York HFC-134A User manual

FIELD ASSEMBLY PROCEDURE FOR
YVAA PHASE C SPLIT SHIP UNITS WITH 22 TO 26 FANS
AIR-COOLED SCREW
LIQUID CHILLERS
INSTALLATION SUPERSEDES: 201.28-N1 (515) Form 201.28-N1 (717)
Issue Date:
July 25, 2017
HFC-134A OR HFC-513A
50 AND 60 HZ
LD15045

JOHNSON CONTROLS
2
FORM 201.28-N1
ISSUE DATE: 7/25/2017
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents 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, instal-
lation, 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
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
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 in-
dividual 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:
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 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 accor-
dance 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 201.28-N1
ISSUE DATE: 7/25/2017
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 or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son 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, rig-
ging, 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.
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.
The Control/VSD Cabinet contains lethal
high AC and DC voltages. Before per-
forming service inside the cabinet, remove
the AC supply feeding the chiller and
verify using a non-contact voltage sensor.
The DC voltage on the VSD DC Bus will
take 5 minutes to bleed off, after AC
power is removed. Always check the DC
Bus Voltage with a Voltmeter to assure
the capacitor charge has bled off before
working on the system.
NEVER short out the DC Bus to dis-
charge the lter capacitors.
NEVER place loose tools, debris, or any
objects inside the Control Panel/VSD
Cabinet.
NEVER allow the Control Panel VSD
Cabinet doors to remain open if there is
a potential for rain to enter the panel.
Keep doors closed and assure all latches
are engaged on each door unless the unit
is being serviced.
ALWAYS lockout the disconnect supply-
ing AC to the chiller.
The 1L Line Inductor will reach operating
temperatures of over 150°C (300°F.) DO
NOT open panel doors during operation.
Assure the inductor is cool whenever
working near the inductor with power
OFF.
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Equipment Pre-Startup and Startup Checklist 201.28-CL2
Installation, Operation and Maintenance 201.28-NM1.1

JOHNSON CONTROLS
4
FORM 201.28-N1
ISSUE DATE: 7/25/2017
NOMENCLATURE
YVAA 044 3AXX 46 AA
12 3 4 5 6 7 8 9 10 11 12 13 14 15
TNAREGIRFER/LEVELEGATLOVNOITARUGIFNOCEZISEMARFEPYTTCUDORPESAB
Y: York ### #: Condenser code 17
: 200 / 3 / 60 #: Development Level
V: Variable Speed
Screw
#: Evaporator code 28
: 230 / 3 / 60 A: Refrigerant R-134a
: Refrigerant R-513A
#: Compressor code 40
: 380 / 3 / 60
A: Air cooled #: Condenser fan & sound kit code
46
: 460 / 3 / 60
A
50
: 380-415 / 3 / 50
58
: 575 / 3 / 60
: Design Series
4 2 : 400 / 3 / 60
TABLE 1 - SPLIT SHIP UNITS MODELS
UNIT
MODEL
SYS 1 & 2
FAN QTY
MAIN/SUB SECTION
FAN QTY
MAIN SECTION
SYS 2 FAN QTY
SYS 1 REF. QTY
(LB/KG)
SYS 2 REF QTY
(LB/KG)
0443
1543 12/12 20/4 8 370/168 370/168
0483
1693 13/13 20/6 7 385/175 385/175
0523
1843 13/13 20/6 7 445/202 445/202
0425
0475 14/10 20/4 6 480/217 365/165
0475
1665 13/13 20/6 7 445/202 445/202
0368
1288 14/8 18/4 4 475/215 320/145
0398
1388 14/10 20/4 6 475/215 360/163
0428
1488 14/12 20/6 6 475/215 385/175

JOHNSON CONTROLS 5
FORM 201.28-N1
ISSUE DATE: 7/25/2017
LIFTING WEIGHTS
Refer to the unit nameplate for unit shipping weight.
Note that weight may vary depending on unit configu-
ration at the time of lifting. See the table on page 7 of
this document for lifting information.
DELIVERY AND STORAGE
To ensure consistent quality and maximum reliability,
all units are tested and inspected before leaving the fac-
tory. Units are shipped completely assembled and con-
taining refrigerant under pressure. Units are shipped
without export crating unless crating has been speci-
fied on the Sales Order.
If the unit is to be put into storage, prior to installation,
the following precautions should be observed:
• The chiller must be “blocked” so that the base is
not permitted to sag or bow.
• Ensure that all openings, such as water connec-
tions, are securely capped.
• Do not store where exposed to ambient air tem-
peratures exceeding 43°C (110°F).
• The condensers should be covered to protect the
coilsandnsfrompotentialdamageandcorrosion,
particularly where building work is in progress.
• The unit should be stored in a location where there
is minimal activity in order to limit the risk of ac-
cidental physical damage.
• To prevent inadvertent operation of the pressure
relief devices the unit must not be steam cleaned.
• It is recommended that the unit is periodically in-
spected during storage.
INSPECTION
Remove any transit packing and inspect the unit to en-
sure that all components have been delivered and that
no damage has occurred during transit. If any damage
is evident, it should be noted on the carrier’s freight bill
and a claim entered in accordance with the instructions
given on the advice note.
Major damage must be reported immediately to your
local Johnson Controls representative.
FIELD ASSEMBLY PROCEDURE FOR YVAA SPLIT UNITS
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 specic
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.
LD19197

JOHNSON CONTROLS
6
FORM 201.28-N1
ISSUE DATE: 7/25/2017
MOVING THE CHILLER
Prior to moving the unit, ensure that the installation
site is suitable for installing the unit and is easily ca-
pable of supporting the weight of the unit and all as-
sociated services.
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 should be taken to avoid damaging the condenser
cooling fins when moving the unit.
UNIT REMOVAL FROM SHIPPING
CONTAINER
1. Place a clevis pin into the holes provided at the
end of each base rail on the unit. Attach chains or
nylon straps through the clevis pins and hook onto
a suitable lift truck for pulling the unit out of the
container.
2. Slowly place tension on the chains or straps until
the unit begins to move and then slowly pull the
unit from the container. Be sure to pull straight so
the sides do not scrape the container.
3. Placealiftingxtureontheforksofthelifttruck
and reattach the chain or strap. Slightly lift the
front of the unit to remove some weight from the
oor of the container. Continue pulling the unit
with an operator on each side to guide the lift
truck operator.
4. Pull the unit until the lifting locations are outside
of the container. Place 4 X 4 blocks of wood under
the base rails of the unit. Gently rest the unit on
the blocks and remove the chains and lift truck.
5. Attach lifting rigging from the crane and slowly
complete the removal from the container then lift
up and away.
LD19197a
LIFTING USING LUGS
Units are provided with lifting holes in the base frame
which accept the accessory lifting lug set as shown in
the figure below. The lugs (RH and LH) should be in-
serted into the respective holes in the base frame and
turned so that the spring loaded pin engages into the
hole and the flanges on the lug lock behind the hole.
The lugs should be attached to the cables/chains using
shackles or safety hooks.
LOCKING PIN
LU
G
FLANGE
LIFTING HOLE
IN BASE FRAME
CORRECT
LOCKING PIN
LUG
LIFTING HOLE
IN BASE FRAME
FLANGE
INCORRECT
LOCKING
PIN
FLANGE
LUG
LD19197b
LIFTING USING SHACKLES
The shackles should be inserted into the respective
holes in the base frame and secured from the inside.
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 keep the chains from hitting the chill-
er 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.
During this procedure operators will be exposed to
lethal voltages and the operators must be qualified to
complete wiring work under these conditions. Risk as-
sessments should be conducted to ensure all appropri-
ate precautions are taken. The operators must comply
with all of Johnson Controls, Inc, electrical safety re-
quirements including “Lock-Out/Tag-Out” procedures
and wearing PPE (Personal Protective Equipment)
gear prior to performing the procedure.

JOHNSON CONTROLS 7
FORM 201.28-N1
ISSUE DATE: 7/25/2017
SCOPE
This procedure covers the assembly and shipment of
the YVAA Phase C Split Units (with total fan quanti-
ties between 22 and 26), to be used by the field service
teams.
During this procedure operators will be exposed to
lethal voltages and the operators must be qualified to
complete wiring work under these conditions. Risk as-
sessments should be conducted to ensure all appropri-
ate precautions are taken. The operators must comply
with all of Johnson Controls, Inc, electrical safety re-
quirements including "Lock-Out/Tag-Out" procedures
and wearing PPE (Personal Protective Equipment)
gear prior to performing the procedure.
FIELD ASSEMBLY PROCEDURE
1. Upon arrival on customer site, follow installa-
tionprocedureasspeciedinForm 201.28-NM1
Installation, Operation, and Maintenance” docu-
ment (Section 4).
Refer to the Installation, Operation and
Maintenance Manual (Form 201.28-
NM1.1) for lifting suggestions and more
details on lifting point locations.
LD19422
Main Section
(Attached to Control Panel)
Sub Section
Split
A B C DE F G H
FIGURE 1 - UNIT AS ASSEMBLED
Use these charts for lifting separated main section and sub-section units individually.
SEE
035-23515-002
FOR RIGGING
MAIN SECTION LIFT POINTS DIMENSIONS TAKEN FROM POWER PANEL END OF UNIT
MODEL A B C D E F
USE
FIGURE 1
Inch Metric Inch Metric Inch Metric Inch Metric Inch Metric Inch Metric
0368/1288 12.3 314 72.6 1845 181.1 4602 237.7 6039 301.6 7662 391.3 9942
0398/1388 12.3 314 72.6 1845 181.1 4602 237.7 6039 301.6 7662 435.3 11059
0425/1515 12.3 314 72.6 1845 181.1 4602 237.7 6039 301.6 7662 435.3 11059
0443/1543 12.3 314 72.6 1845 181.1 4602 237.7 6039 289.6 7358 435.3 11059
0428/1488 12.3 314 72.6 1845 181.1 4602 237.7 6039 301.6 7662 435.3 11059
0475/1665 12.3 314 72.6 1845 181.1 4602 237.7 6039 289.6 7358 435.3 11059
0483/1693 12.3 314 72.6 1845 181.1 4602 237.7 6039 289.6 7358 435.3 11059
0523/1843 12.3 314 72.6 1845 181.1 4602 237.7 6039 289.6 7358 435.3 11059
SUB SECTION LIFT POINTS DIMENSIONS TAKEN FROM END OF SUB SECTION
MODEL G H
0368/1288 10.7 271 77.6 1971
0398/1388 10.7 271 77.6 1971
0425/1515 10.7 271 77.6 1971
0443/1543 10.7 271 77.6 1971
0428/1488 26.8 681 105.3 2676
0475/1665 26.8 681 105.3 2676
0483/1693 26.8 681 105.3 2676
0523/1843 26.8 681 105.3 2676

JOHNSON CONTROLS
8
FORM 201.28-N1
ISSUE DATE: 7/25/2017
2. Upon arrival AT the site, check that the sub sec-
tion is still pressurized with 10-15 PSI of nitrogen,
and then relieve pressure via the relief valve.
3. Once situated, align the main and sub section
angeplates.Removethe angeplates andbolt
the two sections together with gaskets to the cor-
rect torque value as shown in Figures 2 and 3.
4. Pump down the portion of the unit downstream
of the ball valves in the main section (the sub sec-
tion and the last condenser module in the main
section).
Do not open discharge and liquid line ball
valves until there is sufcient water ow
through the evaporator.
LD19423
Flange connection for
discharge and liquid lines
FIGURE 2 - FLANGE CONNECTION FOR DISCHARGE AND LIQUID LINES (VIEW FROM INSIDE UNIT)
Piping and connecting anges is done for
each circuit.
LD19424
Flange connection for
discharge and liquid lines
FIGURE 3 - FLANGE CONNECTION FOR DISCHARGE AND LIQUID LINES (VIEW FROM OUTSIDE UNIT)

JOHNSON CONTROLS 9
FORM 201.28-N1
ISSUE DATE: 7/25/2017
5. Connect main and sub section wiring to the appro-
priate junction boxes as shown in Figure 5.
Be sure to leak check anges between the
Main and Sub Sections before applying
power to the unit to conrm a secure seal
between the two sections.
LD19426
Discharge Line Ball Valve
Liquid Line Ball Valve
FIGURE 4 - DISCHARGE LINE BALL VALVE
LD19425
Split Unit Junction Box
FIGURE 5 - WIRING HARNESS ELECTRICAL CONNECTION
6. Perform continuity checks and fan rotation checks
to ensure fans on the sub section operate properly.
7. Complete the standard commissioning proce-
dures as specied in the Equipment Pre-startup
and Startup Checklist (Form 201.28-CL2) and the
Installation, Operation and Maintenance Manual
(Form 201.28-NM1.1).

5000 Renaissance Drive, New Freedom, Pennsylvania USA 17429 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2017 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 201.28-N1(717)
Issue Date: July 25, 2017
Supersedes: (515)