FIELD RE-ASSEMBLY FOR FORM 3 AND FORM 7 SHIPMENT MODEL YD CHILLERS - MOD A AND B WITH GRAPHIC CONTROL CENTER AND ELECTRO-MECHANICAL STARTER

Transcription

1 CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS Supersedes: NM3 (912) Form NM3 (715) FIELD RE-ASSEMBLY FOR FORM 3 AND FORM 7 SHIPMENT MODEL YD CHILLERS - MOD A AND B WITH GRAPHIC CONTROL CENTER AND ELECTRO-MECHANICAL STARTER Issue Date: July 31, 2015

2 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. During rigging, installation, operation, maintenance, or service, individuals may be exposed to certain components or conditions including, but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and both high and low voltage. 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, installation, 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 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 individual 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. Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution if proper care is not taken or instructions and are not followed. Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment if proper care is not taken. Highlights additional information useful to the technician in completing the work being performed properly. External wiring, unless specified 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 accordance with Johnson Controls published specifications and must be performed only by a qualified 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 warning will void the manufacturer s warranty and cause serious damage to property or personal injury. 2 JOHNSON CONTROLS

3 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous product improvement, the information contained 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 Johnson Controls QuickLIT website at 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, rigging, 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 information and any other changes in spelling, grammar or formatting are not included. Unit Installation OptiView TM Operation Shipping Damage Claim Policy ASSOCIATED LITERATURE MANUAL DESCRIPTION FORM NUMBER N O NM JOHNSON CONTROLS 3

4 NOMENCLATURE YD XF XA J2 CA A MODEL EVAPORATOR CODE XF, XH YF, YG, YH, ZF, ZG, ZH AF, AG, AH CONDENSER CODE XA, XB, XC, XD, YA, YB, YC, YD, ZA, ZB, ZC, ZD, AA, AB, AC, AD POWER SUPPLY - for 60 Hz 5 for 50 Hz COMPRESSOR CODE J1, J2, J3, J4, J5 MOTOR CODE 60 Hz 50 Hz CW CX CY CZ CA CB DA DB DC DD DE DF DH DJ DESIGN LEVEL 5CS 5CT 5CU 5CV 5CW 5CX 5DA 5DB 5DC 5DD 5DE 5DF 5DG 5DH 5DJ YD XH XD J2 DA B MODEL EVAPORATOR CODE KB, KC, KD, K2, K3, K4 HB, HC, HD, H2, H3, H4 GB, GC, GD, G2, G3, G4 FB, FC, FD, F2, F3, F4 EB, EC, ED, E2, E3, E4 DB, DC, DD, D2, D3, D4 CB, CC, CD, C2, C3, C4 BB, BC, BD, B2, B3, B4 COMPRESSOR CODE J1, J2, J3, J4, J5, J7 CONDENSER CODE KB, KC, KD, KE, K2, K3, K4, K5 HB, HC, HD, HE, H2, H3, H4, H5 GB, GC, GD, GE, G2, G3, G4, G5 FB, FC, FD, FE, F2, F3, F4, F5 EB, EC, ED, EE, E2, E3, E4, E5 DB, DC, DD, DE, D2, D3, D4, D5 CB, CC, CD, C2, C3, C4 BB, BC, BD, BE, B2, B3, B4, B5 POWER SUPPLY for 60 Hz 5 for 50 Hz MOTOR CODE 60 Hz 50 Hz CW CX CY CZ CA CB DA DB DC DD DE DF DH DJ DK DL DESIGN LEVEL 5CS 5CT 5CU 5CV 5CW 5CX 5DA 5DB 5DC 5DD 5DE 5DF 5DG 5DH 5DJ 5DK 5DL 4 JOHNSON CONTROLS

5 LIST OF FIGURES FIGURE 1 - Front View Of Assembled Unit...7 FIGURE 2 - Form 7 Shipment...8 FIGURE 3 - Rigging Compressor/Motor Assembly...9 FIGURE 4 - Re-Assembly...10 FIGURE 5 - System Piping FIGURE 6 - System Piping FIGURE 7 - Liquid Line Re-Assembly...12 FIGURE 8 - Oil Pump Housing...13 JOHNSON CONTROLS 5

6 THIS PAGE INTENTIONALLY LEFT BLANK. 6 JOHNSON CONTROLS

7 GENERAL This instruction explains the procedure to be used for reassembling the Model YD Chiller shipped disassembled (Shipping Form 3 and 7). Chillers MUST be field reassembled under the supervision of a Johnson Controls representative. For Installation Instructions other than unit assembly, refer to Form N1 or N2. FORMS OF SHIPMENT Form 3 Driveline Separate From Shells Shipped as three major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Close-coupled compressor/open motor assemblies are removed from shells and skidded. Evaporator/condenser is not skidded. All wiring essential with the compressors is left on them, and all conduit is left on the shells. All openings on the compressors and shells are closed and charged with dry nitrogen (2 to 3 PSIG). Miscellaneous packaging of the Control Center, oil eductor filter, tubing, water temperature controls, wiring, oil, isolators, etc. Refrigerant charge shipped in appropriate cylinders. Form 7 Split Shells Shipped as four major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Close-coupled compressor/open motor assemblies removed from shells and skidded. Evaporator and condenser shells are separated at tube sheets and are not skidded. Refrigerant lines between shells are flanged and capped; tube sheets are also bolted, requiring no welding. MOTOR COMPRESSOR COMPRESSOR MOTOR CONDENSER VSOP PANEL GRAPHIC CONTROL CENTER EVAPORATOR LD09115 Figure 1 - FRONT VIEW OF ASSEMBLED UNIT JOHNSON CONTROLS 7

8 All wiring essential with the compressors is left on them. All wiring harnesses on shells are removed. All openings on the compressors and shells are closed and charged with dry nitrogen (2 or 3 PSIG). Miscellaneous packaging of Control Center, oil eductor filter, tubing, water temperature controls, wiring, oil, isolators, etc. Refrigerant charge shipped in appropriate cylinders. When more than one chiller is involved, the major parts of each unit will be marked to prevent the mixing of assemblies (Piping and Wiring Drawings to be furnished by YORK). 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 immediately for their inspection. YORK will not be responsible for any damage in shipment of at job site or loss of parts. (Refer to Shipping Damage Claims, Form 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 YORK immediately (refer to Shipping Damage Claims, Form NM). DATA PLATES A unit data plate is mounted on the Control Center assembly of each unit, giving unit model number; design working pressure; water passes; refrigerant charge; serial numbers; and motor power characteristics and connection diagrams. A Control Panel data plate, which includes control panel part number and serial number is also included. CONDENSER COOLER 5/8" X 2-1/2" BOLTS, LOCKWASHERS, & HEX NUTS LD03865 Figure 2 - FORM 7 SHIPMENT 8 JOHNSON CONTROLS

9 RE-ASSEMBLY The following is a step-by-step procedure to be used to assemble the chiller. Refer to Installation Instruction, Form N1 or N2 for other instructions. Form 7 Shipment (See Figure 2 on page 8) 1. Locate the evaporator and condenser shells in their final position. 2. Bolt the tube sheets together as shown in Figure 2 on page 8. Note that the outside surfaces of the tube sheets must be flush. FORM 3 AND FORM 7 SHIPMENT 1. Level the shells in both directions. The longitudinal alignment of the shell should be checked by placing a level on the top of the shell, next to the discharge connection. The transverse alignment should be checked by placing a level on the tops of both end sheets. Refer to Installation Instruction, Form N1 or N2 for additional instructions to level the unit. After the shell is leveled, wedge and shim each corner of the shell to solidly support it while assembling the other parts. 2. Lift a compressor/motor assembly and remove the packing materials (refer to Figure 3 on page 9 for rigging). Carefully lower the compressor/motor assembly on to the supports on the condenser and evaporator. Fasten with the proper hardware. Do not tighten the bolts until all connections are made to the compressor. 3. Bolt the suction lines between the compressors and the evaporator using the proper gaskets and hardware, see Figure 4 on page Install the isolation valves between the compressors and the condenser using proper gaskets and hardware, see Figure 4 on page Connect the oil drain lines between the compressors oil drain flanges and oil pump housing flanges. Be sure to install the proper gaskets and hardware, see Figure 4 on page 10 and Figure 7 on page Complete the refrigerant liquid piping beneath the evaporator and condenser. Be sure the fill piece, orifice plate, gaskets and hardware are properly installed, see Figure 6 on page Tighten all hardware installed from the previous steps 2 thru Assemble the Control Center to unit. 9. Assemble the VS Oil Pump Control Panel. 10. Install the refrigerant piping and oil return system filters. 11. Pressure test. NOTE: Relief valves must be plugged (or capped) (refer to Form O2). 12. Evacuate and charge with refrigerant (refer to Form O2). 13. All Units Complete installation and finally level the unit per Installation Instruction, Form N1 or N2. LD02140 Figure 3 - RIGGING COMPRESSOR/MOTOR ASSEMBLY JOHNSON CONTROLS 9

10 CONDENSER Motor Compressor #1 Gasket Gasket Isolation Valve with Actuator Gasket O-Ring Oil Pump Housing Gasket EVAPORATOR O-Ring O-Ring Oil Drain Line Compressor #2 Gasket O-Ring Oil Drain Line Flexible Metal Braided Elbow Assembly Compressor Support Gasket VSOP Panel Figure 4 - RE-ASSEMBLY LD JOHNSON CONTROLS

11 Isolation Valve with Actuator Compressor #2 Isolation Valve with Actuator Compressor #1 VSOP Panel LD09431 Figure 5 - SYSTEM PIPING Compressor #2 Compressor #1 VSOP Panel Figure 6 - SYSTEM PIPING LD09433 JOHNSON CONTROLS 11

12 Figure 7 - LIQUID LINE RE-ASSEMBLY LD09435

13 Figure 8 - OIL PUMP HOUSING LD09442

14 P.O. Box 1592, York, Pennsylvania USA Subject to change without notice. Printed in USA Copyright by Johnson Controls ALL RIGHTS RESERVED Form NM3 (715) Issue Date: July 31, 2015 Supersedes: NM3 (912)