Johnson Controls York YK Installation guide
035-27332-100
Form Number: 160.76-O1 (421)
Supersedes: 160.76-O1 (321)
Operations and Maintenance
Issue Date: 2021-04-25
Model YK (Style H), R-134a and R-513A
With OptiView Control Center for Electromechanical
Starter, Solid-State Starter, and Variable Speed Drive
2 Model YK (Style H), R-134a and R-513A
Contents
ContentsGeneral safety guidelines.............................................................................................................................. 5
Safety symbols..................................................................................................................................... 5
Changeability of this document......................................................................................................... 6
Revision notes...................................................................................................................................... 6
Associated literature........................................................................................................................... 6
Conditioned based maintenance...................................................................................................... 7
Nomenclature...................................................................................................................................... 8
Description of system and fundamentals of operation............................................................................ 9
System operation description............................................................................................................ 9
Capacity control................................................................................................................................. 10
System operating procedures.................................................................................................................... 11
Oil heaters.......................................................................................................................................... 11
Oil heater operation.......................................................................................................................... 11
Checking the oil level in the oil reservoir....................................................................................... 11
Start-up............................................................................................................................................... 12
Chiller operation................................................................................................................................ 12
Condenser water temperature control........................................................................................... 13
Operating log sheet.......................................................................................................................... 13
Operating inspections....................................................................................................................... 14
Need for maintenance or service.................................................................................................... 16
Stopping the system......................................................................................................................... 16
Prolonged shutdown......................................................................................................................... 16
System components description................................................................................................................ 17
Compressor........................................................................................................................................ 17
Capacity control................................................................................................................................. 17
Compressor lubrication system....................................................................................................... 17
Oil pump............................................................................................................................................. 18
Oil heater............................................................................................................................................ 20
Motor driveline.................................................................................................................................. 21
Heat exchangers................................................................................................................................ 21
Refrigerant flow control.................................................................................................................... 21
Optional service isolation valves..................................................................................................... 22
Optional hot gas bypass................................................................................................................... 22
OptiView™ Control Center................................................................................................................ 22
Solid state starter (optional)............................................................................................................ 22
Variable speed drive (optional)........................................................................................................ 23
Operational maintenance........................................................................................................................... 24
Oil return system............................................................................................................................... 24
Changing the dehydrator................................................................................................................. 24
The oil charge.................................................................................................................................... 25
Model YK (Style H), R-134a and R-513A 3
Oil charging procedure..................................................................................................................... 25
Troubleshooting........................................................................................................................................... 26
Maintenance................................................................................................................................................. 28
Renewal parts.................................................................................................................................... 28
Checking system for leaks................................................................................................................ 28
Conducting a system pressure test................................................................................................ 28
System evacuation............................................................................................................................ 31
Refrigerant charging......................................................................................................................... 36
Checking and trimming the refrigerant charge............................................................................ 38
Checking the refrigerant charge during unit shutdown.............................................................. 39
Handling refrigerant for dismantling and repairs........................................................................ 39
Megging the motor........................................................................................................................... 41
Compressor........................................................................................................................................ 44
Electrical controls.............................................................................................................................. 44
Preventive maintenance.............................................................................................................................. 45
Compressor........................................................................................................................................ 45
Compressor motor............................................................................................................................ 45
Greased bearings.............................................................................................................................. 45
Motor relubrication instruction....................................................................................................... 45
Leak testing........................................................................................................................................ 52
Evaporator and condenser............................................................................................................... 52
Oil return system............................................................................................................................... 52
Electrical controls.............................................................................................................................. 52
Maintenance inspections.................................................................................................................. 52
Unit conversion............................................................................................................................................ 55
Model YK (Style H), R-134a and R-513A4
General safety guidelines
Important: Read before proceeding.
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certain components or conditions including,
but not limited to: heavy objects, refrigerants, 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 responsibility of rigging, installation, and
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 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 rigging, installation, and operating/service
personnel. It is expected that these individuals possess 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 understood the on-product labels, this
document and any referenced materials. This individual shall also be familiar with and comply
with all applicable industry and 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 specific situations:
DANGER
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.
WARNING
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.
CAUTION
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.
Note: Highlights additional information useful to the technician in completing the work being
performed properly.
5Model YK (Style H), R-134a and R-513A
WARNING
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control 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
manufacturer’s warranty and cause serious damage to property or personal injury.
Changeability of this document
In complying with Johnson Controls’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. Johnson Controls makes no
commitment to update or provide current information automatically to the manual or product
owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson
Controls Service office or accessing the Johnson Controls Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
It is the responsibility of rigging, lifting, and operating/ 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/service personnel should verify whether the equipment
has been modified and if current literature is available from the owner of the equipment prior to
performing any work on the chiller.
Revision notes
Revisions made to this document are indicated in the following table. These revisions are to
technical information, and any other changes in spelling, grammar, or formatting are not included.
Affected pages Description
41 Amended the section on Megging the motor.
54 Add the Smart sensor test item to the annual check list.
Associated literature
Manual description Form
Number
Operation - Variable Speed Drive - TM Model 160.00-O1
Operation and Maintenance - Solid State Starter (Mod B) 160.00-O2
Operation - Floor Mounted MVSSS 160.00-O5.1
Operation - Unit Mounted MVSSS 160.00-O7
Installation – YK Unit 160.76-N1
Installation and Reassembly - YK Unit 160.76-N3
Operation Manual – OptiView™ Control Center 160.76-O2
Wiring Diagram – Field Connections for YK Chiller (Style H) with OptiView™ Control
Center and Unit-Mounted SSS or Remote Medium Voltage SSS, Medium Voltage
VSD, or Medium Voltage EMS
160.76-PW1
Model YK (Style H), R-134a and R-513A6
Manual description Form
Number
Wiring Diagram – Field Connections for YK Chiller (Style H) with OptiView™ Control
Center and Remote Medium Voltage SSS 160.76-PW2
Wiring Diagram – Field Connections for YK Chiller (Style H) with OptiView™ Control
Center and Remote Medium Voltage VSD 160.76-PW3
Wiring Diagram – Field Control Modifications for YK Chiller (Style H) 160.76-PW4
Wiring Diagram – Model YK (Style H) with OptiView™ Control Center and Electro-
Mechanical Starter 160.76-PW5
Wiring Diagram – Model YK (Style H) with OptiView™ Control Center and SSS W/
Modbus, LV VSD W/Modbus 160.76-PW6
Wiring Diagram – Field Connections Model YK Chillers (Style H) with Low Voltage
Variable Speed Drive 160.76-PW7
Conditioned based maintenance
Traditional chiller maintenance is based upon assumed and generalized conditions. In lieu of
the traditional maintenance program, a Johnson Controls YORK Conditioned Based Maintenance
(CBM) program can be substituted. This CBM service plan is built around the specific needs for
the chiller, operating conditions, and annualized impact realized by the chiller. Your local Johnson
Controls Branch can propose a customized Planned Service Agreement that leverages real time
and historical data, delivering performance reporting, corrective actions required and data enabled
guidance for optimal operation and lifecycle assurance. The program will include fault detection
diagnostics, operation code statistics, performance based algorithms and advance rules based
rationale delivered by the Johnson Controls Connected Equipment Portal.
7Model YK (Style H), R-134a and R-513A
Nomenclature
Note: * Refer to YK Engineering Guide (Form 160.76-EG1) for shell, motor, and compressor
combinations.
Model YK (Style H), R-134a and R-513A8
Description of system and fundamentals of
operation
System operation description
The YORK Model YK Chiller is commonly applied 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 flow control.
The chiller is controlled by a modern state of the art Microcomputer Control Center that monitors
its operation. The Control Center is programmed by the operator to suit job specifications.
Automatic timed start-ups and shutdowns are also programmable to suit nighttime, weekends,
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 compatible with an electro-mechanical starter, YORK Solid State Starter
(optional), or Variable Speed Drive (optional).
In operation, a liquid (water or brine to be chilled) flows through the evaporator, 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 flows through finned coils, absorbing heat from the air. The
warmed liquid is then returned to the chiller to complete the chilled liquid circuit.
Figure 1: Compressor pre-rotation vanes
The refrigerant vapor, which is produced by the boiling action in the evaporator, flows to the
compressor where the rotating impeller increases its pressure and temperature and discharges it
into the condenser. Water flowing through the condenser tubes absorbs heat from the refrigerant
vapor, causing it to condense. The condenser water is supplied to the chiller from an external
source, usually a cooling tower. The condensed refrigerant 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.
The major components of a chiller are selected to handle the refrigerant, 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.
9Model YK (Style H), R-134a and R-513A
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 leaving the evaporator. Pre-rotation
vanes (PRV), located at the entrance to the compressor impeller, compensate for variation in load.
See Figure 1.
The position of these vanes is automatically controlled through a lever arm attached to an electric
motor located outside the compressor housing. The automatic adjustment of the vane position in
effect provides the performance of many different compressors to match various load conditions
from full load with vanes wide open to minimum load with vanes completely closed.
Figure 2: Refrigerant flow-through chiller (falling film evaporator)
Model YK (Style H), R-134a and R-513A10
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