chiller - yr

7/28/2019 Chiller - YR

1/56

FORM 160.80-EG1 (808

Model YS Rotary Screw Liquid ChillersDesign Level E

100 thru 675 tons

(315 thru 2375 KW)

r-22 and r-134aRated in Accordance

ith the latest edition of ARI

STANDARD 550/590


2/56

JOHNSON CONTROLS

INTRODUCTION ........................................................... 3

RATINGS ....................................................................... 4

OpTIVIew CONTROL CeNTeR ................................... 5

MeCHANICAL SpeCIFICATIONS ................................ 13

ACCeSSORIeS & MODIFICATIONS ............................ 17

UNIT COMpONeNTS ................................................... 19

AppLICATION DATA ..................................................... 20

DIMeNSIONS STD..................................................... 28

S0-S3 Comrssor .................................................... 28

S4 & S5 Comrssor ............................................... 29

Comact watr Box Nozzl Arrangmnts ............... 30

Floor Layout .............................................................. 31

Coolr Nozzl Arrangmnts .................................... 32

Condnsr Nozzl Arrangmnts ............................. 34

weIGHTS STD........................................................... 36

DIMeNSIONS MeTRIC .............................................. 38

S0-S3 Comrssor .................................................... 38

S4 & S5 Comrssor ............................................... 39

Comact watr Box Nozzl Arrangmnts ............... 40

Floor Layout .............................................................. 41

Coolr Nozzl Arrangmnts .................................... 42

Condnsr Nozzl Arrangmnts ............................. 44

weIGHTS MeTRIC .................................................... 46

GUIDe SpeCIFICATIONS ............................................ 48MeTRIC CONVeRSION TABLeS ................................. 53

NOMENCLATURE

Th modl numbr dnots th folloing charactristics of th unit:

YS BB BA S0 CF E S

Modl

Coolr Cod Dsign Lvl

por Suly:

for 60 Hz

5 for 50 Hz

Condnsr Cod

Comrssor Cod

Motor Cod

Scial Faturs

TABLE OF CONTENTS

pAGe

LIST OF TABLES

1 watr Flo Rat Limits.................. 20

2 Motor Voltag Variations ................ 23

3 60 Hz elctrical Data ..................... 25

4 Motor Startrs ................................ 25

5 50 Hz elctrical Data ..................... 26

6 Availabl Comrssor/Shll/

Motor Combinations

(R-22 & R-134a) ............................ 26

7 Availabl Comrssor/Shll/

Motor Combinations

(50 Hz, R-134a Only)..................... 27

pAGeTABLeNO.


3/56

JOHNSON CONTROLS

FORM 160.80-EG1 (808

Introduction

Th YORK Millennium YS Chillr offrs a comlt com-

bination of faturs for total onr satisfaction.

MATCHED COMPONENTS MAXIMIZE EFFICIENCY

Actual chiller efciency cannot be determined by analyzing

the theoretical efciency of any one chiller component.It requires a specic combination of heat exchanger,

comrssor, and motor rformanc to achiv th lo-

st systm kw/Ton. YORK Millennium chillr tchnology

matchs chillr systm comonnts to rovid maximum

chiller efciency under actual not just theoretical op-

rating conditions.

REAL-wORLD ENERGY PERFORMANCE

Johnson Controls ionrd th trm Ral-world enrgy

to illustrat th nrgy-saving otntial of focusing on

chillr rformanc during off-dsign conditions. Off-d-

sign is not only art load, but full load oration as ll,

ith rducd ntring condnsr atr tmraturs

(eCwTs). This is hr chillrs orat 99% of th tim,

and hr orating costs add u.

Th YS Millennium chillrs ar th only chillrs dsignd

to orat on a continuous basis ith cold eCwT and full

condenser ow at all load points, taking full advantage of

Real-World conditions. This type of operation benets the

cooling tor as ll; rducing cycling of th fan motor

and ensuring good coverage of the cooling ll.

YORK Millennium chillers offer the most efcient Real-world oration of any chillr, maning lor orating

costs and an xcllnt rturn on your chillr invstmnt.

OPEN DRIVE DESIGN

Hrmtic-motor burnout can caus catastrohic damag

to a chillr. Th ntir chillr must b cland, and th

rfrigrant rlacd. YORK Millennium scr chillrs

liminat this risk by utilizing air-coold motors. Rfrig-

rant nvr coms in contact ith th motor, rvnting

contamination of th rst of th chillr.

Insuranc comanis that offr olicis on larg air condi-

tioning quimnt oftn considr air-coold motors a sig-

nicant advantage over hermetic refrigerant cooled units.

HIGH-EFFICIENCY HEAT EXCHANGERS

Millennium chillr hat xchangrs offr th latst tchnology in hat transfr surfac dsign to giv you maxi-

mum efciency and compact design. Water-side and

rfrigrant-sid dsign nhancmnts minimiz both

nrgy consumtion and tub fouling.

FACTORY PACKAGING REDUCES FIELD LABOR

COSTS

YORK Millennium scr chillrs ar dsignd to k

installation costs lo. whr installation accss is not a

roblm, th unit can b shid comltly ackagd

rquiring minimal iing and iring to comlt th in-

stallation.

For thos units utilizing a factory installd Solid-Stat

Startr, th thr or lads rovid all or to th

chillr and its auxiliaris.

TAKE ADVANTAGE OF COLDER COOLING TOwER

wATER TEMPERATURES

YORK Millennium scr chillrs ar dsignd to tak ful

advantag of coldr cooling tor atr tmraturs

hich ar naturally availabl during most orating hours

Considrabl nrgy savings ar availabl by ltting tor

water temperature drop, rather than articially holding itabov 75F (23.9C), scially at lo load, as som

chillrs rquir.

U.L. ACCEPTANCE YOUR ASSURANCE OF RELI

ABILITY

YORK Millennium scr chillrs ar arovd for listing

by Undrritrs Laboratoris for th Unitd Stats and

Canada. Rcognition of safty and rliability is your as-

suranc of troubl-fr rformanc in day-to-day building

oration.


4/56

JOHNSON CONTROLS

Ratings

ARI CERTIFICATION PROGRAM

Th rformanc of YORK Millennium chillers is certied

to th Air Conditioning and Rfrigration Institut (ARI)

complying with the certication sections of the latest issue

of ARI Standard 550/590. Under this Certication Pro-

gram, chillrs ar rgularly tstd in strict comlianc ith

this Standard. This rovids an indndnt, third-arty

verication of chiller performance.

COMPUTERIZED PERFORMANCE RATINGS

each chillr is custom-matchd to mt th individual

building load and nrgy rquirmnts. A larg numbr

of standard hat xchangrs and ass arrangmnts ar

availabl to rovid th bst ossibl match.

It is not ractical to rovid tabulatd rformanc for

ach combination, as th nrgy rquirmnts at both full

and part- load vary signicantly with each heat exchanger

and ass arrangmnt. Comutrizd ratings ar avail-

able through each Johnson Controls sales ofce. These

ratings can be tailored to specic job requirements, and

are part of the ARI Certication Program.

OFF-DESIGN PERFORMANCE

Since the vast majority of its operating hours are spentat off-dsign conditions, a chillr should b chosn not

only to mt th full-load dsign, but also for its ability to

perform efciently at lower loads and lower tower water

tmraturs. It is not uncommon for chillrs ith th

sam full-load Kw/TON to hav an orating cost diffr-

nc of ovr 10% du to art-load oration.

part-load information can b asily and accuratly gnr-

atd by comutr. And bcaus it is so imortant to an

onrs orating budgt, this information is no stan-

dard within the ARI Certication Program in the form of

an Intgratd part-Load Valu (IpLV), and Non-Standardpart-Load Valu (NpLV).

Th IpLV / NpLV formulas from ARI Standard 550/590

closly track chillr orations, and rovid a mor ac-

curat indication of chillr rformanc than th rvi-

ous IpLV / ApLV formula. A mor dtaild analysis must

take into account actual building load proles, and local

athr data. part-load rformanc data should b ob-

tained for each job using its own design criteria.

Ratd in accordanc ith th latst

issu of ARI Standard 550/590.


5/56

5JOHNSON CONTROLS

FORM 160.80-EG1 (808

OptiView Control Center

OPTIVIEw CONTROL CENTER

Th YORK OtiVi Control Cntr, furnishd as standard

on each chiller, provides the ultimate in efciency, monitor-

ing, data rcording, chillr rotction and orating as.

Th control cntr is a factory mountd, ird, and tstd

stat-of-th-art microrocssor basd control systm for

R-134a or R-22 screw chillers. The panel is congured

ith a 10.4 inch diagonal color Liquid Crystal Dislay(LCD) surrounded by soft keys, which are redened with

on kystrok basd on th scrn dislay at that tim.

This rvolutionary dvlomnt maks chillr oration

quickr and asir than vr bfor. Instad of rquiring

kystrok aftr kystrok to hunt for information on a small

monochrom LCD scrn, a singl button rvals a id

array of information on a larg, full-color illustration of th

aroriat comonnt, hich maks information asir

to intrrt. This is all mountd in th middl of a kyad

intrfac and installd in a lockd nclosur.

Th LCD dislay allos grahic animatd dislay of th

chillr, chillr sub-systms and systm aramtrs; thisallos th rsntation of svral orating aramtrs

at onc. In addition, th orator may vi a grahical

rrsntation of th historical oration of th chillr as

ll as th rsnt oration. A Status Bar is dislayd

at all tims on all scrns. It contains th Systm - Status

Lin and Dtails Lin, th Control Sourc, Accss Lvl,

Dat and Tim. All dat rrsntations and calculations

us four digits for th yar to rovid Yar 2000 comli-

anc.

During th Start Squnc and Systm Lockout Dlay, th

systm status ill includ a countdon timr indicating th

tim rmaining. Th control anl is comatibl ith th

YORK Solid Stat Startr (otional), elctro-mchanica

(e-M) startr, or any customr sulid e-M startr tha

comlis ith th YORK R-1051 standard. Th locations

of various chillr aramtrs ar clarly markd and in-

structions for specic operations are provided. The pane

vrbiag is availabl in othr languags as an otion, ith

english alays availabl. Data can b dislayd in ith

english or Mtric units, lus kyad ntry stoints of 0.1

incrmnts.

Scurity accss is rovidd to rvnt unauthorizd ac

css and/or a chang of stoints. This is accomlishd

ith thr diffrnt lvls of accss and assords fo

ach lvl. Thr ar scrns, dislayd valus, rogram

mabl stoints and manual controls not shon availabl

to srvic th chillr. Thy ar only dislayd hn loggd

in at th srvic accss lvl. Th Advancd Diagnostics

and troublshooting information for th chillr and thanl is also includd.

Th anl is fusd through a 1-1/2 or 2 KVA transform

in th comrssor motor startr to rovid individua

ovr-currnt rotctd or for all controls. Numbrd

trminal stris for iring such as Rmot Start/Sto

Flo Sitch, Chilld watr pum and Local or Rmot

Cycling Dvic ar rovidd. Th panl also rovids

eld interlocks that indicate the chiller status. These con

tacts includ a Rmot Mod Rady To Start, a Cycling


6/56

6 JOHNSON CONTROLS

OptiView Control Center- continued

Shutdon, a Safty Shutdon and a chillr Run Contact.

prssur transducrs sns systm rssurs and thrm-

istors sns systm tmraturs. Th outut of ach

transducr is a DC voltag that is analogous to th rs-

sur inut. Th outut of ach thrmistor is a DC voltag

that is analogous to th tmratur it is snsing.

Stoints can b changd from a rmot location via

0-10VDC, 4-20mA, contact closurs or through srial

communications. The adjustable remote reset range [up

to 20F (11.1C)] provides exible, efcient use of remote

signal dnding on rst nds. Srial data intrfac

to th YORK ISN Building Automation Systm (BAS) is

through th Gnral protocol Intrfac Card (GpIC), hich

can b mountd insid th Control Cntr.

This rintd circuit board rqusts th rquird data from

th Micro Board and maks it availabl for th YORK

ISN ntork. This otional board is availabl through thJohnson Controls BAS grou. Th orating rogram

is stord in non-volatil mmory (epROM) to liminat

chillr failur du to AC or failur/battry discharg.

programmd stoints ar rtaind in lithium battry-

backd RTC mmory for 11 yars minimum.

Smart Frz point protction can orat th chillr as

lo as 36F (2.22C) laving chilld atr tmratur,

ithout nuisanc tris on Lo watr Tmratur. Th

sohisticatd rogram and snsor monitors th chillr a-

tr tmratur to rvnt frz-u. each rogrammabl

oint has a o-u scrn ith th alloabl rangs, so

th chillr cannot b rogrammd to orat outsid ofits dsign limits.

Thrmal ic storag systms ar basd on th conct

of using off-ak, lor cost lctricity to build ic for

handling th cooling load during ak hours. Th most

efcient way to build ice is to maximize chiller load and

minimiz run tim. Standard chillr control systms ar not

dsignd for this orating mod. In a tyical alication,

chillrs ill load and unload to maintain a laving chilld

liquid stoint. whn th YORK YS chillr orats in th

thrmal storag control mod, th unit ill rmain at 100%

load until th stoint shutdon tmratur is rachd.

To add greater operating exibility and eliminate unnec-

ssary chillr cycling, to diffrnt Lo watr (Liquid)

Tmratur Rstart Thrsholds can b rogrammd, on

for th ic mod and on for th standard cooling mod.

This control nhancmnt is standard on all YS chillrs.

Th chillr can also b lft in th standard control mod

for tmraturs ranging btn 20 and 70F (-6.7 and

21.1C), for alications involving a rocss cooling duty

that rquirs laving chilld liquid tmratur stoint

control.

whn or is alid to th chillr, th HOME scrn

is dislayd. This scrn dislays a visual rrsntation

of th chillr and a collction of data dtailing imortant

orations and aramtrs. whn th chillr is running,

the ow of chilled liquid is animated by the alternating

shads of color moving in and out of th i nozzls. Thrimary valus that nd to b monitord and controlld

ar shon on this scrn. Thy ar as follos:

Display Only:

Chilld Liquid Tmratur Laving

Chilld Liquid Tmratur Rturn

Condnsr Liquid Tmratur Rturn

Condnsr Liquid Tmratur Laving

Motor Run (LeD)

% Full Load Ams

Orating Hours

with th soft kys th orator is only on touch aay

from the 8 main screens that allow access to the major

information and comonnts of th chillr. Th 8 scrns

ar th SYSTEM, EVAPORATOR, CONDENSER, COM-

PRESSOR, OIL SUMP, MOTOR, SETPOINTS, and th

HISTORY. Also on th Hom Scrn is th ability to LOG

IN, LOG OUT and PRINT. Log In and Log Out is th mans

by hich diffrnt scurity lvls ar accssd.

Th SYSTEM scrn givs a gnral ovrvi of common

chillr aramtrs for both shlls. This is an nd vi ofth chillr ith a 3-D cutaay of both th shlls. Th fol-

loing can b vid from this scrn:

Display Only:

Discharg Tmratur

Chilld Liquid Tmratur Laving

Chilld Liquid Tmratur Rturn

Chilld Liquid Tmratur Stoint

evaorator prssur

evaorator Saturation Tmratur

Condnsr Liquid Tmratur Laving Condnsr Liquid Tmratur Rturn

Condnsr prssur

Condnsr Saturation Tmratur

Oil Tmratur

Diffrntial Oil prssur

% Full Load Ams

Currnt Limit

Slid Valv position


7/56

JOHNSON CONTROLS

FORM 160.80-EG1 (808

Th EVAPORATOR scrn dislays a cutaay vi of

th chillr vaorator. All stoints rlating to th vao-

rator sid of th chillr ar maintaind on this scrn.

Animation of th vaoration rocss indicats hthr

th chillr is rsntly in RUN condition (bubbling) andliquid ow in the pipes is indicated by alternating shades

of color moving in and out of the pipes. Adjustable limits

on th lo atr tmratur stoints allo th chillr

to cycle on and off for greater efciency and less chiller

cycling. Th chillr cycls off hn th laving chilld

water temperature is below setpoint and is adjustable

from 1F (0.55C) blo to a minimum of 36F (2.22C).

Restart is adjustable from setpoint up to a max of 80F

(44.4C). The Panel will check for ow to avoid freeze-

up of the tubes. If ow is interrupted, shutdown will occur

aftr a minimum of to sconds. Th folloing can also

b rformd through this scrn:

Display Only:

Chilld Liquid Flo Sitch (On/Closd)

Chilld Liquid pum (Run/Sto)

evaorator prssur

evaorator Saturation Tmratur

Rturn Chilld Liquid Tmratur

Laving Chilld Liquid Tmratur

evaorator Rfrigrant Tmratur

Small Tmratur Diffrnc

Laving Chilld Liquid Tmratur Stoints

Stoint


Rmot Rang


Shutdon


Shutdon Offst


Rstart


Rstart Offst

Ic Storag Activ (LeD)

Programmable:

Local Laving Chilld Liquid Tmratur Rang

Local Laving Chilld Liquid Tmratur Stoint

Laving Chilld Liquid Tmratur Cycling Offst

Shutdon


Rstart

Th CONDENSER scrn dislays a cutaay vi of th

chiller condenser. The liquid ow is animated to indicate

ow through the condenser. All setpoints relating to the

condnsr sid of th chillr ar maintaind on this scrn

with th ror accss lvl this scrn also srvs as agatay to controlling th Rfrigrant Lvl. Th folloing

can also b vid through this scrn:

Display Only:

Laving Condnsr Liquid Tmratur

Rturn Condnsr Liquid Tmratur

Condnsr prssur


Small Tmratur Diffrnc

High prssur Sitch (On/Closd)

Condnsr Liquid Flo Sitch Condnsr Liquid pum (Run/Sto)

Programmable:

High prssur warning Thrshold

Frz warning (enabld/Disabld)

Frz Tim

Th VARIABLE ORIFICE CONTROL scrn, accssd

from th CONDeNSeR scrn in SeRVICe accss lvl

displays all of the applicable Variable Orice contro

aramtrs and allos a Srvic Tchnician to rogramth Dlta p stoint. Th Lo evaorator prssur and

Surhat Ovrrid LeDs ar locatd on this scrn

A view of the liquid ow piping to the chiller condenser

along with the solenoid ow control valve, is shown. The

folloing can also b rformd through this scrn:

Display Only:

Condnsr prssur

evaorator prssur

Dlta p (Condnsr evaorator)

Discharg Tmratur


Surhat Tmratur

Lo evaorator Ovrrid (LeD)

Surhat Ovrrid (LeD)

Programmable:

Dlta p Stoint


8/56

8 JOHNSON CONTROLS


Th COMPRESSOR scrn dislays a cutaay vi of

th chillr comrssor, rvaling th rotary scr, and

shos all conditions associatd ith th comrssor. Th

slid valv ositioning is animatd and ith th ror

Accss lvl, it can b manually controlld. Animation

of th comrssor rotors indicats hthr th chillr isrsntly in a RUN condition. This scrn also srvs as

a gatay to sub-scrns for calibrating th slid valv

or conguring the optional Hot Gas Bypass. From this

scrn you can vi th folloing:

Display Only:


Oil Tmratur

Discharg Tmratur

Discharg Surhat

Slid Valv position

Oil Rturn Solnoid (LeD)

Full Load Ams (e.M. Startr Only)

phas A, B, C Currnt (SSS Only)

Programmable:

Slid Valv Load (Manual)

Slid Valv Hold (Manual)

Slid Valv Unload (Manual)

Slid Valv Auto

Max. Load Tmratur

Minimum Load FLA

Minimum Load Control Sourc

The HOT GAS BYPASSscrn, accssd from th COM-

PRESSOR scrn, dislays a ictorial of th byass lin

and solnoid valv location on th chillr. Th Hot Gas

ON and OFF Stoints ar rogrammd on this scrn

and systm aramtrs rtinnt to Hot Gas Byass

oration ar dislayd. An LeD illuminats hn th

Hot Gas solnoid is ON. If th chillr is quid ith

th Hot Gas Byass otion, oration must b nabld

on th OPERATIONS scrn. From this scrn you can

rform th folloing:

Display Only:

Slid Valv position

Rturn Chilld Liquid Tmratur

Laving Chilld Liquid Tmratur

Hot Gas Solnoid (LeD)

Programmable:

On Stoint

Off Stoint

Th SLIDE VALVE CALIBRATION scrn dislays a

cutaay vi of th chillr comrssor, rvaling th

rotary scr and slid valv and rovids th caability

of calibrating th slid valv. From this scrn, you can

rform th folloing:

Display Only:

Slid Valv Loading (LeD)

Slid Valv Unloading (LeD)

Calibration Mssag

Programmable:

Start Calibration

Cancl Calibration

Th OIL SEPARATOR scrn dislays a clos-u vi

of th chillr oil sarator/sum and rovids all th nc-

ssary stoints for maintaining th Variabl Sd Oil

pum (VSOP). This scrn also allos manual control

of th Frquncy Command snt to th VSOP. From this

scrn you can rform th folloing:

Display Only:

Discharg Tmratur

Oil Sum Tmratur

Discharg Surhat

Oil prssur

Filtr prssur

Sal prssur


Diffrntial Filtr prssur

Diffrntial Sal prssur

Offst prssur

Oil Rturn Solnoid (LeD)

Lo Sarator Oil Lvl (LeD)

1.Th MOTOR soft ky on th HOMe scrn, hn

rssd, shos a ictur of ithr a YORK elctro-

Mchanical Startr or a Solid Stat Startr, dnding

on chiller conguration. The Programmable pulldown

dmand to automatically limit motor loading can b

usd to minimiz building dmand chargs. pulldon


9/56

9JOHNSON CONTROLS

FORM 160.80-EG1 (808

time period control over four hours, and verication of

tim rmaining in ulldon cycl from dislay radout.

Sarat digital stoint for currnt limiting btn

30 and 100%.

ThELECTRO-MECHANICAL STARTER (EM) scrndislays a ictur of th startr and th folloing valus.

Th ons blo ar common among both offrings and th

valus ill b dislayd on both tys of startr scrns.

From this scrn you can rform th folloing:

Display Only:

Motor Run (LeD)

Motor Currnt % Full Load Ams

Currnt Limit Stoints

pulldon Dmand Tim Lft

Programmable:

Local Motor Currnt Limit

pulldon Dmand Limit

pulldon Dmand Tim

Th SOLID STATE STARTER (SSS) scrn dislays a

ictur of th startr and th folloing valus, hich ar

dislayd in addition to th common ons listd abov.

From this scrn, you can rform th folloing:

Display Only:

Inut por

kw Hours

Startr Modl

Voltag phas A, B, C

Currnt phas A, B, C

Tmratur phas A, B, C

Programmable:

Full Load Ams

Voltag Rang

Starting Currnt

On SCR

Shortd SCR

kwH Rst

Th SETPOINTS scrn rovids a convnint location

for rogramming th most common stoints involvd

in th chillr control. Th Stoints ar shon on othr

individual scrns, but to cut don on ndlss sarch-

ing, thy can all b found on this scrn. This scrn also

serves as a gateway to a sub-screen for dening the setup

of gnral systm aramtrs. From this scrn you can

rform th folloing:

Display Only: Laving Chilld Liquid Tmratur Stoint

Laving Chilld Liquid Tmratur Cycling

Shutdon

Laving Chilld Liquid Tmratur Cycling

Rstart

Currnt Limit Stoint

Programmable:

Local Laving Chilld Liquid Tmratur Rang

Local Laving Chilld Liquid Tmratur Stoint


Shutdon


Rstart

Rmot Analog Inut Rang


pulldon Dmand Limit

pulldon Dmand Tim

print

Th SETUP is the top level of the general conguration aramtrs. It allos rogramming of th tim and

date, along with specications as to how the time will be

displayed. In addition, the chiller conguration as deter

mined by the micro board program jumpers and program

sitchs is dislayd. From this scrn you can rform

th folloing:

Display Only:

Chilld Liquid pum Oration (Dislays Standardo

Enhanced)

Rfrigrant Slction (Dislays R-22orR-134a)

Anti-Rcycl (Dislays DisabledorEnabled)

por Failur Rstart (Dislays Manual orAuto-

matic)

Liquid Ty (Dislays WaterorBrine)

Programmable:

St Dat

St Tim

Clock (enabld/Disabld)

12/24 Hour


10/56

10 JOHNSON CONTROLS


The folloing six subscreens can be accessed from

the SETUP screen:

Th SCHEDULE scrn contains mor rogrammabl

valus than a normal dislay scrn. each rogrammabl

value is not linked to a specic button; instead, the selectky is usd to nabl th cursor arros and chck ky to

rogram th Start/Sto tims for any day of th k u

to 6 eeks in advance. The user has the ability to dene

a standard st of Start/Sto tims that ar utilizd vry

k or scify xctions to crat a scial k.

Programmable:

exction Start/Sto Tims

Schdul (enabl/Disabl)

Rat Sunday Schdul

Standard wk Start/Sto Tims

Rst All exction Days

Slct

print

Th USER screen allows denition of the language for the

chiller to display and denes the unit of measure.

Programmable:

Systm Languag

english/Mtric Units

Th COMMS screen allows the user to dene commu-nications aramtrs.

Programmable:

Chillr ID

COM 2 Baud Rat

COM 2 Data Bit(s)

COM 2 parity Bit(s)

COM 2 Sto Bit(s)

printr Baud Rat

printr Data Bit(s)

printr parity Bit(s)

printr Sto Bit(s)

Th PRINTER screen permits the user to dene com-

munications paramtrs for th printr.

Display Only

Tim Rmaining Until Nxt print

Programmable

Log Start Tim

Outut Intrval

Automatic printr Logging (enabld/Disabld)

print Ty

print Rort

print All Historis

Th SALES ORDER screen allows denition of the order

aramtrs. Note: This information is loaded at the factory

or by the installation service technician.

Display Only

Modl Numbr

panl Srial Numbr

Chillr Srial Numbr

YORK Ordr Numbr

Systm Information

Condnsr and evaorator Dsign Load Information

Namlat Information

Th OPERATIONS screen permits denition of param-

eters pertaining to operation of the chiller. What is dened

is hthr th control of th chillr ill b Local, Digital R-

mot, Analog Rmot, Modm Rmot or ISN Rmot.

Programmable

Control Sourc

Th HISTORY scrn allos th usr to bros throughth last tn faults; ithr safty or cycling shutdons ith

th conditions, hil th chillr is running or stod.

Th faults ar color codd for as in dtrmining

th svrity at a glanc, rcording th dat, tim and

dscrition. (S Dislay Mssags for Color Cod

manings.)

Display Only

Last Normal Shutdon

Last Fault whil Running

Last Tn Faults

Programmable:

print History

print All Historis

By rssing th VIEw DETAILS ky you ill mov to th

HISTORY DETAILS scrn. From ths scrns you

ar abl to s an on-scrn rintout of all th systm

aramtrs at th tim of th slctd shutdon.


11/56

11JOHNSON CONTROLS

FORM 160.80-EG1 (808

Display Only:

History printout

Programmable:

pag U pag Don

print History

Also undr th HISTORY scrn is th TRENDING

scrn, accssibl by th ky markd th sam. On this

scrn, u to six orator-slctd aramtrs, slctd

from a list of ovr 140, can b lottd in an X/Y grah

format. Th grah can b customizd to rcord oints

onc vry scond u to onc vry hour. Thr ar

to tys of charts that can b cratd: singl scrn,

or continuous scrn. Th singl scrn collcts data for

on scrn idth (450 data oints across th X-axis), thnstos. Th continuous scrn ks collcting th data,

but th oldst data dros off th grah from lft to right

at the next data collection interval. For ease of identica-

tion, ach lottd aramtr, titl and associatd Y-axis

labling is color coordinatd.

Display Only:

This scrn allos th usr to vi th grahical

trnding of th slctd aramtrs and is a gatay

to th grah stu scrns.

Programmable: Start

Sto

Y-axis

X-axis

Th TREND SETUP screen is used to congure the trend-

ing scrn. Th aramtrs to b trndd ar slctd

from th Trnd Common Slots scrn, accssd from

th Slot Numbrs button or th Mastr Slot Numbrs

List found in th Orating Manual. Th intrval at hich

all th aramtrs ar samld is slctd undr th

Collction Intrval button. Th data oint minimum andmaximum values may be adjusted closer to increase

viing rsolution.

Programmable:

Chart Ty (slct continuous orone screen)

Collction Intrval

Slct

Data point Slot Numbr (1 - 6)

Data point Min (1 - 6)

Data point Max (1 - 6)

Th TREND COMMON SLOTS scrn dislays th Mas

tr Slot Numbrs List of th monitord aramtrs.

Display Only:

Slot Numbrs

Programmable:

pag U

pag Don

print

DISPLAY MESSAGES

Th Control Cntr continuously monitors th oratingsystm, dislaying and rcording th caus of any shut

dons (Safty, Cycling or Normal). Th condition of th

chillr is dislayd at th Systm Status lin that contains

a mssag dscribing th orating stat of th chillr

hthr it is stod, running, starting or shutting don

A Systm Dtails Lin dislays warning, Cycling, Safty

Start Inhibit and othr mssags that rovid furth

dtails of th Status Bar mssags. Mssags ar color-

codd: Grn Normal Orations; Yllo warnings

Orang Cycling Shutdons; and Rd Safty Shut

dons to aid in idntifying roblms quickly.

Status mssags includ: Systm Rady To Start

Cycling Shutdon Auto Rstart

Safty Shutdon Manual Rstart

Start Squnc Initiatd

Systm Run (ith countdon timrs)

Start Inhibit

Slid Valv Closing Bfor Shutdon

Systm Lockout Dlay

Run Mssags includ:

Laving Chilld Liquid Control

Motor pulldon Limit

Motor High Currnt Limit

Start Inhibit Mssags includ:

Anti-Rcycl XX min/sc.

Slid Valv position >30%

Motor Currnt >15% FLA

LCSSS High-Tmratur phas X - Stod


12/56

1 JOHNSON CONTROLS

warning Mssags includ:

Ral Tim Clock Failur

Stoint Ovrrid

Condnsr High prssur Limit

evaorator Lo prssur Limit

Frz Thrat From Orating Chillr

Frz Thrat, Condnsr Flo Sitch On

Lo Discharg Surhat Limit

Lo Discharg Surhat Dtctd

Maximum Load Load Limit

Minimum Load Load Limit

Oil Dirty Filtr

Oil High Tmratur

Slid Valv Uncalibratd

Routin Shutdon Mssags Includ: Rmot Sto

Local Sto

plac Comrssor Sitch In Run position

Cycling Shutdon Mssags Includ:

Multiunit Cycling Contacts On

Systm Cycling Contacts On

Control panl por Failur

Laving Chilld Liquid Lo Tmratur

Laving Chilld Liquid Flo Sitch On

Condnsr Flo Sitch On

Motor Controllr Contacts On

Motor Controllr Loss of Currnt

por Fault

Control panl Schdul

Solid State Starter Only (LCSSS)

Initialization Faild

Srial Communications

Rqusting Fault Data

Sto Contacts On

por Fault

Lo phas (X) Tmratur Snsor

Run Signal

Invalid Currnt Scal Slction

phas Lockd Loo

Lo Suly Lin Voltag

High Suly Lin Voltag

Logic Board procssor

Logic Board por Suly

phas Loss

Safty Shutdon Mssags includ:

evaorator Lo prssur

evaorator Lo prssur Smart Frz

evaorator Transducr or Laving Liquid prob

evaorator Transducr or Tmratur Snsor

Condnsr High prssur Contacts On

Condnsr High prssur

Condnsr prssur Transducr Out of Rang

Auxiliary Safty Contacts Closd

Discharg High Tmratur

Discharg Lo Tmratur

Oil High Tmratur

Oil Lo Diffrntial prssur

Oil Lo Diffrntial Sal prssur

Oil or Condnsr Transducr error

Oil Cloggd Filtr

Oil High prssur Oil Sarator Lo Lvl


watchdog Softar Rboot

Solid Stat Startr Only (LCSSS)

Shutdon Rqusting Fault Data . . .

High Instantanous Currnt

High phas (X) Hatsink Tmratur Running

105% Motor Currnt Ovrload

Motor or Startr Currnt Imbalanc

On SCR phas Rotation



13/56

1JOHNSON CONTROLS

FORM 160.80-EG1 (808

Mechanical Specifcations

STANDARD UNIT

General

Th YORK Millnnium YS Rotary Scr Chillr is com-

ltly factory-ackagd, including vaorator, condnsr,

sub-coolr, oil sarator, comrssor, motor, lubricationsystm, control cntr and rfrigrant isolation valvs.

Th factory ackag consists of a lak tight dsign. All

units shi as standard ith a full charg of rfrigrant

and oil. Units can also b shid in sctions (otional)

to accommodate job site requirements.

The services of a Johnson Controls factory-trained, eld

srvic rrsntativ ar incurrd to survis or rform

the nal leak testing, charging, the initial start-up, and

concurrnt orator instructions.

Compressor

Th Frick Rotary Tin Scr Comrssor is nginrd

and constructd to mt th xact rquirmnts of th

industrial rfrigration markt. It utilizs stat-of-th-art

tchnology to rovid th most rliabl and nrgy-f-

cient compressor available at all operating conditions.

Th comrssor orats at 3750 RpM for 60 Hrtz and

2975 RpM for 50 Hrtz. Th comrssor housing is mad

of cast iron, rcision-machind to rovid minimal clar-

anc for th rotors. Comrssor housing has a dsign

orking rssur (Dwp) of 300 pSIG (2068 kpa) mini-

mum, and hydro-tstd at 544 pSIG (3751 kpa).

Th rotors ar manufacturd from forgd stl and usasymmetric proles. The compressor incorporates a

comlt anti-friction baring dsign for rducd or

and incrasd rliability. Four sarat cylindrical rollr

barings handl radial loads. To 4-oint angular contact

ball barings handl axial loads. Togthr, thy maintain

accurat rotor ositioning at all rssur ratios, thrby

minimizing blow-by and maintaining efciency.

A chck valv is installd in th comrssor discharg

housing (suction housing for S4 and S5 comrssor) to

rvnt comrssor rotor back sin bcaus of systm

rfrigrant rssur gradints during shutdon.

Th on-driv comrssor shaft sal consists of rci-

sion cramic sal facs, mtallic bllos, rotating mmbr,

PTFE C-Ring static seal, and multi-port oil injection ring.

Th sal cavity is maintaind at intrmdiat rssur

ith its oil dischargd to th oil drain from th comrssor.

Combining intermediate pressure with direct oil injection

rovids cool, non-foaming lubricant to th sal assuring

a longr lifsan.

Capacity Control

Caacity control is achivd by us of a slid valv hich

rovids fully modulating caacity control from 100% to

10% of full load. Th slid valv is actuatd by oil rssur

controlld by xtrnal solnoid valvs via th OtiVi

Control Cntr.

Oil SeparatorTh oil sarator is a horizontal dsign ithout moving

arts. effctiv oil saration is achivd by gravity dro

out of oil from th rfrigrant gas as vlocity dcrass

uon ntring th sarator, and by msh ads to rovid

nal gas/oil separation before gas enters the condenser

Th oil sarator is dsignd for 345 pSIG (2378 kpa

dsign orking rssur, tstd at 517 pSIG (3565 kpa)

and stamd in accordanc ith ASMe Boilr and prs

sur Vssl Cod, Sction VIII - Division 1.

each vssl has a rfrigrant rlif dvic(s) st at 300

pSIG (2068 kpa). In addition to th sring-loadd, r-sat

ing-ty rlif valvs sizd for rssur vssl volum

ach unit is quid ith a rutur disk. This rutur

disk is abl to rliv th ntir uming caacity of th

comrssor if lctronic saftis fail, roviding rotc-

tion for rorty and rsonnl. This dvic is st for

345 pSIG (2378 kpa). Altrnativly, th shll sid may

b dsignd to euroan prssur Vssl Cods and

stamd in accordanc ith A.D. Mrkblattr or othr

euroan prssur Vssl dsign cod. whn rquird

by th rfrigration safty cod, ach vssl has a dua

rfrigrant rlif dvic(s).

LubricationTh main unit oil rsrvoir is locatd in th oil sarator

Th comrssor also has an oil rsrvoir locatd at th

rotor barings to rovid lubrication during start-u, coa

don, and in th vnt of a or failur. During ora

tion, system pressure differential provides proper oil ow

ithout th nd of an auxiliary oil um. This minimizs

nrgy consumtion.

The chiller is shipped with a 3 Micron absolute oil lter

nsuring a clan oil systm and surior comrssor

life. An external, replaceable cartridge oil lter is supplied

ith manual isolation sto valvs for as of srvicing

An optional dual oil lter housing with isolation valves is

availabl on all units. This allos immdiat sitching

from one lter to the other, eliminating downtime during

lter changes. The off-line oil lter can be changed during

chillr oration.

A 500 att (115 volt - 1-has - 60/50Hz) immrsion

oil hatr is locatd in th oil sarator rsrvoir, tm-

perature actuated to efciently remove refrigerant from

th oil. Oil hatr or suly is factory ird from

th control anl. A factory-id rfrigrant-coold oi


14/56

1 JOHNSON CONTROLS

coolr is rovidd as standard. No auxiliary atr i-

ing is rquird. An oil ductor automatically rmovs oil

hich may hav migratd to th vaorator and rturns

it to th comrssor.

MOTOR DRIVELINETh comrssor motor is an on dri-roof, squirrl

cag, induction ty constructd to Johnson Controls

design specications. 60 Hertz motors operate at 3750

RpM; 50 Hrtz motors orat at 2975 RpM. Th on

motor is rovidd ith a D-Flang and is factory-mountd

to a cast-iron adator mountd on th comrssor. This

uniqu dsign allos th motor to b rigidly could to

th comrssor to rovid factory alignmnt of motor and

comrssor shafts.

Motor driv shaft is dirctly connctd to th comrssor

shaft with a exible disc coupling. Coupling has all metal

construction ith no aring arts to assur long lif.

Additionally, no lubrication is rquird roviding lo

maintnanc.

For units utilizing rmot lctro-mchanical startrs,

a larg stl trminal box ith gasktd front accss

cover is provided for eld connected conduit. There are

six trminals (thr for mdium voltag) brought through

th motor casing into th trminal box. Jumrs ar fur-

nishd for thr-lad ty of starting. Motor trminal lugs

ar not furnishd. Ovrload/ovrcurrnt transformrs ar

furnishd ith all units. For units furnishd ith factory-

ackagd Solid Stat Startrs, rfr to th Accssorisand Modications section (page 17).

HEAT EXCHANGERS

Shells

evaorator and condnsr shlls ar fabricatd from

rolld carbon stl lats ith fusion ldd sams.

Carbon stl tub shts, drilld and ramd to accom-

modat th tubs, ar ldd to th nd of ach shll.

Intrmdiat tub suorts ar fabricatd from carbon

stl lats, drilld and ramd to liminat shar dgs,

and sacd no mor than four ft aart. Th rfrigrant

sid of ach shll is dsignd, tstd, and stamd in

accordanc ith ASMe Boilr and prssur Vssl Cod,

Sction VIII Division I, or othr rssur vssl cod

as aroriat.

Tubes

Heat exchanger tubes are state-of-the-art, high efciency,

xtrnally and intrnally nhancd ty to rovid o-

timum rformanc. Tubs in both th vaorator and

condnsr ar 3/4 O.D. cor alloy and utiliz th

skip-n design, providing a smooth internal and external

surfac at ach intrmdiat tub suort. This rovids

xtra all thicknss (u to tic as thick) and non-ork

hardnd cor at th suort location, xtnding th

lif of th hat xchangrs. each tub is rollr xandd

into th tub shts roviding a lak-roof sal, and is

individually rlacabl.

Evaporator

The evaporator is a shell and tube, ooded type heat ex-

changr. A distributor trough rovids uniform distribution

of rfrigrant ovr th ntir shll lngth to yild otimum

heat transfer. A suction bafe or aluminum mesh elimina-

tors ar locatd abov th tub bundl to rvnt liquid

rfrigrant carryovr into th comrssor. A 1-1/2 liquid

lvl sight glass is convnintly locatd on th sid of th

shll to aid in dtrmining ror rfrigrant charg. Th

vaorator shll contains a dual rfrigrant rlif valv

arrangmnt st at 180 pSIG (1241 kpa); or singl-rlif

valv arrangmnt, if th chillr is sulid ith th o-

tional rfrigrant isolation valvs. A 1 rfrigrant chargingvalv is rovidd.

Condenser

Th condnsr is a shll and tub ty, ith a discharg

gas bafe to prevent direct high velocity impingement on

the tubes. The bafe is also used to distribute the refrig-

erant gas ow properly for most efcient heat transfer.

An intgral sub-coolr is locatd at th bottom of th

condnsr shll roviding highly ffctiv liquid rfrigr-

ant subcooling to provide the highest cycle efciency. The

condnsr contains dual rfrigrant rlif valvs st at

235 pSIG (1620 kpa).

water Boxes

Th rmovabl atr boxs ar fabricatd of stl. Th

dsign orking rssur is 150 pSIG (1034 kpa) and th

boxs ar tstd at 225 pSIG (1551 kpa). Intgral stl

water bafes are located and welded within the water box

to rovid th rquird ass arrangmnts. Stub-out atr

nozzl connctions ith ANSI/AwwA C-606 groovs ar

ldd to th atr boxs. Ths nozzl connctions

ar suitabl for ANSI/AwwA C-606 coulings lding or

anges, and are capped for shipment. Plugged 3/4 drain

and vnt connctions ar rovidd in ach atr box.

REFRIGERANT FLOw CONTROL

Th YS Chillr is quid ith a rfrigrant mtring

device consisting of a xed orice and bypass solenoid

valve, which automatically adjusts to all real-world operat-

ing conditions. This control ensures proper refrigerant ow

to th vaorator ovr a id rang of orating condi-

tions, including thrmal storag alications and chilld

atr rst. Valv oration is rogrammabl and can

be customized for a specic application via the control

anl kyboard.

Mechanical Specifcations - continued


15/56

15JOHNSON CONTROLS

FORM 160.80-EG1 (808

REFRIGERANT ISOLATION

Th condnsr shll srvs as a rfrigrant rcivr

to stor th systm charg during srvicing. Manually

oratd isolation valvs ar locatd at th inlt and

outlt of th condnsr. Valvs ar also rovidd to fa-

cilitat rmoval of th rfrigrant from th systm hnncssary.

OPTIVIEw CONTROL CENTER

General

Th chillr is controlld by a stand-alon microrocssor-

basd control cntr. Th chillr control anl rovids

control of chillr oration and monitoring of chillr sn-

sors, actuators, rlays and sitchs.

Control Panel

Th control anl includs a 10.4 inch diagonal color liquidcrystal dislay (LCD) surroundd by soft kys, hich

are redened based on the screen displayed at that time,

mountd in th middl of a kyad intrfac and installd

in a lockd nclosur. Th scrn dtails all orations

and aramtrs, using a grahical rrsntation of th

chiller and its major components. Panel verbiage is avail-

abl in othr languags as an otion ith english alays

availabl. Data can b dislayd in ithr english or Mtric

units. Smart Frz point protction ill run th chillr at

36F (2.22C) laving chilld atr tmratur and not

xrinc nuisanc tris on lo atr tmratur. Th

sohisticatd rogram and snsor monitors th chillr a-

tr tmratur to rvnt frz-u. whn ndd, HotGas Byass is availabl as an otion. Th anl dislays

countdon timr mssags so th orator knos hn

functions ar starting and stoing. evry rogrammabl

oint has a o-u scrn ith th rangs includd, so

th chillr can not b rogrammd to orat outsid of

its dsign limits.

Th control anl includs a thrmal ic storag control

mod hich nhancs systm rformanc during ic

building oration hn comard to standard cooling

logic. In thrmal storag control mod, th chillr ill

orat at 100% load until th stoint shutdon tm-

perature is reached. To add greater operating exibility

and liminat unncssary chillr cycling, to diffrnt

Lo watr (Liquid) Tmratur Rstart Thrsholds ar

rogrammabl, on for th ic mod and on for th stan-

dard cooling mod. Th chillr has th caability to rmain

in th standard control mod for tmraturs btn

20F to 70F (6.7C to 21.1C) for alications involving

a rocss cooling duty that rquirs laving chilld liquid

tmratur stoint control.

The chiller control panel also provides:

1. Systm orating information including:

Rturn and Laving Chilld watr Tmratur

Rturn and Laving Condnsr watr Tm

ratur

evaorator and Condnsr Saturation Tm

ratur

Oil prssur at Comrssor and Oil Filtr

Diffrntial

prcnt Motor Currnt

evaorator and Condnsr Saturation Tm

ratur

Comrssor Discharg Tmratur

Oil Tmratur

prcnt Slid Valv position

Orating Hours

Numbr of Unit Starts

2. Digital programming of Stoints Through Th Uni

vrsal Kyad Including:

Laving Chilld watr Tmratur

prcnt Currnt Limit

pull-Don Dmand Limiting

Six-wk Schdul For Starting and Stoing

Th Chillr, pums and Tor

Rmot Rst Tmratur Rang

3. Status Mssags Indicating:

Systm Rady To Start

Systm Running

Systm Coastdon

Systm Safty Shutdon Manual Rstart

Systm Cycling Shutdon Auto Rstart

Systm prlub

Start Inhibit

4. Th txt dislayd ithin th systm status and sys

tem details eld is displayed as a color-coded mes

sag to indicat svrity: rd for safty fault; orang

for cycling faults; yllo for arnings; and grn fonormal mssags.

5. Safty shutdons ar nunciatd through th dislay

and th status bar, and consist of systm status, sys

tm dtails, day, tim, caus of shutdon, and ty o

restart required. Safety shutdowns with a xed speed

driv includ:

evaorator Lo prssur

evaorator Lo prssur - Smart Frz

evaorator Transducr or Laving Liquid

prob


16/56

16 JOHNSON CONTROLS

evaorator Transducr or Tmratur Sn-

sor

Condnsr High prssur Contacts On

Condnsr High prssur

Condnsr prssur Transducr Out Of

Rang

Auxiliary Safty Contacts Closd

Discharg High Tmratur

Discharg Lo Tmratur

Oil High Tmratur

Oil Lo Diffrntial prssur

Oil Lo Diffrntial Sal prssur

Oil Or Condnsr Transducr error

Oil Cloggd Filtr

Oil High prssur

Oil Sarator Lo Lvl


watchdog Softar Rboot

5.1 Safty shutdons ith a Solid Stat Startr (LCSSS)

includ:

Shutdon - Rqusting Fault Data...

High Instantanous Currnt

High phas (X) Hatsink Tmratur - Run

ning

105% Motor Currnt Ovrload

Motor Or Startr Currnt Imbalanc

phas (X) Shortd SCR

On SCR

phas Rotation

6. Cycling shutdons nunciatd through th dislay

and th status bar, and consists of systm status,

systm dtails, day, tim, caus of shutdon, and

ty of rstart rquird.

Cycling shutdons ith a fixd sd driv in-

clud:

Multiunit Cycling - Contacts On

Systm Cycling - Contacts On

Control panl - por Failur

Laving Chilld Liquid Lo Tmratur

Laving Chilld Liquid Flo Sitch On

Condnsr - Flo Sitch On

Motor Controllr Contacts On

Motor Controllr Loss Of Currnt

por Fault

Mechanical Specifcations - continued

Control panl Schdul

6.1 Cycling shutdons ith a Solid Stat Startr (LCSSS)

includ:

Initialization Faild

Srial Communications Rqusting Fault Data

Sto Contacts On

por Fault

Lo phas (X) Tmratur Snsor

Run Signal

Invalid Currnt Scal Slction

phas Lockd Loo

Lo Suly Lin Voltag

High Suly Lin Voltag

Logic Board procssor Logic Board por Suly

phas Loss

7. Scurity accss to rvnt unauthorizd chang of

stoints, to rmit local or rmot control of th

chillr, and to allo manual oration of th rrota-

tion vans and oil um. Accss is through ID and

password recognition, which is dened by three

diffrnt lvls of usr comtnc: vi, orator,

and srvic.

8. Trnding data ith th ability to customiz oints of

onc vry scond to onc vry hour. Th anlill trnd u to 6 diffrnt aramtrs from a list of

ovr 140, ithout th nd of an xtrnal monitoring

systm.

9. Th orating rogram is stord in non-volatil

mmory (epROM) to liminat rrogramming th

chillr du to AC or failur or battry discharg.

programmd stoints ar rtaind in lithium bat-

try-backd RTC mmory for a minimum of 11 yars

ith or rmovd from th systm.

10. A fusd connction through a transformr in th

comrssor motor startr to rovid individual

ovr-currnt rotctd or for all controls.

11. A numbered terminal strip for all required eld inter-

lock iring.

12. An RS-232 ort to outut all systm orating data,

shutdon/cycling mssag, and a rcord of th last

10 cycling or safety shutdowns to a eld-supplied

rintr. Data logs to a rintr at a st rogrammabl

intrval. This data can b r-rograrnmd to rint

from 1 minut to 1 day.

13. Th caability to intrfac ith a building automation


17/56

1JOHNSON CONTROLS

FORM 160.80-EG1 (808

systm to rovid:

rmot chillr start and sto

remote leaving chilled liquid temperature adjust

remote current limit setpoint adjust

rmot rady to start contacts

safty shutdon contacts

cycling shutdon contacts

run contacts

CODES AND STANDARDS

ASMe Boilr and prssur Vssl Cod Sction

Vlll Division 1.

ARI Standard 550/590 c/U.L. Undrritrs Laboratory

ASHRAe 15 Safty Cod for Mchanical Rfrigra-

tion

ASHRAe Guidlin 3 Rducing emission of Halog-

natd Rfrigrants in Rfrigration and Air-Condition-

ing equimnt and Systms

NeC National elctrical Cod

OSHA Occuational Safty and Halth Act

A.D. Mrkblattr

ISOLATION MOUNTING

Th unit is rovidd ith four vibration isolation mounts

consisting of 1 (25.4 mm) thick norn isolation ads

for eld mounting under the steel mounting pads located

on th tub shts.

REFRIGERANT CONTAINMENT

Th standard unit has bn dsignd as a comlt and

comact factory ackagd chillr. As such, it has mini

mum joints from which refrigerant can leak. The entire

assmbly has bn thoroughly lak tstd at th factory

rior to shimnt. Th YORK chillr includs srvic

valvs convnintly locatd to facilitat transfr of rfrig

rant to a rmot rfrigrant storag/rcycling systmOtional condnsr isolation valvs rmit storag of th

charg in th condnsr.

PAINT

extrior surfacs ar rotctd ith on coat of Carib-

bean blue, durable alkyd-modied, vinyl enamel, ma

chinry aint.


18/56

18 JOHNSON CONTROLS

Accessories and Modifcations

SOLID STATE STARTER

Th Solid Stat Startr is a rducd voltag startr that

controls and maintains a constant current ow to the motor

during startu. It is comact and mountd on th chillr at

th motor trminals. por and control iring is factory

sulid. Availabl for 200-600 volts, th startr nclosur

is NeMA-1 ith a hingd accss door ith lock and ky.

elctrical lugs for incoming or iring ar rovidd.

Standard faturs includ: digital radout at th OtiVi

Control Cntr of th folloing:

Display Only:

3-has voltag A, B, C

3-has currnt A, B, C

Inut or (kw)

kw Hours

Startr Modl

Motor Run (LeD)

Motor Currnt % Full Load Ams

Currnt Limit Stoints

pulldon Dmand Tim Lft

Programmable:


pulldon Dmand Limit

pulldon Dmand Tim

Othr faturs includ: lo lin voltag; 115-volt controltransformr; thr-lg snsing ovrloads; has rotation

and singl-has failur rotction; high tmratur

safty rotction; motor currnt imbalanc and undrvolt-

ag saftis; on and clos SCR rotction; momntary

or intrrution rotction. Th LCSSS is coold by a

closd-loo, frsh atr circuit consisting of a atr-to-

atr hat xchangr and 1/25 Hp circulating um. All

intrconncting atr iing is factory installd and ratd

for 150 pSIG orking rssur. Optional unit-mountd

circuit brakr includs ground fault rotction and

rovids 65,000 am short-circuit ithstand rating in ac-

cordanc ith UL Standard 508. A non-fusd disconnct

sitch is also availabl. Both otions ar adlockabl.

BAS REMOTE CONTROL

A communication intrfac rmitting comlt xchang

of chillr data ith any BAS systm is availabl ith

otional ISN translator. ISN translator also allos BAS

systm to issu commands to th chillr to control its

oration. ISN translators com in to modls, controlling

u to four chillrs and ight chillrs rsctivly.

FACTORY INSULATION OF COOLER

Factory-applied thermal insulation of the exible, closed-

cll lastic ty, 3/4 (19mm) thick is attachd ith va-

por-proof cement to the evaporator shell, ow chamber,

vaorator tub shts, suction connction, and (as

ncssary) to th auxiliary tubing. Not includd is th

insulation of atr boxs and nozzls. This insulation

ill normally rvnt condnsation in nvironmnts ith

rlativ humiditis u to 75% and dry bulb tmraturs

ranging from 50 to 90F (10 to 32C). 1-1/2 (38mm)

thick insulation is also availabl for rlativ humiditis u

to 90% and dry bulb tmraturs ranging from 50 to

90F (10 to 32C).

wATER FLANGES

Four 150 Ib. ANSI raised-face anges, for condenser and

vaorator atr connctions, ar factory ldd to atr

nozzles. Companion anges, bolts, nuts and gaskets are

not includd.

SPRING ISOLATION MOUNTING

Sring Isolation mounting is availabl instad of standard

isolation mounting pads when desired. Four level-adjust-

ing/sring-ty vibration isolator assmblis ith non-skid

pads are provided with mounting brackets for eld instal-lation. Isolators ar dsignd for on-inch (25.4 mm)

deection.

wATER FLOw SwITCHES

Paddle-type, vapor-proof water ow switches suitable

for 150 sig (1034 Kpa) Dwp for chilld and condnsr

atr circuits. Sitch for 115V-1-50/60 Hz srvic. A

chilled water ow switch is required. Condenser water

ow switch is optional.

SEqUENCE CONTROL KIT

For to, thr or four units ith chilld atr circuits con-

nctd in sris or aralll, th kit consists of rturn atr

thrmostat, lad-lag slctor sitch for squnc starting,

and tim dlay rlay, ith NeMA-1 nclosurs, dsignd

for 115V-1-50/60 Hz.


19/56

19JOHNSON CONTROLS

FORM 160.80-EG1 (808

STARTER FIELD INSTALLED

A eld installed, electro-mechanical compressor motor

startr is availabl, slctd for ror siz and ty for

job requirements and in accordance with Johnson Controls

enginring Standard R-1079 for Startrs.

MARINE wATER BOXES

Marin atr boxs allo srvic accss for claning of

th hat xchangr tubs ithout th nd to brak th

atr iing. Boltd-on covrs ar arrangd for conv-

nint accss. ANSI/AwwA C-606 nozzl connctions ar

standard; anges are optional. Marine water boxes are

availabl for condnsr and/or vaorator.

KNOCK-DOwN SHIPMENT

The chiller can be shipped knocked-down into majo

assmblis (vaorator, condnsr, drivlin, tc.) as

rquird to rig into tight sacs. This is articularly conv-

nint for xisting buildings hr quimnt room accss

dos not allo rigging a factory ackagd chillr.

REFRIGERANT STORAGE/RECYCLING SYSTEM

A rfrigrant storag/rcycling systm is a slf-containd

ackag consisting of a rfrigrant comrssor ith oi

separator, storage receiver, water-cooled condenser, lte

drir and ncssary valvs and hoss to rmov, rlac

and distill rfrigrant. All ncssary controls and safty

dvics ar a rmannt art of th systm. Tyically no

rquird if unit isolation valvs ar rovidd.


20/56

0 JOHNSON CONTROLS

Unit Components


21/56

1JOHNSON CONTROLS

FORM 160.80-EG1 (808

29040A

OIL SepARATOR

MOTOR

TeRMINAL

BOX

CONDeNSeR

REAR VIEw


22/56

JOHNSON CONTROLS

Th folloing is a usrs guid in th alication and

installation ofMillennium Chillrs, and ill nsur th rli-

ability and troubl-fr lif for hich this quimnt as

dsignd. whil this guid is dirctd toards normal,

atr-chilling alications, th Johnson Controls sals

rrsntativs can rovid comlt rcommndationson othr tys of alications.

Location

Millnnium Chillrs ar virtually vibration-fr and gn-

rally can b locatd at any lvl in a building hr

th construction ill suort th total systm orating

ight.

The unit site must be a oor, mounting pad or foundation

hich is lvl ithin 1/4 (6.4 mm) and caabl of su-

orting th orating ight of th chillr.

Application Data

Sufcient clearance to permit normal service and mainte-

nanc ork should b rovidd all around and abov th

unit. Additional sac should b rovidd at on nd of

th unit to rmit claning of vaorator and condnsr

tubs as rquird. A dooray or othr rorly locatd

oning may b usd.

Th chillr should b installd in an indoor location

hr tmraturs rang from 40F to 110F (4.4C to

43.3C).

water Circuits

Flow Rate For normal atr chilling duty, vaorator

ow rates are permitted at water velocity levels in the

hat xchangrs tubs of btn 3 ft./scond and 12

ft./second (0.91 m/s and 3.66 m/s). Condenser ow rates

ar rmittd btn 3.33 ft./sc. and 12 ft./sc. (1.01

m/s and 3.66 m/s). Variable ow applications are possible,

TABLE 1 wATeR FLOw RATe LIMITS GpM (L/s)

shELL

CodE

EVaPorator CondEnsEr

Pass MInIMuM MaXIMuM MInIMuM MaXIMuM

Ba

1 308 -19.4 1173 -74 399 -25.2 1435 -90.5

2 147 -9.3 586 -37 209 -13.2 751 -47.4

3 97 -6.1 387 -24.4

BB

1 412 -25 8/9 1572 -99.2 510 -32 1/5 1830 -115.5

2 197 -12 2/5 786 -49.6 264 -16 2/3 948 -59 4/5

3 130 -8 1/5 516 -32.6

Ca

1 535 -33 4/5 2041 -128.8 677 -42.7 2438 -153 4/5

2 256 -16 1/5 1020 -64.4 355 -22.4 1277 -80 3/5

3 171 -10 4/5 680 -42 8/9

CB

1 700 -44.2 2675 -168.8 880 -55.5 3164 -80.6

2 335 -21.1 1337 -84.4 455 -28.7 1639 -103.4

3 223 -14.1 891 -56.2

da

1 664 -41.9 2534 -159.9 1215 -76.7 4376 -276.1

2 317 -20 1267 -79.9 630 -39.8 2269 -143.2

3 212 -13.4 844 -53.3

dB

1 943 -59.5 3602 -227.3 1595 -100.6 5740 -362.2

2 451 -28.5 1793 -113.1 820 -51.7 2950 -186.1

3 301 -19 1195 -175.4

dC

1 1257 -79.3 4810 -303.5

2 602 -38 2405 -151.8

3 399 -25.2 1595 -100.6

Ea

1 637 -40.2 2546 -160.6 1223 -77.2 4406 -270.8

2 317 -20 1267 -79.7 639 -40.3 2300 -145.1

3 212 -13.4 844 -53.3

EB

1 904 -57 3613 -228 1602 -101.1 5770 -364.1

2 452 -28.5 1805 -113.9 828 -55.2 2982 -188.23 301 -19 1196 -75.5

EC

1 1203 -75.9 4810 -303.5

2 602 -38 2405 -151.8

3 399 -25.2 1595 -100.6

Fa

1 1203 -75.9 4810 -303.5 2019 -127.4 7267 -458.5

2 602 -38 2405 -151.8 1043 -65.8 3755 -236.9

3 399 -25.2 1595 -100.6

FB

1 1605 -101.3 6418 -405 2726 -172 9822 -619.8

2 802 -50.6 3202 -202 1397 -88.2 5030 -317.4

3 534 -33.7 2135 -134.7

FC

1 2136 -134.8 8541 -538.9

2 1068 -67.4 4270 -269.4

3 710 -44.8 2839 -179.1


23/56

JOHNSON CONTROLS

FORM 160.80-EG1 (808

and initial chillr slctions should b mad accordingly to

permit proper range of ow while maintaining the minimum

velocity noted above. Variable ow in the condenser is not

rcommndd, as it gnrally raiss th nrgy consum-

tion of th systm by king th condnsr rssur

high in th chillr. Additionally, th rat of fouling in thcondnsr ill incras at lor atr vlocitis associ-

ated with variable ow, raising system maintenance costs.

Cooling tors tyically hav narro rangs of oration

with respect to ow rates, and will be more effective with

full design ow. Ref. Table 1 for ow limits.

Temperature Ranges For normal atr chilling duty,

laving chilld atr tmraturs may b slctd

between 38F (3.3C) [36F (2.2C) with Smart Freeze

nabld) and 70F (21.1C) for atr tmratur rangs

btn 3F and 30F (1.7C and 16.7C).

water quality Th ractical and conomical alica-tion of liquid chillrs rquirs that th quality of th atr

suly for th condnsr and vaorator b analyzd by

a atr tratmnt scialist. watr quality may affct th

rformanc of any chillr through corrosion, dosition of

hat-rsistant scal, or sdimntation or organic groth.

Ths ill dgrad chillr rformanc and incras o-

rating and maintnanc costs. Normally, rformanc

may b maintaind by corrctiv atr tratmnt and

riodic claning of tubs. If atr conditions xist hich

cannot b corrctd by ror atr tratmnt, it may b

ncssary to rovid a largr alloanc for fouling, and/or

to scify scial matrials of construction.

General Piping All chilld atr and condnsr atr

iing should b dsignd and installd in accordanc

ith acctd iing ractic. Chilld atr and con-

dnsr atr ums should b locatd to discharg

through the chiller to assure positive pressure and ow

through th unit. piing should includ offsts to rovid

exibility and should be arranged to prevent drainage of

atr from th vaorator and condnsr hn th ums

ar shut off. piing should b adquatly suortd and

bracd indndntly of th chillr to avoid th imosi-

tion of strain on chillr comonnts. Hangrs must allo

for alignmnt of th i. Isolators in th iing and in

th hangrs ar highly dsirabl in achiving sound andvibration control.

Convenience Considerations To facilitat th r-

formanc of routin maintnanc ork, som or all of th

folloing sts may b takn by th urchasr. Coolr and

condnsr atr boxs ar quid ith luggd vnt and

drain connctions. If dsird, vnt and drain valvs may b

installd ith or ithout iing to an on drain. prssur

gaugs ith sto cocks, and sto valvs, may b installd

in th inlts and outlts of th condnsr and chilld atr

lin as clos as ossibl to th chillr. An ovrhad monorail

or bam may b usd to facilitat srvicing.

Connections Th standard chillr is dsignd for 150

sig (1034 kpa) dsign orking rssur in both th

chilld atr and condnsr atr circuits. Th connc

tions (atr nozzls) to ths circuits ar furnishd ith

groovs for ANSI/AwwA C-606 coulings. piing should

b arrangd for as of disassmbly at th unit for tubclaning. All atr iing should b thoroughly cland

of all dirt and debris before nal connections are made

to th chillr.

Chilled water A ow switch must be installed in the

chilld atr lin of vry unit. Th sitch must b locatd

in th horizontal iing clos to th unit, hr th straigh

horizontal runs on each side of the ow switch are at leas

ve pipe diameters in length. The switch must be electri

cally connctd to th chilld atr intrlock osition in

th unit control cntr. A atr strainr of maximum 1/8

(3.2 mm) perforated holes must be eld-installed in the

chilld atr inlt lin as clos as ossibl to th chillrIf locatd clos nough to th chillr, th chilld atr

pump may be protected by the same strainer. The ow

switch and strainer assure chilled water ow during unit

operation. The loss or severe reduction of water ow could

sriously imair th chillr rformanc or vn rsult in

tub frz u.

Condenser water Th chillr is nginrd for maxi-

mum efciency at both design and part-load operation

by taking advantag of th coldr cooling tor atr

tmraturs hich naturally occur during th int

months. Arciabl or savings ar ralizd from

ths rducd hads.

Th minimum ntring condnsr atr tmratur fo

othr full and art load conditions is rovidd by th fol-

loing quation:

For R-22; Min ECWT = LCHWT + 11+ [(% load/100)

x

(15 - full load condnsr atr T)]

For R-134a; Min ECWT = LCHWT + 16 + [(% load/100)

x

(10 - full load condnsr atr T)]

whr: eCwT = ntring condnsr atr tmra-

turLCHwT = laving chilld atr tmratur

MULTIPLE UNITS

Selection Many alications rquir multil units

to mt th total caacity rquirmnts as ll as to

provide exibility and some degree of protection agains

quimnt shutdon. Thr ar svral common uni

arrangmnts for this ty of alication. Th Millennium

Chillr has bn dsignd to b radily adatd to th

rquirmnts of ths various arrangmnts.


24/56

JOHNSON CONTROLS

Application Data - continued

FIG. 1 pARALLeL COOLeRS

pARALLeL CONDeNSeRS

FIG. SeRIeS COOLeRS

pARALLeL CONDeNSeRS

Parallel Arrangement (Rfr to Fig. 1) Chillrs may

b alid in multils ith chilld and condnsr atr

circuits connctd in aralll btn th units. Fig. 1 r-

rsnts a aralll arrangmnt ith to chillrs. paralll

chillr arrangmnts may consist of qually or unqually

sizd units. whn multil units ar in oration, thyill load and unload at qual rcntags of dsign full

load for th chillr.

Dnding on th numbr of units and orating char-

actristics of th units, loading and unloading schms

should be designed to optimize the overall efciency of

th chillr lant. It is rcommndd to us an vaora-

tor by-pass piping arrangement to bypass uid around

vaorator of any unit hich has cycld off at rducd load

conditions. It is also rcommndd to altrnat th chillr

cycling ordr to qualiz chillr starts and run hours.

Series Arrangement (Rfr to Fig. 2) Th chillrs mayb alid in airs ith chilld atr circuits connctd in

sris and condnsr atr circuits connctd in aralll.

All of the chilled water ows through both evaporators

ith ach unit handling aroximatly on-half of th

total load. whn th load dcrass to a customr s-

lctd load valu, on of th units ill b shut don by a

sequence control. Since all water is owing through the

orating unit, that unit ill cool th atr to th dsird

tmratur.

BRINE APPLICATIONS

Th YS Scr Chillr, utilizing th Frick Rfrigration com-rssor, is a good match for th high had rquirmnts of

lo tmratur brin alications. This is articularly tru

of thrmal ic storag systms, tyically rquiring 22F

(5.6C) to 24F (4.4C) laving brin tmraturs.

This rformanc is nhancd ith th standard thrmal

storag control mod dscribd on ag 6.

particular attntion must b aid to th alication of

to or mor chillrs ith vaorators in aralll or sris

hn th brin tmratur is blo 32F (0C). Th

brin MUST NOT ow through the evaporator of theidl chillr, bcaus it can caus th condnsr atr to

frz. A byass or othr ty of arrangmnt is rquird

that shuts off ow to the idle evaporator. When units are

alid in sris ith lad/lag caability, th units should

b idntical.

REFRIGERANT RELIEF PIPING

each chillr is quid ith rssur rlif dvics. Th

uros of th rlif dvics is to quickly rliv xcss

rssur of th rfrigrant charg to atmoshr, as a

safty rcaution in th vnt of an mrgncy such as

a re. They are set to relieve at an internal pressure of300 sig (2069 Kpa) and ar locatd on th condnsr,

vaorator and oil sarator; and ar rovidd in ac-

cordanc ith ASHRAe 15 Safty Cod and ASMe or

alicabl rssur vssl cod. whn rquird and ds-

ignatd on th ordr form, th rlif dvics ill satisfy th

euroan rquirmnts: (xaml VBG20). Undr ths

circumstancs th rlif dvics may b rlif valvs,

overow valves or type tested Safety Pressure switches

or a combination of ths dvics.

In addition to th sring-loadd, r-sating-ty rlif

valvs that ar sizd for rssur vssl volum, ach unit

is quid ith a rutur disk. This rutur disk is abl

to rliv th ntir uming caacity of th comrssor

if lctronic saftis fail, roviding rotction for rorty

and rsonnl. This dvic is st for 345 sig (2379 Kpa)

[45 psig above the re-seating relief valves set at 300 psig

(2069 Kpa)].

Sizd to th rquirmnts of alicabl cods, a vnt lin

must run from th rlif dvic to th outsid of th build-

ing. This rfrigrant rlif iing must includ a clanabl,


25/56

5JOHNSON CONTROLS

FORM 160.80-EG1 (808

TABLE MOTOR VOLTAGe VARIATIONS

vrtical-lg dirt tra to catch vnt-stack condnsation.

Vnt iing must b arrangd to avoid imosing a strain

on the relief connections and should include one exible

connction.

SOUND AND VIBRATION CONSIDERATIONS

AMillennium chiller is not a source of objectionable sound

and vibration in normal air conditioning alications.

Norn isolation mounts ar furnishd as standard

with each unit. Optional level-adjusting spring isolator as-

semblies designed for 1 static deection are available.

Millennium chillr sound rssur lvl ratings ill b

furnishd uon rqust.

Control of sound and vibration transmission must b takn

into account in th quimnt room construction as ll

as in th slction and installation of th quimnt.

THERMAL INSULATION

No arciabl orating conomy can b achivd by

thrmally insulating th chillr. Hovr, th chillrs

cold surfacs should b insulatd ith a vaor barrir

insulation sufcient to prevent condensation. A chiller can

b factory insulatd ith 3/4 (19mm) or 1-1/2 (38mm)

thick insulation, as an otion. This insulation ill normally

rvnt condnsation in nvironmnts ith dry bulb tm-

raturs of 50F to 90F (10C to 32C) and rlativ

humidities up to 75% [3/4 (19mm) thickness] or 90% [1-

1/2 (38mm) thicknss]. Th insulation is aintd and thsurface is exible and reasonably resistant to wear. It is

intndd for a chillr installd indoors and, thrfor, no

rotctiv covring of th insulation is usually rquird

If insulation is applied to the water boxes at the job site

it must b rmovabl to rmit accss to th tubs for

routin maintnanc.

VENTILATION

Th ASHRAe Standard 15 Safty Cod for Mchanica

Rfrigration rquirs that all machinry rooms b vntd

to th outdoors utilizing mchanical vntilation by on

or mor or-drivn fans. This standard, lus Nationa

Fir protction Association Standard 90A, stat, loca

and other related codes should be reviewed for specic

rquirmnts. Sinc th Millennium chillr motor is air-

coold, vntilation should allo for th rmoval of ha

from th motor.

In addition, th ASHRAe Standard 15 rquirs a rfrigr

ant vaor dtctor to b mloyd for all rfrigrants. It isto b locatd in ara hr rfrigrant from a lak ould

b likly to concntrat. An alarm is to b activatd and

th mchanical vntilation startd at a valu no gratr

than th TLV (Thrshold Limit Valu) of th rfrigrant.

ELECTRICAL CONSIDERATIONS

Motor Voltage Lo voltag motors (200 - 600 volts) ar

furnishd ith six lads. Mdium voltag (2300 - 4160

volts) motors hav thr lads. Motor circuit conducto

siz must b in accordanc ith th National elctrica

Cod (NeC), or othr alicabl cods, for th motor

full-load amrs (FLA). Flxibl conduit should b usdfor th last svral ft to th chillr in ordr to rovid

vibration isolation. Tabl 2 lists th alloabl variation in

voltag sulid to th chillr motor. Th unit namlat

is stamped with the specic motor voltage and frequency

for th aroriat motor.

Starters Th chillr is availabl ith a factory-mountd

and ird YORK Solid Stat Startr for 200 - 600 vol

alications. Othr tys of rmot mountd startrs ar

availabl. Ths lctro-mchanical startrs must b

furnishd in accordanc ith Johnson Controls Standard

R-1079 Specication. This will ensure that starter com

onnts, controls, circuits, and trminal markings ill bsuitabl for rquird ovrall systm rformanc.

Controls A 115 volt, singl has, 60 or 50 Hrtz (4.5

kVa) or suly must b furnishd to th chillr from a

sarat, fusd disconnct or from a control transform

includd as an otion ith lctro-mchanical startrs

No eld control wiring is required, when the YORK SSS

is sulid.

Copper Conductors Only copper conductors should be

connected to compressor motors and starters.Aluminum

conductors hav rovn to b unsatisfactory hn con

nctd to cor lugs. Aluminum oxid and th diffrnc

Freq Rated VoltageOperating Voltage

Min. Max.

60Hz

200 200/208 180 220

230 220/240 208 254

380 380 342 415

416 416 375 457

460 440/460/480 414 508

575 575/600 520 635

2300 2300 2070 2530

3300 3300 2970 3630

4000 4000/4160 3600 4576

50Hz

346 346 311 381

380 380/400 342 423

415 415 374 440

3300 3300 2970 3630

NameplateVoltage


26/56

6 JOHNSON CONTROLS


in thrmal conductivity btn cor and aluminum

cannot guarant th rquird tight connction ovr a

long riod of tim.

Poer Factor Correction Capacitors Caacitors can

b alid to a chillr for th uros of or factor cor-

rction. For rmot-Mountd elctro-Mchanical Startrs,th caacitors should b locatd on th load sid of th

startr. For YORK SSS, th caacitors must b locatd on

th lin sid of th startr. Th caacitors must b sizd

and installd to mt th National elctrical Cod (NeC)

and be veried by JOHNSON CONTROLS.

Ampacity on Load Side of Starter elctrical or

ir siz to th chillr is basd on th minimum unit am-

acity. For YORK SSS, this iring is don at th factory.

For remote starters, the National Electrical Code denes

th calculation of amacity, as summarizd blo. Mor

specic information on actual amperage ratings will be

sulid ith th submittal draings.

Six-lad ty of starting (Star-Dlta)

Minimum circuit amacity r conductor (1 of 6):

Amacity = .721 x comrssor motor ams.

Thr-lad ty of starting

(Across-th-Lin, Autotransformr and

primary Ractor)

Minimum circuit amacity r conductor (1 of 3):

Amacity = 1.25 x comrssor motor ams.

Ampacity on Line Side of Starter Th only additional load on th circuit for th chillr ould

b th control transformr, unlss it is sulid by a

sarat sourc.

125% of compr. + FLA of all otherMin. Circuit Ampacity =

motor amps loads on the circuit

Branch Circuit Overcurrent Protection Th branch

circuit ovrcurrnt rotction dvic(s) should b a

tim-dlay ty, ith a minimum rating qual to th nxtstandard fus/brakr rating abov th calculatd valu.

It is calculatd taking into account th comrssor motor

ams and may also includ control transformr. Rfr to

submittal drawings for the specic calculations for each

alication.

MOTOR ELECTRICAL DATA

Th smallst motor availabl hich quals or xcds

th Inut or (kw) from th chillr rating rogram is

slctd from Tabls 3 and 4. Th full load amrs (FLA)

listd in th tabls ar maximum valus and corrsond

to th maximum motor kw listd. whn th Inut or

(kw) is lss than maximum motor kw, th FLA should b

rducd using th folloing quation:

FLA = Motor kw x Max. Motor FLA

Max. Motor kw

The benet from the FLA correction is the possible use of

smallr or iring and/or startr siz.

Th lockd rotor amrs (LRA) ar rad dirctly from

Tables 3 and 4 for specic Motor Code and voltage. This

is bcaus th LRA is dndnt only on motor siz and

voltag and is indndnt of inut or (kw).

Inrush amrs (IRA) dnd on LRA and th ty of

startr alid. Th inrush can b calculatd using a

rcntag of LRA shon in Tabl 5.


27/56

JOHNSON CONTROLS

FORM 160.80-EG1 (808

TABLE 60 HZ eLeCTRICAL DATA

NOTE: FLA = Full Load Ams; LRA = Lockd Rotor Ams

TABLE MOTOR STARTeRS

MOTOR CODE CF CG CH CJ CK CL CM CN CP CR CS CT CU CV CW CX CY CZ

KW (MAX.) 125 144 161 190 214 240 257 276 302 333 368 395 435 478 514 542 578 617

SHAFT HP 154 177 201 237 270 302 327 351 385 424 468 503 554 608 655 690 740 790FL EFF. % 92 92 93 93 94 94 95 95 95 95 95 95 95 95 95 95 95.5 95.5

FL PF 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9

VOLTS

208FLA 389 447 507 594 680 757 799 886 975 1043 1162

LRA 2702 3235 3235 3962 4732 5096 5689 6011 6011 7644 8106

230FLA 352 404 464 540 610 685 749 804 882 944 1050 1130 1250

LRA 2598 2598 2865 3460 3 788 4 260 4 755 5 162 5 780 5 780 6900 7400 7724

240FLA 337 387 445 518 585 656 718 771 845 905 1006 1083 1198

LRA 2711 2711 3120 3610 3 953 4 445 4 962 5 386 6 031 6 031 7200 7722 8060

380FLA 217 249 285 336 378 421 453 487 534 571 636 684 756 817 879 942 997 1065

LRA 1385 1385 1730 2153 2500 2577 2955 3254 3637 3810 4179 4480 4671 5326 5780 6782 5780 6644

416 FLA199 228 260 307 346 385 412 445 488 522 581 625 691 747 810 860 911 973

LRA 1385 1385 1638 1967 2190 2356 2700 2976 3536 3637 3810 3810 4270 4869 5640 5780 5694 6069

440FLA 184 211 238 281 319 358 392 397 461 493 549 591 646 706 759 813 861 920

LRA 1177 1301 1320 1655 1865 2037 2485 2485 2976 2976 3300 3644 3644 4209 4783 5357 4783 5249

460

FLA 176 202 228 269 305 342 375 380 441 472 525 565 618 675 726 778 824 880

LRA 1230 1360 1380 1730 1950 2130 2598 2598 3111 3111 3450 3810 3810 4400 5000 5600 5000 5488

480FLA 169 194 219 258 292 328 359 364 423 452 503 541 592 647 696 746 790 843

LRA 1283 1419 1440 1805 2035 2223 2711 2711 3246 3246 3600 3976 3976 4591 5217 5843 5217 5727

575FLA 141 162 185 216 250 274 300 318 353 377 420 452 500 540 581 622 659 704

LRA 909 909 1100 1384 1556 1700 1900 2066 2078 2413 2760 2960 3089 3550 4039 4440 4300 4200

600FLA 135 155 177 207 240 263 288 305 338 361 403 433 479 518 557 596 632 675

LRA 949 949 1148 1444 1624 1774 1983 2156 2168 2518 2880 3089 3223 3704 4215 4633 4484 4383

2300 FLA 36 41 46 54 61 68 74 79 87 95 105 113 124 135 146 154 165 176LRA 240 267 298 340 397 435 480 520 530 570 669 719 791 867 935 960 1008 1100

3300FLA 25 29 32 38 43 48 52 55 61 66 73 79 86 94 102 108 115 123

LRA 160 175 210 240 280 310 310 343 382 383 466 501 551 576 652 682 719 744

4000FLA 21 24 27 31 36 40 43 46 50 54 60 65 71 78 84 89 95 101

LRA 135 154 166 195 230 240 260 283 315 315 384 413 455 499 538 540 554 631

4160FLA 20 23 26 30 34 38 41 44 48 52 58 63 68 75 81 85 91 97

LRA 140 160 173 203 239 250 270 294 328 328 399 430 473 519 560 562 576 656

TYPE STARTER STAR DELTA AUTO TRANSFORMER ACROSS THE LINE PRIMARY REACTOR

VOLTAGE LOW LOW LOW LOW LOW/HIGH LOW/HIGH LOW/HIGH HIGH HIGH

60HZ 200-600 200-600 200-600 200-600 200-4160 200-4160 200-4160 2300-4160 2300-4160

50 HZ 380-415 346-415 346-415 346-415 346-3300 346-3300 346-3300 2300-3300 2300-3300

NONE 45 CLOSED 33 OPEN 33 CLOSED 80 64 100 CLOSED 65 65 CLOSED 80 80

SOLID STATE

STARTER

TRANSITION % TAP

INRUSH AS A % OF

LRA

CLOSED 57.7

33

CLOSED 65

42.3


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8 JOHNSON CONTROLS

TABLE 5 50 HZ eLeCTRICAL DATA

NOTE: 1. Chiller performance for 50 Hertz applications is outside the scope of the ARI Certication Program.2. FLA = Full Load Ams; LRA = Lockd Rotor Ams


TABLE 6 AVAILABLe COMpReSSOR/SHeLL/MOTOR COMBINATIONS (R-22 & R-134a)

Motor

CodE5CC 5Cd 5CE 5CF 5CG 5Ch 5CI 5CJ 5CK 5CL 5CM 5Cn 5Co 5CP 5CQ 5Cr 5Cs

shaFt hP

FL EFF. %FL PF

121 136 160 180 201 215 231 254 280 309 332 366 402 432 455 481 518

148 168 198 225 252 272 292 321 353 390 419 462 507 546 575 608 658

91.1 92.4 92.4 93.4 93.4 94.2 94.2 94.2 94.2 94.2 94.2 94.2 94.2 94.2 94.2 94.2 94.7

0.86 0.86 0.86 0.86 0.86 0.86 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.88

VoLts aMPErEs (MaX)

346FLa 224 258 302 340 380 417 437 481 528 584 630 692 578 816 860 909 982

Lra 1385 1721 1790 2208 2467 2598 2840 3081 3350 3706 3810 4177 4830 4944 5373 5780 5780

380FLa 204 235 275 309 346 379 398 438 481 532 572 630 690 743 783 841 895

Lra 1385 1385 1640 1890 2144 2464 2590 2806 3050 3375 3700 3810 4400 4500 4892 5600 5491

400FLa 194 223 261 294 329 360 378 416 457 505 543 599 656 706 744 799 850

Lra 1458 1458 1726 1990 2257 2594 2726 2954 3211 3553 3895 4011 4632 4737 5150 5895 5780

415FLa 187 215 252 284 317 347 364 401 441 487 526 577 632 680 717 764 819

Lra 1283 1385 1490 1700 2031 2175 2366 2569 2794 3088 3402 3478 3810 4117 4480 5130 5108

3300FLa 24 27 32 36 41 44 47 50 56 62 66 73 80 87 91 96 103

Lra 159 162 209 236 241 274 294 318 317 388 423 455 499 516 572 614 644

CoMPrEssor

CodE

CooLEr

shELL

CondEnsEr

shELL

Motor CodE

r-22, 60 hZ r-134a, 60 hZ r-22, 50 hZ

s0BA, BB BA, BB, CA, CB

CF, CG, CH CF, CG, CH 5 CC, 5 CDCA, CB BA, BB, CA, CB

s1 BA, BB BA, BB, CA, CB CF, CG, CH,CJ, CK

CF, CG, CH, 5 CC, 5 CD, 5 CE,5 CFCA, CB BA, BB, CA, CB CJ, CK

s2CA, CB CA, CB, DA, DB CG, CH, CJ,

CK, CL, CM

CF, CG, CH, CJ

CK, CL, CM

5 CD, 5 CE, 5 CF,

DA, DB, DC CA, CB, DA, DB 5 CG, 5 CH

s3 DA, DB, DC CA, CB, DA, DBCJ, CK, CL, CM,

CN, CP, CR

CG, CH, CJ, CK

CL, CM, CN, CP, CR

5 CF, 5 CG, 5 CH,

5 CI, 5 CJ, 5 CK

s4EA, EB, EC

FA, FB, FC

EA, EB, FA, FB

FA, FB

CK, CL, CM, CJ, CK, CL, CM, CN, CP, 5 CF, 5 CG,

CN, CP, CR, CR, CS, CT, CU, CV 5 CH, 5 CI,

s5 FA, FB, FC FA, FBCS, CT, CU,

CV

CK, CL, CM, CN, CP, CR

CS, CT, CU, CV

5 CJ, 5 CK,

5 CL, 5 CM,

5 CN, 5 CO


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9JOHNSON CONTROLS

FORM 160.80-EG1 (808

TABLE AVAILABLe COMpReSSOR/SHeLL/MOTOR COMBINATIONS (50 HZ, R-134a ONLY)

CoMPrEssor

CodE

CooLEr

shELL

CondEnsEr

shELLMotor CodE

s0

BA, BB BA, BB, CA, CB 5 CC, 5 CD

CA, CB BA, BB, CA, CB

s1BA, BB BA, BB, CA, CB 5 CC, 5 CD,

CA, CB BA, BB, CA, CB 5 CE, 5 CF

s2

BA, BB BA, BB, CA, CB 5 CC, 5 CD,

CA, CB BA, BB, CA, CB, DA, DB 5 CE, 5 CF,

DA, DB, DC CA, CB, DA, DB 5 CG, 5 CH

s3CA, CB CA, CB, DA, DB 5 CC, 5 CD, 5 CE, 5 CF,

DA, DB, DC CA, CB, DA, DB 5 CG, 5 CH, 5 CI, 5 CJ, 5 CK

s4

DA, DB, DC CA, CB, DA, DB 5 CE, 5 CF, 5 CG, 5 CH,

EA, EB, EC EA, EB, FA, FB 5 CI, 5 CJ, 5 CK, 5 CL,

FA, FB, FC EA, EB, FA, FB 5 CM, 5 CN, 5 CO

s5

EA, EB, EC EA, EB, FA, FB 5 CF, 5 CG, 5 CH, 5 CI,

FA, FB, FC EA, EB, FA, FB5 CJ, 5 CK, 5 CL,

5 CM, 5 CN, 5 CO


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0 JOHNSON CONTROLS

Dimensions Std

NOTES:

1. All dimensions are approximate. Certied dimensions are available on request.

2. Dtrmin ovrall unit lngth by adding atr box dimnsion to tub sht lngth:

5-1/4 for comact rturn box

14 for comact atr box ith ANSI/AwwA C-606 coulings atr nozzls

Add 1/2 to each compact water box with optional anged water nozzles

3. Unit hight includs stl mounting lats undr tub shts. To dtrmin ovrall hight, add 7/8 for norn isolators

(1 for otional sring isolators).

S0 - S COMPRESSORR- & R-1a UNITS

(50 and 60 Hz)

REFRIGERANT RELIEF VALVE CONNECTIONS

Rfr to Tabls 6 and 7 on ags 26 & 27 for valid comrssor/shll/motor combinations.

dIMEnsIon

s0 and s1 CoMPrEssor s2 CoMPrEssor s2 and s3 CoMPrEssor

shELL CodEs (EVaPorator CondEnsEr)

B-B B-C C-B C-C B-B B-C C-B C-C C-d d-C d-d

a 42-7/8 52-1/2 52-1/2

a1 46-3/4 46-1/4 4-6-3/4 46-1/4 53-3/4 53-3/4

B oVEraLL hEIGht3 58-5/8 511-1/2 510-1/4 511-1/2 511-1/4 63-1/4 63-1/4 63-1/4 67-5/8 68-3/4 69-3/8

C CooLEr C/L 11-7/8 15 15

d CondEnsEr C/L 011-5/8 12-1/4 12-1/4

shELL CodE EVaPorator sIZE CondEnsEr sIZE

B, C 3/4 FPT SINGLE 3/4 FPT DUAL

d 1 FPT SINGLE 3/4 FPT DUAL

CoMPrEssor CodE oIL sEParator sIZE

S0, S1 2 RUPTURE DISK & 3/4 FPT SINGLE

S2, S3 2 RUPTURE DISK & 3/4 FPT DUAL


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1JOHNSON CONTROLS

FORM 160.80-EG1 (808

S - S5 COMPRESSORR- & R-1a UNITS

(50

chiller - yr

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