GAS-FIRED DOUBLE-EFFECT ABSORPTION CHILLER-HEATER

FOR YOUR SAFETY If you smell gas: 1. Open windows (only if installed

indoors) 2. Don’t touch electrical switches 3. Extinguish any open flame 4. DO NOT SMOKE! 5. Immediately call your gas supplier

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other equipment.

CONTENTS GENERAL Page

ABSORPTION PRINCIPLE 2

COOLING OPERATION 3

HEATING OPERATION 4

CONTROLS GENERAL INFORMATION 5

CONTROL ADJUSTMENTS 8

CONTROL SEQUENCE 12

OPERATION COOLING 13

PRECAUTIONS 13

HEATING 13

REMOTE CONTROL 13

Page

SAFETY CONTROLS 13

WINTER SHUTDOWN 14

MAINTENANCE GENERAL INFORMATION 14

MAINTENCE SCHEDULE 14

ROUTINE MAINTENANCE 15

EVACUATION OVERVIEW 15

CHEMICAL MAINTENANCE 17

WINTERIZING 17

TROUBLESHOOTING 17

WATER QUALITY 18

ERROR CODES 19

OPERATING INSTRUCTIONS

CH-MG150

CH-MG200

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This product is a gas-fired 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 150 and 200 tons are complete with operating and safety controls. The chiller-heater is fitted with a low NOx burner, automatic spark ignition systems, power combustion blower and proportional firing control.

When this equipment has been applied correctly, installed in accordance with Yazaki INSTALLATION INSTRUCTIONS (supplied with the chiller-heater), and with proper maintenance on the chiller-heater itself and accompanying support items such as pumps, cooling tower, etc., it can provide many years of trouble free operation.

GENERAL

These instructions are intended to

acquaint the Owner/End User with the operation and general maintenance requirements of Yazaki Gas-Fired Double-Effect Absorption Chiller-Heater units.

Please read ALL instructions carefully and observe precautions. Failure to operate and properly maintain this equipment in accordance with the

OPERATING INSTRUCTIONS may affect the equipment performance and product Warranty.

If the equipment does not operate as expected, check the Troubleshooting Guide in these instructions BEFORE calling your Yazaki Authorized Service Provider (ASP). This approach will not only save cost but also helps to avoid any unnecessary down time.

THE ABSORPTION PRINCIPLE

Yazaki absorption chiller-heaters use a solution of lithium bromide and water, under vacuum, as the working fluid. Water is the refrigerant and lithium bromide is the absorbent. During cooling operation, refrigerant liquid boils under the influence of a deep vacuum in the evaporator and creates a refrigerating effect which removes heat from the chilled water circuit.

The double-effect absorption cycle has two generators – one heated by a gas burner and another heated by

superheated refrigerant vapor. The resulting refrigerant is passed through to the condenser, and is then metered into the evaporator. Lithium bromide solution leaving the generators flows into the absorber.

Heat from the cycle is removed by cooling water flowing inside the condenser and absorber tubing bundles. Heat from the cooling water is rejected most typically to a cooling tower, but may also be rejected by alternative methods, including ground loops.

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COOLING OPERATION High-Temperature Generator (HGE)

The gas burner heats a dilute lithium bromide solution in the High-Temperature Generator resulting in a release of superheated refrigerant vapor. The dilute solution becomes more concentrated due to this release. Gravity, temperature, and pressure differences push the more concentrated solution through Heat Exchangers to recycle heat before the concentrated solution is sent to the Absorber (ABS).

After release, the superheated refrigerant vapor flows through the Low-Temperature Generator (LGE) tubing bundle and is used as the heat source for the dilute solution that the LGE contains. Most, if not all, of the refrigerant vapor will condense into liquid refrigerant during this process. Ultimately, this tubing dumps the liquid refrigerant into the Condenser (COND).

Low-Temperature Generator (LGE)

After release, the superheated refrigerant vapor heats dilute lithium bromide solution in the Low-Temperature Generator. The refrigerant vapor liberated from this solution flows into the Condenser while the lithium bromide solution becomes more concentrated. Gravity, temperature, and pressure differences push this more concentrated solution through Heat Exchangers to recycle heat before the concentrated solution is sent to the Absorber.

Condenser (COND)

In the Condenser, refrigerant vapor is condensed on the outer surface of the condenser tubing bundle. Latent heat is removed by the cooling water that flows inside this tubing bundle. The heat absorbed by the cooling water is rejected to a cooling tower or alternative system.

The liquid refrigerant that drips off the tubing bundle joins the liquid refrigerant that resulted from the operation of the LGE and accumulates in the condenser sump. Liquid refrigerant is routed from the condenser sump through an electronic expansion valve which meters the liquid refrigerant as required into the Evaporator (EVA).

Evaporator (EVA)

In the Evaporator, liquid refrigerant is exposed to a substantially deeper vacuum than in the Condenser due to the influence of the Absorber. As the liquid refrigerant flows over the surface of the Evaporator tubing bundle, it boils and removes heat from the chilled water flowing inside the Evaporator tubing bundle. The heat removed from the chilled water circuit is equal to the latent heat of the refrigerant, roughly 1000 BTU per pound of liquid refrigerant boiling into refrigerant vapor.

Absorber (ABS)

The Evaporator and the Absorber share the same space. A deep vacuum in the ABS is maintained by the affinity of the concentrated solution for refrigerant vapor. The concentrated solution flows over the outside of the Absorber tubing bundle where it is cooled by the cooling water flowing inside the Absorber tubing bundle. When the concentrated solution is cooled, it develops an even greater affinity for the refrigerant vapor. The heat absorbed by the cooling water is rejected to a cooling tower or alternative system.

The deep level of vacuum in the ABS section is maintained by the action of the concentrated solution absorbing the refrigerant vapor that is being generated by the EVA during its normal operation.

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This action dilutes the concentrated solution back to the same concentration level as it was when the cycle began. The dilute solution gathers in the

Absorber sump before being pumped back into the Generators to start the cycle anew.

Fig. 1 – DOUBLE-EFFECT ABSORPTION CYCLE (COOLING)

HEATING OPERATION

High-Temperature Generator (HGE)

Dilute lithium bromide solution is heated in the HGE by the gas burner in the same manner as in the cooling cycle. The solution boils vigorously, releasing superheated refrigerant vapor and leaving a more concentrated solution. The refrigerant vapor flows through a changeover valve into the Evaporator section. The concentrated solution flows through another changeover valve into the Absorber sump.

Low-Temperature Generator (LGE)

Although solution does flow through the LGE, since the superheated refrigerant vapor is not flowing in any meaningful amount through the LGE, the solution does not release any refrigerant vapor and the solution simply flows back into the Absorber sump in essentially a still-diluted state. The lack of this generator operation in heating mode is why the heating capacity is lower than the cooling capacity in these chiller-heaters.

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HEATING OPERATION

Evaporator (EVA)

Superheated refrigerant vapor condenses on the outer surface of the Evaporator tubing bundle. Heat equal to the latent heat of the refrigerant is transferred into the hot water circuit. The liquid refrigerant that condensed on the outer surface simply drips off into the Absorber sump, diluting the solution back to the same concentration level as when it started the cycle.

Absorber (ABS)

Liquid refrigerant that condensed on the outer surface of the Evaporator tubing bundle drips into the Absorber sump. Concentrated solution from the HGE and dilute solution cycled through the LGE also ends up in the Absorber sump. The joining of all the liquids results in diluting the solution back to the state at which it began the cycle. This diluted solution is then pumped to the Generators to begin the cycle anew.

Fig. 2 – DOUBLE-EFFECT ABSORPTION CYCLE (HEATING)

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CONTROLS

GENERAL INFORMATION

A control panel, shown in Fig. 3, is built into each absorption chiller-heater and is located on the front of the control box. The control box is located behind the right-hand service door, as shown in Fig. 4. After inspecting the control panel or changing the mode of operation, make sure that the front panel is latched and locked in order to prevent rain from entering the cabinet and damaging the controls. This will also help to prevent unauthorized tampering with controls and settings.

The chiller-heater may also be supervised and controlled in a limited manner by Building Automation Systems (BAS, BMS) when Remote Operation is engaged. Additional controls and

interlocks may be required in some instances. These controls and their functions can be explained by your Yazaki Authorized Service Provider.

Once COOLING or HEATING operation is selected and the unit has started, the chiller-heater will function automatically and remain in operation for as long as there is a demand for chilled or hot water. The burner modulates the Generator heat input in response to the leaving chilled/hot water temperature. When the chilled water temperature demand is satisfied, the solution pump automatically changes to Dilution Mode and the cooling water pump demand stops after a minimum of 4 minutes additional time.

Fig. 3 – Chiller-Heater Control Panel

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GENERAL INFORMATION

Fig. 4

SOLUTION PUMP CONTROL

The VFD Solution Pump is controlled by a Hitachi VFD Controller. This controller has been set up at the factory and SHOULD NOT BE ADJUSTED!

Universal replacements are NOT recommended. Only use OEM parts for the solution pump and controller.

Fig. 5 – Hitachi VFD Controller

Control Panel located behind this panel in this location.

Evacuation Service Valves A and B are located behind this panel in this location.

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CONTROL ADJUSTMENTS

The chiller-heater is normally operated from the control panel behind the right access door. If it is necessary to open the control box for troubleshooting, observe all safety warnings on the chiller-heater and in these instructions. Only

qualified and trained personnel should have access to the live electrical parts inside the chiller-heater. Failure to observe the safety warnings can result in personal injury, death, and/or damage to property.

Fig. 6 – Control Box (Opened)

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CONTROL ADJUSTMENTS

The ACT5 Maintenance Checker plugs into the Main CPU Board, shown in Fig. 8, and is used in many functions, including choosing the leaving chilled/hot water temperature set points.

This board also has the Mode Setting Switch. This switch must be positioned to the left whenever the unit is to be in normal operating condition. Position this switch to the right when adjusting the

burner. Position this switch to the middle when the unit is to sit dormant and unresponsive, but with power applied to it.

The Unit Number Setting Dip Switch is only used in conjunction with the optional AroTrend Remote Monitoring or an optional LON Adapter. If not being monitored, this dial switch must be set to “0” or “F”.

Fig. 8 – Main CPU Board

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CONTROL ADJUSTMENTS

The leaving chilled water and hot water temperature controls are set at the factory to the Standard Specifications Set Points, which are a cooling set point of 44.6°F (7°C) and a heating set point of 140.0°F (60°C). A Yazaki Authorized Service Provider can adjust these set points using the ACT5 Maintenance Checker. The cooling set point is adjustable from 41°F (5°C) to 53.6°F (12°C). The heating set point is adjustable from 104.0°F (40°C) to 145.4°F (63°C).

The CH-MG Series has an Economy Mode feature as well that can be controlled by the Building Management System. Economy Mode functions in much the same way as night set-back. When engaged, the cooling set point will rise by 5.4°F (3°C) and the heating set point will fall by 9°F (5°C). Dis-engaging the Economy Mode will immediately restore the cooling and heating set points back to their original values.

Fig. 7 – ACT5 Maintenance Checker

Adjusting the chilled and hot water set points can only be done using the ACT5. Using a standard CAT5 cable (one was

provided from the factory), connect the ACT5 to the Main CPU Board located in the upper right of the control box. There is a jack in the upper middle of the CPU Board (See Figure 8) that is for use with the ACT5.

There is also an identical jack on the Sub-Control Board located in the top left corner of the control box. This board’s jack is not functional and should not be used.

To adjust the chilled and hot water set points:

1. On the ACT5, use the “Λ” and “V” buttons to move the cursor to the line “2. Unit data set” and press “ENTER”.

2. Then use the “Λ” and “V” buttons to move the cursor to the line “B2 CB Set” and press “ENTER”.

3. Use the “◄” and “►” buttons to reach the menu displaying data points 13-16.

4. Use the “Λ”, “V”, “<”, and “>” buttons to move the cursor to temperature numbers of data point 14 to change the cooling set point, or data point 15 to change the heating set point.

5. Once highlighting the block to be changed, use the “+” and “-“ buttons to scroll through the available values until the desired value is displayed.

6. Press “ENTER” to save the new setting.

7. Press and hold the “◄” for longer than one full second to back out of the menu, or simply unplug the ACT5 if it is no longer needed for other functions.

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CONTROL ADJUSTMENTS

To enable the Economy Mode, locate terminals TB1-75 and TB1-76 (See Fig. 9) on the I/O Board, located at the middle left in the control box. The board sends voltage out on TB1-75, so no external or field-supplied power should be applied to the circuit or else damage to the board could result.

To engage Economy Mode, close a circuit between TB1-75 and TB1-76. When that circuit is closed, the Main

CPU Board logic will automatically apply a modifier to the temperature set point data in memory. When the circuit is open, no modifier will be applied.

Most often, a relay with dry contacts that is controlled by the BMS is used to control Economy Mode. However, a timer, light sensor, or a simple toggle switch could also be used to make or break this circuit.

Fig. 9 – I/O Board

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CONTROL SEQUENCE

A built-in microprocessor in the chiller-heater controls the external pump demand signals in response to the cooling and heating load. The operating sequence of each pump and the cooling tower fan after start-up, during normal operation, and after a normal stop or abnormal shut down is shown in Fig. 10. It is important that the chiller-heater have control over the pumps to allow for

controlled shut down under normal and abnormal conditions.

Running the chilled water pump at all times is discouraged as the chiller-heater logic will expect to see the flow switch open when the “P” dry contacts are opened. If it does not open, the chiller assumes the flow switch has failed and will generate error code E016.

Fig. 10 – General Control Sequence

CP = Cooling Water Pump Demand Relay CTF = Cooling Tower Fan Demand Relay P = Chilled/Hot Water Pump Demand Relay

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OPERATION

COOLING 1. Select “ON” on the DIRECT

OPERATION section of the control panel.

2. Select “COOLING” on the MODE SELECT section of the control panel.

Cooling operation will commence after all self-check functions have completed. This can take as long as 5 minutes so do not be alarmed if the unit does not seem to respond immediately. If the unit is being switched over from HEATING mode, there is an enforced 30-minute delay period before COOLING mode will engage.

PRECAUTIONS 1. Ensure that all AUTO-OFF-MANUAL

switches for external pumps and the cooling tower fan are set in the AUTO position during normal operation. The chiller-heater is designed to automatically control the chilled/hot water pump, cooling water pump, and cooling tower fan signals as it requires.

2. At the beginning of the cooling season, clean and refill the cooling tower with fresh water. Check strainers for debris and spray nozzles for proper operation.

3. During the heating season, the cooling tower and cooling water circuit should be drained in order to help prevent freezing and scaling in the Absorber and Condenser tubing bundles.

4. When two or more absorption chiller-heaters are installed in parallel, set all units to the same operating mode.

HEATING 1. Select “ON” on the DIRECT

OPERATION section of the control panel.

2. Select “HEATING” on the MODE SELECT section of the control panel.

Heating operation will commence after all self-check functions have completed. This can take as long as 5 minutes so do not be alarmed if the unit does not seem to respond immediately. If the unit is being switched over from COOLING mode, there is an enforced 30-minute delay period before HEATING mode will engage.

REMOTE CONTROL

In order to respond to BMS signals, the chiller-heater must be set to remote operation. Simply press the “REMOTE” button on the REMOTE OPERATION section of the control panel. The LED will illuminate on the “REMOTE” button to indicate remote operation has been engaged.

SAFETY CONTROLS

Safety and limit controls monitor

critical operating conditions in the chiller-heater and may shut down the unit when abnormal conditions occur. Not all abnormal conditions are harmful to the chiller-heater, therefore, the chiller-heater may not always shut down when an error code is displayed.

An Error Code will be displayed when an abnormal condition arises. This error

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code will be displayed by LEDS located at the top left of the control panel. A list of error codes and their meanings is shown in Table 2 at the back of this manual.

Some Error Codes will automatically reset themselves once the abnormal condition clears. Others may require a manual reset by pressing the “RESET” button on the control panel. Some manual reset codes will not clear until certain conditions are met, so if the Error Code does not clear or the chiller-heater does not restart, contact your Yazaki Authorized Service Provider (ASP).

WINTER SHUT DOWN

If a chiller-heater is only used in the cooling mode and is to be shut down for the winter, it is necessary to run the chiller-heater in Heat mode for a minimum of 30 minutes in order to properly return all fluids to the bottom of the unit and to prepare the unit for long term shutdown. Without running in Heat mode, some water will be trapped in upper portions of the chiller-heater and could potentially damage the unit should it freeze in the winter conditions.

See the Service Manual for detailed information on proper Winter Shut Down.

MAINTENANCE

GENERAL INFORMATION

ALL MAINTENANCE SHOULD BE PERFORMED BY SKILLED, EXPERIENCED PERSONNEL. Your Yazaki Authorized Service Provider (ASP) can help you establish a standard maintenance procedure.

For your safety, keep the area around the equipment clear and free of combustible materials, gasoline, and other flammable substances. DO NOT obstruct service access to the equipment.

MAINTENANCE SCHEDULE Every 6 months: Evacuation Inhibitor Check (if required)

Combustion Analysis Gas Pressure Check Flow Rate Check Palladium Cell Heater Check Verify Flow Switch Operation

Every 12 months: Flame Rod Replacement Igniter Rod Replacement Every 3 years: Generator Internal Inspection Average Cycle for Inhibitor

Replenishment

ROUTINE MAINTENANCE

Routine maintenance should be provided throughout the life of the equipment in order to ensure satisfactory operation and performance.

During the warranty period, an ASP must be engaged to provide routine maintenance at the beginning of each cooling season (spring changeover) and heating season (fall changeover). When the chiller-heater is used for process cooling or heavy load operation, it may be necessary to schedule additional service visits to evacuate non-condensable gasses from the vacuum section.

Be aware that during the first few months of operation, non-condensable gases may accumulate at a greater rate than expected as the inhibitor coating in the unit finishes forming. However, after approximately 3 months, the formation of non-condensable gases should decrease to the normal expected rates.

Each routine maintenance item is covered in detail, many in step-by-step detail, in Section 5 of the Service Manual. What is provided here is a brief summary of what the Service Manual covers.

EVACUATION OVERVIEW

Arguably the most important aspect of maintenance for the chiller-heater is maintaining a proper level of vacuum. Evacuation is performed at the front of the machine. The evacuation service valves are referred to as Service Valve A (upper) and Service Valve B (lower). Refer to Fig. 4 for detail on where these valves are located at the front of the unit.

The evacuation service valves are back-seating access valves similar to those used throughout the refrigeration industry. The stem has a 10mm square head. The stem secures a copper seal to a steel seat inside the valve. Do not over-torque this valve or else the seal can become damaged and compromise vacuum integrity.

Yazaki offers a torque wrench (P/N

N7510) specifically for use with this service valve.

A number of precautions should be observed at all times during evacuation. Key points are:

*** Great care must be taken to ensure that no oil enters the Yazaki chiller-heater! Permanent damage could result from even a small amount of oil being introduced into the vacuum section! ***

Never leave a vacuum pump running unattended. Power loss could allow the chiller-heater vacuum section to suck oil out of the pump in a matter of minutes.

Never have the Service Valve open unless the vacuum pump is running and the integrity of the vacuum lines between the valve and the pump has been verified as tight.

Never have the vacuum pump discharge tube in the water bucket unless the vacuum pump is running. The vacuum pump could suck water from the bucket and contaminate the oil charge.

Never pull a vacuum when the unit is running in Heat mode. Only pull a vacuum in “Off” or “Cool” modes.

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Always start with a fresh oil charge in the vacuum pump.

Always use a liquid trap or collection flask.

Always use a vacuum gauge to verify the level of vacuum achieved. Run time has almost nothing to do with the level of vacuum achieved.

Never pull a vacuum if the ACT5 Maintenance Checker indicates an LT temperature exceeding 90°F (32°C).

Never pull an extended vacuum (exceeding a few hours). If such seems to be necessary, there is likely to be something wrong with the vacuum pump or the oil has been contaminated with moisture inherently found inside the chiller-heater vacuum section.

Use only dual-stage, deep vacuum pumps. Typical refrigeration vacuum pumps may not perform well on a vessel as large as the chiller-heater vacuum

section. Just because the vacuum pump has stopped producing bubbles in the water bucket does NOT mean the vacuum level is adequate. A digital vacuum gauge MUST be used in order to determine the true level of vacuum achieved.

The desired level of vacuum on a machine that is not running would be less than 2000 microns (<2mmHg), with less than 1000 microns (<1mmHg) preferred. On a machine actively running in Cool mode (burner engaged), the desired level of vacuum is 5000 microns (5mmHg), no less. Any lower than 5000 microns (5mmHg) on a running machine will cause the vacuum pump to remove an extraordinary amount of refrigerant vapor (water).

A step-by-step, detailed evacuation method is provided in Section 5 of the Service Manual. The general evacuation assembly setup is displayed in Fig. 11.

Fig. 11 – General Evacuation Assembly Setup

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CHEMICAL MAINTENANCE

It is not necessary to perform regular chemical maintenance on the Yazaki chiller-heater itself. The chemical balance has been established in the factory during run testing. Normally, the only chemical that must be maintained is the inhibitor charge. By capturing non-condensable gases, as shown in Fig. 12, comparison can be made to determine if the normal hydrogen byproduct is being produced at anticipated rates. If more hydrogen is being produced than anticipated, a maintenance inhibitor charge may need to be introduced into the machine by the ASP. An inhibitor

charge is typically needed every three years in Yazaki gas-fired chiller-heaters.

Fig. 12 – Capturing Gases

WINTERIZING

When equipment is located outdoors

in climates subject to freezing, cooling water must be drained from the chiller-heater, piping, and cooling tower at the end of the cooling season. Use of glycol may also be permissible. Consult the Service Manual for details concerning Anti-Freeze Strategies.

When draining a fluid loop, make sure to blow through the emptied loop with compressed air (or similar). Blow in both directions through the loop so as to blow out as much of the residual fluid as possible. This is to help prevent potential tube damage during freezing conditions.

TROUBLESHOOTING SYMPTOM: Chiller-Heater does not operate. Possible Cause REMEDY

No High Voltage Check the LED for the Power indication on the Control Panel. If it is not illuminated, check the main power disconnect, fuses, and breakers.

Solution Pump Not Running Check for illumination of the "FAILURE" LED in the row of indicator LEDs for the Solution Pump. If lit, check the VFD Controller.

Manual Reset Device Tripped Check the error codes using the display on the front panel or the ACT5 Maintenance Checker to identify which device is tripped.

Unit Overheated Check combustion, gas pressure, and vent assembly for conditions that cause over-firing or prevent proper venting. Check the VFD controller for the Solution Pump. Improper mass flow through the machine can cause overheating symptoms.

SYMPTOM: Poor cooling capacity.

Possible Cause REMEDY

Poor Vacuum Evacuate the machine per normal maintenance procedure.

High Inlet Cooling Water Temperature

Check the cooling tower fan. Check the cooling tower fluid level.

Low Cooling Water Flow Rate Check the cooling tower sump and cooling water circuit strainers.

Condenser/Absorber Fouling, Scale Buildup

Check the cooling water circuit strainers. It may be necessary to drain the cooling water circuit and open the inspection doors on the chiller-heater condenser and absorber for a visual confirmation.

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WATER QUALITY

It is the responsibility of the Owner or End User to have the cooling water analyzed and chemically treated as often as is necessary so that it conforms to the

limits shown in Table 1. The water quality in the chilled/hot water and the cooling water circuits should not exceed the following limits:

Note: 1. Items shown in the Trend column: An “O” mark indicates the potential issue should this line item go

out of acceptable range. 2. When water temperature rises above 104°F (40°C), the tendency for corrosion rises remarkably. As

such, there may arise a need for additional corrosion protection measures such as buffers and inhibitors.

3. For closed-loop cooling towers, use the Hot Water column data in the Circulating Water chart instead of the Cooling Water column data. For make-up water, use the Chilled Water column data instead of the Cooling Water column data.

Table 1 – Water Quality Charts

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ERROR CODES Error Code

Error Description Notes

1 DCP power error Remote monitoring package has lost power.

2 DCP communication line short Power available to the remote monitoring package but communication line is shorted.

3 DCP communication line noise Remote monitoring package cannot communicate with the chiller-heater.

4 Accessory error Optional fire safety shutdown has been enacted.

5 Chilled/hot water pump interlock error

Voltage signal from terminal CM2 in the junction box is not returning to terminal 3 in the junction box.

6 Cooling water pump interlock error

Voltage signal from terminal CM2 in the junction box is not returning to terminal 4 in the junction box.

7 Cooling tower fan interlock error Voltage signal from terminal CM2 in the junction box is not returning to terminal 5 in the junction box.

8 Solution pump error Solution pump VFD is reporting alarm status.

9 Generator (HGE) over heat error GP sensor indicates 325°F (163°C) or greater. Reset allowed when GP sensor reads below 302°F (150°C).

10 Generator (HGE) temp error GPSC or GPSH manual limit switch open when it should be closed.

12 Generator (HGE) solution level error

Generator level switch has opened when it should be closed. Ignored for first 10 minutes of burner operation.

13 WTO sensor error WTO sensor reads below 14°F (-10°C) or above 212°F (100°C).

16 Flow switch error (FS1) FS1 did not open after "P" dry contacts opened. FS1 assumed stuck closed.

18 Seismic switch error Seismic switch is open when it should be closed.

19 Generator (HGE) over heat alarm The Generator temperature or HPS pressure reading has been unusually elevated for 30 consecutive minutes, but has not reached 325°F (163°C).

20 Cooling water scale alarm The temperature rise through the cooling water circuit is less than expected.

21 Cooling water scale error The temperature rise through the cooling water circuit is less than expected to the point of potentially damaging the chiller-heater.

24 Freeze protection error Freeze protection logic steps have been ineffective.

25 High cooling water temperature Cooling water above acceptable temperatures: CTI above 95°F (35°C) and/or CTO above 108°F (42°C) for 3 consecutive minutes.

26 Generator (HGE) over heat in heating mode

GP sensor reads above 252°F (122°C) in heating mode.

27 Chilled water flow switch error Flow Switch FS1 is open when it should be closed.

28 Cooling water flow switch error Optional cooling water Flow Switch (FS2) is open when it should be closed.

29 CTO sensor error CTO sensor reads below 14°F (-10°C) or above 212°F (100°C). Ignored for first 10 minutes of P2 operation.

30 Exhaust gas temperature error EXH sensor reads above 446°F (230°C)

31 Generator (HGE) pressure error HPS indicates a pressure above 750 mmHg for 10 consecutive seconds. Reset allowed when pressure falls below 550 mmHg.

32 GP sensor error GP sensor reads above 446°F (230°C)

33 CTI sensor error CTI sensor reads below 14°F (-10°C) or above 212°F (100°C). Ignored for first 10 minutes of P2 operation.

35 Aspirator and exhaust fan error The small exhaust fan in the control box has failed or is unable to cool the box properly.

36 CND sensor error CND sensor reads below 14°F (-10°C) or above 212°F (100°C).

40 Loss of cooling capacity LT temperature reading has not fallen below 59°F (15°C) within 30 minutes.

43 Low cooling water temperature CTI sensor reads below 46.4°F (8°C) at start of operation, or has dropped below this limit for 2 consecutive minutes during operation.

44 Changeover valve error Changeover valve end switch has not closed within 22 seconds.

52 Combustion system error Burner control indicates alarm status. This incorporates all burner limits including air pressure switch, gas pressure switches, and flame safeties.

72 LT sensor error LT sensor reads below 14°F (-10°C) or above 212°F (100°C).

77 Generator (HGE) pressure sensor error

HPS output below 0.5vdc for 30 consecutive seconds, OR correlation of HPS pressure reading disagrees with GP senor reading after 10 minutes while GP sensor reads above 212°F (100°C).

88 Corpus pressure error HPS pressure reads above typical atmospheric pressure. Chiller-heater requires tubing inspection to check for tubing breech.

93 Model setting error Configuration and options do not match the model selected in ACT5 Unit Data Set.

94 Check mode neglect Unit left in test mode without interaction longer than 30 minutes.

95 Data initial clear CPU board requires reboot or replacement.

96 Extended Error Code Alert An error code number beyond 99 exists.

101 WTI sensor error WTI sensor reads below 14°F (-10°C) or above 212°F (100°C).

105 Low chilled/hot water temp alert WTO sensor reads below 35.6°F (2°C).

Table 2 – Error Codes

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.

MGUL-OI-1C2-0813