MODEL YD (STYLE A) R-134A (COOLING ONLY) WITH OPTIVIEW ...cgproducts.johnsoncontrols.com/yorkdoc/160.69-n1.pdf · MANUAL DESCRIPTION FORM NUMBER YD Unit Field Reassembly Instructions

LD08634

R-134A

MODEL YD (STYLE A)R-134A (COOLING ONLY)

WITH OPTIVIEW™ CONTROL CENTERAND ELECTRO-MECHANICAL STARTER

CENTRIFUGAL LIQUID CHILLERS

INSTALLATION INSTRUCTION Supersedes: 160.69-N1 (912) Form 160.69-N1 (715)

Issue Date: July 31, 2015

JOHNSON CONTROLS2

FORM 160.69-N1ISSUE DATE: 7/31/2015

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.

Identifies 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 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 accor-dance 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 warn-ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3

FORM 160.69-N1 ISSUE DATE: 7/31/2015

MANUAL DESCRIPTION FORM NUMBER

YD Unit Field Reassembly Instructions 160.69-NM3

YD with OptiView Control Center and EMS (Cooling Only) Operating Manual 160.69-O2

Wiring Diagram 160.69-PW1

YD Unit Installation Checklist and Request for Startup Engineer 160.69-CL1

Service Policy 50.07-NM1

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 BARSRevisions 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.

ASSOCIATED LITERATURE

JOHNSON CONTROLS4


MOTOR CODE60 Hz 50 HzCW 5CSCX 5CTCY 5CUCZ 5CVCA 5CWCB 5CXDA 5DADB 5DBDC 5DCDD 5DDDE 5DEDF 5DF

5DGDH 5DHDJ 5DJ

NOMENCLATURE

YD XF XA J2 – CA A

POWER SUPPLY- for 60 Hz5 for 50 Hz

DESIGN LEVEL

MODEL

CONDENSER CODEXA, XB, XC, XD, YA, YB, YC, YD, ZA, ZB, ZC, ZD, AA, AB, AC, AD

EVAPORATOR CODEXF, XH YF, YG, YH, ZF, ZG, ZH AF, AG, AH

COMPRESSOR CODEJ1, J2, J3, J4, J5

JOHNSON CONTROLS 5

FORM 160.69-N1 ISSUE DATE: 7/31/2015

TABLE OF CONTENTS

SECTION 1 - INTRODUCTION .................................................................................................................................7General .............................................................................................................................................................7Field Assembled Units Only .............................................................................................................................7Shipment ..........................................................................................................................................................7Inspection – Damage – Shortage .....................................................................................................................8Chiller Data Plate .............................................................................................................................................9Rigging .............................................................................................................................................................9Location ............................................................................................................................................................9Motors ..............................................................................................................................................................9Foundation .......................................................................................................................................................9Clearance .........................................................................................................................................................9Neoprene Isolators ......................................................................................................................................... 11Spring Isolators ..............................................................................................................................................13Unit Dimensions .............................................................................................................................................15Unit Weights ...................................................................................................................................................16Motor Weights and Voltage ............................................................................................................................16

SECTION 2 - INSTALLATION ................................................................................................................................17Rigging Unit To Final Location ........................................................................................................................17Locating And Installing Isolator Pads ............................................................................................................17Checking The Isolation Pad Deflection...........................................................................................................17Leveling The Unit............................................................................................................................................17Installing Optional Spring Isolators .................................................................................................................17Piping Connections ........................................................................................................................................17Evaporator And Condenser Water Piping .......................................................................................................18

Chilled Water .........................................................................................................................................18Condenser Water Circuit .......................................................................................................................18Stop Valves ...........................................................................................................................................20Flow Switches .......................................................................................................................................20Drain and Vent Valves ...........................................................................................................................20Checking Piping Circuits and Venting Air ..............................................................................................20

Refrigerant Relief Piping ................................................................................................................................20Unit Piping ......................................................................................................................................................20Control Panel Positioning ..............................................................................................................................20Control Wiring .................................................................................................................................................21Power Wiring ..................................................................................................................................................21

Oil Pump – 3 Phase Starter ...................................................................................................................21YD Motors (Electro-Mechanical Starter) ................................................................................................21

Insulation ........................................................................................................................................................21Installation Check – Request For Start-Up Service ........................................................................................22Compressor Motor Field Connection Diagram ...............................................................................................22

JOHNSON CONTROLS6


LIST OF FIGURES

LIST OF TABLES

FIGURE 1 - Rigging.................................................................................................................................................10

FIGURE 2 - Neoprene Isolators ..............................................................................................................................11

FIGURE 3 - Neoprene Isolators ..............................................................................................................................12

FIGURE 4 - Spring Isolators ....................................................................................................................................13

FIGURE 5 - Model YD Chiller ..................................................................................................................................14

FIGURE 6 - Dimensions – J Compressor Units .....................................................................................................15

FIGURE 7 - Schematic of a Typical Piping Arrangement ........................................................................................19

FIGURE 8 - Typical Refrigerant Vent Piping ............................................................................................................19

FIGURE 9 - Control Panel Positioning ....................................................................................................................20

FIGURE 10 - Motor Connections (Electro Mechanical Starter Application).............................................................22

TABLE 1 - Evaporator - Condenser Shell Codes ....................................................................................................15

TABLE 2 - Approximate Unit Weight Including Motor .............................................................................................16

TABLE 3 - Approximate Unit Motor Weights ...........................................................................................................16

TABLE 4 - Motor Connections ................................................................................................................................22

JOHNSON CONTROLS 7

FORM 160.69-N1 ISSUE DATE: 7/31/2015

1

GENERALThis instruction describes the installation of a MOD-EL YD Liquid Chilling Unit. This unit is shipped as a single factory assembled, piped, wired package, re-quiring a minimum of field labor to make chilled water connections, condenser water connections, refrigerant atmospheric relief connections, and electrical power connections. (Refrigerant and oil charges shipped sep-arately unless optional condenser isolation valves are ordered.)

Chillers can also be shipped dismantled when required by rigging conditions, but generally it is more econom-ical to enlarge access openings to accommodate the factory assembled unit. Chillers shipped dismantled MUST be field assembled under the supervision of a Johnson Controls representative, but otherwise instal-lation will be as described in this instruction.

FIELD ASSEMBLED UNITS ONLYUse Form 160.69-NM3 in conjunction with this instal-lation instruction. This instruction will be furnished with all units that are to be field assembled. Extra cop-ies may be ordered from the Johnson Controls Publica-tion Distribution Center.

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.

The Johnson Controls Warranty may be voided if the following restrictions are not adhered to:

1. No valves or connections should be opened 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 rea-son 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.

SHIPMENTThe chiller may be ordered and shipped in any of the following forms:

Form 1 – Factory Assembled Unit, complete with mo-tor, refrigerant and oil charges.

1. The motor/compressor assembly mounted, with all necessary interconnecting piping assembled. OptiView™ Control Center is mounted on the unit. Complete unit factory leak tested, evacuated and charged with R-134A.

2. Miscellaneous material – Four (4) vibration isolation pads (or optional spring isolators and brackets).

Form 2 – Factory Assembled Unit, complete with motors (refrigerant and oil charges shipped separately).

1. 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.

2. Miscellaneous material – Four (4) vibration iso-lation pads (or optional spring isolators and brack-ets).

Form 3 – Drivelines Separate From Shells – Shipped as three major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then disman-tled for shipment. Compressor/motor assemblies re-moved from shells and skidded. Evaporator/condenser is not skidded.

All wiring integral with compressors are left on them, and all conduit is left on shell. All openings on compressors, oil separator, and shells are closed and charged with dry nitrogen (2 to 3 PSIG) (14-21 kPa).

Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil, isolators, solid state starters (option), etc.; refrigerant charge shipped separately.

SECTION 1 - INTRODUCTION

JOHNSON CONTROLS8

FORM 160.69-N1ISSUE DATE: 7/31/2015SECTION 1 - INTRODUCTION

Units shipped dismantled MUST be re-assembled by, or under the supervision of, a Johnson Controls representative. (See Form 160.69-NM3)

Form 7 – Split Shells – Shipped as four major assem-blies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Compressor/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, requiring no welding.

All wiring integral with compressors are left on them. All wiring harnesses on shells are removed. All open-ings on compressors and shells are closed and charged with dry nitrogen (2 to 3 psig) (14-21 kPa).

Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil isolators, solid state starter (option), etc.; refrigerant charge shipped separately.

Units shipped dismantled MUST be re-assembled by, or under the supervision of, a Johnson Controls representative. (See Form 160.69-NM3)

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 fur-nished by YORK.)

INSPECTION – DAMAGE – SHORTAGEThe 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.

Johnson Controls will not be responsible for any damage in shipment or at job site or loss of parts. (Refer to Shipping Dam-age Claims, Form 50.15-NM)

Rigging and lifting should only be done by a professional rigger in accordance with a written rigging 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.

JOHNSON CONTROLS 9

SECTION 1 - INTRODUCTIONFORM 160.69-N1 ISSUE DATE: 7/31/2015

1When received at the job site all containers should be opened and contents checked against the packing list. Any material shortage should be reported to Johnson Controls immediately. (Refer to Shipping Damage Claims, Form 50.15-NM)

CHILLER DATA PLATEA 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.

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.

RIGGINGThe 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 (4) lifting holes (two in each end) in the end sheets which should 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 1 on page 10.

Do not lift the unit with slings around motor/compressor assemblies or by means of eyebolts in the trapped 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 dimen-sions are given on pages 6 thru 8 as a guide in deter-mining the clearances required for rigging. Add 6" (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 ad-justments to allow for center of gravity adjustments.

Chain spreaders should be used to avoid contact with drive motors or other chiller parts.

LOCATIONYORK Chillers are furnished with vibration isola-tor 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 operat-ing weight and optional spring isolators are used.

Sufficient clearance to facilitate normal service and maintenance work must be provided all around and above the unit and particularly space provided at either end to permit cleaning or replacement of evaporator and condenser tubes – see CLEARANCE. A doorway or other suf-ficiently large opening properly located may be used. The chiller should be located in an indoor location where tempera-tures range from 40°F to 110°F (4.4°C to 43.3°C).

MOTORSThe YK open motor is air cooled. Check state, local and other codes for ventilation requirements.

FOUNDATION

A level floor, mounting pad or foundation must be pro-vided 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 – 18 ft. (5.5 m) (either end)

JOHNSON CONTROLS10


LD09014a

FIGURE 1 - RIGGING

JOHNSON CONTROLS 11


1NEOPRENE ISOLATORS

FIGURE 2 - NEOPRENE ISOLATORS

LD19590

LD19571a

SHELL

END SHEETDIA. HOLE

See Detail A

10"(254)

8"(203)

5"(127)

Y/Y - Y/Y - Up to 225,000 lbs. (102,060 Kgs)

9"(229)

LD19589

SHELL

END SHEETDIA. HOLE

See Detail A

10"(254)

8"(203)

5"(127)

X/X - X/X - Up to 130,000 lbs (58,967 Kgs)Z/Z - Z/Z - Up to 280,000 lbs (127,005 Kgs)A/A - A/A - Up to 280,000 lbs (127,005 Kgs)

MountingBracket

Pad

3/8”(10)

3/4”(19)

DETAIL A

JOHNSON CONTROLS12


NEOPRENE ISOLATORS

*

*

B

FIGURE 3 - NEOPRENE ISOLATORS

SHELL CODE UNIT WEIGHT DIM "A" DIM "B" DIM "C" DIM "D" QUANTITY

Y - Y Up to 190,000 lbs (86,184 Kgs)

12' 9" (3887)

8 x 1" from edge.

9" (229) 10" (254) 8

Z - Z Up to 240,000 lbs (108,862 Kgs)

13' 8" (4166) 11" (279) 10" (254) 8

A - A Up to 240,000 lbs (108,862 Kgs)

14' 8" (4471) 11" (279) 10" (254) 8

Approx weight including motor and 150# compact water boxes.

LD12643a

* Typical both ends.

JOHNSON CONTROLS 13


1SPRING ISOLATORS

FIGURE 4 - SPRING ISOLATORS

SHELL

3-SPRING ISOLATORS

ENDSHEET

CAP SCREW

ADJUSTING BOLT

16 1/4"(413)

3"

(76)

SHELL

12-SPRING ISOLATORS

ENDSHEET

CAP SCREW

ADJUSTING BOLT

6-1/4"(159)

UNIT WEIGHTx/x - x/x - Up to 115,000 lbs (52,163 Kgs)

UNIT WEIGHTY/Y - Y/Y - Up to 190,000 lbs (86,184 Kgs)Z/Z - Z/Z - Up to 240,000 lbs (108,862 Kgs)A/A - A/A - Up to 240,000 lbs (108,862 Kgs)

LD19580LD19591

JOHNSON CONTROLS14


FIGURE 5 - MODEL YD CHILLER

LD08634

OPTIVIEW™CONTROLCENTER

COMPRESSOR #1

EVAPORATOR

MOTOR #1 MOTOR #2

CONDENSER

COMPRESSOR #2

JOHNSON CONTROLS 15


1UNIT DIMENSIONS

TABLE 1 - EVAPORATOR - CONDENSER SHELL CODESSHELL CODE FT.–IN. X-X Y-Y Z-Z A-A

A 10'-7-1/2" (3,240) 11'-5" (3,480) 13'-6" (4,115) 14'-6-1/4" (4,426) 15'-5-1/4" (4,705)B 12'-0" (3,658) 12'-0" (3,658) 13'-0" (3,962) 13'-8" (4,166) 14'-2" (4,318)C 2'-8" (813) 2'-8" (813) 3'-5" (1,041) 3'-9" (1,143) 4'-0" (1,219)D 2'-5 1/2" (749) 2'-5 1/2" (749) 2'-11-1/2" (902) 3'-1-1/2" (955) 3'-4" (1,016)E 18'-0" (5,486) 18'-0" (5,486) 18'-0" (5,486) 18'-0" (5,486) 18'-0" (5,486)F 2'-0-3/4" (629) 2'-0-3/4" (629) 2'-1" (635) 2'-3" (686) 2'-3-9/16" (700)G 1'-4-3/4" (425) 1'-4-3/4" (419) 1'-4-1/4" (413) 1'-6-1/4" (464) 1'-6-7/8" (479)H 0'-11-11/16" (297) 0'-11-11/16" (297) 1'-2-5/8" (371) 1'-3-5/8" (397) 1'-4-1/4" (413)J 1'-7-5/8" (498) 1'-7-5/8" (498) 2'-1-1/2" (648) 2'-2" (660) 2'-1" (635)L 5'-1-1/2" (1562) 5'-1-1/2" (1,562) 6'-4 1/2" (1,943) 6'-10-1/2" (2,096) 7'-4" (2,235)

NOTES:1. All dimensions are approximate. Certified dimensions are

available on request.2. For compact water boxes (shown above), determine overall unit length by

adding 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.

FIGURE 6 - DIMENSIONS – J COMPRESSOR UNITS LD09012

D L CA

M 230 mm

B

FLOOR LINE

EVAPORATOR

CONDENSER

F

J

E G

H

MOTORS

COMPRESSORS

LD09013

SHIPPING WIDTH

ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR

TYPE OF CHILLER MOUNTING FT.-IN. MMNeoprene Pad Isolators 1-3/4" 44Spring Isolators 1" Deflection 1" 25Direct Mount 3/4" 19

JOHNSON CONTROLS16


UNIT WEIGHTS

TABLE 2 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR

SHELLS COMPRESSORSHIPPING WEIGHT (LBS.)

SHIPPING WEIGHT (KGS.)

OPERATING WEIGHT (LBS.)

OPERATING WEIGHT (KGS.)

EST. REFRIGERANT CHARGE (LBS.)

EST. REFRIGERANT CHARGE (KGS.)

X-X J1, J2 75,000 34,300 94,400 42,800 6,000 2,722Y-Y J3 116,000 52,727 146,000 66,364 7,925 3,602Z-Z J4 136,000 61,818 172,000 78,182 9,725 4,420A-A J5 155,000 70,455 197,000 89,545 10,875 4,943

Refer to product drawings for detailed weight information.

MOTOR WEIGHTS AND VOLTAGE

TABLE 3 - APPROXIMATE UNIT MOTOR WEIGHTSMEDIUM VOLTAGE

MOTOR CODE WEIGHT (LBS.)

WEIGHT (KGS.)

MOTOR CODE WEIGHT (LBS.)

WEIGHT (KGS.)60 HZ HP 50 HZ HP

CW 655 4,415 2,007 5CS 658 4,640 2,109CX 690 4,445 2,020 5CT 704 5,800 2,636CY 740 4,540 2,064 5CU 750 5,800 2,636CZ 790 4,640 2,109 5CV 800 5,800 2,636CA 845 5,800 2,636 5CW 850 6,800 3,091CB 900 5,800 2,636 5CX 900 6,800 3,091DA 1000 6,800 3,091 5DA 1000 7,050 3,205DB 1100 6,800 3,091 5DB 1100 7,300 3,318DC 1200 7,050 3,205 5DC 1200 7,300 3,318DD 1300 7,300 3,318 5DD 1300 7,300 3,318DE 1400 7,300 3,318 5DE 1400 7,500 3,409DF 1500 7,500 3,409 5DF 1500 7,500 3,409

5DG 1650 7,900 3,591DH 1750 7,500 3,409 5DH 1750 11,250 5,114DJ 2000 8,500 3,864 5DJ 2000 11,750 5,341

JOHNSON CONTROLS 17

FORM 160.69-N1 ISSUE DATE: 7/31/2015

2

SECTION 2 - INSTALLATION

RIGGING UNIT TO FINAL LOCATIONRig the unit to its final location on the floor or mount-ing pad, lift the unit (or shell assembly) by means of an overhead lift and lower the unit to its mounting posi-tion. (If optional shipping skids are used, remove them before lowering the chiller to its mounting position.)

At this point units shipped dismantled should be assembled under the supervi-sion of a Johnson Controls representative.

If evaporator is to be field insulated, the insulation should be applied to the evaporator before the unit is placed in position while the unit is in the lift position. Be sure unit is properly supported. (See Insulation on page 21)

LOCATING AND INSTALLING ISOLATOR PADS (Refer to Figure 2 on page 11 and Figure 3 on page 12)

The isolator pad mounts are to be located as shown in Figure 2 on page 11 and Figure 3 on page 12.

After the isolator pads have been placed into position on the floor, lower the chiller onto the pads. When the unit is in place, remove the rigging equipment and check that the unit is level. The unit should be level within 1/4" (6 mm) from one end to the other end and from front to the rear. If the chiller is not level within the amount specified, lift it and place shims between the isolation pad and the chiller tube sheets. (Shims furnished by the installer.) Lower unit again and re-check to see that it is level.

CHECKING THE ISOLATION PAD DEFLECTIONAll isolation pads should be checked for the proper de-flection while checking to see if the unit is level. Each pad should be deflected approximately 0.10 inchs (2.5 mm) to 0.20 inchs (5 mm). If an isolation pad is under-deflected, shims should be placed between the unit tube sheet and the top of the pad to equally deflect all pads.

LEVELING THE UNITThe longitudinal alignment of the unit should be checked by placing a level on the top center of the evap-orator shell. Transverse alignment should be checked by placing a level on top of the shell end sheets.

INSTALLING OPTIONAL SPRING ISOLATORS(Refer to Figure 4 on page 13)

When ordered, spring type isolator assemblies will be furnished with the unit. The 4 assemblies are identical and can be placed at any of the 4 corners of the unit.

While the unit is still suspended by the rigging, the iso-lators should be bolted to the unit by inserting the cap screws through the holes in the mounting bracket into the tapped hole in the top of the isolator leveling bolts. Then the unit can be lowered onto the floor.

The leveling bolts should now be rotated one (1) turn at a time, in sequence, until the unit end sheets are clear of the floor by the dimension shown in Figure 4 on page 13 and the unit is level. Check that the unit is level, both longitudinally and transversely (see Leveling the Unit). If the leveling bolts are not long enough to level unit due to an uneven or sloping floor or foundation, steel shims (grouted, if necessary) must be added be-neath the isolator assemblies as necessary.

After the unit is leveled, wedge and shim under each corner to solidly support the unit in this position while piping connections are being made, pipe hangers ad-justed and connections checked for alignment. Then the unit is filled with water and checked for leaks. The leveling bolts should now be finally adjusted until the wedges and shims can be removed. The unit should now be in correct level position, clear of the floor or foundation and without any effect from the weight of the piping.

PIPING CONNECTIONSAfter the unit is leveled (and wedged in place for op-tional spring isolators) the piping connections may be made; chilled water, condenser water and refrigerant relief. The piping should be arranged with offsets for flexibility, and adequately supported and braced inde-pendently of the unit to avoid strain on the unit and vibration transmission. Hangers must allow for align-ment of pipe. Isolators (by others) in the piping and hangers are highly desirable, and may be required by

JOHNSON CONTROLS18

FORM 160.69-N1ISSUE DATE: 7/31/2015SECTION 2 - INSTALLATION

specifications, in order to effectively utilize the vibra-tion isolation characteristics of the vibration isolation mounts of the unit.

Check for piping alignment – Upon completion of piping, a connection in each line as close to the unit as possible should be opened, by removing the flange bolts or coupling and checked for piping alignment. If any of the bolts are bound in their holes, or if the con-nection springs are out of alignment, the misalignment must be corrected by properly supporting the piping or by applying heat to anneal the pipe.

If the piping is annealed to relieve stress the inside of the pipe must be cleaned of scale before it is finally bolted in place.

EVAPORATOR AND CONDENSER WATER PIPINGThe evaporator and condenser liquid heads of chiller have nozzles which are grooved, suitable for welding 150 psig DWP flanges or the use of Victaulic cou-plings. Factory mounted flanges are optional.

The nozzles and water pass arrangements are furnished in accordance with the job requirements (see Product Drawings) furnished with the job. Standard units are designed for 150 psig DWP on the water side. If job requirements are for greater than 150 psig DWP, check the unit data plate before applying pressure to evapora-tor or condenser to determine if the chiller has provi-sions for the required DWP.

Inlet and outlet connections are identified by labels placed adjacent to each nozzle.

Chilled WaterForeign objects which could lodge in, or block flow through, the evaporator and condenser tubes must be kept out of the water circuit. All water piping must be cleaned or flushed before being connected to the chiller pumps, or other equipment.

Permanent strainers (supplied by others) are required in both the evaporator and condenser water circuits to protect the chiller as well as the pumps, tower spray nozzles, chilled water coils and controls, etc. The strainer must be installed in the entering chilled water line, directly upstream of the chiller.

Water piping circuits should be arranged so that the pumps discharge through the chiller, and should be controlled as necessary to maintain essentially constant chilled and condenser water flows through the unit at all load conditions.

If pumps discharge through the chiller, the strainer may be located upstream from pumps to protect both pump and chiller. (Piping between strainer, pump and chiller must be very carefully cleaned before start-up.) If pumps are remotely installed from chiller, strainers should be located directly upstream of the chiller.

Condenser Water CircuitFor proper operation of the unit, condenser refrigerant pressure must be maintained above evaporator pressure. If operating conditions will fulfill this requirement, no attempt should be made to control condenser water temperature by means of automatic valves, cycling of the cooling tower fan or other means, since chillers are designed to function satisfactorily and efficiently when condenser water is allowed to seek its own temperature level at reduced loads and off-peak seasons of the year. However, if entering condenser water temperature can go below the required minimum, (refer to 160.69-O2) condenser water temperature must be maintained equal to or slightly higher than the required minimum. Re-fer to Figure 7 on page 19 for typical water piping schematic.

JOHNSON CONTROLS 19

SECTION 2 - INSTALLATIONFORM 160.69-N1 ISSUE DATE: 7/31/2015

2

FIGURE 7 - SCHEMATIC OF A TYPICAL PIPING ARRANGEMENTLD08529

EVAPORATOR

FIGURE 8 - TYPICAL REFRIGERANT VENT PIPING

OIL PUMP HOUSING

LD09021

JOHNSON CONTROLS20

FORM 160.69-N1ISSUE DATE: 7/31/2015SECTION 2 - INSTALLATION

Stop ValvesStop valves may be provided (by others) in the evapo-rator and condenser water piping adjacent to the unit to facilitate maintenance. Thermometer wells and pres-sure taps should be provided (by others) in the piping as close to the unit as possible to facilitate operating check.

Flow SwitchesThermal type water flow switches are factory mounted in the chilled and condensed water nozzles and are fac-tory wired to the OptiView control panel. These solid-state flow sensors have a small internal heating ele-ment and use the cooling effect of the flowing fluid to sense when an adequate flow rate has been established.

Drain and Vent ValvesDrain and vent valves (by others) should be installed in the connections provided in the evaporator and con-denser liquid heads. These connections may be piped to drain if desired.

Checking Piping Circuits and Venting AirAfter the water piping is completed, but before any water box insulation is applied. Tighten and torque to maintain between 30 and 60 ft. lbs. (41 and 81 N·m) the nuts on the liquid head flanges. Gasket shrinkage and handling during transit cause nuts to loosen. If wa-ter pressure is applied before tightening is done, the gaskets may be damaged and have to be replaced. Fill the chilled and condenser water circuits, operate the pumps manually and carefully check the evaporator and condenser water heads and piping for leaks. Repair leaks as necessary.

Before initial operation of the unit both water circuits should be thoroughly vented of all air at the high points.

REFRIGERANT RELIEF PIPINGEach unit is equipped with pressure relief valves lo-cated on the condenser, on the evaporator, and on the oil pump housing for the purpose of quickly relieving excess pressure of the refrigerant charge to the atmo-sphere as a safety precaution in case of an emergency, such as fire.

Refrigerant relief vent piping (by others), from the re-lief valves to the outside of the building, is required by code in most areas and should be installed on all chillers. The vent line should be sized in accordance with the ANSI/ASHRAE-15, or local code. The vent

line must include a dirt trap in the vertical leg to in-tercept and permit clean out and to trap any vent stack condensation. The piping MUST be arranged to avoid strain on the relief valves, using a flexible connection, if necessary.

UNIT PIPINGCompressor lubricant piping and system external piping are factory installed on all units shipped as-sembled. On units shipped dismantled, the following piping should be completed under the supervision of the Johnson Controls representative: (1) the lubricant piping to oil sump and oil evaporator and system oil return connections using material furnished. See Form 160.69-NM3.

CONTROL PANEL POSITIONING (See Figure 9 on page 20)

The OptiView™ Control Center is placed in a position above the evaporator for shipping. To move the control center into position for operation, proceed as follows:

1. While supporting the control center, remove the hardware between the support arms and the evap-orator.

2. Swing the control center into a vertical position.

3. Slide the control center down the guide rails to the proper position. Tighten securely.

4. Discard unused hardware. Control Wiring

SUPPORTARMS

PANELTRACK

FIGURE 9 - CONTROL PANEL POSITIONINGLD03826

JOHNSON CONTROLS 21

SECTION 2 - INSTALLATIONFORM 160.69-N1 ISSUE DATE: 7/31/2015

CONTROL WIRINGOn units shipped disassembled, after installation of the control center, control wiring must be completed be-tween unit components and control center, solid state starter, or variable speed drive, when used, using wir-ing harness furnished. Refer to Form 160.69-N3.

Field wiring connections for commonly encountered control modifications (by others) if required, are shown on Form 160.69-PW1.

No deviations in unit wiring from that shown on drawings furnished shall be made without prior approval of the John-son Controls representative.

POWER WIRING

Oil Pump – 3 Phase StarterSeparate wiring or a fused disconnect switch should be supplied by the installer and connected to the vari-able speed oil pump panel. DO NOT make final power connections to the chiller until approved by a Johnson Controls representative.

Remote Electro-Mechanical starters for the chiller must be furnished in accor-dance with Johnson Controls Standard (Product Drawing Form 160.69-PA5.1) to provide the features necessary for the starter to function properly with the YORK control system.

Each chiller unit is furnished for a specific electrical power supply as stamped on the Unit Data Plate, which also details the motor connection diagrams.

To insure proper motor rotation the starter power input and starter to motor connec-tions must be check with a phase sequence indicator in the presence of the Johnson Controls representative.

DO NOT cut wires to final length or make final connections to motor terminals or starter power input terminals until ap-proved by the Johnson Controls repre-sentative.

YD Motors (Electro-Mechanical Starter)Figure 10 on page 22 shows the power wiring hook-up for Motor Connections. (Refer to Wiring Labels in Motor Terminal Box for hook-up to suit motor voltage and amperage.) Motor leads are furnished with a crimp type connection having a clearance hole for a 3/8" bolt, motor terminal lugs are not furnished.

The YD Chiller has two motors which must be con-nected to the proper starter. When viewed from the chiller control panel, motor #1 is on the left and motor #2 is on the right.

INSULATION(See Product Drawings Form 160.52-PA1)

DO NOT field insulate until the unit has been leak tested under the supervision of a Johnson Controls representative.

Insulation of the type specified for the job, or mini-mum thickness to prevent sweating of 30°F (-1°C) surfaces should be furnished (by others) and applied to the evaporator shell, end sheets, liquid feed line to flow chamber, compressor suction connection, and evaporator liquid heads and connections. The liquid head flange insulation must be removable, to allow head removal for the tube maintenance. Details of ar-eas to be insulated are given on the Product Drawing.

Units are furnished factory anti-sweat insulated on or-der at additional cost. This includes all low tempera-ture surfaces except the two (2) cooler liquid heads.

JOHNSON CONTROLS22


INSTALLATION CHECK – REQUEST FOR START-UP SERVICEThe services of a Johnson Controls representative will be furnished to check the installation and supervise the initial start-up and operation on all chillers installed within the Continental United States.

After the unit is installed, piped and wired as described in this Instruction, but before any attempt is made to start the unit, the Johnson Controls District Office should be advised so that the start-up service, included in the contract price, can be scheduled. Notification to the Johnson Controls office should be by means of In-stallation Check List and Request, Form 160.69-CL1, in triplicate.

TABLE 4 - MOTOR CONNECTIONS3 PHASE MOTOR

VOLTAGE50 / 60 HZ

MOTOR RATED LOAD AMPS CT RADIO

200:1 350:1 700:1 1400:1

200-600 65-111A 112-224A 225-829A 830-1790A

2300-416011-18C

124-264A 265-518A19-37B

38-123A

NOTES:1. Requires passing motor lead thru current transformer (CT) once

before connecting to power supply.2. Requires passing motor lead thru CT twice before connecting to

power supply.3. Requires passing motor lead thru CT three times before connect-

ing to power supply

COMPRESSOR MOTOR FIELD CONNECTION DIAGRAM

FIGURE 10 - MOTOR CONNECTIONS (ELECTRO MECHANICAL STARTER APPLICATION)

LD00710

JOHNSON CONTROLS 23

FORM 160.69-N1 ISSUE DATE: 7/31/2015

NOTES

P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2015 www.johnsoncontrols.com ALL RIGHTS RESERVEDForm 160.69-N1 (715)Issue Date: July 31, 2015 Supersedes: 160.69-N1 (912)

Documents

MODEL YD (STYLE A) R-134A (COOLING ONLY) WITH OPTIVIEW ...cgproducts.johnsoncontrols.com/yorkdoc/160.69-n1.pdf · MANUAL DESCRIPTION FORM NUMBER YD Unit Field Reassembly Instructions