Johnson Controls YORK YMC2 User manual

LD14000
YMC2MODEL A
WITH OPTIVIEW™ CONTROL CENTER
CENTRIFUGAL LIQUID CHILLERS
INSTALLATION Supersedes: 160.78-N1 (611) Form 160.78-N1 (512)
R-134a
Issue Date:
May 30, 2012

JOHNSON CONTROLS
2
FORM 160.78-N1
ISSUE DATE: 5/30/2012
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 respon-
sibility 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
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
operating/service personnel. It is expected that these
individuals possess independent training that will en-
able 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 this document and any referenced mate-
rials. This individual shall also be familiar with and
comply with all applicable 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 OptiViewTM 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 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 160.78-N1
ISSUE DATE: 5/30/2012
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 owner. Updated manuals, if applicable, can
be obtained by contacting the nearest Johnson Controls
Service office.
Operating/service personnel maintain responsibility for
the applicability of these documents to the equipment.
If there is any question regarding the applicability of
these documents, the technician should verify whether
the equipment has been modified and if current litera-
ture 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
YMC2Operations & Maintenance 160.78-O1
YMC2Unit Re-assembly 160.78-N2
YMC2Centrifugal Chiller Long Term Storage 50.20-NM5
YMC2Field Connections 160.78-PW1
YMC2 Unit Wiring and Field Control Modications 160.78-PW2
YMC2Unit Renewal Parts 160.78-RP1
YMC2OptiViewTM Operation 160.78-O2
OptiSpeedTM VSD Model HYP744 Renewal Parts 160.78-RP3

JOHNSON CONTROLS
4
FORM 160.78-N1
ISSUE DATE: 5/30/2012
VESSEL NOMENCLATURE
Inlet from Front View
R = Right
L = Left
Waterbox Type
C = Compact
M = Marine
Water Side Pressure Code
1 = 150 psi
3 = 300 psi
Water Connection Type
F = Flanges
G = Grooved Standard
A = Victaulic AGS
Number of Passes
Vessel
E = Evaporator
C = Condenser
Vessel Refrigerant Pressure Code
R = Code 180
S = Code 235
T = Code 300
U = Code 350
V = Code 400
Tube Code
B = 3/4" Code 1
C = 3/4" Code 2
D = 3/4" Code 3
E = 3/4" Code 4
2 = 1" Code 1
3 = 1" Code 2
4 = 1" Code 3
5 = 1" Code 4
Heat Exchanger Mod Level
Nominal Inside Diameter (Inches)
Nominal Length (Feet)
Marketing Tube Number
E A 25 14 271 B R 1 1 F C R
COMPRESSOR NOMENCLATURE
Gas Path Revision Level
Impeller Design Revision Level
Motor
Motor Design Level
Impeller Tip Diameter (mm)
Rotation
F = Forward
R = Reverse
M1 B - 197 F A A
SYSTEM NOMENCLATURE
YORK
Centrifugal Chiller
Magnetic Bearing
Mod Level
S = Single Stage
T = Two Stage
Capacity in KW
Refrigerant R-134a
Y M C 2 - S 0756 A A
Liquid DWP
15 = 150 psi
30 = 300 psi
40 = 380V 60Hz
50 = 400V 50Hz
46 = 460V 60Hz
68 = 415V 50Hz
D = Disconnect Switch
B = Circuit Breaker
X = Factory Mount
R = Retrot Model
VARIABLE SPEED DRIVE NOMENCLATURE
Hyper
H = YMC2Chiller
Amps
HYP 744 X H 15 D - 40

JOHNSON CONTROLS 5
FORM 160.78-N1
ISSUE DATE: 5/30/2012
TABLE OF CONTENTS
SECTION 1 - SHIPPING ...........................................................................................................................................7
General.............................................................................................................................................................7
Component Combinations................................................................................................................................7
Field Assembled Units Only .............................................................................................................................8
YMC2Shipment Forms.....................................................................................................................................8
Form 1 .....................................................................................................................................................8
Form 2 .....................................................................................................................................................9
Form 3 .....................................................................................................................................................9
Form 7 ...................................................................................................................................................10
Form 9 ...................................................................................................................................................10
Form 10 ................................................................................................................................................. 11
Form 11 ................................................................................................................................................. 11
Inspection–Damage–Shortage.......................................................................................................................12
Chiller Data Plate ...........................................................................................................................................12
SECTION 2 - INSTALLATION ................................................................................................................................13
Overview ........................................................................................................................................................13
Rig Chiller Unit ...............................................................................................................................................13
Determine Location ........................................................................................................................................14
Foundation Requirements .....................................................................................................................14
Clearance Requirements.......................................................................................................................14
Rig Unit To Final Location...............................................................................................................................14
Install Isolators ...............................................................................................................................................14
Neoprene Isolator Pads.........................................................................................................................14
Install Optional Spring Isolators.............................................................................................................17
Make Connections..........................................................................................................................................19
Piping Connections ...............................................................................................................................19
Refrigerant Relief Piping .......................................................................................................................21
Unit Piping .............................................................................................................................................21
Control Wiring........................................................................................................................................21
Power Wiring .........................................................................................................................................21
Supplied Variable Speed Drive..............................................................................................................21
Apply Insulation ..............................................................................................................................................24
Installation Check – Request For Start-Up Service........................................................................................24
SECTION 3 - DIMENSIONS, NOZZLE ARRANGEMENTS AND WEIGHTS.........................................................25
Compressor Unit Dimensions.........................................................................................................................25
Evaporator Nozzle Arrangements (150 Psi Compact Water Boxes) ..............................................................26
Condenser Nozzle Arrangements (150 Psi Compact Water Boxes) ..............................................................28
Evaporator Nozzle Arrangements (150 PSI Marine Water Boxes).................................................................30
Condenser Nozzle Arrangements (150 Psi Marine Water Boxes)..................................................................32
Weights...........................................................................................................................................................34
150 PSI Compact And Marine Water Boxes Lbs (Kgs) .........................................................................34
Temperature ...................................................................................................................................................35

JOHNSON CONTROLS
6
FORM 160.78-N1
ISSUE DATE: 5/30/2012
LIST OF FIGURES
LIST OF TABLES
FIGURE 1 - YMC2Chiller Components .....................................................................................................................7
FIGURE 2 - Rigging.................................................................................................................................................13
FIGURE 3 - Neoprene Isolators ..............................................................................................................................15
FIGURE 4 - Neoprene Isolators ..............................................................................................................................16
FIGURE 5 - Spring Isolators ...................................................................................................................................17
FIGURE 6 - Spring Isolators....................................................................................................................................18
FIGURE 7 - Typical Refrigerant Vent Piping............................................................................................................19
FIGURE 8 - Schematic Of A Typical Piping Arrangement .......................................................................................20
FIGURE 9 - FAA Unit Insulation ..............................................................................................................................22
FIGURE 10 - FAB Unit Insulation ............................................................................................................................23
FIGURE 11 - Dimensions – 197 & 205 Compressor Units Ft-In (Mm) ....................................................................25
FIGURE 12 - Evaporators - Compact Water Boxes (1-Pass Nozzle Arrangements) .............................................26
FIGURE 13 - Evaporators - Compact Water Boxes (2-Pass Nozzle Arrangements) .............................................26
FIGURE 14 - Evaporators - Compact Water Boxes (3-Pass Nozzle Arrangements) .............................................26
FIGURE 15 - Evaporators - 150 Psi Compact Water Boxes ...................................................................................27
FIGURE 16 - Condensers - Compact Water Boxes (1-Pass Nozzle Arrangements) .............................................28
FIGURE 17 - Condensers - Compact Water Boxes (3-Pass Nozzle Arrangements) .............................................28
FIGURE 18 - Condensers - Compact Water Boxes (2-Pass Nozzle Arrangements) .............................................28
FIGURE 19 - Condensers - 150 Psi Compact Water Boxes ...................................................................................29
FIGURE 20 - Evaporators - Marine Water Boxes (1-Pass Nozzle Arrangements).................................................30
FIGURE 21 - Evaporators - Marine Water Boxes (2-Pass Nozzle Arrangements).................................................30
FIGURE 22 - Evaporators - Marine Water Boxes (3-Pass Nozzle Arrangements).................................................30
FIGURE 23 - Evaporators - 150 Psi Marine Water Boxes.......................................................................................31
FIGURE 24 - Condensers - Marine Water Boxes (1-Pass Nozzle Arrangements).................................................32
FIGURE 25 - Condensers - Marine Water Boxes (2-Pass Nozzle Arrangements).................................................32
FIGURE 26 - Condensers - Marine Water Boxes (3-Pass Nozzle Arrangements).................................................32
FIGURE 27 - Condensers - 150 Psi Marine Water Boxes.......................................................................................33
TABLE 1 - Allowable Motor / Compressor / Evaporator / Condenser Combinations ................................................7
TABLE 2 - Approximate Unit Weight* (Max Tube Count Using 150 Psi Compact Waterboxes) ............................. 34
TABLE 3 - Evaporator Marine Water Box Weights
(To Be Added To Standard Unit Weights Shown On Table 2)................................................................34
TABLE 4 - Condenser Marine Water Box Weights
(To Be Added To Standard Unit Weights Shown On Table 2)................................................................34
TABLE 5 - SI Metric Conversion .............................................................................................................................35

JOHNSON CONTROLS 7
FORM 160.78-N1
ISSUE DATE: 5/30/2012
1
SECTION 1 - SHIPPING
GENERAL
This manual provides instructions for rigging and in-
stalling a YMC2Liquid Chilling Unit.
Chillers can be shipped as a single factory assembled,
piped, wired package, requiring a minimum of field la-
bor to make chilled water connections, condenser wa-
ter connections, refrigerant atmospheric relief connec-
tions, and electrical power connections. (Refrigerant
charges shipped separately unless optional condenser
isolation valves are ordered.)
They can also be shipped dismantled when required by
rigging conditions, but it is generally more economical
to enlarge access openings to accommodate the factory
assembled unit. Chillers that are shipped dismantled
MUST be field-assembled under the supervision of a
Johnson Controls representative, but otherwise instal-
lation will be as described in this manual.
COMPONENT COMBINATIONS
Figure 1 identifies the major components of the YMC2
Chiller. The chiller is customized based on the selected
combination of Motor, Compressor, Evaporator, and
Condenser. Table 1 lists all of the allowable combina-
tions.
TABLE 1 - ALLOWABLE MOTOR / COMPRESSOR /
EVAPORATOR / CONDENSER COMBINATIONS
YMC2
Motor
Codes
Compressor
Codes
Evaporator
Codes
Condenser
Codes
M1 197DFAA EA2510 CA2110
M1 197DFAA EA2510 CA2510
M1 197DFAA EA2514 CA2514
M1 205DFAA EA2510 CA2110
M1 205DFAA EA2510 CA2510
M1 205DFAA EA2514 CA2514
FIGURE 1 - YMC2CHILLER COMPONENTS
LD14022

JOHNSON CONTROLS
8
FORM 160.78-N1
ISSUE DATE: 5/30/2012
SECTION 1 - SHIPPING
• Form 10 (shipped in two assemblies)
• Form 11 (shipped in two assemblies)
Units that are shipped dismantled MUST
be re-assembled by, or under the supervi-
sion of a Johnson Controls representative.
Refer to YMC2Unit Re-assembly Manual
(Form 160.78-N2) for detailed re-assem-
bly instructions.
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.
Form 1
The chiller is shipped complete with miscellaneous
loose items shipped together.
Refrigerant charges are included.
Chiller Unit
The unit is completely assembled at the factory.
• The driveline (compressor/motor assembly) is
mounted and all the necessary interconnecting
piping is assembled.
• The complete unit is factory leak-tested, evacuat-
ed, and shipped charged with R-134A refrigerant.
• The OptiView™ Control Center is mounted on
the unit.
• The Variable Speed Drive (VSD) is mounted,
wired, and shipped with glycol.
Miscellaneous Items
The following items are shipped together:
• Four (4) vibration isolation pads (or optional
spring isolators and brackets).
FIELD ASSEMBLED UNITS ONLY
If the chiller was not shipped complete (as shown in
Form 1 or 2 below), use the YMC2Unit Re-assembly
Manual (Form 160.78-N2) in conjunction with this
installation manual. This manual is furnished with all
units that are to be field assembled.
The services of a Johnson Controls representative will
be furnished to check the installation, supervise the
initial start-up and operation of all chillers installed
within 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 drive or control center.
5. Do not charge the unit with refrigerant.
6. Do not attempt to start the system.
7. Do not run hot water (110°F / 43°C max) or steam
through the evaporator or condenser at any time.
YMC2SHIPMENT FORMS
The chiller may be ordered and shipped in any of the
following forms:
• Form 1 (shipped complete)
• Form 2 (shipped complete)
• Form 3 (shipped in three assemblies)
• Form 7 (shipped in four assemblies)
• Form 9 (shipped in two assemblies)

JOHNSON CONTROLS 9
SECTION 1 - SHIPPING
FORM 160.78-N1
ISSUE DATE: 5/30/2012
1
• VSD Inhibitor
• Other shipped loose items, including piping, wa-
ter temperature controls, wiring, etc.
Form 2
The chiller is shipped complete; miscellaneous loose
items are shipped together.
Refrigerant charges are shipped separately.
Arrangements with the local service ofce
must be made to ensure refrigerant is on-
site when the unit is ready to be charged.
Chiller Unit
The unit is completely assembled at the factory.
• The driveline (compressor/motor assembly) is
mounted and all the necessary interconnecting
piping is assembled.
• The complete unit is factory leak-tested, evacu-
ated, and shipped charged with a 2 to 3 PSIG
(115.122 kPa) holding charge of dry nitrogen.
• The OptiView™ Control Center is mounted on
the unit.
• The Variable Speed Drive (VSD) is mounted,
wired, and shipped with Glycol.
Miscellaneous Items
The following items are shipped together:
• Four (4) vibration isolation pads (or optional
spring isolators and brackets).
• Other shipped loose items, including piping, wa-
ter temperature controls, wiring, etc.
• Inhibitor (VSD)
Form 3
The chiller is shipped in three assemblies:
1. The driveline (compressor/motor assembly)
2. The evaporator/condenser shell assembly
3. The Variable Speed Drive (VSD)
4. Miscellaneous shipped loose items
Refrigerant charges are shipped separately.
Arrangements with the local service ofce
must be made to ensure refrigerant is on-
site when the unit is ready to be charged.
Prior to shipping, the unit is completely assembled at
the factory. Interconnecting piping is assembled and
the complete unit is wired and leak-tested.
The unit is then dismantled and shipped as follows:
Driveline
The driveline (compressor/motor assembly) is re-
moved from the shells and skidded.
• All integral wiring is left on the compressor.
• All openings on the compressor are closed and
shipped charged with a 2 to 3 PSIG (115.122 kPa)
holding charge of dry nitrogen.
Shells
The evaporator and condenser are assembled prepared
for shipping but not skidded.
• All conduit is left on the shells.
• All openings the shells are closed and charged
with a 2 to 3 PSIG (115.122 kPa) holding charge
of dry nitrogen.
Variable Speed Drive (Vsd)
The VSD is skidded and shipped separately from the
assembled chiller.
• The VSD is lled with glycol for shipping.The
VSD Inhibitor is shipped with the other loose
items.
Miscellaneous Material
The following assemblies and items are shipped to-
gether:
• OptiView™ Control Center
• Magnetic Bearing Controller (MBC)
• Four (4) vibration isolation pads (or optional
spring isolators and brackets).

JOHNSON CONTROLS
10
FORM 160.78-N1
ISSUE DATE: 5/30/2012
SECTION 1 - SHIPPING
• Other shipped loose items, including piping, wa-
ter temperature controls, wiring, etc.
• Inhibitor (VSD)
Form 7
The chiller is shipped in four assemblies:
1. The driveline (compressor/motor assembly)
2. The evaporator
3. The condenser
4. The Variable Speed Drive (VSD)
5. Miscellaneous shipped loose items
Refrigerant charges are shipped separately.
Arrangements with the local service of-
ce must be made to ensure refrigerant is
on-site when unit is ready to be charged.
Prior to shipping, the unit is completely assembled at
the factory. Interconnecting piping is assembled and
the complete unit is wired and leak-tested.
The unit is then dismantled and shipped as follows:
Driveline
The driveline (compressor/motor assembly) is re-
moved from shells and skidded.
• All integral wiring is left on the compressor.
• All wiring harnesses on shells are removed.
• All openings on the compressor are closed and
shipped charged with a 2 to 3 PSIG (115.122 kPa)
holding charge of dry nitrogen.
Shells
The evaporator and condenser are separated at the tube
sheets and prepared for shipping separately but not
skidded.
• All conduit is left on the shells.
• Refrigerant lines between shells are anged and
capped, requiring no welding.
• All openings the shells are closed and charged
with a 2 to 3 PSIG (115.122 kPa) holding charge
of dry nitrogen.
Variable Speed Drive (Vsd)
The VSD is skidded and shipped separately from the
assembled chiller.
• The VSD is lled with glycol for shipping.The
VSD Inhibitor ia shipped with the other loose
items.
Miscellaneous Items
The following assemblies and items are shipped to-
gether:
• OptiView™ Control Center
• Magnetic Bearing Controller (MBC)
• Four (4) vibration isolation pads (or optional
spring isolators and brackets).
• VSD Inhibitor
• Other shipped loose items, including piping, wa-
ter temperature controls, wiring, isolators, etc.
Form 9
The chiller is shipped in two assemblies:
1. The chiller unit (less the VSD)
2. The VSD
3. Miscellaneous shipped loose items.
Refrigerant charges are shipped separately.
Arrangements with the local service of-
ce must be made to ensure refrigerant is
on-site when unit is ready to be charged.
Chiller Unit
The unit is first completely assembled at the factory:
• The driveline (compressor/motor assembly) is
mounted, with all necessary interconnecting pip-
ing assembled.