Johnson Controls YORK YMC2 User manual

LD14000

YMC2MODEL A

WITH OPTIVIEW™ CONTROL CENTER

CENTRIFUGAL LIQUID CHILLERS

INSTALLATION Supersedes: 160.78-N1 (611) Form 160.78-N1 (512)

R-134a

Issue Date:

May 30, 2012

JOHNSON CONTROLS

FORM 160.78-N1

ISSUE DATE: 5/30/2012

This equipment is a relatively complicated apparatus.

During installation, operation maintenance or service,

individuals may be exposed to certain components or

conditions including, but not limited to: 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 respon-

sibility of 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

operating/service personnel. It is expected that these

individuals possess independent training that will en-

able 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 this document and any referenced mate-

rials. This individual shall also be familiar with and

comply with all applicable 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 OptiViewTM 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 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 3

FORM 160.78-N1

ISSUE DATE: 5/30/2012

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 owner. Updated manuals, if applicable, can

be obtained by contacting the nearest Johnson Controls

Service office.

Operating/service personnel maintain responsibility for

the applicability of these documents to the equipment.

If there is any question regarding the applicability of

these documents, the technician should verify whether

the equipment has been modified and if current litera-

ture 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

YMC2Operations & Maintenance 160.78-O1

YMC2Unit Re-assembly 160.78-N2

YMC2Centrifugal Chiller Long Term Storage 50.20-NM5

YMC2Field Connections 160.78-PW1

YMC2 Unit Wiring and Field Control Modications 160.78-PW2

YMC2Unit Renewal Parts 160.78-RP1

YMC2OptiViewTM Operation 160.78-O2

OptiSpeedTM VSD Model HYP744 Renewal Parts 160.78-RP3

JOHNSON CONTROLS

FORM 160.78-N1

ISSUE DATE: 5/30/2012

VESSEL NOMENCLATURE

Inlet from Front View

R = Right

L = Left

Waterbox Type

C = Compact

M = Marine

Water Side Pressure Code

1 = 150 psi

3 = 300 psi

Water Connection Type

F = Flanges

G = Grooved Standard

A = Victaulic AGS

Number of Passes

Vessel

E = Evaporator

C = Condenser

Vessel Refrigerant Pressure Code

R = Code 180

S = Code 235

T = Code 300

U = Code 350

V = Code 400

Tube Code

B = 3/4" Code 1

C = 3/4" Code 2

D = 3/4" Code 3

E = 3/4" Code 4

2 = 1" Code 1

3 = 1" Code 2

4 = 1" Code 3

5 = 1" Code 4

Heat Exchanger Mod Level

Nominal Inside Diameter (Inches)

Nominal Length (Feet)

Marketing Tube Number

E A 25 14 271 B R 1 1 F C R

COMPRESSOR NOMENCLATURE

Gas Path Revision Level

Impeller Design Revision Level

Motor

Motor Design Level

Impeller Tip Diameter (mm)

Rotation

F = Forward

R = Reverse

M1 B - 197 F A A

SYSTEM NOMENCLATURE

YORK

Centrifugal Chiller

Magnetic Bearing

Mod Level

S = Single Stage

T = Two Stage

Capacity in KW

Refrigerant R-134a

Y M C 2 - S 0756 A A

Liquid DWP

15 = 150 psi

30 = 300 psi

40 = 380V 60Hz

50 = 400V 50Hz

46 = 460V 60Hz

68 = 415V 50Hz

D = Disconnect Switch

B = Circuit Breaker

X = Factory Mount

R = Retrot Model

VARIABLE SPEED DRIVE NOMENCLATURE

Hyper

H = YMC2Chiller

Amps

HYP 744 X H 15 D - 40

JOHNSON CONTROLS 5

FORM 160.78-N1

ISSUE DATE: 5/30/2012

TABLE OF CONTENTS

SECTION 1 - SHIPPING ...........................................................................................................................................7

General.............................................................................................................................................................7

Component Combinations................................................................................................................................7

Field Assembled Units Only .............................................................................................................................8

YMC2Shipment Forms.....................................................................................................................................8

Form 1 .....................................................................................................................................................8

Form 2 .....................................................................................................................................................9

Form 3 .....................................................................................................................................................9

Form 7 ...................................................................................................................................................10

Form 9 ...................................................................................................................................................10

Form 10 ................................................................................................................................................. 11

Form 11 ................................................................................................................................................. 11

Inspection–Damage–Shortage.......................................................................................................................12

Chiller Data Plate ...........................................................................................................................................12

SECTION 2 - INSTALLATION ................................................................................................................................13

Overview ........................................................................................................................................................13

Rig Chiller Unit ...............................................................................................................................................13

Determine Location ........................................................................................................................................14

Foundation Requirements .....................................................................................................................14

Clearance Requirements.......................................................................................................................14

Rig Unit To Final Location...............................................................................................................................14

Install Isolators ...............................................................................................................................................14

Neoprene Isolator Pads.........................................................................................................................14

Install Optional Spring Isolators.............................................................................................................17

Make Connections..........................................................................................................................................19

Piping Connections ...............................................................................................................................19

Refrigerant Relief Piping .......................................................................................................................21

Unit Piping .............................................................................................................................................21

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

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

Supplied Variable Speed Drive..............................................................................................................21

Apply Insulation ..............................................................................................................................................24

Installation Check – Request For Start-Up Service........................................................................................24

SECTION 3 - DIMENSIONS, NOZZLE ARRANGEMENTS AND WEIGHTS.........................................................25

Compressor Unit Dimensions.........................................................................................................................25

Evaporator Nozzle Arrangements (150 Psi Compact Water Boxes) ..............................................................26

Condenser Nozzle Arrangements (150 Psi Compact Water Boxes) ..............................................................28

Evaporator Nozzle Arrangements (150 PSI Marine Water Boxes).................................................................30

Condenser Nozzle Arrangements (150 Psi Marine Water Boxes)..................................................................32

Weights...........................................................................................................................................................34

150 PSI Compact And Marine Water Boxes Lbs (Kgs) .........................................................................34

Temperature ...................................................................................................................................................35

JOHNSON CONTROLS

FORM 160.78-N1

ISSUE DATE: 5/30/2012

LIST OF FIGURES

LIST OF TABLES

FIGURE 1 - YMC2Chiller Components .....................................................................................................................7

FIGURE 2 - Rigging.................................................................................................................................................13

FIGURE 3 - Neoprene Isolators ..............................................................................................................................15

FIGURE 4 - Neoprene Isolators ..............................................................................................................................16

FIGURE 5 - Spring Isolators ...................................................................................................................................17

FIGURE 6 - Spring Isolators....................................................................................................................................18

FIGURE 7 - Typical Refrigerant Vent Piping............................................................................................................19

FIGURE 8 - Schematic Of A Typical Piping Arrangement .......................................................................................20

FIGURE 9 - FAA Unit Insulation ..............................................................................................................................22

FIGURE 10 - FAB Unit Insulation ............................................................................................................................23

FIGURE 11 - Dimensions – 197 & 205 Compressor Units Ft-In (Mm) ....................................................................25

FIGURE 12 - Evaporators - Compact Water Boxes (1-Pass Nozzle Arrangements) .............................................26

FIGURE 13 - Evaporators - Compact Water Boxes (2-Pass Nozzle Arrangements) .............................................26

FIGURE 14 - Evaporators - Compact Water Boxes (3-Pass Nozzle Arrangements) .............................................26

FIGURE 15 - Evaporators - 150 Psi Compact Water Boxes ...................................................................................27

FIGURE 16 - Condensers - Compact Water Boxes (1-Pass Nozzle Arrangements) .............................................28

FIGURE 17 - Condensers - Compact Water Boxes (3-Pass Nozzle Arrangements) .............................................28

FIGURE 18 - Condensers - Compact Water Boxes (2-Pass Nozzle Arrangements) .............................................28

FIGURE 19 - Condensers - 150 Psi Compact Water Boxes ...................................................................................29

FIGURE 20 - Evaporators - Marine Water Boxes (1-Pass Nozzle Arrangements).................................................30

FIGURE 21 - Evaporators - Marine Water Boxes (2-Pass Nozzle Arrangements).................................................30

FIGURE 22 - Evaporators - Marine Water Boxes (3-Pass Nozzle Arrangements).................................................30

FIGURE 23 - Evaporators - 150 Psi Marine Water Boxes.......................................................................................31

FIGURE 24 - Condensers - Marine Water Boxes (1-Pass Nozzle Arrangements).................................................32

FIGURE 25 - Condensers - Marine Water Boxes (2-Pass Nozzle Arrangements).................................................32

FIGURE 26 - Condensers - Marine Water Boxes (3-Pass Nozzle Arrangements).................................................32

FIGURE 27 - Condensers - 150 Psi Marine Water Boxes.......................................................................................33

TABLE 1 - Allowable Motor / Compressor / Evaporator / Condenser Combinations ................................................7

TABLE 2 - Approximate Unit Weight* (Max Tube Count Using 150 Psi Compact Waterboxes) ............................. 34

TABLE 3 - Evaporator Marine Water Box Weights

(To Be Added To Standard Unit Weights Shown On Table 2)................................................................34

TABLE 4 - Condenser Marine Water Box Weights

(To Be Added To Standard Unit Weights Shown On Table 2)................................................................34

TABLE 5 - SI Metric Conversion .............................................................................................................................35

JOHNSON CONTROLS 7

FORM 160.78-N1

ISSUE DATE: 5/30/2012

SECTION 1 - SHIPPING

GENERAL

This manual provides instructions for rigging and in-

stalling a YMC2Liquid Chilling Unit.

Chillers can be shipped as a single factory assembled,

piped, wired package, requiring a minimum of field la-

bor to make chilled water connections, condenser wa-

ter connections, refrigerant atmospheric relief connec-

tions, and electrical power connections. (Refrigerant

charges shipped separately unless optional condenser

isolation valves are ordered.)

They can also be shipped dismantled when required by

rigging conditions, but it is generally more economical

to enlarge access openings to accommodate the factory

assembled unit. Chillers that are shipped dismantled

MUST be field-assembled under the supervision of a

Johnson Controls representative, but otherwise instal-

lation will be as described in this manual.

COMPONENT COMBINATIONS

Figure 1 identifies the major components of the YMC2

Chiller. The chiller is customized based on the selected

combination of Motor, Compressor, Evaporator, and

Condenser. Table 1 lists all of the allowable combina-

tions.

TABLE 1 - ALLOWABLE MOTOR / COMPRESSOR /

EVAPORATOR / CONDENSER COMBINATIONS

YMC2

Motor

Codes

Compressor

Codes

Evaporator

Codes

Condenser

Codes

M1 197DFAA EA2510 CA2110

M1 197DFAA EA2510 CA2510

M1 197DFAA EA2514 CA2514

M1 205DFAA EA2510 CA2110

M1 205DFAA EA2510 CA2510

M1 205DFAA EA2514 CA2514

FIGURE 1 - YMC2CHILLER COMPONENTS

LD14022

JOHNSON CONTROLS

FORM 160.78-N1

ISSUE DATE: 5/30/2012

SECTION 1 - SHIPPING

• Form 10 (shipped in two assemblies)

• Form 11 (shipped in two assemblies)

Units that are shipped dismantled MUST

be re-assembled by, or under the supervi-

sion of a Johnson Controls representative.

Refer to YMC2Unit Re-assembly Manual

(Form 160.78-N2) for detailed re-assem-

bly instructions.

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.

Form 1

The chiller is shipped complete with miscellaneous

loose items shipped together.

Refrigerant charges are included.

Chiller Unit

The unit is completely assembled at the factory.

• The driveline (compressor/motor assembly) is

mounted and all the necessary interconnecting

piping is assembled.

• The complete unit is factory leak-tested, evacuat-

ed, and shipped charged with R-134A refrigerant.

• The OptiView™ Control Center is mounted on

the unit.

• The Variable Speed Drive (VSD) is mounted,

wired, and shipped with glycol.

Miscellaneous Items

The following items are shipped together:

• Four (4) vibration isolation pads (or optional

spring isolators and brackets).

FIELD ASSEMBLED UNITS ONLY

If the chiller was not shipped complete (as shown in

Form 1 or 2 below), use the YMC2Unit Re-assembly

Manual (Form 160.78-N2) in conjunction with this

installation manual. This manual is furnished with all

units that are to be field assembled.

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 drive or control center.

5. Do not charge the unit with refrigerant.

6. Do not attempt to start the system.

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

through the evaporator or condenser at any time.

YMC2SHIPMENT FORMS

The chiller may be ordered and shipped in any of the

following forms:

• Form 1 (shipped complete)

• Form 2 (shipped complete)

• Form 3 (shipped in three assemblies)

• Form 7 (shipped in four assemblies)

• Form 9 (shipped in two assemblies)

JOHNSON CONTROLS 9

SECTION 1 - SHIPPING

FORM 160.78-N1

ISSUE DATE: 5/30/2012

• VSD Inhibitor

• Other shipped loose items, including piping, wa-

ter temperature controls, wiring, etc.

Form 2

The chiller is shipped complete; miscellaneous loose

items are shipped together.

Refrigerant charges are shipped separately.

Arrangements with the local service ofce

must be made to ensure refrigerant is on-

site when the unit is ready to be charged.

Chiller Unit

The unit is completely assembled at the factory.

• The driveline (compressor/motor assembly) is

mounted and all the necessary interconnecting

piping is assembled.

• The complete unit is factory leak-tested, evacu-

ated, and shipped charged with a 2 to 3 PSIG

(115.122 kPa) holding charge of dry nitrogen.

• The OptiView™ Control Center is mounted on

the unit.

• The Variable Speed Drive (VSD) is mounted,

wired, and shipped with Glycol.

Miscellaneous Items

The following items are shipped together:

• Four (4) vibration isolation pads (or optional

spring isolators and brackets).

• Other shipped loose items, including piping, wa-

ter temperature controls, wiring, etc.

• Inhibitor (VSD)

Form 3

The chiller is shipped in three assemblies:

1. The driveline (compressor/motor assembly)

2. The evaporator/condenser shell assembly

3. The Variable Speed Drive (VSD)

4. Miscellaneous shipped loose items

Refrigerant charges are shipped separately.

Arrangements with the local service ofce

must be made to ensure refrigerant is on-

site when the unit is ready to be charged.

Prior to shipping, the unit is completely assembled at

the factory. Interconnecting piping is assembled and

the complete unit is wired and leak-tested.

The unit is then dismantled and shipped as follows:

Driveline

The driveline (compressor/motor assembly) is re-

moved from the shells and skidded.

• All integral wiring is left on the compressor.

• All openings on the compressor are closed and

shipped charged with a 2 to 3 PSIG (115.122 kPa)

holding charge of dry nitrogen.

Shells

The evaporator and condenser are assembled prepared

for shipping but not skidded.

• All conduit is left on the shells.

• All openings the shells are closed and charged

with a 2 to 3 PSIG (115.122 kPa) holding charge

of dry nitrogen.

Variable Speed Drive (Vsd)

The VSD is skidded and shipped separately from the

assembled chiller.

• The VSD is lled with glycol for shipping.The

VSD Inhibitor is shipped with the other loose

items.

Miscellaneous Material

The following assemblies and items are shipped to-

gether:

• OptiView™ Control Center

• Magnetic Bearing Controller (MBC)

• Four (4) vibration isolation pads (or optional

spring isolators and brackets).

JOHNSON CONTROLS

FORM 160.78-N1

ISSUE DATE: 5/30/2012

SECTION 1 - SHIPPING

• Other shipped loose items, including piping, wa-

ter temperature controls, wiring, etc.

• Inhibitor (VSD)

Form 7

The chiller is shipped in four assemblies:

1. The driveline (compressor/motor assembly)

2. The evaporator

3. The condenser

4. The Variable Speed Drive (VSD)

5. Miscellaneous shipped loose items

Refrigerant charges are shipped separately.

Arrangements with the local service of-

ce must be made to ensure refrigerant is

on-site when unit is ready to be charged.

Prior to shipping, the unit is completely assembled at

the factory. Interconnecting piping is assembled and

the complete unit is wired and leak-tested.

The unit is then dismantled and shipped as follows:

Driveline

The driveline (compressor/motor assembly) is re-

moved from shells and skidded.

• All integral wiring is left on the compressor.

• All wiring harnesses on shells are removed.

• All openings on the compressor are closed and

shipped charged with a 2 to 3 PSIG (115.122 kPa)

holding charge of dry nitrogen.

Shells

The evaporator and condenser are separated at the tube

sheets and prepared for shipping separately but not

skidded.

• All conduit is left on the shells.

• Refrigerant lines between shells are anged and

capped, requiring no welding.

• All openings the shells are closed and charged

with a 2 to 3 PSIG (115.122 kPa) holding charge

of dry nitrogen.

Variable Speed Drive (Vsd)

The VSD is skidded and shipped separately from the

assembled chiller.

• The VSD is lled with glycol for shipping.The

VSD Inhibitor ia shipped with the other loose

items.

Miscellaneous Items

The following assemblies and items are shipped to-

gether:

• OptiView™ Control Center

• Magnetic Bearing Controller (MBC)

• Four (4) vibration isolation pads (or optional

spring isolators and brackets).

• VSD Inhibitor

• Other shipped loose items, including piping, wa-

ter temperature controls, wiring, isolators, etc.

Form 9

The chiller is shipped in two assemblies:

1. The chiller unit (less the VSD)

2. The VSD

3. Miscellaneous shipped loose items.

Refrigerant charges are shipped separately.

Arrangements with the local service of-

ce must be made to ensure refrigerant is

on-site when unit is ready to be charged.

Chiller Unit

The unit is first completely assembled at the factory:

• The driveline (compressor/motor assembly) is

mounted, with all necessary interconnecting pip-

ing assembled.

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