MILLENNIUM TM CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS Supersedes: Nothing 1296 FORM 160.49-N5 MODEL YK M3 M3 G4 THRU YK S6 S4 J2 (STYLE C) R-22 (COOLING ONLY) MODEL YK LB LB G4 THRU YK SE SC J4 (STYLE C) R-134a (COOLING ONLY) WITH MICROCOMPUTER CONTROL CENTER PART # 371-01200-010, 371-01200-011 & 371-01200-015 FOR ELECTRO-MECHANICAL STARTER, SOLID STATE STARTER & VARIABLE SPEED DRIVE 27385A WARNING SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE SERIOUS INJURY COULD RESULT IF PROPER PROCEDURES ARE NOT FOLLOWED WHEN SERVICING SYSTEM. ALL SERVICE WORK SHALL BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN IN ACCORDANCE WITH YORK INSTALLATION/OPERATION MANUAL.
NOMENCLATURE (R-22 UNITS) YK N2 N1 H1 CX C MODEL DESIGN LEVEL (C) POWER SUPPLY for 60 HZ 5 for 50 HZ COMPRESSOR CODE G4, H0, H1, H2, J1, J2 CONDENSER CODE M3, M4, N3, N4, P3, P4, Q3, Q4, R3, R4, S3, S4 COOLER CODE M3, M4, N3, N4, P3, P4, P5, P6, Q3, Q4, Q5, Q6, R3, R4, R5, R6, S5, S6 MOTOR CODE: { 60 HZ 50 HZ CH CX 5CE 5CT CJ CY 5CF 5CU CK CZ 5CG 5CV CL CA 5CH 5CW CM CB 5CI 5CX CN DA 5CJ 5DA CP DB 5CK 5DB CR DC 5CL 5DC CS DD 5CM 5DD CT DE 5CN 5DE CU DF 5CO 5OF CV DH 5CP 5OG CW DJ 5CQ 5OH 5CR 5OJ 5CS NOMENCLATURE (R-134a) YK NB PB H1 CX C DESIGN LEVEL (C) POWER SUPPLY for 60 HZ 5 for 50 HZ COMPRESSOR CODE G4, H0, H1, H2, J1, J2, J3, J4 CONDENSER CODE LB, LC, MB, MC, NB, NC, PB, PC, QB, QC, RB, RC, SB, SC COOLER CODE LB, LC, MB, MC, NB, NC, PB, PC, PD, PE, QB, QC, QD, QE, RB, RC, RD, RE, SD, SE MOTOR CODE: { 60 HZ 50 HZ CH CX 5CE 5CT CJ CY 5CF 5CU CK CZ 5CG 5CV CL CA 5CH 5CW CM CB 5CI 5CX CN DA 5CJ 5DA CP DB 5CK 5DB CR DC 5CL 5DC CS DD 5CM 5DD CT DE 5CN 5DE CU DF 5CO 5DF CV DH 5CP 5DG CW DJ 5CQ 5DH 5CR 5OJ 5CS MODEL 2 YORK INTERNATIONAL
FORM 160.49-N5 TABLE OF CONTENTS DIMENSIONS... 5 CHILLER WEIGHTS... 6 MOTOR WEIGHTS... 8 INTRODUCTION... 9 General... 9 Field Assembed Units Only... 9 Construction Drawings... 9 Shipment... 9 Inspection Damage Shortage... 10 Chiller Data Plate... 10 Rigging... 10 Location... 11 YK Open Motors Ventilation... 11 Foundation... 11 Clearance... 11 Isolators... 12 INSTALLATION... 14 Rigging Unit to Final Location... 14 Locating and Installing Isolator Pads... 14 Checking the Isolation Pad Deflection... 14 Leveling the Unit... 14 Installing Optional Spring Isolators... 14 Piping Connections... 14 Cooler and Condenser Water Piping... 15 Refrigerant Relief Piping... 16 Unit Piping... 16 Control Wiring... 17 Power Wiring... 17 Insulation... 18 Installation Check Request for Start-up Service... 18 YORK INTERNATIONAL 3
COMPRESSOR CONTROL CENTER MOTOR 27385A COOLER FRONT VIEW DISCHARGE OIL PUMP STARTER PRE-ROTATION VANE ACTUATOR OIL RESERVOIR / PUMP 27382A CONDENSER FIG. 1 MODEL YK MILLENNIUM CHILLER REAR VIEW 4 YORK INTERNATIONAL
FORM 160.49-N5 COOLER - CONDENSER SHELL CODE G4, H0 & H1 COMPRESSORS L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-Q A 6' 5" 6' 4" 6' 7" 6' 6" 6' 9" 6' 11" 7' 2" 7' 6" 7' 4-1/2" 7' 8-1/2" 8' 0-1/2" 8' 0" 8' 4" B 7' 11-3/4" 7' 11-3/4" 8' 2-1/4" 8' 1-3/4" 8' 2-1/4" 8' 4-1/4" 8' 5-1/4" 8' 8-1/4" 8' 8-1/4" 9' 0-1/4" 9' 3-1/4" 9' 0-1/4" 9' 3-1/4" C 1' 8-1/2" 1' 8-1/2" 1' 9-1/2" 1' 9-1/2" 1' 9-1/2" 2' 0" 2' 0" 2' 0" 2' 1-1/4" 2' 1-1/4" 2' 1-1/4" 2' 3" 2' 3" D 1' 6" 1' 5-1/2" 1' 6" 1' 5-1/2" 1' 7" 1' 5-1/2" 1' 7" 1' 9" 1' 7" 1' 9" 1' 11" 1' 9" 1' 11" E 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 10-1/4" 1' 5-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" COOLER - CONDENSER SHELL CODE H2 & H3 COMPRESSORS N-N N-P P-N P-P P-Q Q-P Q-Q Q-R R-Q R-R A 7' 2" 7' 6" 7' 4-1/2" 7' 8-1/2" 8' 0-1/2" 8' 0" 8' 4" 9' 2" 9' 0-1/2" 9' 10-1/2" B 8' 5-1/4" 8' 6-1/4" 8' 9-1/4" 8' 9-1/4" 9' 1-1/4" 9' 0-1/4" 9' 1-1/4" 9' 10-1/4" 9' 7-1/4" 10' 2-1/4" C 2' 0" 2' 0" 2' 1-1/4" 2' 1-1/4" 2' 1-1/4" 2' 3" 2' 3" 2' 3" 2' 7-1/4" 2' 7-1/4" D 1' 7" 1' 9" 1' 7" 1' 9" 1' 11" 1' 9" 1' 11" 2' 4" 1' 11" 2' 4" E 1' 5-1/4" 1' 10-1/4" 1' 5-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 2' 2-1/2" 1' 10-1/4" 2' 2-1/2" COOLER - CONDENSER SHELL CODE DIM. J1 & J2 COMPRESSORS P-P P-Q Q-P Q-Q Q-R R-Q R-R R-S S-R S-S A 7' 6" 7' 10" 7' 10-1/2" 8' 2-1/2" 9' 0-1/2" 8' 9" 9' 7" 10' 0" 10' 0" 10' 5" B 9' 9-1/2" 10' 3-1/2" 9' 9-1/2" 10' 3-1/2" 10' 11-1/2" 10' 3-1/2" 10' 11-1/2" 11' 3-1/2" 10' 11-1/2" 11' 3-1/2" C 2' 0" 2' 0" 2' 2-1/4" 2' 2-1/4" 2' 2-1/4" 2' 5-1/2" 2' 5-1/2" 2' 5-1/2" 2' 8" 2' 8" D 1' 9" 1' 11" 1' 9" 1' 11" 2' 4" 1' 11" 2' 4" 2' 6-1/2" 2' 4" 2' 6-1/2" E 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" COOLER - CONDENSER SHELL CODE DIM. J3 & J4 COMPRESSORS R-Q R-R R-S S-R S-S A 8' 9" 9' 7" 10' 0" 10' 0" 10' 5" B 10' 6-3/4" 11' 0-3/4" 11' 4-3/4" 11' 0-3/4" 11' 4-3/4" C 2' 5-1/2" 2' 5-1/2" 2' 5-1/2" 2' 8" 2' 8" D 1' 11" 2' 4" 2' 6-1/2" 2' 4" 2' 6-1/2" E 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" NOTES: S-S (2) 2" 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 flanged connections. 4. To determine overall height with isolators, see Fig. 4 or 5. 5. Use of motors with motor hoods may increase overall unit dimensions. FIG. 2 DIMENSIONS YORK INTERNATIONAL 5 LD00699 DUAL RELIEF VALVES COOLER / COOLER / CONDENSER NPT1 CONDENSER NPT1 SHELL CODE SHELL CODE L-L (2) 1-1/2" P-N (2) 1-1/2" L-M (2) 1-1/2" P-P (2) 1-1/2" M-L (2) 1-1/2" P-Q (2) 1-1/2" M-M (2) 1-1/2" Q-P (2) 1-1/2" M-N (2) 1-1/2" Q-Q (2) 1-1/2" N-M (2) 1-1/2" Q-R (2) 2" N-N (2) 1-1/2" R-Q (2) 2" N-P (2) 1-1/2" R-R (2) 2"
TABLE 1 CHILLER WEIGHTS (R-22 UNITS) G & H COMPRESSORS SHELL LOADING SHIPPING OPERATING CODE PER WEIGHT WEIGHT COOLER ISOLATOR (LBS.) (LBS.) COND. (LBS.) M3-M3 19,325 23,740 5,935 M3-M4 19,695 24,310 6,077 M4-M3 19,560 24,085 6,021 M4-M4 19,930 26,720 6,680 M3-N3 20,485 24,875 6,218 M3-N4 20,956 25,476 6,369 M4-N3 20,720 25,220 6,305 M4-M4 21,191 25,821 6,455 N3-M3 21,123 25,523 6,381 N3-M4 21,493 26,093 6,523 N4-M3 21,448 25,968 6,492 N4-M4 21,818 26,538 6,635 N3-N3 21,885 26,775 6,694 N3-N4 22,356 25,966 6,492 N4-N3 22,210 27,220 6,805 N4-N4 22,681 27,821 6,955 N3-P3 23,964 29,279 6,820 N3-P4 24,567 30,217 7,554 N4-P3 24,189 29,724 7,431 N4-P4 24,892 30,662 7,666 P3-N3 23,824 29,134 7,284 P3-N4 24,295 29,735 7,434 P4-N3 24,274 29,744 7,436 P4-N4 24,745 30,345 7,586 P3-P3 27,434 33,269 8,317 P3-P4 28,137 34,207 8,552 P4-P3 27,857 33,852 8,463 P4-P4 28,560 34,790 8,698 P3-Q3 30,094 37,054 9,264 P3-Q4 31,012 38,282 9,571 P4-Q3 30,516 37,636 9,409 P4-Q4 31,434 38,864 9,716 Q3-P3 30,278 36,933 9,233 Q3-P4 30,991 37,881 9,470 Q4-P3 30,878 37,753 9,438 Q4-P4 31,591 38,701 9,675 Q3-Q3 32,703 40,483 10,121 Q3-Q4 33,621 41,711 10,428 Q4-Q3 33,303 41,303 10,326 Q4-Q4 34,221 42,531 10,633 Q3-R3 36,527 45,747 11,437 Q3-R4 37,831 47,486 11,872 Q4-R3 37,127 46,567 11,642 Q4-R4 38,431 48,306 12,077 R3-Q3 36,984 46,024 11,506 R3-Q4 37,902 47,252 11,813 R4-Q3 37,792 47,137 11,784 R4-Q4 38,710 48,365 12,091 R3-R3 40,685 51,115 12,779 R3-R4 41,989 52,854 13,214 R4-R3 41,493 52,228 13,057 R4-R4 42,797 53,967 13,492 J COMPRESSORS SHELL LOADING SHIPPING OPERATING CODE PER WEIGHT WEIGHT COOLER ISOLATOR (LBS.) (LBS.) COND. (LBS.) P5-P3 27,934 33,769 8,442 P5-P4 28,637 34,707 8,676 P6-P3 28,357 34,352 8,588 P6-P4 29,060 35,290 8,822 P5-Q3 30,594 37,554 9,388 P5-Q4 31,512 38,782 9,696 P6-Q3 31,016 38,136 9,534 P6-Q4 31,934 39,364 9,841 Q5-P3 30,778 37,433 9,358 Q5-P4 31,491 38,381 9,595 Q6-P3 31,378 38,253 9,563 Q6-P4 32,091 39,201 9,800 Q5-Q3 33,203 40,983 10,245 Q5-Q4 34,121 42,211 10,552 Q6-Q3 33,803 41,803 10,450 Q6-Q4 34,721 43,031 10,757 Q5-R3 37,027 46,247 11,561 Q5-R4 38,331 47,586 11,896 Q6-R3 37,627 47,067 11,766 Q6-R4 38,931 48,806 12,200 R5-Q3 37,484 46,524 11,631 R5-Q4 38,402 47,752 11,938 R6-Q3 38,292 47,637 11,910 R6-Q4 39,210 48,865 12,216 R5-R3 41,185 51,615 12,903 R5-R4 42,489 53,354 13,338 R6-R3 41,993 52,728 13,182 R6-R4 43,297 54,467 13,616 R5-S3 49,879 61,824 15,456 R5-S4 51,752 64,697 16,175 R6-S3 50,685 62,935 15,733 R6-S4 52,560 65,810 16,452 S5-R3 47,511 58,901 14,725 S5-R4 48,815 60,640 15,160 S6-R3 47,516 59,426 14,856 S6-R4 48,820 61,165 15,291 S5-S3 53,875 66,780 16,695 S5-S4 55,750 69,655 17,414 S6-S3 53,880 67,305 16,826 S6-S4 55,755 70,180 15,545 6 YORK INTERNATIONAL
FORM 160.49-N5 TABLE 1 (Continued) CHILLER WEIGHTS (R-134a UNITS) G & H COMPRESSORS SHELL LOADING CODE SHIPPING OPERATING PER COOLER WEIGHT WEIGHT ISOLATOR COND. (LBS.) (LBS.) (LBS.) LB-LB 16,615 19,775 4,944 LB-LC 16,860 20,135 5,034 LC-LB 16,780 20,030 5,008 LC-LC 17,020 20,390 5,098 LB-MB 17,840 21,310 5,328 LB-MC 18,180 21,850 5,463 LC-MB 18,000 21,565 5,391 LC-MC 18,340 22,100 5,525 MB-LB 17,575 21,185 5,296 MB-LC 17,815 21,545 5,386 MC-LB 17,760 21,480 5,370 MC-LC 18,000 21,840 5,460 MB-MB 18,780 22,700 5,675 MB-MC 19,120 23,240 5,810 MC-MB 18,965 22,995 5,749 MC-MC 19,305 23,535 5,884 MB-NB 19,915 24,300 6,075 MB-NC 20,345 24,910 6,228 MC-NB 20,100 24,595 6,149 MC-NC 20,580 25,200 6,300 NB-MB 20,040 24,400 6,110 NB-MC 20,380 24,980 6,245 NC-MB 20,345 24,865 6,216 NC-MC 20,685 25,410 6,352 NB-NB 21,170 26,000 6,500 NB-NC 21,650 26,615 6,654 NC-NB 21,480 26,435 6,609 NC-NC 21,960 27,045 6,761 NB-PB 23,175 28,535 7,134 NB-PC 23,855 29,450 7,362 NC-PB 23,485 28,965 7,241 NC-PC 24,165 29,880 7,470 PB-NB 22,990 28,240 7,060 PB-NC 23,470 28,850 7,213 PC-NB 23,460 28,870 7,218 PC-NC 23,940 29,480 7,370 PB-PB 24,980 30,755 7,689 PB-PC 25,660 31,670 7,918 PC-PB 25,450 31,390 7,848 PC-PC 26,130 32,690 8,173 PB-QB 27,175 34,040 8,510 PB-QC 28,045 35,220 8,805 PC-QB 27,650 34,670 8,668 PC-QC 28,520 35,850 8,963 QB-PB 26,930 33,490 8,372 QB-PC 27,610 33,400 8,350 QC-PB 27,475 34,250 8,562 QC-PC 28,155 35,070 8,768 QB-QB 29,120 36,745 9,186 QB-QC 29,990 37,915 9,480 QC-QB 29,660 37,510 9,378 QC-QC 30,530 38,690 9,672 QB-RB 33,700 41,930 10,482 QB-RC 34,865 43,395 10,848 QC-RB 34,240 42,875 10,718 QC-RC 35,410 44,340 11,085 RB-QB 33,860 42,610 10,652 RB-QC 34,830 43,880 10,970 RC-QB 33,860 43,010 10,752 RC-QC 34,830 44,280 11,070 RB-RB 38,445 47,775 11,944 RB-RC 39,610 49,240 12,310 RC-RB 38,445 48,175 12,044 RC-RC 39,610 49,640 12,410 J1 & J2 COMPRESSORS* SHELL LOADING CODE SHIPPING OPERATING PER COOLER WEIGHT WEIGHT ISOLATOR COND. (LBS.) (LBS.) (LBS.) PD-PB 25,480 31,255 7,814 PD-PC 26,160 32,170 8,042 PE-PB 25,950 31,890 7,972 PE-PC 26,630 33,190 8,298 PD-QB 27,675 34,540 8,635 PD-QC 28,545 35,720 8,930 PE-QB 28,150 35,170 8,792 PE-QC 29,020 36,350 9,062 QD-PB 27,430 33,990 8,498 QD-PC 28,110 33,900 8,475 QE-PB 27,975 34,750 8,688 QE-PC 28,655 35,570 8,892 QD-QB 29,620 37,245 9,311 QD-QC 30,490 38,425 9,605 QE-QB 30,160 38,010 9,503 QE-QC 31,030 39,190 9,797 QD-RB 34,200 42,430 10,607 QD-RC 35,365 43,895 10,973 QE-RB 34,740 43,375 10,843 QE-RC 35,910 44,840 11,120 RD-QB 34,360 43,110 10,777 RD-QC 35,330 44,380 11,095 RE-QB 34,360 43,510 10,877 RE-QC 35,330 44,780 11,195 RD-RB 38,945 48,275 12,069 RD-RC 40,110 49,740 12,435 RE-RB 38,945 48,675 12,169 RE-RC 40,110 50,140 12,535 RD-SB 45,430 56,420 14,105 RD-SC 47,150 59,060 14,765 RE-SB 46,170 57,440 14,360 RE-SC 47,895 60,085 15,020 SD-RB 43,250 53,730 13,433 SD-RC 44,450 55,330 13,832 SE-RB 43,254 54,210 13,553 SE-RC 44,455 55,810 13,952 SD-SB 49,105 60,975 15,244 SD-SC 50,830 63,620 15,905 SE-SB 49,110 61,500 15,375 SE-SC 50,835 64,105 16,026 * For units with J3 & J4 compressors, add 1000 lbs. to shipping and operating weights. Add 250 lbs. to loading per isolator. YORK INTERNATIONAL 7
TABLE 2 MOTOR WEIGHTS (LBS.) STANDARD MOTORS LOW VOLTAGE WITHOUT SOUND HOODS MOTOR CODE WEIGHT (LBS.) 60Hz 50 Hz 60Hz 50Hz CH 1,120 1,120 CJ 5CE 1,120 1,120 CK 5CF 1,460 1,460 CL 5CG 1,520 1,520 CM 5CH 1,930 1,930 CN 5CI 1,930 1,930 CP 5CJ 1,980 1,980 CR 5CK 1,980 1,980 CS 5CL 2,370 2,370 CT 5CM 2,480 2,480 CU 5CN 2,480 2,480 CV 5CO 2,635 2,635 STANDARD MOTORS LOW VOLTAGE WITH SOUND HOODS MOTOR CODE WEIGHT (LBS.) 60Hz 50 Hz 60Hz 50Hz CW 5CP 2,755 2,755 CX 5CQ 5,050 5,050 CY 5CR 5,050 5,050 CZ 5CS 6,700 6,700 CA 5CT 6,700 6,700 CB 5CU 6,700 6,700 5CV 6,700 DA 5CW 7,000 7,000 DB 5CX 7,000 7,000 DC 5DA 7,000 7,000 5DB 7,000 STANDARD MOTORS HIGH VOLTAGE WITH SOUND HOODS MOTOR CODE WEIGHT (LBS.) 60Hz 50 Hz 60Hz 50Hz CH 5CD 3,350 3,350 CJ 5CE 3,350 3,350 CK 5CF 3,350 3,350 CL 5CG 3,350 3,350 CM 5CH 3,350 3,350 CN 5CI 3,350 3,350 CP 5CJ 3,350 3,350 CR 5CK 3,350 3,350 CS 5CL 3,950 3,950 CT 5CM 3,950 3,950 CU 5CN 3,950 3,950 CV 5CO 3,950 3,950 CW 5CP 3,950 3,950 CX 5CQ 5,050 5,050 CY 5CR 5,050 5,050 CZ 5CS 6,700 6,700 CA 5CT 6,700 6,700 CB 5CU 6,700 6,700 5CV 6,700 DA 5CW 7,000 7,000 DB 5CX 7,000 7,000 DC 5DA 7,000 7,000 5DB 7,000 7,000 DD 5DC 7,000 7,000 DE 5DD 7,000 7,000 DF 5DE 7,000 7,000 DH 5DF 7,000 7,000 DJ 5DG 7,000 7,000 5DH 7,000 7,000 8 YORK INTERNATIONAL
FORM 160.49-N5 INTRODUCTION GENERAL This instruction describes the installation of a MODEL YK Millennium 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.) 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 YORK representative, but otherwise installation will be as described in this instruction. FIELD ASSEMBLED UNITS ONLY Use Form 160.49-N6 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 York Publication Distribution Center. The services of a YORK representative will be furnished to check the installation, supervise the initial start-up and operation of all chillers installed within Continental United States. CAUTION: The YORK Warranty will 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 YORK representative. 3. When units are shipped dismantled, notify the nearest YORK office in ample time for a YORK 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 motor or control center. 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 max.) or steam through the cooler or condenser at any time. SHIPMENT The chiller may be ordered and shipped in any of the following forms: Form 2 Factory Assembled Unit, complete with motor (refrigerant and oil charges shipped separately). Oil is factory charged on R-22 units. 1. The motor /compressor assembly mounted, with all necessary interconnecting piping assembled. MicroComputer Control Center is mounted on the unit. Complete unit factory 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. 2. Miscellaneous material Four (4) vibration isolation pads (or optional spring isolators and brackets). 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. Compressor/motor assembly removed from shells and skidded. Cooler/condenser is not skidded. All wiring integral with compressor is left on it, and all conduit is left on shell. All openings on compressor, oil separator, and shell are closed and charged with dry nitrogen (2 to 3 psig). Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil, isolators, solid state starter (option), etc.; refrigerant charge shipped separately. NOTE: Units shipped dismantled MUST be re-assembled by, or under the supervision of a YORK representative. (See Form 160.49-N6) YORK INTERNATIONAL 9
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 assembly removed from shells and skidded. Cooler 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 compressor is left on it. All wiring harnesses on shells are removed. All openings on compressor and shells are closed and charged with dry nitrogen (2 to 3 psig). Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil isolators, solid state starter (option), etc.; refrigerant charge shipped separately. NOTE: Units shipped dismantled MUST be re-assembled by, or under the supervision, of a YORK representative. (See Form 160.49-N6) 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. YORK 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) 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 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 plate. 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. (See Fig. 3) 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 Fig. 3. 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. Use of Slings (See Fig. 3 for proper use of slings in rigging.) CAUTION: If necessary to rig the chiller by one end to permit lifting or dropping through a vertical passageway, such as an elevator shaft, contact YORK factory shipping for special rigging instructions. The rigging and operating weights and overall dimensions are given on pages 5 thru 7 as a guide in determining the clearances required for rigging. (Add 6" to overall height for optional skidded unit.) 10 YORK INTERNATIONAL
FORM 160.49-N5 FIG. 3 RIGGING LD00700 LOCATION YK OPEN MOTORS VENTILATION YORK Millennium 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. IMPORTANT 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 cooler 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 to110 F. 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. Front of unit 3 ft. Tube Removal 14 ft. (either end) YORK INTERNATIONAL 11
ALL DIMENSIONS ARE IN INCHES UNIT WEIGHT UP TO 28,835 LBS. LD00701 UNIT WEIGHT 28,836 TO 53,530 LBS. LD00702 LD00703 UNIT WEIGHT 53,531 TO 100,464 LBS. FIG. 4 NEOPRENE ISOLATORS LD00704 12 YORK INTERNATIONAL
FORM 160.49-N5 ALL DIMENSIONS ARE IN INCHES 4-SPRING ISOLATORS LD00705 UNIT WEIGHT 19,564 LBS. UP TO 35,009 LBS. 6-SPRING ISOLATORS LD00706 UNIT WEIGHT 35, 010 LBS. UP TO 58,349 LBS. 9-SPRING ISOLATORS LD00707 FIG. 5 SPRING ISOLATORS UNIT WEIGHT 58,350 LBS. UP TO 89,340 LBS. YORK INTERNATIONAL 13
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.) NOTE: At this point units shipped dismantled should be assembled under the supervision of a YORK representative. If cooler is to be field insulated, the insulation should be applied to the cooler before the unit is placed in position while the unit is in the lift position. Be sure unit is properly supported. (See INSULATION, page 18.) LOCATING AND INSTALLING ISOLATOR PADS (REFER TO FIG. 4) The isolator pad mounts are to be located as shown in Fig 4. 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 both longitudinally and transversely. The unit should be level within 1/4" 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 0.15 inch. 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 cooler shell under the compressor/motor assembly. Transverse alignment should be checked by placing a level on top of the shell end sheets at each end of the chiller. INSTALLING OPTIONAL SPRING ISOLATORS (REFER TO FIG. 5) When ordered, 4 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 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 Fig. 5 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 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. NOTE: 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. 14 YORK INTERNATIONAL
FORM 160.49-N5 COOLER AND CONDENSER WATER PIPING The cooler 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 cooler 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 Foreign objects which could lodge in, or block flow through, the cooler 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 (by others) are required in both the cooler and condenser water circuits to protect the chiller as well as the pumps, tower spray nozzles, chilled water coils and controls, etc. The strainer should 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 cooler 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 160.49-O2) condenser water temperature must be maintained equal to or slightly higher than the required minimum. Refer to Fig. 6 for typical water piping schematic. FIG. 6 SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT LD00708 YORK INTERNATIONAL 15
FIG. 7 REFRIGERANT VENT PIPING LD00709 Stop Valves Stop valves may be provided (by others) in the cooler 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 (Field Installed) A flow switch or pressure differential control in the chilled water line(s) adjacent to the unit is an accessory furnished for connection to the control center. If a flow switch is used, it must be directly in series with the chiller and sensing only water flow through the chiller. The differential switch must sense pressure drop across the unit. Drain and Vent Valves Drain and vent valves (by others) should be installed in the connections provided in the cooler 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.) 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 cooler 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 dual pressure relief valves located on the cooler 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. 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/ ASHRE-15, or local code, but should never be smaller than Relief Valve Size shown in Fig. 2. The vent 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 YORK representative; (1) The lubricant piping to oil sump and oil cooler and system oil return connections using material furnished. See Form 160.49-N6. 16 YORK INTERNATIONAL
FORM 160.49-N5 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 160.49-N6. Field wiring connections for commonly encountered control modifications (by others) if required, are shown on Form 160.49-PW13. NOTE: No deviations in unit wiring from that shown on drawings furnished shall be made without prior approval of the YORK representative. POWER WIRING Chiller with Electro-Mechanical Starter A 115 volt single phase 60 or 50 Hertz power supply of 15 amperes must be furnished to the control center, from the control transformer (2 KVA required) included with the compressor motor starter. DO NOT make final power connections to control center until approved by YORK representative. OIL PUMP 3 PHASE STARTER Separate wiring or a fused disconnect switch should be supplied by the installer. NOTE: Remote Electro-Mechanical starters for the chiller must be furnished in accordance with YORK Standard R-1051 (Product Drawing Form 160.45-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. NOTE: To insure proper motor rotation the starter power input and starter to motor connections must be checked with a phase sequence indicator in the presence of the YORK representative. IMPORTANT DO NOT cut wires to final length or make final connections to motor terminals or starter power input terminals until approved by the YORK representative. 3 PHASE MOTOR RATED LOAD AMPS MOTOR CT RATIO VOLTAGE 50 / 60 Hz 200:1 350:1 700:1 1400:1 200-600 65-111 A 112-224 A 225-829 A 830-1790 A 11-18 C 2300-4160 19-37 B 124-264 A 265-518 A 38-123 A NOTES: A. Requires passing motor lead thru current transformer (CT) once before connecting to power supply. B. Requires passing motor lead thru CT twice before connecting to power supply. C. Requires passing motor lead thru CT three times before connecting to power supply. COMPRESSOR MOTOR FIELD CONNECTION DIAGRAM FIG. 8 YK CHILLER MOTOR CONNECTIONS (ELECTRO MECHANICAL STARTER APPLICATION) YORK INTERNATIONAL 17 LD00710
YK Motors (Electro-Mechanical Starter) Fig. 8 shows the power wiring hook-up 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. Chiller with Solid State Starter or Variable Speed Drive A chiller equipped with a Solid State Starter or Variable Speed Drive does not require wiring to the compressor motor. The motor power wiring is factory connected to the Solid State Starter or Variable Speed Drive (or an optional factory installed disconnect switch). See Field Wiring Diagram. All wiring to the control panel and the oil pump starter is completed by the factory. A control transformer is furnished with the Solid State Starter or Variable Speed Drive. INSULATION (SEE PRODUCT DRAWINGS FORM 160.49-PA1) IMPORTANT DO NOT field insulate until the unit has been leak tested under the supervision of the YORK representative. Insulation of the type specified for the job, or minimum thickness to prevent sweating of 30 F surfaces should be furnished (by others) and applied to the cooler shell, end sheets, liquid feed line to flow chamber, compressor suction connection, and cooler 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. INSTALLATION CHECK REQUEST FOR START-UP SERVICE The services of a YORK representative will be furnished to check the installation and supervise the initial startup 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 YORK District Office should be advised so that the start-up service, included in the contract price, can be scheduled. Notification to the YORK office should be by means of Installation Check List and Request, Form 160.49-CL1, in triplicate. 18 YORK INTERNATIONAL
FORM 160.49-N5 YORK INTERNATIONAL 19
Proud Sponsor of the 1996 U.S. Olympic Team 36USC380 P.O. Box 1592, York, Pennsylvania USA 17405-1592 Copyright by York International Corporation 1996 Form 160.49-N5 (1296) Supersedes: Nothing Subject to change without notice. Printed in USA ALL RIGHTS RESERVED