York Yz model a User manual

YZ MODEL A

MAGNETIC BEARING CENTRIFUGAL CHILLER

WITH OPTIVIEW™ CONTROL CENTER

CENTRIFUGAL LIQUID CHILLERS

WITH R-1233zd REFRIGERANT

OPERATIONS AND MAINTENANCE NEW RELEASE Form 161.01-OM1 (618)

Issue Date:

June 8, 2018

035-27132-100

JOHNSON CONTROLS

FORM 161.01-OM1

ISSUE DATE: 6/8/2018

This equipment is a relatively complicated apparatus.

During rigging, installation, operation, maintenance,

or service, individuals may be exposed to certain com-

ponents 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, instal-

lation, 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

IMPORTANT!

READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

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 in-

dividual 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:

Indicates a possible hazardous situation

which will result in death or serious injury

if proper care is not taken.

Indicates a potentially hazardous situa-

tion which will result in possible injuries

or damage to equipment if proper care is

not taken.

Identies a hazard which could lead to

damage to the machine, damage to other

equipment and/or environmental pollu-

tion if proper care is not taken or instruc-

tions and are not followed.

Highlights additional information useful

to the technician in completing the work

being performed properly.

External wiring, unless specied 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 accor-

dance with Johnson Controls’ published specications and must be performed only by a qualied

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 warn-

ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3

FORM 161.01-OM1

ISSUE DATE: 6/8/2018

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for contin-

uous 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 man-

ual owner. Updated manuals, if applicable, can be ob-

tained by contacting the nearest Johnson Controls Ser-

vice office or accessing the Johnson Controls QuickLIT

website at http://cgproducts.johnsoncontrols.com.

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 litera-

ture is available from the owner of the equipment prior

to performing any work on the chiller.

CHANGE BARS

Revisions made to this document are indicated with a

line along the left or right hand column in the area the

revision was made. These revisions are to technical in-

formation and any other changes in spelling, grammar

or formatting are not included.

ASSOCIATED LITERATURE

MANUAL DESCRIPTION FORM NUMBER

Chiller Operations & Maintenance 161.01-OM1

Unit Installation Checklist 161.01-CL1

Unit Startup Checklist 161.01-CL2

Field Connections Diagram - Water Pump Starters 161.01-PW1

Field Control, Modications 161.01-PW2

Field Connections Diagram 161.01-PW3

Wiring Diagram, Unit 161.01-PW4

Liquid Chiller Log Sheet 161.01-MR1

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

JOHNSON CONTROLS

FORM 161.01-OM1

ISSUE DATE: 6/8/2018

Compressor Family

Diffuser Type

Compressor Size Code

Compressor Cycle

A N 030 N A - A A

Motor Configuration

Bearing Configuration

Bearing Family

Motor Family

Motor HP Code

M A 033 A A

Product Family

Stage End Name

Motor End Name

Special Contract

VSD Name

Unit Mod Level

YZ - MA033 AN030 P042N A -

Voltage

VSD Family

Frequency

VSD Output Amp Code

P 042 N A C A ─ 6 6

Impeller Configuration

Flowpath Configuration

Mechanical Configuration

MOTOR END NAMING

STAGE END NAMING

VARIABLE SPEED DRIVE NOMENCLATURE

SYSTEM NOMENCLATURE

Filter

F= No Filter

H= Harmonic Filter

VSD Mod Level

VSD Cooling

Sediment Accumulator Option

LD26924

JOHNSON CONTROLS 5

FORM 161.01-OM1

ISSUE DATE: 6/8/2018

Cond Length (Feet)

LD26925

EVAPORATOR NAMING

Evap Hinges

Evap Water Inlet Side

Evap Water Connection Type

Cond Tube Type

Cond Bundle Fill

Cond Pass Limit

LR = Inlet Left, Outlet Right

LL = Inlet Left, Outlet Left

RL = Inlet Right, Outlet Left

RR = Inlet Right, Outlet Right

F = Flanges

G = Grooved

A = AGS Victaulic

B = Both Waterboxes

N = No Hinges

2, 3 Pass

Cond Hinges

Cond Nozzle Arrangment

Cond Water Connection Type

B = Both Waterboxes

N = No Hinges

F = Flanges

G = Grooved

A = AGS Victaulic

Evap Tube Type

Evap Bundle Fill

Evap Pass Limit

2 , 3 Pass

Evap Family

Evap Diameter (Inches)

Evap Mod Level

Evap Length (Feet)

Evap Bundle Code

Evap Number of Passes

Evap Waterbox Mod Level

Evap Waterbox Family

Evap Waterside DWP

Cond Family

Cond Diameter (Inches)

Cond Mod Level

Cond Bundle Code

A = 3/4 inch Tubes 1 = 1 inch Tubes

C = Compact Welded

M = Marine Welded

1 = 150 psig 3 = 300 psig

1, 2, 3 Pass

Cond Number of Passes

Cond Waterbox Mod Level

Cond Waterbox Family

Cond Waterside DWP

1 = 150 psig 3 = 300 psig

A = 3/4 inch Tubes 1 = 1 inch Tubes

C = Compact

M = Marine

1, 2, 3 Pass

F A 21 12 ─ A 2 Z 750 ─ 2

C A 1 G LR B

EVAPORATOR WATERBOX NAMING

C A 21 12 ─ A 2 Z 750 ─ 2

CONDENSER NAMING

C A 1 G LR B

CONDENSER WATERBOX NAMING

LR = Inlet Left, Outlet Right

LL = Inlet Left, Outlet Left

RL = Inlet Right, Outlet Left

RR = Inlet Right, Outlet Right

JOHNSON CONTROLS

FORM 161.01-OM1

ISSUE DATE: 6/8/2018

TABLE OF CONTENTS

SECTION 1 - SYSTEM FUNDAMENTALS............................................................................................................. 11

System Components ...................................................................................................................................... 11

System Operation...........................................................................................................................................15

Water Circuits .................................................................................................................................................17

SECTION 2 - SYSTEM OPERATING PROCEDURES ...........................................................................................21

Pre-Starting ....................................................................................................................................................21

Start-Up ..........................................................................................................................................................21

Chiller Operation ............................................................................................................................................22

Chilled Liquid Control Settings .......................................................................................................................22

Operator Setpoints Quick Reference .............................................................................................................23

Stopping The System .....................................................................................................................................24

Safety Stop.....................................................................................................................................................24

Operating Logs...............................................................................................................................................24

Fault Shutdowns.............................................................................................................................................25

Prolonged Shutdown ......................................................................................................................................25

Restart After Prolonged Shutdown .................................................................................................................25

SECTION 3 - OPTIVIEW™ CONTROL CENTER FUNCTIONS AND NAVIGATION............................................. 27

Interface Conventions ....................................................................................................................................27

Languages......................................................................................................................................................29

Analog Input Ranges......................................................................................................................................29

Display Messages ..........................................................................................................................................90

Master Slot Numbers List For Use With Trend Feature .................................................................................87

SECTION 4 - VSD OPERATION...........................................................................................................................107

PYT Model VSD Overview ...........................................................................................................................107

PYT Model VSD Components......................................................................................................................107

PYT Model VSD (330, 420, 780, 1020 & 1280 Amp) ...................................................................................108

Harmonic Filter Option .................................................................................................................................108

Critical Load Power ......................................................................................................................................109

SECTION 5 - MAINTENANCE.............................................................................................................................. 119

Preventative Maintenance............................................................................................................................ 119

Renewal Parts ..............................................................................................................................................120

Operating Inspections ..................................................................................................................................120

Checking System For Leaks ........................................................................................................................120

Conduct Pressure Test .................................................................................................................................120

System Evacuation.......................................................................................................................................121

Vacuum Dehydration ....................................................................................................................................121

Conduct Pressure Test .................................................................................................................................124

Refrigerant Charging ....................................................................................................................................124

Checking The Refrigerant Charge................................................................................................................ 124

Handling Refrigerant For Dismantling And Repairs......................................................................................125

Compressor and Motor................................................................................................................................. 125

Condensers and Evaporators.......................................................................................................................125

Electrical Controls ........................................................................................................................................127

Automatic Battery Health Test – During Shutdown.......................................................................................128

JOHNSON CONTROLS 7

FORM 161.01-OM1

ISSUE DATE: 6/8/2018

SECTION 6 - PRINTING .......................................................................................................................................129

Printing Overview .........................................................................................................................................129

Downloading System Prints to a Laptop ......................................................................................................129

SECTION 7 - DECOMMISSIONING, DISMANTLING, AND DISPOSAL .............................................................139

Temperature .................................................................................................................................................140

APPENDIX - MATERIAL SAFETY DATA SHEETS..............................................................................................141

TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS

FORM 161.01-OM1

ISSUE DATE: 6/8/2018

LIST OF FIGURES

FIGURE 1 - YZ Chiller Components (Rear) ............................................................................................................12

FIGURE 2 - YZ Chiller Components (Front)............................................................................................................12

FIGURE 3 - OptiView Control Center......................................................................................................................13

FIGURE 4 - Refrigerant Flow-Thru Chiller...............................................................................................................19

FIGURE 5 - Liquid Chiller Log Sheets.....................................................................................................................24

FIGURE 6 - Home Screen.......................................................................................................................................30

FIGURE 7 - System Screen ....................................................................................................................................32

FIGURE 8 - Evaporator Screen...............................................................................................................................34

FIGURE 9 - Condenser Screen...............................................................................................................................36

FIGURE 10 - Purge Screen.....................................................................................................................................38

FIGURE 11 - Compressor Screen ...........................................................................................................................40

FIGURE 12 - Capacity Control Screen....................................................................................................................42

FIGURE 13 - Magnetic Bearing Controller (MBC) Screen ......................................................................................45

FIGURE 14 - Surge Protection Screen....................................................................................................................47

FIGURE 15 - Variable Geometry Diffuser (VGD) Screen ........................................................................................49

FIGURE 16 - Motor Details Screen .........................................................................................................................50

FIGURE 17 - UPS Screen.......................................................................................................................................52

FIGURE 18 - Motor - Variable Speed Drive (VSD) Screen .....................................................................................54

FIGURE 19 - Variable Speed Drive (VSD) Details Screen...................................................................................... 56

FIGURE 20 - Harmonic Filter Details Screen..........................................................................................................58

FIGURE 21 - Setpoints Screen ...............................................................................................................................60

FIGURE 22 - Setup Screen.....................................................................................................................................62

FIGURE 23 - Schedule Screen ...............................................................................................................................64

FIGURE 24 - User Screen.......................................................................................................................................66

FIGURE 25 - Comms Screen..................................................................................................................................67

FIGURE 26 - Printer Screen....................................................................................................................................68

FIGURE 27 - Sales Order Screen ...........................................................................................................................70

FIGURE 28 - Operations Screen.............................................................................................................................72

FIGURE 29 - Remote Control Screen .....................................................................................................................73

FIGURE 30 - History Screen ...................................................................................................................................74

FIGURE 31 - History Details Screen .......................................................................................................................76

FIGURE 32 - Custom Screen..................................................................................................................................77

FIGURE 33 - Custom Setup Screen........................................................................................................................78

FIGURE 34 - Trend Screen .....................................................................................................................................80

FIGURE 35 - Trend Setup Screen...........................................................................................................................82

FIGURE 36 - Advanced Trend Setup Screen ..........................................................................................................84

FIGURE 37 - Common Slots Screen.......................................................................................................................86

FIGURE 38 - Drive Cabinet Door (PYT330, PYT420, PYT780 & PYT1020) ........................................................ 110

FIGURE 39 - Drive Cabinet Door (PYT1280)........................................................................................................ 110

FIGURE 40 - Drive Cabinet Model PYT330 .......................................................................................................... 111

FIGURE 41 - Drive Cabinet Model PYT420 .......................................................................................................... 111

FIGURE 42 - Left Side of Drive Cabinet Model PYT780....................................................................................... 112

FIGURE 43 - Right Side of Drive Cabinet Model PYT780..................................................................................... 113

FIGURE 44 - Left Side of Drive Cabinet Model PYT1020..................................................................................... 114

FIGURE 45 - Right Side of Drive Cabinet Model PYT1020................................................................................... 115

FIGURE 46 - Left Side of Drive Cabinet Model PYT1280..................................................................................... 116

FIGURE 47 - Right Side of Drive Cabinet Model PYT1280................................................................................... 117

FIGURE 48 - Evacuation of Chiller........................................................................................................................122

FIGURE 49 - Saturation Curve..............................................................................................................................123

FIGURE 50 - Communications Block Diagram......................................................................................................131

FIGURE 51 - OptiView Panel to PC Serial Cable..................................................................................................131

FIGURE 52 - Sample Printout (Status or History) .................................................................................................132

FIGURE 53 - Sample Printout (Setpoints).............................................................................................................133

FIGURE 54 - Sample Printout (Schedule).............................................................................................................135

JOHNSON CONTROLS 9

FORM 161.01-OM1

ISSUE DATE: 6/8/2018

FIGURE 55 - Sample Printout (Sales Order).........................................................................................................135

FIGURE 56 - Sample Printout (Security Log Report)............................................................................................136

FIGURE 57 - Sample Printout (Trend Data New or Existing Points).....................................................................137

FIGURE 58 - Sample Printout (Custom Screen Report) .......................................................................................137

LIST OF FIGURES (CONT'D)

LIST OF TABLES

TABLE 1 - Input Current Limit Threshold ................................................................................................................22

TABLE 2 - Temperature Setpoint ............................................................................................................................23

TABLE 3 - Input Current Limit Threshold ................................................................................................................23

TABLE 4 - Analog Input Ranges .............................................................................................................................29

TABLE 5 - Status Messages ...................................................................................................................................90

TABLE 6 - Run Messages.......................................................................................................................................91

TABLE 7 - MBC Startup Messages.........................................................................................................................91

TABLE 8 - Start Inhibit Messages ...........................................................................................................................91

TABLE 9 - Warning Messages................................................................................................................................92

TABLE 10 - Routine Shutdown Messages..............................................................................................................94

TABLE 11 - Cycling Shutdown Messages...............................................................................................................95

TABLE 12 - Safety Shutdown Messages ..............................................................................................................101

TABLE 13 - Maintenance Requirements............................................................................................................... 119

TABLE 14 - System Pressures .............................................................................................................................122

TABLE 15 - Approximate Refrigerant and Water Weight ......................................................................................125

TABLE 16 - SI Metric Conversion .........................................................................................................................140