York YD User manual

FIELD RE-ASSEMBLY FOR FORM 3 AND 7 SHIPMENT
MODEL YD CHILLERS - MOD C
WITH OPTIVIEW CONTROL CENTER
CENTRIFUGAL LIQUID CHILLERS
SERVICE INSTRUCTIONS Supersedes: 160.69-NM4 (1215) Form 160.69-NM4 (920)
Issue Date:
September 30, 203
LD09115

JOHNSON CONTROLS
2
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
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 160.69-NM4
ISSUE DATE: 9/30/2020
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Installation Checklist and Request for Start-Up 160.69-CL1
Start-Up Checklist 160.69-CL2
Unit Installation 160.69-N3
Shipping Damage Claim Policy 50.15-NM
Field Control Modications Wiring Diagram 160.69-PW2
Remote Motor Starter Specications 160.69-PW4
Wiring Diagram - with OptiView Control Center and Electro-Mechanical Starter 160.69-PW7
Wiring Diagram - with OptiView Control Center and Medium Voltage Variable Speed Drive 160.69-PW8
Wiring Diagram - with OptiView Control Center and Unit Mounted LVVSD or Floor Mounted MVVSD 160.69-PW9
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for contin-
uous 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 appli-
cable, can be obtained by contacting the nearest John-
son Controls Service office or accessing the Johnson
Controls Knowledge Exchange website at https://docs-
johnsoncontrols-uat.fluidtopics.net/chillers/home.
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.
AFFECTED PAGES DESCRIPTION
3 Conditioned Based Maintenance information added
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.
CONDITIONED BASED MAINTENANCE
Traditional chiller maintenance is based upon assumed
and generalized conditions. In lieu of the traditional
maintenance program, a Johnson Controls YORK
Conditioned Based Maintenance (CBM) program can
be substituted. This CBM service plan is built around
the specific needs for the chiller, operating conditions,
and annualized impact realized by the chiller. Your lo-
cal Johnson Controls Branch can propose a customized
Planned Service Agreement that leverages real time
and historical data, delivering performance reporting,
corrective actions required and data enabled guidance
for optimal operation and lifecycle assurance. The pro-
gram will include fault detection diagnostics, operation
code statistics, performance based algorithms and ad-
vance rules based rationale delivered by the Johnson
Controls Connected Equipment Portal.

JOHNSON CONTROLS
4
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
NOMENCLATURE
YD ND BE K2 — DA C S
DESIGN LEVEL
SPECIAL
MODIFICATIONS
EVAPORATOR CODE
BB, BC, BD, B2, B3, B4,
MB, MC, MD, M2, M3, M4,
NB, NC, ND, N2, N3, N4,
EB, EC, ED, E2, E3, E4,
FB, FC, FD, F2, F3, F4,
GB, GC, GD, G2, G3, G4,
HB, HC, HD, H2, H3, H4,
KB, KC, KD, K2, K3, K4
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
MODEL
CONDENSER CODE
LB, LC, LC, LE, L2, L3, L4, L5,
MB, MC, MD, M2, M3, M4,
BB, BC, BD, BE, B2, B3, B4, B5,
CB, CC, CD, C2, C3, C4,
DB, DC, DD, DE, D2, D3, D4, D5,
EB, EC, ED, EE, E2, E3, E4, E5,
FB, FC, FD, FE, F2, F3, F4, F5,
KB, KC, KD, KE, K2, K3, K4, K5
COMPRESSOR CODE
K1, K2, K3, K4, K7
MOTOR CODE
60 Hz 50 Hz
CV
CW 5CS
CX 5CT
CY 5CU
CZ 5CV
CA 5CW
CB 5CX
DA 5DA
DB 5DB
DC 5DC
DD 5DD
DE 5DE
DF 5DF
5DG
DH 5DH
DJ 5DJ
DK 5DK
DL 5DL
PREMIUM EFFICIENCY
MOTOR CODE
60 Hz 50 Hz
EW 5EP
EX 5EQ
EY 5ER
EZ 5ES
EA 5ET
EB 5EU
FA 5EV
FB 5EW
FC 5EX
FD 5FA
5FB

JOHNSON CONTROLS 5
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
LIST OF FIGURES
FIGURE 1 - Front View Of Assembled Unit ..............................................................................................................7
FIGURE 2 - Form 7 Shipment ..................................................................................................................................8
FIGURE 3 - Dimensions – K Compressor Units Ft.–In. (mm) ................................................................................11
FIGURE 4 - 150 # Design Evaporator, No Hot Gas Bypass...................................................................................13
FIGURE 5 - 150 # Design Condenser, No Hot Gas Bypass...................................................................................15
FIGURE 6 - Rigging – Driveline Assembly.............................................................................................................16
FIGURE 7 - Oil Pump Housing ...............................................................................................................................18
FIGURE 8 - Liquid Line Re-Assembly ....................................................................................................................18
FIGURE 9 - High Pressure Cutout Tubing..............................................................................................................18
FIGURE 10 - System Piping ..................................................................................................................................18
FIGURE 11 - Re-Assembly.....................................................................................................................................19
FIGURE 12 - Variable Speed Drive Bracket ...........................................................................................................20
FIGURE 13 - VSD Bracket Installed.......................................................................................................................20
FIGURE 14 - Variable Speed Drive Rigging ...........................................................................................................21
LIST OF TABLES
TABLE 1 - Dimensions – K Compressor Units Ft.–In.(mm) ...................................................................................10
TABLE 2 - Approximate Unit Weight Including Motor* — English (Metric).............................................................12
TABLE 3 - Marine Waterbox Weight — English (Metric)........................................................................................12
TABLE 4 - Evaporator Shell Weights — 150# Design, No Hot Gas Bypass ..........................................................13
TABLE 5 - Condenser Shell Weights — 150# Design, No Hot Gas Bypass ..........................................................14
TABLE 6 - Compessor Weights..............................................................................................................................16
TABLE 7 - Approximate Unit Motor Weights — English (Metric)............................................................................17
TABLE 8 - Suction/Discharge Piping......................................................................................................................18
TABLE 9 - VSD Weight ..........................................................................................................................................21
TABLE 10 - SI Metric Conversion...........................................................................................................................23

JOHNSON CONTROLS
6
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 7
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
GENERAL
This instruction explains the procedure to be used for
reassembling the Model YD Chiller shipped disassem-
bled (Shipping Form 3 and 7).
Chillers MUST be eld reassembled un-
der the supervision of a Johnson Controls
representative.
For Installation Instructions other than unit assem-
bly, refer to Installation Instructions Manual (Form
160.69-N3).
FORMS OF SHIPMENT
Form 3 – Driveline Separate From Shells
Shipped as three major assemblies. Unit first factory
assembled, refrigerant piped, wired and leak tested;
then dismantled for shipment. Close-coupled compres-
sor/open motor assemblies are removed from shells
and skidded. Evaporator/condenser is not skidded.
All wiring essential with the compressors is left on
them, and all conduit is left on the shells. All openings
on the compressors and shells are closed and charged
with dry nitrogen (5 to 7 PSIG).
Miscellaneous packaging of the Control Center, oil
eductor filter, tubing, water temperature controls, wir-
ing, oil, isolators, etc. Refrigerant charge shipped in
appropriate cylinders.
Form 7 – Split Shells
Shipped as four major assemblies. Unit first factory
assembled, refrigerant piped, wired and leak tested;
then dismantled for shipment. Close-coupled compres-
sor/open motor assemblies removed from shells and
skidded.
Evaporator and condenser shells are separated at tube
sheets and are not skidded. Refrigerant lines between
shells are flanged and capped; tube sheets are also bolt-
ed, requiring no welding.
FIGURE 1 - FRONT VIEW OF ASSEMBLED UNIT
LD09115
COMPRESSOR
MOTOR
GRAPHIC
CONTROL
CENTER
VSOP
PANEL
EVAPORATOR
CONDENSER
COMPRESSOR
MOTOR
DRIVELINE #1
DRIVELINE #2

JOHNSON CONTROLS
8
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
All essential wiring will be secured to the wiring race-
way, and the entire wiring assembly will be attached to
the evaporator. The water sensor wiring for the evapo-
rator nozzles will remain in place.
All openings on the compressors and shells are closed
and charged with dry nitrogen (2 or 3 PSIG).
Miscellaneous packaging of Control Center, oil educ-
tor filter, tubing, water temperature controls, wiring,
oil, isolators, etc. Refrigerant charge shipped in appro-
priate cylinders.
When more than one chiller is involved,
the major parts of each unit will be
marked to prevent the mixing of assem-
blies (Piping and Wiring Drawings to be
furnished by YORK).
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.
YORK will not be responsible for any
damage in shipment of at job site or loss of
parts. (Refer to Shipping Damage Claims,
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 YORK
immediately (refer to Shipping Damage Claims (Form
50.15-NM)).
DATA PLATES
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.
A Control Panel data plate, which includes control
panel part number and serial number is also included.
FIGURE 2 - FORM 7 SHIPMENT
LD03865
CONDENSER
COOLER
5/8" X 2-1/2" BOLTS,
LOCKWASHERS, &
HEX NUTS

JOHNSON CONTROLS 9
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS
10
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
NOTES:
1. All dimensions are approximate. Certified dimensions are available on
request.
2. For compact water boxes (shown above), determine overall unit length by add-
ing water box depth to tube sheet length.
3. Water nozzles can be located on either end of unit. Add 1/2" to nozzle length
for flanges connections.
4. To determine overall height, add dimension "M" for the appropriate
isolator type.
5. Use of motors with motor hoods may increase overall unit dimensions.
TABLE 1 - DIMENSIONS – K COMPRESSOR UNITS FT.–IN.(MM)
EVAPORATOR - CONDENSER SHELL CODES FT. - IN. (MM)
DIMENSION B-L M-M N-B E-C F-D G-E H-F K-K
A11'-6"
(3,505)
11'-6"
(3,505)
11'-11"
(3,632)
13'-4"
(4,064)
14'-6"
(4,420)
14'-6"
(4,420)
15'-0"
(4,572)
16'-0"
(4,877)
B12'-8"
(3,861)
12'-8"
(3,861)
13'-0"
(3,962)
13'-10"
(4,216)
14'-4"
(4,369)
14'-4"
(4,369)
14'-10"
(4,521)
15'-3"
(4,648)
C2'-8"
(813) 2'-8" (813) 2'-11 1/2"
(902)
3'-5"
(1,041)
3'-9"
(1,143)
3'-9"
(1,143)
4'-0"
(1,219)
4'-0"
(1,219)
D2'-5 1/2"
(749)
2'-5 1/2"
(749)
2'-5 1/2"
(749)
2'-8"
(813)
3'-1 1/2"
(953)
3'-1 1/2"
(953)
3'-1 1/2"
(953)
3'-4"
(1,016)
E18'-0"
(5,486)
22'-0"
(6,706)
18'-0"
(5,486)
22'-0"
(6,706)
18'-0"
(5,486)
22'-0"
(6,706)
18'-0"
(5,486)
22'-0"
(6,706)
F2'-3/4"
(629)
2'-3/4"
(629)
2'-1 11/16"
(660)
2'-13/16"
(635)
2'-3"
(686)
2'-3"
(686)
2'-3 9/16"
(699)
2'-3 9/16"
(699)
G1'-4 1/2"
(419)
1'-4 1/2"
(419)
1'-5 11/16"
(445)
1'-4 3/16"
(413)
1'-6 1/4"
(464)
1'-6 1/4"
(464)
1'-6 7/8"
(483)
1'-6 7/8"
(483)
H0'-11 11/16"
(305)
0'-11 11/16"
(305)
0'-11"
(279)
0'-11"
(279)
1'-2 9/16"
(368)
1'-2 9/16"
(368)
1'-3 9/16"
(394)
1'-4 3/16"
(413)
J1'-7 3/8"
(492)
1'-7 3/8"
(492)
1'-7 1/2"
(495)
1'-7 3/8"
(492)
2'-1 1/2"
(648)
2'-1 1/2"
(648)
2'-2"
(660)
2'-13/16"
(635)
L5'-1 1/2"
(1,562)
5'-1 1/2"
(1,562)
5'-5"
(1,651)
6'-1"
(1,854)
6'-10 1/2"
(2,096)
6'-10 1/2"
(2,096)
7'-1 1/2"
(2,172)
7'-4"
(2,235)
N13'-3"
(4039)
13'-3"
(4039)
14'-5"
(4395)
15'-10"
(4826)
17'
(5182) N/A N/A N/A
ADDITIONAL OPERATING HEIGHT
CLEARANCE TO FLOOR
TYPE OF CHILLER MOUNTING M
NEOPRENE PAD ISOLATORS 1-3/4"
(44)
SPRING ISOLATORS 1" DEFLECTION 1"
(25)
DIRECT MOUNT 3/4"
(19)