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EQUIPMENT PRE-STARTUP AND STARTUP …

JOHNSON CONTROLS 1 Supersedes: 201.28-CL2 (1017) EQUIPMENT PRE-STARTUP AND STARTUP CHECKLIST MODEL YVAA Form 201.28-CL2 (318) The following work must be completed in accordance with the installation instructions:

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JOHNSON CONTROLS1Supersedes: (1017)EQUIPMENT PRE-STARTUP AND STARTUP CHECKLISTMODEL YVAAForm (318)The following work must be completed in accordance with the installation instructions:7. Check the control panel to ensure it is free of foreign material (wires, metal chips, tools, documents, etc.). Also check for signs of water or moisture. Ensure door gasket seals are sealing properly and incoming power wiring conduit is caulked. ........................................ .....8. Visually inspect wiring (power and control). Wiring MUST meet , CE, and local codes. 9. Check tightness of the incoming power wiring. ........................................ ..........................10. Does the field wiring match the 3-phase power requirements of the chiller (Refer to the chiller nameplate)? ........................................ ...............11. Is a flow switch is connected between Terminals 2 and 13 on the User Terminal Block 1TB in the panel? It is recommended that the auxiliary pump contacts be placed in series with the flow switch for additional protection, if the pump is turned OFF during chiller operation. Whenever the pump contacts are used, the coil of the pump starter should be suppressed with an RC suppressor (031-00808-000)......................... ..........................12. Is all control wiring connected correctly to the user input terminals? ........................................ ..13. Apply power to the chiller and assure the compressor heaters are turned on 24 hours prior to system startup. .......................PRE-STARTUP UNIT CHECKS (NO POWER)The following basic checks should be made with the customer power to the unit switched : Proper electrical lock out and tag procedures must be the system 24 hours prior to initial start:1. Inspect the unit for shipping or installation damage. Repair as needed. ...............................2. Has all piping been completed?...........................3. Are there refrigerant or water piping leaks? Repair as needed. ........................................ ......4. Open each system liquid shut off valve, economizer shut off valve, discharge shut off valve and oil line ball valve. ...............................5. Adjust spring isolators (if installed) and assure they are not bottomed out. .................................6. Are water pumps on? Check and adjust water pump flow rate preferably using an ultra sonic flow meter. Otherwise adjust pressure drop across the evaporator. .......................................C AUTION: Excessive flow may cause catastrophic damage to the : ____________________________________ADDR ESS: _____________________________________PHO NE: ________________________________________ JOB NAME: ____________________________________LOCA TION: ______________________________________CU STOMER ORDER NO: ___________________________JCI CONTRACT NO: _______________________________CHILLER MODEL NO: ________________________________________ The work (as checked below) is in process and will be completed by: _________________ / _______________ / ______________MMDDYYYYUNIT SERIAL NO: ________________________________________ ___JOHNSON CONTROLS2FORM ISSUE DATE: 03/12/2018 EQUIPMENT STARTUP CHECKLISTNOTE: Before proceeding with the following unit checks, verify the heaters have been run for 24 hours prior to starting the UNIT CHECKS (NO POWER)The following basic checks should be made with the customer power to the unit switched : Proper electrical lock out and tag procedures must be Open each system liquid shut off valve, economizer shut off valve, discharge shut off valve and oil line ball valve. If optional eductor and suction valves are installed, be sure to open them. Failure to open the eductor valve will result in Eductor Clog faults. .............................2. Is the oil separator oil level(s) maintained so that an oil level is visible in the sight glass when a compressor is running at full speed for 15 to 30 minutes? An oil level may not be visible in the sight glass when the compressor is OFF or running below full speed; and it may be necessary to run the compressor at full speed to obtain a level. In shutdown situations and at some load points, much of the oil may be in the evaporator and the level in the separator may fall below the bottom sight glass. .......................Sight glasses will vary in type depending upon the manufacturer. One type will have balls that float in the sight glasses to indicate level. Another type will have a bulls' eye glass. The bulls' eye glass will tend to appear to lose the lines in the bulls' eye when the level is above the glass. Be careful when viewing the sight glass not to confuse a full sight glass with an empty sight glass. Oil level should be visible, but not above the top of the sight glass after operating at full speed for 15 to 30 minutes. In the rare situation where oil levels are high, drain the oil to lower the level until it is visible in the sight glass. This should be done while operating at full speed. Oil levels in the oil separator above the top of the sight glass should be avoided and may cause excessive oil carryover in the system. High oil concentration in the system may cause nuisance trips resulting from low discharge superheat, low solution pressure and incorrect readings from temperature sensors. Temperature sensor errors may result in poor refrigerant control and liquid overfeed to the compressor. Excessive oil will also reduce evaporator the unlikely event it is necessary to add oil, connect a YORK oil pump to the charging valve on the oil separator, but do not tighten the flare 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 flare nut joint, allowing the air to be expelled, and tighten the flare nut. Open the compressor oil charging valve and pump in oil until it reaches the proper level as described Are water pumps are ON? Check and adjust water pump flow rate preferably using an ultra sonic flow meter. Otherwise adjust pressure drop across the evaporator. ...............................CAUTION: Excessive flow may cause catastrophic damage to the Check status of condenser fans. Blades should rotate freely and not hit shield. Refer to Fan information in Section 6 - Commissioning of the Form ........................................ .5. Check tightness of the incoming power wiring inside the power panel and inside the motor terminal boxes. ........................................ ...........6. Check for proper size fuses in control circuits. ........................................ .......................7. Does the field wiring match the 3-phase power requirements of the chiller? (Refer to chiller nameplate) .................................8. Are all water temperature sensors inserted completely in their respective wells and coated with heat conductive compound? .......................9. Is the liquid line temperature sensor tightly strapped on the liquid line and insulated? ...........10. Is the glycol level in the VSD cooling system 9 to 15 inches (23 to 28 cm) from the top of the fill tube? This check should be performed prior to running the pump. ........................................ .......CAUTION: Never run the glycol pump without coolant! Running the glycol pump without coolant may damage the pump fill the system with approved YORK coolant (P/N 013-03344-000) to avoid damage to the pump, cooling system heat sinks and the chiller. Overheating of the heat sinks and power panel will also Are the remote start/stop for Sys #1 on Terminals 2 to 15 and Sys #2 on Terminals 2 to 16 closed on the User Terminal Block 1TB to allow the systems to run? If remote cycling devices are not utilized, place a wire jumper between these terminals. ....................................JOHN SON CONTROLS3 FORM ISSUE DATE: 03/12/201812. Is a flow switch connected between Terminals 2 and 13 on the User Terminal Block 1TB in the panel? Throttle back flow to ensure the flow switch opens with a loss of flow at the minimum recommended flow. It is recommended that auxiliary pump contacts be placed in series with the flow switch for additional protection, if the pump is turned OFF during chiller operation. Whenever the pump contacts are used, the coil of the pump starter must be suppressed with an RC suppressor (031-00808-000). ......................B. STARTUP PANEL CHECKS (POWER ON BOTH SYSTEM SWITCHES OFF)WARNING: You are about to turn power on to this machine. SAFETY IS NUMBER ONE! Only qualified individuals are permitted to service this product. The qualified individual furthermore is to be knowledgeable of, and adhere to, all safe work practices as required by NEC, OSHA, and NFPA 70E. Proper personal protection is to be utilized where and when Is the chiller OFF/ON UNIT switch at the bottom of the keypad is OFF? ........................................ CAUTION: DO NOT apply power to the chiller unless the 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 Apply 3-phase power to the chiller. Turn ON the optional panel circuit breaker if supplied ..............3. Is the control panel display illuminated ................4. Are the system switches under the SYSTEM SWITCHES key in the OFF position? This ensures the compressors from starting. ...............5. Does the voltage supply correspond to the unit requirement and is it within the limits given in Section 5 - Technical Data in Form ........................................ ..6. Are the heaters on each compressor ON using a clamp-on ammeter? Heater current draw is approximately 3A. ........................................ .......7. Are the Factory Set overload potentiometers on the VSD Logic Board set correctly? Press the VSD DATA key and use the arrow keys, to scroll to the compressor overload settings. In the unlikely event that they are not set correctly, adjust the potentiometers until the desired values are achieved. ........................................ ...WARNING: The VSD is powered up and live. High voltage exists in the area of the circuit board on the bus bars, VSD Pole Assemblies, and wiring to the input the potentiometers, if needed, using Table 20 Compressor Motor Overload Settings in the IOM (Form ) The potentiometers are System 1=R19 and System 2=R64. Record the Overload Potentiometer settings below:R19 = System 1 = ______________ AmpsR64 = System 2 = ______________ AmpsCAUTION: Incorrect settings of the potentiometers may cause damage to the equipment. 8. Press the STATUS key. If the following message appears, immediately contact Johnson Controls Product Technical Support. The appearance of this message may mean the chiller has lost important factory programmed information. The serial number and other important data may need to be reprogrammed. ..................................UNIT WARNING: INVALID SERIAL NUMBER ENTER UNIT SERIAL NUMBERNOTE: Changing the programming of this feature requires the date and time to be set on the chiller prior to p rogramming. Additional information regarding this message and how to enter the serial number with the factory provided password is outlined in the Serial Number Programming. 9. Program the required options into the Panel for the desired operating requirements (Refer to Section 8 in Form ). Record the values below: . ...................................Displ ay Language = ________________________Chilled Liquid Mode = _______________________Local/Remote Mode = _______________________Display Units = _____________________________Lead/Lag Control =__________________________Remote Temperature Reset = _________________Remote Current Reset = _____________________Remote Sound Limit ________________________Low Ambient Cutout ________________________CAUTION: Damage to the chiller could result if the options are improperly CONTROLS4FORM ISSUE DATE: 03/12/2018 C. PROGRAMMED VALUES1. Program the required operating values into the microprocessor for cutouts, safeties, etc., and record them below (Refer to Section 8 in Form ). ........................................ ...Suction Pressure Cutout =__________ PSIG (kPa)Low Ambient Cutout = ________________ F Leaving Chilled Liquid Temperature Cutout = _________________ FMotor Current Limit = _________________ % FLAPulldown Current Limit = ______________ % FLAPulldown Current Limit Time = __________ MINSubcooling Setpoint = ________________ FRemote Unit ID # = ________________________Sound Limit Setpoint = ________________ %Eductor Differential = _________________ FEductor Safety Time = ________________ MINMotor Temp Unload = _________________ FD. CHILLED LIQUID SETPOINTProgram the Chilled Liquid Setpoint/Range and record: ........................................ ............................1. Local Cooling Setpoint = ____________ F2. Local Cooling Range = _____ to ______ F3. Maximum Remote Temperature Reset = _______ to ______ FE. DATE/TIME, DAILY SCHEDULE, AND CLOCK JUMPER1. Set the date and time. ........................................ ..2. Program the Daily Schedule start and stop times. ........................................ ...........................3. Place the panel in Service Mode and turn on each fan stage one by one. Ensure the fans rotate in the correct direction, so air flow exits the top of the chiller. ........................................ .....4. Ensure the Data Logging feature is enabled. .......5. To ensure the glycol level in the VSD cooling system is 9 to 15 inches (23 to 28 cm) from the top of the fill tube while running, remove the fill tube cap, place the chiller in the Service Mode and start the pump. Be sure to re-install the cap before stopping the glycol pump to avoid overflow as the glycol pump is turned OFF. The glycol system holds about to gallons of coolant (P/N 013-03344-000). .............................6. Check the optional fan VSD programming (if equipped). ........................................ ...............F. INITIAL STARTUPAfter the control panel has been programmed and the compressor heaters have been energized for at least 8 hours (ambient temperature more than 96 F or 24 hours (ambient temperature less than 86 F, the chiller may be placed into Turn on the UNIT switch and program the system switches on the keypad to the ON position. ........................................ .................2. If cooling demand permits, the compressor(s) will start and a flow of refrigerant will be noted in the sight glass, after the anti recycle timer times out and the precharge of the DC Bus is completed. After several minutes of operation, the bubbles in the liquid line sight glass will disappear and there will be a solid column of liquid when the Condenser Drain (Flash Tank Feed) Valves stabilize. ........................................ .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 startup, the compressor may make sounds different from its normal high-pitched sound. This is due to the compressor coming up to speed and the initial lack of an oil film sealing the clearances in the rotors. This should be of no concern and lasts for only a short time. ........................................ ....................4. Check the system operating parameters. ............G. REFRIGERANT CHARGE1. Record the level of refrigerant in the evaporator sight glass with each system operating at full speed for 15 to 30 minutes. A refrigerant level should be visible in each evaporator sight glass. ......................................LD 15053 System #1System #22. Remove charge if the level is above the sight glass and add charge if the level is below the sight glass. ........................................ ..................H. OIL LEVELSRecord the oil level in the oil separator sight glass with each system operating at full speed for 15 to 30 minutes. An oil level should be visible in the sight glass, but not above the sight glass. System #1System #2To pGlassBottomGlassLD15054Sight GlassJOHNSON CONTROLS5 FORM ISSUE DATE: 03/12/2018I. LIQUID LINE SUBCOOLINGRecord the liquid Line Subcooling from the panel display after operating at full speed for 15 to 30 1 Liquid Subcooling __________________ FSys 2 Liquid Subcooling __________________ FJ. LOG READINGS Record the following temperatures and pressures from the panel display:Chilled Liquid Temperature: ________________ FVSD Frequency: ________________________ HzSys 1 Oil Pressure: _____________________ PSIGSys 1 Discharge Pressure: ______________ PSIGSys 1 Suction Pressure: ________________ PSIGSys 1 Condenser Liquid Pressure: ________ PSIGSys 1 Oil Temperature: ___________________ FSys 1 Eductor Temperature: _______________ FSys 1 Condenser Liquid Temp: _____________ FSys 1 Subcooling: _______________________ FSys 1 Saturated Liquid Temp: ______________ FSys 1 Discharge Temp: ___________________ FSys 1 Discharge Superheat: _______________ FSys 1 SAT Discharge Temp: ________________ FSys 1 Flash Tank Level: ___________________ %Sys 1 Economizer Valve: __________________ %Sys 1 Condenser Subcooling: ______________ FSys 1 Condenser Drain Valve: ______________ % (Flash Tank Feed Valve)Sys 1 Condenser Fans # ON: ________________SYS 1 VSD Fan Speed: ___________________ %Sys 1 VI Step Solenoid 1: __________________Sys 1 VI Step Solenoid 2: __________________Sys 1 Run Time: ____D____HR___MIN___SECSys 2 Oil Pressure: ____________________ PSIGSys 2 Discharge Pressure: ______________ PSIGSys 2 Suction Pressure: ________________ PSIGSys 2 Condenser Liquid Pressure: ________ PSIGSys 2 Oil Temperature: ___________________ FSys 2 Eductor Temperature: _______________ FSys 2 Condenser Liquid Temp: _____________ FSys 2 Subcooling: _______________________ FSys 2 Saturated Liquid Temp: ______________ FSys 2 Discharge Temp: ____________________ FSys 2 Discharge Superheat: _______________ FSys 2 SAT Discharge Temp: _______________ FSys 2 Superheat: _________________________ FSys 2 SAT Discharge Temp: ________________ FSys 2 Flash Tank Level: ___________________ %Sys 2 Economizer Valve: __________________ %Sys 2 Condenser Subcooling: ______________ FSys 2 Condenser Drain Valve: ______________% (Flash Tank Feed Valve)Sys 2 Condenser Fans # ON: ________________SYS 2 VSD Fan Speed: ___________________%Sys 2 VI Step Solenoid 1: __________________Sys 2 VI Step Solenoid 2: __________________Sys 2 Run Time: ___D____HR____MIN___SECK. LEAK CHECKING1. Leak check compressors, fittings, and piping to ensure there are not any leaks. ...................... If the chiller is functioning satisfactorily during the initial operating period with no safety trips; and the chiller controls chilled liquid temperature; the chiller is now ready to be placed into Renaissance Drive, New Freedom, Pennsylvania USA 17349 Subject to change without notice. Printed in USACopyright by Johnson Controls 2017 ALL RIGHTS RESERVEDForm (318)Issue Date: March 12, 2018 Supersedes: (1017)

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