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York YHAU-CGH manual available for free PDF download: Installation Operation & Maintenance
York YHAU-CGH Installation Operation & Maintenance (182 pages)
Direct Fired Absorption Chiller-Heater
Brand:
York
| Category:
Chiller
| Size: 15.4 MB
Table of Contents
Table of Contents
5
Section 1 - General Chiller-Heater Information and Safety
11
About this Manual
11
Introduction
11
Warranty
11
Emergency Shutdown
12
High Temperature and Pressure Cleaning
12
Quality Assurance
12
Safety Labels
13
Section 2 - Product Description
15
Chiller-Heater Components
15
Control Panel
15
Figure 1 - YHAU-CGN/H-120-300EX(H/S) and 360EX - 1600EXW3(H/S)
16
Evaporator
17
Figure 2 - Two Step Direct Fired Absorption Chiller-Heater Cycle Diagram
17
How It Works (Direct Fired Units)
17
(Cooling Mode)
17
Absorber
18
Two-Step Evaporator - Absorber
18
High Temperature Generator (HTG)
19
Low Temperature Generator (LTG)
19
Parallel Flow
19
Plate Type Heat Exchangers
19
Condenser
20
Crystallization
20
Why Does Crystallization Occur
20
Section 3 - Handling, Storage, Installation and Reassembly
21
Inspection
21
Inspection Window
21
Installation Guidelines
22
Figure 3 - Hoisting Procedures (4-Point Listing)
23
Hoisting the Machine
23
Figure 4 - Moving the Machine on Rollers
24
Figure 5 - Moving the Machine on Tir-Rollers
24
Moving the Machine on Rollers
24
Figure 6 - Jack-Up Procedure
25
Figure 7 - Jack-Up Support
25
Electrical
26
Indoor and Outdoor Installation
26
Structural Support and Installation
26
Precautions for Use
27
Electrical Shock Cautions
28
Leak Testing
28
Use of Gas
28
Rupture Disk and Relief Piping
29
Use of Oil
29
Vibration and Isolation Details
29
Figure 8 - Plastic Pipe Stub
30
Rupture Disk Discharge Piping Construction
30
Rupture Disk Discharge Piping Material
30
Figure 10 - Location of Rupture Disks
31
Figure 9 - Location of Rupture Disk
31
Rupture Disk Discharge Piping Sizing
31
Figure 11 - YHAU-CGN/H-120-300EX(H/S) and 360EX(H/S)-1600EXW3(H/S) Nozzle Locations
32
Table 1 - Nozzle Arrangements 120-300EX(H/S) and 360EX(H/S)-1600EXW3(H/S)
32
Table 2 - Nozzle Locations
32
Figure 12 - Fuel Gas Piping System
33
Figure 13 - Oil System
33
Flue Equipment Procedure
34
Figure 14 - Exhaust Gas Flue Diagram
35
Figure 15 - Hot and Cold Insulation Details
36
Hot Insulation/Cold Insulation Procedure
36
Table 3 - Insulating Material and Thickness
36
Table 4 - Points Requiring Hot/Cold Insulation
36
Figure 16 - Interior of Control Panel (MM)
37
Figure 17 - Exterior of Control Panel
37
Section 4 - Technical Data
39
Table 5 - Typical Operational Range
39
Table 6 - Standard Efficiency
40
Table 7 - High Efficiency
41
Table 8 - Physical Data (with Exhaust Gas Temp. Approximately 428°F) - CG/AN
42
Table 9 - Physical Data (with Exhaust Gas Temp. Approximately 428°F) - CG/AH
43
Table 10 - Electrical Data - CG/AN
44
Table 11 - Electrical Data - CG/AH
46
Table 12 - Load Points for High Efficiency - CG/AN
48
Table 13 - Load Points for High Efficiency - CG/AH
48
Table 14 - Load Points for Standard Efficiency - CG/AN
49
Table 15 - Load Points for Standard Efficiency - CG/AH
49
Table 16 - Split Shipment - High Efficiency - CG/AN
50
Table 17 - Split Shipment - High Efficiency - CG/AH
51
Figure 18 - Split Drawing
52
Table 18 - Split Shipment - Standard Efficiency - CG/AH
53
Table 19 - Split Shipment - Standard Efficiency - CG/AH
54
Figure 19 - Power Wiring
56
Figure 20 - Power Supply Wiring
58
Figure 21 - Power Supply Wiring
60
Figure 22 - PLC Input Wiring
62
Figure 23 - PLC Input Wiring
64
Figure 24 - Display Analog Input Wiring
66
Figure 25 - PLC Output Wiring
68
Figure 26 - Display Analog Input Wiring
70
Figure 27 - Display Analog Output Wiring
71
Figure 28 - Output Wiring
72
Figure 29 - Interior of Control Panel
72
Figure 30 - External Connection Terminal Details
73
Table 20 - Contact Specifications
73
Figure 31 - Remote Transmission Signal
74
Figure 32 - Signal Terminal Transition Wiring
74
Figure 33 - in Case of 3 Phase 4-Wire System
75
Figure 34 - Upper Communication System Configuration
76
Scope of Delivery
76
Table 21 - Scope of Delivery
76
Upper Communication Specification
76
Upper Communication System Configuration
76
Communication Specification
77
Connection Port for Ethernet Communication
77
Table 22 - Ethernet Interface Specification
77
Table 23 - Communication Specifications
77
Communication Data
78
Table 24 - Read Command
78
Figure 35 - Connection Detail for Sub 9 Pin
79
Table 25 - Write Command
79
Table 26 - Scope of Delivery of Upper Communication System
79
Table 27 - Cable Diagram (RS-422/RS485)
79
User-Created
79
Figure 40 - Sample Sound Testing
82
Noise Emission Information
82
2 Wire Type Cable Diagrams
80
Figure 36 - 2 - Wire 1:1 Connection with User-Created Cable
80
Figure 37 - 2-Wire N:1 Connection with User-Created Cable
80
4 Wire Type Cable Diagrams
81
Figure 38 - 4-Wire 1:1 Connection with User-Created Cable
81
Figure 39 - 4-Wire N:1 Connection with User-Created Cable
81
Table 28 - Communication Specifications
81
Section 5 - Commissioning
83
Before Operation
83
General Guidelines for Use
83
Precautions for the Use of Water
84
Table 29 - Rotary Pump Rotation
84
Chilled/Hot Water Outlet Temperature Controller
85
Liquid Level Gauges
85
Start the Chiller-Heater
85
Table 30 - Liquid Level Gauges (Sight Glass)
85
Interlocking Procedure
86
Stop the Chiller-Heater
86
Figure 41 - Cooling Start/Stop Diagram
87
Figure 42 - Direct Fire Sequential Flowchart
88
Figure 43 - Stopping Absorption Chiller-Heater Direct Fire Flowchart
88
Section 6 - Operation
89
Common Items
89
YHAU-CGN/H Control Center
89
Change Numeric Values
90
Figure 44 - Main Screen
91
Operating Status
92
Figure 45 - Data Screen
94
Figure 46 - Solution Analysis / Control Panel Parts Replacement Screen
96
Figure 47 - Solution Pump Overhaul / Refrigerant Pump Overhaul Screen
96
Solution Analysis / Control Panel Parts Replacement Screen
96
Solution Pump Overhaul / Refrigerant Pump Overhaul Screen
96
Burner Parts Replacement/ Burner Combustion Check Screen
97
Figure 48 - Burner Parts Replacement/ Burner Combustion Check Screen
97
Figure 49 - Trend Screen
98
Figure 50 - Hourly Operation History
100
Figure 51 - Minutely Operation History
102
Figure 52 - Failure History Screen
104
Figure 53 - Alarm History Screen
106
Failure
108
Figure 54 - Failure and Alarm Screen
108
Table 31 - Failure List
109
Alarm
111
Table 32 - Alarm List
111
Control Parameter
112
Figure 55 - Setting Screen
112
Valve Operation
113
Date and Time
114
Operation Switch
114
Burner Control Panel
115
Figure 56 - Burner Control Panel
115
Select Language
115
Changeover to Cooling Mode for Chiller with Evaporator Heating
116
Changeover to Heating Mode for Chillers with Evaporator Heating
116
Operation Mode Changeover
116
Changeover to Residential Hot Water Sole Supply Mode (Option) for Chillers with Evaporator Heating
117
Use Simultaneous Residential Hot Water Supply Mode (Option) for Chillers with Evaporator Heating
117
Figure 57 - Changeover Valve Locations for Chiller with Evaporator Heating
119
Table 33 - Changeover Valve Operation for Chiller with Evaporator Heating
119
Figure 58 - Changeover Valve Locations for Chillers with Additional Heat Exchanger Heating
120
Table 34 - Changeover Valve Operation for Chillers with Additional Heat Exchanger Heating
120
Section 7 - Maintenance
121
Exhaust Duct Inspection
121
Solenoid Valves
121
Table 35 - Solenoid Valves
121
Valve Inspection
121
Air Purge Valves and Drain Valves
122
Checks after Operation Starts
122
Checks before Operation Starts
122
Pump Shut off Valves
122
Purge Valves
122
Start the Chiller-Heater after It Has Been Stopped Fora Long Period
122
Capacity Check Method of Vacuum Pump
123
Purge Procedure
123
Figure 59 - Location of Manual Valve in Purging System 120-300EX(H/S)
124
Figure 60 - Location of Manual Valve in Purging System 360-500EX(H/S)
125
Figure 61 - Location of Manual Valve in Purging System 560-1600EXW3(H/S)
126
Manual Method to Purge Non-Condensable Gas Directly from Absorber
127
Automatic Method to Purge Non-Condensable Gas from the Purge Tank
128
Manual Method to Purge Non-Condensable Gas from the Purge Tank
128
Figure 62 - YHAU- CGN/H Direct Fired Chiller-Heater with Evaporator Heating
129
Flow Diagram - Cooling Only
129
Figure 63 - YHAU- CGN/H Direct Fired Chiller-Heater with Evaporator Heating
130
Flow Diagram - Heating Only
130
Figure 64 - YHAU- CGN/H Direct Fired Chiller-Heater with Evaporator Heating Flow Diagram Residential Hot Water (Auxiliary Heat Exchanger Only)
131
Figure 65 - YHAU- CGN/H Direct Fired Chiller-Heater with Evaporator Heating Flow Diagram - Simultaneous Cooling and Residential Hot Water Only
132
Figure 66 - YHAU-CGN/H Direct Fired Chiller-Heater with Evaporator Heating Flow Diagram - Simultaneous Heating and Residential Hot Water
133
Table 36 - Purge Valve Operation
133
Figure 67 - YHAU-CH/AN/H Direct Fired Chiller-Heater with Additional Heat Exchanger
134
Heating Flow Diagram - Cooling
134
Table 37 - YHAU-CG/AN/H Direct Fired Chiller-Heater with Additional Heat Exchanger
134
Figure 68 - YHAU-CG/AN/H Direct Fired Chiller-Heater with Additional Heat Exchanger
135
Heating Flow Diagram - Heating
135
Refrigerant Refining Method
136
Decrystallization Method
137
Indications of Crystallization
137
Manual Refrigerant Blow down and Diluting Method
137
Decrystallization
138
Maintenance Items
139
Precautions for Decrystallization
139
Table 38 - Maintenance and Inspection
140
Purge Manual Start and Stop
142
Refrigerant Pump Manual Stop
142
Lifespan for Various Parts
143
Table 39 - Lifespan of Common Parts
143
Chemical Water Treatment
145
Replacement of Water
145
Water Quality Control
145
Chemical Treatment
146
Flow Speed in Tubes
146
Treatment for Long Stoppage of the Absorption Chiller-Heater
146
Table 40 - Tendency of Generation of Scales and Corrosion by Quality of Cooling Water
147
Table 41 - Chilled/Hot and Cooling Water Quality Control (Maximum Concentrations)
148
Figure 69 - Chilled/Hot Water and Cooling Water System Evaporator Heating
149
Figure 70 - Chilled/Hot Water and Cooling Water System (Additional Heat Exchanger Heating)
150
Dry Storage Method
151
Precautions against External Damage
151
Wet Storage Method
151
Table 42 - Wet Storage Method
152
Table 43 - Dry Storage Method
152
Storage Method of the Cooling Water During Heating Operation Period
153
Wet Storage
153
Figure 71 - Wet Storage During Heating Operation Period
154
Dry Storage
155
Figure 72 - Dry Storage During Heating Operation Period
155
Figure 73 - Duhring Diagram / PTX Chart (°F)
156
Figure 74 - Duhring Diagram / PTX Chart (°C)
157
Figure 75 - Specific Gravity - Concentration (°F)
158
Figure 76 - Specific Gravity - Concentration (°C)
159
Section 8 - Troubleshooting
161
Table 44 - Troubleshooting the High Temperature Generator
162
Table 45 - Refrigerant Over-Cooling Relay
162
Table 46 - Chilled or Hot Water Time out or Cooling Water Time out
163
Table 47 - Pump Interlocks
163
Table 48 - Low Cooling Water Inlet Temperature
163
Table 49 - Abnormal Control Sensor
163
Table 50 - CPU Abnormal
164
Table 51 - Chilled or Hot Water Suspension
164
Table 52 - Pump(S) Overloaded or Overheated
164
Table 53 - Troubleshooting Performance Issues
165
Troubleshooting Performance Issues
165
Abnormal Solution and Refrigerant Levels
166
Table 54 - Vacuum Pump Troubleshooting
166
Table 55 - Abnormal Solution and Refrigerant Levels
166
Vacuum Pump
166
Table 56 - Insufficient Vacuum Levels
167
Figure 77 - Troubleshooting Sequence Flow Chart
168
Actions to Take against Power Failure
169
Figure 78 - Actions to Take against Power Failure
169
Section 9 - Decommissioning, Dismantling, and Disposal
171
Appendix 1 - Checklist
173
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