Johnson Controls YORK YK Series, Installation Manual

Page 1: ...60 75 N1 919 Installation Guide Issue Date 2021 10 22 Model YK Style G Centrifugal Liquid Chiller R 134a R 513A or R 1234ze Refrigerant with OptiView Control Center for Electromechanical Starter Solid...

Page 2: ...2 Model YK Style G Centrifugal Liquid Chiller...

Page 3: ...m variable speed drive 12 Inspection damage shortage 12 Chiller data plate 12 Long term storage 13 Shipment form 2 3 7 9 15 Shipment form 1 10 15 Rigging 16 Location 17 Motors 17 Foundation 17 Clearan...

Page 4: ...rboxes ft in mm 42 Condenser compact waterboxes ft in mm 43 Evaporator compact waterboxes A through L evaporators ft in mm 45 Evaporator compact waterboxes M through Z evaporators ft in mm 47 Condense...

Page 5: ...sonnel It is expected that these individuals possess independent training that enables them to perform their assigned tasks properly and safely It is essential that before performing any task on this...

Page 6: ...otice Johnson Controls makes no commitment to update or provide current information automatically to the manual or product owner Updated manuals if applicable can be obtained by contacting the nearest...

Page 7: ...he LTC I O Board 160 75 PW7 Wiring diagrams OptiView Control Center and SSS LV VSD MV VSD 160 75 PW6 Wiring diagrams OptiView Control Center and SSS LV VSD MV VSD with the LTC I O board 160 75 PW8 Wir...

Page 8: ...ith all units that are field assembled The services of a Johnson Controls representative are provided to check the installation supervise the initial start up and operation of all chillers installed i...

Page 9: ...vacuated and charged with R 134a R 513A or R 1234ze An optional solid state starter or variable speed drive can be factory mounted and wired Miscellaneous packaging of four vibration isolation pads or...

Page 10: ...mantled for shipment The compressor and motor assembly is removed from the shells and skidded Evaporator and condenser shells are separated at tube sheets and are not skidded Refrigerant lines between...

Page 11: ...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 11 Model YK Style G...

Page 12: ...ny visible signs of damage Any damage or signs of possible damage must be reported to the transportation company immediately for their inspection Johnson Controls will not be responsible for any damag...

Page 13: ...s until the unit is ready for set up Relieve pressure according to the procedure shown in Figure 3 DANGER Failure to follow the following procedures will cause severe personal injury or death to opera...

Page 14: ...Figure 3 Long term storage tube side Model YK Style G Centrifugal Liquid Chiller 14...

Page 15: ...jury or death to the operator or people in site 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 ni...

Page 16: ...skids When optional skids are used it may be necessary to remove the skids so riggers skates can be used under the unit end sheets to reduce overall height Each unit has four lifting holes two in eac...

Page 17: ...ient clearance to facilitate normal service and maintenance work must be provided all around and above the unit and particularly space provided at either end to permit cleaning or replacement of evapo...

Page 18: ...ar 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 22 ft 6 7 m on shell...

Page 19: ...Figure 6 Neoprene isolators in mm 19 Model YK Style G Centrifugal Liquid Chiller...

Page 20: ...Figure 7 Spring isolators in mm Model YK Style G Centrifugal Liquid Chiller 20...

Page 21: ...Figure 8 Spring isolators continued in mm 21 Model YK Style G Centrifugal Liquid Chiller...

Page 22: ...2 5 mm to 0 20 in 5 mm If an isolation pad is under deflected place shims between the unit tube sheet and the top of the pad to equally deflect all pads Leveling the unit Check the longitudinal alignm...

Page 23: ...gned for 150 psig DWP on the water side If job requirements are for greater than 150 psig DWP check the unit data plate before applying pressure to evaporator or condenser to determine if the chiller...

Page 24: ...nit Operation and Maintenance Form 160 75 O1 condenser water temperature must be maintained equal to or slightly higher than the required minimum See Figure 9 for typical water piping schematic Stop v...

Page 25: ...carefully check the evaporator and condenser water heads and piping for leaks Repair leaks as necessary Before initial operation of the unit both water circuits should be thoroughly vented of all air...

Page 26: ...required by code in most areas and should be installed on all chillers Refrigerant relief vent piping is not supplied by Johnson Controls The vent line should be sized in accordance with the ANSI ASH...

Page 27: ...s to the proper position Tighten securely 4 Discard unused hardware Figure 11 Correct control panel positioning H9 K1 K7 Control wiring On units shipped disassembled after installation of the control...

Page 28: ...ires 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...

Page 29: ...tor shell end sheets liquid feed line to flow chamber compressor suction connection and evaporator liquid heads and connections The liquid head flange insulation must be removable to allow head remova...

Page 30: ...S DP to DS EP to ET EP to ET Q5 Q6 Q7 FQ to FT FQ to FT CH CT EH ET 5CE 5CO 5EE 5EO EP to ET EP to ET P7 FQ to FT FQ to FT CU CY EU EY 5CP 5CU 5EP 5EU P8 GQ to GS EV to EX HQ to HS FV to FX JP to JS J...

Page 31: ...T 5CC 5CO 5EC 5EO CC to CE C3 to C5 CP to CS Q5 DC to DE D3 to D5 DP to DS EC to EE E3 to E5 EP to ET Q5 Q6 Q7 FC to FE F3 to F5 FQ to FT CH CT EH ET 5CE 5CO 5EE 5EO EC to EE E3 to E5 EP to ET P7 FC t...

Page 32: ...4 compressor evaporator condenser shell codes Series C B C C D D E E A 6 ft 4 3 4 in 5 ft 6 in 5 ft 6 in 7 ft 0 in B 7 ft 11 3 8 in 7 ft 2 1 2 in 7 ft 2 1 2 in 7 ft 8 1 2 in C 1 ft 5 1 2 in 1 ft 5 1 2...

Page 33: ...2 ft 0 in 2 ft 0 in 2 ft 1 1 4 in 2 ft 1 1 4 in D 1 ft 5 1 2 in 1 ft 5 1 2 in 1 ft 8 in 1 ft 8 in E 12 ft 0 in 16 ft 0 in 12 ft 0 in 16 ft 0 in Table 12 P9 compressor evaporator condenser shell codes...

Page 34: ...6 1 676 B 2 134 2 229 2 229 C 394 445 445 D 381 394 394 E 3 658 3 658 4 877 Table 15 Q4 compressor evaporator condenser shell codes Series C C mm C B mm D D mm E E mm A 1 676 1 949 1 676 2 134 B 2 197...

Page 35: ...641 641 D 445 445 508 508 E 3 658 4 877 3 658 4 877 Table 20 P9 compressor evaporator condenser shell codes Series H F mm J J mm L L mm A 2 108 2 299 2 299 B 3 124 3 264 3 264 C 610 641 641 D 445 508...

Page 36: ...in 10 ft 10 1 2 in C 2 ft 1 1 4 in 2 ft 1 1 4 in 2 ft 4 1 2 in D 1 ft 8 in 2 ft 3 3 8 in 1 ft 11 in E 14 ft 0 in 14 ft 0 in 14 ft 0 in Note 1 All dimensions are approximate 2 For compact waterboxes se...

Page 37: ...2 616 B 3 150 3 242 3 315 C 641 641 724 D 508 695 584 E 4 267 4 267 4 267 Note 1 All dimensions are approximate 2 For compact waterboxes see Figure 16 determine overall unit length by adding waterbox...

Page 38: ...1 1 4 in E 14 ft 0 in 14 ft 0 in 16 ft 0 in 14 ft 0 in 16 ft 0 in Table 27 K2 compressor evaporator condenser shell codes M M M U N N P P Q Q A 8 ft 7 in 9 ft 6 in 8 ft 7 in 9 ft 1 1 2 in 9 ft 1 1 2 i...

Page 39: ...Z Y Z Z A 10 ft 3 in 12 ft 7 in 11 ft 3 in B 12 ft 2 in 14 ft 1 5 8 in 12 ft 10 in C 2 ft 8 in 2 ft 11 1 2 in 2 ft 11 1 2 in D 2 ft 5 1 2 in 3 ft 4 in 2 ft 8 in E 22 ft 0 in 18 ft 0 in 18 ft 0 in Note...

Page 40: ...B 2 921 3 454 3 454 3 493 3 493 C 641 724 724 749 749 D 508 584 584 641 641 E 4 267 4 267 4 877 4 267 4 877 Table 33 K2 compressor evaporator condenser shell codes M M mm M U mm N N mm P P mm Q Q mm A...

Page 41: ...5 3 429 B 3 708 4 308 3 912 C 813 902 902 D 749 1 016 813 E 6 706 5 486 5 486 Note 1 All dimensions are approximate 2 For compact waterboxes see Figure 18 determine overall unit length by adding water...

Page 42: ...2 ft 1 3 4 in 654 Figure 20 Two pass evaporator dimensions Table 38 One pass evaporators shell codes in mm Dimensions A C D E F G H I J K L M N P Q P S W X Z F 1 ft 2 1 4 in 362 1 ft 3 in 381 1 ft 3 1...

Page 43: ...s Table 40 One pass condensers shell codes ft in mm Dimensions A C D E F J K L M N P Q R S T V W X Z H 1 ft 1 7 8 in 352 1 ft 1 7 8 in 352 1 ft 3 in 381 1 ft 4 in 406 1 ft 2 7 8 in 378 1 ft 4 7 8 in 4...

Page 44: ...10 1 4 in 565 1 ft 8 in 508 2 ft 4 3 4 in 730 1 ft 10 1 2 in 572 J 0 ft 10 1 2 in 267 0 ft 9 in 229 0 ft 11 1 2 in 292 0 ft 8 3 4 in 222 1 ft 1 1 2 in 343 0 ft 10 in 254 1 ft 2 1 4 in 362 1 ft 0 in 30...

Page 45: ...1 2 in 394 1 ft 10 in 559 1 ft 2 in 356 2 ft 6 in 762 1 ft 2 in 356 2 ft 6 in 762 C D 10 in 254 8 in 203 6 in 152 1 ft 5 1 2 in 445 2 ft 0 in 610 1 ft 3 in 381 2 ft 9 in 838 1 ft 3 in 381 2 ft 9 in 8...

Page 46: ...two and three pass nozzle arrangements are available only in pairs shown and for all shell codes Any pair of evaporator nozzles can be used in combination with any pair of condenser nozzles 3 Evaporat...

Page 47: ...Evaporator compact waterboxes M through Z evaporators ft in mm Figure 26 Dimensions of evaporator compact waterboxes M through Z evaporators ft in mm 47 Model YK Style G Centrifugal Liquid Chiller...

Page 48: ...59 4 ft 5 in 1346 1 ft 10 in 559 4 ft 5 in 1 346 QV QT 20 in 508 16 in 406 12 in 305 2 ft 5 1 2 in 749 3 ft 1 1 2 in 953 1 ft 11 1 2 in 597 4 ft 3 1 2 in 1 308 1 ft 11 1 2 in 597 4 ft 3 1 2 in 1 308 R...

Page 49: ...ell code 1 2 3 D CC 5 BB 5 DD 5 BB 5 DD 5 A 10 in 254 6 in 152 6 in 152 1 ft 3 in 381 2 ft 4 in 711 1 ft 9 1 2 in 546 2 ft 10 1 2 in 876 1 ft 9 1 2 in 546 2 ft 10 1 2 in 876 C D 12 in 305 8 in 203 6 i...

Page 50: ...43 M N 20 in 508 14 in 356 10 in 254 1 ft 11 in 584 3 ft 6 in 1 067 2 ft 6 3 8 in 772 4 ft 5 5 8 in 1 362 2 ft 6 3 8 in 772 4 ft 5 5 8 in 1 362 P Q 20 in 508 16 in 406 14 in 356 2 ft 1 1 4 in 641 3 ft...

Page 51: ...in 1 511 T V W 24 in 610 18 in 457 16 in 406 2 ft 5 1 2 in 749 3 ft 11 1 2 in 1 207 2 ft 9 in 838 5 ft 2 in 1 575 2 ft 9 in 838 5 ft 2 in 1 575 X Z 24 in 610 20 in 508 16 in 406 2 ft 8 in 813 4 ft 1 1...

Page 52: ...6 ft 3 7 8 in 1 927 1 ft 5 7 8 in 454 See note in Evaporator compact waterboxes A through L evaporators ft in mm Evaporator nozzle arrangements standard ft in mm Figure 30 Dimensions of evaporator no...

Page 53: ...46 2 ft 6 1 2 in 775 1 ft 1 in 330 Note 1 All dimensions are approximate 2 Standard water nozzles are Schedule 40 pipe size furnished as welding stub outs with grooves allowing the option of welding f...

Page 54: ...in 565 0 ft 9 7 8 in 251 I6 2 ft 3 in 686 1 ft 0 3 4 in 324 1 ft 10 1 2 in 572 0 ft 11 1 2 in 292 0 ft 10 1 2 in 267 1 ft 10 1 2 in 572 0 ft 10 1 2 in 267 J K L 2 ft 8 3 8 in 822 1 ft 3 3 8 in 391 2...

Page 55: ...uplings Factory installed class 150 ANSI B16 5 round slip on forged carbon steel with 1 16 in raised face water flanged nozzles are optional add 1 2 in to nozzle length Companion flanges nuts bolts an...

Page 56: ...0 in 254 1 ft 6 1 2 in 470 E F 14 in 356 10 in 254 8 in 203 1 ft 7 1 2 in 495 4 ft 3 in 1 295 4 ft 3 in 1 295 0 ft 11 in 279 1 ft 9 1 2 in 546 4 ft 3 in 1 295 0 ft 11 in 279 1 ft 9 1 2 in 546 G H 14 i...

Page 57: ...1 2 in 775 6 ft 0 1 8 in 1 832 1 ft 4 1 2 in 419 2 ft 6 1 2 in 775 R S 20 in 508 18 in 457 14 in 356 2 ft 8 in 813 6 ft 5 7 8 in 1 978 6 ft 5 7 8 in 1 978 1 ft 3 3 4 in 400 3 ft 0 1 8 in 918 6 ft 5 7...

Page 58: ...152 1 ft 3 1 2 in 394 4 ft 3 in 1 295 4 ft 3 in 1 295 1 ft 8 in 508 1 ft 6 1 2 in 470 4 ft 3 in 1 295 1 ft 8 in 508 1 ft 6 1 2 in 470 E F 14 in 356 10 in 254 8 in 203 1 ft 5 1 2 in 445 4 ft 7 in 1 397...

Page 59: ...2 007 2 ft 6 1 2 in 775 2 ft 8 1 2 in 825 6 ft 7 in 2 007 2 ft 6 1 2 in 775 2 ft 8 1 2 in 826 T V W 24 in 610 18 in 457 16 in 406 2 ft 5 1 2 in 749 6 ft 10 1 4 in 2 089 6 ft 10 1 4 in 2 089 2 ft 6 in...

Page 60: ...10 in 254 8 in 203 6 in 152 1 ft 8 7 8 in 530 1 ft 9 1 4 in 539 2 ft 6 3 4 in 780 I 14 in 355 10 in 254 8 in 203 1 ft 11 3 8 in 593 1 ft 10 1 4 in 559 2 ft 9 3 8 in 838 O 16 in 406 12 in 305 10 in 254...

Page 61: ...in 406 12 in 305 10 in 254 2 ft 3 3 8 in 695 2 ft 8 3 8 in 822 1 ft 7 5 8 in 498 3 ft 1 7 8 in 962 3 ft 1 7 8 in 962 U 18 in 457 14 in 355 10 in 254 2 ft 4 1 2 in 723 3 ft 8 3 16 in 1 122 2 ft 5 15 1...

Page 62: ...er performance Use for reference only Refer to YORKworks Performance Page or chiller nameplate for actual charge requirement Table 62 Approximate unit weight including motor for hybrid falling film ev...

Page 63: ...3 660 1 660 7 244 3 286 11 552 5 240 5 507 2 498 11 243 5 100 The following condenser marine waterbox weights are to be added to the standard unit weights shown in Table 61 and Table 62 Table 64 Cond...

Page 64: ...ss 3 pass V T W 5 196 2 357 2 565 1 163 5 204 2 361 9 161 4 155 4 012 1 820 8 219 3 728 U 3 641 1 652 1 893 859 3 609 1 637 5 350 2 427 2 556 1 159 4 770 2 164 X Z 5 840 2 649 2 953 1 339 5 380 2 440...

Page 65: ...eters m Length Inches in 25 4 Millimeters mm Weight Pounds lbs 0 4536 Kilograms kg Velocity Feet Second fps 0 3048 Meters Second m s Feet of Water ft 2 989 Kilopascals kPa Pressure Drop Pounds Square...

Page 66: ...2021 Johnson Controls 5000 Renaissance Drive New Freedom York PA 17349 USA Subject to change without notice All rights reserved...