York YHAU-CL Series Owner's manual

SINGLE EFFECT HOT WATER
ABSORPTION CHILLER
INSTALLATION, OPERATION, MAINTENANCE NEW RELEASE Form 155.30-ICOM2.EN.UL(1218)
Issue Date:
December 21, 2018
LD22981
LD22981
Model YHAU-CL / CH
30 - 2000 TON
105 - 7043 kW

JOHNSON CONTROLS
2
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents 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, instal-
lation, 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
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
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 in-
dividual 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 hazard-
ous situation which will result in possible
injuries or damage to equipment if proper
care is not taken.
Caution: Identies 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.
WARNING: External wiring, unless specied 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 specications and must be performed only by a
qualied electrician. Johnson Controls will NOT be responsible for damage/problems resulting from
improper connections to the controls or application of improper control signals. Failure to follow this
warning will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
MANUAL DESCRIPTION FORM NUMBER
Absorption Chiller Long Term Storage 50.20-NM11
Long-Term Storage Checklist - Absorption Chiller 50.20-CL10
Long-Term Storage Requirements - General 50.20-NM10
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for contin-
uous 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 man-
ual or product owner.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, 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 in-
formation and any other changes in spelling, grammar
or formatting are not included.
ASSOCIATED LITERATURE

JOHNSON CONTROLS
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FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
NOMENCLATURE
YHAU C L 500 EXE T LL
NOMINAL
CAPACITY
HEAT SOURCE
L: Low Temp. hot water
H: High Temp. hot water
UNIT
York Absorption
Chiller DESIGN
SYMBOL
MODEL SERIES NAME
EXE: 30 ~ 500 RT nominal
capacity
EXW2S: 630 ~ 1000 RT nomi-
nal capacity
EXW4S: 1120 ~ 2000 RT
nominal capacity
GENERATOR DESIGN
None: Standard
T: Special
LOW TEMP.
CHW
L: 33.8 °F CHW
LL: 23 °F CHW

JOHNSON CONTROLS 5
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER 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 Components........................................................................................................................................15
Control Panel..................................................................................................................................................15
How It Works ..................................................................................................................................................16
Two Step Evaporator-Absorber .....................................................................................................................17
Solution Heat Exchanger................................................................................................................................17
Generator .......................................................................................................................................................18
Condenser......................................................................................................................................................18
Crystallization .................................................................................................................................................18
Why Does Crystallization Occur?...................................................................................................................19
SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY..................................................... 21
Inspection .......................................................................................................................................................22
Hoisting the machine......................................................................................................................................23
Moving the Machine on Rollers ......................................................................................................................23
Jacking the machine.......................................................................................................................................25
Structural Support and Installation .................................................................................................................27
Indoor and Outdoor Installation ......................................................................................................................27
Electrical.........................................................................................................................................................27
Precautions for Use .......................................................................................................................................27
Leak testing ....................................................................................................................................................28
Electrical Shock Cautions...............................................................................................................................28
Vibration and Isolation Details........................................................................................................................29
Rupture Disk And Relief Piping ......................................................................................................................30
Rupture Disk Discharge Piping Material................................................................................................30
Rupture Disk Discharge Piping Construction ........................................................................................30
Rupture Disk Discharge Piping Sizing ..................................................................................................30
Hot Insulation and Cold Insulation Procedure ................................................................................................36
SECTION 4 - TECHNICAL DATA ...........................................................................................................................39
Load Points for EXE and EXW Units - CL Models ........................................................................................43
Load Points for EXE and EXW Units - CH Models.........................................................................................45
Upper Communication Specification ..............................................................................................................81
Upper Communication System Conguration .......................................................................................81
Scope of Delivery ..................................................................................................................................82
Connection Port for Ethernet Communication....................................................................................... 82
Communication Specication ................................................................................................................83
Communication Data.............................................................................................................................83
User-Created ........................................................................................................................................84
4 Wire Type Cable Diagrams ................................................................................................................86

JOHNSON CONTROLS
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FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
TABLE OF CONTENTS (CONT'D)
SECTION 5 - COMMISSIONING ............................................................................................................................89
General Guidelines for Use ............................................................................................................................89
Before Operation ...................................................................................................................................89
Precautions for the Use of Water ...................................................................................................................90
Chilled Water Outlet Temperature Controller..................................................................................................90
Liquid Level Gauges.......................................................................................................................................90
Start the Chiller...............................................................................................................................................90
Stop the Chiller...............................................................................................................................................91
SECTION 6 – OPERATION ..................................................................................................................................103
YHAU-CL/CH Control Center ......................................................................................................................103
Common Items .............................................................................................................................................103
Change Numeric Values...............................................................................................................................104
Operating Status ..........................................................................................................................................105
Failure ..........................................................................................................................................................120
Alarm ............................................................................................................................................................120
Control Parameter ........................................................................................................................................124
Valve Operation............................................................................................................................................125
Date and Time ..............................................................................................................................................125
Select Unit ....................................................................................................................................................126
Select Language ..........................................................................................................................................126
Safety Switches............................................................................................................................................126
SECTION 7 – MAINTENANCE.............................................................................................................................129
Valve Inspection ...........................................................................................................................................129
Solenoid Valves............................................................................................................................................129
Pump Shut Off Valves ..................................................................................................................................129
Air Purge Valves And Drain Valves For Chilled Water, Cooling Water, And Hot Water ................................ 129
Purge Valves ................................................................................................................................................129
Start the Chiller After It Has Been Stopped for A Long Period .....................................................................130
Checks Before Operation Starts..........................................................................................................130
Checks After Operation Starts.............................................................................................................130
Purge Procedure ..........................................................................................................................................130
Capacity Check Method of Vacuum Pump...................................................................................................130
Manual Method To Purge Air Directly From Absorber ..................................................................................131
Manual Method To Purge Non-Condensable Gas From Purging Tank ........................................................ 132
Automatic Method To Purge Non-Condensable Gas From Purging Tank ....................................................132
Refrigerant Refining Method ........................................................................................................................135
Manual Refrigerant Blowdown and Diluting Method ....................................................................................135
Decrystallization Method ..............................................................................................................................136
Indications of Crystallization................................................................................................................136
Decrystallization ..................................................................................................................................136
Precautions for De-crystallization........................................................................................................137

JOHNSON CONTROLS 7
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
Maintenance Items .......................................................................................................................................137
Refrigerant Pump Manual Stop ...........................................................................................................141
Purge Manual Stop and Start ..............................................................................................................141
Lifespan for Various Parts ............................................................................................................................141
Water Quality Control ...................................................................................................................................143
Chemical Water Treatment...........................................................................................................................143
Replacement of Water .................................................................................................................................143
Treatment for Long Stoppage of the Absorption Chiller ..............................................................................143
Chemical Treatment ....................................................................................................................................143
Flow Speed in Tubes ...................................................................................................................................144
Storage Method of the Chiller.......................................................................................................................144
Wet Storage Method ...........................................................................................................................144
Dry Storage Method ............................................................................................................................145
Precautions Against External Damage.........................................................................................................145
SECTION 8 – TROUBLESHOOTING...................................................................................................................155
Troubleshooting Performance Issues...........................................................................................................159
Vacuum Pump ..............................................................................................................................................160
Abnormal Solution and Refrigerant Levels...................................................................................................161
Insufficient Vacuum Levels ...........................................................................................................................162
Actions to Take Against Power Failure .........................................................................................................162
SECTION 9 - DECOMMISSIONING, DISMANTLING, AND DISPOSAL .............................................................165
TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS
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FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
LIST OF FIGURES
FIGURE 1 - YHAU-CL/CH Unit Components..........................................................................................................15
FIGURE 2 - Single Effect Hot Water Absorption Chiller Cycle Diagram..................................................................16
FIGURE 3 - Hoisting Procedure (4 Point Lifting).....................................................................................................23
FIGURE 4 - Moving the Machine on Rollers ..........................................................................................................24
FIGURE 5 - Fitting TIR-rollers to the Machine.........................................................................................................24
FIGURE 6 - Jack-up Procedures.............................................................................................................................25
FIGURE 7 - Jack-up procedures .............................................................................................................................26
FIGURE 8 - Vibration and Isolation Details .............................................................................................................29
FIGURE 9 - Location Of Rupture Disk ....................................................................................................................31
FIGURE 10 - EXE Series Dimensions (Split Shipment)..........................................................................................32
FIGURE 11 - EXW Series Dimensions (Split Shipment) .........................................................................................33
FIGURE 12 - YHAU-CL/CH-30 - 500EXE Nozzle Locations ..................................................................................34
FIGURE 13 - YHAU-CL/CH-630EXW2S-2000EXW4S Nozzle Locations............................................................... 35
FIGURE 14 - Hot/Cold Insulation - EXE Models .....................................................................................................37
FIGURE 15 - Hot/Cold Insulation - EXW Models ....................................................................................................37
FIGURE 16 - Exterior of Control Panel....................................................................................................................38
FIGURE 17 - Interior of Control Panel.....................................................................................................................38
FIGURE 18 - CL-30EXE-500 EXE ..........................................................................................................................43
FIGURE 19 - YHAU-CL Load Points for EXE and EXW Units ................................................................................43
FIGURE 20 - YHAU-CH30EXE-500EXE.................................................................................................................45
FIGURE 21 - YHAU-CH630EXW2S-2000EXW4S ..................................................................................................45
FIGURE 22 - Power Wiring .....................................................................................................................................58
FIGURE 23 - Power Wiring .....................................................................................................................................60
FIGURE 24 - PLC Input Wiring................................................................................................................................62
FIGURE 25 - PLC Input Wiring................................................................................................................................64
FIGURE 26 - PLC output wiring ..............................................................................................................................66
FIGURE 27 - PLC Output Wiring.............................................................................................................................68
FIGURE 28 - Display/Analog Input Wiring...............................................................................................................70
FIGURE 29 - Display/Analog Input Wiring...............................................................................................................72
FIGURE 30 - Display/Analog Output Wiring............................................................................................................74
FIGURE 31 - PLC and Display Wiring.....................................................................................................................75
FIGURE 32 - PLC Input Wiring................................................................................................................................76
FIGURE 33 - External Connection Terminal Details................................................................................................78
FIGURE 34 - Remote Transmission Signal ............................................................................................................. 79
FIGURE 35 - Signal Terminal Transition Wiring ......................................................................................................80
FIGURE 36 - Upper Communication System Conguration....................................................................................81
FIGURE 37 - Connection Detail for D-sub 9 pin......................................................................................................84
FIGURE 38 - 2-Wire 1:1 Connection with User-Created Cable...............................................................................85
FIGURE 39 - 2-Wire n:1 Connection with User-Created Cable...............................................................................85
FIGURE 40 - 4-Wire 1:1 Connection With User-Created Cable..............................................................................86
FIGURE 41 - 4-Wire n:1 Connection With User-Created Cable..............................................................................86
FIGURE 42 - Sample Sound Testing for YHAU-CL/CH Chiller ...............................................................................88
FIGURE 43 - Cooling Start Diagram - START.........................................................................................................92
FIGURE 44 - Cooling Start Diagram - STOP ..........................................................................................................92
FIGURE 45 - Sequential Operation Flowchart ........................................................................................................93
FIGURE 46 - Stop the Absorption Chiller Flowchart................................................................................................93
FIGURE 47 - Main Screen.....................................................................................................................................105
FIGURE 48 - DATA Screen ...................................................................................................................................107
FIGURE 49 - Solution Analysis / Control Panel Parts Replacement Screen.........................................................109
FIGURE 50 - Solution Pump Solution Pump Overhaul / Refrigerant Pump Overhaul Screen .............................. 110
FIGURE 51 - Trend Screen ................................................................................................................................... 111
FIGURE 52 - Hourly Operation History Screen..................................................................................................... 112
FIGURE 53 - Minutely Operation History Screen.................................................................................................. 114
FIGURE 54 - Failure Activation History Screen..................................................................................................... 116
FIGURE 55 - Alarm History Screen....................................................................................................................... 118

JOHNSON CONTROLS 9
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
FIGURE 56 - Failure and Alarm Screen ................................................................................................................120
FIGURE 57 - Setting Screen .................................................................................................................................124
FIGURE 58 - Location of Manual Valve in Purge System .....................................................................................131
FIGURE 59 - Process and Instrumentation Diagram for EXE Series Chiller.........................................................133
FIGURE 60 - Purge Unit........................................................................................................................................134
FIGURE 61 - Chilled Water and Cooling Water System........................................................................................149
FIGURE 62 - Hot Water System............................................................................................................................150
FIGURE 63 - Duhring Diagram / PTX Chart (°F)...................................................................................................151
FIGURE 64 - Duhring Diagram / PTX Chart (°C) ..................................................................................................152
FIGURE 65 - Specic Gravity - Concentration (°F) ...............................................................................................153
FIGURE 66 - Specic Gravity - Concentration (°C)...............................................................................................154
FIGURE 67 - Troubleshooting Sequence Flow Chart............................................................................................163
FIGURE 68 - Actions to Take Against Power Failure.............................................................................................164
LIST OF FIGURES (CONT'D)

JOHNSON CONTROLS
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FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
LIST OF TABLES
TABLE 1 - Split Shipment Dimensions - EXE Series .............................................................................................. 32
TABLE 2 - Split Shipment Dimensions - EXW Series .............................................................................................33
TABLE 3 - Nozzle Arrangements 30 - 500EXE.......................................................................................................34
TABLE 4 - YHAU - CL/CH 630EXW2s-200EXW4S................................................................................................35
TABLE 5 - Insulating Material and Thickness .........................................................................................................36
TABLE 6 - Points Requiring Hot or Cold Insulation.................................................................................................36
TABLE 7 - Typical Operational Range ....................................................................................................................39
TABLE 8 - Weights..................................................................................................................................................40
TABLE 9 - Outline Dimensions ...............................................................................................................................41
TABLE 10 - Physical Data.......................................................................................................................................42
TABLE 11 - Load Points: EXE and EXW Units FOR CL .........................................................................................44
TABLE 12 - Load Points: EXE and EXW Units FOR CH ........................................................................................46
TABLE 13 - Electrical Data .....................................................................................................................................48
TABLE 14 - Contact Specifications .........................................................................................................................80
TABLE 15 - Scope of Delivery ................................................................................................................................82
TABLE 16 - Ethernet Interface Specification...........................................................................................................82
TABLE 17 - Communication Specifications ............................................................................................................83
TABLE 18 - Read Command ..................................................................................................................................83
TABLE 19 - Write Command...................................................................................................................................84
TABLE 20 - Scope of Delivery of Upper Communication System........................................................................... 84
TABLE 21 - Cable Diagram (RS-422/RS-485)........................................................................................................85
TABLE 22 - Communication Specification - Modbus/RTU......................................................................................87
TABLE 23 - Rotary Pump Rotation .........................................................................................................................89
TABLE 24 - Liquid Level Gauges............................................................................................................................90
TABLE 25 - Failure List .........................................................................................................................................121
TABLE 26 - Alarm List...........................................................................................................................................122
TABLE 27 - Safety Switches .................................................................................................................................127
TABLE 28 - Solenoid Valves .................................................................................................................................129
TABLE 29 - Maintenance and Inspection .............................................................................................................138
TABLE 30 - Lifespan of Common Parts ................................................................................................................142
TABLE 31 - Wet Storage Method..........................................................................................................................146
TABLE 32 - Dry Storage Method ..........................................................................................................................146
TABLE 33 - Tendency of Generation of Scales and Corrosion by Quality of Cooling Water ............................... 147
TABLE 34 - Chilled Water, Cooling Water, and Hot Water Quality Control ...........................................................148
TABLE 35 - Troubleshooting the High Temperature Generator ............................................................................156
TABLE 36 - Chilled Water Overcooling or Refrigeration Overcooled....................................................................156
TABLE 37 - Chilled Water Suspension .................................................................................................................157
TABLE 38 - Abnormal Pump Operation ................................................................................................................157
TABLE 39 - Chilled Water Time out or Cooling Water Time Out...........................................................................157
TABLE 40 - Pump Interlocks.................................................................................................................................158
TABLE 41 - Low Cooling Water Inlet Temperature ...............................................................................................158
TABLE 42 - Abnormal Control Sensor ..................................................................................................................158
TABLE 43 - CPU Abnormal...................................................................................................................................158
TABLE 44 - Troubleshooting Performance Issues................................................................................................159
TABLE 45 - Vacuum Pump Troubleshooting ........................................................................................................160
TABLE 46 - Abnormal Solution and Refrigerant Levels ........................................................................................161
TABLE 47 - Insufficient Vacuum Levels ................................................................................................................162

JOHNSON CONTROLS 11
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/15/2018
1
INTRODUCTION
YORK YHAU-CL/CH Absorption chillers are manu-
factured to the highest design and construction stan-
dards to ensure high performance, reliability, and
adaptability to all types of air conditioning installa-
tions.
This chiller is for air conditioning or cooling a manu-
facturing process. Use this chiller after installing the
chilled water pump, cooling water pump, hot water
pump, cooling tower, hot water valve, valves, strain-
ers, pressure gauges, thermometers, and so on,. accord-
ing to the water quality information contained in SEC-
TION 7 – MAINTENANCE .
ABOUT THIS MANUAL
This manual and any other document supplied with
the unit are the property of Johnson Controls which re-
serves 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:
• Includes suggested best working practices and
procedures, which are issued for guidance only,
and they do not take precedence over the above
stated individual responsibility and/or local safety
regulations.
• Contains all the information required for correct
installation and commissioning of the unit, to-
gether with operating and maintenance instruc-
tions.
• Should be read thoroughly before attempting to
operate or service the unit.
• Contains detailed procedures, including installa-
tion, commissioning, and maintenance tasks that
must only be performed by suitably trained and
qualied personnel.
The manufacturer will not be liable for any injury of
damage caused by incorrect installation, commission-
ing, operation, or maintenance resulting from a failure
to follow the procedures and instructions detailed in
this manual.
WARRANTY
Johnson Controls warrants YHAU-CL/CH chillers
in accordance with the Limited Warranty Engineered
Systems Equipment procedure. Refer to Limited War-
ranty (Form 50.05-NM2).
Johnson Controls warrants all equipment and materi-
als 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 labor or extended warranty has been pur-
chased 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 fail-
ure 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 identi-
fication 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 fol-
lowing conditions must be satisfied:
• The initial start of the unit must be carried out
by trained personnel from an authorized Johnson
Controls Field Service Ofce.
• Only genuine YORK approved spare parts, oils,
solutions, chemicals, and refrigerants must be used.
• All of the scheduled maintenance operations de-
tailed in this manual must be performed at the
specied times by suitably trained and qualied
personnel.
Failure to satisfy any of these conditions will auto-
matically void the warranty. Refer to Limited Warranty
(Form 50.05-NM2) for complete details.
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY

JOHNSON CONTROLS
12
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/15/2018
QUALITY ASSURANCE
Units comply with the following directives:
• GB/T 18431-2014 Steam and Hot Water Lithium
Bromide Absorption Chiller
• UL 1995 2011 Ed.4 + R: 03Oct2014 Standard for
Safety Heating and Cooling Equipment
• UL 508A Industrial Control Panel
• NFPA70 National Electrical Code
• NFPA79 Electrical Standard for Industry Machine
• Pressure vessel will follow ASME
The unit must be grounded. No installation or main-
tenance 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 at-
tempted. No attempt should be made to gain access to
the control panel or electrical enclosures during normal
operation of the unit.
Components may also have sharp edges. Reasonable
care should be taken when working in contact with
any components to avoid risk of minor abrasions and
lacerations.
EMERGENCY SHUTDOWN
In case of emergency, the control panel is fitted with
an incoming supply circuit breaker with a red handle
as shown below, which can be used as the emergency
stop for the device. Turn the handle counter clockwise
to shut down the chiller.
HIGH TEMPERATURE AND PRESSURE
CLEANING
Do NOT use high temperature and pressure cleaning
methods (for example, steam cleaning) on any part of
the pressure system. This may cause operation of the
pressure relief devices. Detergents and solvents, which
may cause corrosion, should also be avoided.
LD27461a

JOHNSON CONTROLS 13
SECTION 1 – GENERAL CHILLER INFORMATION AND SAFETY
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
2
SAFETY LABELS
LD15421c
For safe operation, read the instructions
first.
Warning: This machine may start auto-
matically without prior warning.
Caution: Hot surface.
Warning: Safety relief valve may dis-
charge gas or liquid without prior warn-
ing.
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.
MATERIAL SAFETY DATA SHEET
MSDSs specify proper procedures for handling and
working with applicable chemicals, including items
such as physical data, toxicity, health effects, first aid,
storage, disposal, and spill procedures.
NOTE: Be sure to read the MSDS be-
fore working with the equipment or the
operating uids.

JOHNSON CONTROLS
14
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 15
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
2
The principle of refrigeration is the exchange of heat
and, in absorption liquid chilling, there are four basic
heat exchange surfaces: the evaporator, the absorber,
the generator, and the condenser.
Like any refrigeration system, an absorption chiller
uses evaporation and condensation to remove heat. The
single effect absorption cycle uses deionized water as
the refrigerant and lithium bromide (LiBr) as the ab-
sorbent. The entire process occurs in almost a complete
vacuum.
CHILLER COMPONENTS
The absorption chiller unit consists of the following
components:
• evaporator
• absorber
• condenser
• generator
• solution heat exchanger to heighten the cycle ef-
ciency and piping to connect them
• pumps to circulate the refrigerant and solution in
the cycle
• purge unit to purge non-condensable gas from the
machine
SECTION 2 – PRODUCT DESCRIPTION
CONTROL PANEL
The absorption chiller comes with a factory mounted
and pre-wired control system. The control panel en-
closure is equipped with a hinged access door with
lock and key. The control panel includes a touch 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
LD22981
FIGURE 1 - YHAU-CL/CH UNIT COMPONENTS
A
B
C
D
E
F G
H
I
J
K
L
NOTE: Conrm the main power switch
is within 6.56 feet (2 meters) of the
ground. If not, please install the opera-
tion platform.
WARNING: Turn off the power supply
by the handle breaker when opening the
control panel.
ITEM DESCRIPTION
ACooling water inlet
BChilled water inlet
CEvaporator
DAbsorber
EChilled water outlet
FCooling water outlet
GHot water outlet
HCondenser
IGenerator
JHot water inlet
KSolution pump
LDisplay
MControl panel
M

JOHNSON CONTROLS
16
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
SECTION 2 – PRODUCT DESCRIPTION
HOW IT WORKS
The single effect (hot water driven) absorption chiller
uses deionized water as the refrigerant and lithium bro-
mide (LiBr) solution as the absorbent.
The vapor pressure of the lithium bromide solution is
lower than the vapor pressure of the refrigerant. The
vapor pressure of the LiBr solution is directly related
to the amount of refrigerant (water) present in the solu-
tion with the LiBr and the solution temperature.
FIGURE 2 - SINGLE EFFECT HOT WATER ABSORPTION CHILLER CYCLE DIAGRAM
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JOHNSON CONTROLS 17
SECTION 2 – PRODUCT DESCRIPTION
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
2
TWO STEP EVAPORATOR-ABSORBER
The evaporator and the absorber are split into two sec-
tions. This design allows the cycle concentration to be
lower than a conventional absorber / evaporator. The
lower concentrations mean the unit is more reliable,
operates with increased efficiency, has a lower corro-
sion potential, and uses lower temperature hot water in
the generator.
Chilled water flows through both evaporator sections.
It enters the lower evaporator tubes first. It then moves
to and through the upper evaporator tubes before it
leaves the chiller.
Each evaporator operates at a slightly different tem-
perature and pressure. The refrigerant in the lower
evaporator boils at a slightly higher temperature than
in the upper evaporator. The chilled water is cooled in
two steps.
The absorber is split into two sections as well. A strong
solution enters the top of the upper absorber. It flows
down through the upper absorber bundle.
The upper bundle operates at a lower vapor pressure.
As a result, the upper evaporator can operate at a lower
pressure and temperature.
The solution flows into the top of the lower absorber
section. When the LiBr solution enters the lower Ab-
sorber section it is already diluted by the refrigerant
vapor that boiled off in the upper evaporator. Since the
lower evaporator is the first step of the chilled water
cooling, the dilute solution vapor pressure is adequate
to maintain the lower evaporator at the required tem-
perature and pressure.
The cooling tower water enters the lower absorber sec-
tion first, keeping the vapor pressure of the weaker so-
lution as low as possible.
LD19939a1
LD19839a1
Evaporator
(Upper)
Evaporator
(Lower)
Absorber
(Lower)
Absorber
(Upper)
LiBr
Refrigerant
Chilled
Water
Out
Chilled
Water
In
Cooling
Water In
Refrigerant
LiBr
Chilled
Water
Out
Cooling
Water In
Chilled
Water
In
SOLUTION HEAT EXCHANGER
The dilute (weak) LiBr solution leaving the lower
absorber section is pumped to the generator section
through a solution to solution heat exchanger. It is pre-
heated prior to entering the generator section. Such
pre-heating of the dilute solution reduces the driving
heat source requirement in the generator and also helps
to cool down the concentrated (strong) solution before
entering the upper absorber section.
LD19939a2
LD19839a2
(P2)
Solution Heat
Exchanger
Concentrated
Solution
Dilute
Solution
Concentrated
Solution
Dilute
Solution

JOHNSON CONTROLS
18
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
SECTION 2 – PRODUCT DESCRIPTION
GENERATOR
The generator section is of a falling film design. Such
a design ensures substantially reduced wear and tear
at the tube supports compared to the conventional
flooded design. The falling film design ensures supe-
rior heat transfer and extended tube life. It also reduces
the quantity of LiBr solution thereby ensuring reduced
startup time from a cold start. The stainless steel tubes
are arranged in a series counter flow arrangement al-
lowing for design with lower leaving hot water tem-
peratures.
The pre-heated dilute solution enters the generator on
the top of the generator tubes where it is heated by the
hot water (driving heat source) flowing through the
stainless steel tubes. The refrigerant (water) vapors mi-
grate to the condenser, leaving behind a concentrated
(strong) LiBr solution, which is then cooled before be-
ing distributed in the upper absorber section.
LD19939a3
LD19839a3
Hot Water Out
Condenser
Generator
Dilute Solution In
Hot Water In
Concentrated
Solution Out Dilute Solution In
Hot Water In
Concentrated Solution Out
Hot Water Out
CONDENSER
The refrigerant vapors leaving the generator condense
into liquid refrigerant in the condenser section, using
cooling (condenser) water. The liquid refrigerant water
is then distributed first in the lower evaporator section.
LD19939a4
LD19839a4
Condenser
Cooling Water Out
Condensed
Refrigerant Out
Condensed Refrigerant Out
Cooling Water Out
CRYSTALLIZATION
All absorption chillers that use lithium bromide 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 exam-
ple, the solution concentration in the generator of a
single stage absorption unit is typically 64.3% lithium
bromide by weight. LiBr solutions begin to crystallize
at 110°F.
Crystallization happens when the LiBr solution tem-
perature drops too low or the concentration is too high.
The LiBr solution becomes like slush. At this point the
LiBr solution can't absorb any more water and will
start to solidify (crystallize).
Crystallization occurs in the solution heat exchanger.
In addition, it may happen in the generator. It also hap-
pens in pipes that are not well insulated and are located
in rooms where the temperature can affect the solution
moving through the pipes.
You can prevent crystallization by making sure you
keep the solution temperature high and the concentra-
tion at the optimum percentage of less than 64%.

JOHNSON CONTROLS 19
SECTION 2 – PRODUCT DESCRIPTION
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
2
Since the solution temperature in the generator is nor-
mally high enough that no crystallization will occur as
long as the higher temperature is maintained. Before
the unit is shut down, make sure the solution is suffi-
ciently diluted in all areas of the unit to prevent crystal-
lization during the off cycle. Remember, the solution
temperature will eventually become equal to the ambi-
ent temperature of the room.
To prevent crystallization all units employ a dilution
cycle. As long as the unit is allowed to dilute itself dur-
ing an orderly shutdown sequence, the unit should be
able to sit idle at fairly low plant room ambient temper-
atures without any threat of crystallization. Typically,
after a dilution cycle, the average solution concentra-
tion within the chiller will be below 45% lithium bro-
mide by weight. Although the crystallization line on
Figure 64 on page 152 does not extend that far, you
can see that the solution at 45% concentration will not
have a tendency to crystallize at normal ambient tem-
peratures.
WHY DOES CRYSTALLIZATION OCCUR?
The most common reason for crystallization is power
failure. If a chiller is running at full load and power is
interrupted for a sufficient length of time, the concen-
trated solution in the high side of the unit will eventu-
ally cool down. Since no dilution cycle was performed,
the solution concentration in some areas of the unit will
still be high. If the temperature of this concentrated so-
lution is allowed to fall enough, the solution will reach
its crystallization point. Plant room temperature, insu-
lation quality and the solution concentration determine
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 Figure 64
on page 152 and Figure 64 on page 152.

JOHNSON CONTROLS
20
FORM 155.30-ICOM2.EN.UL
ISSUE DATE: 12/21/2018
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