Centrifugal Liquid Chillers: Installation and Reassembly

CENTRIFUGAL LIQUID CHILLERS
INSTALLATION AND REASSEMBLY Supersedes: 160.84-N1 (814) Form 160.84-N1 (1015)
YMC2 MODEL B
WITH OPTIVIEW™ CONTROL CENTER
LD17194
R-134a
Issue Date:
October 25, 2015
FORM 160.84-N1
ISSUE DATE: 10/25/2015
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:
Indicates a possible hazardous situation Identifies a hazard which could lead to

which will result in death or serious injury damage to the machine, damage to other
if proper care is not taken. equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Indicates a potentially hazardous situa- Highlights additional information useful

tion which will result in possible injuries to the technician in completing the work
or damage to equipment if proper care is being performed properly.
not taken.
External wiring, unless specified 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 cabinet. All wiring must be in ac-
cordance 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 could cause serious damage to property or personal injury.
2 JOHNSON CONTROLS
FORM 160.84-N1
CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for con- regarding the applicability of these documents, rig-
tinuous product improvement, the information con- ging, lifting, and operating/service personnel should
tained in this document is subject to change without verify whether the equipment has been modified and
notice. Johnson Controls makes no commitment to if current literature is available from the owner of the
update or provide current information automatically equipment prior to performing any work on the chiller.
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest CHANGE BARS
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts. Revisions made to this document are indicated with a
johnsoncontrols.com. line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
It is the responsibility of rigging, lifting, and operating/ formation and any other changes in spelling, grammar
service personnel to verify the applicability of these or formatting are not included.
documents to the equipment. If there is any question
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER

Chiller Operations & Maintenance 160.84-OM1
Unit Installation Checklist and Request for Startup 160.84-CL1
Unit Startup Checklist 160.84-CL2
Field Connections Diagram 160.84-PW1
Field Control, Wiring and MBC Diagrams 160.84-PW2
Replacement Parts 160.84-RP1
Replacement Parts Variable Speed Drive 160.84-RP3
Liquid Chiller Log Sheet 160.84-MR1
Centrifugal Chiller Long Term Storage 50.20-NM5
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2
JOHNSON CONTROLS 3
FORM 160.84-N1
SYSTEM NOMENCLATURE
Y M C 2 - S 0756 A B
YORK Mod Level
Magnetic Bearing Refrigerant R-134a
Centrifugal Chiller Capacity in KW
S = Single Stage
T = Two Stage
COMPRESSOR NOMENCLATURE
M2 B - 197 F A C D
Motor Down Discharge
Motor Design Level Gas Path Revision Level
Impeller Tip Diameter (mm) Impeller Design Revision Level
Rotation
F = Forward
R = Reverse
VESSEL NOMENCLATURE
E A 25 14 271 B R 1 1 F C R
Inlet from Front View
Vessel
R = Right
E = Evaporator
L = Left
C = Condenser
Heat Exchanger Mod Level Waterbox Type
C = Compact
Nominal Inside Diameter (Inches)
M = Marine
Nominal Length (Feet) Water Connection Type
Marketing Tube Number F = Flanges
Tube Code G = Grooved Standard
B = 3/4" Code 1 A = Victaulic AGS
C = 3/4" Code 2 Number of Passes
D = 3/4" Code 3 Vessel Refrigerant Pressure Code Water Side Pressure Code
E = 3/4" Code 4 R = Code 180 1 = 150 psi
2 = 1" Code 1 S = Code 235 3 = 300 psi
3 = 1" Code 2 T = Code 300
4 = 1" Code 3 U = Code 350
5 = 1" Code 4 V = Code 400
VARIABLE SPEED DRIVE NOMENCLATURE

HYP 0774 X H C 15 D - 40 A
Hyper Mod Level
40 = 380V 60Hz
Amps
50 = 400V 50Hz
0490, 0612, 0774
46 = 460V 60Hz
X = Factory Mount 68 = 415V 50Hz
R = Retrofit Model D = Disconnect Switch
B = Circuit Breaker
H = YMC2 Chiller
Liquid DWP
C = Condenser Cooled
15 = 150 psi
E = Evaporator Cooled
30 = 300 psi
4 JOHNSON CONTROLS
FORM 160.84-N1
TABLE OF CONTENTS
SECTION 1 - OVERVIEW..........................................................................................................................................9
General.............................................................................................................................................................. 9
Component Combinations................................................................................................................................. 9
Inspection – Damage – Shortage.................................................................................................................... 10
Chiller Data Plate............................................................................................................................................ 10
YMC2 Shipment Forms....................................................................................................................................10
Form 1.................................................................................................................................................... 11
Form 2.................................................................................................................................................... 11
Form 3.................................................................................................................................................... 11
Form 7....................................................................................................................................................12
Form 9....................................................................................................................................................12
Form 10 .................................................................................................................................................13
Form 11..................................................................................................................................................14
SECTION 2 - RIGGING AND LIFTING....................................................................................................................15

Form 1 Total Weight........................................................................................................................................ 15
Form 1 Shipment............................................................................................................................................. 15
Unit Rigging............................................................................................................................................15
Form 2 Total Weight........................................................................................................................................ 17
Form 2 Shipment............................................................................................................................................. 17
Unit Rigging............................................................................................................................................17
Form 3 Shipment............................................................................................................................................. 18
Shells......................................................................................................................................................18
Compressor Motor Assembly................................................................................................................. 18
Variable Speed Drive (VSD)...................................................................................................................19
Power Panel...........................................................................................................................................20
OptiView™ Control Center.....................................................................................................................20
Form 7 Shipment............................................................................................................................................. 21
Condenser..............................................................................................................................................21
Evaporator .............................................................................................................................................22
Compressor Motor Assembly................................................................................................................. 22
Power Panel...........................................................................................................................................23
Form 9 Shipment............................................................................................................................................. 24
Unit Rigging............................................................................................................................................25
Form 10 Shipment........................................................................................................................................... 26
Unit Rigging............................................................................................................................................26
Form 11 Shipment........................................................................................................................................... 27
Condenser Assembly.............................................................................................................................27
Evaporator Assembly.............................................................................................................................29
JOHNSON CONTROLS 5
FORM 160.84-N1
TABLE OF CONTENTS (CONT'D)
SECTION 3 - INSTALLATION.................................................................................................................................31
Overview......................................................................................................................................................... 31
Determine Location......................................................................................................................................... 31
Foundation Requirements......................................................................................................................31
Clearance Requirements........................................................................................................................31
Rig Unit To Final Location............................................................................................................................... 31
Install Isolators................................................................................................................................................ 31
Neoprene Isolator Pads..........................................................................................................................31
Install Optional Spring Isolators.............................................................................................................. 34
Make Connections........................................................................................................................................... 35
Piping Connections................................................................................................................................35
Refrigerant Relief Piping........................................................................................................................38
Unit Piping..............................................................................................................................................39
Control Wiring.........................................................................................................................................39
Power Wiring..........................................................................................................................................39
Supplied Variable Speed Drive............................................................................................................... 39
Apply Insulation............................................................................................................................................... 39
Installation Check – Request For Startup Service...........................................................................................39
SECTION 4 - REASSEMBLY...................................................................................................................................41
Form 3 and Form 7 Reassembly............................................................................................................ 41
Form 9 and Form 10 Reassembly.......................................................................................................... 48
Form 11 Reassembly.............................................................................................................................50
Refrigerant Tubing Reassembly...................................................................................................................... 52
Assembly of Straight Thread O-ring Port Fittings................................................................................... 52
Assembly of O-ring Face Seal Fittings................................................................................................... 53
SECTION 5 - DIMENSIONS, NOZZLE ARRANGEMENTS AND WEIGHTS.......................................................... 55

Compressor Unit Dimensions.......................................................................................................................... 55
Evaporator 150 & 300 PSI Compact Water Boxes.......................................................................................... 57
Condenser 150 & 300 PSI Compact Water Boxes..........................................................................................59
Evaporator 150 & 300 PSI Marine Water Boxes.............................................................................................61
Condenser 150 PSI Marine Water Boxes........................................................................................................ 65
Condenser 150 & 300 PSI Marine Water Boxes Dimensions......................................................................... 66
Weights........................................................................................................................................................... 66
6 JOHNSON CONTROLS
FORM 160.84-N1
LIST OF FIGURES
FIGURE 1 - YMC2 Chiller Components�� 9

FIGURE 2 - Form 1 and 2 Rigging with Side Spreader Bar��16
FIGURE 3 - Form 1 and 2 Rigging without Side Spreader Bar��16
FIGURE 4 - Driveline Rigging��18
FIGURE 5 - Form 3 Rigging without Side Spreader Bars��19
FIGURE 6 - Variable Speed Drive Rigging��19
FIGURE 7 - Power Panel��20
FIGURE 8 - OptiView Control Center��20
FIGURE 9 - Form 7 Rigging with Side Spreader Bars��21
FIGURE 10 - Driveline Rigging��22
FIGURE 12 - Power Panel��23
FIGURE 14 - Form 9 and 10 Rigging with Side Spreader Bars��24
FIGURE 15 - Form 9 and 10 Rigging without Side Spreader Bars��25
FIGURE 18 - Form 11 Condenser Assembly Rigging with Side Spreader Bars�� 28
FIGURE 19 - Form 11 Evaporator Assembly Rigging with Side Spreader Bars�� 28
FIGURE 21 - Neoprene Isolators��32
FIGURE 22 - Neoprene Isolators��33
FIGURE 23 - Spring Isolators ��34
FIGURE 24 - Pressure Relief Piping��35
FIGURE 25 - Schematic of a Typical Piping Arrangement��36
FIGURE 26 - Typical Refrigerant Vent Piping��38
FIGURE 27 - Unit Insulation��40
FIGURE 28 - Shell Reassembly��41
FIGURE 29 - YMC2 Piping Reassembly Hardware Identification��43
FIGURE 30 - YMC2 Form 3 Reassembly Hardware Identification��44
FIGURE 32 - VSD Mounting Hardware Identification��46
FIGURE 33 - Power and Control Panel Mounting Hardware Identification�� 47
FIGURE 34 - YMC2 Form 9 and Form 10 Reassembly Hardware Identification�� 49
FIGURE 35 - Shell Reassembly��50
FIGURE 36 - Refrigerant Piping��50
FIGURE 38 - Adjustable End Fitting��52
FIGURE 39 - Back off Locknut��52
FIGURE 40 - Screw Fitting into Port��52
FIGURE 41 - Torque Fitting��53
FIGURE 42 - SAE or ISO 6149 Straight Thread O-ring Port��53
FIGURE 43 - Dimensions - 197 & 246 Compressor Units Ft-In (Mm)��56
FIGURE 44 - Evaporator - Compact Water Boxes (1-Pass Nozzle Arrangements)�� 57
JOHNSON CONTROLS 7
FORM 160.84-N1
LIST OF FIGURES (CONT'D)

FIGURE 47 - Evaporator - 150 & 300 PSI Compact Water Boxes�� 58
FIGURE 48 - Condenser - Compact Water Boxes (1-Pass Nozzle Arrangements)�� 59
FIGURE 51 - Condenser - 150 & 300 PSI Compact Water Boxes�� 60
FIGURE 52 - Evaporator - Marine Water Boxes (1-Pass Nozzle Arrangements)�� 61
FIGURE 55 - Evaporator - 150 and 300 PSI Marine Water Boxes�� 63
FIGURE 56 - Condenser - 150 and 300 PSI Marine Water Boxes�� 64
FIGURE 57 - Condenser - Marine Water Boxes (1-Pass Nozzle Arrangements)�� 65
LIST OF TABLES
TABLE 1 - Compressor Motor Weights ��18

TABLE 2 - Variable Speed Drive Weights��19
TABLE 3 - Power Panel��20
TABLE 4 - Control Panel Weights ��20
TABLE 5 - Compressor Motor Weights ��22
TABLE 7 - Power Panel ��23
TABLE 12 - Assembly Torque Metric for Metric Tube Fittings��42
TABLE 13 - Assembly Torque English for SAE Tube Fittings��42
TABLE 14 - Re-Assembly Torque Values��43
TABLE 15 - Approximate Evaporator Weights 150 PSI Compact Water Boxes�� 66
TABLE 16 - Approximate Condenser Weights 150 PSI Compact Water Boxes�� 66
TABLE 17 - Approximate Variable Speed Drive (VSD) Weights��67
TABLE 18 - Approximate Driveline Weights��67
TABLE 19 - Approximate Refrigerant & Water Weight��67
8 JOHNSON CONTROLS
FORM 160.84-N1
SECTION 1 - OVERVIEW 1
GENERAL They can also be shipped dismantled when required by
rigging conditions, but it is generally more economical
This manual provides instructions for rigging and in-
to enlarge access openings to accommodate the factory
stalling a YMC2 Liquid Chilling Unit.
assembled unit. Chillers that are shipped dismantled
Chillers can be shipped as a single factory assembled, MUST be field-assembled under the supervision of a
piped, wired package, requiring a minimum of field la- Johnson Controls representative, but otherwise instal-
bor to make chilled water connections, condenser wa- lation will be as described in this manual.
ter connections, refrigerant atmospheric relief connec-
tions, and electrical power connections. (Refrigerant COMPONENT COMBINATIONS
charges shipped separately unless optional condenser Figure 1 identifies the major components of the YMC2
isolation valves are ordered.) Chiller. The chiller is customized based on the selected
combination of Motor, Compressor, Evaporator, and
Condenser. Section 5 - Dimensions, Nozzle Arrange-
ments And Weights lists all of the allowable YMC2
Chiller combinations.
OPTIVIEW TRANSFORMERS COMPRESSOR VARIABLE

CONTROL SPEED
PANEL DRIVE
DIRECT-DRIVE
MOTOR
MAGNETIC
BEARING
CONTROLLER
VSD
COOLING POWER
PIPING PANEL
LIFTING
OPENINGS
COMPACT
WATERBOXES
CONDENSER
EVAPORATOR
LD14022b
Figure 1 - YMC2 CHILLER COMPONENTS
JOHNSON CONTROLS 9
FORM 160.84-N1
Section 1 - Overview
INSPECTION – DAMAGE – SHORTAGE 3. When units are shipped dismantled, notify the
nearest Johnson Controls office in ample time for
The unit shipment should be checked on arrival to see
a Johnson Controls representative to supervise
that all major pieces, boxes and crates are received.
rigging the unit to its operating position and the
Each unit should be checked on the trailer or rail car
assembly of components.
when received, before unloading, for any visible signs
of damage. Any damage or signs of possible damage 4. Do not make final power supply connections to
must be reported to the transportation company imme- the compressor motor drive or control center.
diately for their inspection. 5. Do not charge the unit with refrigerant.
JOHNSON CONTROLS WILL NOT BE RESPON- 6. Do not attempt to start the system.
SIBLE FOR ANY DAMAGE IN SHIPMENT OR AT 7. Do not run hot water (>110°F / 43°C max) or
JOB SITE OR LOSS OF PARTS. (Refer to Shipping steam through the evaporator or condenser at any
Damage Claims Form (Form 50.15-NM). time.
When received at the job site all containers should be
CHILLER DATA PLATE
opened and contents checked against the packing list.
Any material shortage should be reported to Johnson A unit data plate is mounted on the control center as-
Controls immediately. (Refer to Shipping Damage sembly of each unit, giving unit model number; design
Claims Form (Form 50.15-NM). working pressure; water passes; refrigerant charge; se-
rial numbers; and motor power characteristics and con-
YMC2 Chillers are not intended to be stored outdoors, nection diagrams.
exposed to rain and moisture. The shipping wrap is for
shipping, not for extended outdoor storage. The chiller Additional information may be found on the compres-
should be tarped during any delays to get indoors and sor and motor data plates. This information should be
moisture desiccant, available for purchase for inside included when contacting the factory on any problem.
electrical panels should be used for damp areas.
YMC2 SHIPMENT FORMS
If the chiller was not shipped complete (as shown in
Form 1 or 2) use the Section 4 - Reassembly in con- The chiller may be ordered and shipped in any of the
junction with this installation manual. following forms:
The services of a Johnson Controls representative will • Form 1 (shipped complete with refrigerant charge)
be furnished to check the installation, supervise the • Form 2 (shipped complete with refrigerant charge
initial start-up and operation of all chillers installed shipped separately)
within the Continental United States.
• Form 3 (shipped in three assemblies)
The Johnson Controls Warranty may be • Form 7 (shipped in four assemblies)
voided if the following restrictions are not
adhered to. • Form 9 (shipped in two assemblies with refriger-
ant charge shipped separately)
• Form 10 (shipped in two assemblies with refriger-
ant charge)
1. No valves or connections should be opened under
• Form 11 (shipped as split shells with refrigerant
any circumstances because such action will result
charge)
in loss of the factory refrigerant (Form 1) or nitro-
gen charge (Form 2). Units that are shipped dismantled MUST
2. Do not dismantle or open the chiller for any rea- be reassembled by, or under the supervi-
son except under the supervision of a Johnson sion of a Johnson Controls representative.
Controls representative. Refer to Section 4 - Reassembly for de-
tailed reassembly instructions.
10 JOHNSON CONTROLS
FORM 160.84-N1
When more than one chiller is involved, • The complete unit is factory leak-tested, evacu-
the major parts of each unit will be ated, and shipped charged with a 3 to 7 PSIG (20 1
marked to prevent mixing of assemblies. to 50 kPa) holding charge of dry nitrogen.
Piping and wiring drawings to be fur-
• The OptiView™ Control Center is mounted on
nished by Johnson Controls.
the unit.
• The Variable Speed Drive (VSD) and Power Pan-
Form 1
el are mounted, wired, and shipped with Glycol.
The chiller is shipped complete with miscellaneous
loose items shipped together and refrigerant charges Miscellaneous Items
are included. The following items are shipped together:
Chiller Unit • Four (4) vibration isolation pads (or optional
The unit is completely assembled at the factory. spring isolators and brackets).
• Other shipped loose items, including piping, wa-
• The driveline (compressor/motor assembly) is
ter temperature controls, wiring, etc.
mounted and all the necessary interconnecting
piping is assembled. • VSD operating coolant (inhibited water)
• The complete unit is factory leak-tested, evacuat- Form 3
ed, and shipped charged with R-134A refrigerant.
Prior to shipping, the unit is completely assembled at
• The OptiView™ Control Center is mounted on the factory. Interconnecting piping is assembled and
the unit. the complete unit is wired and leak-tested.
• The Variable Speed Drive (VSD) and Power Pan- The unit is dismantled and shipped as follows:
el are mounted, wired, and shipped with glycol.
1. The driveline (compressor/motor assembly).
Miscellaneous Items
2. The evaporator/condenser shell assembly.
The following items are shipped together:
3. The Variable Speed Drive (VSD).
• Four (4) vibration isolation pads (or optional
spring isolators and brackets). 4. Miscellaneous shipped loose items.
• VSD operating coolant (inhibited water) 5. Refrigerant charges shipped separately.
• Other shipped loose items, including piping, wa- Arrangements with the local service office must be
ter temperature controls, wiring, etc. made to ensure refrigerant is on-site when the unit is
ready to be charged.
Form 2
Driveline
The chiller is shipped complete with refrigerant charg-
es shipped separately and miscellaneous loose items The driveline (compressor/motor assembly) is re-
shipped together. moved from the shells and skidded.
Arrangements with the local service office must be • All integral wiring is left on the compressor.
made to ensure refrigerant is on-site when the unit is • All openings on the compressor are closed and
ready to be charged. shipped charged with a 3 to 7 PSIG (20 to 50 kPa)
holding charge of dry nitrogen.
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.
JOHNSON CONTROLS 11
FORM 160.84-N1
Shells Driveline
The evaporator and condenser are assembled prepared The driveline (compressor/motor assembly) is removed
for shipping but not skidded. from shells and skidded.
• All conduit is left on the shells. • All integral wiring is left on the compressor.
• All openings the shells are closed and charged • All wiring harnesses on shells are removed.
with a 3 to 7 PSIG (20 to 50 kPa) holding charge
• All openings on the compressor are closed and
of dry nitrogen.
shipped charged with a 3 to 7 PSIG (20 to 50 kPa)
Variable Speed Drive (VSD) holding charge of dry nitrogen.
The VSD is skidded and shipped separately from the Shells
assembled chiller.
The evaporator and condenser are separated at the tube
• The VSD is filled with glycol for shipping. The sheets and prepared for shipping separately but not
VSD operating coolant (inhibited water) is skidded.
shipped with the other loose items.
• All conduit is left on the shells.
Miscellaneous Material • Refrigerant lines between shells are flanged and
The following assemblies and items are shipped to- capped, requiring no welding.
gether:
• All openings the shells are closed and charged
• OptiView™ Control Center with a 3 to 7 PSIG (20 to 50 kPa) holding charge
of dry nitrogen.
• Power Panel
Variable Speed Drive (VSD)
spring isolators and brackets). The VSD is skidded and shipped separately from the
assembled chiller.
ter temperature controls, wiring, etc. • The VSD is filled with glycol for shipping. The
VSD operating coolant (inhibited water) is shipped
• VSD operating coolant (inhibited water)
with the other loose items.
Form 7
Miscellaneous Items
Prior to shipping, the unit is completely assembled at
The following assemblies and items are shipped to-
the factory. Interconnecting piping is assembled and
gether:
the complete unit is wired and leak-tested.
• OptiView™ Control Center
The unit is dismantled and shipped as follows:
• Power Panel
1. The driveline (compressor/motor assembly).
2. The evaporator. spring isolators and brackets).
3. The condenser. • Operating coolant (inhibited water)
4. The Variable Speed Drive (VSD). • Other shipped loose items, including piping, wa-
5. Refrigerant charges shipped separately. ter temperature controls, wiring, isolators, etc.
6. Miscellaneous shipped loose items. Form 9
Arrangements with the local service office must be Prior to shipping, the unit is completely assembled at
made to ensure refrigerant is on-site when the unit is the factory. Interconnecting piping is assembled and
ready to be charged. the complete unit is wired and leak-tested.
12 JOHNSON CONTROLS
FORM 160.84-N1
The chiller is shipped in two assemblies as follows: Form 10

1
1. The chiller unit (less the VSD). Prior to shipping, the unit is completely assembled at
the factory. Interconnecting piping is assembled and
2. The VSD. the complete unit is wired and leak-tested.
3. Refrigerant charges shipped separately. The chiller is shipped in two assemblies:
4. Miscellaneous shipped loose items.
1. The assembled chiller unit.
Arrangements with the local service office must be
2. The VSD.
made to ensure refrigerant is on-site when the unit is
ready to be charged. 3. Refrigerant charges are included.
Chiller Unit 4. Miscellaneous shipped loose items.
The unit is first completely assembled at the factory: Chiller Unit

• The driveline (compressor/motor assembly) is The unit is first completely assembled at the factory:
mounted, with all necessary interconnecting pip- • The driveline (compressor/motor assembly) is
ing assembled. mounted, with all necessary interconnecting pip-
• Interconnecting piping is assembled and the com- ing assembled.
plete unit is factory leak-tested then evacuated • The complete unit is factory leak-tested, evacuat-
and shipped charged with a 3 to 7 PSIG (20 to 50 ed, and shipped charged with R-134A refrigerant.
kPa) holding charge of dry nitrogen.
• The Motor Terminal Box adapter remains at-
• The Motor Terminal Box adapter remains at- tached to the chiller unit.
tached to the chiller unit.
The VSD is skidded and shipped separately from the
The VSD is skidded and shipped separately from the assembled chiller.
assembled chiller.
• The VSD is filled with glycol for shipping. The
• The VSD is filled with glycol for shipping. The VSD operating coolant (inhibited water) shipped
VSD operating coolant (inhibited water) shipped with the other loose items.
with the other loose items.
Miscellaneous Material
Miscellaneous Material
The following assemblies and items are shipped to-
The following assemblies and items are shipped together:
gether:
• Four (4) vibration isolation pads (or optional spring isolators and brackets).
spring isolators and brackets).
• Other shipped loose items, including piping, water temperature controls, wiring, etc.
ter temperature controls, wiring, etc.
JOHNSON CONTROLS 13
FORM 160.84-N1
Form 11 Evaporator-Side Assembly (Evaporator /

Prior to shipping, the unit is completely assembled at Driveline / Power Panel)
the factory. Interconnecting piping is assembled and The evaporator-side assembly consists of the evapo-
the complete unit is wired and leak-tested. rator, the driveline (compressor/motor assembly), and
the Power Panel.
The chiller is split down the middle and shipped in two
assemblies: • All conduit is left on the evaporator shell.
1. The condenser-side assembly. • Interconnecting piping between shells are flanged
and capped, requiring no welding.
2. The evaporator-side assembly.
• All integral wiring is left on the compressor.
3. Refrigerant charges are included.
• All openings on the evaporator shell and driveline
4. Miscellaneous shipped loose items. are closed and shipped charged with a 3 to 5 PSIG
Arrangements with the local service office must be (20 to 50 kPa) holding charge of dry nitrogen.
made to ensure refrigerant is on-site when the unit is
ready to be charged. Miscellaneous Material
The following items are shipped together:
Condenser-Side Assembly (Condenser /
OptiView™ Control Center / Variable Speed • Four (4) vibration isolation pads (or optional
Drive) spring isolators and brackets)
The Condenser-side assembly consists of the Condens- • Other shipped loose items, including piping, wa-
er, the OptiView™ Control Center and the Variable ter temperature controls, wiring, etc.
Speed Drive. • VSD operating coolant (inhibited water)
• All conduit is left on the condenser shell.
• Interconnecting piping between shells are flanged
and capped, requiring no welding.
• All openings on the condenser shell are closed
and shipped charged with a 3 to 7 PSIG (20 to 50
kPa) holding charge of dry nitrogen.
14 JOHNSON CONTROLS
FORM 160.84-N1
SECTION 2 - RIGGING AND LIFTING
Improper use of rigging equipment can FORM 1 SHIPMENT

result in serious injury. Do not operate
The chiller is shipped complete with miscellaneous
without proper training and authorization.
items shipped together with refrigerant charges are in- 2
cluded.
• The unit is completely assembled at the factory.
It is the responsibility of the installer to
have a qualified and certified crane opera- • The driveline (compressor/motor assembly) is
tor and rigger for lifting components and mounted and all the necessary interconnecting
relocating to the new site. piping is assembled.
• The complete unit is factory leak-tested, evacuat-
ed and shipped charged with R-134A refrigerant.
To perform a safe and effective rigging practice the • The OptiView™ Control Center is mounted on
installer is responsible for inspection and operation the unit.
of the lifting equipment, special site considerations,
proper rigging and lifting practices, and any safety • The Power Panel is mounted on the unit.
considerations. • The Variable Speed Drive (VSD) is mounted,
Particular items the installer must be aware of are: wired, and ship with glycol.
• Rope with no visible wear, twisted, kinked, or Unit Rigging

damaged chains. One lifting chain is required for each lift-
• Deformed, cracked, or stretched hooks or safety ing point and each chain having a work-
latch on the hook is not damaged. ing load limit 30% of unit total weight.
• Correct drum spooling as the hook is raised. The lifting chains traversing the evapora-
tor/condenser shells should remain 90°
• Do not operate a damaged or malfunctioning +/- 10° from horizontal. A spreader bar
hoist. may be required to achieve the +/- 10°.
• Do not wrap the hoisting rope or chain around the
load. 1. Attach rigging chains to an adequate lifting device.
• Do not lift loads over people. 2. Attach chains to the lifting holes at the corner of
each end sheet as shown on Figure 2 on page 16.
FORM 1 TOTAL WEIGHT
3. If necessary to avoid contact with chiller compo-
The heaviest possible YMC² combination of total
nents install side spreader bars between the Evap-
weight for Form 1 shipment is 33,863 lbs (15,360 kg)
orator and Condenser end sheet lifting chains.
or 17 ton. See Weights on page 67 for YMC² weight
breakdown. 4. The angle of the lifting chains traversing the en
The actual unit total shipping and operat- sheet should not be less than 65° as shown on Fig-
ing weight is on the submittal drawings. ure 2 on page 16.
5. With an adequate lifting device lift the unit slight-
ly off the ground to determine adjustments neces-
sary to keep the unit level. Make adjustments as
necessary to level the unit.
JOHNSON CONTROLS 15
FORM 160.84-N1
Section 2 - Rigging and Lifting
Side
Spreader
Bar
90°+/-10°
Lifting
Holes Lifting
Holes
Lifting
Holes
LD16719b
Figure 2 - FORM 1 AND 2 RIGGING WITH SIDE SPREADER BAR
65°
Min.
Lifting
Holes Lifting
Holes
Lifting
Holes
LD16719c
Figure 3 - FORM 1 AND 2 RIGGING WITHOUT SIDE SPREADER BAR
16 JOHNSON CONTROLS
FORM 160.84-N1
FORM 2 TOTAL WEIGHT Unit Rigging

The heaviest possible YMC² combination of total One lifting chain is required for each lift-
weight for Form 2 shipment is 21,900 lbs (10,000 kg) ing point and each chain having a work-
or 11 ton. See Weights on page 67 for YMC² weight ing load limit 30% of unit total weight.
breakdown.
The lifting chains traversing the evapora- 2
The actual unit total shipping and operat- tor/condenser shells should remain 90°
ing weight is on the submittal drawings. +/- 10° from horizontal. A spreader bar
may be required to achieve the +/- 10°.
1. Attach rigging chains to an adequate lifting device.

FORM 2 SHIPMENT 2. Attach chains to the lifting holes at the corner of
Arrangements with the local service of- each end sheet as shown on Figure 2 on page 16.
fice must be made to ensure refrigerant is 3. If necessary to avoid contact with chiller compo-
on-site when unit is ready to be charged. nents install side spreader bars between the Evap-
4. The angle of the lifting chains traversing the en
sheet should not be less than 65° as shown on Fig-
The chiller is shipped complete with miscellaneous ure 2 on page 16.
items shipped together.
• The driveline (compressor/motor assembly) is ly off the ground to determine adjustments neces-
mounted and all the necessary interconnecting sary to keep the unit level. Make adjustments as
piping is assembled. necessary to level the unit.
• The complete unit is factory leak-tested, evacu-
ated and shipped charged with a 3 to 7 PSIG (20
to 50 kPa) holding charge of dry nitrogen.
• The OptiView™ Control Center is mounted.
• The Power Panel is mounted on the unit.
• The Variable Speed Drive (VSD) is mounted,
wired and shipped with Glycol.
• Refrigerant charges are shipped separately.
JOHNSON CONTROLS 17
FORM 160.84-N1
FORM 3 SHIPMENT Compressor Motor Assembly

The chiller is shipped in five major assemblies: Table 1 - COMPRESSOR MOTOR WEIGHTS
• The evaporator/condenser shell assembly. Compr Code Pounds Kilograms
• The driveline (compressor/motor assembly). M2C-197FAC 2,861 1298
M2C-197FACD 2,861 1292
• The Variable Speed Drive (VSD).
M2C-205FAC 2,867 1300
• The OptiView™ Control Center assembly. M2C-205FACD 2,867 1295
• The Power Panel assembly. M2C-218FAC 2,987 1355
M2C-233FAC 2,999 1,360
• Miscellaneous shipped loose items.
M2C-246FAC 2,989 1,356
One lifting chain is required for each M6C-331FAC 4,500 2,041
lifting point and each chain having a
working load limit 40% of condenser and 1. Attach rigging chains to each end of the com-
evaporator weight or heat exchanger be- pressor/motor assembly as shown in Figure 4 on
ing lifted. page 18.
The lifting chains traversing the evapora- 2. Lift the compressor/motor assembly off the
tor/condenser shells should remain 90° ground to check for center of gravity. Make ad-
+/- 10° from horizontal. A spreader bar justments as necessary.
may be required to achieve the +/- 10°.
The M2C and M6C Compressor/Motor
has metric lifting lugs
Refrigerant charges are shipped separately.
Arrangements with the local service office
must be made to ensure refrigerant is on-
site when the unit is ready to be charged.
Use lifting chains with working load limit
When optional skids are used it may be each 70% of total driveline weight.
necessary to remove the skids so riggers
skates can be used under the unit end
sheets to reduce overall height.
Shells
2. Attach chains to the lifting holes at the corner of
each end sheet as shown on Figure 5 on page 19.
45°
3. If necessary to avoid contact with chiller compo- Min.
nents install side spreader bars between the Evap- 45°
orator and Condenser end sheet lifting chains. Min.
4. The angle of the lifting chains traversing the en

ure 5 on page 19.
necessary to level the unit. LD17276b
Figure 4 - DRIVELINE RIGGING
18 JOHNSON CONTROLS
FORM 160.84-N1
Lifting 2
Holes
65°
Min.
90°+/-10°
Lifting
Holes
Lifting
Holes
Lifting
Holes
LD16732a
Figure 5 - FORM 3 RIGGING WITHOUT SIDE SPREADER BARS

Table 2 - VARIABLE SPEED DRIVE WEIGHTS 6. Make all necessary connections for the VSD cool-
ing loop to be complete.
Model Pounds Kilograms
HYP0490XH 1,226 556 each 35% of total VSD weight.
HYP0612XH 1,954 886
HYP0774XH 2,060 934
The VSD is shipped with glycol in the

cooling system. The VSD coolant must
be changed to the inhibitor provided with
the shipped loose items prior to starting 65°
Min.
the unit or a VSD over temperature fault
may occur. 65°
Min.
1. Attach rigging chains from an adequate lifting
device to the four lifting holes at the top of the Lifting
Holes
VSD as shown in Figure 6 on page 19, for VSD
weight refer to Table 2 on page 19.
2. Lift the VSD slightly off the ground to check for Lifting
center of gravity. Make adjustments as necessary Holes
to level the VSD.
3. Lift the VSD and remove all packing material.
4. Carefully lower the VSD on to the supports on the
condenser. LD16730a
5. Fasten the VSD to the condenser and to the motor Figure 6 - VARIABLE SPEED DRIVE RIGGING
terminal box duct. Remove the rigging chains.
JOHNSON CONTROLS 19
FORM 160.84-N1
Power Panel OptiView™ Control Center

Table 3 - POWER PANEL The OptiView™ Control Center weighs
Description Pounds Kilograms over 50 pounds and a technician and
Power Panel 300 135 helper are needed for the installation of
the panel.
2. Attach the chains to the lifting holes at the top of the Table 4 - CONTROL PANEL WEIGHTS
Power Panel as shown in Figure 7 on page 20. Description Pounds Kilograms
3. Lift the Power Panel slightly off the ground to OptiView 75 34
check for center of gravity. Make adjustments as
necessary to level the Power Panel. 1. Lift the OptiView™ Control Center and remove
4. Lift the Power Panel and remove all packing ma- all packing material.
terial. 2. Carefully lower the OptiView™ Control Center
5. Carefully lower the Power Panel on to the sup- on to the supports on the condenser.
ports on the evaporator. 3. Attach the OptiView™ Control Center to the con-
6. Attach the Power Panel to the evaporator with the denser with the proper hardware.
proper hardware. Remove the rigging chains. 4. Connect all unit wiring and harnesses (refer to
7. Re-connect all unit wiring and harnesses (refer to YMC2 Unit Wiring and Field Control Modifica-
YMC2 Unit Wiring and Field Control Modifica- tions (Form 160.78-PW2).
tions (Form 160.78-PW2).
each 70 of the Power Panel weight.
Lifting
Holes
45°
Min.
Lifting
Holes
LD16738
Figure 8 - OPTIVIEW CONTROL CENTER
LD17275a
Figure 7 - POWER PANEL
20 JOHNSON CONTROLS
FORM 160.84-N1
FORM 7 SHIPMENT The lifting chains along the axis of the

evaporator/condenser shells should not
The chiller is shipped in six assemblies:
exceed 90° +/- 10°. A spreader bar may
• The driveline (compressor/motor assembly). be required to achieve the +/- 10°.
• The evaporator.
2
• The condenser. One chain is required per each lifting
point.
• The Variable Speed Drive (VSD).
• The OptiView™ Control Center assembly.
each at least 40% of the total shell weight.
• The Power Panel assembly.
Condenser
Arrangements with the local service office 1. Attach rigging chains to an adequate lifting device.
must be made to ensure refrigerant is on- 2. Attach chains to the two lifting holes at the corner of
site when the unit is ready to be charged. each end sheet as shown in Figure 9 on page 21.
When optional skids are used it may be Angles apply to condenser or evaporator.
necessary to remove the skids so riggers
skates can be used under the unit end
sheets to reduce overall height.
Lifting
Holes
45°
Min.
90°+/-10°
Lifting
Lifting
Holes
Holes
Lifting
Holes
CON
DEN EVA
SER POR
ATO
R
LD17059b
Figure 9 - FORM 7 RIGGING WITH SIDE SPREADER BARS
JOHNSON CONTROLS 21
FORM 160.84-N1
3. If necessary to maintain minimum angles in- 1. Attach rigging chains to each end of the compres-
stall spreader bars between the condenser lifting sor/motor assembly as shown in Figure 10 on
chains to have the chains as shown in Figure 9 on page 22.
page 21.
2. Lift the compressor/motor assembly off the
The angle of the lifting chains is critical ground to check for center of gravity. Make ad-
and damage to the unit may occur if the justments as necessary.
rigging is not completed as described.
The M2C and M6C Compressor/Motor
has metric lifting lugs

ly off the ground to check for center of gravity.
Make adjustments as necessary to level the unit. Use lifting chains with working load limit
each 70% of total driveline weight.
Evaporator
1. Attach rigging chains to an adequate lifting
device.
2. Attach chains to the two lifting holes at the cor-
ner of the end sheet as shown in Figure 9 on
page 21.
3. If necessary to maintain minimum angles, in-
stall spreader bars between the Evaporator end
sheets to have the chains as shown in Figure 9 45°
on page 21. Min.
45°
The angle of the lifting chains is critical Min.
and damage to the unit may occur if the

LD17276b
Make adjustments as necessary to level the unit. Figure 10 - DRIVELINE RIGGING
Compressor Motor Assembly

Table 5 - COMPRESSOR MOTOR WEIGHTS
Table 6 - VARIABLE SPEED DRIVE WEIGHTS
Compr Code Pounds Kilograms
M2C-197FAC 2,861 1298
HYP0490XH 1,226 556
M2C-197FACD 2,861 1292
HYP0612XH 1,954 886
M2C-205FAC 2,867 1300
HYP0774XH 2,060 934
M2C-205FACD 2,867 1295
M2C-218FAC 2,987 1355
The VSD is shipped with glycol in the
cooling system. The VSD coolant must
M2C-233FAC 2,999 1,360
M2C-246FAC 2,989 1,356
the shipped loose items prior to starting
M6C-331FAC 4,500 2,041 the unit or a VSD over temperature fault
may occur.
22 JOHNSON CONTROLS
FORM 160.84-N1
1. Attach rigging chains from an adequate lifting de- Use lifting chains with working load limit
vice to the four lifting holes at the top of the VSD each 70% of the Power Panel weight.
as shown in Figure 11 on page 23.
2. Lift the VSD slightly off the ground to check for
center of gravity. Make adjustments as necessary
to level the VSD. 2
3. Lift the VSD and remove all packing material, for
VSD weight refer to Table 6 on page 22.
Use lifting chains with working load limit Lifting
each 35% of total VSD weight. Holes
45°
Min.
Lifting
Holes
65°
Min.
65°
Min.
Lifting
Holes LD17275a
Figure 12 - POWER PANEL

Lifting
Holes
OptiView™ Control Center
The OptiView™ Control Center weighs
over 50 pounds and a technician and
helper are needed for the installation of
LD16730a the panel.
Figure 11 - VARIABLE SPEED DRIVE RIGGING
Table 8 - CONTROL PANEL WEIGHTS

Power Panel Description Pounds Kilograms
Table 7 - POWER PANEL OptiView 75 34
Description Pounds Kilograms
Power Panel 300 135 1. Lift the OptiView™ Control Center and remove
all packing material.
2. Carefully lower the OptiView™ Control Center
2. Attach the chains to the lifting holes at the top on to the supports on the condenser.
of the Power Panel as shown in Figure 12 on
page 23. 3. Attach the OptiView™ Control Center to the con-
denser with the proper hardware.
3. Lift the Power Panel slightly off the ground to
check for center of gravity. Make adjustments as
necessary to level the Power Panel.
4. Lift the Power Panel and remove all packing
material.
JOHNSON CONTROLS 23
FORM 160.84-N1
FORM 9 SHIPMENT
The chiller is shipped in two assemblies:
• The chiller unit (less the VSD).
• The VSD.
The unit is first factory assembled, refrigerant piped,
wired and leak tested; then dismantled for shipment.
All wiring integral with compressor is left on it, and
all conduit is left on shell. All openings on compressor
and shell are closed and charged with dry nitrogen (3 to
7 PSIG (20 to 50 kPa).
LD16738 Arrangements with the local service of-
fice must be made to ensure refrigerant is
on-site when unit is ready to be charged.
Side
Spreader
Bars
65°
Min.
90°+/-10°
Lifting
Holes
Lifting
Holes
Lifting
Holes
LD16739b
Figure 14 - FORM 9 AND 10 RIGGING WITH SIDE SPREADER BARS
24 JOHNSON CONTROLS
FORM 160.84-N1
65° 2
Min.
90°+/-10°
Lifting
Holes
Lifting
Holes
Lifting
Holes
LD16739c
Figure 15 - FORM 9 AND 10 RIGGING WITHOUT SIDE SPREADER BARS
Unit Rigging 5. With an adequate lifting device lift the unit slight-
One lifting chain is required for each lift- sary to keep the unit level. Make adjustments as
ing point and each chain having a work- necessary to level the unit.
ing load limit 40% of unit total weight.
The lifting chains traversing the evapora-
tor/condenser shells should remain 90° Table 9 - VARIABLE SPEED DRIVE WEIGHTS
+/- 10° from horizontal. A spreader bar
may be required to achieve the +/- 10°. Model Pounds Kilograms
HYP0490XH 1,226 556
HYP0612XH 1,954 886
HYP0774XH 2,060 934
2. Attach chains to the lifting holes at the corner The VSD is shipped with glycol in the
of each end sheet as shown on Figure 15 on cooling system. The VSD coolant must
page 25. be changed to the inhibitor provided with
the shipped loose items prior to starting
3. If necessary to avoid contact with chiller compo- the unit or a VSD over temperature fault
nents install side spreader bars between the Evap- may occur.
4. The angle of the lifting chains traversing the en 1. Attach rigging chains from an adequate lifting de-
sheet should not be less than 65° as shown on Fig- vice to the four lifting holes at the top of the VSD
ure 15 on page 25. as shown in Figure 16 on page 26.
2. Lift the VSD slightly off the ground to check for
center of gravity. Make adjustments as necessary
to level the VSD.
JOHNSON CONTROLS 25
FORM 160.84-N1
3. Lift the VSD and remove all packing material, for Unit Rigging
VSD weight refer to Table 10 on page 26. One lifting chain is required for each lift-
4. Carefully lower the VSD on to the supports on the ing point and each chain having a work-
condenser. ing load limit 30% of unit total weight or
heat exchanger being lifted.
5. Fasten the VSD to the condenser and to the motor
terminal box duct. Remove the rigging chains. The lifting chains traversing the evapora-
tor/condenser shells should remain 90°
Use lifting chains with working load limit +/- 10° from horizontal. A spreader bar
each 35% of total VSD weight. may be required to achieve the +/- 10°.

2. Attach chains to the lifting holes at the corner
of each end sheet as shown on Figure 14 on
65° page 24.
Min.
65° 3. If necessary to avoid contact with chiller compo-
Min. nents install side spreader bars between the Evap-
Lifting 4. The angle of the lifting chains traversing the en
Holes
ure 14 on page 24.
Lifting 5. With an adequate lifting device lift the unit slight-
Holes ly off the ground to determine adjustments neces-
necessary to level the unit.

LD16730a
Table 10 - VARIABLE SPEED DRIVE WEIGHTS
Figure 16 - VARIABLE SPEED DRIVE RIGGING
HYP0490XH 1,226 556
FORM 10 SHIPMENT
HYP0612XH 1,954 886
The chiller is shipped in two assemblies: HYP0774XH 2,060 934
• The chiller unit (less the VSD). The VSD is shipped with glycol in the
• The VSD. cooling system. The VSD coolant must
• Miscellaneous shipped loose items. the shipped loose items prior to starting
The complete unit is factory leak-tested, evacuated, the unit or a VSD over temperature fault
and shipped charged with R-134A refrigerant. may occur.
The unit is first factory assembled, refrigerant piped, 1. Attach rigging chains from an adequate lifting de-
wired and leak tested; then dismantled for shipment. vice to the four lifting holes at the top of the VSD
Evaporator/condenser is not skidded. All wiring inte- as shown in Figure 17 on page 27.
gral with compressor is left on it, and all conduit is left 2. Lift the VSD slightly off the ground to check for
on shell. center of gravity. Make adjustments as necessary
to level the VSD.
26 JOHNSON CONTROLS
FORM 160.84-N1
3. Lift the VSD and remove all packing material, for Refrigerant charges are shipped separately.
VSD weight refer to Table 10 on page 26. Arrangements with the local service of-
fice must be made to ensure refrigerant is
4. Carefully lower the VSD on to the supports on the
on-site when unit is ready to be charged.
condenser.
5. Fasten the VSD to the condenser and to the motor 2
terminal box duct. Remove the rigging chains.
Condenser Assembly
Use lifting chains with working load limit The lifting chains along the axis of the
each 35% of total VSD weight. condenser shell should not exceed 90°
+/- 10°. A spreader bar may be required
to achieve the +/- 10°.
One chain is required per each lifting

65°
Min. point.
65° Use lifting chains with working load
Min. limit each at least 40% of the total shell
installed component weight.
Lifting
Holes 1. Attach rigging chains to an adequate lifting device.
2. Attach chains to the lifting holes at the corner of
Lifting the end sheets as shown in Figure 18 on page 28.
Holes
3. If necessary to maintain minimum angles in-
stall side spreader between the condenser end
sheets to have the chains as shown in Figure 18
on page 28.
LD16730a The angle of the lifting chains is critical
Figure 17 - VARIABLE SPEED DRIVE RIGGING and damage to the unit may occur if the
FORM 11 SHIPMENT
The chiller is split down the middle and shipped in
three assemblies: 4. With an adequate lifting device lift the unit slight-
• The condenser-side assembly. ly off the ground to check for center of gravity.
Make adjustments as necessary to level the unit.
• The evaporator-side assembly.
• The OptiView™ Control Center assembly.
The unit is first factory assembled, refrigerant piped,
wired and leak tested; then dismantled for shipment.
All wiring integral with compressor is left on it, and all
conduit is left on shell.
All openings on compressor and shell are closed and
3 to 7 PSIG (20 to 50 kPa) holding charge of dry ni-
trogen.
JOHNSON CONTROLS 27
FORM 160.84-N1
90°+/-10°
Lifting
Side Holes
Spreader
Bar 65°
Min.
Lifting
Holes
CO
ND
Lifting
EN
SE Holes
R
LD17057a
Figure 18 - FORM 11 CONDENSER ASSEMBLY RIGGING WITH SIDE SPREADER BARS
65°
Min.
Side
Spreader 90°+/-10°
Bar
Lifting
Holes
Lifting
Holes
LD17058a
Figure 19 - FORM 11 EVAPORATOR ASSEMBLY RIGGING WITH SIDE SPREADER BARS
28 JOHNSON CONTROLS
FORM 160.84-N1
Evaporator Assembly OptiView™ Control Center

The lifting chains along the axis of the The OptiView™ Control Center weighs
evaporator shell should not exceed 90° over 50 pounds and a technician and
+/- 10°. A spreader bar may be required helper are needed for the installation of
to achieve the +/- 10°. the panel.
2
One chain is required per each lifting Table 11 - CONTROL PANEL WEIGHTS
point. Description Pounds Kilograms
Use lifting chains with working load limit OptiView 75 34
each at least 40% of the total shell and
installed component weight. 1. Lift the OptiView™ Control Center and remove
all packing material.
1. Attach rigging chains to an adequate lifting device. 2. Carefully lower the OptiView™ Control Center
2. Attach chains to the lifting holes at the corner of on to the supports on the condenser.
the end sheets as shown in Figure 19 on page 28. 3. Attach the OptiView™ Control Center to the con-
3. If necessary to maintain minimum angles install denser with the proper hardware.
side spreader bars between the evaporator end 4. Connect all unit wiring and harnesses (refer to
sheets to have the chains at 90° as shown in Fig- YMC2 Unit Wiring and Field Control Modifica-
ure 19 on page 28. tions (Form 160.78-PW2).
The angle of the lifting chains is critical
and damage to the unit may occur if the

Make adjustments as necessary to level the unit.
LD16738
JOHNSON CONTROLS 29
FORM 160.84-N1
THIS PAGE INTENTIONALLY LEFT BLANK.
30 JOHNSON CONTROLS
FORM 160.84-N1
SECTION 3 - INSTALLATION
OVERVIEW Clearance Requirements

The installation process consists of the following steps: Clearances should be adhered to as follows:
1. Determine Location Rear and Above Unit 2 ft (61 cm)
• Foundation Requirements Front of Unit 3 ft (91 cm)
• Clearance Requirements Tube Removal 14 ft* (4.3 m) either end

* 8' (2.4m): 2508 Shell Codes 3
2. Rig Chiller to Final Location 10' (3m): 2110 and 2510 Shell Codes
14' (4.3m): 2514 Shell Codes
3. Install Isolators
• Locate and place Isolator Pads, or RIG UNIT TO FINAL LOCATION
• Install optional Spring Isolators Rig the unit to its final location on the floor or mount-
ing pad, lift the unit (or shell assembly) by means of an
4. Level Chiller
overhead lift and lower the unit to its mounting posi-
5. Make Connections tion. (If optional shipping skids are used, remove them
before lowering the chiller to its mounting position.)
• Piping
At this point units shipped dismantled
• Wiring
should be assembled under the supervi-
6. Apply Insulation sion of a Johnson Controls representative
The rigging, operating weights, and in accordance with the Reassembly sec-
overall dimensions are provided in Sec- tion of this manual.
tion 5 - Dimensions, Nozzle Arrangements
And Weights to help you determine the If evaporator is to be field insulated, the insulation can
clearances required for rigging. Add 6" be applied to the evaporator while the unit is in the lift
(15 cm) to overall height for optional position to gain more access below the shell, if neces-
skidded unit. sary. Be sure unit is properly supported. (Refer to In-
sulation in this section and Figure 21 on page 32 for
DETERMINE LOCATION further information.)
Sufficient clearance to facilitate normal INSTALL ISOLATORS

service and maintenance work must be
Neoprene isolator pads are furnished standard and
provided around and above the unit and
typically satisfy the installation engineer's vibration
particularly space provided at either end to
isolation requirements when the chiller foundation
permit cleaning or replacement of evapo-
is not likely to transmit to occupied spaces. Optional
rator and condenser tubes – see Clear-
spring isolators can be selected when the location of
ance. A doorway or other sufficiently large
the equipment room floor dictates more stringent limits
opening properly located may be used.
on vibration input.
The chiller should be located in an indoor
location where temperatures range from Neoprene Isolator Pads
40°F to 110°F (4.4°C to 43.3°C). Locate And Place Isolator Pads
The isolator pad mounts are to be located and placed
Foundation Requirements rubber-side down as shown in Figure 21 on page 32.
A level floor, mounting pad or foundation must be pro-
vided by others, capable of supporting the operating After the isolator pads have been placed into position
weight of the unit. 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.
JOHNSON CONTROLS 31
FORM 160.84-N1
Section 3 - Installation
Level The Unit Checking The Isolation Pad Deflection

The longitudinal alignment of the unit should be All isolation pads should be checked for the proper de-
checked by placing a level on the top center of the flection while checking to see if the unit is level. Each
evaporator shell under the compressor/motor assem- pad should be deflected approximately 0.10 inches
bly. Transverse alignment should be checked by plac- (2.5 mm) to 0.20 inches (5 mm). If an isolation pad is
ing a level on top of the shell end sheets. under-deflected, shims should be placed between the
unit tube sheet and the top of the pad to equally deflect
The unit should be level within 1/4" (6 mm) from one all pads.
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 are furnished by the install-
er.) Lower unit again and recheck to see that it is level.
ALL DIMENSIONS ARE IN INCHES (MM)
SHELL SHELL
DIA.
END SHEET HOLE END SHEET
DIA.
HOLE
See Detail A See Detail A
LD12638a LD12639a
UNIT WEIGHT UP TO 16,365 Lbs (7,423 Kgs) UNIT WEIGHT 16,366 - 28,835 Lbs (7,424 - 13,080 Kgs)
SHELL
DIA. END SHEET

HOLE
See Detail A
LD12640a
UNIT WEIGHT 28,836 - 53,530 Lbs (13,081 - 24,281 Kgs)
Figure 21 - NEOPRENE ISOLATORS
32 JOHNSON CONTROLS
FORM 160.84-N1
*
*
A
D E
LD12642
OPERATING UNIT WEIGHT DIM "A" DIM "B" DIM "C" DIM "D" DIM "E"
15,001 - 29,000 Lbs
62" (1575) 31" (787) 31" (787) 10" (254) 8" (203)
(6,805 - 13,154 Kgs)
NOTE: Dimensions are shown in Inches (mm)

* Brackets installed when skidded option is selected for Form 7 and 11.
Figure 22 - NEOPRENE ISOLATORS
JOHNSON CONTROLS 33
FORM 160.84-N1
Install Optional Spring Isolators ALL DIMENSIONS ARE IN INCHES (MM)

Bolt Isolators To The Unit
If ordered, spring type isolator assemblies are fur-
nished with the unit. The four assemblies are identical
and can be placed at any of the four corners of the unit. SHELL
While the unit is still suspended by the rigging, the iso-

lators should be bolted to the unit by inserting the cap 5 1/2” 1 3/8”
END
SHEET
screw(s) through the hole(s) in the mounting bracket (140) (35)
CAP
into the tapped hole in the top of the isolator leveling SCREW
bolt(s). Then the unit can be lowered onto the floor. ADJUSTING
BOLT
1
Level The Unit (25”
)
The longitudinal alignment of the unit should be (17 7” 7” 8)

8) (17
checked by placing a level on the top center of the 4-SPRING ISOLATORS LD19572
evaporator shell under the compressor/motor assem- UNIT WEIGHT
10,000 to 19,563 (4,536 to 8,873 Kgs)
bly. Transverse alignment should be checked by plac-
ing a level on top of the shell end sheets.
Rotate the leveling bolts one turn at a time, in sequence,
until the unit end sheets are clear of the floor by the
dimension shown in Figure 23 on page 34 and the SHELL
unit is level. If the leveling bolts are not long enough to
level unit due to an uneven or sloping floor or founda-
tion, steel shims (grouted, if necessary) must be added 5 1/2” 1 3/8”
END
SHEET
beneath the isolator assemblies as necessary. (140) (35)
CAP
SCREW
If the springs are over-compressed at any corner, the
levelling bolt has been extended too far compared to ADJUSTING
BOLT
at least one of the other corners on the same endsheet 1
(25”
)
or same side of the shell and the isolator is bearing an (15 6”
2)
(1 6”
unequal amount of the chiller load. Correct by backing

)
52
off the bolts on the overloaded isolator and adjusting 4-SPRING ISOLATORS LD19573
UNIT WEIGHT
opposite isolators as required. 19,564 Lbs UP TO 24, 457 Lbs (8874 Kgs UP TO 11093 Kgs)
SHELL
END
5 1/2” 1 3/8” SHEET
(140) (35)
CAP
SCREW
ADJUSTING
BOLT
1
(25”
)
(15 6”
2)
(1 6”
)
52
4-SPRING ISOLATORS LD19573
UNIT WEIGHT
30,827 Lbs UP TO 35,009 Lbs (13,983 Kgs UP TO 15,880 Kgs)
Figure 23 - SPRING ISOLATORS
34 JOHNSON CONTROLS
FORM 160.84-N1
MAKE CONNECTIONS 2. Disconnect piping at flange or union connection if

possible. When the piping is disconnected, there
After the unit is leveled, place wedges and/or shims un-
should be no springing or movement noted. The
der each corner to solidly support the unit in this position
piping system must be self supported and in per-
while connecting and hanging the piping, adjusting the
fect alignment with the relief valves.
connections, and checking for proper alignment.
The coolant temperature inside any JCI-supplied liq-
uid-cooled motor starter must be maintained above the
dewpoint temperature in the equipment room to prevent
condensing water vapor inside the starter cabinet. There-
fore, an additional temperature-controlled throttle valve 3
is needed in the flow path for the starter heat exchanger
to regulate cooling above the equipment room dewpoint
for applications using cooling sources other than evapo-
rative air-exchange methods, such as wells, bodies of
water, and chilled water. The temperature control valve
should be the type to open on increasing drive coolant
temperature, fail-closed, and set for a temperature above
dewpoint. It can be requested as factory-supplied on a LD17201
chiller order by special quotation.
Figure 24 - PRESSURE RELIEF PIPING
Piping Connections
After the unit is leveled (and wedged in place for op-
Check for piping alignment – Upon completion of
tional spring isolators) the piping connections may be
piping, a connection in each line as close to the unit
made; chilled water, condenser water and refrigerant
as possible should be opened, by removing the flange
relief. The piping should be arranged with offsets for
bolts or coupling and checked for piping alignment. If
flexibility, and adequately supported and braced inde-
any of the bolts are bound in their holes, or if the con-
pendently of the unit to avoid strain on the unit and
nection springs are out of alignment, the misalignment
vibration transmission refer to Figure 26 on page 38.
must be corrected by properly supporting the piping or
Hangers must allow for alignment of pipe. Isolators
by applying heat to anneal the pipe.
(by others) in the piping are highly desirable, and may
be required by specifications, in order to effectively If the piping is annealed to relieve stress,
utilize the vibration isolation characteristics of the vi- the inside of the pipe must be cleaned of
bration isolation mounts of the unit. Piping connecting scale before it is finally bolted in place.
to chillers on spring isolators should be isolated with
properly aligned and supported flexible connections.
Otherwise, the piping joint becomes the primary resis-
tance to motion and pipe or fittings are likely to deform After the connections are made the unit can be filled
or fatige during operation. with water and checked for leaks.
Check for strain on piping – It is critical that no If spring isolators were installed, final adjustments
strain is present on the relief valve when the piping is can be made to the leveling bolts until the wedges and
connected. Any strain must be eliminated to minimize shims can be removed. The unit should now be in cor-
the potential to deform the seal surfaces and cause rect level position, clear of the floor or foundation and
a leak. When checking for piping stress in Pressure without any effect from the weight of the piping.
Relief Piping:
1. Perform a visual inspection of the existing piping
to determine if there are any clear signs of strain
present.
JOHNSON CONTROLS 35
FORM 160.84-N1
Evaporator And Condenser Water Piping The nozzles and water pass arrangements are furnished
The evaporator and condenser liquid heads of chiller in accordance with the job requirements (see Product
have nozzles which are grooved, but also suitable for Drawings furnished with the job.) Standard units are
welding 150 psig DWP flanges or the use of flexible designed for 150 psig DWP on the water side. If job
couplings. Factory mounted flanges are optional. If requirements are for greater than 150 psig DWP, check
welding is done on the nozzles, flow switches, con- the unit data plate before applying pressure to evapora-
denser level sensor, and water temperature thermistors tor or condenser to determine if the chiller has provi-
should be disconnected and the welding ground MUST sions for the required DWP.
be good contact located at the head to prevent current Inlet and outlet connections are identified by labels
damage to the devices. placed adjacent to each nozzle.
COOLING
TOWER
CONTROLLED COOLING
TOWER BYPASS VALVE
(IF NECESSARY)
C = Compressor
STRAINER M = Motor
CONDENSER
C M
COOLING TOWER
PUMP
COOLING
EVAPORATOR LOAD
CHILLER STRAINER
CHILLED WATER PUMP
LD08529a
Figure 25 - SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT
36 JOHNSON CONTROLS
FORM 160.84-N1
Chilled Water Stop Valves

Foreign objects which could lodge in, or block flow Stop valves may be provided (by others) in the evapora-
through, the evaporator and condenser tubes must be tor and condenser water piping adjacent to the unit to
kept out of the water circuit. All water piping must be facilitate maintenance. Thermometer wells and pressure
cleaned or flushed before being connected to the chill- taps should be provided (by others) in the piping as close
er pumps, or other equipment. to the unit as possible to facilitate operating check.
Permanent strainers (supplied by others) are required Flow Switches
in both the evaporator and condenser water circuits to
Thermal type water flow switches are factory mount-
protect the chiller as well as the pumps, tower spray noz-
zles, chilled water coils and controls, etc. The strainer
ed in the chilled and condensed water nozzles and are 3
factory wired to the OptiView™ Control Panel. These
must be installed in the entering chilled water and con-
solid-state flow sensors have a small internal heating
denser liquid line, upstream and near to the chiller.
element and use the cooling effect of the flowing fluid
Water piping circuits should be arranged to avoid water to sense when flow has been established.
voids to the chiller, and should be controlled as neces-
sary to avoid rapid flow transients. Waterbox Drain And Vent Valves
Drain and vent valves (by others) should be installed
If pumps discharge through the chiller, the strainer
in the connections provided in the evaporator and con-
may be located upstream from pumps to protect both
denser liquid heads. These connections may be piped
pump and chiller. (Piping between strainer, pump and
to drain if desired. They will assist in proper fill and
chiller must be very carefully cleaned before start-up.)
vent of the chiller waterside prior to starting pumps to
If pumps are remotely installed from chiller, strainers
ensure no voids exist that could cause damage from a
should be located directly upstream of the chiller.
water slug.
Condenser Water Circuit
Checking Piping Circuits And Venting Air
For proper operation of the unit, condenser refrigerant
After the water piping is completed, but before any
pressure must be maintained above evaporator pressure.
water box insulation is applied. Tighten and torque to
If operating conditions will fulfill this requirement, no at-
maintain between 30 and 60 ft. lbs. (41 and 81 N·m)
tempt should be made to control condenser water temper-
the nuts on the liquid head flanges. Gasket shrinkage
ature by means of automatic valves, cycling of the cool-
and handling during transit cause nuts to loosen. If wa-
ing tower fan, or other means, since chillers are designed
ter pressure is applied before tightening is done, the
to function satisfactorily and efficiently when condenser
gaskets may be damaged and have to be replaced. Fill
water is allowed to seek its own temperature level at re-
the chilled and condenser water circuits, operate the
duced loads and off-peak seasons of the year. However, if
pumps manually and carefully check the evaporator
it is possible for the entering condenser water temperature
and condenser water heads and piping for leaks. Repair
to go below the required minimum, condenser water tem-
leaks as necessary.
perature must be maintained equal to or slightly higher
than the required minimum. Refer to the YMC2 Engineer- Before initial operation of the unit both water circuits
ing Guide (Form 160.84-EG1) for required minimum should be thoroughly vented of all air at the high points.
Condenser and Evaporator temperatures. Refer to Figure
8 for typical water piping schematic.
JOHNSON CONTROLS 37
FORM 160.84-N1
Refrigerant Relief Piping

Each unit is equipped with pressure relief valves lo- by code in most areas and should be installed on all
cated on the condenser and on the evaporator for the chillers. The vent line should be sized in accordance
purpose of quickly relieving excess pressure of the re- with the ANSI/ASHRAE-15, or local code. The vent
frigerant charge to the atmosphere as a safety precau- line must include a dirt trap in the vertical leg to in-
tion in case of an emergency, such as fire. tercept and permit clean out and to trap any vent stack
condensation. The piping MUST be arranged to avoid
Refrigerant relief vent piping (by others), from the re- strain on the relief valves, using a flexible connection,
lief valves to the outside of the building, is required if necessary.
When installing relief piping an
ANSI flange or a piping union
must be used to make a
servicable piping connection.
Horizontal Vertical Compressed

Mis-aligned Offset
When installing relief piping there
must NOT be any piping strain.
Relief piping must be properly
aligned and supported to eliminate
any possible piping strain.
LD16677
VENT TO ATMOSPHERE
SUPPORT VENT PIPING TO AVOID

FLANGED JOINT STRAIN ON RELIEF PIPING
TO PERMIT PIPING
DISASSEMBLY
FLEXIBLE CONNECTOR
CONDENSATION
TRAP
CONDENSER
DUAL RELIEF
SEE NOTE
VALVES
EVAPORATOR
NOTE: SHELLS MAY BE FURNISHED WITH

ONE OR TWO RELIEF VALVES,
DEPENDING ON SHELL SIZE.
LD03863
Figure 26 - TYPICAL REFRIGERANT VENT PIPING
38 JOHNSON CONTROLS
FORM 160.84-N1
Unit Piping APPLY INSULATION

Compressor refrigerant piping and system external DO NOT field insulate until the unit has
piping are factory installed on all units shipped assem- been leak tested under the supervision of
bled. On units shipped dismantled, the piping should the Johnson Controls representative.
be completed under the supervision of the Johnson
Controls representative.
Control Wiring
Insulation of the type specified for the job, or mini-
On units shipped disassembled, after installation of
mum thickness to prevent sweating of 30°F (-1°C)
the control center, control wiring must be completed
surfaces should be furnished (by others) and applied 3
between unit components and control center, variable
to the evaporator shell, end sheets, liquid feed line to
speed drive and using wiring harness furnished. Refer
flow chamber, compressor suction connection, and
to YMC2 Field Connections Manual (Form 160.84-
evaporator liquid heads and connections (see Figure
PW1).
9). The liquid head flange insulation must be remov-
Field wiring connections for commonly encountered able, to allow head removal for the tube maintenance.
control modifications (by others) if required, are shown
Units are furnished factory anti-sweat insulated on or-
in the YMC2 Unit Wiring and Field Control Modifica-
der at additional cost. This includes all low tempera-
tions Manual (Form 160.84-PW2).
ture surfaces except the two (2) cooler liquid heads.
No deviations in unit wiring from that
INSTALLATION CHECK – REQUEST FOR
shown on drawings furnished shall be
STARTUP SERVICE
made without prior approval of the John-
son Controls representative. 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.
Power Wiring
After the unit is installed, piped and wired as described
DO NOT cut wires to final length or make in this Instruction, but before any attempt is made to
final connections to starter power input start the unit, the Johnson Controls District Office
terminals until approved by the Johnson should be advised so that the start-up service, includ-
Controls representative. ed in the contract price, can be scheduled. Notify the
Johnson Controls office using the Installation Check-
list and Request Form (Form 160.84-CL1).
Supplied Variable Speed Drive.
The factory mounted Variable Speed Drive does not
require wiring to the compressor motor. The mo-
tor power wiring is factory connected to the Variable
Speed Drive (refer to the YMC2 Unit Wiring and Field
Control Modifications Manual (Form 160.84-PW2)).
All wiring to the control panel is completed by the fac-
tory. A control transformer is factory furnished with
the Variable Speed Drive.
JOHNSON CONTROLS 39
FORM 160.84-N1
HOT GAS
LINE LIQUID
LINE
SIGHT GLASS
CONDENSER EVAPORATOR CONDENSER EVAPORATOR
Tape Insulation
around flanges to
allow for removal.
HOT GAS
CONNECTION
SIGHT GLASS
LD03827a
Bold lines and shaded components
represent insulation.
Figure 27 - UNIT INSULATION
40 JOHNSON CONTROLS
FORM 160.84-N1
SECTION 4 - REASSEMBLY
Form 3 and Form 7 Reassembly 6. Lift compressor/motor assembly according to rig-

Refer to Figure 29 on page 43, Figure ging section and remove packing materials. Care-
30 on page 44, Figure 31 on page 45, fully lower the compressor/motor assembly on to
Figure 32 on page 46 and Figure 33 the discharge line and motor support on the evap-
on page 47 for reassembly hardware orator. Fasten compressor/motor assembly with
identification. the proper hardware. Do not tighten the bolts until
all connections are made to the compressor.
1. Rig shells according to the rigging section to final 7. Bolt the suction line between the compressor and
location. See Section 2 - Rigging and Lifting. the evaporator using proper gaskets and hardware.
2. Bolt the tube sheets together as shown in Figure 8. Complete the refrigerant liquid line piping be-
28 on page 41. Note that the outside surfaces of tween the evaporator and condenser. Be sure
hardware are all properly installed. 4
the tube sheets must be flush.
9. Tighten all hardware installed in steps 3 through
6 above to the specified torque values provided in
the reassembly figure.
CONDENSER
10. Install refrigerant piping (Refer to Refrigerant
Tubing Reassembly on page 52).
11. Pressure test the unit with nitrogen per Form
160.84-O1.
12. Lift the Variable Speed Drive in accordance with
rigging instructions and remove all packing ma-
terial. Carefully lower the Variable Speed Drive
EVAPORATOR
on to the supports on the condenser. Fasten the
5/8” x 2-1/2” Variable Speed Drive to the condenser. Make all
Bolts, Lockwashers,
and Hex Nuts necessary connections for the VSD cooling loop
LD14812
to be complete.
Figure 28 - SHELL REASSEMBLY The Variable Speed Drive will be shipped with
glycol in the cooling system. The Variable Speed
3. Assemble vibration isolators to unit. Refer to In- Drive coolant must be changed to the inhibitor
stall Isolators on page 31. provided with the shipped loose items prior to
4. Level shells in both directions. The longitudi- starting the unit or a VSD over temperature fault
nal alignment of the shell should be checked by may occur.
placing a level on the top of the shell, next to the 13. Lift the OptiView Control Center in accordance
discharge connection. The transverse alignment with rigging instructions and remove all pack-
should be checked by placing a level on the tops ing material. Carefully lower the control panel on
of both end sheets. Refer to Section 3 - Installa- to the supports provided on the condenser. Fas-
tion on page 31 for additional instructions to ten the Control Center to the condenser with the
level the unit. After shell is leveled, wedge and proper hardware.
shim each corner of the shell to solidly support it
while assembling the other parts. 14. Re-connect motor power leads in the Variable
Speed Drive to T1, T2, and T3 terminals and
5. Install the discharge piece and optional isolation torque to 18-20 Ft-lbs. per the labels in the VSD.
valve between the compressor and the condenser
using proper gaskets and hardware. 15. Connect the motor terminal box flex duct to the
drive.
JOHNSON CONTROLS 41
FORM 160.84-N1
Section 4 - Reassembly
16. Lift the Power Panel in accordance with rigging Table 12 - ASSEMBLY TORQUE METRIC FOR
instructions and remove all packing material. METRIC TUBE FITTINGS
Carefully lower the Power Panel on to the evapo- PORT- TORQUE
FITTING
rator. Assemble the Power Panel to the evaporator. SIZE
THREAD FT-LB N-M
SIZE
17. Re-connect all unit wiring and harnesses (refer to M10 M10 x 1 17 23
YMC2 Unit Wiring and Field Control Modifica- M12 M12 x1.5 24 33
M14 M14 x 1.5 34 46
18. Remove Nitrogen and charge unit with Refriger- M16 M16 x 1.5 46 63
ant. (Refer to Form 160.84-O1). M18 M18 x 1.5 61 83
19. All Units – Complete installation and finally M22 M22 x 1.5 94 127
level the unit. (Refer Section 3 - Installation on M27 M27 x 2 139 189
page 31). M30 M30 x 2 167 226
M33 M33 x 2 194 263
M42 M42 x 2 265 359
M48 M48 x 2 302 410
M60 M60 x 2 359 487
Table 13 - ASSEMBLY TORQUE ENGLISH FOR SAE TUBE FITTINGS

SAE STRAIGHT SAE STRAIGHT FACE SEAL TUBE-SIDE FACE SEAL
TUBE
THREAD SIZE THREAD THREAD SIZE TUBE-SIDE
SIZE
(O-RING PART NUMBER) TORQUE (FT-LBS.) (O-RING PART NUMBER) TORQUE (FT-LBS.)
7/16-20 9/16-18
1/4" 25 18
(028-12961-001) (028-12961-011)
9/16-18 11/16-16
3/8" 35 30
(028-12961-003) (028-12961-012)
3/4-16 13/16-16
1/2" 60 40
(028-12961-004) (028-12961-013)
7/8-14 1-14
5/8" 100 60
(028-12961-005) (028-12961-014)
1 1/16-12 1-3/16-12
3/4" 135 85
(028-12961-006) (028-12961-015)
1 5/16-12 1-7/16-12
1" 200 110
(028-12961-008) (028-12961-016)
1 5/8-12 1-11/16-12
1-1/4" 250 140
(028-12961-017) (028-12961-022)
1 7/8-12 2-12-UN2A
1-1/2" 305 180
(028-12961-020) (028-12961-019)
2 1/4-12
** 225 - -
(028-12961-)
NOTE:
** = SAE SIGHTGLASS
42 JOHNSON CONTROLS
FORM 160.84-N1
Table 14 - RE-ASSEMBLY TORQUE VALUES

UNIT
YORK PART SAP TORQUE VALUE
ITEM DESCRIPTION QUANTITY
NUMBER NUMBER FT-LBS. N-M
A 4 HCS M24 X 3 X 90MM LG. 021-33185-090 731065 12 170 230
B 10 HCS M20 X 2.5 X 60MM LG. 021-33184-060 731063 1 470 640
C 13 HCS5 0.750-10 X 2.000 GR 5 ZN 021-32012-016 588676 8 50 68
D 30 HCS M6 X 1 X 16MM LG. 021-31205-016 730686 6 50 68
E 32 HCS M20 X 2.5 X 60MM LG. 021-33184-060 731063 12 95 130
F 38 NUT HEX 0.375-16 X GR 5 ZN. 021-32006-501 616900 6 50 68
HOT GAS
G 7 HCS5 0.625-11 X 4.500 GR 5 ZN 021-32010-036 616908 4 65 88
LIQUID LINE
H 5 HCS5 0.625-11 X 2.250 GR 5 ZN 021-32010-018 679632 8 50 68 4
END SHEETS (CON-EVAP ASSY)
J 3 HCS5 0.625-11 X 2.500 GR 5 ZN 021-32010-020 616904 8 154 209
COMPRESSOR PIPING
K 33 Hose, Motor Cooling 1-1/2" (Shell End)
L 33 Hose, Motor Cooling M48x2 (Comp End)
Refer to TABLE 12/13 for Torque Specifications
M 8 Metric, Connr 3/8 O.D. Tube M16x1.5
N 15 Nut, 3/8 O.D. Tube
VSD MOUNTING
O 1 HCS5 0.438-14 X 1.250 GR 5 ZN 021-32007-010 730831 4 50 68
PANEL MOUNTING
P 14 HCS5 0.250-20 X 1.000 GR 5 ZN 021-32004-008 730793 8 7 10
NOTES:
Unless otherwise specified, all screw must be tightened to the follow-
ing torque values with lightly oiled threads.
** Lubricated with oil and graphite on male and female threads and
under bolt heads. Do NOT use Moly-kote.
N
3/8”
K PIPING
3/8”
PIPING
N
LD17283
Figure 29 - YMC2 PIPING REASSEMBLY HARDWARE IDENTIFICATION
JOHNSON CONTROLS 43
FORM 160.84-N1
F D
K
B
LD17303
Refer to Table 14 on page 43 for the torque values.
LD17303
Figure 30 - YMC2 FORM 3 REASSEMBLY HARDWARE IDENTIFICATION
44 JOHNSON CONTROLS
FORM 160.84-N1
F D
C 4
A
G
K B
LD17282
LD17283
JOHNSON CONTROLS 45
FORM 160.84-N1
VSD COOLING PIPING

CONNECTED AT UNION
WITH SEDIMENT ACCUMULATOR
WITHOUT SEDIMENT ACCUMULATOR WITH SEDIMENT ACCUMULATOR & VALVE
LD17284
Figure 32 - VSD MOUNTING HARDWARE IDENTIFICATION
46 JOHNSON CONTROLS
FORM 160.84-N1
LD17285
Figure 33 - POWER AND CONTROL PANEL MOUNTING HARDWARE IDENTIFICATION
JOHNSON CONTROLS 47
FORM 160.84-N1
Form 9 and Form 10 Reassembly

1. Assemble vibration isolators to unit. Refer Sec- The Variable Speed Drive will be shipped with
tion 3 - Installation on page 31. glycol in the cooling system. The Variable Speed
Drive coolant must be changed to the inhibitor
2. Level shells in both directions. The longitudi-
provided with the shipped loose items prior to
nal alignment of the shell should be checked by
starting the unit or a VSD over temperature fault
placing a level on the top of the shell, next to the
may occur.
discharge connection. The transverse alignment
should be checked by placing a level on the tops 5. Re-connect motor power leads in the Variable
of both end sheets refer to refer Section 3 - Instal- Speed Drive to T1, T2, and T3 terminals and
lation on page 31. For additional instructions torque to 18-20 Ft-lbs. per the labels in the VSD.
to level the unit. After shell is leveled, wedge and
6. Re-connect motor winding thermistor shielded
shim each corner of the shell to solidly support it
cable conductors in the Variable Speed Drive at
while assembling the other parts.
TB4 (refer to YMC2 Unit Wiring and Field Con-
3. Tighten all hardware installed to the specified trol Modifications (Form 160.84-PW2).
torque values provided in Table 14 on page 43.
7. Re-connect all unit wiring and harnesses (refer to
4. Lift the Variable Speed Drive in according to the YMC2 Unit Wiring and Field Control Modifica-
rigging section and remove all packing material, tions (Form 160.84-PW2).
for Variable Speed Drive. Carefully lower the
8. For Form 9 shipment remove Nitrogen and charge
Variable Speed Drive on to the supports on the
unit with Refrigerant (refer Form 160.84-OM1).
condenser. Fasten the Variable Speed Drive to the
condenser and to the motor terminal box duct. 9. All Units – Complete installation and finally
Make all necessary connections for the VSD cool- level the unit. Refer Section 3 - Installation on
ing loop to be complete. page 31.
48 JOHNSON CONTROLS
FORM 160.84-N1
LD17497
Figure 34 - YMC2 FORM 9 AND FORM 10 REASSEMBLY HARDWARE IDENTIFICATION
JOHNSON CONTROLS 49
FORM 160.84-N1
Form 11 Reassembly
1. Bolt the tube sheets together as shown in Figure 7. The Variable Speed Drive will be shipped with
35 on page 50. Note that the outside surfaces of glycol in the cooling system. The Variable Speed
the tube sheets must be flush. Drive coolant must be changed to the inhibitor
provided with the shipped loose items prior to
starting the unit or a VSD over temperature fault
may occur.
CONDENSER 8. Re-connect motor power leads in the Variable
Speed Drive to T1, T2, and T3 terminals and
torque to 18-20 Ft-lbs. per the labels in the VSD.
9. Re-connect all unit wiring and harnesses (refer to
YMC2 Unit Wiring and Field Control Modifica-
10. Install refrigerant piping (refer to Refrigerant Tub-
ing Reassembly section of this manual for proper
EVAPORATOR connection of O-ring fittings).
5/8” x 2-1/2”
Bolts, Lockwashers,
and Hex Nuts 11. Pressure test the unit with nitrogen per Form
LD14812
160.84-O1.
Figure 35 - SHELL REASSEMBLY 12. Remove Nitrogen and charge unit with refrigerant
(refer Form 160.84-OM1).
2. Assemble vibration isolators to unit. Refer Sec-
tion 3 - Installation on page 31.
3. Level shells in both directions. The longitudi-
nal alignment of the shell should be checked by
placing a level on the top of the shell, next to the
discharge connection. The transverse alignment
should be checked by placing a level on the tops
of both end sheets. Refer Section 3 - Installation
on page 31 for additional instructions to level
the unit. After shell is leveled, wedge and shim
each corner of the shell to solidly support it while
assembling the other parts.
4. Install the discharge piece and optional isolation 3/8”
Steel
valve between the compressor and the condenser Piping
using proper gaskets and hardware. LD17280
5. Complete the refrigerant liquid piping between Figure 36 - REFRIGERANT PIPING

the evaporator and condenser. Be sure hardware
are all properly installed.
13. Complete installation and finally level the unit per
6. Tighten all hardware installed to the specified Installation Instruction. Refer Section 3 - Installa-
torque values provided on Figure 37 on page 51. tion on page 31.
50 JOHNSON CONTROLS
FORM 160.84-N1
F
4
E
LD17498
JOHNSON CONTROLS 51
FORM 160.84-N1
REFRIGERANT TUBING REASSEMBLY

The following is a step-by-step procedure to be used to
reassemble the chiller refrigerant piping.
Assembly of Straight Thread O-ring Port

Fittings LOCKNUT
COMPLETELY
The male and female ends of SAE and ISO 6149 BACKED-UP
straight thread O-ring ports have UN/UNF or metric
straight threads. An elastomeric O-ring is fitted to the
male end. During assembly, the O-ring is firmly sand-
wiched between the angular sealing surface of the fe-
male port and the shoulder of the male end. Sealing is LD17270
thus affected and maintained by the O-ring compres- Figure 39 - BACK OFF LOCKNUT
sion which results from the clamping force generated
by tightening. The straight threads do NOT offer seal- 5. Screw fitting into port until the back-up washer
ing action; they provide the resistance (holding power) contacts the face of the port. Light wrenching may
for service pressure. be necessary.
Adjustable End Assembly
BACK-UP
WASHER
LOCKNUT CONTACTS
BACK-UP
FACE
WASHER
O-RING
LD17271
LD17269
Figure 40 - SCREW FITTING INTO PORT
Figure 38 - ADJUSTABLE END FITTING
6. To align the tube end of fitting to accept incom-
1. Inspect to ensure that both matching parts are free ing tube or hose assembly, unscrew by required
of burrs, nicks, scratches or any foreign particles. amount, but NOT more than one full turn. More
then one turn makes the locknut push the O-ring
2. Install O-ring on port end of fitting, if it is NOT into the machine threads beyond the fitting land
pre-installed, take care NOT to nick the O-ring. area during step 7.
3. Lubricate O-ring with a light coat of synthetic 7. Using two wrenches, hold fitting in desired posi-
Polyolester (POE) oil or POE grease. tion and tighten locknut to the appropriate torque
4. Back off locknut as far as possible. Make sure value shown in Table 13 on page 42 or Table 12
back-up washer is NOT loose and is pushed up on page 42.
as far as possible. This ensures the O-ring is com- 8. Inspect to ensure that O-ring is NOT pinched and
pletely at the back of the land so it remains in the the back-up washer seats flat on face of port.
land area when the fitting is turned out at Step 6.
52 JOHNSON CONTROLS
FORM 160.84-N1
Assembly of O-ring Face Seal Fittings

The male end and female nut of face seal fittings have
UN/UNF straight threads. An elastomeric O-ring is fit-
ted into the grooved male end. During assembly, the O-
ring is firmly sandwiched between the sealing surfaces.
Sealing is thus affected and maintained by the O-ring
TORQUE compression which results from the clamping force
LOCKNUT
generated by tightening the nut. The straight threads do
NOT offer sealing action; they provide the resistance
(holding power) for service pressure.
O-ring Face Seal Assembly

1. Inspect to ensure that both matching parts are free
LD17272
of burrs, nicks, scratches or any foreign particles.
Figure 41 - TORQUE FITTING
2. Install O-ring in grooved face seal end of fitting,
4
if it is NOT pre-installed, use care NOT to nick
Straight Non-Adjustable End Assembly the O-ring.
1. Inspect to ensure that both matching parts are free 3. Lubricate O-ring with a light coat of synthetic
of burrs, nicks, scratches or any foreign particles. Polyolester (POE) oil or POE grease.
2. Install O-ring on port end of fitting, if it is NOT
pre-installed, use care NOT to nick the O-ring. 4. Thread the nut by hand, and tighten nut to the ap-
propriate torque value shown in Table 13 on page
3. Lubricate O-ring with a light coat of synthetic 42 or Table 12 on page 42.
Polyolester (POE) oil or POE grease.
4. Screw fitting into port until the hex flat contacts
the port face. Light wrenching may be necessary.
5. Tighten to give torque for the specified size as
specified in Table 13 on page 42 or Table 12 on
page 42.
SEALED
WITH
O-RING
THREADED
FOR
HOLDING POWER
LD17273
Figure 42 - SAE OR ISO 6149 STRAIGHT

THREAD O-RING PORT
JOHNSON CONTROLS 53
FORM 160.84-N1
THIS PAGE INTENTIONALLY LEFT BLANK.
54 JOHNSON CONTROLS
FORM 160.84-N1
SECTION 5 - DIMENSIONS, NOZZLE ARRANGEMENTS AND WEIGHTS
COMPRESSOR UNIT DIMENSIONS

Additional Operating Height Clearance To Floor Ft - In (mm)
Type Of Chiller Mounting M
Neoprene Pad Isolators 1 - 3/4" (45)
Spring Isolators 1" Deflection 1" (25)
Direct Mount 3/4" (19)
DIMENSIONS - 197 - 246 COMPRESSOR UNITS FT - IN (MM)

EVAPORATOR CONDENSER
B
CODE CODE A C D E
490 VSD 774 VSD
5'-5" 6'-1/2" 1'-3/8" 1'-1/2" 8' 5
EB2508 CC2508 —
(1651) (1842) (419) (457) (2438)
5'-5-1/4" 6'-9-9/32" 7'-11 1'-4-5/8" 1'-4-5/8" 10'
EB2510 CB2110
(1657) (2065) (2419) (406) (422) (3048)
5'-5-1/4" 6'-7-11/16" 7'-9-11/16" 1'-4-5/8" 1'-4-5/8" 10'
EB2510 CB2510
(1657) (2024) (2380) (406) (422) (3048)
5'-5-1/4" 6'-7-11/16" 7'-9-11/16" 1'-4-5/8" 1'-4-5/8" 14'
EB2514 CB2514
(1657) (2024) (2380) (406) (422) (4267)
5'-7" 6'-9-15/16" 7'-9-5/8" 1'-4" 1'-5-1/2" 10'
EB2910 CB2510
(1702) (2081) (2378) (406) (445) (3048)
5'-10" 7'-2-3/8" 8'-1-7/8" 1'-5-1/2" 1'-5-1/2" 10'
EB2910 CB2910
(1778) (2194) (2486) (445) (445) (3048)
5'-7" 6'-9-15/16" 7'-9-5/8" 1'-4" 1'-5-1/2" 14'
EB2914 CB2514
(1702) (2081) (2378) (406) (445) (4267)
5'-10" 7'-2-3/8" 8'-1-7/8" 1'-5-1/2" 1'-5-1/2" 14'
EB2914 CB2914
(1778) (2194) (2486) (445) (445) (4267)
6'-2" 7'-2-3/8" 8'-1-7/8" 1'-5-1/2" 1'-7-1/2" 10'
EB3310 CB2910
(1880) (2194) (2486) (445) (495) (3048)
6'-7" 7'-3-3/8" 8'-5-5/16" 1'-7-1/2" 10'
EB3310 CB3310 1'-8" (508)
(2007) (2219) (2573) (495) (3048)
6'-2" 7'-2-3/8" 8'-1-7/8" 1'-5-1/2" 1'-7-1/2" 14'
EB3314 CB2914
(1880) (2194) (2486) (445) (495) (4267)
6'-7" 7'-3-3/8" 8'-5-5/16" 1'-7-1/2" 14'
EB3314 CB3314 1'-8" (508)
(2007) (2219) (2573) (495) (4267)
NOTES:
1. See Figure 43 on page 56 for dimension location points as designated on this table.
2. All dimensions are approximate. Certified dimensions are available on request.
3. S tandard water nozzles are Schedule 40 pipe size, furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option
of welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on forged carbon steel
with 1/16" raised face), water flanged nozzles are optional (add 1/2" to nozzle length). Companion flanges, nuts, bolts, and gaskets are not
furnished.
4. O ne, two, and three-pass nozzle arrangements are available only in pairs shown for all shell codes. Any pair of evaporator nozzles may
be used in combination with any pair of condenser nozzles Compact water boxes on one heat exchanger may be used with Marine Water
Boxes on the other heat exchangers.
5. Condenser water must enter the water box through the bottom connection for proper operation of the sub-cooler to achieve rated performance.
6. To determine overall height, add dimension "M" for the appropriate isolator type.
JOHNSON CONTROLS 55
FORM 160.84-N1
Section 5 - Dimensions, Nozzle Arrangements And Weights
VSD
CONTROL
PANEL
M
C D
A 3-3/8”
VSD
COMPRESSOR
MOTOR
CONTROL
PANEL
LD17200
Figure 43 - DIMENSIONS - 197 & 246 COMPRESSOR UNITS FT-IN (MM)
56 JOHNSON CONTROLS
FORM 160.84-N1
EVAPORATOR 150 & 300 PSI COMPACT WATER BOXES
1-Pass Evaporator Nozzle Arrangements

In Out
Left End Right End
Right End Left End
LD17202
Figure 44 - EVAPORATOR - COMPACT WATER BOXES (1-PASS NOZZLE ARRANGEMENTS)

In Out
5
Lower Right End Upper Right End
Lower Left End Upper Left End
LD17203

In Out
Right End Left End
LD17204

In Out
Left End Right End
LD17205
COMPACT WATER BOXES-150 & 300 PSI DIMENSIONS

Nozzle Pipe Size Ft-In (mm) Evaporator Nozzle Dimensions Ft-In (mm)
Evaporator
No. Of Passes 1-Pass 2-Pass 3-Pass
Shell Code C
1 2 3 AA AA BB AA BB
1' - 4-5/8" 1' - 10" 1'-2" 2'-6" 1'-2" 2'-6"
EB25 8" (203) 6" (152) 4" (102)
(422) (559) (356) (762) (356) (762)
1'-5-1/2" 1'-3" 2'-9" 1'-4" 2'-8"
EB29 10" (254) 8" (203) 6" (152) 2' (610)
(445) (381) (838) (406) (813)
1'-7-1/2" 2'-2" 1'-4" 3' 1'-6" 2'-10"
EB33 14" (356) 10" (254) 8" (203)
(495) (660) (406) (914) (457) (864)
JOHNSON CONTROLS 57
FORM 160.84-N1
EVAPORATOR 150 & 300 PSI COMPACT WATER BOXES DIMENSIONS
ONE - PASS
TWO - PASS
THREE - PASS
LD14020
COMPACT WATER BOXES DIMENSIONS FT - IN (MM)

EVAPORATOR 150 PSI 300 PSI
SHELL CODE F G F G
EB25 1'-4-1/8" (410) 0'-6-7/16" (164) 1'-6-1/16" (459) 0'-8-3/16" (208)
EB29 1'-4-13/16" (427) 0'-6-31/32" (177) 1'-7-3/16" (487) 0'-9-7/32" (234)
EB33 1'-5-3/8" (441) 0'-7-1/2" (191) 1'-6-1/4" (464) 0'-9-1/2" (241)
NOTES:
1. All dimensions shown in Ft/In (mm)
2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or
use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.6mm raised face),
water flanged nozzles are optional (add 13mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished.
3. One-, Two- and Three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles
may be used in combination with any pair of condenser nozzles.
4. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance.
5. Connected piping should allow for removal of compact water boxes for tube access and cleaning.
6. Add dimension "M" as shown on the unit dimensions page for the appropriate isolator type.
Figure 47 - EVAPORATOR - 150 & 300 PSI COMPACT WATER BOXES
58 JOHNSON CONTROLS
FORM 160.84-N1
CONDENSER 150 & 300 PSI COMPACT WATER BOXES
1-Pass Condenser Nozzle Arrangements

In Out
Left End Right End
Right End Left End
LD14008
Figure 48 - CONDENSER - COMPACT WATER BOXES (1-PASS NOZZLE ARRANGEMENTS)

In Out
Lower Left End Upper Left End 5
LD14009

In Out
Right End Left End
LD14010

In Out
Left End Right End
LD14011
COMPACT WATER BOXES -150 & 300 PSI DIMENSIONS

Nozzle Pipe Size In (mm) Condenser Nozzle Dimensions Ft-In (mm)
Condenser
No. of Passes 1-Pass 2-Pass 3-Pass
Shell Code C
1 2 3 AA AA BB AA BB
CB21 10" (254) 6" (152) 6" (152) 1'-4" (406) 2'-2-3/8" (670) 1'-7-7/8" (505) 2'-8-7/8" (835) 1'-7-7/8" (505) 2'-8-7/8" (835)
CB25 12" (305) 8" (203) 6" (152) 1'-4" (406) 1'-10" (559) 1'-2-3/8" (365) 2'-5-5/8" (752) 1'-2-3/8" (365) 2'-5-5/8" (752)
CC25 12" (305) 8" (203) 6" (152) 1'-4" (406) 1'-10" (559) 1'-2-3/8" (365) 2'-5-5/8" (752) 1'-2-3/8" (365) 2'-5-5/8" (752)
CB29 14" (356) 10" (254) 8" (203) 1'-4" (406) 1'-10" (559) 1'-1-3/4" (349) 2'-6-1/4" (768) 1'-1-3/4" (349) 2'-6-1/4" (768)
(150 PSI) 14" (356) 10" (254) 8" (203) 1'-5-1/2" (445) 2'-0" (610) 1'-3-3/4" (400) 2'-8-1/4" (819) 1'-3-3/4" (400) 2'-8-1/4" (819)
CB29 14" (356) 10" (254) 8" (203) 1'-4" (406) 1'-10" (559) 1'-1" (330) 2'-7" (787) 1'-1" (330) 2'-7" (787)
(300 PSI) 14" (356) 10" (254) 8" (203) 1'-5-1/2" (445) 2'-0" (610) 1'-3" (381) 2'-9" (838) 1'-3" (381) 2'-9" (838)
CB33 16" (406) 10" (254) 10" (254) 1'-5-1/2" (445) 2'-0" (610) 1'-3" (381) 2'-9" (838) 1'-3" (381) 2'-9" (838)
CB33 16" (406) 10" (254) 10" (254) 1'-8" (508) 2'-1" (635) 1'-4" (406) 2'-10" (864) 1'-4" (406) 2'-10" (864)
JOHNSON CONTROLS 59
FORM 160.84-N1
CONDENSER 150 & 300 PSI COMPACT WATER BOXES DIMENSIONS
ONE - PASS
TWO - PASS
THREE - PASS
LD14020
COMPACT WATER BOXES DIMENSIONS FT - IN (MM)

Condenser 150 PSI 300 PSI
Shell Code F G F NO 6 F NO 8 F NO 10 F NO 12 F NO 14 F NO 16 G
1'-3-3/4" 5-29/32" 1'-6-19/32" 1'-6-21/32" 0'-6-17/32"
CB21 - - - -
(400) (150) (472) (474) (166)
1'-3-3/4" 0'-6-7/16" 1'-7-23/32" 1'-7-25/32" 1'-7-25/32" 0'-7-7/16"
CB25 - - -
(400) (164) (501) (502) (502) (189)
1'-3-3/4" 0'-6-7/16" 1'-7-23/32" 1'-7-25/32" 1'-7-25/32" 0'-7-7/16"
CC25 - - -
(400) (164) (501) (502) (502) (189)
1'-4-7/8" 6-31/32" 1'-7-1/2" 1'-7-1/2" 1'-7-1/2" 0'-8-15/32
CB29 - - -
(429) (177) (495) (495) (495) (215)
1-5-3/8" 0'-7-1/2" 1'-8-1/4" 1'-8-1/4" 0'-8-3/4"
CB33 - - - -
(441) (191) (514) (514) (222)
NOTES:
2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use
of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.6 mm raised face),
water flanged nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished.
3. One-, Two- and Three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles
may be used in combination with any pair of condenser nozzles.
4. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance.
5. Connected piping should allow for removal of compact water boxes for tube access and cleaning.
6. Add dimension "M" as shown on the unit dimensions page for the appropriate isolator type.
Figure 51 - CONDENSER - 150 & 300 PSI COMPACT WATER BOXES
60 JOHNSON CONTROLS
FORM 160.84-N1
EVAPORATOR 150 & 300 PSI MARINE WATER BOXES

In Out
Left End Right End
Right End Left End
LD14012
Figure 52 - EVAPORATOR - MARINE WATER BOXES (1-PASS NOZZLE ARRANGEMENTS)

In Out
LD14013

In Out
Right End Left End
LD14014

In Out
Left End Right End
LD14015
JOHNSON CONTROLS 61
FORM 160.84-N1
MARINE WATER BOXES -150 PSI

NOZZLE PIPE
EVAPORATOR NOZZLE DIMENSIONS FT-IN (MM)
SIZE FT-IN (MM)
EVAPORATOR NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE
C EE EE
1 2 3 AA AA BB EE AA BB EE
FLANG FLANG
1'-4-5/8" 3'-11" 0'-9" 3'-11" 1'-5-1/2" 1'-6" 0'-9" 3'-11" 1'-4" 1'-4-1/2"
EB25 8 6 4 (422) (1194) (229) (1194) (445) (457) (229) (1194) (406) (419)
1'-5-1/2" 4'-3" 0'-10" 4'-3" 1'-6-1/2" 1'-7" 0'-10" 4'-3" 1'-6-1/2" 1'-7"
EB29 10 8 6
(445) (1295) (254) (1295) (470) (483) (254) (1295) (470) (483)
1'-7-1/2" 4'-7" 0'-44" 4'-7" 1'-9-1/2" 1'-10" 0'-11" 4'-7" 1'-9-1/2" 1'-10"
EB33 14 10 8
(495) (1397) (279) (1397) (546) (559) (279) (1397) (546) (559)

See Figure 21 on page 32, Figure 22 on page 33 and Figure 23 on page 34.
MARINE WATER BOXES -300 PSI

NOZZLE PIPE
EVAPORATOR NOZZLE DIMENSIONS FT-IN (MM)
SIZE FT-IN (MM)
EVAPORATOR NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE
C
1'-4-5/8" 3'-11" 0'-9" 3'-11" 1'-6" 0'-9" 3'-11" 1'-4-1/2"

EB25 8 6 4 (422) (1194) (229) (1194) (457) (229) (1194) (419)
1'-5-1/2" 4'-3" 0'-10" 4'-3" 1'-7-3/8" 0'-10" 4'-3" 1'-7-3/8"
EB29 10 8 6
(445) (1295) (254) (1295) (492) (254) (1295) (492)
1'-7-1/2" 4'-7" 0'-11" 4'-7" 1'-10-5/8" 0'-11" 4'-7" 1'-10-5/8"
EB33 14 10 8
(495) (1397) (279) (1397) (575) (279) (1397) (575)

See Figure 21 on page 32, Figure 22 on page 33 and Figure 23 on page 34.
62 JOHNSON CONTROLS
FORM 160.84-N1
EVAPORATOR 150 & 300 PSI MARINE WATER BOXES DIMENSIONS
LD14021
MARINE WATER BOXES DIMENSIONS 150 PSI, FT - IN (MM)

EVAPORATOR 1-PASS 2-PASS 3-PASS
SHELL CODE F I F I G F I
1'-5-5/8" 0'-8-13/16" 1'-3-1/2" 0'-7-3/4" 0'-6-7/16" 1'-3-1/2" 0'-7-3/4"
EB25
(448) (224) (394) (197) (164) (394) (197)
1'-9-1/4" 0'-10-5/8" 1'-7-1/8" 0'-9-9/16" 0'-6-31/32" 1'-7-1/8" 0'-9-9/16" 5
EB29
(540) (270) (486) (243) (177) (486) (243)
2'-0-1/4" 1'-0-1/8" 1'-8-1/2" 0'-10-1/4" 0'-7-1/2" 1'-8-1/2" 0'-10-1/4"
EB33
(616) (308) (521) (260) (191) (521) (260)

EVAPORATOR 1-PASS 2-PASS 3-PASS
1'-6-1/8" 0'-9-1/16" 1'-4-1/8" 0'-8-1/16" 0'-8-3/16" 1'-4-1/8" 0'-8-1/16"
EB25
(460) (230) (410) (205) (208) (410) (205)
1'-9-1/4" 0'-10-5/8" 1'-7-1/8" 0'-9-9/16" 0'-9-7/32" 1'-7-1/8" 0'-9-9/16"
EB29 (270)
(540) (486) (243) (234) (486) (243)
2'-0-1/4" 1'-0-1/8" 1'-8-1/2" 0'-10-1/4" 0'-9-1/2" 1'-8-1/2" 0'-10-1/4"
EB33
(616) (308) (521) (260) (241) (521) (260)
NOTES:
2. All dimensions are approximate. Certified dimensions are available upon request.
3. S
tandard water nozzles are Schedule 40 pipe size, furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of
welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with
1.6 mm raised face), water flanged nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not
furnished.
4. O
ne-, two-, and three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles
may be used in combination with any pair of condenser nozzles. Compact water boxes on one heat exchanger may be used with Marine
Water Boxes on the other heat exchanger.
5. Water must enter the water box through the bottom connection to achieve rated performance.
Figure 55 - EVAPORATOR - 150 AND 300 PSI MARINE WATER BOXES
JOHNSON CONTROLS 63
FORM 160.84-N1
CONDENSER 150 & 300 PSI MARINE WATER BOXES DIMENSIONS
LD14021

CONDENSER 1-PASS 2-PASS 3-PASS
1'-7-3/4" 0'-9-7/8" 1'-3-5/8" 0'-7-13/16" 0'-5-5/32" 1'-3-5/8" 0'-7-13/16"
CB21
(502) (251) (397) (198) (131) (397) (198)
1'-10-1/4" 0'-11-1/8" 1'-6-1/8" 0'-9-1/16" 0'-5-11/32" 1'-6-1/8" 0'-9-1/16"
CB25
(565) (283) (460) (230) (144) (460) (230)
1'-10-1/4" 0'-11-1/8" 1'-6-1/8" 0'-9-1/16" 0'-5-11/32" 1'-6-1/8" 0'-9-1/16"
CC25
(565) (283) (460) (230) (144) (460) (230)
1'-11" 0'-11-1/2" 1'-7-3/4" 0'-9-7/8" 0'-6-7/32" 1'-7-3/4" 0'-9-7/8"
CB29
(584) (292) (502) (251) (158) (502) (251)
2'-1" 1'-1/2" 1'-7-3/4" 0'-9-7/8" 0'-6-3/4" 1'-7-3/4" 0'-9-7/8"
CB33
(635) (318) (502) (251) (171) (502) (251)

CONDENSER 1-PASS 2-PASS 3-PASS
1'-9-13/16" 0'-10-29/32" 1'-5-11/16" 0'-8-27/32" 0'-5-29/32" 1'-5-11/16" 0'-8-27/32"
CB21
(554) (277) (449) (225) (150) (449) (225)
2'-0-1/2" 1'-0-1/4" 1'-8-3/8" 0'-10-3/16" 0'-6-7/16" 1'-8-3/8" 0'-10-3/16"
CB25
(622) (311) (518) (259) (164) (518) (259)
2'-0-1/2" 1'-0-1/4" 1'-8-3/8" 0'-10-3/16" 0'-6-7/16" 1'-8-3/8" 0'-10-3/16"
CC25
(622) (311) (518) (259) (164) (518) (259)
2'-0-1/2" 1'-0-1/4" 1'-9-1/4" 0'-10-5/8" 0'-6-31/32" 1'-9-1/4" 0'-10-5/8"
CB29
(622) (311) (540) (270) (177) (540) (270)
2'-1-3/4" 1'-0-7/8" 1'-8-1/2" 0'-10-1/4" 0'-7-1/2" 1'-8-1/2" 0'-10-1/4"
CB33
(654) (327) (521) (260) (191) (521) (260)
NOTES:
2. All dimensions are approximate. Certified dimensions are available upon request.
3. Standard water nozzles are Schedule 40 pipe size, furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of
welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with
1.6 mm raised face), water flanged nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not
furnished.
4. One-, two-, and three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles
may be used in combination with any pair of condenser nozzles. Compact water boxes on one heat exchanger may be used with Marine
Water Boxes on the other heat exchanger.
5. Condenser water must enter the water box through the bottom connection for proper operation of the sub-cooler to achieve rated perfor-
mance. Add dimension "M" as shown on pages per unit dimensions page for the appropriate isolator type.
Figure 56 - CONDENSER - 150 AND 300 PSI MARINE WATER BOXES
64 JOHNSON CONTROLS
FORM 160.84-N1
CONDENSER 150 PSI MARINE WATER BOXES

In Out
Left End Right End
Right End Left End
LD14016
Figure 57 - CONDENSER - MARINE WATER BOXES (1-PASS NOZZLE ARRANGEMENTS)

In Out
LD14017

In Out
Right End Left End
LD14018

In Out
Left End Right End
LD14019
JOHNSON CONTROLS 65
FORM 160.84-N1
CONDENSER 150 & 300 PSI MARINE WATER BOXES DIMENSIONS
MARINE WATER BOXES -150 & 300 PSI

NOZZLE PIPE SIZE
EVAPORATOR NOZZLE DIMENSIONS FT - IN (MM)
FT - IN (MM)
CONDENSER
SHELL NO. OF PASSES 1-PASS 2-PASS 3-PASS
CODE C EE EE
FLANGE FLANGE
10" 6" 6" 1'-4" 4'-3-3/8" 1'-6-3/8" 4'-3-3/8" 1'-4-1/2" 1'-5-1/2" 1'-6-3/8" 4'-3-3/8" 1'-4-1/2" 1'-5-1/2"
CB21 (254) (152) (152) (406) (1305) (467) (1305) (419) (445) (467) (1305) (419) (445)
12" 8" 6" 1'-4" 4'-1" 1'-0-1/8" 4'-1" 1'-6-1/2" 1'-7-3/8" 1'-0-1/8" 4'-1" 1'-6-1/2" 1'-7-3/8"
CB25 (305) (203) (152) (406) (1245) (308) (1245) (470) (492) (308) (1245) (470) (492)
12" 8" 6" 1'-4" 4'-1" 1'-0-1/8" 4'-1" 1'-6-1/2" 1'-7-3/8" 1'-0-1/8" 4'-1" 1'-6-1/2" 1'-7-3/8"
CC25 (305) (203) (152) (406) (1245) (308) (1245) (470) (492) (308) (1245) (470) (492)
14" 10" 8" 1'-4" 4'-3" 1'-0" 4'-3" 1'-9" 1'-10-1/8" 1'-0" 4'-3" 1'-9" 1'-10-1/8"
(356) (254) (203) (406) (1295) (305) (1295) (533) (562) (305) (1295) (533) (562)
CB29
14" 10" 8" 1'-5-1/2" 4'-5" 1'-2" 4'-5" 1'-9" 1'-10-1/8" 1'-2" 4'-5" 1'-9" 1'-10-1/8"
(356) (254) (203) (445) (1346) (356) (1346) (533) (562) (356) (1346) (533) (562)
16" 10" 10" 1'-5-1/2" 4'-7" 0'-9" 4'-7" 1'-9-1/2" 1'-10-5/8" 0'-9" 4'-7" 1'-9-1/2" 1'-10-5/8"
(406) (254) (254) (445) (1397) (229) (1397) (546) (575) (229) (1397) (546) (575)
CB33
16" 10" 10" 1'-8" 4'-8" 0'-10" 4'-8" 1'-9-1/2" 1'-10-5/8" 0'-10" 4'-8" 1'-9-1/2" 1'-10-5/8"
(406) (254) (254) (508) (1422) (254) (1422) (546) (575) (254) (1422) (546) (575)
WEIGHTS
Table 15 - APPROXIMATE EVAPORATOR WEIGHTS 150 PSI COMPACT WATER BOXES
EVAPORATOR COMPACT WATER BOX WEIGHT LBS (KG) MARINE WATER BOX WEIGHT LBS (KG)
WEIGHT LBS
CODE 1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
(KG)
EB2508 2830 (1284) 264 (120) 269 (122) 272 (123) 474 (215) 563 (255) 514 (233)
EB2510 3628 (1646) 264 (120) 269 (122) 272 (123) 474 (215) 563 (255) 514 (233)
EB2514 4545 (2062) 264 (120) 269 (122) 272 (123) 474 (215) 563 (255) 514 (233)
EB2910 4338 (1968) 332 (151) 355 (161) 360 (163) 624 (283) 731 (332) 688 (312)
EB2914 5502 (2496) 332 (151) 355 (161) 360 (163) 624 (283) 731 (332) 688 (312)
EB3310 5372 (2437) 402 (182) 421 (191) 432 (196) 776 (352) 851 (386) 826 (375)
EB3314 6779 (3075) 402 (182) 421 (191) 432 (196) 776 (352) 851 (386) 826 (375)
NOTE: Weights based on maximum tube bundle allowed per shell.
Table 16 - APPROXIMATE CONDENSER WEIGHTS 150 PSI COMPACT WATER BOXES

CONDENSER COMPACT WATER BOX WEIGHT LBS (KG) MARINE WATER BOX WEIGHT LBS (KG)
WEIGHT
CODE 1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
LBS (KG)
CC2508 2918 (1324) 282 (128) 281 (127) 284 (129) 588 (267) 606 (275) 574 (260)
CB2110 2635 (1195) 230 (104) 219 (99) 230 (104) 464 (210) 457 (207) 444 (201)
CB2510 3309 (1501) 282 (128) 281 (127) 284 (129) 588 (267) 606 (275) 574 (260)
CB2514 4532 (2056) 282 (128) 281 (127) 284 (129) 588 (267) 606 (275) 574 (260)
CB2910 4258 (1931) 340 (154) 354 (161) 354 (161) 688 (312) 752 (341) 710 (322)
CB2914 5854 (2655) 340 (154) 354 (161) 354 (161) 688 (312) 752 (341) 710 (322)
CB3310 5343 (2424) 406 (184) 419 (190) 444 (201) 816 (370) 851 (386) 814 (369)
CB3314 7362 (3339) 406 (184) 419 (190) 444 (201) 816 (370) 851 (386) 814 (369)
NOTE: Weights based on maximum tube bundle allowed per shell.
66 JOHNSON CONTROLS
FORM 160.84-N1
WEIGHTS (CONT'D)
Table 17 - APPROXIMATE VARIABLE SPEED DRIVE (VSD) WEIGHTS
VSD WEIGHT LBS (KG)
HYP0490XH 1226 (556)
HYP0612XH 1954 (886)
HYP0774XH 2060 (934)
Table 18 - APPROXIMATE DRIVELINE WEIGHTS

COMPRESSOR WEIGHT LBS (KG)
M2C-197FAC 2872 (1303)
M2C-197FACD 2,861 (1292)
M2C-205FAC 2879 (1306)
M2C-205FACD 2,867 (1295)
M2C-218FAC 2998 (1360)
M2C-233FAC 3011 (1366) 5
M2C-246FAC 3009 (1365)
M6C-331FAC 4500 (2041)
Table 19 - APPROXIMATE REFRIGERANT & WATER WEIGHT

REFRIGERANT WEIGHT WATER WEIGHT
EVAPORATOR CONDENSER
LBS (KG)* LBS (KG)**
EB2508 CC2508 487 (220) 748 (340)
CB2110 540 (250) 980 (450)
EB2510
CB2510 600 (270) 1310 (600)
EB2514 CB2514 840 (380) 1680 (770)
CB2510 640 (290) 1510 (690)
EB2910
CB2910 860 (390) 1760 (800)
CB2514 900 (410) 1940 (880)
EB2914
CB2914 1210 (550) 2240 (1020)
CB2910 920 (420) 2070 (940)
EB3310
CB3310 980 (450) 2580 (1170)
CB2914 1290 (590) 2640 (1200)
EB3314
CB3314 1380 (630) 3310 (1510)
*Refrigerant Weight based on maximum tube bundle.

** Water Weight is the total water in both shells and for 150PSI, 2-pass, compact water boxes.
Refer to product submittal drawings for

detailed weight information specific to the
unit ordered.
JOHNSON CONTROLS 67
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 160.84-N1 (1015)
Issue Date: October 25, 2015
Supersedes: 160.84-N1 (814)

Centrifugal Liquid Chillers: Installation and Reassembly

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CENTRIFUGAL LIQUID CHILLERS

INSTALLATION AND REASSEMBLY Supersedes: 160.84-N1 (814) Form 160.84-N1 (1015)

Indicates a possible hazardous situation Identifies a hazard which could lead to

Indicates a potentially hazardous situa- Highlights additional information useful

CHANGEABILITY OF THIS DOCUMENT

MANUAL DESCRIPTION FORM NUMBER

VARIABLE SPEED DRIVE NOMENCLATURE

SECTION 2 - RIGGING AND LIFTING....................................................................................................................15

TABLE OF CONTENTS (CONT'D)

SECTION 5 - DIMENSIONS, NOZZLE ARRANGEMENTS AND WEIGHTS.......................................................... 55

LIST OF FIGURES (CONT'D)

FIGURE 45 - Evaporator - Compact Water Boxes (2-Pass Nozzle Arrangements)����������������������������������������������� 57

OPTIVIEW TRANSFORMERS COMPRESSOR VARIABLE

Figure 1 - YMC2 CHILLER COMPONENTS

• VSD operating coolant (inhibited water) 5. Refrigerant charges shipped separately.

The chiller is shipped in two assemblies as follows: Form 10

Chiller Unit 4. Miscellaneous shipped loose items.

The unit is first completely assembled at the factory: Chiller Unit

Form 11 Evaporator-Side Assembly (Evaporator /

SECTION 2 - RIGGING AND LIFTING

Improper use of rigging equipment can FORM 1 SHIPMENT

• Rope with no visible wear, twisted, kinked, or Unit Rigging

Figure 2 - FORM 1 AND 2 RIGGING WITH SIDE SPREADER BAR

Figure 3 - FORM 1 AND 2 RIGGING WITHOUT SIDE SPREADER BAR

FORM 2 TOTAL WEIGHT Unit Rigging

1. Attach rigging chains to an adequate lifting device.

FORM 3 SHIPMENT Compressor Motor Assembly

4. The angle of the lifting chains traversing the en

Figure 4 - DRIVELINE RIGGING

Variable Speed Drive (VSD)

The VSD is shipped with glycol in the

Power Panel OptiView™ Control Center

Figure 8 - OPTIVIEW CONTROL CENTER

Figure 7 - POWER PANEL

FORM 7 SHIPMENT The lifting chains along the axis of the

Figure 9 - FORM 7 RIGGING WITH SIDE SPREADER BARS

4. With an adequate lifting device lift the unit slight-

4. With an adequate lifting device lift the unit slight-

Compressor Motor Assembly

Figure 12 - POWER PANEL

Table 8 - CONTROL PANEL WEIGHTS

Figure 14 - FORM 9 AND 10 RIGGING WITH SIDE SPREADER BARS

Figure 15 - FORM 9 AND 10 RIGGING WITHOUT SIDE SPREADER BARS

1. Attach rigging chains to an adequate lifting device.

Variable Speed Drive (VSD)

One chain is required per each lifting

Figure 18 - FORM 11 CONDENSER ASSEMBLY RIGGING WITH SIDE SPREADER BARS

Figure 19 - FORM 11 EVAPORATOR ASSEMBLY RIGGING WITH SIDE SPREADER BARS

Evaporator Assembly OptiView™ Control Center

4. With an adequate lifting device lift the unit slight-

Figure 20 - OPTIVIEW CONTROL CENTER

THIS PAGE INTENTIONALLY LEFT BLANK.

OVERVIEW Clearance Requirements

1. Determine Location Rear and Above Unit 2 ft (61 cm)

• Foundation Requirements Front of Unit 3 ft (91 cm)

FIGURE 45 - Evaporator - Compact Water Boxes (2-Pass Nozzle Arrangements)�� 57

Figure 42 - SAE OR ISO 6149 STRAIGHT