CENTRIFUGAL LIQUID CHILLERS

OPERATIONS AND MAINTENANCE Supersedes: 160.76-O1 (1018) Form 160.76-O1 (519)

035-27332-100

MODEL YK (STYLE H)
R-134a and R-513A
WITH OPTIVIEWTM CONTROL CENTER
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER AND VARIABLE SPEED DRIVE

LD15222

Issue Date:
May 22, 2019
 FORM 160.76-O1
ISSUE DATE: 05/22/2019

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 rigging, installation, operation, maintenance, death to themselves and people at the site.
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to: This document is intended for use by owner-authorized
heavy objects, refrigerants, materials under pressure, rigging, installation, and operating/service personnel. It
rotating components, and both high and low voltage. is expected that these individuals possess independent
Each of these items has the potential, if misused or training that will enable them to perform their assigned
handled improperly, to cause bodily injury or death. It tasks properly and safely. It is essential that, prior to
is the obligation and responsibility of rigging, instal- performing any task on this equipment, this individual
lation, and operating/service personnel to identify and shall have read and understood the on-product labels,
recognize these inherent hazards, protect themselves, this document and any referenced materials. This in-
and proceed safely in completing their tasks. Failure dividual shall also be familiar with and comply with
to comply with any of these requirements could result all applicable industry and governmental standards and
in serious damage to the equipment and the property in regulations pertaining to the task in question.

SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:

Indicates a possible hazardous situation Identifies a hazard which could lead to

which will result in death or serious injury damage to the machine, damage to other
if proper care is not taken. equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.

Indicates a potentially hazardous situa- Highlights additional information useful

tion which will result in possible injuries to the technician in completing the work
or damage to equipment if proper care is being performed properly.
not taken.

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 accor-
dance 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 warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

2 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con- regarding the applicability of these documents, rig-
tinuous product improvement, the information con- ging, lifting, and operating/service personnel should
tained in this document is subject to change without verify whether the equipment has been modified and
notice. Johnson Controls makes no commitment to if current literature is available from the owner of the
update or provide current information automatically equipment prior to performing any work on the chiller.
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest CHANGE BARS
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts. Revisions made to this document are indicated with a
johnsoncontrols.com. line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
It is the responsibility of rigging, lifting, and operating/ formation and any other changes in spelling, grammar
service personnel to verify the applicability of these or formatting are not included.
documents to the equipment. If there is any question

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 160.76-N1
OptiView™ Control Center – Operation Manual 160.76-O2
Wiring Diagram – Field Connections for YK Chiller (Style H, Q3-Q7) with OptiView™ Control Center and
160.76-PW1
Unit-Mounted SSS or Remote Medium Voltage SSS, Medium Voltage VSD, or Medium Voltage EMS
Wiring Diagram – Field Connections for YK Chiller (Style H, Q3-Q7) with OptiView™ Control Center and
160.76-PW2
Remote Medium Voltage SSS
Wiring Diagram – Field Connections for YK Chiller (Style H, Q3-Q7) with OptiView™ Control Center and
160.76-PW3
Remote Medium Voltage VSD
Wiring Diagram – Field Control Modifications for YK Chiller (Style H, Q3-Q7, H9, K1 & K2) 160.76-PW4
Wiring Diagram – Model YK (Style H, Q3-Q7) with OptiView™ Control Center and Electro-Mechanical
160.76-PW5
Starter
Wiring Diagram – Model YK (Style H, Q3-Q7) with OptiView™ Control Center and SSS W/Modbus, LV
160.76-PW6
VSD W/Modbus
Wiring Diagram – Field Connections Model YK Chillers (Style H, Q3-Q7) with Low Voltage Variable
160.76-PW7
Speed Drive

JOHNSON CONTROLS 3
 FORM 160.76-O1
ISSUE DATE: 05/22/2019

NOMENCLATURE

YK 6A 6Q Q7 – EM H

STYLE (Design Level)

MOTOR CODE

POWER SUPPLY
– for 60 Hz
5 for 50 Hz

COMPRESSOR CODE*

CONDENSER CODE*

EVAPORATOR CODE*

* Refer to YK Engineering Guide for (Form 160.76-EG1)

Shell/Motor/Compressor combinations.
MODEL*

4 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

TABLE OF CONTENTS

SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION..................................... 7

System Operation Description .......................................................................................................................... 7
Capacity Control................................................................................................................................................ 7

SECTION 2 - SYSTEM OPERATING PROCEDURES..........................................................................................9

Oil Heaters........................................................................................................................................................ 9
Oil Heater Operation......................................................................................................................................... 9
Checking The Oil Level In The
Oil Reservoir...................................................................................................................................................... 9
Start-Up............................................................................................................................................................. 9
Chiller Operation............................................................................................................................................. 10
Condenser Water Temperature
Control............................................................................................................................................................. 10
Operating Log Sheet....................................................................................................................................... 10
Operating Inspections..................................................................................................................................... 11
Need For Maintenance Or Service.................................................................................................................. 12
Stopping The System...................................................................................................................................... 12
Prolonged Shutdown....................................................................................................................................... 12

SECTION 3 - SYSTEM COMPONENTS DESCRIPTION....................................................................................13

General............................................................................................................................................................ 13
Compressor..................................................................................................................................................... 13
Capacity Control.............................................................................................................................................. 13
Compressor Lubrication System .................................................................................................................... 13
Oil Pump.......................................................................................................................................................... 13
Oil Heater........................................................................................................................................................ 17
Motor Driveline................................................................................................................................................ 17
Heat Exchangers............................................................................................................................................. 17
Refrigerant Flow Control................................................................................................................................. 17
Optional Service Isolation Valves.................................................................................................................... 18
Optional Hot Gas Bypass................................................................................................................................ 18
Optiview™ Control Center.................................................................................................................................................18
Solid State Starter (Optional).......................................................................................................................... 18
Variable Speed Drive (Optional)...................................................................................................................... 18

SECTION 4 - OPERATIONAL MAINTENANCE..................................................................................................19

Oil Return System........................................................................................................................................... 19
Changing The Dehydrator............................................................................................................................... 19
The Oil Charge................................................................................................................................................ 20
Oil Charging Procedure................................................................................................................................... 20

SECTION 5 - TROUBLESHOOTING....................................................................................................................21

SECTION 6 - MAINTENANCE..............................................................................................................................23
Renewal Parts................................................................................................................................................. 23
Checking System For Leaks........................................................................................................................... 23
Conducting Pressure Test............................................................................................................................... 23
Vacuum Testing............................................................................................................................................... 24

JOHNSON CONTROLS 5
 FORM 160.76-O1
ISSUE DATE: 05/22/2019

TABLE OF CONTENTS (CONT'D)

Vacuum Dehydration....................................................................................................................................... 25
Operation......................................................................................................................................................... 25
Refrigerant Charging....................................................................................................................................... 26
Checking The Refrigerant Charge During Unit Shutdown............................................................................... 26
Handling Refrigerant For Dismantling And Repairs.........................................................................................28
Megging The Motor.......................................................................................................................................... 28
Compressor..................................................................................................................................................... 30
Electrical Controls........................................................................................................................................... 30

SECTION 7 - PREVENTIVE MAINTENANCE.....................................................................................................31

Compressor..................................................................................................................................................... 31
Compressor Motor........................................................................................................................................... 31
Greased Bearings .......................................................................................................................................... 31
Motor Re-lubrication Instruction...................................................................................................................... 32
Leak Testing.................................................................................................................................................... 34
Evaporator And Condenser............................................................................................................................. 34
Oil Return System........................................................................................................................................... 35
Electrical Controls........................................................................................................................................... 35

LIST OF FIGURES
FIGURE 1 - Compressor Pre-rotation Vanes������������������������������������������������������������������������������������������������������������7
FIGURE 2 - Refrigerant Flow-Thru Chiller (Falling Film Evaporator)�����������������������������������������������������������������������8
FIGURE 3 - Oil Level Indicator ��������������������������������������������������������������������������������������������������������������������������������9
FIGURE 4 - Liquid Chiller Log Sheets�������������������������������������������������������������������������������������������������������������������� 11
FIGURE 5 - System Components Front View��������������������������������������������������������������������������������������������������������14
FIGURE 6 - System Components Rear View���������������������������������������������������������������������������������������������������������15
FIGURE 7 - Schematic Drawing – (YK) Compressor Lubrication System�������������������������������������������������������������� 16
FIGURE 8 - Oil Return System�������������������������������������������������������������������������������������������������������������������������������19
FIGURE 9 - Charging Oil Reservoir With Oil����������������������������������������������������������������������������������������������������������20
FIGURE 10 - Parts Navigator���������������������������������������������������������������������������������������������������������������������������������23
FIGURE 11 - Evacuation Of Chiller������������������������������������������������������������������������������������������������������������������������23
FIGURE 12 - Saturation Curve�������������������������������������������������������������������������������������������������������������������������������26
FIGURE 13 - Diagram, Megging Motor Windings���������������������������������������������������������������������������������������������������26
FIGURE 14 - Motor Starter Temperature And Insulation Resistances��������������������������������������������������������������������27

LIST OF TABLES
TABLE 1 - Operation Analysis Chart����������������������������������������������������������������������������������������������������������������������21
TABLE 2 - System Pressures���������������������������������������������������������������������������������������������������������������������������������24
TABLE 3 - Guide to Motor Greasing and Shaft Rotation Intervals�������������������������������������������������������������������������32
TABLE 4 - SI Metric Conversion�����������������������������������������������������������������������������������������������������������������������������37

6 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

SECTION 1 - DESCRIPTION OF SYSTEM AND 1

FUNDAMENTALS OF OPERATION

SYSTEM OPERATION DESCRIPTION

The YORK Model YK Chiller is commonly applied The refrigerant vapor, which is produced by the boil-
to large air conditioning systems, but may be used ing action in the evaporator, flows to the compressor
on other applications. The chiller consists of an open where the rotating impeller increases its pressure and
motor mounted to a compressor (with integral speed temperature and discharges it into the condenser. Wa-
increasing gears), condenser, evaporator and variable ter flowing through the condenser tubes absorbs heat
flow control. from the refrigerant vapor, causing it to condense. The
condenser water is supplied to the chiller from an ex-
The chiller is controlled by a modern state of the art ternal source, usually a cooling tower. The condensed
Microcomputer Control Center that monitors its opera- refrigerant drains from the condenser into the liquid
tion. The Control Center is programmed by the opera- return line, where the variable orifice meters the flow
tor to suit job specifications. Automatic timed start-ups of liquid refrigerant to the evaporator to complete the
and shutdowns are also programmable to suit night- refrigerant circuit.
time, weekends, and holidays. The operating status,
temperatures, pressures, and other information perti- The major components of a chiller are selected to han-
nent to operation of the chiller are automatically dis- dle the refrigerant, which would be evaporated at full
played and read on a graphic display. Other displays load design conditions. However, most systems will
can be observed by pressing the keys as labeled on the be called upon to deliver full load capacity for only a
Control Center. The chiller with the OptiView Control relatively small part of the time the unit is in operation.
Center is compatible with an electro-mechanical start-
er, YORK Solid State Starter (optional), or Variable CAPACITY CONTROL
Speed Drive (optional). The major components of a chiller are selected for full
In operation, a liquid (water or brine to be chilled) load capacities, therefore capacity must be controlled
flows through the evaporator, where boiling refrigerant to maintain a constant chilled liquid temperature leav-
absorbs heat from the liquid. The chilled liquid is then ing the evaporator. Pre-rotation vanes (PRV), located
piped to fan coil units or other air conditioning terminal at the entrance to the compressor impeller, compensate
units, where it flows through finned coils, absorbing for variation in load (See Figure 1).
heat from the air. The warmed liquid is then returned to The position of these vanes is automatically controlled
the chiller to complete the chilled liquid circuit. through a lever arm attached to an electric motor lo-
cated 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.

7619A(D)

Figure 1 - COMPRESSOR PRE-ROTATION VANES

JOHNSON CONTROLS 7
 FORM 160.76-O1
SECTION 1 - DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
ISSUE DATE: 05/22/2019

Refrigerant Flow-Thru Chiller

(Falling Film YK Mod G
Evaporator)
Refrigerant Flow-Thru Cross-Section Diagram
(Falling-Film Evaporator)

LEGEND
High Pressure Vapor

High Pressure Liquid Refrigerant

Low Pressure Liquid Refrigerant

Low Pressure Vapor

COMPRESSOR

HOT GAS PRE-ROTATION

BYPASS VALVE VANES

SUCTION

OPTIONAL HOT GAS

DISCHARGE BYPASS LINE

OPTIONAL LIQUID LEVEL

ISOLATION VALVE
VALVE

EVAPORATOR
CONDENSER

SUCTION
BAFFLE

LIQUID LEVEL
LIQUID LEVEL

SUB-COOLER

OPTIONAL
ISOLATION LD00924A
VALVE

Rev. 2 (10-11-2010)
Figure 2 - REFRIGERANT FLOW-THRU CHILLER (FALLING FILM EVAPORATOR) Dan Sowers
dan.sowers-ext@jci.com
(717) 771-7535

8 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

SECTION 2 - SYSTEM OPERATING PROCEDURES

OIL HEATERS
2
If the oil heater is de-energized during a shutdown pe- • If the oil level during operation is in the OVER
riod, it must be energized for 12 hours prior to starting FULL region of the oil level indicator, oil should
compressor, or remove all oil and recharge compressor be removed from the oil reservoir, This reduces
with new oil. (See Oil Charging Procedure on page the oil level to the OPERATING RANGE.
20.)
• If the oil level during operation is in the LOW
OIL HEATER OPERATION OIL region of the oil level indicator, oil should
be added to the oil reservoir. (See Oil Charging
The oil heater operation is controlled by the OptiV- Procedure on page 20.)
iew™ Control Center. The heater is turned on and off
to maintain the oil temperature differential to a value Comply with EPA and local regulations
50°F (27.8°C) above the condenser saturation tem- when removing or disposing of refrigera-
perature. This target value is maintained by the control tion system oil!
panel.
If the target value is greater than 160°F (71°C), the tar-
get defaults 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). START-UP PROCEDURE
To prevent overheating of the oil in the event of a con-
trol center component failure, the oil heater thermostat Pre-Starting
(1HTR) is set to open at 180°F (82°C). Prior to starting the chiller, observe the Optiview™
Control Center – Operation Manual (160.76-O2).
CHECKING THE OIL LEVEL IN THE Make sure the display reads SYSTEM READY TO
OIL RESERVOIR START.
Proper operating oil level – During operation, the oil Vent any air from the chiller waterboxes
level should fall to the OPERATING RANGE identified prior to starting the water pumps. Failure
on the vertical oil level indicator label (See Figure 3). to do so will result in pass baffle damage.

START-UP
1. The Start/Stop control is operated via the Soft
START button on the Home Screen. When the
user presses the green START button, a dialog
box is displayed instructing the user to press the
ENTER button to start the chiller, or to press the
CANCEL button to abort the start.
2. When the chiller is running, the Start button is
replaced by a red SOFT STOP button. When the
user presses this button, a dialog box is displayed
instructing the user to press the ENTER button to
stop the chiller, or the CANCEL button to abort
LD08647 the stop command. The Soft Stop command will
Figure 3 - OIL LEVEL INDICATOR drive the PRV closed and then shut off the chiller.

JOHNSON CONTROLS 9
 FORM 160.76-O1
SECTION 2 - SYSTEM OPERATING PROCEDURES
ISSUE DATE: 05/22/2019

For display messages and information pertaining to the the operating year. Exact control of condenser water
operation refer to OptiView™ Control Center – Opera- such as a cooling tower bypass, is not necessary for
tion Manual (160.76-O2). most installations. The minimum entering condenser
Any malfunctions that occur during water temperature for full and part load conditions is
STOP/RESET are also displayed. specified in the chiller engineering guide,
where:
% Load
Min. ECWT = LCWT – C RANGE + 5ºF + 12 ( 100 )
% Load
Min. ECWT = LCWT – C RANGE + 2.8ºC + 6.6 ( 100 )

CHILLER OPERATION ECWT = Entering Condensing Water Temperature

The unit capacity will vary to maintain the leaving
LCWT = Leaving Chilled Water Temperature
CHILLED LIQUID TEMPERATURE setpoint by the
Pre-rotation Vanes which are modulated by an actua- C Range = Condensing water temperature range at the
tor under the control of the Microprocessor Board. The given load condition.
vane control routine employs proportional plus de-
rivative (rate) control action. A drop in chilled liquid At start-up, the entering condenser water temperature
temperature will cause the actuator to close the Pre- may be as much as 25°F (14°C) colder than the stand-
rotation Vanes to decrease chiller capacity. When the by return chilled water temperature. Cooling tower fan
chilled liquid temperature rises, the actuator will open cycling will normally provide adequate control of the
the Pre-rotation Vanes to increase the capacity of the entering condenser water temperature on most instal-
chiller. lations.

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 Pre-rotation
Vanes are entirely closed, the chiller will be shut down OPERATING LOG SHEET
by the Leaving Chilled Liquid – Low Temperature
Control. A permanent daily record of system operating condi-
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-
vent condensing water vapor inside the starter cabinet. An optional status printer is available for this purpose
Therefore, an additional temperature-controlled throttle or Figure 4 on page 11 shows a log sheet used by
valve is needed in the flow path for the starter heat ex- Johnson Controls Personnel for recording test data on
changer to regulate cooling above the equipment room chiller systems. It is available from the factory in pads
dewpoint for applications using cooling sources other of 50 sheets each under Form 160.44-F7 and may be
than evaporative air-exchange methods, such as wells, obtained through the nearest Johnson Controls office.
bodies of water, and chilled water. The temperature Automatic data logging is possible by connecting the
control valve should be the type to open on increasing optional printer and programming the DATA LOG-
drive coolant temperature, fail-closed, and set for a tem- GER function.
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.

10 JOHNSON CONTROLS
FORM 160.76-O1
SECTION 2 - SYSTEM OPERATING PROCEDURES
ISSUE DATE: 05/22/2019

OPERATING INSPECTIONS
By following a regular inspection using the display 7. Check the compressor motor current on the
readings of the Microcomputer Control Center, and SYSTEM Screen.
maintenance procedure, the operator will avoid serious 2
8. Check for any signs of dirty or fouled condenser
operating difficulty. The following list of inspections
tubes. (The temperature difference between wa-
and procedures should be used as a guide.
ter leaving condenser and saturated condensing
Daily temperature should not exceed the difference re-
corded for a new unit by more than 4°F (2.2°C)).
1. Check OptiView™ Control Center displays.
Weekly
2. If the compressor is in operation, check the bear-
ing oil pressure on the SYSTEM Screen. Also 1. Check the refrigerant charge. (See Checking The
check the oil level in the oil reservoir. Operating Refrigerant Charge During Unit Shutdown on
oil level should be operating range of oil indicator. page 26.)
Drain or add oil if necessary.
Monthly
3. Check entering and leaving condenser water pres- 1. Leak check the entire chiller.
sure and temperatures for comparison with job
design conditions. Condenser water temperatures Quarterly
can be checked on the SYSTEM Screen.
1. Perform chemical analysis of oil.
4. Check the entering and leaving chilled liquid tem-
peratures and evaporator pressure for compari- Semi-Annually (or more often as required)
son with job design conditions on the SYSTEM 1. Change and inspect compressor oil filter element.
Screen.
2. Oil return system.
5. Check the condenser saturation temperature
a. Change dehydrator.
(based upon condenser pressure sensed by the
condenser transducer) on the SYSTEM Screen. b. Check nozzle of eductor for foreign particles.
6. Check the compressor discharge temperature on 3. Check controls and safety cutouts.
the SYSTEM Screen. During normal operation
discharge temperature should not exceed 220°F
(104°C).

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.

Figure 4 - LIQUID CHILLER LOG SHEETS

JOHNSON CONTROLS 11
 FORM 160.76-O1
SECTION 2 - SYSTEM OPERATING PROCEDURES
ISSUE DATE: 05/22/2019

Annually (more often if necessary)

1. Drain and replace the oil in the compressor oil sump. will stop automatically. The oil pump will contin-
(See Oil Charging Procedure on page 20.) 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
Microcomputer Control Center, in which case it
b. Inspect and clean tubes as required. will shut off automatically simultaneously with
c. Inspect end sheets. the oil pump.). (The actual water pump con-
tact operation is dependent upon the position of
3. Compressor Drive Motor (Refer to the motor man- Microboard jumper J54.)
ufacturers maintenance and service instruction sup-
plied with unit) 3. Open the switch to the cooling tower fan motors,
if used.
a. Clean air passages and windings per manu-
facturers instructions. 4. The compressor sump oil heater is energized when
the unit is stopped.
b. Meg motor windings – See Figure 13 on
page 26 for details. PROLONGED SHUTDOWN
c. Lubricate per motor manufacturer recom- If the chiller is to be shut down for an extended period
mendations. of time (for example, over the winter season), the fol-
lowing paragraphs outline the procedure to be followed:
4. Inspect and service electrical components as necessary.
5. Perform refrigerant analysis. 1. Test all system joints for refrigerant leaks with a
leak detector. If any leaks are found, they should
If quarterly inspection indicates oil is fine, be repaired before allowing the system to stand
replacing the oil is not necessary. for a long period of time.
During long idle periods, the tightness of the sys-
tem should be checked periodically.
2. If freezing temperatures are encountered while
NEED FOR MAINTENANCE OR SERVICE the system is idle, carefully drain the cooling wa-
ter from the cooling tower, condenser, condenser
If the system is malfunctioning in any manner or the
pump, and the chilled water system-chilled water
unit is stopped by one of the safety controls, consult
pump and coils.
the Operation Analysis Chart, Table 1 on page 21 of
this manual. After consulting this chart, if you are un- Open the drains on the evaporator and condenser
able to make the proper repairs or adjustments to start liquid heads to assure complete drainage. (If a
the compressor or the particular trouble continues to Variable Speed Drive, drain its cooling system.
hinder the performance of the unit, please call the near- If Solid State Starter equipped drain liquid from
est Johnson Controls District Office. Failure to report starter cooling loop.)
constant troubles could damage the unit and increase
3. If freezing temperatures are encountered for peri-
the cost of repairs.
ods longer than a few days, the refrigerant should
STOPPING THE SYSTEM be recovered to containers to prevent leakage from
O-ring joints.
The OptiView™ Control Center can be programmed
to start and stop automatically (maximum, once each 4. On the SETUP Screen, disable the clock. This
day) whenever desired. Refer to the OptiView™ Con- conserves the battery.
trol Center – Operation Manual (160.76-O2). To stop 5. Open the main disconnect switches to the com-
the chiller, proceed as follows: pressor motor, condenser water pump and the
1. Push the soft shutdown key on the homescreen on chilled water pump. Open the 115 volt circuit to
the OptiView panel or rapid stop with the COM- the Control Center.
PRESSOR STOP/RESET switch. The compressor

12 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

SECTION 3 - SYSTEM COMPONENTS DESCRIPTION

GENERAL
The YORK Model YK Centrifugal Liquid Chiller is 2. Compressor Driven Shaft (High Speed)
completely factory-packaged including evaporator,
a. Forward and reverse high speed thrust
condenser, compressor, motor, lubrication system, Op-
bearing. 3
tiView™ Control Center, and all interconnecting unit
piping and wiring. b. Two journal bearings.

COMPRESSOR 3. Speed Increasing Gears

The compressor is a single-stage centrifugal type pow- a. Meshing surfaces of drive and pinion gear
ered by an open-drive electric motor. teeth.

The rotor assembly consists of a heat-treated alloy steel To provide the required amount of oil under the neces-
drive shaft and impeller shaft with a cast aluminum, sary pressure to properly lubricate these parts, a motor
fully shrouded impeller. The impeller is designed for driven submersible oil pump is located in a remote oil
balanced thrust and is dynamically balanced and over- sump.
speed tested. The inserted type journal and thrust bear- Upon pressing of the COMPRESSOR START switch
ings are fabricated of aluminum alloy. Single helical on the Control Center, the oil pump is immediately en-
gears with crowned teeth are designed so that more ergized. After a 50 second pre-lube period, the com-
than one tooth is in contact at all times. Gears are inte- pressor motor will start. The oil pump will continue to
grally assembled in the compressor rotor support and run during the entire operation of the compressor, and
are film lubricated. Each gear is individually mounted for 150 seconds during compressor coastdown.
in its own journal and thrust bearings.
The submerged oil pump takes suction from the sur-
The open-drive compressor shaft seal is a double bel- rounding oil and discharges it to the oil cooler where
lows cartridge style with ceramic internal and atmo- heat is rejected. The oil flows from the oil cooler to
spheric seal faces. The seal is oil-flooded at all times the oil filter. The oil leaves the filter and flows to the
and is pressure-lubricated during operation. emergency oil reservoir where it is distributed to the
compressor bearings. The oil lubricates the compressor
CAPACITY CONTROL rotating components and is returned to the oil sump.
Pre-rotation vanes (PRV) modulate chiller capacity
There is an emergency oil reservoir located at the high-
from 100% to as low as 15% of design for normal air
est point in the lubrication system internally in the com-
conditioning applications. Operation is by an external,
pressor. It provides an oil supply to the various bear-
electric PRV actuator which automatically controls the
ings and gears in the event of a system shutdown due
vane position to maintain a constant leaving chilled liq-
to power failure. The reservoir, located on the top of
uid temperature.
the compressor, allows the oil to be distributed through
COMPRESSOR LUBRICATION SYSTEM the passages by gravity flow, thus providing necessary
lubrication during the compressor coastdown.
The chiller lubrication system consists of the oil pump,
oil filter, oil cooler and all interconnecting oil piping OIL PUMP
and passages. There are main points within the com-
For normal operation, the oil pump should operate at
pressor which must be supplied with forced lubrication
all times during chiller operation.
as follows:
On shutdown of the system for any reason, the oil
1. Compressor Drive Shaft (Low Speed)
pump operates and continues to run for 150 seconds.
a. Shaft seal. The system cannot restart during that time interval.
b. Front and rear journal bearings – one on each
side of driving gear.
c. Low speed thrust bearing (forward and reverse).

JOHNSON CONTROLS 13
 FORM 160.76-O1
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
ISSUE DATE: 05/22/2019

OPTIVIEW CONTROL
CENTER

COMPRESSOR

SUCTION

RELIEF
VARIABLE
VALVES
SPEED
DRIVE

EVAPORATOR

LD15222

VARIABLE SPEED
SIGHT
OIL PUMP
GLASS
CONTROL BOX

FRONT VIEW

Figure 5 - SYSTEM COMPONENTS FRONT VIEW

14 JOHNSON CONTROLS
FORM 160.76-O1
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
ISSUE DATE: 05/22/2019

MOTOR
COMPRESSOR

OIL FILTER
DISCHARGE
LINE

LD15223

LIQUID LINE
CONDENSER OIL PUMP
HOUSING

REAR VIEW

Figure 6 - SYSTEM COMPONENTS REAR VIEW

JOHNSON CONTROLS 15
 FORM 160.76-O1
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
ISSUE DATE: 05/22/2019

COMPRESSOR ROTOR
SUPPORT SECTION

H.S.
SHAFT
SEAL
EMERGENCY
OIL RESERVE

HIGH
PRESSURE
TRANSDUCER

MAIN JOURNAL
AND THRUST
BEARING
IMPELLER

THRUST COLLAR BEARING

(PINION GEAR
HIGH SPEED SHAFT)
THRUST COVER
(PRV)
DOUBLE INLET
BELLOWS VALVES
SHAFT SEAL

LOW SPEED- THRUST

GEAR REAR COLLAR
BEARING BEARING

LOW LOW SPEED

SPEED GEAR THRUST
COVER

REFRIG.

SIGHT
HOT GLASSES
THERMISTOR

OIL OIL
HEATER COOLER
LOW OIL
ANGLE PRESSURE
DRAIN VALVE TRANSDUCER

OIL OIL SUBMERSIBLE

SUMP OIL TEMP.
PUMP OIL PUMP CONTROL
OIL SUCTION WITH 3-PHASE MOTOR
FILTER

OIL

LD15200

Figure 7 - SCHEMATIC DRAWING – (YK) COMPRESSOR LUBRICATION SYSTEM

16 JOHNSON CONTROLS
FORM 160.76-O1
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
ISSUE DATE: 05/22/2019

OIL HEATER
During long idle periods, the oil in the compressor oil reliable control. A specifically designed spray distribu-
reservoir tends to absorb as much refrigerant as it can tor provides uniform distribution of refrigerant over
hold, depending upon the temperature of the oil and the entire length to yield optimum heat transfer. The
the pressure in the reservoir. As the oil temperature is hybrid falling film evaporator design has suction baf-
lowered, the amount of refrigerant absorbed will be fles around the sides and above the falling film section
3
increased. If the quantity of refrigerant in the oil be- to prevent liquid refrigerant carryover into the com-
comes excessive, violent oil foaming will result as the pressor.
pressure within the system is lowered on starting. This
foaming is caused by refrigerant boiling out of the oil A 1 1/2 in. (38 mm) liquid level sight glass is conve-
as the pressure is lowered. If this foam reaches the oil niently located on the side of the shell to aid in deter-
pump suction, the bearing oil pressure will fluctuate mining proper refrigerant charge. The evaporator shell
with possible temporary loss of lubrication, causing the contains a dual refrigerant relief valve arrangement set
oil pressure safety cutout to actuate and stop the sys- at 235 psig (16.2 barg) on Q compressor models; or
tem. Refer to OptiView™ Control Center – Operation single-relief valve arrangement, if the chiller is sup-
Manual (160.76-O2). plied with optional refrigerant isolation valves. A 1 in.
(25.4 mm) refrigerant charging valve is provided. The
MOTOR DRIVELINE condenser is a shell and tube type, with a discharge
gas baffle to prevent direct high velocity impingement
The compressor motor is an open-drip-proof, squir- on the tubes. The baffle is also used to distribute the
rel cage, induction type constructed to YORK design refrigerant gas flow properly for most efficient heat
specifications. 60 Hertz motors operate at 3570 rpm. transfer. An integral sub‑cooler is located at the bottom
50 Hertz motors operate at 2975 rpm. of the condenser shell providing highly effective liquid
The open motor is provided with a D-flange, cast iron refrigerant subcooling to provide the highest cycle ef-
adapter mounted to the compressor and supported by a ficiency. The condenser contains dual refrigerant relief
motor support. valves set at 235 psig (16.2 barg).

Motor drive shaft is directly connected to the compres- The removable waterboxes are fabricated of steel. The
sor shaft with a flexible disc coupling. This coupling design working pressure is 150 psig (10.3 barg) and
has all metal construction with no wearing parts to as- the boxes are tested at 225 psig (15.5 barg). Integral
sure long life, and no lubrication requirements to pro- steel water baffles are located and welded within the
vide low maintenance. waterbox to provide the required pass arrangements.
Stub‑out water nozzle connections with ANSI/AWWA
For units utilizing remote Electro-Mechanical starters, C-606 grooves are welded to the waterboxes. These
a terminal box is provided for field connected conduit. nozzle connections are suitable for ANSI/AWWA
Motor terminals are brought through the motor cas- C-606 couplings, welding or flanges, and are capped
ing into the terminal box. Jumpers are furnished for for shipment. Plugged 3/4 in. (19 mm) drain and vent
three-lead type of starting. Motor terminal lugs are not connections are provided in each waterbox.
furnished. Overload/over current transformers are fur-
nished with all units. REFRIGERANT FLOW CONTROL
Refrigerant flow to the evaporator is controlled by a
HEAT EXCHANGERS
variable orifice.
Evaporator and condenser shells are fabricated from
rolled carbon steel plates with fusion welded seams. A level sensor senses the refrigerant level in the con-
denser and outputs an analog voltage to the Microboard
Heat exchanger tubes are internally enhanced type. that represents this level (0% = empty; 100% = full).
Under program control, the Microboard modulates a
The evaporator is a shell and tube type with customer
variable orifice to control the condenser refrigerant
process fluid flowing inside the tubes and refrigerant
level to a programmed setpoint. Other setpoints affect
removing heat on the shell side via evaporation. The
the control sensitivity and response. These setpoints
evaporator utilizes a hybrid falling film design. It con-
must be entered at chiller commissioning by a qualified
tains a balance of falling film technology to optimize
service technician. Only a qualified service technician
efficiency, minimize refrigerant charge, and maintain
may modify these settings.

JOHNSON CONTROLS 17
 FORM 160.76-O1
SECTION 3 - SYSTEM COMPONENTS DESCRIPTION
ISSUE DATE: 05/22/2019

While the chiller is shut down, the orifice will be in the OPTIVIEW™ CONTROL CENTER
fully open position causing the sensed level to be ap-
The OptiView™ Control Center is factory-mounted,
proximately 0%. When the chiller is started, after the
wired and tested. The electronic panel automatically
vane motor end switch (VMS) opens when entering
controls the operation of the unit in meeting system
SYSTEM RUN, if actual level is less than the level
cooling requirements while minimizing energy usage.
setpoint, a linearly increasing ramp is applied to the lev-
For detailed information on the Control Center, see
el setpoint. This ramp causes the setpoint to go from the
SECTION 2 - SYSTEM OPERATING PROCEDURES
initial refrigerant level (approximately 0%) to the pro-
of this manual.
grammed setpoint over a programmable period of time.
If the actual level is greater than the setpoint when the SOLID STATE STARTER (OPTIONAL)
VMS opens, there is no pulldown period, it immedi- The Solid State Starter is a reduced voltage starter that
ately begins to control to the programmed setpoint. controls and maintains a constant current flow to the
motor during start-up. It is mounted on the chiller. Pow-
While the chiller is running, the refrigerant level is nor-
er and control wiring between the starter and chiller
mally controlled to the level setpoint. However, any-
are factory installed. The starter enclosure is NEMA-1
time the vanes fully close (VMS closes), normal level
with a hinged access door with lock and key. Electrical
control is terminated, any refrigerant level setpoint in
lugs for incoming power wiring are provided.
effect is cancelled and the outputs to the level control
will be constant open. VARIABLE SPEED DRIVE (OPTIONAL)
OPTIONAL SERVICE ISOLATION VALVES A Variable Speed Drive can be factory packaged with
the chiller. It is designed to vary the compressor mo-
If your chiller is equipped with optional service iso-
tor speed and pre-rotation vane position by controlling
lation valves on the discharge and liquid line, these
the frequency and voltage of the electrical power to
valves must remain open during operation. These
the motor. Operational information is contained in the
valves are used for isolating the refrigerant charge in
Variable Speed Drive – Operation (Form 160.00-O1).
either the evaporator or condenser to allow service ac-
The control logic automatically adjusts motor speed
cess to the system. A refrigerant pump-out unit will be
and compressor pre-rotation vane position for maxi-
required to isolate the refrigerant.
mum part load efficiency by analyzing information fed
Isolation of the refrigerant in this system to it by sensors located throughout the chiller.
must be performed by a qualified service
technician.

OPTIONAL HOT GAS BYPASS

Hot gas bypass is optional and is used to eliminate
compressor surge during light load or high head op-
eration. The OptiView™ control panel will automati-
cally modulate the hot gas valve open and closed as
required. Adjustment of the hot gas control valve must
be performed by a qualified service technician follow-
ing the Hot Gas Set-up procedure.
Changes in chilled water flow will require
re-adjustment of the hot gas control to
insure proper operation.

18 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

SECTION 4 - OPERATIONAL MAINTENANCE

OIL RETURN SYSTEM CHANGING THE DEHYDRATOR

The oil return system continuously maintains the To change the dehydrator, use the following procedure:
proper oil level in the compressor oil sump (See
Figure 8). 1. Isolate the dehydrator at the stop valves.
2. Remove the dehydrator (See Figure 8).
High pressure condenser gas flows continuously
3. Assemble the new filter-drier.
through the eductor inducing the low pressure, oil rich 4
liquid to flow from the evaporator, through the dehy- 4. Open evaporator stop valve and check dehydrator
drator to the compressor sump. connections for refrigerant leaks.
5. Open all the dehydrator stop valves.

COMPRESSOR

SOLENOID VALVE

CONDENSER

EVAPORATOR

CHECK VALVE OIL EDUCTOR BLOCK

SOLENOID VALVE

STOP VALVE DEHYDRATOR

STOP VALVE

LD08578

Figure 8 - OIL RETURN SYSTEM

JOHNSON CONTROLS 19
 FORM 160.76-O1
SECTION 4 - OPERATIONAL MAINTENANCE
ISSUE DATE: 05/22/2019

THE OIL CHARGE

The nominal oil charge for Q3-Q7 compressors is 11 charging valve (A) located on the remote oil res-
gallons, P7-H9 compressors is 17.5 gallons, K1-K4 ervoir cover plate. (See Figure 9) Do not tighten
compressors is 20 gallons, and K7 compressors is 24 the connection at the charging valve until after the
gallons. air is forced out by pumping a few strokes of the
oil pump. This fills the lines with oil and prevents
New YORK Refrigeration oil must be used in the cen- air from being pumped into the system.
trifugal compressor. Since oil absorbs moisture when
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 4. As soon as oil charging is complete, close the
on the vertical oil level indicator. If the oil level falls power supply to the starter to energize the oil
into the lower sight glass, it is necessary to add oil to heater. This will keep the concentration of refrig-
the compressor oil reservoir. The oil should be charged erant in the oil to a minimum.
into the oil reservoir using the YORK Oil Charging
Pump – YORK P/N 470-10654-000. 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
add oil to bring the level back into the OPERATING
2. Immerse the suction connection of the oil charg-
RANGE of the oil level indicator label.
ing pump in a clean container of new oil and con-
nect the pump discharge connection to the oil

OIL
CHARGING
PUMP

LD08579
OIL CHARGING VALVE LD08648

Figure 9 - CHARGING OIL RESERVOIR WITH OIL

20 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

SECTION 5 - TROUBLESHOOTING

Table 1 - OPERATION ANALYSIS CHART

RESULTS POSSIBLE CAUSE REMEDY
1. SYMPTOM: ABNORMALLY  HIGH  DISCHARGE  PRESSURE
Temperature difference between
condensing temperature and water off Air in condenser.
condenser higher than normal.
Clean condenser tubes. Check water
Condenser tubes dirty or scaled.
conditioning.
High discharge pressure. Reduce condenser water inlet
High condenser water temperature. temperature. (Check cooling tower and 5
water circulation.)
Temperature difference between
condenser water on and water off Increase the quantity of water through
Insufficient condensing water flow.
higher than normal, with normal the condenser to proper value.
evaporator pressure.
2. SYMPTOM: ABNORMALLY LOW SUCTION PRESSURE
Temperature difference between Check for leaks and charge refrigerant
Insufficient charge of refrigerant.
leaving chilled water and refrigerant in into system.
evaporator greater than normal with
Variable orifice problem. Remove obstruction.
high discharge temperature.
Temperature difference between leaving
chilled water and refrigerant in the
Evaporator tubes dirty or restricted. Clean evaporator tubes.
evaporator greater than normal with
normal discharge temperature.
Check pre-rotation vane motor
Temperature of chilled water too low
Insufficient load for system capacity. operation and setting of low water
with low motor amperes.
temperature cutout.
3. SYMPTOM: HIGH EVAPORATOR PRESSURE
Check the pre-rotation vane motor
Pre-rotation vanes fail to open.
positioning circuit.
High chilled water temperature. Be sure the vanes are wide open
System overload. (without overloading the motor) until the
load decreases.
4. SYMPTOM: NO OIL PRESSURE WHEN SYSTEM START BUTTON PUSHED
Check rotation of oil pump (Electrical
Oil pump running in wrong direction.
Low oil pressure displayed on control Connections).
center; compressor will not start. Troubleshoot electrical problem with oil
Oil pump not running.
pump VSD.
5. SYMPTOM: UNUSUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS
Unusually high oil pressure is
displayed when the oil pressure High oil pressure. Transducer Replace low or high oil pressure
display key is pressed when the oil defective. transducer.
pump is running.

JOHNSON CONTROLS 21
 FORM 160.76-O1
SECTION 5 - TROUBLESHOOTING
ISSUE DATE: 05/22/2019

TABLE 1 - OPERATION ANALYSIS CHART (CONT'D)

RESULTS POSSIBLE REMEDY

6. SYMPTOM: OIL PUMP VIBRATES OR IS NOISY
Oil pump vibrates or is extremely noisy
Oil not reaching pump suction inlet in
with some oil pressure when pressing Check oil level.
sufficient quantity.
OIL PRESSURE display key.
When oil pump is run without
an oil supply, it will vibrate
and become extremely noisy.
Worn or failed oil pump. Repair/Replace oil pump.

7. SYMPTOM: REDUCED OIL PUMP CAPACITY

Excessive end clearance pump.
Inspect and replace worn parts.
Oil pump pumping capacity. Other worn pump parts.
Partially blocked oil supply inlet. Check oil inlet for blockage.
8. SYMPTOM: OIL PRESSURE GRADUALLY DECREASES (Noted by Observation of Daily Log Sheets)
When oil pump VSD frequency
increases to 55 + Hz to maintain target Oil filter is dirty. Change oil filter.
oil pressure.
9. SYMPTOM: OIL PRESSURE SYSTEM CEASES TO RETURN AN OIL/REFRIGERANT SAMPLE
Filter-drier in oil return system dirty. Replace old filter-drier with new.
Oil refrigerant return not functioning. Remove jet, inspect for dirt.
Jet or orifice of oil return jet clogged.
Remove dirt using solvent and replace.
10. SYMPTOM: OIL PUMP FAILS TO DELIVER OIL PRESSURE
No oil pressure registers when pressing
Faulty oil pressure transducer.
OIL PRESSURE display key when oil Replace oil pressure transducer.
Faulty wiring/connectors.
pump runs.

22 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

SECTION 6 - MAINTENANCE

RENEWAL PARTS
Please order all replacement parts at www.hvacnaviga- If any leaks are indicated, they must be repaired im-
tor.com (see Figure 10). mediately. Usually, leaks can be stopped by tighten-
ing flare nuts or flange bolts. However, for any major
repair, the refrigerant charge must be removed. (See
Handling Refrigerant For Dismantling And Repairs
on page 28)

CONDUCTING PRESSURE TEST

With the refrigerant charge removed and all known
leaks repaired, the system should be charged with a
small amount of refrigerant mixed with dry nitrogen so
that electronic leak detector can be used to detect any 6
LD28095
leaks too small to be found by the soap test.
Figure 10 - PARTS NAVIGATOR
To test with refrigerant, proceed as follows:
CHECKING SYSTEM FOR LEAKS
1. With no pressure in the system, charge refrigerant
Leak Testing During Operation gas into the system through the charging valve to
a pressure of 2 psig (14 kPa).
The refrigerant side of the system is carefully pressure
tested and evacuated at the factory. 2. Build up the system pressure with dry nitrogen to
approximately 75 psig to 100 psig (517 kPa to 690
After the system has been charged, the system should
kPa). To be sure that the concentration of refriger-
be carefully leak tested with a compatible leak detector
ant has reached all parts of the system, slightly
to be sure that all joints are tight.
open the oil charging valve and test for the pres-
ence of refrigerant with a leak detector.

EVACUATION AND DEHYDRATION OF UNIT

27385A(D)

STOP VALVE

CHARGING VALVE

WET BULB TEMPERATURE VACUUM PUMP

INDICATOR OR VACUUM GAUGE LD00949

Figure 11 - EVACUATION OF CHILLER

JOHNSON CONTROLS 23
 FORM 160.76-O1
SECTION 6 - MAINTENANCE
ISSUE DATE: 05/22/2019

Table 2 - SYSTEM PRESSURES

*GAUGE ABSOLUTE
BOILING
INCHES OF TEMPERATURES
MERCURY (HG) OF
MILLIMETERS OF
BELOW ONE PSIA MICRONS WATER
MERCURY (HG)
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
NOTES: *One standard atmosphere = 14.696 PSIA PSIG = lb. per sq. in. gauge pressure
= 760 mm Hg. absolute pressure at 32°F = Pressure above atmosphere
= 29.921 inches Hg. absolute at 32°F PSIA = lb. per sq. in. absolute pressure
= Sum of gauge plus atmospheric pressure

3. Test around each joint and factory weld. It is im- 2. Open wide all system valves. Be sure that all
portant that this test be thoroughly and carefully valves to the atmosphere are closed.
done, spending as much time as necessary and us-
3. Operate the vacuum pump in accordance with
ing a good leak detector.
VACUUM DEHYDRATION until a wet bulb
4. To check for refrigerant leaks in the evaporator temperature of +32°F (0°C) or a pressure of 5 mm
and condenser, open the vents in the evaporator Hg is reached. See Table 2 on page 24 for cor-
and condenser heads and test for the presence of responding values of pressure.
refrigerant. If no refrigerant is present, the tubes
4. To improve evacuation circulate hot water (not
and tube sheets may be considered tight. If refrig-
to exceed 125°F, 51.7ºC) through the evaporator
erant is detected at the vents, the heads must be
and condenser tubes to thoroughly dehydrate the
removed, the leak located (by means of soap test
shells. If a source of hot water is not readily avail-
or leak detector) and repaired.
able, a portable water heater should be employed.
VACUUM TESTING DO NOT USE STEAM. A suggested method is
to connect a hose between the source of hot water
After the pressure test has been completed, the vacuum under pressure and the evaporator head drain con-
test should be conducted as follows: nection, out the evaporator vent connection, into
1. Connect a high capacity vacuum pump, with in- the condenser head drain and out the condenser
dicator, to the system charging valve as shown in vent. To avoid the possibility of causing leaks, the
Figure 11 on page 23 and start the pump. (See temperature should be brought up slowly so that
Vacuum Dehydration on page 25.) the tubes and shell are heated evenly.

24 JOHNSON CONTROLS
FORM 160.76-O1
SECTION 6 - MAINTENANCE
ISSUE DATE: 05/22/2019

5. Close the system charging valve and the stop the system, the capacity and efficiency of the vacuum
valve between the vacuum indicator and the vac- pump, the room temperature and the quantity of water
uum pump. Then disconnect the vacuum pump present in the system. By the use of the vacuum indi-
leaving the vacuum indicator in place. cator as suggested, the test tube will be evacuated to
the same pressure as the system, and the distilled water
6. Hold the vacuum obtained in Step 3 in the system
will be maintained at the same saturation temperature
for 8 hours; the slightest rise in pressure indicates a
as any free water in the system, and this temperature
leak or the presence of moisture, or both. If, after 24
can be observed on the thermometer.
hours the wet bulb temperature in the vacuum indi-
cator has not risen above 40°F (4.4°C) or a pressure If the system has been pressure tested and found to be
of 6.3 mm Hg, the system may be considered tight. tight prior to evacuation, then the saturation temperature
7. If the vacuum does not hold for 8 hours within the recordings should follow a curve similar to the typical
limits specified in Step 6 above, the leak must be saturation curve as shown as Figure 12 on page 26.
found and repaired. The temperature of the water in the test tube will drop
Be sure that the vacuum indicator is as the pressure decreases, until the boiling point is
valved off while holding the system reached, at which point the temperature will level off 6
vacuum, and be sure to open the valve and remain at this level until all of the water in the shell
between the vacuum indicator and the is vaporized. When this final vaporization has taken
system when checking the vacuum after place the pressure and temperature will continue to
the 8 hour period. drop until eventually a temperature of 35°F (1.6°C) or
a pressure of 5 mm Hg is reached.
VACUUM DEHYDRATION
When this point is reached, practically all of the air has
To obtain a sufficiently dry system, the following in- been evacuated from the system, but there is still a small
structions have been assembled to provide an effective amount of moisture left. In order to provide a medium
method for evacuating and dehydrating a system in the for carrying this residual moisture to the vacuum pump,
field. Although there are several methods of dehydrating nitrogen should be introduced into the system to bring
a system, we are recommending the following, as it pro- it to atmospheric pressure and the indicator temperature
duces one of the best results, and affords a means of ob- will return to approximately ambient temperature. Close
taining accurate readings as to the extent of dehydration. off the system again, and start the second evacuation.
The equipment required to follow this method of de- The relatively small amount of moisture left will be
hydration consists of a wet bulb indicator or vacuum carried out through the vacuum pump and the tem-
gauge, a chart showing the relation between dew point perature or pressure shown by the indicator should
temperature and pressure in inches of mercury (vacuum; drop uniformly until it reaches a temperature of 35°F
see Table 2 on page 24), and a vacuum pump capable (1.6°C) or a pressure of 5 mm Hg.
of pumping a suitable vacuum on the system.
When the vacuum indicator registers this tempera-
OPERATION ture or pressure, it is a positive sign that the system is
evacuated and dehydrated to the recommended limit. If
Dehydration of a refrigerant system can be obtained
this level cannot be reached, it is evident that there is a
by this method because the water present in the system
leak somewhere in the system. Any leaks must be cor-
reacts much as a refrigerant would. By pulling down
rected before the indicator can be pulled down to 35°F
the pressure in the system to a point where its satu-
(1.6°C) or 5 mm Hg in the primary evacuation.
ration temperature is considerably below that of room
temperature, heat will flow from the room through the During the primary pulldown, keep a careful watch on
walls of the system and vaporize the water, allowing the wet bulb indicator temperature, and do not let it fall
a large percentage of it to be removed by the vacuum below 35°F (1.6°C). If the temperature is allowed to
pump. The length of time necessary for the dehydra- fall to 32°F (0°C), the water in the test tube will freeze,
tion of a system is dependent on the size or volume of and the result will be a faulty temperature reading.

JOHNSON CONTROLS 25
 FORM 160.76-O1
SECTION 6 - MAINTENANCE
ISSUE DATE: 05/22/2019

should be purged each time a full container of refriger-

ant is connected and changing containers should be done

NITROGEN ADDED
as quickly as possible to minimize the loss of refrigerant.
INDICATOR READING -°F

SEC ACUA
PRIM
ARY

EV
EVAC
Refrigerant may be furnished in cylinders containing

ON
UATI
ON
either 30, 50, 125, 1,025, or 1750 lb. (13.6, 22.6, 56.6,

DAR ION
464, or 794 kg) of refrigerant.

T
Y
The nameplate on the chiller contains the
correct refrigerant charge information
for the chiller.

TIME
LD00474

CHECKING THE REFRIGERANT CHARGE

Figure 12 - SATURATION CURVE DURING UNIT SHUTDOWN
The refrigerant charge is specified for each chiller model.
REFRIGERANT CHARGING Charge the correct amount of refrigerant and record the
To avoid the possibility of freezing liquid within the level in the evaporator sight glass.
evaporator tubes when charging an evacuated system, The refrigerant charge should always be checked and
only refrigerant vapor from the top of the drum or cyl- trimmed when the system is shut down.
inder must be admitted to the system pressure until the
system pressure is raised above the point correspond- The refrigerant charge level must be checked after the
ing to the freezing point of the evaporator liquid. pressure and temperature have equalized between the
condenser and evaporator. This would be expected to be
While charging, every precaution must be taken to pre- 4 hours or more after the compressor and water pumps
vent moisture laden air from entering the system. Make are stopped. The level should be visible in the sight glass.
up a suitable charging connection from new copper tub-
ing to fit between the system charging valve and the fit- Charge the refrigerant in accordance with the meth-
ting on the charging drum. This connection should be od shown under the REFRIGERANT CHARGING,
as short as possible but long enough to permit sufficient above. The refrigerant level should be observed and
flexibility for changing drums. The charging connection the level recorded after initial charging.

MEGOHM
BETWEEN MEGOHM
WINDINGS METER

MAIN DISCONNECT
MEGOHM EACH
(OPEN)
WINDING TO GROUND
STARTER (OPEN)
MEGOHM METER
LD00475

Figure 13 - DIAGRAM, MEGGING MOTOR WINDINGS

26 JOHNSON CONTROLS
 Minimum Insulation Resistance vs. Temperature (per IEEE Std 43)
Open Motors

1. Megger readings should be taken after Megger voltage has been applied one minute.
FORM 160.76-O1

2. If insulation resistance lies to the right of the applicable curve the motor is acceptable for use.

JOHNSON CONTROLS
ISSUE DATE: 05/22/2019

3. If insulation resistance lies to the left of the applicable curve, the motor should not be run. The motor
should be heated to 250°F 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. A
 ny 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.

LEGEND
A 2
 00 - 600V
DELTA CONN.
B 2
 300V
(Entire Windings)
C 2
 00 - 600V

TEMPERATURE – °F
(Per Phase)
Note 5
D 3
 300 - 4160V
(Entire Windings)

Figure 14 - MOTOR STARTER TEMPERATURE AND INSULATION RESISTANCES

MEGOHMS

27
SECTION 6 - MAINTENANCE

LD00476
6
 FORM 160.76-O1
SECTION 6 - MAINTENANCE
ISSUE DATE: 05/22/2019

HANDLING REFRIGERANT FOR

DISMANTLING AND REPAIRS
If it becomes necessary to open any part of the refriger- Cleaning Evaporator And Condenser Tubes
ant system for repairs, it will be necessary to remove
Evaporator
the charge before opening any part of the unit. If the
chiller is equipped with optional valves, the refrigerant It is difficult to determine by any particular test wheth-
can be isolated in either the condenser or evaporator / er possible lack of performance of the water evaporator
compressor while making any necessary repairs. is due to fouled tubes alone or due to a combination
of troubles. Trouble which may be due to fouled tubes
MEGGING THE MOTOR is indicated when, over a period of time, the cooling
capacity decreases and the split (temperature differ-
While the main disconnect switch and compressor mo-
ence between water leaving the evaporator and the
tor starter are open, meg the motor as follows:
refrigerant temperature in the evaporator) increases. A
1. Using a megohm meter (megger), meg between gradual drop-off in cooling capacity can also be caused
phases and each phase to ground (See Figure 13 on by a gradual leak of refrigerant from the system or by a
page 26); these readings are to be interpreted us- combination of fouled tubes and shortage of refrigerant
ing the graph shown in Figure 14 on page 27. charge. An excessive quantity of oil in the evaporator
2. If readings fall below shaded area, remove exter- can also contribute to erratic performance.
nal leads from motor and repeat test.
Condenser
Motor is to be megged with the starter at
ambient temperature after 24 hours of In a condenser, trouble due to fouled tubes is usually
idle standby. indicated by a steady rise in head pressure, over a pe-
riod of time, accompanied by a steady rise in condens-
ing temperature, and noisy operation. These symptoms
may also be due to foul gas buildup. Purging will re-
move the foul gas revealing the effect of fouling.
Condensers And Evaporators General
Tube Fouling
Maintenance of condenser and evaporator shells is im- Fouling of the tubes can be due to deposits of two types
portant to provide trouble free operation of the chiller. as follows:
The water side of the tubes in the shell must be kept
clean and free from scale. Proper maintenance such as 1. Rust or sludge – which finds its way into the
tube cleaning, and testing for leaks, is covered on the tubes and accumulates there. This material usu-
following pages. ally does not build up on the inner tube surfaces
as scale, but does interfere with the heat transfer.
Chemical Water Treatment Rust or sludge can generally be removed from the
Since the mineral content of the water circulated tubes by a thorough brushing process.
through evaporators and condensers varies with almost 2. Scale – due to mineral deposits. These deposits,
every source of supply, it is possible that the water be- even though very thin and scarcely detectable
ing used may corrode the tubes or deposit heat resistant upon physical inspection, are highly resistant to
scale in them. Reliable water treatment companies are heat transfer. They can be removed most effec-
available in most larger cities to supply a water treat- tively by circulating an acid solution through the
ing process which will greatly reduce the corrosive and tubes.
scale forming properties of almost any type of water.
Tube Cleaning Procedures
As a preventive measure against scale and corrosion and
to prolong the life of evaporator and condenser tubes, a Brush Cleaning of Tubes
chemical analysis of the water should be made prefer- If the tube consists of dirt and sludge, it can usually be
ably before the system is installed. A reliable water treat- removed by means of the brushing process. Drain the
ment company can be consulted to determine whether water sides of the circuit to be cleaned (cooling wa-
water treatment is necessary, and if so, to furnish the ter or chilled water) remove the heads and thorough-
proper treatment for the particular water condition.

28 JOHNSON CONTROLS
FORM 160.76-O1
SECTION 6 - MAINTENANCE
ISSUE DATE: 05/22/2019

ly clean each tube with a soft bristle bronze or nylon and condenser should be valved off from the rest of
brush. DO NOT USE A STEEL BRISTLE BRUSH. A the water circuit and drained immediately to prevent
steel brush may damage the tubes. severe rusting and corrosion. The refrigerant system
should then be drained and purged with dry nitrogen to
Improved results can be obtained by admitting water prevent severe rusting and corrosion. If a tube leak is
into the tube during the cleaning process. This can be indicated, the exact location of the leak may be deter-
done by mounting the brush on a suitable length of 1/8 mined as follows:
in. pipe with a few small holes at the brush end and
connecting the other end by means of a hose to the wa- 1. Remove the heads and listen at each section of
ter supply. tubes for a hissing sound that would indicate gas
leakage. This will assist in locating the section of
The tubes should always be brush cleaned before acid tubes to be further investigated. If the probable
cleaning. location of the leaky tubes has been determined,
treat that section in the following manner (if the
Acid Cleaning Of Tubes
location is not definite, all the tubes will require
If the tubes are fouled with a hard scale deposit, they investigations).
may require acid cleaning. It is important that before
6
acid cleaning, the tubes be cleaned by the brushing 2. Wash off both tube heads and the ends of all tubes
process described above. If the relatively loose foreign with water.
material is removed before the acid cleaning, the acid Do not use carbon tetrachloride for this
solution will have less material to dissolve and flush purpose since its fumes give the same
from the tubes with the result that a more satisfactory flame discoloration that the refrigerant
cleaning job will be accomplished with a probable sav- does.
ing of time.
Acid cleaning should only be performed
by an expert. Please consult your local 3. With nitrogen or dry air, blow out the tubes to
water treatment representative for as- clear them of traces of refrigerant laden moisture
sistance in removing scale buildup and from the circulation water. As soon as the tubes
preventative maintenance programs to are clear, a cork should be driven into each end of
eliminate future problems. the tube. Pressurize the dry system with 50 psig to
100 psig (345 kPa to 690 kPa) of nitrogen. Repeat
this with all of the other tubes in the suspected
Commercial Acid Cleaning section or, if necessary, with all the tubes in the
evaporator or condenser. Allow the evaporator or
In many major cities, commercial organizations now
condenser to remain corked up to 12 to 24 hours
offer a specialized service of acid cleaning evaporators
before proceeding. Depending upon the amount
and condensers. If acid cleaning is required, YORK
of leakage, the corks may blow from the end of a
recommends the use of this type of organization. The
tube, indicating the location of the leakage. If not,
Dow Industries Service Division of the Dow Chemical
it will be necessary to make a very thorough test
Company, Tulsa, Oklahoma, with branches in principal
with the leak detector.
cities is one of the most reliable of these companies.
4. After the tubes have been corked for 12 to 24
Testing For Evaporator And Condenser Tube hours, it is recommended that two men working at
Leaks both ends of the evaporator carefully test each tube
Evaporator and condenser tube leaks may result in re- – one man removing corks at one end and the other
frigerant leaking into the water circuit, or water leak- at the opposite end to remove corks and handle the
ing into the shell depending on the pressure levels. If leak detector. Start with the top row of tubes in the
refrigerant is leaking into the water, it can be detected section being investigated. Remove the corks at
at the liquid head vents after a period of shutdown. If the ends of one tube simultaneously and insert the
water is leaking into the refrigerant, system capacity exploring tube for 5 seconds – this should be long
and efficiency will drop off sharply. If a tube is leak- enough to draw into the detector any refrigerant
ing and water has entered the system, the evaporator gas that might have leaked through the tube walls.
A fan placed at the end of the evaporator opposite

JOHNSON CONTROLS 29
 FORM 160.76-O1
SECTION 6 - MAINTENANCE
ISSUE DATE: 05/22/2019

the detector will assure that any leakage will travel If the unit is shutting down on (HOT) High Oil Tem-
through the tube to the detector. perature or Low Oil Pressure (OP), change the oil filter
element. Examine the oil filter element for the pres-
5. Mark any leaking tubes for later identification. ence of aluminum particles. Aluminum gas seal rings
6. If any of the tube sheet joints are leaking, the leak can contact the impeller and account for some alumi-
should be indicated by the detector. If a tube sheet num particles to accumulate in the oil filter, especially
leak is suspected, its exact location may be found during the initial start up and first several months of
by using a soap solution. A continuous buildup of operation. However, if aluminum particles continue to
bubbles around a tube indicates a tube sheet leak. accumulate and the same conditions continue to stop
the unit operation after a new filter is installed, notify
COMPRESSOR the nearest Johnson Controls office to request the pres-
Maintenance for the compressor assembly consists ence of a Johnson Controls Service Technician.
of checking the operation of the oil return system and
ELECTRICAL CONTROLS
changing the dehydrator, checking and changing the oil,
checking and changing the oil filters, checking the op- For information covering the OptiView™ Control
eration of the oil heater, checking the operation of the oil Center operation, refer to the OptiView™ Control Cen-
pump, and observing the operation of the compressor. ter – Operation Manual (160.76-O2).
Internal wearing of compressor parts could be a seri-
ous problem caused by improper lubrication, brought
about by restricted oil lines, passages, or dirty oil filters.

30 JOHNSON CONTROLS
FORM 160.76-O1
ISSUE DATE: 05/22/2019

SECTION 7 - PREVENTIVE MAINTENANCE

It is the responsibility of the owner to provide the nec- 2. Oil Changing – The oil in the compressor must
essary daily, monthly and yearly maintenance require- be changed annually or earlier if it becomes dark
ments of the system. or cloudy. However, quarterly oil analysis can
IMPORTANT – If a unit failure occurs eliminate the need for an annual change provided
due to improper maintenance during the the analysis indicates there is no problem with the
warranty period, Johnson Controls will oil.
not be liable for costs incurred to return COMPRESSOR MOTOR
the system to satisfactory operation.
1. Check motor mounting screws frequently to en-
sure tightness.
In any operating system it is most important to pro-
vide a planned maintenance and inspection of its func- 2. Meg motor windings annually to check for dete-
tioning parts to keep it operating at its peak efficiency. rioration of windings.
Therefore, the following maintenance should be per-
formed when prescribed. GREASED BEARINGS
7
Motor Operation and Maintenance manuals are sup-
COMPRESSOR
plied with the chillers providing maintenance sched-
1. Oil Filter – When oil pump VSD frequency in- ules and instructions for the specific motors. The fol-
creases to 55 Hz to maintain target oil pressure. lowing are lubrication schedules for the most common
motors:
When the oil filter is changed, it should be in-
spected thoroughly for any aluminum particles
which would indicate possible bearing wear.
If aluminum particles are found this should be
brought to the attention of the nearest Johnson
Controls office for their further investigation and
recommendations.

JOHNSON CONTROLS 31
 FORM 160.76-O1
SECTION 7 - PREVENTIVE MAINTENANCE
ISSUE DATE: 05/22/2019

MOTOR RE-LUBRICATION INSTRUCTION

General
Johnson Controls supplied electric drive motors have ever, always perform a verification with the motor data
maintenance requirements for re-lubrication (greasing) plate - any differences between the quick guide and the
of the drive end (DE) and non-drive end (NDE) ball motor data plate must be communicated to the product
bearings. technical support (PTS) team prior to completing the
greasing application.
In recent years the type of grease to be utilized is typi-
cally identified on the motor data plate. Below, in Table
3 on page 32, we have provided a quick guide. How-

Table 3 - QUICK GUIDE TO MOTOR GREASING AND SHAFT ROTATION INTERVALS

ANTI- MAX
FRICTION/ HOURS SHAFT GREASE ***ALTERNATE
PREFERRED ALTERNATIVE GREASE
BALL TO IDLE METHOD GREASE
GREASE* GREASE* QUANTITY
BEARING LUBE TIME PREFERRED** METHOD
MOTOR FRAME
See Manufacturer's
Operational > 5
WEG 2200 90 Days Mobil Polyrex EM N/A nameplate for ap- Operational
mins
plicable quantity

Toshiba 1000 90 Days Mobil Polyrex EM N/A 1.5 cubic inches At rest Operational

Teco 1000 90 Days Mobil Polyrex EM Chevron SRI-2 1.5 cubic inches At rest N/A

Per data Kluberplex BEM41-

ABB 90 Days Mobilith SCH100 1.5 cubic inches Operational At rest
plate 132

Ram 1000 90 Days Mobil Polyrex EM Chevron SRI-2 1.5 cubic inches At rest Operational

Reliance 1000 90 Days Shell Alvania RL3 Mobilith SHC100 1.5 cubic inches At rest Operational

See manufacturer's See manufacturer's

Siemens 1000 90 Days nameplate for ap- N/A nameplate for ap- At rest N/A
plicable grease plicable grease

* Never mix grease type or brand. If changing from or to the alternate or preferred, the bearing cavities, housings, and lines must be cleaned
of the old grease.
** Follow all standard lookout tag out procedures prior to greasing motor.
** After greasing motor at rest, run motor for a minimum of 45 minutes before replacing plug if equipped.
*** Motor must be equipped with grease extensions on DE bearing for performance of this task.
Verify with motor nameplate any discrepancy before lubricating - contact technical support for additional information/clarification.
Remove grease plug, if equipped, prior to greasing. Not every grease interval will result in used grease discharge.

Work on this equipment should only be done by properly trained personnel who are qualified to
work on this type of equipment. Failure to comply with this requirement could expose the worker,
the equipment, and the building and its inhabitants to the risk of injury or property damage.
The instructions in this document are written assuming the individual who will perform this work
is a fully trained HVAC and R journeyman or equivalent, certified in refrigerant handling and
recovery techniques, and knowledgeable with regard to electrical lock out/tag out procedures. The
individual performing this work must be aware of and comply with all Johnson Controls, national,
state, and local safety and environmental regulations while carrying out this work. Before attempt-
ing to work on any equipment, the individual should be thoroughly familiar with the equipment
by reading and understanding the associated service literature applicable to the equipment. If
you do not have this literature, you may obtain it by contacting a Johnson Controls service office.
Should there by any question concerning any aspect of the tasks outlined in this bulleti, please consult
a Johnson Controls service office prior to attempting the work. Please be aware that this information
may be time sensitive and that Johnson Controls reserves the right to revise at any time. Be certain
you are working with the latest information.

32 JOHNSON CONTROLS
FORM 160.76-O1
SECTION 7 - PREVENTIVE MAINTENANCE
ISSUE DATE: 05/22/2019

Procedure
Greasing
In most cases, re-lubrication must be performed with 2. Pump grease into this container until the grease is
the motor shut down and at rest. However, in some cas- level with the top, counting the number of pumps.
es, it may be performed with the motor operating - see 3. When the grease is level with the top, this is the
Table 3 on page 32. number of pumps for one cubic inch of grease.
The specified amount of grease should be added at 4. Multiply the number of pumps by 1.5 to get the
each specified interval to both the DE and NDE bear- number of pumps for YORK chiller motor bear-
ings. Current YORK OptiView panels provide a warn- ings.
ing message to re-lubricate beginning at a programmed
Over-greasing can be as detrimental as
number of operating hours (the default value is 1000
under-greasing, or total lack of greasing.
hours). At the programmed value plus 400 hours this
A bearing housing over-filled with grease
feature will shut down the chiller if re-lubrication is
can run 20° centigrade higher temperature
not addressed. In plants where chillers run 24/7, there
than one with the proper amount of grease.
is more than 16 days of advance warning prior to shut-
ting down the chiller.
Similarly, for motors requiring a fixed
1. Open the relief port plug below the bearing, if number of grams of grease, a scale should 7
equipped. be used to determine the number of pumps
required to achieve the number of grams
2. Add the specified amount of grease, as per Table prescribed.
3 on page 32.
Only pump the required number Type of Grease
of pumps as determined by the
calibration procedure below. Do All standard YORK chiller motors utilize a polyurea
not expect old grease to exit at the grease, specifically formulated for high-speed rolling
relief port. element bearings. Only two greases are approved for
most standard chiller motors:
3. Run the motor for 30 to 45 minutes. • Preferred choice: Mobil Polyrex EM - Grainger
It is not necessary to see old grease coming out part number 5XB54
from the relief port after adding the new grease. • 2nd choice, for TECO and Ram: Chevron SRI #2
4. Re-install the plug. There are a few exceptions, such as Reliance Q-frame
motors built from 1997 to 2003, and some special or-
Motor Rotation der motors, such as medium-voltage motors from Sie-
All motors must be rotated if idle for 90 days. The rota- mens and ABB. In these cases, use only grease called
tion should allow for the keyway to be positioned dif- for by the motor manufacturer.
ferently than when the rotation process was started. For
example, if the keyway is at the twelve o'clock posi- For Reliance motors, there is a metal tag affixed to the
tion, after the rotation the keyway should be at another motor calling for Texaco Premium RB grease. This is
position, for example, the three o'clock position. a lithium based lubricant and should never be mixed
with polyurea grease. When the two products come to-
Grease Gun Calibration gether, the thickeners release their oil molecules and
oil settles in the bottom of the bearing housing, or exits
Grease guns should be calibrated to determine the
at the relief plug or around the shaft. Bearings can fail
number of pumps required to get 1.5 cubic inches of
within 1000 hours when non-compatible greases be-
grease. To calibrate,
come mixed. If you are unable to locate this specific
1. Form an open-top cardboard cube (1 in. x 1 in. x Texaco product, other approved lithium based greases
1 in.). are Shell Alvania RL3 in NLGI #3 or Mobilith SHC100
NLGI #2, Grainger P/N 4ZF49.

JOHNSON CONTROLS 33
 FORM 160.76-O1
SECTION 7 - PREVENTIVE MAINTENANCE
ISSUE DATE: 05/22/2019

We cannot approve use of any general purpose or "EP" After the number of operational (run) hours listed on
(extended pressure) greases, for the following reasons: the motor's nameplate (for each bearing), install the
specified quantity of the recommended grease into
1. They are unlikely to contain all the properties re- each grease (zerk) fitting.
quired for the very demanding application of roll-
ing element bearings at 3600 RPM. Follow the procedure below:
2. None of these have been approved by any major 1. Remove the grease drain plugs from the drive-end
motor manufacturer or electric motors up to 2000 and non-drive-end
HP.
2. Wipe off the grease fillings with a clean cloth
3. Additives contained in "EP" greases have been
found to chemically attack the windings in elec- 3. Run the motor for at least 5 to 10 minutes (if the
tric motors. motor is not already running)

"EP" greases are intended for very heavy, slow-moving 4. While the motor is still running, add the specified
loads, such as earth-moving equipment. They are not a quantity of grease (listed on the motor's name-
proper grease for electric motors. plate) into each grease fitting
5. Run the motor for an additional 5 to 10 minutes
Unless specifically approved by the motor manufac-
(to allow excess old grease to purge)
turer, no synthetic greases are to be used. It is not best
practice to mix synthetic greases with mineral oil based 6. Replace the grease drain plugs
grease, which is the type of grease that is inside the
Continue normal operation until the next lubrication
motor bearings as shipped from the YORK factory.
interval.
Mixing different greases is not
If the motor is to be stored for more than
recommended.
six months, the bearings must be re-
lubricated according to the WEG manual
before operation. In addition, at least one
time per month, the motor's shaft must be
Operating Temperature rotated by hand at least five revolutions,
stopping the shaft at a different position
Normal operating temperature for grease lubricated
than the previous position. If the motor is
bearings on YORK chillers is 40°C to 65°C (100°F to
fitted with a shaft locking device, remove
150°F). It is normal to see the temperature elevate im-
it before rotating the shaft, and re-install
mediately after re-lubrication, and then come down as
it afterwards.
much as 20°F after a few hours of operation.
• If the temperature exceeds 65°C, at which point a LEAK TESTING
warning is issued, it is an indication that either the
The unit should be leak tested monthly. Any leaks
bearings are in need of lubrication or that some-
found must be repaired immediately.
thing is wrong, and operation should be checked.
• If temperature reaches 70°C, it generally indicates EVAPORATOR AND CONDENSER
some type of problem. The major portion of maintenance on the condenser
• Bearing RTDs are normally set to shut down the and evaporator will deal with maintaining the water
motors at 90°C (194°F), although once this tem- side of the condenser and evaporator in a clean condi-
perature is reached, the bearings most likely have tion.
already been compromised. The use of untreated water in cooling towers, closed
Procedure for WEG Motors water systems, and so on, frequently results in one or
more of the following:
Provided it is not more than six months old (per its
nameplate), a WEG motor should be properly greased 1. Scale Formation.
from the factory and ready to operate directly out of its 2. Corrosion or Rusting.
crate, without the need for additional lubrication.
3. Slime and Algae Formation.
34 JOHNSON CONTROLS
FORM 160.76-O1
SECTION 7 - PREVENTIVE MAINTENANCE
ISSUE DATE: 05/22/2019

It is therefore to the benefit of the user to provide for

proper water treatment to provide for a longer and
more economical life of the equipment. The following
recommendation should be followed in determining
the condition of the water side of the condenser and
evaporator tubes.
1. The condenser tubes should be cleaned annually
or earlier if conditions warrant. If the temperature
difference between the water of the condenser and
the condenser liquid temperature is more than 5°-
6°F (3°-4°C) greater than the difference recorded
on a new unit, it is a good indication that the con-
denser tubes require cleaning. See SECTION 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-
ference between the refrigerant and the chilled 7
water increases slowly over the operating season,
it is an indication that the evaporator tubes may be
fouling or that there may be a water bypass in the
waterbox requiring gasket replacement or refrig-
erant may have leaked from the chiller.
3. Heat recovery condenser tubes should be evalu-
ated similar to evaporator tubes when the heating
circuit is a treated, closed loop. Fouling could be
detected as ability to meet heat load requirements
decreases.

OIL RETURN SYSTEM

1. Change the dehydrator in the oil return system
semi-annually or earlier if the oil return system
fails to operate.
2. When the dehydrator is changed, the nozzle of the
eductor should be checked for any foreign par-
ticles that may be obstructing the jet.

ELECTRICAL CONTROLS
1. All electrical controls should be inspected for ob-
vious malfunctions.
2. It is important that the factory settings of controls
(operation and safety) not be changed. If the set-
tings are changed without Johnson Controls ap-
proval, the warranty will be jeopardized.

JOHNSON CONTROLS 35
36
MAINTENANCE REQUIREMENTS FOR YORK YK CHILLERS

Procedure Daily Weekly Monthly Yearly Other

Record operating conditions (on applicable Log Form) X

Check oil levels X
Check refrigerant levels X
SECTION 7 - PREVENTIVE MAINTENANCE

Check oil return system operation X

Check operation of motor starter X
Check sump heater and thermostat operation X
Check three-phase voltage and current balance X
1
Verify proper operation/setting/calibration of safety controls X
Verify condenser and evaporator water flows X
Leak check and repair leaks as needed1 X
Check and tighten all electrical connections X
Megohm motor windings X
Replace oil filter and oil return filter/driers X
Clean or backflush heat exchanger (VSD, SSS Applications) X
Replace starter coolant (VSD, SSS Applications) X
Replace or clean starter air filters if applicable X2
Perform oil analysis on compressor lube oil1 X
Perform refrigeration analysis1 X
Perform vibration analysis X
Clean tubes X2
Perform Eddy current testing and inspect tubes 2-5 Years
Lubricate motor Refer to motor manufacturer’s recommendations

For operating and maintenance requirements listed above, refer to appropriate service literature, or contact your local Johnson 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)
Issue Date: June 20, 2011

JOHNSON CONTROLS
ISSUE DATE: 05/22/2019
FORM 160.76-O1
FORM 160.76-O1
ISSUE DATE: 05/22/2019

The following factors can be used to convert from

English to the most common SI Metric values.

Table 4 - SI METRIC CONVERSION

MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT

Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW)

Power Horsepower 0.7457 Kilowatts (kW)

Flow Rate Gallons / Minute (gpm) 0.0631 Liters / Second (l/s)

Feet (ft) 0.3048 Meters (m)

Length
Inches (in) 25.4 Millimeters (mm)

Weight Pounds (lbs) 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
To convert degrees Fahrenheit (°F) to degrees Celsius
(°C), subtract 32° and multiply by 5/9 or 0.5556.
Example: (45.0°F - 32°) x 0.5556 = 7.22°C
To convert a temperature range (i.e., a range of 10°F)
from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.
Example: 10.0°F range x 0.5556 = 5.6 °C range

JOHNSON CONTROLS 37
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Form 160.76-O1 (519)
Issue Date: May 22, 2019
Supersedes: 160.76-O1 (1018)