York MaxE YK Series Operating & Maintenance Download Page 2

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YORK INTERNATIONAL

FORM 160.54-O2(1102)

YORK INTERNATIONAL

This equipment is a relatively complicated apparatus.

During installation, operation, maintenance or service,

individuals may be exposed to certain components or

conditions including, but not limited to: refrigerants,

oils, materials under pressure, rotating components,

and both high and low voltage. Each of these items

has the potential, if misused or handled improperly,

to cause bodily injury or death. It is the obligation

and responsibility of operating/service personnel to

identify and recognize these inherent hazards, protect

themselves, and proceed safely in completing their

tasks. Failure to comply with any of these require-

ments could result in serious damage to the equip-

ment and the property in which it is situated, as well

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

as severe personal injury or death to themselves and

people at the site.

This document is intended for use by owner-authorized

operating/service personnel. It is expected that this in-

dividual possesses independent training that will enable

them to perform their assigned tasks properly and safely.

It is essential that, prior to performing any task on this

equipment, this individual shall have read and under-

stood this document and any referenced materials. This

individual shall also be familiar with and comply with

all applicable governmental standards and regulations

pertaining to the task in question.

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to areas of potential hazard:

WARNING indicates a potentially

hazardous situation which, if not

avoided, could result in death or se-

rious injury.

DANGER indicates an imminently

hazardous situation which, if not

avoided, will result in death or serious

injury.

CAUTION identifies a hazard which

could lead to damage to the machine,

damage to other equipment and/or

environmental pollution. Usually an

instruction will be given, together with

a brief explanation.

External wiring, unless specified as an optional connection in the manufacturer’s product

line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,

transducers and controls may NOT be installed inside the micro panel. NO external wiring

is allowed to be run through the micro panel. All wiring must be in accordance with YORK’s

published specifications and must be performed ONLY by qualified YORK personnel. YORK

will not be responsible for damages/problems resulting from improper connections to the

controls or application of improper control signals. Failure to follow this will void the

manufacturer’s warranty and cause serious damage to property or injury to persons.

NOTE is used to highlight additional

information which may be helpful to

you.

Summary of Contents for MaxE YK Series

Page 1: ...ETM CENTRIFUGAL LIQUID CHILLERS Supersedes NOTHING Form 160 54 O2 1102 MODEL YK STYLE E R 134a COOLING ONLY WITH OPTIVIEWTM CONTROL CENTER FOR ELECTRO MECHANICAL STARTER SOLID STATE STARTER VARIABLE SPEED DRIVE 00611VIP LDO5842 ...

Page 2: ... materials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard WARNING indicates a potentially hazardous situation which if not avoided could result in death or se rious injury DANGER indicat...

Page 3: ...CF CG 5CR 5OJ 5CS In complying with YORK s policy for continuous product improvement the information contained in this document is subject to change without notice While YORK makes no commitment to update or provide current information automatically to the manual owner that information if applicable can be obtained by contacting the nearest YORK Applied Systems Service office REFERENCE INSTRUCTION...

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

Page 5: ... 10 FIG 4 CHILLER STARTING SEQUENCE SHUTDOWN SEQUENCE VARIABLE SPEED DRIVE 11 FIG 5 LIQUID CHILLER LOG SHEETS 12 FIG 6 SYSTEM COMPONENTS 15 FIG 7 SCHEMATIC DRAWING YK COMPRESSOR LUBRICATION SYSTEM 16 FIG 8 OIL RETURN SYSTEM 18 FIG 9 CHARGING OIL RESERVOIR WITH OIL 21 FIG 10 EVACUATION OF CHILLER 22 FIG 11 SYSTEM PRESSURES 25 FIG 12 SATURATION CURVE 27 FIG 13 DIAGRAM MEGGING MOTOR WINDINGS 29 FIG 1...

Page 6: ... O Board and Motor Controller circuit Refer to SECTION 1 DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION 00116vip CONDENSER CONTROL CENTER COMPRESSOR MOTOR EVAPORATOR FIG 1 MODEL YK MAXETM CHILLER SYSTEM OPERATION DESCRIPTION SEE FIG 2 The YORK Model YK MaxETM Chiller is commonly applied to large air conditioning systems but may be used on other applications The chiller consists of an open mot...

Page 7: ...eat 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 h...

Page 8: ...L 8 FORM 160 54 O2 1102 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 ...

Page 9: ...fter start up the excess oil may be drained from the oil filter drain valve while the compressor is running If oil level is low oil should be added to the com pressor See Oil Charging Procedure page 22 Comply with EPA and Local regu lations when removing or dispos ing of Refrigeration System oil START UP PROCEDURE Pre Starting Prior to starting the chiller observe the OptiView Control Center Make ...

Page 10: ...mp will start to circulate oil for a 50 second pre run to establish oil flow and adequate lubrication to all bearings gears and rotating sur faces within the compressor The high and low oil pressure transducers OP and the oil temperature sensor RT3 will sense any malfunction in the lubrication system 3 The anti recycle timer software function will op erate after the 50 seconds of pre run time At t...

Page 11: ...rent limit software function plus the 3 phase 100 solid state overload current limiter CM 2 on Electro Mechanical Starter applications or the Solid State Starter current Limit function will override the temperature control func tion and prevent the Prerotation Vanes from opening beyond the CURRENT LIMIT setting NOT FOR ALL SHUTDOWNS REFER TO DISPLAY MES SAGES SECTION OF THIS MANUAL System Operatin...

Page 12: ... entering condenser water tempera ture may be as much as 25 F 14 C colder than the standby return chilled water temperature Cooling tower fan cycling will normally provide adequate control of the entering condenser water temperature on most installations OPERATING LOG SHEET A permanent daily record of system operating condi tions temperatures and pressures recorded at regular intervals throughout ...

Page 13: ...s necessary 5 Perform refrigerant analysis NEED FOR MAINTENANCE OR SERVICE If the system is malfunctioning in any manner or the unit is stopped by one of the safety controls consult the Operation Analysis Chart Table 1 pages 23 and 24 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 contin...

Page 14: ... 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 liquid heads to assure complete drainage If a Variable Speed Drive drain its water cooling sys tem If Solid State Starter drain water from starter cooling loop 3 On the SETUP Screen disable the clock This conser...

Page 15: ...L SECTION 3 SYSTEM COMPONENTS DESCRIPTION MOTOR EVAPORATOR COMPRESSOR SUCTION DUAL RELIEF VALVES SIGHT GLASS VARIABLE SPEED OIL PUMP CONTROL BOX REFRIGERANT CHARGING VALVE 00611vip FRONT VIEW FIG 6 SYSTEM COMPONENTS OPTIVIEW CONTROL CENTER 3 ...

Page 16: ...YORK INTERNATIONAL 16 FORM 160 54 O2 1102 FIG 7 SYSTEM COMPONENTS CONT D 28778A DISCHARGE LINE OIL COOLER OIL RESERVOIR PUMP REAR VIEW System Components Description ...

Page 17: ... all interconnecting oil piping and passages There are main points within the motor 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 thrust bearing...

Page 18: ...YORK INTERNATIONAL 18 FORM 160 54 O2 1102 LOW SPEED GEAR REAR BEARING DOUBLE BELLOWS SHAFT SEAL FIG 8 SCHEMATIC DRAWING YK COMPRESSOR LUBRICATION SYSTEM LD08577 System Components Description ...

Page 19: ...rcurrent transformers are furnished with all 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 exchanger A distributor trough provides uniform distribution of refrigerant over the entire shell length Stainless steel mesh ...

Page 20: ... refrigerant Isolation of the refrigerant in this system must be performed by a quali fied service technician OPTIONAL HOT GAS BYPASS Hot gas bypass is optional and is used to eliminate compressor surge during light load or high head operation The OptiView control panel will automati cally modulate the hot gas valve open and closed as required Adjustment of the hot gas control valve must be perfor...

Page 21: ...nducing the low pressure oil rich liquid to flow from the evaporator through the dehy drator to the compressor sump CHANGING THE DEHYDRATOR To change the dehydrator use the following pro cedure 1 Shut the stop valves on the condenser gas line oil return line to rotor support and inlet end of the dehydrator 2 Remove the dehydrator Refer to Fig 9 3 Assemble the new filter drier 4 Open condenser stop...

Page 22: ...il charging valve A located on the remote oil reservoir cover plate See Fig 9 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 level in the compressor oil res ervoir is abo...

Page 23: ...gerant refrigerant into system greater than 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 pr...

Page 24: ...YMPTOM 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 oil pre...

Page 25: ...ector 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 approximately 75 to 100 PSIG 517 to 690 kPa To be sure that the concentration of refrigerant has reached all pa...

Page 26: ... disconnect the vacuum pump leaving the vacuum 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 indi cator 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 indicat...

Page 27: ... and found to be tight prior to evacuation then the saturation tempera ture recordings should follow a curve similar to the typical saturation curve shown as Fig 12 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 vaporize...

Page 28: ...0 lbs 207 345 862 or 12 066 kg of refrigerant TABLE 3 REFRIGERANT CHARGE CHECKINGTHEREFRIGERANTCHARGE DURINGUNITSHUTDOWN The refrigerant charge is specified for each chiller model See Table 3 Charge the correct amount of refrigerant and record the level in the evaporator sight glass The refrigerant charge should always be checked and trimmed when the system is shut down The refrigerant charge leve...

Page 29: ... the condenser or evaporator compressor while making any necessary repairs While the main disconnect switch and compressor motor starter are open meg the motor as follows 1 Using a megohm meter megger meg between phases and each phase to ground See Fig 13 these readings are to be interpreted using the graph shown in Fig 14 2 If readings fall below shaded area remove ex ternal leads from motor and ...

Page 30: ...TERNATIONAL 30 FORM 160 54 O2 1102 LD00476 FIG 14 MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES Minimum Insulation Resistance vs Temperature per IEEE Std 43 Open Motors Maintenance TEMPERATURE F MEGOHMS ...

Page 31: ...d 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 usually...

Page 32: ...d 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 refrigerant 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 Pressurize the dry system with 5...

Page 33: ...s passages or 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 aluminum particles Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter espe cially during the initial start up and first several months of...

Page 34: ...s are not supplied and bearings are designed for long life under standard conditions Frames 284T thru 587UZ are furnished with double shielded or open ball or roller bearings It is neces sary to re lubricate anti friction bearings periodically See Table 4 Frame Size Standard 8hr Day Continuous 24hr Day Grease Qty oz 143T 256T 7 Years 3 Years 1 284TS 286TS 210 Days 70 Days 1 324TS 587USS 150 Days 5...

Page 35: ... user to provide for proper water treatment to provide for a longer and more economical life of the equipment The following recommendation should be followed in determining the condition of the water side of the condenser and evaporator tubes 1 The condenser tubes should be cleaned annually or earlier if conditions warrant If the temperature difference between the water off the condenser and the c...

Page 36: ...800 861 1001 www york com P O Box 1592 York Pennsylvania USA 17405 1592 Subject to change without notice Printed in USA Copyright by York International Corporation 2002 ALL RIGHTS RESERVED Form 160 54 O2 1102 Supersedes NOTHING ...

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