York YVWA Installation Operation & Maintenance Download Page 5

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JOHNSON CONTROLS

FORM 201.30-ICOM1 (519)

ISSUE DATE: 05/22/2019

TABLE OF CONTENTS

SECTION 1 - GENERAL CHILLER INFORMATION AND SAFETY ...................................................................... 11

Introduction ..................................................................................................................................................... 11

About this Manual ........................................................................................................................................... 11

Warranty ......................................................................................................................................................... 11

Quality Assurance .......................................................................................................................................... 11

Fluorinated Greenhouse Gases .....................................................................................................................12

Responsibility for Safety .................................................................................................................................12

Misuse of Equipment ......................................................................................................................................12

SECTION 2 - PRODUCT DESCRIPTION ...............................................................................................................15

Components ...................................................................................................................................................15

Semi-Hermetic York Screw Compressors .....................................................................................................19

Evaporator .....................................................................................................................................................19

Condenser .....................................................................................................................................................19

Refrigerant Circuit .........................................................................................................................................19

Complete Factory Package ...........................................................................................................................19

Electrical ........................................................................................................................................................19

Building Automation System Capabilities ......................................................................................................19

Microcomputer Control Center .......................................................................................................................20

Options ...........................................................................................................................................................20

SECTION 3 - HANDLING, STORAGE, INSTALLATION AND REASSEMBLY .....................................................23

Shipment and Storage ....................................................................................................................................23

Inspection, Damage, and Shortage ................................................................................................................25

Lifting Weights ................................................................................................................................................26

Moving the Chiller for Forms 1 and 2 .............................................................................................................27

Foundation .....................................................................................................................................................28

Clearance for Service ....................................................................................................................................28

Installing Elastomeric Vibration Isolator Pads ................................................................................................29

Installing Optional Spring Isolators .................................................................................................................30

Form 7 Reassembly .......................................................................................................................................31

Piping Joint Assembly ....................................................................................................................................46

Pipe Thread Joints..........................................................................................................................................46

Gasket Joints ..................................................................................................................................................47

Torque Values .................................................................................................................................................48

Refrigerant Tubing Reassembly .....................................................................................................................48

Brazed Joints .................................................................................................................................................50

Piping Connections ........................................................................................................................................52

Check for Piping Alignment ............................................................................................................................52

Condenser and Chilled Liquid Piping ............................................................................................................52

General Requirements ...................................................................................................................................52

Water Treatment .............................................................................................................................................53

Pipework Arrangement ...................................................................................................................................54

Minimum Water Volume .................................................................................................................................54

Leaving Water Temperature Out of Range .....................................................................................................54

Nozzle Connections .......................................................................................................................................55

Options for Flanges ........................................................................................................................................55

Refrigerant Relief Piping ...............................................................................................................................55

Summary of Contents for YVWA

Page 1: ...E COMPRESSOR 50 HZ AND 60 HZ 125 200 TON 440 700 KW WATER COOLED SCREW LIQUID CHILLERS INSTALLATION OPERATION MAINTENANCE Supersedes 201 30 ICOM1 318 Form 201 30 ICOM1 519 Issue Date May 22 2019 035 2...

Page 2: ...ls this document and any referenced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in...

Page 3: ...atically to the manual or product owner Updated manuals if applicable can be obtained by contacting the nearest Johnson Controls Service office or accessing the John son Controls QuickLIT website at h...

Page 4: ...Shortage A Heat Pump Mod Level YVWA BX FX J 0150 A X B S Nominal Capacity PASS B Evap 2 pass Cond 1 pass C Evap 3 pass Cond 1 pass E Evap 2 pass Cond 2 pass F Evap 3 pass Cond 2 pass H Evap 2 pass Con...

Page 5: ...ECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY 23 Shipment and Storage 23 Inspection Damage and Shortage 25 Lifting Weights 26 Moving the Chiller for Forms 1 and 2 27 Foundation 28 Clearance fo...

Page 6: ...Sequence 84 User Interface 88 Fault Messages 91 Microboard 331 03478 xxx 91 Program Update 93 Data Logging 94 Acceptable Printers 123 Printer Connections 123 Printer Setup 123 Printing a Report 124 BA...

Page 7: ...ATE 05 22 2019 TABLE OF CONTENTS CONT D SECTION 8 TROUBLESHOOTING 147 Abnormal Operation Analysis and Correction 147 Troubleshooting the Compressor and Oil Separation System 147 SECTION 9 DECOMMISSION...

Page 8: ...Control Panel 45 FIGURE 24 VSD Cooling Hoses 45 FIGURE 25 Alternate Piping for VSD 46 FIGURE 26 Torque Pattern 47 FIGURE 27 Adjustable End Fitting 48 FIGURE 28 Back Off Locknut 49 FIGURE 29 Screw Fit...

Page 9: ...IGURE 59 Printer Cable Connection from YVWA Chiller to a Computer 122 FIGURE 60 Printer Cable Connection from YVWA Chiller to a Serial Printer 123 FIGURE 61 Sample Printout 125 FIGURE 62 System Switch...

Page 10: ...ME CE Pin 22 Power Field 63 TABLE 22 Lug Data GB Pin 22 Power Field 63 TABLE 23 Voltage Variations 63 TABLE 24 Complete Pin Number Description 65 TABLE 25 Evaporator Nozzle Dimensions in mm 74 TABLE 2...

Page 11: ...ent procedure Refer to Limited Warranty Form 50 05 NM2 Johnson Controls warrants all equipment and materi als against defects in workmanship and materials for a period of 18 months from the date of sh...

Page 12: ...Personal safety the safety of other personnel and the equipment Correct utilization of the equipment in accordance with the procedures detailed in the manual MISUSE OF EQUIPMENT Suitability For Applic...

Page 13: ...s is recommended when working on the unit The buildup of refrigerant vapor from a leak for example does pose a risk of asphyxiation in confined or enclosed spaces and attention should be given to good...

Page 14: ...JOHNSON CONTROLS 14 FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...e RS 485 opto coupled data link The VSD logic board runs the compressor to the speed requested by the chiller microprocessor to meet the load as shown in Figure 4 on page 18 YORK YVWA chillers are des...

Page 16: ...019 SECTION 2 PRODUCT DESCRIPTION 1 2 3 Figure 2 YVWA CHILLER MAJOR COMPONENTS FRONT VIEW LD17364 1 Control Panel 2 Variable Speed Drive VSD 3 Oil Separator 4 Return Water Box 5 Condenser 6 Condenser...

Page 17: ...FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 2 Figure 3 YVWA CHILLER MAJOR COMPONENTS REAR VIEW LD17365 1 VSD 2 Compressor 3 Evaporator Sight Glass 4 Evaporator Water Nozzle 5 Liquid Level Sensor 6 Liq...

Page 18: ...rd IGBT LD15028 INPUTS Pressure Transducers Temperature Sensors Switches Liquid Flow High Pressure Start Stop Level Customer Supplied Contacts CONTROL PANEL Chiller Control Board Microprocessor User I...

Page 19: ...meters some refrigerant gas to the com pressor to reduce energy consumption COMPLETE FACTORY PACKAGE Each unit is shipped as a complete factory package completely assembled with all interconnecting r...

Page 20: ...ing of each compressor to keep the leaving water tempera ture at the setpoint The control system logic monitors the rate at which the leaving water temperature is approaching the setpoint to ramp up o...

Page 21: ...are mounted in parallel one valve is always operational to assist in valve replace ment during maintenance Electrical Isolation Circuit Breaker UL ASME A unit mounted cir cuit breaker with external lo...

Page 22: ...e provided to ensure adequate head pressure exists SECTION 2 PRODUCT DESCRIPTION The preferred means is cooling tower bypass circuit since this would maintain adequate tube velocity in the condenser b...

Page 23: ...nd maximum reliability all units are tested and inspected before leaving the fac tory The chiller may be ordered and shipped in any of the following forms Form 1 shipped assembled with refrigerant cha...

Page 24: ...sembly and VSD is removed from the shells and skidded separately Form 7 YVWA chillers are shipped in the following as semblies The driveline compressor motor assembly Evaporator Condenser Variable Spe...

Page 25: ...ing the assemblies all containers should be opened and contents checked against the packing list Any material shortage should be reported to John son Controls immediately Refer to Shipping Damage Clai...

Page 26: ...TOR MIN MAX LBS KG LBS KG LBS KG LBS KG FX B B 7694 8329 3490 3778 8254 8995 3744 4080 276 298 125 135 2064 2249 936 1020 C C 8263 8519 3748 3864 8915 9306 4044 4221 331 353 150 160 2229 2326 1011 105...

Page 27: ...onent could result in death or serious injury or possible equipment or property only damage RIGGING The complete standard unit Forms 1 and 2 is shipped without skids When optional skids are used it ma...

Page 28: ...tomer which is capable of supporting the unit operating weight CLEARANCE FOR SERVICE To ensure adequate space for servicing the unit adhere to the following clearances as shown in Figure 8 on page 28...

Page 29: ...on top of the shell end sheets at each end of the unit The unit should be level within 0 25 in 6 mm from one end to the other end and from front to the rear If the chiller is not level within the amou...

Page 30: ...ally and transversely If the leveling bolts are not long enough to level unit due to an uneven or sloping floor or foundation add as many shims as neces sary grouted if necessary under the isolator 4...

Page 31: ...e 20 on page 42 13 Install oil supply piping refer to Figure 21 on page 42 14 Mount the VSD refer to Figure 22 on page 44 15 Connect the VSD cooling lines refer to Figure 24 on page 45 16 Mount and co...

Page 32: ...n page 47 for Torque Specifications 94 Tee UNF F 0 750in UNF F 0 750in UNF 023 25549 000 827494 J 31 Elbow 1 2 O D Tube 90 Deg Male 023 18982 000 146248 OIL SEPARATOR MOUNTING P 18 HCS5 0 375 16 X 2 5...

Page 33: ...shell weight Table 5 EVAPORATOR DIMENSIONS IN MM SHELL CODE PIN 5 LENGTH WIDTH HEIGHT B 96 2438 28 7 729 66 3 1685 C 120 3048 28 7 729 66 3 1685 D 144 3658 28 7 729 66 3 1685 NOTE Refer to Table 3 on...

Page 34: ...lace next to the evaporator 3 Bolt the end sheets of the evaporator and condens er together Note that the outside surfaces of the tube sheets must be flush Leveling the Evaporator and Condenser Use th...

Page 35: ...e total shell weight 2 With an adequate lifting device lift the unit slight ly off the ground to determine adjustments neces sary to keep the unit level Make adjustments as necessary to level the unit...

Page 36: ...JOHNSON CONTROLS 36 FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 SECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY FIGURE 12 ISOLATOR INSTALLATION CONT D LD16471...

Page 37: ...Torque Specifications LD17755 B Figure 15 HEAT EXCHANGER PIPES Installing the Heat Exchanger Piping Use the following instructions after the temporary ship ping brackets supporting the heat exchanger...

Page 38: ...r piping on each side of the chiller using the proper o rings and hardware as shown in Figure 16 on page 38 Refer to Table 4 on page 32 for Torque Specifications LD17756 K L Figure 16 LIQUID INJECTION...

Page 39: ...Do not tighten the bolts until all con nections are made to the compressor Specific shim pads will be bolted to the compressor supports to satisfy the align ment between the compressor and system pipi...

Page 40: ...Figure 19 on page 41 1 Lift the line with muffler and remove the pack ing materials Clean all sealing surfaces 2 Bolt the line to the flange on the oil separator and to compressor discharge using the...

Page 41: ...GE INSTALLATION AND REASSEMBLY FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 3 Refer to Table 4 on page 32 for Torque Specifications LD17759 With Isolation Ball Valve E F P E R R Figure 19 OIL SEPARATOR...

Page 42: ...760 136 145 Compressor Ports J Oil Return from Oil Separator H Oil Return from Eductor J Oil Return from Oil Separator H Oil Return from Eductor Oil Pressure Transducer Oil Pressure Transducer 151 Com...

Page 43: ...he VSD 2 Lift the VSD by means of an overhead lift to the condenser Carefully lower the VSD onto the sup port on the condenser 3 Install the VSD to the plate with the proper hard ware Ensure that enou...

Page 44: ...nel as shown in Figure 23 on page 45 1 Attach the rigging chains from the overhead lift to the two lifting holes one at the top of each end of the Control Panel 2 Lift the Control Panel by means of an...

Page 45: ...AGE INSTALLATION AND REASSEMBLY FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 3 Refer to Table 4 on page 32 for Torque Specifications LD17764 1 4 1 4 1 4 1 4 51 5 Detail A 14 Figure 23 CONTROL PANEL LD1...

Page 46: ...IPE THREAD JOINTS Use the following information to add primer to the pipe thread joints 1 Primer recommended with dissimilar metals 2 Use primer on both male and female components of pipe threads 3 in...

Page 47: ...sembling Gasket Joints Use the following instructions to assemble the gasket joints 1 Clean and lubricate all screw threads unless plated before tightening All threaded fasteners bolts nuts or cap scr...

Page 48: ...ly sand wiched between the angular sealing surface of the fe male port and the shoulder of the male end Sealing is thus affected and maintained by the O ring compression which results from the clampin...

Page 49: ...o the machine threads beyond the fitting land area during step 7 6 Using two wrenches hold fitting in desired posi tion and tighten locknut to the appropriate torque value shown in Table 14 on page 50...

Page 50: ...t coat of synthetic Polyolester POE oil or POE grease 4 Thread the nut by hand and tighten nut to the ap propriate torque value shown in Table 14 on page 50 or Table 15 on page 51 Table 14 ASSEMBLY TO...

Page 51: ...305 2 12 UN2A 028 12961 019 180 2 1 4 12 028 12961 036 225 Table 16 BRAZED JOINTS ACTUAL O D TUBE SIZE IN MALE END FEMALE END OUTSIDE DIAMETER A IN LENGTH K IN INSIDE DIAMETER F IN DEPTH G IN MINIMUM...

Page 52: ...PIPING General Requirements The following piping recommendations are intended to ensure satisfactory operation of the unit Failure to follow these recommendations could cause damage to the unit and ma...

Page 53: ...he year YVWA chillers can be operated with entering condensing wa ter temperature that is less than design conditions Operating the chiller below its minimum ECW could result in low oil differential s...

Page 54: ...sed to meet high leaving liquid tem perature requirements PIPEWORK ARRANGEMENT Piping arrangement vary according to design and facil ity application Figure 33 on page 54 is a suggested piping arrangem...

Page 55: ...ady fitted victaulic adapters are supplied loose The flange dimensions are to ISO 7005 NP10 WELD FLANGE VICTAULIC ADAPTER LD10495 Figure 36 FLANGE ATTACHMENT WELD FLANGE VICTAULIC ADAPTER REFRIGERANT...

Page 56: ...RISTICS PER VALVE COMPONENT DESIGN PRESSURE PSIG BAR AIR FLOW CAPACITY LBS MIN KG SEC OUTLET CONNECTION EVAPORATOR 235 16 2 55 9 0 423 1 NPTF CONDENSER 235 16 2 55 9 0 423 1 NPTF CONDENSER HEAT PUMP O...

Page 57: ...hase power supply must enter via the same cable entry All sources of supply to the unit must be taken via a common point of isolation not supplied by Johnson Controls POWER SUPPLY WIRING Units require...

Page 58: ...10 and 41 of 1TB to switch between chiller and heat pump operation remotely Contacts Open Chiller Mode Contacts Closed Heat Pump Mode Table 20 SYSTEM INPUT CONNECTIONS INPUT 1TB TERMINALS Chilled Liqu...

Page 59: ...e software under the OP TIONS key for the type of input signal to be used The minimum current limit setpoint is achieved at ei ther 10 VDC or 20 mA Sending the minimum signal 0 or 2 VDC 0 or 4 mA base...

Page 60: ...cates a motor winding short 5 Connect the following system inputs to their re spective terminals of 1TB Terminal Box a Chilled Liquid Flow Switch Terminals 2 and 13 b Condenser Liquid Flow Switch Term...

Page 61: ...to the terms of the above contract we are requesting the presence of your JCI Authorized Representative at the job site on ______ ______ ______ to start the system and instruct operating personnel Hav...

Page 62: ...TALLATION AND REASSEMBLY Figure 38 POWER CONNECTIONS VSD CONTROL PANEL STANDARD CONTROL TRANSFORMER UNIT CONTROLS PE LINE REACTOR CIRCUIT BREAKER OPTION AVAILABLE FIELD PROVIDED UNIT POWER SUPPLY SEE...

Page 63: ...il 1 2 1 0AWG 500KCMIL 1 2 2 AWG 600kcmil L 380 60 1 3 2 AWG 600kcmil 1 2 4 0AWG 500KCMIL 2 2 2 AWG 600kcmil 380 50 1 3 2 AWG 600kcmil 1 2 4 0AWG 500KCMIL 2 2 2 AWG 600kcmil 400 50 1 3 2 AWG 600kcmil...

Page 64: ...JOHNSON CONTROLS 64 FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 65: ...LINE FX WTS45 CTS45 GX WTS51 CTS51 11 STARTER J Starter Size L 12 PASS ARRANGEMENT A Evap 1pass Cond 1pass B Evap 2pass Cond 1pass C Evap 3pass Cond 1pass D Evap 1pass Cond 2pass E Evap 2pass Cond 2pa...

Page 66: ...PANEL AND VSD ENCLOSURE TYPE S Ctrl VSD N1 IP20 AT N1 IP20 E Ctrl VSD IP33 Q Special Quote 26 UNIT NEMA TYPE S UNIT NEMA1 OR IP20 Q Special Quote 27 VSD COOLING SOURCE X No selection S Condenser liqui...

Page 67: ...N A B Condenser isolation valves Q Special Quote 39 HOT GAS BYPASS X No Selection Q Special Quote 40 LIQUID INJECTION KIT X No Selection L Liquid injection kit Q Special Quote 41 REFRIGERANT A R134a 4...

Page 68: ...EAVING WATER TEMP LCHWT Temperature QQ Special Quote 54 56 EVAPORATOR TUBE TYPE 321 0 75 x 0 025 Wall 322 0 75 x 0 028 Wall 323 0 75 x 0 035 Wall QQQ Special Quote 57 EVAPORATOR WATER BOX TYPE C Compa...

Page 69: ...x 0 035 Copper Nickel 260 0 75 x 0 025 Copper 261 0 75 x 0 028 Copper 262 0 75 x 0 035 Copper 162 0 75 x 0 028 Titanium QQQ Special Quote 70 CONDENSER WATER BOX TYPE C Compact M Marine 71 CONDENSER C...

Page 70: ...n E Elastomeric pad I 1 inch deflection spring isol F Feet without elastomeric pad Q Special Quote 80 PAINT OPTIONS S Caribbean Blue Q Special Quote 81 STRUCTURAL MODIFICATION X No Selection Q Special...

Page 71: ...uxi base vacuum test doc A Wuxi all document Q Special Quote 87 FACTORY TESTS X No Factory Tests F Function witness incl ctrl P Perf test without witness W Customer perf witness test T Tube side hydro...

Page 72: ...01 30 ICOM1 519 ISSUE DATE 05 22 2019 SECTION 4 TECHNICAL DATA SINGLE COMPRESSOR UNIT DIMENSIONS Figure 39 SINGLE COMPRESSOR UNIT DIMENSIONS LD16476a LD16476b LD16476d N M F G P B D E C I H A J K TOP...

Page 73: ...PASS 2 PASS 3 PASS 1 PASS 2 PASS 3 PASS H 1 1 17 32 344 1 1 17 32 344 1 1 17 32 344 14 1 2 369 14 1 2 369 14 1 2 369 I 1 2 3 8 369 1 2 3 8 369 16 3 32 409 16 3 32 409 DIM REAR HEAD 2 PASS REAR HEAD 2...

Page 74: ...T WATER BOXES 2 PASS NOZZLE ARRANGEMENTS NUMBER OF PASSES EVAPORATOR PIN 5 6 IN OUT 3 G N P F Figure 41 EVAPORATORS COMPACT WATER BOXES 3 PASS Table 25 EVAPORATOR NOZZLE DIMENSIONS IN MM EVAPORATOR SH...

Page 75: ...ODE PIN 7 NOZZLE PIPE SIZE CONDENSER NOZZLE DIMENSIONS ft in mm NO OF PASSES 1 PASS 2 PASS 3 PASS 1 2 3 CC GG BB DD GG BB DD GG B C D 8 5 5 127 1 2 13 32 366 1 1 15 32 366 8 11 16 366 1 8 1 8 366 1 1...

Page 76: ...20 14 890 56 150 9 590 37 CD 330 21 910 57 220 14 660 42 CD 480 30 1950 123 240 15 910 57 DB 240 15 750 47 160 10 490 31 DB 390 25 1560 98 190 12 780 49 130 8 520 33 DC 280 18 870 55 190 12 570 36 DC...

Page 77: ...refrigerant in the evap orator and condenser Evacuation and charging should always be done according to SECTION 7 MAINTENANCE Service and Oil Line Valves If valves are of the back seat type open them...

Page 78: ...motor leads to terminals 11 If the VSD provides an optional circuit break er at the incoming power connection to the VSD make sure the settings are prop erly set per the information on the next page 1...

Page 79: ...ock 1TB in the control panel 18 Check whenever the pump contacts are used the coil of the pump starter should be suppressed with an RC suppressor P N 031 00808 000 B START UP Panel Check Only qualifie...

Page 80: ...mps will get start command when chiller initiates run Continued on following page 8 Press the STATUS key If the following UNIT WARNING message appears immediately contact Johnson Controls Product Tech...

Page 81: ...NIT switch to the OFF position immediately if any unusual noises or other adverse conditions develop 9 When the compressor starts press the relevant System Pressures key to verify that oil differen ti...

Page 82: ...JOHNSON CONTROLS 82 FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 83: ...eft and right side of the keypad Displays Program setpoints History data and To initiate system commands Use the following keys in the center to enter data in the various program modes 0 9 is a NUMERI...

Page 84: ...ed for displaying unit system parameters and operator messages The display has an LED backlight for night viewing and is viewable in direct sunlight BASIC OPERATING SEQUENCE Start Sequence and Loading...

Page 85: ...e compressor is shut off Chilled and Condenser Liquid Flow Switches The chilled and condenser liquid flow switches must have electrical continuity to Terminal 2 to permit the chiller to run Remote Run...

Page 86: ...full scale signal input 100 equates to a posi tive offset to the local setpoint equal to the pro grammable maximum REMOTE TEMP RESET The offset is linear and may be adjusted between 0 and 100 points...

Page 87: ...the LCLT setpoint via the BAS COMMS The control panel will only accept a remote setpoint from the BAS if the control panel is in REMOTE CONTROL MODE under the OPTIONS key If the control panel is in L...

Page 88: ...VICE TIME as programma ble under the UNIT SETUP MODE at the factory for the default value of 15 minutes The low limit is five minutes and the high limit is 60 minutes The remote input will be ignored...

Page 89: ...STATUS CHILLED LIQUID FLOW SWITCH SHUTDOWN Press the STATUS key to display the current whole or individual system s operational status which includes Running status Cooling demand General or fault st...

Page 90: ...LLED LIQ LEAVE TEMP LIMITING Applicable in HEAT PUMP mode only The flow switch is open which is preventing the unit from running There is a one second delay until the unit shuts down UNIT STATUS CONDE...

Page 91: ...in flash memory instead of EPROM Program updates are accomplished by load ing the new program from an SD card inserted into the SD card reader writer This same SD card reader writer also allows the us...

Page 92: ...supply test points should be measured to deter mine the status of the microboard Power Supply Test Points TP1 GND Measure TP2 TP3 TP4 and TP5 in refer ence to this Test Point TP2 3 3V 3 2 to 3 4VDC pr...

Page 93: ...software To update the Program 1 Copy the new software in to the root directory of the SD card 2 Rename this new program file SOFTWARE BIN 3 Turn the Unit Switch OFF 4 Insert the SD card in to the SD...

Page 94: ...lity The controller operating system does not support SD cards larger than 2GB When the SD card becomes full the oldest date file is automatically deleted and a new day log file is written in its plac...

Page 95: ...ge appears which indicates an invalid letter or number exists in a location in the serial number string the chiller may have lost important factory programmed information Contact Johnson Controls Prod...

Page 96: ...are captured by the VSD logic board This data is stored in the board battery backed RAM for safekeep ing and is transferred to the panel via the communica tions link First Fault Code The first fault c...

Page 97: ...n The VSD cooling fan and water pump will remain energized until the internal temperature drops below 148 F 64 4 C at which time the unit will be allowed to restart The VSD cooling fan and water pump...

Page 98: ...h a ramped shutdown if the control board loses communications with the VSD logic board while the chiller is operating On power up the microprocessor board will attempt to initialize communications wit...

Page 99: ...fault using the keypad YYYYYYY GATE DRIVER FAULT Hardware Initiated Fault The VSD IGBT gate driver control board monitors the saturation voltage drop across each IGBT while it commands it gated on If...

Page 100: ...mps 626 amps min 674 amps max and 380V 50 60 Hz and 400 415V 50Hz VSD Frames C and D and 460V 60 Hz Frame D shutdown is 863 3 amps 831 amps min 896 amps max This auto restart safety will lock out on t...

Page 101: ...z 30 4 Hz sec 9 5 sec or 100 Hz 60 sec Current freq 5 Hz 10 Hz sec NOTE 9 5 sec 100 Hz 5 Hz 10 Hz sec the time it takes to ramp from 100 Hz to 5 Hz After the timer expires the fault is linearly ramped...

Page 102: ...til the operator clears the fault using the keypad YYYYYYY LOW EVAP PRESS LCHLT This safety fault causes a lockout on the first fault and is bypassed for the first 10 minutes of chiller run time It is...

Page 103: ...r compressor to the compressor s 105 FLA ADJUST overload potentiometer setting If the current exceeds the setting continuously for 20 seconds the compressor will shut down This safety will lockout a s...

Page 104: ...RATE F M shows the rate of change of the chilled liquid temperature UNIT LEAD SYSTEM NUMBER 1 OR 2 UNIT CHILLED LIQUID FLOW SW ON OR OFF CONDENSER LIQUID FLOW SW ON OR OFF UNIT EVAP COND PUMP RUN ON...

Page 105: ...SUBCOOLED LIQ REEF TEMP F This message will be skipped if the subcooled liquid refrigerant temperature sensor is removed EVAPORATOR TEMP F SUPERHEAT F SAT TEMP F SYSTEM DATA KEY LD19539 Figure 50 SYST...

Page 106: ...34 56 C 302 0 F 150 C Discharge Temp 50 K Thermistor 40 3 F 4 61 C 302 0 F 150 C Evaporator Temp 3 K Thermistor 4 87 F 20 3 C 158 34 F 70 2 C Subcooled Liquid Refrig Temp 3 K Thermistor 18 83 F 7 31...

Page 107: ...values as set under the PROGRAM key remotely by a BAS and REMOTE CURRENT LIMIT input Inactive current limits will display XX instead of a numeric value VSD DC BUS VOLTAGE VDC VSD INTERNAL AMBIENT TEM...

Page 108: ...S screen The list below explains the configurations is the FAULT HISTORY number YYY is the ALL FAULT description ZZ is the ALL FAULT number WW is the total number of ALL FAULTS for the current history...

Page 109: ...e 107 Day of Week Day of Month etc OPTIONS on page 118 Display Language Liquid Type etc PROGRAM on page 112 Chilled Liquid Leaving Temp Cutout Motor Current Limit etc Refer to the specific section of...

Page 110: ...no remote setpoint or range these values will display as SETPOINTS DEF LO HI MAX REMOTE HEATING TEMP RESET F Minimum maximum and default values allowed are listed in Table 37 on page 111 Press the SE...

Page 111: ...CR defines how far above and below the LCHLT setpoint the chiller will stop compressors or the entire unit and restart them to maintain LCHLT within the range The programmable CR defines the setpoint...

Page 112: ...PC KP XX X SEC PROGRAM DEF 50 LO 10 HI 1000 HPC TI XX X SEC PROGRAM DEF 0 LO 0 HI 60 HPC TD XX X SEC Press the PROGRAM key to modify the following nu meric operating parameters which are displayed whe...

Page 113: ...entered by pressing the PROGRAM key entering the password 4245 and pressing ENTER key PROGRAM HPC DIRECTION XXXXXXXXXXXXXXXXXXXXXXXXXXXX PROGRAM DEF 0 0 LO 0 0 HI 100 0 HPC MINIMUM POSITION XX X Tabl...

Page 114: ...I 10 0 VI DEADBAND F SETUP MODE DEF 24 0 LO 2 0 HI 40 0 VI DIFF TEMP OFFSET F SETUP MODE DEF 50 0 LO 50 0 HI 95 0 MIN VSD FREQ SETP HZ SETUP MODE DEF 50 0 LO 50 0 HI 95 0 MIN START FREQ SETP HZ SETUP...

Page 115: ...30 LO 5 HI 50 COND VLV STARTUP POS SETUP MODE DEF 5 LO 0 HI 10 COND VLV CTRL START DLY MIN SETUP MODE REFRIG INJ ENABLED SETUP MODE VI STEP VALVE ENABLED SETUP MODE DEF 195 0 LO 195 0 HI 333 0 HIGH D...

Page 116: ...50 Hz System Low Differential Oil Pressure Setpoint 20 PSID 1 37 Bard 60 PSID 4 14 Bard 30 PSID 2 07 Bard System Low Economizer Superheat 0 0 F 0 0 C 20 0 F 11 1 C 5 0 F 2 8 C Min Oil Pump Diff Setpoi...

Page 117: ...rol Valve Startup Position 5 50 30 Condenser Level Control Startup Delay 0 Minutes 10 Minutes 5 Minutes Condenser Level Ramp Up Time 0 Minutes 10 Minutes 5 Minutes Refrigerant Injection DISABLED ENABL...

Page 118: ...lish French Italian German Spanish Portuguese Polish or Hungarian default is English OPTIONS LIQUID TYPE WATER OR GLYCOL COOLING OPTIONS LOCAL REMOTE CONTROL MODE LOCAL OR REMOTE CONTROL OPTIONS DISPL...

Page 119: ...DC OPTIONS REMOTE CURRENT LIMIT INPUT 2 0 TO 10 VOLTS DC OPTIONS REMOTE CURRENT LIMIT INPUT 0 0 TO 20 0 MILLIAMPS OPTIONS REMOTE CURRENT LIMIT INPUT 4 0 TO 20 0 MILLIAMPS OPTIONS COMPRESSOR SELECT WI...

Page 120: ...the numeric keypad Once the correct values for the START hour and minute are entered press the key The cursor will move to the AM PM selection Change the meridian AM PM value with the or key and ente...

Page 121: ...ay The first display reads SCHEDULE UNIT OPERATING S M T W T F S HOLIDAY NOTED BY Set the holiday times using the same procedure de scribed for the days of the week Press the key after setting the HOL...

Page 122: ...WA CHILLER TO A COMPUTER MANUAL OVERRIDE If this key is pressed during a scheduled shutdown the STATUS key will display MANUAL OVERRIDE which indicates that the DAILY SCHEDULE is being ignored and the...

Page 123: ...guidelines if an unlisted printer is selected 1 All printers must be capable of RS 232 serial communications 2 The primary differences between printers involve the formatting control codes required by...

Page 124: ...the or key until the desired printout is displayed The available printout types are listed in Table 41 on page 124 Table 41 PRINTOUT TYPES PRINTOUT TYPES Operating Data Default All History Buffers Nor...

Page 125: ...ID TEMP 58 2 DEGF ACTIVE REMOTE CONTROL NONE OPERATING HOURS 1 XXXXX 2 XXXXX Figure 61 SAMPLE PRINTOUT START COUNTER 1 XXXXX 2 XXXXX SOFTWARE VERSION C WCS 30 00 UNIT SERIAL NUMBER YYYY XXXZZZ VSD DAT...

Page 126: ...er operating conditions at the time of the fault regardless if a lockout occurred Whenever any fault occurs all system operating data is stored in battery backed memory on the control board at the ins...

Page 127: ...g of the pro grammable values that the user should never change They will be programmed at the factory or by qualified service personnel SYSTEM SWITCHES ON OFF RESET ON OR OFF OR RESET Use the SYSTEM...

Page 128: ...d Data After receiving a valid transmission from the E Link Gateway the unit will transmit operational data or his tory buffer data depending on the HISTORY BUFFER REQUEST Data must be transmitted for...

Page 129: ...PTION 0 ALL OK 1 DATUM TYPE OK TEST FAILED 2 ENGLISH TEXT TOO LONG 3 FLOATING POINT EXCEPTION 4 GET PACKET FAILED 5 GET TYPE FAILED 6 INVALID UNIT CONVERSION 7 INVALID HARDWARE SELECTION 8 REAL TIME F...

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Page 131: ...resistance X Clean or back flush VSD heat exchanger X Replace VSD coolant after cleaning heat exchanger X Perform oil analysis on compressor lube oil X Perform refrigerant analysis X Perform Eddy cur...

Page 132: ...ds change It is normal for the oil level to be at the bottom of the lower sight glass or near the top of the upper sight glass on the oil separator depending on conditions Oil should NOT be added unle...

Page 133: ...the bottom of the lower sight glass Start the chiller and run a load condition between 65 and 80 FLA for a minimum of one hour and then observe the oil level The oil level should become visible in eit...

Page 134: ...as shown in Figure 64 on page 134 3 Open the oil charging valve and pump oil into the system until the oil level in the oil separator is about midway in the upper sight glass and then close the charg...

Page 135: ...n 4 Remove the six cap screws that secure the oil filter cover to the compressor housing as shown in Fig ure 65 on page 135 5 Remove the oil filter housing cover and O ring seal 6 Remove the oil filte...

Page 136: ...o a suit able refrigerant recovery container Filter drier item 2 contains a Schraeder valve for this pur pose 5 Loosen the roto lock nut item 4 at the piping end of the filter drier item 2 6 Remove th...

Page 137: ...4 in male flare Purge air and non condensables from the charg ing hose Add only new refrigerant or refrigerant that has been tested and certified to meet American Refrig eration Institute Standard AR...

Page 138: ...valve piping and evapora tor and condenser tube rolled joints PRESSURE CONNECTIONS All threaded pressure connections used on the YVWA chillers are SAE straight thread O ring face seal fit tings or Pri...

Page 139: ...location of the leaky tubes has been deter mined treat that section in the following manner if the location is not definite investigate all of the tubes 2 Wash off both tube heads and the ends of all...

Page 140: ...present in the system reacts like refrigerant Pulling down the pressure in the system where its saturation temperature is below room temperature heat will flow from the room through the walls of the s...

Page 141: ...evacuation The small amount of moisture left will be carried out through the vacuum pump and the temperature or pres sure shown by the indicator should drop uniformly un til it reaches a temperature o...

Page 142: ...s located in an unheated area susceptible to freezing drain the wa ter from the condenser and evaporator to prevent the tubes from freezing Condenser Tubes Proper condenser water treatment can elimina...

Page 143: ...t Contact a Johnson Controls Field Service Office for a recommended method that is used locally Chemical Cleaning Procedure Acid Cleaning of Tubes If the tubes are fouled with a hard scale deposit the...

Page 144: ...eration after a new filter element is installed contact a John son Controls Field Service Office ELECTRICAL CONTROLS For information covering the control center operation refer to SECTION 6 OPERATION...

Page 145: ...OPERATION 8 Add new coolant if necessary 9 Reinstall the cap before stopping the coolant pump to avoid overflowing the fill tube when the coolant pump is turned off The coolant system holds about 2 ga...

Page 146: ...JOHNSON CONTROLS 146 FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 147: ...Troubleshooting the compressor is limited to iden tifying the probable cause If a mechanical problem is suspected contact the Johnson Controls Field Service Office DO NOT DISASSEMBLE THE COMPRESSOR T...

Page 148: ...ature sensor is defective Check sensor Condenser tubes are dirty or scaled Check and clean tubes Check water conditioning Condenser water flow low Check site pumps valves and strainers Increase quanti...

Page 149: ...ompressor heater Replace compressor heater System Fault Oil Pressure Gradually Decreases Oil filter is dirty Change oil filter Extreme bearing wear Call Johnson Controls Field Service Office to evalua...

Page 150: ...363 NOTE Leaving Entering Condenser Liquid Temperature Sensor Subcooled Liquid Refrigerant Temperature Sensor Eductor Temperature Sensor Economizer Outlet Temperature Sensor Table 48 3K TEMPERATURE SE...

Page 151: ...7 45 0 95 225 2 75 50 2 1 50 1 23 230 3 85 50 1 230 2 8 55 2 26 55 1 3 235 3 92 55 1 05 235 2 85 60 2 42 60 1 37 240 3 99 60 1 1 240 2 9 65 2 58 65 1 45 245 4 06 65 1 15 245 2 95 70 2 74 70 1 52 250 4...

Page 152: ...JOHNSON CONTROLS 152 FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 153: ...egulations Any spilled oil should be mopped up and similarly disposed of 5 Isolate the unit heat exchanger from the external water systems and drain the heat exchanger sec tion of the system If no iso...

Page 154: ...o Celsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 50 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant...

Page 155: ...JOHNSON CONTROLS 155 NOTES...

Page 156: ...ennsylvania USA 17349 Subject to change without notice Printed in USA Copyright by Johnson Controls 2019 ALL RIGHTS RESERVED Form 201 30 ICOM1 519 Issue Date May 22 2019 Supersedes 201 30 ICOM1 318 1...

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