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Johnson Controls York YMC2 Operation And Maintenance

Mod b with optiview. centrifugal liquid chiller with r-134a or r-513a refrigerant
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YMC
Mod B with OptiView™ Control
2
Center
Centrifugal Liquid Chiller with R-134a or R-513A Refrigerant
Operation and Maintenance
Issue Date: 2021-05-10
Form Number: 160.84-OM1 (521)
Supersedes: 160.84-OM1 (321)

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Summary of Contents for Johnson Controls York YMC2

  • Page 1 Mod B with OptiView™ Control Center Centrifugal Liquid Chiller with R-134a or R-513A Refrigerant Operation and Maintenance Form Number: 160.84-OM1 (521) Issue Date: 2021-05-10 Supersedes: 160.84-OM1 (321)
  • Page 2 Mod B with OptiView™ Control Center...

  • Page 3: Table Of Contents

    Contents General safety guidelines..........................7 C o n t e n t s Safety symbols............................. 7 Changeability of this document......................8 Associated literature........................... 8 Conditioned based maintenance...................... 9 Nomenclature............................9 System fundamentals..........................11 System components.......................... 11 Compressor.............................. 11 Motor................................. 11 Heat exchangers............................
  • Page 4 Display only............................28 Programmable........................... 28 Navigation............................29 Languages............................30 Analog input ranges.......................... 30 Home screen............................32 System screen............................ 35 Evaporator screen..........................37 Condenser screen..........................40 Heat pump screen..........................42 Compressor screen........................... 47 Magnetic bearing controller screen....................49 Magnetic bearing controller details screen................... 51 Surge screen............................
  • Page 5 OptiSpeed compressor drive details (0490 and 0774 amp drives)..........141 Smart sensor system..........................142 OptiSpeed compressor drive details (0490A, 0612A, 0730A, and 1278A amp drives)....143 OptiSpeed compressor drive and chiller operation (0490 and 0774 amp models)....154 OptiSpeed compressor drive and chiller operation (0490A, 0612A, 0730A, and 1278A amp models).......................
  • Page 6 Mod B with OptiView™ Control Center...

  • Page 7: General Safety Guidelines

    General safety guidelines Important: Read before proceeding. This equipment is a relatively complicated apparatus. During rigging, installation, operation, maintenance, or service, individuals may be exposed to certain components or conditions including, but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and both high and low voltage.

  • Page 8: Changeability Of This Document

    Johnson Controls makes no commitment to update or provide current information automatically to the manual owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office or accessing the Johnson Controls Knowledge Exchange website at https://docs.johnsoncontrols.com/...

  • Page 9: Conditioned Based Maintenance

    Traditional chiller maintenance is based upon assumed and generalized conditions. In lieu of the traditional maintenance program, a Johnson Controls YORK Conditioned Based Maintenance (CBM) program can be substituted. This CBM service plan is built around the specific needs for the chiller, operating conditions, and annualized impact realized by the chiller.
  • Page 10 Figure 3: Vessel nomenclature Figure 4: Variable speed drive nomenclature Mod B with OptiView™ Control Center...

  • Page 11: System Fundamentals

    System fundamentals System components The YORK Model YMC Centrifugal Liquid Chiller is completely factory-packaged including evaporator, condenser, compressor, motor, variable speed drive, battery power panel, OptiView™ Control Center, and all interconnecting unit piping and wiring (see Figure 5). Figure 5: YMC chiller components Compressor The compressor is a single-stage centrifugal type powered by a hermetic electric motor, on a...

  • Page 12: Evaporator

    Evaporator The evaporator is a shell and tube, hybrid falling film, and flooded type heat exchanger. A distributor trough provides uniform distribution of refrigerant over tubes in the falling film section. Residual refrigerant floods the tubes in the lower section. Suction baffles are located above the tube bundle to prevent liquid refrigerant carryover into the compressor.

  • Page 13: Optional Hot Gas Bypass

    charge in either the evaporator or condenser to allow service access to the system. A refrigerant pump-out unit will be required to isolate the refrigerant.  CAUTION Isolation of the refrigerant in this system must be performed by a qualified service technician. Optional hot gas bypass Hot gas bypass is optional and is used to provide greater turndown than otherwise available for load and head conditions.
  • Page 14 Building Automation System (BAS) allows increased remote control of the chiller, as well as 24-hour performance monitoring via a remote site. An optional circuit board called the SC-EQUIP provides Johnson Controls and YORK mechanical equipment such as the YMC chiller with building automation system (BAS) networking connectivity.

  • Page 15: System Operation Description

    The OptiView panel can be used to control the customer chilled and condenser liquid flow. A set of contacts exists to initiate flow for each shell. Details are in the Field Connections section of the Wiring Diagram (Form 160.84-PW2 and PW4). The chilled water pump contacts close immediately upon execution of a chiller start command.

  • Page 16: Capacity Control

    discharges it into the condenser. Cooling water (or other fluid) flowing through the condenser tubes absorbs heat from the refrigerant vapor, causing it to condense. The cooling water is supplied to the chiller from an external source, usually a cooling tower. The condensed refrigerant drains from the condenser into the subcooler section.

  • Page 17: Anti-Surge Minimum Frequency

    approached, the control will proportionally limit the amount of capacity increase permitted and if exceeded will issue unloading into the capacity control command. Anti-surge minimum frequency In order to maintain sufficient compressor lift to overcome condenser pressure and prevent surge throughout operation, the control maintains and continuously updates a minimum limit for VSD speed.
  • Page 18 output is configurable from the Head Pressure Control screen when the feature is Enabled. Output wiring is described in the Field Connections section of the Wiring Diagram (Form 160.84-PW2 and PW4): Figure 7: Refrigerant flow-through chiller Mod B with OptiView™ Control Center...

  • Page 19: System Operating Procedures

    System operating procedures Pre-starting Before starting the chiller, make sure the display reads SYSTEM READY TO START. The panel can only boot up when line power is available to the VSD transformers and the UPS battery in the power panel is present and connected with its disconnect closed.  CAUTION After periods of waterside maintenance or prolonged shutdown, vent any air from the chiller water boxes prior to starting the water pumps.

  • Page 20: Chiller Operation

    The Start/Stop control depends whether the chiller Control Source is set to Local or one of the Remote types from the chiller Setup - Operations screen. Start is operated: • only the keypad when the chiller is set to local mode, •...

  • Page 21: Chilled Liquid Control Settings

    Chilled liquid control settings Temperature control setpoint The temperature to which the chiller will control the chilled fluid leaving the evaporator must be set by the Operator. The way it is selected depends whether the Operator wants this value set locally or modulated by a remote input.

  • Page 22: Operator Setpoints Quick Reference

    ramped from this value to the programmed LCHLT Setpoint at the programmable LCHLT Setpoint Ramp Rate (default 0.1°F/second). This keeps the chiller from undershooting setpoint excessively during pulldown. Any time the programmed setpoint is changed during operation, the active setpoint is ramped to the new value at this rate. Automatic temperature shutdown The temperature below the LCHLT setpoint at which the chiller is desired to automatically cycle off when load is less than the chiller minimum capability is programmed from the panel as Leaving...

  • Page 23: Stopping The System

    Figure 8 shows an example log sheet used by Johnson Controls Personnel for recording test data on chiller systems. Log sheets are available in pads of 50 sheets and may be obtained through the nearest Johnson Controls office.

  • Page 24: Fault Shutdowns

    Figure 8: Liquid chiller log sheets Note: A pad of 50 log sheets can be ordered from your local Johnson Controls branch by requesting Form 160.84-MR1. An accurate record of readings serves as a valuable reference for operating the system. Readings taken when a system is newly installed will establish normal conditions with which to compare later readings.

  • Page 25: Restart After Prolonged Shutdown

    If freezing temperatures are encountered while the system is idle, carefully drain the cooling water from the cooling tower, condenser, condenser pump, and the chilled water system- chilled water pump and coils. Open the drains on the evaporator and condenser liquid heads to assure complete drainage.
  • Page 26 Table 6: Water flow rate limits in GPM (LPM) – based upon standard tubes at design full load conditions Evaporator Condenser Evaporator model Condenser model 1 pass 2 pass 3 pass 1 pass 2 pass 3 pass 1170 4690 2350 1280 2020 2020...
  • Page 27 Table 6: Water flow rate limits in GPM (LPM) – based upon standard tubes at design full load conditions Evaporator Condenser Evaporator model Condenser model 1 pass 2 pass 3 pass 1 pass 2 pass 3 pass 1960 7850 3930 2500 2020 7270...

  • Page 28: Optiview Control Center Functions And Navigation

    OptiView control center functions and navigation Interface conventions Each screen description in this document will begin with a section entitled Overview which will describe the graphical elements on the screen and give a short summary of the functions available. Each element on the screen will then be categorized into three distinct groups: Display Only, Programmable, and Navigation.

  • Page 29: Navigation

    Change setpoints On screens containing setpoints programmable at the OPERATOR access level, a key with this label will be visible if the present access level is VIEW. This key brings up the Access Level prompt described above. It allows the user to login at a higher Access Level without returning to the Home Screen.

  • Page 30: Languages

    with the graphics for that screen. The following is a layout of all the screens and how they are connected. Figure 9: Screen layout and navigation Languages The screens can be displayed in various languages. Language selection is done on the USER Screen. The desired language is selected from those available.
  • Page 31 Table 7: Analog input ranges English range Metric range Analog input High Units High Units Leaving Chilled Liquid Temperature 82.0 °F -17.7 27.7 °C Return Chilled Liquid Temperature 94.1 °F -17.7 34.5 °C Leaving Condenser Liquid Temperature 133.5 °F -13.3 56.3 °C Return Condenser Liquid Temperature...

  • Page 32: Home Screen

    Home screen Figure 10: Home screen When the chiller system is powered on, the above default display appears. The Home Screen display depicts a visual representation of the chiller itself. Animation indicates chilled liquid flow and/or condenser cooling liquid flow when the flow switch inputs are satisfied. Table 8: Display only fields Field/LED name Description...
  • Page 33 Table 9: Programmable Button Access Description This key allows the user to change Access Level when the Login View correct password is entered at the prompt. This key is displayed when a user is logged in at any level other than VIEW. Pressing it will return the access level to Logout Operator VIEW.
  • Page 34 Table 10: Navigation Button Description A detailed view of the motor and VSD parameters. This allows programming of the Current Limit and the Pulldown Demand Limit values. This screen provides a single location to program the most common system setpoints. It is also the gateway to many of the general system Setpoints setup parameters such as Date/Time, Display Units, Scheduling, Printer Setup, etc.

  • Page 35: System Screen

    System screen Figure 11: System screen This screen gives a general overview of common chiller parameters for both shells. Table 11: Display only fields Field/LED name Description Displays the temperature of the refrigerant in its gaseous state at Discharge Temperature discharge of the compressor as it travels to the condenser.
  • Page 36 Table 11: Display only fields Field/LED name Description Evaporator Saturation Displays the present saturation temperature in the evaporator calculated Temperature from evaporator pressure. Displays the pressure difference between the condenser and evaporator Head Pressure (condenser minus evaporator). Only appears when Head Pressure Control is enabled.

  • Page 37: Evaporator Screen

    Evaporator screen Figure 12: Evaporator screen This screen displays a cutaway view of the chiller evaporator. All setpoints relating to the evaporator side of the chiller are maintained on this screen. Animation of the evaporation process indicates whether the chiller is presently in a RUN condition. Animation of the liquid flow indicates chilled liquid flow.
  • Page 38 Table 13: Display only fields Field/LED name Description Displays the Leaving Chilled Liquid Temperature at which the chiller Leaving Chilled Liquid will restart after it has shutdown on LEAVING CHILLED LIQUID – LOW Temperature Setpoints TEMPERATURE cycling shutdown. This temperature is set as an offset –...
  • Page 39 Table 14: Programmable Button Access Description This value allows the user to define the Leaving Chilled Liquid Temperature that is to be maintained by the chiller. It is programmable over the range of 38.0°F to 70.0°F (water) or 10.0°F to 70.0°F (brine). If Smart Freeze (see below) is Local Leaving Chilled enabled, the range is 36.0°F to 70.0°F (water).

  • Page 40: Condenser Screen

    Condenser screen Figure 13: Condenser screen This screen displays a cutaway view of the chiller condenser. All setpoints relating to the condenser side of the chiller are maintained on this screen. Animation indicates condenser liquid flow. This screen also serves as a gateway to controlling the Refrigerant Level. Table 16: Display only fields Field/LED name Description...
  • Page 41 Table 16: Display only fields Field/LED name Description Condenser Liquid Flow Indicates whether flow is present in the condenser. Switch Condenser Liquid Displays the command presently sent by the control center to the Pump (Run/Stop) Condenser Liquid Pump run contacts. Refrigerant Level Displays the present position of the refrigerant level.

  • Page 42: Heat Pump Screen

    Heat pump screen (Software Version C.OPT.18.04.313 and Later) Figure 14: Heat pump screen Heat Pump is an available option on certain models of YMC chillers. The feature is enabled and disabled on the SETUP Screen (Service level required). When enabled, this HEAT PUMP Screen is accessible from the CONDENSER and the EVAPORATOR Screen.
  • Page 43 Table 18: Display only fields Field/LED name Description Displays the Leaving Condenser Liquid Temperature at which the Leaving Condenser Heat Pump will shut down on LEAVING CONDENSER LIQUID – HIGH Liquid Temperature TEMPERATURE cycling shutdown in Heating mode. See Leaving Setpoints –...
  • Page 44 Table 19: Programmable Button Access Description This setpoint can only be changed when the chiller is stopped. This setpoint sets the Heat Pump operation to Unit Control Mode Operator either Cooling (default), Heating or Cooling & Heating operation. This allows the user to define the Local Mode Heat Pump Leaving Condenser Liquid Temperature Setpoint that is to be maintained in Heating mode.
  • Page 45 Table 19: Programmable Button Access Description This setpoint allows the user to specify the Leaving Condenser Liquid Temperature at which the Heat Pump will shutdown on LEAVING CONDENSER LIQUID – HIGH TEMPERATURE cycling shutdown in Heating mode. This is done by defining an offset above the Leaving Condenser Liquid Temperature Setpoint.
  • Page 46 Table 19: Programmable Button Access Description In Heating mode, the existing LEAVING CHILLED LIQUID TEMPERATURE – LOW TEMPERATURE cycling shutdown logic includes an additional check to its existing logic that will cause a shutdown in Heating mode. This setpoint allows the user to specify the Leaving Chilled Liquid Temperature at which the Heat Pump will shut down on LEAVING CHILLED LIQUID –...

  • Page 47: Compressor Screen

    Compressor screen Figure 15: Compressor screen This screen displays a cutaway view of the chiller compressor, revealing the impeller, and shows all conditions associated with the compressor. Animation of the compressor impeller indicates whether the chiller is presently in a RUN condition. This screen also serves as a gateway to subscreens for jumping to capacity control and displaying MBC, Surge and VGD and Power Panel detail.
  • Page 48 Table 22: Navigation Button Description Home Causes an instant return to the Home Screen. Capacity Control Causes an instant transfer to the Capacity Control Screen. Moves to the subscreen allowing view of the Magnetic Bearing Controller parameters and event log. Moves to the subscreen that allows viewing and programming of the Surge Surge Protection feature.

  • Page 49: Magnetic Bearing Controller Screen

    Magnetic bearing controller screen Figure 16: Magnetic bearing controller screen This screen displays the orientation of the magnetic bearing axes relative to the compressor driveline. Pertinent parameters transmitted to the control panel from the Magnetic Bearing Controller (MBC) are displayed on this screen. Many parameters are shown in the diagram in the locations they represent.
  • Page 50 Table 23: Display only fields Field/LED name Description Displays the shaft position in micrometers from center along the radial V24 Position axis designated “V” for the Opposite Impeller End Bearing. Displays the shaft position in micrometers from center along the radial W24 Position axis designated “W”...

  • Page 51: Magnetic Bearing Controller Details Screen

    Magnetic bearing controller details screen Figure 17: Magnetic bearing controller details screen This screen displays the orientation of the magnetic bearing axes relative to the compressor driveline similar to the MBC Screen. Additional pertinent parameters transmitted to the control panel from the Magnetic Bearing Controller (MBC) are displayed on this screen. Many parameters are shown in the diagram in the locations they represent.
  • Page 52 Table 25: Display only fields Field/LED name Description Displays the vibration amplitude for specific frequencies measured axially by the position sensors. Magnetic bearing currents as described for the MBC Screen are repeated on this screen: • W1 (Current) • V1 (Current) •...
  • Page 53 Table 26: Navigation Button Description Home Causes immediate return to the Home Screen. Compressor Causes immediate transfer to the Compressor Screen. Causes immediate return to the MBC Screen. Mod B with OptiView™ Control Center...

  • Page 54: Surge Screen

    Surge screen Figure 18: Surge screen overview This screen displays the chiller compressor and all parameters relating to the Surge Protection feature. All setpoints relating to this screen are maintained on this screen. Table 27: Display only fields Field/LED name Description A parameter that represents the system differential or HEAD Delta P/P...
  • Page 55 Use the Surge Protection feature to define how many surges are excessive and how the control reacts to an excess surge condition. When excess surging is detected, you can configure the chiller to shut down. The sensitivity of this surge detection is set by the Sensitivity Setpoint on this screen. Table 28: Programmable Button Access...

  • Page 56: Variable Geometry Diffuser Screen

    Variable geometry diffuser screen Figure 19: Variable geometry diffuser screen This screen displays information pertinent to the VGD operation. Table 30: Display only fields Field/LED name Description Displays the Stall Detector output voltage (x.xxVdc), as received by the Active Stall Voltage Microboard, from the stall board.
  • Page 57 Table 31: Navigation Button Description Home Causes an instant return to the Home Screen. Compressor Causes an instant return to the Compressor Screen. Mod B with OptiView™ Control Center...

  • Page 58: Power Panel Screen

    Power panel screen Figure 20: Power panel screen This screen displays information pertaining to the power panel, which includes the uninterruptable power supply (UPS) and storage battery for essential loads necessary for shutdown during a line power loss. Table 32: Display only fields Field/LED name Description Indicates the OptiView control voltage digital input voltage is present,...
  • Page 59 Table 32: Display only fields Field/LED name Description Power Panel Indicates the ambient temperature inside the power panel. Temperature Power Panel Cooling Indicates the power panel coolant pump and coil fan are commanded to System Run (LED) run. Line Low Battery Voltage Offset, Inverter Low Battery Voltage These are control setpoints for battery health fault logic.

  • Page 60: Capacity Control Screen

    Capacity control screen Figure 21: Capacity controls screen This screen displays the pertinent parameters associated with capacity control in relation to Leaving Chilled Liquid temperature, current and pressure overrides, and anti-surge control. This screen also provides a means for a service technician to control VGD, Speed, and Optional Hot Gas Bypass Valve manually for maintenance or service.
  • Page 61 Table 35: Display only fields Field/LED name Description Leaving Chilled Liquid Displays the temperature of the chilled liquid as it leaves the evaporator. Displays the active temperature setpoint to which the chiller is set to control liquid leaving the evaporator. The Active Setpoint is a target to the Local, Remote or BAS (ISN) LCHLT programmed setpoint, depending on the control source selected.
  • Page 62 Table 35: Display only fields Field/LED name Description Displays the difference between condenser refrigerant pressure and Head Pressure evaporator refrigerant pressure. Entering Condenser Displays the temperature of the condenser liquid entering the Liquid Temperature condenser. Displays the following for each of the devices that is available: VSD (Variable Speed Drive), VGD (Variable Geometry Diffuser) or HGBP (Hot Gas Bypass Valve) •...

  • Page 63: Variable Speed Drive Screen

    Variable speed drive screen Figure 22: Variable speed drive screen This screen displays information pertaining to the Variable Speed Drive (VSD). Table 37: Display only fields Field/LED name Description Indicates whether the digital output from the controls is commanding Motor Run (LED) the motor to RUN.
  • Page 64 Table 37: Display only fields Field/LED name Description Output Current (RMS) - Displays the RMS current measured to the motor, per phase. Phase A, B, C Displays the variable geometry diffuser position as a value between 0 VGD Position and 100%. Input kVA Displays the supply kVA measured by the VSD.
  • Page 65 Table 39: Navigation Button Description Home Causes an instant return to the Home Screen. Moves to the subscreen which provides more information about the VSD Details Variable Speed Drive. Capacity Control Moves to the Capacity Control Screen. Access level required: SERVICE Motor Details Moves to a subscreen that provides information and setpoints pertinent to the Motor Monitoring feature.

  • Page 66: Variable Speed Drive (Vsd) Details Screen

    Variable speed drive (VSD) details screen Figure 23: Variable speed drive (VSD) details screen This screen displays more detailed parameters associated with the Variable Speed Drive. This screen also provides a means for a service technician to access setpoints or control the DC Bus manually for maintenance or service.
  • Page 67 Table 40: Display only fields Field/LED name Description Phase Rotation Displays the phase rotation sequencing. Output Current Rating Indicates VSD size reported from VSD. Indicates the digital output from the controls is commanding the motor Motor Run (LED) to RUN. DC Bus Regulating Indicates the VSD is regulating the DC Bus.

  • Page 68: Motor Details Screen

    Motor details screen Figure 24: Motor details screen This screen displays information pertinent to the Motor Temperature Monitoring feature. The feature consists of motor winding temperature and motor housing temperature. Also, individual winding temperature sensors can be disabled on this screen. Table 42: Display only fields Field/LED name Description...
  • Page 69 Table 42: Display only fields Field/LED name Description Displays the calculated change in distance from the two axial position Rotor Elongation sensors for the rotor shaft versus the shutdown baseline set at the factory. This indicates thermal growth and torque effect. Estimated Rotor Displays the temperature derived from physical parameters, elongation, Temperature...

  • Page 70: Setpoints Screen

    Setpoints screen Figure 25: Setpoints screen This screen provides a convenient location for programming the most common setpoints involved in the chiller control. This screen also serves as a gateway to a subscreen for defining the setup of general system parameters. Table 44: Display only fields Field/LED name Description...
  • Page 71 Table 45: Programmable Button Access Description This is the range over which an analog signal or a digital signal (PWM) can reset the Leaving Chilled Liquid Local Leaving Chilled Temperature setpoint above the operator programmed Base Setpoint. Programmable as either 10°F, 20°F, 30°F or Liquid Temperature - Operator Range...
  • Page 72 Table 45: Programmable Button Access Description Allows the user to specify the current limit value (as a percentage of Full Load Amps) to which the chiller will be limited during the specified pulldown limit time. This value will override the Input Current Limit value during Pulldown Demand Operator this time period.

  • Page 73: Setup Screen

    Setup screen Figure 26: Setup screen This screen is the top level of the general configuration parameters. It allows programming of the time and date, along with specifications as to how the time will be displayed (12 or 24 hour format). In addition, the chiller configuration, as determined by the state of the Microboard Program Jumpers and Program Switches is displayed.
  • Page 74 Table 48: Programmable Button Access Description Allows the user to specify the present date. This value is critical to logging system shutdowns accurately and for utilizing the scheduling capabilities. When prompted to enter a date value, the user must enter the day, month, Present Date Operator and four-digit year (using leading zeroes as necessary).
  • Page 75 Table 48: Programmable Button Access Description Allows a service technician to select chilled liquid pump control contacts (I/O Board TB2-44/45) operation as either Chilled Liquid Pump Service Standard or Enhanced. service technicians refer to YORK Operation Service Manual (Form 160.84-M2). Allows the service technician to enable or disable the Head Pressure Control feature.
  • Page 76 Table 49: Navigation Button Description Moves to the subscreen displaying the Sales Order information for the Sales Order chiller system. Moves to the subscreen displaying operating parameters of the chiller Operations system. Access Level Required: operator Diagnostics Moves to the subscreen allowing limited diagnostic capability while operating.

  • Page 77: Schedule Screen

    Schedule screen Figure 27: Schedule screen The schedule screen contains more programmable values than a normal display screen. As such, each programmable value is not linked to a specific button. Instead the Select key is used to enable the cursor arrows which are used to highlight the day and the start or stop time the user wishes to modify.
  • Page 78 Table 50: Programmable Button Access Description For each day of the week, the user may specify a time for the Standard Week Start/ chiller to start and a time for the chiller to stop. The times Operator Stop Times specified in this entry week will be used as the default for every week of chiller operation.

  • Page 79: User Screen

    User screen Figure 28: User screen This screen allows definition of custom User ID’s and matching passwords. This allows the building administrator to assign custom passwords to those who are authorized to maintain the chiller. This screen displays attributes assigned to User IDs. There are no other display options. Table 52: Programmable Button Access...

  • Page 80: Comms Screen

    Comms screen Figure 29: Comms screen This screen allows definition of the necessary communications parameters. See Printing for details on the printer connections and setup. Presently, there are no COM 2 communications features available. This screen displays attributes assigned to COMMS IDs. There are no other display options. Table 54: Programmable Button Access...
  • Page 81 Table 55: Navigation Button Description Home Causes an instant return to the Home Screen. Setup Return to the Setup Screen. Mod B with OptiView™ Control Center...

  • Page 82: Printer Screen

    Printer screen Figure 30: Printer screen This screen allows definition of the necessary communications parameters for the printer. See Printing for details on printer connections and setup. Table 56: Display only fields Field/LED name Description Time Remaining Until Displays the time until the next print log will occur, if the function is Next Print enabled.
  • Page 83 Table 58: Navigation Button Description Home Causes an instant return to the Home Screen. Setup Return to the Setup Screen. Mod B with OptiView™ Control Center...

  • Page 84: Sales Order Screen

    This screen allows definition of the sales order parameters. The Commissioning date is entered by the YORK/Johnson Controls service technician at the time of chiller commissioning. These values should never be changed or entered by anyone other than a qualified service technician. Entry instructions are included in the YORK YMC Service Manual (Form 160.84-M2).
  • Page 85 Table 60: Programmable Button Access Description Print Operator This generates a listing of the Sales Order data. Table 61: Navigation Button Description Home Causes an instant return to the Home Screen. Setup Return to the Setup Screen. Mod B with OptiView™ Control Center...

  • Page 86: Operations Screen

    Operations screen Figure 32: Operations screen This screen allows definition of general parameters having to do with the operation of the chiller. Table 62: Display only fields Field/LED name Description Displays the amount of time the chiller has been running since the last start signal was received.

  • Page 87: History Screen

    History screen Figure 33: History screen This screen allows the user to browse through the faults. In order to get a more thorough reporting of the system conditions at the time of the recorded shutdown, move to the History Details subscreen.
  • Page 88 Table 67: Navigation Button Description Home Causes an instant return to the Home Screen. Causes a move to a subscreen containing the value of select chiller View Details parameters at the time of the associated shutdown. Causes a move to a subscreen allowing the user to view trending data on Trending selected chiller parameters.

  • Page 89: History Details Screen

    History details screen Figure 34: History details screen This screen allows the user to see an on-screen printout of all the system parameters at the time of the selected shutdown. Not all screens are shown above. The number of screens required to display all of the data varies according to type of motor starter and options applied.

  • Page 90: Custom Screen

    Custom screen Figure 35: Custom screen This screen allows up to 10 service technician selected parameters to be displayed. These parameters are selected from a list on the Custom View Setup Screen. This allows the service technician to display parameters pertinent to a particular problem during troubleshooting. At completion of the service call, the display can be cleared or the parameters can be left there for monitoring by operations personnel.

  • Page 91: Custom Setup Screen

    Custom setup screen Figure 36: Custom setup screen This screen allows the service technician to select up to 10 parameters for display on the Custom View Screen. Table 73: Display only fields Field/LED name Description Lists the available parameters that can be displayed. The desired Slot Numbers parameters for display are selected from this list.
  • Page 92 Table 74: Programmable Button Access Description Page Up Scroll up through list of available parameters. Page Down Scroll down through list of available parameters. First use the Page Up and Page Down keys to scroll through the Slot Numbers list and note the number of the parameter(s) to be displayed.

  • Page 93: Trend Screen

    Trend screen Figure 37: Trend screen As many as six Operator selected parameters (data points) can be plotted in an X/Y graph format. The X-axis is scaled to the selected Data Collection Interval and displayed in a time of day or elapsed time format, as selected with the X-axis toggle key.
  • Page 94 Table 76: Programmable Button Access Description Pressing this key clears the graph, starts a new graph, sets the time of day to the present clock time and begins the trending. This key is only available if trending is stopped. If the selected Chart Type is TRIGGERED and TRIGGER Start Operator ACTION is set to START, data collection will not begin until...

  • Page 95: Trend Setup Screen

    Trend setup screen Figure 38: Trend setup screen This screen is used to configure the trending screen. The parameters to be trended are selected from the Common Slots Screen or Common Slots Master list and entered as Slot Numbers for Data Points 1 through 6.
  • Page 96 Table 78: Programmable Button Access Description Use the SELECT key as described above and enter the slot number from the Common Slots Screen or Master Slot Number List of the desired parameter to be trended. The Data Point Slot # (1-6) Operator selected parameter description will be displayed for the Data Point.
  • Page 97 the 450 data points. For example, if the Data Collection Interval is programmed for 900 seconds, the parameter would be sampled every 900 seconds, with the last 112.5 hours (4.7 days) of data viewable on the screen. Therefore, the selected interval is a compromise between resolution and full screen time display.

  • Page 98: Advanced Trend Setup Screen

    Advanced trend setup screen Figure 39: Advanced trend setup screen The desired data collection start/stop triggers are setup on this screen. The trend data collection can be set to start or stop based upon the status of up to two selected Triggers. The Triggers can consist of digital events or analog parameters compared to thresholds.
  • Page 99 This screen displays trending start/stop fields. There are no display only fields on this screen. Table 80: Programmable Button Access Description Selects the first parameter to be evaluated. Selection is made from the Slot Numbers listing on the Trend Common Primary Trigger Operator Slots Screen or the Master Slot Numbers List in this manual.
  • Page 100 Table 80: Programmable Button Access Description Selects the second parameter to be evaluated. Selection is made from the Slot Numbers listing on the Trend Common Secondary Trigger Operator Slots Screen or the Master Slot Numbers List in this manual. Setting this slot number to zero disables the Secondary Trigger.

  • Page 101: Common Slots Screen

    Common slots screen Figure 40: Common slots screen This screen displays the slot numbers of the commonly monitored parameters. The slot numbers for the remainder of the available parameters are listed on the Master Slot Numbers List that follows. From these lists, select up to six parameters to be trended. Return to the Trend Setup Screen and enter the parameters Slot Numbers into Data Points 1 through 6.

  • Page 102: Master Slot Numbers List For Use With Trend Feature

    Master slot numbers list for use with trend feature Slot # Description System Chiller Operating State Coastdown Time Remaining Safety Relay Cycling Relay Warning Relay Operating Hours Run Time (in seconds) Number Of Starts Run Permissive Remote Ready To Start External contact Remote Run / Stop Is Multi Unit Cycling Closed...
  • Page 103 Slot # Description 28716 Heating Shutdown Temperature 28718 Heating Delta T 28719 Active Heating Setpoint Subcooling 2059 Sub Cooling Temperature Drop leg refrigerant 2061 Drop Leg Refrigerant Temperature Head pressure control 19108 Head Pressure 19040 Head Pressure Setpoint 19085 PID Control Mode 19075 Control Valve Command Compressor...
  • Page 104 Slot # Description 8354 VGD Shutdown Command 17408 Discharge Pressure Variable speed drive 2305 Motor Run 2306 Motor % FLA 3047 VSD Fault 18085 Input % Full Load Amps 2823 VSD Output Voltage 2822 VSD Output Frequency 20788 Max Chiller Frequency 2818 Input Power 2819...
  • Page 105 Slot # Description 3060 Motor Winding Phase A Temp Z2 End 3061 Motor Winding Phase B Temp Z1 End 3062 Motor Winding Phase B Temp Z2 End 3063 Motor Winding Phase C Temp Z1 End 3064 Motor Winding Phase C Temp Z2 End 19148 Average Winding Temperature 2362...

  • Page 106: Display Messages

    Slot # Description 21014 Current W1 21015 Current W2 21016 Current W3 21017 Current W4 21018 Current Z1A 21019 Current Z2A 21020 Z1 Temperature 21021 Z2 Temperature 21022 MBC Amplifier Temp 21024 Rotor Elongation 21025 Motor Speed 21041 MBC Fault 21042 First Alarm Code 21043...
  • Page 107 To aid in the meaning of the message, messages are displayed in different colors as follows: • Normal Operation messages - Green • Warning messages - Yellow • Cycling Shutdown messages - Orange • Safety Shutdown messages - Red Warning messages will scroll between all those standing. Shutdowns will show first occurrence. Table 85: Status messages Message Description...
  • Page 108 Table 85: Status messages Message Description The chiller has shut down and removed the run signal from the motor variable speed drive (VSD). The system is waiting for confirmation that SYSTEM COASTDOWN the driveline has stopped rotating. When the MBC and VSD report drive frequency of 0Hz for 5 seconds, coastdown is considered completed.
  • Page 109 Table 86: Run messages Message Description VSD – INPUT The chiller input current will be limited by the pulldown demand limit PULLDOWN LIMIT setpoint. The message clears when the pulldown demand time expires. SYSTEM RUN - ACTIVE The chiller is running, and the Optimizer is Active. OPTIMIZER SYSTEM RUN - The chiller is running, and the Optimizer is Passive.
  • Page 110 Table 89: Warning messages Message Description While the chiller state is Stopped, the Saturated Condenser Temperature WARNING - CONDENSER decreased below 35.0 °F. The condenser pump run contacts close. FREEZE THREAT FROM The message is automatically reset and pump contacts return to prior LOW PRESSURE state when either the chiller is not in stopped state or the Saturated Condenser Temperature is >...
  • Page 111 Table 89: Warning messages Message Description The chiller is running and Refrigerant Level > (Refrigerant Level setpoint +15%) OR Refrigerant Level < (Refrigerant Level setpoint -15%) for 10 WARNING - LIQUID continuous minutes. The Warning is bypassed for the first 30 minutes LEVEL SETPOINT NOT of run to allow stabile operation to establish.
  • Page 112 Table 89: Warning messages Message Description During the time the MBC Rotation Mode is commanded ON by the microboard via serial comms this warning is set if the MBC reports WARNING – MBC – Rotation Mode is OFF by serial comms. This warning is inhibited if MBC ROTATION MODE OFF communication is not initiated and during the first 15 seconds after the Rotation Mode is commanded ON.
  • Page 113 Table 89: Warning messages Message Description This is an auto reset warning. The minimum and maximum Battery Voltage that occurs within each 10 second window is stored. At the end of each 10 second window, if the difference between the min and max battery voltage is greater than 0.5 V, a counter is increased.
  • Page 114 Table 89: Warning messages Message Description This auto reset warning is set when all of the following are true: • Control Voltage digital input is high (indicates line power is WARNING – UPS – available) LINE LOW BATTERY • Battery Voltage < Line Low Battery Voltage Threshold VOLTAGE It releases when Battery Voltage >...
  • Page 115 For cycling shutdown messages, the chiller will automatically restart when the cycling condition clears. Table 91: Cycling shutdown messages Message Description The Chilled Liquid Flow Switch has remained open for 5 continuous seconds while the chiller was running, in soft shutdown, or at least 45 CHILLED LIQUID –...
  • Page 116 Table 91: Cycling shutdown messages Message Description The evaporator pressure, as sensed by the Evaporator Transducer, has decreased to the shutdown threshold. For water cooling applications, the shutdown threshold is a fixed value. For Brine cooling applications, the shutdown threshold varies according to the concentration of the Brine solution.
  • Page 117 Table 91: Cycling shutdown messages Message Description The MBC has shutdown the chiller and the control center has not yet received the cause of the fault from the MBC via the serial communications link. The MBC shuts down the chiller by opening the MBC Fault contacts (located on the MBC control board and connected MBC SHUTDOWN –...
  • Page 118 Table 91: Cycling shutdown messages Message Description The MBC has measured shaft displacement is greater than 90 µm from center in the orthogonal radial axis designated V at the opposite- impeller end radial magnetic bearing during Levitation or Rotation MBC – V24 mode over a 7 second window (approximately 2/3 of the air gap LOW FREQUENCY space to the touchdown bearing).
  • Page 119 Table 91: Cycling shutdown messages Message Description The MBC has measured shaft displacement is greater than 100 µm from center in the orthogonal radial axis designated W at the opposite- impeller end radial magnetic bearing during Levitation or Rotation mode (approximately 2/3 of the air gap space to the touchdown MBC –...
  • Page 120 Table 91: Cycling shutdown messages Message Description The Multiunit Cycling contacts connected to I/O Board TB4-9, have opened to initiate a cycling shutdown. If the chiller is running when this MULTIUNIT CYCLING – occurs, the Pre-rotation Vanes are driven fully closed prior to shutting CONTACTS OPEN down the chiller.
  • Page 121 Table 91: Cycling shutdown messages Message Description The variable speed drive contains two temperature sensors, which monitor the unit’s internal ambient temperature. This shutdown is generated when the higher of the two ambient temperatures exceeds a high limit of 158°F (70°C). The unit’s fan(s) and water pump(s) remain energized until the internal temperature drops below 148°F (64°C), VSD –...
  • Page 122 Table 91: Cycling shutdown messages Message Description Upon application of power, all boards go through the initialization process. At this time, memory locations are cleared, program jumper positions are checked and serial communications links are established. If this process is not completed the OptiView panel will indicate this fault.
  • Page 123 Table 91: Cycling shutdown messages Message Description The OptiView panel will determine this fault when the temperature of the motor baseplate phase A has decreased below the low limit of 37°F VSD – LOW PHASE (2.7°C). All phase temperatures have to increase above the fault-reset A MOTOR BASEPLATE threshold of 42°F (5.5°C), for this fault to be cleared.
  • Page 124 Table 91: Cycling shutdown messages Message Description During Pre-charge, the DC Bus voltage must exceed the minimum threshold which is determined by Line Voltage Setpoint (see the following table) within 4 seconds after the pre-charge signal has been commanded. If this condition is not met, this shutdown is generated. The VSD logic board shall wait 10 seconds before clearing the fault and allowing another pre-charge to start.
  • Page 125 VSD – STOP CONTACTS OPEN message. The chiller can be started after manual resets are performed as detailed below. service and troubleshooting information is contained in the YORK YMC2 Service Manual (Form 160.84-M2) and Chiller Service (Form 160.84-M1).
  • Page 126 Table 92: Safety shutdown messages Message Description The condenser pressure exceeded 170 PSIG for shells with 235 PSIG DWP and 264 PSIG for shells with 350 PSIG DWP while the chiller was stopped. The control determines the shell DWP by the condenser model number on the Sales Order CONDENSER –...
  • Page 127 Table 92: Safety shutdown messages Message Description The evaporator pressure, as sensed by the Evaporator Transducer, has decreased to the shutdown threshold and caused cycling shutdown three times in a 90 minute period. For water cooling applications, the shutdown threshold is a fixed value.
  • Page 128 Table 92: Safety shutdown messages Message Description A possible defective Evaporator pressure Transducer or Refrigerant Temperature Sensor has been detected. The control center converts the evaporator pressure to a Saturated Temperature value and compares this value to the optional Evaporator Refrigerant Temperature Sensor. If the difference between these temperatures is greater than 3.0°F, continuously for 1 minute, this shutdown is performed.
  • Page 129 Table 92: Safety shutdown messages Message Description This Safety Shutdown is set when the MBC control board detects a communication error between the control and amplifier boards of the MBC. The MBC Fault contacts open. The MBC remains in Levitation mode with the MBC –...
  • Page 130 Table 92: Safety shutdown messages Message Description MBC – HIGH Main DC supply voltage to the MBC exceeded 165VDC (150+ 10%) INPUT VOLTAGE This Safety Shutdown is set when OptiView software is commanding MBC Levitation Mode ON but the MBC is not reporting Levitated within 15 seconds. MBC –...
  • Page 131 Table 92: Safety shutdown messages Message Description This Safety Shutdown is set when the panel boots up after a power loss has occurred and the buffer data prior to the shutdown showed motor speed > 0, indicating the motor was rotating when the UPS power was lost. If the Power Fail Landing Counter on the MBC Details Screen is <...
  • Page 132 Table 92: Safety shutdown messages Message Description This Safety Shutdown is set when the MBC is commanded to Rotation mode while it is not indicating acceptable to rotate. The MBC Fault contacts open. MBC – SPV The MBC remains in Levitation mode with the motor shaft levitated until UNAUTHORIZED commanded to de-levitate over serial comms.
  • Page 133 Table 92: Safety shutdown messages Message Description This safety shutdown is set when the Compressor Model field entered on the Setpoints – Setup –Sales Order screen does not conform to the format expected. The format is defined below and the data can be found on the compressor nameplate if it ever needs re-entry in the control: SS/LS SS/LS...
  • Page 134 Table 92: Safety shutdown messages Message Description The Microboard’s software Watchdog initiated a Microprocessor reset because it detected that a portion of the chiller operating program was not being WATCHDOG executed. The result of this reset is a Safety shutdown and re-initialization of the –...
  • Page 135 Table 92: Safety shutdown messages Message Description When the unit is stopped in a mode where no command exists to energize the VSD – DC BUS DC Bus, the DC Bus voltage is monitored and checked against a threshold level LOCKOUT –...
  • Page 136 Table 92: Safety shutdown messages Message Description The motor/inverter IGBT module temperatures are continuously monitored by the gate driver board where the highest temperature for each phase is read. The highest temperature is sent to the VSD logic board where the temperature is compared against a threshold value.
  • Page 137 Table 92: Safety shutdown messages Message Description If three consecutive VSD – Phase A, B or C Input DCCT Offset cycling faults occur, VSD – INPUT this safety shutdown is generated to require investigation and manual reset. DCCT OFFSET When the condition clears the chiller can be started after the CLEAR FAULTS key LOCKOUT is pressed.
  • Page 138 Table 92: Safety shutdown messages Message Description This shutdown provides protection to the compressor motor. High levels of VSD – MOTOR current total harmonic distortion (THD) can cause the motor to overheat. Verify CURRENT THD that all wiring is correctly connected between the inverter and the output FAULT harmonic filter.
  • Page 139 Table 92: Safety shutdown messages Message Description If the unit fails to complete pre-charge (due to VSD – PRECHARGE – LOW DC BUS VOLTAGE or VSD – PRECHARGE – HIGH DC BUS VOLTAGE), the VSD shall time 10 seconds before clearing the fault and allowing another pre-charge to start. VSD –...

  • Page 140: Vsd Operation

    VSD operation OptiSpeed compressor drive overview The new YORK OptiSpeed Compressor Drive (OSCD) is specifically designed for the application of ® driving a permanent magnet high speed motor with magnetic bearings used on the YORK Model Centrifugal Liquid Chiller. This type of design allows the chiller to be designed as a complete system, and take full advantage of the strengths of each major component within the system.

  • Page 141: Optispeed Compressor Drive Details (0490 And 0774 Amp Drives)

    except to drain the cooling system. Also the use of a shell and tube heat exchanger is standard on all models. The OSCD can now be configured for many different input voltage levels. Lower input voltages may de-rate the input power rating of the OSCD, but the OSCD will produce the same output voltage and will use the same motor.

  • Page 142: Smart Sensor System

    The higher bus voltage is required for harmonic current correction at the input of the OSCD, and to provide the correct output voltage for high speed operation of the compressor motor. The AC to DC rectifier uses several power devices. Each phase has one or more modules arranged in a parallel connection depending on the amount of input current required.

  • Page 143: Optispeed Compressor Drive Details (0490A, 0612A, 0730A, And 1278A Amp Drives)

    Figure 41: Black flip dot Figure 42: Red flip dot  WARNING A tripped circuit breaker is an indication of a serious fault condition, and must never be reset without an inspection of the drive by certified techinican. OptiSpeed compressor drive details (0490A, 0612A, 0730A, and 1278A amp drives) The 0490A, 0612A, 0730A, and 1278A amp drives have the same basic function as the 0490 and 0774 amp drives, but the precharge of the drive is different.
  • Page 144 bus capacitors, and the current will be limited by the precharge resistors. This 12 second period is called the precharge time. After 12 seconds has passed, a small relay will close, and cause the supply contactor to close. Shortly, after this time the precharge contactor will open. The drive is now precharged and ready to run.
  • Page 145 Figure 43: Left side of drive cabinet (typical for most of the drive models) Note: Variable speed drive model HYP0774 shown. Mod B with OptiView™ Control Center...
  • Page 146 Figure 44: Left side of 1278A amp drive cabinet Mod B with OptiView™ Control Center...
  • Page 147 Figure 45: Right side of drive cabinet HYP0490 Mod B with OptiView™ Control Center...
  • Page 148 Figure 46: Right side of drive cabinet HYP0490A Mod B with OptiView™ Control Center...
  • Page 149 Figure 47: Right side of drive cabinet HYP0612A Mod B with OptiView™ Control Center...
  • Page 150 Figure 48: Right side of drive cabinet HYP0730A Mod B with OptiView™ Control Center...
  • Page 151 Figure 49: Right side of drive cabinet HYP0774 Figure 50: Center and right section of drive cabinet HYP1278A Mod B with OptiView™ Control Center...
  • Page 152 Figure 51: Drive logic board Figure 52: Rectifier side of the power unit HYP0490, HYP0490A, HYP0612A, and HYP0730A Mod B with OptiView™ Control Center...
  • Page 153 Figure 53: Rectifier side of the power unit HYP0774 and HYP1278A Mod B with OptiView™ Control Center...

  • Page 154: Optispeed Compressor Drive And Chiller Operation (0490 And 0774 Amp Models)

    Figure 54: Smart sensor system components location (shown on HYP0490, other models are similar) Callout Description Smart sensor board mounted behind door rail Smart sensors Note: Model HYP1278A has two additional sensors located to the right of the fan upper assembly.

  • Page 155: 1278A Amp Models)

    In April of 2016 the control for the fans and pumps was changed so that they would continue to run 2 minutes after the stop command. This change occurred in software version C.HYP.03.04.01, and C.HYP.04.04.01. During normal chiller run conditions the control panel provides a speed command to the OSCD. The speed command must take into account minimum speed command from the anti-surge control, and the speed required by the leaving chilled liquid temperature control.

  • Page 156: Maintenance

    Maintenance Preventative maintenance It is the responsibility of the owner to provide the necessary daily, monthly and yearly maintenance requirements of the system. In any operating system it is most important to provide a planned maintenance and inspection of its functioning parts to keep it operating at its peak efficiency. Therefore, the following maintenance should be performed when prescribed.

  • Page 157: Renewal Parts

    Johnson Controls Service Office. Important: If a unit failure occurs due to incorrect maintenance during the warranty period; Johnson Controls will not be liable for costs incurred to return the system to satisfactory operation. Electrical isolation...

  • Page 158: Checking System For Leaks

    Monthly (or more often as required) • Log and compare the VSD input voltage current for balanced values in the readings. • Verify that the unit setpoints have not been changed. Check the setpoints in the Security Log screen. • Verify that the evaporator and condenser water flows are within rated limits.
  • Page 159 To make sure that the concentration of tracer reached all parts of the system, slightly open the service valve and test for the presence of gas with a leak detector. Test around each joint and factory weld carefully and thoroughly. To check for tube or tube joint leaks: a.

  • Page 160: System Evacuation

    System evacuation  WARNING Ensure power is removed from the input side of the VSD at all times when the chiller is under vacuum (less than atmospheric pressure). The VSD maintains voltage to ground on the motor when the chiller is off while voltage is available to the VSD.
  • Page 161 Table 94: System pressures Absolute Gauge Boiling temperatures Inches of mercury Millimeters of of water °F (HG) below one psia Microns mercury (HG) standard atmosphere 0 in. 14.6960 760.00 760,000 10.240 in. 9.6290 500.00 500,000 22.050 in. 3.8650 200.00 200,000 25.980 in.
  • Page 162 Operation Dehydration of a refrigerant system can be obtained by this method because the water present in the system reacts much as a refrigerant would. By pulling down the pressure in the system to a point where its saturation temperature is considerably below that of room temperature, heat will flow from the room through the walls of the system and vaporize the water, allowing a large percentage of it to be removed by the vacuum pump.

  • Page 163: Conduct Pressure Test

    During the primary pulldown, keep a careful watch on the wet bulb indicator temperature, and do not let it fall below 35°F (1.6°C). If the temperature is allowed to fall to 32°F (0°C), the water in the test tube will freeze, and the result will be a faulty temperature reading. Conduct pressure test About this task: If a pressure test indicates all joints are not leaking, proceed to test with appropriate refrigerant as...

  • Page 164: Handling Refrigerant For Dismantling And Repairs

    these parameters. Condenser level is detected by the liquid level sensor and controlled to the programmed setpoint by the chiller control logic. Equations • Evaporator Approach = (LELT) - (SET) • Discharge Superheat = (CDGT) - (SCT) Definitions • SET = Saturated Evaporator Temperature •...

  • Page 165: Condensers And Evaporators

    Table 95: Approximate refrigerant and water weight Evaporator Condenser Refrigerant weight lbs (kg) Water weight lbs CB2914 1290 (590) 2640 (1200) EB3314 CB3314 1380 (630) 3310 (1510) EC3312 CB2912 1331 (605) 2863 (1299) EC3314 CB3314 1626 (739) 3589 (1628) CB3314 1908 (867) 4232 (1920) EC3914...

  • Page 166: Cleaning Evaporator And Condenser Tubes

    Cleaning evaporator and condenser tubes Evaporator It is difficult to determine by any particular test whether possible lack of performance of the evaporator is due to fouled tubes alone or due to a combination of troubles. Trouble which may be due to fouled tubes is indicated when, over a period of time, the cooling capacity decreases and the split (temperature difference between water leaving the evaporator and the refrigerant temperature in the evaporator) increases.

  • Page 167: Testing For Evaporator And Condenser Tube Leaks

    In many major cities, commercial organizations now offer a specialized service of acid cleaning evaporators and condensers. If acid cleaning is required, Johnson Controls recommends the use of this type of organization. The Dow Industries Service Division of the Dow Chemical Company, Tulsa, Oklahoma, with branches in principal cities is one of the most reliable of these companies.

  • Page 168: Electrical Controls

    Ensure electrical connections are tight and connectors are secure annually. It is important that the factory settings of controls (operation and safety) not be changed. If the settings are changed without Johnson Controls approval, the warranty will be jeopardized. Automatic battery health test – during shutdown For periodic maintenance or to diagnose battery faults or warnings, a battery health test can be performed.
  • Page 169 If the 10 minute power loss holdup timer runs out (OptiView power will be lost due to turning off UPS Inverter) before the test completes and power is restored the test is considered failed. UPS Battery Health Test Successful is displayed for 10 seconds when the test passes. UPS Battery Health Test Failed –...

  • Page 170: Printing

    Printing Printing overview A printer can be connected to the Control Center’s Microboard to print the following reports. The screen from which each report can be generated is listed in parenthesis. • Status ‑ Present system parameters (Printer, Home) • Setpoints ‑...

  • Page 171: Oki Data

    Different printers require different formatting control codes. Other printers might provide correct operation when connected to the Control Center. However, the print format may not be correct or as required. Proceed with caution and use the following guidelines if an unlisted printer is selected: All printers must be capable of RS-232 serial communications.

  • Page 172: Brecknell

    The following hardware is required: Cable: #18 AWG stranded 50 ft. maximum length • The following connectors are required: • Microboard: None. Strip 1/4 in. insulation from wire and insert into screw terminal block. • Printers: OKI Data - 25 pin plug DB-25P or equivalent; Shell DB-C2-J9 or equivalent. Setting up the printer The selected printer must be configured as follows.

  • Page 173: Control Center Setup

    Figure 58: Breckman printer Control center setup Chiller ID Access level required: operator Using the COMMS Screen, assign an identification number to the chiller. This number will appear atthe top of each report. Printer setup Access level required: operator Using the COMMS Screen, the Control Center must be configured to transmit data in the same format as the printer is configured to receive the data.

  • Page 174: Downloading System Prints To A Laptop

    Downloading system prints to a laptop About this task: Downloading system histories to a file is another useful method to capture system operating conditions. The following instructions are used to establish communication between the OptiView Control Panel and a laptop computer. Connect the laptop computer to the OptiView™...
  • Page 175 RS-232 PIN ASSIGNMENTS (DB25 PC SIGNAL SET) (OLDER DESKTOPS ONLY) Pin 1 Protective Ground Pin 2 Transmit Data Pin 3 Received Data Pin 4 Request To Send Pin 5 Clear To Send Pin 6 Data Set Ready Pin 7 Signal Ground Received line Signal Detector Pin 8 (Data Carrier Detect)
  • Page 176 Figure 61: Sample printout (status or history) Mod B with OptiView™ Control Center...
  • Page 177 Figure 62: Sample printout (status or history) continued Mod B with OptiView™ Control Center...
  • Page 178 Figure 63: Sample printout (setpoints) Mod B with OptiView™ Control Center...
  • Page 179 Figure 64: Sample printout (setpoints) continued Mod B with OptiView™ Control Center...
  • Page 180 Figure 65: Sample printout (schedule) Mod B with OptiView™ Control Center...
  • Page 181 Figure 66: Sample printout (sales order) Mod B with OptiView™ Control Center...
  • Page 182 Figure 67: Sample printout (security log report) Mod B with OptiView™ Control Center...
  • Page 183 Figure 68: Sample printout (trend data new or existing points) Figure 69: Sample printout (custom screen report) Mod B with OptiView™ Control Center...

  • Page 184: Unit Conversion

    To convert a temperature range (i.e., a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556. Example: 10.0°F range x 0.5556 = 5.6 °C range © 2021 Johnson Controls. 5000 Renaissance Drive, New Freedom, York, PA 17349, USA. Subject to change without notice. All rights reserved.

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