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

Page: 118 / 136

JOHNSON CONTROLS

118

FORM 155.33-ICOM2.EN.GB

ISSUE DATE: 12/4/2017

SECTION 7 – MAINTENANCE

FIGURE 43 -

SPECIFIC GRAVITY - CONCENTRATION (°F)

LD14222f

6 65.70 65.85 66.00 66.14 66.28

66.09 66.24 66.38 66.52 66.67

66.47 66.61 66.76 66.90 67.04

66.84 66.98 67.13 67.27 67.41

6 67.20 67.35 67.49 67.63 67.77

67.56 67.70 67.84 67.98 68.12

SPECIFIC GRAVITY - CONCENTRATION TABLES

AQUEOUS LiBr SOLUTIONS

Refrigerant Table (%LiBr by Weight)

Temperature F

S.G.

100

1.00

––

0.08

0.18

0.28

0.37

0.47

0.57

0.67

1.01

0.98

1.08

1.17

1.27

1.37

1.47

1.56

1.66

1.76

1.85

1.95

2.05

2.15

1.02

2.43

2.52

2.62

2.72

2.82

2.91

3.01

3.11

3.20

3.30

3.40

3.50

3.59

1.03

3.84

3.94

4.03

4.13

4.23

4.33

4.42

4.52

4.62

4.72

4.81

4.91

5.01

1.04

5.22

5.32

5.42

5.51

5.61

5.71

5.81

5.90

6.00

6.10

6.19

6.29

6.39

1.05

6.57

6.67

6.77

6.87

6.96

7.06

7.16

7.26

7.35

7.45

7.55

7.64

7.74

Solution Tables

Temperature F

S.G

100

110

120

130

140

150

160

170

180

1.350

37.27 37.5 37.75 37.98 38.21 38.44 38.67 38.90 39.13 39.35 39.58 39.80 40.02

1.360

38.03 38.26 38.50 38.73 38.96 39.19 39.42 39.64 39.87 40.09 40.31 40.53 40.75

1.370

38.78 39.01 39.24 39.47 39.70 39.93 40.15 40.38 40.60 40.82 41.04 41.26 41.48

1.380

39.52 39.75 39.98 40.20 40.43 40.66 40.88 41.10 41.32 41.54 41.76 41.98 42.20

1.390

40.25 40.48 40.70 40.93 41.16 41.38 41.60 41.82 42.04 42.26 42.48 42.69 42.90

1.400

40.97 41.20 41.42 41.65 41.87 42.09 42.31 42.53 42.75 42.97 43.18 43.39 43.61

1.410

41.69 41.91 42.14 42.36 42.58 42.80 43.02 43.24 43.45 43.67 43.88 44.09 44.30

1.420

42.39 42.62 42.84 43.06 43.28 43.50 43.72 43.93 44.15 44.36 44.57 44.78 44.99

1.430

43.10 43.32 43.54 43.76 43.98 44.19 44.41 44.62 44.83 45.04 45.25 45.46 45.67

1.440

43.79 44.01 44.23 44.45 44.66 44.88 45.09 45.30 45.51 45.72 45.93 46.13 46.34

1.450

44.47 44.69 44.91 45.13 45.34 45.55 45.76 45.97 46.18 46.39 46.59 46.80 47.00

1.460

45.15 45.37 45.58 45.80 46.01 46.22 46.43 46.6 446.85 47.05 47.25 47.46 47.66

1.470

45.82 46.03 46.25 46.46 46.67 46.88 47.09 47.30 47.50 47.70 47.91 48.11 48.30

1.480

46.48 46.69 46.91 47.12 47.33 47.54 47.74 47.95 48.15 48.35 48.55 48.75 48.94

1.490

47.13 47.35 47.56 47.77 47.97 48.18 48.38 48.59 48.79 48.99 49.19 49.38 49.58

1.500

47.78 47.99 48.20 48.41 48.61 48.82 49.02 49.22 49.42 49.62 49.82 50.01 50.20

1.510

48.42 48.63 48.84 49.04 49.25 49.45 49.65 49.85 50.05 50.24 50.44 50.63 50.82

1.520

49.05 49.26 49.46 49.67 49.87 50.07 50.27 50.47 50.66 50.86 51.05 51.24 51.43

1.530

49.67 49.88 50.08 50.28 50.49 50.68 50.88 51.08 51.27 51.46 51.66 51.84 52.03

1.540

50.29 50.49 50.69 50.89 51.09 51.29 51.49 51.68 51.87 52.06 52.25 52.44 52.63

1.550

50.89 51.10 51.30 51.50 51.69 51.89 52.08 52.28 52.47 52.66 52.84 53.03 53.21

1.560

51.49 51.69 51.89 52.09 52.29 52.48 52.67 52.86 53.05 53.24 53.43 53.61 53.79

1.570

52.09 52.28 52.48 52.68 52.87 53.06 53.25 53.44 53.6 353.82 54.00 54.18 54.37

1.580

52.67 52.87 53.06 53.26 53.45 53.64 53.83 54.02 54.20 54.39 54.57 54.75 54.93

1.590

53.25 53.44 53.64 53.83 54.02 54.21 54.39 54.58 54.77 54.95 55.13 55.31 55.49

1.600

53.81 54.01 54.20 54.39 54.58 54.77 54.95 55.14 55.32 55.50 55.68 55.86 56.04

1.610

54.37 54.57 54.76 54.95 55.13 55.32 55.50 55.69 55.87 56.05 56.23 56.40 56.58

1.620

54.93 55.12 55.31 55.49 55.68 55.86 56.05 56.23 56.41 56.59 56.76 56.94 57.11

1.630

55.47 55.66 55.85 56.03 56.22 56.40 56.58 56.76 56.94 57.12 57.29 57.46 57.64

1.640

56.01 56.20 56.38 56.57 56.75 56.93 57.11 57.29 57.46 57.64 57.81 57.98 58.15

1.650

56.54 56.72 56.91 57.09 57.27 57.45 57.63 57.81 57.98 58.15 58.33 58.50 58.67

1.660

57.06 57.25 57.43 57.61 57.79 57.97 58.14 58.32 58.49 58.66 58.83 59.00 59.17

1.670

57.58 57.76 57.94 58.12 58.29 58.47 58.65 58.82 58.99 59.16 59.33 59.50 59.66

1.680

58.08 58.26 58.44 58.62 58.79 58.97 59.14 59.31 59.48 59.65 59.82 59.99 60.15

1.690

58.58 58.76 58.94 59.11 59.29 59.46 59.63 59.80 59.97 60.14 60.30 60.47 60.63

1.700

59.07 59.25 59.42 59.60 59.77 59.94 60.11 60.28 60.45 60.61 60.78 60.94 61.10

1.710

59.55 59.73 59.90 60.08 60.25 60.42 60.59 60.75 60.92 61.08 61.25 61.41 61.57

1.720

60.20 60.38 60.55 60.72 60.88 61.05 61.22 61.38 61.54 61.71 61.87 62.03

1.730

60.67 60.84 61.01 61.18 61.34 61.51 61.67 61.84 62.00 62.16 62.32 62.48

1.740

61.13 61.30 61.46 61.63 61.80 61.96 62.12 62.28 62.44 62.60 62.76 62.92

1.750

61.74 61.91 62.08 62.24 62.40 62.56 62.72 62.88 63.04 63.20 63.35

1.760

62.35 62.51 62.68 62.84 63.00 63.16 63.31 63.47 63.62 63.78

1.770

62.78 62.94 63.10 63.26 63.42 63.58 63.74 63.89 64.04 64.20

1.780

63.37 63.52 63.68 63.84 64.00 64.15 64.30 64.46 64.61

1.790

63.78 63.94 64.09 64.25 64.40 64.56 64.71 64.86 65.01

1.800

64.34 64.50 64.65 64.81 64.96 65.11 65.26 65.41

1.810

64.89 65.05 65.20 65.35 65.50 65.65 65.80

1.820

65.43 65.58 65.73 65.88 66.03 66.18

1.830

65.96 66.11 66.26 66.41 66.55

1.840

66.48 66.63 66.77 66.92

1.850

66.99 67.13 67.27

190

200

210

220

230

240

40.24 40.46 40.68 40.90 41.11 41.33

40.97 41.19 41.41 41.62 41.83 42.05

41.69 41.91 42.12 42.34 42.55 42.76

42.41 42.62 42.83 43.04 43.25 43.46

43.12 43.33 43.54 43.75 43.95 44.16

43.82 44.03 44.23 44.44 44.64 44.85

44.51 44.72 44.92 45.12 45.33 45.53

45.19 45.40 45.60 45.80 46.00 46.20

45.87 46.07 46.27 46.47 46.67 46.87

46.54 46.74 46.94 47.14 47.33 47.53

47.20 47.40 47.60 47.79 47.99 48.18

47.85 48.05 48.25 48.44 48.63 48.82

48.50 48.70 48.89 49.08 49.27 49.46

49.14 49.33 49.52 49.71 49.90 50.09

49.77 49.96 50.15 50.34 50.53 50.71

50.39 50.58 50.77 50.96 51.14 51.33

51.01 51.20 51.38 51.57 51.75 51.93

51.62 51.80 51.99 52.17 52.35 52.53

52.22 52.40 52.59 52.77 52.95 53.12

52.81 52.99 53.18 53.36 53.53 53.71

53.40 53.58 53.76 53.94 54.11 54.29

53.97 54.15 54.33 54.51 54.68 54.86

54.55 54.72 54.90 55.07 55.25 55.42

55.11 55.28 55.46 55.63 55.80 55.97

55.66 55.84 56.01 56.18 56.35 56.52

56.21 56.38 56.55 56.72 56.89 57.06

56.75 56.92 57.09 57.26 57.43 57.59

57.28 57.45 57.62 57.79 57.95 58.12

57.81 57.97 58.14 58.31 58.47 58.63

58.32 58.49 58.66 58.82 58.98 59.14

58.83 59.00 59.16 59.32 59.49 59.65

59.33 59.50 59.66 59.82 59.98 60.14

59.83 59.99 60.15 60.31 60.47 60.63

60.31 60.48 60.64 60.79 60.95 61.11

60.79 60.95 61.11 61.27 61.43 61.58

61.26 61.42 61.58 61.74 61.89 62.05

61.73 61.89 62.04 62.20 62.35 62.50

62.18 62.34 62.50 62.65 62.80 62.95

62.63 62.79 62.94 63.09 63.25 63.40

63.07 63.23 63.38 63.53 63.68 63.83

63.51 63.66 63.81 63.96 64.11 64.26

63.93 64.08 64.23 64.38 64.53 64.68

64.35 64.50 64.65 64.80 64.95 65.09

64.76 64.91 65.06 65.21 65.35 65.50

65.16 65.31 65.46 65.60 65.75 65.89

65.5

65.94

66.32

66.70

67.0

67.42

CRYSTALLIZATION AREA

Summary of Contents for YHAU-CE-JE Series

Page 1: ...E JE 150 1440 TONS 527 5064 KW 50 HZ DOUBLE EFFECT EXHAUST GAS ABSORPTION CHILLER HEATER INSTALLATION OPERATION MAINTENANCE NEW RELEASE Form 155 33 ICOM2 EN GB 1217 Issue Date December 4 2017 COMPLIAN...

Page 2: ...bels this document and any referenced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task i...

Page 3: ...arest Johnson Controls Service office or accessing the John son Controls QuickLIT website at http cgproducts johnsoncontrols com It is the responsibility of rigging lifting and operating service perso...

Page 4: ...Type York Absorption WASTE HOT WATER HEAT RECOVERY None No heat recovery J Heat recovery Standard JE Heat recovery Enlarged type LOW TEMP CHW L 1 0 C CHW LL 5 0 C CHW MODEL SERIES NAME EX 150 700 RT N...

Page 5: ...Plate Type Heat Exchangers 18 Parallel Flow 19 High Temperature Generator HTG 19 Waste Hot Water Driven Generator and Low Temperature Generator 20 Condenser 20 Crystallization 20 Why Does Crystallizat...

Page 6: ...he Use Of Water 50 Chilled Hot Water Outlet Temperature Controller 50 Liquid Level Gauges 50 Start the Chiller Heater 51 Stop the Chiller Heater 51 Interlock Procedure 51 SECTION 6 OPERATION 67 YHAU C...

Page 7: ...pass Manual Operation 103 Exhaust Gas Contaminants 104 Exhaust Gas Chimney Requirements 104 Lifespan of Common Parts 105 Water Quality Control 107 Chemical Water Treatment 108 Replacement of Water 108...

Page 8: ...FIGURE 20 Cooling Start Diagram 52 FIGURE 21 Cooling Stop Diagram 54 FIGURE 22 Exhaust Gas Input Preparation Flow Diagram 55 FIGURE 23 Exhaust Gas Input Stop Preparation Flow Diagram 56 FIGURE 24 Sequ...

Page 9: ...TABLE 18 Purge Valve Operation 94 TABLE 19 Maintenance and Inspection 99 TABLE 20 Exhaust Gas Contaminants 104 TABLE 21 Lifespan of Common Parts 105 TABLE 22 Tendency of Generation of Scales and Corr...

Page 10: ...JOHNSON CONTROLS 10 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 11: ...lure to follow the procedures and instruc tions detailed in this manual WARRANTY Johnson Controls warrants YHAU CE JE chiller heaters in accordance with the Limited Warranty En gineered Systems Equipm...

Page 12: ...361 2001 Safety requirements of lithium bromide absorption water chiller heater heater The unit must be grounded No installation or main tenance work should be attempted on the electrical equipment wi...

Page 13: ...3 SECTION 1 GENERAL CHILLER HEATER AND SAFETY INFORMATION FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 1 LD20923f Caution Risk of getting hand caught in Caution Risk of tumble Caution Prohibited Warni...

Page 14: ...JOHNSON CONTROLS 14 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...circulate the refrigerant and solution in the cycle a purge unit to remove non condensable gas from the machine CONTROL PANEL The absorption chiller heater comes with a factory mounted and pre wired c...

Page 16: ...EVRUEHU 8SSHU EVRUEHU RZHU YDSRUDWRU RZHU RZ 7HPS HQHUDWRU 0 0 0 0 DVWH RW DWHU QOHW DVWH RW DWHU 2XWOHW DVWH RW DWHU 9 0 LJK 7HPS HQHUDWRU LU 3XUJH ORZHU LU 3XUJH DPSHU KDXVW DV 2XWOHW DPSHU HOLYHUH...

Page 17: ...pper Evaporator Lower Chilled Water Out Chilled Water In Dilute Solution Out ABSORBER The concentrated LiBr solution enters the absorber section of the chiller heater There it is sprayed over the abso...

Page 18: ...owever the lower evaporator is the first step of the chilled water cooling cycle The dilute solution s vapor pressure is enough to maintain the required temperature and pressure in the lower evaporato...

Page 19: ...solution heat exchanger The other leads to the low temperature generator in parallel Low Temp Heat Exchanger LD19980_a2 Concentrated Solution Out Dilute Solution Out Dilute Solution In Concentrated So...

Page 20: ...pe liquid seal This completes the cooling cycle Condenser LD19980_a5 Condensed Refrigerant Cooling Water Outlet CRYSTALLIZATION All absorption chillers that use lithium bromide and water as the soluti...

Page 21: ...de by weight Although the crystallization line on Figure 41 on page 116 or Figure 42 on page 117 does not extend that far you can see that the solution at a 45 concentration should not crystallize at...

Page 22: ...JOHNSON CONTROLS 22 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 23: ...hod to be used It is beyond the scope of this manual to specify rigging and lifting details This chiller heater is for air conditioning or cooling a manufacturing process Transport store and use this...

Page 24: ...xhaust gas duct If two or more chiller heaters share a chimney there is a significant risk of exhaust gas getting into a stopped chiller heater or rust getting into a heat exchanger s parts STRUCTURAL...

Page 25: ...s of the control panel Do not allow negative pressure or any devices that cre ate negative pressure to operate in the area around the chiller heater This may cause an incomplete air purge Gas inhalati...

Page 26: ...If you do problems or injuries may take place Apply only the specified source voltage Application of a different source voltage may cause a fire and electric shock Welding should only be done under c...

Page 27: ...4 on page 27 Use liners to adjust the levelness of the unit For unit dimensions see Table 5 on page 41 and Table 6 on page 41 Do not leave any flammable substance or easily combustible object near the...

Page 28: ...oling Water Inlet 2 Chilled Hot Water Inlet 3 Chilled Hot Water Outlet 4 Cooling Water Outlet Even Pass 5 Waste Hot Water Outlet 6 Waste Hot Water Inlet 7 Exhaust Gas Outlet 8 Exhaust Gas Inlet LD2234...

Page 29: ...Water Inlet 2 Chilled Hot Water Inlet 3 Chilled Hot Water Outlet 4 Cooling Water Outlet 5 Exhaust Gas Outlet 1 6 Exhaust Gas Inlet 7 Exhaust Gas Outlet 2 8 Waste Hot Water Outlet 9 Waste Hot Wate Inle...

Page 30: ...AT MUST NOT BE HEAT INSULATED Exhaust gas flue duct Evaporator shell Sight glass Heat exchanger Evaporation water changer casing Valve manipulator High temperature generator Refrigerant spray piping P...

Page 31: ...ASSEMBLY FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 3 LD21899 Figure 7 HOT AND COLD INSULATION EXAMPLE ONE EXHAUST GAS OUTLET FLANGE Cold Insulaton Hot Insulaton Exhaust Gas Insulaton LD22992 Figure...

Page 32: ...JOHNSON CONTROLS 32 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 SECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY LD22917 Figure 9 EXTERIOR OF CONTROL PANEL...

Page 33: ...the unit such as weight dimensions electrical data wiring and sound data Table 3 TYPICAL OPERATIONAL RANGE PARAMETER ALLOWABLE RANGES Chilled Water In 7 25 C Chilled Water Out 4 16 C Cooling Water In...

Page 34: ...E INSTALLATION AND REASSEMBLY Weights and Dimensions The chiller will be designed according to the different temperature and flow of exhaust gas and Jacket water The weight and dimensions of maximum s...

Page 35: ...ND REASSEMBLY FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 4 Physical Data The chiller will be designed according to the different temperature and flow of exhaust gas and Jacket water The physical dat...

Page 36: ...17 SECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY Electrical Data The chiller will be designed according to the different temperature and flow of exhaust gas and Jacket water The electrical da...

Page 37: ...JOHNSON CONTROLS 37 SECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 4 LD22918 Figure 10 EXTERNAL CONNECTION TERMINAL DETAILS...

Page 38: ...REASSEMBLY CONTACT SPECIFICATION ABSORPTION CHILLER HEATER CONTROL PANEL EXTERNAL INPUT TERMINAL RESISTANCE LOAD MAX AC 240 V 2 A MIN DC 5 V 1 mA EXTERNAL OUTPUT TERMINAL ABSORPTION CHILLER HEATER CON...

Page 39: ...aker See Figure 11 on page 38 Connect an interlock if necessary The tells you the interlock is required a Operating interlock Chilled hot water pump start signal Exhaust gas full open interlock b Cool...

Page 40: ...CE JE Series of exhaust gas absorption chiller heaters Upper Communication System Configuration The configuration of the upper communication system is shown in Figure 13 on page 40 LD20594f Central M...

Page 41: ...wiring are included Wiring work for Ethernet connection X Apply twisted pair cable Communication program for central monitoring unit X See Table 6 on page 41 and Table 7 on page 42 for the details of...

Page 42: ...1 unit 0 1 C 3 Temp difference of Automatic start and stop control at cooling mode 5 0 C 00005 0001 1000 unit 1 unit 0 1 C 4 Automatic stop temp at heating mode thermo off temp 62 0 C 00007 0040 1000...

Page 43: ...temp 38 0 C 00093 0001 4000 unit 1 unit 0 1 C 21 High temperature generator solution temp 145 0 C 00095 0001 4000 unit 1 unit 0 1 C 22 Exhaust gas temp 220 0 C 00097 0001 4000 unit 1 unit 0 1 C 23 Hig...

Page 44: ...OR D SUB 9PIN Serial interface COM2 Connect User Created Cable ITEM CUSTOMER JCI REMARKS Control panel with upper communication function X Communication protocol Modbus RTU Wiring work for Modbus RTU...

Page 45: ...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 Send Po...

Page 46: ...LING STORAGE INSTALLATION AND REASSEMBLY LD21547 Figure 16 2 WIRE N 1 CONNECTION WITH USER CREATED CABLE 4 Wire Type Cable Diagrams Without Adaptor The following are sample cable diagrams for 4 wire t...

Page 47: ...the Modbus RTU See Table 8 on page 42 for information about the Read Command or Table 9 on page 43 for informa tion about the Write Command Communication Protocol Modbus RTU Communication path type R...

Page 48: ...3 2 77 83 40 79 49 75 56 72 62 71 68 71 70 70 71 70 70 69 70 71 53 60 3 75 83 41 80 49 75 59 75 62 71 65 68 69 69 71 70 67 66 58 59 44 51 4 78 84 40 79 50 76 61 77 64 73 71 74 71 71 74 73 71 70 65 66...

Page 49: ...a higher discharge pressure The delivery pressure reflects the high vacuum condition of the machine If the inside pressure is atmospheric add 1 0 kg per cm 14 3 psig to the standards in table 9 Remov...

Page 50: ...ooling water and waste hot water use the valves installed at the outlet line to make adjustments When the flow rate change of the chilled hot water is controlled if the flow rate change function is in...

Page 51: ...ater starts the following occurs The solution circulation pump solution spray pump and refrigerant pump start The exhaust gas inlet valve the exhaust outlet valve and the waste hot water control valve...

Page 52: ...temp Temperature control with HW three way valve starts Yes No Yes No Yes Yes No No D A B Remote or local mode selection Turn on power source Initialize self check mechanism Failure activated Engine...

Page 53: ...rts Dilution complete Solution pumps and refrigerant pump stop No Yes FIGURE 20 COOLING START DIAGRAM CONT D No Dilution starts No Cooling water pump stops Yes Thermo OFF light ON No Engine operated N...

Page 54: ...AM Failure alarm No Remote stop command ON Remote Yes No Dilution complete Yes No Temperature control with HW three way valve stops Chilled hot water pump and cooling water pump stop Failure without d...

Page 55: ...IAGRAM Chiller heater stops with failure alarm No Chiller heater stops with failure alarm Yes Inlet and outlet damper open limit signal detected Air purge damper close limit signal detected No Chiller...

Page 56: ...arts No Air purge blower starts Figure 23 EXHAUST GAS INPUT STOP PREPARATION FLOW DIAGRAM Chiller heater stops with failure alarm No Chiller heater stops with failure alarm Yes Air purge damper open l...

Page 57: ...equipment do not need to be used 5 If the waste hot water chilled hot water and cooling water system is the common system it is required to install the isolation valve on the waste hot water chilled...

Page 58: ...ce dimensions Required maintenance space is available around the machine 6 Foundation bolts are properly installed 7 The levelness of the unit is within acceptable range The tolerance for leveling len...

Page 59: ...in the purge line are closed 3 The spindle valve in the purge line is open 4 The changeover valves are set to operation mode 5 Detection component of each thermosensor are in serted into the thermowel...

Page 60: ...______ ________________________________________________________________ ________________________________________________________________ _______________________________________________________________...

Page 61: ...erange See SECTION7 MAIN TENANCE of the manual for more information 35 Check that the chilled water outlet temperature is lower than the chilled water inlet temperature 36 Record the running data on d...

Page 62: ...________________________________ Form Completed by _______________________________________ _______________________________________ Title _____________ ____________ ___________ Month Day Year NOTES ___...

Page 63: ...M S Gnd V Air purge blower M T Gnd V Purge pump M Thermal Relay Setting Refrigerant Purity Temperature Setting Solution circulation pump A Standard 1 040 kg per L or less Cooling Solution spray pump A...

Page 64: ...Pressure gauge 11 Pressure drop DPG or calculation 12 9 Flow rate FM or calculation 10 Chilled hot Water Inlet temperature C Control panel Outlet temperature C Control panel Inlet pressure Pressure ga...

Page 65: ...eight Waterbox OUT P P IN NOTES Operating hours hours Number of purge times times Fill out each specification pressure drop according to the factory inspection report actual value If differential pres...

Page 66: ...k Flame Reaction Test Standard 4 0 cc per min or smaller Reaction Strong Weak None Amount of Gas P cc min Purge Amount from Purge Tank Elapsed time 1 hour Consumed time for measurement m min Total gas...

Page 67: ...level has its own password There are certain screens displayed values programmable set points and manual controls not shown that are used to service the chiller heater LD21525 COMMON ITEMS Buttons ar...

Page 68: ...ure You can do this from any screen We are showing you how to do the procedure starting at the Main screen Before you set the date and time be sure to STOP the chiller heater The control functions of...

Page 69: ...Enter the password 8 Press the ENT key on the keypad After you com plete the password entry the Offline Mode screen displays 9 Tap the drop down arrow to the right of the entry in the OFFLINE LANGUAG...

Page 70: ...ges are correct press the Save button LD22163 LD22163 17 The Save File screen appears 18 Press the Yes button to complete the process LD22164 LD22164 19 Press the Exit button to the right of the Save...

Page 71: ...the lower left corner of the screen are OPER and STOP Press the appropriate button to start or stop the chiller heater When you press the OPER button while the chiller heater is stopped or STOP while...

Page 72: ...Status section contains three buttons C H W P Operat tells you if the chilled hot water pump is operating or not Co W P Operat tells you if the cooling water pump is operating or not Engine Operat te...

Page 73: ...orber HT HEX Solution Outlet Temp temperature of the concentrated solution measured as it leaves the high temperature solution heat exchanger XG Generator Temp temperature of the concentrat ed solutio...

Page 74: ...ling total number of times the absorption machine started in cooling mode Heating total number of times the absorption machine started in heating mode Solution Pump total number of times the solu tion...

Page 75: ...hat triggered the alarm or failure The buttons on the lower left side of the screen are used to move through the messages The Double Up Arrow button moves you to the top of the list The Single Up Arro...

Page 76: ...ure for the fol lowing chilled hot water inlet and outlet cooling water inlet and outlet waste hot water inlet and outlet engine waste gas inlet and outlet These graphs are updated constantly regardle...

Page 77: ...screen shows you the trend of the temperature for the evaporator refrigerant temperature absorber temperature HG temperature HG pressure Press the Left Arrow button to return to the previous Trend sc...

Page 78: ...e alarm sound This can be done before the failure is addressed Turning off the buzzer does NOT fix the problem Press the lit failure button to access an on screen han dling guide for each item An on s...

Page 79: ...uspension Chilled hot water flow stopped during solution pump operation Check the chilled hot water pumps Check the chilled hot water lines Check the chilled hot water flow rate Check the chilled hot...

Page 80: ...ocal Johnson Controls Service Center Solution Circulation P Abnormal Solution circulation pump abnormal Stop without dilution Solution circulation pump motor current exceeded the rated value and activ...

Page 81: ...N within 180 seconds after it received the close signal Inlet Damper Overcurrent The inlet damper motor current exceeded the rated value and the thermal relay was activated Outlet Damper Overcurrent T...

Page 82: ...cation cable between the touch panel and the temperature controller Contact your local Johnson Controls Service Center Control sensor abnormal The chilled hot water outlet temperature sensor the refri...

Page 83: ...ype of alarm will light up in the Alarm section of the screen There is no buzzer Press the lit alarm button to access an on screen han dling guide for each item An on screen guide is avail able for ev...

Page 84: ...ion control The HG XG generator pressure rose enough to trigger the load limit operation The alarm is automatically reset when the pressure falls Check the cooling water line Check the cooling water f...

Page 85: ...al during the remote chilled hot water outlet temperature setting mode The RS485 communication option did not take place Press the ALARM RESET button after the sensor signal is repaired Tighten the te...

Page 86: ...arameter sec tion can be changed See Change Numeric Values on page 68 for more information CONTROL PARAMETER The Control Parameter section of the Setting screen is used to enter parameters for the coo...

Page 87: ...dilution Refrigerant Pump the Stop and Auto buttons control the refrigerant pump Blower Fan the Stop and Auto buttons control the blower fan Waste Hot Water Forced Bypass the ON and OFF buttons contro...

Page 88: ...JOHNSON CONTROLS 88 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 SECTION 6 OPERATION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 89: ...valve During service and maintenance work be sure to turn OFF the main circuit breaker MCB1 If you do not it may cause elec tric shock or a burn Contact your local Johnson Controls Service Office for...

Page 90: ...f the checks show no problems start the chiller heater Checks After Operation Starts 1 10 15 minutes after the chiller heater and the so lution pump start check the level gauge of the re frigerant tan...

Page 91: ...move the plug If the purge unit is operated with the gas ballast closed water is left in the oil The oil will need to be replaced more frequently 4 Set the valves according to pattern A shown in Table...

Page 92: ...e 34 LOCATION OF MANUAL VALVE IN PURGING SYSTEM EXAMPLE A Purge solenoid valve SV2 B Purge solenoid valve SV1 C Purge main valve V20 D Purge valve for purge tank line V19 E Purge valve for purge tank...

Page 93: ...rs 9 Close valve V17 10 Press the Manual Purge OFF button The vacuum pump stops and the solenoid valves close MANUAL METHOD TO PURGE NON CONDENSABLE GAS FROM PURGING TANK While the absorption chiller...

Page 94: ...hile the absorption chiller heater is running be sure to turn off the circuit breaker of the vacuum pump in the control panel If not the vacuum pump could start abruptly and cause injury Table 18 PURG...

Page 95: ...JOHNSON CONTROLS 95 SECTION 7 MAINTENANCE FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 7 LD22170 Figure 35 PURGE SYSTEM...

Page 96: ...JOHNSON CONTROLS 96 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 SECTION 7 MAINTENANCE LD22389 Figure 36 PROCESS AND INSTRUMENTATION DIAGRAM COOLING ONLY...

Page 97: ...on the current load condition Constantly check the liquid level in the refrigerant tank while the refrigerant is refined If the refrigerant liquid level appears in the level gauge of the refrigerant...

Page 98: ...he electrical wiring of the solution pump is disconnected only the refrigerant pump starts 5 Remove the cap of the refrigerant manual blow down valve V2 For the location of the refrigerant manual blow...

Page 99: ...shown in the next table For de tails contact your local Johnson Controls Service Cen ter Inspection frequency may be adjusted according to the actual operating conditions Table 19 MAINTENANCE AND INSP...

Page 100: ...l greatly reduce the corrosive and scale forming properties of almost any type of water Be sure to request the first analysis within one month after the test operation is started Every 2 3 months C Ch...

Page 101: ...the inside of the tubes of the chiller heater refrigerating performance goes down and the tubes become corroded Remove slime soft scales and other foreign matter from the inside of the tubes periodic...

Page 102: ...ate to the Setting screen on the Control Pan el LD21973 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 Ma...

Page 103: ...e be sure to press the Blower Fan Auto button If the chiller heater continues to operate with the blower fan in stop mode damage and failure of the unit may result Waste Hot Water Forced Bypass Manual...

Page 104: ...Liquid sampling Filter with membrane filter Weight3 5 Solid carbide 0 5 mg per Nm3 Filter sampling Weight 6 Oil 0 3 mg per Nm3 Filter sampling Carbon tetrachloride extraction Infrared ray absorption s...

Page 105: ...e exhaust gas driven generator tube Float valve for HG XG float box Every 60 000 hours Float valve for refrigerant tank Pump gasket valve o ring diaphragm rubber Every 24 000 hours Solution heat excha...

Page 106: ...ermal relay Battery for sequencer unit Every 5 years Battery for touch panel Touch panel Every 30 000 hours Inverter option Fan for control panel Differential pressure switch Pressure sensor Pressure...

Page 107: ...all an air vent valve at the highest part of the piping and a drain valve at the lowest part of the piping Keep the cooling water temperature higher than 20 C while the chiller heater operates Turn th...

Page 108: ...ed with sulfurous acid gas 1 month Common district 1 month TREATMENT FOR LONG STOPPAGE OF THE ABSORPTION CHILLER HEATER If the absorption chiller heater is stopped for a long time bacteria in the wate...

Page 109: ...Fe OH 3 to make red water and deposits ferric dioxide Fe2 O3 Iron bacteria grow Reddish brown Black Fe3 corrodes iron and copper tubes badly Reddish brown Black Environmental Factors Water smells bad...

Page 110: ...x 0 1 Max 1 0 Max 1 0 Max 0 1 Residual Chlorine mg CI per I Max 0 3 Max 0 3 Max 0 3 Max 0 3 Max 0 3 Free Carbonate Acid mgCO2 per I Max 4 0 Max 4 0 Max 4 0 Max 4 0 Max 4 0 Stability Index 6 0 7 0 NOTE...

Page 111: ...ge method The wet storage method is available only where chilled hot water cooling water and waste hot water will not freeze Each storage method has its own characteristics Select the method to use ba...

Page 112: ...rocedure is as follows 1 Completely drain the cooling water 2 Clean the water systems by passing clear water through them from a position higher than the chiller heater 3 Fill the cooling water system...

Page 113: ...oes not drop 3 The manual valve on the purge piping should be fully closed See Figure 34 on page 92 STORAGE METHOD OF THE COOLING WATER DURING HEATING OPERATION PERIOD Do NOT operate the cooling water...

Page 114: ...for 30 min to 1 hour 5 Drain all of the cooling water from the absorber and condenser 6 Fill the absorber and condenser with clean water 7 The unit is ready to operate in heating or simul taneous hea...

Page 115: ...corrosion Work Procedure 1 Drain all of the cooling water from the absorber and the condenser 2 Flow the clean water from the higher location than the chiller heater 3 Feed the clean water continuous...

Page 116: ...210 220 CRYSTALLIZATION AREA 6 5 6 0 5 5 5 0 4 5 4 0 4 0 4 5 5 0 5 5 6 0 6 5 7 0 200 200 210 210 220 220 230 230 240 240 250 250 260 260 270 270 280 280 290 290 300 300 310 310 320 320 330 330 340 34...

Page 117: ...1 057 U S quarts 1 U S gallon 3 785 liters 1 inch 25 4 mm 1 ton refrigeration 12 000 Btu hr 3 52 kW Absorption Liquid Chillers Duhring Diagram PTX Chart 4 4 82 2 87 8 93 3 98 9 104 4 110 0 115 6 121 1...

Page 118: ...55 50 55 69 55 87 56 05 56 23 56 40 56 58 1 620 54 93 55 12 55 31 55 49 55 68 55 86 56 05 56 23 56 41 56 59 56 76 56 94 57 11 1 630 55 47 55 66 55 85 56 03 56 22 56 40 56 58 56 76 56 94 57 12 57 29 57...

Page 119: ...52 63 52 81 52 99 53 18 53 36 53 53 53 71 1 55 50 89 51 10 51 30 51 50 51 69 51 89 52 08 52 28 52 47 52 66 52 84 53 03 53 21 53 40 53 58 53 76 53 94 54 11 54 29 1 56 51 49 51 69 51 89 52 09 52 29 52...

Page 120: ...JOHNSON CONTROLS 120 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 121: ...store operations Solution is crystallized The cause of the trouble is not readily apparent Check the causes in order Any of these causes will start the automatic dilution operation then stop the chill...

Page 122: ...ter hot water flow stops the chiller heater stops immediately without diluting the solution If the absorption chiller heater is left as it is the solu tion in it may be crystallized in 4 to 5 hours To...

Page 123: ...on Controls Service Office 4 Non condensable gas remains in machine See Purge Procedure on page 90 Check the performance of the vacuum pump Check the purge unit for a problem Purge non condensable gas...

Page 124: ...abnormal correct it according to the following procedure ABNORMAL SOLUTION AND REFRIGERANT LEVELS SECTION NORMAL CONDITION ABNORMAL CONDITION CAUSE COUNTERMEASURE Refrigerant Overflow LG5 High temper...

Page 125: ...pment connected as elements for a constantly monitoring interlock failure Check the signals from the interlocked devices Check the signals from equipment connected as elements for a constantly monitor...

Page 126: ...s suddenly by checking the start and stop of the fan If the chilled water temperature is low the chiller heater stops immediately It does not do the dilution process If left as is the solution may cry...

Page 127: ...et temperature HG XG solution temperature waste hot water inlet temperature HT HEX solution outlet temperature engine waste exhaust gas inlet temp engine waste exhaust gas outlet temp and or the HG XG...

Page 128: ...The hot water outlet temperature rose suddenly or too high during heating operation Check equipment in heating load line Check chilled hot water low rate Check chilled hot water flow rate control sys...

Page 129: ...lure The close limit switch does not turn ON after 180 seconds have elapsed since the exhaust gas inlet damper closing command was issued 5 There was an exhaust gas outlet damper open failure The open...

Page 130: ...three way valve stops Solution pumps and refrigerant pump stop Chilled hot water and cooling water pump stop Minimum dilution time passed Air conditional machine and cooling tower stop HEX temp diluti...

Page 131: ...m the absorber Stop the machine to ensure the dilution operation takes place The dilution operation takes approximately 15 minutes Power is restored Chiller heater stops No If the power is not restore...

Page 132: ...JOHNSON CONTROLS 132 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 SECTION 8 TROUBLESHOOTING THIS PAGE INTENTIONALLY LEFT BLANK...

Page 133: ...in the heat exchanger sec tion of the system If no isolation valves are in stalled it may be necessary to drain the complete system 8 If glycol was used in the water system or chemi cal additives are...

Page 134: ...170 0 170 0 170 0 170 0 170 0 170 0 Flow volume kg h 2 819 3 383 4 510 5 638 7 517 9 396 11 839 13 155 15 034 16 914 18 793 21 048 22 551 24 055 25 558 27 062 Pressure drop kPa 2 0 2 0 2 0 2 0 2 0 2 0...

Page 135: ...JOHNSON CONTROLS 135 FORM 155 33 ICOM2 EN GB ISSUE DATE 12 4 2017 9 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 136: ...m Pennsylvania USA 17349 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2017 www johnsoncontrols com ALL RIGHTS RESERVED Form 155 33 ICOM2 EN GB 1217 Issue...

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