York YK-EP Operation And Maintenance Manual

Centrifugal liquid chiller with economizer compressor

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Operation and maintenance manual (268 pages)

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Centrifugal Liquid Chiller

with Economizer Compressor

Operation and Maintenance

Supersedes: 160.77-O1 (424)

Form 160.77-O1 (425)

Model YK-EP

2,700 ton to 3,200 ton

R-134a

Issue Date:

April 24, 2025

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Page 1 Centrifugal Liquid Chiller with Economizer Compressor Operation and Maintenance Supersedes: 160.77-O1 (424) Form 160.77-O1 (425) Model YK-EP 2,700 ton to 3,200 ton R-134a Issue Date: April 24, 2025 © 2025 Johnson Controls. All rights reserved...
Page 2: Read Before Proceeding
Form 160.77-O1 Issue Date: 4/24/2025 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: Changeability Of This Document
Long-Term Storage - Periodic Checklist and Logs 50.20-CL5 Operation - Oil Application, Oil Change Interval, and Oil Quality Limits Replacement Recommendations 50.40-O1 Evacuation, Leak Checking, and Refrigerant Charging Procedures for YORK Centrifugal Chiller Products 50.40-O3 © 2025 Johnson Controls. All rights reserved...
Page 4 Planned Service Agreement that leverages real time and generalized conditions. In lieu of the traditional and historical data, delivering performance reporting, maintenance program, a Johnson Controls YORK corrective actions required and data enabled guidance Conditioned Based Maintenance (CBM) program can for optimal operation and lifecycle assurance.
Page 5: Table Of Contents
Form 160.77-O1 Issue Date: 4/24/2025 Table of contents LIST OF FIGURES ..............................6 LIST OF TABLES ..............................6 SECTION 1 - SYSTEM FUNDAMENTALS ......................7 SECTION 2 - SYSTEM OPERATING PROCEDURES ..................15 SECTION 3 - MAINTENANCE ..........................19 SECTION 4 - TROUBLESHOOTING ........................29 © 2025 Johnson Controls.
Page 6: List Of Figures
Form 160.77-O1 Issue Date: 4/24/2025 List of figures FIGURE 1 - YK-EP chiller major components, front view ..................7 FIGURE 2 - YKEP chiller, rear view ..........................8 FIGURE 3 - Medium voltage VSD ..........................8 FIGURE 4 - Medium voltage SSS ..........................8 FIGURE 5 - YK-EP System flow diagram .......................13...
Page 7: Section 1 - System Fundamentals
Starter (LV-SSS) for the economizer compressor motor. The primary compressor starter, both compressor mo- tors, the evaporator, and the condenser are job-specific. Figure 1 on page 7 identifies the major YK-EP components, which are described in detail on the fol- lowing pages. PRIMARY...
Page 8: Figure 2 - Ykep Chiller, Rear View
Medium-Voltage Variable Speed Drive (MV-VSD) (Figure 3 on page 8) and a Unit-Mounted MV-SSS The Primary compressor motor can be equipped with (Figure 4 on page 8). one of two YORK starters, or optionally, supplied by the customer. Customer-supplied starters must be floor-mounted. LD15104...
Page 9 Motors neled through baffles, out the top and on to the econo- YORK YKEP centrifugal chillers utilize air-cooled mizer compressor suction. The remaining liquid feeds motors. This means that refrigerant never comes in out of the economizer through a liquid level control contact with the motor.
Page 10 Refrigerant flow to the evaporator is controlled by the minum mesh eliminators are located above the tube YORK variable orifice control system. Liquid refrig- bundle to prevent liquid refrigerant carryover into the erant level is continuously monitored to provide op- compressor.
Page 11 Form 160.77-O1 SECTION 1 - SYSTEM FUNDAMENTALS Issue Date: 4/24/2025 Control center The position of the vanes is automatically controlled The chiller is controlled by a stand-alone PLC based through a lever arm attached to an electric motor locat- control center. The chiller control center provides all ed outside the compressor housing.
Page 12 YK-EP system flow explanation Step 4. Expansion and economizer The refrigerant liquid from the condenser is partially The YORK YK-EP chiller operates much the same as expanded to a pressure intermediate to the evaporator the YORK YK Single Stage chiller. The only exception and condenser.
Page 13: Figure 5 - Yk-Ep System Flow Diagram
Form 160.77-O1 SECTION 1 - SYSTEM FUNDAMENTALS Issue Date: 4/24/2025 LD15103 Figure 5 - YK-EP System flow diagram © 2025 Johnson Controls. All rights reserved...
Page 15: Section 2 - System Operating Procedures
(Form 160.77-CL2) details the process and procedures Refer to the YK-EP Control Panel Operations Manual used to startup and operate the YK-EP chiller. If the (Form 160.77-O2). Make sure the display reads SYS- oil heater is de-energized during a shutdown period, it TEM READY TO START.
Page 16: Operating Logs
Operating inspections Condenser water temperature control By following a regular inspection using the display The YK-EP chiller is designed to use less power by readings of the YK-EP Control Center, and mainte- taking advantage of lower than design water temper-...
Page 17: Figure 7 - Liquid Chiller Log Sheets
Form 160.77-O1 SECTION 2 - SYSTEM OPERATING PROCEDURES Issue Date: 4/24/2025 Quarterly 2. Check the Evaporator and Condenser. 1. Perform chemical analysis of oil. a. Inspect and clean water strainers. Semi-annually (or more often as required) b. Inspect and clean tubes as required. 1.
Page 18: Need For Maintenance Or Service
Stopping the system The YK-EP Control Center can be programmed to start and stop automatically (maximum - once each day). 2. If freezing temperatures are expected while the For more information on this refer to the YKEP Con- system is idle, carefully drain the cooling water trol Center Operation Manual (Form 160.77-O2).
Page 19: Section 3 - Maintenance
Form 160.77-O1 Issue Date: 4/24/2025 Section 3 - Maintenance Renewal parts Changing the dehydrator To change the dehydrator, use the following procedure: For any required Renewal Parts, refer to the YKEP Unit Renewal Parts Manual (Form 160.77-RP1). 1. Isolate the dehydrator at the stop valves. Oil return system 2.
Page 20: Oil Charge
This will keep the concentration of refrig- YORK Oil Charging Pump (YORK Part No. 070- erant in the oil to a minimum. 10654).
Page 21: Figure 10 - Megging Motor Windings
For guidance on preferred service practices and speci- While the compressor motor leads are lifted at the lugs fication for refrigerant boundary of YORK centrifugal in the drive, meg the motor as follows: chiller products, refer to the Evacuation, Leak Checking, 1.
Page 22: Condensers And Evaporators
Form 160.77-O1 SECTION 3 - MAINTENANCE Issue Date: 4/24/2025 Condensers And Evaporators Chemical Water Treatment The mineral content of the water circulated through Maintenance of condenser and evaporator shells is im- evaporators and condensers varies with almost every portant to provide trouble free operation of the chiller. source of supply.
Page 23: Figure 11 - Motor Starter Temperature And Insulation Resistances
Form 160.77-O1 SECTION 3 - MAINTENANCE Issue Date: 4/24/2025 LD00476 Figure 11 - Motor starter temperature and insulation resistances © 2025 Johnson Controls. All rights reserved...
Page 24 Form 160.77-O1 SECTION 3 - MAINTENANCE Issue Date: 4/24/2025 Improved results can be obtained by admitting water Cleaning the Evaporator and Condenser into the tube during the cleaning process. This can be Tubes done by mounting the brush on a suitable length of 1/8" Evaporator pipe with a few small holes at the brush end and con- necting the other end by means of a hose to the water...
Page 25: Electrical Controls
Form 160.77-O1 SECTION 3 - MAINTENANCE Issue Date: 4/24/2025 Internal wearing of compressor parts could be caused Evaporator And Condenser by improper lubrication, brought about by restricted oil The major portion of maintenance on the condenser lines, passages, or dirty oil filters. If the unit is shut- and evaporator will deal with maintaining the water ting down on High Oil Temperature (HOT) or Low Oil side of the condenser and evaporator in a clean condi-...
Page 26 Form 160.77-O1 SECTION 3 - MAINTENANCE Issue Date: 4/24/2025 Electrical Controls 1. All electrical controls should be inspected for ob- vious malfunctions. 2. It is important that the factory control settings (op- eration and safety) not be changed. If the settings are changed without Johnson Controls approval, the warranty may be voided.
Page 29: Section 4 - Troubleshooting
Form 160.77-O1 Issue Date: 4/24/2025 Section 4 - Troubleshooting If the system is malfunctioning in any manner, refer to est Johnson Controls District Office. Failure to report the Operation Analysis Chart shown in Table 1 on page constant troubles could damage the unit and increase 29.
Page 30 Form 160.77-O1 SECTION 4 - TROUBLESHOOTING Issue Date: 4/24/2025 TABLE 3 - OPERATION ANALYSIS CHART (CONT'D) SYMPTOM RESULTS POSSIBLE CAUSE REMEDY Oil pump vibrates or is extremely noisy Oil not reaching pump with some oil pressure when pressing suction inlet in sufficient Check oil level.
Page 31: Si Metric Conversion
Form 160.77-O1 Issue Date: 4/24/2025 SI Metric Conversion The following factors can be used to convert from imperial to the most common SI Metric values. TABLE 2 - ANALOG INPUT RANGES (LOW PRESSURE CHILLERS) Measurement Multiply imperial Unit By Factor To Obtain Metric Unit Capacity Tons Refrigerant Effect (ton)
Page 32 1-800-524-1330 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 Subject to change without notice. Printed in USA www.johnsoncontrols.com Copyright © by Johnson Controls 2025 ALL RIGHTS RESERVED Form 160.77-O1 (425) Issue Date: April 24, 2025 Supersedes: 160.77-O1 (424)

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