Johnson Controls YORK YK Style G OPTIVIEW Installation guide

MODEL YK (STYLE G)
R-134a
WITH OPTIVIEWTM CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER AND VARIABLE SPEED DRIVE
CENTRIFUGAL LIQUID CHILLERS
OPERATIONS AND MAINTENANCE Supersedes: 160.75-O1 (508) Form 160.75-O1 (211)
LD15222

FORM 160.75-O1 (211)
JOHNSON CONTROLS
2
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,
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 posseses independent training that will enable
them to perform their assigned tasks properly and safe-
ly. It is essential that, prior to performing any task on
this equipment, this individual shall have read and un-
derstood this document and any referenced materials.
This individual shall also be familiar with and comply
with all applicable governmental standards and regula-
tions pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is
not to be connected inside the OptiView cabinet. Devices such as relays, switches, transducers and
controls and any external wiring must not be installed inside the micro panel. All wiring must be in
accordance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warning
will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 160.75-O1 (211)
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for contin-
uous 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 office.
Operating/service personnel maintains the responsi-
bility of the applicability of these documents to the
competitive equipment the kit is installed on. If there
is any question regarding the applicability of these
documents, the technician should verify whether the
equipment has been modified and if current literature
is available with the owner of the equipment prior to
performing any work on the chiller.
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Variable Speed Drive – Operation 160.00-O1
Solid State Starter – Operation and Maintenance 160.00-O2
Floor Mounted MV SSS – Operation 160.00-O5
Unit Mounted MV SSS – Operation 160.00-O7
Installation – Unit 160.75-N1
Optiview™ Control Center – Operation and Maintenance 160.54-O1
Wiring Diagram – Field Connections for YK Chiller (Style G) OptiView Control Center with Remote Low
or Medium Voltage EMS or Unit Mounted Low or Medium Voltage SSS 160.75-PW1
Wiring Diagram – Field Connections for YK Chiller (Style G) OptiView Control Center with Remote
Medium Voltage SSS 160.75-PW2
Wiring Diagram – Field Connections for YK Chiller (Style G) OptiView Control Center with Remote
Medium Voltage VSD 160.75-PW3
Wiring Diagram – Field Control Modications for YK Chiller (Style G) 160.75-PW4
Wiring Diagram – YK Chiller (Style G) OptiView Control Center with Remote Low or Medium Voltage EMS 160.75-PW5
Wiring Diagram – YK Chiller (Style G) OptiView Control Center with Unit Mounted Low or Medium
Voltage SSS, Unit Mounted Low Voltage VSD with Modbus, or Remote Medium Voltage VSD 160.75-PW6
Wiring Diagram – YK Chiller (Style G) OptiView Control Center with LTC I/O Board with Remote Low or
Medium Voltage EMS 160.75-PW7
Wiring Diagram – YK Chiller (Style G) OptiView Control Center w/ LTC I/O Board with Unit Mounted Low
or Medium Voltage SSS, Unit Mounted Low Voltage VSD with Modbus or Remote Medium Voltage VSD 160.75-PW8
Renewal Parts – Unit 160.75-RP1
Renewal Parts – OptiView Control Center 160.54-RP1

FORM 160.75-O1 (211)
JOHNSON CONTROLS
4
NOMENCLATURE
YK KC K4 H9 – CY G
MOTOR CODE
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
COMPRESSOR CODE*
CONDENSER CODE*
EVAPORATOR CODE*
MODEL*
STYLE (Design Level)
* Refer to YK Engineering Guide for (Form 160.75-EG1)
Shell/Motor/Compressor combinations.

JOHNSON CONTROLS 5
FORM 160.75-O1 (211)
TABLE OF CONTENTS
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION ..........................................7
System Operation Description .........................................................................................................................7
Capacity Control...............................................................................................................................................8
SECTION 2 - SYSTEM OPERATING PROCEDURES ........................................................................................... 11
Oil Heaters ..................................................................................................................................................... 11
Oil Heater Operation ...................................................................................................................................... 11
Checking The Oil Level In The Oil Reservoir ................................................................................................. 11
Start-Up Procedure ........................................................................................................................................ 11
Start-Up .......................................................................................................................................................... 11
Chiller Operation ............................................................................................................................................13
Condenser Water Temperature Control..........................................................................................................13
Operating Log Sheet ......................................................................................................................................13
Operating Inspections ....................................................................................................................................13
Need For Maintenance Or Service.................................................................................................................15
Stopping The System .....................................................................................................................................15
Prolonged Shutdown ......................................................................................................................................15
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION .......................................................................................17
General...........................................................................................................................................................17
Compressor....................................................................................................................................................17
Capacity Control.............................................................................................................................................17
Compressor Lubrication System ...................................................................................................................17
Oil Pump.........................................................................................................................................................17
Oil Heater .......................................................................................................................................................21
Motor Driveline ...............................................................................................................................................21
Heat Exchangers............................................................................................................................................21
Refrigerant Flow Control ................................................................................................................................22
Optional Service Isolation Valves ...................................................................................................................22
Optional Hot Gas Bypass ...............................................................................................................................22
OptiView Control Center.................................................................................................................................22
Solid State Starter (Optional) .........................................................................................................................22
Variable Speed Drive (Optional).....................................................................................................................22
SECTION 4 - OPERATIONAL MAINTENANCE.....................................................................................................23
Oil Return System ..........................................................................................................................................23
Changing The Dehydrator ..............................................................................................................................23
The Oil Charge ...............................................................................................................................................24
Oil Charging Procedure..................................................................................................................................24
SECTION 5 - TROUBLESHOOTING......................................................................................................................25
SECTION 6 - MAINTENANCE................................................................................................................................27
Renewal Parts ................................................................................................................................................27
Checking System For Leaks ..........................................................................................................................27
Conducting R-22 Pressure Test......................................................................................................................27
Vacuum Testing ..............................................................................................................................................28
Vacuum Dehydration ......................................................................................................................................29
Operation........................................................................................................................................................29
Refrigerant Charging ......................................................................................................................................29
Checking The Refrigerant Charge During Unit Shutdown..............................................................................30
Handling Refrigerant For Dismantling And Repairs........................................................................................30

FORM 160.75-O1 (211)
JOHNSON CONTROLS
6
LIST OF FIGURES
LIST OF TABLES
FIGURE 1 - Model YK Chiller ....................................................................................................................................7
FIGURE 2 - Compressor Prerotation Vanes..............................................................................................................8
FIGURE 3 - Refrigerant Flow-Thru Chiller (Falling Film Evaporator) ........................................................................9
FIGURE 4 - Refrigerant Flow-Thru Chiller (Flooded Evaporator)............................................................................10
FIGURE 5 - Oil Level Indicator ............................................................................................................................... 11
FIGURE 6 - Chiller Starting Sequence And Shutdown Sequence (Em Starter And Solid State Starter) ................12
FIGURE 7 - Chiller Starting Sequence And Shutdown Sequence (Variable Speed Drive) .....................................12
FIGURE 8 - Liquid Chiller Log Sheets.....................................................................................................................14
FIGURE 9 - System Components Front View .........................................................................................................18
FIGURE 10 - System Components Rear View........................................................................................................19
FIGURE 11 - Schematic Drawing – (YK) Compressor Lubrication System............................................................. 20
FIGURE 12 - Oil Return System..............................................................................................................................23
FIGURE 13 - Charging Oil Reservoir With Oil.........................................................................................................24
FIGURE 14 - Evacuation Of Chiller.........................................................................................................................27
FIGURE 15 - Saturation Curve................................................................................................................................29
FIGURE 16 - Diagram, Megging Motor Windings ...................................................................................................30
FIGURE 17 - Motor Starter Temperature And Insulation Resistances ....................................................................31
Megging The Motor .........................................................................................................................................30
Compressor....................................................................................................................................................33
Electrical Controls ..........................................................................................................................................34
SECTION 7 - PREVENTIVE MAINTENANCE........................................................................................................35
Compressor....................................................................................................................................................35
Compressor Motor..........................................................................................................................................35
Greased Bearings .........................................................................................................................................35
Leak Testing ...................................................................................................................................................36
Evaporator And Condenser ............................................................................................................................36
Oil Return System ..........................................................................................................................................36
Electrical Controls ..........................................................................................................................................36
TABLE OF CONTENTS (CONT'D)
TABLE 1 - Operation Analysis Chart.......................................................................................................................25
TABLE 2 - System Pressures .................................................................................................................................28
TABLE 3 - Bearing Lubrication................................................................................................................................35

JOHNSON CONTROLS 7
FORM 160.75-O1 (211)
nent to operation of the chiller are automatically dis-
played 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 compatible with an electro-mechanical start-
er, YORK Solid State Starter (optional), or Variable
Speed Drive (optional).
In operation, a liquid (water or brine to be chilled)
flows through the evaporator, 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 flows through finned 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
SYSTEM OPERATION DESCRIPTION
The YORK Model YK Chiller is commonly applied
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
flow control.
The chiller is controlled by a modern state of the art
Microcomputer Control Center that monitors its opera-
tion. The Control Center is programmed by the opera-
tor to suit job specifications. Automatic timed start-ups
and shutdowns are also programmable to suit night-
time, weekends, and holidays. The operating status,
temperatures, pressures, and other information perti-
1
LD15222
CONDENSER
CONTROL
CENTER
COMPRESSOR
MOTOR
EVAPORATOR
FIGURE 1 - MODEL YK CHILLER

FORM 160.75-O1 (211)
JOHNSON CONTROLS
8
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
7619A(D)
FIGURE 2 - COMPRESSOR PREROTATION VANES
The refrigerant vapor, which is produced by the boil-
ing action in the evaporator, flows to the compressor
where the rotating impeller increases its pressure and
temperature and discharges it into the condenser. Wa-
ter flowing through the condenser tubes absorbs heat
from the refrigerant vapor, causing it to condense. The
condenser water is supplied to the chiller from an ex-
ternal source, usually a cooling tower. The condensed
refrigerant drains from the condenser into the liquid
return line, where the variable orifice meters the flow
of liquid refrigerant to the evaporator to complete the
refrigerant circuit.
The major components of a chiller are selected to han-
dle 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 rela-
tively small part of the time the unit is in operation.
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 evaporator. Prerotation vanes (PRV), located at
the entrance to the compressor impeller, compensate
for variation in load (Refer to Figure 2 on Page 8).
The position of these vanes is automatically controlled
through a lever arm attached to an electric motor lo-
cated outside the compressor housing. The automatic
adjustment of the vane position in effect provides the
performance of many different compressors to match
various load conditions from full load with vanes wide
open to minimum load with vanes completely closed.

SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
JOHNSON CONTROLS 9
FORM 160.75-O1 (211)
1
Refrigerant Flow-Thru Chiller
(Falling Film Evaporator)
FIGURE 3 - REFRIGERANT FLOW-THRU CHILLER (FALLING FILM EVAPORATOR)
Rev. 2 (10-11-2010)
Dan Sowers
[e-mail]
[phone]
YK Mod G
Refrigerant Flow-Thru Cross-Secon Diagram
(Falling-Film Evaporator)
COMPRESSOR
EVAPORATOR
DISCHARGE
PRE-ROTATION
VANES
SUCTION
BAFFLE
SUB-COOLER
LIQUID LEVEL
CONDENSER
LIQUID LEVEL
VALVE
HOT GAS
BYPASS VALVE
LIQUID LEVEL
SUCTION
OPTIONAL
ISOLATION
VALVE
OPTIONAL
ISOLATION
VALVE
OPTIONAL HOT GAS
BYPASS LINE
LD00924A

FORM 160.75-O1 (211)
JOHNSON CONTROLS
10
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
Refrigerant Flow-Thru Chiller
(Flooded Evaporator)
FIGURE 4 - REFRIGERANT FLOW-THRU CHILLER (FLOODED EVAPORATOR)
Rev. 2 (12-09-2010)
Dan Sowers
[e-mail]
[phone]
YK Mod G
Refrigerant Flow-Thru Cross-Secon Diagram
(Flooded Evaporator)
COMPRESSOR
EVAPORATOR
DISCHARGE
PRE-ROTATION
VANES
MESH ELIMINATORS or
SUCTION BAFFLE
SUB-COOLER
LIQUID LEVEL
CONDENSER
SUCTION
LIQUID LEVEL
VALVE
LIQUID LEVEL
OPTIONAL
ISOLATION
VALVE
OPTIONAL
ISOLATION
VALVE
HOT GAS
BYPASS VALVE
OPTIONAL HOT GAS
BYPASS LINE
LD00924B