Johnson Controls YORK YCAS0130-0230 User manual

SERVICE POLICY & PROCEDURES
YCAS0130-0230 60 HZ, YCAS0098-0208 60HZ,
YCAS0373-0653 50 HZ, YCAS0295-0605 50HZ,
START-UP CHECKLIST
Supersedes: Nothing Form 201.19-CL1 (309)
COMMISSIONING
References to IOM in this document are as
follows:
YCAS0130-0230 (60Hz-R22) - 201.19-NM1
YCAS0098-0208 (60Hz-R407) - 201.19-NM3
YCAS0373-0653 (50Hz-R22) - 201.19-NM5
YCAS0295-0605 (50Hz-R407) - 201.19-NM7
PREPARATION
Commissioning of this unit should only
be carried out by YORK Authorized
personnel.
The Millennium Microcomputer Control System
Operating Instructions must be read in conjunction
with this section.
PREPARATION – POWER OFF
The following checks should be made with the customer
supply/supplies to the unit switched “OFF”.
Inspection
Inspect unit for installation damage. If damage is found
take action and/or repair as appropriate.
Refrigerant Charge
Units are normally shipped as standard with a full
refrigerant operating charge. Check that refrigerant
pressure is present in both systems and that no leaks are
apparent. If no pressure is present a leak test must be
undertaken. The leak(s) should be located and repaired.
Repaired systems and units supplied with a nitrogen
holding charge must be evacuated with a suitable vac-
uum pump/recovery unit as appropriate to below 100
microns.
Do not liquid charge with static water in the evaporator.
Care must also be taken to liquid charge slowly to avoid
excessive thermal stress at the charging point. Once the
vacuum is broken, charge into the condenser coils with
the full operating charge. Reference the Technical Data
Section in the IOM.
Valves
Open each compressor suction, economizer, and dis-
charge valve fully (counter-clockwise) then close one
turn of the stem to ensure operating pressure is fed to
the pressure transducers. Open the liquid line service
valve fully and ensure the oil return line ball valve is
open in each system.
Compressor Oil
To add oil to a circuit - connect a YORK hand oil pump
(Part No. 470-10654-000) to the 1/4" oil charging valve
on the oil separator piping with a length of clean hose
or copper line, but do not tighten the are nut. Using
clean oil of the correct type (“L” oil), pump oil until all
air has been purged from the hose then tighten the nut.
Stroke the oil pump to add oil to the oil system. The oil
level should be between the middle of the lower and
middle of the upper sight glasses of the oil separator.
Approximately 5 gallons is present in the entire chiller
system, with 1-2 gallons in the oil separator.
Fans
Check that all fans are free to rotate and are not dam-
aged. Ensure blades are at the same height when rotated.
Ensure fan guard is securely xed.
Isolation/Protection
Verify that all sources of electrical supply to the unit
are taken from a single point of isolation. Check that
the maximum recommended fuse sizes have not been
exceeded. Reference the Technical Data Section in the
IOM
Control Panel
Check the panel to see that it is free of foreign materials
(wire, metal chips, etc.) and clean out if required.
Power Connections
Check to assure the customer power cables are connected
correctly. Ensure that connections of power cables within
the panels to the circuit breakers, terminal blocks or
switch disconnectors are tight.

FORM 201.19-CL1 (309)
2JOHNSON CONTROLS
Grounding
Verify that the unit’s protective terminal(s) are properly
connected to a suitable grounding point. Ensure that all
unit internal ground connections are tight.
Overloads
Ensure that the fan overloads settings are correct for the
type of fan tted.
Supply Voltage
Verify that the site voltage supply corresponds to the
unit requirement and is within limits. Reference the
Technical Data Section in the IOM.
Control Transformer
The 3-wire control transformer is mounted external to
the panel. It is important to check that the correct primary
tapping has been used:
With the supply voltage to the unit turned off, remove
the lid to the transformer box.
Check that the tapping used conforms to the site supply
voltage. After the tapping is veried, replace the lid.
Switch Settings
Ensure that the unit ON/OFF switch on the display door
and the micro board system switches S2 through S5 are
set to “0” (OFF). Set the red handled emergency stop
device on the options panel to “1” (ON). For units tted
with door interlocked circuit breakers the power panel
doors must be closed and the devices set to “1” (ON).
The customer’s power disconnection devices can now
be set to ON.
The machine is now live!
The unit is tted with an under voltage circuit in each
panel and it may take between 5 to 10 seconds for its
contacts to close and energize the unit’s electronics,
including the display on the main panel.
Compressor Heaters
Verify the compressor heaters are energized. If
the ambient temperature is above 96°F (36°C) the
compressor heaters must be on for at least 8 hours before
start-up to ensure all refrigerant liquid is driven out of
the compressor. If the ambient temperature is below
86°F (30°C) then allow 24 hours.
Water System
Verify that the chilled liquid system has been installed
correctly, and has been commissioned with the correct
direction of water ow through the evaporator. The inlet
should be at the refrigerant pipework connection end of
the evaporator. Purge air from the top of the evaporator
using the plugged air vent mounted on the top of the
evaporator body. Flow rates and pressure drops must
be within the limits given in the Technical Data Section.
Operation outside of these limits is undesirable and could
cause damage.
Flow Switch
Verify a chilled water ow switch is correctly tted in
the customer’s pipework on the evaporator outlet, and
wired into the control panel correctly using shielded
cable. There should be a straight run of at least 5 pipe
diameters on either side of the ow switch. The ow
switch should be connected to terminals 13 and 14 in
the micro panel.
Temperature Sensor(s)
Ensure the leaving liquid temperature sensor is coated
with heat conductive compound (part no. 013-00890-
000) and is inserted in the water outlet sensor pocket
of the evaporator. This sensor also acts as the freeze
protection thermostat sensor and must always be in the
water OUTLET sensor pocket.
Control Supply
Verify the control panel display is illuminated.
Programmed Options
Verify that the options factory programmed into the
Microcomputer Control Center are in accordance with
the customer’s order requirements by pressing the “Op-
tions”key on the keypad and reading the settings from
the display.

FORM 201.19-CL1 (309)
JOHNSON CONTROLS 3
Programmed Settings
Ensure the system cut-out and operational settings
are in accordance with the instructions provided in
Section 8 of the IOM and with the general chiller op-
erational requirements by pressing the “Program”key.
The chilled liquid temperature control settings need to
be set according to the unit model and required operat-
ing conditions.
Date and Time
Program the date and time by rst ensuring that the
CLK jumper J18 on the microprocessor board is in the
ON position (top two pins). Then press the “Clock Set
Time”key and set the date and time.
Start/Stop Schedule
Program the daily and holiday start/stop by pressing the
“Set Schedule/Holiday”key.
Setpoint and Remote Offset
Set the required leaving chilled liquid temperature
setpoint and control range. If remote temperature reset
(offset) is to be used, the maximum reset must be pro-
grammed by pressing the “Remote Reset Temp”key.
First time start-up
During the commissioning period there
should be sufcient heat load to run
the unit under stable full load opera-
tion to enable the unit controls, and
system operation to be set up correctly
and a commissioning log taken. Be
sure that the Micro Panel is properly
programmed and the System Start-up
Check List is completed.
Interlocks
Verify that liquid is owing through the evaporator and
that heat load is present. Ensure that any remote run in-
terlocks are in the run position and that the run schedule
requires the unit to run or is overridden.
System Switches
Place the “Sys 1”switch on the microprocessor board
to the “ON”position.
Start-up
Remove the locking device from the unit Auto/OFF
switch which prevents unauthorized starting of the unit
before commissioning. Press the “Status”key, then turn
the unit switch to the “1” position to start the unit (there
may be a few seconds delay before the rst compressor
starts because of the anti-recycle timer). Be ready when
each compressor starts, to switch the unit OFF immedi-
ately if any unusual noises or other adverse conditions
develop. Use the appropriate emergency stop device if
necessary.
Oil Pressure
When a compressor starts, press the relevant “System
Pressures”key and verify that oil differential pressure
develops immediately (Discharge Pressure minus Oil
Pressure). If oil pressure does not develop, the automatic
controls will shut down the compressor. Under no cir-
cumstances should a restart attempt be made on a com-
pressor which does not develop oil pressure immediately.
Switch the unit switch to the “0”position (OFF).
Refrigerant Flow
When a compressor starts, a ow of liquid refrigerant
will be seen in the liquid line sight glass. After several
minutes operation and providing a full charge of refrig-
erant is in the system, the bubbles will disappear and be
replaced by a solid column of liquid.
Fan Rotation
As discharge pressure rises, the condenser fans oper-
ate in stages to control the pressure. Verify that the fan
operation is correct for the type of unit.
Suction Superheat
Check suction superheat at steady full compressor
load only. Measure suction temperature on the copper
line about 6" (150 mm) before the compressor suction
service valve. Measure suction pressure at the compres-
sor service valve. Superheat should be 10°F to 12°F
(5.6°C to 6.7°C).
Expansion Valve
The electronic expansion valves are factory set and
should not need adjustment.

FORM 201.19-CL1 (309)
4JOHNSON CONTROLS
Economizer Superheat
(Not all models are equipped with economizers)
Check economizer superheat at steady full compres-
sor load only, under conditions when the economizer
solenoid is energized. Measure gas temperature on
the economizer outlet pipe next to the expansion valve
bulb. Measure gas pressure at the back seat port of the
economizer service valve. Superheat as measured should
be 10°F to 12°F (5.6°C to 6.7°C).
Subcooling
Check liquid subcooling at steady full compressor load
only. It is important that all fans are running for the
system. Measure liquid line temperature on the copper
line beside the main liquid line service valve. Measure
liquid pressure at the liquid line service valve. Sub-
cooling should be 12°F to 15°F (6.7°C to 8.3°C). No
bubbles should show in the sight glass. If subcooling
is out of range add or remove refrigerant as required.
Do not overcharge the unit. The liquid ow to the main
evaporator TXV is subcooled further by the economizer,
increasing subcooling to between 22°F and 28°F (12°C
and 15°C) at ambients above 90ºF.
General Operation
After completion of the above checks for System 1, stop
the unit, switch “OFF” the “SYS 1”switch on the main
panel microprocessor board and repeat the process for
each subsequent system. When all run correctly, stop the
unit, switch all applicable switches to the “ON”position
and restart the unit.

FORM 201.19-CL1 (309)
JOHNSON CONTROLS 5
SYSTEM START-UP CHECK LIST
JOB NAME: ______________________________
SALES ORDER #: _________________________
LOCATION:_______________________________
SOLD BY: ________________________________
INSTALLING
CONTRACTOR: ___________________________
START-UP
TECHNICIAN/
COMPANY: _______________________________
START-UP DATE : _________________________
CHILLER MODEL #: _______________________
SERIAL #: ______________________________
__
COMPRESSOR #1
MODEL#: ________________________________
SERIAL #: _______________________________
COMPRESSOR #2
MODEL#: ________________________________
SERIAL #: _______________________________
UNIT CHECKS (NO POWER)
Check the system 24 hours prior to initial start.
1. Inspect the unit for shipping or installation
damage.
2. Assure that all piping has been completed.
3. Check that the unit is properly charged and that
there are no piping leaks.
4. Open each compressor suction service
valve, discharge service valve, economizer
service valve, liquid line stop valve, and oil
line ball valves.
5. The compressor oil level should be maintained
so that an oil level is visible in either of the two
oil separator sight glasses. In other words, oil
level should always be maintained, running or
not, above the bottom of the lower sight glass
and below the top of the upper sight glass.
If it is necessary to add oil, connect a YORK oil
pump to the charging valve on the oil separator,
but do not tighten the are nut on the delivery
tubing. With the bottom (suction end) of the
pump submerged in oil to avoid entrance of air,
operate the pump until oil drips from the are nut
joint, allowing the air to be expelled, and tighten
the are nut. Open the oil charging valve on the
oil separator and pump in oil until it reaches the
proper level as described above.
In actual operation, due to splashing,
an oil level may be seen in both sight
glasses. Run the compressor for a few
minutes fully loaded, shut the system
down, and assure there is an oil level
showing in the bottom or top sight
glass with the compressor “OFF”.
6. Assure water pumps are on. Check and adjust
water pump ow rate and pressure drop across
the evaporator.
Excessive ow may cause catastrophic
damage to the evaporator.
7. Check the control panel to assure it is free of
foreign material (wires, metal chips, etc.).
8. Visually inspect wiring (power and control).
Wiring MUST meet N.E.C. and local codes.
9. Check tightness of power wiring inside the power
panel on both sides of the motor contactors and
inside the motor terminal boxes.
10. Check for proper size fuses in main and control
circuits.
 11.Verify that eld wiring matches the 3‑phase
power requirements of the compressor. See
chiller nameplate.
12.Assure 115VAC Control Power has 30A mini-
mum capacity.
13.Be certain all water temp sensors are inserted
completely in their respective wells and are
coated with heat conductive compound.
14.Assure that evaporator EEV bulbs are strapped
onto the suction lines at 4 or 8 o’clock posi-
tions.
15.Assure that the 15 ton economizer TXV
bulbs are strapped onto the compressor
economizer supply lines at 4 or 8 o’clock posi-
tions.

FORM 201.19-CL1 (309)
6JOHNSON CONTROLS
16.Assure that the Flow Switch is properly installed,
wired correctly, and working.
17. Assure bolts through compressor feet to bottom
frame rails are removed.
PANEL CHECKS
(Power ON – Both System Switches “OFF”)
1. Apply 3-phase power and verify its value.
2. Apply 115VAC and verify its value on the ter-
minal block in the lower left of the Power Panel.
Make the measurement between terminals 5 and
2. The voltage should be 115VAC +/- 10%.
3. Assure the heaters on each compressor are on.
Allow the compressor heaters to remain on a
minimum of 24 hours before start-up. This is
important to assure that no refrigerant is in the
compressor oil at start-up!
4. Program the dip switches on the microprocessor
board for the desired operating requirements.
OPEN = Left side of switch pushed down.
CLOSED = Right side of switch pushed down.
SWITCH SWITCH "OPEN"
SETTING
SWITCH "CLOSED"
SETTING
1Water Cooling Glycol Cooling
2Standard Ambient
Control Low Ambient Control
3Refrigerant R-407C Refrigerant R-22
4Do Not Use YCAS
5Do Not Use
Motor Current
Averaging (Start-Up)
Disabled
6Heat Recovery
Disabled Do Not Use
7Expansion Valve
Thermostatic
Expansion Valve
Electronic*
8Standard Options
Enabled Do Not Use
*Expansion valve electronic should always be selected when an
EEV is installed.
Verify the selections by pressing the OPTIONS Key on
the control panel. Check them off in the chart above.
Damage to the chiller could result if
switches are improperly pro-
grammed.
5. Program the required operating values into the
micro for cut-outs, safeties, etc. and record them
in the chart below.
Record programmed values in the chart below.
PROGRAMMED VALUES
Display Language =_____________________________
Discharge Press Cutout = _______________ PSIG (kPa)
Discharge Press Unload = _______________ PSIG (kPa)
Suction Press Cutout = _________________ PSIG (kPa)
High Amb Cutout = ________________________ °F (°C)
Low Amb Cutout = ________________________ °F (°C)
Leaving Chilled Liquid Temp Cutout = __________ °F (°C)
High Motor Current Unload = _________________ % FLA
Anti-Recycle Time = ________________________ Secs
Local / Remote Mode = __________________________
Display Units = _______________________________
Lead / Lag Control = ____________________________
Power Failure Restart = _________________________
Suction Superheat Setpoint = _______________ °F (°C)
6. Program the Chilled Liquid Setpoint/Range and
record:
Setpoint = __________________ °F (°C)
Range = +/- ________________ °F (°C)
Keep in mind that the setpoint temperature
displayed by the micro should equal the desired
leaving water temperature.
7. Assure that the CLK jumper J18 on the Micro-
processor Board is in the ON position (Top 2
pins).

FORM 201.19-CL1 (309)
JOHNSON CONTROLS 7
1. Place the System Switches on the Microproces-
sor Board to the ON position.
 2. The compressor will start and a ow of refriger-
ant will be noted in the sight glass. After several
minutes of operation, the bubbles in the sight
glass will disappear and there will be a solid col-
umn of liquid when the TXV stabilizes. After the
water temperature stabilizes at desired operating
conditions, the sight glass should be clear.
3. Allow the compressor to run a short time, being
ready to stop it immediately if any unusual noise
or adverse conditions develop. Immediately at
start-up, the compressor will make sounds dif-
ferent from its normal high pitched sound. This
is due to the compressor coming up to speed and
lubrication changing from liquid refrigerant to
oil. This should be of no concern and lasts for
only a short time.
4. Check the system operating parameters. Do this
by selecting various displays such as pressures
and temperatures. Compare these to test gauge
readings.
CHECKING SUBCOOLING AND SUPERHEAT
The subcooling should always be checked when charg-
ing the system with refrigerant and/or before setting
the superheat.
When the refrigerant charge is correct, there will be no
bubbles in the liquid sight glass with the system operat-
ing under full load conditions, and there will be 12 - 15°F
(6 - 8°C) subcooled liquid leaving the condenser.
An overcharged system should be guarded against.
Evidences of overcharge are as follows:
a. If a system is overcharged, the discharge pressure
will be higher than normal. (Normal discharge/
condensing pressure can be found in the refriger-
ant temperature/pressure chart; use entering air
temperature +30°F (17°C) for normal condens-
ing temperature.
b. The temperature of the liquid refrigerant out of
the condenser should be not be more than 15°F
(8°C) less than the condensing temperature (The
temperature corresponding to the condensing
pressure from the refrigerant temperature/pres-
sure chart).
8. Set the Time and Date.
9. Program the Daily Schedule start and stop
times.
10.Check the Factory Service Mode programming
values, assure they are correct, and record the
values below:
Refrigerant Type = ____________________________
R407C Chiller Type = ____________________________
Unit Type = ___________________________________
Heat Recovery = _______________________________
Sys #1 100% FLA = _________________________Amps
Sys #2 100% FLA = _________________________Amps
Sys #1 Motor Protector Input = ________________ Volts
Sys #2 Motor Protector Input = ________________ Volts
Typically, these values should not be
changed. Incorrect programming
may cause catastrophic chiller fail-
ure.
11.Check the Motor Protector Dip Switch program-
ming. The switches should correctly set at the
factory. The switches may be checked visibly
and the total ON switches added using binary
addition to determine the setting or by reading
the display on the motor protector. See Section
8 for programming information. Record the
values below:
Sys #1 Wires thru each hole of the C.T. = ____________
Sys #1 MP Setting = ____________
Sys #2 Wires thru each hole of the C.T. = ____________
Sys #2 MP Setting = ____________
INITIAL START-UP
After the control panel has been programmed and the
compressor heater has been on for 24 hours prior to
start-up, the chiller may be placed into operation.

FORM 201.19-CL1 (309)
8JOHNSON CONTROLS
The subcooling temperature of each system should be
calculated by recording the temperature of the liquid
line at the outlet of the condenser and subtracting it
from the recorded liquid line pressure at the liquid stop
valve, converted to temperature from the temperature/
pressure chart.
Example:
Liquid line pressure =
202 PSIG converted to 102°F (39°C)
minus liquid line temp. - 87°F (31°C)
SUBCOOLING = 15°F (8.3°C)
The subcooling should be adjusted to 12-15°F (6.7 -
8.3°C).
1. Record the liquid line pressure and its corre-
sponding temperature, liquid line temperature
and subcooling below:
SYS 1 SYS 2
Liq Line Press = PSIG (kPa)
Temp = °F (°C)
Liq Line Temp = °F (°C)
Subcooling = °F (°C)
If equipped with an economizer, the
economizer will provide approxi-
mately an additional 20ºF (11.1ºC)
subcooling at the expansion valve in
ambients above 90ºF (32ºC). Below
90ºF (32ºC), the economizer will not
provide additional subcooling.
After the subcooling is set, the suction superheat
should be checked. The superheat should be checked
only after steady state operation of the chiller has been
established, the leaving water temperature has been
pulled down to the required leaving water temperature,
and the unit is running in a fully loaded condition.
Correct superheat setting for a system is 10 - 12°F
(6 - 7°C).
The superheat is calculated as the difference between the
actual temperature of the returned refrigerant gas in the
suction line entering the compressor and the tempera-
ture corresponding to the suction pressure as shown in
a standard pressure/temperature chart.
Example:
Suction Temp = 46°F (8°C)
minus Suction Press
60 PSIG converted
to Temp - 34°F (1°C)
12°F (7°C)
The suction temperature should be taken 6" (13 mm)
before the compressor suction service valve, and the
suction pressure is taken at the compressor suction
service valve.
The EEV is non-adjustable. Superheat
setpoint is programmable from the
keypad.
2. Record the suction temperature, suction pressure,
suction pressure converted to temperature, and
superheat of each system below:
SYS 1 SYS 2
Suction Press = PSIG (kPa)
Suction Temp = °F (°C)
Suction Press
Converted
to Temp = °F (°C)
Superheat = °F (°C)

CHECKING ECONOMIZER SUPERHEAT
(IF APPLICABLE) (15 TON TXV)
The economizer superheat should be checked to assure
proper economizer operation and motor cooling. Correct
superheat setting is approx. 10 - 12°F (6 - 7°C).
The superheat is calculated as the difference between
the pressure at the Economizer Service Valve on the
compressor converted to the corresponding temperature
in a standard pressure/temperature chart and tempera-
ture of the gas at the bulb on the entering piping to the
motor housing.
Example:
Motor Gas Temp = 90°F (32°C)
minus Economizer Press
139 PSIG converted
to Temp - 78°F (26°C)
12°F (6°C)
Normally, the thermal expansion valve need not be
adjusted in the eld. If however, adjustment needs to
be made, the expansion valve adjusting screw should
be turned not more than one turn at a time, allowing
sufcient time (approximately 15 minutes) between
adjustments for the system and the thermal expansion
valve to respond and settle out. Assure that superheat is
set between 10 - 12°F (6 - 7°C).
1. Record the motor gas temperature, economizer
pressure, economizer pressure converted to
temperature, and economizer superheat below:
SYS 1 SYS 2
Economizer Press= PSIG (kPa)
Economizer Temp = °F (°C)
Economizer Press
Converted to Temp= °F (°C)
Superheat = °F (°C)
This superheat should only be checked
in an ambient above 90°F (32°C).
Otherwise, mid-range adjustment (fac-
tory setting) is acceptable. Below 90ºF
(32ºC) ambient, the economizer will
not provide additional subcooling.
LEAK CHECKING
 1. Leak check compressors, ttings, and piping to
assure no leaks.
If the unit is functioning satisfactorily during the initial
operating period, no safeties trip and the compressors
load and unload to control water temperature, the chiller
is ready to be placed into operation.
©2009 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203
www.johnsoncontrols.com
Printed in USA 201.19-CL1 (309)
New Release