Download
Share
Print this page
Johnson Controls York YK H Series Operation And Maintenance
  1. Manuals
  2. Brands
  3. Johnson Controls Manuals
  4. Chiller
  5. York YK H Series
  6. Operation and maintenance
Johnson Controls York YK H Series Operation And Maintenance

Johnson Controls York YK H Series Operation And Maintenance

With r-134a, r-513a, or r-1234ze refrigerant
Hide thumbs Also See for York YK H Series:

Advertisement

Quick Links

Download this manual
Model YK Style H, with R-134a, R-513A, or
R-1234ze Refrigerant
With OptiView Control Center for Electromechanical
Starter, Solid-State Starter, and Variable Speed Drive
Operations and Maintenance
Issue Date: 2024-04-19
© 2024 Johnson Controls. All rights reserved.
Form Number: 160.76-O1 (424)
Supersedes: 160.76-O1 (1223)

Advertisement

loading
Need help?

Need help?

Do you have a question about the York YK H Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Johnson Controls York YK H Series

Summary of Contents for Johnson Controls York YK H Series

  • Page 1 Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant With OptiView Control Center for Electromechanical Starter, Solid-State Starter, and Variable Speed Drive Operations and Maintenance Form Number: 160.76-O1 (424) Issue Date: 2024-04-19 Supersedes: 160.76-O1 (1223) © 2024 Johnson Controls. All rights reserved.
  • Page 2 Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 3: Table Of Contents

    Optional hot gas bypass........................26 OptiView™ Control Center........................26 Solid state starter, optional........................ 27 Variable speed drive, optional......................27 Operational maintenance..........................28 Oil return system..........................28 Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 4 Greased bearings..........................50 Motor relubrication instruction......................50 Leak testing............................56 Evaporator and condenser......................... 56 Oil return system..........................57 Electrical controls..........................58 Maintenance inspections........................59 Unit conversion.............................. 61 Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 5: General Safety Guidelines

    Note: Highlights additional information useful to the technician in completing the work being performed correctly. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 6: Wiring Warning

    All wiring must be in accordance with the published specifications of Johnson Controls and must be performed only by a qualified electrician. Johnson Controls will not be responsible for damage or problems resulting from incorrect connections to the controls or application of incorrect control signals.

  • Page 7: Changeability Of This Document

    ® information contained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual or product owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson...

  • Page 8: Associated Literature

    Modbus, VSD with Modbus Wiring Diagram - Field Connections Model YK Chillers (Style H) with Low Voltage 160.76-PW7 Variable Speed Drive Application Data - A2L Refrigerant Supplement for Johnson Controls Chillers 160.00-AD10 YK Centrifugal Liquid Chillers YORK Proactive Service Guide 160.76-PSG1 YORK Oil Application, Oil Change Interval, and Oil Quality Limits Replacement 50.40-O1...

  • Page 9: Conditioned Based Maintenance

    Conditioned based maintenance Traditional chiller maintenance is based upon assumed and generalized conditions. Instead of the traditional maintenance program, a Johnson Controls YORK Conditioned Based Maintenance (CBM) program can be substituted. This CBM service plan is built around the specific needs for the chiller, operating conditions, and annualized impact realized by the chiller.

  • Page 10: Nomenclature

    Nomenclature Note: * Refer to YK Engineering Guide (Form 160.76-EG1) for shell, motor, and compressor combinations. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 11: Description Of The System And Fundamentals Of Operation

    However, most systems only need to deliver full load capacity for a relatively small part of the time the unit is in operation. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 12 Figure 1: Compressor pre-rotation vanes Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 13 Liquid level valve Evaporator Suction baffle Liquid level Optional isolation valve Sub-cooler Liquid level Condenser Optional isolation valve Discharge Hot gas bypass valve Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 14: Capacity Control

    Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 15: System Operating Procedures

    If the oil level during operation is in the low oil region of the oil level indicator, add oil to the oil reservoir. See Charging the oil. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 16: Start-Up Procedure

    If the load continues to decrease, after the pre-rotation vanes are entirely closed, the chiller is shut down by the Leaving Chilled Liquid – Low Temperature Control. The coolant temperature inside any Johnson Controls supplied liquid-cooled motor starter must be maintained above the dewpoint temperature in the equipment room to prevent condensing water vapor inside the starter cabinet.

  • Page 17: Condenser Water Temperature Control

    Controls personnel for recording test data on chiller systems. It is available from the factory in pads of 50 sheets each under Form 160.54-MR1 and can be obtained through the nearest Johnson Controls office. Automatic data logging is possible by connecting the optional printer and programming the data logger function.

  • Page 18: Operating Inspections

    4°F (2.2°C). Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 19 Conduct vibration testing and record results. 6. Chiller systems: a. Inspect and service all chiller system electrical components as necessary. b. Perform refrigerant analysis. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 20: Need For Maintenance Or Service

    Johnson Controls District Office. Failure to report constant troubles could damage the unit and increase the cost of repairs.

  • Page 21: System Components Description

    The oil lubricates the compressor rotating components and is returned to the oil sump. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 22: Oil Pump

    Callout Description Callout Description Relief valves Variable speed drive Suction Evaporator OptiView control center Variable speed oil pump control box Compressor Sight glass Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 23 Figure 6: System components, rear view Callout Description Callout Description Motor Liquid line Oil filter Oil pump housing Compressor Condenser Discharge line Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 24: Oil Heater

    This foaming is caused by refrigerant boiling out of the oil as Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 25: Motor Driveline

    Plugged 3/4 in. (19 mm) drain and vent connections are provided in each waterbox, except for marine waterboxes with vertical nozzles where there are drain connections only. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 26: Refrigerant Flow Control

    For detailed information on the Control Center, see System operating procedures. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 27: Solid State Starter, Optional

    Drive – Operation, Form 160.00-O1. The control logic automatically adjusts motor speed and compressor pre-rotation vane position for maximum part load efficiency by analyzing information fed to it by sensors located throughout the chiller. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 28: Operational Maintenance

    Refer to Form 50.40-O1 for guidelines relating to oil change intervals, oil quality, operational quantities, application, and storage. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 29: Charging The Oil

    This lowers the oil level in the reservoir. It may then be necessary to add oil to bring the level back into the operating range of the oil level indicator label. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 30 Figure 9: Charging the oil reservoir with oil Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 31: Troubleshooting

    Inspect and replace worn parts. Other worn pump parts. Oil pump pumping capacity. The oil supply inlet is partially Check the oil inlet for blockage. blocked. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 32 Faulty oil pressure transducer. No oil pressure registers when pressing the Oil Replace oil pressure transducer. Pressure display key when the oil pump runs. Faulty wiring/connectors. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 33: Maintenance

    WARNING Care must be taken not to exceed the rated pressure of the unit refrigerant pressure relief valves. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 34 When all leaks have been identified, vent the nitrogen vapor, make the necessary repairs to the chiller, and repeat the gas pressure hold test until a satisfactory hold test is achieved. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 35 10 psig (69 kPa). When using a refrigerant based trace gas, always charge with vapor only to reach the initial 10 psig pressure. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 36: System Evacuation

    Follow the dehydration steps as closely as possible to prevent moisture becoming trapped in the system. If you apply too deep of a vacuum, any trapped moisture might freeze and might not be Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 37 = pound per square inch absolute pressure = sum of gauge plus atmospheric pressure • Shell volume = L*π * r = (Length in feet)*( 3.1416)*(radius squared) = cubic feet Note: Water freezes at 32°F. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 38 Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 39 3. Operate the vacuum pump to evacuate the system to the best attainable vacuum. The vacuum must be less than 500 μm but if that cannot be attained, a vacuum at 1,000 μm or lower is acceptable. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 40: Refrigerant Charging

    The charging line must also contain a sight-glass so that when liquid charging is performed, you can monitor the charging line to determine when the liquid is no longer being transferred to the chiller. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 41 300 (20.68) 157.7 (69.8) 430 (29.65) 187.4 (86.3) 45.0 (3.10) 45.1 (7.3) 175 (12.07) 118.4 (48.0) 305 (21.03) 159.0 (70.6) 435 (29.99) 188.4 (86.9) Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 42 53.78 (3.71) 60 (15.6) 106.23 (7.32) 101 (38.3) 190.16 (13.11) 142 (61.1) 54.76 (3.78) 61 (16.1) 107.87 (7.44) 102 (38.9) 192.69 (13.29) 143 (61.7) Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 43 This may be 24 hours or more after the compressor and water pumps are stopped. The level is visible in the sight glass. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 44: Motor Megging

    Using a megohmmeter (megger), meg between phases and each phase to ground. See the following figure. Interpret these readings using the graph of Figure Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 45 Figure 14: Megging the motor windings, VFD or solid state soft starter Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 46 Figure 15: Motor starter temperature and insulation resistances Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 47: Condenser And Evaporator Maintenance

    Do not use a steel bristle brush. A steel brush may damage the tubes. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 48 If not, it is necessary to make a very thorough test with the leak detector. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 49: Compressor Maintenance

    If aluminum particles continue to accumulate, contact Johnson Controls Service. Refer to Form 50.40-O1 for guidelines relating to oil change intervals, oil quality, operational quantities, application, and storage.

  • Page 50: Preventive Maintenance

    Important: If a unit failure occurs due to improper maintenance during the warranty period, Johnson Controls will not be liable for costs incurred to return the system to satisfactory operation. In any operating system it is most important to provide a planned maintenance and inspection of its functioning parts to keep it operating at its peak efficiency.
  • Page 51 Remove grease plug if equipped before greasing. Not every grease interval results in used grease discharge. • All WEG frame sizes in Table 10 lubricate at 1100 hours regardless of nameplate. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 52 Johnson Controls service office prior to attempting the work. Please be aware that this information may be time sensitive and that Johnson Controls reserves the right to revise at any time. Be certain you are working with the latest information.
  • Page 53 YORK factory. WARNING Mixing different greases is not recommended. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 54 Read these instructions completely before starting the relubrication process. Use the following procedure: Motor overview: Grease the inlet and outlet (relief port) locations, and bearing cap. See Figure Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 55 Figure Figure 17: Grease gun Remove the drain plug and clean old grease from the drain opening. See Figure Figure 18: Grease outlet Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 56: Leak Testing

    • The formation of scale • Incidence of corrosion or rusting • The formation of slime and algae Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 57: Oil Return System

    2. When the dehydrator is changed, the nozzle of the eductor should be checked for any foreign particles that may be obstructing the jet. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 58: Electrical Controls

    1. All electrical controls should be inspected for obvious malfunctions. 2. Do not change the factory settings of controls (operation and safety). If the settings are changed without Johnson Controls approval, the warranty will be jeopardized. Refer to YK Centrifugal Chiller Log Sheets (Form 160.54-MR1) for sign off.

  • Page 59: Maintenance Inspections

    Check the operation of the motor starter. Monitor at unit start-up for any abnormalities. • Check the sump heater and thermostatic control valve operation by noting the oil supply temperature. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 60 Perform driveline vibration analysis. • Check compressor thrust end-play of low speed shaft. • For HYP Model VSDs only, conduct a Smart sensor annual test. Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.

  • Page 61: Unit Conversion

    To convert a temperature range (that is, a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556. Example: 10.0°F range x 0.5556 = 5.6 °C range   Model YK Style H, with R-134a, R-513A, or R-1234ze Refrigerant © 2024 Johnson Controls. All rights reserved.
  • Page 62 © 2024 Johnson Controls. 5000 Renaissance Drive, New Freedom, York, PA 17349, USA. Subject to change without notice. All rights reserved. © 2024 Johnson Controls. All rights reserved.
Save PDF