Johnson Controls YORK User manual

Form Number: 160.79-N1 (320)
Supersedes: 160.79-N1 (118)
Installation Guide
Issue Date: 2020-03-31
Centrifugal Liquid Chillers
Field Reassembly for Form 2, 3, and 7 Shipment, Model YD
(Style D) (Cooling Only) with OptiView Control Center

Contents
General safety guidelines.............................................................................................................. 3
Safety symbols..................................................................................................................................... 3
Changeability of this document......................................................................................................... 4
Associated literature........................................................................................................................... 4
Nomenclature...................................................................................................................................... 6
Shipping........................................................................................................................................... 7
General.................................................................................................................................................. 7
Field assembled units only................................................................................................................. 7
Shipment............................................................................................................................................... 8
Inspection – damage – shortage....................................................................................................... 9
Chiller data plate................................................................................................................................. 9
Long-term storage............................................................................................................................ 10
Rigging................................................................................................................................................ 13
Location.............................................................................................................................................. 14
Motors................................................................................................................................................. 15
Foundation......................................................................................................................................... 15
Clearance............................................................................................................................................ 15
Dimensions and weights............................................................................................................. 16
Unit dimensions................................................................................................................................. 18
Knocked-down unit component dimensions - evaporator.......................................................... 21
Knocked-down unit component dimensions - condenser........................................................... 24
Knocked-down unit component dimensions - driveline............................................................... 27
Neoprene isolators............................................................................................................................ 32
Installation and reassembly........................................................................................................ 37
Rigging unit to final location............................................................................................................ 37
Locating and installing isolator pads.............................................................................................. 37
Checking the isolation pad deflection............................................................................................ 37
Leveling the unit................................................................................................................................ 37
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Installing optional spring isolators................................................................................................. 37
Piping connections............................................................................................................................ 38
Evaporator and condenser water piping........................................................................................ 38
Refrigerant relief piping................................................................................................................... 40
Unit piping.......................................................................................................................................... 41
Control panel positioning................................................................................................................. 41
Control wiring.................................................................................................................................... 42
Power wiring...................................................................................................................................... 42
Insulation............................................................................................................................................ 43
Installation checklist and request for start-up.............................................................................. 44
Reassembly........................................................................................................................................ 44
Unit conversion............................................................................................................................. 57
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General safety guidelines
Important: Read before proceeding.
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.
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WARNING
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance
with Johnson Controls’ published specifications and must be performed only by a qualified electrician.
Johnson Controls will NOT be responsible for damage/problems resulting from improper connections
to the controls or application of improper control signals. Failure to follow this warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
Changeability of this document
In complying with Johnson Controls’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. Johnson Controls makes
no commitment to update or provide current information automatically to the manual or
product owner. Updated manuals, if applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the Johnson Controls QuickLIT website at http://
cgproducts.johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/ service personnel to verify the applicability
of these documents to the equipment. If there is any question regarding the applicability of these
documents, rigging, lifting, and operating/service personnel should verify whether the equipment
has been modified and if current literature is available from the owner of the equipment prior to
performing any work on the chiller.
Revision notes
Revisions made to this document are indicated in the following table. These revisions are to
technical information, and any other changes in spelling, grammar, or formatting are not included.
Affected pages Description
10-12 Section on long-term storage added
Associated literature
Description Form number
Shipping Damage Claims 50.15-NM
Unit Installation Checklist and Request for Startup - YD Style D 160.79-CL1
Unit Startup Checklist - YD Style D 160.79-CL2
Engineering Guide - YD Style D Chillers 160.79-EG1
Operation and Maintenance - YD Style D 160.79-O3
Wiring Diagram - Field Connections YD Style D Chillers with OptiView Control
Center Water Pump Starters 160.79-PW1
Wiring Diagram - YD Style D Chillers with OptiView Control Center Field Control
Modifications 160.79-PW2
Wiring Diagram - YD Style D Chillers with MV Electro-Mech Starters 160.79-PW3
Wiring Diagram - YD Style D Chillers with Electromechanical Starter 160.79-PW4
Wiring Diagram - YD Style D Chillers with OptiView Control Center and Modbus
SSS/VSD 160.79-PW5
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Description Form number
Wiring Diagram - Field Connections YD Style D Optiview Control Center with
Unit Mounted Low Voltage SSS 160.79-PW6
Wiring Diagram - Field Connections YD Style D Optiview Control Center with
Unit Mounted Low Voltage VSD 160.79-PW7
Wiring Diagram - Field Connections YD Style D Optiview Control Center with
Unit Mounted Medium Voltage SSS 160.79-PW8
Wiring Diagram - Field Connections YD Style D Optiview Control Center with
Remote Medium Voltage SSS 160.79-PW9
Wiring Diagram - Field Connections YD Style D Optiview Control Center with
Remote Medium Voltage VSD 160.79-PW10
Wiring Diagram - YD Style D Chillers with Optiview Control Center and Motor
Monitoring 160.79-PW11
Wiring Diagram - YD Style D with Optiview Control Center and Motor Space
Heater 160.79-PW12
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Nomenclature
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Shipping
General
This instruction describes the installation of a model YD liquid chilling unit. The H9, K1 and K2
compressor models are the only chiller combination that can be shipped as a single factory
assembled unit. This would include complete unit assembly, system piping, and system wiring.
Minimal field service will be necessary to complete the chiller installation for the following
connections; evaporator chilled water connections, condenser water connections, refrigerant
atmospheric relief connections and electrical power connections. (Refrigerant and oil charges are
shipped separately).
All other model YD liquid chilling units will be shipped disassembled, Form 7. Chillers shipped
disassembled must be field assembled under the supervision of a Johnson Controls representative,
but otherwise installation will be as described in this instruction.
Field assembled units only
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 Continental United States.
CAUTION
The Johnson Controls Warranty may be voided if the following restrictions are not adhered to.
1. Do not open any valves or connections 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 reason except under the supervision of a Johnson
Controls representative.
3. When units are shipped dismantled, notify the nearest Johnson Controls office in ample time
for a Johnson Controls representative to supervise rigging the unit to its operating position and
the assembly of components.
4. Do not make final power supply connections to the compressor motors or control center.
5. Do not charge the compressors with oil.
6. Do not charge the unit with refrigerant.
7. Do not attempt to start the system.
8. Do not run hot water (110°F / 43°C max) or steam through the evaporator or condenser at any
time.
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Shipment
The chiller may be ordered and shipped in any of the following forms:
• Form 2
• Form 3
• Form 7
Form 2 - Factory assembled unit, complete with motors
Note that the refrigerant and oil charges are shipped separately.
• H9, K1, and K2 liquid chilling units.
• The motor/compressor assemblies mounted, with all necessary interconnecting piping
assembled. OptiView™ Control Center is mounted on the unit. Complete unit factory leak tested,
evacuated and charged with holding charge of nitrogen.
• Miscellaneous material – vibration isolation pads (or optional spring isolators and brackets) will
ship loss.
Note: Units shipped dismantled must be reassembled by, or under the supervision of, a
Johnson Controls representative.
Form 3 - Drivelines separate from shells
• H9, K1, and K2 liquid chilling units.
The chiller is shipped as three major assemblies. The unit first is factory assembled, and the
refrigerant piped, wired, and leak tested. It is then dismantled for shipment. The compressor and
motor assemblies are removed from the shells and skidded. The evaporator and condenser are not
skidded.
All wiring integral with compressors are left on them, and all conduit is left on the shell. All
openings on compressors, oil separator, and shells are closed and charged with dry nitrogen (2 psig
to 3 psig) (14 kPa to 21 kPa).
The control center, oil pump panel, and associated wiring remain mounted on the evaporator
shell. Miscellaneous packaging of tubing, wiring, oil, isolators, and similar components, and the
refrigerant charge are shipped separately.
Form 7 - Split shells
• H9, K1, and K2 optional shipment.
• K3, K4, and K7 standard shipment.
The chiller is shipped as four major assemblies. The unit first is factory assembled, and the
refrigerant piped, wired, and leak tested. It is then dismantled for shipment. The compressor and
motor assemblies are removed from the shells and skidded.
The evaporator and condenser shells are separated at tube sheets and are not skidded. The
refrigerant lines between shells are flanged and capped.
Note: The tube sheets are also bolted, requiring no welding. See Figure 1.
All wiring integral with the compressors are left on them. All wiring harnesses on the shells are
removed. All openings on the compressors and shells are closed and charged with dry nitrogen (2
psig to 3 psig) (14 kPa to 21 kPa).
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