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MODEL YK (STYLE G)
R-134a
WITH OPTIVIEWTM CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER AND VARIABLE SPEED DRIVE
LD15222
FORM 160.75-O1 (211)
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During installation, operation maintenance or service, 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
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 posseses independent training that will enable
potential, if misused or handled improperly, to cause them to perform their assigned tasks properly and safe-
bodily injury or death. It is the obligation and respon- ly. It is essential that, prior to performing any task on
sibility of operating/service personnel to identify and this equipment, this individual shall have read and un-
recognize these inherent hazards, protect themselves, derstood this document and any referenced materials.
and proceed safely in completing their tasks. Failure This individual shall also be familiar with and comply
to comply with any of these requirements could result with all applicable governmental standards and regula-
in serious damage to the equipment and the property in tions pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
External wiring, unless specified as an optional connection in the manufacturers product line, is
not to be connected inside the OptiView cabinet. Devices such as relays, switches, transducers and
controls and any external wiring must not be installed inside the micro panel. All wiring must be in
accordance with Johnson Controls published specifications and must be performed only by a qualified
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warning
will void the manufacturers warranty and cause serious damage to property or personal injury.
2 JOHNSON CONTROLS
FORM 160.75-O1 (211)
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Variable Speed Drive Operation 160.00-O1
Solid State Starter Operation and Maintenance 160.00-O2
Floor Mounted MV SSS Operation 160.00-O5
Unit Mounted MV SSS Operation 160.00-O7
Installation Unit 160.75-N1
Optiview Control Center Operation and Maintenance 160.54-O1
Wiring Diagram Field Connections for YK Chiller (Style G) OptiView Control Center with Remote Low
160.75-PW1
or Medium Voltage EMS or Unit Mounted Low or Medium Voltage SSS
Wiring Diagram Field Connections for YK Chiller (Style G) OptiView Control Center with Remote
160.75-PW2
Medium Voltage SSS
Wiring Diagram Field Connections for YK Chiller (Style G) OptiView Control Center with Remote
160.75-PW3
Medium Voltage VSD
Wiring Diagram Field Control Modifications for YK Chiller (Style G) 160.75-PW4
Wiring Diagram YK Chiller (Style G) OptiView Control Center with Remote Low or Medium Voltage EMS 160.75-PW5
Wiring Diagram YK Chiller (Style G) OptiView Control Center with Unit Mounted Low or Medium
160.75-PW6
Voltage SSS, Unit Mounted Low Voltage VSD with Modbus, or Remote Medium Voltage VSD
Wiring Diagram YK Chiller (Style G) OptiView Control Center with LTC I/O Board with Remote Low or
160.75-PW7
Medium Voltage EMS
Wiring Diagram YK Chiller (Style G) OptiView Control Center w/ LTC I/O Board with Unit Mounted Low
160.75-PW8
or Medium Voltage SSS, Unit Mounted Low Voltage VSD with Modbus or Remote Medium Voltage VSD
Renewal Parts Unit 160.75-RP1
Renewal Parts OptiView Control Center 160.54-RP1
JOHNSON CONTROLS 3
FORM 160.75-O1 (211)
NOMENCLATURE
YK KC K4 H9 CY G
MOTOR CODE
POWER SUPPLY
for 60 Hz
5 for 50 Hz
COMPRESSOR CODE*
CONDENSER CODE*
EVAPORATOR CODE*
* Refer to YK Engineering Guide for (Form 160.75-EG1)
MODEL* Shell/Motor/Compressor combinations.
4 JOHNSON CONTROLS
FORM 160.75-O1 (211)
TABLE OF CONTENTS
JOHNSON CONTROLS 5
FORM 160.75-O1 (211)
LIST OF FIGURES
FIGURE 1 - Model YK Chiller ..................................................................................................................................... 7
FIGURE 2 - Compressor Prerotation Vanes .............................................................................................................. 8
FIGURE 3 - Refrigerant Flow-Thru Chiller (Falling Film Evaporator)......................................................................... 9
FIGURE 4 - Refrigerant Flow-Thru Chiller (Flooded Evaporator) ............................................................................ 10
FIGURE 5 - Oil Level Indicator ................................................................................................................................. 11
FIGURE 6 - Chiller Starting Sequence And Shutdown Sequence (Em Starter And Solid State Starter) ................. 12
FIGURE 7 - Chiller Starting Sequence And Shutdown Sequence (Variable Speed Drive)...................................... 12
FIGURE 8 - Liquid Chiller Log Sheets ..................................................................................................................... 14
FIGURE 9 - System Components Front View .......................................................................................................... 18
FIGURE 10 - System Components Rear View ........................................................................................................ 19
FIGURE 11 - Schematic Drawing (YK) Compressor Lubrication System ............................................................. 20
FIGURE 12 - Oil Return System .............................................................................................................................. 23
FIGURE 13 - Charging Oil Reservoir With Oil ......................................................................................................... 24
FIGURE 14 - Evacuation Of Chiller .......................................................................................................................... 27
FIGURE 15 - Saturation Curve ................................................................................................................................ 29
FIGURE 16 - Diagram, Megging Motor Windings .................................................................................................... 30
FIGURE 17 - Motor Starter Temperature And Insulation Resistances ..................................................................... 31
LIST OF TABLES
TABLE 1 - Operation Analysis Chart ...................................................................................................................... 25
TABLE 2 - System Pressures ................................................................................................................................. 28
TABLE 3 - Bearing Lubrication ............................................................................................................................... 35
6 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SYSTEM OPERATION DESCRIPTION nent to operation of the chiller are automatically dis-
played and read on a graphic display. Other displays
The YORK Model YK Chiller is commonly applied
to large air conditioning systems, but may be used
can be observed by pressing the keys as labeled on the 1
Control Center. The chiller with the OptiView Control
on other applications. The chiller consists of an open
Center is compatible with an electro-mechanical start-
motor mounted to a compressor (with integral speed
er, YORK Solid State Starter (optional), or Variable
increasing gears), condenser, evaporator and variable
Speed Drive (optional).
flow control.
In operation, a liquid (water or brine to be chilled)
The chiller is controlled by a modern state of the art
flows through the evaporator, where boiling refrigerant
Microcomputer Control Center that monitors its opera-
absorbs heat from the liquid. The chilled liquid is then
tion. The Control Center is programmed by the opera-
piped to fan coil units or other air conditioning terminal
tor to suit job specifications. Automatic timed start-ups
units, where it flows through finned coils, absorbing
and shutdowns are also programmable to suit night-
heat from the air. The warmed liquid is then returned to
time, weekends, and holidays. The operating status,
the chiller to complete the chilled liquid circuit.
temperatures, pressures, and other information perti-
COMPRESSOR
CONTROL
CENTER
MOTOR
CONDENSER
LD15222
EVAPORATOR
JOHNSON CONTROLS 7
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION FORM 160.75-O1 (211)
CAPACITY CONTROL
The major components of a chiller are selected for full
load capacities, therefore capacity must be controlled
to maintain a constant chilled liquid temperature leav-
ing the evaporator. Prerotation vanes (PRV), located at
the entrance to the compressor impeller, compensate
for variation in load (Refer to Figure 2 on Page 8).
7619A(D)
8 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
LEGEND 1
High Pressure Vapor
COMPRESSOR
SUCTION
EVAPORATOR
CONDENSER
SUCTION
BAFFLE
LIQUID LEVEL
LIQUID LEVEL
SUB-COOLER
OPTIONAL
ISOLATION LD00924A
VALVE
JOHNSON CONTROLS 9
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION FORM 160.75-O1 (211)
LEGEND
High Pressure Vapor
COMPRESSOR
SUCTION
OPTIONAL
ISOLATION
VALVE MESH ELIMINATORS or
SUCTION BAFFLE
EVAPORATOR
CONDENSER
LIQUID LEVEL
LIQUID LEVEL
SUB-COOLER
10 JOHNSON CONTROLS
FORM 160.75-O1 (211)
START-UP
1. If the chilled water pump is manually operated,
start the pump. The Control Center will not al-
low the chiller to start unless chilled liquid flow is
established through the unit. If the chilled liquid
pump is wired to the Microcomputer Control Cen-
ter the pump will automatically start, therefore,
this step is not necessary.
2. To start the chiller, press the COMPRESSOR
START switch. This switch will automatically
spring return to the RUN position. (If the unit
was previously started, press the STOP/RESET
side of the COMPRESSOR switch and then press
the START side of the switch to start the chill-
LD08647 er.) When the start switch is energized, the Con-
FIGURE 5 - OIL LEVEL INDICATOR trol Center is placed in an operating mode and
any malfunction will be noted by messages on a
graphic display.
JOHNSON CONTROLS 11
SECTION 2 - SYSTEM OPERATING PROCEDURES FORM 160.75-O1 (211)
** Not for all shutdowns. Refer to Display Messages in manual Optiview Control Center Operation and Maintenance (Form 160.54-O1).
FIGURE 6 - CHILLER STARTING SEQUENCE AND SHUTDOWN SEQUENCE (EM STARTER AND SOLID
STATE STARTER)
** Not for all shutdowns. Refer to Display Messages in manual Optiview Control Center Operation and Maintenance (Form 160.54-O1).
FIGURE 7 - CHILLER STARTING SEQUENCE AND SHUTDOWN SEQUENCE (VARIABLE SPEED DRIVE)
12 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 2 - SYSTEM OPERATING PROCEDURES
For display messages and information pertaining to the such as a cooling tower bypass, is not necessary for
operation refer to Optiview Control Center Opera- most installations. The minimum entering condenser
tion and Maintenance (Form 160.54-O1). water temperature for full and part load conditions is
Any malfunctions which occur during specified in the chiller engineering guide.
STOP/RESET are also displayed. where:
% Load
Min. ECWT = LCWT C RANGE + 5F + 12 (
100 )
% Load
Min. ECWT = LCWT C RANGE + 2.8C + 6.6 ( )
100
However, the current draw (amperes) by the compres- Heat recovery chillers and chillers using optional head
sor motor is also limited to FLA setpoint by the micro- pressure control would use a signal provided by the
processor. microprocessor to control main condenser bundle heat
rejection or pressure, respectively.
If the load continues to decrease, after the Prerotation
Vanes are entirely closed, the chiller will be shut down OPERATING LOG SHEET
by the Leaving Chilled Liquid Low Temperature A permanent daily record of system operating condi-
Control. tions (temperatures and pressures) recorded at regular
The coolant temperature inside any JCI-supplied liq- intervals throughout each 24 hour operating period
uid-cooled motor starter must be maintained above the should be kept.
dewpoint temperature in the equipment room to pre- An optional status printer is available for this purpose
vent condensing water vapor inside the starter cabinet. or Figure 8 on Page 14 shows a log sheet used by
Therefore, an additional temperature-controlled throttle Johnson Controls Personnel for recording test data on
valve is needed in the flow path for the starter heat ex- chiller systems. It is available from the factory in pads
changer to regulate cooling above the equipment room of 50 sheets each under Form 160.44-F7 and may be
dewpoint for applications using cooling sources other obtained through the nearest Johnson Controls office.
than evaporative air-exchange methods, such as wells, Automatic data logging is possible by connecting the
bodies of water, and chilled water. The temperature optional printer and programming the DATA LOG-
control valve should be the type to open on increasing GER function.
drive coolant temperature, fail-closed, and set for a tem-
perature above dewpoint. It can be requested as factory- An accurate record of readings serves as a valuable ref-
supplied on a chiller order by special quotation. erence for operating the system. Readings taken when
a system is newly installed will establish normal condi-
CONDENSER WATER TEMPERATURE tions with which to compare later readings.
CONTROL
For example, an increase in condenser approach tem-
The YORK chiller is designed to use less power by tak- perature (condenser temperature minus leaving con-
ing advantage of lower than design temperatures that denser water temperature) may be an indication of
are naturally produced by cooling towers throughout dirty condenser tubes.
the operating year. Exact control of condenser water
JOHNSON CONTROLS 13
SECTION 2 - SYSTEM OPERATING PROCEDURES FORM 160.75-O1 (211)
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.
14 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 2 - SYSTEM OPERATING PROCEDURES
Annually (more often if necessary) 1. Push the soft shutdown key on the homescreen on
1. Drain and replace the oil in the compressor oil the OptiView panel or rapid stop with the COM-
sump. (Refer to Oil Charging Procedure on Page PRESSOR STOP/RESET switch. The compressor
24.) will stop automatically. The oil pump will contin-
ue to run for coastdown period. The oil pump will
2. Evaporator and Condenser. then stop automatically.
A. Inspect and clean water strainers. 2. Stop the chilled water pump (if not wired into the
B. Inspect and clean tubes as required. Microcomputer Control Center, in which case it
will shut off automatically simultaneously with the
C. Inspect end sheets. oil pump.) (The actual water pump contact opera-
3. Compressor Drive Motor (See motor manufactur- tion is dependent upon the position of Microboard
ers maintenance and service instruction supplied jumper J54.)
with unit) 3. Open the switch to the cooling tower fan motors,
A. Clean air passages and windings per manu- if used.
facturers instructions.
4. The compressor sump oil heater is energized when
B. Meg motor windings Refer to Figure 16 on the unit is stopped.
Page 30 for details.
2
C. Lubricate per motor manufacturer recom- PROLONGED SHUTDOWN
mendations.
If the chiller is to be shut down for an extended period
4. Inspect and service electrical components as neces- of time (for example, over the winter season), the fol-
sary. lowing paragraphs outline the procedure to be followed.
5. Perform refrigerant analysis.
1. Test all system joints for refrigerant leaks with a
If quarterly inspection indicates oil is fine, leak detector. If any leaks are found, they should
replacing the oil is not necessary be repaired before allowing the system to stand
for a long period of time.
During long idle periods, the tightness of the sys-
tem should be checked periodically.
16 JOHNSON CONTROLS
FORM 160.75-O1 (211)
JOHNSON CONTROLS 17
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION FORM 160.75-O1 (211)
OPTIVIEW CONTROL
CENTER
COMPRESSOR
SUCTION
RELIEF
VARIABLE
VALVES
SPEED
DRIVE
EVAPORATOR
LD15222
VARIABLE SPEED
SIGHT
OIL PUMP
GLASS
CONTROL BOX
FRONT VIEW
18 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
MOTOR
COMPRESSOR
DISCHARGE
LINE
LD15223
LIQUID LINE
CONDENSER OIL PUMP
HOUSING
REAR VIEW
JOHNSON CONTROLS 19
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION FORM 160.75-O1 (211)
COMPRESSOR ROTOR
SUPPORT SECTION
H.S.
SHAFT
SEAL
EMERGENCY
OIL RESERVE
HIGH
PRESSURE
TRANSDUCER
MAIN JOURNAL
AND THRUST
BEARING
IMPELLER
REFRIG.
SIGHT
HOT GLASSES
THERMISTOR
OIL OIL
HEATER COOLER
LOW OIL
ANGLE PRESSURE
DRAIN VALVE TRANSDUCER
OIL
LD15200
20 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
MOTOR DRIVELINE A 1-1/2" (38 mm) liquid level sight glass is conve-
niently located on the side of the shell to aid in deter-
The compressor motor is an open-drip-proof, squir-
mining proper refrigerant charge. The evaporator shell
rel cage, induction type constructed to YORK design
specifications. 60 hertz motors operate at 3570 rpm. 50
contains a dual refrigerant relief valve arrangement set 3
at 180 psig (12.4 barg) on H and K compressor models;
hertz motors operate at 2975 rpm.
235 psig (16.2 barg) on P and Q compressor models;
The open motor is provided with a D-flange, cast iron or single-relief valve arrangement, if the chiller is sup-
adapter mounted to the compressor and supported by a plied with optional refrigerant isolation valves. A 1"
motor support. mm) refrigerant charging valve is provided. The
condenser is a shell and tube type, with a discharge
Motor drive shaft is directly connected to the compres- gas baffle to prevent direct high velocity impingement
sor shaft with a flexible disc coupling. This coupling on the tubes. The baffle is also used to distribute the
has all metal construction with no wearing parts to as- refrigerant gas flow properly for most efficient heat
sure long life, and no lubrication requirements to pro- transfer. An optional cast steel condenser inlet diffuser
vide low maintenance. may be offered, on "M" and larger condensers, in lieu
For units utilizing remote Electro-Mechanical starters, of the baffle, to provide dynamic pressure recovery and
a terminal box is provided for field connected conduit. enhanced chiller efficiency. An integral sub-cooler is
Motor terminals are brought through the motor cas- located at the bottom of the condenser shell providing
ing into the terminal box. Jumpers are furnished for highly effective liquid refrigerant subcooling to pro-
three-lead type of starting. Motor terminal lugs are not vide the highest cycle efficiency. The condenser con-
furnished. Overload/over current transformers are fur- tains dual refrigerant relief valves set at 235 psig (16.2
nished with all units. barg).
The removable waterboxes are fabricated of steel. The
HEAT EXCHANGERS design working pressure is 150 psig (10.3 barg) and
Evaporator and condenser shells are fabricated from the boxes are tested at 225 psig (15.5 barg). Integral
rolled carbon steel plates with fusion welded seams. steel water baffles are located and welded within the
waterbox to provide the required pass arrangements.
Heat exchanger tubes are internally enhanced type. Stub-out water nozzle connections with ANSI/AWWA
The evaporator is a shell and tube type with customer C-606 grooves are welded to the waterboxes. These
process fluid flowing inside the tubes and refriger- nozzle connections are suitable for ANSI/AWWA C-
ant removing heat on the shell side via evaporation. 606 couplings, welding or flanges, and are capped
Evaporator codes A* to K* utilize a hybrid falling film for shipment. Plugged 3/4" (19 mm) drain and vent
design. It contains a balance of flooded and falling film connections are provided in each waterbox.
technology to optimize efficiency, minimize refriger-
JOHNSON CONTROLS 21
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION FORM 160.75-O1 (211)
22 JOHNSON CONTROLS
FORM 160.75-O1 (211)
COMPRESSOR
SOLENOID VALVE
CONDENSER
EVAPORATOR
SOLENOID VALVE
STOP VALVE
LD08578
JOHNSON CONTROLS 23
SECTION 4 - OPERATIONAL MAINTENANCE FORM 160.75-O1 (211)
THE OIL CHARGE ing valve (A) located on the remote oil reservoir
cover plate. (Refer to Figure 13 on Page 24) Do
The nominal oil charge for all H, K, and P8-P9 YK
not tighten the connection at the charging valve
compressors is 20 gallons, and for Q3-Q7 YK compres-
until after the air is forced out by pumping a few
sors is 10 gallons of type YORK K or YORK H oil.
strokes of the oil pump. This fills the lines with
New YORK Refrigeration oil must be used in the cen- oil and prevents air from being pumped into the
trifugal compressor. Since oil absorbs moisture when 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 reser-
voir is in the OVER FULL region of the oil level
OIL CHARGING PROCEDURE
indicator label. Close the charging valve and dis-
During operation the compressor oil level must be connect the hand oil pump.
maintained in the OPERATING RANGE identified
on the vertical oil level indicator. If the oil level falls 4. As soon as oil charging is complete, close the
into the lower sight glass, it is necessary to add oil to power supply to the starter to energize the oil
the compressor oil reservoir. The oil should be charged heater. This will keep the concentration of refrig-
into the oil reservoir using the YORK Oil Charging erant in the oil to a minimum.
Pump YORK Part No. 070-10654. To charge oil into When the oil reservoir is initially charged with oil, the
the oil reservoir, proceed as follows: oil pump should be started manually to fill the lines,
passages, oil cooler and oil filter. This will lower the
1. The unit must be shut down.
oil level in the reservoir. It may then be necessary to
2. Immerse the suction connection of the oil charging add oil to bring the level back into the OPERATING
pump in a clean container of new oil and connect RANGE of the oil level indicator label.
the pump discharge connection to the oil charg-
OIL
CHARGING
PUMP
LD08648 LD08579
OIL CHARGING VALVE
24 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 5 - TROUBLESHOOTING
JOHNSON CONTROLS 25
SECTION 5 - TROUBLESHOOTING FORM 160.75-O1 (211)
26 JOHNSON CONTROLS
FORM 160.75-O1 (211)
SECTION 6 - MAINTENANCE
6
EVACUATION AND DEHYDRATION OF UNIT
27385A(D)
STOP VALVE
CHARGING
VALVE
WET BULB TEMPERATURE
INDICATOR OR VACUUM GAUGE VACUUM PUMP
LD00949
JOHNSON CONTROLS 27
SECTION 6 - MAINTENANCE FORM 160.75-O1 (211)
*GAUGE ABSOLUTE
BOILING
INCHES OF TEMPERATURES
MERCURY (HG) OF
MILLIMETERS OF
BELOW ONE PSIA MICRONS
MERCURY (HG) WATER
STANDARD
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
WATER
29.842" .039 2. 2,000 15 FREEZES
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 32F = Pressure above atmosphere
= 29.921 inches Hg. absolute at 32F PSIA = Lbs. per sq. in. absolute pressure
= Sum of gauge plus atmospheric pressure
28 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 6 - MAINTENANCE
Be sure the vacuum indicator is valved off taken place the pressure and temperature will continue
while holding the system vacuum and be to drop until eventually a temperature of 35F (1.6C)
sure to open the valve between the vacuum or a pressure of 5 mm Hg. is reached.
indicator and the system when checking
the vacuum after the 8 hour period. When this point is reached, practically all of the air has
been evacuated from the system, but there is still a small
amount of moisture left. In order to provide a medium
VACUUM DEHYDRATION for carrying this residual moisture to the vacuum pump,
To obtain a sufficiently dry system, the following in- nitrogen should be introduced into the system to bring
structions have been assembled to provide an effective it to atmospheric pressure and the indicator temperature
method for evacuating and dehydrating a system in the will return to approximately ambient temperature. Close
field. Although there are several methods of dehydrating off the system again, and start the second evacuation.
a system, we are recommending the following, as it pro- The relatively small amount of moisture left will be
duces one of the best results, and affords a means of ob- carried out through the vacuum pump and the tem-
taining accurate readings as to the extent of dehydration. perature or pressure shown by the indicator should
The equipment required to follow this method of dehy- drop uniformly until it reaches a temperature of 35F
dration consists of a wet bulb indicator or vacuum gauge, (1.6C) or a pressure of 5 mm Hg.
a chart showing the relation between dew point tempera- When the vacuum indicator registers this temperature
ture and pressure in inches of mercury (vacuum), (Refer or pressure, it is a positive sign that the system is evac-
to Table 2 on Page 28) and a vacuum pump capable of uated and dehydrated to the recommended limit. If this
pumping a suitable vacuum on the system. level cannot be reached, it is evident that there is a leak
somewhere in the system. Any leaks must be corrected
OPERATION
before the indicator can be pulled down to 35F or 5
Dehydration of a refrigerant system can be obtained mm Hg. in the primary evacuation.
by this method because the water present in the system
reacts much as a refrigerant would. By pulling down During the primary pulldown, keep a careful watch on
the pressure in the system to a point where its satu- the wet bulb indicator temperature, and do not let it fall
ration temperature is considerably below that of room below 35F (1.6C). If the temperature is allowed to
temperature, heat will flow from the room through the fall to 32F (0C), the water in the test tube will freeze,
walls of the system and vaporize the water, allowing and the result will be a faulty temperature reading.
a large percentage of it to be removed by the vacuum
pump. The length of time necessary for the dehydra- 6
INDICATOR READING -F
JOHNSON CONTROLS 29
SECTION 6 - MAINTENANCE FORM 160.75-O1 (211)
inder must be admitted to the system pressure until the The refrigerant charge level must be checked after the
system pressure is raised above the point correspond- pressure and temperature have equalized between the
ing to the freezing point of the evaporator liquid. For condenser and evaporator. This would be expected to be
water, the pressure corresponding to the freezing point 4 hours or more after the compressor and water pumps
is 8.54 PSIG (58.9 kPa) for R-134a (at sea level). are stopped. The level should visible in the sight glass.
While charging, every precaution must be taken to pre- Charge the refrigerant in accordance with the meth-
vent moisture laden air from entering the system. Make od shown under the REFRIGERANT CHARGING,
up a suitable charging connection from new copper tub- above. The refrigerant level should be observed and
ing to fit between the system charging valve and the fit- the level recorded after initial charging.
ting on the charging drum. This connection should be
HANDLING REFRIGERANT FOR DISMANTLING
as short as possible but long enough to permit sufficient
AND REPAIRS
flexibility for changing drums. The charging connection
should be purged each time a full container of refrigerant If it becomes necessary to open any part of the refriger-
is connected and changing containers should be done as ant system for repairs, it will be necessary to remove
quickly as possible to minimize the loss of refrigerant. the charge before opening any part of the unit. If the
chiller is equipped with optional valves, the refrigerant
Refrigerant may be furnished in cylinders containing can be isolated in either the condenser or evaporator /
either 30, 50, 125, 1,025 or 1750 lbs. (13.6, 22.6, 56.6, compressor while making any necessary repairs.
464 or 794 kg) of refrigerant.
MEGGING THE MOTOR
The nameplate on the chiller contains the
correct refrigerant charge information While the main disconnect switch and compressor mo-
for the chiller. tor starter are open, meg the motor as follows:
1. Using a megohm meter (megger), meg between
phases and each phase to ground (Refer to Figure 16
on Page 30); these readings are to be interpreted
using the graph shown in Figure 17 on Page 31.
CHECKING THE REFRIGERANT CHARGE
DURING UNIT SHUTDOWN 2. If readings fall below shaded area, remove exter-
nal leads from motor and repeat test.
The refrigerant charge is specified for each chiller model.
Charge the correct amount of refrigerant and record the Motor is to be megged with the starter at
level in the evaporator sight glass. ambient temperature after 24 hours of
idle standby.
The refrigerant charge should always be checked and
trimmed when the system is shut down.
MEGOHM
BETWEEN MEGOHM
WINDINGS METER
MAIN DISCONNECT
(OPEN) MEGOHM EACH
WINDING TO GROUND
STARTER (OPEN)
MEGOHM METER
LD00475
30 JOHNSON CONTROLS
JOHNSON CONTROLS
1. Megger readings should be taken after Megger voltage has been applied one minute.
2. If insulation resistance lies to the right of the applicable curve the motor is acceptable for use.
3. If insulation resistance lies to the left of the applicable curve, the motor should not be run. The motor
should be heated to 250F in an effort to remove moisture and obtain an acceptable reading at room
ambient. This can be done either by baking in a forced hot air oven or, if proper voltage is available,
apply 5 - 10% of rated voltage to motor windings.
4. Any gradual or abrupt decrease in Megger readings over an extended period of time is an indication of
deterioration of insulation and / or moisture absorption or oil / dirt contamination.
5. Megger readings of individual phase coils of 200 - 600V motors should be made with coils not under
test being grounded.
TEMPERATURE F
LEGEND
A 200 - 600V
DELTA CONN.
B 2300V
(Entire Windings)
C 200 - 600V
(Per Phase)
Note 5
D 3300 - 4160V
(Entire Windings)
SECTION 6 - MAINTENANCE
MEGOHMS
LD00476
31
6
SECTION 6 - MAINTENANCE FORM 160.75-O1 (211)
32 JOHNSON CONTROLS
FORM 160.75-O1 (211) SECTION 6 - MAINTENANCE
Acid cleaning should only be performed 3. With nitrogen or dry air, blow out the tubes to
by an expert. Please consult your local clear them of traces of refrigerant laden moisture
water treatment representative for as- from the circulation water. As soon as the tubes
sistance in removing scale buildup and are clear, a cork should be driven into each end
preventative maintenance programs to of the tube. Pressurize the dry system with 50 to
eliminate future problems. COMMER- 100 PSIG (345 to 690 kPa) of nitrogen. Repeat
CIAL ACID CLEANING this with all of the other tubes in the suspected
section or, if necessary, with all the tubes in the
In many major cities, commercial organizations now evaporator or condenser. Allow the evaporator or
offer a specialized service of acid cleaning evaporators condenser to remain corked up to 12 to 24 hours
and condensers. If acid cleaning is required, YORK before proceeding. Depending upon the amount
recommends the use of this type of organization. The of leakage, the corks may blow from the end of a
Dow Industries Service Division of the Dow Chemical tube, indicating the location of the leakage. If not,
Company, Tulsa, Oklahoma, with branches in principal if will be necessary to make a very thorough test
cities is one of the most reliable of these companies. with the leak detector.
Testing For Evaporator And Condenser Tube 4. After the tubes have been corked for 12 to 24
Leaks hours, it is recommended that two men working
at both ends of the evaporator carefully test each
Evaporator and condenser tube leaks in R-134a sys-
tube one man removing corks at one end and
tems may result in refrigerant leaking into the water
the other at the opposite end to remove corks and
circuit, or water leaking into the shell depending on the
handle the leak detector. Start with the top row of
pressure levels. If refrigerant is leaking into the water,
tubes in the section being investigated. Remove
it can be detected at the liquid head vents after a period
the corks at the ends of one tube simultaneously
of shutdown. If water is leaking into the refrigerant,
and insert the exploring tube for 5 seconds this
system capacity and efficiency will drop off sharply. If
should be long enough to draw into the detec-
a tube is leaking and water has entered the system, the
tor any refrigerant gas that might have leaked
evaporator and condenser should be valved off from
through the tube walls. A fan placed at the end of
the rest of the water circuit and drained immediately to
the evaporator opposite the detector will assure
prevent severe rusting and corrosion. The refrigerant
that any leakage will travel through the tube to
system should then be drained and purged with dry ni-
the detector.
trogen to prevent severe rusting and corrosion. If a tube
leak is indicated, the exact location of the leak may be 5. Mark any leaking tubes for later identification. 6
determined as follows:
6. If any of the tube sheet joints are leaking, the leak
1. Remove the heads and listen at each section of should be indicated by the detector. If a tube sheet
tubes for a hissing sound that would indicate gas leak is suspected, its exact location may be found
leakage. This will assist in locating the section of by using a soap solution. A continuous buildup of
tubes to be further investigated. If the probable bubbles around a tube indicates a tube sheet leak.
location of the leaky tubes has been determined,
treat that section in the following manner (if the COMPRESSOR
location is not definite, all the tubes will require Maintenance for the compressor assembly consists
investigations). of checking the operation of the oil return system and
2. Wash off both tube heads and the ends of all tubes changing the dehydrator, checking and changing the oil,
with water. checking and changing the oil filters, checking the op-
eration of the oil heater, checking the operation of the oil
Do not use carbon tetrachloride for this pump, and observing the operation of the compressor.
purpose since its fumes give the same
flame discoloration that the refrigerant
does.
JOHNSON CONTROLS 33
SECTION 6 - MAINTENANCE FORM 160.75-O1 (211)
Internal wearing of compressor parts could be a seri- of operation. However, if aluminum particles continue
ous problem caused by improper lubrication, brought to accumulate and the same conditions continue to stop
about by restricted oil lines, passages, or dirty oil fil- the unit operation after a new filter is installed, notify
ters. If the unit is shutting down on (HOT) High Oil the nearest Johnson Controls office to request the pres-
Temperature or Low Oil Pressure (OP), change the oil ence of a Johnson Controls Service Technician.
filter element. Examine the oil filter element for the
presence of aluminum particles. Aluminum gas seal ELECTRICAL CONTROLS
rings can contact the impeller and account for some For information covering the OptiView Control Cen-
aluminum particles to accumulate in the oil filter, espe- ter operation, refer to the Optiview Control Center
cially during the initial start up and first several months Operation and Maintenance (Form 160.54-O1).
34 JOHNSON CONTROLS
FORM 160.75-O1 (211)
It is the responsibility of the owner to provide the nec- RAM Motor Lubrication
essary daily, monthly and yearly maintenance require- Frame 143T thru 256T are furnished with double
ments of the system. sealed ball bearings, pre-lubricated prior to installa-
IMPORTANT If a unit failure occurs tion. Grease fittings are not supplied and bearings are
due to improper maintenance during the designed for long life under standard conditions.
warranty period; Johnson Controls will
not be liable for costs incurred to return Frames 284T thru 587UZ are furnished with double
the system to satisfactory operation. shielded or open ball or roller bearings. It is necessary
to re-lubricate anti-friction bearings periodically. (Re-
fer to Table 3 on Page 35.)
In any operating system it is most important to pro-
vide a planned maintenance and inspection of its func- TABLE 3 - BEARING LUBRICATION
tioning parts to keep it operating at its peak efficiency. FRAME STANDARD CONTINUOUS GREASE
Therefore, the following maintenance should be per- SIZE 8HR/DAY 24HR DAY QUANTITY
formed when prescribed. OZ.
143T-256T *7 Years *3 Years *1
COMPRESSOR 284TS-286TS 210 Days 70 Days 1
1. Oil Filter When oil pump VSD frequency in- 324TS-587USS 150 Days 50 Days 2
creases to 55 hz to maintain target oil pressure.
* On frame sizes 143T - 256T, changing bearings at these
intervals is recommended. However, removing the seal, clean-
When the oil filter is changed, it should be inspect-
ing and refilling the bearing and the cavity with recommended
ed thoroughly for any aluminum particles which grease can re-lubricate these bearings.
would indicate possible bearing wear. If alumi-
num particles are found this should be brought Recommended greases for standard applications:
to the attention of the nearest Johnson Controls
office for their further investigation and recom- OPERATING AMBIENT TEMP. -30C to 50C
mendations. Chevron SRI (Chevron)
Exxon Unirex #2 (Exxon Corp.)
2. Oil Changing The oil in the compressor must
be changed annually or earlier if it becomes dark Exxon Polyrex (Exxon Corp.)
or cloudy. However, quarterly oil analysis can Shell Dolum R (Shell Oil Co.)
eliminate the need for an annual change provided
Westinghouse Motor Lubrication:
the analysis indicates there is no problem with the
oil. Re-greasing should occur at 1000 operating hour 7
intervals.
COMPRESSOR MOTOR
Westinghouse recommends using Westinghouse
1. Check motor mounting screws frequently to in-
Grease No. 53701.
sure tightness.
Motors with shaft diameters less than 2 3/8 inch
2. Meg motor windings annually to check for dete-
require 1 oz of grease per bearing while motors
rioration of windings.
with shaft diameters between 2 3/8 and 3 inches
GREASED BEARINGS require 1.5 oz.
Mixing different greases is not recom-
Motor Operation and Maintenance manuals are sup-
mended
plied with the chillers providing maintenance sched-
ules and instructions for the specific motors. The fol-
lowing are lubrication schedules for the most common
motors:
JOHNSON CONTROLS 35
SECTION 7 - PREVENTIVE MAINTENANCE FORM 160.75-O1 (211)
Additional information on motor lubrica- a new unit, it is a good indication that the con-
tion and other service issues can be found denser tubes require cleaning. Refer to SECTION
in the A-C Motors Instruction Manual. 6 - MAINTENANCE of this manual for condenser
tube cleaning instructions.
2. The evaporator tubes under normal circumstances
will not require cleaning. If the temperature dif-
LEAK TESTING ference between the refrigerant and the chilled
The unit should be leak tested monthly. Any leaks water increases slowly over the operating season,
it is an indication that the evaporator tubes may be
found must be repaired immediately.
fouling or that there may be a water bypass in the
EVAPORATOR AND CONDENSER waterbox requiring gasket replacement or refrig-
erant may have leaked from the chiller.
The major portion of maintenance on the condenser
and evaporator will deal with the maintaining the wa- 3. Heat recovery condenser tubes should be evalu-
ter side of the condenser and evaporator in a clean ated similiar to evaporator tubes when the heating
condition. circuit is a treated, closed loop. Fouling could be
detected as ability to meet heat load requirements
The use of untreated water in cooling towers, closed decreases.
water systems, etc. frequently results in one or more of
the following: OIL RETURN SYSTEM
1. The condenser tubes should be cleaned annually 2. It is important that the factory settings of controls
or earlier if conditions warrant. If the temperature (operation and safety) not be changed. If the set-
difference between the water off the condenser tings are changed without Johnson Controls ap-
and the condenser liquid temperature is more than proval, the warranty will be jeopardized.
4F (2C) greater than the difference recorded on
36 JOHNSON CONTROLS
JOHNSON CONTROLS
For operating and maintenance requirements listed above, refer to appropriate service literature, or contact your local Johns on Controls Service Office. A record of all procedures being successfully car-
ried out (as well as operating logs) must be maintained on file by the equipment owner should proof of adequate maintenance be required at a later date for warranty validation purposes.
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.
2
More frequent service may be required depending on local operating conditions.
160.54-MR1 (611)
Supersedes 160.54-MR1 (801)
37
NOTES
38 JOHNSON CONTROLS
FORM 160.75-O1 (211)
TEMPERATURE
To convert degrees Fahrenheit (F) to degrees Celsius
(C), subtract 32 and multiply by 5/9 or 0.5556.
Example: (45.0F - 32) x 0.5556 = 27.2C
To convert a temperature range (i.e., a range of 10F)
from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.
Example: 10.0F range x 0.5556 = 5.6 C range
JOHNSON CONTROLS 39
P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA
Copyright by Johnson Controls 2011 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 160.75-O1 (211)
Issue Date: February 1, 2011
Supersedes: 160.75-O1 (309)