Supersedes CL2 (512) Form CL2 (615) STARTUP CHECKLIST PHONE: CUSTOMER ORDER NO: JCI TEL NO: JCI ORDER NO: JCI CONTRACT NO:
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1 YMC 2 - MOD A STARTUP CHECKLIST Supersedes CL2 (512) Form CL2 (615) STARTUP CHECKLIST CUSTOMER: JOB NAME: ADDRESS: LOCATION: PHONE: CUSTOMER ORDER NO: JCI TEL NO: JCI ORDER NO: JCI CONTRACT NO: CHILLER MODEL NO: UNIT SERIAL NO: The work (as checked below) is in process and will be completed by: / / The following work must be completed in accordance with the operation manual: Month Day Year A. GENERAL: Review the Installation Checklist (Form CL1) to validate the attributes have been completed. Attach a completed copy for records. Water connection inlet and outlet are at proper locations, have hangers nearby that would support their weight and show no visible strain on chiller nozzles... Relief piping is complete and puts NO strain on the relief valves... Wiring is complete per PW1 and power feed terminations in the VSD are tight... Confirm any field control wiring modifications are in accordance with Form PW2... Verify the chiller is charged with refrigerant (pressures match R134a saturation for ambient temp)... Verify Evaporator pressure transducer isolation valve is open... Verify Condenser pressure transducer isolation valve is open... Verify the Discharge pressure transducer (stall transducer) isolation valve is open... Verify Compressor Discharge Isolation valve is open... Verify Liquid Line Isolation valve is open... Verify Hot Gas Bypass Line Isolation valve (if hot gas is present) is open... Verify the motor stator liquid cooling angle valve just above the shells, below the motor is open... Verify the motor stator liquid cooling strainer service capped ball valve above the motor is open. Verify the VSD shipping antifreeze solution is drained and fill with inhibited water that shipped with the chiller, per OptiSpeed VSD Service Manual... Verify electrical connections in the VSD are tight, especially motor leads to terminals... If an Optional Circuit Breaker was provided for the VSD, ensure its settings are proper according to Form M3... Check the chiller for refrigerant leaks at joints... Ensure jumper installed on OptiView TB6 terminal 24 to JOHNSON CONTROLS 1
2 FORM CL2 B. CONTROL PANEL: Login at SERVICE level access to ensure access to the necessary setpoints. The setpoints are grouped by the screen in which they appear. Enter the as-left value in the corresponding box for each setpoint. Some are ADMIN-controlled chiller configuration and factory defaults that should not be changed. Those that cannot be changed in SERVICE level access are identified with (ADMIN) after the setpoint name and are intended only to be validated and logged at SERVICE level. Those with recommended settings for proper operation are designated with the setting in parenthesis after the setpoint. Others do require specific setup for the site conditions and consideration of the application. Those most likely requiring site-specific setup are marked with italic text. Ensure each setting is logical for the chiller configuration and application. Refer to forms O2 and M2 for procedures to perform calibrations or explanation of setpoints. Start by navigating to the Capacity Control - Setpoints Screen and accept the default capacity control and level control setpoints with the DEFAULT SETPOINTS button on the bottom bar. Return to Home and navigate to each of the following screens. Setpoints: Remote Analog Input Range... Setpoints: Setup Clock... Enter Clock Time and Date... Liquid Type (Program Jumper dependent).. Refrigerant Selection (fixed)... Line Voltage... Line Frequency... Chilled Liquid Pump Operation... Head Pressure Control... Hot Gas Bypass... Setpoints: Setup: Schedule Enable or Disable Scheduled Operation.. Set up Site Schedule if required and Enabled... Setpoints: Setup: User Data Display Mode... System Language... Date Format... Setpoints: Setup: Comms Baud... Data Bits... Parity... Stop Bits... COM 2 Setup... Baud (ADMIN, required)... Data Bits (ADMIN, 8 required)... Parity (ADMIN, None required)... Stop Bits (ADMIN, 2 required)... Chiller ID... Setpoints: Setup: Printer Automatic Printer Logging... Log Start Time... Output Interval... Printer Type... Flow Switch... Power Failure Restart... 2 JOHNSON CONTROLS
3 FORM CL2 Setpoints: Setup: Sales Order Enter Commissioning Date (record here)... Compressor Model must be entered and must be of the format M1B-xxxFAy, where (xxx) is 197 or 205 and (y) is either the ending A or ending B in the compressor model on the compressor nameplate... Ensure Data is entered and obtain a print (Done)... Setpoints: Setup: Operations Control Source... Evaporator Leaving Chilled Local Setpoint... Remote Range... Shutdown Offset... Restart Offset... Refrigerant... Smart Freeze... Condenser High Pressure Warning Threshold... Condenser: Refrigerant Level Control Condenser: Refrigerant Level Control: Setpoints Startup Position... Startup Delay (ADMIN)... Ramp Time (ADMIN)... Zone Transition Delta (ADMIN)... Zone Transition Time (ADMIN)... Liquid Level: Zone 1 Proportional (ADMIN).. Liquid Level: Zone 1 Integral (ADMIN)... Liquid Level: Zone 1 Derivative (ADMIN)... Liquid Level: Zone 2 Proportional (ADMIN).. Liquid Level: Zone 2 Integral (ADMIN)... Liquid Level: Zone 2 Derivative (ADMIN). Compressor: Surge Protection Shutdown... Count Window... Count Limit... Surge Sensitivity... Compressor: VGD Diffuser Gap Control Mode (Auto)... VGD Calibrate (Done)... Level Control Valve Mode (Auto)... Refr Level Setpoint (running)... JOHNSON CONTROLS 3
4 FORM CL2 Compressor: VGD: Setpoints Surge React Time... Surge Wait Time... Probe Wait Time... Open Pulse... High Limit... Low Limit... PRV VGD Inhibit... PRV Offset... Capacity Control Setpoints LCHLT Setpoint Ramp Rate... LCHLT Setpoint Start Offset... *PRV Start Position... *PRV Shutdown Position... VGD Start Position... VGD Shutdown Position... HGBP Start Position... VSD Start Frequency... VSD Soft Shutdown Ramp Rate (ADMIN)... Temperature Control Kp (ADMIN)... Temperature Control Ti (ADMIN)... Temperature Control Td (ADMIN)... Temperature Control Max Loading Delta (ADMIN)... Temperature Control Max Unloading Delta (ADMIN)... VSD Output Gain (ADMIN)... *PRV Output Gain (ADMIN)... VGD Output Gain (ADMIN)... HGBP Output Gain (ADMIN)... Capacity Control Setpoints: Anti-Surge Tuning *Minimum PRV Position... Min Frequency Multiplier... Min Frequency Offset... Min Freq Rate - HGBP Closed (ADMIN)... Min Freq Rate - HGBP Open (ADMIN)... Min Frequency Admin Multiplier (ADMIN). Transient Time Delay... Transient Deadband... Transient Max Change... Min Frequency Mid Position... Min Frequency Coefficient a1... Min Frequency Coefficient a2... Min Frequency Coefficient a3... Min Frequency Coefficient b1... Min Frequency Coefficient b2... Min Frequency Coefficient b3... *Max VGD Knee PRV (ADMIN)... *Max VGD Knee VGD (ADMIN)... *Max VGD Coefficient a (ADMIN)... *Max VGD Coefficient b (ADMIN)... 4 JOHNSON CONTROLS
5 FORM CL2 Variable Speed Drive C. CHILLER SYSTEM: Input Job Full Load Amps... Local Input Current Limit... Pulldown Demand Limit... Pulldown Demand Time... Variable Speed Drive: VSD Details Test Mode (Disabled)... Manual DC Bus (Disabled)... Manual Cooling (Disabled)... VSD: Motor Details Evaluate cooler and condenser water flow indication compared to design information found on the sales order. If shell pressure drop is used, it should be within +/- 15% of the rating information... As the chiller is started, verify the refrigerant level sensor tracks level from empty condenser to fully flooded level sensor probe over the range of <10% to nearly 100% ( M2)... Adjust condenser refrigerant liquid level setpoint to a value that covers the subcooler top and provides proper Evaporator performance ( M1) with the chiller running steady. Update value in Section B... After the chiller is at full load at design Leaving Chilled Liquid Temperature, capture the Operating Data to print or save to text file... Setpoint Offset... Min Housing Temp... Max Winding Temp... Kp (ADMIN)... Ti (ADMIN)... Td (ADMIN)... Motor Cooling Control State is set to AUTO... Capture the chiller setpoints on a print or text file from the Setpoints-Print command. * Compressor model ending in A only. Compressor model ending in B only. JOHNSON CONTROLS 5
6 P.O. Box 1592, York, Pennsylvania USA Subject to change without notice. Printed in USA Copyright by Johnson Controls ALL RIGHTS RESERVED Form CL2 (615) Issue Date: June 18, 2015 Supersedes: CL2 (512)
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