York YK Series Operation And Maintenance Manual
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York YK Series Operation And Maintenance Manual

York YK Series Operation And Maintenance Manual

Centrifugal liquid chillers r-134a cooling only
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MAXE
Centrifugal Liquid Chillers
Supersedes: 160.73-O2 (424)
Operation and Maintenance
Form 160.73-O2 (425)
Model YK (Style F)
R-134a Cooling Only
With OptiView Control Center
For Electro-Mechanical Starter,
Solid State Starter, and Variable Speed Drive
Issue Date:
April 24, 2025
©
2025 Johnson Controls. All rights reserved

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Summary of Contents for York YK Series

  • Page 1 MAXE Centrifugal Liquid Chillers Supersedes: 160.73-O2 (424) Operation and Maintenance Form 160.73-O2 (425) Model YK (Style F) R-134a Cooling Only With OptiView Control Center For Electro-Mechanical Starter, Solid State Starter, and Variable Speed Drive Issue Date: April 24, 2025 © 2025 Johnson Controls.

  • Page 2: Read Before Proceeding

    Form 160.73-O2 (425) Issue Date: 04/24/2025 Important Read before proceeding General safety guidelines This equipment is a relatively complicated apparatus. in which it is situated, as well as severe personal in- During installation, operation, maintenance or service, jury or death to themselves and people at the site. individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, This document is intended for use by owner-authorized...

  • Page 3: Changeability Of This Document

    YK Chiller Maintenance Requirements Chiller Log Sheet 160.54-MR1 YORK Oil Application, Oil Change Interval and Oil Quality Limits Recommendations 50.40-O1 Evacuation, Leak Checking and Refrigerant Charging Procedures for YORK Centrifugal Chiller Products 50.40-O3 YK Centrifugal Liquid Chillers YORK Proactive Service Guide 160.76-PSG1 ©...
  • Page 4 YK Centrifugal Time-based proactive services Liquid Chillers YORK Proactive Service Guide (Form A variety of factors, including unstable power, extreme 160.76-PSG1). ambient conditions, and chilled water system issues Nomenclature –...

  • Page 5: Table Of Contents

    Form 160.73-O2 (425) Issue Date: 04/24/2025 Table of contents SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION ........7 SECTION 2 - SYSTEM OPERATING PROCEDURES ..................10 SECTION 3 - SYSTEM COMPONENTS DESCRIPTION ...................17 SECTION 4 - OPERATIONAL MAINTENANCE ....................23 SECTION 5 - TROUBLESHOOTING ........................25 SECTION 6 - MAINTENANCE ..........................27 SECTION 7 - PREVENTATIVE MAINTENANCE ....................33...
  • Page 6 Form 160.73-O2 (425) Issue Date: 04/24/2025 List of figures MaxE FIGURE 1: Model YK chiller ..........................7 FIGURE 2: Compressor prerotation vanes .......................8 FIGURE 3: Refrigerant flow through chiller ......................9 FIGURE 4: Oil level indicator ..........................10 FIGURE 5: Chiller starting sequence and shutdown sequence (em starter and solid state starter) ...... 11 FIGURE 6: Chiller starting sequence and shutdown sequence (variable speed drive) ..........

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

    System operation description (See Figure 3) The YORK Model YK MaxE Chiller is commonly ing the keys as labeled on the Control Center. The chiller applied to large air conditioning systems, but may be with the OptiView™ Control Center is compatible with used on other applications.

  • Page 8: Capacity Control

    Description of System and Fundamentals of Operation Form 160.73-O2 (425) Issue Date: 04/24/2025 The major components of a chiller are selected to handle the refrigerant, which would be evaporated at full load design conditions. However, most systems will be called upon to deliver full load capacity for only a relatively small part of the time the unit is in operation.

  • Page 9: Figure 3: Refrigerant Flow Through Chiller

    Form 160.73-O2 (425) Issue Date: 04/24/2025 Compressor Prerotation vanes (See detail A) Discharge Suction Discharge baffle Evaporator Condenser Eliminator Sub-cooler Flow control orifice LD00924 Oil cooler Figure 3: Refrigerant flow through chiller © 2025 Johnson Controls. All rights reserved...

  • Page 10: Section 2 - System Operating Procedures

    System Operating Procedures Form 160.73-O2 (425) Issue Date: 04/24/2025 Section 2 - System operating procedures Oil heaters In the oil reservoir If the oil heater is de-energized during a shutdown period, Correct operating oil level – During operation, the oil it must be energized for 12 hours prior to starting com- level should fall to the Operating Range identified on pressor, or remove all oil and recharge compressor with...

  • Page 11: Figure 5: Chiller Starting Sequence And Shutdown Sequence (Em Starter And Solid State Starter)

    Form 160.73-O2 (425) Issue Date: 04/24/2025 2. To start the chiller, press the COMPRESSOR 1. The OptiView Control Center display message will START switch. This switch automatically springs read SYSTEM PRELUBE for the first 50 seconds return to the RUN position. (If the unit was previ- of the starting sequence.

  • Page 12: Figure 6: Chiller Starting Sequence And Shutdown Sequence (Variable Speed Drive)

    Condenser Water Temperature Control PERATURE setpoint. The Prerotation Vanes are modulated by an actuator under the control of the Mi- The YORK MaxE chiller is designed to use less power croprocessor Board. The vane control routine employs by taking advantage of lower than design temperatures proportional plus derivative (rate) control action.

  • Page 13: Operating Log Sheet

    An optional status printer is available for this purpose unit operating data that is outlined in the log. Use or Figure 7 shows a log sheet used by YORK Personnel this data for the following comparisons: for recording test data on chiller systems. It is available...
  • Page 14 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. More frequent service may be required depending on local operating conditions.

  • Page 15: Stopping The System

    • Perform a leak check and repair leaks as needed. YORK District Office. Failure to report constant troubles Refer to Form 50.40-O3. could damage the unit and increase the cost of repairs.

  • Page 16: Prolonged Shutdown

    System Operating Procedures Form 160.73-O2 (425) Issue Date: 04/24/2025 Prolonged shutdown 3. On the SETUP Screen, disable the clock. This con- If the chiller is to be shut down for an extended period serves the battery. of time (for example, over the winter season), complete the following steps: 4.

  • Page 17: Section 3 - System Components Description

    Form 160.73-O2 (425) Issue Date: 04/24/2025 Section 3 - System components description OptiView Control Center Compressor Suction Dual relief valves Motor Evaporator 00611vip Refrigerant charging valve Variable speed oil pump control box Sight glass Front view Figure 8: System components ©...
  • Page 18 System Components Description Form 160.73-O2 (425) Issue Date: 04/24/2025 Discharge line 28778A Oil reservoir pump Oil cooler rear view Figure 8: System components, continued © 2025 Johnson Controls. All rights reserved...

  • Page 19: Compressor Lubrication System

    Form 160.73-O2 (425) Issue Date: 04/24/2025 General The YORK Model YK MaxE Centrifugal Liquid Chiller is completely factory-packaged including evaporator, 1. Compressor Drive Shaft (Low Speed) condenser, compressor, motor, lubrication system, a. Shaft seal. OptiView Control Center, and all interconnecting unit b.

  • Page 20: Figure 9: Schematic Drawing - (Yk) Compressor Lubrication System

    System Components Description Form 160.73-O2 (425) Issue Date: 04/24/2025 DOUBLE BELLOWS SHAFT SEAL LOW SPEED GEAR REAR BEARING Figure 9: Schematic drawing – (YK) compressor lubrication system LD08577 © 2025 Johnson Controls. All rights reserved...
  • Page 21 The compressor motor is an open-drip-proof, squirrel arrangements. Stub-out water nozzle connections with cage, induction type constructed to YORK design spec- Victaulic grooves are welded to the water boxes. These ifications. 60 Hz motors operate at 3570 rpm. 50 Hz nozzle connections are suitable for Victaulic couplings, motors operate at 2975 rpm.

  • Page 22: Optiview Control Center

    System Components Description Form 160.73-O2 (425) Issue Date: 04/24/2025 While the chiller is shut down, the orifice will be in the Changes in chilled water flow require fully open position causing the sensed level to be ap- readjustment of the hot gas control to proximately 0%.

  • Page 23: Section 4 - Operational Maintenance

    Form 160.73-O2 (425) Issue Date: 04/24/2025 Section 4 - Operational maintenance 1. Shut the stop valves on the condenser gas line, oil Oil return system return line to rotor support and inlet end of the de- The oil return system continuously maintains the proper hydrator.

  • Page 24: Oil Charging Procedure

    The oil should be charged into the oil will keep the concentration of refrigerant in the oil reservoir using the YORK Oil Charging Pump – YORK to a minimum. Part No. 070-10654. To charge oil into the oil reservoir,...

  • Page 25: Section 5 - Troubleshooting

    Form 160.73-O2 (425) Issue Date: 04/24/2025 Section 5 - Troubleshooting Table 2: Operational analysis chart RESULTS POSSIBLE CAUSE REMEDY 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE Temperature difference between conden- Air in condenser. sing temperature and water off condenser higher than normal. Condenser tubes dirty or Clean condenser tubes.
  • Page 26 Troubleshooting Form 160.73-O2 (425) Issue Date: 04/24/2025 Table 2: Operation analysis chart, continued RESULTS POSSIBLE CAUSE REMEDY 5. SYMPTOM: UNUSUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS Unusually high oil pressure is displayed High oil pressure. Trans- Replace low or high oil pressure when the oil pressure display key is ducer defective.

  • Page 27: Section 6 - Maintenance

    Section 6 - Maintenance Renewal parts Megging the motor - mechanical starter For any required Renewal Parts, refer to YORK Renewal While the main disconnect switch and compressor Parts Unit Components Manual 160.73-RP1. motor starter are open, meg the motor as follows: 1.

  • Page 28: Figure 13: Megging The Motor Windings - Vfd Or Solid State Starter

    Maintenance Form 160.73-O2 (425) Issue Date: 04/24/2025 Megging the motor - VFD or solid state 2. Using a megohmmeter (megger), meg between phases starter and each phase to ground. See Figure 12. Use the graph in Figure 14 to interpret these readings. 1.

  • Page 29: Figure 14: Motor Starter Temperature And Insulation Resistances

    Form 160.73-O2 (425) Issue Date: 04/24/2025 LD00476 Temperature – °F Figure 14: Motor starter temperature and insulation resistances © 2025 Johnson Controls. All rights reserved...
  • Page 30 Maintenance Form 160.73-O2 (425) Issue Date: 04/24/2025 Condenser and evaporators Maintenance of condenser and evaporator shells is im- Tube fouling portant to provide trouble free operation of the chiller. Fouling of the tubes can be due to deposits of two types The water side of the tubes in the shell must be kept as follows: clean and free from scale.

  • Page 31: Commercial Acid Cleaning

    If acid cleaning is required, YORK Pressurize the dry system with 50 psig to 100 psig recommends the use of this type of organization. The (345 kPa to 690 kPa) of nitrogen.

  • Page 32: Electrical Controls

    Maintenance Form 160.73-O2 (425) Issue Date: 04/24/2025 Compressor Electrical controls Maintenance for the compressor assembly consists For information covering the OptiView Control Center of checking the operation of the oil return system and operation, refer to Form 160.54-O1. changing the dehydrator, checking and changing the oil, checking and changing the oil filters, checking the operation of the oil heater, checking the operation of the oil pump, and observing the operation of the compressor.

  • Page 33: Section 7 - Preventative Maintenance

    IMPORTANT – If a unit failure occurs due to re-lubricate anti-friction bearings periodically. See Table 3. to improper maintenance during the warranty period; YORK will not be liable for costs incurred to return the Table 3: Bearing lubrication system to satisfactory operation. Frame...

  • Page 34: Leak Testing

    The major portion of maintenance on the condenser and (operation and safety) not be changed. If the settings evaporator will deal with the maintaining the water side are changed without YORK’s approval, the warranty of the condenser and evaporator in a clean condition. will be jeopardized.
  • Page 35 Form 160.73-O2 (425) Issue Date: 04/24/2025 The following factors can be used to convert from Imperial to the most common SI Metric values. Table 5 – SI Metric conversion Measurement Multiply Imperial Unit By Factor To Obtain Metric Unit Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW)
  • Page 36 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2025 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.73-O2 (425) Issue Date: April 24, 2025 Supersedes: 160.73-O2 (424)

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