TESTING AND COMMISSIONING

AIR COOLED CHILLER YLAA

I.

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Description
This manual contains all the information required for correct installation and
commissioning of the unit, together with operating and maintenance instructions. The
manual should be read thoroughly before attempting to operate or service the unit. All
procedures detailed in the manuals, including installation, commissioning and
maintenance tasks must only be performed by suitably trained and qualied personnel.

II.

Tools Required
a.
b.
c.
d.
e.

III.

Multimeter
Clampmeter
Sound Level Meter
Phase Rotation Meter
Ultrasonic Flowmeter

Reference Standard
a. Installation, Operation, Maintenance Air Cooled scroll Chiller Form 150.72NM3(811)

IV.

Commissioning test
Commissioning personnel should be thoroughly familiar with the information contained
in this literature, in addition to this section.
Perform the commissioning using the detailed checks outlined in the Equipment Prestartup & Startup Check List as the commissioning procedure is carried out.
a. PREPARATION POWER OFF
The following basic checks should be made with the customer power to the unit
switched OFF.
1) Inspection

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Inspect unit for installation damage. If found, take action and/or repair as
appropriate.

2) Refrigerant Charge
Packaged units are normally shipped as standard with a full refrigerant
operating charge. Check that refrigerant pressure is present in both systems and
that no leaks are apparent. If no pressure is present, a leak test must be
undertaken, the leak(s) located and repaired. Remote systems and units are
supplied with a nitrogen holding charge. These systems must be evacuated with
a suitable vacuum pump/recovery unit as appropriate to below 500 microns.
Do not liquid charge with static water in the cooler. Care must also be taken to
liquid charge slowly to avoid excessive thermal stress at the charging point.
Once the vacuum is broken, charge into the condenser coils with the full
operating charge as given in the Technical Data section of ths IOM.
3) Service and Oil Line Valves
Open each compressor suction, economizer, and discharge service valve. If
valves are the back-seat type, open them fully (counterclockwise) then close
one turn of the stem to ensure operating pressure is fed to pressure transducers.
Open the liquid line service valve and oil return line ball valve fully in each
system.
4) Compressor Oil
To add oil to a circuit connect a YORK hand oil pump (Part No. 470-10654000) to the 1/4" oil charging connection on the compressors with a length of
clean hose or copper line, but do not tighten the are nut. Using clean oil of the
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correct type (V oil), pump oil until all air has been purged from the hose then
tighten the nut. Stroke the oil pump to add oil to the oil system. Approximately
1.8-2.3 gallons is present in the each refrigerant system.
Oil levels in the oil equalizing line sight glass should be between the bottom
and the middle of the sight glass with the system off. High oil levels may cause
excessive oil carryover in the system. High oil concentration in the system may
cause nuisance trips resulting from incorrect readings on the level sensor and
temperature sensors. Temperature sensor errors may result in poor liquid
control and resultant liquid overfeed and subsequent damage to the compressor.
While running, a visible sign of oil splashing in the sight glass is normal.
5) Fans
Check that all fans are free to rotate and are not damaged. Ensure blades are at
the same height when rotated. Ensure fan guards are securely xed.
6) Isolation / Protection
Verify all sources of electrical supply to the unit are taken from a single point
of isolation. Check that the maximum recommended fuse sizes given in the
Technical Data section of ths IOM have not been exceeded.
7) Control Panel
Check the panel to see that it is free of foreign materials (wire, metal chips,
etc.) and clean out if required.
8) Power Connections

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Check that the customer power cables are connected correctly to the terminal
blocks or optional circuit breaker. Ensure that connections of power cables
within the panels to the circuit breaker or terminal blocks are tight.
9) Grounding
Verify that the units protective ground terminal(s) are properly connected to a
suitable grounding point. Ensure that all unit internal ground connections are
tight.
10) Supply Voltage
Verify that the site voltage supply corresponds to the unit requirement and is
within the limits given in the Technical Data.

b. PREPARATION POWER ON
1) Switch Settings
Assure the chiller OFF/ON UNIT switch at the bottom of the keypad is OFF.
Place the optional circuit breaker handle on the panel door to ON. The
customers disconnection devices can now be set to ON.
Verify the control panel display is illuminated. Assure the system switches
under the SYSTEM SWITCHES Key are in the OFF position.
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2) Compressor Heaters
Verify the compressor heaters are energized. If the ambient temperature is
above 96 F (36 C) the compressor heaters must be on for at least 8 hours
before start-up to ensure all refrigerant liquid is driven out of the compressor
and the oil. If the ambient temperature is below 86 F (30 C), allow 24 hours.
3) Water System
Verify the chilled liquid system has been installed correctly, and has been
commissioned with the correct direction of water ow through the cooler. The
inlet should be at the refrigerant piping connection end of the cooler. Purge air
from the top of the cooler using the plugged air vent mounted on the top of the
cooler body.
Flow rates and pressure drops must be within the limits given in the Technical
Data section of ths IOM. Operation outside of these limits is undesirable and
could cause damage.
If main power must be switched OFF for extended maintenance or an extended
shutdown period, the compressor suction, discharge and economizer service
stop valves should be closed (clockwise). If there is a possibility of liquid
freezing due to low ambient temperatures, the coolers should be drained or
power should be applied to the chiller. This will allow the cooler heater to
protect the cooler from freezing down to 20 F. Before placing the unit back
in service, valves should be opened and power must be switched on (if power is
removed for more than 8 hours) for at least 8 hours (24 hours if ambient
temperature is below 86 F [30 C]) before the unit is restarted.
4) Flow Switch

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Verify a chilled water ow switch is correctly tted in the customers piping on

the cooler outlet, and wired into the control panel correctly using shielded
cable.
There should be a straight run of at least 5 pipe diameters on either side of the
ow switch. The ow switch should be connected to terminals 13 and 14 of
XTBC1 on the panel.
5) Temperature Sensor(s)
Ensure the leaving liquid temperature sensor is coated with heat conductive
compound (Part No. 013-00890-000) and is inserted to the bottom of the water
outlet sensor well in the cooler. This sensor also provides some freeze
protection and must always be fully inserted in the water outlet sensor well.
c. Equipment Pre-Startup & Startup Checklist

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EQUIPMENT PRE-STARTUP & STARTUP CHECKLIST

PRE-STARTUP
CHECKING THE SYSTEM
PRIOR TO INITIAL START (NO POWER)
a. Unit Checks
1) Inspect the unit for shipping or installation damage.
2) Assure that all piping has been completed.

3) Visually check for refrigerant piping leaks.

4) Open suction line ball valve, discharge line ball valve, and liquid line valve for
each system.
5) The compressor oil level should be maintained so that an oil level is visible or
splashing in the sight glass when fully loaded. At shutdown, the oil level should
be between the bottom and middle of the oil equalizing sight glass.
6) Assure water pumps are on. Check and adjust water pump ow rate and pressure
drop across the Verify ow switch operation.
7) Check the control panel to ensure it is free of foreign material (wires, metal chips,
etc.).
8) Visually inspect wiring (power and control). Wiring MUST meet N.E.C. and local
codes.

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9) Check tightness of power wiring inside the power panel on both sides of the motor
contactors and overloads.
10) Check for proper size fuses in main and control circuits, and verify overload
setting corresponds with RLA and FLA values in electrical tables.

11) Assure 120VAC Control Power to TB1 has 15 amp minimum capacity.
12) Be certain all water temp sensors are inserted completely in their respective wells
and are coated with heat conductive compound.
13) Assure that evaporator TXV bulbs are strapped onto the suction lines at 4 or 8
oclock positions or suction temperature sensors if EEVs are installed.

14) Apply 120VAC and verify its value between terminals 5 and 2 of XTBC2. The
voltage should be 120VAC +/- 10%. Power must be applied 24 hours prior to
start-up. Each heater should draw approximately 0.5-1A.
b. Panel Checks (Power ON Both Unit Switch OFF)
15) Apply 3-phase power and verify its value. Voltage imbalance should be no more
than 2% of the average voltage.
16) Apply 120VAC and verify its value on the terminal block in the Power Panel.
Make the measurement between terminals 5 and 2 of XTBC2. The voltage should
be 120VAC +/- 10%.
17) Program/verify the Cooling Setpoints, Program

Setpoints, and unit Options.

Record the values in Table 1.

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18) Put the unit into Service Mode (as described under the Service and
Troubleshooting section of this IOM) and cycle each condenser fan to ensure
proper rotation.
19) Prior to this step, turn system 2 off (if applicable refer to Option 2 under the Unit
Keys section of this IOM for more information on system switches). Connect a
manifold gauge to system 1 suction and discharge service valves.
Place the Unit Switch in the control panel to the ON position. As each
compressor cycles on, ensure that the discharge pressure rises and the suction
pressure decreases. If this does not occur, the compressor being tested is operating
in the reverse direction and must be corrected. After verifying proper compressor
rotation, turn the Unit Switch to OFF.
20) Turn system 1 OFF and system 2 ON (refer to Option 2 under the Unit
Keys section of this IOM for more information on system switches).

Place the Unit Switch in the control panel to the ON position. As each
compressor cycles ON, ensure that the discharge pressure rises and the suction
pressure decreases. If this does not occur, the compressor being tested is operating
in the reverse direction and must be corrected. After verifying proper compressor
rotation, turn the Unit Switch to OFF.

V.

Performance Test
21)

With the unit operating against maximum heat load, record data resultant from the

following functional checks, performance tests and measurements:

1. Chiller Sensible Cooling Capacity (kW)
2. Chiller Total Cooling Capacity (kW)
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3. CHW Flow Rate inlet/outlet (L/S)

4. Evaporator CHW Pressure Drop (KPa)
5. CHW Temp Inlet/Outlet (oF)
6. Condenser Airflow Rate (L/S)
7. Condenser Air Flow Temp Inlet & Outlet (oF)
8. Chiller Squencing
9. Oil Pressure (Psig)
10. Compressor Safeties (High Pressure, Oil Pressure, etc)
11. Fan Motor Current (Amps)
12. Fan speeds (RPM)
13. Compressor Discharge Pressure (Psig)
14. Compressor Suction Pressure (Psig)
15. Condensing Pressure (Psig)
16. Compressor Running Current (Amps)
17. Trend Of Stable Control Temperature
18. Load Test (100% load/12 hours)
19. Load Test (110% load/1 hour to bank of chillers)
20. Alarm Functions (All Alarms)
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21. Alarm Status

VI.

Test Record Sheets

1. Pre-Commissioning Check List
2. Commissioning and Testing Record Sheet
22)

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TESTING AND COMMISSIONING

AIR COOLED CHILLER YLAA
23)

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INSTALLATION CHECKLIST AND REQUEST FOR AUTHORIZED STARTUP ENGINEER

24)

CUSTOMER

:___________________

27)

JOB NAME

28)

:_________________________
LOCATION
:___________________

______
25)

ADDRESS

______
26)
PHONE

:___________________
:___________________

______
29)
CUSTOMER ORDER NO
:________________

______
30)
31) CHILLER MODEL NO
:__________________

32) UNIT SERIAL NO

:______________________

33)

A. PRE-STARTUP

5. The compressor oil level should be

maintained so that an oil level is visible

B. CHECKING THE SYSTEM

C. PRIOR TO INITIAL START (NO
POWER)

or splashing in the sight glass when

fully loaded. At shutdown, the oil level
should be between the bottom and
middle of the oil equalizing sight glass.

D. Unit Checks
1. Inspect the unit for shipping or
installation damage.

6. Assure water pumps are on. Check

and adjust water pump ow rate and
pressure drop across the Verify ow

2. Assure that all piping has been

switch operation.

completed
7. Check the control panel to ensure it
3. Visually check for refrigerant piping
leaks.
4. Open suction line ball valve,
discharge line ball valve, and liquid line
valve for each system.

is free of foreign material (wires, metal

chips, etc.).
8. Visually inspect wiring (power and
control). Wiring MUST meet N.E.C.
and local codes.
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9. Check tightness of power wiring

10%. Power must be applied 24 hours

inside the power panel on both sides of

prior to start-up. Each heater should

the motor contactors and overloads.

draw approximately 0.5-1A.

10. Check for proper size fuses in main

G. STARTUP

and control circuits, and verify overload

H. Panel Checks (Power ON Both

setting corresponds with RLA and FLA

Unit Switch OFF)

values in electrical tables.

1. Apply 3-phase power and verify its

11. Assure 120VAC Control Power to

value. Voltage imbalance should be no

TB1 has 15 amp minimum capacity.

more than 2% of the average voltage.

12. Be certain all water temp sensors are

inserted completely in their respective
wells

and

are

coated

with

heat

conductive compound.

2. Apply 120VAC and verify its value

on the terminal block in the Power
Panel. Make the measurement between
terminals 5 and 2 of XTBC2. The

13. Assure that evaporator TXV bulbs

voltage should be 120VAC +/- 10%.

are strapped onto the suction lines at 4

or 8 oclock positions or suction
temperature

sensors

if

EEVs

are

installed.
E. COMPRESSOR HEATERS

3.

Program/verify

the

Cooling

Setpoints, Program Setpoints, and unit

Options. Record the values in Table 1.

4. Put the unit into Service Mode (as

F. (POWER ON 24 HOURS

described under the

Service

and

PRIOR TO START)

Troubleshooting section of this IOM)

and cycle each condenser fan to ensure

1. Apply 120VAC and verify its value

proper rotation.

between terminals 5 and 2 of XTBC2.

The voltage should be 120VAC +/Page 13 of 20

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5. Prior to this step, turn system 2 off

7.5.1
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Unit Switch to OFF.

(if applicable refer to Option 2 under

the Unit Keys section of this IOM for
more information on system switches).
Connect a manifold gauge to system 1
suction and discharge service valves.

6. Turn system 1 OFF and system 2

ON (refer to Option 2 under the Unit
Keys section of this IOM for more
information on system switches). Place
the Unit Switch in the control panel to

I. Place the Unit Switch in the control

the ON position. As each compressor

panel to the ON position. As each

cycles ON, ensure that the discharge

compressor cycles on, ensure that the

pressure rises and the suction pressure

discharge pressure rises and the suction

decreases. If this does not occur, the

pressure decreases. If this does not

compressor being tested is operating in

occur, the compressor being tested is

the reverse direction and must be

operating in the reverse direction and

corrected.

must be corrected. After verifying

compressor rotation, turn the Unit

proper compressor rotation, turn the

Switch to OFF.

After

verifying

proper

Page 14 of 20

J.
K.

L.

Tabel 1. Setpoint Entry List

M. OPTION
N. Display Language

O.

P. Sys 1 Switch

Q.

R. Sys 2 Switch

S.

T. Chilled Liquid

U.

V. Ambient Control*

W.

X. Local/Remote Mode

Y.

Z. Control Mode

AA.

AB.

Display Units

AC.

AD.

Lead/Lag Control*

AE.

AF.Fan Control*

AG.

AH.

AI.

Manual Override

AJ. Current Feedback

AK.

AL.

Unit Type**

AM.

AN.

Refrigerant

AO.

Type**
AP.Expansion Valve Type**
AR.

AQ.

COOLING SETPOINT

AS.

Cooling Setpoint

AT.

AU.

Range

AV.

AW.

EMS-PWM Max.

AX.

Setpoint
AY.
AZ.

PROGRAM

Discharge

BA.

Pressure Cutout
BB.

Suct.

Pressure

BC.

Low Amb. Temp.

BE.

Cutout
BD.
Cutout
BF.Leaving

Liquid

Temp.

BG.

Cutout
BH.

Anti-Recycle-

BI.

Time
BJ. Fan Control ON Pressure

BK.

BL.

BM.

Fan

Differential

OFF Pressure
BN.

Total

of

BO.

Compressors
BP.Number of Fans/System*

BQ.

BR.

BS.

Unit/SysVoltage*

BT.Unit ID
BV.
BW.

BU.

*Not on All Models **Viewable Only

BX.
BY.

CHECKING SUPERHEAT AN SUBCOOL

1. Record the liquid line pressure and its corresponding temperature, liquid line
temperature and subcooling below:

BZ.

CA.

escriptio

Sy

CB.

s1

Sy

CC.

s2

U
nit

n
CD.

Li

CE.

__

q Line

________

Press

___

CH.

Sa

CI. ________

turated

CF.________

CG.

_____

CJ. ________

_____

Ps
ig

CK.

CO.

_____

Temp
CL.

Li

CM.

__

CN.

__

q Line

________

________

Temp

___

___

CP.Subcool

CQ.

__

CR.

__

________

________

___

___

CS.F

CT.
2. Record the suction temperature, suction pressure, suction saturation temperature,
and superheat of each system below:

CU.

escriptio

CV.

Sy
s1

CW.

Sy
s2

CX.

U
nit

n
CY.

Su

CZ.

__

________

________

Temp.

___

___

Su

DD.

ction

DG.

Sa

DE.

__

________

___

___

DH.

turation

__

DI. ________

________

Temp
DK.

__

________

Pressure

DF.Psig

DJ. F

_____

Su

DL.

__

DM.

__

________

________

___

___

DN.

LEAK CHECKING
Leak check compressors, ttings, and piping to ensure no leaks.

DP.
DQ.
DR.
DS.
DT.
DU.
DV.
DW.
DX.

DB.

___

perheat

1.

DA.

ction

DC.

DO.

__

STARTUP PERSONEL

Owners Operating Personnel :

DY.

Name

DZ.

Phone Number :_____________________________________

EA.

Name

EB.

Phone Number :_____________________________________

EC.

Name

ED.

Phone Number :_____________________________________

EE.

Startup Tech

EF.

Phone Number :_____________________________________

EG.

Startup Date

EH.

:_____________________________________

:_____________________________________

:_____________________________________

:_____________________________________

:_____________________________________