YVAM Air-Cooled Centrifugal Liquid

Chiller
Field Installation Procedure for YVAM Units with 20 Fans,
HFC-134A, 60 Hz

035-28539-000

Installation Guide Form Number: 160.88-N1 (822)

Issue Date: 2022-08-15 Supersedes: 160.88-N1 (122)
2 YVAM Air-Cooled Centrifugal Liquid Chiller
 Contents
General safety guidelines................................................................................................................................5
Contents
Safety symbols....................................................................................................................................... 5
Changeability of this document...........................................................................................................6
Revision notes........................................................................................................................................ 6
Associated literature..............................................................................................................................6
Nomenclature........................................................................................................................................ 7
Overview............................................................................................................................................................9
Chiller components............................................................................................................................... 9
Receiving the chiller....................................................................................................................................... 11
Inspection............................................................................................................................................. 11
Delivery and storage........................................................................................................................... 11
Chiller data plate..................................................................................................................................12
Rigging.............................................................................................................................................................13
Scope..................................................................................................................................................... 13
Lifting weights......................................................................................................................................14
Moving the chiller................................................................................................................................ 14
Lifting using accessory lifting lugs.................................................................................................... 14
Chiller dimensions and rigging locations......................................................................................... 15
Installation...................................................................................................................................................... 16
Determine location..............................................................................................................................16
Foundation requirements......................................................................................................................... 16
Ground locations........................................................................................................................................16
Roof locations............................................................................................................................................. 16
Seismic applications...................................................................................................................................16
Other considerations................................................................................................................................. 17
Clearance requirements..................................................................................................................... 17
Recommended clearances for all units................................................................................................... 17
Rig chiller to final location.................................................................................................................. 19
Leveling the chiller...............................................................................................................................19
Anchor the chiller to the final location..............................................................................................19
Isolators................................................................................................................................................ 20
Isolation.......................................................................................................................................................20
Installation of optional spring isolators.................................................................................................. 20
Installation of optional elastomeric isolators......................................................................................... 22
Make piping connections....................................................................................................................24
Evaporator freeze damage....................................................................................................................... 24
Evaporator water piping............................................................................................................................25
Check for piping alignment...................................................................................................................... 26
Permanent strainers.................................................................................................................................. 26
Stop valves.................................................................................................................................................. 27
Flow switches.............................................................................................................................................. 27

YVAM Air-Cooled Centrifugal Liquid Chiller 3

 Waterbox drain and vent valves...............................................................................................................27
Waterbox fill and vent............................................................................................................................... 27
Wiring connections..............................................................................................................................27
Unit power wiring...................................................................................................................................... 27
Unit control wiring..................................................................................................................................... 28
Apply insulation................................................................................................................................... 28
Unit heater operation verification..................................................................................................... 29
Reassembly..................................................................................................................................................... 30
Refrigerant tubing reassembly.......................................................................................................... 31
Assembly of straight thread O-ring port fittings....................................................................................31
Assembly of O-ring face seal fittings....................................................................................................... 33
Unit conversion.............................................................................................................................................. 37

4 YVAM Air-Cooled Centrifugal Liquid Chiller

General safety guidelines
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certain components or conditions including,
but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the potential, if misused or handled improperly,
to cause bodily injury or death. It is the obligation and responsibility of rigging, installation,
and operating or service personnel to identify and recognize these inherent hazards, protect
themselves, and proceed safely in completing their tasks. Failure to comply with any of these
requirements could result in serious damage to the equipment and the property in which it is
situated, as well as severe personal injury or death to themselves and people at the site.
This document is intended for use by owner-authorized rigging, installation, and operating or
service personnel. It is expected that these individuals possess independent training that will enable
them to perform their assigned tasks properly and safely. It is essential that, before performing
any task on this equipment, this individual reads and understands the on-product labels, this
document and any referenced materials. This individual must also be familiar with and comply
with all applicable industry and governmental standards and regulations pertaining to the task in
question.

Safety symbols
The following symbols are used in this document to alert the reader to specific situations:

DANGER

Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.

WARNING

Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.

CAUTION

Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.

Note: Highlights additional information useful to the technician in completing the work being
performed properly.

YVAM Air-Cooled Centrifugal Liquid Chiller 5

 WARNING

External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to
be connected inside the OptiViewTM cabinet.

Devices such as relays, switches, transducers and controls and any external wiring must not be installed
inside the cabinet. All wiring must be in accordance with Johnson Controls’ published specifications
and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for
damage/problems resulting from improper connections to the controls or application of improper
control signals. Failure to follow this warning will void the manufacturer’s warranty and could cause
serious damage to property or personal injury.

Changeability of this document

In complying with Johnson Controls’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. Johnson Controls makes no
commitment to update or provide current information automatically to the manual or product
owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson
Controls Service office or accessing the Johnson Controls Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
It is the responsibility of rigging, lifting, and operating or service personnel to verify the
applicability of these documents to the equipment. If there is any question regarding the
applicability of these documents, rigging, lifting, and operating or service personnel should verify
whether the equipment has been modified and if current literature is available from the owner of
the equipment before performing any work on the chiller.

Revision notes
Revisions made to this document are indicated in the following table. These revisions are to
technical information, and any other changes in spelling, grammar, or formatting are not included.
Table 1: Revision notes
Affected pages Description
6 Removed reference to 50.20-NM5 from Associated literature section
6 Updated title of Screw and Scroll Chiller to Air-Cooled Chiller in Associated
literature section

Associated literature
Table 2: Associated literature
Manual description Form number
Equipment Pre-Startup and Startup Checklist 160.88-CL1
Unit Startup Checklist 160.88-CL2
Installation, Operation, and Maintenance 160.88-OM1
Unit Power Wiring 160.88-PW1
Field Control Wiring 160.88-PW2
Liquid Chiller Log Sheet 160.88-MR1
Air-Cooled Chiller Long Term Storage 50.20-NM7

6 YVAM Air-Cooled Centrifugal Liquid Chiller

Table 2: Associated literature
Manual description Form number
Shipping Damage Claims Form 50.15-NM
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2

Nomenclature
Figure 1: System nomenclature

Figure 2: Compressor nomenclature

YVAM Air-Cooled Centrifugal Liquid Chiller 7

Figure 3: Vessel nomenclature

Figure 4: Variable speed drive nomenclature

8 YVAM Air-Cooled Centrifugal Liquid Chiller

Overview
This manual provides instructions for rigging and installing a Johnson Controls YVAM Liquid Chilling
Unit.
Chillers are shipped as a single factory-assembled, piped, and wired package. The units require a
minimum of field labor to make chilled water connections and electrical power connections.

Chiller components
See Figure 5, Figure 6, and Figure 7 for the major components of the YVAM chiller.

Figure 5: Control panel side view

Callout Component Callout Component

A Control panel B Signal box for condenser fan variable speed
drive (VSD), both sides
C Condenser sections, ten with two fans each D Evaporator water nozzles, inlet at the bottom
and outlet at the top
E Waterbox heater power connections F UPS power panel

YVAM Air-Cooled Centrifugal Liquid Chiller 9

Figure 6: Compressor side view

Callout Component Callout Component

A Evaporator B Motor cooling filter drier
C Expansion valve D Cooling piping for VSD
E Eaton® surge suppressor F Direct drive motor and MBC
G Compressor

Figure 7: VSD end view

Callout Component Callout Component

A VSD B UPS power panel
C Single point power panel

10 YVAM Air-Cooled Centrifugal Liquid Chiller

Receiving the chiller
Inspection
Remove any transit packing. Inspect the unit to ensure that all components have been delivered
according to the bill of lading and that all miscellaneous boxes or materials have been received.
Ensure that no damage to any portion of the chiller or loose items has occurred during transit.
If any damage is evident, it must be noted on the carrier’s freight bill and a claim entered in
accordance with the instructions given on the advice note.
Note: Johnson controls is not responsible for any damage in shipment or at job site or loss of
parts. Refer to Shipping Damage Claims Form, Form 50.15-NM.

Delivery and storage

To ensure consistent quality and maximum reliability, all units are tested and inspected before
leaving the factory. Units are shipped completely assembled and containing refrigerant under
pressure. Units are shipped without export crating unless crating has been specified on the sales
order.
If the unit is put into storage, before installation, observe the following precautions:
• Block the chiller so that the base cannot sag or bow.
• Ensure that all openings, such as water connections, are securely capped.
• Do not store in a location where exposed to ambient air temperatures exceeding 43.3°C
(110°F).
• The condensers must be covered to protect the coils and fins from potential damage and
corrosion, particularly where building work is in progress.
• The unit must be stored in a location where there is minimal activity in order to limit the risk
of accidental physical damage.
• To prevent inadvertent operation of the pressure relief devices, do not steam clean the unit.
• Inspect the unit periodically during storage. Follow all directions for long term storage
requirements as defined in Form 50.20-NM7.
The services of a qualified Johnson Controls service representative are required for the installation
and startup of all YVAM model chillers installed in the continental United States.
Do not attempt to install or start the chiller without the presence of this qualified representative.
This may void all or portions of the chiller warranty.

CAUTION

The Johnson Controls warranty may be voided if the following restrictions are not adhered to.

• Do not open valves or connections under any circumstances because such action will result in
loss of the factory refrigerant (Form 1) or nitrogen charge (Form 2).
• Do not dismantle or open the chiller for any reason except under the supervision of a
Johnson Controls representative.

YVAM Air-Cooled Centrifugal Liquid Chiller 11

 • When units are received, notify the nearest Johnson Controls office in ample time for a
Johnson Controls representative to supervise rigging the unit to its storage or operating
locations.
• Do not make final power supply connections to the single point power panel or any other
power connections without Johnson Controls supervision.
• Do not charge the unit with refrigerant.
• Do not attempt to start the system.
• Do not run hot water, >110°F (43.3°C) maximum, or steam through the evaporator at any
time.

Chiller data plate

There is a unit data plate on the outside of the right side door of the VSD panel assembly of each
unit. It provides the unit model number, design working pressure, refrigerant charge, serial
numbers, and all chiller power characteristics.
Additional information is provided on the evaporator, compressor, and motor data plates. This
information must be included when contacting the factory on any problem.

Figure 8: Chiller data plate

12 YVAM Air-Cooled Centrifugal Liquid Chiller

Rigging
Figure 9: Rigging warning

WARNING

Rigging and lifting should only be done by a professional rigger in accordance with a written rigging
and lifting plan. The most appropriate rigging and lifting method depends on job specific factors, such
as the rigging equipment available and site needs. A professional rigger must determine the rigging
and lifting method to be used. It is beyond the scope of this manual to specify rigging and lifting
details.

Scope
This procedure covers the rigging, locating, and final assembly of the YVAM units with total fan
quantity of 20 fans. It is intended for use by the qualified field service teams.

WARNING

The unit must only be lifted by the base frame at the points provided. Never move the unit on rollers,
or lift the unit using a forklift truck. Care must be taken to avoid damaging the condenser cooling fins
when moving the unit.

YVAM Air-Cooled Centrifugal Liquid Chiller 13

Lifting weights
See Figure 11 for lifting location information. All published weights in this manual are approximate
values at the time of publication. Refer to the unit nameplate or submittal documents for the actual
unit shipping weight.
Note: Weight can vary depending on unit configuration at the time of lifting.

Moving the chiller

Before moving the unit, ensure that the installation site is suitable for installing the unit and can
easily support the weight of the unit and all associated services.

Lifting using accessory lifting lugs

Units are provided with lifting holes in the base frame that accept the accessory lifting lug set as
shown in Figure 10. Insert the lugs (RH and LH) into the respective holes in the base frame. Turn
the lugs so that the spring loaded pin engages into the hole and the flanges on the lug lock behind
the hole. The lugs must be attached to the cables or chains using shackles or safety hooks. See
Figure 10 for lug installation technique and Figure 11 for installation locations.

Figure 10: YVAM chiller rigging using accessory lifting lugs

Callout Component Callout Component

A Lug B Lifting hole in base frame
C Flange D Locking pin

• The accessory lifting lugs must be inserted into the respective holes in the base frame, noting
the right hand and left orientation of these lugs, and secured using the locking pin.
• The following steps are a guide to help the rigger understand some of the risks that chiller rig
may pose and are not intended to provide the final instructions for the lifting event.

14 YVAM Air-Cooled Centrifugal Liquid Chiller

 • Use spreader bars to avoid lifting chains hitting the chiller. Various methods of spreader
bar arrangements may be used, keeping in mind the intent is to keep the unit stable and to
prevent the chains from hitting the chiller and causing damage.
• Never lift the chiller using a forklift or by hooking to the top rails. Use only the lifting holes
provided.
• Lifting instructions are placed on a label on the chiller and on the shipping bag.

Chiller dimensions and rigging locations

Figure 11: Unit rigging lift point dimensions, mm (in.)

YVAM Air-Cooled Centrifugal Liquid Chiller 15

Installation
Determine location
Read these instructions in their entirety before beginning the installation. For optimum
performance and trouble-free service, it is essential that the installation site meets the location and
space requirements for the model being installed.
Important: Make sure that the minimum service access space is maintained for cleaning and
maintenance purposes.
The units are designed for outside installation and can be installed at ground level on a suitable
flat level foundation easily capable of supporting the weight of the unit, or on a suitable rooftop
location. In both cases, an adequate supply of air is required. Avoid locations where the sound
output and air discharge from the unit might be objectionable.
The location must be selected for minimum sun exposure and away from boiler flues and other
sources of airborne chemicals that could attack the condenser coils and steel parts of the unit.
If located in an area accessible to unauthorized persons, steps must be taken to prevent access
to the unit by means of a protective fence. This can help to prevent the possibility of vandalism,
accidental damage, or possible harm caused by unauthorized removal of protective guards or
opening panels to expose rotating or high voltage components.

Foundation requirements
Mount units on a flat and level foundation, ground or roof, that can support the entire operating
weight of the equipment. Contact your nearest Johnson Controls Sales Office for shipping and
operating weights.

Ground locations
For ground level locations, the unit must be installed on a suitable flat and level concrete base that
extends to fully support the two side channels of the unit base frame. A one-piece concrete slab
with footings that extend below the frost line is recommended.
The slab must not be tied to the main building foundation because operational noise can telegraph.
Mounting holes are 5/8 in. (15.88 mm) are provided in the base rails for bolting the unit to its
foundation. See Figure 13 for locations.
For ground installations, precautions must be taken to protect the unit from tampering by or injury
to unauthorized persons. Fasteners on access panels can prevent casual tampering. However,
further safety precautions such as unit enclosure options, a fenced-in enclosure, or locking devices
on the panels may be advisable. Check with local authorities for safety regulations.

Roof locations
Sufficient structure must be provided to safely support the entire operating weight of the unit,
service personnel, and service tooling. Do not damage the roof during installation. If the roof
is of bonded construction, consult a building contractor or architect for special installation
requirements. Use spring isolators to minimize vibration transmission into building structure.
The building must have adequate structural support at the spring isolator locations. This is the
region directly under the side and end base rails of the chiller. Johnson Controls do not supply the
structural support.

Seismic applications
Avoid installing chillers on springs or roofs where earthquakes are a risk. Springs and roofs amplify
earthquake forces. Rigidly mounting chillers to ground level concrete pads is the best option for

16 YVAM Air-Cooled Centrifugal Liquid Chiller

earthquake zones. Contact Johnson Controls equipment specialists for help with projects that have
seismic requirements.

Other considerations
Any ductwork or attenuators fitted to the unit must not have a total static pressure resistance at full
air flow that exceeds the capability of the fans installed on the unit.
When it is required to surround the units in addition to whatever optional louver package is
selected, make sure that the screening can pass the required chiller cfm without exceeding 0.1 in.
wg (24.9084 Pa) external static pressure.

CAUTION

Clearance dimensions provided in Figure 12 are necessary to maintain good airflow and ensure
correct unit operation. It is also necessary to consider access requirements for safe operation and
maintenance of the unit and power and control panels. Local health and safety regulations, or practical
considerations for service replacement of large components, may require larger clearances than those
recommended.

Clearance requirements
Adequate clearances around the units are required for the unrestricted airflow for the air-
cooled condenser coils and to prevent recirculation of warm discharge air back onto the coils.
If these clearances are not maintained, airflow restriction or re-circulation causes a loss of
unit performance, an increase in power consumption, and can cause the unit to malfunction.
Consideration must also be given to the possibility of down drafts, caused by adjacent buildings,
which may cause recirculation or uneven unit airflow.
The results of the restricted airflow or hot air recirculation can diminish performance as outlined
in Form 150.12-AD2, Air-Cooled Chiller Derating Due to Airflow Restrictions. Johnson Controls’ unit
controls optimize the operation without nuisance high pressure safety cutouts. However, the
system designer must consider the potential for performance degradation.
For locations where significant cross winds are expected, such as exposed rooftops, use an
enclosure of solid or louver type to prevent wind turbulence interfering with the unit airflow.
When units are installed in an enclosure, the enclosure height must not exceed the height of the
unit on more than one side. If the enclosure is of louvered construction, the same requirement of
static pressure loss applies as for ducts and attenuators. See Other considerations.

Recommended clearances for all units

• For access to the unit control center, make sure that the unit is not higher than on spring
isolators.
• Minimum clearances are shown in Figure 12 and are as follows:
- Side to wall: 6 ft (1.8 m)
- Rear to wall: 6 ft (1.8 m)
- Control panel end to wall: 4 ft (1.2 m)
- Top: No obstructions whatsoever
- Distance between adjacent units: 10 ft (3 m)
• Ensure that no more than one wall around the chiller yard is higher than the chiller.

YVAM Air-Cooled Centrifugal Liquid Chiller 17

 • Avoid locations near windows or structures where normal operating sounds might be
objectionable.
• The condenser fans are propeller type and must not be used with ductwork, filters, or other
impediments to airflow in the condenser air stream.
• When obstructions to airflow exist, they must not add more than 0.1 in. (2.54 mm) external
static pressure.
• Protection against corrosive environments is available by ordering the units with cured
epoxy-coating on the condenser microchannel. Epoxy-coated coils must be used with any
units being installed at the seashore, or where salt spray can hit the units, where acid rain is
prevalent, and when paired with adiabatic cooling solutions.
• At installations where winter operation and snow accumulations are expected, additional
elevation must be provided to ensure normal condenser airflow.
• Provide adequate space for tubes to be removed from evaporator. For clearances, contact
your nearest Johnson Controls sales office.

Figure 12: Unit clearance dimensions, ft (m)

18 YVAM Air-Cooled Centrifugal Liquid Chiller

Rig chiller to final location
Rig the unit to its final location by the means according to the instructions in the Rigging section.

Leveling the chiller

Make sure that chiller base rail remains straight along the long axis of the chiller during the leveling
process. This can be accomplished with the use of a string along the base rail. Any bowing of the
chiller frame can lead to refrigerant line failures or other component fatigue issues over time.
Check the longitudinal alignment of the unit by placing a level on the base rail of the chiller
at several locations after the base rail has been verified that it is straight and true. Check the
transverse level by placing a level on the base rail at the VSD and opposite ends of the chiller base
frame.
Adhere to all isolator type installation requirements before setting the chiller in the final location.
Certain steps are required before placing the chiller on some isolator types. See the following
section for these requirements.

Anchor the chiller to the final location

See the following mounting options before moving the chiller to its final location. When spring
isolators are used, the unit must be supported in a safe manner before anchoring the chiller. Rig
the unit to its final location by the means as defined in the Rigging section.
Note: The following dimensions are approximate values and must be verified on receipt of the
chiller.

Figure 13: Isolator locations

Table 3: Isolator locations

Locations
Unit model Description Unit
1 2 3 4 5 6
Standard, in. 10.22 95.96 159.87 220.45 299.16 441.86
Isolator X dimension
Metric, mm 259.7 2,437.5 4,060.6 5,599.5 7,598.8 11,223.3
Standard, in. 85.14
Isolator Y dimension
Metric, mm 2,162.4
Locations
YVAM 350 Description Unit
7 8 9 10 11 12
Standard, in. 10.22 95.96 159.87 220.45 299.16 441.86
Isolator X dimension
Metric, mm 259.7 2,437.5 4,060.6 5,599.5 7,598.8 11,223.3
Standard, in. 85.14
Isolator Y dimension
Metric, mm 2,162.4

Note: The isolator Y dimension is hole center base rail to base rail.

YVAM Air-Cooled Centrifugal Liquid Chiller 19

Isolators
Isolation
Do not install YVAM chillers without isolation. Vibration isolation is an important option that must
be accounted for at chiller installation. If isolators are not ordered, they must be selected based on
the loading at the specific chiller locations. Contact Johnson Controls representative for assistance if
isolators have not been provided.

Installation of optional spring isolators

If ordered, spring type isolator assemblies are supplied with the unit. The isolator load rating can
vary based on the location on the chiller. This is due to the weight distribution of the unit and
the isolators must be located as prescribed in the technical data portion of the chiller submittal
package. See Figure 13 for locations. See Table 5 and Table 6 for details of the isolators.
Spring isolators are shipped fully assembled and must be positioned in accordance with the
submittal drawings or as otherwise recommended.
1. Set the isolators on the floor, housekeeping pad, or subbase, ensuring that all isolator
centerlines match the equipment mounting holes.
2. VMC Group recommends that the isolator base (B) be installed on a level surface. Shim or
grout as required, leveling all isolator bases to the same elevation. The maximum difference
that can be tolerated is 1/4 in. (6.35 mm).
3. Bolt or anchor all isolators to supporting structure using the base slotted holes (C).
4. Place the equipment on top of the isolators and make sure that the mounting holes of the
equipment line up with the isolator positioning pin (H).
5. The adjustment process can only begin after the equipment or machine is at its full operating
weight.
6. Adjust each isolator in sequence by turning the spring adjusting bolt (D) one full
counterclockwise turn at a time. Repeat this procedure on all isolators, one at a time.
7. Continue adjusting each isolator until a minimum of 1/4 in. (6.35 mm) clearance is achieved
between the lower housing and upper housing. See Figure 14.
8. To complete the installation, fine adjust the isolators to level the equipment.

20 YVAM Air-Cooled Centrifugal Liquid Chiller

Figure 14: Spring isolator detail

Callout Description Callout Description

A Equipment base B Isolator base
C Base slotted holes D Spring adjusting bolt
E Non-skid elastomeric pad F Lower housing
G Upper housing H Positioning pin

Figure 15: One in. deflection spring isolators dimensions, in. (mm)

Table 4: Spring isolator dimension data, in.

Mount type W D L B C T H
Type A 3 5/8 7 3/4 6 1/2 4 3/4 1/2 5 5/8
Type B 3 5/8 10 1/2 9 1/4 7 3/4 9/16 6

YVAM Air-Cooled Centrifugal Liquid Chiller 21

The following table shows the rated capacity for units with all load points less than 1,785 lb (810 kg).
Table 5: Type A model detail
Type A model P/N Color code Rated capacity, lb Rated capacity, kg YORK P/N
029-25334-002 (433668) Black Up to 434 Up to 197 029-25334-002
029-25334-003 (433669) Dark green 435–765 198–347 029-25334-003
029-25334-004 (433670) Gray 766–1,020 348–463 029-25334-004
029-25334-005 (433871) White 1,021–1,156 464–524 029-25334-005
029-25334-006 (433872) Gray/red 1,157–1,785 525–810 029-25334-006

The following table shows the rated capacity for units with any load point above 1,518 lb (689 kg).
Table 6: Type B model detail
Type B model P/N Color code Rated capacity, lb Rated capacity, kg YORK P/N
029-25334-008 (433997) Dark purple Up to 1,148 Up to 521 029-25334-008
029-25334-009 (433998) Dark green 1,149–1,530 522–694 029-25334-009
029-25334-010 (433999) Gray 1,531–2,040 695–925 029-25334-010
029-25334-012 (434000) White 2,041–2,312 926–1,049 029-25334-012
029-25334-013 (434001) Gray/red 2,313–3,570 1,050–1,619 029-25334-013

Note:
• All dimensions are in in. (mm) in accordance with ANSI Y14.
• Standard finish for housing is powder coated, for spring is powder coated, and for
hardware is zinc electroplate. For color, see the previous tables.
• Installation requires a bolting or anchoring mount to support the structure with a
minimum two 5/8 in. (15.88 mm) diameter bolt or two 1/2 in. (12.7 mm) diameter
concrete anchors.
• All springs are designed for 50% over-travel.
• See Installation of optional spring isolators for installation instructions.
• Isolators with 1 in. (25.4 mm) deflection must be of the same class for the entire unit.
That is, C2Ps must be used at all locations on a selected unit, or all CPs.
• Pin 63 is for isolators, X = no isolators only active selection, 1 = 1 in. (25.4 mm) deflection
not active, N = neoprene not active.

Installation of optional elastomeric isolators

If ordered, elastomeric type isolator assemblies are supplied with the unit. The isolator load rating
can vary based on the location on the chiller. This is due to the weight distribution of the unit and
the isolators must be located as prescribed in the technical data portion of the chiller submittal
package. See Figure 13 for the locations. See Table 8 for isolator details.
Spring isolators are shipped fully assembled and must be positioned in accordance with the
submittal drawings or as otherwise recommended.
1. Set the isolators on the floor, housekeeping pad, or subbase, and ensure that all isolator
centerlines match the equipment mounting holes.
2. VMC Group recommends that the isolator base (A) be installed on a level surface. Shim or
grout as required, leveling all isolator bases to the same elevation. The maximum difference
that can be tolerated is 1/32 in. (0.794 mm).
3. Bolt or anchor all isolators to supporting structure using base slotted holes (B).
4. Remove the top bolt and washer.

22 YVAM Air-Cooled Centrifugal Liquid Chiller

 5. Place the equipment on top of the isolators, making sure that the mounting holes of the
equipment line up with the isolator threaded hole (C).
6. To complete the installation, reinstall the top bolt and washer and tighten.

Figure 16: Elastomeric isolator details

Callout Description Callout Description

A Isolator base B Base slotted holes
C Isolator threaded hole D Cross section points
E Top washer F Top bolt

Note: Isolators are square or rectangular.

Figure 17: Elastomeric isolator cross reference, Type A isolators

YVAM Air-Cooled Centrifugal Liquid Chiller 23

Table 7: Elastomeric isolator dimension data, in. (mm)
Model P/N L W HF AL AD BT CD DW
Type A 029-25335-001 5.50 3.38 2.88 4.13 0.56 0.25 1/2-13 UNC x 1 2.50
(434002) (139.70) (85.85) (73.15) (104.90) (14.22) (6.35) (M27 x 3) (63.50)
Type B 029-25335-002
(434004) 6.25 4.63 2.75 5.00 0.56 0.38 1/2-13 UNC x 1 3.00
Type B 029-25335-004 (158.75) (117.6) (69.85) (127.00) (14.22) (9.65) (M27 x 3) (76.20)
(434005)

Table 8: Elastomeric isolator detail

Model P/N Isolator color Weight range, lb Weight range, kg YORK P/N
029-25335-001 (434002) Charcoal Up to 825 Up to 374 029-25335-001
029-25335-002 (434004) Brick red 826–1688 375–766 029-25335-002
029-25335-004 (434005) Charcoal 1689–4000 767–1814 029-25335-004

Note:
• All dimensions are in in. (mm) in accordance with ANSI Y14.
• See Installation of optional elastomeric isolators for installation instructions.
• Isolators are mount molded in weather-resistant Durulene™ compound as standard.
Isolators are also available in other materials such as natural rubber, extreme high
temperature silicone, high-damped silicone, nitrile, and EDPM.
• AL = mounting hole center to center spacing.
• HF = free height of mount, before loading. The operating height is calculated by the free
height less the static deflection under load. All dimensions are for reference only.
• Hardware uses zinc electroplate coating.

Make piping connections

After the unit is leveled, place wedges or shims under each corner to solidly support the unit in
this position while connecting and hanging the piping, adjusting the connections, and checking for
correct alignment.
Compressor refrigerant piping and system external piping are factory-installed on all units. On
units where the chiller refrigerant piping must be removed for any reason, the piping must only be
completed under the direct supervision of the Johnson Controls representative.

Evaporator freeze damage

CAUTION

Power must remain on the chiller whenever the ambient temperature drops below 32°F (0°C) with
water in the evaporator to avoid evaporator damage. To avoid damage, ensure that the correct heater
option for 0°F (-17.8°C) minimum ambient or -20°F (-28.9°C) minimum ambient temperature is installed,
based on the lowest expected ambient temperature at the chiller location.

24 YVAM Air-Cooled Centrifugal Liquid Chiller

 CAUTION

If glycol is installed in the evaporator, the glycol concentration must ensure that the freeze point is
below the lowest expected ambient temperature at the chiller location to avoid evaporator damage.

Evaporator water piping

After the unit is leveled and wedged in place for optional spring isolators, the piping connections
can be made for the chilled water. The piping must be arranged with offsets for flexibility, and
adequately supported and braced independently of the chiller to avoid pipe strain on the chiller and
for isolation of vibration transmission.
• Hangers must allow for alignment of pipe. Isolators, in the piping are a preferred option,
and may be required by specifications in order to effectively use the vibration isolation
characteristics of the vibration isolation mounts of the unit. Johnson Controls do not supply
the isolators.
• Piping connecting to chillers on spring isolators must be isolated with correctly aligned and
supported flexible connections. Otherwise, the piping joint becomes the primary resistance
to motion, and pipe or fittings are likely to deform or fatigue during operation.
• Piping and fittings immediately next to the evaporator must be readily removable to enable
cleaning before operation and to facilitate visual inspection of the exchanger nozzles.
• The evaporator liquid heads of the chiller have nozzles that are grooved, but are also suitable
for welding 150 psig DWP flanges or the use of flexible couplings. Factory mounted flanges
are optional. If the nozzles are welded, disconnect the flow switches and water temperature
thermistors. Make sure that the welding ground has good electrical contact located directly
on the piping or waterbox to prevent welding voltage or current damage to the devices.
• The nozzles and water pass arrangements are furnished in accordance with the job
requirements. Refer to the product drawings furnished with the job. Standard units are
designed for 150 psig DWP on the water side. If the job requirements are for greater than 150
psig DWP, check the unit data plate before applying pressure to evaporator water circuit to
determine if the chiller has provisions for the required DWP.
• Foreign objects that could lodge in, or block flow through, the evaporator tubes must be kept
out of the water circuit. All water piping must be cleaned or flushed before being connected
to the chiller pumps, or other equipment.
• The evaporator must not be exposed to flushing velocities or debris released during flushing.
Install a suitably sized bypass and valve arrangement to facilitate flushing of the piping
system. The bypass can be used during maintenance to isolate the heat exchanger without
disrupting flow to other units.
Note: The evaporator must be protected by a strainer, preferably of 40 mesh, fitted
as close as possible to the liquid inlet connection, and provided with a means of local
isolation.
• Thermometer and pressure gauge connections must be provided on the inlet and outlet
connections of each evaporator. Johnson Controls do not supply or furnish the gauges or the
thermometers.
• Drain and air vent connections must be provided at all low and high points in the piping to
facilitate drainage of the system and to vent any air in the pipes.

YVAM Air-Cooled Centrifugal Liquid Chiller 25

 • Use insulation and heater tape or a suitable glycol solution to protect liquid system lines that
are at risk of freezing due to low ambient temperatures. Use the liquid pumps to ensure that
liquid is circulated when the ambient temperature approaches freezing point.
• Install insulation around the evaporator nozzles. Use heater tape of 21 W/m under the
insulation, supplied independently and controlled by an ambient temperature thermostat set
to switch on at approximately 4°F (2.2°C) above the freezing temperature of the chilled liquid.
• Evaporator heater mats are installed under the insulation, and are powered from the chiller's
HTR DIST panel. In sub-freezing conditions, unless the evaporator has been drained or an
appropriate water-to-glycol concentration is maintained, high voltage power to the chiller
must be maintained to ensure the heater mats assist in evaporator freeze protection. If there
is a potential for power loss, drain the evaporator or replace the water in the chilled water
circuit with an appropriate water-to-glycol concentration.

CAUTION

Any debris left in the water piping between the strainer and evaporator could cause serious damage
to the tubes in the evaporator and must be avoided. Be sure the piping is clean before connecting it to
the evaporator. Keep evaporator nozzles and chilled liquid piping capped before installation to ensure
construction debris is not allowed to enter.

CAUTION

The installer or user must also ensure that the quality of the water in circulation is adequate, without
any dissolved gases, which can cause oxidation of steel or copper parts within the evaporator.

Check for piping alignment

When the piping is completed, open a connection in each line as close to the unit as possible by
removing the flange bolts or coupling and check for piping alignment. If any of the bolts are bound
in their holes, or if the connection springs are out of alignment, correct the misalignment.
After the connections are made and the alignment verified, fill the unit with water to check for
leaks.
If spring isolators are installed, perform final adjustments to the leveling bolts until the wedges
and shims can be removed. Check that the unit is in the correct level position, clear of the floor or
foundation, and without any effect from the weight of the piping.

Permanent strainers
Permanent strainers are required in the evaporator water circuit to protect the chiller and the
pumps, the chilled water air handler coils and controls, and similar components. Johnson Controls
do not provide the permanent strainers. The strainer must be installed in the entering water circuit
upstream and near to the chiller.
Water piping must be arranged to prevent water voids from entering the chiller, and be controlled
as required to avoid rapid flow transients.
If the pumping arrangement is set up to discharge into the chiller, the strainer can be located
upstream of the pumps to protect both the chiller and the pumps. For this type of arrangement, the
piping between the pump and chiller must be thoroughly cleaned before chiller start up.

26 YVAM Air-Cooled Centrifugal Liquid Chiller

If the pumps and chillers are remote from each other, the strainers must be located directly
upstream of the chiller as described previously.

Stop valves
Stop valves can be provided in the evaporator water piping adjacent to the chiller to facilitate chiller
maintenance. Johnson Controls do not provide the stop valves. To monitor chiller operation, install
site thermometer wells and pressure taps in the piping as close to the chiller as possible.

Flow switches
Thermal dispersion flow switches are factory mounted in the chilled water nozzle and are factory
wired to the chiller OptiView control panel. This solid state flow sensor has no internal moving parts
and consists of a small internal heating element that uses the cooling effect from flowing fluids to
detect that flow has been established.

Waterbox drain and vent valves

Install drain and vent valves in the connections provided in the evaporator liquid heads. Johnson
Controls do not supply the drain and vent valves. These connections can be piped to drain if
required. They assist in proper fill and vent of the chiller waterside before starting pumps to ensure
no voids exist that could cause damage from a water slug.

Waterbox fill and vent

After the water piping is completed, but before any waterbox insulation is applied, tighten the nuts
on the liquid head flanges. Torque to maintain between 30 ft·lb and 60 ft·lb (41 N•m and 81 N•m).
Gasket shrinkage and handling during transit can cause the nuts to loosen. If water pressure is
applied before tightening is completed, the gaskets might be damaged and have to be replaced.
Fill the chilled water circuit, operate the pumps manually, and carefully check the evaporator water
heads and piping for leaks. Repair leaks as necessary.
Before initial operation of the unit, thoroughly vent the chilled water circuit of all air at the high
points.

Wiring connections
Unit power wiring
The factory mounted VSD does not require wiring to the compressor motor. The motor power
wiring is factory connected to the VSD. Refer to the YVAM Unit Wiring and Field Control Modifications
Manual (Form 160.88-PW2). All wiring to the control panel is completed by the factory. A control
power transformer is factory furnished with the VSD.
Power wiring to the chiller is made through the single point power connection enclosure. Refer to
Field connections diagram for Model YVAM Single Point Power Connection Manual (Form 160.88-PW1) for
details.

CAUTION

Do not cut wires to final length or make final connections to the chiller power input terminals without
supervision from a qualified Johnson Controls representative.

YVAM Air-Cooled Centrifugal Liquid Chiller 27

Unit control wiring
If field wiring connections for commonly encountered control modifications are required, refer to
the YVAM Unit Wiring and Field Control Modifications Manual (Form 160.88-PW2) for details. Johnson
Controls do not supply the field wiring connections.
Note: No deviations in unit wiring from that shown on drawings furnished will be made
without prior approval of the Johnson Controls representative.

Apply insulation
All evaporator parts are factory insulated on the shell surfaces, end sheets, liquid feed line to flow
chamber, compressor suction connection, and evaporator liquid heads and water connection
nozzles.
All facility chilled water piping surfaces must be insulated to prevent condensation from causing
any type of operational heat loss or component damage on all piping upstream and downstream of
the chilled water evaporator waterbox nozzles. Johnson Controls do not insulate the facility chilled
water piping surfaces.

28 YVAM Air-Cooled Centrifugal Liquid Chiller

Unit heater operation verification
The YVAM chiller uses various heaters to protect all of the devices that are susceptible to low
ambient temperature limits. As part of the commissioning process of the chiller, it is important to
verify operation of these heaters to ensure reliability of these various components. Verification
of heater operation must be logged using the current values for each heater in Form 160.88-
CL2 during chiller commissioning. Refer to the Maintenance section in Form 160.88-OM1 for the
instructions to test each device.

WARNING

All appropriate electrical safety measures must be followed when testing these heaters since these
circuits will be energized.

CAUTION

The evaporator water loop must be filled before conducting the following tests to prevent damage to
the heaters for the evaporator related components.

The following is a list of the devices that must be verified:

• Evaporator waterbox heaters WBH1 and WBH2
• Evaporator shell heaters EVH1 and EVH2
• Heat trace for VSD coolant HT1 and HT2
• VGD actuator heater mat
• MBC heater mat
• VSD internal heater
• OptiView Control Panel heater
• OptiView Control Panel cooler
• UPS panel heating

YVAM Air-Cooled Centrifugal Liquid Chiller 29

Reassembly
This section provides technical specifics for the chiller, including weights, dimensions, and torque
requirements.
Note: The YVAM chiller is completely factory assembled and does not require any field
assembly. For occasions where field disassembly or reassembly may need to be conducted
for any reason, the following sections are intended to provide technical details for a qualified
Johnson Controls Service representative to safely complete these tasks.
Table 9: Assembly torque metric for metric tube fittings
Fitting size Port thread size Torque value
lb·ft N•m
M10 M10 x 1 17 23
M12 M12 x1.5 24 33
M14 M14 x 1.5 34 46
M16 M16 x 1.5 46 63
M18 M18 x 1.5 61 83
M22 M22 x 1.5 94 127
M27 M27 x 2 139 189
M30 M30 x 2 167 226
M33 M33 x 2 194 263
M42 M42 x 2 265 359
M48 M48 x 2 302 410
M60 M60 x 2 359 487

Table 10: Assembly torque values for SAE tube fittings

Tube size SAE straight thread size SAE straight thread Face seal tube-side Face seal tube-side
(O-ring part number) torque, lb·ft thread size (O-ring part torque, lb·ft
number)
1/4 in. 7/16-20 25 9/16-18 18
(028-12961-001) (028-12961-011)
3/8 in. 9/16-18 35 11/16-16 30
(028-12961-003) (028-12961-012)
1/2 in. 3/4-16 60 13/16-16 40
(028-12961-004) (028-12961-013)
5/8 in. 7/8-14 100 1-14 60
(028-12961-005) (028-12961-014)
3/4 in. 1 1/16-12 135 1-3/16-12 85
(028-12961-006) (028-12961-015)
1 in. 1 5/16-12 200 1-7/16-12 110
(028-12961-008) (028-12961-016)
1 1/4 in. 1 5/8-12 250 1-11/16-12 140
(028-12961-017) (028-12961-022)
1 1/2 in. 1 7/8-12 305 2-12-UN2A 180
(028-12961-020) (028-12961-019)
= SAE 2 1/4-12 225 — —
sightglass (028-12961-)

30 YVAM Air-Cooled Centrifugal Liquid Chiller

Table 11: Chiller hardware torque values
Location Description P/N SAP Quantity Torque value
lb·ft N•m
Suction line flange at M24 X 3 / 90 mm long 021-33185-090 731065 12 230 312
compressor
Discharge line flange at M20 X 2.5 / 70 mm 021-33184-070 731064 8 150 204
compressor long
Liquid line shutoff valve inlet M16 X 2 / 60 mm long 021-35816-060 5399748 4 55 75
flange
Liquid line shutoff valve outlet 5/8 UNC 3.75 in. long 021-32310-030 555972 4 65 89
flange
Liquid line variable orifice 5/8 UNC Stud 5.5 in. 021-12760-000 729652 8 45 61
butterfly valve flanges long
Compressor mounting feet at M20 X 2.5 / 60 mm 021-33184-060 731063 4 441 598
compressor long
Compressor mounting feet at 3/8 UNC / 1.5 in. long 021-19305-024 564228 8 43 59
unit base

Refrigerant tubing reassembly

Use the following are procedures to reassemble the chiller refrigerant piping.

Assembly of straight thread O-ring port fittings

The male and female ends of SAE and ISO 6149 straight thread O-ring ports have UN/UNF or metric
straight threads. An elastomeric O-ring is fitted to the male end. During assembly, the O-ring is
firmly sandwiched between the angular sealing surface of the female port and the shoulder of the
male end. As a result, sealing is affected and maintained by the O-ring compression, which results
from the clamping force generated by tightening. The straight threads do not offer sealing action,
but they provide the resistance, or holding power, for service pressure.

Figure 18: Adjustable end fitting

Adjustable end assembly

1. Inspect to ensure that both matching parts are free of burrs, nicks, scratches, or any foreign
particles.
2. If the O-ring is not pre-installed, install O-ring on port end of fitting. Take care not to nick the
O-ring.
3. Lubricate the O-ring with a light coat of synthetic poly olestor (POE) oil or POE grease.
4. Back off the locknut as far as possible. Make sure that the back-up washer is not loose and
is pushed up as far as possible. This ensures that the O-ring is completely at the back of the
land so that it remains in the land area when the fitting is turned out at Step 6.

YVAM Air-Cooled Centrifugal Liquid Chiller 31

Figure 19: Back off locknut

5. Screw the fitting into the port until the back-up washer contacts the face of the port. Light
wrenching may be necessary.

Figure 20: Screw fitting into port

6. To align the tube end of fitting to accept incoming tube or hose assembly, unscrew by
required amount, but not more than one full turn. More than one turn makes the locknut
push the O-ring into the machine threads beyond the fitting land area during Step 7.
7. Use two wrenches to hold the fitting in the required position. Tighten the locknut to the
appropriate torque value shown in Table 9or Table 10.
8. Inspect to ensure that O-ring is not pinched and that the back-up washer seats flat on face of
port.

Figure 21: Torque fitting

32 YVAM Air-Cooled Centrifugal Liquid Chiller

Straight non-adjustable end assembly
1. Inspect to ensure that both matching parts are free of burrs, nicks, scratches, or any foreign
particles.
2. If the O-ring is not pre-installed, install the O-ring on the port end of fitting. Use care not to
nick the O-ring.
3. Lubricate the O-ring with a light coat of synthetic POE oil or POE grease.
4. Screw the fitting into the port until the hex flat contacts the port face. Light wrenching may
be necessary.
5. Tighten to give torque for the required size as specified in Table 9 or Table 10 .

Figure 22: SAE or ISO 6149 straight thread O-ring port

Assembly of O-ring face seal fittings

The male end and female nut of face seal fittings have UN/UNF straight threads. An elastomeric O-
ring is fitted into the grooved male end. During assembly, the O-ring is firmly sandwiched between
the sealing surfaces. As a result, sealing is affected and maintained by the O-ring compression,
which results from the clamping force generated by tightening the nut. The straight threads do not
provide sealing action, but they provide the resistance, or holding power, for service pressure.

O-ring face seal assembly

1. Inspect to ensure that both matching parts are free of burrs, nicks, scratches, or any foreign
particles.
2. If the O-ring is not pre-installed, install the O-ring in the grooved face seal end of fitting. Use
care not to nick the O-ring.
3. Lubricate the O-ring with a light coat of synthetic POE oil or POE grease.
4. Thread the nut by hand, and tighten the nut to the appropriate torque value shown in Table 9
or Table 10.

Dimensions, nozzle arrangements, and weights

The following figure shows the detail of the evaporator 150 psi compact two-pass waterboxes.

YVAM Air-Cooled Centrifugal Liquid Chiller 33

Figure 23: Two-pass waterbox detail, mm (in.)

34 YVAM Air-Cooled Centrifugal Liquid Chiller

The following figure shows the detail of the evaporator 150 psi compact three-pass waterboxes.

Figure 24: Three-pass waterbox detail, mm (in.)

Table 12: Two-pass and three-pass compact 150 psi nozzle arrangements
Two-pass nozzle arrangements Three-pass nozzle arrangements
In Out In Out
Lower rear side Upper rear side Lower rear side Upper front side
Rear = opposite VSD end Front = VSD end

Table 13: Two-pass and three-pass compact 150 psi nozzle sizes
Evaporator code Condenser Nozzle size, in. (mm)
Two-pass Three-pass
EB2514 25 mm 4G microchannel 6 (152) 4 (102)

YVAM Air-Cooled Centrifugal Liquid Chiller 35

Table 14: Refrigerant and water weights
Evaporator Condenser Refrigerant weight, lb (kg) Water weight, lb (kg)
EB2514 2 5mm 4G microchannel 700 (318) 1680 (762)

Table 15: Waterbox weights

Approximate evaporator and waterbox weights
Evaporator Compact waterbox weights, lb (kg)
Code Weight, lb (kg) One-pass Two-pass Three-pass
EB2514-C 3685 (1672) 264 (120) 269 (122) n/a
EB2514-2 2999 (1361) 264 (120) n/a 272 (124)

36 YVAM Air-Cooled Centrifugal Liquid Chiller

Unit conversion
The following factors can be used to convert from English to the most common SI Metric values.
Table 16: SI metric conversion
Measurement Multiply English unit By factor To obtain metric unit
Capacity Tons refrigerant effect (ton) 3.516 Kilowatts (kW)
Power Horsepower 0.7457 Kilowatts (kW)
Flow rate Gallons/minute (gpm) 0.0631 Liters/second (L/s)
Feet (ft) 0.3048 Meters (m)
Length
Inches (in.) 25.4 Millimeters (mm)
Weight Pounds (lb) 0.4536 Kilograms (kg)
Velocity Feet/second (ft/s) 0.3048 Meters/second (m/s)
Feet of water (ft) 2.989 Kilopascals (kPa)
Pressure drop
Pounds/square inch (psi) 6.895 Kilopascals (kPa)

Temperature
To convert degrees Fahrenheit (°F) to degrees Celsius (°C), subtract 32° and multiply by 5/9 or
0.5556.
Example: (45.0°F - 32°) x 0.5556 = 7.22°C
To convert a temperature range (for example, a range of 10°F) from Fahrenheit to Celsius, multiply
by 5/9 or 0.5556.
Example: 10.0°F range x 0.5556 = 5.6°C range

YVAM Air-Cooled Centrifugal Liquid Chiller 37

© 2022 Johnson Controls. 5000 Renaissance Drive, New Freedom, York, PA 17349, USA. Subject to change without notice. All
rights reserved.