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JOHNSON CONTROLS

Form 160.78-O1

Issue date: 05/19/2021

Table of contents

SECTION 1 - SYSTEM FUNDAMENTALS ............................................................................................................7

System components ......................................................................................................................................... 7

Compressor ............................................................................................................................................. 7

Motor .......................................................................................................................................................7

Heat exchangers .....................................................................................................................................8

Evaporator ............................................................................................................................................... 8

Condenser ............................................................................................................................................... 8

Waterboxes .............................................................................................................................................8

Refrigerant ow control ...........................................................................................................................8

Optional service isolation valves .............................................................................................................8

Optional hot gas bypass .......................................................................................................................... 8

OptiView

Control Center .......................................................................................................................8

Variable speed drive ................................................................................................................................ 9

System operation description ...........................................................................................................................9

Capacity control ................................................................................................................................................9

SECTION 2 - SYSTEM OPERATING PROCEDURES ....................................................................................... 13

Pre-starting ..................................................................................................................................................... 13

Start-up ...........................................................................................................................................................13

Chiller operation .............................................................................................................................................13

Condenser water temperature control ............................................................................................................ 13

Operating logs ................................................................................................................................................13

Operating inspections .....................................................................................................................................14

Daily ......................................................................................................................................................14

Weekly ...................................................................................................................................................15

Monthly .................................................................................................................................................. 15

Semi-annually (or more often as required) ............................................................................................15

Annually (more often if necessary) ........................................................................................................15

Need for maintenance or service ...................................................................................................................15

Stopping the system ....................................................................................................................................... 15

Prolonged shutdown .......................................................................................................................................15

SECTION 3 - MAINTENANCE .............................................................................................................................17

Renewal parts ................................................................................................................................................17

Checking system for leaks .............................................................................................................................17

Leak testing during operation ................................................................................................................17

Conducting R-22 pressure test .......................................................................................................................17

Vacuum testing ............................................................................................................................................... 18

Vacuum dehydration .......................................................................................................................................19

Operation ...............................................................................................................................................19

Refrigerant charging ....................................................................................................................................... 20

Checking the refrigerant charge during unit shutdown ................................................................................... 20

Handling refrigerant for dismantling and repairs ............................................................................................21

Megging the motor .........................................................................................................................................21

Condensers and evaporators .........................................................................................................................21

General ..................................................................................................................................................21

Chemical water treatment .....................................................................................................................21

Cleaning evaporator and condenser tubes ...........................................................................................21