York MaxE YK Series Manual

OPERATING & MAINTENANCE
MAXETM
CENTRIFUGAL LIQUID CHILLERS
Supersedes: NOTHING Form 160.54-O2 (1102)
MODEL YK (STYLE E)
R-134a COOLING ONLY
WITH OPTIVIEWTM CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER & VARIABLE SPEED DRIVE
00611VIP
LDO5842

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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 responsibility 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 require-
ments could result in serious damage to the equip-
ment and the property in which it is situated, as well
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
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 personnel. YORK
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.

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CHANGEABILITY OF THIS DOCUMENT
It is the responsibility of operating/service person-
nel as to the applicability of these documents to the
equipment in question. If there is any question in the
mind of operating/service personnel as to the appli-
cability of these documents, then, prior to working
on the equipment, they should verify with the owner
whether the equipment has been modied and if cur-
rent literature is available.
DESIGN LEVEL (E)
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
COMPRESSOR CODE
G4, H0, H1, H2, H3, H4, H5
H6, H8, J1, J2, J3, J4, P1, P2,
P3, P4, P5, P6, P7
CONDENSER CODE
AB, AC, AD, BB, BC, BD, CR, CG, CH, DF, DG,
DH CB, CC, CD, DB, DC, DD, EB, EC, ED, FB,
FC, FD, GB, GC, GD, HB, HC, HD, JB, JC, JD,
TB, TC, TD, VB, VC, VD
EVAPORATOR CODE
AB, AC, AD, BB, BC, BD, CR, CG, CH, DF, DG, DH
MODEL CB, CC, CD, CE, DB, DC, DD, DE, FB, FC, FD
GB, GC, GD, GF, GH, HB, HC, HF, HH, JF, JG
JH, TF, TG, TH, VF, VH, WF, WH
NOMENCLATURE
YK CB CB G4 – CM E
MOTOR CODE
60 Hz 50 Hz
CH CX 5CE 5CT
CJ CY 5CF 5CU
CK CZ 5CG 5CV
CL CA 5CH 5CW
CM CB 5CI 5CX
CN DA 5CJ 5DA
CP DB 5CK 5DB
CR DC 5CL 5DC
CS DD 5CM 5DD
CT DE 5CN 5DE
CU DF 5CO 5DF
CV DH 5CP 5DG
CW DJ 5CQ 5DH
CF CG 5CR 5OJ
5CS
In complying with YORK’s policy for continuous
product improvement, the information contained in
this document is subject to change without notice.
While YORK makes no commitment to update or
provide current information automatically to the
manual owner, that information, if applicable, can be
obtained by contacting the nearest YORK Applied
Systems Service ofce.
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
VARIABLE SPEED DRIVE – OPERATION 160.00-O1
VARIABLE SPEED DRIVE – SERVICE INSTRUCTIONS 160.00-M1
INSTALLATION 160.54-N1
OPTIVIEW CONTROL CENTER - SERVICE INSTRUCTIONS 160-54-M1
WIRING DIAGRAM – UNIT WITH ELECTRO-MECHANICAL STARTER 160.54-PW1
WIRING DIAGRAM – UNIT WITH MOD “A” SOLID STATE STARTER 160.54-PW2
WIRING DIAGRAM – UNIT WITH MOD “B” SOLID STATE STARTER 160.54-PW2.1
WIRING DIAGRAM – UNIT WITH VARIABLE SPEED DRIVE 160.54-PW3
RENEWAL PARTS – UNIT 160.49-RP4
RENEWAL PARTS – OPTIVIEW CONTROL CENTER 160.54-RP1
WIRING DIAGRAM – UNIT (P Compressors) with ELECTRO-MECHANICAL STARTER 160.54-PW8
WIRING DIAGRAM – UNIT (P Compressors) with MOD “B” SOLID STATE STARTER 160.54-PW9
WIRING DIAGRAM – UNIT (P Compressors) with VARIABLE SPEED DRIVE 160.54-PW10
OPTIVIEW™ PANEL - OPERATION & MAINTENANCE 160.54.O1

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SECTION 1 Description of System and Fundamentals of Operation............................... 7
SECTION 2 System Operating Procedures ...................................................................... 9
SECTION 3 System Components Description ............................................................... 15
SECTION 4 Operational Maintenance ........................................................................... 21
SECTION 5 Troubleshooting.......................................................................................... 23
SECTION 6 Maintenance ............................................................................................... 25
SECTION 7 Preventive Maintenance ............................................................................. 34
TABLE OF CONTENTS

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LIST OF FIGURES
FIG. 1 – MODEL YK MAXETM CHILLER ............................ 7
DETAIL A – COMPRESSOR PREROTATION
VANES.................................................................. 8
FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER..... 9
FIG. 3 – CHILLER STARTING SEQUENCE &
SHUTDOWN SEQUENCE
(EM STARTER & SOLID STATE STARTER)...... 10
FIG. 4 – CHILLER STARTING SEQUENCE &
SHUTDOWN SEQUENCE
(VARIABLE SPEED DRIVE)................................11
FIG. 5 – LIQUID CHILLER LOG SHEETS ....................... 12
FIG. 6 – SYSTEM COMPONENTS .................................. 15
FIG. 7 – SCHEMATIC DRAWING (YK) COMPRESSOR
LUBRICATION SYSTEM.................................... 16
FIG. 8 – OIL RETURN SYSTEM ...................................... 18
FIG. 9 – CHARGING OIL RESERVOIR WITH OIL .......... 21
FIG. 10 – EVACUATION OF CHILLER .............................. 22
FIG. 11 – SYSTEM PRESSURES...................................... 25
FIG. 12 – SATURATION CURVE ....................................... 27
FIG. 13 – DIAGRAM - MEGGING MOTOR WINDINGS .... 29
FIG. 14 – MOTOR STATOR TEMPERATURE &
INSULATION RESISTANCE .............................. 30

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starter, YORK Solid State Starter (optional), or Vari-
able Speed Drive (optional).
There could be either of two different Solid State
Starters applied. Later production chillers are
equipped with the Mod “B” Solid State Starter. This
starter contains a combination Logic/trigger Board
that interfaces the Control Center with a serial com-
munications link. Earlier vintage chillers are equipped
with the Mod “A” Solid State Starter. This starter con-
tains a Trigger Board that interfaces to a Logic Board
that is installed inside of the Control Center.
Chillers that are equipped with “P” Compressors have
certain component variances. These variances are
noted in the appropriate sections of this book. They
have a different Condenser High Pressure Safety
Cutout Switch (HPCO) than supplied on other com-
pressor applications. This switch is mounted on the
condenser shell but has a different wiring interface to
the I/O Board and Motor Controller circuit. Refer to
SECTION 1
DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
00116vip
CONDENSER
CONTROL
CENTER
COMPRESSOR
MOTOR
EVAPORATOR
FIG. 1 – MODEL YK MAXETM CHILLER
SYSTEM OPERATION DESCRIPTION (SEE FIG. 2)
The YORK Model YK MaxETM 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 vari-
able ow control.
The chiller is controlled by a modern state of the
art Microcomputer Control Center that monitors its
operation. The Control Center is programmed by the
operator to suit job specications. Automatic timed
start-ups and shutdowns are also programmable to
suit nighttime, weekends, 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 Con-
trol Center is compatible with an electro-mechanical

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the I/O Board section of this book. Also, “P” com-
pressor applications are equipped with a High Speed
Thrust Bearing Limit Switch instead of the Proximity
Probe supplied on other compressors. This device de-
tects abnormal bearing position through probe contact
instead of distance measurement as performed with
the Proximity Probe.
In operation, a liquid (water or brine to be chilled)
ows through the evaporator, where boiling refriger-
ant 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.
7619A(D)
DETAIL A – COMPRESSOR PREROTATION VANES
Description of System and Fundamentals of Operation
The refrigerant vapor, which is produced by the boil-
ing action in the evaporator, ows to the compressor
where the rotating impeller increases its pressure and
temperature and discharges it into the condenser. Wa-
ter owing 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 orice meters the ow
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.
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 (See Detail A).
The position of these vanes is automatically con-
trolled 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 compres-
sors to match various load conditions from full load
with vanes wide open to minimum load with vanes
completely closed.

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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

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SECTION 2
SYSTEM OPERATING PROCEDURES
OIL HEATERS
If the oil heater is de-energized during a shutdown pe-
riod, it must be energized for 12 hours prior to starting
compressor, or remove all oil and recharge compressor
with new oil. (See “Oil Charging Procedure”, page
22.)
OIL HEATER OPERATION
The oil heater operation is controlled by the
OptiView™ Control Center. The heater is turned on
and off to maintain the oil temperature to a value
50°F (10°C) above the condenser saturation tempera-
ture. This is the target value and if the oil temperature
falls to 4°F (-15.5°C) or more below the target, the
heater is turned on. It is turned off when the oil
temperature increases to 3°F (-16°C) above the target
value.
If the target value is greater than 160°F (71°C), the
target defaults to 160°F (71°C). If the target value
is less than 110°F (43.3°C), it defaults to 110°F
(43.3°C).
To prevent overheating of the oil in the event of a
control center component failure, the oil heater ther-
mostat (1HTR) is set to open at 180°F (82°C).
CHECKING THE OIL LEVEL
IN THE OIL RESERVOIR
Proper operating oil level – the upper and lower
sight glasses.
If the oil is excessively high after start-up, the
excess oil may be drained from the oil lter drain
valve while the compressor is running.
If oil level is low, oil should be added to the com-
pressor. (See “Oil Charging Procedure”, page 22)
Comply with EPA and Local regu-
lations when removing or dispos-
ing of Refrigeration System oil!
START-UP PROCEDURE
Pre-Starting
Prior to starting the chiller, observe the OptiView
Control Center. Make sure the display reads SYS-
TEM READY TO START.
To pre-start the chiller, use the following procedure:
1. Oil Heater – The oil heater must be energized
for 12 hours prior to starting the chiller.
2. Prior to start, the clock must be programmed for
the proper day and time. Any setpoints which are
desired to be changed may be programmed. All
Control Center setpoints should be programmed
before the chiller is started. (Refer to Form
160.54-O1).
Vent ant air from the chiller water
boxes prior to starting the water
pumps. Failure to do so will result
in pass bafe damage.
START-UP
1. If the chilled water pump is manually operated,
start the pump. The Control Center will not allow
the chiller to start unless chilled liquid ow is es-
tablished through the unit. (A eld supplied chilled
water ow switch is required.) If the chilled liquid
pump is wired to the Microcomputer Control Cen-
ter the pump will automatically start, therefore,
this step is not necessary.
System Operating Procedures

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2. To start the chiller, press the COMPRESSOR
START switch. This switch will automatically
spring return to the RUN position. (If the unit
was previously started, press the STOP/RESET
side of the COMPRESSOR switch and then
press the START side of the switch to start the
chiller.) When the start switch is energized, the
Control Center is placed in an operating mode and
any malfunction will be noted by messages on a
graphic display.
Any malfunctions which occur dur-
ing STOP/RESET are also displayed.
When the chiller is shut down, the prerotation vanes
will close automatically to prevent loading the com-
pressor on start-up.
When the chiller starts to operate, the following au-
tomatic sequences are initiated: (Refer to Fig. 3 & 4,
“Chiller Starting & Shutdown Sequence Chart”.)
1. The OptiView Control Center display message
will read SYSTEM PRELUBE for the rst 50
seconds of the starting sequence.
2. The oil pump will start to circulate oil for a 50
second pre-run to establish oil ow and adequate
lubrication to all bearings, gears, and rotating sur-
faces within the compressor.
The high and low oil pressure transducers (OP)
and the oil temperature sensor (RT3) will sense
any malfunction in the lubrication system.
3. The anti-recycle timer software function will op-
erate after the 50 seconds of pre-run time. At this
time, the timer will be initiated and will run for 30
minutes after the compressor starts. If the chiller
shuts down during this period of time, it cannot
be started until the timer completes the 30 minute
cycle.
4. The chilled liquid pump contacts will close, start-
ing the chilled liquid pump, to allow liquid ow
through the evaporator when the COMPRESSOR
start switch is energized.
5. After the rst 50 seconds of operation, the com-
pressor will start.
6. For display messages and information pertaining
to the operation of the OptiView™ Control Center,
refer to Form 160.54-O1.
FIG. 3 – CHILLER STARTING SEQUENCE & SHUTDOWN SEQUENCE
(EM STARTER & SOLID STATE STARTER)
LD04040
** NOT FOR ALL SHUTDOWNS. REFER TO “DISPLAY MES-
SAGES” SECTION OF THIS MANUAL.