CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS Supersedes: N1 (894) Form N1 (197)

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

2 NOMENCLATURE (STYLES A & B) YK N2 N1 H1 CX A MODEL DESIGN LEVEL (A OR B) POWER SUPPLY FOR 60 HZ 5 FOR 50 HZ COMPRESSOR CODE G4, H0, H1, H2, J1, J2, J3, J4 CONDENSER CODE L1, L2, M1, M2, N1, N2, P2, P2, Q1, Q2, R1, R2, S1, S2 COOLER CODE L1, L2, M1, M2, N1, N2, P1, P2, Q1, Q2, R1, R2, S1, S2 { MOTOR CODE 60 HZ 50 HZ CH CX 5CE 5CT CJ CY 5CF 5CU CK CZ 5CG 5CV CL CA 5CH 5CW CM CB 5CI 5CX CN DA 5CJ 5DA CP DB 5CK 5DB CR DC 5CL 5DC CS DD 5CM 5DD CT DE 5CN 5DE CU DF 5CO 5OF CV DH 5CP 5OG CW OJ 5CQ 5OH 5CR 5OJ 5CS NOMENCLATURE (STYLES C) YK NB PB H1 CX C MODEL DESIGN LEVEL (C) POWER SUPPLY FOR 60 HZ 5 FOR 50 HZ COMPRESSOR CODE G4, H0, H1, H2, J1, J2 CONDENSER CODE LB, LC, MB, MC, NB, NC, PB, PC, QB, QC, RB, RC, SB, SC COOLER CODE LB, LC, MB, MC, NB, NC, PB, PC, PD, PE, QB, QC, QD, QE, RB, RC, RD, RE, SD, SE { MOTOR CODE 60 HZ 50 HZ CH CX 5CE 5CT CJ CY 5CF 5CU CK CZ 5CG 5CV CL CA 5CH 5CW CM CB 5CI 5CX CN DA 5CJ 5DA CP DB 5CK 5DB CR DC 5CL 5DC CS DD 5CM 5DD CT DE 5CN 5DE CU DF 5CO 5DF CV DH 5CP 5DG CW DJ 5CQ 5DH 5CR 5OJ 5CS 2 YORK INTERNATIONAL

3 FORM N1 TABLE OF CONTENTS RIGGING WEIGHT OVERALL DIMENSIONS WEIGHTS REFERENCE DRAWINGS INTRODUCTION GENERAL FIELD ASSEMBLED UNITS ONLY SHIPMENT INSPECTION DAMAGE SHORTAGE CODEPAK DATA PLATE RIGGING USE OF SLINGS LOCATION FOUNDATION CLEARANCE ISOLATORS INSTALLATION RIGGING UNIT TO FINAL LOCATION LOCATING AND INSTALLING ISOLATION MOUNTS CHECKING ISOLATION PAD DEFLECTION LEVELING THE UNIT INSTALLING OPTIONAL SPRING ISOLATORS PIPING CONNECTIONS COOLER AND CONDENSER WATER PIPING REFRIGERANT RELIEF PIPING UNIT PIPING CONTROL WIRING POWER WIRING CODEPAK WITH ELECTRO-MECHANICAL STARTER OIL PUMP 3 PHASE STARTER CODEPAK WITH SOLID STATE STARTER INSULATION INSTALLATION CHECK REQUEST FOR START-UP SERVICE YORK INTERNATIONAL 3

4 COMPRESSOR CONTOL CENTER MOTOR 27073A COOLER FRONT VIEW DISCHARGE LINE OIL PUMP STARTER PRE-ROTATION VANE ACTUATOR SUBCOOLER OIL RESEVOIR/ PUMP OIL COOLER 25717A CONDENSER REAR VIEW FIG. 1 MODEL YK CODEPAK (STYLE A &B) 4 YORK INTERNATIONAL

5 FORM N1 COMPRESSOR CONTROL CENTER MOTOR 27385A COOLER FRONT VIEW DISCHARGE FRONT VIEWOIL PUMP STARTER 27382A OIL RESEVOIR/PUMP CONDENSER REAR VIEW FIG. 2 MODEL YK CODEPAK (STYLE C) YORK INTERNATIONAL 5

6 RIGGING DATA OVERALL DIM. LD01041 COOLER-CONDENSER SHELL CODE DIM. G4 COMPRESSOR (ONLY) G4, H0, H1 & H2 COMPRESSORS L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-Q A 5' 11" 6 '2" 6' 1" 6' 4" 6' 5" 6' 5" 6' 6" 6' 9" 6' 10" 7' 1" 7' 5-1/2" 7' 5-1/2" 7' 10" B 8' 2-3/4' 8' 2-3/4" 8' 4-3/4" 8' 4-3/4" 8' 4-3/4" 8' 6-3/4" 8' 6-3/4" 8' 6-3/4" 8' 10-3/4" 8' 10-3/4" 8' 10-3/4" 9' 2-3/4" 9' 2-3/4" C 1' 8-1/2" 1' 8-1/2" 1' 9-1/2" 1' 9-1/2" 1' 9-1/2" 1' 10" 1' 10" 1' 10" 2' 0" 2' 0" 2' 0" 2' 2-1/4" 2' 2-1/4" D 1' 3" 1' 4-1/2" 1' 3" 1' 4-1/2" 1' 5" 1' 4-1/2" 1' 5" 1' 6-1/2" 1' 5" 1' 6-1/2" 1' 8-3/4" 1' 6-1/2" 1' 8-3/4" E 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" 1' 4" F 6' 4-7/8" 6' 4-7/8" 6' 6-7/8" 6' 6-3/4" 6' 6-1/4" 6' 7-3/4" For these shell combinations with H2 Compressor add 1-1/2" to B dimension. COOLER-CONDENSER SHELL CODE DIM. H2 COMPRESSOR (ONLY) J1 & J2 COMPRESSOR Q-R R-Q R-R P-P P-Q Q-P Q-Q Q-R R-Q R-R R-S S-R S-S A 8' 4" 8' 4-1/2" 8' 10-1/2" 7' 1" 7' 5-1/2" 7' 5-1/2" 7' 10" 8' 4" 8' 4-1/2" 8' 10-1/2" 9' 5-1/2" 9' 3-1/2" 9' 10-1/2" B 9' 4-1/4" 9' 9-3/4" 9' 9-3/4" 9' 5-1/4" 9' 8-1/4" 9' 9-1/4" 9' 9-1/4" 10' 2-3/4" 10' 2-3/4" 10' 2-3/4" 10' 6-3/4" 10' 6-3/4" 10' 6-3/4" C 2' 2-1/4" 2' 5-1/2" 2' 5-1/2" 2' 0" 2' 0" 2' 2-1/4" 2' 2-1/4" 2' 2-1/4" 2' 5-1/2" 2' 5-1/2" 2' 5-1/2" 2' 8" 2' 8" D 1' 11-3/4" 1' 8-3/4" 1' 11-3/4" 1' 8-1/2" 1' 8-3/4" 1' 6-1/2" 1' 8-3/4" 1' 11-3/4" 1' 8-3/4" 1' 11-3/4" 2' 3-1/4" 1' 11-3/4" 2' 3-1/4" E 1' 6" 1' 4" 1' 6" 1' 4" 1' 4" 1' 4" 1' 4" 1' 6" 1' 4" 1' 6" 2' 1" 1' 6" 2" 1" F COOLER-CONDENSER SHELL CODE DIM. J3 & J4 COMPRESSOR Q-Q Q-R R-Q R-R R-S S-R S-S A 7' 10" 8' 4" 8' 4-1/2" 8' 10-1/2" 9' 5-1/2" 9' 3-1/2" 9' 10-1/2" B 10' 2-3/4" 10' 8-1/4" 10' 8-1/4" 10' 8-1/4" 11' 0-1/4" 11' 0-1/4" 11' 0-1/4" C 2' 2-1/4" 2' 2-1/4" 2' 5-1/2" 2' 5-1/2" 2' 5-1/2" 2' 8" 2' 8" D 1' 8-3/4" 1' 11-3/4" 1' 8-3/4" 1' 11-3/4" 2' 3-1/4" 1' 11-3/4" 2' 3-1/4" E 1' 4" 1' 6" 1' 4" 1' 6" 1' 2" 1' 6" 2' 1" F DUAL RELIEF VALVES COOLER NPTI L, M, N (2)1-1/4" P, Q, R, S (2) 1-1/2" NOTES: 1. All dimensions are approximate. Certified dimensions are available on request, or see Form PA1. 2. Water nozzles can be located on either end of unit, Add 1/2" to nozzle length for flanged connections. 3. To determine overall installed height, add 7/8" for isolators. (See Figs. 6 & 7.) FIG. 3 DIMENSIONS (STYLE A & B UNITS) STANDARD DIMENSIONS 6 YORK INTERNATIONAL

7 FORM N1 LD01042 COOLER-CONDENSER SHELL CODE G4, H0 & H1 COMPRESSORS L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-Q A 6' 5" 6' 4" 6' 7" 6' 6" 6' 9" 6' 11" 7' 2" 7' 6" 7' 4-1/2" 7' 8-1/2" 8' 0-1/2" 8' 0" 8' 4" B 7' 11-3/4" 7' 11-3/4" 8' 2-1/4" 8' 1-3/4" 8' 2-1/4" 8' 4-1/4" 8' 5-1/4" 8' 8-1/4" 8' 8-1/4" 9' 0-1/4" 9' 3-1/4" 9' 0-1/4" 9' 3-1/4" C 1' 8-1/2" 1' 8-1/2" 1' 9-1/2" 1' 9-1/2" 1' 9-1/2" 2' 0" 2' 0" 2' 0" 2' 1-1/4" 2' 1-1/4" 2' 1-1/4" 2' 3" 2' 3" D 1' 6" 1' 5-1/2" 1' 6" 1' 5-1/2" 1' 7" 1' 5-1/2" 1' 7" 1' 9" 1' 7" 1' 9" 1' 11" 1' 9" 1' 11" E 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 5-1/4" 1' 10-1/4" 1' 5-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" COOLER-CONDENSER SHELL CODE H2 COMPRESSORS N-N N-P P-N P-P P-Q Q-P Q-Q Q-R R-Q R-R A 7' 2" 7' 6" 7' 4-1/2" 7' 8-1/2" 8' 0-1/2" 8' 0" 8' 4" 9' 2" 9' 0-1/2" 9' 10-1/2" B 8' 5-1/4" 8' 6-1/4" 8' 9-1/4" 8' 9-1/4" 9' 1-1/4" 9' 0-1/4" 9' 1-1/4" 9' 10-1/4" 9' 7-1/4" 10' 2-1/4" C 2' 0" 2' 0" 2' 1-1/4" 2' 1-1/4" 2' 1-1/4" 2' 3" 2' 3" 2' 3' 2' 7-1/4' 2' 7-1/4" D 1' 7" 1' 9" 1' 7" 1' 9" 1' 11" 1' 9" 1' 11" 2' 4" 1' 11" 2' 4" E 1' 5-1/4" 1' 10-1/4" 1' 5-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 1' 10-1/4" 2' 2-1/2" 1' 10-1/4" 2' 2-1/2" COOLER -CONDENSER SHELL CODE J1 & J2 COMPRESSORS Q-Q Q-R R-Q R-R R-S S-R S-S A 8' 4-1/2" 9' 0-1/2" 8' 11" 9' 7" 10' 0" 10' 0" 10' 5" B 10' 1-1/2" 10' 10-1/2" 10' 1-3/4" 10' 10-1/2" 11' 3-1/2" 10' 10-1/2" 11' 3-1/2" C 2' 2-1/4" 2' 2-1/4" 2' 5-1/2" 2' 5-1/2" 2' 5-1/2" 2' 8" 2' 8" D 2' 0" 2' 4" 2' 0" 2' 4" 2' 6-1/2" 2' 4" 2' 6-1/2" E 1' 10-1/4" 2' 2-1/2" 1' 10-1/4" 2' 2-1/2" 2' 4" 2' 2-1/2" 2' 4" NOTES: 1. All dimensions are approximate. Certified dimensions are available on request. 2. For compact water boxes (shown above), determine overall unit length by adding water box depth to tube sheet length. 3. Water nozzles can be located on either end of unit. Add 1/2" to nozzle length for flanged connections. 4. To determine overall height, add 7/8" for isolators. (See Figs 6 & 7.) 5. Use of motors with motor hoods may increase overall unit dimensions. DUAL RELIEF VALVES COOLER/ COOLER/ CONDENSER NPTI CONDENSER NPTI SHELL CODE SHELL CODE L-L (2)1-1/2" P-N (2)1-1/2" L-M (2)1-1/2" P-P (2)1-1/2" M-L (2)1-1/2" P-Q (2)1-1/2" M-M (2)1-1/2" Q-P (2)1-1/2" M-N (2)1-1/2" Q-Q (2)1-1/2" N-M (2)1-1/2" Q-R (2)2" N-N (2)1-1/2" R-Q (2)2" N-P (2)1-1/2" R-R (2)2" S-S (2)2" FIG. 4 DIMENSIONS (STYLE C UNITS) STANDARD DIMENSIONS YORK INTERNATIONAL 7

8 RIGGING DATA OVERALL DIM. 375 mm mm mm 2 LD01041 COOLER-CONDENSER SHELL CODE DIM. G4 COMPRESSOR (ONLY) G4, H0, H1 & H2 COMPRESSORS L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-Q A B C D E F For these shell combinations with H2 Compressor add 38 mm to B dimension. COOLER-CONDENSER SHELL CODE DIM. H2 COMPRESSOR (ONLY) J1 & J2 COMPRESSOR Q-R R-Q R-R P-P P-Q Q-P Q-Q Q-R R-Q R-R R-S S-R S-S A B C D E F COOLER-CONDENSER SHELL CODE DIM. J3 & J4 COMPRESSOR DUAL RELIEF VALVES Q-Q Q-R R-Q R-R R-S S-R S-S COOLER NPTI A L, M, N (2)1-1/4" B P, Q, R, S (2) 1-1/2" C D E F NOTES: 1. All dimensions are approximate. Certified dimensions are available on request, or see Form PA1. 2. Water nozzles can be located on either end of unit, Add 13 mm to nozzle length for flanged connections. 3. To determine overall installed height, add 22 mm for isolators. (See Figs. 6 & 7.) FIG. 3A DIMENSIONS (STYLE A & B UNITS) METRIC DIMENSIONS 8 YORK INTERNATIONAL

9 FORM N1 375 mm mm 603 mm 2 LD01042 COOLER-CONDENSER SHELL CODE G4, H0 & H1 COMPRESSORS L-L L-M M-L M-M M-N N-M N-N N-P P-N P-P P-Q Q-P Q-Q A B C D E COOLER-CONDENSER SHELL CODE H2 COMPRESSORS N-N N-P P-N P-P P-Q Q-P Q-Q Q-R R-Q R-R A B C D E COOLER -CONDENSER SHELL CODE J1 & J2 COMPRESSORS Q-Q Q-R R-Q R-R R-S S-R S-S A B C D E NOTES: 1. All dimensions are approximate. Certified dimensions are available on request. 2. For compact water boxes (shown above), determine overall unit length by adding water box depth to tube sheet length. 3. Water nozzles can be located on either end of unit. Add 13 mm to nozzle length for flanged connections. 4. To determine overall height, add 22 mm for isolators. (See Figs 6 & 7.) 5. Use of motors with motor hoods may increase overall unit dimensions. FIG. 4A DIMENSIONS (STYLE C UNITS) METRIC DIMENSIONS DUAL RELIEF VALVES COOLER/ COOLER/ CONDENSER NPTI CONDENSER NPTI SHELL CODE SHELL CODE L-L (2)1-1/2" P-N (2)1-1/2" L-M (2)1-1/2" P-P (2)1-1/2" M-L (2)1-1/2" P-Q (2)1-1/2" M-M (2)1-1/2" Q-P (2)1-1/2" M-N (2)1-1/2" Q-Q (2)1-1/2" N-M (2)1-1/2" Q-R (2)2" N-N (2)1-1/2" R-Q (2)2" N-P (2)1-1/2" R-R (2)2" S-S (2)2" YORK INTERNATIONAL 9

10 TABLE 1 CHILLER WEIGHTS STYLES A & B (LESS MOTOR) LBS. SHELL LOADING SHELL LOADING CODE SHIPPING OPERATING PER CODE SHIPPING OPERATING PER COOLER- WT. (LBS.) WT. (LBS.) ISOLATOR COOLER- WT. (LBS.) WT. (LBS.) ISOLATOR COND. (LBS.) COND. (LBS.) L1 L1 17,400 21,055 5,264 P2 P1 27,857 33,852 8,463 L1 L2 17,660 21,435 5,359 P2 P2 28,560 34,790 8,698 L2 L1 17,570 21,317 5,329 P1 Q1 30,094 37,054 9,264 L2 L2 17,840 21,705 5,426 P1 Q2 31,012 38,282 9,571 L1 M1 18,530 22,605 5,651 P2 Q1 30,516 37,636 9,409 L1 M2 18,900 23,175 5,794 P2 Q2 31,434 38,864 9,716 L2 M1 18,710 22,875 5,719 Q1 P1 30,278 36,933 9,233 L2 M2 19,080 23,445 5,861 Q1 P2 30,991 37,881 9,470 M1 L1 18,200 22,195 5,549 Q2 P1 30,878 37,753 9,438 M1 L2 18,460 22,575 5,644 Q2 P2 31,591 38,701 9,675 M2 L1 18,425 22,530 5,633 Q1 Q1 32,703 40,483 10,121 M2 L2 18,695 22,920 5,730 Q1 Q2 33,621 41,711 10,428 M1 M1 19,325 23,740 5,935 Q2 Q1 33,303 41,303 10,326 M1 M2 19,695 24,310 6,077 Q2 Q2 34,221 42,531 10,633 M2 M1 19,560 24,085 6,021 Q1 R1 36,527 45,747 11,437 M2 M2 19,930 26,720 6,680 Q1 R2 37,831 47,486 11,872 M1 N1 20,485 24,875 6,218 Q2 R1 37,127 46,567 11,642 M1 N2 20,956 25,476 6,369 Q2 R2 38,431 48,306 12,077 M2 N1 20,720 25,220 6,305 R1 Q1 36,984 46,024 11,506 M2 N2 21,191 25,821 6,455 R1 Q2 37,902 47,252 11,813 N1 M1 21,123 25,523 6,381 R2 Q1 37,792 47,137 11,784 N1 M2 21,493 26,093 6,523 R2 Q2 38,710 48,365 12,091 N2 M1 21,448 25,968 6,492 R1 R1 40,685 51,115 12,779 N2 M2 21,818 26,538 6,635 R1 R2 41,989 52,854 13,214 N1 N1 21,885 26,775 6,694 R2 R1 41,493 52,228 13,057 N1 N2 22,356 25,966 6,492 R2 R2 42,797 53,967 13,492 N2 N1 22,210 27,220 6,805 S1 R1 47,011 58,401 14,600 N2 N2 22,681 27,821 6,955 S1 R2 48,315 60,140 15,035 N1 P1 23,864 29,279 6,820 S2 R1 47,016 58,926 14,732 N1 P2 24,567 30,217 7,554 S2 R2 48,320 60,665 15,166 N2 P1 24,189 29,724 7,431 R1 S1 49,379 61,324 15,331 N2 P2 24,892 30,662 7,666 R1 S2 51,252 64,197 16,049 P1 N1 23,824 29,134 7,284 R2 S1 50,185 62,435 15,609 P1 N2 24,295 29,735 7,434 R2 S2 52,060 65,310 16,328 P2 N1 24,274 29,744 7,436 S1 S1 53,375 66,280 16,570 P2 N2 24,745 30,345 7,586 S1 S2 55,250 69,155 17,289 P1 P1 27,434 33,269 8,317 S2 S1 53,380 66,805 16,701 P1 P2 28,137 34,207 8,552 S2 S2 55,255 69,680 17, YORK INTERNATIONAL

11 FORM N1 TABLE 2 CHILLER WEIGHTS STYLES A & B (LESS MOTOR) LBS. G & H COMPRESSORS SHELL LOADING CODE SHIPPING OPERATING PER COOLER WEIGHT WEIGHT ISOLATOR COND. (LBS.) (LBS.) (LBS.) LB LB 16,615 19,775 4,944 LB LC 16,860 20,135 5,034 LC LB 16,780 20,030 5,008 LC LC 17,020 20,390 5,098 LB MB 17,840 21,310 5,328 LB MC 18,180 21,850 5,463 LC MB 18,000 21,565 5,391 LC MC 18,340 22,100 5,525 MB LB 17,575 21,185 5,296 MB LC 17,815 21,545 5,386 MC LB 17,760 21,480 5,370 MC LC 18,000 21,840 5,460 MB MB 18,780 22,700 5,675 MB MC 19,120 23,240 5,810 MC MB 18,965 22,995 5,749 MC MC 19,305 23,535 5,884 MB NB 19,915 24,300 6,075 MB NC 20,345 24,910 6,228 MC NB 20,100 24,595 6,149 MC NC 20,580 25,200 6,300 NB MB 20,040 24,440 6,110 NB MC 20,380 24,980 6,245 NC MB 20,345 24,865 6,216 NC MC 20,685 25,410 6,352 NB NB 21,170 26,000 6,500 NB NC 21,650 26,615 6,654 NC NB 21,480 26,435 6,609 NC NC 21,960 27,045 6,761 NB PB 23,175 28,535 7,134 NB PC 23,855 29,450 7,362 NC PB 23,485 28,965 7,241 NC PC 24,165 29,880 7,470 PB NB 22,990 28,240 7,060 PB NC 23,470 28,850 7,213 PC NB 23,460 28,870 7,218 PC NC 23,940 29,480 7,370 PB PB 24,980 30,755 7,689 PB PC 25,660 31,670 7,918 PC PB 25,450 31,390 7,848 PC PC 26,130 32,690 8,173 PB QB 27,175 34,040 8,150 PB QC 28,045 35,220 8,805 PC QB 27,650 34,670 8,668 PC QC 28,520 35,850 8,963 QB PB 26,930 33,490 8,372 QB PC 27,610 33,400 8,350 QC PB 27,475 34,250 8,562 QC PC 28,155 35,070 8,768 QB QB 29,120 36,745 9,186 QB QC 29,990 37,925 9,480 QC QB 29,660 37,510 9,378 QC QC 30,530 38,690 9,672 G & H COMPRESSORS SHELL LOADING CODE SHIPPING OPERATING PER COOLER WEIGHT WEIGHT ISOLATOR COND. (LBS.) (LBS.) (LBS.) QB RB 33,700 41,930 10,482 QB RC 34,865 43,395 10,848 QC RB 34,240 42,875 10,718 QC RC 35,410 44,340 11,085 RB QB 33,860 42,610 10,652 RB QC 34,830 43,880 10,970 RC QB 33,860 43,010 10,752 RC QC 34,830 44,280 11,070 RB RB 38,445 47,775 11,944 RB RC 39,610 49,240 12,310 RC RB 38,445 48,175 12,044 RC RC 39,610 49,640 12,410 J1 & J2 COMPRESSORS SHELL LOADING CODE SHIPPING OPERATING PER COOLER WEIGHT WEIGHT ISOLATOR COND. (LBS.) (LBS.) (LBS.) QD QB 29,620 37,245 9,311 QD QC 30,490 38,425 9,605 QE QB 30,160 38,010 9,503 QE QC 31,030 39,190 9,797 QD RB 34,200 42,430 10,607 QD RC 35,365 43,895 10,973 QE RB 34,740 43,375 10,843 QE RC 35,910 44,840 11,210 RD QB 34,360 43,110 10,777 RD QC 35,330 44,380 11,095 RE QB 34,360 43,510 10,877 RE QC 35,330 44,780 11,195 RD RB 38,945 48,275 12,069 RD RC 40,110 49,740 12,435 RE RB 38,945 48,675 12,169 RE RC 40,110 50,140 12,535 RD SB 45,430 56,420 14,105 RD SC 47,150 59,060 14,765 RE SB 46,170 57,440 14,360 RE SC 47,895 60,085 15,020 SD RB 43,250 53,730 13,433 SD RC 44,450 55,330 13,832 SE RB 43,254 54,210 13,553 SE RC 44,455 55,810 13,952 SD SB 49,105 60,975 15,244 SD SC 50,830 63,620 15,905 SE SB 49,110 61,500 15,375 SE SC 50,835 64,105 16,026 YORK INTERNATIONAL 11

12 TABLE 1A CHILLER WEIGHTS STYLES A & B (LESS MOTOR) KG SHELL LOADING SHELL LOADING CODE SHIPPING OPERATING PER CODE SHIPPING OPERATING PER COOLER- WT. (KG) WT. (KG) ISOLATOR COOLER- WT. (KG) WT. (KG) ISOLATOR COND. (KG) COND. (KG) L1 L P2 P1 12,636 15, L1 L P2 P2 12,955 15, L2 L P1 Q1 13,651 16, L2 L P1 Q2 14,067 17, L1 M , P2 Q1 13,842 17, L1 M , P2 Q2 14,258 17, L2 M , Q1 P1 13,734 16, L2 M , Q1 P2 14,058 17, M1 L , Q2 P1 14,006 17, M1 L , Q2 P2 14,330 17, M2 L , Q1 Q1 14,834 18, M2 L , Q1 Q2 15,250 18, M1 M , Q2 Q1 15,106 18, M1 M , Q2 Q2 15,523 19, M2 M , Q1 R1 16,569 20, M2 M , Q1 R2 17,160 21, M1 N , Q2 R1 16,841 21, M1 N , Q2 R2 17,432 21, M2 N , R1 Q1 16,776 23, M2 N , R1 Q2 17,192 23, N1 M , R2 Q1 17,142 23, N1 M , R2 Q2 17,559 24, N2 M , R1 R1 18,455 26, N2 M , R1 R2 19,046 27, N1 N , R2 R1 18,821 26, N1 N2 10,140 11, R2 R2 19,413 27, N2 N1 10,744 12, S1 R1 21,324 27, N2 N2 10,288 12, S1 R2 21,916 29, N1 P1 10,825 13, S2 R1 21,326 28, N1 P2 11,144 13, S2 R2 21,918 29, N2 P1 10,972 13, R1 S1 22,398 27, N2 P2 11,291 13, R1 S2 23,248 29, P1 N1 10,807 13, R2 S1 22,764 28, P1 N2 11,020 13, R2 S2 23,614 29, P2 N1 11,011 13, S1 S1 24,211 30, P2 N2 11,224 13, S1 S2 25,061 31, P1 P1 12,444 15, S2 S1 24,213 30, P1 P2 12,763 15, S2 S2 25,064 31, YORK INTERNATIONAL

13 FORM N1 TABLE 2A CHILLER WEIGHTS STYLES A & B (LESS MOTOR) KG G & H COMPRESSORS SHELL LOADING CODE SHIPPING OPERATING PER COOLER WEIGHT WEIGHT ISOLATOR COND. (KG) (KG) (KG) LB LB LB LC LC LB LC LC LB MB LB MC LC MB LC MC , MB LB MB LC MC LB MC LC MB MB , MB MC , MC MB , MC MC , MB NB , MB NC , MC NB , MC NC , NB MB , NB MC , NC MB , NC MC , NB NB , NB NC , NC NB , NC NC , NB PB 10,512 12, NB PC 10,820 13, NC PB 10,653 13, NC PC 10,961 13, PB NB 10,428 12, PB NC 10,646 13, PC NB 10,641 13, PC NC 10,859 13, PB PB 11,331 13, PB PC 11,639 14, PC PB 11,544 14, PC PC 11, PB QB 12,327 15, PB QC 12,721 15, PC QB 12,542 15, PC QC 12,937 16, QB PB 12,215 15, QB PC 12,524 15, QC PB 12,463 15, QC PC 12,771 15, QB QB 13,209 16, QB QC 13,603 17, QC QB 13,454 17, QC QC 13,848 17, G & H COMPRESSORS SHELL LOADING CODE SHIPPING OPERATING PER COOLER WEIGHT WEIGHT ISOLATOR COND. (KG) (KG) (KG) QB RB 15,286 19, QB RC 15,815 19, QC RB 15,531 19, QC RC 16,062 20, RB QB 15,359 19, RB QC 15,799 19, RC QB 15,359 19, RC QC 15,799 20, RB RB 17,439 21, RB RC 17,967 22, RC RB 17,439 21, RC RC 17,967 22, J1 & J2 COMPRESSORS SHELL LOADING CODE SHIPPING OPERATING PER COOLER WEIGHT WEIGHT ISOLATOR COND. (KG) (KG) (KG) QD QB 13,436 16, QD QC 13,830 17, QE QB 13,681 17, QE QC 14,075 17, QD RB 15,513 19, QD RC 16,042 19, QE RB 15,758 19, QE RC 16,289 20, RD QB 15,586 19, RD QC 16,026 20, RE QB 15,586 19, RE QC 16,026 20, RD RB 17,665 21, RD RC 18,194 22, RE RB 17,665 22, RE RC 18,194 22, RD SB 20,607 25, RD SC 21,387 26, RE SB 20,943 26, RE SC 21,725 27, SD RB 19,618 24, SD RC 20,163 25, SE RB 19,620 24, SE RC 20,165 25, SD SB 22,274 27, SD SC 23,056 28, SE SB 22,276 27, SE SC 23,059 29, YORK INTERNATIONAL 13

14 TABLE 3 MOTOR WEIGHTS (LBS.) YK MOTOR WEIGHTS 60 HERTZ YK MOTOR WEIGHTS 50 HERTZ MOTOR CODE LOW VOLTAGE HIGH VOLTAGE LOW VOLTAGE HIGH VOLTAGE MOTOR NO SOUND W/SOUND NO SOUND W/SOUND NO SOUND W/SOUND NO SOUND W/SOUND CODE HOOD HOOD HOOD HOOD HOOD HOOD HOOD HOOD CH 1,100 2,150 2,700 SCE 1,120 2,150 2,700 CJ 1,100 2,150 2,700 SCF 1,460 2,150 2,700 CK 1,460 2,150 2,700 SCG 1,460 2,150 2,700 CL 1,460 2,150 2,700 5CH 1,460 2,150 2,700 CM 1,460 2,150 2,700 5CI 1,460 2,150 2,700 CN 1,460 2,150 2,700 5CJ 1,780 2,150 2,700 CP 1,780 2,150 2,700 5CK 1,780 2,150 2,700 CR 1,780 2,150 2,700 SCL 1,780 3,350 3,950 CS 1,780 3,350 3,950 5CM 2,150 3,350 3,950 CT 2,150 3,350 3,950 5CN 2,150 3,350 3,950 CU 2,150 3,350 3,950 5CO 2,150 3,350 3,950 CV 2,150 3,350 3,950 5CP 3,350 3,950 3,350 3,950 CW 3,350 3,950 3,350 3,950 5CQ 4,350 5,050 4,350 5,050 CX 4,350 5,050 4,350 5,050 5CR 4,350 5,050 4,350 5,050 CY 4,350 5,050 4,350 5,050 5CS 5,000 6,700 5,000 6,700 CZ 5,000 6,700 5,000 6,700 5CT 5,000 6,700 5,000 6,700 CA 5,000 6,700 5,000 6,700 5CU 5,000 6,700 5,000 6,700 CB 5,000 6,700 5,000 6,700 5CV 5,000 6,700 5,000 6,700 DA 6,000 7,300 6,000 7,300 5CW 6,000 7,300 6,000 7,300 DB 6,000 7,300 6,000 7,300 5CX 6,000 7,300 6,000 7,300 DC 6,000 7,300 6,000 7,300 5DA 6,000 7,300 6,000 7,300 DD 6,000 7,300 5DB 6,000 7,300 6,000 7,300 DE 6,000 7,300 5DC 6,000 7,300 DF 6,000 7,300 5DD 6,000 7,300 DH 6,000 7,300 5DE 6,000 7,300 OJ 7,600 9,000 5OF 10,500 12,500 5OG 10,500 12,500 5OH 10,500 12,500 5OJ 12,000 14,000 TABLE 4 REFERENCE DRAWINGS DESCRIPTION Dimensions and Physical Data Wiring Diagram MicroComputer Control Center Solid State Starter Wiring Diagram MicroComputer Control Center Electro-Mechanical Starter Solid State Starter Wiring Diagram Field Wiring Solid State Starter Field Wiring Electro-Mechanical Starter Field Control Modifications Motor Starter Specifications Electro-Mechanical Starter PRODUCT DRAWING FORM NO PA PW PW PW PW PW PW PA YORK INTERNATIONAL

15 FORM N1 TABLE 3A MOTOR WEIGHTS (KG) YK MOTOR WEIGHTS 60 HERTZ YK MOTOR WEIGHTS 50 HERTZ MOTOR CODE LOW VOLTAGE HIGH VOLTAGE LOW VOLTAGE HIGH VOLTAGE MOTOR NO SOUND W/SOUND NO SOUND W/SOUND NO SOUND W/SOUND NO SOUND W/SOUND CODE HOOD HOOD HOOD HOOD HOOD HOOD HOOD HOOD CH SCE CJ SCF CK SCG CL CH CM CI CN CJ CP CK CR SCL CS CM CT CN CU CO CV CP CW CQ CX CR CY CS CZ CT CA CU CB CV DA CW DB CX DC DA DD DB DE DC DF DD DH DE OJ OF OG OH OJ YORK INTERNATIONAL 15

16 INTRODUCTION GENERAL This instruction describes the installation of a MODEL YK CODEPAK Liquid Chilling Unit. This unit is shipped as a single factory assembled, piped, wired package requiring a minimum of field labor to make chilled water connections, condenser water connections, refrigerant atmospheric relief connections, and electrical power connections. (Refrigerant and oil charges shipped separately.) CODEPAKS can also be shipped dismantled when required by rigging conditions, but generally it is more economical to enlarge access openings to accomodate the factory assembled unit. CODEPAKS shipped dismantled MUST be field assembled under the supervision of a YORK representative, but otherwise installation will be as described in this instruction. FIELD ASSEMBLED UNITS ONLY Use Form N3 in conjunction with this installation instruction. This instruction will be furnished with all units that are to be field assembled. Extra copies may be ordered from the YORK Publication Distribution Center. CONSTRUCTION DRAWINGS Construction drawings are furnished for each job as noted in Table 4. These drawings must be carefully followed and used in conjunction with this installation instruction, to insure proper installation of the unit. In event of any differences between drawings and this instruction, the drawings will govern. The services of a YORK representative will be furnished to check the installation, supervise the initial start-up and operation of all CODEPAKS installed within Continental United States. CAUTION: The YORK Warranty will be voided if the following restrictions are not adhered to: 1. No valves or connections should be opened under any circumstances because such action will result in loss of the factory nitrogen charge. 2. Do not dismantle or open the CODEPAK for any reason except under the supervision of a YORK representative. 3. When units are shipped dismantled, notify the nearest YORK office in ample time for a YORK representative to supervise rigging the unit to its operating position and the assembly of components. 4. Do not make final power supply connections to the compressor motor or control center. 5. Do not charge the compressor with oil. 6. Do not charge the unit with refrigerant. 7. Do not attempt to start the system. 8. Do not run hot water (110 F (43.3 C) max.) or steam through the cooler or condenser at any time. SHIPMENT The CODEPAK may be ordered and shipped in any of the following forms: Form 2 Factory Assembled Unit, complete with motor (refrigerant and oil charges shipped separately). 1. The motor/compressor assembly mounted, with all necessary interconnecting piping assembled. MicroComputer Control Center is mounted on the unit. Complete unit factory leak tested, evacuated and charged with holding charge of nitrogen. An optional Solid State Starter can be factory mounted and wired. 2. Miscellaneous material Four (4) vibration isolation pads (or optional spring isolators and brackets). Form 3 Driveline Separate From Shells Shipped as three major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Compressor/motor assembly removed from shells and skidded. Cooler/condenser is not skidded. All wiring integral with compressor is left on it, and all conduit is left on shell. All openings on compressor, oil separator, and shell are closed and charged with dry nitrogen (2 to 3 psig)(13.8 to 21 kpa). Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil, isolators, solid state starter (option), etc.; refrigerant charge shipped separately. NOTE: Units shipped dismantled MUST be reassembled by, or under the supervision of, a YORK representative. (See Form N3.) Form 7 Split Shells Shipped as four major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Compressor/motor assembly removed from shells and skidded. 16 YORK INTERNATIONAL

17 FORM N1 Cooler and condenser shells are separated at tube sheets and are not skidded. Refrigerant lines between shells are flanged and capped, requiring no welding. All wiring integral with compressor is left on it. All wiring harnesses on shells are removed. All openings on compressor and shells are closed and charged with dry nitrogen (2 to 3 psig)(13.8 to 21 kpa). Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil, isolators, solid state starter (option), etc.; refrigerant charge shipped separately. NOTE: Units shipped dismantled MUST be reassembled by, or under the supervision of, a YORK representative. (See Form N3). When more than one CODEPAK is involved, the major parts of each unit will be marked to prevent mixing of assemblies. (Piping and Wiring Drawings to be furnished by YORK.) INSPECTION DAMAGE SHORTAGE The unit shipment should be checked on arrival to see that all major pieces, boxes and crates are received. Each unit should be checked on the trailer or rail car when received, before unloading, for any visible signs of damage. Any damage or signs of possible damage must be reported to the transportation company immediately for their inspection. YORK WILL NOT BE RESPONSIBLE FOR ANY DAM- AGE IN SHIPMENT OR AT JOB SITE OR LOSS OF PARTS. (Refer to Shipping Damage Claims, Form NM). When received at the job site all containers should be opened and contents checked against the packing list. Any material shortage should be reported to YORK immediately. (Refer to Shipping Damage Claims, Form NM.) CODEPAK DATA PLATE A unit data plate is mounted on the control center assembly of each unit, giving unit model number; design working pressure; water passes; refrigerant charge; serial numbers; and motor power characteristics and connection diagrams. Additional information may be found on the motor date plate. This information should be included when contacting the factory on any problem relating to the motor. RIGGING The complete standard CODEPAK is shipped without skids. (When optional skids are used it may be necessary to remove the skids so riggers skates can be used under the unit end sheets to reduce overall height.) Each unit has four (4) lifting holes (two on each end) in the end sheets which should be used to lift the unit. (See Fig. 5.) Care should be taken at all times during rigging and handling of the CODEPAK to avoid damage to the unit and its external connections. Lift only using holes shown in Fig. 5. Do not lift the unit with slings around motor/compressor assembly or by means of eyebolts in the tapped holes of the compressor motor assembly. Do not turn a unit on its side for rigging. Do not rig by one end. Use of Slings (See Fig. 5 for proper use of slings in rigging.) CAUTION : If necessary to rig the CODEPAK by one end to permit lifting or dropping through a vertical passageway, such as an elevator shaft, contact YORK factory shipping for special rigging instructions. The rigging and operating weights and overall dimensions are given on pages 6 thru 13 as a guide in determining the clearances required for rigging. (Add 6" (153 mm) to overall-height for optional skidded unit.) YORK INTERNATIONAL 17

18 FIG. 5 RIGGING LD01043 LOCATION YORK CODEPAKS are furnished with vibration isolator mounts for basement or ground level installations. Units may be located on upper floor levels providing the floor is capable of supporting the total unit operating weight and optional spring isolators are used. IMPORTANT Sufficient clearance to facilitate normal service and maintenance work must be provided all around and above the unit, and particularly space provided at either end to permit cleaning or replacement of cooler and condenser tubes see CLEARANCE. A doorway or other sufficiently large opening properly located may be used. The chiller should be located in an indoor location where temperature range from 40 F (4.4 C) to 110 F (43.3 C). FOUNDATION A level floor, mounting pad or foundation must be provided by others, capable of supporting the operating weight of the unit. CLEARANCE Clearances should be adhered to as follows: Rear and above unit 2 ft. (610 mm) Front of unit 3 ft. (915 mm) Tube Removal 14 ft. (4268 mm)(either end) 18 YORK INTERNATIONAL

19 FORM N1 7/8" (22 mm) DIA. HOLE 7/8" DIA. HOLE (22 mm) 3" (76 mm) 8" (203 mm) 3" (76 mm) 8" (203 mm) 7/8" (22 mm) 1-3/4" (44 mm) 4-1/2" (114 mm) 6" (152 mm) 1-3/4" (44 mm) 3/4" (19 mm) LD01044 UNIT WEIGHT UP TO 28,835 LBS. (13,079 KG) 1" (25 mm) 7/8" (22 mm) 1" (25 mm) 6" (152 mm) 6" (152 mm) 3/4" (19 mm) LD01045 UNIT WEIGHT UP TO 28,836 LBS.(13,080 KG) TO 53,530 LBS. (24,281 KG) 6" (152 mm) 7/8" (22 mm) DIA. HOLE 3" (76 mm) 7/8" (22 mm) 8" (203 mm) 6" (152 mm) 3/4" (19 mm) LD01046 UNIT WEIGHT 53,531 LBS.(24,281 KG) TO 100,464 LBS. (45,570 KG) 3" (76 mm) 8" (203 mm) 8" (203 mm) 3" (76 mm) 6" (152 mm) 6" (152 mm) 2" (51 mm) 2" (51 mm) 3" (76 mm) 168" (4267 mm) 3" (76 mm) FIG. 6 NEOPRENE ISOLATORS LD01047 YORK INTERNATIONAL 19

20 1/2" (13 mm) 7" (178 mm) 6-1/4" (159 mm) 1/2" (13 mm) 1-3/4" (44 mm) 6-1/4" (159 mm) 7" (178 mm) 3/4" (19 mm) 6-1/4" (159 mm) 6-1/4" (159 mm) 168" (4267 mm) 4 SPRING ISOLATORS 1/2" (13 mm) 84" (2133 mm) LD01048 UNIT WEIGHT 26,880 LBS. (12,193 KG) UP TO 35,009 LBS. (15,880 KG) 7-1/8" (181 mm) 1/2" (13 mm) 9-1/2" (241 mm) 1/2" (13 mm) 1-3/4" (44 mm) 7-1/8" (181 mm) 9-1/2" (241 mm) 3/4" (19 mm) 168" (4267 mm) 1/2" (13 mm) 84" (2133 mm) 6-3/8" (162 mm) 9-1/2" (241 mm) LD01049 UNIT WEIGHT 35,010 LBS. (15,880 KG) UP TO 58,349 LBS. (26,467 KG) 1/2" (13 mm) 9-3/4" (248 mm) 9" (229 mm) 1/2" (13 mm) 1-3/4" (44 mm) 3/4" (19 mm) 9" (229 mm) FIG. 7 SPRING ISOLATORS 9" (229 mm) 9" (181 mm) 9-3/4" (248 mm) 1/2" (13 mm) 84" (2133 mm) 168" (4267 mm) 9 SPRING ISOLATORS LD01050 UNIT WEIGHT 58,350 LBS. (26,468 KG) UP TO 89,340 LBS. (40,525 KG) 20 YORK INTERNATIONAL

21 FORM N1 INSTALLATION RIGGING UNIT TO FINAL LOCATION Rig the unit to its final location on the floor or mounting pad, lift the unit (or shell assembly) by means of an overhead lift and lower the unit to its mounting position. (If optional shipping skids are used remove them before lowering the CODEPAK to its mounting position.) NOTE: At this point units shipped dismantled should be assembled under the supervision of a YORK representative. If cooler is to be field insulated, the insulation should be applied to the cooler before the unit is placed in position while the unit is in the lift position. Be sure unit is properly supported. (See INSULATION, page 24.) LOCATING AND INSTALLING ISOLATOR PADS (REFER TO FIG. 6) The isolator pad mounts are to be located as shown in Fig. 6. After the isolator pads have been placed into position on the floor, lower the CODEPAK onto the pads. When the unit is in place remove the rigging equipment and check that the unit is level both longitudinally and transversely. The unit should be level within 1/4" (6.4 mm) from one end to the other end and from front to the rear. If the chiller is not level within the amount specified, lift it and place shims between the isolation pad and the CODEPAK tube sheets. (Shims furnished by the installer.) Lower unit again and recheck to see that it is level. CHECKING THE ISOLATION PAD DEFLECTION All isolation pads should be checked for the proper deflection while checking the level of the CODEPAK. Each pad should be deflected approximately 0.15 inch (3.8 mm). If an isolation pad is under deflected, shims should be placed between the unit tube sheet and the top of the pad to equally deflect all pads. LEVELING THE UNIT The longitudinal alignment of the unit should be checked by placing a level on the top center of the cooler shell under the compressor/motor assembly. Transverse alignment should be checked by placing a level on top of the shell end sheets at each end of the CODEPAK. INSTALLING OPTIONAL SPRING ISOLATORS (RE- FER TO FIG. 7) When ordered, 4 spring type isolator assemblies will be furnished with the unit. The 4 assemblies are identical and can be placed at any of the 4 corners of the unit. While the unit is still suspended by the rigging, the isolators should be bolted to the unit by inserting the cap screw(s) through the hole(s) in the mounting bracket into the tapped hole in the top of the isolator leveling bolt(s). Then the unit can be lowered onto the floor. The leveling bolts should now be rotated one (1) turn at a time, in sequence, until the unit end sheets are about 1-3/4" (44.4 mm) off the floor or foundation, and the unit is level. Check that the unit is level, both longitudinally and transversely (see Leveling The Unit). If the leveling bolts are not long enough to level unit due to an uneven or sloping floor or foundation, steel shims (grouted, if necessary) must be added beneath the isolator assemblies as necessary. After the unit is leveled, wedge and shim under each corner to solidly support the unit in this position while piping connections are being made, pipe hangers adjusted and connections checked for alignment. Then the unit is filled with water and checked for leaks. The leveling bolts should now be finally adjusted until the wedges and shims can be removed. The unit should now be in correct level position, clear of the floor or foundation and without any effect from the weight of the piping. When the unit is properly supported, spring isolator installed height will be 6" to 6-1/4" ( mm). PIPING CONNECTIONS After the unit is leveled (and wedged in place for optional spring isolators) the piping connections may be made up; chilled water, condenser water and refrigerant relief. The piping should be arranged with offsets for flexibility, and adequately supported and braced independently of the unit to avoid strain on the unit and vibration transmission. Hangers must allow for alignment of pipe. Isolators (by others) in the piping and hangers are highly desirable, and may be required by specifications, in order to effectively utilize the vibration isolation characteristics of the vibration isolation mounts of the unit. Check for piping alignment Upon completion of piping, a connection in each line as close to the unit as possible should be opened, by removing the flange bolts or coupling and checked for piping alignment. If any of the bolts are bound in their holes, or if the connection springs out of alignment, the misalignment must be corrected by properly supporting the piping or by applying heat to anneal the pipe. NOTE: If the piping is annealed to relieve stress, the inside of the pipe must be cleaned of scale before it is finally bolted in place. COOLER AND CONDENSER WATER PIPING The cooler and condenser liquid heads of CODEPAK units have nozzles which are grooved, suitable for welding 150 psig DWP flanges or the use of Victaulic couplings. YORK INTERNATIONAL 21

22 The nozzles and water pass arrangements are furnished in accordance with the job requirements (see Product Drawings as referenced in Table 4) furnished with the job. Standard units are designed for 150 psig (1034 kpa) DWP on the water side. If job requirements are for greater than 150 psig (1034 kpa) DWP, check the unit data plate before applying pressure to cooler or condenser to determine if the CODEPAK has provisions for the required DWP. Inlet and outlet connections are identified by labels placed adjacent to each nozzle. Cooling Units Chilled Water Foreign objects which could lodge in, or block flow through, the cooler and condenser tubes must be kept out of the water circuit. All water piping must be cleaned or flushed before being connected to the CODEPAK, pumps, or other equipment. Permanent strainers (by others) are required in both the cooler and condenser water circuits to protect the CODEPAK as well as the pumps, tower spray nozzles, chilled water coils and controls, etc. The strainer should be installed in the entering chilled water line, directly up-stream of the CODEPAK. Water piping circuits should be arranged so that the pumps discharge through the CODEPAK, and should be controlled as necessary to maintain essentially constant chilled and condenser water flows through the unit at all load conditions. If pumps discharge through the CODEPAK, the strainer may be located upstream from pumps to protect both pump and CODEPAK. (Piping between strainer, pump and CODEPAK must be very carefully cleaned before startup.) If pumps are remotely installed from CODE- PAK, strainers should be located directly upstream of the CODEPAK. Cooling Units Condenser Water Circuit For proper operation of the unit, condenser refrigerant pressure must be maintained above cooler pressure. If operating conditions will fulfill this requirement, no attempt should be made to control condenser water temperature by means of automatic valves, cycling of the cooling tower fan or other means, since CODEPAKS are designed to function satisfactorily and efficiently when condenser water is allowed to seek its own temperature level at reduced loads and off-peak seasons of the year. However, if entering condenser water temperature can go below the required minimum, (refer to O1) condenser water temperature must be maintained equal to or slightly higher than the required minimum. Refer to Fig. 8 for typical water piping schematic for cooling CODEPAK. Stop Valves Stop valves may be provided (by others) in the cooler and condenser water piping adjacent to the unit to facilitate maintenance. Thermometer wells and pressure taps should be provided (by others) in the piping as close to the unit as possible to facilitate operating checks. Flow Switches (Field Installed) A flow switch or pressure differential control in the chilled water line(s) adjacent to the unit is an accessory furnished for connection to the control center. If a flow switch is used, it must be directly in series with the CODEPAK and sensing only water flow through the CODEPAK. The differential switch must sense pressure drop across the unit. Drain and Vent Valves Drain and vent valves (by others) should be installed in the connections provided in the cooler and condenser liquid heads. These connections may be piped to drain if desired. Checking Piping Circuits and Venting Air After the water piping is completed, but before any water box insulation is applied. Tighten and torque (to maintain between 30 and 60 ft. lbs. 415 and 830 kgm) the nuts on the liquid head flanges. Gasket shrinkage and handling during transit cause nuts to loosen. If water pressure is applied before this is done, the gaskets may LD01051 FIG. 8 SCHEMATIC OF A TYPICAL PIPING ARRANGEMENT FOR COOLING ONLY CODEPAKS 22 YORK INTERNATIONAL

23 FORM N1 LD01052 FIG. 9 REFRIGERANT VENT PIPING be damaged and have to be replaced. Fill the chilled and condenser water circuits (and hot water circuit on heat recovery unit), operate the pumps manually and carefully check the cooler and condenser water heads and piping for leaks. Repair leaks as necessary. Before initial operation of the unit both water circuits (or all three water circuits heat recovery units) should be thoroughly vented of all air at the high points. REFRIGERANT RELIEF PIPING Each unit is equipped with dual pressure relief valves located on the cooler for the purpose of quickly relieving excess pressure of the refrigerant charge to the atmosphere as a safety precaution in case of an emergency, such as fire. Refrigerant relief vent piping (by others), from the relief valves to the outside of the building, is required by code in most areas and should be installed on all CODEPAKS. The vent line should be sized in accordance with the ANSI/ ASHRE-15, or local code, but should never be smaller than Relief Valve Size shown in Figs. 3 or 4. The vent line must include a dirt trap in the vertical leg to intercept and permit clean out and to trap any vent stack condensation. The piping MUST be arranged to avoid strain on the relief valves, using a flexible connection, if necessary. UNIT PIPING Compressor lubricant piping and system external piping are factory installed on all units shipped assembled. On units shipped dismantled, the following piping should be completed under the supervision of the YORK representative; (1) The lubricant piping to oil sump and oil cooler and system oil return connections using material furnished. See Form N3. CONTROL WIRING On units shipped disassembled, after installation of the control center, control wiring must be completed between unit components and control center or solid state starter when used, using wiring harness furnished. Refer to Form N3 and Wiring Diagrams listed in Table 4. Field wiring connections for commonly-encountered control modifications (by others) if required, are shown on Forms PW3. NOTE: No deviations in unit wiring from that shown on drawings furnished shall be made without prior approval of the YORK representative. POWER WIRING Codepak with Electro-Mechanical Starter A 115 volt single phase 60 or 50 Hertz power supply of 15 amperes must be furnished to the control center, from the control transformer (2 KVA required) included with the compressor motor starter. DO NOT make final power connections to control center until approved by YORK representative. OlL PUMP 3 PHASE STARTER Separate wiring or a fused disconnect switch should be supplied by the installer. Refer to the Field Wiring Diagram shown in Table 4. NOTE: Remote Electro-Mechanical starters for the CODEPAK must be furnished in accordance with YORK Standard R-1051 (Product Drawing Form PA5.1) to provide the features necessary for the starter to function properly with the YORK control system. Each CODEPAK unit is furnished for a specific electrical power supply as stamped on the Unit Data Plate, which also details the motor connection diagrams. NOTE: To insure proper motor rotation the starter power input and starter to motor connections must be checked with a phase sequence indicator in the presence of the YORK representative. YORK INTERNATIONAL 23

24 IMPORTANT DO NOT cut wires to final length or make final connections to motor terminals or starter power input terminals until approved by the YORK representative. YK Motors (Electro-Mechanical Starter) Fig. 8 shows the power wiring hook-up for Motor Connections. (Refer to Wiring Labels in Motor Terminal Box for hook-up to suit motor voltage amd amperage.) Motor leads are furnished with a crimp type connection having a clearance hole for a 3/8" (9 mm) bolt, motor terminal lugs are not furnished. CODEPAK with Solid State Starter A CODEPAK equipped with a Solid State Starter, does not require wiring to the compressor motor. The motor power wiring is factory connected to the Solid State Starter (or an optional factory installed disconnect switch). See Field Wiring Diagram listed in Table 4. All wiring to the control panel and the oil pump starter is completed by the factory. A control transformer is furnished with the Solid State Starter. INSULATION (SEE PRODUCT DRAWING FORM PA1). IMPORTANT DO NOT field insulate until the unit has been leak tested under the supervision of the YORK representative. Insulation of the type specified for the job, or minimum thickness to prevent sweating of 30 F surfaces (water chill application), should be furnished (by others) and applied to the cooler shell, end sheets, liquid feed line to flow chamber, compressor suction connection, and cooler liquid heads and connections. The liquid head flange insulation must be removable, to allow head removal for the tube maintenance. Details of areas to be insulated are given on the Product Drawing. Units are furnished factory anti-sweat insulated on order at additional cost. This includes all low temperature surfaces except the two (2) cooler liquid heads. INSTALLATION CHECK REQUEST FOR START-UP SERVICE The services of a YORK representative will be furnished to check the installation and supervise the initial start-up and operation on all CODEPAKS installed within the Continental United States. After the unit is installed, piped and wired as described in this Instruction, but before any attempt is made to start the unit, the YORK District Office should be advised so that the start-up service, included in the contract price, can be scheduled. Notification to the YORK office should be by means of Installation Check List and Request, Form CL1, in triplicate. 3 PHASE MOTOR RATED LOAD AMPS MOTOR CT RATIO VOLTAGE 50/60 HZ 200:1 350:1 700:1 1400: A A A A C B A A A NOTES: A. REQUIRES PASSING MOTOR LEAD THRU CURRENT TRANSFORMER (CT) ONCE BEFORE CONNECTING TO POWER SUPPLY. B. REQUIRES PASSING MOTOR LEAD THRU CT TWICE BE- FORE CONNECTING TO PWER SUPPLY. C. REQUIRES PASSING MOTOR LEAD THRU CT THREE TIMES BEFORE CONNECTING TO POWER SUPPLY. LD01053 FIG.10 YK CODEPAK MOTOR CONNECTIONS (ELECTRO MECHANICAL STARTER APPLICATION) Proud Sponsor of the 1998 U.S. Olympic Team 36USC380 P.O. Box 1592, York, Pennsylvania USA Copyright by York International Corporation 1997 Form N1 (197) Supersedes: N1 (894) Subject to change without notice. Printed in USA ALL RIGHTS RESERVED

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