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JOHNSON CONTROLS

FORM 160.81-NOM1

ISSUE DATE: 10/3/2020

SECTION 6 – TROUBLESHOOTING

TROUBLESHOOTING GUIDE

Successful problem solving requires an organized ap-

proach to define the problem, identify the cause, and

make the proper correction. Sometimes it is possible

that two relatively obvious problems combine to pro-

vide a set of symptoms that can mislead the trouble-

shooter. Be aware of this possibility and avoid solving

the “wrong problem”.

ABNORMAL OPERATION, ANALYSIS AND

CORRECTION

Four logical steps are required to analyze an operational

problem effectively and make the necessary corrections:

Define the problem and its limits.

2. Identify all possible causes.

3. Test each cause until the source of the problem is

found.

4. Make the necessary corrections.

When an operating problem develops, compare all op-

erating information on the OPERATING DISPLAY

with normal operating conditions. If an Operating Log

has been maintained, the log can help determine what

constitutes normal operation for the compressor unit in

that particular system.

TROUBLESHOOTING THE ROTARY SCREW

COMPRESSOR AND OIL SEPARATION

SYSTEM

Troubleshooting the compressor is limited to identify-

ing the probable cause. If a mechanical problem is sus-

pected contact the Johnson Controls Service Depart-

ment. DO NOT DISASSEMBLE COMPRESSOR.

TABLE 18 -

TROUBLESHOOTING

TROUBLESHOOTING THE ROTARY SCREW COMPRESSOR

SYMPTOM

PROBABLE CAUSES AND CORRECTIONS

Excessive Noise And Vibration

Bearing damage or excessive wear.

Refrigerant flood back. Correct system problem.

Chiller installation.

Room acoustics.

Piping supports.

Slide Valve Will Not Move

Slide valve stuck.

Capacity control block solenoid not energized.

Capacity control block services valves not opened.

Plugged orifi

ces on capacity control block.

TROUBLESHOOTING THE OIL SEPARATION SYSTEM

SYMPTOM

PROBABLE CAUSES AND CORRECTIONS

Gradual Oil Loss With An Oil Level In The

Separator Section Sight Glass

Maintaining too high an oil level, lower level.

Refrigerant carryover or liquid injection overfeeding, correct operation.

Loss of suction superheat

OPERATING ANALYSIS CHART

RESULTS

POSSIBLE CAUSE

REMEDY

1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE

Temperature difference between liquid

refrigerant temperature and water off

condenser higher than normal.

Air in condenser.

Purge unit.

High discharge pressure.

Condenser tubes dirty or

scaled.

Clean condenser tubes. Check water

conditioning.

High condenser water

temperature.

Reduce condenser water inlet temperature.

(Check cooling tower and water circulation.)

Temperature difference between condenser

water on and water off higher than normal,

with normal evaporator pressure.

Insufficient condensing water

flow.

Increase the quantity of water through the

condenser to proper value.

Содержание YR TB TB T0

Страница 1: ...VD T1 YR TB TB T0 THROUGH YR XD XD T3 INCLUDING FIELD RE ASSEMBLY FOR FORM 2 3 7 AND 8 SHIPMENT STYLE A AND B ROTARY SCREW LIQUID CHILLERS INSTALLATION OPERATION MAINTENANCE Supersedes 160 81 NOM1 212...

Страница 2: ...s This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in...

Страница 3: ...Electro Mechanical Starter 160 81 PW1 Wiring Diagram Unit With Mod B Solid State Starter 160 81 PW2 Wiring Diagram Field Control 160 81 PW3 Wiring Diagram Field Control Modifications 160 81 PW5 AFFECT...

Страница 4: ...B TB T0 46 A EVAPORATOR CODE TB TC TD VB VC VD WB WC WD XB XC XD STYLE POWER SUPPLY for 60 Hz 5 for 50 Hz CONDENSER CODE TB TC TD VB VC VD WB WC WD XB XC XD COMPRESSOR CODE T0 T1 T2 T3 MOTOR VOLTAGE V...

Страница 5: ...ssembly 21 Vacuum Dehydration 29 Operation 29 Piping Connections 31 Check for Piping Alignment 31 Evaporator and Condenser Water Piping 31 Refrigerant Relief Piping 35 Unit Piping 36 Control Wiring 36...

Страница 6: ...ant Leak Checking 62 Pressure Connections 62 Condensers and Evaporators 63 Cleaning Evaporator and Condenser Tubes 63 Condenser Water Side Tube Cleaning Procedure 63 Evaporator Tubes 64 MegohmtheMotor...

Страница 7: ...ponent Layout Drawing Design Level A 46 FIGURE 19 YR Screw Chiller System Schematic Design Level A 47 FIGURE 20 Oil Filter System 49 FIGURE 21 Oil Solenoid Valve Assembly 51 FIGURE 22 Variable Orifice...

Страница 8: ...THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS 8 FORM 160 81 NOM1 ISSUE DATE 10 3 2020...

Страница 9: ...truc tion INSTALLATION RESTRICTIONS No valves or connections should be opened under any circumstances because such action will result in loss of the factory refrigerant or nitrogen charge Do not disma...

Страница 10: ...ventilated to allow ad equate heat removal Check ANSI state local or other codes FOUNDATION A level floor mounting pad or foundation must be pro vided by others capable of supporting the operating we...

Страница 11: ...e unit to its mounting position Rig the unit to its final location on the floor or mounting pad by lifting the unit or shell assembly with an overhead lift and lower the unit to its mounting position...

Страница 12: ...0 13974 6338 560 254 3494 1584 TBTA 12954 5875 13765 6243 560 254 3441 1560 TBTB 11740 5325 12990 5892 530 240 3247 1472 TBTC 11790 5347 13080 5932 530 240 3270 1483 TBTD 11890 5393 13230 6001 530 240...

Страница 13: ...472 XBXC 18970 8604 22220 10078 1150 522 5555 2519 XBXD 19300 8754 22750 10319 1150 522 5687 2579 XCXB 18835 8543 22015 9985 1025 465 5503 2496 XCXC 19095 8661 22435 10176 1025 465 5608 2543 XCXD 1942...

Страница 14: ...D STATE STARTER OPTIONAL OPTIVIEW CONTROL PANEL L F C D E G B SECTION A A CONDENSER EVAPORATOR RELIEF VALVE NOTE ONLY SUPPLIED ON UNITS WITH OPTIONAL ISOLATION VALVES ISOLATION VALVE NOTE OPTIONAL H R...

Страница 15: ...2 2 3 4 70 mm 679 mm 2 3 4 70 mm 2 3 4 2 2 3 4 70 mm 679 mm M 1 3 3 3 381 mm 991 mm 1 3 381 mm 1 3 3 3 381 mm 991 mm WATERBOX DIMENSIONS FT IN DIM EVAPORATORS T AND V CONDENSER T AND V 1 PASS 2 PASS 3...

Страница 16: ...one end to the other end and from front to the rear If the chiller is not level within the amount specified lift it and place shims between the isolation pad and the tube sheets CHECKINGTHEISOLATORPA...

Страница 17: ...HEET FLOOR LAYOUT SUPPORT FOOT DIMENSIONS ARE TYPICAL ALL 4 CORNERS 25 76 2 22 mm DIA HOLE 140 114 114 140 13 mm STEEL PLATE 25 mm DEFLECTED HEIGHT 13 UNIT WEIGHT UP TO 7 423 KGS ISOLATOR TO BE CENTER...

Страница 18: ...is level Check that the unit is level both longitudinally and transversely see Leveling the Unit If the leveling bolts are not long enough to level unit due to an uneven or sloping floor or foundatio...

Страница 19: ...9 SECTION 1 INSTALLATION FORM 160 81 NOM1 ISSUE DATE 10 3 2020 1 Figure 6 SPRING ISOLATORS OPTIONAL METRIC ALL DIMENSIONS ARE IN MILLIMETERS LD07379 DIM C SEE FIGURE 2 Pages 12 and 13 DIM A SEE FIGURE...

Страница 20: ...is shipped on the heat exchanger All openings on the compressor oil separa tor and the shell are closed and charged with dry nitro gen 5 psig 34 kPa Miscellaneous chiller components control center oil...

Страница 21: ...ust be reported to the transportation company imme diately for their inspection When received at the job site all containers should be opened and contents checked against the packing list Any material...

Страница 22: ...pendicular to the condenser shell Place gasket on the top side of the shut off valve 9 Remove all cover closures from the oil separator flanges and wipe all connection surfaces clean Lower the oil sep...

Страница 23: ...N CONTROLS 23 SECTION 1 INSTALLATION FORM 160 81 NOM1 ISSUE DATE 10 3 2020 1 LD09971 Figure 9 FORM 3 FIELD ASSEMBLY EXPLODED VIEW 1 10 5 13 14 23 5 24 27 24 13 25 28 25 6 5 16 15 3 4 26 2 9 2 5 6 2 7...

Страница 24: ...of both end sheets After shell is leveled wedge and shim each corner of the shell to solidly sup port it while assembling the other parts 6 Lift compressor motor assembly and remove packing materials...

Страница 25: ...the oil separator with the proper hardware 14 Tighten all screws and nuts on the discharge flange and the support bracket 15 Assemble the Control Center to the unit Refer to Figure 11 on page 26 Also...

Страница 26: ...26 FORM 160 81 NOM1 ISSUE DATE 10 3 2020 SECTION 1 INSTALLATION LD09972 Figure 11 FORM 7 FIELD ASSEMBLY EXPLODED VIEW 1 10 6 5 5 4 11 13 14 12 15 16 17 18 19 20 22 21 23 5 26 24 27 24 13 25 25 28 6 5...

Страница 27: ...pressor discharge port with the oil separa tor connection Push the oil separator connection until it seats itself Use cap screws and washers to fasten the oil separator connection to the com pressor C...

Страница 28: ...JOHNSON CONTROLS 28 FORM 160 81 NOM1 ISSUE DATE 10 3 2020 SECTION 1 INSTALLATION LD09973 Figure 12 FORM 8 FIELD ASSEMBLY EXPLODED VIEW 10 6 5 5 23 1 16 15 13 14 4 3 9 10 29 2 2 2 7...

Страница 29: ...obtaining accurate readings as to the extent of de hydration The equipment required to follow this method of de hydration consists of a wet bulb indicator or vacuum gauge a chart showing the relation...

Страница 30: ...1 38 28 94 481 025 025 000 078 25 29 53 192 010 010 000 052 11 29 67 122 000 6 3 06 300 040 4 29 72 099 005 05 000 035 2 29 842 039 002 02 000 015 9 29 882 019 00 1 0 01 000 0 1 17 29 901 010 00 5 000...

Страница 31: ...starter cabinet Therefore an additional temperature controlled throttle valve is needed in the flow path for the starter heat ex changer to regulate cooling above the equipment room dewpoint for appli...

Страница 32: ...d water flow rate of change is 15 minutes If STR goes below 15 minutes chilled water flow rate of change must be modified as follows Rate of Change from 100 to 50 Flow minutes 15 15 STR Chilled water...

Страница 33: ...ndenser water T Where ECW minimum Minimum Entering Condensing Water Tempera ture F LCWT Leaving Chilled Water Temperature F This is a guideline for estimating ECW minimum Ac tual ECW minimum will vary...

Страница 34: ...ld be installed in the connections provided in the evaporator and con denser liquid heads These connections may be piped to drain if desired Checking Piping Circuits and Venting Air After the water pi...

Страница 35: ...g Refrigeration and Air Condition ing Engineers Standard 15 ASHRAE 15 and set to relieve at 235 PSIG 1621 kPa Refrigerant relief vent piping by others from the re lief valves to the outside of the bui...

Страница 36: ...ol wiring must be completed between unit components and control center or solid state starter when used using the wiring harness fur nished Field wiring connections for commonly encountered control mo...

Страница 37: ...ct price can be scheduled Notification to the Johnson Controls Service Office should be by means of Installation Check List and Request Form 160 81 CL1 in triplicate The services of a Johnson Controls...

Страница 38: ...le b Wiring completed from main power supply to solid state starter but not cut to length or connected to starter 3 CONTROL CENTER a Jumper wire NOT installed between termi nal 24 and 25 located on th...

Страница 39: ...ontact ____________________________________ We understand that the services of the Johnson Controls Authorized Representative will be furnished in accordance with the contract for a period of time of...

Страница 40: ...THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS 40 FORM 160 81 NOM1 ISSUE DATE 10 3 2020 SECTION 1 INSTALLATION...

Страница 41: ...is a Johnson Controls warranty requirement CONDENSER Low Temperature Brine Chillers Verify the freeze point of the brine in the evapo rator Use a hand held optical refractometer or a hydrometer Compre...

Страница 42: ...essure should be recorded as a reference point with which to com pare subsequent readings OPERATING LOG SHEET A permanent daily record of system operating condi tions temperatures and pressures record...

Страница 43: ...ration analysis oil analysis and eddy cur rent testing PRE START CHECKLIST All checkpoints in the following list must be complet ed before placing the Rotary Screw Liquid Chiller in operation Only whe...

Страница 44: ...THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS 44 FORM 160 81 NOM1 ISSUE DATE 10 3 2020 SECTION 2 CHILLER COMMISSIONING...

Страница 45: ...the slide valve moves toward the unloaded position less suction gas is pumped through the compressor The control panel automatically positions the slide valve to match the load requirements The slide...

Страница 46: ...ION 3 OPERATION Figure 18 YR SCREW CHILLER COMPONENT LAYOUT DRAWING DESIGN LEVEL A LD07961 DRIVELINE OIL SEPARATOR EVAPORATOR RELIEF VALVE RELIEF VALVE VALVE STOP ANGLE VERTICAL VALVE STOP ANGLE VERTI...

Страница 47: ...JOHNSON CONTROLS 47 SECTION 3 OPERATION FORM 160 81 NOM1 ISSUE DATE 10 3 2020 3 Figure 19 YR SCREW CHILLER SYSTEM SCHEMATIC DESIGN LEVEL A LD07962...

Страница 48: ...JOHNSON CONTROLS 48 FORM 160 81 NOM1 ISSUE DATE 10 3 2020 SECTION 3 OPERATION FIGURE 17 YR SCREW CHILLER SYSTEM SCHEMATIC DESIGN LEVEL A CONT D LD07963...

Страница 49: ...d This positions it to approximately the 75 closed position prior to starting the compressor motor which occurs at the end of the Start Sequence Initiated period To allow for actua tor timing variance...

Страница 50: ...page 58 YORK Oil Types in the Section 5 Maintenance Oil loss is most often the result of operating conditions at loads under 10 of the chillers rated capacity and with condensing water that is too col...

Страница 51: ...is provided for connecting hoses or transfer lines Table 12 VARIABLE ORIFICE PRESSURE DIF FERENTIAL SETPOINTS REFRIGERANT DIFFERENTIAL PRESSURE RANGE R 134A 15 110 PSID Figure 22 VARIABLE ORIFICE LD0...

Страница 52: ...gh Temperature Discharge Low Temperature Oil High Temperature Oil Low Dif ferential Pressure Oil or Condenser Transducer Error Oil Clogged Filter Oil High Pressure Control Panel Power Failure Motor or...

Страница 53: ...During long idle periods the tightness of the sys tem should be checked periodically 2 If freezing temperatures are encountered while the system is idle carefully drain the cooling wa ter from the coo...

Страница 54: ...THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS 54 FORM 160 81 NOM1 ISSUE DATE 10 3 2020 SECTION 3 OPERATION...

Страница 55: ...scharge temperature should not exceed 212 F 100 C 7 Check the compressor motor voltage and current amps at E M starter on the Control Center dis play for Solid State Starter units 8 Check for any sign...

Страница 56: ...THIS PAGE INTENTIONALLY LEFT BLANK JOHNSON CONTROLS 56 FORM 160 81 NOM1 ISSUE DATE 10 3 2020 SECTION 4 OPERATING INSPECTIONS...

Страница 57: ...coolant After cleaning Hxer SSS Applications X Replace or clean starter air filters if applicable X2 Perform oil analysis on compressor lube oil1 X Perform refrigeration analysis1 X Perform vibration...

Страница 58: ...of the oil separator connect the other end to an approved re frigerant recovery cylinder Open the valve and drain the oil from the oil separator CHARGING UNIT WITH OIL The Oil Charge YORK oil types a...

Страница 59: ...per sight glass If the chiller operates in a low discharge superheat refer to SECTION 6 TROUBLESHOOTING in this manual condition for an extended period of time refrigerant can again condense in the oi...

Страница 60: ...onnect the hand oil pump See Figure 23 on page 59 4 As soon as oil charging is complete close the power supply to the starter to energize the oil heater This will keep the concentration of refrig eran...

Страница 61: ...iffer ential pressure reaches 15 PSID across the oil filter A safety shutdown will be initiated if the oil pressure dif ferential pressure reaches 25 PSID The control panel will display the message CL...

Страница 62: ...A charging valve is located in the liquid line below the evaporator The size of the charging connection is inch male flare Purge air and non condensables from the charging hose Only add new refrigeran...

Страница 63: ...s Maintain a minimum condenser water flow rate through the tubes of at least 3 33 ft sec 1 meter sec Through tube water velocity should not exceed 12 ft sec 3 6 meter sec Condenser tubes must be maint...

Страница 64: ...uantity of oil in the evapora tor can also contribute to erratic performance If cleaning of the evaporator tubes is required follow the condenser cleaning procedure When chemical cleaning of the conde...

Страница 65: ...tightening flare nuts or flange bolts However if it is necessary to repair a welded joint the refrigerant charge must be re moved See the Handling Refrigerant for Dismantling and Repairs on page 67 i...

Страница 66: ...ll are heated evenly 5 Close the system charging valve and the stop valve between the vacuum indicator and the vac uum pump See Figure 19 on page 47 Then disconnect the vacuum pump leaving the vacuum...

Страница 67: ...ained by admitting water into the tube during the cleaning process This can be done by mounting the brush on a suitable length of 1 8 pipe with a few small holes at the brush end and connecting the ot...

Страница 68: ...leak should be indicated by the detector If a tube sheet leak is suspected its exact location may be found by using a soap solution A continuous buildup of bubbles around a tube indicates a tube sheet...

Страница 69: ...the user to provide for proper water treatment to provide for a longer and more economical life of the equipment The following recommendation should be followed in determining the condition of the wat...

Страница 70: ...JOHNSON CONTROLS 70 FORM 160 81 NOM1 ISSUE DATE 10 3 2020 SECTION 5 MAINTENANCE LD009186 Figure 27 EVACUATION OF THE CHILLER Thermistor Vacuum Gauge Vacuum Pump Charging Valve...

Страница 71: ...part ment DO NOT DISASSEMBLE COMPRESSOR Table 18 TROUBLESHOOTING TROUBLESHOOTING THE ROTARY SCREW COMPRESSOR SYMPTOM PROBABLE CAUSES AND CORRECTIONS Excessive Noise And Vibration Bearing damage or exc...

Страница 72: ...ctuates then compressor stops on Oil Pressure Cutout Display reading LOW OIL PRESSURE Unusual starting conditions exist i e oil foaming in reservoir and piping due to lowered system pressure Drain the...

Страница 73: ...45 50 50 54 55 58 60 62 65 66 70 69 75 73 80 76 85 79 90 82 95 85 100 88 110 93 120 98 130 103 140 107 150 112 165 118 180 123 195 129 210 134 225 139 240 143 255 148 270 152 285 156 300 160 perature...

Страница 74: ...119 246 2 48 9 120 248 0 49 4 121 249 8 50 0 122 251 6 50 6 123 253 4 51 1 124 255 2 51 7 125 257 0 52 2 126 258 8 52 8 127 260 6 53 3 128 262 4 53 9 129 264 2 54 4 130 266 0 55 0 131 267 8 55 6 132...

Страница 75: ...elsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range Table 19 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT Capacity Tons Refrigerant Eff...

Страница 76: ...nnsylvania USA 17349 1 800 524 1330 Subject to change without notice Printed in USA Copyright by Johnson Controls 2020 www johnsoncontrols com ALL RIGHTS RESERVED Form 160 81 NOM1 1020 Issue Date Octo...

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