| Document type | Operation Guide |
|---|---|
| Document number | 160.76-O1-EN.CE |
| Equipment | YK Centrifugal Chiller |
| Brand | YORK |
| File size | 11.1 MB |
Fault codes in this document
A2L refrigerant application
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Ventilation airflow failure / failure of the permanent mechanical extraction | The unit shuts down, into safe mode, within 10 s in the event that airflow is reduced below the minimum required flow or in case of any failure of the permanent mechanical extraction. | Airflow reduced below the minimum required flow or failure of the permanent mechanical extraction. | Do not powered on the unit, and maintain safe mode, until the airflow is restored. | 8 |
| Refrigerant concentration reaches 10% of the LFL (first detection threshold) | First refrigerant detection threshold. | Refrigerant concentration reaching the first threshold (10% of the LFL). | Triggers an alarm which alerts authorized persons to take the appropriate action, such as checking potential leakage points, and checking detector and fan functionality. | 9 |
| Refrigerant concentration reaches 25% of the LFL (second detection threshold) | Second refrigerant detection threshold. | Refrigerant concentration reaching the second threshold (25% of the LFL). | Triggers the emergency stop for the facility and its safety measures are implemented. | 9 |
| Failure of the ventilation system, refrigerant detector, or alarm system | Any failure must be indicated. | The unit must be shut down, and the machine room ventilator running until the fault has been resolved. | 8 |
Oil heater
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Oil pressure safety cutout | The oil pressure safety cutout actuates and stops the system. | Violent oil foaming results as the pressure within the system is lowered on starting, caused by refrigerant boiling out of the oil; if this foam reaches the oil pump suction, the bearing oil pressure will fluctuate with possible temporary loss of lubrication. | Refer to OptiView Control Center – Operation Manual (160.76-O2). | 25 |
Troubleshooting — Table 5: Operation analysis chart
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Air is in the condenser. | 31 | |
| abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Condenser tubes dirty or scaled. | Clean condenser tubes. Check water conditioning. | 31 |
| abnormally high discharge pressure | High discharge pressure. | High condenser water temperature. | Reduce condenser water inlet temperature. Check cooling tower and water circulation. | 31 |
| abnormally high discharge pressure | Temperature difference between condenser water on and water off higher than normal, with normal evaporator pressure. | Insufficient condensing water flow. | Increase the quantity of water through the condenser to proper value. | 31 |
| abnormally low suction pressure | Insufficient charge of refrigerant. | Check for leaks and charge refrigerant into system. | 31 | |
| abnormally low suction pressure | Temperature difference between leaving chilled water and refrigerant in evaporator greater than normal with high discharge temperature. | Variable orifice problem. | Remove obstruction. | 31 |
| abnormally low suction pressure | Temperature difference between leaving chilled water and refrigerant in the evaporator greater than normal with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean evaporator tubes. | 31 |
| abnormally low suction pressure | Temperature of chilled water too low with low motor amperes. | Insufficient load for system capacity. | Check pre-rotation vane motor operation and setting of low water temperature cutout. | 31 |
| high evaporator pressure | Pre-rotation vanes fail to open. | Check the pre-rotation vane motor positioning circuit. | 31 | |
| high evaporator pressure | High chilled water temperature. | System overload. | Be sure the vanes are wide open (without overloading the motor) until the load decreases. | 31 |
| no oil pressure when system start button pushed | Low oil pressure displayed on control center; compressor does not start. | Oil pump running in the incorrect direction. | Check rotation of oil pump (Electrical Connections). | 31 |
| no oil pressure when system start button pushed | Low oil pressure displayed on control center; compressor does not start. | Oil pump not running. | Troubleshoot electrical problem with oil pump VSD. | 31 |
| unusually high oil pressure develops when oil pump runs | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure. Transducer defective. | Replace low or high oil pressure transducer. | 31 |
| oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. Note: When oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Oil not reaching pump suction inlet in sufficient quantity. | Check oil level. | 31 |
| oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. Note: When oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Worn or failed oil pump. | Repair or replace oil pump. | 31 |
| reduced oil pump capacity | Oil pump pumping capacity. | Excessive end clearance pump. Other worn pump parts. | Inspect and replace worn parts. | 31 |
| reduced oil pump capacity | Oil pump pumping capacity. | Partially blocked oil supply inlet. | Check oil inlet for blockage. | 31 |
| oil pressure gradually decreases, noted by observing the daily log sheets | When the oil pump VSD frequency increases to 55 + Hz to maintain target oil pressure. | Oil filter is dirty. | Change oil filter. | 31 |
| oil pressure system ceases to return an oil/refrigerant sample | Oil refrigerant return not functioning. | Filter-drier in oil return system dirty. | Replace old filter-drier with a new filter-drier. | 32 |
| oil pressure system ceases to return an oil/refrigerant sample | Oil refrigerant return not functioning. | Jet or orifice of oil return jet clogged. | Remove jet, inspect for dirt. Remove dirt using solvent and replace the jet. | 32 |
| oil pump fails to deliver oil pressure | No oil pressure registers when pressing OIL PRESSURE display key when oil pump runs. | Faulty oil pressure transducer. Faulty wiring/connectors. | Replace oil pressure transducer. | 32 |
Compressor maintenance
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| HOT | Unit shutting down on high oil temperature. | Improper lubrication brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. However, if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed, notify the nearest Johnson Controls office to request the presence of a Johnson Controls Service Technician. | 49 |
| OP | Unit shutting down on low oil pressure. | Improper lubrication brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. However, if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed, notify the nearest Johnson Controls office to request the presence of a Johnson Controls Service Technician. | 49 |
Motor relubrication instruction
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Re-lubrication warning message | Current YORK OptiView panels provide a warning message to re-lubricate beginning at a programmed number of operating hours (the default value is 1000 h). At the programmed value plus 400 h this feature shuts down the chiller if re-lubrication is not addressed. In plants where chillers run 24/7, there is more than 16 days of advance warning before shutting down the chiller. | Programmed number of operating hours reached without re-lubrication. | Address re-lubrication; if re-lubrication is not addressed, the chiller is shut down at the programmed value plus 400 h. | 52 |
| Bearing temperature warning (above 65°C) | Normal operating temperature for grease lubricated bearings on YORK chillers is 40°C to 65°C. If the temperature exceeds 65°C, at which point a warning is issued, it is an indication that either the bearings are in need of lubrication or that something is incorrect. If temperature reaches 70°C, it generally indicates some type of problem. | Bearings in need of lubrication or something is incorrect. | Operation should be checked. | 56 |
| Bearing RTD motor shutdown (90°C) | Bearing RTDs are normally set to shut down the motors at 90°C, although once this temperature is reached, the bearings most likely have already been compromised. | 54 |
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