Johnson Controls YORK YK Installation, Commissioning, Operation And Maintenance Manual
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Johnson Controls YORK YK Installation, Commissioning, Operation And Maintenance Manual

Centrifugal liquid chiller
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Библиотека СОК 
YK - ALL MODELS
INSTALLATION, COMMISSIONING,
035-19569-101 (0109)
REVISION 2
OPERATION AND MAINTENANCE
CENTRIFUGAL LIQUID CHILLER
STYLE G
R134A

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  • Page 1 Библиотека СОК  YK - ALL MODELS INSTALLATION, COMMISSIONING, 035-19569-101 (0109) REVISION 2 OPERATION AND MAINTENANCE CENTRIFUGAL LIQUID CHILLER STYLE G R134A...

  • Page 3: Table Of Contents

    035-19569-101 (0109) Table of Contents 1 SUPPLIER INFORMATION 4 INSTALLATION Introduction Location Warranty Motors Safety Foundation Responsibility for Safety Clearances About this Manual Rigging Unit to Final Location Misuse of Equipment Locating and Installing Isolator Pads Safety Labels Installing Optional Spring Isolators Material Safety Data Piping Connections Evaporator and Condenser Water Piping...
  • Page 4 035-19569-101 (0109) 6 OPERATION 9 TECHNICAL DATA Oil Heater Operation Dimensions Checking the Oil Level in the Oil Reservoir Dimensions - Evaporator Compact Water Boxes Start-up Procedure Nozzle Arrangements - Chiller Operation Evaporator Compact Water Boxes Operating Log Sheet Dimensions - Condenser Compact Water Boxes Stopping the System Nozzle Arrangements -...

  • Page 5: Supplier Information

    For warranty purposes, the following conditions must 1.1 Introduction be satisfi ed: York YK chillers are manufactured to the highest design The initial start of the unit must be carried out by trained and construction standards to ensure high performance, personnel from an Authorised York Service Centre.

  • Page 6: About This Manual

    035-19569-101 (0109) 1.5 About this Manual Mechanical Strength The unit is not designed to withstand loads or stresses The following symbols are used in this document to alert from adjacent equipment, pipework or structures. the reader to areas of potential hazard. Additional components must not be mounted on the unit.

  • Page 7: Safety Labels

    035-19569-101 (0109) High Temperature and Pressure Cleaning High temperature and pressure cleaning methods (e.g. steam cleaning) should not be used on any part of the pressure system as this may cause operation of the pressure relief device(s). Detergents and solvents which may cause corrosion should also be avoided.

  • Page 8: Material Safety Data

    035-19569-101 (0109) 1.9 Material Safety Data Refrigerant Data: Safety Data R134a Toxicity Low. In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. Thaw affected areas with water. Remove contaminated clothing carefully — may adhere to skin in case of freeze burns. Wash affected areas with plenty of warm water.
  • Page 9 035-19569-101 (0109) Spill/leak procedure Ensure suitable personal protective clothing and respiratory protection is worn. Provided it is safe to do so, isolate the source of the leak. Allow small spillage’s to evaporate provided there is suitable ventilation. Large spillage’s: Ventilate area. Contain spillage’s with sand, earth or any suitable absorbent material.
  • Page 10 035-19569-101 (0109) Thermal & Acoustic Materials Data Health Hazard & First Aid Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic. No fi rst aid necessary. Stability / Reactivity Stable. Handling / Use / Disposal No special handling precautions required. Dispose of according to local laws and regulations governing non-biodegradable non-hazardous solid wastes.

  • Page 11: Product Description

    The chilled liquid is then piped to fan The York YK Millennium™ Centrifugal Liquid Chiller is coil units or other air conditioning terminal units, where primarily used for large air conditioning systems, but may it fl...

  • Page 12: Capacity Control

    035-19569-101 (0109) 2.2 Capacity Control (Figure 2.2) The major components of a chiller are selected for full load capacities, therefore capacity must be controlled to maintain a constant chilled liquid temperature leaving the evaporator. Prerotation vanes (PRV), located at the entrance to the compressor impeller, compensate for variation in load (See Detail A).

  • Page 13: Compressor

    035-19569-101 (0109) Figure 2.3 YK Centrifugal Liquid Chiller (Rear View) 2.4 Compressor Lubrication System 2.3 Compressor (Figure 2.4) The compressor is a single-stage centrifugal type The chiller lubrication system consists of the oil pump, powered by an open-drive electric motor. oil fi...
  • Page 14 035-19569-101 (0109) Figure 2.4 Compressor Lubrication System...

  • Page 15: Graphic Control Centre (Optiview)

    035-19569-101 (0109) To provide the required amount of oil under the necessary a motor support. pressure to properly lubricate these parts, a motor driven Motor drive shaft is directly connected to the compressor submersible oil pump is located in a remote oil sump. shaft with a fl...

  • Page 16: Refrigerant Flow Control

    035-19569-101 (0109) Stub-out water nozzle connections with Victaulic grooves 2.9 Options and Accessories are welded to the water boxes. These nozzle connections are suitable for Victaulic couplings, welding or fl anges, 2.9.1 Service Isolation Valves and are capped for shipment. Plugged ¾" drain and vent If the chiller is equipped with optional service isolation connections are provided in each water box.

  • Page 17: Nomenclature

    035-19569-101 (0109) 2.10 Nomenclature YK ER ER Q7 Model Special Modifi cations Evaporator Code Design Level Condenser Code Motor Code Compressor Code Power Supply (5 for 50 Hz)

  • Page 18: Range Of Models

    035-19569-101 (0109) 2.11 Range of Models COMPRESSOR COMPRESSOR EVAPORATOR EVAPORATOR CONDENSER CONDENSER MOTOR CODES MOTOR CODES CODE CODE CODE CODE CODE CODE AP to AS AP to AS AP to AS AP to AS CP to CS CP to CS CP to CS CP to CS Q3, Q4...

  • Page 19: Transportation, Rigging And Storage

    035-19569-101 (0109) TRANSPORTATION, RIGGING AND STORAGE 8. Do not run hot water (40°C maximum.) or steam 3.1 General through the evaporator or condenser at any time. YK units are shipped as a single factory assembled, piped, wired package, requiring minimum installation 3.2 Shipment to make chilled water connections, condenser water The chiller may be ordered and shipped in any of the...

  • Page 20: Inspection, Damage And Shortage

    035-19569-101 (0109) Units shipped dismantled MUST be re- 3.3 Inspection, Damage and Shortage assembled by, or under the supervision of, a York representative. (See Form 160.73-N3) The unit shipment should be checked on arrival to see that all major pieces, boxes and crates are received. NOTE Each unit should be checked before unloading, for any visible signs of damage.

  • Page 21: Rigging

    035-19569-101 (0109) Do not lift the unit with slings around motor/ 3.4 Rigging compressor assembly or by means of eye The complete standard chiller is shipped without skids. bolts in the tapped holes of the compressor (When optional skids are used it may be necessary to motor assembly.
  • Page 22 035-19569-101 (0109) Page Left Intentionally Blank...

  • Page 23: Installation

    035-19569-101 (0109) INSTALLATION 4.5 Rigging Unit to Final Location Rig the unit to its fi nal location on the fl oor or mounting 4.1 Location pad, lift the unit (or shell assembly) by means of an overhead lift and lower the unit to its mounting position. YK units are furnished with vibration isolator mounts (If optional shipping skids are used, remove them before for basement or ground level installations.

  • Page 24: Installing Optional Spring Isolators

    035-19569-101 (0109) 4.7 Installing Optional Spring Isolators 4.8 Piping Connections When ordered, 4 spring type isolator assemblies will be After the unit is levelled (and wedged in place for optional furnished with the unit. The 4 assemblies are identical spring isolators) the piping connections may be made; and can be placed at any of the 4 corners of the unit.
  • Page 25 035-19569-101 (0109) LD08525 UNIT WEIGHT UP TO 7423 Kgs. UNIT WEIGHT 7424 TO 13,080 Kgs. LD08527 LD08528 UNIT WEIGHT 13,081 TO 24,281 Kgs. UNIT WEIGHT 24,281 TO 45,570 Kgs. Condenser Centreline Centreline Dimensions of Vessels Evaporator Centreline Dimensions Figure 4.1 Neoprene Isolators...
  • Page 26 035-19569-101 (0109) 4-Spring Isolators, Unit Weights less than 15880 kg 6-Spring Isolators, Unit Weights 15881 kg to 26467 kg 9-Spring Isolators, Unit Weights greater than 26468 kg Figure 4.2 Spring Isolators...

  • Page 27: Chilled Water Circuit

    035-19569-101 (0109) 4.9.1 Chilled Water Circuit 4.9.2 Condenser Water Circuit Foreign objects which could lodge in, or block fl ow For proper operation of the unit, condenser refrigerant through the evaporator and condenser tubes must be pressure must be maintained above evaporator pressure. kept out of the water circuit.

  • Page 28: Stop Valves

    035-19569-101 (0109) transit may cause the nuts to loosen. If water pressure 4.10 Stop Valves is applied before tightening is done, the gaskets may be Stop valves may be provided (by others) in the damaged and have to be replaced. evaporator and condenser water piping adjacent to Fill the chilled and condenser water circuits, operate the unit to facilitate maintenance.

  • Page 29: Unit Piping

    035-19569-101 (0109) 4.15 Unit Piping 4.17 Control Wiring Compressor lubricant piping and system external piping On units shipped disassembled, after installation of the are factory installed on all units shipped assembled. control panel, control wiring must be completed between On units shipped dismantled, the lubricant piping to oil unit components and control panel, solid state starter, or sump and oil cooler and system oil return connections variable speed drive, when used, using wiring harness...

  • Page 30: Units With Solid State Starter Or Variable Speed Drive

    035-19569-101 (0109) YK Motors (Electro-Mechanical Starter) 4.20 Thermal Insulation (See Product Drawings Form 160.52-PA1) Figure 4.6 shows the power wiring hook-up for Motor Connections. (Refer to Wiring Labels in Motor Terminal DO NOT fi eld insulate until the unit has been Box for hook-up to suit motor voltage and amperage.) leak tested under the supervision of the York representative.

  • Page 31: Commissioning

    035-19569-101 (0109) The customers disconnection devices can now be set COMMISSIONING to ON. 5.1 Preparation The machine is now live! Commissioning of this unit should only be carried out by York authorised personnel. WARNING CAUTION Oil Heater: Verify the oil heater is energised for at least The Graphic Control Centre manual must be read in 12 hours prior to start-up.

  • Page 32: First Time Start-Up

    035-19569-101 (0109) 5.2 First Time Start-up During the commissioning period there should be suffi cient heat load to run the unit under stable full load operation to enable the unit controls, and system operation to be set up correctly and a commissioning log taken.
  • Page 33 035-19569-101 (0109) OPERATION 6.2 Checking the Oil Level in the Oil Reservoir If the oil heater is de-energised during a Correct oil level - During operation, the oil level should shutdown period, it must be energized for 12 fall to the "Operating Range" identifi ed on the vertical hours prior to starting the compressor.
  • Page 34 035-19569-101 (0109) Figure 6.1 Control Centre 6.3.2 Start-up 1. The control centre display message will read 1. If the chilled water pump is manually operated, start SYSTEM PRELUBE for the fi rst 50 seconds of the the pump. The control centre will not allow the chiller to start unless chilled liquid fl...
  • Page 35 035-19569-101 (0109) ** Not for all shutdowns. Refer to Graphic Control Centre Operating Instructions. Figure 6.2 Chiller Starting Sequence and Shutdown Sequence (Electro-mechanical and Solid State Starter Models) ** Not for all shutdowns. Refer to Graphic Control Centre Operating Instructions. Figure 6.2 Chiller Starting Sequence and Shutdown Sequence (Variable Speed Drive Models)
  • Page 36 035-19569-101 (0109) 6.4 Chiller Operation 6.5 Operating Log Sheet After the compressor reaches operating speed, the pre- An accurate record of system operating conditions rotation vanes will begin to open under the control of the (temperatures and pressures) recorded at regular microprocessor which senses the leaving chilled liquid intervals throughout each 24 hour operating period temperature.
  • Page 37 035-19569-101 (0109) 6.6.2 Safety Shutdowns Solid State Starter Shutdowns If the chiller shuts down on a SAFETY shutdown, • LCSSS Shutdown - Requesting Fault Data the chiller will restart when the shutdown condition is • LCSSS - High Instantaneous Current removed.
  • Page 38 035-19569-101 (0109) • VSD - High Converter Heatsink Temperature 6.6.3 Cycling Shutdowns • VSD – Phase A Gate Driver If the chiller shuts down on a CYCLING shutdown, the chiller will automatically restart when the cycling • VSD – Phase B Gate Driver condition is removed.
  • Page 39 035-19569-101 (0109) 6.7 Stopping the System 6.8 Prolonged Shutdown The graphic control centre (OptiView) can be programmed If the chiller is to be shut down for an extended period of to start and stop automatically (maximum, once each time (for example, over the winter season), the following day) whenever desired.
  • Page 40 035-19569-101 (0109) Page Left Intentionally Blank...
  • Page 41 035-19569-101 (0109) 4. Check the entering and leaving chilled liquid MAINTENANCE temperatures and evaporator pressure are correct for design conditions on the SYSTEM Screen. The units have been designed to operate continuously provided they are regularly maintained and operated 5. Check the condenser saturation temperature (based within the limitations given in this manual.
  • Page 42 035-19569-101 (0109) COMPRESSOR SOLENOID VALVE CONDENSER EVAPORATOR CHECK VALVE OIL EDUCTOR BLOCK SOLENOID VALVE DEHYDRATOR STOP VALVE STOP VALVE Figure 7.1 Oil Return System 7.1.6 Annually (more often if necessary) 7.2 Oil Return System 1. Drain and replace the oil in the compressor oil sump The oil return system continuously maintains the proper (See Oil Charging Procedure).
  • Page 43 035-19569-101 (0109) Figure 7.2 Oil Reservoir Charging 7.3 Oil Charge The nominal oil charge for the compressor is 75.7 litres, 4. As soon as oil charging is complete, restore the power of York “K” oil. Only York “K” refrigeration oil must be supply to energise the oil heater.
  • Page 44 035-19569-101 (0109) Figure 7.3 Unit Evacuation 7.4.2 Leak Testing causing leaks, the temperature should be brought up slowly so that the tubes and shell are heated After the system has been charged, the system should evenly. be carefully leak tested with a R134a compatible leak detector to ensure all joints are tight.
  • Page 45 035-19569-101 (0109) 1. The condenser tubes should be cleaned annually 7.4.4 Refrigerant Charging or earlier if conditions warrant. If the temperature When opening any part of the refrigerant difference between the water off the condenser and system for repairs, the refrigerant charge the condenser liquid temperature is more than 2.2 K must be removed.
  • Page 46 035-19569-101 (0109) Condenser Acid Cleaning of Tubes Condenser trouble due to fouled tubes is usually If the tubes are fouled with a hard scale deposit, they indicated by a steady rise in head pressure, over a period may require acid cleaning. It is important that before acid of time, accompanied by a steady rise in condensing cleaning, the tubes be cleaned by the brushing process temperature, and noisy operation.
  • Page 47 035-19569-101 (0109) 4. After the tubes have been corked for 12 to 24 hours, 2. Oil Changing - The oil in the compressor must be it is recommended that two men working at both changed annually or earlier if it becomes dark or ends of the evaporator carefully test each tube –...
  • Page 48 035-19569-101 (0109) 7.8 Electrical Controls 7.9 Testing Motor Winding Insulation All electrical controls should be inspected for With the main disconnect switch and compressor motor obvious malfunctions. starter open, test the motor as follows: It is important that the factory settings of controls 1.
  • Page 49 035-19569-101 (0109) TROUBLSHOOTING Fault Possible Cause Remedy 1. SYMPTOM: Abnormally High Discharge Pressure Temperature difference between Air in condenser. Bleed cooling water circuit. condensing temperature and condenser leaving liquid temperature higher than normal. High discharge pressure. Condenser tubes dirty or scaled. Clean condenser tubes.
  • Page 50 035-19569-101 (0109) Fault Possible Cause Remedy 5. SYMPTOM: Unusually High Oil Pressure develops when Oil Pump Runs Unusually high oil pressure is High oil pressure. Transducer Replace low or high oil pressure displayed when the oil pressure defective. transducer. display key is pressed when the oil pump is running.
  • Page 51 035-19569-101 (0109) TECHNICAL DATA 9.1 Dimensions P and Q Compressors COMPRESSOR OPTIVIEW MOTOR CONTROL CENTER EVAP CONDENSER (SHIPPING WIDTH) (EVAP) (EVAP) ADDITIONALOPERATING HEIGHT CLEARANCE TO FLOOR Q3 COMPRESSOR TYPE OF CHILLER MOUNTING EVAPORATOR-CONDENSER SHELL CODES NEOPRENE PAD ISOLATORS 1549 1676 1676 SPRING ISOLATORS 1"...
  • Page 52 035-19569-101 (0109) H Compressors ADDITIONALOPERATING HEIGHT CLEARANCE TYPE OF CHILLER MOUNTING NEOPRENE PAD ISOLATORS SPRING ISOLATORS 25MMDEFLECTION DIRECT MOUNT H9 COMPRESSORS EVAP.-COND.SHELL CODES 2299 2616 3150 3315 4267 4267 NOTES: 1. All dimensions are approximate. Certified dimensions are available on request. 2.
  • Page 53 035-19569-101 (0109) K Compressors COMPRESSOR MOTOR OPTIVIEW CONTROL CENTER EVAP CONDENSER (EVAP) (SHIPPING WIDTH) (EVAP) 7” K1 COMPRE SS OR, EVAPORATOR-CONDENSER S HELL CODES ADDITIONALOPERATING HEIGHT CLEAR - 2299 2616 2616 2781 2781 ANCE 2921 3454 3454 3493 3493 TYPE OF CHILLER MOUNTING NEOPRENE PAD ISOLATORS SPRING ISOLATORS 1"...
  • Page 54 035-19569-101 (0109) 9.2 Dimensions - Evaporator Compact Water Boxes ONE PASS EVAPORATORS, CODES DIM. J,K,L R,S,W TWO PASS EVAPORATORS, CODES DIM. J,K,L R,S,W THREE PASS EVAPORATORS, CODES DIM. J,K,L R,S,W...
  • Page 55 035-19569-101 (0109) 9.3 Nozzle Arrangements - Evaporator Compact Water Boxes A to K Evaporators 1-PASS FRONT NOZZLE ARRANGEMENTS EVAP. EVAP. UNIT EVAPORATOR NO. OF PASSES MOTOR END COMPRESSOR END FLOOR LINE 2-PASS FRONT EVAP. EVAP. NOZZLE UNIT ARRANGEMENTS NO. OF EVAPORATOR PASSES FLOOR LINE...
  • Page 56 035-19569-101 (0109) Evaporators - Compact Water Boxes - M to Z Evaporators 1 PASS FRONT UNIT 1 PASS SHELL CODE M–Z FLOOR MOTOR END COMPRESSOR END LINE 2 PASS FRONT 2 PA SS SHELL UNIT CODES M–Z FLOOR LINE COMPRESSOR END MOTOR END 3 PASS FRONT...
  • Page 57 035-19569-101 (0109) 9.4 Dimensions - Condenser Compact Water Boxes ONE PASS CONDENSERS, CODES DIM. J,K,L T,V,W TWO PASS CONDENSERS, CODES DIM. J,K,L T,V,W THREE PASS CONDENSERS, CODES DIM. J,K,L T,V,W...
  • Page 58 035-19569-101 (0109) 9.5 Nozzle Arrangements - Condenser Compact Water Boxes FRONT 1-PASS OF UNIT NOZZLE ARRANGEMENTS COND. NO. OF PASSES FLOOR COND. COND. LINE COMPRESSOR END MOTOR END FRONT 2-PASS OF UNIT NOZZLE ARRANGEMENTS COND. NO. OF PASSES FLOOR COND. COND.
  • Page 59 035-19569-101 (0109) 9.6 Dimensions - Evaporator Marine Water Boxes 1-PASS FRONT OF UNIT FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FLOOR LINE COMPRESSOR END MOTOR END 2-PASS FRONT OF UNIT FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END COMPRESSOR END MOTOR END FLOOR LINE...
  • Page 60 035-19569-101 (0109) 9.8 Nozzle Arrangements - Evaporator Marine Water Boxes EVAPORATOR 1-PASS EVAPORATOR 2-PASS 1-PASS 2-PASS 3-PASS EVAP SHELL CODE J,K,L QT,QV R,S,W EVAPORATOR 3-PASS NOTES: 1. All dimensions are approximate. Certified dimensions are available upon request. 2. Standard water nozzles are Schedule 40 pipe size, furnished as welding stub-outs with Victaulic grooves, allowing the option of welding, flanges, or use of Victaulic couplings.
  • Page 61 035-19569-101 (0109) 9.8 Dimensions - Condenser Marine Water Boxes FRONT OF UNIT FRONT OF UNIT 1-PASS FLOOR FLOOR LINE LINE MOTOR END COMPRESSOR END MOTOR END COMPRESSOR END 2-PASS FRONT OF UNIT FRONT OF UNIT FLOOR FLOOR LINE LINE COMPRESSOR END MOTOR END MOTOR END COMPRESSOR END...
  • Page 62 035-19569-101 (0109) 9.8 Nozzle Arrangements - Condenser Marine Water Boxes CONDENSER 1-PASS TUBE TUBE SHEET SHEET (2-PASS RETURN HEAD) CONDENSER 2-PASS 1-PASS 2-PASS 3-PASS CONDSHELL CODE CONDENSER J,K,L 3-PASS T,V,W NOTES: 1. All dimensions are approximate. Certified dimensions are available upon request. 2.
  • Page 63 035-19569-101 (0109) 9.9 Unit Weights 9.9.1 Approximate Unit Weight Including Motor EST. REFRIGERANT CHARGE SHELLS COMPRESSOR SHIPPING WEIGHT (KGS.) OPERATING WEIGHT (KGS.) (KGS.) 5,942 6,804 Q3, Q4 6,768 8,138 6,954 8,324 Q3, Q4 7,809 9,571 7,995 9,757 Q3, Q4 8,142 10,052 Q5,Q6,Q7,P7 8,328...
  • Page 64 035-19569-101 (0109) 9.9.2 Evaporator Marine Water Box Weights Add weights in table below to standard unit weights given in 9.9.2. SHIPPING WEIGHT SHIPPING WEIGHT OPERATING WEIGHT OPERATING WEIGHT INCREASE - KGS . INCREASE - KGS . INCREASE - KGS . INCREASE - KGS .
  • Page 65 035-19569-101 (0109) 9.10 Process and Instrumentation Diagram 9-15...
  • Page 66 035-19569-101 (0109) Page Left Intentionally Blank 9-16...
  • Page 67 035-19569-101 (0109) SPARE PARTS When ordering spare parts, we will require the following information to ensure the correct parts are supplied: Full unit model number, serial number, application and details of the parts required. All requests for parts should be made to your local York Sales and Service Centre.
  • Page 68 035-19569-101 (0109) Page Left Intentionally Blank 10-2...
  • Page 69 035-19569-101 (0109) DE-COMMISSIONING, DISMANTLING AND DISPOSAL Packaged units can generally be removed in one piece Never release refrigerant to the atmosphere after disconnection as above. Any fi xing down bolts when emptying the refrigerating circuits. should be removed and then the unit should be lifted Suitable retrieval equipment must be used.
  • Page 70 035-19569-101 (0109) Page Left Intentionally Blank 11-2...
  • Page 72 www.johnsoncontrols.com 035-19569-101 (0109) Subject to change without notice. ALL RIGHTS RESERVED...

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