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FORM 160.

78-EG1 (610)

Model YMC² Magnetic Bearing Centrifugal Liquid Chillers


Design Level A

215 THROUGH 380 TONS


Products are produced at a (755 through 1340 kW)
facility whose quality-
management systems are Utilizing HFC R-134a
ISO9001 certified.
FORM 160.78-EG1 (610)

Table of Contents
FORM 160.78-EG1 (610)........................................................................................................................................................................................ 1
Introduction............................................................................................................................................................................................................ 3
Ratings................................................................................................................................................................................................................... 6
OptiView Control Center....................................................................................................................................................................................... 7
OptiSpeed™ Variable Speed Drive.................................................................................................................................................................... 14
Unit Components................................................................................................................................................................................................. 16
Mechanical Specifications.................................................................................................................................................................................. 18
Accessories and Modifications.......................................................................................................................................................................... 22
Application Data.................................................................................................................................................................................................. 23
Nomenclature...................................................................................................................................................................................................... 28
Dimensions (Ft. - In.)  -  Unit............................................................................................................................................................................... 30
Dimensions (Ft. - In.)  -  Nozzle Arrangements................................................................................................................................................. 31
Dimensions (Ft. - In.) - Evap Compact Waterboxes......................................................................................................................................... 32
Dimensions (Ft. - In.)  -  Nozzle Arrangements................................................................................................................................................. 33
Dimensions (Ft. - In.) - Cond Compact Waterboxes......................................................................................................................................... 34
Dimensions (Ft. - In.)  -  Nozzle Arrangements................................................................................................................................................. 35
Dimensions (Ft. - In.)  -  Nozzles......................................................................................................................................................................... 36
Dimensions (Ft. - In.)  -  Nozzle Arrangements................................................................................................................................................. 37
Dimensions (Ft. - In.)  -  Nozzles......................................................................................................................................................................... 38
Weights - English................................................................................................................................................................................................ 39
Dimensions (mm)  -  Unit..................................................................................................................................................................................... 40
Dimensions (mm)  -  Nozzle Arrangements....................................................................................................................................................... 41
Dimensions (mm)  -  Evap Nozzle Arrangements............................................................................................................................................. 42
Dimensions (mm) - Cond Compact Water Boxes............................................................................................................................................. 43
Dimensions (mm)  -  Cond Nozzle Arrangements............................................................................................................................................. 44
Dimensions (mm)  -  Nozzle Arrangements....................................................................................................................................................... 45
Dimensions (mm)  -  Nozzles.............................................................................................................................................................................. 46
Dimensions (mm)  -  Nozzle Arrangements....................................................................................................................................................... 47
Dimensions (mm)  -  Nozzles.............................................................................................................................................................................. 48
Weights - SI.......................................................................................................................................................................................................... 49
Guide Specifications........................................................................................................................................................................................... 50
SI Metric Conversion........................................................................................................................................................................................... 55

2 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Introduction
The YORK® YMC²™ offers a full package of features for better efficiency than existing designs at both at full and
total owner satisfaction. part load conditions.

EFFICIENCY Real-World Energy Performance


Johnson Controls pioneered the term “Real-World En-
• Lower energy costs achieved with up to 10% better ergy” to illustrate the energy-saving potential of focusing
efficiency than existing designs at both at full and part on chiller performance during off-design conditions. Off-
load conditions. design conditions are not only seen at part load, but at full
• Space saving design takes up less space in the me- load operation as well, by taking advantage of reduced
chanical room. entering condenser water temperatures (ECWTs). This
• Accurate performance by our best-in-class Johnson is where chillers operate 99% of the time, and where
Controls intuitive chiller control and seamless BAS operating costs add up. YORK YMC² are the only chill-
integration. ers designed to operate on a continuous basis with cold
ECWT and full condenser flow at all load points, taking full
SUSTAINABILITY advantage of Real-World conditions. This type of operation
benefits the cooling tower as well; reducing cycling of the
• Lower direct and indirect environmental impact fan motor and ensuring good coverage of the cooling fill.
through: YORK YMC² chillers offer the most efficient Real-World
o Reduced total energy consumption. operation of any chiller, meaning lower operating costs
and an excellent return on your chiller investment.
o A leak-free design using environmentally friendly
HFC R-134a .
Efficiency Proven in the Most Demanding Applica-
o 30% lower refrigerant charge than traditional tions
systems available in the market. YORK single-stage compressors are working to reduce
o Elimination of oil from the system due to our ex- energy costs. High strength aluminum-alloy compressor
perienced use of the magnetic bearings system. impellers feature backward-curved vanes for high ef-
ficiency. Airfoil shaped pre-rotation vanes minimize flow
QUIET OPERATION disruption for the most efficient part load performance.
Precisely positioned, they allow the compressor to unload
• The quietest performance available in the market smoothly from 100% to minimum load for excellent opera-
(sound rate by ARI 575 rating of less than 73 dBA at tion in air conditioning applications.
full load) made possible, in part, through the use of
YORK OptiSound™ Control and the employment of Space Saving Design Takes Up Less Space in the
magnetic bearing technology. Mechanical Room.
• Quiet throughout its broad operating range (capacity The heat exchangers at YORK YMC² offer the latest
and lift) with magnetic bearing technology. technology such as falling film in addition to the latest
technology in heat transfer surface design to give you
RELIABILITY maximum efficiency, reduced refrigerant charge, and
a compact design. The largest unit has only a 14’ heat
• Highest uptime operation with fewer parts. exchanger length.
• Using proven magnetic driveline technology that has
been incorporated in YORK chiller designs for more Accurate Performance By an Intuitive OPTIVIEW™
than 10 years. Control Center and Seamless BAS Integration
• Field Serviceability and fully trained service support. The YORK OptiView Control Center, furnished as standard
on each chiller, provides the ultimate in efficiency, monitor-
EFFICIENCY ing, data recording, chiller protection and operating ease.
The OptiView Control Center is a factory-mounted, wired
Matched Components Maximize Efficiency and tested state-of-the-art microprocessor based control
Actual chiller efficiency cannot be determined by analyzing system for HFC R-134a centrifugal chillers.
the theoretical efficiency of any one chiller component. It
requires a specific combination of heat exchanger, com- Setpoints can be changed from a remote location via
pressor, and motor performance to achieve the lowest 0-10VDC, 4-20mA, contact closures or through serial
system kW/ton. YORK YMC² technology matches chiller com-munications. The adjustable remote reset range [up
system components to provide maximum chiller efficiency to 20°F (11.1°C)] provides flexible, efficient use of remote
under actual – not just theoretical – operating conditions. signal depending on reset needs. Serial data interface
YORK YMC² lower energy costs achieved with up to 10% to the Building Automation System (BAS) is through

JOHNSON CONTROLS 3
FORM 160.78-EG1 (610)

Introduction - continued
the optional factory mounted E-Link installed inside the QUIET OPERATION
Control Center
OPTISOUND™ CONTROL
SUSTENTABILITY
YORK YMC² chillers are equipped with YORK OptiSound-
Lower Direct and Indirect Environmental Impact. Control as standard. OptiSound Control is a patented
98% of the global warming potential of a centrifugal chiller combination of centrifugal-chiller hardware and software
is from the indirect effect – or the greenhouse gases pro- that reduces operational sound levels, expands the chiller
duced to produce the electricity to run the chiller. 2% of the operating range, and improves chiller performance. The
GWP is from the direct effect or release of the refrigerant OptiSound™ Control feature continuously monitors the
gases into the atmosphere. characteristics of the compressor-discharge gas and
optimizes the diffuser spacing to minimize gas-flow dis-
The YORK YMC² chiller and its superior efficiency ruptions from the impeller. It can also reduce part-load
levels really reduce the indirect effect sound levels below the full-load level
To address the direct effect, the YORK YMC², first reduces
the chances for refrigerant leaks by dramatically reduc- Quiet Operating Range with Magnetic Bearing Tech-
ing the number of connections, down 57% compared to nology
traditional chiller designs. Then we have employed fall- We utilized a permanent-magnet motor and active mag-
ing film evaporator technology that reduces the overall netic-bearing technology to eliminate the friction losses
refrigerant charge by 30% and improves the efficiency of associated with oil-lubricated bearings and also eliminates
the evaporator. This can help qualify your project for up driveline sound.
to 2 more LEED points using the advanced refrigerant-
management credit. Finally, by eliminating the lubrication RELIABILITY
system, the YMC2 lets you avoid all the environmental
issues of handling and disposing refrigerant saturated Single-Stage Compressor Design for Highest uptime
oil. Add it all up and you will see why you can count on operation with fewer parts.
the YORK YMC² to yield a positive environment result. Designed for the most reliable chillers we’ve ever made,
the YMC² YORK Magnetic Bearing you will achieve a
Environmentally Friendly HFC R-134a much better result than the phase-out 2015 HCFC-123
The YORK YMC² chiller employs one the most environ- Centrifugal compressors are based on a successful line
mentally friendly refrigerant available, HFC R-134a , with of efficient YORK single-stage compressors. With fewer
no Ozone Depletion Potential and no phase out date per moving parts and straightforward design, YORK single-
the Montreal Protocol. stage compressors have proven durability in numerous
applications especially applications where minimal down-
You will achieve a much better result than the soon-to-be time is a critical concern.
phasd-out HCFC-123 by using the US Green Building
Council's (USGBC) Template EAc4 (Enhanced Refriger- OPTISPEED™ Variable Speed Drive (VSD) Technology
ant Management) to calculate the refrigerant impact at to delivery Low Harmonics and Flexible Power Input
your project. The YORK YMC² chiller will always be driven by a John-
son Controls OptiSpeed Variable Speed Drive (VSD) to
Environmental Heat Exchangers Technology ensure optimal Real-World performance especially at
The heat exchangers utilized on the YORK YMC² in- part load conditions. Beyond chiller efficiency there are
troduce a proprietary falling film evaporator design that several distinct advantages with the OptiSpeed Variable
helps not only operate more efficiently, but also allows Speed Drive (VSD). First, the OptiSpeed is equipped
us to reduce our refrigerant charges up to 30% beyond with a standard, factory packaged, IEEE-519 harmonic
conventional chiller designs. filter to ensure the % current Total Harmonic Distortion
(THD) is kept below 5% and that a chiller power factor
Elimination of Lubrication System and Oil Manage- of at least 0.97 is maintained. Second, to ensure equip-
ment Hardware ment safety and longevity this chiller is equipped with the
To ensure maximum efficiency, the YORK YMC² utilizes option of either a circuit breaker of a disconnect switch.
a hermetically sealed permanent magnet motor. The Third, a myriad of voltage options are available to serve
compressor is directly driven by the motor, eliminating any our global customers: 380V and 460V (60 Hz), 400V and
losses from using gears for power transmission. Active 415V (50Hz).
magnetic bearings are used to support the motor shaft
allowing this chiller series to be completely OIL FREE Factory Packing Reduces Field Labor Costs and In-
with no oil management system required. crease Reliability
YORK YMC² chillers are designed to keep installation
4 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

costs low. Where installation access is not a problem, why we’ve used this magnetic drive in our military-grade
the unit can be shipped completely packaged including chillers since 1999.
the unit mounted OptiSpeed™ Variable Speed Drive
(VSD), requiring minimal piping and wiring to complete Field Serviceability and Fully Trained Service Support
the installation. YORK YMC² incorporate service design principles that
are consistent with our Model YK Centrifugal Chillers. We
Using Proven Magnetic Driveline Technology That made sure that this chiller, and specifically the driveline,
Has Been Incorporated in YORK Chiller Designs for was field serviceable by a single source supplier, who
More Than 10 years happens to be the industry’s largest service force, differ-
The majority of chiller components on the YMC² have been ent of ours competitors, they need to purchase a back-up
time tested in the tens of thousands of YK chillers operat- driveline to be used while the original driveline is sent back
ing globally. YORK YMC² employ the most advanced drive to the factory for servicing.
available - an active magnetic-bearing drive - to levitate
the driveshaft in mid-air. The result is frictionless operation
and fewer moving parts subject to breakdown, which is

JOHNSON CONTROLS 5
FORM 160.78-EG1 (610)

Ratings
TAKE ADVANTAGE OF COLDER COOLING TOWER as complying with the certification sections of the latest
WATER TEMPERATURES issue of AHRI Standard 550/590. Under this Certification
Program, chillers are regularly tested in strict compliance
The YORK YMC² chillers have been designed to take full
with this Standard. This provides an independent, third-
advantage of colder cooling tower water temperatures,
party verification of chiller performance.
which are naturally available during most operating hours.
Considerable energy savings are available by letting tower
COMPUTERIZED PERFORMANCE RATINGS
water temperature drop, rather than artificially holding it
above 75°F (24°C), especially at low load, as some chill- Each chiller is custom-matched to meet the individual
ers require. building load and energy requirements. A variety of
standard heat exchangers and pass arrangements are
available to provide the best possible match.
YMC2 Performance - 250 Tons
45% Variation It is not practical to provide tabulated performance for
A
each combination, as the energy requirements at both full
and part load vary significantly with each heat exchanger
kW/Ton

B and pass arrangement. Computerized ratings are avail-


able through each Johnson Controls sales office. These
C ratings can be tailored to specific job requirements, and
D are part of the AHRI Certification Program.
A 85F ECWT B 75F ECWT
C 65F ECWT D 55F ECWT OFF-DESIGN PERFORMANCE
20% 30% 40% 50% 60% 70% 80% 90% 100% Since the vast majority of its operating hours are spent
% Load at off-design conditions, a chiller should be chosen not
only to meet the full load design, but also for its ability to
perform efficiently at lower loads and lower tower water
U.L. ACCEPTANCE – YOUR ASSURANCE OF RELI-
temperatures. It is not uncommon for chillers with the
ABILITY
same full load kW/ton to have an operating cost difference
YORK YMC² chillers are approved to UL Standard 1995 of over 10% due to part-load operation.
for listing by a qualified nationally recognized testing
laboratory for the United States and Canada. Recognition Part load information can be easily and accurately gener-
of safety and reliability is your assurance of trouble-free ated by use of the computer. And because it is so important
performance in day-to-day building operation. to an owner’s operating budget, this information has now
been standardized within the AHRI Certification Program
in the form of an Integrated Part Load Value (IPLV), and
Non-Standard Part Load Value (NPLV).

The IPLV/NPLV formulas from AHRI Standard 550/590


much more closely track actual chiller operations, and pro-
vide a more accurate indication of chiller performance than
the previous IPLV/APLV formula. A more detailed analysis
Rated in accordance with the latest must take into account actual building load profiles, and
issuance of ARI Standard 550/590. local weather data. Part load performance data should be
obtained for each job using its own design criteria.
AHRI CERTIFICATION PROGRAM
The performance of YORK YMC² chiller has been certified
to the Air Conditioning and Refrigeration Institute (AHRI)

6 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

OptiView Control Center

OPTIVIEW CONTROL CENTER Security access is provided to prevent unauthorized


changes of setpoints. This is accomplished with three
The YORK OptiView Control Center, furnished as standard
different levels of access and passwords for each level.
on each chiller, provides the ultimate in efficiency, monitor-
There are certain screens, displayed values, program-
ing, data recording, chiller protection and operating ease.
mable setpoints and manual controls not shown that are
The OptiView Control Center is a factory-mounted, wired
for servicing the chiller. They are only displayed when
and tested state-of-the-art microprocessor based control
logged in at service access level. Included in this is the
system for HFC R-134a centrifugal chillers. The panel is
Advanced Diagnostics and troubleshooting information
configured with a 10.4-in. (264 mm) diagonal color Liquid
for the chiller and the panel.
Crystal Display (LCD) surrounded by “soft” keys, which
are redefined with one keystroke based on the screen
The panel is fused through a 1-1/2 or 2 KVA transformer
displayed at that time. This revolutionary development
in the compressor motor starter to provide individual
makes chiller operation quicker and easier than ever
over-current protected power for all controls. Num-
before. Instead of requiring keystroke after keystroke to
bered terminal strips for wiring such as Remote Start/
hunt for information on a small monochrome LCD screen,
Stop, Flow Switches, Chilled Water Pump and Local or
a single button reveals a wide array of information on a
Remote Cycling devices are provided. The Panel also
large, full-color illustration of the appropriate component,
provides field interlocks that indicate the chiller status.
which makes information easier to interpret. This is all
These contacts include a Remote Mode Ready-to-Start,
mounted in the middle of a keypad interface and installed
a Cycling Shutdown, a Safety Shutdown and a chiller Run
in a locked enclosure.
contact. Pressure transducers sense system pressures
and thermistors sense system temperatures. The output
The LCD display allows graphic animated display of the
of each transducer is a DC voltage that is analogous to
chiller, chiller sub-systems and system parameters; this
the pressure input. The output of each thermistor is a DC
allows the presentation of several operating parameters
voltage that is analogous to the temperature it is sensing.
at once. In addition, the operator may view a graphical
representation of the historical operation of the chiller as
Setpoints can be changed from a remote location via
well as the present operation. A Status Bar is displayed
0-10VDC, 4-20mA, contact closures or through serial
at all times on all screens. It contains the System - Status
communications. The adjustable remote reset range [up
Line and Details Line, the Control Source, Access Level,
to 20°F (11.1°C)] provides flexible, efficient use of remote
Time and Date.
signal depending on reset needs. Serial data interface
to the Building Automation System (BAS) is through
The locations of various chiller parameters are clearly
the optional factory mounted E-Link installed inside the
marked and instructions for specific operations are pro-
Control Center
vided for on many of the screens. The panel verbiage is
available in eight languages and can be changed on the
The operating program is stored in non-volatile memory
fly without having to turn off the chiller. Data can be dis-
(EPROM) to eliminate chiller failure due to AC power
played in either English or Metric units plus keypad entry
failure/battery discharge. Programmed setpoints are
of setpoints to 0.1 increments.
JOHNSON CONTROLS 7
FORM 160.78-EG1 (610)

OptiView Control Center - continued


retained in lithium battery-backed RTC memory for 10 • Evaporator Saturation Temperature
years minimum. • Condenser Liquid Temperature – Leaving
• Condenser Liquid Temperature – Return
Smart Freeze Point Protection will run the chiller at 36°F
(2.2°C) leaving chilled water temperature, and not permit • Condenser Pressure
nuisance trips on Low Water Temperature. The sophis- • Condenser Saturation Temperature
ticated program and sensor will monitor the chiller water • % Full Load Amps
temperature to prevent freeze up. Every programmable
• Current Limit
point has a pop-up screen with the allowable ranges, so
that the chiller can not be programmed to operate outside
The EVAPORATOR screen displays a cutaway view of the
of its design limits.
chiller evaporator. All setpoints relating to the evaporator
side of the chiller are maintained on this screen. Animation
When the power is applied to the chiller, the HOME screen
of the evaporation process indicates whether the chiller is
is displayed. This screen displays a visual representation
presently in RUN condition (bubbling) and liquid flow in the
of the chiller and a collection of data detailing important
pipes is indicated by alternating shades of color moving
operations and parameters. When the chiller is running
in and out of the pipes. Adjustable limits on the low water
the flow of chilled liquid is animated by the alternating
temperature setpoints allow the chiller to cycle on and off
shades of color moving in and out of the pipe nozzles. The
for greater efficiency and less chiller cycling. The chiller
primary values that need to be monitored and controlled
cycles off when the leaving chilled water temperature is
are shown on this screen. They are as follows:
below setpoint and is adjustable from 1°F (0.55°C) below
to a minimum of 36°F (2.2°C). Restart is adjustable from
Display Only
setpoint up to a max of 80°F (44.4°C). The panel will
• Chilled Liquid Temperature – Leaving check for flow to avoid freeze up of the tubes. If flow is
• Chilled Liquid Temperature – Return interrupted shutdown will occur after a minimum of two
• Condenser Liquid Temperature – Return seconds. From this screen you can perform the following.
• Condenser Liquid Temperature – Leaving
Display Only
• Motor Run (LED)
• Chilled Liquid Flow Switch (Open/Closed)
• % Full Load Amps
• Chilled Liquid Pump (Run/Stop)
• Operating Hours
• Evaporator Pressure
• Input Power (kW)
• Evaporator Saturation Temperature
With the “soft” keys the operator is only one touch away • Return Chilled Liquid Temperature
from the 8 main screens that allows access to the major • Leaving Chilled Liquid Temperature
information and components of the chiller. The 8 screens • Evaporator Refrigerant Temperature
are the SYSTEM, EVAPORATOR, CONDENSER,
• Small Temperature Difference
COMPRESSOR, CAPACITY CONTROL, MOTOR, SET-
POINTS and the HISTORY. Also on the Home screen • Leaving Chilled Liquid Temperature Setpoints – Con-
is the ability to Run/Stop the unit, Log IN, Log Out and trol Setpoint
Print. Log In and Log Out is the means by which different • Leaving Chilled Liquid Temperature Setpoints – Shut-
security levels are accessed. down
• Leaving Chilled Liquid Temperature Setpoints – Re-
The SYSTEM screen gives a general overview of com- start
mon chiller parameters for both shells. This is an end
view of the chiller with a 3D cutaway of both the shells. Programmable
From this screen you can view the following.
• Local Leaving Chilled Liquid Temperature – Range
Display Only • Local Leaving Chilled Liquid Temperature – Setpoint
• Discharge Temperature • Leaving Chilled Liquid Temperature Cycling Offset –
Shutdown
• Chilled Liquid Temperature – Leaving
• Leaving Chilled Liquid Temperature Cycling Offset –
• Chilled Liquid Temperature – Return
Restart
• Chilled Liquid Temperature – Setpoint
• Evaporator Pressure The CONDENSER screen displays a cutaway view of the
chiller condenser. The liquid flow is animated to indicate
8 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

flow through the condenser. All setpoints relating to the • Input Power
condenser side of the chiller are maintained on this screen. • Kilowatt Hours
With the proper access level, this screen also serves as
• Output Current – Phase A, B, C
a gateway to controlling the Refrigerant Level. From this
screen you can view the following: • Voltage THD (L1, L2, L3)
• Supply Current TDD (L1, L2, L3)
Display Only • Total Supply KVA
• Leaving Condenser Liquid Temperature • Total Power Factor
• Return Condenser Liquid Temperature
• Condenser Pressure The MOTOR DETAILS screen displays additional motor
winding temperature information including:
• Condenser Saturation Temperature
• Small Temperature Difference Display Only
• Drop Leg Refrigerant Temperature • Temperature – Phase A, B, C
• Sub-Cooling Temperature • Average Winding Temperature
• High Pressure Switch (Open/Closed)
• Condenser Liquid Flow Switch The CAPACITY CONTROL screen displays all of the data
and settings relating to top level capacity control. From
• Condenser Liquid Pump (Run/Stop)
this screen you can view and adjust readings and setpoints
• Refrigerant Level Position relating to temperature control, override limits, anti-surge
• Refrigerant Level Setpoint control, Pre-Rotation Vanes, Hot Gas By-Pass, and the
• Ramp Up Time Remaining OptiSpeed Variable Speed Drive (VSD). With proper
access these setpoints can be adjusted and the manual
The COMPRESSOR screen displays a cutaway view of control screen can be accessed. From this screen you
the compressor, this reveals the impeller and shows all can view the following:
the conditions associated with the compressor. When
the compressor impeller is spinning this indicates that Display Only
the chiller is presently in RUN condition. With the proper • Chilled Liquid Temperature - Leaving
access level, the pre-rotation vanes may be manually • Evaporator Pressure
controlled. This screen also serves as a gateway to sub-
• Condenser Pressure
screens for calibrating the pre-rotation vanes, configuring
the Hot Gas Bypass, or providing advanced control of the • Evaporator - Setpoint
Magnetic Bearing Controller (MBC) and the OptiSpeed • Condenser - Setpoint
Variable Speed Drive (VSD). From this screen you can • Motor Current
view the following:
• Input Current
Display Only • PRV Position
• Discharge Temperature • PRV Ramp
• Vane Motor Switch (LED) • HGBP Ramp
• OptiSpeed Frequency Setpoint
The MOTOR screen displays a view of the OptiSpeed • Actual OptiSpeed Frequency
Variable Speed Drive (VSD) and includes a programmable
pulldown demand to automatically limit motor loading Programmable
for minimizing building demand charges. Pulldown time
• Chilled Liquid Temperature – Setpoint
period control over four hours, and verification of time re-
maining in pulldown cycle from display readout. Separate • Motor Current - Setpoint
digital setpoint for current limiting between 30 and 100%. • Input Current - Setpoint

Display Only The OptiSpeed Variable Speed Drive (VSD) screen dis-
• Input Current Limit Setpoint plays a picture of the OptiSpeed and the following values
that are in addition to the common ones listed above. From
• Pulldown Demand Time Left
this screen you can view the following:
• Output Voltage
• Output Frequency

JOHNSON CONTROLS 9
FORM 160.78-EG1 (610)

OptiView Control Center - continued


Display Only switches is displayed. From this screen you can perform
• Frame Size the following:
• Phase Rotation
Display Only
• Indicator Lights for: Motor Run, DC Bus Regulation,
• Chilled Liquid Pump Operation: (displays standard or
Precharge Complete, Input Current Limit, Cooling
enhanced)
System, Precharge Active.
• Motor Type: Variable Speed
• Input Peak Voltage (L1, L2, L3)
• Refrigerant Selection: R134a
• Input RMS Voltage (L1, L2, L3)
• Power Failure Restart: (displays Manual or Automatic)
• Input RMS Current (L1, L2, L3)
• Liquid Type: (Water or Brine)
• DC Bus Voltage
• Coastdown: (displays Standard or Enhanced)
• DC Bus Current
• Pre-Run: (displays Standard or Enhanced)
• Output RMS Voltage – Phase A, B, C
• Power Line Frequency
• Output RMS Current – Phase A, B, C
• Rectifier Baseplate Temperature – Phase A, B, C Programmable
• Inverter Baseplate Temperature – Phase A, B, C • Set Date
• Internal Ambient Temperature 1 and 2 • Set Time
• Clock (Enabled/Disabled)
The SETPOINTS screen provides a convenient location
for programming the most common setpoints involved • 12/24 Hr
in the chiller control. The Setpoints are shown on other
individual screens but to cut down on needless searching The following 6 sub-screens can be accessed from the
they are on this one screen. This screen also serves as a setup screen:
gateway to a subscreen for defining the setup of general
system parameters. From this screen you can perform The SCHEDULE screen contains more programmable
the following: values than a normal display screen. Each programmable
value is not linked to a specific button; instead the select
Display Only key is used to enable the cursor arrows and check key to
program the Start/Stop times for any day of the week up
• Leaving Chilled Liquid Temperature – Setpoint
to 6 weeks in advance. The user has the ability to define
• Leaving Chilled Liquid Temperature Cycling – Shut- a standard set of Start/Stop times that are utilized every
down week or specify exceptions to create a special week.
• Leaving Chilled Liquid Temperature Cycling – Restart
Programmable
Programmable • Exception Start/Stop Times
• Local Leaving Chilled Liquid Temperature – Range • Schedule (Enable/ Disabled)
• Local Leaving Chilled Liquid Temperature – Setpoint • Repeat Sunday Schedule
• Leaving Chilled Liquid Temperature Cycling Offset – • Standard Week Start/Stop Times
Shutdown
• Reset All Exception Days
• Select
• Leaving Chilled Liquid Temperature Cycling Offset –
• Print
Restart
• Motor Current Limit The USER screen allows definition of the language for the
• Pulldown Demand Limit chiller to display and defines the unit of measure.
• Pulldown Demand Time
Programmable
• Print
• System Language
The SETUP is the top level of the general configura- • English/Metric Units
tion parameters. It allows programming of the time and
date, along with specifications as to how the time will be The COMMS screen allows definition of the necessary
displayed. In addition, the chiller configuration as deter- communications parameters.
mined by the microboard program jumpers and program
10 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Programmable the conditions while the chiller is running or stopped. The


• Chiller ID faults are color coded for ease in determining the severity
at a glance, recording the date, time and description. (See
• Com 2 Baud Rate
Display Messages for Color Code meanings.)
• Com 2 Data Bit(s)
• Com 2 Parity Bit(s) Display Only
• Com 2 Stop Bit(s) • Last Normal Shutdown
• Printer Baud Rate • Last Fault While Running
• Printer Data Bit(s) • Last Ten Faults
• Printer Parity Bit(s)
Programmable
• Printer Stop Bit(s)
• Print History
The PRINTER screen allows Definition of the necessary • Print All Histories
communications Parameters for the printer.
By pressing the VIEW DETAILS key you will move to the
Display Only HISTORY DETAILS screen. From these screens you
• Time Remaining Until Next Print are able to see an on-screen printout of all the system
parameters at the time of the selected shutdown.
Programmable
Display Only
• Log Start Time
• History Printout
• Output Interval
• Automatic Printer Logging (Enabled/Disabled) Programmable
• Print Type • Page Up
• Print Report • Page Down
• Print All Histories • Print History

The SALES ORDER screen allows definition of the order Also under the History screen is the TRENDING screen,
parameters. accessible by the key marked the same. On this screen
up to 6 operator-selected parameters selected from a list
Note: This information is loaded at the factory or by the installation/
service technician.
of over 140, can be plotted in an X/Y graph format. The
graph can be customized to record points once every
Display Only second up to once every hour. There are two types of
• Model Number charts that can be created: a single or continuous screen.
• Panel Serial Number The single screen collects data for one screen width (450
• Chiller Serial Number data points across the x-axis) then stops. The continuous
screen keeps collecting the data but the oldest data drops
• Johnson Controls Order Number off the graph from left to right at the next data collection
• System Information interval. For ease of identification, each plotted parameter,
• Condenser and Evaporator Design Load Information title and associated Y- axis labeling is color coordinated.
• Nameplate Information
Display Only
The OPERATIONS screen allows definition of parameters • This screen allows the user to view the graphical
related to the operation of the chiller. What is defined is trending of the selected parameters and is a gateway
whether the control of the chiller will be Local, Digital to the graph setup screens.
Remote, Analog Remote, Modem Remote or Metasys™
Remote. Programmable
• Start
Programmable • Stop
• Control Source • Y-axis
The HISTORY screen allows the user to browse through • X-axis
the last ten faults; either safety or cycling shutdowns with

JOHNSON CONTROLS 11
FORM 160.78-EG1 (610)

OptiView Control Center - continued


The TREND SETUP screen is used to configure the trend- • Start Inhibit
ing screen. The parameters to be trended are selected • Vanes Closing Before Shutdown
from the Trend Common Slots Screen accessed from
the Slot #s button or the Master Slot Numbers List found Run Messages include:
in the operating manual. The interval at which all the
• Leaving Chilled Liquid Control
parameters are sampled is selected under the Collection
Interval button. The data point minimum and maximum • Current Pulldown Limit
values may be adjusted closer within the range to increase
viewing resolution. Start Inhibit Messages include:
• Anti-Recycle XX Min/Sec
Programmable • Vane Motor Switch Open
• Chart Type (select Continuous or One Screen) • Motor Current >15% FLA
• Collection Interval
• Select Warning Messages include:
• Data Point Slot # (1-6) • Real Time Clock Failure
• Data Point Min (1-6) • Condenser or Evaporator Transducer Error
• Data Point Max (1-6) • Refrigerant level Out-of-Range
• Setpoint Override
The TREND COMMON SLOTS screen displays the • Condenser – High Pressure Limit
Master Slot Numbers List of the monitored parameters.
• Evaporator – Low Pressure Limit
Display Only • Vanes Uncalibrated – Fixed Speed
• Slot Numbers • MBC – Position
• MBC – Landing Counter High
Programmable • MBC – High Bearing Temperature
• Page Up • MBC – Vibration
• Page Down • MBC – Low Frequency Displacement
• MBC – Rotor Elongation
DISPLAY MESSAGES
• VSD – Operation Inhibited
The OptiView Control Center continually monitors the
• VSD – Data Loss
operating system displaying and recording the cause of
any shutdowns (Safety, Cycling or Normal). The condition • VSD - Input Frequency Range
of the chiller is displayed at the System Status line that
contains a message describing the operating state of the Routine Shutdown Messages include:
chiller; whether it is stopped, running, starting or shutting • Remote Stop
down. A System Details line displays Warning, Cycling, • Local Stop
Safety, Start Inhibit and other messages that provide
• Place Compressor Switch in Run Position
further details of Status Bar messages. Messages are
color-coded: Green – Normal Operations, Yellow - Warn-
Cycling Shutdown Messages include:
ings, Orange – Cycling Shutdowns, and Red – Safety
Shutdowns to aid in identifying problems quickly. • Multi Unit Cycling – Contacts Open
• System Cycling – Contacts Open
Status Messages include: • Control Panel – Power Failure
• System Ready to Start • Leaving Chilled Liquid – Low Temperature
• Cycling Shutdown – Auto Restart • Leaving Chilled Liquid – Flow Switch Open
• Safety Shutdown – Manual Restart • Condenser – Flow Switch Open
• Soft Shurdown – Manual Restart • Motor Controller – Contacts Open
• MBC Start-Up • Motor Controller – Loss of Current
• System Run (with countdown timers) • MBC – Position
• MBC – Low Frequency Displacement
• System Coastdown (with countdown timers) • MBC – Vibration

12 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

• MBC – High Amplifier Temperature • MBC – High Bearing Current


• MBC – High DC/DC Temperature • MBC – Rotor Elongation
• MBC – No Levitation • MBC – Oscillator Fault
• MBC – Serial Communications Fault • MBC – Power Supply Fault
• Power Fault • MBC – Unauthorized Rotation
• Control Panel – Schedule • MBC – No Rotation
• VSD - Precharge – Low DC Bus Voltage • VSD Shutdown – Requesting Fault Data
• VSD – DC Bus Preregulation • VSD – Stop contacts Open
• VSD – Logic Board Power Supply • VSD – DC Bus Preregulation Lockout
• VSD – High DC Bus Voltage • VSD – Logic Board Plug
• VSD – High Phase __ Input Current (A,B,C) • VSD – Ground Fault
• VSD – High Phase __ Motor Current (A,B,C) • VSD – Phase __ Input DCCT (A,B,C)
• VSD – Phase __ Input Gate Driver (A,B,C) • VSD – Phase __ Motor DCCT (A,B,C)
• VSD – Phase __ Motor Gate Driver (A,B,C) • VSD – Input Current Overload
• VSD – Single Phase Input Power • VSD – 105% Motor Current Overload
• VSD – DC Bus Under Voltage • VSD – High Phase __ Input Baseplate Temperature
• VSD – Low Phase __ Input Baseplate Temperature (A,B,C)
(A,B,C) • VSD – High Phase __ Motor Baseplate Temperature
• VSD – Low Phase __ Motor Baseplate Temperature (A,B,C)
(A,B,C) • VSD – Motor or Stator Current Imbalance
• VSD – High Internal Ambient Temperature • VSD – Motor Current THD Fault
• VSD – Serial Communications • VSD – Motor Synchronization Fault
• VSD – Logic Board Processor • VSD – Rectifier Program Fault
• VSD – Run Signal • VSD – Inverter Program Fault
• VSD Shutdown – Requesting Fault Data
• VSD – Stop Contacts Open
• VSD – Initialization Failed

Safety Shutdown Messages include:


• Evaporator – Low Pressure
• Evaporator – Transducer or Leaving Liquid Probe
• Evaporator – Transducer or Temperature Sensor
• Condenser – High Pressure Contacts Open
• Condenser – High Pressure
• Condenser – Pressure Transducer Out-of-Range
• Auxiliary Safety – Contacts Closed
• Discharge – High Temperature
• Discharge – Low Temperature
• Control Panel – Power Failure
• Watchdog – Software Reboot
• MBC – Internal Fault
• MBC – High Bearing Temperature
• MBC – Cable Fault
• MBC – Speed Signal Fault
• MBC – Overspeed Fault
• MBC – Communication
JOHNSON CONTROLS 13
FORM 160.78-EG1 (610)

OptiSpeed™ Variable Speed Drive

OPTISPEED VARIABLE SPEED DRIVE (VSD) FOR PWM rectifier also contains the proprietary precharge
YMC² CHILLER circuit, which keeps the inrush current into the VSD at a
minimal value, well below the nominal.
The new YORK OptiSpeed Variable Speed Drive (VSD)
is a liquid cooled, insulated gate bipolar transistor (IGBT)-
The DC Link filter section of the drive consists of one basic
based, pulse width modulated (PWM) rectifier/inverter
component, a bank of filter capacitors. The capacitors pro-
in a highly integrated package. This package is small
vide an energy reservoir for use by the DC to AC inverter
enough to mount directly onto the chiller. The power
section of the OptiSpeed. The capacitors are contained in
section of the drive is composed of four major blocks: a
the OptiSpeed Power Pole, as are the “bleeder” resistors,
three-phase AC-to-DC rectifier section with an integrated
which provide a discharge path for the stored energy in
input filter and pre-charge circuit, a DC link filter-section,
the capacitors.
a three-phase DC to AC inverter section, and an output
sine filter-network.
The DC to AC PWM inverter section of the OptiSpeed
serves to convert the DC voltage to AC voltage at the
An input disconnect device connects the AC line to an
proper magnitude and frequency as commanded by the
input filter and then to the AC-to-DC three-phase PWM
OptiSpeed Logic board. The inverter section consists of
rectifier. The disconnect device can be a three-phase
fast switching IGBT transistors mounted on a liquid cooled
rotary disconnect switch (standard offering), or an elec-
heatsink. The inverter IGBT modules (with heatsink), the
tronic circuit breaker (optional offering). The inductors in
rectifier IGBT modules (with heatsink), the DC link filter
the input filter shall limit the amount of fault current into
capacitor, the “bleeder” resistors, the laminated intercon-
the VSD; however, for the additional protection of the
necting bussbar, and the OptiSpeed Gate Driver board
PWM rectifier’s IGBT transistors, semiconductor fuses
form the OptiSpeed Power Pole. The OptiSpeed Gate
are provided between the input disconnect device and
Driver board provides the turn-on, and turn-off commands
input filter. The three-phase PWM rectifier uses IGBT
to the rectifier’s and inverter’s transistors. The OptiSpeed
transistors, mounted on a liquid-cooled heatsink and
Logic board determines when the turn-on, and turn-off
controlled at a high frequency, to convert AC line voltage
commands should occur. Additionally, the OptiSpeed
into a tightly regulated DC voltage. Additionally, the PWM
logic board monitors the status of the OptiSpeed VSD
rectifier shapes the line current into an almost-sinusoidal
system, generates all OptiSpeed system faults (includ-
waveform, allowing every YMC² VSD to comply with the
ing the ground fault), and communicates with OptiView
harmonic distortion requirements of the IEEE Std 519
control panel.
-1992, “IEEE Recommended Practices and Requirements
for Harmonic Control in Electrical Power Systems”. The

14 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

The OptiSpeed output sine filter network is composed of IGBT transistor modules have thermistors mounted on
inductors and capacitors. The job of the output filter net- them that provide information to the OptiSpeed logic
work is to eliminate voltage harmonics from the inverter’s board. These sensors, as well as additional thermistors
output, and provide a high-quality, almost-sinusoidal monitoring the internal ambient temperature, protect the
voltage to the motor. This completely eliminates all is- OptiSpeed from over-temperature conditions. A voltage
sues related to premature motor insulation failures due sensor is used to ensure that the DC link filter capacitors
to high voltage peaks generated by the inverter, and it are properly charged. Three input and three output cur-
additionally allows the motor to run cooler, thus increas- rent transformers protect the drive and motor from over
ing system reliability. current conditions.

Other sensors and boards are used to provide safe


operation of the OptiSpeed Compressor Drive. The

JOHNSON CONTROLS 15
FORM 160.78-EG1 (610)

Unit Components

16 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

JOHNSON CONTROLS 17
FORM 160.78-EG1 (610)

Mechanical Specifications
GENERAL bration reduction and balancing systems to ensure smooth
and reliable operation. In the event of a power failure,
YORK YMC² Centrifugal Liquid Chillers are completely
the magnetic bearings will remain active throughout the
factory-packaged including the evaporator, condenser,
compressor coast down using a reserve energy supply.
compressor, motor, Variable Speed Drive (VSD), control
Rolling element bearings are included as backup to the
center, and all interconnecting unit piping and wiring.
magnetic bearings and designed for emergency touch
down situations.
The initial charge of refrigerant is supplied for each chiller.
When the optional condenser isolation valves are ordered,
The cast aluminum motor housing is designed for 235 psi
most units may ship fully charged with refrigerant. Actual
(16.2 barg) working pressure and hydrostatically pressure
shipping procedures will depend on a number of project-
tested at 355 psig (24.4 barg).
specific details.
OPTISOUND™ CONTROL
The services of a Johnson Controls factory-trained, field
service representative are incurred to supervise or perform YORK YMC² chillers are equipped with YORK Opti-
the final leak testing, charging, the initial start-up, and Sound™ Control as standard. The YORK OptiSound
concurrent operator instructions. Control is a patented combination of centrifugal-chiller
hardware and software that reduces operational sound
COMPRESSOR levels, expands the chiller operating range, and improves
chiller performance. The OptiSound Control feature con-
The compressor is a single-stage centrifugal type directly
tinuously monitors the characteristics of the compressor-
driven by a hermetically sealed high speed permanent
discharge gas and optimizes the diffuser spacing to
magnet motor. A cast-aluminum, fully-shrouded impeller
minimize gas-flow disruptions from the impeller. This
is mounted directly to the motor shaft using a stretched
innovative technology improves operating sound levels of
tie-bolt. Impeller seals employ labyrinth geometry, sized to
the chiller an average of 7 dBA, and up to 13 dBA on the
provide minimal thrust loading on the impeller throughout
largest models. It can also reduce part-load sound levels
the operating range. The impeller is dynamically balanced
below the full-load level.
and overspeed tested for smooth, vibration-free operation.
The cast-iron compressor housings are designed for 235
In addition, the OptiSound Control provides the benefit of
psig (16.2 barg) working pressure and hydrostatically
an expanded operating range. It improves performance
pressure tested at 355 psig (24.4 barg).
and reliability by minimizing diffuser-gas stall at off-design
operation, particularly conditions of very low load com-
CAPACITY CONTROL
bined with little or no condenser-water relief. The elimina-
Capacity control will be achieved by the combined use of tion of the gas-stall condition can also result in improved
variable speed control and pre-rotation vanes (PRV) to chiller efficiency at off design conditions.
provide fully modulating control from maximum to mini-
mum load. For normal air conditioning applications, the OPTISPEED™ VARIABLE SPEED DRIVE (VSD)
chiller can adjust capacity from 100% to 15% of design.
A 460V 3-phase 60 Hz, 380 V 3-phase 60 hz, 415 V
For each condition the speed and the PRV position will
3-phase 50 Hz or 400V 3-phase 50 Hz variable speed
be automatically optimized to maintain a constant leaving
drive is factory-packaged and mounted on the YORK
chilled liquid temperature.
YMC² chiller. It is designed to vary the compressor mo-
tor speed by controlling the frequency and voltage of the
PRV operation is by an external, electric actuator which
electrical power to the motor. The capacity control logic
automatically and precisely positions the rugged airfoil
automatically adjusts motor speed and compressor pre-
shaped, cast manganese-bronze vanes using solid vane
rotation vane position independently for maximum part
linkages.
load efficiency by analyzing information fed to it by sensors
located throughout the chiller.
MOTOR
The compressor motor is a hermetically-sealed, high- The variable speed drive is mounted in a NEMA-1 enclo-
speed design with a permanent magnet rotor supported sure with all power and control wiring between the drive
with active magnetic bearings. Each magnetic bearing and chiller factory-installed. Electrical lugs for incoming
cartridge includes both radial and thrust bearings. The power wiring are provided, and the entire chiller package
bearing controls are based on successful products pro- is UL/cUL listed.
viding a completely oil-free operating system. The motor
rotor and stator are cooled by a pressure driven refriger- The variable speed drive provides automatic power-factor
ant loop to maintain acceptable operating temperatures. correction to 0.975 or better at all load conditions. Sepa-
The active magnetic bearings are equipped with auto vi- rate power-factor correction capacitors are not required.

18 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Standard features include: a door interlocked padlockable bundle to prevent liquid refrigerant carryover into the
disconnect switch or circuit breaker; ground fault protec- compressor. A 1-1/2" (38 mm) liquid level sight glass is
tion; overvoltage and under-voltage protection; 3-phase conveniently located on the side of the shell to aid in de-
sensing motor over-current protection; 3-phase sensing termining proper refrigerant charge. The evaporator shell
input over current protection; single-phase protection; contains a dual refrigerant relief valve arrangement set at
insensitive to phase rotation; over-temperature protection; 235 psig (16.2 barg) or a single-relief valve arrangement,
digital readout at the OptiView Control Center of: if the chiller is supplied with the optional refrigerant isola-
• Output Frequency tion valves. A 1" (25.4 mm) refrigerant charging valve is
provided for service access.
• Output Voltage
• 3-phase input current Condenser
• 3-phase output current The condenser is a shell and tube type, with a discharge
• Input kVA gas baffle to prevent direct high velocity impingement on
the tubes. The baffle is also used to distribute the refrig-
• Input Power (kW)
erant gas flow properly for most efficient heat transfer.
• Kilowatt-Hours (kWH) An integral sub-cooler is located at the bottom of the
• Input Voltage Total harmonic Distortion (THD) condenser shell providing highly effective liquid refriger-
• Input Current Total Demand Distortion (TDD) ant subcooling to provide the highest cycle efficiency.
The condenser contains dual refrigerant relief valves set
• Self diagnostic service parameters
at 235 psig (16.2 barg).

HEAT EXCHANGERS Water Boxes


Shells The removable water boxes are fabricated of steel. The
Evaporator and condenser shells are fabricated from design working pressure is 150 psig (10.3 barg) and the
rolled carbon steel plates with fusion welded seams or boxes are tested at 225 psig (15.5 barg). Integral steel
carbon steel pipe. Carbon steel tube sheets, drilled and water baffles are located and welded within the water box
reamed to accommodate the tubes, are welded to the end to provide the required pass arrangements. Stub-out water
of each shell. Intermediate tube supports are fabricated nozzle connections with ANSI/AWWA C-606 grooves are
from carbon steel plates, drilled and reamed to eliminate welded to the water boxes. These nozzle connections
sharp edges, and spaced no more than four feet apart. are suitable for ANSI/AWWA C-606 couplings, welding
The refrigerant side of each shell is designed, tested, and or flanges, and are capped for shipment. Plugged 3/4"
stamped in accordance with ASME Boiler and Pressure (19 mm) drain and vent connections are provided in each
Vessel Code, Section VIII – Division I, or other pressure water box.
vessel code as appropriate.
REFRIGERANT ISOLATION VALVES
Tubes Factory-installed isolation valves in the compressor
Heat exchanger tubes are state-of-the-art, high-efficiency, discharge line and refrigerant liquid line are provided as
externally and internally enhanced type to provide opti- standard. This allows isolation and storage of the refrig-
mum performance. Tubes in both the evaporator and con- erant charge in the chiller condenser during servicing,
denser are 3/4" (19 mm) O.D. or 1" (25.4 mm) O.D. copper eliminating time-consuming transfers to remote storage
alloy and utilize the “skip-fin” design, providing a smooth vessels. Both valves are positive shut-off, assuring integ-
internal and external surface at each intermediate tube rity of the storage system.
support. This provides extra wall thickness (up to twice
as thick) and non work-hardened copper at the support WATER FLOW SWITCHES
location, extending the life of the heat exchangers. Each
tube is roller-expanded into the tube sheets providing a Thermal type water flow switches are factory mounted in
leak-proof seal, and is individually replaceable. the chilled and condenser water nozzles, and are factory
wired to the OptiView control panel. These solid state
Evaporator flow sensors have a small internal heating-element. They
The evaporator is a shell and tube, hybrid falling film type use the cooling effect of the flowing fluid to sense when
heat exchanger. It contains a balance of flooded and falling an adequate flow rate has been established. The sealed
film technology to optimize efficiency, minimize refriger- sensor probe is 316 stainless steel, which is suited to very
ant charge, and maintain reliable control. A specifically high working pressures.
designed spray distributor provides uniform distribution of
refrigerant over the entire shell length to yield optimum REFRIGERANT FLOW CONTROL
heat transfer. A suction baffle is located above the tube Refrigerant flow to the evaporator is controlled by the
YORK variable orifice control system. Liquid refriger-

JOHNSON CONTROLS 19
FORM 160.78-EG1 (610)

Mechanical Specifications - continued


ant level is continuously monitored to provide optimum b. percent current limit
subcooler, condenser and evaporator performance. The c. pull-down demand limiting
variable orifice electronically adjusts to all Real-World
d. six-week schedule for starting and stopping the
operating conditions, providing the most efficient and
chiller, pumps and tower
reliable operation of refrigerant flow control.
e. remote reset temperature range
OPTIVIEW CONTROL CENTER 3. Status messages indicating:
GENERAL
a. system ready to start
The chiller is controlled by a stand-alone microprocessor
b. system running
based control center. The chiller control panel provides
control of chiller operation and monitoring of chiller sen- c. system safety shutdown – manual restart
sors, actuators, relays and switches. d. system cycling shutdown – auto restart
e. system soft shutdown – manual restart
CONTROL PANEL
f. MBC Start-Up
The control panel includes a 10.4-in. (264 mm) diagonal g. start inhibit
color liquid crystal display (LCD) surrounded by “soft” keys
h. system coastdown
which are redefined based on the screen displayed at that
time, mounted in the middle of a keypad interface and
installed in a locked enclosure. The screen details all op- 4. The text displayed within the system status and system
erations and parameters, using a graphical representation details field is displayed as a color-coded message to
of the chiller and its major components. Panel verbiage indicate severity: red for safety fault, orange for cycling
is available in eight languages and can be changed on faults, yellow for warnings, and green for normal mes-
the fly without having to turn off the chiller. Data can be sages.
displayed in either English or Metric units. Smart Freeze
Point Protection will run the chiller at 36°F (2.2°C) leaving
5. Safety shutdowns enunciated through the display and
chilled water temperature, and not have nuisance trips on
the status bar, and consist of system status, system
low water temperature. The sophisticated program and
details, day, time, cause of shutdown, and type of re-
sensor monitors the chiller water temperature to prevent
start required. See the Optiview control center section
freeze-up. When needed, Hot Gas Bypass control is
for a list of safety shutdown messages.
available as an option. The panel displays countdown
timer messages so the operator knows when functions
are starting and stopping. Every programmable point has 6. Cycling shutdowns enunciated through the display and
a pop-up screen with the allowable ranges, so that the the status bar, and consists of system status, system
chiller cannot be programmed to operate outside of its details, day, time, cause of shutdown, and type of re-
design limits. start required. See the Optiview Control Center section
for a list of cycling shutdowns.
The chiller control panel also provides:

1. System operating information including: 7. Security access to prevent unauthorized change of


setpoints, to allow local or remote control of the chiller,
a. return and leaving chilled water temperature and to allow manual operation of the pre-rotation vanes
b. return and leaving condenser water temperature and oil pump. Access is through ID and password
c. evaporator and condenser saturation pressure recognition, which is defined by three different levels
of user competence: view, operator, and service.
d. percent motor current
e. evaporator and condenser saturation temperature
f. compressor discharge temperature 8. Trending data with the ability to customize points of
once every second to once every hour. The panel will
g. operating hours trend up to 6 different parameters from a list of over
h. number of compressor starts 140, without the need of an external monitoring system.

9. The operating program stored in non-volatile memory


2. Digital programming of setpoints through the universal (EPROM) to eliminate reprogramming the chiller due
keypad including: to AC power failure or battery discharge. Programmed
a. leaving chilled water temperature setpoints are retained in lithium battery-backed RTC

20 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

memory for a minimum of 10 years with power re- tioning Equipment and Systems
moved from the system. • N.E.C. – National Electrical Code
10. A fused connection through a transformer in the com- • OSHA – Occupational Safety and Health Act
pressor motor starter to provide individual over-current • IEEE Std. 519-1992 Compliance
protected power for all controls.
ISOLATION MOUNTING
11. A numbered terminal strip for all required field interlock
wiring. The unit is provided with four vibration isolation mounts of
nominal 1" operating height. The pads have a neoprene
12. An RS-232 port to output all system operating data, pad to contact the foundation, bonded to a steel plate.
shutdown/cycling message, and a record of the last The vibration isolation pads assemblies mount under steel
10 cycling or safety shutdowns to a field-supplied plates affixed to the chiller tube sheets.
printer. Data logs to a printer at a set programmable
interval. This data can be pre-programmed to print REFRIGERANT CONTAINMENT
from 1 minute to 1 day.
The standard unit has been designed as a complete and
13. The capability to interface with a building automation compact factory-packaged chiller. As such, it has mini-
system via hard-wired connections to each feature to mum joints from which refrigerant can leak. The entire
provide: assembly has been thoroughly leak tested at the fac-
tory prior to shipment. The YORK YMC² chiller includes
a. remote chiller start and stop service valves conveniently located to facilitate transfer
b. remote leaving chiller liquid temperature adjust of refrigerant to a remote refrigerant storage/recycling
system. Condenser isolation valves allow storage of the
c. remote current limit setpoint adjust charge in the condenser.
d. remote ready to start contacts
e. safety shutdown contacts PAINT
f. cycling shutdown contacts Exterior surfaces are protected with one coat of Caribbean
g. run contacts blue, durable alkyd-modified, vinyl enamel, machinery
paint.
CODES AND STANDARDS
SHIPMENT
• ASME Boiler and Pressure Vessel Code – Section Vlll
Division 1. Protective covering is furnished on the motor starter,
Control Center VSD and unit-mounted controls. Water
• AHRI Standard 550/590 nozzles are capped with fitted plastic enclosures. Entire
• c/U.L. – Underwriters Laboratory unit is protected with industrial-grade, reinforced shrink-
• ASHRAE 15 – Safety Code for Mechanical Refrigera- wrapped covering.
tion
• ASHRAE Guideline 3 – Reducing Emission of Halo-
genated Refrigerants in Refrigeration and Air-Condi-

JOHNSON CONTROLS 21
FORM 160.78-EG1 (610)

Accessories and Modifications


BAS REMOTE CONTROL nozzles. Companion flanges, bolts, nuts and gaskets are
not included.
A communication interface permitting complete exchange
of chiller data with any BAS System is available with
SPRING ISOLATION MOUNTING
an optional Metasys™ translator. The Metasys transla-
tor also allows BAS System to issue commands to the Spring isolation mounting is available instead of standard
chiller to control its operation. Metasys translators come isolation mounting pads when desired. Four level-adjust
in two models, controlling up to 4 chillers and 8 chillers ing, spring-type vibration isolator assemblies with non
respectively. skid pads are provided for field-installation. Isolators are
designed for one-inch (25 mm) deflection.
FACTORY INSULATION OF EVAPORATOR
MARINE WATER BOXES
Factory-applied thermal insulation of the flexible, closed
cell plastic type, 3/4" (19 mm) thick is attached with va Marine water boxes allow service access for cleaning of
por-proof cement to the evaporator shell, flow chamber, the heat exchanger tubes without the need to break the
tube sheets, suction connection, and (as necessary) to the water piping. Bolted-on covers are arranged for conve
auxiliary tubing. Not included is the insulation of compact nient access. ANSI/AWWA C-606 nozzle connections are
water boxes and nozzles. This insulation will normally pre- standard; flanges are optional. Marine water boxes are
vent condensation in environments with relative humidifies available for condenser and/or evaporator.
up to 75% and dry bulb temperatures ranging from 50° to
90°F (10° to 32.2°C). 1 1/2" (38 mm) thick insulation is also KNOCK-DOWN SHIPMENT
available for relative humidifies up to 90% and dry bulb
The chiller can be shipped knocked down into major
temperatures ranging from 50° to 90°F (10° to 32.2°C).
subassemblies (evaporator, condenser, driveline, etc.) as
required to rig into tight spaces. This is particularly conve
WATER FLANGES
nient for existing buildings where equipment room access
Four 150 lb. ANSI raised-face flanges for condenser and does not allow rigging a factory-packaged chiller.
evaporator water connections are factory-welded to water

22 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Application Data
The following discussion is a user’s guide in the applica- is normally used for better system stability and set point
tion and installation of YORK YMC² chillers to ensure the control. Proper sequencing via the building automation
reliable, trouble-free life for which this equipment was system will make this a very smooth transition.
designed. While this guide is directed towards normal,
water-chilling applications, a Johnson Controls sales en- Temperature Ranges – For normal water chilling duty,
gineer can provide complete recommendations on other leaving chilled water temperatures may be selected
types of applications. between 38°F (3.3°C) [36°F (2.2°C) with Smart Freeze
enabled] and 70°F (21.1°C) for water temperature ranges
LOCATION between 3°F and 30°F (1.7°C and 16.7°C).
YORK YMC² chillers are virtually vibration free and may Water Quality – The practical and economical applica-
generally be located at any level in a building where the tion of liquid chillers requires that the quality of the water
construction will support the total system operating weight. supply for the condenser and evaporator be analyzed by
The unit site must be a floor, mounting pad or foundation a water treatment specialist. Water quality may affect the
which is level within 1/4" (6.4 mm) and capable of sup- performance of any chiller through corrosion, deposition
porting the operating weight of the unit. of heat-resistant scale, sedimentation or organic growth.
These will degrade chiller performance and increase op-
Sufficient clearance to permit normal service and main- erating and maintenance costs. Normally, performance
tenance work should be provided all around and above may be maintained by corrective water treatment and
the unit. Additional space should be provided at one end periodic cleaning of tubes. If water conditions exist which
of the unit to permit cleaning of evaporator and condenser cannot be corrected by proper water treatment, it may be
tubes as required. A doorway or other properly located necessary to provide a larger allowance for fouling, and/
opening may be used. or to specify special materials of construction.
The chiller should be installed in an indoor location where General Piping – All chilled water and condenser water
temperatures range from 40°F to 104°F (4.4°C to 40°C). piping should be designed and installed in accor dance
with accepted piping practice. Chilled water and condens-
WATER CIRCUITS er water pumps should be located to discharge through
Flow Rate – For normal water chilling duty, evaporator and the chiller to assure positive pressure and flow through
condenser flow rates are permitted at water velocity levels the unit. Piping should include offsets to provide flexibility
in the heat exchangers tubes of between 3 ft/sec (3.3 for and should be arranged to prevent drainage of water from
condensers) and 12 ft/sec (0.91 m/s and 3.66 m/s). Two the evaporator and condenser when the pumps are shut
pass units are also limited to 45 ft H20 (134 kPA) water off. Piping should be adequately supported and braced
pressure drop. Three pass limit is 67.5 ft H20 (201 kPA). independently of the chiller to avoid the imposition of strain
Variable flow in the condenser is not recommended, as on chiller components. Hangers must allow for alignment
it generally raises the energy consumption of the system of the pipe. Isolators in the piping and in the hangers are
by keeping the condenser pressure high in the chiller. highly desirable in achieving sound and vibration control.
Additionally, the rate of fouling in the condenser will in-
crease at lower water velocities associated with variable Convenience Considerations – To facilitate the perfor-
flow, raising system maintenance costs. Cooling towers mance of routine maintenance work, some or all of the
typically have narrow ranges of operation with respect to following steps may be taken by the purchaser. Evaporator
flow rates, and will be more effective with full design flow. and condenser water boxes are equipped with plugged
Ref. Table 1 for flow limits at design conditions. vent and drain connections. If desired, vent and drain
valves may be installed with or without piping to an open
There is increasing interest to use variable primary flow drain. Pressure gauges with stop-cocks and stop-valves
(VPF) systems in large chilled water plants. VPF systems may be installed in the inlets and outlets of the condenser
can offer lower installation and operating costs in many and chilled water line as close as possible to the chiller.
cases, but do require more sophisticated control and flow An overhead monorail or beam may be used to facilitate
monitoring. servicing.

YORK YMC² chillers will operate successfully in VPF Connections – The standard chiller is designed for 150
systems. With a minimum allowable evaporator tube psig (10.3 barg) design working pressure in both the
velocity of 1-1/2 fps (.5 m/s) for standard tubes at part- chilled water and condenser water circuits. The connec
load rating conditions, YMC² chillers will accommodate tions (water nozzles) to these circuits are furnished with
the wide variation in flow required by many chilled water grooves to ANSI/AWWA C-606 Standard for grooved and
VPF applications. shouldered joints. Piping should be arranged for ease of
disassembly at the unit for tube cleaning. All water piping
The chillers can tolerate a 50% flow rate change in one should be thoroughly cleaned of all dirt and debris before
minute that is typically associated with the staging on or off final connections are made to the chiller.
of an additional chiller, however a lower flow rate change
JOHNSON CONTROLS 23
FORM 160.78-EG1 (610)

Application Data - continued


TABLE 1 – WATER FLOW RATE LIMITS (GPM) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD
CONDITIONS
EVAPORATOR CONDENSER
MODEL 1 PASS 2 PASS 3 PASS MODEL 1 PASS 2 PASS 3 PASS
MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX
CA2110-BS 479 1727 240 864 160 576
CA2110-CS 612 2205 306 1102 204 735
CA2110-DS 681 2455 341 1227 227 818
CA2110-ES 770 2773 385 1387
CA2110-2S 602 2170 301 1085 201 723
CA2110-3S 838 3019 419 1509
EA2510-BS 629 2516 314 1180 210 745 CA2510-BS 779 2807 389 1404 260 936
EA2510-CS 740 2958 370 1351 247 844 CA2510-CS 896 3228 448 1614 299 1076
EA2510-2S 475 1901 238 950 158 634 CA2510-DS 1120 4035 560 2017 373 1345
EA2510-3S 662 2647 331 1323 221 882 CA2510-ES 1397 5035 699 2517
CA2510-2S 912 3288 456 1644 304 1096
CA2510-3S 1322 4762 661 2381
EA2514-BS 629 2516 314 1003 210 639 CA2514-BS 779 2807 389 1290 260 851
EA2514-CS 740 2958 370 1157 247 732 CA2514-CS 896 3228 448 1470 299 971
EA2514-2S 475 1901 238 950 158 629 CA2514-DS 1120 4035 560 1801 373 1192
EA2514-3S 662 2647 331 1315 221 823 CA2514-ES 1397 5035 699 2181
CA2514-2S 912 3288 456 1644 304 1096
CA2514-3S 1322 4762 661 2381

TABLE 2 – WATER FLOW RATE LIMITS (L/S) — BASED UPON STANDARD TUBES @ DESIGN FULL LOAD
CONDITIONS
EVAPORATOR CONDENSER
MODEL 1 PASS 2 PASS 3 PASS MODEL 1 PASS 2 PASS 3 PASS
MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX
CA2110-BS 30 109 15 54 10 36
CA2110-CS 39 139 19 70 13 46
CA2110-DS 43 155 21 77 14 52
CA2110-ES 49 175 24 87
CA2110-2S 38 137 19 68 13 46
CA2110-3S 53 190 26 95
EA2510-BS 40 159 20 74 13 47 CA2510-BS 49 177 25 89 16 59
EA2510-CS 47 187 23 85 16 53 CA2510-CS 57 204 28 102 19 68
EA2510-2S 30 120 15 60 10 40 CA2510-DS 71 255 35 127 24 85
EA2510-3S 42 167 21 83 14 56 CA2510-ES 88 318 44 159
CA2510-2S 58 207 29 104 19 69
CA2510-3S 83 300 42 150 28 100
EA2514-BS 40 159 20 63 13 40 CA2514-BS 49 177 25 81
EA2514-CS 47 187 23 73 16 46 CA2514-CS 57 204 28 93 19 61
EA2514-2S 30 120 15 60 10 40 CA2514-DS 71 255 35 114 24 75
EA2514-3S 42 167 21 83 14 52 CA2514-ES 88 318 44 138
CA2514-2S 58 207 29 104 19 69
CA2514-3S 83 300 42 150

24 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Chilled Water – A water strainer of maximum 1/8" (3.2 The minimum entering condenser water temperature for
mm) perforated holes must be field-installed in the chilled other full and part load conditions is provided by the fol-
water inlet line as close as possible to the chiller. If located lowing equation:

( )
close enough to the chiller, the chilled water pump may be
%Load
protected by the same strainer. The strainer is important to   Min. ECWT = LCHWT – C RANGE + 5°F + 12
protect the chiller from debris or objects which could block 100
flow through individual heat exchanger tubes. A reduction
in flow through tubes could seriously impair the chiller per-
formance or even result in tube freeze-up. A thermal-type
  Min. ECWT = LCHWT – C RANGE + 2.8°C + 6.6

( ) %Load
100

flow switch is factory installed in the evaporator nozzle and


connected to the OptiView panel, which assures adequate where:
chilled water flow during operation.
ECWT = entering condensing water temperature
Condenser Water – The chiller is engineered for maxi- LCHWT = leaving chilled water tempera-
mum efficiency at both design and part load operation ture
by taking advantage of the colder cooling tower water C RANGE = condensing water temperature range at
temperatures which naturally occur during the winter the given load condition.
months. Appreciable power savings are realized from
these reduced heads. At initial startup, entering condensing water temperature
may be as much as 25°F (13.9°C) colder than the standby
chilled water temperature.

COND. 1

COND. 1 COND. 2
COND. 2

S1
T EVAP. 1 T S1 S2

EVAP. 1 EVAP. 2
EVAP. 2
S2

S   –  Temperature Sensor for Chiller Capacity Control S   –  Temperature Sensor for Chiller Capacity Control

T  –  Thermostat for Chiller Capacity Control T  –  Thermostat for Chiller Capacity Control

FIG. 1  – PARALLEL EVAPORATORS PARALLEL CON- FIG. 2  – SERIES EVAPORATORS PARALLEL CON-
DENSERS DENSERS

COND. 1 COND. 2

T S1 S2
EVAP. 1 EVAP. 2

FIG. 3  – SERIES EVAPORATORS SERIES-COUNTER


FLOW CONDENSERS

JOHNSON CONTROLS 25
FORM 160.78-EG1 (610)

Application Data - continued


MULTIPLE UNITS have chilled and condenser water temperature ranges
greater than typical AHRI.
Selection – Many applications require multiple units to
meet the total capacity requirements as well as to provide
REFRIGERANT RELIEF PIPING
flexibility and some degree of protection against equip
ment shutdown. There are several common unit arrange Each chiller is equipped with dual pressure relief valves
ments for this type of application. The YORK YMC² chiller on the condenser and two dual relief valves on the evapo
has been designed to be readily adapted to the require- rator, or two single relief valves on the evaporator if the
ments of these various arrangements. optional refrigerant isolation valves are ordered. The dual
relief valves on the condenser are redundant and allow
Parallel Arrangement (Refer to Fig. 1, pg 19) – Chillers changing of either valve while the unit is fully charged. The
may be applied in multiples with chilled and condenser purpose of the relief valves is to quickly relieve excess
water circuits connected in parallel between the units. pressure of the refrigerant charge to the atmosphere, as
Fig. 1 represents a parallel arrangement with two chillers. a safety precaution in the event of an emergency such
Parallel chiller arrangements may consist of equally or as fire. They are set to relieve at an internal pressure as
unequally sized units. When multiple units are in operation, noted on the pressure vessel data plate, and are provided
they will load and unload at equal percentages of design in accordance with ASHRAE 15 safety code and ASME
full load for the chiller. or applicable pressure vessel code.

Depending on the number of units and operating char- Sized to the requirements of applicable codes, a vent line
acteristics of the units, loading and unloading schemes must run from the relief device to the outside of the build
should be designed to optimize the overall efficiency of ing. This refrigerant relief piping must include a cleanable,
the chiller plant. It is recommended to use an evaporator vertical leg dirt trap to catch vent-stack condensation.
bypass piping arrangement to bypass fluid around evap- Vent piping must be arranged to avoid imposing a strain
orator of any unit which has cycled off at reduced load on the relief connection and should include one flexible
conditions. It is also recommended to alternate the chiller connection.
cycling order to equalize chiller starts and run hours.
SOUND AND VIBRATION CONSIDERATIONS
Series Arrangement (Refer to Fig. 2, pg 19) – Chillers
A YORK YMC² chiller is not a source of objectionable
may be applied in pairs with chilled water circuits con-
sound and vibration in normal air conditioning applications.
nected in series and condenser water circuits connected
Optional neoprene isolation mounts are available with
in parallel. All of the chilled water flows through both evapo
each unit to reduce vibration transmission. Optional level-
rators with each unit handling approximately one-half of
adjusting spring isolator assemblies designed for 1" (25
the total load. When the load decreases to a customer
mm) static deflection are also available for more isolation.
selected load value, one of the units will be shut down by
YORK YMC² sound pressure level ratings will be furnished
a sequence control. Since all water is flowing through the
on request. Control of sound and vibration transmission
operating unit, that unit will cool the water to the desired
must be taken into account in the equipment room con-
temperature.
struction as well as in the selection and installation of the
equipment.
Series Counter Flow Arrangement (Refer to Fig. 3, pg
19) - Chillers may be applied in pairs with chilled water
THERMAL INSULATION
circuits connected in series and with the condenser water
in series counter flow. All of the chilled water flows through No appreciable operating economy can be achieved by
both evaporators. All of the condenser water flows through thermally insulating the chiller. However, the chiller’s cold
both condensers. The water ranges are split, which al surfaces should be insulated with a vapor barrier insu
lows a lower temperature difference or "head" on each lation sufficient to prevent condensation. A chiller can
chiller, than multiple units in parallel. For equal chillers, the be factory-insulated with 3/4" (19 mm) or 1-1/2" (38 mm)
machine at higher temperature level will typically provide thick insulation, as an option. This insulation will normally
slightly more than half the capacity. The compressor mo prevent condensation in environments with dry bulb tem
tors and gear codes on the two chillers are often matched, peratures of 50°F to 90°F (10°C to 32°C) and relative
such that the high temperature machine can operate at humidities up to 75% [3/4" (19 mm) thickness] or 90%
the low temperature conditions when one unit is cycled [1-1/2" (38 mm) thickness]. The insulation is painted and
off at part loads (as compared to series-parallel chillers the surface is flexible and reasonably resistant to wear. It
which are typically not identical). is intended for a chiller installed indoors and, therefore,
no protective covering of the insulation is usually required.
Series counter flow application can provide a significant If insulation is applied to the water boxes at the job site,
building energy savings for large capacity plants which

26 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

it must be removable to permit access to the tubes for Starters – A separate starter is not required since the
routine maintenance. YORK YMC² chiller is equipped with a factory installed
unit mounted Variable Speed Drive (VSD).
VENTILATION
Controls – No field control wiring is required since the
The ASHRAE Standard 15 Safety Code for Mechanical
Optispeed Variable Speed Drive is factory installed as
Refrigeration requires that all machinery rooms be vented
standard. The chiller including VSD is completely con-
to the outdoors utilizing mechanical ventilation by one
trolled by the control panel.
or more power-driven fans. This standard, plus National
Fire Protection Association Standard 90A, state, local and
Copper Conductors – Only copper conductors should
any other related codes should be reviewed for specific
be connected to compressor motors and starters.
requirements. Since the YORK YMC² motor is hermeti-
Aluminum conductors have proven to be un satisfactory
cally sealed, no additional ventilation is needed due to
when connected to copper lugs. Aluminum oxide and the
motor heat.
difference in thermal conductivity between copper and
aluminum cannot guarantee the required tight connection
In addition, the ASHRAE Standard 15 requires a refrig
over a long period of time.
erant vapor detector to be employed for all refrigerants.
It is to be located in an area where refrigerant from a
Power-factor Correction Capacitors – The YORK YMC²
leak would be likely to concentrate. An alarm is to be ac
is equipped with a factory mounted Optispeed VSD pro-
tivated and the mechanical ventilation started at a value
viding automatic power-factor correction to a minimum of
no greater than the TLV (Threshold Limit Value) of the
0.97 at all operating condi tions, so additional capacitors
refrigerant.
are not required.
ELECTRICAL CONSIDERATIONS
Branch Circuit Overcurrent Protection – The branch
Unit input conductor size must be in accordance with circuit overcurrent protection device(s) should be a
the National Electrical Code (N.E.C.), or other applicable time-delay type, with a minimum rating equal to the next
codes, for the unit full load amperes (FLA). Please refer standard fuse/breaker rating above the calculated value.
to the submittal drawings for the FLA and Minimum Cur- Refer to submittal drawings for the specific calculations
rent Ampacity (MCA) specific to each application. Flexible for each application.
conduit should be used for the last several feet to the
chiller in order to provide vibration isolation. Table 3 lists
the allowable variation in voltage supplied to the chiller.
The unit nameplate is stamped with the unit voltage, and
frequency.

TABLE 3 – VOLTAGE VARIATIONS


NAME- OPERATING VOLTAGE
RATED
FREQ. PLATE
VOLTAGE
VOLTAGE MIN. MAX.

380 380 342 423


60 HZ
460 440/460/480 414 508
400 380/400 342 423
50 HZ
415 415 374 456

JOHNSON CONTROLS 27
FORM 160.78-EG1 (610)

Nomenclature

Unit Nomenclature
Position: 1,2,3,4 - 5 6,7,8,9 10 11
YMC2 Chiller Model
S Single Stage Compressor
#### Capacity in KW
A Refrigerant HFC R-134a
A Mod Level

Compressor Nomenclature
Position: 1,2 3 - 4 5 6 7 8 9
M1 Motor
A Motor Revision Level
# # # Impeller
F Forward Rotation
A Impeller Design Revision Level
A Gas Path Revision Level

28 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Heat Exchanger Nomenclature

Position: 1 2 3,4 5,6 - 7 8 9 - 10 11 12 - 13 14 15 16


E Evaporator
C Condenser
A Heat Exchanger Mod Level
XX Nominal Inside Diameter in inches
YY Nominal Length in feet
# # # Tube Number
B 3/4" Tube count code 1
C 3/4" Tube count code 2
D 3/4" Tube count code 3
E 3/4" Tube count code 4
2 1" Tube count code 1
3 1" Tube count code 2
4 1" Tube count code 3
5 1" Tube count code 4
S Vessel Refrigerant Side Pressure Code, 235
1 Water Side Pressure Code, 150 psi
3 Water Side Pressure Code, 300 psi
# Number of passes
G Water connection type, Grooved, Standard
F Water connection type, Flanged
C Water box type, compact
M Water box type, Marine
R Inlet on Right (when viewing control panel)
L Inlet on Left (when viewing control panel)

JOHNSON CONTROLS 29
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.)  -  Unit


VSD VSD

COMPRESSOR
MOTOR
CONTROL CONTROL
PANEL PANEL

H J
B

M
C D 3-3/8” F E G
A (EVAP.) (EVAP.)

ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR


TYPE OF CHILLER MOUNTING M
NEOPRENE PAD ISOLATORS 1-3/4"
SPRING ISOLATORS 1" DEFLECTION 1"
DIRECT MOUNT 3/4"

EVAPORATOR CONDENSER DIMENSIONS (FT-IN)


CODE CODE A B C D E
EA2510 CA2110 5’-5” 7’-4” 1’-3-1/2” 1’-3-1/2” 10’-0”
EA2510 CA2510 5’-5” 7’-9” 1’-3-1/2” 1’-3-1/2” 10’-0”
EA2514 CA2514 5’-5” 7’-9” 1’-3-1/2” 1’-3-1/2” 14’-0”

NOTES:
1. All dimensions are approximate. Certified dimensions are available on request.
2. Standard water nozzles are Schedule 40 pipe size, furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of weld-
ing, 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.
3. One, two, and three-pass nozzle arrangements are available only in pairs shown for all shell codes. Any pair of evaporator nozzles many
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.
4. Condenser water must enter the water box through the bottom connection for proper operation of the sub-cooler to achieve rated performance.
5. To determine overall height, add dimension "M" for the appropriate isolator type.

30 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.)  -  Nozzle Arrangements


EVAPORATORS  –  COMPACT WATER BOXES
FRONT
OF UNIT
1-PASS
1-PASS
NOZZLE ARRANGEMENTS
NO. OF PASSES EVAPORATOR
IN OUT
AA AA
FLOOR LEFT END RIGHT END
LINE 1 RIGHT
LEFT END
END
M C C M
LEFT END RIGHT END

FRONT
OF UNIT
2-PASS

2-PASS
NOZZLE ARRANGEMENTS
BB BB
EVAPORATOR
NO. OF PASSES
AA AA IN OUT
FLOOR
LINE LOWER RIGHT END UPPER RIGHT END
2
EE C
LOWER LEFT END UPPER LEFT END
M EE M
EE
C EE

LEFT END RIGHT END

FRONT
OF UNIT
3-PASS

3-PASS
NOZZLE ARRANGEMENTS

BB EVAPORATOR
NO. OF PASSES
AA IN OUT
FLOOR
LINE 3 RIGHT END LEFT END

EE
M EE M
C C

LEFT END RIGHT END

FRONT
OF UNIT

3-PASS
NOZZLE ARRANGEMENTS
NO. OF PASSES EVAPORATOR
IN OUT
AA BB
FLOOR 3 LEFT END RIGHT END
LINE

M EE M
EE
C C

LEFT END RIGHT END

COMPACT WATER BOXES-150 PSI


NOZZLE PIPE SIZE (IN) EVAPORATOR NOZZLE DIMENSIONS (FT-IN)
EVAPORATOR
NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE C
1 2 3 AA 5
AA 5
BB 5
EE AA 5
BB5 EE
EA25 8 6 4 1'-3-1/2" 1'-10" 1'-5" 2'-3" 0'-5" 1'-5" 2'-3" 0'-5"

JOHNSON CONTROLS 31
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.) - Evap Compact Waterboxes


EVAPORATORS – COMPACT WATER BOXES

F F

ONE PASS

G
F

TWO PASS

F F

THREE PASS

EVAPORATOR DIMENSION (FT-IN)


SHELL CODE F G
EA25 1'-2-1/8" 0'-6-5/16"

NOTES:
1. 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 1/16" raised face), water flanged nozzles are optional (add 1/2" to nozzle
length). Companion flanges, nuts, bolts, and gaskets are not furnished.
2. 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.
3. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance.
4. Connected piping should allow for removal of compact water boxes for tube access and cleaning.
5. Add dimension "M" as shown on the unit dimensions page for the appropriate isolator type.
6. Standard 150 PSI design pressure boxes shown.

32 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.)  -  Nozzle Arrangements


CONDENSERS  –  COMPACT WATER BOXES
FRONT
OF UNIT
1-PASS

1-PASS
NOZZLE ARRANGEMENTS
NO. OF CONDENSER
AA AA PASSES IN OUT
FLOOR
LINE LEFT END RIGHT END
1
RIGHT END LEFT END
M C C M
LEFT END RIGHT END

FRONT
OF UNIT
2-PASS

2-PASS
NOZZLE ARRANGEMENTS
BB BB CONDENSER
NO. OF PASSES
AA AA
IN OUT
FLOOR
LINE
LOWER RIGHT END UPPER RIGHT END
2
LOWER LEFT END UPPER LEFT END
M C C M

LEFT END RIGHT END

FRONT
OF UNIT 3-PASS

3-PASS
NOZZLE ARRANGEMENTS
BB
EVAPORATOR
AA NO. OF PASSES
FLOOR IN OUT
LINE
3 RIGHT END LEFT END

M C C M
LEFT END RIGHT END

FRONT
OF UNIT

3-PASS
NOZZLE ARRANGEMENTS
BB EVAPORATOR
NO. OF PASSES
AA IN OUT
FLOOR
LINE 3 LEFT END RIGHT END

M C C M
LEFT END RIGHT END

COMPACT WATER BOXES-150 PSI


NOZZLE PIPE SIZE (IN) CONDENSER NOZZLE DIMENSIONS (FT-IN)
CONDENSER
NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE C
1 2 3 AA5 AA5 BB5 AA5 BB5
CA21 10 6 6 1'-3/12" 1'-11-1/2" 1'-5" 2'-6" 1'-5" 2'-6"
CA25 12 8 6 1'-3/12" 2'-1-1/2" 1'-5-7/8" 2'-9-1/8" 1'-5-7/8" 2'-9-1/8"

JOHNSON CONTROLS 33
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.) - Cond Compact Waterboxes


CONDENSERS – COMPACT WATER BOXES

F F

ONE PASS

G
F

TWO PASS

F F

THREE PASS

CONDENSER
SHELL CODE DIMENSION (FT-IN)
H J
CA21 1'-1-3/4" 0'-5-13/16"
CA25 1'-1-3/4" 0'-6-5/16"

NOTES:
1. 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 1/16" raised face), water flanged nozzles are optional (add 1/2" to nozzle
length). Companion flanges, nuts, bolts, and gaskets are not furnished.
2. 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.
3. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance.
4. Connected piping should allow for removal of compact water boxes for tube access and cleaning.
5. Add dimension "M" as shown on the unit dimensions page for the appropriate isolator type.
6. Standard 150 PSI design pressure boxes shown.

34 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.)  -  Nozzle Arrangements


EVAPORATORS  –  MARINE WATER BOXES
FRONT
OF UNIT
1-PASS
1-PASS
NOZZLE ARRANGEMENTS

AA NO. OF PASSES EVAPORATOR


AA
IN OUT
FLOOR LEFT END RIGHT END
LINE 1 RIGHT
LEFT END
END
M C C M
LEFT END RIGHT END

FRONT
OF UNIT
2-PASS

BB BB 2-PASS
NOZZLE ARRANGEMENTS
EVAPORATOR
AA AA
NO. OF PASSES
FLOOR
IN OUT
LINE LOWER RIGHT END UPPER RIGHT END
2
C C
LOWER LEFT END UPPER LEFT END
M M
EE EE

LEFT END RIGHT END


FRONT
OF UNIT 3-PASS

BB 3-PASS
NOZZLE ARRANGEMENTS
EVAPORATOR
NO. OF PASSES
AA IN OUT
FLOOR
LINE 3 RIGHT END LEFT END

C C
M M
EE

LEFT END RIGHT END

FRONT
OF UNIT
3-PASS
BB NOZZLE ARRANGEMENTS
NO. OF PASSES EVAPORATOR
IN OUT
AA 3 LEFT END RIGHT END

C C
M FLOOR M
EE LINE

LEFT END RIGHT END

MARINE WATER BOXES-150 PSI


NOZZLE PIPE SIZE (IN) EVAPORATOR NOZZLE DIMENSIONS (FT-IN)
EVAPORATOR
NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE C
1 2 3 AA 5
AA 5
BB 5
EE AA 5
BB5 EE
EA25 8 6 4 1'-3/12" 3'-7" 1'-2" 3'-7" 1'-5-1/2" 1'-2" 3'-7" 1'-5-1/2"

JOHNSON CONTROLS 35
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.)  -  Nozzles


EVAPORATORS  –  MARINE WATER BOXES

EVAPORATOR 1-PASS 2-PASS 3-PASS


SHELL CODE F I F I G F I
EA25 1'-6-5/8" 0'-8-11/16" 1'-4-1/2" 0'-7-5/8" 0'-6-5/16" 1'-4-1/2" 0'-7-5/8"

NOTES:
1. All dimensions are approximate. Certified dimensions are available upon request.
2. 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 1/16" raised face),
water flanged nozzles are optional (add 1/2" 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. Compact water boxes on one heat exchanger may be used with Marine Water Boxes on
the other heat exchanger.
4. Condenser water must enter the water box through the bottom connection for proper operation of the sub-cooler to achieve rated
performance.
5. Add dimension "M" as shown on pages per unit dimensions page for the appropriate isolator type.

36 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.)  -  Nozzle Arrangements


CONDENSERS  –  MARINE WATER BOXES
FRONT
OF UNIT
1-PASS

1-PASS
NOZZLE ARRANGEMENTS
AA AA
NO. OF CONDENSER
PASSES IN OUT
FLOOR
LINE LEFT END RIGHT END
1
RIGHT END LEFT END
M C C M
LEFT END RIGHT END

FRONT
OF UNIT
2-PASS

BB
2-PASS
BB
NOZZLE ARRANGEMENTS
CONDENSER
NO. OF PASSES
AA IN OUT
LOWER RIGHT END UPPER RIGHT END
2
LOWER LEFT END UPPER LEFT END
C FLOOR C
M M
LINE EE
EE

LEFT END RIGHT END

FRONT 3-PASS
OF UNIT

BB 3-PASS
NOZZLE ARRANGEMENTS
EVAPORATOR
AA NO. OF PASSES
IN OUT
3 RIGHT END LEFT END
C C
M FLOOR M
LINE EE

LEFT END RIGHT END

FRONT
OF UNIT
3-PASS
NOZZLE ARRANGEMENTS
BB
EVAPORATOR
NO. OF PASSES
IN OUT
3 LEFT END RIGHT END
AA

C C
M FLOOR M
EE LINE

LEFT END RIGHT END

MARINE WATER BOXES-150 PSI


NOZZLE PIPE SIZE (IN) CONDENSER NOZZLE DIMENSIONS (FT-IN)
CONDENSER
NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE C
1 2 3 AA 5
AA 5
BB 5
AA 5
AA 5
BB5 EE
CA21 10 6 6 1'-3/12" 3'-10-1/2" 1'-5-1/2" 3'-10-1/2" 1'-4-1/2" 1'-5-1/2" 3'-10-1/2" 1'-4-1/2"
CA25 12 8 6 1'-3/12" 4'-0-1/2" 1'-5-1/2" 4'-0-1/2" 1'-6-1/2" 1'-5-1/2" 4'-0-1/2" 1'-6-1/2"

JOHNSON CONTROLS 37
FORM 160.78-EG1 (610)

Dimensions (Ft. - In.)  -  Nozzles


CONDENSERS  –  MARINE WATER BOXES

CONDENSER 1-PASS 2-PASS 3-PASS


SHELL CODE
F I F I G F I
CA21 1'-8-9/16" 0'-9-3/4" 1'-4-7/16" 0'-7-11/16" 0'-5-13/16" 1'-4-7/16" 0'-7-11/16"
CA25 1'-11-1/4" 0'-11" 1'-7-1/8" 0'-8-15/16" 0'-6-5/16" 1'-7-1/8" 0'-8-15/16"

NOTES:
1. All dimensions are approximate. Certified dimensions are available upon request.
2. 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 1/16" raised face),
water flanged nozzles are optional (add 1/2" 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. Compact water boxes on one heat exchanger may be used with Marine Water Boxes on
the other heat exchanger.
4. Condenser water must enter the water box through the bottom connection for proper operation of the sub-cooler to achieve rated
performance.
5. Add dimension "M" as shown on pages per unit dimensions page for the appropriate isolator type.

38 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Weights - English
TABLE 4 – APPROXIMATE UNIT WEIGHT* (MAX TUBE COUNT USING 150 PSI COMPACT WATERBOXES)
OPERATING
COMPRESSOR EVAP COND EST REF CHRG SHIPPING WEIGHT
WEIGHT
EA2510 CA2110 555 11770 12740
M1-197FAA EA2510 CA2510 610 12790 14070
EA2514 CA2514 860 14970 16620
EA2510 CA2110 555 11790 12760
M1-205FAA EA2510 CA2510 610 12810 14090
EA2514 CA2514 860 14990 16630
1. REFRIGERANT CHARGE QUANTITY AND WEIGHTS WILL VARY BASED ON TUBE COUNT.
2. SHIPPING WEIGHT BASED ON FORM 1 SHIPMENT
* REFER TO PRODUCT DRAWINGS FOR DETAILED WEIGHT INFORMATION

TABLE 5 – EVAPORATOR MARINE WATER BOX WEIGHTS (TO BE ADDED TO STANDARD UNIT WEIGHTS
SHOWN ON TABLE 4)
SHIPPING WEIGHT INCREASE (LBS) OPERATING WEIGHT INCREASE (LBS)
EVAPORATOR
1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
EA2510 702 365 737 1192 561 1130
EA2514 702 365 737 1192 561 1130

TABLE 6 – CONDENSER MARINE WATER BOX WEIGHTS (TO BE ADDED TO STANDARD UNIT WEIGHTS
SHOWN ON TABLE 4)
SHIPPING WEIGHT INCREASE (LBS) OPERATING WEIGHT INCREASE (LBS)
CONDENSER
1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
CA2110 557 269 551 996 413 843
CA2510 797 403 805 1453 708 1400
CA2514 797 403 805 1453 708 1400

JOHNSON CONTROLS 39
FORM 160.78-EG1 (610)

Dimensions (mm)  -  Unit

VSD VSD

COMPRESSOR
MOTOR
CONTROL CONTROL
PANEL PANEL

H J
B

M
C D 3-3/8” F E G
A (EVAP.) (EVAP.)

ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR


TYPE OF CHILLER MOUNTING M
NEOPRENE PAD ISOLATORS 45
SPRING ISOLATORS 1" DEFLECTION 25
DIRECT MOUNT 19

EVAPORATOR CONDENSER DIMENSIONS (MM)


CODE CODE A B C D E
EA2510 CA2110 1651 2235 394 394 3048
EA2510 CA2510 1651 2362 394 394 3048
EA2514 CA2514 1651 2362 394 394 4267

NOTES:
1. All dimensions are approximate. Certified dimensions are available on request.
2. For all water boxes (compact shown above), determine overall unit length by adding water box depth to tube sheet length.
3. Water nozzles can be located on either end of unit. Add 13 mm to nozzle length for flanged connections.
4. To determine overall height, add dimension "M" for the appropriate isolator type.
5. Use of motors with motor hoods may increase overall unit dimensions.

40 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Dimensions (mm)  -  Nozzle Arrangements


EVAPORATORS  –  COMPACT WATER BOXES
FRONT
OF UNIT
1-PASS
1-PASS
NOZZLE ARRANGEMENTS
NO. OF PASSES EVAPORATOR
IN OUT
AA AA
FLOOR LEFT END RIGHT END
LINE 1 RIGHT
LEFT END
END
M C C M
LEFT END RIGHT END

FRONT
OF UNIT
2-PASS

2-PASS
NOZZLE ARRANGEMENTS
BB BB
EVAPORATOR
NO. OF PASSES
AA AA IN OUT
FLOOR
LINE LOWER RIGHT END UPPER RIGHT END
2
EE C
LOWER LEFT END UPPER LEFT END
M EE M
EE
C EE

LEFT END RIGHT END

FRONT
OF UNIT
3-PASS

3-PASS
NOZZLE ARRANGEMENTS

BB EVAPORATOR
NO. OF PASSES
AA IN OUT
FLOOR
LINE 3 RIGHT END LEFT END

EE
M EE M
C C

LEFT END RIGHT END

FRONT
OF UNIT

3-PASS
NOZZLE ARRANGEMENTS
NO. OF PASSES EVAPORATOR
IN OUT
AA BB
FLOOR 3 LEFT END RIGHT END
LINE

M EE M
EE
C C

LEFT END RIGHT END

COMPACT WATER BOXES-150 PSI


NOZZLE PIPE SIZE (IN) EVAPORATOR NOZZLE DIMENSIONS (MM)
EVAPORATOR
NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE C
1 2 3 AA 5
AA 5
BB 5
EE AA 5
BB5 EE
EA25 8 6 4 394 559 432 686 127 432 686 127

JOHNSON CONTROLS 41
FORM 160.78-EG1 (610)

Dimensions (mm)  -  Evap Nozzle Arrangements


EVAPORATORS – COMPACT WATER BOXES

F F

ONE PASS

G
F

TWO PASS

F F

THREE PASS

EVAPORATOR DIMENSION (MM)


SHELL CODE F G
EA25 359 160

NOTES:
1. 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.
2. 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.
3. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance.
4. Connected piping should allow for removal of compact water boxes for tube access and cleaning.
5. Add dimension "M" as shown on the unit dimensions page for the appropriate isolator type.
6. Standard 150 PSI (10.3 barg) design pressure boxes shown.

42 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Dimensions (mm) - Cond Compact Water Boxes


CONDENSERS  –  COMPACT WATER BOXES
FRONT
OF UNIT
1-PASS

1-PASS
NOZZLE ARRANGEMENTS
NO. OF CONDENSER
AA AA PASSES IN OUT
FLOOR
LINE LEFT END RIGHT END
1
RIGHT END LEFT END
M C C M
LEFT END RIGHT END

FRONT
OF UNIT
2-PASS

2-PASS
NOZZLE ARRANGEMENTS
BB BB CONDENSER
NO. OF PASSES
AA AA
IN OUT
FLOOR
LINE
LOWER RIGHT END UPPER RIGHT END
2
LOWER LEFT END UPPER LEFT END
M C C M

LEFT END RIGHT END

FRONT
OF UNIT 3-PASS

3-PASS
NOZZLE ARRANGEMENTS
BB
EVAPORATOR
AA NO. OF PASSES
FLOOR IN OUT
LINE
3 RIGHT END LEFT END

M C C M
LEFT END RIGHT END

FRONT
OF UNIT

3-PASS
NOZZLE ARRANGEMENTS
BB EVAPORATOR
NO. OF PASSES
AA IN OUT
FLOOR
LINE 3 LEFT END RIGHT END

M C C M
LEFT END RIGHT END

COMPACT WATER BOXES-150 PSI


NOZZLE PIPE SIZE (IN) CONDENSER NOZZLE DIMENSIONS (MM)
CONDENSER
NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE C
1 2 3 AA5 AA5 BB5 AA5 BB5
CA21 10 6 6 394 597 432 762 432 762
CA25 12 8 6 394 648 454 841 454 841

JOHNSON CONTROLS 43
FORM 160.78-EG1 (610)

Dimensions (mm)  -  Cond Nozzle Arrangements


CONDENSERS – COMPACT WATER BOXES

F F

ONE PASS

G
F

TWO PASS

F F

THREE PASS

CONDENSER DIMENSION (MM)


SHELL CODE H J
CA21 349 148
CA25 349 160

NOTES:
1. 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.
2. 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.
3. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance.
4. Connected piping should allow for removal of compact water boxes for tube access and cleaning.
5. Add dimension "M" as shown on the unit dimensions page for the appropriate isolator type.
6. Standard 150 PSI design pressure boxes shown.

44 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Dimensions (mm)  -  Nozzle Arrangements


EVAPORATORS  –  MARINE WATER BOXES
FRONT
OF UNIT
1-PASS
1-PASS
NOZZLE ARRANGEMENTS

AA NO. OF PASSES EVAPORATOR


AA
IN OUT
FLOOR LEFT END RIGHT END
LINE 1 RIGHT
LEFT END
END
M C C M
LEFT END RIGHT END

FRONT
OF UNIT
2-PASS

BB BB 2-PASS
NOZZLE ARRANGEMENTS
EVAPORATOR
AA AA
NO. OF PASSES
FLOOR
IN OUT
LINE LOWER RIGHT END UPPER RIGHT END
2
C C
LOWER LEFT END UPPER LEFT END
M M
EE EE

LEFT END RIGHT END


FRONT
OF UNIT 3-PASS

BB 3-PASS
NOZZLE ARRANGEMENTS
EVAPORATOR
NO. OF PASSES
AA IN OUT
FLOOR
LINE 3 RIGHT END LEFT END

C C
M M
EE

LEFT END RIGHT END

FRONT
OF UNIT
3-PASS
BB NOZZLE ARRANGEMENTS
NO. OF PASSES EVAPORATOR
IN OUT
AA 3 LEFT END RIGHT END

C C
M FLOOR M
EE LINE

LEFT END RIGHT END

MARINE WATER BOXES-150 PSI


NOZZLE PIPE SIZE (IN) EVAPORATOR NOZZLE DIMENSIONS (MM)
EVAPORATOR
NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE C
1 2 3 AA 5
AA 5
BB 5
EE AA 5
BB5 EE
EA25 8 6 4 394 1092 356 1092 445 356 1092 445

JOHNSON CONTROLS 45
FORM 160.78-EG1 (610)

Dimensions (mm)  -  Nozzles


EVAPORATORS  –  MARINE WATER BOXES

EVAPORATOR 1-PASS 2-PASS 3-PASS


SHELL CODE F I F I G F I
EA25 473 221 419 194 160 419 194

NOTES:
1. All dimensions are approximate. Certified dimensions are available upon request.
2. 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.
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. Compact water boxes on one heat exchanger may be used with Marine
Water Boxes on the other heat exchanger.
4. Water must enter the water box through the bottom connection to achieve rated performance.
5. Add dimension "M" as shown on the unit dimensions page for the appropriate isolator type.

46 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Dimensions (mm)  -  Nozzle Arrangements


CONDENSERS  –  MARINE WATER BOXES
FRONT
OF UNIT
1-PASS

1-PASS
AA AA NOZZLE ARRANGEMENTS
NO. OF CONDENSER
FLOOR PASSES IN OUT
LINE
LEFT END RIGHT END
1
C C RIGHT END LEFT END
M M
LEFT END RIGHT END

FRONT
OF UNIT
2-PASS

BB BB 2-PASS
NOZZLE ARRANGEMENTS
CONDENSER
AA
NO. OF PASSES
IN OUT
LOWER RIGHT END UPPER RIGHT END
2
C C LOWER LEFT END UPPER LEFT END
M FLOOR M
LINE EE
EE

LEFT END RIGHT END

FRONT 3-PASS
OF UNIT

BB
3-PASS
NOZZLE ARRANGEMENTS
EVAPORATOR
AA NO. OF PASSES
IN OUT
3 RIGHT END LEFT END
C C
M FLOOR M
LINE EE

LEFT END RIGHT END

FRONT
OF UNIT
3-PASS

BB
NOZZLE ARRANGEMENTS
EVAPORATOR
NO. OF PASSES
IN OUT
AA 3 LEFT END RIGHT END

C C
M FLOOR M
EE LINE

LEFT END RIGHT END

MARINE WATER BOXES-150 PSI


NOZZLE PIPE SIZE (IN) CONDENSER NOZZLE DIMENSIONS (MM)
CONDENSER
NO. OF PASSES 1-PASS 2-PASS 3-PASS
SHELL CODE C
1 2 3 AA 5
AA 5
BB 5
AA 5
AA 5
BB5 EE
CA21 10 6 6 394 1181 445 1181 419 445 1181 419
CA25 12 8 6 394 1232 445 1232 470 445 1232 470

JOHNSON CONTROLS 47
FORM 160.78-EG1 (610)

Dimensions (mm)  -  Nozzles


CONDENSERS  –  MARINE WATER BOXES

CONDENSER 1-PASS 2-PASS 3-PASS


SHELL CODE F I F I G F I
CA21 522 248 418 195 148 418 195
CA25 591 279 486 227 160 418 227

NOTES:
1. All dimensions are approximate. Certified dimensions are available upon request.
2. 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.
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. Compact water boxes on one heat exchanger may be used with Marine
Water Boxes on the other heat exchanger.
4. Condenser water must enter the water box through the bottom connection for proper operation of the sub-cooler to achieve rated performance.
5. Add dimension "M" as shown on the unit dimension page for the appropriate isolator type.

48 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

Weights - SI

TABLE 7 – APPROXIMATE UNIT WEIGHT*(MAX TUBE COUNT USING COMPACT WATERBOXES)


OPERATING
COMPRESSOR EVAP COND EST REF CHRG SHIPPING WEIGHT
WEIGHT
EA2510 CA2110 255 5340 5780
M1-197FAA EA2510 CA2510 280 5800 6380
EA2514 CA2514 390 6790 7530
EA2510 CA2110 255 5340 5780
M1-205FAA EA2510 CA2510 280 5810 6390
EA2514 CA2514 390 6800 7540
1. REFRIGERANT CHARGE QUANTITY AND WEIGHTS WILL VARY BASED ON TUBE COUNT.
2. SHIPPING WEIGHT BASED ON FORM 1 SHIPMENT
* REFER TO PRODUCT DRAWINGS FOR DETAILED WEIGHT INFORMATION

TABLE 8 – EVAPORATOR MARINE WATER BOX WEIGHTS (TO BE ADDED TO STANDARD UNIT WEIGHTS
SHOWN ON TABLE 7)
SHIPPING WEIGHT INCREASE (KG) OPERATING WEIGHT INCREASE (KG)
EVAPORATOR
1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
EA2510 318 166 334 541 254 513
EA2514 318 166 334 541 254 513

TABLE 9 – CONDENSER MARINE WATER BOX WEIGHTS (TO BE ADDED TO STANDARD UNIT WEIGHTS
SHOWN ON TABLE 7)
SHIPPING WEIGHT INCREASE (KG) OPERATING WEIGHT INCREASE (KG)
CONDENSER
1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS
CA2110 253 122 250 452 187 382
CA2510 362 183 365 659 321 635
CA2514 362 183 365 659 321 635

JOHNSON CONTROLS 49
FORM 160.78-EG1 (610)

Guide Specifications
GENERAL permanent magnet type directly coupled to the compres-
Furnish YORK YMC² Unit(s) as indicated on the drawings. sor. The motor will be bolted to a cast iron adapter plate
mounted on the compressor to provide factory alignment
Each unit shall produce a capacity of ____ tons, cooling of the shaft. The motor shaft shall be supported on active
____ gpm of _____ from ____ to ____ °F when supplied magnetic radial and thrust bearings. Magnetic bearing
with ____ gpm of condenser water at ____°F. Power control shall be equipped with auto vibration reduction
input shall not exceed ____ KW with an IPLV of ____. and balancing systems. During a power failure event,
The cooler shall be selected for _____ fouling factor and the magnetic bearings shall remain active throughout
a maximum liquid pressure drop of ____ ft. Water side the compressor coast down. Rolling element bearings
shall be designed for ____ psig working pressure. The shall be provided as a backup to the magnetic bearings
condenser shall be selected for _____ fouling factor and designed for emergency touch down situations. Motor
maximum liquid pressure drop of ___ ft. Water side shall stator and rotor shall be equipped with a pressure driven
be designed for ____ psig working pressure. Power shall refrigerant cooling loop to maintain acceptable operating
be supplied to the unit at ____ volts – 3 phase - ___ Hertz. temperatures.
The chiller shall use HFC R-134a.
VARIABLE SPEED DRIVE
Each unit shall be completely factory packaged includ-
A variable speed drive shall be factory installed on the
ing evaporator, unit mounted OptiSpeed Variable Speed
chiller. It will vary the compressor motor speed by control-
Drive (VSD), condenser, sub-cooler, compressor, hermetic
ling the frequency and voltage of the electrical power to
motor, OptiView Control Center, and all interconnecting
the motor. The capacity control logic shall automatically
unit piping and wiring. The chiller shall be painted prior
adjust motor speed and compressor pre-rotation vane
to shipment.
position independently for maximum part-load efficiency
by analyzing information fed to it by sensors located
Performance shall be certified in accordance with AHRI
throughout the chiller.
Standard 550/590. Only chillers that are listed in the AHRI
Certification Program for Centrifugal and Rotary Screw
Drive shall be PWM type utilizing IGBT’s with a power
Water Chillers are acceptable.
factor of 0.95 or better at all loads and speeds.
The initial charge of refrigerant shall be supplied, shipped
The variable speed drive shall be unit mounted in a NEMA
in containers and cylinders for field installation or factory
-1 enclosure with all power and control wiring between
charged in the chiller.
the drive and chiller factory installed. Field power wiring
shall be a single point connection and electrical lugs for
COMPRESSOR
incoming power wiring will be provided. The entire chiller
The compressor shall be a single stage centrifugal type package shall be UL listed.
powered by a high speed electric motor. A cast aluminum,
fully shrouded impeller shall be mounted directly to the The variable speed drive shall be cooled using condenser
motor shaft. The impeller shall be designed for balanced water and all cooling connections shall be factory installed.
thrust, dynamically balanced and overspeed tested for
smooth, vibration free operation. Compressor castings The following features will be provided:
shall be designed for 235 psig (16 barg) working pressure a. Door interlocked rotary disconnect switch or cir-
and hydrostatically pressure tested at 355 psig for HFC cuit breaker capable of being padlocked.
R-134a units.
b. Ground fault protection.
Capacity control will be achieved by the combined use of c. Over voltage and under voltage protection.
variable speed control and pre-rotation vanes to provide d. 3-phase sensing motor over current protection.
fully modulating control from maximum to minimum load. e. 3-phase sensing input over current protection.
The unit shall be capable of operating with lower tem-
f. Single phase protection.
perature cooling tower water during part load operation
in accordance with AHRI Standard 550/590. Pre-rotation g. Insensitive to phase rotation.
vane position will be automatically controlled by an exter- h. Over temperature protection.
nal electric actuator to maintain constant leaving chilled i. IEEE Std. 519-1992 compliance.
water temperature.
j. Digital readout at the chiller unit control panel of
output frequency, output voltage, 3-phase input
MOTOR
current, 3-phase output current, input kVA, Kilo-
The compressor motor shall be a hermetic, oil free, watts and Kilowatt-hours, input voltage THD, input

50 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

current TDD, self-diagnostic service parameters. boxes shall be designed for 150 psi (10.3 bar) design
Separate meters for this information will not be working pressure and tested at 225 psig (15.5 bar). Vent
acceptable. and drain connections with plugs will be provided on each
k. KW Meter - The unit’s input power consumption water box. Low flow protection shall be provided by a
will be measured and displayed digitally via the thermal-type flow sensor, factory mounted in the water
unit’s control panel. The KW meter accuracy is nozzle connection and wired to the chiller OptiView™
typically +/- 3% of reading. KW meter scale is Control Center.
0 - 788 KW.
CONDENSER
l. KWh Meter – The unit’s cumulative input power
consumption is measured and displayed digitally Condenser shall be of the shell and tube type, designed
via the unit’s control panel. The KWh meter is for 235 psig (16 barg) working pressure on the refrigerant
resettable and its accuracy is typically +/- 3% of side. Shell shall be fabricated from rolled carbon steel
reading. KWh meter scale is 0 – 999,999 kWh. plate with fusion welded seams; have carbon steel tube
m. Ammeter – Simultaneous three-phase true RMS sheets, drilled and reamed to accommodate the tubes;
digital readout via the unit control panel. Six cur- and intermediate tube supports spaced no more than four
rent transformers provide isolated sensing. The feet apart. The refrigerant side shall be designed, tested
ammeter accuracy is typically +/- 3% of readming. and stamped in accordance with ASME Boiler and Pres-
Ammeter scale is 0 - 545 A RMS. sure Vessel Code, Section VIII- Division 1. Tubes shall
be high-efficiency, internally and externally enhanced
n. Voltmeter – Simultaneous three-phase true RMS
type having plain copper lands at all intermediate tube
digital readout of input current and motor current
supports to provide maximum tube wall thickness at the
via the unit control panel. The voltmeter accuracy
support area. Each tube shall be roller expanded into the
is typically +/- 3% of reading. Voltmeter scale is
tube sheets providing a leak proof seal, and be individu-
0 – 670 VAC.
ally replaceable. Water velocity through the tubes shall
o. Elapsed Time Meter – Digital readout of the unit’s not exceed 12 fps.
elapsed running time (0 – 876,600 hours, rese-
table) is displayed via the unit control panel. Water boxes shall be removable to permit tube cleaning
and replacement. Stubout water connections having
EVAPORATOR ANSI/AWWA C-606 grooves will be provided. Waterboxes
Evaporator shall be a shell and tube, hybrid falling film shall be designed for 150 psi (10.3 bar) design working
type designed for 235 psig (16 barg) working pressure on pressure and tested at 225 psig (15.5 bar). Vent and drain
the refrigerant side. Shell shall be fabricated from rolled connections with plugs will be provided on each water box.
carbon steel plate with fusion welded seams; have carbon
steel tube sheets, drilled and reamed to accommodate REFRIGERANT ISOLATION VALVES
the tubes; and intermediate tube supports spaced no Factory-installed isolation valves in the compressor dis-
more than four feet apart. The refrigerant side shall be charge line and refrigerant liquid line shall be provided.
designed, tested and stamped in accordance with ASME These valves shall be allow isolation and storage of the re-
Boiler and Pressure Vessel Code, Section VIII- Division frigerant charge in the chiller condenser during servicing,
1. Tubes shall be high-efficiency, internally and externally eliminating time-consuming transfers to remote storage
enhanced type having plain copper lands at all intermedi- vessels. Both valves shall be positive shut-off, assuring
ate tube supports to provide maximum tube wall thickness integrity of the storage system.
at the support area. Each tube shall be roller expanded
into the tube sheets providing a leak proof seal, and be REFRIGERANT FLOW CONTROL
individually replaceable. Water velocity through the tubes
shall not exceed 12 fps. A liquid level sight glass will be Refrigerant flow to the evaporator shall be controlled by
located on the side of the shell to aid in determining proper a variable orifice. The variable orifice control shall auto-
refrigerant charge. A suction baffle eliminator will be lo- matically adjust to maintain proper refrigerant level in the
cated above the tube bundle to prevent liquid refrigerant condenser and evaporator. This shall be controlled by
carryover to the compressor. The evaporator shall have monitoring refrigerant liquid level in the condenser, as-
a refrigerant relief device sized to meet the requirements suring optimal subcooler performance.
of ASHRAE 15 Safety Code for Mechanical Refrigeration.
OPTIVIEW CONTROL CENTER
Water boxes shall be removable to permit tube cleaning General: The chiller shall be controlled by a stand-alone
and replacement. Stubout water connections having microprocessor based control center. The chiller OptiView
ANSI/AWWA C-606 grooves shall be provided. Water- Control Center shall provide control of chiller operation

JOHNSON CONTROLS 51
FORM 160.78-EG1 (610)

Guide Specification - continued


and monitoring of chiller sensors, actuators, relays and 3. Status messages indicating:
switches.
a. system ready to start
Control panel: The control panel shall include a 10.4 in. b. system running
diagonal color liquid crystal display (LCD) surrounded by c. system coastdown
“soft“ keys which are redefined based on the screen dis-
d. system safety shutdown-manual restart
played at that time. This shall be mounted in the middle
of a keypad interface and installed in a locked enclosure. e. system cycling shutdown-auto restart
The screen shall detail all operations and parameters, f. MBC startup
using a graphical representation of the chiller and its g. start inhibit
major components. Panel verbiage shall be available in
English as standard and in other languages as an option
4. The text displayed within the system status and sys-
with English always available. Data shall be displayed in
tem details field shall be displayed as a color coded
either English or Metric units. Smart Freeze Point Protec-
message to indicate severity: red for safety fault,
tion shall run the chiller at 36.00°F leaving chilled water
orange for cycling faults, yellow for warnings, and
temperature, and not have nuisance trips on low water
green for normal messages.
temperature. The sophisticated program and sensor shall
monitor the chiller water temperature to prevent freeze up. 5. Safety shutdowns enunciated through the display and
When needed Hot Gas Bypass is available as an option. the status bar, and consist of system status, system
The panel shall display countdown timer messages so the details, day, time, cause of shutdown, and type of
operator knows when functions are starting and stopping. restart required. Safety shutdowns shall include:
Every programmable point shall have a pop-up screen
with the allowable ranges, so that the chiller can not be a. Evaporator – Low Pressure
programmed to operate outside of its design limits. b. Evaporator – Transducer or Leaving Liquid Probe
c. Evaporator – Transducer or Temperature Sensor
The chiller control panel shall also provide: d. Condenser – High Pressure Contacts Open
e. Condenser – High Pressure
1. System operating information including: f. Condenser – Pressure Transducer Out-of-Range
g. Auxiliary Safety – Contacts Closed
a. return and leaving chilled liquid temperature
h. Discharge – High Temperature
b. return and leaving condenser liquid temperature
i. Discharge – Low Temperature
c. evaporator and condenser saturation temperature
j. Control Panel – Power Failure
d. evaporator and condenser pressure
k. Watchdog – Software Reboot
e. compressor discharge temperature
l. MBC – Internal Fault
f. percent full load motor current
m. MBC – High Bearing Temperature
g. motor frequency
n. MBC – Cable Fault
h. magnetic bearing levitation status
o. MBC – Speed Signal Fault
i. magnetic bearing temperatures
p. MBC – Overspeed Fault
j. operating hours
q. MBC – Communication
k. number of compressor starts
r. MBC – High Bearing Current
2. Digital programming of setpoints through the universal s. MBC – Rotor Elongation
keypad including: t. MBC – Oscillator Fault
u. MBC – Power Supply Fault
a. leaving chilled liquid temperature
v. MBC – Unauthorized Rotation
b. percent current limit
w. MBC – No Rotation
c. pull-down demand limiting
x. VSD Shutdown – Requesting Fault Data
d. six-week schedule for starting and stopping the
chiller, pumps and tower y. VSD – Stop contacts Open
e. remote reset temperature range z. VSD – DC Bus Preregulation Lockout
aa. VSD – Logic Board Plug

52 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

bb. VSD – Ground Fault z. VSD – Single Phase Input Power


cc. VSD – Phase __ Input DCCT (A,B,C) aa. VSD – DC Bus Under Voltage
dd. VSD – Phase __ Motor DCCT (A,B,C) bb. VSD – Low Phase __ Input Baseplate Tempera-
ee. VSD – Input Current Overload ture (A,B,C)
ff. VSD – 105% Motor Current Overload cc. VSD – Low Phase __ Motor Baseplate Tempera-
ture (A,B,C)
gg. VSD – High Phase __ Input Baseplate Tempera-
ture (A,B,C) dd. VSD – High Internal Ambient Temperature
hh. VSD – High Phase __ Motor Baseplate Tempera- ee. VSD – Serial Communications
ture (A,B,C) ff. VSD – Logic Board Processor
ii. VSD – Motor or Stator Current Imbalance gg. VSD – Run Signal
jj. VSD – Motor Current THD Fault hh. VSD - Shutdown – Requesting Fault Data
kk. VSD – Motor Synchronization Fault ii. VSD – Stop Contacts Open
ll. VSD – Rectifier Program Fault jj. VSD – Initialization Failed
mm. VSD – Inverter Program Fault
7. Security access to prevent unauthorized change
6. Cycling shutdowns enunciated through the display of setpoints, to allow local or remote control of the
and the status bar, and consists of system status, chiller, and to allow manual operation of the prerota-
system details, day, time, cause of shutdown, and type tion vanes. Access shall be through ID and password
of restart required. Cycling shutdowns shall include: recognition, which is defined by three different levels
of user competence: view, operator, and service.
a. Multi Unit Cycling – Contacts Open
8. Trending data with the ability to customize points of
b. System Cycling – Contacts Open
once every second to once every hour. The panel
c. Control Panel – Power Failure shall trend up to 6 different parameters from a list of
d. Leaving Chilled Liquid – Low Temperature over 140, without the need of an external monitoring
e. Leaving Chilled Liquid – Flow Switch Open system.
f. Condenser – Flow Switch Open 9. The operating program stored in non-volatile memory
g. Motor Controller – Contacts Open (EPROM) to eliminate reprogramming the chiller due
h. Motor Controller – Loss of Current to AC power failure or battery discharge. Programmed
setpoints shall be retained in lithium battery-backed
i. MBC – Position
RTC memory for a minimum of 11 years with power
j. MBC – Low Frequency Displacement removed from the system.
k. MBC – Vibration
10. A fused connection through a transformer in the com-
l. MBC – High Amplifier Temperature
pressor motor starter to provide individual over-current
m. MBC – High DC/DC Temperature protected power for all controls.
n. MBC – No Levitation
o. MBC – Serial Communications Fault 11. A numbered terminal strip for all required field interlock
wiring.
p. Power Fault
q. Control Panel – Schedule 12. An RS-232 port to output all system operating data,
r. VSD - Precharge – Low DC Bus Voltage shutdown / cycling message, and a record of the last
10 cycling or safety shutdowns to a field-supplied
s. VSD – DC Bus Preregulation printer. Data logs to a printer at a set programmable
t. VSD – Logic Board Power Supply interval. This data can be preprogrammed to print
u. VSD – High DC Bus Voltage from 1minute to 1day.
v. VSD – High Phase __ Input Current (A,B,C) 13. The capability to interface with a building automation
w. VSD – High Phase __ Motor Current (A,B,C) system to provide:
x. VSD – Phase __ Input Gate Driver (A,B,C)
a. remote chiller start and stop
y. VSD – Phase __ Motor Gate Driver (A,B,C)
b. remote leaving chiller liquid temperature adjust

JOHNSON CONTROLS 53
FORM 160.78-EG1 (610)

Guide Specifications - continued


c. remote current limit setpoint adjust relative humidity up to 75% and dry bulb temperatures
d. remote ready to start contacts ranging from 50 to 90 °F.
e. safety shutdown contacts
ISOLATION MOUNTING
f. cycling shutdown contacts
Included with the unit are four vibration isolation mounts,
g. run contacts
consisting of 1" thick neoprene isolation pads, for field
mounting. The pads are to be mounted under the steel
STARTUP AND OPERATOR TRAINING
mounting pads on the tube sheets. Suitable for ground
The services of a factory trained, field service represen- floor installation.
tative will be provided to supervise the final leak testing,
charging and the initial startup and conduct concurrent
operator instruction. SHIPMENT FORM #1
The unit shall be completely assembled, with all main,
FACTORY INSULATION
auxiliary, and control piping installed, controls wired, leak
Factory-applied, anti-sweat insulation shall be attached to tests completed, air run tests completed, and refrigerant
the cooler shell, flow chamber, tube sheets, suction con- charge in place. Other miscellaneous materials shall be
nection, and (as necessary) to the auxiliary tubing. The packed separately.
insulation shall be a flexible, closed-cell plastic type, ¾
inch thick, applied with vapor-proof cement. The insula-
tion will normally prevent sweating in environments with

54 JOHNSON CONTROLS
FORM 160.78-EG1 (610)

SI Metric Conversion
Values provided in this manual are in the English inch‑pound (I‑P) system.
The following factors can be used to convert from English to the most common Sl Metric values.

MULTIPLY THIS TO OBTAIN THIS


MEASUREMENT BY
ENGLISH  VALUE METRIC VALUE
CAPACITY TONS REFRIGERANT EFFECT (TON) 3.516 KILOWATTS (KW)
KILOWATTS (KW) NO CHANGE KILOWATTS (KW)
POWER
HORSEPOWER (HP) 0.7457 KILOWATTS (KW)
FLOW RATE GALLONS / MINUTE (GPM) 0.0631 LITERS / SECOND (L/S)
FEET (FT) 304.8 MILLIMETERS (MM)
LENGTH
INCHES (IN) 25.4 MILLIMETERS (MM)
WEIGHT POUNDS (LB) 0.4536 KILOGRAMS (KG)
VELOCITY FEET / SECOND (FPS) 0.3048 METERS / SECOND (M/S)
FEET OF WATER (FT) 2.989 KILOPASCALS (KPA)
PRESSURE DROP
POUNDS / SQ. INCH (PSI) 6.895 KILOPASCALS (K PA)

TEMPERATURE ENGLISH l‑P EQUIVALENT Sl METRIC


To convert degrees Fahrenheit (°F) to degrees Celsius (fl2 °F hr/Btu) (m2 k/kW)
(°C), subtract 32° and multiply by 5/9 or 0.5556. 0.0001 .018
0.00025 .044
To convert a temperature range (i.e., 10°F or 12°F chilled
water range) from Fahrenheit to Celsius, multiply by 5/9 0.0005 .088
or 0.5556. 0.00075 .132
EFFICIENCY
In the English l‑P system, chiller efficiency is measured
in kW / ton:
kW input
kW / ton =
tons refrigerant effect

In the Sl Metric system, chiller efficiency is measured


in Coefficient of Performance (COP).
kW refrigeration effect
COP =
kW input

kW / ton and COP are related as follows:


3.516
kW/ton =
COP
3.516
COP =
kW/ton
FOULING FACTOR

JOHNSON CONTROLS 55
Form 160.78-EG1 (610) Supersedes: 160.78-EG1 (310)
10