York YHAU-CE Owner's manual

DOUBLE-EFFECT EXHAUST GAS
ABSORPTION CHILLER-HEATER
INSTALLATION, OPERATION, MAINTENANCE NEW RELEASE Form 155.35-ICOM2.EN.CE/GB (1018)
Issue Date:
October 30, 2018
MODEL YHAU-CE
150-1440 TONS
527-5064 KW
50 HZ
LDxxxxx
C

JOHNSON CONTROLS
2
FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
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:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment or environmental pollution if
proper care is not taken or instructions
and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
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 electri-
cian. Johnson Controls will NOT be responsible for damage or problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
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 155.35-CL1
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained 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 John-
son 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, 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-
heater.
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. Any other changes in spelling, grammar or
formatting are not included.
ASSOCIATED LITERATURE

JOHNSON CONTROLS
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FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
NOMENCLATURE
Approvals
• GB/T 18431-2014
For Europe:
• CE
• EN ISO 12100:2010
• EN 60204-1: 2006+A1: 2009
• EMC Directive 201 4/30 EC
• EN 55011: 2009+A1: 2010 (Group 1, Class A)
• EN 61000-6-2: 2005
Images contained in this document may represent the standard product with available options.
YHAU C E 500 EX S
NOMINAL
CAPACITY (RT)
Unit Type
York Absorption
LD26804
LOW TEMP. CHW
L :
1.0 °C CHW
LL: -5.0 °C CHW
MODEL SERIES NAME
EX= 150 - 700 RT NOMINAL CAPACITY
EXW- 800 - 1000 RT NOMINAL CAPACITY
EXW3- 1120-1440 RT NOMINAL CAPACITY
EFFICIENCY
None: Highest efficiency
H = High efficiency
S = Standard efficiency
FUEL
E: Exhaust
Gas
DESIGN
SYMBOL
LL
LD26804

JOHNSON CONTROLS 5
FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
TABLE OF CONTENTS
SECTION 1 – GENERAL CHILLER-HEATER AND SAFETY INFORMATION...................................................... 11
Introduction..................................................................................................................................................... 11
About this Manual........................................................................................................................................... 11
Warranty ......................................................................................................................................................... 11
Quality Assurance .........................................................................................................................................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 (Exhaust Gas Units).................................................................................................................16
Evaporator......................................................................................................................................................17
Absorber.........................................................................................................................................................17
Two-step Evaporator – Absorber....................................................................................................................18
Plate Type Heat Exchangers..........................................................................................................................18
Parallel Flow...................................................................................................................................................19
High Temperature Generator (HTG)...............................................................................................................19
Low Temperature Generator...........................................................................................................................20
Condenser......................................................................................................................................................20
Crystallization .................................................................................................................................................21
Why Does Crystallization Occur?..........................................................................................................21
SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY.....................................................23
Inspection .......................................................................................................................................................24
Inspection Window .........................................................................................................................................24
Installation Guidelines ....................................................................................................................................24
Hoisting the Machine......................................................................................................................................25
Moving the Machine on Rollers ......................................................................................................................26
Structural Support and Installation .................................................................................................................29
Indoor and Outdoor Installation ......................................................................................................................29
Electrical.........................................................................................................................................................29
Precautions for Use .......................................................................................................................................29
Leak Testing ...................................................................................................................................................30
Electrical Shock Cautions...............................................................................................................................30
Use of Gas .....................................................................................................................................................31
Exhaust Gas Damper .....................................................................................................................................31
Exhaust Gas Temperature Sensor .................................................................................................................31
Vibration and Isolation Details........................................................................................................................32
Hot Insulation and cold Insulation Procedure.................................................................................................35

JOHNSON CONTROLS
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FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
TABLE OF CONTENTS (CONT'D)
SECTION 4 - TECHNICAL DATA ...........................................................................................................................39
Weights and Dimensions................................................................................................................................40
Upper Communication Specification ..............................................................................................................46
Upper Communication System Conguration .......................................................................................46
Scope of Delivery ..................................................................................................................................47
Connection Port for Ethernet Communication.......................................................................................47
Communication Specication ................................................................................................................47
Communication Data.............................................................................................................................48
User-Created ........................................................................................................................................49
2-Wire Cable Diagrams Without Adaptor ..............................................................................................50
4 Wire Type Cable Diagrams Without Adaptor......................................................................................51
SECTION 5 - COMMISSIONING ............................................................................................................................55
General Guidelines for Use ............................................................................................................................55
Before Operation ...................................................................................................................................55
Precautions For The Use Of Water ................................................................................................................56
Chilled / Hot Water Outlet Temperature Controller .........................................................................................56
Liquid Level Gauges.......................................................................................................................................56
Start the Chiller-Heater...................................................................................................................................57
Stop the Chiller-Heater...................................................................................................................................57
Interlock Procedure .......................................................................................................................................57
SECTION 6 – OPERATION ....................................................................................................................................63
YHAU-CE Control Center ..............................................................................................................................63
Common Items ...............................................................................................................................................63
Change Numeric Values.................................................................................................................................64
Date and Time ................................................................................................................................................64
Operating Status ............................................................................................................................................67
Failure ............................................................................................................................................................74
Alarm ..............................................................................................................................................................79
Control Parameter ..........................................................................................................................................82
Operation Switch ............................................................................................................................................83
Select Language ............................................................................................................................................83
SECTION 7 – MAINTENANCE...............................................................................................................................85
Exhaust Duct Inspection.................................................................................................................................85
Valve Inspection .............................................................................................................................................85
Solenoid Valves..............................................................................................................................................85
Pump Shut Off Valves .................................................................................................................................... 85
Air Purge Valves and Drain Valves.................................................................................................................85
Purge Valves ..................................................................................................................................................86
Start the Chiller-Heater After It Has Been Stopped for A Long Period ...........................................................86
Checks After Operation Starts...............................................................................................................86

JOHNSON CONTROLS 7
FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
Performance Check Method of Vacuum Pump ..............................................................................................87
Purge Procedure ............................................................................................................................................89
Manual Method to Purge Non-condensable Gas Directly from Absorber..............................................89
Manual Method to Purge Non-condensable Gas from Purging Tank ....................................................89
Automatic Method to Purge Non-condensable Gas from Purging Tank................................................90
Refrigerant Refining Method ..........................................................................................................................93
Manual Refrigerant Blowdown and Dilution Method ......................................................................................93
Decrystallization Method ................................................................................................................................94
Indications of Crystallization..................................................................................................................94
Decrystallization ....................................................................................................................................94
Precautions for Decrystallization ....................................................................................................................95
Maintenance Items .........................................................................................................................................95
Refrigerant Pump Manual Stop .............................................................................................................98
Purge Manual Start and Stop ................................................................................................................98
Operation Mode Selection.....................................................................................................................98
Blower Fan Manual Stop .......................................................................................................................99
Exhaust Gas Contaminants............................................................................................................................99
Exhaust Gas Chimney Requirements ...................................................................................................99
Lifespan of Common Parts...........................................................................................................................100
Water Quality Control ...................................................................................................................................102
Chemical Water Treatment...........................................................................................................................103
Replacement of Water ................................................................................................................................. 103
Treatment For Long Stoppage Of The Absorption Chiller-Heater ................................................................103
Chemical Treatment ....................................................................................................................................103
Flow Speed in Tubes ...................................................................................................................................103
Storage Method of the Chiller-Heater...........................................................................................................106
Wet Storage Method ...........................................................................................................................106
Dry Storage Method ............................................................................................................................107
Precautions Against External Damage.........................................................................................................107
Storage Method of the Cooling Water During Heating Operation Period .....................................................108
Wet Storage ........................................................................................................................................108
Work Procedure ..................................................................................................................................109
Dry Storage ......................................................................................................................................... 110
Work Procedure .................................................................................................................................. 110
SECTION 8 – TROUBLESHOOTING................................................................................................................... 115
Troubleshooting Performance Issues........................................................................................................... 117
Vacuum Pump .............................................................................................................................................. 118
Abnormal Solution and Refrigerant Levels................................................................................................... 118
Actions to Take Against Power Failure .........................................................................................................124
SECTION 9 - DECOMMISSIONING, DISMANTLING, AND DISPOSAL .............................................................125
TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS
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FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
LIST OF FIGURES
FIGURE 1 - YHAU-CE Components .......................................................................................................................15
FIGURE 2 - Exhaust Gas Absorption Chiller-Heater Diagram (Cooling Mode).......................................................16
FIGURE 3 - Hoisting Procedure ..............................................................................................................................25
FIGURE 4 - Moving the Machine on Rollers ...........................................................................................................26
FIGURE 5 - Moving the Machine on Tir-Rollers ......................................................................................................27
FIGURE 6 - Jack-Up Procedure..............................................................................................................................28
FIGURE 7 - Vibration and Isolation Details .............................................................................................................32
FIGURE 8 - Nozzle Locations (Example - One Exhaust Gas Outlet Flange)..........................................................33
FIGURE 9 - Nozzle Locations (Example - Two Exhaust Gas Outlet Flanges) ........................................................34
FIGURE 10 - Hot and Cold Insulation (Example - One Exhaust Gas Outlet Flange)..............................................36
FIGURE 11 - Hot and Cold Insulation (Example -Two Exhaust Gas Outlet Flange) ...............................................37
FIGURE 12 - Exterior of Control Panel....................................................................................................................38
FIGURE 13 - External Connection Terminal Details for CE.....................................................................................43
FIGURE 14 - External Connection Details For GB..................................................................................................44
FIGURE 15 - Upper Communication System Conguration For CE ....................................................................... 46
FIGURE 16 - 2-Wire 1:1 Connection with User-Created Cable...............................................................................50
FIGURE 17 - 2-Wire n:1 Connection with User-Created Cable...............................................................................51
FIGURE 18 - 4-Wire 1:1 Connection With User-Created Cable..............................................................................51
FIGURE 19 - 4-Wire N:1 Connection with User Created Cable. ............................................................................52
FIGURE 20 - Sample Sound Testing.......................................................................................................................53
FIGURE 21 - Cooling Start Diagram .......................................................................................................................58
FIGURE 22 - Cooling Start Diagram ......................................................................................................................59
FIGURE 23 - Cooling Stop Diagram........................................................................................................................60
FIGURE 24 - Sequential Operation Flowchart ........................................................................................................61
FIGURE 25 - Shutdown Exhaust Gas Chiller-Heater Flowchart .............................................................................61
FIGURE 26 - Main Screen.......................................................................................................................................67
FIGURE 27 - Data Screen.......................................................................................................................................69
FIGURE 28 - Alarm History Screen.........................................................................................................................71
FIGURE 29 - Trend Screen .....................................................................................................................................72
FIGURE 30 - Trend Screen - Part 2 ........................................................................................................................73
FIGURE 31 - Failure Screen ...................................................................................................................................74
FIGURE 32 - Alarm Screen .....................................................................................................................................79
FIGURE 33 - Setting Screen ...................................................................................................................................82
FIGURE 34 - Location of Manual Valve in Purging System (Example) ...................................................................88
FIGURE 35 - Purge System ....................................................................................................................................91
FIGURE 36 - Process and Instrumentation Diagram - Cooling Only.......................................................................92
FIGURE 37 - Chilled / Hot Water, Cooling Water and Waste Exhaust Gas System (Example of One Exhaust Gas
Outlet Flange)........................................................................................................................................................101
FIGURE 38 - Chilled / Hot Water, Cooling Water and Waste Exhaust Gas System (Example of Two Exhaust Gas
Outlet Flange)........................................................................................................................................................102
FIGURE 39 - Wet Storage During Heating Period ................................................................................................109
FIGURE 40 - Dry Storage During Heating Period ................................................................................................. 110
FIGURE 41 - Duhring Diagram PTX Chart (°F)..................................................................................................... 111
FIGURE 42 - Duhring Diagram PTX Chart (°C) .................................................................................................... 112
FIGURE 43 - Specic Gravity - Concentration (°F) ............................................................................................... 113
FIGURE 44 - Specic Gravity - Concentration (°C)............................................................................................... 114
FIGURE 45 - Trouble Sequence Flowchart ...........................................................................................................123
FIGURE 46 - Actions to Take Against Power Failure.............................................................................................124

JOHNSON CONTROLS 9
FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
LIST OF TABLES
TABLE 1 - Insulating Material and Thickness .........................................................................................................35
TABLE 2 - Points Requiring Hot or Cold Insulation ................................................................................................35
TABLE 3 - Typical Operational Range ....................................................................................................................39
TABLE 4 - Contact Specifications ...........................................................................................................................45
TABLE 5 - Scope of Delivery ..................................................................................................................................47
TABLE 6 - Ethernet Interface Specification.............................................................................................................47
TABLE 7 - Communication Specifications ..............................................................................................................47
TABLE 8 - Read Command ....................................................................................................................................48
TABLE 9 - Write Command.....................................................................................................................................49
TABLE 10 - Scope of Delivery of Upper Communication System...........................................................................49
TABLE 11 - Cable Diagram (RS-422 or RS485) .....................................................................................................50
TABLE 12 - Communication Specifications ............................................................................................................52
TABLE 13 - Sound Data..........................................................................................................................................53
TABLE 14 - Rotary Pump Rotation .........................................................................................................................55
TABLE 15 - Liquid Level Gauges (Sight Glass) ......................................................................................................56
TABLE 16 - Failure List ...........................................................................................................................................75
TABLE 17 - Alarm List.............................................................................................................................................80
TABLE 18 - Solenoid Valves ...................................................................................................................................85
TABLE 19 - Purge Valve Operation ........................................................................................................................90
TABLE 20 - Maintenance and Inspection ...............................................................................................................95
TABLE 21 - Exhaust Gas Contaminants.................................................................................................................99
TABLE 22 - Lifespan of Common Parts ................................................................................................................100
TABLE 23 - Tendency of Generation of Scales and Corrosion by Quality of Cooling Water ................................104
TABLE 24 - Chilled / Hot and Cooling Water Quality Control (Maximum Concentrations) ...................................105
TABLE 25 - Wet Storage.......................................................................................................................................107
TABLE 26 - Dry Storage Method ..........................................................................................................................108
TABLE 27 - Troubleshooting the High Temperature Generator ............................................................................115
TABLE 28 - Refrigerant Overcooled .....................................................................................................................116
TABLE 29 - Chilled / Hot Water Suspension.........................................................................................................116
TABLE 30 - Pumps Overloaded or Overheated.................................................................................................... 116
TABLE 31 - Troubleshooting Performance Issues ................................................................................................117
TABLE 32 - Vacuum Pump Troubleshooting ........................................................................................................ 118
TABLE 33 - Abnormal Solution and refrigerant Levels.......................................................................................... 118
TABLE 34 - Interlock Troubleshooting ..................................................................................................................119
TABLE 35 - Pump Troubleshooting.......................................................................................................................119
TABLE 36 - Chilled Water Overcooling Troubleshooting ......................................................................................120
TABLE 37 - Communication Errors.......................................................................................................................120
TABLE 38 - Other Failure Troubleshooting ...........................................................................................................121
TABLE 39 - Damper Failure Troubleshooting .......................................................................................................122

JOHNSON CONTROLS
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FORM 155.35-ICOM2.EN.CE/GB (1018)
DATE: 10/30/2018
THIS PAGE INTENTIONALLY LEFT BLANK.