York YHAU-CGN Owner's manual

MODEL YHAU-CGN/H
120-1600 TON
422-5626 KW
Direct Fired Absorption Chiller-Heater
Installation, Operation, Maintenance
Form 155.32-ICOM2.EN.UL (1018)
Issue Date: October 1, 2018
New Release
LD26829

FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
2JOHNSON CONTROLS
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
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.

FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 3
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. Updated manuals, if applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the Johnson Controls QuickLIT website at http://cgproducts.johnsoncontrols.com.
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.
CHANGE BARS
Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made.
These revisions are to technical information and any other changes in spelling, grammar or formatting are not included.
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

FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
4JOHNSON CONTROLS
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FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 5
TABLE OF CONTENTS
SECTION 1 - GENERAL CHILLER-HEATER INFORMATION AND SAFETY . . . . . . . . . . . . . . . . . . . . . . 11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High Temperature and Pressure Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 2 - PRODUCT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chiller-Heater Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How It Works (Direct Fired Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Two-step Evaporator – Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Plate Type Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parallel Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
High Temperature Generator (HTG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Low Temperature Generator (LTG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Crystallization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Why Does Crystallization Occur? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 3 - HANDLING, STORAGE, INSTALLATION AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspection Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hoisting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Moving the Machine on Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Structural Support and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Indoor and Outdoor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Precautions for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical Shock Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Use of Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Use of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Vibration and Isolation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rupture Disk And Relief Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rupture Disk Discharge Piping Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rupture Disk Discharge Piping Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rupture Disk Discharge Piping Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Flue Equipment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hot Insulation/Cold Insulation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
6JOHNSON CONTROLS
TABLE OF CONTENTS
SECTION 4 - TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Upper Communication Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Upper Communication System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connection Port for Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Communication Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Communication Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
User-Created . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2-Wire Type Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4-Wire Type Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Noise Emission Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION 5 - COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
General Guidelines for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Precautions for The Use Of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Chilled/Hot Water Outlet Temperature Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Liquid Level Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Start The Chiller-Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Stop The Chiller-Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Interlocking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
SECTION 6 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
YHAU-CGN/H Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Common Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Change Numeric Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Operating Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Solution Analysis / Control Panel Parts Replacement Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Solution Pump Overhaul / Refrigerant Pump Overhaul Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Burner Parts Replacement/ Burner Combustion Check Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Control Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Date And Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Operation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Select Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Burner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Operation Mode Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Changeover to Cooling Mode for Chiller with Evaporator Heating . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Changeover to Heating Mode for Chillers with Evaporator Heating . . . . . . . . . . . . . . . . . . . . . . . . . 116
Use Simultaneous Residential Hot Water Supply Mode (Option) for Chillers
with Evaporator Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Changeover to Residential Hot Water Sole Supply Mode (Option) for Chillers
with Evaporator Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 7
TABLE OF CONTENTS
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Exhaust Duct Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Pump Shut Off Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Air Purge Valves and Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Purge Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Start The Chiller-Heater After It Has Been Stopped For a Long Period . . . . . . . . . . . . . . . . . . . . . . . . 122
Checks Before Operation Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Checks After Operation Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Purge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Capacity Check Method of Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Manual Method to Purge Non-Condensable Gas Directly from Absorber . . . . . . . . . . . . . . . . . . . . . . . 127
Manual Method to Purge Non-Condensable Gas from the Purge Tank . . . . . . . . . . . . . . . . . . . . . . . . 128
Automatic Method to Purge Non-Condensable Gas from the Purge Tank . . . . . . . . . . . . . . . . . . . . . . 128
Refrigerant Refining Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Manual Refrigerant Blow Down and Diluting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Decrystallization Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Indications of Crystallization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Decrystallization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Precautions for Decrystallization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Refrigerant Pump Manual Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Purge Manual Start and Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Lifespan for Various Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Water Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Chemical Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Replacement of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Treatment For Long Stoppage Of The Absorption Chiller-Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Chemical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Flow Speed in Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Wet Storage Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Dry Storage Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Precautions Against External Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Storage Method of the Cooling Water During Heating Operation Period . . . . . . . . . . . . . . . . . . . . . . . 153
Wet Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Dry Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
SECTION 8 – TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Troubleshooting Performance Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Abnormal Solution and Refrigerant Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Actions to Take Against Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
SECTION 9 - DECOMMISSIONING, DISMANTLING, AND DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . 171
APPENDIX 1 - CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
8JOHNSON CONTROLS
LIST OF FIGURES
Figure 1 - YHAU-CGN/H-120-300EX(H/S) and 360EX - 1600EXW3(H/S). . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 2 - Two Step Direct Fired Absorption Chiller-Heater Cycle Diagram
(Cooling Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 3 - Hoisting Procedures (4-point Listing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 4 - Moving the Machine on Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 5 - Moving the Machine on Tir-Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 6 - Jack-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 7 - Jack-Up Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 8 - Plastic Pipe Stub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 9 - Location of Rupture Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 10 - Location of Rupture Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 11 - YHAU-CGN/H-120-300EX(H/S) and 360EX(H/S)-1600EXW3(H/S) Nozzle Locations . . . . . . . 32
Figure 12 - Fuel Gas Piping System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 13 - Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 14 - Exhaust Gas Flue Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 15 - Hot and Cold Insulation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 16 - Interior of Control Panel (MM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 17 - Exterior of Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 18 - Split Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 19 - Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 20 - Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 21 - Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 22 - PLC Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 23 - PLC Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 24 - Display Analog Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 25 - PLC Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 26 - Display Analog Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 27 - Display Analog Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 28 - Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 29 - Interior of Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 30 - External Connection Terminal Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 31 - Remote Transmission Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 32 - Signal Terminal Transition Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 33 - In Case of 3 Phase 4-Wire System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 34 - Upper Communication System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 35 - Connection Detail For Sub 9 PiN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 36 - 2 - Wire 1:1 Connection With User-Created Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 37 - 2-Wire N:1 Connection With User-Created Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 38 - 4-wire 1:1 Connection With User-Created Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 39 - 4-wire N:1 Connection With User-Created Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 40 - Sample Sound Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 41 - Cooling Start/Stop Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 42 - Direct Fire Sequential Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 43 - Stopping absorption chiller-Heater Direct Fire Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 44 - Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 45 - Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 46 - Solution Analysis / Control Panel Parts Replacement Screen . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 47 - Solution Pump Overhaul / Refrigerant Pump Overhaul Screen . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 48 - Burner Parts Replacement/ Burner Combustion Check Screen . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 49 - Trend Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 50 - Hourly Operation History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 51 - Minutely Operation History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 52 - Failure History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 53 - Alarm History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 54 - Failure and Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

FORM 155.32-ICOM2.EN.UL LIST OF FIGURES
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 9
LIST OF FIGURES
Figure 55 - Setting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 56 - Burner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 57 - Changeover Valve Locations for Chiller with Evaporator Heating . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 58 - Changeover Valve Locations for Chillers with Additional Heat Exchanger Heating . . . . . . . . . 120
Figure 59 - Location of Manual Valve in Purging System 120-300EX(H/S) . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 60 - Location of Manual Valve in Purging System 360-500EX(H/S) . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 61 - Location of Manual Valve in Purging System 560-1600EXW3(H/S) . . . . . . . . . . . . . . . . . . . . . 126
Figure 62 - YHAU- CGN/H Direct Fired Chiller-Heater with Evaporator Heating
Flow Diagram - Cooling Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 63 - YHAU- CGN/H Direct Fired Chiller-Heater with Evaporator Heating
Flow Diagram - Heating only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 64 - YHAU- CGN/H Direct Fired Chiller-Heater with Evaporator Heating
Flow Diagram Residential Hot Water (Auxiliary Heat Exchanger only) . . . . . . . . . . . . . . . . . . 131
Figure 65 - YHAU- CGN/H Direct Fired Chiller-Heater with Evaporator Heating
Flow Diagram - Simultaneous Cooling and Residential Hot Water Only . . . . . . . . . . . . . . . . . . 132
Figure 66 - YHAU-CGN/H Direct Fired Chiller-Heater with Evaporator Heating
Flow Diagram - Simultaneous Heating and Residential Hot Water . . . . . . . . . . . . . . . . . . . . . 133
Figure 67 - YHAU-CH/AN/H Direct Fired Chiller-Heater with Additional Heat Exchanger
Heating Flow Diagram - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 68 - YHAU-CG/AN/H Direct Fired Chiller-Heater with Additional Heat Exchanger
Heating Flow Diagram - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 69 - Chilled/Hot Water and Cooling Water System Evaporator Heating . . . . . . . . . . . . . . . . . . . . . . 149
Figure 70 - Chilled/Hot Water and Cooling Water System (Additional Heat Exchanger Heating) . . . . . . . . 150
Figure 71 - Wet Storage During Heating Operation Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 72 - Dry Storage During Heating Operation Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Figure 73 - Duhring Diagram / PTX Chart (°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Figure 74 - Duhring Diagram / PTX Chart (°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Figure 75 - Specific Gravity - Concentration (°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Figure 76 - Specific Gravity - Concentration (°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Figure 77 - Troubleshooting Sequence Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Figure 78 - Actions to Take Against Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

LIST OF TABLES FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
10 JOHNSON CONTROLS
LIST OF TABLES
Table 1 - Nozzle Arrangements 120-300EX(H/S) and 360EX(H/S)-1600EXW3(H/S) . . . . . . . . . . . . . . . . . . . . . 32
Table 2 - Nozzle Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 3 - Insulating Material and Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 4 - Points Requiring Hot/Cold Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 5 - Typical Operational Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 6 - Standard Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 7 - High Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 8 - Physical Data (with Exhaust Gas Temp. Approximately 428°F) - CG/AN . . . . . . . . . . . . . . . . . . . . . . . 42
Table 9 - Physical Data (with Exhaust Gas Temp. Approximately 428°F) - CG/AH . . . . . . . . . . . . . . . . . . . . . . . 43
Table 10 - Electrical Data - CG/AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 11 - Electrical Data - CG/AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 12 - Load Points for High Efficiency - CG/AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 13 - Load Points for High Efficiency - CG/AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 14 - Load Points for Standard Efficiency - CG/AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table 15 - Load Points for Standard Efficiency - CG/AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table 16 - Split Shipment - High Efficiency - CG/AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table 17 - Split Shipment - High Efficiency - CG/AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table 18 - Split Shipment - Standard Efficiency - CG/AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 19 - Split Shipment - Standard Efficiency - CG/AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Table 20 - Contact Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Table 21 - Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table 22 - Ethernet Interface Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 23 - Communication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 24 - Read Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Table 25 - Write Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Table 26 - Scope of Delivery of Upper Communication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Table 27 - Cable Diagram (RS-422/RS485) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Table 28 - Communication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Table 29 - Rotary Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Table 30 - Liquid Level Gauges (Sight Glass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Table 31 - Failure List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Table 32 - Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Table 33 - Changeover Valve Operation for Chiller with Evaporator Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Table 34 - Changeover Valve Operation for Chillers with Additional Heat Exchanger Heating . . . . . . . . . . . . . . 120
Table 35 - Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Table 36 - Purge Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Table 37 - YHAU-CG/AN/H Direct Fired Chiller-Heater With Additional Heat Exchanger
Heating Flow Diagram - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Table 38 - Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Table 39 - Lifespan of Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Table 40 - Tendency of Generation of Scales and Corrosion by Quality of Cooling Water . . . . . . . . . . . . . . . . . . 147
Table 41 - Chilled/Hot and Cooling Water Quality Control (Maximum Concentrations) . . . . . . . . . . . . . . . . . . . . 148
Table 42 - Wet Storage Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Table 43 - Dry Storage Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Table 44 - Troubleshooting the High Temperature Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Table 45 - Refrigerant Over-cooling Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Table 46 - Chilled or Hot Water Time Out or Cooling Water Time Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Table 47 - Pump Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Table 48 - Low Cooling Water Inlet Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Table 49 - Abnormal Control Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Table 50 - CPU Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Table 51 - Chilled or Hot Water Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Table 52 - Pump(s) Overloaded or Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Table 53 - Troubleshooting Performance Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Table 54 - Vacuum Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Table 55 - Abnormal Solution and Refrigerant Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Table 56 - Insufficient Vacuum Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

FORM 155.32-ICOM2.EN.UL SECTION 1 - GENERAL CHILLER-HEATER INFORMATION AND SAFETY
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 11
SECTION 1 - GENERAL CHILLER-HEATER
INFORMATION AND SAFETY
INTRODUCTION
YORK YHAU-CGN/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/hot water pump, cooling water pump, cooling tower,
valves, strainers, pressure gauges and thermometers according to the water quality
information contained in SECTION 7 – 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 guid-
ance 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 mainte-
nance 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 in-
stallation, commissioning, operation, or maintenance resulting from a failure to follow
the procedures and instructions detailed in this manual.
WARRANTY
Johnson Controls warrants YHAU-CGN/H chiller-heaters in accordance with the Limited
Warranty Engineered Systems Equipment procedure. Refer to the Limited Warranty (Form
50.05-NM2) for more information.
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.
WARNING: External wiring, unless specified as an optional connection in the manufac-
turer’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 in-
stalled inside the micro panel. All wiring must be in accordance with Johnson Controls’
published specifications and must be performed only by a qualified electrician. John-
son 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 prop-
erty or personal injury.

SECTION 1 - GENERAL CHILLER-HEATER INFORMATION AND SAFETY FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
12 JOHNSON CONTROLS
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 per-
formed 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 1995-2015 Standard for Safety Heating and Cooling Equipment
• UL 508A Industrial Control panel
• NFPA70 National Electrical Code
•NFPA79 Electrical Standard for Industrial Machinery
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 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.
HIGH TEMPERATURE AND PRESSURE CLEANING
High temperature and pressure cleaning methods (such as steam cleaning) should not be
used on any part of the pressure system as this may cause operation of the pressure relief
device(s). Detergents and solvents, which may cause corrosion should also be avoided.
LD27461
Turn counter clockwise

FORM 155.32-ICOM2.EN.UL SECTION 1 - GENERAL CHILLER-HEATER INFORMATION AND SAFETY
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 13
SAFETY LABELS
For safe operation, read the
instructions first.
Warning: This machine may start
automatically without prior warning.
Caution: 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: Risk of fire.
Warning: Risk of gas poisoning.
Warning: Risk of electrical arc.

FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
14 JOHNSON CONTROLS
THIS PAGE INTENTIONALLY LEFT BLANK

FORM 155.32-ICOM2.EN.UL SECTION 2 - PRODUCT DESCRIPTION
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 15
SECTION 2 - 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 er.
See Figure 1 on page 16.
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 an almost complete
vacuum.
CHILLER-HEATER COMPONENTS
The absorption chiller-heater consists of the following components:
• evaporator
• absorber
• condenser
• generator
• 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 metric units. For details of the control panel, see SECTION 6 –
OPERATION.
The unit is also equipped with two methods to start and stop operations:
• touch panel
• external signal
NOTE: Confirm the main power switch is within 6.56 feet (2 meters) of the ground. If not,
please install the operation platform.
WARNING: Turn off the power supply by the handle breaker when opening the control
panel.

SECTION 2 - PRODUCT DESCRIPTION FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
16 JOHNSON CONTROLS
Figure 1 - YHAU-CGN/H-120-300EX(H/S) and 360EX - 1600EXW3(H/S)
A
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C
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FORM 155.32-ICOM2.EN.UL SECTION 2 - PRODUCT DESCRIPTION
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 17
HOW IT WORKS (DIRECT FIRED UNITS)
The double effect (direct fired) absorption chiller-heater uses water as the refrigerant and LiBr as the absorbent. The vapor
pressure of the LiBr 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.
Figure 2 - Two Step Direct Fired Absorption Chiller-Heater Cycle Diagram
(Cooling Mode)
NOTE: Temperatures and pressures on this graphic are representative; actual values may differ.
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, the refrigerant
gradually vaporizes. The refrigerant remaining in a liquid state at the bottom drains into the refrigerant tank and is pumped back
up to the top of the tube bundle where the process is repeated.
P11
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LG4
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LD19981_UL
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Evaporator
(Upper)
Absorber
(Upper)
Absorber
(Lower)
Evaporator
(Lower)
95˚F86˚F
44˚F
53.6˚F
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High
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LowTemp.
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Solution
Circulation
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SprayPump
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CoolingWater
Refrigerant
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ConcentratedSolution
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Chilled
Water
Outlet
Chilled
WaterInlet

SECTION 2 - PRODUCT DESCRIPTION FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
18 JOHNSON CONTROLS
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, will eventually stop as the solution temperature will 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 increasingly 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.
The following section describes the unique 2-step evaporator-absorber design of the
YHAU-CGN/H direct fired absorption chiller-heater.
TWO-STEP EVAPORATOR – ABSORBER
The evaporator, as well as the absorber, is split into two sections. This design, similar to a
series-counter-flow chiller-heater arrangement along with the parallel flow cycle, enables
lower LiBr solution concentrations. This reduces pressure, the potential for corrosion, the
risk of crystallization, and improves efficiency in conjunction with other advanced
components described later in this section.
The two evaporators are in series with respect to the chilled water flow through the tubes.
In other words, the chilled water flows through the lower evaporator tubes first and then to
the upper evaporator tubes. Each evaporator operates at a slightly different temperature
and pressure. The refrigerant in the lower evaporator boils at a slightly higher temperature
than in the upper evaporator, consequently cooling the chilled water in two steps.
The two absorber sections are split as well, with the strong solution first entering the top of
the uppermost absorber and flowing down through the top absorber bundle. It then flows
into the top of the lower absorber section. The strong solution entering the upper absorber
takes advantage of its lower vapor pressure allowing the upper evaporator to operate at a
lower pressure and temperature.
When the LiBr solution enters the lower absorber section it is somewhat diluted from the
refrigerant vapor that boiled off in the upper evaporator. At this lower concentration the
solution vapor pressure would normally not be sufficient to provide an evaporator pressure
low enough to satisfy the leaving chilled water design. However, the lower evaporator is the
first step of the chilled water cooling cycle, and the dilute solution’s vapor pressure is
adequate to maintain the required temperature and pressure in the lower evaporator.
The cooling tower water enters the lower absorber section first, keeping the vapor pressure
of the weaker solution as low as possible.
Both the refrigerant (water) and LiBr dispersion system are gravity fed and constructed of
stainless steel.
LD19880_a3
LG4
Evaporator
(Upper)
Absorber
(Upper)
Absorber
(Lower)
Evaporator
(Lower)
Concentrated
LiBr
Refrigerant
Chilled
Water
Out
Chilled
Water
In

FORM 155.32-ICOM2.EN.UL SECTION 2 - PRODUCT DESCRIPTION
ISSUE DATE:1/10/2018
JOHNSON CONTROLS 19
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 heat exchangers.
The relatively high temperature solution streams from the two generators are used to pre-
heat 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 high temperature generator has the unique liquid tube design in which 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 which 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 in which the exhaust gas is inside the tubes while
the LiBr solution is on the shell side. Being more efficient, the exhaust gas leaving
temperature is lower than the smoke tube design.
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, therefore 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 condenseses into hot
refrigerant liquid and is sent to the condenser via 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.
Concentrated
Solution In
Dilute
Solution In
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SECTION 2 - PRODUCT DESCRIPTION FORM 155.32-ICOM2.EN.UL
ISSUE DATE:1/10/2018
20 JOHNSON CONTROLS
CONDENSER
The cooling water from the absorber section enters into the condenser section. This helps
condense the refrigerant vapors produced in the LTG as well as 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). 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 only 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 typically 64.3% LiBr by weight. LiBr begins to crystallize
at 110°F (43.3°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 will start to solidify (crystallize).
Crystallization will occur in the solution heat exchanger and sometimes even in the
generator. It will also happen in pipes 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%).
Since the solution temperature in the generator is normally high enough in most load
conditions, no crystallization will occur 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, since the solution temperature will eventually equal the surrounding ambient
temperature. All units employ some sort of dilution cycle, which 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 within the chiller-heater will be below 45% LiBr by weight and will
have no tendency to crystallize at normal ambient temperatures.
WHY DOES CRYSTALLIZATION OCCUR?
The most common reason for crystallization is due to power failures. If a chiller-heater is
running at full load and power is interrupted for a sufficient length of time, the concentrated
solution in the high side of the unit (Condenser/Generator Section) will eventually cool
down. Since no dilution cycle was performed, the solution concentration in some areas of
the unit may still be relatively high. If the temperature of this concentrated solution is
allowed to fall low enough, the solution will reach its crystallization point. Plant room
temperature, insulation quality, and the solution concentration all play a part in determining
how long it will take before the unit will crystallize. See SECTION 7 – MAINTENANCE for
information on water quality control and crystallization. The Duhring Diagram / PTX Chart
shows the specific temperatures and pressures of the crystallization area. See the Duhring
Diagram / PTX Chart (°F) on page 156 and Figure 74 on page 157.
LD19980_a6
Condenser
Cooling
Water
Outlet
Condensed
Refrigeration