Johnson Controls York YHAU-CGN-CXR Series Guide

Form: 155.42-ICOM2.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, 105 kW to 1055 kW

Contents
ContentsGeneral safety guidelines.............................................................................................................. 5
Safety symbols..................................................................................................................................... 5
Changeability of this document......................................................................................................... 6
Associated literature........................................................................................................................... 6
Nomenclature...................................................................................................................................... 7
General chiller-heater information and safety........................................................................... 8
Introduction......................................................................................................................................... 8
About this manual............................................................................................................................... 8
Warranty............................................................................................................................................... 9
Quality assurance................................................................................................................................ 9
Emergency shutdown....................................................................................................................... 10
High temperature and pressure 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
Parallel flow........................................................................................................................................ 17
High temperature generator (HTG)................................................................................................ 17
Low temperature generator (LTG).................................................................................................. 17
Condenser.......................................................................................................................................... 17
Crystallization..................................................................................................................................... 18
Why does crystallization occur?...................................................................................................... 19
Handling, storage, installation, and reassembly...................................................................... 20
Inspection........................................................................................................................................... 21
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater i

Inspection window............................................................................................................................ 21
Installation guidelines....................................................................................................................... 21
Hoisting the machine........................................................................................................................ 23
Moving the machine on rollers........................................................................................................ 23
Storage method of the chiller-heater............................................................................................. 26
Structural support and installation................................................................................................. 26
Indoor and outdoor installation...................................................................................................... 26
Electrical.............................................................................................................................................. 27
Precautions for use........................................................................................................................... 27
Leak testing........................................................................................................................................ 28
Electrical shock cautions................................................................................................................... 28
Use of gas........................................................................................................................................... 28
Vibration and isolation details......................................................................................................... 29
Rupture disk and relief piping......................................................................................................... 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 procedure...................................................................... 37
Technical data............................................................................................................................... 40
Upper communication specification............................................................................................... 76
Sound data......................................................................................................................................... 83
Commissioning............................................................................................................................. 84
General guidelines for use............................................................................................................... 84
Precautions for the use of water..................................................................................................... 85
Chilled/hot water outlet temperature controller.......................................................................... 85
Liquid level gauges............................................................................................................................ 86
Start the chiller-heater...................................................................................................................... 86
Stop the chiller-heater...................................................................................................................... 87
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heaterii

Interlocking procedure..................................................................................................................... 87
Operation.................................................................................................................................... 103
YHAU-CGN/H-CXR(M) control center............................................................................................ 103
Common items................................................................................................................................ 103
Change numeric values.................................................................................................................. 105
Main screen...................................................................................................................................... 106
Operating status.............................................................................................................................. 106
Control parameter........................................................................................................................... 128
Valve operation................................................................................................................................ 129
Date and time.................................................................................................................................. 130
Operation switch............................................................................................................................. 131
Select language............................................................................................................................... 131
Weishaupt burner operation LCD................................................................................................. 132
Single loop controller...................................................................................................................... 132
Maintenance............................................................................................................................... 144
Exhaust duct inspection................................................................................................................. 144
Valve inspection............................................................................................................................... 144
Solenoid valves................................................................................................................................ 145
Air 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 method of service vacuum pump....................................................................... 146
Manual method to purge non-condensable gas directly from absorber................................. 147
Manual method to purge non-condensable gas from the purge tank.................................... 148
Automatic method to purge non-condensable gas from the purge tank................................ 148
Refrigerant refining method.......................................................................................................... 152
Manual refrigerant blow down and diluting method................................................................. 153
iiiModel YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

Decrystallization method................................................................................................................ 153
Decrystallization.............................................................................................................................. 154
Precautions for decrystallization................................................................................................... 155
Maintenance items.......................................................................................................................... 155
Lifespan for various parts.............................................................................................................. 158
Water quality control...................................................................................................................... 159
Chemical water treatment.............................................................................................................. 159
Replacement of water..................................................................................................................... 160
Treatment for long stoppage of the absorption chiller-heater................................................. 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 period................................. 165
Troubleshooting......................................................................................................................... 173
Troubleshooting performance issues........................................................................................... 177
Abnormal solution and refrigerant levels.................................................................................... 177
Actions to take against power failure........................................................................................... 180
Decommissioning, dismantling, and disposal........................................................................ 181
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heateriv

General safety guidelines
Important
Read before proceeding.
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certain components or conditions including,
but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the potential, if misused or handled improperly,
to cause bodily injury or death. It is the obligation and responsibility of rigging, installation, and
operating/service personnel to identify and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to comply with any of these requirements
could result in serious damage to the equipment and the property in which it is situated, as well as
severe personal injury or death to themselves and people at the site.
This document is intended for use by owner-authorized rigging, installation, and operating/service
personnel. It is expected that these individuals possess independent training that will enable them
to perform their assigned tasks properly and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read and understood the on-product labels, this
document and any referenced materials. This individual shall also be familiar with and comply
with all applicable industry and governmental standards and regulations pertaining to the task in
question.
Safety symbols
The following symbols are used in this document to alert the reader to specific situations:
DANGER
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.
WARNING
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.
CAUTION
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.
Note: Highlights additional information useful to the technician in completing the work being
performed properly.
5Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

WARNING
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance
with Johnson Controls’ published specifications and must be performed only by a qualified electrician.
Johnson Controls will NOT be responsible for damage/problems resulting from improper connections
to the controls or application of improper control signals. Failure to follow this warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
Changeability of this document
In complying with Johnson Controls’ policy for continuous product improvement, the 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.
It is the responsibility of rigging, lifting, and operating/service personnel to verify the applicability
of these documents to the equipment. If there is any question regarding the applicability of these
documents, rigging, lifting, and operating/service personnel should verify whether the equipment
has been modified and if current literature is available from the owner of the equipment prior to
performing any work on the chiller-heater.
Associated literature
Manual description Form number
Absorption Chiller-Heater Long Term Storage 50.20-NM11
Long-Term Storage Checklist - Absorption Chiller-Heater 50.20-CL10
Long-Term Storage Requirements - General 50.20-NM10
Chiller-Heater Start-Up and Commissioning Checklist 155.42-CL2
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater6

Nomenclature
7Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

General chiller-heater information and safety
Introduction
YORK YHAU-CGN/H-CXR(M) absorption chiller-heaters are manufactured to the highest design and
construction standards to ensure high performance, reliability, and adaptability to all types of air
conditioning installations.
This chiller-heater is for air conditioning or cooling a manufacturing process. Use this chiller-heater
after installing the chilled/hot water pump, cooling water pump, cooling tower, valves, strainers,
pressure gauges, thermometers, or other relevant pumps and gauges, according to the water
quality information contained in Maintenance.
About this manual
This manual and any other document supplied with the unit are the property of Johnson Controls
which reserves all rights. This manual may not be reproduced, in whole or in part, 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 suggested best working practices and procedures, which are issued for guidance only,
and they do not take precedence over the stated individual responsibility and/or local safety
regulations.
• Contains all the information required for correct installation and commissioning of the unit,
together with operating and maintenance instructions.
• Contains detailed procedures, including installation, commissioning, and maintenance tasks that
must be performed by suitably trained and qualified personnel.
• The manufacturer will not be liable for any injury or damage caused by incorrect installation,
commissioning, operation, or maintenance resulting from a failure to follow the procedures and
instructions detailed in this manual.
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater8

Warranty
WARNING
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accordance
with Johnson Controls’ published specifications and must be performed only by a qualified electrician.
Johnson Controls will NOT be responsible for damage/problems resulting from improper connections
to the controls or application of improper control signals. Failure to follow this warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
Johnson Controls warrants YHAU-CGN/H-CXR(M) chiller-heaters in accordance with the Limited
Warranty Engineered Systems Equipment Procedure. Refer to the Limited Warranty (Form 50.05-
NM2).
Johnson Controls warrants all equipment and materials against defects in workmanship and
materials for a period of 18 months from the date of shipment or 12 months from the date of start-
up, whichever comes first, unless extended warranty has been purchased as part of the contract.
The warranty is limited to parts only replacement and shipping of any faulty part, or subassembly,
which has failed due to defects in workmanship 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 claims must specify the unit model, serial number, order number, and run hours/
starts. Model and serial number information is printed on the unit identification plate.
The unit warranty will be void if any modification to the unit is carried out without prior written
approval from Johnson Controls. For warranty purposes, the following conditions must be satisfied:
• The initial start of the unit must be carried out by trained personnel from an authorized Johnson
Controls Field Service Office.
• Only genuine Johnson Controls approved spare parts, oils, solutions, chemicals, and refrigerants
must be used.
• All of the scheduled maintenance operations detailed in this manual must be performed at the
specified times by suitably trained and qualified personnel.
Failure to satisfy any of these conditions will automatically void the warranty. Refer to Limited
Warranty (Form 50.05-NM2) for complete details.
Quality assurance
Units comply with the following directives:
• GB/T 18431-2014 Direct Fired Lithium Bromide Absorption Water Chiller-Heater
• UL 1995 2011 Ed.4 + R:03Oct2014 Standard for Safety Heating and Cooling Equipment
• UL 508A Industrial Control panel
• NFPA70 National Electrical Code
• NFPA79 Electrical Standard for Industrial Machinery
9Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

The unit must be grounded. No installation or maintenance work should be attempted on the
electrical equipment without first switching the power off, then isolating and locking-off the power
supply. Servicing and maintenance on live equipment must not be attempted. No attempt should
be made to gain access to the control panel or electrical enclosures during normal operation of the
unit.
Components may also have sharp edges. Reasonable care should be taken when working in contact
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. Turn the handle counter clockwise to shut down the chiller.
Figure 1: Emergency shutdown handle
High temperature and pressure cleaning
High temperature and pressure cleaning methods (for example, steam cleaning) must not be
used on any part of the pressure system as this can cause operation of the pressure relief devices.
Detergents and solvents, that can cause corrosion, must also be avoided.
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater10

Safety labels
For safe operation, read the instructions first.
WARNING: This machine may start automatically without prior
warning.
WARNING: Hot surface.
WARNING: Safety relief valve may discharge gas or liquid
without prior warning.
WARNING: Risk of electric shock. General attention symbol.
WARNING: On isolating the supply it may take up to 300 seconds
for the capacitor voltage to fall below 50 volts.
WARNING: On isolating the supply it may take up to 300 seconds
for the capacitor voltage to fall below 50 volts.
WARNING: Risk of fire.
WARNING: Risk of electrical arc.
WARNING: Risk of gas posioning.
CAUTION: Risk of getting hand caught in machinery.
CAUTION: Prohibited.
CAUTION: Risk of fall.
11Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

CAUTION: Risk of getting hand caught in machinery.
CAUTION: Protect ears.
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater12

Product description
The principle of refrigeration is the exchange of heat. In absorption liquid chilling, there are four
basic heat exchange surfaces: the evaporator, the absorber, the generator, and the condenser. See
Figure 2.
Like any refrigeration system, absorption chilling uses evaporation and condensation to remove
heat. The absorption cycle uses water as the refrigerant and lithium bromide (LiBr) as the
absorbent. It is the strong affinity that these two substances have for one another that makes the
cycle work. The entire process occurs in almost a complete vacuum.
Chiller-heater components
The absorption chiller-heater consists of the following components:
• Evaporator
• Absorber
• Condenser
• Generators
• Solution heat exchangers 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-heater comes with a factory mounted and pre-wired control system. The
control panel enclosure is equipped with a hinged access door with lock and key. The control panel
includes a touch panel showing all system parameters in various languages with numeric data in
imperial or metric units. For details of the control panel, see Operation.
Note: Verify that the main power switch is within 6.56 ft (2 m) off the ground. If not, install the
operation platform.
WARNING
Turn off the power supply by the handle breaker when opening the control panel.
The unit is also equipped with two methods to start and stop operations:
• Touch panel
• External signal
13Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

Figure 2: YHAU-CGN-CXR components
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater14

How it works (direct fired units)
The double effect (direct fired) absorption chiller-heater uses water as the refrigerant and lithium
bromide (LiBr) as the absorbent. It is the strong affinity that these two substances have for one
another that makes the chiller-heater cycle work. The vapor pressure of the lithium bromide
solution is lower than the vapor pressure of the refrigerant. The vapor pressure of the LiBr solution
is directly related to the amount of refrigerant (water) present in the solution with the LiBr salt and
the solution temperature. The entire absorption process occurs in almost a complete vacuum.
Figure 3: YHAU-CGN/H-CXR(M) chiller-heater cycle diagram-cooling
Evaporator
Liquid refrigerant 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 through the tubes causes the refrigerant to flash from a liquid to a vapor. The
temperature at which this happens depends on the evaporator shell pressure which is dictated
by the absorber section of the chiller-heater. The refrigerant vapor passes through the mist
eliminators and into the absorber section of the chiller-heater. As the liquid refrigerant passes
down through the bundle of evaporator tubes, more and more of the refrigerant vaporizes. The
refrigerant remaining in a liquid state at the bottom drains into the refrigerant tank and is pumped
back up the top of the tube bundle where the process is repeated.
15Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

Absorber
Concentrated LiBr solution enters the absorber section of the chiller-heater and is sprayed over
the absorber tube bundle. Because the vapor pressure of the concentrated solution is very low, the
refrigerant (water) vapor from the evaporator flows into the absorber and is absorbed into the LiBr
solution. This mass transfer process lowers the concentration of the LiBr solution as the refrigerant
(water) is absorbed into the solution. This dilution process generates heat and, if not cooled,
would eventually stop as the solution temperature would rise with a corresponding rise in vapor
pressure. This would be similar to closing the vanes or slowing down a centrifugal compressor on a
centrifugal chiller where the load was constant. The water flowing inside the absorber tube bundle
comes from the cooling tower and serves to cool the LiBr solution as it flows down over 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
section, it goes into the suction of the solution pump. The liquid is then pumped to the generators.
Figure 4: Evaporator-absorber
Plate type heat exchangers
The dilute (weak) LiBr solution leaving the absorber section is pumped through various plate type
heat exchangers (such as the low temperature heat exchanger, LTG refrigerant condensate heat
exchanger, and high temperature heat exchanger) before it enters the high temperature generator
and low temperature generator sections. These plate type heat exchangers provide cycle efficiency
by preheating the dilute solution. Preheating the dilute solution reduces the consumption of the
driving heat source in the high temperature generator section. The concentrated solution flows out
of the generators and back through the various heat exchangers.
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater16

Figure 5: Plate type heat exchanger
The relatively high temperature solution streams from the two generators are used to preheat the
weak solution stream leaving the absorber.
Parallel flow
The unique parallel flow divides the solution between the low temperature generator and the high
temperature generator sections into two parallel, balanced paths. The result is a safer and more
efficient operation at a much lower pressure than conventional series-flow designs. The various
solution-to-solution plate type heat exchangers optimize efficiency by enabling effective heat
transfer between the diluted (weak) and the concentrated LiBr solutions.
High temperature generator (HTG)
YHAU’s HTG section has the unique liquid tube design where the dilute LiBr solution coming from
the high temperature heat exchanger is inside the tubes. The products of combustion (exhaust gas
from burning of natural gas) are on the shell side. The hot refrigerant vapor boiled off is sent to the
low temperature generator. This leaves behind a strong solution that is returned through the high
temperature heat exchanger.
The liquid tube design is efficient 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 design also benefits from less volume of LiBr solution and hence faster startup time.
It does not require any ceramic refractory compared to the conventional design, and this ensures
improved reliability.
Low temperature generator (LTG)
The hot refrigerant vapor from the high temperature generator heats up the dilute solution coming
in from the low temperature heat exchanger. This vapor then condenses into hot refrigerant liquid
and is sent to the condenser through the drain heat exchanger. The additional vapor produced in
the LTG by heating up the dilute solution is sent to the condenser.
The LTG is of a falling film design, ensuring superior heat transfer and enhanced life by eliminating
wear and tear at the tube supports.
Condenser
The cooling water from the absorber section enters into the condenser section. This helps
condense the refrigerant vapors produced in the LTG and the condensed refrigerant from the drain
heat exchanger. The liquid refrigerant is then sent back to the evaporator section through a U-pipe
(liquid seal).
17Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater

Figure 6: Condenser
This completes the cooling cycle.
Crystallization
All absorption chiller-heaters that use LiBr and water as the solution/refrigerant pair are subject
to crystallization. This is due to the fact that some areas of the unit operate with solution liquid
concentration levels that are solely possible at higher than the normal ambient temperature
surrounding the unit. For example, the solution concentration in the generator of a single effect
absorption unit is usually 64.3% LiBr by weight. LiBr begins to crystallize at 110°F (43.4°C).
Crystallization is the result of the LiBr solution temperature going too low or the concentration too
high. The LiBr solution becomes like slush. At this point the LiBr solution cannot absorb any more
water and starts to solidify (crystallize).
Crystallization occurs in the solution heat exchanger and sometimes even in the generator. It also
happens in pipes that are not well insulated, where room temperature can affect the solution
moving 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 generator is normally high enough in most load conditions, no
crystallization occurs as long as the higher solution temperatures are maintained. Special measures
do have to be taken before the unit is shut down so that the solution is sufficiently diluted in
all areas of the unit to prevent crystallization during the off cycle, as the solution temperature
eventually equals the surrounding ambient temperature.
All units employ some sort of dilution cycle that fulfills this requirement. As long as the unit
is allowed to dilute itself during an orderly shutdown sequence, the unit should be able to sit
idle at fairly low plant room ambient temperatures for extended periods of time without any
threat of crystallization. Typically, after a dilution cycle, the average solution concentration in the
chiller-heater is below 45% LiBr by weight and has no tendency to crystallize at normal ambient
temperatures.
Model YHAU-CGN/H-CXR(M)Double Effect Direct Fired Small Absorption Chiller-Heater18