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Johnson Controls YORK YVAM 0350 - User Manual

Johnson Controls YORK YVAM 0350
162 pages
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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

Table of Contents

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Johnson Controls YORK YVAM 0350 Specifications

General IconGeneral
ModelYVAM 0350
CategoryChiller
Cooling Capacity350 tons
RefrigerantR-134a
Phase3
Voltage460V
Sound Power LevelVaries with model and operating conditions. Consult factory for specific data.

Summary

General Safety Guidelines and Symbols

Safety Symbols

Symbols used to alert readers to specific situations and hazards, indicating potential for death, injury, or damage.

Document and Literature Information

Changeability of this document

Information subject to change without notice due to product improvement policies.

Associated literature

Lists related manual descriptions and their corresponding form numbers for further reference.

Conditioned Based Maintenance Program

Describes the CBM service plan for chiller maintenance, leveraging real-time and historical data.

Nomenclature Explanation

System Nomenclature

Explains the naming conventions for system components, including unit type, frame size, and refrigerant.

Compressor Nomenclature

Details the naming conventions for compressor components like motor, design level, and rotation.

Vessel Nomenclature

Defines the naming conventions for vessel components such as evaporator, heat exchanger, and waterboxes.

System Fundamentals and Components

System Components Overview

Lists the main components of the YORK Model YVAM Centrifugal Liquid Chiller.

Compressor Details

Describes the compressor as a single-stage centrifugal type with a hermetic electric motor.

Motor Specifications

Details the compressor motor type, bearings, and control center functions.

Heat Exchanger Description

Explains the evaporator shell fabrication and internal heat exchanger tube enhancements.

Evaporator Functionality

Describes the evaporator as a shell and tube heat exchanger with a distributor trough.

Condenser Design

Details the condenser's microchannel design, cooling fans, and sub-cooling function.

Waterbox Construction

Provides specifications for the removable compact waterboxes, including pressure ratings and nozzle connections.

Refrigerant Flow Control Mechanism

Explains how refrigerant flow is controlled via the condenser drain valve to maintain subcooling setpoint.

Variable Speed Drive (VSD) Function

Describes the VSD's role in varying compressor motor speed by controlling electrical power.

Power Panel Components

Details the power panel's uninterruptable power supply and storage battery for essential loads.

Optional Service Isolation Valves

Explains the function and mandatory open status of optional service isolation valves during operation.

System Operation Description and Controls

System Operation Overview

Explains the chiller's operation, heat transfer process, and refrigerant circuit flow.

Capacity Control Strategies

Discusses modulating capacity through compressor speed, VGD, and hot gas bypass.

Anti-Surge Minimum Frequency

Details the calculation and application of the active anti-surge minimum frequency for VSD speed.

Smart Freeze Protection Feature

Explains the Smart Freeze feature to prevent shutdowns from brief chilled liquid flow fluctuations.

Surge Protection Mechanism

Describes the surge protection feature's detection of surge events and reaction to excess surging.

System Operating Procedures

Pre-starting Procedures

Outlines necessary checks and conditions before initiating chiller startup.

Chiller Start-Up Sequence

Details the sequence of events and conditions required for a successful chiller start-up.

Chiller Operation Sequence

Describes the operational sequence upon start request, including VSD pre-charging and motor runs.

Chilled Liquid Control Settings

Covers temperature setpoint, automatic shutdown, and restart parameters for chilled liquid.

Temperature Control Setpoint Configuration

Explains how the Leaving Chilled Liquid Temperature setpoint is programmed locally or remotely.

Automatic Temperature Shutdown Logic

Defines the LCHLT cycling offset for automatic chiller shutdown based on load conditions.

Automatic Temperature Restart Logic

Defines the LCHLT cycling offset for automatic chiller restart after low temperature shutdown.

Operator Setpoints Quick Reference

Provides a quick reference to common operator setpoints and their locations within the interface.

Stopping the Chiller System

Details the procedure for stopping the chiller using soft stop or safety stop buttons.

Safety Stop Functionality

Explains the safety stop button's purpose for maintenance and immediate shutdown.

Operating Logs and Data Logging

Describes how to maintain daily records of system conditions and use automatic data logging.

Fault Shutdown Conditions

Explains the two types of fault conditions: Cycling and Safety shutdowns.

Prolonged Shutdown Procedure

Provides a procedure for shutting down the chiller for an extended period, like winter season.

Restart After Prolonged Shutdown

Details the steps for restarting the chiller after it has been shut down for a long period.

Freeze Damage Protection Measures

Outlines critical steps to protect the evaporator against freeze damage in subfreezing temperatures.

Physical Data and Unit Conversion

YVAM Model Physical Specifications

Presents physical data for the YVAM model, including dimensions, weights, and component details.

SI Metric Unit Conversion Factors

Provides conversion factors for common measurements from English to SI Metric units.

OptiView Control Center Navigation and Functions

Screen Navigation Overview

Describes how to navigate between screens and categorize information into Display Only, Programmable, and Navigation.

Display Only Fields Explanation

Explains read-only parameters displayed on the OptiView panel, including value representations.

Programmable Values and Access Levels

Details values that can be changed by users, requiring specific access levels for modification.

Access Level Management

Outlines the View, Operator, and Service access levels and their permissions.

Setpoint Programming Procedure

Provides a step-by-step procedure for programming setpoints on the control center interface.

Manual Controls and Free Cursor Usage

Explains manual control buttons and the free cursor function for setpoint adjustment.

Screen Navigation Methods

Describes how to move between screens using navigation buttons and soft keys.

Language and Analog Input Settings

Covers language selection and valid display ranges for analog input values.

Home Screen Interface

Describes the default Home screen display and its visual representation of the chiller.

System Screen Overview

Provides a general overview of common chiller parameters displayed on the System screen.

Evaporator Screen Details

Displays a cutaway view of the evaporator and its related setpoints and operating status.

Condenser Screen Information

Displays the air-cooled condenser with heat ejection animation and related parameters.

Compressor Screen Functionality

Shows a cutaway view of the compressor, impeller, and associated conditions and parameters.

Magnetic Bearing Controller Screens

Displays orientation of magnetic bearing axes and parameters transmitted from the MBC.

Magnetic Bearing Controller Details

Provides detailed orientation and parameters from the MBC, similar to the MBC screen.

Surge Protection Screen

Displays compressor parameters related to the surge protection feature and setpoints.

Variable Geometry Diffuser (VGD) Screen

Displays information pertinent to the VGD operation, including position and command status.

Power Panel Screen Information

Displays information on the uninterruptable power supply (UPS) and storage battery.

Capacity Control Screen Parameters

Displays parameters for capacity control, including pressure overrides and anti-surge control.

Variable Speed Drive (VSD) Screen

Displays information pertaining to the variable speed drive's operational parameters.

VSD Details Screen Functionality

Provides more detailed parameters associated with the variable speed drive for maintenance.

VSD Cooling Screen Parameters

Displays information related to the VSD cooling system and its control parameters.

Motor Details Screen Information

Displays information on motor temperature monitoring, including winding and housing temperatures.

Setpoints Screen for Configuration

Provides a convenient location for programming common setpoints and navigating to setup screens.

Remote Control Screen Operations

Allows users to view remote control status and change certain setpoints.

Setup Screen for System Configuration

The top-level screen for general configuration parameters like time, date, and chiller specifications.

Schedule Screen for Operation Times

Allows defining standard and exception start/stop times for chiller operation.

User Screen for Customization

Used to define custom User IDs, passwords, and assign custom passwords to users.

Comms Screen for Communication Setup

Allows definition of necessary communications parameters for the chiller.

Printer Screen Setup and Reports

Allows definition of communication parameters and setup for the printer.

Sales Order Screen Data

Displays sales order parameters, including commissioning date and model information.

Operations Screen Overview

Allows definition of general parameters related to the chiller's operation.

History Screen for Fault Browsing

Allows browsing through faults and provides reporting of system conditions at shutdown.

History Details Screen Printout

Displays an on-screen printout of all system parameters at the time of a selected shutdown.

Custom Screen for Troubleshooting

Allows display of technician-selected parameters for troubleshooting specific issues.

Custom Setup Screen Parameter Selection

Allows selection of up to 10 parameters for display on the Custom screen.

Trend Screen for Data Visualization

Displays graphical trending of selected parameters and provides access to graph setup.

Trend Setup Screen Configuration

Configures the trending screen by selecting parameters and setting Y-axis values.

Common Slots Screen for Trending Data

Displays slot numbers of commonly monitored parameters for trending selection.

Master Slot Numbers List

Provides a master list of slot numbers for use with the Trend feature.

Display Messages Overview

Explains status bar messages and their associated colors and meanings.

Status Messages Reference

Lists and describes various status messages displayed on the chiller's status line.

Run Messages Reference

Lists and describes messages indicating the chiller's operational status while running.

Routine Shutdown Messages

Lists and describes routine shutdown messages like LOCAL STOP and REMOTE STOP.

Cycling Shutdown Messages

Describes cycling shutdown messages and the conditions that trigger them.

Safety Shutdown Messages

Lists and describes safety shutdown messages and their recovery procedures.

Drive Operation and System Components

OptiSpeed Compressor Drive Overview

Details the OSCD design, its purpose, and key features for the YVAM chiller.

OptiSpeed Compressor Drive Features

Highlights specific features of the HYP0490B drive model, including ground fault detection and liquid cooling.

Smart Sensor System Functionality

Explains the smart sensor system for early detection of overheating due to electrical connections.

OptiSpeed Drive Details (0490 B Amp)

Details the internal circuitry of the OSCD, including power modules and cooling systems.

Harmonic Filter Benefits

Explains the benefits of the integrated input harmonic filter for improving power factor and reducing interference.

Harmonic Filter General Information

Discusses the integrated harmonic filter, its components, and advantages.

OSCD Operation with YVAM Chiller

Describes the OSCD's pre-charge process and motor control for HYP drives.

Maintenance Procedures and Schedules

Preventative Maintenance Requirements

Lists daily, weekly, monthly, yearly, and other maintenance procedures for YVAM chillers.

Electrical Isolation Procedures

Details procedures for isolating electrical power and plant fluid flow for service.

Operating Inspections Schedule

Provides a list of weekly and monthly inspections to avoid operating difficulties.

Annual Maintenance Checks

Lists annual checks for evaporator, condenser, and compressor drive motor.

Checking System for Leaks

Explains how to perform leak testing on the refrigerant system.

Vapor Connection Locations Identification

Identifies vapor connection locations for proper system service and leak testing.

System Pressure Test Procedure

Details how to perform a system pressure test after leak repair and charging.

Gas Pressure Hold Test Procedure

Provides steps for monitoring system pressure over time for leak detection.

Soap Visual Gas Leak Test

Explains how to test for leaks using soap solution and a leak detector.

Optional Trace Gas Leak Test

Details the procedure for using trace gas and a detector to find leaks.

System Evacuation Process

Outlines procedures for evacuating the system to a dry state.

Vacuum Dehydration Steps

Provides instructions for evacuating and dehydrating the system in the field.

Dehydration Process Guidance

Explains the dehydration process and factors affecting its duration.

Conducting Dehydration Process

Details the steps for performing the dehydration process using a vacuum pump.

Conducting Final Evacuation

Outlines the steps for conducting the final evacuation after pressure testing.

Refrigerant Charging Procedure

Provides critical steps for charging the system with refrigerant, emphasizing vapor-only charging.

Removing Refrigerant Charge for Service

Details the procedure for removing refrigerant from the system for service.

Checking and Trimming Refrigerant Charge

Explains how to verify and adjust the refrigerant charge based on operating conditions.

Compressor and Motor Maintenance Checks

Advises checking mounting screws and piping joint nuts for tightness.

Evaporator Maintenance Importance

Emphasizes maintaining the evaporator shell's water side clean and free from scale.

Chemical Water Treatment Recommendations

Recommends chemical water treatment to prevent scale and corrosion in evaporator tubes.

Cleaning Evaporator Tubes

Discusses determining evaporator performance issues and causes of fouled tubes.

Tube Fouling Causes and Types

Identifies types of deposits causing tube fouling, such as rust, sludge, and scale.

Tube Cleaning Procedures

Outlines brush cleaning and acid cleaning methods for evaporator tubes.

Brush Cleaning of Evaporator Tubes

Details the process of cleaning tubes using a soft bristle nylon brush.

Acid Cleaning of Evaporator Tubes

Explains when acid cleaning is required and the preparation steps.

Commercial Acid Cleaning Services

Suggests using commercial organizations for specialized acid cleaning services.

Evaporator Tube Leak Detection

Discusses how evaporator tube leaks can affect refrigerant and water circuits.

Testing for Evaporator Tube Leaks

Provides a step-by-step procedure to locate evaporator tube leaks.

Condenser Maintenance Requirements

Emphasizes regular cleaning of condenser microchannel coils for performance and integrity.

Microchannel Heat Exchanger Cleaning

Outlines essential care points for cleaning MCHX coils to avoid damage.

Cleaning Standard MCHX Coils

Provides a cleaning procedure for Standard and Environment Guard MCHX coils.

Cleaning Environment Guard Premium MCHX Coils

Details the cleaning procedure for Environment Guard Premium MCHX coils with black epoxy coating.

Electrical Controls Checks

Recommends annual checks for tight electrical connections and secure connectors.

Unit Heater Operation Verification

Explains the importance of verifying heater operation for low ambient temperature protection.

Testing Evaporator Waterbox Heaters

Details the procedure for testing evaporator waterbox heaters.

Testing Evaporator Shell Heaters

Outlines the steps for testing evaporator shell heaters.

Testing Heat Trace for Drive Coolant

Describes testing the heat trace for variable speed drive coolant.

Testing VGD Actuator Heater Mat

Details how to measure current and test the VGD actuator heater mat.

Testing MBC Heater Mat

Explains how to measure current and test the MBC heater mat.

Testing Drive Internal Heater

Describes how to measure current and test the internal drive heater.

Testing OptiView Control Panel Heater

Details how to measure current and test the OptiView control panel heater.

Testing OptiView Control Panel Cooler

Explains how to test the OptiView panel cooler operation by adjusting the thermostat.

Testing UPS Panel Heating

Explains that UPS panel heating relies on chiller coolant loop; no direct testing.

Automatic Battery Health Test During Shutdown

Describes how to perform a battery health test from the Power Panel screen.

Printing and System Setup

Printing Overview and Reports

Lists various reports that can be printed from the Control Center.

Acceptable Printers and Requirements

Lists printers compatible with the Control Center and their RS-232 serial interface requirement.

Printer Connection Details

Details specific connections for printers like Okidata OkiPos 441 to the Control Center Microboard.

Printer Setup Procedures

Explains printer configuration steps for models like OKI Data OKIPOS 441.

Brecknell Printer Specifications

Lists specifications and part numbers for the Brecknell CP130 printer.

Control Center Setup Options

Covers chiller ID assignment, printer configuration, and automatic data logging setup.

Automatic Data Logging Configuration

Explains how to set up automatic printing of status reports at specified intervals.

Downloading System Prints to Laptop

Provides instructions for capturing system histories to a file using HyperTerminal.

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