MaxE TM

centrifugal liquid chillers

operating & maintenance Supersedes: 160.75-O1 Form 160.75-O1

MODEL YK (STYLE G)
R-134a

WITH OPTIVIEW TM CONTROL CENTER

FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER & VARIABLE SPEED DRIVE

00611VIP

LDO5842
 FORM 160.75-O1

IMPORTANT!
Read BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. in which it is situated, as well as severe personal in-
During installation, operation, maintenance or service, jury or 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
oils, 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 possesses independent training that will enable
potential, if misused or handled improperly, to cause them to perform their assigned tasks properly and safely.
bodily injury or death. It is the obligation and respon- It is essential that, prior to performing any task on this
sibility of operating/service personnel to identify and equipment, this individual shall have read and under-
recognize these inherent hazards, protect themselves, stood this document and any referenced materials. This
and proceed safely in completing their tasks. Failure individual shall also be familiar with and comply with
to comply with any of these requirements could result all applicable governmental standards and regulations
in serious damage to the equipment and the property 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:

DANGER indicates an imminently CAUTION identifies a hazard which

hazardous situation which, if not could lead to damage to the machine,
avoided, will result in death or serious damage to other equipment and/or
injury. environmental pollution. Usually an
instruction will be given, together with
a brief explanation.

WARNING indicates a potentially NOTE is used to highlight additional

hazardous situation which, if not information which may be helpful to
avoided, could result in death or se- you.
rious injury.

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 John-
son Controls published specifications and must be performed only by qualified Johnson
Controls personnel. Johnson Controls will not be responsible for damages/problems result-
ing 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.

2 JOHNSON CONTROLS
 FORM 160.75-O1

Changeability of this document

In complying with Johnson Controls policy for continu- It is the responsibility of operating/service personnel as
ous product improvement, the information contained in to the applicability of these documents to the equipment
this document is subject to change without notice. While in question. If there is any question in the mind of oper-
Johnson Controls makes no commitment to update or ating/service personnel as to the applicability of these
provide current information automatically to the manual documents, then, prior to working on the equipment,
owner, that information, if applicable, can be obtained by they should verify with the owner whether the equipment
contacting the nearest Johnson Controls Service office. has been modified and if current literature is available.

REFERENCE INSTRUCTIONS
DESCRIPTION FORM NO.
SOLID 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 160.00-M6
INSTALLATION 160.75-n1
OptiView™ Control Center - service instructions 160-54-m1
Optiview™ control Center - Operation and Maintenance 160.54-O1
WIRING DIAGRAM – Field Connections 160.75-pW1
WIRING DIAGRAM – Unit w/ remote MV SSS 160.75-PW2
WIRING DIAGRAM – Unit w/ MV VSD 160.75-PW3
Wiring Diagram - Field Control Modifications 160.75-PW4
Wiring Diagram - Unit w/ MV SSS 160.75-PW5
Wiring Diagram - Unit w/ SSS, LV VSD w/ modbus, MV VSD 160.75-PW6
Wiring Diagram - Unit w/ LTC I/O Board w/ EM Starter 160.75-PW7
Wiring Diagram - Unit w/ LTC I/O Board w/ MV VSD 160.75-PW8
RENEWAL PARTS – UNIT 160.75-RP1
RENEWAL PARTS – OptiView Control Center 160.54-RP1

nomenclature
yK CB CB p6 – CM G

DESIGN LEVEL (G)

MOTOR CODE

POWER SUPPLY

COMPRESSOR CODE

CONDENSER CODE

EVAPORATOR CODE

MODEL

JOHNSON CONTROLS 3
 FORM 160.75-O1

TABLE OF CONTENTS

SECTION 1 Description of System 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

4 JOHNSON CONTROLS
 FORM 160.75-O1

LIST OF FIGURES

fig. 1 – Model YK MaxE TM Chiller............................................... 6

Detail A – Compressor PRV............................................ 7

fig. 2 – Refrigerant flow-through Chiller...................................... 8

fig. 3 – Oil 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

JOHNSON CONTROLS 5
 Description of System and Fundamentals of Operation
FORM 160.75-O1

SECTION 1
DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
COMPRESSOR

CONTROL
CENTER MOTOR

CONDENSER

00116vip

EVAPORATOR
FIG. 1 – MODEL YK MaxE TM CHILLER

SYSTEM OPERATION DESCRIPTION (See Fig. 2)

The YORK Model YK MaxE TM Chiller is commonly ap- electro-mechanical starter, YORK Solid State Starter
plied to large air conditioning systems, but may be used on (optional), or Variable Speed Drive (optional).
other applications. The chiller consists of an open motor In operation, a liquid (water or brine to be chilled)
mounted to a compressor (with integral speed increasing flows through the evaporator, where boiling refrigerant
gears), condenser, evaporator and variable flow control. absorbs heat from the liquid. The chilled liquid is then
piped to fan coil units or other air conditioning terminal
The chiller is controlled by a modern state of the art Mi- units, where it flows through finned coils, absorbing heat
crocomputer Control Center that monitors its operation. from the air. The warmed liquid is then returned to the
The Control Center is programmed by the operator to suit chiller to complete the chilled liquid circuit.
job specifications. Automatic timed start-ups and shut-
downs are also programmable to suit nighttime, week- The refrigerant vapor, which is produced by the boil-
ends, and holidays. The operating status, temperatures, ing action in the evaporator, flows to the compressor
pressures, and other information pertinent to operation where the rotating impeller increases its pressure and
of the chiller are automatically displayed and read on a temperature and discharges it into the condenser. Water
graphic display. Other displays can be observed by press- flowing through the condenser tubes absorbs heat from
ing the keys as labeled on the Control Center. The chiller the refrigerant vapor, causing it to condense. The con-
with the OptiView Control Center is compatible with an denser water is supplied to the chiller from an external

6 JOHNSON CONTROLS
 FORM 160.75-O1

The major components of a chiller are selected to handle

the refrigerant, which would be evaporated at full load
design conditions. However, most systems will be called
upon to deliver full load capacity for only a relatively
small part of the time the unit is in operation.

CAPACITY CONTROL
1
The major components of a chiller are selected for full
load capacities, therefore capacity must be controlled to
maintain a constant chilled liquid temperature leaving
the evaporator. Prerotation vanes (PRV), located at the
entrance to the compressor impeller, compensate for
variation in load (See Detail A).
The position of these vanes is automatically controlled
through a lever arm attached to an electric motor located
7619A(D) outside the compressor housing. The automatic adjust-
DETAIL A – COMPRESSOR PREROTATION VANES ment of the vane position in effect provides the perfor-
mance of many different compressors to match various
load conditions from full load with vanes wide open to
source, usually a cooling tower. The condensed refrig- minimum load with vanes completely closed.
erant drains from the condenser into the liquid return
line, where the variable orifice meters the flow of liquid
refrigerant to the evaporator to complete the refrigerant
circuit.

JOHNSON CONTROLS 7
 System Operating Procedures
FORM 160.75-O1

COMPRESSOR

PREROTATION VANES
(See Detail A)

DISCHARGE
SUCTION

DISCHARGE
BAFFLE

EVAPORATOR

CONDENSER

ELIMINATOR
SUB-COOLER

FLOW CONTROL
ORIFICE

LD00924

OIL COOLER

FIG. 2 – REFRIGERANT FLOW-THRU CHILLER

8 JOHNSON CONTROLS
 FORM 160.75-O1

SECTION 2
SYSTEM OPERATING PROCEDURES
OIL HEATERS CHECKING THE OIL LEVEL
IN THE OIL RESERVOIR
If the oil heater is de-energized during a shutdown period,
it must be energized for 12 hours prior to starting compres- Proper operating oil level – During operation, the oil
sor, or remove all oil and recharge compressor with new level should fall to the “Operating Range” identified on
oil. (See “Oil Charging Procedure”, page 21.) the vertical oil level indicator label (See Figure 3).
• If the oil level during operation is in
OIL HEATER OPERATION the “Over Full” region of the oil level
indicator, oil should be removed from
The oil heater operation is controlled by the OptiV- the oil reservoir, This reduces the oil
iew™ Control Center. The heater is turned on and off to level to the “Operating Range”.
maintain the oil temperature differential to a value 50°F • If the oil level during operation is in
(27.8°C) above the condenser saturation temperature. the “Low Oil” region of the oil level
This target value is maintained by the control panel. indicator, oil should be added to the
oil reservoir. (See “Oil Charging Pro-
If the target value is greater than 160°F (71°C), the target cedure”, page 21)
defaults to 160°F (71°C). If the target value is less than
110°F (43.3°C), it defaults to 110°F (43.3°C).

To prevent overheating of the oil in the event of a con-

trol center component failure, the oil heater thermostat
(1HTR) is set to open at 180°F (82°C).
FIG. 3 – OIL LEVEL INDICATOR
LD08647

Comply with EPA and Local regula-

tions when removing or disposing of
Refrigeration System oil!

START-UP PROCEDURE

Pre-Starting
to the Microcomputer Control Center the pump will
Prior to starting the chiller, observe the OptiView Con-
automatically start, therefore, this step is not neces-
trol Center (Refer to Form 160.54-O1). Make sure the
sary.
display reads "SYSTEM READY TO START".
2. To start the chiller, press the COMPRESSOR
Vent any air from the chiller water START switch. This switch will automatically spring
boxes prior to starting the water return to the RUN position. (If the unit was previ-
ously started, press the STOP/RESET side of the
pumps. Failure to do so will result in
COMPRESSOR switch and then press the START
pass baffle damage. 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
START-UP by messages on a graphic display.

1. If the chilled water pump is manually operated, start For display messages and information pertaining
the pump. The Control Center will not allow the to the operation of the OptiView™ Control Center,
chiller to start unless chilled liquid flow is established refer to Form 160.54-O1.
through the unit. If the chilled liquid pump is wired

JOHNSON CONTROLS 9
 System Operating Procedures
FORM 160.75-O1

Any malfunctions which occur during Condenser Water Temperature Control

STOP/RESET are also displayed.
The YORK MaxE TM 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
CHILLER OPERATION most installations. The minimum entering condenser
water temperature for full and part load conditions is
The unit capacity will vary to maintain the leaving specified in the chiller engineering guide.
Chilled Liquid Temperature setpoint by the
Pre-rotation Vanes which are modulated by an actuator where:
under the control of the Microprocessor Board. The vane Min. ECWT = LCWT – C RANGE + 5ºF + 12 ( % Load
)
100
control routine employs proportional plus derivative
(rate) control action. A drop in chilled liquid temperature Min. ECWT = LCWT – C RANGE + 2.8ºC + 6.6 (
% Load
100 )
will cause the actuator to close the Prerotation Vanes
to decrease chiller capacity. When the chilled liquid ECWT = Entering Condensing Water Temperature
temperature rises, the actuator will open the Prerotation LCWT = Leaving Chilled Water Temperature
Vanes to increase the capacity of the chiller. C Range = Condensing water temperature range at the
given load condition.
However, the current draw (amperes) by the compressor
motor is also limited to FLA setpoint by the micropro- At start-up, the entering condenser water temperature
cessor. may be as much as 25°F (14°C) colder than the standby
return chilled water temperature. Cooling tower fan
If the load continues to decrease, after the Prerotation Vanes cycling will normally provide adequate control of the
are entirely closed, the chiller will be shut down by the entering condenser water temperature on most instal-
Leaving Chilled Liquid – Low Temperature Control. 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
rejection or pressure, respectively.

10 JOHNSON CONTROLS
 FORM 160.75-O1

OPERATING LOG SHEET Daily

A permanent daily record of system operating conditions 1. Check OptiView™ Control Center displays.
(temperatures and pressures) recorded at regular inter-
2. If the compressor is in operation, check the bearing
vals throughout each 24 hour operating period should
oil pressure on the SYSTEM Screen. Also check
be kept.
the oil level in the oil reservoir. Operating oil level
should be operating range of oil indicator. Drain or
An optional status printer is available for this purpose
add oil if necessary.
or FIG. 4 shows a log sheet used by Johnson Controls
Personnel for recording test data on chiller systems. It 3. Check entering and leaving condenser water pressure
is available from the factory in pads of 50 sheets each and temperatures for comparison with job design
under Form 160.44-F7 and may be obtained through the conditions. Condenser water temperatures can be
nearest YORK office. Automatic data logging is possible checked on the SYSTEM Screen.
by connecting the optional printer and programming the 4. Check the entering and leaving chilled liquid temper-
DATA LOGGER function. atures and evaporator pressure for comparison with
job design conditions on the SYSTEM Screen.
An accurate record of readings serves as a valuable 5. Check the condenser saturation temperature (based
reference for operating the system. Readings taken upon condenser pressure sensed by the condenser 2
when a system is newly installed will establish normal transducer) on the SYSTEM Screen.
conditions with which to compare later readings. 6. Check the compressor discharge temperature on
the SYSTEM Screen. During normal operation
For example, an increase in condenser approach tem- discharge temperature should not exceed 220°F
perature (condenser temperature minus leaving con- (104°C).
denser water temperature) may be an indication of dirty
condenser tubes. 7. Check the compressor motor current on the SYSTEM
Screen.
8. Check for any signs of dirty or fouled condenser
OPERATING INSPECTIONS – See Section 2
tubes. (The temperature difference between water
leaving condenser and saturated condensing tem-
By following a regular inspection using the display
perature should not exceed the difference recorded
readings of the Microcomputer Control Center, and
for a new unit by more than 4°F (2.2°C)).
maintenance procedure, the operator will avoid serious
operating difficulty. The following list of inspections
and procedures should be used as a guide.

LD00467

23889A
*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.

FIG. 4 – LIQUID CHILLER LOG SHEETS

JOHNSON CONTROLS 11
 System Operating Procedures
FORM 160.75-O1

Weekly NEED FOR MAINTENANCE OR SERVICE

If the system is malfunctioning in any manner or the
1. Check the refrigerant charge. (See “Checking The unit is stopped by one of the safety controls, consult
Refrigerant Charge”, page 28.) the “Operation Analysis Chart”, (Table 1), pages 22
and 23 of this instruction. After consulting this chart,
Monthly if you are unable to make the proper repairs or adjust-
ments to start the compressor or the particular trouble
1. Leak check the entire chiller. continues to hinder the performance of the unit, please
call the nearest Johnson Controls District Office. Failure
Quarterly to report constant troubles could damage the unit and
increase the cost of repairs.
1. Perform chemical analysis of oil.
STOPPING THE SYSTEM
Semi-Annually (or more often as required)

1. Change and inspect compressor oil filter element. The Optiview™ Control Center can be programmed to
start and stop automatically (maximum, once each day)
2. Oil return system. whenever desired. Refer to Form 160.54-O1. To stop the
a. Change dehydrator. chiller, proceed as follows:

b. Check nozzle of eductor for foreign particles.

1. Push the soft shutdown key on the homescreen on the
3. Check controls and safety cutouts. OptiView panel or rapid stop with the COMPRES-
SOR STOP/RESET switch. The compressor will
Annually (more often if necessary) stop automatically. The oil pump will continue to
run for coastdown period. The oil pump will then
If quarterly inspection indicates oil is stop automatically.
fine, replacing the oil is not necessary. 2. Stop the chilled water pump (if not wired into the
Microcomputer Control Center, in which case it will
shut off automatically simultaneously with the oil
pump.) (The actual water pump contact operation is
dependent upon the position of Microboard jumper
1. Drain and replace the oil in the compressor oil sump. J54.)
(See “Oil Charging Procedure” page 21.) 3. Open the switch to the cooling tower fan motors, if
2. Evaporator and Condenser. used.
4. The compressor sump oil heater is energized when
a. Inspect and clean water strainers.
the unit is stopped.
b. Inspect and clean tubes as required.
c. Inspect end sheets.
3. Compressor Drive Motor (See motor manufacturers
maintenance and service instruction supplied with
unit)
a. Clean air passages and windings per manufactur-
ers instructions.
b. Meg motor windings – See FIG. 11 for details.
c. Lubricate per motor manufacturer recommenda-
tions.
4. Inspect and service electrical components as neces-
sary.
5. Perform refrigerant analysis.

12 JOHNSON CONTROLS
 FORM 160.75-O1

PROLONGED SHUTDOWN 3. If freezing temperatures are encountered for peri-

ods longer than a few days, the refrigerant should
If the chiller is to be shut down for an extended period of be recovered to containers to prevent leakage from
time (for example, over the winter season), the following O-ring joints.
paragraphs outline the procedure to be followed.
4. On the SETUP Screen, disable the clock. This con-
1. Test all system joints for refrigerant leaks with a
serves the battery.
leak detector. If any leaks are found, they should be
repaired before allowing the system to stand for a 5. Open the main disconnect switches to the compres-
long period of time. sor motor, condenser water pump and the chilled
During long idle periods, the tightness of the system water pump. Open the 115 volt circuit to the Control
should be checked periodically. Center.
2. If freezing temperatures are encountered while the
system is 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-
2
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.)

JOHNSON CONTROLS 13
 System Operating Procedures
FORM 160.75-O1

SECTION 3
SYSTEM COMPONENTS DESCRIPTION

OptiView control
center

compressor

suction

dual relief
valves

motor

EVAPORATOR

00611vip

refrigerant
charging valve

variable speed
oil pump control
box
sight
glass

front view

fig. 5 – system components

14 JOHNSON CONTROLS
 FORM 160.75-O1

discharge line

28778A

oil reservoir
pump

oil cooler

rear view

fig. 5 – system components (cont’d)

JOHNSON CONTROLS 15
 System Components Description
FORM 160.75-O1

GENERAL 1. Compressor Drive Shaft (Low Speed)

a. Shaft seal.
The YORK Model YK MaxE TM Centrifugal Liquid b. Front and rear journal bearings – one on each
Chiller is completely factory-packaged including evapo- side of driving gear.
rator, condenser, compressor, motor, lubrication system,
c. Low speed thrust bearing (forward and reverse).
OptiView Control Center, and all interconnecting unit
piping and wiring. 2. Compressor Driven Shaft (High Speed)
a. Forward and reverse high speed thrust
COMPRESSOR bearing.
b. Two journal bearings.
The compressor is a single-stage centrifugal type pow- 3. Speed Increasing Gears
ered by an open-drive electric motor. a. Meshing surfaces of drive and pinion gear teeth.
The rotor assembly consists of a heat-treated alloy steel To provide the required amount of oil under the nec-
drive shaft and impeller shaft with a cast aluminum, essary pressure to properly lubricate these parts, a motor
fully shrouded impeller. The impeller is designed for bal- driven submersible oil pump is located in a remote oil
anced thrust and is dynamically balanced and over-speed sump.
tested. The inserted type journal and thrust bearings are
fabricated of aluminum alloy. Single helical gears with Upon pressing of the COMPRESSOR START switch
crowned teeth are designed so that more than one tooth on the Control Center, the oil pump is immediately
is in contact at all times. Gears are integrally assembled energized. After a 50 second pre-lube period, the com-
in the compressor rotor support and are film lubricated. pressor motor will start. The oil pump will continue to
Each gear is individually mounted in its own journal run during the entire operation of the compressor, and
and thrust bearings. for 150 seconds during compressor coastdown.
The open-drive compressor shaft seal is a double bellows The submerged oil pump takes suction from the sur-
cartridge style with ceramic internal and atmospheric rounding oil and discharges it to the oil cooler where heat
seal faces. The seal is oil-flooded at all times and is is rejected. The oil flows from the oil cooler to the oil
pressure-lubricated during operation. filter. The oil leaves the filter and flows to the emergency
oil reservoir where it is distributed to the compressor
CAPACITY CONTROL bearings. The oil lubricates the compressor rotating
components and is returned to the oil sump.
Prerotation vanes (PRV) modulate chiller capac-
ity from 100% to as low as 15% of design for There is an emergency oil reservoir located at the
normal air conditioning applications. Operation highest point in the lubrication system internally in
is by an external, electric PRV actuator which the compressor. It provides an oil supply to the various
automatically controls the vane position to main- bearings and gears in the event of a system shutdown
tain a constant leaving chilled liquid temperature. due to power failure. The reservoir, located on the top of
the compressor, allows the oil to be distributed through
COMPRESSOR LUBRICATION SYSTEM the passages by gravity flow, thus providing necessary
(See Fig. 6) lubrication during the compressor coastdown.

The chiller lubrication system consists of the oil pump,

oil filter, 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:

16 JOHNSON CONTROLS
 FORM 160.75-O1

FIG. 6 – schematic drawing – (yk) compressor lubrication system LD08577a

JOHNSON CONTROLS 17
 System Components Description
FORM 160.75-O1

OIL PUMP HEAT EXCHANGERS

For normal operation, the oil pump should operate at all Evaporator and condenser shells are fabricated from
times during chiller operation. rolled carbon steel plates with fusion welded seams.
On shutdown of the system for any reason, the oil pump Heat exchanger tubes are internally enhanced type.
operates and continues to run for 150 seconds. The sys-
tem cannot restart during that time interval. The evaporator is a shell and tube, flooded type heat ex-
changer. A distributor trough provides uniform distribu-
OIL HEATER
tion of refrigerant over the entire shell length. Stainless
steel mesh eliminators or suction baffles are located
During long idle periods, the oil in the compressor oil
above the tube bundle to prevent liquid refrigerant car-
reservoir tends to absorb as much refrigerant as it can
ryover into the compressor. A 2" liquid level sight glass
hold, depending upon the temperature of the oil and
is located on the side of the shell to aid in determining
the pressure in the reservoir. As the oil temperature is
proper refrigerant charge. The evaporator shell contains
lowered, the amount of refrigerant absorbed will be
dual refrigerant relief valves unless condenser isolation
increased. If the quantity of refrigerant in the oil be-
is installed.
comes excessive, violent oil foaming will result as the
pressure within the system is lowered on starting. This
The condenser is a shell and tube type, with a discharge
foaming is caused by refrigerant boiling out of the oil
gas baffle to prevent direct high velocity impingement
as the pressure is lowered. If this foam reaches the oil
on the tubes. A separate subcooler (except heat recov-
pump suction, the bearing oil pressure will fluctuate with
ery chillers) is located in the condenser to enhance
possible temporary loss of lubrication, causing the oil
performance. Dual refrigerant relief valves are located
pressure safety cutout to actuate and stop the system.
on condenser shells and optional refrigerant isolation
See “Control Center” Form 160.54-O1.
valves are available.
MOTOR DRIVELINE The removable compact water boxes are fabricated of
steel. The design working pressure is 150 PSIG (1034
The compressor motor is an open-drip-proof, squir- kPa) and the boxes are tested at 225 PSIG (1551 kPa).
rel cage, induction type constructed to YORK design Integral steel water baffles provide the required pass
specifications. 60 hertz motors operate at 3570 rpm. 50 arrangements. Stub-out water nozzle connections with
hertz motors operate at 2975 rpm. Victaulic grooves are welded to the water boxes. These
nozzle connections are suitable for Victaulic couplings,
The open motor is provided with a D-flange, cast iron welding or flanges, and are capped for shipment. Plugged
adapter mounted to the compressor and supported by a 3/4" drain and vent connections are provided in each
motor support. water box. Optional marine waterboxes are available.
Motor drive shaft is directly connected to the compressor
REFRIGERANT FLOW CONTROL
shaft with a flexible disc coupling. This coupling has
all metal construction with no wearing parts to assure
Refrigerant flow to the evaporator is controlled by a
long life, and no lubrication requirements to provide
variable orifice.
low maintenance.
A level sensor senses the refrigerant level in the con-
For units utilizing remote Electro-Mechanical starters,
denser and outputs an analog voltage to the Microboard
a terminal box is provided for field connected conduit.
that represents this level (0% = empty; 100% = full).
Motor terminals are brought through the motor casing
Under program control, the Microboard modulates a
into the terminal box. Jumpers are furnished for three-
variable orifice to control the condenser refrigerant
lead type of starting. Motor terminal lugs are not fur-
level to a programmed setpoint. Other setpoints affect
nished. Overload/overcurrent transformers are furnished
the control sensitivity and response. These setpoints
with all units.
must be entered at chiller commissioning by a qualified
service technician. Only a qualified service technician
may modify these settings.

18 JOHNSON CONTROLS
 FORM 160.75-O1

While the chiller is shut down, the orifice will be in the Changes in chilled water flow will
fully open position causing the sensed level to be ap- require re-adjustment of the hot gas
proximately 0%. When the chiller is started, after the control to insure proper operation.
vane motor end switch (VMS) opens when entering
SYSTEM RUN, if actual level is less than the level
setpoint, a linearly increasing ramp is applied to the
level setpoint. This ramp causes the setpoint to go from OTIVIEW CONTROL CENTER
the initial refrigerant level (approximately 0%) to the (See Section 2)
programmed setpoint over a programmable period of
time. The OptiView Control Center is factory-mounted, wired
and tested. The electronic panel automatically controls
If the actual level is greater than the setpoint when the the operation of the unit in meeting system cooling re-
VMS opens, there is no pulldown period, it immediately quirements while minimizing energy usage. For detailed
begins to control to the programmed setpoint. information on the Control Center, refer to “Section 2”
of this manual.
While the chiller is running, the refrigerant level is nor-
mally controlled to the level setpoint. However, anytime SOLID STATE STARTER (Optional)
the vanes fully close (VMS closes), normal level control
is terminated, any refrigerant level setpoint in effect is The Solid State Starter is a reduced voltage starter that
cancelled and the outputs to the level control will be controls and maintains a constant current flow to the
constant open. motor during start-up. It is mounted on the chiller. Power 3
and control wiring between the starter and chiller are
optional service isolation valves factory installed. The starter enclosure is NEMA-1 with
a hinged access door with lock and key. Electrical lugs
If your chiller is equipped with optional service isola- for incoming power wiring are provided.
tion valves on the discharge and liquid line, these valves
must remain open during operation. These valves are
VARIABLE SPEED DRIVE (Optional)
used for isolating the refrigerant charge in either the
evaporator or condenser to allow service access to the
A Variable Speed Drive can be factory packaged with
system. A refrigerant pump-out unit will be required to
the chiller. It is designed to vary the compressor motor
isolate the refrigerant.
speed and prerotation vane position by controlling the
frequency and voltage of the electrical power to the
Isolation of the refrigerant in this sys- motor. Operational information is contained in Form
tem must be performed by a qualified 160.00-O1. The control logic automatically adjusts mo-
service technician. tor speed and compressor prerotation vane position for
maximum part load efficiency by analyzing information
fed to it by sensors located throughout the chiller.

optional hot gas bypass

Hot 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.

JOHNSON CONTROLS 19
 System Components Description
FORM 160.75-O1

SECTION 4
OPERATIONAL MAINTENANCE

OIL RETURN SYSTEM 1. Isolate the dehydrator at the stop valves.

The oil return system continuously maintains the proper 2. Remove the dehydrator (See to FIG. 7).
oil level in the compressor oil sump (See Fig. 7).
3. Assemble the new filter-drier.
High pressure condenser gas flows continuously through
the eductor inducing the low pressure, oil rich liquid to 4. Open evaporator stop valve and check dehydrator
flow from the evaporator, through the dehydrator to the connections for refrigerant leaks.
compressor sump.
5. Open all the dehydrator stop valves.
CHANGING THE DEHYDRATOR

To change the dehydrator, use the following pro-

cedure:

COMPRESSOR

SOLENOID VALVE

CHECK VALVE OIL EDuCTOR BLOCK

SOLENOID VALVE

STOP VALVE DEHYDRATOR

STOP VALVE

LD08578

FIG. 7 – OIL RETURN SYSTEM

20 JOHNSON CONTROLS
 FORM 160.75-O1

THE OIL CHARGE pump in a clean container of new oil and connect
the pump discharge connection to the oil charging
The nominal oil charge for all H, K, & P8-P9 YK com- valve (A) located on the remote oil reservoir cover
pressors is 20 gallons, and for Q3-Q7 YK compressors plate (See Fig. 8.) Do not tighten the connection at
is 10 gallons of type “YORK K”. the charging valve until after the air is forced out by
pumping a few strokes of the oil pump. This fills the
New YORK Refrigeration oil must be used in the cen- lines with oil and prevents air from being pumped
trifugal compressor. Since oil absorbs moisture when into the 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 reservoir
is in the “Over Full” region of the oil level indicator
OIL CHARGING PROCEDURE label. Close the charging valve and disconnect the
hand oil pump.
During operation the compressor oil level must be 4. As soon as oil charging is complete, close the power
maintained in the "Operating Range" identified on the supply to the starter to energize the oil heater. This
vertical oil level indicator. If the oil level falls into the will keep the concentration of refrigerant in the oil
lower sight glass, it is necessary to add oil to the com- to a minimum.
pressor oil reservoir. The oil should be charged into
the oil reservoir using the YORK Oil Charging Pump When the oil reservoir is initially charged with oil, the
– YORK Part No. 070-10654. To charge oil into the oil oil pump should be started manually to fill the lines,
reservoir, proceed as follows: passages, oil cooler and oil filter. This will lower the oil
level in the reservoir. It may then be necessary to add
1. The unit must be shut down. oil to bring the level back into the “Operating Range”
2. Immerse the suction connection of the oil charging of the oil level indicator label.
4

LD08579
OIL CHARGING VALVE
LD08648

FIG. 8 – CHARGING OIL RESERVOIR WITH OIL

JOHNSON CONTROLS 21
 Operational Maintenance
FORM 160.75-O1

SECTION 5 – TROUBLESHOOTING
TaBLE 1 – OPERATION ANALYSIS CHART

RESULTS POSSIBLE CAUSE REMEDY

1 . S Y MPTOM : A B NORMALL Y  HIGH  DISCHARGE  PRESSURE

Temperature difference between conden-
sing temperature and water off condenser Air in condenser.
higher than normal.
Condenser tubes dirty or Clean condenser tubes. Check water
scaled conditioning.
High discharge pressure.
High condenser water Reduce condenser water inlet
temperature. (Check cooling tower
temperature.
and water circulation.)
Temperature difference between conden- Insufficient condensing Increase the quantity of water through
ser water on and water off higher than water flow. the condenser to proper value.
normal, with normal evaporator pressure.
2 . S Y MPTOM : A B NORMALL Y LO W SUCTION PRESSURE
Temperature difference between leaving Insufficient charge of Check for leaks and charge
chilled water and refrigerant in evaporator refrigerant. refrigerant into system.
greater than normal with high discharge
temperature. Variable orifice problem. Remove obstruction.

Temperature difference between leaving

chilled water and refrigerant in the evaporator Evaporator tubes dirty or Clean evaporator tubes.
greater than normal with normal discharge restricted.
temperature.
Insufficient load for Check prerotation vane motor opera-
Temperature of chilled water too low with
system capacity. tion and setting of low water temper-
with low motor amperes.
ature cutout.

3 . S Y MPTOM : HIGH E V APORATOR PRESSURE

Prerotation vanes fail to Check the prerotation vane motor
open. positioning circuit.
High chilled water temperature.
Be sure the vanes are wide open
System overload. (without overloading the motor) until
the load decreases.

4. S Y MPTOM : NO OIL PRESSURE W HEN S Y STEM START B UTTON PUSHED

Oil pump running in wrong Check rotation of oil pump
Low oil pressure displayed on control direction. (Electrical Connections).
center; compressor will not start.
Troubleshoot electrical problem
Oil pump not running.
with oil pump VSD.

22 JOHNSON CONTROLS
 FORM 160.75-O1

TABLE 1 – OPERATion ANALYSIS CHART (Continued)

RESULTS POSSIBLE CAUSE REMEDY

5. SYMPTOM: UNUSUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS
Unusually high oil pressure is displayed High oil pressure. Trans- Replace low or high oil pressure
when the oil pressure display key is ducer defective. transducer.
pressed when the oil pump is running.

6. SYMPTOM: OIL PUMP VIBRATES OR IS NOISY

Oil pump vibrates or is extremely noisy Oil not reaching pump Check oil level.
with some oil pressure when pressing suction inlet in sufficient
OIL PRESSURE display key. quantity.
When oil pump is run
without an oil supply it Worn or failed oil pump. Repair/Replace oil pump.
will vibrate and
become extremely noisy.

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. 5
to 55 + hz to maintain target oil pressure.

9. SYMPTOM: OIL PRESSURE SYSTEM CEASES TO RETURN AN OIL/REFRIGERANT SAMPLE

Oil refrigerant return not functioning. Filter-drier in oil return Replace old filter-drier with new.
system dirty.
Jet or orifice of oil return Remove jet, inspect for dirt. Remove
jet clogged. dirt using solvent and replace.

10. SYMPTOM: OIL PUMP FAILS TO DELIVER OIL PRESSURE

No oil pressure registers when pressing Faulty oil pressure Replace oil pressure transducer.
OIL PRESSURE display key when oil transducer
pump runs. Faulty wiring/connectors.

JOHNSON CONTROLS 23
 Troubleshooting
FORM 160.75-O1

SECTION 6
MAINTENANCE
RENEWAL PARTS To test with R-22, proceed as follows:

For any required Renewal Parts, refer to YORK Renewal 1. With no pressure in the system, charge R-22 gas into
Parts Unit Components Manual 160.75-RP1. the system through the charging valve to a pressure
of 2 PSIG (14 kPa).
CHECKING SYSTEM FOR LEAKS
2. Build up the system pressure with dry nitrogen to ap-
Leak Testing During Operation proximately 75 to 100 PSIG (517 to 690 kPa). To be
The refrigerant side of the system is carefully pressure sure that the concentration of refrigerant has reached
tested and evacuated at the factory. all part of the system, slightly open the oil charging
valve and test for the presence of refrigerant with a
After the system has been charged, the system should 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 impor-
tant that this test be thoroughly and carefully done,
If any leaks are indicated, they must be repaired im- spending as much time as necessary and using a good
mediately. Usually, leaks can be stopped by tightening leak detector.
flare nuts or flange bolts. However, for any major repair,
the refrigerant charge must be removed. (See “Handling 4. To check for refrigerant leaks in the evaporator and
Refrigerant for Dismantling and Repair”, page 29.) condenser, open the vents in the evaporator and con-
denser heads and test for the presence of refrigerant.
CONDUCTING R-22 PRESSURE TEST If no refrigerant is present, the tubes and tube sheets
may be considered tight. If refrigerant is detected at the
With the R-134a charge removed and all known leaks vents, the heads must be removed, the leak located (by
repaired, the system should be charged with a small means of soap test or leak detector) and repaired.
amount of R-22 mixed with dry nitrogen so that a halide
torch or electronic leak detector can be used to detect
any leaks too small to be found by the soap test.

EVACUATION AND DEHYDRATION OF UNIT

27385A(D)

LD00949

FIG. 9 – EVACUATION OF CHILLER

24 JOHNSON CONTROLS
 FORM 160.75-O1

*GAUGE ABSOLUTE
BOILING
INCHES OF TEMPERATURES
MERCURY (HG) MILLIMETERS OF
BELOW ONE PSIA OF MERCURY MICRONS WATER
STANDARD (HG) °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. in. gauge pressure
= 760 mm Hg. absolute pressure at 32°F = Pressure above atmosphere
= 29.921 inches Hg. absolute at 32°F Psia = Lbs. per sq. in. absolute pressure
= Sum of gauge plus atmospheric pressure

tABLE 2 – SYSTEM PRESSURES

VACUUM TESTING
possibility of causing leaks, the temperature should
After the pressure test has been completed, the vacuum be brought up slowly so that the tubes and shell are
test should be conducted as follows: heated evenly.
5. Close the system charging valve and the stop valve 6
1. Connect a high capacity vacuum pump, with indica- between the vacuum indicator and the vacuum pump.
tor, to the system charging valve as shown in Fig. 9 Then disconnect the vacuum pump leaving the vac-
and start the pump. (See “Vacuum Dehydration”.) uum indicator in place.
2. Open wide all system valves. Be sure all valves to 6. Hold the vacuum obtained in Step 3 in the system for
the atmosphere are closed. 8 hours; the slightest rise in pressure indicates a leak
3. Operate the vacuum pump in accordance with or the presence of moisture, or both. If, after 24 hours
VACUUM DEHYDRATION until a wet bulb the wet bulb temperature in the vacuum indicator has
temperature of +32°F or a pressure of 5 mm Hg is not risen above 40°F (4.4°C) or a pressure of 6.3 mm
reached. See Table 2 for corresponding values of Hg, the system may be considered tight.
pressure. Be sure the vacuum indicator is valved
4. To improve evacuation circulate hot water (not to off while holding the system vacuum
exceed 125°F, 51.7ºC) through the evaporator and and be sure to open the valve between
condenser tubes to thoroughly dehydrate the shells.
the vacuum indicator and the system
If a source of hot water is not readily available, a
when checking the vacuum after the
portable water heater should be employed. DO NOT
USE STEAM. A suggested method is to connect a 8 hour period.
hose between the source of hot water under pres-
sure and the evaporator head drain connection, out 7. If the vacuum does not hold for 8 hours within the
the evaporator vent connection, into the condenser limits specified in Step 6 above, the leak must be
head drain and out the condenser vent. To avoid the found and repaired.

JOHNSON CONTROLS 25
 Maintenance
FORM 160.75-O1 (309)

VACUUM DEHYDRATION

To obtain a sufficiently dry system, the following instruc-

tions have been assembled to provide an effective method
for evacuating and dehydrating a system in the field. Al-
though there are several methods of dehydrating a system,
we are recommending the following, as it produces one of
the best results, and affords a means of obtaining accurate
readings as to the extent of dehydration.

The equipment required to follow this method of de-

hydration consists of a wet bulb indicator or vacuum
gauge, a chart showing the relation between dew point
temperature and pressure in inches of mercury (vacuum),
(See Table 2) and a vacuum pump capable of pumping
LD00474
a suitable vacuum on the system.
FIG. 10 – SATURATION CURVE
OPERATION

Dehydration of a refrigerant system can be obtained

by this method because the water present in the system When this point is reached, practically all of the air has
reacts much as a refrigerant would. By pulling down been evacuated from the system, but there is still a small
the pressure in the system to a point where its satu- amount of moisture left. In order to provide a medium
ration temperature is considerably below that of room for carrying this residual moisture to the vacuum pump,
temperature, heat will flow from the room through the nitrogen should be introduced into the system to bring it
walls of the system and vaporize the water, allowing to atmospheric pressure and the indicator temperature will
a large percentage of it to be removed by the vacuum return to approximately ambient temperature. Close off
pump. The length of time necessary for the dehydration the system again, and start the second evacuation.
of a system is dependent on the size or volume of the
system, the capacity and efficiency of the vacuum pump, The relatively small amount of moisture left will be car-
the room temperature and the quantity of water present ried out through the vacuum pump and the temperature
in the system. By the use of the vacuum indicator as or pressure shown by the indicator should drop uni-
suggested, the test tube will be evacuated to the same formly until it reaches a temperature of 35°F (1.6°C)
pressure as the system, and the distilled water will be or a pressure of 5 mm Hg.
maintained at the same saturation temperature as any
free water in the system, and this temperature can be When the vacuum indicator registers this temperature
observed on the thermometer. or pressure, it is a positive sign that the system is evac-
uated and dehydrated to the recommended limit. If this
If the system has been pressure tested and found to be level cannot be reached, it is evident that there is a leak
tight prior to evacuation, then the saturation temperature somewhere in the system. Any leaks must be corrected
recordings should follow a curve similar to the typical before the indicator can be pulled down to 35°F or 5
saturation curve shown as Fig. 10. mm Hg. in the primary evacuation.
The temperature of the water in the test tube will drop as During the primary pulldown, keep a careful watch on
the pressure decreases, until the boiling point is reached, the wet bulb indicator temperature, and do not let it fall
at which point the temperature will level off and remain below 35°F (1.6°C). If the temperature is allowed to fall
at this level until all of the water in the shell is vaporized. to 32°F (0°C), the water in the test tube will freeze, and
When this final vaporization has taken place the pressure the result will be a faulty temperature reading.
and temperature will continue to drop until eventually
a temperature of 35°F (1.6°C) or a pressure of 5 mm
Hg. is reached.

26 JOHNSON CONTROLS
 FORM 160.75-O1

REFRIGERANT CHARGING
To avoid the possibility of freezing liquid within the fit between the system charging valve and the fitting on
evaporator tubes when charging an evacuated system, the charging drum. This connection should be as short as
only refrigerant vapor from the top of the drum or cyl- possible but long enough to permit sufficient flexibility
inder must be admitted to the system pressure until the for changing drums. The charging connection should be
system pressure is raised above the point corresponding purged each time a full container of refrigerant is con-
to the freezing point of the evaporator liquid. For water, nected and changing containers should be done as quickly
the pressure corresponding to the freezing point is 8.54 as possible to minimize the loss of refrigerant.
PSIG (58.9 kPa) for R-134a (at sea level).
Refrigerant may be furnished in cylinders containing
While charging, every precaution must be taken to prevent either 30, 50, 125, 1,025 or 1750 lbs. (13.6, 22.6, 56.6,
moisture laden air from entering the system. Make up a 464 or 794 kg) of refrigerant.
suitable charging connection from new copper tubing to

tABLE 3 – REFRIGERANT CHARGE

Factory Factory
Cond Cond
Evap Code Charged Evap Code Charged
Code Code
Lbs. Lbs.
AP 828 HQ 2626
AQ AP, AQ, 794 HR FV, FW, FX 2506
AR AR, AS 739 HS 2385
AS 752 JP 2557
CP 1525 JQ JP, JQ, JR, 2401
CQ 1460 JR JS 2143
BW, BX
CR 1400 JS 2051
CS 1400 LQ 3175
CP 1221 LR LQ, LR, LS 2857
CQ CP, CQ, 1185 LS 2734
CR CR, CS 1100 KP 2920
CS 1091 KQ 2742
DP 1628 KR 2490 6
DQ DP, DQ, 1580 KS 2384
DR DR, DS 1466 KT 2992
DS 1455 KV 2808
KP, KQ,
EP 1721 KW 2571
KR, KS
EQ 1718 KX 2462
EP, EQ, K2, K3, K4
ER 1635 K2 3146
ER, ES, ET
ES 1574 K3 3065
ET 1474 K4 2983
EP 1805 K5 3248
EQ 1775 K6 3165
ER IW, IX 1710 K7 3081
ES 1680 MQ 3540
ET 1615 MR 3325
FQ 2162 MS UW, UX 3135
FR FQ, FR, 2160 M2 U8, U9 3760
FS FS, FT 2099 M3 3635
FT 1966 M4 3385
GQ 1990
GR EV, EW, EX 1899
GS 1808

JOHNSON CONTROLS 27
 Maintenance
FORM 160.75-O1

tABLE 3 (Con't) – REFRIGERANT CHARGE

Factory Factory
Cond Cond
Evap Code Charged Evap Code Charged
Code Code
Lbs. Lbs.
MQ 3394 SQ 5467
MR MP, MQ, 3194 SS VP, VQ, 5110
MS MR, MS 2988 SV VR, VS 4950
M2 M2, M3, 3665 S3 V2, V3, V4, 5300
M3 M4 3496 S5 V5 5171
M4 3236 S7 5177
NQ 3953 WP 7871
NR 3689 WR 7383
NP, NQ, WQ,
NS 3451 WT 6895
NR, NS WR, WS
N2 4233 W1 8002
N2, N3, N4 W1, W2,
N3 4038 W2 7654
W3, W4
N4 3738 W4 7378
PQ 3770 W6 7089
PR 3561 XQ 5191
PS PQ, PR, PS 3452 XR 4890
TP, TQ, TR,
P2 P2, P3, P4 3862 XS 4684
TS, T2, T3,
P3 3677 X2 5338
T4, T5
P4 3508 X3 4987
QQ 4214 X4 4727
QR 3980 XQ 5689
QS 3858 XR 5419
QQ,
QT 4215 XS XQ, XR, XS 5212
QR, QS
QV 3939 X2 X2, X3, X4 5866
Q2, Q3, Q4
Q2 4265 X3 5515
Q3 4060 X4 5255
Q4 3874 ZQ 6475
RP 4775 ZR 6137
RQ 4673 ZS ZQ, ZR, ZS 5911
RR 4429 Z1 Z1, Z2, Z3, 6984
RS 4359 Z2 Z4 6627
RT 4046 Z3 6243
RQ,
RV 4183 Z4 5958
RR, RS
R2 4581 ZQ 6555
R2, R3, R4
R3 4539 ZR 6305
R4 4364 ZS 6060
YW, YX
R5 4418 Z1 7175
Y8, Y9
R6 4137 Z2 6805
R7 4398 Z3 6400
SQ 4929 Z4 6150
SS 4626
SV SQ, SR, SS 4412
S3 S2, S3, S4 4817
S5 4688
S7 4639

28 JOHNSON CONTROLS
 FORM 160.75-O1

CHECKING THE REFRIGERANT CHARGE

DURING UNIT SHUTDOWN
The refrigerant charge is specified for each chiller model condenser and evaporator. This would be expected to be
(See Table 3). Charge the correct amount of refrigerant 4 hours or more after the compressor and water pumps
and record the level in the evaporator sight glass. are stopped. The level should visible in the sight glass.

The refrigerant charge should always be checked and Charge the refrigerant in accordance with the method
trimmed when the system is shut down. shown under the “Refrigerant Charging”, above. The
refrigerant level should be observed and the level re-
The refrigerant charge level must be checked after the corded after initial charging.
pressure and temperature have equalized between the

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 / compressor while making
any necessary repairs.

MEGGING THE MOTOR
While the main disconnect switch and compressor motor 2. If readings fall below shaded area, remove external
starter are open, meg the motor as follows: leads from motor and repeat test.

1. Using a megohm meter (megger), meg between Motor is to be megged with the starter
phases and each phase to ground (See Fig. 11); these at ambient temperature after 24 hours
readings are to be interpreted using the graph shown of idle standby.
in Fig. 12.

LD00475
FIG. 11 – DIAGRAM, MEGGING MOTOR WINDINGS

JOHNSON CONTROLS 29
 Maintenance
FORM 160.75-O1

Minimum Insulation Resistance vs. Temperature (per IEEE Std 43)

Open Motors

MEGOHMS

LD00476
TEMPERATURE – °f

FIG. 12 – MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES

30 JOHNSON CONTROLS
 FORM 160.75-O1

CONDENSERS AND EVAPORATORS
GENERAL TUBE FOULING

Maintenance 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 1. Rust or sludge – which finds its way into the tubes
clean and free from scale. Proper maintenance such as and accumulates there. This material usually does not
tube cleaning, and testing for leaks, is covered on the build up on the inner tube surfaces as scale, but does
following pages. interfere with the heat transfer. Rust or sludge can
generally be removed from the tubes by a thorough
CHEMICAL WATER TREATMENT brushing process.
2. Scale – due to mineral deposits. These deposits, even
Since the mineral content of the water circulated through
though very thin and scarcely detectable upon phys-
evaporators and condensers varies with almost every
ical inspection, are highly resistant to heat transfer.
source of supply, it is possible that the water being used
They can be removed most effectively by circulating
may corrode the tubes or deposit heat resistant scale in
an acid solution through the tubes.
them. Reliable water treatment companies are available
in most larger cities to supply a water treating process TUBE CLEANING PROCEDURES
which will greatly reduce the corrosive and scale form-
Brush Cleaning of Tubes
ing properties of almost any type of water.
If the tube consists of dirt and sludge, it can usually be
As a preventive measure against scale and corrosion and removed by means of the brushing process. Drain the
to prolong the life of evaporator and condenser tubes, a water sides of the circuit to be cleaned (cooling water
chemical analysis of the water should be made preferably or chilled water) remove the heads and thoroughly clean
before the system is installed. A reliable water treatment each tube with a soft bristle bronze or nylon brush. DO
company can be consulted to determine whether water NOT USE A STEEL BRISTLE BRUSH. A steel brush
treatment is necessary, and if so, to furnish the proper may damage the tubes.
treatment for the particular water condition.
Improved results can be obtained by admitting water into
the tube during the cleaning process. This can be done by
CLEANING EVAPORATOR AND CONDENSER TUBES mounting the brush on a suitable length of 1/8" pipe with a
few small holes at the brush end and connecting the other
Evaporator end by means of a hose to the water supply.
It is difficult to determine by any particular test whether 6
possible lack of performance of the water evaporator The tubes should always be brush cleaned before acid
is due to fouled tubes alone or due to a combination cleaning.
of troubles. Trouble which may be due to fouled tubes
ACID CLEANING OF TUBES
is indicated when, over a period of time, the cooling
capacity decreases and the split (temperature differ- If the tubes are fouled with a hard scale deposit, they
ence between water leaving the evaporator and the may require acid cleaning. It is important that before acid
refrigerant temperature in the evaporator) increases. A cleaning, the tubes be cleaned by the brushing process
gradual drop-off in cooling capacity can also be caused described above. If the relatively loose foreign material
by a gradual leak of refrigerant from the system or by a is removed before the acid cleaning, the acid solution will
combination of fouled tubes and shortage of refrigerant have less material to dissolve and flush from the tubes
charge. An excessive quantity of oil in the evaporator with the result that a more satisfactory cleaning job will
can also contribute to erratic performance. be accomplished with a probable saving of time.

Condenser
Acid cleaning should only be performed
In a condenser, trouble due to fouled tubes is usually by an expert. Please consult your local
indicated by a steady rise in head pressure, over a period water treatment representative for as-
of time, accompanied by a steady rise in condensing sistance in removing scale buildup and
temperature, and noisy operation. These symptoms may preventative maintenance programs to
also be due to foul gas buildup. Purging will remove the eliminate future problems.
foul gas revealing the effect of fouling.

JOHNSON CONTROLS 31
 Maintenance
FORM 160.75-O1

COMMERCIAL ACID CLEANING 3. With nitrogen or dry air, blow out the tubes to clear
them of traces of refrigerant laden moisture from the
In many major cities, commercial organizations now circulation water. As soon as the tubes are clear, a
offer a specialized service of acid cleaning evaporators cork should be driven into each end of the tube. Pres-
and condensers. If acid cleaning is required, YORK surize the dry system with 50 to 100 PSIG (345 to
recommends the use of this type of organization. The 690 kPa) of nitrogen. Repeat this with all of the other
Dow Industries Service Division of the Dow Chemical tubes in the suspected section or, if necessary, with
Company, Tulsa, Oklahoma, with branches in principal all the tubes in the evaporator or condenser. Allow
cities is one of the most reliable of these companies. the evaporator or condenser to remain corked up to
12 to 24 hours before proceeding. Depending upon
TESTING FOR EVAPORATOR AND CONDENSER the amount of leakage, the corks may blow from the
Tube Leaks end of a tube, indicating the location of the leakage.
If not, if will be necessary to make a very thorough
Evaporator and condenser tube leaks in R-134a systems test with the leak detector.
may result in refrigerant leaking into the water circuit,
or water leaking into the shell depending on the pres-
4. After the tubes have been corked for 12 to 24 hours,
sure levels. If refrigerant is leaking into the water, it
it is recommended that two men working at both
can be detected at the liquid head vents after a period
ends of the evaporator carefully test each tube – one
of shutdown. If water is leaking into the refrigerant,
man removing corks at one end and the other at the
system capacity and efficiency will drop off sharply. If
opposite end to remove corks and handle the leak
a tube is leaking and water has entered the system, the
detector. Start with the top row of tubes in the sec-
evaporator and condenser should be valved off from
tion being investigated. Remove the corks at the ends
the rest of the water circuit and drained immediately to
of one tube simultaneously and insert the exploring
prevent severe rusting and corrosion. The refrigerant
tube for 5 seconds – this should be long enough to
system should then be drained and purged with dry ni-
draw into the detector any refrigerant gas that might
trogen to prevent severe rusting and corrosion. If a tube
have leaked through the tube walls. A fan placed at
leak is indicated, the exact location of the leak may be
the end of the evaporator opposite the detector will
determined as follows:
assure that any leakage will travel through the tube
to the detector.
1. Remove the heads and listen at each section of tubes
for a hissing sound that would indicate gas leakage.
This will assist in locating the section of tubes to be 5. Mark any leaking tubes for later identification.
further investigated. If the probable location of the
leaky tubes has been determined, treat that section in 6. If any of the tube sheet joints are leaking, the leak
the following manner (if the location is not definite, should be indicated by the detector. If a tube sheet
all the tubes will require investigations). leak is suspected, its exact location may be found
by using a soap solution. A continuous buildup of
2. Wash off both tube heads and the ends of all tubes bubbles around a tube indicates a tube sheet leak.
with water.

Do not use carbon tetrachloride for

this purpose since its fumes give the
same flame discoloration that the re-
frigerant does.

32 JOHNSON CONTROLS
 FORM 160.75-O1

COMPRESSOR
Maintenance for the compressor assembly consists of or Low Oil Pressure (OP), change the oil filter element.
checking the operation of the oil return system and chang- Examine the oil filter element for the presence of alumi-
ing the dehydrator, checking and changing the oil, check- num particles. Aluminum gas seal rings can contact the
ing and changing the oil filters, checking the operation of impeller and account for some aluminum particles to
the oil heater, checking the operation of the oil pump, and accumulate in the oil filter, especially during the initial
observing the operation of the compressor. start up and first several months of operation. However,
if aluminum particles continue to accumulate and the
Internal wearing of compressor parts could be a serious
same conditions continue to stop the unit operation after
problem caused by improper lubrication, brought about
a new filter is installed, notify the nearest Johnson Con-
by restricted oil lines, passages, or dirty oil filters. If the
trols office to request the presence of a Johnson controls
unit is shutting down on (HOT) High Oil Temperature
Service Technician.

ELECTRICAL CONTROLS

For information covering the OptiView™ Con-

trol Center operation, refer to Form 160.54-O1.

JOHNSON CONTROLS 33
 Preventive Maintenance
FORM 160.75-O1

SECTION 7
PREVENTIVE MAINTENANCE
It is the responsibility of the owner to provide the nec- Frames 284T thru 587UZ are furnished with double
essary daily, monthly and yearly maintenance require- shielded or open ball or roller bearings. It is necessary
ments of the system. to re-lubricate anti-friction bearings periodically.
(See Table 4)
IMPORTANT – If a unit failure occurs
due to improper maintenance during the tABLE 4 – BEARING LUBRICATION
warranty period; Johnson Controls will Frame Standard Continuous Grease
not be liable for costs incurred to return Size 8hr/Day 24hr Day Qty. oz.
the system to satisfactory operation. 143T-256T *7 Years *3 Years *1
284TS - 286TS 210 Days 70 Days 1
In any operating system it is most important to provide
324TS - 587USS 150 Days 50 Days 2
a planned maintenance and inspection of its functioning
parts to keep it operating at its peak efficiency. Therefore,
the following maintenance should be performed when * - On frame sizes 143T - 256T, changing bearings at these intervals
prescribed. is recommended. However, removing the seal, cleaning and refilling
the bearing and the cavity with recommended grease can re-lubricate
these bearings.
COMPRESSOR
1. Oil Filter – When oil pump VSD frequency increases Recommended greases for standard applications:
to 55 hz to maintain target oil pressure. OPERATING AMBIENT TEMP. -30ºC to 50ºC
When the oil filter is changed, it should be inspected Chevron SRI (Chevron)
thoroughly for any aluminum particles which would Exxon Unirex #2 (Exxon Corp.)
indicate possible bearing wear. If aluminum particles Exxon Polyrex (Exxon Corp.)
are found this should be brought to the attention of
Shell Dolum R (Shell Oil Co.)
the nearest Johnson Controls office for their further
investigation and recommendations.
2. Oil Changing – The oil in the compressor must be Westinghouse Motor Lubrication:
changed annually or earlier if it becomes dark or • Re-greasing should occur at 1000 operating hour
cloudy. However, quarterly oil analysis can eliminate intervals.
the need for an annual change provided the analysis • Westinghouse recommends using Westinghouse
indicates there is no problem with the oil. Grease No. 53701.
• Motors with shaft diameters less than 2 3/8 inch
COMPRESSOR MOTOR
require 1 oz of grease per bearing while motors with
1. Check motor mounting screws frequently to insure shaft diameters between 2 3/8 and 3 inches require
tightness. 1.5 oz.
2. Meg motor windings annually to check for dete-
rioration of windings. Mixing different greases is not
recommended
Greased Bearings

Motor Operation and Maintenance manuals are supplied

with the chillers providing maintenance schedules and
instructions for the specific motors. The following are Additional information on motor lubri-
lubrication schedules for the most common motors: cation and other service issues can be
found in the A-C Motors Instruction
RAM Motor Lubrication Manual.
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 standard conditions.
34 JOHNSON CONTROLS
 FORM 160.75-O

LEAK TESTING OIL RETURN SYSTEM

The unit should be leak tested monthly. Any leaks found 1. Change the dehydrator in the oil return system semi-
must be repaired immediately. annually or earlier if the oil return system fails to
operate.
EVAPORATOR AND CONDENSER
The major portion of maintenance on the condenser and 2. When the dehydrator is changed, the nozzle of the
evaporator will deal with the maintaining the water side eductor should be checked for any foreign particles
of the condenser and evaporator in a clean condition. that may be obstructing the jet.

The use of untreated water in cooling towers, closed ELECTRICAL CONTROLS

water systems, etc. frequently results in one or more of
the following: 1. All electrical controls should be inspected for ob-
1. Scale Formation. vious malfunctions.
2. Corrosion or Rusting. 2. It is important that the factory settings of controls
3. Slime and Algae Formation. (operation and safety) not be changed. If the settings
are changed without Johnson Controls approval, the
It is therefore to the benefit of the user to provide for
warranty will be jeopardized.
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 condenser liquid temperature is more than
4°F (2°C) greater than the difference recorded on a
new unit, it is a good indication 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- 7
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 there may be a water bypass in the water box
requiring gasket replacement or refrigerant may have
leaked from the chiller.
3. Heat recovery condenser tubes should be evaluated
similiar to evaporator tubes when the heating circuit
is a treated, closed loop. Fouling could be detected as
ability to meet heat load requirements decreases.

JOHNSON CONTROLS 35
 FORM 160.75-O1

SI metric conversion

36 JOHNSON CONTROLS
 MAINTENANCE REQUIREMENTS FOR YORK YK CHILLERS

JOHNSON CONTROLS
PROCEDURE DAILY WEEKLY MONTHLY YEARLY OTHER

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
Perform oil analysis on compressor lube oil1 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 manufacturer’s 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 160.75-O1

Form 160.54-MR1 (801)

37
LD13598
 FORM 160.75-O1

NOTES

38 JOHNSON CONTROLS
 FORM 160.75-O1

NOTES

JOHNSON CONTROLS 39
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2009 www.york.com ALL RIGHTS RESERVED
Form 160.75-O1
Supersedes: 160.75-O1