Millennium TM. 100 thru 675 Tons (315 thru 2375 kw) renewal parts. Supersedes: RP1 (1099) Form RP1 (710) R-22 and R-134a 00202VIP

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Morgan Daniel
6 years ago
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1 Millennium TM Rotary Screw Liquid Chillers renewal parts Supersedes: RP1 (1099) Form RP1 (710) Model YS BA CB S0 thru YS FA FB S5 (Style E) 100 thru 675 Tons (315 thru 2375 kw) 00202VIP R-22 and R-134a

2 FORM RP1 (710) Table of Contents Nomenclature... 3 Available Compressor/shell/motor combinations... 3 units components... 4 Current transformers kits oil separator orifice plate water box gaskets Tubes isolators multiple-unit sequence kit controls miscellaneous & accessories list of figures 1 unit front view Unit rear view unit end view oil eductor schematic oil piping schematic OPTIONAL DUAL OIL FILTER PIPING SCHEMATIC capacity control piping schematic WAY SOLENOID VALVE AND SUBPLATE frequent replaceable parts IteM description part qty number number 18 teflon seal washer * filter - drier suction * filter - drier oil filter element o-ring, oil filter * Each filter/drier Item #19 and #27 requires (2) teflon seal washers Item #18. 2

3 FORM RP1 (710) Nomenclature YS BB BA S1 CF E S SPECIAL FEATURES design LEVEL MOTOR CODE POWER SUPPLY = 60HZ 5 = 50HZ COMPRESSOR CODE CONDENSER CODE COOLER CODE MODEL CODE available compressor/shell/motor combination COMPRESSOR COOLER CONDENSER MOTOR CODE code shell shell r-22, 60 HZ r-134a, 60 HZ r-22, 50 HZ S0 BA, BB BA, BB, CA, CB CF, CG, CH CF, CG, CH 5 CC, 5 CD CA, CB BA, BB, CA, CB S1 ba, BB BA, BB, CA, CB CF, CG, CH, CF, CG, CH, 5 CC, 5 CD, 5 CE, CA, CB BA, BB, CA, CB CJ, CK CJ, CK 5 CF S2 CA, CB CA, CB, DA, DB CG, CH, CJ, CF, CG, CH, CJ 5 CD, 5 CE, 5 CF, DA, DB, DC CA, CB, DA, DB CK, CL, CM CK, CL, CM 5 CG, 5 CH S3 da, DB, DC CA, CB, DA, DB CJ, CK, CL, CM, CG, CH, CJ, CK 5 CF, 5 CG, 5 CH, CN, CP, CR CL, CM, CN, CP, CR 5 CI, 5 CJ, 5 CK S4 ea, EB, EC EA, EB, FA, FB CK, CL, CM, CJ, CK, CL, CM, CN, CP, 5 CF, 5 CG, FA, FB, FC FA, FB CN, CP, CR, CR, CS, CT, CU, CV 5 CH, 5 CI, S5 CS, CT, CU, CK, CL, CM, CN, CP, CR 5 CJ, 5 CK, FA, FB, FC FA, FB CV CS, CT, CU, CV 5 CL, 5 CM, 5 CN, 5 CO COMpressor cooler condenser MOTOR CODE code shell shell S0 BA, bb ba, BB, CA, CB 5 CC, 5 CD CA, Cb ba, BB, CA, CB S1 ba, bb ba, BB, CA, CB 5 CC, 5 CD, CA, Cb ba, BB, CA, CB 5 CE, 5 CF S2 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 S3 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 S4 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 S5 ea, EB, EC ea, EB, FA, FB 5 CF, 5 CG, 5 CH, 5 CI, FA, FB, FC ea, EB, FA, FB 5 CJ, 5 CK, 5 CL, 5 CM, 5 CN, 5 CO 3

4 FORM RP1 (710) Unit Components item description part number quantity reference number per unit figure 1 Valve, Angle Stop - Rotalock ,2 2 Cap,Flare ,2 3 Gasket, Seal ,2 4 Shim, Motor Mounting Shim, Motor Mounting Shim, Motor Mounting Bottle, Oil Rupture Disk, 2 inch, Oil Separator 1 1,3 S0-S1 R S0-S1 R-134a S2-S3 R S2-S3 R-134a S4 R S4 R-134a S5 R S5 R-134a A Rupture Disk, 2 inch S4 & S5 Compressors A 9 Safety Head, 2 inch Rupture Disk (S0-S3) 1, 1A, 3 2 (S4-S5) 10 Gasket, Round Rupture Disk (S0-S3) 1, 1A, 3 5 (S4-S5) 1, 1A 11 Switch, High Pressure Cutout -270 psig , 3 12 Valve, Safety Relief 1,2, 3 S0-S1 Chillers - 3/4 inch S2 Chiller - 3/4 inch (B & C Cooler Code) S2 Chiller - 3/4 inch (D Cooler Code) S4-S5 Chillers - I inch Valve 3-way stop for relief valves (S0-S1) 1, 2, 3 2 (S2-S5) 14A Connector, Union 7/8-14 adjustable , 2, 3 15 Well, Sensor (cooler and condenser water) , 2 16 Sensor, Temp (cooler and condenser water) k ohm , 2 17 Valve, Angle Stop - Rotalock , 1B. 2B, 4 18 Filer/Drier, Oil Separator (requires two of item 54) , 2, 3, 4 19 Filer/Drier, Suction (requires two of item 54) ,4 20 Eductor, Oil Return 1, 1B., 4, 5 S0, S1 Chillers - R S0, S1 Chillers - R134a S2, S3 Chillers - R S2, S3 Chillers - R134a S4, S5 Chillers - R S4, S5 Chillers - R134a Valve, Angle Stop - Transducer Isolation , 1A, 3, 5 22 Gasket, Compressor Suction 1 1 S0,S1 Compressors - 9-7/8 OD, 6-5/8 ID S2,S3 Compressors /8 OD, 8-5/8 ID S4,S5 Compressors /4 OD, 10-3/4 ID Sensor, Temp (oil and discharge temp) 50K ohm C,3, 5 includes Item #63 O-ring 25 Valve, 1/4 inch Pressure Release C, 2A, 5 28 Valve Angle Stop, Oil Separator Filter/Drier , 4 29 Sight Glass , 2 31 Float Switch, Oil Level Safety * Special Primore Rotalock Fitting - Requires (2) teflon seal washers P/N

5 FORM RP1 (710) This Page Intentionally Left Blank 5

6 FORM RP1 (710) MOTOR 4, 5, 6 1, 2, , 54 19, (2) 54 29, 68 19, (2) A S4 & S5 ONLY SEE VIEW A COMPRESSOR 22 COOLER LD02685 OIL SEPARATOR 12, 14, 64 18, (2) 54 8, 9, 10 (SEE VIEW A) 11 12, , VIP 14a, 64 fig. 1 Unit Front View 6

7 FORM RP1 (710) (Assembly) 8A Part of 9 10 rupture disk assembly VIEW A LD , , (2) 54 VIEW B 00079VIP 25, , fig. 1 Unit Front View (CONT D) VIEW C 00078VIP 7

8 15, 16 12 11 18, (2) 54 28, 54 12 12 29, 68 14A 14 32 35 42 (See View B) 36, 37, 38 39 (SEE

8 8 15, , (2) 54 28, , 68 14A (See View B) 36, 37, (SEE VIEW C) 31 29, CONDENSER 33 1, 2, A FORM RP1 (710) fig. 2 unit Rear view

Inlet Oil Refrigerant Gas to Evaporator Outlet Oil Liquid Refrigerant to Evaporator 42 Refrigerant Gas from Oil

9 FORM RP1 (710) MAINTENANCE VIEW A 00210VIP Sub Cooled Liquid Refrigerant Inlet Oil Refrigerant Gas to Evaporator Outlet Oil Liquid Refrigerant to Evaporator 42 Refrigerant Gas from Oil Cooler 74, 65 (2) *see ORIFICE PLATE LIST- ING ON PAGE 13 VIEW b LD , , MAINTENANCE , 67 1, 2 55 fig. 2 unit Rear view (cont d) 00209VIP 9

10 FORM RP1 (710) Unit Components item description part number quantity reference number per unit figure 32 Valve, Oil Line Solenoid S0, S1, S2, and S3 Chillers , 2A, 4 S4 and S5 Chillers Not Required 33 Oil Heater, 500 watt Valve Butterfly, Oil Separator/Condenser 1 2 S0, S1 Chillers, 4 inch S2, S3 Chillers, 6 inch S4, S5 Chillers, 8 inch Gasket Butterfly Valve 2 2 S0, S1 Chillers 7-1/8 OD, 4-1/2 ID S2, S3 Chillers 9-7/8 OD, 6-5/8 ID S4, S5 Chillers 12-1/8 OD, 8-5/8 ID Oil Filter, Complete Includes Items 37 and , (2) with optional dual oil filter 2, 2A, 5 37 Element Oil Filter, 3 Micron , (2) with optional dual oil filter 2, 2A, 5 38 O-ring Oil Filter Element Replacement , (2) with optional dualoil filter 2, 2A, 5 39 Oil Cooler 2, 2C S0, S1, S2, and S3 Chillers S4 and S5 Chillers Valve, Ball - Variable Orifice Line Manifold, Oil Distribution Block Compressor Port SB Valve, Liquid Line Ball Valve 2-1/ , 2B, 5 43 Gasket, Round Orifice Plate, 5-1/8 OD, 2-7/8 ID Valve, Ball Liquid Charging 3/4 Male Flare B 45 Valve, Solenoid Variable Orifice Valve, 4-way Solenoid, Capacity Control (Continental) A Manifold, 4-way Solenoid Sub-plate , 7 47 Valve, Angle Stop, Compressor Port SC11 and Oil Cooler B, 4 48 Gasket, Compressor Discharge 1 3 S0, S1 Compressor - 7-1/8 OD, 4-1/2 ID S2, S3 Compressor - 9-7/8 OD, 6-5/8 ID S4, S5 Compressor /8 OD, 8-5/8 ID Transducer, High Pressure - Condensing Pressure Filter Pressure, Oil Pressure, Seal Oil Pressure psig, with Item #61 O-ring 50 Valve, Ball Oil Filter Isolation Transducer,Evaporator Pressure 1 per chiller R-22 Water, psig, with Item #61 O-ring R-22 Brine, psig, with Item #61 O-ring R-134a, Water or Brine, 6-74 psig, with item #61 O-ring Suppressor, Inductive Load S0, S1, S2, and S3 Chillers 4 S4 and S5 Chillers 3 53 Valve, 3-Way 1, Optional Dual Oil Filters-All Sizes Seal, Teflon Fiber, 3/4 OD, 5/8 ID Seal, Teflon Fiber,1 OD, 7/8 ID Seal, O-ring SAE Straight Thread, 7/16-20 UNF-2A Seal, O-ring SAE Straight Thread, 1/2-20 UNF-2A Seal, O-ring SAE Straight Thread, 9/16 18 UNF-2A Seal, O-ring SAE Straight Thread, 3/4-16 UNF-2A * Special Primore Rotalock Fitting - Requires (2) teflon seal washers P/N

11 FORM RP1 (710) 46a (See Fig. 7) 47, , , 9, (2) 54 28, A (2) VIP fig. 3 unit end view 11

12 FORM RP1 (710) * Item 49 and 51 are furnished with O-Ring, p/n unit components item description part number quantity reference number per unit figure 64 Seal, O-ring SAE Straight Thread, 7/8-14 UNF-2A Seal, O-ring SAE Straight Thread, 1-1/16-12UN-2A Seal, O-ring SAE Straight Thread, 1-3/16-12UN-2A Seal, O-ring SAE Straight Thread, 1-5/16-12UN-2A Seal, O-ring SAE Straight Thread, 2-1/4-12UN-2A Seal, O-ring SAE Face Seal, 1/4 Tube Seal, O-ring SAE Face Seal, 3/8 Tube Seal, O-ring SAE Face Seal, 1/2 Tube Seal, O-ring SAE Face Seal, 3/4 Tube Seal, O-ring SAE Face Seal, 1 Tube Seal, O-ring SAE Face Seal, 1-5/8-12UNEF-2A Used in Oil Line Solenoid Valve (1 SOL), Refrigerant Level Solenoid Vavle (2 SOL) and Slide Valve Solenoid (2 Req d). 2. Used in Refrigerant Level Solenoid Valve (2 SOL) and Slide Valve Solenoid (2 Req d). 12

13 Mixture of Oil and Refrigerant Gas to Compressor Port SC - 5 FORM RP1 (710) LD04919 Mixture of Oil and Liquid Refrigerant to Compressor Suction High Pressure Oil and Refrigerant Gas from Oil Separator Orifice Reduced Pressure Area Nozzle , 53 Suction Gas to Compressor 17, 18 High Pressure Oil and Refrigerant Gas from Oil Separator 63, Low Pressure Oil and Refrigerant from Evaporator Mixture of Oil and Refrigerant to Compressor Suction Jet Pump Cross Section Eductor block contains two jet pumps 20 17, 54 63, , 54 Oil - Rich Refrigerant from Evaporator Oil from Evaporator Trough fig. 4 oil eductor schematic 13

14 FORM RP1 (710) Oil Supply to Capacity Control Port "P" Refrigerant Gas from OIl Cooler Liquid Refrigerant to Oil Cooler Service Maintenance , 75 25, , , Oil to Compressor Port SB (2) 67, Oil from 36Oil Separator 67, Oil to Compressor Port SB , 65 LD fig. 5 oil piping schematic 14

15 FORM RP1 (710) To SB-2 Manifold Block 53 25, 60 67, SERVICE , 75 67, , SERVICE 38 67, 75 Oil from Oil Separator 67, , 75 LD04895 fig. 6 optional DUAL OIL FILTER PIPING SCHEMATIC 15

FORM160.80-RP1 (710) 62, 71 62, 71 (4) 60 62, 71 (4) 62 (4) 71 LD04920 fig.

16 FORM RP1 (710) 62, 71 62, 71 (4) 60 62, 71 (4) 62 (4) 71 LD04920 fig. 7 capacity control piping schematic (4 Req d) (4) 62 (4) 71 46A 00208VIP fig. 8 4-way solenoid valve and subplate 16

17 FORM RP1 (710) current transformer kits field installed electro-mechanical starters only part NUMBER MOTOR FLA CT use WITH voltage ratio FACTORY-MOUNTED MOTORS ONLY : / : : : : / : : : CT ratio transformer only part NUMBER 200: : : : COMpressor SIZE oil separator part NUMBER S S S S S S orifice plate code part NUMBER C d e F G H J k L M code part NUMBER N P Q R S T u V W

18 FORM RP1 (710) water box gaskets LD02690 cooler with standard compact water boxes 150 PSI 1 pass 2 pass 3 PASS SHELL CODE GASKET FEET GASKET FEET GASKET FEET part NO. REQ D PART NO. REQ D PART NO. REQ D BA,BB CA,CB DA,DB,DC EA,EB,EC FA,FB,FC cooler with marine water boxes 150 PSI 1 pass 2 pass 3 PASS SHELL CODE GASKET FEET GASKET FEET GASKET FEET part NO. REQ D PART NO. REQ D PART NO. REQ D BA,BB CA,CB DA,DB,DC EA,EB,EC FA,FB,FC cooler with marine water boxes 300 PSI 1 pass 2 pass 3 PASS SHELL CODE GASKET FEET GASKET FEET GASKET FEET part NO. REQ D PART NO. REQ D PART NO. REQ D BA,BB CA,CB DA,DB,DC EA,EB,EC FA,FB,FC

19 FORM RP1 (710) water box gaskets condenser with standard compact water boxes 150 PSI SHELL 1 pass 2 PASS CODE GASKET FT. GASKET FT. PART NO. REQ D PART NO. REQ D BA,BB CA,CB DA,DB EA,EB FA,FB condenser with marine water boxes 150 PSI SHELL 1 pass 2 PASS CODE GASKET FT. GASKET FT. PART NO. REQ D PART NO. REQ D BA,BB CA,CB DA,DB EA,EB FA,FB condenser with marine water boxes 300 PSI SHELL 1 pass 2 PASS CODE GASKET FT. GASKET FT. PART NO. REQ D PART NO. REQ D BA,BB CA,CB DA,DB EA,EB FA,FB cooler tubes shell shell tube code id quantity PART NUMBER BA BB CA CB DA DB DC PART NUMBER EA EB EC FA FB FC TUBEs condenser tubes shell shell tube code id quantity PART NUMBER BA 17-1/4 133 BB 17-1/4 169 CA 20-1/2 226 CB 20-1/2 292 DA DB PART NUMBER EA EB FA 32-1/2 670 FB 32-1/

20 FORM RP1 (710) neoprene vibration isolators system OPERATING weight part NUMBER includes Quantity KILOGRAMs pounds of 4 Pads pad SIZE Up to 7423 Up to /2 x 4 1/ to to /2 x to to x 6 SPRING ISOLATORS (4 Per Unit) ENGLISH COMPRESSOR SYSTEM OPERATING PART NO. SIZe weight (Lbs.) UP to 6, ,866 to 9, S0, S1, 9,819 to 12, S2, S3 12,183 to 15, ,273 to 18, ,273 to 22, UP to 22, S4, S5 22,910 to 26, ,045 to 32, SPRING ISOLATORS (4 Per Unit) SI COMPRESSOR SYSTEM OPERATING PART NO. SIZe weight (mm) UP to 3, ,115 to 4, S0, S1, 4,454 to 5, S2, S3 5,526 to 6, ,928 to 8, ,289 to 10, UP to 10, S4, S5 10,392 to 11, ,814 to 14,

21 FORM RP1 (710) MULTIPLE UNIT SEQUENCE KIT CONTROLS STYLES C & D UNITS 2 3 TWO UNITS ITEM DESCRIPTION QUANTITY PART NUMBER 1 1 Controller, RWT Relay, Time Delay Switch, Toggle Not Shown. Remote Mounted. LD THREE UNITS ITEM DESCRIPTION QUANTITY PART NUMBER 1 Controller, RWT Relay, Time Delay Relay, Control Relay, Control Switch, Toggle Switch, Toggle LD FOUR UNITS 4 4 ITEM DESCRIPTION QUANTITY PART NUMBER 1 Controller, RWT Relay, Time Delay Relay, Control Relay, Control Switch, Toggle Switch, Rotary LD

22 FORM RP1 (710) miscellaneous and accessories compound description part NUMBer quantity Compound, Heat Conductive (For Thermometer Wells) Oz. Can touch-up paints spray cans description part NUMBER Caribbean Blue Enamel Black (Control Center) Purchase Locally temperature recorder description part NUMBER HZ NUMBER OF PENS flow switch control description part NUMBER 150 DWP DWP differential pressure control description part NUMBER Control, Differential Pressure* *300 Psi Maximum Working Pressure YS OIL USAGE TABLE chiller oil r-22 REFrigerant r-134a REFRIGERANT SIZE QUAN. (GALS.) OIL TYPE PART NUMBER OIL TYPE PART NUMBER S0 10 york C OIL YORK H OIL S1 10 york C OIL YORK H OIL S2 10 york C OIL YORK H OIL S3 10 york S OIL YORK H OIL S4 15 york S OIL YORK H OIL S5 15 york S OIL YORK H OIL S7 100 york C OIL The part numbers listed above are 5 gallon containers. 22

23 FORM RP1 (710) notes 23

24 2010 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI Printed in USA RP1 (710) New Release

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

CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS Supersedes: 160.49-N1 (894) Form 160.49-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