York YK Series Operation And Maintenance
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York YK Series Operation And Maintenance

Centrifugal liquid chillers
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CENTRIFUGAL LIQUID CHILLERS
OPERATIONS AND MAINTENANCE
New Release
Form 160.76-O1 (615)
MODEL YK (STYLE H)
R-134a
WITH OPTIVIEW
CONTROL CENTER
TM
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER AND VARIABLE SPEED DRIVE
LD15222
Issue Date:
June 15, 2015

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  • Page 1 CENTRIFUGAL LIQUID CHILLERS OPERATIONS AND MAINTENANCE New Release Form 160.76-O1 (615) MODEL YK (STYLE H) R-134a WITH OPTIVIEW CONTROL CENTER FOR ELECTRO-MECHANICAL STARTER, SOLID STATE STARTER AND VARIABLE SPEED DRIVE LD15222 Issue Date: June 15, 2015...
  • Page 2 FORM 160.76-O1 ISSUE DATE: 6/15/2015 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or During rigging, installation, operation, maintenance, death to themselves and people at the site. or service, individuals may be exposed to certain com- This document is intended for use by owner-authorized ponents or conditions including, but not limited to:...
  • Page 3 FORM 160.76-O1 ISSUE DATE: 6/15/2015 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for con- regarding the applicability of these documents, rig- tinuous product improvement, the information con- ging, lifting, and operating/service personnel should tained in this document is subject to change without verify whether the equipment has been modified and notice.
  • Page 4 FORM 160.76-O1 ISSUE DATE: 6/15/2015 NOMENCLATURE – STYLE (Design Level) MOTOR CODE POWER SUPPLY – for 60 Hz 5 for 50 Hz COMPRESSOR CODE* CONDENSER CODE* EVAPORATOR CODE* * Refer to YK Engineering Guide for (Form 160.76-EG1) Shell/Motor/Compressor combinations. MODEL* JOHNSON CONTROLS...

  • Page 5: Table Of Contents

    FORM 160.76-O1 ISSUE DATE: 6/15/2015 TABLE OF CONTENTS SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION .......... 7 System Operation Description ......................... 7 Capacity Control ............................... 7 SECTION 2 - SYSTEM OPERATING PROCEDURES .....................9 Oil Heaters ............................... 9 Oil Heater Operation ............................
  • Page 6 FORM 160.76-O1 ISSUE DATE: 6/15/2015 TABLE OF CONTENTS (CONT'D) Vacuum Testing .............................. 26 Vacuum Dehydration ............................27 Operation ................................ 27 Refrigerant Charging ............................27 Checking The Refrigerant Charge During Unit Shutdown ................28 Handling Refrigerant For Dismantling And Repairs ..................28 Megging The Motor ............................

  • Page 7: Section 1 - Description Of System And Fundamentals Of Operation

    The refrigerant vapor, which is produced by the boil- ing action in the evaporator, flows to the compressor The YORK Model YK Chiller is commonly applied where the rotating impeller increases its pressure and to large air conditioning systems, but may be used temperature and discharges it into the condenser.

  • Page 8: Figure 2 - Refrigerant Flow-Thru Chiller (Falling Film Evaporator)

    FORM 160.76-O1 SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION ISSUE DATE: 6/15/2015 Refrigerant Flow-Thru Chiller YK Mod G (Falling Film Evaporator) Refrigerant Flow-Thru Cross-Section Diagram (Falling-Film Evaporator) LEGEND High Pressure Vapor High Pressure Liquid Refrigerant Low Pressure Liquid Refrigerant Low Pressure Vapor COMPRESSOR PRE-ROTATION...

  • Page 9: Section 2 - System Operating Procedures

    FORM 160.76-O1 ISSUE DATE: 6/15/2015 SECTION 2 - SYSTEM OPERATING PROCEDURES OIL HEATERS • If the oil level during operation is in the OVER FULL region of the oil level indicator, oil should If the oil heater is de-energized during a shutdown pe- be removed from the oil reservoir, This reduces riod, it must be energized for 12 hours prior to starting the oil level to the OPERATING RANGE.

  • Page 10: Figure 4 - Chiller Starting Sequence And Shutdown Sequence (Em Starter And Solid State Starter)

    FORM 160.76-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 6/15/2015 DISPLAY AUTO ZEROING DIFFERENTIAL MESSAGE OIL PRESSURE TRANSDUCERS "SYSTEM RUN" ENERGIZE (OPEN) OIL RETURN SOLENOID & LIQUID LINE SOLENOID (J COMPRESSOR ONLY) "SYSTEM PRELUBE" MAN. OIL PUMP ** "VANES CLOSING DISABLED ** VANES CLOSING - TIME BEFORE...

  • Page 11: Chiller Operation

    CONTROL For example, an increase in condenser approach tem- The YORK chiller is designed to use less power by tak- perature (condenser temperature minus leaving con- ing advantage of lower than design temperatures that...

  • Page 12: Operating Inspections

    FORM 160.76-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 6/15/2015 OPERATING INSPECTIONS 7. Check the compressor motor current on the SYSTEM Screen. By following a regular inspection using the display readings of the Microcomputer Control Center, and 8. Check for any signs of dirty or fouled condenser maintenance procedure, the operator will avoid serious tubes.

  • Page 13: Need For Maintenance Or Service

    FORM 160.76-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 6/15/2015 Annually (more often if necessary) 1. Push the soft shutdown key on the homescreen on the OptiView panel or rapid stop with the COM- 1. Drain and replace the oil in the compressor oil PRESSOR STOP/RESET switch.
  • Page 14 FORM 160.76-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 6/15/2015 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 15: Section 3 - System Components Description

    SECTION 3 - SYSTEM COMPONENTS DESCRIPTION c. Low speed thrust bearing (forward and re- GENERAL verse). The YORK Model YK Centrifugal Liquid Chiller is completely factory-packaged including evaporator, 2. Compressor Driven Shaft (High Speed) condenser, compressor, motor, lubrication system, a. Forward and reverse high speed thrust OptiView Control Center, and all interconnecting unit bearing.

  • Page 16: Figure 7 - System Components Front View

    FORM 160.76-O1 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ISSUE DATE: 6/15/2015 OPTIVIEW CONTROL CENTER COMPRESSOR SUCTION RELIEF VARIABLE VALVES SPEED DRIVE EVAPORATOR LD15222 VARIABLE SPEED SIGHT OIL PUMP GLASS CONTROL BOX FRONT VIEW FIGURE 7 - SYSTEM COMPONENTS FRONT VIEW JOHNSON CONTROLS...

  • Page 17: Figure 8 - System Components Rear View

    FORM 160.76-O1 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ISSUE DATE: 6/15/2015 MOTOR COMPRESSOR OIL FILTER DISCHARGE LINE LD15223 LIQUID LINE CONDENSER OIL PUMP HOUSING REAR VIEW FIGURE 8 - SYSTEM COMPONENTS REAR VIEW JOHNSON CONTROLS...

  • Page 18: Figure 9 - Schematic Drawing - (Yk) Compressor Lubrication System

    FORM 160.76-O1 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ISSUE DATE: 6/15/2015 COMPRESSOR ROTOR SUPPORT SECTION H.S. SHAFT SEAL EMERGENCY OIL RESERVE HIGH PRESSURE TRANSDUCER MAIN JOURNAL AND THRUST BEARING IMPELLER THRUST COLLAR BEARING (PINION GEAR HIGH SPEED SHAFT) THRUST COVER (PRV) INLET DOUBLE...

  • Page 19: Oil Heater

    The compressor motor is an open-drip-proof, squir- transfer. An integral sub-cooler is located at the bottom rel cage, induction type constructed to YORK design of the condenser shell providing highly effective liquid specifications. 60 hertz motors operate at 3570 rpm. 50 refrigerant subcooling to provide the highest cycle ef- hertz motors operate at 2975 rpm.

  • Page 20: Optional Service Isolation Valves

    FORM 160.76-O1 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ISSUE DATE: 6/15/2015 While the chiller is shut down, the orifice will be in the OPTIVIEW CONTROL CENTER fully open position causing the sensed level to be ap- The OptiView Control Center is factory-mounted, proximately 0%.

  • Page 21: Section 4 - Operational Maintenance

    FORM 160.76-O1 ISSUE DATE: 6/15/2015 SECTION 4 - OPERATIONAL MAINTENANCE OIL RETURN SYSTEM CHANGING THE DEHYDRATOR The oil return system continuously maintains the To change the dehydrator, use the following procedure: proper oil level in the compressor oil sump (Refer to 1.

  • Page 22: The Oil Charge

    The nominal oil charge for Q3-Q7 YK compressors is until after the air is forced out by pumping a few 11 gallons of type YORK K or YORK H oil. strokes of the oil pump. This fills the lines with oil and prevents air from being pumped into the New YORK Refrigeration oil must be used in the cen- system.

  • Page 23: Section 5 - Troubleshooting

    FORM 160.76-O1 ISSUE DATE: 6/15/2015 SECTION 5 - TROUBLESHOOTING TABLE 1 - OPERATION ANALYSIS CHART RESULTS POSSIBLE CAUSE REMEDY 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE Temperature difference between condensing temperature and water off Air in condenser. condenser higher than normal. Clean condenser tubes.
  • Page 24 FORM 160.76-O1 SECTION 5 - TROUBLESHOOTING ISSUE DATE: 6/15/2015 TABLE 1 - OPERATION ANALYSIS CHART (CONT'D) RESULTS POSSIBLE REMEDY 6. SYMPTOM: OIL PUMP VIBRATES OR IS NOISY Oil pump vibrates or is extremely noisy Oil not reaching pump suction inlet in Check oil level.

  • Page 25: Section 6 - Maintenance

    FORM 160.76-O1 ISSUE DATE: 6/15/2015 SECTION 6 - MAINTENANCE RENEWAL PARTS To test with R-134a, proceed as follows: For any required Renewal Parts, refer to the Renewal 1. With no pressure in the system, charge R-134a gas Parts – Unit (Form 160.75-RP1). into the system through the charging valve to a pressure of 2 PSIG (14 kPa).

  • Page 26: Vacuum Testing

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 6/15/2015 TABLE 2 - SYSTEM PRESSURES *GAUGE ABSOLUTE BOILING INCHES OF TEMPERATURES MERCURY (HG) MILLIMETERS OF BELOW ONE PSIA MICRONS WATER MERCURY (HG) STANDARD °F ATMOSPHERE 14.696 760. 760,000 10.24" 9.629 500. 500,000 22.05"...

  • Page 27: Vacuum Dehydration

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 6/15/2015 Be sure the vacuum indicator is valved off taken place the pressure and temperature will continue while holding the system vacuum and be to drop until eventually a temperature of 35°F (1.6°C) sure to open the valve between the vacuum or a pressure of 5 mm Hg.

  • Page 28: Checking The Refrigerant Charge During Unit Shutdown

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 6/15/2015 inder must be admitted to the system pressure until the The refrigerant charge level must be checked after the system pressure is raised above the point correspond- pressure and temperature have equalized between the ing to the freezing point of the evaporator liquid.

  • Page 29: Figure 15 - Motor Starter Temperature And Insulation Resistances

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 6/15/2015 LD00476 TEMPERATURE – °F FIGURE 15 - MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES JOHNSON CONTROLS...
  • Page 30 FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 6/15/2015 Condensers And Evaporators General Tube Fouling Maintenance of condenser and evaporator shells is im- Fouling of the tubes can be due to deposits of two types portant to provide trouble free operation of the chiller. as follows: The water side of the tubes in the shell must be kept 1.
  • Page 31 12 to 24 hours and condensers. If acid cleaning is required, YORK before proceeding. Depending upon the amount recommends the use of this type of organization. The...

  • Page 32: Compressor

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 6/15/2015 COMPRESSOR rings can contact the impeller and account for some Maintenance for the compressor assembly consists aluminum particles to accumulate in the oil filter, espe- of checking the operation of the oil return system and cially during the initial start up and first several months changing the dehydrator, checking and changing the oil, of operation.

  • Page 33: Section 7 - Preventive Maintenance

    Multiply this number of pumps times which would indicate possible bearing wear. 1.5 to get the number of pumps for York chiller motor If aluminum particles are found this should be bearings.

  • Page 34: Leak Testing

    If you are unable to locate this specific Texa- co product, another approved lithium based grease is Shell Alvania RL in NLGI #3. The motors on York chillers must utilize the greas- Additional information on motor lubrica- es mentioned above. Approval of any other type of tion and other service issues can be found grease will not be granted.

  • Page 35: Oil Return System

    FORM 160.76-O1 SECTION 7 - PREVENTIVE MAINTENANCE ISSUE DATE: 6/15/2015 2. The evaporator tubes under normal circumstances OIL RETURN SYSTEM will not require cleaning. If the temperature dif- 1. Change the dehydrator in the oil return system ference between the refrigerant and the chilled semi-annually or earlier if the oil return system water increases slowly over the operating season, fails to operate.
  • Page 36 FORM 160.76-O1 SECTION 7 - PREVENTIVE MAINTENANCE ISSUE DATE: 6/15/2015 JOHNSON CONTROLS...

  • Page 37: Temperature

    FORM 160.76-O1 SECTION 7 - PREVENTIVE MAINTENANCE ISSUE DATE: 6/15/2015 The following factors can be used to convert from English to the most common SI Metric values. TABLE 3 - SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect (ton) 3.516...
  • Page 38 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2015 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.76-O1 (615) Issue Date: June 15, 2015 New Release...

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