GAS-FIRED DOUBLE-EFFECT ABSORPTION CHILLER-HEATER

This product is a gas-fired double-effect absorption unit which provides chilled water for cooling or hot water for heating in central plant-type air conditioning systems. Units with nominal refrigeration capacities of 30, 40, 50, 60, 80 and 100 tons are complete with operating and safety controls.

CONTENTS

GENERAL Page

GENERAL 2

MODEL DESIGNATION 2

STANDARD SPECIFICATIONS 3

ACCESSORIES 4

EQUIPMENT DIMENSIONS 5

TYPICAL SYSTEM DESIGN 6

INTERNAL WIRING DIAGRAM 6

CAPACITY CONTROL 9

TYPICAL FIELD WIRING DIAGRAM 10

INSTALLATION

RECEIVING 11

OVERHEAD RIGGING 11

CENTER OF GRAVITY 11

Page

LOCATION 12

FOUNDATION 12

LEVELING 13

COMBUSTION AIR SUPPLY 13

VENTING 14

PIPING 16

CHILLED/HOT WATER PIPING 16

COOLING WATER PIPING 17

FREEZE PROTECTION 18

GAS SUPPLY PIPING 18

ELECTRICAL 20

WATER QUALITY 22

INSTALLATION CHECK &

REQUEST FOR STARTUP 22

INSTALLATION INSTRUCTIONS

CH-K30 ► CH-K100

2

GENERAL

This equipment should only be

installed by trained and qualified personnel who are familiar with absorption chillers. All precautions in these instructions, as well as on tags and labels attached to the unit, must be observed to ensure the safety of the personnel and maintain warranty validation.

Each Yazaki absorption chiller-heater

has been evacuated, charged with lithium bromide and water solution, and run tested prior to leaving the factory.

Field wiring, water piping, and gas

piping connections are located at the rear of the unit.

After the equipment has been

installed, a Yazaki Authorized Service Provider (ASP) must check the installation and supervise or conduct the initial startup and operation of the unit. Additionally, a copy of the startup sheet, the Installation Check & Request for Startup sheet, and the Warranty Card must be received by Yazaki Energy Systems, Inc., in order for warranty to be in force. Further, maintenance records should be kept with copies sent to Yazaki

Energy Systems, Inc., in order to maintain warranty coverage.

CAUTION

THE YAZAKI WARRANTY WILL BE VOIDED IF THE FOLLOWING RESTRICTIONS ARE NOT OBSERVED:

1. DO NOT OPEN ANY VACUUM VALVES WITHOUT A PROPER EVACUATION ASSEMBLY ATTACHED TO THEM AS SUCH ACTION WILL RESULT IN LOSS OF VACUUM AND INTRODUCTION OF GASES TO THE INTERIOR OF THE MACHINE WHICH COULD CAUSE CORROSION.

2. ALWAYS HANDLE THE EQUIPMENT WITH CARE AND MAINTAIN IN A NEAR-VERTICAL POSITION DURING RIGGING. IF THE EQUIPMENT MUST BE TILTED, CAREFULLY FOLLOW INSTRUCTIONS PROVIDED WITHIN THIS DOCUMENT.

3. DISCONNECT GAS PIPING FROM EQUIPMENT WHEN PRESSURE TESTING AT 0.5 PSI OR GREATER IN ORDER TO AVOID DAMAGE TO THE GAS VALVES.

4. DO NOT ATTEMPT TO START THE SYSTEM WITHOUT SUPERVISION FROM A YAZAKI AUTHORIZED SERVICE PROVIDER (ASP).

MODEL DESIGNATION

CH-K ###

Double-Effect Absorption Chiller-Heater (K Series) Cooling Capacity: 30 = 30 ton, 40 = 40 ton, etc.

3

STANDARD SPECIFICATIONS

NOTES: Power Consumption does not include external pumps or cooling tower fan motors. Fuel Input is based on the high heat value of gas. “Height” does not include level bolts, but “Height with Vent Cap” does includes the level bolts.

4

ACCESSORIES

ACT3 Maintenance Checker

Eye Bolts (4)

Installation Instructions

Leveling Bolts (4)

Operating Instructions

Spare Fuses (5) (in control box)

Vent Cap (in separate box)

Standard

(UL

Model

Only)

Cooling Tower Mixing Valve Kit

Gas Appliance Regulator

Gas Meter

L-Anchor Assembly

Metric Flare to 1/4" SAE Flare

Conversion Kit (KITMFA2)

Remote Control Panel

Water Pressure Tap English

Conversion Kit (KITWPC4)

WTI Sensor

Optional

Cooling Tower Mixing Valve Kit Gas Appliance Regulator

Gas Meter KITMFA2 KITWPC4

L-Anchor Assembly Remote Control Panel WTI Sensor

5

EQUIPMENT DIMENSIONS

All dimensions in Inches

6

TYPICAL SYSTEM DESIGN

INTERNAL WIRING DIAGRAMS

Burner Diagram

7

8

SYMBOL DESCRIPTION REMARKS

A thru I Remote Control Panel Connection Terminals

Field-Installed Optional Remote Control Panel Accessory

AC24V 24V Power Source

AL Alarm Condition Dry Contact 24V, 60va Max

AX Auxiliary Gas Valve 120V Coil

BM Burner Blower Motor 208/230V

C1 Cool Mode

CAPS Combustion Air Proving Switch

CHD Enable Signal Dry Contact 24V, 60va Max

CHE Alarm Condition Dry Contact 24V, 60va Max

CHOFF Disable Signal

CHON Enable Signal

CHSTN Chiller Disabled Dry Contact 24V, 60va Max

CIR Cool Mode Interrupt Cooling Tower Level Confirmation

CL Cool Mode LED on Remote Control Panel

CM Cool Mode Dry Contact 24V, 60va Max

CM1 Common for Pump & Fan Dry Contact Relays

Field-Supplied Voltage

CM2 Common for Safety Interlocks

15V DC Signal

CND Condenser Thermister

COM Common for External Signal Relays

15V DC Signal

CON Changeover Valve Actuator Cool Position Confirmation

CP Cooling Water Pump Dry Contact

24V, 60va Max

CTF Cooling Tower Fan Dry Contact

24V, 60va Max

CTI Entering Cooling Water Thermister

CTO Leaving Cooling Water Thermister

CVR Changeover Valve 24V

DCP Digital Communication Protocol Interface

For AroTrend Monitoring

EDM Enable LED

EGS External Gas Safety

ESC1 External Signal for Cool Mode

ESH1 External Signal for Heat Mode

ESOFF External Signal to Disable

ESON External Signal to Enable

EXF Exhaust Fan Dry Contact Not Used

F Cooling Tower Fan

F11 200V Circuit Fuse Fuji Model FGAO-2; 250v, 2 Amp

F12 200V Circuit Fuse Fuji Model FGAO-2; 250v, 2 Amp

SYMBOL DESCRIPTION REMARKS

F2 24V Control Circuit Fuse Bussman Model GLQ-3, GMQ-3, or GMQ-3-2/10

F31 32V Control Circuit Fuse Fuji Model FGAO-1; 250v, 1 Amp

F32 32V Control Circuit Fuse Fuji Model FGAO-1; 250v, 1 Amp

F4 24V Control Circuit Fuse Fuji Model FGAO-2; 250v, 2 Amp

FB11 Burner Control Circuit Fuse Fuji Model FGAO-2; 250v, 2 Amp

FB12 Burner Control Circuit Fuse Fuji Model FGAO-2; 250v, 2 Amp

FB21 Burner Blower Motor Fuse Nagasawa Model GAB15

FB22 Burner Blower Motor Fuse Nagasawa Model GAB15

FE Cooling Tower Fan Safety Interlock

FP Fuse for PCH Fuji Model FGAO-1; 250v, 1 Amp

FS1 Chilled/Hot Water Flow Switch

FS2 Cooling Water Flow Switch

Field-Installed Option

FT1 TR1-ULCE Primary Voltage Fuse

Fuji Model FGAO-5; 250v, 5 Amp

FT2 TR1-ULCE Primary Voltage Fuse

Fuji Model FGAO-5; 250v, 5 Amp

FT3 TR1-ULCE Primary Voltage Fuse

Fuji Model FGAO-5; 250v, 5 Amp

GLS Generator Level Switch

GP Generator Thermister

GPSC Generator Thermal Limit Switch for Cooling Mode

GPSH Generator Thermal Limit Switch for Heating Mode

GV Main Gas Valve 120V Coil

H1 Heat Mode

HIR Heat Mode Interrupt Cooling Tower Drainage Confirmation

HL Heat Mode LED on Remote Control Panel

HM Heat Mode Dry Contact 24V, 60va Max

HON Changeover Valve Actuator Heat Position Confirmation

IF1 Chilled/Hot Water Freeze Protection Circuit

IF2 Cooling Water Freeze Protection Circuit

IGN Ignition Transformer 120V AC Primary; 6000V AC Secondary

IRS Independent Remote Switch Not Used

9

SYMBOL DESCRIPTION REMARKS --- --- ---

LCOM Common for LEDs

LS Expansion Tank / Cistern Level Switch

Not Used

LT Evaporator Thermister

LTPV Refrigerant Proportional Control Valve

40V; 0-400mA

MB Burner Motor Contactor 120V Coil

MF Flame Failure Dry Contact Not Used

MP SP Starter

OP Enable Signal Dry Contact 24V, 60va Max

OPL Run Mode LED on Remote Control Panel

P Chilled/Hot Water Pump Dry Contact

24V, 60va Max

P1 Chilled/Hot Water Pump

P12E Cooling Water Pump Safety Interlock

P1E Chilled/Hot Water Pump Safety Interlock

P2 Cooling Water Pump

PCH Palladium Cell Heater 200V; 30 Watts

PV Pilot Valve 120V Coil

R1 Burner Alarm Relay 120V Coil

R2 Mod Motor Control Relay 120V Coil

RBL Gas Burner Demand Dry Contact

24V, 60va Max

RBP Burner Power Control Relay 24V Coil

RBPW Burner Demand Control Relay

RCVR CVR Motor Control Relay

RMP MP Control Relay 24V Coil

RRBH Burner High/Low Control Relay

24V Coil

RRBL Burner Start/Stop Control Relay

24V Coil

SYMBOL DESCRIPTION REMARKS RV2 SV2 & SV22 Control Relay 24V Coil

RV9 SV9 & SV92 Control Relay 24V Coil

SA1 MOV Surge Protector

SA2 MOV Surge Protector

SP Solution Pump

ST2 External Safety Interface

Configurable for NO or NC switches

SV1 Evaporator Freeze Protection Valve

24V Coil

SV10 High Fire Burner Demand Control Relay

SV2 Solution Flow Control Valve

200V Coil; CH-K60, 80, & 100 Only

SV22 Solution Flow Control Valve 200V Coil; CH-K80 & 100 Only

SV4 Low Fire Burner Demand Control Relay

SV9 Concentrated Solution Bypass Valve

200V Coil

SV92 Concentrated Solution Bypass Valve

200V Coil; CH-K80 & 100 Only

THRP SP Over-Current Relay

TR BOX Transformer Box

TR1-ULCE

Power Transformer

208V or 230V AC Primary; 200V, 24V, & 32V AC Secondary

TR2-UL Power Transformer 208V or 230V AC Primary; 120V AC Secondary

TR-LV Power Transformer 24V AC Primary; 18V & 15V AC Secondary

WTI Entering Chilled/Hot Water Thermister

Field-Installed Option

WTO Leaving Chilled/Hot Water Thermister

CAPACITY CONTROL COOLING

HEATING

10

TYPICAL FIELD WIRING DIAGRAM

11

INSTALLATION

RECEIVING

When the absorption chiller-heater is delivered, inspect it for transit damage. Should any damage have occurred, do not proceed with installation until the Yazaki distributor has been notified and any required remedial actions have been completed.

Remember to properly plan the route to the installation site. Also, keep in mind when choosing the site, the unit will someday have to be replaced, so be mindful of permanent and semi-permanent barriers.

Dimension CH-K30, CH-K40

CH-K50, CH-K60

CH-K80, CH-K100

A 98 (2490) 113 (2870)

B 78 (1980) 90 (2285) 95 (2415)

C 78 (1980) 90 (2285) 95 (2415)

D 80 (2030) 90 (2285) 95 (2415)

Dimensions in Inches (mm)

OVERHEAD RIGGING

The Yazaki chiller-heater is designed for overhead rigging with four eye bolts installed in the top panel at the factory.

Remove the crate from the unit. The skid and the leveling bolts can remain in place unless the additional height causes trouble getting it to the installation area.

Care should be taken at all times

during rigging and handling to avoid damage to the panels and external connections. DO NOT DROP!

CENTER OF GRAVITY

To properly rig the unit, the rigger must know the Center of Gravity. The Center of Gravity of a CH-K Series machine is almost dead center in the unit, approximately 40” (1m) up from the

base rail and centered on each side. Corner weights are equal on all corners and are equal to the overall weight indicated in the Specifications on page 3 of this document multiplied by 0.32.

12

LOCATION

Particular care must be taken when placing the machine so as to provide adequate clearance for access to each side of the machine.

Maintenance is mostly done through the front of the unit, but in repair scenario, any panel on any side may need to be removed to access components behind them.

Finally, as with all mechanical devices, the unit will have to be replaced someday. Keep that in mind as well when choosing the final placement site.

The minimum clearance space is shown on the chart and diagram below.

Drawing not to scale

Model Installation Area Maintenance Clearances

A B C D E F

CH-K30, 40 141 (3580) 114 (2895)

28 (700) 40 (1000) 28 (700) 40 (1000) CH-K50, 60 150 (3810) 126 (3200)

CH-K80, 100 155 (3935) 129 (3275)

All Dimensions in Inches (mm)

FOUNDATION

All aspects of foundation and support computations must be in accordance with national and local codes.

The chiller-heater must be mounted on a level, non-combustible foundation capable of supporting the weight of the machinery. This is particularly important for rooftop installations. Always make

certain the structure can support not only the chiller-heater, but the pumps, piping, cooling towers, etc. as may be required. The rooftop area should be in a well-drained area and be at least 7’ (2 m) from the edge of the roof. Anti-fall measures should always be taken if the chiller-heater is installed within 12’ (4 m) of the edge of the roof.

13

Additionally, for protection of the roofing material, it is recommended a suitable platform or walkway be provided around all sides of the unit.

If the chiller-heater is to be installed outside, but at ground level, make certain the concrete base and the soil beneath are sufficient for the task. Settling over

time could cause the unit to become unlevel, which could have a serious negative impact on the performance and lifespan of the unit. Concrete foundations are recommended to be sized so that at least 12” (300 mm) extends beyond the unit in all directions to accommodate potential mounting and anchoring hardware.

LEVELING

CH-K series units must be level in order for the fluids to be distributed properly over their respective tube bundles. There is a level bar mounted on the front of the machine. The unit must be level to both the longitudinal and transverse alignments.

In cases of multiple units installed side-by-side, the units should all be level individually as well as in respect to each other. It is essential that all leveling be completed before any piping connections are attempted.

COMBUSTION AIR SUPPLY

As with all gas-fired appliances, careful consideration must be given in regard to the provision of sufficient free air for combustion and venting. The rules for such are found in the National Fuel Gas Code, NFPA Standard 54. The code supersedes anything found in print here or in any other Yazaki documentation. Provided here are guidelines to help toward proper installation of the equipment.

When installed outdoors, no special provisions are usually needed in regard to combustion air. However, if the unit is in a confined area outside, some issues could arise if external forces cause a negative pressure area around the unit. An example of such would be having the unit installed in an alcove, yet a strong, sustained wind blows by along the edge of the building. Such occurrences are rare, but should be considered.

14

Of greater concern are indoor installations, especially in areas with more than one gas-fired appliance. Keep in mind that whatever combustion air supply is present, it must be capable of supporting every gas-fired appliance in the space while all of them operate at full capacity. Combustion air openings are also often the source for dilution air for Category I appliances, so it is recommended to consult the manuals on all appliance in the area in order to ensure all requirements are being considered. Never install a gas-fired appliance in an unventilated space.

ASME Section VI – Recommended Rules for the Care and Operations of Heating Boilers, Reference 6.04 states:

“The boiler room must have adequate air supply to permit clean, safe combustion and to minimize soot formation. An unobstructed air opening should be provided. It may be sized on the basis of 1-square inch free area per 2000 BTUh maximum fuel input of combined burners located in the boiler room, or as specified in the National Fire Protection Association standards for oil and gas burner installations for the particular job. The boiler

room air supply openings must be kept clear at all times.”

Model Upper Opening Lower Opening

CH-K30 180 (1160) 180 (1160)

CH-K40 240 (1550) 240 (1550)

CH-K50 300 (1935) 300 (1935)

CH-K60 360 (2320) 360 (2320)

CH-K80 480 (3095) 480 (3095)

CH-K100 600 (3870) 600 (3870) Opening = Total Area of Opening x Free Area Modifier Value

of Louver. (Consult Louver Manufacturer.)

Dimensions are Inches² (cm²)

VENTING

Venting the flue products safely is a key concern when installing any gas-fired appliance and Yazaki chiller-heaters are no exception. As with combustion air, rules for the proper venting of gas-fired appliances are also covered in the National Fuel Gas Code, NFPA Section 54.

All CH-K series chiller-heaters are Category I appliances. When choosing vent material size, the chillers-heaters are classified as “fan” vent type since the fan on the burner assists in moving flue products through the unit. The fan does NOT provide enough force to do more

than push the flue products a few feet down the vent, so it does not have enough force to qualify as Category III, side discharge venting. There are aftermarket kits that can provide Category III capability for Category I appliances should the need arise, but Yazaki offers no kit for this. Warranty may be void on the Yazaki chiller-heater if such a kit is used, but not installed or applied correctly. Carefully follow all instructions when applying these kits, and if necessary, contact Yazaki Energy Systems, Inc. for guidance on integration of the kit to the unit control safeties.

15

A number of quick rules can be listed in regard to venting.

1. Always use B-Type double wall vent material. 2. Vent should never run downhill. 3. Vent must terminate at least 7’ above public

walkways. 4. Vent must terminate at least 4’ above vertically

or 10’ horizontally from openings into living areas or air intakes.

5. Vent must terminate no closer than 10’ from an inside corner unless it terminates 2’ above said inside corner.

6. Vent should terminate at least 2’ above the highest point within 10’.

7. Rise (Height) should be greater than the Run (Lateral).

8. It is recommended that each unit be vented separately if possible. If the vent is taller than 7’, a barometric damper (also known as a draft regulator) may be required. The range of draft pressure allowed at the vent connection on the chiller-heater is 0.0” wc to -0.05” wc. If the draft pressure is outside of this range, a barometric damper should be used to correct this in order to prevent sooting and possible damage to the HGE.

In instances where multiple units are to be vented, and individual venting is impractical or undesirable, combined venting (Common

Venting) is permitted so long as it follows proper venting rules. It should be noted that there will be separate and special charts for sizing common venting applications. Follow the rules given by the vent material manufacturer.

Things that do not change by manufacturer:

1. Barometric dampers (draft regulators) are no

longer an option. They are required so that vent conditions of one unit do not affect the operation/venting of the other(s). Use a separate damper for each chiller-heater with the damper located as close as possible to the unit (location A). If there is insufficient room for installation at location A, use location B as an alternative.

2. Size connecting Tees properly.

3. The maximum allowable lateral length (L) is equal to 1.5 x diameter of the pipe.

4. When the common pipe grows to become 7x greater in area than the interconnecting pipe, special rules will apply. Consult the pipe manufacturer for these details and/or special rules.

16

PIPING

After the chiller-heater has been leveled properly, the piping for the chilled/hot water and cooling water circuits may be installed. Piping arrangements should be made with care so that there is no interference with service access or panel removal. Piping should be adequately supported and braced independently of the unit so as to avoid undue strain on the unit piping connections. Maximum allowable pressure in any fluid circuit is 85.3 PSI (588 kPa).

CAUTION

1. Do not exceed 85.3 PSI (588 kPa) in either the chilled/hot water or the cooling water circuits of the Yazaki chiller-heater.

2. Do not install any valves in expansion pipe line.

Thermo-wells, pressure gauges,

Pete’s Plugs, etc. may be installed at the inlet and/or outlet of each fluid circuit

connection to facilitate startup, future service, and routine maintenance. Strainers in each circuit, particularly the cooling water circuit, are recommended as well. These should be placed before the inlet connection of the chiller-heater.

Piping rules and conventions used

with Yazaki chiller-heaters are exactly the same as used with any other type of chiller; therefore, this installation manual will not delve deeply into piping design.

CHILLED/HOT WATER PIPING

A balance valve should be installed at the chilled/hot water outlet and a stop valve should be installed at the chilled/hot water inlet. Both valves should be placed in close proximity to the chiller-heater.

After thoroughly testing for leaks, insulate the piping circuit, ensuring an adequate vapor barrier is obtained. Be sure to allow access to any valves, wells, and ports that may be present. Also, ensure the chiller-heater panels are not restricted by the insulation.

17

COOLING WATER PIPING

Cooling water should be supplied at 85°F (29.5°C) or less. The CH-K Series can typically accept cooling water down to 77°F (25°C) without use of a mixing valve. However, the inlet cooling water temperature must not be below 46.4°F (8°C) when the cooling cycle starts, nor may it drop to 46.4°F (8°C) and remain there for more than 3 minutes at any point in time. Such cases will result in the generation of error code E043. To prevent this, a mixing valve or a diverting valve should be installed so that when cooling water is too cold, the cooling water returning from the chiller-heater is diverted directly into the sump of the cooling tower in order to preserve and build up heat. Once the cooling water temperature rises to an acceptable temperature, the valve can allow the returning cooling water to flow through the tower medium once more.

Temperatures above 85°F (29.5°C) can result in a loss of capacity. If cooling water exceeds 90°F (32°C), the refrigerant vapor may no longer condense properly, which could lead to a loss of capacity as well. If the cooling water becomes consistently too hot, the unit may lock out.

If possible, the cooling tower should be installed at or above the level of the chiller-heater. If this is not possible, give

careful consideration to the prevention of drain-back and loss of cooling water due to overflow of the tower.

The design engineer must also take proper and appropriate steps to prevent damage to the cooling tower fill media as a result of mode change-over. When switching from heat to cool mode, for a short time the cooling water can return from the chiller-heater at temperatures in excess of 130°F (54°C). This hot slug of water must not be allowed to damage the fill media. Use of a mixing valve can prevent this.

As with the chilled/hot water connections, balance valve should be installed on the cooling water inlet and a stop valve installed on the cooling water outlet. Both valves should be in close proximity to the chiller-heater. After thoroughly testing for leaks, insulate the piping circuit, ensuring an adequate vapor barrier is obtained. Be sure to allow access to any valves, wells, and ports that may be present. Also, ensure the chiller-heater panels are not restricted by the insulation.

Additionally, there should be flush and drain valves installed between the machine and the balance/stop valves so as to allow for chemical cleaning of the absorber-condenser coils should it ever become necessary.

18

FREEZE PROTECTION

When the chiller-heater and/or associated piping are installed in a location that is subject to freezing conditions, appropriate anti-freeze steps must be taken. Many anti-freeze methods are available including heat tape, but the most common method in the USA is the use of glycol in the fluid loop.

Glycol may be permitted for use in Yazaki chiller-heaters with certain restrictions and observations.

1. In the chilled/hot water circuit, it should only be used during heating operation. It is not recommended for use in the chilled water circuit in cooling mode as the loss of heat transfer performance could result in tube failure under certain extreme conditions.

2. Glycol may be used in the cooling water circuit in any operating mode.

3. Do not use automotive glycol (Antifreeze) since it contains chemical additives that are inappropriate and potentially damaging to the Yazaki chiller-heater. Use only glycol appropriate for use with copper tubing.

4. Do not exceed a mixture of 50% by weight.

5. Be aware that loss of performance will result when glycol is used. In higher concentrations, the impact can be very significant.

6. Propylene Glycol is preferred wherever possible. It has very similar anti-freeze characteristics to Ethylene Glycol, but is non-toxic. It is also less viscous than Ethylene Glycol, which reduces the required pump power. Finally, it provides a heat transfer performance closer to that of water than EG.

7. Use of glycol can cause the unit to operate at a slightly higher internal temperature since heat transfer is dampened. This may result in depletion of inhibitor at a faster rate than what may be perceived as normal.

It should be noted that all Yazaki CH-K

Series chiller-heaters contain logic that will ask for a fluid circuit’s pump to energize if that circuit is observed to be approaching 37.4°F (3°C). If the circuit is observed to approach 33.8°F (1°C), the unit may even attempt to engage the burner in an effort to prevent the loop from freezing. To use the logic, it must be enabled by jumping terminals on the I/O Board. Jumping TB1-9 to TB1-10 will enable IF1, the anti-freeze logic for the chilled/hot water loop. Jumping TB1-11 to TB1-12 will enable IF2, the anti-freeze logic for the cooling water loop.

GAS SUPPLY PIPING

Before connecting the gas supply pipe, check the UNIT NAMEPLATE to confirm that it is compatible with the gas type available.

The gas piping must be selected and installed in accordance with local building codes and the National Fuel Gas Code (ANSI Z233.1, latest edition). Typically, the pipe size is selected at the maximum gas pressure input and with 0.5 inches water column maximum pressure loss

between the gas meter and the equipment.

CAUTION

TO AVOID DAMAGE TO THE GAS VALVES IN THE CHILLER-HEATER, DISCONNECT THE GAS PIPE WHEN THE TEST PRESSURE EXCEEDS 0.5 PSI (3.4 kPa).

19

Allowable supply gas pressure range: 5 – 10.5 inches water column except for

CH-K100 which is 7 – 10.5 in wc

The maximum and rated gas

pressures are measured when the burner is operating at 100% fire rate. Install a manual shut-off valve and a sediment trap within 6 feet of the equipment.

A gas meter is supplied in order to facilitate burner setup when the primary gas meter is remote from the installation site, or when multiple gas-fired appliances exist on the supply lines. This gas meter allows for gas volume determination without the need to isolate other appliances during burner setup.

Installation of an appliance regulator is also recommended, especially when multiple gas-fired appliances exist on the supply lines. This optional appliance regulator should be sized to handle the 100% fire rate gas supply and should be

located as the last item in the gas supply line before it enters the chiller-heater.

The minimum gas supply pressure is 5 inches water column (7 in wc for the CH-K100) at the burner gas valve. The maximum gas supply pressure is 10.5 inches water column at the burner gas valve. Combustion with supply gas pressure outside of this range cannot be guaranteed to provide the correct flame shape in the HGE and could potentially cause damage to the HGE itself.

The gas pipe connection on the chiller-heater does NOT mean that size is appropriate for bringing the gas supply to the unit. The gas supply piping must be capable of carrying the total MBtuh/hr capacity of all gas-fired appliances on the line when each is fired simultaneously at full firing rates. Reduce the required pipe size as close to the chiller-heater as is reasonably possible.

20

ELECTRICAL

Each chiller-heater has a junction box located at the rear of the unit. This junction box is a single point where all electrical interface, be it high voltage or controls, is intended to enter the unit.

High voltage connections should be

made to L1, L2, L3, and G. If the voltage supply has a “wild leg” or “high leg”, that

leg should attach to L2. Be aware that not all regions have high legs.

A rotation test must be performed as

well. Clockwise rotation is desired. If incorrect rotation is discovered, swap L1 and L3 wires to reverse the rotation. A rotation meter is the simplest method to determine rotation.

The center section of the junction box

has the pump controls. Supply voltage is provided from a field-supplied 24v transformer to terminal CM1. The unit will take that voltage and route it to terminal P when there is a chilled/hot water pump demand. It will take that same voltage and route it to terminal CP when there is a demand for the cooling water pump. It will use that same voltage

to cycle the cooling tower fan, applying that voltage to CTF when the incoming cooling water is at 84.2F (29C) or greater, and taking it away when the incoming cooling water drops to 80.5F (27C). This logic function of cooling water temperature control is provided for convenience, and is not intended to supersede more sophisticated controls such as VFD fan controls, etc.

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Terminals A through I in the upper right section of the junction box are intended for use with the optional Yazaki Remote Control Panel. However, these terminals can also be used to interface with Building Management Systems.

When interfacing with a BMS, it is recommended that two SPST relays be used and controlled by the BMS. Each relay should have the E terminal (which supplies a DC voltage signal) of the junction box connected to its common lead on the relay contacts. One of these relays will be used to determine whether the unit is in Heat or Cool mode. The other will Enable or Disable the unit. For the mode relay, designated ESC, the normally closed contact should be attached to the B terminal in the junction box. The normally open contact should be attached to the A terminal in the junction box. For the Enable/Disable relay, designated ESON, the normally closed contact should be attached to the D terminal in the junction box. The normally open contact should be attached to the C terminal in the junction box.

Finally, in the lower right section of the junction box lies a terminal strip with terminals 3, 4, 5, 6, and CM2. Terminal CM2 supplies a DC voltage signal that MUST return to terminals 3, 4, and 5. Terminal 6 is not used in a CH-K chiller-heater. These are pump and motor overload interlocks. Each starter for the chilled/hot water pump, cooling water pump, and cooling tower fan motor should have a set of auxiliary contacts on their overloads. Each starter should receive the DC voltage from terminal CM2 in the junction box and route it through normally closed contacts to return to the appropriate terminal. Terminal 3 should receive the return signal from the chilled/hot water pump overload auxiliary contacts. Terminal 4 should receive the return signal from the cooling water pump overload auxiliary contacts. Terminal 5 should receive the return signal from the cooling tower fan overload auxiliary contacts. If the return signal is not sensed, the unit will immediately generate an error code (E005, E006, and/or E007).

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WATER QUALITY

Water used in the chilled/hot water and cooling circuits may cause scaling and/or corrosion if not correctly analyzed and maintained within specified limits. In some areas, the water supply may contain minerals that cause scaling or may be extremely soft and corrosive. Where these conditions exist, a water treatment company should be consulted.

If the absorption chiller-heater is damaged as a result of scaling, corrosion, or erosion caused by poor water quality control, the equipment warranty may be void.

Water quality should not exceed the following limits:

ITEM CHILLED/

HOT WATER

COOLING WATER

MAKE-UP WATER

Sta

nd

ard

pH (at 77°F) 6.8 - 8.0 6.5 - 8.2 6.8 - 8.0

Conductivity (S/cm at 77°F) 400 800 300

Chloride ion (Cl- ppm) 50 200 50

Sulfate ion (SO42-

ppm) 50 200 50

M-alkalinity (CaCO3 ppm) 50 100 50

Total hardness (CaCO3 ppm) 70 200* 70

Calcium hardness (CaCO3 ppm) 50 150 50

Ionic silica (SiO2 ppm) 30 50 30

Refe

ren

ce

Total iron (Fe ppm) 1.0 1.0 0.3

Copper (Cu ppm) 1.0 0.3 0.1

Sulfide ion (S2-

ppm) ND ND ND

Ammonium ion (NH4+ ppm) 1.0 1.0 0.1

Residual chlorine (Cl ppm) 0.3 0.3 0.3

Free carbon dioxide (CO2 ppm) 4.0 4.0 4.0

Ryzner stability index - 6.0 - 7.0 - NOTES: 1. ND (Not Detectable) 2. *Maximum total hardness of make-up water shall not exceed 70 ppm when bleed off is the only method used to control water

quality.

INSTALLATION CHECK & REQUEST FOR STARTUP

After the absorption chiller-heater has been installed, piped, and wired as described in these instructions, but before any attempt is made to start the unit, the Yazaki Authorized Service Provider should be advised so that the startup can be scheduled. Complete the REQUEST FOR STARTUP form and

send it to the ASP or to Yazaki Energy Systems, Inc., at least 2 weeks prior to the required startup date.

The contractor is expected to provide personnel to assist with final adjustments to the system controls and fluid flow rates as may be necessary.

23

YAZAKI CH-K SERIES CHILLER-HEATER

INSTALLATION CHECK AND REQUEST FOR START-UP

Yazaki Service Provider:

Address:

Project Name:

Project Address:

A. CHILLER-HEATER

1. Unit placed on foundation □

2. Unit leveled properly □

3. Service clearance provided on all

sides and top (40 in. front) □

4. Chiller-heater anchored by L-Anchor

plates to foundation (if required) □ *Anchors may be required by some state and local codes.

B. WATER PIPING

1. Chilled/hot water piping installed between chiller-heater, pumps and

air handling unit(s) □

2. Cooling water piping installed between chiller-heater, pumps, and

cooling tower □

3. Water piping leak tested and flushed □

4. System filled with water and glycol

(if required) and trapped air vented □

5. Flow setters installed in water piping □

6. Test plugs (Pete’s plugs) and/or thermowells installed in the inlet and

outlet piping of each chiller-heater □

7. Valves installed at each chiller-heater

for flow balancing and isolation □

8. Air vent valves installed on piping □

9. Strainers present and clean □

10. Expansion tank (properly charged) and water make-up piping installed to

chilled/hot water system □

11. Water make-up and fill lines installed

to the cooling tower □

12. Pressure relief valves, set at 85 psi (max.) installed on piping adjacent to each

chiller-heater (if required) □ C. GAS PIPING

1. Natural Gas supply is available between 5” wc (7” wc for CH-K100) and

10.5” wc □

2. Gas piping installation completed □

3. Gas cock and sediment trap installed □

4. Gas meter and appliance regulator

installed at each chiller- heater □

5. Gas pipe leak tested and purged □

D. VENTING 1. Factory-provided vent cap installed

(outdoor installation) □

2. Barometric damper and Type-B vent extension installed on each chiller-

heater outlet (indoor installation) □

E. POWER WIRING 1. Power supply, indicated on the UNIT

NAMEPLATE, is connected □

2. Wiring completed between the chiller-heater, motor contactors and the following motors: Chilled/hot water pump, cooling water pump and

cooling tower fan □

3. Rotation of each motor checked □

4. Power supply wiring connected between a fused disconnect and each chiller-heater. (DO NOT operate

the chiller-heater) □

5. Power supply available near the

chiller-heater for a vacuum pump □ F. CONTROL WIRING

1. Motor contactors and manual controls

installed for all external motors □

2. Control wiring installed between chiller-heater and pump/motor

contactors □

3. Interlock wiring installed between chiller-heater and thermal overloads on the following motors: Chilled/hot water pump, cooling water pump and

cooling tower fan □

4. Wiring installed between chiller-heater and auxiliary contact on the cooling

tower fan motor contactor □

G. CONDITIONS 1. Personnel available to assist with

start-up who are familiar with the

system □

Model No: Serial No:

Anticipated Startup Date:

-24-

YAZAKI AUTHORIZED SERVICE PROVIDER

For information concerning service, operation or technical assistance, please contact your

Yazaki Authorized Service Provider or the following:

YAZAKI ENERGY SYSTEMS, INC. 701 E PLANO PKWY, SUITE 305

PLANO, TEXAS 75074-6700

Phone: 469-229-5443 Fax: 469-229-5448

Email: yazaki@yazakienergy.com Web: www.yazakienergy.com

This symbol on the product’s nameplate means it is listed by UNDERWRITERS LABORATORIES, INC.

Yazaki reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

KUL-II-1A2-1114