Page 1 YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A) 120 ton to 1600 ton 422 kW to 5626 kW Installation, Operation, and Maintenance Form: 155.32-ICOM1.EN.GB (422) Issue Date: 2022-04-19 Supersedes: 155.32-ICOM1.EN.GB (318)
Page 2 YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 3: Table Of Contents
Contents General safety guidelines..........................7 Safety symbols............................7 Changeability of this document......................8 Associated literature..........................8 Nomenclature............................9 General chiller-heater information and safety................... 10 Introduction............................10 About this manual..........................10 Warranty............................... 10 Quality assurance..........................11 High temperature and pressure cleaning..................11 Emergency shutdown......................... 12 Safety labels............................13 Product description............................14 Chiller-heater components.........................14...
Page 4 Use of oil............................... 31 Vibration and isolation details......................32 Nozzle arrangements..........................32 Fuel gas and oil piping system......................35 Hot insulation or cold insulation procedure..................37 Pressure release valve and relief piping...................39 Pressure release valve discharge pipe material................40 Pressure release valve piping construction..................40 Rupture disk and relief piping (option).....................41 Rupture disk discharge piping material...................
Page 5 Burner parts replacement or burner combustion check screen............108 Trend screen............................. 109 Hourly operation history screen......................111 Minutely operation history screen......................113 Failure history screen..........................115 Alarm history screen..........................117 Failure and alarm screen........................119 Failure................................ 119 Alarm................................. 122 Setting screen............................ 123 Control parameter...........................
Page 6 Manual refrigerant blow down and diluting method..............152 Decrystallization method........................153 Indications of crystallization........................153 Decrystallization..........................153 Precautions for decrystallization..................... 154 Maintenance items..........................154 Refrigerant pump manual stop......................156 Purge manual start and stop........................157 Lifespan for various parts.........................157 Water quality control.........................159 Chemical water treatment........................160 Replacement of water........................
Page 7: General Safety Guidelines
General safety guidelines Important: Read before proceeding. This equipment is a relatively complicated apparatus. During rigging, installation, operation, maintenance, or service, individuals may be exposed to certain components or conditions including, but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and both high and low voltage.
Page 8: Changeability Of This Document
All wiring must be in accordance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will not be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals.
Page 9: Nomenclature
Nomenclature YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 10: General Chiller-Heater Information And Safety
Maintenance. About this manual This manual and any other document supplied with the unit are the property of Johnson Controls which reserves all rights. This manual may not be reproduced, in whole or in part, without prior written authorization from an authorized Johnson Controls representative.
Page 11: Quality Assurance
• Only genuine Johnson Controls approved spare parts, oils, solutions, chemicals, and refrigerants must be used. • All of the scheduled maintenance operations detailed in this manual must be performed at the specified times by suitably trained and qualified personnel.
Page 12: Emergency Shutdown
Emergency shutdown In case of emergency, the control panel is fitted with an incoming supply circuit breaker with a red handle. Turn the handle counter clockwise to shut down the chiller. Figure 1: Emergency shutdown breaker YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 13: Safety Labels
Safety labels For safe operation, read the instructions first. WARNING: This machine may start automatically without prior warning. WARNING: Hot surface. WARNING: Safety relief valve may discharge gas or liquid without prior warning. WARNING: Risk of electric shock. WARNING: General attention symbol. WARNING: On isolating the supply it may take up to 300 seconds for the capacitor voltage to fall below 50 volts.
Page 14: Product Description
Product description The principle of refrigeration is the exchange of heat. In absorption liquid chilling, there are four basic heat exchange surfaces: the evaporator, the absorber, the generator, and the condenser. See Figure 2. Like any refrigeration system, absorption chilling uses evaporation and condensation to remove heat.
Page 15: How Direct Fired Units Work
Figure 2: Main components of direct fired absorption chiller-heater Callout Component Chilled or hot water outlet Absorber Cooling water outlet Condenser Low temperature generator High temperature generator Burner fan motor Natural gas inlet Burner fan Control panel Solution pump Cooling water inlet Chilled or hot water inlet Evaporator How direct fired units work...
Page 16 is directly related to the amount of refrigerant, or water, present in the solution with the LiBr salt and the solution temperature. The entire absorption process occurs in almost a complete vacuum. Figure 3: Two step direct fired absorption chiller-heater cycle diagram (cooling mode) for model EX(H/S) or model EXW(H/S) Note: Temperatures and pressures on this graphic are representative, actual values may differ.
Page 17: Evaporator
Evaporator Liquid refrigerant enters the evaporator and is distributed over the top of the tube bundle. As the refrigerant droplets cover the outside surface of the tubes, the heat from the returning chilled water passing through the tubes causes the refrigerant to flash from a liquid to a vapor. The temperature at which this happens depends on the evaporator shell pressure which is dictated by the absorber section of the chiller-heater.
Page 18: Plate Type Heat Exchangers
The cooling tower water enters the lower absorber section first, keeping the vapor pressure of the weaker solution as low as possible. Both the refrigerant, or water, and the LiBr dispersion system are gravity fed and made of stainless steel. Plate type heat exchangers The diluted, or weak, LiBr solution that leaves the absorber section is pumped through various plate type heat exchangers, such as the low temperature heat exchanger, LTG refrigerant...
Page 19: High Temperature Generator (Htg)
High temperature generator (HTG) YHAU’s high temperature generator section has the unique liquid tube design in which the dilute Lithium Bromide solution coming from the high temperature heat exchanger is inside the tubes. The products of combustion, or exhaust gas from burning of natural gas, are on the shell side. The hot refrigerant vapor boiled off is sent to the low temperature generator.
Page 20: Crystallization
Crystallization All absorption chiller-heaters that use lithium bromide and water as the solution or the refrigerant pair are subject to crystallization. This is due to the fact that some areas of the unit operate with solution liquid concentration levels that are only possible at higher than the normal ambient temperature surrounding the unit.
Page 21: Handling, Storage, Installation And Reassembly
Handling, storage, installation and reassembly DANGER Rigging and lifting should only be done by a professional rigger in accordance with a written rigging and lifting plan. The most appropriate rigging and lifting method will depend on job specific factors, such as the rigging equipment available and site needs. Therefore, a professional rigger must determine the rigging and lifting method to be used, and it is beyond the scope of this manual to specify rigging and lifting details.
Page 22: Inspection
Inspection The unit must be inspected prior to customer use by a Johnson Controls Service representative. All damage or possible damage must be reported to the transportation company. For further details, see Commissioning. Note: The unit is delivered without charging the solution and refrigerant and charges N2 to 4 psig (0.3 barg) to pressurize the unit.
Page 23 For further information on the sealing with N2 option, contact your nearest authorized Johnson Controls Service Center. To protect the machine from soot and dust, or other air particulates,...
Page 24: Hoisting The Machine
CAUTION Use care that foreign matter does not enter the drain valve and air vent valve in the water chamber casing. Keep these valves fully open while the machine is in storage. Hoisting the machine When hoisting the machine, attach a shackle to each of the four eye plates and lift the machine using care that the angle formed by the wire is within 60°...
Page 25 Figure 6: Moving the machine on rollers If using a tir-roller to move the machine, fit the tir-roller set to each of the four holes shown in Figure 7. Figure 7: Moving the machine on tir-rollers When jacking the machine, be sure to fit the jack in each of the jack-up supports as shown in Figure YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 26: Structural Support And Installation
Figure 8: Jack-up procedure Operate the front and rear jacks alternately. Do not jack up the machine more than about 20 mm at a time. Each time the machine is jacked up, adhere it with a suitable crosstie. Use the jack-up support on the main shell of the body as shown in Figure 9. If using a high temperature generator, use secondary jack-up support.
Page 27 Install foundation bolts in level concrete to secure the unit and prevent shifting in the event of an earthquake. It is the customer’s responsibility to furnish the foundation bolts, nuts and washers. Rubber vibration isolator pads must be fitted to the unit base before installation as shown in Figure 11.
Page 28: Indoor And Outdoor Installation
Minimum allowable temperature for outdoor installation is 0°C, provided that the chiller-heater includes the cold ambient option. Outdoor installations are considered on a case-by-case basis by a Johnson Controls Service Representative and the appropriate instruction for installation is provided at that time.
Page 29: Precautions For Use
Do not place anything heavy on the machine or its control panel; it may fall and injure a worker. Do not climb up the unit without safety harnessing. Contact your local Johnson Controls service office for inspection and maintenance of the unit. Incorrect inspection and maintenance can not only cause a machine problem but also injure workers.
Page 30: Leak Testing
WARNING During service and maintenance work, be sure to turn OFF the main circuit breaker (MCB1) and follow all required Lockout or Tagout procedures Close the main valve of the fuel gas line. Failure to close this line may cause electric shock or injury. If the cables of the solution pump, refrigerant pump, burner fan, or vacuum pump are disconnected for service and maintenance work, be sure to check the rotating direction of the pump motor.
Page 31: Electrical Shock Cautions
Only use the fuel specified on the unit name plate. Inspect the exhaust duct periodically to check for gas leaks. If black and white smoke is produced, stop the machine and contact your local Johnson Controls Service Office for assistance.
Page 32: Vibration And Isolation Details
WARNING During service and maintenance work, be sure to turn OFF the main circuit breaker (MCB1) and follow all required Lockout and/or Tagout procedures Close the main valve of the fuel gas line. Failure to close the gas line may cause electric shock and burn. Vibration and isolation details Before installing the unit, fit rubber vibration isolators to the unit base as shown in Figure 11.
Page 33 Note: These images are representations of nozzle arrangements. Reference general arrangement drawings found in the contract documents for detailed nozzle locations for each specific unit. Figure 12: YHAU-CGN/H-120-300EX(H/S)(L) nozzle locations Item Description Chilled or hot water outlet (odd pass) Cooling water outlet (odd pass) Gas inlet Cooling water outlet (even pass) Chilled or hot water outlet (even pass)
Page 34 Figure 13: YHAU-CGN/H-360EX(H/S)(L)-1600EXW3(H/S)(L) nozzle locations Item Description Chilled or hot water outlet (even pass) Cooling water outlet (even pass) Gas inlet Cooling water inlet Chilled or hot water inlet Cooling water outlet (odd pass) Chilled or hot water outlet (odd pass) Exhaust gas outlet YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 35: Fuel Gas And Oil Piping System
Fuel gas and oil piping system Figure 14: Fuel gas piping system YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 36 Connect the oil return pipe to the vapor phase part above the service tank. Do not locate any shut off valve on this oil return line. To prevent aeration into the oil supply, or delivery pipe, set the oil return pipe apart from the delivery line and install a baffle plate on the return pipe. Install a flow meter on the oil supply, or delivery pipe, to the oil service tank.
Page 37: Hot Insulation Or Cold Insulation Procedure
• Cleaning the furnace and gas duct at fixed intervals is necessary. Hot insulation or cold insulation procedure The recommended materials and their thickness for hot insulation or cold insulation are shown in Table 3. Use a bonding agent, iron wire, iron band, or other recommended bonding agents, to fix the hot insulation/cold insulation materials.
Page 38 Figure 16: Hot insulation or cold insulation Figure 17: Interior of control panel (mm) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 39: Pressure Release Valve And Relief Piping
Figure 18: Exterior of control panel (mm) Pressure release valve and relief piping YHAU units furnish one pressure release valve on shell side. It is set to blow at 0.8 bar(g). The pressure release valve protects the integrity of the chiller. In the unlikely event that there is a rupture in the tube, the pressure release valve opens and the LiBr solution blows out to release the pressure.
Page 40: Pressure Release Valve Discharge Pipe Material
Pressure release valve discharge pipe material Johnson Controls recommends using schedule 40 steel pipe for the rupture disk discharge line material. Pressure release valve piping construction For the piping material, use carbon steel. The relief piping must be fabricated and constructed in accordance with piping best practices.
Page 41: Rupture Disk And Relief Piping (Option)
Figure 20: Location of pressure release valve Burner LT Generator HT Generator Pressure release valve Purge tank Rupture disk and relief piping (option) YHAU furnished the rupture disc (option) which is a metallic, one time use, rupture disk burst rated at 83.0 kPa.g±12.5 kPa.
Page 42: Rupture Disk Discharge Piping Material
Note: Do not loosen the bolts around the flange or remove the disk from the holder. If the disk is removed for any reason, it must be replaced with a new one. The outer flange of the disk holder has a plastic plug supplied by the factory for shipping purposes. The plastic plug must be removed.
Page 43: Rupture Disk Discharge Piping Sizing
Rupture disk discharge piping sizing The sizing of the rupture disk discharge piping must not be less than the rupture disk diameter. Where two or more relief devices are connected to a common line or header, the effect of back- pressure that is developed when more than one relief device operates, must be considered.
Page 44 Figure 23: Location of rupture disk Rupture disk Burner LT Generator HT Generator Purge tank YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 45 Figure 24: Recommended rupture disk or pressure release valve discharge pipe Rupture disk Flexible connection Union Discharge pipe Barrel or safety discharge area YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 46: Technical Data
The numbers shown in Table 5 are the allowable ranges for each parameter. Not all combinations are possible. Check with your Johnson Controls Service Center to see if your temperature differential is possible. Note: The data in this section is for reference only. For actual data, see the rating sheet.
Page 47 Table 6: Weight data for standard efficiency Weights - CGN Weights - CGH Shipment Shipment Emergency Emergency YHAU with Operating with Operating (filled with water) (filled with water) shipment shipment (ton) (ton) charge charge (ton) (ton) (ton) (ton) (ton) (ton) 1400EXW3S(L) 37.5 44.4...
Page 48 Table 8: Physical data (with exhaust gas temp. approximately 220°C) - CGN Outline dimension Holding volume Tube Cold Chilled Exhaust gas Cooling insulation insulation YHAU-CGN extracting or hot Length Width Height volume (m water (mm) (mm) (mm) space area (m area (m water 240EX(H/S)(L)
Page 49 Table 10: Electrical data Main breaker Solution circulation pump Solution spray pump Power source YHAU-CGN Rated Frame (V-Ph-Hz) current size AC380V-3Ph-50Hz 23.0 23.0 120 EX(H/S)(L) 32 A 63 A AC400V-3Ph-50HZ 24.0 3.45 24.0 AC380V-3Ph-50Hz 23.0 23.0 150 EX(H/S)(L) 32 A 63 A AC400V-3Ph-50Hz 24.0...
Page 50 Table 11: Electrical data continued Refrigerant pump Vacuum pump Burner fan Total Total YHAU-CGN capacity consumption SCCR kA 12.9 120 EX(H/S)(L) 0.75 0.75 1.12 13.1 10.0 12.9 150 EX(H/S)(L) 0.75 0.75 1.12 13.1 10.0 12.9 11.8 180 EX(H/S)(L) 0.75 0.75 1.65 13.1 12.0...
Page 51 Table 12: Electrical data - CGH Main breaker Solution circulation pump Solution spray pump Power source YHAU-CGH Rated Frame (V-Ph-Hz) current size AC380V-3Ph-50Hz 14.2 60.0 23.0 450 EX(H/S)(L) 40 A 63 A AC400V-3Ph-50Hz 13.5 63.0 24.0 AC380V-3Ph-50Hz 14.2 60.0 23.0 500 EX(H/S)(L) 40 A 63 A...
Page 52 Table 13: Electrical data - CGH continued Refrigerant Pump Vacuum Pump Burner Fan Total Total YHAU-CGH Capacity Consumption SCCR kA 79.8 21.2 17.0 450 EX(H/S)(L) 0.75 1.65 84.0 21.5 17.2 79.8 21.2 17.0 500 EX(H/S)(L) 0.75 1.65 84.0 21.5 17.2 79.8 21.2 17.0...
Page 53 Table 14: Load points for high efficiency - CGN YHAU-CGN Load point 1 Load point 2 Load point 3 Load point 4 1400EXW3H(L) 15.7 10.9 16.3 11.2 1500EXW3H(L) 16.7 10.9 16.4 12.5 1600EXW3H(L) 17.2 10.6 15.9 13.5 Table 15: Load points for high efficiency - CGH YHAU-CGH Load point 1 Load point 2...
Page 54 Figure 25: Load points YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 55 Table 16: Load points for standard efficiency - CGN YHAU-CGN Load point 1 Load point 2 Load point 3 Load point 4 120EXS(L) 2.25 1.84 2.76 1.40 150EXS(L) 2.25 1.84 2.76 1.40 180EXS(L) 2.72 2.16 3.24 1.72 240EXS(L) 2.82 2.53 3.79 1.91 300EXS(L)
Page 56 Table 18: Split shipment - high efficiency - CGN Double effect direct fired absorption chiller Main shell unit HX unit HG unit YHAU-CGN Length Width Height Weight Length Width Height Weight Length Width Height Weight (ton) (ton) (ton) 120EXH(L) 150EXH(L) 180EXH(L) 240EXH(L) 300EXH(L)
Page 57 Figure 26: Split shipment diagram Table 19: Split shipment - high efficiency - CGH Double effect direct fired absorption chiller Main shell unit HX unit HG unit YHAU-CGH Length Width Height Weight Length Width Height Weight Length Width Height Weight (ton) (ton) (ton)
Page 58 Table 19: Split shipment - high efficiency - CGH Double effect direct fired absorption chiller Main shell unit HX unit HG unit YHAU-CGH Length Width Height Weight Length Width Height Weight Length Width Height Weight (ton) (ton) (ton) 360EXH(L) 400EXH(L) 450EXH(L) 500EXH(L) 10.0...
Page 59 Table 21: Split shipment - standard efficiency - CGH Double effect direct fired absorption chiller Main shell unit HX Unit HG Unit YHAU-CGH Length Width Height Weight Length Width Height Weight Length Width Height Weight (ton) (ton) (ton) 120EXS(L) 150EXS(L) 180EXS(L) 240EXS(L) 300EXS(L)
Page 60 Figure 27: Power wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 61 Figure 28: Power wiring for inverter YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 62 Figure 29: Control power supply wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 63 Figure 30: Burner control wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 64 Figure 31: PLC input wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 65 Figure 32: PLC input wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 66 Figure 33: PLC output wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 67 Figure 34: PLC output wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 68 Figure 35: PLC Analog input wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 69 Figure 36: Display or analog input wiring YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 70 Figure 37: Optional wiring for residential hot water YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 71 Figure 38: External connection terminal details YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 72 Figure 39: Optional terminal for residential hot water Note: The wiring and terminal diagrams in this document are for reference only. For actual wiring information, see the field wiring diagrams in the control panel. YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 73 Table 22: Contact specifications Contact specification • Max. start & stop voltage: AC250 V/ DC30 V • Max start & stop current: 2 A/1 POINT Digital signal (RESISTANCE LOAD) Absorption chiller-heater control panel • Max start & stop voltage: AC250 V/DC30 ->...
Page 74 Figure 41: Signal terminal transition wiring Note: Every unit must be grounded correctly. Connect one of the following interlocks if necessary. Operating interlock *Chilled or hot water operation interlock Air handling unit interlock Gas duct damper full open interlock Cooling water pump interlock *Cooling water pump operation interlock Normally monitoring interlock Seismoscope relay...
Page 75: Upper Communication Specification
Figure 42: Upper communication system configuration Modbus TCP protocol communication Johnson Controls scope of delivery for the upper communication system covers the control panels for the upper communication function. The customer is responsible to deliver all other related equipment: concentrator (HUB), installation, wiring, communication program for the central monitoring unit, and other applicable communication cables.
Page 76: Connection Port For Ethernet Communication
Table 23: Scope of delivery for Modbus TCP Item Customer Remarks Wiring work for Ethernet Apply twisted pair cable connection See Table 25, Table 29, and Table 30 for the Communication program for details of the IP address, function code, central monitoring unit communication data address, and other relevant communication information.
Page 77: User-Created
Table 27 contains information regarding the communication specifications needed for the Modbus RTU. See Table 29 for information about the Read Command or Table 30 for information about the Write Command. Table 27: Communication specifications for Modbus RTU Communication protocol Modbus/RTU Communication path RS422/RS485 Data Length: 8 Bit Stop Bit: 1 Bit Parity: EVEN Speed: 9600 type...
Page 78: Two-Wire Type Cable Diagrams
Table 28: Cable diagram (RS-422/RS485) RS-422/RS-485 PIN Connection PIN. No. Signal name Direction Meaning Input Receive data A (+) Input Receive data B (-) Output Send data A (+) Output Data terminal ready A (+) Signal ground Input Send possible B (-) Output Send data B (-) Input...
Page 79: Four-Wire Type Cable Diagrams
Figure 45: Two-wire N:1 connection with user-created cable Four-wire type cable diagrams The following are sample cable diagrams for four-wire type connections. They use a GP4000 series (COM2). Figure 46: Four-wire 1:1 connection with user-created cable YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 80 Figure 47: Four-wire N:1 connection with user-created cable YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 81: Communication Data
Communication data Table 29: Read command Item Display Unit Address Content Set Point (Chilled/Hot 0050~1000 unit, 1 °C 00001 water outlet unit=0.1°C temp.) Automatic stop temp. at 0040~1000 unit, 1 cooling mode °C 00003 unit=0.1°C (thermo-off temp) Temp. difference of Automatic 0001~1000 unit, 1 °C...
Page 82 Table 29: Read command Item Display Unit Address Content Control -0100~1100 unit, 1 manipulated 00023 unit=0.1% variable 0:NORMAL OPERATION 13 Failure signal 0 or 1 01011 1:FAILURE OCCUR 0:NORMAL OPERATION 14 Alarm signal 0 or 1 01013 1:ALARM OCCUR Chilled/Hot 0001~4000 unit, 1 water inlet 12.0...
Page 83: Noise Emission
Table 30: Write command Item Address Content ON at CHILLER-HEATER OPERATION, PULSE Chiller-heater operation 02001 SIGNAL signal 2 Chiller-heater stop signal 02002 ON at CHILLER-HEATER STOP, PULSE SIGNAL 3 Set point 00203 0050~1000 unit, 1 unit=0.1°C Noise emission The direct fired chiller-heater running with the burner may produce the A-weighted emission sounds in excess of 80 dB (A), normally the A-weighted sound power level is less than 100 dB(A).
Page 84: Commissioning
Commissioning General guidelines for use Before operation Charge the solution and the refrigerant water if the solution and refrigerant water is in the drum during delivery. During commissioning, check the motor’s rotating direction of the solution pump, refrigerant pump, and purge pump: CAUTION The flow of fluid cannot be seen because the solution and refrigerant pumps are hermetically sealed.
Page 85: Precautions For The Use Of Water
Table 31: Rotary pump rotation Pump Correction rotation Solution circulation pump 0.10 to 0.20 MPa.G Solution spray pump -0.05 to 0.02 MPa.G Refrigerant pump -0.08 to -0.02 MPa.G After the completion of the installation of the chiller-heater and the thermal insulation for cold and hot surfaces, operate the chiller-heater and measure the noise around the chiller-heater unit.
Page 86: Chilled Or Hot Water Outlet Temperature Controller
Chilled or hot water outlet temperature controller The chilled or hot water outlet temperature controller (23A) is located on the sequencer and controls the chilled or hot water outlet temperature. Liquid level gauges Liquid level gauges are used to check the conditions of the chiller-heater components. Table 32: Liquid level gauges (sight glass) Liquid level gauge name Symbol...
Page 87: Stop The Chiller-Heater
Stop the chiller-heater • Press the STOP button on the Main screen of the Control Panel. To stop the chiller-heater from a remote location, enter the remote stop signal. When the chiller-heater stops, the following occurs: • The capacity control valves close. •...
Page 88 Figure 49: Cooling start/stop diagram Note: Do not start the cooling water pump and cooling tower fan during the heating model. If the unit runs the heating model with the auxiliary heat exchanger, the process is not active in the dotted line frame. YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 89 Figure 50: Direct fire sequential operation flowchart Note: Implement sequential operation of the chilled or hot water pump and the cooling water pump from the chiller-heater. If there is only one air conditioner, secure interlock for the air conditioner operation indicated in Figure 50.
Page 90 Note: Verify that the air conditioner has stopped after the chiller dilution operation is complete. Otherwise, the chiller may become damaged due to freezing of the chilled water or crystallization of the solution. The installation and interlocking of these valves with the chiller control panel is mandatory for safe and reliable operation of the chiller and to prevent potential crystallization of LiBr solution and freezing of the evaporator tubes.
Page 91 2. The following and its related equipment are ready for operation: b. Cooling water............a. Chilled or hot water pump ........c. Residential hot water pump ......... b. Cooling water pump ..........JOHNSON CONTROLS YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 92 4. Close the measuring port valves for the pilot and main gas line............. 5. Open the valves for the pilot and main gas lines..JOHNSON CONTROLS YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 93 14. Press the OPER. button on the Control Panel..15. Check that the following start properly: a. Solution circulation pump ........b. Solution spray pump ..........c. Refrigerant pump ..........NOTES: ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ JOHNSON CONTROLS YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 94 Review the operation and maintenance instructions with the customer............a. Customer Names: Customer Signature: _______________________________________ Title: _______________________________________ Form Completed by: _______________________________________ Date: ___________ ____________ / ____________ / Year Month JOHNSON CONTROLS YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 95 Appropriate Range of Refrigerant Density (kg/L) 0.0 to 0.9 1.095 to 1.115 1.0 to 1.9 1.078 to 1.098 2.0 to 2.9 1.060 to 1.080 3.0 to 3.9 1.041 to 1.061 JOHNSON CONTROLS YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 96 EXHAUST GAS °C Control panel ≤250 TEMPERATURE NOTES: If gas flow rate is taken as m /h, calculate m N/h with fuel pressure and ambient temperature. Ambient temperature: °C LD20247 JOHNSON CONTROLS YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 97 If flow meter (FM) is not available, calculate each flow rate as below. [1] = [2] x √[3] / [4] [5] = [6] x √[3] / [4] Waterbox LD20020 JOHNSON CONTROLS YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 98 FORM 155.32-CL1 ISSUE DATE: 04/11/2022 TABLE 1 - PURGE AMOUNT MEASUREMENT DATA SHEET (1/1) User: Model: YHAU - MFG.No.: User's machine code: Measured Date: Measured by: Purge Amount from Purge Line Flame Reaction Test Standard: 4.0 cc/min. or smaller Reaction (Strong/Weak/None) Amount of Gas (P) cc/min Purge Amount from Purge Tank...
Page 99: Operation
Operation YHAU-CGN/H Control Center The YHAU-CGN/H Control Center, furnished as standard on each chiller-heater, allows for efficiency, monitoring, data recording, chiller-heater protection, and operating ease. The Control Center is factory-mounted, wired, and tested. It used as a control system for lithium bromide absorption chiller-heaters.
Page 100: Change Numeric Values
Figure 52: Control center screen When you press the OPER. button while the chiller-heater is stopped, or STOP while the chiller- heater is operating, a confirmation message appears. Press YES or NO depending on whether you want to continue or cancel your selection. Figure 53: Control center dialog Screen Name Buttons - Each screen includes buttons for changing screens.
Page 101: Main Screen
Figure 54: Changing numeric values Enter the new value on the keypad. Press the ENT button to set it. Main screen Figure 55: Main screen The Main screen displays the equipment status, for example, the chiller-heater start or stop, operating, pumps ON or OFF, purge pump ON or OFF, and chilled or hot, and cooling water pumps ON or OFF.
Page 102: Operating Status
Operating status On the upper left of the screen below the LOCAL and REMOTE buttons is a list of options. Each has a lamp to indicate on or off for the following: Startup Lights if the chiller-heater is ready to start. Light is off if the chiller-heater is stopping •...
Page 103: Data Screen
Pump Solution circulating pump / solution spray pump / refrigerant pump / purge pump / chilled/ hot water pump / cooling water pump Flickers green during operation. Remains red when the pump is stopped. 69WC1/69WC2 (option) Differential pressure switch of chilled or hot water (69WC1) and cooling water (69WC2) Black when water is flowing.
Page 104 In the Measured Value section of the data screen, the following items are displayed: Chilled/Hot Water Inlet Temp.: Temperature of the chilled or hot water measured as it enters the evaporator. Chilled/Hot Water Outlet Temp.: Temperature of the chilled or hot water measured as it leaves the evaporator.
Page 105 The History Menu section on the right side of the screen gives you access to the operation history, Alarm History and to the Failure History screens. It contains four buttons: • Hourly Operation Move to the Hourly Operation History screen. •...
Page 106: Solution Analysis Or Control Panel Parts Replacement Screen
When maintenance is overdue, the maintenance alarm is activated with the warning Solution analysis should be done. When the warning appears, contact your local Johnson Controls Service Center. The Control Panel Parts Replacement section of the screen shows the maintenance interval and current operation hours since the last control panel maintenance.
Page 107: Solution Pump Overhaul Or Refrigerant Pump Overhaul Screen
Solution pump overhaul or refrigerant pump overhaul screen Figure 58: Solution pump overhaul or 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 108: Burner Parts Replacement Or Burner Combustion Check Screen
When the required maintenance interval has passed, the maintenance alarm is activated with the warning Burner parts should be replaced. When the warning appears, contact your local Johnson Controls service center.
Page 109: Trend Screen
Trend screen Figure 60: Trend screen To view the Trend Screen, press the Trend button above the History Menu section on the Data screen. This screen graphically illustrates the trend of the temperature and the pressure for the following: Chilled/Hot Water Inlet Temperature of the chilled or hot water measured as it enters the •...
Page 110 Use the numeric keypad to make the changes. For more information on the procedure, see Change numeric values. To move to another screen, press the any of the available buttons along the bottom of the screen. YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 111: Hourly Operation History Screen
Hourly operation history screen Figure 61: Hourly Operation History To view the Hourly Operation History screen, press the Hourly Operation button in the History Menu screen section of the Data screen. The Hourly Operation History screen shows operational information for the last 12 hours and contains the following fields of information.
Page 112 The Chilled/Hot water section of the screen shows you the following information: Inlet Temperature: Temperature of the chilled or hot water measured as it enters the evaporator. Outlet Temp.: Temperature of the chilled or hot water measured as it leaves the evaporator. The Cooling Water section shows you: Inlet Temperature: Temperature of the cooling water measured as it enters the absorber.
Page 113: Minutely Operation History Screen
Minutely operation history screen Figure 62: Minutely operation history To view the Minutely Operation History screen, press the Minutely Operation button in the History Menu section of the Data screen. The Minutely Operation History screen shows operational information for the last 12 minutes and contains the following fields of information: Operation: Operation status of the chiller-heater.
Page 114 Outlet Temp.: Temperature of the chilled or hot water measured as it leaves the evaporator. The Cooling Water section shows you: Inlet Temperature: Temperature of the cooling water measured as it enters the absorber. Outlet Temp.: Temperature of the cooling water measured as it leaves the condenser. Refrigerant Temp.: Temperature of the refrigerant in the evaporator.
Page 115: Failure History Screen
Failure history screen Figure 63: Failure history screen You move to the Failure History screen after you press the Failure History button in the History Menu screen section. The Failure History screen shows failure information for the last failure and up to six previous failures.
Page 116 Outlet Temp.: Temperature of the chilled or hot water measured as it leaves the evaporator. The Cooling Water section shows you: Inlet Temperature: Temperature of the cooling water measured as it enters the absorber. Outlet Temp: Temperature of the cooling water measured as it leaves the condenser. Refrigerant Temp.: Temperature of the refrigerant in the evaporator.
Page 117: Alarm History Screen
Alarm history screen Figure 64: Alarm history screen View the Alarm History screen after you press the Alarm button in the History Menu section of the screen. The Alarm History screen shows alarm information for the last alarm and up to six previous alarms. The alarm section contains the following fields of information: Alarm Name: Name or type of alarm.
Page 118 Auto Purge Frequency: How many times an automatic purge has been performed. The Chilled/Hot water section of the screen shows you the following information: Inlet Temperature: Temperature of the chilled or hot water measured as it enters the evaporator. Outlet Temp.: Temperature of the chilled or hot water measured as it leaves the evaporator. The Cooling Water section shows you: Inlet Temperature: Temperature of the cooling water measured as it enters the absorber.
Page 119: Failure And Alarm Screen
Failure and alarm screen Figure 65: Failure and alarm screen This screen displays failure indications (time-outs, operation interlock, overcooled refrigerant, over and under temperatures, and problems with the unit’s pumps) and system alarms. The failure light in the upper right corner is red. The alarm light is orange. Failure When a failure occurs, an alarm sounds (buzzer).
Page 120 Check whether or not the pipe is clogged. Combustion signal was not established within 3 minutes after combustion command output, Contact your local Johnson Controls Service Ignition Time Out due to malfunction of air pressure switch or Center. control motor.
Page 121 Purge manually (according to High Cut temperature relay was activated. instructions in Maintenance). Exhaust gas temperature at HG outlet increased Contact your local Johnson Controls Service High Exhaust Gas Temperature abnormally. Center. Flame signal was not detected during operation, Stop after dilution...
Page 122: Alarm
The alarm is reset through alarm reset. Service Center. Temperature difference between the exhaust gas temperature and HG temperature Contact your local Johnson Controls Service HG Tube Fouling widened, therefore fouling of HG tube inside is likely to be accumulated. The alarm is Center.
Page 123: Setting Screen
Setting screen Figure 67: Setting screen This screen displays control parameters (setting method and each setting parameter), valve operation (control valve mode auto / manual, and valve position setting), operation switch (forced dilution, refrigerant pump, purge mode, and manual purge, and other applicable gauges and pumps), language (Japanese, English, Chinese,and Deutsch) and date and time parameters.
Page 124 If you press the REMOTE button, the setting characteristics of the remote Set Point are determined based on the setting base temperature and the remote setting differential. The actual target temperature is calculated depending on these settings and the remote Set Point setting signal (4-20 mADC).
Page 125: Valve Operation
Valve operation Control Valve Mode Auto / Manual indicates whether the control valve is being operated automatically or manually. To change to manual operation mode, press and hold the Manual button for 3 seconds. Note: The Valve Position Setting may be changed ONLY when the Control Valve Mode Manual button is pushed.
Page 126: Operation Switch
Operation switch In this screen section, choices can be made about the mode of operation for the various devices. Use the buttons to make your choice. The choices are: Forced Dilution: Indicates whether forced dilution is on or off. Refrigerant Pump: Indicates whether the refrigerant pump is operating automatically (Auto mode) or is stopped (Stop mode).
Page 127: Single Loop Controller
Single loop controller The YHAU-CGN/H chiller-heater may have additional controllers. Each SDC35 Single Loop Controller is located to the left of the touch screen on the Control Panel on the front cover of the unit. The maximum number of controller units is two. One use of the controller is to manage the air damper of the burner unit.
Page 128: Run Mode
Mode Key: Press and hold the key to choose from any of 8 operational modes: • 0: Mode key does not operate • 1: Choose between AUTO or MANUAL mode (available only for residential hot water control valve controllers) • 2: Choose between RUN or READY mode •...
Page 129: Ready Mode
Ready mode When the Control Panel command is OFF, the controller is in READY (stand-by) mode. The controller is waiting for the command to shift to RUN mode. In READY mode, the Multi Status Display flashes slowly. All the lamps in the display are lit. Figure 73: Ready mode Alarm mode When the controller receives an alarm signal, the Upper Display flashes slowly.
Page 130: Alarm Codes
Alarm codes The following table contains the alarm codes for the controller, the name of the failure that triggered the alarm, the cause of the alarm, and the action needed to correct the problem. The codes are the same for both mechanisms covered in this document. Table 35: Alarm codes Alarm code Failure name...
Page 131: Operational Display
Operational display Air damper control When the controller is being used to manage the Air Damper, press the Display key to view the following: • Upper Display: Air damper opening (shown as a %) or Fb (feedback value is indicated in the lower display).
Page 132: Auto/Manual Mode (Rhw Only)
Figure 76: Hot water control valve Auto/manual mode (RHW only) The ability to choose between automatic and manual mode is available when the controller is being used to manage the residential hot water control valve. It is not available for any other mechanism. To access manual mode, press the Display button.
Page 133: Operation Mode Changeover
Operation mode changeover Changeover to cooling mode Press and hold the Operation Mode Cooling button on the Setting screen for 15 seconds. See Setting screen. Press the Cool or Heat Simultaneous OFF button on the Setting screen See Setting screen Press the RHW only operation OFF button (if applicable) on the Setting screen.
Page 134: Use Simultaneous Residential Hot Water Supply Mode (Option)
Use simultaneous residential hot water supply mode (option) In this mode, residential hot water is supplied through the auxiliary heat exchanger (option) while chilled water or hot water is supplied through the evaporator. Figure 78: Characteristics of simultaneous cooling and residential hot water supply operation Figure 79: Example of a residential hot water system Note: Three-way control valve (option) and residential hot water outlet temperature sensor are delivered separately.
Page 135: Changeover To Residential Hot Water Sole Supply Mode (Option)
Press the RHW only operation OFF button on the Setting screen. Set each Cooling or Heating changeover valve and manual valve to the desired operation mode (“Simultaneous cooling and residential hot water supply” mode or “Simultaneous heating and residential hot water supply” mode). See Table 36. Changeover to residential hot water sole supply mode (option) In this mode, residential hot water is supplied through the auxiliary heat exchanger (option), No chilled/hot water is supplied through the evaporator.
Page 136 16. Press and hold the Operation Mode Heating button for 15 seconds. The button is located on the Setting screen. See Setting screen. 17. Press the RHW only operation ON button on the Setting screen. 18. While the chiller-heater is stopping, purge the purging tank and absorber. See Manual method to purge non-condensable gas from the purge tank Manual method to purge...
Page 137 Table 36: Changeover valve operation Valve operation/location Operation mode HG - LG ->C Ref HG Sol RHW Ref RHW Ref LG->HG E->A Ref HG Sol Supply Purge valves >E Ref Return Return Supply Return Ref Return Set to automatic Cooling Ø...
Page 138: Maintenance
If not, it may cause electric shock and burn. CAUTION Contact your local Johnson Controls Service Office for inspection and maintenance of the unit. Improper inspection and maintenance can cause a machine malfunction and injury.
Page 139: Solenoid Valves
Solenoid valves The absorption chiller-heater is equipped with the following solenoid valves. Table 37: Solenoid valves Solenoid valve name Symbol Function Purge solenoid valve (1) Open and close vacuum pump piping Purge solenoid valve (2) Open and close automatic refrigerant blow Refrigerant blow solenoid valve piping Solution blow solenoid valve for...
Page 140: Checks After Operation Starts
Checks after operation starts 10 to 15 minutes after the chiller-heater and the solution pump start, check the level gauge of the refrigerant tank. If the refrigerant level is within the level gauge, press the Refrigerant Pump Auto button. Observe the operation for a while. Check that the refrigerant liquid level does not drop. Use the procedure shown in Purge procedure , to purge air from the low pressure side...
Page 141 Figure 81: Location of manual valve in purging system 120-300EX(H/S)(L) Purge valve for purge tank (V10) Purge valve for absorber (V13) Purge valve for purge tank (V11) Purge main valve (V14) Purge valve for absorber (V16) C/H Changeover valve VL (Option) Refrigerant pump Refrigerant blow manual valve (V8) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 142 Figure 82: Location of manual valve in purging system 360-500EX(H/S)(L) Purge valve for purge tank (V10) Purge valve for purge tank (V11) Purge valve for absorber (V13) Purge valve for absorber (V16) Purge main valve (V14) C/H changeover valve VL (option) Refrigerant blow manual valve (V8) Refrigerant pump YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 143 Figure 83: Location of manual valve in purging system 560-1600EXW3(H/S)(L) C/H changeover valve VL (Option) Purge main valve (V14) Purge valve for purge tank (V11) Purge valve for purge tank (V10) Purge valve for absorber (V16) Refrigerant pump Refrigerant blow valve (V8) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 144: Manual Method To Purge Non-Condensable Gas Directly From Absorber
Manual method to purge non-condensable gas directly from absorber When the chiller-heater operates at a lower capacity than usual for a long period of time or when it restarts after a power failure, the absorber may contain non-condensable gases. If the machine starts under these conditions, its performance and efficiency go down.
Page 145: Automatic Method To Purge Non-Condensable Gas From The Purge Tank
10. Open the ballast valve partly. 11. Press the Purge Pump OFF button. The vacuum pump stops. For information on how to set up an automatic purge, see Automatic method to purge non- condensable gas from the purge tank. Automatic method to purge non-condensable gas from the purge tank This chiller-heater has an automatic purge system.
Page 146 Figure 84: YHAU- CGN/H Direct Fired Chiller-Heater flow diagram - cooling only YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 147 Figure 85: YHAU- CGN/H Direct Fired Chiller-heater Flow Diagram - Heating Only (evaporator) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 148 Figure 86: YHAU- CGN/H Direct Fired Chiller-Heater flow diagram - residential hot water (auxiliary heat exchanger) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 149 Figure 87: YHAU- CGN/H Direct Fired Chiller-heater flow diagram - simultaneous cooling and residential hot water only YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 150 Figure 88: YHAU- CGN/H Direct Fired Chiller-Heater flow diagram - simultaneous heating and residential hot water YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 151 Figure 89: Process and instrumentation diagram - cooling only YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 152: Refrigerant Refining Method
Refrigerant refining method Note: • Only deionized water can be used as the refrigerant in the chiller-heater. • If the unit is the EX(H/S)L/EXW(H/S)L model, control the refrigerant density. See Table With an increase in the operation time of the chiller-heater, some of the solution can mix in with the refrigerant.
Page 153: Decrystallization Method
Since it becomes more difficult to melt the crystals as time passes, perform the following operation immediately when crystallization is detected. If the crystals cannot be melted by the following procedure, notify your local Johnson Controls Service Center immediately.
Page 154: Precautions For Decrystallization
Maintenance items Maintenance and inspection items along with standard inspection periods are shown in Table 39. For details, contact your local Johnson Controls Service Center. Inspection frequency can be adjusted according to the actual operating conditions. Table 39: Maintenance and inspection...
Page 155 Table 39: Maintenance and inspection Task Contents Frequency Scope Replacement of oil in vacuum Replace the oil in the vacuum pump. pump After the replacement of the lubricant oil for the vacuum pump, Check of Vacuum Pump be sure to pull the pulley belt and check the smooth motion of the pulley.
Page 156: Refrigerant Pump Manual Stop
Check and adjust combustion Collect the combustion data. Check the data collected during the commissioning. Note: C = Customer, S = Johnson Controls Service Refrigerant pump manual stop The refrigerant pump can be stopped manually for maintenance purposes. It can be stopped even while the chiller-heater operates.
Page 157: Purge Manual Start And Stop
Purge manual start and stop The purge can be started or stopped manually. Navigate to the Setting screen on the Control Panel. Press the Purge Mode Manual button. Press the Manual Purge ON button. The purge solenoid valves open. The purge operation begins. Press the Manual Purge OFF button when the purge process is complete.
Page 158 Table 40: Lifespan of common parts Description Applicable models or sections Lifespan of common parts Main Circuit Board Relay AF and MS Timer H3Y-2 Every 30,000 hrs Fuse Power Unit RWS series AX series for magnet switch. TA25 series for Magnet Switch, Thermal Relay thermal relay.
Page 159: Water Quality Control
Table 40: Lifespan of common parts Description Applicable models or sections Lifespan of common parts Oil For Purge Pump ULVAC R-7 Every 3,000 h Refrigerant density meter (model EX(H/ Proline Promass I 300 Every 60,000/h S)L/EXW(H/S)L only) Solution blow solenoid valve (model EX(H/ AB41 Every 30,000/h S)L/EXW(H/S)L only)
Page 160: Chemical Water Treatment
Chemical water treatment Since the mineral content of the water circulated through the evaporator, condenser, and absorbers varies, the water used may corrode the tubes or deposit heat resistant scale in them. Perform a chemical analysis of the water before the system is installed. Consult a reliable water treatment company to determine if treatment is necessary.
Page 161: Flow Speed In Tubes
Since the water flow speed in the tubes is closely related to any existing corrosion, do not increase the water supply rate more than recommended. If the flow speed reaches 3.5 to 4 meters per second, the tubes may erode. When changing the flow rate, contact your local Johnson Controls Service Center.
Page 162 Table 42: Chilled or hot and cooling water quality control (maximum concentrations) Cooling water system Chilled/hot water system Tendency Non- circulating Circulating type Element (1) (6) water Replenish Circulating water Replenish Scale Circulating water Passing water Corrosion water (20°C or lower) water forming pH (25°C)
Page 163 The items shown above are representative factors in corrosion and scale formation. Figure 90: Chilled or hot water and cooling water system YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 164: Storage Method Of The Chiller-Heater
Nitrogen gas pressurization inside the absorption chiller-heater is required when the storage period exceeds 6 months. Contact your local Johnson Controls Service Center for more details. DANGER The chiller-heater is not explosion proof. Highly flammable items, gas, or liquids should not be handled or stored near the chiller-heater.
Page 165: Precautions Against External Damage
If it is not possible to protect the machine, fill the interior with N2 to minimize the amount of air leakage. For details, contact your local Johnson Controls service center. Table 43: Wet storage method...
Page 166: Storage Method Of The Cooling Water During Heating Operation Period
Table 44: Dry storage method Storage Part Storage method Notes period Chilled or hot 1. Chilled or hot water and cooling water Dried and water system systems should be drained completely and pressurized dried by nitrogen blow, then pressurized with Nitrogen Less than 6 Cooling with nitrogen and left as is.
Page 167: Dry Storage
DANGER Cooling water temperature can rise up to approximately 80 °C due to the residual heat during heating operation. Be careful of burns when handling the water drain valves or other hot surfaces. Note: With the increased cooling water temperature, the volume of the cooling water expands.
Page 168 Condition around the chiller-heater: • During the heating operation period, there is concern of cooling water freezing. • Cooling tower is installed at the same level, or height, of the chiller-heater. • Lining pipe is used for the cooling water piping system. CAUTION Do not leave the tubes in absorber and condenser as is after simply draining the remained cooling water.
Page 169 Figure 93: Duhring diagram / PTX chart (°F) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 170 Figure 94: Duhring diagram / PTX chart (°C) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 171 Figure 95: Specific gravity - concentration (°F) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 172 Figure 96: Specific gravity - concentration (°C) YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 173: Troubleshooting
Use the procedures listed below to fix the problem. If the cause is not clear, using the countermeasure cannot repair the problem, or if the chiller- heater seems to have a serious problem, contact your local Johnson Controls Service Center immediately.
Page 174 Use the instructions shown in Maintenance. Heat exchange tube is dirty (chilled or hot water, cooling water). Solution is crystallized. Contact your local Johnson Controls Service Office. Corrosion inhibitor is worn. Air leaks in absorption chiller-heater. Table 46: Refrigerant overcooling relay...
Page 175 EX(H/S)L and EXW(H/S)L. Heat exchange tube is dirty (chilled or hot water). Contact your local Johnson Controls Service Office. Temperature controller or safety switch is broken. Table 47: Chilled or hot water time out or cooling water time out Item...
Page 176 Table 50: Abnormal control sensor Item Cause Countermeasure Contact failure Tighten terminal in control panel Sensor abnormal or disconnected Contact your local Johnson Controls Service Office. Inductive noise Table 51: CPU abnormal Item Cause Countermeasure Control board malfunction Contact your local Johnson Controls Service Office.
Page 177: Troubleshooting Performance Issues
If the performance is insufficient while the capacity control valve is fully opened or if the capacity control valve does not fully open while the load is sufficient, check numbers 1-6 in the following table in order. If the cause is found in numbers above 6, contact your local Johnson Controls Service Center immediately.
Page 178: Vacuum Pump
When the Purge Abnormal Alarm lights, the vacuum pump needs to be disassembled for inspection. Contact your local Johnson Controls Service Center. When the Abnormal Purge Frequency Alarm lights or the vacuum level of the purging line did not reach the specified level during the vacuum pump capacity check, the whole of the purge line needs to be inspected.
Page 179: Abnormal Solution And Refrigerant Levels
Abnormal solution and refrigerant levels Causes of abnormal levels of solution and refrigerant and countermeasures against them are shown below. If the level of the solution or refrigerant is abnormal, correct it according to the following procedure. Table 56: Abnormal solution and refrigerant levels Normal Abnormal Section...
Page 180 Causes of insufficient vacuum level of the purge line and countermeasure against the insufficient level. Table 57: Insufficient vacuum levels Item Cause Countermeasure Contact your local Johnson Controls Purge pump trouble. Service Office. Deterioration of vacuum pump oil. Replace the vacuum pump oil. • See Purge procedure.
Page 181 Figure 97: Troubleshooting sequence flow chart YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 182: Actions To Take Against Power Failure
Actions to take against power failure If the main power fails, take the following actions. Figure 98: Actions to take against power failure Note: If the chilled water design is less than 3°C and uses pure water, add the UPS to the chilled water pump to avoid freezing.
Page 183: Decommissioning, Dismantling, And Disposal
Decommissioning, dismantling, and disposal Unless otherwise indicated, the operations described below can be performed by any adequately trained maintenance technician. Isolate all sources of electrical supply to the unit, including any control system supplies switched by the unit. Make sure that all points of isolation are secured in the off position. Disconnect and remove the supply cables.
Page 184: Optional Applications
Optional applications Low temperature chilled water supply (model EX(H/S)L and EXW(H/S)L) By applying this option, the chiller can supply 1.0°C to 4.0°C of the chilled water constantly without freezing of the refrigerant. To prevent freezing of the refrigerant in the evaporator, a small amount of lithium bromide solution is mixed with the refrigerant in the evaporator and its concentration has been monitored and kept within an appropriate range.
Page 185 Figure 99: Main screen for model EX(H/S)L/EXW(H/S)L YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 186 Figure 100: Failure/alarm screen for model EX(H/S)L and EXW(H/S)L Figure 101: Direct fired chiller-heater cycle diagram for EX(H/S)L and EXW(H/S)L YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 187 Figure 102: PI&D drawing for EX(H/S)L and EXW(H/S)L YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)
Page 188 © 2022 Johnson Controls. All rights reserved. All specifications and other information shown were current as of document revision and are subject to change without notice. https://industrial.hitachiaircon.com/en...

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