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York YHAU-CL Series Installation Operation & Maintenance

Single effect hot water absorption chiller
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SINGLE EFFECT HOT WATER
ABSORPTION CHILLER
NEW RELEASE
Form 155.30-ICOM2.EN.UL(1218)
INSTALLATION, OPERATION, MAINTENANCE
Model YHAU-CL / CH
30 - 2000 TON
105 - 7043 kW
LD22981
LD22981
Issue Date:
December 21, 2018

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Summary of Contents for York YHAU-CL Series

  • Page 1 SINGLE EFFECT HOT WATER ABSORPTION CHILLER NEW RELEASE Form 155.30-ICOM2.EN.UL(1218) INSTALLATION, OPERATION, MAINTENANCE Model YHAU-CL / CH 30 - 2000 TON 105 - 7043 kW LD22981 LD22981 Issue Date: December 21, 2018...
  • Page 2 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or During rigging, installation, operation, maintenance, death to themselves and people at the site. or service, individuals may be exposed to certain com- This document is intended for use by owner-authorized ponents or conditions including, but not limited to:...
  • Page 3 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for contin- verify whether the equipment has been modified and uous product improvement, the information contained if current literature is available from the owner of the in this document is subject to change without notice.
  • Page 4 L: Low Temp. hot water L: 33.8 °F CHW capacity H: High Temp. hot water UNIT LL: 23 °F CHW EXW2S: 630 ~ 1000 RT nomi- York Absorption nal capacity Chiller DESIGN EXW4S: 1120 ~ 2000 RT SYMBOL nominal capacity...
  • Page 5 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 TABLE OF CONTENTS SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ..............11 Introduction ..............................11 About this Manual ............................11 Warranty ................................. 11 Quality Assurance ............................12 Emergency Shutdown ............................ 12 High Temperature and Pressure Cleaning ....................12 Safety Labels ..............................
  • Page 6 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 TABLE OF CONTENTS (CONT'D) SECTION 5 - COMMISSIONING ..........................89 General Guidelines for Use ..........................89 Before Operation ...........................89 Precautions for the Use of Water ........................90 Chilled Water Outlet Temperature Controller ....................90 Liquid Level Gauges ............................90 Start the Chiller ...............................
  • Page 7 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 TABLE OF CONTENTS (CONT'D) Maintenance Items ............................137 Refrigerant Pump Manual Stop ......................141 Purge Manual Stop and Start ......................141 Lifespan for Various Parts ..........................141 Water Quality Control ........................... 143 Chemical Water Treatment ........................... 143 Replacement of Water ..........................

  • Page 8: Table Of Contents

    FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 LIST OF FIGURES FIGURE 1 - YHAU-CL/CH Unit Components ......................15 FIGURE 2 - Single Effect Hot Water Absorption Chiller Cycle Diagram ..............16 FIGURE 3 - Hoisting Procedure (4 Point Lifting) .....................23 FIGURE 4 - Moving the Machine on Rollers ......................24 FIGURE 5 - Fitting TIR-rollers to the Machine ......................24 FIGURE 6 - Jack-up Procedures ..........................25 FIGURE 7 - Jack-up procedures ..........................26...
  • Page 9 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 LIST OF FIGURES (CONT'D) FIGURE 56 - Failure and Alarm Screen ........................120 FIGURE 57 - Setting Screen ..........................124 FIGURE 58 - Location of Manual Valve in Purge System ..................131 FIGURE 59 - Process and Instrumentation Diagram for EXE Series Chiller............133 FIGURE 60 - Purge Unit ............................134 FIGURE 61 - Chilled Water and Cooling Water System ..................149 FIGURE 62 - Hot Water System ..........................150...
  • Page 10 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 LIST OF TABLES TABLE 1 - Split Shipment Dimensions - EXE Series ....................32 TABLE 2 - Split Shipment Dimensions - EXW Series .....................33 TABLE 3 - Nozzle Arrangements 30 - 500EXE .......................34 TABLE 4 - YHAU - CL/CH 630EXW2s-200EXW4S ....................35 TABLE 5 - Insulating Material and Thickness ......................36 TABLE 6 - Points Requiring Hot or Cold Insulation ....................36 TABLE 7 - Typical Operational Range ........................39...
  • Page 11 Johnson gether with operating and maintenance instruc- Controls Field Service Office. tions. • Only genuine YORK approved spare parts, oils, • Should be read thoroughly before attempting to solutions, chemicals, and refrigerants must be used. operate or service the unit.
  • Page 12 FORM 155.30-ICOM2.EN.UL SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ISSUE DATE: 12/15/2018 QUALITY ASSURANCE HIGH TEMPERATURE AND PRESSURE CLEANING Units comply with the following directives: Do NOT use high temperature and pressure cleaning • GB/T 18431-2014 Steam and Hot Water Lithium methods (for example, steam cleaning) on any part of Bromide Absorption Chiller the pressure system.
  • Page 13 FORM 155.30-ICOM2.EN.UL SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ISSUE DATE: 12/21/2018 SAFETY LABELS MATERIAL SAFETY DATA SHEET MSDSs specify proper procedures for handling and For safe operation, read the instructions working with applicable chemicals, including items first. such as physical data, toxicity, health effects, first aid, storage, disposal, and spill procedures.
  • Page 14 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 15: Figure 1 - Yhau-Cl/Ch Unit Components

    FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 2 – PRODUCT DESCRIPTION The principle of refrigeration is the exchange of heat CONTROL PANEL and, in absorption liquid chilling, there are four basic The absorption chiller comes with a factory mounted heat exchange surfaces: the evaporator, the absorber, and pre-wired control system.

  • Page 16: Figure 2 - Single Effect Hot Water Absorption Chiller Cycle Diagram

    FORM 155.30-ICOM2.EN.UL SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/21/2018 HOW IT WORKS The single effect (hot water driven) absorption chiller uses deionized water as the refrigerant and lithium bro- mide (LiBr) solution as the absorbent. The vapor pressure of the lithium bromide solution is lower than the vapor pressure of the refrigerant.
  • Page 17 FORM 155.30-ICOM2.EN.UL SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/21/2018 TWO STEP EVAPORATOR-ABSORBER LiBr LiBr The evaporator and the absorber are split into two sec- Refrigerant Refrigerant tions. This design allows the cycle concentration to be Chilled lower than a conventional absorber / evaporator. The Water Chilled lower concentrations mean the unit is more reliable,...
  • Page 18 FORM 155.30-ICOM2.EN.UL SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/21/2018 GENERATOR CONDENSER The generator section is of a falling film design. Such The refrigerant vapors leaving the generator condense a design ensures substantially reduced wear and tear into liquid refrigerant in the condenser section, using at the tube supports compared to the conventional cooling (condenser) water.
  • Page 19 FORM 155.30-ICOM2.EN.UL SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/21/2018 Since the solution temperature in the generator is nor- WHY DOES CRYSTALLIZATION OCCUR? mally high enough that no crystallization will occur as The most common reason for crystallization is power long as the higher temperature is maintained.
  • Page 20 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...
  • Page 21 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY LD18119 This chiller is for air conditioning or a cooling manu- DANGER: Rigging and lifting should facturing process. Transport, store, and use this chiller only be done by a professional rigger in under the following conditions: accordance with a written rigging and lifting plan.
  • Page 22 FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 INSPECTION Deterioration of electrical parts caused by rainwater The unit must be inspected prior to customer use by a (moisture) Johnson Controls Service representative. All damage or possible damage must be reported to the transpor- d.

  • Page 23: Figure 3 - Hoisting Procedure (4 Point Lifting)

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 HOISTING THE MACHINE MOVING THE MACHINE ON ROLLERS When hoisting the machine, attach a shackle to each of Plan the entrance for the machine from Figure 4 below. the four eye plates and lift the machine using care that Do not incline the machine more than 10 degrees.

  • Page 24: Figure 4 - Moving The Machine On Rollers

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 7.86 Maximum Machine Length 7.86 Maximum Machine Width Skid Base 3.93 3.93 Approx Approx LD22924_UL FIGURE 4 - MOVING THE MACHINE ON ROLLERS MACHINE BASE HOLE { 22} FOR FITTTING TIR-ROLLER SET ANCHOR BOLT HOLE...

  • Page 25: Figure 6 - Jack-Up Procedures

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 JACKING THE MACHINE When jacking up the machine, be sure to fit a jack in each of the jack-up supports as Shown in Figure 7 be- low. JACK-UP SUPPORT JACK-UP SUPPORT JACK-UP SUPPORT...

  • Page 26: Figure 7 - Jack-Up Procedures

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 Operate the front and rear jacks alternately. Do not jack up the machine more than about 0.78 inch at a time. Each time the machine is jacked up, adhere it with a suitable crosstie.
  • Page 27 FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 CAUTION: The chiller does NOT arrive STRUCTURAL SUPPORT AND INSTALLATION with a ground fault (earth leakage) cir- Structural support of the unit must be provided as indi- cuit breaker installed.
  • Page 28 FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 If the cables of the solution pump, refrigerant pump, or ELECTRICAL SHOCK CAUTIONS vacuum pump are disconnected for service and main- Do not touch any switch in the control panel with wet tenance work, be sure to check the rotating direction hands;...

  • Page 29: Figure 8 - Vibration And Isolation Details

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 DIAGRAM 1 DIAGRAM 2 LD20193 VIBRATION AND ISOLATION DETAILS Before installing the unit, fit rubber vibration isolators to the unit base as shown in Figure 9 on page 31. Use liners to adjust the levelness of the unit.
  • Page 30 FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 RUPTURE DISK AND RELIEF PIPING Rupture Disk Discharge Piping Construction NOTE: The ANSI/ASHRAE 15-2001 For the piping material, Johnson Controls recommends safety standard code was recently carbon steel. The relief piping must be fabricated and revised to include absorption chiller constructed in accordance with piping best practices.

  • Page 31: Figure 9 - Location Of Rupture Disk

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 Condenser Absorber Rupture Disk Rupture Disk Purge Tank Evaporator Control Panel Generator Solution Heat Exchanger LD28267 FIGURE 9 - LOCATION OF RUPTURE DISK JOHNSON CONTROLS...

  • Page 32: Figure 10 - Exe Series Dimensions (Split Shipment)

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 TABLE 1 - SPLIT SHIPMENT DIMENSIONS - EXE SERIES SINGLE EFFECT HOT WATER ABSORPTION CHILLER (EXE SERIES) MAIN SHELL UNIT SOLUTION HEAT EXCHANGER UNIT YHAU-CL/CH WEIGHT CL WEIGHT CH WEIGHT FT (M)

  • Page 33: Figure 11 - Exw Series Dimensions (Split Shipment)

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 TABLE 2 - SPLIT SHIPMENT DIMENSIONS - EXW SERIES SINGLE EFFECT HOT WATER ABSORPTION CHILLER (EXE SERIES) MAIN SHELL UNIT SOLUTION HEAT EXCHANGER UNIT YHAU-CL/CH WEIGHT CL WEIGHT CH WEIGHT FT (M)

  • Page 34: Figure 12 - Yhau-Cl/Ch-30 - 500Exe Nozzle Locations

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 TABLE 3 - NOZZLE ARRANGEMENTS 30 - 500EXE NOZZLE LOCATION YHAU-CL/CH CHILLED WATER (CHW) COOLING WATER (COW) HOT WATER (HW) INLET OUTLET INLET OUTLET INLET OUTLET PASS PASS PASS 30-500EXE...

  • Page 35: Figure 13 - Yhau-Cl/Ch-630Exw2S-2000Exw4S Nozzle Locations

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 TABLE 4 - YHAU - CL/CH 630EXW2S-200EXW4S NOZZLE LOCATION YHAU-CL/CH CHILLED WATER (CHW) COOLING WATER (COW) HOT WATER (HW) INLET OUTLET INLET INLET OUTLET PASS PASS PASS 630EXW2S-2000EXW4S EVEN EVEN...

  • Page 36: Table 5 - Insulating Material And Thickness

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 HOT INSULATION AND COLD INSULATION 4. Make the outer covering, flanged parts, and evap- PROCEDURE orator water chamber casing easily removable to facilitate servicing. 1. The recommended materials and their thickness for hot insulation or cold insulation are shown in 5.

  • Page 37: Figure 14 - Hot/Cold Insulation - Exe Models

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 Hot Insulation Cold Insulation LD20596 FIGURE 14 - HOT/COLD INSULATION - EXE MODELS LD20595 FIGURE 15 - HOT/COLD INSULATION - EXW MODELS JOHNSON CONTROLS...

  • Page 38: Figure 16 - Exterior Of Control Panel

    FORM 155.30-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 LD28253 FIGURE 16 - EXTERIOR OF CONTROL PANEL External Handle Buzzer Touch Panel Door Stopper (90°) Ground Terminal LD28266 FIGURE 17 - INTERIOR OF CONTROL PANEL JOHNSON CONTROLS...

  • Page 39: Table 7 - Typical Operational Range

    FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 4 - TECHNICAL DATA The numbers shown in Table 7 on page 39 are the This section includes technical information allowable ranges for each parameter. Not all combi- about the unit, such as weight, dimensions, and nations are possible.

  • Page 40: Table 8 - Weights

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 8 - WEIGHTS WEIGHT EMERGENCY EMERGENCY YHAU MAXIMUM MAXIMUM OPERATION (FILLED WITH OPERATION (FILLED WITH SHIPPING SHIPPING LBS (TON) WATER) LBS (TON) WATER) LBS (TON) LBS (TON) LBS (TON) LBS (TON) 5,512 6,393...

  • Page 41: Table 9 - Outline Dimensions

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 9 - OUTLINE DIMENSIONS OUTLINE DIMENSION TUBE EXTRACTING YHAU-CL/CH LENGTH LENGTH WIDTH HEIGHT SPACE FT (M) CL FT (M) CH FT (M) FT (M) FT (M) 5.74 6.23 5.09 6.89 30EXE (1.75)

  • Page 42: Table 10 - Physical Data

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 10 - PHYSICAL DATA WATER VOLUME AMOUNT OF AMOUNT OF COLD RADIATION RADIATION COOLING CHILLED INSULATION INSULATION (WITH (WITHOUT WATER YHAU-CL/CH WATER WATER AREA AREA INSULATION, INSULATION, (ABS & (EVAP) (GEN) AMBIENT TEMP.

  • Page 43: Figure 18 - Cl-30Exe-500 Exe

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LOAD POINTS FOR EXE AND EXW UNITS - CL MODELS Load Point 1 Load Point 2 Load Point 4 Load Point 3 LD22036 FIGURE 18 - CL-30EXE-500 EXE Load Point 4 Load Point 3 Load Point 1 Load Point 2...

  • Page 44: Table 11 - Load Points: Exe And Exw Units For Cl

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 11 - LOAD POINTS: EXE AND EXW UNITS FOR CL UNIT LOAD POINT 1 LOAD POINT 2 LOAD POINT 3 LOAD POINT 4 LBS (TON) LBS (TON) LBS (TON) LBS (TON) 1,521 1,676...

  • Page 45: Figure 20 - Yhau-Ch30Exe-500Exe

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LOAD POINTS FOR EXE AND EXW UNITS - CH MODELS Load Point 1 Load Point 2 Load Point 4 Load Point 3 LD22997A FIGURE 20 - YHAU-CH30EXE-500EXE Load Point 4 Load Point 3 Load Point 1 Load Point 2...

  • Page 46: Table 12 - Load Points: Exe And Exw Units For Ch

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 12 - LOAD POINTS: EXE AND EXW UNITS FOR CH LOAD POINT 1 LOAD POINT 2 LOAD POINT 3 LOAD POINT 4 UNIT LBS (TON) LBS (TON) LBS (TON) LBS (TON) 30EXE 1,830...
  • Page 47 SECTION 4 - TECHNICAL DATA THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 48: Table 13 - Electrical Data

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP VOLTAGE YHAU-CL/CH (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 25.2 25.2 AC200V-3Ph-60Hz 160A 22.2 22.2 AC220V-3Ph-60Hz 24.6 24.6 AC380V-3Ph-50Hz 12.1 12.1...

  • Page 49: 65Exe

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA (CONT'D) REFRIGERANT VACUUM PUMP PUMP CAPACITY CONSUMPTION SCCR YHAU-CL/CH 20.6 20.6 2.06 20.6 30EXE 0.75 1.12 1.14 1.03 1.05 20.6 20.6 2.06 20.6 40EXE 0.75 1.12 1.14 1.03...

  • Page 50: 130Exe

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA (CONT'D) MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP VOLTAGE YHAU-CL/CH (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 25.2 25.2 AC200V-3Ph-60Hz 160A 22.2 22.2 AC220V-3Ph-60Hz 24.6 24.6 AC380V-3Ph-50Hz 12.1...
  • Page 51 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA (CONT'D) REFRIGERANT VACUUM PUMP PUMP CAPACITY CONSUMPTION SCCR YHAU-CL/CH 20.6 20.6 2.06 20.6 100EXE 0.75 1.12 1.14 1.03 1.05 20.6 20.6 2.06 20.6 130EXE 0.75 1.12 1.14 1.03...

  • Page 52: 320Exe

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA (CONT'D) MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP VOLTAGE YHAU-CL/CH (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 15.6 60.0 11.6 48.0 AC200V-3Ph-60Hz 160A 14.8 53.2 11.4 40.6 AC220V-3Ph-60Hz...

  • Page 53: 320Exe

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13- ELECTRICAL DATA (CONT'D) REFRIGERANT VACUUM PUMP PUMP CAPACITY CONSUMPTION SCCR YHAU-CL/CH 20.6 12.2 20.6 11.5 20.6 12.2 11.9 11.9 320EXE 0.75 1.65 12.1 12.5 10.0 11.5 1.45 12.2 12.6 10.1 20.6...

  • Page 54: 800Exw2S

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA (CONT'D) MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP VOLTAGE YHAU-CL/CH (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 26.0 132.0 12.4 42.0 AC200V-3Ph-60Hz 160A 25.0 118.0 11.6 46.0 AC220V-3Ph-60Hz...
  • Page 55 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA (CONT'D) REFRIGERANT VACUUM PUMP PUMP CAPACITY CONSUMPTION SCCR YHAU-CL/CH 25.6 20.6 17.6 14.0 25.0 20.6 16.7 13.3 26.0 20.6 17.1 13.7 11.9 17.7 14.1 10.7 17.3 13.8 800EXW2S...

  • Page 56: 1500Exw4S

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA (CONT'D) MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP VOLTAGE YHAU-CL/CH (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 38.4 144.0 20.2 72.0 AC200V-3Ph-60Hz 160A 36.0 134.0 19.0 70.0 AC220V-3Ph-60Hz...

  • Page 57: 1900Exw4S

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA (CONT'D) REFRIGERANT VACUUM CAPACITY CONSUMPTION SCCR PUMP PUMP YHAU-CL/ 26.0 20.6 25.0 20.0 24.0 20.6 23.4 18.8 26.4 20.6 24.5 19.6 12.5 24.6 19.7 24.2 19.4 1500EXW4S 0.75...

  • Page 58: Figure 22 - Power Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 22 - POWER WIRING JOHNSON CONTROLS...
  • Page 59 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28190_UL FIGURE 22 - POWER WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 60: Figure 23 - Power Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 23 - POWER WIRING JOHNSON CONTROLS...
  • Page 61 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28191_UL FIGURE 23 - POWER WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 62: Figure 24 - Plc Input Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 24 - PLC INPUT WIRING JOHNSON CONTROLS...
  • Page 63 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28192_UL FIGURE 24 - PLC INPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 64: Figure 25 - Plc Input Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 25 - PLC INPUT WIRING JOHNSON CONTROLS...
  • Page 65 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28193_UL FIGURE 25- PLC INPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 66: Figure 26 - Plc Output Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 26 - PLC OUTPUT WIRING JOHNSON CONTROLS...
  • Page 67 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28195_UL FIGURE 26 - PLC OUTPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 68: Figure 27 - Plc Output Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 27 - PLC OUTPUT WIRING JOHNSON CONTROLS...
  • Page 69 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28196_UL FIGURE 27 - PLC OUTPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 70: Figure 28 - Display/Analog Input Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 28 - DISPLAY/ANALOG INPUT WIRING JOHNSON CONTROLS...
  • Page 71 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28197_UL FIGURE 28 - DISPLAY/ANALOG WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 72: Figure 29 - Display/Analog Input Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 29 - DISPLAY/ANALOG INPUT WIRING JOHNSON CONTROLS...
  • Page 73 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28198_UL FIGURE 29 - DISPLAY/ANALOG INPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 74: Figure 30 - Display/Analog Output Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL LD28199_UL FIGURE 30 - DISPLAY/ANALOG OUTPUT WIRING JOHNSON CONTROLS...

  • Page 75: Figure 31 - Plc And Display Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 31 - PLC AND DISPLAY WIRING JOHNSON CONTROLS...

  • Page 76: Figure 32 - Plc Input Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram for UL FIGURE 32 - PLC INPUT WIRING JOHNSON CONTROLS...
  • Page 77 FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD28200_UL FIGURE 32 - PLC INPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 78: Figure 33 - External Connection Terminal Details

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 LD20543a FIGURE 33 - EXTERNAL CONNECTION TERMINAL DETAILS JOHNSON CONTROLS...

  • Page 79: Figure 34 - Remote Transmission Signal

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Ancillary Equipment Board Absorption Chiller Control (Out of Scope) Panel (Scope of Supply) Z3 Terminal Block Remote Start-Up (No Voltage) Pulse Start-Stop) (Option) Common Remote Start-Up Remote Stop Z3 Terminal Block Remote Start-Up (DC24V Pulse Start-Stop;...

  • Page 80: Figure 35 - Signal Terminal Transition Wiring

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 STARTING PANEL FOR CHILLED WATER Z1 TERMINAL BLOCK COMMON OPERATING SIGNAL INTERLOCK FAILURE SIGNAL CHILLING WATER PUMP OPERATING SIGNAL COOLING WATER PUMP OPERATING SIGNAL TEST STARTING PANEL FOR CHILLER WATER INTERLOCK TEST Example diagram of transition wiring if start panel of...

  • Page 81: Figure 36 - Upper Communication System Configuration

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 UPPER COMMUNICATION SPECIFICATION The information in this section applies to both the EXE Series and the EXW series of hot water absorp- tion chillers. Upper Communication System Configuration The configuration of the upper communication system is shown in Figure 38 on page 85 Central Monitoring Unit Data concentrator (HUB)

  • Page 82: Table 15 - Scope Of Delivery

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Scope of Delivery Johnson Controls scope of delivery for the upper com- munication system covers the control panels for the upper communication function. The customer is re- sponsible to deliver all other related equipment: con- centrator (HUB), installation, wiring, communication program for the central monitoring unit, and other rel- evant equipment.

  • Page 83: Table 17 - Communication Specifications

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Communication Specification TABLE 17 - COMMUNICATION SPECIFICATIONS Communication Protocol Modbus TCP Communication Path Type 10BASE-T/100BASE-TX IP Address (No. 1) 192.168.1.1, (No.2) 192.168.1.2, (No. 3) 192.168.1.3 Subnet Mask 255.255.255.0 Function Code Read Command (Digital Signal) 01/Read Coil (Analog Signal) 03/Read Holding Register...

  • Page 84: Figure 37 - Connection Detail For D-Sub 9 Pin

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 19 - WRITE COMMAND ITEM ADDRESS CONTENT Chiller operation signal 02001 ON at CHILLER OPERATION, PULSE SIGNAL Chiller stop signal 02002 ON at CHILLER STOP, PULSE SIGNAL Hot water control valve upper limit 00201 0000~1000 unit, 1 unit=0.1% Set point...

  • Page 85: Figure 38 - 2-Wire 1:1 Connection With User-Created Cable

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 21 - CABLE DIAGRAM (RS-422/RS-485) PIN CONNECTION PIN. RS-422/RS-485 SIGNAL NAME DIRECTION MEANING Input Receive Data A (+) Input Receive Data B (-) Output Send Data A (+) Output Data Terminal Ready A (+) Signal Ground Input...

  • Page 86: Figure 40 - 4-Wire 1:1 Connection With User-Created Cable

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 4 Wire Type Cable Diagrams The following are sample cable diagrams for 4-wire type connections. These use a GP4000 series (COM2). (Slave) External Device D-sub 9 pin (socket) (Master) Shield Termination resistance Signal name...

  • Page 87: Table 22 - Communication Specification - Modbus/Rtu

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 The following table contains information about the communication specifications required by the Modbus/RTU. TABLE 22 - COMMUNICATION SPECIFICATION - MODBUS/RTU Communication protocol Modbus/RTU Communication path type RS422/RS485 Data Length: 8 Bit Stop Bit: 1 Bit Parity: EVEN Speed: 9600 bps Connector D-Sub 9pin...

  • Page 88: Figure 42 - Sample Sound Testing For Yhau-Cl/Ch Chiller

    FORM 155.30-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 NOISE EMISSION The chiller may produce the A-weighted emission sound presssure level in excess of 80 dB (A), normally the A-weighted sound power level is less than 100 dB (A). Hearing protection must be worn at all times when op- erating the chiller.

  • Page 89: Table 23 - Rotary Pump Rotation

    FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 5 - COMMISSIONING GENERAL GUIDELINES FOR USE Before Operation 5. Operate the pump. Charge the solution and the refrigerant water if the so- 6. Open the valve. lution and refrigerant water is in the barrels during the 7.

  • Page 90: Table 24 - Liquid Level Gauges

    The steps and procedures MUST be performed by a YORK/Johnson Controls Service Be sure to install a strainer of 20 mesh before the hot person prior to customer use.
  • Page 91 FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 • Check that the Refrigerant Pump Auto button is • The hot water control valve closes. pressed. • The dilution operation starts and continues for After the review is complete, start the chiller. 7-10 minutes.

  • Page 92: Figure 43 - Cooling Start Diagram - Start

    FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 Stop Operation Power on Dilution Time count Initialize Self-Check Mechanism Hot water pump stop Remote Remote/Local Operation Change Hot Water Control Valve close Local Remote Start Operation Local Start Operation Dilution time increasing Chilled/Cooling/Hot Water Air Conditioning Machine/ Solution Pump/...

  • Page 93: Figure 45 - Sequential Operation Flowchart

    FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 Sequential Operation Chilled Water Pump Air Conditioner Interlock Sequential Operation Cooling Tower Cooling Water Pump Sequential Operation Hot Water Pump Sequential Operation Interlock Interlock Other interlocks, including earthquake sensor, abnormal room temperature sensor, and so on. NOTES: 1.
  • Page 94 ............... 1. All major pieces, boxes, and crates have been 2. Air vent valves and drain valves are closed for: received and accounted for by a YORK/Johnson a. Chilled water ............Controls Service Representative......b. Cooling water ............
  • Page 95 FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.30-CL1.EN.UL ISSUE DATE:12/11/2018 D. Electrical 7. Clean the mesh strainers on the line ....... 1. Main and control power supply is available..... 8. Start the following: a. Chilled water pump..........2.
  • Page 96 FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.30-CL1.EN.UL ISSUE DATE: 12/11/2018 G. Panel Checks F. Evacuate Nitrogen Charge 1. The thermal relays conform to the factory inspec- 1. Remove plug in the purge line ......... tion sheet..............2.
  • Page 97 FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.30-CL1.EN.UL ISSUE DATE:12/11/2018 START UP CHECKLIST 16. Gradually open the hot water control valve....17. Press the Control Valve Mode Auto button..... A. Operation Check 18. Check that the hot water control valve works automatically according to the chilled water outlet 1.
  • Page 98 FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.30-CL1.EN.UL ISSUE DATE: 12/11/2018 D. Remote Operation Check 1. Check that the chiller starts and stops using a remote signal................ E. Operation Instruction Review the operation and maintenance instructions in the manual with the customer.
  • Page 99 FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.30-CL1.EN.UL ISSUE DATE:12/11/2018 TABLE 1 - COMMISSIONING DATA SHEET (1/2) (HOT WATER SINGLE-EFFECT ABSORPTION CHILLER) User: Model: MFG.No.: User's machine code: Insulation Resistance Electric Power Supply Standard: 5 MΩ or more (with 500 V meg- R-Gnd S-Gnd T-Gnd...
  • Page 100 FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.30-CL1.EN.UL ISSUE DATE: 12/11/2018 TABLE 2 - COMMISSIONING DATA SHEET (2/2) (HOT WATER SINGLE-EFFECT ABSORPTION CHILLER) User: Model: MFG.No.: User's machine code: Running Data Date: Measured by Specification Standard Hot water valve position Control panel °F Inlet temperature...
  • Page 101 FORM 155.30-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.30-CL1.EN.UL ISSUE DATE:12/11/2018 TABLE 3 - PURGE AMOUNT MEASUREMENT DATA SHEET (1/1) User: Model: YHAU - MFG.No.: User's machine code: Measured Date: Measured by: Purge Amount from Purge Line Flame Reaction Test Standard: 4.0 cc/min.
  • Page 102 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...
  • Page 103 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 6 – OPERATION YHAU-CL/CH CONTROL CENTER The Control Center screens have items that are appli- cable to each feature of the Control Center. This in- The YHAU-CL/CH Control Center, furnished as stan- cludes the following common items: dard on each chiller, allows for efficiency, monitoring, data recording, chiller protection, and operating ease.
  • Page 104 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 1. Touch the number to be changed. A numeric key- pad appears. LD21975_UL • Screen Name Buttons: Located along the bottom of the screen. These are used to change screens. LD21976_UL The selected button lights when it is active.

  • Page 105: Figure 47 - Main Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 MAIN SCREEN LD27805_UL FIGURE 47 - MAIN SCREEN • Load Limit: Light is lit if the load restriction ac- The Main Screen displays the equipment status (chiller start or stop, operating, pumps ON or OFF, purge pump tivates due to the cooling water temperature, re- ON or OFF, and chilled and cooling water pumps ON frigerant temperature, or generator temperature or...
  • Page 106 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 An illustration of the system shows the following in- 69WC1 or 69WC2 (option) formation: Differential pressure switch of chilled water • 3-way valve control output (69WC1) and cooling water (69WC2) • Chilled water entering / leaving temperature - White when water is flowing.

  • Page 107: Figure 48 - Data Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 DATA SCREEN LD20030_UL FIGURE 48 - DATA SCREEN The Data Screen displays values showing tempera- Generator Temp.: temperature of the concentrated so- tures, operating hours, operating frequency, data trends lution in the generator and a history of failures, alarms, and time based tem- Hot Water Inlet Temp.: temperature of the hot water perature trends.
  • Page 108 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 The frequency of failures, alarms, and purges is shown The History Menu section on the right side of the in the Frequency section: screen gives you access to the operation history, alarm history and to the failure history information.

  • Page 109: Figure 49 - Solution Analysis / Control Panel Parts Replacement Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 SOLUTION ANALYSIS / CONTROL PANEL PARTS REPLACEMENT SCREEN FIGURE 49 - SOLUTION ANALYSIS / CONTROL PANEL PARTS REPLACEMENT SCREEN The Solution Analysis section of the screen shows the The Control Panel Parts Replacement section of the maintenance interval and current operation hours since screen shows the maintenance interval and current op- the last inhibitor solution maintenance.

  • Page 110: Figure 50 - Solution Pump Solution Pump Overhaul / Refrigerant Pump Overhaul Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 SOLUTION PUMP OVERHAUL / REFRIGERANT PUMP OVERHAUL SCREEN FIGURE 50 - SOLUTION PUMP SOLUTION PUMP OVERHAUL / REFRIGERANT PUMP OVERHAUL SCREEN When the required maintenance period has passed, the The Solution Pump Overhaul section of the screen and maintenance alarm is activated with the warning, "So- the Refrigerant Pump Overhaul section of the screen lution Pump should be overhauled"...

  • Page 111: Figure 51 - Trend Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TREND SCREEN LD20031_UL FIGURE 51 - TREND SCREEN To view the Trend Screen, press the Trend button The display ranges in the Trend screen can be changed. above the History Menu section on the Data screen. This screen graphically illustrates the trend of the tem- perature and the pressure for the following: •...

  • Page 112: Figure 52 - Hourly Operation History Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 HOURLY OPERATION HISTORY SCREEN LD20032_UL FIGURE 52 - HOURLY OPERATION HISTORY SCREEN To view the Hourly Operation History screen, press the Ope. Frequency: how many times the chiller has Hourly Operation button in the History Menu screen started using the OPER.
  • Page 113 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 Ref. Temp.: temperature of the refrigerant in the evap- The buttons in the History Menu section allow you to move between the various history screens: orator. Hourly Operation: Press this button to access the Abs.

  • Page 114: Figure 53 - Minutely Operation History Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 MINUTELY OPERATION HISTORY SCREEN LD20033_UL FIGURE 53 - MINUTELY OPERATION HISTORY SCREEN To view the Minutely Operation History screen, press Purge Freq.: how many times a purge has been per- the Minutely Operation button in the History Menu formed automatically section of the Data screen.
  • Page 115 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 Gen. Temp.: temperature of the concentrated solution The buttons in the History Menu section allow you to in the generator. move between the various screens: Gen. Press.: pressure in the generator. Hourly Operation: Press this button to access the Hourly Operation History screen.

  • Page 116: Figure 54 - Failure Activation History Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 FAILURE ACTIVATION HISTORY SCREEN LD20034_UL FIGURE 54 - FAILURE ACTIVATION HISTORY SCREEN Ope. Freq.: how many times the chiller has started us- You move to the Failure Activation History screen af- ter pressing the Failure Activation button in the His- ing the OPER.
  • Page 117 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 The Cooling Water section shows you: There are two sets of buttons on the right side of the screen. The first set gives you access to information In Temp.: temperature of the cooling water measured about past occurrences.

  • Page 118: Figure 55 - Alarm History Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 ALARM ACTIVATION HISTORY SCREEN LD20035_UL FIGURE 55 - ALARM HISTORY SCREEN View the Alarm History screen after you press the Ope. Freq.: how many times the chiller has started us- Alarm button in the History Menu section of the ing the OPER.
  • Page 119 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 The Cooling Water section shows you: There are two sets of buttons on the right side of the screen. The first set gives you access to information In Temp.: temperature of the cooling water measured about past occurrences.

  • Page 120: Figure 56 - Failure And Alarm Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 FAILURE AND ALARM SCREEN LD27806 FIGURE 56 - FAILURE AND ALARM SCREEN If a failure occurs, the red Failure light lights and the If an alarm occurs, the orange Alarm light lights. Press chiller stops.

  • Page 121: Table 25 - Failure List

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TABLE 25 - FAILURE LIST BUTTON LABEL OPERATION AT FAILURE CAUSE (FAILURE NAME) OCCURRENCE Chilled water pump operation interlock and/or chilled Chilled W. Time Out water suspension relay was not established within a set (Chilled Water Time Out) time while start-up.

  • Page 122: Table 26 - Alarm List

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TABLE 26 - ALARM LIST BUTTON LABEL CAUSE OF ALARM AND COUNTERMEASURES (ALARM NAME) CONDITION TO RESET • Purge frequency within a set time exceeded Abnormal Purge its defined value, therefore chiller is Freq.
  • Page 123 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TABLE 27 - ALARM LIST (CONT'D) BUTTON LABEL CAUSE OF ALARM AND COUNTERMEASURES (ALARM NAME) CONDITION TO RESET Cooling water inlet temperature rose to the High Cool. W. upper limit or higher during cooling operation, •...

  • Page 124: Figure 57 - Setting Screen

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 SETTING SCREEN LD20028_UL FIGURE 57 - SETTING SCREEN This screen displays control parameters (setting Remote Set. Diff.: the setting range with external 4-20 method and each setting parameter), valve operation mADC signal (control valve mode auto / manual and valve position Set Point (Display): the set point of the chilled water setting), operation switch (forced dilution, refrigerant...
  • Page 125 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 This calculated temperature is shown in Set Point as NOTE: To move to the Menu screen, set the present target temperature. If remote set point set- the Control Valve Mode to Auto. ting signal (4-20 mADC) is out of its range when you press the REMOTE button, the Recording Sensor Abnormal Alarm button lights.
  • Page 126 FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 OPERATION SWITCH SELECT UNIT SI unit: It is to select the metric unit display. In this screen section, choices can be made about the US unit: It is to select the imperial unit display. mode of operation for the various devices.

  • Page 127: Table 27 - Safety Switches

    FORM 155.30-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TABLE 27 - SAFETY SWITCHES SAFETY SWITCH NAME LOCATION SYMBOL OPERATION Chilled water differential pressure switch 69WC1 Operates when the flow rate lowers. Solution circulating pump thermal switch In control Operates when the current rises above the Solution spray pump thermal switch panel set value.
  • Page 128 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 129: Table 28 - Solenoid Valves

    FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 7 – MAINTENANCE When inspecting and maintaining the absorption chill- SOLENOID VALVES er, observe the following items: The absorption chiller is equipped with the following • Never splash water over the electrical parts in- solenoid valves.
  • Page 130 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 START THE CHILLER AFTER IT HAS BEEN PURGE PROCEDURE STOPPED FOR A LONG PERIOD Air must be purged from the chiller to maintain its per- When starting the chiller after stopping it for a long formance and prevent deterioration of its internal parts.

  • Page 131: Figure 58 - Location Of Manual Valve In Purge System

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 EXE Type EXW2/4ST Type Purging operating valve for purge tank line Purging operating valve for absorber line LD19949 Purge main valve FIGURE 58 - LOCATION OF MANUAL VALVE IN PURGE SYSTEM MANUAL METHOD TO PURGE AIR DIRECTLY NOTE: If the pressure decreases when FROM ABSORBER...
  • Page 132 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 MANUAL METHOD TO PURGE NON- AUTOMATIC METHOD TO PURGE NON- CONDENSABLE GAS FROM PURGING TANK CONDENSABLE GAS FROM PURGING TANK While the absorption chiller operates, non-condensable This chiller has an automatic purge system. The vac- gas collects in the purging tank.

  • Page 133: Figure 59 - Process And Instrumentation Diagram For Exe Series Chiller

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 LD22003 FIGURE 59 - PROCESS AND INSTRUMENTATION DIAGRAM FOR EXE SERIES CHILLER JOHNSON CONTROLS...

  • Page 134: Figure 60 - Purge Unit

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 Vacuum Gauge SV1 SV2 80.6 °F 89.6 °F P/T1 Purge Separator Tank T/C2 Press T/C1 Sensor RTD2 Purge Pump Condenser P/T2 42.8 °F Evaporator Absorber Hot Water (Upper) (Upper) Control Valve T/C6 Purge 161.6 °F...
  • Page 135 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 REFRIGERANT REFINING METHOD MANUAL REFRIGERANT BLOWDOWN AND DILUTING METHOD NOTE: Only deionized water may be used as the refrigerant in the chiller! When the chiller stops suddenly due to a power failure, the solution can become crystallized.
  • Page 136 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 6. Turn the spindle in the valve to the left with the DECRYSTALLIZATION METHOD 0.3 inch hexagon wrench. Even if the solution in the absorption chiller is crystal- NOTE: The refrigerant in the refrigerant lized during operation, it can be melted if the crystal- tank diverts into the absorber.
  • Page 137 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 Precautions for De-crystallization MAINTENANCE ITEMS • Cycle the chilled and cooling water pumps off and Maintenance and inspection items along with standard on during the melting process. inspection periods are shown in the next table. For de- tails, contact your local Johnson Controls Service Cen- •...

  • Page 138: Table 29 - Maintenance And Inspection

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 29 - MAINTENANCE AND INSPECTION TASK CONTENTS FREQUENCY SCOPE Collect the operation data (Refer to 155.30-CL1) Recording of operation and check the data with the data collected during 1 weekly data the factory test.
  • Page 139 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 29 - MAINTENANCE AND INSPECTION (CONT'D) TASK CONTENTS FREQUENCY SCOPE Check continuity of Check continuity of protective bonding circuit. Yearly protective bonding circuit See Water Quality Control on page 143. Control Analysis of quality of the quality of chilled water, cooling water, and hot chilled water, cooling...
  • Page 140 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 29 - MAINTENANCE AND INSPECTION (CONT'D) TASK CONTENTS FREQUENCY SCOPE Cleaning of tubes with brush or water jet Yearly (Absorber, condenser) If foreign matter sticks to the inside of the tubes of Cleaning of tubes the chiller, refrigerating performance is lowered and with brush or water jet...
  • Page 141 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 Refrigerant Pump Manual Stop The purge solenoid valves open. The purge operation begins. The refrigerant pump can be stopped manually for maintenance purposes. It can be stopped even while 4. Press the Manual Purge OFF button when the the chiller operates.

  • Page 142: Table 30 - Lifespan Of Common Parts

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 30 - LIFESPAN OF COMMON PARTS PART NAME LIFESPAN OF COMMON PARTS REMARKS CHW Waterbox Gasket Every 2 years CW Waterbox Gasket Yearly HW Waterbox Gasket Every 2 years Gasket, O-ring, Diaphragm Every 24,000/Hr Evaporator tube About 15 years...
  • Page 143 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 WATER QUALITY CONTROL CHEMICAL WATER TREATMENT Use the following guidelines to be sure of the highest Since the mineral content of the water circulated water quality control standards: through the evaporator, condenser, absorber, and gen- erator varies, the water used may corrode the tubes or •...
  • Page 144 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 FLOW SPEED IN TUBES There are two storage methods available for the chiller during off-season (winter) or plant suspension; the wet Since the water flow speed in the tubes is closely relat- storage method and the dry storage method.
  • Page 145 FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 Dry Storage Method 3. Fill the water systems with clear water. The dry storage method should be used if the chilled 4. Circulate the clear water through the water pump water, cooling water, and/or the hot water system may for 30 minutes to one hour to clean it.

  • Page 146: Table 31 - Wet Storage Method

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 31 - WET STORAGE METHOD PART STORAGE METHOD NOTES Storage Period; Chilled water line 1. The manual valve on the purge piping should be fully closed. less than 2 months Cooling water line Filled with water 2.

  • Page 147: Table 33 - Tendency Of Generation Of Scales And Corrosion By Quality Of Cooling Water

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 33 - TENDENCY OF GENERATION OF SCALES AND CORROSION BY QUALITY OF COOLING WATER GENERAL TENDENCY QUALITY OF COOLING WATER SCALE AND ITS COLOR CORROSION AND ITS COLOR Dark brown Hard scales are generated Severe corrosion of ~ Pale...

  • Page 148: Table 34 - Chilled Water, Cooling Water, And Hot Water Quality Control

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 34 - CHILLED WATER, COOLING WATER, AND HOT WATER QUALITY CONTROL COOLING WATER CHILLED WATER HOT WATER TENDENCY (2) ELEMENT (1) Circulating Feeding Circulating Feeding Circulating Feeding Scale Corrosion Water Water Water Water...

  • Page 149: Figure 61 - Chilled Water And Cooling Water System

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 CHILLED WATER AND COOLING WATER SYSTEM Cooling Water Scope of Supply Chilled Water and Cooling Water System Tapping for Chemical Cleaning Cooling Tower Cooling Water Chilled Water Scope of Supply Tapping for Chemical Cleaning Strainer Absorption Chiller Cooling Tower...

  • Page 150: Figure 62 - Hot Water System

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 FLOW DIVERTING CONTROL WITH THREE-WAY VALVE HOT WATER THREE-WAY TAPPING FOR CHEMICAL CLEANING VALVE SUPPLY SCOPE OF TO HEAT SOURCE GENERATOR SAFETY VALVE FROM HEAT SOURCE STRAINER HOT WATER PUMP LD22039 FLOW MIXING CONTROL WITH THREE-WAY VALVE HOT WATER THREE-WAY...

  • Page 151: Figure 63 - Duhring Diagram / Ptx Chart (°F)

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 FIGURE 63 - DUHRING DIAGRAM / PTX CHART (°F) LD14221a JOHNSON CONTROLS...

  • Page 152: Figure 64 - Duhring Diagram / Ptx Chart (°C)

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 FIGURE 64 - DUHRING DIAGRAM / PTX CHART (°C) LD20933 JOHNSON CONTROLS...

  • Page 153: Figure 65 - Specific Gravity - Concentration (°F)

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 SPECIFIC GRAVITY - CONCENTRATION TABLES AQUEOUS LiBr SOLUTIONS Refrigerant Table (%LiBr by Weight) Temperature F S.G. 1.00 –– –– –– –– –– –– 0.08 0.18 0.28 0.37 0.47 0.57 0.67 1.01 0.98 1.08 1.17...

  • Page 154: Figure 66 - Specific Gravity - Concentration (°C)

    FORM 155.30-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 SPECIFIC GRAVITY – CONCENTRATION TABLES AQUEOUS LiBr SOLUTIONS Refrigerant Table (%LiBr by Weight) Temperature °C S.G. 10.0 12.8 15.6 18.3 21.1 23.9 26.7 29.4 32.2 35.0 37.8 1.00 0.08 0.18 0.28 0.37 0.47 0.57...
  • Page 155 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 8 – TROUBLESHOOTING If the chiller malfunctions or an abnormal condition is • See if the cooling tower is operating normally. detected while it operates, it is important to find the • Check the valves and pumps of the cooling water cause.

  • Page 156: Table 35 - Troubleshooting The High Temperature Generator

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 TABLE 35 - TROUBLESHOOTING THE HIGH TEMPERATURE GENERATOR ITEM CAUSE COUNTERMEASURE • See if the cooling water supply rate matches the specification. • Check the flow meter, discharge pressure of the cooling water pump, current, Cooling water is insufficient or and other relevant pumps.

  • Page 157: Table 37 - Chilled Water Suspension

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 TABLE 37 - CHILLED WATER SUSPENSION ITEM CAUSE COUNTERMEASURE Chilled water pump has a Check the chilled water pump for a problem. problem Check to see if the chilled water flow rate is below the setpoint of the water Chilled water flow rate is suspension switch.

  • Page 158: Table 40 - Pump Interlocks

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 TABLE 40 - PUMP INTERLOCKS ITEM CAUSE COUNTERMEASURE Water pump interlock was Check the water pump interlock. not established TABLE 41 - LOW COOLING WATER INLET TEMPERATURE ITEM CAUSE COUNTERMEASURE Cooling water inlet •...

  • Page 159: Table 44 - Troubleshooting Performance Issues

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 TROUBLESHOOTING PERFORMANCE ISSUES TABLE 44 - TROUBLESHOOTING PERFORMANCE ISSUES ITEM CAUSE COUNTERMEASURE Cooling water temperature is high. Check the capacity of the cooling tower. • See if the cooling water supply rate matches the specification. •...

  • Page 160: Table 45 - Vacuum Pump Troubleshooting

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 VACUUM PUMP When the Purge Abnormal button lights on the Fail- ure and Alarm screen, the vacuum pump needs to be disassembled for inspection. Contact your local John- son Controls Service Center. The entire purge line must be inspected if the Abnormal Purge Freq.

  • Page 161: Table 46 - Abnormal Solution And Refrigerant Levels

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 ABNORMAL SOLUTION AND REFRIGERANT LEVELS Causes of abnormal levels of solution and refrigerant and countermeasures against them are shown in the table below. If the level of the solution or refrigerant is abnormal, correct it according to the following pro- cedure.

  • Page 162: Table 47 - Insufficient Vacuum Levels

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 INSUFFICIENT VACUUM LEVELS Causes of insufficient vacuum level of purging line and countermeasures against them. TABLE 47 - INSUFFICIENT VACUUM LEVELS ITEM CAUSE COUNTERMEASURE Purge pump trouble Contact your local Johnson Controls Service Office. Deterioration of vacuum pump oil Replace the vacuum pump oil.

  • Page 163: Figure 67 - Troubleshooting Sequence Flow Chart

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 Emergency stop External outlet Audible alarm Failure indicator issues (buzzer) “ON” light “ON” Reset operation Stop with dilution operation (buzzer “OFF”) • Operation interlock • Control sensor abnormal • Cooling water interlock •...

  • Page 164: Figure 68 - Actions To Take Against Power Failure

    FORM 155.30-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 Power failure Chiller stops Power is restored Power failure interval is shorter Continue running machine than the controller back up interval Power failure interval is shorter than 5 minutes Power failure interval is shorter than 1 hour.
  • Page 165 FORM 155.30-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 9 - DECOMMISSIONING, DISMANTLING, AND DISPOSAL Unless otherwise indicated, the operations described 8. If glycol was used in the water system, or chemi- below can be performed by any properly trained main- cal additives are contained, dispose of the solu- tenance technician.
  • Page 166 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2018 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 155.30-ICOM2.EN.UL (1218) Issue Date: December 15, 2018 NEW RELEASE...

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