York YS User Manual

FORM 160.80-EG1 (808)

Rated in Accordance

with the latest edition of ARI

STANDARD 550/590

Model YS Rotary Screw Liquid Chillers

Design Level E

100 thru 675 tons
(315 thru 2375 KW)

r-22 and r-134a

TABLE OF CONTENTS

PAGE

INTRODUCTION ........................................................... 3

RATINGS ....................................................................... 4

OPTIVIEW CONTROL CENTER ................................... 5

MECHANICAL SPECIFICATIONS ................................ 13

ACCESSORIES & MODIFICATIONS ............................ 17

UNIT COMPONENTS ................................................... 19

APPLICATION DATA ..................................................... 20

DIMENSIONS – STD ..................................................... 28

S0-S3 Compressor .................................................... 28

S4 & S5 Compressor ............................................... 29

Compact Water Box Nozzle Arrangements ............... 30

Floor Layout .............................................................. 31

Cooler Nozzle Arrangements .................................... 32

Condenser Nozzle Arrangements ............................. 34

WEIGHTS – STD ........................................................... 36

DIMENSIONS – METRIC .............................................. 38

S0-S3 Compressor .................................................... 38

S4 & S5 Compressor ............................................... 39

Compact Water Box Nozzle Arrangements ............... 40

Floor Layout .............................................................. 41

Cooler Nozzle Arrangements .................................... 42

Condenser Nozzle Arrangements ............................. 44

WEIGHTS – METRIC .................................................... 46

GUIDE SPECIFICATIONS ............................................ 48

METRIC CONVERSION TABLES ................................. 53

LIST OF TABLES

TABLE

NO.

1 Water Flow Rate Limits.................. 20

2 Motor Voltage Variations ................ 23

3 60 Hz Electrical Data ..................... 25

4 Motor Starters ................................ 25

5 50 Hz Electrical Data ..................... 26

6 Available Compressor/Shell/
Motor Combinations

(R-22 & R-134a) ............................ 26

7 Available Compressor/Shell/
Motor Combinations

(50 Hz, R-134a Only) ..................... 27

PAGE

NOMENCLATURE

The model number denotes the following characteristics of the unit:

YS BB BA S0 – CF E S

Model

Cooler Code

Condenser Code

Compressor Code

Power Supply:
– for 60 Hz
5 for 50 Hz

2 JOHNSON CONTROLS

Special Features

Design Level

Motor Code

Introduction

FORM 160.80-EG1 (808)

The YORK Millennium YS Chiller offers a complete com-
bination of features for total owner satisfaction.

MATCHED COMPONENTS MAXIMIZE EFFICIENCY

Actual chiller efciency cannot be determined by analyzing
the theoretical efciency of any one chiller component.
It requires a specic combination of heat exchanger,

compressor, and motor performance to achieve the low­est system kW/Ton. YORK Millennium chiller technology
matches chiller system components to provide maximum
chiller efciency 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 Millennium chillers are the only chillers designed
to operate on a continuous basis with cold ECWT and full

condenser ow at all load points, taking full advantage of
Real-World conditions. This type of operation benets the

cooling tower as well; reducing cycling of the fan motor

and ensuring good coverage of the cooling ll.

YORK Millennium chillers offer the most efcient Real-
World operation of any chiller, meaning lower operating
costs and an excellent return on your chiller investment.

Insurance companies that offer policies on large air condi­tioning equipment often consider air-cooled motors a sig-

nicant advantage over hermetic refrigerant cooled units.

HIGH-EFFICIENCY HEAT EXCHANGERS

Millennium chiller heat exchangers offer the latest tech­nology in heat transfer surface design to give you maxi-

mum efciency and compact design. Water-side and

refrigerant-side design enhancements minimize both
energy consumption and tube fouling.

FACTORY PACKAGING REDUCES FIELD LABOR
COSTS

YORK Millennium 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 Solid-State
Starter, the three power leads provide all power to the
chiller and its auxiliaries.

TAKE ADVANTAGE OF COLDER COOLING TOWER
WATER TEMPERATURES

YORK Millennium 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 articially holding it

above 75°F (23.9°C), especially at low load, as some
chillers require.

OPEN DRIVE DESIGN

Hermetic-motor burnout can cause catastrophic damage
to a chiller. The entire chiller must be cleaned, and the
refrigerant replaced. YORK Millennium screw chillers
eliminate this risk by utilizing air-cooled motors. Refrig­erant never comes in contact with the motor, preventing
contamination of the rest of the chiller.

U.L. ACCEPTANCE – YOUR ASSURANCE OF RELI­ABILITY

YORK Millennium screw chillers are approved for listing
by Underwriter’s Laboratories for the United States and
Canada. Recognition of safety and reliability is your as­surance of trouble-free performance in day-to-day building
operation.

3JOHNSON CONTROLS

Ratings

Rated in accordance with the latest
issue of ARI Standard 550/590.

ARI CERTIFICATION PROGRAM

The performance of YORK Millennium chillers is certied
to the Air Conditioning and Refrigeration Institute (ARI)

complying with the certication sections of the latest issue
of ARI Standard 550/590. Under this Certication Pro-

gram, chillers are regularly tested in strict compliance with
this Standard. This provides an independent, third-party

verication of chiller performance.

COMPUTERIZED PERFORMANCE RATINGS

Each chiller is custom-matched 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 signicantly with each heat exchanger

and pass arrangement. Computerized ratings are avail-

able through each Johnson Controls sales ofce. These
ratings can be tailored to specic job requirements, and
are part of the ARI Certication Program.

OFF-DESIGN PERFORMANCE

Since the vast majority of its operating hours are spent

at off-design conditions, a chiller should be chosen not
only to meet the full-load design, but also for its ability to

perform efciently at lower loads and lower tower water

temperatures. It is not uncommon for chillers with the
same full-load KW/TON to have an operating cost differ­ence of over 10% due to part-load operation.

Part-load information can be easily and accurately gener­ated by computer. And because it is so important to an
owner’s operating budget, this information is now stan-

dard within the ARI Certication Program in the form of

an Integrated Part-Load Value (IPLV), and Non-Standard
Part-Load Value (NPLV).

The IPLV / NPLV formulas from ARI 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 proles, and local

weather data. Part-load performance data should be ob-

tained for each job using its own design criteria.

4 JOHNSON CONTROLS

OptiView Control Center

FORM 160.80-EG1 (808)

OPTIVIEW CONTROL CENTER

The YORK OptiView Control Center, furnished as standard
on each chiller, provides the ultimate in efciency, 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 or R-22 screw chillers. The panel is congured

with a 10.4 inch diagonal color Liquid Crystal Display

(LCD) surrounded by “soft” keys, which are redened 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. All date representations and calculations
use four digits for the year to provide Year 2000 compli­ance.

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
(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 in-

structions for specic 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
eld interlocks that indicate the chiller status. These con­tacts include a Remote Mode Ready To Start, a Cycling

5JOHNSON CONTROLS

OptiView Control Center - continued

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.

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 20°F (11.1°C)] provides exible, efcient use of remote

signal depending on reset needs. Serial data interface
to the YORK ISN 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 Micro Board and makes it available for the YORK
ISN network. This optional board is available through the
Johnson Controls BAS 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 battery­backed RTC memory for 11 years minimum.

Smart Freeze Point Protection can operate the chiller as
low as 36°F (2.22°C) 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.

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 ow 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:

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, COM-

PRESSOR, 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:

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

efcient 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 exibility 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 70°F (-6.7 and

21.1°C), for applications involving a process cooling duty
that requires leaving chilled liquid temperature setpoint
control.

6 JOHNSON CONTROLS

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

FORM 160.80-EG1 (808)

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 ow 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 efciency and less chiller

cycling. The chiller cycles off when the leaving chilled

water temperature is below setpoint and is adjustable

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

Restart is adjustable from setpoint up to a max of 80°F
(44.4°C). The Panel will check for ow to avoid freeze­up of the tubes. If ow 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

• Leaving Chilled Liquid Temperature Setpoints –
Remote Range

• Leaving Chilled Liquid Temperature Setpoints –
Shutdown

• Leaving Chilled Liquid Temperature Setpoints –
Shutdown Offset

• Leaving Chilled Liquid Temperature Setpoints –
Restart

• Leaving Chilled Liquid Temperature Setpoints –
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

• Leaving Chilled Liquid Temperature Cycling Offset –

Restart

The CONDENSER screen displays a cutaway view of the

chiller condenser. The liquid ow is animated to indicate
ow 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

• Condenser Saturation Temperature

• 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 Orice control

parameters and allows a Service Technician to program
the Delta P setpoint. The Low Evaporator Pressure and
Superheat Override LED’s are located on this screen.

A view of the liquid ow piping to the chiller condenser,
along with the solenoid ow control valve, is shown. The

following can also be performed through this screen:

Display Only:

• Condenser Pressure

• Evaporator Pressure

• Delta P (Condenser – Evaporator)

• Discharge Temperature

• Condenser Saturation Temperature

• Superheat Temperature

• Low Evaporator Override (LED)

• Superheat Override (LED)

Programmable:

• Delta P Setpoint

7JOHNSON CONTROLS

OptiView Control Center - continued

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 conguring the optional Hot Gas Bypass. From this

screen you can view the following:

Display Only:

• Differential Oil Pressure

• Oil Temperature

• Discharge Temperature

• Discharge Superheat

• Slide Valve Position

• 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:

• Slide Valve Position

• 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
perform the following:

Display Only:

• Slide Valve Loading (LED)

• Slide Valve Unloading (LED)

• Calibration Message

Programmable:

• Start Calibration

• Cancel Calibration

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:

• Discharge Temperature

• Oil Sump Temperature

• Discharge Superheat

• Oil Pressure

• Filter Pressure

• Seal Pressure

• Differential Oil 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 conguration. The Programmable pulldown

demand to automatically limit motor loading can be
used to minimize building demand charges. Pulldown

8 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

time period control over four hours, and verication of

time remaining in pulldown cycle from display readout.
Separate digital setpoint for current limiting between
30 and 100%.

The ELECTRO-MECHANICAL STARTER (E–M) 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

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

ing, they can all be found on this screen. This screen also

serves as a gateway to a sub-screen for dening the setup

of general system parameters. From this screen you can
perform the following:

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

• Leaving Chilled Liquid Temperature Cycling Offset –

Shutdown

• Leaving Chilled Liquid Temperature Cycling Offset –

Restart

• Remote Analog Input Range

• Local Motor Current Limit

• Pulldown Demand Limit

• Pulldown Demand Time

• Print

The SETUP is the top level of the general congura­tion parameters. It allows programming of the time and

date, along with specications as to how the time will be
displayed. In addition, the chiller conguration as deter­mined by the micro board program jumpers and program

switches is displayed. From this screen you can perform
the following:

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 search-

Display Only:

• Chilled Liquid Pump Operation (Displays Standard or
Enhanced)

• Refrigerant Selection (Displays R-22 or R-134a)

• Anti-Recycle (Displays Disabled or Enabled)

• Power Failure Restart (Displays Manual or Auto-
matic)

• Liquid Type (Displays Water or Brine)

Programmable:

• Set Date

• Set Time

• Clock (Enabled/Disabled)

• 12/24 Hour

9JOHNSON CONTROLS

OptiView Control Center - continued

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 specic 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 dene
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 denition of the language for the

chiller to display and denes the unit of measure.

Programmable:

• System Language

• English/Metric Units

• Output Interval

• Automatic Printer Logging (Enabled/Disabled)

• Print Type

• Print Report

• Print All Histories

The SALES ORDER screen allows denition 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 denition of param-

eters pertaining to operation of the chiller. What is dened

is whether the control of the chiller will be Local, Digital Re­mote, Analog Remote, Modem Remote or ISN Remote.

Programmable

• Control Source

The COMMS screen allows the user to dene 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 dene com­munications Parameters for the Printer.

Display Only

• Time Remaining Until Next Print

Programmable

• Log Start Time

The HISTORY screen allows the user to browse through
the last ten faults; either safety or cycling shutdowns with
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.

10 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

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 identica­tion, 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.

• Data Point Min (1 - 6)

• Data Point Max (1 - 6)

The TREND COMMON SLOTS screen displays the Mas-
ter 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.

Programmable:

• Start

• Stop

• Y-axis

• X-axis

The TREND SETUP screen is used to congure the trend-
ing 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)

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

• 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

11JOHNSON CONTROLS

OptiView Control Center - continued

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

Solid State Starter Only (LCSSS)

• Initialization Failed

• Serial Communications

• Requesting Fault Data

• Stop Contacts Open

• 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

• Discharge – High Temperature

• Discharge – Low Temperature

• Oil – High 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

• Control Panel – Power Failure

• 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

12 JOHNSON CONTROLS

Mechanical Specications

FORM 160.80-EG1 (808)

STANDARD UNIT

General

The YORK Millennium YS Rotary Screw Chiller is com­pletely factory-packaged, 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.

The services of a Johnson Controls factory-trained, eld

service representative are incurred to supervise or perform

the nal leak testing, charging, the initial start-up, and

concurrent operator instructions.

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-ef-

cient 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).

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

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

nal 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.

Each vessel has a refrigerant relief device(s) set at 300
PSIG (2068 kPa). In addition to the spring-loaded, re-seat­ing-type relief valves sized for pressure vessel volume,
each unit is equipped with a rupture disk. This rupture
disk is able to relieve the entire pumping capacity of the
compressor if electronic safeties fail, providing protec­tion for property and personnel. This device is set for
345 PSIG (2378 kPa). Alternatively, the shell side may
be designed to European Pressure Vessel Codes and
stamped in accordance with A.D. Merkblatter or other
European Pressure Vessel design code. When required
by the refrigeration safety code, each vessel has a dual
refrigerant relief device(s).

The rotors are manufactured from forged steel and use

asymmetric proles. 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 efciency.

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

provides cool, non-foaming lubricant to the seal assuring
a longer lifespan.

Capacity Control

Capacity control is achieved by use of a slide valve which

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, coat
down, and in the event of a power failure. During opera-

tion, system pressure differential provides proper oil ow

without the need of an auxiliary oil pump. This minimizes
energy consumption.

The chiller is shipped with a 3 Micron absolute oil lter,

ensuring a clean oil system and superior compressor

life. An external, replaceable cartridge oil lter is supplied

with manual isolation stop valves for ease of servicing.

An optional dual oil lter housing with isolation valves is

available on all units. This allows immediate switching

from one lter to the other, eliminating downtime during
lter changes. The off-line oil lter 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, tem-

perature actuated to efciently remove refrigerant from

the oil. Oil heater power supply is factory wired from
the control panel. A factory-piped refrigerant-cooled oil

13JOHNSON CONTROLS

Mechanical Specications - continued

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.

MOTOR DRIVELINE

The compressor motor is an open drip-proof, squirrel
cage, induction type constructed to Johnson Controls

design specications. 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.

Motor drive shaft is directly connected to the compressor

shaft with a exible disc coupling. Coupling has all metal

construction with no wearing parts 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 eld 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 Modications 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, drilled and reamed to accom­modate the tubes, are welded to the end of each shell.
Intermediate tube supports are fabricated from carbon
steel plates, drilled and reamed to eliminate sharp edges,
and spaced no more than four feet apart. The refrigerant
side of each shell is designed, tested, and stamped in
accordance with ASME Boiler and Pressure Vessel Code,
Section VIII – Division I, or other pressure vessel code
as appropriate.

Tubes

Heat exchanger tubes are state-of-the-art, high efciency,

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-n” 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.

Evaporator

The evaporator is a shell and tube, ooded type heat ex­changer. A distributor trough provides uniform distribution
of refrigerant over the entire shell length to yield optimum
heat transfer. A suction bafe or aluminum mesh elimina­tors are located above the tube bundle to prevent liquid
refrigerant carryover into the compressor. A 1-1/2” 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.

Condenser

The condenser is a shell and tube type, with a discharge

gas bafe to prevent direct high velocity impingement on
the tubes. The bafe is also used to distribute the refrig­erant gas ow properly for most efcient heat transfer.

An integral sub-cooler is located at the bottom of the
condenser shell providing highly effective liquid refriger-

ant subcooling to provide the highest cycle efciency. 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 bafes are located and welded within the water box

to provide the required pass arrangements. Stub-out 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

anges, 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 xed orice and bypass solenoid
valve, which automatically adjusts to all real-world operat­ing conditions. This control ensures proper refrigerant ow

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 specic application via the control

panel keyboard.

14 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

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 fa­cilitate removal of the refrigerant from the system when
necessary.

OPTIVIEW CONTROL CENTER

General

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.

Control Panel

The control panel includes a 10.4 inch diagonal color liquid
crystal display (LCD) surrounded by “soft” keys, which

are redened 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
36°F (2.22°C) 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.

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 tem-

perature is reached. To add greater operating exibility

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
20°F to 70°F (–6.7°C to 21.1°C) 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

• Evaporator and Condenser Saturation Tem
perature

• Oil Pressure at Compressor and Oil Filter

Differential

• Percent Motor Current

• Evaporator and Condenser Saturation Tem
perature

• Compressor Discharge Temperature

• Oil Temperature

• Percent Slide Valve Position

• Operating Hours

• 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 sys-

tem details eld 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 xed speed

drive include:

• Evaporator – Low Pressure

• Evaporator – Low Pressure - Smart Freeze

• Evaporator – Transducer or Leaving Liquid

Probe

15JOHNSON CONTROLS

Mechanical Specications - continued

• Evaporator – Transducer or Temperature Sen­ sor

• Condenser – High Pressure Contacts Open

• Condenser – High Pressure

• Condenser – Pressure Transducer Out Of
Range

• Auxiliary Safety – Contacts Closed

• Discharge – High Temperature

• Discharge – Low Temperature

• Oil – High 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

• Control Panel – Power Failure

• 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 in-

clude:

• 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

6.1 Cycling shutdowns with a Solid State Starter (LCSSS)
include:

• Initialization Failed

• Serial Communications

• Requesting Fault Data

• Stop Contacts Open

• 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

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 dened 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 non-volatile
memory (EPROM) to eliminate reprogramming the
chiller due to AC power failure or battery discharge.
Programmed setpoints are retained in lithium bat­tery-backed 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
over-current protected power for all controls.

11. A numbered terminal strip for all required eld 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 eld-supplied

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.

13. The capability to interface with a building automation

16 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

system to provide:

• remote chiller start and stop

• remote leaving chilled liquid temperature adjust

• remote current limit setpoint adjust

• remote ready to start contacts

• safety shutdown contacts

• cycling shutdown contacts

• run contacts

CODES AND STANDARDS

• ASME Boiler and Pressure Vessel Code – Section
Vlll Division 1.

• ARI 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

• A.D. Merkblatter

ISOLATION MOUNTING

The unit is provided with four vibration isolation mounts
consisting of 1” (25.4 mm) thick neoprene isolation pads

for eld 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 refrig­erant 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 alkyd-modied, vinyl enamel, ma-

chinery paint.

17JOHNSON CONTROLS

Accessories and Modications

SOLID STATE STARTER

The Solid State Starter is a reduced voltage starter that

controls and maintains a constant current ow 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)

• Motor Current % Full Load Amps

• Current Limit Setpoints

• Pulldown Demand Time Left

Programmable:

• Local Motor Current Limit

• Pulldown Demand Limit

• Pulldown Demand Time

Other features include: low line voltage; 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

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 exible, closed-

cell plastic type, 3/4” (19mm) thick is attached with va-

por-proof cement to the evaporator shell, ow 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 90°F (10° to 32°C). 1-1/2” (38mm)
thick insulation is also available for relative humidities up
to 90% and dry bulb temperatures ranging from 50° to
90°F (10° to 32°C).

WATER FLANGES

Four 150 Ib. ANSI raised-face anges, for condenser and

evaporator water connections, are factory welded to water

nozzles. Companion anges, 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 eld instal­lation. Isolators are designed for one-inch (25.4 mm)

deection.

WATER FLOW SWITCHES

Paddle-type, vapor-proof water ow 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 ow switch is required. Condenser water
ow switch is optional.

SEQUENCE CONTROL KIT

For two, three or four units with chilled water circuits con­nected in series or parallel, the kit consists of return water
thermostat, lead-lag selector switch for sequence starting,
and time delay relay, with NEMA-1 enclosures, designed
for 115V-1-50/60 Hz.

18 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

STARTER – FIELD INSTALLED

A eld installed, electro-mechanical compressor motor

starter is available, selected for proper size and type for

job requirements and in accordance with Johnson Controls

Engineering Standard R-1079 for Starters.

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; anges 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 conve­nient 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, lter

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.

19JOHNSON CONTROLS

Unit Components

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20 JOHNSON CONTROLS

OIL SEPARATOR

FORM 160.80-EG1 (808)

MOTOR
TERMINAL
BOX

REAR VIEW

29040A

CONDENSER

21JOHNSON CONTROLS

Application Data

The following is a user’s guide in the application and
installation of Millennium Chillers, and will ensure the reli-
ability 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

Millennium 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 oor, mounting pad or foundation

which is level within 1/4” (6.4 mm) and capable of sup­porting the operating weight of the chiller.

TABLE 1 – WATER FLOW RATE LIMITS – GPM (L/s)

shELL

CodE

Ba

BB

Ca

CB

da

dB

dC

Ea

EB

EC

Fa

FB

FC

Pass MInIMuM MaXIMuM MInIMuM MaXIMuM

1 308 -19.4 1173 -74 399 -25.2 1435 -90.5
2 147 -9.3 586 -37 209 -13.2 751 -47.4
3 97 -6.1 387 -24.4 –– –– –– ––
1 412 -25 8/9 1572 -99.2 510 -32 1/5 1830 -115.5
2 197 -12 2/5 786 -49.6 264 -16 2/3 948 -59 4/5
3 130 -8 1/5 516 -32.6 –– –– –– ––
1 535 -33 4/5 2041 -128.8 677 -42.7 2438 -153 4/5
2 256 -16 1/5 1020 -64.4 355 -22.4 1277 -80 3/5
3 171 -10 4/5 680 -42 8/9 –– –– –– ––
1 700 -44.2 2675 -168.8 880 -55.5 3164 -80.6
2 335 -21.1 1337 -84.4 455 -28.7 1639 -103.4
3 223 -14.1 891 -56.2 –– –– –– ––
1 664 -41.9 2534 -159.9 1215 -76.7 4376 -276.1
2 317 -20 1267 -79.9 630 -39.8 2269 -143.2
3 212 -13.4 844 -53.3 –– –– –– ––
1 943 -59.5 3602 -227.3 1595 -100.6 5740 -362.2
2 451 -28.5 1793 -113.1 820 -51.7 2950 -186.1
3 301 -19 1195 -175.4 –– –– –– ––
1 1257 -79.3 4810 -303.5 –– –– –– ––
2 602 -38 2405 -151.8 –– –– –– ––
3 399 -25.2 1595 -100.6 –– –– –– ––
1 637 -40.2 2546 -160.6 1223 -77.2 4406 -270.8
2 317 -20 1267 -79.7 639 -40.3 2300 -145.1
3 212 -13.4 844 -53.3 –– –– –– ––
1 904 -57 3613 -228 1602 -101.1 5770 -364.1
2 452 -28.5 1805 -113.9 828 -55.2 2982 -188.2
3 301 -19 1196 -75.5 –– –– –– ––
1 1203 -75.9 4810 -303.5 –– –– –– ––
2 602 -38 2405 -151.8 –– –– –– ––
3 399 -25.2 1595 -100.6 –– –– –– ––
1 1203 -75.9 4810 -303.5 2019 -127.4 7267 -458.5
2 602 -38 2405 -151.8 1043 -65.8 3755 -236.9
3 399 -25.2 1595 -100.6 –– –– –– ––
1 1605 -101.3 6418 -405 2726 -172 9822 -619.8
2 802 -50.6 3202 -202 1397 -88.2 5030 -317.4
3 534 -33.7 2135 -134.7 –– –– –– ––
1 2136 -134.8 8541 -538.9 –– –– –– ––
2 1068 -67.4 4270 -269.4 –– –– –– ––
3 710 -44.8 2839 -179.1 –– –– –– ––

EVaPorator CondEnsEr

Sufcient clearance to permit normal service and mainte­nance work should be provided all around and above the
unit. Additional space should be provided at one end of
the unit to permit cleaning of evaporator and condenser
tubes as required. A doorway or other properly located
opening may be used.

The chiller should be installed in an indoor location
where temperatures range from 40°F to 110°F (4.4°C to

43.3°C).

Water Circuits

Flow Rate – For normal water chilling duty, evaporator

ow 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 ow rates

are permitted between 3.33 ft./sec. and 12 ft./sec. (1.01

m/s and 3.66 m/s). Variable ow applications are possible,

22 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

and initial chiller selections should be made accordingly to

permit proper range of ow while maintaining the minimum
velocity noted above. Variable ow 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 associ-

ated with variable ow, raising system maintenance costs.

Cooling towers typically have narrow ranges of operation

with respect to ow rates, and will be more effective with
full design ow. Ref. Table 1 for ow limits.

Temperature Ranges – For normal water chilling duty,
leaving chilled water temperatures may be selected

between 38°F (3.3°C) [36°F (2.2°C) with Smart Freeze

enabled) and 70°F (21.1°C) for water temperature ranges
between 3°F and 30°F (1.7°C and 16.7°C).

Water Quality – The practical and economical applica­tion of liquid chillers requires that the quality of the water
supply for the condenser and evaporator be analyzed by
a water treatment specialist. Water quality may affect the
performance of any chiller through 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 ow

through the unit. Piping should include offsets to provide

exibility 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.

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 nal connections are made

to the chiller.

Chilled Water – A ow 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 ow switch are at least
ve pipe diameters in length. The switch must be electri-

cally 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 eld-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 ow
switch and strainer assure chilled water ow during unit
operation. The loss or severe reduction of water ow could

seriously impair the chiller performance or even result in
tube freeze up.

Condenser Water – The chiller is engineered for maxi-

mum efciency 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-22; Min ECWT = LCHWT + 11+ [(% load/100)

x
(15 - full load condenser water ∆ T)]

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

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
line as close as possible to the chiller. An overhead monorail
or beam may be used to facilitate servicing.

MULTIPLE UNITS

Selection – Many applications require multiple units

to meet the total capacity requirements as well as to

provide exibility and some degree of protection against

equipment shutdown. There are several common unit
arrangements for this type of application. The Millennium
Chiller has been designed to be readily adapted to the
requirements of these various arrangements.

23JOHNSON CONTROLS

Application Data - continued

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 efciency of

the chiller plant. It is recommended to use an evapora-

tor by-pass piping arrangement to bypass uid 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 ows 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 owing through the

operating unit, that unit will cool the water to the desired
temperature.

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 32°F (0°C). The
brine MUST NOT ow 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 ow 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 re. 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,

overow valves or type tested Safety Pressure switches

or a combination of these devices.

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 22°F
(–5.6°C) to 24°F (–4.4°C) leaving brine temperatures.
This performance is enhanced with the standard thermal

In addition to the spring-loaded, re-seating-type relief
valves that are sized for pressure vessel volume, each unit
is equipped with a rupture disk. This rupture disk is able
to relieve the entire pumping capacity of the compressor
if electronic safeties fail, providing protection for property
and personnel. This device is set for 345 psig (2379 KPa)

[45 psig above the re-seating relief valves set at 300 psig

(2069 KPa)].

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,

FIG. 1 – PARALLEL COOLERS
PARALLEL CONDENSERS

24 JOHNSON CONTROLS

FIG. 2 – SERIES COOLERS

PARALLEL CONDENSERS

FORM 160.80-EG1 (808)

Sheet1

Freq Rated Voltage

Operating Voltage

Min. Max.

60Hz

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

50Hz

346 346 311 381

380 380/400 342 423

415 415 374 440

3300 3300 2970 3630

Nameplate

Voltage

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 exible

connection.

SOUND AND VIBRATION CONSIDERATIONS

A Millennium chiller is not a source of objectionable sound
and vibration in normal air conditioning applications.
Neoprene isolation mounts are furnished as standard

with each unit. Optional level-adjusting spring isolator as­semblies designed for 1” static deection are available.

Millennium 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 chiller’s
cold surfaces should be insulated with a vapor barrier

insulation sufcient 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 50°F to 90°F (10°C to 32°C) and relative

humidities up to 75% [3/4” (19mm) thickness] or 90% [1-

1/2” (38mm) thickness]. The insulation is painted and the

surface is exible and reasonably resistant to wear. It is

intended for a chiller installed indoors and, therefore, no

TABLE 2 – MOTOR VOLTAGE VARIATIONS

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
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 specic

requirements. Since the Millennium chiller motor is air­cooled, 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 specic 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 Specication. 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 eld 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

25JOHNSON CONTROLS

Application Data - continued

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
and installed to meet the National Electrical Code (NEC)
and be veried 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 denes

the calculation of ampacity, as summarized below. More

specic 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)

125% of compr. + FLA of all other
Min. Circuit Ampacity =

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

submittal drawings for the specic 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 x Max. Motor FLA
Max. Motor kW

The benet from the FLA correction is the possible use of

smaller power wiring and/or starter size.

motor amps loads on the circuit

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.

The locked rotor amperes (LRA) are read directly from

Tables 3 and 4 for specic 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.

26 JOHNSON CONTROLS

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 154 177 201 237 270 302 327 351 385 424 468 503 554 608 655 690 740 790

FL EFF. – % 92

92 93 93 94 94 95 95 95 95 95 95 95 95 95 95 95.5 95.5

FL PF 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 0.9

VOLTS

208

FLA

389 447 507 594 680 757 799 886 975 1043 1162 — — — — — — —

LRA

2702 3235 3235 3962 4732 5096 5689 6011 6011 7644 8106 — — — — — — —

230

FLA

352 404 464 540 610 685 749 804 882 944 1050 1130 1250 — — — — —

LRA

2598 2598 2865 3460 3788 4260 4755 5162 5780 5780 6900 7400 7724 — — — — —

240

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 — — — — —

380

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

416

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

440

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

460

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

480

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

575

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

600

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

2300

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

3300

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

4000

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

4160

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

Sheet1

TYPE STARTER 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

NONE — 45 CLOSED — 33 OPEN — 33 CLOSED 80 64 — — 100 CLOSED 65 65 CLOSED 80 80

SOLID STATE

STARTER

TRANSITION % TAP
INRUSH AS A % OF

LRA

CLOSED 57.7

33

CLOSED 65

42.3

FORM 160.80-EG1 (808)

NOTE: FLA = Full Load Amps; LRA = Locked Rotor Amps

TABLE 4 – MOTOR STARTERS

27JOHNSON CONTROLS

Application Data - continued

TABLE 5 – 50 HZ ELECTRICAL DATA

Motor

CodE

shaFt hP

FL EFF. – %

FL PF

VoLts aMPErEs (MaX)

346

380

400

415

3300

NOTE: 1. Chiller performance for 50 Hertz applications is outside the scope of the ARI Certication Program.

2. FLA = Full Load Amps; LRA = Locked Rotor Amps

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

224 258 302 340 380 417 437 481 528 584 630 692 578 816 860 909 982

FLa

1385 1721 1790 2208 2467 2598 2840 3081 3350 3706 3810 4177 4830 4944 5373 5780 5780

Lra

204 235 275 309 346 379 398 438 481 532 572 630 690 743 783 841 895

FLa

1385 1385 1640 1890 2144 2464 2590 2806 3050 3375 3700 3810 4400 4500 4892 5600 5491

Lra

194 223 261 294 329 360 378 416 457 505 543 599 656 706 744 799 850

FLa

1458 1458 1726 1990 2257 2594 2726 2954 3211 3553 3895 4011 4632 4737 5150 5895 5780

Lra

187 215 252 284 317 347 364 401 441 487 526 577 632 680 717 764 819

FLa

1283 1385 1490 1700 2031 2175 2366 2569 2794 3088 3402 3478 3810 4117 4480 5130 5108

Lra

FLa

Lra

24 27 32 36 41 44 47 50 56 62 66 73 80 87 91 96 103

159 162 209 236 241 274 294 318 317 388 423 455 499 516 572 614 644

TABLE 6 – AVAILABLE COMPRESSOR/SHELL/MOTOR COMBINATIONS (R-22 & R-134a)

CoMPrEssor

CodE

s0

s1

s2

s3

s4

s5

CooLEr

shELL

BA, BB BA, BB, CA, CB

CA, CB BA, BB, CA, CB

BA, BB BA, BB, CA, CB

CA, CB BA, BB, CA, CB CJ, CK

CA, CB CA, CB, DA, DB

DA, DB, DC CA, CB, DA, DB 5 CG, 5 CH

DA, DB, DC CA, CB, DA, DB

EA, EB, EC

FA, FB, FC

FA, FB, FC FA, FB

CondEnsEr

shELL

EA, EB, FA, FB

FA, FB

r-22, 60 hZ r-134a, 60 hZ r-22, 50 hZ

CF, CG, CH CF, CG, CH 5 CC, 5 CD

CF, CG, CH,

CJ, CK

CG, CH, CJ,
CK, CL, CM

CJ, CK, CL, CM,

CN, CP, CR

CK, CL, CM, CJ, CK, CL, CM, CN, CP, 5 CF, 5 CG,

CN, CP, CR, CR, CS, CT, CU, CV 5 CH, 5 CI,

CS, CT, CU,

CV

Motor CodE

CF, CG, CH,

CF, CG, CH, CJ

CK, CL, CM

CG, CH, CJ, CK

CL, CM, CN, CP, CR

CK, CL, CM, CN, CP, CR

CS, CT, CU, CV

5 CC, 5 CD, 5 CE,

5 CF

5 CD, 5 CE, 5 CF,

5 CF, 5 CG, 5 CH,

5 CI, 5 CJ, 5 CK

5 CJ, 5 CK,

5 CL, 5 CM,

5 CN, 5 CO

28 JOHNSON CONTROLS

TABLE 7 – AVAILABLE COMPRESSOR/SHELL/MOTOR COMBINATIONS (50 HZ, R-134a ONLY)

FORM 160.80-EG1 (808)

CoMPrEssor

CodE

s0

s1

s2

s3

s4

s5

CooLEr

shELL

BA, BB BA, BB, CA, CB 5 CC, 5 CD

CA, CB BA, BB, CA, CB

BA, BB BA, BB, CA, CB 5 CC, 5 CD,

CA, CB BA, BB, CA, CB 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

CondEnsEr

shELL

Motor CodE

5 CJ, 5 CK, 5 CL,

5 CM, 5 CN, 5 CO

29JOHNSON CONTROLS

Dimensions – Std

S0 - S3 COMPRESSOR

R-22 & R-134a UNITS

(50 and 60 Hz)

s0 and s1 CoMPrEssor s2 CoMPrEssor s2 and s3 CoMPrEssor

dIMEnsIon

B-B B-C C-B C-C B-B B-C C-B C-C C-d d-C d-d

a

1

a

B – oVEraLL hEIGht

C – CooLEr C/L

d – CondEnsEr C/L

Refer to Tables 6 and 7 on pages 26 & 27 for valid compressor/shell/motor combinations.

4’–6-3/4” 4’–6-1/4” 4’-6-3/4” 4’–6-1/4” 5’–3-3/4” 5’–3-3/4”

3

5’–8-5/8” 5’–11-1/2” 5’–10-1/4” 5’–11-1/2” 5’–11-1/4” 6’–3-1/4” 6’–3-1/4” 6’–3-1/4” 6’–7-5/8” 6’–8-3/4” 6’–9-3/8”

4’–2-7/8” 5’–2-1/2” 5’–2-1/2”

1’–1-7/8” 1’–5” 1’–5”

0’–11-5/8” 1’–2-1/4” 1’–2-1/4”

shELL CodEs (EVaPorator – CondEnsEr)

REFRIGERANT RELIEF VALVE CONNECTIONS

shELL CodE EVaPorator sIZE CondEnsEr sIZE

B, C

d

NOTES:

1. All dimensions are approximate. Certied 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 anged 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).

3/4” FPT SINGLE 3/4” FPT DUAL

1” FPT SINGLE 3/4” FPT DUAL

CoMPrEssor CodE oIL sEParator sIZE

S0, S1 2” RUPTURE DISK & 3/4” FPT SINGLE

S2, S3 2” RUPTURE DISK & 3/4” FPT DUAL

30 JOHNSON CONTROLS

S4 - S5 COMPRESSOR

R-22 & R-134a UNITS

(50 and 60 Hz)

FORM 160.80-EG1 (808)

NOTES:

s4 CoMPrEssor s4 and s5 CoMPrEssor

dIMEnsIon

d-C d-d E-E E-F F-E F-F

a

1

a

2

a

B – oVEraLL hEIGht

C – CooLEr C/L

d – CondEnsEr C/L

Refer to Tables 6 and 7 on pages 26 & 27 for valid compressor/shell/motor combinations.

1. All dimensions are approximate. Certied dimensions are available on request.

2. Determine overall unit length by adding water box depth from table below to tube sheet length:

tYPE CoMPaCt WatEr BoX d E F d E F

3

EVaPorator

CondEnsEr

oIL sEParator

RETURN BOX

WITH VICTAULIC CONN.

WITH FLANGED CONN. 1’–2-3/8” 1’–2-3/8” 1’–3-5/8” 1’–2-3/8” 1’–2-3/8” 1’–3-5/8”

6’–2” 6’–2” 6’–2” 6’–4-1/2” 6’–6-1/2” 6’–9”

6’–9-7/8” 6’–9-7/8” 6’–9-7/8” 7’–0-3/8” 7’–3-5/8” 7’–2-5/8”

6’–3-3/8” 6’–3-3/8” — — — —

7’–9-1/8” 7’–9-1/8” 7’–9-1/8” 8’–2-1/4” 8’–2-1/4” 8’–2-1/4”

1’–7-3/4” 1’–7-3/4” 1’–7-3/4” 1’–7-3/4” 1’–10” 1’–10”

1’–5-1/4” 1’–5-1/4” 1’–5-1/4” 1’–6-1/2” 1’–5-1/4” 1’–6-1/2”

rEFrIGErant rELIEF VaLVE ConnECtIons

VEssEL

shELL CodEs (EVaPorator – CondEnsEr)

SIZE

1” FPT SINGLE

1” FPT DUAL

1” FPT DUAL & 2” NOM RUPTURE DISK

EVaPorator CodE CondEnsEr CodE

0’–5-1/2” 0’–5-1/2” 0’–7-3/4” 0’–5-1/4” 0’–5-1/4” 0’–7-5/8”

1’–1-7/8” 1’–1-7/8” 1’–3-1/8” 1’–1-7/8” 1’–1-7/8” 1’–3-1/8”

3. 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).

31JOHNSON CONTROLS

Dimensions - Std - continued

COMPACT WATER BOX NOZZLE ARRANGEMENTS

R-22 & R-134a UNITS

NOZZLE ARRANGEMENTS

no. oF

PassEs

1

2

3

CooLEr

In-out

A-H
H-A

E-B
D-C
M-J
L-K

P-F
G-N

Cond.

In-out

P-Q
Q-P

R-S
T-U

CooLEr

CodE

B

C

d

E

F

no. oF PassEs

1 2 3 aa BB CC dd EE FF

8 6 4 10 11 3/4 14-3/4 17-3/4 19-1/2 5

10 6 6 12 3/4 13 7/8 16 3/4 19 5/8 20 3/4 5 7/8

12 8 6 12 7/8 15 1/4 19 1/4 23 1/4 25 7/8 6 5/8

12 8 6 12 7/8 15 3/8 19 3/8 23 3/8 25 7/8 7 1/2

14 10 8 14-5/8 17 1/2 22 1/4 27 29 7/8 9 1/4

COOLER NOZZLE DIMENSIONS

noZZLE

sIZE (In.)

dIMEnsIons (In.)

CONDENSER NOZZLE DIMENSIONS

noZZLE

CondEnsEr

CodE

B

C

d, E

F

NOTES:

1. All dimensions are approximate (shown for 150 psig DWP water side). Certied 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, anges, 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

anged nozzles are optional. Companion anges, 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.

sIZE (In.)

no. oF PassEs

1 2 GG hh JJ KK

8 6 13 16 3/4 20 1/4 4 1/2

10 8 11 1/2 16 3/4 22 1/8 4 3/8

12 10 14 1/4 20 25 7/8 6

14 12 17 24 1/2 32 7 3/4

dIMEnsIons (In.)

32 JOHNSON CONTROLS

FLOOR LAYOUT – NEOPRENE ISOLATORS

R-22 & R-134a UNITS

FORM 160.80-EG1 (808)

shELL

CoMPrEssor

s0, s1

s2

s2, s3

s4

s4, s5

NOTES:

1. All dimensions are approximate. Certied dimensions are available on request.

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 at and level within 1/4”, capable of carrying the operating weight of the unit.

4. Millennium unit has four steel plate foot supports located under the tube sheets at each corner of shell package. Neoprene isolator pads are

eld installed between foot support and oor.

5. All four neoprene isolator pads are identical. Pads are 1” thick with nominal 0.15” static deection. 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.

CodEs

CooLEr-Cond.

B-B
B-C
C-B
C-C
B-B

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

4’–2-7/8” 10’ 1-7/8” 2-1/2”

5’–2-1/2” 10’ 1-7/8” 2-1/2”B-C

5’–2-1/2” 10’ 1-7/8” 2-1/2”

6’–2” 10’ 1-7/8” 2-1/2”

6’–2”
6’–4-1/2”
6’–6-1/2”

6’–9”

(to outsIdE oF tuBE

B

shELL LEnGth

shEEts)

12’ 1-7/8” 2-1/2”

12’ 1-7/8” 2-1/2”

C

EVaPorator

sIdE

d

CondEnsEr

sIdE

33JOHNSON CONTROLS

Dimensions – Std

EVAPORATOR NOZZLE ARRANGEMENTS – MARINE WATER BOXES

R-22 & R-134a UNITS

1-PASS

MOTOR END COMPR. END MOTOR END COMPR. END

2-PASS

1-PASS

2-PASS

MOTOR END MOTOR ENDCOMPR. END COMPR. END

3-PASS 3-PASS

MOTOR END MOTOR END

CooLEr

sIZE

B
C
d
E
F

a B C d E a B C d E a B C d E

15 1/2 15 1/4 19 — 7 3/4 13 1/2 9 1/2 19 21 6 3/4 13 1/2 11 19 19 1/2 6 3/4
17 1/2 16 3/4 20 3/4 — 8 3/4 13 1/2 11 1/4 20 3/4 22 1/4 6 3/4 13 1/2 13 1/4 20 3/4 22 7/8 6 3/4

20 19 1/4 23 3/4 — 10 15 1/2 14 1/2 23 3/4 29 1/2 7 3/4 15 1/2 13 3/4 23 3/4 25 1/4 7 3/4
20 19 3/8 24 5/8 — 10 16 15 1/8 24 5/8 29 1/8 8 16 13 7/8 24 3/8 25 3/8 8
21 22 3/8 28 1/4 — 10 1/2 19 16 1/4 28 1/4 33 9 1/2 17 15 1/4 28 1/4 29 1/4 8 1/2

1-Pass 2-Pass 3-Pass

COMPR. END COMPR. END

dIMEnsIons (In.)

34 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

EVAPORATOR NOZZLE ARRANGEMENTS – MARINE WATER BOXES

R-22 & R-134a UNITS

MOTOR END

MOTOR END

COMPR. END

1-PASS & 3-PASS EVAPORATORS

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.

EVAPORATORS NOZZLE SIZES

EVaPorator

CodE

B

C

d

E

F

noZZLE sIZE (In.)

no. oF PassEs

1 2 3

8 6 4

10 6 6

12 8 6

12 8 6

12 10 8

EVaPorator

CodE

B

C

d

E

F

WEIGHTS

(To be added to Standard Unit Weights on pages 36-37)

shIPPInG WEIGht

InCrEasE – LBs

1-Pass 2-Pass 3-Pass 1-Pass 2-Pass 3-Pass

554 295 562 788 391 755

810 417 668 1207 592 955

872 439 768 1316 600 1090

1040 607 996 1674 924 1535

1280 875 1130 1900 1025 1685

oPEratInG WEIGht

InCrEasE – LBs

35JOHNSON CONTROLS

Dimensions – Std - continued

CONDENSER NOZZLE ARRANGEMENTS – MARINE WATER BOXES

R-22 & R-134a UNITS

1-PASS

2-PASS

1-PASS

MOTOR END MOTOR END

COMPR. END COMPR. END

2-PASS

CondEnsEr

sIZE

B

C

d

E

F

COMPR. END COMPR. END

dIMEnsIons (In.)

1-Pass 2-Pass

a B C d E a B C d E

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

MOTOR ENDMOTOR END

36 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

CONDENSER NOZZLE ARRANGEMENTS – MARINE WATER BOXES

R-22 & R-134a UNITS

MOTOR END

MOTOR END

1-PASS

COMPR. END

*

*

COMPR. END

2-PASS

* Applies to compressor end if connections are on motor end.
** Applies to motor end if connections are on motor end.

CONDENSER NOZZLE SIZES

CondEnsEr

CodE

B

C

d

E

F

noZZLE sIZE (In.)

no. oF PassEs

1 2

8 6

10 8

12 10

12 10

14 12

WEIGHTS

(To be added to Standard Unit Weights on pages 36-37)

CondEnsEr

CodE

B

C

d

E

F

shIPPInG WEIGht

InCrEasE – LBs

1-Pass 2-Pass 1-Pass 2-Pass

542 241 744 327

686 328 1018 475

818 317 1235 466

818 317 1235 466

1004 459 1586 704

oPEratInG WEIGht

InCrEasE – LBs

37JOHNSON CONTROLS

Weights – Std

R-22 & R-134a UNITS

shELL

CodE
EVaP.

– Cond.

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

CoM-

PrEs-

sor

S0 8,388 9,019 490 441
S0 8,538 9,235 490 441
S0 8494 9187 460 414
S0 8644 9403 460 414
S0 9,142 9,996 520 468
S0 9,416 10,388 520 468
S0 9,271 10186 480 432
S0 9,545 10,579 480 432
S0 9,297 10,084 620 558
S0 9,448 10,299 620 558
S0 9,528 10,412 620 558
S0 9,679 10,627 620 558
S0 10,011 11,020 650 585
S0 10,285 11,413 650 585
S0 10,242 11,348 650 585
S0 10,516 11,740 650 585
S1 8,454 9,085 490 441
S1 8,608 9,301 490 441
S1 8,560 9,253 460 414
S1 8,711 9,469 460 414
S1 9,208 9,974 520 468
S1 9,482 10,454 520 468
S1 9,337 10,252 480 432
S1 9,611 10,645 480 432
S1 9,363 10,150 620 558
S1 9,513 10,365 620 558
S1 9,594 10,478 620 558
S1 9,745 10,693 620 558
S1 10,077 11,086 650 585
S1 10,351 11,479 650 585
S1 10,308 11,414 650 585
S1 10,582 11,806 650 585
S2 10,542 11,174 — 441
S2 10,693 11,390 — 441
S2 10,648 11,342 — 414
S2 10,797 11,558 — 414
S2 11,298 12,065 — 468
S2 11,571 12,547 — 468
S2 11,426 12,342 — 432
S2 11,701 12,735 — 432
S2 11,452 12,241 — 558
S2 11,604 12,457 — 558
S2 11,683 12,567 — 558
S2 11,833 12,783 — 558
S2 12,146 13,155 680 612
S2 12,419 13,547 680 612
S2 12,377 13,483 680 612
S2 12,650 13,874 680 612

shIP­PInG

Wt.

(LBs.)

oPEr­atInG

Wt.

(LBs.)

rEFrIG-

Erant

CharGE

(LBs.
r-22)

rEFrIG-

Erant

CharGE

(LBs.

r-134a)

shELL

CodE
EVaP.

– Cond.

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

CoM-

PrEs-

sor

S2 13,357 14,765 750 675
S2 13,874 15,506 750 675
S2 13,588 15,093 750 11/5/1901
S2 14105 15833 750 675
S2 13293 14480 840 756
S2 13,577 14872 840 756
S2 13,668 15008 840 756
S2 13941 15400 840 756
S2 14,026 15,552 840 756
S2 14,299 15,943 840 756
S2 14,549 16,124 950 855
S2 15,066 16,864 950 855
S2 14,869 16,608 910 819
S2 15,386 17,348 910 819
S2 15,215 17,437 840 756
S2 15,732 16,781 840 756
S3 12,360 13,372 — 612
S3 12,633 13,764 — 612
S3 12,591 13,698 — 612
S3 12,865 14,090 — 612
S3 13,574 14,983 — 675
S3 14,090 15,726 — 675
S3 13,804 15,313 — 675
S3 14,324 16,054 — 675
S3 13,497 14,673 840 756
S3 13,770 15,065 840 756
S3 13,861 15,201 840 756
S3 14,134 15,593 840 756
S3 14,219 15,744 840 756
S3 14,491 16,135 840 756
S3 14,741 16,316 950 855
S3 15,258 17,057 950 855
S3 15,061 16,800 910 819
S3 15,578 17,541 910 819
S3 15,408 17,333 840 756
S3 15,925 18,073 840 756
S4 17,068 18,247 — 740
S4 17,341 18,639 — 740
S4 17,431 18,776 — 740
S4 17,705 19,168 — 740
S4 17,791 19,320 — 740
S4 18,064 19,710 — 740
S4 18,313 19,893 — 830
S4 18,833 20,634 — 830
S4 18,635 20,378 — 800
S4 19,153 21,119 — 800
S4 18,983 20,912 — 740
S4 19,426 21,652 — 740

shIP-

PInG

Wt.

(LBs.)

oPEr­atInG

Wt.

(LBs.)

rEFrIG-

Erant

CharGE

(LBs.
r-22)

rEFrIG-

Erant

CharGE

(LBs.

r-134a)

38 JOHNSON CONTROLS

R-22 & R-134a UNITS

50 AND 60 HZ

FORM 160.80-EG1 (808)

shELL

CodE
EVaP.

– Cond.

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

CoM-

PrEs-

sor

S4 20,460 21,890 1,400 1,260
S4 21,104 22,743 1,400 1,260
S4 20,955 22,484 1,350 1,215
S4 21533 23337 1,350 1,215
S4 21362 23139 1,300 1,170
S4 22,000 23991 1,300 1,170
S4 23,485 25592 1,520 1,368
S4 24695 27192 1,520 1,368
S4 23,914 26,180 1,520 1,368
S4 25,119 27,781 1,450 1,305
S4 24,382 26,840 1,450 1,305
S4 25,592 28,435 1,450 1,305
S4 22,922 24,998 — 1,690
S4 23,638 25,853 — 1,690
S4 23,711 25,902 — 1,690
S4 24,288 26,757 — 1,690
S4 24,171 27,076 — 1,620
S4 25,141 27,929 — 1,620
S4 25,977 28,655 2,000 1,800
S4 27,187 30,256 2,000 1,800
S4 26,626 29,552 2,000 1,800
S4 27,830 31,153 1,900 1,710
S4 27,148 30,730 1,900 1,710
S4 28,688 32,325 1,900 1,710

shIP­PInG

Wt.

(LBs.)

oPEr­atInG

Wt.

(LBs.)

rEFrIG-

Erant

CharGE

(LBs.
r-22)

rEFrIG-

Erant

CharGE

(LBs.

r-134a)

shELL

CodE

EVaP

– Cond.

EA-EA S5 20,777 22,210 — 1,260
EA-EB S5 21,423 23,065 — 6/13/1903
EB-EA S5 21275 22807 — 1215
EB-EB S5 21853 23682 — 1215
EC-EA S5 21,681 23462 — 1,170
EC-EB S5 22,322 24317 — 1,170
EA-FA S5 23808 25919 — 1368
EA-FB S5 25,020 27,521 — 1,368
EB-FA S5 24,240 26,508 — 1,368
EB-FB S5 25,445 28,112 — 1,305
EC-FA S5 24,707 27,171 — 1,305
EC-FB S5 25,919 28,769 — 1,305
FA-EA S5 23,274 25,280 — 1,690
FA-EB S5 23,920 26,135 — 1,690
FB-EA S5 23,991 26,184 — 1,690
FB-EB S5 24,568 27,036 — 1,620
FC-EA S5 24,453 27,356 — 1,620
FC-EB S5 25,423 28,211 — 1,620
FA-FA S5 26,257 28,936 2,000 1,800
FA-FB S5 27,467 30,536 2,000 1,800
FB-FA S5 26,906 29,832 2,000 1,800
FB-FB S5 28,111 31,433 1,900 1,710
FC-FA S5 27,759 31,009 1,900 1,710
FC-FB S5 28,969 32,604 1,900 1,710

CoM-

PrEs-

sor

shIP-

PInG

Wt.

(LBs.)

oPEr­atInG

Wt.

(LBs.)

rEFrIG-

Erant

CharGE

(LBs.
r-22)

rEFrIG-

Erant

CharGE

(LBs.

r-134a)

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.

4. Operating weight based on R-22. Subtract difference in refrigerant charge if using R-134a.

MOTOR WEIGHTS

SOLID STATE STARTER

WEIGHT

Motor CodE WEIGht

60 hZ 50 hZ (LBs)

CF 5 CC 1,080
CG 5 CC 1,080
CH 5 CD 1,120

CJ 5 CE 1,120

CK 5 CF 1,460

CL 5 CG 1,520
CM 5 CH 1930
CN 5 CI 1930

CP 5 CJ 1,980
CR 5 CK 1,980

CS 5 CL 2370

CT 5 CM 2,480
CU 5 CN 2,480

CV 5 CO 2,635

sIZE LBs

7L, 14L 200

26L, 33L 300

39JOHNSON CONTROLS

Dimensions – Metric

S0 - S3 COMPRESSOR

R-22 & R-134a UNITS

(50 and 60 Hz)

DIMENSIONS (mm)

s0 and s1 CoMPrEssor s2 CoMPrEssor s2 and s3 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

a1 – oVEraLL WIdth

B – oVEraLL hEIGht

C – CooLEr C/L

d – CondEnsEr C/L

Refer to Tables 6 and 7 on pages 26 & 27 for valid compressor/shell/motor combinations.

3

1292 1292 1292 1292 1588 1588 1588 1588 1588 1588 1588

1349 1349 1349 1349 1591 1591 1591 1591 1591 1591 1591

1816 1895 1857 1899 1848 1946 1946 1946 2054 2102 2102

351 351 351 351 432 432 432 432 432 432 432

295 291 295 295 362 362 362 362 362 362 362

REFRIGERANT RELIEF VALVE CONNECTIONS

shELL CodE EVaP. sIZE CondEnsEr sIZE

B, C

d

NOTES:

1. All dimensions are approximate. Certied dimensions are available on request.

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 anged water nozzles

3. Unit height includes steel mounting plates under tube sheets. To determine overall installed height, add 22mm for neoprene isolators (25 mm
for optional spring isolators).

3/4” FPT SINGLE 3/4” FPT DUAL

1” FPT SINGLE 3/4” FPT DUAL

CoMPrEssor CodE oIL sEParator sIZE

s0, s1

s2, s3

2” RUPTURE DISK & 3/4” FPT SINGLE

2” RUPTURE DISK & 3/4” FPT DUAL

40 JOHNSON CONTROLS

S4 - S5 COMPRESSOR

R-22 & R-134a UNITS

(50 and 60 Hz)

FORM 160.80-EG1 (808)

DIMENSIONS (mm)

s4 CoMPrEssor s4 and s5 CoMPrEssor

shELL CodEs (EVaPorator – CondEnsEr)

d-C d-d E-E E-F F-E F-F

a – tuBE shEEt WIdth

a1 – WIth soLId statE startEr

a2 – oVEraLL WIdth (LEss s.s.s)

B – oVEraLL hEIGht3

C – EVaPorator C/L

d – CondEnsEr C/L

Refer to Tables 6 and 7 on pages 26 & 27 for valid compressor/shell/motor combinations.

NOTES:

1. All dimensions are approximate. Certied dimensions are available on request.

2. Determine overall unit length by adding water box depth from table below to tube sheet length:

tYPE CoMPaCt WatEr BoX

rEturn BoX

WIth VICtauLIC ConnECtIon

WIth FLanGEd ConnECtIon

1,880 1,880 1,880 1,943 1,994 2,057

2,080 2,080 2,080 2,143 2,226 2,200

1,915 1,915 — — — —

2,365 2,365 2,365 2,496 2,496 2,496

502 502 502 502 559 559

438 438 438 470 438 470

rEFrIGErant rELIEF VaLVE ConnECtIons

VEssEL sIZE

EVaPorator

CondEnsEr

oIL sEParator

1” FPT DUAL & 2” NOM RUPTURE DISK

CooLEr CodE CondEnsEr CodE

d E F d E F

140 140 197 133 133 194

352 352 384 352 352 384

365 365 397 365 365 397

1” FPT SINGLE

1” FPT DUAL

3. 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).

41JOHNSON CONTROLS

Dimensions – Metric - continued

COMPACT WATER BOX NOZZLE ARRANGEMENTS

R-22 and R-134a UNITS

NOZZLE ARRANGEMENTS

no. oF

PassEs

1

2

3

EVaPorator

In-out

A - H P - Q

H - A Q - P

E - B R - S

D - C T - U

M - J

L - K

P - F

G - N

Cond.
In-out

EVaP.
CodE

B

C

d

E

F

EVAPORATOR NOZZLE DIMENSIONS

noZZLE

sIZE (In.)

no. oF PassEs

1 2 3 aa BB CC dd EE FF

8 6 4 254 298 375 451 495 127

10 6 6 324 352 425 498 527 149

12 8 6 327 387 489 591 657 168

12 8 6 327 391 492 594 657 191

14 10 8 371 445 565 686 759 235

dIMEnsIons (MM)

CONDENSER NOZZLE DIMENSIONS

noZZLE

Cond.
CodE

B

C

d

E

F

NOTES:

1. All dimensions are approximate (shown for 1031 KPa DWP water side). Certied 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, anges, 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 anged nozzles are optional. Companion anges, 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.

sIZE (In.)

no. oF PassEs

1 2 GG hh JJ KK

8 6 330 425 514 114

10 8 292 425 562 111

12 10 368 514 660 152

12 10 375 521 667 152

14 12 432 622 813 197

dIMEnsIons (MM)

42 JOHNSON CONTROLS

FLOOR LAYOUT – NEOPRENE ISOLATORS

R-22 & R-134a UNITS

FORM 160.80-EG1 (808)

shELL

CoMPrEssor

s0, s1

s2

s2, s3

s4

s4, s5

NOTES:

1. All dimensions are approximate. Certied dimensions are available on request.

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 at 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

eld installed between foot support and oor.

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.

CodEs

EVaP. - Cond.

B-B
B-C
C-B

C-C

B-B

C-B
C-C
C-D
D-C
D-D
D-C
D-D

E-E 1880MM

E-F 1943MM

F-E 1994MM

F-F 2057MM

a

tuBE shEEt

WIdth

1292MM 3048MM 48MM 64MM

1588MM 3048MM 48MM 64MMB-C

1588MM 3048MM 48MM 64MM

1588MM 3048MM 48MM 64MM

1880MM 3048MM 48MM 64MM

(to outsIdE oF tuBE

B

shELL LEnGth

shEEts)

3658MM 48MM 64MM

3658MM 48MM 64MM

C

EVaP

sIdE

d

CondEnsEr

sIdE

43JOHNSON CONTROLS

Dimensions – Metric - continued

COOLER NOZZLE ARRANGEMENTS – MARINE WATER BOXES

R-22 and R-134a UNITS

1-PASS 1-PASS

MOTOR END MOTOR END

COMPR. END COMPR. END

2-PASS 2-PASS

MOTOR END MOTOR END

COMPR. END COMPR. END

3-PASS 3-PASS

MOTOR END MOTOR END

CooLEr

sIZE

B

C

d

E

F

a B C d E a B C d E a B C d E

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

1-Pass 2-Pass 3-Pass

COMPR. END COMPR. END

DIMENSIONS (mm)

44 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

COOLER NOZZLE ARRANGEMENTS – MARINE WATER BOXES

R-22 & R-134a UNITS

MOTOR END

COMPR. END

1-PASS & 3-PASS COOLERS

COMPR. ENDMOTOR END

2-PASS COOLERS

* Applies to compressor end if connections are on motor end.
** Applies to motor end if connections are on motor end.

EVAP. NOZZLE SIZES

EVaPorator

CodE

B

C

d

E

F

noZZLE sIZE (In.)

no. oF PassEs

1 2 3

8 6 4

10 6 6

12 8 6

12 8 6

12 10 8

WEIGHTS (To be added to Metric Unit Weights on pages 46-47)

CooLEr

CodE

B

C

d

E

F

shIPPInG WEIGht

InCrEasE – KG

1-Pass 2-Pass 3-Pass 1-Pass 2-Pass 3-Pass

252 134 255 358 178 343

368 190 304 549 269 434

396 200 349 598 273 495

473 276 453 761 420 698

582 398 514 864 466 764

oPEratInG WEIGht

InCrEasE – KG

45JOHNSON CONTROLS

Dimensions – Metric - continued

CONDENSER NOZZLE ARRANGEMENTS – MARINE WATER BOXES

R-22 & R-134a UNITS

1-PASS 1-PASS

MOTOR END

COMPR. END COMPR. END

2-PASS

MOTOR END MOTOR END

COMPR. END

MOTOR END

2-PASS

COMPR. END

DIMENSIONS (mm)

CondEnsEr

sIZE

B

C

d

E

F

a B C d E a B C d E

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

1-Pass 2-Pass

46 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

CONDENSER NOZZLE ARRANGEMENTS – MARINE WATER BOXES

R-22 & R-134a UNITS

MOTOR END

MOTOR END

COMPR. END

1-PASS

*

*

COMPR. END

2-PASS

* Applies to compressor end if connections are on motor end.
** Applies to motor end if connections are on motor end.

CONDENSER NOZZLE SIZES

CondEnsEr

CodE

B

C

d

E

F

noZZLE sIZE (In.)

no. oF PassEs

1 2

8 6

10 8

12 10

12 10

14 12

WEIGHTS (To be added to Metric Unit Weights on pages 46-

CondEnsEr

CodE

B

C

d

E

F

shIPPInG WEIGht

InCrEasE – KGs

1-Pass 2-Pass 1-Pass 2-Pass

246 110 338 149

312 149 463 216

372 144 561 212

372 144 561 212

456 209 721 320

oPEratInG WEIGht

InCrEasE – KGs

47JOHNSON CONTROLS

Weights – Metric - continued

R-22 & R-134a UNITS

50 AND 60 HERTZ

REFRIG­REFRIG-

SHELL

CHARGE

COOLER

– COND.

BA-BA S0 3,805 4,091 222 200
BA-BB S0 3,873 4,189 222 200
BB-BA S0 3,853 4,167 209 188
BB-BB S0 3,921 4,265 209 188
BA-CA S0 4,147 4,534 236 212
BA-CB S0 4,271 4,712 236 212
BB-CA S0 4,205 4,620 218 196
BB-CB S0 4,330 4,799 218 196
CA-BA S0 4,217 4,574 281 253
CA-BB S0 4,286 4,672 281 253
CB-BA S0 4,322 4,723 281 253
CB-BB S0 4,390 4,820 281 253
CA-CA S0 4,541 4,999 295 265
CA-CB S0 4,665 5,177 295 265
CB-CA S0 4,646 5,147 295 265
CB-CB S0 4,770 5,325 295 265
BA-BA S1 3,835 4,121 222 200
BA-BB S1 3,905 4,219 222 200
BB-BA S1 3,883 4,197 209 188
BB-BB S1 3,951 4,295 209 188
BA-CA S1 4,177 4,524 236 212
BA-CB S1 4,301 4,742 236 212
BB-CA S1 4,235 4,650 218 196
BB-CB S1 4,360 4,829 218 196
CA-BA S1 4,247 4,604 281 253
CA-BB S1 4,315 4,702 281 253
CB-BA S1 4,352 4,753 281 253
CB-BB S1 4,420 4,850 281 253
CA-CA S1 4,571 5,029 295 265
CA-CB S1 4,695 5,207 295 265
CB-CA S1 4,676 5,177 295 265
CB-CB S1 4,800 5,355 295 265
BA-BA S2 4,782 5,069 — 200
BA-BB S2 4,850 5,167 — 200
BB-BA S2 4,830 5,145 — 188
BB-BB S2 4,898 5,243 — 188
BA-CA S2 5,125 5,473 — 212
BA-CB S2 5,249 5,691 — 212
BB-CA S2 5,183 5,598 — 196
BB-CB S2 5,308 5,777 — 196
CA-BA S2 5,195 5,553 — 253
CA-BB S2 5,264 5,650 — 253
CB-BA S2 5,299 5,700 — 253
CB-BB S2 5,367 5,798 — 253
CA-CA S2 5,509 5,967 308 278
CA-CB S2 5,633 6,145 308 278

CODE

COM-

PRES-

SOR

SHIP- OPER-

PING ATING

WT. WT.

(Kgs.) (Kgs.)

ERANT ERANT
CHARGE

(Kgs. (Kgs.

R-22) R-134a)

REFRIG- REFRIG-

SHELL

COOLER

– COND.

CA-DA S2 6,059 6,697 340 306
CA-DB S2 6,293 7,034 340 306
CB-DA S2 6,164 6,846 340 306
CB-DB S2 6,398 7,182 340 306
DA-CA S2 6,030 6,568 381 343
DA-CB S2 6,159 6,746 381 343
DB-CA S2 6,200 6,808 381 343
DB-CB S2 6,324 6,985 381 343
DC-CA S2 6,362 7,054 381 343
DC-CB S2 6,486 7,232 381 343
DA-DA S2 6,599 7,314 431 388
DA-DB S2 6,834 7,650 431 388
DB-DA S2 6,745 7,533 413 371
DB-DB S2 6,979 7,869 413 371
DC-DA S2 6,902 7,909 381 343
DC-DB S2 7,136 7,612 381 343
CA-CA S3 5,606 6,066 — 278
CA-CB S3 5,730 6,243 — 278
CB-CA S3 5,711 6,213 — 278
CB-CB S3 5,836 6,391 — 278
CA-DA S3 6,157 6,796 — 306
CA-DB S3 6,391 7,133 — 306
CB-DA S3 6,261 6,946 — 306
CB-DB S3 6,497 7,282 — 306
DA-CA S3 6,122 6,656 381 343
DA-CB S3 6,246 6,833 381 343
DB-CA S3 6,287 6,895 381 343
DB-CB S3 6,411 7,073 381 343
DC-CA S3 6,450 7,141 381 343
DC-CB S3 6,573 7,319 381 343
DA-DA S3 6,687 7,401 431 388
DA-DB S3 6,921 7,737 431 388
DB-DA S3 6,832 7,620 413 371
DB-DB S3 7,066 7,957 413 371
DC-DA S3 6,989 7,862 381 343
DC-DB S3 7,224 8,198 381 343
DA-CA S4 7,742 8,277 — 336
DA-CB S4 7,866 8,455 — 336
DB-CA S4 7,907 8,517 — 336
DB-CB S4 8,031 8,695 — 336
DC-CA S4 8,070 8,764 — 336
DC-CB S4 8,194 8,940 — 336
DA-DA S4 8,307 9,023 — 376
DA-DB S4 8,543 9,360 — 376
DB-DA S4 8,453 9,243 — 363
DB-DB S4 8,688 9,580 — 363
DC-DA S4 8,611 9,486 — 336
DC-DB S4 8,812 9,821 — 336

CODE

COM-

PRES-

SOR

SHIP- OPER-

PING ATING

WT. WT.

(Kgs.) (Kgs.)

ERANT ERANT

CHARGE CHARGE

(Kgs. (Kgs.

R-22) R-134a)

48 JOHNSON CONTROLS

R-22 & R-134a UNITS

50 AND 60 HERTZ

FORM 160.80-EG1 (808)

REFRIG- REFRIG-

SHELL

CODE

COOLER

– COND.

COM-

PRES-

SOR

SHIP- OPER-

PING ATING

WT. WT.

(Kgs.) (Kgs.)

ERANT ERANT

CHARGE CHARGE

(Kgs. (Kgs.

R-22) R-134a)

EA-EA S4 9,281 9,929 635 572
EA-EB S4 9,573 10,316 635 572
EB-EA S4 9,505 10,199 612 551
EB-EB S4 9,767 10,586 612 551
EC-EA S4 9,690 10,496 590 531
EC-EB S4 9,979 10,882 590 531
EA-FA S4 10,653 11,609 689 621
EA-FB S4 11,202 12,334 689 621
EB-FA S4 10,847 11,875 689 621
EB-FB S4 11,394 12,601 658 592
EC-FA S4 11,060 12,175 658 592
EC-FB S4 11,609 12,898 658 592
FA-EA S4 10,397 11,339 — 767
FA-EB S4 10,722 11,727 — 767
FB-EA S4 10,755 11,749 — 767
FB-EB S4 11,017 12,137 — 767
FC-EA S4 10,964 12,282 — 735
FC-EB S4 11,404 12,669 — 735
FA-FA S4 11,783 12,998 907 816
FA-FB S4 12,332 13,724 907 816
FB-FA S4 12,078 13,405 907 816
FB-FB S4 12,624 14,131 862 776
FC-FA S4 12,314 13,939 862 776
FC-FB S4 13,013 14,662 862 776

REFRIG- REFRIG-

SHELL

CODE
COOLER
– COND.

COM-

PRES-

SOR

SHIP- OPER-

PING ATING

WT. WT.

(Kgs.) (Kgs.)

ERANT ERANT
CHARGE CHARGE

(Kgs. (Kgs.

R-22) R-134a)

EA-EA S5 9,424 10,074 — 572
EA-EB S5 9,717 10,462 — 572
EB-EA S5 9,650 10,345 — 551
EB-EB S5 9,913 10,742 — 551
EC-EA S5 9,835 10,642 — 531
EC-EB S5 10,125 11,030 — 531
EA-FA S5 10,799 11,757 — 621
EA-FB S5 11,349 12,484 — 621
EB-FA S5 10,995 12,024 — 621
EB-FB S5 11,542 12,752 — 592
EC-FA S5 11,207 12,325 — 592
EC-FB S5 11,757 13,050 — 592
FA-EA S5 10,557 11,467 — 767
FA-EB S5 10,850 11,855 — 767
FB-EA S5 10,882 11,877 — 767
FB-EB S5 11,144 12,264 — 735
FC-EA S5 11,092 12,409 — 735
FC-EB S5 11,532 12,797 — 735
FA-FA S5 11,910 13,125 907 816
FA-FB S5 12,459 13,851 907 816
FB-FA S5 12,205 13,532 907 816
FB-FB S5 12,751 14,258 862 776
FC-FA S5 12,591 14,066 862 776
FC-FB S5 13,140 14,789 862 776

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 WEIGHT
60 Hz 50 Hz

CF 5 CC 490
CG 5 CC 490
CH 5 CD 508
CJ 5 CE 508
CK 5 CF 662
CL 5 CG 689
CM 5 CH 875
CN 5 CI 875
CP 5 CJ 898
CR 5 CK 898
CS 5 CL 1,075
CT 5 CM 1,125
CU 5 CN 1,125
CV 5 CO 1,195

(Kgs)

SOLID STATE STARTER

WEIGHT

SIZE Kgs

7L, 14L 91

26L, 33L 136

49JOHNSON CONTROLS

Guide Specications

GENERAL

Furnish and install where indicated on the drawings
YORK Millennium 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 Millennium 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 evaporator shall be selected for M2
°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 certied or rated in accordance with

the latest edition of ARI Standard 550/590-98 as appli-

cable. Only chillers that are listed in the ARI Certication

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
(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 proles 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, Teon® 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 intermedi-

ate pressure with direct oil injection provides cool, non-

foaming 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 ARI 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.

50 JOHNSON CONTROLS

FORM 160.80-EG1 (808)

All chillers shall be provided with a single oil lter hous­ing with isolation valves. An optional dual lter is avail­able which allows immediate switching from one lter
to the other, eliminating downtime during lter changes.
The off-line oil lter must be capable of being changed

during chiller operation. The chiller shall ship with a 3

micron absolute oil lter, (two lters for dual lter 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 refrig-

erant piping in the eld. 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 (A.D. Merkblatter or other European Pressure
Vessel Code).

Motor Driveline

Evaporator shall be of the shell-and-tube, ooded 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 Pressure Vessel Code, Section VIII – Division
1 (A.D. Merkblatter or other European Pressure Vessel
Code). 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-efciency, 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.

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-ange, 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 exible 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 eld

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

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 efciency. The refrigerant side shall be

designed, tested and stamped in accordance with ASME
Boiler and Pressure Vessel Code, Section VIII – Division
1 (A.D. Merkblatter or other European Pressure Vessel
Code). 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-efciency, 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

51JOHNSON CONTROLS

Guide Specications - continued

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 xed orice and solenoid valve

controlled via the OptiView Control Center. This control

ensures proper refrigerant ow 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 specic

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.

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 operat-

ing exibility 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 70°F (-6.7 to 21.1°C) for
applications involving a process cooling duty that requires
leaving chilled liquid temperature setpoint control.

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 lter

differential

e. Percent motor current

OPTIVIEW CONTROL CENTER

General – The chiller shall be controlled by a stand-alone

microprocessor based control center. The chiller control
panel shall provide control of chiller operation and monitor­ing of chiller sensors, actuators, relays and switches.

Control Panel – The control panel shall include a 10.4­in. diagonal color liquid crystal display (LCD) surrounded

by “soft “ keys which are redened 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 36°F (2.22°C) leaving chilled water temperature, and
not have nuisance trips on low water temperature. The
sophisticated program and sensor shall monitor the chiller
water temperature to prevent freeze-up. When needed,
Hot Gas Bypass is available as an option. 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.

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

The control panel shall be provided with a thermal ice
storage control mode to enhance system performance

52 JOHNSON CONTROLS

f. System prelube

FORM 160.80-EG1 (808)

g. Start inhibit

4. The text displayed within the system status and

system details eld 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 xed speed

drive shall include:

a. Evaporator - low pressure

b. Evaporator - low pressure - smart freeze

c. Evaporator - transducer or leaving liquid probe

d. Evaporator - transducer or temperature sensor

e. Condenser - high pressure contacts open

f. Condenser - high pressure

g. Condenser - pressure transducer out of range

h. Auxiliary safety - contacts closed

i. Discharge - high temperature

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 xed speed drive shall

include:

a. Multiunit cycling - contacts open

b. System cycling - contacts open

c. Control panel - power failure

d. Leaving chilled liquid - low temperature

e. Leaving chilled liquid - ow switch open

f. Condenser - ow switch open

g. Motor controller - contacts open

h. Motor controller - loss of current

i. Power fault

j. Control panel - schedule

6.1 Cycling shutdowns with a Solid State Starter (LCSSS)
shall include:

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 lter

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. Shutdown - requesting fault data...

b. High instantaneous current

c. High phase (X) heatsink temperature - running

d. 105% motor current overload

e. Motor or starter - current imbalance

f. Phase (X) shorted SCR

g. Open SCR

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

m. Logic board power supply

n. Phase loss

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 dened by three

different levels of user competence: view, operator,

53JOHNSON CONTROLS

Guide Specications- continued

and service.

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.

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 eld 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 eld-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

Standard features include: digital readout at the OptiView
Control Center of the following:

Display Only:

• 3-phase voltage A, B, C

• 3-phase current A, B, C

• Input power (kW)

• kW Hours

• Starter Model

• Motor Run (LED)

• Motor Current % Full Load Amps

• Current Limit Setpoints

• Pulldown Demand Time Left

Programmable:

• Local Motor Current Limit

• Pulldown Demand Limit

• Pulldown Demand Time

Other features include: low-line voltage, 115-volt control
transformer; three-leg sensing overloads; phase rotation
and single-phase failure protection; high temperature
safety protection, motor current imbalance and 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.

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

rectiers, 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.

54 JOHNSON CONTROLS

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 manufac-

turer’s starter specications and as specied elsewhere
in these specications.

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, lter 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.

START-UP AND OPERATOR TRAINING

The chiller manufacturer shall include the services of a

factory-trained, eld service representative to supervise
the nal leak testing, charging and the initial start-up and

concurrent operator instruction.

FORM 160.80-EG1 (808)

55JOHNSON CONTROLS

Printed on recycled paper

© 2008 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53201 Printed in USA
www.johnsoncontrols.com

Metric Conversion Tables

MEASUREMENT MULTIPLY THIS BY TO OBTAIN THIS
ENGLISH VALUE METRIC VALUE

CAPACITY TONS REFRIGERANT EFFECT (ton) 3.516 KILOWATTS (kW)
POWER KILOWATTS (kW) NO CHANGE KILOWATTS (kW)
HORSEPOWER (hp) 0.7457 KILOWATTS (kW)
FLOW RATE GALLONS / MINUTE (gpm) 0.0631 LITERS / SECONDS (L/s)
LENGTH FEET (ft) 304.8 MILLIMETERS (mm)
INCHES (in) 25.4 MILLIMETERS (mm)
WEIGHT POUNDS (lb) 0.4536 KILOGRAMS (kg)
VELOCITY FEET / SECOND (fps) 0.3048 METERS / SECOND (m/s)
PRESSURE DROP FEET OF WATER (ft) 2.989 KILOPASCALS (k Pa)
POUNDS / SQ. INCH (psi) 6.895 KILOPASCALS (k Pa)

Temperature

To convert degrees Fahrenheit (°F) to degrees Celsius (°C),
subtract 32° and multiply by 5/9 or 0.5556.

To convert a temperature range (i.e., 10°F or 12°F chilled
water range) from Fahrenheit to Celsius, multiply by 5/9
or 0.5556.

Efciency

In the English I-P system, chiller efciency is measured

in kW / ton:

kW / ton =

kW input

tons refrigerant effect

In the SI Metric system, chiller efciency is measured in
Coefcient of Performance (COP).

COP =

kW refrigeration effect

kW input

kW / ton and COP are related as follows:

3.516

kW / ton =

COP =

COP

3.516

kW / ton

Integrated Part Load Value (IPLV)

In the English I-P system, IPLV is calculated by the following
formula. A full explanation is shown on page 4:

1
IPLV* =

0.01
A

+

0.42
B

+

0.45
C

+

0.12
D

Where: A = kW / ton at 100% Load @ 85°F ECFT
B = kW / ton at 75% Load @ 75°F ECFT
C = kW / ton at 50% Load @ 65°F ECFT
D = kW / ton at 25% Load @ 65°F ECFT

In SI Metric, the formula is:

IPLV* = 0.01A + 0.42B + 0.45C + 0.12D

Where: A = COP at 100% Load @ 29.4°C ECFT
B = COP at 75% Load @ 23.9°C ECFT
C = COP at 50% Load @ 18.3°C ECFT
D = COP at 25% Load @ 18.3°C 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

65°F (18.3°C) from 100% to 50% loads, and xed at 65°F

(18.3°C) for 50% to 0% loads.

FOULING FACTOR

ENGLISH I-P EQUIVALENT SI METRIC
(ft2 °F hr/BTU) (M2 K/kW)

0.0001 0.018

0.00025 0.044

0.0005 0.088

0.00075 0.132

Form 160.80-EG1 (708) Supersedes 160.80-EG1 (900)