Johnson Controls YORK YK MaxE User manual

OPERATION MANUAL

OPTIVIEWTM CONTROL CENTER

MAXETM CENTRIFUGAL LIQUID CHILLERS

Supersedes: 160.54-O1 Form 160.54-O1

MODEL YK (THROUGH STYLE G)

R-134a COOLING ONLY

WITH OPTIVIEWTM CONTROL CENTER

FOR ELECTRO-MECHANICAL STARTER,

SOLID STATE STARTER

& VARIABLE SPEED DRIVE

29420A

JOHNSON CONTROLS

FORM 160.54-O1

This equipment is a relatively complicated apparatus.

During installation, operation, maintenance or service,

individuals may be exposed to certain components or

conditions including, but not limited to: refrigerants,

oils, materials under pressure, rotating components, and

both high and low voltage. Each of these items has the

potential, if misused or handled improperly, to cause

bodily injury or death. It is the obligation and respon-

sibility of operating/service personnel to identify and

recognize these inherent hazards, protect themselves,

and proceed safely in completing their tasks. Failure

to comply with any of these requirements could result

in serious damage to the equipment and the property in

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

which it is situated, as well as severe personal injury or

death to themselves and people at the site.

This document is intended for use by owner-authorized

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

dividual possesses independent training that will enable

them to perform their assigned tasks properly and safely.

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

equipment, this individual shall have read and under-

stood this document and any referenced materials. This

individual shall also be familiar with and comply with

all applicable governmental standards and regulations

pertaining to the task in question.

SAFETY SYMBOLS

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

WARNING indicates a potentially

hazardous situation which, if not

avoided, could result in death or se-

rious injury.

DANGER indicates an imminently

hazardous situation which, if not

avoided, will result in death or serious

injury.

CAUTION identies a hazard which

could lead to damage to the machine,

damage to other equipment and/or

environmental pollution. Usually an

instruction will be given, together with

a brief explanation.

External wiring, unless specied as an optional connection in the manufacturer’s product

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

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

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

published specications and must be performed ONLY by qualied YORK/Johnson Controls

personnel. Johnson Controls will not be responsible for damages/problems resulting from

improper connections to the controls or application of improper control signals. Failure to

follow this will void the manufacturer’s warranty and cause serious damage to property or

injury to persons.

NOTE is used to highlight additional

information which may be helpful to

you.

FORM 160.54-O1

JOHNSON CONTROLS

NOMENCLATURE

REFERENCE INSTRUCTIONS

DESCRIPTION FORM NO.

SOLID STATE STARTER (MOD “A”) – OPERATION & MAINTENANCE 160.46-OM3.1

SOLID STATE STARTER (MOD “B”) – OPERATION & MAINTENANCE 160.00-O2

MEDIUM VOLTAGE SOLID STATE STARTER – OPERATION 160.00-O5

MEDIUM VOLTAGE SOLID STATE STARTER – SERVICE 160.00-M5

VARIABLE SPEED DRIVE – OPERATION 160.00-O1

VARIABLE SPEED DRIVE – SERVICE INSTRUCTIONS 160.00-M4

MEDIUM VOLTAGE VARIABLE SPEED DRIVE – OPERATION 160.00-O6

MEDIUM VOLTAGE VARIABLE SPEED DRIVE – SERVICE 160.00-M6

VARIABLE SPEED OIL PUMP DRIVE 160.52-M2

INSTALLATION 160.54-N1

OPTIVIEW CONTROL CENTER - SERVICE INSTRUCTIONS 160-54-M1

WIRING DIAGRAM – UNIT STYLE E WITH ELECTRO-MECHANICAL STARTER 160.54-PW1

WIRING DIAGRAM – UNIT STYLE E WITH MOD “A” SOLID STATE STARTER 160.54-PW2

WIRING DIAGRAM – UNIT STYLE E WITH MOD “B” SOLID STATE STARTER 160.54-PW2.1

WIRING DIAGRAM – UNIT STYLE E WITH VARIABLE SPEED DRIVE 160.54-PW3

RENEWAL PARTS – UNIT 160.49-RP4

RENEWAL PARTS – OPTIVIEW CONTROL CENTER 160.54-RP1

WIRING DIAGRAM – UNIT STYLE E (P Compressors) with ELECTRO-MECHANICAL STARTER 160.54-PW8

WIRING DIAGRAM – UNIT STYLE E (P Compressors) with MOD “B” SOLID STATE STARTER 160.54-PW9

WIRING DIAGRAM – UNIT STYLE E (P Compressors) with VARIABLE SPEED DRIVE 160.54-PW10

WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH ELECTRO-MECHANICAL STARTER 160.73-PW1

WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH MOD “B” SOLID STATE STARTER 160.73-PW2

WIRING DIAGRAM – UNIT STYLE F (all compressors) WITH VARIABLE SPEED DRIVE 160.73-PW3

WIRING DIAGRAM – UNIT (STYLE F) (all compressors) WITH MEDIUM VOLTAGE VSD OR MEDIUM VOLTAGE SSS 160.73-PW5

WIRING DIAGRAM – FIELD CONTROL MODIFICATIONS (STYLE G) 160.75-PW4

WIRING DIAGRAM – UNIT STYLE G WITH ELECTRO-MECHANICAL STARTER 160.75-PW5

WIRING DIAGRAM – UNIT STYLE G WITH SSS, LV VSD WITH MODBUS & MV VSD 160.75-PW6

YK CB CB G4 – CM E

MOTOR CODE

POWER SUPPLY

– for 60 Hz

5 for 50 Hz

COMPRESSOR CODE

CONDENSER CODE

EVAPORATOR CODE

MODEL

STYLE (Design Level)

JOHNSON CONTROLS

FORM 160.54-O1

SECTION 1 Description of System and Fundamentals of Operation ................... 7

SECTION 2OptiView Control Center ................................................................. 11

SECTION 3Printers..........................................................................................167

TABLE OF CONTENTS

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls policy for continu-

ous product improvement, the information contained

in this document is subject to change without notice.

While Johnson Controls makes no commitment to up-

date or provide current information automatically to

the manual owner, that information, if applicable, can

be obtained by contacting the nearest Johnson Controls

Service ofce.

It is the responsibility of operating/service personnel

as to the applicability of these documents to the equip-

ment in question. If there is any question in the mind

of operating/service personnel as to the applicability of

these documents, then, prior to working on the equip-

ment, they should verify with the owner whether the

equipment has been modied and if current literature

is available.

FORM 160.54-O1

JOHNSON CONTROLS

LIST OF FIGURES

FIG. 1 – MODEL YK MAXE™ CHILLER ............................. 6

DETAIL A – COMPRESSOR PREROTATION

VANES.................................................................. 7

FIG. 2 – REFRIGERANT FLOW-THROUGH CHILLER..... 8

FIG. 3 – OPTIVIEW CONTROL CENTER.........................11

FIG. 4 – HOME SCREEN................................................. 16

FIG. 5 – SYSTEM SCREEN............................................. 19

FIG. 6 – EVAPORATOR SCREEN ................................... 21

FIG. 7 – CONDENSER SCREEN..................................... 24

FIG. 7A – HEAT RECOVERY SCREEN ............................. 26

FIG. 7B – HEAD PRESSURE SCREEN............................. 30

FIG. 8 – REFRIGERANT LEVEL CONTROL SCREEN

(Flash Memory Card version C.MLM.01.06.XXX

and earlier) ......................................................... 32

FIG. 8A – REFRIGERANT LEVEL CONTROL SCREEN

(Software Version C.MLM.01.07.xxx to

C.MLM.01.10D.xxx or C.OPT.01.10D and earlier) .. 34

FIG 8B – REFRIGERANT LEVEL CONTROL SETPOINTS

SCREEN (Software Version C.MLM.01.07.xxx to

C.MLM.01.10D.xxx or C.OPT.01.10D

(and earlier)) ....................................................... 36

FIG 8C – REFRIGERANT LEVEL CONTROL SCREEN

(Software version C.MLM.01.14.xxx (and later) or

C.OPT.01.14.306 (and later)) ............................. 38

FIG. 9 – COMPRESSOR SCREEN

(All “P” Compressors and Style F chillers with

G, Q or H5-8 compressors) ................................ 40

FIG. 9A – COMPRESSOR SCREEN (Style E and earlier

chillers with G, H or J compressors and Style F

and later chillers with J or H3 compressors)....... 42

FIG. 10 – PROXIMITY PROBE CALIBRATION SCREEN

(Style E and earlier chillers with G, H and J

compressors and Style F and later chillers with

J or H3 compressors) ......................................... 44

FIG. 11 – HOT GAS BYPASS SCREEN ............................ 46

FIG. 12 – SURGE PROTECTION SCREEN ...................... 48

FIG. 12A – VARIABLE GEOMETRY DIFFUSER SCREEN.. 52

FIG. 12B – VARIABLE GEOMETRY DIFFUSER SETPOINTS

SCREEN............................................................. 54

FIG. 13 – PRE-ROTATION VANES CALIBRATION

SCREEN............................................................. 56

FIG. 14 – VSD TUNING SCREEN ..................................... 58

FIG. 15 – OIL SUMP SCREEN........................................... 60

FIG. 16 – ELECTRO-MECHANICAL STARTER SCREEN.... 64

FIG. 17 – MOD “A” SOLID STATE STARTER SCREEN .... 66

FIG. 18 – MOD “B” SOLID STATE STARTER SCREEN .... 68

FIG. 18A – MEDIUM VOLTAGE SOLID STATE STARTER

SCREEN............................................................. 70

FIG. 19 – VARIABLE SPEED DRIVE SCREEN ................. 72

FIG. 19A – MEDIUM VOLTAGE VARIABLE SPEED DRIVE

SCREEN (Software Version C.OPT.01.16.xxx

and Later) ........................................................... 74

FIG. 20 – VARIABLE SPEED DRIVE DETAILS SCREEN

(Style D VSD and VSD with part number

371-03789-xxx (503 HP 60 Hz; 419 HP 50 Hz).. 78

FIG. 21 – VARIABLE SPEED DRIVE DETAILS SCREEN

(VSD with Part Number 371-02767-XXX

(60 Hz) or 371-03700-XXX (50 HZ))................... 80

FIG. 22 – ADAPTIVE CAPACITY CONTROL SCREEN

(software version C.OPT.01.18.307 and earlier) 82

FIG. 22A – ADAPTIVE CAPACITY CONTROL SCREEN

(YORK protocol conguration)

(software version C.OPT.01.19.307 and later) ... 84

FIG. 22B – ADAPTIVE CAPACITY CONTROL SCREEN

(Modbus protocol conguration)

(software version C.OPT.01.19.307 and later) ... 86

FIG. 22C – SURGE MAP SCREEN - TABLE VIEW

(software version C.OPT.01.19.307 and later) ... 90

FIG. 22D – SURGE MAP SCREEN - LIST VIEW

(software version C.OPT.01.19.307 and Later) .. 92

FIG. 23 – HARMONIC FILTER DETAILS SCREEN

(Style D VSD and VSD with part number

371-03789-xxx (503 HP 60 Hz; 419 HP 50 Hz).. 94

FIG. 24 – HARMONIC FILTER DETAILS SCREEN

(VSD with Part Number 371-02767-XXX (60 Hz)

or 371-03700-XXX (50 Hz)) ............................... 96

FIG. 25 – MOTOR LUBRICATION SCREEN (Software version

C.MLM.01.14.xxx (and later) or C.OPT.01.14.306

(and later)) .......................................................... 98

FIG. 26 – SETPOINTS SCREEN ..................................... 100

FIG. 27 – SETUP SCREEN.............................................. 104

FIG. 27A – QUICK START SCREEN.................................. 108

FIG. 28 – SCHEDULE SCREEN .......................................112

FIG. 29 – USER SCREEN.................................................114

FIG. 30 – COMMS SCREEN.............................................116

FIG. 31 – PRINTER SCREEN...........................................118

FIG. 32 – SALES ORDER SCREEN ................................ 120

FIG. 33 – OPERATIONS SCREEN .................................. 122

FIG. 34 – HISTORY SCREEN.......................................... 124

FIG. 35 – HISTORY DETAILS SCREEN .......................... 126

FIG. 36 – SECURITY LOG SCREEN............................... 127

FIG. 37 – SECURITY LOG DETAILS SCREEN ............... 128

FIG. 38 – CUSTOM VIEW SCREEN................................ 129

FIG. 39 – CUSTOM VIEW SETUP SCREEN

................... 130

FIG. 40 – TREND SCREEN ............................................. 132

FIG. 41 – TREND SETUP SCREEN ................................ 134

FIG. 42 – ADVANCED TREND SETUP SCREEN............ 136

FIG. 43 – COMMON SLOTS SCREEN ............................ 138

FIG. 44 – PRINTERS ....................................................... 164

FIG. 45 – SAMPLE PRINTOUT (STATUS)....................... 170

FIG. 46 – SAMPLE PRINTOUT (SETPOINTS)................ 172

FIG. 47 – SAMPLE PRINTOUT (SCHEDULE)................. 174

FIG. 48 – SAMPLE PRINTOUT (SALES ORDER)........... 175

FIG. 49 – SAMPLE PRINTOUT (HISTORY) .................... 176

FIG. 50 – SAMPLE PRINTOUT (SECURITY LOG).......... 178

FIG. 51 – SAMPLE PRINTOUT (TREND)........................ 178

FIG. 52 – SAMPLE PRINTOUT – (CUSTOM SCREEN).. 179

FIG. 53 – SAMPLE PRINTOUT – (ADAPTIVE CAPACITY

CONTROL NEW MAP POINT)......................... 179

FIG. 54 – SAMPLE PRINTOUT (ADAPTIVE CAPACITY

CONTROL EXISTING MAP POINTS) .............. 179

JOHNSON CONTROLS

FORM 160.54-O1

Description of System and Fundamentals of Operation

THIS PAGE INTENTIONALLY LEFT BLANK

FORM 160.54-O1

JOHNSON CONTROLS

When the compressor motor is driven by a YORK Solid

State Starter, one of three different Starters could be ap-

plied. Later production chillers are equipped with either

the Style B Liquid Cooled Solid State Starter (LCSSS)

or the Medium Voltage Solid State Starter (MVSSS).

Earlier vintage chillers are equipped with the Mod “A”

Solid State Starter. This starter contains a Trigger Board

that interfaces to a Logic Board that is installed inside of

the Control Center.

When the compressor motor is driven by a YORK Vari-

able Speed Drive, there could be a Variable Speed Drive

(VSD) or a Medium Voltage Variable Speed Drive (MV

VSD) applied.

In operation, a liquid (water or brine to be chilled) ows

through the cooler, where boiling refrigerant absorbs heat

from the liquid. The chilled liquid is then piped to fan

coil units or other air conditioning terminal units, where

it ows through nned coils, absorbing heat from the

air. The warmed liquid is then returned to the chiller to

complete the chilled liquid circuit.

SECTION 1

DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION

00611vip

CONDENSER

CONTROL

CENTER

COMPRESSOR

MOTOR

EVAPORATOR

FIG. 1 – MODEL YK MaxE™ CHILLER

SYSTEM OPERATION DESCRIPTION (SEE FIG. 2)

The YORK Model YK MaxE™ Chiller is commonly ap-

plied to large air conditioning systems, but may be used on

other applications. The chiller consists of an open motor

mounted to a compressor (with integral speed increasing

gears), condenser, evaporator and variable ow control.

The chiller is controlled by a modern state of the art Mi-

crocomputer Control Center that monitors its operation.

The Control Center is programmed by the operator to suit

job specications. Automatic timed start-ups and shut-

downs are also programmable to suit nighttime, week-

ends, and holidays. The operating 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 keys as labeled on the Control Center. The

chiller with the OptiView Control Center is applied with

an electro-mechanical starter, YORK Solid State Starter

(optional), or Variable Speed Drive (optional).

JOHNSON CONTROLS

FORM 160.54-O1

The refrigerant vapor, which is produced by the boiling

action in the cooler, ows to the compressor where the

rotating impeller increases its pressure and temperature

and discharges it into the condenser. Water owing

through the condenser tubes absorbs heat from the refrig-

erant vapor, causing it to condense. The condenser water

is supplied to the chiller from an external source, usu-

ally a cooling tower. The condensed refrigerant drains

from the condenser into the liquid return line, where the

variable orice meters the ow of liquid refrigerant to the

cooler to complete the refrigerant circuit.

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.

7619A(D)

DETAIL A – COMPRESSOR PREROTATION VANES

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 cooler. 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

outside the compressor housing. The automatic adjust-

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

minimum load with vanes completely closed.

Description of System and Fundamentals of Operation

FORM 160.54-O1

JOHNSON CONTROLS

FIG. 2 – REFRIGERANT FLOW-THRU CHILLER

PREROTATION VANES

(See Detail A)

SUCTION

EVAPORATOR

ELIMINATOR

OIL COOLER

LD00924

FLOW CONTROL

ORIFICE

SUB-COOLER

CONDENSER

DISCHARGE

BAFFLE

DISCHARGE

COMPRESSOR

JOHNSON CONTROLS

FORM 160.54-O1

OptiView Control Center

THIS PAGE INTENTIONALLY LEFT BLANK

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