York YHAU-CE-JE Series Installation Operation & Maintenance
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York YHAU-CE-JE Series Installation Operation & Maintenance

Double-effect exhaust gas absorption chiller-heater
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DOUBLE-EFFECT EXHAUST GAS
ABSORPTION CHILLER-HEATER
NEW RELEASE
Form 155.33-ICOM2.EN.GB (1217)
INSTALLATION, OPERATION, MAINTENANCE
Model YHAU-CE-JE
150-1440 TONS
527-5064 KW
50 HZ
LD22864
GB
Issue Date:
COMPLIANT
December 4, 2017

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  • Page 1 DOUBLE-EFFECT EXHAUST GAS ABSORPTION CHILLER-HEATER NEW RELEASE Form 155.33-ICOM2.EN.GB (1217) INSTALLATION, OPERATION, MAINTENANCE Model YHAU-CE-JE 150-1440 TONS 527-5064 KW 50 HZ LD22864 Issue Date: COMPLIANT December 4, 2017...
  • Page 2 FORM 155.33-ICOM2.EN.GB ISSUE DATE: 12/4/2017 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 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls’ policy for con- regarding the applicability of these documents, rig- tinuous product improvement, the information con- ging, lifting, and operating/service personnel should tained in this document is subject to change without verify whether the equipment has been modified and notice.
  • Page 4 FORM 155.33-ICOM2.EN.GB ISSUE DATE: 12/4/2017 NOMENCLATURE YHAU Unit Type LOW TEMP. CHW York Absorption L : 1.0 °C CHW NOMINAL LL: -5.0 °C CHW CAPACITY (RT) FUEL E: Exhaust WASTE HOT WATER DESIGN HEAT RECOVERY SYMBOL None: No heat recovery...

  • Page 5: Table Of Contents

    FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 TABLE OF CONTENTS SECTION 1 – GENERAL CHILLER-HEATER AND SAFETY INFORMATION ............11 Introduction ..............................11 About this Manual ............................11 Warranty ................................. 11 Quality Assurance ............................12 High Temperature and Pressure Cleaning ....................12 Safety Labels ..............................12 SECTION 2 –...
  • Page 6 FORM 155.33-ICOM2.EN.GB ISSUE DATE: 12/4/2017 TABLE OF CONTENTS (CONT'D) SECTION 4 - TECHNICAL DATA ...........................33 Upper Communication Specification ......................40 Upper Communication System Configuration ..................40 Scope of Delivery ..........................41 Connection Port for Ethernet Communication ..................41 Communication Specification ........................ 42 Communication Data ..........................42 User-Created ............................44 2-Wire Cable Diagrams Without Adaptor ....................
  • Page 7 FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 TABLE OF CONTENTS (CONT'D) Manual Method to Purge Non-condensable Gas Directly from Absorber ............93 Manual Method to Purge Non-condensable Gas from Purging Tank ............. 93 Automatic Method to Purge Non-condensable Gas from Purging Tank ............93 Refrigerant Refining Method ..........................
  • Page 8 FORM 155.33-ICOM2.EN.GB ISSUE DATE: 12/4/2017 LIST OF FIGURES FIGURE 1 - YHAU-CE-JE Components ........................15 FIGURE 2 - Two Step Exhaust Gas Absorption Chiller-Heater Cycle Diagram (Cooling Mode) ......16 FIGURE 3 - Warning ...............................23 FIGURE 4 - Vibration and Isolation Details ......................27 FIGURE 5 - Nozzle Locations (Example - One Exhaust Gas Outlet Flange) ............
  • Page 9 FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 LIST OF TABLES TABLE 1 - Insulating Material and Thickness ......................30 TABLE 2 - Points Requiring Hot or Cold Insulation ....................30 TABLE 3 - Typical Operational Range ........................33 TABLE 4 - Contact Specifications ...........................38 TABLE 5 - Scope of Delivery ..........................41 TABLE 6 - Ethernet Interface Specification ......................41 TABLE 7 - Communication Specifications ......................42 TABLE 8 - Read Command ............................42...
  • Page 10 FORM 155.33-ICOM2.EN.GB ISSUE DATE: 12/4/2017 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

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

    ISSUE DATE:12/4/2017 SECTION 1 – GENERAL CHILLER-HEATER AND SAFETY INFORMATION INTRODUCTION WARRANTY YORK YHAU-CE-JE Absorption chiller-heaters are Johnson Controls warrants YHAU-CE-JE chiller- heaters in accordance with the Limited Warranty En- manufactured to the highest design and construction standards to ensure high performance, reliability, and gineered Systems Equipment procedure.

  • Page 12: Quality Assurance

    FORM 155.33-ICOM2.EN.GB SECTION 1 – GENERAL CHILLER-HEATER AND SAFETY INFORMATION ISSUE DATE: 12/4/2017 SAFETY LABELS QUALITY ASSURANCE For safe operation, read the instructions Units comply with the following directives: first. • GB/T 18362-2008 Direct fired lithium bromide absorption water chiller-heater (heater) •...
  • Page 13 FORM 155.33-ICOM2.EN.GB SECTION 1 – GENERAL CHILLER-HEATER AND SAFETY INFORMATION ISSUE DATE:12/4/2017 Warning: Rotating object Caution: Prohibited Caution: Risk of tumble Caution: Risk of getting hand caught in LD20923f JOHNSON CONTROLS...
  • Page 14 FORM 155.33-ICOM2.EN.GB ISSUE DATE: 12/4/2017 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 15: Section 2 - Product Description

    FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 SECTION 2 – PRODUCT DESCRIPTION The principle of refrigeration is the exchange of heat. • solution heat exchangers to heighten the cycle In absorption liquid chilling, there are four basic heat efficiency exchange surfaces: the evaporator, the absorber, the •...

  • Page 16: How It Works (Exhaust Gas Units)

    FORM 155.33-ICOM2.EN.GB SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/4/2017 HOW IT WORKS (EXHAUST GAS UNITS) The double effect exhaust gas absorption chiller-heat- The vapor pressure of the lithium bromide solution is er uses deionized water as the refrigerant and lithium lower than the vapor pressure of the refrigerant.

  • Page 17: Evaporator

    FORM 155.33-ICOM2.EN.GB SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE:12/4/2017 EVAPORATOR ABSORBER Liquid refrigerant enters the evaporator where it is dis- The concentrated LiBr solution enters the absorber tributed over the top of the tube bundle. The tubes used section of the chiller-heater. There it is sprayed over in the evaporator are made of low residual phosphorus the absorber tube bundle.

  • Page 18: Two-Step Evaporator - Absorber

    FORM 155.33-ICOM2.EN.GB SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/4/2017 TWO-STEP EVAPORATOR – ABSORBER Concentrated LiBr Refrigerant The evaporator, as well as the absorber, is split into two sections. This design allows for lower LiBr solu- Chilled tion concentrations. The lower concentration reduces Water Evaporator Absorber...

  • Page 19: Parallel Flow

    FORM 155.33-ICOM2.EN.GB SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE:12/4/2017 PARALLEL FLOW HIGH TEMPERATURE GENERATOR (HTG) The lithium bromide solution flow type is a parallel The high temperature generator section is a flooded, flow cycle. The flow of weak solution pumped from smoke tube design.

  • Page 20: Waste Hot Water-Driven Generator And Low Temperature Generator

    FORM 155.33-ICOM2.EN.GB SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE: 12/4/2017 WASTE HOT WATER-DRIVEN GENERATOR CONDENSER AND LOW TEMPERATURE GENERATOR The refrigerant vapor from the low temperature gener- The upper section is the waste hot water-driven genera- ator as well as the condensed refrigerant from the high tor.

  • Page 21: Why Does Crystallization Occur

    FORM 155.33-ICOM2.EN.GB SECTION 2 – PRODUCT DESCRIPTION ISSUE DATE:12/4/2017 Since the solution temperature in the generator is typi- WHY DOES CRYSTALLIZATION OCCUR? cally high enough, no crystallization will occur as long The most common reason for crystallization is power as the higher temperature is maintained. Before the failure.
  • Page 22 FORM 155.33-ICOM2.EN.GB ISSUE DATE: 12/4/2017 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 23: Section 3 - Handling, Storage, Installation And Reassembly

    FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY LD18119 FIGURE 3 - WARNING This chiller-heater is for air conditioning or cooling a Rigging and lifting should only be manufacturing process. Transport, store, and use this done by a professional rigger in chiller-heater under the following conditions: accordance with a written plan.

  • Page 24: Inspection

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 INSPECTION STRUCTURAL SUPPORT AND INSTALLATION The unit must be inspected prior to customer use by a Structural support of the unit must be provided for Johnson Controls Service representative. All damage maximum efficiency.

  • Page 25: Electrical

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 When installing the unit indoors, have a specialized Do not allow negative pressure or any devices that cre- company provide a suitable flue or smokestack, as ate negative pressure to operate in the area around the well as air supply and exhaust equipment.

  • Page 26: Leak Testing

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 Periodically inspect the strainer for the air purge blow- Welding should only be done under certain circum- er to prevent clogs and an incomplete air purge. stances. Be careful not to compromise the integrity of the vessel.

  • Page 27: Vibration And Isolation Details

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 VIBRATION AND ISOLATION DETAILS Before installing the unit, fit rubber vibration isolators to the unit base as shown in Figure 4 on page 27. Use liners to adjust the levelness of the unit. For unit dimensions, see Table 5 on page 41 and Table 6 on page 41.

  • Page 28: Figure 5 - Nozzle Locations (Example - One Exhaust Gas Outlet Flange)

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 LD22349 ITEM DESCRIPTION Cooling Water Inlet Chilled / Hot Water Inlet Chilled / Hot Water Outlet Cooling Water Outlet (Even Pass) Waste Hot Water Outlet Waste Hot Water Inlet Exhaust Gas Outlet Exhaust Gas Inlet Note: The chiller will be designed according to the different temperature and flow of exhaust gas...

  • Page 29: Figure 6 - Nozzle Locations (Example - Two Exhaust Gas Outlet Flanges)

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 LD22993 Note: The chiller will be designed according to the different temperature and flow of exhaust gas and Jacket water. The nozzle arrangement will be manufactured to the actual chiller design. ITEM DESCRIPTION Cooling Water Inlet...

  • Page 30: Hot Insulation And Cold Insulation Procedure

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 HOT INSULATION AND COLD INSULATION PROCEDURE 3. Make sure that the outer covering, flanged parts, The installation of insulation is out of and evaporator water chamber casing can be eas- scope.

  • Page 31: Figure 7 - Hot And Cold Insulation (Example - One Exhaust Gas Outlet Flange)

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 Cold Insulaton Hot Insulaton Exhaust Gas Insulaton LD21899 FIGURE 7 - HOT AND COLD INSULATION (EXAMPLE - ONE EXHAUST GAS OUTLET FLANGE) LD22992 FIGURE 8 - HOT AND COLD INSULATION (EXAMPLE - TWO EXHAUST GAS OUTLET FLANGES) JOHNSON CONTROLS...

  • Page 32: Figure 9 - Exterior Of Control Panel

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 LD22917 FIGURE 9 - EXTERIOR OF CONTROL PANEL JOHNSON CONTROLS...

  • Page 33: Section 4 - Technical Data

    FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 SECTION 4 - TECHNICAL DATA This section includes technical information about the unit, such as weight, dimensions, electrical data, wiring, and sound data. TABLE 3 - TYPICAL OPERATIONAL RANGE PARAMETER ALLOWABLE RANGES Chilled Water In 7 - 25°C Chilled Water Out 4 - 16°C Cooling Water In...
  • Page 34 FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 Weights and Dimensions The chiller will be designed according to the different temperature and flow of exhaust gas and Jacket water. The weight and dimensions of maximum shipping, operation and emergency will be documented according to the actual chiller results.
  • Page 35 FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 Physical Data The chiller will be designed according to the different temperature and flow of exhaust gas and Jacket water. The physical data will be documented according to the actual chiller results. JOHNSON CONTROLS...
  • Page 36 FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 Electrical Data The chiller will be designed according to the different temperature and flow of exhaust gas and Jacket water. The electrical data will be documented according to the actual chiller results. JOHNSON CONTROLS...

  • Page 37: Figure 10 - External Connection Terminal Details

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 LD22918 FIGURE 10 - EXTERNAL CONNECTION TERMINAL DETAILS JOHNSON CONTROLS...

  • Page 38: Figure 11 - 3 Phase 4 Wire Power Supply Wiring

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 TABLE 4 - CONTACT SPECIFICATIONS CONTACT SPECIFICATION ABSORPTION CHILLER-HEATER CONTROL PANEL -> RESISTANCE LOAD EXTERNAL INPUT TERMINAL MAX: AC 240 V 2 A MIN: DC 5 V 1 mA EXTERNAL OUTPUT TERMINAL ->...

  • Page 39: Figure 12 - Signal Terminal Transition Wiring

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 Example: Transition wiring in case the start panel of the chilled / hot water pump and cooling water pump are sepa- rately equipped. LD22352 FIGURE 12 - SIGNAL TERMINAL TRANSITION WIRING c.

  • Page 40: Upper Communication Specification

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 UPPER COMMUNICATION SPECIFICATION The information in this section applies to the YHAU- CE-JE Series of exhaust gas absorption chiller-heaters. Upper Communication System Configuration The configuration of the upper communication system is shown in Figure 13 on page 40.

  • Page 41: Scope Of Delivery

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 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 must de- liver all other related equipment: concentrator (HUB), installation, wiring, communication program for the central monitoring unit, and so on.

  • Page 42: Communication Specification

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 Communication Specification TABLE 7 - COMMUNICATION SPECIFICATIONS Communication Protocol Modbus TCP Communication Path Type 10BASE-T or 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...

  • Page 43: Table 9 - Write Command

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 TABLE 8 - READ COMMAND (CONT'D.) ITEM DISPLAY UNIT ADDRESS CONTENT Chilled / Hot water inlet temp. 12.0 °C 00083 0001~4000 unit, 1 unit=0.1 °C Chilled / Hot water outlet temp. °C 00085 0001~4000 unit, 1 unit=0.1 °C...

  • Page 44: User-Created

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 User-Created The diagrams and tables that follow detail some of the work that must be performed by the customer to be sure that the communication systems work properly. Serial interface (COM2) Connect User-Created Cable LD20597f...

  • Page 45: 2-Wire Cable Diagrams Without Adaptor

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 TABLE 11 - CABLE DIAGRAM (RS-422 OR RS485) PIN CONNECTION PIN. RS-422 OR RS-485 SIGNAL NAME DIRECTION MEANING Input Receive Data A (+) Input Receive Data B (-) Output Send Data A (+) Output...

  • Page 46: Wire Type Cable Diagrams Without Adaptor

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 LD21547 FIGURE 16 - 2-WIRE N:1 CONNECTION WITH USER-CREATED CABLE 4 Wire Type Cable Diagrams Without Adaptor The following are sample cable diagrams for 4-wire type connections. LD21548 FIGURE 17 - 4-WIRE 1:1 CONNECTION WITH USER-CREATED CABLE JOHNSON CONTROLS...

  • Page 47: Figure 18 - 4-Wire N:1 Connection With User-Created Cable

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE:12/4/2017 LD21549 FIGURE 18 - 4-WIRE N:1 CONNECTION WITH USER-CREATED CABLE The next table contains information about the commu- nication specifications needed for the Modbus RTU. See Table 8 on page 42 for information about the Read Command or Table 9 on page 43 for informa- tion about the Write Command.

  • Page 48: Figure 19 - Sample Sound Testing

    FORM 155.33-ICOM2.EN.GB SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY ISSUE DATE: 12/4/2017 Evaporator Side B Side A Side Background Noise Generator Side LD22348 OCTAVE BAND LOCATION* OVERALL 31.5 Hz 63 Hz 125 Hz 250 Hz 500 Hz 1 kHz 2 kHz 4 kHz 8 kHz...

  • Page 49: Section 5 - Commissioning

    The steps and procedures 5. Operate the pump and open the valve. MUST be performed by a YORK/Johnson Controls 6. Read and record the delivery pressure of the solu- Service person prior to customer use.

  • Page 50: Precautions For The Use Of Water

    FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE: 12/4/2017 When the flow rate change of the chilled / hot water PRECAUTIONS FOR THE USE OF WATER is controlled (if the flow rate change function is in- Staining and corrosion of the tubes in the evaporator, stalled), the load change speed is limited.

  • Page 51: Start The Chiller-Heater

    FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE:12/4/2017 START THE CHILLER-HEATER STOP THE CHILLER-HEATER Before starting the chiller-heater, review the following: 1. To stop the chiller-heater, press the STOP but- ton on the Control Panel Main screen. To stop the •...

  • Page 52: Figure 20 - Cooling Start Diagram

    FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE: 12/4/2017 Turn on power source Initialize self-check mechanism Cooling water Chiller-Heater stops with pump interlock ON? failure indication (within 3 min.) Remote or local Remote mode selection Local Remote operation ON Local operation ON Exhaust gas forced bypass switch OFF?
  • Page 53 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE:12/4/2017 Dilution starts EG input preparation starts. See Figure 22 on page 55 Dilution complete? Temperature control with EG bypass damper starts Solution pumps and refrigerant pump stop Cooling water pump EG outlet stops temp ≤...

  • Page 54: Figure 21 - Cooling Stop Diagram

    FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE: 12/4/2017 Chiller-heater operating Remote or local Remote Failure alarm? mode selection Local Local stop command ON Remote stop command Failure without dilution?* *The chiller-heater stops without dilution due to the following alarms: - Solution Circulation Pump Abnormal - Solution Spray Pump Abnormal - Refrigerant Pump Abnormal...

  • Page 55: Figure 22 - Exhaust Gas Input Preparation Flow Diagram

    FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE:12/4/2017 EG input preparation starts Chiller-heater stops with Bypass damper open failure alarm limit signal detected? Air purge damper close operation starts Air purge blower stops Air purge damper Chiller-heater stops with close limit signal failure alarm detected? 30 seconds...

  • Page 56: Figure 23 - Exhaust Gas Input Stop Preparation Flow Diagram

    FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE: 12/4/2017 EG input stop preparation starts Bypass damper open operation starts Bypass damper open Chiller-heater stops with limit signal detected? failure alarm Inlet damper close Outlet damper close operation starts operation starts Inlet and Outlet Chiller-heater stops with damper close limit signal...

  • Page 57: Figure 24 - Sequential Operation Flowchart

    FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE:12/4/2017 Sequential Operation Chilled / Hot Water Sequential Operation Air Conditioner Pump Interlock Cooling Water Pump Sequential Operation Interlock Sequential Operation Cooling Tower Interlock (Answerback) Gas Engine Other interlock device and equipment (Earthquake sensor, gas leak detector, ventilation fan, etc. Other Sequential Operation device and equipment (Ventilation fan, etc.) NOTES: 1.
  • Page 58 A. General ture part of the exhaust gas line ....... 1. All major pieces, boxes, and crates have been received and accounted for by a YORK/Johnson B. Piping Controls Service Representative......1. Piping is installed between the unit and the source 2.
  • Page 59 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE:12/4/2017 FORM 155.31-CL1 ISSUE DATE: 11/20/2017 C. Valve and Sensor Check 6. Clean the mesh strainer on the line ......1. Adjusting valves are set correctly......7. Air vent valves and drain valves are closed on the: a.
  • Page 60 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE: 12/4/2017 FORM 155.31-CL1 ISSUE DATE: 11/20/2017 START UP CHECKLIST 4. Navigate to the Setting screen in the Control Panel. 5. Press the Operation Mode Cooling button....A. Operation Check 6. Press the Purge Mode Manual button to start the vacuum pump.
  • Page 61 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE:12/4/2017 FORM 155.31-CL1 ISSUE DATE: 11/20/2017 19. Check for water leaks around the waste hot water 37. Check that the waste hot water temperature is box cover during operation with waste hot water within the normal range.
  • Page 62 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE: 12/4/2017 FORM 155.31-CL1 ISSUE DATE: 11/20/2017 D. Operation instruction Review the operation and maintenance instructions in the manual with the customer........a. Customer Names: NOTE: We recommend you operate the unit with a limited load for the first 50-200 hours.
  • Page 63 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE:12/4/2017 FORM 155.31-CL1 ISSUE DATE: 11/20/2017 EXHAUST GAS ABSORPTION CHILLER-HEATER COMMISSIONING DATA SHEET (1/2) User: Model: YHAU MFG. No.: User's machine code: Insulation Resistance Electric Power Supply Standard: 5 MΩ or more (with 500 V megger) R-Gnd S-Gnd T-Gnd...
  • Page 64 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE: 12/4/2017 FORM 155.31-CL1 ISSUE DATE: 11/20/2017 EXHAUST GAS ABSORPTION CHILLER-HEATER COMMISSIONING DATA SHEET (2/2) User: Model: YHAU MFG. No.: User's machine code: Running Data Date: Measured by Specification Standard Inlet damper position Damper indicator Outlet damper position Damper indicator...
  • Page 65 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE:12/4/2017 FORM 155.31-CL1 ISSUE DATE: 11/20/2017 NOTES: Same Operating hours hours Height Number of purge times times Fill out each specification pressure drop according to the factory inspection report (actual value). If differential pressure gauge (DPG) is not available, calculate each pressure drop. If flow meter (FM) is not available, calculate each flow rate as below.
  • Page 66 FORM 155.33-ICOM2.EN.GB SECTION 5 - COMMISSIONING ISSUE DATE: 12/4/2017 FORM 155.31-CL1 ISSUE DATE: 11/20/2017 PURGE AMOUNT DATA SHEET (1/1) User: Model: YHAU MFG. No.: User's machine code: Measured Date: Measured by: Purge Amount from Purge Tank Flame Reaction Test Standard: 4.0 cc per min. or smaller Reaction ( Strong / Weak / None ) Amount of Gas (P) cc/min...

  • Page 67: Section 6 - Operation

    FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 SECTION 6 – OPERATION YHAU-CE-JE CONTROL CENTER COMMON ITEMS Buttons are listed in the order they are The YHAU-CE-JE Control Center, furnished as stan- seen on the screen: left to right and top dard on each chiller-heater, allows for efficiency, mon- to bottom.

  • Page 68: Change Numeric Values

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 CHANGE NUMERIC VALUES DATE AND TIME Many numeric values, such as the set point and the To set the date and time, use the following procedure. ranges on the Trend screen, can be changed. Here’s You can do this from any screen.
  • Page 69 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 5. Press the Offline button. LD21987 LD21988 11. Press the Date and Time button in the lower right LD21986 LD21986 corner of the screen. 6. Tap the Password field on the screen that displays. The numeric keypad displays.
  • Page 70 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 15. Check the date and time in the lower right corner of the screen LD22165 LD22165 20. The Exit screen displays. Press the Yes button. LD22162 LD22162 16. If the changes are correct, press the Save button. LD22166 LD22166 21.

  • Page 71: Operating Status

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 MAIN SCREEN LD21527 FIGURE 26 - MAIN SCREEN OPERATING STATUS The Main screen is the ONLY screen where you can start or stop the chiller-heater. The two buttons in the lower left corner of the screen are: •...
  • Page 72 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 On the Main screen, the lit buttons tell you which sys- The Waste Gas Damper Status section contains the fol- tems are running. lowing sub-sections: On the upper left of the screen below the LOCAL and •...

  • Page 73: Figure 27 - Data Screen

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 DATA SCREEN LD21529 FIGURE 27 - DATA SCREEN The Data screen Measured Values section shows the XG Generator Pressure: pressure in the high tem- following: perature generator Chilled / Hot Water Inlet Temp.: temperature of the Waste Hot Water Inlet Temp.: temperature of the chilled / hot water measured as it enters the evaporator waste hot water measured as it enters the waste hot wa-...
  • Page 74 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 The Operation Hours section shows the following: The History Menu section of the screen contains two buttons. • Cooling: total operating hours of the absorption machine in cooling mode To view the Alarm History Screen, press the Failure History button.

  • Page 75: Figure 28 - Alarm History Screen

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 ALARM HISTORY SCREEN LD21528 LD21528 FIGURE 28 - ALARM HISTORY SCREEN The Single Down Arrow button moves you downward The Alarm History Screen shows information for the through the list one event at a time. The Double Down last alarm or failure and up to twenty previous events.

  • Page 76: Figure 29 - Trend Screen

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 TREND SCREEN LD21530 LD21530 FIGURE 29 - TREND SCREEN Press the Trend button on the Data screen to access this information. There are two Trend screens. The first screen graphi- cally illustrates the trend of the temperature for the fol- lowing: •...

  • Page 77: Figure 30 - Trend Screen, Part 2

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 LD21531 FIGURE 30 - TREND SCREEN, PART 2 The second Trend screen shows you the trend of the temperature for the: • evaporator refrigerant temperature • absorber temperature • HG temperature • HG pressure Press the Left Arrow button to return to the previous Trend screen.

  • Page 78: Failure

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 FAILURE SCREEN LD21533 FIGURE 31 - FAILURE SCREEN If there is a failure in the unit this screen automatically displays. The red failure light at the top right of the screen lights. At that time, you can see which failure button is lit.

  • Page 79: Table 15 - Failure List

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 The failures addressed in this screen are listed in the following table. TABLE 15 - FAILURE LIST OPERATION BUTTON LABEL AT FAILURE CAUSE COUNTERMEASURES (FAILURE NAME) OCCURRENCE Operation interlock (chilled / hot water Check interlocked equipment for Operation interlock pump, etc.) signal was not established...
  • Page 80 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 TABLE 15 - FAILURE LIST, CONT'D OPERATION BUTTON LABEL AT FAILURE CAUSE COUNTERMEASURES (FAILURE NAME) OCCURRENCE HG (XG) High HG (XG) pressure rose too high or too • Check the cooling water line. Pressure quickly •...
  • Page 81 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 TABLE 15 - FAILURE LIST, CONT'D OPERATION BUTTON LABEL AT FAILURE CAUSE COUNTERMEASURES (FAILURE NAME) OCCURRENCE The inlet damper open limit switch did Inlet Damper Open not turn ON within 180 seconds after it Failure received the open signal.
  • Page 82 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 TABLE 15 - FAILURE LIST, CONT'D OPERATION BUTTON LABEL AT FAILURE CAUSE COUNTERMEASURES (FAILURE NAME) OCCURRENCE High Waste Gas Inlet Press. (High Waste HG (XG) waste exhaust gas inlet Contact your local Johnson Controls Gas Exhaust Gas pressure rose too high or too quickly.

  • Page 83: Alarm

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 ALARM SCREEN LD21535 FIGURE 32 - ALARM SCREEN If an alarm occurs, the orange Alarm light at the top of Press the lit alarm button to access an on-screen han- any screen lights. Press the ALARM button to see the dling guide for each item.

  • Page 84: Table 16 - Alarm List

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 The alarms are listed in the following table. TABLE 16 - ALARM LIST BUTTON LABEL (ALARM CAUSE OF ALARM AND COUNTERMEASURES NAME) CONDITION TO RESET • The air purge blower motor current exceeded the rated value.
  • Page 85 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 TABLE 16 - ALARM LIST, CONT'D BUTTON LABEL (ALARM CAUSE OF ALARM AND COUNTERMEASURES NAME) CONDITION TO RESET • The chilled / hot water inlet temperature sensor, the absorber temperature sensor, or the waste hot water outlet sensor detected an abnormal value due to a disconnection, short circuit, etc.

  • Page 86: Control Parameter

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 SETTING SCREEN LD21532 FIGURE 33 - SETTING SCREEN CONTROL PARAMETER The Control Parameter section of the Setting screen is • Automatic Restart Differential: the temperature used to enter parameters for the cooling and heating op- difference between the temperature at which the eration, such as target temperature, automatic stop tem- chiller-heater will automatically stop and the tem-...

  • Page 87: Operation Switch

    FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE:12/4/2017 OPERATION SWITCH The Operation Switch section contains a group of but- • Purge Mode: the Auto and Manual buttons con- tons that you can use to control the unit. trol how the purge operation is managed. •...
  • Page 88 FORM 155.33-ICOM2.EN.GB SECTION 6 – OPERATION ISSUE DATE: 12/4/2017 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 89: Section 7 - Maintenance

    FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 SECTION 7 – MAINTENANCE When inspecting and maintaining the absorption chill- SOLENOID VALVES er-heater, note the following: The absorption chiller-heater is equipped with the fol- lowing solenoid valves. • Never splash water over the electrical parts in- stalled in the control panel and absorption chiller- TABLE 17 - SOLENOID VALVES heater.

  • Page 90: Start The Chiller-Heater After It Has Been Stopped For A Long Period

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 START THE CHILLER-HEATER AFTER IT HAS Checks After Operation Starts BEEN STOPPED FOR A LONG PERIOD 1. 10-15 minutes after the chiller-heater and the so- lution pump start, check the level gauge of the re- When you start the chiller-heater after it has not run for frigerant tank.

  • Page 91: Performance Check Method Of Vacuum Pump

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 PERFORMANCE CHECK METHOD OF VACUUM PUMP When the purge unit starts, check the performance of 5. Navigate to the Setting screen on the Control Panel the vacuum pump first according to the following pro- 6.

  • Page 92: Figure 34 - Location Of Manual Valve In Purging System (Example)

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 LD22001 Purge solenoid valve (SV2) Purge solenoid valve (SV1) Purge main valve (V20) Purge valve for purge tank line (V19) Purge valve for purge tank line (V18) Purge valve for absorber line (V17) Purge valve for absorber line (V14) Purge valve for absorber line (V15) FIGURE 34 - LOCATION OF MANUAL VALVE IN PURGING SYSTEM (EXAMPLE)

  • Page 93: Manual Method To Purge Non-Condensable Gas Directly From Absorber

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 MANUAL METHOD TO PURGE NON- MANUAL METHOD TO PURGE NON- CONDENSABLE GAS DIRECTLY FROM CONDENSABLE GAS FROM PURGING TANK ABSORBER While the absorption chiller-heater operates, non- When the chiller-heater operates at a lower capacity condensable gas collects in the purging tank.

  • Page 94: Table 18 - Purge Valve Operation

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 During the automatic purge operation, the vacuum pump starts when the purging tank pressure increases to 7 kPa abs and stops when it decreases to 3 kPa abs. When you replace the oil in the vacuum pump or belt or perform maintenance work while the absorption chiller-heater is running, be sure to turn off the circuit...

  • Page 95: Figure 35 - Purge System

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 FIGURE 35 - PURGE SYSTEM LD22170 JOHNSON CONTROLS...

  • Page 96: Figure 36 - Process And Instrumentation Diagram - Cooling Only

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 LD22389 FIGURE 36 - PROCESS AND INSTRUMENTATION DIAGRAM - COOLING ONLY JOHNSON CONTROLS...

  • Page 97: Refrigerant Refining Method

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 REFRIGERANT REFINING METHOD MANUAL REFRIGERANT BLOWDOWN AND DILUTION METHOD With an increase in the operation time of the chiller- heater, some of the solution can mix in with the refrig- When the chiller-heater stops suddenly due to a power erant.

  • Page 98: Decrystallization Method

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 6. Turn the spindle in the valve to the left with the 8 DECRYSTALLIZATION METHOD mm hexagon wrench. Even if the solution in the absorption chiller-heater is The refrigerant in the refrigerant tank crystallized during operation, it can be melted if the diverts into the absorber.

  • Page 99: Precautions For Decrystallization

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 23. Watch the liquid level in the absorber while the • Remove any sensors that are sensitive to heat be- solution pump runs. fore you start the melting operation. The tempera- ture of the chilled / hot water and cooling water 24.
  • Page 100 FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 TABLE 19 - MAINTENANCE AND INSPECTION, CONT'D TASK CONTENTS FREQUENCY SCOPE Measure the insulation resistance of the main circuit Measurement of insulation and motors (solution pump, refrigerant pump) mainly to resistance of electric check for lowering of insulation.
  • Page 101 FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 TABLE 19 - MAINTENANCE AND INSPECTION, CONT'D TASK CONTENTS FREQUENCY SCOPE Repair paint (epoxy paint) Chilled / hot water: of inside wall of chilled / Every 2 years Repair the paint of the inside wall periodically. hot water and cooling Cooling water: Yearly waterboxes...

  • Page 102: Refrigerant Pump Manual Stop

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 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 the 4. Press the Manual Purge OFF button when the chiller-heater is operating.

  • Page 103: Blower Fan Manual Stop

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 Blower Fan Manual Stop Waste Hot Water Forced Bypass Manual Operation 1. Navigate to the Control Panel Setting screen. 1. Navigate to the Control Panel Setting screen. 2. Press the Blower Fan Stop button. 2.

  • Page 104: Exhaust Gas Contaminants

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 EXHAUST GAS CONTAMINANTS TABLE 20 - EXHAUST GAS CONTAMINANTS CONTAMINANT NAME ALLOWABLE RANGE MEASUREMENT METHOD 50 mg per Nm 3 Soot Dust density Nitrogen Oxide 600 ppm Chemiluminescence Sulfur Oxide 0 ppm Non dispersive Infrared gas analyzer 0.5 mg per Nm 3...

  • Page 105: Lifespan Of Common Parts

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 LIFESPAN OF COMMON PARTS The replacement periods for some parts are shown below. (The following periods are shown for refer- ence only. The replacement period may be changed according to the actual environment, frequency of use, etc.

  • Page 106: Figure 37 - Chilled / Hot Water, Cooling Water, Waste Hot Water, And Waste Exhaust Gas System (Example)

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 TABLE 21- LIFESPAN OF COMMON PARTS, CONT'D LIFESPAN AND REPLACEMENT PART NAME REMARKS INTERVAL Sequencer unit Relay Timer Every 30,000 hours Fuse DC power unit Magnetic contactor, thermal relay Battery for sequencer unit Every 5 years Battery for touch panel Touch panel...

  • Page 107: Water Quality Control

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 LD22991a FIGURE 38 - CHILLED / HOT WATER, COOLING WATER, WASTE HOT WATER, AND WASTE EXHAUST GAS SYSTEM (EXAMPLE) (TWO EXHAUST GAS OUTLET FLANGES) Or, you may bypass the cooling water WATER QUALITY CONTROL through a three-way valve to keep the Use the following guidelines to be sure of the highest cooling water at an appropriate tempera-...

  • Page 108: Chemical Water Treatment

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 If the chiller-heater runs without the TREATMENT FOR LONG STOPPAGE OF THE valves completely open, a strong turbulent ABSORPTION CHILLER-HEATER flow can be generated. The turbulence If the absorption chiller-heater is stopped for a long may cause damage in the water chamber time, bacteria in the water or in the tubes may grow.

  • Page 109: Table 22 - Tendency Of Generation Of Scales And Corrosion By Quality Of Cooling Water

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 TABLE 22 - 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 Corrosion of iron and ~ Pale Water pH low...

  • Page 110: Table 23 - Chilled / Hot And Cooling Water Quality Control (Maximum Concentrations)

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 TABLE 23 - CHILLED / HOT AND COOLING WATER QUALITY CONTROL (MAXIMUM CONCENTRATIONS) COOLING WATER SYSTEM CHILLED / HOT WATER NON- TENDENCY CIRCULATING SYSTEM CIRCULATING TYPE WATER ELEMENT (1) (6) CIRCULATING CIRCULATING REPLENISH PASSING...

  • Page 111: Storage Method Of The Chiller-Heater

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 WET STORAGE METHOD STORAGE METHOD OF THE CHILLER- HEATER The wet storage method may be used when there is no concern about chilled / hot water, cooling water, and If the chiller-heater needs to be stored long-term, the waste hot water freezing in winter.

  • Page 112: Dry Storage Method

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 DRY STORAGE METHOD The dry storage method should be used if the chilled / 4. Circulate the clear water through the water pump hot water system and/or the cooling water system may for 30 minutes to one hour to clean it.

  • Page 113: Storage Method Of The Cooling Water During Heating Operation Period

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 TABLE 25 - DRY STORAGE METHOD PART STORAGE METHOD Chilled / hot water system Dried and pressurized with Nitrogen Cooling water system (0.01~0.02 MPaG) Storage Period; less than 6 months Waste hot water line Inside of shells Vacuum Chilled / hot water system...

  • Page 114: Work Procedure

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 Work Procedure 5. Drain all of the cooling water from the absorber 1. If the quality of the remaining cooling water has and condenser. deteriorated, drain all the cooling water from the absorber and the condenser.

  • Page 115: Dry Storage

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 Work Procedure Dry Storage 1. Drain all of the cooling water from the absorber Dry storage involves draining the water from the tubes. It most often used when the unit is installed in an out- and the condenser.

  • Page 116: Figure 41 - Duhring Diagram Ptx Chart (°F)

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 LD14221f FIGURE 41 - DUHRING DIAGRAM PTX CHART (°F) JOHNSON CONTROLS...

  • Page 117: Figure 42 - Duhring Diagram Ptx Chart (°C)

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 FIGURE 42 - DUHRING DIAGRAM PTX CHART (°C) JOHNSON CONTROLS...

  • Page 118: Figure 43 - Specific Gravity - Concentration (°F)

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE: 12/4/2017 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 119: Figure 44 - Specific Gravity - Concentration (°C)

    FORM 155.33-ICOM2.EN.GB SECTION 7 – MAINTENANCE ISSUE DATE:12/4/2017 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 0.67...
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  • Page 121: Section 8 - Troubleshooting

    FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 SECTION 8 – TROUBLESHOOTING If the chiller-heater has any problems while it is operat- • See if the cooling tower is operating normally. ing, you need to find the cause and try to fix it. If the •...

  • Page 122: Table 27 - Refrigerant Overcooled

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/4/2017 TABLE 27 - REFRIGERANT OVERCOOLED ITEM CAUSE COUNTERMEASURE Chilled / hot water flow See if the chilled / hot water flow rate changes quickly (particularly in the case rate drops or changes of variable flow rate specification).

  • Page 123: Troubleshooting Performance Issues

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE:12/4/2017 TROUBLESHOOTING PERFORMANCE ISSUES of the trouble is other than numbers 1 to 7, it may be If the performance is low while the capacity control one of numbers 8 through 14. In this case, contact your valve is fully open or if the capacity control valve does local Johnson Controls Service Center immediately.

  • Page 124: Vacuum Pump

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/4/2017 VACUUM PUMP When the Purge Abnormal alarm button lights or ed. See Table 31 on page 124. Or, the vacuum pump the vacuum level of the purging line did not reach the may need to be disassembled for inspection.

  • Page 125: Table 32 - Interlock Troubleshooting

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE:12/4/2017 TABLE 32 - INTERLOCK TROUBLESHOOTING ITEM CAUSE COUNTERMEASURE There is an interlock error. The error is caused by • Check the interlocked devices. the chilled / hot water pump operation answerback • Check the equipment connected as elements for an signal, the air conditioner operation answerback operation interlock failure.

  • Page 126: Table 34 - Chilled Water Overcooling Troubleshooting

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/4/2017 TABLE 34 - CHILLED WATER OVERCOOLING TROUBLESHOOTING ITEM CAUSE COUNTERMEASURE Chilled water flow rate drops or See if the chilled water flow rate changes suddenly (particularly changes suddenly in case of variable flow rate specification). If it changes suddenly, apply a limit of the change rate to the chilled water flow or take another measure.

  • Page 127: Table 35 - Communication Errors

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE:12/4/2017 TABLE 35 - COMMUNICATION ERRORS ITEM CAUSE COUNTERMEASURE Communication between the touch • Check the communication cable between the touch panel panel and the temperature controller is and the temperature controller. not established. •...

  • Page 128: Table 36 - Other Failure Troubleshooting

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/4/2017 TABLE 36 - OTHER FAILURE TROUBLESHOOTING ITEM CAUSE COUNTERMEASURE The HG (XG) solution level dropped. The solution level of the HG (XG) decreased • See Purge Procedure on page 90. when the waste exhaust gas was •...

  • Page 129: Table 37 - Damper Failure Troubleshooting

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE:12/4/2017 TABLE 37 - DAMPER FAILURE TROUBLESHOOTING ITEM CAUSE COUNTERMEASURE There was an air damper open failure. The open limit switch does not turn ON after 180 seconds have elapsed since the air purge damper opening command. There was an air damper close failure.

  • Page 130: Figure 45 - Troubleshooting Sequence Flow Chart

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/4/2017 Chiller-heater operating Failure alarm? Alarm buzzer Failure lamp lit External output signal Press BUZZER STOP failure lamp lights. Button Temperature control with EG input stops HW three-way valve stops Failure without dilution? (see note) Dilution starts Minimum dilution...

  • Page 131: Actions To Take Against Power Failure

    FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE:12/4/2017 ACTIONS TO TAKE AGAINST POWER FAILURE If the main power fails, take the following actions. Power failure Chiller-heater 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 132 FORM 155.33-ICOM2.EN.GB SECTION 8 – TROUBLESHOOTING ISSUE DATE: 12/4/2017 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...

  • Page 133: Section 9 - Decommissioning, Dismantling, And Disposal

    FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 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 134 FORM 155.33-ICOM2.EN.GB SECTION 9 - DECOMMISSIONING, DISMANTLING, AND DISPOSAL ISSUE DATE: 12/4/2017 Exhaust Gas Multi Energy Spec Sheet JOHNSON CONTROLS...
  • Page 135 FORM 155.33-ICOM2.EN.GB ISSUE DATE:12/4/2017 THIS PAGE INTENTIONALLY LEFT BLANK. JOHNSON CONTROLS...
  • Page 136 5000 Renaissance Drive, New Freedom, Pennsylvania USA 17349 800-861-1001 Subject to change without notice. Printed in USA Copyright © by Johnson Controls 2017 www.johnsoncontrols.com ALL RIGHTS RESERVED Form 155.33-ICOM2.EN.GB (1217) Issue Date: December 4, 2017 New Release...

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