CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

24
INSTALLATION INSTRUCTIONS Supersedes: 160.49-N1 (894) Form 160.49-N1 (197) CENTRIFUGAL LIQUID CHILLERS MODEL YK L1 L1 G4 THRU YK S2 S2 J4 (STYLES A & B) R-22 AND R-134a (COOLING ONLY) AND MODEL YK LB LB G4 THRU YK SE SC J2 (STYLE C) R-134a (COOLING ONLY) WITH MICROCOMPUTER CONTROL CENTER PART #371-01200-004 FOR ELECTRO-MECHANICAL STARTER & SOLID STATE STARTER STYLE C 27385A STYLE A & B 27073A

Transcript of CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

Page 1: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS Supersedes: 160.49-N1 (894) Form 160.49-N1 (197)

CENTRIFUGAL LIQUID CHILLERS

MODEL YK L1 L1 G4 THRU YK S2 S2 J4 (STYLES A & B)R-22 AND R-134a (COOLING ONLY)

ANDMODEL YK LB LB G4 THRU YK SE SC J2 (STYLE C)

R-134a (COOLING ONLY)

WITH MICROCOMPUTER CONTROL CENTER PART #371-01200-004FOR ELECTRO-MECHANICAL STARTER & SOLID STATE STARTER

STYLE C

27385A

STYLE A & B

27073A

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NOMENCLATURE (STYLES A & B)

YK N2 N1 H1 – CX A

DESIGN LEVEL (A OR B)

POWER SUPPLY – FOR 60 HZ 5 FOR 50 HZ

COMPRESSOR CODE G4, H0, H1, H2, J1, J2, J3, J4

CONDENSER CODE L1, L2, M1, M2, N1, N2, P2, P2, Q1, Q2, R1, R2, S1, S2

COOLER CODE L1, L2, M1, M2, N1, N2, P1, P2, Q1, Q2, R1, R2, S1, S2

MODEL

MOTOR CODE

60 HZ 50 HZ

CH CX 5CE 5CTCJ CY 5CF 5CUCK CZ 5CG 5CVCL CA 5CH 5CWCM CB 5CI 5CXCN DA 5CJ 5DACP DB 5CK 5DBCR DC 5CL 5DCCS DD 5CM 5DDCT DE 5CN 5DECU DF 5CO 5OFCV DH 5CP 5OGCW OJ 5CQ 5OH

5CR 5OJ5CS

{

NOMENCLATURE (STYLES C)

YK NB PB H1 – CX C

DESIGN LEVEL (C)

POWER SUPPLY – FOR 60 HZ 5 FOR 50 HZ

COMPRESSOR CODE G4, H0, H1, H2, J1, J2

CONDENSER CODE LB, LC, MB, MC, NB, NC, PB, PC, QB, QC, RB, RC, SB, SC

COOLER CODE LB, LC, MB, MC, NB, NC, PB, PC, PD, PE, QB, QC, QD, QE, RB, RC, RD, RE, SD, SE

MODEL

MOTOR CODE

60 HZ 50 HZ

CH CX 5CE 5CTCJ CY 5CF 5CUCK CZ 5CG 5CVCL CA 5CH 5CWCM CB 5CI 5CXCN DA 5CJ 5DACP DB 5CK 5DBCR DC 5CL 5DCCS DD 5CM 5DDCT DE 5CN 5DECU DF 5CO 5DFCV DH 5CP 5DGCW DJ 5CQ 5DH

5CR 5OJ5CS

{

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FORM 160.49-N1

TABLE OF CONTENTS

RIGGING WEIGHT – OVERALL DIMENSIONS .................................................................................... 6 – 9

WEIGHTS ................................................................................................................................................ 10 – 15

REFERENCE DRAWINGS ...................................................................................................................... 14

INTRODUCTION ...................................................................................................................................... 16GENERAL ....................................................................................................................................... 16FIELD ASSEMBLED UNITS ONLY .................................................................................................. 16SHIPMENT ...................................................................................................................................... 16INSPECTION – DAMAGE – SHORTAGE ..................................................................................... 17CODEPAK DATA PLATE .................................................................................................................. 17RIGGING ......................................................................................................................................... 17USE OF SLINGS ............................................................................................................................. 17LOCATION ....................................................................................................................................... 18FOUNDATION.................................................................................................................................. 18CLEARANCE ................................................................................................................................... 18ISOLATORS ..................................................................................................................................... 19 – 20

INSTALLATION ........................................................................................................................................ 21RIGGING UNIT TO FINAL LOCATION ............................................................................................ 21LOCATING AND INSTALLING ISOLATION MOUNTS ..................................................................... 21CHECKING ISOLATION PAD DEFLECTION................................................................................... 21LEVELING THE UNIT ...................................................................................................................... 21INSTALLING OPTIONAL SPRING ISOLATORS ............................................................................. 21PIPING CONNECTIONS ................................................................................................................. 21COOLER AND CONDENSER WATER PIPING ............................................................................... 21REFRIGERANT RELIEF PIPING .................................................................................................... 23UNIT PIPING ................................................................................................................................... 23CONTROL WIRING ......................................................................................................................... 24POWER WIRING ............................................................................................................................. 23

CODEPAK WITH ELECTRO-MECHANICAL STARTER ......................................................... 23OIL PUMP 3 PHASE STARTER .............................................................................................. 23CODEPAK WITH SOLID STATE STARTER ............................................................................. 24

INSULATION.................................................................................................................................... 24INSTALLATION CHECK – REQUEST FOR START-UP SERVICE ................................................. 24

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FIG. 1 – MODEL YK CODEPAK (STYLE A &B)

COMPRESSOR

MOTOR

COOLER

CONTOL CENTER

FRONT VIEW

27073A

DISCHARGE LINE

PRE-ROTATIONVANE ACTUATOR

OIL PUMPSTARTER

CONDENSEROIL COOLER

OIL RESEVOIR/PUMP

SUBCOOLER

REAR VIEW

25717A

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FORM 160.49-N1

FRONT VIEW

MOTOR

COMPRESSOR

27385A

COOLER

CONTROLCENTER

FIG. 2 – MODEL YK CODEPAK (STYLE C)

REAR VIEW

DISCHARGEOIL PUMPSTARTER

CONDENSER

OIL RESEVOIR/PUMP

27382A

FRONT VIEW

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RIGGING DATA – OVERALL DIM.

LD01041

COOLER-CONDENSER SHELL CODE

DIM. J3 & J4 COMPRESSOR

Q-Q Q-R R-Q R-R R-S S-R S-S

A 7'–10" 8'–4" 8'–4-1/2" 8'–10-1/2" 9'–5-1/2" 9'–3-1/2" 9'–10-1/2"

B 10'–2-3/4" 10'–8-1/4" 10'–8-1/4" 10'–8-1/4" 11'–0-1/4" 11'–0-1/4" 11'–0-1/4"

C 2'–2-1/4" 2'–2-1/4" 2'–5-1/2" 2'–5-1/2" 2'–5-1/2" 2'–8" 2'–8"

D 1'–8-3/4" 1'–11-3/4" 1'–8-3/4" 1'–11-3/4" 2'–3-1/4" 1'–11-3/4" 2'–3-1/4"

E 1'–4" 1'–6" 1'–4" 1'–6" 1'–2" 1'–6" 2'–1"

F — — — — — — —

DUAL RELIEF VALVES

COOLER NPTI

L, M, N (2)1-1/4"

P, Q, R, S (2) 1-1/2"

COOLER-CONDENSER SHELL CODE

DIM. G4 COMPRESSOR (ONLY) G4, H0, H1 & H2 COMPRESSORS

L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-QA 5'–11" 6–'2" 6'–1" 6'–4" 6'–5" 6'–5" 6'–6" 6'–9" 6'–10" 7'–1" 7'–5-1/2" 7'–5-1/2" 7'–10"

B 8'–2-3/4' 8'–2-3/4" 8'–4-3/4" 8'–4-3/4" 8'–4-3/4" 8'–6-3/4" 8'–6-3/4" 8'–6-3/4" 8'–10-3/4" 8'–10-3/4" 8'–10-3/4" 9'–2-3/4" 9'–2-3/4"

C 1'–8-1/2" 1'–8-1/2" 1'–9-1/2" 1'–9-1/2" 1'–9-1/2" 1'–10" 1'–10" 1'–10" 2'–0" 2'–0" 2'–0" 2'–2-1/4" 2'–2-1/4"

D 1'–3" 1'–4-1/2" 1'–3" 1'–4-1/2" 1'–5" 1'–4-1/2" 1'–5" 1'–6-1/2" 1'–5" 1'–6-1/2" 1'–8-3/4" 1'–6-1/2" 1'–8-3/4"

E 1'–4" 1'–4" 1'–4" 1'–4" 1'–4" 1'–4" 1'–4" 1'–4" 1'–4" 1'–4" 1'–4" 1'–4" 1'–4"

F 6'–4-7/8" 6'–4-7/8" 6'–6-7/8" 6'–6-3/4" 6'–6-1/4" 6'–7-3/4" — — — — — — —

COOLER-CONDENSER SHELL CODE

DIM. H2 COMPRESSOR (ONLY) J1 & J2 COMPRESSOR

Q-R R-Q R-R P-P P-Q Q-P Q-Q Q-R R-Q R-R R-S S-R S-S

A 8'–4" 8'–4-1/2" 8'–10-1/2" 7'–1" 7'–5-1/2" 7'–5-1/2" 7'–10" 8'–4" 8'–4-1/2" 8'–10-1/2" 9'–5-1/2" 9'–3-1/2" 9'–10-1/2"

B 9'–4-1/4" 9'–9-3/4" 9'–9-3/4" 9'–5-1/4" 9'–8-1/4" 9'–9-1/4" 9'–9-1/4" 10'–2-3/4" 10'–2-3/4" 10'–2-3/4" 10'–6-3/4" 10'–6-3/4" 10'–6-3/4"

C 2'–2-1/4" 2'–5-1/2" 2'–5-1/2" 2'–0" 2'–0" 2'–2-1/4" 2'–2-1/4" 2'–2-1/4" 2'–5-1/2" 2'–5-1/2" 2'–5-1/2" 2'–8" 2'–8"

D 1'–11-3/4" 1'–8-3/4" 1'–11-3/4" 1'–8-1/2" 1'–8-3/4" 1'–6-1/2" 1'–8-3/4" 1'–11-3/4" 1'–8-3/4" 1'–11-3/4" 2'–3-1/4" 1'–11-3/4" 2'–3-1/4"

E 1'–6" 1'–4" 1'–6" 1'–4" 1'–4" 1'–4" 1'–4" 1'–6" 1'–4" 1'–6" 2'–1" 1'–6" 2"–1"

F — — — — — — — — — — — — —

For these shell combinations with H2 Compressor add 1-1/2" to “B” dimension.

NOTES: 1. All dimensions are approximate. Certified dimensions are available on request, or see Form160.49-PA1.

2. Water nozzles can be located on either end of unit, Add 1/2" to nozzle length for flanged connections.

3. To determine overall installed height, add 7/8" for isolators. (See Figs. 6 & 7.)

FIG. 3 – DIMENSIONS (STYLE A & B UNITS) – STANDARD DIMENSIONS

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FORM 160.49-N1

NOTES:

1. All dimensions are approximate. Certified dimensions are available on request.2. For compact water boxes (shown above), determine overall unit length by adding wa-

ter box depth to tube sheet length.3. Water nozzles can be located on either end of unit. Add 1/2" to nozzle length for flanged

connections.4. To determine overall height, add 7/8" for isolators. (See Figs 6 & 7.)5. Use of motors with motor hoods may increase overall unit dimensions.

COOLER-CONDENSER SHELL CODE

G4, H0 & H1 COMPRESSORS

L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-Q

A 6'–5" 6'–4" 6'–7" 6'–6" 6'–9" 6'–11" 7'–2" 7'–6" 7'–4-1/2" 7'–8-1/2" 8'–0-1/2" 8'–0" 8'–4"

B 7'–11-3/4" 7'–11-3/4" 8'–2-1/4" 8'–1-3/4" 8'–2-1/4" 8'–4-1/4" 8'–5-1/4" 8'–8-1/4" 8'–8-1/4" 9'–0-1/4" 9'–3-1/4" 9'–0-1/4" 9'–3-1/4"

C 1'–8-1/2" 1'–8-1/2" 1'–9-1/2" 1'–9-1/2" 1'–9-1/2" 2'–0" 2'–0" 2'–0" 2'–1-1/4" 2'–1-1/4" 2'–1-1/4" 2'–3" 2'–3"

D 1'–6" 1'–5-1/2" 1'–6" 1'–5-1/2" 1'–7" 1'–5-1/2" 1'–7" 1'–9" 1'–7" 1'–9" 1'–11" 1'–9" 1'–11"

E 1'–5-1/4" 1'–5-1/4" 1'–5-1/4" 1'–5-1/4" 1'–5-1/4" 1'–5-1/4" 1'–5-1/4" 1'–10-1/4" 1'–5-1/4" 1'–10-1/4" 1'–10-1/4" 1'–10-1/4" 1'–10-1/4"

COOLER-CONDENSER SHELL CODE

H2 COMPRESSORS

N-N N-P P-N P-P P-Q Q-P Q-Q Q-R R-Q R-R

A 7'–2" 7'–6" 7'–4-1/2" 7'–8-1/2" 8'–0-1/2" 8'–0" 8'–4" 9'–2" 9'–0-1/2" 9'–10-1/2"

B 8'–5-1/4" 8'–6-1/4" 8'–9-1/4" 8'–9-1/4" 9'–1-1/4" 9'–0-1/4" 9'–1-1/4" 9'–10-1/4" 9'–7-1/4" 10'–2-1/4"

C 2'–0" 2'–0" 2'–1-1/4" 2'–1-1/4" 2'–1-1/4" 2'–3" 2'–3" 2'–3' 2'–7-1/4' 2'–7-1/4"

D 1'–7" 1'–9" 1'–7" 1'–9" 1'–11" 1'–9" 1'–11" 2'–4" 1'–11" 2'–4"

E 1'–5-1/4" 1'–10-1/4" 1'–5-1/4" 1'–10-1/4" 1'–10-1/4" 1'–10-1/4" 1'–10-1/4" 2'–2-1/2" 1'–10-1/4" 2'–2-1/2"

LD01042

COOLER -CONDENSER SHELL CODE

J1 & J2 COMPRESSORS

Q-Q Q-R R-Q R-R R-S S-R S-S

A 8'–4-1/2" 9'–0-1/2" 8'–11" 9'–7" 10'–0" 10'–0" 10'–5"

B 10'–1-1/2" 10'–10-1/2" 10'–1-3/4" 10'–10-1/2" 11'–3-1/2" 10'–10-1/2" 11'–3-1/2"

C 2'–2-1/4" 2'–2-1/4" 2'–5-1/2" 2'–5-1/2" 2'–5-1/2" 2'–8" 2'–8"

D 2'–0" 2'–4" 2'–0" 2'–4" 2'–6-1/2" 2'–4" 2'–6-1/2"

E 1'–10-1/4" 2'–2-1/2" 1'–10-1/4" 2'–2-1/2" 2'–4" 2'–2-1/2" 2'–4"

FIG. 4 – DIMENSIONS (STYLE C UNITS) – STANDARD DIMENSIONS

DUAL RELIEF VALVES

COOLER/ COOLER/CONDENSER NPTI CONDENSER NPTISHELL CODE SHELL CODE

L-L (2)1-1/2" P-N (2)1-1/2"

L-M (2)1-1/2" P-P (2)1-1/2"M-L (2)1-1/2" P-Q (2)1-1/2"M-M (2)1-1/2" Q-P (2)1-1/2"M-N (2)1-1/2" Q-Q (2)1-1/2"N-M (2)1-1/2" Q-R (2)2"N-N (2)1-1/2" R-Q (2)2"N-P (2)1-1/2" R-R (2)2"

S-S (2)2"

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RIGGING DATA – OVERALL DIM.

LD01041

COOLER-CONDENSER SHELL CODE

DIM. G4 COMPRESSOR (ONLY) G4, H0, H1 & H2 COMPRESSORS

L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-QA 1803 1880 1854 1930 1956 1956 1981 2057 2083 2159 2273 2273 2388

B 2508 2508 2559 2559 2559 2610 2610 2610 2711 2711 2711 2813 2813

C 521 521 546 546 546 559 559 559 610 610 610 667 667

D 381 419 381 419 432 419 432 470 432 470 527 470 527

E 406 406 406 406 406 406 406 406 406 406 406 406 406

F 1953 1953 2004 2000 1988 2026 — — — — — — —

For these shell combinations with H2 Compressor add 38 mm to “B” dimension.

COOLER-CONDENSER SHELL CODE

DIM. H2 COMPRESSOR (ONLY) J1 & J2 COMPRESSOR

Q-R R-Q R-R P-P P-Q Q-P Q-Q Q-R R-Q R-R R-S S-R S-S

A 2540 2553 2705 2159 2273 2273 2388 2540 2553 2705 2883 2832 3010

B 2851 2991 2991 2877 2953 2978 2978 3118 3118 3118 3219 3219 3219

C 667 749 749 610 610 667 667 667 749 749 749 813 813

D 603 527 603 521 527 470 527 603 527 603 692 603 692

E 457 406 457 406 406 406 406 457 406 457 635 457 635

F — — — — — — — — — — — — —

COOLER-CONDENSER SHELL CODE

DIM. J3 & J4 COMPRESSOR

Q-Q Q-R R-Q R-R R-S S-R S-S

A 2388 3759 2553 2705 2883 2832 3010

B 3118 3258 3258 3258 3359 3359 3359

C 667 667 749 749 749 813 813

D 527 603 527 603 692 603 692

E 406 457 406 457 635 457 635

F — — — — — — —

DUAL RELIEF VALVES

COOLER NPTI

L, M, N (2)1-1/4"

P, Q, R, S (2) 1-1/2"

FIG. 3A – DIMENSIONS (STYLE A & B UNITS) – METRIC DIMENSIONS

603 mm2

4267 mm2

375 mm2

NOTES: 1. All dimensions are approximate. Certified dimensions are available on request, or see Form 160.49-PA1.

2. Water nozzles can be located on either end of unit, Add 13 mm to nozzle length for flanged connections.

3. To determine overall installed height, add 22 mm for isolators. (See Figs. 6 & 7.)

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FORM 160.49-N1

4267 mm 603 mm2

375 mm2

COOLER-CONDENSER SHELL CODE

G4, H0 & H1 COMPRESSORS

L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-Q

A 1956 1930 2007 1981 2057 2108 2184 2286 2248 2350 2451 2438 2540

B 2432 2432 2496 2483 2496 2546 2572 2648 2648 2750 2838 2750 2838

C 521 521 546 546 546 610 610 610 641 641 641 686 686

D 457 445 457 445 483 445 483 533 483 533 584 533 584

E 438 438 438 438 438 438 438 565 438 565 565 565 565

COOLER-CONDENSER SHELL CODE

H2 COMPRESSORS

N-N N-P P-N P-P P-Q Q-P Q-Q Q-R R-Q R-R

A 2184 2286 2248 2350 2451 2438 2540 2794 2756 3010

B 2572 2597 2673 2673 2775 2750 2775 3004 2927 3105

C 610 610 641 641 641 686 686 686 794 794

D 483 533 483 533 584 533 584 711 584 711

E 438 565 438 565 565 565 565 673 565 673

LD01042

COOLER -CONDENSER SHELL CODE

J1 & J2 COMPRESSORS

Q-Q Q-R R-Q R-R R-S S-R S-S

A 2553 2750 2718 3315 3048 3048 3175

B 3080 3315 3092 3315 3442 3315 3442

C 667 667 749 749 749 813 813

D 610 711 610 711 775 711 775

E 565 673 565 673 711 673 711

FIG. 4A – DIMENSIONS (STYLE C UNITS) – METRIC DIMENSIONS

DUAL RELIEF VALVES

COOLER/ COOLER/CONDENSER NPTI CONDENSER NPTISHELL CODE SHELL CODE

L-L (2)1-1/2" P-N (2)1-1/2"

L-M (2)1-1/2" P-P (2)1-1/2"M-L (2)1-1/2" P-Q (2)1-1/2"M-M (2)1-1/2" Q-P (2)1-1/2"M-N (2)1-1/2" Q-Q (2)1-1/2"N-M (2)1-1/2" Q-R (2)2"N-N (2)1-1/2" R-Q (2)2"N-P (2)1-1/2" R-R (2)2"

S-S (2)2"

NOTES:1. All dimensions are approximate. Certified dimensions are available on request.2. For compact water boxes (shown above), determine overall unit length by adding wa-

ter box depth to tube sheet length.3. Water nozzles can be located on either end of unit. Add 13 mm to nozzle length for

flanged connections.4. To determine overall height, add 22 mm for isolators. (See Figs 6 & 7.)5. Use of motors with motor hoods may increase overall unit dimensions.

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SHELL LOADING SHELL LOADINGCODE SHIPPING OPERATING PER CODE SHIPPING OPERATING PER

COOLER- WT. (LBS.) WT. (LBS.) ISOLATOR COOLER- WT. (LBS.) WT. (LBS.) ISOLATORCOND. (LBS.) COND. (LBS.)

L1 – L1 17,400 21,055 5,264 P2 – P1 27,857 33,852 8,463

L1 – L2 17,660 21,435 5,359 P2 – P2 28,560 34,790 8,698L2 – L1 17,570 21,317 5,329 P1 – Q1 30,094 37,054 9,264L2 – L2 17,840 21,705 5,426 P1 – Q2 31,012 38,282 9,571

L1 – M1 18,530 22,605 5,651 P2 – Q1 30,516 37,636 9,409L1 – M2 18,900 23,175 5,794 P2 – Q2 31,434 38,864 9,716L2 – M1 18,710 22,875 5,719 Q1 – P1 30,278 36,933 9,233

L2 – M2 19,080 23,445 5,861 Q1 – P2 30,991 37,881 9,470M1 – L1 18,200 22,195 5,549 Q2 – P1 30,878 37,753 9,438M1 – L2 18,460 22,575 5,644 Q2 – P2 31,591 38,701 9,675

M2 – L1 18,425 22,530 5,633 Q1 – Q1 32,703 40,483 10,121M2 – L2 18,695 22,920 5,730 Q1 – Q2 33,621 41,711 10,428M1 – M1 19,325 23,740 5,935 Q2 – Q1 33,303 41,303 10,326

M1 – M2 19,695 24,310 6,077 Q2 – Q2 34,221 42,531 10,633M2 – M1 19,560 24,085 6,021 Q1 – R1 36,527 45,747 11,437M2 – M2 19,930 26,720 6,680 Q1 – R2 37,831 47,486 11,872

M1 – N1 20,485 24,875 6,218 Q2 – R1 37,127 46,567 11,642M1 – N2 20,956 25,476 6,369 Q2 – R2 38,431 48,306 12,077M2 – N1 20,720 25,220 6,305 R1 – Q1 36,984 46,024 11,506

M2 – N2 21,191 25,821 6,455 R1 – Q2 37,902 47,252 11,813N1 – M1 21,123 25,523 6,381 R2 – Q1 37,792 47,137 11,784N1 – M2 21,493 26,093 6,523 R2 – Q2 38,710 48,365 12,091

N2 – M1 21,448 25,968 6,492 R1 – R1 40,685 51,115 12,779N2 – M2 21,818 26,538 6,635 R1 – R2 41,989 52,854 13,214N1 – N1 21,885 26,775 6,694 R2 – R1 41,493 52,228 13,057

N1 – N2 22,356 25,966 6,492 R2 – R2 42,797 53,967 13,492N2 – N1 22,210 27,220 6,805 S1 – R1 47,011 58,401 14,600N2 – N2 22,681 27,821 6,955 S1 – R2 48,315 60,140 15,035

N1 – P1 23,864 29,279 6,820 S2 – R1 47,016 58,926 14,732N1 – P2 24,567 30,217 7,554 S2 – R2 48,320 60,665 15,166N2 – P1 24,189 29,724 7,431 R1 – S1 49,379 61,324 15,331

N2 – P2 24,892 30,662 7,666 R1 – S2 51,252 64,197 16,049P1 – N1 23,824 29,134 7,284 R2 – S1 50,185 62,435 15,609P1 – N2 24,295 29,735 7,434 R2 – S2 52,060 65,310 16,328

P2 – N1 24,274 29,744 7,436 S1 – S1 53,375 66,280 16,570P2 – N2 24,745 30,345 7,586 S1 – S2 55,250 69,155 17,289P1 – P1 27,434 33,269 8,317 S2 – S1 53,380 66,805 16,701

P1 – P2 28,137 34,207 8,552 S2 – S2 55,255 69,680 17,420

TABLE 1 – CHILLER WEIGHTS – STYLES A & B (LESS MOTOR) – LBS.

Page 11: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

YORK INTERNATIONAL 11

FORM 160.49-N1

TABLE 2 – CHILLER WEIGHTS – STYLES A & B (LESS MOTOR) – LBS.

SHELL LOADINGCODE SHIPPING OPERATING PER

COOLER – WEIGHT WEIGHT ISOLATORCOND. (LBS.) (LBS.) (LBS.)

QD – QB 29,620 37,245 9,311QD – QC 30,490 38,425 9,605

QE – QB 30,160 38,010 9,503QE – QC 31,030 39,190 9,797QD – RB 34,200 42,430 10,607

QD – RC 35,365 43,895 10,973QE – RB 34,740 43,375 10,843QE – RC 35,910 44,840 11,210

RD – QB 34,360 43,110 10,777RD – QC 35,330 44,380 11,095RE – QB 34,360 43,510 10,877

RE – QC 35,330 44,780 11,195RD – RB 38,945 48,275 12,069RD – RC 40,110 49,740 12,435

RE – RB 38,945 48,675 12,169RE – RC 40,110 50,140 12,535RD – SB 45,430 56,420 14,105

RD – SC 47,150 59,060 14,765RE – SB 46,170 57,440 14,360RE – SC 47,895 60,085 15,020

SD – RB 43,250 53,730 13,433SD – RC 44,450 55,330 13,832SE – RB 43,254 54,210 13,553

SE – RC 44,455 55,810 13,952SD – SB 49,105 60,975 15,244SD – SC 50,830 63,620 15,905

SE – SB 49,110 61,500 15,375SE – SC 50,835 64,105 16,026

J1 & J2 COMPRESSORS

SHELL LOADINGCODE SHIPPING OPERATING PER

COOLER – WEIGHT WEIGHT ISOLATORCOND. (LBS.) (LBS.) (LBS.)

QB – RB 33,700 41,930 10,482QB – RC 34,865 43,395 10,848QC – RB 34,240 42,875 10,718

QC – RC 35,410 44,340 11,085RB – QB 33,860 42,610 10,652RB – QC 34,830 43,880 10,970

RC – QB 33,860 43,010 10,752RC – QC 34,830 44,280 11,070RB – RB 38,445 47,775 11,944

RB – RC 39,610 49,240 12,310RC – RB 38,445 48,175 12,044RC – RC 39,610 49,640 12,410

G & H COMPRESSORS

SHELL LOADINGCODE SHIPPING OPERATING PER

COOLER – WEIGHT WEIGHT ISOLATORCOND. (LBS.) (LBS.) (LBS.)

LB – LB 16,615 19,775 4,944LB – LC 16,860 20,135 5,034LC – LB 16,780 20,030 5,008LC – LC 17,020 20,390 5,098LB – MB 17,840 21,310 5,328LB – MC 18,180 21,850 5,463LC – MB 18,000 21,565 5,391LC – MC 18,340 22,100 5,525MB – LB 17,575 21,185 5,296MB – LC 17,815 21,545 5,386MC – LB 17,760 21,480 5,370MC – LC 18,000 21,840 5,460MB – MB 18,780 22,700 5,675MB – MC 19,120 23,240 5,810MC – MB 18,965 22,995 5,749MC – MC 19,305 23,535 5,884MB – NB 19,915 24,300 6,075MB – NC 20,345 24,910 6,228MC – NB 20,100 24,595 6,149MC – NC 20,580 25,200 6,300NB – MB 20,040 24,440 6,110NB – MC 20,380 24,980 6,245NC – MB 20,345 24,865 6,216NC – MC 20,685 25,410 6,352NB – NB 21,170 26,000 6,500NB – NC 21,650 26,615 6,654NC – NB 21,480 26,435 6,609NC – NC 21,960 27,045 6,761NB – PB 23,175 28,535 7,134NB – PC 23,855 29,450 7,362NC – PB 23,485 28,965 7,241NC – PC 24,165 29,880 7,470PB – NB 22,990 28,240 7,060PB – NC 23,470 28,850 7,213PC – NB 23,460 28,870 7,218PC – NC 23,940 29,480 7,370PB – PB 24,980 30,755 7,689PB – PC 25,660 31,670 7,918PC – PB 25,450 31,390 7,848PC – PC 26,130 32,690 8,173PB – QB 27,175 34,040 8,150PB – QC 28,045 35,220 8,805PC – QB 27,650 34,670 8,668PC – QC 28,520 35,850 8,963QB – PB 26,930 33,490 8,372QB – PC 27,610 33,400 8,350QC – PB 27,475 34,250 8,562QC – PC 28,155 35,070 8,768QB – QB 29,120 36,745 9,186QB – QC 29,990 37,925 9,480QC – QB 29,660 37,510 9,378QC – QC 30,530 38,690 9,672

G & H COMPRESSORS

Page 12: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

12 YORK INTERNATIONAL

SHELL LOADING SHELL LOADINGCODE SHIPPING OPERATING PER CODE SHIPPING OPERATING PER

COOLER- WT. (KG) WT. (KG) ISOLATOR COOLER- WT. (KG) WT. (KG) ISOLATORCOND. (KG) COND. (KG)

L1 – L1 7892 9550 2388 P2 – P1 12,636 15,355 3839

L1 – L2 8011 9723 2431 P2 – P2 12,955 15,781 3945L2 – L1 7970 9669 2417 P1 – Q1 13,651 16,808 4202L2 – L2 8092 9845 2461 P1 – Q2 14,067 17,365 4341

L1 – M1 8405 10,254 2563 P2 – Q1 13,842 17,072 4268L1 – M2 8573 10,512 2628 P2 – Q2 14,258 17,629 4407L2 – M1 8487 10,376 2594 Q1 – P1 13,734 16,753 4188

L2 – M2 8655 10,635 2659 Q1 – P2 14,058 17,183 4296M1 – L1 8256 10,068 2517 Q2 – P1 14,006 17,125 4281M1 – L2 8373 10,240 2560 Q2 – P2 14,330 17,555 4389

M2 – L1 8358 10,220 2555 Q1 – Q1 14,834 18,363 4591M2 – L2 8480 10,397 2599 Q1 – Q2 15,250 18,920 4730M1 – M1 8766 10,768 2692 Q2 – Q1 15,106 18,735 4684

M1 – M2 8934 11,027 2757 Q2 – Q2 15,523 19,292 4823M2 – M1 8872 10,924 2731 Q1 – R1 16,569 20,876 5188M2 – M2 9040 12,120 3030 Q1 – R2 17,160 21,434 5385

M1 – N1 9292 11,283 2820 Q2 – R1 16,841 21,381 5281M1 – N2 9506 11,556 2889 Q2 – R2 17,432 21,938 5478M2 – N1 9399 11,440 2860 R1 – Q1 16,776 23,186 5219

M2 – N2 9612 11,712 2928 R1 – Q2 17,192 23,975 5358N1 – M1 9581 11,577 2894 R2 – Q1 17,142 23,691 5345N1 – M2 9749 11,836 2959 R2 – Q2 17,559 24,479 5484

N2 – M1 9729 11,780 2945 R1 – R1 18,455 26,491 5797N2 – M2 9897 12,038 3010 R1 – R2 19,046 27,280 5994N1 – N1 9927 12,145 3036 R2 – R1 18,821 26,729 5923

N1 – N2 10,140 11,778 2945 R2 – R2 19,413 27,518 6120N2 – N1 10,744 12,347 2967 S1 – R1 21,324 27,817 6623N2 – N2 10,288 12,620 3155 S1 – R2 21,916 29,120 6820

N1 – P1 10,825 13,281 3094 S2 – R1 21,326 28,321 6682N1 – P2 11,144 13,706 3426 S2 – R2 21,918 29,625 6879N2 – P1 10,972 13,483 3371 R1 – S1 22,398 27,817 6954

N2 – P2 11,291 13,908 3477 R1 – S2 23,248 29,120 7280P1 – N1 10,807 13,215 3304 R2 – S1 22,764 28,321 7080P1 – N2 11,020 13,488 3372 R2 – S2 23,614 29,625 7406

P2 – N1 11,011 13,492 3373 S1 – S1 24,211 30,065 7516P2 – N2 11,224 13,764 3341 S1 – S2 25,061 31,369 7842P1 – P1 12,444 15,091 3773 S2 – S1 24,213 30,303 7576

P1 – P2 12,763 15,516 3879 S2 – S2 25,064 31,607 7902

TABLE 1A – CHILLER WEIGHTS – STYLES A & B (LESS MOTOR) – KG

Page 13: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

YORK INTERNATIONAL 13

FORM 160.49-N1

SHELL LOADINGCODE SHIPPING OPERATING PER

COOLER – WEIGHT WEIGHT ISOLATORCOND. (KG) (KG) (KG)

LB – LB 7537 8970 2243LB – LC 7648 9133 2283LC – LB 7611 9086 2272LC – LC 7720 9249 2312LB – MB 8092 9666 2417LB – MC 8246 9911 2478LC – MB 8165 9782 2445LC – MC 8319 10,025 5525MB – LB 7972 9610 2402MB – LC 8081 9773 2443MC – LB 8056 9743 2436MC – LC 8165 9907 2477MB – MB 8519 10,297 2574MB – MC 8673 10,542 2635MC – MB 8603 10,431 2608MC – MC 8757 10,675 2669MB – NB 9033 11,022 2756MB – NC 9228 11,299 2825MC – NB 9117 11,156 2789MC – NC 9335 11,431 2858NB – MB 9090 11,086 2767NB – MC 9244 11,331 2833NC – MB 9228 11,279 2820NC – MC 9383 11,526 2881NB – NB 9603 11,794 2948NB – NC 9820 12,073 3018NC – NB 9743 11,991 2998NC – NC 9961 12,268 3067NB – PB 10,512 12,943 3236NB – PC 10,820 13,359 3339NC – PB 10,653 13,139 3285NC – PC 10,961 13,554 3388PB – NB 10,428 12,810 3202PB – NC 10,646 13,086 3272PC – NB 10,641 13,095 3274PC – NC 10,859 13,372 3343PB – PB 11,331 13,950 3488PB – PC 11,639 14,366 3592PC – PB 11,544 14,239 3560PC – PC 11,853 14828 3707PB – QB 12,327 15,441 3860PB – QC 12,721 15,976 3994PC – QB 12,542 15,726 3932PC – QC 12,937 16,262 4066QB – PB 12,215 15,191 3798QB – PC 12,524 15,150 3788QC – PB 12,463 15,536 3884QC – PC 12,771 15,908 3977QB – QB 13,209 16,668 4167QB – QC 13,603 17,203 4300QC – QB 13,454 17,015 4254QC – QC 13,848 17,550 4387

G & H COMPRESSORS

TABLE 2A – CHILLER WEIGHTS – STYLES A & B (LESS MOTOR) – KG

SHELL LOADINGCODE SHIPPING OPERATING PER

COOLER – WEIGHT WEIGHT ISOLATORCOND. (KG) (KG) (KG)

QB – RB 15,286 19,019 4755

QB – RC 15,815 19,684 4921QC – RB 15,531 19,448 4862QC – RC 16,062 20,113 5028

RB – QB 15,359 19,328 4832RB – QC 15,799 19,904 4976RC – QB 15,359 19,509 4877

RC – QC 15,799 20,085 5021RB – RB 17,439 21,671 5418RB – RC 17,967 22,335 5584

RC – RB 17,439 21,852 5463RC – RC 17,967 22,517 5629

G & H COMPRESSORS

SHELL LOADINGCODE SHIPPING OPERATING PER

COOLER – WEIGHT WEIGHT ISOLATORCOND. (KG) (KG) (KG)

QD – QB 13,436 16,894 4223QD – QC 13,830 17,430 4357QE – QB 13,681 17,241 4311

QE – QC 14,075 17,777 4444QD – RB 15,513 19,246 4811QD – RC 16,042 19,911 4977

QE – RB 15,758 19,675 4918QE – RC 16,289 20,339 5085RD – QB 15,586 19,555 4888

RD – QC 16,026 20,131 5033RE – QB 15,586 19,736 4934RE – QC 16,026 20,312 5078

RD – RB 17,665 21,898 5474RD – RC 18,194 22,562 5641RE – RB 17,665 22,079 5520

RE – RC 18,194 22,743 5686RD – SB 20,607 25,592 6398RD – SC 21,387 26,790 6697

RE – SB 20,943 26,055 6514RE – SC 21,725 27,255 6813SD – RB 19,618 24,372 6093

SD – RC 20,163 25,098 6274SE – RB 19,620 24,590 6148SE – RC 20,165 25,315 6329

SD – SB 22,274 27,658 6915SD – SC 23,056 28,858 7215SE – SB 22,276 27,896 6974

SE – SC 23,059 29,078 7269

J1 & J2 COMPRESSORS

Page 14: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

14 YORK INTERNATIONAL

TABLE 3 – MOTOR WEIGHTS (LBS.)

MOTORLOW VOLTAGE HIGH VOLTAGE

MOTORLOW VOLTAGE HIGH VOLTAGE

CODENO SOUND W/SOUND NO SOUND W/SOUND

CODENO SOUND W/SOUND NO SOUND W/SOUND

HOOD HOOD HOOD HOOD HOOD HOOD HOOD HOOD

CH 1,100 — 2,150 2,700 SCE 1,120 — 2,150 2,700CJ 1,100 — 2,150 2,700 SCF 1,460 — 2,150 2,700

CK 1,460 — 2,150 2,700 SCG 1,460 — 2,150 2,700CL 1,460 — 2,150 2,700 5CH 1,460 — 2,150 2,700CM 1,460 — 2,150 2,700 5CI 1,460 — 2,150 2,700

CN 1,460 — 2,150 2,700 5CJ 1,780 — 2,150 2,700CP 1,780 — 2,150 2,700 5CK 1,780 — 2,150 2,700CR 1,780 — 2,150 2,700 SCL 1,780 — 3,350 3,950

CS 1,780 — 3,350 3,950 5CM 2,150 — 3,350 3,950CT 2,150 — 3,350 3,950 5CN 2,150 — 3,350 3,950CU 2,150 — 3,350 3,950 5CO 2,150 — 3,350 3,950

CV 2,150 — 3,350 3,950 5CP 3,350 3,950 3,350 3,950CW 3,350 3,950 3,350 3,950 5CQ 4,350 5,050 4,350 5,050CX 4,350 5,050 4,350 5,050 5CR 4,350 5,050 4,350 5,050

CY 4,350 5,050 4,350 5,050 5CS 5,000 6,700 5,000 6,700CZ 5,000 6,700 5,000 6,700 5CT 5,000 6,700 5,000 6,700CA 5,000 6,700 5,000 6,700 5CU 5,000 6,700 5,000 6,700

CB 5,000 6,700 5,000 6,700 5CV 5,000 6,700 5,000 6,700DA 6,000 7,300 6,000 7,300 5CW 6,000 7,300 6,000 7,300DB 6,000 7,300 6,000 7,300 5CX 6,000 7,300 6,000 7,300

DC 6,000 7,300 6,000 7,300 5DA 6,000 7,300 6,000 7,300DD — — 6,000 7,300 5DB 6,000 7,300 6,000 7,300DE — — 6,000 7,300 5DC — — 6,000 7,300

DF — — 6,000 7,300 5DD — — 6,000 7,300DH — — 6,000 7,300 5DE — — 6,000 7,300OJ — — 7,600 9,000 5OF — — 10,500 12,500

5OG — — 10,500 12,5005OH — — 10,500 12,5005OJ — — 12,000 14,000

YK MOTOR WEIGHTS 60 HERTZ YK MOTOR WEIGHTS 50 HERTZ

DESCRIPTIONPRODUCT DRAWING

FORM NO.

Dimensions and Physical Data 160.49-PA1Wiring Diagram MicroComputer Control CenterSolid State Starter

160.49-PW4

Wiring Diagram MicroComputer Control CenterElectro-Mechanical Starter

160.49-PW1

Solid State Starter Wiring Diagram 160 49-PW6

Field Wiring Solid State Starter 160.49-PW5Field Wiring Electro-Mechanical Starter 160.49-PW2Field Control Modifications 160.49-PW3

Motor Starter Specifications160.45-PA5.1

Electro-Mechanical Starter

TABLE 4 – REFERENCE DRAWINGS

Page 15: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

YORK INTERNATIONAL 15

FORM 160.49-N1

TABLE 3A – MOTOR WEIGHTS (KG)

MOTORLOW VOLTAGE HIGH VOLTAGE

MOTORLOW VOLTAGE HIGH VOLTAGE

CODENO SOUND W/SOUND NO SOUND W/SOUND

CODENO SOUND W/SOUND NO SOUND W/SOUND

HOOD HOOD HOOD HOOD HOOD HOOD HOOD HOOD

CH 499 — 975 1225 SCE 508 — 975 1225CJ 499 — 975 1225 SCF 662 — 975 1225

CK 662 — 975 1225 SCG 662 — 975 1225CL 662 — 975 1225 5CH 662 — 975 1225CM 662 — 975 1225 5CI 662 — 975 1225

CN 662 — 975 1225 5CJ 807 — 975 1225CP 807 — 975 1225 5CK 807 — 975 1225CR 807 — 975 1225 SCL 807 — 1520 1792

CS 807 — 1520 1792 5CM 975 — 1520 1792CT 975 — 1520 1792 5CN 975 — 1520 1792CU 975 — 1520 1792 5CO 975 — 1520 1792

CV 975 — 1520 1792 5CP 1520 1792 1520 1792CW 1520 1792 1520 1792 5CQ 1973 2291 1973 2291CX 1973 2291 1973 2291 5CR 1973 2291 1973 2291

CY 1973 2291 1973 2291 5CS 2268 3039 2268 3039CZ 2268 3039 2268 3039 5CT 2268 3039 2268 3039CA 2268 3039 2268 3039 5CU 2268 3039 2268 3039

CB 2268 3039 2268 3039 5CV 2268 3039 2268 3039DA 2722 3311 2722 3311 5CW 2722 3311 2722 3311DB 2722 3311 2722 3311 5CX 2722 3311 2722 3311

DC 2722 3311 2722 3311 5DA 2722 3311 2722 3311DD — — 2722 3311 5DB 2722 3311 2722 3311DE — — 2722 3311 5DC — — 2722 3311

DF — — 2722 3311 5DD — — 2722 3311DH — — 2722 3311 5DE — — 2722 3311OJ — — 3447 4082 5OF — — 4763 5670

5OG — — 4763 56705OH — — 4763 56705OJ — — 5443 6350

YK MOTOR WEIGHTS 60 HERTZ YK MOTOR WEIGHTS 50 HERTZ

Page 16: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

16 YORK INTERNATIONAL

GENERAL

This instruction describes the installation of a MODELYK CODEPAK Liquid Chilling Unit. This unit is shippedas a single factory assembled, piped, wired packagerequiring a minimum of field labor to make chilled waterconnections, condenser water connections, refrigerantatmospheric relief connections, and electrical powerconnections. (Refrigerant and oil charges shipped sepa-rately.)

CODEPAKS can also be shipped dismantled whenrequired by rigging conditions, but generally it is moreeconomical to enlarge access openings to accomodatethe factory assembled unit. CODEPAKS shipped dis-mantled MUST be field assembled under the supervi-sion of a YORK representative, but otherwise installa-tion will be as described in this instruction.

FIELD ASSEMBLED UNITS ONLY

Use Form 160.49-N3 in conjunction with this installationinstruction. This instruction will be furnished with all unitsthat are to be field assembled. Extra copies may be or-dered from the YORK Publication Distribution Center.

CONSTRUCTION DRAWINGS

Construction drawings are furnished for each job asnoted in Table 4. These drawings must be carefully fol-lowed and used in conjunction with this installation in-struction, to insure proper installation of the unit. In eventof any differences between drawings and this instruc-tion, the drawings will govern.

The services of a YORK representative will be furnishedto check the installation, supervise the initial start-upand operation of all CODEPAKS installed within Conti-nental United States.

CAUTION: The YORK Warranty will be voided if thefollowing restrictions are not adhered to:

1. No valves or connections should be opened underany circumstances because such action will resultin loss of the factory nitrogen charge.

2. Do not dismantle or open the CODEPAK for any rea-son except under the supervision of a YORK repre-sentative.

3. When units are shipped dismantled, notify the near-est YORK office in ample time for a YORK represen-tative to supervise rigging the unit to its operatingposition and the assembly of components.

4. Do not make final power supply connections to thecompressor motor or control center.

5. Do not charge the compressor with oil.

6. Do not charge the unit with refrigerant.

7. Do not attempt to start the system.

8. Do not run hot water (110°F (43.3°C) max.) or steamthrough the cooler or condenser at any time.

SHIPMENT

The CODEPAK may be ordered and shipped in any ofthe following forms:

Form 2 – Factory Assembled Unit, complete with mo-tor (refrigerant and oil charges shipped sepa-rately).

1. The motor/compressor assembly mounted,with all necessary interconnecting piping as-sembled. MicroComputer Control Center ismounted on the unit. Complete unit factoryleak tested, evacuated and charged withholding charge of nitrogen.An optional Solid State Starter can be fac-tory mounted and wired.

2. Miscellaneous material – Four (4) vibrationisolation pads (or optional spring isolatorsand brackets).

Form 3 – Driveline Separate From Shells – Shipped asthree major assemblies. Unit first factoryassembled, refrigerant piped, wired and leaktested; then dismantled for shipment. Com-pressor/motor assembly removed from shellsand skidded. Cooler/condenser is not skidded.

All wiring integral with compressor is left on it,and all conduit is left on shell. All openings oncompressor, oil separator, and shell are closedand charged with dry nitrogen (2 to 3psig)(13.8 to 21 kPa).

Miscellaneous packaging of control center,tubing, water temperature controls, wiring,oil, isolators, solid state starter (option), etc.;refrigerant charge shipped separately.

NOTE: Units shipped dismantled MUST be re-assembled by, or under the supervision of, aYORK representative. (See Form 160.49-N3.)

Form 7 – Split Shells – Shipped as four major assem-blies. Unit first factory assembled, refriger-ant piped, wired and leak tested; then dis-mantled for shipment. Compressor/motorassembly removed from shells and skidded.

INTRODUCTION

Page 17: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

YORK INTERNATIONAL 17

FORM 160.49-N1

Cooler and condenser shells are separatedat tube sheets and are not skidded. Refrig-erant lines between shells are flanged andcapped, requiring no welding.

All wiring integral with compressor is left onit. All wiring harnesses on shells are removed.All openings on compressor and shells areclosed and charged with dry nitrogen (2 to 3psig)(13.8 to 21 kPa).

Miscellaneous packaging of control center,tubing, water temperature controls, wiring,oil, isolators, solid state starter (option), etc.;refrigerant charge shipped separately.

NOTE: Units shipped dismantled MUST be re-assembled by, or under the supervision of, aYORK representative. (See Form 160.49-N3).

When more than one CODEPAK is involved, the majorparts of each unit will be marked to prevent mixing ofassemblies. (Piping and Wiring Drawings to be furnishedby YORK.)

INSPECTION – DAMAGE – SHORTAGE

The unit shipment should be checked on arrival to seethat all major pieces, boxes and crates are received.Each unit should be checked on the trailer or rail carwhen received, before unloading, for any visible signsof damage. Any damage or signs of possible damagemust be reported to the transportation company imme-diately for their inspection.

YORK WILL NOT BE RESPONSIBLE FOR ANY DAM-AGE IN SHIPMENT OR AT JOB SITE OR LOSS OFPARTS. (Refer to Shipping Damage Claims, Form50.15-NM).

When received at the job site all containers should beopened and contents checked against the packing list.Any material shortage should be reported to YORK im-mediately. (Refer to Shipping Damage Claims, Form50.15-NM.)

CODEPAK DATA PLATE

A unit data plate is mounted on the control center as-sembly of each unit, giving unit model number; designworking pressure; water passes; refrigerant charge;serial numbers; and motor power characteristics andconnection diagrams.

Additional information may be found on the motor dateplate. This information should be included when con-tacting the factory on any problem relating to the motor.

RIGGING

The complete standard CODEPAK is shipped withoutskids. (When optional skids are used it may be neces-sary to remove the skids so riggers skates can be usedunder the unit end sheets to reduce overall height.)

Each unit has four (4) lifting holes (two on each end) inthe end sheets which should be used to lift the unit.(See Fig. 5.)

Care should be taken at all times during rigging andhandling of the CODEPAK to avoid damage to the unitand its external connections. Lift only using holes shownin Fig. 5.

Do not lift the unit with slings around motor/com-pressor assembly or by means of eyebolts in thetapped holes of the compressor motor assembly.Do not turn a unit on its side for rigging. Do not rigby one end.

Use of Slings (See Fig. 5 for proper use of slings inrigging.)

CAUTION : If necessary to rig the CODEPAK by one endto permit lifting or dropping through a verti-cal passageway, such as an elevator shaft,contact YORK factory shipping for specialrigging instructions.

The rigging and operating weights and overall dimen-sions are given on pages 6 thru 13 as a guide in deter-mining the clearances required for rigging. (Add 6" (153mm) to overall-height for optional skidded unit.)

Page 18: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

18 YORK INTERNATIONAL

LD01043

FIG. 5 – RIGGING

LOCATION

YORK CODEPAKS are furnished with vibration isolatormounts for basement or ground level installations. Unitsmay be located on upper floor levels providing the flooris capable of supporting the total unit operating weightand optional spring isolators are used.

IMPORTANT

Sufficient clearance to facilitate normal service andmaintenance work must be provided all around andabove the unit, and particularly space provided ateither end to permit cleaning or replacement ofcooler and condenser tubes – see CLEARANCE.

A doorway or other sufficiently large opening properlylocated may be used. The chiller should be located in

an indoor location where temperature range from 40°F(4.4°C) to 110°F (43.3°C).

FOUNDATION

A level floor, mounting pad or foundation must be pro-vided by others, capable of supporting the operatingweight of the unit.

CLEARANCE

Clearances should be adhered to as follows:Rear and above unit – 2 ft. (610 mm)Front of unit – 3 ft. (915 mm)Tube Removal –14 ft. (4268 mm)(either end)

Page 19: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

YORK INTERNATIONAL 19

FORM 160.49-N1

FIG. 6 – NEOPRENE ISOLATORS LD01047

UNIT WEIGHT 53,531 LBS.(24,281 KG) TO 100,464 LBS. (45,570 KG)

UNIT WEIGHT UP TO 28,835 LBS. (13,079 KG) UNIT WEIGHT UP TO 28,836 LBS.(13,080 KG)TO 53,530 LBS. (24,281 KG)

LD01046

LD01045LD01044

7/8" (22 mm) DIA. HOLE

3" (76 mm)

7/8" (22 mm)

1-3/4" (44 mm)

4-1/2" (114 mm)

1-3/4" (44 mm)

3/4" (19 mm)

7/8" DIA. HOLE (22 mm)

7/8" (22 mm)

1" (25 mm)

6" (152 mm) 6" (152 mm)

1" (25 mm)

3/4" (19 mm)

7/8" (22 mm) DIA. HOLE

7/8" (22 mm)

3" (76 mm)

8"(203 mm)

6"

(152 mm)

3/4" (19 mm)

8"(203 mm)

6" (152 mm)

3" (76 mm)

2" (51 mm)

3" (76 mm) 3" (76 mm)

2" (51mm)

3" (76 mm)

8"(203 mm)

6" (152 mm)

168" (4267 mm)

6"

(152 mm)

8"(203 mm)

3" (76 mm)

6

"

(152 mm)

8"(203 mm)

Page 20: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

20 YORK INTERNATIONAL

UNIT WEIGHT 26,880 LBS. (12,193 KG) UP TO 35,009 LBS. (15,880 KG)

LD01048

1/2" (13 mm)

1-3/4" (44 mm)

3/4" (19 mm)

6-1/4"(159 mm) 6-1/4" (159 mm)

168"(4267 mm)

84" (2133 mm)

1/2"(13 mm)

6-1/4" (159 mm)7" (178 mm)

6-1/4" (159 mm)

1/2" (13 mm)7" (178 mm)

1/2" (13 mm)

1-3/4" (44 mm)

3/4" (19 mm)

6-3/8"(162 mm) 9-1/2" (241 mm)

UNIT WEIGHT 35,010 LBS. (15,880 KG) UP TO 58,349 LBS. (26,467 KG)

168"(4267 mm)

84" (2133 mm)1/2"

(13 mm)

9-1/2" (241 mm)7-1/8" (181 mm)

9-1/2" (241 mm)

1/2" (13 mm)

7-1/8" (181 mm)

LD01049

LD01050

FIG. 7 – SPRING ISOLATORS

1/2" (13 mm)

1-3/4" (44 mm)

3/4" (19 mm)

9"(229 mm) 9

"

(229 mm)

UNIT WEIGHT 58,350 LBS. (26,468 KG) UP TO 89,340 LBS. (40,525 KG)

168"(4267 mm)

9 SPRING ISOLATORS

84" (2133 mm)1/2"

(13 mm)

9" (181 mm) 9-3/4"(248 mm)

9-3/4" (248 mm)1/2" (13 mm)

9" (229 mm)

4 SPRING ISOLATORS

Page 21: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

YORK INTERNATIONAL 21

FORM 160.49-N1

RIGGING UNIT TO FINAL LOCATION

Rig the unit to its final location on the floor or mountingpad, lift the unit (or shell assembly) by means of an over-head lift and lower the unit to its mounting position. (Ifoptional shipping skids are used remove them beforelowering the CODEPAK to its mounting position.)

NOTE: At this point units shipped dismantled shouldbe assembled under the supervision of a YORKrepresentative.

If cooler is to be field insulated, the insulation should beapplied to the cooler before the unit is placed in positionwhile the unit is in the lift position. Be sure unit is prop-erly supported. (See INSULATION, page 24.)

LOCATING AND INSTALLING ISOLATORPADS (REFER TO FIG. 6)

The isolator pad mounts are to be located as shown inFig. 6.

After the isolator pads have been placed into positionon the floor, lower the CODEPAK onto the pads. Whenthe unit is in place remove the rigging equipment andcheck that the unit is level both longitudinally and trans-versely. The unit should be level within 1/4" (6.4 mm)from one end to the other end and from front to the rear.If the chiller is not level within the amount specified, liftit and place shims between the isolation pad and theCODEPAK tube sheets. (Shims furnished by the in-staller.) Lower unit again and recheck to see that it islevel.

CHECKING THE ISOLATION PAD DEFLECTION

All isolation pads should be checked for the properdeflection while checking the level of the CODEPAK.Each pad should be deflected approximately 0.15 inch(3.8 mm). If an isolation pad is under deflected, shimsshould be placed between the unit tube sheet and thetop of the pad to equally deflect all pads.

LEVELING THE UNIT

The longitudinal alignment of the unit should be checkedby placing a level on the top center of the cooler shellunder the compressor/motor assembly. Transverse align-ment should be checked by placing a level on top of theshell end sheets at each end of the CODEPAK.

INSTALLING OPTIONAL SPRING ISOLATORS (RE-FER TO FIG. 7)

When ordered, 4 spring type isolator assemblies will befurnished with the unit. The 4 assemblies are identicaland can be placed at any of the 4 corners of the unit.

While the unit is still suspended by the rigging, the isola-tors should be bolted to the unit by inserting the cap

screw(s) through the hole(s) in the mounting bracketinto the tapped hole in the top of the isolator levelingbolt(s). Then the unit can be lowered onto the floor.

The leveling bolts should now be rotated one (1) turn ata time, in sequence, until the unit end sheets are about1-3/4" (44.4 mm) off the floor or foundation, and the unitis level. Check that the unit is level, both longitudinallyand transversely (see Leveling The Unit). If the levelingbolts are not long enough to level unit due to an unevenor sloping floor or foundation, steel shims (grouted, ifnecessary) must be added beneath the isolator assem-blies as necessary.

After the unit is leveled, wedge and shim under eachcorner to solidly support the unit in this position whilepiping connections are being made, pipe hangers ad-justed and connections checked for alignment. Then theunit is filled with water and checked for leaks. The level-ing bolts should now be finally adjusted until the wedgesand shims can be removed. The unit should now be incorrect level position, clear of the floor or foundationand without any effect from the weight of the piping.When the unit is properly supported, spring isolator in-stalled height will be 6" to 6-1/4" (152-159 mm).

PIPING CONNECTIONS

After the unit is leveled (and wedged in place for optionalspring isolators) the piping connections may be madeup; chilled water, condenser water and refrigerant relief.The piping should be arranged with offsets for flexibility,and adequately supported and braced independently ofthe unit to avoid strain on the unit and vibration transmis-sion. Hangers must allow for alignment of pipe. Isolators(by others) in the piping and hangers are highly desir-able, and may be required by specifications, in order toeffectively utilize the vibration isolation characteristics ofthe vibration isolation mounts of the unit.

Check for piping alignment – Upon completion of pip-ing, a connection in each line as close to the unit aspossible should be opened, by removing the flange boltsor coupling and checked for piping alignment. If any ofthe bolts are bound in their holes, or if the connectionsprings out of alignment, the misalignment must be cor-rected by properly supporting the piping or by applyingheat to anneal the pipe.

NOTE: If the piping is annealed to relieve stress, theinside of the pipe must be cleaned of scale be-fore it is finally bolted in place.

COOLER AND CONDENSER WATER PIPING

The cooler and condenser liquid heads of CODEPAK unitshave nozzles which are grooved, suitable for welding 150psig DWP flanges or the use of Victaulic couplings.

INSTALLATION

Page 22: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

22 YORK INTERNATIONAL

FIG. 8 – SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT FOR COOLING ONLY CODEPAKS

The nozzles and water pass arrangements are furnishedin accordance with the job requirements (see ProductDrawings as referenced in Table 4) furnished with thejob. Standard units are designed for 150 psig (1034 kPa)DWP on the water side. If job requirements are forgreater than 150 psig (1034 kPa) DWP, check the unitdata plate before applying pressure to cooler or con-denser to determine if the CODEPAK has provisions forthe required DWP.

Inlet and outlet connections are identified by labelsplaced adjacent to each nozzle.

Cooling Units – Chilled Water

Foreign objects which could lodge in, or block flowthrough, the cooler and condenser tubes must be keptout of the water circuit. All water piping must be cleanedor flushed before being connected to the CODEPAK,pumps, or other equipment.

Permanent strainers (by others) are required in boththe cooler and condenser water circuits to protect theCODEPAK as well as the pumps, tower spray nozzles,chilled water coils and controls, etc. The strainer shouldbe installed in the entering chilled water line, directlyup-stream of the CODEPAK.

Water piping circuits should be arranged so that thepumps discharge through the CODEPAK, and shouldbe controlled as necessary to maintain essentially con-stant chilled and condenser water flows through the unitat all load conditions.

If pumps discharge through the CODEPAK, the strainermay be located upstream from pumps to protect bothpump and CODEPAK. (Piping between strainer, pumpand CODEPAK must be very carefully cleaned beforestartup.) If pumps are remotely installed from CODE-PAK, strainers should be located directly upstream ofthe CODEPAK.

Cooling Units – Condenser Water Circuit

For proper operation of the unit, condenser refrigerantpressure must be maintained above cooler pressure. Ifoperating conditions will fulfill this requirement, no at-

tempt should be made to control condenser watertemperature by means of automatic valves, cycling ofthe cooling tower fan or other means, since CODEPAKSare designed to function satisfactorily and efficientlywhen condenser water is allowed to seek its own tem-perature level at reduced loads and off-peak seasonsof the year. However, if entering condenser water tem-perature can go below the required minimum, (refer to160.49-O1) condenser water temperature must be main-tained equal to or slightly higher than the required mini-mum. Refer to Fig. 8 for typical water piping schematicfor cooling CODEPAK.

Stop Valves

Stop valves may be provided (by others) in the coolerand condenser water piping adjacent to the unit to fa-cilitate maintenance. Thermometer wells and pressuretaps should be provided (by others) in the piping as closeto the unit as possible to facilitate operating checks.

Flow Switches (Field Installed)

A flow switch or pressure differential control in the chilledwater line(s) adjacent to the unit is an accessory fur-nished for connection to the control center. If a flowswitch is used, it must be directly in series with theCODEPAK and sensing only water flow through theCODEPAK. The differential switch must sense pressuredrop across the unit.

Drain and Vent Valves

Drain and vent valves (by others) should be installed inthe connections provided in the cooler and condenserliquid heads. These connections may be piped to drainif desired.

Checking Piping Circuits and Venting Air

After the water piping is completed, but before any wa-ter box insulation is applied. Tighten and torque (to main-tain between 30 and 60 ft. lbs. – 415 and 830 kgm) thenuts on the liquid head flanges. Gasket shrinkage andhandling during transit cause nuts to loosen. If waterpressure is applied before this is done, the gaskets may

LD01051

Page 23: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

YORK INTERNATIONAL 23

FORM 160.49-N1

FIG. 9 – REFRIGERANT VENT PIPING

LD01052

be damaged and have to be replaced. Fill the chilledand condenser water circuits (and hot water circuit onheat recovery unit), operate the pumps manually andcarefully check the cooler and condenser water headsand piping for leaks. Repair leaks as necessary.

Before initial operation of the unit both water circuits (orall three water circuits heat recovery units) should bethoroughly vented of all air at the high points.

REFRIGERANT RELIEF PIPING

Each unit is equipped with dual pressure relief valveslocated on the cooler for the purpose of quickly reliev-ing excess pressure of the refrigerant charge to the at-mosphere as a safety precaution in case of an emer-gency, such as fire.

Refrigerant relief vent piping (by others), from the reliefvalves to the outside of the building, is required by codein most areas and should be installed on all CODEPAKS.The vent line should be sized in accordance with theANSI/ ASHRE-15, or local code, but should never besmaller than “Relief Valve Size” shown in Figs. 3 or4. The vent line must include a dirt trap in the verticalleg to intercept and permit clean out and to trap anyvent stack condensation. The piping MUST be arrangedto avoid strain on the relief valves, using a flexible con-nection, if necessary.

UNIT PIPING

Compressor lubricant piping and system external pip-ing are factory installed on all units shipped assembled.On units shipped dismantled, the following piping shouldbe completed under the supervision of the YORK rep-resentative; (1) The lubricant piping to oil sump and oilcooler and system oil return connections using mate-rial furnished. See Form 160.49-N3.

CONTROL WIRING

On units shipped disassembled, after installation of thecontrol center, control wiring must be completed be-

tween unit components and control center or solid statestarter when used, using wiring harness furnished. Re-fer to Form 160.49-N3 and Wiring Diagrams listed inTable 4.

Field wiring connections for commonly-encounteredcontrol modifications (by others) if required, are shownon Forms 160.49-PW3.

NOTE: No deviations in unit wiring from that shownon drawings furnished shall be made withoutprior approval of the YORK representative.

POWER WIRING

Codepak with Electro-Mechanical Starter

A 115 volt – single phase – 60 or 50 Hertz power sup-ply of 15 amperes must be furnished to the control cen-ter, from the control transformer (2 KVA required) in-cluded with the compressor motor starter. DO NOT makefinal power connections to control center until approvedby YORK representative.

OlL PUMP – 3 PHASE STARTER

Separate wiring or a fused disconnect switch should besupplied by the installer. Refer to the Field Wiring Dia-gram shown in Table 4.

NOTE: Remote Electro-Mechanical starters for theCODEPAK must be furnished in accordancewith YORK Standard R-1051 (Product Draw-ing Form 160.45-PA5.1) to provide the featuresnecessary for the starter to function properlywith the YORK control system.

Each CODEPAK unit is furnished for a specific electri-cal power supply as stamped on the Unit Data Plate,which also details the motor connection diagrams.

NOTE: To insure proper motor rotation the starter powerinput and starter to motor connections must bechecked with a phase sequence indicator in thepresence of the YORK representative.

Page 24: CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS

FIG.10 – YK CODEPAK MOTOR CONNECTIONS (ELECTRO MECHANICAL STARTER APPLICATION)

LD01053

NOTES:

A. REQUIRES PASSING MOTOR LEAD THRU CURRENTTRANSFORMER (CT) ONCE BEFORE CONNECTING TOPOWER SUPPLY.

B. REQUIRES PASSING MOTOR LEAD THRU CT TWICE BE-FORE CONNECTING TO PWER SUPPLY.

C. REQUIRES PASSING MOTOR LEAD THRU CT THREE TIMESBEFORE CONNECTING TO POWER SUPPLY.

IMPORTANT

DO NOT cut wires to final length or make final con-nections to motor terminals or starter power input ter-minals until approved by the YORK representative.

YK Motors (Electro-Mechanical Starter)

Fig. 8 shows the power wiring hook-up for Motor Connec-tions. (Refer to Wiring Labels in Motor Terminal Box forhook-up to suit motor voltage amd amperage.)

Motor leads are furnished with a crimp type connectionhaving a clearance hole for a 3/8" (9 mm) bolt, motorterminal lugs are not furnished.

CODEPAK with Solid State Starter

A CODEPAK equipped with a Solid State Starter, doesnot require wiring to the compressor motor. The motorpower wiring is factory connected to the Solid StateStarter (or an optional factory installed disconnectswitch). See Field Wiring Diagram listed in Table 4. Allwiring to the control panel and the oil pump starter iscompleted by the factory. A control transformer is fur-nished with the Solid State Starter.

INSULATION (SEE PRODUCT DRAWING FORM160.49-PA1).

IMPORTANT

DO NOT field insulate until the unit has been leaktested under the supervision of the YORK repre-sentative.

Insulation of the type specified for the job, or minimumthickness to prevent sweating of 30°F surfaces (waterchill application), should be furnished (by others) andapplied to the cooler shell, end sheets, liquid feed lineto flow chamber, compressor suction connection, andcooler liquid heads and connections. The liquid headflange insulation must be removable, to allow head re-moval for the tube maintenance. Details of areas to beinsulated are given on the Product Drawing.

Units are furnished factory anti-sweat insulated on or-der at additional cost. This includes all low temperaturesurfaces except the two (2) cooler liquid heads.

INSTALLATION CHECK – REQUEST FORSTART-UP SERVICE

The services of a YORK representative will be furnishedto check the installation and supervise the initial start-upand operation on all CODEPAKS installed within theContinental United States.

After the unit is installed, piped and wired as describedin this Instruction, but before any attempt is made tostart the unit, the YORK District Office should be ad-vised so that the start-up service, included in the con-tract price, can be scheduled. Notification to the YORKoffice should be by means of Installation Check List andRequest, Form 160.49-CL1, in triplicate.

Proud Sponsorof the 1998U.S. Olympic Team

36USC380

P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USACopyright © by York International Corporation 1997 ALL RIGHTS RESERVED

Form 160.49-N1 (197)Supersedes: 160.49-N1 (894)

3 PHASE MOTOR RATED LOAD AMPSMOTOR CT RATIOVOLTAGE50/60 HZ 200:1 350:1 700:1 1400:1

200–600 65–111A 112–224A 225–829A 830–1790A

11–18C

2300–4160 19–37B 124–264A 265–518A

28–123A