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FORM 160.67-O2
ISSUE DATE: 10/9/2020
VERIFY THE COMPRESSOR PRE-ROTATION
VANE OPERATION
The chiller cannot be started until the pre-rotation
vanes have been calibrated. On standard YST chill-
ers, the pre-rotation vanes are calibrated at the factory
during functional testing. For retrofit applications, the
vanes must be calibrated per the OptiView™ Control
Center Service Instructions Form 160.67-M3. After
completing the calibration, the operation must be veri-
fied. While viewing the AUTO/MANUAL SCREEN,
place the pre-rotation vanes in Manual and manually
drive the vanes fully open and then fully closed while
observing the position indicator on the operating shaft.
When the PRV control signal is set to 0% in the Man-
ual mode, the vane actuator closed limit switch (VMS)
may not be activated. Place the control signal back to
the Auto mode to activate the switch.
VERIFY THE HOT GAS BYPASS AND
SUBCOOLER LEVEL CONTROL VALVE
OPERATION
While viewing the AUTO/MANUAL SCREEN, place
each valve in Manual and manually drive the valve
fully closed and then fully open while observing the
position indicator on the operating shaft. The hot gas
valve is fully closed when the flats on the valve stem
are perpendicular to the pipe it is installed in.
PREPARE THE STEAM CONDENSER
HOTWELL AND PUMPS
Ensure that the water level in the hotwell is at approxi-
mately 50% (refer to Figure 5 on page 17). If the
water level is less than 50%, close the drain valve and
open the main isolation valve at the edge of the base
frame. Open the valve next to the fill connection on
the hotwell and fill the hotwell to approximately 62%.
While viewing the CONDENSATE SCREEN on the
OptiView™ Control Center, verify that the condensate
level display is indicating the correct level.
Ensure that the high and low level switches are secured
at the correct elevations per Figure 5 on page 17.
Check each switch function by viewing the switch in-
dicators on the CONDENSATE SCREEN and raising
and lowering the hotwell liquid level. The switch in-
dicator will display OPEN when the level reaches the
switch actuation point.
Ensure that the Hotwell Pump Motor Protector Over-
load Switches are both in the OFF position.
JOHNSON CONTROLS
SECTION 2 - PRE-STARTUP AND SYSTEM OPERATING PROCEDURES
BUMP test the condensate pump and standby pump (if
supplied) motors for proper rotation. The easiest way
to do this is to first put the selected pump in the Man-
ual mode using the Pump Mode key on the CONDEN-
SATE SCREEN, and immediately place the selected
hotwell pump motor protector overload switch in the
Power Panel in the ON position (within 10 seconds)
and immediately back to the OFF position after the
pump starts. In the Manual Mode, if the pump motor
does not start within 5 seconds after the pump start is
initiated an alarm is sounded. Since the standby pump
will not start (Overload switch is OFF), the Mode key
will revert back to Auto after 5 seconds and the Pump
Run Output will go off. The condensate pump should
rotate clockwise when viewed from the back of the
motor. If pump runs backwards, interchange two wires.
Reverse operation can cause extensive
damage to the pump. Failure to correct the
rotation could result in injury or property
damage.
Before starting a condensate pump, open the suction-
side isolation valve, both vent line valves and partially
open the discharge valve of the selected pump and the
standby pump (if supplied). Start the pump by plac-
ing the hotwell pump motor protector overload switch
in the Power Panel in the ON position and using the
hotwell Pump Mode key to manually start the selected
pump. Slowly open the discharge valve allowing the
level controller to react to the change in the level. The
hotwell fill valve may be opened to make up water
used to fill the condensate discharge piping. When the
level appears to be stable, close the fill line valve and
open the discharge valve fully.
Verify the operation of the level control system by
adding water to the hot well and viewing the action of
the valves. As the level in the hot well increases, the
I/P transducer pneumatic output signal to the valves
should decrease to open the overboard valve and close
the recirculation valve. Refer to the PID Tuning sec-
tion of the OptiView™ Control Center Service Instruc-
tions Form 160.67-M3 for more details on the hotwell
level control tuning parameters.
Check piping connections for leaks. Pipe unions and
flanges may loosen during shipment.
necessary.
After testing, return the pump to the AUTOMATIC
mode.
2
Retighten as
23
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