CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTION Supersedes: 160.69-N1 (912) Form 160.69-N1 (715) MODEL YD (STYLE A) R-134A (COOLING ONLY) WITH OPTIVIEW CONTROL CENTER AND ELECTRO-MECHANICAL STARTER LD08634 R-134A Issue Date: July 31, 2015
IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES FORM 160.69-N1 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
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 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, 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. ASSOCIATED LITERATURE MANUAL DESCRIPTION YD Unit Field Reassembly Instructions YD with OptiView Control Center and EMS (Cooling Only) Operating Manual Wiring Diagram YD Unit Installation Checklist and Request for Startup Engineer Service Policy FORM NUMBER 160.69-NM3 160.69-O2 160.69-PW1 160.69-CL1 50.07-NM1 JOHNSON CONTROLS 3
NOMENCLATURE YD XF XA J2 CA A DESIGN LEVEL MODEL EVAPORATOR CODE XF, XH YF, YG, YH, ZF, ZG, ZH AF, AG, AH COMPRESSOR CODE J1, J2, J3, J4, J5 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 MOTOR CODE 60 Hz 50 Hz CW 5CS CX 5CT CY 5CU CZ 5CV CA 5CW CB 5CX DA 5DA DB 5DB DC 5DC DD 5DD DE 5DE DF 5DF 5DG DH 5DH DJ 5DJ 4 JOHNSON CONTROLS
TABLE OF CONTENTS SECTION 1 - INTRODUCTION...7 General...7 Field Assembled Units Only...7 Shipment...7 Inspection Damage Shortage...8 Chiller Data Plate...9 Rigging...9 Location...9 Motors...9 Foundation...9 Clearance...9 Neoprene Isolators... 11 Spring Isolators...13 Unit Dimensions...15 Unit Weights...16 Motor Weights and Voltage...16 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 Chilled Water...18 Condenser Water Circuit...18 Stop Valves...20 Flow Switches...20 Drain and Vent Valves...20 Checking Piping Circuits and Venting Air...20 Refrigerant Relief Piping...20 Unit Piping...20 Control Panel Positioning...20 Control Wiring...21 Power Wiring...21 Oil Pump 3 Phase Starter...21 YD Motors (Electro-Mechanical Starter)...21 Insulation...21 Installation Check Request For Start-Up Service...22 Compressor Motor Field Connection Diagram...22 JOHNSON CONTROLS 5
LIST OF FIGURES FIGURE 1 - Rigging...10 FIGURE 2 - Neoprene Isolators...11 FIGURE 3 - Neoprene Isolators...12 FIGURE 4 - Spring Isolators...13 FIGURE 5 - Model YD Chiller...14 FIGURE 6 - Dimensions J Compressor Units...15 FIGURE 7 - Schematic of a Typical Piping Arrangement...19 FIGURE 8 - Typical Refrigerant Vent Piping...19 FIGURE 9 - Control Panel Positioning...20 FIGURE 10 - Motor Connections (Electro Mechanical Starter Application)...22 LIST OF TABLES TABLE 1 - Evaporator - Condenser Shell Codes...15 TABLE 2 - Approximate Unit Weight Including Motor...16 TABLE 3 - Approximate Unit Motor Weights...16 TABLE 4 - Motor Connections...22 6 JOHNSON CONTROLS
SECTION 1 - INTRODUCTION 1 GENERAL This instruction describes the installation of a MOD- EL YD Liquid Chilling Unit. This unit is shipped as a single factory assembled, piped, wired package, requiring a minimum of field labor to make chilled water connections, condenser water connections, refrigerant atmospheric relief connections, and electrical power connections. (Refrigerant and oil charges 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 economical 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 installation will be as described in this instruction. FIELD ASSEMBLED UNITS ONLY Use Form 160.69-NM3 in conjunction with this installation instruction. This instruction will be furnished with all units that are to be field assembled. Extra copies may be ordered from the Johnson Controls Publication Distribution Center. 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 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 reason except under the supervision of a Johnson Controls representative. 3. When units are shipped dismantled, notify the nearest Johnson Controls office 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 final power supply connections to the compressor motors or control center. 5. Do not charge the compressors 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 motor, refrigerant and oil charges. 1. The motor/compressor assembly mounted, with all necessary interconnecting piping assembled. OptiView Control Center is mounted on the unit. Complete unit factory leak tested, evacuated and charged with R-134A. 2. Miscellaneous material Four (4) vibration isolation pads (or optional spring isolators and brackets). Form 2 Factory Assembled Unit, complete with motors (refrigerant and oil charges shipped separately). 1. The motor/compressor assemblies mounted, with all necessary interconnecting piping assembled. OptiView Control Center is mounted on the unit. Complete unit factory leak tested, evacuated and charged with holding charge of nitrogen. 2. Miscellaneous material Four (4) vibration isolation pads (or optional spring isolators and brackets). Form 3 Drivelines Separate From Shells Shipped as three major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Compressor/motor assemblies removed from shells and skidded. Evaporator/condenser is not skidded. All wiring integral with compressors are left on them, and all conduit is left on shell. All openings on compressors, oil separator, and shells are closed and charged with dry nitrogen (2 to 3 PSIG) (14-21 kpa). Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil, isolators, solid state starters (option), etc.; refrigerant charge shipped separately. JOHNSON CONTROLS 7
SECTION 1 - INTRODUCTION Units shipped dismantled MUST be reassembled by, or under the supervision of, a Johnson Controls representative. (See Form 160.69-NM3) FORM 160.69-N1 Units shipped dismantled MUST be reassembled by, or under the supervision of, a Johnson Controls representative. (See Form 160.69-NM3) Form 7 Split Shells Shipped as four major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Compressor/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, requiring no welding. All wiring integral with compressors are left on them. All wiring harnesses on shells are removed. All openings on compressors and shells are closed and charged with dry nitrogen (2 to 3 psig) (14-21 kpa). Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil isolators, solid state starter (option), etc.; refrigerant charge shipped separately. 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 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. Johnson Controls will not be responsible for any damage in shipment or at job site or loss of parts. (Refer to Shipping Damage Claims, Form 50.15-NM) Rigging and lifting should only be done by a professional rigger in accordance with a written rigging and lifting plan. The most appropriate rigging and lifting method will depend on job specific 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. 8 JOHNSON CONTROLS
SECTION 1 - INTRODUCTION 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 assembly of each unit, giving unit model number; design working pressure; water passes; refrigerant charge; serial numbers; and motor power characteristics and connection diagrams. Additional information may be found on the motor data plates. This information should be included when contacting the factory on any problem relating to the motor. 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 1 on page 10. Do not lift the unit with slings around motor/compressor assemblies or by means of eyebolts in the trapped holes of the compressor motor assemblies. Do not turn a unit on its side for rigging. Do not rig vertically. The rigging and operating weights and overall dimensions are given on pages 6 thru 8 as a guide in determining the clearances required for rigging. Add 6" (15 cm) to overall height for optional skidded unit. The lengthwise rigging bar should be longer than the chiller tube length, and must have counter or clevis adjustments to allow for center of gravity adjustments. Chain spreaders should be used to avoid contact with drive motors or other chiller parts. LOCATION YORK Chillers are furnished with vibration isolator 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 operating weight and optional spring isolators are used. MOTORS Sufficient 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 sufficiently 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). 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 provided 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 18 ft. (5.5 m) (either end) 1 JOHNSON CONTROLS 9
SECTION 1 - INTRODUCTION FORM 160.69-N1 LD09014a Figure 1 - RIGGING 10 JOHNSON CONTROLS
SECTION 1 - INTRODUCTION NEOPRENE ISOLATORS 1 SHELL SHELL DIA. HOLE END SHEET DIA. HOLE END SHEET 5" (127) 10" (254) 5" (127) 10" (254) 8" (203) 8" (203) See Detail A See Detail A 9" (229) Y/Y - Y/Y - Up to 225,000 lbs. (102,060 Kgs) X/X - X/X - Up to 130,000 lbs (58,967 Kgs) Z/Z - Z/Z - Up to 280,000 lbs (127,005 Kgs) A/A - A/A - Up to 280,000 lbs (127,005 Kgs) LD19590 LD19589 Mounting Bracket 3/8 (10) Pad 3/4 (19) LD19571a DETAIL A Figure 2 - NEOPRENE ISOLATORS JOHNSON CONTROLS 11
SECTION 1 - INTRODUCTION FORM 160.69-N1 NEOPRENE ISOLATORS * * B * Typical both ends. LD12643a SHELL CODE UNIT WEIGHT DIM "A" DIM "B" DIM "C" DIM "D" QUANTITY Y - Y Z - Z A - A Up to 190,000 lbs (86,184 Kgs) Up to 240,000 lbs (108,862 Kgs) Up to 240,000 lbs (108,862 Kgs) 12' 9" (3887) Approx weight including motor and 150# compact water boxes. 9" (229) 10" (254) 8 8 x 1" 13' 8" (4166) 11" (279) 10" (254) 8 from edge. 14' 8" (4471) 11" (279) 10" (254) 8 Figure 3 - NEOPRENE ISOLATORS 12 JOHNSON CONTROLS
SECTION 1 - INTRODUCTION SPRING ISOLATORS 1 END SHEET SHELL END SHEET SHELL 16 1/4" (413) 3" (76) 6-1/4" (159) CAP SCREW ADJUSTING BOLT CAP SCREW ADJUSTING BOLT 12-SPRING ISOLATORS LD19580 3-SPRING ISOLATORS LD19591 UNIT WEIGHT x/x - x/x - Up to 115,000 lbs (52,163 Kgs) UNIT WEIGHT Y/Y - Y/Y - Up to 190,000 lbs (86,184 Kgs) Z/Z - Z/Z - Up to 240,000 lbs (108,862 Kgs) A/A - A/A - Up to 240,000 lbs (108,862 Kgs) Figure 4 - SPRING ISOLATORS JOHNSON CONTROLS 13
SECTION 1 - INTRODUCTION FORM 160.69-N1 MOTOR #1 MOTOR #2 COMPRESSOR #2 COMPRESSOR #1 OPTIVIEW CONTROL CENTER EVAPORATOR CONDENSER LD08634 Figure 5 - MODEL YD CHILLER 14 JOHNSON CONTROLS
SECTION 1 - INTRODUCTION UNIT DIMENSIONS CONDENSER 1 EVAPORATOR B COMPRESSORS MOTORS M D L C A SHIPPING WIDTH FLOOR LINE J LD09013 230 mm H F E G Figure 6 - DIMENSIONS J COMPRESSOR UNITS LD09012 Table 1 - EVAPORATOR - CONDENSER SHELL CODES SHELL CODE FT. IN. X-X Y-Y Z-Z A-A A 10'-7-1/2" (3,240) 11'-5" (3,480) 13'-6" (4,115) 14'-6-1/4" (4,426) 15'-5-1/4" (4,705) B 12'-0" (3,658) 12'-0" (3,658) 13'-0" (3,962) 13'-8" (4,166) 14'-2" (4,318) C 2'-8" (813) 2'-8" (813) 3'-5" (1,041) 3'-9" (1,143) 4'-0" (1,219) D 2'-5 1/2" (749) 2'-5 1/2" (749) 2'-11-1/2" (902) 3'-1-1/2" (955) 3'-4" (1,016) E 18'-0" (5,486) 18'-0" (5,486) 18'-0" (5,486) 18'-0" (5,486) 18'-0" (5,486) F 2'-0-3/4" (629) 2'-0-3/4" (629) 2'-1" (635) 2'-3" (686) 2'-3-9/16" (700) G 1'-4-3/4" (425) 1'-4-3/4" (419) 1'-4-1/4" (413) 1'-6-1/4" (464) 1'-6-7/8" (479) H 0'-11-11/16" (297) 0'-11-11/16" (297) 1'-2-5/8" (371) 1'-3-5/8" (397) 1'-4-1/4" (413) J 1'-7-5/8" (498) 1'-7-5/8" (498) 2'-1-1/2" (648) 2'-2" (660) 2'-1" (635) L 5'-1-1/2" (1562) 5'-1-1/2" (1,562) 6'-4 1/2" (1,943) 6'-10-1/2" (2,096) 7'-4" (2,235) NOTES: 1. All dimensions are approximate. Certified dimensions are available on request. 2. For compact water boxes (shown above), determine overall unit length by adding water box depth to tube sheet length. 3. Water nozzles can be located on either end of unit. Add 1/2" to nozzle length for flanges connections. 4. To determine overall height, add dimension "M" for the appropriate isolator type. 5. Use of motors with motor hoods may increase overall unit dimensions. ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR TYPE OF CHILLER MOUNTING FT.-IN. MM Neoprene Pad Isolators 1-3/4" 44 Spring Isolators 1" Deflection 1" 25 Direct Mount 3/4" 19 JOHNSON CONTROLS 15
SECTION 1 - INTRODUCTION FORM 160.69-N1 UNIT WEIGHTS Table 2 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR SHELLS COMPRESSOR SHIPPING WEIGHT (LBS.) SHIPPING WEIGHT (KGS.) OPERATING WEIGHT (LBS.) OPERATING WEIGHT (KGS.) EST. REFRIGERANT CHARGE (LBS.) EST. REFRIGERANT CHARGE (KGS.) X-X J1, J2 75,000 34,300 94,400 42,800 6,000 2,722 Y-Y J3 116,000 52,727 146,000 66,364 7,925 3,602 Z-Z J4 136,000 61,818 172,000 78,182 9,725 4,420 A-A J5 155,000 70,455 197,000 89,545 10,875 4,943 Refer to product drawings for detailed weight information. MOTOR WEIGHTS AND VOLTAGE Table 3 - APPROXIMATE UNIT MOTOR WEIGHTS MEDIUM VOLTAGE MOTOR CODE WEIGHT WEIGHT MOTOR CODE 60 HZ HP (LBS.) (KGS.) 50 HZ HP WEIGHT (LBS.) WEIGHT (KGS.) CW 655 4,415 2,007 5CS 658 4,640 2,109 CX 690 4,445 2,020 5CT 704 5,800 2,636 CY 740 4,540 2,064 5CU 750 5,800 2,636 CZ 790 4,640 2,109 5CV 800 5,800 2,636 CA 845 5,800 2,636 5CW 850 6,800 3,091 CB 900 5,800 2,636 5CX 900 6,800 3,091 DA 1000 6,800 3,091 5DA 1000 7,050 3,205 DB 1100 6,800 3,091 5DB 1100 7,300 3,318 DC 1200 7,050 3,205 5DC 1200 7,300 3,318 DD 1300 7,300 3,318 5DD 1300 7,300 3,318 DE 1400 7,300 3,318 5DE 1400 7,500 3,409 DF 1500 7,500 3,409 5DF 1500 7,500 3,409 5DG 1650 7,900 3,591 DH 1750 7,500 3,409 5DH 1750 11,250 5,114 DJ 2000 8,500 3,864 5DJ 2000 11,750 5,341 16 JOHNSON CONTROLS
SECTION 2 - INSTALLATION RIGGING UNIT TO FINAL LOCATION Rig the unit to its final location on the floor or mounting pad, lift the unit (or shell assembly) by means of an overhead lift and lower the unit to its mounting position. (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 supervision 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 Insulation on page 21) LOCATING AND INSTALLING ISOLATOR PADS (Refer to Figure 2 on page 11 and Figure 3 on page 12) The isolator pad mounts are to be located as shown in Figure 2 on page 11 and Figure 3 on page 12. 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 recheck to see that it is level. CHECKING THE ISOLATION PAD DEFLECTION All isolation pads should be checked for the proper deflection while checking to see if the unit is level. Each pad should be deflected approximately 0.10 inchs (2.5 mm) to 0.20 inchs (5 mm). If an isolation pad is underdeflected, 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. Transverse alignment should be checked by placing a level on top of the shell end sheets. INSTALLING OPTIONAL SPRING ISOLATORS (Refer to Figure 4 on page 13) 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 isolators should be bolted to the unit by inserting the cap screws through the holes in the mounting bracket into the tapped hole in the top of the isolator leveling bolts. 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 4 on page 13 and the unit is level. Check that the unit is level, both longitudinally and transversely (see Leveling the Unit). 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 adjusted 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 optional 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 independently of the unit to avoid strain on the unit and vibration transmission. Hangers must allow for alignment of pipe. Isolators (by others) in the piping and hangers are highly desirable, and may be required by 2 JOHNSON CONTROLS 17
SECTION 2 - INSTALLATION specifications, in order to effectively utilize the vibration 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 bolts or coupling and checked for piping alignment. If any of the bolts are bound in their holes, or if the connection 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 finally 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 Victaulic couplings. Factory mounted flanges are optional. The nozzles and water pass arrangements are furnished in accordance with the job requirements (see Product Drawings) 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. Chilled Water FORM 160.69-N1 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. Condenser Water Circuit For proper operation of the unit, condenser refrigerant pressure must be maintained above evaporator pressure. If operating conditions will fulfill this requirement, no attempt should be made to control condenser water temperature by means of automatic valves, cycling of the cooling tower fan or other means, since chillers are designed to function satisfactorily and efficiently 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 minimum, (refer to 160.69-O2) condenser water temperature must be maintained equal to or slightly higher than the required minimum. Refer to Figure 7 on page 19 for typical water piping schematic. 18 JOHNSON CONTROLS
SECTION 2 - INSTALLATION 2 EVAPORATOR Figure 7 - SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT LD08529 OIL PUMP HOUSING Figure 8 - TYPICAL REFRIGERANT VENT PIPING LD09021 JOHNSON CONTROLS 19
SECTION 2 - INSTALLATION FORM 160.69-N1 Stop Valves Stop valves may be provided (by others) in the evaporator 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 mounted in the chilled and condensed water nozzles and are factory wired to the OptiView control panel. These solidstate flow sensors have a small internal heating element and use the cooling effect of the flowing fluid to sense when an adequate flow rate has been established. Drain and Vent Valves Drain and vent valves (by others) should be installed in the connections provided in the evaporator and condenser 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 water box 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 water 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. REFRIGERANT RELIEF PIPING Each unit is equipped with pressure relief valves located on the condenser, on the evaporator, and on the oil pump housing for the purpose of quickly relieving excess pressure of the refrigerant charge to the atmosphere as a safety precaution in case of an emergency, such as fire. line must include a dirt trap in the vertical leg to intercept 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. UNIT PIPING Compressor lubricant piping and system external piping are factory installed on all units shipped assembled. On units shipped dismantled, the following piping should be completed under the supervision of the Johnson Controls representative: (1) the lubricant piping to oil sump and oil evaporator and system oil return connections using material furnished. See Form 160.69-NM3. CONTROL PANEL POSITIONING (See Figure 9 on page 20) The OptiView Control Center is placed in a position above the evaporator for shipping. To move the control center into position for operation, proceed as follows: 1. While supporting the control center, remove the hardware between the support arms and the evaporator. 2. Swing the control center into a vertical position. 3. Slide the control center down the guide rails to the proper position. Tighten securely. 4. Discard unused hardware. Control Wiring SUPPORT ARMS PANEL TRACK Refrigerant relief vent piping (by others), from the relief 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 Figure 9 - CONTROL PANEL POSITIONING LD03826 20 JOHNSON CONTROLS
SECTION 2 - INSTALLATION CONTROL WIRING On units shipped disassembled, after installation of the control center, control wiring must be completed between unit components and control center, solid state starter, or variable speed drive, when used, using wiring harness furnished. Refer to Form 160.69-N3. Field wiring connections for commonly encountered control modifications (by others) if required, are shown on Form 160.69-PW1. POWER WIRING No deviations in unit wiring from that shown on drawings furnished shall be made without prior approval of the Johnson Controls representative. Oil Pump 3 Phase Starter Separate wiring or a fused disconnect switch should be supplied by the installer and connected to the variable speed oil pump panel. DO NOT make final power connections to the chiller until approved by a Johnson Controls representative. Remote Electro-Mechanical starters for the chiller must be furnished in accordance with Johnson Controls Standard (Product Drawing Form 160.69-PA5.1) to provide the features necessary for the starter to function properly with the YORK control system. Each chiller unit is furnished for a specific electrical power supply as stamped on the Unit Data Plate, which also details the motor connection diagrams. To insure proper motor rotation the starter power input and starter to motor connections must be check with a phase sequence indicator in the presence of the Johnson Controls representative. YD Motors (Electro-Mechanical Starter) Figure 10 on page 22 shows the power wiring hookup for Motor Connections. (Refer to Wiring Labels in Motor Terminal Box for hook-up to suit motor voltage and amperage.) Motor leads are furnished with a crimp type connection having a clearance hole for a 3/8" bolt, motor terminal lugs are not furnished. The YD Chiller has two motors which must be connected to the proper starter. When viewed from the chiller control panel, motor #1 is on the left and motor #2 is on the right. INSULATION (See Product Drawings Form 160.52-PA1) DO NOT field insulate until the unit has been leak tested under the supervision of a Johnson Controls representative. Insulation of the type specified for the job, or minimum thickness to prevent sweating of 30 F (-1 C) surfaces should be furnished (by others) and applied to the evaporator 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 removal for the tube maintenance. Details of areas to be insulated are given on the Product Drawing. Units are furnished factory anti-sweat insulated on order at additional cost. This includes all low temperature surfaces except the two (2) cooler liquid heads. DO NOT cut wires to final length or make final connections to motor terminals or starter power input terminals until approved by the Johnson Controls representative. JOHNSON CONTROLS 21
INSTALLATION CHECK REQUEST FOR START-UP SERVICE The services of a Johnson Controls representative will be furnished to check the installation and supervise the initial start-up and operation on all chillers installed within the Continental United States. After the unit is installed, piped and wired as described in this Instruction, but before any attempt is made to start the unit, the Johnson Controls District Office should be advised so that the start-up service, included in the contract price, can be scheduled. Notification to the Johnson Controls office should be by means of Installation Check List and Request, Form 160.69-CL1, in triplicate. Table 4 - MOTOR CONNECTIONS 3 PHASE MOTOR VOLTAGE 50 / 60 HZ MOTOR RATED LOAD AMPS CT RADIO 200:1 350:1 700:1 1400:1 200-600 65-111 A 112-224 A 225-829 A 830-1790 A 2300-4160 NOTES: 11-18 C 124-264 A 265-518 A 19-37 B 38-123 A 1. Requires passing motor lead thru current transformer (CT) once before connecting to power supply. 2. Requires passing motor lead thru CT twice before connecting to power supply. 3. Requires passing motor lead thru CT three times before connecting to power supply COMPRESSOR MOTOR FIELD CONNECTION DIAGRAM LD00710 Figure 10 - MOTOR CONNECTIONS (ELECTRO MECHANICAL STARTER APPLICATION) 22 JOHNSON CONTROLS
NOTES JOHNSON CONTROLS 23
P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA Copyright by Johnson Controls 2015 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 160.69-N1 (715) Issue Date: July 31, 2015 Supersedes: 160.69-N1 (912)