Johnson Controls YORK YCAL0043E Series, Installation Operation & Maintenance

Page: 58 / 188

JOHNSON CONTROLS
58
FORM 150.62-NM9 (709)
INTRODUCTION
jOB NAME: ______________________________
SALES ORDER #: _________________________
LOCATION: ______________________________
SOLD BY: ________________________________
INSTALLING
CONTRACTOR: ___________________________
START-UP
TECHNICIAN/
COMPANY: _______________________________
START-UP DATE : _________________________
CHILLER MODEL #: _______________________
SERIAL #: _______________________________
PRE-STARTUP
CHECKING THE SYSTEM
PRIOR TO INITIAL START (NO POWER)
Unit Checks

1. Inspect the unit for shipping or installation dam-
age.

2. Assure that all piping has been completed.

3. Visually check for refrigerant piping leaks.

4. Open suction line ball valve, discharge line ball
valve, and liquid line valve for each system.

5. The compressor oil level should be maintained so
that an oil level is visible in the sight glass. The oil
level can only be tested when the compressor is
running in stabilized conditions, guaranteeing that
there is no liquid refrigerant in the lower shell of the
compressor. In this case, the oil should be between
1/4 and 3/4 in the sight glass. At shutdown, the oil
level can fall to the bottom limit of the oil sight
glass.

6. Assure water pumps are on. Check and adjust water
pump flow rate and pressure drop across the cooler
(see LIMITATIONS). Verify flow switch opera
-
tion.
Excessive flow may cause catastrophic
damage to the evaporator.

7. Check the control panel to ensure it is free of
foreign material (wires, metal chips, etc.).
PRE-STARTUP AND STARTUP CHECKLIST

8. Visually inspect wiring (power and control). Wiring
MUST meet N.E.C. and local codes. See Figures
2- 5, pages 14 - 17.

9. Check tightness of power wiring inside the power
panel on both sides of the motor contactors and
overloads.

10. Check for proper size fuses in main and control
circuits, and verify overload setting corresponds
with RLA and FLA values in electrical tables.

11. Assure 120VAC Control Power to CTB2 has 15
amp minimum capacity. See Table 1, page 20.

12. Be certain all water temp sensors are inserted
completely in their respective wells and are
coated with heat conductive compound.

13. Assure that evaporator TxV bulbs are strapped
onto the suction lines at 4 or 8 o’clock positions
or suction temp. sensors if EEVs are installed.

14. Assure oil level in the compressor or oil line sight
glasses is between 1/4 - 3/4.

15. Check the tightness of the heaters on each com-
pressor. Tighten the heater if the heater fingers
do not touch the compressor housing. Inspect the
heater around the entire perimeter of each com-
pressor. The heater should be torqued to 26 in./
lbs., ± 4 in./lbs.
COMPRESSOR HEATERS
(POWER ON – 24 HOURS PRIOR TO START)

1. Apply 120VAC and verify its value between ter-
minals 5 and 2 of CTB2. The voltage should be
/- 10%.
Power must be applied 24 hours prior to
start-up.
Each heater should draw approximately 0.5-1A.
PANEL CHECKS
(POWER ON – BOTH UNIT SWITCH OFF)

1. Apply 3-phase power and verify its value. Volt-
age imbalance should be no more than 2% of the
average voltage.

2. Apply 120VAC and verify its value on the terminal
block in the Power Panel. Make the measurement
between terminals 5 and 2 of CTB2. The voltage
should be /- 10%.

3. Program/verify the Cooling Setpoints, Program
Setpoints, and unit Options. Record the values
below (see sections on Setpoints and Unit Keys
for programming instruction).

4. Put the unit into Service Mode (as described
under the Control Service and Troubleshooting
section) and cycle each condenser fan to ensure
proper rotation.