AIR-COOLED SCREW LIQUID CHILLERS - Johnson …

1 AIR-COOLED SCREW . LIQUID CHILLERS . INSTALLATION, OPERATION, MAINTENANCE Supersedes (315) Form (616). 035-20552-000. YCAV STYLE A. MODELS YCAV0157-0267, 60 HZ. (150-260 TONS). E/V HIGH EFFICIENCY AND S/P STANDARD EFFICIENCY. LD10477. R134a Issue Date: June 30, 2016. FORM (616). IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES. This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or During rigging, installation, operation, maintenance, death to themselves and people at the site. or service, individuals may be exposed to certain com- ponents or conditions including, but not limited to: This document is intended for use by owner-authorized heavy objects, refrigerants, materials under pressure, rigging, installation, and operating/service personnel.

2 It rotating components, and both high and low voltage. is expected that these individuals possess independent Each of these items has the potential, if misused or training that will enable them to perform their assigned handled improperly, to cause bodily injury or death. It tasks properly and safely. It is essential that, prior to is the obligation and responsibility of rigging, instal- performing any task on this equipment, this individual lation, and operating/service personnel to identify and shall have read and understood the on-product labels, recognize these inherent hazards, protect themselves, this document and any referenced materials. This in- and proceed safely in completing their tasks. Failure dividual shall also be familiar with and comply with to comply with any of these requirements could result all applicable industry and governmental standards and in serious damage to the equipment and the property in regulations pertaining to the task in question.

3 SAFETY SYMBOLS. The following symbols are used in this document to alert the reader to specific situations: Indicates a possible hazardous situation Identifies a hazard which could lead to which will result in death or serious injury damage to the machine, damage to other if proper care is not taken. equipment and/or environmental pollu- tion if proper care is not taken or instruc- tions and are not followed. Indicates a potentially hazardous situa- Highlights additional information useful tion which will result in possible injuries to the technician in completing the work or damage to equipment if proper care is being performed properly. not taken. External wiring, unless specified as an optional connection in the manufacturer's product line, is not to be connected inside the control cabinet.

4 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 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 warn- ing will void the manufacturer's warranty and cause serious damage to property or personal injury. 2 Johnson CONTROLS. FORM (616). CHANGEABILITY OF THIS DOCUMENT. In complying with Johnson Controls' policy for con- regarding the applicability of these documents, rig- tinuous product improvement, the information con- ging, lifting, and operating/service personnel should tained in this document is subject to change without verify whether the equipment has been modified and notice.

5 Johnson Controls makes no commitment to if current literature is available from the owner of the update or provide current information automatically equipment prior to performing any work on the chiller . to the manual or product owner. Updated manuals, if applicable, can be obtained by contacting the nearest CHANGE BARS. Johnson Controls Service office or accessing the John- Revisions made to this document are indicated with a son Controls QuickLIT website at http://cgproducts. line along the left or right hand column in the area the revision was made. These revisions are to technical in- It is the responsibility of rigging, lifting, and operating/ formation and any other changes in spelling, grammar service personnel to verify the applicability of these or formatting are not included.

6 Documents to the equipment. If there is any question Johnson CONTROLS 3. FORM (616). The control /VSD Cabinet contains lethal High AC and DC voltages. Before performing service inside the cabinet, remove the AC supply feeding the chiller and verify using a non-contact voltage sensor. The DC Voltage on the VSD DC Bus will take 5 minutes to bleed off, after AC. power is removed. Always check the DC Bus Voltage with a Voltmeter to assure the capacitor charge has bled off before working on the system. NEVER short out the DC Bus to discharge the filter capacitors. NEVER place loose tools, debris, or any objects inside the control Panel/VSD. Cabinet. NEVER allow the control Panel VSD Cabinet doors to remain open if there is a potential for rain to enter the panel.

7 Keep doors closed and assure all latches are engaged on each door unless the unit is being serviced. ALWAYS lockout the disconnect supplying AC to the chiller . The 1L Line Inductor will reach operating temperatures of over 300 F. DO. NOT open panel doors during operation. Assure the inductor is cool whenever working near the inductor with power off. 4 Johnson CONTROLS. FORM (616). TABLE OF CONTENTS. SECTION 1 - GENERAL chiller SECTION 3 - RIGGING, HANDLING & STORAGE. INFORMATION & SAFETY. DELIVERY AND MOVING THE Lifting Standards for UNIT RESPONSIBILITY FOR ABOUT THIS SECTION 4 - INSTALLATION. MISUSE OF Suitability for LOCATION Structural OUTDOOR Mechanical INDOOR General LOCATION Pressure 11 VIBRATION 11 Rotating 11 SHIPPING Sharp 11 CHILLED LIQUID Refrigerant & 11 General High Temperature & Pressure 11 WATER Emergency 11 CONNECTION TYPES & COOLER SECTION 2 - PRODUCT DESCRIPTION Option REFRIGERANT RELIEF VALVE DUCTWORK General System General ELECTRICAL POWER 115 VAC control SUPPLY Flash Tank Feed / Drain control PANEL Oil Separator / Oil VOLTS FREE Relief Chilled LIQUID Pump Oil Run Capacity Alarm Power and control SYSTEM Microprocessor & VSD Flow Remote Optional Remote Setpoint Offset Unit Optional Remote Setpoint Offset Sound Variable Speed Drive (VSD).

8 18. ACCESSORIES & SECTION 5 - COMMISSIONING. Single Point Circuit Building Automation System (BAS) Condensor Coil PREPARATION - POWER DX COOLER SERVICE VALVE Refrigerant UNIT Service and Oil Line Compressor SOUND REDUCTION VIBRATION Isolation / UNIT control PRODUCT IDENTIFICATION Power Johnson CONTROLS 5. FORM (616). TABLE OF CONTENTS (CONT'D). chiller ELECTRONIC Water Flow Temperature Sensor(s)..37 chiller control Programmed Relay Output Programmed VSD (Variable Speed Drive)..161. Date & AC to DC Start / SCR Trigger Setpoint & Remote DC Link FIRST TIME 1L Line AC to DC Unit Laminated Bus VSD Logic Oil control Panel to VSD Refrigerant IBGT Gate Driver Current Condensor & Fan DV/DT Output Suppression Suction Super Flash Tank Feed/Drain Valve DC Bus Voltage Isolation General chiller Circuit SECTION 6 - TECHNICAL DATA chiller CONFIGURATION Number of Compressors Configuration 168.

9 WATER PRESSURE DROP VSD LOGIC TO chiller MICROPROCESSOR. GLYCOL CORRECTION BOARD RS-485 COMMUNICATION. WATER TEMP. AND CONFIGURATION PHYSICAL OPERATING LIMITATIONS AND SOUND 48 MAX VSD ELECTRICAL ELECTRICAL SECTION 7 - OPERATION. ELEMENTARY WIRING CONNECTION OPERATING LOCATION BASIC OPERATING NUMBER OF COMPRESSORS TO TECHNICAL DATA (CLEARANCES)..122 WEIGHT DIST. & ISOLATOR Standard ISOLATOR MOUNTING Optional Optimized SEISMIC ISOLATOR MINIMUM VSD COMPRESSOR. NEOPRENE ISOLATOR START/RUN 1" DEFLECTION ISOLATOR Minimum VSD Start REFRIGERANT FLOW Minimum VSD Run PROCESS & INSTRUMENTATION 134 ACCELERATION/DECELERATION RATE. COMPONENT WHEN STARTING & STOPPING. EQUIPMENT START-UP CHECK Unit Checks (NO power)..152 VSD Acceleration/ Deceleration Panel Checks STANDARD IPLV CAPACITY (Power ON-both system switches OFF).

10 154 Fuzzy Logic Programmed Hot Water Chilled LIQUID Lag Compressor Operation in Load Date/Time, Daily Schedule, & Clock OPTIONAL IPLV CAPACITY Initial Fuzzy Check Subcooling & Hot Water Leak LOAD LIMITING 6 Johnson CONTROLS. FORM (616). TABLE OF CONTENTS (CONT'D). FLASH TANK DRAIN/FEED VALVE UNIT SETUP DEFAULT PROGRAMMABLE Valve Controller & control Algorithm ..185 SERIAL PORT ECONOMIZER ANALOG INPUT CONDENSER FAN DIGITAL INPUT VSD TEMPERATURE control /FAN ANALOG OUTPUT control DIGITAL OUTPUT REMOTE TEMPERATURE RESET ISN COMMUNICATIONS & TRANSMITTED DATA 284. Local Current Limit Pulldown Current Limit SECTION 9 - MAINTENANCE. REMOTE CURRENT LIMIT RESET ..194. Sound Limit R-134A CONVERSION SECTION 8 - MICROPANEL General MAINTENANCE VSD OPERATION & TROUBLESHOOTING VSD Cooling and Cooling EVACUATING A VSD WARRANTY IBGT Gate Driver (Hardware) New Power Supply (Hardware) Reconditioned or Replacement UNIT All Warranties are VIOD UNIT CHILLED LIQUID & SUCTION TEMP.