Centrifugal Liquid Chillers: Installation Instructions
Centrifugal Liquid Chillers: Installation Instructions
Centrifugal Liquid Chillers: Installation Instructions
Issue Date:
April 15, 2019
FORM 160.75-N3
ISSUE DATE: 04/15/2019
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During rigging, installation, operation, maintenance, death to themselves and people at the site.
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to: This document is intended for use by owner-authorized
heavy objects, refrigerants, materials under pressure, rigging, installation, and operating/service personnel. It
rotating components, and both high and low voltage. is expected that these individuals possess independent
Each of these items has the potential, if misused or training that will enable them to perform their assigned
handled improperly, to cause bodily injury or death. It tasks properly and safely. It is essential that, prior to
is the obligation and responsibility of rigging, instal- performing any task on this equipment, this individual
lation, and operating/service personnel to identify and shall have read and understood the on-product labels,
recognize these inherent hazards, protect themselves, this document and any referenced materials. This in-
and proceed safely in completing their tasks. Failure dividual shall also be familiar with and comply with
to comply with any of these requirements could result all applicable industry and governmental standards and
in serious damage to the equipment and the property in regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
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 accor-
dance 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 warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.
2 JOHNSON CONTROLS
FORM 160.75-N3
ISSUE DATE: 04/15/2019
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Installation Checklist/Start-Up Request 160.75-CL1
Unit Start-Up Checklist 160.75-CL2
Installation - Unit 160.75-N1
Installation - MV VSD - 2300 VAC – 6600 VAC 160.00-N6
Installation - MV VSD - 10 kV – 13.8 kV 160.00-N8
Wiring Diagrams - Field Connections - Unit-Mounted SSS, MV SSS, or Remote Mounted MV SSS, MV EMS 160.75-PW1
Wiring Diagrams - Field Connections - Remote Mounted MV SSS 160.75-PW2
Wiring Diagrams - Field Connections - Remote Mounted MV VSD 160.75-PW3
Wiring Diagrams - Field Connections - LV VSD 160.54-PW6
Wiring Diagrams - OptiView Control Center and EMS 160.75-PW5
Wiring Diagrams - OptiView Control Center and EMS with the LTC I/O Board 160.75-PW7
Wiring Diagrams - OptiView Control Center and SSS, LV VSD, MV VSD 160.75-PW6
Wiring Diagrams - OptiView Control Center and SSS, LV VSD, MV VSD with the LTC I/O Board 160.75-PW8
Wiring Diagrams - Field Control Modifications 160.75-PW4
Unit Operation and Maintenance 160.75-O1
Operation OptiView Panel 160.54-O1
Operation - Variable Speed Drive - TM Model 160.00-O1
Operation and Maintenance - Solid State Starter (Mob "B") 160.00-O2
Operation - Variable Speed Drive - VSD and LVD Model 160.00-O4
Operation - Variable Speed Drive - HYP Model 160.00-O10
Operation - Floor Mounted MV SSS, Manufactured Before 2007 160.00-O5
Operation - Floor Mounted MV SSS, Manufactured After 2007 160.00-O5.1
Operation - Unit Mounted MV SSS 160.00-O7
Operation - MV VSD - 2300 VAC – 6600 VAC 160.00-O6
Operation - MV VSD - 10 kV – 13.8 kV 160.00-O8
Service Policy - Shipping Damage Claims 50-15-NM
JOHNSON CONTROLS 3
FORM 160.75-N3
ISSUE DATE: 04/15/2019
NOMENCLATURE
YK KC K4 H9 – CY G
MOTOR CODE
POWER SUPPLY
– for 60 Hz
5 for 50 Hz
COMPRESSOR CODE*
CONDENSER CODE*
EVAPORATOR CODE*
* Refer to YK Engineering Guide (Form 160.75-EG1)
MODEL* for Shell/Motor/Compressor combinations.
4 JOHNSON CONTROLS
FORM 160.75-N3
ISSUE DATE: 04/15/2019
TABLE OF CONTENTS
SECTION 1 - SHIPPING AND REASSEMBLY......................................................................................................7
Introduction........................................................................................................................................................ 7
Forms of Shipment............................................................................................................................................ 7
Inspection – Damage – Shortage...................................................................................................................... 8
Data Plates........................................................................................................................................................ 9
Long-Term Storage............................................................................................................................................ 9
Reassembly..................................................................................................................................................... 11
Q3-Q7 and P7 Compressors (Without Falling Film)........................................................................................ 14
Q3-Q7 and P7 Compressors (with Falling Film)..............................................................................................16
Q3-Q7 and P7 Compressors (System Piping)................................................................................................ 18
K Compressors................................................................................................................................................ 19
P8-P9 and H9 Compressors (Without Falling Film)........................................................................................ 22
P8-P9 and H9 Compressors (with Falling Film).............................................................................................. 24
P8-P9 and H9 Ccompressors (System Piping)............................................................................................... 26
JOHNSON CONTROLS 5
FORM 160.75-N3
ISSUE DATE: 04/15/2019
LIST OF FIGURES
FIGURE 1 - Front View Of Assembled Unit��������������������������������������������������������������������������������������������������������������7
FIGURE 2 - Form 7 Shipment����������������������������������������������������������������������������������������������������������������������������������8
FIGURE 3 - Long Term Storage - Tube Side����������������������������������������������������������������������������������������������������������10
FIGURE 4 - Rigging – Compressor/Motor Assembly���������������������������������������������������������������������������������������������12
FIGURE 5 - Variable Speed Drive Rigging�������������������������������������������������������������������������������������������������������������13
FIGURE 6 - Form 3 Shipment (Q3-Q7 And P7 Compressors Without Falling Film)����������������������������������������������� 14
FIGURE 7 - Form 7 Shipment (Q3-Q7 And P7 Compressors Without Falling Film))��������������������������������������������� 15
FIGURE 8 - Form 3 Shipment (Q3-Q7 And P7 Compressors With Falling Film)���������������������������������������������������� 16
FIGURE 9 - Form 7 Shipment (Q3-Q7 And P7 Compressors With Falling Film)���������������������������������������������������� 17
FIGURE 10 - System Piping (Q3-Q7 And P7 Compressors)����������������������������������������������������������������������������������18
FIGURE 11 - Form 3 Shipment (K Compressors)��������������������������������������������������������������������������������������������������19
FIGURE 12 - Form 7 Shipment (K Compressors)��������������������������������������������������������������������������������������������������20
FIGURE 13 - System Piping (K Compressors)�������������������������������������������������������������������������������������������������������21
FIGURE 14 - Form 3 Shipment (P8-P9 And H9 Compressors Without Falling Film)��������������������������������������������� 22
FIGURE 15 - Form 7 Shipment (P8-P9 And H9 Compressors Without Falling Film)��������������������������������������������� 23
FIGURE 16 - Form 3 Shipment (P8-P9 And H9 Compressors With Falling Film)�������������������������������������������������� 24
FIGURE 17 - Form 7 Shipment (P8-P9 And H9 Compressors With Falling Film)�������������������������������������������������� 25
FIGURE 18 - System Piping (P8-P9 And H9 Compressors)����������������������������������������������������������������������������������26
6 JOHNSON CONTROLS
FORM 160.75-N3
ISSUE DATE: 04/15/2019
COMPRESSOR
CONTROL
CENTER
MOTOR
CONDENSER
LD15222
EVAPORATOR
JOHNSON CONTROLS 7
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
All wiring integral with the compressor is left on. All All wiring integral with compressor is left on it, and all
wiring harnesses on the shells are removed. conduit is left on shell.
All openings on the compressor and shells are closed Miscellaneous packaging of tubing, water temperature
and charged with dry nitrogen (2 psig or 3 psig). controls, wiring, isolators, etc. The unit is shipped with
refrigerant charge. See Figure 5 on Page 13.
The shipment may include miscellaneous packaging of
control center, oil eductor filter, tubing, water tempera- INSPECTION – DAMAGE – SHORTAGE
ture controls, wiring, oil, isolators, solid state starter, or
variable speed drive (options). The refrigerant charge Check unit shipment on arrival to see that all major
is shipped in appropriate cylinders. For P and Q com- pieces, boxes, and crates are received. Each unit should
pressors the control panel is removed for shipment. For be checked on the trailer or rail car when received, be-
H9 and K compressors the control panel is shipped on fore unloading, for any visible signs of damage. Report
a folded bracket. Refer to the Installation - Unit (Form any damage or signs of possible damage to the trans-
160.75-N1) for more details. portation company immediately for their inspection.
8 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
DATA PLATES
1
A unit data plate is mounted on the Control Center as- 3. Monitor the pressure gauge (Item 2). The pressure
sembly of each unit, giving unit model number; design should decline gradually.
working pressure; water passes; refrigerant charge; se-
4. When the pointer of pressure gauge stops moving
rial numbers; and motor power characteristics and con-
and no nitrogen is released from the valve (Item
nection diagrams.
5), it means that no positive pressure exists in the
A Control Panel data plate, which includes control waterbox.
panel part number and serial number is also included.
5. Now it is safe to remove the flange cover (Item 6)
If the unit is equipped with a Solid State Starter or Vari-
or sealing cap (Item 9).
able Speed Drive (optional), it has its own data plate
with serial number. 6. Close the valve (Item 5) and remove the warning
tag (Item 1).
LONG-TERM STORAGE
Shipment Form 2/3/7/9
To protect the waterbox of pressure vessels from rust-
ing, the tube side (water side) has been purged and All openings on the compressor, shells including evap-
charged with nitrogen to a positive pressure of 5 psig orator and condenser, and oil reservoir are closed and
to 7 psig. charged with nitrogen (2 psig to 3 psig). To remove the
closures, sealing caps, or sealing plug under pressure is
Do not break the seal or remove closures until ready extremely dangerous, and may cause severe injury or
for set up. Relieve pressure as per the following proce- death to the operator or people in site.
dure (see Figure 3 on Page 10).
Before trying to remove the closures,
Failure to follow the following procedures caps, or plugs on compressor and shells,
will cause severe personal injury or death relieve the pressure in compressor, shells,
to operators themselves or people on-site. or system that are charged with nitrogen
It is the obligation and responsibility of by opening the valves on them slowly until
operators to identify and recognize the fully open.
inherent hazards of material under pres-
sure and to protect themselves. When relieving the pressure from com-
pressor, shells, or system, conduct the
1. Check that the working space is open and has nitrogen to outside to prevent the potential
good ventilation. If is does not have good ventila- risk of asphyxiation.
tion, connect a hose or pipe to the valve (Item 5)
and route it to outside.
2. Slowly open the valve (Item 5) until fully opened.
JOHNSON CONTROLS 9
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
5
4
3
ITEM DESCRIPTION
8 1 Tag Warning Dennison 8E
9 2 Gauge Press 2 Dia 0-30
3 Tag GlvSt Wire Speed
4 Bush Pipe 3/4 - 14 NPTE X
5 Valve, Transducer 1/4 NPTE X
6 Flange Cover
7 Gasket
Nozzle without flanges 8 Victaulic Coupling
(Lines 4 in. through 12 in.) 9 Sealing Cap
8
10 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
JOHNSON CONTROLS 11
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
NOTE: Rig the driveline into place on the chiller, supporting the compressor with two lifting
lugs and the motor with either, one, two, or four legs depending on motor design.
LD02140a
12 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
5. Reconnect motor power leads in the Variable 10. All Units – Complete installation and finally level
Speed Drive to T1, T2, and T3 terminals and the unit (refer to Installation - Unit (Form 160.75- 1
torque to 18-20 Ft-lbs. per the labels in the VSD. N1).
6. Reconnect motor winding thermistor shielded ca- 65°
ble conductors in the Variable Speed Drive at TB4 Min.
(refer to Wiring Diagrams - Field Connections -
Remote Mounted MV SSS (Form 160.75-PW2). 65°
Min.
7. Reconnect all unit wiring and harnesses (refer to
Lifting
Wiring Diagrams - Field Connections - Remote Holes
Mounted MV SSS (Form 160.75-PW2).
8. Pressure test the unit.
Lifting
Relief valves must be plugged or capped Holes
(refer to Unit Operations and Mainte-
nance, Form 160.75-O1).
LD16730
JOHNSON CONTROLS 13
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
DISCHARGE
LINE
DISCHARGE
ISOLATION
VALVE
(IF FURNISHED) RING GASKETS
HOT GAS (See NOTE *)
VALVE
(IF FURNISHED)
CON
DEN
SER
EVA
POR
ATO
R
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
LD13170
14 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
ISOLATION
VALVE
(IF FURNISHED)
HOT GAS
VALVE
(IF FURNISHED)
RING GASKETS
(See NOTE *)
CO
ND LIQUID LINE
EN
SE
R VALVE
(IF FURNISHED)
EV
AP
OR
AT
OR
LD13171
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
JOHNSON CONTROLS 15
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
DISCHARGE
LINE
DISCHARGE
ISOLATION
VALVE
(IF FURNISHED)
HOT GAS RING GASKETS
VALVE (See NOTE*)
(IF FURNISHED)
LD13170a
CON
LIQUID LINE
DEN
SER
EVAP
ORA
TOR
EVAPORATOR
CONDENSER
LD13171b
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
16 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
ISOLATION
VALVE
(IF FURNISHED)
HOT GAS
VALVE
(IF FURNISHED)
RING GASKETS
(See NOTE*)
LD13171a
LIQUID LINE
CO
ND
EN
SE
R
EVAPORATOR
EV
AP
OR
AT
OR
CONDENSER
LD13171b
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
JOHNSON CONTROLS 17
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
3/8”
OIL
RETURN
LINE
3/8”
COMPRESSOR
3/4”
TO
OIL
VSOP
RETURN
PANEL
LINE
3/4”
OIL
SUPPLY
LINE
3/8”
OIL
RETURN
LINE
LD13174
18 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
K COMPRESSORS 1
DISCHARGE
SPOOL
ISOLATION
VALVE
(IF FURNISHED)
SUCTION
LINE
OIL
LINE
Ring Gaskets
(See NOTE *)
HOT GAS
VALVE
(IF FURNISHED)
OIL
PUMP
PANEL
CO
ND
EN
SE CONTROL
R
PANEL
EV
AP
OR
AT
OR
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
LD13172
Figure 11 - FORM 3 SHIPMENT (K COMPRESSORS)
JOHNSON CONTROLS 19
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
K COMPRESSORS (CONT’D)
DISCHARGE
SPOOL
SUCTION
LINE
ISOLATION
VALVE
(IF FURNISHED)
OIL
LINE
RING GASKETS
(See NOTE*)
HOT GAS
(IF FURNISHED)
CO
ND
EN
SE
R
LIQUID
LINE
EV
AP
OR
AT
OR
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
LD13173
20 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
K COMPRESSORS (CONT’D) 1
3/4"
OIL SUPPLY
LINE
1"
OIL SUMP
VENT
LINE
3/8"
LIQUID
3/8"
INJECTION
OIL
LINE
RETURN
LINE
1"
REFRIGERANT
RETURN
LINE
LD13175
JOHNSON CONTROLS 21
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
DISCHARGE
SPOOL
ISOLATION
VALVE
(IF FURNISHED) RING GASKETS
(See NOTE*)
HOT GAS
VALVE
(IF FURNISHED)
OIL PUMP
PANEL
CO
ND
EN
SE CONTROL
R
PANEL
EV
AP
OR
AT
OR
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
LD13184
22 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
DISCHARGE
SPOOL
DISCHARGE
ISOLATION
VALVE
(IF FURNISHED)
RING GASKETS
(See NOTE *)
CO
ND
EN
SE
R
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
LD13185
JOHNSON CONTROLS 23
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
DISCHARGE
SPOOL
ISOLATION
VALVE
(IF FURNISHED) RING GASKETS
(See NOTE *)
HOT GAS
VALVE
(IF FURNISHED)
OIL PUMP
PANEL
CO
ND
EN CONTROL
SE
R PANEL
EV
AP
OR
AT
OR
TO TO
EVAPORATOR EVAPORATOR
FROM FROM
CONDENSER CONDENSER
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
LD13185a
24 JOHNSON CONTROLS
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
DISCHARGE
SPOOL
DISCHARGE
ISOLATION
VALVE
(IF FURNISHED)
RING GASKETS
(See NOTE *)
TO TO
EVAPORATOR EVAPORATOR
FROM FROM
CONDENSER CONDENSER
NOTE:
* Ring Gaskets NOT used for elastomer-lined flange faces at the Isolation Valve.
LD13185b
JOHNSON CONTROLS 25
FORM 160.75-N3
Section 1 - Shipping and Reassembly
ISSUE DATE: 04/15/2019
SUCTION
LINE
3/8”
OIL
RETURN
LINE
3/8”
COMPRESSOR
3/4”
TO
OIL
VSOP
RETURN
PANEL
LINE
3/4”
OIL
SUPPLY
LINE
3/8”
OIL
RETURN
LINE
LD13174
26 JOHNSON CONTROLS
FORM 160.75-N3
ISSUE DATE: 04/15/2019
TEMPERATURE
To convert degrees Fahrenheit (°F) to degrees Celsius
(°C), subtract 32° and multiply by 5/9 or 0.5556.
Example: (45.0°F - 32°) x 0.5556 = 7.22°C
To convert a temperature range (i.e., a range of 10°F)
from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.
Example: 10.0°F range x 0.5556 = 5.6°C range
JOHNSON CONTROLS 27
5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 1-800-524-1330 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2019 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 160.75-N3 (419)
Issue Date: April 15, 2019
Supersedes: 160.75-N3 (615)