Johnson Controls York YHAU-C Installation, Operation And Maintenance Manual Download Page 25

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Figure 4: Hoisting procedure (4 point lifting)

Figure 5: Moving the machine on rollers

YHAU-C Single Effect Steam-Fired Absorption Chiller

Summary of Contents for York YHAU-C

Page 1: ...155 34 ICOM2 EN UL 1219 New release Installation Operation and Maintenance Issue Date 2019 12 27 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 2: ......

Page 3: ...y assurance 9 Emergency shutdown 9 High temperature and pressure cleaning 9 Safety labels 10 Material safety data sheet 11 Product description 12 Chiller components 12 Control panel 14 How it works 15...

Page 4: ...ical data 38 Upper communication specification 89 Upper communication system configuration 89 Scope of delivery 90 Connection port for Ethernet communication 90 Communication specification 91 Communic...

Page 5: ...led water and cooling water 143 Purge valves 143 Starting the chiller after it has been stopped for a long period 143 Checks before operation starts 143 Checks after operation starts 143 Purge procedu...

Page 6: ...57 Treatment for long stoppage of the absorption chiller 158 Chemical treatment 158 Flow speed in tubes 158 Storage method of the chiller 158 Wet storage method 159 Dry storage method 159 Precautions...

Page 7: ...is expected that these individuals possess independent training that will enable them to perform their assigned tasks properly and safely It is essential that prior to performing any task on this equi...

Page 8: ...r Updated manuals if applicable can be obtained by contacting the nearest Johnson Controls Service office or accessing the Johnson Controls QuickLIT website at http cgproducts johnsoncontrols com It i...

Page 9: ...rk Absorption Unit Design Symbol Model Series name EXE 30 500RT nominal capacity EXW2S 630 1000RT nominal capacity EXW4S 1120 2000RT nominal capacity Generator Design None Standard T Special Low temp...

Page 10: ...ed by suitably trained and qualified personnel The manufacturer will not be liable for any injury of damage caused by incorrect installation commissioning operation or maintenance resulting from a fai...

Page 11: ...l equipment without first switching the power off then isolating and locking off the power supply Servicing and maintenance on live equipment must not be attempted Do not attempt to gain access to the...

Page 12: ...or warning WARNING Risk of electric shock General attention symbol WARNING On isolating the supply it may take up to 300 seconds for the capacitor voltage to fall below 50 V WARNING Risk of gas poison...

Page 13: ...ets MSDS specify proper procedures for handling and working with applicable chemicals including items such as physical data toxicity health effects first aid storage disposal and spill procedures 11 Y...

Page 14: ...fect absorption cycle uses deionized water as the refrigerant and lithium bromide LiBr as the absorbent The entire process occurs in almost a complete vacuum Chiller components The absorption chiller...

Page 15: ...s A Cooling Water Inlet B Touch Panel Display C Control Panel D Cooling Water Outlet E Chilled Water Inlet F Absorber G Solution spray pump H Evaporator I Solution Circulation Pump 13 YHAU C Single Ef...

Page 16: ...n various languages with numeric data in metric units For details of the control panel see Operation Note Confirm the main power switch is within 6 56 ft 2 m of the ground If not install the operation...

Page 17: ...sure of the lithium bromide solution is lower than the vapor pressure of the refrigerant The vapor pressure of the LiBr solution is directly related to the amount of refrigerant water present in the s...

Page 18: ...oled in two steps The absorber is split into two sections also A strong solution enters the top of the upper absorber It flows down through the upper absorber bundle The upper bundle operates at a low...

Page 19: ...elps to cool down the concentrated strong solution before entering the upper absorber section Generator The generator is a falling film design The steam passes through the stainless steel tubes There...

Page 20: ...hat are not well insulated and are located in rooms where the temperature can affect the solution moving through the pipes To prevent crystallization make sure that the solution temperature is high an...

Page 21: ...eas of the unit is still high If the temperature of this concentrated solution falls enough the solution reaches its crystallization point Plant room temperature insulation quality and the solution co...

Page 22: ...he most appropriate method depends on job specific factors such as the rigging equipment available and site needs A professional rigger must determine the rigging and lifting method to be used and it...

Page 23: ...ng of thin pipes caused by freezing of the refrigerant water sealed in the machine and resulting air leak if solution and refrigerant is charged b Breaking and air leak due to external damage c Deteri...

Page 24: ...to the machine The machine is a high vacuum vessel containing a corrosive solution Use diligence in protecting the machine as repair is labor intensive and costly Lift the machine horizontally If the...

Page 25: ...Figure 4 Hoisting procedure 4 point lifting Figure 5 Moving the machine on rollers 23 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 26: ...Figure 6 Fitting tir rollers to the machine YHAU C Single Effect Steam Fired Absorption Chiller 24...

Page 27: ...supports as shown in Figure 8 Figure 7 Jack up procedures Operate the front and rear jacks alternately Do not jack up the machine more than 0 78 in at a time Each time the machine is jacked up adhere...

Page 28: ...floor in case of future leaks Dimensions can be found in Table 8 For the external dimensions of the machine and foundation see the full view of the machine and the foundation drawing For serviceabilit...

Page 29: ...he machine Improper inspection and maintenance can cause a machine problem and also injure workers Keep the chilled water cooling water and steam under the maximum usage pressure If levels exceed the...

Page 30: ...voltage Application of a different voltage can cause a fire and electric shock Only weld in certain circumstances If welding is done be careful not to compromise the integrity of the vessel Before we...

Page 31: ...rupture disc depends on the chiller capacity The rupture disk protects the chiller s integrity if there ever is a tube rupture or in the very unlikely event that the unit s refrigerant vapor pressure...

Page 32: ...sociated with this the rupture disk vent piping must have a flexible connection between the rupture disk outlet and the relief piping The installing contractor must supply the flexible connection and...

Page 33: ...Figure 11 Location of rupture disk 31 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 34: ...5 1 6 3 28 1 1600 0 8 130EXET 10 17 3 1 5 91 1 8 6 89 2 1 12600 6 3 10 17 3 1 5 25 1 6 3 28 1 2000 1 160EXET 12 14 3 7 5 91 1 8 6 89 2 1 14800 7 4 11 81 3 6 5 25 1 6 3 28 1 2200 1 1 200EXET 14 76 4 5...

Page 35: ...3 3 3 11 15 3 4 78400 39 2 22 31 6 8 10 50 3 2 3 94 1 2 8200 4 1 1400EXW4ST 26 90 8 2 10 83 3 3 11 15 3 4 82000 41 24 61 7 5 10 50 3 2 3 94 1 2 8800 4 4 1500EXW4ST 28 54 8 7 10 83 3 3 12 14 3 7 85600...

Page 36: ...e general arrangement drawings for detailed nozzle locations for each specific unit Figure 14 YHAU C 30 500EXET nozzle locations LDxxxxx B Side A Side Item Description 1 Chilled water outlet odd pass...

Page 37: ...nozzle arrangements Reference general arrangement drawings for detailed nozzle locations for each specific unit Figure 15 YHAU C 630EXW2ST 2000EXW4ST nozzle locations Item Description 1 Chilled water...

Page 38: ...Install the generator insulation so that the front sides and rear sections can be removed separately All parts of the insulation on each side is removable Table 5 Insulating material and thickness Ho...

Page 39: ...Figure 16 Hot cold insulation 30 500EXET models Figure 17 Hot cold insulation 630EXW2ST 2000EXW4ST models 37 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 40: ...75 15 58 1 9 6 23 2 5 8 20 4 13 12 18200 9 1 20400 10 2 36600 18 3 255EXET 3 4 11 15 2 35 7 71 3 2 10 50 2 55 8 37 23800 11 9 27400 13 7 42400 21 2 320EXET 4 05 13 29 2 35 7 71 3 2 10 50 3 2 10 50 27...

Page 41: ...81 22 3 9 48 8 16 60 0 47 42 02 1 19 3 53 0 1 500EXET 215 28 20 312 15 29 4 9 60 7 19 42 0 55 47 67 1 35 4 24 0 12 630EXW2ST 312 15 29 333 68 31 6 0 71 0 39 91 1 13 81 93 2 32 5 65 0 16 700EXW2ST 333...

Page 42: ...XET 8160 4 08 8160 4 08 6540 3 27 6540 3 27 500EXET 9940 4 97 9940 4 97 7660 3 83 7660 3 83 630EXW2ST 12620 6 31 9480 4 74 12620 6 31 9480 4 74 700EXW2ST 13600 6 8 10200 5 1 13600 6 8 10200 5 1 800EXW...

Page 43: ...Figure 19 Interior of control panel LD29626 Figure 20 Exterior of control panel 41 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 44: ...2 22 2 6 2 22 2 AC220 V 3 Ph 60 Hz 32 A 160 A 6 1 24 6 6 1 24 6 AC380 V 3 Ph 50 Hz 3 4 12 1 3 4 12 1 AC380 V 3 Ph 60 Hz 3 2 10 7 3 2 10 7 AC400 V 3 Ph 50 Hz 3 45 12 6 3 45 12 6 AC415 V 3 Ph 50 Hz 3 6...

Page 45: ...7 2 5 8 2 0 6 8 3 4 20 6 6 5 5 2 2 06 7 6 3 4 20 6 7 0 5 6 50 1 1 3 0 1 8 9 0 6 7 5 3 1 0 2 5 1 8 9 0 6 4 5 1 1 12 3 3 1 8 9 0 7 1 5 7 1 14 3 9 1 8 9 0 7 6 6 1 1 0 3 4 1 6 9 0 6 4 5 1 36 1 03 3 8 1 6...

Page 46: ...2 AC220 V 3 Ph 60 Hz 50 A 160 A 10 6 44 8 6 1 24 6 AC380 V 3 Ph 50 Hz 6 1 23 0 3 4 12 1 AC380 V 3 Ph 60 Hz 6 2 19 0 3 2 10 7 AC400 V 3 Ph 50 Hz 5 8 24 0 3 45 12 6 AC415 V 3 Ph 50 Hz 5 75 24 4 3 6 13...

Page 47: ...3 8 20 6 8 9 7 1 2 0 6 8 3 4 20 6 8 3 6 6 2 06 7 6 3 4 20 6 8 7 7 0 50 1 1 3 0 1 8 9 0 8 5 6 8 1 0 2 5 1 8 9 0 8 3 6 7 1 12 3 3 1 8 9 0 8 7 7 0 1 14 3 9 1 8 9 0 9 1 7 3 1 0 3 4 1 6 9 0 8 2 6 6 36 1 0...

Page 48: ...V 3 Ph 60 Hz 50 A 160 A 14 4 59 0 10 6 44 8 AC380 V 3 Ph 50 Hz 8 1 29 0 6 1 23 0 AC380 V 3 Ph 60 Hz 8 2 23 0 6 2 19 0 AC400 V 3 Ph 50 Hz 7 8 30 0 5 8 24 0 AC415 V 3 Ph 50 Hz 7 7 31 0 5 75 24 4 AC400...

Page 49: ...2 3 4 20 6 11 5 9 2 2 9 9 0 3 4 20 6 12 2 9 8 50 1 6 4 2 1 8 9 0 11 9 9 5 1 4 3 9 1 8 9 0 11 9 9 5 1 65 4 4 1 8 9 0 12 1 9 7 1 7 4 7 1 8 9 0 12 5 10 0 1 4 4 1 1 6 9 0 11 5 9 2 36 1 45 4 5 1 6 9 0 12 2...

Page 50: ...AC220 V 3 Ph 60 Hz 63 A 160 A 22 8 130 0 11 0 48 0 AC380 V 3 Ph 50 Hz 14 2 60 0 6 5 20 3 AC380 V 3 Ph 60 Hz 14 0 51 0 6 3 18 0 AC400 V 3 Ph 50 Hz 13 5 63 0 6 2 21 0 AC415 V 3 Ph 50 Hz 13 0 66 0 6 0 2...

Page 51: ...25 0 3 4 20 6 16 7 13 3 7 0 26 0 3 4 20 6 17 1 13 7 50 3 9 11 9 1 8 9 0 17 7 14 1 3 7 10 7 1 8 9 0 17 3 13 8 3 8 12 8 1 8 9 0 17 8 14 3 3 7 13 2 1 8 9 0 17 9 14 3 3 6 12 5 1 6 9 0 16 6 13 3 36 3 5 13...

Page 52: ...Ph 60 Hz 80 A 160 A 34 0 146 0 18 0 74 0 AC380 V 3 Ph 50 Hz 19 8 68 6 10 6 34 0 AC380 V 3 Ph 60 Hz 19 3 60 0 10 3 30 0 AC400 V 3 Ph 50 Hz 19 2 72 0 10 1 36 0 AC415 V 3 Ph 50 Hz 18 6 73 5 9 8 37 0 AC40...

Page 53: ...0 3 4 20 6 23 4 18 8 8 0 26 4 3 4 20 6 24 5 19 6 50 4 7 12 5 1 8 9 0 24 6 19 7 4 9 9 0 1 8 9 0 24 2 19 4 4 5 13 0 1 8 9 0 25 0 20 0 4 4 13 5 1 8 9 0 25 2 20 1 4 2 12 0 1 6 9 0 23 4 18 7 36 4 0 13 2 1...

Page 54: ...220 V 3 Ph 60 Hz 125 A 160 A 47 6 197 2 34 0 146 0 AC380 V 3 Ph 50 Hz 27 5 99 1 19 8 68 6 AC380 V 3 Ph 60 Hz 27 2 89 0 19 3 60 0 AC400 V 3 Ph 50 Hz 26 3 104 0 19 2 72 0 AC415 V 3 Ph 50 Hz 25 5 108 0 1...

Page 55: ...3 1 8 9 0 36 9 29 5 6 3 18 0 1 8 9 0 36 2 29 0 6 2 21 0 1 8 9 0 37 4 29 9 6 0 22 0 1 8 9 0 37 6 30 1 5 8 23 0 1 6 9 0 35 9 28 7 36 5 5 24 0 1 6 9 0 36 8 29 4 2000 EXW4ST 2 2 5 4 24 5 0 75 1 6 9 0 37 3...

Page 56: ...he diagrams in this manual LD29585 Power supply Three phase 208 406 V 60 Hz MCCB Note 1 BK note 1 G Y note 1 MMS1 Note 1 5 3C MC1 5 3D BK note 1 G Y note 1 Note 1 Solution circulation pump VFD 1 optio...

Page 57: ...ding to pump configuration sheet 2 Remove jumper if there is constantly monitoring interlock 3 Do not install ventilation fan for NEMA4 4X enclosure 4 See transformer table 5 Condensate control for st...

Page 58: ...86 115 VAC power supply control valve 115 VAC power supply WS burner controller 24 VAC power supply control valve Noise filter for control circuit 24 VDC power supply control relay YHAU C Single Effec...

Page 59: ...586a 24 VDC power supply control relay 24 VDC power supply on delay relay 24 VDC power supply 24 VDC power supply for PLC HMI CN3 for PLC CN1 for HMI 57 YHAU C Single Effect Steam Fired Absorption Chi...

Page 60: ...l free signal Remote stop potential free signal Input com Input com PF WS burner overload PF WS burner failure Vacuum pump interlock High temperature generator solution level PF WS burner operation Ch...

Page 61: ...interlock Combustion monitoring interlock Spare Hot water pump interlock note 6 Spare Spare Spare Spare VFDs failure note 8 Input com Input com If a constantly monitoring cable is used remove jumper c...

Page 62: ...witch option High temperature generator pressure switch Input com Refrigerant pump interlock Solution circulation pump interlock Solution spray pump interlock 24 VDC power supply control relay Input c...

Page 63: ...h 1 Input com High temperature generator solution level 115 VAC Input CN1C PLC Solution electrode 33SL2 LD29588a If a constantly monitoring cable is used remove jumper cable 61 YHAU C Single Effect St...

Page 64: ...ng water pump operation Output com Solution circulation pump Refrigerant pump Purge gas solenoid valve 1 Solution blow solenoid valve Output com Failure Relay output TB1A PLC Fan LD29589 YHAU C Single...

Page 65: ...hilled water pump operation Hot water pump operation Solution spray pump Vacuum pump Purge gas solenoid valve 2 Chiller operation Alarm Contact output TB1A LD29589a 63 YHAU C Single Effect Steam Fired...

Page 66: ...g heating Cooling water temperature abnormal Refrigerant blow solenoid valve Condensate drain solenoid valve steam fired only Spare Spare WS burner reset Spare Relay output TB1B PLC LD29590 YHAU C Sin...

Page 67: ...S burner operation ventilation fan operation direct fired only steam shut off solenoid valve option Spare Output com WS burner reset com Output com Contact output TB1A Standard 5 LD29590a 65 YHAU C Si...

Page 68: ...nput wiring Cooling water inlet temperature Absorber temperature Chilled water outlet temperature Chilled water inlet temperature Cooling water outlet temperature LD29591 YHAU C Single Effect Steam Fi...

Page 69: ...or temperature direct fired only hot water inlet temperature hot water fired only Exhaust gas temperature direct fired only hot water outlet temperature hot water fired only Refrigerant temperature LD...

Page 70: ...put wiring High temperature generator generator pressure Remote chilld water temperature setting Remote load limit setting Purge tank pressure LD29611 4 20 MA Input CN2 PLC YHAU C Single Effect Steam...

Page 71: ...Refrigerant density Spare 25 VDC power supply for refrigerant density LD29611a 69 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 72: ...nalog output wiring Cooling water variable flow option Control valve Control signal Spare Burner control valve Control signal LD29612 4 20 MA Output CN2 PLC YHAU C Single Effect Steam Fired Absorption...

Page 73: ...Weishaupt burner control signal Option 3 4 20 MA amplifier for Weishaupt burner 4 20 MA output CN2 PLC Option 3 LD29616 71 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 74: ...r flow switch option 69WC3 Cooling water flow switch option 69WC2 High temperature generator pressure exhaust gas temperature switch 63SH1 26EG Refrigerant tank float switch 33RL1 PF burner start stop...

Page 75: ...S burner control wiring for direct fired chiller WS burner control wiring WS burner start stop WS burner reset WS burner alarm WS burner combustion LD29613a 73 YHAU C Single Effect Steam Fired Absorpt...

Page 76: ...rature switchover wiring for direct fired chiller Chilled water hot water hot water outlet temperature Chilled water hot water hot water inlet temperature TC RTD Input TB2 PLC LD29614 YHAU C Single Ef...

Page 77: ...ed water hot water temperature reading switching Option 1 Auxiliary heat exchanger for heating for direct fired chiller Relay output TB1B PLC LD29614a 75 YHAU C Single Effect Steam Fired Absorption Ch...

Page 78: ...LD29615 VFD wiring drawing option VFDs control signal Option 2 4 20 MA Output CN2 PLC YHAU C Single Effect Steam Fired Absorption Chiller 76...

Page 79: ...ing drawing option Option 2 VFDs controls for solution pumps VFD1 Start stop VFD2 Start stop VFD1 Control VFD2 Control VFD panel ventilation fan Option 2 LD29615a 77 YHAU C Single Effect Steam Fired A...

Page 80: ...Figure 34 Low chilled water control wiring option Absorber pressure PV1 Spare PV2 Spare PV3 Spare PV4 Power supply RS485 Option 4 LD29617 YHAU C Single Effect Steam Fired Absorption Chiller 78...

Page 81: ...Option 4 Low temperature chilled water controls for double effect chiller Please set PLC SW1 and SW2 as shown LD29617a 79 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 82: ...Figure 35 Freeze protection wiring option Relay output TB1B PLC Option 5 115 VAC power supply heating cable LD29618 YHAU C Single Effect Steam Fired Absorption Chiller 80...

Page 83: ...Option 5 Freeze protection for low ambient temperature Heating cable Option 5 LD29618a 81 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 84: ...Figure 36 Load limitation wiring option Remote load limit setting Option 6 0 10 V load limit input Option 6 4 20 MA input CN2 PLC LD29619 YHAU C Single Effect Steam Fired Absorption Chiller 82...

Page 85: ...Figure 37 PLC and touch screen communication wiring 83 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 86: ...Figure 38 PLC and touch screen communication wiring LD29620a YHAU C Single Effect Steam Fired Absorption Chiller 84...

Page 87: ...cope of supply Interlock Test Reset Interlock Test Reset Steam control valves steam inlet pressure above 6 bar out of scope of supply Steam control valve control signal 4 20 mA Z1 terminal block LD296...

Page 88: ...signal Remote stop potential free pulse signal Ancillary equipment board out of scope of supply Absorption chiller control panel scope of supply Z3 terminal block Z1 terminal block Steam shut off valv...

Page 89: ...ock b Cooling water pump interlock Cooling water pump interlock c Normally monitoring interlock Seismoscope relay Abnormal room temperature sensor 3 Use a shield wire with a maximum extension of 650 f...

Page 90: ...30 V Max open close current 2 A 1 Point resistance load Max common current 8 A resistance load Absorption chiller control panel external output terminal Analog signal Allowed resistance load 550 Ohm E...

Page 91: ...e 2 These are reference values as the chiller unit was not insulated and water pipes were not permanently secured during the measurement 3 Position of measuring instrument Upper communication specific...

Page 92: ...a concentrator HUB X Installation and wiring are included Wiring work for Ethernet connection X Apply twisted pair cable Communication program for central monitoring unit X Refer to this section for t...

Page 93: ...0 STOP 1 COOLING OPERATION 5 Local remote mode condition 0 or 1 01001 0 LOCAL 1 REMOTE 6 Solution pump condition 0 or 1 01003 0 STOP 1 OPERATION 7 Refrigerant pump condition 0 or 1 01005 0 STOP 1 OPE...

Page 94: ...d by the customer to ensure that the communication systems work correctly Table 18 Scope of delivery of upper communication system Item Customer JCI Remarks Control panel with upper communication func...

Page 95: ...ng 1 RDA Input Receive Data A 2 RDB Input Receive Data B 3 SDA Output Send Data A 4 ERA Output Data Terminal Ready A 5 SG Signal Ground 6 CSB Input Send Possible B 7 SDB Output Send Data B 8 CSA Input...

Page 96: ...sample cable diagram for a 2 wire type connection It uses a GP4000 series COM2 Figure 45 2 Wire 1 1 connection with user created cable Figure 46 2 Wire n 1 connection with user created cable YHAU C Si...

Page 97: ...ample cable diagrams for 4 wire type connections They use a GP4000 series COM2 Figure 47 4 Wire 1 1 connection with user created cable Figure 48 4 Wire n 1 connection with user created cable 95 YHAU C...

Page 98: ...ype RS422 RS485 Data Length 8 Bit Stop Bit 1 Bit Parity EVEN Speed 9600 bps Connector D Sub 9pin Function Code Read Coil Status 01 Read Holding Register 03 Device Digital Signal Coil Analog Signal Hol...

Page 99: ...firm that the absorber and refrigerant tank contain enough solution and refrigerant 4 Connect a compound gauge NPT 1 2 in to the sampling valve with Teflon tape Note The gauge s scale must be 760 mmHg...

Page 100: ...as chilled water hot water and cooling water As a result water quality must be checked periodically for stain and corrosion to prevent problems If water quality is not controlled and maintained corre...

Page 101: ...install a mist separator A drain trap does not need to be installed in the steam drain line between the chiller and the hot well tank The condensed water draining from the chiller is sub cooled enoug...

Page 102: ...ntrol valve is automatically controlled according to the chilled water outlet temperature Stopping the chiller 1 Navigate to the Control Panel Main screen 2 Press the STOP button on the Control Panel...

Page 103: ...Figure 49 Cooling start diagram 101 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 104: ...Figure 50 Cooling stop diagram YHAU C Single Effect Steam Fired Absorption Chiller 102...

Page 105: ...hen the chilled water pump stops the cooling water pump also stops d If the chilled and cooling water system is the common system install the isolation valve on the chilled water and cooling water inl...

Page 106: ...er Note Verify that the air conditioner has stopped after the chiller dilution operation is complete Otherwise the chiller can become damaged due to freezing of the chilled water and crystallization o...

Page 107: ...perly installed 7 The levelness of the unit is within acceptable range The tolerance for leveling length and width 1 0 in for every 1 000 in 8 Generator compound gauge displays the same pressure readi...

Page 108: ...on the purge line are closed 3 Open the spindle valve in the purge line 4 The detection component of the thermosensor is inserted into the thermowell according to design requirements D Electrical 1 M...

Page 109: ...Panel Checks 1 Thermal relays conform to the factory inspection sheet 2 Interlock and answerback signal s for the follow ing are available a Chilled water pump b Cooling water pump 3 Indicators on th...

Page 110: ...e chilled water outlet temperature 19 Press the STOP button on the Control Panel 20 Check that the dilution process is complete 21 Press the OPER button on the Control Panel 22 Operate the chiller for...

Page 111: ...________________ Title _____________ ____________ ___________ Month Day Year NOTES ________________________________________________________________ ____________________________________________________...

Page 112: ...n pump M S T V Solution spray pump M R Gnd V Refrigerant pump RP M S Gnd V Purge pump VP M T Gnd V Thermal Relay Setting Refrigerant Purity Temperature Setting Solution circulation pump A Standard 1 0...

Page 113: ...89 6 F Outlet temperature F Control panel 68 89 6 F Inlet pressure PSIG Pressure gauge Outlet pressure PSIG Pressure gauge 7 Pressure drop PSIG DPG or calculation 8 5 Flow rate ft3 h FM or calculation...

Page 114: ...k None Amount of Gas P cc min Purge Amount from Purge Tank Elapsed time 1 hour Consumed time for measurement m min Total gas amount a cc Actual gas amount b cc b a P x m Purge Amount from Absorber Sta...

Page 115: ...etric units plus keypad entry of set points to 0 1 increments Security access using passwords is provided to prevent unauthorized changes of set points There are three levels of access Each level has...

Page 116: ...button while the chiller is stopped or STOP while the chiller is operating a confirmation message appears Press YES or NO depending on whether you want to continue or cancel your choice YHAU C Single...

Page 117: ...Stop operation Screen Name Buttons Located along the bottom of the screen These are used to change screens The selected button lights when it is active 115 YHAU C Single Effect Steam Fired Absorption...

Page 118: ...ranges on the Trend screen can be changed Here s how 1 Touch the number to be changed A numeric keypad appears 1 Figure 55 Change numeric values 2 Enter the new value on the keypad 3 Press the ENT bu...

Page 119: ...emperature falls to the automatic stop temperature Turns off when the temperature rises enough to support an automatic restart Load Limit Light is lit if the load restriction activates due to the cool...

Page 120: ...lve refrigerant blow valve or purge tank valve White indicates valve is shut off Any other color indicates the valve is open The condition lights show the current operating mode and status of the syst...

Page 121: ...Out Temp Temperature of the cooling water measured as it leaves the condenser Evap Refrigerant Temp Temperature of the refrigerant in the evaporator Absorber Temp Temperature of the diluted solution i...

Page 122: ...d to the failure history information It contains four buttons Hourly Operation Move to the Hourly Operation History screen Minutely Operation Move to the Minutely Operation History screen Failure Acti...

Page 123: ...m 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 s...

Page 124: ...ate the maintenance interval and the current operation hours since the last maintenance When the required maintenance period has passed the maintenance alarm is activated with the warning Solution Pum...

Page 125: ...Chilled Water Out Temperature of the chilled water measured as it leaves the evaporator Cooling Water In Temperature of the cooling water as it enters the absorber Cooling Water Out Temperature of th...

Page 126: ...meric keypad to make the changes For more information on the procedure see Change numeric values To move to another screen press any of the available buttons along the bottom of the screen YHAU C Sing...

Page 127: ...ion method local or remote Sol Pump Operation status of the solution pump Ref Pump Operation status of the refrigerant pump Ope Hours How many hours the chiller has been operating Ope Frequency How ma...

Page 128: ...right side of the screen The first set gives you access to information about past occurrences For instance if you press the 3 times ago button the settings appear as they did 3 hours ago The buttons...

Page 129: ...s started using the OPER button or the remote start signal Fail Freq How many times the chiller has had a failure alarm Alarm Freq How many times an alarm has been triggered for the chiller Purge Freq...

Page 130: ...nce if you press the 3 times ago button the settings appears as they did 3 minutes ago The buttons in the History Menu section allow you to move between the various screens Hourly Operation Press this...

Page 131: ...mp Ref Pump Operation status of the refrigerant pump Ope Hours Total operation hours Ope Freq How many times the chiller has started using the OPER button or the remote start signal Fail Freq How many...

Page 132: ...ccess to information about past occurrences For instance if you press the 3 times ago button the settings appear as they did 3 events ago You can see up to 6 past events The buttons in the History Men...

Page 133: ...e refrigerant pump Ope Hours Total operation hours Ope Freq How many times the chiller has started using the OPER button or the remote start signal Fail Freq How many times the chiller has had a failu...

Page 134: ...ccess to information about past occurrences For instance if you press the 3 times ago button the settings appear as they did 3 events ago You can see up to 6 past events The buttons in the History Men...

Page 135: ...he FAILURE RESET button to reset the lighted failure button If you press the FAILURE RESET button before fixing the failure the lighted failure button remains visible and the buzzer sounds again If an...

Page 136: ...fell down abnormally during cooling operation and then refrigerant overcool relay was activated Low Cool W Inlet Temp Low Cooling Water Inlet Temperature Stop after dilution Cooling water inlet temper...

Page 137: ...e cooling water line Check the cooling water flow rate Check the cooling tower Purge manually according to instructions shown in Maintenance Contact your local Johnson Controls Service Center Gen Hi P...

Page 138: ...ensor and or absorber temperature sensor detected abnormal value due to disconnection short circuit power outage and so on Remote setting signal is abnormal during remote SP mode remote chilled water...

Page 139: ...calculating the set point Remote Set Diff The setting range with external 4 20 mADC signal Set Point Display The set point of the chilled water leaving temperature Automatic Stop The temperature at wh...

Page 140: ...cates 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 can be cha...

Page 141: ...on 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...

Page 142: ...hese operations can be changed Select language Press the button to choose the language to be shown in the Control Center Various languages are available YHAU C Single Effect Steam Fired Absorption Chi...

Page 143: ...eration control switch 23AS Turns OFF when the chilled water temperature at the outlet falls lower than the set value and turns ON when the chilled water temperature rises higher than the set value Pu...

Page 144: ...d maintenance work turn OFF the main circuit breaker MCCB and fully close the main valve of the steam line Failure to do so can cause electric shock and burn CAUTION Contact your local Johnson Control...

Page 145: ...valves V8 are fully closed 4 Check the vacuum level in the machine Use the pressure gauge of the generator 5 Check the steam supply 6 Press the Refrigerant Pump Stop button If the checks show no probl...

Page 146: ...water is left in the oil The oil then needs to be replaced more frequently 4 Set the valves according to pattern A shown in Figure 69 5 Press the Purge Mode MANUAL button 6 Press the Manual Purge ON b...

Page 147: ...er manually according to the following procedure 1 Set the valves according to pattern B shown in Figure 69 2 Press the Purge Mode Manual button 3 Press the Manual Purge ON button The vacuum pump star...

Page 148: ...valves according to pattern C shown in Figure 69 2 Press the Purge Mode Manual button 3 Press the Manual Purge ON button The vacuum pump starts The solenoid valves SV1 and SV2 open 4 3 4 minutes afte...

Page 149: ...es automatically open and close During the automatic purge operation the vacuum pump starts when the purging tank pressure increases to 60 mmHg Abs 8 kPa and stops when it decreases to 30 mmHg Abs kPa...

Page 150: ...Figure 69 Process and instrumentation diagram for EXW series chiller YHAU C Single Effect Steam Fired Absorption Chiller 148...

Page 151: ...the purging tank O O O Note 1 O Open valve 2 X Closed valve Refrigerant refining method Note Only use deionized water as the refrigerant in the chiller With an increase in the operation time of the ch...

Page 152: ...appens dilute the solution manually according to the following procedure Note Perform the following procedure immediately after the power is restored 1 Press the Forced Dilution ON button The solution...

Page 153: ...Navigate to the Setting screen on the Control Panel 4 Press the Forced Dilution ON button Note As the electrical wiring of the solution pump is disconnected only the refrigerant pump starts 5 Remove t...

Page 154: ...t in the machine the paint on the inside walls can be peeled off Maintenance items Maintenance and inspection items along with standard inspection periods are shown in the next table For details conta...

Page 155: ...ontinuity of protective bonding circuit Yearly S Analysis of quality of chilled water cooling water and steam drain See Water quality control Control the quality of chilled water cooling water and ste...

Page 156: ...s periodically Every 4 years S Chemical cleaning of tubes Absorber condenser Every 2 years S Chemical cleaning of tubes Evaporator Every 4 years S Chemical cleaning of tubes Generator Since hard scale...

Page 157: ...Figure 71 Control panel setting screen 2 Press the Purge Mode Manual button 3 Press the Manual Purge ON button The purge solenoid valves open The purge operation begins 4 Press the Manual Purge OFF b...

Page 158: ...Magnet switch Thermal relay Every 30 000 Hr Battery for main circuit board Every 3 years Battery for touch panel Every 5 years Touch panel Every 30 000 Hr Fan for control panel Every 30 000 Hr Steam...

Page 159: ...te If the chiller runs without the valves completely open a strong turbulent flow can be generated This turbulence can cause damage in the water chamber case and the copper tube of the chiller If you...

Page 160: ...e tube Control the flow rate on the outlet side The eddy current caused by foreign matter in the heat exchanger is also a factor in corrosion Install a strainer on the inlet side of the heat exchanger...

Page 161: ...water again 7 Store the machine Dry storage method The dry storage method must be used if the chilled water and the cooling water system can freeze in the winter or if the chilled water and cooling w...

Page 162: ...month 5 If the storage period exceeds 6 months apply pressure 1 5 3 psig with Nitrogen inside the shells and leave as it is Internal pressure must be checked periodically at least one time each week...

Page 163: ...e 3 corrode iron and copper tubes badly Reddish brown black Water smells bad Contains compounds of sulfur hydrogen sulfide H2S ammonium ion NH4 methane and other compounds Scales are generated easily...

Page 164: ...S 2 I No ions allowed X Ammonium Ion mgNH4 I Max 1 0 Max 0 1 Max 1 0 Max 1 0 Max 0 1 X Residual Chlorine mgCI I Max 0 3 Max 0 3 Max 0 3 Max 0 3 Max 0 3 X Free Carbonate Acid mgCO2 I Max 4 0 Max 4 0 Ma...

Page 165: ...nstallation of expansion joints for the chilled water and cooling water connections Figure 72 Chilled water and cooling water system Table 33 Steam drain quality control Component Standard value PH 7...

Page 166: ...Figure 73 Steam and drain system YHAU C Single Effect Steam Fired Absorption Chiller 164...

Page 167: ...Figure 74 Duhring diagram PTX chart F 165 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 168: ...Figure 75 Duhring diagram PTX chart C YHAU C Single Effect Steam Fired Absorption Chiller 166...

Page 169: ...Figure 76 Specific gravity concentration F 167 YHAU C Single Effect Steam Fired Absorption Chiller...

Page 170: ...Figure 77 Specific gravity concentration C YHAU C Single Effect Steam Fired Absorption Chiller 168...

Page 171: ...the valves and pumps of the cooling water system Verify the flow rate Contact your local Johnson Controls Service Center if any of the following apply The water flow rate setting is unknown It takes...

Page 172: ...shown in Manual refrigerant blowdown and diluting method 3 Load lowers sharply Check if the load changes sharply 4 Refrigerant is dirty contains solution Check if the refrigerant refining operation h...

Page 173: ...water inlet temperature control system is abnormal Check the cooling water inlet temperature control system If this problem occurs the absorption chiller performs the diluting operation automatically...

Page 174: ...ins in machine Check Purge procedure Check the capacity of the vacuum pump Check the purge unit for trouble Purge air from the absorption chiller If partial load operation is continued for a long peri...

Page 175: ...gerant levels Section Normal condition Abnormal condition Cause Countermeasure Cooling water temperature at inlet is high Chilled water temperature at outlet is low Heat exchange tube is dirty Purging...

Page 176: ...e vacuum pump oil 3 Incorrect operation of purging line switching when vacuum pump capacity was checked See Purge procedure Confirm the valves are open or closed 4 Deterioration of vacuum pump belt 5...

Page 177: ...ions to take against power failure If the main power fails follow the steps displayed in this chart Figure 78 Actions to take against power failure 175 YHAU C Single Effect Steam Fired Absorption Chil...

Page 178: ...Figure 79 Troubleshooting sequence flow chart YHAU C Single Effect Steam Fired Absorption Chiller 176...

Page 179: ...exchanger from the external water systems and drain the heat exchanger section of the system If no isolation valves are installed it is necessary to drain the complete system 8 If glycol is used in th...

Page 180: ...2019 Johnson Controls All rights reserved All specifications and other information shown were current as of document revision and are subject to change without notice www johnsoncontrols com...

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