GAS-FIRED DOUBLE-EFFECT ABSORPTION CHILLER-HEATER

Transcription

1 INSTALLATION INSTRUCTIONS CH-K30 CH-K80 with G Series Control Package 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. These units are available with nominal refrigeration capacities of 30, 40, 50, 60, or 80 tons and are complete with operating and safety controls. These instructions are for use with CH-K Series units that employ the G Series control package. This control package utilizes a VFD solution pump and other enhancements to improve the overall efficiency of the K-Series units from the previous 1.02 COP. With the G Series control package, the new COP is 1.1. While many of the instructions contained within are the same for the CH-K units utilizing the older control package, there are significant differences between CH-K units in regard to these two different control packages. Therefore, verify that the instructions match the unit received. A simple visual difference is the presence or lack of a VFD controller in the control panel. If confusion remains, contact Yazaki Energy Systems, Inc. for further assistance. CONTENTS GENERAL Page Page GENERAL 2 MODEL DESIGNATION 2 STANDARD SPECIFICATIONS 3 FACTORY OPTIONS 5 ACCESSORIES 5 EQUIPMENT DIMENSIONS 6 TYPICAL SYSTEM DESIGN 7 WIRING DIAGRAMS 8 CAPACITY CONTROL 12 INSTALLATION RECEIVING 13 OVERHEAD RIGGING 13 CENTER OF GRAVITY 13 LOCATION 14 FOUNDATION 14 LEVELING 16 CHANGEOVER VALVE & FLOW SWITCH CONNECTION 17 COMBUSTION AIR SUPPLY 18 VENTING 19 PIPING 20 CHILLED/HOT WATER PIPING 21 COOLING WATER PIPING 21 FREEZE PROTECTION 22 GAS SUPPLY PIPING 23 ELECTRICAL 24 WATER QUALITY 26 INSTALLATION CHECK & REQUEST FOR STARTUP 26

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 chillerheater 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 Double-Effect Absorption Chiller-Heater (K Series) Cooling Capacity: 30 = 30 tons 40 = 40 tons 50 = 50 tons 60 = 60 tons 80 = 80 tons CH-K ### 2

3 STANDARD SPECIFICATIONS English Units Model Using G Controls CH-K High Fire MBTUh Cooling Low Fire MBTUh High Fire MBTUh Heating Low Fire MBTUh Capacity¹ Chilled / Hot Water² Cooling Water² Electrical³ Burner Construction⁴ Piping Capacity Control (High/ Low) 100% / 75% 100% / 63% 100% / 70% Inlet F 54.5 Cooling Outlet F 44.6 Inlet F Heating Outlet F Rated Water Flow GPM Evaporator Pressure Loss² PSI 9.2² 11.4² Maximum Operating Pressure PSI 85.3 (High pressure option available 142 PSI) Water Retention Volume Gal Total Heat Rejection MBTUh Inlet Temperature F 85.1 Outlet Temperature F Rated Water Flow GPM Condenser / Absorber Pressure Loss² PSI 9.9² 12.8² 9.2² Maximum Operating Pressure PSI 85.3 (High pressure option available 142 PSI) Water Retention Volume Gal Power Supply 208V or 230V / 60 Hz / 3-Phase Consumption³ Watts 900³ 1200³ 1250³ 1600³ 1800³ Minimum Circuit Amps Amps MOCP Max. Fuse Size Amps Burner High Fire¹ MBTUh 327¹ 436¹ 545¹ 655¹ 873¹ Input Low Fire¹ MBTUh 245¹ 327¹ 409¹ 413¹ 611¹ Supply Gas Pressure Inches W.C w.c w.c. Type Forced Draft with Category I Venting Gas Dedicated: Natural or Propane. Not convertible. Ignition Type Intermittent or Interrupted Spark Flame Detection Optical or UV Scanner Dimensions Weight Width Inches Depth⁵ Inches 60.6⁵ 70.1⁵ 74.8⁵ Height⁴ Inches 79.1⁴ 94.5⁴ Height with Vent Cap Installed⁴ Dry Lbs Inches 96.1⁴ 111.1⁴ Operating Lbs Cabinet UL50E Type 3R, Silver Metallic Pre-Painted Hot Dip Zinc-Coated Sheet Steel Noise Level db(a) Chilled / Hot Inches 2 NPT 2-1/2 NPT 3 NPT 4 Flanged Cooling Inches 2-1/2 NPT 3 NPT 5 Flanged Gas Inches 1-1/2 NPT 2 NPT 2-1/2 NPT Flue Diameter Inches NOTES: 1. Fuel Input is based on the high heat value of gas. 2. Pressure Loss ratings are +/- 10%. 3. Power Consumption does not include external pumps or cooling tower fan motors. 4. Height does not include level bolts. Height with Vent Cap includes both the cap and level bolts. 5. Depth does not include Junction Box. Junction box adds 3.9 to the Depth dimension. 3

4 STANDARD SPECIFICATIONS Metric Units Model Using G Controls CH-K High Fire kw Cooling Low Fire kw High Fire kw Heating Low Fire kw Capacity¹ Chilled / Hot Water² Cooling Water² Electrical³ Burner Construction⁴ Piping Capacity Control (High/ Low) 100% / 75% 100% / 63% 100% / 70% Inlet C 12.5 Cooling Outlet C 7.0 Inlet C Heating Outlet C 55.0 Rated Water Flow liters/sec Evaporator Pressure Loss² kpa 63.4² 78.6² Maximum Operating Pressure kpa 588 (High Pressure option available 980 kpa) Water Retention Volume liters Total Heat Rejection kw Inlet Temperature C 29.5 Outlet Temperature C Rated Water Flow liters/sec Condenser / Absorber kpa 68.3² 88.3² 63.4² Pressure Loss² Maximum Operating Pressure kpa 588 (High Pressure option available 980 kpa) Water Retention Volume liters Power Supply 208V or 230V / 60 Hz / 3-Phase Consumption³ Watts 900³ 1200³ 1250³ 1600³ 1800³ Minimum Circuit Amps Amps MOCP Max. Fuse Size Amps Burner Input High Fire¹ kw 96¹ 128¹ 160¹ 192¹ 256¹ Low Fire¹ kw 72¹ 96¹ 120¹ 121¹ 179¹ Supply Gas Pressure kpa kpa kpa Type Forced Draft with Category I Venting Gas Dedicated: Natural or Propane. Not convertible. Ignition Type Intermittent or Interrupted Spark Flame Detection Optical or UV Scanner Dimensions Weight Width mm Depth⁵ mm 1540⁵ 1780⁵ 1900⁵ Height⁴ mm 2010⁴ 2400⁴ Height with Vent Cap Installed⁴ mm 2440⁴ 2820⁴ Dry kg Operating kg Cabinet UL50E Type 3R, Silver Metallic Pre-Painted Hot Dip Zinc-Coated Sheet Steel Noise Level db(a) Chilled / Hot Inches 2 NPT 2-1/2 NPT 3 NPT 4 Flanged Cooling Inches 2-1/2 NPT 3 NPT 5 Flanged Gas Inches 1-1/2 NPT 2 NPT 2-1/2 NPT Flue Diameter mm NOTES: Metric units listed here are converted from English dimensions. 1. Fuel Input is based on the high heat value of gas. 2. Pressure Loss ratings are +/- 10%. 3. Power Consumption does not include external pumps or cooling tower fan motors. 4. Height does not include level bolts. Height with Vent Cap includes both the cap and level bolts. 5. Depth does not include Junction Box. Junction box adds 100mm to the Depth dimension. 4

5 FACTORY OPTIONS FS2 Cooling Water Circuit Flow Switch Maximum Operating Pressure in Chilled/Hot Water and Cooling Water PSI Reinforcement for Horizontal Rigging (No Horizontal Transport!) WTI Sensor ACCESSORIES Standard (UL Model Only) ACT5 Maintenance Checker (shipped in control box) Eye Bolts (4) Installation Instructions Leveling Bolts (4) Operating Instructions Spare Fuses (in control box) Vent Cap (in separate box) Changeover Valve Actuator (shipped in box with Vent Cap) Optional Accessories Gas Appliance Regulator Gas Meter LON Adapter Kit Metric Flare Adapters Remote Control Panel Water Pressure Tap English Conversion Kit (KITWPC4) WTI Sensor Gas Appliance Regulator Gas Meter KITWPC4 Remote Control Panel WTI Sensor LON Adapter 5

6 EQUIPMENT DIMENSIONS CH-K30, CH-K40 (Measurements in Inches. Drawings Not to Scale) CH-K50, CH-K60 6

7 CH-K80 TYPICAL SYSTEM DESIGN 7

8 WIRING DIAGRAMS 8

9 9

10 SYMBOL DESCRIPTION A thru I BMS and/or Remote Control Panel Connection Terminals REMARKS Field-Installed Optional Remote Control Panel Accessory AL# Alarm Contact Terminal ANOUT Analog Signal Output AX Auxiliary Gas Valve 120V Coil BM Burner Blower Motor 208/230V BN# Burner Wiring Circuit Located on Terminal Terminal Strip BNPW Burner Demand Relay On Circuit Board BON Burner Operation Demand Dry Contact 24V, 60va Max CAPS Combustion Air Proving Switch CHD Enable Signal Dry Contact 24V, 60va Max CHE Alarm Condition Dry Contact 24V, 60va Max CH No. For AroTrend Channel Number / Monitoring / Unit Address LON Adapter Use CHSTN Chiller Disabled Dry Contact 24V, 60va Max CIR Cool Mode Interrupt CM Cool Mode Dry Contact 24V, 60va Max CM1 Common for Pump & Field-Supplied Fan Dry Contact Relays Voltage CM2 Common for Safety 15V DC Unit- Interlocks Provided Signal CN# Molex Connector CND Condenser Thermister COM# Common for External 15V DC Unit- Signal Relays Provided Signal Changeover Valve Actuator CON 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 DCL DC Reactor For VFD DCP# Digital Communication For AroTrend Protocol Interface Monitoring EDF Exhaust Damper/Fan Confirmation Signal EDM Enable LED EMG# Alarm Signal ESC1 External Signal for Cool Mode ESH1 External Signal for Heat Mode ESOFF External Signal to Disable ESON External Signal to Enable F Cooling Tower Fan FAN Control Box Cooling Fan SYMBOL DESCRIPTION REMARKS FD, FE Cooling Tower Fan Safety Interlock FS1 Chilled/Hot Water Flow Switch FS2 Cooling Water Flow Field-Installed Switch Option Fuji Model FGAO- FU11 200V Circuit Fuse 2; 250v, 2 Amp Fuji Model FGAO- FU12 200V Circuit Fuse 2; 250v, 2 Amp Fuji Model FGAO- FU2 24V Control Circuit Fuse 2; 250v, 2 Amp Fuji Model FGAO- FU31 32V Control Circuit Fuse 1; 250v, 1 Amp Fuji Model FGAO- FU32 32V Control Circuit Fuse 1; 250v, 1 Amp G Electrical Ground GBN Electrical Ground for Burner GLS Generator Level Switch GND Electrical Ground GP Generator Thermister GPJ Generator Over-Temp Detection Thermister GPSC Generator Thermal Limit Switch for Cooling Mode GPSH Generator Thermal Limit Switch for Heating Mode GV Main Gas Valve 120V Coil Controls High / Low HF# Burner Firing Rate Circuit Firing Rate Selection HIR Heat Mode Interrupt HM Heat Mode Dry Contact 24V, 60va Max Changeover Valve Actuator HON Heat Position Confirmation High/Low Fire Demand HU IN Control Relay On Circuit Board IF1 Chilled/Hot Water Freeze Protection Circuit IF2 Cooling Water Freeze Protection Circuit IGN Ignition Transformer 120V AC Pri. 6000V AC Sec. INV Inverter (VFD) Controller Hitachi WJ-200 INV SIG # Inverter Signal Line IRS Independent Remote Switch Not Used JP# Fuse on Circuit Board F1:6A ; F2:3A LCOM Common for LEDs LS Expansion Tank / Cistern Level Switch Not Used LT Evaporator Thermister LTPV Refrigerant Proportional Control Valve 32V; 0-400mA MB Burner Motor Contactor 120V Coil MBPW Blower Power Relay 24V Coil Maintenance Required MENTE Dry Contacts 24V, 60va Max MF Flame Failure Dry Contact Not Used 10

11 SYMBOL DESCRIPTION REMARKS MHU High Fire Demand Control Relay On Circuit Board MOP Burner Demand Relay On Circuit Board MRC GPSC Enable Relay On Circuit Board Field-Installed MS Seismic Sensor Terminals Option Solution Pump Enable MSP Control Relay On Circuit Board NFB Non-Fused Breaker OPa Unit Enabled Status Dry Contact 24V, 60va Max P Chilled/Hot Water Pump Dry Contact 24V, 60va Max P1 Chilled/Hot Water Pump P1D, P1E Chilled/Hot Water Pump Safety Interlock P2 Cooling Water Pump P2D, P2E Cooling Water Pump Safety Interlock PCH Palladium Cell Heater 200V; 30 Watts PD Dilution Mode Status Dry Contact 24V, 60va Max PV Pilot Valve 120V Coil R1 Burner Alarm Relay 120V Coil R2 Mod Motor Control Relay 120V Coil RC Cooling Control Relay RFAN Control Box Cooling Fan Control Relay RH Heating Control Relay RRBH Burner High/Low Control Relay 24V Coil RRBL Burner Start/Stop Control Relay 24V Coil Solution Pump RSP VFD Enable/Disable Relay On/Off Signal RSV9 SV91 & SV92 Control Relay 24V Coil SYMBOL DESCRIPTION REMARKS Control Board Relay to RYPW Engage MBPW Junction Box Unit Status S#, S## Terminals, Dry Contacts 24V, 60va Max S1, S2 Selector Switch SA# MOV Surge Protector SP Solution Pump Configurable for ST2 External Safety Interface NO or NC switches SV1 Evaporator Freeze Protection Valve 24V Coil SV91 Concentrated Solution Bypass Valve 200V Coil SV92 Concentrated Solution 200V Coil; Bypass Valve #2 CH-K80 Only TB# Terminal Block THR# Over-Current Relay / Safety Signal THW Set Point Set Back Signal Not Used TR# Transformer Circuit Wiring Terminal 24V AC Primary; TR04M- Power Transformer 18V, 15V, 14V, & UL 13V AC Secondary TR1- ULCE TR2- UL115V WFC- TRUL1 WTI WTO Power Transformer Power Transformer Power Transformer Entering Chilled/Hot Water Thermister Leaving Chilled/Hot Water Thermister 208V or 230V AC Primary; 200V, 24V, & 32V AC Secondary 208V or 230V AC Primary; 120V AC Secondary 208V or 230VAC Primary; 24VAC Secondary Field Wiring Diagram in Junction Box 11

12 Typical Field Wiring CAPACITY CONTROL COOLING HEATING Lo% Lo% NOTE: Lo% = 75% for (K30, K40, K50), 63% for K60, or 70% for K80. 12

13 RECEIVING INSTALLATION 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 semipermanent barriers. Dimension Drawing Not To Scale CH-K30, CH-K40 CH-K50, CH-K60 CH-K80 A 98 (2490) 113 (2870) B 78 (1980) 90 (2285) 95 (2415) C 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. Care should be taken at all times during rigging and handling to avoid damage to the panels and external connections. DO NOT DROP! Remove the crate from the unit. Install the level bolts screwing them in only until the threads reach all the way through the frame bolt. The leveling bolts can remain in place unless the additional height causes trouble getting it to the installation area. CENTER OF GRAVITY The Center of Gravity of all K- Series chiller-heaters is almost dead center of the machine, 40 (1m) up from the base. The Corner Weight of each unit is the same on all four corners. The chart shows corner weights for each size. Unit Corner Weight - lbs (kg) CH-K (650) CH-K (705) CH-K (870) CH-K (920) CH-K (1320) 13

14 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, (3580) 114 (2895) CH-K50, (3810) 126 (3200) 40 (1000) 40 (1000) 28 (700) 28 (700) CH-K (3935) 129 (3275) FOUNDATION All Dimensions in Inches (mm) 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. Antifall measures should always be taken if the chiller-heater is installed within 12 (4 m) of the edge of the roof. 14

15 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 hardware. Yazaki chiller-heaters are designed to use L-anchor plates to secure them to their respective foundations. These anchor plates are included in the accessories box with each K-Series chiller-heater. There are holes in the base rail of the unit for use in bolting the L- anchor plate to the unit. Anchoring the L-anchor plate to the foundation should be done in accordance with the needs of the site and dictates of code. The details of the L-anchor plate follow. L-Anchor Plate Despite the chiller-heater s considerable mass, it is sometimes required that the unit be tied down or anchored in place, usually as part of an applicable seismic code. Follow code requirements in all such cases. CH-K Base Dimensions 15

16 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. 16

17 CHANGEOVER VALVE AND FLOW SWITCH CONNECTION Once the unit is in place and level, there are two additional items that need attending to. First is the installation of the Changeover Valve Actuator Motor. This valve actuator motor is shipped loose. It is wrapped in packing and shipped inside the vent cap. Be careful not to dispose of actuator motor inadvertently as it is absolutely required for the function of the chiller-heater. Replacement of lost actuator motors is not considered a warranty event. The Changeover Valve itself is located at the rear of the unit, just above the Junction Box. Examining the actuator motor assembly and the valve itself, it can be observed that the drive tang has a shallow and a deep end as does the tang receptor on the valve itself. These must be aligned properly before the mounting screws can be properly tightened. Dangling nearby will be a Molex plug which should be connected to the Molex plug on the Changeover Valve Actuator Motor. Next, locate the Chilled/Hot Water Flow Switch (FS1). It is located at the rear of the unit on the right side. The water tubes for it to sense pressure differential are not attached to the flow switch itself when shipped. Rather, the tubes are tied to other nearby tubes so that they do not break during shipping. It is necessary to remove the ties, attach the flare nuts to the flow switch, and tighten properly. 17

18 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. 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 appliances in the area in order to ensure all requirements are being considered. Never install a gas-fired appliance in an unventilated space. Air Openings for CH-K Series (Units With G Control Package Only) Direct to Outdoor Upper Opening Lower Opening CH-K30 82 (530) x FAM 82 (530) x FAM CH-K (704) x FAM 109 (704) x FAM CH-K (884) x FAM 137 (884) x FAM CH-K (1058) x FAM 164 (1058) x FAM CH-K (1413) x FAM 219 (1413) x FAM Ducted to Upper Opening Lower Opening Outdoor CH-K (1060) x FAM 164 (1060) x FAM CH-K (1408) x FAM 218 (1408) x FAM CH-K (1768) x FAM 274 (1768) x FAM CH-K (2116) x FAM 328 (2116) x FAM CH-K (2826) x FAM 438 (2826) x FAM One Opening Direct to Outdoor Upper Opening Lower Opening CH-K (704) x FAM Not Used CH-K (942) x FAM Not Used CH-K (1175) x FAM Not Used CH-K (1413) x FAM Not Used CH-K (1878) x FAM Not Used Free Area Modifier (FAM) Value of Louver. If unknown, use 2.0. (Consult Louver Manufacturer for FAM value.) Dimensions are Inches² (cm²) 18

19 VENTING Venting the flue products safely is a key concern when installing any gas-fired appliance including Yazaki chiller-heaters. Rules for the proper venting of gas-fired appliances are covered in the National Fuel Gas Code, NFPA Section 54. For chimney design purposes, the exhaust gas flow rates listed below reflect input fuel rate operating at high fire with proper combustion air supply, with CO at 8.5%, O2 at 5.5%, and no more than 40% excess air (32% is ideal). Venting gases will be approximately 392 F (200 C) at a density of lbs/ft³. Exhaust Gas Volume CFM (m³/hr) Unit Model CH-K30 (w/ G Control Package) 100 (170) CH-K40 (w/ G Control Package) 134 (228) CH-K50 (w/ G Control Package) 167 (284) CH-K60 (w/ G Control Package) 201 (342) CH-K80 (w/ G Control Package) 267 (454) Exhaust Gas Volume 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. 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 the integration of the kit into the unit control safeties. 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 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 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. 19

20 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. 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) unless a high pressure option was purchased. 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. 20

21 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. 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, usually displaying error code E

22 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 sump overflow. 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 or diverting valve can help prevent this. If the cooling water remains in the lines during heat mode, ensure that any method of isolating the cooling water for heat mode operation does not cause a closed loop within the unit itself. Otherwise, heating of the closed fluid loop can cause water expansion pressure in the loop to quickly build well beyond the pressure limitations of the fluid circuit and can cause catastrophic failure of the fluid loop. Such an event results in immediate end-of-life condition for the unit. Such failure will not be considered a warranty event. 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. 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 nontoxic. 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. 22

23 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). Allowable supply gas pressure range: in. wc. ( in. wc. For K80) 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 recommended 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 optional gas meter Gas Piping Pressure Drop Data Mbtu/hr Capacity Equivalent Pipe Size Length of Straight 1-1/2" 2" 2-1/2" 3" Pipe in Feet 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 at the burner gas valve (7 inches water column for K80 units). 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 could cause an incorrect flame shape in the High Temperature Generator (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. Equivalent Lengths of Pipe Fittings in Feet 1-1/2" 2" 2-1/2" 3" Standard Ell Ell Tee Specific Gravity Correction Factors Natural Gas Multiplier Propane-Air Mix Propane Butane

24 ELECTRICAL Model CH-K Power Supply 208V or 230V / 60 Hz / 3-Phase Consumption³ Watts 900³ 1200³ 1250³ 1600³ 1800³ Minimum Circuit Amps Amps MOCP Max. Fuse Size Amps Power Consumption does not include external pumps or cooling tower fan motors. Electrical³ 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 84.2 F (29 C) or greater, and taking it away when the incoming cooling water drops to 80.6 F (27 C). 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. Terminals A through I in the lower 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. 24

25 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. 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 (the unit 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. In the upper right section of the junction box lies a terminal strip with terminals 1, 2, 3, 4, 5, and CM2 on the left end. Terminals 1 and 2 are for digital communication to the accessory LON Adapter. Terminal CM2 supplies a DC voltage signal that MUST return to terminals 3, 4, and 5. These are pump and motor overload interlocks. Each Each starter overload s auxiliary contacts 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). Finally, in the upper right section of the junction box lies a terminal strip with terminals S5, S6, S7, S8, S11, S12, S13, and S14 on the right end. These terminals are used in pairs and provide sets of dry contacts for feedback of particular conditions. The use for each set of contacts is: S5 S6: Closes when unit is in Cool Mode S7 S8: Closes when unit is in Heat Mode S11 S12: Closes when the unit is Enabled S13 S14: Closes when unit is in Alarm 25

26 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 ph (at 77 F) Conductivity (µs/cm at 77 F) Standard Chloride ion (Cl - ppm) Sulfate ion (SO 2-4 ppm) M-alkalinity (CaCO 3 ppm) Total hardness (CaCO 3 ppm) * 70 Calcium hardness (CaCO 3 ppm) Ionic silica (SiO 2 ppm) Total iron (Fe ppm) Copper (Cu ppm) Reference Sulfide ion (S 2- ppm) ND ND ND Ammonium ion (NH 4 + ppm) Residual chlorine (Cl ppm) Free carbon dioxide (CO 2 ppm) Ryzner stability index 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. 26

27 YAZAKI CH-KG SERIES CHILLER-HEATER INSTALLATION CHECK AND REQUEST FOR START-UP Yazaki Service Provider: Address: Project Name: Project Address: Model No: Anticipated Startup Date: A. CHILLER-HEATER 1. Unit placed and leveled on foundation 2. Service clearance provided on all sides and top (40 in. front) 3. Chiller-heater anchored by L-Anchor plates to foundation (if required) 4. Changeover Valve Actuator Motor located and installed. 5. Flow Switch FS1 flare nuts released from shipping ties and tightened. 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. Flow switch piping attached 4. Water piping leak tested and flushed 5. System filled with water and glycol (if required) and trapped air vented 6. Flow setters installed in water piping 7. Test plugs (Pete s plugs) and/or thermowells installed in the inlet and outlet piping of each chiller-heater 8. Valves installed at each chiller-heater for flow balancing and isolation 9. Air vent valves installed on piping 10. Strainers present and clean 11. Expansion tank (properly charged) and water make-up piping installed to chilled/hot water system 12. Water make-up and fill lines installed to the cooling tower 13. 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 K80) 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 Serial No: 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 chillerheater outlet (indoor installation) E. POWER WIRING 1. Power supply, indicated on the UNIT NAMEPLATE, is connected 2. Wiring completed between the chillerheater, 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) vac 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 2. Adequate vacuum pump available 27

28 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 Phone: Fax: yazaki@yazakienergy.com Web: 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 KGUL-II-1F1-0316