Johnson Controls YORK YVAM 0350 Troubleshooting guide

Form Number: 160.88-OM1 (122)
New Release
Operation and Maintenance
Issue Date: 2022-01-14
YVAM Control Center
Centrifugal Liquid Chiller with R-134a Refrigerant

2 YVAM Control Center

Contents
ContentsGeneral safety guidelines................................................................................................................................7
Safety symbols....................................................................................................................................... 7
Changeability of this document...........................................................................................................8
Associated literature..............................................................................................................................8
Conditioned based maintenance.........................................................................................................8
Nomenclature........................................................................................................................................ 9
System fundamentals.................................................................................................................................... 11
System components............................................................................................................................11
Compressor.................................................................................................................................................12
Motor........................................................................................................................................................... 13
Heat exchangers........................................................................................................................................ 13
Evaporator...................................................................................................................................................13
Condenser...................................................................................................................................................13
Waterboxes................................................................................................................................................. 13
Refrigerant flow control............................................................................................................................ 13
Variable speed drive.................................................................................................................................. 14
Power panel................................................................................................................................................ 14
Optional service isolation valves.............................................................................................................. 14
OptiView control center.............................................................................................................................17
System operation description............................................................................................................ 19
Capacity control..........................................................................................................................................19
Anti-surge minimum frequency............................................................................................................... 20
Smart Freeze...............................................................................................................................................20
Surge protection.........................................................................................................................................21
System operating procedures...................................................................................................................... 22
Pre-starting...........................................................................................................................................22
Start-up................................................................................................................................................. 22
Chiller operation.................................................................................................................................. 23
Chilled liquid control settings.............................................................................................................23
Temperature control setpoint.................................................................................................................. 23
Automatic temperature shutdown.......................................................................................................... 25
Automatic temperature restart................................................................................................................ 25
Operator setpoints quick reference.................................................................................................. 25
Stopping the system............................................................................................................................26
Safety stop............................................................................................................................................ 26
Operating logs..................................................................................................................................... 26
Fault shutdowns...................................................................................................................................27
Performing prolonged shutdown......................................................................................................27
Restart after prolonged shutdown....................................................................................................27
Freeze damage protection..................................................................................................................27
Physical data.........................................................................................................................................29
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OptiView control center functions and navigation.................................................................................... 30
Display only.......................................................................................................................................... 30
Programmable..................................................................................................................................... 30
Access level................................................................................................................................................. 30
Change setpoints....................................................................................................................................... 30
Programming setpoints............................................................................................................................ 31
Manual controls......................................................................................................................................... 31
Free cursor..................................................................................................................................................31
Navigation............................................................................................................................................ 31
Languages............................................................................................................................................ 32
Analog input ranges............................................................................................................................32
OptiView screens................................................................................................................................. 34
Home screen...............................................................................................................................................34
System screen.............................................................................................................................................36
Evaporator screen......................................................................................................................................37
Condenser screen...................................................................................................................................... 39
Compressor screen....................................................................................................................................40
Magnetic bearing controller screen........................................................................................................ 42
Magnetic bearing controller details screen............................................................................................44
Surge screen...............................................................................................................................................46
Variable geometry diffuser screen.......................................................................................................... 48
Power panel screen................................................................................................................................... 49
Capacity control screen.............................................................................................................................51
Variable speed drive screen......................................................................................................................53
Variable speed drive (VSD) details screen...............................................................................................55
VSD cooling screen.................................................................................................................................... 57
Motor details screen..................................................................................................................................58
Setpoints screen.........................................................................................................................................60
Remote control screen.............................................................................................................................. 62
Setup screen............................................................................................................................................... 64
Schedule screen......................................................................................................................................... 66
User screen................................................................................................................................................. 68
Comms screen............................................................................................................................................69
Printer screen............................................................................................................................................. 70
Sales order screen......................................................................................................................................71
Operations screen......................................................................................................................................72
History screen.............................................................................................................................................73
History details screen................................................................................................................................ 74
Custom screen............................................................................................................................................75
Custom setup screen.................................................................................................................................76
Trend screen............................................................................................................................................... 77
Trend setup screen.................................................................................................................................... 79
Common slots screen................................................................................................................................82
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Master slot numbers list.....................................................................................................................83
Display messages................................................................................................................................ 88
Status messages........................................................................................................................................ 88
Run messages............................................................................................................................................ 89
MBC startup messages..............................................................................................................................90
Start inhibit messages...............................................................................................................................90
Warning messages.................................................................................................................................... 90
Routine shutdown messages................................................................................................................... 93
Cycling shutdown messages.................................................................................................................... 94
Safety shutdown messages.................................................................................................................... 101
Drive operation.............................................................................................................................................111
OptiSpeed compressor drive overview...........................................................................................111
OptiSpeed compressor drive features............................................................................................111
Smart sensor system.........................................................................................................................112
OptiSpeed compressor drive details (0490B amp drive).............................................................. 114
Harmonic filter benefits.......................................................................................................................... 114
Harmonic filter general information..................................................................................................... 115
OptiSpeed compressor drive and chiller operation (0490B amp models)................................. 120
Maintenance................................................................................................................................................. 121
Preventative maintenance................................................................................................................121
Renewal parts.................................................................................................................................... 122
Operating inspections.......................................................................................................................122
Weekly....................................................................................................................................................... 122
Monthly..................................................................................................................................................... 122
Semi-annually...........................................................................................................................................122
Annually.....................................................................................................................................................123
Checking system for leaks................................................................................................................123
Leak testing...............................................................................................................................................123
Vapor connection locations.................................................................................................................... 123
System pressure test.........................................................................................................................124
Conducting the gas pressure hold test.................................................................................................125
Conducting the soap visual gas leak test..............................................................................................126
Conducting the optional trace gas leak test.........................................................................................127
System evacuation.............................................................................................................................128
Vacuum dehydration.........................................................................................................................128
Conducting the dehydration process....................................................................................................131
Conducting the final evacuation............................................................................................................ 131
Refrigerant charging.........................................................................................................................132
Removing the refrigerant charge for service....................................................................................... 134
Checking and trimming the refrigerant charge...................................................................................135
Checking the refrigerant charge during unit shutdown.....................................................................135
Compressor and motor maintenance.............................................................................................135
Evaporator maintenance.................................................................................................................. 136
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Chemical water treatment...................................................................................................................... 136
Cleaning evaporator tubes..................................................................................................................... 137
Tube fouling..............................................................................................................................................137
Tube cleaning procedures...................................................................................................................... 137
Evaporator tube leaks............................................................................................................................. 138
Testing for evaporator tube leaks..........................................................................................................138
Condenser maintenance.................................................................................................................. 139
Cleaning requirements of microchannel heat exchangers................................................................ 139
Cleaning Standard and Environment Guard MCHX coils....................................................................139
Cleaning Environment Guard Premium MCHX coils............................................................................140
Electrical controls...............................................................................................................................140
Unit heater operation verification...................................................................................................140
Testing evaporator waterbox heaters WBH1 and WBH2....................................................................141
Testing evaporator shell heaters EVH1 and EVH2................................................................................141
Testing heat trace for drive coolant HT1 and HT2............................................................................... 141
Testing the VGD actuator heater mat....................................................................................................142
Testing the MBC heater mat...................................................................................................................142
Testing the drive internal heater............................................................................................................142
Testing the OptiView control panel heater........................................................................................... 143
Testing the OptiView control panel cooler............................................................................................144
Testing UPS panel heating......................................................................................................................145
Automatic battery health test during shutdown...........................................................................145
Printing..........................................................................................................................................................147
Printing overview...............................................................................................................................147
Acceptable printers........................................................................................................................... 147
OKI Data.................................................................................................................................................... 148
Brecknell....................................................................................................................................................149
Control center setup......................................................................................................................... 150
Downloading system prints to a laptop..........................................................................................151
Unit conversion............................................................................................................................................ 162
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General safety guidelines
Important: Read before proceeding.
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certain components or conditions including,
but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the potential, if misused or handled improperly,
to cause bodily injury or death. It is the obligation and responsibility of rigging, installation, and
operating/service personnel to identify and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to comply with any of these requirements could
result in serious damage to the equipment and the property in which it is situated, as well as severe
personal injury or death to themselves and people at the site.
This document is intended for use by owner-authorized rigging, installation, and operating/service
personnel. It is expected that these individuals possess independent training that will enable them
to perform their assigned tasks properly and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read and understood the on-product labels, this
document and any referenced materials. This individual shall also be familiar with and comply
with all applicable industry and governmental standards and regulations pertaining to the task in
question.
Safety symbols
The following symbols are used in this document to alert the reader to specific situations:
DANGER
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.
WARNING
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.
CAUTION
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.
Note: Highlights additional information useful to the technician in completing the work being
performed properly.
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WARNING
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance
with Johnson Controls’ published specifications and must be performed only by a qualified electrician.
Johnson Controls will NOT be responsible for damage/problems resulting from improper connections
to the controls or application of improper control signals. Failure to follow this warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
Changeability of this document
In complying with Johnson Controls’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. Johnson Controls makes no
commitment to update or provide current information automatically to the manual owner. Updated
manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office or
accessing the Johnson Controls Knowledge Exchange website at https://docs.johnsoncontrols.com/
chillers/.
Operating/service personnel maintain responsibility for the applicability of these documents to the
equipment. If there is any question regarding the applicability of these documents, the technician
should verify whether the equipment has been modified and if current literature is available from
the owner of the equipment prior to performing any work on the chiller.
Associated literature
Table 1: Associated literature
Manual description Form number
Installation and Reassembly 160.88-N1
Unit Installation Checklist and Request for Startup 160.88-CL1
Unit Startup Checklist 160.88-CL2
Field Connections Diagram 160.88-PW1
Field Control, Wiring, and MBC Diagrams 160.88-PW2
Centrifugal Chiller Long Term Storage 50.20-NM5
All Products - Replacement Parts Electrical Connectors 50.20-RP1
All Products - Replacement Parts Fittings 50.20-RP2
Conditioned based maintenance
Traditional chiller maintenance is based upon assumed and generalized conditions. In lieu of
the traditional maintenance program, a Johnson Controls YORK Conditioned Based Maintenance
(CBM) program can be substituted. This CBM service plan is built around the specific needs for
the chiller, operating conditions, and annualized impact realized by the chiller. Your local Johnson
Controls Branch can propose a customized Planned Service Agreement that leverages real time
and historical data, delivering performance reporting, corrective actions required and data enabled
guidance for optimal operation and life cycle assurance. The program will include fault detection
diagnostics, operation code statistics, performance based algorithms and advance rules based
rationale delivered by the Johnson Controls Connected Equipment Portal.
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Nomenclature
Figure 1: System nomenclature
Figure 2: Compressor nomenclature
Figure 3: Vessel nomenclature
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Figure 4: Variable speed drive nomenclature
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