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York YHAU-CW Manual

Double effect steam-fired absorption chiller
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DOUBLE EFFECT STEAM-FIRED
ABSORPTION CHILLER
NEW RELEASE
Form 155.31-ICOM2.EN.UL (1218)
INSTALLATION, OPERATION, MAINTENANCE
Model YHAU-CW
150 - 2000 TON
527 - 7,033 KW
LD22831
Issue Date:
December 21, 2018

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  • Page 1 DOUBLE EFFECT STEAM-FIRED ABSORPTION CHILLER NEW RELEASE Form 155.31-ICOM2.EN.UL (1218) INSTALLATION, OPERATION, MAINTENANCE Model YHAU-CW 150 - 2000 TON 527 - 7,033 KW LD22831 Issue Date: December 21, 2018...
  • Page 2 FORM 155.31-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 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for contin- ging, lifting, and operating/service personnel should uous product improvement, the information contained verify whether the equipment has been modified and in this document is subject to change without notice. if current literature is available from the owner of the Johnson Controls makes no commitment to update or equipment prior to performing any work on the chiller.
  • Page 4 FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 NOMENCLATURE YHAU UNIT York Absorption Unit Nominal Capacity (RT) <Low Temp. CHW Design Symbol L: 33.8 °F CHW LL: 23 °F CHW TYPE OF ABSORPTION W=Double Effect Steam WASTE HOT WATER HEAT RECOVERY NONE = NO HEAT RECOVERY...

  • Page 5: Table Of Contents

    FORM 155.31-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 Chilled Water Outlet Temperature Controller ....................95 Liquid Level Gauges ..........................95 Start the Chiller ............................... 95 Stop the Chiller ............................... 95 SECTION 6 – OPERATION ..........................105 YHAU-CW Control Center ........................... 105 Common Items ............................. 105 Change Numeric Values ..........................106 Operating Status ............................107 Failure ..............................122 Alarm ..............................124...
  • Page 7 FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 TABLE OF CONTENTS (CONT'D) SECTION 7 – MAINTENANCE ..........................131 Valve Inspection ............................131 Solenoid Valves ............................131 Pump Shut Off Valves ..........................131 Air Purging Valves and Draining Valves ....................... 131 Purging Valves.............................. 131 Start the Chiller After It Has Been Stopped for A Long Period ..............132 Checks Before Operation Starts ......................
  • Page 8 FIGURE 33 - 4 Wire 1:1 Connection With User-Created Cable ................90 FIGURE 34 - 4 Wire N:1 Connection With User-Created Cable ................90 FIGURE 35 - Sample Sound Testing for YHAU-CW Chiller ..................92 FIGURE 36 - Cooling Start Diagram ........................96 FIGURE 37 - Cooling Stop Diagram........................96 FIGURE 38 - Steam Sequential Operation Flowchart .....................97...
  • Page 9 FIGURE 50 - Setting Screen ..........................127 FIGURE 51 - Location of Manual Valve in Purging System ..................133 FIGURE 52 - YHAU-CW steam fired Chiller Flow Diagram .................135 FIGURE 53 - Process and Instrumentation Diagram ....................136 FIGURE 54 - Chilled Water and Cooling System ....................147 FIGURE 55 - Steam and Drain System for steam control valve................147...
  • Page 10 FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 LIST OF TABLES TABLE 1 - Split Shipment .................................32 TABLE 2 - Split Shipment Component Dimensions* ........................33 TABLE 3 - Nozzle Arrangements 150-300EX(S), 360-800EX(S), 900-1100EXW(S), 1200-1600EXW3(S), 1000-2000EXW4(S) ......................34 TABLE 4 - Insulating Material and Thickness ..........................35 TABLE 5 - Points Requiring Hot or Cold Insulation ........................35 TABLE 6 - Typical Operational Range ............................37 TABLE 7 - High Efficiency Weights and Dimensions .........................38...

  • Page 11: Section 1 - General Chiller Information And Safety

    SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY INTRODUCTION WARRANTY YORK YHAU-CW Absorption chillers are manufac- Johnson Controls warrants YHAU-CW chillers in ac- tured to the highest design and construction standards cordance with the Limited Warranty Engineered Sys- to ensure high performance, reliability, and adaptabil- tems Equipment Policy (Form 50.05-NM2).

  • Page 12: Quality Assurance

    FORM 155.31-ICOM2.EN.UL SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ISSUE DATE: 12/21/2018 QUALITY ASSURANCE EMERGENCY SHUTDOWN Units comply with the following directives: In case of emergency, the control panel is fitted with an incoming supply circuit breaker with a red handle. •...

  • Page 13: Safety Labels

    FORM 155.31-ICOM2.EN.UL SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY ISSUE DATE: 12/21/2018 SAFETY LABELS MATERIAL SAFETY DATA SHEET For safe operation, read the instructions MSDSs specify proper procedures for handling and first. working with applicable chemicals, including items such as physical data, toxicity, health effects, first aid, storage, disposal, and spill procedures.
  • Page 14 FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 15: Section 2 - Product Description

    FORM 155.31-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: How It Works

    The vapor pressure of the LiBr NOTE: Temperatures and pressures on this graphic are representative; actual values may differ. FIGURE 2 - YHAU-CW COMPONENTS JOHNSON CONTROLS...

  • Page 17: Evaporator

    Refrigerant LiBr Chilled The following section describes the unique 2-step Water evaporator-absorber design of the YHAU-CW steam Absorber Evaporator (Upper) (Upper) chiller. TWO-STEP EVAPORATOR-ABSORBER Chilled...

  • Page 18: Plate Type Heat Exchangers

    FORM 155.31-ICOM2.EN.UL SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/21/2018 PARALLEL FLOW PLATE TYPE HEAT EXCHANGERS The unique parallel flow divides the solution between The diluted (weak) lithium bromide solution leaving the low temperature generator and the high tempera- the absorber section is pumped through various plate ture generator sections into two parallel, balanced type heat exchangers (such as the low temperature heat paths.

  • Page 19: Condenser

    FORM 155.31-ICOM2.EN.UL SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/21/2018 CONDENSER Since the solution temperature in the generator is nor- The refrigerant vapor from the low temperature gener- mally high enough, no crystallization will occur as ator as well as the condensed refrigerant from the high long as the higher temperature is maintained.
  • Page 20 FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 21: Section 3 - Handling, Storage, Installation And Reassembly

    FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY LD18119 FIGURE 3 - WARNING This chiller is for air conditioning or a cooling manu- Rigging and lifting should only be done by facturing process. Transport, store, and use this chiller a professional rigger in accordance with a under the following conditions: written rigging and lifting plan.

  • Page 22: Inspection

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 2. Problems and Preventative Measures INSPECTION The unit must be inspected prior to customer use by a PROBLEM PREVENTATIVE MEASURE Johnson Controls Service representative. All damage Freezing of Store the machine where the ambient or possible damage must be reported to the transporta- refrigerant in...

  • Page 23: Hoisting The Machine

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 HOISTING THE MACHINE Be sure to lift the machine horizontally. If the machine is inclined, the solution and refrigerant inside will shift When hoisting the machine, attach a shackle to each of producing an offset load.

  • Page 24: Moving The Machine On Rollers

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 MOVING THE MACHINE ON ROLLERS Use care not to apply shock to the machine. The ma- chine is a high-vacuum vessel containing a corrosive Plan the entrance of the machine. solution.

  • Page 25: Jack Up Procedure

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 If using a tir roller to move the machine, fit the tir roller set to each of the four holes shown in the figure below. Hole (Ø22) for Fitting Tir Roller Set Anchor Bolt Hole Tir Roller Set Tir Roller Set...

  • Page 26: Figure 8 - Jack-Up Procedure

    FORM 155.31-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 0.78 inch at a time. Each time the machine is jacked up, adhere it with a suitable crosstie.

  • Page 27: Structural Support And Installation

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 STRUCTURAL SUPPORT AND INSTALLATION The chiller does NOT arrive with a ground fault (earth leakage) circuit breaker Structural support of the unit must be provided as in- installed.

  • Page 28: Leak Testing

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 During service and maintenance work, be ELECTRICAL SHOCK CAUTIONS sure to turn OFF the main circuit breaker Do not touch the control panel with wet hands. This (MCB1) and follow all required lockout/ can cause electric shock.

  • Page 29: Vibration And Isolation Details

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 VIBRATION AND ISOLATION DETAILS Before you install the unit, fit rubber vibration isolators to the unit base as shown in Figure 9 on page 29. Use liners to adjust the levelness of the unit. For unit dimensions, see Table 7 on page 38, Table 8 on page 39.

  • Page 30: Rupture Disk And Relief Piping

    FORM 155.31-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 re- carbon steel.

  • Page 31: Figure 10 - Location Of Rupture Disk

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 High Temperature Generator Purge Tank Pressure Release Condenser Valve Absorber Rupture Disk Low Temperature Generator Evaporator Rupture Disk High Temperature Generator LD28268 FIGURE 10 - LOCATION OF RUPTURE DISK JOHNSON CONTROLS...

  • Page 32: Table 1 - Split Shipment

    SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 TABLE 1 - SPLIT SHIPMENT DOUBLE EFFECT STEAM FIRED ABSORPTION CHILLER MAIN SHELL UNIT SOLUTION HEAT EXCHANGER UNIT WEIGHT WEIGHT YHAU-CW LBS (TON) LENGTH WIDTH HEIGHT WEIGHT LENGTH WIDTH...

  • Page 33: Table 2 - Split Shipment Component Dimensions

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 TABLE 2 - SPLIT SHIPMENT COMPONENT DIMENSIONS* MAIN SHELL UNIT SOLUTION HEAT EXCHANGER UNIT YHAU-CW WEIGHT WEIGHT (TON) (TON) 10.17 150EX(S) 6.56 (2) 7.55 (2.3) 8818.49 (4) 9.19 (2.8)

  • Page 34: Figure 11 - Yhau-Cw150-300Ex(S), 360-800Ex(Sw), 900-1100Exw(S), 1200-1600Exw3(S), 1000-2000Exw4(S) Nozzle Locations

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 TABLE 3 - NOZZLE ARRANGEMENTS 150-300EX(S), 360-800EX(S), 900-1100EXW(S), 1200-1600EXW3(S), 1000-2000EXW4(S) NOZZLE LOCATION STEAM STEAM YHAU-CW CHILLED WATER (CHW) COOLING WATER (COW) (STM) DRAIN (DRN) INLET OUTLET INLET OUTLET...

  • Page 35: Hot Insulation Or Cold Insulation Procedure

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 HOT INSULATION OR COLD INSULATION 3. 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 4.

  • Page 36: Figure 13 - Interior Of Control Panel

    FORM 155.31-ICOM2.EN.UL SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/21/2018 For Europe 2-Ground MCB1 PSU1 Terminal 2-Ground PWX PWT Terminal Door Stopper For Other Countries LD22863 FIGURE 13 - INTERIOR OF CONTROL PANEL External Handle Buzzer Touch Panel Door Stopper (90°) Ground Terminal LD28262...

  • Page 37: Section 4 - Technical Data

    FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 4 - TECHNICAL DATA This section includes technical information about the The numbers shown in Table 6 on page 37 are the unit, such as weight, dimensions, electrical data, wir- allowable ranges for each parameter. Not all combi- ing, and sound data.

  • Page 38: Table 7 - High Efficiency Weights And Dimensions

    TABLE 7 - HIGH EFFICIENCY WEIGHTS AND DIMENSIONS DIMENSION FEET (METERS) WEIGHT LBS (TONS) TUBE EMERGENCY MODEL MAXIMUM LENGTH WIDTH HEIGHT EXTRACTING OPERATION (FILLED WITH YHAU-CW SHIPPING SPACE WATER) LBS (TON) FT (M) FT (M) FT (M) LBS (TON) LBS (TON) FT (M) 9.84 7.55 8.53 6.56...

  • Page 39: Table 8 - High Efficiency Physical Data

    TABLE 8 - HIGH EFFICIENCY PHYSICAL DATA WATER VOLUME RADIATION RADIATION COLD HEAT LOSS HOT INSULATION HEAT LOSS (WITH CHILLED COOLING INSULATION (WITHOUT STEAM YHAU-CW AREA INSULATION, WATER WATER (ABS AREA INSULATION, (GEN) AMBIENT TEMP. (EVAP) AND COND) AMBIENT TEMP. F³ (M³) 50°F) (KW)

  • Page 40: Table 9 - Standard Weights And Dimensions

    TABLE 9 - STANDARD WEIGHTS AND DIMENSIONS DIMENSION FEET (METERS) WEIGHT LBS (TONS) TUBE EMERGENCY MODEL MAXIMUM LENGTH WIDTH HEIGHT EXTRACTING OPERATION (FILLED WITH YHAU-CW SHIPPING SPACE WATER) LBS (TON) FT (M) FT (M) FT (M) LBS (TON) LBS (TON) FT (M) 9.84 7.55 8.53 6.56...

  • Page 41: Table 10 - Standard Physical Data

    TABLE 10 - STANDARD PHYSICAL DATA WATER VOLUME RADIATION RADIATION COLD HEAT LOSS HEAT LOSS COOLING CHILLED INSULATION INSULATION (WITH (WITHOUT WATER STEAM YHAU-CW WATER AREA AREA INSULATION, INSULATION, (ABS AND (GEN) (EVAP) AMBIENT TEMP. AMBIENT TEMP. COND) F³ (M³) F³ (M³) 50°F) (KW) 50°F) (KW)

  • Page 42: Figure 15 - Load Points For Double-Effect Steam Units

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 SIDE 1 SIDE 2 SIDE 1 SIDE 2 Load Point 4 Load Point 3 Load Point 1 Load Point 2 LD22376 FIGURE 15 - LOAD POINTS FOR DOUBLE-EFFECT STEAM UNITS JOHNSON CONTROLS...
  • Page 43 SECTION 4 - TECHNICAL DATA THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 44: Table 11 - Load Points For Double-Effect Ex & Exw Units - High Efficiency

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 11 - LOAD POINTS FOR DOUBLE-EFFECT EX & EXW UNITS - HIGH EFFICIENCY LOAD POINT 1 LOAD POINT 2 LOAD POINT 3 LOAD POINT 4 (TON) (TON) (TON) (TON) 4,057 4,387 3,571...

  • Page 45: Table 12 - Load Points For Double-Effect Ex & Exw Units - Standard Efficiency

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 12 - LOAD POINTS FOR DOUBLE-EFFECT EX & EXW UNITS - STANDARD EFFICIENCY LOAD POINT 1 LOAD POINT 2 LOAD POINT 3 LOAD POINT 4 (TON) (TON) (TON) (TON) 3,770 4,079 3,329...

  • Page 46: Table 13 - Electrical Data

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP POWER SOURCE YHAU-CW (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 100A 11.6 48.0 25.2 AC200V-3Ph-60Hz(JIS) 100A 11.4 40.6 22.2...
  • Page 47 FORM 155.31-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-CW 20.6 20.6 20.6 2.06 20.6 150EX(S) 0.75 1.12 1.14 1.03 1.05 20.6 10.8 20.6 10.3 20.6 10.3...
  • Page 48 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP POWER SOURCE YHAU-CW (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 100A 15.6 60.0 11.6 48.0 AC200V-3Ph-60Hz(JIS) 100A 14.8 53.2...
  • Page 49 FORM 155.31-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-CW 20.6 12.2 20.6 11.5 20.6 11.5 20.6 12.2 11.9 11.9 360EX(S) 0.75 1.65 12.1 12.5 10.0 11.5...
  • Page 50 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP POWER SOURCE YHAU-CW (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 100A 26.0 132.0 11.6 48.0 AC200V-3Ph-60Hz(JIS) 100A 25.0 118.0...
  • Page 51 FORM 155.31-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-CW 20.6 15.8 12.6 20.6 15.1 12.0 20.6 15.1 12.0 20.6 15.4 12.3 15.9 12.7 15.7 12.6 560EX(S) 0.75...
  • Page 52 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP POWER SOURCE YHAU-CW (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 100A 26.0 132.0 12.4 42.0 AC200V-3Ph-60Hz(JIS) 100A 25.0 118.0...
  • Page 53 FORM 155.31-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-CW 25.6 20.6 17.6 14.0 25.0 20.6 16.7 13.3 25.0 20.6 16.7 13.3 26.0 20.6 17.1 13.7 11.9...
  • Page 54 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 13 - ELECTRICAL DATA MAIN SOLUTION CIRCULATION SOLUTION SPRAY BREAKER PUMP PUMP POWER SOURCE YHAU-CW (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 100A 100A 38.4 144.0 20.2 72.0 AC200V-3Ph-60Hz(JIS) 100A 100A 36.0...
  • Page 55 FORM 155.31-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-CW 26.0 20.6 25.0 20.0 24.0 20.6 23.4 18.8 24.0 20.6 23.4 18.8 26.4 20.6 24.5 19.6 12.5...
  • Page 56 FORM 155.31-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 POWER SOURCE YHAU-CW (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 100A 100A 38.4 144.0 20.2 72.0 AC200V-3Ph-60Hz(JIS)
  • Page 57 FORM 155.31-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-CW 26.0 20.6 25.0 20.0 24.0 20.6 23.4 18.8 24.0 20.6 23.4 18.8 26.4 20.6 24.5 19.6 12.5...
  • Page 58 FORM 155.31-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 POWER SOURCE YHAU-CW (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 100A 100A 38.4 144.0 20.2 72.0 AC200V-3Ph-60Hz(JIS)
  • Page 59 FORM 155.31-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-CW 26.0 20.6 25.0 20.0 24.0 20.6 23.4 18.8 24.0 20.6 23.4 18.8 26.4 20.6 24.5 19.6 12.5...
  • Page 60 FORM 155.31-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 POWER SOURCE YHAU-CW (VOLTAGE-PH-HZ) RATED FRAME CURRENT SIZE AC200V-3Ph-50Hz 150A 225A 52.6 208.0 38.4 144.0 AC200V-3Ph-60Hz(JIS)
  • Page 61 FORM 155.31-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-CW 12.4 42.0 20.6 37.4 29.9 11.6 46.0 20.6 36.0 28.8 11.6 46.0 20.6 36.0 28.8 11.0 48.0...

  • Page 62: Figure 16 - Power Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram FIGURE 16 - POWER WIRING JOHNSON CONTROLS...
  • Page 63 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28254_UL FIGURE 16 - POWER WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 64: Figure 17 - Power Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram FIGURE 17 - POWER WIRING JOHNSON CONTROLS...
  • Page 65 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28255_UL FIGURE 17 - POWER WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 66: Figure 18 - Plc Input Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram FIGURE 18 - PLC INPUT WIRING JOHNSON CONTROLS...
  • Page 67 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28256_UL FIGURE 18 - PLC INPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 68: Figure 19 - Plc Input Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram FIGURE 19 - PLC INPUT WIRING JOHNSON CONTROLS...
  • Page 69 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28257_UL FIGURE 19 - PLC INPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 70: Figure 20 - Plc Output Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram FIGURE 20 - PLC OUTPUT WIRING JOHNSON CONTROLS...
  • Page 71 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28258_UL FIGURE 20 - PLC OUTPUT WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 72: Figure 21 - Display/Analog Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram FIGURE 21 - DISPLAY/ANALOG WIRING JOHNSON CONTROLS...
  • Page 73 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28260_UL FIGURE 21 - DISPLAY/ANALOG WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 74: Figure 22 - Display/Analog Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram FIGURE 22 - DISPLAY/ANALOG WIRING JOHNSON CONTROLS...
  • Page 75 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28261_UL FIGURE 22 - DISPLAY/ANALOG WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 76: Figure 23 - Plc Analog Output Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28262_UL FIGURE 23 - PLC ANALOG OUTPUT WIRING JOHNSON CONTROLS...

  • Page 77: Figure 24 - Plc And Touch Screen Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28264_UL FIGURE 24 - PLC AND TOUCH SCREEN WIRING JOHNSON CONTROLS...

  • Page 78: Figure 25 - Steam Control Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram FIGURE 25 - STEAM CONTROL WIRING JOHNSON CONTROLS...
  • Page 79 FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Electrical Diagram LD28263_UL FIGURE 25 - STEAM CONTROL WIRING (CONT'D) JOHNSON CONTROLS...

  • Page 80: Figure 26 - External Connection Terminal Details

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Ancillar Equipment Board Absorption Chiller Control Panel (Out of Scope of Supply) (Scope of Supply) Power Source Z3 Terminal Block Chilled Water Pump Interlock Constantly Monitering Interlock Cooling Water Pump Interlock Common Remote Operation (No Voltage Level Start/Stop)

  • Page 81: Figure 27 - Remote Transmission Signal

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Absorption Chiller Ancillary Equipment Board Control Panel (Out of Scope of Supply) (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 82: Figure 28 - Signal Terminal Transition Wiring

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 Terminal Block Starting Panel for Chilled Water Common Operating Signal Failure Signal Chilled Water Pump Operating Signal Cooling Water Pump Operating Signal Starting Panel For Cooling Water Example Diagram of Starting Panel if Chilled/Hot Water Pump and Cooling Water Pump are Separately Equipped.

  • Page 83: Additional Information

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 14 - CONTACT SPECIFICATIONS CONTACT SPECIFICATION Max. Open/Close Voltage: AC250 V/DC30 V Absorption Chiller Control Digital Signal Max. Open/Close Current: 2A/1 Point (Resistance Load) Panel - External Output Max. Common Current: 8 A (Resistance Load) Terminal Analog Signal Allowed Resistance Load: 550 Ohm...

  • Page 84: Upper Communication Specification

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 UPPER COMMUNICATION SPECIFICATION The information in this section applies to both the CW- EX Series and the CW-EXW series of steam absorp- tion chillers. Upper Communication System Configuration The configuration of the upper communication system is shown in the figure below.

  • Page 85: Scope Of Delivery

    FORM 155.31-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 relevant communication modes.

  • Page 86: Communication Specification

    FORM 155.31-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 87: User-Created

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 19 - COMMUNICATION DATA/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 Steam control valve upper limit 00201 0000~1000 unit, 1 unit=0.1% Set point...

  • Page 88: Table 21 - Cable Diagram (Rs422/Rs485)

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 TABLE 21 - CABLE DIAGRAM (RS422/RS485) 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 89: Figure 31 - 2 Wire 1:1 Connection With User-Created Cable

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 2 Wire Type Cable Diagrams The following are sample cable diagrams for a 2-wire type connection. They use a GP4000 series (COM2). (Slave) D-sub 9 Pin External Device (socket) Termination Shield (Master) Termination...

  • Page 90: Wire Type Cable Diagrams

    FORM 155.31-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. They use a GP4000 series (COM2). (Slave) External Device D-sub 9 pin (socket) (Master) Shield Termination resistance Signal name...

  • Page 91: Table 22 - Communication Specifications

    FORM 155.31-ICOM2.EN.UL SECTION 4 - TECHNICAL DATA ISSUE DATE: 12/21/2018 The following table contains information about the communication specifications needed for the Modbus RTU. See Table 18 on page 86 for more information about the Read Command or Table 19 on page 87 for more information about the Write Command.

  • Page 92: Noise Emisson

    NOTE: These data are reference values, as the chiller unit was not covered with the thermal insulation materials and the water pipes (for chilled water, cooling water, and steam) were temporary during the measurement. FIGURE 35 - SAMPLE SOUND TESTING FOR YHAU-CW CHILLER JOHNSON CONTROLS...

  • Page 93: Section 5 - Commissioning

    FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 5 - COMMISSIONING GENERAL GUIDELINES FOR USE 7. Read and record the delivery pressure of the solu- tion pump and the refrigerant pump. Before Operation 8. Close the valve. Charge the solution and the refrigerant water if the so- lution and refrigerant water is in the barrels during the 9.

  • Page 94: Precautions For The Use Of Steam

    The steps and procedures MUST be performed by a YORK/Johnson Controls Service • The load change condition to limit the chilled wa- person prior to customer use.

  • Page 95: Chilled Water Outlet Temperature Controller

    FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 The OPER. and STOP buttons are avail- A drain trap does not need to be installed in the steam able on the Main, Data, and Setting drain line between the chiller and the hot well tank. screen.

  • Page 96: Figure 36 - Cooling Start Diagram

    FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 Power on Stop operation Initialize self-check Dilution time count mechanism Steam control valve or steam drain control valve, steam drain solenoid valve, steam shut off valve(option) Remote Remote / local operation change close Local...

  • Page 97: Figure 38 - Steam Sequential Operation Flowchart

    FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 Sequential Sequential Operation Operation Chilled water pump Air conditioner Interlock Sequential operation Cooling water pump Cooling tower Sequential operation Interlock Other interlocks, including earthquake sensor, abnormal room temperature sensor or other relevant sensors. NOTES: 1.
  • Page 98 B. Piping 1. All major pieces, boxes, and crates have been 1. Piping is installed between the unit at the source of received and accounted for by a YORK/Johnson supply............... Controls Service Representative......2. Air vent valves and drain valves are closed for: 2.
  • Page 99 FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.31-CL1.EN.UL ISSUE DATE: 12/21/2018 10. A mesh strainer is installed on the: C. Valve and Sensor Check a. Chilled water inlet line .......... 1. Adjusting valves are set correctly......b.
  • Page 100 FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 START UP CHECKLIST Form 155.31-CL1.EN.UL ISSUE DATE: 12/21/2018 A. Operation Check F. Evacuate Nitrogen Charge 1. Manually start each water pump......1. Remove the plug in the purge line......2.
  • Page 101 FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.31-CL1.EN.UL ISSUE DATE: 12/21/2018 START UP B. Purge Amount check 1. Verify that the purge amount from the absorber is A. Operation check within acceptable range ........... 2. Close the spindle valve to facilitate purging from 1.
  • Page 102 FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM155.31-CL1.EN.UL ISSUE DATE: 12/21/2018 DOUBLE EFFECT STEAM ABSORPTION CHILLER COMMISSIONING DATA SHEET (1/2) User: Model: MFG.No.: User's machine code: Insulation Resistance Electric Power Supply Standard: 5 MΩ or more (with 500 V R-Gnd S-Gnd T-Gnd...
  • Page 103 FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 FORM 155.31-CL1.EN.UL ISSUE DATE: 12/14/2018 DOUBLE EFFECT STEAM ABSORPTION CHILLER COMMISSIONING DATA SHEET (2/2) User: Model: MFG.No.: User's machine code: Running Data Date: Measured by Specification Standard Steam control valve or Control panel steam drain control valve position...
  • Page 104 FORM 155.31-ICOM2.EN.UL SECTION 5 - COMMISSIONING ISSUE DATE: 12/21/2018 Form 155.31-CL1.EN.UL ISSUE DATE: 12/21/2018 PURGE AMOUNT DATA SHEET (1/1) User: Model: MFG.No.: User's machine code: Measured Date: Measured by: Purge Amount from Purge Tank Flame Reaction Test Standard: 4.0 cc/min. or smaller Reaction ( Strong / Weak / None ) Amount of Gas (P) cc/min...

  • Page 105: Section 6 - Operation

    SECTION 6 – OPERATION YHAU-CW CONTROL CENTER COMMON ITEMS Buttons are listed in the order they are The YHAU-CW Control Center, furnished as standard seen on the screen: left to right and top on each chiller, allows for efficiency, monitoring, data to bottom.

  • Page 106: Change Numeric Values

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 When you press the OPER. button while the chiller is CHANGE NUMERIC VALUES stopped, or STOP while the chiller is operating, a con- Many numeric values, such as the set point and the firmation message appears.

  • Page 107: Operating Status

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 MAIN SCREEN LD20042_UL FIGURE 40 - MAIN SCREEN • Temp. Control: Light is lit if the temperature The Main Screen displays the equipment status (chiller control of the microcomputer panel changes to start or stop, operating, pumps ON or OFF, purge pump RUN status.
  • Page 108 FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 Set Point: The set point of chilled water leaving tem- Items in the chiller process diagram are: perature is shown on the left of the screen. Pump The system illustration lights (lines fill in) when the Solution Circulating Pump, Solution Spray Pump, system is operating.

  • Page 109: Figure 41 - Data Screen

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 DATA SCREEN LD20044_UL LD20044 FIGURE 41 - DATA SCREEN The Data Screen displays values showing tempera- Evap. Refrigerant Temp.: temperature of the refriger- tures, operating hours, operating frequency, data trends ant in the evaporator and a history of failures, alarms, and time based tem- Absorber Temp.: temperature of the diluted solution perature trends.
  • Page 110 FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 The Operation Hours section shows the following: To move to the Trend screen, press the Trend button at the upper right of the screen. • Operation: displays how long the chiller has been running.

  • Page 111: Figure 42 - Solution Analysis / Control Panel Parts Replacement Screen

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 SOLUTION ANALYSIS / CONTROL PANEL PARTS REPLACEMENT SCREEN LD21347 FIGURE 42 - SOLUTION ANALYSIS / CONTROL PANEL PARTS REPLACEMENT SCREEN The Solution Analysis section of the screen shows The Control Panel Parts Replacement section of the the maintenance interval and current operation hours screen shows the maintenance interval and current op- since the last inhibitor solution maintenance.

  • Page 112: Figure 43 - Solution Pump Overhaul / Refrigerant Pump Overhaul Screen

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 SOLUTION PUMP OVERHAUL / REFRIGERANT PUMP OVERHAUL SCREEN LD21554 FIGURE 43 - SOLUTION PUMP OVERHAUL / REFRIGERANT PUMP OVERHAUL SCREEN The Solution Pump Overhaul section of the screen and the Refrigerant Pump Overhaul section of the screen both indicate the maintenance interval and the current operation hours since the last maintenance.

  • Page 113: Figure 44 - Trend Screen

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TREND SCREEN LD20045_UL FIGURE 44 - TREND SCREEN The graphs are updated constantly regardless of the op- To view the Trend Screen, press the Trend button erating status of the chiller. above the History Menu section on the Data screen.

  • Page 114: Figure 45 - Hourly Operation History Screen By Hours

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 HOURLY OPERATION HISTORY SCREEN LD20079_UL FIGURE 45 - HOURLY OPERATION HISTORY SCREEN BY HOURS To view the Hourly Operation History screen, press the Sol. Pump: operation status of the solution pump. Hourly Operation button in the History Menu screen Ref.
  • Page 115 FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 The Chilled water section of the screen shows you the There are two sets of buttons on the right side of the following information: screen. The first set gives you access to information about past occurrences.

  • Page 116: Figure 46 - Operation History Screen By Minutes

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 MINUTELY OPERATION HISTORY SCREEN LD20080_UL FIGURE 46 - OPERATION HISTORY SCREEN BY MINUTES Ope. Freq.: how many times the chiller has started us- To view the Minutely Operation History screen, press ing the OPER.
  • Page 117 FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 There are two sets of buttons on the right side of the The Cooling Water section shows you: screen. The first set gives you access to information In Temp.: temperature of the cooling water measured about past occurrences.

  • Page 118: Figure 47 - Failure History Screen

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 FAILURE HISTORY SCREEN LD20076a LD20076_UL FIGURE 47 - FAILURE HISTORY SCREEN You move to the Failure History screen after you press Ope. Freq.: how many times the chiller has started us- the Failure button in the History Menu screen section.
  • Page 119 FORM 155.31-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 48 - Alarm History Screen

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 ALARM HISTORY SCREEN LD20081 LD20081 FIGURE 48 - 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 121 FORM 155.31-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 122: Failure

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 FAILURE AND ALARM SCREEN LD19932_UL LD19932 FIGURE 49 - FAILURE AND ALARM SCREEN This screen displays failure indications (time-outs, op- eration interlock, overcooled refrigerant, over and un- der temperatures, and problems with the unit's pumps) and system alarms.

  • Page 123: Table 25 - Failure List

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 The failures addressed in Failure section of this screen are: TABLE 25 - FAILURE LIST BUTTON LABEL OPERATION (FAILURE AT FAILURE CAUSE COUNTER MEASURES NAME) OCCURRENCE Chilled water pump operation Chilled W. Time interlock and/or chilled water Out (Chilled suspension relay was not...

  • Page 124: Alarm

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TABLE 26 - FAILURE LIST (CONT'D) BUTTON LABEL OPERATION (FAILURE AT FAILURE CAUSE COUNTER MEASURES NAME) OCCURRENCE HG High HG solution temperature rose • Check the cooling water line. Temperature abnormally. •...

  • Page 125: Table 26 - Alarm List

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TABLE 26 - ALARM LIST BUTTON LABEL CAUSE OF ALARM AND COUNTER MEASURES (ALARM NAME) CONDITION TO RESET • Purge frequency within a set time exceeded its defined value, therefore chiller Abnormal Purge is suspected of poor air-tightness, , or other Freq.
  • Page 126 FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 TABLE 26 - ALARM LIST (CONT'D) BUTTON LABEL CAUSE OF ALARM AND COUNTER MEASURES (ALARM NAME) CONDITION TO RESET • Check the cooling water line. HG Hi Conce. • Check the cooling water flow rate. High solution concentration and load limit Prevent.

  • Page 127: Control Parameter

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 SETTING SCREEN LD19933 LD19933_UL FIGURE 50 - SETTING SCREEN Set Point (Display): the set point of the chilled water This screen displays control parameters (setting method and each setting parameter), valve operation leaving temperature (control valve mode auto / manual and valve position Automatic Stop: the temperature at which the chiller...

  • Page 128: Date And Time

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 If you press the REMOTE button, the setting charac- To move to the Menu screen, press the Control Valve Mode Auto button. teristics of the remote set point are determined based on the setting base temperature and the remote setting differential.

  • Page 129: Operation Switch

    FORM 155.31-ICOM2.EN.UL SECTION 6 – OPERATION ISSUE DATE: 12/21/2018 If the clock is not keeping the correct time, use the fol- • Purge Mode: The Auto and Manual buttons lowing to fix it: control the purge operation. The lit button indi- 1.
  • Page 130 FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 131: Section 7 - Maintenance

    FORM 155.31-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 solenoid valves. • Never splash water over the electrical parts in- stalled to the control panel and absorption chiller.

  • Page 132: Start The Chiller After It Has Been Stopped For A Long Period

    FORM 155.31-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 peak When you start the chiller after it has not run for more performance and prevent deterioration of the internal than 15 days, use the procedure below: parts.

  • Page 133: Manual Method To Purge Non-Condensable Gas Directly From Absorber With Vacuum Pump

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 YHAU-CW(L) 400-2000EX(W)(4)(S)P YHAU-CW(L)150-300EX(S)P LD19978 Purging operating valve for purge tank line Purge main valve Purging operating valve for purge tank line Purging operating valve for absorber line Purge main valve Purging operating valve for absorber line...

  • Page 134: Manual Method To Purge Non-Condensable Gas From Purging Tank With Vacuum Pump

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 If the pressure decreases when valve V16 7. The manual purge procedure is complete when opens, the vacuum pump capacity is too the pressure reaches 0.44 PSI.abs or less on the small.

  • Page 135: Figure 52 - Yhau-Cw Steam Fired Chiller Flow Diagram

    × × Preparation × × × Manual purging from purging tank Starting purging × × Automatic purge of the purging tank × × : Open valve. X: Closed valve. FIGURE 52 - YHAU-CW STEAM FIRED CHILLER FLOW DIAGRAM JOHNSON CONTROLS...

  • Page 136: Figure 53 - Process And Instrumentation Diagram

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 LD22375 FIGURE 53 - PROCESS AND INSTRUMENTATION DIAGRAM JOHNSON CONTROLS...

  • Page 137: Refrigerant Refining Method

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 REFRIGERANT REFINING METHOD MANUAL REFRIGERANT BLOW DOWN AND DILUTING METHOD With an increase in the operation time of the chiller, some of the solution can mix in with the refrigerant. When the chiller stops suddenly due to a power failure, Mixing the solution and the refrigerant lowers the re- the solution can become crystallized.

  • Page 138: Decrystallization Method

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 DECRYSTALLIZATION METHOD Even if the solution in the absorption chiller is crystal- For the location of the refrigerant manual lized during operation, it can be melted if the crystalli- blow valve, see Figure 51 on page 133. zation is not severe.

  • Page 139: Precautions For De-Crystallization

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 20. Press the Refrigerant Pump Auto button. MAINTENANCE ITEMS Maintenance and inspection items along with standard 21. Return the valve cap. There is an O-ring between inspection periods are shown in the next table. For de- the cap and valve.
  • Page 140 FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 28 - MAINTENANCE AND INSPECTION (CONT'D) TASK CONTENTS FREQUENCY SCOPE Measure the insulation resistance of the main circuit and motors Measurement of (solution pump, refrigerant pump) mainly to check for lowering insulation resistance of of insulation.
  • Page 141 FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 28 - MAINTENANCE AND INSPECTION (CONT'D) TASK CONTENTS FREQUENCY SCOPE Repair of paint (tar epoxy paint) of inside wall of Chilled water: 2 years Repair the paint of the inside wall. chilled water and cooling Cooling water: \1 year waterboxes...

  • Page 142: Refrigerant Pump Manual Stop

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 Refrigerant Pump Manual Stop 6. Press the Purge Mode Auto button. The refrigerant pump can be stopped manually for LIFESPAN FOR VARIOUS PARTS maintenance purposes. It can be stopped even while The replacement periods for some parts are shown the chiller operates.

  • Page 143: Table 29 - Lifespan Of Common Parts

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 29 - LIFESPAN OF COMMON PARTS DESCRIPTION APPLICABLE MODELS OR SECTIONS LIFESPAN OF COMMON PARTS Gasket CHW Water Box Every 2 years Gasket CW Water Box Every 1 year Gasket, O-Ring, Diaphragm Every 24,000/Hr Evaporator Tube Absorber Tube...

  • Page 144: Water Quality Control

    FORM 155.31-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 145: Treatment For Long Stoppage Of The Absorption Chiller

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TREATMENT FOR LONG STOPPAGE OF THE FLOW SPEED IN TUBES ABSORPTION CHILLER Since the water flow speed in the tubes is closely re- If the absorption chiller is stopped for 15 days or lon- lated to any existing corrosion, do not increase the wa- ger, bacteria in the water or in the tubes may grow.

  • Page 146: Table 30 - Tendency Of Generation Of Scales And Corrosion By Quality Of Cooling Water

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 30 - 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 Bad corrosion of iron ~ Pale...

  • Page 147: Figure 54 - Chilled Water And Cooling System

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 Cooling Water Chilled Water Return Header Cooling Tower Scope of Supply Chilled Water PI TI Feeding Water Chilled Straner Water Absorption Chiller (10 mesh) Pump PI TI Cooling Water Thermostat PI TI Chilled Water Strainer Supply Header...

  • Page 148: Figure 56 - Steam And Drain System For Steam Drain Control Valve

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 LD27812 FIGURE 56 - STEAM AND DRAIN SYSTEM FOR STEAM DRAIN CONTROL VALVE TABLE 31 - STEAM DRAIN QUALITY CONTROL COMPONENT STANDARD VALUE 7.5 ~ 8.5 (ppm) ≤ 20 (ppm) ≤ 10 S (ppm) DO (ppm) ≤...

  • Page 149: Table 32 - Chilled And Cooling Water Quality Control (Maximum Concentrations)

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 32 - CHILLED AND COOLING WATER QUALITY CONTROL (MAXIMUM CONCENTRATIONS) COOLING WATER SYSTEM NON- CHILLED WATER SYSTEM TENDENCY CIRCULATING CIRCULATING TYPE WATER ELEMENT (1) (6) CIRCULATING CIRCULATING REPLENISH PASSING WATER REPLENISH WATER WATER...

  • Page 150: Storage Method Of The Chiller

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 STORAGE METHOD OF THE CHILLER Wet Storage Method The wet storage method is applicable in cases where In case of long-term storage of the chiller (3 months there is no concern of chilled water and/or cooling or longer), the storage method varies depending on the water freezing in winter.

  • Page 151: Dry Storage Method

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 Dry Storage Method PRECAUTIONS AGAINST EXTERNAL DAMAGE The dry storage method should be used if the chilled or cooling water system may freeze in the winter or, if the Avoid storing the machine in a place that is easily ac- chilled or cooling water system has a lining tube.

  • Page 152: Table 33 - Wet Storage Method

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 TABLE 33 - WET STORAGE METHOD PART STORAGE METHOD NOTES Storage Period; Chilled water line 1. The manual valve on the purge piping should be fully Filled with water closed (See Figure 51 on page 133). less than 2 months Cooling water line 2.

  • Page 153: Figure 57 - Duhring Diagram / Ptx Chart (°F)

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 LD14221a FIGURE 57 - DUHRING DIAGRAM / PTX CHART (°F) JOHNSON CONTROLS...

  • Page 154: Figure 58 - Duhring Diagram / Ptx Chart (°C)

    FORM 155.31-ICOM2.EN.UL SECTION 7 – MAINTENANCE ISSUE DATE: 12/21/2018 FIGURE 58 - DUHRING DIAGRAM / PTX CHART (°C) LD14221a JOHNSON CONTROLS...

  • Page 155: Figure 59 - Specific Gravity - Concentration (°F)

    FORM 155.31-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 156: Figure 60 - Specific Gravity - Concentration (°C)

    FORM 155.31-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 157: Section 8 - Troubleshooting

    FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 8 – TROUBLESHOOTING If the chiller malfunctions or an abnormal condition • See if the valves of the chilled water system is detected while it operates, locate the cause. Use the and cooling water system are set correctly. procedures listed below to fix the problem.

  • Page 158: Table 35 - Troubleshooting The High Temperature Generator

    FORM 155.31-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 conforms to the specification. Check the flow meter, discharge pressure of the cooling water pump, current,and other applicable Cooling water is Insufficient pumps or pressures.

  • Page 159: Table 37 - Chilled Water Suspension

    FORM 155.31-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 In the case of chilled water suspension, the absorption chiller does not perform the dilution operation. It stops immediately. If the absorption chiller is left as it is, the solution in it may crystallize in 4-5 hours. To prevent this, dilute the solution.

  • Page 160: Table 40 - Pump Interlocks

    FORM 155.31-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 TABLE 40 - PUMP INTERLOCKS ITEM CAUSE COUNTERMEASURE Water pump interlock was not Check the water pump interlock. established TABLE 41 - LOW COOLING WATER INLET TEMPERATURE ITEM CAUSE COUNTERMEASURE Cooling water inlet Check the cooling water inlet temperature control system.

  • Page 161: Troubleshooting Performance Issues

    FORM 155.31-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 TROUBLESHOOTING PERFORMANCE ISSUES If the performance is insufficient while the steam con- trol valve is fully opened or if the steam control valve does not fully open while the load is sufficient, check numbers 1-7 in the following table in order.

  • Page 162: Vacuum Pump

    FORM 155.31-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 VACUUM PUMP When the Purge Abnormal alarm button lights, the vacuum pump needs to be disassembled for inspection. Contact your local Johnson Controls Service Center. When the Abnormal Purge Freq. alarm button lights or the vacuum level of the purging line did not reach the specified level during the vacuum pump capacity, check to see if the entire purge line needs to be inspect-...

  • Page 163: Abnormal Solution And Refrigerant Levels

    FORM 155.31-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 wrong, correct it according to the following procedure.

  • Page 164: Insufficient Vacuum Levels

    FORM 155.31-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.

  • Page 165: Figure 61 - Troubleshooting Sequence Flow Chart

    FORM 155.31-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 • HG High temperature • Cooling water pump interlock •...

  • Page 166: Actions To Take Against Power Failure

    FORM 155.31-ICOM2.EN.UL SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/21/2018 ACTIONS TO TAKE AGAINST POWER FAILURE If the main power fails, take the following actions. 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...

  • Page 167: Section 9 - Decommissioning, Dismantling, And Disposal

    FORM 155.31-ICOM2.EN.UL ISSUE DATE: 12/21/2018 SECTION 9 - DECOMMISSIONING, DISMANTLING, AND DISPOSAL Unless otherwise indicated, the operations described 9. Remove fixing down bolts. Lift the unit from po- below can be performed by any properly trained main- sition, using the points provided and equipment tenance technician.
  • Page 168 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 155.31-ICOM2.EN.UL (1118) Issue Date: December 21, 2018 NEW RELEASE...

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