York YK Style H User manual

LD15222
MODEL YK (STYLE H)
R-134a
WITH OPTIVIEW™ CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER AND VARIABLE SPEED DRIVE
OPTIVIEW™ CONTROL CENTER
CENTRIFUGAL LIQUID CHILLERS
OPERATION MANUAL New Release Form 160.76-O2 (615)
Issue Date:
June 15, 2015

FORM 160.76-O2
issue date: 6/15/2015
JOHNsON CONtROLs
2
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, 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 responsibility of rigging, instal-
lation, and 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
rigging, installation, and operating/service personnel. It
is expected that these individuals possess 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 understood the on-product labels,
this document and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and 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 cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance 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 warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 160.76-O2
issue date: 6/15/2015
MANUAL DESCRIPTION FORM NUMBER
Installation 160.76-N1
Wiring Diagram - Unit Style H with Electro-Mechanical Starter 160.76-PW1
Wiring Diagram - Unit Style H with Mod "B" Solid State Starter 160.76-PW2.1
Wiring Diagram - Unit Style H with Variable Speed Drive 160.76-PW3
Renewal Parts - OptiView Control Center 160.76-RP1
Wiring Diagram – Unit Style H (P Compressors) with Electro-Mechanical Starter 160.76-PW8
Wiring Diagram – Unit Style H (P Compressors) with Mod “B” Solid State Starter 160.76-PW9
Wiring Diagram – Unit Style H (P Compressors) with Variable Speed Drive 160.76-PW10
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 or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts.
johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
ASSOCIATED LITERATURE

FORM 160.76-O2
issue date: 6/15/2015
JOHNsON CONtROLs
4
NOMENCLATURE
YK 6A 6Q Q7 – EM H
MOTOR CODE
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
COMPRESSOR CODE*
CONDENSER CODE*
EVAPORATOR CODE*
MODEL*
STYLE (Design Level)
* Refer to YK Engineering Guide for (Form 160.76-EG1)
Shell/Motor/Compressor combinations.

JOHNSON CONTROLS 5
FORM 160.76-O2
issue date: 6/15/2015
TABLE OF CONTENTS
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION .......................................... 9
SYSTEM OPERATION DESCRIPTION ...........................................................................................................9
Capacity Control.............................................................................................................................................10
SECTION 2 - OPTIVIEW CONTROL CENTER INTRODUCTION..........................................................................13
Optiview Control Center .................................................................................................................................15
Safety Stop.....................................................................................................................................................16
Interface Conventions Overview ....................................................................................................................16
DISPLAY ONLY ..............................................................................................................................................16
PROGRAMMABLE......................................................................................................................................... 16
NAVIGATION..................................................................................................................................................17
Home Screen .................................................................................................................................................21
System Screen ...............................................................................................................................................25
Displays the temperature of the liquid as it enters the condenser..................................................................26
Evaporator Screen .........................................................................................................................................27
Condenser Screen .........................................................................................................................................31
Heat Recovery/Head Pressure Control Screen.............................................................................................. 35
Head Pressure Control Screen ......................................................................................................................39
Heat Pump Screen .........................................................................................................................................41
Refrigerant Level Control Screen ...................................................................................................................45
Compressor Screen .......................................................................................................................................47
Capacity Control Screen ................................................................................................................................51
Capacity Control Setpoints Screen ................................................................................................................55
Anti-Surge Turning Screen .............................................................................................................................57
Capacity Control Override Turning Screen.....................................................................................................59
Proximity Probe Calibration Screen ...............................................................................................................61
Hot Gas Bypass Screen .................................................................................................................................63
Surge Protection Screen ................................................................................................................................65
Variable Geometry Diffuser Screen................................................................................................................69
Variable Geometry Diffuser Setpoints Screen................................................................................................71
Variable Geometry Diffuser Calibration Screen..............................................................................................73
Pre-Rotation Vanes Calibration Screen..........................................................................................................75
VSD Tuning Screen........................................................................................................................................77
Oil Sump Screen ............................................................................................................................................79
Electro-Mechanical Starter Screen................................................................................................................. 83
Mod “B” Solid State Starter Screen ................................................................................................................85
Medium Voltage Solid State Starter Screen ...................................................................................................87
Vyper/Mod D Variable Speed Drive Screen ................................................................................................... 89
Raptyr Variable Speed Drive Screen..............................................................................................................91
Medium Voltage Variable Speed Drive Screen...............................................................................................93
Adaptive Capacity Control Details Screen .....................................................................................................97
Surge Map Screen - Table View ................................................................................................................... 101
Surge Map Screen - List View......................................................................................................................103
Harmonic Filter Details Screen..................................................................................................................... 105
Motor Lubrication Screen .............................................................................................................................107
Motor Details Screen.................................................................................................................................... 111
Motor Setpoints Screen................................................................................................................................ 115
Setpoints Screen .......................................................................................................................................... 119
Setup Screen................................................................................................................................................123
Quick Start Screen .......................................................................................................................................127

FORM 160.76-O2
issue date: 6/15/2015
JOHNsON CONtROLs
6
TABLE OF CONTENTS (CONT'D)
Schedule Screen ..........................................................................................................................................131
User Screen .................................................................................................................................................133
COMMS Screen ...........................................................................................................................................135
Printer Screen ..............................................................................................................................................137
Sales Order Screen......................................................................................................................................139
Operations Screen .......................................................................................................................................141
History Screen..............................................................................................................................................143
History Details Screen..................................................................................................................................145
Security Log Screen .....................................................................................................................................147
Security Log Details Screen .........................................................................................................................149
Custom View Screen....................................................................................................................................151
Custom View Setup Screen..........................................................................................................................153
Trend Screen................................................................................................................................................155
Trend Setup Screen .....................................................................................................................................157
Advanced Trend Setup Screen ....................................................................................................................159
Common Slots Screen .................................................................................................................................161
SECTION 3 - DISPLAY MESSAGES....................................................................................................................165
Status Messages..........................................................................................................................................165
Run Messages .............................................................................................................................................166
Start Inhibit Messages..................................................................................................................................167
Warning Messages.......................................................................................................................................167
Routine Shutdown Messages....................................................................................................................... 170
Cycling Shutdown Messages .......................................................................................................................170
Mod “B” Solid State Starter Cycling Shutdown Messages ...........................................................................173
Compressor Motor Variable Speed Drive: Cycling Shutdown Messages.....................................................174
Safety Shutdown Messages.........................................................................................................................179
Mod “B” Solid State Starter Safety Shutdown Messages.............................................................................185
Compressor Motor Variable Speed Drive: Safety Shutdown Messages ......................................................186
SECTION 4 - PRINTING .......................................................................................................................................189
Printing Overview .........................................................................................................................................189
Acceptable Printers ......................................................................................................................................190
Printer Connections......................................................................................................................................190
Printer Setup ................................................................................................................................................191
Control Center Setup....................................................................................................................................191
Downloading System Prints to a
Laptop ..........................................................................................................................................................191
Printer Connections......................................................................................................................................193

JOHNSON CONTROLS 7
FORM 160.76-O2
issue date: 6/15/2015
LIST OF FIGURES
FIGURE 1 - Model YK Chiller....................................................................................................................................9
FIGURE 2 - Compressor Pre-rotation Vanes ..........................................................................................................10
FIGURE 3 - Refrigerant Flow-Thru Chiller............................................................................................................... 11
FIGURE 4 - Optiview Control Center.......................................................................................................................15
FIGURE 5 - Home Screen.......................................................................................................................................21
FIGURE 6 - Home Screen With Stop Button...........................................................................................................23
FIGURE 7 - System Screen ....................................................................................................................................25
FIGURE 8 - Evaporator Screen...............................................................................................................................27
FIGURE 9 - Condenser Screen...............................................................................................................................31
FIGURE 10 - Heat Recovery/HEad Pressure Control Screen.................................................................................35
FIGURE 11 - Head Pressure Control Screen ..........................................................................................................39
FIGURE 12 - Heat Pump Screen ............................................................................................................................41
FIGURE 13 - Refrigerant Level Control Screen ......................................................................................................45
FIGURE 14 - Compressor Screen (Screen Shown is a Unit with Proximity Probe) ...............................................47
FIGURE 15 - Capacity Control Screen....................................................................................................................51
FIGURE 16 - Capacity Control Setpoints Screen (Screen Shown is Heating/Cooling Unit with Raptyr VSD)........ 55
FIGURE 17 - Anti Surge Screen (PRV Capacity Control Screen Shown) ...............................................................57
FIGURE 18 - Capacity Control Override Turning Screen ........................................................................................59
FIGURE 19 - Proximity Probe Calibration Screen...................................................................................................61
FIGURE 20 - Hot Gas Bypass Screen ....................................................................................................................63
FIGURE 21 - Surge Protection Screen....................................................................................................................65
FIGURE 22 - Variable Geometry Diffuser Screen ...................................................................................................69
FIGURE 23 - Variable Geometry Diffuser Setpoints Screen ...................................................................................71
FIGURE 24 - Variable Geometry Diffuser Calibration Screen .................................................................................73
FIGURE 25 - Pre-Rotation Vanes Calibration Screen .............................................................................................75
FIGURE 26 - VSD Tuning Screen ...........................................................................................................................77
FIGURE 27 - Oil Sump Screen................................................................................................................................79
FIGURE 28 - Electro-Mechanical Starter Screen....................................................................................................83
FIGURE 29 - Mod “B” Solid State Starter Screen ...................................................................................................85
FIGURE 30 - Medium Voltage Solid State Starter Screen ......................................................................................87
FIGURE 31 - Vyper/MOd D Variable Speed Drive Screen......................................................................................89
FIGURE 32 - Raptyr Variable Speed Drive Screen .................................................................................................91
FIGURE 33 - Medium Voltage Variable Speed Drive Screen .................................................................................93
FIGURE 34 - Adaptive Capacity Control Details Screen .........................................................................................97
FIGURE 35 - Surge Map Screen - Table View ......................................................................................................101
FIGURE 36 - Surge Map Screen - List View ......................................................................................................... 103
FIGURE 37 - Harmonic Filter Details Screen (Style D VSD and VSD with Part Number 371-03789-XXX (503hp
60Hz; 419hp 50Hz) .........................................................................................................................105
FIGURE 38 - Motor Lubrication Screen.................................................................................................................107
FIGURE 39 - Motor Details Screen ....................................................................................................................... 111
FIGURE 40 - Motor Setpoints Screen ................................................................................................................... 115
FIGURE 41 - Setpoints Screen ............................................................................................................................. 119
FIGURE 42 - Setup Screen...................................................................................................................................123
FIGURE 43 - Quick Start Screen...........................................................................................................................127
FIGURE 44 - Schedule Screen .............................................................................................................................131
FIGURE 45 - User Screen.....................................................................................................................................133
FIGURE 46 - COMMS Screen...............................................................................................................................135
FIGURE 47 - Printer Screen..................................................................................................................................137
FIGURE 48 - Sales Order Screen .........................................................................................................................139
FIGURE 49 - Operations Screen...........................................................................................................................141
FIGURE 50 - History Screen .................................................................................................................................143
FIGURE 51 - History Details Screen .....................................................................................................................145
FIGURE 52 - Security Log Screen ........................................................................................................................147
FIGURE 53 - Security Log Details Screen ............................................................................................................149
FIGURE 54 - Custom View Screen .......................................................................................................................151

FORM 160.76-O2
issue date: 6/15/2015
JOHNsON CONtROLs
8
LIST OF FIGURES (CONT'D)
LIST OF TABLES
FIGURE 55 - Custom View Setup Screen.............................................................................................................153
FIGURE 56 - Trend Screen ...................................................................................................................................155
FIGURE 57 - Trend Setup Screen.........................................................................................................................157
FIGURE 58 - Advanced Trend Setup Screen........................................................................................................159
FIGURE 59 - Common Slots Screen.....................................................................................................................161
FIGURE 60 - Printer ..............................................................................................................................................189
FIGURE 62 - Communications Block Diagram......................................................................................................193
FIGURE 61 - Breckman Printer.............................................................................................................................193
FIGURE 63 - Sample Printout (Status)..................................................................................................................194
FIGURE 64 - Sample Printout (Setpoints).............................................................................................................196
FIGURE 65 - Sample Printout (Schedule).............................................................................................................198
FIGURE 66 - Sample Printout (Sales Order).........................................................................................................198
FIGURE 67 - Sample Printout (History).................................................................................................................200
FIGURE 68 - Sample Printout (Security Log Report)............................................................................................202
FIGURE 69 - Sample Printout (Trend Data New or Existing Points).....................................................................202
FIGURE 70 - Sample Printout (Custom Screen Report) ....................................................................................... 202
FIGURE 71 - Sample Printout (Adaptive Capacity Control New Map Point Report)..............................................203
FIGURE 72 - Sample Printout (Adaptive Capacity Control Existing Map Points Report)......................................203
TABLE 1 - Addresses and Associated Data............................................................................................................19
TABLE 2 - Capacity Control Setpoint Programmable Settings ...............................................................................56
TABLE 3 - Voltage (V).............................................................................................................................................94
TABLE 4 - Master Slot Numbers List for Use with Trend Feature.........................................................................162
TABLE 5 - OKIDATA OKIPOS 441........................................................................................................................190
TABLE 6 - Brecknell CP130..................................................................................................................................193
TABLE 7 - SI Metric Conversion ...........................................................................................................................205

JOHNSON CONTROLS 9
FORM 160.76-O2
issue date: 6/15/2015
1
nent to operation of the chiller are automatically dis-
played and read on a graphic display. Other displays
can be observed by pressing the keys as labeled on the
Control Center. The chiller with the OptiView Control
Center is applied with an Electro-Mechanical Starter,
YORK Solid State Starter (optional), or Variable Speed
Drive (optional).
When the compressor motor is driven by a YORK
Solid State Starter, one of two different starters could
be applied. Later production chillers are equipped with
either the Style B Liquid Cooled Solid State Starter
(LCSSS) or the Medium Voltage Solid State Starter
(MVSSS).
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS
OF OPERATION
SYSTEM OPERATION DESCRIPTION
The YORK Model YK Chiller is commonly applied
to large air conditioning systems, but may be used
on other applications. The chiller consists of an open
motor mounted to a compressor (with integral speed
increasing gears), condenser, evaporator and variable
flow control.
The chiller is controlled by a modern state of the art
Microcomputer Control Center that monitors its opera-
tion. The Control Center is programmed by the opera-
tor to suit job specifications. Automatic timed start-ups
and shutdowns are also programmable to suit night-
time, weekends, and holidays. The operating status,
temperatures, pressures, and other information perti-
LD15222
CONDENSER
CONTROL
CENTER
COMPRESSOR
VSD
Motor
EVAPORATOR
FIGURE 1 - MODEL YK CHILLER

FORM 160.76-O2
issue date: 6/15/2015
JOHNsON CONtROLs
10
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALSOF OPERATION
7619A(D)
FIGURE 2 - COMPRESSOR PRE-ROTATION VANES
When the compressor motor is driven by a YORK
Variable Speed Drive, there could be a Variable Speed
Drive (VSD) or a Medium Voltage Variable Speed
Drive (MV VSD) applied.
In operation, a liquid (water or brine to be chilled) flows
through the cooler, 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 cooler, flows to the compressor where
the rotating impeller increases its pressure and tem-
perature 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
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 liq-
uid refrigerant to the cooler to complete the refrigerant
circuit.
The major components of a chiller are selected to han-
dle the refrigerant, which would be evaporated at full
load design conditions. However, most systems will
be called upon to deliver full load capacity for only a
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 cooler. Pre-rotation Vanes (PRV), located at the
entrance to the compressor impeller, compensate for
variation in load (Refer to Figure 2 on Page 10).
The position of these vanes is automatically controlled
through a lever arm attached to an electric motor lo-
cated outside the compressor housing. The automatic
adjustment of the vane position in effect provides the
performance of many different compressors to match
various load conditions from full load with vanes wide
open to minimum load with vanes completely closed.