Johnson Controls York YKEP, Operation And Maintenance

Page 1: ...LD15101 CENTRIFUGAL LIQUID CHILLER WITH ECONOMIZER COMPRESSOR OPERATION AND MAINTENANCE Supersedes 160 77 O1 1111 Form 160 77 O1 1020 R 134a Issue Date October 22 2020 MODEL YKEP 2700 3200 TON...

Page 2: ...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 th...

Page 3: ...ior to performing any work on the chiller ASSOCIATED LITERATURE MANUAL DESCRIPTION FORM NUMBER YKEP Installation Re assembly 160 77 N1 YKEP Unit Operation Maintenance 160 77 O1 YKEP Control Center Ope...

Page 4: ...c needs for the chiller operating conditions and annualized impact realized by the chiller Your lo cal Johnson Controls Branch can propose a customized Planned Service Agreement that leverages real ti...

Page 5: ...vice 18 Stopping The System 18 Prolonged Shutdown 18 SECTION 3 MAINTENANCE 19 Renewal Parts 19 Oil Return System 19 Checking System For Leaks 21 Conducting An R 22 Pressure Test 22 Vacuum Testing 23 V...

Page 6: ...am 13 FIGURE 6 Oil Livel Indicator 15 FIGURE 7 Liquid Chiller Log Sheets 17 FIGURE 8 Oil Return System 19 FIGURE 9 Charging Oil Reservoir With Oil 20 FIGURE 10 Evacuation of Chiller 21 FIGURE 11 Satur...

Page 7: ...city COMPONENTS YKEP chillers are equipped with Single Stage Flash Economizer Primary Compressor K7 Model YDHA119 Economizer Compressor Q3 Model HF416 YORK Unit Mounted Low Voltage Solid State Starter...

Page 8: ...plied by the customer Available YORK starters include a Floor Mounted Medium Voltage Variable Speed Drive MV VSD Figure 3 on Page 8 and a Unit Mounted MV SSS Figure 4 on Page 8 Customer supplied start...

Page 9: ...t load ef ficiency by analyzing information fed to it by sensors located throughout the chiller Operational information for the VSD can be found in MV VSD 2300v 6600v Operation Form 160 00 O6 and MV V...

Page 10: ...sig 16 2 barg Water Boxes The removable water boxes are fabricated of steel The design working pressure is 150 psig 10 3 barg and the boxes are tested at 225 psig 15 5 barg Integral steel water baffle...

Page 11: ...a combination of prerotation vanes PRV located at the entrance to the compressor impeller op tional hot gas bypass and variable compressor speed to control capacity The position of the vanes is automa...

Page 12: ...high pressure re frigerant vapor rejects heat to the cooling liquid that is passing through the tubes The cooling liquid will reject its heat to the environment in a cooling tower When the refrigerant...

Page 13: ...JOHNSON CONTROLS 13 FORM 160 77 O1 ISSUE DATE 10 22 2020 Section 1 System Fundamentals Figure 5 YKEP SYSTEM FLOW DIAGRAM LD15103 1 2 3 4 5 1...

Page 14: ...FORM 160 77 O1 ISSUE DATE 10 22 2020 JOHNSON CONTROLS 14 This page intentionally left blank...

Page 15: ...rging Procedure page 20 Always comply with EPAand Local regu lations when removing or disposing of Refrigeration System Oil Figure 6 OIL LIVEL INDICATOR LD08647 PRE STARTING Prior to starting the chil...

Page 16: ...temperature Pressure and motor current overrides also apply as necessary to maintain operating limits CONDENSERWATERTEMPERATURECONTROL The YKEP chiller is designed to use less power by tak ing advant...

Page 17: ...3 Inspect the Compressor Drive Motors see motor manufacturers maintenance and service instruc tion supplied with the unit a Meg motor windings Refer to Figure 12 on Page 26 for details 4 Inspect and...

Page 18: ...ll er is not running brine should not be run through the evaporator However if there is brine running through the evaporator there must be flow through the condenser to prevent tubes from freezing 3 O...

Page 19: ...inducing 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 procedure 1 Iso...

Page 20: ...onnection to the oil charg ing valve located on the remote oil reservoir cover plate see Figure 8 on Page 19 Do not tighten the connection at the charging valve until after the air is forced out by pu...

Page 21: ...at section in the fol lowing manner if the location is not definite all the tubes will need to be checked 2 Wash off both tube heads and the ends of all tubes with water Do not use carbon tetrachlorid...

Page 22: ...ely 75 to 100 PSIG 517 to 690 kPa To be sure that the concentration of refrigerant has reached all parts of the system test for the pres ence of refrigerant with a leak detector at an ap propriate ser...

Page 23: ...f gauge plus atmospheric pressure Water Freezes bulb temperature of 32 F 0 C or a pressure of 5 mm Hg is reached Refer to Table 1 on Page 23 for corresponding pressure values 4 To improve evacuation c...

Page 24: ...le vacuum on the system OPERATION Dehydration of a refrigerant system can be obtained by this method because the water present in the sys tem reacts similar to refrigerant By pulling down the pressure...

Page 25: ...the freezing point is 29 PSIG 200 kPa for R 134a at sea level While charging every precaution must be taken to pre vent moisture laden air from entering the system Fab ricate a suitable charging conn...

Page 26: ...um during the megging procedure CONDENSERS AND EVAPORATORS Maintenance of condenser and evaporator shells is im portant to provide trouble free operation of the chiller The water side of the tubes in...

Page 27: ...JOHNSON CONTROLS 27 FORM 160 77 O1 ISSUE DATE 10 22 2020 Section 3 Maintenance Figure 13 MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES LD00476 3...

Page 28: ...chilled water remove the heads and thoroughly clean each tube with a soft bristle bronze or nylon brush DO NOT USE A STEEL BRISTLE BRUSH A steel brush may damage the tubes Improved results can be obta...

Page 29: ...er side of the condenser and evaporator in a clean condi tion The use of untreated water in cooling towers closed water systems etc frequently results in one or more of the following Scale Formation C...

Page 30: ...nalysis 1 X Perform vibration analysis X Clean tubes X 2 Perform Eddy current testing and inspect tubes 2 5 Years Lubricate motor Refer to motor manufacturer s recommendations 1 2 MAINTENANCE REQUIREM...

Page 31: ...rough the condenser to proper value Abnormally Low Suction Pressure Temperature difference between leaving chilled water and refrigerant in evapo rator greater than normal with high discharge temperat...

Page 32: ...y inlet Check oil inlet for blockage Symptom Oil Pressure Gradually Decreases Noted by Observation of Daily Log Sheets When oil pump VSD frequency in creases to 55 hz to maintain target oil pressure O...

Page 33: ...elsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 4 ANALOG INPUT RANGES LOW PRESSURE CHILLERS MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity...

Page 34: ...ennsylvania USA 17349 Subject to change without notice Printed in USA Copyright by Johnson Controls 2020 ALL RIGHTS RESERVED Form 160 77 O1 1020 Issue Date October 22 2020 Supersedes 160 77 O1 1111 1...