YZ Mod A with OptiView Control Center

035-27133-100

Installation Guide Form Number: 161.01-N1 (120)

Issue Date: 2020-01-31 Supersedes: 161.01-N1 (1019)
 Contents
General safety guidelines.............................................................................................................. 5

Safety symbols..................................................................................................................................... 5

Changeability of this document......................................................................................................... 6

Change bars............................................................................................................................... 6

MSDS information............................................................................................................................... 6

Associated literature........................................................................................................................... 7

Nomenclature...................................................................................................................................... 8

Overview........................................................................................................................................ 10

General................................................................................................................................................ 10

Component combinations................................................................................................................ 10

Inspection – Damage – Shortage.................................................................................................... 10

Chiller data plate............................................................................................................................... 11

YZ shipment forms............................................................................................................................ 11

Rigging................................................................................................................................................ 13

Shipping and rigging................................................................................................................... 14

Form 1 total weight........................................................................................................................... 14

Form 1 shipment............................................................................................................................... 14

Miscellaneous items............................................................................................................... 15

Form 2 total weight........................................................................................................................... 15

Form 2 shipment............................................................................................................................... 15

Miscellaneous items............................................................................................................... 15

Unit rigging.............................................................................................................................. 16

Form 3 shipment............................................................................................................................... 17

Shells......................................................................................................................................... 17

Driveline................................................................................................................................... 17

Variable speed drive (VSD).................................................................................................... 18

Miscellaneous material.......................................................................................................... 18

Form 7 shipment............................................................................................................................... 18

YZ Mod A with OptiView Control Center i

 Form 11 shipment............................................................................................................................. 18

Condenser................................................................................................................................ 19

Evaporator............................................................................................................................... 19

Driveline................................................................................................................................... 19

Shells......................................................................................................................................... 20

Variable speed drive (VSD).................................................................................................... 20

Miscellaneous items............................................................................................................... 20

Suction line elbow............................................................................................................................. 22

Motor end assembly......................................................................................................................... 22

Stage end assembly.......................................................................................................................... 23

Variable speed drive (VSD)............................................................................................................... 24

OptiView™ control center....................................................................................................... 25

Installation.................................................................................................................................... 27

Overview............................................................................................................................................. 27

Determining the location................................................................................................................. 27

Foundation requirements...................................................................................................... 27

Clearance requirements......................................................................................................... 28

Rigging unit to final location............................................................................................................ 28

Isolator installation........................................................................................................................... 28

Neoprene isolator pads.......................................................................................................... 28

Neoprene isolators................................................................................................................. 30

Installing optional spring isolators....................................................................................... 31

Making connections.......................................................................................................................... 33

Piping connections................................................................................................................. 33

Refrigerant relief piping......................................................................................................... 35

Purge pump exhaust piping.................................................................................................. 38

Unit piping............................................................................................................................... 40

Control wiring.......................................................................................................................... 40

Power wiring............................................................................................................................ 41

ii YZ Mod A with OptiView Control Center

 Supplied variable speed drive............................................................................................... 41

Applying insulation............................................................................................................................ 41

Installation check – request for startup service............................................................................ 41

Reassembly................................................................................................................................... 43

Form 3, 7, and Form 11 reassembly................................................................................................ 43

Refrigerant tubing reassembly........................................................................................................ 48

Assembling straight thread O-ring port fittings................................................................. 48

Assembling O-ring face seal fittings..................................................................................... 51

Dimensions, nozzle arrangements, and weights..................................................................... 53

Unit conversion............................................................................................................................. 57

Temperature....................................................................................................................................... 57

YZ Mod A with OptiView Control Center iii

General safety guidelines
Important: Read before proceeding.

This equipment is a relatively complicated apparatus. During rigging, installation, operation,

maintenance, or service, individuals may be exposed to certain components or conditions including,
but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the potential, if misused or handled improperly,
to cause bodily injury or death. It is the obligation and responsibility of rigging, installation, and
operating/service personnel to identify and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to comply with any of these requirements
could result in serious damage to the equipment and the property in which it is situated, as well as
severe personal injury or death to themselves and people at the site.
This document is intended for use by owner-authorized rigging, installation, and operating/service
personnel. It is expected that these individuals possess independent training that will enable them
to perform their assigned tasks properly and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read and understood the on-product labels, this
document and any referenced materials. This individual shall also be familiar with and comply
with all applicable industry and governmental standards and regulations pertaining to the task in
question.

Safety symbols
The following symbols are used in this document to alert the reader to specific situations:

 DANGER

Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.

 WARNING

Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.

 CAUTION

Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.

Note: Highlights additional information useful to the technician in completing the work being
performed properly.

YZ Mod A with OptiView Control Center 5

  WARNING

External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance
with Johnson Controls’ published specifications and must be performed only by a qualified electrician.
Johnson Controls will NOT be responsible for damage/problems resulting from improper connections
to the controls or application of improper control signals. Failure to follow this warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.

Changeability of this document

In complying with Johnson Controls’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. Johnson Controls makes
no commitment to update or provide current information automatically to the manual or
product owner. Updated manuals, if applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the Johnson Controls QuickLIT website at http://
cgproducts.johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/service personnel to verify the applicability
of these documents to the equipment. If there is any question regarding the applicability of these
documents, rigging, lifting, and operating/service personnel should verify whether the equipment
has been modified and if current literature is available from the owner of the equipment prior to
performing any work on the chiller.

Change bars
Revisions made to this document are indicated with a line along the left or right hand column in the
area the revision was made. These revisions are to technical information and any other changes in
spelling, grammar or formatting are not included.

MSDS information
Material Safety Data Sheets (MSDS) information can be obtained by calling (800) 451-8346 in
the U.S. or by e-mailing MSDS@3Ecompany.com. Provide the product name, manufacturer, part
number, and the specific language required. JCI employees can refer to the following for more
information: https://my.jci.com/sites/BE/NASafety.

6 YZ Mod A with OptiView Control Center

Associated literature
Manual description Form number
Chiller Operations and Maintenance 161.01-OM1
Unit Installation Checklist 161.01-CL1
Unit Startup Checklist 161.01-CL2
Field Connections Diagram - Water Pump Starters 161.01-PW1
Field Control, Modifications 161.01-PW2
Field Connections Diagram 161.01-PW3
Wiring Diagram, Unit 161.01-PW4
Liquid Chiller Log Sheet 161.01-MR1
Service Instructions - How to Service Coolant Loops 160.00-M12
Service Policy - Shipping Damage Claims 50.15-NM
Centrifugal Chiller Long Term Storage 50.20-NM5
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2

YZ Mod A with OptiView Control Center 7

Nomenclature
SYSTEM NOMENCLATURE
YZ - MA033 AN030 P042N A -
Product Family Special Contract

Motor End Name Unit Mod Level

Stage End Name VSD Name

MOTOR END NAMING

M A 033 A A
Bearing Family Bearing Configuration
Motor Configuration
Motor H P Code
Motor Family

STAGE END NAMING

A N 030 N A - A A
Mechanical Configuration
Compressor Family
Flowpath Configuration

Diffuser Type Impeller Configuration

Compressor Cycle
Compressor Size Code

VARIABLE SPEED DRIVE NOMENCLATURE

PYT 0330 G X N01 Z C 30 B 02 M L Z - 46 A

VSD Family Mod Level

VSD Output Amp Code Input Voltage / Frequency Codes
0330 = 330 A 40 = 380 V / 60 Hz
0420 = 420 A 50 = 380 V / 50 Hz
0780 = 780 A 42 = 400 V / 60 Hz
1020 = 1020 A 43 = 400 V / 50 Hz
1280 = 1280 A 68 = 415 V / 50 Hz
Design Center 46 = 460 V / 60 Hz
G = Global
Optional Filter
Mounting System Z = Base Model
X = Unit H = Filter Model

Enclosure Type cUL / cETL

N01 = NEMA 1
Bearing Type
Chiller Type M = Magnetic
Z = YZ L = Oil

Cooling System Circuit Breaker Rating

C = Condenser Liquid 02 = 250 A
W = Water 04 = 400 A
06 = 600 A
08 = 800 A
12 = 1200 A
Input Type
B = Circuit Breaker
Heat Exchanger Rating
30 = 300 psig
LD27334a

8 YZ Mod A with OptiView Control Center

 EVAPORATOR NAMING
F A 21 12 - A 2 Z 750 - 2
Evap Number of Passes
Evap Family
1, 2, 3 Pass
Evap Mod Level Evap Tube Type

Evap Diameter (Inches) Evap Bundle Fill

Evap Length (Feet)
Evap Bundle Code Evap Pass Limit
A = 3/4 in. Tubes 1 = 1 in. Tubes 2, 3 Pass

EVAPORATOR WATERBOX NAMING

C A 1 G LR B
Evap Hinges
Evap Waterbox Family B = Both Waterboxes
C = Compact Welded N = No Hinges
M = Marine Welded
Evap Water Inlet Side
Evap Waterbox Mod Level LR = Inlet Left, Outlet Right
LL = Inlet Left, Outlet Left
Evap Waterside DWP RL = Inlet Right, Outlet Left
RR = Inlet Right, Outlet Right
1 = 150 psig 3 = 300 psig
Evap Water Connection Type
F = Flanges
G = Grooved
A = AGS Victaulic
CONDENSER NAMING
C A 21 12 - A 2 Z 750 - 2
Cond Family Cond Number of Passes
1, 2, 3 Pass

Cond Tube Type

Cond Mod Level Cond Bundle Fill

Cond Diameter (Inches)
Cond Length (Feet)
Cond Bundle Code Cond Pass Limit
A = 3/4 in. Tubes 1 = 1 in. Tubes 2, 3 Pass

CONDENSER WATERBOX NAMING

C A 1 G LR B
Cond Hinges
B = Both Waterboxes
N = No Hinges
Cond Waterbox Family
Cond Nozzle Arrangment
C = Compact
M = Marine LR = Inlet Left, Outlet Right
LL = Inlet Left, Outlet Left
RL = Inlet Right, Outlet Left
Cond Waterbox Mod Level RR = Inlet Right, Outlet Right

Cond Water Connection Type

F = Flanges
Cond Waterside DWP
G = Grooved
1 = 150 psig 3 = 300 psig A = AGS Victaulic
LD26925

YZ Mod A with OptiView Control Center 9

Overview
Note: In no cases must rigging be done out of horizontal level by more than 10 degrees.

General
This manual provides instructions for rigging and installing a YZ Liquid Chilling Unit.
The chiller can be shipped as a single, factory-assembled, piped and wired package, ready for field
connections, with refrigerant charges shipped separately unless the optional condenser isolation
valves are ordered. The chiller can also be shipped dismantled when required by rigging conditions.
Note: Chillers that are shipped dismantled must be field-assembled under the supervision of a
Johnson Controls representative.

Component combinations
The major components of the YZ chiller are identified in Figure 1 and Figure 2. The chiller is
customized based on the selected combination of motor, compressor, evaporator, and condenser.
All of the allowable YZ chiller combinations are listed in Dimensions, nozzle arrangements, and
weights.

Inspection – Damage – Shortage

The unit shipment should be checked upon arrival, before unloading, to ensure all major pieces,
boxes and parts are received and that there are no visible signs of damage. Any material shortage
should be reported to Johnson Controls immediately.
Note: Any damage or signs of damage must be reported to the transportation company
immediately for their inspection. Johnson Controls will not be responsible for any damage in
shipment or at job site or loss of parts.

Refer to Shipping Damage Claims Form (Form 50.15-NM).

YZ Chillers are not intended to be stored outdoors, exposed to rain and moisture. The shipping
wrap is for shipping, not for extended outdoor storage. The chiller should be tarped during any
delays to get indoors and moisture desiccant should be used for damp areas.
If the chiller was not shipped complete (as shown in Form 1 or 2) use the Reassembly in conjunction
with this installation manual.
The services of a Johnson Controls representative will be furnished to check the installation and
to supervise the initial start-up and operation of all chillers installed within the Continental United
States.

 CAUTION

The Johnson Controls Warranty may be voided if the following restrictions are not adhered to.

1. No valves or connections should be opened under any circumstances because such action will
result in loss of the factory refrigerant (Form 1) or nitrogen charge (Form 2).

2. Do not dismantle or open the chiller for any reason except under the supervision of a Johnson
Controls representative.

10 YZ Mod A with OptiView Control Center

3. When units are shipped dismantled, notify the nearest Johnson Controls office in ample time
for a Johnson Controls representative to supervise rigging the unit to its operating position and
the assembly of components.

4. Do not make final power supply connections to the compressor motor drive or control center.

5. Do not charge the unit with refrigerant.

6. Do not attempt to start the system.

7. Do not run hot water (greater than 110°F or 43°C maximum) or steam through the evaporator
or condenser at any time.

Chiller data plate

A unit data plate is mounted on the control center assembly of each unit, giving unit model
number, design working pressure, water passes, refrigerant charge serial numbers, motor power
characteristics and connection diagrams.
Additional information may be found on the compressor and motor data plates. This information
should be included when contacting the factory for any problem.

YZ shipment forms
The chiller may be ordered and shipped in any of the following forms:

• Form 1 (shipped complete with refrigerant charge)

• Form 2 (shipped complete with nitrogen charge; refrigerant charge shipped separately)

• Form 3 (shipped in three assemblies)

• Form 7 (shipped in four assemblies)

• Form 11 (shipped in two assemblies)

Note: Units that are shipped dismantled MUST be reassembled by, or under the supervision of
a Johnson Controls representative. See Reassembly for detailed reassembly instructions.

Note: When more than one chiller is involved, the major parts of each unit will be marked to
prevent mixing of assemblies. Piping and wiring drawings to be furnished by Johnson Controls.

YZ Mod A with OptiView Control Center 11

Figure 1: YZ chiller components (rear)

Figure 2: YZ chiller components (front)

12 YZ Mod A with OptiView Control Center

Rigging
Figure 3: Rigging warning

 DANGER

Rigging and lifting must only be done by a professional rigger in accordance with a written rigging and
lifting plan. The most appropriate rigging and lifting method depends on job-specific factors, such as
the rigging equipment available and site needs. Therefore, a professional rigger must determine the
rigging and lifting method to be used, and it is beyond the scope of this manual to specify rigging and
lifting details.

The complete standard chiller is shipped without skids. When optional skids are used, it may be
necessary to remove the skids so that riggers skates can be used under the unit end sheets to
reduce overall height.
Each unit has four lifting holes (two in each end) in the end sheets, which must be used to lift the
unit.
Care should be taken at all times during rigging and handling of the chiller to avoid damage to the
unit and its external connections. Lift only using the holes shown in Figure 4.

 CAUTION

Do not lift the unit with slings around the motor or compressor assembly, or by means of eyebolts in
the tapped holes of the compressor motor assembly. Do not turn a unit on its side for rigging. Do not
rig vertically.

The rigging and operating weights and overall dimensions are given in Dimensions, nozzle
arrangements, and weights as a guide in determining the clearances required for rigging. Add 6 in.
(15 cm) to the overall height for an optional skidded unit.

YZ Mod A with OptiView Control Center 13

Shipping and rigging
Note: In no cases must rigging be done out of horizontal level by more than 10 degrees.

 DANGER

Improper use of rigging equipment can result in serious injury. Do not operate without proper training
and authorization.

Note: It is the responsibility of the installer to have a qualified and certified crane operator and
rigger for lifting components and relocating to the new site.

To ensure a safe and effective rigging practice the installer is responsible for inspection and
operation of the lifting equipment, special site considerations, proper rigging and lifting practices,
and any safety considerations.
Particular items the installer must be aware of are as follows:
• Rope with visible wear: twisted, kinked, or damaged chains.

• Deformed, cracked, or stretched hooks or if the safety latch on the hook is damaged.

• Correct drum spooling as the hook is raised.

• Do not operate a damaged or malfunctioning hoist.

• Do not wrap the hoisting rope or chain around the load.

• Do not lift loads over people.

Form 1 total weight

For total weight information, refer to the unit submittal drawings.
Note: The actual unit total shipping and operating weight is on the submittal drawings.

Form 1 shipment
The chiller is shipped completely assembled and charged with refrigerant; all miscellaneous items
are shipped loose.

• The unit is completely assembled at the factory.

• The compressor (motor and stage) is mounted and all the necessary interconnecting piping is
assembled.

• The complete unit is factory leak-tested, evacuated and shipped charged with refrigerant.

• The OptiView™ Control Center is mounted on the unit.

• The Variable Speed Drive (VSD) is mounted, wired, and shipped with glycol.

14 YZ Mod A with OptiView Control Center

Miscellaneous items
The following items are shipped together:

• Four vibration isolation pads (or optional spring isolators and brackets)

• VSD operating coolant (inhibited water)

• Other shipped loose items, including piping, water temperature controls, wiring, and similar
items

Form 2 total weight

For total weight information, refer to the unit submittal drawings.
Note: The actual unit total shipping and operating weight is on the submittal drawings.

Form 2 shipment
Note: Arrangements with the local service office must be made to ensure refrigerant is on-site
when unit is ready to be charged.

The chiller is shipped completely assembled, with refrigerant charges shipped separately and
miscellaneous loose items shipped together.
The unit is completely assembled at the factory.

• The compressor (motor and stage) is mounted and all the necessary interconnecting piping is
assembled.

• The complete unit is factory leak-tested, evacuated and shipped charged with a 3 psig to 7 psig
(20 kPa to 50 kPa) holding charge of dry nitrogen.

• The OptiView™ Control Center is mounted.

• The VSD is mounted, wired, and shipped with glycol.

• Refrigerant charges are shipped separately.

Miscellaneous items
The following items are shipped together:

• Four vibration isolation pads (or optional spring isolators and brackets)

• Other shipped loose items, including piping, water temperature controls, wiring, and similar
items

• VSD operating coolant (inhibited water)

YZ Mod A with OptiView Control Center 15

Unit rigging

 CAUTION

One lifting chain is required for each lifting point and each chain having a working load limit 30% of unit
total weight. The lifting chains traversing the evaporator/condenser shells should remain 90° +/- 10°
from horizontal.

1. Attach rigging chains to an adequate lifting device.

2. Attach chains to the lifting holes at the corner of each end sheet as shown in Figure 4.

3. The angle of the lifting chains traversing the end sheet should not be less than 65° as shown
on Figure 4.

4. With an adequate lifting device lift the unit slightly off the ground to determine adjustments
necessary to keep the unit level.

5. Make adjustments as necessary to level the unit.

Figure 4: Form 1 and Form 2 rigging

16 YZ Mod A with OptiView Control Center

Form 3 shipment
Prior to shipping, the unit is completely assembled at the factory. Interconnecting piping is
assembled and the complete unit is wired and leak-tested.
The unit is dismantled and shipped as follows:

1. The compressor (motor and stage)

2. The evaporator/condenser shell assembly

3. The VSD

4. OptiView™ Control Center

5. Miscellaneous shipped loose items

6. Refrigerant charges shipped separately

Note: Refrigerant charges are shipped separately. Arrangements with the local service office
must be made to ensure refrigerant is on-site when the unit is ready to be charged. When
optional skids are used it may be necessary to remove the skids so riggers skates can be used
under the unit end sheets to reduce overall height.

Shells
The evaporator and condenser are assembled and prepared for shipping but not skidded.

• All conduit is left on the shells.

• All openings on the shells are closed and charged with a 3 psig to 7 psig (20 kPa to 50 kPa)
holding charge of dry nitrogen.

a. Attach rigging chains to an adequate lifting device.

b. Attach chains to the lifting holes at the corner of each end sheet as shown on Figure 5.

c. The angle of the lifting chains traversing the end sheet should not be less than 65° as
shown on Figure 5.

d. With an adequate lifting device lift the unit slightly off the ground to determine
adjustments necessary to keep the unit level.

e. Make adjustments as necessary to level the unit.

Driveline
The compressor (motor and stage) is removed from the shells and skidded.

• All integral wiring is left on the compressor.

• All openings on the compressor are closed and shipped charged with a 3 psig to 7 psig (20 kPa to
50 kPa) holding charge of dry nitrogen.

YZ Mod A with OptiView Control Center 17

Variable speed drive (VSD)
The VSD is skidded and shipped separately from the assembled chiller.

• The VSD is filled with glycol for shipping. The VSD operating coolant (inhibited water) is shipped
with the other loose items.

Miscellaneous material
The following assemblies and items are shipped together:

• OptiView™ Control Center

• Four vibration isolation pads (or optional spring isolators and brackets)

• Other shipped loose items, including piping, water temperature controls, wiring, and similar
items

• VSD operating coolant (inhibited water)

Form 7 shipment
Prior to shipping, the unit is completely assembled at the factory. Interconnecting piping is
assembled and the complete unit is wired and leak-tested.
The unit is dismantled and shipped as follows:

1. The compressor (motor and stage)

2. The evaporator

3. The condenser

4. The VSD

5. Refrigerant charges shipped separately

6. Miscellaneous shipped loose items

Note: Arrangements with the local service office must be made to ensure refrigerant is on-site
when unit is ready to be charged.

Form 11 shipment
Prior to shipping, the unit is completely assembled at the factory. Interconnecting piping is
assembled and the complete unit is wired and leak-tested.

• Condenser side assembly (Condenser/OptiView™/VSD) – not skidded

• Evaporator side assembly (Evaporator/Driveline/Magnetic Bearing Controller) – not skidded

Note:
Refrigerant charges are shipped separately. Arrangements with the local service office must be
made to ensure refrigerant is on-site when the unit is ready to be charged.

When optional skids are used it may be necessary to remove the skids so riggers skates can be
used under the unit end sheets to reduce overall height.

18 YZ Mod A with OptiView Control Center

 Note: The lifting chains along the axis of the evaporator/condenser shells should not exceed
90° +/- 10°.

 CAUTION

One chain is required per each lifting point.

Use lifting chains with a working load limit each at least 40% of the total shell weight.

Condenser
1. Attach rigging chains to an adequate lifting device.

2. Attach chains to the two lifting holes at the corner of each end sheet as shown in Figure 6.

 CAUTION

The angle of the lifting chains is critical and damage to the unit may occur if the rigging is not
completed as described.

3. With an adequate lifting device lift the unit slightly off the ground to check for center of gravity.

4. Make adjustments as necessary to level the unit.

Evaporator
1. Attach rigging chains to an adequate lifting device.

2. Attach chains to the two lifting holes at the corner of the end sheet as shown in Figure 7.

 CAUTION

The angle of the lifting chains is critical and damage to the unit may occur if the rigging is not
completed as described.

3. With an adequate lifting device lift the unit slightly off the ground to check for center of gravity.

4. Make adjustments as necessary to level the unit.

Driveline
The compressor (motor and stage) is removed from shells and skidded.

• All integral wiring is left on the compressor.

• All wiring harnesses on shells are removed.

• All openings on the compressor are closed and shipped charged with a 3 psig to 7 psig (20 kPa to
50 kPa) holding charge of dry nitrogen.

YZ Mod A with OptiView Control Center 19

Shells
The evaporator and condenser are separated at the tube sheets and prepared for shipping
separately but not skidded.

• All conduit is left on the shells.

• Refrigerant lines between shells are flanged and capped, requiring no welding.

• All openings on the shells are closed and charged with a 3 psig to 7 psig (20 kPa to 50 kPa)
holding charge of dry nitrogen.

Variable speed drive (VSD)

The VSD is skidded and shipped separately from the assembled chiller.

• The VSD is filled with glycol for shipping. The VSD operating coolant (inhibited water) is shipped
with the other loose items.

Miscellaneous items
The following assemblies and items are shipped together:

• OptiView™ Control Center

• Four vibration isolation pads (or optional spring isolators and brackets)

• Operating coolant (inhibited water)

• Other shipped loose items, including piping, water temperature controls, wiring, isolators, and
similar items

Figure 5: Form 3 rigging

20 YZ Mod A with OptiView Control Center

  DANGER

Do not use waterbox lifting lug to lift the chiller.

Figure 6: Form 7 rigging

Figure 7: Form 11 rigging

YZ Mod A with OptiView Control Center 21

Suction line elbow
Table 1: Suction line elbow weights
Weight
Compressor size (ton) P/N
lb kg
300TR 064-56167-000 371 168
450TR 064-56169-000 459 208
520TR 064-56170-000 518 235
630TR 064-56171-000 574 260
880TR 064-56173-000 695 315
1000TR 064-56800-000 810 367
1200TR 064-56175-000 930 420

Figure 8: Suction line elbow rigging

Motor end assembly

Table 2: Motor end weights
Weight
Motor model Horsepower
lb kg
MA033AA 330 1,912 868
MA041AA 410 2,899 1,316
MA580AA 580 2,875 1,305
MA068AA 680 3,369 1,529
MA079AA 790 3,424 1,554
MA095AA 950 3,871 1,757
MA108AA 1,080 3,959 1,797
MA129AA 1,290 4,237 1,923

22 YZ Mod A with OptiView Control Center

1. Attach rigging chains to each end of the compressor assembly as shown in Figure 9.

2. Lift the compressor assembly off the ground to check for center of gravity.

3. Make adjustments as necessary.

Note: The YZ Compressor has metric lifting lugs. The Driveline Rigging Kit (P/
N 364-52982-000), as found in Form 161.01-M1, contains the necessary lifting lugs.

 CAUTION

Use lifting chains with working load limit each 70% of total driveline weight.

Figure 9: Motor stage assembly rigging

Stage end assembly

Table 3: Stage end weights
Driveline motor and stage end Compressor/stage end only
Compressor model
lb kg lb kg
AN022 3,261 1,480 1,533 696
AN030 3,569 1,620 1,657 752
AN037A 4,120 1,870 2,208 1,002
AN045 5,243 2,380 2,344 1,064
BV052 5,464 2,480 2,589 1,175
BV063 6,896 3,130 3,527 1,601
BV075 7,689 3,490 4,265 1,936
BV088 9,495 4,310 5,625 2,553
BV100 10,531 4,780 6,572 2,983
BV120 16,393 7,441 7,052 3,201

YZ Mod A with OptiView Control Center 23

Variable speed drive (VSD)
1. Attach rigging chains from an adequate lifting device to the four lifting holes at the top of the
VSD as shown in Figure 10. For VSD weights, see Table 4.

2. Lift the VSD slightly off the ground to check for center of gravity.

3. Make adjustments as necessary to level the VSD.

4. Lift the VSD and remove all packing material.

5. Carefully lower the VSD on to the supports on the condenser.

6. Fasten the VSD to the condenser and to the motor terminal box duct.

7. Remove the rigging chains.

8. Make all necessary connections for the VSD cooling loop to be complete.

 CAUTION

Use lifting chains with working load limit each 35% of total VSD weight.

Table 4: VSD weights

Weight
Drive model
lb kg
P033HA 1,000 454
P042HA 1,230 558
P078HA 1,576 715
P102HA 1,984 900
P128HA 2,466 1,119

 CAUTION

The VSD is shipped with glycol in the cooling system. The glycol solution must be drained and flushed
from the VSD cooling system. Refer to service instruction 160.00-M12 to flush the VSD cooling system
before commissioning the VSD.

24 YZ Mod A with OptiView Control Center

Figure 10: VSD rigging

OptiView™ control center

 DANGER

The OptiView Control Center weighs over 50 lb; a technician and helper are needed for the installation
of the panel.

Table 5: Control panel weights

Weight
Description
lb kg
OptiView 75 34

1. Lift the OptiView™ Control Center and remove all packing material.

2. Carefully lower the OptiView™ Control Center onto the supports on the condenser.

3. Attach the OptiView™ Control Center to the condenser with the proper hardware.

4. Connect all unit wiring and harnesses. Refer to Form 161.01-PW2 YZ Unit Wiring and Field Control
Modifications for additional information.

YZ Mod A with OptiView Control Center 25

Figure 11: OptiView control center

26 YZ Mod A with OptiView Control Center

Installation
Note: In no cases must rigging be done out of horizontal level by more than 10°.

Overview
The installation process consists of the following steps:

1. Determine location

- Foundation requirements

- Clearance requirements

2. Rig chiller to final location

3. Install preferred isolators

- Locate and place isolator pads

- Install optional spring isolators

4. Level chiller

5. Make connections

- Piping

- Wiring

6. Apply insulation

Note: The rigging, operating weights, and overall dimensions are provided in Dimensions,
nozzle arrangements, and weights to help you determine the clearances required for rigging.
Add 6 in. (15 cm) to the overall height for optional skidded unit.

Determining the location

 CAUTION

Sufficient clearance to facilitate normal service and maintenance work must be provided around and
above the unit and particularly space provided at either end to permit cleaning or replacement of
evaporator and condenser tubes – see Clearance requirements. A doorway or other sufficiently large
opening properly located may be used.

The chiller must be located in an indoor location where temperatures range from 40°F to 110°F (4.4°C to
43.3°C).

Foundation requirements
A level floor, mounting pad or foundation capable of supporting the operating weight of the unit
must be provided by others.

YZ Mod A with OptiView Control Center 27

Clearance requirements
Clearances should be adhered to as follows:
Table 6: Clearances
Unit part Minimum clearance
Rear and Above Unit 2 ft (61 cm)
Front of Unit 3 ft (91 cm)
10 ft (3 m) either end
Tube Removal 12 ft (3.6 m) either end
14 ft (4.3 m) either end

Rigging unit to final location

To rig the unit to its final location on the floor or mounting pad, lift the unit (or shell assembly) by
means of an overhead lift and lower the unit to its mounting position. (If optional shipping skids are
used, remove them before lowering the chiller to its mounting position.)
Note: At this point units shipped dismantled should be assembled under the supervision of a
Johnson Controls representative in accordance with the Reassembly section of this manual.

If the evaporator is to be field insulated, the insulation can be applied to the evaporator while
the unit is in the lift position to gain more access below the shell, if necessary. Ensure the unit is
properly supported. See Applying insulation in this section.

Isolator installation
Neoprene isolator pads are furnished standard and typically satisfy the installation engineer’s
vibration isolation requirements when the chiller foundation is not likely to transmit to occupied
spaces. Optional spring isolators can be selected when the location of the equipment room floor
dictates more stringent limits on vibration input.

Neoprene isolator pads

Locating and placing isolator pads
The isolator pad mounts are to be located and placed rubber-side down as shown in Figure 13.
After the isolator pads have been placed into position on the floor, lower the chiller onto the pads.
When the unit is in place, remove the rigging equipment and check that the unit is level.
Leveling the unit
The longitudinal alignment of the unit should be checked by placing a level on the top center of the
evaporator shell under the compressor. Transverse alignment should be checked by placing a level
on top of the shell end sheets.
The unit should be level within 1/4 in. (6 mm) from one end to the other end and from the front to
the rear. If the chiller is not level within the amount specified, lift it and place shims between the
isolation pad and the chiller tube sheets. Shims are furnished by the installer. Lower unit again and
recheck to see that it is level.
Checking the isolation pad deflection
All isolation pads should be checked for the proper deflection while checking to see if the unit
is level. Each pad should be deflected approximately 0.10 in. (2.5 mm) to 0.20 in. (5 mm). If an
isolation pad is under-deflected, shims should be placed between the unit tube sheet and the top of
the pad to equally deflect all pads.

28 YZ Mod A with OptiView Control Center

Figure 12: Skid options

Table 7: Isolation pad dimensions

Evaporator Condenser
DIM A DIM B DIM C DIM D DIM E
Code Code
FB29 CA21 70 (1,776) 33 (839) 37 (940) 6 (153) 8 (204)
FB29 SA25 74 (1,880) 37 (940) 37 (940) 6 (153) 8 (204)
FA33 SA25, CA25 82 (2,084) 38 (942) 45 (1,143) 6 (153) 8 (204)
FA33 SA33 89 (2,261) 44 (1,118) 45 (1,143) 6 (153) 8 (204)
FA39 SA33, CA33 95 (2,407) 44 (1,118) 51 (1,289) 6 (153) 8 (204)
FA39 SA39 101.5 (2,578) 50.8 (1,289) 50.8 (1,289) 6 (153) 8 (204)
FB48 SA39, CA39 110.7 (2,812) 50.8 (1,289) 60 (1,523) 6 (153) 8 (204)
FB48 SA44 119.5 (3,035) 59.5 (1,512) 60 (1,523) 6 (153) 8 (204)
FB56 SA44 130.6 (3,316) 59.5 (1,512) 71 (1,804) 6 (153) 8 (204)

Note:

1. Dimensions are shown in inches (millimeters).

2. Brackets installed when skidded option is selected for Form 7.

3. Largest Diameter heat exchanger shown for shell length.

YZ Mod A with OptiView Control Center 29

Neoprene isolators

Figure 13: Neoprene isolators

Note: All dimensions are in inches (millimeters).

30 YZ Mod A with OptiView Control Center

Installing optional spring isolators
Bolting isolators to the unit
If ordered, spring type isolator assemblies are furnished with the unit. The four assemblies are
identical and can be placed at any of the four corners of the unit.
While the unit is still suspended by the rigging, the isolators should be bolted to the unit by
inserting the cap screw(s) through the hole(s) in the mounting bracket and into the tapped hole in
the top of the isolator leveling bolt(s). Then the unit may then be lowered onto the floor.
Leveling the unit
The longitudinal alignment of the unit should be checked by placing a level on the top center of the
evaporator shell under the compressor/motor assembly. Transverse alignment should be checked
by placing a level on top of the shell end sheets.
Rotate the leveling bolts one turn at a time, in sequence, until the unit end sheets are clear of
the floor by the dimension shown in Figure 14 and the unit is level. If the leveling bolts are not
long enough to level unit due to an uneven or sloping floor or foundation, steel shims (grouted, if
necessary) must be added beneath the isolator assemblies as necessary.
If the isolator springs are over-compressed at any corner, the leveling bolt has been extended too
far. This means the isolator is bearing an unequal amount of the chiller load. Correct by backing off
the bolts on the overloaded isolator and adjusting opposite isolators as required.

Figure 14: Spring isolators

Note: All dimensions are in inches (millimeters).

YZ Mod A with OptiView Control Center 31

Figure 15: Spring isolators

Note: All dimensions are in inches (millimeters).

32 YZ Mod A with OptiView Control Center

Making connections
After the unit is leveled, place wedges or shims under each corner to solidly support the unit in
this position while connecting and hanging the piping, adjusting the connections, and checking for
proper alignment.

Piping connections
After the unit is leveled (and wedged in place for optional spring isolators) the piping connections
may be made for chilled water, condenser water and refrigerant relief. The piping should be
arranged with offsets for flexibility, and adequately supported and braced independently of the
unit to avoid strain on the unit and vibration transmission; see Figure 18. Hangers must allow for
alignment of pipe. Isolators (by others) in the piping are highly desirable, and may be required by
specifications, in order to effectively utilize the vibration isolation characteristics of the vibration
isolation mounts of the unit. Piping connecting to chillers on spring isolators should be isolated
with properly aligned and supported flexible connections. Otherwise, the piping joint becomes the
primary resistance to motion and pipe or fittings are likely to deform or fatigue during operation.
Check for strain on piping – It is critical that no strain is present on the relief valve when the
piping is connected. Any strain must be eliminated to minimize the potential to deform the seal
surfaces and cause a leak. When checking for piping stress in Pressure Relief Piping:

1. Perform a visual inspection of the existing piping to determine if there are any clear signs of
strain present.

2. Disconnect piping at flange or union connection if possible. When the piping is disconnected,
there should be no springing or movement noted. The piping system must be self supported
and in perfect alignment with the relief valves.

Figure 16: Pressure relief piping

Check for piping alignment – Upon completion of piping, a connection in each line as close to
the unit as possible should be opened, by removing the flange bolts or coupling and checked for
piping alignment. If any of the bolts are bound in their holes, or if the connection springs are out of
alignment, the misalignment must be corrected by properly supporting the piping or by applying
heat to anneal the pipe.
Note: If the piping is annealed to relieve stress, the inside of the pipe must be cleaned of scale
before it is finally bolted in place.

After the connections are made the unit can be filled with water and checked for leaks.
If spring isolators were installed, final adjustments can be made to the leveling bolts until the
wedges and shims can be removed. The unit should now be in a level position, clear of the floor or
foundation and without any effect from the weight of the piping.

YZ Mod A with OptiView Control Center 33

Evaporator and condenser water piping
The evaporator and condenser liquid heads of the chiller have nozzles which are grooved, but also
suitable for welding 150 psig DWP flanges or the use of flexible couplings. Factory mounted flanges
are optional. If welding is done on the nozzles, flow switches, condenser level sensor, and water
temperature thermistors should be disconnected and the welding ground MUST have good contact
with the head to prevent current damage to the devices.
The nozzles and water pass arrangements are furnished in accordance with the job requirements
(refer to Product Drawings furnished with the job). Standard units are designed for 150 psig DWP
on the water side. If job requirements are for greater than 150 psig DWP, check the unit data plate
before applying pressure to evaporator or condenser to determine if the chiller has provisions for
the required DWP.
Inlet and outlet connections are identified by labels placed adjacent to each nozzle.

Figure 17: Schematic of a typical piping arrangement

Chilled water
Foreign objects must be kept out of the water circuit to prevent blockage. All water piping must be
cleaned or flushed before being connected to the chiller pumps or other equipment.
Permanent strainers (supplied by others) are required in both the evaporator and condenser water
circuits to protect the chiller as well as the pumps, tower spray nozzles, chilled water coils and
controls, and so on. The strainer must be installed in the entering chilled water and condenser
liquid line, upstream and near to the chiller.
Water piping circuits should be arranged to avoid water voids to the chiller, and should be
controlled as necessary to avoid rapid flow transients.
If pumps discharge through the chiller, the strainer may be located upstream from pumps to
protect both pump and chiller. (Piping between strainer, pump and chiller must be very carefully
cleaned before start-up.) If pumps are remotely installed from chiller, strainers should be located
directly upstream of the chiller.
Condenser water circuit
For proper operation of the unit, condenser refrigerant pressure must be maintained above
evaporator pressure. If operating conditions will fulfill this requirement, no attempt should be
made to control condenser water temperature by means of automatic valves, cycling of the cooling
tower fan, or other means, since chillers are designed to function satisfactorily and efficiently

34 YZ Mod A with OptiView Control Center

when condenser water is allowed to seek its own temperature level at reduced loads and off-peak
seasons of the year. However, if it is possible for the entering condenser water temperature to
go below the required minimum, condenser water temperature must be maintained equal to or
slightly higher than the required minimum. Refer to the YZ Engineering Guide (Form 161.01-EG1) for
required minimum Condenser and Evaporator temperatures.
Stop valves
Stop valves may be provided (by others) in the evaporator and condenser water piping adjacent to
the unit to facilitate maintenance. Thermometer wells and pressure taps should be provided (by
others) in the piping as close to the unit as possible to facilitate operating check.
Flow switches
Thermal type water flow switches are factory mounted in the chilled and condensed water nozzles
and are factory wired to the OptiView™ Control Panel. These solid-state flow sensors have a small
internal heating element and use the cooling effect of the flowing fluid to sense when flow has
been established.
Waterbox drain and vent valves
Drain and vent valves (by others) should be installed in the connections provided in the evaporator
and condenser liquid heads. These connections may be piped to drain if desired. They will assist
in proper fill and vent of the chiller waterside prior to starting pumps to ensure no voids exist that
could cause damage from a water slug.
Checking piping circuits and venting air
After the water piping is completed, but before any water box insulation is applied, tighten and
torque the nuts on the liquid head flanges to maintain between 30 ft·lb and 60 ft·lb (41 N·m and
81 N·m). Gasket shrinkage and handling during transit cause nuts to loosen. If water pressure
is applied before tightening is done, the gaskets may be damaged and have to be replaced. Fill
the chilled and condenser water circuits, operate the pumps manually and carefully check the
evaporator and condenser water heads and piping for leaks. Repair leaks as necessary.
Before initial operation of the unit both water circuits should be thoroughly vented of all air at the
high points.

Refrigerant relief piping

Each unit is equipped with pressure relief valves located on the condenser and on the evaporator
for the purpose of quickly relieving excess pressure of the refrigerant charge to the atmosphere as
a safety precaution in case of an emergency, such as fire.
Refrigerant relief vent piping (by others), from the relief valves to the outside of the building, is
required by code in most areas and should be installed on all chillers. The vent line should be
sized in accordance with the ANSI/ASHRAE-15, or local code. The vent line must include a trap in
the vertical leg to capture any vent stack condensation, intercept dirt and permit cleaning out.
The piping MUST be arranged to avoid strain on the relief valves, using a flexible connection, if
necessary.

YZ Mod A with OptiView Control Center 35

Figure 18: Typical refrigerant vent piping

Item Description
A Horizontal misaligned
B Vertical offset
C Compressed

Note:

• When installing relief piping there must not be any piping strain. Relief piping must be
properly aligned and supported to eliminate any possible piping strain.

• When installing ANSI flange, a piping union must be used to make a serviceable piping
connection.

• Set the manifold valve with the stem either in the fully IN or the fully OUT position. No other
position is permitted by ASME code.

36 YZ Mod A with OptiView Control Center

Figure 19: Typical refrigerant vent piping (cont'd)

Item Description
1 Flanged joint to permit piping disassembly
2 To purge pump exhaust from any point downstream of this location
3 Condensation trap
4 Dual relief valves
5 Vent to atmosphere
6 Support vent piping to avoid strain on relief piping
7 Flexible connection
8* Purge connection
9** Relief valves

Note:
* Install connection downstream of the relief valves.

** Shells may be furnished with one or two relief valves, depending on shell sizes.

Purge must vent to atmosphere.

YZ Mod A with OptiView Control Center 37

Purge pump exhaust piping
The purge pump exhaust piping must be routed outside of the equipment space following all
applicable local codes. The purge pump exhaust piping can use the relief valve vent piping, as long
as the following conditions are met.
The location where the exhaust piping connects into the relief valve manifold must be downstream
of all unit relief valves and the manifold drip leg. The purge pump must also have a factory-installed
check valve on the purge pump outlet connection.
Purge pump rating
The purge pump is a diaphragm style pump and is rated 0.7 cfm, 0.0558 # Air/min at 25 ft/H2O total
head. Any exhaust piping must not impart any restrictions that exceeds this capability. These values
apply to units with and without check valves because the same style pump is used on both. These
limits must not be exceeded.
Venting of non-condensable gases
The venting of this gas is dependent of the version of the purge unit and if there is a check valve
present on the exhaust piping of the purge unit. If the unit has a purge pump check valve, the
purge pump exhaust piping can be routed to the relief valve piping with impact to unit operation
or safety. If there is no check valve, then the purge exhaust must have a dedicated piping system to
vent the non-condensable gas out of the building to meet local codes.
No check valve
Units without check valves are very few in number but they must be accounted for in any
instruction. They were manufactured before June 2018 and are most likely field trial units. These
purge exhaust piping on these units must be piped independent of the relief piping system
because there is no check valve to protect the purge unit. The piping connection at the purge pump
outlet is 1/4 in. female pipe thread (FPT). This connection is in the same location as shown in Figure
20.

38 YZ Mod A with OptiView Control Center

Purge units with check valves
There are two styles of purge units that have check valves. These check valves are spring check
styles and resemble basket strainers. The first released version installed the purge check valve on
the piping to the suction of the purge pump. The exhaust piping connection location is at the purge
pump outboard fitting. The piping can be routed into the relief valve vent piping as outlined in this
section. The piping connection is 1/4 in. FPT. See the following figure.

Figure 20: Purge unit with check valve on piping to the suction of purge pump

Item Description
1 Spring check valve
2 Purge pump
3 Purge pump 1/4 in. FPT exhaust fitting

YZ Mod A with OptiView Control Center 39

The next released version also has spring check valves that resemble basket strainers. These check
valves are installed on the purge exhaust piping from the purge pump. The exhaust piping can be
routed into the relief valve vent piping. The exhaust piping connection location is under the purge
pump base on front left corner standing front of it. The piping connection is 3/8 in. FPT. See the
following figure.

Figure 21: Purge unit with check valve on purge exhaust piping

Item Description
1 Purge pump
2 Spring check valve
3 Purge pump 3/8 in. FPT exhaust fitting below base

Unit piping
Compressor refrigerant piping and system external piping are factory installed on all units shipped
assembled. On units shipped dismantled, the piping should be completed under the supervision of
the Johnson Controls representative.

Control wiring
On units shipped disassembled, after installation of the control center, control wiring must be
completed between the unit components, control center, and VSD using wiring harness furnished.
Refer to YZ Unit Wiring (Form 161.01-PW4).
Field wiring connections that are commonly used for control modifications are available in YZ Unit
Wiring and Field Control Modifications Manual (Form 161.01-PW2).
Note: Do not change the unit wiring from that shown on drawings furnished with the unit
without prior approval of the Johnson Controls representative.

40 YZ Mod A with OptiView Control Center

Power wiring

 CAUTION

Do not cut wires to final length or make final connections to starter power input terminals until
approved by the Johnson Controls representative.

Supplied variable speed drive

The factory mounted VSD does not require wiring to the compressor motor. The motor power
wiring is factory connected to the VSD. Refer to the YZ Unit Wiring (Form 161.01-PW4). All wiring to
the control panel is completed by the factory. A control transformer is factory furnished with the
VSD.

Applying insulation

 CAUTION

Do not field insulate until the unit has been leak tested under the supervision of the Johnson Controls
representative.

If ordered, factory insulation is furnished and applied to the following:

• Evaporator shell

• End sheets

• Liquid feed line to flow chamber

• Compressor suction connection

• Evaporator liquid heads and connections

The insulation prevents the surfaces from sweating at 30°F (-1°C). The liquid head flange insulation
must be removable, to allow head removal for the tube maintenance.
Units are furnished factory anti-sweat insulated on order at additional cost. This includes all low
temperature surfaces except the two cooler liquid heads.

Installation check – request for startup service

The services of a Johnson Controls representative will be furnished to check the installation and
supervise the initial start-up and operation on all chillers installed within the Continental United
States.
After the unit is installed, piped and wired as described in this Instruction, but before any attempt
is made to start the unit, the Johnson Controls District Office should be advised so that the start-up
service, included in the contract price, can be scheduled. Notify the Johnson Controls office using
the Startup Checklist (Form 161.01-CL2).

YZ Mod A with OptiView Control Center 41

Figure 22: Unit insulation

Note: Bold lines and shaded components represent insulation.

42 YZ Mod A with OptiView Control Center

Reassembly
Note: In no cases must rigging be done out of horizontal level by more than 10°.

Form 3, 7, and Form 11 reassembly

Note: See Figure 24, Figure 25, and Figure 26 for reassembly hardware identification.

1. Rig shells according to the rigging section to the final location. See Shipping and rigging.

2. Bolt the tube sheets together as shown in Figure 23. Note that the outside surfaces of the tube
sheets must be flush.

Figure 23: Shell reassembly

3. Assemble vibration isolators to unit. See Installing optional spring isolators.

4. Level shells in both directions. The longitudinal alignment of the shell must be checked
by placing a level on the top of the shell, next to the discharge connection. The transverse
alignment should be checked by placing a level on the tops of both end sheets. See Installation
for additional instructions to level the unit. After shell is leveled, wedge and shim each corner
of the shell to solidly support it while assembling the other parts.

5. Install the discharge piece and optional isolation valve between the compressor and the
condenser using proper gaskets and hardware.

6. Lift compressor/motor assembly according to Shipping and rigging section and remove
packing materials. Carefully lower the compressor/motor assembly on to the discharge line
and motor support on the evaporator. Fasten compressor/motor assembly with the proper
hardware. Do not tighten the bolts until all connections are made to the compressor.

YZ Mod A with OptiView Control Center 43

7. Bolt the suction line between the compressor and the evaporator using proper gaskets and
hardware.

8. Complete the refrigerant liquid line piping between the evaporator and condenser. Be sure
hardware are all properly installed.

9. Tighten all hardware installed in steps 3 through 6 above to the specified torque values
provided in the reassembly figure.

10. Install refrigerant piping. See Refrigerant tubing reassembly.

11. Pressure test the unit with nitrogen. Refer to Form 161.01-OM1.

12. Lift the VSD in accordance with rigging instructions and remove all packing material. Carefully
lower the VSD on to the supports on the condenser. Fasten the VSD to the condenser. Make all
necessary connections for the VSD cooling loop to be complete.

The VSD will be shipped with glycol in the cooling system. The VSD coolant must be changed to
the inhibitor provided with the shipped loose items prior to starting the unit or a VSD over tem-
perature fault may occur.
13. Lift the OptiView Control Center in accordance with rigging instructions and remove all packing
material. Carefully lower the control panel on to the supports provided on the condenser.
Fasten the Control Center to the condenser with the proper hardware.

14. Reconnect motor power leads in the VSD to T1, T2, and T3 terminals and torque to 18 lb·ft to 20
lb·ft per the labels in the VSD.

15. Connect the motor adapter box to the drive.

16. Reconnect all unit wiring and harnesses. Refer to YZ Unit Wiring (Form 161.01-PW4).

17. Remove the nitrogen and charge unit with refrigerant. Refer to Form 161.01-OM1.

18. All Units – Complete installation and finally level the unit. See Installation.

44 YZ Mod A with OptiView Control Center

Table 8: Reassembly torque values
YORK part Torque value
Item Description SAP number Quantity
number lb·ft N·m
Unit
Screw Cap Hvy Hex M16
2 021-35816-045 5402017 12 115–127 155–172
x 2 L = 45 mm
Screw Cap Hvy Hex 3/4
4 021-32312-036 667928 16 65–75 88–102
UNC L = 4-1/2 in.
Screw Heavy Hex 7/8
UNC L = 4 in. Steel GR5 021-32314-032 683035 12 45–50 61–67
(with isolation valve)
9
Screw Heavy Hex 7/8
UNC L = 4 in. Steel GR7 021-32314-032 683035 12 110–125 149–170
(without isolation valve)
Screw Cap Hex M20 x 2.5
20 021-31275-050 5451533 2 82–86 111–117
L = 50 mm STL
Hot gas
Screw Cap Hvy Hex 5/8
7 021-32310-038 616943 4 45–50 61–67
UNC L = 4 3/4 in.
Liquid line
Screw Cap Hvy Hex 5/8
8 UNC L = 4 3/4 in. (with 021-32310-038 616943 4 45–50 61–67
isolation valve)
Screw Cap Hvy Hex
10 5/8 UNC L = 3 1/4 in. 021-32310-026 616937 4 45–55 61–75
(without isolation valve)
End sheets (condenser-evaporator assy)
HSC5 0.625-11 X 2.500
3 021-32010-020 616904 8 45–55 61–75
GR 5ZN

Note:

• Unless otherwise specified, all screws must be tightened to the following torque values with
lightly oiled threads.

• Lubricated with oil and graphite on male and female threads and under bolt heads. Do not
use Molykote.

YZ Mod A with OptiView Control Center 45

Figure 24: YZ Form 3 reassembly hardware identification

See Table 8 for the torque values.

46 YZ Mod A with OptiView Control Center

Figure 25: YZ Form 7 reassembly hardware identification

See Table 8 for the torque values.

YZ Mod A with OptiView Control Center 47

Figure 26: YZ Form 11 reassembly hardware identification

See Table 8 for the torque values.

Refrigerant tubing reassembly

The following is a step-by-step procedure to be used to reassemble the chiller refrigerant piping.

Assembling straight thread O-ring port fittings

The male and female ends of SAE and ISO 6149 straight thread O-ring ports have UN/UNF or metric
straight threads. An elastomeric O-ring is fitted to the male end. During assembly, the O-ring is
firmly sandwiched between the angular sealing surface of the female port and the shoulder of the
male end. Sealing is thus affected and maintained by the O-ring compression which results from
the clamping force generated by tightening. The straight threads do NOT offer sealing action; they
provide the resistance (holding power) for service pressure.

48 YZ Mod A with OptiView Control Center

Adjustable end assembly
Figure 27: Adjustable end fitting

1. Inspect to ensure that both matching parts are free of burrs, nicks, scratches or any foreign
particles.

2. Install O-ring on port end of fitting, if it is NOT preinstalled, take care NOT to nick the O-ring.

3. Lubricate O-ring with a light coat of synthetic Polyolester (POE) oil or POE grease.

4. Back off locknut as far as possible. Make sure back-up washer is NOT loose and is pushed up as
far as possible. This ensures the O-ring is completely at the back of the land so it remains in the
land area when the fitting is turned out at Step 6.

Figure 28: Back off locknut

5. Screw fitting into port until the back-up washer contacts the face of the port. Light wrenching
may be necessary.

YZ Mod A with OptiView Control Center 49

Figure 29: Screw fitting into port

6. To align the tube end of fitting to accept incoming tube or hose assembly, unscrew by required
amount, but NOT more than one full turn. More then one turn makes the locknut push the O-
ring into the machine threads beyond the fitting land area during Step 7.

7. Using two wrenches, hold fitting in desired position and tighten locknut to the appropriate
torque value shown in Table 9 or Table 10.

8. Inspect to ensure that O-ring is NOT pinched and the back-up washer seats flat on face of port.

Figure 30: Torque fitting

Straight nonadjustable end assembly

1. Inspect to ensure that both matching parts are free of burrs, nicks, scratches or any foreign
particles.

2. Install O-ring on port end of fitting, if it is NOT preinstalled, use care NOT to nick the O-ring.

3. Lubricate O-ring with a light coat of synthetic Polyolester (POE) oil or POE grease.

4. Screw fitting into port until the hex flat contacts the port face. Light wrenching may be
necessary.

50 YZ Mod A with OptiView Control Center

5. Tighten to give torque for the specified size as specified in Table 9 or Table 10.

Figure 31: SAE or ISO 6149 straight thread O-ring port

Assembling O-ring face seal fittings

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

O-ring face seal assembly

1. Inspect to ensure that both matching parts are free of burrs, nicks, scratches or any foreign
particles.

2. Install O-ring in grooved face seal end of fitting, if it is NOT preinstalled, use care NOT to nick
the O-ring.

3. Lubricate O-ring with a light coat of synthetic Polyolester (POE) oil or POE grease.

4. Thread the nut by hand, and tighten nut to the appropriate torque value shown in Table 9 or
Table 10.

Table 9: Assembly torque metric for metric tube fittings

3
Torque (+10%-0)
ISO 6149-2 stud ISO 6149-3 stud
Fitting size Port-thead size
ends (S-series) ends (L-series)
N·m ft·lb N·m ft·lb
M8 M8 x 1 10 7.5 8 6
M10 M10 x 1 20 15 15 11
M12 M12 x1.5 35 26 25 18
M14 M14 x 1.5 45 33 35 26
M16 M16 x 1.5 55 41 40 30
M18 M18 x 1.5 70 52 45 33
M20 M20 x 1.5 80 59 – –

YZ Mod A with OptiView Control Center 51

Table 9: Assembly torque metric for metric tube fittings
3
Torque (+10%-0)
ISO 6149-2 stud ISO 6149-3 stud
Fitting size Port-thead size
ends (S-series) ends (L-series)
N·m ft·lb N·m ft·lb
M22 M22 x 1.5 100 74 60 44
M27 M27 x 2 170 125 100 74
M30 M30 x 2 235 175 130 95
M33 M33 x 2 310 230 160 120
M38 M38 x 2 320 235 185 135
M42 M42 x 2 330 245 210 155
M48 M48 x 2 420 310 260 190
M60 M60 x 2 500 370 315 230

Note: These torques are for steel fittings, assembled lubricated; for brass (and other soft
metals), decrease torque value by 35%.

Table 10: Assembly torque English for SAE tube fittings

SAE straight thread SAE straight Face seal tube-side Face seal tube-
Tube
size (O-ring part thread torque thread size (O-ring side torque
size (in.)
number) (lb·ft) part number) (lb·ft)
7/16-20 9/16-18
1/4 25 18
(028-12961-001) (028-12961-011)
9/16-18 11/16-16
3/8 35 30
(028-12961-003) (028-12961-012)
3/4-16 13/16-16
1/2 60 40
(028-12961-004) (028-12961-013)
7/8-14
5/8 100 1-14 (028-12961-014) 60
(028-12961-005)
1 1/16-12 1-3/16-12
3/4 135 85
(028-12961-006) (028-12961-015)
1 5/16-12 1-7/16-12
1 200 110
(028-12961-008) (028-12961-016)
1 5/8-12 1-11/16-12
1 1/4 250 140
(028-12961-017) (028-12961-022)
1 7/8-12 2-12-UN2A
1 1/2 305 180
(028-12961-020) (028-12961-019)
** 2 1/4-12 (028-12961-) 225 – –

Note: ** = SAE sightglass

52 YZ Mod A with OptiView Control Center

Dimensions, nozzle arrangements, and weights
Note: In no cases must rigging be done out of horizontal level by more than 10°.

Table 11: Unit dimensions

Heat exchanger A - Height, m (ft) B - Length, m (ft) C - Length*, m D - Tube removal
size (ft) clearance, m (ft)
FC512/CB2112 2.3 (7.3) 1.8 (5.8) 3.7 (12) 3.7 (12)
FB2910/CA2110 2.3 (7.4) 1.8 (5.9) 3.1 (10) 3.1 (10)
FB2912/SA2512 2.4 (7.9) 1.9 (6.2) 3.7 (12) 3.7 (12)
FC2912/CB2112 2.5 (8.3) 2.0 (6.5) 3.7 (12) 3. 7 (12)
FC2912/CB2512 2.5 (8.3) 2.1 (6.9) 3.7 (12) 3. 7 (12)
FC3312/CA2512 2.6 (8.5) 2.1 (6.9) 3.7 (12) 3. 7 (12)
FA3312/SA2512 2.5 (8.2) 2.1 (6.9) 3.7 (12) 3.7 (12)
FC3312/CB2512 2.5 (8.3) 2.1 (6.9) 3.7 (12) 3.7 (12)
FA3314/SA3314 2.8 (9.2) 2.3 (7.5) 4.3 (14) 4.3 (14)
FC3614/CB2914 2.8 (9.2) 2.3 (7.4) 4.3 (14) 4.3 (14)
FA3914/CA3314 3.1 (10.0) 2.4 (7.9) 4.3 (14) 4.3 (14)
FA3914/SA3314 2.9 (9.4) 2.4 (7.9) 4.3 (14) 4.3 (14)
FA3914/CB3314 2.8 (9.2) 2.3 (7.6) 4.3 (14) 4.3 (14)
FC3914/CB3314 2.8 (9.2) 2.4 (7.9) 4.3 (14) 4.3 (14)
FA3916/SA3916 3.3 (10.7) 2.6 (8.5) 4.9 (16) 4.9 (16)
FC3916/CB3316 3.0 (10.0) 2.5 8.2) 4.9 (16) 4.9 (16)
FC4416/CB3316 3.5 (11.5) 2.7 (8.7) 4.9 (16) 4.9 (16)
FC4416/CB3636 3.5 (11.5) 2.8 (9.2) 4.9 (16) 4.9 (16)
FC4416/CB3916 3.5 (11.5) 2.8 (9.2) 4.9 (16) 4.9 (16)
FB4816/CB3916 3.5 (11.4) 2.0 (9.3) 4.9 (16) 4.9 (16)
FB4816/SA3916 3.4 (11.2) 2.9 (9.3) 4.9 (16) 4.9 (16)
FC4816/CB3316 3.2 (10.6) 2.7 (8.9) 4.9 (16) 4.9 (16)
FB4816/CA3916 3.5 (11.4) 2.9 (9.3) 4.9 (16) 4.9 (16)
FB4818/SA4418 3.9 (12.5) 3.1 (10.0) 5.5 (18) 5.5 (18)
FB5618/CA4418 3.9 (12.8) 3.4 (11.2) 5.5 (18) 5.5 (18)
FB5618/CB4418 3.9 (12.8) 3.4 (11.2) 5.5 (18) 5.5 (18)
FB5618/SA4418 4.0 (13.0) 3.4 (10.9) 5.5 (18) 5.5 (18)
FB5618/CB4818 3.9 (12.8) 3.5 (11.6) 5.5 (18) 5.5 (18)

Note: * Length (C) does not include the length of waterboxes.

YZ Mod A with OptiView Control Center 53

Figure 32: Unit weight and dimensions

Figure 33: Unit weight and dimensions

54 YZ Mod A with OptiView Control Center

Table 12: Evaporator shell weights
Evaporator code Evaporator weight (lb) Evaporator weight (kg)
FC2510 4,154 1,886
FC2512 4,403 1,999
FB2910 5,100 2,315
FB2912 5,706 2,590
FC2912 7,384 3,352
FA3312 8,550 3,881
FA3314 9,312 4,227
FC3312 8,999 4,085
FC3614 9,835 4,464
FA3914 12,751 5,788
FA3916 12,854 5,834
FC3914 12,782 5,802
FC3916 11,970 5,433
FC4416 15,946 7,238
FB4816 21,960 9,968
FB4818 22,032 10,000
FC4816 21,859 9,922
FC4818 19,219 8,724
FB5618 31,086 14,110
FC5618 34,814 15,802

Table 13: Condenser shell weights

Condenser code Condenser weight (lb) Condenser weight (kg)
CA2110 4,372 1,984
CB2110 4,845 2,199
CB2112 5,242 2,379
CA2512 6,391 2,901
CB2512 6,275 2,848
SA2512 8,300 3,767
CB2912 8,753 3,973
CB2914 9,376 4,256
CA3314 10,657 4,837
CB3314 12,456 5,654
CB3316 14,594 6,624
SA3314 11,719 5,319
CB3616 15,824 7,183
CA3916 18,528 8,410
CB3916 18,814 8,540

YZ Mod A with OptiView Control Center 55

Table 13: Condenser shell weights
Condenser code Condenser weight (lb) Condenser weight (kg)
SA3916 19,153 8,694
CA4418 26,366 11,968
CB4418 23,933 10,863
SA4418 25,976 11,791
CB4818 27,759 12,600

Note: Refer to product submittal drawings for detailed weight information specific to the unit
ordered.

56 YZ Mod A with OptiView Control Center

Unit conversion
The following factors can be used to convert from English to the most common SI metric values.
Table 14: SI metric conversion
Measurement Multiply English unit By factor To obtain metric unit
Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW)
Power Horsepower 0.7457 Kilowatts (kW)
Flow Rate Gallons / Minute (gpm) 0.0631 Liters / Second (L/s)
Feet (ft) 0.3048 Meters (m)
Length
Inches (in.) 25.4 Millimeters (mm)
Weight Pounds (lb) 0.4536 Kilograms (kg)
Velocity Feet / Second (fps) 0.3048 Meters / Second (m/s)
Feet of Water (ft) 2.989 Kilopascals (kPa)
Pressure Drop
Pounds / Square Inch (psi) 6.895 Kilopascals (kPa)

Temperature
To convert degrees Fahrenheit (°F) to degrees Celsius (°C), subtract 32° and multiply by 5/9 or
0.5556.
Example: (45.0°F - 32°) x 0.5556 = 7.22°C
To convert a temperature range (i.e., a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or
0.5556.
Example: 10.0°F range x 0.5556 = 5.6°C range

YZ Mod A with OptiView Control Center 57

© 2020 Johnson Controls. All rights reserved. All specifications and other information shown were current as of document
revision and are subject to change without notice. www.johnsoncontrols.com