YK — Centrifugal liquid chiller, YK Style G

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                    YK - ALL MODELS
ENGINEERING GUIDE           Revision 0   Form 160.75-EG1.EN.CE/PED (1210)




            CENTRIFUGAL LIQUID CHILLER
              STYLE G (879 - 10,500 KW)




                                                                R134a
Form No. 160.75-EG1.EN.CE/PED (1210)
TABLE OF CONTENTS

Introduction ........................................................ 3
Ratings .............................................................. 4
OptiView Control Center .................................... 5
Mechanical Specifications ................................. 8
Accessories and Modifications ........................ 12
Application Data .............................................. 14
Dimensions (mm) - Unit ................................. 24
Dimensions (mm) - Nozzle Arrangements ..... 27
Weights ........................................................... 38




                                                          NOMENCLATURE
                                          YK         ER         ER         Q7   5   CS   G      S

                                                                                                        Special Features
    Model
                                                                                                    Design Level
             Evaporator Code
                                                                                                Motor Code
                       Condenser Code
                                                                                             Power Supply
                                  Compressor Code                                            5 for 50 Hz




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                                                                              Form No. 160.75-EG1.EN.CE/PED (1210)
INTRODUCTION                                                     SINGLE STAGE COMPRESSOR DESIGN
                                                                 AND EFFICIENCY PROVEN IN THE MOST
YORK YK Chillers offer a complete combination of                 DEMANDING APPLICATIONS
features for total owner satisfaction.
                                                                 Designed to be the most reliable chillers we’ve ever
MATCHED COMPONENTS MAXIMIZE                                      made, YORK YK centrifugal chillers incorporate single-
EFFICIENCY                                                       stage compressor design. With fewer moving parts and
                                                                 straightforward, efficient engineering, YORK single-stage
Actual chiller efficiency cannot be determined by analyzing      compressors have proven durability records in hospitals,
the theoretical efficiency of any one chiller component.         chemical plants, gas processing plants, the U.S. Navy,
It requires a specific combination of heat exchanger,            and in other applications where minimal downtime is a
compressor, and motor performance to achieve the lowest          crucial concern.
system kW/kW. YORK chiller technology matches chiller
system components to provide maximum chiller efficiency          In thousands of installations worldwide, YORK single-
under actual – not just theoretical – operating conditions.      stage compressors are working to reduce energy costs.
                                                                 High strength aluminum-alloy compressor impellers
REAL-WORLD ENERGY PERFORMANCE                                    feature backward curved vanes for high efficiency. Airfoil
                                                                 shaped pre rotation vanes minimize flow disruption
Johnson Controls pioneered the term “Real-World Energy”          for the most efficient part load performance. Precisely
to illustrate the energy-saving potential of focusing on         positioned and tightly fitted, they allow the compressor to
chiller performance during off-design conditions. Off-           unload smoothly from 100% to minimum load for excellent
design is not only part load, but full load operation as well,   operation in air conditioning applications.
with reduced entering condenser water temperatures
(ECWTs). This is where chillers operate 99% of the time,         PRECISION CONTROL OF COMPRESSOR OIL
and where operating costs add up.                                PRESSURE
The YK chillers are the only chillers designed to operate        Utilizing our expertise in variable speed drive technology
on a continuous basis with cold ECWT and full condenser          and applications, Johnson Controls has moved beyond the
flow at all load points, taking full advantage of Real-World     fixed head and bypass approach of oil pressure control.
conditions. This type of operation benefits the cooling          The old approach only assures oil pressure at the outlet
tower as well; reducing cycling of the fan motor and             of the pump rather than at the compressor, and allows no
ensuring good coverage of the cooling fill.                      adjustment during chiller operation. The YK chillers feature
                                                                 a variable speed drive oil pump, monitoring and providing
YORK YK chillers offer the most efficient Real-World
                                                                 the right amount of oil flow to the compressor on a
operation of any chiller, meaning lower operating costs
                                                                 continuous basis. This design also provides sophisticated
and an excellent return on your chiller investment.
                                                                 electronic monitoring and protection of the oil pump
OPEN-DRIVE DESIGN                                                electrical supply, ensuring long life and reliable operation
                                                                 of the oil pump motor. Variable speed drive technology
Hermetic motor burnout can cause catastrophic damage             reduces oil pump power consumption, running only at the
to a chiller. The entire chiller must be cleaned, and the        speed required, rather than at full head with a pressure
refrigerant replaced.YORK YK centrifugal chillers eliminate      regulating bypass valve.
this risk by utilizing air-cooled motors. Refrigerant never
comes in contact with the motor, preventing contamination        FACTORY PACKAGING                  REDUCES          FIELD
of the rest of the chiller.                                      LABOUR COSTS

Insurance companies that offer policies on large air             YORK YK centrifugal chillers are designed to keep
conditioning equipment often consider air-cooled motors          installation costs low. Where installation access is not a
a significant advantage over hermetic refrigerant-cooled         problem, the unit can be shipped completely packaged,
units.                                                           requiring minimal piping and wiring to complete the
                                                                 installation.
HIGH EFFICIENCY HEAT EXCHANGERS
                                                                 For those units utilizing Variable Speed Drive or a factory-
YK chiller heat exchangers offer the latest technology           installed Solid-State Starter, the three power leads provide
in heat transfer surface design to give you maximum              all power to the chiller and its auxiliaries.
efficiency and compact design. Waterside and refrigerant
side design enhancements minimize both energy
consumption and tube fouling.




                                                                                                                           3
Form No. 160.75-EG1.EN.CE/PED (1210)
RATINGS                                                       COMPUTERIZED PERFORMANCE RATINGS
                                                              Each chiller is custom-matched to meet the individual
TAKE ADVANTAGE OF COLDER COOLING                              building load and energy requirements. A variety of
TOWER WATER TEMPERATURES                                      standard heat exchangers and pass arrangements are
                                                              available to provide the best possible match.
YORK YK centrifugal chillers have been designed to take
full advantage of colder cooling tower water temperatures,    It is not practical to provide tabulated performance
which are naturally available during most operating hours.    for each combination, as the energy requirements
Considerable energy savings are available by letting tower    at both full and part load vary significantly with each
water temperature drop, rather than artificially holding it   heat exchanger and pass arrangement. Computerized
above 23.9°C, especially at low load, as some chillers        ratings are available through each Johnson Controls
require.                                                      sales office. These ratings can be tailored to specific
                                                              job requirements.
SPECIFICATION
                                                              OFF-DESIGN PERFORMANCE
YK chillers are designed within EN ISO 9001 and
built within an EN ISO 9002 accredited manufacturing          Since the vast majority of its operating hours are spent
organisation.                                                 at off-design conditions, a chiller should be chosen not
                                                              only to meet the full load design, but also for its ability to
Chillers conform with the following European Directives:
                                                              perform efficiently at lower loads and lower tower water
• Machinery directive (2006/42/EC)                            temperatures. It is not uncommon for chillers with the
                                                              same full load kW to have an operating cost difference
• EMC Directive (2004/108/EC)                                 of over 10% due to part-load operation.
• Pressure Equipment Directive (97/23/EC)                     Part load information can be easily and accurately
                                                              generated by use of the computer. And because it
• Safety Code for Mechanical Refrigeration                    is so important to an owner’s operating budget, this
  (EN378-2 (2008))                                            information has now been standardized.

                                                              A more detailed analysis must take into account actual
                                                              building load profiles, and local weather data. Part load
                                                              performance data should be obtained for each job
                                                              using its own design criteria.




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                                                                           Form No. 160.75-EG1.EN.CE/PED (1210)
OPTIVIEW CONTROL CENTER                                       for specific operations are provided for on many of




YK OPTIVIEW CONTROL CENTER                                    the screens. The panel verbiage is available in eight
                                                              languages as standard and can be changed on the
The YORK OptiView™ Control Center, furnished                  fly without having to turn off the chiller. Data can be
as standard on each chiller, provides the ultimate            displayed in either English or Metric units plus keypad
in efficiency, monitoring, data recording, chiller            entry of setpoints to 0.1 increments.
protection and operating ease. The Control Center
is a factory-mounted, wired and tested state-of-the-          Security access is provided to prevent unauthorized
art microprocessor based control system for R134a             changes of setpoints. This is accomplished with three
centrifugal chillers. The panel is configured with a 10.4-    different levels of access and passwords for each
in. (264 mm) diagonal color Liquid Crystal Display (LCD)      level. There are certain screens, displayed values,
surrounded by “soft” keys, which are redefined with one       Programmable setpoints and manual controls not
keystroke based on the screen displayed at that time.         shown that are for servicing the chiller. They are only
This revolutionary development makes chiller operation        displayed when logged in at service access level.
quicker and easier than ever before. Instead of requiring     Included in this is the Advanced Diagnostics and
keystroke after keystroke to hunt for information on          troubleshooting information for the chiller and the panel.
a small monochrome LCD screen, a single button
reveals a wide array of information on a large, full-color    The panel is fused through a 1.5 or 2 KVA transformer
illustration of the appropriate component, which makes        in the compressor motor starter to provide individual
information easier to interpret. This is all mounted in the   over-current protected power for all controls. Numbered
middle of a keypad interface and installed in a locked        terminal strips for wiring such as Remote Start/Stop,
enclosure.                                                    Flow Switches, Chilled Water Pump and Local or
                                                              Remote Cycling devices are provided. The Panel also
The LCD display allows graphic animated display of            provides field interlocks that indicate the chiller status.
the chiller, chiller sub-systems and system parameters;       These contacts include a Remote Mode Ready-to-
this allows the presentation of several operating             Start, a Cycling Shutdown, a Safety Shutdown and a
parameters at once. In addition, the operator may view        chiller Run contact. Pressure transducers sense system
a graphical representation of the historical operation of     pressures and thermistors sense system temperatures.
the chiller as well as the present operation. A Status        The output of each transducer is a DC voltage that is
Bar is displayed at all times on all screens. It contains     analogous to the pressure input. The output of each
the System - Status Line and Details Line, the Control        thermistor is a DC voltage that is analogous to the
Source, Access Level, Time and Date.                          temperature it is sensing.

During pre-lube and coast-down, the system status will        Setpoints can be changed from a remote location via
include a countdown timer indicating the time remaining.      0-10VDC, 4-20mA, contact closures or through serial
The control panel is compatible with the YORK Solid-          communications. The adjustable remote reset range
State Starter (optional); YORK Variable Speed Drive           11.1°C provides flexible, efficient use of remote signal
(VSD) (Optional); Electro-mechanical (E-M) starter or         depending on reset needs. Serial data interface to
any customer supplied E-M starter that complies with          the Building Automation System (BAS) is through the
the YORK R-1132 standard. The locations of various            optional microgateway, which can be mounted inside
chiller parameters are clearly marked and instructions        the Control Center.

                                                                                                                       5
Form No. 160.75-EG1.EN.CE/PED (1210)
This printed circuit board requests the required data           HEAT RECOVERY
from the microboard and makes it available for the
Johnson Controls Metasys® network. This optional                The HEAT RECOVERY screen displays a cutaway view
board is available through the Johnson Controls                 of the chiller condenser. The liquid flow is animated to
Building Efficiency group. The operating program is             indicate flow when there is flow in either the lower tower
stored in non-volatile memory (EPROM) to eliminate              bundle or upper heating bundle. All setpoints relating to
chiller failure due to AC power failure/battery discharge.      the upper heating bundle are maintained on this screen.
Programmed setpoints are retained in lithium battery-
                                                                The COMPRESSOR screen displays a cutaway view of
backed RTC memory for 10 years minimum.
                                                                the compressor; this reveals the impeller and shows all
Smart Freeze Point Protection will run the chiller at           the conditions associated with the compressor. When
2.2°C leaving chilled water temperature, and not                the compressor impeller is spinning this indicates that
permit nuisance trips on Low Water Temperature.                 the chiller is presently in RUN condition. With the proper
The sophisticated program and sensor will monitor               access level, the pre-rotation vanes may be manually
the chiller water temperature to prevent freeze up.             controlled. This screen also serves as a gateway to
Every Programmable point has a pop-up screen with               sub-screens for calibrating the pre-rotation vanes, the
the allowable ranges, so that the chiller cannot be             proximity probe, configuring the Hot Gas Bypass, or
programmed to operate outside of its design limits.             providing advanced control of the compressor motor
                                                                Variable Speed Drive.
When the power is applied to the chiller, the HOME
screen is displayed. This screen displays a visual              The OIL SUMP screen displays a close-up view of the
representation of the chiller and a collection of data          chiller oil sump and provides all the necessary setpoints
detailing important operations and parameters. When             for maintaining the Variable Speed Oil Pump (VSOP).
the chiller is running the flow of chilled liquid is animated   This screen also allows manual control of the frequency
by the alternating shades of color moving in and out of         command sent to the VSOP.
the pipe nozzles. The primary values that need to be
                                                                The MOTOR “soft” key on the Home screen when
monitored and controlled are shown on this screen.
                                                                pressed shows a picture of a YORK Electro-Mechanical
With the “soft” keys the operator is only one touch             Starter, Solid-State Starter or a Variable Speed
away from the 8 main screens that allows access to              Drive Screen depending on chiller configuration.
the major information and components of the chiller.            Programmable pulldown demand to automatically limit
The 8 screens are the SYSTEM, EVAPORATOR,                       motor loading for minimizing building demand charges
CONDENSER, COMPRESSOR, OIL SUMP, MOTOR,                         is provided. Pulldown time period control over four
SETPOINTS and the HISTORY. Also on the Home                     hours, and verification of time remaining in pulldown
screen is the ability to Log IN, Log Out and Print. Log         cycle from display readout. Separate digital setpoint for
In and Log Out is the means by which different security         current limiting between 30 and 100%.
levels are accessed.
                                                                The ELECTRO-MECHANICAL STARTER – (E-M)
The SYSTEM screen gives a general overview of                   screen displays a picture of the starter and additional
common chiller parameters for both shells. This is an           values.
end view of the chiller with a 3D cutaway of both the
                                                                The SOLID STATE STARTER – (SSS) screen displays
shells.
                                                                a picture of the starter and additional values.
The EVAPORATOR screen displays a cutaway view
                                                                The VARIABLE SPEED DRIVE - (VSD) screen displays
of the chiller evaporator. All setpoints relating to the
                                                                a picture of the VSD and additional values:
evaporator side of the chiller are maintained on this
screen. Animation of the evaporation process indicates          There are two additional screens (sub-screens) that
whether the chiller is presently in RUN condition               have further VSD information.
(bubbling) and liquid flow in the pipes is indicated by
alternating shades of color moving in and out of the            The SETPOINTS screen provides a convenient
pipes. Adjustable limits on the low water temperature           location for programming the most common setpoints
setpoints allow the chiller to cycle on and off for greater     involved in the chiller control. The Setpoints are shown
efficiency and less chiller cycling. The chiller cycles off     on other individual screens but to cut down on needless
when the leaving chilled water temperature is below             searching they are on this one screen. This screen also
the setpoint and is adjustable from 0.55°C below to             serves as a gateway to a sub-screen for defining the
a minimum of 2.2°C. Restart is adjustable from the              setup of general system parameters.
setpoint up to a max of 44.4°C. The panel will check for
flow to avoid freeze up of the tubes. If flow is interrupted    The SETUP is the top level of the general configuration
shutdown will occur after a minimum of two seconds.             parameters. It allows programming of the time and
                                                                date, along with specifications as to how the time will
The CONDENSER screen displays a cutaway view                    be displayed. In addition, the chiller configuration as
of the chiller condenser. The liquid flow is animated           determined by the microboard program jumpers and
to indicate flow through the condenser. All setpoints           program switches is displayed. From this screen you
relating to the condenser side of the chiller are               can perform the following:
maintained on this screen. With the proper access level,
this screen also serves as a gateway to controlling the         The following 6 sub-screens can be accessed from the
Refrigerant Level.                                              setup screen:

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                                                                           Form No. 160.75-EG1.EN.CE/PED (1210)
The SCHEDULE screen contains more programmable                DISPLAY MESSAGES
values than a normal display screen. Each
programmable value is not linked to a specific button;        The Control Center continually monitors the operating
instead the select key is used to enable the cursor           system displaying and recording the cause of any
arrows and check key to program the Start/Stop times          shutdowns (Safety, Cycling or Normal). The condition
for any day of the week up to 6 weeks in advance. The         of the chiller is displayed at the System Status line that
user has the ability to define a standard set of Start/Stop   contains a message describing the operating state of
times that are utilized every week or specify exceptions      the chiller; whether it is stopped, running, starting or
to create a special week.                                     shutting down. A System Details line displays Warning,
                                                              Cycling, Safety, Start Inhibit and other messages
The USER screen allows definition of the language for         that provide further details of Status Bar messages.
the chiller to display and defines the unit of measure.       Messages are color-coded: Green – Normal Operations,
                                                              Yellow - Warnings, Orange – Cycling Shutdowns, and
The COMMS screen allows definition of the necessary           Red – Safety Shutdowns to aid in identifying problems
communications parameters.                                    quickly.
The PRINTER screen allows Definition of the necessary
communications Parameters for the printer.

The SALES ORDER screen allows definition of the
order parameters.

The OPERATIONS screen allows definition of
parameters related to the operation of the chiller. What
is defined is whether the control of the chiller will be
Local, Digital Remote, Analog Remote, Modem Remote
or Metasys™ Remote.

The HISTORY screen allows the user to browse
through the last ten faults; either safety or cycling
shutdowns with the conditions while the chiller is
running or stopped. The faults are color coded for ease
in determining the severity at a glance, recording the
date, time and description. (See Display Messages for
Color Code meanings.)

By pressing the VIEW DETAILS key you will move to the
HISTORY DETAILS screen. From these screens you
are able to see an on-screen printout of all the system
parameters at the time of the selected shutdown.

Also under the History screen is the TRENDING
screen, accessible by the key marked the same. On
this screen up to six operator-selected parameters,
selected from a list of over 140, can be plotted in an X/Y
graph format, The graph can be customized to record
points once every second up to once every hour. There
are two types of charts that can be created: a single or
continuous screen. The single screen collects data for
one screen width (450 data points across the x-axis)
then stops. The continuous screen keeps collecting
the data but the oldest data drops off the graph from
left to right at the next data collection interval. For
ease of identification, each plotted parameter, title and
associated Y- axis labeling is color coordinated.

The TREND SETUP screen is used to configure
the trending screen. The parameters to be trended
are selected from the Trend Common Slots Screen
accessed from the Slot #s button or the Master Slot
Numbers List found in the operating manual. The
interval at which all the parameters are sampled is
selected under the Collection Interval button. The data
point min. and max. values may be adjusted closer
within the range to increase viewing resolution.

The TREND COMMON SLOTS screen displays the
Master Slot Numbers List of the monitored parameters.

                                                                                                                      7
Form No. 160.75-EG1.EN.CE/PED (1210)
MECHANICAL SPECIFICATIONS                                      Oil is filtered by an externally mounted 1/2 micron
                                                               replaceable cartridge oil filter equipped with service
                                                               valves. Oil is cooled via a refrigerant-cooled oil cooler,
GENERAL                                                        eliminating the requirement for field water piping. The
The YORK YK Centrifugal Liquid Chillers are completely         oil side of the oil cooler is provided with service valves.
factory-packaged including the evaporator, condenser,          An automatic oil return system recovers any oil that
compressor, motor, lubrication system, control center,         may have migrated to the evaporator. Oil piping is
and all interconnecting unit piping and wiring.                completely factory-installed.

The initial charge of refrigerant and oil is supplied for      WATER-COOLED OIL COOLER
each chiller. When the optional condenser isolation
valves are ordered, most units may ship fully charged          Optional condenser water-cooled oil cooler is offered
with refrigerant and oil. Actual shipping procedures will      for units with Q3 compressors C-D shells only. This oil
depend on a number of project-specific details.                cooler is a shell and tube heat exchanger. Water from
                                                               condenser supply waterbox circulates through the tube
The services of a Johnson Controls factory-trained,            side of the heat exchanger and discharges back into the
field service representative are incurred to supervise or      return side of the waterbox. Hot oil circulates through
perform the final leak testing, charging, the initial start-   the tubes within the oil cooler, and is cooled by the cold
up, and concurrent operator instructions.                      condenser water. The cooled oil is then sent back to the
                                                               compressor through a temperature regulator valve and
COMPRESSOR                                                     oil filters. Both the oil and water piping are completely
                                                               factory-installed, eliminating the requirement for field
The compressor is a single stage centrifugal type              piping.
powered by an open drive electric motor. The casing
is fully accessible with vertical circular joints and          MOTOR DRIVELINE
fabricated of close grain cast iron. The complete
operating assembly is removable from the compressor            The compressor motor is an open drip proof, squirrel
and scroll housing.                                            cage, induction type constructed to YORK design
                                                               specifications.
The rotor assembly consists of a heat treated alloy steel
drive shaft and impeller shaft with a high strength, cast      The open motor is provided with a D flange, and is
aluminum alloy, fully shrouded impeller. The impeller          factory-mounted to a cast iron adaptor mounted on the
is designed for balanced thrust and is dynamically             compressor. This unique design allows the motor to be
balanced and overspeed tested for smooth, vibration            rigidly coupled to the compressor to provide factory
free operation.                                                alignment of motor and compressor shafts.

The insert-type journal and thrust bearings are                Motor drive shaft is directly connected to the compressor
fabricated of aluminum alloy and are precision bored           shaft with a flexible disc coupling. Coupling has all
and axially grooved. The specially engineered, single          metal construction with no wearing parts to assure
helical gears with crowned teeth are designed so               long life, and no lubrication requirements to provide low
that more than one tooth is in contact at all times to         maintenance.
provide even distribution of compressor load and
quiet operation. Gears are assembled as part of the            For units utilizing remote electro mechanical starters,
compressor rotor support and are film lubricated. Each         a large, steel terminal box with gasketed front access
gear is individually mounted in its own journal and thrust     cover is provided for field-connected conduit. There
bearings to isolate it from impeller and motor forces.         are six terminals (three for medium voltage) brought
                                                               through the motor casing into the terminal box. Jumpers
CAPACITY CONTROL                                               are furnished for three-lead types of starting. Motor
                                                               terminal lugs are not furnished. Overload/over-current
Pre-rotation vanes (PRV) modulate chiller capacity             transformers are furnished with all units. For units
from 100% to 15% of design for normal air conditioning         furnished with factory-packaged Solid-State Starters
applications. Operation is by an external, electric            or Variable Speed Drive, refer to the Accessories and
PRV actuator which automatically controls the vane             Modifications Section.
position to maintain a constant leaving chilled liquid
temperature. Rugged airfoil-shaped, cast-manganese-            HEAT EXCHANGERS
bronze vanes are precisely positioned by solid vane
linkages connected to the electric actuator.                   Shells
                                                               Evaporator and condenser shells are fabricated from
LUBRICATION SYSTEM                                             rolled carbon steel plates with fusion welded seams
Lubrication oil is force-fed to all bearings, gears and        or carbon steel pipe. Carbon steel tube sheets, drilled
rotating surfaces by a variable speed drive pump which         and reamed to accommodate the tubes, are welded to
operates prior to startup, continuously during operation       the end of each shell. Intermediate tube supports are
and during coastdown. A gravity fed oil reservoir is built     fabricated from carbon steel plates, drilled and reamed
into the top of the compressor to provide lubrication          to eliminate sharp edges, and spaced no more than
during coastdown in the event of a power failure.              four feet apart. The refrigerant side of each shell is
                                                               designed, tested, and stamped in accordance with the
An oil reservoir, separate from the compressor,                pressure vessel code as appropriate.
contains the submersible oil pump, 1.5 kW pump motor
and 3000 watt immersion type oil heater. The oil heater
is thermostatically controlled to remove refrigerant from
the oil.

8
                                                                           Form No. 160.75-EG1.EN.CE/PED (1210)
Tubes                                                         REFRIGERANT FLOW CONTROL
Heat exchanger tubes are state-of-the-art, high-              Refrigerant flow to the evaporator is controlled by the
efficiency, externally and internally enhanced type           YORK variable orifice control system. Liquid refrigerant
to provide optimum performance. Tubes in both the             level is continuously monitored to provide optimum
evaporator and condenser are 19 mm O.D. standard              subcooler, condenser and evaporator performance.
or 25.4 mm optional in some shells] copper alloy and          The variable orifice electronically adjusts to all Real-
utilize the “skip-fin” design, providing a smooth internal    World operating conditions, providing the most efficient
and external surface at each intermediate tube support.       and reliable operation of refrigerant flow control.
This provides extra wall thickness (up to twice as thick)
and non work-hardened copper at the support location,         OPTIVIEW CONTROL CENTER
extending the life of the heat exchangers. Each tube is
roller expanded into the tube sheets providing a leak-        General
proof seal, and is individually replaceable.
                                                              The chiller is controlled by a stand-alone microprocessor
Evaporator                                                    based control center. The chiller control panel provides
                                                              control of chiller operation and monitoring of chiller
The evaporator is a shell and tube, flooded type heat         sensors, actuators, relays and switches.
exchanger. A distributor trough provides uniform
distribution of refrigerant over the entire shell length to   Control Panel
yield optimum heat transfer. A suction baffle or aluminum
mesh eliminators are located above the tube bundle to         The control panel includes a 10.4-in. (264 mm)
prevent liquid refrigerant carryover into the compressor.     diagonal color liquid crystal display (LCD) surrounded
A 38 mm liquid level sight glass is conveniently located      by “soft” keys which are redefined based on the screen
on the side of the shell to aid in determining proper         displayed at that time, mounted in the middle of a
refrigerant charge. The evaporator shell contains a dual      keypad interface and installed in a locked enclosure.
refrigerant relief valve arrangement set at 12.4 barg on      The screen details all operations and parameters,
H and K Compressor models; 16.2 barg on P and Q               using a graphical representation of the chiller and its
Compressor models; or single-relief valve arrangement,        major components. Panel verbiage is available in eight
if the chiller is supplied with the optional refrigerant      languages and can be changed on the fly without
isolation valves. A 25.4 mm refrigerant charging valve        having to turn off the chiller. Data can be displayed
is provided.                                                  in either English or Metric units. Smart Freeze Point
                                                              Protection will run the chiller at 2.2°C leaving chilled
Condenser                                                     water temperature, and not have nuisance trips on
                                                              low water temperature. The sophisticated program
The condenser is a shell and tube type, with a discharge      and sensor monitors the chiller water temperature to
gas baffle to prevent direct high velocity impingement        prevent freeze-up. When needed, Hot Gas Bypass is
on the tubes. The baffle is also used to distribute the       available as an option. The panel displays countdown
refrig¬erant gas flow properly for most efficient heat        timer messages so the operator knows when functions
transfer. An optional cast steel condenser inlet diffuser     are starting and stopping. Every programmable point
may be offered, on "M" and larger condensers, in lieu         has a pop-up screen with the allowable ranges, so that
of the baffle, to provide dynamic pressure recovery and       the chiller cannot be programmed to operate outside of
enhanced chiller efficiency. An integral sub cooler is        its design limits.
located at the bottom of the condenser shell providing
highly effective liquid refrigerant subcooling to provide     The chiller control panel also provides:
the highest cycle efficiency. The condenser contains
dual refrigerant relief valves set at 16.2 barg.              1. System operating information including:

Waterboxes                                                       A. Return and leaving chilled water temperature

The removable waterboxes are fabricated of steel. The            B. Return and leaving condenser water temperature
design working pressure is 10.3 barg and the boxes
are tested at 15.5 barg. Integral steel water baffles are        C. Evaporator and condenser saturation pressure
located and welded within the waterbox to provide the
                                                                 D. Differential oil pressure
required pass arrangements. Water nozzle connections
with grooves are welded to the water boxes. These                E. Percent motor current
nozzle connections are suitable couplings, welding or
flanges, and are capped for shipment. Plugged 19 mm              F. Evaporator      and         condenser   saturation
drain and vent connections are provided in each water               temperature
box.
                                                                 G. Compressor discharge temperature
WATER FLOW SWITCHES
                                                                 H. Oil reservoir temperature
Thermal type water flow switches are factory mounted
in the chilled and condenser water nozzles, and are              I. Compressor thrust bearing positioning (K com-
factory wired to the OptiView control panel. These                  pressors only)
solid state flow sensors have a small internal heating-
element. They use the cooling effect of the flowing              J. Operating hours
fluid to sense when an adequate flow rate has been
                                                                 K. Number of compressor starts
established. The sealed sensor probe is 316 stainless
steel, which is suited to very high working pressures.


                                                                                                                     9
Form No. 160.75-EG1.EN.CE/PED (1210)
2. Digital programming of setpoints through the              R. Thrust bearing – proximity probe clearance (K
   universal keypad including:                                  compressors only)

     A. Leaving chilled water temperature                    S. Thrust bearing – proximity probe out-of-range (K
                                                                compressors only)
     B. Percent current limit
                                                             T. Thrust bearing – position switch (P, Q & H9
     C. Pulls-down demand limiting                              compressors)
     D. Six-week schedule for starting and stopping the      U. Watchdog – software reboot
        chiller, pumps and tower
                                                             Safety shutdowns with a VSD include:
     E. Rremote reset temperature range                      A. VSD shutdown – requesting fault data
3. Status messages indicating:                               B. VSD – stop contacts open
     A. System ready to start                                C. VSD – 105% motor current overload
     B. System running                                       D. VSD – high phase A, B, C inverter heat-sink
                                                                temp.
     C. System coastdown
                                                             E. VSD – high converter heat-sink temperature
     D. System safety shutdown – manual restart
                                                                  (Filter Option Only)
     E. System cycling shutdown – auto restart
                                                             F. Harmonic filter – high heat-sink temperature
     F. System pre-lube
                                                             G. Harmonic filter – high total demand distortion
     G. Start inhibit
                                                          6. Cycling shutdowns enunciated through the display
4. The text displayed within the system status and           and the status bar, and consists of system status,
   system details field is displayed as a color-coded        system details, day, time, cause of shutdown, and
   message to indicate severity: red for safety fault,       type of restart required.
   orange for cycling faults, yellow for warnings, and       Cycling shutdowns with a fixed speed drive include:
   green for normal messages.
                                                             A. Multi unit cycling – contacts open
5. Safety shutdowns enunciated through the display
   and the status bar, and consist of system status,         B. System cycling – contacts open
   system details, day, time, cause of shutdown, and
                                                             C. Oil – low temperature differential
   type of restart required. Safety shutdowns with a
   fixed-speed- drive include:                               D. Oil – low temperature

     A. Evaporator – low pressure                            E. Control panel – power failure

     B. Evaporator – transducer or leaving liquid probe      F. Leaving chilled liquid – low temperature

     C. Evaporator – transducer or temperature sensor        G. Leaving chilled liquid – flow switch open

     D. Condenser – high pressure contacts open              H. Motor controller – contacts open

     E. Condenser – high pressure                            I. Motor controller – loss of current

     F. Condenser – pressure transducer out-of-range         J. Power fault

     G. Auxiliary safety – contacts closed                   K. Control panel – schedule

     H. Discharge – high temperature                         L. Starter – low supply line voltage (SSS option)

     I. Discharge – low temperature                          M. Starter – high supply line voltage (SSS option)

     J. Oil – high temperature                               N. Proximity probe – low supply voltage (K
                                                                Compressor)
     K. Oil – low differential pressure
                                                             O. Oil – variable speed pump – drive contacts open
     L. Oil – high differential pressure
                                                             Cycling shutdowns with a VSD include:
     M. Oil – sump pressure transducer out-of-range
                                                             A.   VSD shutdown – requesting fault data
     N. Oil – differential pressure calibration
                                                             B.   VSD – stop contacts open
     O. Oil – variable speed pump – pressure setpoint
        not achieved                                         C. VSD – initialization failed

     P. Control panel – power failure                        D. VSD – high phase A, B, C instantaneous current

     Q. Motor or starter – current imbalance                 E. VSD – phase A, B, C gate driver

10
                                                                         Form No. 160.75-EG1.EN.CE/PED (1210)
   F. VSD – single phase input power                           printer. Data logs to a printer at a set programmable
                                                               interval. This data can be preprogrammed to print
   G. VSD – high DC bus voltage                                from 1 minute to 1 day.
   H. VSD – precharge DC bus voltage imbalance
                                                            13.The capability to interface with a building automation
   I. VSD – high internal ambient temperature                  system via hard-wired connections to each feature
                                                               to provide:
   J. VSD – invalid current scale selection
                                                               A. Remote chiller start and stop
   K. VSD – low phase A, B, C inverter heat-sink temp.
   L. VSD – low converter heat-sink temperature                B. Remote leaving chiller liquid temperature adjust

   M. VSD – precharge – low DC bus voltage                     C. Remote current limit setpoint adjust

   N. VSD – logic board processor                              D. Remote ready to start contacts

   O. VSD – run signal                                         E. Safety shutdown contacts
   P. VSD – serial communications (Filter Option               F. Cycling shutdown contacts
      Only)
                                                               G. Run contacts
   Q. Harmonic filter – logic board or communications
                                                            CODES AND STANDARDS
   R. Harmonic filter – high DC bus voltage
                                                            Chillers conform with the following European Directives:
   S. Harmonic filter – high phase A, B, C current
   T. Harmonic filter – phase locked loop                   • Machinery directive (2006/42/EC)

   U. Harmonic filter – precharge – low DC bus voltage      • EMC Directive (2004/108/EC)

   V. Harmonic filter – DC bus voltage imbalance            • Pressure Equipment Directive (97/23/EC)

   W. Harmonic filter – 110% input current overload         • Safety Code for Mechanical Refrigeration
                                                              (EN378-2 (2008))
   X. Harmonic filter – logic board power supply
   Y. Harmonic filter – run signal                          ISOLATION MOUNTING

   Z. Harmonic filter – DC current transformer 1            The unit is provided with four vibration isolation mounts
                                                            of nominal 25mm operating height. The pads have a
   AA. Harmonic filter – DC current transformer 2           neoprene pad to contact the foundation, bonded to a
                                                            steel plate. The vibration isolation pads assemblies
7. Security access to prevent unauthorized change           mount under steel plates affixed to the chiller tube
   of setpoints, to allow local or remote control of the    sheets.
   chiller, and to allow manual operation of the pre-
   rotation vanes and oil pump. Access is through ID        REFRIGERANT CONTAINMENT
   and password recognition, which is defined by three
                                                            The standard unit has been designed as a complete
   different levels of user competence: view, operator,     and compact factory-packaged chiller. As such, it has
   and service.                                             minimum joints from which refrigerant can leak. The
                                                            entire assembly has been thoroughly leak tested at the
8. Trending data with the ability to customize points of
                                                            factory prior to shipment. The YORK YK chiller includes
   once every second to once every hour. The panel          service valves conveniently located to facilitate transfer
   will trend up to 6 different parameters from a list of   of refrigerant to a remote refrigerant storage/recycling
   over 140, without the need of an external monitoring     system. Optional condenser isolation valves allow
   system.                                                  storage of the charge in the condenser.
9. The operating program stored in non-volatile             PAINT
   memory (EPROM) to eliminate reprogramming the
   chiller due to AC power failure or battery discharge.    Exterior surfaces are protected with one coat of
   Programmed setpoints are retained in lithium             Caribbean blue, durable alkyd modified, vinyl enamel
   battery-backed RTC memory for a minimum of 10            machinery paint.
   years with power removed from the system.
                                                            SHIPMENT
10.A fused connection through a transformer in the          Protective covering is furnished on the motor starter,
   compressor motor starter to provide individual over-     Control Center VSD and unit mounted controls. Water
   current protected power for all controls.                nozzles are capped with fitted plastic enclosures. Entire
                                                            unit is protected with industrial-grade, reinforced shrink-
11.A numbered terminal strip for all required field         wrapped covering.
   interlock wiring.

12.An RS-232 port to output all system operating data,
   shutdown/cycling message, and a record of the last
   10 cycling or safety shutdowns to a field-supplied
                                                                                                                    11
Form No. 160.75-EG1.EN.CE/PED (1210)
ACCESSORIES AND MODIFICATIONS                                 QUICK START
                                                              The Quick Start feature is targeted towards data centers
OPTISPEED DRIVE                                               and process control applications where the goal is to
A 400V – 3-Ph – 50Hz variable speed drive is factory-         re-establish process cooling as fast as possible after
packaged and mounted on the YORK YK chiller. It is            a power failure event. The Quick Start feature does
designed to vary the compressor motor speed by                this by reducing the time cycle for chiller restart and by
controlling the frequency and voltage of the electrical       loading the chiller as fast as possible, once running, to
power to the motor. The adaptive capacity control logic       rapidly achieve the leaving chilled water temperature
automatically adjusts motor speed and compressor              setpoint. The main objective is to provide minimum
pre-rotation vane position independently for maximum          downtime and the fastest restart/loading as possible.
part load efficiency by analyzing information fed to it by    Once the chiller is running and close to setpoint, it will
sensors located throughout the chiller.                       return to standard YK control to minimize risk.

The variable speed drive is mounted in a IP54 enclosure       Quick Start Feature can be used with a UPS (supplied
with all power and control wiring between the drive and       by others) or without a UPS. In order to start the most
chiller factory-installed. Electrical lugs for incoming       quickly, the OptiView control panel and VSD control
power wiring are provided.                                    circuit (except the trigger board) must be on a UPS. If
                                                              a slightly longer restart time can be tolerated, the UPS
The variable speed drive provides automatic power-            is not required.
factor correction to 0.95 or better at all load conditions.
Separate power-factor correction capacitors are not           Depending on the compressor and the horsepower of
required. The power-factor is 0.98 or better when the         the drive, a 3 kVA or 4 kVA UPS (supplied by others)
optional harmonic filter is provided.                         with sine wave output is required to power the OptiView
                                                              and required portions of the VSD control circuit.
Standard features include: a door interlocked lockable
circuit breaker; ground fault protection; over-voltage and    Please refer to Form 160.75-TD4; Quick Start Feature
under-voltage protection; 3-phase sensing motor over-         for YK Mod G Chillers for additional information.
current protection; single-phase protection; insensitive      Quick Start Feature Availability - This feature applies
to phase rotation; over-temperature protection; digital       only to YK chillers with Variable Speed Drives.
parameter readout at the OptiView Control Center.
                                                              BAS REMOTE CONTROL
An optional harmonic filter limits electrical power supply
distortion from the variable speed drive                      A communication interface permitting complete
                                                              exchange of chiller data with any BAS System is
SOLID-STATE STARTER                                           available with an optional Metasys™ translator. The
The Solid-State Starter is a reduced voltage starter that     Metasys™ translator also allows BAS System to
controls and maintains a constant current flow to the         issue commands to the chiller to control its operation.
motor during startup. It is compact and mounted on the        Metasys™ translators come in two models, controlling
unit. Power and control wiring between the starter and        up to 4 chillers and 8 chillers respectively.
the chiller are factory-installed. The starter enclosure
                                                              FACTORY INSULATION OF EVAPORATOR
is IP54, with a hinged access door with lock and key.
Electrical lugs for incoming power wiring are provided.       Factory-applied thermal insulation of the flexible, closed-
                                                              cell plastic type, 19 mm thick is attached with vapor-
Standard Features include digital readout of parameters
                                                              proof cement to the evaporator shell, flow chamber,
at the OptiView Control Center
                                                              tube sheets, suction connection, and (as necessary)
Other features include: low line voltage; 115-volt            to the auxiliary tubing. Not included is the insulation of
control transformer; three-leg, motor-current-sensing         compact waterboxes and nozzles. This insulation will
overloads; phase rotation and single-phase failure            normally prevent condensation in environments with
protection; high temperature safety protection; motor         relative humidifies up to 75% and dry bulb temperatures
current imbalance and under-voltage safeties; open and        ranging from 10° to 32.2°C. 38 mm thick insulation is
shorted SCR protection; momentary power interruption          also available for relative humidifies up to 90% and dry
protection. The Solid-State Starter is cooled by a            bulb temperatures ranging from 10° to 32.2°C.
closed-loop, fresh-water-circuit consisting of a water-
to-water heat exchanger and a fractional horsepower
                                                              WATER FLANGES
circulating pump. All interconnecting water piping            Raised-face flanges for condenser and evaporator
is factory-installed and rated for 10.3 barg working          water connections are factory-welded to water nozzles.
pressure. Optional electronic trip circuit breaker with       Companion flanges, bolts, nuts and gaskets are not
integral ground fault protection is available with short      included
circuit withstand ratings of:

        65KA for 400V models

A non-fused disconnect switch is also available. Both
options are lockable.


12
                                                                            Form No. 160.75-EG1.EN.CE/PED (1210)
SPRING ISOLATION MOUNTING                                     HIGH AMBIENT TEMPERATURE
Spring isolation mounting is available instead of             Chiller modifications are available to allow for installation
standard isolation mounting pads when desired.                in high ambients 50°C. Special drive motors are required
Four level-adjusting, spring-type vibration isolator          above 40°C. H9 and K compressor evaporator design
assemblies with non-skid pads are provided for field-         pressures must be increased for ambient temperatures
installation. Isolators are designed for 25 mm deflection.    above 45°C. The OptiView panel and VSD are suited for
                                                              50°C ambient.
SEQUENCE CONTROL KIT
                                                              OPTISOUND™ CONTROL
For two, three or four units with chilled water circuits
connected in series or parallel, the kit consists of return   The YORK® OptiSound™ Control is a patented
water thermostat, lead-lag selector switch for sequence       combination of centrifugal-chiller hardware and
starting, and time delay relay, with IP54 enclosures.         software that reduces operational sound levels,
                                                              expands the chiller operating range, and improves
STARTER - FIELD-INSTALLED                                     chiller performance. The OptiSound Control feature
                                                              continuously monitors the characteristics of the
A field-installed, electro-mechanical compressor motor
                                                              compressor-discharge gas and optimizes the diffuser
starter is available, selected for proper size and type
                                                              spacing to minimize gas-flow disruptions from the
for job requirements and in accordance with Johnson
                                                      

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