Johnson Controls YORK YK Series Installation Instructions Manual
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Johnson Controls YORK YK Series Installation Instructions Manual

Centrifugal liquid chillers with optiview control center for electromechanical starter, solid state starter, and variable speed drive
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CENTRIFUGAL LIQUID CHILLERS
INSTALLATION INSTRUCTIONS
Supersedes: 160.75-N1 (1217)
Form 160.75-N1 (419)
MODEL YK (STYLE G)
R-134a or R-513A
WITH OPTIVIEW™ CONTROL CENTER
FOR ELECTROMECHANICAL STARTER,
SOLID STATE STARTER, AND VARIABLE SPEED DRIVE
Issue Date:
April 15, 2019

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  • Page 1 CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS Supersedes: 160.75-N1 (1217) Form 160.75-N1 (419) MODEL YK (STYLE G) R-134a or R-513A WITH OPTIVIEW™ CONTROL CENTER FOR ELECTROMECHANICAL STARTER, SOLID STATE STARTER, AND VARIABLE SPEED DRIVE Issue Date: April 15, 2019...
  • Page 2 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.
  • Page 3 FORM 160.75-N1 ISSUE DATE: 04/15/2019 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for con- regarding the applicability of these documents, rig- tinuous product improvement, the information con- ging, lifting, and operating/service personnel should tained in this document is subject to change without verify whether the equipment has been modified and notice.
  • Page 4 ISSUE DATE: 04/15/2019 NOMENCLATURE – STYLE (Design Level) MOTOR CODE POWER SUPPLY – for 60 Hz 5 for 50 Hz COMPRESSOR CODE* CONDENSER CODE* EVAPORATOR CODE* * Refer to YK Engineering Guide (Form 160.75-EG1) for Shell/Motor/Compressor combinations. MODEL* JOHNSON CONTROLS...

  • Page 5: Table Of Contents

    Condenser – Nozzle Arrangements – Standard - Ft-In (mm) ............... 39 Evaporator Marine Waterbox Nozzle Arrangements - Ft-In (mm) ..............40 Condenser Marine Waterbox Nozzle Arrangements - Ft-In (mm) ..............41 Condensers Marine Waterboxes Heat Recovery Units - Main (Tower) Circuit Only ........42 JOHNSON CONTROLS...
  • Page 6 TABLE 3 - Approximate Unit Weight Including Motor for Hybrid Falling Film Evaporator Units - Lb (kg) ....45 TABLE 4 - Evaporator Marine Waterbox Weights - Lb (kg) ...................45 TABLE 5 - Condenser Marine Waterbox Weights - Lb (kg) ...................46 TABLE 6 - SI Metric Conversion ..........................47 JOHNSON CONTROLS...

  • Page 7: Section 1 - Introduction

    ISSUE DATE: 04/15/2019 SECTION 1 - INTRODUCTION GENERAL The services of a Johnson Controls representative will This manual describes the installation of a YORK YK Mod "G" Centrifugal Chiller. This unit can be shipped be furnished to check the installation, supervise the...

  • Page 8: Shipment

    • The motor/compressor assembly mounted, assembled by, or under the supervision of, with all necessary interconnecting piping a Johnson Controls representative. Refer assembled. OptiView™ Control Center is to Installation and Reassembly - Unit mounted on the unit. Complete unit fac- (Form 160.75-N3)

  • Page 9: Inspection - Damage - Shortage

    The unit is first factory assembled, refrigerant piped, diately for their inspection. Johnson Controls will not wired and leak tested; then dismantled for shipment. be responsible for any damage in shipment, at job site, Evaporator/condenser is not skidded.

  • Page 10: Figure 3 - Long Term Storage - Tube Side

    Valve, Transducer 1/4 NPTE X Flange Cover Gasket Nozzle without flanges Victaulic Coupling (Lines 4 in. through 12 in.) Sealing Cap Nozzle without flanges LD29123 (Lines 14 in. through 24 in.) FIGURE 3 - LONG TERM STORAGE - TUBE SIDE JOHNSON CONTROLS...
  • Page 11 Before trying to remove the closures, caps, or plugs on compressor and shells, relieve the pressure in compressor, shells, or system that are charged with nitrogen by opening the valves on them slowly until fully open. JOHNSON CONTROLS...

  • Page 12: Rigging

    Lift only using holes shown in ging. Add 6" (15 cm) to overall height for optional Figure 4 on page 13. skidded unit. JOHNSON CONTROLS...

  • Page 13: Location

    40°F to 110°F (4.4°C to 43.3°C). * 16 ft (4.9 meters) on shell codes Q-Q, N-N, R-R, X-T and X-X. ** 18 ft (5.5 meters) on shell code S-S, S-V, Z-Z. *** 22 ft (6.7 meters) on shell code W-W. JOHNSON CONTROLS...

  • Page 14: Figure 5 - Neoprene Isolators

    See Detail A See Detail A 3/4” (19) 9" (229) LD19571a LD12642a LD19578 UNIT WEIGHT 100,465 - 130,000 Lbs UNIT WEIGHT UP TO 200,928 Lbs DETAIL A (45,570 - 58,967 Kgs) (UP TO 91,332 Kgs) FIGURE 5 - NEOPRENE ISOLATORS JOHNSON CONTROLS...

  • Page 15: Figure 6 - Spring Isolators

    6-SPRING ISOLATORS 9-SPRING ISOLATORS LD19579 LD19419 UNIT WEIGHT UNIT WEIGHT 35,010 Lbs UP TO 58,349 Lbs 58,350 Lbs. UP TO 89,340 Lbs (15,881 Kgs UP TO 26,467 Kgs) (26,468 Kgs UP TO 40,525 Kgs) FIGURE 6 - SPRING ISOLATORS JOHNSON CONTROLS...

  • Page 16: Figure 7 - Spring Isolators

    12-SPRING ISOLATORS 3-SPRING ISOLATORS LD19580 LD19581 UNIT WEIGHT UNIT WEIGHT 89,341 Lbs UP TO 115,000 Lbs 115,000 Lbs. UP TO 190,000 Lbs (40,526 Kgs UP TO 52,163 Kgs) (52,163 Kgs UP TO 86,183 Kgs) FIGURE 7 - SPRING ISOLATORS JOHNSON CONTROLS...

  • Page 17: Section 2 - Installation

    Johnson Controls representative. bolt(s). Then the unit can be lowered onto the floor. The leveling bolts should now be rotated one (1) turn at...

  • Page 18: Evaporator And Condenser Water Piping

    TOWER BYPASS VALVE C = COMPRESSOR (IF NECESSARY) M = MOTOR STRAINER CONDENSER FLOW SWITCH COOLING TOWER COOLING PUMP UNIT EVAPORATOR COOLING UNIT CODEPAK STRAINER CHILLED WATER PUMP LD08529 FIGURE 8 - SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT JOHNSON CONTROLS...

  • Page 19: Unit Piping

    Refer to Installation ing element and use the cooling effect of the flowing and Reassembly - Unit (Form 160.75-N3). fluid to sense when an adequate flow rate has been established. JOHNSON CONTROLS...

  • Page 20: Refrigerant Relief Piping

    TO PERMIT PIPING DISASSEMBLY FLEXIBLE CONNECTOR CONDENSATION TRAP CONDENSER DUAL RELIEF SEE NOTE VALVES EVAPORATOR NOTE: SHELLS MAY BE FURNISHED WITH ONE OR TWO RELIEF VALVES, DEPENDING ON SHELL SIZE. LD03863 FIGURE 9 - TYPICAL REFRIGERANT VENT PIPING JOHNSON CONTROLS...

  • Page 21: Control Panel Positioning

    CONTROL WIRING starter power input terminals until ap- On units shipped disassembled, after installation of the proved by the Johnson Controls repre- control center, control wiring must be completed be- sentative. tween unit components and control center, solid state...

  • Page 22: Insulation

    DO NOT field insulate until the unit has been leak tested under the supervision of A chiller equipped with a factory mounted Solid State the Johnson Controls representative. Starter or Variable Speed Drive does not require wir- ing to the compressor motor. The motor power wiring is factory connected to the Solid State Starter or Vari- able Speed Drive.

  • Page 23: Installation Check - Request For Start-Up Service

    ISSUE DATE: 04/15/2019 INSTALLATION CHECK – REQUEST FOR START-UP SERVICE The services of a Johnson Controls representative will start the unit, the Johnson Controls District Office be furnished to check the installation and supervise the should be advised so that the start-up service, included initial start-up and operation on all chillers installed in the contract price, can be scheduled.
  • Page 24 QB, QD, QF, Q5, Q7, Q8 QQ, QR, QS, Q2, Q3, Q4 NB, ND, NF, N5, N7, N8, N9 NP, NQ, NR, NS, N2, N3, N4 DA-DJ 5DA-5DH FA-FD 5FA-5FB QD, QF, QH, Q5, Q7, Q8, Q9 QQ, QR, QS, Q2, Q3, Q4 JOHNSON CONTROLS...

  • Page 25: P And Q Compressor Units (Standard)

    3. Water nozzles can be located on either end of unit. Add 1/2" (13 mm) to nozzle length for flanges connections. 4. To determine overall height, add 7/8" (22 mm) for isolators. 5. Use of motors with motor hoods may increase overall unit dimensions. FIGURE 12 - DIMENSIONS – P AND Q COMPRESSOR UNITS (FT–IN) JOHNSON CONTROLS...

  • Page 26: P And Q Compressor Units (Metric)

    3. Water nozzles can be located on either end of unit. Add 13 mm (1/2 inch) to nozzle length for flanges connections. 4. To determine overall height, add 22 mm (7/8 inch) for isolators. 5. Use of motors with motor hoods may increase overall unit dimensions. FIGURE 13 - DIMENSIONS – P AND Q COMPRESSOR UNITS (MM) JOHNSON CONTROLS...

  • Page 27: H Compressor Units (Standard)

    3. Water nozzles can be located on either end of unit. Add 1/2" (13 mm) to nozzle length for flanges connections. 4. To determine overall height, add 7/8" (22 mm) for isolators. 5. Use of motors with motor hoods may increase overall unit dimensions. FIGURE 14 - DIMENSIONS – H COMPRESSOR UNITS (FT–IN) JOHNSON CONTROLS...

  • Page 28: H Compressor Units (Metric)

    3. Water nozzles can be located on either end of unit. Add 13 mm (1/2 inch) to nozzle length for flanges connections. 4. To determine overall height, add 22 mm (7/8 inch) for isolators. 5. Use of motors with motor hoods may increase overall unit dimensions. FIGURE 15 - DIMENSIONS – H COMPRESSOR UNITS (MM) JOHNSON CONTROLS...

  • Page 29: K Compressor Units (Standard)

    3. Water nozzles can be located on either end of unit. Add 1/2" (13 mm) to nozzle length for flanges connections. 4. To determine overall height, add 7/8" (22 mm) for isolators. 5. Use of motors with motor hoods may increase overall unit dimensions. FIGURE 16 - DIMENSIONS – K COMPRESSOR UNITS (FT–IN) JOHNSON CONTROLS...

  • Page 30: K Compressor Units (Metric)

    3. Water nozzles can be located on either end of unit. Add 13 mm (1/2 inch) to nozzle length for flanges connections. 4. To determine overall height, add 22 mm ( 7/8 inch) for isolators. 5. Use of motors with motor hoods may increase overall unit dimensions. FIGURE 17 - DIMENSIONS – K COMPRESSOR UNITS (MM) JOHNSON CONTROLS...

  • Page 31: Evaporator Compact Waterboxes - Ft-In (Mm)

    1'-2 1/4" 1'-3" 1'-3 1/2" 1'-3 3/4" 1'-5 1/2" 1'-11 5/8" 1'-11 5/8" 2'-0 5/8" 2'-1 3/4" (362) (381) (394) (400) (445) (600) (600) (625) (654) See Notes on page 25. FIGURE 18 - DIMENSIONS – EVAPORATOR COMPACT WATERBOXES JOHNSON CONTROLS...

  • Page 32: Condenser Compact Waterboxes - Ft-In (Mm)

    1'-5" 1'-7 1/2" 1'-4 3/4" 1'-9 1/2" 1'-6" 1'-10 1/4" 1'-8" 2'-4 3/4" 1'-10 1/2" (470) (432) (495) (425) (546) (457) (565) (508) (730) (572) See Notes on page 25. FIGURE 19 - DIMENSIONS – CONDENSER COMPACT WATERBOXES JOHNSON CONTROLS...

  • Page 33: Evaporators - Compact Waterboxes - A Through L Evaporators - Ft-In (Mm)

    4. Connected piping should allow for removal of compact waterboxes for tube access and cleaning. 5. Add dimension "M" as shown on the unit dimensions page for the appropriate isolator type. 6. Standard 150 PSI design pressure boxes shown. FIGURE 20 - DIMENSIONS – EVAPORATOR COMPACT WATERBOXES A THROUGH L EVAPORATORS JOHNSON CONTROLS...

  • Page 34: Evaporators - Compact Waterboxes - M Through Z Evaporators - Ft-In (Mm)

    3'-9 3/4" 2'-8 3/4" 4'-10 3/4" 0'-11" 2'-2 7/8" 5'-4 5/8" (508) (457) (356) (902) (1162) (832) (1492) (279) (683) (1641) See Notes on page 33. FIGURE 21 - DIMENSIONS – EVAPORATOR COMPACT WATERBOXES M THROUGH Z EVAPORATORS JOHNSON CONTROLS...

  • Page 35: Condenser - Compact Waterboxes - Standard - Ft-In (Mm)

    20" 16" 14" 2'-1 1/4" 3'-8" 2'-7" 4'-9" 2'-7" 4'-9" (508) (406) (356) (641) (1118) (787) (1,448) (787) (1,448) See Notes on page 33. FIGURE 22 - DIMENSIONS – CONDENSER COMPACT WATERBOXES - A THROUGH Q -STANDARD (MM) JOHNSON CONTROLS...

  • Page 36: Figure 23 - Dimensions - Condenser Compact Waterboxes - R Through Z - Standard (Mm)

    4'-1 1/4" 2'-9 1/4" 5'-5 1/4" 2'-9 1/4" 5'-5 1/4" (610) (508) (406) (813) (1251) (845) (1,657) (845) (1,657) See Notes on page 33. FIGURE 23 - DIMENSIONS – CONDENSER COMPACT WATERBOXES - R THROUGH Z - STANDARD (MM) JOHNSON CONTROLS...

  • Page 37: Condenser - Heat Recovery Compact Waterboxes - Standard - Ft-In (Mm)

    (894) (1,595) (314) 24" 20" 16" 3'-4" 3'-3 15/16" 6'-3 7/8" 1'-5 7/8" (609) (508) (406) (1,016) (1,014) (1,927) (454) See Notes on page 33. FIGURE 24 - DIMENSIONS – CONDENSER HEAT RECOVERY COMPACT WATERBOXES - STANDARD (MM) JOHNSON CONTROLS...

  • Page 38: Evaporator - Nozzle Arrangements - Standard - Ft-In (Mm)

    4. Condenser water must enter the waterbox through the bottom connection for proper operation of the sub-cooler to achieve rated performance. 5. Add dimension "M" as shown on pages per unit dimensions page for the appropriate isolator type. FIGURE 25 - DIMENSIONS – EVAPORATOR NOZZLE ARRANGEMENTS - STANDARD (MM) JOHNSON CONTROLS...

  • Page 39: Condenser - Nozzle Arrangements - Standard - Ft-In (Mm)

    5. Add dimension "M" as shown on pages per unit dimensions page for the appropriate isolator type. 6. Heat recovery units offer marine waterbox option for tower (lower) bundle only. FIGURE 26 - DIMENSIONS – CONDENSER NOZZLE ARRANGEMENTS - STANDARD (MM) JOHNSON CONTROLS...

  • Page 40: Evaporator Marine Waterbox Nozzle Arrangements - Ft-In (Mm)

    20" 18" 14" 2'-11 1/2" 6'-11 1/2" 6'-11 1/2" 2'-1 3/4" 3'-2 1/8" 6'-11 1/2" 1'-8 1/4" 3'-2 1/8" (508) (457) (356) (902) (2121) (2121) (654) (968) (2121) (514) (968) FIGURE 27 - DIMENSIONS – EVAPORATOR MARINE WATERBOXES JOHNSON CONTROLS...

  • Page 41: Condenser Marine Waterbox Nozzle Arrangements - Ft-In (Mm)

    24" 20" 16" 2'-8" 7'-2" 7'-2" 2'-7 3/4" 2'-11 1/2" 7'-2" 2'-7 3/4" 2'-11 1/2" (610) (508) (406) (813) ( 2184) ( 2184) ( 806) (902) (2184 ) (806) (902) FIGURE 28 - DIMENSIONS – CONDENSER MARINE WATERBOXES JOHNSON CONTROLS...

  • Page 42: Condensers Marine Waterboxes Heat Recovery Units - Main (Tower) Circuit Only

    U nit C om pressor End M otor End C om pressor End M otor End C om pressor End M otor End C om pressor End M otor End LD18181 CONDENSER COOLING WATER NOZZLE OPTIONS 3 PASS JOHNSON CONTROLS...
  • Page 43 (254) (723) (1122) (760) (932) (991) 24" 20" 16" 3'-4" 4'-4 5/16" 2'-7 7/16" 4'-2 1/16" 4'-6 13/16" (610) (508) (406) (1016) (1328) (798) (1271) (1392) NOTE: Add dimension "M" as shown on page 27 or page 28. JOHNSON CONTROLS...

  • Page 44: Table 2 - Approximate Unit Weight Including Motor For Flooded Evaporator Units - Lb (Kg)

    80,500 (36,515) 105,000 (47,628) 6,275 (2,846) NOTE: Refrigerant charge quantity and weights will vary based on tube count, configuration, and chiller performance. Use for reference only. Refer to YORKworks Performance Page or chiller nameplate for actual charge requirement. JOHNSON CONTROLS...

  • Page 45: Table 3 - Approximate Unit Weight Including Motor For Hybrid Falling Film Evaporator Units - Lb (Kg)

    (2,858) 5,982 3,281 5,724 10,854 5,277 9,442 (2,713) (1,488) (2,596) (4,923) (2,394) (4,283) 4,804 2,700 4,912 8,522 4,516 8,187 R,S,W (2,179) (1,225) (2,228) (3,866) (2,048) (3,714) 7,088 3,660 7,244 11,552 5,507 11,243 (3,215) (1,660) (3,286) (5,240) (2,498) (5,100) JOHNSON CONTROLS...

  • Page 46: Table 5 - Condenser Marine Waterbox Weights - Lb (Kg)

    (1,820) (3,728) 3,641 1,893 3,609 5,350 2,556 4,770 (1,652) (859) (1,637) (2,427) (1,159) (2,164) 5,840 2,953 5,380 9,900 4,649 8,100 (2,649) (1,339) (2,440) (4,491) (2,109) (3,674) 9,094 4,762 9,058 13,326 6,524 12,409 (4,125) (2,160) (4,109) (6,045) (2,959) (5,465) JOHNSON CONTROLS...

  • Page 47: Table 6 - Si Metric Conversion

    (°C), subtract 32° and multiply by 5/9 or 0.5556. Example: (45.0°F - 32°) x 0.5556 = 7.22°C To convert a temperature range (i.e., a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556. Example: 10.0°F range x 0.5556 = 5.6 °C range JOHNSON CONTROLS...
  • Page 48 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2019 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.75-N1 (419) Issue Date: April 15, 2019 Supersedes: 160.75-N1 (1217)

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