Johnson Controls York YK Guide

INSTALLATION, COMMISSIONING,
OPERATION AND MAINTENANCE
YK - ALL MODELS
035-19569-101 (0109)
CENTRIFUGAL LIQUID CHILLER
STYLE G
R134A
REVISION 2
Библиотека СОК 

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Table of Contents
1 SUPPLIER INFORMATION 1-1
1.1 Introduction 1-1
1.2 Warranty 1-1
1.3 Safety 1-1
1.4 Responsibility for Safety 1-1
1.5 About this Manual 1-2
1.6 Misuse of Equipment 1-2
1.8 Safety Labels 1-3
1.9 Material Safety Data 1-4
2 PRODUCT DESCRIPTION 2-1
2.1 General 2-1
2.2 Capacity Control 2-2
2.3 Compressor 2-3
2.4 Compressor Lubrication System 2-3
2.6 Graphic Control Centre (OptiView) 2-5
2.7 Heat Exchangers 2-5
2.8 Refrigerant Flow Control 2-6
2.9 Options and Accessories 2-6
2.10 Nomenclature 2-7
2.11 Range of Models 2-8
3 TRANSPORTATION, RIGGING AND STORAGE 3-1
3.1 General 3-1
3.2 Shipment 3-1
3.3 Inspection, Damage and Shortage 3-2
3.4 Rigging 3-3
4 INSTALLATION 4-1
4.1 Location 4-1
4.2 Motors 4-1
4.3 Foundation 4-1
4.4 Clearances 4-1
4.5 Rigging Unit to Final Location 4-1
4.6 Locating and Installing Isolator Pads 4-1
4.7 Installing Optional Spring Isolators 4-2
4.8 Piping Connections 4-2
4.9 Evaporator and Condenser Water Piping 4-2
4.9.1 Chilled Water Circuit 4-5
4.9.2 Condenser Water Circuit 4-5
4.10 Stop Valves 4-6
4.11 Flow Switches 4-6
4.12 Drain and Vent Valves 4-6
4.13 Checking Piping Circuits and Venting Air 4-6
4.14 Refrigerant Relief Piping 4-6
4.15 Unit Piping 4-7
4.16 Control Panel Positioning 4-7
4.17 Control Wiring 4-7
4.18 Power Wiring 4-7
4.19 Units with Solid State Starter or
Variable Speed Drive 4-8
4.20 Thermal Insulation 4-8
4.21 Installation Check 4-8
5 COMMISSIONING 5-1
5.1 Preparation 5-1
5.2 First Time Start-up 5-2

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6 OPERATION 6-1
6.1 Oil Heater Operation 6-1
6.2 Checking the Oil Level in the Oil Reservoir 6-1
6.3 Start-up Procedure 6-1
6.4 Chiller Operation 6-4
6.5 Operating Log Sheet 6-4
6.7 Stopping the System 6-7
6.8 Prolonged Shutdown 6-7
6.9 Start-up after Prolonged Shutdown 6-7
7 MAINTENANCE 7-1
7.1 Inspections 7-1
7.2 Oil Return System 7-2
7.3 Oil Charge 7-3
7.4 Refrigerant Charge 7-3
7.5 Condenser and Evaporator 7-5
7.6 Compressor 7-7
7.7 Compressor Motor 7-7
7.8 Electrical Controls 7-8
7.9 Testing Motor Winding Insulation 7-8
8 TROUBLSHOOTING 8-1
9 TECHNICAL DATA 9-1
9.1 Dimensions 9-1
9.2 Dimensions -
Evaporator Compact Water Boxes 9-4
9.3 Nozzle Arrangements -
Evaporator Compact Water Boxes 9-5
9.4 Dimensions -
Condenser Compact Water Boxes 9-7
9.5 Nozzle Arrangements -
Condenser Compact Water Boxes 9-8
9.6 Dimensions -
Evaporator Marine Water Boxes 9-9
9.8 Nozzle Arrangements -
Evaporator Marine Water Boxes 9-10
9.8 Dimensions -
Condenser Marine Water Boxes 9-11
9.8 Nozzle Arrangements -
Condenser Marine Water Boxes 9-12
9.9 Unit Weights 9-13
9.10 Process and Instrumentation Diagram 9-15
10 SPARE PARTS 10-1
11 DE-COMMISSIONING, DISMANTLING AND
DISPOSAL 11-1
11.1 General 11-1

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1 SUPPLIER INFORMATION
For warranty purposes, the following conditions must
be satisfied:
The initial start of the unit must be carried out by trained
personnel from an Authorised York Service Centre.
Only genuine York approved spare parts, oils and
refrigerants must be used.
All the scheduled maintenance operations detailed in
this manual must be performed at the specified times
by suitably trained and qualified personnel.
Failure to satisfy any of these conditions will automatically
void the warranty.
1.3 Safety
Standards for Safety
YK chillers are designed and built within an EN ISO 9001
accredited design and manufacturing organisation and,
within the limits specified in this manual, are in conformity
with the essential health and safety requirements of the
following European Union Directives:
Machinery Directive (98/37/EEC)
Low Voltage Directive (2006/95/EC)
EMC Directive (2004/108/EC)
Pressure Equipment Directive (97/23/EEC)
1.4 Responsibility for Safety
Every care has been taken in the design and manufacture
of the units to ensure that they meet the safety
requirements listed in the previous paragraph. However,
the individual operating or working on any machinery is
primarily responsible for:
■Personal safety, safety of other personnel, and the
machinery.
■Correct utilisation of the machinery in accordance
with the procedures detailed in the manuals.
The owner must comply with the Governmental
Standards and Regulations for the commissioning and
in-service inspections of the unit, in particular those
relating to pressure equipments.
1.1 Introduction
York YK chillers are manufactured to the highest design
and construction standards to ensure high performance,
reliability and adaptability to all types of air conditioning
installations.
The units are intended for cooling water or glycol
solutions and are not suitable for purposes other than
those specified in this manual.
This manual and the Control System Operating
Instructions contain all the information required for correct
installation and commissioning of the unit, together with
operating and maintenance instructions. The manuals
should be read thoroughly before attempting to operate
or service the unit.
All procedures detailed in the manuals, including
installation, commissioning and maintenance tasks
must only be performed by suitably trained and qualified
personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, commissioning,
operation or maintenance resulting from a failure to
follow the procedures and instructions detailed in the
manuals.
1.2 Warranty
York International warrants all equipment and materials
against defects in workmanship and materials for one
year from initial start-up, or eighteen months from delivery
(whichever occurs first) unless extended warranty has
been agreed as part of the contract.
The warranty is limited to free replacement and shipping
of any faulty part, or sub-assembly which has failed due
to poor quality or manufacturing errors. All claims must
be supported by evidence that the failure has occurred
within the warranty period, and that the unit has been
operated within the designed parameters specified.
All warranty claims must specify the unit model, serial
number and order number.
The unit warranty will be void if any modification to the
unit is carried out without prior written approval from
York International.

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1.5 About this Manual
The following symbols are used in this document to alert
the reader to areas of potential hazard.
WARNING
A Warning is given in this document to
identify a hazard which could lead to
personal injury. Usually an instruction will
be given, together with a brief explanation
and the possible result of ignoring the
instruction.
CAUTION
A Caution identifies 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 and the possible result
of ignoring the instruction.
NOTE
A Noteis used to highlight additional information
which may be helpful to you but where there
are no special safety implications.
The contents of this manual include suggested best
working practices and procedures. These are issued
for guidance only, they do not take precedence over
the above stated individual responsibility and/or local
safety regulations.
This manual and any other document supplied with
the unit, are the property of York which reserves all
rights. They may not be reproduced, in whole or in part,
without prior written authorisation from an Authorised
York representative.
1.6 Misuse of Equipment
Suitability for Application
The unit is intended for cooling water or glycol solutions
and is not suitable for purposes other than those
specified in these instructions. Any use of the equipment
other than its intended use, or operation of the equipment
contrary to the relevant procedures may result in injury
to the operator, or damage to the equipment.
The unit must not be operated outside the design limits
specified in this manual.
Structural Support
Structural support of the unit must be provided as
indicated in these instructions. Failure to provide proper
support may result in injury to the operator, or damage
to the equipment.
Mechanical Strength
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures.
Additional components must not be mounted on the unit.
Any such extraneous loads may cause structural failure
and may result in injury to the operator, or damage to
the equipment.
General Access
There are a number of areas and features which may
be a hazard and potentially cause injury when working
with the unit unless suitable safety precautions are taken.
It is important to ensure access to the unit is restricted
to suitably qualified persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.
Pressure Systems
The unit contains refrigerant vapour and liquid under
pressure, release of which can be a danger and cause
injury. The user should ensure that care is taken during
installation, operation and maintenance to avoid damage
to the pressure system. No attempt should be made
to gain access to the component parts of the pressure
system other than by suitably trained and qualified
personnel.
Electrical
The unit must be earthed. No installation or maintenance
work should be attempted on electrical equipment
without first switching off, isolating and locking-off the
power supplies. Work on live equipment must only be
carried-out by suitably trained and qualified personnel.
No attempt should be made to gain access to inside of
the control panel, wiring or other electrical enclosures
during normal operation of the unit.
Rotating Parts
Motor air vent guards and drive coupling guards must
be fitted at all times and not removed unless the main
power supply has been isolated.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally
non-toxic, non-flammable and non-corrosive, and pose
no special safety hazards. Use of gloves and safety
glasses are, however, recommended when working on
the unit. Build up of refrigerant vapour, from a leak for
example, does pose a risk of asphyxiation in confined or
enclosed spaces and attention should be given to good
ventilation. For more comprehensive information on
safety precautions for use of refrigerants and oils, refer
to the Materials Safety Data tables provided.

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High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the
pressure relief device(s). Detergents and solvents which
may cause corrosion should also be avoided.
1.8 Safety Labels
The following labels are fixed to each unit to give
instruction, or to indicate potential hazards which may
exist.
White symbol on blue background
For safe operation, read the Instructions
first
Black symbol on yellow background
Warning: This machine may start
automatically without prior warning
Black symbol on yellow background
Warning: Hot surface
Black symbol on yellow background
Warning: Safety relief valve may discharge
gas or liquid without prior warning
Black symbol on yellow background
Warning: Isolate all electrical sources of
supply before opening or removing the
cover, as lethal voltages may exist
Black symbol on yellow background
General attention symbol

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1.9 Material Safety Data
Refrigerant Data:
Safety Data R134a
Toxicity Low.
In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous
by skin absorption. Thaw affected areas with water. Remove contaminated
clothing carefully — may adhere to skin in case of freeze burns. Wash
affected areas with plenty of warm water. If symptoms occur (irritation or
blistering) obtain medical attention.
In contact with eyes Vapour has no effect. Liquid splashes or spray may cause freeze burns.
Immediately irrigate with eyewash solution or clean water for at least 10
minutes. Obtain immediate medical attention.
Ingested Highly unlikely to occur — but should this occur freeze burn will occur. Do not
induce vomiting. Provided patient is conscious, wash mouth with water and
give about 250 ml (0.5 pint) to drink. Obtain immediate medical attention.
Inhalation High atmospheric concentrations may have an anaesthetic effect, including
loss of consciousness. Very high exposures may cause an abnormal heart
rhythm and prove suddenly fatal.
At higher concentration there is a danger from asphyxiation due to reduced
oxygen content of atmosphere. Remove patient to fresh air, keep warm and
at rest. Administer oxygen if necessary. Apply artificial respiration if breathing
has ceased or shows signs of failing. In event of cardiac arrest apply external
cardiac massage. Obtain immediate medical attention.
Further medical advice Symptomatic and supportive therapy is indicated. Cardiac sensitisation has
been described which may, in the presence of circulating catecholamines
such as adrenalin, give rise to cardiac arrhythmia’s and subsequent arrest
following exposure to high concentrations.
Long term exposure A lifetime inhalation study in rats has shown that exposure to 50,000 ppm
resulted in benign tumours of the testis. This is not considered to be of
relevance to humans exposed to concentrations at or below the occupational
exposure limit.
Occupational exposure limits Recommended limit: 1000 ppm v/v - 8 hr TWA.
Stability Not specified.
Conditions to avoid Use in presence of naked flames, red hot surfaces and high moisture
levels.
Hazardous reactions May react violently with sodium, potassium, barium and other alkali and
alkaline earth metals. Incompatible materials: Magnesium and alloys
containing more then 2% magnesium.
Hazardous decomposition products Halogen acids by thermal decomposition and hydrolysis.
General precautions Avoid inhalation of high concentrations of vapours. Atmospheric
concentrations should be minimised and kept as low as reasonably
practicable below the occupational exposure limit. The vapour is heavier than
air and collects at low level and in confined areas. Ventilate by extraction
at lowest levels.
Respiratory protection Where doubt exists on atmospheric concentration, approved breathing
apparatus should be worn. This should be self contained or of the long
breather type.
Storage Keep containers dry and in a cool place away from fire risk, direct sunlight,
and all sources of heat such as radiators. Keep at temperatures not
exceeding 45°C.
Protective clothing Wear overalls, impervious gloves and goggles/face protection.

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Spill/leak procedure Ensure suitable personal protective clothing and respiratory protection is
worn. Provided it is safe to do so, isolate the source of the leak. Allow small
spillage’s to evaporate provided there is suitable ventilation.
Large spillage’s: Ventilate area. Contain spillage’s with sand, earth or
any suitable absorbent material. Prevent liquid from entering drains,
sewers, basements and work pits since vapour may create a suffocating
atmosphere.
Disposal Best to recover and recycle. If this is not possible, destruction is to be in
an approved facility which is equipped to absorb and neutralise acids and
other toxic processing products.
Fire extinguishing data Non-flammable at atmospheric conditions.
Containers Fire exposed containers should be kept cool with water sprays. Containers
may burst if overheated.
Fire fighting protective equipment Self contained breathing apparatus and protective clothing must be worn
in fire conditions.
Refrigerant Oil Data
Safety Data York "K" Oil
Classification Non-hazardous
In contact with skin Minimally irritating. No first aid necessary. Exercise reasonable personal
cleanliness including cleansing exposed skin areas several times daily with
soap and water. Launder soiled work clothes at least weekly.
In contact with eyes Flush eyes with eyewash solution or clean water for 15 minutes and consult
a physician.
Ingested May cause nausea and diahorrhea. Obtain immediate medical attention.
Inhalation If oil mist is inhaled, remove to fresh air and consult a physician.
Occupational exposure limits Not determined.
Stability Stable but hygroscopic - store in sealed containers.
Conditions to avoid Strong oxidisers, caustic or acid solutions, excessive heat. May degrade
some paints and rubber materials.
Hazardous decomposition Not fully, Analogous compounds evolve carbon monoxide, carbon dioxide
and other unidentified fragments when burned. Burning may evolve irritating/
noxious fumes.
Respiratory protection Use in well ventilated areas - ventilate locally.
Protective clothing Goggles or face shield should be worn. Gloves not necessary, but
recommended, especially for prolonged exposure.
Spill / Leak procedure Wear suitable protective equipment. Especially goggles. Stop source of
spill. Use absorbent materials to soak up fluid (i.e. sand, sawdust and
commercially available materials).
Disposal Incinerate the oil and all associated wastes in an approved facility in
accordance with local laws and regulations governing oily wastes.
Fire extinguishing data Flash point over 300°C. Use dry chemical, carbon dioxide or foam. Spraying
water on hot or burning liquid may cause frothing or splashing.
If a leak or spill has not ignited use water spray to disperse the vapours and
to provided protection for persons attempting to stop the leak.
Containers Fire exposed containers should be kept cool with water sprays.
Fire fighting protective equipment Self contained breathing apparatus should be worn in fire conditions.

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Thermal & Acoustic Materials Data
Health Hazard & First Aid Toxicity Index <10 to NES713 Issue 3 (1991): Non-hazardous, non-toxic.
No first aid necessary.
Stability / Reactivity Stable.
Handling / Use / Disposal No special handling precautions required. Dispose of according to local
laws and regulations governing non-biodegradable non-hazardous solid
wastes.
Fire & Explosion Flammability rating Class 1 to BS 476 pt 7: Non-flammable. If forced to
burn, combustion products are typically over 95% carbon dioxide and
carbon monoxide.

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2 PRODUCT DESCRIPTION
2.1 General (Figures 2.1 and 2.2)
The York YK Millennium™ Centrifugal Liquid Chiller is
primarily used for large air conditioning systems, but may
be used on other applications. The chiller is completely
factory-packaged including evaporator, condenser,
compressor, motor, lubrication system, graphic control
centre (OptiView), and all interconnecting unit piping
and wiring. The initial charge of refrigerant and oil is
supplied for each unit.
The chiller is controlled by a modern state of the art
microprocessor control centre that monitors its operation.
The control centre is programmed by the operator to suit
job specifications. 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 labelled on the control centre.
The chiller with the graphic control centre (OptiView) is
compatible with an electro-mechanical starter, 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.
The refrigerant vapour, which is produced by the boiling
action in the evaporator, flows to the compressor
where the rotating impeller increases its pressure and
temperature and discharges it into the condenser.
Water flowing through the condenser tubes absorbs
heat from the refrigerant vapour, causing it to condense.
The condenser water is supplied to the chiller from an
external 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 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.
Figure 2.1 YK Centrifugal Liquid Chiller (Front View)

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2.2 Capacity Control (Figure 2.2)
The major components of a chiller are selected for full
load capacities, therefore capacity must be controlled
to maintain a constant chilled liquid temperature leaving
the evaporator. 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
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.
Figure 2.2 YK Refrigerant Flow Diagram

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2.3 Compressor
The compressor is a single-stage centrifugal type
powered by an open-drive electric motor.
The rotor assembly consists of a heat-treated alloy steel
drive shaft and impeller shaft with a cast aluminum,
fully shrouded impeller. The impeller is designed for
balanced thrust and is dynamically balanced and over-
speed tested.
The inserted type journal and thrust bearings are
fabricated of aluminum alloy. Single helical gears with
crowned teeth are designed so that more than one tooth
is in contact at all times. Gears are integrally assembled
in the compressor rotor support and are film lubricated.
Each gear is individually mounted in its own journal and
thrust bearings.
The open-drive compressor shaft seal is a double bellows
cartridge style with ceramic internal and atmospheric
seal faces. The seal is oil-flooded at all times and is
pressure-lubricated during operation.
Figure 2.3 YK Centrifugal Liquid Chiller (Rear View)
2.4 Compressor Lubrication System
(Figure 2.4)
The chiller lubrication system consists of the oil pump,
oil filter, oil cooler and all interconnecting oil piping and
passages. The main points within the compressor which
must be supplied with forced lubrication:
1. Compressor Drive Shaft (Low Speed)
a. Shaft seal.
b. Front and rear journal bearings –
one on each side of driving gear.
c. Low speed thrust bearing
(forward and reverse).
2. Compressor Driven Shaft (High Speed)
a. Forward and reverse high speed thrust
bearing.
b. Two journal bearings.
3. Speed Increasing Gears
a. Meshing surfaces of drive and pinion gear
teeth.

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Figure 2.4 Compressor Lubrication System

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To provide the required amount of oil under the necessary
pressure to properly lubricate these parts, a motor driven
submersible oil pump is located in a remote oil sump.
Upon pressing of the COMPRESSOR START switch on
the control panel, the oil pump is immediately energized.
After a 50 second pre-lube period, the compressor motor
will start. The oil pump will continue to run during the
entire operation of the compressor, and for 150 seconds
during compressor shutdown.
The submerged oil pump takes suction from the
surrounding oil and discharges it to the oil cooler where
heat is rejected. The oil flows from the oil cooler to the oil
filter. The oil leaves the filter and flows to the emergency
oil reservoir where it is distributed to the compressor
bearings. The oil lubricates the compressor rotating
components and is returned to the oil sump.
There is an emergency oil reservoir located at the
highest point in the lubrication system internally in the
compressor. It provides an oil supply to the various
bearings and gears in the event of a system shutdown
due to power failure. The reservoir, located on the top of
the compressor, allows the oil to be distributed through
the passages by gravity flow, thus providing necessary
lubrication during the compressor shutdown.
2.4.1 Oil Pump
For normal operation, the oil pump should operate at all
times during chiller operation.
On shutdown of the system for any reason, the oil pump
operates and continues to run for 150 seconds. The
system cannot restart during that time interval.
2.4.2 Oil Heater
During long idle periods, the oil in the compressor oil
reservoir tends to absorb as much refrigerant as it can
hold, depending upon the temperature of the oil and
the pressure in the reservoir. As the oil temperature
is lowered, the amount of refrigerant absorbed will be
increased. If the quantity of refrigerant in the oil becomes
excessive, violent oil foaming will result as the pressure
within the system is lowered on starting. This foaming is
caused by refrigerant boiling out of the oil as the pressure
is lowered. If this foam reaches the oil pump suction, the
bearing oil pressure will fluctuate with possible temporary
loss of lubrication, causing the oil pressure safety cutout
to actuate and stop the system (Refer to Control Centre
Manual 160.54.OI).
2.5 Compressor Motor
The compressor motor is an open-drip-proof, squirrel
cage, induction type constructed to York design
specifications, 50 hertz motors operate at 2975 rpm.
The open motor is provided with a D-flange, cast iron
adapter mounted to the compressor and supported by
a motor support.
Motor drive shaft is directly connected to the compressor
shaft with a flexible disc coupling. This coupling has
all metal construction with no wearing parts to assure
long life, and no lubrication requirements to provide low
maintenance.
For units utilising remote electro-mechanical starters,
a terminal box is provided for field connected conduit.
Motor terminals are brought through the motor casing into
the terminal box. Jumpers are furnished for three-lead
type of starting. Motor terminal lugs are not furnished.
Overload/overcurrent transformers are furnished with
all units.
For units furnished with factory packaged Solid State
Starters, (optional) see Options Section.
2.6 Graphic Control Centre (OptiView)
The graphic control centre is factory-mounted, wired
and tested. The electronic panel automatically controls
the operation of the unit in meeting system cooling
requirements while minimizing energy usage. For
detailed information on the Graphic Control Centre, refer
to Form 160.54-O1
2.7 Heat Exchangers
Evaporator and condenser shells are fabricated from
rolled carbon steel plates with fusion welded seams.
Heat exchanger tubes are internally enhanced type.
2.7.1 Evaporator
The evaporator is a shell and tube, flooded type heat
exchanger. A distributor trough provides uniform
distribution of refrigerant over the entire shell length.
Stainless steel mesh eliminators or suction baffles
are located above the tube bundle to prevent liquid
refrigerant carryover into the compressor. A 2" liquid
level sight glass is located on the side of the shell to aid
in determining proper refrigerant charge. The evaporator
shell contains dual refrigerant relief valves.
2.7.2 Condenser
The condenser is a shell and tube type, with a discharge
gas baffle to prevent direct high velocity impingement
on the tubes. A separate subcooler is located in the
condenser to enhance performance. Dual refrigerant
relief valves are located on condenser shells with
optional isolation refrigerant isolation valves.
2.7.3 Water Boxes
The removable compact water boxes are fabricated of
steel. The design working pressure is 1034 kPa and the
boxes are tested at 1551 kPa. Integral steel water baffles
provide the required pass arrangements.

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Stub-out water nozzle connections with Victaulic grooves
are welded to the water boxes. These nozzle connections
are suitable for Victaulic couplings, welding or flanges,
and are capped for shipment. Plugged ¾" drain and vent
connections are provided in each water box.
2.8 Refrigerant Flow Control
Refrigerant flow to the evaporator is controlled by a
variable orifice.
Alevel sensor senses the refrigerant level in the condenser
and outputs an analog voltage to the microprocessor
that represents this level (0% = empty; 100% = full).
Under program control, the microprocessor modulates
a variable orifice to control the condenser refrigerant
level to a programmed setpoint. Other setpoints affect
the control sensitivity and response. These setpoints
must be entered at chiller commissioning by a qualified
service technician. Only a qualified service technician
may modify these settings.
While the chiller is shut down, the orifice will be in
the fully open position causing the sensed level to be
approximately 0%. When the chiller is started, after the
vane motor end switch (VMS) opens when entering
SYSTEM RUN, if actual level is less than the level
setpoint, a linearly increasing ramp is applied to the
level setpoint. This ramp causes the setpoint to go from
the initial refrigerant level (approximately 0%) to the
programmed setpoint over a period of 15 minutes.
If the actual level is greater than the setpoint when the
VMS opens, there is no pulldown period, it immediately
begins to control to the programmed setpoint.
While the chiller is running, the refrigerant level is
normally controlled to the level setpoint. However,
anytime the vanes fully close (VMS closes), normal
level control is terminated, any refrigerant level setpoint
pulldown in effect is cancelled and the outputs to the level
control will be opposite that which is supplied to the vane
motor (i.e., when a close pulse is applied to the vane
motor, an open pulse is applied to the level control, etc.).
When the VMS opens, if the refrigerant level is less than
the level setpoint, a refrigerant level setpoint pulldown
is initiated as described above. Otherwise, the level is
controlled to the programmed setpoint.
2.9 Options and Accessories
2.9.1 Service Isolation Valves
If the chiller is equipped with optional service isolation
valves on the discharge and liquid line, these valves
must remain open during operation. These valves are
used for isolating the refrigerant charge in either the
evaporator or condenser to allow service access to the
system. A refrigerant pump-out unit will be required to
isolate the refrigerant.
Isolation of the refrigerant in this system must be
performed by a qualified service technician.
2.9.2 Hot Gas Bypass
Hot gas bypass is optional and is used to eliminate
compressor surge during light load or high head
operation. The control panel will automatically modulate
the hot gas valve open and closed as required.
Adjustment of the hot gas control valve must be
performed by a qualified service technician following
the Hot Gas Set-up procedure.
Changes in chilled water flow will require re-adjustment
of the hot gas control to insure proper operation.
2.9.3 Solid State Starter
The optional Solid State Starter is a reduced voltage
starter that controls and maintains a constant current
flow to the motor during start-up. It is mounted on the
chiller. Power and control wiring between the starter and
chiller are factory installed. Available for 380-600 volts,
the starter enclosure is IP54 with a hinged access door
with lock and key. Electrical lugs for incoming power
wiring are provided.
2.9.4 Variable Speed Drive
An optional 400V – 3-Ph – 60/50Hz Variable Speed Drive
can be factory packaged with the chiller. It is designed to
vary the compressor motor speed and pre-rotation vane
position by controlling the frequency and voltage of the
electrical power to the motor. Operational information
is contained in Form 160.00-O1 (VSD 658 HP and 900
HP) or 160.00-O4 (VSD OptiSpeed 292 HP and 419
HP). The control logic automatically adjusts motor speed
and compressor pre-rotation vane position for maximum
part load efficiency by analysing information fed to it by
sensors located throughout the chiller.
The VSD eliminates the need for a starter and has a
soft starting characteristic that never exceeds 100%
full load amps. It also provides automatic power factor
correction.
An optional harmonic filter limits electrical power supply
distortion from the variable speed drive and further
improves power factor correction.

035-19569-101 (0109)
2-7
GB
2.10 Nomenclature
YK ER ER Q7 5 CS G S
Model Special Modifications
Evaporator Code Design Level
Condenser Code Motor Code
Compressor Code Power Supply (5 for 50 Hz)

035-19569-101 (0109)
2-8 GB
2.11 Range of Models
COMPRESSOR EVAPORATOR CONDENSER
CODE CODE CODE
Q3 AP to AS AP to AS
CP to CS CP to CS
DP to DS DP to DS
Q4 EP to ET EP to ET
CP to CS CP to CS
DP to DS DP to DS
EP to ET EP to ET
FQ to FT FQ to FT
EP to ET EP to ET
FQ to FT FQ to FT
P8 GQ to GS EV to EX
HQ to HS FV to FX
JP to JS JP to JS
LQ to LS LQ to LS
KP to KS, K2 to K4 KP to KS, K2 to K4
MQ to MS, M2 to M4 MQ to MS, M2 to M4
K1 KT to KX, K5 to K7 KP to KS, K2 to K4
MQ to MS, M2 to M4 MQ to MS, M2 to M4
NQ to NS, N2 to N4 NP to NS, N2 to N4
PQ to PS, P2 to P4 PQ to PS, P2 to P4
QQ to QS, Q2 to Q4 QQ to QS, Q2 to Q4
NQ to NS, N2 to N4 NP to NS, N2 to N4
QQ to QS, Q2 to Q4 QQ to QS, Q2 to Q4
RQ, RS, RV, R3, R5, R7 RQ to RS, R2 to R4
RP, RR, RT, R2, R4, R6 RQ to RS, R2 to R4
SQ to SS, S2 to S4
VP to VS, V2 to V5
TP to TS, T2 to T5
XQ to XS, X2 to X4
WP to WT, W2, W4, W6 WQ to WS, W1 to W4
ZQ to ZS, Z1 to Z4 ZQ to ZS, Z1 to Z4
Q3, Q4
Q5
Q5, Q6, Q7
P7
P8, P9
H9
K1, K2
K3
MOTOR CODES
K4 SQ, SS, SV, S3, S5, S7
K7
XQ to XS, X2 to X4
5CC-5CO
5CE-5CO
5CP-5CU
5CE-5CU
5CK-5CW
5CN-5DC
5DA-5DH
5DA-5DJ
5DD-5DL
COMPRESSOR EVAPORATOR CONDENSER
CODE CODE CODE
Q3 AP to AS AP to AS
CP to CS CP to CS
DP to DS DP to DS
Q4 EP to ET EP to ET
CP to CS CP to CS
DP to DS DP to DS
EP to ET EP to ET
FQ to FT FQ to FT
EP to ET EP to ET
FQ to FT FQ to FT
P8 GQ to GS EV to EX
HQ to HS FV to FX
JP to JS JP to JS
LQ to LS LQ to LS
KP to KS, K2 to K4 KP to KS, K2 to K4
MQ to MS, M2 to M4 MQ to MS, M2 to M4
K1 KT to KX, K5 to K7 KP to KS, K2 to K4
MQ to MS, M2 to M4 MQ to MS, M2 to M4
NQ to NS, N2 to N4 NP to NS, N2 to N4
PQ to PS, P2 to P4 PQ to PS, P2 to P4
QQ to QS, Q2 to Q4 QQ to QS, Q2 to Q4
NQ to NS, N2 to N4 NP to NS, N2 to N4
QQ to QS, Q2 to Q4 QQ to QS, Q2 to Q4
RQ, RS, RV, R3, R5, R7 RQ to RS, R2 to R4
RP, RR, RT, R2, R4, R6 RQ to RS, R2 to R4
SQ to SS, S2 to S4
VP to VS, V2 to V5
TP to TS, T2 to T5
XQ to XS, X2 to X4
WP to WT, W2, W4, W6 WQ to WS, W1 to W4
ZQ to ZS, Z1 to Z4 ZQ to ZS, Z1 to Z4
Q3, Q4
Q5
Q5, Q6, Q7
P7
P8, P9
H9
K1, K2
K3
MOTOR CODES
K4 SQ, SS, SV, S3, S5, S7
K7
XQ to XS, X2 to X4
5CC-5CO
5CE-5CO
5CP-5CU
5CE-5CU
5CK-5CW
5CN-5DC
5DA-5DH
5DA-5DJ
5DD-5DL

035-19569-101 (0109)
3-1
GB
3 TRANSPORTATION, RIGGING AND STORAGE
8. Do not run hot water (40°C maximum.) or steam
through the evaporator or condenser at any time.
3.2 Shipment
The chiller may be ordered and shipped in any of the
following forms:
Form 1 – Factory Assembled Unit (complete with
motor, refrigerant and oil charges)
1. The motor/compressor assembly mounted, with
all necessary interconnecting piping assembled.
Graphic control centre (OptiView) is mounted on the
unit. Complete unit factory leak tested, evacuated
and charged with R134a.
An optional Solid State Starter or Variable Speed
Drive can be factory mounted and wired.
2. Miscellaneous material – Four (4) vibration isolation
pads (or optional spring isolators and brackets).
Form 2 – Factory Assembled Unit (complete with
motor, refrigerant and oil charges shipped separately).
1. The motor/compressor assembly mounted, with
all necessary interconnecting piping assembled.
Graphic control centre (OptiView) is mounted on the
unit. Complete unit factory leak tested, evacuated
and charged with holding charge of nitrogen.
An optional Solid State Starter or Variable Speed
Drive can be factory mounted and wired.
2. Miscellaneous material – Four (4) vibration isolation
pads (or optional spring isolators and brackets).
Form 3 – Driveline Separate From Shells
Shipped as three major assemblies. Unit first
factory assembled, refrigerant piped, wired and leak
tested; then dismantled for shipment. Compressor/
motor assembly removed from shells and skidded.
Evaporator/condenser shells are not skidded.
All compressor wiring attached, and all conduit is left
on shell. All openings on compressor, oil separator,
and shell are closed and charged with dry nitrogen
(1.4 to 2 kPag).
Miscellaneous packaging of control centre, tubing,
water temperature controls, wiring, oil, isolators, solid
state starter (option), etc.; refrigerant charge shipped
separately.
3.1 General
YK units are shipped as a single factory assembled,
piped, wired package, requiring minimum installation
to make chilled water connections, condenser water
connections, refrigerant atmospheric relief connections,
and electrical power connections.
Refrigerant and oil charges are shipped separately
(unless optional condenser isolation valves are
ordered).
Chillers can also be shipped dismantled when required
by rigging conditions, but generally it is more economical
to enlarge access openings to accommodate the factory
assembled unit. Chillers shipped dismantled MUST
be field assembled under the supervision of a York
representative.
FIELD ASSEMBLED UNITS ONLY
Use Form 160.73-N3 in conjunction with this manual.
This instruction will be furnished with all units that are to
be field assembled. Extra copies may be ordered from
the York Publication Distribution Centre.
A York authorised representative must check the
installation, supervise the initial start-up and operation
of all newly installed chillers.
CAUTION
The York Warranty may be voided if the
following restrictions are not adhered to:
1. No valves or connections should be opened under
any circumstances because such action will result in
loss of the factory nitrogen charge.
2. Do not dismantle or open the chiller for any
reason except under the supervision of a York
representative.
3. When units are shipped dismantled, notify the nearest
York office in ample time for a York representative
to supervise rigging the unit to its operating position
and the assembly of components.
4. Do not make final power supply connections to the
compressor motor or control centre.
5. Do not charge the compressor with oil.
6. Do not charge the unit with refrigerant.
7. Do not attempt to start the system.

035-19569-101 (0109)
3-2 GB
NOTE
Units shipped dismantled MUST be re-
assembled by, or under the supervision of, a
York representative. (See Form 160.73-N3)
Form 7 – Split Shells
Shipped as four major assemblies. Unit first factory
assembled, refrigerant piped, wired and leak tested;
then dismantled for shipment. Compressor/motor
assembly removed from shells and skidded.
Evaporator and condenser shells are separated at
tube sheets and are not skidded. Refrigerant lines
between shells are flanged and capped, requiring no
welding.
All compressor wiring attached. All wiring harnesses
on shells are removed. All openings on compressor
and shells are closed and charged with dry nitrogen
(1.4 to 2 kPag).
Miscellaneous packaging of control centre, tubing,
water temperature controls, wiring, oil isolators, solid
state starter (option), etc.; refrigerant charge shipped
separately.
NOTE
Units shipped dismantled MUST be re-
assembled by, or under the supervision of, a
York representative. (See Form 160.73-N3)
When more than one chiller is ordered, the major
parts of each unit will be marked to prevent mixing
of assemblies. (Piping and Wiring Drawings will be
furnished by York.)
3.3 Inspection, Damage and Shortage
The unit shipment should be checked on arrival to see
that all major pieces, boxes and crates are received.
Each unit should be checked before unloading, for any
visible signs of damage. Any damage or signs of possible
damage must be reported to the transportation company
immediately for their inspection.
York will not be responsible for any damage in shipment
or at job site or loss of parts.
When received at the job site all containers should
be opened and contents checked against the packing
list. Any material shortage should be reported to York
immediately.
Chiller Data Plate
A unit data plate is mounted on the control panel
assembly of each unit, giving unit model number; design
working pressure; water passes; refrigerant charge;
serial numbers; and motor power characteristics and
connection diagrams.
Additional information may be found on the motor
data plate. This information should be included when
contacting the factory on any problem relating to the
motor.