YORK® Chillers Proactive Parts Replacement Recommendations: Model YD Centrifugal Liquid Chillers

YORK® Chillers Proactive Parts
Replacement Recommendations
Model YD Centrifugal Liquid Chillers
Service Manual Form Number: 160.79-M2 (1020)

Issue Date: 2020-10-16 New Release
Johnson Controls - Confidential

2 YORK® Chillers Proactive Parts Replacement Recommendations

Proactive not reactive
Chillers are important assets to any mechanical room. They can be expected to run for 15-25 years.
In some situations, the cold water they provide for cooling or other processes is critical to a facility
and its operations. There are proactive steps that can be taken to maximize uptime on a chiller.
These proactive measures can be especially valuable in mission-critical applications. Johnson
Controls provides guidelines for facilities seeking to take these types of proactive measures.
In conjunction with recommended planned standard maintenance and condition-based
maintenance, proactive parts replacement can help improve uptime and extend the overall life of
the chiller while maintaining peak performance.
Naturally, chillers age over time. Some mechanical components that move during operation may
experience wear. Additionally, a variety of factors, including unstable power, extreme ambient
conditions, or chilled water system issues, can contribute to increased wear on certain components.
The bottom line is proactive replacement can help prevent unplanned downtime – this approach
maintains efficiency, boosts uptime, and can provide savings on unplanned repair costs.
Proactive parts replacement for maximum uptime

Johnson Controls has experts that can advise you on parts that can be inspected and replaced
proactively to prevent unexpected downtime. Using a combination of engineering expertise, field
experience, and data analysis, these recommendations cover replaceable components in the
chiller’s major systems.
Based on the chiller’s run hours, we can help you understand what parts could be proactively
replaced in the off-season or during planned downtime in order to maintain maximum uptime for
chillers, especially in mission-critical applications.
The time intervals provided are not the standard life expectancy of parts but are intended to
provide guidance on parts replacement based on when we see mechanical components beginning
to wear and before end of life.
The recommendations may be for a replacement or a simple inspection, to check if it is time to
replace a component.
Benefits of genuine YORK® parts

When proactively replacing parts, it is important to use genuine YORK® components to ensure the
correct fit and to avoid potential damage to other systems of the chiller.
Non-YORK® parts may not meet the strict specifications or tolerance requirements to ensure
correct compatibility with the chiller equipment. This may result in issues with reassembly,
accelerated wear on mechanical parts, increased power consumption for the equipment, or
premature failure of the replaced part.
YORK® replacement parts result in maintained energy consumption and provide longer service
lifetimes. Also, by securing genuine YORK® parts, you ensure that you have the latest compatible
version of the part and can take advantage of continued engineering improvements that may not
have been available when the chiller was initially purchased.
Global parts network – service wherever you are in the world

Johnson Controls has global parts supply centers and regional online portals to make sourcing
replacement parts for your chillers as simple as possible.
YORK® Chillers Proactive Parts Replacement Recommendations 3

If your original equipment originated from a North American factory, the Parts Navigator
Customer Portal helps get the job done. Navigator provides the products, tools, support and
expertise to find what you need at the Baltimore Parts Center. Find products and parts you need
and then configure, quote, and price them all in a single location. Place your order, track your
shipment, and manage your warranties without having to log on to multiple systems or download
software for updates.
Please visit https://www.hvacnavigator.com/ for more information.
For equipment that originated from a European factory, our Parts Centre Service platform, enables
you to consult and retrieve technical specifications for YORK® chiller parts and place your order to
ensure quick delivery. The Parts Centre Service platform makes ordering and servicing your facility
easy to do, ensuring reliability and continuity with genuine parts.
Please visit easyparts.johnsoncontrols.com for more information.
For equipment that originated from a factory in Asia, the Johnson Controls team at the Shanghai
Distribution Center is ready to help whenever you need spare parts. Contact your local Johnson
Controls office and they will support you in finding the genuine YORK® chiller replacement parts
you need and place an order for you.
4 YORK® Chillers Proactive Parts Replacement Recommendations

Proactive parts replacement recommendations for
YD mod level C and D
The following table provides recommendations on proactive inspection and replacement intervals
based on the chiller run hours the equipment has experienced. The chiller run hours can be found
in the OptiView panel.
Table 1: Proactive parts replacement recommendations for YD chillers
Proactively check,
inspect, or replace
Major component Part description interval
(chiller run hours)
Chiller system O-rings
Waterbox channel gasket 26,280
and gaskets
Chiller system O-rings
Waterbox head gasket 26,280
and gaskets
Chiller system valves and
Oil return solenoid valve / O-ring 43,800
actuators
43,800
Coupling assembly (disk pack) - inspect for
Compressor
cracking Inspect; replace only
if necessary
Chiller system sensors Entering chilled water temperature sensor 52,560
Chiller system sensors Leaving chilled water temperature sensor 52,560
Chiller system sensors Entering condenser water temperature sensor 52,560
Chiller system sensors Leaving condenser water temperature sensor 52,560
Condenser liquid refrigerant temperature
Chiller system sensors 52,560
sensor
Chiller system sensors High pressure cutout switch / O-ring 52,560
Chiller system sensors Evaporator and condenser water flow sensor 61,320
Chiller system sensors Kit, PRV/VGD position sensor 61,320
Chiller system sensors PRV/VGD potentiometer (5000 ohm) 61,320
61,320
Compressor PRV/VGD actuators
Inspect; replace only
if necessary
OptiView Coin cell battery 70,080
Chiller system sensors Stall/Discharge pressure transducer / O-ring 87,600
High oil pressure transducer (located on
compressor) / O-ring
Low oil pressure transducer (located on sump) /
O-ring
Chiller system sensors Condenser pressure transducer / O-ring 87,600
Chiller system sensors Evaporator pressure transducer / O-ring 87,600
YORK® Chillers Proactive Parts Replacement Recommendations 5

Table 1: Proactive parts replacement recommendations for YD chillers
Proactively check,
inspect, or replace
Major component Part description interval
(chiller run hours)
Variable orifice actuator 87,600
actuators
Hot gas actuator (if applicable) 87,600
actuators
1
PCBAs VSD logic board 87,600
PCBAs
1 Filter logic board 87,600
OptiView SD card 87,600
87,600
2
Compressor Impeller
Check; inspect only if
necessary
87,600
Compressor
2 Impeller seal rings
Check; inspect only if
necessary
Oil system Panel, VSOP drive 87,600
VSD
1 DC bus capacitors - main pole 100,000
VSD
1 DC bus capacitors - filter pole 100,000
OptiView Display (backlight) 100,000
PCBAs
1 Gate driver board 100,000
PCBAs
1 SCR trigger board 100,000
OptiView IO board (relays) 131,400
OptiView Keypad 131,400
1 These components are only applicable to units with variable speed drives.
2 Johnson Controls does not recommend teardown of centrifugal compressors based on time intervals. Please contact
Product Technical Support if you think the compressor needs to be inspected in detail and they will guide you through
special checks.
This document does not cover recommended maintenance items. Refer to Form 160.69-MR1 and
Form 160.79-MR1 for detailed maintenance recommendations for your equipment.
This document is intended for YORK® chillers that are out of the standard factory warranty.
The guidance in this document is proactive, not reactive. The document is for indicative purposes
only and is based on a wide variety of factors that differ globally, such as installation, usage,
environmental conditions, and maintenance performed since the initial start-up of the chiller.
Additionally, not all parts are stocked in parts centers, and lead times are subject to change. For
your specific chiller installation recommendations, lead times, and pricing guidance, please consult
with your local Johnson Controls service team.
© 2020 Johnson Controls. 5000 Renaissance Drive, New Freedom, York, PA 17349, USA. Subject to change without notice. All
rights reserved.

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YORK® Chillers Proactive Parts

Service Manual Form Number: 160.79-M2 (1020)

Johnson Controls - Confidential

Johnson Controls - Confidential

Proactive parts replacement for maximum uptime

Benefits of genuine YORK® parts

Global parts network – service wherever you are in the world

YORK® Chillers Proactive Parts Replacement Recommendations 3

Johnson Controls - Confidential

4 YORK® Chillers Proactive Parts Replacement Recommendations

Johnson Controls - Confidential

YORK® Chillers Proactive Parts Replacement Recommendations 5

Johnson Controls - Confidential

Johnson Controls - Confidential

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