Johnson Controls YORK YKKCK4H9-CYG Installation Instructions Manual

Brand: Johnson Controls

Model: YORK YKKCK4H9-CYG

Type: Installation Instructions Manual

This manual is also suitable for

YORK YK Series

MODEL YK (STYLE G)

R-134a or R-513A

WITH OPTIVIEW™ CONTROL CENTER

FOR ELECTROMECHANICAL STARTER,

SOLID STATE STARTER, AND VARIABLE SPEED DRIVE

CENTRIFUGAL LIQUID CHILLERS

INSTALLATION INSTRUCTIONS Supersedes: 160.75-N1 (1217) Form 160.75-N1 (419)

Issue Date:

April 15, 2019

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

This equipment is a relatively complicated apparatus.

During rigging, installation, operation, maintenance,

or service, individuals may be exposed to certain com-

ponents or conditions including, but not limited to:

heavy objects, refrigerants, materials under pressure,

rotating components, and both high and low voltage.

Each of these items has the potential, if misused or

handled improperly, to cause bodily injury or death. It

is the obligation and responsibility of rigging, instal-

lation, and operating/service personnel to identify and

recognize these inherent hazards, protect themselves,

and proceed safely in completing their tasks. Failure

to comply with any of these requirements could result

in serious damage to the equipment and the property in

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

which it is situated, as well as severe personal injury or

death to themselves and people at the site.

This document is intended for use by owner-authorized

rigging, installation, and operating/service personnel. It

is expected that these individuals possess independent

training that will enable them to perform their assigned

tasks properly and safely. It is essential that, prior to

performing any task on this equipment, this individual

shall have read and understood the on-product labels,

this document and any referenced materials. This in-

dividual shall also be familiar with and comply with

all applicable industry and governmental standards and

regulations pertaining to the task in question.

SAFETY SYMBOLS

The following symbols are used in this document to alert the reader to specific situations:

Indicates a possible hazardous situation

which will result in death or serious injury

if proper care is not taken.

Indicates a potentially hazardous situa-

tion which will result in possible injuries

or damage to equipment if proper care is

not taken.

Identies a hazard which could lead to

damage to the machine, damage to other

equipment and/or environmental pollu-

tion if proper care is not taken or instruc-

tions and are not followed.

Highlights additional information useful

to the technician in completing the work

being performed properly.

External wiring, unless specied as an optional connection in the manufacturer’s product line, is not

to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls

and any external wiring must not be installed inside the micro panel. All wiring must be in accor-

dance with Johnson Controls’ published specications and must be performed only by a qualied

electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper

connections to the controls or application of improper control signals. Failure to follow this warn-

ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con-

tinuous product improvement, the information con-

tained in this document is subject to change without

notice. 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

Johnson Controls Service office or accessing the John-

son Controls QuickLIT website at http://cgproducts.

johnsoncontrols.com.

It is the responsibility of rigging, lifting, and operating/

service personnel to verify the applicability of these

documents to the equipment. If there is any question

regarding the applicability of these documents, rig-

ging, lifting, and operating/service personnel should

verify whether the equipment has been modified and

if current literature is available from the owner of the

equipment prior to performing any work on the chiller.

CHANGE BARS

Revisions made to this document are indicated with a

line along the left or right hand column in the area the

revision was made. These revisions are to technical in-

formation and any other changes in spelling, grammar

or formatting are not included.

ASSOCIATED LITERATURE

MANUAL DESCRIPTION FORM NUMBER

Installation Checklist/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

Wiring Diagrams - Field Connections - Remote Mounted MV SSS 160.75-PW2

Wiring Diagrams - Field Connections - Remote Mounted MV VSD 160.75-PW3

Wiring Diagrams - Field Connections - LV VSD 160.54-PW6

Wiring Diagrams - OptiView Control Center and EMS 160.75-PW5

Wiring Diagrams - OptiView Control Center and EMS with the 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

Wiring Diagrams - Field Control Modications 160.75-PW4

Unit Operation and Maintenance 160.75-O1

Operation OptiView Panel 160.54-O1

Operation - Variable Speed Drive - TM Model 160.00-O1

Operation and Maintenance - Solid State Starter (Mod "B") 160.00-O2

Operation - Variable Speed Drive - VSD and LVD Model 160.00-O4

Operation - Variable Speed Drive - HYP Model 160.00-O10

Operation - Floor Mounted MV SSS, Manufactured Before 2007 160.00-O5

Operation - Floor Mounted MV SSS, Manufactured After 2007 160.00-O5.1

Operation - Unit Mounted MV SSS 160.00-O7

Operation - MV VSD - 2300 VAC – 6600 VAC 160.00-O6

Operation - MV VSD - 10 kV – 13.8 kV 160.00-O8

Service Policy - Shipping Damage Claims 50-15-NM

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

NOMENCLATURE

YK KC K4 H9 – CY G

MOTOR CODE

POWER SUPPLY

– for 60 Hz

5 for 50 Hz

COMPRESSOR CODE*

CONDENSER CODE*

EVAPORATOR CODE*

MODEL*

STYLE (Design Level)

* Refer to YK Engineering Guide (Form 160.75-EG1)

for Shell/Motor/Compressor combinations.

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

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 ...........................................................................................................................................................12

Location .......................................................................................................................................................... 13

Motors ............................................................................................................................................................13

Foundation .....................................................................................................................................................13

Clearance .......................................................................................................................................................13

SECTION 2 - INSTALLATION ................................................................................................................................17

Rigging Unit to Final Location ........................................................................................................................17

Locating and Installing Isolator Pads ..............................................................................................................17

Checking the Isolation Pad Deflection ............................................................................................................17

Leveling the Unit .............................................................................................................................................17

Installing Optional Spring Isolators ................................................................................................................. 17

Piping Connections ........................................................................................................................................17

Evaporator and Condenser Water Piping .......................................................................................................18

Unit Piping ......................................................................................................................................................19

Refrigerant Relief Piping ................................................................................................................................20

Control Panel Positioning ...............................................................................................................................21

Control Wiring .................................................................................................................................................21

Power Wiring ..................................................................................................................................................21

Oil Pump – 3 Phase Starter ............................................................................................................................21

Insulation ........................................................................................................................................................22

Installation Check – Request for Start-Up Service .........................................................................................23

P and Q Compressor Units (Standard)...........................................................................................................25

P and Q Compressor Units (Metric) ............................................................................................................... 26

H Compressor Units (Standard) .....................................................................................................................27

H Compressor Units (Metric) .......................................................................................................................... 28

K Compressor Units (Standard) .....................................................................................................................29

K Compressor Units (METRIC) ......................................................................................................................30

Evaporator Compact Waterboxes - Ft-In (mm) ..............................................................................................31

Condenser Compact Waterboxes - Ft-In (mm) ..............................................................................................32

Evaporators – Compact Waterboxes – A through L Evaporators - Ft-In (mm).............................................. 33

Evaporators – Compact Waterboxes – M through Z Evaporators - Ft-In (mm) ............................................ 34

Condenser – Compact Waterboxes – Standard - Ft-In (mm) .......................................................................35

Condenser – Heat Recovery Compact Waterboxes – Standard - Ft-In (mm) .............................................. 37

Evaporator – Nozzle Arrangements – Standard - Ft-In (mm) ....................................................................... 38

Condenser – Nozzle Arrangements – Standard - Ft-In (mm) ....................................................................... 39

Evaporator Marine Waterbox Nozzle Arrangements - Ft-In (mm) ..................................................................40

Condenser Marine Waterbox Nozzle Arrangements - Ft-In (mm) ..................................................................41

Condensers Marine Waterboxes Heat Recovery Units - Main (Tower) Circuit Only ......................................42

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

LIST OF FIGURES

LIST OF TABLES

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 - Spring Isolators ...................................................................................................................................15

FIGURE 7 - Spring Isolators ...................................................................................................................................16

FIGURE 8 - Schematic of a Typical Piping Arrangement ........................................................................................18

FIGURE 9 - Typical Refrigerant Vent Piping ............................................................................................................20

FIGURE 10 - Control Panel Positioning (H9, K1-K7) ..............................................................................................21

FIGURE 11 - Unit Insulation ....................................................................................................................................22

FIGURE 12 - Dimensions – P and Q Compressor Units (Ft–In) .............................................................................25

FIGURE 13 - Dimensions – P and Q Compressor Units (mm) ................................................................................26

FIGURE 14 - Dimensions – H Compressor Units (Ft–In) ........................................................................................ 27

FIGURE 15 - Dimensions – H Compressor Units (mm) ..........................................................................................28

FIGURE 16 - Dimensions – K Compressor Units (Ft–In) ........................................................................................29

FIGURE 17 - Dimensions – K Compressor Units (mm) ..........................................................................................30

FIGURE 18 - Dimensions – Evaporator Compact Waterboxes ..............................................................................31

FIGURE 19 - Dimensions – Condenser Compact Waterboxes ..............................................................................32

FIGURE 20 - Dimensions – Evaporator Compact Waterboxes A through L Evaporators .......................................33

FIGURE 21 - Dimensions – Evaporator Compact Waterboxes M through Z Evaporators ...................................... 34

FIGURE 22 - Dimensions – Condenser Compact Waterboxes - A through Q -Standard (mm) .............................. 35

FIGURE 23 - Dimensions – Condenser Compact Waterboxes - R through Z - Standard (mm) ............................. 36

FIGURE 24 - Dimensions – Condenser Heat Recovery Compact Waterboxes - Standard (mm) ........................... 37

FIGURE 25 - Dimensions – Evaporator Nozzle Arrangements - Standard (mm) ....................................................38

FIGURE 26 - Dimensions – Condenser Nozzle Arrangements - Standard (mm) ....................................................39

FIGURE 27 - Dimensions – Evaporator Marine Waterboxes .................................................................................40

FIGURE 28 - Dimensions – Condenser Marine Waterboxes .................................................................................41

TABLE 1 - Available Compressor/Shell/Motor Combinations .................................................................................23

TABLE 2 - Approximate Unit Weight Including Motor for Flooded Evaporator Units - Lb (kg) ................................44

TABLE 3 - Approximate Unit Weight Including Motor for Hybrid Falling Film Evaporator Units - Lb (kg) ..............45

TABLE 4 - Evaporator Marine Waterbox Weights - Lb (kg) ...................................................................................45

TABLE 5 - Condenser Marine Waterbox Weights - Lb (kg) ...................................................................................46

TABLE 6 - SI Metric Conversion .............................................................................................................................47

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 1 - INTRODUCTION

The services of a Johnson Controls representative will

be furnished to check the installation, supervise the

initial start-up and operation of all chillers installed

within the Continental United States.

The Johnson Controls Warranty may be

voided if the following restrictions are not

adhered to:

1. No valves or connections should be opened under

any circumstances because such action will result

in loss of the factory nitrogen charge.

2. Do not dismantle or open the chiller for any rea-

son except under the supervision of a Johnson

Controls representative.

3. When units are shipped dismantled, notify the

nearest Johnson Controls ofce in ample time for

a Johnson Controls representative to supervise

rigging the unit to its operating position and the

assembly of components.

4. Do not make nal power supply connections to

the compressor motor or control center.

LD15222

CONDENSER

CONTROL

CENTER

COMPRESSOR

MOTOR

EVAPORATOR

FIGURE 1 - MODEL YK CHILLER

GENERAL

This manual describes the installation of a YORK YK

Mod "G" Centrifugal Chiller. This unit can be shipped

as a single factory assembled, piped, wired package,

requiring a minimum of field labor to make chilled

water connections, condenser water connections, re-

frigerant atmospheric relief connections, and electri-

cal power connections. Refrigerant and oil charges are

shipped separately unless optional condenser isolation

valves are ordered.

Chillers can also be shipped dismantled when required

by rigging conditions, but generally it is more econom-

ical to enlarge access openings to accommodate the

factory assembled unit. Chillers shipped dismantled

MUST be field assembled under the supervision of a

Johnson Controls representative, but otherwise instal-

lation will be as described in this instruction.

FIELD ASSEMBLED UNITS ONLY

Use Installation and Reassembly - Unit (Form 160.75-

N3) in conjunction with this installation instruction. This

instruction will be furnished with all units that are to be

field assembled.

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 1 - INTRODUCTION

5. Do not charge the compressor with oil.

6. Do not charge the unit with refrigerant.

7. Do not attempt to start the system.

8. Do not run hot water (110°F / 43°C max) or steam

through the evaporator or condenser at any time.

SHIPMENT

The chiller may be ordered and shipped in any of the

following forms:

Form 1 – Factory Assembled Unit, complete with mo-

tor, refrigerant, and oil charges.

• The motor/compressor assembly mounted,

with all necessary interconnecting piping

assembled. OptiView™ Control Center is

mounted on the unit. Complete unit fac-

tory leak tested, evacuated and charged with

R-134a.

An optional Solid State Starter or Variable

Speed Drive can be factory mounted and

wired.

• Miscellaneous material – Four (4) vibration

isolation pads (or optional spring isolators

and brackets). K7 units will be shipped with

8 Vibration Isolation Pads.

Form 2 – Factory Assembled Unit, complete with mo-

tor (refrigerant and oil charges shipped sepa-

rately).

• The motor/compressor assembly mounted,

with all necessary interconnecting piping

assembled. OptiView™ Control Center is

mounted on the unit. Complete unit fac-

tory leak tested, evacuated and charged with

holding charge of nitrogen.

An optional Solid State Starter or Variable

Speed Drive can be factory mounted and

wired.

• Miscellaneous material – Four (4) vibration

isolation pads (or optional spring isolators).

K7 units will be shipped with 8 Vibration

Isolation Pads.

Form 3 – Driveline Separate From Shells – Shipped as

two major assemblies. Unit first factory assem-

bled, refrigerant piped, wired and leak tested;

then dismantled for shipment.

• Compressor/motor assembly removed from

shells and skidded. Evaporator/condenser is

not skidded.

• All wiring integral with compressor is left on

it, and all conduit is left on shell. All open-

ings on compressor, oil separator, and shell

are closed and charged with dry nitrogen (2

psig to 3 psig) (115/122 kPa).

• Miscellaneous packaging of control center,

tubing, water temperature controls, wiring,

oil, isolators, solid state starter (option), etc.;

refrigerant charge shipped separately.

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 – Shipped as three major assem-

blies. Unit first factory assembled, refriger-

ant piped, wired and leak tested; then dis-

mantled for shipment.

• Compressor/motor assembly removed from

shells and skidded.

• Evaporator and condenser shells are sepa-

rated at tube sheets and are not skidded. Re-

frigerant lines between shells are flanged and

capped, requiring no welding.

• All wiring integral with compressor is left

on it. All wiring harnesses on shells are re-

moved. All openings on compressor and

shells are closed and charged with dry nitro-

gen (2 to 3 psig) (115/122 kPa).

• Miscellaneous packaging of control center,

tubing, water temperature controls, wiring,

oil isolators, solid state starter (option), etc.;

refrigerant charge shipped separately.

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)

When more than one chiller is involved, the major

parts of each unit will be marked to prevent mixing

of assemblies. (Piping and Wiring Drawings to be fur-

nished by Johnson Controls)

JOHNSON CONTROLS

SECTION 1 - INTRODUCTION

FORM 160.75-N1

ISSUE DATE: 04/15/2019

INSPECTION – DAMAGE – SHORTAGE

The unit shipment should be checked on arrival to see

that all major pieces, boxes and crates are received.

Each unit should be checked on the trailer or rail car

when received, before unloading, for any visible signs

of damage. Any damage or signs of possible damage

must be reported to the transportation company imme-

diately for their inspection. Johnson Controls will not

be responsible for any damage in shipment, at job site,

or loss of parts. (Refer to Shipping Damage Claims,

Form 50.15-NM.)

When 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

A unit data plate is mounted on the control center as-

sembly of each unit, giving unit model number; design

working pressure; water passes; refrigerant charge; se-

rial numbers; and motor power characteristics and con-

nection diagrams.

Additional information may be found on the motor data

plate. This information should be included when con-

tacting the factory on any problem relating to the motor.

LONG-TERM STORAGE

To protect the waterbox of pressure vessels from rust-

ing, the tube side (water side) has been purged and

charged with nitrogen to a positive pressure of 5 psig

to 7 psig.

Do not break the seal or remove closures until ready

for set up. Relieve pressure as per the following proce-

dure (see Figure 3 on page 10).

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 pres-

sure and to protect themselves.

FORM 9 – Unit Separate from Variable Speed

Drive

Shipped as two major assemblies:

• Chiller Unit

• Variable Speed Drive

The unit is first factory assembled, refrigerant piped,

wired and leak tested; then dismantled for shipment.

Evaporator/condenser is not skidded.

All wiring integral with compressor is left on it, and

all conduit is left on shell. All openings on compressor,

and shell are closed and charged with dry nitrogen (2

to 3 PSIG).

Miscellaneous packaging of tubing, water temperature

controls, wiring, isolators, etc. The unit is shipped with

a nitrogen charge. Refrigerant charge shipped in ap-

propriate cylinders. See Figure 2.

FORM 10 – Unit Separate from Variable Speed

Drive

Shipped as two major assemblies:

• Chiller Unit

• Variable Speed Drive

The unit is first factory assembled, refrigerant piped,

wired and leak tested; then dismantled for shipment.

Evaporator/condenser is not skidded.

All wiring integral with compressor is left on it, and all

conduit is left on shell.

Miscellaneous packaging of tubing, water temperature

controls, wiring, isolators, etc. The unit is shipped with

refrigerant charge. See Figure 2.

LD16730

Lifting

Holes

Lifting

Holes

65°

Min.

65°

Min.

FIGURE 2 - VARIABLE SPEED DRIVE RIGGING

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 1 - INTRODUCTION

LD29123

Nozzle with flange

150 lb and 300 lb closures

Nozzle without flanges

(Lines 4 in. through 12 in.)

Nozzle without flanges

(Lines 14 in. through 24 in.)

ITEM DESCRIPTION

1 Tag Warning Dennison 8E

2 Gauge Press 2 Dia 0-30

3 Tag GlvSt Wire Speed

4 Bush Pipe 3/4 - 14 NPTE X

5 Valve, Transducer 1/4 NPTE X

6 Flange Cover

7 Gasket

8 Victaulic Coupling

9 Sealing Cap

FIGURE 3 - LONG TERM STORAGE - TUBE SIDE

JOHNSON CONTROLS

SECTION 1 - INTRODUCTION

FORM 160.75-N1

ISSUE DATE: 04/15/2019

Relieve pressure as follows:

1. Check the working space to make sure that it is

open and has a good ventilation; if not, connect a

hose or pipe to the valve (Item 5) and route it to

outside.

2. Slowly open the valve (Item 5) until fully opened.

3. Monitor the pressure gauge (Item 2). The pressure

should decline gradually.

4. When the pointer of pressure gauge does not

move and no nitrogen comes out of valve (Item

5), it means that no positive pressure exists in the

waterbox.

5. Now it is safe to remove the ange cover (Item 6)

or sealing cap (Item 9).

6. Close the valve (Item 5) and remove the warning

tag (Item 1).

Shipment Form 2/3/7/9

All openings on the compressor, shells including evap-

orator and condenser, and oil reservoir are closed and

charged with nitrogen (2 psig to 3 psig). 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 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 nitrogen

by opening the valves on them slowly until

fully open.

When relieving the pressure from com-

pressor, shells, or system, conduct the

nitrogen to outside to prevent the potential

risk of asphyxiation.

Shipment Form 1/10

The unit is shipped with refrigerant charge; it is not

needed to relieve the pressure. So DO NOT try to open

any valves to relieve pressure or open closures, cap, or

plugs on the compressor, shells, and elsewhere on the

system.

Reclaim the refrigerant in the system before any ser-

vice activities being done to refrigeration system. Fully

relieve system pressure and then repair.

The unit is charged with tons of refrig-

erant; once an uncontrollable leak is

found, inform all of the relevant people

to evacuate from the building to prevent

from asphyxiation.

Never touch the refrigerant that is leak-

ing, especially the liquid refrigerant; this

will cause severe freezing to your hands

or body.

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 1 - INTRODUCTION

Rigging and lifting should only be done by a professional rigger in accordance with a written rig-

ging and lifting plan. The most appropriate rigging and lifting method will depend on job specic

factors, such as the rigging equipment available and site needs. Therefore, a professional rigger

must determine the rigging and lifting method to be used, and it is beyond the scope of this manual

to specify rigging and lifting details.

LD19197

RIGGING

The complete standard chiller is shipped without 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 (4) lifting holes (two in each end)

in the end sheets which should be used to lift the unit.

Care should be taken at all times during rigging and

handling of the chiller to avoid damage to the unit and

its external connections. Lift only using holes shown in

Figure 4 on page 13.

Do not lift the unit with slings around

motor/compressor assembly or by means

of eyebolts in the tapped holes of the

compressor motor assembly. Do not turn

a unit on its side for rigging. Do not rig

vertically.

The rigging and operating weights and overall dimen-

sions are given on page 25 through page 46 as a

guide in determining the clearances required for rig-

ging. Add 6" (15 cm) to overall height for optional

skidded unit.

JOHNSON CONTROLS

SECTION 1 - INTRODUCTION

FORM 160.75-N1

ISSUE DATE: 04/15/2019

FIGURE 4 - RIGGING

LD19569

LOCATION

YORK Chillers are furnished with vibration isola-

tor mounts for basement or ground level installations.

Units may be located on upper floor levels providing

the floor is capable of supporting the total unit operat-

ing weight and optional spring isolators are used.

Sufcient 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 evaporator and condenser tubes – see

Clearance. A doorway or other sufciently

large opening properly located may be

used. The chiller should be located in an

indoor location where temperatures range

from 40°F to 110°F (4.4°C to 43.3°C).

MOTORS

The YK open motor is air cooled. Check state, local,

and other codes for ventilation requirements.

FOUNDATION

A level floor, mounting pad or foundation must be pro-

vided by others, capable of supporting the operating

weight of the unit.

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 meters) on shell codes Q-Q, N-N, R-R, X-T and X-X.

** 18 ft (5.5 meters) on shell code S-S, S-V, Z-Z.

*** 22 ft (6.7 meters) on shell code W-W.

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 1 - INTRODUCTION

Mounting

Bracket

Pad

3/8”

(10)

3/4”

(19)

DETAIL A

LD19571a

SHELL

END SHEET

DIA.

HOLE

See Detail A

SHELL

END SHEET

DIA.

HOLE

See Detail A

SHELL

END SHEET

DIA.

HOLE

See Detail A

SHELL

END SHEET

DIA.

HOLE

See Detail A

ALL DIMENSIONS ARE IN INCHES (MM)

UNIT WEIGHT 53,531 - 100,464 Lbs (24,283 - 45,559 Kgs)

LD12641a

UNIT WEIGHT UP TO 16,365 Lbs (7,423 Kgs)

LD12638a

UNIT WEIGHT 16,366 - 28,835 Lbs (7,424 - 13,080 Kgs)

LD12639a

UNIT WEIGHT 28,836 - 53,530 Lbs (13,081 - 24,281 Kgs)

LD12640a

FIGURE 5 - NEOPRENE ISOLATORS

SHELL

END SHEET

DIA.

HOLE

See Detail A

UNIT WEIGHT 100,465 - 130,000 Lbs

(45,570 - 58,967 Kgs)

UNIT WEIGHT UP TO 200,928 Lbs

(UP TO 91,332 Kgs)

LD12642a

LD19578

SHELL

END SHEET

DIA.

HOLE

(229)

(127)

(229)

See Detail A

JOHNSON CONTROLS

SECTION 1 - INTRODUCTION

FORM 160.75-N1

ISSUE DATE: 04/15/2019

ALL DIMENSIONS ARE IN INCHES (MM)

FIGURE 6 - SPRING ISOLATORS

UNIT WEIGHT

35,010 Lbs UP TO 58,349 Lbs

(15,881 Kgs UP TO 26,467 Kgs)

SHELL

6-SPRING ISOLATORS

END

SHEET

CAP

SCREW

ADJUSTING

BOLT

5 1/2"

(140)

LD19579

UNIT WEIGHT

58,350 Lbs. UP TO 89,340 Lbs

(26,468 Kgs UP TO 40,525 Kgs)

SHELL

9-SPRING ISOLATORS

END

SHEET

CAP

SCREW

ADJUSTING

BOLT

9”

(229)

9”

(229)

6-1/4"

(159)

LD19419

SHELL

4-SPRING ISOLATORS

END

SHEET

CAP

SCREW

ADJUSTING

BOLT

1”

(25)

5 1/2”

(140)

1 3/8”

(35)

6”

(152)

6”

(152)

LD19573

SHELL

4-SPRING ISOLATORS

END

SHEET

CAP

SCREW

ADJUSTING

BOLT

7”

(178)

7”

(178)

1”

(25)

5 1/2”

(140)

1 3/8”

(35)

LD19572

UNIT WEIGHT

10,000 to 19,563

(4,536 to 8,873 Kgs)

UNIT WEIGHT

19,564 Lbs UP TO 35,009 Lbs

(8,874 Kgs UP TO 15,880 Kgs)

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 1 - INTRODUCTION

ALL DIMENSIONS ARE IN INCHES (MM)

FIGURE 7 - SPRING ISOLATORS

UNIT WEIGHT

89,341 Lbs UP TO 115,000 Lbs

(40,526 Kgs UP TO 52,163 Kgs)

SHELL

12-SPRING ISOLATORS

END

SHEET

CAP

SCREW

ADJUSTING

BOLT

6-1/4"

(159)

LD19580

UNIT WEIGHT

115,000 Lbs. UP TO 190,000 Lbs

(52,163 Kgs UP TO 86,183 Kgs)

SHELL

3-SPRING ISOLATORS

END

SHEET

CAP

SCREW

ADJUSTING

BOLT

16 1/4"

(413)

5 1/4"

(133)

LD19581

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 2 - INSTALLATION

RIGGING UNIT TO FINAL LOCATION

Rig the unit to its final location on the floor or mount-

ing pad, lift the unit (or shell assembly) by means of an

overhead lift and lower the unit to its mounting posi-

tion. (If optional shipping skids are used, remove them

before lowering the chiller to its mounting position.)

At this point units shipped dismantled

should be assembled under the supervi-

sion of a Johnson Controls representative.

If 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.

Be sure unit is properly supported. (See Figure 4 on

page 13)

LOCATING AND INSTALLING ISOLATOR PADS

The isolator pad mounts are to be located as shown in

Figure 5 on page 14 (rubber side down).

After the isolator pads have been placed into position

on the floor, lower the chiller onto the pads. When the

unit is in place, remove the rigging equipment and

check that the unit is level. The unit should be level

within 1/4" (6 mm) from one end to the other end and

from front to the rear. If the chiller is not level within

the amount specified, lift it and place shims between

the isolation pad and the chiller tube sheets. (Shims

furnished by the installer.) Lower unit again and re-

check to see that it is level.

CHECKING THE ISOLATION PAD DEFLECTION

All isolation pads should be checked for the proper de-

flection while checking to see if the unit is level. Each

pad should be deflected approximately 0.10 inches

(2.5 mm) to 0.20 inches (5 mm). If an isolation pad is

under-deflected, shims should be placed between the

unit tube sheet and the top of the pad to equally deflect

all pads.

LEVELING THE UNIT

The longitudinal alignment of the unit should be

checked by placing a level on the top center of the

evaporator shell under the compressor/motor assem-

bly. Transverse alignment should be checked by plac-

ing a level on top of the shell end sheets.

INSTALLING OPTIONAL SPRING ISOLATORS

When ordered, spring type isolator assemblies will be

furnished with the unit. The 4 assemblies are identical

and can be placed at any of the 4 corners of the unit.

While the unit is still suspended by the rigging, the iso-

lators should be bolted to the unit by inserting the cap

screw(s) through the hole(s) in the mounting bracket

into the tapped hole in the top of the isolator leveling

bolt(s). Then the unit can be lowered onto the floor.

The leveling bolts should now be rotated one (1) turn at

a time, in sequence, until the unit end sheets are clear

of the floor by the dimension shown in Figure 6 on

page 15 and Figure 7 on page 16 and the unit is

level. Check that the unit is level, both longitudinally

and transversely (see Leveling the Unit on page 17).

If the leveling bolts are not long enough to level unit

due to an uneven or sloping floor or foundation, steel

shims (grouted, if necessary) must be added beneath

the isolator assemblies as necessary.

After the unit is leveled, wedge and shim under each

corner to solidly support the unit in this position while

piping connections are being made, pipe hangers ad-

justed and connections checked for alignment. Then

the unit is filled with water and checked for leaks. The

leveling bolts should now be finally adjusted until the

wedges and shims can be removed. The unit should

now be in correct level position, clear of the floor or

foundation and without any effect from the weight of

the piping.

PIPING CONNECTIONS

After the unit is leveled (and wedged in place for op-

tional spring isolators) the piping connections may be

made; chilled water, condenser water and refrigerant

relief. The piping should be arranged with offsets for

flexibility, and adequately supported and braced inde-

pendently of the unit to avoid strain on the unit and

vibration transmission. Hangers must allow for align-

ment of pipe. Isolators (by others) in the piping and

hangers are highly desirable, and may be required by

specifications, in order to effectively utilize the vibra-

tion isolation characteristics of the vibration isolation

mounts of the unit.

Check for piping alignment – Upon completion of

piping, a connection in each line as close to the unit

as possible should be opened, by removing the flange

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 2 - INSTALLATION

bolts or coupling and checked for piping alignment. If

any of the bolts are bound in their holes, or if the con-

nection springs are out of alignment, the misalignment

must be corrected by properly supporting the piping or

by applying heat to anneal the pipe.

If the piping is annealed to relieve stress,

the inside of the pipe must be cleaned of

scale before it is nally bolted in place.

EVAPORATOR AND CONDENSER WATER

PIPING

The evaporator and condenser liquid heads of chiller

have nozzles which are grooved, suitable for welding

150 psig DWP flanges or the use of flexible couplings.

Factory mounted flanges are optional.

The nozzles and water pass arrangements are furnished in ac-

cordance with the job requirements (refer to Product Draw-

ings) furnished with the job. Standard units are designed 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 has provisions for the required DWP.

Inlet and outlet connections are identified by labels

placed adjacent to each nozzle.

The coolant temperature inside any JCI-supplied liquid-

cooled motor starter must be maintained above the dewpoint

temperature in the equipment room to prevent condensing

water vapor inside the starter cabinet. Therefore, an addi-

tional temperature-controlled throttle valve is needed in the

flow path for the starter heat exchanger to regulate cooling

above the equipment room dewpoint for applications using

cooling sources other than evaporative air-exchange meth-

ods, such as wells, bodies of water, and chilled water. The

temperature control valve should be the type to open on in-

creasing drive coolant temperature, fail-closed, and set for a

temperature above dewpoint. It can be requested as factory-

supplied on a chiller order by special quotation.

Chilled Water

Foreign objects which could lodge in, or block flow

through, the evaporator and condenser tubes must be

kept out of the water circuit. All water piping must be

cleaned or flushed before being connected to the chiller

pumps, or other equipment.

Permanent strainers (supplied by others) are required

in both the evaporator and condenser water circuits to

protect the chiller as well as the pumps, tower spray

nozzles, chilled water coils and controls, etc. The

strainer must be installed in the entering chilled water

line, directly upstream of the chiller.

Water piping circuits should be arranged so that the

pumps discharge through the chiller, and should be

controlled as necessary to maintain essentially constant

chilled and condenser water flows through the unit at

all load conditions.

If pumps discharge through the chiller, the strainer

may be located upstream from pumps to protect both

pump and chiller. (Piping between strainer, pump and

chiller must be very carefully cleaned before start-up.)

If pumps are remotely installed from chiller, strainers

should be located directly upstream of the chiller.

FIGURE 8 - SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT

LD08529

EVAPORATOR

CONDENSER

STRAINER

COOLING

TOWER

COOLING

UNIT

C = COMPRESSOR

M = MOTOR

FLOW SWITCH

CHILLED WATER PUMP

COOLING TOWER

PUMP

COOLING UNIT

CODEPAK

CONTROLLED COOLING

TOWER BYPASS VALVE

(IF NECESSARY)

JOHNSON CONTROLS

SECTION 2 - INSTALLATION

FORM 160.75-N1

ISSUE DATE: 04/15/2019

Condenser Water Circuit

For proper operation of the unit, condenser refrigerant

pressure must be maintained above evaporator pres-

sure. If operating conditions will fulfill this require-

ment, no attempt should be made to control condenser

water temperature by means of automatic valves, cy-

cling of the cooling tower fan or other means, since

chillers are designed to function satisfactorily and ef-

ficiently when condenser water is allowed to seek its

own temperature level at reduced loads and off-peak

seasons of the year. However, if entering condenser

water temperature can go below the required mini-

mum, refer to Unit Operation and Maintenance (Form

160.75-O1); condenser water temperature must be

maintained equal to or slightly higher than the required

minimum. See Figure 8 on page 18 for typical water

piping schematic.

Stop Valves

Stop valves may be provided (by others) in the evapora-

tor and condenser water piping adjacent to the unit to

facilitate maintenance. Thermometer wells and pressure

taps should be provided (by others) in the piping as close

to the unit as possible to facilitate operating check.

Flow Switches

Thermal type water flow switches are factory mount-

ed in the chilled and condensed water nozzles and are

factory wired to the OptiView™ control panel. These

solid-state flow sensors have a small internal heat-

ing element and use the cooling effect of the flowing

fluid to sense when an adequate flow rate has been

established.

Waterbox Drain and Vent Valves

Drain and vent valves (by others) should be installed

in the connections provided in the evaporator and con-

denser liquid heads. These connections may be piped

to drain if desired.

Checking Piping Circuits and Venting Air

After the water piping is completed, but before any

waterbox insulation is applied. Tighten and torque to

maintain between 30 and 60 ft. lbs. (41 and 81 N·m)

the nuts on the liquid head flanges. Gasket shrinkage

and handling during transit cause nuts to loosen. If wa-

ter pressure is applied before tightening is done, the

gaskets may be damaged and have to be replaced. Fill

the chilled and condenser water circuits, operate the

pumps manually and 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 at the high points.

UNIT PIPING

Compressor lubricant piping and system external pip-

ing are factory installed on all units shipped assembled.

On units shipped dismantled, the following piping

should be completed under the supervision of the John-

son Controls representative: (1) the lubricant piping to

oil sump and oil evaporator and system oil return con-

nections using material furnished. Refer to Installation

and Reassembly - Unit (Form 160.75-N3).

JOHNSON CONTROLS

FORM 160.75-N1

ISSUE DATE: 04/15/2019

SECTION 2 - INSTALLATION

REFRIGERANT RELIEF PIPING

Each unit is equipped with pressure relief valves lo-

cated on the condenser and on the evaporator for the

purpose of quickly relieving excess pressure of the re-

frigerant charge to the atmosphere as a safety precau-

tion in case of an emergency, such as fire.

Refrigerant relief vent piping (by others), from the re-

lief valves to the outside of the building, is required

by code in most areas and should be installed on all

chillers. 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 in-

tercept and permit clean out and to trap any vent stack

condensation. The piping MUST be arranged to avoid

strain on the relief valves, using a flexible connection,

if necessary.

FIGURE 9 - TYPICAL REFRIGERANT VENT PIPING

FLANGED JOINT

TO PERMIT PIPING

DISASSEMBLY

CONDENSATION

TRAP

DUAL RELIEF

VALVES

VENT TO ATMOSPHERE

SUPPORT VENT PIPING TO AVOID

STRAIN ON RELIEF PIPING

FLEXIBLE CONNECTOR

CONDENSER

EVAPORATOR

SEE NOTE

NOTE: SHELLS MAY BE FURNISHED WITH

ONE OR TWO RELIEF VALVES,

DEPENDING ON SHELL SIZE.

LD03863

When installing relief piping there

must NOT be any piping strain.

Relief piping must be properly

aligned and supported to eliminate

any possible piping strain.

When installing relief piping an

ANSI flange or a piping union

must be used to make a

servicable piping connection.

Horizontal

Mis-aligned

Vertical

Offset

Compressed

LD16677

Page is loading ...

Johnson Controls YORK YKKCK4H9-CYG Installation Instructions Manual

Brand: Johnson Controls

Model: YORK YKKCK4H9-CYG

Type: Installation Instructions Manual

This manual is also suitable for

YORK YK Series

Download PDF

report

Johnson Controls YORK YKKCK4H9-CYG Installation Instructions Manual

This manual is also suitable for

Johnson Controls YORK YKKCK4H9-CYG Installation Instructions Manual

Related papers

Other documents