Model YS Rotary Screw Liquid Chillers Design Level E: FORM 160.80-EG1

FORM 160.

80-EG1 (210)

Model YS Rotary Screw Liquid Chillers

Design Level E
100 THRU 675 TONS

(315 THRU 2375 KW)
R-134
Products are produced at a

facility whose qualitymanagement systems are
ISO9001 certified.
FORM 160.80-EG1 (210)
Contents
Introduction............................................................................................................................................................................................................ 3
Ratings................................................................................................................................................................................................................... 4
OptiView Control Center....................................................................................................................................................................................... 5
Mechanical Specifications.................................................................................................................................................................................. 13
Accessories and Modifications.......................................................................................................................................................................... 18
Unit Components................................................................................................................................................................................................. 20
Application Data.................................................................................................................................................................................................. 22
Dimensions - Std .............................................................................................................................................................................................. 30
Dimensions - Std................................................................................................................................................................................................. 34
Weights - Std....................................................................................................................................................................................................... 38
Dimensions - Metric............................................................................................................................................................................................ 40
Guide Specifications........................................................................................................................................................................................... 50
Metric Conversion Tables................................................................................................................................................................................... 56
NOMENCLATURE
The model number denotes the following characteristics of the unit:
YS
Model
BA
S0
CF
S
Special Features
Cooler Code
Condenser Code
Compressor Code
BB
Design Level
Motor Code
Power Supply:
for 60 Hz
5 for 50 Hz
JOHNSON CONTROLS
Introduction
The YORK YS Chiller offers a complete combination of
features for total owner satisfaction.
MATCHED COMPONENTS MAXIMIZE EFFICIENCY
Actual chiller efficiency cannot be determined by analyzing
the theoretical efficiency of any one chiller component. It
requires a specific combination of heat exchanger, compressor, and motor performance to achieve the lowest
system kW/Ton. YORK chiller technology matches chiller
system components to provide maximum chiller efficiency
under actual not just theoretical operating conditions.
REAL-WORLD ENERGY PERFORMANCE
Johnson Controls pioneered the term Real-World Energy to illustrate the energy-saving potential of focusing on chiller performance during off-design conditions.
Off-design is not only part load, but full load operation as
well, with reduced entering condenser water temperatures
(ECWTs). This is where chillers operate 99% of the time,
and where operating costs add up.
The YS chillers are the only chillers designed to operate
on a continuous basis with cold ECWT and full condenser
flow at all load points, taking full advantage of Real-World
conditions. This type of operation benefits the cooling
tower as well; reducing cycling of the fan motor and ensuring good coverage of the cooling fill.
YORK chillers offer the most efficient Real-World operation of any chiller, meaning lower operating costs and an
excellent return on your chiller investment.
OPEN DRIVE DESIGN
Hermeticmotor burnout can cause catastrophic dam
age to a chiller. The entire chiller must be cleaned, and
the refrigerant replaced. YORK screw chillers eliminate
this risk by utilizing aircooled motors. Refrigerant never
comes in contact with the motor, preventing contamination
of the rest of the chiller.
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
Insurance companies that offer policies on large air conditioning equipment often consider aircooled motors a
significant advantage over hermetic refrigerantcooled units.
HIGHEFFICIENCY HEAT EXCHANGERS
YORK heat exchangers offer the latest technology in heat
transfer surface design to give you maximum efficiency
and compact design. Waterside and refrigerantside design enhancements minimize both energy consumption
and tube fouling.
FACTORY PACKAGING REDUCES FIELD LABOR
COSTS
YORK YS screw chillers are designed to keep installation
costs low. Where installation access is not a problem,
the unit can be shipped completely packaged, requiring
minimal piping and wiring to complete the installation.
For those units utilizing a factory installed SolidState
Starter, the three power leads provide all power to the
chiller and its auxiliaries.
TAKE ADVANTAGE OF COLDER COOLING TOWER
WATER TEMPERATURES
YORK YS screw chillers are designed to take full advantage of colder cooling tower water temperatures, which
are naturally available during most operating hours. Considerable energy savings are available by letting tower
water temperature drop, rather than artificially holding
it above 75F (23.9C), especially at low load, as some
chillers require.
U.L. ACCEPTANCE YOUR ASSURANCE OF RELIABILITY
YORK YS screw chillers are approved for listing by Underwriters Laboratories for the United States and Canada.
Recognition of safety and reliability is your assurance of
troublefree performance in dayto-day building operation.
FORM 160.80-EG1 (210)
Ratings
Rated in accordance
with the latest issue of
AHRI Standard 550/590.
AHRI CERTIFICATION PROGRAM

The performance of YORK chillers is certified to the Air
Conditioning and Refrigeration Institute (AHRI) complying
with the certification sections of the latest issue of AHRI
Standard 550/590. Under this Certification Program,
chillers are regularly tested in strict compliance with this
Standard. This provides an independent, thirdparty verification of chiller performance.
COMPUTERIZED PERFORMANCE RATINGS
Each chiller is custommatched to meet the individual
building load and energy requirements. A large number
of standard heat exchangers and pass arrangements are
available to provide the best possible match.
It is not practical to provide tabulated performance for
each combination, as the energy requirements at both full
and part load vary significantly with each heat exchanger
and pass arrangement. Computerized ratings are available through each Johnson Controls sales office. These
ratings can be tailored to specific job requirements, and

are part of the AHRI Certification Program.
OFF-DESIGN PERFORMANCE
Since the vast majority of its operating hours are spent
at offdesign conditions, a chiller should be chosen not
only to meet the fullload design, but also for its ability to
perform efficiently at lower loads and lower tower water
temperatures. It is not uncommon for chillers with the
same fullload KW/TON to have an operating cost difference of over 10% due to partload operation.
Partload information can be easily and accurately generated by computer. And because it is so important to an
owners operating budget, this information is now standard
within the AHRI Certification Program in the form of an
Integrated PartLoad Value (IPLV), and Non-Standard
PartLoad Value (NPLV).
The IPLV / NPLV formulas from AHRI Standard 550/590
closely track chiller operations, and provide a more accurate indication of chiller performance than the previous IPLV/APLV formula. A more detailed analysis must
take into account actual building load profiles, and local
weather data. Partload performance data should be obtained for each job using its own design criteria.
JOHNSON CONTROLS
OptiView Control Center
OPTIVIEW CONTROL CENTER

The YORK OptiView Control Center, furnished as standard on each chiller, provides the ultimate in efficiency,
monitoring, data recording, chiller protection and operating ease. The control center is a factory mounted, wired,
and tested state-of-the-art microprocessor based control
system for R-134a screw chillers. The panel is configured
with a 10.4 inch diagonal color Liquid Crystal Display
(LCD) surrounded by soft keys, which are redefined with
one keystroke based on the screen display at that time.
This revolutionary development makes chiller operation
quicker and easier than ever before. Instead of requiring
keystroke after keystroke to hunt for information on a small
monochrome LCD screen, a single button reveals a wide
array of information on a large, full-color illustration of the
appropriate component, which makes information easier
to interpret. This is all mounted in the middle of a keypad
interface and installed in a locked enclosure.
The LCD display allows graphic animated display of the
chiller, chiller sub-systems and system parameters; this
allows the presentation of several operating parameters
at once. In addition, the operator may view a graphical
representation of the historical operation of the chiller as
well as the present operation. A Status Bar is displayed
at all times on all screens. It contains the System - Status
Line and Details Line, the Control Source, Access Level,
Date and Time.
During the Start Sequence and System Lockout Delay, the
system status will include a countdown timer indicating the
time remaining. The control panel is compatible with the
YORK Solid State Starter (optional), Electro-mechanical
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
(E-M) starter, or any customer supplied E-M starter that

complies with the YORK R-1051 standard. The locations
of various chiller parameters are clearly marked and instructions for specific operations are provided. The panel
verbiage is available in other languages as an option, with
English always available. Data can be displayed in either
English or Metric units, plus keypad entry setpoints of 0.1
increments.
Security access is provided to prevent unauthorized access and/or a change of setpoints. This is accomplished
with three different levels of access and passwords for
each level. There are screens, displayed values, programmable setpoints and manual controls not shown available
to service the chiller. They are only displayed when logged
in at the service access level. The Advanced Diagnostics
and troubleshooting information for the chiller and the
panel is also included.
The panel is fused through a 1-1/2 or 2 KVA transformer
in the compressor motor starter to provide individual
over-current protected power for all controls. Numbered
terminal strips for wiring such as Remote Start/Stop,
Flow Switch, Chilled Water Pump and Local or Remote
Cycling Device are provided. The Panel also provides
field interlocks that indicate the chiller status. These contacts include a Remote Mode Ready To Start, a Cycling
Shutdown, a Safety Shutdown and a chiller Run Contact.
Pressure transducers sense system pressures and thermistors sense system temperatures. The output of each
transducer is a DC voltage that is analogous to the pressure input. The output of each thermistor is a DC voltage
that is analogous to the temperature it is sensing.
5
OptiView Control Center - continued

Setpoints can be changed from a remote location via
0-10VDC, 4-20mA, contact closures or through serial
communications. The adjustable remote reset range [up
to 20F (11.1C)] provides flexible, efficient use of remote
signal depending on reset needs. Serial data interface
to the Building Automation System (BAS) is through the
General Protocol Interface Card (GPIC), which can be
mounted inside the Control Center.
This printed circuit board requests the required data from
the Microboard and makes it available for the Johnson
Controls Metasys network. This optional board is available through the Johnson Controls Building Efficiency
group. The operating program is stored in non-volatile
memory (EPROM) to eliminate chiller failure due to AC
power failure/battery discharge. Programmed setpoints
are retained in lithium battery-backed RTC memory for
10 years minimum.
Smart Freeze Point Protection can operate the chiller as
low as 36F (2.22C) leaving chilled water temperature,
without nuisance trips on Low Water Temperature. The
sophisticated program and sensor monitors the chiller water temperature to prevent freeze-up. Each programmable
point has a pop-up screen with the allowable ranges, so
the chiller cannot be programmed to operate outside of
its design limits.
Thermal ice storage systems are based on the concept
of using off-peak, lower cost electricity to build ice for
handling the cooling load during peak hours. The most
efficient way to build ice is to maximize chiller load and
minimize run time. Standard chiller control systems are not
designed for this operating mode. In a typical application,
chillers will load and unload to maintain a leaving chilled
liquid setpoint. When the YORK YS chiller operates in the
thermal storage control mode, the unit will remain at 100%
load until the setpoint shutdown temperature is reached.
To add greater operating flexibility and eliminate unnecessary chiller cycling, two different Low Water (Liquid)
Temperature Restart Thresholds can be programmed, one
for the ice mode and one for the standard cooling mode.
This control enhancement is standard on all YS chillers.
The chiller can also be left in the standard control mode
for temperatures ranging between 20 and 70F (-6.7 and
21.1C), for applications involving a process cooling duty
that requires leaving chilled liquid temperature setpoint
control.
When power is applied to the chiller, the HOME screen
is displayed. This screen displays a visual representation
of the chiller and a collection of data detailing important
operations and parameters. When the chiller is running,
the flow of chilled liquid is animated by the alternating
shades of color moving in and out of the pipe nozzles. The
primary values that need to be monitored and controlled
are shown on this screen. They are as follows:
6
FORM 160.80-EG1 (210)
Display Only:
Chilled Liquid Temperature Leaving
Chilled Liquid Temperature Return
Condenser Liquid Temperature Return
Condenser Liquid Temperature Leaving
Motor Run (LED)
% Full Load Amps
Operating Hours
With the soft keys the operator is only one touch away
from the 8 main screens that allow access to the major
information and components of the chiller. The 8 screens
are the SYSTEM, EVAPORATOR, CONDENSER, COMPRESSOR, OIL SUMP, MOTOR, SETPOINTS, and the
HISTORY. Also on the Home Screen is the ability to LOG
IN, LOG OUT and PRINT. Log In and Log Out is the means
by which different security levels are accessed.
The SYSTEM screen gives a general overview of common
chiller parameters for both shells. This is an end view of
the chiller with a 3-D cutaway of both the shells. The following can be viewed from this screen:
Display Only:
Discharge Temperature
Chilled Liquid Temperature Leaving
Chilled Liquid Temperature Return
Chilled Liquid Temperature Setpoint
Evaporator Pressure
Evaporator Saturation Temperature
Condenser Liquid Temperature Leaving
Condenser Liquid Temperature Return
Condenser Pressure
Condenser Saturation Temperature
Oil Temperature
Differential Oil Pressure
% Full Load Amps
Current Limit
Slide Valve Position
The EVAPORATOR screen displays a cutaway view of
the chiller evaporator. All setpoints relating to the evaporator side of the chiller are maintained on this screen.
Animation of the evaporation process indicates whether
the chiller is presently in RUN condition (bubbling) and
liquid flow in the pipes is indicated by alternating shades
of color moving in and out of the pipes. Adjustable limits
on the low water temperature setpoints allow the chiller
to cycle on and off for greater efficiency and less chiller
cycling. The chiller cycles off when the leaving chilled
water temperature is below setpoint and is adjustable
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
from 1F (0.55C) below to a minimum of 36F (2.22C).

Restart is adjustable from setpoint up to a max of 80F
(44.4C). The Panel will check for flow to avoid freezeup of the tubes. If flow is interrupted, shutdown will occur
after a minimum of two seconds. The following can also
be performed through this screen:
Display Only:
Chilled Liquid Flow Switch (Open/Closed)
Chilled Liquid Pump (Run/Stop)
Evaporator Pressure
Evaporator Saturation Temperature
Return Chilled Liquid Temperature
Leaving Chilled Liquid Temperature
Evaporator Refrigerant Temperature
Small Temperature Difference
Leaving Chilled Liquid Temperature Setpoints
Setpoint
Remote Range
Shutdown
Shutdown Offset
Restart
Restart Offset
Ice Storage Active (LED)
Programmable:
Local Leaving Chilled Liquid Temperature Range
Local Leaving Chilled Liquid Temperature Setpoint
Leaving Chilled Liquid Temperature Cycling Offset
Shutdown
Restart
The CONDENSER screen displays a cutaway view of the
chiller condenser. The liquid flow is animated to indicate
flow through the condenser. All setpoints relating to the
condenser side of the chiller are maintained on this screen.
With the proper access level this screen also serves as a
gateway to controlling the Refrigerant Level. The following
can also be viewed through this screen:
Display Only:
Leaving Condenser Liquid Temperature
Return Condenser Liquid Temperature
Condenser Pressure
JOHNSON CONTROLS

Small Temperature Difference
High Pressure Switch (Open/Closed)
Condenser Liquid Flow Switch
Condenser Liquid Pump (Run/Stop)
Programmable:
High Pressure Warning Threshold
Freeze Warning (Enabled/Disabled)
Freeze Time
The Variable ORIFICE CONTROL screen, accessed from
the CONDENSER screen in SERVICE access level, displays all of the applicable Variable Orifice control parameters and allows a Service Technician to program the Delta
P setpoint. The Low Evaporator Pressure and Superheat
Override LEDs are located on this screen. A view of the
liquid flow piping to the chiller condenser, along with the
solenoid flow control valve, is shown. The following can
also be performed through this screen:
Display Only:
Condenser Pressure
Evaporator Pressure
Delta P (Condenser Evaporator)
Superheat Temperature
Low Evaporator Override (LED)
Superheat Override (LED)
Programmable:
Delta P Setpoint
The COMPRESSOR screen displays a cutaway view of
the chiller compressor, revealing the rotary screw, and
shows all conditions associated with the compressor. The
slide valve positioning is animated and with the proper
Access level, it can be manually controlled. Animation
of the compressor rotors indicates whether the chiller is
presently in a RUN condition. This screen also serves as
a gateway to sub-screens for calibrating the slide valve
or configuring the optional Hot Gas Bypass. From this
screen you can view the following:
Display Only:
Oil Temperature
Discharge Superheat
7


Oil Return Solenoid (LED)
Full Load Amps (E.M. Starter Only)
Phase A, B, C Current (SSS Only)
Programmable:
Slide Valve Load (Manual)
Slide Valve Hold (Manual)
Slide Valve Unload (Manual)
Slide Valve Auto
Max. Load Temperature
Minimum Load FLA
Minimum Load Control Source
The HOT GAS BYPASS screen, accessed from the COM-
PRESSOR screen, displays a pictorial of the bypass line

and solenoid valve location on the chiller. The Hot Gas
ON and OFF Setpoints are programmed on this screen
and system parameters pertinent to Hot Gas Bypass
operation are displayed. An LED illuminates when the
Hot Gas solenoid is ON. If the chiller is equipped with
the Hot Gas Bypass option, operation must be enabled
on the OPERATIONS screen. From this screen you can
perform the following:
Display Only:
Return Chilled Liquid Temperature
Leaving Chilled Liquid Temperature
Hot Gas Solenoid (LED)
Programmable:
On Setpoint
Off Setpoint
The SLIDE VALVE CALIBRATION screen displays a
cutaway view of the chiller compressor, revealing the
rotary screw and slide valve and provides the capability
of calibrating the slide valve. From this screen, you can
Display Only:
Slide Valve Loading (LED)
Slide Valve Unloading (LED)
Calibration Message
Programmable:
Start Calibration
Cancel Calibration
FORM 160.80-EG1 (210)
The OIL SEPARATOR screen displays a close-up view

of the chiller oil separator/sump and provides all the necessary setpoints for maintaining the Variable Speed Oil
Pump (VSOP). This screen also allows manual control
of the Frequency Command sent to the VSOP. From this
screen you can perform the following:
Display Only:
Oil Sump Temperature
Discharge Superheat
Oil Pressure
Filter Pressure
Seal Pressure
Differential Filter Pressure
Differential Seal Pressure
Offset Pressure
Oil Return Solenoid (LED)
Low Separator Oil Level (LED)

1. The MOTOR soft key on the HOME screen, when
pressed, shows a picture of either a YORK ElectroMechanical Starter or a Solid State Starter, depending
on chiller configuration. The Programmable pulldown
demand to automatically limit motor loading can be
used to minimize building demand charges. Pulldown
time period control over four hours, and verification of
time remaining in pulldown cycle from display readout.
Separate digital setpoint for current limiting between
30 and 100%.
The ELECTRO-MECHANICAL STARTER (EM) screen
displays a picture of the starter and the following values.
The ones below are common among both offerings and the
values will be displayed on both types of starter screens.
From this screen you can perform the following:
Display Only:
Motor Run (LED)
Motor Current % Full Load Amps
Current Limit Setpoints
Pulldown Demand Time Left
Programmable:
Local Motor Current Limit
Pulldown Demand Limit
Pulldown Demand Time
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
The SOLID STATE STARTER (SSS) screen displays a

picture of the starter and the following values, which are
displayed in addition to the common ones listed above.
From this screen, you can perform the following:
Display Only:
Input Power
kW Hours
Starter Model
Voltage Phase A, B, C
Current Phase A, B, C
Temperature Phase A, B, C
Programmable:
Full Load Amps
Voltage Range
Starting Current
Open SCR
Shorted SCR
kWH Reset
The SETPOINTS screen provides a convenient location
for programming the most common setpoints involved
in the chiller control. The Setpoints are shown on other
individual screens, but to cut down on needless searching, they can all be found on this screen. This screen also
serves as a gateway to a sub-screen for defining the setup
of general system parameters. From this screen you can
Display Only:
Leaving Chilled Liquid Temperature Setpoint
Leaving Chilled Liquid Temperature Cycling
Shutdown
Leaving Chilled Liquid Temperature Cycling
Restart
Current Limit Setpoint
Programmable:
Local Leaving Chilled Liquid Temperature Range
Local Leaving Chilled Liquid Temperature Setpoint
Shutdown
Restart
Remote Analog Input Range
JOHNSON CONTROLS

Print
The SETUP is the top level of the general configuration parameters. It allows programming of the time and
date, along with specifications as to how the time will be
displayed. In addition, the chiller configuration as determined by the micro board program jumpers and program
switches is displayed. From this screen you can perform
the following:
Display Only:
Chilled Liquid Pump Operation (Displays Standard or
Enhanced)
Refrigerant Selection (Displays R-134a)
Anti-Recycle (Displays Disabled or Enabled)
Power Failure Restart (Displays Manual or Automatic)
Liquid Type (Displays Water or Brine)
Programmable:
Set Date
Set Time
Clock (Enabled/Disabled)
12/24 Hour
The following six subscreens can be accessed from
the SETUP screen:
The SCHEDULE screen contains more programmable
values than a normal display screen. Each programmable
value is not linked to a specific button; instead, the select
key is used to enable the cursor arrows and check key to
program the Start/Stop times for any day of the week up
to 6 weeks in advance. The user has the ability to define
a standard set of Start/Stop times that are utilized every
week or specify exceptions to create a special week.
Programmable:
Exception Start/Stop Times
Schedule (Enable/Disable)
Repeat Sunday Schedule
Standard Week Start/Stop Times
Reset All Exception Days
Select
Print
The USER screen allows definition of the language for the
chiller to display and defines the unit of measure.
Programmable:
System Language
9

English/Metric Units
The COMMS screen allows the user to define communications parameters.
Programmable:
Chiller ID
COM 2 Baud Rate
COM 2 Data Bit(s)
COM 2 Parity Bit(s)
COM 2 Stop Bit(s)
Printer Baud Rate
Printer Data Bit(s)
Printer Parity Bit(s)
Printer Stop Bit(s)
The PRINTER screen permits the user to define communications Parameters for the Printer.
Display Only
Time Remaining Until Next Print
Programmable
Log Start Time
Output Interval
Automatic Printer Logging (Enabled/Disabled)
Print Type
Print Report
Print All Histories
The SALES ORDER screen allows definition of the order
parameters. Note: This information is loaded at the factory
or by the installation service technician.
Display Only
Model Number
Panel Serial Number
Chiller Serial Number
YORK Order Number
System Information
Condenser and Evaporator Design Load Information
Nameplate Information
The OPERATIONS screen permits definition of parameters pertaining to operation of the chiller. What is defined
is whether the control of the chiller will be Local, Digital
Remote, Analog Remote, Modem Remote or ISN Remote.
Programmable
Control Source
The HISTORY screen allows the user to browse through
the last ten faults; either safety or cycling shutdowns with
10
FORM 160.80-EG1 (210)
the conditions, while the chiller is running or stopped.

The faults are color coded for ease in determining
the severity at a glance, recording the date, time and
description. (See Display Messages for Color Code
meanings.)
Display Only
Last Normal Shutdown
Last Fault While Running
Last Ten Faults

Programmable:
Print History
Print All Histories
By pressing the VIEW DETAILS key you will move to the
HISTORY DETAILS screen. From these screens you
are able to see an on-screen printout of all the system
parameters at the time of the selected shutdown.
Display Only:
History Printout
Programmable:
Page Up
Page Down
Print History
Also under the HISTORY screen is the TRENDING
screen, accessible by the key marked the same. On this
screen, up to six operator-selected parameters, selected
from a list of over 140, can be plotted in an X/Y graph
format. The graph can be customized to record points
once every second up to once every hour. There are
two types of charts that can be created: single screen,
or continuous screen. The single screen collects data for
one screen width (450 data points across the X-axis), then
stops. The continuous screen keeps collecting the data,
but the oldest data drops off the graph from left to right
at the next data collection interval. For ease of identification, each plotted parameter, title and associated Y-axis
labeling is color coordinated.
Display Only:
This screen allows the user to view the graphical
trending of the selected parameters and is a gateway
to the graph setup screens.
Programmable:
Start
Stop
Y-axis
X-axis
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
The TREND SETUP screen is used to configure the trending screen. The parameters to be trended are selected
from the Trend Common Slots screen, accessed from
the Slot Numbers button or the Master Slot Numbers
List found in the Operating Manual. The interval at which
all the parameters are sampled is selected under the
Collection Interval button. The data point minimum and
maximum values may be adjusted closer to increase
viewing resolution.
Programmable:
Chart Type (select continuous or one screen)
Collection Interval
Select
Data Point Slot Number (1 - 6)
Data Point Min (1 - 6)
Data Point Max (1 - 6)
The TREND COMMON SLOTS screen displays the Master Slot Numbers List of the monitored parameters.
Display Only:
Slot Numbers
Programmable:
Page Up
Page Down
Print
DISPLAY MESSAGES
The Control Center continuously monitors the operating
system, displaying and recording the cause of any shutdowns (Safety, Cycling or Normal). The condition of the
chiller is displayed at the System Status line that contains
a message describing the operating state of the chiller;
whether it is stopped, running, starting or shutting down.
A System Details Line displays Warning, Cycling, Safety,
Start Inhibit and other messages that provide further
details of the Status Bar messages. Messages are colorcoded: Green Normal Operations; Yellow Warnings;
Orange Cycling Shutdowns; and Red Safety Shutdowns to aid in identifying problems quickly.
Status messages include:
System Ready To Start
Cycling Shutdown Auto Restart
Safety Shutdown Manual Restart
Start Sequence Initiated
System Run (with countdown timers)
Start Inhibit
Slide Valve Closing Before Shutdown
JOHNSON CONTROLS
System Lockout Delay

Run Messages include:
Leaving Chilled Liquid Control
Motor Pulldown Limit
Motor High Current Limit
Start Inhibit Messages include:
Anti-Recycle XX min/sec.
Slide Valve Position >30%
Motor Current >15% FLA
LCSSS High-Temperature Phase X - Stopped
Warning Messages include:
Real Time Clock Failure
Setpoint Override
Condenser High Pressure Limit
Evaporator Low Pressure Limit
Freeze Threat From Operating Chiller
Freeze Threat, Condenser Flow Switch Open
Low Discharge Superheat Limit
Low Discharge Superheat Detected
Maximum Load Load Limit
Minimum Load Load Limit
Oil Dirty Filter
Oil High Temperature
Slide Valve Uncalibrated
Routine Shutdown Messages Include:
Remote Stop
Local Stop
Place Compressor Switch In Run Position
Cycling Shutdown Messages Include:
Multiunit Cycling Contacts Open
System Cycling Contacts Open
Control Panel Power Failure
Leaving Chilled Liquid Low Temperature
Leaving Chilled Liquid Flow Switch Open
Condenser Flow Switch Open
Motor Controller Contacts Open
Motor Controller Loss of Current
Power Fault
Control Panel Schedule
olid State Starter Only (LCSSS)
S
Initialization Failed
Serial Communications
Requesting Fault Data
Stop Contacts Open
11

Power Fault
Low Phase (X) Temperature Sensor
Run Signal
Invalid Current Scale Selection
Phase Locked Loop
Low Supply Line Voltage
High Supply Line Voltage
Logic Board Processor
Logic Board Power Supply
Phase Loss
Safety Shutdown Messages include:

Evaporator Low Pressure
Evaporator Low Pressure Smart Freeze
Evaporator Transducer or Leaving Liquid Probe
Evaporator Transducer or Temperature Sensor
Condenser High Pressure Contacts Open
Condenser High Pressure
Condenser Pressure Transducer Out of Range
Auxiliary Safety Contacts Closed
12
FORM 160.80-EG1 (210)
Discharge High Temperature

Discharge Low Temperature
Oil Low Differential Pressure
Oil Low Differential Seal Pressure
Oil or Condenser Transducer Error
Oil Clogged Filter
Oil High Pressure
Oil Separator Low Level
Watchdog Software Reboot
Solid State Starter Only (LCSSS)

Shutdown Requesting Fault Data . . .
High Instantaneous Current
High Phase (X) Heatsink Temperature Running
105% Motor Current Overload
Motor or Starter Current Imbalance
Open SCR
Phase Rotation
JOHNSON CONTROLS
Mechanical Specifications
STANDARD UNIT
General
FORM 160.80-EG1 (210)
provides cool, non-foaming lubricant to the seal assuring

a longer lifespan.
The YORK YS Rotary Screw Chiller is completely factorypackaged, including evaporator, condenser, sub-cooler,
oil separator, compressor, motor, lubrication system,
control center and refrigerant isolation valves. The factory
package consists of a leak tight design. All units ship as
standard with a full charge of refrigerant and oil. Units can
also be shipped in sections (optional) to accommodate
job site requirements.
Capacity Control
The services of a Johnson Controls factory-trained, field

service representative are incurred to supervise or perform
the final leak testing, charging, the initial start-up, and
concurrent operator instructions.
The oil separator is a horizontal design without moving

parts. Effective oil separation is achieved by gravity dropout of oil from the refrigerant gas as velocity decreases
upon entering the separator, and by mesh pads to provide
final gas/oil separation before gas enters the condenser.
The oil separator is designed for 345 PSIG (2378 kPa)
design working pressure, tested at 517 PSIG (3565 kPa),
and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII - Division 1.
Heat Pump
The YS is capable of providing simultaneous heating
and cooling when ordered with the optional heat pump
package. The unit can supply leaving condenser water
temperatues up to 140F (60C)
Compressor
The Frick Rotary Twin Screw Compressor is engineered
and constructed to meet the exact requirements of the
industrial refrigeration market. It utilizes state-of-the-art
technology to provide the most reliable and energy-efficient compressor available at all operating conditions.
The compressor operates at 3750 RPM for 60 Hertz and
2975 RPM for 50 Hertz. The compressor housing is made
of cast iron, precision-machined to provide minimal clearance for the rotors. Compressor housing has a design
working pressure (DWP) of 300 PSIG (2068 kPa) minimum, and hydro-tested at 544 PSIG (3751 kPa).
The rotors are manufactured from forged steel and use
asymmetric profiles. The compressor incorporates a
complete anti-friction bearing design for reduced power
and increased reliability. Four separate cylindrical roller
bearings handle radial loads. Two 4-point angular contact
ball bearings handle axial loads. Together, they maintain
accurate rotor positioning at all pressure ratios, thereby
minimizing blow-by and maintaining efficiency.
A check valve is installed in the compressor discharge
housing (suction housing for S4 and S5 compressor) to
prevent compressor rotor back spin because of system
refrigerant pressure gradients during shutdown.
The open-drive compressor shaft seal consists of precision ceramic seal faces, metallic bellows, rotating member,
PTFE C-Ring static seal, and multi-port oil injection ring.
The seal cavity is maintained at intermediate pressure
with its oil discharged to the oil drain from the compressor.
Combining intermediate pressure with direct oil injection
JOHNSON CONTROLS
Capacity control is achieved by use of a slide valve which

provides fully modulating capacity control from 100% to
10% of full load. The slide valve is actuated by oil pressure,
controlled by external solenoid valves via the OptiView
Control Center.
Oil Separator
Each vessel has a refrigerant relief device(s) set at 300

PSIG (2068 kPa). A. When required by the refrigeration
safety code, each vessel has a dual refrigerant relief
device(s).
Lubrication
The main unit oil reservoir is located in the oil separator.
The compressor also has an oil reservoir located at the
rotor bearings to provide lubrication during start-up, coast
down, and in the event of a power failure. During operation, system pressure differential provides proper oil flow
without the need of an auxiliary oil pump. This minimizes
energy consumption.
The chiller is shipped with a 3 Micron absolute oil filter,
ensuring a clean oil system and superior compressor
life. An external, replaceable cartridge oil filter is supplied
with manual isolation stop valves for ease of servicing.
An optional dual oil filter housing with isolation valves is
available on all units. This allows immediate switching
from one filter to the other, eliminating downtime during
filter changes. The off-line oil filter can be changed during
chiller operation.
A 500 watt (115 volt - 1-phase - 60/50Hz) immersion
oil heater is located in the oil separator reservoir, temperature actuated to efficiently remove refrigerant from
the oil. Oil heater power supply is factory wired from
the control panel. A factory-piped refrigerant-cooled oil
cooler is provided as standard. No auxiliary water piping is required. An oil eductor automatically removes oil
which may have migrated to the evaporator and returns
it to the compressor.
13
FORM 160.80-EG1 (210)
Mechanical Specifications - continued

MOTOR DRIVELINE
Evaporator
The compressor motor is an open drip-proof, squirrel

cage, induction type constructed to Johnson Controls
design specifications. 60 Hertz motors operate at 3750
RPM; 50 Hertz motors operate at 2975 RPM. The open
motor is provided with a D-Flange and is factory-mounted
to a cast-iron adaptor mounted on the compressor. This
unique design allows the motor to be rigidly coupled to
the compressor to provide factory alignment of motor and
compressor shafts.
The evaporator is a shell and tube, flooded type heat exchanger. A distributor trough provides uniform distribution
of refrigerant over the entire shell length to yield optimum
heat transfer. A suction baffle or aluminum mesh eliminators are located above the tube bundle to prevent liquid
refrigerant carryover into the compressor. A 11/2 liquid
level sight glass is conveniently located on the side of the
shell to aid in determining proper refrigerant charge. The
evaporator shell contains a dual refrigerant relief valve
arrangement set at 180 PSIG (1241 kPa); or single-relief
valve arrangement, if the chiller is supplied with the optional refrigerant isolation valves. A 1 refrigerant charging
valve is provided.
Motor drive shaft is directly connected to the compressor shaft with a flexible disc coupling. Coupling has all
metal construction with no wearingparts to assure long
life. Additionally, no lubrication is required providing low
maintenance.
For units utilizing remote electro-mechanical starters,
a large steel terminal box with gasketed front access
cover is provided for field connected conduit. There are
six terminals (three for medium voltage) brought through
the motor casing into the terminal box. Jumpers are furnished for three-lead type of starting. Motor terminal lugs
are not furnished. Overload/overcurrent transformers are
furnished with all units. For units furnished with factorypackaged Solid State Starters, refer to the Accessories
and Modifications section (page 17).
HEAT EXCHANGERS
Shells
Evaporator and condenser shells are fabricated from
rolled carbon steel plates with fusion welded seams. Carbon steel tube sheets are drilled and welded to the end
of each shell. Intermediate tube supports are fabricated
from carbon steel plates, drilled and reamed to eliminate
sharp edges, and spaced no more than four feet apart.
The refrigerant side of each shell is designed, tested, and
stamped in accordance with ASME Boiler and Pressure
Vessel Code, Section VIII Division I, or other pressure
vessel code as appropriate.
Tubes
Heat exchanger tubes are state-of-the-art, high efficiency,
externally and internally enhanced type to provide optimum performance. Tubes in both the evaporator and
condenser are 3/4 O.D. copper alloy and utilize the
skip-fin design, providing a smooth internal and external
surface at each intermediate tube support. This provides
extra wall thickness (up to twice as thick) and non-work
hardened copper at the support location, extending the
life of the heat exchangers. Each tube is roller expanded
into the tube sheets providing a leak-proof seal, and is
individually replaceable.
14
Condenser
The condenser is a shell and tube type, with a discharge
gas baffle to prevent direct high velocity impingement on
the tubes. The baffle is also used to distribute the refrig
erant gas flow properly for most efficient heat transfer.
An integral subcooler is located at the bottom of the
condenser shell providing highly effective liquid refriger
ant subcooling to provide the highest cycle efficiency. The
condenser contains dual refrigerant relief valves set at
235 PSIG (1620 kPa).
Water Boxes
The removable water boxes are fabricated of steel. The
design working pressure is 150 PSIG (1034 kPa) and the
boxes are tested at 225 PSIG (1551 kPa). Integral steel
water baffles are located and welded within the water box
to provide the required pass arrangements. Stubout water
nozzle connections with ANSI/AWWA C-606 grooves are
welded to the water boxes. These nozzle connections
are suitable for ANSI/AWWA C-606 couplings welding or
flanges, and are capped for shipment. Plugged 3/4 drain
and vent connections are provided in each water box.
REFRIGERANT FLOW CONTROL
The YS Chiller is equipped with a refrigerant metering
device consisting of a fixed orifice and bypass solenoid
valve, which automatically adjusts to all real-world operating conditions. This control ensures proper refrigerant flow
to the evaporator over a wide range of operating conditions, including thermal storage applications and chilled
water reset. Valve operation is programmable and can
be customized for a specific application via the control
panel keyboard.
REFRIGERANT ISOLATION
The condenser shell serves as a refrigerant receiver
to store the system charge during servicing. Manually
operated isolation valves are located at the inlet and
outlet of the condenser. Valves are also provided to faJOHNSON CONTROLS
FORM 160.80-EG1 (210)
cilitate removal of the refrigerant from the system when

necessary.
General
Evaporator and Condenser Saturation Tem

perature
Oil Pressure at Compressor and Oil Filter
Differential
Percent Motor Current
The chiller is controlled by a stand-alone microprocessorbased control center. The chiller control panel provides
control of chiller operation and monitoring of chiller sensors, actuators, relays and switches.
Evaporator and Condenser Saturation Tem

perature
Control Panel
Percent Slide Valve Position
The control panel includes a 10.4 inch diagonal color liquid

crystal display (LCD) surrounded by soft keys, which
are redefined based on the screen displayed at that time,
mounted in the middle of a keypad interface and installed
in a locked enclosure. The screen details all operations
and parameters, using a graphical representation of the
chiller and its major components. Panel verbiage is available in other languages as an option with English always
available. Data can be displayed in either English or Metric
units. Smart Freeze Point Protection will run the chiller at
36F (2.22C) leaving chilled water temperature and not
experience nuisance trips on low water temperature. The
sophisticated program and sensor monitors the chiller water temperature to prevent freeze-up. When needed, Hot
Gas Bypass is available as an option. The panel displays
countdown timer messages so the operator knows when
functions are starting and stopping. Every programmable
point has a pop-up screen with the ranges included, so
the chiller can not be programmed to operate outside of
its design limits.
Operating Hours
The control panel includes a thermal ice storage control

mode which enhances system performance during ice
building operation when compared to standard cooling
logic. In thermal storage control mode, the chiller will
operate at 100% load until the setpoint shutdown temperature is reached. To add greater operating flexibility
and eliminate unnecessary chiller cycling, two different
Low Water (Liquid) Temperature Restart Thresholds are
programmable, one for the ice mode and one for the standard cooling mode. The chiller has the capability to remain
in the standard control mode for temperatures between
20F to 70F (6.7C to 21.1C) for applications involving
a process cooling duty that requires leaving chilled liquid
temperature setpoint control.
The chiller control panel also provides:
1. System operating information including:
Return and Leaving Chilled Water Temperature
Return and Leaving Condenser Water Tem
perature
JOHNSON CONTROLS
Compressor Discharge Temperature

Oil Temperature
Number of Unit Starts

2. Digital Programming of Setpoints Through The Universal Keypad Including:
Leaving Chilled Water Temperature
Percent Current Limit
Pull-Down Demand Limiting
Six-Week Schedule For Starting and Stopping
The Chiller, Pumps and Tower
Remote Reset Temperature Range
3. Status Messages Indicating:
System Ready To Start
System Running
System Coastdown
System Safety Shutdown Manual Restart
System Cycling Shutdown Auto Restart
System Prelube
Start Inhibit
4. The text displayed within the system status and system details field is displayed as a color-coded message to indicate severity: red for safety fault; orange
for cycling faults; yellow for warnings; and green for
normal messages.
5. Safety shutdowns are enunciated through the display
and the status bar, and consist of system status, system details, day, time, cause of shutdown, and type of
restart required. Safety shutdowns with a fixed speed
drive include:
Evaporator Low Pressure
Evaporator Low Pressure - Smart Freeze
Evaporator Transducer or Leaving Liquid
Probe
Evaporator Transducer or Temperature Sen-
sor
Condenser High Pressure Contacts Open
Condenser High Pressure
15
FORM 160.80-EG1 (210)
Mechanical Specifications - continued

Condenser Pressure Transducer Out Of
Range
Requesting Fault Data
Auxiliary Safety Contacts Closed
Power Fault
Discharge High Temperature

Discharge Low Temperature
Oil Low Differential Pressure
Oil Low Differential Seal Pressure
Oil Or Condenser Transducer Error
Oil Clogged Filter
Oil High Pressure
Oil Separator Low Level
Watchdog Software Reboot
5.1 Safety shutdowns with a Solid State Starter (LCSSS)
include:
Shutdown Requesting Fault Data...
High Instantaneous Current
High Phase (X) Heatsink Temperature Run
ning
105% Motor Current Overload
Motor Or Starter Current Imbalance
Phase (X) Shorted SCR
Open SCR
Phase Rotation
6. Cycling shutdowns enunciated through the display
and the status bar, and consists of system status,
system details, day, time, cause of shutdown, and
type of restart required.
Cycling shutdowns with a fixed speed drive include:
Multiunit Cycling Contacts Open
System Cycling Contacts Open
Leaving Chilled Liquid Low Temperature
Leaving Chilled Liquid Flow Switch Open
Condenser Flow Switch Open
Motor Controller Contacts Open
Motor Controller Loss Of Current
Stop Contacts Open

Low Phase (X) Temperature Sensor
Run Signal
Invalid Current Scale Selection
Phase Locked Loop
Low Supply Line Voltage
High Supply Line Voltage
Logic Board Processor
Logic Board Power Supply
Phase Loss
7. Security access to prevent unauthorized change of
setpoints, to permit local or remote control of the
chiller, and to allow manual operation of the prerotation vanes and oil pump. Access is through ID and
password recognition, which is defined by three
different levels of user competence: view, operator,
and service.
8. Trending data with the ability to customize points of
once every second to once every hour. The panel
will trend up to 6 different parameters from a list of
over 140, without the need of an external monitoring
system.
9. The operating program is stored in nonvolatile
memory (EPROM) to eliminate reprogramming the
chiller due to AC power failure or battery discharge.
Programmed setpoints are retained in lithium batterybacked RTC memory for a minimum of 11 years
with power removed from the system.
10. A fused connection through a transformer in the
compressor motor starter to provide individual
overcurrent protected power for all controls.
11. A numbered terminal strip for all required field interlock wiring.
12. An RS232 port to output all system operating data,
shutdown/cycling message, and a record of the last 10
cycling or safety shutdowns to a fieldsupplied printer.
Data logs to a printer at a set programmable
interval. This data can be pre-prograrnmed to print
from 1 minute to 1 day.
Power Fault
13. The capability to interface with a building automation

system to provide:
Control Panel Schedule
remote chiller start and stop
6.1 Cycling shutdowns with a Solid State Starter (LCSSS)

include:
remote leaving chilled liquid temperature adjust
Initialization Failed
Serial Communications
16
remote current limit setpoint adjust

remote ready to start contacts
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
safety shutdown contacts

run contacts
LCWT setpoint temperatures desired. At any time, these

setpoints can be changed either manually in the chiller
control panel, via a software input (LON, BACNET, etc.)
or hardwired input (4-20 mA/0-10V) signal.
HEAT PUMP CONTROL LOGIC
CODES AND STANDARDS
General: The Optiview control panel will be supplied with

three available operating modes, chilled water mode, heat
pump mode, and auto mode.
ASME Boiler and Pressure Vessel Code Section

Vlll Division 1.
AHRI Standard 550/590
c/U.L. Underwriters Laboratory
ASHRAE 15 Safety Code for Mechanical Refrigeration
ASHRAE Guideline 3 Reducing Emission of Halogenated Refrigerants in Refrigeration and Air-Conditioning Equipment and Systems
NEC National Electrical Code
OSHA Occupational Safety and Health Act
cycling shutdown contacts
CHILLED WATER MODE

The compressor will load and unload to maintain the
LEWT setpoint as in a WATER CHILLER. The LCWT will
float uncontrolled and be determined by the compressor
loading required to satisfy the LEWT setpoint.
HEAT PUMP MODE
The compressor will load and unload to maintain the
LCWT setpoint as in a HEAT PUMP. The LEWT will float
uncontrolled and be determined by the compressor loading required to satisfy the LCWT setpoint.
AUTO MODE
The automatic mode will optimize the operation of the
YS chiller/heat pump as the primary cooling source in
the winter and the primary heating source in the summer. This automatic mode will eliminate the need for the
chiller plant control system to switch between cooling
and heating control. The user will establish setpoints for
leaving evaporator water temperature (LEWT) and leaving condenser water temperature (LCWT). At start-up,
the control panel will load the machine until one of the
setpoints (LEWT or LCWT) is reached and control to that
parameter, as described below.
If the LEWT setpoint is satisfied first (indicating that the
heat pump chiller can produce all of the cooling required
by the system), the unit will load and unload to maintain
the LEWT as in a WATER CHILLER. The LCWT will float
uncontrolled and be determined by the compressor loading required to satisfy the LEWT setpoint.
If the LCWT setpoint is satisfied first, (indicating that the
heat pump chiller can produce all of the heat required
by the system), the unit will load and unload to maintain
the LCWT, as in a HEAT PUMP. The LEWT will float uncontrolled and be determined by the compressor loading
required to satisfy the LCWT setpoint.
In either scenarioo, there is no need for the user to select
an operating mode; only to determine the LEWT and
JOHNSON CONTROLS
ISOLATION MOUNTING
The unit is provided with four vibration isolation mounts
consisting of 1 (25.4 mm) thick neoprene isolation pads
for field mounting under the steel mounting pads located
on the tube sheets.
REFRIGERANT CONTAINMENT
The standard unit has been designed as a complete and
compact factory packaged chiller. As such, it has mini
mum joints from which refrigerant can leak. The entire
assembly has been thoroughly leak tested at the factory
prior to shipment. The YORK chiller includes service
valves conveniently located to facilitate transfer of refrig
erant to a remote refrigerant storage/recycling system.
Optional condenser isolation valves permit storage of the
charge in the condenser.
PAINT
Exterior surfaces are protected with one coat of Carib
bean blue, durable alkydmodified, vinyl enamel, ma
chinery paint.
SHIPMENT
Protective covering is furnished on the motor, Control
Center and unitmounted controls. Water nozzles are
capped with fitted plastic enclosures.
17
FORM 160.80-EG1 (210)
Accessories and Modifications

SOLID STATE STARTER
The Solid State Starter is a reduced voltage starter that
controls and maintains a constant current flow to the motor
during startup. It is compact and mounted on the chiller at
the motor terminals. Power and control wiring is factory
supplied. Available for 200-600 volts, the starter enclosure
is NEMA-1 with a hinged access door with lock and key.
Electrical lugs for incoming power wiring are provided.
Standard features include: digital readout at the OptiView
Control Center of the following:
Display Only:
3-phase voltage A, B, C

3-phase current A, B, C
Input power (kW)
kW Hours
Starter Model
Motor Run (LED)
Programmable:

Other features include: low line voltage; 115-volt control

transformer; three-leg sensing overloads; phase rotation
and single-phase failure protection; high temperature
safety protection; motor current imbalance and undervoltage safeties; open and close SCR protection; momentary
power interruption protection. The LCSSS is cooled by a
closed-loop, fresh water circuit consisting of a water-towater heat exchanger and 1/25 HP circulating pump. All
interconnecting water piping is factory installed and rated
for 150 PSIG working pressure. Optional unit-mounted
circuit breaker includes ground fault protection and
provides 65,000 amp short-circuit withstand rating in accordance with UL Standard 508. A non-fused disconnect
switch is also available. Both options are padlockable.
BAS REMOTE CONTROL
A communication interface permitting complete exchange
of chiller data with any BAS system is available with
18
optional ISN translator. ISN translator also allows BAS

system to issue commands to the chiller to control its
operation. ISN translators come in two models, controlling
up to four chillers and eight chillers respectively.
FACTORY INSULATION OF COOLER
Factory-applied thermal insulation of the flexible, closedcell plastic type, 3/4 (19mm) thick is attached with vapor-proof cement to the evaporator shell, flow chamber,
evaporator tube sheets, suction connection, and (as
necessary) to the auxiliary tubing. Not included is the
insulation of water boxes and nozzles. This insulation
will normally prevent condensation in environments with
relative humidities up to 75% and dry bulb temperatures
ranging from 50 to 90F (10 to 32C). 1-1/2 (38mm)
thick insulation is also available for relative humidities up
to 90% and dry bulb temperatures ranging from 50 to
90F (10 to 32C).
WATER FLANGES
Four 150 Ib. ANSI raised-face flanges, for condenser and
evaporator water connections, are factory welded to water
nozzles. Companion flanges, bolts, nuts and gaskets are
not included.
SPRING ISOLATION MOUNTING
Spring Isolation mounting is available instead of standard
isolation mounting pads when desired. Four level-adjusting/spring-type vibration isolator assemblies with non-skid
pads are provided with mounting brackets for field installation. Isolators are designed for one-inch (25.4mm)
deflection.
WATER FLOW SWITCHES
Paddle-type, vapor-proof water flow switches suitable
for 150 psig (1034 KPa) DWP for chilled and condenser
water circuits. Switch for 115V-1-50/60 Hz service. A
chilled water flow switch is required. Condenser water
flow switch is optional.
STARTER FIELD INSTALLED
A field installed, electro-mechanical compressor motor
starter is available, selected for proper size and type for
job requirements and in accordance withJohnson Controls
Engineering Standard R-1079 for Starters.
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
MARINE WATER BOXES

Marine water boxes allow service access for cleaning of
the heat exchanger tubes without the need to break the
water piping. Bolted-on covers are arranged for convenient access. ANSI/AWWA C-606 nozzle connections are
standard; flanges are optional. Marine water boxes are
available for condenser and/or evaporator.
KNOCK-DOWN SHIPMENT
The chiller can be shipped knocked-down into major
assemblies (evaporator, condenser, driveline, etc.) as
required to rig into tight spaces. This is particularly conve-
JOHNSON CONTROLS
nient for existing buildings where equipment room access

does not allow rigging a factory packaged chiller.
REFRIGERANT STORAGE/RECYCLING SYSTEM
A refrigerant storage/recycling system is a self-contained
package consisting of a refrigerant compressor with oil
separator, storage receiver, water-cooled condenser, filter
drier and necessary valves and hoses to remove, replace
and distill refrigerant. All necessary controls and safety
devices are a permanent part of the system. Typically not
required if unit isolation valves are provided.
19
Unit Components
20
FORM 160.80-EG1 (210)
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
OIL SEPARATOR
MOTOR
TERMINAL
BOX
29040A
CONDENSER
REAR VIEW
JOHNSON CONTROLS
21
FORM 160.80-EG1 (210)
Application Data
The following is a users guide in the application and
installation of Chillers, and will ensure the reliability and
trouble-free life for which this equipment was designed.
While this guide is directed towards normal, water-chilling
applications, the Johnson Controls sales representatives
can provide complete recommendations on other types
of applications.
Location
Chillers are virtually vibration-free and generally can be
located at any level in a building where the construction
will support the total system operating weight.
The unit site must be a floor, mounting pad or foundation
which is level within 1/4 (6.4 mm) and capable of supporting the operating weight of the chiller.
Sufficient clearance to permit normal service and maintenance work should be provided all around and above the
unit. Additional space should be provided at one end of
the unit to permit cleaning of evaporator and condenser
tubes as required. A doorway or other properly located
opening may be used.
The chiller should be installed in an indoor location
where temperatures range from 40F to 110F (4.4C to
43.3C).
Water Circuits
Flow Rate For normal water chilling duty, evaporator
flow rates are permitted at water velocity levels in the
heat exchangers tubes of between 3 ft./second and 12
ft./second (0.91 m/s and 3.66 m/s). Condenser flow rates
are permitted between 3.33 ft./sec. and 12 ft./sec. (1.01
TABLE 1 WATER FLOW RATE LIMITS GPM (l/s)

SHELL
CODE
BA
BB
CA
CB
DA
DB
DC
EA
EB
EC
FA
FB
FC
22
EVAPORATOR
PASS
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
308
147
97
412
197
130
535
256
171
700
335
223
664
317
212
943
451
301
1257
602
399
637
317
212
904
452
301
1203
602
399
1203
602
399
1605
802
534
2136
1068
710
MINIMUM
19
9
6
26
12
8
34
16
11
44
21
14
42
20
13
59
28
19
79
38
25
40
20
13
57
29
19
76
38
25
76
38
25
101
51
34
135
67
45
CONDENSER
MAXIMUM
1173
74
586
37
387
24
1572
99
786
50
516
33
2041
129
1020
64
680
43
2675
169
1337
84
891
56
2534
160
1267
80
844
53
3602
227
1793
113
1195
75
4810
303
2405
152
1595
101
2546
161
1267
80
844
53
3613
228
1805
114
1196
75
4810
303
2405
152
1595
101
4810
303
2405
152
1595
101
6418
405
3202
202
2135
135
8541
539
4270
269
2839
179
399
209
510
264
677
355
880
455
1215
630
1595
820
1223
639
1602
828
2019
1043
2726
1397
MINIMUM
25
13
32
17
43
22
56
29
77
40
101
52
77
40
101
52
127
66
172
88
MAXIMUM
1435
91
751
47
1830
115
948
60
2438
154
1277
81
3164
200
1639
103
4376
276
2269
143
5740
362
2950
186
4406
278
2300
145
5770
364
2982
188
7267
458
3755
237
9822
620
5030
317
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
m/s and 3.66 m/s). Variable flow applications are possible,

and initial chiller selections should be made accordingly to
permit proper range of flow while maintaining the minimum
velocity noted above. Variable flow in the condenser is not
recommended, as it generally raises the energy consumption of the system by keeping the condenser pressure
high in the chiller. Additionally, the rate of fouling in the
condenser will increase at lower water velocities associated with variable flow, raising system maintenance costs.
Cooling towers typically have narrow ranges of operation
with respect to flow rates, and will be more effective with
full design flow. Ref. Table 1 for flow limits.
line as close as possible to the chiller. An overhead monorail

or beam may be used to facilitate servicing.
Temperature Ranges For normal water chilling duty,

leaving chilled water temperatures may be selected
between 38F (3.3C) [36F (2.2C) with Smart Freeze
enabled) and 70F (21.1C) for water temperature ranges
between 3F and 30F (1.7C and 16.7C).
Chilled Water A flow switch must be installed in the

chilled water line of every unit. The switch must be located
in the horizontal piping close to the unit, where the straight
horizontal runs on each side of the flow switch are at least
five pipe diameters in length. The switch must be electrically connected to the chilled water interlock position in
the unit control center. A water strainer of maximum 1/8
(3.2 mm) perforated holes must be field-installed in the
chilled water inlet line as close as possible to the chiller.
If located close enough to the chiller, the chilled water
pump may be protected by the same strainer. The flow
switch and strainer assure chilled water flow during unit
operation. The loss or severe reduction of water flow could
seriously impair the chiller performance or even result in
tube freeze up.
Water Quality The practical and economical application of liquid chillers requires that the quality of the water
supply for the condenser and evaporator be analyzed by
a water treatment specialist. Water quality may affect the
performance of any chiller through corrosion, deposition of
heat-resistant scale, or sedimentation or organic growth.
These will degrade chiller performance and increase operating and maintenance costs. Normally, performance
may be maintained by corrective water treatment and
periodic cleaning of tubes. If water conditions exist which
cannot be corrected by proper water treatment, it may be
necessary to provide a larger allowance for fouling, and/or
to specify special materials of construction.
General Piping All chilled water and condenser water
piping should be designed and installed in accordance
with accepted piping practice. Chilled water and condenser water pumps should be located to discharge
through the chiller to assure positive pressure and flow
through the unit. Piping should include offsets to provide
flexibility and should be arranged to prevent drainage of
water from the evaporator and condenser when the pumps
are shut off. Piping should be adequately supported and
braced independently of the chiller to avoid the imposition of strain on chiller components. Hangers must allow
for alignment of the pipe. Isolators in the piping and in
the hangers are highly desirable in achieving sound and
vibration control.
Convenience Considerations To facilitate the performance of routine maintenance work, some or all of the
following steps may be taken by the purchaser. Cooler and
condenser water boxes are equipped with plugged vent and
drain connections. If desired, vent and drain valves may be
installed with or without piping to an open drain. Pressure
gauges with stop cocks, and stop valves, may be installed
in the inlets and outlets of the condenser and chilled water
JOHNSON CONTROLS
Connections The standard chiller is designed for 150

psig (1034 kPa) design working pressure in both the
chilled water and condenser water circuits. The connections (water nozzles) to these circuits are furnished with
grooves for ANSI/AWWA C-606 couplings. Piping should
be arranged for ease of disassembly at the unit for tube
cleaning. All water piping should be thoroughly cleaned
of all dirt and debris before final connections are made
to the chiller.
Condenser Water The chiller is engineered for maximum efficiency at both design and part-load operation
by taking advantage of the colder cooling tower water
temperatures which naturally occur during the winter
months. Appreciable power savings are realized from
these reduced heads.
The minimum entering condenser water temperature for
other full and part load conditions is provided by the following equation:
For R-134a; Min ECWT = LCHWT + 16 + [(% load/100)

x

(10 - full load condenser water T)]
Where: ECWT = entering condenser water tempera-

ture

LCHWT = leaving chilled water temperature
MULTIPLE UNITS
Selection Many applications require multiple units to
meet the total capacity requirements as well as to provide
flexibility and some degree of protection against equipment shutdown. There are several common unit arrangements for this type of application. The Chiller has been
designed to be readily adapted to the requirements of
23
FORM 160.80-EG1 (210)
Application Data - continued

these various arrangements.
Parallel Arrangement (Refer to Fig. 1) Chillers may
be applied in multiples with chilled and condenser water
circuits connected in parallel between the units. Fig. 1 represents a parallel arrangement with two chillers. Parallel
chiller arrangements may consist of equally or unequally
sized units. When multiple units are in operation, they
will load and unload at equal percentages of design full
load for the chiller.
Depending on the number of units and operating characteristics of the units, loading and unloading schemes
should be designed to optimize the overall efficiency of
the chiller plant. It is recommended to use an evaporator by-pass piping arrangement to bypass fluid around
evaporator of any unit which has cycled off at reduced load
conditions. It is also recommended to alternate the chiller
cycling order to equalize chiller starts and run hours.
Series Arrangement (Refer to Fig. 2) The chillers may
be applied in pairs with chilled water circuits connected in
series and condenser water circuits connected in parallel.
All of the chilled water flows through both evaporators
with each unit handling approximately one-half of the
total load. When the load decreases to a customer selected load value, one of the units will be shut down by a
sequence control. Since all water is flowing through the
operating unit, that unit will cool the water to the desired
temperature.
BRINE APPLICATIONS
The YS Screw Chiller, utilizing the Frick Refrigeration compressor, is a good match for the high head requirements of
low temperature brine applications. This is particularly true
of thermal ice storage systems, typically requiring 22F
(5.6C) to 24F (4.4C) leaving brine temperatures.
This performance is enhanced with the standard thermal

storage control mode described on page 6.
Particular attention must be paid to the application of
two or more chillers with evaporators in parallel or series
when the brine temperature is below 32F (0C). The
brine MUST NOT flow through the evaporator of the
idle chiller, because it can cause the condenser water to
freeze. A bypass or other type of arrangement is required
that shuts off flow to the idle evaporator. When units are
applied in series with lead/lag capability, the units should
be identical.
REFRIGERANT RELIEF PIPING
Each chiller is equipped with pressure relief devices. The
purpose of the relief devices is to quickly relieve excess
pressure of the refrigerant charge to atmosphere, as a
safety precaution in the event of an emergency such as
a fire. They are set to relieve at an internal pressure of
300 psig (2069 KPa) and are located on the condenser,
evaporator and oil separator; and are provided in accordance with ASHRAE 15 Safety Code and ASME or
applicable pressure vessel code. When required and designated on the order form, the relief devices will satisfy the
European requirements: (example VBG20). Under these
circumstances the relief devices may be relief valves,
overflow valves or type tested Safety Pressure switches
or a combination of these devices.
Sized to the requirements of applicable codes, a vent line
must run from the relief device to the outside of the building. This refrigerant relief piping must include a cleanable,
vertical-leg dirt trap to catch vent-stack condensation.
Vent piping must be arranged to avoid imposing a strain
on the relief connections and should include one flexible
connection.
SOUND AND VIBRATION CONSIDERATIONS
A YS chiller is not a source of objectionable sound and
FIG. 1 PARALLEL COOLERS

PARALLEL CONDENSERS
24
FIG. 2 SERIES COOLERS

PARALLEL CONDENSERS
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
vibration in normal air conditioning applications. Neoprene

isolation mounts are furnished as standard with each
unit. Optional level-adjusting spring isolator assemblies
designed for 1 static deflection are available.
The chiller sound pressure level ratings will be furnished
upon request.
Control of sound and vibration transmission must be taken
into account in the equipment room construction as well
as in the selection and installation of the equipment.
THERMAL INSULATION
No appreciable operating economy can be achieved by
thermally insulating the chiller. However, the chillers
cold surfaces should be insulated with a vapor barrier
insulation sufficient to prevent condensation. A chiller can
be factory insulated with 3/4 (19mm) or 1-1/2 (38mm)
thick insulation, as an option. This insulation will normally
prevent condensation in environments with dry bulb temperatures of 50F to 90F (10C to 32C) and relative
humidities up to 75% [3/4 (19mm) thickness] or 90% [11/2 (38mm) thickness]. The insulation is painted and the
surface is flexible and reasonably resistant to wear. It is
intended for a chiller installed indoors and, therefore, no
protective covering of the insulation is usually required.
If insulation is applied to the water boxes at the job site,
it must be removable to permit access to the tubes for
routine maintenance.
VENTILATION
The ASHRAE Standard 15 Safety Code for Mechanical
Refrigeration requires that all machinery
rooms be vented
Sheet1
TABLE 2 MOTOR VOLTAGE VAHRIATIONS
Freq
60Hz
50Hz
Operating Voltage
Rated Voltage
Nameplate
Voltage
Min.
Max.
200
200/208
180
220
230
220/240
208
254
380
380
342
415
416
416
375
457
460
440/460/480
414
508
575
575/600
520
635
2300
2300
2070
2530
3300
3300
2970
3630
4000
4000/4160
3600
4576
346
346
311
381
380
380/400
342
423
415
415
374
440
3300
3300
2970
3630
JOHNSON CONTROLS
to the outdoors utilizing mechanical ventilation by one or

more power-driven fans. This standard, plus National Fire
Protection Association Standard 90A, state, local and other related codes should be reviewed for specific requirements. Since the chiller motor is air-cooled, ventilation
should allow for the removal of heat from the motor.
In addition, the ASHRAE Standard 15 requires a refrigerant vapor detector to be employed for all refrigerants. It is
to be located in area where refrigerant from a leak would
be likely to concentrate. An alarm is to be activated and
the mechanical ventilation started at a value no greater
than the TLV (Threshold Limit Value) of the refrigerant.
ELECTRICAL CONSIDERATIONS
Motor Voltage Low voltage motors (200 - 600 volts) are
furnished with six leads. Medium voltage (2300 - 4160
volts) motors have three leads. Motor circuit conductor
size must be in accordance with the National Electrical
Code (NEC), or other applicable codes, for the motor
full-load amperes (FLA). Flexible conduit should be used
for the last several feet to the chiller in order to provide
vibration isolation. Table 2 lists the allowable variation in
voltage supplied to the chiller motor. The unit nameplate
is stamped with the specific motor voltage and frequency
for the appropriate motor.
Starters The chiller is available with a factory-mounted
and wired YORK Solid State Starter for 200 - 600 volt
applications. Other types of remote mounted starters are
available. These electro-mechanical starters must be
furnished in accordance with Johnson Controls Standard
R-1079 Specification. This will ensure that starter components, controls, circuits, and terminal markings will be
suitable for required overall system performance.
Controls A 115 volt, single phase, 60 or 50 Hertz (4.5
kVa) power supply must be furnished to the chiller from a
separate, fused disconnect or from a control transformer
included as an option with electro-mechanical starters.
No field control wiring is required, when the YORK SSS
is supplied.
Copper Conductors Only copper conductors should be
connected to compressor motors and starters. Aluminum
conductors have proven to be unsatisfactory when connected to copper lugs. Aluminum oxide and the difference
in thermal conductivity between copper and aluminum
cannot guarantee the required tight connection over a
long period of time.
Power Factor Correction Capacitors Capacitors can
be applied to a chiller for the purpose of power factor correction. For remote-Mounted Electro-Mechanical Starters,
the capacitors should be located on the load side of the
starter. For YORK SSS, the capacitors must be located on
the line side of the starter. The capacitors must be sized
25
FORM 160.80-EG1 (210)

and installed to meet the National Electrical Code (NEC)
and be verified by JOHNSON CONTROLS.
Ampacity on Load Side of Starter Electrical power
wire size to the chiller is based on the minimum unit ampacity. For YORK SSS, this wiring is done at the factory.
For remote starters, the National Electrical Code defines
the calculation of ampacity, as summarized below. More
specific information on actual amperage ratings will be
supplied with the submittal drawings.
Six-lead type of starting (Star-Delta)

Minimum circuit ampacity per conductor (1 of 6):

Ampacity = .721 x compressor motor amps.
Three-lead type of starting

(Across-the-Line, Autotransformer and
Primary Reactor)

Minimum circuit ampacity per conductor (1 of 3):

Ampacity = 1.25 x compressor motor amps.
Ampacity on Line Side of Starter

The only additional load on the circuit for the chiller would
be the control transformer, unless it is supplied by a
separate source.

125% of compr. +
FLA of all other
Min. Circuit Ampacity =
motor amps
loads on the circuit
submittal drawings for the specific calculations for each

application.
MOTOR ELECTRICAL DATA
The smallest motor available which equals or exceeds
the Input power (kW) from the chiller rating program is
selected from Tables 3 and 4. The full load amperes (FLA)
listed in the tables are maximum values and correspond
to the maximum motor kW listed. When the Input power
(kW) is less than maximum motor kW, the FLA should be
reduced using the following equation:
FLA
=

Motor kW
Max. Motor kW
Max. Motor FLA
The benefit from the FLA correction is the possible use of

smaller power wiring and/or starter size.
The locked rotor amperes (LRA) are read directly from
Tables 3 and 4 for specific Motor Code and voltage. This
is because the LRA is dependent only on motor size and
voltage and is independent of input power (kW).
Inrush amperes (IRA) depend on LRA and the type of
starter applied. The inrush can be calculated using a
percentage of LRA shown in Table 5.
Branch Circuit Overcurrent Protection The branch

circuit overcurrent protection device(s) should be a
time-delay type, with a minimum rating equal to the next
standard fuse/breaker rating above the calculated value.
It is calculated taking into account the compressor motor
amps and may also include control transformer. Refer to
26
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
TABLE 3 60 HZ ELECTRICAL DATA
Sheet1
MOTOR CODE
CF
CG
CH
CJ
CK
CL
CM
CN
CP
CR
CS
CT
CU
CV
CW
CX
CY
CZ
KW (MAX.)
125
144
161
190
214
240
257
276
302
333
368
395
435
478
514
542
578
617
SHAFT HP
154
FL EFF. %
92
177
92
201
93
237
93
270
94
302
94
327
95
351
95
385
95
424
95
468
95
503
95
554
95
608
95
655
95
690
95
740
95.5
790
95.5
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
FL PF
0.9
VOLTS
FLA
208
LRA
389
447
507
594
680
757
799
886
975
1043
1162
2702
3235
3235
3962
4732
5096
5689
6011
6011
7644
8106
FLA
352
404
464
540
610
685
749
804
882
944
1050
1130
1250
LRA
2598
2598
2865
3460
3788
4260
4755
5162
5780
5780
6900
7400
7724
FLA
337
387
445
518
585
656
718
771
845
905
1006
1083
1198
LRA
2711
2711
3120
3610
3953
4445
4962
5386
6031
6031
7200
7722
8060
230
240
380
416
440
FLA
217
249
285
336
378
421
453
487
534
571
636
684
756
817
879
942
997
1065
LRA
1385
1385
1730
2153
2500
2577
2955
3254
3637
3810
4179
4480
4671
5326
5780
6782
5780
6644
FLA
199
228
260
307
346
385
412
445
488
522
581
625
691
747
810
860
911
973
LRA
1385
1385
1638
1967
2190
2356
2700
2976
3536
3637
3810
3810
4270
4869
5640
5780
5694
6069
FLA
184
211
238
281
319
358
392
397
461
493
549
591
646
706
759
813
861
920
LRA
1177
1301
1320
1655
1865
2037
2485
2485
2976
2976
3300
3644
3644
4209
4783
5357
4783
5249
FLA
176
202
228
269
305
342
375
380
441
472
525
565
618
675
726
778
824
880
LRA
1230
1360
1380
1730
1950
2130
2598
2598
3111
3111
3450
3810
3810
4400
5000
5600
5000
5488
FLA
169
194
219
258
292
328
359
364
423
452
503
541
592
647
696
746
790
843
LRA
1283
1419
1440
1805
2035
2223
2711
2711
3246
3246
3600
3976
3976
4591
5217
5843
5217
5727
FLA
141
162
185
216
250
274
300
318
353
377
420
452
500
540
581
622
659
704
LRA
909
909
1100
1384
1556
1700
1900
2066
2078
2413
2760
2960
3089
3550
4039
4440
4300
4200
FLA
135
155
177
207
240
263
288
305
338
361
403
433
479
518
557
596
632
675
LRA
949
949
1148
1444
1624
1774
1983
2156
2168
2518
2880
3089
3223
3704
4215
4633
4484
4383
460
480
575
600
2300
3300
4000
4160
FLA
36
41
46
54
61
68
74
79
87
95
105
113
124
135
146
154
165
176
LRA
240
267
298
340
397
435
480
520
530
570
669
719
791
867
935
960
1008
1100
FLA
25
29
32
38
43
48
52
55
61
66
73
79
86
94
102
108
115
123
LRA
160
175
210
240
280
310
310
343
382
383
466
501
551
576
652
682
719
744
FLA
21
24
27
31
36
40
43
46
50
54
60
65
71
78
84
89
95
101
LRA
135
154
166
195
230
240
260
283
315
315
384
413
455
499
538
540
554
631
FLA
20
23
26
30
34
38
41
44
48
52
58
63
68
75
81
85
91
97
LRA
140
160
173
203
239
250
270
294
328
328
399
430
473
519
560
562
576
656
NOTE: FLA = Full Load Amps; LRA = Locked Rotor Amps

TABLE 4 MOTOR STARTERS
TYPE STARTER
SOLID STATE
STARTER
Sheet1
STAR DELTA
AUTO TRANSFORMER
ACROSS THE LINE
PRIMARY REACTOR
VOLTAGE
LOW
LOW
LOW
LOW
LOW/HIGH
LOW/HIGH
LOW/HIGH
HIGH
HIGH
60HZ
200-600
200-600
200-600
200-600
200-4160
200-4160
200-4160
2300-4160
2300-4160
50 HZ
380-415
346-415
346-415
346-415
346-3300
346-3300
346-3300
2300-3300
2300-3300
TRANSITION % TAP
INRUSH AS A % OF
LRA
NONE 45
CLOSED 33
OPEN 33
CLOSED 57.7
33
CLOSED 65
42.3
CLOSED 80 64
100
CLOSED 65 65
CLOSED 80 80
JOHNSON CONTROLS
27
FORM 160.80-EG1 (210)

TABLE 5 50 HZ ELECTRICAL DATA
MOTOR
CODE
SHAFT HP
FL EFF. %
FL PF
5CC
5CD
5CE
5CF
5CG
5CH
5CI
5CJ
5CK
5CL
5CM
5CN
5CO
5CP
5CQ
5CR
5CS
121
136
160
180
201
215
231
254
280
309
332
366
402
432
455
481
518
148
168
198
225
252
272
292
321
353
390
419
462
507
546
575
608
658
91.1
92.4
92.4
93.4
93.4
94.2
94.2
94.2
94.2
94.2
94.2
94.2
94.2
94.2
94.2
94.2
94.7
0.86
0.86
0.86
0.86
0.86
0.86
0.87
0.87
0.87
0.87
0.87
0.87
0.87
0.87
0.87
0.87
0.88
VOLTS
346
380
400
415
3300
AMPERES (MAX)
FLA
224
258
302
340
380
417
437
481
528
584
630
692
578
816
860
909
982
LRA
1385
1721
1790
2208
2467
2598
2840
3081
3350
3706
3810
4177
4830
4944
5373
5780
5780
FLA
204
235
275
309
346
379
398
438
481
532
572
630
690
743
783
841
895
LRA
1385
1385
1640
1890
2144
2464
2590
2806
3050
3375
3700
3810
4400
4500
4892
5600
5491
FLA
194
223
261
294
329
360
378
416
457
505
543
599
656
706
744
799
850
LRA
1458
1458
1726
1990
2257
2594
2726
2954
3211
3553
3895
4011
4632
4737
5150
5895
5780
FLA
187
215
252
284
317
347
364
401
441
487
526
577
632
680
717
764
819
LRA
1283
1385
1490
1700
2031
2175
2366
2569
2794
3088
3402
3478
3810
4117
4480
5130
5108
FLA
24
27
32
36
41
44
47
50
56
62
66
73
80
87
91
96
103
LRA
159
162
209
236
241
274
294
318
317
388
423
455
499
516
572
614
644
NOTE: 1. Chiller performance for 50 Hertz applications is outside the scope of the AHRI Certification Program.

2. FLA = Full Load Amps; LRA = Locked Rotor Amps
TABLE 6 AVAILABLE COMPRESSOR/SHELL/MOTOR COMBINATIONS (R-134a)

COMPRESSOR
CODE
S0
S1
S2
CONDENSER
SHELL
BA, BB
BA, BB, CA, CB
CA, CB
BA, BB, CA, CB
BA, BB
MOTOR CODE
R-134A, 60 HZ
50 HZ
CF, CG, CH
5 CC, 5 CD
BA, BB, CA, CB
CF, CG, CH,
CA, CB
BA, BB, CA, CB
CJ, CK
5 CC, 5 CD, 5 CE,

5 CF
CA, CB
CA, CB, DA, DB

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

CK, CL, CM
5 CD, 5 CE, 5 CF,
DA, DB, DC
CG, CH, CJ, CK

CL, CM, CN, CP, CR
5 CF, 5 CG, 5 CH,

5 CI, 5 CJ, 5 CK
CJ, CK, CL, CM, CN, CP,
5 CF, 5 CG,
CR, CS, CT, CU, CV
5 CH, 5 CI,
CK, CL, CM, CN, CP, CR

CS, CT, CU, CV
5 CJ, 5 CK,
5 CL, 5 CM,
5 CN, 5 CO
S3
DA, DB, DC
CA, CB, DA, DB
S4
EA, EB, EC
FA, FB, FC
EA, EB, FA, FB

FA, FB
FA, FB, FC
FA, FB
S5
28
COOLER
SHELL
5 CG, 5 CH
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
TABLE 7 AVAILABLE COMPRESSOR/SHELL/MOTOR COMBINATIONS (50 HZ, R-134a ONLY)

COMPRESSOR CODE
S0
S1
S2
S3
S4
S5
JOHNSON CONTROLS
COOLER SHELL
CONDENSER SHELL
MOTOR CODE
5 CC, 5 CD
BA, BB
BA, BB, CA, CB
CA, CB
BA, BB, CA, CB
BA, BB
BA, BB, CA, CB
CA, CB
BA, BB, CA, CB
5 CC, 5 CD,
5 CE, 5 CF
BA, BB
BA, BB, CA, CB
5 CC, 5 CD,
CA, CB
BA, BB, CA, CB, DA, DB
5 CE, 5 CF,
DA, DB, DC
CA, CB, DA, DB
5 CG, 5 CH
CA, CB
CA, CB, DA, DB
5 CC, 5 CD, 5 CE, 5 CF,
DA, DB, DC
CA, CB, DA, DB
5 CG, 5 CH, 5 CI, 5 CJ, 5 CK
DA, DB, DC
CA, CB, DA, DB
5 CE, 5 CF, 5 CG, 5 CH,
EA, EB, EC
EA, EB, FA, FB
5 CI, 5 CJ, 5 CK, 5 CL,
FA, FB, FC
EA, EB, FA, FB
5 CM, 5 CN, 5 CO
EA, EB, EC
EA, EB, FA, FB
5 CF, 5 CG, 5 CH, 5 CI,
FA, FB, FC
EA, EB, FA, FB
5 CJ, 5 CK, 5 CL,

5 CM, 5 CN, 5 CO
29
FORM 160.80-EG1 (210)
Dimensions - Std
S0 - S3 COMPRESSOR
R-134a UNITS
(50 and 60 Hz)
S0 AND S1 COMPRESSOR
DIMENSION
S2 COMPRESSOR
SHELL CODES (EVAPORATOR CONDENSER)

B-B
B-C
C-B
C-C
B-B
42-7/8
B-C
C-B
C-C
C-D
52-1/2
A1
46-3/4
46-1/4
4-6-3/4
46-1/4
B OVERALL HEIGHT3
58-5/8
511-1/2
510-1/4
511-1/2
53-3/4
511-1/4
63-1/4
D-C
D-D
52-1/2
53-3/4
63-1/4
63-1/4
67-5/8
68-3/4
C COOLER C/L
11-7/8
15
15
D CONDENSER C/L
011-5/8
12-1/4
12-1/4
69-3/8
Refer to Tables 6 and 7 on pages 26 & 27 for valid compressor/shell/motor combinations.
REFRIGERANT RELIEF VALVE CONNECTIONS

SHELL CODE
EVAPORATOR SIZE
B, C
3/4 FPT SINGLE
CONDENSER SIZE
3/4 FPT DUAL
1 FPT SINGLE
3/4 FPT DUAL
NOTES:

1. All dimensions are approximate. Certified dimensions are available on request.
2. Determine overall unit length by adding water box dimension to tube sheet length:

5-1/4 for compact return box

14 for compact water box with ANSI/AWWA C-606 couplings water nozzles

Add 1/2 to each compact water box with optional flanged water nozzles
3. Unit height includes steel mounting plates under tube sheets. To determine overall height, add 7/8 for neoprene isolators

(1 for optional spring isolators).
30
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
S4 - S5 COMPRESSOR
R-134a UNITS
(50 and 60 Hz)
S4 COMPRESSOR
DIMENSION

D-C
D-D
E-E
E-F
F-E
F-F
62
62
62
64-1/2
66-1/2
69
A1
69-7/8
69-7/8
69-7/8
70-3/8
73-5/8
72-5/8
A2
63-3/8
63-3/8
B OVERALL HEIGHT3
79-1/8
79-1/8
79-1/8
82-1/4
82-1/4
82-1/4
C COOLER C/L
17-3/4
17-3/4
17-3/4
17-3/4
110
110
D CONDENSER C/L
15-1/4
15-1/4
15-1/4
16-1/2
15-1/4
16-1/2

SIZE
1 FPT SINGLE
1 FPT DUAL
VESSEL
EVAPORATOR
CONDENSER
EVAPORATOR CODE
TYPE COMPACT WATER
D
E
F
BOX
05-1/2 05-1/2 07-3/4
RETURN BOX
WITH VICTAULIC CONN.
11-7/8 11-7/8 13-1/8
WITH FLANGED CONN.
NOTES:
1.
2.
3.

12-3/8
12-3/8
13-5/8
CONDENSER CODE
D
05-1/4
05-1/4
07-5/8
11-7/8
11-7/8
13-1/8
12-3/8
12-3/8
13-5/8
All dimensions are approximate. Certified dimensions are available on request.

Determine overall unit length by adding water box depth from table below to tube sheet length:
Unit height includes steel mounting plates under tube sheets. To determine overall installed height,
add 7/8 for neoprene isolators (1 for optional spring isolators).
JOHNSON CONTROLS
31
FORM 160.80-EG1 (210)
Dimensions - Std - continued

COMPACTWATER BOX NOZZLE ARRANGEMENTS
R-134a UNITS
NOZZLE ARRANGEMENTS
NO. OF
PASSES
1
COOLER
IN-OUT
A-H
H-A
COND.
IN-OUT
P-Q
Q-P
E-B
D-C
M-J
L-K
R-S
T-U
P-F
G-N
COOLER NOZZLE DIMENSIONS

COOLER
CODE
NOZZLE
SIZE (IN.)
NO. OF PASSES
1
DIMENSIONS (IN.)
AA
BB
CC
DD
EE
FF
10
11 3/4
14-3/4
17-3/4
19-1/2
10
12 3/4
13 7/8
16 3/4
19 5/8
20 3/4
5 7/8
6 5/8
12
12 7/8
15 1/4
19 1/4
23 1/4
25 7/8
12
12 7/8
15 3/8
19 3/8
23 3/8
25 7/8
7 1/2
14
10
14-5/8
17 1/2
22 1/4
27
29 7/8
9 1/4
CONDENSER NOZZLE DIMENSIONS

NOZZLE
SIZE (IN.)
CONDENSER
NO. OF PASSES
CODE
DIMENSIONS (IN.)
GG
HH
JJ
KK
13
16 3/4
20 1/4
4 1/2
4 3/8
10
11 1/2
16 3/4
22 1/8
D, E
12
10
14 1/4
20
25 7/8
14
12
17
24 1/2
32
7 3/4
NOTES:
1. All dimensions are approximate (shown for 150 psig DWP water side). Certified dimensions are available on request.
2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use of
ANSI/AWWA C-606 couplings couplings. Factory installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1/16 raised face), water
flanged nozzles are optional. Companion flanges, nuts, bolts and gaskets are not furnished.
3. Add 7/8 to all height dimensions to obtain installed height when using neoprene mounts or 1 for optional spring vibration isolator mounts.
4. One, two and three pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles may be
used in combination with any pair of condenser nozzles.
5. Condenser water must enter the water box through the bottom connection for proper operation of the subcooler to achieve rated performance.
6. Cooler water must enter the water box through the bottom connection to achieve rated performance.
7. Connected piping should allow for removal of compact water box for tube access and cleaning.
32
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
FLOOR LAYOUT NEOPRENE ISOLATORS

R-134a UNITS
COMPRESSOR
SHELL
CODES
COOLER-COND.
S0, S1
S2
S2, S3
S4
S4, S5
B-B
B-C
C-B
C-C
B-B
B-C
C-B
C-C, C-D
D-C, D-D
D-C
D-D
E-E
E-F
F-E
F-F
A
TUBE SHEET
WIDTH
B
SHELL LENGTH
(TO OUTSIDE OF
TUBE SHEETS)
C
EVAPORATOR
SIDE
D
CONDENSER
SIDE
42-7/8
10
1-7/8
2-1/2
52-1/2
10
1-7/8
2-1/2
52-1/2
10
1-7/8
2-1/2
62
10
1-7/8
2-1/2
12
1-7/8
2-1/2
12
1-7/8
2-1/2
62
64-1/2
66-1/2
69
NOTES:
2. Service clearance must be allowed as follows:

2 at rear (condenser side) of unit and overhead.

3 at front (evaporator/control center side) of unit.
10 (12 on S4/S5 compressor) on either end of unit for tube cleaning or replacement. A doorway or properly located opening may be used.
2 on either end to allow for removal of water boxes for tube access and cleaning.
3. No special foundation required. Floor must be flat and level within 1/4, capable of carrying the operating weight of the unit.
4. unit has four steel plate foot supports located under the tube sheets at each corner of shell package. Neoprene isolator pads are
field installed between foot support and floor.
5. All four neoprene isolator pads are identical. Pads are 1 thick with nominal 0.15 static deflection. Unit operating weights under 16,365 Ibs.
use 4-1/2 x 4-1/2 isolators; weights above 16,365 Ibs use 4-1/2 x 6 isolators.
6. Loading per isolator pad equals operating weight divided by four.
JOHNSON CONTROLS
33
FORM 160.80-EG1 (210)
Dimensions - Std
EVAPORATOR NOZZLE ARRANGEMENTS MARINE WATER BOXES

R-134a UNITS
1-PASS
1-PASS
MOTOR END
COMPR. END
MOTOR END
2-PASS
2-PASS
MOTOR END
COMPR. END
MOTOR END
3-PASS
B
C
D
E
F
34
COMPR. END
3-PASS
COMPR. END
MOTOR END
COOLER
SIZE
COMPR. END
COMPR. END
MOTOR END
DIMENSIONS (IN.)
1-PASS
A
15 1/2
17 1/2
20
20
21
B
15 1/4
16 3/4
19 1/4
19 3/8
22 3/8
C
19
20 3/4
23 3/4
24 5/8
28 1/4
2-PASS
D
E
7 3/4
8 3/4
10
10
10 1/2
A
13 1/2
13 1/2
15 1/2
16
19
B
9 1/2
11 1/4
14 1/2
15 1/8
16 1/4
C
19
20 3/4
23 3/4
24 5/8
28 1/4
3-PASS
D
21
22 1/4
29 1/2
29 1/8
33
E
6 3/4
6 3/4
7 3/4
8
9 1/2
A
13 1/2
13 1/2
15 1/2
16
17
B
11
13 1/4
13 3/4
13 7/8
15 1/4
C
19
20 3/4
23 3/4
24 3/8
28 1/4
D
19 1/2
22 7/8
25 1/4
25 3/8
29 1/4
E
6 3/4
6 3/4
7 3/4
8
8 1/2
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
EVAPORATOR NOZZLE ARRANGEMENTS MARINE WATER BOXES

R-134a UNITS
MOTOR END
COMPR. END
1-PASS & 3-PASS EVAPORATORS
MOTOR END
COMPR. END
2-PASS EVAPORATORS
* Applies to compressor end if connections are on motor end.
** Applies to motor end if connections are on motor end.
WEIGHTS
EVAPORATORS NOZZLE SIZES

NOZZLE SIZE (IN.)
NO. OF PASSES
(To be added to Standard Unit Weights on pages 36-37)

SHIPPING WEIGHT
INCREASE LBS
OPERATING WEIGHT
INCREASE LBS
EVAPORATOR
CODE
1-PASS
2-PASS
3-PASS
1-PASS
2-PASS
3-PASS
554
295
562
788
391
755
10
810
417
668
1207
592
955
12
872
439
768
1316
600
1090
12
1040
607
996
1674
924
1535
12
10
1280
875
1130
1900
1025
1685
EVAPORATOR CODE
JOHNSON CONTROLS
35
FORM 160.80-EG1 (210)
Dimensions - Std - continued
CONDENSER NOZZLE ARRANGEMENTS MARINE WATER BOXES

R-134a UNITS
1-PASS
1-PASS
COMPR. END
MOTOR END
COMPR. END
MOTOR END
2-PASS
2-PASS
COMPR. END
MOTOR END
COMPR. END
MOTOR END
DIMENSIONS (IN.)
CONDENSER
SIZE
B
15 1/2
16 7/8
17 5/8
7 3/4
13 1/2
11 1/8
17 5/8
22 5/8
6 3/4
17 1/2
16 3/4
18 1/2
8 3/4
15 1/2
12
18 1/2
26
7 3/4
20
20
21 1/8
10
17 1/2
15
21 1/8
31 3/4
8 3/4
20
20
21 1/8
10
17 1/2
15
21 1/8
31 3/4
8 3/4
21
24 1/2
25 1/8
10 1/2
21
18 1/2
25 1/8
38 1/4
10 1/2
36
1-PASS
2-PASS
JOHNSON CONTROLS
FORM 160.80-EG1 (210)

R-134a UNITS
MOTOR END
COMPR. END
1-PASS
MOTOR END
COMPR. END
2-PASS
CONDENSER NOZZLE SIZES

CONDENSER
CODE
NOZZLE SIZE (IN.)

NO. OF PASSES
WEIGHTS
(To be added to Standard Unit Weights on pages 36-37)

CONDENSER
CODE
SHIPPING WEIGHT
INCREASE LBS
OPERATING WEIGHT
INCREASE LBS
1-PASS
2-PASS
1-PASS
2-PASS
542
241
744
327
10
686
328
1018
475
12
10
818
317
1235
466
12
10
818
317
1235
466
14
12
1004
459
1586
704
JOHNSON CONTROLS
37
FORM 160.80-EG1 (210)
Weights - Std
R-134a UNITS
SHELL
CODE
EVAP.
COND.
COMPRESSOR
SHIPPING
WT.
(LBS.)
OPERATING
WT.
(LBS.)
BA-BA
BA-BB
BB-BA
BB-BB
BA-CA
BA-CB
BB-CA
BB-CB
CA-BA
CA-BB
CB-BA
CB-BB
CA-CA
CA-CB
CB-CA
CB-CB
BA-BA
BA-BB
BB-BA
BB-BB
BA-CA
BA-CB
BB-CA
BB-CB
CA-BA
CA-BB
CB-BA
CB-BB
CA-CA
CA-CB
CB-CA
CB-CB
BA-BA
BA-BB
BB-BA
BB-BB
BA-CA
BA-CB
BB-CA
BB-CB
CA-BA
CA-BB
CB-BA
CB-BB
CA-CA
CA-CB
CB-CA
CB-CB
S0
S0
S0
S0
S0
S0
S0
S0
S0
S0
S0
S0
S0
S0
S0
S0
S1
S1
S1
S1
S1
S1
S1
S1
S1
S1
S1
S1
S1
S1
S1
S1
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
8,388
8,538
8494
8644
9,142
9,416
9,271
9,545
9,297
9,448
9,528
9,679
10,011
10,285
10,242
10,516
8,454
8,608
8,560
8,711
9,208
9,482
9,337
9,611
9,363
9,513
9,594
9,745
10,077
10,351
10,308
10,582
10,542
10,693
10,648
10,797
11,298
11,571
11,426
11,701
11,452
11,604
11,683
11,833
12,146
12,419
12,377
12,650
9,019
9,235
9187
9403
9,996
10,388
10186
10,579
10,084
10,299
10,412
10,627
11,020
11,413
11,348
11,740
9,085
9,301
9,253
9,469
9,974
10,454
10,252
10,645
10,150
10,365
10,478
10,693
11,086
11,479
11,414
11,806
11,174
11,390
11,342
11,558
12,065
12,547
12,342
12,735
12,241
12,457
12,567
12,783
13,155
13,547
13,483
13,874
38
REFRIGERANT
CHARGE
(LBS.
R-134A)
441
441
414
414
468
468
432
432
558
558
558
558
585
585
585
585
441
441
414
414
468
468
432
432
558
558
558
558
585
585
585
585
441
441
414
414
468
468
432
432
558
558
558
558
612
612
612
612
SHELL
CODE
EVAP.
COND.
COMPRESSOR
SHIPPING
WT.
(LBS.)
OPERATING
WT.
(LBS.)
CA-DA
CA-DB
CB-DA
CB-DB
DA-CA
DA-CB
DB-CA
DB-CB
DC-CA
DC-CB
DA-DA
DA-DB
DB-DA
DB-DB
DC-DA
DC-DB
CA-CA
CA-CB
CB-CA
CB-CB
CA-DA
CA-DB
CB-DA
CB-DB
DA-CA
DA-CB
DB-CA
DB-CB
DC-CA
DC-CB
DA-DA
DA-DB
DB-DA
DB-DB
DC-DA
DC-DB
DA-CA
DA-CB
DB-CA
DB-CB
DC-CA
DC-CB
DA-DA
DA-DB
DB-DA
DB-DB
DC-DA
DC-DB
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S2
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S3
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
13,357
13,874
13,588
14105
13293
13,577
13,668
13941
14,026
14,299
14,549
15,066
14,869
15,386
15,215
15,732
12,360
12,633
12,591
12,865
13,574
14,090
13,804
14,324
13,497
13,770
13,861
14,134
14,219
14,491
14,741
15,258
15,061
15,578
15,408
15,925
17,068
17,341
17,431
17,705
17,791
18,064
18,313
18,833
18,635
19,153
18,983
19,426
14,765
15,506
15,093
15833
14480
14872
15008
15400
15,552
15,943
16,124
16,864
16,608
17,348
17,437
16,781
13,372
13,764
13,698
14,090
14,983
15,726
15,313
16,054
14,673
15,065
15,201
15,593
15,744
16,135
16,316
17,057
16,800
17,541
17,333
18,073
18,247
18,639
18,776
19,168
19,320
19,710
19,893
20,634
20,378
21,119
20,912
21,652
REFRIGERANT
CHARGE
(LBS.
R-134A)
675
675
11/5/1901
675
756
756
756
756
756
756
855
855
819
819
756
756
612
612
612
612
675
675
675
675
756
756
756
756
756
756
855
855
819
819
756
756
740
740
740
740
740
740
830
830
800
800
740
740
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
R-134a UNITS
50 AND 60 HZ
SHELL
CODE
EVAP.
COND.
COMPRESSOR
SHIPPING
WT.
(LBS.)
OPERATING
WT.
(LBS.)
EA-EA
EA-EB
EB-EA
EB-EB
EC-EA
EC-EB
EA-FA
EA-FB
EB-FA
EB-FB
EC-FA
EC-FB
FA-EA
FA-EB
FB-EA
FB-EB
FC-EA
FC-EB
FA-FA
FA-FB
FB-FA
FB-FB
FC-FA
FC-FB
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
20,460
21,104
20,955
21533
21362
22,000
23,485
24695
23,914
25,119
24,382
25,592
22,922
23,638
23,711
24,288
24,171
25,141
25,977
27,187
26,626
27,830
27,148
28,688
21,890
22,743
22,484
23337
23139
23991
25592
27192
26,180
27,781
26,840
28,435
24,998
25,853
25,902
26,757
27,076
27,929
28,655
30,256
29,552
31,153
30,730
32,325
NOTE:

REFRIGERANT
CHARGE
(LBS.
R-134A)
1,260
1,260
1,215
1,215
1,170
1,170
1,368
1,368
1,368
1,305
1,305
1,305
1,690
1,690
1,690
1,690
1,620
1,620
1,800
1,800
1,800
1,710
1,710
1,710
SHELL
CODE
EVAP
COND.
COMPRESSOR
SHIPPING
WT.
(LBS.)
OPERATING
WT.
(LBS.)
EA-EA
EA-EB
EB-EA
EB-EB
EC-EA
EC-EB
EA-FA
EA-FB
EB-FA
EB-FB
EC-FA
EC-FB
FA-EA
FA-EB
FB-EA
FB-EB
FC-EA
FC-EB
FA-FA
FA-FB
FB-FA
FB-FB
FC-FA
FC-FB
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
20,777
21,423
21275
21853
21,681
22,322
23808
25,020
24,240
25,445
24,707
25,919
23,274
23,920
23,991
24,568
24,453
25,423
26,257
27,467
26,906
28,111
27,759
28,969
22,210
23,065
22807
23682
23462
24317
25919
27,521
26,508
28,112
27,171
28,769
25,280
26,135
26,184
27,036
27,356
28,211
28,936
30,536
29,832
31,433
31,009
32,604
REFRIGERANT
CHARGE
(LBS.
R-134A)
1,260
6/13/1903
1215
1215
1,170
1,170
1368
1,368
1,368
1,305
1,305
1,305
1,690
1,690
1,690
1,620
1,620
1,620
1,800
1,800
1,800
1,710
1,710
1,710
1. Calculate total chiller weight by adding motor weight, solid state starter weight, and marine water box weights, if applicable.
2. Shipping weight includes refrigerant and oil charge. Operating weight includes water in tubes and water boxes.
3. Weights based on standard tubes in evaporators and condensers.
MOTOR WEIGHTS
MOTOR CODE
60 HZ
CF
CG
CH
CJ
CK
CL
CM
CN
CP
CR
CS
CT
CU
CV
JOHNSON CONTROLS
SOLID STATE STARTER

WEIGHT
WEIGHT
50 HZ
5 CC
5 CC
5 CD
5 CE
5 CF
5 CG
5 CH
5 CI
5 CJ
5 CK
5 CL
5 CM
5 CN
5 CO
(LBS)
1,080
1,080
1,120
1,120
1,460
1,520
1930
1930
1,980
1,980
2370
2,480
2,480
2,635
SIZE
LBS
7L, 14L
200
26L, 33L
300
39
FORM 160.80-EG1 (210)
Dimensions - Metric
S0 - S3 COMPRESSOR
R-134a UNITS
(50 and 60 Hz)
DIMENSIONS (mm)
S2 COMPRESSOR
SHELL CODES (COOLER CONDENSER)

B-B
B-C
C-B
C-C
B-B
B-C
C-B
C-C
C-D
D-C
D-D
A TUBE SHEET WIDTH
1292
1292
1292
1292
1588
1588
1588
1588
1588
1588
1588
A1 OVERALL WIDTH
1349
1349
1349
1349
1591
1591
1591
1591
1591
1591
1591
B OVERALL HEIGHT3
1816
1895
1857
1899
1848
1946
1946
1946
2054
2102
2102
C COOLER C/L
351
351
351
351
432
432
432
432
432
432
432
D CONDENSER C/L
295
291
295
295
362
362
362
362
362
362
362

SHELL CODE
EVAP. SIZE
CONDENSER SIZE
B, C
3/4 FPT SINGLE
3/4 FPT DUAL
1 FPT SINGLE
3/4 FPT DUAL
NOTES:
2. Determine overall unit length by adding water box dimension to tube sheet length:

132mm for compact return box

356mm for compact water box with ANSI/AWWA C-606 couplings water nozzles

Add 12.6mm to each compact water box with optional flanged water nozzles
3. Unit height includes steel mounting plates under tube sheets. To determine overall installed height, add 22mm for neoprene isolators (25mm
for optional spring isolators).
40
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
S4 - S5 COMPRESSOR
R-134a UNITS
(50 and 60 Hz)
DIMENSIONS (mm)
S4 COMPRESSOR
D-C
D-D
E-E
E-F
F-E
F-F
A TUBE SHEET WIDTH
1,880
1,880
1,880
1,943
1,994
2,057
A1 WITH SOLID STATE STARTER
2,080
2,080
2,080
2,143
2,226
2,200
A2 OVERALL WIDTH (LESS S.S.S)
1,915
1,915
B OVERALL HEIGHT3
2,365
2,365
2,365
2,496
2,496
2,496
C EVAPORATOR C/L
502
502
502
502
559
559
D CONDENSER C/L
438
438
438
470
438
470

VESSEL
SIZE
EVAPORATOR
1 FPT SINGLE
CONDENSER
1 FPT DUAL
TYPE COMPACT WATER BOX
NOTES: 1.
2.
3.

COOLER CODE
CONDENSER CODE
RETURN BOX
140
140
197
133
133
194
WITH VICTAULIC CONNECTION
352
352
384
352
352
384
WITH FLANGED CONNECTION
365
365
397
365
365
397
All dimensions are approximate. Certified dimensions are available on request.

Determine overall unit length by adding water box depth from table below to tube sheet length:
Unit height includes steel mounting plates under tube sheets. To determine overall installed height,
add 22mm for neoprene isolators (25.4 for optional spring isolators).
JOHNSON CONTROLS
41
FORM 160.80-EG1 (210)
Dimensions - Metric - continued

COMPACTWATER BOX NOZZLE ARRANGEMENTS
R-134a UNITS
NOZZLE ARRANGEMENTS
NO. OF
PASSES
1
EVAPORATOR
IN-OUT
A-H
COND.
IN-OUT
P-Q
H-A
Q-P
E-B
R-S
D-C
T-U
M-J
L-K
P-F
G-N
EVAPORATOR NOZZLE DIMENSIONS

EVAP.
CODE
NOZZLE
SIZE (IN.)
DIMENSIONS (MM)
NO. OF PASSES
1
AA
BB
CC
DD
EE
FF
254
298
375
451
495
127
10
324
352
425
498
527
149
12
327
387
489
591
657
168
12
327
391
492
594
657
191
14
10
371
445
565
686
759
235
CONDENSER NOZZLE DIMENSIONS

COND.
CODE
NOZZLE
SIZE (IN.)
NO. OF PASSES
DIMENSIONS (MM)
GG
HH
JJ
KK
330
425
514
114
10
292
425
562
111
12
10
368
514
660
152
12
10
375
521
667
152
14
12
432
622
813
197
NOTES:
1. All dimensions are approximate (shown for 1031 KPa DWP water side). Certified dimensions are available on request.
2. Standard water nozzles are furnished as welding stub-outs with ANSI/AWWA C-606 grooves, allowing the option of welding, flanges, or use of
ANSI/AWWA C-606 couplings couplings. Factory installed, class 150 (ANSI B16.5, round slip-on, forged carbon steel with 1/16 raised face),
water flanged nozzles are optional. Companion flanges, nuts, bolts and gaskets are not furnished.
3. Add 22mm to all height dimensions to obtain installed height when using neoprene mounts or 25mm for optional spring vibration isolator
mounts.
4. One, two and three-pass nozzle arrangements are available only in pairs shown and for all shell codes. Any pair of evaporator nozzles may be
used in combination with any pair of condenser nozzles.
5. Condenser water must enter the water box through the bottom connection for proper operation of the subevaporator to achieve rated performance.
6. Cooler water must enter the water box through the bottom connection to achieve rated performance.
7. Connected piping should allow for removal of compact water box for tube access and cleaning.
42
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
FLOOR LAYOUT NEOPRENE ISOLATORS

R-134a UNITS
COMPRESSOR
SHELL
CODES
EVAP. - COND.
S0, S1
S2
S2, S3
S4
S4, S5
B-B
B-C
C-B
C-C
B-B
B-C
C-B
C-C
C-D
D-C
D-D
D-C
D-D
E-E
E-F
F-E
F-F
A
TUBE SHEET
WIDTH
B
SHELL LENGTH
(TO OUTSIDE OF
TUBE SHEETS)
C
EVAP
SIDE
D
CONDENSER
SIDE
1292MM
3048MM
48MM
64MM
1588MM
3048MM
48MM
64MM
1588MM
3048MM
48MM
64MM
1588MM
3048MM
48MM
64MM
1880MM
3048MM
48MM
64MM
3658MM
48MM
64MM
3658MM
48MM
64MM
1880MM
1943MM
1994MM
2057MM
NOTES:
2. Service clearance must be allowed as follows:

610mm at rear (condenser side) of unit and overhead.

915mm at front (evaporator/control center side) of unit.
3050mm (3660mm on S4/S5 compressor) on either end of unit for tube cleaning or replacement. A doorway or properly located

opening may be used.
610mm on either end to allow for removal of water boxes for tube access and cleaning.
3. No special foundation required. Floor must be flat and level within 6mm, capable of carrying the operating weight of the unit.
4. Unit has four steel plate foot supports located under the tube sheets at each corner of shell package. Neoprene isolator pads are
field installed between foot support and floor.
5. All four neoprene isolator pads are identical. Pads are 25mm thick. Unit operating weights under 7423 kg. use 114mm x 114mm isolators; weights
above 7423 kg. use 114mm x 152mm isolators.
6. Loading per isolator pad equals operating weight divided by four.
JOHNSON CONTROLS
43
FORM 160.80-EG1 (210)
Dimensions - Metric - contiued
COOLER NOZZLE ARRANGEMENTS MARINE WATER BOXES

R-134a UNITS
1-PASS
1-PASS
COMPR. END
MOTOR END
COMPR. END
MOTOR END
2-PASS
2-PASS
COMPR. END
MOTOR END
COMPR. END
MOTOR END
3-PASS
3-PASS
COMPR. END
MOTOR END
DIMENSIONS (mm)
1-PASS
COMPR. END
MOTOR END
2-PASS
3-PASS
COOLER
SIZE
394
387
483
197
343
241
483
533
171
343
279
483
495
171
445
425
527
222
343
286
527
565
171
343
337
527
581
171
508
489
603
254
394
368
603
749
197
394
349
603
641
197
508
492
625
254
406
384
625
740
203
406
352
619
644
203
533
568
719
266
483
413
718
838
241
432
387
718
743
216
44
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
COOLER NOZZLE ARRANGEMENTS MARINE WATER BOXES

R-134a UNITS
COMPR. END
MOTOR END
1-PASS & 3-PASS COOLERS
MOTOR END
COMPR. END
2-PASS COOLERS
EVAP. NOZZLE SIZES

EVAPORATOR
CODE
WEIGHTS (To be added to Metric Unit Weights on pages 46-47)
NOZZLE SIZE (IN.)

NO. OF PASSES
1
10
12
12
12
10
JOHNSON CONTROLS
COOLER
CODE
SHIPPING WEIGHT
INCREASE KG
OPERATING WEIGHT
INCREASE KG
1-PASS
2-PASS
3-PASS
1-PASS
2-PASS
252
134
255
358
178
3-PASS
343
368
190
304
549
269
434
396
200
349
598
273
495
473
276
453
761
420
698
582
398
514
864
466
764
45
FORM 160.80-EG1 (210)
Dimensions - Metric - continued

R-134a UNITS
1-PASS
1-PASS
MOTOR END
COMPR. END
MOTOR END
COMPR. END
2-PASS
2-PASS
MOTOR END
COMPR. END
MOTOR END
COMPR. END
DIMENSIONS (mm)
1-PASS
2-PASS
CONDENSER
SIZE
394
429
448
197
343
283
448
575
171
445
425
470
222
394
305
470
660
197
508
508
537
254
445
381
537
806
222
508
508
537
254
445
381
537
806
222
533
622
638
267
533
470
638
972
267
46
JOHNSON CONTROLS
FORM 160.80-EG1 (210)

R-134a UNITS
MOTOR END
COMPR. END
1-PASS
MOTOR END
COMPR. END
2-PASS
CONDENSER NOZZLE SIZES

CONDENSER
CODE
NOZZLE SIZE (IN.)

NO. OF PASSES
WEIGHTS (To be added to Metric Unit Weights on pages 46-47)

CONDENSER
CODE
1-PASS
2-PASS
246
110
338
149
312
149
463
216
372
144
561
212
10
372
144
561
212
12
456
209
721
320
10
12
10
12
14
1-PASS
OPERATING WEIGHT
INCREASE KGS
2-PASS
JOHNSON CONTROLS
SHIPPING WEIGHT
INCREASE KGS
47
FORM 160.80-EG1 (210)
Weights - Metric - continued

R-134a UNITS
50 AND 60 HERTZ
SHELL
CODE
COOLER
COND.
COMPRESSOR
SHIPPING
WT.
(Kgs.)
OPERATING
WT.
(Kgs.)
REFRIGERANT
CHARGE
(Kgs.
R-134a)
48
SHELL
CODE
COOLER
COND.
COMPRESSOR
SHIPPING
WT.
(Kgs.)
OPERATING
WT.
(Kgs.)
REFRIGERANT
CHARGE
(Kgs.
R-134a)
BA-BA
S0
3,805
4,091
200
BA-BA
S0
3,805
4,091
200
BA-BB
S0
3,873
4,189
200
BA-BB
S0
3,873
4,189
200
BB-BA
S0
3,853
4,167
188
BB-BA
S0
3,853
4,167
188
BB-BB
S0
3,921
4,265
188
BB-BB
S0
3,921
4,265
188
BA-CA
S0
4,147
4,534
212
BA-CA
S0
4,147
4,534
212
BA-CB
S0
4,271
4,712
212
BA-CB
S0
4,271
4,712
212
BB-CA
S0
4,205
4,620
196
BB-CA
S0
4,205
4,620
196
BB-CB
S0
4,330
4,799
196
BB-CB
S0
4,330
4,799
196
CA-BA
S0
4,217
4,574
253
CA-BA
S0
4,217
4,574
253
CA-BB
S0
4,286
4,672
253
CA-BB
S0
4,286
4,672
253
CB-BA
S0
4,322
4,723
253
CB-BA
S0
4,322
4,723
253
CB-BB
S0
4,390
4,820
253
CB-BB
S0
4,390
4,820
253
CA-CA
S0
4,541
4,999
265
CA-CA
S0
4,541
4,999
265
CA-CB
S0
4,665
5,177
265
CA-CB
S0
4,665
5,177
265
CB-CA
S0
4,646
5,147
265
CB-CA
S0
4,646
5,147
265
CB-CB
S0
4,770
5,325
265
CB-CB
S0
4,770
5,325
265
BA-BA
S1
3,835
4,121
200
BA-BA
S1
3,835
4,121
200
BA-BB
S1
3,905
4,219
200
BA-BB
S1
3,905
4,219
200
BB-BA
S1
3,883
4,197
188
BB-BA
S1
3,883
4,197
188
BB-BB
S1
3,951
4,295
188
BB-BB
S1
3,951
4,295
188
BA-CA
S1
4,177
4,524
212
BA-CA
S1
4,177
4,524
212
BA-CB
S1
4,301
4,742
212
BA-CB
S1
4,301
4,742
212
BB-CA
S1
4,235
4,650
196
BB-CA
S1
4,235
4,650
196
BB-CB
S1
4,360
4,829
196
BB-CB
S1
4,360
4,829
196
CA-BA
S1
4,247
4,604
253
CA-BA
S1
4,247
4,604
253
CA-BB
S1
4,315
4,702
253
CA-BB
S1
4,315
4,702
253
CB-BA
S1
4,352
4,753
253
CB-BA
S1
4,352
4,753
253
CB-BB
S1
4,420
4,850
253
CB-BB
S1
4,420
4,850
253
CA-CA
S1
4,571
5,029
265
CA-CA
S1
4,571
5,029
265
CA-CB
S1
4,695
5,207
265
CA-CB
S1
4,695
5,207
265
CB-CA
S1
4,676
5,177
265
CB-CA
S1
4,676
5,177
265
CB-CB
S1
4,800
5,355
265
CB-CB
S1
4,800
5,355
265
BA-BA
S2
4,782
5,069
200
BA-BA
S2
4,782
5,069
200
BA-BB
S2
4,850
5,167
200
BA-BB
S2
4,850
5,167
200
BB-BA
S2
4,830
5,145
188
BB-BA
S2
4,830
5,145
188
BB-BB
S2
4,898
5,243
188
BB-BB
S2
4,898
5,243
188
BA-CA
S2
5,125
5,473
212
BA-CA
S2
5,125
5,473
212
BA-CB
S2
5,249
5,691
212
BA-CB
S2
5,249
5,691
212
BB-CA
S2
5,183
5,598
196
BB-CA
S2
5,183
5,598
196
BB-CB
S2
5,308
5,777
196
BB-CB
S2
5,308
5,777
196
CA-BA
S2
5,195
5,553
253
CA-BA
S2
5,195
5,553
253
CA-BB
S2
5,264
5,650
253
CA-BB
S2
5,264
5,650
253
CB-BA
S2
5,299
5,700
253
CB-BA
S2
5,299
5,700
253
CB-BB
S2
5,367
5,798
253
CB-BB
S2
5,367
5,798
253
CA-CA
S2
5,509
5,967
278
CA-CA
S2
5,509
5,967
278
CA-CB
S2
5,633
6,145
278
CA-CB
S2
5,633
6,145
278
CB-CA
S2
5,614
6,116
278
CB-CA
S2
5,614
6,116
278
CB-CB
S2
5,738
6,293
278
CB-CB
S2
5,738
6,293
278
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
R-134a UNITS
50 AND 60 HERTZ
SHELL
CODE
COOLER
COND.
COMPRESSOR
SHIPPING
WT.
(Kgs.)
OPERATING
WT.
(Kgs.)
EA-EA
EA-EB
EB-EA
EB-EB
EC-EA
EC-EB
EA-FA
EA-FB
EB-FA
EB-FB
EC-FA
EC-FB
FA-EA
FA-EB
FB-EA
FB-EB
FC-EA
FC-EB
FA-FA
FA-FB
FB-FA
FB-FB
FC-FA
FC-FB
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
S4
9,281
9,573
9,505
9,767
9,690
9,979
10,653
11,202
10,847
11,394
11,060
11,609
10,397
10,722
10,755
11,017
10,964
11,404
11,783
12,332
12,078
12,624
12,314
13,013
9,929
10,316
10,199
10,586
10,496
10,882
11,609
12,334
11,875
12,601
12,175
12,898
11,339
11,727
11,749
12,137
12,282
12,669
12,998
13,724
13,405
14,131
13,939
14,662
REFRIGERANT
CHARGE
(Kgs.
R-134a)
572
572
551
551
531
531
621
621
621
592
592
592
767
767
767
767
735
735
816
816
816
776
776
776
SHELL
CODE
COOLER
COND.
COMPRESSOR
SHIPPING
WT.
(Kgs.)
OPERATING
WT.
(Kgs.)
EA-EA
EA-EB
EB-EA
EB-EB
EC-EA
EC-EB
EA-FA
EA-FB
EB-FA
EB-FB
EC-FA
EC-FB
FA-EA
FA-EB
FB-EA
FB-EB
FC-EA
FC-EB
FA-FA
FA-FB
FB-FA
FB-FB
FC-FA
FC-FB
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
S5
9,424
9,717
9,650
9,913
9,835
10,125
10,799
11,349
10,995
11,542
11,207
11,757
10,557
10,850
10,882
11,144
11,092
11,532
11,910
12,459
12,205
12,751
12,591
13,140
10,074
10,462
10,345
10,742
10,642
11,030
11,757
12,484
12,024
12,752
12,325
13,050
11,467
11,855
11,877
12,264
12,409
12,797
13,125
13,851
13,532
14,258
14,066
14,789
REFRIGERANT
CHARGE
(Kgs.
R-134a)
572
572
551
551
531
531
621
621
621
592
592
592
767
767
767
735
735
735
816
816
816
776
776
776
NOTE:
1. Calculate total chiller weight by adding motor weight, solid state starter weight, and marine water box weights, if applicable.
2. Shipping weight includes refrigerant and oil charge. Operating weight includes water in tubes and water boxes.
3. Weights based on standard tubes in evaporators and condensers.
MOTOR WEIGHTS
MOTOR CODE
60 Hz
50 Hz
CF
5 CC
CG
5 CC
CH
5 CD
CJ
5 CE
CK
5 CF
CL
5 CG
CM
5 CH
CN
5 CI
CP
5 CJ
CR
5 CK
CS
5 CL
CT
5 CM
CU
5 CN
CV
5 CO
JOHNSON CONTROLS
WEIGHT
(Kgs)
490
490
508
508
662
689
875
875
898
898
1,075
1,125
1,125
1,195
SOLID STATE STARTER

WEIGHT
SIZE
7L, 14L
26L, 33L
Kgs
91
136
49
FORM 160.80-EG1 (210)
Guide Specifications
GENERAL
Furnish and install where indicated on the drawings
YORK YS Rotary Screw Liquid Chilling Units(s). Each
unit shall produce a capacity of
tons, cooling
GPM of
from
F to
F when supplied
with
GPM of condenser water at
F. Power
input shall not exceed
kW with an IPLV (APLV)
of
. The evaporator shall be selected for
ft2
F hr/BTU fouling factor and a maximum liquid pressure
drop of
ft. Water side shall be designed for 150
psig working pressure. The condenser shall be selected
for
fouling factor and maximum liquid pressure
drop of
ft. Water side shall be designed for 150
psig working pressure. Power shall be supplied to the
compressor motor at
volts 3-phase (60)(50)
Hertz and controls at 115 volts 1-phase (60)(50) Hertz.

(or)
Furnish and install where indicated on the drawings

YORK YS Rotary Screw Liquid Chilling Units(s). Each unit
shall produce a capacity of
kW, cooling
L/S
of
from
C to
C when supplied with
L/S of condenser water at
C. Power input shall
not exceed
kW with an IPLV (APLV) of
. The
2
evaporator shall be selected for
M C/W fouling
factor and a maximum liquid pressure drop of
kPa.
Water side shall be designed for 1034 kPa working
pressure. The condenser shall be selected for
M2
C/W fouling factor and maximum liquid pressure drop of
kPa. Water side shall be designed for 1034 kPa working
pressure. Power shall be supplied to the compressor
motor at
volts 3-phase 50 Hertz and controls
at 115 volts 1-phase 50 Hertz.
Performance shall be certified or rated in accordance
with the latest edition of AHRI Standard 550/590-98 as
applicable. Only chillers that are listed in the AHRI Certification Program for Water Chilling Packages using the
vapor compression cycle are acceptable.
Each unit shall be completely factory packaged including
evaporator, condenser, subcooler, oil separator, compressor, open motor, lubrication system, OptiView Control
Center, Solid State Starter, refrigerant isolation valves
and all interconnecting piping and wiring. The factory
package shall consist of a Leaktight design, with no pipe
thread connections that can loosen and leak over time. All
units shall ship with a full charge of refrigerant (HCFC-22
or HFC-134a) and oil. (Alternatively, the chiller shall be
shipped with the compressor, control panel and oil separator removed (Form 3) or also with the shells separated
50
(Form 7) to allow rigging into the equipment room. All units

that ship disassembled shall be assembled and factory
run tested prior to disassembly and shipment).
Compressor
The compressor shall be an open-drive, rotary-screw type.
The compressor housing shall be of cast iron, precision
machined to provide minimal clearance for the rotors. The
rotors shall be manufactured from forged steel and use
asymmetric profiles operating at a maximum speed of
(3570 RPM/60 Hz) (2975 RPM/50 Hz). The compressor
shall incorporate a complete anti-friction bearing design
to reduce power and increase reliability; four separate
cylindrical roller bearings to handle radial loads; and two
4-point angular contact ball bearings to handle axial loads.
A spring actuated positive seating check valve shall be
incorporated in the compressor housing to prevent rotor
backspin during shutdown. The open-drive compressor shaft seal consists of a bellows-type spring loaded
precision lapped ceramic ring, Teflon static seal, and a
precision lapped ceramic rotating collar. The seal cavity is
maintained at intermediate pressure with its oil discharged
to the oil drain from the compressor. Combining intermediate pressure with direct oil injection provides cool, nonfoaming lubricant to the seal which assures a long life.
Capacity control shall be achieved by use of a slide
valve to provide fully modulating control from 100% to
10% of full load. The slide valve shall be actuated by oil
pressure, controlled by external solenoid valves through
the OptiView Control Center. The unit shall be capable
of operating with lower temperature cooling tower water
during part-load operation in accordance with AHRI Standard 550/590. If the unit can not operate at the minimum
load, the manufacturer shall provide a hot-gas-bypass
system to allow operation at 10% load, and advise the
minimum load and power input of the unit at the point
hot-gas-bypass is actuated.
Lubrication System
An adequate supply of oil shall be available to the compressor at all times. During start-up and coastdown, this
shall be achieved by oil reservoirs in the compressor.
During operation, oil shall be delivered by positive system
pressure differential.
All chillers shall be provided with a single oil filter housing with isolation valves. An optional dual filter is available which allows immediate switching from one filter
to the other, eliminating downtime during filter changes.
The off-line oil filter must be capable of being changed
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
during chiller operation. The chiller shall ship with a 3

micron absolute oil filter, (two filters for dual filter option)
maintaining a clean oil system and ensuring superior
compressor life.
A 1500W immersion oil heater shall be provided and
temperature actuated to effectively remove refrigerant
from the oil. Power wiring to the Control Center shall be
factory installed. The oil cooler shall be refrigerant cooled
and factory piped, requiring no auxiliary water or refrigerant piping in the field. An oil eductor shall be provided
to automatically remove oil which may have migrated to
the evaporator and return it to the compressor. The oil
separator shall be of a horizontal design with no moving
parts, and shall provide effective oil separation before the
refrigerant enters the heat exchangers. The oil separator
shall be designed, tested and stamped in accordance
with ASME Boiler and Pressure Vessel Code, Section
VIII Division 1.
Motor Driveline
The compressor motor shall be an open drip-proof, squirrel-cage, induction type operating at 3570 RPM (2975
RPM for 50 Hz operation).
The open motor shall be provided with a D-flange, bolted
to a cast-iron adaptor mounted on the compressor to allow
the motor to be rigidly coupled to the compressor to provide factory alignment of motor and compressor shafts.
Motor drive shaft shall be directly connected to the
compressor shaft with a flexible disc coupling. Coupling
shall have all metal construction with no wearing parts
to assure long life, and no lubrication requirements to
provide low maintenance. For units utilizing remote electromechanical starters, a large steel terminal box with
gasketed front access cover shall be provided for field
connected conduit. Overload/overcurrent transformers
shall be furnished with all units. (For units furnished
with factory packaged Solid State Starters, refer to the
Options section.)
Evaporator
Evaporator shall be of the shell-and-tube, flooded type
designed for 300 psig (2069 KPa) working pressure on
the refrigerant side. Shell shall be fabricated from rolled
carbon steel plate with fusion welded seams; have carbon
steel tube sheets, drilled and reamed to accommodate the
tubes; and intermediate tube supports spaced no more
than four feet apart. The refrigerant side shall be designed,
tested and stamped in accordance with ASME Boiler and
JOHNSON CONTROLS
Pressure Vessel Code, Section VIII Division 1. When

required by the refrigeration safety code, the vessel shall
have a refrigerant relief device(s) set at 300 psig (2069
KPa). Tubes shall be high-efficiency, internally enhanced
type. Each tube shall be roller expanded into the tube
sheets providing a leak-proof seal, and be individually
replaceable. Water velocity through the tubes shall not
exceed 12 FPS (3.6 m/s). Liquid level sight glass shall
be located on the side of the shell to aid in determining
proper refrigerant charge.
Water boxes shall be removable to permit tube cleaning and replacement. Stubout water connections having
ANSI/AWWA C-606 grooves shall be provided. Water
boxes shall be designed for 150 psig (1034 KPa) design
working pressure and be tested at 225 psig (1551 KPa).
Vent and drain connections with plugs shall be provided
on each water box.
Condenser
Condenser shall be of the shell-and-tube type, designed
for 300 psig (2069 KPa) working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel
plate with fusion welded seams; have carbon steel tube
sheets, drilled and reamed to accommodate the tubes;
and intermediate tube supports spaced no more than four
feet apart. A refrigerant subcooler shall be provided for
improved cycle efficiency. The refrigerant side shall be
designed, tested and stamped in accordance with ASME
Boiler and Pressure Vessel Code, Section VIII Division
1. When required by the refrigeration safety code, the
vessel shall have a refrigerant relief device(s) set at 300
psig (2069 KPa). Tubes shall be high-efficiency, internally
enhanced type. Each tube shall be roller expanded into the
tube sheets providing a leak-proof seal, and be individually replaceable. Water velocity through the tubes shall
not exceed 12 FPS.
Water boxes shall be removable to permit tube cleaning and replacement. Stubout water connections having
ANSI/AWWA C-606 grooves shall be provided. Water
Boxes shall be designed for 150 psig (1034 KPa) design
working pressure and be tested at 225 psig (1551 KPa).
Vent and drain connections with plugs shall be provided
on each water box.
Refrigerant System
The YS chiller is equipped with a refrigerant metering
device consisting of a fixed orifice and solenoid valve
controlled via the OptiView Control Center. This control
ensures proper refrigerant flow to the evaporator over a
51
FORM 160.80-EG1 (210)
Guide Specifications - continued

wide range of operating conditions, including thermal storage applications and chilled water reset. Valve operation
is programmable and can be customized for a specific
application via the OptiView Control Center keypad.
The condenser shell shall be capable of storing the entire
system refrigerant charge during servicing. Isolation from
the rest of the system shall be by manually operated isolation valves located at the inlet and outlet of the condenser.
Additional valves shall be provided to facilitate removal of
refrigerant charge from the system.
General The chiller shall be controlled by a stand-alone
microprocessor based control center. The chiller control
panel shall provide control of chiller operation and monitoring of chiller sensors, actuators, relays and switches.
Control Panel The control panel shall include a 10.4in. diagonal color liquid crystal display (LCD) surrounded
by soft keys which are redefined based on the screen
displayed at that time. This shall be mounted in the middle
of a keypad interface and installed in a locked enclosure.
The screen shall detail all operations and parameters,
using a graphical representation of the chiller and its
major components. Panel verbiage shall be available in
other languages as an option with English always available. Data shall be displayed in either English or Metric
units. Smart Freeze Point Protection shall run the chiller
at 36F (2.22C) leaving chilled water temperature, and
not have nuisance trips on low water temperature. The
sophisticated program and sensor shall monitor the chiller
water temperature to prevent freeze-up. When needed,
Hot Gas Bypass is available as an option. The panel shall
display countdown timer messages so the operator knows
when functions are starting and stopping. Every programmable point shall have a pop-up screen with the allowable
ranges, so that the chiller can not be programmed to
operate outside of its design limits.
The control panel shall be provided with a thermal ice
storage control mode to enhance system performance
during ice building operation. In the thermal storage control
mode, the chiller shall stay at 100% load until the setpoint
shutdown temperature is reached. To add greater operating flexibility and eliminate unnecessary chiller cycling,
two different Low Water (Liquid) Temperature Restart
Thresholds shall be programmable, one for the ice mode
and one for the standard cooling mode. The chiller shall
have the capability to remain in the standard control mode
for temperatures between 20 to 70F (-6.7 to 21.1C) for
applications involving a process cooling duty that requires
leaving chilled liquid temperature setpoint control.
52
The chiller control panel shall also provide:

1. System operating information including:
a. Return and leaving chilled water temperature
b. Return and leaving condenser water temp.
c. Evaporator and condenser saturation temp.
d. Oil pressure at compressor and oil filter
differential
e. Percent motor current
f. Evaporator and condenser saturation temp.
g. Compressor discharge temperature
h. Oil temperature
i. Percent slide valve position
j. Operating hours
k. Number of unit starts
2. Digital programming of setpoints through the universal keypad including:
a. Leaving chilled water temperature
b. Percent current limit
c. Pull-down demand limiting
d. Six-week schedule for starting and stopping the
chiller, pumps and tower
e. Remote reset temperature range
3. Status messages indicating:
a. System ready to start
b. System running
c. System coastdown
d. System safety shutdown-manual restart
e. System cycling shutdown-auto restart
f. System prelube
g. Start inhibit
4. The text displayed within the system status and
system details field shall be displayed as a color
coded message to indicate severity: red for safety
fault, orange for cycling faults, yellow for warnings,
and green for normal messages.
5. Safety shutdowns enunciated through the display and
the status bar, and consist of system status, system
details, day, time, cause of shutdown, and type of
restart required. Safety shutdowns with a fixed speed
drive shall include:
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
a. Evaporator - low pressure
d. Leaving chilled liquid - low temperature
b. Evaporator - low pressure - smart freeze
e. Leaving chilled liquid - flow switch open
c. Evaporator - transducer or leaving liquid probe
f. Condenser - flow switch open
d. Evaporator - transducer or temperature sensor
g. Motor controller - contacts open
e. Condenser - high pressure contacts open
h. Motor controller - loss of current
f. Condenser - high pressure
i. Power fault
g. Condenser - pressure transducer out of range
j. Control panel - schedule
h. Auxiliary safety - contacts closed
6.1 Cycling shutdowns with a Solid State Starter (LCSSS)

shall include:
i. Discharge - high temperature

j. Discharge - low temperature
k. Oil - high temperature
l. Oil - low differential pressure
m. Oil - low differential seal pressure
n. Oil or condenser transducer error
o. Oil - clogged filter
p. Oil- high pressure
q. Oil - separator - low level
r. Control panel - power failure
s. Watchdog - software reboot
5.1. Safety shutdowns with a Solid State Starter (LCSSS)
shall include:
a. Initialization failed
b. Serial communications
c. Requesting fault data
d. Stop contacts open
e. Power fault
f. Low phase (X) temperature sensor
g. Run signal
h. Invalid current scale selection
i. Phase locked loop
j. Low supply line voltage
k. High supply line voltage
l. Logic board processor
a. Shutdown - requesting fault data...
m. Logic board power supply
b. High instantaneous current
n. Phase loss
c. High phase (X) heatsink temperature - running
7. Security access to prevent unauthorized change

of setpoints, to allow local or remote control of the
chiller, and to allow manual operation of the prerotation vanes and oil pump. Access shall be through ID
and password recognition, which is defined by three
different levels of user competence: view, operator,
and service.
d. 105% motor current overload

e. Motor or starter - current imbalance
f. Phase (X) shorted SCR
g. Open SCR
h. Phase rotation
6. Cycling shutdowns enunciated through the display
and the status bar, and consisting of system status,
system details, day, time, cause of shutdown, and
type of restart required.
Cycling shutdowns with a fixed speed drive shall
include:
a. Multiunit cycling - contacts open
b. System cycling - contacts open
8. Trending data with the ability to customize points of

once every second to once every hour. The panel
shall trend up to 6 different parameters from a list of
over 140, without the need of an external monitoring
system.
9. The operating program stored in non-volatile
memory (EPROM) to eliminate reprogramming the
chiller due to AC power failure or battery discharge.
Programmed setpoints shall be retained in lithium
battery-backed RTC memory for a minimum of 11
years with power removed from the system.
c. Control panel - power failure

JOHNSON CONTROLS
53
Guide Specifications- continued

10. A fused connection through a transformer in the
compressor motor starter to provide individual overcurrent protected power for all controls.
11. A numbered terminal strip for all required field interlock wiring.
12. An RS-232 port to output all system operating data,
shutdown/cycling message, and a record of the last
10 cycling or safety shutdowns to a field-supplied
printer. Data logs to a printer at a set programmable
interval. This data can be preprogrammed to print
from 1 minute to 1 day.
13. The capability to interface with a building automation
system to provide:
a. Remote chiller start and stop
b. Remote leaving chiller liquid temperature adjust
c. Remote current limit setpoint adjust
d. Remote ready to start contacts
e. Safety shutdown contacts
f. Cycling shutdown contacts
g. Run contacts
COMPRESSOR MOTOR STARTER
(OPTION, 200 - 600V)
The chiller manufacturer shall furnish a reduced-voltage
Solid State Starter for the compressor motor. Starter
shall be factory-mounted and wired on the chiller. The
starter shall provide, through the use of silicon controlled
rectifiers, a smooth acceleration of the motor without
current transitions or transients. The starter enclosure
shall be NEMA 1, with a hinged access door with lock
and key. Electrical lugs for incoming power wiring shall
be provided.
FORM 160.80-EG1 (210)
Display Only:
3-phase voltage A, B, C
3-phase current A, B, C
Input power (kW)
kW Hours
Starter Model
Motor Run (LED)
Programmable:
Other features include: low-line voltage, 115-volt control
transformer; three-leg sensing overloads; phase rotation
and single-phase failure protection; high temperature
safety protection, motor current imbalance and undervoltage safeties; open and close SCR protection; momentary
power interruption protection. The LCSSS is cooled by a
closed loop, fresh water circuit consisting of a water-towater heat exchanger and 1/25 HP circulating pump. All
interconnecting water piping is factory installed and rated
for 150 PSIG working pressure. Optional unit-mounted
circuit breaker includes ground fault protection and provides 65,000 amp. Short circuit withstand rating in accordance with UL Standard 508. A non-fused disconnect
switch is also available. Both options are padlockable.
REMOTE ELECTRO-MECHANICAL COMPRESSOR
MOTOR STARTER (OPTIONAL)
A remote electro-mechanical starter of the R-1051 type
shall be furnished for each compressor motor. The starter
shall be furnished in accordance with the chiller manufacturers starter specifications and as specified elsewhere
in these specifications.
Standard features include: digital readout at the OptiView

Control Center of the following:
54
JOHNSON CONTROLS
FORM 160.80-EG1 (210)
PORTABLE REFRIGERANT STORAGE/RECYCLING

SYSTEM
A portable, self-contained refrigerant storage/recycling
system shall be provided consisting of a refrigerant compressor with oil separator, storage receiver, water cooled
condenser, filter drier and necessary valves and hoses
to remove, replace and distill refrigerant. All necessary
controls and safety devices shall be a permanent part of
the system.
JOHNSON CONTROLS
START-UP AND OPERATOR TRAINING

The chiller manufacturer shall include the services of a
factory-trained, field service representative to supervise
the final leak testing, charging and the initial start-up and
concurrent operator instruction.
55
Metric Conversion Tables

MEASUREMENT

MULTIPLY THIS

BY
ENGLISH VALUE

CAPACITY

POWER

FLOW RATE

LENGTH

WEIGHT

VELOCITY

PRESSURE DROP

TONS REFRIGERANT EFFECT (ton)

KILOWATTS (kW)
HORSEPOWER (hp)
GALLONS / MINUTE (gpm)
FEET (ft)
INCHES (in)
POUNDS (lb)
FEET / SECOND (fps)
FEET OF WATER (ft)
POUNDS / SQ. INCH (psi)
TO OBTAIN THIS
METRIC VALUE
3.516
NO CHANGE
0.7457
0.0631
304.8
25.4
0.4536
0.3048
2.989
6.895
KILOWATTS (kW)
KILOWATTS (kW)
KILOWATTS (kW)
LITERS / SECONDS (L/s)
MILLIMETERS (mm)
MILLIMETERS (mm)
KILOGRAMS (kg)
METERS / SECOND (m/s)
KILOPASCALS (k Pa)
KILOPASCALS (k Pa)
Temperature
Integrated Part Load Value (IPLV)
To convert degrees Fahrenheit (F) to degrees Celsius (C),

subtract 32 and multiply by 5/9 or 0.5556.
In the English I-P system, IPLV is calculated by the following

formula. A full explanation is shown on page 4:
To convert a temperature range (i.e., 10F or 12F chilled

water range) from Fahrenheit to Celsius, multiply by 5/9
or 0.5556.

1
IPLV* =
0.01
0.42
0.45
0.12

+
+
+
A
B
C
D

Where: A = kW / ton at 100% Load @ 85F ECFT

B = kW / ton at 75% Load @ 75F ECFT

C = kW / ton at 50% Load @ 65F ECFT

D = kW / ton at 25% Load @ 65F ECFT
Efficiency
In the English I-P system, chiller efficiency is measured
in kW / ton:

kW / ton =

kW input
tons refrigerant effect
In SI Metric, the formula is:

IPLV* = 0.01A + 0.42B + 0.45C + 0.12D
In the SI Metric system, chiller efficiency is measured in

Coefficient of Performance (COP).

COP

kW refrigeration effect
kW input
kW / ton and COP are related as follows:

kW / ton =

COP =

3.516
COP
3.516
kW / ton
Printed on recycled paper

Form 160.80-EG1 (210) Supersedes: 160.80-EG1 (808)
2008 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53201 Printed in USA
www.johnsoncontrols.com
Where: A =
B =
C =
D =
COP at 100% Load @ 29.4C ECFT

* NOTE: The Non-Standard Part-Load Value (NPLV) uses

the IPLV formula with the following exceptions: the ECFT
for part-load points varies linearly from the selected EFT to
65F (18.3C) from 100% to 50% loads, and fixed at 65F
(18.3C) for 50% to 0% loads.
FOULING FACTOR

ENGLISH I-P
(ft2 F hr/BTU)
0.0001
0.00025
0.0005
0.00075
EQUIVALENT SI METRIC
(M2 K/kW)
0.018
0.044
0.088
0.132

Model YS Rotary Screw Liquid Chillers Design Level E: FORM 160.80-EG1

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FORM 160.

Model YS Rotary Screw Liquid Chillers

100 THRU 675 TONS

Products are produced at a

FORM 160.80-EG1 (210)

FORM 160.80-EG1 (210)

FORM 160.80-EG1 (210)

AHRI CERTIFICATION PROGRAM

ratings can be tailored to specific job requirements, and

OptiView Control Center

OPTIVIEW CONTROL CENTER

FORM 160.80-EG1 (210)

(E-M) starter, or any customer supplied E-M starter that

OptiView Control Center - continued

FORM 160.80-EG1 (210)

FORM 160.80-EG1 (210)

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

Condenser Saturation Temperature

OptiView Control Center - continued

Slide Valve Position

The HOT GAS BYPASS screen, accessed from the COM-

PRESSOR screen, displays a pictorial of the bypass line

FORM 160.80-EG1 (210)

The OIL SEPARATOR screen displays a close-up view

FORM 160.80-EG1 (210)

The SOLID STATE STARTER (SSS) screen displays a

Pulldown Demand Time

OptiView Control Center - continued

FORM 160.80-EG1 (210)

the conditions, while the chiller is running or stopped.

FORM 160.80-EG1 (210)

System Lockout Delay

OptiView Control Center - continued

Safety Shutdown Messages include:

FORM 160.80-EG1 (210)

Discharge High Temperature

Solid State Starter Only (LCSSS)

FORM 160.80-EG1 (210)

provides cool, non-foaming lubricant to the seal assuring

The services of a Johnson Controls factory-trained, field

The oil separator is a horizontal design without moving

Capacity control is achieved by use of a slide valve which

Each vessel has a refrigerant relief device(s) set at 300

FORM 160.80-EG1 (210)

Mechanical Specifications - continued

The compressor motor is an open drip-proof, squirrel

FORM 160.80-EG1 (210)

cilitate removal of the refrigerant from the system when

Evaporator and Condenser Saturation Tem

Evaporator and Condenser Saturation Tem

Percent Slide Valve Position

The control panel includes a 10.4 inch diagonal color liquid

The control panel includes a thermal ice storage control

Compressor Discharge Temperature

Number of Unit Starts

FORM 160.80-EG1 (210)

Mechanical Specifications - continued

Requesting Fault Data

Auxiliary Safety Contacts Closed