York R-134a Operation And Maintenance Manual
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York R-134a Operation And Maintenance Manual

Centrifugal liquid chillers
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CENTRIFUGAL LIQUID CHILLERS
OPERATIONS AND MAINTENANCE
Supersedes: 160.76-O1 (1018)
Form 160.76-O1 (519)
035-27332-100
MODEL YK (STYLE H)
R-134a and R-513A
WITH OPTIVIEW
CONTROL CENTER
TM
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER AND VARIABLE SPEED DRIVE
LD15222
Issue Date:
May 22, 2019

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  • Page 1 CENTRIFUGAL LIQUID CHILLERS OPERATIONS AND MAINTENANCE Supersedes: 160.76-O1 (1018) Form 160.76-O1 (519) 035-27332-100 MODEL YK (STYLE H) R-134a and R-513A WITH OPTIVIEW CONTROL CENTER FOR ELECTRO-MECHANICAL STARTER, SOLID STATE STARTER AND VARIABLE SPEED DRIVE LD15222 Issue Date: May 22, 2019...
  • Page 2 FORM 160.76-O1 ISSUE DATE: 05/22/2019 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: 05/22/2019 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: 05/22/2019 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: 05/22/2019 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: 05/22/2019 TABLE OF CONTENTS (CONT'D) Vacuum Dehydration ............................25 Operation ................................ 25 Refrigerant Charging ............................26 Checking The Refrigerant Charge During Unit Shutdown ................26 Handling Refrigerant For Dismantling And Repairs ..................28 Megging The Motor ............................28 Compressor ..............................

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

    SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION SYSTEM OPERATION DESCRIPTION The YORK Model YK Chiller is commonly applied The refrigerant vapor, which is produced by the boil- to large air conditioning systems, but may be used ing action in the evaporator, flows to the compressor on other applications.

  • 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: 05/22/2019 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: 05/22/2019 SECTION 2 - SYSTEM OPERATING PROCEDURES OIL HEATERS • If the oil level during operation is in the OVER If the oil heater is de-energized during a shutdown pe- FULL region of the oil level indicator, oil should riod, it must be energized for 12 hours prior to starting be removed from the oil reservoir, This reduces compressor, or remove all oil and recharge compressor...

  • Page 10: 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 11: Operating Inspections

    FORM 160.76-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 05/22/2019 OPERATING INSPECTIONS 7. Check the compressor motor current on the By following a regular inspection using the display SYSTEM Screen. readings of the Microcomputer Control Center, and maintenance procedure, the operator will avoid serious 8.

  • Page 12: Need For Maintenance Or Service

    FORM 160.76-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 05/22/2019 Annually (more often if necessary) 1. Drain and replace the oil in the compressor oil sump. will stop automatically. The oil pump will contin- (See Oil Charging Procedure on page 20.) ue to run for coastdown period.

  • Page 13: Section 3 - System Components Description

    ISSUE DATE: 05/22/2019 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION GENERAL 2. Compressor Driven Shaft (High Speed) The YORK Model YK Centrifugal Liquid Chiller is completely factory-packaged including evaporator, a. Forward and reverse high speed thrust condenser, compressor, motor, lubrication system, Op- bearing.

  • Page 14: Figure 5 - System Components Front View

    FORM 160.76-O1 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ISSUE DATE: 05/22/2019 OPTIVIEW CONTROL CENTER COMPRESSOR SUCTION RELIEF VARIABLE VALVES SPEED DRIVE EVAPORATOR LD15222 VARIABLE SPEED SIGHT OIL PUMP GLASS CONTROL BOX FRONT VIEW FIGURE 5 - SYSTEM COMPONENTS FRONT VIEW JOHNSON CONTROLS...

  • Page 15: Figure 6 - System Components Rear View

    FORM 160.76-O1 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ISSUE DATE: 05/22/2019 MOTOR COMPRESSOR OIL FILTER DISCHARGE LINE LD15223 LIQUID LINE CONDENSER OIL PUMP HOUSING REAR VIEW FIGURE 6 - SYSTEM COMPONENTS REAR VIEW JOHNSON CONTROLS...

  • Page 16: Figure 7 - Schematic Drawing - (Yk) Compressor Lubrication System

    FORM 160.76-O1 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ISSUE DATE: 05/22/2019 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 17: Oil Heater

    The compressor motor is an open-drip-proof, squir- on the tubes. The baffle is also used to distribute the rel cage, induction type constructed to YORK design refrigerant gas flow properly for most efficient heat specifications. 60 Hertz motors operate at 3570 rpm.

  • Page 18: Optional Service Isolation Valves

    FORM 160.76-O1 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ISSUE DATE: 05/22/2019 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 19: Section 4 - Operational Maintenance

    FORM 160.76-O1 ISSUE DATE: 05/22/2019 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 (See 1.

  • Page 20: The Oil Charge

    This fills the lines with oil and prevents New YORK Refrigeration oil must be used in the cen- air from being pumped into the system. trifugal compressor. Since oil absorbs moisture when 3.

  • Page 21: Section 5 - Troubleshooting

    FORM 160.76-O1 ISSUE DATE: 05/22/2019 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 22 FORM 160.76-O1 SECTION 5 - TROUBLESHOOTING ISSUE DATE: 05/22/2019 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 23: Section 6 - Maintenance

    FORM 160.76-O1 ISSUE DATE: 05/22/2019 SECTION 6 - MAINTENANCE RENEWAL PARTS Please order all replacement parts at www.hvacnaviga- If any leaks are indicated, they must be repaired im- tor.com (see Figure 10). mediately. Usually, leaks can be stopped by tighten- ing flare nuts or flange bolts.

  • Page 24: Vacuum Testing

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 05/22/2019 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 25: Vacuum Dehydration

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 05/22/2019 5. Close the system charging valve and the stop the system, the capacity and efficiency of the vacuum valve between the vacuum indicator and the vac- pump, the room temperature and the quantity of water uum pump.

  • Page 26: Refrigerant Charging

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 05/22/2019 should be purged each time a full container of refriger- ant is connected and changing containers should be done as quickly as possible to minimize the loss of refrigerant. Refrigerant may be furnished in cylinders containing either 30, 50, 125, 1,025, or 1750 lb.

  • Page 27: Figure 14 - Motor Starter Temperature And Insulation Resistances

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 05/22/2019 LD00476 TEMPERATURE – °F FIGURE 14 - MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES JOHNSON CONTROLS...

  • Page 28: Handling Refrigerant For Dismantling And Repairs

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 05/22/2019 HANDLING REFRIGERANT FOR DISMANTLING AND REPAIRS Cleaning Evaporator And Condenser Tubes If it becomes necessary to open any part of the refriger- ant system for repairs, it will be necessary to remove Evaporator the charge before opening any part of the unit.
  • Page 29 Depending upon the amount and condensers. If acid cleaning is required, YORK of leakage, the corks may blow from the end of a recommends the use of this type of organization. The tube, indicating the location of the leakage.

  • Page 30: Compressor

    FORM 160.76-O1 SECTION 6 - MAINTENANCE ISSUE DATE: 05/22/2019 If the unit is shutting down on (HOT) High Oil Tem- the detector will assure that any leakage will travel perature or Low Oil Pressure (OP), change the oil filter through the tube to the detector. element.

  • Page 31: Section 7 - Preventive Maintenance

    FORM 160.76-O1 ISSUE DATE: 05/22/2019 SECTION 7 - PREVENTIVE MAINTENANCE 2. Oil Changing – The oil in the compressor must It is the responsibility of the owner to provide the nec- essary daily, monthly and yearly maintenance require- be changed annually or earlier if it becomes dark or cloudy.

  • Page 32: Motor Re-Lubrication Instruction

    FORM 160.76-O1 SECTION 7 - PREVENTIVE MAINTENANCE ISSUE DATE: 05/22/2019 MOTOR RE-LUBRICATION INSTRUCTION General ever, always perform a verification with the motor data Johnson Controls supplied electric drive motors have maintenance requirements for re-lubrication (greasing) plate - any differences between the quick guide and the motor data plate must be communicated to the product of the drive end (DE) and non-drive end (NDE) ball technical support (PTS) team prior to completing the...
  • Page 33 The specified amount of grease should be added at 4. Multiply the number of pumps by 1.5 to get the each specified interval to both the DE and NDE bear- number of pumps for YORK chiller motor bear- ings. Current YORK OptiView panels provide a warn- ings.

  • Page 34: Leak Testing

    Normal operating temperature for grease lubricated than the previous position. If the motor is bearings on YORK chillers is 40°C to 65°C (100°F to fitted with a shaft locking device, remove 150°F). It is normal to see the temperature elevate im-...

  • Page 35: Oil Return System

    FORM 160.76-O1 SECTION 7 - PREVENTIVE MAINTENANCE ISSUE DATE: 05/22/2019 It is therefore to the benefit of the user to provide for proper water treatment to provide for a longer and more economical life of the equipment. The following recommendation should be followed in determining the condition of the water side of the condenser and evaporator tubes.
  • Page 36 FORM 160.76-O1 SECTION 7 - PREVENTIVE MAINTENANCE ISSUE DATE: 05/22/2019 JOHNSON CONTROLS...

  • Page 37: Table 4 - Si Metric Conversion

    FORM 160.76-O1 ISSUE DATE: 05/22/2019 The following factors can be used to convert from English to the most common SI Metric values. TABLE 4 - SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW) Power...
  • Page 38 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2019 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.76-O1 (519) Issue Date: May 22, 2019 Supersedes: 160.76-O1 (1018)

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