Johnson Controls YORK YHAU-CGN Installation and operating instructions

Form: 155.32-ICOM1.EN.GB (422)
Supersedes: 155.32-ICOM1.EN.GB (318)
Installation, Operation, and Maintenance
Issue Date: 2022-04-19
YHAU-CGN/H Double Effect Direct Fired
Absorption Chiller-Heater (Mod A)
120 ton to 1600 ton 422 kW to 5626 kW

2 YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)

Contents
ContentsGeneral safety guidelines................................................................................................................................7
Safety symbols....................................................................................................................................... 7
Changeability of this document...........................................................................................................8
Associated literature..............................................................................................................................8
Nomenclature........................................................................................................................................ 9
General chiller-heater information and safety...........................................................................................10
Introduction..........................................................................................................................................10
About this manual............................................................................................................................... 10
Warranty............................................................................................................................................... 10
Quality assurance................................................................................................................................ 11
High temperature and pressure cleaning........................................................................................ 11
Emergency shutdown......................................................................................................................... 12
Safety labels..........................................................................................................................................13
Product description........................................................................................................................................14
Chiller-heater components.................................................................................................................14
Control panel........................................................................................................................................14
How direct fired units work................................................................................................................ 15
Evaporator............................................................................................................................................ 17
Absorber............................................................................................................................................... 17
Two-step evaporator – absorber....................................................................................................... 17
Plate type heat exchangers................................................................................................................ 18
Parallel flow.......................................................................................................................................... 18
High temperature generator (HTG).................................................................................................. 19
Low temperature generator (LTG).................................................................................................... 19
Condenser............................................................................................................................................ 19
Crystallization.......................................................................................................................................20
Why crystallization occurs.................................................................................................................. 20
Handling, storage, installation and reassembly.........................................................................................21
Inspection............................................................................................................................................. 22
Inspection window.............................................................................................................................. 22
Installation guidelines.........................................................................................................................22
Hoisting the machine.......................................................................................................................... 24
Moving the machine on rollers..........................................................................................................24
Structural support and installation................................................................................................... 26
Indoor and outdoor installation........................................................................................................ 28
Electrical................................................................................................................................................28
Precautions for use..............................................................................................................................29
Leak testing.......................................................................................................................................... 30
Electrical shock cautions.....................................................................................................................31
Use of gas............................................................................................................................................. 31
YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A) 3

Use of oil............................................................................................................................................... 31
Vibration and isolation details........................................................................................................... 32
Nozzle arrangements..........................................................................................................................32
Fuel gas and oil piping system...........................................................................................................35
Hot insulation or cold insulation procedure.................................................................................... 37
Pressure release valve and relief piping...........................................................................................39
Pressure release valve discharge pipe material.............................................................................. 40
Pressure release valve piping construction..................................................................................... 40
Rupture disk and relief piping (option).............................................................................................41
Rupture disk discharge piping material........................................................................................... 42
Rupture disk discharge piping construction....................................................................................42
Rupture disk discharge piping sizing................................................................................................43
Technical data.................................................................................................................................................46
Upper communication specification................................................................................................. 75
Upper communication system configuration.........................................................................................75
Modbus TCP protocol communication....................................................................................................75
Connection port for Ethernet communication....................................................................................... 76
Communication specification................................................................................................................... 76
Modbus RTU protocol communication................................................................................................... 76
User-created............................................................................................................................................... 77
Two-wire type cable diagrams..................................................................................................................78
Four-wire type cable diagrams.................................................................................................................79
Communication data................................................................................................................................. 81
Noise emission........................................................................................................................................... 83
Commissioning...............................................................................................................................................84
General guidelines for use................................................................................................................. 84
Before operation........................................................................................................................................84
Precautions for the use of water....................................................................................................... 85
Chilled or hot water outlet temperature controller........................................................................ 86
Liquid level gauges..............................................................................................................................86
Start the chiller-heater........................................................................................................................86
Stop the chiller-heater........................................................................................................................ 87
Interlocking procedure....................................................................................................................... 87
Operation........................................................................................................................................................ 99
YHAU-CGN/H Control Center............................................................................................................. 99
Common items.....................................................................................................................................99
Change numeric values.................................................................................................................... 100
Main screen........................................................................................................................................101
Operating status...................................................................................................................................... 102
Data screen........................................................................................................................................ 103
Solution analysis or control panel parts replacement screen............................................................106
Solution pump overhaul or refrigerant pump overhaul screen.........................................................107
YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)4

Burner parts replacement or burner combustion check screen....................................................... 108
Trend screen............................................................................................................................................. 109
Hourly operation history screen............................................................................................................ 111
Minutely operation history screen.........................................................................................................113
Failure history screen.............................................................................................................................. 115
Alarm history screen................................................................................................................................117
Failure and alarm screen..................................................................................................................119
Failure........................................................................................................................................................119
Alarm......................................................................................................................................................... 122
Setting screen.................................................................................................................................... 123
Control parameter................................................................................................................................... 123
Valve operation........................................................................................................................................ 125
Date and time...........................................................................................................................................125
Operation switch......................................................................................................................................126
Select language........................................................................................................................................ 126
Single loop controller........................................................................................................................127
Run mode..................................................................................................................................................128
Ready mode..............................................................................................................................................129
Alarm mode.............................................................................................................................................. 129
Alarm codes.............................................................................................................................................. 130
Operational display..................................................................................................................................131
Auto/manual mode (RHW only).............................................................................................................132
Operation mode changeover...........................................................................................................133
Changeover to cooling mode................................................................................................................. 133
Changeover to heating mode.................................................................................................................133
Use simultaneous residential hot water supply mode (option).........................................................134
Changeover to residential hot water sole supply mode (option)......................................................135
Maintenance................................................................................................................................................. 138
Exhaust duct inspection....................................................................................................................138
Valve inspection.................................................................................................................................138
Solenoid valves.................................................................................................................................. 139
Pump shut off valves (option)..........................................................................................................139
Air release valves and drain valves (option)...................................................................................139
Purge valves....................................................................................................................................... 139
Start the chiller-heater after it has been stopped for a long period...........................................139
Checks before operation starts..............................................................................................................139
Checks after operation starts...........................................................................................................140
Purge procedure................................................................................................................................140
Capacity check method of vacuum pump...................................................................................... 140
Manual method to purge non-condensable gas directly from absorber...................................144
Manual method to purge non-condensable gas from the purge tank...................................... 144
Automatic method to purge non-condensable gas from the purge tank..................................145
Refrigerant refining method............................................................................................................152
5YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)

Manual refrigerant blow down and diluting method................................................................... 152
Decrystallization method..................................................................................................................153
Indications of crystallization...................................................................................................................153
Decrystallization................................................................................................................................ 153
Precautions for decrystallization..................................................................................................... 154
Maintenance items............................................................................................................................154
Refrigerant pump manual stop..............................................................................................................156
Purge manual start and stop..................................................................................................................157
Lifespan for various parts.................................................................................................................157
Water quality control.........................................................................................................................159
Chemical water treatment................................................................................................................160
Replacement of water.......................................................................................................................160
Treatment for long stoppage of the absorption chiller-heater................................................... 160
Chemical treatment...........................................................................................................................160
Flow speed in tubes...........................................................................................................................161
Storage method of the chiller-heater............................................................................................. 164
Wet storage method................................................................................................................................164
Dry storage method................................................................................................................................ 164
Precautions against external damage............................................................................................165
Storage method of the cooling water during heating operation period................................... 166
Wet storage...............................................................................................................................................166
Dry storage............................................................................................................................................... 167
Troubleshooting...........................................................................................................................................173
Troubleshooting performance issues.............................................................................................177
Vacuum pump....................................................................................................................................178
Abnormal solution and refrigerant levels...................................................................................... 179
Actions to take against power failure............................................................................................. 182
Decommissioning, dismantling, and disposal..........................................................................................183
Optional applications...................................................................................................................................184
Low temperature chilled water supply (model EX(H/S)L and EXW(H/S)L).................................184
YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)6

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 incorrectly,
to cause bodily injury or death. It is the obligation and responsibility of rigging, installation,
and operating or 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 or
service personnel. It is expected that these individuals possess independent training that enables
them to perform their assigned tasks correctly and safely. It is essential that, before performing
any task on this equipment, this individual reads and understands the on-product labels, this
document and any referenced materials. This individual must 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.
7YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)

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 or 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 or service personnel must verify
whether the equipment has been modified and if current literature is available from the owner of
the equipment before 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 155.32-CL1
YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)8

Nomenclature
9YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)

General chiller-heater information and safety
Introduction
Hitachi YHAU-CG/H 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 or the hot water pump, the cooling water pump, the 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, that are issued for guidance
only, and they do not take precedence over the stated individual responsibility 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.
Warranty
Johnson Controls warrants YHAU-CG/H 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 a labor or 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.
YHAU-CGN/H Double Effect Direct Fired Absorption Chiller-Heater (Mod A)10