Johnson Controls YORK YK Series User manual

MODEL YK (STYLE G)
R-134a or R-513A
WITH OPTIVIEW™ CONTROL CENTER
FOR ELECTROMECHANICAL STARTER,
SOLID STATE STARTER, AND VARIABLE SPEED DRIVE
CENTRIFUGAL LIQUID CHILLERS
INSTALLATION INSTRUCTIONS Supersedes: 160.75-N1 (1217) Form 160.75-N1 (419)
Issue Date:
April 15, 2019

JOHNSON CONTROLS
2
FORM 160.75-N1
ISSUE DATE: 04/15/2019
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 160.75-N1
ISSUE DATE: 04/15/2019
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
MANUAL DESCRIPTION FORM NUMBER
Installation Checklist/Start-Up Request 160.75-CL1
Unit Start-Up Checklist 160.75-CL2
Installation and Reassembly - Unit 160.75-N3
Installation - MV VSD - 2300 VAC – 6600 VAC 160.00-N6
Installation - MV VSD - 10 kV – 13.8 kV 160.00-N8
Wiring Diagrams - Field Connections - Unit-Mounted SSS, MV SSS, or Remote Mounted MV SSS, MV EMS 160.75-PW1
Wiring Diagrams - Field Connections - Remote Mounted MV SSS 160.75-PW2
Wiring Diagrams - Field Connections - Remote Mounted MV VSD 160.75-PW3
Wiring Diagrams - Field Connections - LV VSD 160.54-PW6
Wiring Diagrams - OptiView Control Center and EMS 160.75-PW5
Wiring Diagrams - OptiView Control Center and EMS with the LTC I/O Board 160.75-PW7
Wiring Diagrams - OptiView Control Center and SSS, LV VSD, MV VSD 160.75-PW6
Wiring Diagrams - OptiView Control Center and SSS, LV VSD, MV VSD with the LTC I/O Board 160.75-PW8
Wiring Diagrams - Field Control Modications 160.75-PW4
Unit Operation and Maintenance 160.75-O1
Operation OptiView Panel 160.54-O1
Operation - Variable Speed Drive - TM Model 160.00-O1
Operation and Maintenance - Solid State Starter (Mod "B") 160.00-O2
Operation - Variable Speed Drive - VSD and LVD Model 160.00-O4
Operation - Variable Speed Drive - HYP Model 160.00-O10
Operation - Floor Mounted MV SSS, Manufactured Before 2007 160.00-O5
Operation - Floor Mounted MV SSS, Manufactured After 2007 160.00-O5.1
Operation - Unit Mounted MV SSS 160.00-O7
Operation - MV VSD - 2300 VAC – 6600 VAC 160.00-O6
Operation - MV VSD - 10 kV – 13.8 kV 160.00-O8
Service Policy - Shipping Damage Claims 50-15-NM

JOHNSON CONTROLS
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FORM 160.75-N1
ISSUE DATE: 04/15/2019
NOMENCLATURE
YK KC K4 H9 – CY G
MOTOR CODE
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
COMPRESSOR CODE*
CONDENSER CODE*
EVAPORATOR CODE*
MODEL*
STYLE (Design Level)
* Refer to YK Engineering Guide (Form 160.75-EG1)
for Shell/Motor/Compressor combinations.

JOHNSON CONTROLS 5
FORM 160.75-N1
ISSUE DATE: 04/15/2019
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION.................................................................................................................................7
General.............................................................................................................................................................7
Field Assembled Units Only .............................................................................................................................7
Shipment ..........................................................................................................................................................8
Inspection – Damage – Shortage.....................................................................................................................9
Chiller Data Plate .............................................................................................................................................9
Long-Term Storage.................................................................................................................................................9
Rigging ...........................................................................................................................................................12
Location..........................................................................................................................................................13
Motors ............................................................................................................................................................13
Foundation .....................................................................................................................................................13
Clearance .......................................................................................................................................................13
SECTION 2 - INSTALLATION ................................................................................................................................17
Rigging Unit to Final Location ........................................................................................................................17
Locating and Installing Isolator Pads..............................................................................................................17
Checking the Isolation Pad Deflection............................................................................................................17
Leveling the Unit.............................................................................................................................................17
Installing Optional Spring Isolators.................................................................................................................17
Piping Connections ........................................................................................................................................17
Evaporator and Condenser Water Piping.......................................................................................................18
Unit Piping ......................................................................................................................................................19
Refrigerant Relief Piping ................................................................................................................................20
Control Panel Positioning ...............................................................................................................................21
Control Wiring.................................................................................................................................................21
Power Wiring ..................................................................................................................................................21
Oil Pump – 3 Phase Starter............................................................................................................................21
Insulation ........................................................................................................................................................22
Installation Check – Request for Start-Up Service .........................................................................................23
P and Q Compressor Units (Standard)...........................................................................................................25
P and Q Compressor Units (Metric) ...............................................................................................................26
H Compressor Units (Standard) .....................................................................................................................27
H Compressor Units (Metric)..........................................................................................................................28
K Compressor Units (Standard) .....................................................................................................................29
K Compressor Units (METRIC) ......................................................................................................................30
Evaporator Compact Waterboxes - Ft-In (mm) ..............................................................................................31
Condenser Compact Waterboxes - Ft-In (mm) ..............................................................................................32
Evaporators – Compact Waterboxes – A through L Evaporators - Ft-In (mm)..............................................33
Evaporators – Compact Waterboxes – M through Z Evaporators - Ft-In (mm) ............................................34
Condenser – Compact Waterboxes – Standard - Ft-In (mm) .......................................................................35
Condenser – Heat Recovery Compact Waterboxes – Standard - Ft-In (mm) ..............................................37
Evaporator – Nozzle Arrangements – Standard - Ft-In (mm) .......................................................................38
Condenser – Nozzle Arrangements – Standard - Ft-In (mm) .......................................................................39
Evaporator Marine Waterbox Nozzle Arrangements - Ft-In (mm) ..................................................................40
Condenser Marine Waterbox Nozzle Arrangements - Ft-In (mm) ..................................................................41
Condensers Marine Waterboxes Heat Recovery Units - Main (Tower) Circuit Only ......................................42

JOHNSON CONTROLS
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FORM 160.75-N1
ISSUE DATE: 04/15/2019
LIST OF FIGURES
LIST OF TABLES
FIGURE 1 - Model YK Chiller....................................................................................................................................7
FIGURE 2 - Variable Speed Drive Rigging................................................................................................................9
FIGURE 3 - Long Term Storage - Tube Side...........................................................................................................10
FIGURE 4 - Rigging.................................................................................................................................................13
FIGURE 5 - Neoprene Isolators ..............................................................................................................................14
FIGURE 6 - Spring Isolators ...................................................................................................................................15
FIGURE 7 - Spring Isolators ...................................................................................................................................16
FIGURE 8 - Schematic of a Typical Piping Arrangement ........................................................................................18
FIGURE 9 - Typical Refrigerant Vent Piping............................................................................................................20
FIGURE 10 - Control Panel Positioning (H9, K1-K7) ..............................................................................................21
FIGURE 11 - Unit Insulation ....................................................................................................................................22
FIGURE 12 - Dimensions – P and Q Compressor Units (Ft–In) ............................................................................. 25
FIGURE 13 - Dimensions – P and Q Compressor Units (mm)................................................................................26
FIGURE 14 - Dimensions – H Compressor Units (Ft–In)........................................................................................ 27
FIGURE 15 - Dimensions – H Compressor Units (mm) ..........................................................................................28
FIGURE 16 - Dimensions – K Compressor Units (Ft–In) ........................................................................................29
FIGURE 17 - Dimensions – K Compressor Units (mm) .......................................................................................... 30
FIGURE 18 - Dimensions – Evaporator Compact Waterboxes ..............................................................................31
FIGURE 19 - Dimensions – Condenser Compact Waterboxes ..............................................................................32
FIGURE 20 - Dimensions – Evaporator Compact Waterboxes A through L Evaporators .......................................33
FIGURE 21 - Dimensions – Evaporator Compact Waterboxes M through Z Evaporators ......................................34
FIGURE 22 - Dimensions – Condenser Compact Waterboxes - A through Q -Standard (mm) ..............................35
FIGURE 23 - Dimensions – Condenser Compact Waterboxes - R through Z - Standard (mm) .............................36
FIGURE 24 - Dimensions – Condenser Heat Recovery Compact Waterboxes - Standard (mm)...........................37
FIGURE 25 - Dimensions – Evaporator Nozzle Arrangements - Standard (mm).................................................... 38
FIGURE 26 - Dimensions – Condenser Nozzle Arrangements - Standard (mm).................................................... 39
FIGURE 27 - Dimensions – Evaporator Marine Waterboxes .................................................................................40
FIGURE 28 - Dimensions – Condenser Marine Waterboxes .................................................................................41
TABLE 1 - Available Compressor/Shell/Motor Combinations .................................................................................23
TABLE 2 - Approximate Unit Weight Including Motor for Flooded Evaporator Units - Lb (kg) ................................44
TABLE 3 - Approximate Unit Weight Including Motor for Hybrid Falling Film Evaporator Units - Lb (kg) ..............45
TABLE 4 - Evaporator Marine Waterbox Weights - Lb (kg) ...................................................................................45
TABLE 5 - Condenser Marine Waterbox Weights - Lb (kg) ...................................................................................46
TABLE 6 - SI Metric Conversion .............................................................................................................................47

JOHNSON CONTROLS 7
FORM 160.75-N1
ISSUE DATE: 04/15/2019
1
SECTION 1 - INTRODUCTION
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 the 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 motor or control center.
LD15222
CONDENSER
CONTROL
CENTER
COMPRESSOR
MOTOR
EVAPORATOR
FIGURE 1 - MODEL YK CHILLER
GENERAL
This manual describes the installation of a YORK YK
Mod "G" Centrifugal Chiller. This unit can be shipped
as a single factory assembled, piped, wired package,
requiring a minimum of field labor to make chilled
water connections, condenser water connections, re-
frigerant atmospheric relief connections, and electri-
cal power connections. Refrigerant and oil charges are
shipped separately 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 Installation and Reassembly - Unit (Form 160.75-
N3) in conjunction with this installation instruction. This
instruction will be furnished with all units that are to be
field assembled.

JOHNSON CONTROLS
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FORM 160.75-N1
ISSUE DATE: 04/15/2019
SECTION 1 - INTRODUCTION
5. Do not charge the compressor 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.
• The motor/compressor assembly mounted,
with all necessary interconnecting piping
assembled. OptiView™ Control Center is
mounted on the unit. Complete unit fac-
tory leak tested, evacuated and charged with
R-134a.
An optional Solid State Starter or Variable
Speed Drive can be factory mounted and
wired.
• Miscellaneous material – Four (4) vibration
isolation pads (or optional spring isolators
and brackets). K7 units will be shipped with
8 Vibration Isolation Pads.
Form 2 – Factory Assembled Unit, complete with mo-
tor (refrigerant and oil charges shipped sepa-
rately).
• The motor/compressor assembly mounted,
with all necessary interconnecting piping
assembled. OptiView™ Control Center is
mounted on the unit. Complete unit fac-
tory leak tested, evacuated and charged with
holding charge of nitrogen.
An optional Solid State Starter or Variable
Speed Drive can be factory mounted and
wired.
• Miscellaneous material – Four (4) vibration
isolation pads (or optional spring isolators).
K7 units will be shipped with 8 Vibration
Isolation Pads.
Form 3 – Driveline Separate From Shells – Shipped as
two major assemblies. Unit first factory assem-
bled, refrigerant piped, wired and leak tested;
then dismantled for shipment.
• Compressor/motor assembly removed from
shells and skidded. Evaporator/condenser is
not skidded.
• All wiring integral with compressor is left on
it, and all conduit is left on shell. All open-
ings on compressor, oil separator, and shell
are closed and charged with dry nitrogen (2
psig to 3 psig) (115/122 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. Refer
to Installation and Reassembly - Unit
(Form 160.75-N3)
Form 7 – Split Shells – Shipped as three major assem-
blies. Unit first factory assembled, refriger-
ant piped, wired and leak tested; then dis-
mantled for shipment.
• Compressor/motor assembly removed from
shells and skidded.
• Evaporator and condenser shells are sepa-
rated at tube sheets and are not skidded. Re-
frigerant lines between shells are flanged and
capped, requiring no welding.
• All wiring integral with compressor is left
on it. All wiring harnesses on shells are re-
moved. All openings on compressor and
shells are closed and charged with dry nitro-
gen (2 to 3 psig) (115/122 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. Refer
to Installation and Reassembly - Unit
(Form 160.75-N3)
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 Johnson Controls)

JOHNSON CONTROLS 9
SECTION 1 - INTRODUCTION
FORM 160.75-N1
ISSUE DATE: 04/15/2019
1
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, at job site,
or loss of parts. (Refer to Shipping Damage Claims,
Form 50.15-NM.)
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
plate. This information should be included when con-
tacting the factory on any problem relating to the motor.
LONG-TERM STORAGE
To protect the waterbox of pressure vessels from rust-
ing, the tube side (water side) has been purged and
charged with nitrogen to a positive pressure of 5 psig
to 7 psig.
Do not break the seal or remove closures until ready
for set up. Relieve pressure as per the following proce-
dure (see Figure 3 on page 10).
Failure to follow the following procedures
will cause severe personal injury or death
to operators themselves or people on-site.
It is the obligation and responsibility of
operators to identify and recognize the
inherent hazards of material under pres-
sure and to protect themselves.
FORM 9 – Unit Separate from Variable Speed
Drive
Shipped as two major assemblies:
• Chiller Unit
• Variable Speed Drive
The unit is first factory assembled, refrigerant piped,
wired and leak tested; then dismantled for shipment.
Evaporator/condenser is not skidded.
All wiring integral with compressor is left on it, and
all conduit is left on shell. All openings on compressor,
and shell are closed and charged with dry nitrogen (2
to 3 PSIG).
Miscellaneous packaging of tubing, water temperature
controls, wiring, isolators, etc. The unit is shipped with
a nitrogen charge. Refrigerant charge shipped in ap-
propriate cylinders. See Figure 2.
FORM 10 – Unit Separate from Variable Speed
Drive
Shipped as two major assemblies:
• Chiller Unit
• Variable Speed Drive
The unit is first factory assembled, refrigerant piped,
wired and leak tested; then dismantled for shipment.
Evaporator/condenser is not skidded.
All wiring integral with compressor is left on it, and all
conduit is left on shell.
Miscellaneous packaging of tubing, water temperature
controls, wiring, isolators, etc. The unit is shipped with
refrigerant charge. See Figure 2.
LD16730
Lifting
Holes
Lifting
Holes
65°
Min.
65°
Min.
FIGURE 2 - VARIABLE SPEED DRIVE RIGGING

JOHNSON CONTROLS
10
FORM 160.75-N1
ISSUE DATE: 04/15/2019
SECTION 1 - INTRODUCTION
LD29123
Nozzle with flange
150 lb and 300 lb closures
1
2
3
4
5
6
7
Nozzle without flanges
(Lines 4 in. through 12 in.)
Nozzle without flanges
(Lines 14 in. through 24 in.)
8
9
8
9
ITEM DESCRIPTION
1Tag Warning Dennison 8E
2Gauge Press 2 Dia 0-30
3Tag GlvSt Wire Speed
4Bush Pipe 3/4 - 14 NPTE X
5Valve, Transducer 1/4 NPTE X
6Flange Cover
7Gasket
8Victaulic Coupling
9Sealing Cap
FIGURE 3 - LONG TERM STORAGE - TUBE SIDE