel.

In larger multiple engine sites, the normal 15° or 20°F(8° to 11°C) temperature rise guidelines for enginerooms require unobtainable or uncomfortable air ve-locities. For larger sites, a ventilation system that givespriority to the items listed above and provides a bottomto top air flow similar to that shown in Figs. 4 and 5 canbe designed for temperature rise of 30°F (17°C). Formore information on Engine Room Ventilation, refer toForm 160.60-AD1.

EXHAUST SYSTEM

General

Exhaust systems collect exhaust gases from enginecylinders and discharge them as quickly and silentlyas possible. A primary aim of the exhaust system is tominimize backpressure since exhaust gas restrictionscause horsepower losses and exhaust temperature in-creases.

FIG. 4 � CORRECT VENTILATION

LD00765

FIG. 5 � CORRECT VENTILATION

LD00765

YORK INTERNATIONAL10

Exhaust Backpressure

The exhaust backpressure for Caterpillar gas enginesis limited to 27 in. H

2O (6.7 kPa) on turbocharged (TA)

engines.

Measure exhaust system backpressure from a straightlength of the exhaust pipe at least 3 to 5 pipe diam-eters away from the last size transition and as close tothe engine as is possible.

Piping

Physical characteristics of the equipment room deter-mine exhaust system layouts. Arrangements with mini-

FIG. 6 � INCORRECT VENTILATION

LD00766

LD00767

LD00768

FIG. 7 � AIR FLOW EXAMPLES

mum backpressures are favored. Securely supportpipes with rubber dampers or springs installed in thebracing to isolate vibrations.

Piping must be designed with engine service in mind.In many cases, an overhead crane will be used to ser-vice the heavier engine components.

Install piping with 9 in. (229 mm) minimum clearancefrom combustible materials. Lagging exhaust pipes withsuitable, high temperature insulation or installing pre-fabricated insulation sections over the pipe preventsheat radiation. Exhaust piping passing through woodenwalls or roofs require metal thimble guards 12 in. (305mm) larger than the pipe diameter, see Fig. 8.

FORM 160.66-N1

11YORK INTERNATIONAL

Extend exhaust stacks to avoid heat, fumes and odors.Also, the exhaust pipes should not be in close proximityto the air intake system for the engine or the crankcaseventilation system. Engine air cleaners, turbochargers,and aftercoolers clogged with exhaust product can causepremature failures. Pipe outlets cut at 30° to 45° angleswill reduce gas turbulence and noise. Rain caps forcedopen by exhaust pressure will keep water from enter-ing. Gas engines burning natural gas create one poundof water for each 10 ft3 of natural gas burned. For thisreason, long runs of exhaust piping require traps to drainmoisture. Traps installed at the lowest point of the linenear the exhaust outlet prevent rain water from reach-ing the engine. Slope exhaust lines from engine to thetrap so condensation will drain, see Fig. 8.

Although economically tempting, a common exhaustsystem for multiple installations is not acceptable. Com-bined exhaust systems with boilers or other enginesallow operating engines to force exhaust gases into

engines not operating. Water vapor created during com-bustion will condense in cold engines and quicklycauses engine damage. Duct valves separating engineexhausts is also discouraged. High temperatures warpvalve seats, causing leakage.

Exhaust draft fans have been applied successfully incombined exhaust ducts, but most operate only when-ever exhaust is present. To prevent turbochargerwindmilling (without lubrication), the fans should notbe operable when the engine is shut down. The ex-haust system of non-running engines must be closedand vented.

Flexible Connections

The exhaust pipe must be isolated from the engine withflexible connections. Install the flexible connectionsclose to the engine exhaust outlet. A flexible exhaustconnection has three primary functions:

FIG. 8 � EXHAUST PIPING � ExampleLD00769


� To isolate the weight of the exhaust piping from theengine.

� To relieve exhaust components of excessive vibra-tional fatigue stresses.

� Allow relative shifting of exhaust components. Thishas numerous causes. It may result from expan-sion and contraction due to temperature changes,by creep processes that take place throughout thelife of any structure, or torque reactions when theengine mounts on spring type isolators.

Pre-stretch the exhaust bellows during installation toallow for thermal growth. Four small straps can be tack-welded between the two end flanges to hold the en-gine exhaust bellows in a rigid position during exhaustpiping installation. This will prevent the bellows frombeing installed in a flexed condition. Attach a warningtag to the bellows noting that the weld straps must beremoved prior to starting the engine.

The installation limitations of the Caterpillar suppliedflexible exhaust bellows are shown on Fig. 9.

Section long pipe runs with expansion joints. Each sec-tion is fixed at one end and allowed to expand at theother. Supports are located to allow expansion away fromengine, avoid strains or distortions to connected equip-ment, and to allow equipment removal without additionalsupport. A restraint member is often used to keep theends of a long pipe run fixed in place, forcing all thermalgrowth towards the expansion joints. See Fig. 10.

Flexible pipe connections, when insulated, must ex-pand and contract freely within the insulation. This gen-erally requires a soft material or insulated sleeve toencase the connection.

Piping connected to chillers requires isolation. Thesepipes could otherwise transmit vibrations long dis-

A B C

HOSE MAXIMUM OFFSET MAXIMUM COMPRESSION MAXIMUM EXTENSION

DIAMETER BETWEEN FLANGES FROM FREE LENGTH FROM FREE LENGTH

in. mm in. mm in mm

4" & 5" 1.0 25.4 0.25 6.25 0.25 6.25

6" 1.5 38.1 0.25 6.25 0.25 6.25

Installation Limitations of Flexible Metal Hose-Type Exhaust Fittings

A B C

BELLOWS MAXIMUM OFFSET MAXIMUM COMPRESSION MAXIMUM EXTENSION

DIAMETER BETWEEN FLANGES FROM FREE LENGTH FROM FREE LENGTH

in. mm in. mm in mm

8" & 12" 0.75 19.05 1.50 38.1 1.00 25.40

14" 0.75 19.05 3.00 76.2 1.00 25.40

18" 0.90 22.86 3.00 76.2 1.75 44.45

Installation Limitations of Bellows -Type Flexible Exhaust Fittings

FIG. 9 � FLEXIBLE EXHAUST BELLOWS

Spring Rate for Bellows-Type Flexible Fittings

DIAMETERSPRING TYPE

lb./in. kN/m

8" 170 29.712" 194 33.914" 391 68.918" 110 19.3

LD00770

FORM 160.66-N1


tances. Isolator pipe hangers, if used, should havesprings to attenuate low frequencies, and rubber or corkto minimize high frequency transmissions. To preventbuild-up of resonant pipe vibrations, support long pip-ing runs at unequal distances. See Fig. 11.

Exhaust Connections

All gas engines use a fixed, 5" round exhaust outlet.

Cleanliness

Install an identifiable blanking plate to prevent debrisfrom falling into the turbocharger during installation. TheCaterpillar shipping cover can be used for this purpose.Install it directly on top of the turbine housing. Attach awarning tag to the plate indicating it must be removedprior to starting the engine.

Silencer Selection and Installation

The following are some general guidelines to aid inproper selection of the silencer.

LD00771

LD00772

FIG. 11 � PIPE SUPPORT SPACING

Use silencer supplier data, correct for outlet tempera-ture and velocity. Determine silencer size and type thatsatisfies noise reduction criteria with 2 to 3 in. H

2O, (.5

to .75 kPa) maximum pressure drop.

After calculating pressure loss, it may be necessary tocheck a second silencer, or a different pipe size, be-fore an optimum combination is achieved.

FIG. 10 � DRY EXHAUST SYSTEM


INSTALLATION: Provide a minimum of 5 diametersof straight piping upstream from the silencer inlet, and2.5 diameters downstream from the silencer outlet tominimize turbulence and backpressure.

When practical, orient the silencer vertically and useside inlets to eliminate extra inlet and discharge elbows.If not practical, insure the radius of all elbows is twotimes the pipe diameter.

A heat resistant material is required if lagging is usedon the silencer to reduce radiated heat.

Exhaust thimbles separate the exhaust pipe from wallsor ceiling to provide mechanical and thermal isolation.Single sleeve thimbles must have diameters at least12 in. (305 mm) larger than the exhaust pipe. Doublethimbles (inner and outer sleeve) should have outsidediameters at least 6 in. (152 mm) larger than the ex-haust pipe.

CRANKCASE VENTILATION

General

Normal combustion pressures of an internal combus-tion engine cause a certain amount of blow-by pastpiston rings into the crankcase. To prevent pressurebuildup within the crankcase, vent tubes are providedto allow gas to escape.

Do not vent crankcase fumes into the engine room.Fumes will clog air filters and increase air inlet temper-ature, possibly causing engine damage. Problems inelectrical equipment can be caused by exposure to thefumes. The fumes can also be a health hazard if dis-charged in a poorly ventilated room.

Discharge crankcase fumes to the atmosphere throughventing systems. A separate vent line for each engineis required on engines with a passive ventilation sys-tem. This is to prevent fumes and moisture producedby a running engine from entering an idle engine. Thiscauses corrosion and buildup of harmful deposits.

Crankcase vent pipes must be large enough to mini-mize back pressure. Normal blow-by on a new enginewill be approximately .5 ft3/hr bhp (.02 m3/hr bkW). Ad-equately size the pipes to accommodate a worn en-gine, 1 ft3/hr bhp (.04 m3/hr bkW). Size the vent pipewith a maximum of 0.5 in. H

2O (13 mm H

2O) pressure

drop at full load.

Loops or low spots in a crankcase vent pipe must beavoided to prevent condensation from building up inthe pipe and restricting the normal fumes discharge.Where horizontal runs are required, install the pipe witha gradual, 1/2 in/ft (41.7 mm/m), slope from the en-gine, see Fig. 12. The weight of the vent pipes will re-quire separate off-engine supports as part of the in-stallation design. Any horizontal or vertical run of pipethat cannot be disassembled for cleaning should haveclean-out ports installed.

Crankcase fumes must not discharge into the air venti-lation ducts or exhaust pipes. They will become coatedwith oily deposits creating a fire hazard.

Vent the crankcase pipe directly into the atmosphereand direct it to keep rain or spray from entering theengine. Give consideration to equipment located nearthe discharge area as well as to the building itself. Ifnot handled properly, very small amount of oil carry-over can accumulate and become unsightly and evenharmful to auxiliary equipment.

FIG. 12 � CRANKCASE VENTILATIONLD00773

FORM 160.66-N1


A drip collector installed near the engine will minimizethe amount of oil discharge through the vent pipe. It isnecessary to provide some type of trap that will pre-vent crankcase gases from venting into the engineroom, see Fig. 13. If a trap like in Fig. 13 is used, thedesigner must be sure the drip collector can be removedor drained for disposal. Another alternative is to installa valve on the end of the drip pipe and periodicallydrain it.

Under no circumstances should crankcase pressuresvary more than 1.0 in. H

2O (25.4 mm H

2O) from ambient

barometric pressure. Restrictions higher than the limiton passive systems will worsen any oil leaks. A pow-ered system should draw no more than a 1.0 in. H

2O

(25.4 mm H2O) vacuum, or dirt and dust could be drawn

into the engine past the main seals. Measurement shouldbe made at the engine dipstick location with the engineat operating temperature, speed and load.

FIG. 13 � CRANKCASE VENTILATION

LD00774


Fig. 14 illustrates a powered fumes disposal systemfor a multiple engine installation. There are two mainadvantages to a powered system: the fumes will be-come diluted with air for better dispersal into the atmo-sphere, and it can improve oil life by removing the ni-tric oxides from the crankcase before they can causenitration of the oil.

Since a vacuum will be drawn with a powered system,the addition of a small air filter somewhere on the en-gine crankcase is required. This will filter the air enter-ing the crankcase and prevent dirt from being introducedinto the oil. A valve connected in the line to each enginecontrols the flow of crankcase fumes out of the engine.

Sometimes it is difficult to precisely size the blower fora powered system. If the only blower available is toolarge, it may draw too much vacuum on the crankcaseventilation valves and make adjustments difficult. Toovercome this problem, a balance valve can be con-nected on the vacuum side of the blower to allow air tobe drawn in the system and reduce the vacuum pres-sure on the adjusting valves.

On G3600 Engines, a relief valve is required to limitcrankcase pressure to .14 kPa (.5 in H

2O) to avoid a

shutdown if the crankcase ventilation fan is not en-gaged.

LD00775

FIG. 14 � POWERED CRANKCASE VENTILATION (MULTIPLE ENGINES)

FORM 160.66-N1


STARTING SYSTEMS

The engine starting system can be furnished as eitherelectric or air start. An electric starting system includes24 volt DC starting motor(s), starting relay, batterycharger (if supplied), and automatic reset circuit breakerto protect against butt engagement. Batteries are leadacid type mounted on a corrosion resistant rack nearthe starting motor. The battery charger is shipped sepa-rately for field mounting. All electric starting system com-ponents including wiring and cable will be furnished andinstalled by the engine manufacturer. (See Fig. 15.)

FIG. 15 � ELECTRIC START

An air start system includes air starting motor(s), si-lencer, start valve, and pressure regulator. Batteriesare also supplied for 24 volt DC back-up.

Compressed air from a 110 to 250 psi (758 to 1723kPa) source is regulated to 110 psi (759 kPa) and pipedto the air motor. Allowances must be made for pres-sure drops in the air lines from the air source to theregulator. Compressed air may originate from air re-ceivers and plant air.

A check valve between plant air and receiver assuresthat failure of plant air will not deplete the backup sup-ply.

Air motor supply pipes (field supplied) should be short,direct, and at least equal in size to the motor intakeopening. Black iron pipe is preferable and should besupported to avoid stresses on the compressor. Flex-ible connections between motor and piping are re-quired.

COMPRESSOR CLUTCH

A source of compressed air is required for the com-pressor clutch. A packaged air compressor with the fol-lowing characteristics is suitable:

Min. Compressor Rating � 1 HP

Min. Storage Tank Volume � 30 Gal.

Min. Capacity � 5 SCFM

CLUTCH AIR PRESSURE ADJUSTMENT

Connect the air supply to the unit air pressure regula-tor.

Set the source (air compressor / facility air line supply)to 130 psi and open the shutoff valve.

Open the Caterpillar control panel and put a jumperwire across terminals 301 and 5 on the Caterpillar ter-minal strip.

When the jumper wire is attached, the clutch solenoidwill energize and fill the clutch air bladder with air. Ad-just the clutch air pressure regulator to 110 psi.

Verify that there are no air leaks when the clutch airbladder is filled with air. Pay special attention to the airpipe on the clutch spider assembly.

ENGINE CUT IN CUT OUTSIZE PRESSURE PRESSURE

3406 105 PSI 120 PSI

28708A


The clutch should fill with air and reach full pressurewithin two (2) seconds after applying the jumper wire.

Adjust the clutch air needle valve as required to get thedesired rate of fill. Turn the needle valve CCW (open)for more air � less time.

Remove the jumper wire from one of the terminals tode-energize the clutch solenoid valve. The air bladdershould exhaust through the muffler located on the so-lenoid valve. The exhaust should be complete withintwo (2) seconds after the jumper wire is removed.

Go through several fill / exhaust cycles to confirm op-eration.

DISCONNECT AND REMOVE the jumper wire be-tween terminals 301P and 5 in the Caterpillar Panel.

COOLING SYSTEMS

Cooling System � All waterside heat rejection fromthe driveline will be accomplished through a manifoldedassembly of heat exchangers such that only a singlepoint tower water supply and return connection is re-quired. (See Figs. 2 or 3 for piping connection loca-tion.) The engine jacket water cooling system is a closedcircuit design with provision for filling, expansion anddeaeration. The cooling pump will be driven by the en-gine. The engine jacket coolant loop will in turn becooled with a cleanable plate type heat exchanger op-erating with cooling tower water. The maximum design

cooling tower water supply temperature is 85°F. SeeTable 1 for water flow rates. Aftercooler will be plateand frame type heat exchanger. Oil cooler is shell andtube type.

Cooling system water must be clean and free of for-eign material. A strainer (3/32" mesh max.) should beinstalled in the water inlet line to the cooler(s) and con-denser. As a preventive measure against scale andcorrosion and to prolong the life of coolers, a chemicalanalysis of the water should be made, preferably be-fore the system is installed. A reliable water treatmentcompany can be consulted to determine whether treat-ment is necessary, and if so, to furnish the proper treat-ment for the particular water condition.

Coolant temperature will be internally regulated to by-pass external cooling systems until operating tempera-ture is achieved. Also see section on PIPING (Fig. 17)or refer to Form 160.60-AD1.

PIPING

Cooling

After the driveline is leveled (and wedged in place) thepiping connections may be made up. The piping is tobe arranged, adequately supported, and braced inde-pendently of the unit to avoid strain on the unit. Hang-ers must allow for alignment of pipe. Isolators (by oth-ers) in the piping and hangers are highly desirable, andmay be required by specifications, in order to effec-tively utilize the vibration isolation characteristics of the

TABLE 1 � DRIVELINE COOLING SYSTEM DATA

ENGINE MODEL G3406

Water Flow (GPM) 130.0

Max. Temp. IN (°F) 85.0

Temp Out (°F) 105.0

TABLE 2 � GAS SUPPLY PRESSURE TO DRIVELINE

Required Gas ENGINE MODEL

Pressure (PSIG) G3406

MIN. 1.5

MAX. 5

FORM 160.66-N1


vibration isolation mounts of the unit. Flexible connec-tions must be used to allow for driveline movement andreduce vibration transmission.

Check for piping alignment � Upon completion ofpiping, a connection in each line as close to the unit aspossible should be opened, by removing the flange boltsor coupling and checked for piping alignment. If any ofthe bolts are bound in their holes, or if the connectionsprings out of alignment, the misalignment must becorrected by properly supporting the piping or by ap-plying heat to anneal the pipe.

NOTE: If the piping is annealed to relieve stress, theinside of the pipe must be cleaned of scalebefore it is finally bolted in place.

Fuel Piping

Piping must be supplied to the fuel inlet on the drive-line. Fuel inlet connection is a 150 lb., 2" ANSI flange.(See Figs. 2, 3 or 4.) Gas supply pressure to the drive-line mounted regulator must be maintained as shownin Table 2. The gas supply pressure must be maintainedwithin + 0.25 psi above the nominal setpoint through-out the engine operating range. Piping should be madewith flexible connections. This will isolate the fuel linefrom the vibration and movement of the engine. Theflexible connection must be compatible with the opera-tional gas, pressures and temperatures.

All piping must be cleaned, leak tested, pressure testedand bled of air. The fuel piping must include a dirt trapin the vertical leg to intercept any foreign material andpermit clean-out. A connection for measuring gas pres-sure should be included.

WATER AND REFRIGERANT RELIEF PIPING

After the unit is leveled (and wedged in place) the pip-ing connections may be made up; chilled water, con-denser water, driveline heat exchanger, and refriger-ant relief. The piping should be arranged with offsetsfor flexibility, and adequately supported and braced in-dependently of the unit to avoid strain on the unit andvibration transmission. Flexible connections should beused to reduce vibration transmission. Hangers mustallow for alignment of pipe. Isolators (by others) in thepiping and hangers are highly desirable, and may berequired by specifications, in order to effectively utilizethe vibration isolation characteristics of the vibrationisolation mounts of the unit.

Check for piping alignment � Upon completion of pip-ing, a connection in each line as close to the unit aspossible should be opened, by removing the flange boltsor coupling and checked for piping alignment. If any ofthe bolts are bound in their holes, or if the connectionsprings out of alignment, the misalignment must be cor-rected by properly supporting the piping or by applyingheat to anneal the pipe.

NOTE: If the piping is annealed to relieve stress, theinside of the pipe must be cleaned of scale be-fore it is finally bolted in place.

COOLER AND CONDENSER WATER PIPING

The cooler and condenser liquid heads have nozzleswhich are fitted with 150 lb. ANSI raised face flanges.

The nozzles and water pass arrangements are fur-nished in accordance with the job requirements. Stan-dard units are designed for 150 PSIG DWP on the wa-ter side. If job requirements are for greater than 150PSIG DWP, check the unit data plate before applyingpressure to cooler or condenser to determine if the unithas provisions for the required DWP.

Chilled Water

Foreign objects which could lodge in, or block flowthrough, the cooler and condenser tubes must be keptout of the water circuit. All water piping must be cleanedor flushed before being connected to the shells, pumps,or other equipment.

Permanent strainers (3/32" mesh max. by others) arerequired in both the cooler and condenser water cir-cuits to protect the chiller as well as the pumps, towerspray nozzles, chilled water coils and controls, etc. Thestrainers should be installed in the entering water lines,up-stream of the chiller.

Water piping circuits should be arranged so the pumpsdischarge through the chiller, and should be controlledas necessary to maintain essentially constant chilledand condenser water flows through the unit at all loads.

If pumps discharge through the chiller, the strainer maybe located upstream from pumps to protect both pumpand chiller. (Piping between strainer, pump and chillermust be very carefully cleaned before startup.) If pumpsare remotely installed from chiller, strainers should belocated directly upstream of the chiller.


Condenser Water Circuit

For proper operation of the unit, condenser refrigerantpressure must be maintained above cooler pressure.If operating conditions will fulfill the requirement, no at-tempt should be made to control condenser water tem-perature by means of automatic valves, cycling of thecooling tower fan or other means, since chillers aredesigned to function satisfactorily and efficiently whencondenser water is allowed to seek its own tempera-ture level at reduced loads and off-peak seasons ofthe year. On chiller installations where cooling towerreturn water temperature is controlled, controllertuning must be adjusted such that at least two andone half minutes elapse for each one degree changein return water temperature supplied to the chillercondenser. At start-up, the entering condenser watertemperature may be as much as 25°F colder than thestandard return chilled water temperature. Refer to Fig.17 for typical water piping schematic.

Install a cleanable strainer (3/32" mesh max.) in theentering water side of the condenser.

NOZZLE SIZES RANGE FROM 8" THRU 18" PIPE AND UTILIZEANSI 150# SLIP-ON RAISED FACE FLANGES.

NOZZLE SIZE GASKET O.D.

8" 11"10" 13-3/8"12" 16-1/8"14" 17-3/4"16" 20-1/4"18" 21-5/8"

FIG. 18 � CONDENSER OUTLET

LD00779

FIG. 17 � SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT FOR GAS-ENGINE-DRIVE CHILLER

LD02596

NOTES:

1. Driveline shown separate from shells for clarity.

2. Engine heat exchanger piping factory mounted.

FORM 160.66-N1


FIG. 18 � REFRIGERANT VENT PIPING LD00781

Stop Valves

Stop valves may be provided (by others) in the coolerand condenser water piping, and auxiliary heat ex-changer adjacent to the unit to facilitate maintenance.Thermometer wells and pressure taps should be pro-vided (by others) in the piping as close to the unit aspossible to facilitate operating checks.

Flow Switches (Field Installed)

A flow switch or pressure differential control by YORKor others must be installed in the chilled water line(s)adjacent to the unit for connection to the control cen-ter. If a flow switch is used, it must be directly in serieswith the chiller and sensing only water flow through thechiller. It should be located in cooler outlet side. Thedifferential switch must sense pressure drop across theunit.

Drain and Vent Valves

Drain and vent valves (by others) should be installedin the connections provided in the cooler and condenserliquid heads. These connections may be piped to drainif desired.

Checking Piping Circuits and Venting Air

After the water piping is completed, but before any wa-ter box insulation is applied, tighten and torque (to main-tain between 30 and 60 ft. lbs.) the nuts on the liquidhead flanges. Gasket shrinkage and handling during

transit cause nuts to loosen. If water pressure is ap-plied before this is done, the gaskets may be damagedand have to be replaced. Fill the chilled and condenserwater circuits, operate the pumps manually and care-fully check the cooler and condenser water heads andpiping for leaks. Repair leaks as necessary.

Before initial operation of the unit, both water circuitsshould be thoroughly vented of all air at the high points.Also, purge air through valves on top of the water boxes.

REFRIGERANT RELIEF PIPING

Each unit is equipped with dual pressure relief valveslocated on the cooler for the purpose of quickly reliev-ing excess pressure of the refrigerant charge to theatmosphere as a safety precaution in case of an emer-gency, such as fire.

Refrigerant relief vent piping (by others), from the re-lief valves to the outside of the building, is required bycode in most areas and should be installed on all chill-ers. The vent line should be sized in accordance withthe ANSI/ASHRE-15, or local code, but should neverbe smaller than shown in Fig. 18. The vent line mustinclude a dirt trap in the vertical leg to intercept andpermit clean out and to trap any vent stack condensa-tion. The piping MUST be arranged to avoid strain onthe relief valves, using a flexible connection, if neces-sary. Operation is with one valve open and one valveclosed.


SOUND ENCLOSURE

If the installation is to include a sound enclosure aroundthe chiller, the following points should be considered:

1. The room must be well lighted (by others).

2. The panels must be removable and open outwards.

3. Be sure control panels are visible through the pan-els and/or door.

4. Be sure there is adequate fresh air supply for theengine. (See Combustion Air Requirement, page 8

and �Engine Room Ventilation�, Figs 4, 5, 6, and 7.)Also there must be adequate air removal so the roomtemperature does not exceed 110°F (43.3°C). Forbest results, the intake air into the room should befiltered.

5. Maintain ample space to perform daily checkssuch as checking and adding oil, checking andadding glycol and checking and changing the aircleaners.

POWER AND CONTROL WIRING

POWER WIRING

480-460 Volt, 3-Phase, 60 Hertz power must be sup-plied to the Power Panel. (See Fig. 19.)

The 115 Volt to YORK panel is made when 480 Volt issupplied to Caterpillar panel.

Control power supply (115V - 50/60 Hz) 15 ampere ca-pacity for control center, is supplied by a control powertransformer, factory mounted and wired.

115-1-60 current must be supplied to the battery charg-er, via a field installed circuit connected to terminal 119and 2 in the Power Distribution Panel.

28715A

FIG. 19 � AC POWER PANEL

CONTROL WIRING

Most control wiring is completed at the factory. How-ever, all wiring between the driveline and shells mustbe completed in the field. Shielded cables for all shell-

side sensors are bundled for shipment behind the mi-cro panel. The high pressure cutout switch circuit mustbe completed in the field. Refer to Fig. 20 for locationof connection points.

TABLE 3 � ELECTICAL REQUIREMENTS

AC POWER PANEL LUG SIZE RANGE #14 - #4

JACKET WATER HEATER KW 6

MINIMUM CIRCUIT AMPACITY 17.1

MINIMUM FUSE SIZE 25

MAXIMUM FUSE SIZE 30

NOTE: All values are for 460V � 3-Phase � 60 Hz electrical service.

FORM 160.66-N1


FIG. 20 � YORK MICRO PANEL THERMISTORS AND TRANSDUCERS

LEGEND

RT1 LEAVING CHILLED WATER SENSORRT2 DISCHARGE TEMP. SENSORRT3 OIL TEMP SENSORRT4 LEAVING CONDENSER WATER SENSORRT5 ENTERING CONDENSER WATER SENSORRT9 ENTERING CHILLED WATER SENSORRT10 AFTER-COOLER GLYCOL TEMP.T1 TRANSFORMERLLS LIQUID LEVEL SENSORHOP HIGH OIL PRESS TRANSDUCERLOP LOW OIL PRESS. TRANSDUCERCP CONDENSER PRESS. TRANSDUCEREP EVAPORATOR PRESS. TRANSDUCER1-SOL OIL RETURN SOLENOID VALVE2-SOL LIQUID LINE SOLENOID VALVE3-SOL* VENT LINE SOLENOID VALVE4-SOL HIGH SPEED THRUST SOLENOID VALVE1 HTR OIL RESERVOIR HEATER (115VAC)2 HTR OIL RESERVOIR HEATER (OIL PUMP VOLTAGE)PRV PRE-ROTATION VANE MOTOROVA ORIFICE VALVE ACTUATORVMP EXTERNAL MOTOR VANE POT.VTS VIBRATION TRANSMITTER SENSOR(CES) CLUTCH ENGAGED SOLENOID(CEPS) CLUTCH ENGAGED PRESSURE SWITCH(HGOTS) HIGH GEAR OIL TEMP.(LGOTS) LOW GEAR OIL TEMP.(IMPT) INLET MANIFOLD PRESSURE TRANSDUCER(OPT) OIL PRESSURE TRANSDUCER(WLS) LOW JACKET WATER LEVEL SENSOR(LGOP) LOW GEAR OIL PRESSURE( ) CATERPILLAR ITEMS.

* UNITS BUILT AFTER JUNE 1997 WILL NOT HAVE THE VENTLINE SOLENOID INSTALLED.

LD02398(R)

VTS

RT10

RTDW.L.S.

(IMPT)

(OPT)

J.W.HEATER

RT2

PRV

4-SOL

2-SOL

1-SOL

GEAR OILHEATER

T1

BATTERYCHARGER

ENGINEPANEL

YORK MICROCOMPUTERCONTROL CENTER

(CES)

(CEPS)

OILRESERVOIR(SEE DETAIL)

COOLER

RT1

RT9

CONDENSER

RT4

RT5LLS

H.P. CUTOUT

*3-SOL

VMP

(LGOP)

(LGOTS)(HGOTS)

OVALOP

2 HTR

RT3

1 HTR

OIL RESERVOIR DETAIL

LD02397

PROX PROBELOCATION ONCOMPRESSOR


PRESSURE/LEAK CHECK

The following procedure is to be performed in the fieldbefore insulating the unit.

Contractor to provide supply of N2 sufficient to pressur-

ize system to 180 PSIG. Several pressurizations maybe required. Leak test will be made with electronic leakdetector and R22/N

2 gas mixture composition of 5%/

95% R22/N2 respectively. �S� shells will require 64 lbm

R22 and 390 lbm N2 minimum to do one leak check,

approximately (4) N2 cylinders with 125 lbm charge.

1. Remove relief valve from shells, if factory installed,and plug shell connection.

2. Install bar manifold gauge, or other appropriategauge to read from 30" mercury vacuum to at least200 PSIG, on shells.

3. Open low side charging valve (see Fig. 26) andevacuate system to 29 inch mercury vacuum.

4. Gas off system with R22 until pressure rises to 14inch mercury vacuum.

5. Connect N2 supply and gradually raise system pres-

sure to 180 PSIG. Check for leaks with electronicleak detector. Steady leakage rates in excess of 1oz. per year are not acceptable.

6. If an excessive steady leak is found, the pressureshould be reduced, the leak repaired, and the testrepeated.

7. After successful leak check, reduce system pres-sure to 1 atmosphere and install the relief valve onits shell connection.

8. Evacuate the system to 2 mm mercury absolute(2000 micron). Stop the vacuum pump and checkpressure rise rate over at least a one hour period.Pressure must not rise greater than 150 micron/hour.

9. Locate and repair vacuum leaks if required.

TABLE 4 � SYSTEM PRESSURES (STANDARD)

*GAUGE ABSOLUTEBOILING

INCHES OF TEMPERATURESMERCURY (HG) MILLIMETERS OF

BELOW ONE PSIA OF MERCURY MICRONS WATERSTANDARD (HG) °F

ATMOSPHERE

0 14.696 760. 760,000 21210.24" 9.629 500. 500,000 19222.05" 3.865 200. 200,000 15125.98" 1.935 100. 100,000 12427.95" .968 50. 50,000 10128.94" .481 25. 25,000 7829.53" .192 10. 10,000 5229.67" .122 6.3 6,300 4029.72" .099 5. 5,000 3529.842" .039 2. 2,000 1529.882" .019 1.0 1,000 +129.901" .010 .5 500 �1129.917" .002 .1 100 �3829.919" .001 .05 50 �5029.9206" .0002 .01 10 �7029.921" 0 0 0

*One standard atmosphere = 14.696 PSIA

= 760 mm Hg. absolute pressure at 32°F

= 29.921 inches Hg. absolute at 32°F

NOTES: PSIA = Lbs. per sq. in. gauge pressure= Pressure above atmosphere

PSIA = Lbs. per sq. in. absolute pressure= Sum of gauge plus atmospheric pressure

FORM 160.66-N1


TABLE 4A � SYSTEM PRESSURES (METRIC)

GAUGE ABSOLUTEBOILING

TEMPERATURESKILOPASCALS MILLIBARS OFBELOW ONE KILOPASCALS OF MERCURY MICRONS WATERSTANDARD (HG) °C

ATMOSPHERE

0 101.3 1013.1 760,000 100.0

34.7 66.4 666.5 500,000 88.9

74.7 26.6 266.6 200,000 66.1

88.0 13.3 133.3 100,000 51.1

94.6 6.7 66.7 50,000 38.3

98.0 3.3 33.3 25,000 25.6

100.0 1.3 13.3 10,000 11.1

100.5 .84 8.4 6,300 4.4

100.6 .68 6.7 5,000 1.7

101.1 .27 2.7 2,000 �9.4

101.2 .13 1.3 1,000 �17.2

101.3 .069 .67 500 �23.9

101.3 .014 .13 100 �38.9

101.3 .007 .07 50 �45.6

101.3 .0014 .013 10 �56.7

101.3 0 0 0


INSULATION

NOTE:Do not insulate until the unit has been leak testedunder the supervision of the YORK representa-tive.

No appreciable operating economy can be achievedby thermally insulating the chiller. However, the chillercold surfaces should be insulated with a vapor barrierinsulation to prevent condensation. The insulation de-scribed below will normally prevent condensation in en-vironments with dry bulb temperatures of 50°F to 90°Fand relative humidities up to 75%.

Insulate the chiller water lines, water boxes, and ex-haust piping. Tape insulation around water boxes toallow for removal. Do not glue.

Insulation at flanged joints must be designed to permitremoval for access to nuts and bolts.

Insulation is not furnished by YORK. Insulation sheetshall be flexible, closed cell composition of expandedpolyvinyl chloride (PVC). Suitable for thermal insula-tion and condensation control. 3/4" thick minimum. Kat 75°F = 0.25 max Btu-In./Sq. Ft./Hr./°F.

Testing to prove system leak-tight to be done prior toinstalling insulation.

COUPLING ALIGNMENT

Final (Cold) Alignment

Before starting this procedure the unit must be chargedwith refrigerant, the compressor oil sump must becharged with 20 gallons YORK �K� Oil, (4-5 gallon con-tainers, YORK P/N 011-00533-000 per 5 gallon con-tainer), supplied with the unit; and have water in thecooler and condenser.

Check the oil level sight glass on the side of the Phila-delphia Gear box to make sure the oil level is at the�full indicator line� (approximately ½ way on the oillevel sight glass) If it is not, add �EP� oil YORK P/N011-00857-000 until the oil level reaches the horizon-tal line on the sight glass.

The pre-startup/final alignment check may be doneusing dial indicators or a Laser Alignment tool.

Remove the safety guards from the clutch on the Cat-erpillar engine and the coupling on the low speed shaftfrom the gear box to the compressor. Remove the �shimpacks� from the compressor coupling.

The maximum number of shims under any one mount-ing foot is five (5).

When making any adjustments on the gear box or thecompressor ALL mounting bolts MUST be loosenedto permit free movement.

Cold Alignment Procedure

Cold alignment can only be done when the unit isCOLD. The alignment cannot be done if the systemhas run or has had AC power turned on within eight (8)hours.

Compressor to Speed Increaser Axial:

Position the compressor shaft all the way forward andthe speed increaser shaft at midplay. Target separa-tion from the end of the compressor low speed shaft tothe end of the speed increaser high speed shaft is 6.75inches +/- 0.010 inches.

Actual Separation = _______ Inches.

Compressor To Speed Increaser Hub to Hub, Faceand Rim Alignment:

Face and rim alignment is to be checked wit the cou-pling disk packs removed. An index mark is to be madeon the speed increaser hub at the point where the �A�readings are taken. When taking the �B�, �C� and �D�readings the speed increaser shaft is to be rotated suchthat the index mark is in line with the dial indicator point.The dial indicator bracket is to be mounted to thecompressor hub with the readings taken from thespeed increaser hub face and rim.

Rim Targets and tolerance:

(D-B); Target = 0.000 inch, Allowable = +/- 0.010 inch,Actual = _______ Inches

(A-C); Target = +0.006, Allowable = +0.016 to -0.004inches,Actual =__________ Inches

B D

A

C

FORM 160.66-N1


Compressor to Speed Increaser Face Targets andTolerance:

(D-B); Target = 0.000 inches, Allowable = +/- 0.004inches Actual_________ Inches

(A-C); Target = 0.000 inches, Allowable = +/- 0.004inches, Actual _______ Inches

Speed Increaser Low Speed Shaft to Flywheel Pi-lot Axial:

The axial separation is to be measured from the speedincreaser low speed shaft end to the machined pilotsurface of the flywheel. The target separation is 12.75inches, +/- 0.010 inches.

Speed Increaser to Flywheel Pilot Face and RimAlignment:

The dial indicator bracket is to be mounted to thespeed increaser low speed shaft. The dial indicatorbracket should be of a triangulated construction tominimize bracket sag. Face readings are to be takenfrom the Vulkan coupling aluminum ring face. Rim read-ings are to be taken from the Vulkan coupling alumi-num ring outside diameter. An index mark is to be madeon the ring at the point where the �A� readings are taken.The CAT barring tool, P/N 5P3707 is to be used to ro-tate the flywheel such that the index mark is in line withthe indicator when taking the B, C, and D readings.

Speed Increaserto Vulkan CouplingRim Targets andTolerance

(D-B); Target = 0.000 inches, Allowable = +/- 0.008inches. Actual = _____ Inches.

(A-C); Target = -0.006 inches, Allowable = -o.014 inchesto +0.002 inches, Actual _______ Inches.

Face Targets and Tolerance:

(D-B); = 0.000 inches, Allowable = +/- 0.014 inches,Actual _______ Inches.

(A-C); = 0.000 inches, Allowable = +/- 0.014 inches,Actual _______ Inches.

DOWELING

After the final alignment has been made to the abovespecifications the driveline components are ready tobe doweled into position. This operation should be donebefore starting the unit for the first time.

Use 1/2" straight dowel pins to dowel the two (2) front(end opposite the shaft) of the Caterpillar engine andthe two (2) right side (opposite the panels) mountingfeet of the gear box.

SERVICE DURING WARRANTY

REPORTING PROBLEMS

To report a problem with a YORK YG chiller (in war-ranty), follow these steps:

1. CALL YOUR LOCAL YORK SERVICE OFFICE.

2. YORK will dispatch a certified YORK technician tothe jobsite at which time he will diagnose the prob-lem. If it is a YORK problem, the technician will makethe necessary repairs, restart the chiller, fill out theservice form and distribute the necessary copies tothe appropriate offices.

3. If the problem is with the Caterpillar engine/con-trols** the YORK service technician will notify hisoffice and the YORK service office will notify thelocal Caterpillar service dealer at which time theCaterpillar dealer will dispatch a certified Caterpil-lar technician to the jobsite, diagnose and repairthe problem, notify the local YORK service officethat the chiller has been repaired and to have aYORK technician dispatched to the jobsite to re-start the chiller. The Caterpillar technician will fillout the service form and distribute copies to theappropriate offices.

B D

A

C

** If the YORK technician determines the problem is with Caterpillar engine/controls, he should not attempt to restart the equipment or try toreset the Caterpillar control panel . Turning the Cat Control Panel to �Off/Reset� will erase the Diagnostic Code(s) on the Cat engine. Whenthe Caterpillar technician arrives on the job, he can connect his �DDT� (Digital Diagnostic Tool) to the engine to read the fault codes thatcaused the engine to shut down. The fault codes are essential for the Caterpillar organization to diagnose an engine problem.


NOTE: Pages 29 thru 35are perforated for easyremoval and copying.

FORM 160.66-N1


SERVICE CALL INFORMATION

Please see instructions on back side. If you need additional space, please use a blank sheet of paper.

DATE ___________

JOB NAME __________________________________

ADDRESS __________________________________

__________________________________

JOB CONTACT & PHONE NO. _______________________________

UNIT MODEL NO.* _____________________________ SERIAL NO. _______________________

COMPRESSOR MODEL NO. _____________________ SERIAL NO. _______________________

ENGINE MODEL NO. ___________________________ SERIAL NO. _______________________

* This information is on the data plate on the condenser shell.

PERSON(S) PERFORMING STARTUP ______________________________ YORK / Caterpillar

______________________________ YORK / Caterpillar



Reason for Service? ________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

What problem(s) did you find? ________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

List all corrective action taken: ________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________


NOTE to the YORK Service Technician:

Please �dump� the control panel of the history printout and take a currentreading at design conditions after the unit has been put back on line. Fax thisinformation along with a copy of this form to the York, PA Service Departmentat 717-771-6844, ATTN: Don Bull / Steve Baer, and also send the same infor-mation to the Caterpillar Lafayette Plant Fax. No. 317-448-5985, ATTN: Den-nis Chaney / Gary Keffeler.

NOTE to the Caterpillar Technician:

If the strip chart from the control panel is not available, take a reading of theconditions and record them on the daily log sheet and send that informationto the Fax numbers listed above. Also include any previous copies of the logsheets that are available.

FORM 160.66-N1


START-UP INFORMATION

Please see instructions on back side. If you need additional space, please use a blank sheet of paper.

DATE ___________

JOB NAME __________________________________

ADDRESS __________________________________

__________________________________

JOB CONTACT & PHONE NO. _______________________________

UNIT MODEL NO.* _____________________________ SERIAL NO. _______________________

COMPRESSOR MODEL NO. _____________________ SERIAL NO. _______________________

ENGINE MODEL NO. ___________________________ SERIAL NO. _______________________

* This information is on the data plate on the condenser shell.

PERSON(S) PERFORMING START-UP _______________________________ YORK / Caterpillar

_______________________________ YORK / Caterpiller

_______________________________ YORK / Caterpiller

_______________________________ YORK / Caterpillar

Have you encountered any problems at start-up? If so, what were they?

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

How were these problems corrected? __________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________


NOTE to the YORK Service Technician:

Please �dump� the control panel of the history printout and take a currentreading at design conditions after the unit has been put back on line. Fax thisinformation along with a copy of this form to the York, PA Service Departmentat 717-771-6844, ATTN: Don Bull / Steve Baer, and also send the same infor-mation to the Caterpillar Lafayette Plant Fax. No. 317-448-5985, ATTN: Den-nis Chaney / Gary Keffeler.

NOTE to the Caterpillar Technician:

If the strip chart from the control panel is not available, take a reading of theconditions and record them on the daily log sheet and send that informationto the Fax numbers listed above. Also include any previous copies of the logsheets that are available.

FORM 160.66-N1


DateTimeOperating HoursStartsChilled Water (°F / °C) In

OutLeaving Water (°F / °C) In

OutChiller DataSaturated Suction Temp (°F / °C)Saturated Discharge Temp (°F / °C)Compressor DataSuction Pressure (PSIG / kPa)Discharge Pressure (PSIG / kPa)Suction Temperature (°F / °C)Discharge Temperature (°F / °C)Oil Pressure (PSID / kPa)Oil Temperature (°F / °C)Proximity Sensor (POS)Proximity Sensor (REF)High Speed Drain Temperature (°F / °C)% VanesRefrigerant Level %Level Setpoint %Engine DataJacket Water Temperature (°F / °C)AC Water Temperature (°F / °C) <90°F / °CRPMOil Pressure (PSID / kPa)Oil Temperature (°F / °C)Engine Loaded %Battery ChargeVolts (DC)AmpsGear BoxGauge Off Cooler (°F / °C)Gauge Off Pump (PSIG / kPa)Air Comp. Supply Pressure (PSIG / kPa)Clutch Pressure Gauge (PSIG / kPa)Technician’s NameRemarks

LOG SHEET FOR 3406 SERIES ENGINE

JOB NAME: ______________________________________________________________________________

MODEL NO.: _____________________________________________________________________________

SERIAL NO.: _____________________________________________________________________________

YORK CONTRACT NO.: ____________________________________________________________________


CATERPILLAR ENGINE GAUGE RANGES

3406GAUGE

MINIMUM MAXIMUM

Jacket Water Temperature (°F / °C) 185 / 85 210 / 199

After Cooler Water Temperature (°F / °C) maintain inlet

89.6 / 32 manifold above 85 / 29.4

RPM 1350 1850

Oil Pressure (PSI / kPa) 40 / 276 87 / 600

Oil Temperature (°F / °C) 170 / 76.7 210 / 98.9

% Engine Load 25 100

Selector Switch Cylinder Port Temperature (°F / °C) 10% below Average 670

Selector Switch Cylinder Bank Temperature (°F / °C) 10% below Average 640

Battery Charge Volts 22 26

Battery Charge Amps 10 10

Gear Box Off Bearings Temperature (°F / °C) 65 / 18.3 150

Gear Box Off Pump (PSIG / kPa) 10 / 68.9 20

Air Compressor Supply Pressure (PSIG / kPa) 100 / 690 150

Clutch Pressure Gauge (PSIG / kPa) 100 / 690 110

FORM 160.66-N1


INSTALLATION CHECKLIST AND REQUEST FOR AUTHORIZED STARTUP ENGINEER

* TO _________________________________ JOB NAME: ______________________________

_________________________________ LOCATION: ______________________________

_________________________________ CUSTOMER ORDER NO. ___________________

YORK TEL. NO. ___________________ YORK CONTRACT NO. ______________________________

MODEL NO. YB ________________________ SERIAL NO. ______________________________

The work (as checked below) is in process and will be completed by ______________________________

ALL ITEMS ON THIS PAGE ARE DESCRIBED IN DE-TAIL WITHIN THIS MANUAL.

A. YORK GAS ENGINE DRIVEN CHILLER� Accessory parts box(es) must be opened and in-

ventoried. All parts must be on the jobsite prior tostartup. Short-shipped item must be reported tothe York International Customer Service Depart-ment in York, PA.

� Vibration isolators installed and properly adjustedso that the unit is level.

� Unit pressure tested, leak checked, and chargedwith refrigerant and oil.

� Final alignment of Driveline components com-pleted. (NOTE: This cannot be done until the unithas been charged with refrigerant and oil and haswater in the shells.)

B. PIPING

� Condenser and evaporator supply and return linesinstalled with flex connections; and 3/32" strain-ers in both supply lines.

� All water piping pressure tested and leak checked.All chilled water lines insulated up to and includ-ing the evaporator water boxes.

� Flow switches or differential switches installed incondenser and evaporator leaving water lines.

� Air compressor and air lines installed to the unit(air starter if applicable). Air pressure checked andair pressure regulator adjusted.

� Exhaust piping and muffler (catalyst if needed) in-stalled with flex connection supplied with the unit.All exhaust piping and muffler insulated.

� Refrigerant relief piping run to atmosphere.

� All gas piping installed to the building and unit gasregulator, leak checked and pressure tested. Gaspressure checked and set properly.

� All piping conforms to local code.

C. ELECTRICAL� 480 volts supplied to and wired to the Power Panel.

� External wiring completed from YORK ControlPanel to chilled water flow switch or interlocks inaccordance with the YORK wiring diagram.

� Air compressor wired for operation.

� YORK and Caterpillar Control Panels checked forproper operation.

� Vane feedback pot calibrated.� Variable orifice checked for proper operation.� Power available and wiring completed to the fol-

lowing starters, motors, and pumps; rotation ofeach one checked:1. Chilled water pump2. Condenser water pump3. Cooling tower fan4. Gear box oil pump5. Compressor oil pump

D. CONDITIONS

� YORK oil for compressor on job.

� Cooling load available for startup and testing.

� Personnel available for startup and testing.

� Owners operating personnel available for instruction.

Names of operators receiving instruction:

1. _____________________________________

2. _____________________________________

3. _____________________________________

4. _____________________________________

5. _____________________________________

With reference to the terms of the above contract, we arerequesting the presence of your Authorized Repre-sentative at the jobsite on Month ___________ /Day ________ / Year __________ to start the equipmentand instruct operating personnel. HAVE HIM CONTACT:________________________________________

Phone No. ________________________________

Authorized YORK Signature __________________

Title _____________________________________

CUSTOMER:

This Installation Check List provides you with a quick,convenient way to check whether all necessary instal-lation work has been complete in accordance with thismanual, and when completed, acts as a request forthe startup supervision to be furnished by YORK.

Proud Sponsorof the 1998U.S. Olympic Team

36USC380

P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA

Copyright © by York International Corporation 1997 ALL RIGHTS RESERVED

Form 160.66-N1 (1297)

Supersedes: Nothing

Documents

MODEL YB (DESIGN LEVEL A) - docs.johnsoncontrols.com