Johnson Controls YORK YVAM User manual

035-28539-000
Form Number: 160.88-N1 (122)
New Release
Installation Guide
Issue Date: 2022-01-21
YVAM Air-Cooled Centrifugal Liquid
Chiller
Field Installation Procedure for YVAM Units with 20 Fans,
HFC-134A, 60 Hz

2 YVAM Air-Cooled Centrifugal Liquid Chiller

Contents
ContentsGeneral safety guidelines................................................................................................................................5
Safety symbols....................................................................................................................................... 5
Changeability of this document...........................................................................................................6
Associated literature..............................................................................................................................6
Nomenclature........................................................................................................................................ 7
Overview............................................................................................................................................................9
Chiller components............................................................................................................................... 9
Receiving......................................................................................................................................................... 11
Inspection............................................................................................................................................. 11
Delivery and storage........................................................................................................................... 11
Chiller data plate..................................................................................................................................12
Rigging.............................................................................................................................................................13
Scope.....................................................................................................................................................13
Lifting weights......................................................................................................................................14
Moving the chiller................................................................................................................................ 14
Lifting using accessory lifting lugs.................................................................................................... 14
Chiller dimensions and rigging locations......................................................................................... 15
Installation...................................................................................................................................................... 16
Determine location..............................................................................................................................16
Foundation requirements......................................................................................................................... 16
Ground locations........................................................................................................................................16
Roof locations............................................................................................................................................. 16
Seismic applications...................................................................................................................................16
Other considerations.................................................................................................................................17
Clearance requirements..................................................................................................................... 17
Recommended clearances for all units................................................................................................... 17
Rig chiller to final location.................................................................................................................. 18
Leveling the chiller...............................................................................................................................19
Anchor the chiller to the final location..............................................................................................19
Isolators................................................................................................................................................ 20
Installation without isolation....................................................................................................................20
Installation of optional spring isolators.................................................................................................. 20
Installation of optional elastomeric isolators.........................................................................................22
Make piping connections....................................................................................................................24
Evaporator freeze damage....................................................................................................................... 24
Evaporator water piping............................................................................................................................24
Check for piping alignment...................................................................................................................... 26
Permanent strainers, supplied by others................................................................................................26
Stop valves, supplied by others................................................................................................................26
Flow switches..............................................................................................................................................26
Waterbox drain and vent valves...............................................................................................................27
YVAM Air-Cooled Centrifugal Liquid Chiller 3

Waterbox fill and vent............................................................................................................................... 27
Wiring connections..............................................................................................................................27
Unit power wiring...................................................................................................................................... 27
Unit control wiring..................................................................................................................................... 27
Apply insulation................................................................................................................................... 27
Unit heater operation verification.....................................................................................................28
Reassembly..................................................................................................................................................... 29
Refrigerant tubing reassembly..........................................................................................................30
Assembly of straight thread O-ring port fittings....................................................................................30
Assembly of O-ring face seal fittings.......................................................................................................32
Dimensions, nozzle arrangements, and weights.......................................................................................33
Unit conversion.............................................................................................................................................. 36
YVAM Air-Cooled Centrifugal Liquid Chiller4

General safety guidelines
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certain components or conditions including,
but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the potential, if misused or handled improperly,
to cause bodily injury or death. It is the obligation and responsibility of rigging, installation, and
operating/service personnel to identify and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to comply with any of these requirements could
result in serious damage to the equipment and the property in 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.
5YVAM Air-Cooled Centrifugal Liquid Chiller

WARNING
External wiring, unless specified 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 cabinet. 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 could 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.
Associated literature
Table 1: Associated literature
Manual description Form number
Equipment Pre-Startup and Startup Checklist 160.88-CL1
Unit Startup Checklist 160.88-CL2
Installation, Operation, and Maintenance 160.88-OM1
Unit Power Wiring 160.88-PW1
Field Control Wiring 160.88-PW2
Liquid Chiller Log Sheet 160.88-MR1
Centrifugal Chiller Long Term Storage 50.20-NM5
Screw and Scroll Chiller Long Term Storage 50.20-NM7
Shipping Damage Claims Form 50.15-NM
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2
YVAM Air-Cooled Centrifugal Liquid Chiller6

Nomenclature
Figure 1: System nomenclature
Figure 2: Compressor nomenclature
Figure 3: Vessel nomenclature
7YVAM Air-Cooled Centrifugal Liquid Chiller

Figure 4: Variable speed drive nomenclature
YVAM Air-Cooled Centrifugal Liquid Chiller8

Overview
This manual provides instructions for rigging and installing a Johnson Controls YVAM Liquid Chilling
Unit.
Chillers are shipped as a single factory-assembled, piped, and wired package. The units require a
minimum of field labor to make chilled water connections and electrical power connections.
Chiller components
See Figure 5, Figure 6, and Figure 7 for the major components of the YVAM chiller.
Figure 5: Control panel side view
Callout Component Callout Component
A Control panel B Signal box for condenser fan variable speed
drive, typical both sides
C Condenser sections, typically ten with two fans
each
D Evaporator water nozzles, inlet at the bottom
and outlet at the top
E Waterbox heater power connections F UPS power panel
9YVAM Air-Cooled Centrifugal Liquid Chiller

Figure 6: Compressor side view
Callout Component Callout Component
A Evaporator B Motor cooling filter drier
C Expansion valve D Cooling piping for variable speed drive
E Eaton® surge suppressor F Direct drive motor and MBC
G Compressor
Figure 7: Variable speed drive end view
Callout Component Callout Component
A Variable speed drive B UPS power panel
C Single point power panel
YVAM Air-Cooled Centrifugal Liquid Chiller10

Receiving
Inspection
Remove any transit packing. Inspect the unit to ensure that all components have been delivered
according to the bill of lading and that all miscellaneous boxes or materials have been received.
Ensure that no damage to any portion of the chiller or loose items has occurred during transit.
If any damage is evident, it must be noted on the carrier’s freight bill and a claim entered in
accordance with the instructions given on the advice note.
Note: Johnson controls is not responsible for any damage in shipment or at job site or loss of
parts. Refer to Shipping Damage Claims Form, Form 50.15-NM.
Delivery and storage
To ensure consistent quality and maximum reliability, all units are tested and inspected before
leaving the factory. Units are shipped completely assembled and containing refrigerant under
pressure. Units are shipped without export crating unless crating has been specified on the Sales
Order.
If the unit is to be put into storage, before installation, the following precautions must be observed:
• The chiller must be blocked so that the base cannot sag or bow.
• Ensure that all openings, such as water connections, are securely capped.
• Do not store where exposed to ambient air temperatures exceeding 43.3°C (110°F).
• The condensers must be covered to protect the coils and fins from potential damage and
corrosion, particularly where building work is in progress.
• The unit must be stored in a location where there is minimal activity in order to limit the risk
of accidental physical damage.
• To prevent inadvertent operation of the pressure relief devices, the unit must not be steam
cleaned.
• Inspect the unit periodically during storage. Follow all directions for long term storage
requirements as defined in Form 50.20-NM7.
The services of a qualified Johnson Controls Service representative is required for the installation
and startup of all YVAM model chillers installed in the continental United States.
Do not attempt to install or start the chiller without the presence of this qualified representative, as
this may void all or portions of the chiller warranty.
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 because such action will result in
loss of the factory refrigerant (Form 1) or nitrogen charge (Form 2).
• Do not dismantle or open the chiller for any reason except under the supervision of a
Johnson Controls representative.
11YVAM Air-Cooled Centrifugal Liquid Chiller

• When units are received, notify the nearest Johnson Controls office in ample time for a
Johnson Controls representative to supervise rigging the unit to its storage or operating
locations.
• Do not make final power supply connections to the single point power panel or any other
power connections without Johnson Controls supervision.
• Do not charge the unit with refrigerant.
• Do not attempt to start the system.
• Do not run hot water (>110°F or 43.3°C maximum) or steam through the evaporator at any
time.
Chiller data plate
A unit data plate is mounted on the outside of the right side door of the Variable Speed Drive panel
assembly of each unit. It provides the unit model number, design working pressure, refrigerant
charge, serial numbers, and all chiller power characteristics.
Additional information is provided on the evaporator, compressor, and motor data plates. This
information must be included when contacting the factory on any problem.
Figure 8: Chiller data plate
YVAM Air-Cooled Centrifugal Liquid Chiller12

Rigging
Figure 9: Rigging warning
WARNING
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. A professional rigger must determine the rigging
and lifting method to be used. It is beyond the scope of this manual to specify rigging and lifting
details.
Scope
This procedure covers the rigging, locating, and final assembly of the YVAM units with total fan
quantity of 20 fans. It is intended for use by the qualified field service teams.
WARNING
The unit must only be lifted by the base frame at the points provided. Never move the unit on rollers,
or lift the unit using a forklift truck. Care must be taken to avoid damaging the condenser cooling fins
when moving the unit.
13YVAM Air-Cooled Centrifugal Liquid Chiller

Lifting weights
Note that weight can vary depending on unit configuration at the time of lifting. See Figure 11 for
lifting location information. All published weights in this manual are approximate values at the time
of publication. Refer to the unit nameplate or submittal documents for unit shipping weight.
Moving the chiller
Before moving the unit, ensure that the installation site is suitable for installing the unit and can
easily support the weight of the unit and all associated services.
Lifting using accessory lifting lugs
Units are provided with lifting holes in the base frame that accept the accessory lifting lug set as
shown in Figure 10. Insert the lugs (RH and LH) into the respective holes in the base frame. Turn
the lugs so that the spring loaded pin engages into the hole and the flanges on the lug lock behind
the hole. The lugs must be attached to the cables or chains using shackles or safety hooks. See
Figure 10 for lug installation technique and Figure 11 for installation locations.
Figure 10: YVAM chiller rigging using accessory lifting lugs
Callout Component Callout Component
A Lug B Lifting hole in base frame
C Flange D Locking pin
• The accessory lifting lugs must be inserted into the respective holes in the base frame, noting
the right hand and left orientation of these lugs, and secured using the locking pin.
• The following steps are a guide to help the rigger understand some of the risks that chiller rig
may pose and are not intended to provide the final instructions for the lifting event.
YVAM Air-Cooled Centrifugal Liquid Chiller14

• Use spreader bars to avoid lifting chains hitting the chiller. Various methods of spreader
bar arrangements may be used, keeping in mind the intent is to keep the unit stable and to
prevent the chains from hitting the chiller and causing damage.
• Never lift the chiller using a forklift or by hooking to the top rails. Use only the lifting holes
provided.
• Lifting instructions are placed on a label on the chiller and on the shipping bag.
Chiller dimensions and rigging locations
Figure 11: Unit rigging lift point dimensions, mm (in.)
15YVAM Air-Cooled Centrifugal Liquid Chiller

Installation
Determine location
Read these instructions in their entirety before beginning the installation. For optimum
performance and trouble-free service, it is essential that the installation site meets the location and
space requirements for the model being installed.
Important: Make sure that the minimum service access space is maintained for cleaning and
maintenance purposes.
The units are designed for outside installation and can be installed at ground level on a suitable
flat level foundation easily capable of supporting the weight of the unit, or on a suitable rooftop
location. In both cases, an adequate supply of air is required. Avoid locations where the sound
output and air discharge from the unit might be objectionable.
The location must be selected for minimum sun exposure and away from boiler flues and other
sources of airborne chemicals that could attack the condenser coils and steel parts of the unit.
If located in an area accessible to unauthorized persons, steps must be taken to prevent access
to the unit by means of a protective fence. This can help to prevent the possibility of vandalism,
accidental damage, or possible harm caused by unauthorized removal of protective guards or
opening panels to expose rotating or high voltage components.
Foundation requirements
Mount units on a flat and level foundation, ground or roof, that can support the entire operating
weight of the equipment. Contact your nearest Johnson Controls Sales Office for shipping and
operating weights.
Ground locations
For ground level locations, the unit must be installed on a suitable flat and level concrete base that
extends to fully support the two side channels of the unit base frame. A one-piece concrete slab
with footings that extend below the frost line is recommended.
The slab must not be tied to the main building foundation because operational noise can telegraph.
Mounting holes (5/8 in.) are provided in the base rails for bolting the unit to its foundation. See
Figure 13 for locations.
For ground installations, precautions must be taken to protect the unit from tampering by or injury
to unauthorized persons. Fasteners on access panels can prevent casual tampering. However,
further safety precautions such as unit enclosure options, a fenced-in enclosure, or locking devices
on the panels may be advisable. Check with local authorities for safety regulations.
Roof locations
Sufficient structure must be provided to safely support the entire operating weight of the unit,
service personnel, and service tooling. Do not damage the roof during installation. If the roof
is of bonded construction, consult a building contractor or architect for special installation
requirements. Use spring isolators to minimize vibration transmission into building structure.
The building must have adequate structural support (by others) at the spring isolator locations.
Typically this is region directly under the side and end base rails of the chiller.
Seismic applications
Avoid installing chillers on springs or roofs where earthquakes are a risk. Springs and roofs amplify
earthquake forces. Rigidly mounting chillers to ground level concrete pads is generally the best
option for earthquake zones. Contact Johnson Controls equipment specialists for help with projects
that have seismic requirements.
YVAM Air-Cooled Centrifugal Liquid Chiller16

Other considerations
Any ductwork or attenuators fitted to the unit must not have a total static pressure resistance at full
air flow that exceeds the capability of the fans installed on the unit.
When it is required to surround the unit(s) in addition to whatever optional louver package is
selected, make sure that the screening can pass the required chiller CFM without exceeding 0.1 in.
wg (24.9084 Pa) external static pressure.
CAUTION
Clearance dimensions provided in Figure 12 are necessary to maintain good airflow and ensure
correct unit operation. It is also necessary to consider access requirements for safe operation and
maintenance of the unit and power and control panels. Local health and safety regulations, or practical
considerations for service replacement of large components, may require larger clearances than those
recommended.
Clearance requirements
Adequate clearances around the unit(s) are required for the unrestricted airflow for the air-
cooled condenser coils and to prevent recirculation of warm discharge air back onto the coils.
If these clearances are not maintained, airflow restriction or re-circulation will cause a loss of
unit performance, an increase in power consumption, and may cause the unit to malfunction.
Consideration must also be given to the possibility of down drafts, caused by adjacent buildings,
which may cause recirculation or uneven unit airflow.
The results of the restricted airflow or hot air recirculation can diminish performance as outlined
in Form 150.12-AD2, Air-Cooled Chiller Derating Due to Airflow Restrictions. Johnson Controls’ unit
controls optimize the operation without nuisance high pressure safety cutouts. However, the
system designer must consider the potential for performance degradation.
For locations where significant cross winds are expected, such as exposed rooftops, use an
enclosure of solid or louver type to prevent wind turbulence interfering with the unit airflow.
When units are installed in an enclosure, the enclosure height must not exceed the height of the
unit on more than one side. If the enclosure is of louvered construction, the same requirement of
static pressure loss applies as for ducts and attenuators. See Other considerations.
Recommended clearances for all units
• For access to the unit control center, make sure that the unit is no higher than on spring
isolators.
• Minimum clearances are shown in Figure 12 and are as follows:
- Side to wall: 6 ft (1.8 m)
- Rear to wall: 6 ft (1.8 m)
- Control panel end to wall: 4 ft (1.2 m)
- Top: no obstructions whatsoever
- Distance between adjacent units: 10 ft (3 m)
• Ensure that no more than one wall around the chiller yard is higher than the chiller.
• Avoid locations near windows or structures where normal operating sounds might be
objectionable.
• The condenser fans are propeller type and must not be used with ductwork, filters, or other
impediments to airflow in the condenser air stream.
17YVAM Air-Cooled Centrifugal Liquid Chiller

• When obstructions to airflow exist, they must not add more than 0.1 in. external static
pressure.
• Protection against corrosive environments is available by ordering the units with cured
epoxy-coating on the condenser microchannel. Epoxy-coated coils must be used with any
units being installed at the seashore, or where salt spray can hit the units, where acid rain is
prevalent, and when paired with adiabatic cooling solutions.
• At installations where winter operation and snow accumulations are expected, additional
elevation must be provided to ensure normal condenser airflow.
• Provide adequate space for tubes to be removed from evaporator. For clearances, contact
your nearest Johnson Controls Sales Office.
Figure 12: Unit clearance dimensions, ft (m)
Rig chiller to final location
Rig the unit to its final location by the means as defined in the Rigging section.
YVAM Air-Cooled Centrifugal Liquid Chiller18

Leveling the chiller
Make sure that chiller base rail remains straight along the long axis of the chiller during the leveling
process. This can be accomplished with the use of a string along the base rail. Any bowing of the
chiller frame can lead to refrigerant line failures or other component fatigue issues over time.
Check the longitudinal alignment of the unit by placing a level on the base rail of the chiller
at several locations after the base rail has been verified that it is straight and true. Check the
transverse level by placing a level on the base rail at the variable speed drive and opposite ends of
the chiller base frame.
Adhere to all isolator type installation requirements before setting the chiller in the final location.
Certain steps are required before placing the chiller on some isolator types. See the following
section for these requirements.
Anchor the chiller to the final location
See the following mounting options before moving the chiller to its final location. When spring
isolators are used, the unit must be supported in a safe manner before anchoring the chiller. Rig
the unit to its final location by the means as defined in the Rigging section.
Note: All the following dimensions are approximate values and must be verified on receipt of
the chiller.
Figure 13: Isolator locations
Table 2: Isolator locations
Locations
Unit model Description Unit 123456
Standard, in. 10.22 95.96 159.87 220.45 299.16 441.86
Isolator X dimension Metric, mm 259.7 2,437.5 4,060.6 5,599.5 7,598.8 11,223.3
Standard, in. 85.14
Isolator Y dimension Metric, mm 2,162.4
Locations
Description Unit 7 8 9 10 11 12
Standard, in. 10.22 95.96 159.87 220.45 299.16 441.86
Isolator X dimension Metric, mm 259.7 2,437.5 4,060.6 5,599.5 7,598.8 11,223.3
Standard, in. 85.14
YVAM 350
Isolator Y dimension Metric, mm 2,162.4
Note: The isolator Y dimension is hole center base rail to base rail.
19YVAM Air-Cooled Centrifugal Liquid Chiller

Isolators
Installation without isolation
This method is not recommended as an option for YVAM chillers. Vibration isolation is an important
option that must be accounted for at chiller installation. If isolators are not ordered, they must
be selected based on the loading at the specific chiller locations. Contact Johnson Controls
representative for assistance if isolators have not been provided.
Installation of optional spring isolators
If ordered, spring type isolator assemblies are supplied with the unit. The isolator load rating can
vary based on the location on the chiller. This is due to the weight distribution of the unit and
the isolators must be located as prescribed in the technical data portion of the chiller submittal
package. See Figure 13 for locations. See Table 4 and Table 5 for details of the isolators.
Spring isolators are shipped fully assembled and must be positioned in accordance with the
submittal drawings or as otherwise recommended.
1. Set the isolators on the floor, housekeeping pad, or subbase, ensuring that all isolator
centerlines match the equipment mounting holes.
2. VMC Group recommends that the isolator base (B) be installed on a level surface. Shim or
grout as required, leveling all isolator bases to the same elevation. The maximum difference
that can be tolerated is 1/4 in. (6.35 mm).
3. Bolt or anchor all isolators to supporting structure using the base slotted holes (C).
4. Place the equipment on top of the isolators and make sure that the mounting holes of the
equipment line up with the isolator positioning pin (H).
5. The adjustment process can only begin after the equipment or machine is at its full operating
weight.
6. Adjust each isolator in sequence by turning the spring adjusting bolt (D) one full
counterclockwise turn at a time. Repeat this procedure on all isolators, one at a time.
7. Continue adjusting each isolator until a minimum of 1/4 in. (6.35 mm) clearance is achieved
between the lower housing and upper housing. See Figure 14.
8. To complete the installation, fine adjust the isolators to level the equipment.
YVAM Air-Cooled Centrifugal Liquid Chiller20