Johnson Controls York YK Series Installation Manual
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Johnson Controls York YK Series Installation Manual

Centrifugal liquid chiller
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Model YK (Style G) Centrifugal Liquid
Chiller
R-134a, R-513A, or R-1234ze Refrigerant, with OptiView
Control Center for Electromechanical Starter, Solid State
Starter, and Variable Speed Drive
Installation Guide
Issue Date: 2021-10-22
Form Number: 160.75-N1 (1021)
Supersedes: 160.75-N1 (919)

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  • Page 1 Model YK (Style G) Centrifugal Liquid Chiller R-134a, R-513A, or R-1234ze Refrigerant, with OptiView Control Center for Electromechanical Starter, Solid State Starter, and Variable Speed Drive Installation Guide Form Number: 160.75-N1 (1021) Issue Date: 2021-10-22 Supersedes: 160.75-N1 (919)
  • Page 2 Model YK (Style G) Centrifugal Liquid Chiller...

  • Page 3: Table Of Contents

    Contents General safety guidelines..........................5 C o n t e n t s Safety symbols............................5 Changeability of this document......................6 Revision notes...............................6 Associated literature............................7 Nomenclature............................7 Introduction..............................8 General..............................8 Field assembled units only........................8 Shipment..............................9 Form 1 - Factory assembled unit, with motor, refrigerant, and oil charges......... 9 Form 2 - Factory assembled unit, with motor only..................
  • Page 4 Refrigerant relief piping........................26 Control panel positioning........................27 Control wiring............................27 Power wiring............................28 Chiller with electromechanical starter.....................28 Oil pump - three-phase starter......................28 YK motors with electromechanical starter....................28 Chiller with solid state starter or variable speed drive................28 Insulation..............................29 Installation check - request for start-up service................30 P and Q compressor units (standard)....................32 P and Q compressor units (metric)....................

  • Page 5: General Safety Guidelines

    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.

  • Page 6: Changeability Of This Document

    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 or problems resulting from improper connections to the controls or application of improper control signals.

  • Page 7: Associated Literature

    Associated literature Table 1: List of associated literature Manual description Form number Installation checklist and start-up request 160.75-CL1 Unit start-up checklist 160.75-CL2 Installation and reassembly - unit 160.75-N3 Installation - MV VSD - 2300 VAC – 6600 VAC 160.00-N6 Installation - MV VSD - 10 kV – 13.8 kV 160.00-N8 Wiring Diagrams - field connections - unit-mounted SSS, MV SSS, or remote mounted MV SSS, MV EMS 160.75-PW1...

  • Page 8: Introduction

    Continental United States. CAUTION The Johnson Controls Warranty may be voided if the following restrictions are not adhered to: No valves or connections should be opened under any circumstances because such action will result in loss of the factory nitrogen charge.

  • Page 9: Shipment

    When more than one chiller is involved, the major parts of each unit are marked to prevent mixing assemblies. Piping and wiring drawings are provided by Johnson Controls. Form 1 - Factory assembled unit, with motor, refrigerant, and oil charges The unit is shipped as one major assembly.

  • Page 10: Form 3 - Driveline Seperated From Shells

    Note: Units shipped dismantled must be re-assembled by, or under the supervision of, a Johnson Controls representative. Refer to Installation and Reassembly - Unit (Form 160.75-N3). Form 7 - Split shells The unit is shipped as three major assemblies: •...
  • Page 11 Miscellaneous packaging of tubing, water temperature controls, wiring, isolators, and similar items. The unit is shipped with a nitrogen charge. Refrigerant shipped separately in appropriate cylinders. See Figure 2. Model YK (Style G) Centrifugal Liquid Chiller...

  • Page 12: Form 10 - Unit Separate From Variable Speed Drive

    50.15-NM. When the unit is 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 plate...

  • Page 13: Long-Term Storage

    Long-term storage About this task: To protect the waterbox of pressure vessels from rusting, the tube side (water side) is purged and charged with nitrogen to a positive pressure of 5 psig to 7 psig. Do not break the seal or remove closures until the unit is ready for set up. Relieve pressure according to the procedure shown in Figure 3.
  • Page 14 Figure 3: Long term storage - tube side Model YK (Style G) Centrifugal Liquid Chiller...

  • Page 15: Shipment Form 2/3/7/9

    To relieve pressure from the unit, complete the following steps: Check the working space to make sure that it is open and has good ventilation. If the space is not well ventilated, connect a hose or pipe to the valve (Item 5) and route it to outside. Open the valve slowly until it is fully opened.

  • Page 16: Rigging

    Rigging Figure 4: Rigging warning DANGER 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 depends on job specific factors, such as the rigging equipment available and site needs. A professional rigger must determine the rigging and lifting method to be used.

  • Page 17: Location

    The YK open motor is air cooled. Check state, local, and other codes for ventilation requirements. Foundation A level floor, mounting pad, or foundation not provided by Johnson Controls, capable of supporting the operating weight of the unit. Model YK (Style G) Centrifugal Liquid Chiller...

  • Page 18: Clearance

    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: 14 ft. (4.3 m) (either end) 16 ft (4.9 m) on shell codes Q-Q, N-N, R-R, X-T and X-X. 18 ft (5.5 m) on shell code S-S, S-V, Z-Z.
  • Page 19 Figure 6: Neoprene isolators, in. (mm) Model YK (Style G) Centrifugal Liquid Chiller...
  • Page 20 Figure 7: Spring isolators, in. (mm) Model YK (Style G) Centrifugal Liquid Chiller...
  • Page 21 Figure 8: Spring isolators continued, in. (mm) Model YK (Style G) Centrifugal Liquid Chiller...

  • Page 22: Installation

    Note: At this point units shipped dismantled should be assembled under the supervision of a Johnson Controls representative. If the 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.

  • Page 23: Piping Connections

    Hangers must allow for alignment of pipe. Isolators, not supplied by Johnson Controls, in the piping and hangers can be required by specifications, in order to effectively utilize the vibration isolation characteristics of the vibration isolation mounts of the unit.

  • Page 24: Condenser Water Circuit

    Waterbox drain and vent valves Drain and vent valves are not provided by Johnson Controls. If using drain and vent valves install them in the connections provided in the evaporator and condenser liquid heads. These connections can be piped to drain.

  • Page 25: Checking Piping Circuits And Venting Air

    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. Refer to Installation and Reassembly - Unit (Form 160.75-N3).

  • Page 26: Refrigerant Relief Piping

    Refrigerant relief vent piping is not supplied by Johnson Controls. 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 intercept and permit clean out and to trap any vent stack condensation.

  • Page 27: Control Panel Positioning

    Refer to Installation and Reassembly - Unit (Form 160.75-N3). Field wiring connections for commonly encountered control modifications not by Johnson Controls, if required, are shown on Wiring Diagrams – Field Control Modifications (Form 160.75-PW4).

  • Page 28: Power Wiring

    CAUTION Do not cut wires to final length or make final connections to motor terminals or starter power input terminals until approved by the Johnson Controls representative. YK motors with electromechanical starter Motor leads are furnished with a crimp type connection having a clearance hole for a 3/8 in. (9.5 mm) bolt, motor terminal lugs are not furnished.

  • Page 29: Insulation

    Insulation CAUTION Do not field insulate until the unit has been leak tested under the supervision of the Johnson Controls representative. Insulation, not supplied by Johnson Controls, of the type specified for the job, or minimum thickness to prevent sweating of 30°F (-1°C) surfaces can be furnished and applied to the evaporator shell, end sheets, liquid feed line to flow chamber, compressor suction connection, and evaporator liquid heads and connections.

  • Page 30: Installation Check - Request For Start-Up Service

    After the unit is installed, piped and wired as described in these instructions, 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. Use the Installation Checklist and Start-up Request (Form 160.75-CL1).
  • Page 31 Table 3: Available compressor, shell or motor combinations for YK Mod G heat recovery Compressor codes Evaporator codes Condenser codes Motor codes 60 Hz 50 Hz CP, CQ, CR, CS BV, BW, BX CF-CT 5CC-5CO EP, EQ, ER, ES, ET IV, IW, IX EF-ET 5EC-5EO...

  • Page 32: P And Q Compressor Units (Standard)

    P and Q compressor units (standard) Figure 13: P and Q compressor unit dimensions (ft in.) Table 5: Additional operating height clearance to floor Type of chiller mounting M (in.) Neoprene pad isolators 1 3/4 Spring isolators 1 in. deflection Direct mount Table 6: Q3 compressor, evaporator - condensor shell codes Series...
  • Page 33 Table 9: Q6 compressor, evaporator - condenser shell codes Series E–E F–F 7 ft 0 in. 7 ft 0 in. 8 ft 3 in. 8 ft 3 in. 1 ft 7 1/2 in. 1 ft 7 1/2 in. 1 ft 5 1/2 in. 1 ft 5 1/2 in.

  • Page 34: P And Q Compressor Units (Metric)

    P and Q compressor units (metric) Figure 14: P and Q compressor unit dimensions (mm) Table 13: Additional operating height clearance Type of chiller mounting M (mm) Neoprene pad isolators Spring isolators 25 mm deflection Direct mount Table 14: Q3 compressor, evaporator - condenser shell codes Series A–A (mm) C–C (mm)
  • Page 35 Table 17: Q6 compressor, evaporator - condenser shell codes Series E–E (mm) F–F (mm) 2,134 2,134 2,515 2,515 3,658 4,877 Table 18: P7, Q7 compressor, evaporator - condenser shell codes Series E–E (mm) E–I (mm) F–F (mm) 1,880 2,178 1,880 2,299 2,642 2,299...

  • Page 36: H Compressor Units (Standard)

    H compressor units (standard) Figure 15: H compressor unit dimensions (ft in.) Table 21: Additional operating height clearance to floor Type of chiller mounting M (in.) Neoprene pad isolators 1 3/4 Spring isolators 1 in. deflection Direct mount Table 22: H9 compressor evaporator - condenser shell codes I-K, K–K K–O M–M...

  • Page 37: H Compressor Units (Metric)

    H compressor units (metric) Figure 16: H compressor unit dimensions (mm) Table 23: Additional operating height clearance Type of chiller mounting M (mm) Neoprene pad isolators Spring isolators 25mm deflection Direct mount Table 24: H9 compressor evaporator - condenser shell codes I-K, K–K (mm) K–O (mm) M–M (mm)

  • Page 38: K Compressor Units (Standard)

    K compressor units (standard) Figure 17: K compressor unit dimensions (ft in.) Table 25: Additional operating height clearance Type of chiller mounting M (in.) Neoprene pad isolators 1 3/4 Spring isolators 1 in. deflection Direct mount Table 26: K1 compressor, evaporator - condenser shell I-K, K–K M–M N–N...
  • Page 39 Table 29: K4 compressor, evaporator - condenser shell codes R–R S–S S–V X–T X–X 9 ft 9 in. 9 ft 9 in. 10 ft 3 in. 10 ft 10 in. 11 ft 3 in. 11 ft 11 in. 11 ft 11 in. 12 ft 4 in.

  • Page 40: K Compressor Units (Metric)

    K compressor units (metric) Figure 18: K compressor unit dimensions (mm) Table 31: Additional operating height clearance Type of chiller mounting M (mm) Neoprene pad isolators Spring isolators 25 mm deflection Direct mount Table 32: K1 compressor, evaporator - condenser shell codes I-K, K–K (mm) M–M (mm) N–N (mm)
  • Page 41 Table 35: K4 compressor, evaporator - condenser shell codes R–R (mm) S–S (mm) S–V (mm) X–T (mm) X–X (mm) 2,972 2,972 3,124 3,302 3,429 3,632 3,632 3,759 3,759 3,759 4,877 5,486 5,486 4,877 4,877 Table 36: K7 compressor, evaporator - condenser shell codes W–W (mm) Z–Y (mm) Z–Z (mm)

  • Page 42: Evaporator Compact Waterboxes - Ft In. (Mm)

    Evaporator compact waterboxes - ft in. (mm) Figure 19: One pass evaporator dimensions Table 37: Two pass evaporators, shell codes ft in. (mm) Dimensions I,J,K,L R,S,W 1 ft 2 1/4 1 ft 3 in. 1 ft 3 1/2 1 ft 3 3/4 1 ft 5 1/2 1 ft 11 5/8 1 ft 11 5/8...

  • Page 43: Condenser Compact Waterboxes - Ft In. (Mm)

    Figure 21: Three pass evaporator dimensions Table 39: Three pass evaporators, shell codes in. (mm) Dimensions I,J,K,L P,S,W 1 ft 2 1/4 1 ft 3 in. 1 ft 3 1/2 1 ft 3 3/4 1 ft 5 1/2 1 ft 11 5/8 1 ft 11 5/8 2 ft 0 5/8 2 ft 1 3/4...
  • Page 44 Figure 23: Two pass condensers dimensions Table 42: Two pass condensers, shell codes ft in. (mm) Dimensions J,K,L T,V,W 1 ft 1 7/8 1 ft 1 7/8 1 ft 3 in. 1 ft 4 in. 1 ft 2 7/8 1 ft 4 7/8 1 ft 7 3/8 1 ft 7 1/2 1 ft 9 3/4...

  • Page 45: Evaporator - Compact Waterboxes - A Through L Evaporators - Ft In. (Mm)

    See note in P and Q compressor units (standard). Evaporator - compact waterboxes - A through L evaporators - ft in. (mm) Figure 25: Dimensions of evaporator compact waterboxes A through L evaporators ft in. (mm) Table 46: Dimensions of compact waterboxes - 150 psi round Condenser shell code Nozzle pipe size in.
  • Page 46 Note: Standard water nozzles are furnished as welding stub-outs with grooves, allowing the option of welding, flanges, or use of grooved couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1/16 in. (1.6 mm) raised face), water flanged nozzles are optional (add 1/2 in.

  • Page 47: Evaporator - Compact Waterboxes - M Through Z Evaporators - Ft In. (Mm)

    Evaporator - compact waterboxes - M through Z evaporators - ft in. (mm) Figure 26: Dimensions of evaporator compact waterboxes M through Z evaporators ft in. (mm) Model YK (Style G) Centrifugal Liquid Chiller...
  • Page 48 Table 47: Dimensions of compact waterboxes - 150 psi rectangular Evaporator shell code Nozzle pipe size in. (mm) Evaporator nozzle dimensions ft in. (mm) Number of passes 1-pass 2-pass 3-pass 18 in. 14 in. 12 in. 2 ft 4 1/2 3 ft 0 in.

  • Page 49: Condenser - Compact Waterboxes - A Through Q - Standard - Ft In. (Mm)

    Condenser - compact waterboxes - A through Q - standard - ft in. (mm) Figure 27: Dimensions of condenser compact waterboxes - A through Q - standard (mm) Table 48: Dimensions of compact waterboxes - 150 psi round Condenser shell code Nozzle pipe size in.

  • Page 50: Condenser - Compact Waterboxes - R Through Z - Standard - Ft In. (Mm)

    Table 48: Dimensions of compact waterboxes - 150 psi round Condenser shell code Nozzle pipe size in. (mm) Condenser nozzle dimensions ft in. (mm) Number of passes 1-pass 2-pass 3-pass J,K,L 16 in. 10 in. 10 in. 1 ft 8 in. 3 ft 0 in.

  • Page 51: Condenser - Heat Recovery Compact Waterboxes - Standard - Ft In. (Mm)

    Table 49: Dimensions of compact waterboxes - 150 psi round Condenser shell code Nozzle pipe size in. (mm) Condenser nozzle dimensions ft in. (mm) Number of passes 1-pass 2-pass 3-pass 20 in. 18 in. 14 in. 2 ft 3 1/2 3 ft 10 1/2 2 ft 9 1/2 4 ft 11 1/2...

  • Page 52: Evaporator - Nozzle Arrangements - Standard - Ft In. (Mm)

    Table 50: Dimensions of heat recovery compact waterboxes - 150 psi rectangular Condenser shell code Nozzle pipe size in. (mm) Condenser nozzle dimensions ft in. (mm) Number of passes 1, 2 or 3 pass 2 pass 10 in. 8 in. 6 in.
  • Page 53 Table 51: Evaporator nozzle dimensions Evaporator shell code Evaporator nozzle dimensions ft in. (mm) 1-pass 2-pass 3-pass I,J,K,L 2 ft 9 5/16 1 ft 3 1/2 in. 2 ft 9 5/16 2 ft 0 5/8 1 ft 3 1/2 in. 2 ft 9 5/16 1 ft 3 1/2 in.

  • Page 54: Condenser - Nozzle Arrangements - Standard - Ft In. (Mm)

    Condenser - nozzle arrangements - standard - ft in. (mm) Figure 31: Dimensions of condenser - nozzle arrangements - standard (mm) Table 52: Condenser nozzle dimensions Condenser shell code Condenser nozzle dimensions ft in. (mm) 1-pass 2-pass 3-pass 1 ft 9 in. 0 ft 9 7/8 in.
  • Page 55 Table 52: Condenser nozzle dimensions Condenser shell code Condenser nozzle dimensions ft in. (mm) 1-pass 2-pass 3-pass 2 ft 8 in. 1 ft 3 in. 2 ft 4 in. 1 ft 2 1/4 in. 1 ft 1 in. 2 ft 4 in. 1 ft 1 in.

  • Page 56: Evaporator Marine Waterbox Nozzle Arrangements - Ft In. (Mm)

    Evaporator marine waterbox nozzle arrangements - ft in. (mm) Figure 32: Dimensions of evaporator marine waterboxes ft in. (mm) Table 53: Dimensions of marine waterboxes - 150 psi round Evaporator Nozzle pipe size in. (mm) 1-pass 2-pass 3-pass shell code Number of passes 8 in.
  • Page 57 Table 53: Dimensions of marine waterboxes - 150 psi round Evaporator Nozzle pipe size in. (mm) 1-pass 2-pass 3-pass shell code Number of passes 18 in. 14 in. 12 in. 2 ft 5 1/2 6 ft 0 1/8 6 ft 0 1/8 1 ft 3 in.

  • Page 58: Condenser Marine Waterbox Nozzle Arrangements - Ft In. (Mm)

    Condenser marine waterbox nozzle arrangements - ft in. (mm) Figure 33: Dimensions of condenser marine waterboxes ft in. (mm) Table 54: Dimensions of marine waterboxes - 150 psi round Condenser Nozzle pipe 1-pass 2-pass 3-pass shell code size in. (mm) Number of passes 10 in.

  • Page 59: Condenser Marine Waterboxes Heat Recovery Units - Main (Tower) Circuit Only

    Table 54: Dimensions of marine waterboxes - 150 psi round Condenser Nozzle pipe 1-pass 2-pass 3-pass shell code size in. (mm) Number of passes 20 in. 16 in. 14 in. 2 ft 1 6 ft 2 3/8 6 ft 2 3/8 2 ft 4 2 ft 5 6 ft 2 3/8...
  • Page 60 Table 56: 2 pass condenser nozzle options Cooling water Table 57: 3 pass condenser nozzle options Cooling water Table 58: Dimensions of 1 pass marine waterboxes - 150 psi (rectangular) - ft in. (mm) Condenser shell code Nozzle pipe size in. (mm) 10 in.

  • Page 61: Weights

    Table 59: Dimensions of 2 pass marine waterboxes - 150 psi (rectangular) - ft in. (mm) Condenser shell Nozzle pipe size in. (mm) code 10 in. 8 in. 6 in. 1 ft 8 7/8 in. 2 ft 3 7/16 in. 1 ft 1 15/16 2 ft 4 3/4 in.
  • Page 62 Table 61: Approximate unit weight including motor for flooded evaporator units - lb (kg) Shells Compressor Shipping weight lb (kg) Operating weight lb (kg) Estimate refrigerant charge lb (kg) 28,530 (12,941) 36,000 (16,330) 2,925 (1,327) 31,100 (14,107) 36,200 (16,420) 3,248 (1,473) 34,483 (15,641) 44,776 (20,310) 3,260 (1,479)
  • Page 63 Add the following evaporator marine waterbox weights to the standard unit weights shown in Table 61 and Table 62 Table 63: Evaporator marine waterbox weights - lb (kgs). Evaporator Shipping weight Operating weight code Increase - lb (kg) Increase - lb (kg) 1-pass 2-pass 3-pass...
  • Page 64 Table 64: Condenser marine waterbox weights - lb (kg). Shipping weight Operating weight Condenser code Increase - lb (kg) Increase - lb (kg) 1-pass 2-pass 3-pass 1-pass 2-pass 3-pass 5,196 2,565 5,204 9,161 4,012 8,219 V,T,W (2,357) (1,163) (2,361) (4,155) (1,820) (3,728) 3,641...

  • Page 65: Unit Conversion

    Unit conversion The following factors can be used to convert from English to the most common SI Metric values. Table 65: SI metric conversion Measurement Multiply English unit By factor To obtain metric unit Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW) Power Horsepower...
  • Page 66 © 2021 Johnson Controls. 5000 Renaissance Drive, New Freedom, York, PA 17349, USA. Subject to change without notice. All rights reserved.

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