Model YVAM Startup Checklist

Form Number: 160.88-CL2 (1121)

New Release
Issue Date: 2021-11-09

Startup checklist
Customer:
Job name:
Address:
Location:
Phone:
Customer order number:
JCI telephone number:
JCI order number:
JCI contract number:

Chiller model number:

Unit serial number:
The work (as checked below) is in progress
___________________ /___________________ /___________________
and will be completed by (MM/DD/YYYY):

The following work must be completed in accordance with installation instructions:

A. General
Review the installation checklist, Form 160.88-CL1,
to validate that the actions have been completed.
Attach a completed copy for records.
1. Water connection inlet and outlet are at
correct locations, have hangers nearby
that can support their weight, and show no
visible strain on chiller nozzles.
2. Check for refrigerant or water piping leaks.
Repair as needed.
3. Verify that the chiller is charged with
refrigerant and that the pressures
match refrigerant saturation for ambient
temperature.
4. Verify that the unit isolators are set up in
accordance with 160.88-N1.
5. Verify that the evaporator pressure
transducer isolation valve is open.
6. Verify that the condenser pressure
transducer isolation valves are open.
7. Verify that the discharge pressure
transducer (stall transducer) isolation valve
is open.
8. Verify that the compressor discharge
isolation valves are open.
9. Verify that the liquid line isolation valve is
open.
10. If hot gas is present, verify that the hot gas
bypass line isolation valve is open.
11. Verify that the motor liquid cooling angle
valve from the liquid line at the inlet to the
level control valve is open.
12. Verify that the motor stator liquid cooling
strainer service capped ball valve below the
motor is open.
13. Check the VSD, single point power panel,
UPS panel, waterbox heater panel, and
control panel to ensure that they are free of
foreign material, for example wires, metal
chips, tools, documents. Also check for
signs of water or moisture.
14. Ensure that door gasket seals are sealing
correctly and that incoming power wiring
conduit is caulked
15. Ensure that a jumper is installed on
OptiView™ TB6 terminal 21 to 24.
16. Power the chiller and ensure that the
battery disconnect switch on the power
panel is closed to allow the battery to
charge (12.8 VDC is required for startup).
17. If the unit is equipped with SC-EQ, set up
according to 450.50-N1, Section 2.
 18. Check the tightness of the power supply
connection to the water box heater kit, if
applicable. Make sure the waterproofing
level of connection can meet IP65.
19. Ensure that all water temperature sensors
are inserted completely in their respective
wells and are coated with heat conductive
compound.
B. Electrical
Review the appropriate manuals, 160.88-PW1, 160.88-
PW2, and 160.88-M3 to complete the following
actions:
WARNING
Correct electrical lockout and tagout procedures
must be followed.
D. Chiller power up
1. Ensure that the incoming power wiring is
not aluminum. Copper wire must be used.
2. All Main power wiring connections must be
made in accordance with Form 160.88-PW1.
3. If the power source is transferable from
utility to generator and from generator to
utility, ensure there is a 10 second delay
between the transfers of power sources.
4. Visually inspect the power wiring and
control wiring. Wiring must meet NEC, CE,
and local codes.
5. Ensure that the field wiring matches the
three-phase power requirements of the
chiller. Refer to the chiller nameplate.
6. If the power factor correction capacitors
are applied between the power source and
the VSD, they must be removed or turned
off.
7. Ensure that the power supply connection
to waterbox heater kit is correctly made, if
applicable.
C. Single point power panel
1. Ensure that wiring is completed from the
single point power supply to the HYP drive.
2. Ensure that there are no penetrations in to
the drive enclosure other than the factory
provided connections.
Note: Do not cut power wire to length or con-
nect power wire to the single point power panel
without supervision from a Johnson Controls
representative.
2 Model YVAM Startup Checklist
3. Measure and cut power wire to length
outside of the power panel enclosure. Use a
tool designed to cut large diameter power
wire.
4. Ensure that the conduit connections are
made at the single point power panel as
outlined in 160.88-PW1. No other enclosure
penetrations are allowed.
5. Inspect power feed terminations torque
marks to the drive circuit breaker.
6. Ensure that wiring to the single point
power panel is complete.
7. Verify that the circuit breaker settings
match the settings shown in the
OptiSpeed™ VSD service manual. Refer to
160.88-M3.
8. Ensure that external control wiring is
completed in accordance with 160.88-PW2 .
WARNING
You are about to turn on the power of this
machine. Safety is number one. Only qualified
individuals are permitted to service this product.
The qualified individual furthermore must be
knowledgeable of, and adhere to, all safe work
practices as required by NEC, OSHA, and NFPA
70E. Use correct personal protection equipment
(PPE) where and when required.
CAUTION
Do not apply power to the chiller unless the
chilled water system is filled with water or glycol.
If the chiller is equipped with the -20°F option,
applying power to an empty chilled liquid system
will cause the evaporator immersion heaters to
fail.
1. Apply three-phase power to the chiller.
2. Check that the control panel display is
illuminated.
3. Navigate to the VSD screen and verify that
the line voltage supply corresponds to the
unit data plate requirement and is in the
limits given in the Technical data section in
Form 160.88-OM1.
4. Confirm that the power supply to waterbox E. Chilled water pumps
heater kit is either 115 V/60 Hz or 220 V/50 Check the following:
Hz. If the evaporator is filled with water in
waterside, turn on the two-pole-breaker 1. Verify that the chilled water pump is wired
inside of the waterbox heater kit. for chiller control in locations where sub-
freezing conditions are possible. Failure to
5. Confirm that all the heaters on the do so will void the warranty.
evaporator can function normally, including
the shell heater and waterbox heaters. 2. Verify that flow rates will not exceed the
upper and lower flow limits of the chiller
6. Confirm that the chilled water pump can according to the chiller rating.
be automatically started by the chiller
controller, especially in the subfreezing
region.
CAUTION
7. Verify heater operation on each of the
following locations. Refer to 160.88-PW2 for
heater power wiring locations and 160.88- Excessive flow may cause catastrophic damage
N1 for more detailed instructions. to the evaporator.
Note: For all of the following checks, the chiller
cannot be operating.
a. Waterbox heater WBH1. Record F. Condenser fans
the value. Check the following:
b. Waterbox heater WBH2. Record 1. Power is available.
the value.
2. Wiring is complete.
c. Evaporator shell heater EVH1.
Record the value.
3. Check rotation.
d. Evaporator shell heater EVH2.
Record the value. 4. Check the status of the condenser fans.
Ensure that the blades rotate freely and do
e. VSD coolant heat trace HT1. not hit the shield. Refer to fan information
Record the value. in 160.88-OM1.
f. VSD coolant heat trace HT2.
Record the value.
G. VSD coolant system
g. VGD actuator heater mat. Record 1. Check that the glycol level in the VSD
the value. cooling system is 9 in. to 15 in. (23 cm to 38
cm) from the top of the fill tube. Perform
h. MBC heater mat. Record the value.
this check before running the pump.

i. VSD internal heater. Record the

value. CAUTION
j. OptiView. Record the value.
Never run the glycol pump without coolant.
k. UPS panel. Record the value. Running the glycol pump without coolant may
damage the pump seals.

2. Always fill the system with approved

YORK® coolant (P/N 013-03344-000) to
avoid damage to the pump, cooling system
base plates, and the chiller, and to prevent
overheating of the base plates and power
panel.

Model YVAM Startup Checklist 3

H. Control panel Date Format
Log on at Service level access to ensure access to
the necessary setpoints. The setpoints that are
site-specific are listed and must be verified to the 5. Setpoints > Setup > Comms
required values. They are grouped by the screen Baud
in which they appear. Enter the as-left value in the
corresponding box for each setpoint.
Start by navigating to the Capacity Data Bits
Control > Setpoints Screen and accept the default
capacity control and level control setpoints with the
Parity
Default Setpoints button on the lower bar. Return
to Home and navigate to each of the following
screens: Stop Bits
1. Setpoints
Remote Analog Input Range Coms 2 Setup

2. Setpoints > Setup Baud (Admin, 38400 required)

Clock
Data Bits (Admin, 8 required)
Enter clock time and date
Parity (Admin, None required)
Liquid Type
Stop Bits (Admin, 2 required)
Refrigerant Selection
Chiller ID
Line Voltage
6. Setpoints > Setup > Printer
Line Frequency Automatic Printer Logging

Chilled Liquid Pump Operation Log Start Time

Head Pressure Control Output Interval

Hot Gas Bypass Printer Type

Flow Switch 7. Setpoints > Setup > Sales Order

Enter Commissioning Date here
Power Failure Restart
Compressor Model must be entered
3. Setpoints > Setup > Schedule and must be of the format M2C-
***FAC, where “***” is impeller size
Enable or Disable Scheduled from the compressor nameplate.
Operation
Ensure data is entered and obtain a
Set up Site Schedule if required and print out.
select enabled
8. Setpoints > Setup > Operations
4. Setpoints > Setup > User
Control source
Data Display Mode
9. Variable Speed Drive
System Language
Input Job Full Load Amps

4 Model YVAM Startup Checklist

 10. Evaporator 4. After the chiller is at full load at design
Leaving Chilled Liquid Temperature,
Refrigerant capture the Operating Data to print or save
to a text file. Forms 160.88-OM1 or 160.88-
Smart Freeze M2 explain how to capture data from the
panel.

11. Condenser
J. Chiller setpoints print
High Pressure Warning Threshold
1. Capture the chiller Setpoints to print or to a
text file from the Setpoints-Print command.
12. Condenser > Refrigerant Level Control
Sub Cooler Level Setpoint

Start Up Position

Start Up Delay

Ramp Time

13. Compressor > Surge Protection

Shutdown enabled

Count Window

Count Limit

Surge Sensitivity

14. Compressor > VGD Actuator

VGD Stroke Calibration Complete LED lit

VGD Feedback Calibrated LED lit

I. Chiller operation
1. Evaluate the cooler and condenser water
flow indication compared to the design
information found on the sales order. If
shell pressure drop is used, it must be
within ±15% of the rating information.
2. While the chiller is starting, verify that the
refrigerant level sensor tracks level from
empty condenser to fully flooded level
sensor probe over the range of <10% to
nearly 100%. Refer to 160.88-M2 if it needs
to be serviced.
3. Adjust the condenser refrigerant liquid
level setpoint to a value that covers the
subcooler top by 1/2 in. to 1 in. (1.3 cm to
2.5 cm) and provides correct evaporator
performance (160.88-M1) with the chiller
running steady. Update the setpoint value
in Section H.12 of this checklist.

Model YVAM Startup Checklist 5

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reserved.