Johnson Controls York OptiView YK G Series, Operation And Maintenance

Page 1: ...O1 621 Supersedes 160 75 O1 820 Operations and Maintenance Issue Date 2021 06 05 Model YK Style G R 134a or R 513A with OptiView Control Center for Electromechanical Starter Solid State Starter and Va...

Page 2: ...2 Model YK Style G R 134a or R 513A...

Page 3: ...ter temperature control 15 Operating log sheet 15 Operating inspections 16 Need for maintenance or service 17 Stopping the system 18 Prolonged shutdown 18 System components description 19 General 19 C...

Page 4: ...34 Checking the refrigerant charge during unit shutdown 35 Handling refrigerant for dismantling and repairs 35 Megging the motor mechanical starter 36 Megging the motor VFD powered or solid state sof...

Page 5: ...is expected that these individuals possess independent training that enables them to perform their assigned tasks correctly and safely It is essential that prior to performing any task on this equipm...

Page 6: ...operating and service personnel to verify the applicability of these documents to the equipment If there is any question regarding the applicability of these documents rigging lifting and operating an...

Page 7: ...mote Medium Voltage VSD 160 75 PW8 Renewal Parts Unit 160 75 RP1 Renewal Parts OptiView Control Center 160 54 RP1 Conditioned based maintenance Traditional chiller maintenance is based upon assumed an...

Page 8: ...ting status temperatures pressures and other information pertinent to operation of the chiller are automatically displayed and read on a graphic display Other displays can be observed by pressing the...

Page 9: ...nt which would be evaporated at full load design conditions However most systems are called upon to deliver full load capacity for only a relatively small part of the time the unit is in operation Cap...

Page 10: ...Figure 3 Refrigerant flow through chiller falling film evaporator Model YK Style G R 134a or R 513A 10...

Page 11: ...Figure 4 Refrigerant flow through chiller flooded evaporator 11 Model YK Style G R 134a or R 513A...

Page 12: ...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 control center component failure the oil heater thermostat 1...

Page 13: ...he control center does not allow the chiller to start unless chilled liquid flow is established through the unit If the chilled liquid pump is wired to the microcomputer control center the pump starts...

Page 14: ...utdowns Refer to Display Messages in the manual OptiView Control Center Operation and Maintenance Form 160 54 O1 Figure 7 Chiller starting sequence and shutdown sequence variable speed drive Note Not...

Page 15: ...ooling sources other than evaporative air exchange methods such as wells bodies of water and chilled water The temperature control valve should be the type to open on increasing drive coolant temperat...

Page 16: ...ance procedure the operator can avoid serious operating difficulty The following list of inspections and procedures should be used as a guide Figure 8 Liquid chiller log sheets Note These items can be...

Page 17: ...ssary 1 Drain and replace the oil in the compressor oil sump See Oil charging procedure 2 Evaporator and condenser a Inspect and clean the water strainers b Inspect and clean the tubes as required c I...

Page 18: ...n About this task If the chiller is to be shut down for an extended period of time for example over the winter season complete the following steps 1 Test all of the system joints for refrigerant leaks...

Page 19: ...anes PRV modulate chiller capacity from 100 to as low as 15 of design for normal air conditioning applications Operation is by an external electric PRV actuator which automatically controls the vane p...

Page 20: ...tem internally in the compressor It provides an oil supply to the various bearings and gears in the event of a system shutdown due to a power failure The reservoir located on the top of the compressor...

Page 21: ...Figure 10 System components rear view 21 Model YK Style G R 134a or R 513A...

Page 22: ...Figure 11 Schematic drawing YK compressor lubrication system Model YK Style G R 134a or R 513A 22...

Page 23: ...ed type The evaporator is a shell and tube type with customer process fluid flowing inside the tubes and refrigerant removing heat on the shell side through evaporation Evaporator codes A to K utilize...

Page 24: ...the vane motor end switch VMS opens when entering SYSTEM RUN if the actual level is less than the level setpoint a linearly increasing ramp is applied to the level setpoint This ramp causes the setpoi...

Page 25: ...lled The starter enclosure is NEMA 1 with a hinged access door with lock and key Electrical lugs for incoming power wiring are provided Variable speed drive optional A variable speed drive can be fact...

Page 26: ...o change the dehydrator use the following procedure 1 Isolate the dehydrator at the stop valves 2 Remove the dehydrator See Figure 12 3 Assemble the new filter drier 4 Open evaporator stop valve and c...

Page 27: ...late See Figure 13 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 be...

Page 28: ...antity of water through the condenser to correct value 2 Symptom Abnormally low suction pressure Insufficient charge of refrigerant Check for leaks and charge refrigerant into system Temperature diffe...

Page 29: ...il pressure Transducer defective Replace low or high oil pressure transducer 6 Symptom Oil pump vibrates or is noisy Oil not reaching pump suction inlet in sufficient quantity Check oil level Oil pump...

Page 30: ...ing Jet or orifice of oil return jet clogged Remove jet inspect for dirt Remove dirt using solvent and replace 10 Symptom Oil pump fails to deliver oil pressure No oil pressure registers when pressing...

Page 31: ...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...

Page 32: ...0 00 50 000 101 28 9400 in 481 25 00 25 000 78 29 5300 in 192 10 00 10 000 52 29 6700 in 122 6 30 6 300 40 29 7200 in 099 5 00 5 000 35 29 8420 in 039 2 00 2 000 15 29 8820 in 019 1 00 1 000 1 29 901...

Page 33: ...imits specified in Step 6 above the leak must be found and repaired Note Be sure the vacuum indicator is valved off while holding the system vacuum and be sure to open the valve between the vacuum ind...

Page 34: ...isters this temperature or pressure it is a positive sign that the system is evacuated and dehydrated to the correct limit If this level cannot be reached it is evidence that there is a leak somewhere...

Page 35: ...tem is shut down The refrigerant charge level must be checked after the pressure and temperature have equalized between the condenser and evaporator This would be expected to be 4 hours or more after...

Page 36: ...with the starter at ambient temperature after 24 hours of idle standby Figure 16 Megging the motor windings mechanical starter Megging the motor VFD powered or solid state soft starter 1 Disconnect p...

Page 37: ...the condenser and evaporator shells is important to provide trouble free operation of the chiller The water side of the tubes in the shell must be kept clean and free from scale Correct maintenance su...

Page 38: ...evaporator can also contribute to erratic performance Condenser In a condenser trouble due to fouled tubes is usually indicated by a steady rise in head pressure over a period of time accompanied by a...

Page 39: ...red the system the evaporator and condenser should be valved off from the rest of the water circuit and drained immediately to prevent severe rusting and corrosion The refrigerant system should then b...

Page 40: ...king the operation of the oil return system and changing the dehydrator checking and changing the oil checking and changing the oil filters checking the operation of the oil heater checking the operat...

Page 41: ...sis indicates there is no problem with the oil Compressor motor 1 Check the motor mounting screws frequently to insure tightness 2 Meg the motor windings annually to check for any deterioration of the...

Page 42: ...y leaks found immediately Evaporator and condenser The major portion of the maintenance of the condenser and evaporator involves maintaining the water side of the condenser and evaporator in a clean c...

Page 43: ...n the heating circuit is a treated closed loop Fouling could be detected as the ability to meet heat load requirements decreases Oil return system 1 Change the dehydrator in the oil return system semi...

Page 44: ...mm Weight Pounds lb 0 4536 Kilograms kg Velocity Feet Second fps 0 3048 Meters Second m s Feet of Water ft 2 989 Kilopascals kPa Pressure Drop Pounds Square Inch psi 6 895 Kilopascals kPa Temperature...