Johnson Controls York MaxE YK Series Manual Download

Page: 90 / 139

ForM 160.75-N1 (309)

JohNSoN CoNtroLS

all diMEnsions arE in inchEs (MM)

UNIT WEIGHT 53,531 - 100,464

lbs

(45,570 - 58,968 Kgs)

LD12641

UNIT WEIGHT UP TO 16,365

lbs

(7,423 Kgs)

LD12638

UNIT WEIGHT 16,366 - 28,835

lbs

(7,424 - 13,080 Kgs)

LD12639

UNIT WEIGHT 28,836 - 53,530

lbs

(13,081 - 24,281 Kgs)

LD12640

fig. 19 – nEoPrEnE isolators

UNIT WEIGHT 100,465 - 130,000

lbs

(45,570 - 58,967 Kgs)

LD12642

Summary of Contents for York MaxE YK Series

Page 1: ...view form lists the comments of the reviewer No Exceptions Taken The submittals have not been marked X Make Corrections Noted A copy of this review must remain with each copy Amend Resubmit of the submittal Rejected NO COMMENTS Condenser and evaporator shells shall have 150 lb flanged pipe connections not grooved pipe connections Note special requirements for CAPACITY TEST penalty for factory perf...

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Page 64: ...ons MaxETM centrifugal liquid chillers Supersedes 160 75 N1 607 Form 160 75 N1 309 MODEL YK STYLE G R 134a WITH OPTIVIEW CONTROL CENTER FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER VARIABLE SPEED DRIVE 00611VIP LD05842 ...

Page 65: ...d comply with all applicable governmental standards and regulations pertaining to the task in question safety symbols The following symbols are used in this document to alert the reader to areas of potential hazard CAUTION identifies a hazard which could lead to damage to the machine damage to other equipment and or environmental pollution Usually an instruction will be given together with a brief...

Page 66: ...to KS K5 to K7 CW DC 5CS 5DC K1 K2 MQ to MS M2 to M4 MP to MS M2 to M4 NQ to NS N2 to N4 NP to NS N2 to N4 PQ to PS P2 to P4 PQ to PS P2 to P4 QQ to QS Q2 to Q4 QQ to QS Q2 to Q4 K3 NQ to NS N2 to N4 NP to NS N2 to N4 DA DJ 5DA 5DH QQ to QV Q2 to Q4 QQ to QS Q2 to Q4 RQ RS RV R3 R5 R7 RQ to RS R2 to R4 K4 RP RR RT R2 R4 R6 RQ to RS R2 to R4 DA DJ 5DA 5DJ SQ SS SV S3 S5 S7 SQ to SS S2 to S4 VP to V...

Page 67: ...ES Fig 1 Model YK MaxE Chiller 5 Fig 2 Dimensions P Q Compressors Ft In 6 Fig 3 Dimensions P Q Compressors Metric 7 Fig 4 Dimensions H Compressors Ft In 8 Fig 5 Dimensions H Compressors Metric 9 Fig 6 Dimensions K Compressors Ft In 10 Fig 7 Dimensions K Compressors Metric 11 Fig 8 Dimensions Evaporator Compact Waterboxes 12 Fig 9 Dimensions Condenser Compact Waterboxes 13 Fig 10 Dimensions Evapora...

Page 68: ...Typical Refrigerant Vent Piping 33 Fig 25 Control Panel Positioning 34 Fig 26 Unit Insulation 35 LIST OF TABLES TABLE 1 Approximate Unit Weight Including Motor 22 TABLE 2A Evaporator Marine Waterbox Weights 23 TABLE 2B Condenser Marine Waterbox Weights 23 NOMENCLATURE YK CF CF G4 CM G S Special Modifications Model Design Level Evaporator Code Motor Code Condenser Code Power Supply for 60 Hz Compre...

Page 69: ...APORATOR CONDENSER SHELL CODES G E H F J J L L A 6 11 6 11 7 6 1 2 7 6 1 2 B 10 6 10 6 10 11 10 11 C 2 0 2 0 2 1 1 4 2 1 1 4 D 1 5 1 2 1 5 1 2 1 8 1 8 E 12 0 16 0 12 0 16 0 P9 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES H F J J L L A 6 11 7 6 1 2 7 6 1 2 B 10 3 10 8 1 2 10 8 1 2 C 2 0 2 1 1 4 2 1 1 4 D 1 5 1 2 1 8 1 8 E 16 0 12 0 16 0 Q6 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES E E F F A 7 0 7 ...

Page 70: ...94 445 E 3 658 3 658 4 877 P8 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES E E F F G G H H A 2 108 2 108 2 299 2 299 B 3 200 3 200 3 327 3 327 C 610 610 641 641 D 445 445 508 508 E 3 658 4 877 3 658 4 877 P9 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES H F J J L L A 2 108 2 299 2 299 B 3 124 3 264 3 264 C 610 641 641 D 445 508 508 E 4 877 3 658 4 877 Q3 COMPRESSOR EVAPORATOR CONDENSER SHELL CODES A ...

Page 71: ...termine overall height add 7 8 22 mm for isolators 5 Use of motors with motor hoods may increase overall unit dimensions fig 4 dimensions H COMPRESSOR UNITS ft in H compressor units standard ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR TYPE OF CHILLER MOUNTING M NEOPRENE PAD ISOLATORS 1 3 4 SPRING ISOLATORS 1 DEFLECTION 1 DIRECT MOUNT 3 4 H9 COMPRESSORS EVAP COND SHELL CODES K K K O M M A 7 6 1 ...

Page 72: ...nections 4 To determine overall height add 22 mm 7 8 inch for isolators 5 Use of motors with motor hoods may increase overall unit dimensions fig 5 dimensions H COMPRESSOR UNITS mm H compressor units Metric ADDITIONAL OPERATING HEIGHT CLEARANCE TYPE OF CHILLER MOUNTING M NEOPRENE PAD ISOLATORS 44 SPRING ISOLATORS 25mm DEFLECTION 25 DIRECT MOUNT 19 H9 COMPRESSORS EVAP COND SHELL CODES K K K O M M A...

Page 73: ... 0 14 0 16 0 14 0 16 0 Additional Operating Height Clearance Type of Chiller Mounting M Neoprene Pad Isolators 1 3 4 Spring Isolators 1 Deflection 1 Direct Mount 3 4 K7 Compressor Evap Cond Shell Codes W W Z Y Z Z A 10 3 12 7 11 3 B 12 2 14 1 5 8 12 10 C 2 8 2 11 1 2 2 11 1 2 D 2 5 1 2 3 4 2 8 E 22 0 18 0 18 0 K3 Compressor Evap Cond Shell Codes N N Q Q R R A 8 7 9 1 1 2 9 9 B 10 8 11 6 11 10 C 2 ...

Page 74: ...Codes N N Q Q R R A 2 616 2 781 2 972 B 3 251 3 505 3 607 C 724 749 813 D 584 641 699 E 4 877 4 877 4 877 Additional Operating Height Clearance Type of Chiller Mounting M Neoprene Pad Isolators 44 Spring Isolators 1 Deflection 25 Direct Mount 19 K4 Compressor Evaporator Condenser Shell Codes R R S S S V X T X X A 2 972 2 972 3 124 3 302 3 429 B 3 632 3 632 3 759 3 759 3 759 C 813 813 813 902 902 D...

Page 75: ... 2 1 3 4 654 Two Pass Evaporators Codes DIM A C D E F G H J K L M N P Q R S W X Z F 1 2 1 4 362 1 3 381 1 3 1 2 394 1 3 3 4 400 1 5 1 2 445 1 11 5 8 600 1 11 5 8 600 2 0 5 8 625 2 1 3 4 654 G 0 6 1 2 165 0 7 178 0 7 1 2 191 0 7 3 4 197 0 9 1 2 241 1 3 5 8 397 1 3 5 8 397 1 4 3 4 425 1 5 3 4 451 Three Pass Evaporators Codes DIM A C D E F G H J K L M N P Q R S W X Z F 1 2 1 4 362 1 3 381 1 3 1 2 394...

Page 76: ...2 572 Double Bundle Heat Recovery Condensers Codes B I O U Y DIM TOWER HEATING TOWER HEATING TOWER HEATING TOWER HEATING TOWER HEATING H 1 6 1 2 470 1 5 432 1 7 1 2 495 1 4 3 4 425 1 9 1 2 546 1 6 457 1 10 1 4 565 1 8 508 2 4 3 4 730 1 10 1 2 572 J 0 10 1 2 267 0 9 229 0 11 1 2 292 0 8 3 4 222 1 1 1 2 343 0 10 254 1 2 1 4 362 1 0 305 1 8 3 4 527 1 2 1 2 368 Three Pass Condensers Codes DIM A C D E ...

Page 77: ...55 10 254 8 203 1 7 483 2 2 660 1 4 406 3 0 914 1 4 406 3 0 914 G H 14 355 10 254 8 203 2 0 610 2 3 1 2 699 1 3 1 2 394 3 3 1 2 1 003 1 3 1 2 394 3 3 1 2 1 003 J K L 16 406 12 305 10 254 2 1 1 4 641 2 6 762 1 5 432 3 7 1092 1 5 432 3 7 432 LD07598a NOTES 1 Standard water nozzles are furnished as welding stub outs with grooves allowing the option of welding flanges or use of Victaulic couplings Fac...

Page 78: ...14 356 12 304 2 4 1 2 724 2 2 660 2 2 660 1 0 1 2 318 2 2 660 P Q 18 457 14 356 12 304 2 5 1 2 749 2 2 3 4 679 2 2 3 4 679 1 0 1 2 318 2 2 3 4 679 QV QT 20 508 18 457 14 356 2 5 1 2 749 2 2 3 4 679 2 2 3 4 679 1 0 1 2 318 2 2 3 4 679 RP RR RT R2 R4 R6 W 20 508 18 457 14 356 2 8 813 2 7 1 16 789 2 7 1 16 789 1 3 381 2 7 1 16 789 RQ RS RV R3 R4 R5 S 20 508 18 457 14 356 2 8 813 2 8 1 4 819 2 8 1 4 8...

Page 79: ...3 1 2 394 2 6 762 1 10 3 8 568 3 1 5 8 956 1 10 3 8 568 3 1 5 8 956 E F 14 356 10 254 8 203 1 5 1 2 445 2 8 813 1 11 3 4 603 3 4 1 4 1022 1 11 3 4 603 3 4 1 4 1022 J K L 16 406 10 254 10 254 1 8 508 3 0 914 2 3 686 3 9 1 143 2 3 686 3 9 1 143 M N 20 508 14 356 10 254 1 11 584 3 6 1067 2 6 3 8 772 4 5 5 8 1 362 2 6 3 8 772 4 5 5 8 1 362 P Q 20 508 16 406 14 356 2 1 1 4 641 3 8 1118 2 7 787 4 9 1 44...

Page 80: ...wer heat recovery heat recovery Cooling tower Cooling tower V GG hh Y 1 PASS NOZZLE ARRANGEMENTS IN OUT HEAT RECOVERY EE FF FF EE COOLING TOWER P Q Q P 2 PASS NOZZLE ARRANGEMENTS IN OUT HEAT RECOVERY AA BB CC DD BB AA DD CC COOLING TOWER R S T U S R U T 3 PASS NOZZLE ARRANGEMENTS IN OUT HEAT RECOVERY GG HH HH GG COOLING TOWER V Y Y V heat recovery COMPACT WATER BOXES 150 PSI Rectangular Condenser ...

Page 81: ...on of the sub cooler to achieve rated performance 5 Add dimension M as shown on pages per unit dimensions page for the appropriate isolator type Evaporator Shell Code Evaporator Nozzle Dimensions Ft in mm 1 PASS 2 PASS 3 PASS F I F G I F I A 1 7 483 0 8 3 4 222 1 5 432 0 6 1 2 165 0 7 3 4 197 1 5 432 0 7 3 4 197 C D 1 10 3 4 578 0 10 5 8 270 1 8 5 8 524 0 7 178 0 9 1 2 241 1 8 5 8 524 0 9 1 2 241 ...

Page 82: ... 2 PASS 3 PASS H K H J K H K A 1 9 533 0 9 7 8 251 1 4 3 4 425 0 6 152 0 7 3 4 197 1 4 3 4 425 0 7 3 4 197 B6 1 10 1 2 572 0 10 1 2 267 1 8 508 0 10 1 2 267 0 9 1 4 235 1 8 508 0 9 1 4 235 C D 2 0 610 0 11 1 8 283 1 7 1 2 495 0 6 3 8 162 0 9 229 1 7 1 2 495 0 9 229 E F 2 0 1 2 622 0 11 1 2 292 1 10 1 4 565 0 7 178 0 9 7 8 251 1 10 1 4 565 0 9 7 8 251 I6 2 3 686 1 0 3 4 324 1 10 1 2 572 0 11 1 2 29...

Page 83: ...9 0 11 279 1 9 7 8 556 J K L 16 406 12 305 10 254 2 1 1 4 641 5 0 3 8 1 534 5 0 3 8 1 534 0 10 1 2 267 2 2 1 2 673 5 0 3 8 1 534 0 10 1 2 267 2 2 1 2 673 M N 18 457 14 356 12 305 2 4 1 2 724 5 8 1 2 1 740 5 8 1 2 1 740 1 2 356 2 2 1 2 673 5 8 1 2 1 740 1 2 356 2 4 3 4 730 P Q 18 457 14 356 12 305 2 5 1 2 749 6 0 1 8 1 832 6 0 1 8 1 832 1 3 381 2 6 1 2 775 6 0 1 8 1 832 1 3 381 2 6 1 2 775 QT QV 20...

Page 84: ...3 3 8 391 3 11 1 194 1 8 508 1 3 3 8 391 C D 12 305 8 203 6 152 1 3 1 2 394 4 3 1 295 4 3 1 295 1 8 508 1 6 1 2 470 4 3 1295 1 8 508 1 6 1 2 470 E F 14 356 10 254 8 203 1 5 1 2 445 4 7 1 397 4 7 1 397 1 10 559 1 9 533 4 7 1 397 1 10 559 1 9 533 J K L 16 406 10 254 10 254 1 8 508 5 1 1 549 5 1 1 549 1 9 533 1 9 1 2 546 5 1 1 549 1 10 559 1 10 7 8 581 M N 20 508 14 356 10 254 1 11 584 5 9 7 8 1 775 ...

Page 85: ...L P8 P9 27 400 12 429 33 900 15 377 3 165 1 436 K K H9 28 530 12 941 36 000 16 329 2 925 1 327 K K K1 31 100 14 107 36 200 16 420 3 248 1 473 K O H9 34 483 15 641 44 776 20 310 3 260 1 479 M M H9 34 200 15 513 43 600 19 777 3 665 1 662 M M K1 K2 38 300 17 373 47 100 21 364 3 665 1 662 M U K2 45 178 20 493 58 017 26 316 3 540 1 606 N N K1 K2 28 530 18 549 50 800 23 043 4 225 1 916 N N K3 48 000 21 ...

Page 86: ...ts LBS KGS To be added to standard unit weights shown in table 1 Condenser Code SHIPPING WEIGHT OPERATING WEIGHT INCREASE Lbs Kgs INCREASE Lbs Kgs 1 Pass 2 Pass 3 Pass 1 Pass 2 Pass 3 Pass A 762 346 566 257 810 367 1 274 578 1 078 489 1 322 600 B 1 569 712 874 396 1 677 761 2 113 958 1 094 496 2 071 939 C D 946 429 778 353 1 046 474 1 692 767 1 524 691 1 792 813 E F 726 329 811 368 791 359 1 337 6...

Page 87: ...ismantled notify the nearest Johnson Controls office in ample time for a Johnson Controls representative to supervise rigging the unit to its operating position and the assembly of components 4 Do not make final power supply connections to the compressor motor or control center 5 Do not charge the compressor with oil 6 Do not charge the unit with refrigerant 7 Do not attempt to start the system 8 ...

Page 88: ...ipment should be checked on arrival to see that all major pieces boxes and crates are received Each unit should be checked on the trailer or rail car when received before unloading for any visible signs of damage Any damage or signs of possible damage must be reported to the transportation company immediately for their inspection JOHNSONCONTROLSwillnotberesponsible foranydamage in shipmentoratjob ...

Page 89: ...cularly space provided at either end to permit cleaning or replacement of evaporator and condenser tubes see Clearance A doorway or other sufficiently large opening properly located may be used The LD00700 R FIG 18 RIGGING chiller should be located in an indoor location where temperatures range from 40 F to 110 F 4 4 C to 43 3 C motors TheYK open motor is air cooled Check state local and other cod...

Page 90: ...3 531 100 464 Lbs 45 570 58 968 Kgs LD12641 UNIT WEIGHT UP TO 16 365 Lbs 7 423 Kgs LD12638 UNIT WEIGHT 16 366 28 835 Lbs 7 424 13 080 Kgs LD12639 UNIT WEIGHT 28 836 53 530 Lbs 13 081 24 281 Kgs LD12640 FIG 19 NEOPRENE ISOLATORS UNIT WEIGHT 100 465 130 000 Lbs 45 570 58 967 Kgs LD12642 ...

Page 91: ...G s 2 7 See FIG s 2 7 6 152mm 8 203mm 16 366 28 835 Lbs 7 424 13 08 Kgs See FIG s 2 7 See FIG s 2 7 6 152mm 8 203mm 28 836 53 530 Lbs 13 081 24 281 Kgs See FIG s 2 7 See FIG s 2 7 6 152mm 8 203mm 53 531 100 464 Lbs 24 281 45 569 Kgs See FIG s 2 7 See FIG s 2 7 10 254mm 8 203mm 100 465 130 000 Lbs 45 570 58 967 Kgs See FIG s 2 7 See FIG s 2 7 10 254mm 8 203mm LD12643 ...

Page 92: ...45 LD126544 UNIT WEIGHT 10 000 Lbs UP TO 35 009 Lbs 4 536 Kgs UP TO 15 880 Kgs UNIT WEIGHT 35 010 Lbs UP TO 58 349 Lbs 15 881 Kgs UP TO 26 467 Kgs UNIT WEIGHT 89 341 Lbs UP TO 115 000 Lbs 40 252 Kgs UP TO 52 164 Kgs LD12646 UNIT WEIGHT 115 000 Lbs UP TO 190 000 Lbs 52 163 Kgs UP TO 86 182 Kgs LD12647 ...

Page 93: ...9 Lbs 4 536 15 880 Kgs See FIG s 2 7 See FIG s 2 7 6 152 6 7 8 175 5 1 2 140 35 010 58 349 Lbs 15 881 26 467 Kgs See FIG s 2 7 See FIG s 2 7 9 229 7 178 6 1 4 159 89 341 115 000 Lbs 40 252 52 164 Kgs See FIG s 2 7 See FIG s 2 7 13 1 2 343 8 203 5 127 115 000 190 000 Lbs 52 163 86 182 Kgs See FIG s 2 7 See FIG s 2 7 16 406 17 432 16 1 4 413 LD12643a ...

Page 94: ...or assemblies will be furnished with the unit The 4 assemblies are identical and can be placed at any of the 4 corners of the unit While the unit is still suspended by the rigging the isolators should be bolted to the unit by inserting the cap screw s through the hole s in the mounting bracket into the tapped hole in the top of the isolator leveling bolt s Then the unit can be lowered onto the flo...

Page 95: ... protect the chiller as well as the pumps tower spray nozzles chilled water coils and controls etc The strainer must be installed in the entering chilled water line directly upstream of the chiller Water piping circuits should be arranged so that the pumps discharge through the chiller and should be controlled as necessary to maintain essentially constant chilled and condenser water flows through ...

Page 96: ...ser water heads and piping for leaks Repair leaks as necessary Before initial operation of the unit both water circuits should be thoroughly vented of all air at the high points refrigerant relief piping Each unit is equipped with pressure relief valves located on the condenser and on the evaporator for the purpose of quickly relieving excess pressure of the refrigerant charge to the atmosphere as...

Page 97: ...gle phase 60 or 50 Hertz power supply of 20 amperes must be furnished to the control center from the control transformer 2 KVArequired included with the compressor motor starter Do NOT make final power connections to control center until approved by YORK representative oil pump 3 phase starter Separate wiring or a fused disconnect switch should be supplied by the installer sUPPort ArMs PAnEl trACK...

Page 98: ...e evaporator shell end sheets liquid feed line to flow chamber compressor suction connection and evaporator liquid heads and connections The liquid head flange insulation must be removable to allow head removal for the tube maintenance Details of areas to be insulated are given on the Product Drawing Units are furnished factory anti sweat insulated on order at additional cost This includes all low...

Page 99: ...1 1001 www york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by Johnson Controls 2009 ALL RIGHTS RESERVED Form 160 75 N1 309 Supersedes 160 75 N1 607 ...

Page 100: ... MaxETM centrifugal liquid chillers Supersedes 160 75 O1 508 Form 160 75 O1 309 MODEL YK STYLE G R 134a WITH OPTIVIEWTM CONTROL CENTER FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER VARIABLE SPEED DRIVE 00611VIP LDO5842 ...

Page 101: ...vidual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question safety symbols The following symbols are used in this document to alert the reader to areas of potential hazard WARNING indicates a potentially hazardous situation which if not avoided could result in death or se rious injury DANGER indicates an imminently haz...

Page 102: ...LID STATE STARTER OPERATION MAINTENANCE 160 00 o2 SOLID STATE STARTER Service Instructions 160 00 M4 VARIABLE SPEED DRIVE OPERATION 160 00 o1 VARIABLE SPEED DRIVE service instructions 160 00 m1 Floor Mounted MV SSS Operation 160 00 O5 UNit Mounted MV SSS Operation 160 00 O7 Medium voltage Solid State Starter Service Instructions 160 00 M5 Medium voltage Variable Speed Drive Service Instructions 16...

Page 103: ...ystem and Fundamentals of Operation 6 SECTION 2 System Operating Procedures 9 SECTION 3 System Components Description 14 SECTION 4 Operational Maintenance 20 SECTION 5 Troubleshooting 22 SECTION 6 Maintenance 24 SECTION 7 Preventive Maintenance 34 TABLE OF CONTENTS ...

Page 104: ... Level Indicator 9 fig 4 Liquid Chiller Log Sheets 11 fig 5 System Components 14 fig 6 Schematic Drawing YK Compressor Lubrication System 17 fig 7 Oil Return System 20 fig 8 Charging Oil Reservoir with Oil 21 fig 9 Evacuation of Chiller 24 fig 10 Saturation Curve 26 fig 11 Diagram Megging Motor Windings 29 fig 12 Motor Stator Temperature Insulation Resistance 30 ...

Page 105: ...ESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION 00116vip CONDENSER CONTROL CENTER COMPRESSOR MOTOR EVAPORATOR FIG 1 MODEL YK MaxETM CHILLER SYSTEM OPERATION DESCRIPTION See Fig 2 The YORK Model YK MaxETM Chiller is commonly ap pliedtolargeairconditioningsystems butmaybeusedon other applications The chiller consists of an open motor mounted to a compressor with integral speed increasing gears co...

Page 106: ...y small part of the time the unit is in operation CAPACITY CONTROL The major components of a chiller are selected for full load capacities therefore capacity must be controlled to maintain a constant chilled liquid temperature leaving the evaporator Prerotation vanes PRV located at the entrance to the compressor impeller compensate for variation in load See Detail A The position of these vanes is ...

Page 107: ...1 309 8 FIG 2 REFRIGERANT FLOW THRU CHILLER PREROTATION VANES See Detail A SUCTION EVAPORATOR ELIMINATOR OIL COOLER LD00924 FLOW CONTROL ORIFICE SUB COOLER CONDENSER DISCHARGE BAFFLE DISCHARGE COMPRESSOR System Operating Procedures ...

Page 108: ...RTswitch This switch will automatically spring return to the RUN position If the unit was previ ously started press the STOP RESET side of the COMPRESSOR switch and then press the START side of the switch to start the chiller When the start switch is energized the Control Center is placed in an operating mode and any malfunction will be noted by messages on a graphic display For display messages a...

Page 109: ...ol TheYORK MaxETM chiller is designed to use less power by taking advantage of lower than design temperatures that are naturally produced by cooling towers throughout the operating year Exact control of condenser water such as a cooling tower bypass is not necessary for most installations The minimum entering condenser water temperature for full and part load conditions is specified in the chiller...

Page 110: ...ist of inspections and procedures should be used as a guide FIG 4 LIQUID CHILLER LOG SHEETS NOTE These items can be printed by an electronic printer connected to the Microboard and pressing the PRINT key on the Keypad or automatically using the Data Logger feature LD00467 23889A Daily 1 Check OptiView Control Center displays 2 If the compressor is in operation check the bearing oil pressure on the...

Page 111: ...tioning in any manner or the unit is stopped by one of the safety controls consult the Operation Analysis Chart Table 1 pages 22 and 23 of this instruction After consulting this chart if you are unable to make the proper repairs or adjust ments to start the compressor or the particular trouble continues to hinder the performance of the unit please call the nearest Johnson Controls District Office ...

Page 112: ...idle carefully drain the cooling water from the cooling tower condenser condenser pump and the chilled water system chilled water pump and coils Open the drains on the evaporator and condenser liq uid heads to assure complete drainage If a Variable Speed Drive drain its cooling system If Solid State Starter equipped drain liquid from starter cooling loop 3 If freezing temperatures are encountered ...

Page 113: ...STEM COMPONENTS DESCRIPTION motor EVAPORATOR compressor suction dual relief valves sight glass variable speed oil pump control box refrigerant charging valve 00611vip front view fig 5 system components OptiView control center System Operating Procedures ...

Page 114: ...FORM 160 75 O1 309 15 JOHNSON CONTROLS 3 fig 5 system components cont d 28778A discharge line oil cooler oil reservoir pump rear view ...

Page 115: ...ter oil cooler and all interconnecting oil piping and passages There are main points within the com pressor which must be supplied with forced lubrication as follows 1 Compressor Drive Shaft Low Speed a Shaft seal b Front and rear journal bearings one on each side of driving gear c Low speed thrust bearing forward and reverse 2 Compressor Driven Shaft High Speed a Forward and reverse high speed th...

Page 116: ...FORM 160 75 O1 309 17 JOHNSON CONTROLS 3 FIG 6 schematic drawing yk compressor lubrication system LD08577a ...

Page 117: ...ll units HEAT EXCHANGERS Evaporator and condenser shells are fabricated from rolled carbon steel plates with fusion welded seams Heat exchanger tubes are internally enhanced type The evaporator is a shell and tube flooded type heat ex changer Adistributor trough provides uniform distribu tion of refrigerant over the entire shell length Stainless steel mesh eliminators or suction baffles are locate...

Page 118: ...t gas bypass is optional and is used to eliminate com pressor surge during light load or high head operation The OptiView control panel will automatically modulate the hot gas valve open and closed as required Adjust ment of the hot gas control valve must be performed by a qualified service technician following the Hot Gas Set up procedure Changes in chilled water flow will require re adjustment o...

Page 119: ...he compressor oil sump See Fig 7 High pressure condenser gas flows continuously through the eductor inducing the low pressure oil rich liquid to flow from the evaporator through the dehydrator to the compressor sump CHANGING THE DEHYDRATOR To change the dehydrator use the following pro cedure 1 Isolate the dehydrator at the stop valves 2 Remove the dehydrator See to FIG 7 3 Assemble the new filter...

Page 120: ...ect the pump discharge connection to the oil charging valve A located on the remote oil reservoir cover plate See Fig 8 Do not tighten the connection at the charging valve until after the air is forced out by pumping a few strokes of the oil pump This fills the lines with oil and prevents air from being pumped into the system 3 Open the oil charging valve and pump oil into the system until oil lev...

Page 121: ...han normal with high discharge Variable orifice problem Remove obstruction temperature Temperature difference between leaving Evaporator tubes dirty or Clean evaporator tubes chilled water and refrigerant in the evaporator restricted greater than normal with normal discharge temperature Temperature of chilled water too low with Insufficient load for Check prerotation vane motor opera with low moto...

Page 122: ...isy 7 SYMPTOM REDUCED OIL PUMP CAPACITY Oil pump pumping capacity Excessive end clearance Inspect and replace worn parts pump Other worn pump parts Partially blocked oil supply Check oil inlet for blockage inlet 8 SYMPTOM OIL PRESSURE GRADUALLY DECREASES Noted by Observation of Daily Log Sheets When oil pump VSD frequency increases Oil filter is dirty Change oil filter to 55 hz to maintain target ...

Page 123: ...ic leak detector can be used to detect any leaks too small to be found by the soap test To test with R 22 proceed as follows 1 With no pressure in the system charge R 22 gas into the system through the charging valve to a pressure of 2 PSIG 14 kPa 2 Build up the system pressure with dry nitrogen to ap proximately 75 to 100 PSIG 517 to 690 kPa To be sure that the concentration of refrigerant has re...

Page 124: ...hen disconnect the vacuum pump leaving the vac uum indicator in place 6 Hold the vacuum obtained in Step 3 in the system for 8 hours the slightest rise in pressure indicates a leak or the presence of moisture or both If after 24 hours the wet bulb temperature in the vacuum indicator has not risen above 40 F 4 4 C or a pressure of 6 3 mm Hg the system may be considered tight Be sure the vacuum indi...

Page 125: ...ested and found to be tight prior to evacuation then the saturation temperature recordings should follow a curve similar to the typical saturation curve shown as Fig 10 The temperature of the water in the test tube will drop as the pressure decreases until the boiling point is reached at which point the temperature will level off and remain at this level until all of the water in the shell is vapo...

Page 126: ... 1580 DR 1466 DS 1455 EP EP EQ ER ES ET 1721 EQ 1718 ER 1635 ES 1574 ET 1474 EP IW IX 1805 EQ 1775 ER 1710 ES 1680 ET 1615 FQ FQ FR FS FT 2162 FR 2160 FS 2099 FT 1966 GQ EV EW EX 1990 GR 1899 GS 1808 Evap Code Cond Code Factory Charged Lbs HQ FV FW FX 2626 HR 2506 HS 2385 JP JP JQ JR JS 2557 JQ 2401 JR 2143 JS 2051 LQ LQ LR LS 3175 LR 2857 LS 2734 KP KP KQ KR KS K2 K3 K4 2920 KQ 2742 KR 2490 KS 23...

Page 127: ...4046 RV 4183 R2 4581 R3 4539 R4 4364 R5 4418 R6 4137 R7 4398 SQ SQ SR SS S2 S3 S4 4929 SS 4626 SV 4412 S3 4817 S5 4688 S7 4639 Evap Code Cond Code Factory Charged Lbs SQ VP VQ VR VS V2 V3 V4 V5 5467 SS 5110 SV 4950 S3 5300 S5 5171 S7 5177 WP WQ WR WS W1 W2 W3 W4 7871 WR 7383 WT 6895 W1 8002 W2 7654 W4 7378 W6 7089 XQ TP TQ TR TS T2 T3 T4 T5 5191 XR 4890 XS 4684 X2 5338 X3 4987 X4 4727 XQ XQ XR XS ...

Page 128: ...vel should be observed and the level re corded after initial charging HANDLING REFRIGERANT FOR DISMANTLING AND REPAIRS If it becomes necessary to open any part of the refrigerant system for repairs it will be necessary to remove the charge before opening any part of the unit If the chiller is equipped with optional valves the refrigerant can be isolated in either the condenser or evaporator compre...

Page 129: ...N CONTROLS FORM 160 75 O1 309 30 LD00476 FIG 12 MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES Minimum Insulation Resistance vs Temperature per IEEE Std 43 Open Motors Maintenance TEMPERATURE f MEGOHMS ...

Page 130: ...n head pressure over a period of time accompanied by a steady rise in condensing temperature and noisy operation These symptoms may also be due to foul gas buildup Purging will remove the foul gas revealing the effect of fouling TUBE FOULING Fouling of the tubes can be due to deposits of two types as follows 1 Rust or sludge which finds its way into the tubes and accumulates there This material us...

Page 131: ...the ends of all tubes with water Do not use carbon tetrachloride for this purpose since its fumes give the same flame discoloration that the re frigerant does 3 With nitrogen or dry air blow out the tubes to clear them of traces of refrigerant laden moisture from the circulation water As soon as the tubes are clear a cork should be driven into each end of the tube Pres surize the dry system with 5...

Page 132: ...dirty oil filters If the unit is shutting down on HOT High Oil Temperature or Low Oil Pressure OP change the oil filter element Examine the oil filter element for the presence of alumi num particles Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter especially during the initial start up and first several months of operation How...

Page 133: ...and Maintenance manuals are supplied with the chillers providing maintenance schedules and instructions for the specific motors The following are lubrication schedules for the most common motors RAM Motor Lubrication Frame 143T thru 256T are furnished with double sealed ball bearings pre lubricated prior to installation Grease fittings are not supplied and bearings are designed for long life under...

Page 134: ... that the condenser tubes require cleaning Refer to the Maintenance section of this manual for condenser tube cleaning instructions 2 The evaporator tubes under normal circumstances will not require cleaning If the temperature differ ence between the refrigerant and the chilled water increases slowly over the operating season it is an indication that the evaporator tubes may be fouling or that the...

Page 135: ...JOHNSON CONTROLS FORM 160 75 O1 309 36 SI metric conversion ...

Page 136: ... air filters if applicable X 2 Perform oil analysis on compressor lube oil 1 X Perform refrigeration analysis 1 X Perform vibration analysis X Clean tubes X 2 Perform Eddy current testing and inspect tubes 2 5 Years Lubricate motor Refer to motor manufacturer s recommentations For operating and maintenance requirements listed above refer to appropriate service literature or contact your local YORK...

Page 137: ...JOHNSON CONTROLS FORM 160 75 O1 309 38 NOTES ...

Page 138: ...FORM 160 75 O1 309 39 JOHNSON CONTROLS NOTES ...

Page 139: ...1 1001 www york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by Johnson Controls 2009 ALL RIGHTS RESERVED Form 160 75 O1 309 Supersedes 160 75 O1 508 ...

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