Johnson Controls YORK YK Series User manual

Form Number: 160.76-N1 (121)
Supersedes: 160.76-N1 (619)
Installation Guide
Issue Date: 2021-01-15
Model YK (Style H) Centrifugal Liquid
Chillers
R-134a or R-513A with OptiView Control Center for
Electromechanical Starter, Solid State Starter, and Variable
Speed Drive

2 Model YK (Style H) Centrifugal Liquid Chillers

Contents
ContentsGeneral safety instructions........................................................................................................................... 5
Introduction.................................................................................................................................................... 8
Field assembled units only................................................................................................................. 8
Shipment............................................................................................................................................... 9
Inspection – damage – shortage...................................................................................................... 11
Chiller data plate............................................................................................................................... 12
Long-term storage............................................................................................................................ 12
Rigging................................................................................................................................................ 15
Location.............................................................................................................................................. 16
Motors................................................................................................................................................. 16
Foundation......................................................................................................................................... 17
Clearance............................................................................................................................................ 17
Installation.................................................................................................................................................... 21
Rigging unit to final location............................................................................................................ 21
Locating and installing isolator pads.............................................................................................. 21
Checking the isolation pad deflection............................................................................................ 21
Leveling the unit................................................................................................................................ 21
Installing optional spring isolators................................................................................................. 21
Piping connections............................................................................................................................ 22
Evaporator and condenser water piping........................................................................................ 22
Unit piping.......................................................................................................................................... 24
Refrigerant relief piping................................................................................................................... 24
Control panel positioning................................................................................................................. 26
Control wiring.................................................................................................................................... 26
Power wiring...................................................................................................................................... 26
Oil pump – 3-phase starter............................................................................................................... 27
Insulation............................................................................................................................................ 27
Installation check – request for start-up service........................................................................... 28
Compressor units.............................................................................................................................. 33
Evaporator compact waterboxes..................................................................................................... 38
Condenser compact waterboxes..................................................................................................... 42
Condenser heat recovery compact waterboxes............................................................................ 45
Evaporator marine waterboxes....................................................................................................... 46
Condenser marine waterboxes....................................................................................................... 49
Weights............................................................................................................................................... 52
Unit conversion............................................................................................................................................ 55
Model YK (Style H) Centrifugal Liquid Chillers 3

4 Model YK (Style H) Centrifugal Liquid Chillers

General safety instructions
Important: Read before proceeding.
This equipment is a relatively complicated apparatus. During installation, operation maintenance or
service, individuals may be exposed to certain components or conditions including, but not limited
to: 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 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 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 individual 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:
DANGER
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.
WARNING
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.
CAUTION
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.
Note: Highlights additional information useful to the technician in completing the work being
performed properly.
5Model YK (Style H) Centrifugal Liquid Chillers

WARNING
External wiring, unless specified 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 accordance
with Johnson Controls’ published specifications and must be performed only by a qualified 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 warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
Changeability of this document
In complying with Johnson Controls’ policy for continuous product improvement, the information
contained 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 Johnson Controls Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
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, rigging, 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.
Revision notes
Revisions made to this document are indicated in the following table. These revisions are to
technical information, and any other changes in spelling, grammar, or formatting are not included.
Affected pages Description
24 Refrigerant relief piping paragraph updated
29–32 Table for compressor, evaporator, condenser, and motor combinations
updated
33–37 Tables for dimensions of compressor units updated
40–41 Tables for dimensions (end and side) of evaporator compact waterboxes
updated
43–44 Tables for dimensions (end and side) of condenser compact waterboxes
updated
45 Section for condenser heat recovery compact waterboxes added
47–48 Tables for dimensions (end and side) of evaporator marine waterboxes
updated
50–51 Tables for dimensions (end and side) of condenser marine waterboxes
updated
52–54 Weights section and tables updated
Model YK (Style H) Centrifugal Liquid Chillers6

Associated literature
Manual description Form number
Installation Checklist/Start-Up Request 160.76-CL1
Unit Start-Up Checklist 160.76-CL2
Installation and Reassembly - Unit 160.76-N3
Installation - MVVSD - 2300 VAC to 6600 VAC 160.00-N6
Installation - MVVSD - 10 kV to 13.8 kV 160.00-N8
Wiring Diagrams - Field Connections - Unit-Mounted SSS or Remote Mounted
MVSSS, MVEMS 160.76-PW1
Wiring Diagrams - Field Connections - Remote Mounted MVSSS 160.76-PW2
Wiring Diagrams - Field Connections - Remote Mounted MVVSD 160.76-PW3
Wiring Diagrams - Field Connections - LVVSD 160.76-PW7
Wiring Diagrams - OptiView Control Center and EMS 160.76-PW5
Wiring Diagrams - OptiView Control Center and SSS, LVVSD 160.76-PW6
Wiring Diagrams - Field Control Modifications 160.76-PW4
Unit Operation and Maintenance 160.76-O1
Operation - OptiView Panel 160.76-O2
Operation - Variable Speed Drive - TM Model 160.00-O1
Operation and Maintenance - Solid State Starter (Mob 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 MVSSS 160.00-O5.1
Operation - Unit Mounted MVSSS 160.00-O7
Operation - MVVSD - 2300 VAC to 6600 VAC 160.00-O6
Operation - MVVSD - 10 kV to 13.8 kV 160.00-O8
Nomenclature
* Refer to YK Engineering Guide (Form 160.76-EG1) for shell, motor, and compressor combinations.
7Model YK (Style H) Centrifugal Liquid Chillers

Introduction
This manual describes the installation of a YORK YK Mod H 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, refrigerant atmospheric relief
connections, and electrical 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 economical 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 installation is as described in this instruction.
Field assembled units only
Use Unit - Installation Instructions (Form 160.76-N3) in conjunction with this installation instruction.
This instruction is furnished with all units that are assembled in the field.
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.
CAUTION
The Johnson Controls Warranty may be voided if the following restrictions are not adhered to.
• Do not open valves or connections under any circumstances, as such action will result in loss
of the factory nitrogen charge.
• Do not dismantle or open the chiller for any reason except under the supervision of a
Johnson Controls representative.
• When the units are shipped dismantled, notify the nearest Johnson Controls office in ample
time for a Johnson Controls representative to supervise rigging the unit to its operating
position and the assembly of components.
• Do not make final power supply connections to the compressor motor or control center.
• Do not charge the compressor with oil.
• Do not charge the unit with refrigerant.
• Do not attempt to start the system.
• Do not run hot water (110°F / 43°C max) or steam through the evaporator or condenser at
any time.
Model YK (Style H) Centrifugal Liquid Chillers8

Figure 1: Model YK chiller
Shipment
The chiller may be ordered and shipped in any of the following forms:
• Form 1
• Form 2
• Form 3
• Form 7
• Form 9
• Form 10
Form 1
Factory assembled unit, complete with motor, 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 factory leak
tested, evacuated and charged with refrigerant.
An optional Solid State Starter or Variable Speed Drive can be factory mounted and wired.
• Miscellaneous material: Four vibration isolation pads or optional spring isolators and
brackets. K7 units are shipped with eight vibration isolation pads.
9Model YK (Style H) Centrifugal Liquid Chillers

Form 2
Factory Assembled Unit, complete with motor. The refrigerant and oil charges are shipped
separately.
• 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 holding charge of nitrogen.
An optional Solid State Starter or Variable Speed Drive can be factory mounted and wired.
• Miscellaneous material: Four vibration isolation pads or optional spring isolators. K7 units
are shipped with eight vibration isolation pads.
Form 3
Driveline Separate From Shells. Shipped as two major assemblies. The unit is first factory
assembled, and the refrigerant is piped, wired, and leak tested. It is 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 openings
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), and so on. The refrigerant charge is shipped separately.
Note: Units shipped dismantled MUST be re-assembled by, or under the supervision of, a
Johnson Controls representative. Refer to Installation - Unit (Form 160.76-N3).
Form 7
Split Shells. Shipped as three major assemblies. The unit is first factory assembled, and the
refrigerant is piped, wired, and leak tested. It is then dismantled for shipment.
• Compressor/motor assembly removed from shells and skidded.
• The evaporator and condenser shells are separated at tube sheets and are not skidded. The
refrigerant lines between shells are flanged and capped, requiring no welding.
• All wiring integral with compressor is left on it. All wiring harnesses on the shells are
removed. All openings on the compressor and shells 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), and similar components. The refrigerant charge shipped
separately.
Note: Units shipped dismantled MUST be re-assembled by, or under the supervision of, a
Johnson Controls representative. Refer to Installation - Unit (Form 160.76-N3).
When more than one chiller is involved, the major parts of each unit are marked to prevent mixing
of assemblies. Piping and Wiring Drawings are furnished by Johnson Controls.
Form 9
Unit separate from variable speed drive. The unit is shipped as the following two major assemblies:
• Chiller unit
• Variable speed drive
Model YK (Style H) Centrifugal Liquid Chillers10

The unit is first factory assembled, refrigerant piped, wired and leak tested; then dismantled for
shipment. The evaporator/condenser is not skidded.
All wiring integral with the 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 psig to 3 psig (115 kPa to
122 kPa.
Miscellaneous packaging of tubing, water temperature controls, wiring, isolators, etc. The unit is
shipped with a nitrogen charge. Refrigerant charge shipped in appropriate cylinders. See Table 28.
Form 10
Unit separate from variable speed drive. The unit is shipped as the following 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, and similar
components. The unit is shipped with refrigerant charge. See Table 28.
Figure 2: Variable speed drive rigging
Inspection – damage – shortage
The unit shipment should be checked on arrival to see that all major pieces, boxes and crates
are received. Check each unit on the trailer or rail car when received, before unloading, for any
visible signs of damage. Report any damage or signs of possible damage to the transportation
company immediately for their inspection. Johnson Controls is 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, open all containers and check contents against the packing list. Any
material shortage should be reported to Johnson Controls immediately. Refer to Shipping Damage
Claims, Form 50.15-NM.
11Model YK (Style H) Centrifugal Liquid Chillers

Chiller data plate
A unit data plate is mounted on the control center assembly of each unit, giving the following
information:
• Unit model number
• Design working pressure
• Water passes
• Refrigerant charge
• Serial numbers
• Motor power characteristics and connection diagrams
Additional information may be found on the motor data plate. Include this information when
contacting the factory on any problem relating to the motor.
Long-term storage
About this task:
To protect the waterbox of pressure vessels from rusting, the tube side (water side) is 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 setup. Use the following procedure to
relieve pressure. See Figure 3.
WARNING
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 pressure and to protect themselves.
1. Check that the working space is open and has good ventilation. If not, it does not have
good ventilation, and you should 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 stops moving and no nitrogen is released from the valve
(Item 5), no positive pressure exists in the waterbox.
5. When there is no positive pressure in the waterbox, it is safe to remove the flange cover (Item
6) or sealing cap (Item 9).
6. Close the valve (Item 5) and remove the warning tag (Item 1).
Model YK (Style H) Centrifugal Liquid Chillers12

Figure 3: Long term storage - tube side
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
13Model YK (Style H) Centrifugal Liquid Chillers

Shipment Form 2/3/7/9
All openings on the compressor, shells including evaporator 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 on-site.
WARNING
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.
WARNING
When relieving the pressure from compressor, 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 necessary to relieve the pressure. 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 carrying out any service activities on the refrigeration
system. Fully relieve system pressure and then repair.
DANGER
The unit is charged with tons of refrigerant; if an uncontrollable leak is found, inform all of the relevant
people to evacuate from the building to prevent risk of asphyxiation.
Never touch the refrigerant that is leaking, especially the liquid refrigerant; this will cause severe
freezing to your hands or body.
Model YK (Style H) Centrifugal Liquid Chillers14

Rigging
Figure 4: Rigging warning
DANGER
Rigging and lifting should only be done by a professional rigger in accordance with a written rigging
and lifting plan. The most appropriate rigging and lifting method depends on job specific 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.
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 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 5.
CAUTION
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 dimensions are given from page as a guide in
determining the clearances required for rigging. Add 6 in. (15 cm) to overall height for optional
skidded unit.
15Model YK (Style H) Centrifugal Liquid Chillers

Location
YORK® chillers are furnished with vibration isolator 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 operating weight and optional spring isolators are used.
CAUTION
Sufficient 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 sufficiently 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).
Figure 5: Rigging
Motors
The YK open motor is air cooled. Check state, local, and other codes for ventilation requirements.
The minimum clearance to the nearest wall must be at least one-quarter of the length of the fan
cover diameter. Check the cooling fan condition. Clean the air inlet and outlet openings to ensure
that there is free airflow over the motor.
For units that are shipped disassembled, before rigging is completed, make sure that the eyebolts
are properly selected and tightened. Use all of the designed eyebolts to lift the motor. The coupling
alignment must be fulfilled correctly.
Model YK (Style H) Centrifugal Liquid Chillers16

Foundation
A level floor, mounting pad or foundation must be provided by others, capable of supporting the
operating weight of the unit.
Clearance
Clearances must be adhered to as follows:
• Rear and above unit: 2 ft (61 cm)
• Front of unit: 3 ft (91 cm)
• Tube removal: 12 ft (3.7 m), either end
Note: Tube removal: 12 ft* (3.7 m), either end
• *14 ft (4.3 m) on shell codes: K-F, H-F, K-K, O-O, M-K, Q-Q
• *16 ft (4.9 m) on shell codes: L-L, P-P, N-L, R-R
17Model YK (Style H) Centrifugal Liquid Chillers

Figure 6: Neoprene isolators
Unit weight up to 16,365 lb (7,423 kg) Unit weight 16,366 - 28,835 lb (7,424 - 13,080 kg)
Unit weight 28,836 - 53,530 lb (13,081 - 24,281 kg) Unit weight 53,531 - 100,464 lb (24,283 - 45,559 kg)
Unit weight 100,465 - 130,000 lb (45,570 - 58,967 kg) Unit weight up to 200,928 lb (up to 91,332 kg)
Note: All dimensions are in inches (mm)
Model YK (Style H) Centrifugal Liquid Chillers18

Figure 7: Neoprene isolator supports without/with skids, shipment forms 1, 2, 3, 7, 9, 10
19Model YK (Style H) Centrifugal Liquid Chillers

Figure 8: Spring isolators
Unit weight 10,000 lb to 19,563 lb (4,536 kg to 8,873 kg) Unit weight 19,564 lb up to 35,009 lb (8,874 kg up to 15,880 kg)
Unit weight 35,010 lb up to 58,349 lb (15,881 kg up to 26,467 kg) Unit weight 58,350 lb up to 89,340 lb (26,468 kg up to 40,525 kg)
Unit weight 89,341 lb up to 115,000 lb (40,526 kg up to 52,163 kg) Unit weight 115,000 lb up to 190,000 lb (52,163 kg up to 86,183 kg)
Note: All dimensions are in inches (mm)
Model YK (Style H) Centrifugal Liquid Chillers20