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
Centrifugal Liquid Chillers i

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
Centrifugal Liquid Chillersii

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.
3Centrifugal Liquid Chillers

WARNING
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance
with Johnson Controls’ published specifications and must be performed only by a qualified electrician.
Johnson Controls will NOT be responsible for damage/problems resulting from improper connections
to the controls or application of improper control signals. Failure to follow this warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
Changeability of this document
In complying with Johnson Controls’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. Johnson Controls makes
no commitment to update or provide current information automatically to the manual or
product owner. Updated manuals, if applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the Johnson Controls 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
Centrifugal Liquid Chillers4

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
5Centrifugal Liquid Chillers

Nomenclature
Centrifugal Liquid Chillers6

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.
7Centrifugal Liquid Chillers

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).
Centrifugal Liquid Chillers8

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 refrigerant
charge are shipped separately.
When more than one chiller is involved, the major parts of each unit are marked to prevent mixing
of assemblies. Piping and Wiring Drawings to be furnished by Johnson Controls.
Figure 1: Form 7 shipment
Inspection – damage – shortage
Check the unit shipment on arrival to see that all major pieces, boxes, and crates are received.
Check each unit on the trailer or rail car when received, before unloading, for any visible signs
of damage. Report any damage or signs of possible damage to the transportation company
immediately for their inspection.
Note: Johnson Controls will not be responsible for any damage in shipment or at job site or
loss of parts. Refer to Shipping Damage Claims (Form 50.15-NM).
When received at the job site, open all containers and check the contents against the packing list.
Report any material shortage to Johnson Conrols immediately. Refer to Shipping Damage Claims
(Form 50.15-NM).
Chiller data plate
A unit data plate is mounted on the control center assembly of each unit, giving the following
information:
• Unit model number
• Design working pressure
9Centrifugal Liquid Chillers

• Water passes
• Refrigerant charge
• Serial numbers
• Motor power characteristics and connection diagrams
Additional information may be found on the motor data plates. This information should be included
when contacting the factory on any problem relating to the motor.
Long-term storage
To protect the waterbox of pressure vessels from rusting, the tube side (water side) has been
purged and charged with nitrogen to a positive pressure of 5 psig to 7 psig.
Do not break the seal or remove closures until ready for set up. Relieve pressure as per the
following procedure (see Figure 2 ).
WARNING
Failure to follow the following procedures will cause severe personal injury or death to operators
themselves or people on-site. It is the obligation and responsibility of operators to identify and
recognize the inherent hazards of material under pressure and to protect themselves.
Centrifugal Liquid Chillers10

Figure 2: Long term storage - tube side
LD29123a
Nozzle with flange
150 lb and 300 lb closures
1
2
3
4
5
6
7
Nozzle without flanges
(Lines 4 in. through 12 in.)
Nozzle without flanges
(Lines 14 in. through 24 in.)
8
9
8
9
Item Description
1 Tag Warning Dennison 8E
2 Gauge Press 2 Dia 0-30
3 Tag GlvSt Wire Speed
4 Bush Pipe 3/4 - 14 NPTE X
5 Valve, Transducer 1/4 NPTE X
6 Flange Cover
7 Gasket
8 Victaulic Coupling
9 Sealing Cap
Relieve pressure as follows:
1. Check the working space to make sure that it is open and has a good ventilation; if not,
connect a hose or pipe to the valve (Item 5) and route it to outside.
2. Slowly open the valve (Item 5) until fully opened.
11Centrifugal Liquid Chillers

3. Monitor the pressure gauge (Item 2). The pressure should decline gradually.
4. When the pointer of pressure gauge does not move and no nitrogen comes out of valve (Item
5), it means that no positive pressure exists in the waterbox.
5. Now it is safe to remove the flange cover (Item 6) or sealing cap (Item 9).
6. Close the valve (Item 5) and remove the warning tag (Item 1).
Shipment Form 2/3/7/9
All openings on the compressor, shells including evaporator and condenser, and oil reservoir are
closed and charged with nitrogen (2 psig to 3 psig). To remove the closures, sealing caps, or sealing
plug under pressure is extremely dangerous, and may cause severe injury or death to the operator
or people in site.
WARNING
Before trying to remove the closures, caps, or plugs on compressor and shells, relieve the pressure in
compressor, shells, or system that are charged with nitrogen by opening the valves on them slowly
until fully open.
WARNING
When relieving the pressure from compressor, shells, or system, conduct the nitrogen to outside to
prevent the potential risk of asphyxiation.
Shipment Form 1/10
The unit is shipped with refrigerant charge; it is not needed to relieve the pressure. So DO NOT try
to open any valves to relieve pressure or open closures, cap, or plugs on the compressor, shells,
and elsewhere on the system.
Reclaim the refrigerant in the system before any service activities being done to refrigeration
system. Fully relieve system pressure and then repair.
DANGER
The unit is charged with tons of refrigerant; once an uncontrollable leak is found, inform all of the
relevant people to evacuate from the building to prevent from asphyxiation.
Never touch the refrigerant that is leaking, especially the liquid refrigerant; this will cause severe
freezing to your hands or body.
Centrifugal Liquid Chillers12

Rigging
The complete standard chiller is shipped without skids. When optional skids are used it may be
necessary to remove the skids so riggers skates can be used under the unit end sheets to reduce
overall height.
Each unit has four lifting holes (two in each end) in the end sheets which must be used to lift the
unit.
Care should be taken at all times during rigging and handling of the chiller to avoid damage to the
unit and its external connections. Lift only using holes shown in Figure 4.
CAUTION
Never lift the unit with slings around motor/compressor assemblies or by means of eyebolts in the
tapped holes of the compressor motor assemblies. Do not turn a unit on its side for rigging. Do not rig
vertically.
The rigging and operating weights and overall dimensions are given in Dimensions and weights as
a guide in determining the clearances required for rigging. Add 6 in. (15 cm) to overall height for
optional skidded unit.
The lengthwise rigging bar should be longer than the chiller tube length, and must have counter or
clevis adjustments to allow for center of gravity adjustments.
Chain spreaders should be used to avoid contact with drive motors or other chiller parts.
Figure 3: Rigging warning
13Centrifugal Liquid Chillers

DANGER
Rigging and lifting should only be done by a professional rigger in accordance with a written rig-
ging and lifting plan. The most appropriate rigging and lifting method will depend on job specific
factors, such as the rigging equipment available and site needs. Therefore, a professional rigger must
determine the rigging and lifting method to be used, and it is beyond the scope of this manual to
specify rigging and lifting details.
Figure 4: YD Form 2 rigging
Location
YORK Chillers are furnished with vibration isolator mounts for basement or ground level
installations. Units may be located on upper floor levels providing the floor is capable of supporting
the total unit operating weight and optional spring isolators are used. 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).
Centrifugal Liquid Chillers14

CAUTION
Sufficient clearance to facilitate normal service and maintenance work must be provided all around
and above the unit. Ample space should be provided at either end to permit cleaning or replacement
of evaporator and condenser tubes – see Clearance. A doorway or other sufficiently large opening
properly located may be used.
Motors
The YD open motor is air cooled. Check state, local and other codes for ventilation requirements.
Foundation
A level floor, mounting pad, or foundation must be provided by others, capable of supporting the
operating weight of the unit.
Clearance
Clearances should be adhered to as follows:
• Rear and above unit – 2 ft (61 cm)
• Front of unit – 3 ft (91 cm)
• Tube Removal – Shell Codes:
- Q, R = 16 ft (4.9 m) (either end)
- N, B, F, D, H = 18 ft (5.5 m) (either end)
- M, C, E, K, G, W = 22 ft (6.7 m) (either end)
15Centrifugal Liquid Chillers

Dimensions and weights
Figure 5: Chiller front view
Component Description
1 System 1 Motor
2 System 1 Compressor
3 Optiview Control Panel
4 Evaporator
5 Marine Waterboxes (Optional)
6 Hot Gas Bypass (Optional)
7 Unit Mounted Starters/ Drives (Optional)
Centrifugal Liquid Chillers16

Figure 6: Chiller back view
Component Description
1 System 1 Motor
2 System 1 Compressor
3 Terminal Box
4 Discharge Isolation Valve
5 Marine Waterbox
6 Condenser
7 Oil Sump Housing
8 Variable Speed Oil Pump Control Panel
9 System 2 Motor
Note: No starters shown
17Centrifugal Liquid Chillers

Unit dimensions
See Table 1 for specific dimensions based on Evaporator-Condensor shell combinations.
Figure 7: Dimensions - K compressor units ft.–in. (mm)
Centrifugal Liquid Chillers18