York YVAM User manual

Model YVAM Start-up Checklist
Start-up checklist
Customer:
Job name:
Address:
Location:
Phone:
Customer order number:
Johnson Controls telephone number:
Johnson Controls order number:
Johnson Controls contract number:
Chiller model number:
Unit serial number:
The work (as checked below) is in progress
and will be completed by (MM/DD/YYYY): ___________________ /___________________ /___________________
The following work must be completed in accordance with installation instructions:
A. General
Review the installation checklist, Form 160.88-CL1,
to validate that the actions have been completed.
Attach a completed copy for records.
1. Water connection inlet and outlet are at
correct locations, have hangers nearby
that can support their weight, and show no
visible strain on chiller nozzles.
2. Check for refrigerant or water piping leaks.
Repair as needed.
3. Verify that the chiller is charged with
refrigerant and that the pressures
match refrigerant saturation for ambient
temperature.
4. Verify that the unit isolators are set up in
accordance with 160.88-N1.
5. Verify that the evaporator pressure
transducer isolation valve is open.
6. Verify that the condenser pressure
transducer isolation valves are open.
7. Verify that the compressor suction pressure
transducer is open.
8. Verify that the discharge pressure
transducer (stall transducer) isolation valve
is open.
9. Verify that the compressor discharge
isolation valves are open.
10. Verify that the condenser liquid drain line
isolation valve is open.
11. If hot gas is present, verify that the hot gas
bypass line isolation valve is open.
12. Verify that the motor liquid cooling angle
valve from the liquid line at the inlet to the
level control valve is open.
13. Verify that the motor stator liquid cooling
strainer service capped ball valve below the
motor is open.
14. Check the VSD, single point power panel,
UPS panel, waterbox heater panel, and
control panel to ensure that they are free of
foreign material, for example wires, metal
chips, tools, documents. Also check for
signs of water or moisture.
15. Ensure that door gasket seals are sealing
correctly and that incoming power wiring
conduit is caulked
16. Ensure that a jumper is installed on
OptiView™ TB6 terminal 24 to 25.
17. Ensure that the battery disconnect switch
on the power panel is closed so that the
battery can charge. 12.8 VDC is required for
start-up.
Form Number: 160.88-CL2 (922)
Supersedes: 160.88-CL2 (1121)
Issue Date: 2022-09-13

18. Verify that the VSD coolant propylene glycol
(PG) percentage is 44%.
19. Verify that the chilled liquid loop PG or EG
percentage corresponds with the chiller
order. If needed, contact the chiller sales
team for verification.
20. If the unit is equipped with SC-EQ, set up
according to 450.50-N1, Section 2.
21. Check the tightness of the power supply
connection to the waterbox heater kit, if
applicable. Make sure the waterproofing
level of connection can meet IP65.
22. Ensure that all water temperature sensors
are inserted completely in their respective
wells and are coated with heat conductive
compound.
B. Electrical
Review the appropriate manuals, 160.88-PW1, 160.88-
PW2, and 160.88-M3 to complete the following
actions:
WARNING
Correct electrical lockout and tagout procedures
must be followed.
1. Ensure that the incoming power wiring is
not aluminum. Copper wire must be used.
2. All Main power wiring connections must be
made in accordance with Form 160.88-PW1.
3. If the power source is transferable from
utility to generator and from generator to
utility, ensure there is a 10 second delay
between the transfers of power sources.
4. Visually inspect the power wiring and
control wiring. Wiring must meet NEC, CE,
and local codes.
5. Ensure that the field wiring matches the
three-phase power requirements of the
chiller. Refer to the chiller nameplate.
6. If the power factor correction capacitors
are applied between the power source and
the VSD, they must be removed or turned
off.
7. Ensure that the power supply connection
to waterbox heater kit is correctly made, if
applicable.
C. Single point power panel
1. Ensure that wiring is completed from the
single point power supply to the HYP drive.
2. Ensure that there are no penetrations in to
the drive enclosure other than the factory
provided connections.
Note: Do not cut power wire to length or con-
nect power wire to the single point power panel
without supervision from a Johnson Controls
representative.
3. Measure and cut power wire to length
outside of the power panel enclosure. Use a
tool designed to cut large diameter power
wire.
4. Ensure that the conduit connections are
made at the single point power panel as
outlined in 160.88-PW1. No other enclosure
penetrations are allowed.
5. Inspect power feed terminations torque
marks to the drive circuit breaker.
6. Ensure that wiring to the single point
power panel is complete.
7. Verify that the circuit breaker settings
match the settings shown in the
OptiSpeed™ VSD service manual. Refer to
160.88-M3.
8. Ensure that external control wiring is
completed in accordance with 160.88-PW2 .
D. Chiller power-up
WARNING
You are about to turn on the power of this
machine. Safety is number one. Only qualified
individuals are permitted to service this product.
The qualified individual furthermore must be
knowledgeable of, and adhere to, all safe work
practices as required by NEC, OSHA, and NFPA
70E. Use correct personal protection equipment
(PPE) where and when required.
CAUTION
Do not apply power to the chiller unless the
chilled water system is filled with water or glycol.
If the chiller is equipped with the -20°F option,
applying power to an empty chilled liquid system
will cause the evaporator immersion heaters to
fail.
1. Apply three-phase power to the chiller.
2. Check that the control panel display is
illuminated.
Model YVAM Start-up Checklist2

3. Navigate to the VSD screen and verify that
the line voltage supply corresponds to the
unit data plate requirement and is in the
limits given in the Technical data section in
Form 160.88-OM1.
4. Confirm that the power supply to waterbox
heater kit is either 115 V/60 Hz or 220 V/50
Hz. If the evaporator is filled with water in
waterside, turn on the two-pole-breaker
inside of the waterbox heater kit.
5. Confirm that all the heaters on the
evaporator can function normally, including
the shell heater and waterbox heaters.
6. Confirm that the chilled water pump can
be automatically started by the chiller
controller, especially in the subfreezing
region.
7. Verify heater operation on each of the
following locations. Refer to 160.88-PW2 for
heater power wiring locations and 160.88-
N1 for more detailed instructions.
Note: For all of the following checks, the chiller
cannot be operating.
a. Waterbox heater WBH1. Record
the value.
b. Waterbox heater WBH2. Record
the value.
c. Evaporator shell heater EVH1.
Record the value.
d. Evaporator shell heater EVH2.
Record the value.
e. VSD coolant heat trace HT1.
Record the value.
f. VSD coolant heat trace HT2.
Record the value.
g. VGD actuator heater mat. Record
the value.
h. MBC heater mat. Record the value.
i. VSD internal heater. Record the
value.
j. OptiView. Record the value.
k. UPS panel. Record the value.
E. Chilled water pumps
Check the following:
1. Verify that the chilled water pump is wired
for chiller control in locations where sub-
freezing conditions are possible. Failure to
do so will void the warranty.
2. Verify that flow rates will not exceed the
upper and lower flow limits of the chiller
according to the chiller rating.
CAUTION
Excessive flow may cause catastrophic damage
to the evaporator.
F. Condenser fans
Check the following:
1. Power is available.
2. Wiring is complete.
3. Check rotation.
4. Check the status of the condenser fans.
Ensure that the blades rotate freely and do
not hit the shield. Refer to fan information
in 160.88-OM1.
G. VSD coolant system
1. Check that the glycol level in the VSD
cooling system is 9 in. to 15 in. (23 cm to 38
cm) from the top of the fill tube. Perform
this check before running the pump.
CAUTION
Never run the glycol pump without coolant.
Running the glycol pump without coolant may
damage the pump seals.
2. Always fill the system with approved
YORK® coolant (P/N 013-03344-000) to
avoid damage to the pump, cooling system
base plates, and the chiller, and to prevent
overheating of the base plates and power
panel.
Model YVAM Start-up Checklist 3

H. Control panel
Log on at Service level access to ensure access to
the necessary setpoints. The setpoints that are
site-specific are listed and must be verified to the
required values. They are grouped by the screen
in which they appear. Enter the as-left value in the
corresponding box for each setpoint.
Navigate to the screen by pressing
Home > Setpoints > Setup > Diagnostics. To
accept the default capacity control and level control
setpoints, press the Default Unit Setpoints button
on the lower bar. Return to Home and navigate to
each of the following screens:
1. Setpoints
Run/Stop Control Source
Cooling Setpoint Control Source
Input Current Limit Control Source
2. Setpoints > Setup
Enter clock time and date
Liquid Type (SW1 position 1):
Water = On, Brine = Off
Refrigerant Type
Condenser Fan Type
Variable Water Outlet Control
VSD Cooling Protection
VSD Cooling Source
Auxiliary VSD Cooling Control
Line Voltage
Line Frequency
Chilled Liquid Pump Operation
Hot Gas Bypass
Flow Switch Input
Power Failure Restart
3. Setpoints > Setup > Schedule
Enable or Disable Scheduled
Operation
Set up Site Schedule if required and
select enabled
4. Setpoints > Setup > User
Data Display Mode
System Language
Date Format
5. Setpoints > Setup > Comms
Baud
Data Bits
Parity
Stop Bits
Chiller ID
6. Setpoints > Setup > Printer
Automatic Printer Logging
Log Start Time
Output Interval
Printer Type
7. Setpoints > Setup > Sales Order
Enter Commissioning Date here
Enter the Compressor Model. It must
be of the format M2C-***FAC, where
*** is the impeller size from the
compressor nameplate.
Ensure the data is entered and obtain
a printout or export to SD.
8. Setpoints > Setup > Operations
Control source
9. Variable Speed Drive
Input Job Full Load Amps
Model YVAM Start-up Checklist4

10. Evaporator
Refrigerant
Smart Freeze
11. Condenser
High Pressure Warning Threshold
12. Condenser > Refrigerant Level Control
Sub Cooling Setpoint
Start Up Position
Start Up Delay
Ramp Time
13. Compressor > Surge Protection
Shutdown enabled
Count Window
Count Limit
Surge Sensitivity
14. Compressor > VGD Actuator
VGD Stroke Calibration Complete LED lit
VGD Feedback Calibrated LED lit
I. Chiller operation
1. Evaluate the evaporator water flow
indication compared to the design
information found on the sales order. If
shell pressure drop is used, it must be
within ±15% of the rating information.
2. After the chiller is at full load at design
Leaving Chilled Liquid Temperature,
capture the Operating Data to print or save
to a text file. Forms 160.88-OM1 or 160.88-
M2 explain how to capture data from the
panel.
J. Chiller setpoints print
1. Capture the chiller Setpoints to print or to a
text file from the Setpoints-Print command.
Model YVAM Start-up Checklist 5

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