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)

JOHNSON CONTROLS 11
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
UNIT DIMENSIONS
FIGURE 3 - DIMENSIONS – K COMPRESSOR UNITS FT.–IN. (MM)
Refer to Table 1 on page 10 for specific dimensions based on Evaporator-Condensor shell combinations.
M
LOW VOLTAGE
VSD
CONDENSER
EVAPORATOR
LD18374

JOHNSON CONTROLS
12
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
UNIT WEIGHTS
TABLE 2 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR* — ENGLISH (METRIC)
SHELLS COMPRESSOR SHIPPING WEIGHT (LBS/ KGS) ** OPERATION WEIGHT
(LBS/ KGS)
EST. REFRIGERANT
CHARGE (LBS/ KGS) ***
B-L K1 74,800 (33,926) 92,500 (41,953) 6,000 (2,721)
M-M K2 83,200 (37,735) 104,100 (47,215) 7,300 (3,311)
N-B K2 84,200 (38,189) 105,100 (47,668) 7,200 (3,266)
E-C K3 116,600 (52,884) 147,100 (66,717) 10,600 (4,808)
F-D K3 125,500 (56,921) 157,500 (71,434) 9,800 (4,445)
G-E K4 141,100 (63,996) 179,100 (81,231) 12,200 (5,533)
H-F K4 139,000 (63,043) 176,300 (79,961) 11,500 (5,216)
K-K K7 174,100 (78,963) 222,200 (100,779) 15,800 (7,166)
* Refer to product drawings for detailed weight information
** Does not include Refrigerant Charge.
*** Add 5% for 1" tube option.
TABLE 3 - MARINE WATERBOX WEIGHT — ENGLISH (METRIC)
EVAP CODE SHIPPING WEIGHT INCREASE (LBS/ KGS) OPERATING WEIGHT INCREASE (LBS/ KGS)
1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
B7,124
(3,231)
3,851
(1,747)
7,086
(3,214)
8,966
(4,067)
5,520
(2,504)
8,755
(3,971)
M7,124
(3,231)
3,851
(1,747)
7,086
(3,214)
8,966
(4,067)
5,520
(2,504)
8,755
(3,971)
N7,088
(3,215)
3,604
(1,635)
7,244
(3,286)
9,319
(4,227)
5,758
(2,612)
9,320
(4,227)
E 10,692
(4,849)
6,554
(2,973)
13,316
(6,039)
14,334
(6,501)
9,502
(4,310)
15,708
(7,124)
F15,696
(7,119)
8,370
(3,796)
16,778
(7,610)
19,517
(8,852)
12,191
(5,529)
20,599
(9,343)
G15,696
(7,119)
8,370
(3,796)
16,778
(7,610)
19,517
(8,852)
12,191
(5,529)
20,599
(9,343)
H17,374
(7,880)
8,478
(3,845)
16,744
(7,594)
22,366
(10,144)
12,630
(5,728)
20,267
(9,192)
K17,374
(7,880)
8,478
(3,845)
16,744
(7,594)
22,366
(10,144)
12,630
(5,728)
20,267
(9,192)
COND CODE 1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
L3,808
(1,727)
1,947
(8,83)
3,960
(1,796)
5,901
(2,676)
3,195
(1,449)
5,256
(2,384)
M3,808
(1,727)
1,947
(8,83)
3,960
(1,796)
5,901
(2,676)
3,195
(1,789)
5,256
(2,384)
B5,092
(2,309)
2,498
(1,133)
5,060
(2,295)
7,103
(3,222)
3,945
(1,789)
6,631
(3,007)
C 5,768
(2,616)
2,882
(1,307)
5,826
(2,642)
8,127
(3,686)
4,864
(2,206)
7,872
(3,571)
D7,394
(3,354)
3,889
(1,764)
7,592
(3,443)
10,256
(4,652)
6,333
(2,872)
9,722
(4,409)
E7,394
(3,354)
3,889
(1,764)
7,592
(3,443)
10,256
(4,652)
6,333
(2,872)
9,722
(4,409)
F8,422
(3,820)
4,643
(2,106)
8,910
(4,041)
11,745
(5,327)
7,965
(3,613)
11,637
(5,278)
K10,332
(4,686)
5,520
(2,504)
10,798
(4,897)
14,048
(6,371)
9,236
(4,189)
13,809
(6,263)

JOHNSON CONTROLS 13
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
TABLE 4 - EVAPORATOR SHELL WEIGHTS — 150# DESIGN, NO HOT GAS BYPASS
SHELL CODE WEIGHT KGS
BB 18600 40920
BC 20100 44220
BD 21600 47520
B2 16800 36960
B3 17800 39160
B4 18600 40920
MB 20200 44440
MC 21800 47960
MD 23200 51040
M2 18500 40700
M3 19400 42680
M4 20200 44440
NB 23300 51260
NC 24300 53460
ND 25100 55220
N2 20900 45980
N3 22000 48400
N4 22800 50160
EB 37200 81840
EC 38900 85580
ED 40600 89320
E2 33400 73480
E3 34500 75900
E4 35600 78320
SHELL CODE WEIGHT KGS
FB 41500 91300
FC 43200 95040
FD 44800 98560
F3 37600 82720
F3 38700 85140
F4 39900 87780
GB 49200 108240
GC 51300 112860
GD 53300 117260
G2 44400 97680
G3 45800 100760
G4 47300 104060
HB 47200 103840
HC 48800 107360
HD 50800 111760
H2 42700 93940
H3 43900 96580
H4 45200 99440
KB 54800 120560
KC 56700 124740
KD 59300 130460
K2 49500 108900
K3 51100 112420
K4 52700 115940
LD19862
FIGURE 4 - 150 # DESIGN EVAPORATOR, NO HOT GAS BYPASS

JOHNSON CONTROLS
14
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
TABLE 5 - CONDENSER SHELL WEIGHTS — 150# DESIGN, NO HOT GAS BYPASS
SHELL CODE WEIGHT KGS
LB 18400 40480
LCL 19300 42460
LD 23900 52580
L2 15100 33220
L3 16100 35420
L4 17200 37840
MB 20200 44440
MC 21800 47960
MD 23200 51040
M2 17700 38940
M3 18900 41580
M4 20200 44440
BB 21000 46200
BC 21100 46420
BD 22600 49720
BE 23200 51040
B2 17300 38060
B3 18100 39820
B4 18800 41360
B5 19700 43340
CB 28900 63580
CC 30400 66880
CD 32500 71500
C2 23100 50820
C3 25400 55880
C4 27800 61160
DB 31400 69080
DC 32900 72380
DD 34300 75460
SHELL CODE WEIGHT KGS
DE 35100 77220
D2 27100 59620
D3 28100 61820
D4 28900 63580
D5 30300 66660
EB 35700 78540
EC 37600 82720
ED 36400 80080
EE 40200 88440
E2 30500 67100
E3 31600 69520
E4 32700 71940
E5 34400 75680
FB 35500 78100
FC 37200 81840
FD 38500 84700
FE 39300 86460
F2 30500 67100
F3 31500 69300
F4 32700 71940
F5 34000 74800
KB 49900 109780
KC 52400 115280
KD 53900 118580
KE 55200 121440
K2 42000 92400
K3 43500 95700
K4 45100 99220
K5 47400 104280

JOHNSON CONTROLS 15
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
LD19865
Condenser
FIGURE 5 - 150 # DESIGN CONDENSER, NO HOT GAS BYPASS

JOHNSON CONTROLS
16
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
RE-ASSEMBLY
The following is a step-by-step procedure to be used to
assemble the chiller. Refer to Installation Instruction
(Form 160.69-N3) for other instructions.
Form 7 Shipment
1. Locate the evaporator and condenser shells in
their nal position. (See Figure 2 on page 8)
2. Bolt the tube sheets together as shown in Figure
2 on page 8. Note that the outside surfaces of
the tube sheets must be ush.
FORM 3 AND FORM 7 SHIPMENT
1. Level the shells in both directions. The longitudi-
nal alignment of the shell should be checked by
placing a level on the top of the shell, next to the
discharge connection. The transverse alignment
should be checked by placing a level on the tops
of both end sheets. Refer to Installation Instruc-
tion (Form 160.69-N3) for additional instructions
to level the unit. After the shell is leveled, wedge
and shim each corner of the shell to solidly sup-
port it while assembling the other parts.
2. Discharge lines and suction lines should be sten-
ciled as "Drive #1" or "Drive #2". Correct orienta-
tion is necessary for proper t.
3. Install discharge nozzle onto condenser heat ex-
changer connection using the proper gaskets and
hardware. Verify that the discharge pipe is level in
both directions. Install discharge isolation valve
n top of discharge pipe using proper gaskets and
hardware. Please note that the actuator valve uti-
lizes o-rings instad of a at gasket. If utilizing any
oil on the o-ring, it's recommended that you use
York "K" oil. See discharge line weight in Table 8
on page 18.
4. Lift a compressor/motor assembly and remove the
packing materials (refer to Figure 6 on page 16
for rigging). Carefully lower the compressor/mo-
tor assembly on to the supports on the condenser
discharge valve. Fasten with the proper hardware.
Do not tighten the bolts until all connections are
made to the compressor.
5. Install suction line nozzle onto evaporator heat
exchanger connection using the proper gaskets
and hardware. See discharge line weight in Table
8 - Suction/Discharge Piping on page 18.
TABLE 6 - COMPESSOR WEIGHTS
COMPRESSOR ASSEMBLY WEIGHT
LBS.
WEIGHT
KGS
K1 364-53357-201 4100 9020
K2 364-53362-201 4200 9240
K3 364-53348-201 6100 13420
K4 364-53349-201 6400 14080
K7 364-53350-201 8100 17820
FIGURE 6 - RIGGING – DRIVELINE ASSEMBLY
LD19863a

JOHNSON CONTROLS 17
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
TABLE 7 - APPROXIMATE UNIT MOTOR WEIGHTS — ENGLISH (METRIC)
LOW VOLTAGE
60 HZ HP WEIGHT
LBS.
WEIGHT
KGS 50 HZ HP WEIGHT LBS.
WEIGHT
KGS
CW 655 2,835 1,289 5CT 704 5,750 2,614
CX 690 2,835 1,289 5CU 750 5,750 2,614
CY 740 3,105 1,411 5CV 800 5,750 2,614
CZ 790 3,180 1,445 5CW 850 6,800 3,091
CA 845 4,190 1,905 5CX 900 6,800 3,091
CB 900 5,750 2,614 5DA 1000 7,300 3,318
DA 1000 6,800 3,091 5DB 1100 7,300 3,318
DB 1100 6,800 3,091 ————
PREMIUM EFFICIENCY MOTORS
60 HERTZ 50 HERTZ
MOTOR
CODE HP WEIGHT WEIGHT MOTOR CODE HP WEIGHT WEIGHT
LBS. KGS LBS. KGS
EW 655 4630 10186 5EP 546 4630 10186
EX 690 4630 10186 5EQ 575 4630 10186
EY 740 4741 10430 5ER 617 4741 10430
EZ 790 5072 11158 5ES 658 5072 11158
EA 845 5072 11158 5ET 704 5072 11158
EB 900 5733 12613 5EU 750 5733 12613
FA 1000 5733 12613 5EV 800 5733 12613
FB 1100 6615 14553 5EW 850 5733 12613
FC 1200 6615 14553 5EX 900 6615 14553
FD 1300 6615 14553 5FA 1000 6615 14553
5FB 1100 6615 14553

JOHNSON CONTROLS
18
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
MEDIUM VOLTAGE
MODEL WEIGHT
(LBS.)
WEIGHT
(KGS.)
MODEL WEIGHT
(LBS.)
WEIGHT
(KGS.)
60 HZ HP 50 HZ HP
CW 655 4,415 2,007 5CS 658 4,640 2,109
CX 690 4,445 2,020 5CT 704 5,800 2,636
CY 740 4,540 2,064 5CU 750 5,800 2,636
CZ 790 4,640 2,109 5CV 800 5,800 2,636
CA 845 5,800 2,636 5CW 850 6,800 3,091
CB 900 5,800 2,636 5CX 900 6,800 3,091
DA 1000 6,800 3,091 5DA 1000 7,050 3,205
DB 1100 6,800 3,091 5DB 1100 7,300 3,318
DC 1200 7,050 3,205 5DC 1200 7,300 3,318
DD 1300 7,300 3,318 5DD 1300 7,300 3,318
DE 1400 7,300 3,318 5DE 1400 7,500 3,409
DF 1500 7,500 3,409 5DF 1500 7,500 3,409
5DG 1650 7,900 3,591
DH 1750 7,500 3,409 5DH 1750 11,250 5,114
DJ 2000 8,500 3,864 5DJ 2000 11,750 5,341
DK 2250 11,750 5,341 5DK 1750 12,750 5,795
DL 2500 12,750 5,795 5DL 2000 13,250 6,023
TABLE 8 - SUCTION/DISCHARGE PIPING
EVAP
CODE
COND
CODE
SUCTION
LINE W/
FLANGES
DISCHARGE
LINE
B L 494 250
M M 494 250
N B 483 255
E C 558 310
F D 524 331
G E 524 331
H F 524 331
K K 659 418
TABLE 7 - APPROXIMATE UNIT MOTOR WEIGHTS — ENGLISH (METRIC) (CONT'D)

JOHNSON CONTROLS 19
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
6. Connect the oil drain lines between the com-
pressors oil drain anges and oil pump housing
anges. Be sure to install the proper gaskets and
hardware, see Figure 7 on page 19. The oil
pump and heater wiring have been disconneted at
the unit VSOP panel, see Figure 11 on page 20.
The wiring has been secured to the oil pump hous-
ing for shipment. Reconnect wiring to VSOP lo-
cated on evaporator.
FIGURE 7 - OIL PUMP HOUSING
LD09442
7. Complete the refrigerant liquid piping beneath the
evaporator and condenser. Be sure the ll piece,
orice plate, gaskets and hardware are properly
installed.
FIGURE 8 - LIQUID LINE RE-ASSEMBLY
LD09435a
8. Tighten all hardware installed from the previous
steps 2 thru 8.
9. Assemble the Control Center to unit.
10. Assemble the VS Oil Pump Control Panel.
11. Install high pressure cutout tubing. Refer to Fig-
ure 9 on page 19.
FIGURE 9 - HIGH PRESSURE CUTOUT TUBING
LD09431
Isolation Valve
with Actuator
Compressor #1
VSOP Panel
Isolation Valve
with Actuator
Compressor #2
12. Install the refrigerant piping and oil return system
lters. Refer to Figure 10 on page 19.
FIGURE 10 - SYSTEM PIPING
LD09433
Compressor #2
Compressor #1
VSOP Panel

JOHNSON CONTROLS
20
FORM 160.69-NM4
ISSUE DATE: 9/30/2020
FIGURE 11 - RE-ASSEMBLY LD09430
Compressor #2
Compressor #1
Motor
Isolation Valve with Actuator
CONDENSER
EVAPORATOR
VSOP Panel
Compressor Support
Oil Drain Line Flexible Metal Braided
Oil Drain Line
O-Ring
O-Ring
O-Ring
O-Ring
Gasket Gasket
Gasket
Gasket
Gasket
Gasket
Oil Pump Housing
Elbow Assembly