York YK Series User manual

Form Number: 160.76-N3 (121)
Supersedes: 160.76-N3 (619)
Installation Guide
Issue Date: 2021-01-15
Model YK Chillers (Style H) Field
Reassembly for Form 3, 7, 9, and 10
Shipment
R-134a and R-513A (Cooling Only) with Graphic Control
Center for Electromechanical Starter, Solid State Starter,
and Variable Speed Drive

2 Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

Contents
ContentsGeneral safety guidelines.............................................................................................................................. 5
Safety symbols..................................................................................................................................... 5
Changeability of this document......................................................................................................... 6
Associated literature........................................................................................................................... 6
Nomenclature...................................................................................................................................... 7
Shipping and reassembly.............................................................................................................................. 8
Forms of shipment.............................................................................................................................. 8
Form 3 – Driveline separate from shells................................................................................................. 8
Form 7 – Split shells................................................................................................................................... 9
Form 9 – Unit separate from variable speed drive................................................................................ 9
Form 10 – Unit separate from variable speed drive.............................................................................. 9
Inspection – damage – shortage..................................................................................................... 10
Data plates......................................................................................................................................... 10
Long-term storage............................................................................................................................ 11
Shipment Form 2/3/7/9........................................................................................................................... 13
Shipment Form 1/10................................................................................................................................ 13
Reassembly........................................................................................................................................ 13
Form 7 shipment...................................................................................................................................... 13
Form 3 and Form 7 shipment................................................................................................................. 14
Form 9 and Form 10 reassembly........................................................................................................... 15
Q3-Q8 compressors (with falling film)............................................................................................ 17
Q3-Q8 compressors.......................................................................................................................... 19
P8-P9, H9 compressors (with falling film)...................................................................................... 20
P8-P9 and H9 compressors.............................................................................................................. 22
K compressors................................................................................................................................... 23
Weights.......................................................................................................................................................... 26
Unit conversion............................................................................................................................................ 34
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment 3

4 Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

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.
5Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

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 Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
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
6 Associated literature table updated
17–19 Compressors updated to Q8 compressors
17–18, 20–21, 23–24 Ring gasket for suction line added to images
26 Compressor weights table updated
31–33 Tables for unit weights, evaporator marine waterbox weights, and
condenser marine waterbox weights updated
Associated literature
Manual description Form number
Installation Checklist/Start-Up Request 160.76-CL1
Unit Start-Up Checklist 160.76-CL2
Installation - Unit 160.76-N1
Installation - MVVSD - 2300 VAC to 6600 VAC 160.00-N6
Installation - MVVSD - 10 kV to 13.8 kV 160.00-N8
Wiring Diagrams - Field Connections - Unit-Mounted SSS or Remote Mounted
MVSSS, MVEMS 160.76-PW1
Wiring Diagrams - Field Connections - Remote Mounted MVSSS 160.76-PW2
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment6

Manual description Form number
Wiring Diagrams - Field Connections - Remote Mounted MVVSD 160.76-PW3
Wiring Diagrams - Field Control Modifications 160.76-PW4
Wiring Diagrams - OptiView Control Center and EMS 160.76-PW5
Wiring Diagrams - OptiView Control Center and SSS, LVVSD 160.76-PW6
Wiring Diagrams - Field Connections - LVVSD 160.76-PW7
Unit Operation and Maintenance 160.76-O1
Operation - OptiView Panel 160.76-O2
Operation - Variable Speed Drive - TM Model 160.00-O1
Operation and Maintenance - Solid State Starter (Mod B) 160.00-O2
Operation - Variable Speed Drive - VSD and LVD Model 160.00-O4
Operation - Variable Speed Drive - HYP Model 160.00-O10
Operation - Floor Mounted MVSSS, Manufactured Before 2007 160.00-O5
Operation - Floor Mounted MVSSS, Manufactured After 2007 160.00-O5.1
Operation - Unit Mounted MVSSS 160.00-O7
Operation - MVVSD - 2300 VAC to 6600 VAC 160.00-O6
Operation - MVVSD - 10 kV to 13.8 kV 160.00-O8
Nomenclature
7Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

Shipping and reassembly
This instruction explains the procedure to be used for reassembling the Model YK Chiller shipped
disassembled (Shipping Form 3, 7, 9, and 10).
Note: Chillers must be field reassembled under the supervision of a Johnson Controls
representative.
For instructions on installing the unit, refer to the Unit Installation Instructions (Form 160.76-N1).
Figure 1: Front view of assembled unit
Callout Description
1 Condenser
2 Control center
3 Compressor
4 VSD panel
5 Evaporator
Forms of shipment
Form 3 – Driveline separate from shells
Shipped as two major assemblies. The unit is first factory assembled, refrigerant piped, wired and
leak tested; then dismantled for shipment. Close-coupled compressor/open motor assembly is
removed from shells and skidded; however, the evaporator/condenser is not skidded.
All wiring integral with compressor is left on it, and all conduit is left on the shell. All openings on
the compressor and shell are closed and charged with dry nitrogen (2 psig to 3 psig).
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment8

The shipment may include miscellaneous packaging of the control center, oil eductor filter,
tubing, water temperature controls, wiring, oil, isolators, solid state starter or variable speed drive
(options). The refrigerant charge is shipped in appropriate cylinders. For P and Q compressors, the
control panel is removed for shipment. For H9 and K compressors the control panel is shipped on a
folded bracket. Refer to the Unit Installation Instructions (Form 160.76-N1) for more details.
Form 7 – Split shells
Shipped as three major assemblies. The unit is first factory assembled, refrigerant piped, wired
and leak tested; then dismantled for shipment. Close-coupled compressor/open motor assembly is
removed from shells and skidded.
The evaporator and condenser shells are separated at tube sheets and are not skidded. The
refrigerant lines between the shells are flanged and capped. The tube sheets are also bolted,
requiring no welding.
All wiring integral with the compressor is left on. All wiring harnesses on shells are removed.
All openings on compressor and shells are closed and charged with dry nitrogen (2 psig or 3 psig).
The shipment may include miscellaneous packaging of control center, oil eductor filter, tubing,
water temperature controls, wiring, oil, isolators, solid state starter or variable speed drive
(options). The refrigerant charge is shipped in appropriate cylinders. For P and Q compressors, the
control panel is removed for shipment. For H9 and K compressors, the control panel is shipped on a
folded bracket. Refer to the Unit Installation Instructions (Form 160.76-N1) for more details.
Note: When more than one chiller is involved, the major parts of each unit will be marked to
prevent mixing of assemblies. Piping and wiring drawings to be furnished by Johnson Controls.
Form 9 – Unit separate from variable speed drive
Shipped as two major assemblies:
• Chiller unit
• Variable speed drive
The unit is first factory assembled, refrigerant piped, wired and leak tested; then dismantled for
shipment. Evaporator/condenser is not skidded.
All wiring integral with compressor is left on it, and all conduit is left on shell. All openings on
compressor, and shell are closed and charged with dry nitrogen (2 psig to 3 psig).
The shipment includes miscellaneous packaging of tubing, water temperature controls, wiring,
isolators, and so on. The unit is shipped with a nitrogen charge. Refrigerant charge shipped in
appropriate cylinders. See Table 7.
Form 10 – Unit separate from variable speed drive
Shipped as two major assemblies:
• Chiller unit
• Variable speed drive
The unit is first factory assembled, refrigerant piped, wired and leak tested; then dismantled for
shipment. Evaporator/condenser is not skidded.
All wiring integral with compressor is left on it, and all conduit is left on shell.
The shipment includes miscellaneous packaging of tubing, water temperature controls, wiring,
isolators, and similar components. The unit is shipped with refrigerant charge. See Table 7.
9Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

Inspection – damage – shortage
The unit shipment must be checked on arrival to see that all major pieces, boxes, and crates are
received. Each unit must 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 immediately for their inspection.
Figure 2: Form 7 shipment
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, all containers must be opened and contents checked against the
packing list. Any material shortage must be reported to Johnson Controls immediately. Refer to
Shipping Damage Claims (Form 50.15-NM).
Data plates
A unit data plate is mounted on the Control Center assembly of each unit, giving the following
information:
• Unit model number
• Design working pressure
• Water passes
• Refrigerant charge
• Serial numbers
• Motor power characteristics and connection diagrams
A Control Panel data plate, which includes control panel part number and serial number, is also
included. If the unit is equipped with a Solid State Starter or Variable Speed Drive (optional), it has
its own data plate with serial number.
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment10

Long-term storage
About this task:
In order 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 setup. Use the following procedure to
relieve pressure. See Figure 3.
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.
1. Check that the working space is open and has good ventilation. If is does not have good
ventilation, 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.
3. Monitor the pressure gauge (Item 2). The pressure should decline gradually.
4. When the pointer of the pressure gauge stops moving and no nitrogen is released from the
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).
11Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

Figure 3: Long term storage - tube side
Item Description
1Tag warning Dennison 8E
2Gauge press 2 dia. 0-30
3Tag GlvSt wire speed
4Bush pipe 3/4 - 14 NPTE X
5Valve, transducer 1/4 NPTE X
6Flange cover
7Gasket
8Victaulic coupling
9Sealing cap
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment12

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).
WARNING
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 on-site.
Before trying to remove these, 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 necessary to relieve the pressure. 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 are carried out on the
refrigeration system. Fully relieve system pressure and then repair.
DANGER
The unit is charged with tons of refrigerant; if an uncontrollable leak is found, inform all of the relevant
people to evacuate from the building to prevent risk of asphyxiation.
Never touch the refrigerant that is leaking, especially the liquid refrigerant; this will cause severe
freezing to your hands or body.
Reassembly
The following is a step-by-step procedure to be used to reassemble the chiller. Refer to the Unit
Installation Instructions (Form 160.76-N1) for other instructions.
Form 7 shipment
1. Locate cooler and condenser shells in their final position. Rigging holes exist on the top
corners of each tube sheet, four for each shell.
2. Bolt the tube sheets together as shown in Figure 2. Note that the outside surfaces of the tube
sheets must be flush.
13Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

Form 3 and Form 7 shipment
1. Assemble vibration isolators to unit. Refer to the Unit Installation Instructions (Form 160.76-N1).
2. Level shells in both directions. Check the longitudinal alignment of the shell by placing a level
on the top of the shell, next to the discharge connection. Check the transverse alignment by
placing a level on the tops of both end sheets. Refer to the Unit Installation Instructions (Form
160.76-N1) for additional instructions to level the unit. After the shell is leveled, wedge and
shim each corner of the shell to solidly support it while assembling the other parts.
3. Lift compressor/motor assembly and remove packing materials. See Figure 4. Carefully lower
the compressor/motor assembly on to the supports on the cooler. Fasten compressor/motor
assembly with the proper hardware. Do not tighten the bolts until all connections are made
to the compressor.
4. Bolt the suction line between the compressor and the cooler using proper gaskets and
hardware.
5. Install the fill piece or isolation valve between the compressor and the condenser using
proper gaskets and hardware.
6. Connect the oil line between the compressor oil drain flange and the oil sump flange. Be sure
to install proper gaskets and hardware.
7. Complete the refrigerant liquid piping beneath the cooler and condenser. Be sure the fill
piece, orifice plate, gaskets and hardware are properly installed.
8. Tighten all hardware installed in steps 3 through 7 above.
9. Assemble the Control Center to unit.
Note: Large units have panel mounted on brackets for shipping. Small units are shipped
separately.
10. Assemble the Oil Pump Control Panel.
11. Install refrigerant piping and oil return system filters.
12. Perform pressure test.
Note: Relief valves must be plugged (or capped). Refer to Operation - Unit (Form 160.76-
O1).
13. Evacuate and charge with refrigerant. Refer to Operation - Unit (Form 160.76-O1).
14. All Units: Complete installation and finally level the unit per the Unit Installation Instructions
(Form 160.76-N1).
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment14

Figure 4: Rigging – compressor/motor assembly
Note: Rig the driveline into place on the chiller, supporting the compressor with two lifting
lugs and the motor with either, one, two, or four legs depending on motor design.
Form 9 and Form 10 reassembly
1. Assemble vibration isolators to unit. Refer to YK Mod H Installation Manual (Form 160.76-N1).
2. Level shells in both directions. Check the longitudinal alignment of the shell by placing a level
on the top of the shell, next to the discharge connection. Check the transverse alignment by
placing a level on the tops of both end sheets. Refer to YK Mod H Installation Manual (Form
160.76-N1) for additional instructions to level the unit. After shell is leveled, wedge and shim
each corner of the shell to solidly support it while assembling the other parts.
3. Tighten all hardware installed to the specified torque.
4. Lift the Variable Speed Drive and remove all packing material. Carefully lower the Variable
Speed Drive on to the supports on the condenser. Fasten the Variable Speed Drive to the
condenser and to the motor terminal box duct. Make all necessary connections for the VSD
cooling loop to be complete.
The Variable Speed Drive will be shipped with glycol in the cooling system. The Variable
Speed Drive coolant must be changed to the inhibitor provided with the shipped loose items
before starting the unit.
5. Reconnect the motor power leads in the Variable Speed Drive to the T1, T2, and T3 terminals
and torque to 18 lb·ft to 20 lb·ft (24 N•m to 27 N•m) as indicated by the labels in the VSD.
6. Reconnect motor winding thermistor shielded cable conductors in the Variable Speed Drive at
TB4. Refer to Unit Wiring and Field Control Modifications (Form 160.76-PW2).
7. Reconnect all unit wiring and harnesses. Refer to Unit Wiring and Field Control Modifications
(Form 160.76-PW2).
8. Pressure test the unit.
15Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

Note: Relief valves must be plugged or capped. Refer to Operations and Maintenance
(Form 160.76-O1).
9. Form 9 - Remove nitrogen and charge unit with refrigerant. Refer to Operations and
Maintenance (Form 160.76-O1).
10. All Units: Complete installation and finally level the unit. Refer to Installation Manual (Form
160.76-N1).
Figure 5: Variable speed drive rigging
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment16

Q3-Q8 compressors (with falling film)
Figure 6: Form 3 shipment (Q3-Q8 compressors with falling film)
Note: * Ring Gaskets NOT used for elastomer-lined flange faces at the isolation valve.
17Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

Figure 7: Form 7 shipment (Q3-Q8 compressors with falling film)
Note: * Ring Gaskets NOT used for elastomer-lined flange faces at the isolation valve.
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment18

Q3-Q8 compressors
Figure 8: System piping (Q3-Q8 compressors)
19Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment

P8-P9, H9 compressors (with falling film)
Figure 9: Form 3 shipment (P8-P9 and H9 compressors with falling film)
Note: * Ring Gaskets NOT used for elastomer-lined flange faces at the isolation valve.
Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment20