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JOHNSON CONTROLS

133

SECTION 7 - MAINTENANCE

FORM 201.30-ICOM1 (519)

ISSUE DATE: 05/22/2019

When the chiller motor is not running, a quali-

fied technician should confirm the compressor

oil heater is working properly, and is energized.

If it is the first start-up for the cooling season, the

technician should confirm the oil heater has been

energized for at least 24 hours prior to start-up.

During start-up, the chiller should be manually

unloaded until a discharge superheat temperature

(displayed on the SYSTEM DATA key) of 18°F

(10°C) or greater is maintained and liquid level

drops below the top of the upper sight glass on

the oil separator. The chiller should continue to

be held in part-load operation until the foaming

in the oil separator is minimized. The chiller can

then be returned to the position or load control to

meet the cooling load requirements.

Operation

Oil level should be visible in or below the upper

sight glass:

If the chiller operates in a low dis-

charge superheat condition for an extended period

of time, refrigerant can condense in the oil separa-

tor. Unload and hold the chiller at a capacity that

allows the discharge superheat to increase above

18°F (10°C), and until the level drops below the

top of the upper sight glass and foaming is mini-

mized. The chiller can then be loaded normally as

the building/process load requires.

2. If there is no visible oil in either sight glass, a

problem may exist with the oil return system. If

load is such that the compressor is operating at

least 100

the oil should be present in the sight

glass. At lower loads, oil level may be below the

lower sight glass. If the proper amount of oil is in

the chiller, the bearings will be adequately lubri-

cated. The chiller should be loaded when validat-

ing oil capacity in the chiller. A qualified techni-

cian should add only enough oil to create a visible

level in 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 either the lower or upper sight

glass, depending on conditions. A qualified techni-

cian should then remove the approximate amount

added to start the chiller.

Oil Analysis

An annual oil analysis is recommended to verify the

continued use of the compressor oil.

The oil sample should not be exposed

to the atmosphere for more than 15

minutes because it will absorb mois-

ture from the atmosphere and may

yield erroneous results.

Change the compressor oil when the oil analysis indi-

cates that the oil has moisture, and the acid numbers

exceed the limits set in

Table 44 on page 133

TABLE 44 -

COMPRESSOR OIL LIMITS

MOISTURE

YORK OIL TYPE

MOISTURE

CONTENT

(KARL FISHER

METHOD) PPM

TAN

(TOTAL ACID

NUMBER)

MGKOH/ML

< 300

< 0.5

The YVWA chiller compressors use rolling element

bearings (ball and roller bearings); no sleeve bearings

are used. Oil analysis that include metals, such as iron,

copper, titanium, zinc, lead, tin and silicon, may cause

confusion when the results are compared to other

equipment that utilize different bearing types. Ignore

these metals in the oil analysis because they are ac-

ceptable if < 100 ppm. If an oil analysis indicates >300

ppm of iron, combined with > 50 ppm of chromium

and nickel, consult the Johnson Controls Field Service

Office because these amounts could indicate bearing

damage and wear.

Removing the Compressor Oil

Use the following instructions to remove the compres-

sor oil. Drain the existing oil in the oil separator, which

is under positive pressure at ambient temperature, into

an approved refrigerant recovery container.

1. Connect one end of a refrigeration charging hose

to the service valve located at the bottom of the

oil separator; connect the other end to an ap-

proved container.

2. Open the valve, and drain the

existing

oil from the

oil separator.

3. Additional oil is in the compressor that can

be drained through the plug under the motor

housing.

Содержание YVWA

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 130: ...JOHNSON CONTROLS 130 FORM 201 30 ICOM1 519 ISSUE DATE 05 22 2019 THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 155: ...JOHNSON CONTROLS 155 NOTES...

Страница 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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