York Operation & Maitenance Manual

CENTRIFUGAL LIQUID CHILLERS
OPERATIONS AND MAINTENANCE Supersedes: 160.75-O1 (508) Form 160.75-O1 (211)
MODEL YK (STYLE G)
R-134a
WITH OPTIVIEWTM CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER AND VARIABLE SPEED DRIVE
LD15222
FORM 160.75-O1 (211)
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During installation, operation maintenance or service, death to themselves and people at the site.
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, This document is intended for use by owner-authorized
materials under pressure, rotating components, and operating/service personnel. It is expected that this in-
both high and low voltage. Each of these items has the dividual posseses independent training that will enable
potential, if misused or handled improperly, to cause them to perform their assigned tasks properly and safe-
bodily injury or death. It is the obligation and respon- ly. It is essential that, prior to performing any task on
sibility of operating/service personnel to identify and this equipment, this individual shall have read and un-
recognize these inherent hazards, protect themselves, derstood this document and any referenced materials.
and proceed safely in completing their tasks. Failure This individual shall also be familiar with and comply
to comply with any of these requirements could result with all applicable governmental standards and regula-
in serious damage to the equipment and the property in tions 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 !"#$%&'#() *) +*,*-") .+&/+) /012") 2#*") %0)
which will result in death or serious injury damage to the machine,damage to other
if proper care is not taken. equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Indicates a potentially hazardous situa- Highlights additional information useful

tion which will result in possible injuries to the technician in completingthe work
or damage to equipment if proper care is beingperformed properly.
not taken.
34%#-$*2).&-&$56 )1$2#(()(7#/&'#")*()*$)07%&0$*2)/0$$#/%&0$)&$)%+#)8*$19*/%1-#-: ()7-0"1/%)2&$#6)&()

not to be connected inside the OptiView cabinet. Devices such as relays,switches,transducers and
controls and any external wiringmust not be installed inside the micro panel. All wiringmust be in
*//0-"*$/#).&%+);0+$(0$)<0$%-02(: )71=2&(+#")(7#/&'/*%&0$()*$")81(%)=#)7#-90-8#")0$2>)=>)*)?1*2&'#")
electrician. Johnson Controls will NOTbe responsible for damage/ problems resultingfrom improper
connections to the controls or application of improper control signals. Failure to follow this warning
.&22)@0&")%+#)8*$19*/%1-#-: ().*--*$%>)*$")/*1(#)(#-&01()"*8*5#)%0)7-07#-%>)0-)7#-(0$*2)&$A1->B
2 JOHNSON CONTROLS
FORM 160.75-O1 (211)
CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controlspolicy for contin- Operating/service personnel maintains the responsi-
uous product improvement, the information contained bility of the applicability of these documents to the
in this document is subject to change without notice. competitive equipment the kit is installed on. If there
W hile Johnson Controls makes no commitment to up- is any question regarding the applicability of these
date or provide current information automatically to documents, the technician should verify whether the
the manual owner, that information, if applicable, can equipment has been modified and if current literature
be obtained by contacting the nearest Johnson Controls is available with the owner of the equipment prior to
Service office. performing any work on the chiller.
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Vari
abl
e Speed Dri
ve Operati
on 160.00-O1
Sol
id State Starter Operati
on and Mai
ntenance 160.00-O2
Fl
oor Mounted MV SSS Operati
on 160.00-O5
Uni
tMounted MV SSS Operati
on 160.00-O7
Instal
lati
on Uni
t 160.75-N1
Opti
view ControlCenter Operati
on and Mai
ntenance 160.54-O1
Wi ri
ng Di
agram Fi
eld Connecti
ons for YK Chi
ll
er (Styl
e G) Opti
View ControlCenter wi
th Remote Low
160.75-PW 1
or Medium Vol
tage EMS or UnitMounted Low or Medi um Voltage SSS
Wiri
ng Di
agram Fi
eld Connecti
ons for YK Chi
ll
er (Styl
e G) Opti
th Remote
160.75-PW 2
Medium Vol
tage SSS
Wiri
ng Di
agram Fi
eld Connecti
ons for YK Chi
ll
er (Styl
e G) Opti
th Remote
160.75-PW 3
Medium Vol
tage VSD
!"#"$%&'"(%#()&*&+",-.&/0$1#0-&20."34(1"0$5&60#&78&/9"--,#&:;1<-,&=> 160.75-PW 4
Wi
ri
ng Di
agram YK Chi
ll
er (Styl
e G) Opti
th Remote Low or Medi
um Vol
tage EMS 160.75-PW 5
Wiring Diagram YK Chi
ll
er (Styl
e G) Opti
th Uni
tMounted Low or Medi
um
160.75-PW 6
Voltage SSS,Uni tMounted Low Voltage VSD with Modbus,or Remote Medi
um Vol tage VSD
Wiri
ng Di
agram YK Chi
ll
er (Styl
e G) Opti
th LTC I/O Board wi
th Remote Low or
160.75-PW 7
Medium Vol
tage EMS
Wi ri
ng Di
agram YK Chi
ll
er (Styl
e G) Opti
View ControlCenter w/LTC I/O Board wi
th UnitMounted Low
160.75-PW 8
or Medium Vol
tage SSS,Uni tMounted Low Voltage VSD with Modbus or Remote Medi um Vol
tage VSD
RenewalParts Uni
t 160.75-RP1
RenewalParts Opti
View ControlCenter 160.54-RP1
JOHNSON CONTROLS 3
FORM 160.75-O1 (211)
NOMENCLATURE
YK KC K4 H9 CY G
STYLE (Desi
gn Level
)
MOTOR CODE
POW ER SUPPLY
for 60 Hz
5 for 50 Hz
COMPRESSOR CODE*
CONDENSER CODE*
EVAPORATOR CODE*
*Refer to YK Engineering Guide for (Form 160.75-EG1)
MODEL* Shell/M otor/Compressor combinations.
4 JOHNSON CONTROLS
FORM 160.75-O1 (211)
TABLE OF CONTENTS
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION .......................................... 7

System Operation Descri pti on ......................................................................................................................... 7
CapacityControl............................................................................................................................................... 8
SECTION 2 - SYSTEM OPERATING PROCEDURES ........................................................................................... 11
OilHeaters ..................................................................................................................................................... 11
OilHeater Operati on ...................................................................................................................................... 11
Checki ng The Oi lLevelIn The Oi lReservoi r ................................................................................................. 11
Start-Up Procedure ........................................................................................................................................ 11
Start-Up .......................................................................................................................................................... 11
Chill
er Operati on ............................................................................................................................................ 13
Condenser W ater Temperature Control.......................................................................................................... 13
Operati ng Log Sheet...................................................................................................................................... 13
Operati ng Inspecti ons .................................................................................................................................... 13
Need For Mai ntenance Or Servi ce ................................................................................................................. 15
Stoppi ng The System ..................................................................................................................................... 15
Prolonged Shutdown...................................................................................................................................... 15
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION .......................................................................................17
General........................................................................................................................................................... 17
Compressor .................................................................................................................................................... 17
Capaci tyControl............................................................................................................................................. 17
Compressor Lubri cati on System ................................................................................................................... 17
OilPump ......................................................................................................................................................... 17
OilHeater ....................................................................................................................................................... 21
Motor Drivel ine ............................................................................................................................................... 21
HeatExchangers ............................................................................................................................................ 21
Refri
gerantFl ow Control................................................................................................................................ 22
OptionalServi ce Isol ati on Val ves ................................................................................................................... 22
OptionalHotGas Bypass ............................................................................................................................... 22
OptiView ControlCenter ................................................................................................................................. 22
Soli
d State Starter (Opti onal ) ......................................................................................................................... 22
Vari
abl e Speed Dri ve (Opti onal ) ..................................................................................................................... 22
SECTION 4 - OPERATIONAL MAINTENANCE .....................................................................................................23
OilReturn System .......................................................................................................................................... 23
Changing The Dehydrator .............................................................................................................................. 23
The OilCharge ............................................................................................................................................... 24
OilCharging Procedure .................................................................................................................................. 24
SECTION 5 - TROUBLESHOOTING ......................................................................................................................25
SECTION 6 - MAINTENANCE ................................................................................................................................27
RenewalParts ................................................................................................................................................ 27
Checking System For Leaks .......................................................................................................................... 27
Conducting R-22 Pressure Test...................................................................................................................... 27
Vacuum Testi ng.............................................................................................................................................. 28
Vacuum Dehydrati on...................................................................................................................................... 29
Operation........................................................................................................................................................ 29
Refri
gerantChargi ng...................................................................................................................................... 29
Checking The Refri gerantCharge Duri ng Uni tShutdown.............................................................................. 30
Handling Refri gerantFor Di smantl ing And Repai rs ........................................................................................ 30
JOHNSON CONTROLS 5
FORM 160.75-O1 (211)
TABLE OF CONTENTS (CONT'

D)
MeggingThe Motor ......................................................................................................................................... 30
Compressor .................................................................................................................................................... 33
El
ectri
calControl s .......................................................................................................................................... 34
SECTION 7 - PREVENTIVE MAINTENANCE ........................................................................................................35
Compressor .................................................................................................................................................... 35
Compressor Motor .......................................................................................................................................... 35
Greased Beari ngs ......................................................................................................................................... 35
LeakTesting................................................................................................................................................... 36
Evaporator And Condenser ............................................................................................................................ 36
OilReturn System .......................................................................................................................................... 36
Electri
calControl s .......................................................................................................................................... 36
LIST OF FIGURES
FIGURE 1 - ModelYK Chi
ll
er ....................................................................................................................................7
FIGURE 2 - Compressor Prerotati
on Vanes..............................................................................................................8
FIGURE 3 - Refri
gerantFl
ow-Thru Chi
ll
er (Fal
li
ng Fi
lm Evaporator) ........................................................................ 9
FIGURE 4 - Refri
gerantFl
ow-Thru Chi
ll
er (Fl
ooded Evaporator)............................................................................10
FIGURE 5 - Oi
lLevelIndi
cator ............................................................................................................................... 11
FIGURE 6 - Chi
ll
er Starti
ng Sequence And Shutdown Sequence (Em Starter And Sol
id State Starter) ................ 12
FIGURE 7 - Chi
ll
er Starti
ng Sequence And Shutdown Sequence (Vari
abl
e Speed Dri
ve) ..................................... 12
FIGURE 8 - Li
qui
d Chi
ll
er Log Sheets .....................................................................................................................14
FIGURE 9 - System Components FrontVi
ew .........................................................................................................18
FIGURE 10 - System Components Rear Vi
ew ........................................................................................................19
FIGURE 11 - Schemati
cDrawi
ng (YK) Compressor Lubri
cati
on System............................................................. 20
FIGURE 12 - Oi
lReturn System..............................................................................................................................23
FIGURE 13 - Chargi
ng Oi
lReservoi
r Wi
th Oi
l.........................................................................................................24
FIGURE 14 - Evacuati
on OfChi
ll
er .........................................................................................................................27
FIGURE 15 - Saturati
on Curve ................................................................................................................................29
FIGURE 16 - Di
agram,Meggi
ng Motor W i
ndi
ngs ...................................................................................................30
FIGURE 17 - Motor Starter Temperature And Insul
ati
on Resi
stances .................................................................... 31
LIST OF TABLES
TABLE 1 - Operati
onAnal
ysi
s Chart.......................................................................................................................25
TABLE 2 - System Pressures .................................................................................................................................28
TABLE 3 - Beari
ng Lubri
cati
on................................................................................................................................35
6 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 1 - DESCRIPTION OF SYSTEM AND

FUNDAMENTALS OF OPERATION
SYSTEM OPERATION DESCRIPTION nent to operation of the chiller are automatically dis-
played and read on a graphic display. Other displays
The YORK M odel YK Chiller is commonly applied
to large air conditioning systems, but may be used
can be observed by pressing the keys as labeled on the 1
Control Center. The chiller with the OptiView Control
on other applications. The chiller consists of an open
Center is compatible with an electro-mechanical start-
motor mounted to a compressor (with integral speed
er, YORK Solid State Starter (optional), or Variable
increasing gears), condenser, evaporator and variable
Speed Drive (optional).
flow control.
In operation, a liquid (water or brine to be chilled)
The chiller is controlled by a modern state of the art
flows through the evaporator, where boiling refrigerant
M icrocomputer Control Center that monitors its opera-
absorbs heat from the liquid. The chilled liquid is then
tion. The Control Center is programmed by the opera-
piped to fan coil units or other air conditioning terminal
tor to suit job specifications. Automatic timed start-ups
units, where it flows through finned coils, absorbing
and shutdowns are also programmable to suit night-
heat from the air. The warmed liquid is then returned to
time, weekends, and holidays. The operating status,
the chiller to complete the chilled liquid circuit.
temperatures, pressures, and other information perti-
COMPRESSOR
CONTROL
CENTER
MOTOR
CONDENSER
LD15222
EVAPORATOR
FIGURE 1 - MODELYK CHILLER
JOHNSON CONTROLS 7
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION FORM 160.75-O1 (211)
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 orifice meters the flow
of liquid refrigerant to the evaporator 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 rela-
tively 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 (Refer to Figure 2 on Page 8).
7619A(D)
The position of these vanes is automatically controlled

FIGURE 2 - COMPRESSOR PREROTATION VANES
through a lever arm attached to an electric motor lo-
cated outside the compressor housing. The automatic
The refrigerant vapor, which is produced by the boil- adjustment of the vane position in effect provides the
ing action in the evaporator, flows to the compressor performance of many different compressors to match
where the rotating impeller increases its pressure and various load conditions from full load with vanes wide
temperature and discharges it into the condenser. Wa- open to minimum load with vanes completely closed.
ter flowing through the condenser tubes absorbs heat
8 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
RefrigerantFlow-Thru Chiller
YK Mod G
(Falling Fi lm Evaporator)
!"#$%&"$'()*+,-./01$2*3$-44/5"67-(*8%'&$'9
(Falling-Film Evaporator)
COMPRESSOR
HOT GAS PRE-ROTATION

BYPASS VALVE VANES
SUCTION
OPTIONAL HOT GAS

DISCHARGE BYPASS LINE
OPTIONAL LIQUID LEVEL

ISOLATION VALVE
VALVE
EVAPORATOR
CONDENSER
SUCTION
BAFFLE
LIQUID LEVEL
LIQUID LEVEL
SUB-COOLER
OPTIONAL
ISOLATION LD00924A
VALVE
Rev. 2 (10-11-2010)
FIGURE 3 - REFRIGERANT FLOW -THRU CHILLER (FALLING FILM EVAPORATOR) Dan Sowers
[email protected]
(717) 771-7535
JOHNSON CONTROLS 9
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION FORM 160.75-O1 (211)
RefrigerantFlow-Thru Chiller
(Flooded Evaporator)
YK Mod G
!"#$%&"$'()*+,-./01$2*3$-44/5"67-(*8%'&$'9
(Flooded Evaporator)
COMPRESSOR
HOT GAS PRE-ROTATION

BYPASS VALVE VANES
SUCTION
DISCHARGE OPTIONAL HOT GAS

BYPASS LINE
OPTIONAL
ISOLATION
VALVE MESH ELIMINATORS or
SUCTION BAFFLE
EVAPORATOR
CONDENSER
LIQUID LEVEL
LIQUID LEVEL
SUB-COOLER
OPTIONAL LIQUID LEVEL

ISOLATION VALVE
LD00924B
VALVE
Rev. 2 (12-09-2010)
Dan Sowers
[email protected]
FIGURE 4 - REFRIGERANT FLOW -THRU CHILLER (FLOODED EVAPORATOR) (717) 771-7535
10 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 2 - SYSTEM OPERATING PROCEDURES
OIL HEATERS !" If the oil level during operation is in the OVER
FULL region of the oil level indicator, oil should
If the oil heater is de-energized during a shutdown pe-
be removed from the oil reservoir, This reduces
riod, it must be energized for 12hours prior to starting
the oil level to the OPERATING RANGE.
compressor, or remove all oil and recharge compres-
sor with new oil. (Refer to OilCharging Procedure on !" If the oil level during operation is in the LOW
Page 24. ) OIL region of the oil level indicator, oil should be
added to the oil reservoir. (Refer to OilCharging
OIL HEATER OPERATION Procedure on Page 24. )
The oil heater operation is controlled by the OptiV-
Comply with EPA and local regulations
iew Control Center. The heater is turned on and off
when removingor disposingof refrigera-
to maintain the oil temperature differential to a value
tion system oil!
50F (27.8C) above the condenser saturation tem-
perature. This target value is maintained by the control
panel. 2
If the target value is greater than 160F (71C), the tar-
get defaults to 160F (71C). If the target value is less START-UP PROCEDURE
than 110F (43.3C), it defaults to 110F (43.3C).
Pre-Starting
To prevent overheating of the oil in the event of a con-
Prior to starting the chiller, observe the Optiview
trol center component failure, the oil heater thermostat
Cont rolCenter Operat ion and Maintenance (Form
(1HTR) is set to open at 180F (82C).
160.54-O1).M ake sure the display reads SYSTEM
CHECKING THE OIL LEVEL IN THE READY TO START.
OIL RESERVOIR Vent any air from the chiller waterboxes
Proper operating oil level During operation, the oil prior to startingthe water pumps. Failure
level should fall to the OPERATING RANGE identified %0)"0)(0).&22)-#(12%)&$)7*(()=*9C#)"*8*5#B
on the vertical oil level indicator label (Refer to Figure 5
on Page 11).
START-UP
1. If the chilled water pump is manually operated,
start the pump. The Control Center will not al-
#$%"& '(")'* ##(+"&$",&
-+&
"./#(,,")'*##(0"#*1.*0"2$%"*,"
established through the unit. If the chilled liquid
pump is wired to the M icrocomputer Control Cen-
ter the pump will automatically start, therefore,
this step is not necessary.
2. To start the chiller, press the COM PRESSOR
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 COM PRESSOR switch and then press
the START side of the switch to start the chill-
LD08647
er.) W hen the start switch is energized, the Con-
FIGURE 5 - OIL LEVEL INDICATOR trol Center is placed in an operating mode and
any malfunction will be noted by messages on a
graphic display.
JOHNSON CONTROLS 11
SECTION 2 - SYSTEM OPERATING PROCEDURES FORM 160.75-O1 (211)
LD15609
** Notfor al
lshutdowns. Refer to Di
spl
ayMessagesi
n manualOptiview Control Center Operation and Maintenance (Form 160.54-O1).
FIGURE 6 - CHILLER STARTING SEQUENCE AND SHUTDOW N SEQUENCE (EM STARTER AND SOLID
STATE STARTER)
LD15610
** Notfor al
lshutdowns. Refer to Di
spl
ayMessagesi
n manualOptiview Control Center Operation and Maintenance (Form 160.54-O1).
FIGURE 7 - CHILLER STARTING SEQUENCE AND SHUTDOW N SEQUENCE (VARIABLE SPEED DRIVE)
12 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 2 - SYSTEM OPERATING PROCEDURES
For display messages and information pertaining to the At start-up, the entering condenser water temperature
operation refer to Opt
iview ControlCent er Opera- may be as much as 25F (14C) colder than the stand-
tion andMaint enance (Form 160.54-O1). by return chilled water temperature. Cooling tower fan
Any malfunctions which occur during cycling will normally provide adequate control of the
STOP/RESET are also displayed. entering condenser water temperature on most instal-
lations.
Heat recovery chillers and chillers using optional head
pressure control would use a signal provided by the
microprocessor to control main condenser bundle heat
CHILLER OPERATION rejection or pressure, respectively.
The unit capacity will vary to maintain the leaving OPERATING LOG SHEET
CHILLED LIQUID TEM PERATURE setpoint by the
Pre-rotation Vanes which are modulated by an actua- A permanent daily record of system operating condi-
tor under the control of the M icroprocessor Board. The tions (temperatures and pressures) recorded at regular
vane control routine employs proportional plus deriva- intervals throughout each 24 hour operating period
tive (rate) control action. A drop in chilled liquid tem- should be kept.
2
perature will cause the actuator to close the Prerotation An optional status printer is available for this purpose
Vanes to decrease chiller capacity. W hen the chilled or Figure 8 on Page 14 shows a log sheet used by
liquid temperature rises, the actuator will open the Pre- Johnson Controls Personnel for recording test data on
rotation Vanes to increase the capacity of the chiller. chiller systems. It is available from the factory in pads
However, the current draw (amperes) by the compres- of 50 sheets each under Form 160.44-F7 and may be
sor motor is also limited to FLA setpoint by the micro- obtained through the nearest Johnson Controls office.
processor. Automatic data logging is possible by connecting the
optional printer and programming the DATA LOG-
If the load continues to decrease, after the Prerotation GER function.
Vanes are entirely closed, the chiller will be shut down
by the Leaving Chilled Liquid Low Temperature An accurate record of readings serves as a valuable ref-
Control. erence for operating the system. Readings taken when
a system is newly installed will establish normal condi-
CONDENSER WATER TEMPERATURE tions with which to compare later readings.
CONTROL For example, an increase in condenser approach tem-
The YORK chiller is designed to use less power by tak- perature (condenser temperature minus leaving con-
ing advantage of lower than design temperatures that denser water temperature) may be an indication of
are naturally produced by cooling towers throughout dirty condenser tubes.
the operating year. Exact control of condenser water
such as a cooling tower bypass, is not necessary for OPERATING INSPECTIONS
most installations. The minimum entering condenser By following a regular inspection using the display
water temperature for full and part load conditions is readings of the M icrocomputer Control Center, and
specified in the chiller engineering guide. maintenance procedure, the operator will avoid serious
where: operating difficulty. The following list of inspections
and procedures should be used as a guide.
% Load
Min. ECWT = LCWT C RANGE + 5F + 12 ( 100 )
% Load Daily
Min. ECWT = LCWT C RANGE + 2.8C + 6.6 ( 100 )
1. Check OptiView Control Center displays.
ECW T = Entering Condensing Water Temperature
2. If the compressor is in operation, check the bear-
LCW T = Leaving Chilled Water Temperature ing oil pressure on the SYSTEM Screen. Also
check the oil level in the oil reservoir. Operating
C Range = Condensing water temperature range at the
oil level should be operating range of oil indicator.
given load condition.
Drain or add oil if necessary.
JOHNSON CONTROLS 13
3. Check entering and leaving condenser water pres- Weekly

sure and temperatures for comparison with job 1. Check the refrigerant charge. (Refer to Checking
design conditions. Condenser water temperatures The RefrigerantCharge During UnitShutdown
can be checked on the SYSTEM Screen. on Page 30.)
4. Check the entering and leaving chilled liquid tem-
Monthly
peratures and evaporator pressure for compari-
son with job design conditions on the SYSTEM 1. Leak check the entire chiller.
Screen.
Quarterly
5. Check the condenser saturation temperature
1. Perform chemical analysis of oil.
(based upon condenser pressure sensed by the
condenser transducer) on the SYSTEM Screen. Sem i-Annually (orm ore often as required)
6. Check the compressor discharge temperature on 1. 3'-/4("-/0"*/,5()&
")$65+(,,$+"$*
#"7#
&(+"(#(6(/&8
the SYSTEM Screen. During normal operation
2. Oil return system.
discharge temperature should not exceed 220F
(104C). A. Change dehydrator.
7. Check the compressor motor current on the B. Check nozzle of eductor for foreign par-
SYSTEM Screen. ticles.
8. Check for any signs of dirty or fouled condenser 3. Check controls and safety cutouts.
tubes. (The temperature difference between water
leaving condenser and saturated condensing tem-
perature should not exceed the difference recorded
for a new unit by more than 4F (2.2C)).
LD00467
23889A
*NOTE:These i tems can be pri
nted byan el
ectroni
cprinter connected to the Mi
croboard
ng the PRINT keyon the Keypad,or automati
and pressi call
yusing the Data Logger feature.
FIGURE 8 - LIQUID CHILLER LOG SHEETS
14 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 2 - SYSTEM OPERATING PROCEDURES
Annually (m ore often ifnecessary) 1. Push the soft shutdown key on the homescreen on
1. Drain and replace the oil in the compressor oil the OptiView panel or rapid stop with the COM -
sump. (Refer to OilCharging Procedure on Page PRESSOR STOP/RESET switch. The compressor
24.
) will stop automatically. The oil pump will contin-
ue to run for coastdown period. The oil pump will
2. Evaporator and Condenser. then stop automatically.
A. Inspect and clean water strainers. 2. Stop the chilled water pump (if not wired into the
B. Inspect and clean tubes as required. M icrocomputer Control Center, in which case it
will shut off automatically simultaneously with the
C. Inspect end sheets. oil pump.) (The actual water pump contact opera-
3. Compressor Drive M otor (See motor manufactur- tion is dependent upon the position of M icroboard
ers maintenance and service instruction supplied jumper J54.)
with unit) 3. Open the switch to the cooling tower fan motors,
A. Clean air passages and windings per manu- if used.
facturers instructions.
4. The compressor sump oil heater is energized when
B. M eg motor windings Refer to Figure 16on the unit is stopped. 2
Page 30for details.
PROLONGED SHUTDOWN
C. Lubricate per motor manufacturer recom-
mendations. If the chiller is to be shut down for an extended period
of time (for example, over the winter season), the fol-
4. Inspect and service electrical components as neces- lowing paragraphs outline the procedure to be followed.
sary.
1. Test all system joints for refrigerant leaks with a
5. Perform refrigerant analysis. leak detector. If any leaks are found, they should
!9)?1*-%#-2>)&$(7#/%&0$)&$"&/*%#()0&2)&()'$#6
) be repaired before allowing the system to stand
replacingthe oil is not necessary for a long period of time.
During long idle periods, the tightness of the sys-
tem should be checked periodically.
2. If freezing temperatures are encountered while
the system is idle, carefully drain the cooling wa-
NEED FOR MAINTENANCE OR SERVICE
ter from the cooling tower, condenser, condenser
If the system is malfunctioning in any manner or the pump, and the chilled water system-chilled water
unit is stopped by one of the safety controls, consult pump and coils.
the Operation Anal ysisChart,Tabl e 1 on Page 25 of
this manual. After consulting this chart, if you are un- Open the drains on the evaporator and condenser
able to make the proper repairs or adjustments to start liquid heads to assure complete drainage. (If a
the compressor or the particular trouble continues to Variable Speed Drive, drain its cooling system.
hinder the performance of the unit, please call the near- If Solid State Starter equipped drain liquid from
est Johnson Controls District Office. Failure to report starter cooling loop.)
constant troubles could damage the unit and increase 3. If freezing temperatures are encountered for peri-
the cost of repairs. ods longer than a few days, the refrigerant should
be recovered to containers to prevent leakage from
STOPPING THE SYSTEM O-ring joints.
The Optiview Control Center can be programmed to 4. On the SETUP Screen, disable the clock. This
start and stop automatically (maximum, once each day) conserves the battery.
whenever desired. Refer to the Opt iview Control
Cent er Operation and Maintenance (Form 160. 54- 5. Open the main disconnect switches to the com-
O1). To stop the chiller, proceed as follows: pressor motor, condenser water pump and the
chilled water pump. Open the 115 volt circuit to
the Control Center.
JOHNSON CONTROLS 15
THIS PAGE INTENTIONALLY LEFT BLANK
16 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
GENERAL C. Low speed thrust bearing (forward and re-

verse).
The YORK M odel YK Centrifugal Liquid Chiller is
completely factory-packaged including evaporator, 2. Compressor Driven Shaft (High Speed)
condenser, compressor, motor, lubrication system,
A. Forward and reverse high speed thrust
OptiView Control Center, and all interconnecting unit
bearing.
piping and wiring.
B. Two journal bearings.
COMPRESSOR
3. Speed Increasing Gears
The compressor is a single-stage centrifugal type pow-
ered by an open-drive electric motor. A. M eshing surfaces of drive and pinion gear
teeth.
The rotor assembly consists of a heat-treated alloy steel
drive shaft and impeller shaft with a cast aluminum, To provide the required amount of oil under the neces-
fully shrouded impeller. The impeller is designed for sary pressure to properly lubricate these parts, a motor
balanced thrust and is dynamically balanced and over- driven submersible oil pump is located in a remote oil
speed tested. The inserted type journal and thrust bear- sump.
ings are fabricated of aluminum alloy. Single helical Upon pressing of the COM PRESSOR START switch
gears with crowned teeth are designed so that more on the Control Center, the oil pump is immediately en-
than one tooth is in contact at all times. Gears are inte-
3
ergized. After a 50 second pre-lube period, the com-
grally assembled in the compressor rotor support and pressor motor will start. The oil pump will continue to
are film lubricated. Each gear is individually mounted run during the entire operation of the compressor, and
in its own journal and thrust bearings. for 150seconds during compressor coastdown.
The open-drive compressor shaft seal is a double bel- The submerged oil pump takes suction from the sur-
lows cartridge style with ceramic internal and atmo- rounding oil and discharges it to the oil cooler where
spheric seal faces. The seal is oil-flooded at all times heat is rejected. The oil flows from the oil cooler to
and is pressure-lubricated during operation. the oil filter. The oil leaves the filter and flows to the
emergency oil reservoir where it is distributed to the
CAPACITY CONTROL
compressor bearings. The oil lubricates the compressor
Prerotation vanes (PRV) modulate chiller capacity rotating components and is returned to the oil sump.
from 100% to as low as 15% of design for normal air
conditioning applications. Operation is by an external, There is an emergency oil reservoir located at the high-
electric PRV actuator which automatically controls the est point in the lubrication system internally in the com-
vane position to maintain a constant leaving chilled liq- pressor. It provides an oil supply to the various bear-
uid temperature. ings and gears in the event of a system shutdown due
to power failure. The reservoir, located on the top of
COMPRESSOR LUBRICATION SYSTEM the compressor, allows the oil to be distributed through
the passages by gravity flow, thus providing necessary
The chiller lubrication system consists of the oil pump, lubrication during the compressor coastdown.
oil filter, oil cooler and all interconnecting oil piping
and passages. There are main points within the com- OIL PUMP
pressor which must be supplied with forced lubrication
as follows: For normal operation, the oil pump should operate at
all times during chiller operation.
1. Compressor Drive Shaft (Low Speed)
On shutdown of the system for any reason, the oil
A. Shaft seal. pump operates and continues to run for 150 seconds.
The system cannot restart during that time interval.
B. Front and rear journal bearings one on each
side of driving gear.
JOHNSON CONTROLS 17
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION FORM 160.75-O1 (211)
OPTIVIEW CONTROL
CENTER
COMPRESSOR
SUCTION
RELIEF
VARIABLE
VALVES
SPEED
DRIVE
EVAPORATOR
LD15222
VARIABLE SPEED
SIGHT
OIL PUMP
GLASS
CONTROL BOX
FRONT VIEW
FIGURE 9 - SYSTEM COMPONENTS FRONT VIEW
18 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
MOTOR
COMPRESSOR
DISCHARGE
LINE
LD15223
LIQUID LINE
CONDENSER OIL PUMP
HOUSING
REAR VIEW
FIGURE 10 - SYSTEM COMPONENTS REAR VIEW
JOHNSON CONTROLS 19
COMPRESSOR ROTOR
SUPPORT SECTION
H.S.
SHAFT
SEAL
EMERGENCY
OIL RESERVE
HIGH
PRESSURE
TRANSDUCER
MAIN JOURNAL
AND THRUST
BEARING
IMPELLER
THRUST COLLAR BEARING

(PINION GEAR
HIGH SPEED SHAFT)
THRUST COVER
(PRV)
DOUBLE INLET
BELLOWS VALVES
SHAFT SEAL
LOW SPEED- THRUST

GEAR REAR COLLAR
BEARING BEARING
LOW LOW SPEED

SPEED GEAR THRUST
COVER
REFRIG.
SIGHT
HOT GLASSES
THERMISTOR
OIL OIL
HEATER COOLER
LOW OIL
ANGLE PRESSURE
DRAIN VALVE TRANSDUCER
OIL OIL SUBMERSIBLE

SUMP OIL TEMP.
PUMP OIL PUMP CONTROL
OIL SUCTION WITH 3-PHASE MOTOR
FILTER
OIL
LD15200
FIGURE 11 - SCHEMATIC DRAW ING (YK) COMPRESSOR LUBRICATION SYSTEM
20 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
OIL HEATER ant charge, and maintain reliable control. A specifically

designed spray distributor provides uniform distribu-
During long idle periods, the oil in the compressor oil
tion of refrigerant over the entire length to yield opti-
reservoir tends to absorb as much refrigerant as it can
mum heat transfer. The hybrid falling film evaporator
hold, depending upon the temperature of the oil and
design has suction baffles around the sides and above
the pressure in the reservoir. As the oil temperature is
the falling film section to prevent liquid refrigerant car-
lowered, the amount of refrigerant absorbed will be
ryover into the compressor.
increased. If the quantity of refrigerant in the oil be-
comes excessive, violent oil foaming will result as the Evaporators codes M *thru Z*are flooded type, with a
pressure within the system is lowered on starting. This liquid inlet distributor trough underneath the tube bun-
foaming is caused by refrigerant boiling out of the oil dle which provides uniform distribution of refrigerant
as the pressure is lowered. If this foam reaches the oil over the entire shell length to yield optimum heat trans-
pump suction, the bearing oil pressure will fluctuate fer. Flooded evaporator designs have a suction baffle
with possible temporary loss of lubrication, causing the on M * shells with H9 compressors and an aluminum
oil pressure safety cutout to actuate and stop the sys- mesh eliminator on K*- Z*shells with K compressors
tem. Refer to Opt iview Cont rolCenter Operat ion located above the tube bundle to prevent liquid refrig-
andMaint enance (Form 160. 54-O1). erant carryover into the compressor.
MOTOR DRIVELINE A 1-1/2" (38 mm) liquid level sight glass is conve-
niently located on the side of the shell to aid in deter-
The compressor motor is an open-drip-proof, squir-
mining proper refrigerant charge. The evaporator shell
rel cage, induction type constructed to YORK design
specifications. 60hertz motors operate at 3570rpm. 50
contains a dual refrigerant relief valve arrangement set 3
at 180psig (12.4barg) on H and K compressor models;
hertz motors operate at 2975rpm.
235 psig (16.2 barg) on P and Q compressor models;
The open motor is provided with a D-flange, cast iron or single-relief valve arrangement, if the chiller is sup-
adapter mounted to the compressor and supported by a plied with optional refrigerant isolation valves. A 1"
motor support. (25.4mm) refrigerant charging valve is provided. The
condenser is a shell and tube type, with a discharge
M otor drive shaft is directly connected to the compres- gas baffle to prevent direct high velocity impingement
sor shaft with a flexible disc coupling. This coupling on the tubes. The baffle is also used to distribute the
has all metal construction with no wearing parts to as- refrigerant gas flow properly for most efficient heat
sure long life, and no lubrication requirements to pro- transfer. An optional cast steel condenser inlet diffuser
vide low maintenance. may be offered, on "M "and larger condensers, in lieu
For units utilizing remote Electro-M echanical starters, of the baffle, to provide dynamic pressure recovery and
a terminal box is provided for field connected conduit. enhanced chiller efficiency. An integral sub-cooler is
M otor terminals are brought through the motor cas- located at the bottom of the condenser shell providing
ing into the terminal box. Jumpers are furnished for highly effective liquid refrigerant subcooling to pro-
three-lead type of starting. M otor terminal lugs are not vide the highest cycle efficiency. The condenser con-
furnished. Overload/over current transformers are fur- tains dual refrigerant relief valves set at 235psig (16.2
nished with all units. barg).
The removable waterboxes are fabricated of steel. The
HEAT EXCHANGERS design working pressure is 150 psig (10.3 barg) and
Evaporator and condenser shells are fabricated from the boxes are tested at 225 psig (15.5 barg). Integral
rolled carbon steel plates with fusion welded seams. steel water baffles are located and welded within the
waterbox to provide the required pass arrangements.
Heat exchanger tubes are internally enhanced type. Stub-out water nozzle connections with ANSI/AW WA
The evaporator is a shell and tube type with customer C-606 grooves are welded to the waterboxes. These
process fluid flowing inside the tubes and refriger- nozzle connections are suitable for ANSI/AW WA
ant removing heat on the shell side via evaporation. C-606 couplings, welding or flanges, and are capped
Evaporator codes A*to K*utilize a hybrid falling film for shipment. Plugged 3/4" (19 mm) drain and vent
design. It contains a balance of flooded and falling film connections are provided in each waterbox.
technology to optimize efficiency, minimize refriger-
JOHNSON CONTROLS 21
REFRIGERANT FLOW CONTROL OPTIONAL HOT GAS BYPASS

Refrigerant flow to the evaporator is controlled by a Hot gas bypass is optional and is used to eliminate
variable orifice. compressor surge during light load or high head op-
eration. The OptiView control panel will automatically
A level sensor senses the refrigerant level in the con- modulate the hot gas valve open and closed as required.
denser and outputs an analog voltage to the M icroboard Adjustment of the hot gas control valve must be per-
that represents this level (0% = empty;100% = full). formed by a qualified service technician following the
Under program control, the M icroboard modulates a Hot Gas Set-up procedure.
variable orifice to control the condenser refrigerant
level to a programmed setpoint. Other setpoints affect <+*$5#()&$)/+&22#").*%#-)C0.).&22)-#?1&-#)
the control sensitivity and response. These setpoints re-adjustment of the hot gas control to
must be entered at chiller commissioning by a qualified insure proper operation.
service technician. Only a qualified service technician
may modify these settings.
W hile the chiller is shut down, the orifice will be in the
fully open position causing the sensed level to be ap- OPTIVIEW CONTROL CENTER
proximately 0%. W hen the chiller is started, after the The OptiView Control Center is factory-mounted,
vane motor end switch (VM S) opens when entering wired and tested. The electronic panel automatically
SYSTEM RUN, if actual level is less than the level controls the operation of the unit in meeting system
setpoint, a linearly increasing ramp is applied to the lev- cooling requirements while minimizing energy usage.
el setpoint. This ramp causes the setpoint to go from the For detailed information on the Control Center, refer to
initial refrigerant level (approximately 0%) to the pro- SECTION 2 - SYSTEM OPERATING PROCEDURES
grammed setpoint over a programmable period of time. of this manual.
If the actual level is greater than the setpoint when the SOLID STATE STARTER (OPTIONAL)
VM S opens, there is no pulldown period, it immedi-
ately begins to control to the programmed setpoint. The Solid State Starter is a reduced voltage starter that
controls and maintains a constant current flow to the
W hile the chiller is running, the refrigerant level is nor- motor during start-up. It is mounted on the chiller. Pow-
mally controlled to the level setpoint. However, any- er and control wiring between the starter and chiller
time the vanes fully close (VM S closes), normal level are factory installed. The starter enclosure is NEM A-1
control is terminated, any refrigerant level setpoint in with a hinged access door with lock and key. Electrical
effect is cancelled and the outputs to the level control lugs for incoming power wiring are provided.
will be constant open.
VARIABLE SPEED DRIVE (OPTIONAL)
OPTIONAL SERVICE ISOLATION VALVES
A Variable Speed Drive can be factory packaged with
If your chiller is equipped with optional service isola- the chiller. It is designed to vary the compressor mo-
tion valves on the discharge and liquid line, these valves tor speed and prerotation vane position by controlling
must remain open during operation. These valves are the frequency and voltage of the electrical power to
used for isolating the refrigerant charge in either the the motor. Operational information is contained in the
evaporator or condenser to allow service access to the Variabl e SpeedDrive Operation (Form 160. 00-O1).
system. A refrigerant pump-out unit will be required to The control logic automatically adjusts motor speed
isolate the refrigerant. and compressor prerotation vane position for maxi-
Isolation of the refrigerant in this system mum part load efficiency by analyzing information fed
81(%)=#)7#-90-8#")=>)*)?1*2&'#")(#-@&/#) to it by sensors located throughout the chiller.
technician.
22 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 4 - OPERATIONAL MAINTENANCE
OIL RETURN SYSTEM CHANGING THE DEHYDRATOR

The oil return system continuously maintains the To change the dehydrator, use the following procedure:
proper oil level in the compressor oil sump (Refer to
Figure 12 on Page 23). 1. Isolate the dehydrator at the stop valves.
2. Remove the dehydrator (Refer to Figure 12 on
High pressure condenser gas flows continuously Page 23).
through the eductor inducing the low pressure, oil rich
3. 9,,(6:# ("&
'("/(%"7#&(+;0+*(+ 8
liquid to flow from the evaporator, through the dehy-
drator to the compressor sump. 4. Open evaporator stop valve and check dehydrator
connections for refrigerant leaks.
5. Open all the dehydrator stop valves.
COMPRESSOR
SOLENOID VALVE
CHECK VALVE OIL EDUCTOR BLOCK
SOLENOID VALVE
STOP VALVE DEHYDRATOR
STOP VALVE
LD08578
FIGURE 12 - OIL RETURN SYSTEM
JOHNSON CONTROLS 23
SECTION 4 - OPERATIONAL MAINTENANCE FORM 160.75-O1 (211)
THE OIL CHARGE ing valve (A) located on the remote oil reservoir
cover plate. (Refer to Figure 13 on Page 24) Do
The nominal oil charge for all H, K, and P8-P9 YK
not tighten the connection at the charging valve
compressors is 20gallons, and for Q3-Q7YK compres-
until after the air is forced out by pumping a few
sors is 10gallons of type YORK K or YORK H oil.
,&+$<(,"$="&'("$*#"5.658 ">'*,"7#
#,"&'("#*/(,"%*&'"
New YORK Refrigeration oil must be used in the cen- oil and prevents air from being pumped into the
trifugal compressor. Since oil absorbs moisture when system.
exposed to the atmosphere, it should be kept tightly 3. Open the oil charging valve and pump oil into the
capped until used. system until oil level in the compressor oil reser-
voir is in the OVER FULL region of the oil level
OIL CHARGING PROCEDURE
indicator label. Close the charging valve and dis-
During operation the compressor oil level must be connect the hand oil pump.
maintained in the OPERATING RANGE identified
on the vertical oil level indicator. If the oil level falls 4. As soon as oil charging is complete, close the
into the lower sight glass, it is necessary to add oil to power supply to the starter to energize the oil
the compressor oil reservoir. The oil should be charged heater. This will keep the concentration of refrig-
into the oil reservoir using the YORK Oil Charging erant in the oil to a minimum.
Pump YORK Part No. 070-10654. To charge oil into W hen the oil reservoir is initially charged with oil, the
the oil reservoir, proceed as follows: oil pump should be started manually to fill the lines,
passages, oil cooler and oil filter. This will lower the
1. The unit must be shut down.
oil level in the reservoir. It may then be necessary to
2. Immerse the suction connection of the oil charging add oil to bring the level back into the OPERATING
pump in a clean container of new oil and connect RANGE of the oil level indicator label.
the pump discharge connection to the oil charg-
LD08648 LD08579
OIL CHARGING VALVE
FIGURE 13 - CHARGING OIL RESERVOIR W ITH OIL
24 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 5 - TROUBLESHOOTING
TABLE 1 - OPERATION ANALYSIS CHART

RESULTS POSSIBLE CAUSE REMEDY
1.SYMPTOM:ABNORMALLY HIGH DISCHARGE PRESSURE
Temperature di
fference between
condensi
ng temperature and water off Ai
rin condenser.
condenser hi
gher than normal.
Clean condenser tubes. Checkwater
Condenser tubes di
rtyor scal
ed.
condi
tioni
ng.
Hi
gh di
scharge pressure. Reduce condenser water inlettempera-
Hi
gh condenser water temperature. ture. (Checkcool
ing tower and water
circulati
on.)
Temperature difference between con-
denser water on and water offhi
gher Increase the quantityofwater through
?$5@634",$1&40$.,$5"$%&A(1,#&B0AC
than normal,with normalevaporator the condenser to proper val
ue.
pressure.
2.SYMPTOM:ABNORMALLY LOW SUCTION PRESSURE
Temperature di fference between leavi
ng Checkfor leaks and charge refri
gerant
?$5@634",$1&49(#%,&06&#,6#"%,#($1C
chill
ed water and refri geranti
n evapo- i
nto system.
rator greater than normalwi th hi
gh
D(#"(E-,&0#"34,&F#0E-,)C Remove obstructi
on.
discharge temperature.
Temperature difference between leav-
i
ng chi
ll
ed water and refri geranti
n the
Evaporator tubes di
rtyor restri
cted. Cl
ean evaporator tubes.
evaporator greater than normalwi th
normaldischarge temperature.
Checkprerotation vane motor operati
on
Temperature ofchil
led water too l
ow
with wi
th l
ow motor amperes.
?$5@634",$1&-0(.&60#&5<51,)&4(F(4"1<C and setti
ng ofl
ow water temperature 5
cutout.
3.SYMPTOM:HIGH EVAPORATOR PRESSURE
Checkthe prerotati
on vane motor posi
-
Prerotati
on vanes fai
lto open.
ti
oni
ng ci
rcuit.
Hi
gh chi
ll
ed water temperature. Be sure the vanes are wide open (wi th-
System overl
oad. outoverloadi ng the motor) unti
lthe l
oad
decreases.
4.SYMPTOM:NO OIL PRESSURE WHEN SYSTEM START BUTTON PUSHED
Checkrotati
on ofoi
lpump (El
ectri
cal
Oi
lpump runni
ng i
n wrong di
recti
on.
Low oilpressure di
spl
ayed on control Connecti
ons).
center;compressor wil
lnotstart. Troubl
eshootel
ectri
calprobl
em wi
th oi
l
Oi
lpump notrunni
ng.
pump VSD.
5.SYMPTOM:UNUSUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS
Unusual l
yhi
gh oilpressure i
s dis-
played when the oi
lpressure displ ay High oi
lpressure. Transducer defec- Replace l
ow or hi
gh oi
lpressure trans-
keyis pressed when the oilpump i s ti
ve. ducer.
running.
JOHNSON CONTROLS 25
SECTION 5 - TROUBLESHOOTING FORM 160.75-O1 (211)
TABLE 1 - OPERATION ANALYSIS CHART (CONT'

D)
RESULTS POSSIBLE REMEDY

6.SYMPTOM:OIL PUMP VIBRATES OR IS NOISY
Oilpump vibrates or i
s extremel
ynoisy
Oilnotreachi ng pump sucti
on i
nleti
n
with some oi
lpressure when pressi
ng Checkoi
llevel
.
5@634",$1&G@($1"1<C
OIL PRESSURE di splaykey.
When oil pump is run without
an oil supply it will vibrate
and become extremely noisy.
W orn or fai
led oi
lpump. Repai
r/Repl
ace oi
lpump.
7.SYMPTOM:REDUCED OIL PUMP CAPACITY

Excessive end cl
earance pump.
Inspectand repl
ace worn parts.
Oi
lpump pumpi
ng capaci
ty. Other worn pump parts.
Parti
all
ybl
ocked oi
lsuppl
yinl
et. Checkoi
linl
etfor bl
ockage.
8.SYMPTOM:OIL PRESSURE GRADUALLY DECREASES (Noted by Observation ofDaily Log Sheets)
W hen oilpump VSD frequencyi n-
creases to 55 + hzto mai
ntai
n targetoi
l H"-&3-1,#&"5&."#1<C /9($%,&0"-&3-1,#C
pressure.
9.SYMPTOM:OIL PRESSURE SYSTEM CEASES TO RETURN AN OIL/REFRIGERANT SAMPLE
Fi
lter-dri
er i
n oi
lreturn system di
rty. I,F-(4,&0-.&3-1,#J.#",#&A"19&$,AC
Oi
lrefri
gerantreturn notfuncti
oni
ng. I,)0M,&L
,1N&"$5F,41&60#&."#1C&
K,1&0#&0#"34,&06&0"-&#,1@#$&L
,1&4-0%%,.C
Remove dirtusing solventand repl
ace.
10.SYMPTOM:OIL PUMP FAILS TO DELIVER OIL PRESSURE
No oilpressure regi
sters when pressi
ng
Faul
tyoi
lpressure transducer.
OIL PRESSURE di splaykeywhen oi l Repl
ace oi
lpressure transducer.
Faul
tywiri
ng/connectors.
pump runs.
26 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 6 - MAINTENANCE
RENEWAL PARTS To test with R-22, proceed as follows:

For any required Renewal Parts, refer to the Renewal 1. W ith no pressure in the system, charge R-22 gas
PartsUnit(Form 160. 75-RP1). into the system through the charging valve to a
pressure of 2PSIG (14kPa).
CHECKING SYSTEM FOR LEAKS
2. Build up the system pressure with dry nitrogen to
Leak Testing During Operation approximately 75to 100PSIG (517to 690kPa).
The refrigerant side of the system is carefully pressure To be sure that the concentration of refrigerant has
tested and evacuated at the factory. reached all part of the system, slightly open the oil
charging valve and test for the presence of refrig-
After the system has been charged, the system should erant with a leak detector.
be carefully leak tested with a R-134a compatible leak
detector to be sure all joints are tight. 3. Test around each joint and factory weld. It is im-
portant that this test be thoroughly and carefully
If any leaks are indicated, they must be repaired im- done, spending as much time as necessary and us-
mediately. Usually, leaks can be stopped by tighten- ing a good leak detector.
ing flare nuts or flange bolts. However, for any major
repair, the refrigerant charge must be removed. (Refer 4. To check for refrigerant leaks in the evaporator
to Handl ing Ref rigerantFor Dismant ling AndRepairs and condenser, open the vents in the evaporator
on Page 30) and condenser heads and test for the presence of
refrigerant. If no refrigerant is present, the tubes
CONDUCTING R-22 PRESSURE TEST and tube sheets may be considered tight. If refrig-
erant is detected at the vents, the heads must be
W ith the R-134a charge removed and all known leaks
removed, the leak located (by means of soap test
repaired, the system should be charged with a small
or leak detector) and repaired.
amount of R-22mixed with dry nitrogen so that a ha-
lide torch or electronic leak detector can be used to de-
tect any leaks too small to be found by the soap test.
6
EVACUATION AND DEHYDRATION OF UNIT
27385A(D)
LD00949
FIGURE 14 - EVACUATION OF CHILLER
JOHNSON CONTROLS 27
SECTION 6 - MAINTENANCE FORM 160.75-O1 (211)
TABLE 2 - SYSTEM PRESSURES
*GAUGE ABSOLUTE
BOILING
INCHES OF TEMPERATURES
MERCURY (HG) OF
MILLIMETERS OF
BELOW ONE PSIA MICRONS WATER
MERCURY (HG)
STANDARD F
ATMOSPHERE
0 14.696 760. 760,000 212
10.24" 9.629 500. 500,000 192
22.05" 3.865 200. 200,000 151
25.98" 1.935 100. 100,000 124
27.95" .968 50. 50,000 101
28.94" .481 25. 25,000 78
29.53" .192 10. 10,000 52
29.67" .122 6.3 6,300 40
29.72" .099 5. 5,000 35
29.842" .039 2. 2,000 15
29.882" .019 1.0 1,000 +1
29.901" .010 .5 500 11
29.917" .002 .1 100 38
29.919" .001 .05 50 50
29.9206" .0002 .01 10 70
29.921" 0 0 0
*One standard atmosphere = 14.696 PSIA NOTES: PSIA = Lbs. per sq. i
n. gauge pressure
= 760 mm Hg. absolute pressure at32F = Pressure above atmosphere
= 29.921 i
nches Hg. absolute at32F PSIA = Lbs. per sq. i
n. absol
ute pressure
= Sum ofgauge pl us atmosphericpressure
VACUUM TESTING DO NOT USE STEAM . A suggested method is

After the pressure test has been completed, the vacuum to connect a hose between the source of hot water
test should be conducted as follows: under pressure and the evaporator head drain con-
nection, out the evaporator vent connection, into
1. Connect a high capacity vacuum pump, with in- the condenser head drain and out the condenser
dicator, to the system charging valve as shown in vent. To avoid the possibility of causing leaks, the
Figure 14 on Page 27 and start the pump. (Re- temperature should be brought up slowly so that
fer to Vacuum Dehydrat ion on Page 29.) the tubes and shell are heated evenly.
2. Open wide all system valves. Be sure all valves to 5. Close the system charging valve and the stop valve
the atmosphere are closed. between the vacuum indicator and the vacuum
pump. Then disconnect the vacuum pump leaving
3. Operate the vacuum pump in accordance with
the vacuum indicator in place.
VACUUM DEHYDRATION until a wet bulb
temperature of +32F or a pressure of 5mm Hg is 6. Hold the vacuum obtained in Step 3in the system
reached. Refer to Table 2 on Page 28 for cor- for 8hours;the slightest rise in pressure indicates a
responding values of pressure. leak or the presence of moisture, or both. If, after 24
hours the wet bulb temperature in the vacuum indi-
4. To improve evacuation circulate hot water (not
cator has not risen above 40F (4.4C) or a pressure
to exceed 125F, 51.7C) through the evaporator
of 6.3mm Hg, the system may be considered tight.
and condenser tubes to thoroughly dehydrate the
shells. If a source of hot water is not readily avail- 7. If the vacuum does not hold for 8hours within the
able, a portable water heater should be employed. #*6*&,",5()*7(0"*
/"?&(5"@"-:$A(B "&
'("#
(-<"6.,& ":("
found and repaired.
28 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 6 - MAINTENANCE
Be sure the vacuum indicator is valved off taken place the pressure and temperature will continue
while holdingthe system vacuum and be to drop until eventually a temperature of 35F (1.6C)
sure to open the valve between the vacuum or a pressure of 5mm Hg. is reached.
indicator and the system when checking
the vacuum after the 8hour period. W hen this point is reached, practically all of the air has
been evacuated from the system, but there is still a small
amount of moisture left. In order to provide a medium
VACUUM DEHYDRATION for carrying this residual moisture to the vacuum pump,
To obtain a sufficiently dry system, the following in- nitrogen should be introduced into the system to bring
structions have been assembled to provide an effective it to atmospheric pressure and the indicator temperature
method for evacuating and dehydrating a system in the will return to approximately ambient temperature. Close
field. Although there are several methods of dehydrating off the system again, and start the second evacuation.
a system, we are recommending the following, as it pro- The relatively small amount of moisture left will be
duces one of the best results, and affords a means of ob- carried out through the vacuum pump and the tem-
taining accurate readings as to the extent of dehydration. perature or pressure shown by the indicator should
The equipment required to follow this method of dehy- drop uniformly until it reaches a temperature of 35F
dration consists of a wet bulb indicator or vacuum gauge, (1.6C) or a pressure of 5mm Hg.
a chart showing the relation between dew point tempera- W hen the vacuum indicator registers this temperature
ture and pressure in inches of mercury (vacuum), (Refer or pressure, it is a positive sign that the system is evac-
to Tabl e 2 on Page 28) and a vacuum pump capable of uated and dehydrated to the recommended limit. If this
pumping a suitable vacuum on the system. level cannot be reached, it is evident that there is a leak
somewhere in the system. Any leaks must be corrected
OPERATION
before the indicator can be pulled down to 35F or 5
Dehydration of a refrigerant system can be obtained mm Hg. in the primary evacuation.
by this method because the water present in the system
reacts much as a refrigerant would. By pulling down During the primary pulldown, keep a careful watch on
the pressure in the system to a point where its satu- the wet bulb indicator temperature, and do not let it fall
ration temperature is considerably below that of room below 35F (1.6C). If the temperature is allowed to
temperature, heat will flow from the room through the fall to 32F (0C), the water in the test tube will freeze,
walls of the system and vaporize the water, allowing and the result will be a faulty temperature reading.
a large percentage of it to be removed by the vacuum 6
pump. The length of time necessary for the dehydra-
tion of a system is dependent on the size or volume of
the system, the capacity and efficiency of the vacuum
pump, the room temperature and the quantity of water
present in the system. By the use of the vacuum indi-
cator as suggested, the test tube will be evacuated to
the same pressure as the system, and the distilled water
will be maintained at the same saturation temperature
as any free water in the system, and this temperature
can be observed on the thermometer.
If the system has been pressure tested and found to be
tight prior to evacuation, then the saturation tempera- LD00474
ture recordings should follow a curve similar to the typ-
ical saturation curve shown as Figure 15on Page 29. FIGURE 15 - SATURATION CURVE
The temperature of the water in the test tube will drop

as the pressure decreases, until the boiling point is REFRIGERANT CHARGING
reached, at which point the temperature will level off To avoid the possibility of freezing liquid within the
and remain at this level until all of the water in the evaporator tubes when charging an evacuated system,
shell is vaporized. W hen this final vaporization has only refrigerant vapor from the top of the drum or cyl-
JOHNSON CONTROLS 29
inder must be admitted to the system pressure until the The refrigerant charge level must be checked after the
system pressure is raised above the point correspond- pressure and temperature have equalized between the
ing to the freezing point of the evaporator liquid. For condenser and evaporator. This would be expected to be
water, the pressure corresponding to the freezing point 4hours or more after the compressor and water pumps
is 8.54PSIG (58.9kPa) for R-134a (at sea level). are stopped. The level should visible in the sight glass.
W hile charging, every precaution must be taken to pre- Charge the refrigerant in accordance with the meth-
vent moisture laden air from entering the system. M ake od shown under the REFRIGERANT CHARGING,
up a suitable charging connection from new copper tub- above. The refrigerant level should be observed and
ing to fit between the system charging valve and the fit- the level recorded after initial charging.
ting on the charging drum. This connection should be
HANDLING REFRIGERANT FOR DISMANTLING
as short as possible but long enough to permit sufficient
AND REPAIRS
flexibility for changing drums. The charging connection
should be purged each time a full container of refrigerant If it becomes necessary to open any part of the refriger-
is connected and changing containers should be done as ant system for repairs, it will be necessary to remove
quickly as possible to minimize the loss of refrigerant. the charge before opening any part of the unit. If the
chiller is equipped with optional valves, the refrigerant
Refrigerant may be furnished in cylinders containing can be isolated in either the condenser or evaporator /
either 30, 50, 125, 1,025or 1750lbs. (13.6, 22.6, 56.6, compressor while making any necessary repairs.
464or 794kg) of refrigerant.
MEGGING THE MOTOR
The nameplate on the chiller contains the
correct refrigerant charge information W hile the main disconnect switch and compressor mo-
for the chiller. tor starter are open, meg the motor as follows:
1. Using a megohm meter (megger), meg between
phases and each phase to ground (Refer to Figure 16
on Page 30);these readings are to be interpreted
CHECKING THE REFRIGERANT CHARGE using the graph shown in Figure 17on Page 31.
DURING UNIT SHUTDOWN 2. If readings fall below shaded area, remove exter-
The refrigerant charge is specified for each chiller model. nal leads from motor and repeat test.
Charge the correct amount of refrigerant and record the M otor is to be megged with the starter at
level in the evaporator sight glass. ambient temperature after 24 hours of
idle standby.
The refrigerant charge should always be checked and
trimmed when the system is shut down.
LD00475
FIGURE 16 - DIAGRAM,MEGGING MOTOR W INDINGS
30 JOHNSON CONTROLS
Minim um Insulation Resistance vs.Tem perature (perIEEE Std 43)

Open Motors
MEGOHMS
6
LD00476
TEMPERATURE F
FIGURE 17 - MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES
JOHNSON CONTROLS 31
CondensersAndEvaporators General Tube Fouling

M aintenance of condenser and evaporator shells is im- Fouling of the tubes can be due to deposits of two types
portant to provide trouble free operation of the chiller. as follows:
The water side of the tubes in the shell must be kept
clean and free from scale. Proper maintenance such as 1. Rustor sl udge " %'*)'" 7/0," * &," %-C" */&$" &'("
tube cleaning, and testing for leaks, is covered on the tubes and accumulates there. This material usu-
following pages. ally does not build up on the inner tube surfaces
as scale, but does interfere with the heat transfer.
Chem icalWaterTreatm ent Rust or sludge can generally be removed from the
tubes by a thorough brushing process.
Since the mineral content of the water circulated
through evaporators and condensers varies with almost 2. Scale due to mineral deposits. These deposits,
every source of supply, it is possible that the water be- even though very thin and scarcely detectable
ing used may corrode the tubes or deposit heat resistant upon physical inspection, are highly resistant to
scale in them. Reliable water treatment companies are heat transfer. They can be removed most effec-
available in most larger cities to supply a water treat- tively by circulating an acid solution through the
ing process which will greatly reduce the corrosive and tubes.
scale forming properties of almost any type of water.
Tube Cleaning Procedures
As a preventive measure against scale and corrosion
and to prolong the life of evaporator and condenser Brush Cleaning of Tubes
tubes, a chemical analysis of the water should be made If the tube consists of dirt and sludge, it can usually be
preferably before the system is installed. A reliable wa- removed by means of the brushing process. Drain the
ter treatment company can be consulted to determine water sides of the circuit to be cleaned (cooling wa-
whether water treatment is necessary, and if so, to fur- ter or chilled water) remove the heads and thorough-
nish the proper treatment for the particular water con- ly clean each tube with a soft bristle bronze or nylon
dition. brush. DO NOT USE A STEEL BRISTLE BRUSH. A
steel brush may damage the tubes.
Cleaning EvaporatorAnd CondenserTubes
Improved results can be obtained by admitting water
Evaporator into the tube during the cleaning process. This can be
It is difficult to determine by any particular test wheth- done by mounting the brush on a suitable length of 1/8"
er possible lack of performance of the water evaporator pipe with a few small holes at the brush end and con-
is due to fouled tubes alone or due to a combination necting the other end by means of a hose to the water
of troubles. Trouble which may be due to fouled tubes supply.
is indicated when, over a period of time, the cooling
The tubes should always be brush cleaned before acid
capacity decreases and the split (temperature differ-
cleaning.
ence between water leaving the evaporator and the
refrigerant temperature in the evaporator) increases. A Acid Cleaning OfTubes
gradual drop-off in cooling capacity can also be caused
by a gradual leak of refrigerant from the system or by a If the tubes are fouled with a hard scale deposit, they
combination of fouled tubes and shortage of refrigerant may require acid cleaning. It is important that before
charge. An excessive quantity of oil in the evaporator acid cleaning, the tubes be cleaned by the brushing
can also contribute to erratic performance. process described above. If the relatively loose foreign
material is removed before the acid cleaning, the acid
Condenser solution will have less material to dissolve and flush
from the tubes with the result that a more satisfactory
In a condenser, trouble due to fouled tubes is usually
cleaning job will be accomplished with a probable sav-
indicated by a steady rise in head pressure, over a pe-
ing of time.
riod of time, accompanied by a steady rise in condens-
ing temperature, and noisy operation. These symptoms
may also be due to foul gas buildup. Purging will re-
move the foul gas revealing the effect of fouling.
32 JOHNSON CONTROLS
Acid cleaningshould only be performed 3. W ith nitrogen or dry air, blow out the tubes to
by an expert. Please consult your local clear them of traces of refrigerant laden moisture
water treatment representative for as- from the circulation water. As soon as the tubes
sistance in removing scale buildup and are clear, a cork should be driven into each end
preventative maintenance programs to of the tube. Pressurize the dry system with 50 to
eliminate future problems. COM M ER- 100 PSIG (345 to 690 kPa) of nitrogen. Repeat
CIALACID CLEANING this with all of the other tubes in the suspected
section or, if necessary, with all the tubes in the
In many major cities, commercial organizations now evaporator or condenser. Allow the evaporator or
offer a specialized service of acid cleaning evaporators condenser to remain corked up to 12to 24hours
and condensers. If acid cleaning is required, YORK before proceeding. Depending upon the amount
recommends the use of this type of organization. The of leakage, the corks may blow from the end of a
Dow Industries Service Division of the Dow Chemical tube, indicating the location of the leakage. If not,
Company, Tulsa, Oklahoma, with branches in principal if will be necessary to make a very thorough test
cities is one of the most reliable of these companies. with the leak detector.
Testing ForEvaporatorAnd CondenserTube 4. After the tubes have been corked for 12 to 24
Leaks hours, it is recommended that two men working
at both ends of the evaporator carefully test each
Evaporator and condenser tube leaks in R-134a sys-
tube one man removing corks at one end and
tems may result in refrigerant leaking into the water
the other at the opposite end to remove corks and
circuit, or water leaking into the shell depending on the
handle the leak detector. Start with the top row of
pressure levels. If refrigerant is leaking into the water,
tubes in the section being investigated. Remove
it can be detected at the liquid head vents after a period
the corks at the ends of one tube simultaneously
of shutdown. If water is leaking into the refrigerant,
and insert the exploring tube for 5seconds this
system capacity and efficiency will drop off sharply. If
should be long enough to draw into the detec-
a tube is leaking and water has entered the system, the
tor any refrigerant gas that might have leaked
evaporator and condenser should be valved off from
through the tube walls. A fan placed at the end of
the rest of the water circuit and drained immediately to
the evaporator opposite the detector will assure
prevent severe rusting and corrosion. The refrigerant
that any leakage will travel through the tube to
system should then be drained and purged with dry ni-
the detector.
trogen to prevent severe rusting and corrosion. If a tube
leak is indicated, the exact location of the leak may be 5. D -+<"-/C"#(-<*
/4"&
.:(,"=$+"#-&(+"*0(/&*7)-&*$/8 6
determined as follows:
6. If any of the tube sheet joints are leaking, the leak
1. Remove the heads and listen at each section of should be indicated by the detector. If a tube sheet
tubes for a hissing sound that would indicate gas leak is suspected, its exact location may be found
leakage. This will assist in locating the section of by using a soap solution. A continuous buildup of
tubes to be further investigated. If the probable bubbles around a tube indicates a tube sheet leak.
location of the leaky tubes has been determined,
treat that section in the following manner (if the COMPRESSOR
#$)-&*$/"* ,"/$&"0(7/* &
(B"-##"&
'("&.:(,"%* #
#"+(1.*+(" M aintenance for the compressor assembly consists
investigations). of checking the operation of the oil return system and
2. Wash off both tube heads and the ends of all tubes changing the dehydrator, checking and changing the oil,
with water. checking and changing the oil filters, checking the op-
eration of the oil heater, checking the operation of the oil
Do not use carbon tetrachloride for this pump, and observing the operation of the compressor.
purpose since its fumes give the same
C*8#) "&(/020-*%&0$) %+*%) %+#) -#9-&5#-*$%)
does.
JOHNSON CONTROLS 33
Internal wearing of compressor parts could be a seri- of operation. However, if aluminum particles continue
ous problem caused by improper lubrication, brought to accumulate and the same conditions continue to stop
about by restricted oil lines, passages, or dirty oil fil- the unit operation after a new filter is installed, notify
ters. If the unit is shutting down on (HOT) High Oil the nearest Johnson Controls office to request the pres-
Temperature or Low Oil Pressure (OP), change the oil ence of a Johnson Controls Service Technician.
filter element. Examine the oil filter element for the
presence of aluminum particles. Aluminum gas seal ELECTRICAL CONTROLS
rings can contact the impeller and account for some For information covering the OptiView Control Cen-
aluminum particles to accumulate in the oil filter, espe- ter operation, refer to the Optiview ControlCenter
cially during the initial start up and first several months Operat ion andMaint enance (Form 160.54-O1).
34 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 7 - PREVENTIVE MAINTENANCE
It is the responsibility of the owner to provide the nec- RAM MotorLubrication

essary daily, monthly and yearly maintenance require- Frame 143T thru 256T are furnished with double
ments of the system. sealed ball bearings, pre-lubricated prior to installa-
IM PORTANT If a unit failure occurs tion. Grease fittings are not supplied and bearings are
due to improper maintenance duringthe designed for long life under standard conditions.
warranty period;Johnson Controls will
not be liable for costs incurred to return Frames 284T thru 587UZ are furnished with double
the system to satisfactory operation. shielded or open ball or roller bearings. It is necessary
to re-lubricate anti-friction bearings periodically. (Re-
fer to Table 3on Page 35. )
In any operating system it is most important to pro-
vide a planned maintenance and inspection of its func- TABLE 3 - BEARING LUBRICATION
tioning parts to keep it operating at its peak efficiency. FRAME STANDARD CONTINUOUS GREASE
Therefore, the following maintenance should be per- SIZE 8HR/DAY 24HR DAY QUANTITY
formed when prescribed. OZ.
143T-256T *7 Years *3 Years *1
COMPRESSOR 284TS-286TS 210 Days 70 Days 1
1. Oi lFilter W hen oil pump VSD frequency in- 324TS-587USS 150 Days 50 Days 2
creases to 55hz to maintain target oil pressure.
* On frame si zes 143T - 256T,changi ng bearings atthese
interval
si s recommended. However,removi ng the seal
,cl
ean-
W hen the oil filter is changed, it should be inspect-
"$%&($.&#,3--"$%&19,&E,(#"$%&($.&19,&4(M"1<&A"19&#,40)),$.,.&
ed thoroughly for any aluminum particles which grease can re-l ubricate these bearings.
would indicate possible bearing wear. If alumi-
num particles are found this should be brought Recommended greases for standard applications:
to the attention of the nearest Johnson Controls
office for their further investigation and recom- OPERATING AMBIENT TEMP.-30C to 50C
mendations. Chevron SRI (Chevron)
Exxon Uni
rex#2 (Exxon Corp.)
2. OilChangi ng The oil in the compressor must
be changed annually or earlier if it becomes dark Exxon Pol
yrex (Exxon Corp.)
or cloudy. However, quarterly oil analysis can Shel
lDol
um R (Shel
lOi
lCo.)
eliminate the need for an annual change provided
Westinghouse M otor Lubrication:
the analysis indicates there is no problem with the
oil. !" Re-greasing should occur at 1000operating hour 7
intervals.
COMPRESSOR MOTOR
!" Westinghouse recommends using Westinghouse
1. Check motor mounting screws frequently to in-
Grease No. 53701.
sure tightness.
!" M otors with shaft diameters less than 2 3/8 inch
2. M eg motor windings annually to check for dete-
require 1 oz of grease per bearing while motors
rioration of windings.
with shaft diameters between 2 3/8 and 3 inches
GREASED BEARINGS require 1.5oz.
M ixing different greases is not recom-
M otor Operation and M aintenance manuals are sup-
mended
plied with the chillers providing maintenance sched-
ules and instructions for the specific motors. The fol-
lowing are lubrication schedules for the most common
motors:
JOHNSON CONTROLS 35
SECTION 7 - PREVENTIVE MAINTENANCE FORM 160.75-O1 (211)
Additional information on motor lubrica- a new unit, it is a good indication that the con-
tion and other service issues can be found denser tubes require cleaning. Refer to SECTION
in the A-C M otors Instruction M anual. 6- MAINTENANCE of this manual for condenser
tube cleaning instructions.
2. The evaporator tubes under normal circumstances
will not require cleaning. If the temperature dif-
LEAK TESTING ference between the refrigerant and the chilled
water increases slowly over the operating season,
The unit should be leak tested monthly. Any leaks
it is an indication that the evaporator tubes may be
found must be repaired immediately.
fouling or that there may be a water bypass in the
EVAPORATOR AND CONDENSER waterbox requiring gasket replacement or refrig-
erant may have leaked from the chiller.
The major portion of maintenance on the condenser
and evaporator will deal with the maintaining the wa- 3. Heat recovery condenser tubes should be evalu-
ter side of the condenser and evaporator in a clean ated similiar to evaporator tubes when the heating
condition. circuit is a treated, closed loop. Fouling could be
detected as ability to meet heat load requirements
The use of untreated water in cooling towers, closed decreases.
water systems, etc. frequently results in one or more of
the following: OIL RETURN SYSTEM
1. Scale Formation. 1. Change the dehydrator in the oil return system

semi-annually or earlier if the oil return system
2. Corrosion or Rusting. fails to operate.
3. Slime and Algae Formation. 2. W hen the dehydrator is changed, the nozzle of the
It is therefore to the benefit of the user to provide for eductor should be checked for any foreign par-
proper water treatment to provide for a longer and ticles that may be obstructing the jet.
more economical life of the equipment. The following
ELECTRICAL CONTROLS
recommendation should be followed in determining
the condition of the water side of the condenser and 1. All electrical controls should be inspected for ob-
evaporator tubes. vious malfunctions.
1. The condenser tubes should be cleaned annually 2. It is important that the factory settings of controls
or earlier if conditions warrant. If the temperature (operation and safety) not be changed. If the set-
difference between the water off the condenser tings are changed without Johnson Controls ap-
and the condenser liquid temperature is more than proval, the warranty will be jeopardized.
4F (2C) greater than the difference recorded on
36 JOHNSON CONTROLS
JOHNSON CONTROLS
FORM 160.75-O1 (211)

MA INT E NA NC E R E Q UIR E ME NT S F OR Y OR K Y K C HIL L E R S
P R OC E DUR E DA IL Y WE E K L Y MONT HL Y YE AR LY OT HE R
Record operating conditions (on applicable Log Form) X

Check oil levels X
Check refrigerant levels X
Check oil return system operation X
Check operation of motor starter X
Check sump heater and thermostat operation X
Check three-phase voltage and current balance X
Verify proper operation/setting/calibration of safety controls1 X
Verify condenser and evaporator water flows X
Leak check and repair leaks as needed1 X
Check and tighten all electrical connections X
Megohm motor windings X
Replace oil filter and oil return filter/driers X
Clean or backflush heat exchanger (VSD, SSS Applications) X
Replace starter coolant (VSD, SSS Applications) X
Replace or clean starter air filters if applicable X2
1
Perform oil analysis on compressor lube oil X
Perform refrigeration analysis1 X
Perform vibration analysis X
Clean tubes X2
Perform Eddy current testing and inspect tubes 2 - 5 Years
Lubricate motor Refer to motor manufacturers recommentations
For operating and maintenance requirements listed above, refer to appropriate service literature, or contact your local YORK Service Office.
1
This procedure must be performed at the specified time interval by an Industry Certified Technician who has been trained and qualified to work on this type of YORK
equipment. A record of this procedure being successfully carried out must be maintained on file by the equipment owner should proof of adequate maintenance be required
at a later date for warranty validation purposes.
2
More frequent service may be required depending on local operating conditions.
Form 160.54-MR1 (801)
37
LD13598
FORM 160.75-O1 (111)
NOTES
38 JOHNSON CONTROLS
FORM 160.75-O1 (211)
The following factors can be used to convert from

English to the most common SI M etric values.
TABLE 4 - SIMETRIC CONVERSION
MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT
Capaci
ty Tons Refri
gerantEffect(ton) 3.516 Ki
lowatts (kW )
Power Horsepower 0.7457 Ki

lowatts (kW )
Fl
ow Rate Gal
lons /Mi
nute (gpm) 0.0631 Li
ters /Second (l
/s)
Feet(ft) 304.8 Meters (m)

Length
Inches (i
n) 25.4 Mi
ll
imeters (mm)
W ei
ght Pounds (l
bs) 0.4538 Ki
lograms (kg)
Vel
oci
ty Feet/Second (fps) 0.3048 Meters /Second (m/s)
FeetofW ater (ft) 2.989 Ki

lopascal
s (kPa)
Pressure Drop
Pounds /Square Inch (psi
) 6.895 Ki
lopascal
s (kPa)
TEMPERATURE
To convert degrees Fahrenheit (F) to degrees Celsius
(C), subtract 32and multiply by 5/9or 0.5556.
Example: (45.0F - 32) x 0.5556= 27.2C
To convert a temperature range (i.e., a range of 10F)
from Fahrenheit to Celsius, multiply by 5/9or 0.5556.
Example: 10.0F range x 0.5556= 5.6C range
JOHNSON CONTROLS 39
OCHC&P0Q&RSTUN&70#VN&O,$$5<-M($"(&W;X&RYZ[SJRSTU& Tel
e. 800-861-1001 ;@EL
,41&10&49($%,&A"190@1&$01"4,C&O#"$1,.&"$&W;X
Copyright byJohnson Control s 2011 www.york.com ALL RIGHTS RESERVED
Form 160.75-O1 (211)
Supersedes: 160.75-O1 (309)

York Operation & Maitenance Manual

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CENTRIFUGAL LIQUID CHILLERS

OPERATIONS AND MAINTENANCE Supersedes: 160.75-O1 (508) Form 160.75-O1 (211)

Indicates a potentially hazardous situa- Highlights additional information useful

34%#-$*2).&-&$56 )1$2#(()(7#/&'#")*()*$)07%&0$*2)/0$$#/%&0$)&$)%+#)8*$19*/%1-#-: ()7-0"1/%)2&$#6)&()

CHANGEABILITY OF THIS DOCUMENT

SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION .......................................... 7

TABLE OF CONTENTS (CONT'

SECTION 1 - DESCRIPTION OF SYSTEM AND

FIGURE 1 - MODELYK CHILLER

from the refrigerant vapor, causing it to condense. The

The position of these vanes is automatically controlled

HOT GAS PRE-ROTATION

OPTIONAL HOT GAS

OPTIONAL LIQUID LEVEL

HOT GAS PRE-ROTATION

DISCHARGE OPTIONAL HOT GAS

OPTIONAL LIQUID LEVEL

SECTION 2 - SYSTEM OPERATING PROCEDURES

3. Check entering and leaving condenser water pres- Weekly

FIGURE 8 - LIQUID CHILLER LOG SHEETS

THIS PAGE INTENTIONALLY LEFT BLANK

SECTION 3 - SYSTEM COMPONENTS DESCRIPTION

GENERAL C. Low speed thrust bearing (forward and re-

FIGURE 9 - SYSTEM COMPONENTS FRONT VIEW

FIGURE 10 - SYSTEM COMPONENTS REAR VIEW

THRUST COLLAR BEARING

LOW SPEED- THRUST

LOW LOW SPEED

OIL OIL SUBMERSIBLE

FIGURE 11 - SCHEMATIC DRAW ING (YK) COMPRESSOR LUBRICATION SYSTEM

OIL HEATER ant charge, and maintain reliable control. A specifically

REFRIGERANT FLOW CONTROL OPTIONAL HOT GAS BYPASS

SECTION 4 - OPERATIONAL MAINTENANCE

OIL RETURN SYSTEM CHANGING THE DEHYDRATOR

CHECK VALVE OIL EDUCTOR BLOCK

STOP VALVE DEHYDRATOR

FIGURE 12 - OIL RETURN SYSTEM

FIGURE 13 - CHARGING OIL RESERVOIR W ITH OIL

TABLE 1 - OPERATION ANALYSIS CHART

TABLE 1 - OPERATION ANALYSIS CHART (CONT'

RESULTS POSSIBLE REMEDY

7.SYMPTOM:REDUCED OIL PUMP CAPACITY

RENEWAL PARTS To test with R-22, proceed as follows:

FIGURE 14 - EVACUATION OF CHILLER

TABLE 2 - SYSTEM PRESSURES

VACUUM TESTING DO NOT USE STEAM . A suggested method is

The temperature of the water in the test tube will drop

FIGURE 16 - DIAGRAM,MEGGING MOTOR W INDINGS

Minim um Insulation Resistance vs.Tem perature (perIEEE Std 43)

CondensersAndEvaporators General Tube Fouling

SECTION 7 - PREVENTIVE MAINTENANCE

It is the responsibility of the owner to provide the nec- RAM MotorLubrication

1. Scale Formation. 1. Change the dehydrator in the oil return system

FORM 160.75-O1 (211)

Record operating conditions (on applicable Log Form) X

The following factors can be used to convert from

34%#-$2).&-&$56 )1$2#(()(7#/&'#")()$)07%&0$2)/0$$#/%&0$)&$)%+#)8$19/%1-#-: ()7-0"1/%)2&$#6)&()