York YMC2 A Operation And Maintenance
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York YMC2 A Operation And Maintenance

Centrifugal liquid chillers
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CENTRIFUGAL LIQUID CHILLERS
OPERATIONS AND MAINTENANCE
Supersedes: 160.78-O1 (412)
Form 160.78-O1 (1112)
YMC
MODEL A
2
WITH OPTIVIEW™ CONTROL CENTER
8.1415 in
LD14000
R-134a
Issue Date:
November 30, 2012

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Summary of Contents for York YMC2 A

  • Page 1 CENTRIFUGAL LIQUID CHILLERS OPERATIONS AND MAINTENANCE Supersedes: 160.78-O1 (412) Form 160.78-O1 (1112) MODEL A WITH OPTIVIEW™ CONTROL CENTER 8.1415 in LD14000 R-134a Issue Date: November 30, 2012...
  • Page 2 FORM 160.78-O1 ISSUE DATE: 11/30/2012 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 installation, operation maintenance or service, death to themselves and people at the site. individuals may be exposed to certain components or This document is intended for use by owner-authorized conditions including, but not limited to: refrigerants,...
  • Page 3 FORM 160.78-O1 ISSUE DATE: 11/30/2012 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for con- these documents, the technician should verify whether tinuous product improvement, the information con- the equipment has been modified and if current litera- tained in this document is subject to change without ture is available from the owner of the equipment prior notice.
  • Page 4 FORM 160.78-O1 ISSUE DATE: 11/30/2012 SYSTEM NOMENCLATURE Y M C 2 - S 0756 A A YORK Mod Level Magnetic Bearing Refrigerant R-134a Centrifugal Chiller Capacity in KW S = Single Stage T = Two Stage COMPRESSOR NOMENCLATURE M1 B - 197 F A A...

  • Page 5: Table Of Contents

    FORM 160.78-O1 ISSUE DATE: 11/30/2012 TABLE OF CONTENTS Section 1 - System Fundamentals .........................7 System Components ............................7 Compressor .............................7 Motor ...............................7 Heat Exchangers .............................8 Evaporator ...............................8 Condenser ...............................8 Water Boxes ............................8 Refrigerant Flow Control .........................8 Optional Service Isolation Valves ......................8 Optional Hot Gas Bypass ........................
  • Page 6 Acid Cleaning of Tubes .........................20 Testing for Evaporator and Condenser Tube Leaks ................20 Compressor ..............................21 Electrical Controls ............................21 Maintenance Requirements For York Ymc2 Chillers ..................22 Preventative Maintenance ..........................23 Compressor And Motor ..........................23 Leak Testing ..............................23 Evaporator And Condenser ..........................

  • Page 7: Section 1 - System Fundamentals

    SYSTEM COMPONENTS The motor includes angular contact ball bearings only for control of the rotor during shutdown after rotation The YORK Model YMC Centrifugal Liquid Chiller is stopped or during shutdown due to loss of power to is completely factory-packaged including evaporator, the magnetic bearings.

  • Page 8: Heat Exchangers

    FORM 160.78-O1 SECTION 1 - SYSTEM FUNDAMENTALS ISSUE DATE: 11/30/2012 Heat Exchangers service technician. Only a qualified service technician may modify these settings. Evaporator and condenser shells are fabricated from rolled carbon steel plates with fusion welded seams. While the chiller is shut down, the orifice will be pre Heat exchanger tubes are internally enhanced type.

  • Page 9: Variable Speed Drive

    SYSTEM OPERATION DESCRIPTION duced as much as possible while maintaining chilled water temperature and sufficient pressure differen- The YORK Model YMC Chiller is commonly applied tial. When the speed cannot be further reduced due to to large air conditioning systems, but may be used on pressure difference required for the specified leaving other applications.

  • Page 10: Figure 3 - Refrigerant Flow-Thru Chiller

    FORM 160.78-O1 SECTION 1 - SYSTEM FUNDAMENTALS ISSUE DATE: 11/30/2012 HGBP is used to re-circulate some refrigerant through passing through the compressor at reduced flow rates the compressor without using it for cooling the chilled needed for low capacity operation. Compressor models with gas path revision level “B”...

  • Page 11: Section 2 - System Operating Procedures

    1. If the chilled water pump is manually operated, CONDENSER WATER TEMPERATURE CONTROL start the pump. The Control Center will not al- The YORK YMC chiller is designed to use less power low the chiller to start unless chilled liquid flow is established through the unit.

  • Page 12: Operating Inspections

    FORM 160.78-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 11/30/2012 is available for this purpose. Figure 4 shows an ex- Daily ample log sheet used by Johnson Controls Personnel 1. Check OptiView™ Control Center displays. for recording test data on chiller systems. Log sheets 2.

  • Page 13: Weekly

    FORM 160.78-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 11/30/2012 leaving condenser and saturated condensing tem- 1. Push the soft shutdown key on the homescreen of perature should not exceed the difference recorded the OptiView panel. The compressor will stop for a new unit by more than 4°F (2.2°C)).
  • Page 14 FORM 160.78-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES ISSUE DATE: 11/30/2012 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 15: Section 3 - Maintenance

    FORM 160.78-O1 ISSUE DATE: 11/30/2012 SECTION 3 - MAINTENANCE RENEWAL PARTS To test with R-22, proceed as follows: For any required Renewal Parts, refer to the YMC Unit 1. With no pressure in the system, charge R-22 gas Renewal Parts Manual (Form 160.78-RP1). into the system through the charging valve to a pressure of 2 PSIG (14 kPa).

  • Page 16: Vacuum Testing

    FORM 160.78-O1 SECTION 3 - MAINTENANCE ISSUE DATE: 11/30/2012 TABLE 1 - SYSTEM PRESSURES *GAUGE ABSOLUTE BOILING INCHES OF TEMPERATURES MERCURY (HG) MILLIMETERS BELOW ONE PSIA OF MERCURY MICRONS WATER STANDARD (HG) °F ATMOSPHERE 0" 14.6960 760.00 760,000 10.240" 9.6290 500.00 500,000 22.050"...

  • Page 17: Vacuum Dehydration

    FORM 160.78-O1 SECTION 3 - MAINTENANCE ISSUE DATE: 11/30/2012 DO NOT USE STEAM. A suggested method is the pressure in the system to a point where its satu- to connect a hose between the source of hot water ration temperature is considerably below that of room under pressure and the evaporator head drain con- temperature, heat will flow from the room through the nection, out the evaporator vent connection, into...

  • Page 18: Refrigerant Charging

    FORM 160.78-O1 SECTION 3 - MAINTENANCE ISSUE DATE: 11/30/2012 temperature. Close off the system again, and start the While charging, every precaution must be taken to pre- second evacuation. vent moisture laden air from entering the system. Make up a suitable charging connection from new copper The relatively small amount of moisture left will be tubing to fit between the system charging valve and the carried out through the vacuum pump and the tem-...

  • Page 19: Handling Refrigerant For Dismantling And Repairs

    FORM 160.78-O1 SECTION 3 - MAINTENANCE ISSUE DATE: 11/30/2012 HANDLING REFRIGERANT FOR DISMANTLING Cleaning Evaporator and Condenser Tubes AND REPAIRS Evaporator If it becomes necessary to open any part of the refriger- It is difficult to determine by any particular test wheth- ant system for repairs, it will be necessary to remove er possible lack of performance of the water evaporator the charge before opening any part of the unit.

  • Page 20: Tube Cleaning Procedures

    FORM 160.78-O1 SECTION 3 - MAINTENANCE ISSUE DATE: 11/30/2012 Tube Cleaning Procedures Testing for Evaporator and Condenser Tube Leaks Brush Cleaning of Tubes Evaporator and condenser tube leaks in R-134a sys- If the tube consists of dirt and sludge, it can usually be tems may result in refrigerant leaking into the water removed by means of the brushing process.

  • Page 21: Compressor

    FORM 160.78-O1 SECTION 3 - MAINTENANCE ISSUE DATE: 11/30/2012 of leakage, the corks may blow from the end of a 6. If any of the tube sheet joints are leaking, the leak tube, indicating the location of the leakage. If not, should be indicated by the detector.

  • Page 22: Maintenance Requirements For York Ymc2 Chillers

    This procedure must be performed at the specified time interval by an Industry Certified Technician who has been trained and qualified to work on this type of YORK equipment. A record of this procedure being successfully carried out must be maintained on file by the equipment owner should proof of adequate maintenance be required at a later date for warranty validation purposes.

  • Page 23: Preventative Maintenance

    FORM 160.78-O1 SECTION 3 - MAINTENANCE ISSUE DATE: 11/30/2012 PREVENTATIVE MAINTENANCE recommendation should be followed in determining the condition of the water side of the condenser and It is the responsibility of the owner to provide the nec- evaporator tubes. essary daily, monthly and yearly maintenance require- ments of the system.
  • Page 24 FORM 160.78-O1 SECTION 3 - MAINTENANCE ISSUE DATE: 11/30/2012 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 25: Section 4 - Troubleshooting

    FORM 160.78-O1 ISSUE DATE: 11/30/2012 SECTION 4 - TROUBLESHOOTING TABLE 4 - OPERATION ANALYSIS CHART RESULTS POSSIBLE CAUSE REMEDY 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE Temperature difference between condens- Condenser tubes dirty ing temperature and water off condenser Clean condenser tubes. Check water conditioning. or scaled.
  • Page 26 FORM 160.78-O1 ISSUE DATE: 11/30/2012 THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS...

  • Page 27: Metric Conversion

    FORM 160.78-O1 ISSUE DATE: 11/30/2012 The following factors can be used to convert from English to the most common SI Metric values. TABLE 5 - SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW) Power...
  • Page 28 P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2012 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.78-O1 (1112) Issue Date: November 30, 2012 Supersedes: 160.78-O1 (412)

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R-134a

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