Johnson Controls YORK YK MaxE User manual

OPERATION MANUAL
OPTIVIEWTM CONTROL CENTER
MAXETM CENTRIFUGAL LIQUID CHILLERS
Supersedes: 160.54-O1 Form 160.54-O1
MODEL YK (THROUGH STYLE G)
R-134a COOLING ONLY
WITH OPTIVIEWTM CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER
& VARIABLE SPEED DRIVE
29420A

JOHNSON CONTROLS
2
FORM 160.54-O1
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and respon-
sibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this in-
dividual possesses independent training that will enable
them to perform their assigned tasks properly and safely.
It is essential that, prior to performing any task on this
equipment, this individual shall have read and under-
stood this document and any referenced materials. This
individual shall also be familiar with and comply with
all applicable governmental standards and regulations
pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or se-
rious injury.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
CAUTION identies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instruction will be given, together with
a brief explanation.
External wiring, unless specied as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specications and must be performed ONLY by qualied YORK/Johnson Controls
personnel. Johnson Controls will not be responsible for damages/problems resulting from
improper connections to the controls or application of improper control signals. Failure to
follow this will void the manufacturer’s warranty and cause serious damage to property or
injury to persons.
NOTE is used to highlight additional
information which may be helpful to
you.

FORM 160.54-O1
3
JOHNSON CONTROLS
NOMENCLATURE
REFERENCE INSTRUCTIONS
DESCRIPTION FORM NO.
SOLID STATE STARTER (MOD “A”) – OPERATION & MAINTENANCE 160.46-OM3.1
SOLID STATE STARTER (MOD “B”) – OPERATION & MAINTENANCE 160.00-O2
MEDIUM VOLTAGE SOLID STATE STARTER – OPERATION 160.00-O5
MEDIUM VOLTAGE SOLID STATE STARTER – SERVICE 160.00-M5
VARIABLE SPEED DRIVE – OPERATION 160.00-O1
VARIABLE SPEED DRIVE – SERVICE INSTRUCTIONS 160.00-M4
MEDIUM VOLTAGE VARIABLE SPEED DRIVE – OPERATION 160.00-O6
MEDIUM VOLTAGE VARIABLE SPEED DRIVE – SERVICE 160.00-M6
VARIABLE SPEED OIL PUMP DRIVE 160.52-M2
INSTALLATION 160.54-N1
OPTIVIEW CONTROL CENTER - SERVICE INSTRUCTIONS 160-54-M1
WIRING DIAGRAM – UNIT STYLE E WITH ELECTRO-MECHANICAL STARTER 160.54-PW1
WIRING DIAGRAM – UNIT STYLE E WITH MOD “A” SOLID STATE STARTER 160.54-PW2
WIRING DIAGRAM – UNIT STYLE E WITH MOD “B” SOLID STATE STARTER 160.54-PW2.1
WIRING DIAGRAM – UNIT STYLE E WITH VARIABLE SPEED DRIVE 160.54-PW3
RENEWAL PARTS – UNIT 160.49-RP4
RENEWAL PARTS – OPTIVIEW CONTROL CENTER 160.54-RP1
WIRING DIAGRAM – UNIT STYLE E (P Compressors) with ELECTRO-MECHANICAL STARTER 160.54-PW8
WIRING DIAGRAM – UNIT STYLE E (P Compressors) with MOD “B” SOLID STATE STARTER 160.54-PW9
WIRING DIAGRAM – UNIT STYLE E (P Compressors) with VARIABLE SPEED DRIVE 160.54-PW10
WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH ELECTRO-MECHANICAL STARTER 160.73-PW1
WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH MOD “B” SOLID STATE STARTER 160.73-PW2
WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH VARIABLE SPEED DRIVE 160.73-PW3
WIRING DIAGRAM – UNIT (STYLE F) (all compressors) WITH MEDIUM VOLTAGE VSD OR MEDIUM VOLTAGE SSS 160.73-PW5
WIRING DIAGRAM – FIELD CONTROL MODIFICATIONS (STYLE G) 160.75-PW4
WIRING DIAGRAM – UNIT STYLE G WITH ELECTRO-MECHANICAL STARTER 160.75-PW5
WIRING DIAGRAM – UNIT STYLE G WITH SSS, LV VSD WITH MODBUS & MV VSD 160.75-PW6
YK CB CB G4 – CM E
MOTOR CODE
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
COMPRESSOR CODE
CONDENSER CODE
EVAPORATOR CODE
MODEL
STYLE (Design Level)

JOHNSON CONTROLS
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FORM 160.54-O1
SECTION 1 Description of System and Fundamentals of Operation ................... 7
SECTION 2OptiView Control Center ................................................................. 11
SECTION 3Printers..........................................................................................167
TABLE OF CONTENTS
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continu-
ous product improvement, the information contained
in this document is subject to change without notice.
While Johnson Controls makes no commitment to up-
date or provide current information automatically to
the manual owner, that information, if applicable, can
be obtained by contacting the nearest Johnson Controls
Service ofce.
It is the responsibility of operating/service personnel
as to the applicability of these documents to the equip-
ment in question. If there is any question in the mind
of operating/service personnel as to the applicability of
these documents, then, prior to working on the equip-
ment, they should verify with the owner whether the
equipment has been modied and if current literature
is available.

FORM 160.54-O1
5
JOHNSON CONTROLS
LIST OF FIGURES
FIG. 1 – MODEL YK MAXE™ CHILLER ............................. 6
DETAIL A – COMPRESSOR PREROTATION
VANES.................................................................. 7
FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER..... 8
FIG. 3 – OPTIVIEW CONTROL CENTER.........................11
FIG. 4 – HOME SCREEN................................................. 16
FIG. 5 – SYSTEM SCREEN............................................. 19
FIG. 6 – EVAPORATOR SCREEN ................................... 21
FIG. 7 – CONDENSER SCREEN..................................... 24
FIG. 7A – HEAT RECOVERY SCREEN ............................. 26
FIG. 7B – HEAD PRESSURE SCREEN............................. 30
FIG. 8 – REFRIGERANT LEVEL CONTROL SCREEN
(Flash Memory Card version C.MLM.01.06.XXX
and earlier) ......................................................... 32
FIG. 8A – REFRIGERANT LEVEL CONTROL SCREEN
(Software Version C.MLM.01.07.xxx to
C.MLM.01.10D.xxx or C.OPT.01.10D and earlier) .. 34
FIG 8B – REFRIGERANT LEVEL CONTROL SETPOINTS
SCREEN (Software Version C.MLM.01.07.xxx to
C.MLM.01.10D.xxx or C.OPT.01.10D
(and earlier)) ....................................................... 36
FIG 8C – REFRIGERANT LEVEL CONTROL SCREEN
(Software version C.MLM.01.14.xxx (and later) or
C.OPT.01.14.306 (and later)) ............................. 38
FIG. 9 – COMPRESSOR SCREEN
(All “P” Compressors and Style F chillers with
G, Q or H5-8 compressors) ................................ 40
FIG. 9A – COMPRESSOR SCREEN (Style E and earlier
chillers with G, H or J compressors and Style F
and later chillers with J or H3 compressors)....... 42
FIG. 10 – PROXIMITY PROBE CALIBRATION SCREEN
(Style E and earlier chillers with G, H and J
compressors and Style F and later chillers with
J or H3 compressors) ......................................... 44
FIG. 11 – HOT GAS BYPASS SCREEN ............................ 46
FIG. 12 – SURGE PROTECTION SCREEN ...................... 48
FIG. 12A – VARIABLE GEOMETRY DIFFUSER SCREEN.. 52
FIG. 12B – VARIABLE GEOMETRY DIFFUSER SETPOINTS
SCREEN............................................................. 54
FIG. 13 – PRE-ROTATION VANES CALIBRATION
SCREEN............................................................. 56
FIG. 14 – VSD TUNING SCREEN ..................................... 58
FIG. 15 – OIL SUMP SCREEN........................................... 60
FIG. 16 – ELECTRO-MECHANICAL STARTER SCREEN.... 64
FIG. 17 – MOD “A” SOLID STATE STARTER SCREEN .... 66
FIG. 18 – MOD “B” SOLID STATE STARTER SCREEN .... 68
FIG. 18A – MEDIUM VOLTAGE SOLID STATE STARTER
SCREEN............................................................. 70
FIG. 19 – VARIABLE SPEED DRIVE SCREEN ................. 72
FIG. 19A – MEDIUM VOLTAGE VARIABLE SPEED DRIVE
SCREEN (Software Version C.OPT.01.16.xxx
and Later) ........................................................... 74
FIG. 20 – VARIABLE SPEED DRIVE DETAILS SCREEN
(Style D VSD and VSD with part number
371-03789-xxx (503 HP 60 Hz; 419 HP 50 Hz).. 78
FIG. 21 – VARIABLE SPEED DRIVE DETAILS SCREEN
(VSD with Part Number 371-02767-XXX
(60 Hz) or 371-03700-XXX (50 HZ))................... 80
FIG. 22 – ADAPTIVE CAPACITY CONTROL SCREEN
(software version C.OPT.01.18.307 and earlier) 82
FIG. 22A – ADAPTIVE CAPACITY CONTROL SCREEN
(YORK protocol conguration)
(software version C.OPT.01.19.307 and later) ... 84
FIG. 22B – ADAPTIVE CAPACITY CONTROL SCREEN
(Modbus protocol conguration)
(software version C.OPT.01.19.307 and later) ... 86
FIG. 22C – SURGE MAP SCREEN - TABLE VIEW
(software version C.OPT.01.19.307 and later) ... 90
FIG. 22D – SURGE MAP SCREEN - LIST VIEW
(software version C.OPT.01.19.307 and Later) .. 92
FIG. 23 – HARMONIC FILTER DETAILS SCREEN
(Style D VSD and VSD with part number
371-03789-xxx (503 HP 60 Hz; 419 HP 50 Hz).. 94
FIG. 24 – HARMONIC FILTER DETAILS SCREEN
(VSD with Part Number 371-02767-XXX (60 Hz)
or 371-03700-XXX (50 Hz)) ............................... 96
FIG. 25 – MOTOR LUBRICATION SCREEN (Software version
C.MLM.01.14.xxx (and later) or C.OPT.01.14.306
(and later)) .......................................................... 98
FIG. 26 – SETPOINTS SCREEN ..................................... 100
FIG. 27 – SETUP SCREEN.............................................. 104
FIG. 27A – QUICK START SCREEN.................................. 108
FIG. 28 – SCHEDULE SCREEN .......................................112
FIG. 29 – USER SCREEN.................................................114
FIG. 30 – COMMS SCREEN.............................................116
FIG. 31 – PRINTER SCREEN...........................................118
FIG. 32 – SALES ORDER SCREEN ................................ 120
FIG. 33 – OPERATIONS SCREEN .................................. 122
FIG. 34 – HISTORY SCREEN.......................................... 124
FIG. 35 – HISTORY DETAILS SCREEN .......................... 126
FIG. 36 – SECURITY LOG SCREEN............................... 127
FIG. 37 – SECURITY LOG DETAILS SCREEN ............... 128
FIG. 38 – CUSTOM VIEW SCREEN................................ 129
FIG. 39 – CUSTOM VIEW SETUP SCREEN
................... 130
FIG. 40 – TREND SCREEN ............................................. 132
FIG. 41 – TREND SETUP SCREEN ................................ 134
FIG. 42 – ADVANCED TREND SETUP SCREEN............ 136
FIG. 43 – COMMON SLOTS SCREEN ............................ 138
FIG. 44 – PRINTERS ....................................................... 164
FIG. 45 – SAMPLE PRINTOUT (STATUS)....................... 170
FIG. 46 – SAMPLE PRINTOUT (SETPOINTS)................ 172
FIG. 47 – SAMPLE PRINTOUT (SCHEDULE)................. 174
FIG. 48 – SAMPLE PRINTOUT (SALES ORDER)........... 175
FIG. 49 – SAMPLE PRINTOUT (HISTORY) .................... 176
FIG. 50 – SAMPLE PRINTOUT (SECURITY LOG).......... 178
FIG. 51 – SAMPLE PRINTOUT (TREND)........................ 178
FIG. 52 – SAMPLE PRINTOUT – (CUSTOM SCREEN).. 179
FIG. 53 – SAMPLE PRINTOUT – (ADAPTIVE CAPACITY
CONTROL NEW MAP POINT)......................... 179
FIG. 54 – SAMPLE PRINTOUT (ADAPTIVE CAPACITY
CONTROL EXISTING MAP POINTS) .............. 179

JOHNSON CONTROLS
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FORM 160.54-O1
Description of System and Fundamentals of Operation
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FORM 160.54-O1
7
JOHNSON CONTROLS
When the compressor motor is driven by a YORK Solid
State Starter, one of three different Starters could be ap-
plied. Later production chillers are equipped with either
the Style B Liquid Cooled Solid State Starter (LCSSS)
or the Medium Voltage Solid State Starter (MVSSS).
Earlier vintage chillers are equipped with the Mod “A”
Solid State Starter. This starter contains a Trigger Board
that interfaces to a Logic Board that is installed inside of
the Control Center.
When the compressor motor is driven by a YORK Vari-
able Speed Drive, there could be a Variable Speed Drive
(VSD) or a Medium Voltage Variable Speed Drive (MV
VSD) applied.
In operation, a liquid (water or brine to be chilled) ows
through the cooler, where boiling refrigerant absorbs heat
from the liquid. The chilled liquid is then piped to fan
coil units or other air conditioning terminal units, where
it ows through nned coils, absorbing heat from the
air. The warmed liquid is then returned to the chiller to
complete the chilled liquid circuit.
SECTION 1
DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
00611vip
CONDENSER
CONTROL
CENTER
COMPRESSOR
MOTOR
EVAPORATOR
FIG. 1 – MODEL YK MaxE™ CHILLER
SYSTEM OPERATION DESCRIPTION (SEE FIG. 2)
The YORK Model YK MaxE™ Chiller is commonly ap-
plied to large air conditioning systems, but may be used on
other applications. The chiller consists of an open motor
mounted to a compressor (with integral speed increasing
gears), condenser, evaporator and variable ow control.
The chiller is controlled by a modern state of the art Mi-
crocomputer Control Center that monitors its operation.
The Control Center is programmed by the operator to suit
job specications. Automatic timed start-ups and shut-
downs are also programmable to suit nighttime, week-
ends, and holidays. The operating status, temperatures,
pressures, and other information pertinent to operation
of the chiller are automatically displayed and read on
a graphic display. Other displays can be observed by
pressing the keys as labeled on the Control Center. The
chiller with the OptiView Control Center is applied with
an electro-mechanical starter, YORK Solid State Starter
(optional), or Variable Speed Drive (optional).

JOHNSON CONTROLS
8
FORM 160.54-O1
The refrigerant vapor, which is produced by the boiling
action in the cooler, ows to the compressor where the
rotating impeller increases its pressure and temperature
and discharges it into the condenser. Water owing
through the condenser tubes absorbs heat from the refrig-
erant vapor, causing it to condense. The condenser water
is supplied to the chiller from an external source, usu-
ally a cooling tower. The condensed refrigerant drains
from the condenser into the liquid return line, where the
variable orice meters the ow of liquid refrigerant to the
cooler to complete the refrigerant circuit.
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.
7619A(D)
DETAIL A – COMPRESSOR PREROTATION VANES
CAPACITY CONTROL
The major components of a chiller are selected for full
load capacities, therefore capacity must be controlled
to maintain a constant chilled liquid temperature leav-
ing the cooler. Prerotation vanes (PRV), located at the
entrance to the compressor impeller, compensate for
variation in load (See Detail A).
The position of these vanes is automatically controlled
through a lever arm attached to an electric motor located
outside the compressor housing. The automatic adjust-
ment of the vane position in effect provides the perfor-
mance of many different compressors to match various
load conditions from full load with vanes wide open to
minimum load with vanes completely closed.
Description of System and Fundamentals of Operation

FORM 160.54-O1
9
JOHNSON CONTROLS
1
FIG. 2 – REFRIGERANT FLOW-THRU CHILLER
PREROTATION VANES
(See Detail A)
SUCTION
EVAPORATOR
ELIMINATOR
OIL COOLER
LD00924
FLOW CONTROL
ORIFICE
SUB-COOLER
CONDENSER
DISCHARGE
BAFFLE
DISCHARGE
COMPRESSOR

JOHNSON CONTROLS
10
FORM 160.54-O1
OptiView Control Center
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