York YK Installation Instructions Manual
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York YK Installation Instructions Manual

York YK Installation Instructions Manual

Centrifugal liquid chillers
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CENTRIFUGAL LIQUID CHILLERS
INSTALLATION INSTRUCTIONS
Supersedes: 160.76-N1 (419)
Form 160.76-N1 (619)
MODEL YK (STYLE H)
R-134a or R-513A
WITH OPTIVIEW CONTROL CENTER
FOR ELECTROMECHANICAL STARTER,
SOLID STATE STARTER, AND VARIABLE SPEED DRIVE
Issue Date:
June 21, 2019

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  • Page 1 CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS Supersedes: 160.76-N1 (419) Form 160.76-N1 (619) MODEL YK (STYLE H) R-134a or R-513A WITH OPTIVIEW CONTROL CENTER FOR ELECTROMECHANICAL STARTER, SOLID STATE STARTER, AND VARIABLE SPEED DRIVE Issue Date: June 21, 2019...
  • Page 2 FORM 160.76-N1 ISSUE DATE: 06/21/2019 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or During installation, operation maintenance or service, death to themselves and people at the site. individuals may be exposed to certain components or This document is intended for use by owner-authorized conditions including, but not limited to: refrigerants,...
  • Page 3 FORM 160.76-N1 ISSUE DATE: 06/21/2019 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 NOMENCLATURE SYSTEM NOMENCLATURE – MODEL* STYLE (Design Level) EVAPORATOR CODE* MOTOR CODE CONDENSER CODE* COMPRESSOR CODE* POWER SUPPLY – for 60 Hz 5 for 50 Hz LD28273 * Refer to YK Engineering Guide for (Form 160.76-EG1) Shell/Motor/Compressor combinations. JOHNSON CONTROLS...

  • Page 5: Table Of Contents

    FORM 160.76-N1 ISSUE DATE: 06/21/2019 TABLE OF CONTENTS SECTION 1 - INTRODUCTION ..........................7 General ................................7 Field Assembled Units Only ..........................7 Shipment ................................8 Inspection – Damage – Shortage ........................9 Chiller Data Plate ............................. 9 Long-Term Storage ............................9 Rigging ................................
  • Page 6 FORM 160.76-N1 ISSUE DATE: 06/21/2019 LIST OF FIGURES FIGURE 1 - Model YK Chiller ............................7 FIGURE 2 - Variable Speed Drive Rigging ........................9 FIGURE 3 - Long Term Storage - Tube Side ......................10 FIGURE 4 - Rigging..............................13 FIGURE 5 - Neoprene Isolators ..........................14 FIGURE 6 - Neoprene Isolator Supports without/with Skids ...................15...

  • Page 7: Section 1 - Introduction

    SECTION 1 - INTRODUCTION GENERAL The services of a Johnson Controls representative will This manual describes the installation of a YORK YK Mod "H" Centrifugal Chiller. This unit can be shipped be furnished to check the installation, supervise the initial start-up and operation of all chillers installed...

  • Page 8: Shipment

    FORM 160.76-N1 SECTION 1 - INTRODUCTION ISSUE DATE: 06/21/2019 • Do not charge the compressor with oil. • Compressor/motor assembly removed from shells and skidded. Evaporator/condenser is • Do not charge the unit with refrigerant. not skidded. • Do not attempt to start the system. •...

  • Page 9: Inspection - Damage - Shortage

    FORM 160.76-N1 SECTION 1 - INTRODUCTION ISSUE DATE: 06/21/2019 Form 9 – Unit Separate from Variable Speed INSPECTION – DAMAGE – SHORTAGE Drive The unit shipment should be checked on arrival to see Shipped as two major assemblies: that all major pieces, boxes and crates are received. Check each unit on the trailer or rail car when received, •...

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

    FORM 160.76-N1 SECTION 1 - INTRODUCTION ISSUE DATE: 06/21/2019 Nozzle with flange 150 lb and 300 lb closures 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...
  • Page 11 FORM 160.76-N1 SECTION 1 - INTRODUCTION ISSUE DATE: 06/21/2019 When relieving the pressure from com- To relieve pressure, complete the following steps: pressor, shells, or system, conduct the 1. Check that the working space is open and has nitrogen to outside to prevent the potential good ventilation.

  • Page 12: Rigging

    RIGGING LOCATION The complete standard chiller is shipped without skids. YORK Chillers are furnished with vibration isola- (When optional skids are used it may be necessary to tor mounts for basement or ground level installations. remove the skids so riggers skates can be used under Units may be located on upper floor levels providing the unit end sheets to reduce overall height.)

  • Page 13: Motors

    LD19569 FIGURE 4 - RIGGING MOTORS CLEARANCE The YK open motor is air cooled. Check state, local, Clearances should be adhered to as follows: and other codes for ventilation requirements. • Rear and above unit – 2 ft (61 cm).

  • Page 14: Figure 5 - Neoprene Isolators

    FORM 160.76-N1 SECTION 1 - INTRODUCTION ISSUE DATE: 06/21/2019 ALL DIMENSIONS ARE IN INCHES (MM) See Detail A See Detail A LD28107 LD28106 UNIT WEIGHT UP TO 16,365 Lbs (7,423 Kgs) UNIT WEIGHT 16,366 - 28,835 Lbs (7,424 - 13,080 Kgs) See Detail A See Detail A LD28108...

  • Page 15: Figure 6 - Neoprene Isolator Supports Without/With Skids

    FORM 160.76-N1 SECTION 1 - INTRODUCTION ISSUE DATE: 06/21/2019 Compressor Code - Q, P, H, K1 - K3 Shipment Forms 1, 2, 3, 7, 9, 10 SHELL END SHEET DIA. HOLE LD28112 Compressor Code - K4, K7 Shipment Forms 1, 2, 3, 7, 9, 10 SHELL DIA.

  • Page 16: Figure 7 - Spring Isolators

    FORM 160.76-N1 SECTION 1 - INTRODUCTION ISSUE DATE: 06/21/2019 ALL DIMENSIONS ARE IN INCHES (MM) SHELL SHELL SHEET SHEET SCREW SCREW ADJUSTING ADJUSTING BOLT BOLT 4-SPRING ISOLATORS 4-SPRING ISOLATORS LD19573 LD19572 UNIT WEIGHT UNIT WEIGHT 19,564 Lbs UP TO 35,009 Lbs 10,000 to 19,563 (8,874 Kgs UP TO 15,880 Kgs) (4,536 to 8,873 Kgs)
  • Page 17 FORM 160.76-N1 SECTION 1 - INTRODUCTION ISSUE DATE: 06/21/2019 ALL DIMENSIONS ARE IN INCHES (MM) SHELL SHELL SHEET SHEET 1 / 4 " ( 4 1 1 / 4 " SCREW SCREW ADJUSTING BOLT ADJUSTING BOLT 12-SPRING ISOLATORS 3-SPRING ISOLATORS LD19580 LD19581 UNIT WEIGHT...
  • Page 18 FORM 160.76-N1 ISSUE DATE: 06/21/2019 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 19: Section 2 - Installation

    FORM 160.76-N1 ISSUE DATE: 06/21/2019 SECTION 2 - INSTALLATION RIGGING UNIT TO FINAL LOCATION INSTALLING OPTIONAL SPRING ISOLATORS Rig the unit to its final location on the floor or mount- When ordered, spring type isolator assemblies are fur- ing pad, lift the unit (or shell assembly) by means of an nished with the unit.

  • Page 20: Evaporator And Condenser Water Piping

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 any of the bolts are bound in their holes, or if the con- flow path for the starter heat exchanger to regulate cooling nection springs are out of alignment, the misalignment above the equipment room dewpoint for applications using must be corrected by properly supporting the piping or cooling sources other than evaporative air-exchange meth-...

  • Page 21: Unit Piping

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 Condenser Water Circuit Additionally, a differential pressure switch is available For proper operation of the unit, condenser refrigerant with 300 psi of maximum working pressure. The oper- pressure must be maintained above evaporator pres- ating range of the differential pressure switch is up to sure.

  • Page 22: Refrigerant Relief Piping

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 REFRIGERANT RELIEF PIPING Each unit is equipped with pressure relief valves lo- by code in most areas and should be installed on all cated on the condenser and on the evaporator for the chillers.

  • Page 23: Control Panel Positioning

    SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 CONTROL PANEL POSITIONING On large YK chillers equipped with H9 and K1-K7 No deviations in unit wiring from that compressors, the control panel height can be adjusted. shown on drawings furnished shall be...

  • Page 24: Insulation

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 Chiller with Solid State Starter or Variable Speed Drive A chiller equipped with a factory mounted Solid State Insulation of the type specified for the job, or mini- Starter or Variable Speed Drive does not require wiring mum thickness to prevent sweating of 30°F (-1°C) sur- to the compressor motor.

  • Page 25: Figure 11 - Unit Insulation

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 Hot Gas Tape Insulation Connection to Filter Drier CONDENSER CONDENSER EVAPORATOR EVAPORATOR 2” Liquid Level Indicator Refigerant from Oil Cooler to Cooler Input Drain Liquid Line Hot Gas Charging Connection Tape Insulation around flanges to allow for removal NOTE: Bold lines represent Insulation...

  • Page 26: Table 1 - Available Compressor/Evaporator/Condenser/Motor Combinations

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 TABLE 1 - AVAILABLE COMPRESSOR/EVAPORATOR/CONDENSER/MOTOR COMBINATIONS MOTOR CODES COMPRESSOR EVAPORATOR SHELL CODES CONDENSER SHELL CODES 60 HZ 50 HZ 2C, 2D, 2E 2P, 2Q, 2R, 2S, 22, 23 CH-CZ 5CE-5CU Q3, Q4 EH-EZ 5EE-5EU 4C, 4D, 4E, 4F, 4G, 4H, 4I...
  • Page 27 WC, WE, WG, WK, WC, WG, W1, W2, W3, W5, W6, W7, W9 W1, W3, W4, W5, W6, W7, W9 YC, YE, YG, YK, ZC, ZG, Y1, Y2, Y3, Y5, Y6, Y7, Y9 Z1, Z3, Z4, Z5, Z6, Z7, Z9...

  • Page 28: Compressor Units

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 COMPRESSOR UNITS COMPRESSOR OPTIVIEW MOTOR CONTROL CENTER CONDENSER EVAPORATOR (SHIPPING WIDTH) LD07134 ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR TYPE OF CHILLER MOUNTING M DIMENSION 1-3/4" NEOPRENE PAD ISOLATORS (45) 1" SPRING ISOLATORS 1" DEFLECTION (25) 3/4"...

  • Page 29: Table 2 - Dimensions - Compressor Units

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 COMPRESSOR UNITS (CONT'D) TABLE 2 - DIMENSIONS – COMPRESSOR UNITS COMPRESSOR EVAPORATOR-CONDENSER EVAPORATOR-CONDENSER SHELL CODES SHELL CODE SERIES 2*-2* 4*-4* 2*-2* 4*-4* 5'-0" 5'-2" 5'-0" 5'-2" (1524) (1575) (1524) (1575) 6'-9 3/8" 7'-5/8"...
  • Page 30 FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 COMPRESSOR UNITS (CONT'D) TABLE 2 - DIMENSIONS – COMPRESSOR UNITS (CONT'D) COMPRESSOR P8 EVAPORATOR-CONDENSER SHELL CODES SERIES G*-E* H*-F* K*-K* 6'-4 3/8" 6'-4 3/8" 7'-4" (1940) (1940) (2235) 9'-3 1/2" 9'-3 1/2" 9'-8 1/2"...
  • Page 31 FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 COMPRESSOR UNITS (CONT'D) TABLE 2 - DIMENSIONS – COMPRESSOR UNITS (CONT'D) COMPRESSOR K2 EVAPORATOR-CONDENSER SHELL CODES SERIES M*-K* N*-L* O*-O* P*-P* Q*-Q* R*-R* S*-S* 7'-6 7/8" 7'-6 7/8" 8'-2 7/8" 8'-2 7/8" 8'-10 7/8"...

  • Page 32: Evaporator Compact Waterboxes - A Through L Evaporators - Ft-In. (Mm)

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 EVAPORATOR COMPACT WATERBOXES – A THROUGH L EVAPORATORS - FT-IN. (MM) 1-PASS FRONT 1-PASS UNIT EVAPORATOR NO. OF PASSES COMPRESSOR END FLOOR LINE MOTOR END 2-PASS FRONT UNIT 2-PASS NO. OF EVAPORATOR PASSES COMPRESSOR END...

  • Page 33: Evaporator Compact Waterboxes - M Through Z Evaporators - Ft-In. (Mm)

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 EVAPORATOR COMPACT WATERBOXES – M THROUGH Z EVAPORATORS - FT-IN. (MM) FRONT UNIT 1-PASS SHELL CODE M–Z FLOOR LINE COMPRESSOR END MOTOR END FRONT UNIT 2-PASS SHELL CODE M, N, P, Q FLOOR LINE COMPRESSOR END MOTOR END...

  • Page 34: Table 3 - Dimensions (End) - Evaporator Compact Waterboxes

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 EVAPORATOR COMPACT WATERBOXES - FT-IN. (MM) (CONT'D) TABLE 3 - DIMENSIONS (END) – EVAPORATOR COMPACT WATERBOXES COMPACT WATERBOXES - 150 PSI ROUND NOZZLE PIPE SIZE (IN) 1-PASS 2-PASS 3-PASS EVAPORATOR NUMBER OF PASSES SHELL CODE 8"...

  • Page 35: Figure 14 - Dimensions (Side) - Evaporator Compact Waterboxes

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 EVAPORATOR COMPACT WATERBOXES - FT-IN. (MM) (CONT'D) ONE-PASS TWO-PASS THREE-PASS LD07619b ONE-PASS EVAPORATOR SHELL CODES DIM. G / H K / L M / N O / P Q / R S / T U / V W / Y...

  • Page 36: Condenser Compact Waterboxes - Standard - Ft-In. (Mm)

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 CONDENSER COMPACT WATERBOXES – STANDARD - FT-IN. (MM) FRONT UNIT ONE-PASS CONDENSER FLOOR LINE COMPRESSOR END MOTOR END FRONT UNIT TWO-PASS CONDENSER FLOOR LINE COMPRESSOR END MOTOR END FRONT UNIT THREE-PASS CONDENSER FLOOR LINE...

  • Page 37: Table 4 - Dimensions (End) - Condenser Compact Waterboxes - Standard

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 CONDENSER COMPACT WATERBOXES – STANDARD - FT-IN. (MM) (CONT'D) TABLE 4 - DIMENSIONS (END) – CONDENSER COMPACT WATERBOXES - STANDARD COMPACT WATERBOXES - 150 PSI ROUND CONDENSER NOZZLE PIPE SIZE (IN) 1-PASS 2-PASS 3-PASS...

  • Page 38: Figure 16 - Dimensions (Side) - Condenser Compact Waterboxes - Standard

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 CONDENSER COMPACT WATERBOXES – STANDARD - FT-IN. (MM) (CONT'D) ONE PASS TWO PASS LD07619b THREE PASS ONE-PASS CONDENSER SHELL CODES DIMENSION E / F K / L O / P Q / R S / T U / V W / Z...

  • Page 39: Evaporator Marine Waterboxes - Ft-In. (Mm)

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 EVAPORATOR MARINE WATERBOXES - FT-IN. (MM) FRONT FRONT OF UNIT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE COMPRESSOR END MOTOR END FLOOR LINE FRONT FRONT OF UNIT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE COMPRESSOR END...

  • Page 40: Table 5 - Dimensions (End) - Evaporator Marine Waterboxes

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 EVAPORATOR MARINE WATERBOXES - FT-IN. (MM) (CONT'D) TABLE 5 - DIMENSIONS (END) – EVAPORATOR MARINE WATERBOXES MARINE WATERBOXES - 150 PSI ROUND NOZZLE PIPE SIZE (IN) CONDENSER 1-PASS 2-PASS 3-PASS NUMBER OF SHELL PASSES CODE...

  • Page 41: Figure 18 - Dimensions (Side) - Evaporator Marine Waterboxes

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 EVAPORATOR MARINE WATERBOXES - FT-IN. (MM) (CONT'D) LD01342B_1 1-PASS 2-PASS 3-PASS EVAPORATOR SHELL CODE 1'-6 7/8" 0'-8 13/16" 1'-4 5/8" 0'-7 5/8" 0'-5 11/16" (479) (224) (419) (194) (144) 1'-8 5/8" 0'-8 3/16"...

  • Page 42: Condenser Marine Waterboxes - Ft-In. (Mm)

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 CONDENSER MARINE WATERBOXES - FT-IN. (MM) FRONT OF UNIT FRONT OF UNIT COMPRESSOR END MOTOR END COMPRESSOR END MOTOR END FRONT OF UNIT FRONT OF UNIT COMPRESSOR END MOTOR END COMPRESSOR END MOTOR END FRONT OF UNIT FRONT OF UNIT...

  • Page 43: Table 6 - Dimensions (End) - Condenser Marine Waterboxes

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 CONDENSER MARINE WATERBOXES - FT-IN. (MM) (CONT'D) TABLE 6 - DIMENSIONS (END) – CONDENSER MARINE WATERBOXES MARINE WATERBOXES - 150 PSI ROUND NOZZLE PIPE SIZE (IN) CONDENSER 1-PASS 2-PASS 3-PASS SHELL NUMBER OF CODE PASSES...

  • Page 44: Figure 20 - Dimensions (Side) - Condenser Marine Waterboxes

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 CONDENSER MARINE WATERBOXES - FT-IN. (MM) (CONT'D) LD01342C CONDENSER 1-PASS 2-PASS 3-PASS SHELL CODE 1'-9" 0'-9 7/8" 1'-4 3/4" 0'-7 3/4" 0'-6" 1'-4 3/4" 0'-7 3/4" (533) (251) (425) (197) (425) (197) (152) 1'-11 3/4"...

  • Page 45: Weights

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 WEIGHTS TABLE 7 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR FOR HYBRID FALLING FILM EVAPORATOR UNITS SHIPPING WEIGHT, OPERATING WEIGHT, EST. REFRIGERANT UNIT COMPRESSOR LB (KG) LB (KG) CHARGE, LB (KG) 2C-2E Q3, Q4 10083 (4574) 12094 (5486)

  • Page 46: Table 9 - Condenser Marine Waterbox Weights Lb (Kg) (To Be Added To Standard Unit Weights Shown In Table 7)

    FORM 160.76-N1 SECTION 2 - INSTALLATION ISSUE DATE: 06/21/2019 TABLE 9 - CONDENSER MARINE WATERBOX WEIGHTS LB (KG) (TO BE ADDED TO STANDARD UNIT WEIGHTS SHOWN IN TABLE 7) SHIPPING WEIGHT OPERATING WEIGHT UNIT COMPRESSOR INCREASE, LB (KG) INCREASE, LB (KG) 1-PASS 2-PASS 3-PASS...

  • Page 47: Table 10 - Si Metric Conversion

    FORM 160.76-N1 ISSUE DATE: 06/21/2019 The following factors can be used to convert from English to the most common SI Metric values. TABLE 10 - SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW) Power...
  • 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 160.76-N1 (619) Issue Date: June 21, 2019 Supersedes: 160.76-N1 (419)

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