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.

JOHNSON CONTROLS 11
SECTION 1 - SHIPPING
FORM 160.78-N1
ISSUE DATE: 5/30/2012
1
• Interconnecting piping is assembled and the com-
plete unit is factory leak-tested then evacuated
and shipped charged with a 2 to 3 PSIG (115.122
kPa) holding charge of dry nitrogen.
• The Motor Terminal Box adapter remains at-
tached to the chiller unit.
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:
• Four (4) vibration isolation pads (or optional
spring isolators and brackets).
• Other shipped loose items, including piping, wa-
ter temperature controls, wiring, etc.
• VSD Inhibitor
Form 10
The chiller is shipped in two assemblies:
1. The assembled chiller unit (less the VSD)
2. The VSD
3. Miscellaneous shipped loose items.
Refrigerant charges are included.
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.
• The complete unit is factory leak-tested, evacuat-
ed, and shipped charged with R-134A refrigerant.
• The Motor Terminal Box adapter remains at-
tached to the chiller unit.
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:
• Four (4) vibration isolation pads (or optional
spring isolators and brackets).
• Other shipped loose items, including piping, wa-
ter temperature controls, wiring, etc.
• VSD Inhibitor
Form 11
The chiller is split down the middle and shipped in two
assemblies:
1. The condenser-side assembly
2. The evaporator-side assembly
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.
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 into two assemblies and
shipped as follows:

JOHNSON CONTROLS
12
FORM 160.78-N1
ISSUE DATE: 5/30/2012
SECTION 1 - SHIPPING
Condenser-Side Assembly (Condenser /
Optiview™ Control Center / Variable Speed
Drive)
The Condenser-side assembly consists of the Condens-
er, the OptiView™ Control Center and the Variable
Speed Drive.
• All conduit is left on the condenser shell.
• Interconnectingpipingbetweenshellsareanged
and capped, requiring no welding.
• All openings on the condenser shell are closed
and shipped charged with a 2 to 3 PSIG (115.122
kPa) holding charge of dry nitrogen.
Evaporator-Side Assembly (Evaporator /
Driveline / Magnetic Bearing Controller)
The evaporator-side assembly consists of the evapo-
rator, the driveline (compressor/motor assembly), and
the Magnetic Bearing Controller.
• All conduit is left on the evaporator shell.
• Interconnectingpipingbetweenshellsareanged
and capped, requiring no welding.
• All integral wiring is left on the compressor.
• All openings on the evaporator shell and driveline
are closed and shipped charged with a 2 to 3 PSIG
(115.122 kPa) holding charge of dry nitrogen.
Miscellaneous Material
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.
• VSD Inhibitor
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 RESPON-
SIBLE FOR ANY DAMAGE IN SHIPMENT OR AT
JOB SITE OR LOSS OF PARTS. (Refer to Shipping
Damage Claims Form (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 (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
contacting the factory on any problem relating to the
motor.

JOHNSON CONTROLS 13
FORM 160.78-N1
ISSUE DATE: 5/30/2012
2
OVERVIEW
The installation process consists of the following steps:
1. Rig Chiller Unit
2. Determine Location
• Foundation Requirements
• Clearance Requirements
3. Rig Chiller to Final Location
4. Install Isolators
• Locate and place Isolator Pads, or
• Install optional Spring Isolaters
5. Level Chiller
6. Make Connections
• Piping
• Wiring
7. Apply Insulation
RIG CHILLER UNIT
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 sheet).
Lift the unit using these holes only, as shown in Figure 2.
Care should be taken at all times during rigging and
handling of the chiller to avoid damage to the unit and
its external connections.
Do not lift the unit with slings around the
driveline (compressor/motor 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.
SECTION 2 - INSTALLATION
LD03864
FIGURE 2 - RIGGING

JOHNSON CONTROLS
14
FORM 160.78-N1
ISSUE DATE: 5/30/2012
SECTION 2 - INSTALLATION
The rigging, operating weights, and over-
all dimensions are provided in Section 3
- Unit Weights and Measurements to help
you determine the clearances required for
rigging. Add 6" (15 cm) to overall height
for optional skidded unit.
DETERMINE LOCATION
YMC2Chillers 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 operat-
ing weight and optional spring isolators are used.
Sufcient clearance to facilitate normal
service and maintenance work must be
provided around and above the unit and
particularly space provided at either end to
permit cleaning or replacement of evapo-
rator and condenser tubes – see Clear-
ance. 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).
Foundation Requirements
A level floor, mounting pad or foundation must be pro-
vided by others, capable of supporting the operating
weight of the unit.
Clearance Requirements
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
* 10' (3m): 2110 & 2510 Shell Codes
14' (4.3m): 2514 Shell Codes
RIG 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. (Refer to Insulation
in this section and Figure 9 for further information.)
INSTALL ISOLATORS
Neoprene Isolator Pads
Locate And Place Isolator Pads
The isolator pad mounts are to be located and placed
rubber-side down as shown in Figures 3 and 4.
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.
Level 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.
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 are furnished by the install-
er.) Lower unit again and recheck to see that it is level
Checking The Isolation Pad Deection
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.

JOHNSON CONTROLS 15
SECTION 2 - INSTALLATION
FORM 160.78-N1
ISSUE DATE: 5/30/2012
2
UNIT WEIGHT 15,001 - 29,000 Lbs (6,805 - 13,154 Kgs)
LD12641
UNIT WEIGHT UP TO 5,500 Lbs (2,494 Kgs)
LD12638
UNIT WEIGHT 5,501 - 8,000 Lbs (2,495 - 3,628 Kgs)
LD12639
UNIT WEIGHT 8,001 - 15,000 Lbs (3,629 - 6,804 Kgs)
LD12640
FIGURE 3 - NEOPRENE ISOLATORS
NOTE: Dimensions are shown in Inches (mm)

JOHNSON CONTROLS
16
FORM 160.78-N1
ISSUE DATE: 5/30/2012
SECTION 2 - INSTALLATION
A
BC
D
E
DDD
LD12642
FIGURE 4 - NEOPRENE ISOLATORS
OPERATING UNIT WEIGHT DIM "A" DIM "B" DIM "C" DIM "D" DIM "E"
15,001 - 29,000 Lbs (6,805 - 13,154
Kgs) 62" (1575) 31" (787) 31" (787) 10" (254) 8" (203)
NOTE: Dimensions are shown in Inches (mm)

JOHNSON CONTROLS 17
SECTION 2 - INSTALLATION
FORM 160.78-N1
ISSUE DATE: 5/30/2012
2
Install Optional Spring Isolators
Bolt Isolators To The Unit
If ordered, spring type isolator assemblies are fur-
nished with the unit. The four assemblies are identical
and can be placed at any of the four 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.
Level 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.
Rotate the leveling bolts one turn at a time, in sequence,
until the unit end sheets are clear of the floor by the di-
mension shown in Figures 5 and 6 and the unit is level.
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.
FIGURE 5 - SPRING ISOLATORS
UNIT WEIGHT
Up To 35,009 Lbs (15,880 Kgs)
LD126544

JOHNSON CONTROLS
18
FORM 160.78-N1
ISSUE DATE: 5/30/2012
SECTION 2 - INSTALLATION
A
BC
D
E
F
F
FIGURE 6 - SPRING ISOLATORS
OPERATING UNIT WEIGHT DIM "A" DIM "B" DIM "C" DIM "D" DIM "E" DIM "F"
Up to 35,000 Lbs (15,880 Kgs) 62" (1575) 31" (787) 31" (787) 6" (152) 6-7/8" (175) 5-1/2" (140)
NOTE: Dimensions are shown in Inches (mm)
LD12643

JOHNSON CONTROLS 19
SECTION 2 - INSTALLATION
FORM 160.78-N1
ISSUE DATE: 5/30/2012
2
MAKE CONNECTIONS
After the unit is leveled, place wedges and/or shims un-
der each corner to solidly support the unit in this position
while connecting and hanging the piping, adjusting the
connections, and checking for proper alignment.
After the connections are made and insulation is applied,
the unit can be filled with water and checked for leaks.
If spring isolators were installed, final adjustments
can be made to the leveling bolts until the wedges and
shims can be removed. The unit should now be in cor-
rect level position, clear of the floor or foundation and
without any effect from the weight of the piping.
The coolant temperature inside any JCI-supplied liq-
uid-cooled motor starter must be maintained above the
dewpoint temperature in the equipment room to prevent
condensing water vapor inside the starter cabinet. There-
fore, an additional 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 evapo-
rative air-exchange methods, such as wells, bodies of
water, and chilled water. The temperature control valve
should be the type to open on increasing 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.
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 vi-
bration transmission (refer to Figure 7). Hangers must
allow for alignment of pipe. Isolators (by others) in the
piping and hangers are highly desirable, and may be re-
quired by specifications, in order to effectively utilize
the vibration isolation characteristics of the vibration
isolation mounts of the unit.
Check for piping alignment – Upon completion of pip-
ing, a connection in each line as close to the unit as
possible should be opened, by removing the flange
bolts or coupling and checked for piping alignment. If
any of the bolts are bound in their holes, or if the con-
nection springs are out of alignment, the misalignment
must be corrected by properly supporting the piping or
by applying heat to anneal the pipe.
If the piping is annealed to relieve stress,
the inside of the pipe must be cleaned of
scale before it is nally bolted in place.
FIGURE 7 - TYPICAL REFRIGERANT VENT PIPING
LD03863

JOHNSON CONTROLS
20
FORM 160.78-N1
ISSUE DATE: 5/30/2012
SECTION 2 - INSTALLATION
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. If welding is
done on the nozzles, flow switches, condenser level
sensor, and water temperature thermistors should be
disconnected and the welding ground MUST be good
contact located at the head to prevent current damage
to the devices.
The nozzles and water pass arrangements are furnished
in accordance with the job requirements (see Product
Drawings) furnished with the job. Standard units are
designed for 150 psig DWP on the water side. If job
requirements are for greater than 150 psig DWP, check
the unit data plate before applying pressure to evapora-
tor or condenser to determine if the chiller has provi-
sions for the required DWP.
Inlet and outlet connections are identified by labels
placed adjacent to each nozzle.
Chilled Water
Foreign objects which could lodge in, or block flow
through, the evaporator and condenser tubes must be
kept out of the water circuit. All water piping must be
cleaned or flushed before being connected to the chiller
pumps, or other equipment.
Permanent strainers (supplied by others) are required
in both the evaporator and condenser water circuits to
protect the chiller as well as the pumps, tower spray noz-
zles, chilled water coils and controls, etc. The strainer
must be installed in the entering chilled water and con-
denser liquid line, directly upstream of the chiller.
Water piping circuits should be arranged so that the
pumps discharge through the chiller, and should be
controlled as necessary to maintain essentially constant
chilled and condenser water flows through the unit at
all load conditions.
If pumps discharge through the chiller, the strainer
may be located upstream from pumps to protect both
pump and chiller. (Piping between strainer, pump and
chiller must be very carefully cleaned before start-up.)
If pumps are remotely installed from chiller, strainers
should be located directly upstream of the chiller.
Condenser Water Circuit
For proper operation of the unit, condenser refrigerant
pressure must be maintained above evaporator pressure.
If operating conditions will fulfill this requirement, no at-
tempt should be made to control condenser water temper-
ature by means of automatic valves, cycling of the cool-
ing tower fan, or other means, since chillers are designed
to function satisfactorily and efficiently when condenser
water is allowed to seek its own temperature level at re-
duced loads and off-peak seasons of the year. However, if
it is possible for the entering condenser water temperature
to go below the required minimum, condenser water tem-
perature must be maintained equal to or slightly higher
than the required minimum. Refer to the YMC2Engineer-
FIGURE 8 - SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT
LD08529