York YHAU-CW Manual Download

Page: 147 / 168

JOHNSON CONTROLS

147

SECTION 7 – MAINTENANCE

FORM 155.31-ICOM2.EN.UL

ISSUE DATE: 12/21/2018

LD22369

Chilled Water

Return Header

Chilled Water

Supply Header

Straner

(10 mesh)

Chilled

Water

Pump

Cooling Water

Scope of Supply

Absorption Chiller

Tapping for Chemical Cleaning

Cooling Tower

Feeding Water

Cooling Water

Thermostat

Strainer

(20 mesh)

Cooling Water

Pump

PI TI

FIGURE 54 -

CHILLED WATER AND COOLING SYSTEM

LD22006

Scope of Supply

High Temp. Generator

Go Down to Chiller

Steam Inlet

Press. Gauge

Steam Shut Off

Valve

Safety Relief

Valve

Straner

(60-70mesh)

Steam Header

Steam

Steam Control

Valve

Drain Trap

h< (Drain Back Press.)

- (Press. Loss of Piping)

Hotwell Tank

Check Valve

Drain Back Press.

Adjusting Valve

Steam

Drain

FIGURE 55 -

STEAM AND DRAIN SYSTEM FOR STEAM CONTROL VALVE

Summary of Contents for YHAU-CW

Page 1: ...Model YHAU CW 150 2000 TON 527 7 033 KW DOUBLE EFFECT STEAM FIRED ABSORPTION CHILLER INSTALLATION OPERATION MAINTENANCE NEW RELEASE Form 155 31 ICOM2 EN UL 1218 Issue Date December 21 2018 LD22831...

Page 2: ...els 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 in...

Page 3: ...owner Updated manuals if applicable can be obtained by contacting the nearest Johnson Controls Service office It is the responsibility of rigging lifting and operating service personnel to verify the...

Page 4: ...800RT NOMINAL CAPACITY EXW 900 1100RT NOMINAL CAPACITY EXW3 1200 1600RT NOMINAL CAPACITY EXW4 1000 2000RT NOMINAL CAPACITY EFFICIENCY GRADE NONE HIGH EFFICIENCY S STANDARD EFFICIENCY WASTE HOT WATER...

Page 5: ...High Temperature Generator HTG 18 Low Temperature Generator LTG 18 Condenser 19 Crystallization 19 Why Does Crystallization Occur 19 SECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY 21 Inspectio...

Page 6: ...s 90 NOISE EMISSON 92 SECTION 5 COMMISSIONING 93 General Guidelines for Use 93 Before Operation 93 Precautions for the Use of Steam 94 Chilled Water Outlet Temperature Controller 95 Liquid Level Gauge...

Page 7: ...rant Refining Method 137 Manual Refrigerant Blow Down and Diluting Method 137 Decrystallization Method 138 Indications of Crystallization 138 Decrystallization 138 Precautions for De crystallization 1...

Page 8: ...PLC and Touch Screen Wiring 77 FIGURE 25 Steam Control Wiring 78 FIGURE 26 External Connection Terminal Details 80 FIGURE 27 Remote Transmission Signal 81 FIGURE 28 Signal Terminal Transition Wiring 8...

Page 9: ...Diagram 136 FIGURE 54 Chilled Water and Cooling System 147 FIGURE 55 Steam and Drain System for steam control valve 147 FIGURE 56 Steam and Drain System for steam drain control valve 148 FIGURE 57 Duh...

Page 10: ...y of Upper Communication System 87 TABLE 21 Cable Diagram RS422 RS485 88 TABLE 22 Communication Specifications 91 TABLE 23 Rotary Pump Rotation 93 TABLE 24 Liquid Level Gauges 95 TABLE 25 Failure List...

Page 11: ...ance resulting from a failure to follow the procedures and instructions detailed in this manual WARRANTY Johnson Controls warrants YHAU CW chillers in ac cordance with the Limited Warranty Engineered...

Page 12: ...pply Servicing and maintenance on live equipment must not be at tempted No attempt should be made to gain access to the control panel or electrical enclosures during normal operation of the unit Compo...

Page 13: ...storage disposal and spill procedures For safe operation read the instructions first Warning This machine may start auto matically without prior warning Caution Hot surface Warning Safety relief valv...

Page 14: ...JOHNSON CONTROLS 14 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...absorption chiller comes with a factory mounted and pre wired control system The control panel en closure is equipped with a hinged access door with lock and key The control panel includes a touch pa...

Page 16: ...RROLQJ DWHU QOHW RQGHQVHU 3 RZ 7HPS HDW FKDQJHU 6WHDP UDLQ 2XWOHW RZ 7HPS RQGHQVDWH UDLQ RROHU LJK 7HPS RQGHQVDWH UDLQ RROHU LJK 7HPS HDW FKDQJHU LJK 7HPS HQHUDWRU 3 KLOOHG DWHU RROLQJ DWHU 5HIULJHUD...

Page 17: ...bes the unique 2 step evaporator absorber design of the YHAU CW steam chiller TWO STEP EVAPORATOR ABSORBER The evaporator as well as the absorber is split into two sections This design similar to a se...

Page 18: ...tween the low temperature generator and the high tempera ture generator sections into two parallel balanced paths The result is a safer and more efficient operation at a much lower pressure than conve...

Page 19: ...r mally high enough no crystallization will occur as long as the higher temperature is maintained Before the unit is shut down make sure the solution is suffi ciently diluted in all areas of the unit...

Page 20: ...JOHNSON CONTROLS 20 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 21: ...ging equipment available and site needs Therefore a professional rigger must determine the rigging and lifting method to be used and it is beyond the scope of this manual to specify rigging and liftin...

Page 22: ...machine where the ambient temperature is higher than 32 F If the ambient temperature drops below 32 F use a heater to warm the machine If a heater is not accessible the following options are availabl...

Page 23: ...e not to apply shock to the machine The ma chine is a high vacuum vessel containing a corrosive solution Use diligence in protecting the machine as repair is labor intensive and costly Be sure to lift...

Page 24: ...ant will need to be extracted beforehand Use care not to apply shock to the machine The ma chine is a high vacuum vessel containing a corrosive solution Use diligence in protecting the machine as repa...

Page 25: ...les shown in the figure below LD22947 Hole 22 for Fitting Tir Roller Set Anchor Bolt Hole Tir Roller Set Tir Roller Set Figure 6 MOVING THE MACHINE ON TIR ROLLERS Figure 7 JACK UP PROCEDURE JACK UP PR...

Page 26: ...ks alternately Do not jack up the machine more than 0 78 inch at a time Each time the machine is jacked up adhere it with a suitable crosstie Use the jack up support on the main shell of the body as s...

Page 27: ...and technical standards for electrical equipment found in SECTION 4 TECHNICAL DATA Use the specified cables to complete the wiring and fasten them to the according terminals securely Loose fitting cab...

Page 28: ...to do so may result in suffocation ELECTRICAL SHOCK CAUTIONS Do not touch the control panel with wet hands This can cause electric shock Do not touch the wiring in the control panel Do not touch any...

Page 29: ...ators to the unit base as shown in Figure 9 on page 29 Use liners to adjust the levelness of the unit For unit dimensions see Table 7 on page 38 Table 8 on page 39 Table 9 on page 40 and Table 10 on p...

Page 30: ...on Con trols recommends using schedule 40 steel pipe for the rupture disk discharge line material Rupture Disk Discharge Piping Construction For the piping material Johnson Controls recommends carbon...

Page 31: ...SEMBLY FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 3 LD28268 Rupture Disk Low Temperature Generator High Temperature Generator Condenser Absorber Evaporator Pressure Release Valve Purge Tank High Te...

Page 32: ...637 8 18 298 8 3 1 000EXW S 24 28 7 4 8 86 2 7 8 86 2 7 47 620 21 6 23 95 7 3 9 19 2 8 6 56 2 18 739 8 5 19 621 8 9 1 100EXW S 26 57 8 1 8 86 2 7 8 86 2 7 51 588 23 4 26 25 8 9 19 2 8 6 56 2 20 062 9...

Page 33: ...EXW S 23 95 7 3 8 53 2 6 8 86 2 7 45415 23 20 6 21 65 6 6 8 53 2 6 6 56 2 18739 29 8 5 1000EXW S 26 25 8 8 53 2 6 8 86 2 7 49163 08 22 3 23 95 7 3 8 53 2 6 6 56 2 19841 6 9 1120EXW S 29 53 9 8 53 2 6...

Page 34: ...rrangement drawings found in the contract documents for detailed nozzle locations for each specific unit LD19970 Steam 150 300EX S B Side A Side 1 2 3 4 5 6 7 8 LD19971 360 800 EX S 900 1100EXW S 1200...

Page 35: ...for vacuuming factory use only Relay Insertion Hole HOT INSULATION OR COLD INSULATION PROCEDURE 1 The recommended materials and their thickness for hot insulation or cold insulation are shown in Table...

Page 36: ...gure 13 INTERIOR OF CONTROL PANEL Figure 14 EXTERIOR OF CONTROL PANEL LD22863 250 850 700 Th6 Th3 Th1 Th2 NF1 MCB1 CP1 PSU1 TB PWX PWT ZR MC1 MC2 MC3 MC6 Z0 Z1 Z3 Z2 l For Other Countries For Europe 2...

Page 37: ...ATIONAL RANGE PARAMETER ALLOWABLE RANGES Chilled Water In 44 6 77 F Chilled Water Out 39 2 60 8 F Cooling Water In 68 98 6 F Cooling Water Out 77 107 6 F Steam Inlet Pressure 29 145 PSIG Condensate Ou...

Page 38: ...0 4 1000EXW 24 28 7 4 10 17 3 1 10 5 3 2 20 67 6 3 59 745 27 1 80 469 36 5 121 475 55 1 1100EXW 26 57 8 1 10 17 3 1 10 5 3 2 22 97 7 64 595 29 3 86 862 39 4 130 293 59 1 1200EXW3 26 57 8 1 10 17 3 1 1...

Page 39: ...0 13 800EX 247 57 23 495 14 46 5 50 31 08 0 88 66 39 1 88 5 3 0 15 900EXW 344 45 32 538 2 50 5 56 43 79 1 24 83 34 2 36 6 0 17 1000EXW 376 74 35 570 49 53 6 62 47 32 1 34 88 99 2 52 6 71 0 19 1100EXW...

Page 40: ...000EXWS 24 28 7 4 9 51 2 9 10 5 3 2 22 97 7 58 863 26 7 76 059 34 5 124 782 56 6 1100EXWS 26 57 8 1 10 17 3 1 10 33 3 15 22 97 7 61 068 27 7 82 453 37 4 123 679 56 1 1200EXW3S 26 57 8 1 10 17 3 1 10 8...

Page 41: ...XS 247 57 23 495 14 46 5 53 31 08 0 88 66 39 1 88 5 3 0 15 900EXWS 344 45 32 538 2 50 6 60 43 79 1 24 83 34 2 36 6 0 17 1000EXWS 376 74 35 570 49 53 6 67 47 32 1 34 88 99 2 52 6 71 0 19 1100EXWS 409 0...

Page 42: ...S 42 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA LD22376 Load Point 2 Load Point 3 Load Point 1 Load Point 4 SIDE 1 SIDE 2 SIDE 1 SIDE 2 Figure 15 LOAD POINTS FOR DOUBLE EFF...

Page 43: ...JOHNSON CONTROLS 43 SECTION 4 TECHNICAL DATA 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 44: ...17 152 7 78 16 028 7 27 900EXW 18 475 8 38 18 475 8 38 18 475 8 38 18 475 8 38 1000EXW 20 128 9 13 20 128 9 13 20 128 9 13 20 128 9 13 1100EXW 21 716 9 85 21 716 9 85 21 716 9 85 21 716 9 85 1200EXW3...

Page 45: ...226 7 36 15 190 6 89 900EXWS 17 593 7 98 17 593 7 98 17 593 7 98 17 593 7 98 1000EXWS 19 026 8 63 19 026 8 63 19 026 8 63 19 026 8 63 1100EXWS 20 613 9 35 20 613 9 35 20 613 9 35 20 613 9 35 1200EXW3...

Page 46: ...0Hz 6 2 19 0 6 2 19 0 AC400V 3Ph 50Hz 5 8 24 0 5 8 24 0 AC415V 3Ph 50Hz 5 75 24 4 5 75 24 4 AC400V 3Ph 60Hz 5 7 20 3 5 7 20 3 AC440V 3Ph 60Hz 5 3 22 4 5 3 22 4 AC460V 3Ph 60Hz 15A 125A 5 2 24 0 5 2 24...

Page 47: ...2 1 8 9 0 10 6 8 5 1 4 3 9 1 8 9 0 10 6 8 5 1 65 4 4 1 8 9 0 10 7 8 6 1 7 4 7 1 8 9 0 11 1 8 9 1 4 4 1 1 6 9 0 10 3 8 2 1 45 4 5 1 6 9 0 10 7 8 6 1 5 4 7 1 6 9 0 11 1 8 8 5 240EX S 0 4 3 3 8 8 0 75 3...

Page 48: ...Hz 8 2 23 0 6 2 19 0 AC400V 3Ph 50Hz 7 8 30 0 5 8 24 0 AC415V 3Ph 50Hz 7 7 31 0 5 75 24 4 AC400V 3Ph 60Hz 7 4 26 6 5 7 20 3 AC440V 3Ph 60Hz 7 2 29 5 5 3 22 4 AC460V 3Ph 60Hz 25A 125A 7 1 31 0 5 2 24 0...

Page 49: ...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 1 45 4 5 1 6 9 0 12 2 9 7 1 5 4 7 1 6 9 0 12 6 10 1 5 450EX S 0 4 3 3 8 8 0 75 3 8 20...

Page 50: ...14 0 51 0 6 2 19 0 AC400V 3Ph 50Hz 13 5 63 0 5 8 24 0 AC415V 3Ph 50Hz 13 0 66 0 5 75 24 4 AC400V 3Ph 60Hz 12 5 59 0 5 7 20 3 AC440V 3Ph 60Hz 11 4 65 0 5 3 22 4 AC460V 3Ph 60Hz 30A 125A 11 0 68 0 5 2 2...

Page 51: ...1 8 9 0 15 9 12 7 1 4 3 9 1 8 9 0 15 7 12 6 1 65 4 4 1 8 9 0 16 1 12 8 1 7 4 7 1 8 9 0 16 3 13 0 1 4 4 1 1 6 9 0 15 0 12 0 1 45 4 5 1 6 9 0 15 4 12 3 1 5 4 7 1 6 9 0 15 7 12 5 5 700EX S 0 4 3 3 8 8 0...

Page 52: ...60 0 6 3 18 0 AC400V 3Ph 50Hz 19 2 72 0 6 2 21 0 AC415V 3Ph 50Hz 18 6 73 5 6 0 22 0 AC400V 3Ph 60Hz 18 0 67 0 5 8 23 0 AC440V 3Ph 60Hz 17 0 73 0 5 5 24 0 AC460V 3Ph 60Hz 45A 125A 16 5 76 0 5 4 24 5 11...

Page 53: ...0 21 4 17 1 3 7 10 7 1 8 9 0 20 8 16 6 3 8 12 8 1 8 9 0 21 8 17 4 3 7 13 2 1 8 9 0 21 9 17 5 3 6 12 5 1 6 9 0 20 4 16 3 3 5 13 0 1 6 9 0 21 3 17 1 3 4 14 0 1 6 9 0 21 7 17 4 5 1100 EXW S 1 5 9 0 26 0...

Page 54: ...9 3 60 0 10 3 30 0 AC400V 3Ph 50Hz 19 2 72 0 10 1 36 0 AC415V 3Ph 50Hz 18 6 73 5 9 8 37 0 AC400V 3Ph 60Hz 18 0 67 0 9 5 35 0 AC440V 3Ph 60Hz 17 0 73 0 9 0 37 0 AC460V 3Ph 60Hz 50A 125A 16 5 76 0 8 8 3...

Page 55: ...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 4 0 13 2 1 6 9 0 24 4 19 5 3 9 13 8 1 6 9 0 24 8 19 9 5 1600 EXW3 S 1 5 9 0 26...

Page 56: ...19 3 60 0 10 3 30 0 AC400V 3Ph 50Hz 19 2 72 0 10 1 36 0 AC415V 3Ph 50Hz 18 6 73 5 9 8 37 0 AC400V 3Ph 60Hz 18 0 67 0 9 5 35 0 AC440V 3Ph 60Hz 17 0 73 0 9 0 37 0 AC460V 3Ph 60Hz 50A 125A 16 5 76 0 8 8...

Page 57: ...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 4 0 13 2 1 6 9 0 24 4 19 5 3 9 13 8 1 6 9 0 24 8 19 9 5 1400EXW S 1400EXW4...

Page 58: ...C380V 3Ph 60Hz 19 3 60 0 10 3 30 0 AC400V 3Ph 50Hz 19 2 72 0 10 1 36 0 AC415V 3Ph 50Hz 18 6 73 5 9 8 37 0 AC400V 3Ph 60Hz 18 0 67 0 9 5 35 0 AC440V 3Ph 60Hz 17 0 73 0 9 0 37 0 AC460V 3Ph 60Hz 50A 125A...

Page 59: ...4 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 4 0 13 2 1 6 9 0 24 4 19 5 3 9 13 8 1 6 9 0 24 8 19 9 5 1800EXW4 S 2 2 12 4 42 0 0 7...

Page 60: ...00V 3Ph 50Hz 150A 225A 11 0 52 6 208 0 7 5 38 4 144 0 AC200V 3Ph 60Hz JIS 150A 225A 52 0 180 0 36 0 134 0 AC200V 3Ph 60Hz US 150A 225A 52 0 180 0 36 0 134 0 AC220V 3Ph 60Hz 150A 225A 47 6 197 2 34 0 1...

Page 61: ...KW FLA LRA 2000EXW4 S 2 2 12 4 42 0 0 75 3 8 20 6 37 4 29 9 5 11 6 46 0 3 4 20 6 36 0 28 8 11 6 46 0 3 4 20 6 36 0 28 8 11 0 48 0 3 4 20 6 36 9 29 5 6 6 5 20 3 1 8 9 0 36 9 29 5 6 3 18 0 1 8 9 0 36 2...

Page 62: ...JOHNSON CONTROLS 62 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Electrical Diagram Figure 16 POWER WIRING...

Page 63: ...JOHNSON CONTROLS 63 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 LD28254_UL FIGURE 16 POWER WIRING CONT D Electrical Diagram...

Page 64: ...JOHNSON CONTROLS 64 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Electrical Diagram Figure 17 POWER WIRING...

Page 65: ...JOHNSON CONTROLS 65 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 LD28255_UL FIGURE 17 POWER WIRING CONT D Electrical Diagram...

Page 66: ...JOHNSON CONTROLS 66 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Electrical Diagram Figure 18 PLC INPUT WIRING...

Page 67: ...JOHNSON CONTROLS 67 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 FIGURE 18 PLC INPUT WIRING CONT D Electrical Diagram LD28256_UL...

Page 68: ...JOHNSON CONTROLS 68 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Figure 19 PLC INPUT WIRING Electrical Diagram...

Page 69: ...JOHNSON CONTROLS 69 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 FIGURE 19 PLC INPUT WIRING CONT D Electrical Diagram LD28257_UL...

Page 70: ...JOHNSON CONTROLS 70 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Figure 20 PLC OUTPUT WIRING Electrical Diagram...

Page 71: ...JOHNSON CONTROLS 71 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 FIGURE 20 PLC OUTPUT WIRING CONT D Electrical Diagram LD28258_UL...

Page 72: ...JOHNSON CONTROLS 72 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Electrical Diagram Figure 21 DISPLAY ANALOG WIRING...

Page 73: ...JOHNSON CONTROLS 73 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 Electrical Diagram LD28260_UL FIGURE 21 DISPLAY ANALOG WIRING CONT D...

Page 74: ...JOHNSON CONTROLS 74 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Figure 22 DISPLAY ANALOG WIRING Electrical Diagram...

Page 75: ...JOHNSON CONTROLS 75 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 FIGURE 22 DISPLAY ANALOG WIRING CONT D Electrical Diagram LD28261_UL...

Page 76: ...JOHNSON CONTROLS 76 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Figure 23 PLC ANALOG OUTPUT WIRING Electrical Diagram LD28262_UL...

Page 77: ...JOHNSON CONTROLS 77 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 Figure 24 PLC AND TOUCH SCREEN WIRING Electrical Diagram LD28264_UL...

Page 78: ...JOHNSON CONTROLS 78 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 SECTION 4 TECHNICAL DATA Electrical Diagram Figure 25 STEAM CONTROL WIRING...

Page 79: ...JOHNSON CONTROLS 79 SECTION 4 TECHNICAL DATA FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 4 FIGURE 25 STEAM CONTROL WIRING CONT D Electrical Diagram LD28263_UL...

Page 80: ...on No Voltage Level Start Stop Remote CHW Temp Setting Z3 Terminal Block Z1 Terminal Block Common Operating Signal Failure Signal Chilled Water Pump Operating Signal Cooling Water Pump Operating Signa...

Page 81: ...k Z3 Terminal Block Ancillary Equipment Board Out of Scope of Supply Absorption Chiller Control Panel Scope of Supply Remote Start Up No Voltage Pulse Start Stop Option Remote Start Up Remote Stop Rem...

Page 82: ...ting Panel if Chilled Hot Water Pump and Cooling Water Pump are Separately Equipped Starting Panel For Cooling Water Starting Panel for Chilled Water Z1 Terminal Block Common Operating Signal Failure...

Page 83: ...n about breaker capacity see Table 14 on page 83 46 3 If you need information about the contact specifica tions see Table 14 Contact Specifications on page 83 4 Connect the following absorption chille...

Page 84: ...ries and the CW EXW series of steam absorp tion chillers Upper Communication System Configuration The configuration of the upper communication system is shown in the figure below LD20594a Central Moni...

Page 85: ...ed Wiring work for Ethernet connection X Apply twisted pair cable Communication program for central monitoring unit X See Table 16 on page 85 and Table 17 on page 86 for the details of the IP address...

Page 86: ...n pump condition 0 or 1 01003 0 STOP 1 OPERATION 7 Refrigerant pump condition 0 or 1 01005 0 STOP 1 OPERATION 8 Load limit condition 0 or 1 01009 0 NORMALLY OPERATION 1 LOAD LIMIT OPERATION 9 Control...

Page 87: ...erformed by the customer to be sure that the communication systems work properly Serial Interface COM2 Connect User Created Cable LD20597a Figure 30 CONNECTION DETAIL FOR D SUB 9PIN Table 20 SCOPE OF...

Page 88: ...RS 422 RS 485 5 1 9 6 LD20598 SIGNAL NAME DIRECTION MEANING 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...

Page 89: ...External Device Master Shield Slave D sub 9 Pin socket Your own cable Signal Name Signal Name Pin Figure 31 2 WIRE 1 1 CONNECTION WITH USER CREATED CABLE LD20945 RDA RDB SDA SDB SG 100 1 2W 2 3 7 5 4...

Page 90: ...r Your own cable Pin Signal name Termination resistance Termination resistance Shell FG LD20946 Figure 33 4 WIRE 1 1 CONNECTION WITH USER CREATED CABLE LD20947 2 3 7 5 4 SG 1 RDB SDA SDB RDA 9 6 CSA E...

Page 91: ...nformation about the Read Command or Table 19 on page 87 for more information about the Write Command Table 22 COMMUNICATION SPECIFICATIONS Communication Protocol Modbus RTU Communication Path Type RS...

Page 92: ...ng water and steam were temporary during the measurement Figure 35 SAMPLE SOUND TESTING FOR YHAU CW CHILLER NOISE EMISSON LOCATION OVERALL OCTAVE BAND 31 5 Hz 63 Hz 125 Hz 250 Hz 500 Hz 1 kHz 2 kHz 4...

Page 93: ...ks after use 5 Operate the pump 6 Open the valve 7 Read and record the delivery pressure of the solu tion pump and the refrigerant pump 8 Close the valve 9 Check the pressure readings See Table 23 on...

Page 94: ...ooling water use the valves to adjust the flow When the flow rate change of the chilled water is con trolled the load change speed is limited The flow rate change function must be installed first The...

Page 95: ...that the Refrigerant Pump Auto button is pressed After the review is complete start the chiller The OPER and STOP buttons are avail able on the Main Data and Setting screen We recommend that you use...

Page 96: ...fective signal output Remote Local No 3 minutes 10 minutes Yes Time up Temperature control running Figure 36 COOLING START DIAGRAM Stop operation Dilution time count Steam control valve or steam drain...

Page 97: ...m is the common system you must install the isolation valve on the chilled water and cooling water inlet pipe entering the chiller and interlock these isolation valves with the chiller control panel T...

Page 98: ...aintenance 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 length and width 1 0 inch f...

Page 99: ...n the purge line are fully closed 3 Spindle valve is in the purge line is open 4 Detection component of the thermosensor is in serted into the thermowell according to design requirements D Electrical...

Page 100: ...properly START UP CHECKLIST A Operation Check 1 Manually start each water pump 2 Confirm the water box covers do not leak during water pump operation 3 Stop each water pump manually 4 Set each water p...

Page 101: ...nlet temperature 12 Record the running data on the data sheets B Purge Amount check 1 Verify that the purge amount from the absorber is within acceptable range 2 Close the spindle valve to facilitate...

Page 102: ...Refrigerant Purity Temperature Setting Solution circulation pump A Standard 1 040 kg L or less Set base temp F Solution spray pump A Specific gravity Auto stop temp F Refrigerant pump A Turbidity Auto...

Page 103: ...g Water Inlet temperature F Control panel 68 0 89 6 F Outlet temperature F Control panel 68 0 99 5 F Inlet pressure Pressure gauge Outlet pressure Pressure gauge 7 Pressure drop DPG or calculation 8 5...

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

Page 105: ...g to turn off the chiller Data can be displayed in metric and imperial units plus keypad entry of set points to 0 1 increments Security access using passwords is provided to prevent unauthorized chang...

Page 106: ...ou want to continue or cancel your selection LD21476_UL Screen Name Buttons Located along the bottom of the screen These are used to change screens The selected button lights when it is active CHANGE...

Page 107: ...g The steam control valve stays in the low position before the automatic temperature control process runs Temp Control Light is lit if the temperature control of the microcomputer panel changes to RUN...

Page 108: ...p Solution Circulating Pump Solution Spray Pump Refrigerant Pump Purge Pump Chilled Water pump Cooling Water pump Flickers white during operation Remains black when the pump is stopped 69WC1 or 69WC2...

Page 109: ...er measured as it leaves the evaporator Cooling Water In Temp temperature of the cooling water measured as it enters the absorber Cooling Water Out Temp temperature of the cool ing water measured as i...

Page 110: ...matically To move to the Trend screen press the Trend button at the upper right of the screen The History Menu section on the right side of the screen gives you access to the Operation History Alarm H...

Page 111: ...tion 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 your lo cal Johnson Cont...

Page 112: ...e screen and the Refrigerant Pump Overhaul section of the screen both indicate the maintenance interval and the current operation hours since the last maintenance When the required maintenance period...

Page 113: ...aporator Cooling Water In temperature of the cooling water as it enters the absorber Cooling Water Out temperature of the cooling water as it leaves the condenser HG Temperature temperature of the con...

Page 114: ...s are available to select measurements for up to 12 times ago to cover the 12 hour period The following information displays Operation operation status of the chiller Ope Method selected operation met...

Page 115: ...temperature generator HG Press pressure in the high temperature generator HG Concent concentration of the concentrated solu tion in the high temperature generator Ctrl Valve percentage that the valve...

Page 116: ...cted operation method 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 run ning Ope Freq how many times th...

Page 117: ...trated solu tion in the high temperature generator Ctrl 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 to informat...

Page 118: ...of the chiller Ope Method selected operation method Sol Pump operation status of the solution pump Ref Pump operation status of the refrigerant pump Ope Hours total operation hours FAILURE HISTORY SC...

Page 119: ...n in the high temperature generator Ctrl 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 to information about past...

Page 120: ...er Ope Method selected operation method Sol Pump operation status of the solution pump Ref Pump operation status of the refrigerant pump Ope Hours total operation hours ALARM HISTORY SCREEN Ope Freq h...

Page 121: ...n in the high temperature generator Ctrl 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 to information about past...

Page 122: ...ghts 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 Turning off the buzzer does NOT fix the problem...

Page 123: ...terlock Constant monitoring interlock was not established Check the components of the constant monitoring interlock If any of the components are not working contact your local Johnson Controls Service...

Page 124: ...Stop after dilution Temperature sensor and or pressure sensor detected abnormal value due to disconnection short circuit or other applicable sensors Tighten terminal in control panel Contact your loca...

Page 125: ...n Control HG pressure rose and the load limit operation was activated The alarm resets if the HG pressure falls Check the cooling water line Check the cooling water flow rate Check the cooling tower P...

Page 126: ...water inlet temperature sensor and or absorber temperature sensor detected abnormal value due to disconnection short circuit or other abnormal sensor readings Remote setting signal was abnormal durin...

Page 127: ...lit indicates if the set point is being set using the Control Panel or from a remote location Setting Base Temp the base temperature for calculat ing the set point Remote Set Diff the setting range w...

Page 128: ...Numeric Values on page 106 Valve Operation Control Valve Mode the Auto and Manual buttons indicate whether the control valve is being operated automatically or manually To change to manual op eration...

Page 129: ...op mode Purge Mode The Auto and Manual buttons control the purge operation The lit button indi cates if the purge mode is Automatic or Manual Manual Purge The ON and OFF buttons con trol the manual pu...

Page 130: ...JOHNSON CONTROLS 130 FORM 155 31 ICOM2 EN UL ISSUE DATE 12 21 2018 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 131: ...ric shock and burn Contact your local Johnson Controls Service Office for inspection and mainte nance of the machine Improper inspec tion and maintenance can cause a chiller malfunction or injury SOLE...

Page 132: ...ater may be used as the refrigerant in the chiller PURGE PROCEDURE Air must be purged from the chiller to maintain peak performance and prevent deterioration of the internal parts This chiller has an...

Page 133: ...rates at a lower capacity than usual for a long period of time or when it restarts after a pow er failure the absorber may contain non condensable gases If the machine starts under these conditions it...

Page 134: ...pump starts con firm that the vacuum gauge stands at 0 0 15 PSI abs 5 Verify that valve V10 is open 6 Reading the vacuum gauge gradually open valve V11 7 The manual purge procedure is complete when th...

Page 135: ...RQ RZ 7HPS HQHUDWRU RZ 7HPS HQHUDWRU UDLQ HDW FKDQJHU 6WHDP UDLQ 2XWOHW YDSRUDWRU 8SSHU EVRUEHU 8SSHU EVRUEHU RZHU YDSRUDWRU RZHU 6WHDP 3 RQWURO 9DOYH 6WHDP 3XUJH 3XPS 3 0 69 69 9 9 9 9 9 9 9 9 9 9 3U...

Page 136: ...ssure Release Valve Gas Separator To Safety Area Evaporator Absorber Ref Pump RP Condenser Low Temp Generator Steam Drain Outlet Steam Inlet Low Temperature Generator Drain Heat Exchanger High Tempera...

Page 137: ...e refrigerant depends 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 gaug...

Page 138: ...wiring of the solution pump is disconnected only the refrigerant pump starts 5 Remove the cap of the refrigerant manual blow down valve For the location of the refrigerant manual blow valve see Figur...

Page 139: ...and check the data with the data collected during the factory test Weekly C Check the steam control valve Check to see that the steam control valve operates smoothly C Check of liquid level See Table...

Page 140: ...operties 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 Check of quantity of solution and refrigerant The sol...

Page 141: ...bes with brush or water jet High temperature generator Every 4 years S Chemical cleaning of tubes Absorber condenser Since hard scales sticking to the tubes cannot be removed with a brush or water jet...

Page 142: ...Panel Setting screen LD19933_UL 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 button w...

Page 143: ...eries Every 30 000 Hr Fan for Control Panel Every 30 000 Hr Steam Control Valve Every 60 000 Hr Steam Shut Off Valve Option Every 60 000 Hr Steam Drain Solenoid Valve PVS series Every 30 000 Hr Differ...

Page 144: ...bulent flow can be generated The turbulence may cause damage in the water chamber case and the copper tube of the chiller If you need to adjust the flow rate of the chilled and cooling water be sure t...

Page 145: ...uality temperature flow speed metals used existence of crevices and deposits and type of water system are also part of the equation For more information about corrosion preventive mea sures consult a...

Page 146: ...of ferric dioxide Fe2 O3 Iron bacteria propagate remarkably Reddish brown Black Fe3 corrodes iron and copper tubes Reddish brown Black Environmental Factors Water smells bad Containing compounds of su...

Page 147: ...Cooling Water Thermostat Strainer 20 mesh Cooling Water Pump PI TI PI TI PI TI TE PI TI TH Figure 54 CHILLED WATER AND COOLING SYSTEM LD22006 Scope of Supply High Temp Generator Go Down to Chiller Ste...

Page 148: ...K XGOT XGV 9GLKZ_ 8KROKL GR K KTKXGZUX 9ZKGS XGOT XGOT GIQ 6XKYY XK JP YZOTM GR K NKIQ GR K XGOT GIQ 6XKYY XK 6XKYY XK 2UYY UL 6OVOTM N UZ KRR GTQ 9ZGTKX d SKYN 9ZKGS KGJKX 9ZKGS N 9ZKGS XGOT UTZXUR G...

Page 149: ...0 Max 0 1 Residual Chlorine mgCI I Max 0 3 Max 0 3 Max 0 3 Max 0 3 Max 0 3 Free Carbonate Acid mgCO2 I Max 4 0 Max 4 0 Max 4 0 Max 4 0 Max 4 0 Stability Index 6 0 7 0 NOTES 1 The item names their defi...

Page 150: ...rage method Wet storage method is available only in case where chilled water and cooling water will not freeze Each storage method has its own characteristics Select the method to use based on the pla...

Page 151: ...e is an open system 1 Completely drain the water 2 Clean the water systems by passing clear water through them from a position higher than the chiller 3 Fill the water systems with clear water 4 Circu...

Page 152: ...ide of shells Vacuum Storage Period more than 6 months Chilled water system Filled with water Cooling water system Steam line Dried and pressurized with Nitrogen 1 5 3 PSIG Inside of shells Pressurize...

Page 153: ...00 210 220 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...

Page 154: ...gal 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 1...

Page 155: ...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 5...

Page 156: ...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 4...

Page 157: ...l items should be checked routinely whenever the chiller experiences any trouble or abnormality Check to see if the main steam valve was closed by mistake Open the main valve See if the valves of the...

Page 158: ...sorption chiller Table 36 CHILLED WATER OVERCOOLING OR REFRIGERANT OVERCOOLED ITEM CAUSE COUNTERMEASURE 1 Chilled water flow rate lowers or changes sharply See if the chilled water flow rate changes s...

Page 159: ...ogged Contact your local Johnson Controls Service Office 4 Water suspension switch is broken If the chiller has a pump problem it does not perform the dilution operation It stops immediately If left a...

Page 160: ...ng operation did not occur dilute the solution according to the procedure shown in Manual Refrigerant Blow Down and Diluting Method on page 137 If these problems occur the absorption chiller per forms...

Page 161: ...ur local Johnson Controls Service Office 4 Non condensable gas remains in machine See Purge Procedure on page 132 Check the capacity of the vacuum pump Check the purge unit for a problem Purge air fro...

Page 162: ...el during the vacuum pump capacity check to see if the entire purge line needs to be inspect ed See Table 45 on page 162 Table 45 VACUUM PUMP TROUBLESHOOTING ITEM CAUSE COUNTERMEASURE 1 Deterioration...

Page 163: ...low check the opening ratio of the flow controller valve and check the strainer for clogging Check the capacity of the cooling tower See Purge Procedure on page 132 Check the capacity of the vacuum pu...

Page 164: ...ffice 2 Deterioration of vacuum pump oil Replace the vacuum pump oil 3 Wrong operation of purging line switching when vacuum pump capacity was checked See Purge Procedure on page 132 Confirm that the...

Page 165: ...outlet issues No Yes Dilution time up Yes Stop with dilution operation Steam control valve or steam drain control valve steam drain solenoid valve and steam shut off valve option close Dilution time...

Page 166: ...ocated on the chiller Monitor until chiller returns to normal operation Purge directly from the absorber Stop the machine to ensure the dilution operation takes place The dilution operation takes appr...

Page 167: ...tems Drain the heat exchanger section of the system If no isolation valves are installed it may be necessary to drain the complete system 8 If glycol was used in the water system or chemi cal additive...

Page 168: ...m Pennsylvania USA 17349 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2018 www johnsoncontrols com ALL RIGHTS RESERVED Form 155 31 ICOM2 EN UL 1118 Issue...

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