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
4
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
8
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

JOHNSON CONTROLS 11
SECTION 1 - INTRODUCTION
FORM 160.75-N1
ISSUE DATE: 04/15/2019
1
Relieve pressure as follows:
1. Check the working space to make sure that it is
open and has a good ventilation; if not, connect a
hose or pipe to the valve (Item 5) and route it to
outside.
2. Slowly open the valve (Item 5) until fully opened.
3. Monitor the pressure gauge (Item 2). The pressure
should decline gradually.
4. When the pointer of pressure gauge does not
move and no nitrogen comes out of valve (Item
5), it means that no positive pressure exists in the
waterbox.
5. Now it is safe to remove the ange cover (Item 6)
or sealing cap (Item 9).
6. Close the valve (Item 5) and remove the warning
tag (Item 1).
Shipment Form 2/3/7/9
All openings on the compressor, shells including evap-
orator and condenser, and oil reservoir are closed and
charged with nitrogen (2 psig to 3 psig). To remove the
closures, sealing caps, or sealing plug under pressure is
extremely dangerous, and may cause severe injury or
death to the operator or people in site.
Before trying to remove the closures,
caps, or plugs on compressor and shells,
relieve the pressure in compressor, shells,
or system that are charged with nitrogen
by opening the valves on them slowly until
fully open.
When relieving the pressure from com-
pressor, shells, or system, conduct the
nitrogen to outside to prevent the potential
risk of asphyxiation.
Shipment Form 1/10
The unit is shipped with refrigerant charge; it is not
needed to relieve the pressure. So DO NOT try to open
any valves to relieve pressure or open closures, cap, or
plugs on the compressor, shells, and elsewhere on the
system.
Reclaim the refrigerant in the system before any ser-
vice activities being done to refrigeration system. Fully
relieve system pressure and then repair.
The unit is charged with tons of refrig-
erant; once an uncontrollable leak is
found, inform all of the relevant people
to evacuate from the building to prevent
from asphyxiation.
Never touch the refrigerant that is leak-
ing, especially the liquid refrigerant; this
will cause severe freezing to your hands
or body.

JOHNSON CONTROLS
12
FORM 160.75-N1
ISSUE DATE: 04/15/2019
SECTION 1 - INTRODUCTION
Rigging and lifting should only be done by a professional rigger in accordance with a written rig-
ging and lifting plan. The most appropriate rigging and lifting method will depend on job specic
factors, such as the rigging equipment available and site needs. Therefore, a professional rigger
must determine the rigging and lifting method to be used, and it is beyond the scope of this manual
to specify rigging and lifting details.
LD19197
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 4 on page 13.
Do not lift the unit with slings around
motor/compressor assembly or by means
of eyebolts in the tapped holes of the
compressor motor assembly. 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 page 25 through page 46 as a
guide in determining the clearances required for rig-
ging. Add 6" (15 cm) to overall height for optional
skidded unit.

JOHNSON CONTROLS 13
SECTION 1 - INTRODUCTION
FORM 160.75-N1
ISSUE DATE: 04/15/2019
1
FIGURE 4 - RIGGING
LD19569
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 temperatures 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 – 14 ft.* (4.3 m) (either end)
* 16 ft (4.9 meters) on shell codes Q-Q, N-N, R-R, X-T and X-X.
** 18 ft (5.5 meters) on shell code S-S, S-V, Z-Z.
*** 22 ft (6.7 meters) on shell code W-W.

JOHNSON CONTROLS
14
FORM 160.75-N1
ISSUE DATE: 04/15/2019
SECTION 1 - INTRODUCTION
Mounting
Bracket
Pad
3/8”
(10)
3/4”
(19)
DETAIL A
LD19571a
SHELL
END SHEET
DIA.
HOLE
See Detail A
SHELL
END SHEET
DIA.
HOLE
See Detail A
SHELL
END SHEET
DIA.
HOLE
See Detail A
SHELL
END SHEET
DIA.
HOLE
See Detail A
ALL DIMENSIONS ARE IN INCHES (MM)
UNIT WEIGHT 53,531 - 100,464 Lbs (24,283 - 45,559 Kgs)
LD12641a
UNIT WEIGHT UP TO 16,365 Lbs (7,423 Kgs)
LD12638a
UNIT WEIGHT 16,366 - 28,835 Lbs (7,424 - 13,080 Kgs)
LD12639a
UNIT WEIGHT 28,836 - 53,530 Lbs (13,081 - 24,281 Kgs)
LD12640a
FIGURE 5 - NEOPRENE ISOLATORS
SHELL
END SHEET
DIA.
HOLE
See Detail A
UNIT WEIGHT 100,465 - 130,000 Lbs
(45,570 - 58,967 Kgs)
UNIT WEIGHT UP TO 200,928 Lbs
(UP TO 91,332 Kgs)
LD12642a
LD19578
SHELL
END SHEET
DIA.
HOLE
9"
(229)
5"
(127)
9"
(229)
See Detail A

JOHNSON CONTROLS 15
SECTION 1 - INTRODUCTION
FORM 160.75-N1
ISSUE DATE: 04/15/2019
1
ALL DIMENSIONS ARE IN INCHES (MM)
FIGURE 6 - SPRING ISOLATORS
UNIT WEIGHT
35,010 Lbs UP TO 58,349 Lbs
(15,881 Kgs UP TO 26,467 Kgs)
SHELL
6-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
5 1/2"
(140)
LD19579 UNIT WEIGHT
58,350 Lbs. UP TO 89,340 Lbs
(26,468 Kgs UP TO 40,525 Kgs)
SHELL
9-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
9”
(229)
9”
(229)
6-1/4"
(159)
LD19419
SHELL
4-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
1”
(25)
5 1/2”
(140)
1 3/8”
(35)
6”
(152)
6”
(152)
LD19573
SHELL
4-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
7”
(178)
7”
(178)
1”
(25)
5 1/2”
(140)
1 3/8”
(35)
LD19572
UNIT WEIGHT
10,000 to 19,563
(4,536 to 8,873 Kgs)
UNIT WEIGHT
19,564 Lbs UP TO 35,009 Lbs
(8,874 Kgs UP TO 15,880 Kgs)

JOHNSON CONTROLS
16
FORM 160.75-N1
ISSUE DATE: 04/15/2019
SECTION 1 - INTRODUCTION
ALL DIMENSIONS ARE IN INCHES (MM)
FIGURE 7 - SPRING ISOLATORS
UNIT WEIGHT
89,341 Lbs UP TO 115,000 Lbs
(40,526 Kgs UP TO 52,163 Kgs)
SHELL
12-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
6-1/4"
(159)
LD19580 UNIT WEIGHT
115,000 Lbs. UP TO 190,000 Lbs
(52,163 Kgs UP TO 86,183 Kgs)
SHELL
3-SPRING ISOLATORS
END
SHEET
CAP
SCREW
ADJUSTING
BOLT
16 1/4"
(413)
5 1/4"
(133)
LD19581

JOHNSON CONTROLS 17
FORM 160.75-N1
ISSUE DATE: 04/15/2019
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 Figure 4 on
page 13)
LOCATING AND INSTALLING ISOLATOR PADS
The isolator pad mounts are to be located as shown in
Figure 5 on page 14 (rubber side down).
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 inches
(2.5 mm) to 0.20 inches (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
evaporator shell under the compressor/motor assem-
bly. Transverse alignment should be checked by plac-
ing 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.
While the unit is still suspended by the rigging, the iso-
lators should be bolted to the unit by inserting the cap
screw(s) through the hole(s) in the mounting bracket
into the tapped hole in the top of the isolator leveling
bolt(s). 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 Figure 6 on
page 15 and Figure 7 on page 16 and the unit is
level. Check that the unit is level, both longitudinally
and transversely (see Leveling the Unit on page 17).
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 isolator 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
piping, a connection in each line as close to the unit
as possible should be opened, by removing the flange

JOHNSON CONTROLS
18
FORM 160.75-N1
ISSUE DATE: 04/15/2019
SECTION 2 - INSTALLATION
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 flexible couplings.
Factory mounted flanges are optional.
The nozzles and water pass arrangements are furnished in ac-
cordance with the job requirements (refer to Product Draw-
ings) 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 evaporator or condenser to determine if
the chiller has provisions for the required DWP.
Inlet and outlet connections are identified by labels
placed adjacent to each nozzle.
The coolant temperature inside any JCI-supplied liquid-
cooled motor starter must be maintained above the dewpoint
temperature in the equipment room to prevent condensing
water vapor inside the starter cabinet. Therefore, an addi-
tional temperature-controlled throttle valve is needed in the
flow path for the starter heat exchanger to regulate cooling
above the equipment room dewpoint for applications using
cooling sources other than evaporative air-exchange meth-
ods, such as wells, bodies of water, and chilled water. The
temperature control valve should be the type to open on in-
creasing drive coolant temperature, fail-closed, and set for a
temperature above dewpoint. It can be requested as factory-
supplied on a chiller order by special quotation.
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.
FIGURE 8 - SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT
LD08529
EVAPORATOR
CONDENSER
STRAINER
STRAINER
COOLING
TOWER
COOLING
UNIT
C = COMPRESSOR
M = MOTOR
FLOW SWITCH
CHILLED WATER PUMP
COOLING TOWER
PUMP
COOLING UNIT
CODEPAK
CONTROLLED COOLING
TOWER BYPASS VALVE
(IF NECESSARY)

JOHNSON CONTROLS 19
SECTION 2 - INSTALLATION
FORM 160.75-N1
ISSUE DATE: 04/15/2019
2
Condenser Water Circuit
For proper operation of the unit, condenser refrigerant
pressure must be maintained above evaporator pres-
sure. If operating conditions will fulfill this require-
ment, no attempt should be made to control condenser
water temperature by means of automatic valves, cy-
cling of the cooling tower fan or other means, since
chillers are designed to function satisfactorily and ef-
ficiently 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 mini-
mum, refer to Unit Operation and Maintenance (Form
160.75-O1); condenser water temperature must be
maintained equal to or slightly higher than the required
minimum. See Figure 8 on page 18 for typical water
piping schematic.
Stop Valves
Stop valves may be provided (by others) in the evapora-
tor and condenser water piping adjacent to the unit to
facilitate maintenance. Thermometer wells and pressure
taps should be provided (by others) in the piping as close
to the unit as possible to facilitate operating check.
Flow Switches
Thermal type water flow switches are factory mount-
ed in the chilled and condensed water nozzles and are
factory wired to the OptiView™ control panel. These
solid-state flow sensors have a small internal heat-
ing element and use the cooling effect of the flowing
fluid to sense when an adequate flow rate has been
established.
Waterbox Drain and Vent Valves
Drain and vent valves (by others) should be installed
in the connections provided in the evaporator and con-
denser liquid heads. These connections may be piped
to drain if desired.
Checking Piping Circuits and Venting Air
After the water piping is completed, but before any
waterbox insulation is applied. Tighten and torque to
maintain between 30 and 60 ft. lbs. (41 and 81 N·m)
the nuts on the liquid head flanges. Gasket shrinkage
and handling during transit cause nuts to loosen. If wa-
ter pressure is applied before tightening is done, the
gaskets may be damaged and have to be replaced. Fill
the chilled and condenser water circuits, operate the
pumps manually and carefully check the evaporator
and condenser water heads and piping for leaks. Repair
leaks as necessary.
Before initial operation of the unit both water circuits
should be thoroughly vented of all air at the high points.
UNIT PIPING
Compressor lubricant piping and system external pip-
ing are factory installed on all units shipped assembled.
On units shipped dismantled, the following piping
should be completed under the supervision of the John-
son Controls representative: (1) the lubricant piping to
oil sump and oil evaporator and system oil return con-
nections using material furnished. Refer to Installation
and Reassembly - Unit (Form 160.75-N3).

JOHNSON CONTROLS
20
FORM 160.75-N1
ISSUE DATE: 04/15/2019
SECTION 2 - INSTALLATION
REFRIGERANT RELIEF PIPING
Each unit is equipped with pressure relief valves lo-
cated on the condenser and on the evaporator for the
purpose of quickly relieving excess pressure of the re-
frigerant charge to the atmosphere as a safety precau-
tion in case of an emergency, such as fire.
Refrigerant relief vent piping (by others), from the re-
lief valves to the outside of the building, is required
by code in most areas and should be installed on all
chillers. The vent line should be sized in accordance
with the ANSI/ASHRAE-15, or local code. The vent
line must include a dirt trap in the vertical leg to in-
tercept and permit clean out and to trap any vent stack
condensation. The piping MUST be arranged to avoid
strain on the relief valves, using a flexible connection,
if necessary.
FIGURE 9 - TYPICAL REFRIGERANT VENT PIPING
FLANGED JOINT
TO PERMIT PIPING
DISASSEMBLY
CONDENSATION
TRAP
DUAL RELIEF
VALVES
VENT TO ATMOSPHERE
SUPPORT VENT PIPING TO AVOID
STRAIN ON RELIEF PIPING
FLEXIBLE CONNECTOR
CONDENSER
EVAPORATOR
SEE NOTE
NOTE: SHELLS MAY BE FURNISHED WITH
ONE OR TWO RELIEF VALVES,
DEPENDING ON SHELL SIZE.
LD03863
When installing relief piping there
must NOT be any piping strain.
Relief piping must be properly
aligned and supported to eliminate
any possible piping strain.
When installing relief piping an
ANSI flange or a piping union
must be used to make a
servicable piping connection.
Horizontal
Mis-aligned
Vertical
Offset
Compressed
LD16677