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

Johnson Controls York YK H Series Installation Manual

Field reassembly for form 3, 7, 9, and 10 shipment, r-134a, r-513a, and r-1234ze (cooling only) with graphic control center for electromechanical starter, solid state starter, and variable speed drive
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Model YK Chillers (Style H) Field
Reassembly for Form 3, 7, 9, and 10
Shipment
R-134a, R-513A, and R-1234ze (Cooling Only) with Graphic
Control Center for Electromechanical Starter, Solid State
Starter, and Variable Speed Drive
Installation Guide
Issue Date: 2023-12-22
Form Number: 160.76-N3 (1223)
Supersedes: 160.76-N3 (1222)

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  • Page 1 Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment R-134a, R-513A, and R-1234ze (Cooling Only) with Graphic Control Center for Electromechanical Starter, Solid State Starter, and Variable Speed Drive Installation Guide Form Number: 160.76-N3 (1223) Issue Date: 2023-12-22 Supersedes: 160.76-N3 (1222)
  • Page 2 Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • Page 3: Table Of Contents

    Contents General safety guidelines..........................5 C o n t e n t s Safety symbols............................5 Wiring warning............................6 Refrigerant warning..........................6 Changeability of this document......................6 Associated literature..........................7 Nomenclature............................8 Shipping and reassembly..........................9 Forms of shipment..........................10 Form 3: Driveline separate from shells....................10 Form 7: Split shells.............................
  • Page 4 Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • 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 might 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: Wiring Warning

    All wiring must be in accordance with the published specifications of Johnson Controls and must be performed only by a qualified electrician. Johnson Controls will not be responsible for damage or problems resulting from incorrect connections to the controls or application of incorrect control signals.

  • Page 7: Associated Literature

    Wiring Diagram - Field Connections Model YK Chillers (Style H) with Low Voltage 160.76-PW7 Variable Speed Drive Application Data - A2L Refrigerant Supplement for Johnson Controls Chillers 160.00-AD10 Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • Page 8: Nomenclature

    Nomenclature Note: * Refer to YK Engineering Guide (Form 160.76-EG1) for shell, motor, and compressor combinations. Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • Page 9: Shipping And Reassembly

    Shipping and reassembly This section provides information for the reassembly of the Model YK Chiller when it is shipped disassembled, for example with shipping Form 3, 7, 9, and 10. Note: The relevant personnel must reassemble the chiller under the supervision of a Johnson Controls representative.

  • Page 10: Forms Of Shipment

    Refer to the Unit Installation Instructions (Form 160.76-N1) for more details. Note: When more than one chiller is involved, the major parts of each unit are marked to prevent mixing of assemblies. Piping and wiring drawings are provided by Johnson Controls. Form 9: Unit separate from variable speed drive The unit is shipped as the following two major assemblies: •...

  • Page 11: Form 10: Unit Separate From Variable Speed Drive

    Form 10: Unit separate from variable speed drive The unit is shipped as the following two major assemblies: • Chiller unit • Variable speed drive The unit is first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment.

  • Page 12: Inspection, Damage, And Shortage

    Report any damage or signs of possible damage to the transportation company immediately for their inspection. Note: Johnson Controls is not responsible for any damage in shipment or at job site or loss of parts. Refer to Shipping Damage Claims (Form 50.15-NM).
  • Page 13 Figure 2: Long term storage - tube side Item Description Tag warning Dennison 8E Gauge press 2 dia. 0-30 Tag GlvSt wire speed Bush pipe 3/4 - 14 NPTE X Valve, transducer 1/4 NPTE X Flange cover Gasket Victaulic coupling Sealing cap Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • Page 14: Shipment Form 2, 3, 7, And 9

    Shipment Form 2, 3, 7, and 9 All openings on the compressor, shells including evaporator and condenser, and oil reservoir are closed and charged with nitrogen to a pressure of 2 psig to 3 psig. WARNING To remove the closures, sealing caps, or sealing plug under pressure is extremely dangerous, and may cause severe injury or death to the operator or people on-site.

  • Page 15: Reassembly

    Reassembly Use the following step-by-step procedure to reassemble the chiller. Refer to the Unit Installation Instructions (Form 160.76-N1) for other instructions. Reassembling Form 7 shipment For units with falling film evaporators with the liquid inlet on top, bolt the liquid line to either one of the shells to ensure that it is in the correct location before joining the two shells.
  • Page 16 b. Fasten compressor and motor assembly with the correct hardware. Note: Do not tighten the bolts until all connections are made to the compressor. Bolt the suction line between the compressor and the cooler using the correct gaskets and hardware. Install the fill piece or isolation valve between the compressor and the condenser using the correct gaskets and hardware.

  • Page 17: Reassembling Form 9 And Form 10 Reassembly

    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 the motor design. Reassembling Form 9 and Form 10 reassembly Attach the vibration isolators to the unit.
  • Page 18 Reconnect the motor winding thermistor shielded cable conductors in the variable speed drive at TB4. Refer to Unit Wiring and Field Control Modifications (Form 160.76-PW2). Reconnect all unit wiring and harnesses. Refer to Unit Wiring and Field Control Modifications (Form 160.76-PW2). Pressure test the unit.

  • Page 19: Q3 To Q8 Compressors With Falling Film

    Q3 to Q8 compressors with falling film Figure 6: Form 3 shipment for Q3 to Q8 compressors with falling film Note: Ring gaskets not used for elastomer-lined flange faces at the isolation valve. Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 20 Callout Description Callout Description Hot gas valve Ring gaskets Discharge isolation valve Condenser Discharge valve Evaporator Suction line Callout Description Callout Description From condenser Liquid line To evaporator Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 21 Figure 7: Form 7 shipment for Q3 to Q8 compressors with falling film Note: Ring gaskets not used for elastomer-lined flange faces at the isolation valve. Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 22 Callout Description Callout Description Hot gas valve Ring gaskets Isolation valve Condenser Suction line Evaporator Callout Description Callout Description From condenser Liquid line To evaporator Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • Page 23: Q3 To Q8 Compressors, System Piping

    Q3 to Q8 compressors, system piping Figure 8: System piping for Q3 to Q8 compressors Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 24 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 Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • Page 25: P8, P9, And H9 Compressors With Falling Film

    P8, P9, and H9 compressors with falling film Figure 9: Form 3 shipment for P8 to P9 and H9 compressors with falling film Note: Ring gaskets not used for elastomer-lined flange faces at the isolation valve. Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 26 Callout Description Callout Description Hot gas valve Oil pump panel Isolation valve Control panel Discharge spool Condenser Suction line Evaporator Ring gaskets Callout Description Callout Description From condenser Liquid line To evaporator Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 27 Figure 10: Form 7 shipment for P8 to P9 and H9 compressors with falling film Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 28 Note: Ring gaskets not used for elastomer-lined flange faces at the isolation valve. Callout Description Callout Description Hot gas valve Oil pump control panel Discharge isolation valve Control panel Discharge spool Condenser Suction line Evaporator Ring gaskets Callout Description Callout Description From condenser Liquid line...

  • Page 29: P8, P9, And H9 Compressors, System Piping

    P8, P9, and H9 compressors, system piping Figure 11: System piping for P8,P9, and H9 compressors Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 30 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 Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • Page 31: K Compressors

    K compressors Figure 12: Form 3 shipment for K compressors Note: Ring gaskets not used for elastomer-lined flange faces at the isolation valve. Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 32 Callout Description Callout Description Hot gas valve Ring gaskets Suction line Oil pump panel Isolation valve Control panel Discharge spool Condenser Oil line Evaporator Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 33 Figure 13: Form 7 shipment for K compressors Note: Ring gaskets not used for elastomer-lined flange faces at the isolation valve. Callout Description Callout Description Hot gas valve Ring gaskets Isolation valve Liquid line Suction line Condenser Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 34 Callout Description Callout Description Discharge spool Evaporator Oil line Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 35 Figure 14: System piping for K compressors Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...
  • Page 36 Callout Description Callout Description 3/8 in. liquid injection line 3/8 in. oi return line 1 in. oil sump vent line 1 in. refrigerant return line 3/4 in. oil supply line Model YK Chillers (Style H) Field Reassembly for Form 3, 7, 9, and 10 Shipment...

  • Page 37: Weights

    Weights Table 3: Compressor weights Compressor Compressor only D Flange only Total model 1835 2272 1030 1835 2272 1030 2162 2616 1186 2162 2616 1186 2075 2524 1145 1974 2418 1097 2776 1259 3281 1488 2897 1314 3408 1546 4271 1937 4989 2262...
  • Page 38 Table 4: WEG - Low voltage premium efficiency motor weights 60 Hz 50 Hz Code Weight (lb) Weight (kg) Code Weight (lb) Weight (kg) 1367 1367 1610 1610 1653 1653 1764 1764 2227 1012 2227 1012 2293 1042 2293 1042 2293 1042 2293...
  • Page 39 Table 5: 60 Hz - Medium voltage (2300, 3300, 4000, 4160) motor weights Code Weight (lb) Weight (kg) 6950 3159 6950 3159 6950 3159 7420 3373 7420 3373 7420 3373 7714 3506 7714 3506 7714 3506 7714 3506 7714 3506 7714 3506 10531...
  • Page 40 Table 7: 60 Hz - Low voltage variable speed drives Rigging weight Shipping weight Model number VSD270RKFT-40 1,038 1,338 VSD351RKFT-46 1,038 1,338 VSD385RKFT-40 1,038 1,338 VSD424RKFT-58 1,038 1,338 VSD503RKFT-46 1,226 1,560 VSD608RKFT-40 1,582 1,902 VSD608RKFT-42 1,226 1,902 VSD608RKFT-58 1,226 1,560 VSD790RKFT-46 1,582 1,902...
  • Page 41 Table 8: 50 Hz - Low voltage variable speed drives Rigging weight Shipping weight Model number VSD292RKFT-50 1,058 1,358 VSD292RKFT-68 1,058 1,358 VSD419RKFT-50 1,246 1,546 VSD419RKFT-68 1,246 1,546 VSD658RKFT-43 1,602 1,952 VSD658RKFT-50 1,602 1,952 VSD704RKFT-68 1,602 1,952 VSD868RKFT-50 1,730 1,900 VSD914RKFT-43 1,730 1,900...
  • Page 42 Note: The weights provided in the following table are intended to be a general reference only. The weights are based on the heaviest anticipated unit combinations as of December 2020. There are numerous factors that can impact these values based on the chiller options selected at the time of the final unit rating.
  • Page 43 The evaporator marine waterbox weights are to be added to the standard unit weights shown in Table Table 10: Approximate evaporator marine waterbox weights, lb (kg) Unit Compressor Shipping weight Operating weight evaporator increase, lb (kg) increase, lb (kg) code 1-pass 2-pass 3-pass...
  • Page 44 The condenser marine waterbox weights are to be added to the standard unit weights shown in Table Table 11: Approximate condenser marine waterbox weights, lb (kg) Unit Compressor Shipping weight Operating weight increase, lb (kg) increase, lb (kg) 1-pass 2-pass 3-pass 1-pass 2-pass...

  • Page 45: Unit Conversion

    Unit conversion The following factors can be used to convert from English to the most common SI Metric values. Table 12: SI metric conversion Measurement Multiply English unit By factor To obtain metric unit Capacity Tons refrigerant effect (ton) 3.516 Kilowatts (kW) Power Horsepower (hp)
  • Page 46 © 2023 Johnson Controls. 5000 Renaissance Drive, New Freedom, York, PA 17349, USA. Subject to change without notice. All rights reserved.

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