Johnson Controls York YKEP Series User manual

CENTRIFUGAL LIQUID CHILLER
WITH ECONOMIZER COMPRESSOR
CONTROL CENTER OPERATION Form 160.77-02 (611) Form 160.77-02 (1111)
R-134a
Issue Date:
November 15, 2011
MODEL YKEP
2700 - 3200 TON
LD15301a

FORM 160.77-O2
ISSUE DATE: 11/15/2011
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 these
individuals possess independent training that will en-
able 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
understood this document and any referenced mate-
rials. 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 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 control panel cabinet. Devices such as relays, switches, transducers
and controls and any external wiring must not be installed inside the control 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.

FORM 160.77-O2
ISSUE DATE: 11/15/2011
JOHNSON CONTROLS 3
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically to
the manual owner. Updated manuals, if applicable, can
be obtained by contacting the nearest Johnson Controls
Service office.
Operating/service personnel maintain responsibility for
the applicability of these documents to the equipment.
If there is any question regarding the applicability of
these documents, the technician should verify whether
the equipment has been modified and if current litera-
ture is available from the owner of the equipment prior
to performing any work on the chiller.
ASSOCIATED LITERATURE
NOMENCLATURE
MANUAL DESCRIPTION FORM NUMBER
YKEP Installation & Re-assembly 160.77-N1
YKEP Unit Operation & Maintenance 160.77-O1
YKEP Control Center Operation 160.77-O2
YKEP Unit & Control Panel Renewal Parts 160.77-RP1
YKEP Installation Checklist 160.77-CL1
YKEP Startup Checklist 160.77-CL2
YKEP Wiring Diagram - Field Connections 160.77-PW1
YKEP Wiring Diagram - Unit Wiring and Field Control Modication 160.77-PW2
Liquid Cooled Solid State Starter - Operation 160.00-O2
Medium Voltage Variable Speed Drive (2300v - 6600v) - Operation 160.00-O6
Medium Voltage Variable Speed Drive (10,000v - 13,800v) - Operation 160.00-O8
Unit Mounted Medium Voltage Solid State Starter (2300v - 4160v) - Operation 160.00-O7
Long-Term Storage Requirements - General 50.20-NM1
Long-Term Storage Requirements - Field Preparation 50.20-NM5
Long-Term Storage - Periodic Checklist and Logs 50.20-CL5
* For both Primary and Economizer power supply: “-” = 60Hz and “5” = 50Hz
Primary Motor
Primary Power Supply *
Economizer Compressor
Primary Compressor
Economizer Motor
Economizer Power Supply *
Condenser
Modification LevelEvaporator
Special FeaturesModel
YKEP BD B5 K7 Q3 DL CF5 A S
-
LD15116

FORM 160.77-O2
ISSUE DATE: 11/15/2011
JOHNSON CONTROLS
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FORM 160.77-O2
ISSUE DATE: 11/15/2011
JOHNSON CONTROLS 5
TABLE OF CONTENTS
LIST OF TABLES
TABLE 1 - YKEP Control System Sensors .............................................................................................................18
TABLE 2 - Trend Pen Assignments.........................................................................................................................92
TABLE 3 - Modbus RTU Slot List............................................................................................................................93
TABLE 4 - Status Line Messages and Colors.......................................................................................................109
TABLE 5 - LCSSS High Supply Line Voltage Thresholds.....................................................................................118
TABLE 6 - LCSSS Low Supply Line Voltage Thresholds......................................................................................118
TABLE 7 - Over-Current Trip.................................................................................................................................123
SECTION 1 - YKEP CHILLER OVERVIEW..............................................................................................................7
SECTION 2 - YKEP CONTROL CENTER INTRODUCTION..................................................................................17
SECTION 3 - YKEP CONTROL PANEL OPERATION........................................................................................... 21
Home Screen .................................................................................................................................................25
System Screen ...............................................................................................................................................28
Manual / Auto Stations Screen .......................................................................................................................32
Subcooler Screen...........................................................................................................................................34
Economizer Screen ........................................................................................................................................36
Evaporator Screen .........................................................................................................................................38
Hot Gas Screen..............................................................................................................................................40
Condenser Screen .........................................................................................................................................42
Primary Compressor Screen ..........................................................................................................................44
Primary Proximitor Calibration Screen ...........................................................................................................48
PRV Calibration Screen.................................................................................................................................. 50
Oil Sump Screen ............................................................................................................................................52
Primary Variable Geometry Diffuser Screen...................................................................................................54
Primary Motor Screen (EM Starter)................................................................................................................56
Primary Motor Screen (MV SSS) ................................................................................................................... 58
Primary Motor Screen (MV VSD) ...................................................................................................................60
Capacity Controls Screen with Hot Gas (Fixed Speed) .................................................................................62
Capacity Controls Screen without Hot Gas (Fixed Speed) ............................................................................64
Capacity Controls Screen (Speed Option) ..................................................................................................... 66
Capacity Controls Screen (Vane Anti-Surge) ................................................................................................. 68
Primary Capacity Tuning Screen....................................................................................................................70
Primary Anti-Surge Screen.............................................................................................................................72
Capacity Limits Screen...................................................................................................................................74
Economizer Compressor Screen ................................................................................................................... 76
Economizer Motor LCSSS Screen .................................................................................................................78
Economizer Capacity Screen .........................................................................................................................80
Setpoints Screen ............................................................................................................................................82
Factory Setup Screen..................................................................................................................................... 84
Comms Screen...............................................................................................................................................86
Alarm History Screen ..................................................................................................................................... 88
Active Alarms Screen .....................................................................................................................................89
Trip Status Screen..........................................................................................................................................90
Trending Screen .............................................................................................................................................91
SECTION 4 - MODBUS RTU SLOT LIST...............................................................................................................93
SECTION 5 - DISPLAY MESSAGES....................................................................................................................109

FORM 160.77-O2
ISSUE DATE: 11/15/2011
JOHNSON CONTROLS
6
FIGURE 1 - YKEP System Component Identication ...............................................................................................7
FIGURE 2 - YKEP Chiller System Diagram ..............................................................................................................8
FIGURE 3 - YKEP Chiller Operation Sequence Timing Diagram..............................................................................9
FIGURE 4 - YKEP Chiller Oil Management System................................................................................................ 11
FIGURE 5 - Capacity Control Model .......................................................................................................................13
FIGURE 6 - System Anti-Surge Map.......................................................................................................................15
FIGURE 7 - Logic Controller....................................................................................................................................17
FIGURE 8 - Control Panel.......................................................................................................................................17
FIGURE 9 - YKEP Control System Sensors ...........................................................................................................19
FIGURE 10 - Red Lion Touch-Screen Display ........................................................................................................21
FIGURE 11 - Security Manager...............................................................................................................................22
FIGURE 12 - Username ..........................................................................................................................................22
FIGURE 13 - Password...........................................................................................................................................22
FIGURE 14 - Setpoint Program Dialog Box ............................................................................................................23
FIGURE 15 - Menu Screen .....................................................................................................................................23
FIGURE 16 - Navigation..........................................................................................................................................24
FIGURE 17 - Home Screen.....................................................................................................................................25
FIGURE 18 - System Screen ..................................................................................................................................28
FIGURE 19 - Manual / Auto Stations Screen ..........................................................................................................32
FIGURE 20 - Subcooler Screen ..............................................................................................................................34
FIGURE 21 - Economizer Screen ...........................................................................................................................36
FIGURE 22 - Evaporator Screen.............................................................................................................................38
FIGURE 23 - Hot Gas Screen .................................................................................................................................40
FIGURE 24 - Condenser Screen.............................................................................................................................42
FIGURE 25 - Primary Compressor Screen .............................................................................................................44
FIGURE 26 - Primary Proximity Calibration Screen................................................................................................ 48
FIGURE 27 - PrV Calibration Screen ......................................................................................................................50
FIGURE 28 - Oil Sump Screen................................................................................................................................52
FIGURE 29 - Primary variable Geometry Diffuser Screen ......................................................................................54
FIGURE 30 - Primary Motor Screen (EM Starter) ...................................................................................................56
FIGURE 31 - Primary Motor Screen (MV SSS).......................................................................................................58
FIGURE 32 - Primary Motor Screen (MV VSD).......................................................................................................60
FIGURE 33 - Capacity Controls Screen (Fixed Speed with Hot Gas).....................................................................62
FIGURE 34 - Capacity Controls Screen (Fixed Speed without Hot Gas)................................................................64
FIGURE 35 - Capacity Controls Screen (Speed Option).........................................................................................66
FIGURE 36 - Capacity Controls Screen (Vane Anti-Surge).....................................................................................68
FIGURE 37 - Primary Capacity Tuning Screen .......................................................................................................70
FIGURE 38 - Primary Anti-Surge Screen ................................................................................................................72
FIGURE 39 - Capacity Limits Screen......................................................................................................................74
FIGURE 40 - Economizer Compressor Screen.......................................................................................................76
FIGURE 41 - Economizer Motor LCSSS Screen ....................................................................................................78
FIGURE 42 - Economizer Capacity Screen ............................................................................................................80
FIGURE 43 - Setpoints Screen ...............................................................................................................................82
FIGURE 44 - Factory Setup Screen........................................................................................................................84
FIGURE 45 - Comms Screen..................................................................................................................................86
FIGURE 46 - Alarm History Screen.........................................................................................................................88
FIGURE 47 - Active Alarms Screen.........................................................................................................................89
FIGURE 48 - Trip Status Screen .............................................................................................................................90
FIGURE 49 - Trending Screen ................................................................................................................................91
FIGURE 50 - System Status / System Details.......................................................................................................109
LIST OF FIGURES

FORM 160.77-O2
ISSUE DATE: 11/15/2011
JOHNSON CONTROLS 7
11
CHILLER PRINCIPLE OF OPERATION
The YKEP chiller (Figure 1 on Page 7) consists
of the components of a standard high pressure single
stage centrifugal chiller plus the addition of a flash
economizer and a secondary compressor to draw flash
gas from the economizer when required and discharge
to the condenser. The secondary compressor is referred
to as the economizer compressor. A system diagram is
shown in Figure 2 on Page 8.
The chiller operates in three configurations depending
on the lift required and the load.
1. The primary compressor can operate indepen-
dently with the economizer off, drawing suction
from the evaporator, discharging to the condenser,
with condensed liquid return to the evaporator via
ow through the idle economizer. The discharge
of the economizer compressor includes a check
valve to prevent backow from the condenser to
the economizer vessel in this operating mode.
2. When the calculated gas ow through the primary
compressor reaches a prescribed threshold as fol-
lows, the economizer compressor start is initiated.
The economizer compressor draws suction from
the economizer vessel and discharges to the con-
denser. The economizer compressor capacity is
controlled to maintain the economizer pressure at
a target value between the condenser and evapo-
rator pressures. In this mode the chiller is econo-
mizing to gain refrigeration effect for the primary
compressor and improve efciency.
Economizer compressor start criteria:
Primary Compressor Calculated Flow ≥ Flow Target de-
fined as a straight line between the points.
• Saturation Pressure of Subcooled Liquid - Evapo-
rator pressure = 64 PSID: 6000 CFM Required
• Saturation Pressure of Subcooled Liquid - Evapo-
rator Pressure = 30 PSID: 8200 CFM Required
Additionally:
• The Economizer Liquid Level must be below 90%
• The Leaving Chilled Liquid Temperature is not be-
low Setpoint
• The Economizer Saturation Temperature is not
below the Target Temperature
FIGURE 1 - YKEP SYSTEM COMPONENT IDENTIFICATION
LD15301
EVAPORATOR
CONDENSER
PRIMARY (K7)
COMPRESSOR
PRIMARY
OPEN-DRIVE
MOTOR
ECONOMIZER
OPEN-DRIVE
MOTOR
CONTROL
CENTER
ECONOMIZER (Q3)
COMPRESSOR
SUBCOOLER
VALVE
ISOLATION
VALVE
ECONOMIZER
COMPRESSOR
SOLID STATE
STARTER
ECONOMIZER
OIL PUMP
HOUSING
OIL PUMP
PANEL
SECTION 1 - YKEP CHILLER OVERVIEW

FORM 160.77-O2
ISSUE DATE: 11/15/2011
JOHNSON CONTROLS
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SECTION 1 - YKEP CHILLER OVERVIEW
Economizer Compressor Stop criteria:
Primary Compressor Calculated Flow ≤ the prescribed
Start criteria line minus 2000 CFM
3. When the primary compressor capacity reaches
full capacity dened by either 100% input cur-
rent FLA or fully open PRV and full speed (VSD
starter types), the economizer compressor switch-
es to Boost operating mode. In this mode, the
economizer compressor capacity is controlled
to maintain leaving chilled liquid temperature
at setpoint and the primary compressor is given
a leaving chilled liquid temperature target 1 de-
gree F below the chiller setpoint to keep it fully
loaded. The economizer compressor is then con-
trolled to maintain the chiller programmed leav-
ing chilled liquid temperature setpoint using its
PRV’s. As additional capacity is required, the
economizer compressor draws the economizer
pressure lower, increasing the refrigeration effect
PRIMARY COMPRESSOR
CONDENSER
ECONOMIZER COMPRESSOR
ECONOMIZER
EVAPORATOR
CHILLED
LIQUID
(OPTIONAL)
HOT GAS
BYPASS VALVE
ECONOMIZER
LEVEL VALVE
ECONOMIZER
LEVEL
SUBCOOLER
LEVEL
COOLING
LIQUID
PRV
VGD
VGD
CHECK
VALVE PRV
SUBCOOLER
LEVEL VALVE
FIGURE 2 - YKEP CHILLER SYSTEM DIAGRAM
LD16021

FORM 160.77-O2
ISSUE DATE: 11/15/2011
SECTION 1 - YKEP CHILLER OVERVIEW
JOHNSON CONTROLS 9
1
of the mass owing through the primary and in-
creasing chiller capacity. Upon unloading, when
the economizer compressor PRV closed switch is
activated, signifying the economizer compressor
is completely unloaded, or the economizer satu-
ration temperature is 0.5 Degrees F above what
the target saturation temperature would be for
economizing mode, the economizer compressor
switches back to economizing operation. Then
the primary compressor control returns to fol-
lowing the chiller programmed leaving chilled
liquid temperature and the economizer compres-
sor is following its target economizer pressure as
described in (2) above.
A timing diagram of the compressors’ start sequence
and shutdown is shown in Figure 3 on Page 9.
FIGURE 3 - YKEP CHILLER OPERATION SEQUENCE TIMING DIAGRAM
LD16023
0 10 13 45 50 110
(0.17) (0.22) (0.75) (0.83) (1.83)
VANES
CLOSED
MAN. OIL
PUMP
DISABLED
AUTO ZEROING DIFFERENTIAL
OIL PRESSURE TRANSDUCERS
** VANES CLOSING - TIME
DEPENDENT ON INITIAL
VANE POSITION
OIL PRESSURE CHECK
OIL PUMP ON
"SYSTEM
COASTDOWN"
"SYSTEM
SHUTDOWN"
TIME IN SECONDS (MINUTES)
DISPLAY
MESSAGE
"SYSTEM RUN"
"SYSTEM PRELUBE"
** "VANES CLOSING
BEFORE
SHUTDOWN"
ENERGIZE (OPEN)
LIQUID GEAR COOLING
SOLENOID (PRIMARY COMPRESSOR)
RESTART AFTER
ANTI-RECYCLE
(FOR EM STARTERS, 30 MIN)
(FOR VSD STARTERS, 5 STARTS THEN 10 MIN)
240 SEC
(4 MIN) K7
Q3
150 SEC
(2.5 MIN)
FLOW
SWITCH
BYPASS
START STOP

FORM 160.77-O2
ISSUE DATE: 11/15/2011
JOHNSON CONTROLS
10
SECTION 1 - YKEP CHILLER OVERVIEW
YKEP OIL MANAGEMENT
Figure 4 on Page 11 shows the layout of the chiller
oil management system. Each compressor has a dedi-
cated oil pump in a common oil sump with the other
pump. Oil for each is passed through its individual
oil cooler and filter set to the compressor bearings.
Each compressor has supervisory pressure monitoring
against the sump pressure to ensure sufficient supply to
its bearings. Refrigerant liquid flow to each oil cooler
is regulated with a thermostatic expansion valve sens-
ing oil temperature at the outlet of the cooler to 110° F.
Oil drains from the rotor support of each compressor
back to the sump. Oil to each compressor fills a drain-
down reservoir in the housing to provide coastdown oil
in the event of a power loss while running.
Oil temperature is maintained to a target 50° F above
condenser saturation temperature when the chiller is
not running. Electric oil heaters are operated by the
control system to accomplish this. At no time will the
control allow the oil heaters to continue to operate with
oil temperature above 160°F.
Oil return from the refrigerant system is accomplished
with a single eductor block. The block has three pas-
sages with eductor nozzles, all driven by condenser gas
from a common manifold within the block.
The venturi stream of each of the nozzles draws fluid
from:
• the evaporator
• the primary compressor PRV cavity in two adja-
cent locations
• the economizer compressor PRV cavity.
The outlet of the eductor sections goes to a common
plenum in the block and vented to the oil sump. The oil
sump is vented to the suction of the Primary compres-
sor behind the pre-rotation vanes.
The primary compressor is also supplied with liquid
refrigerant gear cooling that is initiated with a solenoid
valve that opens for compressor run.