wfc-sc10, 20, 30 installation instructions wfc-sh10, 20, 30 · 2017. 6. 29. · capacities of 10,...
TRANSCRIPT
WATER FIRED SINGLE-EFFECTABSORPTION CHILLER AND CHILLER-HEATER
This product is a water fired absorption unit which provides chilled water for cooling or hot waterfor heating in central plant type air conditioning systems. Units with nominal refrigeration capacities of 10, 20, and 30 tons are complete with operating and safety controls. The absorp-tion chiller or chiller-heater is energized by heat medium (hot water) at 158oF to 203oF from a process, cogeneration, solar or other waste heat source.
CONTENTS
INSTALLATION INSTRUCTIONSWFC-SC10, 20, 30WFC-SH10, 20, 30
GENERAL Page• STANDARD SPECIFICATIONS 2• PHYSICAL DATA 3• 3SEIROSSECCA• MODEL DESIGNATION 3• CONTROL ADJUSTMENTS 3• EQUIPMENT DIMENSIONS 4• TYPICAL SYSTEM DESIGN 6• INTERNAL WIRING 8INSTALLATION• 01GNIVIECER
Page• UNIT NAMEPLATE 10• 01GNIGGIR• 01NOITACOL• 21NOITADNUOF• 21TNEMECALP• 21GNIPIP• 51LACIRTCELE• WATER QUALITY 24• INSTALLATION CHECK AND
REQUEST FOR START-UP 24
GENERAL
STANDARD SPECIFICATIONS
03HS03CS02HS02CS01HS01CSCFWLEDOMCooling Capacity (Btu/hr x 1000) 120.0 240.0 360.0 Heating Capacity (Btu/hr x 1000) 166.3 332.6 498.9
Outlet Temperature (oF) Cooling 44.6, Heating 131.0Rated Water Flow (gpm) 24.2 48.4 72.6Evaporator Press. Drop (psi) 8.1 9.6 10.1
3.58 )isp(.sserP gnitarepO.xaMWater Retention Volume (gal) 4.5 12.4 19.3 Heat Rejection (Btu/hr x 1000) 291.4 582.8 874.2 Inlet Temperature (o )dradnatS( 8.78 )FRated Water Flow (gpm) 80.8 161.7 242.5 Cond./Abs. Press. Drop (psi) 12.3 6.6 6.7
3.58 )isp(.sserP gnitarepO.xaMWater Retention Volume (gal) 17.4 33.0 51.3 Input (Btu/hr x 1000) 171.4 342.8 514.2
Inlet Temperature (oF) 190.4 (Standard) Temperature Range 158 (min.) - 203 (max.)
Rated Water Flow (gpm) 38.0 76.1 114.1 Generator Press. Drop (psi) 13.1 6.7 8.8
3.58 )isp(.sserP gnitarepO.xaMWater Retention Volume (gal) 5.5 14.3 22.2
Electrical hp 3 ,zH06 ,V802 ylppuS rewoPConsumption (W) 210 260 310
ffO - nO lortnoC yticapaC
2
This equipment should only be installed bytrained and qualified personnel who are familiarwith absorption chillers. All precautions in theseinstructions, on tags and labels attached to theunit, must be observed to ensure the safety ofpersonnel and warranty validation.
Each absorption chiller and chiller-heater hasbeen evacuated, charged with lithium bromide-watersolution and tested prior to leaving the factory.
Field wiring connections are located on theleft side and piping connections are located on the rear of each unit.
After the equipment has been installed anAuthorized Yazaki Service Provider will check theinstallation and supervise the initial start-up andoperation of the absorption unit.
CAUTION
THE YAZAKI WARRANTY WILL BE VOIDED IF THE FOLLOWING RESTRICTIONS ARE NOT OBSERVED:
1. DO NOT OPEN ANY SERVICE VALVES BECAUSE SUCH ACTION WILL RESULT IN LOSS OF VACUUM.
2. ALWAYS HANDLE THE EQUIPMENT WITHCARE AND MAINTAIN IN A NEAR VERTICALPOSITION DURING RIGGING. IF THEEQUIPMENT MUST BE TILTED, NOTIFY
THE AUTHORIZED YAZAKI SERVICEPROVIDER FOR INSTRUCTIONS.
3. DO NOT ATTEMPT TO START THE ABSORPTION CHILLER WITHOUT SUPER-VISION FROM THE AUTHORIZED YAZAKI SERVICE PROVIDER.
Chilled/HotWater
CoolingWater
HeatMedium
PHYSICAL DATA03HS03CS02HS02CS01HS01CSCFWLEDOM
3.457.149.92)ni( htdiW0.362.152.83 )ni( htpeD
Height [Note] (in) 74.8 [75.6] 79.1 [79.9] 80.5 [81.3]Chilled/Hot Water (in) 1-1/2 NPT 2 NPT 2 NPTCooling Water (in) 2 NPT 2 NPT 2-1/2 NPTHeat Medium (in) 1-1/2 NPT 2 NPT 2-1/2 NPT
002,3 050,2 001,1 )bl( yrDOperating (lb) 1,329 2,548 3,975
foorprehtaeW epyTleets dezinavlag deppid toh detniap-erP lairetaM
cillatem revliS hsiniF
Note: Dimensions in [ ] include leveling plate.
ACCESSORIES
Standard Eye Bolts (4), Shims (6), Fuses (4), Installation Instructions (1) and Operating Instructions (1)
MODEL DESIGNATIONWFC -
Water Fired Single-Effect Absorption Chiller/Chiller-Heater
Model Selection: SC...Chiller, SH...Chiller-Heater
Cooling Capacity: 10...10RT, 20...20RT, 30...30RT
CONTROL ADJUSTMENTS
3
Dimensions
Piping
Weight
Cabinet
• Standard Rating Point Standard Control Settings
The leaving chilled water and hot water temperature controls are set at the factory to theStandard Specifications. The Authorized YazakiService Provider can adjust the setpoints with the ACT-3 maintenance checker to accommodate step control on multiple units or
satisfy alternative design temperatures, however, the differential is fixed. Standard factory setpoints are adjustable from 59.9oF to41.9oF (leaving chilled water) and 122.9oF to140.9oF (leaving hot water).
EQUIPMENT DIMENSIONS
WFC-SC10/SH10
WFC-SC20/SH20
Top
RearFront ViewLeft Side
44.9
51.2
41.7
5.9
42.5
79.1
0.8
23.3
34.3
29.8
40.0
4.5 4.532.3
16.7
23.0
20.9
Heat Medium Outlet2 NPT
Heat Medium Inlet2 NPT
Chilled/Hot Water Outlet2 NPT
Chilled/Hot Water Inlet2 NPT
Cooling Water Condenser Inlet 2 Npt
Cooling Water Condenser Outlet2 NPT (3C)
Cooling Water Absorber Outlet2 NPT
Cooling Water Absorber Inlet 2 NPT (3C)
10.4
Note: Cooling Water Crossover Pipe Field Connectons Shown In ( ) Are 3" Sweat Type L Copper.
10.8 10.0
12.0
16.4
6.1
9.0
11.0
37.8
3.5
38.6
7.9
20.8
Cooling Water Crossover (Optional)
4 Eye Bolts For Lifting
Mounting Plate Field Wiring
Junction Box
19.1
4
TOP
3.5
Field WiringJunction Box
31.5
4.9
26.4
29.933.1
26.4
4 Eye Bolts For Lifting
Mounting Plate
7.5
38.2
LEFTFRONT REAR0.
874
.8
9.0
6.1
12.516.4
Cooling Water Outlet 2 NPT
Cooling Water Inlet 2 NPT
Heat Medium Outlet1-1/2 NPT
Heat Medium Inlet1-1/2 NPT
Chilled/Hot Water Outlet1-1/2 NPT
Chilled/Hot Water Inlet1-1/2 NPT
18.4
8.7
20.8
19.5
20.1
45.3
3.3 22.8 3.3
Note: Cooling Water Crossover Pipe Field ConnectionsShown In ( ) Are 3" Sweat Type L Copper.
Heat MediumOutlet2 NPT
Heat MediumInlet2 NPT
Chilled/HotWater Outlet2 NPT
Chilled/HotWater Inlet2 NPT
Cooling Water Condenser Outlet
2 NPT (3C)
Cooling WaterCondenser Inlet
2 NPT
Cooling WaterAbsorber Outlet
2 NPT
Cooling WaterAbsorber Inlet
2 NPT (3C)
Field WiringJunction Box
TOP
REARFRONTLEFT
Cooling WaterCrossover (By others)
4 Eye BoltsFor Lifting
MountingPlate
Top View
Rear ViewFront ViewLeft Side
49.6
63.0
54.3
55.1
0.8
80.5
5.3
30.7
35.4
37.3
17.3
19.7
23.1
12.5 10.0
12.3
9.0
6.1
16.4
57.5
Cooling Water Crossover (Optional)
3.5 22.5
11.7
50.4
5.5
7.9
4 Eye Bolts For Lifting
Mounting Plate
Field Wiring Junction Box
43.35.3
10.6
22.4 Chilled/Hot Water Inlet
2 NPT
Chilled/Hot Water Outlet2 NPT
Heat Medium Inlet2-1/2 NPT
Heat Medium Outlet2-1/2 NPT
Cooling Water CondenserOutlet2-1/2 NPT (3C)
Cooling Water Condenser Inlet2-1/2 NPT
Cooling Water Absorber Outlet2-1/2 NPT
Cooling Water Absorber Inlet2-1/2 NPT (3C)
Note: Cooling Water Crossover Pipe Field Connections Shown In ( ) Are 3" Sweat Type L Copper.
14.8
5
EQUIPMENT DIMENSIONS
WFC-SC30/SH30
All dimensions shown in inches.
Note: Cooling Water Crossover Pipe Field ConnectionsShown In ( ) Are 3" Sweat Type L Copper.
Heat MediumOutlet2-1/2 NPT
Heat MediumInlet2-1/2 NPT
Chilled/HotWater Outlet2 NPT
Chilled/HotWater Inlet2 NPT
Cooling WaterCondenser Outlet
2-1/2 NPT (3C)
Cooling WaterCondenser Inlet
2-1/2 NPT
Cooling Water Absorber Outlet
2-1/2 NPT
Cooling WaterAbsorber Inlet
2-1/2 NPT (3C)
TOP
REARFRONTLEFT
MountingPlate
4 Eye BoltsFor Lifting
Field WiringJunction Box
Cooling WaterCrossover (By others)
TYPICAL SYSTEM DESIGN(SINGLE MODULE)
WFC-SC10/SH10
WFC-SC20/SH20WFC-SC30/SH30
6
TYPICAL SYSTEM DESIGN(MULTIPLE MODULES)
2 X MODULES(WFC-SC20/SH20, WFC-SC30/SH30)
7
TERMINALSSYMBOL LOCATION REMARK
Control boxJunction box Field wiring
connectionsControl box (I/O board)Connector
8
INTERNAL WIRING
FUSE RATINGSYMBOL AMPS (A) REPLACEMENT
Bussmann model F2 3 GLQ-3 or GMQ-3.2,
rated 300 V AC F11, F12 2 Fuji model FGAO-2,F4 2 rated 250 V ACFT1, FT2 5
SOLUTION PUMP OVERLOAD SETTINGS
SYMBOL WFC MODEL (*208 V AC)SC/SH10 SC/SH20 SC/SH30
THRP 0.4 0.7 2.0
* Power supply tolerance +10%, -5%
L1
L2
L3
G
L1
L2
L3
G
SP
U V W MP
2
SV9
3
FT2 TR5
WFC-TRUL1
TR2
FT1 TR4
F11
F12
TR7
TR8
OV 24V
AC
A1
208VA2
TR1
THRP
MP
208V, 60Hz, 3PHPOWER SUPPLY
JUNCTIONBOX
G
G
SA1RMP RV9
CN12
*
CVR
1 2 6 3 4
1 2 3 6
1 2
54
5 CM2 CTF CM1 PP3A
P3B
A B C D E
A B C D E
F G H
HL
CL
CM3
CHOFF
CHON
H1
C1
CP
P P3A
P3B
CM1
CM2
FD
P1D
P2D
P3D
CTF
OPL
LCOM
EDM
HM
CM
COM
ESOFF
ESON
ESH1
ESC1
LCOM
I
IOCN1
IOCN2
TMC1
CPU
CPU
CPU
S3EGBON HM CM CHD CHE
S4 S5 S6 S7 S8 S11 S12 S13 S14
S3 S4 S5 S6 S7 S8 S11 S12 S13 S14
CP
TB2
CN-16
LTPVCIRCUIT
LTVP
FEP2EP1ECIRHIRIRSLS AC24VDCPST2IF1IF2
MGC2-4
OUC-5
TB2 TB4TB1
CHE
1F3
EGON
EGON
P3D
P3D
MGC2
EXFRFH(MF)
EGBON(RBL)RCVR
RBPW
SV9OPSPAC24V
AC24V
AC18V
TR-LV
TR9TR11
TR10F2
F4
SA2
A1 A2
AC15V
MONITORINGUNIT
DC POWER
JUNCTION BOX
I/O BOARD
P2P1
FS1
FS2
CN11
NCTr
1 28 9 3 125410 115131411 721 6 8 12 9104 119 710 8 4 5 631 211 912 10 6 3 4 1 2 13 1457 8CNC2-1
CNPV
5 6 3 4 1 2
1 4 1 3 2 4
RP3
HMCHSTN CM OP CHD AL
T B3(MS)
OUC2-GTMC2-2(GSPS)
17
1847351
1387124 1
371542114543
HC
26
CON
HON
207231183725432
3614
1234
615181
116 1 3 6
12 3 5 4
82 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
3 1 2
18THRP
RFHS14S13S12S11S8S7
S10BO
S9
S6S5S3
SV1
SV10
CNC2-2BPC
S4
S1 S2SV11SV1
RBORP3 RV9 EGS GPSCGPSHRMP
CNC-1
CN13
CN13CN12
MGC-1G
Only installed on SH model chiller-heaters.
TRC3
TRC1 TRC2
OUC-4
PWC
C H
* *
RBO
OPTIONAL I/O BOARD CONNECTIONSTERMINAL DESCRIPTION REMARKSTB No.
INTERNAL WIRINGSYMBOL DESCRIPTION REMARK
0
OPTIONAL JUNCTION BOX CONNECTIONSTERMINAL DESCRIPTION REMARKS1, 2 (DCP) Remote monitoringA (C1) Cooling mode selection RemoteB (H1) Heating mode selection selection ofC (CHON) Start selection COOL, HEAT,D (CHOFF) Stop selection ON, OFFE (CM3) Common 3
CTFCooling tower fancontrol (84.2oF ON,80.6oF OFF)
S11, S12
e
(CHD)
(CHE) alarm
9
STANDARD JUNCTION BOX CONNECTIONSTERMINAL DESCRIPTION REMARKS
3 (P1D/P1E) Chilled/hot water pumpthermal overload
4 (P2D/P2E) Cooling water pump Interlocksthermal overload (NC or NO)
5 (FD/FE) Cooling tower fan for thermalthermal overload overload tripHeat medium pump contacts
6 (P3D/P3E) thermal overload or heat medium bypassvalve limit switch
CM1 Common 1
S3, S4 Heat medium pump( )NOBGE
1
MGC2
3
7,8(ST2)9,10(IF1)
3,7(IF3)7,8
(CHSTN)13,14(OP)17,18(AL)
Shutdown interlock
Chilled/hot waterfreeze protection
Heat mediumfreeze protectionChiller-heaterstandby modeOperating status
General fault alarm
Additionalinterlock (NC or NO)Input controlfrom temp.switch(36.5°F ON,39.2°F OFF)
OPTIONAL CONTROL BOX CONNECTIONSTERMINAL DESCRIPTION REMARKS
S1, S2 Heat medium supply(RFH) shutdown S9, S10 Auxiliary boiler(BO)
Chiller Enabled
CP (P2) Cooling water pump
P3A Heat medium pump orheat medium bypass
P3B valve
P (P1) Chilled/hot water pump
17, 18 Input(EGON) Heat available control from
temp. switch
2, 3 on Cooling water Input controlCN11 (FS2) flow switch from flow
switch
S5, S6(HM) Heating mode
S7, S8(CM) Cooling mode
SP Solution pump
MP Solution pumpmotor contactor
THRP Solution pumpthermal overload
CVR Changeover valve SH model only
WFC-TRUL1 Class 2 transformer 208/24V ACTR-LV Low voltage 24/18,
transformer 16 V AC
SA1, SA2 Surge absorbers
F2, F4,F11, F12FT1, FT2
FusesRefer toFuse RatingTable
SV1 Refrigerant freezeprotection valve
SV9 Concentrated solutionbypass valve
SV11 Refrigerant drain valve SH model only
LTPV Refrigerant proportionalcontrol valve
LT Evaporatortemperature sensor
WTO Chilled/hot watertemperature sensor
CTI Cooling watertemperature sensor
HWT Heat mediumtemperature sensor
FS1 Chilled/hot waterflow switch
RMP, RP3, Control relaysRV9, RB0
RECEIVINGWhen the absorption chiller is delivered to
the job site, inspect for any transit damage. Reportany damage to the carrier and note on the bill oflading. Notify the Yazaki Sales Representative orDistributor before proceeding with the installationof a damaged unit.
UNIT NAMEPLATEThe UNIT NAMEPLATE is located on the
lower right hand side of the front panel on eachabsorption chiller unit. Check that the model number, flow rates and electrical specifications are compatible with the system design and services available.
RIGGINGRemove the crate from the absorption chiller.
When access is restricted, it may be necessary toremove the skid to reduce overall height.
Each unit has four eye bolts in the top panelwhich should be used for lifting.
Care should be taken at all times during rigging and handling of the absorption chiller toavoid damage to the panels and external pipeconnections. DO NOT DROP.
Attach a sling to the four eye bolts in the toppanel as shown in Fig.1 and ensure that the ropeangle is greater than 60O to the horizontal plane.Always carry the absorption chiller in a NEARVERTICAL POSITION. DO NOT TIP OVER.
The dry weight and overall dimensions areshown in PHYSICAL DATA on Page 3 as a guidefor rigging (add 6 in. to overall height for skid).
When moving the absorption chiller, checkthat the route is accessible. The minimum accessdimensions for a skid mounted chiller are shown in Fig.2.
LOCATIONYazaki absorption chillers have a weather-
proof cabinet suitable for either indoor or outdoorinstallation.
Select a location with due consideration forthe proximity of the cooling tower, chilled/hotwater coils and service access.
The minimum space requirements, shown inFig.3, must be provided around and above eachchiller for installation and service access.
Fig. 1 RIGGING
MODEL
DIMENSION WFC-SC10 WFC-SC20 WFC-SC30WFC-SH10 WFC-SH20 WFC-SH30
A 93 98 98 B 63 75 88 C 63 75 88 D 63 75 88
Fig. 2 ACCESS CLEARANCES (IN.)
The roof on which equipment is to be installed shall be capable of supporting the operating weight of the absorption chiller, associated pumps, cooling tower and piping.Install the equipment on a well drained surface ofthe roof at least 6 ft. from the edge. If the roof ispoorly drained at the equipment or in the passageway to the equipment a suitable platformof walkway should be provided adjacent to theequipment and control panels so that it can beserviced safely.
10
INSTALLATION
C 29.9
49.9
B
10.0
E
33.1
38.2
DF
A
26.4
46.2
7.5
4.0
MountingPlate
51.2
61.9
10.0
59.2
4.0
41.9
44.9
51.2
71.0
71.0
61.9
10.0
54.3
57.5
MountingPlate
74.3
10.0
59.2
4.0
9.14C
44.9
MountingPlate
MountingPlate
10.0
59.2
51.2 A
DF
38.6
7.9
131.8
10.0
59.2
41.9 E
44.9
B
B
28.0
4.0
38.6
7.9 63
.0
50.4
7.9
4.0
63.0
50.4
7.9
FRONT
WFC-SC30/SH30
54.3
57.5
10.0
FRONT
WFC-SC30/SH30
54.3
57.5
FRONT
WFC-SC30/SH30
FRONT
WFC-SC20/SH20
FRONT
WFC-SC20/SH20
A
C
FRONT
WFC-SC20/SH20
FRONT
WFC-SC10/SH10
D
E
F
MountingPlate
Fig. 3 INSTALLATION CLEARANCES (IN.)
11
INSTALLATION AREAMODEL DIM. (IN)
No. WFC A B 1 SC10/SH10 118.2 85.9 1 SC20/SH20 131.2 97.9 1 SC30/SH30 143.0 110.3 2 SC20/SH20 131.2 167.8 2 SC30/SH30 143.0 192.6
SERVICE CLEARANCESIDE DIMENSION (IN)
LEFT (C) 28 REAR (D) 40 RIGHT (E) 28 FRONT (F) 40
ANCHOR BOLT DETAIL
SHIM DETAIL
2.8
3.1
1.2
Cabinet
ShimWFCNut And Washer
Anchor Bolt (1/2")
Mounting Plate
Material: 304SS
Thickness 2mm
1.6
5.9
3.1
Foundation
Installation Area
Foundation
Installation Area
12
FOUNDATION
Mount the absorption chiller on a level floor orfoundation capable of supporting the operatingweight of the unit (refer to PHYSICAL DATA onPage 3).
A concrete base, with dimensions shown inFig. 4, should be at least 12 in. thick and reinforced with crushed rock or steel.
PLACEMENT
When the absorption chiller has been movedinto final position, remove the skid (if not alreadyremoved). Place a spirit level on the level bar,shown in Fig. 5, and insert stainless steel slotted
PIPING
GENERALAfter leveling the absorption chiller, the piping
for chilled/hot water, cooling water and heat medium should be installed. Arrange the pipingwith offsets so that it does not interfere withremoval of panels or service access to the equipment. Adequately support and brace the piping independently of the unit to avoid strain onthe pipe connections. Provide thermowells at eachinlet and outlet connection for measurement offluid temperatures during start-up and routinemaintenance (not required on cooling watercrossover piping).
CHILLED/HOT WATER PIPINGThe chilled/hot water piping contains chilled
water during cooling operation and hot water during heating operation and must be
adjustment plates (shims) between each mounting plate and the foundation, as shown inFig. 6. Adjust the shim thickness for longitudinaland transverse alignment of the absorption chiller.
pressurized, as shown in Fig. 7, by either an opencistern or closed expansion tank. Install pipingwith a rising grade of 1/200 and install manualvent valves at high points to expel trapped air.
A balancing valve should be installed adjacent to the chilled/hot water outlet on eachunit to facilitate flow rate adjustments within specified limits. Install a stop valve adjacent to thechilled/hot water inlet on each chiller. This valvemust be in the full open position when the equipment is operating. DO NOT CLOSE the stopvalve except for disconnection or relocation of themachine.
Insulate piping AFTER LEAK TESTING toprevent heat transfer and sweating. Coverinsulation with a vapor barrier and ensure all stopvalves, balancing valves and thermowells areaccessible.
Fig. 4 FOUNDATION EXAMPLE
Fig. 5 LEVEL BAR Fig. 6 ADJUSTMENT (SHIM) PLATE
Whenever the absorption chiller or thechilled/hot water piping is installed outdoors andsubject to ambient temperatures below freezing,the circuit should be filled with a glycol solution ofadequate concentration to prevent freezing. It isimportant that the glycol solution contain inhibitors to protect the copper tubes in theabsorption chiller from corrosion. If glycol is notused for freeze protection, install a temperaturelimit switch in the lowest outdoor section of the
HEAT MEDIUM PIPINGThe heat medium piping contains water which
must be pressurized, as shown in Fig. 8, by eitheran open cistern or closed expansion tank. Installpiping with a rising grade of 1/200 and install man-ual vent valves at high points to expel trapped air.
A balancing valve should be installed adja-cent to the heat medium outlet on each unit tofacilitate flow rate adjustments within specifiedlimits. Install a stop valve adjacent to the heatmedium inlet on each chiller. This valve must be inthe full open position when the equipment isoperating. DO NOT CLOSE the stop valve exceptfor disconnection or relocation of the machine.
Insulate piping AFTER LEAK TESTING toprevent heat loss and ensure that all stop valves,balancing valves and thermowells are accessible.
Whenever the absorption chiller or the heatmedium piping is installed outdoors and subjectto ambient temperatures below freezing, the
chilled/hot water pipe and interlock the switch withthe absorption chiller controls (refer to OptionalField Wiring Connections).
circuit should be filled with a glycol solution ofadequate concentration to prevent freezing. It isimportant that the glycol solution contain inhibitors to protect the stainless steel tubes in the absorption chiller from corrosion. If glycol isnot used for freeze protection, install a temperature limit switch in the lowest outdoor section of the heat medium pipe and interlock theswitch with the absorption chiller controls (refer toOptional Field Wiring Connections).
Install a motorized 3-way bypass valve (HMV)with limit switches to control the heat input to theabsorption chiller.
Fig. 8 HEAT MEDIUM PIPING
13
CAUTION1. DO NOT EXCEED 80 - 120% OF
STANDARD CHILLED/HOT WATER FLOW.2. DO NOT EXCEED 85.3 PSI IN THE
CHILLED/HOT WATER CIRCUIT AT THEABSORPTION CHILLER.
3. DO NOT INSTALL ANY VALVES IN THEEXPANSION LINE.
CAUTION1. DO NOT EXCEED 30 - 120% OF
STANDARD HEAT MEDIUM FLOW.2. DO NOT EXCEED 85.3 PSI IN THE
HEAT MEDIUM CIRCUIT AT THEABSORPTION CHILLER.
3. DO NOT INSTALL ANY VALVES IN THEEXPANSION LINE.
Heat Medium Outlet
Heat Medium Inlet
T
Drain
IF3 Switch (Optional)
Heat Medium Pump
Air VentChiller/Chiller - Heater
T
Water Make-Up/Expansion Line
Check/Reducing Valve
Expansion Tank
Relief Valve
Water Supply
Heat Medium Bypass Valve (HMV)
P P
Fig. 7 CHILLED/HOT WATER PIPING
T
T
Chilled/Hot Water Pump
IF1 Switch (Optional)
Air Vent
Drain
Water Supply
Check/Reducing Valve
Expansion Tank
Relief ValveWater Make-Up/Expansion Line
Chilled/Hot Water Outlet
Chilled/Hot WaterInlet
Chiller/Chiller - Heater
P P
14
COOLING WATER PIPINGHeat from the absorption chiller is rejected to
a well, river or cooling tower and cooling water ismaintained at 85OF or less during the cooling season. Provide drain valves at all low points inthe piping so that the circuit can be drained during the winter and for maintenance.
All 20 and 30 ton absorption chillers (ModelsWFC-SC20, WFC-SH20, WFC-SC30 and WFC-SH30) require cooling water crossover piping toconnect the condenser and absorber in parallel.Install crossover piping, in accordance with Fig.9, to ensure balanced cooling water flow throughthe condenser and absorber. If the crossoverdesign is changed, install balancing valves at thecondenser outlet and absorber outlet connectionsso that the flow rate through each circuit can beadjusted in accordance with the chiller specifications. As an alternative, install the optional Yazaki cooling water crossover pipeassemblies.
A balancing valve should be installed adjacent to the cooling water outlet on each absorption chiller to facilitate flow rate adjustments within specified limits. Install a stopvalve adjacent to the cooling water inlet as shown in Fig. 9. This valve must be in the full open position when the equipment is operating. DO NOTCLOSE the stop valve except for disconnection orrelocation of the absorption chiller unit.
If the cooling water inlet temperature is below65OF and likely to remain at this condition after the first 30 minutes of cooling operation, a cooling water temperature control system, as shown in Fig. 10 must be installed. The motorized 3-way valve (CWV) will bypass coolingwater to the sump whenever the cooling water inlet temperature is below 65OF.
Wherever possible, install the cooling tower at the same level or above the absorption chiller.If this cannot be accomplished, give careful consideration to the piping design to avoid overflowing the cooling tower sump every time the cooling water pump stops.
If cooling water remains in the condenser andabsorber section of the chiller-heater during heating operation, and the unit is immediatelyswitched to cooling mode, a slug of hot water
NOTES:1. Each standard crossover pipe has similar
pressure losses for balanced cooling water flow through the absorber and condenser.
2. Install flow balancing valves in each circuit for non-standard crossover pipe designs.
3. Install cooling water flow valves 5 pipe diameters (min.) upstream and downstream of the respective “T” fitting.
4. The crossover pipe configuration must provide clear access to the rear of the absorption chiller for maintenance.
Fig. 9 COOLING WATER CROSSOVER PIPING
Fig. 10 COOLING WATER PIPING
CAUTION1. DO NOT EXCEED 100 - 120% OF
STANDARD COOLING WATER FLOW.2. DO NOT EXCEED 85.3 PSI IN THE
COOLING WATER CIRCUIT AT THEABSORPTION CHILLER.
Balancing Valve
Stop Valve
3" Cu Tube
3" Cu Tube
Cooling WaterCondenser Outlet
Cooling Water Absorber Outlet
Cooling Water Condenser Inlet
Cooling WaterAbsorber Inlet
2" Cu Tube (WFC-SC20/SH20)2 1/2" Cu Tube (WFC-SC30/SH30)
Note 3
Note 3
Union (CxM)
Cooling Water Outlet
Cooling WaterInlet
Chiller/Chiller - Heater
Condenser Water Inlet
Absorber Water Outlet
Cooling Tower
T
Drain
Cooling Water Pump
FlushValve
FlushValve
T
Temp. Control (CWTS)
Cooling Water Control Valve (CWV)
Drain
Water Supply
Crossover Piping For WFC-SC20/SH20 & WFC-SC30/SH30 ONLY
P P
15
above 120OF may damage the cooling tower fillmaterial at the start of cooling operation. Thisproblem can be prevented by overriding themotorized 3-way valve (CWV) to bypass coolingwater to the sump for at least 1 minute each timecooling operation is selected or by utilizing a hightemperature fill material in the cooling tower. In an extended heating season the cooling water
ELECTRICAL
GENERALEach absorption chiller and chiller-heater is
factory wired for the voltage specified on the UNIT NAMEPLATE.The standard field wiring con-nections are provided in the junction box located on the left side of each unit.
Optional field wiring connections for accessories and alarms are provided in the
should be drained from the chiller-heater.When the cooling water circuit is not drained
but is subject to ambient temperatures below freezing, install a heater in the cooling tower sump.All exposed piping below the water level should beprotected by electric heat tape and insulation.
junction box and control box (terminal strip on I/Oboard) of the chiller-heater control box. Refer topage 9 for further details.
All absorption chillers must be electricallygrounded and field wiring installed in accordancewith the National Electrical Code (NFPA 70, latest edition).
Option 1: HEAT INPUT CONTROL BY HEAT MEDIUM PUMP AND HEAT MEDIUM BYPASS VALVE
FIELD WIRING DIAGRAM (SINGLE MODULE)
P3A
16
Option 2: HEAT INPUT CONTROL BY HEAT MEDIUM PUMP ONLY
Option 3: HEAT INPUT CONTROL BY HEAT MEDIUM BYPASS VALVE ONLY
OPTIONAL COOLING WATERTEMPERATURE CONTROL
(With Cooling Water Valve Override)
OPTIONAL COOLING WATERTEMPERATURE CONTROL
(Without Cooling Water Valve Override)
INTERLOCK CONTACTS (NC)
P3A
EXTERNAL WIRING (SINGLE MODULE)SYMBOL DESCRIPTION REMARKS
FD2 Cooling water pump fused disconnect
FDF Cooling tower fanfused disconnect Supplied
FD3 Heat medium pump by othersfused disconnect
FDV Heat medium bypassvalve fused disconnect
MC1 Chilled/hot water pumpmotor contactor
MC2 Cooling water pumpmotor contactor Supplied by
MCF Cooling tower others (24Vfan motor contactor AC coil)
MC3 Heat medium pumpmotor contactor
THR1 Chilled/hot water pumpthermal overload Supplied by
THR2 Cooling water pump othersthermal overload (1xNC andTHRF Cooling tower fan 1xNOthermal overload contact)THR3 Heat medium pump
thermal overload CTF Cooling tower fan
P3 Heat medium pump Interlock relays for
R, R3 power supply andHMV limit switch
RT1, RT2, Interlock relays forRT3, RTF thermal overloads
RCW, R3W Control relays for CWVRC3 Control relay for HMV
T3W Timer (1 min. TDO)for CWV
STANDARD JUNCTION BOX CONNECTIONSTERMINAL DESCRIPTION REMARKS
3 (P1D/P1E) Chilled/hot water pump thermal overload
4 (P2D/P2E) Cooling water pump thermal overload
5 (FD/FE) Cooling tower fan thermal overloadHeat medium pump
6 (P3D/P3E) thermal overload and/or heat medium bypass valve limit switch
P (P1) Chilled/hot water pump
17
EXTERNAL WIRING (SINGLE MODULE)SYMBOL DESCRIPTION REMARKS
FDC Chiller or chiller-heaterfused disconnect
Supplied byothers
Supplied byothers
CHILLER OR CHILLER-HEATER JUNCTION BOX
Six knockouts in bottom of junction box to suit 1/2in. trade size conduit.
Interlocks(NC or NO)for thermaloverloadtripcontacts
S3, S4 Heat medium pump(EGBON)
CP (P2) Cooling water pump
FD1 Chilled/hot water pumpfused disconnect
P3A Heat medium pumpor heat mediumbypass valveP3B
Outputcontrol (NO)Outputcontrol (NC)
CM1 Common 1
P1 Chilled/hot water pumpP2 Cooling water pump
SW1 Chilled/hot water pumpAuto/Manual switch
SW2 Cooling water pumpAuto/Manual switch
SW3 Heat medium pumpAuto/Manual switch
SWF Cooling tower fanAuto/Manual switch
OPTIONAL JUNCTION BOX CONNECTIONSTERMINAL DESCRIPTION REMARKSS11, S12(CHD) S5, S6 (HM) Heating mode S7, S8 (CM) Cooling mode S13, S14 General shutdown(CHE) alarm
EXTERNAL WIRING (SINGLE MODULE)SYMBOL DESCRIPTION REMARKS
CWV Cooling water temp.control valve (3-way)Cooling water temp.
CWTS switch (70oF ON, 75oF OFF)
CTS Cooling tower switch (81.5oF ON, 77oF OFF)
HMV Heat medium bypass valve (3-way)
3VOPLimit switch for HMVopen position
NOTES:1. The Heat Medium Pump (P3) and/or Heat
Medium Bypass Valve (HMV) are controlledby the chiller/chiller-heater in response to thechilled/hot water outlet temperature.The valvecycle time must be less than 30 seconds.
2. An optional Cooling Water TemperatureSwitch (CWTS) controls the cooling waterinlet temperature by modulating the CoolingWater Valve (CWV). It is required when thecooling water inlet temperature is likely to fallbelow 65oF during cooling operation in lowambient weather.
3. A Cooling Tower Switch (CTS), installed in the cooling tower sump, controls the coolingwater temperature by cycling the coolingtower fan.
4. A Limit Switch (3VOP), installed on the heatmedium bypass valve, closes when the valveis open.
5. Optional controls override the Cooling WaterValve (CWV) to bypass “hot” cooling water tothe cooling tower sump for one minute eachtime cooling operation is selected. This prevents damage to the cooling tower fillmaterial from “hot” cooling water when itremains in the chiller-heater during heatingoperation.
6.
OPTIONAL JUNCTION BOX CONNECTIONSTERMINAL DESCRIPTION REMARKS1, 2 (DCP) Remote monitoring A (C1) Cooling mode selection B (H1) Heating mode selection C (CHON) Start selection D (CHOFF) Stop selection E (CM3) Common 3
Cooling tower fanCTF control (84.2OF ON,
80.6OF OFF)
Remoteselection ofCOOL,HEAT, ON,OFFAlternativeto CTStemp. control
Supplied byothers
OPTIONAL FIELD WIRING CONNECTIONS
18
Supplied byothers (Max. 30sec. valve cycletime)
Chiller Enabled
Field wiring shown as a broken line.7. All circuits except power supply are low
voltage.8. Confirm that the voltage rating on the chiller
or chiller-heater nameplate is compatible withthe local power supply.
9. All wiring must comply with local and nationalelectrical codes.
OPTIONAL I/O BOARD CONNECTIONSTERMINAL DESCRIPTION REMARKSTB No.
7, 8 Shutdown interlockAdditional
1 (ST2) interlock (NC or NO)
9,10 Chilled/hot water Input control(IF1) freeze protection from temp.MG 3, 7 Heat medium switchC2 (IF3) freeze protection (36.5°F ON,
39.2°F OFF)
7, 8 Chiller-heater(CHSTN) standby mode 13, 14 Operating status3 (OP)17, 18 General fault alarm(AL)
OPTIONAL CONTROL BOX CONNECTIONSTERMINAL DESCRIPTION REMARKS S1, S2 Heat medium(RFH) supply shutdown S9, S10 Auxiliary boiler(BO)
17, 18 Input control(EGON) Heat available from temp.
switch
2, 3 on CN Cooling Water flow Input control11 (FS2) switch from flow
switch
NOTES:1. Set switch 1 on DIP switch DP1 (located on
I/O Board) to ON for normally open (NO)interlock contacts and to OFF for normallyclosed (NC) interlock contacts.
2. Field wiring shown as a broken line.3. All circuits are low voltage.4. All wiring must comply with local and
national electrical codes.5. Remove jumpers from terminals when field
wiring installed.
19
7 8
NOTES:1. Full Load Amps (FLA) marked on motor nameplate.2. Use minimum 14 AWG copper conductors for absorption chiller power supply.
Table 1 ELECTRICAL DATA
MODEL
WFC-SC10WFC-SH10WFC-SC20WFC-SH20WFC-SC30WFC-SH30
POWERSUPPLY
(V)
208
208
208
SOLUTION PUMP(3 PH)
OUTPUT FLA(HP) (A)
1/8 0.46
1/6 0.75
1/3 2.04
POWER SUPPLY
MIN. CIRCUIT AMPS MAX. FUSE SIZE)A()A(
516.0
519.0
516.2
20
POWER WIRINGSelect the disconnect, fuses and supply
conductors for each absorption chiller based onthe minimum circuit ampacity and maximum fusesize on the UNIT NAMEPLATE as per theElectrical Data in Table 1. Install conduit to thefield wiring junction box and leave sufficient clear-ance for removal of panels and service access.DO NOT attach conduit to the absorption chillercabinet. The 1/2 in. trade size conduit entry in the junction box will accommodate four (3 live and 1
grounded) 14 AWG copper conductors in mostwire styles. DO NOT USE ALUMINUM CONDUCTORS.
Locate the disconnect within sight of andreadily accessible to the equipment, per Section440-14 of the National Electrical Code.
DO NOT CLOSE THE DISCONNECT untilapproved by an Authorized Yazaki ServiceProvider.
CONTROL WIRINGAll field control wiring connections to the
absorption chiller are low voltage (less than 30 VAC) class 2 circuits and may be installed with orwithout conduit. A 1/2 in. trade size conduit shouldbe installed to protect the wire against physicaldamage or for aesthetic reasons. If conduit is not used, a bushing must be insertedinto the wire entries of the junction box. Routeadditional wiring to the control box for optionalinput and output controls through the absorptionchiller junction box.
Motor contactors and overload relays for thechilled/hot water pump, cooling water pump, heatmedium pump and cooling tower fan are notinstalled in the absorption chiller and must be supplied by others. Refer to the relevant FieldWiring Diagram (Single Module or MultipleModules) for the recommended wiring of thesecontrols.
Use 18 AWG type T wire or equivalent for alllow voltage field circuits up to 50 ft. (for longer distances use a 16 AWG conductor).
WATER QUALITY
NOTES:ND = Not Detectable*(Maximum total hardness of make-up water shall not exceed 70 ppm when bleed off is the only methodused to control water quality)
Table 2 WATER QUALITY REQUIREMENTS
INSTALLATION CHECK & REQUEST FOR START-UP
21
ITEM
pH (at 77oF)Conductivity (µS/cm at 77oF)Chloride ion (Cl-ppm)Sulfate ion (SO4
2- ppm)M-alkalinity (CaCO3 ppm)Total hardness (CaCO3 ppm)Calcium hardness (CaCO3 ppm)Ionic Silica (SiO2 ppm)Total iron (Fe ppm)Copper (Cu ppm)Sulfide ion (S2- ppm)Ammonium ion (NH4
+ ppm)Residual chlorine (Cl ppm)Free carbon dioxide (CO2 ppm)Ryzner stability index
Stan
dard
Ref
eren
ce
CHILLED/HOT
WATER6.8 - 8.0
4005050507050301.01.0ND1.00.34.0—
HEATMEDIUM
7.0 - 8.03003030507050301.01.0ND0.10.10.4—
COOLINGWATER
6.5 - 8.2800200200100200*150501.00.3ND1.00.34.0
6.0 - 7.0
MAKE-UPWATER
6.8 - 8.03005050507050300.30.1ND0.10.34.0—
Water used in the chilled/hot water, coolingwater and heat medium circuits may cause scal-ing or corrosion if not correctly analyzed andmaintained within the limits specified in Table 2.
In some areas the water supply will containminerals that cause scaling or may be extremelysoft and corrosive. When these conditions exist awater treatment company should be consulted.
If the absorption chiller is damaged as a resultof scaling, corrosion or erosion caused by poorwater quality control the equipment warranty isvoided.
The water quality in the chilled/hot water,cooling water, and heat medium circuits shall notexceed the following limits:
After the absorption chiller or chiller-heaterhas been installed, piped and wired as describedin these instructions, but before any attempt ismade to start the unit, the Authorized YazakiService Provider should be advised so that thestart-up can be scheduled. Complete theINSTALLATION CHECK AND REQUEST FOR
START-UP FORM and send to the Yazaki SalesRepresentative or Distributor at least 2 weeksprior to the required start-up date.
The contractor is expected to provide person-nel to assist with final adjustment of system con-trols and flow rates.
A. CHILLER OR CHILLER-HEATER1. Unit placed on foundation ...............................❑2. Service clearance provided on all sides and
top (40 in. front) ...............................................❑3. Shims placed under mounting plates and
level adjusted for longitudinal and transverse alignment .........................................................❑
4. Chiller anchored to foundation (if required by code) .........................................❑
5. Chilled/hot water flow switch pipingconnected ........................................................❑
B. WATER PIPING1. Chilled/hot water piping installed between chiller,
pumps and air handling units ..........................❑2. Cooling water piping installed between
chiller, pumps and cooling tower .....................❑3. Heat medium piping installed between
chiller, pumps and heat source .......................❑4. Flow setters installed in water piping
(only required for glycol circuits) .....................❑5. Water make-up and fill lines installed to
cooling tower ...................................................❑6. Expansion tank and water make-up piping
installed to chilled/hot water system.................❑7. Expansion tank and water make-up piping
installed in heat medium system .....................❑8. Temperature test plugs (P/T Plug) or
thermowells installed in the inlet and outlet piping of each chiller .......................................❑
9. Valves installed at each chiller for flow balancingand isolation ....................................................❑
10. Air vent valves installed on piping ...................❑11. Water piping leak tested and flushed, and
strainers cleaned .............................................❑12.System filled with water and glycol (if required)
and trapped air vented ....................................❑
C. POWER WIRING1. Power supply, indicated on the
UNIT NAMEPLATE, is connected ...................❑
2. Wiring installed between the motor contactors and chilled/hot water pump, cooling water pump, heat medium pump and cooling tower fan .......❑
3. Rotation of each motor checked .....................❑4. Power supply wiring installed between a fused
disconnect and each chiller. (DO NOT operate the chiller) ........................................................❑
5. Power supply available near the chiller for a vacuum pump ..................................................❑
D. CONTROL WIRING1. Motor contactors and manual controls installed
for all external motors ......................................❑2. Control wiring (24V AC) installed between chiller
and motor contactors ......................................❑3. Control wiring installed between chiller and heat
medium bypass valve ......................................❑4. Interlock wiring installed between chiller and limit
switch on heat medium bypass valve ..............❑5. Interlock wiring installed between chiller and
thermal overloads on the following motors:Chilled/hot water pump, cooling water pump,heat medium pump and cooling tower fan .....❑
6. Control wiring (24V AC) installed between chiller control box and cooling water temperature control valve (if installed) .................................❑
7. Low voltage (24V AC) wiring connected to chiller for remote control, operating status and general alarm annunciation ..........................................❑
E. Arotrend REMOTE MONITORING (IF INSTALLED)1. Wiring installed between Monitoring Unit and
each chiller ......................................................❑2. Dedicated telephone line installed adjacent to
the Monitoring Unit ..........................................❑
F. CONDITIONSPersonnel available to assist with start-up who are familiar with the system ..........................❑
YAZAKI WATER FIRED CHILLERINSTALLATION CHECK AND REQUEST FOR START-UP
To: ____________________________________________________________________ (Yazaki Service Provider)
Address: ____________________________________________________________________________________
Project Name: ________________________________________________________________________________
Address: ____________________________________________________________________________________
Model No:______________________________ Serial No: __________________________________________
The Work (as checked below) is in progress and will be completed by: __________________________________
28
AUTHORIZED YAZAKI SERVICE PROVIDER
For information concerning service, operationor technical assistance, please contact your
Authorized Yazaki Service Provider or the following:
YAZAKI ENERGY SYSTEMS, INC. 701 E. PLANO PARKWAY, SUITE 305 PLANO, TEXAS 75074-6700
Phone: 469-229-5443Fax: 469-229-5448
Email: [email protected]: www.yazakienergy.com
This symbol on the product’s nameplatemeans 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.
IN-WFCS-0909