York MaxE YK Manual

OPERATING & MAINTENANCE
MAXETM
CENTRIFUGAL LIQUID CHILLERS
Supersedes: 160.73-O2 (1202) Form 160.73-O2 (605)
MODEL YK (STYLE F)
R-134a COOLING ONLY
WITH OPTIVIEWTM CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER & VARIABLE SPEED DRIVE
00611VIP
LDO5842

YORK INTERNATIONAL
FORM 160.73-O2 (605)
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,
oils, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and respon-
sibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
in which it is situated, as well as severe personal in-
jury 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 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.
External wiring, unless specified 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 specifications and must be performed ONLY by qualified 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.

FORM 160.73-O2 (605)
3
YORK INTERNATIONAL
CHANGEABILITY OF THIS DOCUMENT
It is the responsibility of operating/service personnel
as to the applicability of these documents to the equip-
ment in question. If there is any question in the mind
of operating/service personnel as to the applicability of
these documents, then, prior to working on the equipment,
they should verify with the owner whether the equipment
has been modified and if current literature is available.
DESIGN LEVEL (F)
POWERSUPPLY
– for 60 Hz
5 for 50 Hz
COMPRESSOR CODE
H4, H5, H6, H7, H8, H9, J1,
J2, J3, J4, J5, P1, P2, P3,
P4, P5, P6, P7, P8, P9, Q7
CONDENSER CODE
AA, AB, AC, AD, BA, BB, BC, BD, CD, CE, CF, CG, CH,
DE, DF, DG, DH, EB, EC, ED, EK, EL, EM, FA, FB, FC,
FD, FK, Fl, FM, GB, GC, GD, GJ, GK, GL, GM, HB, HC,
HD, HK, HL, HM, JB, JC, JD, KJ, KK, KL, KM, TB, TC, TD
, VB, VC, VD, XA, XB, XC, XD
EVAPORATOR CODE
AA, AB, AC, AD, BA, BB, BC, BD, CD, CE, CF, CG, CH, DE, DF, DG,
DH, EB, EK, EL, EM, FB, FC, FD, FK, FL, FM, GB, GC, GD, GF, GH,
GJ, GK, GL, GM, HB, HC, HF, HH, HK, HL, HM, JF, JG, JH, KD, KJ,
KK, KL, KM, LK, LL, LM, TB, TC, TD, TF, TG, TH, VF, VH, WF, WH, XF, XH
NOMENCLATURE
YK CB CB P6 – CM F
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 prod-
uct improvement, the information contained in this doc-
ument is subject to change without notice. While YORK
makes no commitment to update or provide current
information automatically to the manual owner, that in-
formation, if applicable, can be obtained by contacting
the nearest YORK Applied Systems Service office.
REFERENCE INSTRUCTIONS
DESCRIPTION FORM NO.
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 160.73-N1
OPTIVIEW CONTROL CENTER - SERVICE INSTRUCTIONS 160-54-M1
WIRING DIAGRAM – UNIT WITH ELECTRO-MECHANICAL STARTER 160.73-PW1
WIRING DIAGRAM – UNIT WITH MOD “A” SOLID STATE STARTER 160.73-PW2
WIRING DIAGRAM – UNIT WITH VARIABLE SPEED DRIVE 160.73-PW3
RENEWAL PARTS – UNIT 160.73-RP4
RENEWAL PARTS – OPTIVIEW CONTROL CENTER 160.54-RP1
OPTIVIEW™ PANEL - OPERATION & MAINTENANCE 160.54.O1
MODEL

YORK INTERNATIONAL
FORM 160.73-O2 (605)
4
SECTION 1 Description of System and Fundamentals of Operation............................... 6
SECTION 2 System Operating Procedures ...................................................................... 9
SECTION 3System Components Description ............................................................... 15
SECTION 4Operational Maintenance ........................................................................... 21
SECTION 5Troubleshooting.......................................................................................... 23
SECTION 6Maintenance ............................................................................................... 25
SECTION 7Preventive Maintenance ............................................................................. 34
TABLE OF CONTENTS

FORM 160.73-O2 (605)
5
YORK INTERNATIONAL
LIST OF FIGURES
FIG. 1 – MODEL YK MAXETM CHILLER................................... 6
DETAIL A – COMPRESSOR PREROTATION
VANES.................................................................. 7
FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER ........... 8
FIG. 3 – OIL LEVEL INDICATOR LABEL.................................. 9
FIG. 4 – CHILLER STARTING SEQUENCE &
SHUTDOWN SEQUENCE
(EM STARTER & SOLID STATE STARTER)...... 10
FIG. 5 – CHILLER STARTING SEQUENCE &
SHUTDOWN SEQUENCE
(VARIABLE SPEED DRIVE)................................11
FIG. 6 – LIQUID CHILLER LOG SHEETS.............................. 12
FIG. 7 – SYSTEM COMPONENTS ........................................ 15
FIG. 8 – SCHEMATIC DRAWING (YK) COMPRESSOR
LUBRICATION SYSTEM.................................... 16
FIG. 9 – OIL RETURN SYSTEM ............................................ 21
FIG. 10 – CHARGING OIL RESERVOIR WITH OIL............... 22
FIG. 11 – EVACUATION OF CHILLER................................... 25
FIG. 12 – SATURATION CURVE............................................ 27
FIG. 13 – DIAGRAM - MEGGING MOTOR WINDINGS......... 29
FIG. 14 – MOTOR STATOR TEMPERATURE &
INSULATION RESISTANCE .............................. 30

YORK INTERNATIONAL
FORM 160.73-O2 (605)
6
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 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. Water
flowing through the condenser tubes absorbs heat from
the refrigerant vapor, causing it to condense. The con-
denser water is supplied to the chiller from an external
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 ap-
plied to large air conditioning systems, but may be used on
other applications. The chiller consists of an open motor
mounted to a compressor (with integral speed increasing
gears), condenser, evaporator and variable flow control.
The chiller is controlled by a modern state of the art Mi-
crocomputer Control Center that monitors its operation.
The Control Center is programmed by the operator to suit
job 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 press-
ing the keys as labeled on the Control Center. The chiller
with the OptiView Control Center is compatible with an

FORM 160.73-O2 (605)
7
YORK INTERNATIONAL
1
source, usually a cooling tower. The condensed refrig-
erant 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.
7619A(D)
DETAIL A – COMPRESSOR PREROTATION VANES
Description of System and Fundamentals of Operation
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 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 adjust-
ment of the vane position in effect provides the perfor-
mance of many different compressors to match various
load conditions from full load with vanes wide open to
minimum load with vanes completely closed.

YORK INTERNATIONAL
FORM 160.73-O2 (605)
8
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

FORM 160.73-O2 (605)
9
YORK INTERNATIONAL
CHECKING THE OIL LEVEL
IN THE OIL RESERVOIR
Proper operating oil level – During operation, the oil
level should fall to the “Operating Range” identified on
the vertical oil level indicator label. See Figure 3.
• If the oil level during operation is in the “Over
Full” region of the oil level indicator, oil should be
removed from the oil reservoir, This reduces the oil
level to the “Operating Range”.
• If the oil level during operation is in
the “Low Oil” region of the oil level
indicator, oil should be added to the
oil reservoir. (See “Oil Charging Pro-
cedure”, page 22)
START-UP PROCEDURE
Pre-Starting
Prior to starting the chiller, observe the OptiView
Control Center. Make sure the display reads SYSTEM
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 Cen-
ter setpoints should be programmed before the chiller
is started. (Refer to Form 160.54-O1).
Vent any air from the chiller water
boxes prior to starting the water
pumps. Failure to do so will result in
pass baffle 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 flow is established
through the unit. (A field supplied chilled water flow
switch is required.) If the chilled liquid pump is wired
to the Microcomputer Control Center the pump will
automatically start, therefore, this step is not neces-
sary.
System Operating Procedures
SECTION 2
SYSTEM OPERATING PROCEDURES
OIL HEATERS
If the oil heater is de-energized during a shutdown period,
it must be energized for 12 hours prior to starting com-
pressor, 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 main-
tain the oil temperature differential to a value 50°F
(27.8°C) above the condenser saturation temperature.
This is the target value and if the oil temperature falls to
4°F (2.2°C) or more below the target, the heater is turned
on. It is turned off when the oil temperature increases to
3°F (1.7°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 con-
trol center component failure, the oil heater thermostat
(1HTR) is set to open at 180°F (82°C). FIG. 3 – OIL LEVEL INDICATOR
LD08647
Comply with EPA and Local regu-
lations when removing or disposing
of Refrigeration System oil!

YORK INTERNATIONAL
FORM 160.73-O2 (605)
10
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 during
STOP/RESET are also displayed.
When the chiller is shut down, the prerotation vanes will
close automatically to prevent loading the compressor
on start-up.
When the chiller starts to operate, the following au-
tomatic sequences are initiated: (Refer to Fig. 4 & 5,
“Chiller Starting & Shutdown Sequence Chart”.)
1. The OptiView Control Center display message will
read SYSTEM PRELUBE for the first 50 seconds
of the starting sequence.
2. The oil pump will start to circulate oil for a 50 second
pre-run to establish oil flow and adequate lubrication
to all bearings, gears, and rotating surfaces within
the compressor.
The high and low oil pressure transducers (OP) and
the oil temperature sensor (RT3) will sense any mal-
function in the lubrication system.
3. The anti-recycle timer (non-VSD Chillers only)
software function will operate after the 50 seconds
of pre-run time. At this time, the timer will be initi-
ated 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 flow
through the evaporator when the COMPRESSOR
start switch is energized.
5. After the first 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. 4 – CHILLER STARTING SEQUENCE & SHUTDOWN SEQUENCE
(EM STARTER & SOLID STATE STARTER)
LD04040
** NOT FOR ALL SHUTDOWNS. REFER TO “DISPLAY MES-
SAGES” SECTION OF THIS MANUAL.