Johnson Controls York YHAU-CGH-CXR Series Installation, Commissioning, Operation, And Maintenance Download

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Figure 2: YHAU-CGN-CXR components

Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

Summary of Contents for York YHAU-CGH-CXR Series

Page 1: ...2 EN UL 320 New Release Installation Commissioning Operation and Maintenance Issue Date 2020 03 12 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 30 ton to 300 ton 1...

Page 2: ......

Page 3: ...ressure cleaning 10 Safety labels 11 Product description 13 Chiller heater components 13 Control panel 13 How it works direct fired units 15 Evaporator 15 Absorber 16 Plate type heat exchangers 16 Par...

Page 4: ...ng 30 Rupture disk discharge piping material 31 Rupture disk discharge piping construction 31 Rupture disk discharge piping sizing 32 Flue equipment procedure 35 Hot insulation cold insulation common...

Page 5: ...r purge valves and drain valves 145 Purge valves 145 Start the chiller heater after it has been stopped for a long period 145 Checks after operation starts 145 Purge procedure 146 Capacity check metho...

Page 6: ...r 160 Chemical treatment 160 Flow speed in tubes 160 Storage method of the chiller heater 163 Precautions against external damage 165 Storage method of the cooling water during heating operation perio...

Page 7: ...t 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 equipment this indi...

Page 8: ...information contained in this document is subject to change without notice Johnson Controls makes no commitment to update or provide current information automatically to the manual or product owner I...

Page 9: ...Nomenclature 7 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 10: ...rt without prior written authorization from an authorized Johnson Controls representative In addition this manual Should be read thoroughly before attempting to operate or service the unit Includes su...

Page 11: ...ip and materials All claims must be supported by evidence that the failure has occurred within the warranty period and that the unit was operated within the designed parameters specified All warranty...

Page 12: ...tact with any components to avoid risk of minor abrasions and lacerations Emergency shutdown In case of emergency the control panel is fitted with an incoming supply circuit breaker with a red handle...

Page 13: ...l WARNING On isolating the supply it may take up to 300 seconds for the capacitor voltage to fall below 50 volts WARNING On isolating the supply it may take up to 300 seconds for the capacitor voltage...

Page 14: ...CAUTION Risk of getting hand caught in machinery CAUTION Protect ears Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 12...

Page 15: ...changers to heighten the cycle efficiency Pumps to circulate the refrigerant and solution in the cycle Purge unit to remove non condensable gas from the machine Control panel The absorption chiller he...

Page 16: ...Figure 2 YHAU CGN CXR components Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 14...

Page 17: ...rant 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 throu...

Page 18: ...the tube bundle This allows the absorption process to continue and the solution becomes more diluted as it absorbs more refrigerant vapors When the LiBr solution reaches the bottom of the absorber se...

Page 19: ...cient and compact with lower pressure drop as compared to the conventional smoke tube type design where the exhaust gas is inside the tubes while the LiBr solution is on the shell side The liquid tube...

Page 20: ...ing through the pipes You can prevent crystallization by making sure you keep the solution temperature high and the concentration at the optimum percentage 64 As the solution temperature in the genera...

Page 21: ...t can still be relatively high If the temperature of this concentrated solution falls low enough the solution can reach its crystallization point Plant room temperature insulation quality and the solu...

Page 22: ...s beyond the scope of this manual to specify rigging and lifting details CAUTION This unit cannot be lifted or moved using a forklift This chiller heater is for air conditioning or a cooling manufactu...

Page 23: ...ing water in the cooling tower This can lower the quality of the cooling water resulting in corrosion and scale formation As sulfides and carbides contained in the exhaust gas are condensed low temper...

Page 24: ...r other air particles cover the entire machine including the control panel instruments and gauges located on top of the machine with a vinyl sheet Use caution not to apply too much pressure to the con...

Page 25: ...hine horizontally If the machine is inclined the solution and refrigerant inside shifts producing an offset load This can cause damage to the machine and pose a risk to the machine installer or person...

Page 26: ...gure 9 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 10 Figure 10 Moving the machine on tir rollers When jack...

Page 27: ...ach 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 12 If you are using a high temperature generator use a sec...

Page 28: ...Maintain adequate maintenance space around the chiller heater so work can be safely performed Foundation bolts must be installed in the vibration area Johnson Control recommends to install the chiller...

Page 29: ...t be removed when the moisture is absorbed Otherwise the silica gel can corrode the electrical parts of the control panel Do not allow negative pressure or any devices that create negative pressure to...

Page 30: ...ontrol panel with wet hands this can cause electric shock Do not touch the wiring in the control panel this can cause electric shock Do not touch any part other than the control panel of the machine a...

Page 31: ...the levelness of the unit For unit dimensions see Table 4 and Table 5 Note Place the unit and frame on flat ground If no vibration conditions are evident the foundation bolts are not necessary WARNIN...

Page 32: ...e revised code For YHAU units this device is a metallic one time use rupture disk burst rated at 12 0 psig 2 0 psig 82 7 kPa 13 8 kPa The size of the rupture disc will depend on the chiller capacity T...

Page 33: ...3 C in some cases Use schedule 40 steel pipe for the rupture disk discharge line material Rupture disk discharge piping construction For the piping material use carbon steel The relief piping must be...

Page 34: ...effect of back pressure that is developed when more than one relief device operates must be considered The sizing of the discharge line for the outlined condition must be based on the sum of each rup...

Page 35: ...ed on this oil return line In addition to prevent aeration into the oil supply delivery pipe the oil return pipe should be set apart from the delivery line and a baffle plate should be installed on th...

Page 36: ...l leakage Adequate flushing of the connection piping must be performed During commissioning be sure to purge air from the oil pump Prevent foreign materials such as water sludge or other materials fro...

Page 37: ...sed see the procedural drawing for sequential operation The flues should be as short as possible In particular the horizontal flue led from the chiller heater outlet must be as short as possible in or...

Page 38: ...flue are out of scope of delivery It is the customer s responsibility to provide these items 4 For dimensions of the flue connections see the delivery specifications in Technical data in this manual...

Page 39: ...rature relay and sensor Note The cold and hot insulation standard unit is of factory scope The SQ or optional design gives the insulation guide later such as split type with auxiliary heat exchanger d...

Page 40: ...Figure 21 Interior of control panel in Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 38...

Page 41: ...Figure 22 Exterior of control panel in 39 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 42: ...6 4690 7143 3240 7650 3470 10339 6 4690 80 CXR 8928 7 4050 9546 4330 12941 1 5870 8928 7 4050 9546 4330 12941 1 5870 100 CXR 9920 8 4500 10714 4 4860 14682 7 6660 9920 8 4500 10714 4 4860 14682 7 6660...

Page 43: ...0 2 1 0 060 3 8 0 110 60 CXR 27545 4 780 7 9 2409 4 5 1391 6 3 1950 4 4 1350 2 6 0 075 4 5 0 130 80 CXR 36727 2 1040 8 8 2696 4 7 1461 6 3 1950 5 2 1600 3 3 0 095 5 6 0 160 100 CXR 45909 1300 9 3 2854...

Page 44: ...2 2 0 75 3 4 40CXR AC460V 3pH 60Hz 15 125 1 1 3 0 2 1 05 0 75 1 6 AC208V 3pH 60Hz 25 125 1 1 6 2 0 2 2 0 75 3 4 50CXR AC460V 3pH 60Hz 15 125 1 1 3 0 2 1 05 0 75 1 6 AC208V 3pH 60Hz 25 125 1 1 6 2 0 2...

Page 45: ...AC460V 3pH 60Hz 15 125 1 1 3 0 2 1 05 0 75 1 6 AC208V 3pH 60Hz 25 125 1 1 6 2 0 2 2 0 75 3 4 50CXR AC460V 3pH 60Hz 15 125 1 1 3 0 2 1 05 0 75 1 6 AC208V 3pH 60Hz 25 125 1 1 6 2 0 2 2 0 75 3 4 60CXR AC...

Page 46: ...e 24 Power wiring LD29650a Power supply three phase 208 460V 60 Hz Refrigerant pump Solution circulation pump Switch box Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heat...

Page 47: ...Figure 24 Power wiring LD29650b Vacuum pump option Switch box 45 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 48: ...upply wiring LD29703a 115 VAC power supply WS burner fan 115 VAC power supply WS burner controller Noise filter for control circuit Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption C...

Page 49: ...3b 24 VDC power supply control relay 24 VDC power supply on delay relay 24 VDC power supply 24 VDC power supply for PLC and HMI CN3 for PLC CN1 for HMI 47 Model YHAU CGN H CXR M Double Effect Direct F...

Page 50: ...tial free signal Remote stop potential free signal Input COM Input COM WS burner overload WS burner failure Vacuum pump interlock High temperature generator solution level WS burner operation Model YH...

Page 51: ...rlock Constantly monitoring interlock Cooling water pump interlock Combustion monitoring inerlock spare Hot water pump interlock spare spare spare spare spare Input COM Input COM 49 Model YHAU CGN H C...

Page 52: ...h option Cooling water flow switch option High temperture generator pressure switch Input COM Refrigerant pump interlock Solution circulation pump interlock 24 VDC power supply control relay Input COM...

Page 53: ...PLC I O input wiring LD29705b Absorber float switch Input COM High temperature generator solution level Solution electrode 51 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chille...

Page 54: ...water pump operation Output COM Solution circulation pump Refrigerant pump Purge water solenoid valve 1 Solution blow solenoid valve option Output COM Failure Relay output Model YHAU CGN H CXR M Doub...

Page 55: ...er operation Chilled water pump operation Hot water pump operation Solution spray pump Vacuum pump Purge gas solenoid valve 2 3 Standard 7 Chiller operation Alarm 53 Model YHAU CGN H CXR M Double Effe...

Page 56: ...9707a Combustion Cooling heating Cooling water teperature abnormal Refrigerant blow solenoid valve spare spare spare spare WS burner modulating control Model YHAU CGN H CXR M Double Effect Direct Fire...

Page 57: ...Output COM Dilution Remote local Standard 5 spare WS burner operation and ventilation fan operation spare Output COM Output COM WS burner modulating control 55 Model YHAU CGN H CXR M Double Effect Di...

Page 58: ...08a Cooling water inlet temperature Absorber temperature Cooling water outlet temperature Chilled water inlet temperature Cooling water outlet temperature Model YHAU CGN H CXR M Double Effect Direct F...

Page 59: ...PLC analog input wiring LD29708b High temperature generator temperature spare Exhaust gas temperature Refrigerant temperature 57 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chil...

Page 60: ...9a High temperature generator generator pressure Remote chilled water temperature setting Remote load limit setting Purge tank pressure Refrigerant density Model YHAU CGN H CXR M Double Effect Direct...

Page 61: ...Figure 31 PLC analog input wiring LD29709b spare 24 VDC power supply for refrigerant density 59 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 62: ...nalog output wiring LD29710 Cooling water variable flow option Control valve control signal spare Weishaupt burner control signal Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chi...

Page 63: ...61 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 64: ...69WC1 Hot water flow switch option 69WC3 Cooling water flow switch option 69WC2 High temperature generator pressure and exhaust gas temperature switch 63SH1 26EG Absorber float switch 33SL Model YHAU...

Page 65: ...er control wiring LD29711b WS burner control wiring WS burner start stop WS burner modulating control WS burner alarm WS burner combustion 63 Model YHAU CGN H CXR M Double Effect Direct Fired Small Ab...

Page 66: ...for direct fired chiller option 1 LD29712a Chilled water hot water hot water outlet temperature Chilled water hot water hot water inlet temperature Model YHAU CGN H CXR M Double Effect Direct Fired S...

Page 67: ...direct fired chiller option 1 LD29712b Option 1 External heat exchanger for direct fired chiller Chilled water hot water temperature reading switching 65 Model YHAU CGN H CXR M Double Effect Direct F...

Page 68: ...Figure 36 Freeze protection for low ambient temperature option 5 LD29713a 115 VAC power supply heating cable Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 66...

Page 69: ...rotection for low ambient temperature option 5 LD29713b Option 5 Option 5 Freeze protection for low ambient temperature Heating cable 67 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorpt...

Page 70: ...Figure 37 Residential hot water option 7 LD29715a Residential hot water outlet temperature Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 68...

Page 71: ...n 7 LD29715b Please set PLC SW1 and SW2 as shown Option 7 Residential hot water Residential hot water pump operation 115 VAC power supply control valve 69 Model YHAU CGN H CXR M Double Effect Direct F...

Page 72: ...Figure 38 Display connection details Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 70...

Page 73: ...Figure 38 Display connection details 71 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 74: ...ock Residential hot water control valve control signal 4 20 mA Residential hot water control valve control signal 4 20 mA Residential hot water contrl valve option out of scope of supply Test Interloc...

Page 75: ...scope of supply Z3 terminal block Remote start potential free pulse signal Remote stop potential free pulse signal Option Starting panel for residential hot water pump out of scope of supply Z5 termi...

Page 76: ...er flow signal 4 mA 50 flow 20 mA 100 flow Digital signal Rated voltage current DC24 V 7 mA External output terminal Absorption chiller heater control panel Analog signal Chilled or hot water outlet t...

Page 77: ...tion interlock Air handling unit interlock Gas duct damper full open interlock b Cooling water pump interlock c Cooling water pump operation interlock d Normally monitoring interlock Seismoscope relay...

Page 78: ...igures are already connected in the factory indicates a connection is required Upper communication specification The information in this section applies to the CG Series of direct fired absorption chi...

Page 79: ...information Connection port for Ethernet communication Make sure that the Ethernet cable is plugged into the correct port on the control panel The Ethernet connection port is located at the bottom lef...

Page 80: ...100 1100 unit 1 unit 0 1 13 Failure signal 0 or 1 01011 0 Normal operation 1 Failure occur Operation condition 14 Alarm signal 0 or 1 01013 0 Normal operation 1 Alarm occur 15 Chilled Hot water inlet...

Page 81: ...y Figure 44 Connection detail for D sub 9 pin serial interface COM2 Table 21 Scope of delivery of upper communication system Item Customer JCI Remarks Control panel with upper communication function X...

Page 82: ...und 6 CSB Input Send possible B 7 SDB Output Send data B 8 CSA Input Send possible A 9 ERB Output Data terminal ready B Shell FG Frame ground common with SG Two wire type cable diagrams The following...

Page 83: ...e type cable diagrams The following are sample cable diagrams for four wire type connections They use a GP4000 series COM2 Figure 47 Four wire 1 1 connection with user created cable 81 Model YHAU CGN...

Page 84: ...le 20 about the write command Table 23 Communication specifications Communication protocol Modbus RTU Communication path type RS422 RS485 data length 8 Bit Stop Bit 1 Bit Parity EVEN Speed 9600 bps Co...

Page 85: ...4 72 80 26 62 40 65 58 74 57 65 65 68 59 59 60 59 55 53 46 43 25 25 30 60 CXR 5 54 62 25 48 25 47 35 50 39 47 44 47 44 43 44 43 38 36 25 25 25 25 1 70 80 33 68 58 73 58 73 56 66 57 60 59 60 55 55 52 5...

Page 86: ...g valves 2 Make sure the valves are completely closed 3 Confirm that the absorber and refrigerant tank contain enough solution and refrigerant 4 Connect a compound gauge NPT in to the sampling valve w...

Page 87: ...oling water Water quality must be checked periodically to prevent problems If water quality is not controlled and maintained correctly premature tube failure can result Causes of bad quality water inc...

Page 88: ...pressure is kept at the required specification Check that the refrigerant pump Auto button is pressed After the review is complete start the chiller heater Note The OPER and STOP buttons are availabl...

Page 89: ...ilution operation the solution circulation pump and the refrigerant pump operate When the dilution operation is complete the solution circulation pump and the refrigerant pump stop Then the chilled ho...

Page 90: ...e cooling water pump and cooling tower fan during the heating model 2 If the unit runs the heating model with the auxiliary heat exchanger the process is not active in the red frame Model YHAU CGN H C...

Page 91: ...he cooling water stops too 4 If the chilled hot and cooling water system is on a common system it is necessary to install the isolation valve on the chilled hot water and cooling water inlet pipe ente...

Page 92: ...se the chiller heater can become damaged due to freezing of the chilled water and or crystallization of the solution 2 If the unit runs the heating model with the auxiliary heat exchanger the process...

Page 93: ...st Customer Address Phone JCI tel no Job name Location Customer order no JCI order no JCI contract no Unit model no Unit serial no The work as checked below is in process and will be completed by MM D...

Page 94: ...for every 39 in and width is 0 039 in for every 39 in length 1 0 for every 1 000 mm and width 1 0 for every 1 000 mm 6 HG compound gauge pressure reading is about the same as before shipment 7 Thermal...

Page 95: ...pump 9 The flow rate is adjusted within acceptable range for a Chilled or hot water b Cooling water c Residential hot water 10 The flue damper has an open limit switch Its signal is connected to the...

Page 96: ...until the HT GEN compound gauge indicates approximately 0 005 MP a G 0 725 PSI 3 Connect the vacuum hose of the additional service vacuum pump with the absorber purging valve 4 Evacuate the nitrogen...

Page 97: ...he non condensable gas from the absorber Use the procedure detailed in the Maintenance section of the manual 9 Open the refrigerant manual blow valve 10 Navigate to the Control Panel Setting screen 11...

Page 98: ...ptable range when the exhaust gas is at high combustion 20 Collect the combustion data 21 Verify that the flame current is within the acceptable range 22 Verify that the draft pressure is within the a...

Page 99: ...re 12 Record the running data on the data sheets B Purge Amount Check 1 Verify that the purge amount from the absorber by the additional service vacuum pump is within acceptable range 2 Continuously p...

Page 100: ...T V Solution circulation pump M S T V R Gnd V Refrigerant pump M S Gnd V T Gnd V Thermal Relay Setting Refrigerant Purity Temperature Setting Solution circulation pump A Standard 1 040 kg L or less C...

Page 101: ...Notes 9 YHAU CGN H CXR M Small Direct Fired Absorption Chiller Heater Checklist 99 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 102: ...Exhaust Gas CO Concentration ppm Exhaust gas analyzer 100 Exhaust Gas CO2 Concentration Exhaust gas analyzer Exhaust gas NOx concentration ppm Exhaust gas analyzer Wind Box Pressure Water manometer Dr...

Page 103: ...erature F Control panel 68 0 99 5 F Inlet pressure Pressure gauge Outlet pressure Pressure gauge 7 Pressure drop DPG or calculation 8 Cooling Water 5 Flow rate FM or calculation 6 HG pressure gauge PS...

Page 104: ...e Line Flame Reaction Test Standard 4 0 mm Abs Hg min or smaller Reaction Strong Weak None Amount of Gas P mm Abs Hg min Purge Amount from Purge Tank Elapsed time 1 hour Consumed time for measurement...

Page 105: ...rial 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 i...

Page 106: ...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 Model YHAU CGN H CXR M Double...

Page 107: ...Change numeric values Many numeric values such as the set point and the ranges on the trend screen can be changed To change the values complete the following steps 1 Touch the number to be changed A n...

Page 108: ...w position before the automatic temperature control process runs Temp Control The light is lit if the temperature control of the microcomputer panel changes to RUN status It turns off if the chiller h...

Page 109: ...mp refrigerant pump chilled hot water pump cooling water pump Flickers green during operation Remains red when the pump is stopped 69WC1 69WC2 option 69WC3 with auxiliary heat exchanger Differential p...

Page 110: ...er Cooling Water Outlet Temp Temperature of the cooling water measured as it leaves the condenser Evaporator Refrigerant Temp Temperature of the refrigerant in the evaporator Absorber Temp Temperature...

Page 111: ...ow many times the system has experienced a failure Alarm Displays how many times an alarm has been activated Auto Purge Displays how many times the automatic purge system has started To move to the Tr...

Page 112: ...of the solution and addition of inhibitor is required When maintenance is overdue the maintenance alarm is activated with the warning Solution analysis should be done When the warning appears contact...

Page 113: ...rval and the current operation hours from when the last maintenance was performed When the required maintenance period has passed the maintenance alarm is activated with the warning Solution Pump shou...

Page 114: ...be replaced When the warning appears contact your local Johnson Controls service center The burner combustion check section of the screen indicates the maintenance interval and current operation hours...

Page 115: ...ot water measured as it leaves the evaporator Cooling Water Inlet Temperature of the cooling water as it enters the absorber Cooling Water Outlet Temperature of the cooling water as it leaves the cond...

Page 116: ...eration history screen Figure 59 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...

Page 117: ...t 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 r...

Page 118: ...mode cooling or heating Combustion Status of the combustion ON or OFF Operation Hours How many hours the chiller heater has been running Operation Freq How many times the chiller heater has started u...

Page 119: ...en To move to another history screen press the required screen button to move to the required screen in the history menu Hourly Operation Failure or Alarm There are two sets of buttons on the right si...

Page 120: ...Refrigerant Pump Operation status of the refrigerant pump Burner Fan Operation status of the burner fan Combustion Status of the combustion ON or OFF Operation Hours Total operation hours Operation Fr...

Page 121: ...e concentrated solution in the high temperature generator Control Valve Percentage that the valve is open There are two sets of buttons on the right side of the screen The first set gives you access t...

Page 122: ...ation status of the refrigerant pump Burner Fan Operation status of the burner fan Combustion Status of the combustion ON or OFF Operation Hours Total operation hours Operation Freq How many times the...

Page 123: ...e concentrated solution in the high temperature generator Control Valve Percentage that the valve is open There are two sets of buttons on the right side of the screen The first set gives you access t...

Page 124: ...sounds buzzer The type of failure button lights in the Failure section of the screen Press the BUZZER STOP button to turn off the alarm sound This can be done even before the failure is addressed Tur...

Page 125: ...m press the FAILURE RESET button to reset the lighted failure button If you press the FAILURE RESET button before fixing the problem the lighted failure button stays lighted and the buzzer sounds agai...

Page 126: ...water pump Check the cooling water line Check the cooling water flow Check the cooling water suspension relay Check whether or not the pipe is clogged Ignition Time Out Not start Combustion signal was...

Page 127: ...ow Contact your local Johnson Controls Service Center Constantly Monitoring Interlock Constant monitoring interlock was not established Check the components of the constant monitoring interlock If any...

Page 128: ...y or overheat switch was activated Burner Fan Abnormal or Oil Pump Abnormal Stop after dilution Burner fan thermal relay was activated Contact your local Johnson Controls Service Center Absorber Low L...

Page 129: ...s output Press the Refrigerant Pump Auto button HG High Pressure Prevention HG pressure increased and the load limit operation was activated The alarm is reset when the HG pressure reaches 85 3 kPa HG...

Page 130: ...tting range with external 4 20 mADC signal Set Point Display The set point of the chilled hot water leaving temperature Auto Stop Temp Temperature at which the chiller heater will automatically stop A...

Page 131: ...ration Note The valve operation buttons can be found in the Maintenance interface on the touch screen Control Valve Mode Auto Manual indicates whether the control valve is being operated automatically...

Page 132: ...the control valve mode to auto Date and time The date and time settings can be changed if you press the Date and Time button above the Main button The date and time screen displays Use the following p...

Page 133: ...rol the purge operation The lit button indicates if the purge mode is Automatic or Manual Manual Purge The ON and OFF buttons control the manual purge operation The lit button tells you if the manual...

Page 134: ...l of hot water or the optional simultaneous operation The SDC35 Single Loop Controller is located to the right of the touch screen on the control panel on the front cover of the unit All of the inform...

Page 135: ...as a MV graph a Digital Input DI monitor and an internal event monitor as well At times the display may flash Mode Key Press and hold the key to choose from any of eight operational modes 0 Mode key...

Page 136: ...the unit is in RUN mode The graph tells you what the control output of the unit is from 0 to 100 Ready mode When the control panel command is OFF the controller is in READY stand by mode The controlle...

Page 137: ...ternates between the normal information and the alarm code In addition the multi status display lights ripple through the left and right lights See an example of what the single loop controller in ala...

Page 138: ...or both 2 A current exceeding the upper limit of the display range was measured The number of CT turns or the number of CT power wire loops is incorrectly set Or the wiring is incorrect Use a CT with...

Page 139: ...ears release the Mode button The information in the Lower Display changes to the control output for the hot water control valve At this point the information can be changed Press the Up Down arrow key...

Page 140: ...al method to purge non condensable gas directly from absorber 11 Operate the chiller heater 12 Purge the absorber again See Manual method to purge non condensable gas directly from absorber 13 Press t...

Page 141: ...this mode residential hot water is supplied through the auxiliary heat exchanger option No chilled hot water is supplied through the evaporator 1 Choose how to treat the cooling water in the absorber...

Page 142: ...perature generator gradually rises 14 After the solution liquid level in the high temperature generator shows full close the two manual valves V2 and V3 a V3 on the weak solution line from the low tem...

Page 143: ...tion Operation mode Refrigerant vapor from LG E VA Refrigerant E A VB Purge valves Cooling water valve Cooling Close Close Open VC and V15 Inlet outlet open Heating Open Open Close VC and V15 Inlet Cl...

Page 144: ...Figure 73 Changeover valve locations for high temperature hot water design Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 142...

Page 145: ...ve Cooling Open Close Open Open Open VC V15 VB close Inlet outlet open Inlet outlet open Inlet Close Outlet Open slightly Heating Close Open Close Close Close V15 V16 VD opens 30 seconds when necessar...

Page 146: ...e the machine or manipulate the switches until the gas smell vanishes Valve inspection The chiller heater is equipped with a refrigerant manual blow valve VB that blows refrigerant from the refrigeran...

Page 147: ...fter stopping it for a long period check it according to the following procedure Checks before operation starts 1 Check the insulation of the Control Center and electric system 2 Check the operation o...

Page 148: ...the control panel but when the vacuum power is 208 V 3 Ph 60 Hz the max current of vacuum pump is 4 A When the vacuum power is 460 V 3 Ph 60 Hz the max current of vacuum pump is 2 5 A If the vacuum p...

Page 149: ...rvice vacuum pump to U6 V6 W6 of the MC6 contactor in the control panel terminal Connect the purge hose from the absorber purging valve to the vacuum pump suction port 2 Press the purge pump Mg SW ON...

Page 150: ...enoid valve SV1 and SV2 open Note The chilled water inlet pressure must be higher than 14 5 psig 1 barg to confirm the performance of water ejector The discharge chilled water volume is 50 to 60 L tim...

Page 151: ...e SV3 closes Note The max water ejector operation time is 10 minutes per time Note The chilled water inlet pressure must be higher than 14 5 psig 1 barg to confirm the performance of water ejector The...

Page 152: ...Figure 76 Cycle flow diagram heating Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 150...

Page 153: ...Figure 77 Cycle flow diagram for high temperature hot water design heating 151 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 154: ...rant according to the following procedure The chiller heater must be operating to refine refrigerant When refining refrigerant operate the absorption chiller heater under a low load 50 or less for hig...

Page 155: ...3 in hexagon wrench The refrigerant in the refrigerant tank is diverted into the absorber 4 Watch the liquid level of the refrigerant tank Immediately after the refrigerant liquid level appears in th...

Page 156: ...low valve see Figure 75 6 Turn the spindle in the valve to the left with the 8 mm 0 3 in hexagon wrench Note The refrigerant in the refrigerant tank diverts into the absorber 7 Watch the liquid level...

Page 157: ...standard inspection periods are shown in the next table For details contact your local Johnson Controls Service Center Inspection frequency can be adjusted according to the actual operating conditions...

Page 158: ...rocess which will greatly reduce the corrosive and scale forming properties of almost any type of water Request the first analysis within one month after the test operation is started Every 2 3 months...

Page 159: ...for slight leakage Vacuum and airtightness must be maintained to ensure the reliability and performance of the absorption chiller heater Accordingly recommend that the machine should be checked for sl...

Page 160: ...Circuit Board Relay MY 2N MY 4N Timer H3Y 2 Power Unit RWS series Magnet Switch AX series Every 30 000 hrs Battery for main circuit board CR2032 Every 3 years Battery for touch panel PFXZCBBT1 Every 5...

Page 161: ...t the lowest part of the piping Replace the water regularly and control the water quality Operating the chiller heater for long periods of time with low quality water causes corrosion and the producti...

Page 162: ...ver the metal surfaces For effective use of the corrosion inhibitors types of them must be selected and their concentration must be determined according to the conditions of the chiller heater system...

Page 163: ...k Fe 3 corrodes iron and copper tubes Reddish brown Black Water smells bad Contains compounds of sulfur hydrogen sulfide H2S ammonium ion NH 4 methane and other gases Scales are generated easily and s...

Page 164: ...Max 1 0 Max 0 3 Max 1 0 Max 1 0 Max 0 3 O O Copper mgCu I Max 0 3 Max 0 1 Max 0 1 Max 0 1 Max 0 1 O Sulfurization Ion mgS 3 I No ions allowed Ammonium Ion mgNH4 I Max 1 0 Max 0 1 Max 1 0 Max 1 0 Max 0...

Page 165: ...hod of the chiller heater If the chiller heater needs to be stored long term the storage method varies A lot depends on the machine room temperature condition and the storage period If the machine roo...

Page 166: ...the water systems by passing clear water through them from a position higher than the chiller heater 3 Fill the water systems with clear water 4 Circulate the clear water through the water pump for 3...

Page 167: ...es Chilled hot water system Cooling water system Dried and pressurized with nitrogen 1 5 3PSIG 0 01 0 02 MPa Storage Period less than 6 months Inside of shells Vacuum Chilled hot water system Cooling...

Page 168: ...nds Slightly open the valve at the cooling water outlet side of the chiller heater Figure 80 Wet storage during heating operation period heating through evaporator Work procedure 1 If the quality of t...

Page 169: ...Do not leave the tubes in absorber and condenser as is after simply draining the remained cooling water If you do the heat transfer tubes will be at high risk of corrosion and rusty water red rust ge...

Page 170: ...m the absorber and the condenser 6 Dry inside of each water chamber and heat transfer tube well 7 Keep this condition during heating operation period Model YHAU CGN H CXR M Double Effect Direct Fired...

Page 171: ...Figure 82 Duhring diagram PTX chart F 169 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 172: ...Figure 83 Duhring diagram PTX chart C Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 170...

Page 173: ...Figure 84 Specific gravity concentration F 171 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 174: ...Figure 85 Specific gravity concentration C Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater 172...

Page 175: ...xperiences any trouble or abnormality Check to see if the main fuel gas valve was closed by mistake Open the main valve See if the valves of the chilled hot system and cooling water system are set cor...

Page 176: ...e case of variable flow rate specification If it changes sharply apply a limit of the change rate to the chilled hot flow control or take another measure 2 Cooling water temperature at inlet changes s...

Page 177: ...that the dilution took place If it did not take place dilute the solution according to the procedure shown in Manual refrigerant blow down and diluting method Table 44 Abnormal control sensor Item Cau...

Page 178: ...in 4 5 hours To prevent this contact your local Johnson Controls Service Office immediately Table 47 Pump s overloaded or overheated Item Cause Countermeasure 1 Bearings of the pump are worn or clogg...

Page 179: ...bsorption chiller heater If partial load operation is continued for a long period non condensable gas tends to stay in the absorber See Purge procedure Even if the automatic purge unit is installed pu...

Page 180: ...ater inlet temperature is low Setpoint error of automatic start stop switch Check cooling water inlet temperature Check the setpoint Purging is in sufficient See Purge procedure Adjusting valve openin...

Page 181: ...Figure 86 Troubleshooting sequence flow chart 179 Model YHAU CGN H CXR M Double Effect Direct Fired Small Absorption Chiller Heater...

Page 182: ...ollowing actions Note If the unit runs heating with the auxiliary heat exchanger do not do the following action against the power failure Figure 87 Actions to take against power failure Model YHAU CGN...

Page 183: ...n valves are installed it is necessary to drain the complete system 6 If glycol was used in the water system or chemical additives are contained dispose of the solution in a suitable and safe manner N...

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Johnson Controls York YHAU-CGH-CXR Series, Installation, Commissioning, Operation, And Maintenance

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