Yazaki AROACE CH-MG150 User manual

GAS-FIRED DOUBLE-EFFECT
ABSORPTION CHILLER-HEATER
This product is a gas-fired double-effect absorption unit which provides chilled water
for cooling or hot water for heating in central plant-type air conditioning systems. Units
with nominal refrigeration capacities of 150 and 200 tons are complete with operating
and safety controls. The chiller-heater is fitted with a low NOx burner, automatic ignition
system, power combustion blower, and proportional firing control.
CONTENTS
GENERAL Page
GENERAL 2
MODEL DESIGNATION 2
STANDARD SPECIFICATIONS 3
EQUIPMENT DIMENSIONS 4
INTERNAL WIRING DIAGRAM 6
INSTALLATION
RECEIVING 9
RIGGING 10
CENTER OF GRAVITY 11
INSTALLATION CLEARANCES 12
LOCATION 13
FOUNDATION 13
Page
LEVELING 14
COMBUSTION AIR SUPPLY 14
VENTING 15
PIPING 17
TYPICAL SYSTEM DESIGN 18
CHILLED/HOT WATER PIPING 19
COOLING WATER PIPING 19
FREEZE PROTECTION 20
GAS SUPPLY PIPING 21
ELECTRICAL 22
TYPICAL FIELD WIRING DIAGRAM 24
WATER QUALITY 26
INSTALLATION CHECK &
REQUEST FOR STARTUP 26
INSTALLATION INSTRUCTIONS
CH-MG150
CH-MG200

2
GENERAL
This equipment should only be
installed by trained and qualified
personnel who are familiar with
absorption chillers. All precautions in
these instructions, as well as on tags and
labels attached to the unit, must be
observed to ensure the safety of the
personnel and maintain warranty
validation.
Each Yazaki absorption chiller-heater
has been evacuated, charged with
lithium bromide and water solution, and
run tested prior to leaving the factory.
Field wiring connections are located
on the right side of the unit when facing
the front of the unit. Piping connections,
including gas piping, are all located at the
rear of the unit.
After the equipment has been
installed, a Yazaki Authorized Service
Provider (ASP) must check the
installation and supervise or conduct the
initial startup and operation of the unit.
CAUTION
THE YAZAKI WARRANTY WILL BE
VOIDED IF THE FOLLOWING
RESTRICTIONS ARE NOT
OBSERVED:
1. DO NOT OPEN ANY VACUUM VALVES
WITHOUT A PROPER EVACUATION
ASSEMBLY ATTACHED TO THEM AS SUCH
ACTION WILL RESULT IN LOSS OF
VACUUM AND INTRODUCTION OF GASES
TO THE INTERIOR OF THE MACHINE
WHICH COULD CAUSE CORROSION.
2. ALWAYS HANDLE THE EQUIPMENT WITH
CARE AND MAINTAIN IN A NEAR-
VERTICAL POSITION DURING RIGGING.
3. DISCONNECT GAS PIPING FROM
EQUIPMENT WHEN PRESSURE TESTING
AT 0.5 PSI OR GREATER IN ORDER TO
AVOID DAMAGE TO THE GAS VALVES.
4. DO NOT ATTEMPT TO START THE
SYSTEM WITHOUT SUPERVISION FROM A
YAZAKI AUTHORIZED SERVICE PROVIDER
(ASP).
MODEL DESIGNATION
CH-MG ###
Double-Effect Absorption Chiller-Heater (MG Series)
Cooling Capacity: 150 = 150 ton, 200 = 200 ton

3
STANDARD SPECIFICATIONS
SPECIFICATIONS
English (Metric)
CH-MG150
CH-MG200
Capacity
Cooling
MBTU/hr (kW/hr)
1,800 (527.5)
2,400 (703.4)
Heating
MBTU/hr (kW/hr)
1,245 (364.9)
1,660 (486.5)
Chilled/Hot
Water
Chilled Water
Temperature
Inlet
°F (°C)
53.6 (12)
Outlet
°F (°C)
44.6 (7)
Hot Water
Temperature
Inlet
°F (°C)
132.8 (56)
Outlet
°F (°C)
140.0 (60)
Evaporator Pressure Loss
PSI (kPa)
10.5 (72.4)
9.2 (63.4)
Maximum Operating Pressure
PSI (kPa)
113.9 (785)
Rated Water Flow
GPM (l/s)
399.4 (25.2)
532.6 (33.6)
Water Retention Volume
Gal (liters)
48 (181.7)
69 (261.2)
Cooling
Water
Heat Rejection
MBTU/hr (kW/hr)
3,045 (892.4)
4,060 (1189.9)
Cooling Water
Temperature
Inlet
°F (°C)
85.1 (29.5)
Outlet
°F (°C)
94.3 (34.6)
Abs/Cond Pressure Loss
PSI (kPa)
7.5 (57.1)
7.2 (49.6)
Maximum Operating Pressure
PSI (kPa)
113.9 (785)
Rated Water Flow
GPM (l/s)
658.6 (41.6)
878.1 (55.4)
Water Retention Volume
Gal (liters)
114 (431.5)
153 (579.2)
Fuel
Type of Fuel
Natural Gas
Consumption
MBTU/hr (kW/hr)
1,500 (439.6)
2,000 (586.1)
Electrical
Power Source
208v or 230v / 60Hz / 3-phase
Consumption
kW
2.9
3.3
Minimum Circuit Amps
Amps
24.4
29.0
Maximum Overcurrent Protection
Amps
30
35
Capacity
Control
Cooling
30-100% Proportional
Heating
30-100% Proportional
Combustion
Burner Type
Low NOx Forced Draft (Proportional)
Flame Detection
Flame Rod
Ignition Type
Pilot w/ Intermittent Spark
Sound
dB(A)
74
Dimension
Width
Inches (mm)
77.0 (1957)
80.9 (2057)
Depth
Inches (mm)
144.2 (3665)
147.0 (3735)
Height (without vent cap)
Inches (mm)
88.2 (2240)
97.6 (2480)
Height (including vent cap)
Inches (mm)
108.8 (2775)
118.1 (3000)
Piping
Chilled/Hot Water
Inches
4 (Flange)
5 (Flange)
Cooling Water
Inches
5 (Flange)
6 (Flange)
Gas Piping
Inches
2 NPT
Weight
Dry
lbs (kg)
12,346 (5600)
14,330 (6500)
Operating
lbs (kg)
13,698 (6213)
16,183 (7340)
Note: All metric values are calculated from the Imperial values and are only approximate values.
1. Fuel Input is based on the high heat value of gas. Burner efficiency = 83%. Allowable supply gas pressure is 7”-10.5” wc.
2. Power consumption does not include external pumps or cooling tower fan motors.
3. “Width” dimension does not include Junction Box.
4. Specifications are all based upon water in all fluid circuits and fouling factor of 0.0005 ft²-hr-°F/Btu.
5. Pressure Loss ratings are +/- 10%.
6. Minimum Cooling Water flow is 100%.
Table 1 –Specifications

4
EQUIPMENT DIMENSIONS
Figure 1 –MG150 Dimensions

5
EQUIPMENT DIMENSIONS
Figure 2 –MG200 Dimensions

6
INTERNAL WIRING DIAGRAM

7

8
Table 2 –Internal Wiring Diagram Legend
KRCH
relay has
been
replaced by
the KCH
relay.

9
INSTALLATION
RECEIVING
When the absorption chiller-heater is
delivered, inspect it for transit damage.
Should any damage have occurred, do
not proceed with installation until the
Yazaki distributor has been notified and
any required remedial actions have been
completed.
The MG-Series units are too large for
the typical fork lift. Special handling
procedures must be followed in order to
safely remove the unit from a covered
trailer. An open flat-bed trailer is
preferred for easiest delivery, but is not
always an option.
Remember to properly plan the route
to the installation site. Also, keep in mind
when choosing the site, the unit will
someday have to be replaced, so be
mindful of permanent and semi-
permanent barriers.
The unit typically must be pulled out of
a container or trailer and often must be
pulled into position on site. The frame of
the unit is specifically designed for the
forces due to horizontal pulling. Attach
cable or acceptable equivalent to the
frame only at the provided holes. No
other points should be used for horizontal
pulling.
Figure 3 –Horizontal Movement
Figure 4 –Hallway Clearances

10
RIGGING
The Yazaki chiller-heater is designed
for overhead rigging with openings in the
cabinet and holes in the equipment frame
intended for such use. Ensure that the
crane being used is proper for the mass
to be lifted.
When rigging for overhead lift, remove
the four cardboard or sheet metal covers
on the top panel to expose the lugs for
rigging. Attach shackle bolts to these
lugs. Bring the four individual rigging
cables together at a point high enough
that the angle between the rigging line
and the top of the unit is no less than
60°, as shown in the drawings below.
Once the unit is in final position, locate
the four top panel blanks which are
included in the accessories box. Install
these blanks in order to keep the cabinet
weatherproof.
Cable
(from Top
View)
Minimum Length
ft (m)
A
11.5 (3.5)
B
11.0 (3.3)
C
9.75 (3.0)
D
8.75 (2.7)
Figure 5 –Rigging

11
Model
Center of Gravity Position
Operating
Weight
A - inches(mm)
B - inches(mm)
C - inches(mm)
lbs(kg)
CH-MG150
40.2 (1020)
34.3 (870)
67.3 (1710)
13,700 (6,215)
CH-MG200
43.7 (1110)
36.2 (920)
65.7 (1670)
16,200 (7,350)
Weight Distribution
CH-MG150
CH-MG200
Dry - lbs(kg)
Operating - lbs(kg)
Dry - lbs(kg)
Operating - lbs(kg)
Front Left
1,528 (693)
1,688 (766)
1,831 (831)
2,074 (941)
Front Right
1,448 (657)
1,600 (726)
1,735 (797)
1,965 (892)
Middle Left
3,353 (1,521)
3,704 (1,681)
3,777 (1,714)
4,279 (1,941)
Middle Right
2,698 (1,224)
2,981 (1,353)
3,103 (1,408)
3,515 (1,595)
Back Left
1,746 (792)
1,929 (875)
1,985 (901)
2,249 (1,021)
Back Right
1,627 (738)
1,797 (816)
1,869 (848)
2,118 (961)
Total
12,400 (5,625)
13,700 (6,215)
14,300 (6,487)
16,200 (7,350)
Figure 6 –Center of Gravity and Corner Weights

12
INSTALLATION CLEARANCES
Figure 7 –Installation and Service Clearances

13
LOCATION
Particular care must be taken when
placing the machine so as to provide
adequate clearance for access to each
side of the machine.
Maintenance is mostly done through
the front of the unit, but in repair
scenario, any panel on any side may
need to be removed to access
components behind them.
Further, with the shell and tube design
of the MG-Series fluid circuits, it is
possible to clean and/or replace tubes
during the life cycle of the machine,
therefore, clearance must be available to
be able to perform such maintenance
and repair tasks.
Finally, as with all mechanical devices,
the unit will have to be replaced
someday. Keep that in mind as well
when choosing the final placement site.
The minimum clearance space is
shown on the chart and diagram below.
Note that the tube removal clearances
can be provided either in front or back.
Also, it is not necessary that the 114.2”
(2900 mm) clearance for tube access be
provided across the entire end of the
unit.
FOUNDATION
All aspects of foundation and support
computations must be in accordance with
national and local codes.
The chiller-heater must be mounted
on a level, non-combustible foundation
capable of supporting the considerable
weight of the machinery. This is
particularly important for rooftop
installations. Always make certain the
structure can support not only the chiller-
heater, but also the pumps, piping,
cooling towers, etc. as may be required.
The rooftop area should be well-drained
and be at least 7 feet (2 meters) from the
edge of the roof. Anti-fall measures
should always be taken if the chiller-
heater is installed within 12 feet (4 meters)
of the edge of the roof.
Additionally, for protection of the
roofing material, it is recommended a
suitable platform or walkway be provided
around all sides of the unit.
If the chiller-heater is to be installed
outside, but at ground level, make certain
the concrete base and the soil beneath
are sufficient for the task. Settling over
time could cause the unit to become
unlevel, which could have a serious
negative impact on the performance and
lifespan of the unit. Concrete
foundations are recommended to be
sized so that at least 12” (300 mm)
extends beyond the unit in all directions
to accommodate potential mounting and
anchoring hardware.
Figure 8 –Foundation Detail

14
LEVELING
MG-Series units must be level in order
for the fluids to be distributed properly
over their respective tube bundles.
There is a level bar mounted on the front
of the machine right above the absorber
section, near the fusible plug.
Figure 9 –Level Bar
The unit must be level to both the
longitudinal and transverse alignments.
In cases of multiple units installed side-
by-side, the units should all be level
individually as well as in respect to each
other. It is essential that all leveling be
completed before any piping connections
are attempted.
Use shim plates to level the machine.
Shims are typically field-supplied when
needed and should be of galvanized, flat,
hot-rolled mild steel in dimension of at
least 0.2” (5 mm) thick, 10.2” (260 mm)
long, and 7.9” (200 mm) wide. When shims
are required, place them under the
machine tie-down points.
Figure 10 –L-Anchor Plate Detail
(all dimensions in inches)
COMBUSTION AIR SUPPLY
As with all gas-fired appliances,
careful consideration must be given in
regard to the provision of sufficient free
air for combustion and venting. The
rules for such are found in the National
Fuel Gas Code, NFPA Standard 54. The
code supersedes anything found in print
here or in any other Yazaki
documentation. What has been provided
here are only guidelines to help toward
proper installation of the unit.
When installed outdoors, no special
provisions are usually needed in regard
to combustion air. However, if the unit is
in a confined area outside, some issues
could arise if external forces cause a
negative pressure area around the unit.
An example of such would be having the
unit installed in an alcove with a strong,
sustained wind blowing by along the
edge of the building. Such occurrences
are rare, but should be considered.
Of greater concern are indoor
installations, especially in areas with
more than one gas-fired appliance. Keep
in mind that whatever combustion air
supply is present, it must be capable of
supporting every gas-fired appliance in
the space while all of them operate at full
capacity. Combustion air openings are
also often the source for dilution air for
Category I appliances, so it is
recommended to consult the manuals on
all appliance in the area in order to

15
ensure all requirements are being
considered. Never install a gas-fired
appliance in an unventilated space.
ASME Section VI –Recommended
Rules for the Care and Operations of
Heating Boilers, Reference 6.04” states:
“The boiler room must have adequate air
supply to permit clean, safe combustion and to
minimize soot formation. An unobstructed air
opening should be provided. It may be sized
on the basis of 1-square inch free area per
2000 BTUh maximum fuel input of combined
burners located in the boiler room, or as
specified in the National Fire Protection
Association standards for oil and gas burner
installations for the particular job. The boiler
room air supply openings must be kept clear at
all times.”
Figure 11 –Combustion Air Detail
VENTING
Each chiller-heater is supplied with a
suitable vent cap intended for installation
on the exhaust outlet when the
equipment is installed outdoors. Remove
the right side panel on the cabinet and
attach the vent cap to the exhaust tube
with ten M10 (or 3/8”) bolts (field-supplied).
Figure 12 –Factory Vent Cap
In cases where an extended vent is
necessary, follow the normal venting
rules. Venting the flue products safely is
a key concern when installing any gas-
fired appliance and Yazaki chiller-heaters
are no exception. As with combustion
air, rules for the proper venting of gas-
fired appliances are also covered in the
National Fuel Gas Code, NFPA Section
54.
All MG-Series chiller-heaters are
Category I appliances. When choosing
vent material size, the chillers are
classified as “fan” vent-type since the fan
on the burner only assists in moving flue
products through the unit. The fan does
NOT provide enough force to do more
than push the flue products a few feet
down the vent, so it does not have
enough force to qualify as Category III,
side discharge venting. There are
aftermarket kits that can provide
Category III capability for Category I
appliances should the need arise.
Yazaki has no kit for this. Warranty may
be void on the Yazaki chiller-heater if
such a kit is used, but not installed or
applied correctly. Carefully follow all
instructions when applying these kits,
and if necessary, contact Yazaki Energy
Systems, Inc. for guidance on integration
of the kit to the unit control safeties.

16
Exhaust gas volume to be handled by
the vent system is listed in the chart
below. The table reflects gas
consumption with the burner operating at
100% fire rate with CO2 at 8.5% and O2
at 5.5% (31.8% combustion excess air).
These conditions release exhaust gas on
the order of 392°F (200°C) at a density of
0.011 lbs/ft³ (0.175 kg/m³).
Model Exhaust Gas Volume
at 392°F (200°C)
CH-MG150 531 CFM (14.5 m³/min)
CH-MG100 707 CFM (20.0 m³/min)
A number of quick rules can be listed
in regard to venting.
1. Always use B-Type double wall vent material.
2. Vent should never run downhill.
3. Vent must terminate at least 7’ (2.2m) above
public walkways.
4. Vent must terminate at least 4’ above vertically
or 10’ (3m) horizontally from openings into
living areas or air intakes.
5. Vent must terminate no closer than 10’ (3m)
from an inside corner unless it terminates 2’
(600mm) above said inside corner.
6. Vent should terminate at least 2’ (600mm)
above the highest point within 10’ (3m), with a
minimum height above the roof of 3’ (1m).
Figure 13
7. Rise (Height) should be greater than the Run
(Lateral).
Figure 14
8. It is recommended that each unit be vented
separately if possible. If the vent is taller than
7’ (2.2m), a barometric damper (also known as
a draft regulator) may be required. The range
of draft pressure allowed at the vent
connection on the chiller-heater is 0.0” wc to -
0.05” wc. If the draft pressure is outside of
this range, a barometric damper should be
used to correct this in order to prevent sooting
and possible damage to the HGE.
9. Always measure draft as closely as possible to
the vent outlet of the unit.
10.Maintain a minimum of 18” (460mm) separation
between the ceiling and any horizontal run of
vent pipe.
In instances where multiple units must
be vented, and individual venting is
impractical or undesirable, combined
venting (Common Venting) is permitted so
long as it follows proper venting rules.
There will be separate and special charts
for sizing common venting applications.
Follow the rules given by the vent
material manufacturer.
Things that do not change by
manufacturer:
1. Barometric dampers (draft regulators) are no
longer an option. They are required so that
vent conditions of one unit do not affect the
operation/venting of the other(s). Use a
separate damper for each chiller-heater with
the damper located as close as possible to the
unit (location A in preference to location B).
Figure 15
2. Size connecting Tees properly.
Figure 16

17
3. The maximum allowable lateral length (L) is
equal to 1.5’x diameter of the pipe in inches.
Connector Lateral Length Allowance
Pipe
Diameter
Inches
10
12
14
16
18
Maximum
Lateral
Length
Feet
15
18
21
24
27
Table 3
4. When the common pipe grows to become 7x
greater in area than any of the other
interconnecting pipe, special rules will apply.
Consult the pipe manufacturer for these
details and/or special rules.
PIPING
After the chiller-heater has been
leveled properly, the piping for the
chilled/hot water and cooling water
circuits may be installed. Piping
arrangements should be made with care
so that there is no interference with
service access or panel removal. Piping
should be adequately supported and
braced independently of the unit so as to
avoid undue strain on the unit piping
connections. Maximum allowable
pressure in any fluid circuit is 113.8 PSI
(785 kPa).
Piping rules and conventions used
with Yazaki chiller-heaters are exactly
the same as used with any other type of
chiller; therefore, this installation manual
will not delve deeply into piping design.
CAUTION
1. Do not exceed 113.8 PSI (785 kPa) in
either the chilled/hot water or the
cooling water circuits of the Yazaki
chiller-heater.
2. Do not install any valves in expansion
pipe line.
Thermo-wells, pressure gauges,
Pete’s Plugs, etc. may be installed at the
inlet and/or outlet of each fluid circuit
connection to facilitate startup, future
service, and routine maintenance.
Strainers in each circuit, particularly the
cooling water circuit, are recommended
as well. These should be placed before
the inlet connection of the chiller-heater.
Figure 17 –Typical System Piping

18
TYPICAL SYSTEM DESIGN
Figure 18 –Example of Single Module Installation
MULTIPLE MODULES
Figure 19 –Example of Multiple Module Installation

19
CHILLED/HOT WATER PIPING
A balance valve should be installed at
the chilled/hot water outlet and a stop
valve should be installed at the
chilled/hot water inlet. Both valves
should be placed in close proximity to the
chiller-heater.
After thoroughly testing for leaks,
insulate the piping circuit, ensuring an
adequate vapor barrier is obtained. Be
sure to allow access to any valves, wells,
and ports that may be present. Also,
ensure the chiller-heater panels are not
restricted by the insulation.
Figure 20 –Chilled/Hot Water Piping
COOLING WATER PIPING
Cooling water should be supplied at
85°F (29.5°C) or less. The CH-MG Series
can adapt to cooling water down to 65°F
(18.5°C) without the need of a mixing
valve. However, the inlet cooling water
temperature must not be below 46.4°F
(8°C) when the cooling cycle starts, nor
may it drop to 46.4°F (8°C) and remain
there for more than 3 minutes at any
point in time. Such cases will result in
the generation of error code E043. This
error code will automatically reset itself
once the cooling water warms above
48.2°F (9°C).
To prevent a hot slug of water from
potentially damaging the cooling tower, a
Cooling Water Control Valve (CWV)
should be used and set so that it
bypasses into the sump of the cooling
tower for the first 2 minutes of the first
cooling cycle after the unit has changed
over from heating mode. This same
valve can also be used to divert water
that is too cold into the sump of the
cooling tower until the water has warmed
up to an acceptable temperature.
Higher temperatures than 85°F (29.5°C)
can result in a loss of capacity. In some
cases, the burner will simply be able to
ramp up the firing rate to compensate,
but this lowers the efficiency of the unit
and should be avoided. If cooling water
exceeds 90°F (32°C), the refrigerant
vapor may no longer condense properly,
which could lead to a loss of capacity as
well. If the cooling water becomes
consistently too hot, the unit may lock
out.
Figure 21 –Cooling Water Piping

20
If possible, the cooling tower should
be installed at the same level or above
the level of the chiller-heater. If this is
not possible, give careful consideration to
the prevention of drain-back and loss of
cooling water due to overflow of the
tower. Such matters must be given prior
consideration by the design engineer.
As with the chilled/hot water
connections, a balance valve should be
installed on the cooling water inlet and a
stop valve installed on the cooling water
outlet. Both valves should be in close
proximity to the chiller-heater. After
thoroughly testing for leaks, insulate the
piping circuit, ensuring an adequate
vapor barrier is obtained. Be sure to
allow access to any valves, wells, and
ports that may be present. Also, ensure
the chiller-heater panels are not
restricted by the insulation.
Additionally, there should be flush and
drain valves installed between the
machine and the balance/stop valves so
as to allow for flushing of the absorber-
condenser coils should it ever become
necessary.
FREEZE PROTECTION
When the chiller-heater and/or
associated piping are installed in a
location that is subject to freezing
conditions, appropriate anti-freeze steps
must be taken. Many anti-freeze
methods are available including heat
tape, but the most common method in
the USA is the use of glycol in the fluid
loop.
Glycol may be permitted for use in
Yazaki chiller-heaters with certain
restrictions and observations.
1. In the chilled/hot water circuit, it should
only be used during heating operation. It is
not recommended for use in the chilled water
circuit in cooling mode as the loss of heat
transfer performance could result in tube
failure under certain extreme conditions.
2. Glycol may be used in the cooling water circuit
in any operating mode.
3. Do not use automotive glycol (Antifreeze) since
it contains chemical additives that are
inappropriate and potentially damaging to the
Yazaki chiller-heater. Use only glycol
appropriate for use with copper tubing.
4. Do not exceed a mixture of 50% by weight.
5. Be aware that loss of performance will result
when glycol is used. In higher concentrations,
the impact can be very significant.
6. Propylene Glycol is preferred wherever
possible. It has very similar anti-freeze
characteristics to Ethylene Glycol, but is non-
toxic. It is also less viscous than Ethylene
Glycol, which reduces the required pump
power.
7. Use of glycol can cause the unit to operate at
a slightly higher internal temperature since
heat transfer is dampened. This may result in
depletion of inhibitor at a faster rate than what
may be perceived as normal.