Johnson Controls York YD User manual

LD08634
MODEL YD (STYLE B)
R-134A (COOLING ONLY)
WITH OPTIVIEW™ CONTROL CENTER
AND ELECTRO-MECHANICAL STARTER
CENTRIFUGAL LIQUID CHILLERS
INSTALLATION INSTRUCTION Supersedes: 160.69-N2 (912) Form 160.69-N2 (715)
Issue Date:
July 31, 2015
R-134A

JOHNSON CONTROLS
2
FORM 160.69-N2
ISSUE DATE: 7/31/2015
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, refrigerants, materials under pressure,
rotating components, and both high and low voltage.
Each of these items has the potential, if misused or
handled improperly, to cause bodily injury or death. It
is the obligation and responsibility of rigging, instal-
lation, and operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
rigging, installation, and operating/service personnel. It
is expected that these individuals possess independent
training that will enable them to perform their assigned
tasks properly and safely. It is essential that, prior to
performing any task on this equipment, this individual
shall have read and understood the on-product labels,
this document and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied 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 specications and must be performed only by a qualied
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.

JOHNSON CONTROLS 3
FORM 160.69-N2
ISSUE DATE: 7/31/2015
MANUAL DESCRIPTION FORM NUMBER
Product Drawing 160.69-PA5.1
YD Unit Field Reassembly Instructions 160.69-NM3
Field Connections 160.69-PW1
Unit Wiring and Field Control Modications 160.69-PW2
YD Unit Installation Checklist and Request for Startup Engineer 160.69-CL1
YD with OptiView Control Center and EMS (Cooling Only) Operating Manual 160.69-O2
All Products - Service Policy 50.15-NM
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts.
johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
ASSOCIATED LITERATURE

JOHNSON CONTROLS
4
FORM 160.69-N2
ISSUE DATE: 7/31/2015
NOMENCLATURE
MOTOR CODE
60 Hz 50 Hz
CW 5CS
CX 5CT
CY 5CU
CZ 5CV
CA 5CW
CB 5CX
DA 5DA
DB 5DB
DC 5DC
DD 5DD
DE 5DE
DF 5DF
5DG
DH 5DH
DJ 5DJ
DK 5DK
DL 5DL
COMPRESSOR
CODE
J1, J2, J3, J4, J5, J7
YD XH XD J2 – DA B
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
DESIGN LEVEL
CONDENSER
CODE
KB, KC, KD, KE, K2, K3, K4, K5
HB, HC, HD, HE, H2, H3, H4, H5
GB, GC, GD, GE, G2, G3, G4, G5
FB, FC, FD, FE, F2, F3, F4, F5
EB, EC, ED, EE, E2, E3, E4, E5
DB, DC, DD, DE, D2, D3, D4, D5
CB, CC, CD, C2, C3, C4
BB, BC, BD, BE, B2, B3, B4, B5
EVAPORATOR
CODE
KB, KC, KD, K2, K3, K4
HB, HC, HD, H2, H3, H4
GB, GC, GD, G2, G3, G4
FB, FC, FD, F2, F3, F4
EB, EC, ED, E2, E3, E4
DB, DC, DD, D2, D3, D4
CB, CC, CD, C2, C3, C4
BB, BC, BD, B2, B3, B4
MODEL

JOHNSON CONTROLS 5
FORM 160.69-N2
ISSUE DATE: 7/31/2015
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION.................................................................................................................................7
General.............................................................................................................................................................7
Field Assembled Units Only .............................................................................................................................7
Shipment ..........................................................................................................................................................7
Inspection – Damage – Shortage..................................................................................................................... 8
Chiller Data Plate .............................................................................................................................................9
Rigging .............................................................................................................................................................9
Location............................................................................................................................................................9
Motors ..............................................................................................................................................................9
Foundation .......................................................................................................................................................9
Clearance .........................................................................................................................................................9
Neoprene Isolators ......................................................................................................................................... 11
Spring Isolators ..............................................................................................................................................13
Unit Dimensions .............................................................................................................................................16
Unit Weights ...................................................................................................................................................17
SECTION 2 - INSTALLATION ................................................................................................................................19
Rigging Unit To Final Location........................................................................................................................19
Checking The Isolation Pad Deflection...........................................................................................................19
Leveling The Unit............................................................................................................................................19
Installing Optional Spring Isolators.................................................................................................................19
Piping Connections ........................................................................................................................................19
Evaporator And Condenser Water Piping.......................................................................................................20
Chilled Water.........................................................................................................................................20
Condenser Water Circuit .......................................................................................................................20
Stop Valves ...........................................................................................................................................22
Flow Switches .......................................................................................................................................22
Drain and Vent Valves ...........................................................................................................................22
Checking Piping Circuits and Venting Air ..............................................................................................22
Refrigerant Relief Piping ................................................................................................................................22
Unit Piping ......................................................................................................................................................22
Control Panel Positioning ..............................................................................................................................22
Control Wiring.................................................................................................................................................23
Power Wiring ..................................................................................................................................................23
Oil Pump – 3 Phase Starter...................................................................................................................23
YD Motors (Electro-Mechanical Starter)................................................................................................23
Insulation ........................................................................................................................................................23
Installation Check – Request For Start-Up Service........................................................................................24
Compressor Motor Field Connection Diagram ...............................................................................................24

JOHNSON CONTROLS
6
FORM 160.69-N2
ISSUE DATE: 7/31/2015
LIST OF FIGURES
LIST OF TABLES
FIGURE 1 - Rigging.................................................................................................................................................10
FIGURE 2 - Neoprene Isolators ..............................................................................................................................11
FIGURE 3 - Neoprene Isolators ..............................................................................................................................12
FIGURE 4 - Spring Isolators....................................................................................................................................13
FIGURE 5 - Model YD Chiller..................................................................................................................................14
FIGURE 6 - Dimensions – J Compressor Units ......................................................................................................15
FIGURE 7 - Schematic of a Typical Piping Arrangement ........................................................................................21
FIGURE 8 - Typical Refrigerant Vent Piping............................................................................................................21
FIGURE 9 - Control Panel Positioning ....................................................................................................................22
FIGURE 10 - Motor Connections (Electro Mechanical Starter Application).............................................................24
TABLE 1 - Evaporator – Condenser Shell Codes .................................................................................................16
TABLE 2 - Approximate Unit Weight Including Motor and Compact Water Boxes..................................................17
TABLE 3 - Marine Waterbox Weight .......................................................................................................................17
TABLE 4 - Approximate Unit Motor Weights ...........................................................................................................18
TABLE 5 - Motor Connections ................................................................................................................................24

JOHNSON CONTROLS 7
FORM 160.69-N2
ISSUE DATE: 7/31/2015
1
GENERAL
This instruction describes the installation of a MOD-
EL YD Liquid Chilling Unit. This unit is shipped as
a single factory assembled, piped, wired package, re-
quiring a minimum of field labor to make chilled water
connections, condenser water connections, refrigerant
atmospheric relief connections, and electrical power
connections. (Refrigerant and oil charges shipped sep-
arately unless optional condenser isolation valves are
ordered.)
Chillers can also be shipped dismantled when required
by rigging conditions, but generally it is more econom-
ical to enlarge access openings to accommodate the
factory assembled unit. Chillers shipped dismantled
MUST be field assembled under the supervision of a
Johnson Controls representative, but otherwise instal-
lation will be as described in this instruction.
FIELD ASSEMBLED UNITS ONLY
Use Form 160.69-NM3 in conjunction with this instal-
lation instruction. This instruction will be furnished
with all units that are to be field assembled.
The services of a Johnson Controls representative will
be furnished to check the installation, supervise the
initial start-up and operation of all chillers installed
within Continental United States.
The Johnson Controls Warranty may be voided if
the following restrictions are not adhered to:
1. No valves or connections should be opened under
any circumstances because such action will result
in loss of the factory nitrogen charge.
2. Do not dismantle or open the chiller for any rea-
son except under the supervision of a Johnson
Controls representative.
3. When units are shipped dismantled, notify the
nearest Johnson Controls ofce in ample time for
a Johnson Controls representative to supervise
rigging the unit to its operating position and the
assembly of components.
4. Do not make nal power supply connections to
the compressor motors or control center.
5. Do not charge the compressors with oil.
6. Do not charge the unit with refrigerant.
7. Do not attempt to start the system.
8. Do not run hot water (110°F / 43°C max) or steam
through the evaporator or condenser at any time.
SHIPMENT
The chiller may be ordered and shipped in any of the
following forms:
Form 1 – Factory Assembled Unit, complete with mo-
tor, refrigerant and oil charges.
1. The motor/compressor assembly mounted, with
all necessary interconnecting piping assembled.
OptiView™ Control Center is mounted on the
unit. Complete unit factory leak tested, evacuated
and charged with R-134A.
2. Miscellaneous material – Four (4) vibration
isolation pads (or optional spring isolators and
brackets).
Form 2 – Factory Assembled Unit, complete with
motors (refrigerant and oil charges shipped separately).
1. The motor/compressor assemblies mounted, with
all necessary interconnecting piping assembled.
OptiView™ Control Center is mounted on the
unit. Complete unit factory leak tested, evacuated
and charged with holding charge of nitrogen.
2. Miscellaneous material – Four (4) vibration iso-
lation pads (or optional spring isolators and brack-
ets).
Form 3 – Drivelines Separate From Shells – Shipped
as three major assemblies. Unit first factory assembled,
refrigerant piped, wired and leak tested; then disman-
tled for shipment. Compressor/motor assemblies re-
moved from shells and skidded. Evaporator/condenser
is not skidded.
All wiring integral with compressors are left on
them, and all conduit is left on shell. All openings on
compressors, oil separator, and shells are closed and
charged with dry nitrogen (2 to 3 PSIG) (14-21 kPa).
Miscellaneous packaging of control center, tubing,
water temperature controls, wiring, oil, isolators, solid
state starters (option), etc.; refrigerant charge shipped
separately.
SECTION 1 - INTRODUCTION

JOHNSON CONTROLS
8
FORM 160.69-N2
ISSUE DATE: 7/31/2015
SECTION 1 - INTRODUCTION
Units shipped dismantled MUST be re-
assembled by, or under the supervision of,
a Johnson Controls representative. (See
Form 160.69-NM3)
Form 7 – Split Shells - Shipped as four major assem
blies. Unit first factory assembled, refrigerant piped,
wired and leak tested; then dismantled for shipment.
Compressor/motor assemblies removed from shells
and skidded.
Evaporator and condenser shells are separated at tube
sheets and are not skidded. Refrigerant lines between
shells are flanged and capped, requiring no welding.
All wiring integral with compressors are left on them.
All wiring harnesses on shells are removed. All open-
ings on compressors and shells are closed and charged
with dry nitrogen (2 to 3 psig) (14-21 kPa).
Miscellaneous packaging of control center, tubing,
water temperature controls, wiring, oil isolators, solid
state starter (option), etc.; refrigerant charge shipped
separately.
Units shipped dismantled MUST be re-
assembled by, or under the supervision of,
a Johnson Controls representative. (See
Form 160.69-NM3)
When more than one chiller is involved, the major
parts of each unit will be marked to prevent mixing
of assemblies. (Piping and Wiring Drawings to be fur-
nished by YORK.)
INSPECTION – DAMAGE – SHORTAGE
The unit shipment should be checked on arrival to see
that all major pieces, boxes and crates are received.
Each unit should be checked on the trailer or rail car
when received, before unloading, for any visible signs
of damage. Any damage or signs of possible damage
must be reported to the transportation company imme-
diately for their inspection.
Johnson Controls will not be responsible
for any damage in shipment or at job site
or loss of parts. (Refer to Shipping Dam-
age Claims, Form 50.15-NM)
Rigging and liing should only be done by a professional rigger in accordance with a written rigging
and liing plan. e most appropriate rigging and liing method will depend on job specic factors,
such as the rigging equipment available and site needs. erefore, a professional rigger must determine
the rigging and liing method to be used, and it is beyond the scope of this manual to specify rigging
and liing details.

JOHNSON CONTROLS 9
SECTION 1 - INTRODUCTION
FORM 160.69-N2
ISSUE DATE: 7/31/2015
1
When received at the job site all containers should be
opened and contents checked against the packing list.
Any material shortage should be reported to Johnson
Controls immediately. (Refer to Shipping Damage
Claims, Form 50.15-NM)
CHILLER DATA PLATE
A unit data plate is mounted on the control center as-
sembly of each unit, giving unit model number; design
working pressure; water passes; refrigerant charge; se-
rial numbers; and motor power characteristics and con-
nection diagrams.
Additional information may be found on the motor
data plates. This information should be included when
contacting the factory on any problem relating to the
motor.
RIGGING
The complete standard chiller is shipped without skids.
(When optional skids are used it may be necessary to
remove the skids so riggers skates can be used under
the unit end sheets to reduce overall height.)
Each unit has four (4) lifting holes (two in each end)
in the end sheets which should be used to lift the unit.
Care should be taken at all times during rigging and
handling of the chiller to avoid damage to the unit and
its external connections. Lift only using holes shown
in Figure 1 on page 10.
Do not lift the unit with slings around
motor/compressor assemblies or by
means of eyebolts in the tapped holes of
the compressor motor assemblies. Do not
turn a unit on its side for rigging. Do not
rig vertically.
The rigging and operating weights and overall dimen-
sions are given on pages 6 thru 8 as a guide in deter-
mining the clearances required for rigging. Add 6" (15
cm) to overall height for optional skidded unit.
The lengthwise rigging bar should be longer than the
chiller tube length, and must have counter or clevis ad-
justments to allow for center of gravity adjustments.
Chain spreaders should be used to avoid contact with
drive motors or other chiller parts.
LOCATION
YORK Chillers are furnished with vibration isola-
tor mounts for basement or ground level installations.
Units may be located on upper floor levels providing
the floor is capable of supporting the total unit operat-
ing weight and optional spring isolators are used.
Sufcient clearance to facilitate normal
service and maintenance work must be
provided all around and above the unit
and particularly space provided at either
end to permit cleaning or replacement
of evaporator and condenser tubes – see
CLEARANCE. A doorway or other suf-
ciently large opening properly located
may be used. The chiller should be located
in an indoor location where tempera-
tures range from 40°F to 110°F (4.4°C
to 43.3°C).
MOTORS
The YK open motor is air cooled. Check state, local
and other codes for ventilation requirements.
FOUNDATION
A level floor, mounting pad or foundation must be pro-
vided by others, capable of supporting the operating
weight of the unit.
CLEARANCE
Clearances should be adhered to as follows:
• Rear and above unit – 2 ft (61 cm).
• Front of unit – 3 ft (91 cm).
• Tube Removal – 22 ft. (6.7 m) (either end)
18 ft. (5.5 m) (either end)

JOHNSON CONTROLS
10
FORM 160.69-N2
ISSUE DATE: 7/31/2015
SECTION 1 - INTRODUCTION
LD09014a
FIGURE 1 - RIGGING

JOHNSON CONTROLS 11
SECTION 1 - INTRODUCTION
FORM 160.69-N2
ISSUE DATE: 7/31/2015
1
NEOPRENE ISOLATORS
FIGURE 2 - NEOPRENE ISOLATORS
LD19590a
LD19571a
SHELL
END SHEET
DIA.
HOLE
See Detail A
10"
(254)
8"
(203)
5"
(127)
C/C and D/D - Up to 225,000 lbs. (102,060 Kgs)
9"
(229)
LD19589a
SHELL
END SHEET
DIA.
HOLE
See Detail A
10"
(254)
8"
(203)
5"
(127)
B/B - Up to 130,000 lbs (58,967 Kgs)
E/E, F/F, G/G, H/H and K/K - Up to 280,000 lbs (127,005 Kgs)
Mounting
Bracket
Pad
3/8”
(10)
3/4”
(19)
DETAIL A

JOHNSON CONTROLS
12
FORM 160.69-N2
ISSUE DATE: 7/31/2015
SECTION 1 - INTRODUCTION
NEOPRENE ISOLATORS
**
B
FIGURE 3 - NEOPRENE ISOLATORS
SHELL CODE UNIT WEIGHT DIM "A" DIM "B" DIM "C" DIM "D" QTY
B B Up to 130,000 lbs (58,967 Kgs) 10' 3" (3124)
8 x 1"
from edge.
11" (279) 12 (305) 8
C C Up to 225,000 lbs (102,060 Kgs) 11' 5" (3176) 11" (279) 10" (254) 8
D D Up to 225,000 lbs (102,060 Kgs) 12' 9" (3887) 11" (279) 10" (254) 8
E E Up to 280,000 lbs (127,005 Kgs) 12' 9" (3887) 11" (279) 12 (305) 8
F F Up to 280,000 lbs (127,005 Kgs) 13' 9" (4192) 11" (279) 12 (305) 8
G G Up to 280,000 lbs (127,005 Kgs) 13' 9" (4192) 11" (279) 12 (305) 8
H H Up to 280,000 lbs (127,005 Kgs) 14' 8" (4471) 11" (279) 12 (305) 8
K K Up to 280,000 lbs (127,005 Kgs) 14' 8" (4471) 11" (279) 12 (305) 8
Approx weight including motor and 150# compact water boxes.
LD12643a
* Typical both ends.

JOHNSON CONTROLS 13
SECTION 1 - INTRODUCTION
FORM 160.69-N2
ISSUE DATE: 7/31/2015
1
SPRING ISOLATORS
FIGURE 4 - SPRING ISOLATORS
SHELL
3-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
16 1/
4"
(413)
3"
(76)
SHELL
12-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
6-1/4"
(159)
SHELL
4-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
15 1/4"
(387)
3"
(76)
UNIT WEIGHT
B-B - Up to 115,000 lbs (52,163 Kgs)
UNIT WEIGHT
C-C - Up to 190,000 lbs (86,184 Kgs)
E-E and F-F - Up to 240,000 lbs (108,862 Kgs)
G-G and H-H - Up to 240,000 lbs (108,862 Kgs)
LD19580
LD19592
LD19591
K-K - Up to 250,000 lbs (113,400 Kgs)
K-K - Up to 320,000 lbs (145,150 Kgs)

JOHNSON CONTROLS
14
FORM 160.69-N2
ISSUE DATE: 7/31/2015
SECTION 1 - INTRODUCTION
FIGURE 5 - MODEL YD CHILLER
LD08634
OPTIVIEW™
CONTROL
CENTER
COMPRESSOR #1
EVAPORATOR
MOTOR #1 MOTOR #2
CONDENSER
COMPRESSOR #2

JOHNSON CONTROLS 15
SECTION 1 - INTRODUCTION
FORM 160.69-N2
ISSUE DATE: 7/31/2015
1
FIGURE 6 - DIMENSIONS – J COMPRESSOR UNITS
LD09012
D L C
A
M
9"
B
FLOOR LINE
EVAPORATOR
CONDENSER
F
J
E G
H
MOTORS
COMPRESSORS
LD09013
SHIPPING WIDTH

JOHNSON CONTROLS
16
FORM 160.69-N2
ISSUE DATE: 7/31/2015
SECTION 1 - INTRODUCTION
TABLE 1 - EVAPORATOR – CONDENSER SHELL CODES
SHELL B B C C D D E E F F G G H H K K
A11' 5"
(3,480)
12'-6"
(3,810)
13'-6"
(4,115)
13'-6"
(4,115)
14'-6 1/4"
(4,426)
14'-6 1/4"
(4,426)
15'-5 1/4"
(4,705)
15'-6"
(4,724)
B12'-1 3/4"
(3,683)
12'-10"
(3,759)
13'-0"
(3,962)
13'-0"
(3,962)
13'-8"
(4,166)
13'-8"
(4,166)
14'-2"
(4,318)
16'-0"
(4,877)
C2'-8"
(813)
2"-11 1/2"
(914)
3'-5"
(1,041)
3'-5"
(1,041)
3'-9"
(1,143)
3'-9"
(1,143)
4'-0"
(1,219)
4'-0"
(1,219)
D2'-5 1/2"
(749)
2'-9"
(826)
2'-11 1/2"
(902)
2'-11 1/2"
(902)
3'-1 1/2"
(953)
3'-1 1/2"
(955)
3'-4"
(1,016)
3'-4"
(1,016)
E18'-0"
(5,486)
22'-0"
(6,706)
18'-0"
(5,486)
22'-0"
(6,706)
18'-0"
(5,486)
22'-0"
(6,706)
18'-0"
(5,486)
22'-0"
(6,706)
F2'-0 3/4"
(629)
1'-10"
(629)
2'-1"
(635)
2'-1"
(635)
2'-3"
(686)
2'-3"
(686)
2'-3 9/16"
(700)
2'-3 9/16"
(700)
G1'-4 3/4"
(425)
1'-1 5/8"
(425)
1'-4 1/4"
(413)
1'-4 1/4"
(413)
1'-6 1/4"
(464)
1'-6 1/4"
(464)
1'-6 7/8"
(479)
1'-6 7/8"
(479)
H0'-11 11/16"
(297)
1'-1 3/4"
(297)
1'-2 5/8"
(371)
1'-2 5/8"
(371)
1'-3 5/8"
(397)
1'-3 5/8"
(397)
1'-4 1/4"
(413)
1'-4 1/4"
(413)
J1'-7 5/8"
(498)
1'-9 1/4"
(498)
2'-1 1/2"
(648)
2'-1 1/2"
(648)
2'-2"
(660)
2'-2"
(660)
2'-1"
(635)
2'-1"
(65)
L5'-1 1/2"
(1,562)
5'-8 1/2"
(1,740)
6'-4 1/2"
(1,943)
6'-4 1/2"
(1,943)
6'-10 1/2"
(2,096)
6'-10 1/2"
(2,096)
7'-4"
(2,235)
7'-4"
(2,235)
NOTES:
1. All dimensions are approximate. Certied dimensions are
available on request.
2. For compact water boxes (shown above), determine overall unit length
by adding water box depth to tube sheet length.
3. Water nozzles can be located on either end of unit. Add 1/2" to nozzle
length for anges connections.
4. To determine overall height, add dimension "M" for the
appropriate isolator type.
5. Use of motors with motor hoods may increase overall unit dimensions.
UNIT DIMENSIONS
ADDITIONAL OPERATING HEIGHT
CLEARANCE TO FLOOR
TYPE OF CHILLER MOUNTING FT.-IN. MM
Neoprene Pad Isolators 1-3/4" 44
Spring Isolators 1" Deection 1" 25
Direct Mount 3/4" 19

JOHNSON CONTROLS 17
SECTION 1 - INTRODUCTION
FORM 160.69-N2
ISSUE DATE: 7/31/2015
1
UNIT WEIGHTS
TABLE 2 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR AND COMPACT WATER BOXES
SHELLS COMPRESSOR SHIPPING WEIGHT
LBS (KGS)**
OPERATION WEIGHT
LBS (KGS)
EST. REFRIGERANT
CHARGE LBS (KGS)***
B B J1, J2 76,800 (34,833) 95,450 (43,291) 6,000 (2,721)
C C J3 108,750 (49,324) 134,400 (60,957) 8,050 (3,651)
D D J3 117,950 (53,496) 145,550 (66,014) 7,925 (3,594)
E E J4 130,100 (59,007) 162,550 (73,725) 9,850 (4,467)
F F J4 133,700 (60,640) 167,700 (76,060) 9,725 (4,411)
G G J5 149,000 (67,579) 188,900 (85,676) 11,900 (5,397)
H H J5 147,250 (66,785) 186,200 (84,451) 10,875 (4,932)
K K J7 177,200 (80,369) 223,000 (101,142) 13,300 (6,032)
*Refer to product drawings for detailed weight information.
**Does not include Refrigerant Charge.
***Add 5% for 1” tube option in the evaporator
TABLE 3 - MARINE WATERBOX WEIGHT
EVAP SHIPPING WEIGHT INCREASE (LBS) OPERATING WEIGHT INCREASE (LBS)
1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
B4,832
(2,192)
2,348
(1,065)
4,526
(2,053)
5,094
(3,149)
3,378
(1,532)
5,896
(2,674)
C6,938
(3,147)
3,342
(1,516)
6,842
(3,103)
10,638
(4,825)
4,523
(2,051)
9,112
(4,133)
D10,692
(4,849)
6,554
(2,973)
13,316
(6,039)
18,095
(8,207)
9,508
(4,312)
18,186
(8,248)
E10,692
(4,849)
6,554
(2,973)
13,316
(6,039)
18,095
(8,207)
9,508
(4,312)
18,186
(8,248)
F15,146
(6,869)
8,071
(7,428)
16,378
(7,428)
24,507
(11,115)
11,784
(5,345)
23,026
(10,443)
G15,146
(6,869)
8,071
(7,428)
16,378
(7,428)
24,507
(11,115)
11,784
(5,345)
23,026
(10,443)
H17,374
(7,880)
8,478
(3,845)
16,744
(7,594)
27,740
(12,581)
12,614
(5,721)
24,041
(10,904)
K17,374
(7,880)
8,478
(3,845)
16,744
(7,594)
27,740
(12,581)
12,614
(5,721)
24,041
(10,904)
COND 1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
B5,094
(2,310)
2,276
(1,032)
4,522
(2,051)
9,809
(4,449)
4,021
(1,824)
7,735
(3,508)
C5,790
(2,626)
2,953
(1,339)
5,220
(2,368)
9,779
(4,435)
4,649
(2,109)
6,990
(3,170)
D7,394
(3,354)
3,889
(1,764)
7,538
(3,419)
13,211
(5,992)
6,109
(2,771)
11,613
(5,267)
E7,394
(3,354)
3,889
(1,764)
7,538
(3,419)
13,211
(5,992)
6,109
(2,771)
11,613
(5,267)
F8,424
(3,821)
4,644
(2,106)
8,764
(3,975)
14,920
(6,767)
7,846
(3,559)
14,063
(6,378)
G8,424
(3,821)
4,644
(2,106)
8,764
(3,975)
14,920
(6,767)
7,846
(3,559)
14,063
(6,378)
H10,332
(4,686)
5,521
(2,504)
10,371
(4,703)
17,704
(8,030)
9,161
(4,155)
16,412
(7,444)
K10,332
(4,686)
5,521
(2,504)
10,371
(4,703)
17,704
(8,030)
9,161
(4,155)
16,412
(7,444)

JOHNSON CONTROLS
18
FORM 160.69-N2
ISSUE DATE: 7/31/2015
SECTION 1 - INTRODUCTION
TABLE 4 - APPROXIMATE UNIT MOTOR WEIGHTS
MEDIUM VOLTAGE
MODEL WEIGHT
(LBS.)
WEIGHT
(KGS.)
MODEL WEIGHT
(LBS.)
WEIGHT
(KGS.)
60 HZ HP 50 HZ HP
CW 655 4,415 2,007 5CS 658 4,640 2,109
CX 690 4,445 2,020 5CT 704 5,800 2,636
CY 740 4,540 2,064 5CU 750 5,800 2,636
CZ 790 4,640 2,109 5CV 800 5,800 2,636
CA 845 5,800 2,636 5CW 850 6,800 3,091
CB 900 5,800 2,636 5CX 900 6,800 3,091
DA 1000 6,800 3,091 5DA 1000 7,050 3,205
DB 1100 6,800 3,091 5DB 1100 7,300 3,318
DC 1200 7,050 3,205 5DC 1200 7,300 3,318
DD 1300 7,300 3,318 5DD 1300 7,300 3,318
DE 1400 7,300 3,318 5DE 1400 7,500 3,409
DF 1500 7,500 3,409 5DF 1500 7,500 3,409
5DG 1650 7,900 3,591
DH 1750 7,500 3,409 5DH 1750 11,250 5,114
DJ 2000 8,500 3,864 5DJ 2000 11,750 5,341
DK 2250 11,750 5,341 5DK 1750 12,750 5,795
DL 2500 12,750 5,795 5DL 2000 13,250 6,023

JOHNSON CONTROLS 19
FORM 160.69-N2
ISSUE DATE: 7/31/2015
2
SECTION 2 - INSTALLATION
RIGGING UNIT TO FINAL LOCATION
Rig the unit to its final location on the floor or mount-
ing pad, lift the unit (or shell assembly) by means of an
overhead lift and lower the unit to its mounting posi-
tion. (If optional shipping skids are used, remove them
before lowering the chiller to its mounting position.)
At this point units shipped dismantled
should be assembled under the supervi-
sion of a Johnson Controls representative.
If evaporator is to be field insulated, the insulation
should be applied to the evaporator before the unit is
placed in position while the unit is in the lift position.
Be sure unit is properly supported. (See Insulation on
page 23)
LOCATING AND INSTALLING ISOLATOR PADS
(Refer to Figure 2 on page 11 or Figure 3 on page
12)
After the isolator pads have been placed into position
on the floor, lower the chiller onto the pads. When the
unit is in place, remove the rigging equipment and
check that the unit is level. The unit should be level
within 1/4" (6 mm) from one end to the other end and
from front to the rear. If the chiller is not level within
the amount specified, lift it and place shims between
the isolation pad and the chiller tube sheets. (Shims
furnished by the installer.) Lower unit again and re-
check to see that it is level.
CHECKING THE ISOLATION PAD
DEFLECTION
All isolation pads should be checked for the proper de-
flection while checking to see if the unit is level. Each
pad should be deflected approximately 0.10 inchs (2.5
mm) to 0.20 inchs (5 mm). If an isolation pad is under-
deflected, shims should be placed between the unit tube
sheet and the top of the pad to equally deflect all pads.
LEVELING THE UNIT
The longitudinal alignment of the unit should be
checked by placing a level on the top center of the evap-
orator shell. Transverse alignment should be checked
by placing a level on top of the shell end sheets.
INSTALLING OPTIONAL SPRING ISOLATORS
When ordered, spring type isolator assemblies will be
furnished with the unit. The 4 assemblies are identical
and can be placed at any of the 4 corners of the unit.
(Refer to Figure 4 on page 13.)
While the unit is still suspended by the rigging, the iso-
lators should be bolted to the unit by inserting the cap
screws through the holes in the mounting bracket into
the tapped hole in the top of the isolator leveling bolts.
Then the unit can be lowered onto the floor.
The leveling bolts should now be rotated one (1) turn at
a time, in sequence, until the unit end sheets are clear
of the floor by the dimension shown in Fig. 7 or 8 and
the unit is level. Check that the unit is level, both lon-
gitudinally and transversely (see Leveling the Unit). If
the leveling bolts are not long enough to level unit due
to an uneven or sloping floor or foundation, steel shims
(grouted, if necessary) must be added beneath the iso-
lator assemblies as necessary.
After the unit is leveled, wedge and shim under each
corner to solidly support the unit in this position while
piping connections are being made, pipe hangers ad-
justed and connections checked for alignment. Then
the unit is filled with water and checked for leaks. The
leveling bolts should now be finally adjusted until the
wedges and shims can be removed. The unit should
now be in correct level position, clear of the floor or
foundation and without any effect from the weight of
the piping.
PIPING CONNECTIONS
After the unit is leveled (and wedged in place for op-
tional spring isolators) the piping connections may be
made; chilled water, condenser water and refrigerant
relief. The piping should be arranged with offsets for
flexibility, and adequately supported and braced inde-
pendently of the unit to avoid strain on the unit and
vibration transmission. Hangers must allow for align-
ment of pipe. Isolators (by others) in the piping and
hangers are highly desirable, and may be required by
specifications, in order to effectively utilize the vibra-
tion isolation characteristics of the vibration isolation
mounts of the unit.
Check for piping alignment – Upon completion of

JOHNSON CONTROLS
20
FORM 160.69-N2
ISSUE DATE: 7/31/2015
SECTION 2 - INSTALLATION
piping, a connection in each line as close to the unit
as possible should be opened, by removing the flange
bolts or coupling and checked for piping alignment. If
any of the bolts are bound in their holes, or if the con-
nection springs are out of alignment, the misalignment
must be corrected by properly supporting the piping or
by applying heat to anneal the pipe.
If the piping is annealed to relieve stress
the inside of the pipe must be cleaned of
scale before it is nally bolted in place.
EVAPORATOR AND CONDENSER WATER
PIPING
The evaporator and condenser liquid heads of chiller
have nozzles which are grooved, suitable for welding
150 psig DWP flanges or the use of Victaulic cou-
plings. Factory mounted flanges are optional.
The nozzles and water pass arrangements are furnished
in accordance with the job requirements (see Product
Drawings) furnished with the job. Standard units are
designed for 150 psig DWP on the water side. If job
requirements are for greater than 150 psig DWP, check
the unit data plate before applying pressure to evapora-
tor or condenser to determine if the chiller has provi-
sions for the required DWP.
Inlet and outlet connections are identified by labels
placed adjacent to each nozzle.
Chilled Water
Foreign objects which could lodge in, or block flow
through, the evaporator and condenser tubes must be
kept out of the water circuit. All water piping must be
cleaned or flushed before being connected to the chiller
pumps, or other equipment.
Permanent strainers (supplied by others) are required
in both the evaporator and condenser water circuits to
protect the chiller as well as the pumps, tower spray
nozzles, chilled water coils and controls, etc. The
strainer must be installed in the entering chilled water
line, directly upstream of the chiller.
Water piping circuits should be arranged so that the
pumps discharge through the chiller, and should be
controlled as necessary to maintain essentially constant
chilled and condenser water flows through the unit at
all load conditions.
If pumps discharge through the chiller, the strainer
may be located upstream from pumps to protect both
pump and chiller. (Piping between strainer, pump and
chiller must be very carefully cleaned before start-up.)
If pumps are remotely installed from chiller, strainers
should be located directly upstream of the chiller.
Condenser Water Circuit
For proper operation of the unit, condenser refrigerant
pressure must be maintained above evaporator pressure.
If operating conditions will fulfill this requirement, no
attempt should be made to control condenser water
temperature by means of automatic valves, cycling of
the cooling tower fan or other means, since chillers are
designed to function satisfactorily and efficiently when
condenser water is allowed to seek its own temperature
level at reduced loads and off-peak seasons of the year.
However, if entering condenser water temperature can
go below the required minimum, (refer to 160.69-O2)
condenser water temperature must be maintained equal
to or slightly higher than the required minimum. Re-
fer to Figure 7 on page 21 for typical water piping
schematic.