Johnson Controls YORK YK Installation Manual
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Johnson Controls YORK YK Installation Manual

Johnson Controls YORK YK Installation Manual

Chiller field reassembly for form 3 and form 7
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Model YK (Style G) Chiller Field
Reassembly for Form 3 and Form 7
R-134a, R-513A, or R-1234ze (Cooling Only)
Installation Guide
Issue Date: 2022-05-25
Form Number: 160.75-N3.EN.CE (522)
New Release

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  • Page 1 Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7 R-134a, R-513A, or R-1234ze (Cooling Only) Installation Guide Form Number: 160.75-N3.EN.CE (522) Issue Date: 2022-05-25 New Release...
  • Page 2 Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...

  • 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 Associated literature..........................6 Nomenclature............................6 Shipping and reassembly..........................7 Forms of shipment..........................7 Form 3 – Driveline separate from shells....................7 Form 7 – Split shells............................. 8 Inspection, damage, and shortage......................
  • Page 4 Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...

  • 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: Shipping And Reassembly

    Form 3 – Driveline separate from shells Form 7 – Split shells. Note: Chillers must be field reassembled under the supervision of a Johnson Controls representative. For instructions on installing the unit, refer to the Installation guide (Form 160.75-N1.EN.CE). Figure 1: Front view of assembled unit...

  • Page 8: Form 7 - Split Shells

    Refer to the Installation guide (Form 160.75-N1.EN.CE) for more details. Note: When more than one chiller is involved, the major parts of each unit are marked to prevent mixing of assemblies. Piping and wiring drawings are provided by Johnson Controls. Inspection, damage, and shortage Check the unit shipment on arrival to confirm that all major pieces, boxes, and crates are received.

  • Page 9: Data Plates

    Evaporator 5/8 in. x 2 1/2 in. bolts, lock washers, and hex nuts Note: Johnson Controls are not be responsible for any damage in shipment or at job site or loss of parts. When you receive the containers at the job site, open and check the contents against the packing list.

  • Page 10: Long-Term Storage

    Long-term storage About this task: 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 0.5 barg to 1 barg. Do not break the seal or remove closures until ready for set up. Use the following procedure to relieve pressure.

  • Page 11: Shipment Form 3 And 7

    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. Check that the working space is open and has good ventilation.

  • Page 12: Reassembly

    Reassembly Use the following procedure to reassemble the chiller. Refer to the Installation guide (Form 160.75- N1.EN.CE) for other instructions. Form 7 shipment only About this task: The following steps related to shipment form 7. When complete, move to Form 3 and form 7 shipments.
  • Page 13 14. Evacuate and charge with refrigerant. Refer to Operation and maintenance (Form 160.75- O1.EN.CE). 15. Complete installation and finally level the unit according to the Installation guide (Form 160.75- N1.EN.CE). Figure 4: Rigging – compressor and 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.

  • Page 14: Q3 To Q7 And P7 Compressors Without Falling Film

    Q3 to Q7 and P7 compressors without falling film Figure 5: Form 3 shipment, Q3 to Q7 and P7 compressors without falling film Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 15 Callout Description Callout Description Condenser Discharge line Evaporator Suction line Hot gas valve Ring gasket Discharge isolation valve Note: • Do not use ring gaskets for elastomer-lined flange faces at the isolation valve. • The hot gas valve and discharge isolation valve are available if they are furnished. Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 16 Figure 6: Form 7 shipment, Q3 to Q7 and P7 compressors without falling film Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 17 Callout Description Callout Description Condenser Suction line Evaporator Ring gasket Hot gas valve Liquid line valve Isolation valve Note: • Do not use ring gaskets for elastomer-lined flange faces at the isolation valve. • The hot gas valve, the isolation valve, and the liquid line valve are available if furnished. Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...

  • Page 18: Q3 To Q7 And P7 Compressors With Falling Film

    Q3 to Q7 and P7 compressors with falling film Figure 7: Form 3 shipment, Q3–Q7 and P7 compressors with falling film Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 19 Callout Description Callout Description Condenser Discharge isolation valve Evaporator Discharge line Liquid line Suction line Hot gas valve Ring gaskets Note: • Do not use ring gaskets for elastomer-lined flange faces at the isolation valve. • The hot gas valve and the discharge isolation valve are present if furnished. Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 20 Figure 8: Form 7 shipment, Q3 to Q7 and P7 compressors with falling film Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 21 Callout Description Callout Description Condenser Isolation valve Evaporator Suction line Liquid line Ring gaskets Hot gas valve Note: • Do not use ring gaskets used for elastomer-lined flange faces at the isolation valve. • The hot gas valve and the isolation valve are available if furnished. Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...

  • Page 22: Q3 To Q7 And P7 Compressors, System Piping

    Q3 to Q7 and P7 compressors, system piping Figure 9: System piping, Q3 to Q7 and P7 compressors Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 23 Callout Description Callout Description 3/8 in. oil return line 3/8 in. oil return line 3/4 in. oil supply line Suction line 3/4 in. oil return line 3/8 in. compressor to VSOP panel Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...

  • Page 24: K Compressors

    K compressors Figure 10: Form 3 shipment, K compressors Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 25 Callout Description Callout Description Condenser Discharge spool Evaporator Oil line Hot gas valve Ring gaskets Suction line Oil pump panel Isolation valve Control panel Note: • Do not use ring gaskets for elastomer-lined flange faces at the isolation valve. • The hot gas valve and the isolation valve are available if furnished.
  • Page 26 Figure 11: Form 7 shipment, K compressors Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 27 Callout Description Callout Description Condenser Discharge spool Evaporator Oil line Hot gas Ring gaskets Isolation valve Liquid line Suction line Note: • Do not use ring gaskets for elastomer-lined flange faces at the isolation valve. • Hot gas and the isolation valve are available if furnished. Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 28 Figure 12: System piping, K compressors Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 29 Callout Description Callout Description 3/8 in. liquid injection line 3/8 in. oil return line 1 in. oil sump vent line 1 in. refrigerant return line 3/4 in. oil supply line Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...

  • Page 30: P8, P9, And H9 Compressors Without Falling Film

    P8, P9, and H9 compressors without falling film Figure 13: Form 3 shipment, P8,P9, and H9 compressors without falling film Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 31 Callout Description Callout Description Condenser Suction line Evaporator Ring gaskets Hot gas valve Oil pump panel Isolation valve Control panel Discharge spool Note: • Do no use ring gaskets for elastomer-lined flange faces at the isolation valve. • The hot gas valve and the isolation valve are available if furnished. Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 32 Figure 14: Form 7 shipment, P8, P9, and H9 compressors without falling film Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 33 Callout Description Callout Description Condenser Suction line Evaporator Ring gaskets Hot gas valve Oil pump control Discharge isolation valve Control panel Discharge spool Liquid line valve Note: • Do no use ring gaskets for elastomer-lined flange faces at the isolation valve. •...

  • Page 34: P8, P9, And H9 Compressors With Falling Film

    P8, P9, and H9 compressors with falling film Figure 15: Form 3 shipment, P8, P9, and H9 compressors with falling film Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 35 Callout Description Callout Description Condenser Discharge spool Evaporator Suction line Liquid line Ring gaskets Hot gas valve Oil pump panel Isolation valve Control panel Note: • Do no use ring gaskets for elastomer-lined flange faces at the isolation valve. • The hot gas valve and the isolation valve are available if furnished.
  • Page 36 Figure 16: Form 7 shipment, P8, P9, and H9 compressors with falling film Model YK (Style G) Chiller Field Reassembly for Form 3 and Form 7...
  • Page 37 Callout Description Callout Description Condenser Discharge spool Evaporator Suction line Liquid line Ring gaskets Hot gas valve Oil pump control panel Discharge isolation valve Control panel Note: • Do no use ring gaskets for elastomer-lined flange faces at the isolation valve. •...

  • Page 38: P8, P9, And H9 Compressor, System Piping

    P8, P9, and H9 compressor, system piping Figure 17: System piping, P8, P9, and H9 compressors Callout Description Callout Description 3/8 in. oil return line 3/8 in. oil return line 3/4 in. oil supply line Suction line 3/4 in. oil return line 3/8 in.

  • Page 39: Unit Conversion

    Unit conversion The following factors can be used to convert from English to the most common SI metric values. Table 1: 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 40 © Johnson Controls 2022. 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349. Subject to change without notice. All rights reserved.

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