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BE_YK_EngineeringGuide_G

H
Harold Schnetzka

This document provides an overview of Johnson Controls YK centrifugal chillers ranging from 250 to 3000 tons. It describes key features such as matched components that maximize efficiency, open-drive design that eliminates risk of refrigerant contamination, and precision control of compressor oil pressure. It also summarizes approvals, nomenclature, contents, dimensions, weights, specifications, and metric conversions.

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FORM 160.75-EG1 (915) MODEL YK CENTRIFUGAL LIQUID CHILLERS STYLE G 250 THROUGH 3000 TONS (879 through 10,500 kW) Utilizing HFC-134a
JOHNSON CONTROLS FORM 160.75-EG1 (915) 2 Approvals See CODES AND STANDARDS on page 21 for Approvals. Nomenclature COMPRESSOR CODE YK ED ER Q7 - ES G S MOTOR CODE POWER SUPPLY - for 60Hz 5 for 50Hz DESIGN LEVEL CONDENSER CODE EVAPORATOR CODE UNIT TYPE YORK YK Centrifugal Chiller SPECIAL Dimensions in this guide are English (SI)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 3 Table Of Contents INTRODUCTION....................................................................................................................................................... 5 SUSTAINABILITY FOCUS....................................................................................................................................... 9 EQUIPMENT OVERVIEW....................................................................................................................................... 13 OPTIVIEW CONTROL CENTER............................................................................................................................ 24 ACCESSORIES AND MODIFICATIONS................................................................................................................ 32 APPLICATION DATA.............................................................................................................................................. 44 DIMENSIONS.......................................................................................................................................................... 76 WEIGHTS................................................................................................................................................................ 99 GUIDE SPECIFICATIONS.................................................................................................................................... 101 SI METRIC CONVERSION................................................................................................................................... 114
JOHNSON CONTROLS FORM 160.75-EG1 (915) 4 THIS PAGE INTENTIONALLY LEFT BLANK.
FORM 160.75-EG1 (915) JOHNSON CONTROLS 5 The YORK YK Chillers, manufactured by Johnson Controls, offer a complete combination of features for total owner satisfaction. MATCHED COMPONENTS MAXIMIZE EFFICIENCY Actual chiller efficiency cannot be determined by analyzing the theoretical efficiency of any one chiller component. It requires a specific combination of heat exchanger, com- pressor, and motor performance to achieve the lowest system kW/ton. YORK chiller tech- nology matches chiller system components to provide maximum chiller efficiency under actual – not just theoretical – operating conditions. REAL-WORLD ENERGY PERFORMANCE Johnson Controls pioneered the concept of “Real-World Energy” to illustrate the energy- saving potential of focusing on chiller performance during off-design conditions. Off-de- sign is not only part load, but full load operation as well, with reduced entering condenser water temperatures (ECWTs). This is where chillers operate 99% of the time, and where operating costs add up. The YORK YK chillers are the only chillers designed to operate on a continuous basis with cold ECWT and full condenser flow at all load points, taking full advantage of Real- World conditions. This type of operation benefits the cooling tower as well by reducing the cycling of the fan motor and ensuring good coverage of the cooling fill. YORK YK chillers offer the most efficient Real-World operation of any chiller, meaning lower operating costs and an excellent return on your chiller investment. OPEN-DRIVE DESIGN Hermetic motor burnout can cause catastrophic damage to a chiller. The entire chiller must be cleaned, and the refrigerant replaced. YORK YK centrifugal chillers eliminate this risk by utilizing air-cooled motors. Refrigerant never comes in contact with the motor, preventing contamination of the rest of the chiller. Insurance companies that offer policies on large air conditioning equipment often consider air-cooled motors a significant advantage over hermetic refrigerant-cooled units. HIGH EFFICIENCY HEAT EXCHANGERS YORK YK chiller heat exchangers offer the latest technology in heat transfer surface de- sign to give you maximum efficiency and compact design. Waterside and refrigerant side design enhancements minimize both energy consumption and tube fouling. Introduction
JOHNSON CONTROLS FORM 160.75-EG1 (915) 6 SINGLE STAGE COMPRESSOR DESIGN AND EFFICIENCY PROVEN IN THE MOST DEMANDING APPLICATIONS Designed to be the most reliable chillers we’ve ever made, YORK YK centrifugal chill- ers incorporate single-stage compressor design. With fewer moving parts and straight- forward, efficient engineering, YORK single-stage compressors have proven durability records in hospitals, chemical plants, gas processing plants, the U.S. Navy, and in other applications where minimal downtime is a crucial concern. In thousands of installations worldwide, YORK single-stage compressors are working to reduce energy costs. High strength aluminum-alloy compressor impellers feature back- ward curved vanes for high efficiency. Airfoil shaped pre rotation vanes minimize flow dis- ruption for the most efficient part load performance. Precisely positioned and tightly fitted, they allow the compressor to unload smoothly from 100% to minimum load for excellent operation in air conditioning applications. AHRI CERTIFICATION PROGRAM YORK YK chillers have been tested and certified by Air-Conditioning, Heating and Refrigeration Institute (AHRI) in accordance with the latest edition of AHRI Standard 550/590 (I-P). Under this Certification Program, chillers are regularly tested in strict compliance with this Standard. This provides an independent, third-party verification of chiller performance. Refer to the AHRI site at: http://www.ahrinet.org/water_ chilling+packages+using+vap or+compression+cycle+_water_cooled_.aspx for complete Program Scope, Inclusions, and Exclusions as some options listed herein fall outside the scope of the AHRI certification program. For verification of certification, go to the AHRI Directory at www.ahridirectory.org. PRECISION CONTROL OF COMPRESSOR OIL PRESSURE Utilizing our expertise in variable speed drive technology and applications, Johnson Con- trols has moved beyond the fixed head and bypass approach of oil pressure control. The old approach only assures oil pressure at the outlet of the pump rather than at the com- pressor, and allows no adjustment during chiller operation. The YORK YK chillers feature a variable speed drive oil pump, monitoring and providing the right amount of oil flow to the compressor on a continuous basis. This design also provides sophisticated electronic monitoring and protection of the oil pump electrical supply, ensuring long life and reliable operation of the oil pump motor. Variable speed drive technology reduces oil pump power consumption, running only at the speed required, rather than at full head with a pressure regulating bypass valve. Introduction (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 7 Introduction (Cont'd) FACTORY PACKAGING REDUCES FIELD LABOR COSTS YORK YK centrifugal chillers are designed to keep installation costs low. Where instal- lation access is not a problem, the unit can be shipped completely packaged, requiring minimal piping and wiring to complete the installation. For those units utilizing Variable Speed Drive or a factory-installed Solid-State Starter, the three power leads provide all power to the chiller and its auxiliaries. TAKE ADVANTAGE OF COLDER COOLING TOWER WATER TEMPERATURES YORK YK centrifugal chillers have been designed to take full advantage of colder cool- ing tower water temperatures, which are naturally available during most operating hours. Considerable energy savings are available by letting tower water temperature drop, rather than artificially holding it above 75°F (23.9°C), especially at low load, as some chillers require. UL COMPLIANCE  –  YOUR ASSURANCE OF RELIABILITY YORK YK centrifugal chillers are approved to UL Standard 1995 for listing by a qualified nationally recognized testing laboratory for the United States and Canada. Recognition of safety and reliability is your assurance of trouble free performance in day to-day building operation. Some chiller options or modifications may affect the UL compliance of the chiller. Some examples include: special motor enclosures ( like TEFC, TEWAC, or TEAAC) or special panels (NEMA 4X) or special unit wiring options (anything other than NEMA 1). For further clarification, contact Johnson Controls Large Tonnage Marketing. COMPUTERIZED PERFORMANCE RATINGS Each chiller is custom matched to meet the individual building load and energy require- ments. A large number of standard heat exchangers and pass arrangements are available to provide the best possible match. It is not practical to provide tabulated performance for each combination, as the energy requirements at both full and part load vary significantly with each heat exchanger and pass arrangement. Computerized ratings are available through each Johnson Controls Sales Office. These ratings can be tailored to specific job requirements, and are part of the AHRI Certification Program.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 8 OFF-DESIGN PERFORMANCE Since the vast majority of its operating hours are spent 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 temperatures. It is not uncommon for chill- ers with the same full load kW/ton to have an operating cost difference of over 10% due to part load operation. Part load information can be easily and accurately generated by use of the computer. And because it is so important 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 provide a more accurate indication of chiller performance than the previous IPLV/APLV formula. A more detailed analysis must take into account actual building load profiles, and local weather data. Part load performance data should be ob- tained for each job using its own design criteria. Introduction (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 9 OZONE-DEPLETION POTENTIAL (ODP) The YORK YK chiller employs one the most environmentally friendly refrigerants available today, HFC-134a, with no Ozone Depletion Potential (ODP) and no phase out date per the Montreal Protocol. Ozone is a very small part of the atmosphere, but its presence is nevertheless vital to human well-being. Most ozone resides in the upper part of the atmosphere. This region, called the stratosphere, is more than 10 kilometers (6 miles) above the Earth’s surface. There, about 90% of atmospheric ozone is contained in the “ozone layer,” which shields us from harmful ultraviolet radiation from the sun. However, it was discovered in the mid- 1970s that some human-produced chemicals could destroy ozone and deplete the ozone layer. The resulting increase in ultraviolet radiation at the Earth’s surface may increase the incidences of skin cancer and eye cataracts. Following the discovery of this environmental issue, researchers focused on gaining a better understanding of this threat to the ozone layer. Sustainability Focus Table 1 - GLOBAL REFRIGERANT USAGE REFRIGERANT COMMON USE ODP GWP STATUS 2007 GLOBAL USAGE (TONS) CFC CFC-11 Centrifugals 1.00 5000 Phased Out Trace CFC-12 Centrifugals 0.80 8500 Phased Out Trace HCFC HCFC-22 Scrolls, Screws, Unitary products 0.05 1700 Phasing Out 700,000 HCFC-123 Centrifugals 0.02 120 Phasing Out 4,000 HFC HFC-134a Centrifugals, Screws - 1300 No Phase Out 250,000 HFC-407c Screws, Scrolls - 1600 No Phase Out 100,000 HFC-410A Scrolls, Unitary products - 1890 No Phase Out HFC-404A - 3750 No Phase Out HFC-245fa Centrifugals - 1020 No Phase Out Trace HFO HFO-1234yf Centrifugals - 4 No Phase Out New HC(NaturalRefr.) HC-717 (NH3) Screws, Centrifugals - 1 No Phase Out HC-718 (water) Absorption, Vapor Compression - 0 No Phase Out HC-290 (propane) - 3 No Phase Out HC-600a (butane) - 3 No Phase Out HC-744 (CO2 ) - 1 No Phase Out
JOHNSON CONTROLS FORM 160.75-EG1 (915) 10 Monitoring stations showed that ozone-depleting chemicals were steadily increasing in the atmosphere. These trends were linked to growing production and use of chemicals like chlorofluorocarbons (CFCs) for refrigeration and air conditioning, foam blowing, and industrial cleaning. Measurements in the laboratory and the atmosphere characterized the chemical reactions that were involved in ozone destruction. Computer models em- ploying this information could predict how much ozone depletion was occurring and how much more could occur in the future. Observations of the ozone layer showed that depletion was indeed occurring. The most severe and most surprising ozone loss was discovered to be recurring in springtime over Antarctica. The loss in this region is commonly called the “ozone hole” because the ozone depletion is so large and localized. A thinning of the ozone layer also has been observed over other regions of the globe, such as the Arctic and northern middle latitudes. The work of many scientists throughout the world has provided a basis for building a broad and solid scientific understanding of the ozone depletion process. With this understanding, we know that ozone depletion is occurring and why. And, most important, we know that if ozone-depleting gases were to continue to accumulate in the atmosphere, the result would be more depletion of the ozone layer. In response to the prospect of increasing ozone depletion, the governments of the world crafted the 1987 United Nations Montreal Protocol as a global means to address this global issue. As a result of the broad compli- ance with the Protocol and its Amendments and Adjustments and, of great significance, industry’s development of “ozone friendly” substitutes for the now-controlled chemicals, the total global accumulation of ozone-depleting gases has slowed and begun to de- crease. This has reduced the risk of further ozone depletion. THE MONTREAL PROTOCOL ADDRESSED CFC’S AND HCFC’S The Montreal Protocol (MP) addressed CFC’s and HCFC’s with phase out schedule for all member parties of the MP based on the ODP characteristics. So this affects the first two categories of refrigerants listed in the table. Manufacturers in developed nations are in the final processes of converting from HCFC’s to HFC’s in accordance with the Montreal Protocol treaty. Markets in developing countries are already seeing a transition away from HCFC’s ahead of legislative requirements. HCFC’s were used as a transitional refrigerant as they were a “Lesser Evil” and allowed the HVAC industry to quickly transition away from CFCs while maintaining energy efficien- cy. The fact remains that they destroy the ozone layer and are legislated to be completely phased out. The Montreal Protocol does not extend to HFC’s as they have no ODP nor does it extend to natural refrigerants for the same reason. The typical usage of the refrigerant, the phase-out status by the Montreal Protocol and the global usage of refrigerant in tons is shown in the table on page 11. The chart on page 11 shows the growing use of HFC-134a in centrifugal chillers from 1995 up to 2010 and the forecast until the phase-out of HCFC’s. Sustainability Focus (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 11 Sustainability Focus (Cont'd) '' CFC-11 CFC-12 HCFC-22 ''# HCFC-123 HFC-134a HCFC-22 CFC-11 CFC-12 HCFC-123 HFC-134a HCFC-22 HCFC-123 HFC-134a HCFC-22 HFC-134a New Low GWP HCFC-123 CFC-11 CFC-12 HCFC-22 HCFC-123 HFC-134a New Low GWP GLOBAL WARMING POTENTIAL (GWP) Another main environmental topic is Global Warming potential (GWP), and when we talk about global warming we’re primarily talking about smoke stacks and tail pipes. 85% of GWP is attributed to CO2 emissions, while only about 2% is related to HFC’s. However, when we talk about the direct impact our YORK YK Centrifugal Chiller has on the environment we can make strides forward, like ensuring leak tight designs are cre- ated, and manufacturers are working to reduce refrigerant charges as much as possible. CO2 85% CH4 8% N2O 5% PFCs, SF6 1% HFC 2% Figure 1 - USAGE OF HFC-134A Figure 2 - CO2 EMISSIONS
JOHNSON CONTROLS FORM 160.75-EG1 (915) 12 DIRECT INDIRECT GLOBAL WARMING POTENTIAL 98% of the global warming potential of a centrifugal chiller is from the indirect effect or the greenhouse gases produced to generate the electricity to run the chiller. The YORK YK centrifugal chiller and its superior efficiency levels dramatically reduces the indirect GWP. Two percent of the GWP is from the direct effect or release of the refrigerant gases into the atmosphere. , Minimizing the total climatic impact (direct and indirect GWP) requires a comprehensive approach to refrigerant choice. Sustainability Focus (Cont'd) Figure 3 - DIRECT AND INDIRECT GLOBAL WARMING POTENTIAL
FORM 160.75-EG1 (915) JOHNSON CONTROLS 13 YORK YK chillers are completely factory-packaged including the evaporator, condenser, compressor, motor, lubrication system, control center, and all interconnecting unit piping and wiring. The initial charge of refrigerant and oil is supplied for each chiller. When the optional con- denser isolation valves are ordered, most units may ship fully charged with refrigerant and oil. Actual shipping procedures will depend on a number of project-specific details. The services of a Johnson Controls factory-trained, field service representative are in- curred to supervise or perform the final leak-testing, charging, the initial start-up, and concurrent operator instructions. COMPRESSOR The compressor is a single stage centrifugal type, powered by an open drive electric mo- tor. The casing is fully accessible with vertical circular joints and fabricated of close grain cast iron. The complete operating assembly is removable from the compressor and scroll housing. The rotor assembly consists of a heat treated alloy steel drive shaft and impeller shaft with a high strength, cast aluminum alloy, fully shrouded impeller. The impeller is designed for balanced thrust and is dynamically balanced and overspeed tested for smooth, vibration free operation. Each impeller receives a special finishing treatment that improves aerody- namic performance. The insert-type journal and thrust bearings are fabricated of aluminum alloy and are precision bored and axially grooved. The specially engineered, single helical gears with crowned teeth are designed so that more than one tooth is in contact at all times to pro- vide even distribution of compressor load and quiet operation. Gears are assembled as part of the compressor rotor support and are film lubricated. Each gear is individually mounted in its own journal and thrust bearings to isolate it from impeller and motor forces. CAPACITY CONTROL Pre-rotation vanes (PRV) modulate chiller capacity from 100% to 15% of design for nor- mal air conditioning applications. Operation is by an external, electric PRV actuator which automatically controls the vane position to maintain a constant leaving chilled liquid tem- perature. Rugged airfoil-shaped, cast-manganese-bronze vanes are precisely positioned by solid vane linkages connected to the electric actuator. LUBRICATION SYSTEM Lubrication oil is force-fed to all bearings, gears and rotating surfaces by a variable speed drive pump which operates prior to startup, continuously during operation and during coastdown. A gravity fed oil reservoir is built into the top of the compressor to provide lubrication during coastdown in the event of a power failure. An oil reservoir, separate from the compressor, contains the submersible oil pump, 2 HP (1.5 kW) pump motor and 3000 watt immersion type oil heater. The oil heater is thermo- statically controlled to remove refrigerant from the oil. Equipment Overview
JOHNSON CONTROLS FORM 160.75-EG1 (915) 14 Oil is filtered by an externally mounted 1/2 micron replaceable cartridge oil filter equipped with service valves. Oil is cooled via a refrigerant-cooled oil cooler, eliminating the require- ment for field water piping. The oil side of the oil cooler is provided with service valves. An automatic oil return system recovers any oil that may have migrated to the evaporator. Oil piping is completely factory-installed. WATER-COOLED OIL COOLER An optional condenser water-cooled oil cooler is offered for units with Q3 compressors C-D shells only. This oil cooler is a shell and tube heat exchanger. Water from condenser supply waterbox circulates through the tube side of the heat exchanger and discharges back into the return side of the waterbox. Hot oil circulates through the tubes within the oil cooler, and is cooled by the cold condenser water. The cooled oil is then sent back to the compressor through a temperature regulator valve and oil filters. Both the oil and water piping are completely factory-installed, eliminating the requirement for field piping. MOTOR DRIVELINE The compressor motor is an open drip proof, squirrel cage, induction type constructed to YORK design specifications. The 60 hertz motors operate at 3570 rpm and the 50 hertz motors operate at 2975 rpm. The open motor is provided with a D flange, and is factory-mounted to a cast iron adaptor mounted on the compressor. This unique design allows the motor to be rigidly coupled to the compressor to provide factory alignment of motor and compressor shafts. Motor drive shaft is directly connected to the compressor shaft with a flexible disc cou- pling. Coupling has all metal construction with no wearing parts to assure long life, and no lubrication requirements to provide low maintenance. For units utilizing remote electro-mechanical starters, a large, steel terminal box with gas- keted front access cover is provided for field-connected conduit. There are six terminals (three for medium voltage) brought through the motor casing into the terminal box. Jump- ers are furnished for three-lead types of starting. Motor terminal lugs are not furnished. Overload/over-current transformers are furnished with all units. For units furnished with factory-packaged Solid-State Starters or Variable Speed Drive, refer to the Accessories and Modifications on page 32. HEAT EXCHANGERS Shells Evaporator and condenser shells are fabricated from rolled carbon steel plates with fu- sion welded seams or carbon steel pipe. Carbon steel tube sheets, drilled and reamed to accommodate the tubes, are welded to the end of each shell. Intermediate tube supports are fabricated from carbon steel plates, drilled and reamed to eliminate sharp edges, and spaced no more than four feet apart. The refrigerant side of each shell is designed, tested, and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII – Division I, or other pressure vessel code as appropriate. Equipment Overview (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 15 Tubes Heat exchanger tubes are state-of-the-art, high-efficiency, externally and internally en- hanced type to provide optimum performance. Tubes in both the evaporator and con- denser are 3/4 (19 mm) O.D. standard [or 1 (25.4 mm) optional in some shells] copper alloy and utilize the “skip-fin” design, providing a smooth internal and external surface at each intermediate tube support. This provides extra wall thickness (up to twice as thick) and non work-hardened copper at the support location, extending the life of the heat ex- changers. Each tube is roller expanded into the tube sheets providing a leak-proof seal, and is individually replaceable. Evaporator The evaporator is a shell and tube type with customer process fluid flowing inside the tubes and refrigerant removing heat on the shell side via evaporation. Evaporator codes A_ thru Q_ utilize a hybrid falling film design. It contains a balance of flooded and falling film technology to optimize efficiency, minimize refrigerant charge, and maintain reliable control. A specifically designed spray distributor provides uniform distribution of refriger- ant over the entire length to yield optimum heat transfer. The hybrid falling film evaporator design has suction baffles around the sides and above the falling film section to prevent liquid refrigerant carryover into the compressor. Evaporator codes R_ thru Z_ are flooded type, with a liquid inlet distributor trough under- neath the tube bundle. This provides uniform distribution of refrigerant over the entire shell length to yield optimum heat transfer. Flooded evaporator designs have an aluminum mesh eliminator on R_ thru Z_ shells located above the tube bundle to prevent liquid re- frigerant carryover into the compressor. A 1-1/2 (38 mm) liquid level sight glass is conveniently located on the side of the shell to aid in determining proper refrigerant charge. The evaporator shell contains a dual refrig- erant relief valve arrangement set at 180 psig (12.4 barg) on H and K compressor models; 235 psig (16.2 barg) on P and Q compressor models; or single-relief valve arrangement, if the chiller is supplied with optional refrigerant isolation valves. A 1 (25.4 mm) refrigerant charging valve is provided. Condenser The condenser is a shell and tube type, with a discharge gas baffle to prevent direct high velocity impingement on the tubes. The baffle is also used to distribute the refrigerant gas flow properly for most efficient heat transfer. An optional cast steel condenser inlet diffuser may be offered, on M and larger condensers, in lieu of the baffle, to provide dynamic pressure recovery and enhanced chiller efficiency. An integral sub cooler is located at the bottom of the condenser shell providing highly effective liquid refrigerant subcooling to provide the highest cycle efficiency. The condenser contains dual refrigerant relief valves set at 235 psig (16.2 barg). Waterboxes The removable waterboxes are fabricated of steel. The design working pressure is 150 psig (10.3 barg) and the boxes are tested at 225 psig (15.5 barg). Integral steel water baffles are located and welded within the waterbox to provide the required pass arrange- ments. Stub out water nozzle connections with ANSI/AWWA C-606 grooves are welded to the waterboxes. These nozzle connections are suitable for ANSI/AWWA C-606 couplings, welding or flanges, and are capped for shipment. Plugged 3/4 (19 mm) drain and vent connections are provided in each waterbox. Equipment Overview (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 16 WATER FLOW SWITCHES Thermal type water flow switches are factory mounted in the chilled and condenser water nozzles, and are factory wired to the OptiView control panel. These solid-state flow sen- sors have a small internal heating-element. They use the cooling effect of the flowing fluid to sense when an adequate flow rate has been established. The sealed sensor probe is 316 stainless steel, which is suited to very high working pressures. OPTIVIEW CONTROL CENTER The chiller is controlled by a stand-alone microprocessor based control center. The chiller control panel provides control of chiller operation and monitoring of chiller sensors, actua- tors, relays and switches. Control Panel The control panel includes a 10.4-in. (264 mm) diagonal color liquid crystal display (LCD) surrounded by “soft” keys 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 operations and parameters, using a graphical representation of the chiller and its major components. Panel verbiage is available in eight languages and can be changed on the fly without having to turn off the chiller. Data can be displayed in either English or Metric units. Smart Freeze Point Protection will run the chiller at 36°F (2.2°C) leaving chilled water temperature, and not have nuisance trips on low water temperature. The sophisticated program and sensor monitors the chiller water temperature to prevent freeze-up. When needed, Hot Gas Bypass is available as an option. The panel displays countdown timer messages so the operator knows when functions are starting and stop- ping. Every programmable point has a pop-up screen with the allowable ranges, so that the chiller cannot be programmed to operate outside of its design limits. The chiller control panel also provides: A. System operating information including: 1. Return and leaving chilled water temperature. 2. Return and leaving condenser water temperature. 3. Evaporator and condenser saturation pressure. 4. Differential oil pressure. 5. Percent motor current. 6. Evaporator and condenser saturation temperature. 7. Compressor discharge temperature. 8. Oil reservoir temperature. 9. Compressor thrust bearing positioning (K compressors only). 10. Operating hours. 11. Number of compressor starts. Equipment Overview (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 17 B. Digital programming of setpoints through the universal keypad including: 1. Leaving chilled water temperature. 2. Percent current limit. 3. Pulls-down demand limiting. 4. Six-week schedule for starting and stopping the chiller, pumps and tower. 5. Remote reset temperature range. C. Status messages indicating: 1. System ready to start. 2. System running. 3. System coastdown. 4. System safety shutdown – manual restart. 5. System cycling shutdown – auto restart. 6. System pre-lube. 7. Start inhibit. D. The text displayed within the system status and system details field is displayed as a color-coded message to indicate severity: red for safety fault, orange for cycling faults, yellow for warnings, and green for normal messages. E. Safety shutdowns enunciated through the display and the status bar, and consist of system status, system details, day, time, cause of shutdown, and type of restart re- quired. Safety shutdowns with a fixed-speed- drive include: 1. Evaporator – low pressure. 2. Evaporator – transducer or leaving liquid probe. 3. Evaporator – transducer or temperature sensor. 4. Condenser – high pressure contacts open. 5. Condenser – high pressure. 6. Condenser – pressure transducer out-of-range. 7. Auxiliary safety – contacts closed. 8. Discharge – high temperature. 9. Discharge – low temperature. 10. Oil – high temperature. 11. Oil – low differential pressure. 12. Oil – high differential pressure. Equipment Overview (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 18 13. Oil – sump pressure transducer out-of-range. 14. Oil – differential pressure calibration. 15. Oil – variable speed pump – pressure setpoint not achieved. 16. Control panel – power failure. 17. Motor or starter – current imbalance. 18. Thrust bearing – proximity probe clearance (K compressors only). 19. Thrust bearing – proximity probe out-of-range (K compressors only). 20. Thrust bearing – position switch (P, Q H9 compressors). 21. Watchdog – software reboot. F. Safety shutdowns with a VSD include: 1. VSD shutdown – requesting fault data. 2. VSD – stop contacts open. 3. VSD – 105% motor current overload. 4. VSD – high phase A, B, C inverter heat-sink temp. 5. VSD – high converter heat-sink temperature (Filter Option Only). 6. Harmonic filter – high heat-sink temperature. 7. Harmonic filter – high total demand distortion. G. Cycling shutdowns enunciated through the display and the status bar, and consists of system status, system details, day, time, cause of shutdown, and type of restart required. H. Cycling shutdowns with a fixed speed drive include: 1. Multi unit cycling – contacts open. 2. System cycling – contacts open. 3. Oil – low temperature differential. 4. Oil – low temperature. 5. Control panel – power failure. 6. Leaving chilled liquid – low temperature. 7. Leaving chilled liquid – flow switch open. 8. Motor controller – contacts open. 9. Motor controller – loss of current. 10. Power fault. 11. Control panel – schedule. 12. Starter – low supply line voltage (SSS option). Equipment Overview (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 19 13. Starter – high supply line voltage (SSS option). 14. Proximity probe – low supply voltage (K Compressor). 15. Oil – variable speed pump – drive contacts open. I. Cycling shutdowns with a VSD include: 1. VSD shutdown – requesting fault data. 2. VSD – stop contacts open. 3. VSD – initialization failed. 4. VSD – high phase A, B, C instantaneous current. 5. VSD – phase A, B, C gate driver. 6. VSD – single phase input power. 7. VSD – high DC bus voltage. 8. VSD – precharge DC bus voltage imbalance. 9. VSD – high internal ambient temperature. 10. VSD – invalid current scale selection. 11. VSD – low phase A, B, C inverter heat-sink temp. 12. VSD – low converter heat-sink temperature. 13. VSD – precharge – low DC bus voltage. 14. VSD – logic board processor. 15. VSD – run signal. 16. VSD – serial communications (Filter Option Only). 17. Harmonic filter – logic board or communications. 18. Harmonic filter – high DC bus voltage. 19. Harmonic filter – high phase A, B, C current. 20. Harmonic filter – phase locked loop. 21. Harmonic filter – precharge – low DC bus voltage. 22. Harmonic filter – DC bus voltage imbalance. 23. Harmonic filter – 110% input current overload. 24. Harmonic filter – logic board power supply. 25. Harmonic filter – run signal. 26. Harmonic filter – DC current transformer 1. 27. Harmonic filter – DC current transformer 2. Equipment Overview (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 20 J. Security access to prevent unauthorized change of setpoints, to allow local or remote control of the chiller, and to allow manual operation of the pre-rotation vanes and oil pump. Access is through ID and password recognition, which is defined by three differ- ent levels of user competence: view, operator, and service. K. Trending data with the ability to customize points of once every second to once every hour. The panel will trend up to 6 different parameters from a list of over 140, without the need of an external monitoring system. L. The operating program stored in non-volatile memory (EPROM) to eliminate repro- gramming the chiller due to AC power failure or battery discharge. Programmed setpoints are retained in lithium battery-backed RTC memory for a minimum of 5 years with power removed from the system. M. A fused connection through a transformer in the compressor motor starter to provide individual over-current protected power for all controls. N. A numbered terminal strip for all required field interlock wiring. O. An RS-232 port to output all system operating data, shutdown/cycling message, and a record of the last 10 cycling or safety shutdowns to a field-supplied printer. Data logs to a printer at a set programmable interval. This data can be preprogrammed to print from 1 minute to 1 day. P. The capability to interface with a building automation system via hard-wired connec- tions to each feature to provide: 1. Remote chiller start and stop. 2. Remote leaving chiller liquid temperature adjust. 3. Remote current limit setpoint adjust. 4. Remote ready to start contacts. 5. Safety shutdown contacts. 6. Cycling shutdown contacts. 7. Run contacts. REFRIGERANT FLOW CONTROL Refrigerant flow to the evaporator is controlled by the YORK variable orifice control sys- tem. Liquid refrigerant level is continuously monitored to provide optimum subcooler, condenser and evaporator performance. The variable orifice electronically adjusts to all Real-World operating conditions, providing the most efficient and reliable operation of refrigerant flow control. Equipment Overview (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 21 CODES AND STANDARDS • ASME Boiler and Pressure Vessel Code  – Section Vlll Division 1. • UL 1995  –  Heating and Cooling Equipment. • ASHRAE 15  –  Safety Code for Mechanical Refrigeration. • ASHRAE Guideline 3 – Reducing Emission of Halogenated Refrigerants in Refrig- eration and Air-Conditioning Equipment and Systems. • N.E.C.  –  National Electrical Code. • OSHA  –  Occupational Safety and Health Act. ISOLATION MOUNTING The unit is provided with four vibration isolation mounts of nominal 1 operating height. The pads have a neoprene pad to contact the foundation, bonded to a steel plate. The vibration isolation pads assemblies mount under steel plates affixed to the chiller tube sheets. Equipment Overview (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 22 IBC/OSHPD SEISMIC CERTIFICATION YORK YK chillers meet the IBC seismic requirements. YORK YK chillers also meet the California Office of Statewide Health Planning and Development (OSHPD) Special Seismic Preapproval (OSP). To earn the OSP, several models within a product line are required to successfully demonstrate functional operation after a shaker-table test. All Johnson Controls equipment is engineered and manufactured for the highest level of safety. Contact a Johnson Controls sales office to obtain a specific selection for a seismic compliance application. Figure 4 - SPECIAL SEISMIC CERTIFICATION PREAPPROVAL REFRIGERANT CONTAINMENT The standard unit has been designed as a complete and compact factory-packaged chill- er. As such, it has minimum joints from which refrigerant can leak. The entire assembly has been thoroughly leak tested at the factory prior to shipment. The YORK YK chiller includes service valves conveniently located to facilitate transfer of refrigerant to a remote refrigerant storage/recycling system. Optional condenser isolation valves allow storage of the charge in the condenser. SDS level of 1.6g mounted on neoprene pads. Equipment Overview (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 23 PAINT Exterior surfaces are protected with one coat of Caribbean blue, durable alkyd modified, vinyl enamel machinery paint. SHIPMENT A protective covering is furnished on the motor starter, Control Center VSD and unit mounted controls. Water nozzles are capped with fitted plastic caps. The entire unit is protected with a industrial-grade, reinforced shrink-wrapped covering. Equipment Overview (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 24 OptiView Control Center NOTE: Please refer to the OptiVew Control Center Operator's Manual for a complete description of features and functionality. The YORK OptiView Control Center is a factory mounted, wired and tested microproces- sor based control system for HFC-134a centrifugal chillers. For the YK, it controls the leaving chilled liquid temperature and limits the motor current via control of the Variable Geometry Diffuser (VGD) and Variable Speed Drive (VSD). The panel comes configured with a full screen LCD Graphic Display mounted in the mid- dle of a keypad interface with soft keys, which are redefined with one keystroke based on the screen displayed at the time. The graphic display allows the presentation of several operating parameters at once. In addition, the operator may view a graphical represen- tation of the historical operation of the chiller as well as the present operation. For the novice user, the locations of various chiller parameters are clearly and intuitively marked. Instructions for specific operations are provided on many of the screens. To prevent unau- thorized changes of set points and operating conditions, security access is provided with three different levels of access and passwords. The graphic display also allows information to be represented in both English (tempera- tures in °F and pressures in PSIG) and Metric (temperatures in °C and pressures in kPa) mode. The advantages are most apparent, however, in the ability to display many lan- guages. The Control Center continually monitors the system operation and records the cause of any shutdowns (Safety, Cycling or Normal). This information is recorded in memory and is preserved even through a power failure condition. The user may recall it for viewing at any time. During operation, the user is continually advised of the operating conditions by various status and warning messages. In addition, it may be configured to notify the user of certain conditions via alarms. The Control Center expands the capabilities of remote control and communications. By providing a common networking protocol through the Building Automation System (BAS), YORK Chillers not only work well individually, but also as a team. This new protocol allows increased remote control of the chiller, as well as 24-hour performance monitoring via a remote site. In addition, compatibility is maintained with the present network of BAS communications. The chiller also maintains the standard LD18607
FORM 160.75-EG1 (915) JOHNSON CONTROLS 25 OptiView Panel (Cont'd) digital remote capabilities as well. Both of these remote control capabilities allow for the standard Energy Management System (EMS) interface: 1. Remote Start. 2. Remote Stop. 3. Remote Leaving Chilled Liquid Temperature Setpoint adjustment (0 to 10VDC, 2 to 10VDC, 0 to 20mA or 4 to 20mA) or Pulse Width Modulation. 4. Remote Current Limit Setpoint adjustment. 5. (0 to 10VDC, 2 to 10VDC, 0 to 20mA or 4 to 20mA) or Pulse Width Modulation. 6. Remote READY TO START Contacts. 7. Safety Shutdown Contacts. 8. Cycling Shutdown Contacts. The following are examples of the information displayed on some of the more important screens: SYSTEM SCREEN This screen gives a general overview of common chiller parameters. LD18608
JOHNSON CONTROLS FORM 160.75-EG1 (915) 26 OptiView Panel (Cont'd) EVAPORATOR SCREEN This screen displays a cutaway view of the chiller evaporator. All setpoints relating to the evaporator side of the chiller are maintained on this screen. Animation of the evaporation process indicates whether the chiller is presently in a RUN condition (bubbling) and liquid flow in the pipes is indicated by alternating shades of color moving in and out of the pipes. CONDENSER SCREEN This screen displays a cutaway view of the chiller condenser. All setpoints relating to the condenser side of the chiller are maintained on this screen. Animation indicates con- denser liquid flow. LD18610 LD18609
FORM 160.75-EG1 (915) JOHNSON CONTROLS 27 OptiView Panel (Cont'd) COMPRESSOR SCREEN This screen displays a cutaway view of the chiller compressor, revealing the impeller, and shows all conditions associated with the compressor. Animation of the compressor impel- ler indicates whether the chiller is presently in a RUN condition. This screen also serves as a gateway to subscreens for the Variable Geometry Diffuser (VGD) and the Power Panel. HOT GAS BYPASS SCREEN This screen displays a cutaway view of the Hot Gas Bypass Valve. The setpoints relating to the Hot Gas Bypass Control are maintained on this screen. Related Hot Gas control pa- rameters are displayed for reference. The Hot Gas Valve can be manually controlled from this screen. Through animation, the relative valve position is displayed. The parameters dis- played on this screen vary according to the software version and the selection made for the Motor Communications Protocol Setpoint when equipped with Variable Speed Drive (VSD) or Medium Voltage Variable Speed Drive (MVVSD). LD18611 LD13826
JOHNSON CONTROLS FORM 160.75-EG1 (915) 28 OptiView Panel (Cont'd) VARIABLE GEOMETRY DIFFUSER This can be accessed from the COMPRESSOR screen and gives the basic stall, position, and pressure details. HISTORY SCREEN This screen allows the user to browse through the faults. In order to get a more thorough reporting of the system conditions at the time of the recorded shutdown, move to the sub- screen HISTORY DETAILS. LD18615 00661VIPc
FORM 160.75-EG1 (915) JOHNSON CONTROLS 29 OptiView Panel (Cont'd) CAPACITY CONTROL SCREEN This screen displays capacity control information and includes a programmable pulldown demand to automatically limit VSD input loading for minimizing building demand charg- es. Pulldown time period control over four hours, and verification of time remaining in pulldown cycle from display readout. Separate digital setpoint for current limiting between 30 and 100%. SETPOINTS This screen provides a convenient location for programming the most common chiller control setpoints. Changing setpoints and setup requires proper password access. This screen also serves as a gateway to a subscreen for defining the setup of general system parameters. LD18615 LD18616
JOHNSON CONTROLS FORM 160.75-EG1 (915) 30 OptiView Panel (Cont'd) OPERATIONS This screen allows definition of general parameters having to do with the operation of the chiller. DISPLAY MESSAGES The OptiView Control Center continually monitors the operating system displaying and recording the cause of any shutdowns (Safety, Cycling or Normal). The condition of the chiller is displayed at the System Status line that contains a message describing the operating state of the chiller; whether it is stopped, running, starting or shutting down. A System Details line displays Warning, Cycling, Safety, Start Inhibit and other messages that provide further details of Status Bar messages. Messages are color-coded: Green – Normal Operations, Yellow - Warnings, Orange – Cycling Shutdowns, and Red – Safety Shutdowns to aid in identifying problems quickly. LD09578a
FORM 160.75-EG1 (915) JOHNSON CONTROLS 31 THIS PAGE INTENTIONALLY LEFT BLANK.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 32 JOHNSON CONTROLS OPTISPEED™ DRIVE STARTER When a YORK YK chiller is equipped with a variable speed drive, it incorporates ad- vanced Adaptive Capacity Control logic, which continually optimizes chiller operation. It closely examines critical operating parameters, and then determines the most efficient way to operate. In addition, it allows optimized savings when using intelligent control strat- egies, such as chilled-water reset. Adaptive Capacity Control logic also accommodates the characteristics of the refrigerant used in the chiller — today and tomorrow. The variable speed drive was specifically developed for commercial air-conditioning ap- plications. No one matches Johnson Controls experience in the application of variable speed drive technology to chillers. Since pioneering the concept in 1978, Johnson Con- trols has installed more variable speed drive chillers than all other chiller manufacturers combined. Variable speed drives will save in both single-chiller installations and multiple-chiller in- stallations. In multiple-chiller installations, cycling chillers off as the building load falls will result in higher loads on the remaining chillers. This would seem to reduce the opportunity for drives to save energy. However, even though chiller loads remain high, entering con- denser-water temperature has most likely fallen. And, reductions in entering condenser water temperature offer a far greater potential to enhance chiller efficiency than load re- ductions do. Therefore, variable speed drive will deliver major energy savings in multiple- chiller plants, too. The OptiSpeed Drive is available for low and medium voltage options for the compressor motor (See Table 2). Table 2 - OPTISPEED DRIVE STARTER OPTION LOW VOLTAGE STARTERS 60 HZ 50 HZ OPTISPEED VARIABLE SPEED DRIVE UNIT MOUNTED 380V 460V 575V 600V 380V 400V 415V X X X X X X X – 60 HZ MEDIUM VOLTAGE STARTERS OPTISPEED VARIABLE SPEED DRIVE FLOOR MOUNTED 2300V 3300V 4000V 4160V 6000V 6600V 12470V 13800V X X X X O O O O 50 HZ MEDIUM VOLTAGE STARTERS OPTISPEED VARIABLE SPEED DRIVE FLOOR MOUNTED 2300V 3000V 3300V 6000V 6600V 10000V 11000V – – X O O O O – X=Available O=Available by Special Quotes (SQ) Accessories and Modifications
FORM 160.75-EG1 (915) JOHNSON CONTROLS 33 LOW VOLTAGE OPTISPEED DRIVE The Low Voltage OptiSpeed variable speed drive is factory-packaged and mounted on the YORK YK chiller. It is designed to vary the compressor motor speed by controlling the frequency and voltage of the electrical power to the motor. The adaptive capacity control logic automatically adjusts motor speed and compressor pre-rotation vane position inde- pendently for maximum part load efficiency by analyzing information fed to it by sensors located throughout the chiller. The variable speed drive is mounted in a NEMA-1 enclosure with all power and control wiring between the drive and chiller factory-installed. Electrical lugs for incoming power wiring are provided. The variable speed drive provides automatic displacement power factor correction to 0.95 or better at all load conditions. Separate displacement power factor correction capacitors are not required. The displacement power factor is 0.98 or better when the optional har- monic filter is provided. Additionally, variable speed drives have the following advantages: • Lowest chiller life cycle through part load energy savings. • Application-specific designs enable efficient, precise load control and seamless inte- gration with equipment control panel and BAS. • Soft start with input current less than full load current. • Smooth acceleration reduces stresses on motor and driveline. • Reduces compressor sound levels at most operating conditions. • Rugged and reliable with no moving parts. • IEEE-519 2014 compliant if used with an optional harmonic filter. Standard features include: a door interlocked lockable circuit breaker; UL/cUL listed ground fault protection; over-voltage and under-voltage protection; 3-phase sensing mo- tor over-current protection; single-phase protection; insensitive to phase rotation; over- temperature protection; digital readout at the OptiView Control Center of: • Output Frequency. • Output Voltage. • 3-phase output current. • Input Power (kW). • Self diagnostic service parameters. • Kilowatt-Hours (kWh). An optional harmonic filter limits electrical power supply distortion from the variable speed drive to help the building comply with the guidelines of IEEE STD. 519-2014. The filter is unit mounted within the same NEMA-1 enclosure and is UL listed. The following digital readout is standard with the optional filter: • Input kVA. • Total power-factor. • 3-phase input voltage. Accessories and Modifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 34 Accessories and Modifications (Cont'd) • 3-phase input current. • 3-phase input voltage total harmonic distortion (THD). • 3-phase input current total demand distortion (TDD). • Self-diagnostic service parameters. LOW VOLTAGE OPTISPEED DRIVE WITH QUICK START OPTION The Quick Start feature is targeted towards data centers and process control applications where the goal is to re-establish process cooling as fast as possible after a power failure event. The Quick Start feature does this by reducing the time cycle for chiller restart and by loading the chiller as fast as possible. Once running, its goal is to rapidly achieve the leaving chilled water temperature setpoint. The main objective is to provide minimum downtime and the fastest restart/loading as possible. After the chiller is running and close to setpoint, it will return to standard YK control to minimize risk. The Quick Start Feature can be used with a UPS (supplied by others) or without a UPS. In order to start the most quickly, the OptiView control panel and VSD control circuit (except the trigger board) must be on a UPS. If a slightly longer restart time can be tolerated, the UPS is not required. Depending on the compressor and the horsepower of the drive, a 3 kVA or 4 kVA UPS (supplied by others) with sine wave output is required to power the OptiView and required portions of the VSD control circuit to 115V - 1 phase - 60 Hz. Please refer to Form 160.75-TD4; Quick Start Feature for YK Mod G Chillers for additional information. Quick Start Feature Availability - This feature applies only to YK chillers with Low Volt- age Variable Speed Drives. MEDIUM VOLTAGE OPTISPEED DRIVE A variable speed drive is factory-packaged and configured for easy remote mounting. It is designed to vary the compressor motor speed by controlling the frequency and voltage of the electrical power to the motor. The adaptive capacity control logic automatically adjusts motor speed and compressor pre-rotation vane position independently for maximum part load efficiency by analyzing information fed to it by sensors located throughout the chiller. The variable speed drive is mounted in a NEMA-1 enclosure and comes with a certifica- tion label from a nation-ally recognized testing laboratory. The connection points between the drive and chiller are factory labeled. Electrical lugs for incoming power wiring are NOT provided. The variable speed drive provides automatic displacement power factor correction to 0.98 or better at all load conditions. Separate displacement power factor correction capacitors are not required. Additional advantages of the variable speed drive are as follows: • Lowest chiller life cycle through part load energy savings. • Application-specific designs enable efficient, precise load control and seamless inte- gration with equipment control panel and BAS. • Soft start with input current less than full load current.
FORM 160.75-EG1 (915) JOHNSON CONTROLS 35 Accessories and Modifications (Cont'd) • Smooth acceleration reduces stresses on motor and driveline. • Reduces compressor sound levels at most operating conditions. • Rugged and reliable with no moving parts. • IEEE-519 2014 compliant with a harmonic filter. • Multi-level PWM output closely simulates a true sine wave, allowing the use of stan- dard motors and bearings. Standard features include: a lockable door interlocked disconnect switch; UL listed ground fault protection; over-voltage and under-voltage protection; 3-phase sensing motor over- current protection; single-phase protection; insensitive to phase rotation; over-tempera- ture protection; digital readout at the Control Center of: • Output frequency. • 3-phase output voltage. • 3-phase output current. • Input power (kW). • Self diagnostic service parameters. • Kilowatt-hours (kWh). • Input KVA . • Total power-factor. • 3-phase input voltage. • 3-phase input current. • Self diagnostic service parameters. The 24 pulse design limits the electrical power supply distortion from the variable speed drive to comply with the guidelines of IEEE STD. 519-2014. LOW VOLTAGE SOLID-STATE STARTER The Low Voltage Solid-State Starter is compact and mounted on the unit. Power and con- trol wiring between the starter and the chiller are factory-installed. Available for 200 - 600 volts (see Table 3), the starter enclosure is NEMA-1, with a hinged access door with lock and key. Electrical lugs for incoming power wiring are provided. Table 3 - LOW VOLTAGE SOLID-STATE STARTER LOW VOLTAGE SOLID-STATE STARTER (UNIT MOUNTED) 60HZ 50HZ 380V 440V 460V 480V 575V 600V 380V 400V 415V 440V X X X X X X X X X X X=Available
JOHNSON CONTROLS FORM 160.75-EG1 (915) 36 Standard Features include digital readout at the Control Center of the following: Display Only • 3-phase input voltage. • 3-phase current. • Input Power (kW). • Kilowatt-Hours (kWh). • Starter Model. • Motor Run (LED). • Motor Current % Full Load Amps. • Current Limit Setpoints. • Pulldown Demand Time Left. Programmable • Local Motor Current Limit. • Pulldown Demand Limit. • Pulldown Demand Time. Other features include: low line voltage; 115V control transformer; three-leg, motor-cur- rent-sensing overloads; phase rotation and single-phase failure protection; high tem- perature safety protection; motor current imbalance and under-voltage safeties; open and shorted SCR protection; momentary power interruption protection. The Solid-State Starter is cooled by a closed-loop, fresh-water-circuit consisting of a water-to-water heat exchanger and a fractional horsepower circulating pump. All interconnecting water piping is factory-installed and rated for 150 psig (10.3 barg) working pressure. Optional elec- tronic trip circuit UL listed circuit breaker with integral ground fault protection is available with short circuit withstand ratings of: • 65KA for 460V 200V, 400V models. • 50KA for 33L 575V models. • 35KA for 14L 575V models. • 22KA for 7L 575V models. A non-fused disconnect switch is also available. Both options are lockable. Additional advantages of Solid-State Starters are as follows: • Smooth, controlled start profile. • Unit mounted, factory wired and tested. • Rugged and reliable with no moving parts. • Adjustable acceleration times. Accessories and Modifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 37 • Reduces compressor sound levels at most operating conditions. • Rugged and reliable with no moving parts. • Application-specific designs enable seamless integration with equipment control panel and BAS. MEDIUM VOLTAGE SOLID-STATE STARTER The Medium Voltage Solid-State Starter is a reduced voltage in-line bypass starter that controls and maintains a constant current flow to the motor during startup. Power and control wiring between the starter and the chiller for the unit mounted version is factory- installed. Available for 2300 - 4160 volts (see Table 4), the starter enclosure is NEMA-1, with a hinged access door with lock and key. Electrical lugs for incoming power wiring are not provided. Table 4 - MEDIUM VOLTAGE SOLID-STATE STARTER MEDIUM VOLTAGE SOLID-STATE STARTER * 60 HZ 50 HZ 2300V 3300V 4000V 4160V 3300V UNIT MOUNTED X** X** X** X** X** FLOOR MOUNTED X X X X X X=Available * Unit Mounted version available for Compressor H9 or Larger ** For Higher Voltage contact Application Engineering Department for a Special Quote ( SQ) Standard Features include digital readout at the Control Center of the following: Display Only • 3-phase input voltage. • 3-phase current. • Input Power (kW). • Killowatt-Hours (kWh). • Starter Model. • Motor Run (LED). • Motor Current % Full Load Amps. • Current Limit Setpoints. • Pulldown Demand Time Left. Programmable • Local Motor Current Limit. • Pulldown Demand Limit. • Pulldown Demand Time. Accessories and Modifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 38 Other features include: low line voltage; 115V control transformer; three-leg motor current sensing overloads; phase rotation and single-phase failure protection; high temperature safety protection; motor current imbalance and under-voltage safeties; open and shorted SCR protection; momentary power interruption protection. The Solid-State Starter is air cooled generating about the same heat as an auto-transformer E-M starter. Ground fault protection and surge protection are also standard features. The 50,000 amp short circuit withstand rating is in accordance with UL Standard 508. ELECTRO-MECHANICAL STARTER - (FIELD-INSTALLED) Characteristics - For comparison purposes, here is a description of some of the gen- eral characteristics of electromechanical starters. Until the development of the Solid- State Starter, all centrifugal chillers required the use of starters using electro-mechanical contactors, which are limited to operating totally ON, or totally OFF. There was no alter- native to this mechanical equipment with its inability to control applied voltage or power. This contrasts markedly with the YORK Medium Voltage Solid-State Starter which auto- matically maintains a predetermined current during starting, regardless of variations in line voltage or motor load, to give optimum acceleration without surges. Even with the addition of transformers, reactors, resistors and additional contactors, timers and relays, the mechanical controllers offer limited adjustment, no positive control during starting and impose an objectionable transition spike. Some also require modified motors. A field- installed, electro-mechanical compressor motor starter is available, selected for proper size and type for job requirements and in accordance with Johnson Controls Engineering Standard (R-1132) for Starters. The most common failure mode of mechanical contactors is OFF. This occurs due to the coil open-circuiting or failure of a pole to make an electrical contact when it closes. How- ever, failure in the ON mode is not completely uncommon and can be a more dramatic type of failure, particularly if this failure mode exists at the same time that equipment safety controls are demanding a shutdown. When contacts are “made,” the current builds up to its maximum value from zero, but when contacts are separated the current tends to flow through the gap thus formed and causes an arc. This arcing depends upon the voltage between the separating contacts. For medium voltage the use of vacuum contactors mitigates this problem somewhat by providing an environment to extinguish the arc. In the alternating current circuit, the sepa- ration of contacts may take place when the current is zero or maximum or at any value in between. An alternating current passes through zero and reverses its polarity twice during each cycle. If two or more contacts, one in each leg of a polyphase system, are separated simultaneously, the current values in each will vary. In a three-phase system, if one contact has zero current when opened, the other two contacts will have 86.6% of their maximum values, as an example. Additionally, when inductive circuits are broken, the voltage is increased at the contacts due to the counter (induced) EMF of the circuit. The instant the contacts separate, the voltage between them momentarily rises from zero to the maximum of the circuit, or higher if inductance is present in the circuit. In practice, every time the contacts close, they bounce. When they bounce, they arc. The arcing that occurs as the contacts make or break may result in rapid and excessive erosion of the contacts, causing prematurely short contact life. Accessories and Modifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 39 Types - YORK chillers are designed for use with the following types of electro-mechanical starters, here briefly described. Across-the-Line (ACL) – These are the simplest and lowest-cost starters available. They apply full voltage to the three motor leads at the instant of starting. Since inrush is 100% of LRA and starting torque is 100%, this is the roughest type of starting on the motor and driveline. In physical size, the ACL is the smallest of electro-mechanical starters and there is no transition surge. In most areas, utilities will not permit the use of this type of starter for chiller-size motors because of their large current draw on startup. Auto-Transformer (AT) – These starters are reduced-voltage starters. Transformers are used to step down the voltage to the motor during startup. The result is reduced inrush current and starting torque at the level of 42% or 64% depending upon whether 65% or 80% voltage taps are used. They provide closed transition (with three-lead motors) with reduced line disturbance. Star-Delta Starters – During starting, the motor is connected in a Star or Wye configura- tion. This reduces the voltage to the motor stator by a factor of three. This 1/3 voltage results in 1/3 current into the motor at start and 1/3 torque to the shaft. Centrifugal com- pressor starting torque requirements are low enough to allow the motor to start at 1/3 of full load torque. Star-Delta starting creates some stresses for the starter's switch-gear, building electrical system, power grid, and chiller mechanical driveline.  Although these stresses are 1/3 of the stresses generated by an ACL starter, they cause wear on the system. As a result, Johnson Controls recommends using a Solid State Starter or Variable Speed Drive in- stead of a Star-Delta starter. Table 5 - ELECTRO-MECHANICAL STARTER STARTER OPTIONS LOW VOLTAGE/FREQUENCY LV ACROSS THE LINE (DOL) (FLOOR MOUNTED) 60HZ 50HZ 380V 440V 460V 480V 575V 380V 400V 415V X X X X X X X X LV STAR-DELTA CLOSED (FLOOR MOUNTED) 60HZ 50HZ 380V 440V 460V 480V 575V 380V 400V 415V X X X X X X X X STARTER OPTIONS MEDIUM VOLTAGE / FREQUENCY MV ACROSS THE LINE (DOL) (FLOOR MOUNTED) 60HZ 50HZ 2300 3300 4000 4160 6000 6600 12470 13200 2300 3000 3300 6000 6600 10000 11000 X X X X O O O O X X X O O O O MV AUTOTRANSFORMER 65% (FLOOR MOUNTED) 60HZ 50HZ 2300 3300 4000 4160 6000 6600 12470 13200 2300 3000 3300 6000 6600 10000 11000 X X X X O O O O X X* X* O O O O MV AUTOTRANSFORMER 80% (FLOOR MOUNTED) 60HZ 50HZ 2300 3300 4000 4160 6000 6600 12470 13200 2300 3000 3300 6000 6600 10000 11000 X X X X O O O O X X X O O O O X = Available * = Not available with 5DJ motor O = SQ Accessories and Modifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 40 GENERAL ACCESSORIES AND MODIFICATIONS Medium Voltage Motors - Medium voltage motors (4160V/60Hz to 13800V/60Hz and 3300V/50Hz to 11000V/50Hz) are available for YK units; Contact JCI Sales Office for special rating. SPECIAL MOTORS ENCLOSURES There are job applications, primarily in manufacturing, comfort cooling plants, and pro- cess applications, where more motor protection is required. Listed below are several alter- natives. NOTE: Chiller certification to UL by a third party could be affected. Contact your JCI sales office for a specific selection. Weather-Protected Type I Motors (WP-I) – A Weather-Protected Type I motor is an open machine with its ventilating passages constructed to prevent the passage of a cylindrical rod ¾” in diameter. This affords protection against intrusion of rodents and some types of debris. These are regularly used in the pulp industry and where grime is present. Weather-Protected Type II Motors (WP-II) – A Weather-Protected Type II motor has, in addition to the enclosure defined for Weather-Protected Type I motor, ventilating passag- es at both intake and exhaust so arranged that high-velocity air and air-borne particles, blown into the motor, can be discharged without entering the internal ventilating passages leading directly to the electric parts of the machine itself. Space heaters are required with WP-II. Totally Enclosed Fan-Cooled Motors (TEFC) – TEFC motors are used where the loca- tion is extremely dirty, dusty, or wet, both indoors and outdoors. A totally enclosed fan- cooled unit is enclosed to prevent the free exchange of air between the inside and outside of the case but not sufficiently enclosed as to be termed air-tight. It is air-cooled by means of a fully guarded fan blowing cooling air over the outside of the motor. The fan is exter- nally mounted on the motor shaft. Totally Enclosed Air-to-Air Cooled (TEAAC) – TEAAC motors are used when the envi- ronment is dirty or corrosive. A TEAAC motor is a totally enclosed motor, cooled by circu- lating the internal air through an air-to-air heat exchanger. Totally Enclosed Water-to-Air Cooled (TEWAC) – TEWAC motors are used when the environment is dirty or corrosive, in hazardous areas, or where minimum noise levels are required. A TEWAC motor is a totally enclosed machine which is cooled by circulat- ing internal air which, in turn, is cooled by circulating water. It is provided with an internal water-cooled heat exchanger for cooling the internal air and fans, integral with the rotor shaft for circulating the internal air. BAS REMOTE CONTROL A communication interface permitting complete exchange of chiller data with any BAS system is available with an optional E-Link® gateway. The E-Link also allows the BAS system to issue commands to the chiller to control its operation. E-Link gateways come in four models, depending on the communication protocol and the mounting arrangement. Accessories and Modifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 41 Accessories and Modifications (Cont'd) FACTORY INSULATION OF EVAPORATOR Factory-applied thermal insulation of the flexible, closed-cell plastic type, 3/4 (19 mm) thick is attached with vapor-proof cement to the evaporator shell, flow chamber, tube sheets, suction connection, and (as necessary) to the auxiliary tubing. Not included is the insulation of compact waterboxes and nozzles. This insulation will normally prevent con- densation in environments with relative humidifies 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 available for relative humidifies up to 90% and dry bulb temperatures ranging from 50° to 90°F (10° to 32.2°C). WATER FLANGES Four 150 lb. ANSI raised-face flanges for condenser and evaporator water connections are factory-welded to water nozzles. Companion flanges, bolts, nuts and gaskets are not included. SPRING ISOLATION MOUNTING Spring isolation mounting is available instead of standard isolation mounting pads when desired. Four level-adjusting, spring-type vibration isolator assemblies with non-skid pads are provided for field-installation. Isolators are designed for one-inch (25 mm) deflection. WATERBOXES Marine Waterboxes - Marine waterboxes allow service access for cleaning of the heat ex- changer tubes without the need to break the water piping. Bolted-on covers are arranged for convenient access. ANSI/AWWA C-606 nozzle connections are standard; flanges are optional. Marine waterboxes are available for condenser and/or evaporator. Hinged Waterboxes - Hinged waterboxes allow fast and safe service access for clean- ing heat exchanger tubes. Hinged waterboxes on a non-nozzle end give access to the tubes without having to disconnect the water piping. Hinged waterboxes are available for condenser and/or evaporator for compact and marine waterboxes. KNOCK-DOWN SHIPMENT The chiller can be shipped knocked down into major subassemblies (evaporator, con- denser, driveline, etc.) as required to rig into tight spaces. This is particularly convenient for existing buildings where equipment room access does not allow rigging a factory- packaged chiller. REFRIGERANT ISOLATION VALVES Optional factory-installed isolation valves in the compressor discharge line and refrigerant liquid line are available. This allows isolation and storage of the refrigerant charge in the chiller condenser during servicing, eliminating time-consuming transfers to remote stor- age vessels. Both valves are positive shut-off, assuring integrity of the storage system.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 42 REFRIGERANT STORAGE/RECYCLING SYSTEM A refrigerant storage/recycling system is a self-contained package consisting of a refriger- ant compressor with oil separator, storage receiver, water-cooled condenser, filter drier and necessary valves and hoses to remove, replace and distill refrigerant. All necessary controls and safety devices are a permanent part of the system. A storage receiver is typi- cally not required if optional unit isolation valves are provided. HIGH AMBIENT TEMPERATURE Chiller modifications are available to allow for installation in high ambients of up to 122°F (50°C). Special drive motors are required above 104°F (40°C). H9 and K compressor evaporator design pressures must be increased for ambient temperatures above 112.8°F (45°C). The OptiView panel and low voltage VSD are suited for 122°F (50°C) ambient. Low and medium voltage Solid-State Starters must be derated and/or modified above 110°F (43.3°C). The free standing MVVSD option must be derated above its standard 104°F (40°C) limit. OPTISOUND™ CONTROL The YORK OptiSound™ Control is a patented combination of centrifugal-chiller hardware and software that reduces operational sound levels, expands the chiller operating range, and improves chiller performance. The OptiSound Control feature continuously monitors the characteristics of the compressor-discharge gas and optimizes the diffuser spacing to minimize gas-flow disruptions from the impeller. This innovative technology improves operating sound levels of the chiller an average of 7 dBA, and up to 13 dBA on the largest models. It can also reduce part-load sound levels below the full-load level. See Figure 2. In addition, the OptiSound Control provides the benefit of an expanded operating range. It improves performance and reliability by minimizing diffuser-gas stall at off-design opera- tion, particularly conditions of very low load combined with little or no condenser-water re- lief. The elimination of the gas-stall condition can also result in improved chiller efficiency at off-design conditions. Johnson Controls recommends the OptiSound Control for chiller applications with elevat- ed entering condenser-water temperatures (high-head) or applications requiring low-load operation with constant condenser temperature. At high-head conditions, improved chiller operation is visible at all load points. Accessories and Modifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 43 OptiSound Control Availability Standard: Compressors P8, P9, H9, K1, K2, K3, K4, K7 Optional: Compressors Q3, Q4, Q5, Q6, Q7, P7 Figure 5 - TYPICAL OPTIMIZED CENTRIFUGAL COMPRESSOR Accessories and Modifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 44 Application Data The following discussion is a user’s guide in the application and installation of YK chillers to ensure the reliable, trouble free life for which this equipment was designed. While this guide is directed towards normal, water chilling applications, the Johnson Controls sales representative can provide complete recommendations on other types of applications. LOCATION YK chillers are virtually vibration free and may generally be located at any level in a build- ing where the construction will support the total system operating weight. The unit site must be a floor, mounting pad or foundation which is level within 1/4 (6.4 mm) and capable of supporting the operating weight of the unit. Sufficient clearance to permit normal service and maintenance work should be provided all around and above the unit. Additional space should be provided at one end of the unit to permit cleaning of evaporator and condenser tubes as required. A doorway or other properly located opening may be used. The chiller should be installed in an indoor location where temperatures range from 40°F to 104°F (4.4°C to 40°C). The dew point temperature in the equipment room must be below the entering condenser water temperature to prevent condensing water vapor in- side of the low voltage VSD or low voltage SSS cabinet (if applicable). Applications using cooling sources other than evaporative or closed loop air exchange methods need to request a factory-supplied temperature control valve to prevent condensation inside the VSD or SSS cabinet. Other areas susceptible to water vapor condensate are outside of the condenser shell and condenser water boxes. Example applications include cooling condenser water using chilled water, wells, river or other low temperature fluids. For outdoor applications, please contact Large Tonnage Application Team. WATER CIRCUITS Flow Rate – For normal water chilling duty, evaporator and condenser flow rates are permitted at water velocity levels in the heat exchangers tubes of between 3 fps (0.91 m/s) [3.3 fps (1.0 m/s) for condensers] and 12 fps (3.66 m/s). Two pass units are also limited to 45 ft H2 0 (134 kPa) water pressure drop. The three pass limit is 67.5 ft H2 0 (201 kPa). Variable flow in the condenser is not recommended, as it generally raises the energy con- sumption of the system by keeping the condenser pressure high in the chiller. Additionally, the rate of fouling in the condenser will increase at lower water velocities associated with variable flow, raising system maintenance costs. Cooling towers typically have narrow ranges of operation with respect to flow rates, and will be more effective with full design flow. Refer to Tables 5 through 7 for flow limits at design conditions. There is increasing interest to use variable primary flow (VPF) systems in large chilled water plants. VPF systems can offer lower installation and operating costs in many cases, but do require more sophisticated control and flow monitoring.
FORM 160.75-EG1 (915) JOHNSON CONTROLS 45 YORK YK Style G chillers will operate successfully in VPF systems. With a minimum al- lowable evaporator tube velocity of 1-1/2 fps (0.5 m/s) for standard tubes at part-load rat- ing conditions, YK chillers will accommodate the wide variation in flow required by many chilled water VPF applications. The chillers can tolerate a 50% flow rate change in one minute that is typically associ- ated with the staging on or off of an additional chiller, however a lower flow rate change is normally used for better system stability and set point control. Proper sequencing via the building automation system will make this a very smooth transition. Temperature Ranges – For normal water chilling duty, leaving chilled water tempera- tures may be selected between 38°F (3.3°C) [36°F (2.2°C) with Smart Freeze enabled] and 70°F (21.1°C) to obtain temperature deltas between entering chilled and leaving chilled water temperature of 3°F up to 30°F (1.7°C and 16.7°C). Water Quality  –  The practical and economical application of liquid chillers requires that the quality of the water supply for the condenser and evaporator be analyzed by a water treatment specialist. Water quality may affect the performance of any chiller through cor- rosion, deposition of heat resistant scale, sedimentation or organic growth. These will degrade chiller performance and increase operating and maintenance costs. Normally, performance may be maintained by corrective water treatment and periodic cleaning of tubes. If water conditions exist which cannot be corrected by proper water treatment, it may be necessary to provide a larger allowance for fouling, and/or to specify special ma- terials of construction. General Piping  –  All chilled water and condenser water piping should be designed and installed in accordance with accepted piping practice. Chilled water and condenser wa- ter pumps should be located to discharge through the chiller to assure positive pressure and flow through the unit. Piping should include offsets to provide flexibility and should be arranged to prevent drainage of water from the evaporator and condenser when the pumps are shut off. Piping should be adequately supported and braced independently of the chiller to avoid the imposition of strain on chiller components. Hangers must allow for alignment of the pipe. Isolators in the piping and in the hangers are highly desirable in achieving sound and vibration control. Convenience Considerations – To facilitate the performance of routine maintenance work, some or all of the following steps may be taken by the purchaser. Evaporator and condenser waterboxes are equipped with plugged vent and drain connections. If desired, vent and drain valves may be installed with or without piping to an open drain. Pressure gauges with stop cocks and stop valves may be installed in the inlets and outlets of the condenser and chilled water line as close as possible to the chiller. An overhead monorail or beam may be used to facilitate servicing. Connections  –  The standard chiller is designed for 150 psig (10.3 barg) design working pressure in both the chilled water and condenser water circuits. The connections (water nozzles) to these circuits are furnished with grooves to ANSI/AWWA C-606 Standard for grooved and shouldered joints. Piping should be arranged for ease of disassembly at the unit for tube cleaning. All water piping should be thoroughly cleaned of all dirt and debris before final connections are made to the chiller. Chilled Water – A water strainer of maximum 1/8 (3.2 mm) perforated holes must be field-installed in the chilled water inlet line as close as possible to the chiller. If located close enough to the chiller, the chilled water pump may be protected by the same strainer. The strainer is important to protect the chiller from debris or objects which could block flow through individual heat exchanger tubs. A reduction in flow through tubes could seriously impair the chiller performance or even result in tube freeze-up. A thermal-type flow switch Application Data (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 46 is factory installed in the evaporator nozzle and connected to the OptiView panel, which assures adequate chilled water flow during operation. Condenser Water  –  The chiller is engineered for maximum efficiency at both design and part load operation by taking advantage of the colder cooling tower water temperatures which naturally occur during the winter months. Appreciable power savings are realized from these reduced heads. The minimum entering condenser water temperature for other full and part load conditions is provided by the following equation: Min. ECWT = LCHWT – C RANGE + 5°F + 12 ( %Load )100 or Min. ECWT = LCHWT – C RANGE + 2.8°C + 6.6 ( %Load )100 where: ECWT = entering condensing water temperature LCHWT = leaving chilled water temperature C RANGE = condensing water temperature range at the given load condition. At initial startup, entering condensing water temperature may be as much as 25°F (13.9°C) colder than the standby chilled water temperature. BRINE APPLICATIONS Various types of brine can be used in both the evaporator and condenser in lieu of water. The OptiView Control panel is programmed in the factory to allow extending the evapora- tor leaving brine temperature setpoint below 36°F (2.2°C). The low evaporator pressure cutout is factory programmed to the appropriate value depending on the percent (%) con- centration and type of brine solution. When the chiller is not running, brine should not be run through the evaporator. However, if there is brine running through the evaporator, there must be flow through the condenser to prevent tubes from freezing. In brine applications the condenser pump control will close when the condenser saturation temperature reaches 35°F (1.7°C) and the pump will shut off when the temperature increases to 40°F (4.4°C). This is applicable if tied to the condenser pump control. MULTIPLE UNITS Selection – Many applications require multiple units to meet the total capacity require- ments as well as to provide flexibility and some degree of protection against equipment shutdown. There are several common unit arrangements for this type of application. The YK chiller has been designed to be readily adapted to the requirements of these various arrangements. Application Data (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 47 Application Data (Cont'd) Parallel Arrangement (Figure 6 - PARALLEL EVAPORATORS PARALLEL CONDENS- ERS on page 47) – Chillers may be applied in multiples with chilled and condenser water circuits connected in parallel between the units. Figure 1 represents a parallel ar- rangement with two chillers. Parallel chiller arrangements may consist of equally or un- equally sized units. When multiple units are in operation, they will load and unload at equal percentages of design full load for the chiller. Depending on the number of units and operating characteristics of the units, loading and unloading schemes should be designed to optimize the overall efficiency of the chiller plant. It is recommended to use an evaporator bypass piping arrangement to bypass fluid around evaporator of any unit which has cycled off at reduced load conditions. It is also recommended to alternate the chiller cycling order to equalize chiller starts and run hours. Series Arrangement (Figure 7 - SERIES EVAPORATORS PARALLEL CONDENSERS on page 47) – Chillers may be applied in pairs with chilled water circuits connected in series and condenser water circuits connected in parallel. All of the chilled water flows through both evaporators with each unit handling approximately one half of the total load. COND. 1 COND. 2 EVAP. 1 EVAP. 2 LD18370 Figure 6 - PARALLEL EVAPORATORS PARALLEL CONDENSERS EVAP. 1 EVAP. 2 T S1 S2 COND. 1 COND. 2 Figure 7 - SERIES EVAPORATORS PARALLEL CONDENSERS
JOHNSON CONTROLS FORM 160.75-EG1 (915) 48 When the load decreases to a customer selected load value, one of the units will be shut down by a sequence control. Since all water is flowing through the operating unit, that unit will cool the water to the desired temperature. Series Counter Flow Arrangement (Figure 8 - SERIES EVAPORATORS SERIES COUN- TERFLOW CONDENSERS on page 48) - Chillers may be applied in pairs with chilled water circuits connected in series and with the condenser water in series counter flow. All of the chilled water flows through both evaporators. All of the condenser water flows through both condensers. The water ranges are split, which allows a lower temperature difference or head on each chiller, than multiple units in parallel. For equal chillers, the machine at higher temperature level will typically provide slightly more than half the capacity. The compressor motors and gear codes on the two chillers are often matched, such that the high temperature machine can operate at the low temperature conditions when one unit is cycled off at part loads (as compared to series-parallel chillers which are typically not identical). Series counter flow application can provide a significant building energy savings for large capacity plants which have chilled and condenser water temperature ranges greater than typical AHRI. HEAT RECOVERY Heat recovery may be used in buildings, where there is a need for heating and cooling loads concurrently. By utilizing some or all of the heat rejection of a normal vapor-com- pression cycle cooling system, overall operating energy savings result. Heat recovery uses available heat as a by-product of the cooling function, which differs from heat pumps where the heating can be considered the primary process. Also, the heat recovery usage is often a winter seasonal duty, where the chiller may be expected to operate in summer using heat rejection to a conventional cooling tower. As heating loops and cooling tower water circuits are separate in the majority of buildings, this dictates the need for two water circuits in the condenser of a heat recovery chiller. Application Data (Cont'd) COND. 1 COND. 2 EVAP.1 EVAP.2 T S1 S2 Figure 8 - SERIES EVAPORATORS SERIES COUNTERFLOW CONDENSERS
FORM 160.75-EG1 (915) JOHNSON CONTROLS 49 Application Data (Cont'd) Very simply, heat recovery allows you to utilize the heat, [which would otherwise be wast- ed (to the cooling tower)], to serve a useful purpose. This heat of rejection can be used to: • Pre-heat domestic hot water needs like in hotels or hospitals for use in: • Laundry, showers, swimming pools, cooking/dishwashing, hot tub. • Comfort heating (perimeter heating). • Reheating of air. • Preheating of boiler makeup water or process hot water. The main difference between a cooling only chiller and a heat recovery chiller is in the heat recovery chiller's added ability to reject the free condenser heat to the cooling tower and/or the heating system. Since heat is being removed from the area to be cooled, the cooling load supports the heating load. There must be a simultaneous cooling and heat- ing load in the building. When using a Solid-State Starter or Variable Speed Drive for a heat recovery application, the starters will be chilled water cooled. Please refer to Form 160.75-AD2; YK Mod G Heat Recovery Application Data for addi- tional information. Heat Recovery Availability Standard: Compressors Q4, Q7, H9, K2, K7 REFRIGERANT RELIEF PIPING Each chiller is equipped with dual pressure relief valves on the condenser and two dual relief valves on the evaporator, or two single relief valves on the evaporator if the optional refrigerant isolation valves are ordered. The dual relief valves on the condenser are re- dundant and allow changing of either valve while the unit is fully charged. The purpose of the relief valves is to quickly relieve excess pressure of the refrigerant charge to the atmosphere, as a safety precaution in the event of an emergency such as fire. They are set to relieve at an internal pressure as noted on the pressure vessel data plate, and are provided in accordance with ASHRAE 15 safety code and ASME or applicable pressure vessel code. Sized to the requirements of applicable codes, a vent line must run from the relief device to the outside of the building. This refrigerant relief piping must include a cleanable, verti- cal leg dirt trap to catch vent stack condensation. Vent piping must be arranged to avoid imposing a strain on the relief connection and should include one flexible connection. SOUND AND VIBRATION CONSIDERATIONS A YK chiller is not a source of objectionable sound and vibration in normal air conditioning applications. Neoprene isolation mounts are furnished as standard with each unit. Op- tional level adjusting spring isolator assemblies designed for 1 (25 mm) static deflection are available from Johnson Controls. YK chiller sound pressure level ratings will be furnished on request. Control of sound and vibration transmission must be taken into account in the equipment room construction as well as in the selection and installation of the equipment.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 50 THERMAL INSULATION No appreciable operating economy can be achieved by thermally insulating the chiller. However, the chiller’s cold surfaces should be insulated with vapor barrier insulation suf- ficient to prevent condensation. A chiller can be factory-insulated with 3/4 (19 mm) or 1 1/2 (38 mm) thick insulation, as an option. This insulation will normally prevent conden- sation in environments with dry bulb temperatures of 50°F to 90°F (10°C to 32°C) and relative humidities up to 75% [3/4 (19 mm) thickness] or 90% [1 1/2 (38 mm) thickness]. The insulation is painted and the surface is flexible and reasonably resistant to wear. It is intended for a chiller installed indoors and, therefore, no protective covering of the insula- tion is usually required. If insulation is applied to the waterboxes at the job site, it must be removable to permit access to the tubes for routine maintenance. VENTILATION The ASHRAE Standard 15 Safety Code for Mechanical Refrigeration requires that all ma- chinery rooms be vented to the outdoors utilizing mechanical ventilation by one or more power driven fans. This standard, plus National Fire Protection Association Standard 90A, state, local and any other related codes should be reviewed for specific requirements. Since the YK chiller motor is air-cooled, ventilation should allow for the removal of heat from the motor. In addition, the ASHRAE Standard 15 requires a refrigerant vapor detector to be em- ployed for all refrigerants. It is to be located in an area where refrigerant from a leak would be likely to concentrate. An alarm is to be activated and the mechanical ventilation started at a value no greater than the TLV (Threshold Limit Value) of the refrigerant. ELECTRICAL CONSIDERATIONS Motor Voltage – Low voltage motors (200 to 600 volts) are furnished with six leads. Medium voltage (2300 to 13800 volts) motors have three leads. Motor circuit conductor size must be in accordance with the National Electrical Code (N.E.C.), or other applicable codes, for the motor full load amperes (FLA). Flexible conduit should be used for the last several feet to the chiller in order to provide vibration isolation. Table 6 - MOTOR VOLTAGE VARIATIONS on page 52 lists the allowable variation in voltage supplied to the chiller motor. The unit name plate is stamped with the specific motor voltage, and frequency for the appropriate motor. Starters – A separate starter is not required if the chiller is equipped with a Variable Speed Drive (VSD). The YK Chillers are also available with a factory mounted and wired York Solid-State Starter for low and medium voltage applications. Other types of remote mounted starters are available. Electromechanical starters must be furnished in accor- dance with YORK Standard Specifications (R-1132). This will ensure that starter compo- nents, controls, circuits, and terminal markings will be suitable for required overall system performance. Remote-mounted medium voltage York Solid-State Starters are also avail- able. Controls – A 115 volt, single-phase, 60 or 50 Hertz 2 KVA power supply must be fur- nished to the chiller from a separate, fused disconnect or from a control transformer in- cluded as an option with electro-mechanical starters. No field control wiring is required when the low voltage YORK Variable Speed Drive or Solid-State Starter is supplied. Application Data (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 51 Application Data (Cont'd) Oil Pump Power Supply  –  A separate 3 phase power supply with a fused disconnect for the factory-mounted oil pump variable speed drive is required unless the low voltage VSD or SSS is supplied. Power can also be supplied through an electro-mechanical starter, remote mounted Medium Voltage Solid-State Starter (MVSSS) or Medium Voltage Vari- able Speed Drive (MVVSD). Copper Conductors  –  Only copper conductors should be connected to compressor mo- tors and starters. Aluminum conductors have proven to be unsatisfactory when connected to copper lugs. Aluminum oxide and the difference in thermal conductivity between copper and aluminum cannot guarantee the required tight connection over a long period of time. Displacement Power-factor Correction Capacitors – When the chiller is equipped with a VSD, automatic displacement power factor correction to a minimum of 0.95 is pro- vided at all operating conditions, so additional capacitors are not required. For other start- ing methods, capacitors can be applied to a chiller for the purpose of displacement power factor correction. For remote-mounted electro-mechanical starters, the capacitors should be located on the load side of the starter. For YORK Solid-State Starters the capacitors must be located on the line side of the starter. The capacitors must be sized and installed to meet the National Electrical Code and be verified by Johnson Controls. Ampacity on Load Side of Starter  –  Electrical power wire size to the chiller is based on the minimum unit ampacity. For Solid-State Starters or Variable Speed Drive, this wiring is done at the factory. For remote starters, the National Electrical Code defines the calcu- lation of ampacity, as summarized below. More specific information on actual amperage ratings will be supplied with the submittal drawings: • Six lead type of starting (Star Delta) Minimum circuit ampacity per conductor (1 of 6): Ampacity = 721 x compressor motor amps. • Three lead type of starting (Across the Line, Autotransformer and Primary Reactor) Minimum circuit ampacity per conductor (1 of 3): Ampacity = 1.25 x compressor mo- tor amps. Ampacity on Line Side of Starter  –  The only additional load on the circuit for the chiller would be the control transformer and oil pump motor unless they are supplied by a sepa- rate source. Minimum Circuit Ampacity = 125% of compressor motor amps + FLA of all other loads on the circuit. Branch Circuit Overcurrent Protection – The branch circuit overcurrent protection device(s) should be a time delay type, with a minimum rating equal to the next standard fuse/breaker rating above the calculated value. It is calculated taking into account the compressor motor amps and may also include control transformer and oil pump motor. Refer to submittal drawings for the specific calculations for each application. See Table 15 - LOW VOLTAGE VARIABLE SPEED MODELS on page 69.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 52 Table 6 - MOTOR VOLTAGE VARIATIONS FREQ. RATED VOLTAGE NAMEPLATE VOLTAGE* OPERATING VOLTAGE MIN. MAXIMUM 60 HZ 200 200/208 180 220 230 220/240 208 254 380 380 342 415 416 416 375 457 460 440/460/480 414 508 575 575/600 520 635 2300 2300 2070 2530 3300 3300 2970 3630 4000 4000/4160 3600 4576 50 HZ 346 346 311 381 380 380/400 342 423 415 415 374 440 3300 3300 2970 3630 *For motor voltage above 4160V/60Hz and 3300V/50HZ contact your JCI Sales Office for a specific selection. MOTOR ELECTRICAL DATA The smallest motor available which equals or exceeds the Input power (kW) from the chiller rating program is selected from Tables 10. The full load amperes (FLA) listed in the tables is maximum values and corresponds to the maximum motor kW listed. When the input power (kW) is less than maximum motor kW, the FLA should be reduced per the following equation: FLA = Motor kW x Maximum Motor FLA Maximum Motor kW The benefit from the FLA correction is the possible use of smaller power wiring and/or starter size. The locked rotor amperes (LRA) are read directly from Table 10 for specific Motor Code and voltage. This is because the LRA is dependent only on motor size and voltage and is independent of input power (kW). Inrush amperes (IRA) depend on LRA and the type of starter applied. The inrush can be calculated using a percentage of LRA shown in Tables 13 to 17. Application Data (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 53 Application Data (Cont'd) Table 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS FLOODED EVAPORATORS 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 AP 329 (21) 1316 (83) 164 (10) 587 (37) 110 (7) 380 (24) AP 479 (30) 1727 (109) 240 (15) 856 (54) 160 (10) 576 (36) AQ 403 (25) 1613 (102) 202 (13) 713 (45) 134 (8) 460 (29) AQ 612 (39) 2205 (139) 306 (19) 1068 (67) 204 (13) 732 (46) AR 493 (31) 1973 (125) 247 (16) 861 (54) 164 (10) 552 (35) AR 681 (43) 2455 (155) 341 (21) 1173 (74) 227 (14) 812 (51) AS 602 (38) 2408 (152) 301 (19) 1032 (65) 201 (13) 655 (41) AS 770 (49) 2773 (175) 385 (24) 1300 (82) – – CP 648 (41) 2594 (164) 324 (20) 1151 (73) 216 (14) 755 (48) CP 779 (49) 2807 (177) 389 (25) 1397 (88) 260 (16) 922 (58) CQ 729 (46) 2917 (184) 365 (23) 1286 (81) 243 (15) 844 (53) CQ 896 (57) 3228 (204) 448 (28) 1590 (100) 299 (19) 1050 (66) CR 866 (55) 3463 (218) 433 (27) 1509 (95) 289 (18) 992 (63) CR 1120 (71) 4035 (255) 560 (35) 1941 (122) 373 (24) 1285 (81) CS 1043 (66) 4170 (263) 521 (33) 1787 (113) 348 (22) 1176 (74) CS 1397 (88) 5035 (318) 699 (44) 2340 (148) – – DP 648 (41) 2594 (164) 324 (20) 988 (62) 216 (14) 648 (41) DP 779 (49) 2807 (177) 389 (25) 1203 (76) 260 (16) 793 (50) DQ 729 (46) 2917 (184) 365 (23) 1106 (70) 243 (15) 725 (46) DQ 896 (57) 3228 (204) 448 (28) 1372 (87) 299 (19) 906 (57) DR 866 (55) 3463 (218) 433 (27) 1301 (82) 289 (18) 854 (54) DR 1120 (71) 4035 (255) 560 (35) 1685 (106) 373 (24) 1114 (70) DS 1043 (66) 4170 (263) 521 (33) 1547 (98) 348 (22) 1017 (64) DS 1397 (88) 5035 (318) 699 (44) 2048 (129) – – EP 859 (54) 3438 (217) 430 (27) 1535 (97) 286 (18) 1009 (64) EP 1120 (71) 4035 (255) 560 (35) 2017 (127) 373 (24) 1337 (84) EQ 1046 (66) 4183 (264) 523 (33) 1853 (117) 349 (22) 1220 (77) EQ 1344 (85) 4842 (305) 672 (42) 2394 (151) 448 (28) 1590 (100) ER 1232 (78) 4927 (311) 616 (39) 2164 (136) 411 (26) 1428 (90) ER 1583 (100) 5705 (360) 792 (50) 2779 (175) 528 (33) 1853 (117) ES 1452 (92) 5809 (366) 726 (46) 2519 (159) 484 (31) 1667 (105) ES 1750 (110) 6308 (398) 875 (55) 3037 (192) 583 (37) 2031 (128) ET 1676 (106) 6702 (423) 838 (53) 2865 (181) 559 (35) 1903 (120) ET 1946 (123) 7012 (442) 973 (61) 3328 (210) – – FQ 1046 (66) 4183 (264) 523 (33) 1591 (100) 349 (22) 1046 (66) FQ 1344 (85) 4842 (305) 672 (42) 2064 (130) 448 (28) 1368 (86) FR 1232 (78) 4927 (311) 616 (39) 1862 (117) 411 (26) 1226 (77) FR 1583 (100) 5705 (360) 792 (50) 2405 (152) 528 (33) 1599 (101) FS 1452 (92) 5809 (366) 726 (46) 2175 (137) 484 (31) 1436 (91) FS 1750 (110) 6308 (398) 875 (55) 2636 (166) 583 (37) 1756 (111) FT 1676 (106) 6702 (423) 838 (53) 2482 (157) 559 (35) 1643 (104) FT 1946 (123) 7012 (442) 973 (61) 2898 (183) – – GQ 1443 (91) 5771 (364) 721 (46) 2504 (158) 481 (30) 1657 (105) EV 1583 (100) 5705 (360) 792 (50) 2779 (175) 528 (33) 1853 (117) GR 1629 (103) 6516 (411) 814 (51) 2794 (176) 543 (34) 1855 (117) EW 1750 (110) 6308 (398) 875 (55) 3037 (192) 583 (37) 2031 (128)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 54 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 GS 1843 (116) 7372 (465) 922 (58) 3115 (197) 614 (39) 2075 (131) EX 1946 (123) 7012 (442) 973 (61) 3328 (210) – – – – – – – – E3 1416 (89) 5101 (322) 708 (45) 2551 (161) 472 (30) 1700 (107) – – – – – – E4 1738 (110) 6263 (395) 869 (55) 3131 (198) – – HQ 1443 (91) 5771 (364) 721 (46) 2162 (136) 481 (30) 1427 (90) FV 1583 (100) 5705 (360) 792 (50) 2405 (152) 528 (33) 1599 (101) HR 1629 (103) 6516 (411) 814 (51) 2419 (153) 543 (34) 1600 (101) FW 1750 (110) 6308 (398) 875 (55) 2636 (166) 583 (37) 1756 (111) HS 1843 (116) 7372 (465) 922 (58) 2707 (171) 614 (39) 1796 (113) FX 1946 (123) 7012 (442) 973 (61) 2898 (183) – – – – – – – – F3 1416 (89) 5101 (322) 708 (45) 2551 (161) 472 (30) 1700 (107) – – – – – – F4 1738 (110) 6263 (395) 869 (55) 3131 (198) – – JP 1545 (97) 6181 (390) 773 (49) 2735 (173) 515 (32) 1807 (114) JP 1583 (100) 5705 (360) 792 (50) 2779 (175) 528 (33) 1899 (120) JQ 1918 (121) 7670 (484) 959 (60) 3349 (211) 639 (40) 2224 (140) JQ 1892 (119) 6819 (430) 946 (60) 3249 (205) 631 (40) 2253 (142) JR 2395 (151) 9582 (604) 1198 (76) 4098 (259) 798 (50) 2742 (173) JR 2479 (156) 8933 (564) 1239 (78) 4054 (256) 826 (52) 2903 (183) JS 2616 (165) 10463 (660) 1308 (83) 4427 (279) 872 (55) 2974 (188) JS 2756 (174) 9933 (627) 1378 (87) 4395 (277) – – KP, KT 1545 (97) 6181 (390) 773 (49) 2522 (159) 515 (32) 1664 (105) KP 1583 (100) 5705 (360) 792 (50) 2574 (162) 528 (33) 1750 (110) KQ,KV 1918 (121) 7670 (484) 959 (60) 3094 (195) 639 (40) 2051 (129) KQ 1892 (119) 6819 (430) 946 (60) 3019 (190) 631 (40) 2078 (131) KR,KW 2395 (151) 9582 (604) 1198 (76) 3797 (240) 798 (50) 2533 (160) KR 2479 (156) 8933 (564) 1239 (78) 3790 (239) 826 (52) 2684 (169) KS,KX 2616 (165) 10463 (660) 1308 (83) 4109 (259) 872 (55) 2750 (174) KS 2756 (174) 9933 (627) 1378 (87) 4121 (260) – – K2,K5 1844 (116) 7374 (465) 922 (58) 3687 (233) 615 (39) 2458 (155) K2 1617 (102) 5829 (368) 809 (51) 2914 (184) 539 (34) 1943 (123) K3,K6 2163 (136) 8651 (546) 1081 (68) 4325 (273) 721 (45) 2884 (182) K3 1927 (122) 6946 (438) 964 (61) 3473 (219) 642 (41) 2315 (146) K4,K7 2488 (157) 9951 (628) 1244 (78) 4903 (309) 829 (52) 3312 (209) K4 2584 (163) 9313 (588) 1292 (82) 4657 (294) – – LQ 1918 (121) 7670 (484) 959 (60) 2886 (182) 639 (40) 1910 (120) LQ 1892 (119) 6819 (430) 946 (60) 2827 (178) 631 (40) 1936 (122) LR 2395 (151) 9582 (604) 1198 (76) 3550 (224) 798 (50) 2363 (149) LR 2479 (156) 8933 (564) 1239 (78) 3567 (225) 826 (52) 2504 (158) LS 2616 (165) 10463 (660) 1308 (83) 3845 (243) 872 (55) 2567 (162) LS 2756 (174) 9933 (627) 1378 (87) 3888 (245) – – – – – – – – MP 2192 (138) 7899 (498) 1096 (69) 3626 (229) 731 (46) 2391 (151)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 55 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 MQ 2426 (153) 9706 (612) 1213 (77) 3906 (246) 809 (51) 2606 (164) MQ 2570 (162) 9263 (584) 1285 (81) 4206 (265) 857 (54) 2776 (175) MR 2830 (179) 11319 (714) 1415 (89) 4499 (284) 943 (60) 3022 (191) MR 2949 (186) 10626 (670) 1474 (93) 4765 (301) 983 (62) 3149 (199) MS 3246 (205) 12982 (819) 1623 (102) 5088 (321) 1082 (68) 3444 (217) MS 3271 (206) 11786 (744) 1635 (103) 5225 (330) – – M2 2003 (126) 8013 (506) 1002 (63) 4006 (253) 668 (42) 2671 (169) M2 2131 (134) 7678 (484) 1065 (67) 3839 (242) 710 (45) 2559 (161) M3 2375 (150) 9502 (599) 1188 (75) 4751 (300) 792 (50) 3167 (200) M3 2639 (166) 9510 (600) 1319 (83) 4755 (300) 880 (55) 3170 (200) M4 2949 (186) 11794 (744) 1474 (93) 5837 (368) 983 (62) 3931 (248) M4 3246 (205) 11699 (738) 1623 (102) 5849 (369) – – – – – – – – NP 2192 (138) 7899 (498) 1096 (69) 3381 (213) 731 (46) 2229 (141) NQ 2426 (153) 9706 (612) 1213 (77) 3644 (230) 809 (51) 2426 (153) NQ 2570 (162) 9263 (584) 1285 (81) 3927 (248) 857 (54) 2591 (163) NR 2830 (179) 11319 (714) 1415 (89) 4205 (265) 943 (60) 2815 (178) NR 2949 (186) 10626 (670) 1474 (93) 4456 (281) 983 (62) 2943 (186) NS 3246 (205) 12982 (819) 1623 (102) 4763 (300) 1082 (68) 3210 (203) NS 3271 (206) 11786 (744) 1635 (103) 4892 (309) – – N2 2003 (126) 8013 (506) 1002 (63) 3870 (244) 668 (42) 2580 (163) N2 2131 (134) 7678 (484) 1065 (67) 3839 (242) 710 (45) 2559 (161) N3 2375 (150) 9502 (599) 1188 (75) 4527 (286) 792 (50) 3040 (192) N3 2639 (166) 9510 (600) 1319 (83) 4755 (300) 880 (55) 3170 (200) N4 2949 (186) 11794 (744) 1474 (93) 5484 (346) 983 (62) 3731 (235) N4 3246 (205) 11699 (738) 1623 (102) 5849 (369) – – PQ 2755 (174) 11021 (695) 1378 (87) 4391 (277) 918 (58) 2946 (186) PQ 3662 (231) 13195 (832) 1831 (116) 5954 (376) 1221 (77) 4003 (253) PR 3131 (198) 12523 (790) 1565 (99) 4928 (311) 1044 (66) 3328 (210) PR 4097 (258) 14763 (931) 2048 (129) 6587 (416) 1366 (86) 4452 (281) PS 3360 (212) 13441 (848) 1680 (106) 5246 (331) 1120 (71) 3558 (224) PS 4545 (287) 16377 (1033) 2272 (143) 7216 (455) – – P2 2523 (159) 10093 (637) 1262 (80) 5046 (318) 841 (53) 3364 (212) P2 3229 (204) 11635 (734) 1614 (102) 5817 (367) 1076 (68) 3878 (245) P3 2960 (187) 11842 (747) 1480 (93) 5857 (370) 987 (62) 3947 (249) P3 3917 (247) 14114 (890) 1958 (124) 7057 (445) 1306 (82) 4705 (297) P4 3356 (212) 13425 (847) 1678 (106) 6499 (410) 1119 (71) 4475 (282) P4 4760 (300) 17152 (1082) 2380 (150) 8576 (541) – – QQ 2755 (174) 11021 (695) 1378 (87) 4103 (259) 918 (58) 2744 (173) QQ 3662 (231) 13195 (832) 1831 (116) 5563 (351) 1221 (77) 3731 (235) QR 3131 (198) 12523 (790) 1565 (99) 4611 (291) 1044 (66) 3102 (196) QR 4097 (258) 14763 (931) 2048 (129) 6163 (389) 1366 (86) 4152 (262) QS 3360 (212) 13441 (848) 1680 (106) 4913 (310) 1120 (71) 3318 (209) QS 4545 (287) 16377 (1033) 2272 (143) 6762 (427) – – Q2 2523 (159) 10093 (637) 1262 (80) 4780 (302) 841 (53) 3221 (203) Q2 3229 (204) 11635 (734) 1614 (102) 5817 (367) 1076 (68) 3878 (245)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 56 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 Q3 2960 (187) 11842 (747) 1480 (93) 5503 (347) 987 (62) 3745 (236) Q3 3917 (247) 14114 (890) 1958 (124) 7057 (445) 1306 (82) 4705 (297) Q4 3356 (212) 13425 (847) 1678 (106) 6121 (386) 1119 (71) 4207 (265) Q4 4760 (300) 17152 (1082) 2380 (150) 8576 (541) – – QT 3602 (227) 14410 (909) 1801 (114) 5225 (330) 1201 (76) 3544 (224) – – – – – – QV 4142 (261) 16569 (1045) 2071 (131) 5893 (372) 1381 (87) 4037 (255) – – – – – – RQ 3770 (238) 15080 (951) 1885 (119) 5689 (359) 1257 (79) 3737 (236) RQ 4907 (310) 17684 (1116) 2454 (155) 7428 (469) 1636 (103) 4917 (310) RS 4605 (291) 18418 (1162) 2302 (145) 6863 (433) 1535 (97) 4517 (285) RR 5390 (340) 19423 (1225) 2695 (170) 8086 (510) 1797 (113) 5360 (338) RV 5405 (341) 21621 (1364) 2703 (171) 7946 (501) 1802 (114) 5240 (331) RS 5753 (363) 20730 (1308) 2876 (181) 8570 (541) – – R3 3870 (244) 15482 (977) 1935 (122) 7403 (467) 1290 (81) 4872 (307) R2 4228 (267) 15235 (961) 2114 (133) 7618 (481) 1409 (89) 5078 (320) R5 4603 (290) 18413 (1162) 2302 (145) 8650 (546) 1534 (97) 5708 (360) R3 4996 (315) 18005 (1136) 2498 (158) 9002 (568) 1665 (105) 6002 (379) R7 5241 (331) 20965 (1323) 2621 (165) 9682 (611) 1747 (110) 6404 (404) R4 5914 (373) 21311 (1344) 2957 (187) 10655 (672) – – RP 3103 (196) 12411 (783) 1551 (98) 4722 (298) 1034 (65) 3098 (195) – – – – – RR 3829 (242) 15316 (966) 1914 (121) 5774 (364) 1276 (81) 3793 (239) – – – – – – RT 4633 (292) 18530 (1169) 2316 (146) 6902 (435) 1544 (97) 4542 (287) – – – – – – R2 3800 (240) 15198 (959) 1900 (120) 7278 (459) 1267 (80) 4789 (302) – – – – – – R4 4296 (271) 17183 (1084) 2148 (136) 8135 (513) 1432 (90) 5362 (338) – – – – – – R6 4816 (304) 19263 (1215) 2408 (152) 9000 (568) 1605 (101) 5943 (375) – – – – – – SQ 3770 (238) 15080 (951) 1885 (119) 5345 (337) 1257 (79) 3510 (221) SQ 4907 (310) 17684 (1116) 2454 (155) 6992 (441) 1636 (103) 4626 (292) SS 4605 (291) 18418 (1162) 2302 (145) 6457 (407) 1535 (97) 4247 (268) SR 5390 (340) 19423 (1225) 2695 (170) 7619 (481) 1797 (113) 5047 (318) SV 5405 (341) 21621 (1364) 2703 (171) 7487 (472) 1802 (114) 4933 (311) SS 5753 (363) 20730 (1308) 2876 (181) 8081 (510) – – S3 3870 (244) 15482 (977) 1935 (122) 6975 (440) 1290 (81) 4588 (289) S2 4228 (267) 15235 (961) 2114 (133) 7549 (476) 1409 (89) 4993 (315) S5 4603 (290) 18413 (1162) 2302 (145) 8166 (515) 1534 (97) 5384 (340) S3 4996 (315) 18005 (1136) 2498 (158) 8795 (555) 1665 (105) 5832 (368) S7 5241 (331) 20965 (1323) 2621 (165) 9157 (578) 1747 (110) 6050 (382) S4 5914 (373) 21311 (1344) 2957 (187) 10192 (643) – – – – – – – – TP 5396 (340) 19446 (1227) 2698 (170) 8095 (511) 1799 (113) 5470 (345)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 57 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 – – – – – – TQ 5973 (377) 21525 (1358) 2987 (188) 8859 (559) 1991 (126) 6020 (380) – – – – – – TR 6576 (415) 23696 (1495) 3288 (207) 9629 (607) 2192 (138) 6583 (415) – – – – – – TS 6929 (437) 24969 (1575) 3464 (219) 10067 (635) – – – – – – – – T2 4607 (291) 16602 (1047) 2304 (145) 8301 (524) 1536 (97) 5534 (349) – – – – – – T3 5710 (360) 20578 (1298) 2855 (180) 10289 (649) 1903 (120) 6859 (433) – – – – – – T4 6299 (397) 22700 (1432) 3150 (199) 11300 (713) 2100 (132) 7567 (477) – – – – – – T5 7093 (447) 25559 (1613) 3546 (224) 12421 (784) – – – – – – – – VP 5396 (340) 19446 (1227) 2698 (170) 7628 (481) 1799 (113) 5140 (324) – – – – – – VQ 5973 (377) 21525 (1358) 2987 (188) 8358 (527) 1991 (126) 5660 (357) – – – – – – VR 6576 (415) 23696 (1495) 3288 (207) 9097 (574) 2192 (138) 6194 (391) – – – – – – VS 6929 (437) 24969 (1575) 3464 (219) 9518 (600) – – – – – – – – V2 4607 (291) 16602 (1047) 2304 (145) 8143 (514) 1536 (97) 5497 (347) – – – – – – V3 5710 (360) 20578 (1298) 2855 (180) 9865 (622) 1903 (120) 6749 (426) – – – – – – V4 6299 (397) 22700 (1432) 3150 (199) 10725 (677) 2100 (132) 7395 (467) – – – – – – V5 7093 (447) 25559 (1613) 3546 (224) 11818 (746) – – WP 3103 (196) 12411 (783) 1551 (98) 3973 (251) 1034 (65) 2605 (164) WQ 5368 (339) 19343 (1220) 2684 (169) 6844 (432) 1789 (113) 4591 (290) WR 3829 (242) 15316 (966) 1914 (121) 4871 (307) 1276 (81) 3197 (202) WR 5891 (372) 21230 (1339) 2946 (186) 7456 (470) 1964 (124) 5020 (317) WT 4633 (292) 18530 (1169) 2316 (146) 5842 (369) 1544 (97) 3840 (242) WS 6415 (405) 23117 (1458) 3207 (202) 8054 (508) – – W1 3173 (200) 12693 (801) 1587 (100) 5209 (329) 1058 (67) 3419 (216) W1 4250 (268) 15314 (966) 2125 (134) 6785 (428) 1417 (89) 4540 (286) W2 3800 (240) 15198 (959) 1900 (120) 6180 (390) 1267 (80) 4062 (256) W2 5260 (332) 18955 (1196) 2630 (166) 8290 (523) 1753 (111) 5603 (354) W4 4296 (271) 17183 (1084) 2148 (136) 6929 (437) 1432 (90) 4559 (288) W3 6140 (387) 22127 (1396) 3070 (194) 9526 (601) 2047 (129) 6502 (410) W6 4816 (304) 19263 (1215) 2408 (152) 7693 (485) 1605 (101) 5069 (320) W4 6785 (428) 24450 (1543) 3392 (214) 10386 (655) – – XQ 4769 (301) 19076 (1204) 2385 (150) 7089 (447) 1590 (100) 4667 (294) XQ 6241 (394) 22491 (1419) 3121 (197) 9429 (595) 2080 (131) 6272 (396)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 58 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 XR 5272 (333) 21087 (1330) 2636 (166) 7769 (490) 1757 (111) 5121 (323) XR 6967 (440) 25105 (1584) 3483 (220) 10411 (657) 2322 (147) 6943 (438) XS 5740 (362) 22961 (1449) 2870 (181) 8386 (529) 1913 (121) 5534 (349) XS 7900 (498) 28470 (1796) 3950 (249) 11627 (734) – – X2 4769 (301) 19074 (1203) 2384 (150) 8923 (563) 1590 (100) 5891 (372) X2 4969 (313) 17905 (1130) 2484 (157) 8952 (565) 1656 (104) 5968 (377) X3 5637 (356) 22549 (1423) 2819 (178) 10296 (650) 1879 (119) 6820 (430) X3 6487 (409) 23378 (1475) 3244 (205) 11689 (737) 2162 (136) 7793 (492) X4 6281 (396) 25125 (1585) 3141 (198) 11250 (710) 2094 (132) 7470 (471) X4 8099 (511) 29185 (1841) 4049 (255) 14441 (911) – – ZQ 4769 (301) 19076 (1204) 2385 (150) 6671 (421) 1590 (100) 4390 (277) ZQ 6241 (394) 22491 (1419) 3121 (197) 8878 (560) 2080 (131) 5899 (372) ZR 5272 (333) 21087 (1330) 2636 (166) 7318 (462) 1757 (111) 4820 (304) ZR 6967 (440) 25105 (1584) 3483 (220) 9814 (619) 2322 (147) 6536 (412) ZS 5740 (362) 22961 (1449) 2870 (181) 7907 (499) 1913 (121) 5214 (329) ZS 7900 (498) 28470 (1796) 3950 (249) 10978 (693) – – Z1 3959 (250) 15836 (999) 1980 (125) 7122 (449) 1320 (83) 4686 (296) Z1 4138 (261) 14912 (941) 2069 (131) 7435 (469) 1379 (87) 4914 (310) Z2 4769 (301) 19074 (1203) 2384 (150) 8427 (532) 1590 (100) 5559 (351) Z2 4969 (313) 17905 (1130) 2484 (157) 8866 (559) 1656 (104) 5880 (371) Z3 5637 (356) 22549 (1423) 2819 (178) 9748 (615) 1879 (119) 6450 (407) Z3 6487 (409) 23378 (1475) 3244 (205) 11332 (715) 2162 (136) 7567 (477) Z4 6281 (396) 25125 (1585) 3141 (198) 10672 (673) 2094 (132) 7077 (447) Z4 8099 (511) 29185 (1841) 4049 (255) 13715 (865) – –
FORM 160.75-EG1 (915) JOHNSON CONTROLS 59 Application Data (Cont'd) Table 8 - HYBRID FALLING FILM EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D HYBRID FALLING FILM EVAPORATORS MODEL 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX AC 705 (44) 2819 (178) 352 (22) 1194 (75) 235 (15) 825 (52) AD 882 (56) 3527 (223) 441 (28) 1436 (91) 294 (19) 1018 (64) A3 674 (43) 2695 (170) 337 (21) 1347 (85) 225 (14) 898 (57) A4 812 (51) 3248 (205) 406 (26) 1624 (102) 271 (17) 1083 (68) CC 796 (50) 3186 (201) 398 (25) 1410 (89) 265 (17) 945 (60) CD 999 (63) 3995 (252) 499 (32) 1734 (109) 333 (21) 1178 (74) CE 1270 (80) 5082 (321) 635 (40) 2140 (135) 423 (27) 1484 (94) C3 746 (47) 2983 (188) 373 (24) 1492 (94) 249 (16) 994 (63) C4 938 (59) 3753 (237) 469 (30) 1877 (118) 313 (20) 1251 (79) C5 1221 (77) 4884 (308) 611 (39) 2442 (154) 407 (26) 1628 (103) DC 796 (50) 3186 (201) 398 (25) 1214 (77) 265 (17) 809 (51) DD 999 (63) 3995 (252) 499 (32) 1501 (95) 333 (21) 1010 (64) DE 1270 (80) 5082 (321) 635 (40) 1865 (118) 423 (27) 1275 (80) D3 746 (47) 2983 (188) 373 (24) 1463 (92) 249 (16) 982 (62) D4 938 (59) 3753 (237) 469 (30) 1803 (114) 313 (20) 1228 (77) D5 1221 (77) 4884 (308) 611 (39) 2261 (143) 407 (26) 1578 (100) EC 980 (62) 3919 (247) 490 (31) 1758 (111) 327 (21) 1168 (74) ED 1296 (82) 5183 (327) 648 (41) 2289 (144) 432 (27) 1537 (97) EE 1637 (103) 6548 (413) 819 (52) 2831 (179) 546 (34) 1929 (122) E3 986 (62) 3946 (249) 493 (31) 1973 (124) 329 (21) 1315 (83) E4 1233 (78) 4932 (311) 617 (39) 2466 (156) 411 (26) 1644 (104) E5 1522 (96) 6087 (384) 761 (48) 3044 (192) 507 (32) 2029 (128) FC 980 (62) 3919 (247) 490 (31) 1508 (95) 327 (21) 998 (63) FD 1296 (82) 5183 (327) 648 (41) 1972 (124) 432 (27) 1316 (83) FE 1637 (103) 6548 (413) 819 (52) 2452 (155) 546 (34) 1654 (104)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 60 TABLE 8 - HYBRID FALLING FILM EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D Application Data (Cont'd) HYBRID FALLING FILM EVAPORATORS MODEL 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX F3 986 (62) 3946 (249) 493 (31) 1956 (123) 329 (21) 1304 (82) F4 1233 (78) 4932 (311) 617 (39) 2410 (152) 411 (26) 1622 (102) F5 1522 (96) 6087 (384) 761 (48) 2914 (184) 507 (32) 1989 (125) GC 1293 (82) 5170 (326) 646 (41) 2284 (144) 431 (27) 1533 (97) GD 1618 (102) 6472 (408) 809 (51) 2802 (177) 539 (34) 1907 (120) GE 2108 (133) 8432 (532) 1054 (66) 3521 (222) 703 (44) 2455 (155) G3 1269 (80) 5077 (320) 635 (40) 2538 (160) 423 (27) 1692 (107) G4 1588 (100) 6352 (401) 794 (50) 3176 (200) 529 (33) 2117 (134) G5 1973 (124) 7892 (498) 986 (62) 3946 (249) 658 (41) 2631 (166) HC 1293 (82) 5170 (326) 646 (41) 1967 (124) 431 (27) 1312 (83) HD 1618 (102) 6472 (408) 809 (51) 2426 (153) 539 (34) 1635 (103) HE 2108 (133) 8432 (532) 1054 (66) 3075 (194) 703 (44) 2112 (133) H3 1269 (80) 5077 (320) 635 (40) 2474 (156) 423 (27) 1668 (105) H4 1588 (100) 6352 (401) 794 (50) 3025 (191) 529 (33) 2072 (131) H5 1973 (124) 7892 (498) 986 (62) 3637 (229) 658 (41) 2546 (161) KC 2117 (134) 8470 (534) 1059 (67) 3424 (216) 706 (45) 2305 (145) KD 2784 (176) 11137 (703) 1392 (88) 4378 (276) 928 (59) 3004 (190) K8 1540 (97) 6159 (389) 770 (49) 3080 (194) 513 (32) 2053 (130) K9 2057 (130) 8228 (519) 1029 (65) 4114 (260) 686 (43) 2743 (173) K0 2695 (170) 10779 (680) 1347 (85) 5316 (335) 898 (57) 3593 (227) IB 2124 (134) 8496 (536) 1062 (67) 3274 (207) 707 (45) 2170 (137) ID 2378 (150) 9510 (600) 1189 (75) 3633 (229) 793 (50) 2419 (153) IF 2793 (176) 11171 (705) 1395 (88) 4193 (265) 929 (59) 2807 (177) IH 2916 (184) 11666 (736) 1458 (92) 4360 (275) – – I2 1547 (98) 6187 (390) 773 (49) 3093 (195) 514 (32) 2054 (130)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 61 TABLE 8 - HYBRID FALLING FILM EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D Application Data (Cont'd) HYBRID FALLING FILM EVAPORATORS MODEL 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX I4 1812 (114) 7250 (457) 906 (57) 3606 (228) 604 (38) 2399 (151) I6 2066 (130) 8265 (521) 1033 (65) 4060 (256) 689 (43) 2713 (171) I8 2864 (181) 11455 (723) 1432 (90) 5367 (339) – – MB 2479 (156) 9916 (626) 1239 (78) 3833 (242) 824 (52) 2550 (161) MD 2891 (182) 11564 (730) 1446 (91) 4418 (279) 964 (61) 2965 (187) MF 3370 (213) 13479 (850) 1683 (106) 5067 (320) – – M5 2048 (129) 8192 (517) 1021 (64) 4084 (258) 683 (43) 2731 (172) M7 2429 (153) 9715 (613) 1214 (77) 4790 (302) 810 (51) 3226 (204) M8 3015 (190) 12059 (761) 1504 (95) 5780 (365) 1003 (63) 3947 (249) M9 3420 (216) 13678 (863) 1710 (108) 6434 (406) – – NB 2479 (156) 9916 (626) 1239 (78) 3577 (226) 824 (52) 2374 (150) ND 2891 (182) 11564 (730) 1446 (91) 4129 (261) 964 (61) 2763 (174) NF 3370 (213) 13479 (850) 1683 (106) 4744 (299) – – N5 2048 (129) 8192 (517) 1021 (64) 3827 (241) 683 (43) 2558 (161) N7 2429 (153) 9715 (613) 1214 (77) 4492 (283) 810 (51) 3015 (190) N8 3015 (190) 12059 (761) 1504 (95) 5437 (343) 1003 (63) 3695 (233) N9 3420 (216) 13678 (863) 1710 (108) 6065 (383) – – PB 2815 (178) 11260 (710) 1407 (89) 4312 (272) 938 (59) 2890 (182) PD 3199 (202) 12794 (807) 1598 (101) 4837 (305) 1065 (67) 3263 (206) PF 3680 (232) 14722 (929) 1839 (116) 5639 (356) 1227 (77) 3728 (235) P5 2580 (163) 10319 (651) 1287 (81) 5045 (318) 858 (54) 3409 (215) P7 3027 (191) 12107 (764) 1510 (95) 5800 (366) 1009 (64) 3969 (250) P8 3625 (229) 14500 (915) 1812 (114) 6745 (426) 1208 (76) 4682 (295) QB 2815 (178) 11260 (710) 1407 (89) 4029 (254) 938 (59) 2693 (170) QD 3199 (202) 12794 (807) 1598 (101) 4526 (286) 1065 (67) 3042 (192)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 62 HYBRID FALLING FILM EVAPORATORS MODEL 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX QF 3680 (232) 14722 (929) 1839 (116) 5268 (332) 1227 (77) 3479 (220) QH 1902 (120) 7608 (480) 951 (60) 2799 (177) – – Q5 8283 (523) 33132 (2090) 4138 (261) 11049 (697) 2761 (174) 8597 (542) Q7 2580 (163) 10319 (651) 1287 (81) 4734 (299) 858 (54) 3187 (201) Q8 3027 (191) 12107 (764) 1510 (95) 5456 (344) 1009 (64) 3716 (234) TABLE 8 - HYBRID FALLING FILM EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D Application Data (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 63 Application Data (Cont'd) Table 9 - HEAT RECOVERY WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D MODEL HEAT RECOVERY CONDENSER - TOWER BUNDLE HEAT RECOVERY CONDENSER - HEATING BUNDLE 1 PASS 2 PASS 3 PASS 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX BW 1435 (91) 5171 (326) 717 (45) 2392 (151) 478 (30) 1590 (100) 555 (35) 2000 (126) 278 (18) 1000 (63) 185 (12) 665 (42) BX 1435 (91) 5171 (326) 717 (45) 2392 (151) 478 (30) 1590 (100) 861 (54) 3103 (196) 430 (27) 1529 (96) 287 (18) 1010 (64) IW 2123 (134) 7649 (483) 1061 (67) 3579 (226) 708 (45) 2409 (152) 763 (48) 2750 (174) 382 (24) 1367 (86) 254 (16) 917 (58) IX 2123 (134) 7649 (483) 1061 (67) 3579 (226) 708 (45) 2409 (152) 1344 (85) 4842 (305) 672 (42) 2260 (143) 448 (28) 1586 (100) OW 3129 (197) 11274 (711) 1564 (99) 4892 (309) 1043 (66) 3322 (210) 940 (59) 3387 (214) 470 (30) 1571 (99) 313 (20) 1038 (65) OX 3129 (197) 11274 (711) 1564 (99) 4892 (309) 1043 (66) 3322 (210) 1984 (125) 7149 (451) 992 (63) 3138 (198) 661 (42) 2102 (133) O8 3053 (193) 11002 (694) 1527 (96) 5501 (347) 1018 (64) 3667 (231) 1122 (71) 4043 (255) 561 (35) 2021 (128) 374 (24) 1348 (85) O9 3053 (193) 11002 (694) 1527 (96) 5501 (347) 1018 (64) 3667 (231) 1791 (113) 6455 (407) 896 (57) 3228 (204) 597 (38) 2152 (136) UW 3293 (208) 11865 (749) 1646 (104) 5256 (332) 1098 (69) 3477 (219) 1069 (67) 3853 (243) 535 (34) 1799 (113) 356 (22) 1188 (75) UX 3293 (208) 11865 (749) 1646 (104) 5256 (332) 1098 (69) 3477 (219) 2091 (132) 7535 (475) 1045 (66) 3415 (215) 697 (44) 2281 (144) U8 3403 (215) 12263 (774) 1701 (107) 6131 (387) 1134 (72) 4088 (258) 1178 (74) 4244 (268) 589 (37) 2122 (134) 393 (25) 1415 (89) U9 3403 (215) 12263 (774) 1701 (107) 6131 (387) 1134 (72) 4088 (258) 1891 (119) 6813 (430) 945 (60) 3406 (215) 630 (40) 2271 (143) YW 7705 (486) 27765 (1752) 3852 (243) 10738 (677) 2568 (162) 7169 (452) 2596 (164) 9353 (590) 1298 (82) 3797 (240) 865 (55) 2513 (159) YX 7705 (486) 27765 (1752) 3852 (243) 10738 (677) 2568 (162) 7169 (452) 4917 (310) 17718 (1118) 2458 (155) 6991 (441) 1639 (103) 4693 (296) Y8 7963 (502) 28696 (1810) 3982 (251) 13330 (841) 2654 (167) 8951 (565) 3236 (204) 11660 (736) 1618 (102) 5830 (368) 1079 (68) 3887 (245) Y9 7963 (502) 28696 (1810) 3982 (251) 13330 (841) 2654 (167) 8951 (565) 5244 (331) 18897 (1192) 2622 (165) 9287 (586) 1748 (110) 6299 (397)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 64 Application Data (Cont'd) Table 10 - 60 HZ ELECTRICAL DATA MOTOR CODE CF CG CH CJ CK CL CM CN CP CR CS CT CU CV CW SHAFT HP (MAX) 154 177 201 237 270 302 327 351 385 424 468 503 554 608 655 INPUT KW (MAX) 123 140 161 190 214 240 257 276 302 333 367 395 435 477 514 F.L. EFF. - % 1 93.6 94.5 93.3 93 94 94 95 95 95 95 95 95 95 95 95 F.L. POWER FACTOR 1 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.87 0.87 0.87 0.87 0.87 0.87 VOLTS AMPERES (MAXIMUM) 200 FLA 405 465 527 618 707 787 831 921 1014 1085 1208 - - - - LRA 2598 3111 3111 3810 4550 4900 5470 5780 5780 7350 7794 - - - - 208 FLA 389 447 507 594 680 757 799 886 975 1043 1162 - - - - LRA 2702 3235 3235 3962 4732 5096 5689 6011 6011 7644 8106 - - - - 230 FLA 352 404 464 540 610 685 749 804 882 944 1050 1130 - - - LRA 2598 2598 2865 3460 3788 4260 4755 5162 5780 5780 6900 7400 - - - 240 FLA 337 387 445 518 585 656 718 771 845 905 1006 1083 - - - LRA 2711 2711 3120 3610 3953 4445 4962 5386 6031 6031 7200 7722 - - - 380 FLA 217 249 285 336 378 421 453 487 534 571 636 684 756 817 879 LRA 1385 1385 1730 2153 2500 2577 2955 3254 3637 3810 4179 4480 4671 5326 5780 416 FLA 199 228 260 307 346 385 412 445 488 522 581 625 691 747 810 LRA 1385 1385 1638 1967 2190 2356 2700 2976 3536 3637 3810 3810 4270 4869 5640 440 FLA 184 211 238 281 319 358 392 397 461 493 549 591 646 706 759 LRA 1177 1301 1320 1655 1865 2037 2485 2485 2976 2976 3300 3644 3644 4209 4783 460 FLA 176 202 228 269 305 342 375 380 441 472 525 565 618 675 726 LRA 1230 1360 1380 1730 1950 2130 2598 2598 3111 3111 3450 3500 3810 4400 4880 480 FLA 169 194 219 258 292 328 359 364 423 452 503 541 592 647 696 LRA 1283 1419 1440 1805 2035 2223 2711 2711 3246 3246 3600 3976 3976 4591 5217 575 FLA 141 162 185 216 250 274 300 318 353 377 420 452 500 540 581 LRA 909 909 1100 1384 1556 1700 1900 2066 2078 2413 2760 2960 3089 3550 4039 600 FLA 135 155 177 207 240 263 288 305 338 361 403 433 479 518 557 LRA 949 949 1148 1444 1624 1774 1983 2156 2168 2518 2880 3089 3223 3704 4215 2300 FLA 36 41.1 46 55 63 70 73.9 80 87 95 106 113 124 135 146 LRA 240 267 298 340 397 435 480 520 543 590 669 719 791 867 935 3300 FLA 25.5 29 33 39 44 49 52 55.3 61 67 72.8 79 86.1 94.4 102 LRA 160 175 210 240 280 310 310 343 382 415 466 501 551 576 652 4000 FLA 21 24 26.7 32 36 40 42.5 46 50.1 55 60.1 65.2 71 77.9 84 LRA 135 154 166 195 230 240 270 283 315 340 384 413 455 499 538 4160 FLA 20.2 23 25.7 30.8 34.6 38.5 40.9 44.2 48.2 52.9 57.8 62.7 68.3 74.9 80.8 LRA 140 160 173 203 239 250 270 294 328 328 399 430 473 519 560 Table 11 - 50 HZ ELECTRICAL DATA MOTOR CODE 5CC 5CD 5CE 5CF 5CG 5CH 5CI 5CJ 5CK 5CL 5CM 5CN 5CO 5CP 5CQ 5CR 5CS SHAFT HP (MAX) 148 168 198 225 252 272 292 321 353 390 419 462 507 546 575 617 658 INPUT KW (MAX) 119 135 158 179 201 215 231 254 279 309 332 363 398 429 451 484 516 F.L. EFF. - % 1 93 93 93.4 93.7 93.7 94.2 94.2 94.2 94.2 94.2 94.2 95 95 95 95 95 95 F.L. POWER FACTOR 1 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.88 VOLTS AMPERES (MAXIMUM) 346 FLA 230 261 306 347 389 418 448 493 536 592 636 696 763 822 866 929 979 LRA 1385 1721 1790 2208 2467 2598 2840 3081 3350 3706 3810 4177 4830 4944 5373 5780 5780 380 FLA 210 238 278 316 354 380 408 449 488 539 579 633 695 748 788 846 892 LRA 1385 1385 1640 1890 2144 2464 2590 2806 3050 3375 3700 3810 4400 4500 4892 5600 5491 400 FLA 200 226 264 300 336 361 388 427 464 512 550 601 660 711 749 804 847 LRA 1458 1458 1726 1990 2257 2594 2726 2954 3211 3533 3895 4011 4632 4737 5149 5895 5780 415 FLA 192 218 255 290 324 348 374 411 447 494 530 580 636 685 722 774 817 LRA 1283 1385 1490 1700 2031 2175 2366 2569 2794 3088 3402 3478 3810 4117 4480 5130 5108 3300 FLA 24.1 27.4 32.2 36.4 40.8 43.8 47 51.7 56.2 62.1 66.7 72.9 80 86.2 90.8 97.4 103 LRA 159 162 209 236 241 274 294 318 317 388 423 455 499 516 572 614 644 NOTES: 1. High voltage and special motor designs may not meet efficiency, power factor or amperes values shown for standard motors. 2. Min. reduced voltage tap 80%.
FORM 160.75-EG1 (915) JOHNSON CONTROLS 65 Application Data (Cont'd) TABLE 810 - 60 HZ ELECTRICAL DATA CONT'D MOTOR CODE CX CY CZ CA CB DA DB DC DD DE DF DH DJ DK DL SHAFT HP (MAX) 690 740 790 845 900 1000 1100 1200 1300 1400 1500 1750 2000 2250 2500 INPUT KW (MAX) 542 578 618 660 703 781 859 937 1015 1093 1171 1359 1554 1748 1942 F.L. EFF. - % 1 95 95.5 95.3 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5 96 96 96 96 F.L. POWER FACTOR 1 0.87 0.88 0.88 0.89 0.89 0.87 0.87 0.87 0.88 0.88 0.88 0.87 0.89 0.89 0.89 VOLTS AMPERES (MAXIMUM) 200 FLA - - - - - - - - - - - - - - - LRA - - - - - - - - - - - - - - - 208 FLA - - - - - - - - - - - - - - - LRA - - - - - - - - - - - - - - - 230 FLA - - - - - - - - - - - - - - - LRA - - - - - - - - - - - - - - - 240 FLA - - - - - - - - - - - - - - - LRA - - - - - - - - - - - - - - - 380 FLA 942 997 1065 1126 1200 1364 1500 1636 - - - - - - - LRA 5780 5780 6644 7610 7513 7794 8491 9431 - - - - - - - 416 FLA 860 911 973 1029 1096 1246 1370 1495 - - - - - - - LRA 5670 5694 6069 6900 6863 7120 7755 8618 - - - - - - - 440 FLA 813 861 920 973 1036 1178 1295 1413 - - - - - - - LRA 5357 4783 5249 5791 5529 6160 6709 7455 - - - - - - - 460 FLA 778 824 880 931 991 1127 1239 1352 - - - - - - - LRA 4960 5280 5330 6054 5780 6440 7014 7794 - - - - - - - 480 FLA 746 790 843 892 950 1080 1187 1296 - - - - - - - LRA 5843 5217 5727 6317 6031 6720 7319 8133 - - - - - - - 575 FLA 622 659 704 744 793 901 991 1081 - - - - - - - LRA 4100 4200 4200 5225 4963 5148 5610 6232 - - - - - - - 600 FLA 596 632 675 713 760 863 950 1036 - - - - - - - LRA 4633 4487 4383 5452 5179 5372 5854 6503 - - - - - - - 2300 FLA 154 165 176 186 198 225 248 267 290 312 334 383 438 493 548 LRA 960 1008 1100 1172 1230 1350 1592 1592 1882 2031 2171 2390 2879 3199 3356 3300 FLA 108 115 123 130 138 157 173 186 202 217 233 267 306 344 382 LRA 682 719 744 819 858 942 1110 1110 1311 1416 1514 1661 2011 2388 2479 4000 FLA 88.6 94.8 101 107 114 130 143 154 166 179 192 220 252 283 315 LRA 540 554 631 674 713 780 923 923 1077 1177 1246 1428 1669 1842 2047 4160 FLA 85.2 91.1 97.1 102 110 125 137 148 160 172 185 212 242 273 303 LRA 562 576 656 701 742 811 960 960 1120 1224 1296 1485 1736 1772 1968 TABLE 11 - 50 HZ ELECTRICAL DATA (CONT'D) MOTOR CODE 5CT 5CU 5CV 5CW 5CX 5DA 5DB 5DC 5DD 5DE 5DF 5DG 5DH 5DJ2 5DK 5DL SHAFT HP (MAX) 704 750 800 850 900 1000 1100 1200 1300 1400 1500 1650 1750 2000 2250 2500 INPUT KW (MAX) 553 589 628 667 706 785 863 942 1015 1093 1171 1288 1359 1554 1748 1942 F.L. EFF. - % 1 95 95 95 95 95 95 95 95 95.5 95.5 95.5 95.5 96 96 96 96 F.L. POWER FACTOR 1 0.88 0.89 0.89 0.89 0.89 0.88 0.87 0.88 0.88 0.88 0.88 0.88 0.89 0.89 0.89 0.89 VOLTS AMPERES (MAXIMUM) 346 FLA 1048 1104 1177 1251 1325 1488 1656 - - - - - - - - - LRA 6615 6931 7356 7794 8319 8559 9346 - - - - - - - - - 380 FLA 954 1005 1072 1139 1206 1355 1508 - - - - - - - - - LRA 5491 6313 6694 7113 7404 7794 8511 - - - - - - - - - 400 FLA 906 955 1018 1082 1146 1287 1433 - - - - - - - - - LRA 5780 6645 7046 7487 7794 8204 8959 - - - - - - - - - 415 FLA 874 920 982 1043 1104 1241 1381 - - - - - - - - - LRA 5512 5780 6131 6513 6938 7138 7794 - - - - - - - - - 3300 FLA 110 116 123 131 139 156 174 187 202 217 233 256 267 306 344 382 LRA 693 725 744 819 875 871 1135 1135 1135 1415 1415 1415 1667 1836 2233 2481 NOTES: 1. High voltage and special motor designs may not meet efficiency, power factor or amperes values shown for standard motors. 2. Min. reduced voltage tap 80%.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 66 Application Data (Cont'd) NOTES: 1. High voltage and special motor designs may not meet efficiency, power factor or amperes values shown for standard motors. 2. Min. reduced voltage tap 80%. Table 12 - 60 HZ ELECTRICAL DATA - PREMIUM EFFICIENCY MOTOR CODE EF EG EH EJ EK EL EM EN EP ER ES ET EU EV SHAFT HP (MAX) 154 177 201 237 270 302 327 351 385 424 468 503 554 608 INPUT KW (MAX) 122 139 158 185 211 236 256 274 300 330 364 392 431 473 F.L. EFF. - % 94.5 95 95 95.4 95.4 95.4 95.4 95.4 95.8 95.8 95.8 95.8 95.8 95.8 F.L. POWER FACTOR 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 VOLTS AMPERES (MAXIMUM) 200 FLA 399 456 518 608 692 774 838 900 983 1083 1195 - - - LRA 2815 3128 3128 3979 4550 4900 5635 5865 6686 7350 7935 - - - 208 FLA 383 438 498 584 666 745 806 865 945 1041 1149 - - - LRA 2928 3235 3235 4138 4732 5096 5860 6100 6953 7644 8252 - - - 230 FLA 347 396 450 528 602 673 729 783 855 941 1039 1117 - - LRA 2598 2720 2865 3460 3788 4260 4900 5162 5814 6200 6900 8513 - - 240 FLA 332 380 431 506 577 645 699 750 819 902 996 1070 - - LRA 2711 2838 2990 3610 3953 4445 5113 5386 6067 6470 7200 8883 - - 380 FLA 210 240 272 320 364 408 441 474 517 570 629 676 745 817 LRA 1482 1646 1730 2153 2500 2578 2966 3254 3637 3810 4179 4480 4671 5326 416 FLA 192 219 249 292 333 372 403 433 473 521 575 617 680 746 LRA 1385 1504 1638 1967 2190 2356 2709 2976 3536 3637 3815 3826 4270 5418 440 FLA 181 207 235 276 315 352 381 409 447 492 543 584 643 706 LRA 1177 1301 1320 1655 1865 2037 2485 2485 2976 2976 3300 3348 3644 4687 460 FLA 173 198 225 264 301 337 365 391 427 471 520 558 615 675 LRA 1230 1360 1380 1730 1950 2130 2598 2598 3111 3111 3450 3500 3810 4900 480 FLA 166 190 216 253 288 323 349 375 410 451 498 535 589 647 LRA 1283 1419 1440 1805 2035 2223 2711 2711 3246 3246 3600 3652 3976 5113 575 FLA 139 159 180 211 241 269 292 313 342 377 416 447 492 540 LRA 979 1088 1100 1384 1556 1704 1960 2066 2326 2413 2760 2960 3089 3550 600 FLA 133 152 173 203 231 258 279 300 328 361 398 428 472 517 LRA 1021 1135 1148 1444 1624 1778 2045 2156 2427 2518 2880 3089 3223 3704 NOTE: These motors are designed to meet or exceed NEMA Premium (MG1-2006) and European IE2 efficiency requirements. Table 13 - 50 HZ ELECTRICAL DATA - PREMIUM EFFICIENCY MOTOR CODE 5EC 5ED 5EE 5EF 5EG 5EH 5EI 5EJ 5EK 5EL 5EM 5EN 5EO SHAFT HP (MAX) 148 168 198 225 252 272 292 321 353 390 419 462 507 INPUT KW (MAX) 117 133 156 177 198 214 229 252 277 305 328 361 396 F.L. EFF. - % 94.3 94.5 94.7 94.9 95 95 95 95 95 95.4 95.4 95.4 95.4 F.L. POWER FACTOR 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 VOLTS AMPERES (MAXIMUM) 346 FLA 222 251 296 335 375 405 435 478 525 578 621 685 751 LRA 1521 1721 1790 2208 2467 2706 2840 3081 3350 3706 3810 4177 5150 380 FLA 202 229 269 305 342 369 396 435 478 526 565 623 684 LRA 1385 1385 1640 1890 2144 2464 2590 2806 3050 3375 3700 3810 4690 400 FLA 192 217 256 290 324 350 376 413 454 500 537 592 650 LRA 1458 1458 1726 1989 2257 2594 2726 2954 3211 3553 3895 4011 4937 415 FLA 185 210 246 280 313 338 362 398 438 482 518 571 627 LRA 1283 1385 1502 1700 2031 2175 2366 2569 2794 3088 3402 3478 4027
FORM 160.75-EG1 (915) JOHNSON CONTROLS 67 Application Data (Cont'd) NOTES: 1. High voltage and special motor designs may not meet efficiency, power factor or amperes values shown for standard motors. 2. Min. reduced voltage tap 80%. TABLE 12 - 60 HZ ELECTRICAL DATA - PREMIUM EFFICIENCY (CONT'D) MOTOR CODE EW EX EY EZ EA EB FA SHAFT HP (MAX) 655 690 740 790 845 900 1000 INPUT KW (MAX) 508 535 574 612 655 698 775 F.L. EFF. - % 96.2 96.2 96.2 96.2 96.2 96.2 96.2 F.L. POWER FACTOR 0.87 0.87 0.88 0.87 0.88 0.88 0.87 VOLTS AMPERES (MAXIMUM) 200 FLA - - - - - - - LRA - - - - - - - 208 FLA - - - - - - - LRA - - - - - - - 230 FLA - - - - - - - LRA - - - - - - - 240 FLA - - - - - - - LRA - - - - - - - 380 FLA 887 934 990 1069 1131 1204 1354 LRA 5780 5859 6244 6644 7106 7513 7794 416 FLA 810 853 905 977 1033 1100 1237 LRA 5640 5670 5704 6069 6489 6863 7120 440 FLA 766 807 855 924 977 1040 1169 LRA 4668 4744 5050 5098 5529 5782 6160 460 FLA 732 772 818 883 934 995 1118 LRA 4880 4960 5280 5330 5780 6045 6440 480 FLA 702 739 784 847 895 954 1072 LRA 5092 5175 5510 5562 6031 6308 6720 575 FLA 586 617 654 707 747 796 895 LRA 4039 4100 4200 4200 4694 4963 5148 600 FLA 562 592 627 677 716 763 857 LRA 4214 4278 4383 4383 5452 5179 5372 NOTE: These motors are designed to meet or exceed NEMA Premium (MG1-2006) and European IE2 efficiency requirements. TABLE 13 - 50 HZ ELECTRICAL DATA - PREMIUM EFFICIENCY (CONT'D) MOTOR CODE 5EP 5EQ 5ER 5ES 5ET 5EU 5EV 5EW SHAFT HP (MAX) 546 575 617 658 704 750 800 850 INPUT KW (MAX) 425 448 480 512 548 584 623 662 F.L. EFF. - % 95.8 95.8 95.8 95.8 95.8 95.8 95.8 95.8 F.L. POWER FACTOR 0.87 0.87 0.87 0.87 0.88 0.88 0.87 0.87 VOLTS AMPERES (MAXIMUM) 346 FLA 815 858 921 982 1039 1107 1194 1269 LRA 5063 5373 5780 5780 6615 6931 7356 7794 380 FLA 742 782 839 894 946 1008 1087 1155 LRA 4610 4892 5600 5491 5491 6313 6694 7113 400 FLA 705 743 797 850 899 958 1033 1098 LRA 4853 5149 5895 5780 5780 6645 7046 7487 415 FLA 680 716 768 819 866 923 996 1058 LRA 4221 4480 5130 5108 5512 5780 6131 6513
JOHNSON CONTROLS FORM 160.75-EG1 (915) 68 Application Data (Cont'd) NOTES: 1. For motor starters above 4160V/60Hz and 3300/50Hz contact the Johnson Controls Sales Office for a specific selection. 2. Minimum tap for 5DJ motor is 80%. Table 14 - MOTOR STARTERS TYPE STARTER SOLID- STATE STARTER STAR DELTA AUTO TRANSFORMER ACROSS- THE-LINE PRIMARY REACTOR VOLTAGE LOW/ MEDIUM LOW LOW LOW/ MEDIUM LOW/ MEDIUM LOW/ MEDIUM MEDIUM MEDIUM 60 HZ 200-4160 200-600 200-600 200-4160 200-4160 200-4160 2300-4160 2300-4160 50 HZ 380-3300 346-415 346-415 346-3300 346-3300 346-3300 2300-3300 2300-3300 TRANSITION % TAP INRUSH AS A % OF LRA — CLOSED CLOSED CLOSED CLOSED — CLOSED CLOSED — — 57.7 65 80 — 65 80 45 33 33 42.3 64 100 65 80
FORM 160.75-EG1 (915) JOHNSON CONTROLS 69 Application Data (Cont'd) Table 15 - LOW VOLTAGE VARIABLE SPEED MODELS FRAME LV-VSD MAXIMUM LRA MAXIMUM MOTOR HP MINIMUM FLA MAXIMUM FLA RATED VOLTAGE ACTUAL VOLTAGE PHASE HZ I 2500 270 80 364 380 380 3 60 II 3637 385 120 517 III 5326 608 200 817 IV 7610 845 300 1126 I 2598 351 80 380 460 440/ 460/ 480 II 3652 503 120 565 III 5777 790 200 880 IV 7014 1048 300 1180 I 2413 424 80 377 575 575/600 II 3550 608 120 540 I 2727 292 80 380 380 380/400 3 50 II 2895 419 120 565 III 5780 658 200 880 IV 8205 917 300 1180 I 2366 292 80 362 415 415 II 3402 419 120 518 III 5512 704 200 876 IV 6938 900 300 1108
JOHNSON CONTROLS FORM 160.75-EG1 (915) 70 Table 16 - MEDIUM VOLTAGE VARIABLE SPEED DRIVE MODELS MV-VSD MAXIMUM MOTOR HP MAXIMUM FLA VOLTAGE PHASE HZ MVVSD0500RK-80 500 107 2300 3 60 MVVSD0600RK-80 600 129 MVVSD0700RK-80 700 157 MVVSD0800RK-80 800 172 MVVSD0900RK-80 900 202 MVVSD1000RK-80 1000 224 MVVSD1250RK-80 1250 280 MVVSD1500RK-80 1500 336 MVVSD1750RK-80 1750 392 MVVSD2000RK-80 2000 438 MVVSD2250RK-80 2250 494 MVVSD2500RK-80 2500 561 MVVSD0500RK-94 500 78 3300 3 60 MVVSD0600RK-94 600 93 MVVSD0700RK-94 700 110 MVVSD0800RK-94 800 124 MVVSD0900RK-94 900 141 MVVSD1000RK-94 1000 156 MVVSD1250RK-94 1250 195 MVVSD1500RK-94 1500 235 MVVSD1750RK-94 1750 274 MVVSD2000RK-94 2000 312 MVVSD2250RK-94 2250 345 MVVSD2500RK-94 2500 391 MVVSD0500RK-92S 500 62 4160 3 60 MVVSD0600RK-92S 600 74 MVVSD0700RK-92S 700 87 MVVSD0800RK-92S 800 99 MVVSD0900RK-92S 900 112 MVVSD1000RK-92S 1000 125 MVVSD1250RK-92S 1250 155 MVVSD1500RK-92S 1500 186 MVVSD1750RK-92S 1750 217 MVVSD2000RK-92S 2000 248 MVVSD2250RK-92S 2250 274 MVVSD2500RK-92S 2500 310 MVVSD0500RK-92 500 78 3300 3 50 MVVSD0600RK-92 600 93 MVVSD0700RK-92 700 110 MVVSD0800RK-92 800 124 MVVSD0900RK-92 900 141 MVVSD1000RK-92 1000 156 MVVSD1250RK-92 1250 195 MVVSD1500RK-92 1500 235 MVVSD1750RK-92 1750 274 MVVSD2000RK-92 2000 312 MVVSD2250RK-92 2250 345 MVVSD2500RK-92 2500 391 Application Data (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 71 Application Data (Cont'd) MEDIUM VOLTAGE VARIABLE SPEED DRIVE NOMENCLATURE MVVSD 2500 R K - 80 VOLTAGE CODE 80 = 2300V/60Hz 92 = 3300V/50Hz 94 = 4180V/60Hz K = YK OIL PUMP SUPPLY R = FIELD INSTALLED MAXIMUM DRIVE HORSEPOWER 0500 - 500 HP 0600 - 600 HP 0700 - 700 HP 0800 - 800 HP 0900 - 900 HP 1000 - 1000 HP 1250 - 1250 HP 1500 - 1500 HP 1750 - 1750 HP 2000 - 2000 HP 2250 - 2250 HP 2500 - 2500 HP LD19167
JOHNSON CONTROLS FORM 160.75-EG1 (915) 72 Application Data (Cont'd) Table 17 - LOW VOLTAGE SOLID-STATE STARTER MODELS SSS- MAXIMUM LRA MINIMUM FLA MAXIMUM FLA RATED VOLTAGE ACTUAL VOLTAGE PHASE HZ 7L-46B 1556 35 260 460 440/460/480 3 60 7L-40B 1556 35 260 380 380 3 60 7L-50B 1556 35 260 400 380/440/415 3 50 7L-58B 1556 35 260 575 575/600 3 60 14L-17B 3111 65 510 200 200/208 3 60 14L-28B 3111 65 510 230 230/240 3 60 14L-40B 3111 65 510 380 380 3 60 14L-46B 3111 65 510 460 440/460/480 3 60 14L-50B 3111 65 510 400 380/400/415 3 50 14L-58B 3111 65 510 575 575/600 3 60 26L-17B 5780 125 850 200 200/208 3 60 26L-28B 5780 125 850 230 230/240 3 60 26L-40B 5780 125 850 380 380 3 60 26L-46B 5780 125 850 460 440/460/480 3 60 26L-50B 5780 125 850 400 380/400/415 3 50 26L-58B 5780 125 850 575 575/600 3 60 33L-17B 7333 215 1050 200 200/240 3 60 33L-40B 7333 215 1050 380 380 3 60 33L-46B 7333 215 1050 230 230/240 3 60 33L-50B 7333 215 1050 400 380/400/415 3 50 33L-58B 7333 215 1050 460 440/460/480 3 60
FORM 160.75-EG1 (915) JOHNSON CONTROLS 73 Application Data (Cont'd) Table 18 - MEDIUM VOLTAGE UNIT MOUNTED SOLID-STATE STARTER MODELS UNIT MOUNTED MV-SSS MAXIMUM FLA MAXIMUM LRA RATED VOLTAGE FREQUENCY UMVSSS0853K105-V V 105 1896 2300/60HZ 3300/50Hz 4160/60HZ UMVSSS0853K190-V V 190 1896 UMVSSS0853K280-V V 280 1896 UMVSSS0853K389-V V 389 1896 UMVSSS1708K389-V V 389 3796 MEDIUM VOLTAGE UNIT MOUNTED SOLID STATE STARTER NOMENCLATURE UMVSSS 0853 K 105 - 80 VOLTAGE CODE 80 = 2300V/60Hz 92 = 3300V/50Hz 94 = 4180V/60Hz K = YK OIL PUMP SUPPLY MAXIMUM JOB FLA CURRENT 105 = 105 AMPS 190 = 190 AMPS 280 = 280 AMPS 389 = 389 AMPS MAXIMUM STARTING CURRENT 0853 - 853 AMPS 1708 - 1708 AMPS LD19168
JOHNSON CONTROLS FORM 160.75-EG1 (915) 74 Application Data (Cont'd) Table 19 - MEDIUM VOLTAGE FLOOR MOUNTED SOLID-STATE STARTER MODELS FLOOR MOUNTED MV-SSS MAXIMUM FLA MAXIMUM LRA 36 CABINET UNIT MODEL REFERENCE CHART MVSSS0853R_042-V 42 1896 MVSSS0853R_050-V 50 1896 MVSSS0853R_065-V 65 1896 MVSSS0853R_095-V 95 1896 MVSSS0853R_105-V 105 1896 MVSSS0853R_140-V 140 1896 MVSSS0853R_190-V 190 1896 MVSSS0853R_280-V 280 1896 MVSSS0853R_310-V 310 1896 MVSSS0853R_360-V 360 1896 MVSSS1708R_360-V 360 3796 72 CABINET UNIT MODEL REFERENCE CHART MVSSS1708R_550-V 550 3796
FORM 160.75-EG1 (915) JOHNSON CONTROLS 75 MEDIUM VOLTAGE FLOOR MOUNTED SOLID STATE STARTER NOMENCLATURE MVVSD 2500 R K 042 - 80 VOLTAGE CODE 80 = 2300V/60Hz 92 = 3300V/50Hz 94 = 4180V/60Hz K = YK OIL PUMP SUPPLY X = NO OIL PUMP SUPPLY R = FIELD INSTALLED LD19169 MAXIMUM STARTING CURRENT 0853 - 853 AMPS 1708 - 1708 AMPS MAXIMUM JOB FLA CURRENT 042 = 042 AMPS 050 = 050 AMPS 065 = 065 AMPS 095 = 095 AMPS 105 = 105 AMPS 140 = 140 AMPS 190 = 190 AMPS 280 = 280 AMPS 310 = 310 AMPS 360 = 360 AMPS 550 = 550 AMPS Application Data (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 76 Application Data (Cont'd) Table 20 - AVAILABLE COMPRESSOR/SHELL/MOTOR COMBINATIONS YK MOD G COMBINATIONS COMPRESSOR CODES EVAPORATOR CODES CONDENSER CODES MOTOR CODES 60 HZ 50 HZ Q3 AP TO AS AP TO AS CF-CT EF-ET 5CC-5CO 5EC-5EO Q3, Q4 CP TO CS CP TO CS DP TO DS DP TO DS Q4 EP TO ET EP TO ET Q5 CP TO CS CP TO CS CH-CT EH-ET 5CE-5CO 5EE-5EO DP TO DS DP TO DS Q5, Q6, Q7 EP TO ET EP TO ET FQ TO FT FQ TO FT P7 EP TO ET EP TO ET CU-CY EU-EY 5CP-5CU 5EP-5EUFQ TO FT FQ TO FT P8 GQ TO GS EV TO EX CH-CZ EH-EZ 5CE-5CU 5EE-5EUP8, P9 HQ TO HS FV TO FX JP TO JS JP TO JS LQ TO LS LQ TO LS H9 KP TO KS, K2 TO K4 KP TO KS, K2 TO K4 CN-CA EN-EA 5CK-5CW 5EK-5EWMQ TO MS, M2 TO M4 MP TO MS, M2 TO M4 K1 KT TO KX, K5 TO K7 KP TO KS, K2 TO K4 CS-DC ES-FC 5CN-5DC 5EN-5FBK1, K2 MQ TO MS, M2 TO M4 MP TO MS, M2 TO M4 NQ TO NS, N2 TO N4 NP TO NS, N2 TO N4 PQ TO PS, P2 TO P4 PQ TO PS, P2 TO P4 QQ TO QS, Q2 TO Q4 QQ TO QS, Q2 TO Q4 K3 NQ TO NS, N2 TO N4 NP TO NS, N2 TO N4 DA-DJ FA-FD 5DA-5DH 5FA-5FB QQ TO QV, Q2 TO Q4 QQ TO QS, Q2 TO Q4 —­ RQ, RR, RS, R2, R3, R4 K4 — RQ, RR, RS, R2, R3, R4 DA-DJ FA-FD 5DA-5DJ 5FA-5FB — SQ, SR, SS, S2, S3, S4 VP, VQ, VR, VS, V2, V3, V4, V5 — TP, TQ, TR, TS, T2, T3, T4, T5 XQ, XR, XS, X2, X3, X4 K7 — WQ, WR, WS, W1, W2, W3, W4 DD-DL 5DD-5DL — ZQ, ZR, ZS, Z1, Z2, Z3, Z4
FORM 160.75-EG1 (915) JOHNSON CONTROLS 77 TABLE 20 - AVAILABLE COMPRESSOR/SHELL/MOTOR COMBINATIONS CONT'D YK MOD G HEAT RECOVERY COMBINATIONS COMPRESSOR CODES EVAPORATOR CODES CONDENSER CODES MOTOR CODES 60 HZ 50 HZ Q4 CP, CQ, CR, CS BV, BW, BX CF-CT EF-ET 5CC-5CO 5EC-5EOQ7 EP, EQ, ER, ES, ET IV, IW, IX H9 KP, KQ, KR, KS, K2, K3, K4 OW, OX, O7, O8, O9 CN-CA EN-EA 5CK-5CW 5EK-5EW K2 MQ, MR, MS, M2, M3, M4 UW, UX, U7, U8, U9 CS-DC ES-FC 5CN-5DC 5EN-5FB K7 ZQ, ZR, ZS, Z1, Z2, Z3, Z4 YW, YX, Y7, Y8, Y9 DD-DL 5DD-5DL YK MOD G HYBRID FALLING FILM COMBINATIONS COMPRESSOR CODES HYBRID FALLING FILM EVAPORATOR CODES CONDENSER CODES MOTOR CODES 60 HZ 50 HZ Q3 AC, AD, A3, A4 AP TO AS CF-CT EF-ET 5CC-5CO 5EC-5EO CC TO CE, C3 TO C5 CP TO CS Q4 CC TO CE, C3 TO C5 CP TO CS DC TO DE, D3 TO D5 DP TO DS Q5 CC TO CE, C3 TO C5 CP TO CS CH-CT EH-ET 5CE-5CO 5EE-5EO DC TO DE, D3 TO D5 DP TO DS Q5, Q6, Q7 EC TO EE, E3 TO E5 EP TO ET FC TO FE, F3 TO F5 FQ TO FT P7 EC TO EE, E3 TO E5 EP TO ET CU-CY EU-EY 5CP-5CU 5EP-5EUFC TO FE, F3 TO F5 FQ TO FT P8, P9 GC TO GE, G3 TO G5 EV TO EX, E3 TO E4 CH-CZ EH-EZ 5CE-5CU 5EE-5EUHC TO HE, H3 TO H5 FV TO FX, F3 TO F4 H9 KC, KD, K8, K9, K0 KP, KQ, KR, KS, K2, K3, K4 CN-CA EN-EA 5CK-5CW 5EK-5EW IB, ID, IF, IH, I2, I4, I6, I8 KP, KQ, KR, KS, K2, K3, K4 MB, MD, MF, M5, M7, M8 MP, MQ, MR, MS, M2, M3, M4 K1 IB, ID, IF, IH, I2, I4, I6, I8 KP, KQ, KR, KS, K2, K3, K4 CS-DC ES-FC 5CN-5DC 5EN-5FBK1, K2 MB, MD, MF, M5, M7, M8, M9 MP, MQ, MR, MS, M2, M3, M4 NB, ND, NF, N5, N7, N8, N9 NP, NQ, NR, NS, N2, N3, N4 PB, PD, PF, P5, P7, P8 PQ, PR, PS, P2, P3, P4 QB, QD, QF, Q5, Q7, Q8 QQ, QR, QS, Q2, Q3, Q4 K3 NB, ND, NF, N5, N7, N8, N9 NP, NQ, NR, NS, N2, N3, N4 DA-DJ FA-FD 5DA-5DH 5FA-5FBQD, QF, QH, Q5, Q7, Q8, Q9 QQ, QR, QS, Q2, Q3, Q4 Application Data (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 78 CONDENSER (SHIPPING WIDTH) OPTIVIEW CONTROL CENTER COMPRESSOR MOTOR EVAPORATOR ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR TYPE OF CHILLER MOUNTING M NEOPRENE PAD ISOLATORS 1-3/4 (45) SPRING ISOLATORS 1 DEFLECTION 1 (25) DIRECT MOUNT 3/4 (19) P7, Q7 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES E-E E-I F-F A 6'-2 (1880) 7'-1 3/4 (2178) 6'-2 (1880) B 8'-0 5/8 (2454) 8'-8 (2642) 8'-0 5/8 (2454) C 1'-7 1/2 (495) 1'-7 1/2 (495) 1'-7 1/2 (495) D 1'-5 1/2 (445) 1'-11 3/8 (594) 1'-5 1/2 (445) E 12'-0 (3658) 12'-0 (3658) 16'-0 (4877) P8 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES G-E H-F J-J L-L A 6'-11 (2108) 6'-11 (2108) 7'-6 1/2 (2299) 7'-6 1/2 (2299) B 10'-6 (3200) 10'-6 (3200) 10'-11 (3327) 10'-11 (3327) C 2'-0 (610) 2'-0 (610) 2'-1 1/4 (641) 2'-1 1/4 (641) D 1'-5 1/2 (445) 1'-5 1/2 (445) 1'-8 (508) 1'-8 (508) E 12'-0 (3658) 16'-0 (4877) 12'-0 (3658) 16'-0 (4877) Dimensions P9 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES H-F J-J L-L A 6'-11 (2108) 7'-6 1/2 (2299) 7'-6 1/2 (2299) B 10'-3 (3124) 10'-8 1/2 (3264) 10'-8 1/2 (3264) C 2'-0 (610) 2'-1 1/4 (641) 2'-1 1/4 (641) D 1'-5 1/2 (445) 1'-8 (508) 1'-8 (508) E 16'-0 (4877) 12'-0 (3658) 16'-0 (4877) LD07134 H, P, Q COMPRESSOR UNITS
FORM 160.75-EG1 (915) JOHNSON CONTROLS 79 Q3 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES A-A C-C D-D A 5'-1 (1549) 5'-6 (1676) 5'-6 (1676) B 7'-0 (2134) 7'-3 3/4 (2229) 7'-3 3/4 (2229) C 1'-3 1/2 (394) 1'-5 1/2 (445) 1'-5 1/2 (445) D 1'-3 (381) 1'-3 1/2 (394) 1'-3 1/2 (394) E 12'-0 (3658) 12'-0 (3658) 16'-0 (4877) Q4 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODE C-B C-C D-D E-E A 6'-4 3/4 (1949) 5'-6 (1676) 5'-6 (1676) 7'-0 (2134) B 7'-11 3/8 (2423) 7'-2 1/2 (2197) 7'-2 1/2 (2197) 7'-8 1/2 (2350) C 1'-5 1/2 (445) 1'-5 1/2 (445) 1'-5 1/2 (445) 1'-7 1/2 (495) D 1'-8 7/8 (530) 1'-3 1/2 (394) 1'-3 1/2 (394) 1'-5 1/2 (445) E 12'-0 (3658) 12'-0 (3658) 16'-0 (4877) 12'-0 (3658) Q5 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES C-C D-D E-E F-F A 5'-6 (1676) 5'-6 (1676) 7'-0 (2134) 7'-0 (2134) B 7'-10 5/8 (2403) 7'-10 5/8 (2403) 8'-3 (2578) 8'-3 (2578) C 1'-5 1/2 (445) 1'-5 1/2 (445) 1'-7 1/2 (495) 1'-7 1/2 (495) D 1'-3 1/2 (394) 1'-3 1/2 (394) 1'-5 1/2 (445) 1'-5 1/2 (445) E 12'-0 (3658) 16'-0 (4877) 12'-0 (3658) 16'-0 (4877) Q6 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES E-E F-F A 7'-0 (2134) 7'-0 (2134) B 8'-3 (2515) 8'-3 (2515) C 1'-7 1/2 (495) 1'-7 1/2 (495) D 1'-5 1/2 (445) 1'-5 1/2 (445) NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connections. 5. To determine overall height, add dimension M on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions. Dimensions (Cont'd) H9 COMPRESSORS EVAP.-COND. SHELL CODES DIM I-K K-K K-O M-M A 7'-6 1/2 (2299) 8'-9 1/4 (2673) 8'-7 (2616) B 10'-4 (3150) 10'-7 5/8 (3242) 10'-10 1/2 (3315) C 2'-1 1/4 (641) 2'-1 1/4 (641) 2'-4 1/2 (724) D 1'-8 (508) 2'-3 3/8 (695) 1'-11 (584) E 14'-0 (4267) 14'-0 (4267) 14'-0 (4267) H, P, Q COMPRESSOR UNITS
JOHNSON CONTROLS FORM 160.75-EG1 (915) 80 A DC B1,5 M E J2 H2 G2 F2 7 EVAPORATOR CONDENSER (SHIPPING WIDTH) OPTIVIEW CONTROL CENTER COMPRESSOR MOTOR K COMPRESSOR UNITS Dimensions (Cont'd) K1 COMPRESSOR, EVAPORATOR-CONDENSER SHELL CODES DIM I-K K-K M-M N-N P-P Q-Q A 7'-6 1/2 (2299) 8'-7 (2616) 8'-7 (2616) 9'-1 1/2 (2781) 9'-1 1/2 (2781) B 9'-7 (2921) 11'-4 (3454) 11'-4 (3454) 11'-5 1/2 (3493) 11'-5 1/2 (3493) C 2'-1 1/4 (641) 2'-4 1/2 (724) 2'-4 1/2 (724) 2'-5 1/2 (749) 2'-5 1/2 (749) D 1'-8 (508) 1'-11 (584) 1'-11 (584) 2'-1 1/4 (641) 2'-1 1/4 (641) E 14'-0 (4267) 14'-0 (4267) 16'-0 (4877) 14'-0 (4267) 16'-0 (4877) ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR TYPE OF CHILLER MOUNTING M NEOPRENE PAD ISOLATORS 1-3/4 (45) SPRING ISOLATORS 1 DEFLECTION 1 (25) DIRECT MOUNT 3/4 (19) K2 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES DIM M-M M-U N-N P-P Q-Q A 8'-7 (2616) 9'-6 (2896) 8'-7 (2616) 9'-1 1/2 (2781) 9'-1 1/2 (2781) B 11'-4 (3454) 11'-10 (3607) 11'-4 (3454) 11'-5 (3480) 11'-5 (3480) C 2'-4 1/2 (724) 2'-4 1/2 (724) 2'-4 1/2 (724) 2'-5 1/2 (749) 2'-5 1/2 (749) D 1'-11 (584) 2'-4 1/2 (724) 1'-11 (584) 2'-1 1/4 (641) 2'-1 1/4 (641) E 14'-0 (4267) 14'-0 (4267) 16'-0 (4877) 14'-0 (4267) 16'-0 (4877) LD07134
FORM 160.75-EG1 (915) JOHNSON CONTROLS 81 Dimensions (Cont'd) K COMPRESSOR UNITS K4 COMPRESSOR, EVAPORATOR- CONDENSER SHELL CODES DIM R-R S-S S-V X-T X-X A 9'-9 (2972) 9'-9 (2972) 10'-3 (3124) 10'-10 (3302) 11'-3 (3429) B 11'-11 (3632) 11'-11 (3632) 12'-4 (3759) 12'-4 (3759) 12'-4 (3759) C 2'-8 (813) 2'-8 (813) 2'-8 (813) 2'-11 1/2 (902) 2'-11 1/2 (902) D 2'-3 1/2 (699) 2'-3 1/2 (699) 2'-5 1/2 (749) 2'-5 1/2 (749) 2'-8 (813) E 16'-0 (4877) 18'-0 (5486) 18'-0 (5486) 16'-0 (4877) 16'-0 (4877) NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connec- tions. 5. To determine overall height, add dimension M on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions. K3 COMPR., EVAP.-COND. SHELL CODES N-N Q-Q R-R A 8'-7 (2616) 9'-1 1/2 (2781) 9'-9 (2972) B 10'-8 (3251) 11'-6 (3505) 11'-10 (3607) C 2'-4 1/2 (724) 2'-5 1/2 (749) 2'-8 (813) D 1'-11 (584) 2'-1 1/4 (641) 2'-3 1/2 (699) E 16'-0 (4877) 16'-0 (4877) 16'-0 (4877) K7 COMPR., EVAP.-COND SHELL CODES DIM W-W Z-Y Z-Z A 10'-3 (3124) 12'-7 (3835) 11'-3 (3429) B 12'-2 (3708) 14'-1 5/8 (4308) 12'-10 (3912) C 2'-8 (813) 2'-11 1/2 (902) 2'-11 1/2 (902) D 2'-5 1/2 (749) 3'-4 (1016) 2'-8 (813) E 22'-0 (6706) 18'-0 (5486) 18'-0 (5486)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 82 Dimensions (Cont'd) C C AA M AA M A H M MC C B C J K BB BB DD DD MM C C F G N P BB DD BB DD 1-PASS 2-PASS 3-PASS LD07598a EVAPORATORS  –  COMPACT WATER BOXES – A THRU L EVAPORATORS 1-PASS NO. OF PASSES EVAPORATOR IN OUT 1 A H H A 2-PASS NO. OF PASSES EVAPORATOR IN OUT 2 C B K J 3-PASS NO. OF PASSES EVAPORATOR IN OUT 3 G N P F FRONT OF UNIT FLOOR LINECOMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINECOMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINECOMPRESSOR END MOTOR END
FORM 160.75-EG1 (915) JOHNSON CONTROLS 83 Dimensions (Cont'd) COMPACT WATER BOXES - 150 PSI ROUND EVAPORATOR SHELL CODE NOZZLE PIPE SIZE(IN) NO. OF PASSES EVAPORATOR NOZZLE DIMENSIONS C 1-PASS 2-PASS 3-PASS 1 2 3 AA5 BB5 DD5 BB5 DD5 A 8 6 4 1'-3 1/2 (394) 1'-10 (559) 1'-2 (356) 2'-6 (762) 1'-2 (356) 2'-6 (762) C,D 10 8 6 1'-5 1/2 (445) 2'-0 (610) 1'-3 (381) 2'-9 (838) 1'-3 (381) 2'-9 (838) E,F 14 10 8 1'-7 (483) 2'-2 (660) 1'-4 (406) 3'-0 (914) 1'-4 (406) 3'-0 (914) G,H 14 10 8 2'-0 (610) 2'-3 1/2 (699) 1'-3 1/2 (394) 3'-3 1/2 (1003) 1'-3 1/2 (394) 3'-3 1/2 (1003) I, J, K, L 16 12 10 2'-1 1/4 (641) 2'-6 (762) 1'-5 (432) 3'-7 (1092) 1'-5 (432) 3'-7 (1092) EVAPORATORS  –  COMPACT WATER BOXES – A THRU L EVAPORATORS NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connections. 5. To determine overall height, add dimension M on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 84 Dimensions (Cont'd) LD07173a EVAPORATORS  –  COMPACT WATERBOXES – M THRU Z EVAPORATORS SHELL CODE 1 PASS IN OUT M–Z AA HH HH AA SHELL CODE 2 PASS IN OUT M,N,P,Q CC BB KK JJ SHELL CODES 2 PASS IN OUT R, S, W X Z DD CC EE BB LL KK MM JJ SHELL CODES 3 PASS IN OUT M–Z GG NN PP FF FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END
FORM 160.75-EG1 (915) JOHNSON CONTROLS 85 Dimensions (Cont'd) EVAPORATORS  –  COMPACT WATERBOXES – M THRU Z EVAPORATORS COMPACT WATER BOXES - 150 PSI EVAP SHELL CODE NOZZLE PIPE SIZE(IN) EVAPORATOR NOZZLE DIMENSIONS (FT-IN.) NO. OF PASSES 1-PASS 2-PASS 3-PASS 1 2 3 C AA4 BB4 DD4 EE BB4 DD4 M,N 18 14 12 2'-4 1/2 (724) 3'-0 (914) 1'-8 1/2 (521) 4'-3 1/2 (1308) - 1'-8 1/2 (521) 4'-3 1/2 (1308) P,Q 18 14 12 2'-5 1/2 (749) 3'-1 1/2 (953) 1'-10 (559) 4'-5 (1346) - 1'-10 (559) 4'-5 (1346) PF, QF, QH, QV, QT 20 16 12 2'-5 1/2 (749) 3'-1 1/2 (953) 1'-11 1/2 (597) 4'-3 1/2 (1308) - 1'-11 1/2 (597) 4'-3 1/2 (1308) R,S,W 20 18 14 2'-8 (813) 3'-5 1/4 (1048) 2'-4 1/2 (724) 4'-6 1/2 (1384) 0'-10 1/2 (267) 2'-1 (635) 4'-10 (1473) X,Z 20 18 14 2'-11 1/2 (902) 3'-9 3/4 (1162) 2'-8 3/4 (832) 4'-10 3/4 (1492) 0'-11 (279) 2'-2 7/8 (683) 5'-4 5/8 (1641) NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connections. 5. Add dimension M as shown on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 86 F F F F F G ONE,TWO, THREE PASS EVAPORATOR CODES DIM. A C,D E,F G,H I,J,K,L M,N P,Q R,S,W X,Z A 1'-2 1/4 (362) 1'-3 (381) 1'-3 1/2 (394) 1'-3 3/4 (400) 1'-5 1/2 (445) 1'-11 5/8 (565) 1'-11 5/8 (600) 2'-0 5/8 (613) 2'-1 3/4 (600) B 0'-6 1/2 (165) 0'-7 (178) 0'-7 1/2 (191) 0'-7 3/4 (197) 0'-9 1/2 (241) 1'-3 5/8 (365) 1'-3 5/8 (391) 1'-4 3/4 (391) 1'-5 3/4 (416) EVAPORATORS – COMPACT WATERBOXES Dimensions (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 87 THIS PAGE INTENTIONALLY LEFT BLANK.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 88 Dimensions (Cont'd) CONDENSERS  –  COMPACT WATER BOXES LD07131a 1-PASS7 NO. OF PASSES CONDENSER IN OUT 1 P Q Q P 2-PASS7 NO. OF PASSES CONDENSER IN OUT 2 R S T U 3-PASS7 NO. OF PASSES CONDENSER IN OUT 3 V Y X W FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END
FORM 160.75-EG1 (915) JOHNSON CONTROLS 89 Dimensions (Cont'd) COMPACT WATER BOXES - 150 PSI ROUND CONDENSER SHELL CODE NOZZLE PIPE SIZE(IN) D 1-PASS 2-PASS 3-PASS NO. OF PASSES 1 2 3 CC5 BB5 DD5 BB5 DD5 A 10 6 6 1'-3 (381) 2'-4 (711) 1'-9 1/2 (546) 2'-10 1/2 (876) 1'-9 1/2 (546) 2'-10 1/2 (876) C,D 12 8 6 1'-3 1/2 (394) 2'-6 (762) 1'-10 3/8 (568) 3'-1 5/8 (956) 1'-10 3/8 (568) 3'-1 5/8 (956) E,F 14 10 8 1'-5 1/2 (445) 2'-8 (813) 1'-11 3/4 (603) 3'-4 1/4 (1022) 1'-11 3/4 (603) 3'-4 1/4 (1022) J,K,L 16 10 10 1'-8 (508) 3'-0 (914) 2'-3 (686) 3'-9 (1143) 2'-3 (686) 3'-9 (1143) M,N 20 14 10 1'-11 (584) 3'-6 (1067) 2'-6 3/8 (772) 4'-5 5/8 (1362) 2'-6 3/8 (772) 4'-5 5/8 (1362) P,Q 20 16 14 2'-1 1/4 (641) 3'-8 (1118) 2'-7 (787) 4'-9 (1448) 2'-7 (787) 4'-9 (1448) R,S 20 18 14 2'-3 1/2 (699) 3'-10 1/2 (1181) 2'-9 1/2 (851) 4'-11 1/2 (1511) 2'-9 1/2 (851) 4'-11 1/2 (1511) T,V,W 24 18 16 2'-5 1/2 (749) 3'-11 1/2 (1207) 2'-9 (838) 5'-2 (1575) 2'-9 (838) 5'-2 (1575) X,Z 24 20 16 2'-8 (813) 4'-1 1/4 (1251) 2'-9 1/4 (845) 5'-5 1/4 (1657) 2'-9 1/4 (845) 5'-5 1/4 (1657) NOTES: 1. All dimensions are ft-inches (mm). 2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.6 mm raised face), water flanges nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished. 3. One, two and three pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles may be used in combination with any pair of condenser nozzles. 4. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance. 5. Connected piping should allow for removal of compact water boxes for tube access and cleaning. 6. Add dimension M as shown on page 78 for the appropriate isolator type. 7. Standard 150 psi (1034 kPa) design pressure water boxes shown. 8. Shell codes R,S,T,V,W,X, Z use double letter nozzle codes in the same orientation as the single letter e.g. P = PP. CONDENSERS  –  COMPACT WATER BOXES
JOHNSON CONTROLS FORM 160.75-EG1 (915) 90 Dimensions (Cont'd) SINGLE BUNDLE CONDENSERS, CODES DIM. A C,D E,F J,K,L M,N P,Q R,S T,V,W X,Z A 1'-1 7/8 (352) 1'-1 7/8 (352) 1'-3 (381) 1'-3 1/2 (394) 1'-3 3/8 (391) 1'-5 1/2 (445) 1'-8 3/4 (527) 1'-10 1/2 (572) 1'-11 5/8 (600) B 0'-5 7/8 (149) 0'-6 1/2 (165) 0'-7 (178) 0'-7 1/2 (191) 0'-7 3/4 (197) 0'-9 1/2 (241) 1'-2 3/8 (365) 1'-3 3/8 (391) 1'-4 3/8 (416) DOUBLE BUNDLE HEAT RECOVERY CONDENSERS, CODES B I O U Y DIM. TOWER HEATING TOWER HEATING TOWER HEATING TOWER HEATING TOWER HEATING A 1'-6 1/2 (470) 1'-5 (432) 1'-7 1/2 (495) 1'-4 3/4 (425) 1'-9 1/2 (546) 1'-6 (457) 1'-10 1/4 (565) 1'-8 (508) 2'-4 3/4 (730) 1'-10 1/2 (572) B 0'-10 1/2 (267) 0'-9 (229) 0'-11 1/2 (292) 0'-8 3/4 (222) 1'-1 1/2 (343) 0'-10 (254) 1'-2 1/4 (362) 1'-0 (305) 1'-8 3/4 (527) 1'-2 1/2 (368) H H H H H J ONE PASS TWO PASS THREE PASS LD07619b CONDENSERS  –  COMPACT WATER BOXES
FORM 160.75-EG1 (915) JOHNSON CONTROLS 91 LD18382 Dimensions (Cont'd) HEAT RECOVERY UNITS 1 PASS IN OUT HEAT RECOVERY EE FF FF EE COOLING TOWER P Q Q P 2 PASS IN OUT HEAT RECOVERY AA BB BB AA CC DD DD CC COOLING TOWER R S S R T U U T 3 PASS IN OUT HEAT RECOVERY GG HH HH GG COOLING TOWER V Y Y V COMPACT WATER BOXES - 150 PSI (RECTANGULAR) CONDENSER SHELL CODE NOZZLE PIPE SIZE (IN) 1, 2 OR 3 PASS 2 PASSMAIN BUNDLE HEAT RECOVERY BUNDLE NUMBER OF PASSES NUMBER OF PASSES 1 2 3 1 2 3 D K L I B 10 8 6 10 8 6 1'-8 7/8 (530) 1'-9 1/4 (540) 3'-6 1/2 (1080) 0'-9 1/16 (230) I 14 10 8 12 8 8 1'-11 3/8 (594) 1'-10 1/4 (565) 3'-8 1/8 (1121) 0'-10 1/8 (257) O 16 12 10 14 10 8 2'-3 3/8 (695) 2'-0 3/8 (619) 4'-1 1/8 (1248) 0'-11 13/16 (300) U 18 14 10 16 12 10 2'-4 1/2 (724) 2'-11 3/16 (894) 5'-2 13/16 (1595) 1'-0 3/8 (314) Y 24 20 16 20 18 16 3'-4 (1016) 3'-3 15/16 (1014) 6'-3 7/8 (1927) 1'-5 7/8 (454) HEAT RECOVERY COOLING TOWER HEAT RECOVERY COOLING TOWER FRONT OF UNIT COMPRESSOR END MOTOR END HEAT RECOVERY COOLING TOWER HEAT RECOVERY COOLING TOWER FRONT OF UNIT COMPRESSOR END MOTOR END HEAT RECOVERY COOLING TOWER HEAT RECOVERY COOLING TOWER FRONT OF UNIT COMPRESSOR END MOTOR END Add dimension M as shown on page 78.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 92 Dimensions (Cont'd) EVAPORATORS – MARINE WATERBOXES LD07175a FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE EVAPORATOR 1-PASS IN OUT 1 6 6 1 EVAPORATOR 2-PASS IN OUT 2 3 7 8 EVAPORATOR 3-PASS IN OUT 5 10 9 4
FORM 160.75-EG1 (915) JOHNSON CONTROLS 93 Dimensions (Cont'd) NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connections. 5. Add dimension M as shown on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions. EVAPORATORS – MARINE WATERBOXES MARINE WATER BOXES - 150 PSI ROUND EVAPORATOR SHELL CODE NOZZLE PIPE SIZE(IN) NO. OF PASSES 1-PASS 2-PASS 3-PASS 1 2 3 C P5 P5 Q5 R P5 Q5 R A 8 6 4 1'-3 1/2 (394) 3'-7 (1092) 3'-7 (1092) 0'-11 (279) 1'-3 1/4 (387) 3'-7 (1092) 0'-11 (279) 1'-3 1/4 (387) C,D 10 8 6 1'-5 1/2 (445) 3'-11 (1194) 3'-11 (1194) 0'-10 (254) 1'-6 1/2 (470) 3'-11 (1194) 0'-10 (254) 1'-6 1/2 (470) E,F 14 10 8 1'-7 1/2 (495) 4'-3 (1295) 4'-3 (1295) 0'-11 (279) 1'-9 1/2 (546) 4'-3 (1295) 0'-11 (279) 1'-9 1/2 (546) G,H 14 10 8 2'-0 (610) 4'-7 3/8 (1407) 4'-7 3/8 (1407) 0'-10 1/2 (267) 1'-11 1/2 (597) 4'-7 3/8 (1407) 0'-10 1/2 (267) 1'-11 1/2 (597) I,J,K,L 16 12 10 2'-1 1/4 (641) 5'-0 3/8 (1534) 5'-0 3/8 (1534) 0'-10 1/2 (267) 2'-2 1/2 (673) 5'-0 3/8 (1534) 0'-10 1/2 (267) 2'-2 1/2 (673) M,N 18 14 12 2'-4 1/2 (724) 5'-8 1/2 (1740) 5'-8 1/2 (1740) 1'-2 (356) 2'-2 1/2 (673) 5'-8 1/2 (1740) 1'-2 (356) 2'-4 3/4 (730) P,Q 18 14 12 2'-5 1/2 (749) 6'-0 1/8 (1832) 6'-0 1/8 (1832) 1'-3 (381) 2'-6 1/2 (775) 6'-0 1/8 (1832) 1'-3 (381) 2'-6 1/2 (775) PF, QF, QH, QT,QV 20 16 12 2'-5 1/2 (749) 6'-0 1/8 (1832) 6'-0 1/8 (1832) 1'-4 1/2 (419) 2'-6 1/2 (775) 6'-0 1/8 (1832) 1'-4 1/2 (419) 2'-6 1/2 (775) R,S 20 18 14 2'-8 (813) 6'-5 7/8 (1978) 6'-5 7/8 (1978) 1-3 3/4 (57) 3'-0 1/8 (918) 6'-5 7/8 (1978) 1-3 3/4 (57) 3'-0 1/8 (918) W 20 18 14 2'-8 (813) 6'-5 7/8 (1978) 6'-5 7/8 (1978) 1-3 3/4 (57) 3'-0 1/8 (918) 6'-5 7/8 (1978) 1-3 3/4 (57) 3'-0 1/8 (918) X,Z 20 18 14 2'-11 1/2 (902) 7'-1 3/8 (2169) 7'-1 3/8 (2169) 1'-9 1/4 (540) 3'-0 3/4 (933) 7'-1 3/8 (2169) 1'-9 1/4 (540) 3'-0 3/4 (933)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 94 Dimensions (Cont'd) EVAPORATOR SHELL CODE 1-PASS 2-PASS 3-PASS A C A B C A C A 1'-7 (483) 0'-8 3/4 (222) 1'-5 (432) 0'-6 1/2 (165) 0'-7 3/4 (197) 1'-5 (432) 0'-7 3/4 (197) C,D 1'-10 3/4' (578) 0'-10 5/8 (270) 1'-8 5/8 (524) 0'-7 (178) 0'-9 1/2 (241) 1'-8 5/8 (524) 0'-9 1/2 (241) E,F 2'-1 3/4 (654) 1'-0 1/8 (308) 1'-10 (559) 0'-7 1/2 (191) 0'-10 1/4 (260) 1'-10 (559) 0'-10 1/4 (260) G,H 2'-2 (660) 0'-11 7/8 (302) 1'-10 1/2 (572) 0'-11 1/4 (286) 0'-10 1/4 (260) 1'-10 1/2 (572) 0'-10 1/4 (260) i,J,K,L 2'-3 (686) 1'-0 3/8 (314) 1'-11 1/2 (597) 0'-9 1/2 (241) 0'-10 9/16 (268) 1'-11 1/2 (597) 0'-10 1/2 (267) M,N 2'-6 (762) 1'-1 1/2 (343) 2'-2 (660) 1'-0 1/8 (308) 0'-11 1/2 (292) 2'-2 (660) 0'-11 1/2 (292) P,Q 2'-6 (762) 1'-1 1/2 (343) 2'-2 (660) 1'-1 1/2 (343) 0'-11 1/2 (292) 2'-2 (660) 0'-11 1/2 (292) QT,QV 2'-8 (813) 1'-2 1/2 (368) 2'-4 (711) 1'-1 1/2 (343) 1'-0 1/2 (318) 2'-4 (711) 1'-0 1/2 (318) R,S,W 2'-8 (813) 1'-2 5/8 (371) 2'-6 (762) 1'-2 1/2 (368) 1'-1 5/8 (346) 2'-6 (762) 1'-1 5/8 (346) X,Z 2'-9 (838) 1'-2 5/8 (371) 2'-6 (762) 1'-3 1/2 (394) 1'-1 5/8 (346) 2'-6 (762) 1'-1 5/8 (346) EVAPORATORS – MARINE WATERBOXES F
FORM 160.75-EG1 (915) JOHNSON CONTROLS 95 THIS PAGE INTENTIONALLY LEFT BLANK.
JOHNSON CONTROLS FORM 160.75-EG1 (915) 96 CONDENSERS – MARINE WATERBOXES LD07178a FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END Dimensions (Cont'd) CONDENSER 1-PASS IN OUT 11 16 16 11 CONDENSER 2-PASS IN OUT 12 13 17 18 CONDENSER 3-PASS IN OUT 15 20 19 14
FORM 160.75-EG1 (915) JOHNSON CONTROLS 97 MARINE WATER BOXES - 150 PSI ROUND CONDENSER SHELL CODE NOZZLE PIPE SIZE(IN) 1-PASS 2-PASS 3-PASS NO. OF PASSES 1 2 3 D S5 S5 T5 U S5 T5 U A 10 6 6 1'-3 (381) 3'-11 (1194) 3'-11 (1194) 1'-8 (508) 1'-3 3/8 (391) 3'-11 (1194) 1'-8 (508) 1'-3 3/8 (391) C,D 12 8 6 1'-3 1/2 (394) 4'-3 (1295) 4'-3 (1295) 1'-8 (508) 1'-6 1/2 (470) 4'-3 (1295) 1'-8 (508) 1'-6 1/2 (470) E,F 14 10 8 1'-5 1/2 (445) 4'-7 (1397) 4'-7 (1397) 1'-10 (559) 1'-9 (533) 4'-7 (1397) 1'-10 (559) 1'-9 (533) J,K,L 16 10 10 1'-8 (508) 5'-1 (1549) 5'-1 (1549) 1'-9 (533) 1'-9 1/2 (546) 5'-1 (1549) 1'-9 (533) 1'-9 1/2 (546) M,N 20 14 10 1'-11 (584) 5'-9 7/8 (1775) 5'-9 7/8 (1775) 2'-4 (711) 2'-1 1/2 (648) 5'-9 7/8 (1775) 2'-4 (711) 2'-1 1/2 (648) P,Q 20 16 14 2'-1 1/4 (641) 6'-2 3/8 (1889) 6'-2 3/8 (1889) 2'-4 1/2 (724) 2'-5 1/2 (749) 6'-2 3/8 (1889) 2'-4 1/2 (724) 2'-5 1/2 (749) R,S 20 18 14 2'-3 1/2 (699) 6'-7 (2007) 6'-7 (2007) 2'-6 1/2 (775) 2'-8 1/2 (826) 6'-7 (2007) 2'-6 1/2 (775) 2'-8 1/2 (826) T,V,W 24 18 16 2'-5 1/2 (749) 6'-10 1/4 (2089) 6'-10 1/4 (2089) 2'-6 (762) 2'-10 (864) 6'-10 1/4 (2089) 2'-6 (762) 2'-10 (864) X,Z 24 20 16 2'-8 (813) 7'-2 (2184) 7'-2 (2184) 2'-7 3/4 (806) 2'-11 1/2 (902) 7'-2 (2184) 2'-7 3/4 (806) 2'-11 1/2 (902) NOTES: 1. All dimensions are ft-inches (mm). 2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.6 mm raised face), water flanges nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished. 3. One, two and three pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles may be used in combination with any pair of condenser nozzles. 4. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance. 5. Connected piping should allow for removal of compact water boxes for tube access and cleaning. 6. Add dimension M as shown on page 78 for the appropriate isolator type. 7. Standard 150 psi (1034 kPa) design pressure water boxes shown. 8. Shell codes R,S,T,V,W,X, Z use double letter nozzle codes in the same orientation as the single letter e.g. P = PP. CONDENSERS – MARINE WATERBOXES Dimensions (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 98 11 16 M M SS D D U U C L LC 13 M M S D U CL 12 T T 18 M S D U CL 17 T T D CL D CL M V V M M S U CL 15 T T M S D U CL 19 T T D CL D CL M 20 14 S V VD 1-PASS 2-PASS 3-PASS LD18383 CONDENSERS  –  MARINE WATER BOXES Heat Recovery Units - Main (Tower) Circuit Only Dimensions (Cont'd)Dimensions (Cont'd) FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END CONDENSER 1-PASS IN OUT 11 16 16 11 CONDENSER 2-PASS IN OUT 12 13 17 18 CONDENSER 3-PASS IN OUT 15 20 19 14
FORM 160.75-EG1 (915) JOHNSON CONTROLS 99 MARINE WATER BOXES - 150 PSI (RECTANGULAR) COND SHELL CODE NOZZLE PIPE SIZE (IN) 1 PASS 2 PASS 3 PASS NO. OF PASSES 1 2 3 D S U S T U V S T U V B 10 8 6 1'-8 7/8 (530) 1'-9 1/4 (540) 2'-6 3/4 (781) 2'-3 7/16 (697) 1'-1 15/16 (354) 2'-4 3/4 (730) 2'-7 1/8 (791) 2'-4 1/2 (724) 1'-5 1/2 (445) 2'-6 3/4 (781) 2'-6 3/4 (781) I 14 10 8 1'-11 3/8 (594) 1'-10 1/4 (565) 2'-9 3/8 (848) 2'-4 1/2 (724) 1'-1 (330) 2'-5 1/8 (740) 2'-10 5/8 (879) 2'-5 1/2 (749) 1'-6 3/8 (467) 2'-9 1/8 (841) 2'-9 1/8 (841) O 16 12 10 2'-3 3/8 (695) 2'-0 3/8 (619) 3'-2 3/8 (975) 2'-7 1/8 (791) 1'-1 3/8 (340) 2'-10 1/4 (870) 3'-4 1/2 (1029) 2'-8 3/8 (822) 1'-7 5/8 (498) 3'-1 7/8 (962) 3'-1 7/8 (962) U 18 14 10 2'-4 1/2 (724) 2'-11 3/16 (894) 3'-5 9/16 (1056) 3'-6 9/16 (1081) 1'-11 3/16 (589) 3'-1 7/8 (962) 3'-7 1/2 (1105) 3'-8 3/16 (1122) 2'-5 15/16 (760) 3'-0 11/16 (932) 3'-3 (991) Y 24 20 16 3'-4 (1016) 3'-3 15/16 (1014) 4'-7 9/16 (1411) 4'-2 5/16 (1278) 1'-10 5/16 (567) 4'-4 3/4 (1340) 4'-11 11/16 (1516) 4'-4 5/16 (1329) 2'-7 7/16 (799) 4'-2 1/16 (1272) 4'-6 13/16 (1392) CONDENSERS  –  MARINE WATER BOXES Heat Recovery Units - Main (Tower) Circuit Only NOTES: 1. All dimensions are ft-inches (mm). 2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.6 mm raised face), water flanges nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished. 3. One, two and three pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles may be used in combination with any pair of condenser nozzles. 4. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance. 5. Connected piping should allow for removal of compact water boxes for tube access and cleaning. 6. Add dimension M as shown on page 78 for the appropriate isolator type. 7. Standard 150 psi (1034 kPa) design pressure water boxes shown. 8. Shell codes R,S,T,V,W,X, Z use double letter nozzle codes in the same orientation as the single letter e.g. P = PP. Dimensions (Cont'd)Dimensions (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 100 CONDENSER 1-PASS 2-PASS 3-PASS A C A B C A C A 1'-9 (533) 0'-9 7/8 (251) 1'-4 3/4 (425) 0'-6 (152) 0'-7 3/4 (197) 1'-4 3/4 (425) 0'-7 3/4 (197) B6 1'-10 1/2 (572) 0'-10 1/2 (267) 1'-8 (508) 0'-10 1/2 (267) 0'-9 1/4 (235) 1'-8 (508) 0'-9 1/4 (235) C,D 2'-0 (610) 0'-11 1/8 (283) 1'-7 1/2 (495) 0'-6 3/8 (162) 0'-9 (229) 1'-7 1/2 (495) 0'-9 (229) E,F 2'-0 1/2 (622) 0'-11 1/2 (292) 1'-10 1/4 (565) 0'-7 (178) 0'-9 7/8 (251) 1'-10 1/4 (565) 0'-9 7/8 (251) I6 2'-3 (686) 1'-0 3/4 (324) 1'-10 1/2 (572) 0'-11 1/2 (292) 0'-10 1/2 (267) 1'-10 1/2 (572) 0'-10 1/2 (267) J,K,L 2'-3 (686) 1'-0 1/2 (318) 1'-11 (584) 0'-7 1/2 (191) 0'-10 1/4 (260) 1'-11 (584) 0'-10 1/4 (260) M,N 2'-8 (813) 1'-2 7/8 (378) 2'-2 (660) 0'-8 (203) 1'-0 (305) 2'-2 (660) 1'-0 (305) O6 2'-6 1/4 (768) 1'-2 1/4 (362) 2'-1 3/4 (654) 1'-1 1/2 (343) 1'-0 (305) 2'-1 3/4 (654) 1'-0 (305) P,Q 2'-8 (813) 1'-2 1/2 (368) 2'-4 (711) 0'-9 1/2 (241) 1'-0 1/2 (318) 2'-4 (711) 1'-0 1/2 (318) R,S 2'-8 (813) 1'-2 1/2 (368) 2'-6 (762) 1'-0 (305) 1'-1 1/2 (343) 2'-6 (762) 1'-1 1/2 (343) T,V,W 3'-0 (914) 1'-4 1/2 (419) 2'-6 (762) 0'-11 (279) 1'-1 1/2 (343) 2'-6 (762) 1'-1 1/2 (343) U6 2'-8 (813) 1'-3 (381) 2'-4 (711) 1'-2 1/4 (362) 1'-1 (330) 2'-4 (711) 1'-1 (330) X,Z 3'-0 (914) 1'-4 5/8 (422) 2'-8 (813) 0'-11 (279) 1'-2 5/8 (371) 2'-8 (813) 1'-2 (356) Y6 3'-4 3/4 (1035) 1'-7 1/4 (489) 3'-0 1/4 (921) 1'-8 3/4 (527) 1'-5 (432) 3'-0 1/4 (921) 1'-5 (432) CONDENSERS  –  MARINE WATER BOXES Heat Recovery Units - Main (Tower) Circuit Only Dimensions (Cont'd) F
FORM 160.75-EG1 (915) JOHNSON CONTROLS 101 SHELLS COMPRESSOR SHIPPING WEIGHT LBS. (KGS.) OPERATING WEIGHT LBS. (KGS.) EST. REFRIGERANT CHARGE LBS. (KGS.) 1 A-A Q3 13100 (5942) 15000 (6804) 828 (376) C-B Q4 18023 (8175) 22323 (10126) 1525 (692) C-C Q3, Q4 14920 (6768) 17940 (8138) 1221 (554) C-C Q5 15330 (6954) 18350 (8324) 1221 (554) D-D Q3, Q4 17215 (7809) 21100 (9571) 1628 (738) D-D Q5 17625 (7995) 21510 (9757) 1628 (738) E-E Q3, Q4 17950 (8142) 22160 (10052) 1710 (776) E-E Q5,Q6,Q7,P7 18360 (8328) 22570 (10238) 1710 (776) E-I Q7 23567 (10690) 29384 (13328) 1805 (819) F-F Q5,Q6,Q7,P7 18720 (8491) 23880 (10832) 2175 (987) G-E P8 20300 (9208) 24200 (10977) 1990 (903) H-F P8,P9 23100 (10478) 28000 (12701) 2610 (1184) J-J P8,P9 24000 (10886) 29100 (13200) 2550 (1157) L-L P8,P9 27400 (12429) 33900 (15377) 3165 (1436) K-K H9 28530 (12941) 36000 (16329) 2925 (1327) K-K K1 31100 (14107) 36200 (16420) 3248 (1473) K-O H9 34483 (15641) 44776 (20310) 3260 (1479) M-M H9 34200 (15513) 43600 (19777) 3665 (1662) M-M K1,K2 38300 (17373) 47100 (21364) 3665 (1662) M-U K2 45178 (20493) 58017 (26316) 3540 (1606) N-N K1,K2 40893 (18549) 50800 (23043) 4225 (1916) N-N K3 48000 (21773) 54100 (24540) 4225 (1916) P-P K1,K2 41500 (18824) 51900 (23542) 3855 (1749) Q-Q K1,K2 45300 (20548) 56800 (25764) 4255 (1930) Q-Q K3 46000 (20865) 60200 (27307) 4255 (1930) R-R K3 52800 (23950) 70300 (31888) 4600 (2087) R-R K4 53000 (24041) 70600 (32024) 4600 (2087) S-S K4 59000 (26762) 76300 (34609) 4815 (2184) S-V K4 60100 (27261) 81300 (36877) 5467 (2480) X-T K4 59200 (26853) 80000 (36288) 5338 (2421) X-X K4 66000 (29937) 87000 (39463) 5875 (2665) W-W K7 79500 (36061) 104000 (47174) 8002 (3630) Z-Y K7 95230 (43196) 123015 (55799) 7175 (3255) Z-Z K7 80500 (36515) 105000 (47628) 6984 (3168) 1 Refrigerant charge quantity and weights will vary based on tube count. SHELLS COMPRESSOR SHIPPING WEIGHT LBS. (KGS.) OPERATING WEIGHT LBS. (KGS.) EST. REFRIGERANT CHARGE LBS. (KGS.)1 A-A Q3 12850 (5829) 14419 (6540) 695 (315) C-C Q3, Q4 14570 (6609) 16848 (7642) 875 (397) C-C Q5 15000 (6804) 17278 (7837) 875 (397) D-D Q4 17000 (7711) 20051 (9095) 1180 (535) D-D Q5 17410 (7897) 20461 (9281) 1180 (535) E-E Q5,Q6,Q7,P7 18700 (8482) 21700 (9843) 1120 (508) F-F Q5,Q6,Q7,P7 19220 (8718) 23142 (10497) 1415 (642) G-E P8, P9 20640 (9362) 24036 (10903) 1320 (599) H-F P8, P9 23540 (10678) 28083 (12738) 1775 (805) I-K H9 28849 (13086) 34078 (15458) 1820 (826) K-K H9 28850 (13086) 34079 (15458) 1820 (826) I-K K1 31350 (14220) 35145 (15942) 1820 (826) M-M K1,K2 34520 (15658) 46055 (20890) 2300 (1043) N-N K1,K2 41273 (18721) 49605 (22501) 2650 (1202) N-N K3 48380 (21945) 52905 (23998) 2650 (1202) P-P K1,K2 41950 (19028) 51595 (23403) 3100 (1406) Q-Q K1,K2 45800 (20775) 56545 (25649) 3500 (1588) Q-Q K3 46500 (21092) 59945 (27191) 3500 (1588) 1 Refrigerant charge quantity and weights will vary based on tube count and configuration. Use for reference only. Weights Table 21 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR FOR FLOODED EVAPORATOR UNITS Table 22 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR FOR HYBRID FALLING FILM EVAPORATOR UNITS
JOHNSON CONTROLS FORM 160.75-EG1 (915) 102 EVAPORATOR SHIPPING WEIGHT OPERATING WEIGHT INCREASE - LBS. (KGS.) INCREASE - LBS. (KGS.) 1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS A 924 (419) 744 (337) 978 (444) 1468 (666) 1288 (584) 1522 (690) C,D 1352 (613) 1114 (505) 1480 (671) 2224 (1009) 1986 (901) 2352 (1067) E,F 1878 (852) 1260 (572) 2080 (943) 3378 (1532) 2760 (1252) 3580 (1624) G,H 1213 (550) 1296 (588) 1293 (587) 2655 (1204) 2738 (1242) 2735 (1241) I,J,K,L 1751 (794) 1843 (836) 1856 (842) 3864 (1753) 3956 (1794) 3969 (1800) M,N 4290 (1946) 2036 (924) 4140 (1878) 7535 (3418) 3264 (1481) 6300 (2858) P,Q 4662 (2115) 2250 (1021) 4646 (2107) 7746 (3514) 3486 (1581) 7392 (3353) R,S,W 4804 (2179) 2700 (1225) 4912 (2228) 8522 (3866) 4516 (2048) 8187 (3714) X,Z 7088 (3215) 3660 (1660) 7244 (3286) 11552 (5240) 5507 (2498) 11243 (5100) CONDENSER SHIPPING WEIGHT OPERATING WEIGHT INCREASE - KGS. INCREASE - KGS. 1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS A 762 (346) 566 (257) 810 (367) 1274 (578) 1078 (489) 1322 (600) B 1569 (712) 874 (396) 1677 (761) 2113 (958) 1094 (496) 2071 (939) C,D 946 (429) 778 (353) 1046 (474) 1692 (767) 1524 (691) 1792 (813) E,F 726 (329) 811 (368) 791 (359) 1337 (606) 1722 (781) 1702 (772) I 2066 (937) 1070 (485) 2032 (922) 3017 (1369) 1416 (642) 2738 (1242) J,K,L 1029 (467) 1167 (529) 1151 (522) 2309 (1047) 2447 (1110) 2431 (1103) M,N 2466 (1119) 1330 (603) 2324 (1054) 4863 (2206) 2448 (1110) 4582 (2078) O 2985 (1354) 1443 (655) 2987 (1355) 4435 (2012) 2172 (985) 3979 (1805) P,Q 3700 (1678) 1858 (843) 3752 (1702) 6561 (2976) 3132 (1421) 5991 (2717) R,S 3806 (1726) 1946 (883) 3960 (1796) 6657 (3020) 3195 (1449) 6352 (2881) V,T,W 5196 (2357) 2565 (1163) 5204 (2361) 9161 (4155) 4012 (1820) 8219 (3728) U 3641 (1652) 1893 (859) 3609 (1637) 5350 (2427) 2556 (1159) 4770 (2164) X,Z 5840 (2649) 2953 (1339) 5380 (2440) 9900 (4491) 4649 (2109) 8100 (3674) Y 9094 (4125) 4762 (2160) 9058 (4109) 13326 (6045) 6524 (2959) 12049 (5465) Weights (Cont'd) Table 23 - EVAPORATOR MARINE WATERBOX WEIGHTS LBS (KG) (TO BE ADDED TO STANDARD UNIT WEIGHTS SHOWN ON TABLE 21 OR 22) Table 24 - CONDENSER MARINE WATERBOX WEIGHTS LBS (KG) (TO BE ADDED TO STANDARD UNIT WEIGHTS SHOWN ON TABLE 21 OR 22)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 103 GENERAL Furnish and install where indicated on the drawings____ YORK YK Centrifugal Liquid Chilling Unit(s). Each unit shall produce a capacity ____ tons, cooling ____ GPM of ____ from ____ °F to ____ °F when supplied with ____ GPM of condenser water at ____ °F. Power input shall not exceed ____ kW with an IPLV (NPLV) of ____. The evaporator shall be selected for a ____ fouling factor and a maximum liquid pressure drop of ____ ft. The water-side shall be designed for 150 psig working pressure. The condenser shall be se- lected for ____ fouling factor and maximum liquid pressure drop of ____ ft. The waterside shall be designed for 150 psig working pressure. Power shall be supplied to the compres- sor motor at ____ volts- 3 phase-60 Hertz and controls at 115 volts -1-phase-60 Hertz. Or Furnish and install where indicated on the drawings ___ YORK YK Centrifugal Liquid Chilling Unit(s). Each unit shall produce a capacity of kW, cooling____ l/s of ____ from ____ °C to ____ °C when supplied with ____ l/s of condenser water at ____°C. Power input shall not exceed ____ kW with an IPLV (NPLV) of ____. The evaporator shall be selected for ____m2 C/W fouling factor and maximum liquid pressure drop of ____kPa. The waterside shall be designed for 10.3 barg working pressure. The condenser shall be selected for ____ fouling factor and maximum liquid pressure drop of ____ kPa. The waterside shall be designed for 10.3 barg working pressure. Power shall be supplied to the compressor motor at ____ volts - 3-phase-50 Hertz and controls at 115 volts -1-phase-50 Hertz. Or FOR DOUBLE BUNDLE HEAT RECOVERY UNIT: In cooling mode, each unit shall produce a capacity of ___ tons, cooling ____ gpm of _____ from _____ °F to _____ °F when supplied with ____ gpm of condenser water at _____°F. Power input shall not exceed ___ kW with an NPLV of _____. The cooler shall be selected for ______ fouling factor and a maximum liquid pressure drop of _____ ft. The waterside shall be designed for ____ psig working pressure. The condenser shall be selected for _____ fouling factor and maximum liquid pressure drop of _____ ft. Tower condenser bundle water side shall be designed for psig working pressure. In heating mode, each unit shall produce a capacity of ___ tons, cooling ____ gpm of _______ from _____ to _____ °F while providing heating through the heat recovery bun- dle of ____ gpm of _______ from _____ °F to _____ °F . Power input shall not exceed ____ kW. The heat recovery bundle shall be selected for ______ fouling factor and maxi- mum liquid pressure drop of ____ ft. Heating condenser bundle water side shall be de- signed for ____ psig working pressure. Power shall be supplied to the compressor motor at ___ volts – __ phase - __ Hertz and controls at ____ volts – __ - phase - __ Hertz. Guide Specifications
JOHNSON CONTROLS FORM 160.75-EG1 (915) 104 Or In cooling mode, each unit shall produce a capacity of ___ kW, cooling ____ l/s of _____ from _____ °C to _____ °C when supplied with ____ l/s of condenser water at _____°C. Power input shall not exceed ___ kW with an NPLV of _____. The cooler shall be se- lected for ______ fouling factor and a maximum liquid pressure drop of _____ kPa. The waterside shall be designed for ____ barg working pressure. The condenser shall be selected for _____ fouling factor and maximum liquid pressure drop of _____ kPa. Tower condenser bundle waterside shall be designed for ___ barg working pressure. In heating mode, each unit shall produce a capacity of ___ tons, cooling ____ l/s of ______ from _____ to _____ °C while providing heating through the heat recovery bundle of ____ l/s of ______ from _____ °C to _____ °C . Power input shall not exceed ____ kW. The heat recovery bundle shall be selected for ______ fouling factor and maximum liquid pres- sure drop of ____ kPa. The heating condenser bundle water side shall be designed for ____ barg working pressure. Power shall be supplied to the compressor motor at ___ volts – __ phase - __ Hertz and controls at ____ volts – __ - phase - __ Hertz. Performance shall be certified or rated in accordance with the latest edition of AHRI Stan- dard 550/590 as applicable. Only chillers that are listed in the AHRI Certification Program for Water Chilling Packages Using the Vapor Compression Cycle are acceptable. Each unit shall be completely factory packaged including evaporator, condenser, sub cooler, compressor, open motor, lubrication system, OptiView Control Center, Variable Speed Drive or Solid-State Starter, and all interconnecting unit piping and wiring. The chiller shall be painted prior to shipment. The initial charge of oil and refrigerant shall be supplied factory charged in the chiller or shipped in containers and cylinders for field installation. COMPRESSOR The compressor shall be a single stage centrifugal type powered by an open drive electric motor. The housing shall be fully accessible with vertical circular joints, with the com- plete operating assembly removable from the compressor and scroll housing. Compres- sor castings shall be designed for a minimum 235 psig (16.2 barg) working pressure and hydrostatically pressure tested at a minimum of 352 psig (24.3 barg). The rotor assembly shall consist of a heat treated steel alloy drive shaft and impeller shaft with cast aluminum, fully shrouded impeller. The impeller shall be designed for balanced thrust, dynamically balanced and overspeed tested for smooth, vibration free operation. Insert type journal and thrust bearings shall be fabricated of aluminum alloy, precision bored and axially grooved. Internal single helical gears with crowned teeth shall be designed so that more than one tooth is in contact at all times to provide even load distribution and quiet operation. Each gear shall be individually mounted in its own journal and thrust bearings to isolate it from impeller and motor forces. Shaft seal shall be provided as a double bellows, double-seal, cartridge type. A gravity-fed oil reservoir shall be built into the top of the compressor to provide lubrication during coastdown in the event of a power failure. (Fixed Speed Drive) Capacity control shall be achieved by use of pre-rotation vanes to provide fully modulating control from full load to minimum load. (Variable Speed Drive) Capacity control shall be accomplished by the Adaptive Capacity Control (ACC), providing Guide Specifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 105 optimal relationship between compressor speed and inlet pre-rotation vane position for maximum energy efficiency. Control shall automatically compensate for adverse operat- ing conditions, such as fouled tubes, and adjust to prior operation after correction of these conditions. The unit shall be capable of continuous, reliable operation with low ECWT at all load conditions as outlined on the equipment schedule. An external electric actuator shall au- tomatically control pre-rotation vane position. LUBRICATION SYSTEM Lubrication oil shall be force-fed to all compressor bearings, gears, and rotating surfaces by an external variable speed oil pump. The oil pump shall vary oil flow to the com- pressor based on operating and stand-by conditions, ensuring adequate lubrication at all times. The oil pump shall operate prior to start-up, during compressor operation and dur- ing coastdown. Compressor shall have an auxiliary reservoir to provide lubrication during coastdown in the event of a power failure. An oil reservoir, separate from the compressor, shall contain the submersible 2 HP oil pump and a 3000 watt oil heater, thermostatically controlled to remove refrigerant from the oil. The oil reservoir shall be listed as part of the chiller by a nationally recognized testing laboratory and shall be factory air strength tested at 1.1 times design working pressure. Oil shall be filtered by an externally-mounted 1/2 micron replaceable cartridge oil filter equipped with service valves. Oil cooling shall be done via refrigerant cooled oil cooler, with all piping factory-installed. Oil side of the oil cooler shall be provided with service valves. An automatic oil return system to recover any oil that may have migrated to the evaporator shall be provided. Oil piping shall be completely factory-installed and tested. WATER-COOLED OIL COOLER Optional condenser water-cooled oil cooler is offered for units with Q3 compressors only. The four tube pass and one shell pass oil cooler is by API Basco, Model 05036 (shell di- ameter 5 OD, tube length 36). The shell is steel pipe or tubing and tube sheets are steel to ASME specification. Bafflers are precision hot-rolled, punched, carbon steel to assure effective circulation by providing minimum clearances between the tubes and tube holes. The cooler is a straight-tube type and has 180 plain copper tubes of 1/4 OD with 24 BWG. The heat exchanger has either cast iron bonnets to be used for 150 psig (10.3 barg) con- denser waterboxes or carbon steel bonnets to be used for 300 psig (20.6 barg) condenser waterboxes. Condenser water is the cooling medium and water circulation is obtained by the water pressure drop across the condenser shell. The minimum requirement of 7 to 8 gpm (0.4 to 0.5 l/s) water for this oil cooler is provided at a pressure drop as low as 3 ft. with the Q3 piping arrangement. MOTOR DRIVELINE The compressor motor shall be an open drip proof, squirrel cage, induction type operating at 3570 rpm for 60Hz operation and 2975 rpm for 50 Hz operation. The open motor shall be provided with a D-flange. The D-flange is bolted to a cast iron adaptor mounted on the compressor. This allows the motor to be rigidly coupled to the compressor to provide factory alignment of motor and compressor shafts. Guide Specifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 106 The motor drive shaft shall be directly connected to the compressor shaft with a flexible disc coupling. Coupling shall have all metal construction with no wearing parts to assure long life, and no lubrication requirements to provide low maintenance. For units utilizing remote electro-mechanical starters, a large steel terminal box with gasketed front access cover shall be provided for field-connected conduit. Overload/overcurrent transformers shall be furnished with all units. (For units furnished with factory-packaged Solid-State Starters or Variable Speed Drive, refer to the “Options” section.) EVAPORATOR Evaporator shall be a shell and tube type, hybrid falling film (evaporator codes A_ to Q_) or flooded type (evaporator codes R_ to Z_) designed for a minimum of 180 psig (12.4 barg) on H K compressor models, 235 psig (16.2 barg) on P Q compressor models; working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel plates with fusion welded seams, carbon steel tube sheets, drilled and reamed to accommodate the tubes, and intermediate tube supports spaced no more than four feet apart. The refrigerant side of each shell is designed, tested and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII - Division 1, or other pressure vessel code as appropriate. Heat exchanger tubes shall be high-efficiency, externally and internally enhanced type. Tubes shall utilize the “skip-fin” design, providing a smooth internal and external surface at each intermediate tube support. This provides extra wall thickness and non-work hard- ened copper at the support location, extending the life of the heat exchangers. If skip-fin tubes are not used, minimum tube wall thickness shall be 0.035 (~1 mm). Each tube shall be roller expanded into the tube sheets providing a leak-proof seal, and be individually replaceable. Water velocity through the tubes shall not exceed 12 ft./sec. (3.7 m/sec.). A liquid level sight glass shall be provided on the side of the shell to aid in determining proper refrigerant charge and to check condition of the refrigerant charge. The hybrid fall- ing film evaporator design has suction baffles around the sides and above the falling film section to prevent liquid refrigerant carryover into the compressor. Flooded evaporator designs have a suction baffle on M shells with H9 compressors and an aluminum mesh eliminator on K - Z shells with K compressors located above the tube bundle to prevent liquid refrigerant carryover into the compressor. The evaporator shall have a refrigerant relief device sized to meet the requirements of the ASHRAE 15 Safety Code for Mechani- cal Refrigeration. Waterboxes shall be removable to permit tube cleaning and replacement. Stub-out wa- ter connections having ANSI/AWWA C-606 grooves to ANSI/AWWA C-606 Standard for Grooved End Shoulder Joints shall be provided. Waterboxes shall be designed for 150 psig (10.3 barg) design working pressure and be tested at 225 psig (15.5 barg). Vent and drain connections with plugs shall be provided on each waterbox. Low flow protection shall be provided by a thermal-type water flow sensor, factory mounted in the water nozzle connection and wired to the chiller control panel. CONDENSER Condenser shall be of the shell-and-tube type, designed for a minimum of 235 psig (16.2 barg) working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel plates with fusion-welded seams. Carbon steel tube sheets, drilled and reamed to accommodate the tubes, are welded to the end of each shell. Intermediate tube supports, fabricated from carbon steel plates, are drilled and reamed to eliminate sharp edges. The Guide Specifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 107 refrigerant side of each shell is designed, tested and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII – Division I, or other pressure vessel code as appropriate. Heat exchanger tubes shall be high efficiency, externally and internally enhanced type. Tubes shall utilize the “skip-fin” design, providing a smooth internal and external surface at each intermediate tube support. This provides extra wall thickness and non work-hard- ened copper at the support location, extending the life of the heat exchangers. If skip-fin tubes are not used, minimum tube wall thickness shall be 0.035 (~1 mm). Each tube shall be roller expanded into the tube sheets providing a leak-proof seal, and be individually replaceable. Water velocity through the tubes shall not exceed 12 ft. /sec. (3.7 m/sec.). A liquid level sight glass shall be provided on the side of the shell to aid in determining proper refrigerant charge and to check condition of the refrigerant charge. The condenser shall have dual refrigerant relief devices; each sized to meet the require- ments of the ASHRAE 15 Safety Code for Mechanical Refrigeration. Arrangement shall allow either valve to be isolated and replaced without removing the unit refrigerant charge. (Option) The condenser shall be provided with positive shutoff valves in the compressor discharge line to the condenser and in the liquid line leaving the condenser. This will allow pumpdown and storage of the refrigerant charge in the condenser. Due to the possibility of not seating properly, check valves are not acceptable for isolation purposes. If a check valve is used, a positive shutoff valve must be provided in series with the check valve. Waterboxes shall be removable to permit tube cleaning and replacement. Stubout water connections having ANSI/AWWA C-606 grooves shall be provided. Waterboxes shall be designed for 150 psig (10.3 barg) design working pressure and be tested at 225 psig (15.5 barg). Vent and drain connections with plugs shall be provided on each waterbox. REFRIGERANT FLOW CONTROL Refrigerant flow to the evaporator shall be controlled by a variable orifice. The variable ori- fice control shall automatically adjust to maintain proper refrigerant level in the condenser and evaporator. This shall be controlled by monitoring the refrigerant liquid level in the condenser, assuring optimal subcooler performance. OPTIVIEW CONTROL CENTER General – The chiller shall be controlled by a stand-alone, microprocessor based control center. The chiller control panel shall provide control of chiller operation and monitoring of chiller sensors, actuators, relays and switches. Control Panel – The control panel shall include a 10.4-in. (264 mm) diagonal color liquid crystal display (LCD) surrounded by “soft“ keys which are redefined based on the screen displayed at that time. This shall be mounted in the middle of a keypad interface and in- stalled in a locked enclosure. The screen shall detail all operations and parameters, using a graphical representation of the chiller and its major components. The panel verbiage is available in eight languages as standard and can be changed on the fly without having to turn off the chiller. Data shall be displayed in either English or Metric units. Smart Freeze Point Protection shall run the chiller at 36°F (2°C) leaving chilled water temperature, and not have nuisance trips on low water temperature. The sophisticated program and sensor shall monitor the chiller water temperature to prevent freeze-up. When needed, Hot Gas Bypass is available as an option. Guide Specifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 108 The panel shall display countdown timer messages so the operator knows when functions are starting and stopping. Every programmable point shall have a pop-up screen with the allowable ranges, so that the chiller cannot be programmed to operate outside of its design limits. The chiller control panel shall also provide: A. System operating information including: 1. Return and leaving chilled water temperature. 2. Return and leaving condenser water temperature. 3. Evaporator and condenser saturation temperature. 4. Differential oil pressure. 5. Percent motor current. 6. Compressor discharge temperature. 7. Oil reservoir temperature. 8. Compressor thrust bearing positioning and oil temperature. 9. Operating hours. 10. Number of unit starts. B. Digital programming of setpoints through the universal keypad including: 1. Leaving chilled water temperature. 2. Percent current limit. 3. Pull-down demand limiting. 4. Six-week schedule for starting and stopping the chiller, pumps and tower. 5. Remote reset temperature range. C. Status messages indicating: 1. System ready to start. 2. System running. 3. System coastdown. 4. System safety shutdown – manual restart. 5. System cycling shutdown – auto restart. 6. System pre-lube. 7. Start inhibit. D. The text displayed within the system status and system details field shall be displayed as a color-coded message to indicate severity: red for safety fault, orange for cycling faults, yellow for warnings, and green for normal messages. Guide Specifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 109 E. Safety shutdowns enunciated through the display and the status bar, and consist of system status, system details, day, time, cause of shutdown, and type of restart re- quired. Safety shutdowns with a fixed speed drive shall include: 1. Evaporator – low pressure. 2. Evaporator – transducer or leaving liquid probe. 3. Evaporator – transducer or temperature sensor. 4. Condenser – high pressure contacts open. 5. Condenser – high pressure. 6. Condenser – pressure transducer out-of-range. 7. Auxiliary safety – contacts closed. 8. Discharge – high temperature. 9. Discharge – low temperature. 10. Oil – high temperature. 11. Oil – low differential pressure. 12. Oil – high differential pressure. 13. Oil – sump pressure transducer out-of-range. 14. Oil – differential pressure calibration. 15. Oil – variable speed pump – pressure setpoint not achieved. 16. Control panel – power failure. 17. Motor or starter – current imbalance. 18. Thrust bearing – proximity probe clearance (K compressors only). 19. Thrust bearing – proximity probe out-of-range (K compressors only). 20. Thrust bearing – position switch (P, Q H9 compressors). 21. Watchdog – software reboot. F. Safety shutdowns with a VSD shall include: 1. VSD shutdown – requesting fault data. 2. VSD – stop contacts open. 3. VSD – 105% motor current overload. 4. VSD – high phase A, B, C inverter heat-sink temp. 5. VSD – high converter heat-sink temperature. Guide Specifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 110 (Filter Option Only) 6. Harmonic filter – high heat-sink temperature. 7. Harmonic filter – high total demand distribution. G. Cycling shutdowns enunciated through the display and the status bar, and consists of system status, system details, day, time, cause of shutdown, and type of restart required. Cycling shutdowns with a fixed speed drive shall include: 1. Multi-unit cycling – contacts open. 2. System cycling – contacts open. 3. Oil – low temperature differential. 4. Oil – low temperature. 5. Control panel – power failure. 6. Leaving chilled liquid – low temperature. 7. Leaving chilled liquid – flow switch open. 8. Motor controller – contacts open. 9. Motor controller – loss of current. 10. Power fault. 11. Control panel – schedule. 12. Starter – low supply line voltage (SSS option). 13. Starter – high supply line voltage (SSS option). 14. Proximity probe – low supply voltage (K compressors). 15. Oil – variable speed pump – drive contacts open. H. Cycling shutdowns with a VSD shall include: 1. VSD shutdown – requesting fault data. 2. VSD – stop contacts open. 3. VSD – initialization failed. 4. VSD – high phase A, B, C instantaneous current. 5. VSD – Phase A, B, C gate driver. 6. VSD – single phase input power. 7. VSD – high DC bus voltage. 8. VSD – pre charge DC bus voltage imbalance. 9. VSD – high internal ambient temperature. 10. VSD – invalid current scale selection. Guide Specifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 111 11. VSD – low phase A, B, C inverter heat-sink temp. 12. VSD – low converter heat-sink temperature. 13. VSD – pre-charge – low DC bus voltage. 14. VSD – logic board processor. 15. VSD – run signal. 16. VSD – serial communications. (Filter Option Only) 1. Harmonic filter – logic board or communications. 2. Harmonic filter – high DC bus voltage. 3. Harmonic filter – high phase A, B, C current. 4. Harmonic filter – phase locked loop. 5. Harmonic filter – pre-charge – low DC bus voltage. 6. Harmonic filter – DC bus voltage imbalance. 7. Harmonic filter – 110% input current overload. 8. Harmonic filter – logic board power supply. 9. Harmonic filter – run signal. 10. Harmonic filter – DC current transformer. 11. Harmonic filter – DC current transformer. I. Security access to prevent unauthorized change of setpoints, to allow local or remote control of the chiller, and to allow manual operation of the pre-rotation vanes and oil pump. Access shall be through ID and password recognition, which is defined by three different levels of user need: view, operator, and service. J. Trending data with the ability to customize points of once every second to once every hour. The panel shall trend up to 6 different parameters from a list of over 140, without the need of an external monitoring system. K. The operating program stored in non-volatile memory (EPROM) to eliminate repro- gramming the chiller due to AC power failure or battery discharge. Programmed setpoints shall be retained in lithium battery-backed RTC memory for a minimum of 10 years with power removed from the system. L. A fused connection through a transformer in the compressor motor starter to provide individual over-current protected power for all controls. M. A numbered terminal strip for all required field interlock wiring. N. An RS-232 port to output all system operating data, shutdown/cycling message, and a record of the last 10 cycling or safety shutdowns to a field-supplied printer. Data logs to a printer at a set programmable interval. This data can be preprogrammed to print from 1 minute to 1 day. Guide Specifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 112 O. The capability to interface with a building automation system via hard-wired connec- tions to each feature to provide: 1. Remote chiller start and stop. 2. Remote leaving chiller liquid temperature adjust. 3. Remote current limit setpoint adjust. 4. Remote ready to start contacts. 5. Safety shutdown contacts. 6. Cycling shutdown contacts. 7. Run contacts. VARIABLE SPEED DRIVE A variable speed drive shall be factory-installed on the chiller. It shall vary the compressor motor speed by controlling the frequency and voltage of the electrical power to the motor. The adaptive capacity control logic shall automatically adjust motor speed and compres- sor pre-rotation vane position independently for maximum part load efficiency by analyz- ing information fed to it by sensors located throughout the chiller. Drive shall be PWM type utilizing IGBTs with a displacement power factor of 0.95 or better at all loads and speeds. The variable speed drive shall be unit-mounted in a NEMA- 1 enclosure with all power and control wiring between the drive and chiller factory-installed, including power to the chiller oil pump. Field power wiring shall be a single-point connection and electrical lugs for incoming power wiring shall be provided. The entire chiller package shall be certified to standard UL-1995 by a nationally recognized testing laboratory. The variable speed drive is cooled by a closed loop, fresh water circuit consisting of a water-to water heat exchanger and circulating pump. All interconnecting water piping is factory installed and rated for 150 psig (10.3 barg) working pressure. The following features shall be provided: a door interlocked circuit breaker, capable of being padlocked; UL listed ground fault protection; overvoltage and under voltage protec- tion; 3-phase sensing motor overcurrent protection; single phase protection; insensitive to phase rotation; over temperature protection; digital readout at the chiller unit control panel of: • Output Frequency. • Output Voltage. • 3-phase output current. • Input Kilowatts (kW) and Kilowatt-hours (kWh). • Self diagnostic service parameters. Separate meters for this information shall not be acceptable. Guide Specifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 113 (Optional) A harmonic filter that limits electrical power supply distortion from the variable speed drive in order to help the building comply with the guidelines of IEEE STD. 519- 2014 shall be provided. The filter shall be unit mounted within the same NEMA 1 enclo- sure and shall be UL listed. The following digital readouts shall be provided at the chiller unit control panel as part of the filter package: • Input KVA. • Total power-factor. • 3-phase input voltage. • 3-phase input current. • 3-phase input voltage total harmonic distortion (THD). • 3-phase input current total demand distortion (TDD). • Self diagnostic service parameters. Separate meters for this information shall not be acceptable. FACTORY-INSTALLED COMPRESSOR MOTOR STARTER [OPTION THROUGH 900 HP (671 KW) 200 600 VOLTS] The chiller manufacturer shall furnish a reduced voltage Solid-State Starter for the com- pressor motor. Starter shall be factory mounted and wired on the chiller. The starter shall provide, through the use of silicon-controlled rectifiers, a smooth acceleration of the motor without current transitions or transients. The starter enclosure shall be NEMA 1, with a hinged access door with lock and key. Electrical lugs for incoming power wiring shall be provided. Standard Features include: digital readout at the OptiView Control Center of the following: Display Only • 3-phase voltage A, B, C. • 3-phase current A, B, C. • Input Power (kW). • kW Hours. • Starter Model. • Motor Run (LED). • Motor Current % Full Load Amps. • Current Limit Setpoints. • Pulldown Demand Time Left. Guide Specifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 114 Programmable • Local Motor Current Limit. • Pulldown Demand Limit. • Pulldown Demand Time. Other features include: low line voltage; 115-volt control transformer; three-leg sensing overloads; phase rotation and single-phase failure protection; high temperature safety protection; motor current imbalance and under voltage safeties; open and close SCR protection; momentary power interruption protection. The Solid-State Starter is cooled by a closed loop, fresh water circuit consisting of a water-to-water heat exchanger and cir- culating pump. All interconnecting water piping is factory-installed and rated for 150 psig (10.3 barg) working pressure. (Optional) Unit-mounted circuit breaker includes ground fault protection and provides 65,000 amps. Short circuit withstand rating in accordance with UL Standard 508. A non- fused disconnect switch is also available. Both options have keyed locks for safety. FACTORY-INSTALLED COMPRESSOR MOTOR STARTER (2300V 4160V/3/60HZ OR 3300V/3/50HZ- UNIT MOUNTED FOR H9 COMPRESSOR OR LARGER ONLY) The chiller manufacturer shall furnish a reduced-volt-age, Medium Voltage Solid-State Starter, in accordance with the chiller manufacturer’s starter specifications. The starter shall be of modular construction with complete access to all parts. The starter shall be tested and the design starting current and overload settings adjusted at the factory. The starter shall provide, through the use of six in-line (not inside the Delta) silicon controlled rectifiers (2 per phase), a smooth acceleration of the motor without current transitions or transients. The following protective devices and convenience items shall be factory mounted and wired to the starter: A. 3-leg sensing electronic overloads – shuts unit down if current exceeds 105% of FLA to protect the motor windings. B. Phase rotation protection circuit – denies start-up when detecting incorrect power wir- ing phase sequence to the starter which could cause reverse motor rotation and dam- age the equipment. C. Single-phase failure protection circuit – ensures against motor burnout by shutting the unit down if power loss occurs in any of the incoming lines during start-up. D. High temperature safety protection system – temperature activated switches on heat sinks will shut the unit down if the SCR temperature exceeds acceptable limits. E. 3-phase digital ammeter and digital voltmeter readout via control center – easily cross- check design current and voltage limitations against supply characteristics. F. Starter mounted load break rated input disconnect switch with interlocked lockable handle. Positive disconnecting means shall be visible from outside the enclosure, in operator area. All doors shall be interlocked with the disconnecting means. G. Open/Shorted SCR Protection – Failed semiconductor devices are automatically de- tected and reported via the Control Center. Guide Specifications (Cont'd)
FORM 160.75-EG1 (915) JOHNSON CONTROLS 115 H. Power Fault Protection – momentary power interruption protection detects power in- terruptions within 3 line cycles and interrupts power to the compressor motor within 1 additional line cycle. I. Electrical Connections – these tin-plated or copper bus bars provide easy connection to incoming copper power lines. J. Wattmeter – An instantaneous wattmeter tells the customer how much power the chill- er is consuming. A kilowatt-hour energy meter is also provided to measure power con- sumption over a period of time. K. Shutdown History – The Medium Voltage Solid-State Starter shall provide the system control panel with ten histories of previous unit shutdowns initiated by the starter. In addition, the Starter shall include as standard, the following convenience items already mounted and wired to the starter at the factory: • Auxiliary control supply transformer – eliminates the need for running separate 115V- 1 phase-50/60 Hz power source wiring to the chiller Control Center. REMOTE ELECTRO-MECHANICAL COMPRESSOR MOTOR STARTER (OPTION) A remote electro-mechanical starter of the R-1132 type shall be furnished for each com- pressor motor. The starter shall be furnished in accordance with the chiller manufacturer’s starter specifications and as specified elsewhere in these specifications. PORTABLE REFRIGERANT STORAGE/RECYCLING SYSTEM A portable, self-contained refrigerant storage/recycling system shall be provided consist- ing of a refrigerant compressor with oil separator, storage receiver, water-cooled condens- er, filter drier and necessary valves and hoses to remove, replace and distill refrigerant. All necessary controls and safety devices shall be a permanent part of the system. Guide Specifications (Cont'd)
JOHNSON CONTROLS FORM 160.75-EG1 (915) 116 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. TEMPERATURE To convert degrees Fahrenheit (°F) to degrees Celsius (°C), subtract 32° and multiply by 5/9 or 0.5556. To convert a temperature range (i.e., 10°F or 12°F chilled water range) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556. EFFICIENCY In the English l‑P system, chiller efficiency is measured in kW / ton: kW/ton = kW input tons refrigeration effect In the Sl Metric system, chiller efficiency is measured in Coefficient of Performance (COP). kW/ton = kW input kW refrigeration effect kW / ton and COP are related as follows: kW/ton = 3.516 COP COP = 3.516 kW/ton SI Metric Conversion MEASUREMENT MULTIPLY THIS ENGLISH  VALUE BY TO OBTAIN THIS METRIC VALUE CAPACITY TONS REFRIGERANT EFFECT (ton) 3.516 KILOWATTS (kW) POWER KILOWATTS (kW) NO CHANGE KILOWATTS (kW) HORSEPOWER (hp) 0.7457 KILOWATTS (kW) FLOW RATE GALLONS / MINUTE (gpm) 0.0631 LITERS / SECOND (L/s) LENGTH FEET (ft) 304.8 MILLIMETERS (mm) INCHES (in) 25.4 MILLIMETERS (mm) WEIGHT POUNDS (lb) 0.4536 KILOGRAMS (kg) VELOCITY FEET / SECOND (fps) 0.3048 METERS / SECOND (m/s) PRESSURE DROP FEET OF WATER (ft) 2.989 KILOPASCALS (kPa) POUNDS / SQ. INCH (psi) 6.895 KILOPASCALS (k Pa) FOULING FACTOR ENGLISH l‑P (fT2 °F hr/Btu) EQUIVALENT Sl METRIC (m2 k/kW) 0.0001 0.018 0.00025 0.044 0.0005 0.088 0.00075 0.132
FORM 160.75-EG1 (915) JOHNSON CONTROLS 117
Printed on recycled paper Form 160.75-EG1 (915) Supersedes:160.75-EG1 (615) © 2015 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI  53201 Printed in USA www.johnsoncontrols.com Issued on 09/09/2015

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BE_YK_EngineeringGuide_G

  • 1. FORM 160.75-EG1 (915) MODEL YK CENTRIFUGAL LIQUID CHILLERS STYLE G 250 THROUGH 3000 TONS (879 through 10,500 kW) Utilizing HFC-134a
  • 2. JOHNSON CONTROLS FORM 160.75-EG1 (915) 2 Approvals See CODES AND STANDARDS on page 21 for Approvals. Nomenclature COMPRESSOR CODE YK ED ER Q7 - ES G S MOTOR CODE POWER SUPPLY - for 60Hz 5 for 50Hz DESIGN LEVEL CONDENSER CODE EVAPORATOR CODE UNIT TYPE YORK YK Centrifugal Chiller SPECIAL Dimensions in this guide are English (SI)
  • 3. FORM 160.75-EG1 (915) JOHNSON CONTROLS 3 Table Of Contents INTRODUCTION....................................................................................................................................................... 5 SUSTAINABILITY FOCUS....................................................................................................................................... 9 EQUIPMENT OVERVIEW....................................................................................................................................... 13 OPTIVIEW CONTROL CENTER............................................................................................................................ 24 ACCESSORIES AND MODIFICATIONS................................................................................................................ 32 APPLICATION DATA.............................................................................................................................................. 44 DIMENSIONS.......................................................................................................................................................... 76 WEIGHTS................................................................................................................................................................ 99 GUIDE SPECIFICATIONS.................................................................................................................................... 101 SI METRIC CONVERSION................................................................................................................................... 114
  • 4. JOHNSON CONTROLS FORM 160.75-EG1 (915) 4 THIS PAGE INTENTIONALLY LEFT BLANK.
  • 5. FORM 160.75-EG1 (915) JOHNSON CONTROLS 5 The YORK YK Chillers, manufactured by Johnson Controls, offer a complete combination of features for total owner satisfaction. MATCHED COMPONENTS MAXIMIZE EFFICIENCY Actual chiller efficiency cannot be determined by analyzing the theoretical efficiency of any one chiller component. It requires a specific combination of heat exchanger, com- pressor, and motor performance to achieve the lowest system kW/ton. YORK chiller tech- nology matches chiller system components to provide maximum chiller efficiency under actual – not just theoretical – operating conditions. REAL-WORLD ENERGY PERFORMANCE Johnson Controls pioneered the concept of “Real-World Energy” to illustrate the energy- saving potential of focusing on chiller performance during off-design conditions. Off-de- sign is not only part load, but full load operation as well, with reduced entering condenser water temperatures (ECWTs). This is where chillers operate 99% of the time, and where operating costs add up. The YORK YK chillers are the only chillers designed to operate on a continuous basis with cold ECWT and full condenser flow at all load points, taking full advantage of Real- World conditions. This type of operation benefits the cooling tower as well by reducing the cycling of the fan motor and ensuring good coverage of the cooling fill. YORK YK chillers offer the most efficient Real-World operation of any chiller, meaning lower operating costs and an excellent return on your chiller investment. OPEN-DRIVE DESIGN Hermetic motor burnout can cause catastrophic damage to a chiller. The entire chiller must be cleaned, and the refrigerant replaced. YORK YK centrifugal chillers eliminate this risk by utilizing air-cooled motors. Refrigerant never comes in contact with the motor, preventing contamination of the rest of the chiller. Insurance companies that offer policies on large air conditioning equipment often consider air-cooled motors a significant advantage over hermetic refrigerant-cooled units. HIGH EFFICIENCY HEAT EXCHANGERS YORK YK chiller heat exchangers offer the latest technology in heat transfer surface de- sign to give you maximum efficiency and compact design. Waterside and refrigerant side design enhancements minimize both energy consumption and tube fouling. Introduction
  • 6. JOHNSON CONTROLS FORM 160.75-EG1 (915) 6 SINGLE STAGE COMPRESSOR DESIGN AND EFFICIENCY PROVEN IN THE MOST DEMANDING APPLICATIONS Designed to be the most reliable chillers we’ve ever made, YORK YK centrifugal chill- ers incorporate single-stage compressor design. With fewer moving parts and straight- forward, efficient engineering, YORK single-stage compressors have proven durability records in hospitals, chemical plants, gas processing plants, the U.S. Navy, and in other applications where minimal downtime is a crucial concern. In thousands of installations worldwide, YORK single-stage compressors are working to reduce energy costs. High strength aluminum-alloy compressor impellers feature back- ward curved vanes for high efficiency. Airfoil shaped pre rotation vanes minimize flow dis- ruption for the most efficient part load performance. Precisely positioned and tightly fitted, they allow the compressor to unload smoothly from 100% to minimum load for excellent operation in air conditioning applications. AHRI CERTIFICATION PROGRAM YORK YK chillers have been tested and certified by Air-Conditioning, Heating and Refrigeration Institute (AHRI) in accordance with the latest edition of AHRI Standard 550/590 (I-P). Under this Certification Program, chillers are regularly tested in strict compliance with this Standard. This provides an independent, third-party verification of chiller performance. Refer to the AHRI site at: http://www.ahrinet.org/water_ chilling+packages+using+vap or+compression+cycle+_water_cooled_.aspx for complete Program Scope, Inclusions, and Exclusions as some options listed herein fall outside the scope of the AHRI certification program. For verification of certification, go to the AHRI Directory at www.ahridirectory.org. PRECISION CONTROL OF COMPRESSOR OIL PRESSURE Utilizing our expertise in variable speed drive technology and applications, Johnson Con- trols has moved beyond the fixed head and bypass approach of oil pressure control. The old approach only assures oil pressure at the outlet of the pump rather than at the com- pressor, and allows no adjustment during chiller operation. The YORK YK chillers feature a variable speed drive oil pump, monitoring and providing the right amount of oil flow to the compressor on a continuous basis. This design also provides sophisticated electronic monitoring and protection of the oil pump electrical supply, ensuring long life and reliable operation of the oil pump motor. Variable speed drive technology reduces oil pump power consumption, running only at the speed required, rather than at full head with a pressure regulating bypass valve. Introduction (Cont'd)
  • 7. FORM 160.75-EG1 (915) JOHNSON CONTROLS 7 Introduction (Cont'd) FACTORY PACKAGING REDUCES FIELD LABOR COSTS YORK YK centrifugal chillers are designed to keep installation costs low. Where instal- lation access is not a problem, the unit can be shipped completely packaged, requiring minimal piping and wiring to complete the installation. For those units utilizing Variable Speed Drive or a factory-installed Solid-State Starter, the three power leads provide all power to the chiller and its auxiliaries. TAKE ADVANTAGE OF COLDER COOLING TOWER WATER TEMPERATURES YORK YK centrifugal chillers have been designed to take full advantage of colder cool- ing tower water temperatures, which are naturally available during most operating hours. Considerable energy savings are available by letting tower water temperature drop, rather than artificially holding it above 75°F (23.9°C), especially at low load, as some chillers require. UL COMPLIANCE  –  YOUR ASSURANCE OF RELIABILITY YORK YK centrifugal chillers are approved to UL Standard 1995 for listing by a qualified nationally recognized testing laboratory for the United States and Canada. Recognition of safety and reliability is your assurance of trouble free performance in day to-day building operation. Some chiller options or modifications may affect the UL compliance of the chiller. Some examples include: special motor enclosures ( like TEFC, TEWAC, or TEAAC) or special panels (NEMA 4X) or special unit wiring options (anything other than NEMA 1). For further clarification, contact Johnson Controls Large Tonnage Marketing. COMPUTERIZED PERFORMANCE RATINGS Each chiller is custom matched to meet the individual building load and energy require- ments. A large number of standard heat exchangers and pass arrangements are available to provide the best possible match. It is not practical to provide tabulated performance for each combination, as the energy requirements at both full and part load vary significantly with each heat exchanger and pass arrangement. Computerized ratings are available through each Johnson Controls Sales Office. These ratings can be tailored to specific job requirements, and are part of the AHRI Certification Program.
  • 8. JOHNSON CONTROLS FORM 160.75-EG1 (915) 8 OFF-DESIGN PERFORMANCE Since the vast majority of its operating hours are spent 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 temperatures. It is not uncommon for chill- ers with the same full load kW/ton to have an operating cost difference of over 10% due to part load operation. Part load information can be easily and accurately generated by use of the computer. And because it is so important 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 provide a more accurate indication of chiller performance than the previous IPLV/APLV formula. A more detailed analysis must take into account actual building load profiles, and local weather data. Part load performance data should be ob- tained for each job using its own design criteria. Introduction (Cont'd)
  • 9. FORM 160.75-EG1 (915) JOHNSON CONTROLS 9 OZONE-DEPLETION POTENTIAL (ODP) The YORK YK chiller employs one the most environmentally friendly refrigerants available today, HFC-134a, with no Ozone Depletion Potential (ODP) and no phase out date per the Montreal Protocol. Ozone is a very small part of the atmosphere, but its presence is nevertheless vital to human well-being. Most ozone resides in the upper part of the atmosphere. This region, called the stratosphere, is more than 10 kilometers (6 miles) above the Earth’s surface. There, about 90% of atmospheric ozone is contained in the “ozone layer,” which shields us from harmful ultraviolet radiation from the sun. However, it was discovered in the mid- 1970s that some human-produced chemicals could destroy ozone and deplete the ozone layer. The resulting increase in ultraviolet radiation at the Earth’s surface may increase the incidences of skin cancer and eye cataracts. Following the discovery of this environmental issue, researchers focused on gaining a better understanding of this threat to the ozone layer. Sustainability Focus Table 1 - GLOBAL REFRIGERANT USAGE REFRIGERANT COMMON USE ODP GWP STATUS 2007 GLOBAL USAGE (TONS) CFC CFC-11 Centrifugals 1.00 5000 Phased Out Trace CFC-12 Centrifugals 0.80 8500 Phased Out Trace HCFC HCFC-22 Scrolls, Screws, Unitary products 0.05 1700 Phasing Out 700,000 HCFC-123 Centrifugals 0.02 120 Phasing Out 4,000 HFC HFC-134a Centrifugals, Screws - 1300 No Phase Out 250,000 HFC-407c Screws, Scrolls - 1600 No Phase Out 100,000 HFC-410A Scrolls, Unitary products - 1890 No Phase Out HFC-404A - 3750 No Phase Out HFC-245fa Centrifugals - 1020 No Phase Out Trace HFO HFO-1234yf Centrifugals - 4 No Phase Out New HC(NaturalRefr.) HC-717 (NH3) Screws, Centrifugals - 1 No Phase Out HC-718 (water) Absorption, Vapor Compression - 0 No Phase Out HC-290 (propane) - 3 No Phase Out HC-600a (butane) - 3 No Phase Out HC-744 (CO2 ) - 1 No Phase Out
  • 10. JOHNSON CONTROLS FORM 160.75-EG1 (915) 10 Monitoring stations showed that ozone-depleting chemicals were steadily increasing in the atmosphere. These trends were linked to growing production and use of chemicals like chlorofluorocarbons (CFCs) for refrigeration and air conditioning, foam blowing, and industrial cleaning. Measurements in the laboratory and the atmosphere characterized the chemical reactions that were involved in ozone destruction. Computer models em- ploying this information could predict how much ozone depletion was occurring and how much more could occur in the future. Observations of the ozone layer showed that depletion was indeed occurring. The most severe and most surprising ozone loss was discovered to be recurring in springtime over Antarctica. The loss in this region is commonly called the “ozone hole” because the ozone depletion is so large and localized. A thinning of the ozone layer also has been observed over other regions of the globe, such as the Arctic and northern middle latitudes. The work of many scientists throughout the world has provided a basis for building a broad and solid scientific understanding of the ozone depletion process. With this understanding, we know that ozone depletion is occurring and why. And, most important, we know that if ozone-depleting gases were to continue to accumulate in the atmosphere, the result would be more depletion of the ozone layer. In response to the prospect of increasing ozone depletion, the governments of the world crafted the 1987 United Nations Montreal Protocol as a global means to address this global issue. As a result of the broad compli- ance with the Protocol and its Amendments and Adjustments and, of great significance, industry’s development of “ozone friendly” substitutes for the now-controlled chemicals, the total global accumulation of ozone-depleting gases has slowed and begun to de- crease. This has reduced the risk of further ozone depletion. THE MONTREAL PROTOCOL ADDRESSED CFC’S AND HCFC’S The Montreal Protocol (MP) addressed CFC’s and HCFC’s with phase out schedule for all member parties of the MP based on the ODP characteristics. So this affects the first two categories of refrigerants listed in the table. Manufacturers in developed nations are in the final processes of converting from HCFC’s to HFC’s in accordance with the Montreal Protocol treaty. Markets in developing countries are already seeing a transition away from HCFC’s ahead of legislative requirements. HCFC’s were used as a transitional refrigerant as they were a “Lesser Evil” and allowed the HVAC industry to quickly transition away from CFCs while maintaining energy efficien- cy. The fact remains that they destroy the ozone layer and are legislated to be completely phased out. The Montreal Protocol does not extend to HFC’s as they have no ODP nor does it extend to natural refrigerants for the same reason. The typical usage of the refrigerant, the phase-out status by the Montreal Protocol and the global usage of refrigerant in tons is shown in the table on page 11. The chart on page 11 shows the growing use of HFC-134a in centrifugal chillers from 1995 up to 2010 and the forecast until the phase-out of HCFC’s. Sustainability Focus (Cont'd)
  • 11. FORM 160.75-EG1 (915) JOHNSON CONTROLS 11 Sustainability Focus (Cont'd) '' CFC-11 CFC-12 HCFC-22 ''# HCFC-123 HFC-134a HCFC-22 CFC-11 CFC-12 HCFC-123 HFC-134a HCFC-22 HCFC-123 HFC-134a HCFC-22 HFC-134a New Low GWP HCFC-123 CFC-11 CFC-12 HCFC-22 HCFC-123 HFC-134a New Low GWP GLOBAL WARMING POTENTIAL (GWP) Another main environmental topic is Global Warming potential (GWP), and when we talk about global warming we’re primarily talking about smoke stacks and tail pipes. 85% of GWP is attributed to CO2 emissions, while only about 2% is related to HFC’s. However, when we talk about the direct impact our YORK YK Centrifugal Chiller has on the environment we can make strides forward, like ensuring leak tight designs are cre- ated, and manufacturers are working to reduce refrigerant charges as much as possible. CO2 85% CH4 8% N2O 5% PFCs, SF6 1% HFC 2% Figure 1 - USAGE OF HFC-134A Figure 2 - CO2 EMISSIONS
  • 12. JOHNSON CONTROLS FORM 160.75-EG1 (915) 12 DIRECT INDIRECT GLOBAL WARMING POTENTIAL 98% of the global warming potential of a centrifugal chiller is from the indirect effect or the greenhouse gases produced to generate the electricity to run the chiller. The YORK YK centrifugal chiller and its superior efficiency levels dramatically reduces the indirect GWP. Two percent of the GWP is from the direct effect or release of the refrigerant gases into the atmosphere. , Minimizing the total climatic impact (direct and indirect GWP) requires a comprehensive approach to refrigerant choice. Sustainability Focus (Cont'd) Figure 3 - DIRECT AND INDIRECT GLOBAL WARMING POTENTIAL
  • 13. FORM 160.75-EG1 (915) JOHNSON CONTROLS 13 YORK YK chillers are completely factory-packaged including the evaporator, condenser, compressor, motor, lubrication system, control center, and all interconnecting unit piping and wiring. The initial charge of refrigerant and oil is supplied for each chiller. When the optional con- denser isolation valves are ordered, most units may ship fully charged with refrigerant and oil. Actual shipping procedures will depend on a number of project-specific details. The services of a Johnson Controls factory-trained, field service representative are in- curred to supervise or perform the final leak-testing, charging, the initial start-up, and concurrent operator instructions. COMPRESSOR The compressor is a single stage centrifugal type, powered by an open drive electric mo- tor. The casing is fully accessible with vertical circular joints and fabricated of close grain cast iron. The complete operating assembly is removable from the compressor and scroll housing. The rotor assembly consists of a heat treated alloy steel drive shaft and impeller shaft with a high strength, cast aluminum alloy, fully shrouded impeller. The impeller is designed for balanced thrust and is dynamically balanced and overspeed tested for smooth, vibration free operation. Each impeller receives a special finishing treatment that improves aerody- namic performance. The insert-type journal and thrust bearings are fabricated of aluminum alloy and are precision bored and axially grooved. The specially engineered, single helical gears with crowned teeth are designed so that more than one tooth is in contact at all times to pro- vide even distribution of compressor load and quiet operation. Gears are assembled as part of the compressor rotor support and are film lubricated. Each gear is individually mounted in its own journal and thrust bearings to isolate it from impeller and motor forces. CAPACITY CONTROL Pre-rotation vanes (PRV) modulate chiller capacity from 100% to 15% of design for nor- mal air conditioning applications. Operation is by an external, electric PRV actuator which automatically controls the vane position to maintain a constant leaving chilled liquid tem- perature. Rugged airfoil-shaped, cast-manganese-bronze vanes are precisely positioned by solid vane linkages connected to the electric actuator. LUBRICATION SYSTEM Lubrication oil is force-fed to all bearings, gears and rotating surfaces by a variable speed drive pump which operates prior to startup, continuously during operation and during coastdown. A gravity fed oil reservoir is built into the top of the compressor to provide lubrication during coastdown in the event of a power failure. An oil reservoir, separate from the compressor, contains the submersible oil pump, 2 HP (1.5 kW) pump motor and 3000 watt immersion type oil heater. The oil heater is thermo- statically controlled to remove refrigerant from the oil. Equipment Overview
  • 14. JOHNSON CONTROLS FORM 160.75-EG1 (915) 14 Oil is filtered by an externally mounted 1/2 micron replaceable cartridge oil filter equipped with service valves. Oil is cooled via a refrigerant-cooled oil cooler, eliminating the require- ment for field water piping. The oil side of the oil cooler is provided with service valves. An automatic oil return system recovers any oil that may have migrated to the evaporator. Oil piping is completely factory-installed. WATER-COOLED OIL COOLER An optional condenser water-cooled oil cooler is offered for units with Q3 compressors C-D shells only. This oil cooler is a shell and tube heat exchanger. Water from condenser supply waterbox circulates through the tube side of the heat exchanger and discharges back into the return side of the waterbox. Hot oil circulates through the tubes within the oil cooler, and is cooled by the cold condenser water. The cooled oil is then sent back to the compressor through a temperature regulator valve and oil filters. Both the oil and water piping are completely factory-installed, eliminating the requirement for field piping. MOTOR DRIVELINE The compressor motor is an open drip proof, squirrel cage, induction type constructed to YORK design specifications. The 60 hertz motors operate at 3570 rpm and the 50 hertz motors operate at 2975 rpm. The open motor is provided with a D flange, and is factory-mounted to a cast iron adaptor mounted on the compressor. This unique design allows the motor to be rigidly coupled to the compressor to provide factory alignment of motor and compressor shafts. Motor drive shaft is directly connected to the compressor shaft with a flexible disc cou- pling. Coupling has all metal construction with no wearing parts to assure long life, and no lubrication requirements to provide low maintenance. For units utilizing remote electro-mechanical starters, a large, steel terminal box with gas- keted front access cover is provided for field-connected conduit. There are six terminals (three for medium voltage) brought through the motor casing into the terminal box. Jump- ers are furnished for three-lead types of starting. Motor terminal lugs are not furnished. Overload/over-current transformers are furnished with all units. For units furnished with factory-packaged Solid-State Starters or Variable Speed Drive, refer to the Accessories and Modifications on page 32. HEAT EXCHANGERS Shells Evaporator and condenser shells are fabricated from rolled carbon steel plates with fu- sion welded seams or carbon steel pipe. Carbon steel tube sheets, drilled and reamed to accommodate the tubes, are welded to the end of each shell. Intermediate tube supports are fabricated from carbon steel plates, drilled and reamed to eliminate sharp edges, and spaced no more than four feet apart. The refrigerant side of each shell is designed, tested, and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII – Division I, or other pressure vessel code as appropriate. Equipment Overview (Cont'd)
  • 15. FORM 160.75-EG1 (915) JOHNSON CONTROLS 15 Tubes Heat exchanger tubes are state-of-the-art, high-efficiency, externally and internally en- hanced type to provide optimum performance. Tubes in both the evaporator and con- denser are 3/4 (19 mm) O.D. standard [or 1 (25.4 mm) optional in some shells] copper alloy and utilize the “skip-fin” design, providing a smooth internal and external surface at each intermediate tube support. This provides extra wall thickness (up to twice as thick) and non work-hardened copper at the support location, extending the life of the heat ex- changers. Each tube is roller expanded into the tube sheets providing a leak-proof seal, and is individually replaceable. Evaporator The evaporator is a shell and tube type with customer process fluid flowing inside the tubes and refrigerant removing heat on the shell side via evaporation. Evaporator codes A_ thru Q_ utilize a hybrid falling film design. It contains a balance of flooded and falling film technology to optimize efficiency, minimize refrigerant charge, and maintain reliable control. A specifically designed spray distributor provides uniform distribution of refriger- ant over the entire length to yield optimum heat transfer. The hybrid falling film evaporator design has suction baffles around the sides and above the falling film section to prevent liquid refrigerant carryover into the compressor. Evaporator codes R_ thru Z_ are flooded type, with a liquid inlet distributor trough under- neath the tube bundle. This provides uniform distribution of refrigerant over the entire shell length to yield optimum heat transfer. Flooded evaporator designs have an aluminum mesh eliminator on R_ thru Z_ shells located above the tube bundle to prevent liquid re- frigerant carryover into the compressor. A 1-1/2 (38 mm) liquid level sight glass is conveniently located on the side of the shell to aid in determining proper refrigerant charge. The evaporator shell contains a dual refrig- erant relief valve arrangement set at 180 psig (12.4 barg) on H and K compressor models; 235 psig (16.2 barg) on P and Q compressor models; or single-relief valve arrangement, if the chiller is supplied with optional refrigerant isolation valves. A 1 (25.4 mm) refrigerant charging valve is provided. Condenser The condenser is a shell and tube type, with a discharge gas baffle to prevent direct high velocity impingement on the tubes. The baffle is also used to distribute the refrigerant gas flow properly for most efficient heat transfer. An optional cast steel condenser inlet diffuser may be offered, on M and larger condensers, in lieu of the baffle, to provide dynamic pressure recovery and enhanced chiller efficiency. An integral sub cooler is located at the bottom of the condenser shell providing highly effective liquid refrigerant subcooling to provide the highest cycle efficiency. The condenser contains dual refrigerant relief valves set at 235 psig (16.2 barg). Waterboxes The removable waterboxes are fabricated of steel. The design working pressure is 150 psig (10.3 barg) and the boxes are tested at 225 psig (15.5 barg). Integral steel water baffles are located and welded within the waterbox to provide the required pass arrange- ments. Stub out water nozzle connections with ANSI/AWWA C-606 grooves are welded to the waterboxes. These nozzle connections are suitable for ANSI/AWWA C-606 couplings, welding or flanges, and are capped for shipment. Plugged 3/4 (19 mm) drain and vent connections are provided in each waterbox. Equipment Overview (Cont'd)
  • 16. JOHNSON CONTROLS FORM 160.75-EG1 (915) 16 WATER FLOW SWITCHES Thermal type water flow switches are factory mounted in the chilled and condenser water nozzles, and are factory wired to the OptiView control panel. These solid-state flow sen- sors have a small internal heating-element. They use the cooling effect of the flowing fluid to sense when an adequate flow rate has been established. The sealed sensor probe is 316 stainless steel, which is suited to very high working pressures. OPTIVIEW CONTROL CENTER The chiller is controlled by a stand-alone microprocessor based control center. The chiller control panel provides control of chiller operation and monitoring of chiller sensors, actua- tors, relays and switches. Control Panel The control panel includes a 10.4-in. (264 mm) diagonal color liquid crystal display (LCD) surrounded by “soft” keys 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 operations and parameters, using a graphical representation of the chiller and its major components. Panel verbiage is available in eight languages and can be changed on the fly without having to turn off the chiller. Data can be displayed in either English or Metric units. Smart Freeze Point Protection will run the chiller at 36°F (2.2°C) leaving chilled water temperature, and not have nuisance trips on low water temperature. The sophisticated program and sensor monitors the chiller water temperature to prevent freeze-up. When needed, Hot Gas Bypass is available as an option. The panel displays countdown timer messages so the operator knows when functions are starting and stop- ping. Every programmable point has a pop-up screen with the allowable ranges, so that the chiller cannot be programmed to operate outside of its design limits. The chiller control panel also provides: A. System operating information including: 1. Return and leaving chilled water temperature. 2. Return and leaving condenser water temperature. 3. Evaporator and condenser saturation pressure. 4. Differential oil pressure. 5. Percent motor current. 6. Evaporator and condenser saturation temperature. 7. Compressor discharge temperature. 8. Oil reservoir temperature. 9. Compressor thrust bearing positioning (K compressors only). 10. Operating hours. 11. Number of compressor starts. Equipment Overview (Cont'd)
  • 17. FORM 160.75-EG1 (915) JOHNSON CONTROLS 17 B. Digital programming of setpoints through the universal keypad including: 1. Leaving chilled water temperature. 2. Percent current limit. 3. Pulls-down demand limiting. 4. Six-week schedule for starting and stopping the chiller, pumps and tower. 5. Remote reset temperature range. C. Status messages indicating: 1. System ready to start. 2. System running. 3. System coastdown. 4. System safety shutdown – manual restart. 5. System cycling shutdown – auto restart. 6. System pre-lube. 7. Start inhibit. D. The text displayed within the system status and system details field is displayed as a color-coded message to indicate severity: red for safety fault, orange for cycling faults, yellow for warnings, and green for normal messages. E. Safety shutdowns enunciated through the display and the status bar, and consist of system status, system details, day, time, cause of shutdown, and type of restart re- quired. Safety shutdowns with a fixed-speed- drive include: 1. Evaporator – low pressure. 2. Evaporator – transducer or leaving liquid probe. 3. Evaporator – transducer or temperature sensor. 4. Condenser – high pressure contacts open. 5. Condenser – high pressure. 6. Condenser – pressure transducer out-of-range. 7. Auxiliary safety – contacts closed. 8. Discharge – high temperature. 9. Discharge – low temperature. 10. Oil – high temperature. 11. Oil – low differential pressure. 12. Oil – high differential pressure. Equipment Overview (Cont'd)
  • 18. JOHNSON CONTROLS FORM 160.75-EG1 (915) 18 13. Oil – sump pressure transducer out-of-range. 14. Oil – differential pressure calibration. 15. Oil – variable speed pump – pressure setpoint not achieved. 16. Control panel – power failure. 17. Motor or starter – current imbalance. 18. Thrust bearing – proximity probe clearance (K compressors only). 19. Thrust bearing – proximity probe out-of-range (K compressors only). 20. Thrust bearing – position switch (P, Q H9 compressors). 21. Watchdog – software reboot. F. Safety shutdowns with a VSD include: 1. VSD shutdown – requesting fault data. 2. VSD – stop contacts open. 3. VSD – 105% motor current overload. 4. VSD – high phase A, B, C inverter heat-sink temp. 5. VSD – high converter heat-sink temperature (Filter Option Only). 6. Harmonic filter – high heat-sink temperature. 7. Harmonic filter – high total demand distortion. G. Cycling shutdowns enunciated through the display and the status bar, and consists of system status, system details, day, time, cause of shutdown, and type of restart required. H. Cycling shutdowns with a fixed speed drive include: 1. Multi unit cycling – contacts open. 2. System cycling – contacts open. 3. Oil – low temperature differential. 4. Oil – low temperature. 5. Control panel – power failure. 6. Leaving chilled liquid – low temperature. 7. Leaving chilled liquid – flow switch open. 8. Motor controller – contacts open. 9. Motor controller – loss of current. 10. Power fault. 11. Control panel – schedule. 12. Starter – low supply line voltage (SSS option). Equipment Overview (Cont'd)
  • 19. FORM 160.75-EG1 (915) JOHNSON CONTROLS 19 13. Starter – high supply line voltage (SSS option). 14. Proximity probe – low supply voltage (K Compressor). 15. Oil – variable speed pump – drive contacts open. I. Cycling shutdowns with a VSD include: 1. VSD shutdown – requesting fault data. 2. VSD – stop contacts open. 3. VSD – initialization failed. 4. VSD – high phase A, B, C instantaneous current. 5. VSD – phase A, B, C gate driver. 6. VSD – single phase input power. 7. VSD – high DC bus voltage. 8. VSD – precharge DC bus voltage imbalance. 9. VSD – high internal ambient temperature. 10. VSD – invalid current scale selection. 11. VSD – low phase A, B, C inverter heat-sink temp. 12. VSD – low converter heat-sink temperature. 13. VSD – precharge – low DC bus voltage. 14. VSD – logic board processor. 15. VSD – run signal. 16. VSD – serial communications (Filter Option Only). 17. Harmonic filter – logic board or communications. 18. Harmonic filter – high DC bus voltage. 19. Harmonic filter – high phase A, B, C current. 20. Harmonic filter – phase locked loop. 21. Harmonic filter – precharge – low DC bus voltage. 22. Harmonic filter – DC bus voltage imbalance. 23. Harmonic filter – 110% input current overload. 24. Harmonic filter – logic board power supply. 25. Harmonic filter – run signal. 26. Harmonic filter – DC current transformer 1. 27. Harmonic filter – DC current transformer 2. Equipment Overview (Cont'd)
  • 20. JOHNSON CONTROLS FORM 160.75-EG1 (915) 20 J. Security access to prevent unauthorized change of setpoints, to allow local or remote control of the chiller, and to allow manual operation of the pre-rotation vanes and oil pump. Access is through ID and password recognition, which is defined by three differ- ent levels of user competence: view, operator, and service. K. Trending data with the ability to customize points of once every second to once every hour. The panel will trend up to 6 different parameters from a list of over 140, without the need of an external monitoring system. L. The operating program stored in non-volatile memory (EPROM) to eliminate repro- gramming the chiller due to AC power failure or battery discharge. Programmed setpoints are retained in lithium battery-backed RTC memory for a minimum of 5 years with power removed from the system. M. A fused connection through a transformer in the compressor motor starter to provide individual over-current protected power for all controls. N. A numbered terminal strip for all required field interlock wiring. O. An RS-232 port to output all system operating data, shutdown/cycling message, and a record of the last 10 cycling or safety shutdowns to a field-supplied printer. Data logs to a printer at a set programmable interval. This data can be preprogrammed to print from 1 minute to 1 day. P. The capability to interface with a building automation system via hard-wired connec- tions to each feature to provide: 1. Remote chiller start and stop. 2. Remote leaving chiller liquid temperature adjust. 3. Remote current limit setpoint adjust. 4. Remote ready to start contacts. 5. Safety shutdown contacts. 6. Cycling shutdown contacts. 7. Run contacts. REFRIGERANT FLOW CONTROL Refrigerant flow to the evaporator is controlled by the YORK variable orifice control sys- tem. Liquid refrigerant level is continuously monitored to provide optimum subcooler, condenser and evaporator performance. The variable orifice electronically adjusts to all Real-World operating conditions, providing the most efficient and reliable operation of refrigerant flow control. Equipment Overview (Cont'd)
  • 21. FORM 160.75-EG1 (915) JOHNSON CONTROLS 21 CODES AND STANDARDS • ASME Boiler and Pressure Vessel Code  – Section Vlll Division 1. • UL 1995  –  Heating and Cooling Equipment. • ASHRAE 15  –  Safety Code for Mechanical Refrigeration. • ASHRAE Guideline 3 – Reducing Emission of Halogenated Refrigerants in Refrig- eration and Air-Conditioning Equipment and Systems. • N.E.C.  –  National Electrical Code. • OSHA  –  Occupational Safety and Health Act. ISOLATION MOUNTING The unit is provided with four vibration isolation mounts of nominal 1 operating height. The pads have a neoprene pad to contact the foundation, bonded to a steel plate. The vibration isolation pads assemblies mount under steel plates affixed to the chiller tube sheets. Equipment Overview (Cont'd)
  • 22. JOHNSON CONTROLS FORM 160.75-EG1 (915) 22 IBC/OSHPD SEISMIC CERTIFICATION YORK YK chillers meet the IBC seismic requirements. YORK YK chillers also meet the California Office of Statewide Health Planning and Development (OSHPD) Special Seismic Preapproval (OSP). To earn the OSP, several models within a product line are required to successfully demonstrate functional operation after a shaker-table test. All Johnson Controls equipment is engineered and manufactured for the highest level of safety. Contact a Johnson Controls sales office to obtain a specific selection for a seismic compliance application. Figure 4 - SPECIAL SEISMIC CERTIFICATION PREAPPROVAL REFRIGERANT CONTAINMENT The standard unit has been designed as a complete and compact factory-packaged chill- er. As such, it has minimum joints from which refrigerant can leak. The entire assembly has been thoroughly leak tested at the factory prior to shipment. The YORK YK chiller includes service valves conveniently located to facilitate transfer of refrigerant to a remote refrigerant storage/recycling system. Optional condenser isolation valves allow storage of the charge in the condenser. SDS level of 1.6g mounted on neoprene pads. Equipment Overview (Cont'd)
  • 23. FORM 160.75-EG1 (915) JOHNSON CONTROLS 23 PAINT Exterior surfaces are protected with one coat of Caribbean blue, durable alkyd modified, vinyl enamel machinery paint. SHIPMENT A protective covering is furnished on the motor starter, Control Center VSD and unit mounted controls. Water nozzles are capped with fitted plastic caps. The entire unit is protected with a industrial-grade, reinforced shrink-wrapped covering. Equipment Overview (Cont'd)
  • 24. JOHNSON CONTROLS FORM 160.75-EG1 (915) 24 OptiView Control Center NOTE: Please refer to the OptiVew Control Center Operator's Manual for a complete description of features and functionality. The YORK OptiView Control Center is a factory mounted, wired and tested microproces- sor based control system for HFC-134a centrifugal chillers. For the YK, it controls the leaving chilled liquid temperature and limits the motor current via control of the Variable Geometry Diffuser (VGD) and Variable Speed Drive (VSD). The panel comes configured with a full screen LCD Graphic Display mounted in the mid- dle of a keypad interface with soft keys, which are redefined with one keystroke based on the screen displayed at the time. The graphic display allows the presentation of several operating parameters at once. In addition, the operator may view a graphical represen- tation of the historical operation of the chiller as well as the present operation. For the novice user, the locations of various chiller parameters are clearly and intuitively marked. Instructions for specific operations are provided on many of the screens. To prevent unau- thorized changes of set points and operating conditions, security access is provided with three different levels of access and passwords. The graphic display also allows information to be represented in both English (tempera- tures in °F and pressures in PSIG) and Metric (temperatures in °C and pressures in kPa) mode. The advantages are most apparent, however, in the ability to display many lan- guages. The Control Center continually monitors the system operation and records the cause of any shutdowns (Safety, Cycling or Normal). This information is recorded in memory and is preserved even through a power failure condition. The user may recall it for viewing at any time. During operation, the user is continually advised of the operating conditions by various status and warning messages. In addition, it may be configured to notify the user of certain conditions via alarms. The Control Center expands the capabilities of remote control and communications. By providing a common networking protocol through the Building Automation System (BAS), YORK Chillers not only work well individually, but also as a team. This new protocol allows increased remote control of the chiller, as well as 24-hour performance monitoring via a remote site. In addition, compatibility is maintained with the present network of BAS communications. The chiller also maintains the standard LD18607
  • 25. FORM 160.75-EG1 (915) JOHNSON CONTROLS 25 OptiView Panel (Cont'd) digital remote capabilities as well. Both of these remote control capabilities allow for the standard Energy Management System (EMS) interface: 1. Remote Start. 2. Remote Stop. 3. Remote Leaving Chilled Liquid Temperature Setpoint adjustment (0 to 10VDC, 2 to 10VDC, 0 to 20mA or 4 to 20mA) or Pulse Width Modulation. 4. Remote Current Limit Setpoint adjustment. 5. (0 to 10VDC, 2 to 10VDC, 0 to 20mA or 4 to 20mA) or Pulse Width Modulation. 6. Remote READY TO START Contacts. 7. Safety Shutdown Contacts. 8. Cycling Shutdown Contacts. The following are examples of the information displayed on some of the more important screens: SYSTEM SCREEN This screen gives a general overview of common chiller parameters. LD18608
  • 26. JOHNSON CONTROLS FORM 160.75-EG1 (915) 26 OptiView Panel (Cont'd) EVAPORATOR SCREEN This screen displays a cutaway view of the chiller evaporator. All setpoints relating to the evaporator side of the chiller are maintained on this screen. Animation of the evaporation process indicates whether the chiller is presently in a RUN condition (bubbling) and liquid flow in the pipes is indicated by alternating shades of color moving in and out of the pipes. CONDENSER SCREEN This screen displays a cutaway view of the chiller condenser. All setpoints relating to the condenser side of the chiller are maintained on this screen. Animation indicates con- denser liquid flow. LD18610 LD18609
  • 27. FORM 160.75-EG1 (915) JOHNSON CONTROLS 27 OptiView Panel (Cont'd) COMPRESSOR SCREEN This screen displays a cutaway view of the chiller compressor, revealing the impeller, and shows all conditions associated with the compressor. Animation of the compressor impel- ler indicates whether the chiller is presently in a RUN condition. This screen also serves as a gateway to subscreens for the Variable Geometry Diffuser (VGD) and the Power Panel. HOT GAS BYPASS SCREEN This screen displays a cutaway view of the Hot Gas Bypass Valve. The setpoints relating to the Hot Gas Bypass Control are maintained on this screen. Related Hot Gas control pa- rameters are displayed for reference. The Hot Gas Valve can be manually controlled from this screen. Through animation, the relative valve position is displayed. The parameters dis- played on this screen vary according to the software version and the selection made for the Motor Communications Protocol Setpoint when equipped with Variable Speed Drive (VSD) or Medium Voltage Variable Speed Drive (MVVSD). LD18611 LD13826
  • 28. JOHNSON CONTROLS FORM 160.75-EG1 (915) 28 OptiView Panel (Cont'd) VARIABLE GEOMETRY DIFFUSER This can be accessed from the COMPRESSOR screen and gives the basic stall, position, and pressure details. HISTORY SCREEN This screen allows the user to browse through the faults. In order to get a more thorough reporting of the system conditions at the time of the recorded shutdown, move to the sub- screen HISTORY DETAILS. LD18615 00661VIPc
  • 29. FORM 160.75-EG1 (915) JOHNSON CONTROLS 29 OptiView Panel (Cont'd) CAPACITY CONTROL SCREEN This screen displays capacity control information and includes a programmable pulldown demand to automatically limit VSD input loading for minimizing building demand charg- es. Pulldown time period control over four hours, and verification of time remaining in pulldown cycle from display readout. Separate digital setpoint for current limiting between 30 and 100%. SETPOINTS This screen provides a convenient location for programming the most common chiller control setpoints. Changing setpoints and setup requires proper password access. This screen also serves as a gateway to a subscreen for defining the setup of general system parameters. LD18615 LD18616
  • 30. JOHNSON CONTROLS FORM 160.75-EG1 (915) 30 OptiView Panel (Cont'd) OPERATIONS This screen allows definition of general parameters having to do with the operation of the chiller. DISPLAY MESSAGES The OptiView Control Center continually monitors the operating system displaying and recording the cause of any shutdowns (Safety, Cycling or Normal). The condition of the chiller is displayed at the System Status line that contains a message describing the operating state of the chiller; whether it is stopped, running, starting or shutting down. A System Details line displays Warning, Cycling, Safety, Start Inhibit and other messages that provide further details of Status Bar messages. Messages are color-coded: Green – Normal Operations, Yellow - Warnings, Orange – Cycling Shutdowns, and Red – Safety Shutdowns to aid in identifying problems quickly. LD09578a
  • 31. FORM 160.75-EG1 (915) JOHNSON CONTROLS 31 THIS PAGE INTENTIONALLY LEFT BLANK.
  • 32. JOHNSON CONTROLS FORM 160.75-EG1 (915) 32 JOHNSON CONTROLS OPTISPEED™ DRIVE STARTER When a YORK YK chiller is equipped with a variable speed drive, it incorporates ad- vanced Adaptive Capacity Control logic, which continually optimizes chiller operation. It closely examines critical operating parameters, and then determines the most efficient way to operate. In addition, it allows optimized savings when using intelligent control strat- egies, such as chilled-water reset. Adaptive Capacity Control logic also accommodates the characteristics of the refrigerant used in the chiller — today and tomorrow. The variable speed drive was specifically developed for commercial air-conditioning ap- plications. No one matches Johnson Controls experience in the application of variable speed drive technology to chillers. Since pioneering the concept in 1978, Johnson Con- trols has installed more variable speed drive chillers than all other chiller manufacturers combined. Variable speed drives will save in both single-chiller installations and multiple-chiller in- stallations. In multiple-chiller installations, cycling chillers off as the building load falls will result in higher loads on the remaining chillers. This would seem to reduce the opportunity for drives to save energy. However, even though chiller loads remain high, entering con- denser-water temperature has most likely fallen. And, reductions in entering condenser water temperature offer a far greater potential to enhance chiller efficiency than load re- ductions do. Therefore, variable speed drive will deliver major energy savings in multiple- chiller plants, too. The OptiSpeed Drive is available for low and medium voltage options for the compressor motor (See Table 2). Table 2 - OPTISPEED DRIVE STARTER OPTION LOW VOLTAGE STARTERS 60 HZ 50 HZ OPTISPEED VARIABLE SPEED DRIVE UNIT MOUNTED 380V 460V 575V 600V 380V 400V 415V X X X X X X X – 60 HZ MEDIUM VOLTAGE STARTERS OPTISPEED VARIABLE SPEED DRIVE FLOOR MOUNTED 2300V 3300V 4000V 4160V 6000V 6600V 12470V 13800V X X X X O O O O 50 HZ MEDIUM VOLTAGE STARTERS OPTISPEED VARIABLE SPEED DRIVE FLOOR MOUNTED 2300V 3000V 3300V 6000V 6600V 10000V 11000V – – X O O O O – X=Available O=Available by Special Quotes (SQ) Accessories and Modifications
  • 33. FORM 160.75-EG1 (915) JOHNSON CONTROLS 33 LOW VOLTAGE OPTISPEED DRIVE The Low Voltage OptiSpeed variable speed drive is factory-packaged and mounted on the YORK YK chiller. It is designed to vary the compressor motor speed by controlling the frequency and voltage of the electrical power to the motor. The adaptive capacity control logic automatically adjusts motor speed and compressor pre-rotation vane position inde- pendently for maximum part load efficiency by analyzing information fed to it by sensors located throughout the chiller. The variable speed drive is mounted in a NEMA-1 enclosure with all power and control wiring between the drive and chiller factory-installed. Electrical lugs for incoming power wiring are provided. The variable speed drive provides automatic displacement power factor correction to 0.95 or better at all load conditions. Separate displacement power factor correction capacitors are not required. The displacement power factor is 0.98 or better when the optional har- monic filter is provided. Additionally, variable speed drives have the following advantages: • Lowest chiller life cycle through part load energy savings. • Application-specific designs enable efficient, precise load control and seamless inte- gration with equipment control panel and BAS. • Soft start with input current less than full load current. • Smooth acceleration reduces stresses on motor and driveline. • Reduces compressor sound levels at most operating conditions. • Rugged and reliable with no moving parts. • IEEE-519 2014 compliant if used with an optional harmonic filter. Standard features include: a door interlocked lockable circuit breaker; UL/cUL listed ground fault protection; over-voltage and under-voltage protection; 3-phase sensing mo- tor over-current protection; single-phase protection; insensitive to phase rotation; over- temperature protection; digital readout at the OptiView Control Center of: • Output Frequency. • Output Voltage. • 3-phase output current. • Input Power (kW). • Self diagnostic service parameters. • Kilowatt-Hours (kWh). An optional harmonic filter limits electrical power supply distortion from the variable speed drive to help the building comply with the guidelines of IEEE STD. 519-2014. The filter is unit mounted within the same NEMA-1 enclosure and is UL listed. The following digital readout is standard with the optional filter: • Input kVA. • Total power-factor. • 3-phase input voltage. Accessories and Modifications (Cont'd)
  • 34. JOHNSON CONTROLS FORM 160.75-EG1 (915) 34 Accessories and Modifications (Cont'd) • 3-phase input current. • 3-phase input voltage total harmonic distortion (THD). • 3-phase input current total demand distortion (TDD). • Self-diagnostic service parameters. LOW VOLTAGE OPTISPEED DRIVE WITH QUICK START OPTION The Quick Start feature is targeted towards data centers and process control applications where the goal is to re-establish process cooling as fast as possible after a power failure event. The Quick Start feature does this by reducing the time cycle for chiller restart and by loading the chiller as fast as possible. Once running, its goal is to rapidly achieve the leaving chilled water temperature setpoint. The main objective is to provide minimum downtime and the fastest restart/loading as possible. After the chiller is running and close to setpoint, it will return to standard YK control to minimize risk. The Quick Start Feature can be used with a UPS (supplied by others) or without a UPS. In order to start the most quickly, the OptiView control panel and VSD control circuit (except the trigger board) must be on a UPS. If a slightly longer restart time can be tolerated, the UPS is not required. Depending on the compressor and the horsepower of the drive, a 3 kVA or 4 kVA UPS (supplied by others) with sine wave output is required to power the OptiView and required portions of the VSD control circuit to 115V - 1 phase - 60 Hz. Please refer to Form 160.75-TD4; Quick Start Feature for YK Mod G Chillers for additional information. Quick Start Feature Availability - This feature applies only to YK chillers with Low Volt- age Variable Speed Drives. MEDIUM VOLTAGE OPTISPEED DRIVE A variable speed drive is factory-packaged and configured for easy remote mounting. It is designed to vary the compressor motor speed by controlling the frequency and voltage of the electrical power to the motor. The adaptive capacity control logic automatically adjusts motor speed and compressor pre-rotation vane position independently for maximum part load efficiency by analyzing information fed to it by sensors located throughout the chiller. The variable speed drive is mounted in a NEMA-1 enclosure and comes with a certifica- tion label from a nation-ally recognized testing laboratory. The connection points between the drive and chiller are factory labeled. Electrical lugs for incoming power wiring are NOT provided. The variable speed drive provides automatic displacement power factor correction to 0.98 or better at all load conditions. Separate displacement power factor correction capacitors are not required. Additional advantages of the variable speed drive are as follows: • Lowest chiller life cycle through part load energy savings. • Application-specific designs enable efficient, precise load control and seamless inte- gration with equipment control panel and BAS. • Soft start with input current less than full load current.
  • 35. FORM 160.75-EG1 (915) JOHNSON CONTROLS 35 Accessories and Modifications (Cont'd) • Smooth acceleration reduces stresses on motor and driveline. • Reduces compressor sound levels at most operating conditions. • Rugged and reliable with no moving parts. • IEEE-519 2014 compliant with a harmonic filter. • Multi-level PWM output closely simulates a true sine wave, allowing the use of stan- dard motors and bearings. Standard features include: a lockable door interlocked disconnect switch; UL listed ground fault protection; over-voltage and under-voltage protection; 3-phase sensing motor over- current protection; single-phase protection; insensitive to phase rotation; over-tempera- ture protection; digital readout at the Control Center of: • Output frequency. • 3-phase output voltage. • 3-phase output current. • Input power (kW). • Self diagnostic service parameters. • Kilowatt-hours (kWh). • Input KVA . • Total power-factor. • 3-phase input voltage. • 3-phase input current. • Self diagnostic service parameters. The 24 pulse design limits the electrical power supply distortion from the variable speed drive to comply with the guidelines of IEEE STD. 519-2014. LOW VOLTAGE SOLID-STATE STARTER The Low Voltage Solid-State Starter is compact and mounted on the unit. Power and con- trol wiring between the starter and the chiller are factory-installed. Available for 200 - 600 volts (see Table 3), the starter enclosure is NEMA-1, with a hinged access door with lock and key. Electrical lugs for incoming power wiring are provided. Table 3 - LOW VOLTAGE SOLID-STATE STARTER LOW VOLTAGE SOLID-STATE STARTER (UNIT MOUNTED) 60HZ 50HZ 380V 440V 460V 480V 575V 600V 380V 400V 415V 440V X X X X X X X X X X X=Available
  • 36. JOHNSON CONTROLS FORM 160.75-EG1 (915) 36 Standard Features include digital readout at the Control Center of the following: Display Only • 3-phase input voltage. • 3-phase current. • Input Power (kW). • Kilowatt-Hours (kWh). • Starter Model. • Motor Run (LED). • Motor Current % Full Load Amps. • Current Limit Setpoints. • Pulldown Demand Time Left. Programmable • Local Motor Current Limit. • Pulldown Demand Limit. • Pulldown Demand Time. Other features include: low line voltage; 115V control transformer; three-leg, motor-cur- rent-sensing overloads; phase rotation and single-phase failure protection; high tem- perature safety protection; motor current imbalance and under-voltage safeties; open and shorted SCR protection; momentary power interruption protection. The Solid-State Starter is cooled by a closed-loop, fresh-water-circuit consisting of a water-to-water heat exchanger and a fractional horsepower circulating pump. All interconnecting water piping is factory-installed and rated for 150 psig (10.3 barg) working pressure. Optional elec- tronic trip circuit UL listed circuit breaker with integral ground fault protection is available with short circuit withstand ratings of: • 65KA for 460V 200V, 400V models. • 50KA for 33L 575V models. • 35KA for 14L 575V models. • 22KA for 7L 575V models. A non-fused disconnect switch is also available. Both options are lockable. Additional advantages of Solid-State Starters are as follows: • Smooth, controlled start profile. • Unit mounted, factory wired and tested. • Rugged and reliable with no moving parts. • Adjustable acceleration times. Accessories and Modifications (Cont'd)
  • 37. FORM 160.75-EG1 (915) JOHNSON CONTROLS 37 • Reduces compressor sound levels at most operating conditions. • Rugged and reliable with no moving parts. • Application-specific designs enable seamless integration with equipment control panel and BAS. MEDIUM VOLTAGE SOLID-STATE STARTER The Medium Voltage Solid-State Starter is a reduced voltage in-line bypass starter that controls and maintains a constant current flow to the motor during startup. Power and control wiring between the starter and the chiller for the unit mounted version is factory- installed. Available for 2300 - 4160 volts (see Table 4), the starter enclosure is NEMA-1, with a hinged access door with lock and key. Electrical lugs for incoming power wiring are not provided. Table 4 - MEDIUM VOLTAGE SOLID-STATE STARTER MEDIUM VOLTAGE SOLID-STATE STARTER * 60 HZ 50 HZ 2300V 3300V 4000V 4160V 3300V UNIT MOUNTED X** X** X** X** X** FLOOR MOUNTED X X X X X X=Available * Unit Mounted version available for Compressor H9 or Larger ** For Higher Voltage contact Application Engineering Department for a Special Quote ( SQ) Standard Features include digital readout at the Control Center of the following: Display Only • 3-phase input voltage. • 3-phase current. • Input Power (kW). • Killowatt-Hours (kWh). • Starter Model. • Motor Run (LED). • Motor Current % Full Load Amps. • Current Limit Setpoints. • Pulldown Demand Time Left. Programmable • Local Motor Current Limit. • Pulldown Demand Limit. • Pulldown Demand Time. Accessories and Modifications (Cont'd)
  • 38. JOHNSON CONTROLS FORM 160.75-EG1 (915) 38 Other features include: low line voltage; 115V control transformer; three-leg motor current sensing overloads; phase rotation and single-phase failure protection; high temperature safety protection; motor current imbalance and under-voltage safeties; open and shorted SCR protection; momentary power interruption protection. The Solid-State Starter is air cooled generating about the same heat as an auto-transformer E-M starter. Ground fault protection and surge protection are also standard features. The 50,000 amp short circuit withstand rating is in accordance with UL Standard 508. ELECTRO-MECHANICAL STARTER - (FIELD-INSTALLED) Characteristics - For comparison purposes, here is a description of some of the gen- eral characteristics of electromechanical starters. Until the development of the Solid- State Starter, all centrifugal chillers required the use of starters using electro-mechanical contactors, which are limited to operating totally ON, or totally OFF. There was no alter- native to this mechanical equipment with its inability to control applied voltage or power. This contrasts markedly with the YORK Medium Voltage Solid-State Starter which auto- matically maintains a predetermined current during starting, regardless of variations in line voltage or motor load, to give optimum acceleration without surges. Even with the addition of transformers, reactors, resistors and additional contactors, timers and relays, the mechanical controllers offer limited adjustment, no positive control during starting and impose an objectionable transition spike. Some also require modified motors. A field- installed, electro-mechanical compressor motor starter is available, selected for proper size and type for job requirements and in accordance with Johnson Controls Engineering Standard (R-1132) for Starters. The most common failure mode of mechanical contactors is OFF. This occurs due to the coil open-circuiting or failure of a pole to make an electrical contact when it closes. How- ever, failure in the ON mode is not completely uncommon and can be a more dramatic type of failure, particularly if this failure mode exists at the same time that equipment safety controls are demanding a shutdown. When contacts are “made,” the current builds up to its maximum value from zero, but when contacts are separated the current tends to flow through the gap thus formed and causes an arc. This arcing depends upon the voltage between the separating contacts. For medium voltage the use of vacuum contactors mitigates this problem somewhat by providing an environment to extinguish the arc. In the alternating current circuit, the sepa- ration of contacts may take place when the current is zero or maximum or at any value in between. An alternating current passes through zero and reverses its polarity twice during each cycle. If two or more contacts, one in each leg of a polyphase system, are separated simultaneously, the current values in each will vary. In a three-phase system, if one contact has zero current when opened, the other two contacts will have 86.6% of their maximum values, as an example. Additionally, when inductive circuits are broken, the voltage is increased at the contacts due to the counter (induced) EMF of the circuit. The instant the contacts separate, the voltage between them momentarily rises from zero to the maximum of the circuit, or higher if inductance is present in the circuit. In practice, every time the contacts close, they bounce. When they bounce, they arc. The arcing that occurs as the contacts make or break may result in rapid and excessive erosion of the contacts, causing prematurely short contact life. Accessories and Modifications (Cont'd)
  • 39. FORM 160.75-EG1 (915) JOHNSON CONTROLS 39 Types - YORK chillers are designed for use with the following types of electro-mechanical starters, here briefly described. Across-the-Line (ACL) – These are the simplest and lowest-cost starters available. They apply full voltage to the three motor leads at the instant of starting. Since inrush is 100% of LRA and starting torque is 100%, this is the roughest type of starting on the motor and driveline. In physical size, the ACL is the smallest of electro-mechanical starters and there is no transition surge. In most areas, utilities will not permit the use of this type of starter for chiller-size motors because of their large current draw on startup. Auto-Transformer (AT) – These starters are reduced-voltage starters. Transformers are used to step down the voltage to the motor during startup. The result is reduced inrush current and starting torque at the level of 42% or 64% depending upon whether 65% or 80% voltage taps are used. They provide closed transition (with three-lead motors) with reduced line disturbance. Star-Delta Starters – During starting, the motor is connected in a Star or Wye configura- tion. This reduces the voltage to the motor stator by a factor of three. This 1/3 voltage results in 1/3 current into the motor at start and 1/3 torque to the shaft. Centrifugal com- pressor starting torque requirements are low enough to allow the motor to start at 1/3 of full load torque. Star-Delta starting creates some stresses for the starter's switch-gear, building electrical system, power grid, and chiller mechanical driveline.  Although these stresses are 1/3 of the stresses generated by an ACL starter, they cause wear on the system. As a result, Johnson Controls recommends using a Solid State Starter or Variable Speed Drive in- stead of a Star-Delta starter. Table 5 - ELECTRO-MECHANICAL STARTER STARTER OPTIONS LOW VOLTAGE/FREQUENCY LV ACROSS THE LINE (DOL) (FLOOR MOUNTED) 60HZ 50HZ 380V 440V 460V 480V 575V 380V 400V 415V X X X X X X X X LV STAR-DELTA CLOSED (FLOOR MOUNTED) 60HZ 50HZ 380V 440V 460V 480V 575V 380V 400V 415V X X X X X X X X STARTER OPTIONS MEDIUM VOLTAGE / FREQUENCY MV ACROSS THE LINE (DOL) (FLOOR MOUNTED) 60HZ 50HZ 2300 3300 4000 4160 6000 6600 12470 13200 2300 3000 3300 6000 6600 10000 11000 X X X X O O O O X X X O O O O MV AUTOTRANSFORMER 65% (FLOOR MOUNTED) 60HZ 50HZ 2300 3300 4000 4160 6000 6600 12470 13200 2300 3000 3300 6000 6600 10000 11000 X X X X O O O O X X* X* O O O O MV AUTOTRANSFORMER 80% (FLOOR MOUNTED) 60HZ 50HZ 2300 3300 4000 4160 6000 6600 12470 13200 2300 3000 3300 6000 6600 10000 11000 X X X X O O O O X X X O O O O X = Available * = Not available with 5DJ motor O = SQ Accessories and Modifications (Cont'd)
  • 40. JOHNSON CONTROLS FORM 160.75-EG1 (915) 40 GENERAL ACCESSORIES AND MODIFICATIONS Medium Voltage Motors - Medium voltage motors (4160V/60Hz to 13800V/60Hz and 3300V/50Hz to 11000V/50Hz) are available for YK units; Contact JCI Sales Office for special rating. SPECIAL MOTORS ENCLOSURES There are job applications, primarily in manufacturing, comfort cooling plants, and pro- cess applications, where more motor protection is required. Listed below are several alter- natives. NOTE: Chiller certification to UL by a third party could be affected. Contact your JCI sales office for a specific selection. Weather-Protected Type I Motors (WP-I) – A Weather-Protected Type I motor is an open machine with its ventilating passages constructed to prevent the passage of a cylindrical rod ¾” in diameter. This affords protection against intrusion of rodents and some types of debris. These are regularly used in the pulp industry and where grime is present. Weather-Protected Type II Motors (WP-II) – A Weather-Protected Type II motor has, in addition to the enclosure defined for Weather-Protected Type I motor, ventilating passag- es at both intake and exhaust so arranged that high-velocity air and air-borne particles, blown into the motor, can be discharged without entering the internal ventilating passages leading directly to the electric parts of the machine itself. Space heaters are required with WP-II. Totally Enclosed Fan-Cooled Motors (TEFC) – TEFC motors are used where the loca- tion is extremely dirty, dusty, or wet, both indoors and outdoors. A totally enclosed fan- cooled unit is enclosed to prevent the free exchange of air between the inside and outside of the case but not sufficiently enclosed as to be termed air-tight. It is air-cooled by means of a fully guarded fan blowing cooling air over the outside of the motor. The fan is exter- nally mounted on the motor shaft. Totally Enclosed Air-to-Air Cooled (TEAAC) – TEAAC motors are used when the envi- ronment is dirty or corrosive. A TEAAC motor is a totally enclosed motor, cooled by circu- lating the internal air through an air-to-air heat exchanger. Totally Enclosed Water-to-Air Cooled (TEWAC) – TEWAC motors are used when the environment is dirty or corrosive, in hazardous areas, or where minimum noise levels are required. A TEWAC motor is a totally enclosed machine which is cooled by circulat- ing internal air which, in turn, is cooled by circulating water. It is provided with an internal water-cooled heat exchanger for cooling the internal air and fans, integral with the rotor shaft for circulating the internal air. BAS REMOTE CONTROL A communication interface permitting complete exchange of chiller data with any BAS system is available with an optional E-Link® gateway. The E-Link also allows the BAS system to issue commands to the chiller to control its operation. E-Link gateways come in four models, depending on the communication protocol and the mounting arrangement. Accessories and Modifications (Cont'd)
  • 41. FORM 160.75-EG1 (915) JOHNSON CONTROLS 41 Accessories and Modifications (Cont'd) FACTORY INSULATION OF EVAPORATOR Factory-applied thermal insulation of the flexible, closed-cell plastic type, 3/4 (19 mm) thick is attached with vapor-proof cement to the evaporator shell, flow chamber, tube sheets, suction connection, and (as necessary) to the auxiliary tubing. Not included is the insulation of compact waterboxes and nozzles. This insulation will normally prevent con- densation in environments with relative humidifies 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 available for relative humidifies up to 90% and dry bulb temperatures ranging from 50° to 90°F (10° to 32.2°C). WATER FLANGES Four 150 lb. ANSI raised-face flanges for condenser and evaporator water connections are factory-welded to water nozzles. Companion flanges, bolts, nuts and gaskets are not included. SPRING ISOLATION MOUNTING Spring isolation mounting is available instead of standard isolation mounting pads when desired. Four level-adjusting, spring-type vibration isolator assemblies with non-skid pads are provided for field-installation. Isolators are designed for one-inch (25 mm) deflection. WATERBOXES Marine Waterboxes - Marine waterboxes allow service access for cleaning of the heat ex- changer tubes without the need to break the water piping. Bolted-on covers are arranged for convenient access. ANSI/AWWA C-606 nozzle connections are standard; flanges are optional. Marine waterboxes are available for condenser and/or evaporator. Hinged Waterboxes - Hinged waterboxes allow fast and safe service access for clean- ing heat exchanger tubes. Hinged waterboxes on a non-nozzle end give access to the tubes without having to disconnect the water piping. Hinged waterboxes are available for condenser and/or evaporator for compact and marine waterboxes. KNOCK-DOWN SHIPMENT The chiller can be shipped knocked down into major subassemblies (evaporator, con- denser, driveline, etc.) as required to rig into tight spaces. This is particularly convenient for existing buildings where equipment room access does not allow rigging a factory- packaged chiller. REFRIGERANT ISOLATION VALVES Optional factory-installed isolation valves in the compressor discharge line and refrigerant liquid line are available. This allows isolation and storage of the refrigerant charge in the chiller condenser during servicing, eliminating time-consuming transfers to remote stor- age vessels. Both valves are positive shut-off, assuring integrity of the storage system.
  • 42. JOHNSON CONTROLS FORM 160.75-EG1 (915) 42 REFRIGERANT STORAGE/RECYCLING SYSTEM A refrigerant storage/recycling system is a self-contained package consisting of a refriger- ant compressor with oil separator, storage receiver, water-cooled condenser, filter drier and necessary valves and hoses to remove, replace and distill refrigerant. All necessary controls and safety devices are a permanent part of the system. A storage receiver is typi- cally not required if optional unit isolation valves are provided. HIGH AMBIENT TEMPERATURE Chiller modifications are available to allow for installation in high ambients of up to 122°F (50°C). Special drive motors are required above 104°F (40°C). H9 and K compressor evaporator design pressures must be increased for ambient temperatures above 112.8°F (45°C). The OptiView panel and low voltage VSD are suited for 122°F (50°C) ambient. Low and medium voltage Solid-State Starters must be derated and/or modified above 110°F (43.3°C). The free standing MVVSD option must be derated above its standard 104°F (40°C) limit. OPTISOUND™ CONTROL The YORK OptiSound™ Control is a patented combination of centrifugal-chiller hardware and software that reduces operational sound levels, expands the chiller operating range, and improves chiller performance. The OptiSound Control feature continuously monitors the characteristics of the compressor-discharge gas and optimizes the diffuser spacing to minimize gas-flow disruptions from the impeller. This innovative technology improves operating sound levels of the chiller an average of 7 dBA, and up to 13 dBA on the largest models. It can also reduce part-load sound levels below the full-load level. See Figure 2. In addition, the OptiSound Control provides the benefit of an expanded operating range. It improves performance and reliability by minimizing diffuser-gas stall at off-design opera- tion, particularly conditions of very low load combined with little or no condenser-water re- lief. The elimination of the gas-stall condition can also result in improved chiller efficiency at off-design conditions. Johnson Controls recommends the OptiSound Control for chiller applications with elevat- ed entering condenser-water temperatures (high-head) or applications requiring low-load operation with constant condenser temperature. At high-head conditions, improved chiller operation is visible at all load points. Accessories and Modifications (Cont'd)
  • 43. FORM 160.75-EG1 (915) JOHNSON CONTROLS 43 OptiSound Control Availability Standard: Compressors P8, P9, H9, K1, K2, K3, K4, K7 Optional: Compressors Q3, Q4, Q5, Q6, Q7, P7 Figure 5 - TYPICAL OPTIMIZED CENTRIFUGAL COMPRESSOR Accessories and Modifications (Cont'd)
  • 44. JOHNSON CONTROLS FORM 160.75-EG1 (915) 44 Application Data The following discussion is a user’s guide in the application and installation of YK chillers to ensure the reliable, trouble free life for which this equipment was designed. While this guide is directed towards normal, water chilling applications, the Johnson Controls sales representative can provide complete recommendations on other types of applications. LOCATION YK chillers are virtually vibration free and may generally be located at any level in a build- ing where the construction will support the total system operating weight. The unit site must be a floor, mounting pad or foundation which is level within 1/4 (6.4 mm) and capable of supporting the operating weight of the unit. Sufficient clearance to permit normal service and maintenance work should be provided all around and above the unit. Additional space should be provided at one end of the unit to permit cleaning of evaporator and condenser tubes as required. A doorway or other properly located opening may be used. The chiller should be installed in an indoor location where temperatures range from 40°F to 104°F (4.4°C to 40°C). The dew point temperature in the equipment room must be below the entering condenser water temperature to prevent condensing water vapor in- side of the low voltage VSD or low voltage SSS cabinet (if applicable). Applications using cooling sources other than evaporative or closed loop air exchange methods need to request a factory-supplied temperature control valve to prevent condensation inside the VSD or SSS cabinet. Other areas susceptible to water vapor condensate are outside of the condenser shell and condenser water boxes. Example applications include cooling condenser water using chilled water, wells, river or other low temperature fluids. For outdoor applications, please contact Large Tonnage Application Team. WATER CIRCUITS Flow Rate – For normal water chilling duty, evaporator and condenser flow rates are permitted at water velocity levels in the heat exchangers tubes of between 3 fps (0.91 m/s) [3.3 fps (1.0 m/s) for condensers] and 12 fps (3.66 m/s). Two pass units are also limited to 45 ft H2 0 (134 kPa) water pressure drop. The three pass limit is 67.5 ft H2 0 (201 kPa). Variable flow in the condenser is not recommended, as it generally raises the energy con- sumption of the system by keeping the condenser pressure high in the chiller. Additionally, the rate of fouling in the condenser will increase at lower water velocities associated with variable flow, raising system maintenance costs. Cooling towers typically have narrow ranges of operation with respect to flow rates, and will be more effective with full design flow. Refer to Tables 5 through 7 for flow limits at design conditions. There is increasing interest to use variable primary flow (VPF) systems in large chilled water plants. VPF systems can offer lower installation and operating costs in many cases, but do require more sophisticated control and flow monitoring.
  • 45. FORM 160.75-EG1 (915) JOHNSON CONTROLS 45 YORK YK Style G chillers will operate successfully in VPF systems. With a minimum al- lowable evaporator tube velocity of 1-1/2 fps (0.5 m/s) for standard tubes at part-load rat- ing conditions, YK chillers will accommodate the wide variation in flow required by many chilled water VPF applications. The chillers can tolerate a 50% flow rate change in one minute that is typically associ- ated with the staging on or off of an additional chiller, however a lower flow rate change is normally used for better system stability and set point control. Proper sequencing via the building automation system will make this a very smooth transition. Temperature Ranges – For normal water chilling duty, leaving chilled water tempera- tures may be selected between 38°F (3.3°C) [36°F (2.2°C) with Smart Freeze enabled] and 70°F (21.1°C) to obtain temperature deltas between entering chilled and leaving chilled water temperature of 3°F up to 30°F (1.7°C and 16.7°C). Water Quality  –  The practical and economical application of liquid chillers requires that the quality of the water supply for the condenser and evaporator be analyzed by a water treatment specialist. Water quality may affect the performance of any chiller through cor- rosion, deposition of heat resistant scale, sedimentation or organic growth. These will degrade chiller performance and increase operating and maintenance costs. Normally, performance may be maintained by corrective water treatment and periodic cleaning of tubes. If water conditions exist which cannot be corrected by proper water treatment, it may be necessary to provide a larger allowance for fouling, and/or to specify special ma- terials of construction. General Piping  –  All chilled water and condenser water piping should be designed and installed in accordance with accepted piping practice. Chilled water and condenser wa- ter pumps should be located to discharge through the chiller to assure positive pressure and flow through the unit. Piping should include offsets to provide flexibility and should be arranged to prevent drainage of water from the evaporator and condenser when the pumps are shut off. Piping should be adequately supported and braced independently of the chiller to avoid the imposition of strain on chiller components. Hangers must allow for alignment of the pipe. Isolators in the piping and in the hangers are highly desirable in achieving sound and vibration control. Convenience Considerations – To facilitate the performance of routine maintenance work, some or all of the following steps may be taken by the purchaser. Evaporator and condenser waterboxes are equipped with plugged vent and drain connections. If desired, vent and drain valves may be installed with or without piping to an open drain. Pressure gauges with stop cocks and stop valves may be installed in the inlets and outlets of the condenser and chilled water line as close as possible to the chiller. An overhead monorail or beam may be used to facilitate servicing. Connections  –  The standard chiller is designed for 150 psig (10.3 barg) design working pressure in both the chilled water and condenser water circuits. The connections (water nozzles) to these circuits are furnished with grooves to ANSI/AWWA C-606 Standard for grooved and shouldered joints. Piping should be arranged for ease of disassembly at the unit for tube cleaning. All water piping should be thoroughly cleaned of all dirt and debris before final connections are made to the chiller. Chilled Water – A water strainer of maximum 1/8 (3.2 mm) perforated holes must be field-installed in the chilled water inlet line as close as possible to the chiller. If located close enough to the chiller, the chilled water pump may be protected by the same strainer. The strainer is important to protect the chiller from debris or objects which could block flow through individual heat exchanger tubs. A reduction in flow through tubes could seriously impair the chiller performance or even result in tube freeze-up. A thermal-type flow switch Application Data (Cont'd)
  • 46. JOHNSON CONTROLS FORM 160.75-EG1 (915) 46 is factory installed in the evaporator nozzle and connected to the OptiView panel, which assures adequate chilled water flow during operation. Condenser Water  –  The chiller is engineered for maximum efficiency at both design and part load operation by taking advantage of the colder cooling tower water temperatures which naturally occur during the winter months. Appreciable power savings are realized from these reduced heads. The minimum entering condenser water temperature for other full and part load conditions is provided by the following equation: Min. ECWT = LCHWT – C RANGE + 5°F + 12 ( %Load )100 or Min. ECWT = LCHWT – C RANGE + 2.8°C + 6.6 ( %Load )100 where: ECWT = entering condensing water temperature LCHWT = leaving chilled water temperature C RANGE = condensing water temperature range at the given load condition. At initial startup, entering condensing water temperature may be as much as 25°F (13.9°C) colder than the standby chilled water temperature. BRINE APPLICATIONS Various types of brine can be used in both the evaporator and condenser in lieu of water. The OptiView Control panel is programmed in the factory to allow extending the evapora- tor leaving brine temperature setpoint below 36°F (2.2°C). The low evaporator pressure cutout is factory programmed to the appropriate value depending on the percent (%) con- centration and type of brine solution. When the chiller is not running, brine should not be run through the evaporator. However, if there is brine running through the evaporator, there must be flow through the condenser to prevent tubes from freezing. In brine applications the condenser pump control will close when the condenser saturation temperature reaches 35°F (1.7°C) and the pump will shut off when the temperature increases to 40°F (4.4°C). This is applicable if tied to the condenser pump control. MULTIPLE UNITS Selection – Many applications require multiple units to meet the total capacity require- ments as well as to provide flexibility and some degree of protection against equipment shutdown. There are several common unit arrangements for this type of application. The YK chiller has been designed to be readily adapted to the requirements of these various arrangements. Application Data (Cont'd)
  • 47. FORM 160.75-EG1 (915) JOHNSON CONTROLS 47 Application Data (Cont'd) Parallel Arrangement (Figure 6 - PARALLEL EVAPORATORS PARALLEL CONDENS- ERS on page 47) – Chillers may be applied in multiples with chilled and condenser water circuits connected in parallel between the units. Figure 1 represents a parallel ar- rangement with two chillers. Parallel chiller arrangements may consist of equally or un- equally sized units. When multiple units are in operation, they will load and unload at equal percentages of design full load for the chiller. Depending on the number of units and operating characteristics of the units, loading and unloading schemes should be designed to optimize the overall efficiency of the chiller plant. It is recommended to use an evaporator bypass piping arrangement to bypass fluid around evaporator of any unit which has cycled off at reduced load conditions. It is also recommended to alternate the chiller cycling order to equalize chiller starts and run hours. Series Arrangement (Figure 7 - SERIES EVAPORATORS PARALLEL CONDENSERS on page 47) – Chillers may be applied in pairs with chilled water circuits connected in series and condenser water circuits connected in parallel. All of the chilled water flows through both evaporators with each unit handling approximately one half of the total load. COND. 1 COND. 2 EVAP. 1 EVAP. 2 LD18370 Figure 6 - PARALLEL EVAPORATORS PARALLEL CONDENSERS EVAP. 1 EVAP. 2 T S1 S2 COND. 1 COND. 2 Figure 7 - SERIES EVAPORATORS PARALLEL CONDENSERS
  • 48. JOHNSON CONTROLS FORM 160.75-EG1 (915) 48 When the load decreases to a customer selected load value, one of the units will be shut down by a sequence control. Since all water is flowing through the operating unit, that unit will cool the water to the desired temperature. Series Counter Flow Arrangement (Figure 8 - SERIES EVAPORATORS SERIES COUN- TERFLOW CONDENSERS on page 48) - Chillers may be applied in pairs with chilled water circuits connected in series and with the condenser water in series counter flow. All of the chilled water flows through both evaporators. All of the condenser water flows through both condensers. The water ranges are split, which allows a lower temperature difference or head on each chiller, than multiple units in parallel. For equal chillers, the machine at higher temperature level will typically provide slightly more than half the capacity. The compressor motors and gear codes on the two chillers are often matched, such that the high temperature machine can operate at the low temperature conditions when one unit is cycled off at part loads (as compared to series-parallel chillers which are typically not identical). Series counter flow application can provide a significant building energy savings for large capacity plants which have chilled and condenser water temperature ranges greater than typical AHRI. HEAT RECOVERY Heat recovery may be used in buildings, where there is a need for heating and cooling loads concurrently. By utilizing some or all of the heat rejection of a normal vapor-com- pression cycle cooling system, overall operating energy savings result. Heat recovery uses available heat as a by-product of the cooling function, which differs from heat pumps where the heating can be considered the primary process. Also, the heat recovery usage is often a winter seasonal duty, where the chiller may be expected to operate in summer using heat rejection to a conventional cooling tower. As heating loops and cooling tower water circuits are separate in the majority of buildings, this dictates the need for two water circuits in the condenser of a heat recovery chiller. Application Data (Cont'd) COND. 1 COND. 2 EVAP.1 EVAP.2 T S1 S2 Figure 8 - SERIES EVAPORATORS SERIES COUNTERFLOW CONDENSERS
  • 49. FORM 160.75-EG1 (915) JOHNSON CONTROLS 49 Application Data (Cont'd) Very simply, heat recovery allows you to utilize the heat, [which would otherwise be wast- ed (to the cooling tower)], to serve a useful purpose. This heat of rejection can be used to: • Pre-heat domestic hot water needs like in hotels or hospitals for use in: • Laundry, showers, swimming pools, cooking/dishwashing, hot tub. • Comfort heating (perimeter heating). • Reheating of air. • Preheating of boiler makeup water or process hot water. The main difference between a cooling only chiller and a heat recovery chiller is in the heat recovery chiller's added ability to reject the free condenser heat to the cooling tower and/or the heating system. Since heat is being removed from the area to be cooled, the cooling load supports the heating load. There must be a simultaneous cooling and heat- ing load in the building. When using a Solid-State Starter or Variable Speed Drive for a heat recovery application, the starters will be chilled water cooled. Please refer to Form 160.75-AD2; YK Mod G Heat Recovery Application Data for addi- tional information. Heat Recovery Availability Standard: Compressors Q4, Q7, H9, K2, K7 REFRIGERANT RELIEF PIPING Each chiller is equipped with dual pressure relief valves on the condenser and two dual relief valves on the evaporator, or two single relief valves on the evaporator if the optional refrigerant isolation valves are ordered. The dual relief valves on the condenser are re- dundant and allow changing of either valve while the unit is fully charged. The purpose of the relief valves is to quickly relieve excess pressure of the refrigerant charge to the atmosphere, as a safety precaution in the event of an emergency such as fire. They are set to relieve at an internal pressure as noted on the pressure vessel data plate, and are provided in accordance with ASHRAE 15 safety code and ASME or applicable pressure vessel code. Sized to the requirements of applicable codes, a vent line must run from the relief device to the outside of the building. This refrigerant relief piping must include a cleanable, verti- cal leg dirt trap to catch vent stack condensation. Vent piping must be arranged to avoid imposing a strain on the relief connection and should include one flexible connection. SOUND AND VIBRATION CONSIDERATIONS A YK chiller is not a source of objectionable sound and vibration in normal air conditioning applications. Neoprene isolation mounts are furnished as standard with each unit. Op- tional level adjusting spring isolator assemblies designed for 1 (25 mm) static deflection are available from Johnson Controls. YK chiller sound pressure level ratings will be furnished on request. Control of sound and vibration transmission must be taken into account in the equipment room construction as well as in the selection and installation of the equipment.
  • 50. JOHNSON CONTROLS FORM 160.75-EG1 (915) 50 THERMAL INSULATION No appreciable operating economy can be achieved by thermally insulating the chiller. However, the chiller’s cold surfaces should be insulated with vapor barrier insulation suf- ficient to prevent condensation. A chiller can be factory-insulated with 3/4 (19 mm) or 1 1/2 (38 mm) thick insulation, as an option. This insulation will normally prevent conden- sation in environments with dry bulb temperatures of 50°F to 90°F (10°C to 32°C) and relative humidities up to 75% [3/4 (19 mm) thickness] or 90% [1 1/2 (38 mm) thickness]. The insulation is painted and the surface is flexible and reasonably resistant to wear. It is intended for a chiller installed indoors and, therefore, no protective covering of the insula- tion is usually required. If insulation is applied to the waterboxes at the job site, it must be removable to permit access to the tubes for routine maintenance. VENTILATION The ASHRAE Standard 15 Safety Code for Mechanical Refrigeration requires that all ma- chinery rooms be vented to the outdoors utilizing mechanical ventilation by one or more power driven fans. This standard, plus National Fire Protection Association Standard 90A, state, local and any other related codes should be reviewed for specific requirements. Since the YK chiller motor is air-cooled, ventilation should allow for the removal of heat from the motor. In addition, the ASHRAE Standard 15 requires a refrigerant vapor detector to be em- ployed for all refrigerants. It is to be located in an area where refrigerant from a leak would be likely to concentrate. An alarm is to be activated and the mechanical ventilation started at a value no greater than the TLV (Threshold Limit Value) of the refrigerant. ELECTRICAL CONSIDERATIONS Motor Voltage – Low voltage motors (200 to 600 volts) are furnished with six leads. Medium voltage (2300 to 13800 volts) motors have three leads. Motor circuit conductor size must be in accordance with the National Electrical Code (N.E.C.), or other applicable codes, for the motor full load amperes (FLA). Flexible conduit should be used for the last several feet to the chiller in order to provide vibration isolation. Table 6 - MOTOR VOLTAGE VARIATIONS on page 52 lists the allowable variation in voltage supplied to the chiller motor. The unit name plate is stamped with the specific motor voltage, and frequency for the appropriate motor. Starters – A separate starter is not required if the chiller is equipped with a Variable Speed Drive (VSD). The YK Chillers are also available with a factory mounted and wired York Solid-State Starter for low and medium voltage applications. Other types of remote mounted starters are available. Electromechanical starters must be furnished in accor- dance with YORK Standard Specifications (R-1132). This will ensure that starter compo- nents, controls, circuits, and terminal markings will be suitable for required overall system performance. Remote-mounted medium voltage York Solid-State Starters are also avail- able. Controls – A 115 volt, single-phase, 60 or 50 Hertz 2 KVA power supply must be fur- nished to the chiller from a separate, fused disconnect or from a control transformer in- cluded as an option with electro-mechanical starters. No field control wiring is required when the low voltage YORK Variable Speed Drive or Solid-State Starter is supplied. Application Data (Cont'd)
  • 51. FORM 160.75-EG1 (915) JOHNSON CONTROLS 51 Application Data (Cont'd) Oil Pump Power Supply  –  A separate 3 phase power supply with a fused disconnect for the factory-mounted oil pump variable speed drive is required unless the low voltage VSD or SSS is supplied. Power can also be supplied through an electro-mechanical starter, remote mounted Medium Voltage Solid-State Starter (MVSSS) or Medium Voltage Vari- able Speed Drive (MVVSD). Copper Conductors  –  Only copper conductors should be connected to compressor mo- tors and starters. Aluminum conductors have proven to be unsatisfactory when connected to copper lugs. Aluminum oxide and the difference in thermal conductivity between copper and aluminum cannot guarantee the required tight connection over a long period of time. Displacement Power-factor Correction Capacitors – When the chiller is equipped with a VSD, automatic displacement power factor correction to a minimum of 0.95 is pro- vided at all operating conditions, so additional capacitors are not required. For other start- ing methods, capacitors can be applied to a chiller for the purpose of displacement power factor correction. For remote-mounted electro-mechanical starters, the capacitors should be located on the load side of the starter. For YORK Solid-State Starters the capacitors must be located on the line side of the starter. The capacitors must be sized and installed to meet the National Electrical Code and be verified by Johnson Controls. Ampacity on Load Side of Starter  –  Electrical power wire size to the chiller is based on the minimum unit ampacity. For Solid-State Starters or Variable Speed Drive, this wiring is done at the factory. For remote starters, the National Electrical Code defines the calcu- lation of ampacity, as summarized below. More specific information on actual amperage ratings will be supplied with the submittal drawings: • Six lead type of starting (Star Delta) Minimum circuit ampacity per conductor (1 of 6): Ampacity = 721 x compressor motor amps. • Three lead type of starting (Across the Line, Autotransformer and Primary Reactor) Minimum circuit ampacity per conductor (1 of 3): Ampacity = 1.25 x compressor mo- tor amps. Ampacity on Line Side of Starter  –  The only additional load on the circuit for the chiller would be the control transformer and oil pump motor unless they are supplied by a sepa- rate source. Minimum Circuit Ampacity = 125% of compressor motor amps + FLA of all other loads on the circuit. Branch Circuit Overcurrent Protection – The branch circuit overcurrent protection device(s) should be a time delay type, with a minimum rating equal to the next standard fuse/breaker rating above the calculated value. It is calculated taking into account the compressor motor amps and may also include control transformer and oil pump motor. Refer to submittal drawings for the specific calculations for each application. See Table 15 - LOW VOLTAGE VARIABLE SPEED MODELS on page 69.
  • 52. JOHNSON CONTROLS FORM 160.75-EG1 (915) 52 Table 6 - MOTOR VOLTAGE VARIATIONS FREQ. RATED VOLTAGE NAMEPLATE VOLTAGE* OPERATING VOLTAGE MIN. MAXIMUM 60 HZ 200 200/208 180 220 230 220/240 208 254 380 380 342 415 416 416 375 457 460 440/460/480 414 508 575 575/600 520 635 2300 2300 2070 2530 3300 3300 2970 3630 4000 4000/4160 3600 4576 50 HZ 346 346 311 381 380 380/400 342 423 415 415 374 440 3300 3300 2970 3630 *For motor voltage above 4160V/60Hz and 3300V/50HZ contact your JCI Sales Office for a specific selection. MOTOR ELECTRICAL DATA The smallest motor available which equals or exceeds the Input power (kW) from the chiller rating program is selected from Tables 10. The full load amperes (FLA) listed in the tables is maximum values and corresponds to the maximum motor kW listed. When the input power (kW) is less than maximum motor kW, the FLA should be reduced per the following equation: FLA = Motor kW x Maximum Motor FLA Maximum Motor kW The benefit from the FLA correction is the possible use of smaller power wiring and/or starter size. The locked rotor amperes (LRA) are read directly from Table 10 for specific Motor Code and voltage. This is because the LRA is dependent only on motor size and voltage and is independent of input power (kW). Inrush amperes (IRA) depend on LRA and the type of starter applied. The inrush can be calculated using a percentage of LRA shown in Tables 13 to 17. Application Data (Cont'd)
  • 53. FORM 160.75-EG1 (915) JOHNSON CONTROLS 53 Application Data (Cont'd) Table 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS FLOODED EVAPORATORS 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 AP 329 (21) 1316 (83) 164 (10) 587 (37) 110 (7) 380 (24) AP 479 (30) 1727 (109) 240 (15) 856 (54) 160 (10) 576 (36) AQ 403 (25) 1613 (102) 202 (13) 713 (45) 134 (8) 460 (29) AQ 612 (39) 2205 (139) 306 (19) 1068 (67) 204 (13) 732 (46) AR 493 (31) 1973 (125) 247 (16) 861 (54) 164 (10) 552 (35) AR 681 (43) 2455 (155) 341 (21) 1173 (74) 227 (14) 812 (51) AS 602 (38) 2408 (152) 301 (19) 1032 (65) 201 (13) 655 (41) AS 770 (49) 2773 (175) 385 (24) 1300 (82) – – CP 648 (41) 2594 (164) 324 (20) 1151 (73) 216 (14) 755 (48) CP 779 (49) 2807 (177) 389 (25) 1397 (88) 260 (16) 922 (58) CQ 729 (46) 2917 (184) 365 (23) 1286 (81) 243 (15) 844 (53) CQ 896 (57) 3228 (204) 448 (28) 1590 (100) 299 (19) 1050 (66) CR 866 (55) 3463 (218) 433 (27) 1509 (95) 289 (18) 992 (63) CR 1120 (71) 4035 (255) 560 (35) 1941 (122) 373 (24) 1285 (81) CS 1043 (66) 4170 (263) 521 (33) 1787 (113) 348 (22) 1176 (74) CS 1397 (88) 5035 (318) 699 (44) 2340 (148) – – DP 648 (41) 2594 (164) 324 (20) 988 (62) 216 (14) 648 (41) DP 779 (49) 2807 (177) 389 (25) 1203 (76) 260 (16) 793 (50) DQ 729 (46) 2917 (184) 365 (23) 1106 (70) 243 (15) 725 (46) DQ 896 (57) 3228 (204) 448 (28) 1372 (87) 299 (19) 906 (57) DR 866 (55) 3463 (218) 433 (27) 1301 (82) 289 (18) 854 (54) DR 1120 (71) 4035 (255) 560 (35) 1685 (106) 373 (24) 1114 (70) DS 1043 (66) 4170 (263) 521 (33) 1547 (98) 348 (22) 1017 (64) DS 1397 (88) 5035 (318) 699 (44) 2048 (129) – – EP 859 (54) 3438 (217) 430 (27) 1535 (97) 286 (18) 1009 (64) EP 1120 (71) 4035 (255) 560 (35) 2017 (127) 373 (24) 1337 (84) EQ 1046 (66) 4183 (264) 523 (33) 1853 (117) 349 (22) 1220 (77) EQ 1344 (85) 4842 (305) 672 (42) 2394 (151) 448 (28) 1590 (100) ER 1232 (78) 4927 (311) 616 (39) 2164 (136) 411 (26) 1428 (90) ER 1583 (100) 5705 (360) 792 (50) 2779 (175) 528 (33) 1853 (117) ES 1452 (92) 5809 (366) 726 (46) 2519 (159) 484 (31) 1667 (105) ES 1750 (110) 6308 (398) 875 (55) 3037 (192) 583 (37) 2031 (128) ET 1676 (106) 6702 (423) 838 (53) 2865 (181) 559 (35) 1903 (120) ET 1946 (123) 7012 (442) 973 (61) 3328 (210) – – FQ 1046 (66) 4183 (264) 523 (33) 1591 (100) 349 (22) 1046 (66) FQ 1344 (85) 4842 (305) 672 (42) 2064 (130) 448 (28) 1368 (86) FR 1232 (78) 4927 (311) 616 (39) 1862 (117) 411 (26) 1226 (77) FR 1583 (100) 5705 (360) 792 (50) 2405 (152) 528 (33) 1599 (101) FS 1452 (92) 5809 (366) 726 (46) 2175 (137) 484 (31) 1436 (91) FS 1750 (110) 6308 (398) 875 (55) 2636 (166) 583 (37) 1756 (111) FT 1676 (106) 6702 (423) 838 (53) 2482 (157) 559 (35) 1643 (104) FT 1946 (123) 7012 (442) 973 (61) 2898 (183) – – GQ 1443 (91) 5771 (364) 721 (46) 2504 (158) 481 (30) 1657 (105) EV 1583 (100) 5705 (360) 792 (50) 2779 (175) 528 (33) 1853 (117) GR 1629 (103) 6516 (411) 814 (51) 2794 (176) 543 (34) 1855 (117) EW 1750 (110) 6308 (398) 875 (55) 3037 (192) 583 (37) 2031 (128)
  • 54. JOHNSON CONTROLS FORM 160.75-EG1 (915) 54 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 GS 1843 (116) 7372 (465) 922 (58) 3115 (197) 614 (39) 2075 (131) EX 1946 (123) 7012 (442) 973 (61) 3328 (210) – – – – – – – – E3 1416 (89) 5101 (322) 708 (45) 2551 (161) 472 (30) 1700 (107) – – – – – – E4 1738 (110) 6263 (395) 869 (55) 3131 (198) – – HQ 1443 (91) 5771 (364) 721 (46) 2162 (136) 481 (30) 1427 (90) FV 1583 (100) 5705 (360) 792 (50) 2405 (152) 528 (33) 1599 (101) HR 1629 (103) 6516 (411) 814 (51) 2419 (153) 543 (34) 1600 (101) FW 1750 (110) 6308 (398) 875 (55) 2636 (166) 583 (37) 1756 (111) HS 1843 (116) 7372 (465) 922 (58) 2707 (171) 614 (39) 1796 (113) FX 1946 (123) 7012 (442) 973 (61) 2898 (183) – – – – – – – – F3 1416 (89) 5101 (322) 708 (45) 2551 (161) 472 (30) 1700 (107) – – – – – – F4 1738 (110) 6263 (395) 869 (55) 3131 (198) – – JP 1545 (97) 6181 (390) 773 (49) 2735 (173) 515 (32) 1807 (114) JP 1583 (100) 5705 (360) 792 (50) 2779 (175) 528 (33) 1899 (120) JQ 1918 (121) 7670 (484) 959 (60) 3349 (211) 639 (40) 2224 (140) JQ 1892 (119) 6819 (430) 946 (60) 3249 (205) 631 (40) 2253 (142) JR 2395 (151) 9582 (604) 1198 (76) 4098 (259) 798 (50) 2742 (173) JR 2479 (156) 8933 (564) 1239 (78) 4054 (256) 826 (52) 2903 (183) JS 2616 (165) 10463 (660) 1308 (83) 4427 (279) 872 (55) 2974 (188) JS 2756 (174) 9933 (627) 1378 (87) 4395 (277) – – KP, KT 1545 (97) 6181 (390) 773 (49) 2522 (159) 515 (32) 1664 (105) KP 1583 (100) 5705 (360) 792 (50) 2574 (162) 528 (33) 1750 (110) KQ,KV 1918 (121) 7670 (484) 959 (60) 3094 (195) 639 (40) 2051 (129) KQ 1892 (119) 6819 (430) 946 (60) 3019 (190) 631 (40) 2078 (131) KR,KW 2395 (151) 9582 (604) 1198 (76) 3797 (240) 798 (50) 2533 (160) KR 2479 (156) 8933 (564) 1239 (78) 3790 (239) 826 (52) 2684 (169) KS,KX 2616 (165) 10463 (660) 1308 (83) 4109 (259) 872 (55) 2750 (174) KS 2756 (174) 9933 (627) 1378 (87) 4121 (260) – – K2,K5 1844 (116) 7374 (465) 922 (58) 3687 (233) 615 (39) 2458 (155) K2 1617 (102) 5829 (368) 809 (51) 2914 (184) 539 (34) 1943 (123) K3,K6 2163 (136) 8651 (546) 1081 (68) 4325 (273) 721 (45) 2884 (182) K3 1927 (122) 6946 (438) 964 (61) 3473 (219) 642 (41) 2315 (146) K4,K7 2488 (157) 9951 (628) 1244 (78) 4903 (309) 829 (52) 3312 (209) K4 2584 (163) 9313 (588) 1292 (82) 4657 (294) – – LQ 1918 (121) 7670 (484) 959 (60) 2886 (182) 639 (40) 1910 (120) LQ 1892 (119) 6819 (430) 946 (60) 2827 (178) 631 (40) 1936 (122) LR 2395 (151) 9582 (604) 1198 (76) 3550 (224) 798 (50) 2363 (149) LR 2479 (156) 8933 (564) 1239 (78) 3567 (225) 826 (52) 2504 (158) LS 2616 (165) 10463 (660) 1308 (83) 3845 (243) 872 (55) 2567 (162) LS 2756 (174) 9933 (627) 1378 (87) 3888 (245) – – – – – – – – MP 2192 (138) 7899 (498) 1096 (69) 3626 (229) 731 (46) 2391 (151)
  • 55. FORM 160.75-EG1 (915) JOHNSON CONTROLS 55 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 MQ 2426 (153) 9706 (612) 1213 (77) 3906 (246) 809 (51) 2606 (164) MQ 2570 (162) 9263 (584) 1285 (81) 4206 (265) 857 (54) 2776 (175) MR 2830 (179) 11319 (714) 1415 (89) 4499 (284) 943 (60) 3022 (191) MR 2949 (186) 10626 (670) 1474 (93) 4765 (301) 983 (62) 3149 (199) MS 3246 (205) 12982 (819) 1623 (102) 5088 (321) 1082 (68) 3444 (217) MS 3271 (206) 11786 (744) 1635 (103) 5225 (330) – – M2 2003 (126) 8013 (506) 1002 (63) 4006 (253) 668 (42) 2671 (169) M2 2131 (134) 7678 (484) 1065 (67) 3839 (242) 710 (45) 2559 (161) M3 2375 (150) 9502 (599) 1188 (75) 4751 (300) 792 (50) 3167 (200) M3 2639 (166) 9510 (600) 1319 (83) 4755 (300) 880 (55) 3170 (200) M4 2949 (186) 11794 (744) 1474 (93) 5837 (368) 983 (62) 3931 (248) M4 3246 (205) 11699 (738) 1623 (102) 5849 (369) – – – – – – – – NP 2192 (138) 7899 (498) 1096 (69) 3381 (213) 731 (46) 2229 (141) NQ 2426 (153) 9706 (612) 1213 (77) 3644 (230) 809 (51) 2426 (153) NQ 2570 (162) 9263 (584) 1285 (81) 3927 (248) 857 (54) 2591 (163) NR 2830 (179) 11319 (714) 1415 (89) 4205 (265) 943 (60) 2815 (178) NR 2949 (186) 10626 (670) 1474 (93) 4456 (281) 983 (62) 2943 (186) NS 3246 (205) 12982 (819) 1623 (102) 4763 (300) 1082 (68) 3210 (203) NS 3271 (206) 11786 (744) 1635 (103) 4892 (309) – – N2 2003 (126) 8013 (506) 1002 (63) 3870 (244) 668 (42) 2580 (163) N2 2131 (134) 7678 (484) 1065 (67) 3839 (242) 710 (45) 2559 (161) N3 2375 (150) 9502 (599) 1188 (75) 4527 (286) 792 (50) 3040 (192) N3 2639 (166) 9510 (600) 1319 (83) 4755 (300) 880 (55) 3170 (200) N4 2949 (186) 11794 (744) 1474 (93) 5484 (346) 983 (62) 3731 (235) N4 3246 (205) 11699 (738) 1623 (102) 5849 (369) – – PQ 2755 (174) 11021 (695) 1378 (87) 4391 (277) 918 (58) 2946 (186) PQ 3662 (231) 13195 (832) 1831 (116) 5954 (376) 1221 (77) 4003 (253) PR 3131 (198) 12523 (790) 1565 (99) 4928 (311) 1044 (66) 3328 (210) PR 4097 (258) 14763 (931) 2048 (129) 6587 (416) 1366 (86) 4452 (281) PS 3360 (212) 13441 (848) 1680 (106) 5246 (331) 1120 (71) 3558 (224) PS 4545 (287) 16377 (1033) 2272 (143) 7216 (455) – – P2 2523 (159) 10093 (637) 1262 (80) 5046 (318) 841 (53) 3364 (212) P2 3229 (204) 11635 (734) 1614 (102) 5817 (367) 1076 (68) 3878 (245) P3 2960 (187) 11842 (747) 1480 (93) 5857 (370) 987 (62) 3947 (249) P3 3917 (247) 14114 (890) 1958 (124) 7057 (445) 1306 (82) 4705 (297) P4 3356 (212) 13425 (847) 1678 (106) 6499 (410) 1119 (71) 4475 (282) P4 4760 (300) 17152 (1082) 2380 (150) 8576 (541) – – QQ 2755 (174) 11021 (695) 1378 (87) 4103 (259) 918 (58) 2744 (173) QQ 3662 (231) 13195 (832) 1831 (116) 5563 (351) 1221 (77) 3731 (235) QR 3131 (198) 12523 (790) 1565 (99) 4611 (291) 1044 (66) 3102 (196) QR 4097 (258) 14763 (931) 2048 (129) 6163 (389) 1366 (86) 4152 (262) QS 3360 (212) 13441 (848) 1680 (106) 4913 (310) 1120 (71) 3318 (209) QS 4545 (287) 16377 (1033) 2272 (143) 6762 (427) – – Q2 2523 (159) 10093 (637) 1262 (80) 4780 (302) 841 (53) 3221 (203) Q2 3229 (204) 11635 (734) 1614 (102) 5817 (367) 1076 (68) 3878 (245)
  • 56. JOHNSON CONTROLS FORM 160.75-EG1 (915) 56 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 Q3 2960 (187) 11842 (747) 1480 (93) 5503 (347) 987 (62) 3745 (236) Q3 3917 (247) 14114 (890) 1958 (124) 7057 (445) 1306 (82) 4705 (297) Q4 3356 (212) 13425 (847) 1678 (106) 6121 (386) 1119 (71) 4207 (265) Q4 4760 (300) 17152 (1082) 2380 (150) 8576 (541) – – QT 3602 (227) 14410 (909) 1801 (114) 5225 (330) 1201 (76) 3544 (224) – – – – – – QV 4142 (261) 16569 (1045) 2071 (131) 5893 (372) 1381 (87) 4037 (255) – – – – – – RQ 3770 (238) 15080 (951) 1885 (119) 5689 (359) 1257 (79) 3737 (236) RQ 4907 (310) 17684 (1116) 2454 (155) 7428 (469) 1636 (103) 4917 (310) RS 4605 (291) 18418 (1162) 2302 (145) 6863 (433) 1535 (97) 4517 (285) RR 5390 (340) 19423 (1225) 2695 (170) 8086 (510) 1797 (113) 5360 (338) RV 5405 (341) 21621 (1364) 2703 (171) 7946 (501) 1802 (114) 5240 (331) RS 5753 (363) 20730 (1308) 2876 (181) 8570 (541) – – R3 3870 (244) 15482 (977) 1935 (122) 7403 (467) 1290 (81) 4872 (307) R2 4228 (267) 15235 (961) 2114 (133) 7618 (481) 1409 (89) 5078 (320) R5 4603 (290) 18413 (1162) 2302 (145) 8650 (546) 1534 (97) 5708 (360) R3 4996 (315) 18005 (1136) 2498 (158) 9002 (568) 1665 (105) 6002 (379) R7 5241 (331) 20965 (1323) 2621 (165) 9682 (611) 1747 (110) 6404 (404) R4 5914 (373) 21311 (1344) 2957 (187) 10655 (672) – – RP 3103 (196) 12411 (783) 1551 (98) 4722 (298) 1034 (65) 3098 (195) – – – – – RR 3829 (242) 15316 (966) 1914 (121) 5774 (364) 1276 (81) 3793 (239) – – – – – – RT 4633 (292) 18530 (1169) 2316 (146) 6902 (435) 1544 (97) 4542 (287) – – – – – – R2 3800 (240) 15198 (959) 1900 (120) 7278 (459) 1267 (80) 4789 (302) – – – – – – R4 4296 (271) 17183 (1084) 2148 (136) 8135 (513) 1432 (90) 5362 (338) – – – – – – R6 4816 (304) 19263 (1215) 2408 (152) 9000 (568) 1605 (101) 5943 (375) – – – – – – SQ 3770 (238) 15080 (951) 1885 (119) 5345 (337) 1257 (79) 3510 (221) SQ 4907 (310) 17684 (1116) 2454 (155) 6992 (441) 1636 (103) 4626 (292) SS 4605 (291) 18418 (1162) 2302 (145) 6457 (407) 1535 (97) 4247 (268) SR 5390 (340) 19423 (1225) 2695 (170) 7619 (481) 1797 (113) 5047 (318) SV 5405 (341) 21621 (1364) 2703 (171) 7487 (472) 1802 (114) 4933 (311) SS 5753 (363) 20730 (1308) 2876 (181) 8081 (510) – – S3 3870 (244) 15482 (977) 1935 (122) 6975 (440) 1290 (81) 4588 (289) S2 4228 (267) 15235 (961) 2114 (133) 7549 (476) 1409 (89) 4993 (315) S5 4603 (290) 18413 (1162) 2302 (145) 8166 (515) 1534 (97) 5384 (340) S3 4996 (315) 18005 (1136) 2498 (158) 8795 (555) 1665 (105) 5832 (368) S7 5241 (331) 20965 (1323) 2621 (165) 9157 (578) 1747 (110) 6050 (382) S4 5914 (373) 21311 (1344) 2957 (187) 10192 (643) – – – – – – – – TP 5396 (340) 19446 (1227) 2698 (170) 8095 (511) 1799 (113) 5470 (345)
  • 57. FORM 160.75-EG1 (915) JOHNSON CONTROLS 57 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 – – – – – – TQ 5973 (377) 21525 (1358) 2987 (188) 8859 (559) 1991 (126) 6020 (380) – – – – – – TR 6576 (415) 23696 (1495) 3288 (207) 9629 (607) 2192 (138) 6583 (415) – – – – – – TS 6929 (437) 24969 (1575) 3464 (219) 10067 (635) – – – – – – – – T2 4607 (291) 16602 (1047) 2304 (145) 8301 (524) 1536 (97) 5534 (349) – – – – – – T3 5710 (360) 20578 (1298) 2855 (180) 10289 (649) 1903 (120) 6859 (433) – – – – – – T4 6299 (397) 22700 (1432) 3150 (199) 11300 (713) 2100 (132) 7567 (477) – – – – – – T5 7093 (447) 25559 (1613) 3546 (224) 12421 (784) – – – – – – – – VP 5396 (340) 19446 (1227) 2698 (170) 7628 (481) 1799 (113) 5140 (324) – – – – – – VQ 5973 (377) 21525 (1358) 2987 (188) 8358 (527) 1991 (126) 5660 (357) – – – – – – VR 6576 (415) 23696 (1495) 3288 (207) 9097 (574) 2192 (138) 6194 (391) – – – – – – VS 6929 (437) 24969 (1575) 3464 (219) 9518 (600) – – – – – – – – V2 4607 (291) 16602 (1047) 2304 (145) 8143 (514) 1536 (97) 5497 (347) – – – – – – V3 5710 (360) 20578 (1298) 2855 (180) 9865 (622) 1903 (120) 6749 (426) – – – – – – V4 6299 (397) 22700 (1432) 3150 (199) 10725 (677) 2100 (132) 7395 (467) – – – – – – V5 7093 (447) 25559 (1613) 3546 (224) 11818 (746) – – WP 3103 (196) 12411 (783) 1551 (98) 3973 (251) 1034 (65) 2605 (164) WQ 5368 (339) 19343 (1220) 2684 (169) 6844 (432) 1789 (113) 4591 (290) WR 3829 (242) 15316 (966) 1914 (121) 4871 (307) 1276 (81) 3197 (202) WR 5891 (372) 21230 (1339) 2946 (186) 7456 (470) 1964 (124) 5020 (317) WT 4633 (292) 18530 (1169) 2316 (146) 5842 (369) 1544 (97) 3840 (242) WS 6415 (405) 23117 (1458) 3207 (202) 8054 (508) – – W1 3173 (200) 12693 (801) 1587 (100) 5209 (329) 1058 (67) 3419 (216) W1 4250 (268) 15314 (966) 2125 (134) 6785 (428) 1417 (89) 4540 (286) W2 3800 (240) 15198 (959) 1900 (120) 6180 (390) 1267 (80) 4062 (256) W2 5260 (332) 18955 (1196) 2630 (166) 8290 (523) 1753 (111) 5603 (354) W4 4296 (271) 17183 (1084) 2148 (136) 6929 (437) 1432 (90) 4559 (288) W3 6140 (387) 22127 (1396) 3070 (194) 9526 (601) 2047 (129) 6502 (410) W6 4816 (304) 19263 (1215) 2408 (152) 7693 (485) 1605 (101) 5069 (320) W4 6785 (428) 24450 (1543) 3392 (214) 10386 (655) – – XQ 4769 (301) 19076 (1204) 2385 (150) 7089 (447) 1590 (100) 4667 (294) XQ 6241 (394) 22491 (1419) 3121 (197) 9429 (595) 2080 (131) 6272 (396)
  • 58. JOHNSON CONTROLS FORM 160.75-EG1 (915) 58 Application Data (Cont'd) TABLE 7 - FLOODED EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D FLOODED EVAPORATORS 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 XR 5272 (333) 21087 (1330) 2636 (166) 7769 (490) 1757 (111) 5121 (323) XR 6967 (440) 25105 (1584) 3483 (220) 10411 (657) 2322 (147) 6943 (438) XS 5740 (362) 22961 (1449) 2870 (181) 8386 (529) 1913 (121) 5534 (349) XS 7900 (498) 28470 (1796) 3950 (249) 11627 (734) – – X2 4769 (301) 19074 (1203) 2384 (150) 8923 (563) 1590 (100) 5891 (372) X2 4969 (313) 17905 (1130) 2484 (157) 8952 (565) 1656 (104) 5968 (377) X3 5637 (356) 22549 (1423) 2819 (178) 10296 (650) 1879 (119) 6820 (430) X3 6487 (409) 23378 (1475) 3244 (205) 11689 (737) 2162 (136) 7793 (492) X4 6281 (396) 25125 (1585) 3141 (198) 11250 (710) 2094 (132) 7470 (471) X4 8099 (511) 29185 (1841) 4049 (255) 14441 (911) – – ZQ 4769 (301) 19076 (1204) 2385 (150) 6671 (421) 1590 (100) 4390 (277) ZQ 6241 (394) 22491 (1419) 3121 (197) 8878 (560) 2080 (131) 5899 (372) ZR 5272 (333) 21087 (1330) 2636 (166) 7318 (462) 1757 (111) 4820 (304) ZR 6967 (440) 25105 (1584) 3483 (220) 9814 (619) 2322 (147) 6536 (412) ZS 5740 (362) 22961 (1449) 2870 (181) 7907 (499) 1913 (121) 5214 (329) ZS 7900 (498) 28470 (1796) 3950 (249) 10978 (693) – – Z1 3959 (250) 15836 (999) 1980 (125) 7122 (449) 1320 (83) 4686 (296) Z1 4138 (261) 14912 (941) 2069 (131) 7435 (469) 1379 (87) 4914 (310) Z2 4769 (301) 19074 (1203) 2384 (150) 8427 (532) 1590 (100) 5559 (351) Z2 4969 (313) 17905 (1130) 2484 (157) 8866 (559) 1656 (104) 5880 (371) Z3 5637 (356) 22549 (1423) 2819 (178) 9748 (615) 1879 (119) 6450 (407) Z3 6487 (409) 23378 (1475) 3244 (205) 11332 (715) 2162 (136) 7567 (477) Z4 6281 (396) 25125 (1585) 3141 (198) 10672 (673) 2094 (132) 7077 (447) Z4 8099 (511) 29185 (1841) 4049 (255) 13715 (865) – –
  • 59. FORM 160.75-EG1 (915) JOHNSON CONTROLS 59 Application Data (Cont'd) Table 8 - HYBRID FALLING FILM EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D HYBRID FALLING FILM EVAPORATORS MODEL 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX AC 705 (44) 2819 (178) 352 (22) 1194 (75) 235 (15) 825 (52) AD 882 (56) 3527 (223) 441 (28) 1436 (91) 294 (19) 1018 (64) A3 674 (43) 2695 (170) 337 (21) 1347 (85) 225 (14) 898 (57) A4 812 (51) 3248 (205) 406 (26) 1624 (102) 271 (17) 1083 (68) CC 796 (50) 3186 (201) 398 (25) 1410 (89) 265 (17) 945 (60) CD 999 (63) 3995 (252) 499 (32) 1734 (109) 333 (21) 1178 (74) CE 1270 (80) 5082 (321) 635 (40) 2140 (135) 423 (27) 1484 (94) C3 746 (47) 2983 (188) 373 (24) 1492 (94) 249 (16) 994 (63) C4 938 (59) 3753 (237) 469 (30) 1877 (118) 313 (20) 1251 (79) C5 1221 (77) 4884 (308) 611 (39) 2442 (154) 407 (26) 1628 (103) DC 796 (50) 3186 (201) 398 (25) 1214 (77) 265 (17) 809 (51) DD 999 (63) 3995 (252) 499 (32) 1501 (95) 333 (21) 1010 (64) DE 1270 (80) 5082 (321) 635 (40) 1865 (118) 423 (27) 1275 (80) D3 746 (47) 2983 (188) 373 (24) 1463 (92) 249 (16) 982 (62) D4 938 (59) 3753 (237) 469 (30) 1803 (114) 313 (20) 1228 (77) D5 1221 (77) 4884 (308) 611 (39) 2261 (143) 407 (26) 1578 (100) EC 980 (62) 3919 (247) 490 (31) 1758 (111) 327 (21) 1168 (74) ED 1296 (82) 5183 (327) 648 (41) 2289 (144) 432 (27) 1537 (97) EE 1637 (103) 6548 (413) 819 (52) 2831 (179) 546 (34) 1929 (122) E3 986 (62) 3946 (249) 493 (31) 1973 (124) 329 (21) 1315 (83) E4 1233 (78) 4932 (311) 617 (39) 2466 (156) 411 (26) 1644 (104) E5 1522 (96) 6087 (384) 761 (48) 3044 (192) 507 (32) 2029 (128) FC 980 (62) 3919 (247) 490 (31) 1508 (95) 327 (21) 998 (63) FD 1296 (82) 5183 (327) 648 (41) 1972 (124) 432 (27) 1316 (83) FE 1637 (103) 6548 (413) 819 (52) 2452 (155) 546 (34) 1654 (104)
  • 60. JOHNSON CONTROLS FORM 160.75-EG1 (915) 60 TABLE 8 - HYBRID FALLING FILM EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D Application Data (Cont'd) HYBRID FALLING FILM EVAPORATORS MODEL 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX F3 986 (62) 3946 (249) 493 (31) 1956 (123) 329 (21) 1304 (82) F4 1233 (78) 4932 (311) 617 (39) 2410 (152) 411 (26) 1622 (102) F5 1522 (96) 6087 (384) 761 (48) 2914 (184) 507 (32) 1989 (125) GC 1293 (82) 5170 (326) 646 (41) 2284 (144) 431 (27) 1533 (97) GD 1618 (102) 6472 (408) 809 (51) 2802 (177) 539 (34) 1907 (120) GE 2108 (133) 8432 (532) 1054 (66) 3521 (222) 703 (44) 2455 (155) G3 1269 (80) 5077 (320) 635 (40) 2538 (160) 423 (27) 1692 (107) G4 1588 (100) 6352 (401) 794 (50) 3176 (200) 529 (33) 2117 (134) G5 1973 (124) 7892 (498) 986 (62) 3946 (249) 658 (41) 2631 (166) HC 1293 (82) 5170 (326) 646 (41) 1967 (124) 431 (27) 1312 (83) HD 1618 (102) 6472 (408) 809 (51) 2426 (153) 539 (34) 1635 (103) HE 2108 (133) 8432 (532) 1054 (66) 3075 (194) 703 (44) 2112 (133) H3 1269 (80) 5077 (320) 635 (40) 2474 (156) 423 (27) 1668 (105) H4 1588 (100) 6352 (401) 794 (50) 3025 (191) 529 (33) 2072 (131) H5 1973 (124) 7892 (498) 986 (62) 3637 (229) 658 (41) 2546 (161) KC 2117 (134) 8470 (534) 1059 (67) 3424 (216) 706 (45) 2305 (145) KD 2784 (176) 11137 (703) 1392 (88) 4378 (276) 928 (59) 3004 (190) K8 1540 (97) 6159 (389) 770 (49) 3080 (194) 513 (32) 2053 (130) K9 2057 (130) 8228 (519) 1029 (65) 4114 (260) 686 (43) 2743 (173) K0 2695 (170) 10779 (680) 1347 (85) 5316 (335) 898 (57) 3593 (227) IB 2124 (134) 8496 (536) 1062 (67) 3274 (207) 707 (45) 2170 (137) ID 2378 (150) 9510 (600) 1189 (75) 3633 (229) 793 (50) 2419 (153) IF 2793 (176) 11171 (705) 1395 (88) 4193 (265) 929 (59) 2807 (177) IH 2916 (184) 11666 (736) 1458 (92) 4360 (275) – – I2 1547 (98) 6187 (390) 773 (49) 3093 (195) 514 (32) 2054 (130)
  • 61. FORM 160.75-EG1 (915) JOHNSON CONTROLS 61 TABLE 8 - HYBRID FALLING FILM EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D Application Data (Cont'd) HYBRID FALLING FILM EVAPORATORS MODEL 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX I4 1812 (114) 7250 (457) 906 (57) 3606 (228) 604 (38) 2399 (151) I6 2066 (130) 8265 (521) 1033 (65) 4060 (256) 689 (43) 2713 (171) I8 2864 (181) 11455 (723) 1432 (90) 5367 (339) – – MB 2479 (156) 9916 (626) 1239 (78) 3833 (242) 824 (52) 2550 (161) MD 2891 (182) 11564 (730) 1446 (91) 4418 (279) 964 (61) 2965 (187) MF 3370 (213) 13479 (850) 1683 (106) 5067 (320) – – M5 2048 (129) 8192 (517) 1021 (64) 4084 (258) 683 (43) 2731 (172) M7 2429 (153) 9715 (613) 1214 (77) 4790 (302) 810 (51) 3226 (204) M8 3015 (190) 12059 (761) 1504 (95) 5780 (365) 1003 (63) 3947 (249) M9 3420 (216) 13678 (863) 1710 (108) 6434 (406) – – NB 2479 (156) 9916 (626) 1239 (78) 3577 (226) 824 (52) 2374 (150) ND 2891 (182) 11564 (730) 1446 (91) 4129 (261) 964 (61) 2763 (174) NF 3370 (213) 13479 (850) 1683 (106) 4744 (299) – – N5 2048 (129) 8192 (517) 1021 (64) 3827 (241) 683 (43) 2558 (161) N7 2429 (153) 9715 (613) 1214 (77) 4492 (283) 810 (51) 3015 (190) N8 3015 (190) 12059 (761) 1504 (95) 5437 (343) 1003 (63) 3695 (233) N9 3420 (216) 13678 (863) 1710 (108) 6065 (383) – – PB 2815 (178) 11260 (710) 1407 (89) 4312 (272) 938 (59) 2890 (182) PD 3199 (202) 12794 (807) 1598 (101) 4837 (305) 1065 (67) 3263 (206) PF 3680 (232) 14722 (929) 1839 (116) 5639 (356) 1227 (77) 3728 (235) P5 2580 (163) 10319 (651) 1287 (81) 5045 (318) 858 (54) 3409 (215) P7 3027 (191) 12107 (764) 1510 (95) 5800 (366) 1009 (64) 3969 (250) P8 3625 (229) 14500 (915) 1812 (114) 6745 (426) 1208 (76) 4682 (295) QB 2815 (178) 11260 (710) 1407 (89) 4029 (254) 938 (59) 2693 (170) QD 3199 (202) 12794 (807) 1598 (101) 4526 (286) 1065 (67) 3042 (192)
  • 62. JOHNSON CONTROLS FORM 160.75-EG1 (915) 62 HYBRID FALLING FILM EVAPORATORS MODEL 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX QF 3680 (232) 14722 (929) 1839 (116) 5268 (332) 1227 (77) 3479 (220) QH 1902 (120) 7608 (480) 951 (60) 2799 (177) – – Q5 8283 (523) 33132 (2090) 4138 (261) 11049 (697) 2761 (174) 8597 (542) Q7 2580 (163) 10319 (651) 1287 (81) 4734 (299) 858 (54) 3187 (201) Q8 3027 (191) 12107 (764) 1510 (95) 5456 (344) 1009 (64) 3716 (234) TABLE 8 - HYBRID FALLING FILM EVAPORATOR WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D Application Data (Cont'd)
  • 63. FORM 160.75-EG1 (915) JOHNSON CONTROLS 63 Application Data (Cont'd) Table 9 - HEAT RECOVERY WATER FLOW RATE LIMITS GPM (L/S) – BASED UPON STANDARD TUBES @ DESIGN FULL LOAD CONDITIONS CONT'D MODEL HEAT RECOVERY CONDENSER - TOWER BUNDLE HEAT RECOVERY CONDENSER - HEATING BUNDLE 1 PASS 2 PASS 3 PASS 1 PASS 2 PASS 3 PASS MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX BW 1435 (91) 5171 (326) 717 (45) 2392 (151) 478 (30) 1590 (100) 555 (35) 2000 (126) 278 (18) 1000 (63) 185 (12) 665 (42) BX 1435 (91) 5171 (326) 717 (45) 2392 (151) 478 (30) 1590 (100) 861 (54) 3103 (196) 430 (27) 1529 (96) 287 (18) 1010 (64) IW 2123 (134) 7649 (483) 1061 (67) 3579 (226) 708 (45) 2409 (152) 763 (48) 2750 (174) 382 (24) 1367 (86) 254 (16) 917 (58) IX 2123 (134) 7649 (483) 1061 (67) 3579 (226) 708 (45) 2409 (152) 1344 (85) 4842 (305) 672 (42) 2260 (143) 448 (28) 1586 (100) OW 3129 (197) 11274 (711) 1564 (99) 4892 (309) 1043 (66) 3322 (210) 940 (59) 3387 (214) 470 (30) 1571 (99) 313 (20) 1038 (65) OX 3129 (197) 11274 (711) 1564 (99) 4892 (309) 1043 (66) 3322 (210) 1984 (125) 7149 (451) 992 (63) 3138 (198) 661 (42) 2102 (133) O8 3053 (193) 11002 (694) 1527 (96) 5501 (347) 1018 (64) 3667 (231) 1122 (71) 4043 (255) 561 (35) 2021 (128) 374 (24) 1348 (85) O9 3053 (193) 11002 (694) 1527 (96) 5501 (347) 1018 (64) 3667 (231) 1791 (113) 6455 (407) 896 (57) 3228 (204) 597 (38) 2152 (136) UW 3293 (208) 11865 (749) 1646 (104) 5256 (332) 1098 (69) 3477 (219) 1069 (67) 3853 (243) 535 (34) 1799 (113) 356 (22) 1188 (75) UX 3293 (208) 11865 (749) 1646 (104) 5256 (332) 1098 (69) 3477 (219) 2091 (132) 7535 (475) 1045 (66) 3415 (215) 697 (44) 2281 (144) U8 3403 (215) 12263 (774) 1701 (107) 6131 (387) 1134 (72) 4088 (258) 1178 (74) 4244 (268) 589 (37) 2122 (134) 393 (25) 1415 (89) U9 3403 (215) 12263 (774) 1701 (107) 6131 (387) 1134 (72) 4088 (258) 1891 (119) 6813 (430) 945 (60) 3406 (215) 630 (40) 2271 (143) YW 7705 (486) 27765 (1752) 3852 (243) 10738 (677) 2568 (162) 7169 (452) 2596 (164) 9353 (590) 1298 (82) 3797 (240) 865 (55) 2513 (159) YX 7705 (486) 27765 (1752) 3852 (243) 10738 (677) 2568 (162) 7169 (452) 4917 (310) 17718 (1118) 2458 (155) 6991 (441) 1639 (103) 4693 (296) Y8 7963 (502) 28696 (1810) 3982 (251) 13330 (841) 2654 (167) 8951 (565) 3236 (204) 11660 (736) 1618 (102) 5830 (368) 1079 (68) 3887 (245) Y9 7963 (502) 28696 (1810) 3982 (251) 13330 (841) 2654 (167) 8951 (565) 5244 (331) 18897 (1192) 2622 (165) 9287 (586) 1748 (110) 6299 (397)
  • 64. JOHNSON CONTROLS FORM 160.75-EG1 (915) 64 Application Data (Cont'd) Table 10 - 60 HZ ELECTRICAL DATA MOTOR CODE CF CG CH CJ CK CL CM CN CP CR CS CT CU CV CW SHAFT HP (MAX) 154 177 201 237 270 302 327 351 385 424 468 503 554 608 655 INPUT KW (MAX) 123 140 161 190 214 240 257 276 302 333 367 395 435 477 514 F.L. EFF. - % 1 93.6 94.5 93.3 93 94 94 95 95 95 95 95 95 95 95 95 F.L. POWER FACTOR 1 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.87 0.87 0.87 0.87 0.87 0.87 VOLTS AMPERES (MAXIMUM) 200 FLA 405 465 527 618 707 787 831 921 1014 1085 1208 - - - - LRA 2598 3111 3111 3810 4550 4900 5470 5780 5780 7350 7794 - - - - 208 FLA 389 447 507 594 680 757 799 886 975 1043 1162 - - - - LRA 2702 3235 3235 3962 4732 5096 5689 6011 6011 7644 8106 - - - - 230 FLA 352 404 464 540 610 685 749 804 882 944 1050 1130 - - - LRA 2598 2598 2865 3460 3788 4260 4755 5162 5780 5780 6900 7400 - - - 240 FLA 337 387 445 518 585 656 718 771 845 905 1006 1083 - - - LRA 2711 2711 3120 3610 3953 4445 4962 5386 6031 6031 7200 7722 - - - 380 FLA 217 249 285 336 378 421 453 487 534 571 636 684 756 817 879 LRA 1385 1385 1730 2153 2500 2577 2955 3254 3637 3810 4179 4480 4671 5326 5780 416 FLA 199 228 260 307 346 385 412 445 488 522 581 625 691 747 810 LRA 1385 1385 1638 1967 2190 2356 2700 2976 3536 3637 3810 3810 4270 4869 5640 440 FLA 184 211 238 281 319 358 392 397 461 493 549 591 646 706 759 LRA 1177 1301 1320 1655 1865 2037 2485 2485 2976 2976 3300 3644 3644 4209 4783 460 FLA 176 202 228 269 305 342 375 380 441 472 525 565 618 675 726 LRA 1230 1360 1380 1730 1950 2130 2598 2598 3111 3111 3450 3500 3810 4400 4880 480 FLA 169 194 219 258 292 328 359 364 423 452 503 541 592 647 696 LRA 1283 1419 1440 1805 2035 2223 2711 2711 3246 3246 3600 3976 3976 4591 5217 575 FLA 141 162 185 216 250 274 300 318 353 377 420 452 500 540 581 LRA 909 909 1100 1384 1556 1700 1900 2066 2078 2413 2760 2960 3089 3550 4039 600 FLA 135 155 177 207 240 263 288 305 338 361 403 433 479 518 557 LRA 949 949 1148 1444 1624 1774 1983 2156 2168 2518 2880 3089 3223 3704 4215 2300 FLA 36 41.1 46 55 63 70 73.9 80 87 95 106 113 124 135 146 LRA 240 267 298 340 397 435 480 520 543 590 669 719 791 867 935 3300 FLA 25.5 29 33 39 44 49 52 55.3 61 67 72.8 79 86.1 94.4 102 LRA 160 175 210 240 280 310 310 343 382 415 466 501 551 576 652 4000 FLA 21 24 26.7 32 36 40 42.5 46 50.1 55 60.1 65.2 71 77.9 84 LRA 135 154 166 195 230 240 270 283 315 340 384 413 455 499 538 4160 FLA 20.2 23 25.7 30.8 34.6 38.5 40.9 44.2 48.2 52.9 57.8 62.7 68.3 74.9 80.8 LRA 140 160 173 203 239 250 270 294 328 328 399 430 473 519 560 Table 11 - 50 HZ ELECTRICAL DATA MOTOR CODE 5CC 5CD 5CE 5CF 5CG 5CH 5CI 5CJ 5CK 5CL 5CM 5CN 5CO 5CP 5CQ 5CR 5CS SHAFT HP (MAX) 148 168 198 225 252 272 292 321 353 390 419 462 507 546 575 617 658 INPUT KW (MAX) 119 135 158 179 201 215 231 254 279 309 332 363 398 429 451 484 516 F.L. EFF. - % 1 93 93 93.4 93.7 93.7 94.2 94.2 94.2 94.2 94.2 94.2 95 95 95 95 95 95 F.L. POWER FACTOR 1 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.86 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.88 VOLTS AMPERES (MAXIMUM) 346 FLA 230 261 306 347 389 418 448 493 536 592 636 696 763 822 866 929 979 LRA 1385 1721 1790 2208 2467 2598 2840 3081 3350 3706 3810 4177 4830 4944 5373 5780 5780 380 FLA 210 238 278 316 354 380 408 449 488 539 579 633 695 748 788 846 892 LRA 1385 1385 1640 1890 2144 2464 2590 2806 3050 3375 3700 3810 4400 4500 4892 5600 5491 400 FLA 200 226 264 300 336 361 388 427 464 512 550 601 660 711 749 804 847 LRA 1458 1458 1726 1990 2257 2594 2726 2954 3211 3533 3895 4011 4632 4737 5149 5895 5780 415 FLA 192 218 255 290 324 348 374 411 447 494 530 580 636 685 722 774 817 LRA 1283 1385 1490 1700 2031 2175 2366 2569 2794 3088 3402 3478 3810 4117 4480 5130 5108 3300 FLA 24.1 27.4 32.2 36.4 40.8 43.8 47 51.7 56.2 62.1 66.7 72.9 80 86.2 90.8 97.4 103 LRA 159 162 209 236 241 274 294 318 317 388 423 455 499 516 572 614 644 NOTES: 1. High voltage and special motor designs may not meet efficiency, power factor or amperes values shown for standard motors. 2. Min. reduced voltage tap 80%.
  • 65. FORM 160.75-EG1 (915) JOHNSON CONTROLS 65 Application Data (Cont'd) TABLE 810 - 60 HZ ELECTRICAL DATA CONT'D MOTOR CODE CX CY CZ CA CB DA DB DC DD DE DF DH DJ DK DL SHAFT HP (MAX) 690 740 790 845 900 1000 1100 1200 1300 1400 1500 1750 2000 2250 2500 INPUT KW (MAX) 542 578 618 660 703 781 859 937 1015 1093 1171 1359 1554 1748 1942 F.L. EFF. - % 1 95 95.5 95.3 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5 96 96 96 96 F.L. POWER FACTOR 1 0.87 0.88 0.88 0.89 0.89 0.87 0.87 0.87 0.88 0.88 0.88 0.87 0.89 0.89 0.89 VOLTS AMPERES (MAXIMUM) 200 FLA - - - - - - - - - - - - - - - LRA - - - - - - - - - - - - - - - 208 FLA - - - - - - - - - - - - - - - LRA - - - - - - - - - - - - - - - 230 FLA - - - - - - - - - - - - - - - LRA - - - - - - - - - - - - - - - 240 FLA - - - - - - - - - - - - - - - LRA - - - - - - - - - - - - - - - 380 FLA 942 997 1065 1126 1200 1364 1500 1636 - - - - - - - LRA 5780 5780 6644 7610 7513 7794 8491 9431 - - - - - - - 416 FLA 860 911 973 1029 1096 1246 1370 1495 - - - - - - - LRA 5670 5694 6069 6900 6863 7120 7755 8618 - - - - - - - 440 FLA 813 861 920 973 1036 1178 1295 1413 - - - - - - - LRA 5357 4783 5249 5791 5529 6160 6709 7455 - - - - - - - 460 FLA 778 824 880 931 991 1127 1239 1352 - - - - - - - LRA 4960 5280 5330 6054 5780 6440 7014 7794 - - - - - - - 480 FLA 746 790 843 892 950 1080 1187 1296 - - - - - - - LRA 5843 5217 5727 6317 6031 6720 7319 8133 - - - - - - - 575 FLA 622 659 704 744 793 901 991 1081 - - - - - - - LRA 4100 4200 4200 5225 4963 5148 5610 6232 - - - - - - - 600 FLA 596 632 675 713 760 863 950 1036 - - - - - - - LRA 4633 4487 4383 5452 5179 5372 5854 6503 - - - - - - - 2300 FLA 154 165 176 186 198 225 248 267 290 312 334 383 438 493 548 LRA 960 1008 1100 1172 1230 1350 1592 1592 1882 2031 2171 2390 2879 3199 3356 3300 FLA 108 115 123 130 138 157 173 186 202 217 233 267 306 344 382 LRA 682 719 744 819 858 942 1110 1110 1311 1416 1514 1661 2011 2388 2479 4000 FLA 88.6 94.8 101 107 114 130 143 154 166 179 192 220 252 283 315 LRA 540 554 631 674 713 780 923 923 1077 1177 1246 1428 1669 1842 2047 4160 FLA 85.2 91.1 97.1 102 110 125 137 148 160 172 185 212 242 273 303 LRA 562 576 656 701 742 811 960 960 1120 1224 1296 1485 1736 1772 1968 TABLE 11 - 50 HZ ELECTRICAL DATA (CONT'D) MOTOR CODE 5CT 5CU 5CV 5CW 5CX 5DA 5DB 5DC 5DD 5DE 5DF 5DG 5DH 5DJ2 5DK 5DL SHAFT HP (MAX) 704 750 800 850 900 1000 1100 1200 1300 1400 1500 1650 1750 2000 2250 2500 INPUT KW (MAX) 553 589 628 667 706 785 863 942 1015 1093 1171 1288 1359 1554 1748 1942 F.L. EFF. - % 1 95 95 95 95 95 95 95 95 95.5 95.5 95.5 95.5 96 96 96 96 F.L. POWER FACTOR 1 0.88 0.89 0.89 0.89 0.89 0.88 0.87 0.88 0.88 0.88 0.88 0.88 0.89 0.89 0.89 0.89 VOLTS AMPERES (MAXIMUM) 346 FLA 1048 1104 1177 1251 1325 1488 1656 - - - - - - - - - LRA 6615 6931 7356 7794 8319 8559 9346 - - - - - - - - - 380 FLA 954 1005 1072 1139 1206 1355 1508 - - - - - - - - - LRA 5491 6313 6694 7113 7404 7794 8511 - - - - - - - - - 400 FLA 906 955 1018 1082 1146 1287 1433 - - - - - - - - - LRA 5780 6645 7046 7487 7794 8204 8959 - - - - - - - - - 415 FLA 874 920 982 1043 1104 1241 1381 - - - - - - - - - LRA 5512 5780 6131 6513 6938 7138 7794 - - - - - - - - - 3300 FLA 110 116 123 131 139 156 174 187 202 217 233 256 267 306 344 382 LRA 693 725 744 819 875 871 1135 1135 1135 1415 1415 1415 1667 1836 2233 2481 NOTES: 1. High voltage and special motor designs may not meet efficiency, power factor or amperes values shown for standard motors. 2. Min. reduced voltage tap 80%.
  • 66. JOHNSON CONTROLS FORM 160.75-EG1 (915) 66 Application Data (Cont'd) NOTES: 1. High voltage and special motor designs may not meet efficiency, power factor or amperes values shown for standard motors. 2. Min. reduced voltage tap 80%. Table 12 - 60 HZ ELECTRICAL DATA - PREMIUM EFFICIENCY MOTOR CODE EF EG EH EJ EK EL EM EN EP ER ES ET EU EV SHAFT HP (MAX) 154 177 201 237 270 302 327 351 385 424 468 503 554 608 INPUT KW (MAX) 122 139 158 185 211 236 256 274 300 330 364 392 431 473 F.L. EFF. - % 94.5 95 95 95.4 95.4 95.4 95.4 95.4 95.8 95.8 95.8 95.8 95.8 95.8 F.L. POWER FACTOR 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 VOLTS AMPERES (MAXIMUM) 200 FLA 399 456 518 608 692 774 838 900 983 1083 1195 - - - LRA 2815 3128 3128 3979 4550 4900 5635 5865 6686 7350 7935 - - - 208 FLA 383 438 498 584 666 745 806 865 945 1041 1149 - - - LRA 2928 3235 3235 4138 4732 5096 5860 6100 6953 7644 8252 - - - 230 FLA 347 396 450 528 602 673 729 783 855 941 1039 1117 - - LRA 2598 2720 2865 3460 3788 4260 4900 5162 5814 6200 6900 8513 - - 240 FLA 332 380 431 506 577 645 699 750 819 902 996 1070 - - LRA 2711 2838 2990 3610 3953 4445 5113 5386 6067 6470 7200 8883 - - 380 FLA 210 240 272 320 364 408 441 474 517 570 629 676 745 817 LRA 1482 1646 1730 2153 2500 2578 2966 3254 3637 3810 4179 4480 4671 5326 416 FLA 192 219 249 292 333 372 403 433 473 521 575 617 680 746 LRA 1385 1504 1638 1967 2190 2356 2709 2976 3536 3637 3815 3826 4270 5418 440 FLA 181 207 235 276 315 352 381 409 447 492 543 584 643 706 LRA 1177 1301 1320 1655 1865 2037 2485 2485 2976 2976 3300 3348 3644 4687 460 FLA 173 198 225 264 301 337 365 391 427 471 520 558 615 675 LRA 1230 1360 1380 1730 1950 2130 2598 2598 3111 3111 3450 3500 3810 4900 480 FLA 166 190 216 253 288 323 349 375 410 451 498 535 589 647 LRA 1283 1419 1440 1805 2035 2223 2711 2711 3246 3246 3600 3652 3976 5113 575 FLA 139 159 180 211 241 269 292 313 342 377 416 447 492 540 LRA 979 1088 1100 1384 1556 1704 1960 2066 2326 2413 2760 2960 3089 3550 600 FLA 133 152 173 203 231 258 279 300 328 361 398 428 472 517 LRA 1021 1135 1148 1444 1624 1778 2045 2156 2427 2518 2880 3089 3223 3704 NOTE: These motors are designed to meet or exceed NEMA Premium (MG1-2006) and European IE2 efficiency requirements. Table 13 - 50 HZ ELECTRICAL DATA - PREMIUM EFFICIENCY MOTOR CODE 5EC 5ED 5EE 5EF 5EG 5EH 5EI 5EJ 5EK 5EL 5EM 5EN 5EO SHAFT HP (MAX) 148 168 198 225 252 272 292 321 353 390 419 462 507 INPUT KW (MAX) 117 133 156 177 198 214 229 252 277 305 328 361 396 F.L. EFF. - % 94.3 94.5 94.7 94.9 95 95 95 95 95 95.4 95.4 95.4 95.4 F.L. POWER FACTOR 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 0.88 VOLTS AMPERES (MAXIMUM) 346 FLA 222 251 296 335 375 405 435 478 525 578 621 685 751 LRA 1521 1721 1790 2208 2467 2706 2840 3081 3350 3706 3810 4177 5150 380 FLA 202 229 269 305 342 369 396 435 478 526 565 623 684 LRA 1385 1385 1640 1890 2144 2464 2590 2806 3050 3375 3700 3810 4690 400 FLA 192 217 256 290 324 350 376 413 454 500 537 592 650 LRA 1458 1458 1726 1989 2257 2594 2726 2954 3211 3553 3895 4011 4937 415 FLA 185 210 246 280 313 338 362 398 438 482 518 571 627 LRA 1283 1385 1502 1700 2031 2175 2366 2569 2794 3088 3402 3478 4027
  • 67. FORM 160.75-EG1 (915) JOHNSON CONTROLS 67 Application Data (Cont'd) NOTES: 1. High voltage and special motor designs may not meet efficiency, power factor or amperes values shown for standard motors. 2. Min. reduced voltage tap 80%. TABLE 12 - 60 HZ ELECTRICAL DATA - PREMIUM EFFICIENCY (CONT'D) MOTOR CODE EW EX EY EZ EA EB FA SHAFT HP (MAX) 655 690 740 790 845 900 1000 INPUT KW (MAX) 508 535 574 612 655 698 775 F.L. EFF. - % 96.2 96.2 96.2 96.2 96.2 96.2 96.2 F.L. POWER FACTOR 0.87 0.87 0.88 0.87 0.88 0.88 0.87 VOLTS AMPERES (MAXIMUM) 200 FLA - - - - - - - LRA - - - - - - - 208 FLA - - - - - - - LRA - - - - - - - 230 FLA - - - - - - - LRA - - - - - - - 240 FLA - - - - - - - LRA - - - - - - - 380 FLA 887 934 990 1069 1131 1204 1354 LRA 5780 5859 6244 6644 7106 7513 7794 416 FLA 810 853 905 977 1033 1100 1237 LRA 5640 5670 5704 6069 6489 6863 7120 440 FLA 766 807 855 924 977 1040 1169 LRA 4668 4744 5050 5098 5529 5782 6160 460 FLA 732 772 818 883 934 995 1118 LRA 4880 4960 5280 5330 5780 6045 6440 480 FLA 702 739 784 847 895 954 1072 LRA 5092 5175 5510 5562 6031 6308 6720 575 FLA 586 617 654 707 747 796 895 LRA 4039 4100 4200 4200 4694 4963 5148 600 FLA 562 592 627 677 716 763 857 LRA 4214 4278 4383 4383 5452 5179 5372 NOTE: These motors are designed to meet or exceed NEMA Premium (MG1-2006) and European IE2 efficiency requirements. TABLE 13 - 50 HZ ELECTRICAL DATA - PREMIUM EFFICIENCY (CONT'D) MOTOR CODE 5EP 5EQ 5ER 5ES 5ET 5EU 5EV 5EW SHAFT HP (MAX) 546 575 617 658 704 750 800 850 INPUT KW (MAX) 425 448 480 512 548 584 623 662 F.L. EFF. - % 95.8 95.8 95.8 95.8 95.8 95.8 95.8 95.8 F.L. POWER FACTOR 0.87 0.87 0.87 0.87 0.88 0.88 0.87 0.87 VOLTS AMPERES (MAXIMUM) 346 FLA 815 858 921 982 1039 1107 1194 1269 LRA 5063 5373 5780 5780 6615 6931 7356 7794 380 FLA 742 782 839 894 946 1008 1087 1155 LRA 4610 4892 5600 5491 5491 6313 6694 7113 400 FLA 705 743 797 850 899 958 1033 1098 LRA 4853 5149 5895 5780 5780 6645 7046 7487 415 FLA 680 716 768 819 866 923 996 1058 LRA 4221 4480 5130 5108 5512 5780 6131 6513
  • 68. JOHNSON CONTROLS FORM 160.75-EG1 (915) 68 Application Data (Cont'd) NOTES: 1. For motor starters above 4160V/60Hz and 3300/50Hz contact the Johnson Controls Sales Office for a specific selection. 2. Minimum tap for 5DJ motor is 80%. Table 14 - MOTOR STARTERS TYPE STARTER SOLID- STATE STARTER STAR DELTA AUTO TRANSFORMER ACROSS- THE-LINE PRIMARY REACTOR VOLTAGE LOW/ MEDIUM LOW LOW LOW/ MEDIUM LOW/ MEDIUM LOW/ MEDIUM MEDIUM MEDIUM 60 HZ 200-4160 200-600 200-600 200-4160 200-4160 200-4160 2300-4160 2300-4160 50 HZ 380-3300 346-415 346-415 346-3300 346-3300 346-3300 2300-3300 2300-3300 TRANSITION % TAP INRUSH AS A % OF LRA — CLOSED CLOSED CLOSED CLOSED — CLOSED CLOSED — — 57.7 65 80 — 65 80 45 33 33 42.3 64 100 65 80
  • 69. FORM 160.75-EG1 (915) JOHNSON CONTROLS 69 Application Data (Cont'd) Table 15 - LOW VOLTAGE VARIABLE SPEED MODELS FRAME LV-VSD MAXIMUM LRA MAXIMUM MOTOR HP MINIMUM FLA MAXIMUM FLA RATED VOLTAGE ACTUAL VOLTAGE PHASE HZ I 2500 270 80 364 380 380 3 60 II 3637 385 120 517 III 5326 608 200 817 IV 7610 845 300 1126 I 2598 351 80 380 460 440/ 460/ 480 II 3652 503 120 565 III 5777 790 200 880 IV 7014 1048 300 1180 I 2413 424 80 377 575 575/600 II 3550 608 120 540 I 2727 292 80 380 380 380/400 3 50 II 2895 419 120 565 III 5780 658 200 880 IV 8205 917 300 1180 I 2366 292 80 362 415 415 II 3402 419 120 518 III 5512 704 200 876 IV 6938 900 300 1108
  • 70. JOHNSON CONTROLS FORM 160.75-EG1 (915) 70 Table 16 - MEDIUM VOLTAGE VARIABLE SPEED DRIVE MODELS MV-VSD MAXIMUM MOTOR HP MAXIMUM FLA VOLTAGE PHASE HZ MVVSD0500RK-80 500 107 2300 3 60 MVVSD0600RK-80 600 129 MVVSD0700RK-80 700 157 MVVSD0800RK-80 800 172 MVVSD0900RK-80 900 202 MVVSD1000RK-80 1000 224 MVVSD1250RK-80 1250 280 MVVSD1500RK-80 1500 336 MVVSD1750RK-80 1750 392 MVVSD2000RK-80 2000 438 MVVSD2250RK-80 2250 494 MVVSD2500RK-80 2500 561 MVVSD0500RK-94 500 78 3300 3 60 MVVSD0600RK-94 600 93 MVVSD0700RK-94 700 110 MVVSD0800RK-94 800 124 MVVSD0900RK-94 900 141 MVVSD1000RK-94 1000 156 MVVSD1250RK-94 1250 195 MVVSD1500RK-94 1500 235 MVVSD1750RK-94 1750 274 MVVSD2000RK-94 2000 312 MVVSD2250RK-94 2250 345 MVVSD2500RK-94 2500 391 MVVSD0500RK-92S 500 62 4160 3 60 MVVSD0600RK-92S 600 74 MVVSD0700RK-92S 700 87 MVVSD0800RK-92S 800 99 MVVSD0900RK-92S 900 112 MVVSD1000RK-92S 1000 125 MVVSD1250RK-92S 1250 155 MVVSD1500RK-92S 1500 186 MVVSD1750RK-92S 1750 217 MVVSD2000RK-92S 2000 248 MVVSD2250RK-92S 2250 274 MVVSD2500RK-92S 2500 310 MVVSD0500RK-92 500 78 3300 3 50 MVVSD0600RK-92 600 93 MVVSD0700RK-92 700 110 MVVSD0800RK-92 800 124 MVVSD0900RK-92 900 141 MVVSD1000RK-92 1000 156 MVVSD1250RK-92 1250 195 MVVSD1500RK-92 1500 235 MVVSD1750RK-92 1750 274 MVVSD2000RK-92 2000 312 MVVSD2250RK-92 2250 345 MVVSD2500RK-92 2500 391 Application Data (Cont'd)
  • 71. FORM 160.75-EG1 (915) JOHNSON CONTROLS 71 Application Data (Cont'd) MEDIUM VOLTAGE VARIABLE SPEED DRIVE NOMENCLATURE MVVSD 2500 R K - 80 VOLTAGE CODE 80 = 2300V/60Hz 92 = 3300V/50Hz 94 = 4180V/60Hz K = YK OIL PUMP SUPPLY R = FIELD INSTALLED MAXIMUM DRIVE HORSEPOWER 0500 - 500 HP 0600 - 600 HP 0700 - 700 HP 0800 - 800 HP 0900 - 900 HP 1000 - 1000 HP 1250 - 1250 HP 1500 - 1500 HP 1750 - 1750 HP 2000 - 2000 HP 2250 - 2250 HP 2500 - 2500 HP LD19167
  • 72. JOHNSON CONTROLS FORM 160.75-EG1 (915) 72 Application Data (Cont'd) Table 17 - LOW VOLTAGE SOLID-STATE STARTER MODELS SSS- MAXIMUM LRA MINIMUM FLA MAXIMUM FLA RATED VOLTAGE ACTUAL VOLTAGE PHASE HZ 7L-46B 1556 35 260 460 440/460/480 3 60 7L-40B 1556 35 260 380 380 3 60 7L-50B 1556 35 260 400 380/440/415 3 50 7L-58B 1556 35 260 575 575/600 3 60 14L-17B 3111 65 510 200 200/208 3 60 14L-28B 3111 65 510 230 230/240 3 60 14L-40B 3111 65 510 380 380 3 60 14L-46B 3111 65 510 460 440/460/480 3 60 14L-50B 3111 65 510 400 380/400/415 3 50 14L-58B 3111 65 510 575 575/600 3 60 26L-17B 5780 125 850 200 200/208 3 60 26L-28B 5780 125 850 230 230/240 3 60 26L-40B 5780 125 850 380 380 3 60 26L-46B 5780 125 850 460 440/460/480 3 60 26L-50B 5780 125 850 400 380/400/415 3 50 26L-58B 5780 125 850 575 575/600 3 60 33L-17B 7333 215 1050 200 200/240 3 60 33L-40B 7333 215 1050 380 380 3 60 33L-46B 7333 215 1050 230 230/240 3 60 33L-50B 7333 215 1050 400 380/400/415 3 50 33L-58B 7333 215 1050 460 440/460/480 3 60
  • 73. FORM 160.75-EG1 (915) JOHNSON CONTROLS 73 Application Data (Cont'd) Table 18 - MEDIUM VOLTAGE UNIT MOUNTED SOLID-STATE STARTER MODELS UNIT MOUNTED MV-SSS MAXIMUM FLA MAXIMUM LRA RATED VOLTAGE FREQUENCY UMVSSS0853K105-V V 105 1896 2300/60HZ 3300/50Hz 4160/60HZ UMVSSS0853K190-V V 190 1896 UMVSSS0853K280-V V 280 1896 UMVSSS0853K389-V V 389 1896 UMVSSS1708K389-V V 389 3796 MEDIUM VOLTAGE UNIT MOUNTED SOLID STATE STARTER NOMENCLATURE UMVSSS 0853 K 105 - 80 VOLTAGE CODE 80 = 2300V/60Hz 92 = 3300V/50Hz 94 = 4180V/60Hz K = YK OIL PUMP SUPPLY MAXIMUM JOB FLA CURRENT 105 = 105 AMPS 190 = 190 AMPS 280 = 280 AMPS 389 = 389 AMPS MAXIMUM STARTING CURRENT 0853 - 853 AMPS 1708 - 1708 AMPS LD19168
  • 74. JOHNSON CONTROLS FORM 160.75-EG1 (915) 74 Application Data (Cont'd) Table 19 - MEDIUM VOLTAGE FLOOR MOUNTED SOLID-STATE STARTER MODELS FLOOR MOUNTED MV-SSS MAXIMUM FLA MAXIMUM LRA 36 CABINET UNIT MODEL REFERENCE CHART MVSSS0853R_042-V 42 1896 MVSSS0853R_050-V 50 1896 MVSSS0853R_065-V 65 1896 MVSSS0853R_095-V 95 1896 MVSSS0853R_105-V 105 1896 MVSSS0853R_140-V 140 1896 MVSSS0853R_190-V 190 1896 MVSSS0853R_280-V 280 1896 MVSSS0853R_310-V 310 1896 MVSSS0853R_360-V 360 1896 MVSSS1708R_360-V 360 3796 72 CABINET UNIT MODEL REFERENCE CHART MVSSS1708R_550-V 550 3796
  • 75. FORM 160.75-EG1 (915) JOHNSON CONTROLS 75 MEDIUM VOLTAGE FLOOR MOUNTED SOLID STATE STARTER NOMENCLATURE MVVSD 2500 R K 042 - 80 VOLTAGE CODE 80 = 2300V/60Hz 92 = 3300V/50Hz 94 = 4180V/60Hz K = YK OIL PUMP SUPPLY X = NO OIL PUMP SUPPLY R = FIELD INSTALLED LD19169 MAXIMUM STARTING CURRENT 0853 - 853 AMPS 1708 - 1708 AMPS MAXIMUM JOB FLA CURRENT 042 = 042 AMPS 050 = 050 AMPS 065 = 065 AMPS 095 = 095 AMPS 105 = 105 AMPS 140 = 140 AMPS 190 = 190 AMPS 280 = 280 AMPS 310 = 310 AMPS 360 = 360 AMPS 550 = 550 AMPS Application Data (Cont'd)
  • 76. JOHNSON CONTROLS FORM 160.75-EG1 (915) 76 Application Data (Cont'd) Table 20 - AVAILABLE COMPRESSOR/SHELL/MOTOR COMBINATIONS YK MOD G COMBINATIONS COMPRESSOR CODES EVAPORATOR CODES CONDENSER CODES MOTOR CODES 60 HZ 50 HZ Q3 AP TO AS AP TO AS CF-CT EF-ET 5CC-5CO 5EC-5EO Q3, Q4 CP TO CS CP TO CS DP TO DS DP TO DS Q4 EP TO ET EP TO ET Q5 CP TO CS CP TO CS CH-CT EH-ET 5CE-5CO 5EE-5EO DP TO DS DP TO DS Q5, Q6, Q7 EP TO ET EP TO ET FQ TO FT FQ TO FT P7 EP TO ET EP TO ET CU-CY EU-EY 5CP-5CU 5EP-5EUFQ TO FT FQ TO FT P8 GQ TO GS EV TO EX CH-CZ EH-EZ 5CE-5CU 5EE-5EUP8, P9 HQ TO HS FV TO FX JP TO JS JP TO JS LQ TO LS LQ TO LS H9 KP TO KS, K2 TO K4 KP TO KS, K2 TO K4 CN-CA EN-EA 5CK-5CW 5EK-5EWMQ TO MS, M2 TO M4 MP TO MS, M2 TO M4 K1 KT TO KX, K5 TO K7 KP TO KS, K2 TO K4 CS-DC ES-FC 5CN-5DC 5EN-5FBK1, K2 MQ TO MS, M2 TO M4 MP TO MS, M2 TO M4 NQ TO NS, N2 TO N4 NP TO NS, N2 TO N4 PQ TO PS, P2 TO P4 PQ TO PS, P2 TO P4 QQ TO QS, Q2 TO Q4 QQ TO QS, Q2 TO Q4 K3 NQ TO NS, N2 TO N4 NP TO NS, N2 TO N4 DA-DJ FA-FD 5DA-5DH 5FA-5FB QQ TO QV, Q2 TO Q4 QQ TO QS, Q2 TO Q4 —­ RQ, RR, RS, R2, R3, R4 K4 — RQ, RR, RS, R2, R3, R4 DA-DJ FA-FD 5DA-5DJ 5FA-5FB — SQ, SR, SS, S2, S3, S4 VP, VQ, VR, VS, V2, V3, V4, V5 — TP, TQ, TR, TS, T2, T3, T4, T5 XQ, XR, XS, X2, X3, X4 K7 — WQ, WR, WS, W1, W2, W3, W4 DD-DL 5DD-5DL — ZQ, ZR, ZS, Z1, Z2, Z3, Z4
  • 77. FORM 160.75-EG1 (915) JOHNSON CONTROLS 77 TABLE 20 - AVAILABLE COMPRESSOR/SHELL/MOTOR COMBINATIONS CONT'D YK MOD G HEAT RECOVERY COMBINATIONS COMPRESSOR CODES EVAPORATOR CODES CONDENSER CODES MOTOR CODES 60 HZ 50 HZ Q4 CP, CQ, CR, CS BV, BW, BX CF-CT EF-ET 5CC-5CO 5EC-5EOQ7 EP, EQ, ER, ES, ET IV, IW, IX H9 KP, KQ, KR, KS, K2, K3, K4 OW, OX, O7, O8, O9 CN-CA EN-EA 5CK-5CW 5EK-5EW K2 MQ, MR, MS, M2, M3, M4 UW, UX, U7, U8, U9 CS-DC ES-FC 5CN-5DC 5EN-5FB K7 ZQ, ZR, ZS, Z1, Z2, Z3, Z4 YW, YX, Y7, Y8, Y9 DD-DL 5DD-5DL YK MOD G HYBRID FALLING FILM COMBINATIONS COMPRESSOR CODES HYBRID FALLING FILM EVAPORATOR CODES CONDENSER CODES MOTOR CODES 60 HZ 50 HZ Q3 AC, AD, A3, A4 AP TO AS CF-CT EF-ET 5CC-5CO 5EC-5EO CC TO CE, C3 TO C5 CP TO CS Q4 CC TO CE, C3 TO C5 CP TO CS DC TO DE, D3 TO D5 DP TO DS Q5 CC TO CE, C3 TO C5 CP TO CS CH-CT EH-ET 5CE-5CO 5EE-5EO DC TO DE, D3 TO D5 DP TO DS Q5, Q6, Q7 EC TO EE, E3 TO E5 EP TO ET FC TO FE, F3 TO F5 FQ TO FT P7 EC TO EE, E3 TO E5 EP TO ET CU-CY EU-EY 5CP-5CU 5EP-5EUFC TO FE, F3 TO F5 FQ TO FT P8, P9 GC TO GE, G3 TO G5 EV TO EX, E3 TO E4 CH-CZ EH-EZ 5CE-5CU 5EE-5EUHC TO HE, H3 TO H5 FV TO FX, F3 TO F4 H9 KC, KD, K8, K9, K0 KP, KQ, KR, KS, K2, K3, K4 CN-CA EN-EA 5CK-5CW 5EK-5EW IB, ID, IF, IH, I2, I4, I6, I8 KP, KQ, KR, KS, K2, K3, K4 MB, MD, MF, M5, M7, M8 MP, MQ, MR, MS, M2, M3, M4 K1 IB, ID, IF, IH, I2, I4, I6, I8 KP, KQ, KR, KS, K2, K3, K4 CS-DC ES-FC 5CN-5DC 5EN-5FBK1, K2 MB, MD, MF, M5, M7, M8, M9 MP, MQ, MR, MS, M2, M3, M4 NB, ND, NF, N5, N7, N8, N9 NP, NQ, NR, NS, N2, N3, N4 PB, PD, PF, P5, P7, P8 PQ, PR, PS, P2, P3, P4 QB, QD, QF, Q5, Q7, Q8 QQ, QR, QS, Q2, Q3, Q4 K3 NB, ND, NF, N5, N7, N8, N9 NP, NQ, NR, NS, N2, N3, N4 DA-DJ FA-FD 5DA-5DH 5FA-5FBQD, QF, QH, Q5, Q7, Q8, Q9 QQ, QR, QS, Q2, Q3, Q4 Application Data (Cont'd)
  • 78. JOHNSON CONTROLS FORM 160.75-EG1 (915) 78 CONDENSER (SHIPPING WIDTH) OPTIVIEW CONTROL CENTER COMPRESSOR MOTOR EVAPORATOR ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR TYPE OF CHILLER MOUNTING M NEOPRENE PAD ISOLATORS 1-3/4 (45) SPRING ISOLATORS 1 DEFLECTION 1 (25) DIRECT MOUNT 3/4 (19) P7, Q7 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES E-E E-I F-F A 6'-2 (1880) 7'-1 3/4 (2178) 6'-2 (1880) B 8'-0 5/8 (2454) 8'-8 (2642) 8'-0 5/8 (2454) C 1'-7 1/2 (495) 1'-7 1/2 (495) 1'-7 1/2 (495) D 1'-5 1/2 (445) 1'-11 3/8 (594) 1'-5 1/2 (445) E 12'-0 (3658) 12'-0 (3658) 16'-0 (4877) P8 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES G-E H-F J-J L-L A 6'-11 (2108) 6'-11 (2108) 7'-6 1/2 (2299) 7'-6 1/2 (2299) B 10'-6 (3200) 10'-6 (3200) 10'-11 (3327) 10'-11 (3327) C 2'-0 (610) 2'-0 (610) 2'-1 1/4 (641) 2'-1 1/4 (641) D 1'-5 1/2 (445) 1'-5 1/2 (445) 1'-8 (508) 1'-8 (508) E 12'-0 (3658) 16'-0 (4877) 12'-0 (3658) 16'-0 (4877) Dimensions P9 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES H-F J-J L-L A 6'-11 (2108) 7'-6 1/2 (2299) 7'-6 1/2 (2299) B 10'-3 (3124) 10'-8 1/2 (3264) 10'-8 1/2 (3264) C 2'-0 (610) 2'-1 1/4 (641) 2'-1 1/4 (641) D 1'-5 1/2 (445) 1'-8 (508) 1'-8 (508) E 16'-0 (4877) 12'-0 (3658) 16'-0 (4877) LD07134 H, P, Q COMPRESSOR UNITS
  • 79. FORM 160.75-EG1 (915) JOHNSON CONTROLS 79 Q3 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES A-A C-C D-D A 5'-1 (1549) 5'-6 (1676) 5'-6 (1676) B 7'-0 (2134) 7'-3 3/4 (2229) 7'-3 3/4 (2229) C 1'-3 1/2 (394) 1'-5 1/2 (445) 1'-5 1/2 (445) D 1'-3 (381) 1'-3 1/2 (394) 1'-3 1/2 (394) E 12'-0 (3658) 12'-0 (3658) 16'-0 (4877) Q4 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODE C-B C-C D-D E-E A 6'-4 3/4 (1949) 5'-6 (1676) 5'-6 (1676) 7'-0 (2134) B 7'-11 3/8 (2423) 7'-2 1/2 (2197) 7'-2 1/2 (2197) 7'-8 1/2 (2350) C 1'-5 1/2 (445) 1'-5 1/2 (445) 1'-5 1/2 (445) 1'-7 1/2 (495) D 1'-8 7/8 (530) 1'-3 1/2 (394) 1'-3 1/2 (394) 1'-5 1/2 (445) E 12'-0 (3658) 12'-0 (3658) 16'-0 (4877) 12'-0 (3658) Q5 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES C-C D-D E-E F-F A 5'-6 (1676) 5'-6 (1676) 7'-0 (2134) 7'-0 (2134) B 7'-10 5/8 (2403) 7'-10 5/8 (2403) 8'-3 (2578) 8'-3 (2578) C 1'-5 1/2 (445) 1'-5 1/2 (445) 1'-7 1/2 (495) 1'-7 1/2 (495) D 1'-3 1/2 (394) 1'-3 1/2 (394) 1'-5 1/2 (445) 1'-5 1/2 (445) E 12'-0 (3658) 16'-0 (4877) 12'-0 (3658) 16'-0 (4877) Q6 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES E-E F-F A 7'-0 (2134) 7'-0 (2134) B 8'-3 (2515) 8'-3 (2515) C 1'-7 1/2 (495) 1'-7 1/2 (495) D 1'-5 1/2 (445) 1'-5 1/2 (445) NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connections. 5. To determine overall height, add dimension M on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions. Dimensions (Cont'd) H9 COMPRESSORS EVAP.-COND. SHELL CODES DIM I-K K-K K-O M-M A 7'-6 1/2 (2299) 8'-9 1/4 (2673) 8'-7 (2616) B 10'-4 (3150) 10'-7 5/8 (3242) 10'-10 1/2 (3315) C 2'-1 1/4 (641) 2'-1 1/4 (641) 2'-4 1/2 (724) D 1'-8 (508) 2'-3 3/8 (695) 1'-11 (584) E 14'-0 (4267) 14'-0 (4267) 14'-0 (4267) H, P, Q COMPRESSOR UNITS
  • 80. JOHNSON CONTROLS FORM 160.75-EG1 (915) 80 A DC B1,5 M E J2 H2 G2 F2 7 EVAPORATOR CONDENSER (SHIPPING WIDTH) OPTIVIEW CONTROL CENTER COMPRESSOR MOTOR K COMPRESSOR UNITS Dimensions (Cont'd) K1 COMPRESSOR, EVAPORATOR-CONDENSER SHELL CODES DIM I-K K-K M-M N-N P-P Q-Q A 7'-6 1/2 (2299) 8'-7 (2616) 8'-7 (2616) 9'-1 1/2 (2781) 9'-1 1/2 (2781) B 9'-7 (2921) 11'-4 (3454) 11'-4 (3454) 11'-5 1/2 (3493) 11'-5 1/2 (3493) C 2'-1 1/4 (641) 2'-4 1/2 (724) 2'-4 1/2 (724) 2'-5 1/2 (749) 2'-5 1/2 (749) D 1'-8 (508) 1'-11 (584) 1'-11 (584) 2'-1 1/4 (641) 2'-1 1/4 (641) E 14'-0 (4267) 14'-0 (4267) 16'-0 (4877) 14'-0 (4267) 16'-0 (4877) ADDITIONAL OPERATING HEIGHT CLEARANCE TO FLOOR TYPE OF CHILLER MOUNTING M NEOPRENE PAD ISOLATORS 1-3/4 (45) SPRING ISOLATORS 1 DEFLECTION 1 (25) DIRECT MOUNT 3/4 (19) K2 COMPRESSOR EVAPORATOR-CONDENSER SHELL CODES DIM M-M M-U N-N P-P Q-Q A 8'-7 (2616) 9'-6 (2896) 8'-7 (2616) 9'-1 1/2 (2781) 9'-1 1/2 (2781) B 11'-4 (3454) 11'-10 (3607) 11'-4 (3454) 11'-5 (3480) 11'-5 (3480) C 2'-4 1/2 (724) 2'-4 1/2 (724) 2'-4 1/2 (724) 2'-5 1/2 (749) 2'-5 1/2 (749) D 1'-11 (584) 2'-4 1/2 (724) 1'-11 (584) 2'-1 1/4 (641) 2'-1 1/4 (641) E 14'-0 (4267) 14'-0 (4267) 16'-0 (4877) 14'-0 (4267) 16'-0 (4877) LD07134
  • 81. FORM 160.75-EG1 (915) JOHNSON CONTROLS 81 Dimensions (Cont'd) K COMPRESSOR UNITS K4 COMPRESSOR, EVAPORATOR- CONDENSER SHELL CODES DIM R-R S-S S-V X-T X-X A 9'-9 (2972) 9'-9 (2972) 10'-3 (3124) 10'-10 (3302) 11'-3 (3429) B 11'-11 (3632) 11'-11 (3632) 12'-4 (3759) 12'-4 (3759) 12'-4 (3759) C 2'-8 (813) 2'-8 (813) 2'-8 (813) 2'-11 1/2 (902) 2'-11 1/2 (902) D 2'-3 1/2 (699) 2'-3 1/2 (699) 2'-5 1/2 (749) 2'-5 1/2 (749) 2'-8 (813) E 16'-0 (4877) 18'-0 (5486) 18'-0 (5486) 16'-0 (4877) 16'-0 (4877) NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connec- tions. 5. To determine overall height, add dimension M on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions. K3 COMPR., EVAP.-COND. SHELL CODES N-N Q-Q R-R A 8'-7 (2616) 9'-1 1/2 (2781) 9'-9 (2972) B 10'-8 (3251) 11'-6 (3505) 11'-10 (3607) C 2'-4 1/2 (724) 2'-5 1/2 (749) 2'-8 (813) D 1'-11 (584) 2'-1 1/4 (641) 2'-3 1/2 (699) E 16'-0 (4877) 16'-0 (4877) 16'-0 (4877) K7 COMPR., EVAP.-COND SHELL CODES DIM W-W Z-Y Z-Z A 10'-3 (3124) 12'-7 (3835) 11'-3 (3429) B 12'-2 (3708) 14'-1 5/8 (4308) 12'-10 (3912) C 2'-8 (813) 2'-11 1/2 (902) 2'-11 1/2 (902) D 2'-5 1/2 (749) 3'-4 (1016) 2'-8 (813) E 22'-0 (6706) 18'-0 (5486) 18'-0 (5486)
  • 82. JOHNSON CONTROLS FORM 160.75-EG1 (915) 82 Dimensions (Cont'd) C C AA M AA M A H M MC C B C J K BB BB DD DD MM C C F G N P BB DD BB DD 1-PASS 2-PASS 3-PASS LD07598a EVAPORATORS  –  COMPACT WATER BOXES – A THRU L EVAPORATORS 1-PASS NO. OF PASSES EVAPORATOR IN OUT 1 A H H A 2-PASS NO. OF PASSES EVAPORATOR IN OUT 2 C B K J 3-PASS NO. OF PASSES EVAPORATOR IN OUT 3 G N P F FRONT OF UNIT FLOOR LINECOMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINECOMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINECOMPRESSOR END MOTOR END
  • 83. FORM 160.75-EG1 (915) JOHNSON CONTROLS 83 Dimensions (Cont'd) COMPACT WATER BOXES - 150 PSI ROUND EVAPORATOR SHELL CODE NOZZLE PIPE SIZE(IN) NO. OF PASSES EVAPORATOR NOZZLE DIMENSIONS C 1-PASS 2-PASS 3-PASS 1 2 3 AA5 BB5 DD5 BB5 DD5 A 8 6 4 1'-3 1/2 (394) 1'-10 (559) 1'-2 (356) 2'-6 (762) 1'-2 (356) 2'-6 (762) C,D 10 8 6 1'-5 1/2 (445) 2'-0 (610) 1'-3 (381) 2'-9 (838) 1'-3 (381) 2'-9 (838) E,F 14 10 8 1'-7 (483) 2'-2 (660) 1'-4 (406) 3'-0 (914) 1'-4 (406) 3'-0 (914) G,H 14 10 8 2'-0 (610) 2'-3 1/2 (699) 1'-3 1/2 (394) 3'-3 1/2 (1003) 1'-3 1/2 (394) 3'-3 1/2 (1003) I, J, K, L 16 12 10 2'-1 1/4 (641) 2'-6 (762) 1'-5 (432) 3'-7 (1092) 1'-5 (432) 3'-7 (1092) EVAPORATORS  –  COMPACT WATER BOXES – A THRU L EVAPORATORS NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connections. 5. To determine overall height, add dimension M on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions.
  • 84. JOHNSON CONTROLS FORM 160.75-EG1 (915) 84 Dimensions (Cont'd) LD07173a EVAPORATORS  –  COMPACT WATERBOXES – M THRU Z EVAPORATORS SHELL CODE 1 PASS IN OUT M–Z AA HH HH AA SHELL CODE 2 PASS IN OUT M,N,P,Q CC BB KK JJ SHELL CODES 2 PASS IN OUT R, S, W X Z DD CC EE BB LL KK MM JJ SHELL CODES 3 PASS IN OUT M–Z GG NN PP FF FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END
  • 85. FORM 160.75-EG1 (915) JOHNSON CONTROLS 85 Dimensions (Cont'd) EVAPORATORS  –  COMPACT WATERBOXES – M THRU Z EVAPORATORS COMPACT WATER BOXES - 150 PSI EVAP SHELL CODE NOZZLE PIPE SIZE(IN) EVAPORATOR NOZZLE DIMENSIONS (FT-IN.) NO. OF PASSES 1-PASS 2-PASS 3-PASS 1 2 3 C AA4 BB4 DD4 EE BB4 DD4 M,N 18 14 12 2'-4 1/2 (724) 3'-0 (914) 1'-8 1/2 (521) 4'-3 1/2 (1308) - 1'-8 1/2 (521) 4'-3 1/2 (1308) P,Q 18 14 12 2'-5 1/2 (749) 3'-1 1/2 (953) 1'-10 (559) 4'-5 (1346) - 1'-10 (559) 4'-5 (1346) PF, QF, QH, QV, QT 20 16 12 2'-5 1/2 (749) 3'-1 1/2 (953) 1'-11 1/2 (597) 4'-3 1/2 (1308) - 1'-11 1/2 (597) 4'-3 1/2 (1308) R,S,W 20 18 14 2'-8 (813) 3'-5 1/4 (1048) 2'-4 1/2 (724) 4'-6 1/2 (1384) 0'-10 1/2 (267) 2'-1 (635) 4'-10 (1473) X,Z 20 18 14 2'-11 1/2 (902) 3'-9 3/4 (1162) 2'-8 3/4 (832) 4'-10 3/4 (1492) 0'-11 (279) 2'-2 7/8 (683) 5'-4 5/8 (1641) NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connections. 5. Add dimension M as shown on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions.
  • 86. JOHNSON CONTROLS FORM 160.75-EG1 (915) 86 F F F F F G ONE,TWO, THREE PASS EVAPORATOR CODES DIM. A C,D E,F G,H I,J,K,L M,N P,Q R,S,W X,Z A 1'-2 1/4 (362) 1'-3 (381) 1'-3 1/2 (394) 1'-3 3/4 (400) 1'-5 1/2 (445) 1'-11 5/8 (565) 1'-11 5/8 (600) 2'-0 5/8 (613) 2'-1 3/4 (600) B 0'-6 1/2 (165) 0'-7 (178) 0'-7 1/2 (191) 0'-7 3/4 (197) 0'-9 1/2 (241) 1'-3 5/8 (365) 1'-3 5/8 (391) 1'-4 3/4 (391) 1'-5 3/4 (416) EVAPORATORS – COMPACT WATERBOXES Dimensions (Cont'd)
  • 87. FORM 160.75-EG1 (915) JOHNSON CONTROLS 87 THIS PAGE INTENTIONALLY LEFT BLANK.
  • 88. JOHNSON CONTROLS FORM 160.75-EG1 (915) 88 Dimensions (Cont'd) CONDENSERS  –  COMPACT WATER BOXES LD07131a 1-PASS7 NO. OF PASSES CONDENSER IN OUT 1 P Q Q P 2-PASS7 NO. OF PASSES CONDENSER IN OUT 2 R S T U 3-PASS7 NO. OF PASSES CONDENSER IN OUT 3 V Y X W FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END FRONT OF UNIT FLOOR LINE COMPRESSOR END MOTOR END
  • 89. FORM 160.75-EG1 (915) JOHNSON CONTROLS 89 Dimensions (Cont'd) COMPACT WATER BOXES - 150 PSI ROUND CONDENSER SHELL CODE NOZZLE PIPE SIZE(IN) D 1-PASS 2-PASS 3-PASS NO. OF PASSES 1 2 3 CC5 BB5 DD5 BB5 DD5 A 10 6 6 1'-3 (381) 2'-4 (711) 1'-9 1/2 (546) 2'-10 1/2 (876) 1'-9 1/2 (546) 2'-10 1/2 (876) C,D 12 8 6 1'-3 1/2 (394) 2'-6 (762) 1'-10 3/8 (568) 3'-1 5/8 (956) 1'-10 3/8 (568) 3'-1 5/8 (956) E,F 14 10 8 1'-5 1/2 (445) 2'-8 (813) 1'-11 3/4 (603) 3'-4 1/4 (1022) 1'-11 3/4 (603) 3'-4 1/4 (1022) J,K,L 16 10 10 1'-8 (508) 3'-0 (914) 2'-3 (686) 3'-9 (1143) 2'-3 (686) 3'-9 (1143) M,N 20 14 10 1'-11 (584) 3'-6 (1067) 2'-6 3/8 (772) 4'-5 5/8 (1362) 2'-6 3/8 (772) 4'-5 5/8 (1362) P,Q 20 16 14 2'-1 1/4 (641) 3'-8 (1118) 2'-7 (787) 4'-9 (1448) 2'-7 (787) 4'-9 (1448) R,S 20 18 14 2'-3 1/2 (699) 3'-10 1/2 (1181) 2'-9 1/2 (851) 4'-11 1/2 (1511) 2'-9 1/2 (851) 4'-11 1/2 (1511) T,V,W 24 18 16 2'-5 1/2 (749) 3'-11 1/2 (1207) 2'-9 (838) 5'-2 (1575) 2'-9 (838) 5'-2 (1575) X,Z 24 20 16 2'-8 (813) 4'-1 1/4 (1251) 2'-9 1/4 (845) 5'-5 1/4 (1657) 2'-9 1/4 (845) 5'-5 1/4 (1657) NOTES: 1. All dimensions are ft-inches (mm). 2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.6 mm raised face), water flanges nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished. 3. One, two and three pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles may be used in combination with any pair of condenser nozzles. 4. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance. 5. Connected piping should allow for removal of compact water boxes for tube access and cleaning. 6. Add dimension M as shown on page 78 for the appropriate isolator type. 7. Standard 150 psi (1034 kPa) design pressure water boxes shown. 8. Shell codes R,S,T,V,W,X, Z use double letter nozzle codes in the same orientation as the single letter e.g. P = PP. CONDENSERS  –  COMPACT WATER BOXES
  • 90. JOHNSON CONTROLS FORM 160.75-EG1 (915) 90 Dimensions (Cont'd) SINGLE BUNDLE CONDENSERS, CODES DIM. A C,D E,F J,K,L M,N P,Q R,S T,V,W X,Z A 1'-1 7/8 (352) 1'-1 7/8 (352) 1'-3 (381) 1'-3 1/2 (394) 1'-3 3/8 (391) 1'-5 1/2 (445) 1'-8 3/4 (527) 1'-10 1/2 (572) 1'-11 5/8 (600) B 0'-5 7/8 (149) 0'-6 1/2 (165) 0'-7 (178) 0'-7 1/2 (191) 0'-7 3/4 (197) 0'-9 1/2 (241) 1'-2 3/8 (365) 1'-3 3/8 (391) 1'-4 3/8 (416) DOUBLE BUNDLE HEAT RECOVERY CONDENSERS, CODES B I O U Y DIM. TOWER HEATING TOWER HEATING TOWER HEATING TOWER HEATING TOWER HEATING A 1'-6 1/2 (470) 1'-5 (432) 1'-7 1/2 (495) 1'-4 3/4 (425) 1'-9 1/2 (546) 1'-6 (457) 1'-10 1/4 (565) 1'-8 (508) 2'-4 3/4 (730) 1'-10 1/2 (572) B 0'-10 1/2 (267) 0'-9 (229) 0'-11 1/2 (292) 0'-8 3/4 (222) 1'-1 1/2 (343) 0'-10 (254) 1'-2 1/4 (362) 1'-0 (305) 1'-8 3/4 (527) 1'-2 1/2 (368) H H H H H J ONE PASS TWO PASS THREE PASS LD07619b CONDENSERS  –  COMPACT WATER BOXES
  • 91. FORM 160.75-EG1 (915) JOHNSON CONTROLS 91 LD18382 Dimensions (Cont'd) HEAT RECOVERY UNITS 1 PASS IN OUT HEAT RECOVERY EE FF FF EE COOLING TOWER P Q Q P 2 PASS IN OUT HEAT RECOVERY AA BB BB AA CC DD DD CC COOLING TOWER R S S R T U U T 3 PASS IN OUT HEAT RECOVERY GG HH HH GG COOLING TOWER V Y Y V COMPACT WATER BOXES - 150 PSI (RECTANGULAR) CONDENSER SHELL CODE NOZZLE PIPE SIZE (IN) 1, 2 OR 3 PASS 2 PASSMAIN BUNDLE HEAT RECOVERY BUNDLE NUMBER OF PASSES NUMBER OF PASSES 1 2 3 1 2 3 D K L I B 10 8 6 10 8 6 1'-8 7/8 (530) 1'-9 1/4 (540) 3'-6 1/2 (1080) 0'-9 1/16 (230) I 14 10 8 12 8 8 1'-11 3/8 (594) 1'-10 1/4 (565) 3'-8 1/8 (1121) 0'-10 1/8 (257) O 16 12 10 14 10 8 2'-3 3/8 (695) 2'-0 3/8 (619) 4'-1 1/8 (1248) 0'-11 13/16 (300) U 18 14 10 16 12 10 2'-4 1/2 (724) 2'-11 3/16 (894) 5'-2 13/16 (1595) 1'-0 3/8 (314) Y 24 20 16 20 18 16 3'-4 (1016) 3'-3 15/16 (1014) 6'-3 7/8 (1927) 1'-5 7/8 (454) HEAT RECOVERY COOLING TOWER HEAT RECOVERY COOLING TOWER FRONT OF UNIT COMPRESSOR END MOTOR END HEAT RECOVERY COOLING TOWER HEAT RECOVERY COOLING TOWER FRONT OF UNIT COMPRESSOR END MOTOR END HEAT RECOVERY COOLING TOWER HEAT RECOVERY COOLING TOWER FRONT OF UNIT COMPRESSOR END MOTOR END Add dimension M as shown on page 78.
  • 92. JOHNSON CONTROLS FORM 160.75-EG1 (915) 92 Dimensions (Cont'd) EVAPORATORS – MARINE WATERBOXES LD07175a FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE FRONT OF UNIT COMPRESSOR END MOTOR END FLOOR LINE EVAPORATOR 1-PASS IN OUT 1 6 6 1 EVAPORATOR 2-PASS IN OUT 2 3 7 8 EVAPORATOR 3-PASS IN OUT 5 10 9 4
  • 93. FORM 160.75-EG1 (915) JOHNSON CONTROLS 93 Dimensions (Cont'd) NOTES: 1. All dimensions are ft-inches (mm). 2. All dimensions are approximate. Certified dimensions are available on request. 3. For all waterboxes (compact boxes shown above), determine overall unit length by adding waterbox depth to tube sheet length. 4. Water nozzles can be located on either end of unit. Add 1/2 (12mm) to nozzle length for flanges connections. 5. Add dimension M as shown on page 78 for the appropriate isolator type. 6. Use of motors with motor hoods may increase overall unit dimensions. EVAPORATORS – MARINE WATERBOXES MARINE WATER BOXES - 150 PSI ROUND EVAPORATOR SHELL CODE NOZZLE PIPE SIZE(IN) NO. OF PASSES 1-PASS 2-PASS 3-PASS 1 2 3 C P5 P5 Q5 R P5 Q5 R A 8 6 4 1'-3 1/2 (394) 3'-7 (1092) 3'-7 (1092) 0'-11 (279) 1'-3 1/4 (387) 3'-7 (1092) 0'-11 (279) 1'-3 1/4 (387) C,D 10 8 6 1'-5 1/2 (445) 3'-11 (1194) 3'-11 (1194) 0'-10 (254) 1'-6 1/2 (470) 3'-11 (1194) 0'-10 (254) 1'-6 1/2 (470) E,F 14 10 8 1'-7 1/2 (495) 4'-3 (1295) 4'-3 (1295) 0'-11 (279) 1'-9 1/2 (546) 4'-3 (1295) 0'-11 (279) 1'-9 1/2 (546) G,H 14 10 8 2'-0 (610) 4'-7 3/8 (1407) 4'-7 3/8 (1407) 0'-10 1/2 (267) 1'-11 1/2 (597) 4'-7 3/8 (1407) 0'-10 1/2 (267) 1'-11 1/2 (597) I,J,K,L 16 12 10 2'-1 1/4 (641) 5'-0 3/8 (1534) 5'-0 3/8 (1534) 0'-10 1/2 (267) 2'-2 1/2 (673) 5'-0 3/8 (1534) 0'-10 1/2 (267) 2'-2 1/2 (673) M,N 18 14 12 2'-4 1/2 (724) 5'-8 1/2 (1740) 5'-8 1/2 (1740) 1'-2 (356) 2'-2 1/2 (673) 5'-8 1/2 (1740) 1'-2 (356) 2'-4 3/4 (730) P,Q 18 14 12 2'-5 1/2 (749) 6'-0 1/8 (1832) 6'-0 1/8 (1832) 1'-3 (381) 2'-6 1/2 (775) 6'-0 1/8 (1832) 1'-3 (381) 2'-6 1/2 (775) PF, QF, QH, QT,QV 20 16 12 2'-5 1/2 (749) 6'-0 1/8 (1832) 6'-0 1/8 (1832) 1'-4 1/2 (419) 2'-6 1/2 (775) 6'-0 1/8 (1832) 1'-4 1/2 (419) 2'-6 1/2 (775) R,S 20 18 14 2'-8 (813) 6'-5 7/8 (1978) 6'-5 7/8 (1978) 1-3 3/4 (57) 3'-0 1/8 (918) 6'-5 7/8 (1978) 1-3 3/4 (57) 3'-0 1/8 (918) W 20 18 14 2'-8 (813) 6'-5 7/8 (1978) 6'-5 7/8 (1978) 1-3 3/4 (57) 3'-0 1/8 (918) 6'-5 7/8 (1978) 1-3 3/4 (57) 3'-0 1/8 (918) X,Z 20 18 14 2'-11 1/2 (902) 7'-1 3/8 (2169) 7'-1 3/8 (2169) 1'-9 1/4 (540) 3'-0 3/4 (933) 7'-1 3/8 (2169) 1'-9 1/4 (540) 3'-0 3/4 (933)
  • 94. JOHNSON CONTROLS FORM 160.75-EG1 (915) 94 Dimensions (Cont'd) EVAPORATOR SHELL CODE 1-PASS 2-PASS 3-PASS A C A B C A C A 1'-7 (483) 0'-8 3/4 (222) 1'-5 (432) 0'-6 1/2 (165) 0'-7 3/4 (197) 1'-5 (432) 0'-7 3/4 (197) C,D 1'-10 3/4' (578) 0'-10 5/8 (270) 1'-8 5/8 (524) 0'-7 (178) 0'-9 1/2 (241) 1'-8 5/8 (524) 0'-9 1/2 (241) E,F 2'-1 3/4 (654) 1'-0 1/8 (308) 1'-10 (559) 0'-7 1/2 (191) 0'-10 1/4 (260) 1'-10 (559) 0'-10 1/4 (260) G,H 2'-2 (660) 0'-11 7/8 (302) 1'-10 1/2 (572) 0'-11 1/4 (286) 0'-10 1/4 (260) 1'-10 1/2 (572) 0'-10 1/4 (260) i,J,K,L 2'-3 (686) 1'-0 3/8 (314) 1'-11 1/2 (597) 0'-9 1/2 (241) 0'-10 9/16 (268) 1'-11 1/2 (597) 0'-10 1/2 (267) M,N 2'-6 (762) 1'-1 1/2 (343) 2'-2 (660) 1'-0 1/8 (308) 0'-11 1/2 (292) 2'-2 (660) 0'-11 1/2 (292) P,Q 2'-6 (762) 1'-1 1/2 (343) 2'-2 (660) 1'-1 1/2 (343) 0'-11 1/2 (292) 2'-2 (660) 0'-11 1/2 (292) QT,QV 2'-8 (813) 1'-2 1/2 (368) 2'-4 (711) 1'-1 1/2 (343) 1'-0 1/2 (318) 2'-4 (711) 1'-0 1/2 (318) R,S,W 2'-8 (813) 1'-2 5/8 (371) 2'-6 (762) 1'-2 1/2 (368) 1'-1 5/8 (346) 2'-6 (762) 1'-1 5/8 (346) X,Z 2'-9 (838) 1'-2 5/8 (371) 2'-6 (762) 1'-3 1/2 (394) 1'-1 5/8 (346) 2'-6 (762) 1'-1 5/8 (346) EVAPORATORS – MARINE WATERBOXES F
  • 95. FORM 160.75-EG1 (915) JOHNSON CONTROLS 95 THIS PAGE INTENTIONALLY LEFT BLANK.
  • 96. JOHNSON CONTROLS FORM 160.75-EG1 (915) 96 CONDENSERS – MARINE WATERBOXES LD07178a FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END Dimensions (Cont'd) CONDENSER 1-PASS IN OUT 11 16 16 11 CONDENSER 2-PASS IN OUT 12 13 17 18 CONDENSER 3-PASS IN OUT 15 20 19 14
  • 97. FORM 160.75-EG1 (915) JOHNSON CONTROLS 97 MARINE WATER BOXES - 150 PSI ROUND CONDENSER SHELL CODE NOZZLE PIPE SIZE(IN) 1-PASS 2-PASS 3-PASS NO. OF PASSES 1 2 3 D S5 S5 T5 U S5 T5 U A 10 6 6 1'-3 (381) 3'-11 (1194) 3'-11 (1194) 1'-8 (508) 1'-3 3/8 (391) 3'-11 (1194) 1'-8 (508) 1'-3 3/8 (391) C,D 12 8 6 1'-3 1/2 (394) 4'-3 (1295) 4'-3 (1295) 1'-8 (508) 1'-6 1/2 (470) 4'-3 (1295) 1'-8 (508) 1'-6 1/2 (470) E,F 14 10 8 1'-5 1/2 (445) 4'-7 (1397) 4'-7 (1397) 1'-10 (559) 1'-9 (533) 4'-7 (1397) 1'-10 (559) 1'-9 (533) J,K,L 16 10 10 1'-8 (508) 5'-1 (1549) 5'-1 (1549) 1'-9 (533) 1'-9 1/2 (546) 5'-1 (1549) 1'-9 (533) 1'-9 1/2 (546) M,N 20 14 10 1'-11 (584) 5'-9 7/8 (1775) 5'-9 7/8 (1775) 2'-4 (711) 2'-1 1/2 (648) 5'-9 7/8 (1775) 2'-4 (711) 2'-1 1/2 (648) P,Q 20 16 14 2'-1 1/4 (641) 6'-2 3/8 (1889) 6'-2 3/8 (1889) 2'-4 1/2 (724) 2'-5 1/2 (749) 6'-2 3/8 (1889) 2'-4 1/2 (724) 2'-5 1/2 (749) R,S 20 18 14 2'-3 1/2 (699) 6'-7 (2007) 6'-7 (2007) 2'-6 1/2 (775) 2'-8 1/2 (826) 6'-7 (2007) 2'-6 1/2 (775) 2'-8 1/2 (826) T,V,W 24 18 16 2'-5 1/2 (749) 6'-10 1/4 (2089) 6'-10 1/4 (2089) 2'-6 (762) 2'-10 (864) 6'-10 1/4 (2089) 2'-6 (762) 2'-10 (864) X,Z 24 20 16 2'-8 (813) 7'-2 (2184) 7'-2 (2184) 2'-7 3/4 (806) 2'-11 1/2 (902) 7'-2 (2184) 2'-7 3/4 (806) 2'-11 1/2 (902) NOTES: 1. All dimensions are ft-inches (mm). 2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.6 mm raised face), water flanges nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished. 3. One, two and three pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles may be used in combination with any pair of condenser nozzles. 4. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance. 5. Connected piping should allow for removal of compact water boxes for tube access and cleaning. 6. Add dimension M as shown on page 78 for the appropriate isolator type. 7. Standard 150 psi (1034 kPa) design pressure water boxes shown. 8. Shell codes R,S,T,V,W,X, Z use double letter nozzle codes in the same orientation as the single letter e.g. P = PP. CONDENSERS – MARINE WATERBOXES Dimensions (Cont'd)
  • 98. JOHNSON CONTROLS FORM 160.75-EG1 (915) 98 11 16 M M SS D D U U C L LC 13 M M S D U CL 12 T T 18 M S D U CL 17 T T D CL D CL M V V M M S U CL 15 T T M S D U CL 19 T T D CL D CL M 20 14 S V VD 1-PASS 2-PASS 3-PASS LD18383 CONDENSERS  –  MARINE WATER BOXES Heat Recovery Units - Main (Tower) Circuit Only Dimensions (Cont'd)Dimensions (Cont'd) FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END FRONT OF UNIT COMPRESSOR END MOTOR END CONDENSER 1-PASS IN OUT 11 16 16 11 CONDENSER 2-PASS IN OUT 12 13 17 18 CONDENSER 3-PASS IN OUT 15 20 19 14
  • 99. FORM 160.75-EG1 (915) JOHNSON CONTROLS 99 MARINE WATER BOXES - 150 PSI (RECTANGULAR) COND SHELL CODE NOZZLE PIPE SIZE (IN) 1 PASS 2 PASS 3 PASS NO. OF PASSES 1 2 3 D S U S T U V S T U V B 10 8 6 1'-8 7/8 (530) 1'-9 1/4 (540) 2'-6 3/4 (781) 2'-3 7/16 (697) 1'-1 15/16 (354) 2'-4 3/4 (730) 2'-7 1/8 (791) 2'-4 1/2 (724) 1'-5 1/2 (445) 2'-6 3/4 (781) 2'-6 3/4 (781) I 14 10 8 1'-11 3/8 (594) 1'-10 1/4 (565) 2'-9 3/8 (848) 2'-4 1/2 (724) 1'-1 (330) 2'-5 1/8 (740) 2'-10 5/8 (879) 2'-5 1/2 (749) 1'-6 3/8 (467) 2'-9 1/8 (841) 2'-9 1/8 (841) O 16 12 10 2'-3 3/8 (695) 2'-0 3/8 (619) 3'-2 3/8 (975) 2'-7 1/8 (791) 1'-1 3/8 (340) 2'-10 1/4 (870) 3'-4 1/2 (1029) 2'-8 3/8 (822) 1'-7 5/8 (498) 3'-1 7/8 (962) 3'-1 7/8 (962) U 18 14 10 2'-4 1/2 (724) 2'-11 3/16 (894) 3'-5 9/16 (1056) 3'-6 9/16 (1081) 1'-11 3/16 (589) 3'-1 7/8 (962) 3'-7 1/2 (1105) 3'-8 3/16 (1122) 2'-5 15/16 (760) 3'-0 11/16 (932) 3'-3 (991) Y 24 20 16 3'-4 (1016) 3'-3 15/16 (1014) 4'-7 9/16 (1411) 4'-2 5/16 (1278) 1'-10 5/16 (567) 4'-4 3/4 (1340) 4'-11 11/16 (1516) 4'-4 5/16 (1329) 2'-7 7/16 (799) 4'-2 1/16 (1272) 4'-6 13/16 (1392) CONDENSERS  –  MARINE WATER BOXES Heat Recovery Units - Main (Tower) Circuit Only NOTES: 1. All dimensions are ft-inches (mm). 2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use of ANSI/AWWA C-606 couplings. Factory-installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1.6 mm raised face), water flanges nozzles are optional (add 13 mm to nozzle length). Companion flanges, nuts, bolts, and gaskets are not furnished. 3. One, two and three pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles may be used in combination with any pair of condenser nozzles. 4. Evaporator and condenser water must enter the water box through the bottom connection to achieve rated performance. 5. Connected piping should allow for removal of compact water boxes for tube access and cleaning. 6. Add dimension M as shown on page 78 for the appropriate isolator type. 7. Standard 150 psi (1034 kPa) design pressure water boxes shown. 8. Shell codes R,S,T,V,W,X, Z use double letter nozzle codes in the same orientation as the single letter e.g. P = PP. Dimensions (Cont'd)Dimensions (Cont'd)
  • 100. JOHNSON CONTROLS FORM 160.75-EG1 (915) 100 CONDENSER 1-PASS 2-PASS 3-PASS A C A B C A C A 1'-9 (533) 0'-9 7/8 (251) 1'-4 3/4 (425) 0'-6 (152) 0'-7 3/4 (197) 1'-4 3/4 (425) 0'-7 3/4 (197) B6 1'-10 1/2 (572) 0'-10 1/2 (267) 1'-8 (508) 0'-10 1/2 (267) 0'-9 1/4 (235) 1'-8 (508) 0'-9 1/4 (235) C,D 2'-0 (610) 0'-11 1/8 (283) 1'-7 1/2 (495) 0'-6 3/8 (162) 0'-9 (229) 1'-7 1/2 (495) 0'-9 (229) E,F 2'-0 1/2 (622) 0'-11 1/2 (292) 1'-10 1/4 (565) 0'-7 (178) 0'-9 7/8 (251) 1'-10 1/4 (565) 0'-9 7/8 (251) I6 2'-3 (686) 1'-0 3/4 (324) 1'-10 1/2 (572) 0'-11 1/2 (292) 0'-10 1/2 (267) 1'-10 1/2 (572) 0'-10 1/2 (267) J,K,L 2'-3 (686) 1'-0 1/2 (318) 1'-11 (584) 0'-7 1/2 (191) 0'-10 1/4 (260) 1'-11 (584) 0'-10 1/4 (260) M,N 2'-8 (813) 1'-2 7/8 (378) 2'-2 (660) 0'-8 (203) 1'-0 (305) 2'-2 (660) 1'-0 (305) O6 2'-6 1/4 (768) 1'-2 1/4 (362) 2'-1 3/4 (654) 1'-1 1/2 (343) 1'-0 (305) 2'-1 3/4 (654) 1'-0 (305) P,Q 2'-8 (813) 1'-2 1/2 (368) 2'-4 (711) 0'-9 1/2 (241) 1'-0 1/2 (318) 2'-4 (711) 1'-0 1/2 (318) R,S 2'-8 (813) 1'-2 1/2 (368) 2'-6 (762) 1'-0 (305) 1'-1 1/2 (343) 2'-6 (762) 1'-1 1/2 (343) T,V,W 3'-0 (914) 1'-4 1/2 (419) 2'-6 (762) 0'-11 (279) 1'-1 1/2 (343) 2'-6 (762) 1'-1 1/2 (343) U6 2'-8 (813) 1'-3 (381) 2'-4 (711) 1'-2 1/4 (362) 1'-1 (330) 2'-4 (711) 1'-1 (330) X,Z 3'-0 (914) 1'-4 5/8 (422) 2'-8 (813) 0'-11 (279) 1'-2 5/8 (371) 2'-8 (813) 1'-2 (356) Y6 3'-4 3/4 (1035) 1'-7 1/4 (489) 3'-0 1/4 (921) 1'-8 3/4 (527) 1'-5 (432) 3'-0 1/4 (921) 1'-5 (432) CONDENSERS  –  MARINE WATER BOXES Heat Recovery Units - Main (Tower) Circuit Only Dimensions (Cont'd) F
  • 101. FORM 160.75-EG1 (915) JOHNSON CONTROLS 101 SHELLS COMPRESSOR SHIPPING WEIGHT LBS. (KGS.) OPERATING WEIGHT LBS. (KGS.) EST. REFRIGERANT CHARGE LBS. (KGS.) 1 A-A Q3 13100 (5942) 15000 (6804) 828 (376) C-B Q4 18023 (8175) 22323 (10126) 1525 (692) C-C Q3, Q4 14920 (6768) 17940 (8138) 1221 (554) C-C Q5 15330 (6954) 18350 (8324) 1221 (554) D-D Q3, Q4 17215 (7809) 21100 (9571) 1628 (738) D-D Q5 17625 (7995) 21510 (9757) 1628 (738) E-E Q3, Q4 17950 (8142) 22160 (10052) 1710 (776) E-E Q5,Q6,Q7,P7 18360 (8328) 22570 (10238) 1710 (776) E-I Q7 23567 (10690) 29384 (13328) 1805 (819) F-F Q5,Q6,Q7,P7 18720 (8491) 23880 (10832) 2175 (987) G-E P8 20300 (9208) 24200 (10977) 1990 (903) H-F P8,P9 23100 (10478) 28000 (12701) 2610 (1184) J-J P8,P9 24000 (10886) 29100 (13200) 2550 (1157) L-L P8,P9 27400 (12429) 33900 (15377) 3165 (1436) K-K H9 28530 (12941) 36000 (16329) 2925 (1327) K-K K1 31100 (14107) 36200 (16420) 3248 (1473) K-O H9 34483 (15641) 44776 (20310) 3260 (1479) M-M H9 34200 (15513) 43600 (19777) 3665 (1662) M-M K1,K2 38300 (17373) 47100 (21364) 3665 (1662) M-U K2 45178 (20493) 58017 (26316) 3540 (1606) N-N K1,K2 40893 (18549) 50800 (23043) 4225 (1916) N-N K3 48000 (21773) 54100 (24540) 4225 (1916) P-P K1,K2 41500 (18824) 51900 (23542) 3855 (1749) Q-Q K1,K2 45300 (20548) 56800 (25764) 4255 (1930) Q-Q K3 46000 (20865) 60200 (27307) 4255 (1930) R-R K3 52800 (23950) 70300 (31888) 4600 (2087) R-R K4 53000 (24041) 70600 (32024) 4600 (2087) S-S K4 59000 (26762) 76300 (34609) 4815 (2184) S-V K4 60100 (27261) 81300 (36877) 5467 (2480) X-T K4 59200 (26853) 80000 (36288) 5338 (2421) X-X K4 66000 (29937) 87000 (39463) 5875 (2665) W-W K7 79500 (36061) 104000 (47174) 8002 (3630) Z-Y K7 95230 (43196) 123015 (55799) 7175 (3255) Z-Z K7 80500 (36515) 105000 (47628) 6984 (3168) 1 Refrigerant charge quantity and weights will vary based on tube count. SHELLS COMPRESSOR SHIPPING WEIGHT LBS. (KGS.) OPERATING WEIGHT LBS. (KGS.) EST. REFRIGERANT CHARGE LBS. (KGS.)1 A-A Q3 12850 (5829) 14419 (6540) 695 (315) C-C Q3, Q4 14570 (6609) 16848 (7642) 875 (397) C-C Q5 15000 (6804) 17278 (7837) 875 (397) D-D Q4 17000 (7711) 20051 (9095) 1180 (535) D-D Q5 17410 (7897) 20461 (9281) 1180 (535) E-E Q5,Q6,Q7,P7 18700 (8482) 21700 (9843) 1120 (508) F-F Q5,Q6,Q7,P7 19220 (8718) 23142 (10497) 1415 (642) G-E P8, P9 20640 (9362) 24036 (10903) 1320 (599) H-F P8, P9 23540 (10678) 28083 (12738) 1775 (805) I-K H9 28849 (13086) 34078 (15458) 1820 (826) K-K H9 28850 (13086) 34079 (15458) 1820 (826) I-K K1 31350 (14220) 35145 (15942) 1820 (826) M-M K1,K2 34520 (15658) 46055 (20890) 2300 (1043) N-N K1,K2 41273 (18721) 49605 (22501) 2650 (1202) N-N K3 48380 (21945) 52905 (23998) 2650 (1202) P-P K1,K2 41950 (19028) 51595 (23403) 3100 (1406) Q-Q K1,K2 45800 (20775) 56545 (25649) 3500 (1588) Q-Q K3 46500 (21092) 59945 (27191) 3500 (1588) 1 Refrigerant charge quantity and weights will vary based on tube count and configuration. Use for reference only. Weights Table 21 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR FOR FLOODED EVAPORATOR UNITS Table 22 - APPROXIMATE UNIT WEIGHT INCLUDING MOTOR FOR HYBRID FALLING FILM EVAPORATOR UNITS
  • 102. JOHNSON CONTROLS FORM 160.75-EG1 (915) 102 EVAPORATOR SHIPPING WEIGHT OPERATING WEIGHT INCREASE - LBS. (KGS.) INCREASE - LBS. (KGS.) 1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS A 924 (419) 744 (337) 978 (444) 1468 (666) 1288 (584) 1522 (690) C,D 1352 (613) 1114 (505) 1480 (671) 2224 (1009) 1986 (901) 2352 (1067) E,F 1878 (852) 1260 (572) 2080 (943) 3378 (1532) 2760 (1252) 3580 (1624) G,H 1213 (550) 1296 (588) 1293 (587) 2655 (1204) 2738 (1242) 2735 (1241) I,J,K,L 1751 (794) 1843 (836) 1856 (842) 3864 (1753) 3956 (1794) 3969 (1800) M,N 4290 (1946) 2036 (924) 4140 (1878) 7535 (3418) 3264 (1481) 6300 (2858) P,Q 4662 (2115) 2250 (1021) 4646 (2107) 7746 (3514) 3486 (1581) 7392 (3353) R,S,W 4804 (2179) 2700 (1225) 4912 (2228) 8522 (3866) 4516 (2048) 8187 (3714) X,Z 7088 (3215) 3660 (1660) 7244 (3286) 11552 (5240) 5507 (2498) 11243 (5100) CONDENSER SHIPPING WEIGHT OPERATING WEIGHT INCREASE - KGS. INCREASE - KGS. 1-PASS 2-PASS 3-PASS 1-PASS 2-PASS 3-PASS A 762 (346) 566 (257) 810 (367) 1274 (578) 1078 (489) 1322 (600) B 1569 (712) 874 (396) 1677 (761) 2113 (958) 1094 (496) 2071 (939) C,D 946 (429) 778 (353) 1046 (474) 1692 (767) 1524 (691) 1792 (813) E,F 726 (329) 811 (368) 791 (359) 1337 (606) 1722 (781) 1702 (772) I 2066 (937) 1070 (485) 2032 (922) 3017 (1369) 1416 (642) 2738 (1242) J,K,L 1029 (467) 1167 (529) 1151 (522) 2309 (1047) 2447 (1110) 2431 (1103) M,N 2466 (1119) 1330 (603) 2324 (1054) 4863 (2206) 2448 (1110) 4582 (2078) O 2985 (1354) 1443 (655) 2987 (1355) 4435 (2012) 2172 (985) 3979 (1805) P,Q 3700 (1678) 1858 (843) 3752 (1702) 6561 (2976) 3132 (1421) 5991 (2717) R,S 3806 (1726) 1946 (883) 3960 (1796) 6657 (3020) 3195 (1449) 6352 (2881) V,T,W 5196 (2357) 2565 (1163) 5204 (2361) 9161 (4155) 4012 (1820) 8219 (3728) U 3641 (1652) 1893 (859) 3609 (1637) 5350 (2427) 2556 (1159) 4770 (2164) X,Z 5840 (2649) 2953 (1339) 5380 (2440) 9900 (4491) 4649 (2109) 8100 (3674) Y 9094 (4125) 4762 (2160) 9058 (4109) 13326 (6045) 6524 (2959) 12049 (5465) Weights (Cont'd) Table 23 - EVAPORATOR MARINE WATERBOX WEIGHTS LBS (KG) (TO BE ADDED TO STANDARD UNIT WEIGHTS SHOWN ON TABLE 21 OR 22) Table 24 - CONDENSER MARINE WATERBOX WEIGHTS LBS (KG) (TO BE ADDED TO STANDARD UNIT WEIGHTS SHOWN ON TABLE 21 OR 22)
  • 103. FORM 160.75-EG1 (915) JOHNSON CONTROLS 103 GENERAL Furnish and install where indicated on the drawings____ YORK YK Centrifugal Liquid Chilling Unit(s). Each unit shall produce a capacity ____ tons, cooling ____ GPM of ____ from ____ °F to ____ °F when supplied with ____ GPM of condenser water at ____ °F. Power input shall not exceed ____ kW with an IPLV (NPLV) of ____. The evaporator shall be selected for a ____ fouling factor and a maximum liquid pressure drop of ____ ft. The water-side shall be designed for 150 psig working pressure. The condenser shall be se- lected for ____ fouling factor and maximum liquid pressure drop of ____ ft. The waterside shall be designed for 150 psig working pressure. Power shall be supplied to the compres- sor motor at ____ volts- 3 phase-60 Hertz and controls at 115 volts -1-phase-60 Hertz. Or Furnish and install where indicated on the drawings ___ YORK YK Centrifugal Liquid Chilling Unit(s). Each unit shall produce a capacity of kW, cooling____ l/s of ____ from ____ °C to ____ °C when supplied with ____ l/s of condenser water at ____°C. Power input shall not exceed ____ kW with an IPLV (NPLV) of ____. The evaporator shall be selected for ____m2 C/W fouling factor and maximum liquid pressure drop of ____kPa. The waterside shall be designed for 10.3 barg working pressure. The condenser shall be selected for ____ fouling factor and maximum liquid pressure drop of ____ kPa. The waterside shall be designed for 10.3 barg working pressure. Power shall be supplied to the compressor motor at ____ volts - 3-phase-50 Hertz and controls at 115 volts -1-phase-50 Hertz. Or FOR DOUBLE BUNDLE HEAT RECOVERY UNIT: In cooling mode, each unit shall produce a capacity of ___ tons, cooling ____ gpm of _____ from _____ °F to _____ °F when supplied with ____ gpm of condenser water at _____°F. Power input shall not exceed ___ kW with an NPLV of _____. The cooler shall be selected for ______ fouling factor and a maximum liquid pressure drop of _____ ft. The waterside shall be designed for ____ psig working pressure. The condenser shall be selected for _____ fouling factor and maximum liquid pressure drop of _____ ft. Tower condenser bundle water side shall be designed for psig working pressure. In heating mode, each unit shall produce a capacity of ___ tons, cooling ____ gpm of _______ from _____ to _____ °F while providing heating through the heat recovery bun- dle of ____ gpm of _______ from _____ °F to _____ °F . Power input shall not exceed ____ kW. The heat recovery bundle shall be selected for ______ fouling factor and maxi- mum liquid pressure drop of ____ ft. Heating condenser bundle water side shall be de- signed for ____ psig working pressure. Power shall be supplied to the compressor motor at ___ volts – __ phase - __ Hertz and controls at ____ volts – __ - phase - __ Hertz. Guide Specifications
  • 104. JOHNSON CONTROLS FORM 160.75-EG1 (915) 104 Or In cooling mode, each unit shall produce a capacity of ___ kW, cooling ____ l/s of _____ from _____ °C to _____ °C when supplied with ____ l/s of condenser water at _____°C. Power input shall not exceed ___ kW with an NPLV of _____. The cooler shall be se- lected for ______ fouling factor and a maximum liquid pressure drop of _____ kPa. The waterside shall be designed for ____ barg working pressure. The condenser shall be selected for _____ fouling factor and maximum liquid pressure drop of _____ kPa. Tower condenser bundle waterside shall be designed for ___ barg working pressure. In heating mode, each unit shall produce a capacity of ___ tons, cooling ____ l/s of ______ from _____ to _____ °C while providing heating through the heat recovery bundle of ____ l/s of ______ from _____ °C to _____ °C . Power input shall not exceed ____ kW. The heat recovery bundle shall be selected for ______ fouling factor and maximum liquid pres- sure drop of ____ kPa. The heating condenser bundle water side shall be designed for ____ barg working pressure. Power shall be supplied to the compressor motor at ___ volts – __ phase - __ Hertz and controls at ____ volts – __ - phase - __ Hertz. Performance shall be certified or rated in accordance with the latest edition of AHRI Stan- dard 550/590 as applicable. Only chillers that are listed in the AHRI Certification Program for Water Chilling Packages Using the Vapor Compression Cycle are acceptable. Each unit shall be completely factory packaged including evaporator, condenser, sub cooler, compressor, open motor, lubrication system, OptiView Control Center, Variable Speed Drive or Solid-State Starter, and all interconnecting unit piping and wiring. The chiller shall be painted prior to shipment. The initial charge of oil and refrigerant shall be supplied factory charged in the chiller or shipped in containers and cylinders for field installation. COMPRESSOR The compressor shall be a single stage centrifugal type powered by an open drive electric motor. The housing shall be fully accessible with vertical circular joints, with the com- plete operating assembly removable from the compressor and scroll housing. Compres- sor castings shall be designed for a minimum 235 psig (16.2 barg) working pressure and hydrostatically pressure tested at a minimum of 352 psig (24.3 barg). The rotor assembly shall consist of a heat treated steel alloy drive shaft and impeller shaft with cast aluminum, fully shrouded impeller. The impeller shall be designed for balanced thrust, dynamically balanced and overspeed tested for smooth, vibration free operation. Insert type journal and thrust bearings shall be fabricated of aluminum alloy, precision bored and axially grooved. Internal single helical gears with crowned teeth shall be designed so that more than one tooth is in contact at all times to provide even load distribution and quiet operation. Each gear shall be individually mounted in its own journal and thrust bearings to isolate it from impeller and motor forces. Shaft seal shall be provided as a double bellows, double-seal, cartridge type. A gravity-fed oil reservoir shall be built into the top of the compressor to provide lubrication during coastdown in the event of a power failure. (Fixed Speed Drive) Capacity control shall be achieved by use of pre-rotation vanes to provide fully modulating control from full load to minimum load. (Variable Speed Drive) Capacity control shall be accomplished by the Adaptive Capacity Control (ACC), providing Guide Specifications (Cont'd)
  • 105. FORM 160.75-EG1 (915) JOHNSON CONTROLS 105 optimal relationship between compressor speed and inlet pre-rotation vane position for maximum energy efficiency. Control shall automatically compensate for adverse operat- ing conditions, such as fouled tubes, and adjust to prior operation after correction of these conditions. The unit shall be capable of continuous, reliable operation with low ECWT at all load conditions as outlined on the equipment schedule. An external electric actuator shall au- tomatically control pre-rotation vane position. LUBRICATION SYSTEM Lubrication oil shall be force-fed to all compressor bearings, gears, and rotating surfaces by an external variable speed oil pump. The oil pump shall vary oil flow to the com- pressor based on operating and stand-by conditions, ensuring adequate lubrication at all times. The oil pump shall operate prior to start-up, during compressor operation and dur- ing coastdown. Compressor shall have an auxiliary reservoir to provide lubrication during coastdown in the event of a power failure. An oil reservoir, separate from the compressor, shall contain the submersible 2 HP oil pump and a 3000 watt oil heater, thermostatically controlled to remove refrigerant from the oil. The oil reservoir shall be listed as part of the chiller by a nationally recognized testing laboratory and shall be factory air strength tested at 1.1 times design working pressure. Oil shall be filtered by an externally-mounted 1/2 micron replaceable cartridge oil filter equipped with service valves. Oil cooling shall be done via refrigerant cooled oil cooler, with all piping factory-installed. Oil side of the oil cooler shall be provided with service valves. An automatic oil return system to recover any oil that may have migrated to the evaporator shall be provided. Oil piping shall be completely factory-installed and tested. WATER-COOLED OIL COOLER Optional condenser water-cooled oil cooler is offered for units with Q3 compressors only. The four tube pass and one shell pass oil cooler is by API Basco, Model 05036 (shell di- ameter 5 OD, tube length 36). The shell is steel pipe or tubing and tube sheets are steel to ASME specification. Bafflers are precision hot-rolled, punched, carbon steel to assure effective circulation by providing minimum clearances between the tubes and tube holes. The cooler is a straight-tube type and has 180 plain copper tubes of 1/4 OD with 24 BWG. The heat exchanger has either cast iron bonnets to be used for 150 psig (10.3 barg) con- denser waterboxes or carbon steel bonnets to be used for 300 psig (20.6 barg) condenser waterboxes. Condenser water is the cooling medium and water circulation is obtained by the water pressure drop across the condenser shell. The minimum requirement of 7 to 8 gpm (0.4 to 0.5 l/s) water for this oil cooler is provided at a pressure drop as low as 3 ft. with the Q3 piping arrangement. MOTOR DRIVELINE The compressor motor shall be an open drip proof, squirrel cage, induction type operating at 3570 rpm for 60Hz operation and 2975 rpm for 50 Hz operation. The open motor shall be provided with a D-flange. The D-flange is bolted to a cast iron adaptor mounted on the compressor. This allows the motor to be rigidly coupled to the compressor to provide factory alignment of motor and compressor shafts. Guide Specifications (Cont'd)
  • 106. JOHNSON CONTROLS FORM 160.75-EG1 (915) 106 The motor drive shaft shall be directly connected to the compressor shaft with a flexible disc coupling. Coupling shall have all metal construction with no wearing parts to assure long life, and no lubrication requirements to provide low maintenance. For units utilizing remote electro-mechanical starters, a large steel terminal box with gasketed front access cover shall be provided for field-connected conduit. Overload/overcurrent transformers shall be furnished with all units. (For units furnished with factory-packaged Solid-State Starters or Variable Speed Drive, refer to the “Options” section.) EVAPORATOR Evaporator shall be a shell and tube type, hybrid falling film (evaporator codes A_ to Q_) or flooded type (evaporator codes R_ to Z_) designed for a minimum of 180 psig (12.4 barg) on H K compressor models, 235 psig (16.2 barg) on P Q compressor models; working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel plates with fusion welded seams, carbon steel tube sheets, drilled and reamed to accommodate the tubes, and intermediate tube supports spaced no more than four feet apart. The refrigerant side of each shell is designed, tested and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII - Division 1, or other pressure vessel code as appropriate. Heat exchanger tubes shall be high-efficiency, externally and internally enhanced type. Tubes shall utilize the “skip-fin” design, providing a smooth internal and external surface at each intermediate tube support. This provides extra wall thickness and non-work hard- ened copper at the support location, extending the life of the heat exchangers. If skip-fin tubes are not used, minimum tube wall thickness shall be 0.035 (~1 mm). Each tube shall be roller expanded into the tube sheets providing a leak-proof seal, and be individually replaceable. Water velocity through the tubes shall not exceed 12 ft./sec. (3.7 m/sec.). A liquid level sight glass shall be provided on the side of the shell to aid in determining proper refrigerant charge and to check condition of the refrigerant charge. The hybrid fall- ing film evaporator design has suction baffles around the sides and above the falling film section to prevent liquid refrigerant carryover into the compressor. Flooded evaporator designs have a suction baffle on M shells with H9 compressors and an aluminum mesh eliminator on K - Z shells with K compressors located above the tube bundle to prevent liquid refrigerant carryover into the compressor. The evaporator shall have a refrigerant relief device sized to meet the requirements of the ASHRAE 15 Safety Code for Mechani- cal Refrigeration. Waterboxes shall be removable to permit tube cleaning and replacement. Stub-out wa- ter connections having ANSI/AWWA C-606 grooves to ANSI/AWWA C-606 Standard for Grooved End Shoulder Joints shall be provided. Waterboxes shall be designed for 150 psig (10.3 barg) design working pressure and be tested at 225 psig (15.5 barg). Vent and drain connections with plugs shall be provided on each waterbox. Low flow protection shall be provided by a thermal-type water flow sensor, factory mounted in the water nozzle connection and wired to the chiller control panel. CONDENSER Condenser shall be of the shell-and-tube type, designed for a minimum of 235 psig (16.2 barg) working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel plates with fusion-welded seams. Carbon steel tube sheets, drilled and reamed to accommodate the tubes, are welded to the end of each shell. Intermediate tube supports, fabricated from carbon steel plates, are drilled and reamed to eliminate sharp edges. The Guide Specifications (Cont'd)
  • 107. FORM 160.75-EG1 (915) JOHNSON CONTROLS 107 refrigerant side of each shell is designed, tested and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII – Division I, or other pressure vessel code as appropriate. Heat exchanger tubes shall be high efficiency, externally and internally enhanced type. Tubes shall utilize the “skip-fin” design, providing a smooth internal and external surface at each intermediate tube support. This provides extra wall thickness and non work-hard- ened copper at the support location, extending the life of the heat exchangers. If skip-fin tubes are not used, minimum tube wall thickness shall be 0.035 (~1 mm). Each tube shall be roller expanded into the tube sheets providing a leak-proof seal, and be individually replaceable. Water velocity through the tubes shall not exceed 12 ft. /sec. (3.7 m/sec.). A liquid level sight glass shall be provided on the side of the shell to aid in determining proper refrigerant charge and to check condition of the refrigerant charge. The condenser shall have dual refrigerant relief devices; each sized to meet the require- ments of the ASHRAE 15 Safety Code for Mechanical Refrigeration. Arrangement shall allow either valve to be isolated and replaced without removing the unit refrigerant charge. (Option) The condenser shall be provided with positive shutoff valves in the compressor discharge line to the condenser and in the liquid line leaving the condenser. This will allow pumpdown and storage of the refrigerant charge in the condenser. Due to the possibility of not seating properly, check valves are not acceptable for isolation purposes. If a check valve is used, a positive shutoff valve must be provided in series with the check valve. Waterboxes shall be removable to permit tube cleaning and replacement. Stubout water connections having ANSI/AWWA C-606 grooves shall be provided. Waterboxes shall be designed for 150 psig (10.3 barg) design working pressure and be tested at 225 psig (15.5 barg). Vent and drain connections with plugs shall be provided on each waterbox. REFRIGERANT FLOW CONTROL Refrigerant flow to the evaporator shall be controlled by a variable orifice. The variable ori- fice control shall automatically adjust to maintain proper refrigerant level in the condenser and evaporator. This shall be controlled by monitoring the refrigerant liquid level in the condenser, assuring optimal subcooler performance. OPTIVIEW CONTROL CENTER General – The chiller shall be controlled by a stand-alone, microprocessor based control center. The chiller control panel shall provide control of chiller operation and monitoring of chiller sensors, actuators, relays and switches. Control Panel – The control panel shall include a 10.4-in. (264 mm) diagonal color liquid crystal display (LCD) surrounded by “soft“ keys which are redefined based on the screen displayed at that time. This shall be mounted in the middle of a keypad interface and in- stalled in a locked enclosure. The screen shall detail all operations and parameters, using a graphical representation of the chiller and its major components. The panel verbiage is available in eight languages as standard and can be changed on the fly without having to turn off the chiller. Data shall be displayed in either English or Metric units. Smart Freeze Point Protection shall run the chiller at 36°F (2°C) leaving chilled water temperature, and not have nuisance trips on low water temperature. The sophisticated program and sensor shall monitor the chiller water temperature to prevent freeze-up. When needed, Hot Gas Bypass is available as an option. Guide Specifications (Cont'd)
  • 108. JOHNSON CONTROLS FORM 160.75-EG1 (915) 108 The panel shall display countdown timer messages so the operator knows when functions are starting and stopping. Every programmable point shall have a pop-up screen with the allowable ranges, so that the chiller cannot be programmed to operate outside of its design limits. The chiller control panel shall also provide: A. System operating information including: 1. Return and leaving chilled water temperature. 2. Return and leaving condenser water temperature. 3. Evaporator and condenser saturation temperature. 4. Differential oil pressure. 5. Percent motor current. 6. Compressor discharge temperature. 7. Oil reservoir temperature. 8. Compressor thrust bearing positioning and oil temperature. 9. Operating hours. 10. Number of unit starts. B. Digital programming of setpoints through the universal keypad including: 1. Leaving chilled water temperature. 2. Percent current limit. 3. Pull-down demand limiting. 4. Six-week schedule for starting and stopping the chiller, pumps and tower. 5. Remote reset temperature range. C. Status messages indicating: 1. System ready to start. 2. System running. 3. System coastdown. 4. System safety shutdown – manual restart. 5. System cycling shutdown – auto restart. 6. System pre-lube. 7. Start inhibit. D. The text displayed within the system status and system details field shall be displayed as a color-coded message to indicate severity: red for safety fault, orange for cycling faults, yellow for warnings, and green for normal messages. Guide Specifications (Cont'd)
  • 109. FORM 160.75-EG1 (915) JOHNSON CONTROLS 109 E. Safety shutdowns enunciated through the display and the status bar, and consist of system status, system details, day, time, cause of shutdown, and type of restart re- quired. Safety shutdowns with a fixed speed drive shall include: 1. Evaporator – low pressure. 2. Evaporator – transducer or leaving liquid probe. 3. Evaporator – transducer or temperature sensor. 4. Condenser – high pressure contacts open. 5. Condenser – high pressure. 6. Condenser – pressure transducer out-of-range. 7. Auxiliary safety – contacts closed. 8. Discharge – high temperature. 9. Discharge – low temperature. 10. Oil – high temperature. 11. Oil – low differential pressure. 12. Oil – high differential pressure. 13. Oil – sump pressure transducer out-of-range. 14. Oil – differential pressure calibration. 15. Oil – variable speed pump – pressure setpoint not achieved. 16. Control panel – power failure. 17. Motor or starter – current imbalance. 18. Thrust bearing – proximity probe clearance (K compressors only). 19. Thrust bearing – proximity probe out-of-range (K compressors only). 20. Thrust bearing – position switch (P, Q H9 compressors). 21. Watchdog – software reboot. F. Safety shutdowns with a VSD shall include: 1. VSD shutdown – requesting fault data. 2. VSD – stop contacts open. 3. VSD – 105% motor current overload. 4. VSD – high phase A, B, C inverter heat-sink temp. 5. VSD – high converter heat-sink temperature. Guide Specifications (Cont'd)
  • 110. JOHNSON CONTROLS FORM 160.75-EG1 (915) 110 (Filter Option Only) 6. Harmonic filter – high heat-sink temperature. 7. Harmonic filter – high total demand distribution. G. Cycling shutdowns enunciated through the display and the status bar, and consists of system status, system details, day, time, cause of shutdown, and type of restart required. Cycling shutdowns with a fixed speed drive shall include: 1. Multi-unit cycling – contacts open. 2. System cycling – contacts open. 3. Oil – low temperature differential. 4. Oil – low temperature. 5. Control panel – power failure. 6. Leaving chilled liquid – low temperature. 7. Leaving chilled liquid – flow switch open. 8. Motor controller – contacts open. 9. Motor controller – loss of current. 10. Power fault. 11. Control panel – schedule. 12. Starter – low supply line voltage (SSS option). 13. Starter – high supply line voltage (SSS option). 14. Proximity probe – low supply voltage (K compressors). 15. Oil – variable speed pump – drive contacts open. H. Cycling shutdowns with a VSD shall include: 1. VSD shutdown – requesting fault data. 2. VSD – stop contacts open. 3. VSD – initialization failed. 4. VSD – high phase A, B, C instantaneous current. 5. VSD – Phase A, B, C gate driver. 6. VSD – single phase input power. 7. VSD – high DC bus voltage. 8. VSD – pre charge DC bus voltage imbalance. 9. VSD – high internal ambient temperature. 10. VSD – invalid current scale selection. Guide Specifications (Cont'd)
  • 111. FORM 160.75-EG1 (915) JOHNSON CONTROLS 111 11. VSD – low phase A, B, C inverter heat-sink temp. 12. VSD – low converter heat-sink temperature. 13. VSD – pre-charge – low DC bus voltage. 14. VSD – logic board processor. 15. VSD – run signal. 16. VSD – serial communications. (Filter Option Only) 1. Harmonic filter – logic board or communications. 2. Harmonic filter – high DC bus voltage. 3. Harmonic filter – high phase A, B, C current. 4. Harmonic filter – phase locked loop. 5. Harmonic filter – pre-charge – low DC bus voltage. 6. Harmonic filter – DC bus voltage imbalance. 7. Harmonic filter – 110% input current overload. 8. Harmonic filter – logic board power supply. 9. Harmonic filter – run signal. 10. Harmonic filter – DC current transformer. 11. Harmonic filter – DC current transformer. I. Security access to prevent unauthorized change of setpoints, to allow local or remote control of the chiller, and to allow manual operation of the pre-rotation vanes and oil pump. Access shall be through ID and password recognition, which is defined by three different levels of user need: view, operator, and service. J. Trending data with the ability to customize points of once every second to once every hour. The panel shall trend up to 6 different parameters from a list of over 140, without the need of an external monitoring system. K. The operating program stored in non-volatile memory (EPROM) to eliminate repro- gramming the chiller due to AC power failure or battery discharge. Programmed setpoints shall be retained in lithium battery-backed RTC memory for a minimum of 10 years with power removed from the system. L. A fused connection through a transformer in the compressor motor starter to provide individual over-current protected power for all controls. M. A numbered terminal strip for all required field interlock wiring. N. An RS-232 port to output all system operating data, shutdown/cycling message, and a record of the last 10 cycling or safety shutdowns to a field-supplied printer. Data logs to a printer at a set programmable interval. This data can be preprogrammed to print from 1 minute to 1 day. Guide Specifications (Cont'd)
  • 112. JOHNSON CONTROLS FORM 160.75-EG1 (915) 112 O. The capability to interface with a building automation system via hard-wired connec- tions to each feature to provide: 1. Remote chiller start and stop. 2. Remote leaving chiller liquid temperature adjust. 3. Remote current limit setpoint adjust. 4. Remote ready to start contacts. 5. Safety shutdown contacts. 6. Cycling shutdown contacts. 7. Run contacts. VARIABLE SPEED DRIVE A variable speed drive shall be factory-installed on the chiller. It shall vary the compressor motor speed by controlling the frequency and voltage of the electrical power to the motor. The adaptive capacity control logic shall automatically adjust motor speed and compres- sor pre-rotation vane position independently for maximum part load efficiency by analyz- ing information fed to it by sensors located throughout the chiller. Drive shall be PWM type utilizing IGBTs with a displacement power factor of 0.95 or better at all loads and speeds. The variable speed drive shall be unit-mounted in a NEMA- 1 enclosure with all power and control wiring between the drive and chiller factory-installed, including power to the chiller oil pump. Field power wiring shall be a single-point connection and electrical lugs for incoming power wiring shall be provided. The entire chiller package shall be certified to standard UL-1995 by a nationally recognized testing laboratory. The variable speed drive is cooled by a closed loop, fresh water circuit consisting of a water-to water heat exchanger and circulating pump. All interconnecting water piping is factory installed and rated for 150 psig (10.3 barg) working pressure. The following features shall be provided: a door interlocked circuit breaker, capable of being padlocked; UL listed ground fault protection; overvoltage and under voltage protec- tion; 3-phase sensing motor overcurrent protection; single phase protection; insensitive to phase rotation; over temperature protection; digital readout at the chiller unit control panel of: • Output Frequency. • Output Voltage. • 3-phase output current. • Input Kilowatts (kW) and Kilowatt-hours (kWh). • Self diagnostic service parameters. Separate meters for this information shall not be acceptable. Guide Specifications (Cont'd)
  • 113. FORM 160.75-EG1 (915) JOHNSON CONTROLS 113 (Optional) A harmonic filter that limits electrical power supply distortion from the variable speed drive in order to help the building comply with the guidelines of IEEE STD. 519- 2014 shall be provided. The filter shall be unit mounted within the same NEMA 1 enclo- sure and shall be UL listed. The following digital readouts shall be provided at the chiller unit control panel as part of the filter package: • Input KVA. • Total power-factor. • 3-phase input voltage. • 3-phase input current. • 3-phase input voltage total harmonic distortion (THD). • 3-phase input current total demand distortion (TDD). • Self diagnostic service parameters. Separate meters for this information shall not be acceptable. FACTORY-INSTALLED COMPRESSOR MOTOR STARTER [OPTION THROUGH 900 HP (671 KW) 200 600 VOLTS] The chiller manufacturer shall furnish a reduced voltage Solid-State Starter for the com- pressor motor. Starter shall be factory mounted and wired on the chiller. The starter shall provide, through the use of silicon-controlled rectifiers, a smooth acceleration of the motor without current transitions or transients. The starter enclosure shall be NEMA 1, with a hinged access door with lock and key. Electrical lugs for incoming power wiring shall be provided. Standard Features include: digital readout at the OptiView Control Center of the following: Display Only • 3-phase voltage A, B, C. • 3-phase current A, B, C. • Input Power (kW). • kW Hours. • Starter Model. • Motor Run (LED). • Motor Current % Full Load Amps. • Current Limit Setpoints. • Pulldown Demand Time Left. Guide Specifications (Cont'd)
  • 114. JOHNSON CONTROLS FORM 160.75-EG1 (915) 114 Programmable • Local Motor Current Limit. • Pulldown Demand Limit. • Pulldown Demand Time. Other features include: low line voltage; 115-volt control transformer; three-leg sensing overloads; phase rotation and single-phase failure protection; high temperature safety protection; motor current imbalance and under voltage safeties; open and close SCR protection; momentary power interruption protection. The Solid-State Starter is cooled by a closed loop, fresh water circuit consisting of a water-to-water heat exchanger and cir- culating pump. All interconnecting water piping is factory-installed and rated for 150 psig (10.3 barg) working pressure. (Optional) Unit-mounted circuit breaker includes ground fault protection and provides 65,000 amps. Short circuit withstand rating in accordance with UL Standard 508. A non- fused disconnect switch is also available. Both options have keyed locks for safety. FACTORY-INSTALLED COMPRESSOR MOTOR STARTER (2300V 4160V/3/60HZ OR 3300V/3/50HZ- UNIT MOUNTED FOR H9 COMPRESSOR OR LARGER ONLY) The chiller manufacturer shall furnish a reduced-volt-age, Medium Voltage Solid-State Starter, in accordance with the chiller manufacturer’s starter specifications. The starter shall be of modular construction with complete access to all parts. The starter shall be tested and the design starting current and overload settings adjusted at the factory. The starter shall provide, through the use of six in-line (not inside the Delta) silicon controlled rectifiers (2 per phase), a smooth acceleration of the motor without current transitions or transients. The following protective devices and convenience items shall be factory mounted and wired to the starter: A. 3-leg sensing electronic overloads – shuts unit down if current exceeds 105% of FLA to protect the motor windings. B. Phase rotation protection circuit – denies start-up when detecting incorrect power wir- ing phase sequence to the starter which could cause reverse motor rotation and dam- age the equipment. C. Single-phase failure protection circuit – ensures against motor burnout by shutting the unit down if power loss occurs in any of the incoming lines during start-up. D. High temperature safety protection system – temperature activated switches on heat sinks will shut the unit down if the SCR temperature exceeds acceptable limits. E. 3-phase digital ammeter and digital voltmeter readout via control center – easily cross- check design current and voltage limitations against supply characteristics. F. Starter mounted load break rated input disconnect switch with interlocked lockable handle. Positive disconnecting means shall be visible from outside the enclosure, in operator area. All doors shall be interlocked with the disconnecting means. G. Open/Shorted SCR Protection – Failed semiconductor devices are automatically de- tected and reported via the Control Center. Guide Specifications (Cont'd)
  • 115. FORM 160.75-EG1 (915) JOHNSON CONTROLS 115 H. Power Fault Protection – momentary power interruption protection detects power in- terruptions within 3 line cycles and interrupts power to the compressor motor within 1 additional line cycle. I. Electrical Connections – these tin-plated or copper bus bars provide easy connection to incoming copper power lines. J. Wattmeter – An instantaneous wattmeter tells the customer how much power the chill- er is consuming. A kilowatt-hour energy meter is also provided to measure power con- sumption over a period of time. K. Shutdown History – The Medium Voltage Solid-State Starter shall provide the system control panel with ten histories of previous unit shutdowns initiated by the starter. In addition, the Starter shall include as standard, the following convenience items already mounted and wired to the starter at the factory: • Auxiliary control supply transformer – eliminates the need for running separate 115V- 1 phase-50/60 Hz power source wiring to the chiller Control Center. REMOTE ELECTRO-MECHANICAL COMPRESSOR MOTOR STARTER (OPTION) A remote electro-mechanical starter of the R-1132 type shall be furnished for each com- pressor motor. The starter shall be furnished in accordance with the chiller manufacturer’s starter specifications and as specified elsewhere in these specifications. PORTABLE REFRIGERANT STORAGE/RECYCLING SYSTEM A portable, self-contained refrigerant storage/recycling system shall be provided consist- ing of a refrigerant compressor with oil separator, storage receiver, water-cooled condens- er, filter drier and necessary valves and hoses to remove, replace and distill refrigerant. All necessary controls and safety devices shall be a permanent part of the system. Guide Specifications (Cont'd)
  • 116. JOHNSON CONTROLS FORM 160.75-EG1 (915) 116 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. TEMPERATURE To convert degrees Fahrenheit (°F) to degrees Celsius (°C), subtract 32° and multiply by 5/9 or 0.5556. To convert a temperature range (i.e., 10°F or 12°F chilled water range) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556. EFFICIENCY In the English l‑P system, chiller efficiency is measured in kW / ton: kW/ton = kW input tons refrigeration effect In the Sl Metric system, chiller efficiency is measured in Coefficient of Performance (COP). kW/ton = kW input kW refrigeration effect kW / ton and COP are related as follows: kW/ton = 3.516 COP COP = 3.516 kW/ton SI Metric Conversion MEASUREMENT MULTIPLY THIS ENGLISH  VALUE BY TO OBTAIN THIS METRIC VALUE CAPACITY TONS REFRIGERANT EFFECT (ton) 3.516 KILOWATTS (kW) POWER KILOWATTS (kW) NO CHANGE KILOWATTS (kW) HORSEPOWER (hp) 0.7457 KILOWATTS (kW) FLOW RATE GALLONS / MINUTE (gpm) 0.0631 LITERS / SECOND (L/s) LENGTH FEET (ft) 304.8 MILLIMETERS (mm) INCHES (in) 25.4 MILLIMETERS (mm) WEIGHT POUNDS (lb) 0.4536 KILOGRAMS (kg) VELOCITY FEET / SECOND (fps) 0.3048 METERS / SECOND (m/s) PRESSURE DROP FEET OF WATER (ft) 2.989 KILOPASCALS (kPa) POUNDS / SQ. INCH (psi) 6.895 KILOPASCALS (k Pa) FOULING FACTOR ENGLISH l‑P (fT2 °F hr/Btu) EQUIVALENT Sl METRIC (m2 k/kW) 0.0001 0.018 0.00025 0.044 0.0005 0.088 0.00075 0.132
  • 118. Printed on recycled paper Form 160.75-EG1 (915) Supersedes:160.75-EG1 (615) © 2015 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI  53201 Printed in USA www.johnsoncontrols.com Issued on 09/09/2015