155 21-Om1 PDF

SINGLE STAGE YIA
ABSORPTION Chillers
WITH OPTIVIEW TM CONTROL CENTER
OPERATION and maintenance New Release Form 155.21-oM1 (510)
YIA MOD D
SINGLE STAGE
STEAM / HOT WATER
WITH OPTIVIEW TM CONTROL CENTER
LD14498
1A1 through 14F3

FORM 155.21-OM1 (510)
IMPORTANT!
Read BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. This document is intended for use by owner-authorized
During installation, operation, maintenance or service, operating/service personnel. It is expected that this
individuals may be exposed to certain components or individual possesses independent training that will
conditions including, but not limited to: refrigerants, enable them to perform their assigned tasks properly
oils, materials under pressure, rotating components, and and safely. It is essential that, prior to performing any
both high and low voltage. Each of these items has the task on this equipment, this individual shall have read
potential, if misused or handled improperly, to cause and understood this document and any referenced
bodily injury or death. It is the obligation and responsi- materials. This individual shall also be familiar with
bility of operating/service personnel to identify and and comply with all applicable governmental stan-
recognize these inherent hazards, protect themselves, dards and regulations pertaining to the task in ques-
and proceed safely in completing their tasks. Failure to tion.
comply with any of these requirements could result in
serious damage to the equipment and the property in
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
safety symbols
The following symbols are used in this document to alert the reader to areas of potential hazard:
DANGER indicates an imminently CAUTION identifies a hazard which

hazardous situation which, if not could lead to damage to the machine,
avoided, will result in death or seri- damage to other equipment and/or
ous injury. environmental pollution. Usually an
instruction will be given, together
with a brief explanation.
WARNING indicates a potentially NOTE is used to highlight additional

hazardous situation which, if not information which may be helpful to
avoided, could result in death or seri- you.
ous injury.
External wiring, unless specified as an optional connection in the manufacturer’s product

line, is not to be connected inside the micro panel cabinet. Devices such as relays, switch-
es, transducers and controls may not be installed inside the micro panel. No external
wiring is allowed to be run through the micro panel. All wiring must be in accordance with
YORK’s published specifications and must be performed only by qualified Johnson
Controls personnel. Johnson Controls will not be responsible for damages/problems result-
ing from improper connections to the controls or application of improper control signals.
Failure to follow this will void the manufacturer’s warranty and cause serious damage to
property or injury to persons.
2 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
Changeability of this document

In complying with YORK/Johnson Controls policy It is the responsibility of operating/service personnel
for continuous product improvement, the information as to the applicability of these documents to the equip-
contained in this document is subject to change with- ment in question. If there is any question in the mind
out notice. While Johnson Controls makes no com- of operating/service personnel as to the applicability of
mitment to update or provide current information these documents, then, prior to working on the equip-
automatically to the manual owner, that information, ment, they should verify with the owner whether the
if applicable, can be obtained by contacting the near- equipment has been modified and if current literature
est YORK/Johnson Controls Service Office. is available.
Associated Literature
DESCRIPTION FORM NO.
OPERATION – YIA UNIT 155.21-OM1
INSTALLATION – YIA UNIT 155.21-N1
SERVICE – YIA OptiView Control Center 155.21-M1
RENEWAL PARTS – YIA OptiView Control Center 155.21-RP1
RENEWAL PARTS – YIA UNIT 155.21-Rp2
WIRING DIAGRAM – YIA UNIT 155.21-W1
WIRING DIAGRAM – YIA Field Control Modifications 155.21-W2
WIRING DIAGRAM – YIA Field CoNNECTIONS 155.21-W3
Application Data – Chiller materials for various water qualities 160.00-AD5
nomenclature
yIA ST 1A1 46 C S D
SPECIAL DESIGN LEVEL
COOLING ONLY
S = Std Tubes
VOLTAGE CODE
X = Special Tubes
UNIT SIZE 17=208-3-60
1A1 - 14F3 28=230-3-60
HEAT SOURCE
46=460-3-60
ST=Steam
50=380/400/415-3-50
HW=Hot Water
58=575-3-60
UNIT TYPE
YORK IsoFlow Absorption Chiller
JOHNSON CONTROLS 3
FORM 155.21-OM1 (510)
table of contents
Section 1 INTRODUCTION............................................................................................ 7

GENERAL................................................................................................... 7
Section 2 ABSORPTION SYSTEM OPERATION......................................................... 9

GENERAL INFORMATION......................................................................... 9
Evaporator................................................................................................ 9
Absorber................................................................................................... 9
Generator................................................................................................. 9
Condenser................................................................................................ 9
DESCRIPTION OF MAJOR COMPONENTS AND SUB-SYSTEMS......... 9
General Condenser Shell Assembly........................................................ 9
Evaporator-Absorber Shell Assembly...................................................... 9
Solution Pump.........................................................................................11
Refrigerant Pump....................................................................................11
Heat Exchanger......................................................................................11
Purge System..........................................................................................11
Controls and Wiring................................................................................11
CONTROL DESCRIPTIONS.....................................................................11
Components in the Control Center.........................................................11
Components of Power Panel..................................................................11
Components External to the Control Center......................................... 12
CONTROL SEQUENCE........................................................................... 13
SYSTEM OPERATION............................................................................. 19
General................................................................................................... 19
Capacity Control.............................................................................. 20
General................................................................................................... 19
Maximum Load Limits at Reduced Condensing Water Temperatures.. 19
Solution and Refrigerant Interchange During Operation....................... 19
Anti-Freeze Line..................................................................................... 22
Chilled Water Control Stability............................................................... 22
Stabilizer Refrigerant Solenoid (2SOL).................................................. 22
Capacity Control Valve Override............................................................ 22
Automatic Decrystallization Control....................................................... 22
DISCUSSION OF SUB-SYSTEM OPERATION....................................... 22
Automatic Decrystallization Feature...................................................... 22
Basic Automatic Decrystallization Piping Circuit – Model YIA, All Sizes... 22
ADC Flush Line...................................................................................... 23
Combination of Basic ADC Piping Circuit and ADC Control Feature.... 23
2SOL – Refrigerant Valve Blowdown..................................................... 23
Section 3 PURGing and non-condensables................................................... 27

NON-CONDENSABLES........................................................................... 27
INTERNAL PURGING WHILE UNIT IS OPERATING.............................. 27
PURGE COMPONENTS.......................................................................... 27
4 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
Section 4 PURGE PUMP OPERATION....................................................................... 33

GENERAL................................................................................................. 33
Cleanliness............................................................................................. 33
Types of Lubricants................................................................................ 33
PURGE PUMP PIPING AND OPERATING VALVES................................ 33
The Principle of Gas Ballast.................................................................. 33
OIL LEVEL DETERMINATION.................................................................. 33
Section 5 PURGE PUMP MAINTENANCE................................................................. 35

VACUUM PROBLEMS.............................................................................. 35
Pressure Determinations....................................................................... 35
Oil Contamination................................................................................... 35
Oil Changes and Oil Levels........................................................... 35
Draining The Pump................................................................................ 35
Flushing The Pump................................................................................ 35
Refilling The Pump................................................................................. 36
SHAFT SEAL REPLACEMENT................................................................ 36
REPAIRING OIL LEAKS........................................................................... 36
Location, Cause and Effect.................................................................... 36
Repairing Technique.............................................................................. 36
Drive Problems.................................................................................. 36

Section 6 BUFFALO PUMPS...................................................................................... 39

INTRODUCTION....................................................................................... 39
TROUBLESHOOTING.............................................................................. 39
Pump Tripping On Overloads................................................................ 39
Pump Tripping On Thermal Protection.................................................. 39
Unusual Noise/Vibration......................................................................... 39
Pump Overhaul...................................................................................... 39
Section 7 STEAM AND WATER QUALITY CONTROL.............................................. 41

GENERAL.................................................................................................... 41
STEAM/CONDENSATE OR HOT WATER QUALITY................................. 41
TUBE CLEANING........................................................................................ 42

Section 8 UNIT OPERATING PROCEDURES............................................................ 43

GENERAL................................................................................................. 43
START-UP (NORMAL).............................................................................. 43
OPERATING DATA................................................................................... 44
General................................................................................................... 44
Performance Data and Calculations...................................................... 44
JOHNSON CONTROLS 5
Introduction
FORM 155.21-OM1 (510)
Section 9 PTX CHART................................................................................................. 47

READING THE PTX CHART....................................................................... 47
CRYSTALLIZATION..................................................................................... 47
REFRIGERANT CONCENTRATION........................................................... 47
PRESSURE DROP CURVES...................................................................... 53

Section 10 PREVENTATIVE MAINTENANCE.............................................................. 65
CLEANING AND MAINTAINING THE TUBES WITHIN THE SHELLS....... 65

Tubes......................................................................................................... 65
Brush Cleaning of Tubes.................................................................. 65
TROUBLESHOOTING TABLE..................................................................... 66
PREVENTATIVE MAINTENANCE SCHEDULE.......................................... 67
APPENDIX
Glossary Of Terms.................................................................................... 69
list of FIGURES
FIGURE 1 - COMPLETE CYCLE DIAGRAM...........................................................................................................10
FIGURE 2 - TYPICAL POWER PANEL (60 Hz, NEMA 1 standard unit power panel shown)................ 12
FIGURE 3 - MODEL YIa ABSORPTION UNIT, FRONT VIEW.................................................................................15
FIGURE 4 - system control component locations...............................................................................16
FIGURE 5 - BASIC FLOW DIAGRAM......................................................................................................................18
FIGURE 6 - Evaporator.....................................................................................................................................19
FIGURE 7 - Absorber..........................................................................................................................................19
FIGURE 8 - SOlution Pump................................................................................................................................19
FIGURE 9 - Generator.......................................................................................................................................19
FIGURE 10 - Condenser.....................................................................................................................................20
FIGURE 11 - Solution and refrigerant level variation with load................................................. 21
FIGURE 12 - EVAPORATOR AUX. DRAIN PAN......................................................................................................21
FIGURE 13 - automatic decrystallization feature...............................................................................25
FIGURE 14 - YIA PURGE SYSTEM.........................................................................................................................28
FIGURE 15 - YIA PURGE TANK..............................................................................................................................29
FIGURE 16 - PURGE EDUCTOR............................................................................................................................29
FIGURE 17 - GAS SEPARATOR.............................................................................................................................30
FIGURE 18 - THE COMPLETE ISOflow PURGE SYSTEM.................................................................................32
FIGURE 19 - purge pump piping and valves - normal operation....................................................... 33
FIGURE 20 - MODEL 1402 VACUUM PUMP FOR YORK.......................................................................................37
FIGURE 21 - flow of refrigerant water or lithium bromide through pump............................. 40
FIGURE 22 - acceptable internal unit pressures.................................................................................43
FIGURE 23 - OPERATING DATA SHEET................................................................................................................45
FIGURE 24 - PTX CHART.......................................................................................................................................48
FIGURE 25 - SPECIFIC GRAVITY - CONCENTRATION........................................................................................49
FIGURE 26 - pressure drop curves.............................................................................................................53
FIGURE 28 - pressure equivalents..............................................................................................................73
FIGURE 29 - vacuum units of measurement..............................................................................................73
6 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 1 – INTRODUCTION
1
GENERAL Procedures and checks to be conducted by the operator
are described extensively for all areas of operation.
This manual contains instructions and information These involve the Pre-Start modes of units, normal
required by the operator for proper operation and pre operation of units and operational functions related to
ventative maintenance of the YORK IsoFlow Absorption general performance of the system. Information and
Liquid Chillers. guides are given pertaining to care and general mainte-
nance of the unit.
Included in this instruction are discussions of the basic
principles of operation of Lithium Bromide Absorption A glossary of terms has been included in the back of this
Systems and descriptions of the functional operation of manual. Review these definitions in order to be familiar
major components and sub-systems. Instructions relat with the concepts found throughout this manual.
ed to the controls and normal operating sequence of the
various modifications of the IsoFlow units can be found
in YIA Control Panel Operation Manual Form 155.21-
O1 and YIA Installation Manual Form 155.21-N1.
JOHNSON CONTROLS 7
Absorption System Operation
FORM 155.21-OM1 (510)
THIS PAGE INTENTIONALLY LEFT BLANK
8 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 2 – ABSORPTION SYSTEM OPERATION

GENERAL INFORMATION interior of the tubes. The amount of heat input from the
steam or hot water is controlled by a motorized valve
The principle of refrigeration is the exchange of heat and is in response to the required cooling load. The hot
and, in absorption liquid chilling, there are four basic generator tubes boil the dilute solution, releasing refrig-
heat exchange surfaces: the evaporator, the absorber, erant vapor.
the generator and the condenser (refer to FIGURE 1).
2
Condenser
In absorption chilling, the refrigerant is water like any The refrigerant vapor rises to the condenser and is
refrigeration system, absorption chilling uses evapora- condensed by the cooler tower water running through
tion and condensation to remove heat. To maintain the condenser tubes. The liquid refrigerant flows back
effective evaporation and condensation, absorption to the lower shell, and is once again sprayed over the
chilling employs two shells which operate at different evaporator. The refrigerant cycle has been completed.
controlled vacuums. Now the concentrated lithium bromide solution flows
from the generator back to the absorber in the lower
The lower shell (Evaporator and Absorber) has an inter shell, ready to absorb more refrigerant. Its cycle has
nal absolute pressure of about one one-hundredth that also been completed.
of the outside atmosphere - or six millimeters of mer
cury, a relatively high vacuum. The vacuum allows DESCRIPTION OF MAJOR COMPONENTS AND
water (the refrigerant) to boil at a temperature below SUB-SYSTEMS
that of the liquid being chilled. Thus, chilled liquid
entering the evaporator can be cooled for air condition- YORK IsoFlow Absorption Chillers consist of the fol-
ing or process cooling applications. lowing major components and sub-systems:
Evaporator
Refrigerant enters the top of the lower shell and is Generator-Condenser Shell Assembly
sprayed over the evaporator tube bundle. Heat from the This is the upper of two cylindrical shells, and it con-
liquid being chilled evaporates the refrigerant. tains two tube bundles - the generator and the condens
er. The generator is a single pass flooded tube bundle
Absorber when operated with steam, and may be a one or two-
The refrigerant vapor then migrates to the bottom half pass flooded tube bundle when operated with hot
of the lower shell. Here the vapor is absorbed by a water.
lithium bromide solution. Lithium bromide solution is
basically nothing more than salt water. However, lithi- The steam or hot water flowing through the tube bundle
um bromide is a salt with an especially strong attraction boils the water vapor from the solution that surrounds
for water. The mixture of lithium bromide and the the outside surface of the generator tubes. The condens
refrigerant vapor - called the “dilute solution” - now er section of this shell assembly consists of a single-
collects in the bottom of the lower shell. pass tube bundle through which cooling water is circu-
lated (condensing the water vapor boiled off in the
Generator generator) and a condenser pan to collect the water.
The dilute solution is then pumped through the heat
exchanger, where it is preheated by hot concentrated Evaporator-Absorber Shell Assembly
solution from the generator. The heat exchanger This is the lower shell assembly and it also contains
improves the efficiency of the cycle by reducing the two sections, the evaporator and the absorber.
amount of steam or hot water required to heat the dilute
solution in the generator. The evaporator consists of a single or multi-pass tube
bundle, a refrigerant pan, and a refrigerant spray header
The dilute solution then continues to the upper shell assembly. The liquid to be chilled (usually water) flows
containing the Generator and Condenser, where the through the tubes to be cooled by vaporization of the
absolute pressure is approximately one-tenth that of the liquid refrigerant (water condensed in the condenser).
outside atmosphere, or seventy millimeters of mercury. The liquid refrigerant is pumped through the sprays and
The dilute solution flows over the generator tubes and flows down over the outside surface of the evaporator
is heated by steam or hot water passing through the tubes.
JOHNSON CONTROLS 9
FORM 155.21-OM1 (510)
model yia standard steam cycle diagram
KEY HP1
PT1
CoNCENTRATED CoNDENSER RT4
SoLUTIoN (LiBr) TowER wATER
DILUTE SoLUTIoN VR40 oUTLET
(LiBr) PT4
INTERMEDIATE
SoLUTIoN (LiBr) HT1
VP10
CHILLED LIqUID RT9
TowER STEAM oR HoT wATER PURGE
wATER
CoNTRoL VALVE TANK
REFRIGERANT LIqUID
Low TEMPERATURE RT7
HoT wATER oR
REFRIGERANT LIqUID
HIGH TEMPERATURE
STEAM
GENERAToR **PT2 Typ 2 Places

DILUTE PURGE LIqUID
GENERAToR
GAS / VAPoR
VS3
VENT Anti-Freeze Line
VP2
RT1
CHILLED
wATER VP4
oUTLET
To GENERAToR
RT6 CHILLED
wATER
INLET
EVAPoRAToR
***VP1
RT8
AUToMATIC DE-CRYSTALLIZATIoN PIPE
FRoM GENERAToR
1F Abs. Press.
Gauge
RT5 TowER
wATER
INLET
RT2
7 SoL
ABSoRBER
RT3 PT3
3F VR10
VS17 8 SoL
2SoL Suction Bypass Line VR8
(Stabilizer)
ADC Flush Line VR9 1-1/2” Purge oil Trap

REF. Absorber Return
VR11
PUMP
VP8
3SoL
(Unloader) SoL
PUMP
1A1 & 1A2
VS12
RT10 Units only VS13
VS20
VS18 VS19 Purge

Pump
* orifices may differ between various models.

** PT2 is for Steam units only.
*** May differ between various models.
Not Installed on Models 5C3, 6C4, 12F1, 13F2, & 14F3
Not Installed on Models 7D1, 7D2, 8D3, 9E2, 10E3, & 14F3
LD04763
Note: Some orifices may differ between various models.
FIGURE 1 - COMPLETE CYCLE DIAGRAM
10 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
The absorber consists of a single or multi-pass tube Controls and Wiring

bundle, the absorber spray header assembly, and the An electronic control system is provided with each
lower part of the shell, which serves as a solution stor absorption unit to permit automatic or manual control
age pan. Tower water is circulated through the absorber of the system. Provisions are made for the following:
tubes to cool the lithium bromide solution being 1. Automatic capacity control involving electronic
sprayed over the outside of the tubes. This aids the controls for steam or hot water valves.
absorption process.
2. Safety controls involving flow switches, float 2
switches, low refrigerant temperature cut-out,
Solution Pump
motor overloads and protective thermostats.
The unit has one solution pump mounted under the
lower shell. This pump transfers dilute solution to the 3. Special control features to provide for steam econ
generator from the absorber and, with the aid of an omy and for prevention of crystallization.
eductor, pumps mixed (intermediate) solution to the 4. Functional controls which permit operation over a
absorber sprays. wide range of condenser water temperatures.
Refrigerant Pump Components in the Control Center

All units have one refrigerant pump mounted beneath
the lower shell to recirculate refrigerant to the evapora- See IsoFlow Control Panel Operation, Form 155.21-O1.
tor sprays and over the evaporator tubes.
Components in Power Panel
(see FIGURE 2)
Heat Exchanger
The heat exchanger is mounted under the lower shell to
1SW – Service Disconnect Switch
improve system efficiency by transferring heat from the
This is a non-fused, service disconnect switch. The
warm concentrated solution (low water content) to the
incoming power lines from the customer-supplied
relatively cool dilute solution (high water content) on
fused disconnect switch or circuit breaker should be
its way to the generator. This assists both the generator
connected to terminals L1, L2, and L3 of this switch.
in heating and the absorber in cooling the dilute and
concentrated solutions respectively.
1T – Transformer
This is a step-down transformer that reduces the unit's
Purge System incoming power (primary) down to the required control
YORK absorption systems are designed and manufac voltage of 120/115-1-50/60 (secondary).
tured for extreme leak tightness to ensure against
infiltration of non-condensables into the high-vacuum 1FU, 2FU, 3FU – Control Fuses
system. Leakage of air into the system will deteriorate These are used on all 60 Hz standard (NEMA 1) units.
the refrigeration capability of the unit as the absolute 1FU and 2FU are on the primary side of the 1T trans-
pressure in the unit rises, and corrosion problems former. The amperage rating of these fuses depends on
could develop. the unit's voltage. The 3FU fuse is always a 10-amp
fuse and is on one leg of the secondary coil of the 1T
The purge system provides a means for ridding the unit transformer. It is used for the control panel voltage.
of any such accumulation of non-condensables. The
system consists of a purge header arrangement in the 1CB – Circuit Breaker
bottom absorber section, a purge eductor, gas separator, This takes the place of 1FU and 2FU on 60 Hz NEMA
purge storage tank, associated piping connections, wir- 4 units and 50 HZ, 380 volts units.
ing, solenoid valves, transducers and purge pump. The
control logic provides for automatic and continuous 2CB – Circuit Breaker
purging of non-condensables from the unit. The logic This takes the place of 3FU on 60 Hz NEMA 4 units
will monitor, track and display non-condensables purg- and 50 Hz, 380 volts units.
ing trends. The system allows for manually purging of
non-condensables directly from the unit or the purge
tank.
JOHNSON CONTROLS 11
FORM 155.21-OM1 (510)
1M – Starter/Contactor for Solution Pump MTH1 and MTH2 – Motor Thermostats

This is used on all units. These are used on all units with Buffalo Pumps. These
Klixon type thermostats are imbedded in the motor
2M – Starter/Contactor for Refrigerant Pump windings and will open when the motor internal tem-
This is used on all units. perature reaches 300°F (150°C) to 392°F (200°C),
depending on pump type. The thermostats will auto-
3M – Starter/Contactor for Purge Pump matically reset when the motor windings cool down
This is used on all units. 27°F (15°C) from the trip point.
1OL thru 3OL – Overloads

Each starter/contactor is accompanied by a heater ele-
ment overload with resetting capability. The designa-
tion number of the overload matches the designation
number of the starter/contactor.
POWER SERVICE
TRANSFORMER DISCONNECT SWITCH
1FU
2FU
3FU
1OL 2OL 3OL
1M 2M 3M TB2 GROUND
LD14568
FIGURE 2 - TYPICAL POWER PANEL (60 Hz, NEMA 1 standard unit power panel shown)
12 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
Control Components External to 3SOL – Refrigerant Level Solenoid Valve

the Control Center (see Figure 3) (Unloader Valve)
The function of 3SOL is to transfer solution to the
Hermetic Motor Thermostats (not shown) refrigerant circuit of the machine. Normally, this is
The Solution and Refrigerant pump motors are cooled not a desired condition. However, is some situations it
by the circulating fluid. In the case of inadequate cool- is used effectively to allow the unit to stay on line,
ing, each motor has an internal motor protector of the make it run more stabwle, and keep the pumps from 2
Klixon type imbedded in the motor windings to pro- cavitating. Please refer to the OptiView Service
tect the motor from damage if overheating occurs. Manual, Form 155.21-M1 for additional details on
Refer to Section 6 for additional details. this valve and how it operates.
1F – Refrigerant Level Float Switch 4SOL – Automatic Shut-Off Valve

This level switch is located in separate chamber on the (not shown)
side of the refrigerant outlet box. Its function is to This valve is a customer supplied and installed valve.
determine if a refrigerant level is present or not. If the It ensures 100% shut-off during a cycling/safety shut-
refrigerant level is not present, either from a low down or a power failure. It works in conjunction with
chiller load or low tower water temperature, it could the 6SOL steam condensate drain solenoid valve. For
cause the refrigerant pump to cavitate, overheat or additional details on this valve, if installed, refer to
make the unit cycle on and off. In these cases the Installation Manual, Form 155.21-N1.
unloader solenoid valve (3SOL) will open to allow
solution to mix with refrigerant. This mixing will 5SOL – Purge Solenoid Valve
cause the refrigerant level to increase to satisfy the This valve is no longer used with units that have
pump needs and sustain unit operation. Welsh vacuum pumps installed from the factory.
3F – Refrigerant Pump Cutout Float Switch 6SOL – Steam Condensate Drain Solenoid
This level switch is located in a separate chamber just Valve (if applicable)
below the refrigerant outlet box on the vertical section This valve is located on the condensate outlet box of
of pipe leading to the pump. Like the 3F switch, it the generator shell, opposite the steam inlet. It is a
monitors the refrigerant level to determine if a level is normally closed (NC) valve and is energized at all
present or not. If no level is detected the control logic times during unit operation. The function of this valve
will shutdown the refrigerant pump after some pro- is to stop all steam flow through the generator when
grammable refrigerant pump parameters are met. the unit is off or during a power failure. This valve is
shipped loose with the unit for field installation. See
Flow Switches (not shown) Form 155.21-N1, “IsoFlow Installation Manual” for
Units fabricated at the release of this document will be details on installing this valve, and applicability.
equipped with factory supplied and mounted analog
thermal type flow sensors in the outlet nozzle of the
HP1 – High Pressure Cutout Switch
evaporator and condenser sections. These devices will
This digital safety switch is located off the top of the
be wired into the control panel so no further installa-
condenser shell, and is hardwired directly into the
tion process is necessary.
control panel. It is factory preset to trip the unit when
the unit internal pressure reaches 710 mm Hg Abs. It
1SOL – Motor Coolant Solenoid Valve
will automatically reset itself when the units pres-
These are not used on units with Buffalo Pumps.
sure reduces to 40 mm Hg Abs.
2SOL – Stabilizer Refrigerant Solenoid Valve
The function of 2SOL is to supply refrigerant to the HT1 – High Temperature Cutout Switch
generators solution outlet line to reduce the solution This digital safety switch is located on the control
concentration. There are certain conditions in which panel side of the generator shell with an accompany-
this valve will open automatically during unit opera- ing thermistor inserted into an adjacent thermowell. It
tion. This valve can also be opened manually to is hardwired directly into the control panel and fac-
facilitate service procedures. Refer to Control Panel tory set to trip the unit when the generator shell skin
Service manual 155.21-M1 for additional detail on temperature reaches 330°F (165.6°C). It has a manual
this valve and how it operates. reset push button and an amber light on the control to
indicate it is functioning.
JOHNSON CONTROLS 13
FORM 155.21-OM1 (510)
LRT – Low Refrigerant Temperature Cutout Control Valve (not shown)

Switch This valve is used to control the amount of heat energy
This digital safety switch is located on the opposite (steam or hot water) that enters the generator section
side of the refrigerant outlet box from the 1F float of the unit. It receives a control signal from the
switch. It has an attached thermistor, which is inserted Control Panel to open or close to control the leaving
into a thermowell that is located on the refrigerant line chilled Water Temperature (LCHLT) to the leaving
leading out of the bottom of the refrigerant outlet box. Chilled Water Temperature Setpoint. If the heat source
The switch protects the unit from freezing refrigerant. is steam, the maximum inlet temperature is 337°F
It is factory preset to trip at 34°F (1.1°C). It will auto- (169°C). If the heat source is hot water, the maximum
matically reset when the temperature difference inlet temperature is 266°F (130°C).
increases 4°F.
14 JOHNSON CONTROLS
Major Component Location
power HIGH-TEMP Hi-PressurE RUPTURE GENERATOR

panel PURGE TANK
JOHNSON CONTROLS
CUTOUT (HT1) CUTOUT DISK OUTLET BOX
SWITCH (HP1)
CONDENSER
GENERATOR
EVAPORATOR
FIGURE 3 - MODEL YIa ABSORPTION UNIT, FRONT VIEW

ABSORBER
SOLUTION
RETURN
FROm
GENERATOR
Refrigerant REFRIGERANT Auto
SOLUTION OIl PURGE SOLUTION GAS REFRIGERANT Pump Refrigerant PUMP OPTIVIEW DECRYSTALLIZATION
SIGHT GLASS TRAP PUMP PUMP SEPARATOR OUTLET BOX Cutout Level switch CONTROL PANEL PIPE (ADC)
switch (3F) (1F)
15
FORM 155.21-OM1 (510)
LD14500
2
FORM 155.21-OM1 (510)
PT1 HP1
RT9
HT1
PT4 8SOL
7SOL
RT3
3SOL
RT10
RT8 2SOL
LRT 3F 1F
RT2
LD14498
LEGEND
1F Refrrigerant Level Switch

3F Reffrigerant Pump Cutout Switch
HP1 HIGH PRESSURe CUTOUT SWITCH
HT1 HIGH TEMP. CUTOUT SWITCH
PT1 GENERATOR PRESSURE TRANSDUCER
PT2 STEAm supply pressure transducer (Steam units only)
RT1 TEMPERATURE Sensor leaving chilled water
RT2 Temperature sensor auto-decrystallization
RT3 Temperature sensor strong solution
RT4 Temperature sensor Leaving Tower water
RT5 Temperature Sensor Entering Tower Water
RT6 Temperature Sensor Entering chilled water
RT7 temperature Sensor Steam / hot water supply
RT8 Refigerant Temperature Sensor
RT9 Refrigerant Temp. Leaving the condenser
RT10 STRONG SOLutioN TEMP. LEAVING HEAT EX.
2SOL Stabilizer Refrigerant Solenoid (for decrystallization)
3SOL refrigerant Level Solenoid (unloading)
6SOL Steam Condensate Drain Solenoid valve (NOT Shown) (not applicable on all units)
7SOL Purge tank solenoid
8SOL Purge Pump Solenoid
LRT Low refrigerant temperature cutout switch
FIGURE 4 - system control component locations
16 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
6SOL
(NOT SHOWN)
2
EVAPORATOR
SIGHT GLASSES
RT5 RT1
ld14570
LEFT END of unit
RT4
PT2
RT7
RT6
RT1
ld14569
Right END of unit
figURE 4 (CONT'D) – system control component locations
JOHNSON CONTROLS 17
FORM 155.21-OM1 (510)
KEY HP1
PT1
CoNCENTRATED CoNDENSER RT4
SoLUTIoN (LiBr) TowER wATER
DILUTE SoLUTIoN VR40 oUTLET
(LiBr) PT4
INTERMEDIATE
SoLUTIoN (LiBr) HT1
VP10
CHILLED LIqUID RT9
TowER STEAM oR HoT wATER PURGE
wATER
CoNTRoL VALVE TANK
REFRIGERANT LIqUID
Low TEMPERATURE RT7
HoT wATER oR
REFRIGERANT LIqUID
HIGH TEMPERATURE
STEAM
GENERAToR **PT2 Typ 2 Places

DILUTE PURGE LIqUID
GENERAToR
GAS / VAPoR
VS3
VENT Anti-Freeze Line
VP2
RT1
CHILLED
wATER VP4
oUTLET
To GENERAToR
RT6 CHILLED
wATER
INLET
EVAPoRAToR
***VP1
RT8
FRoM GENERAToR
1F Abs. Press.
Gauge
RT5 TowER
wATER
INLET
RT2
To 7 SoL
ABSoRBER PURGE SYSTEM
RT3 PT3
3F VR10
VS17 8 SoL
2SoL Suction Bypass Line VR8
(Stabilizer)
ADC Flush Line VR9 1-1/2” Purge oil Trap

REF. Absorber Return
VR11
PUMP
VP8
3SoL
(Unloader) SoL
PUMP
1A1 & 1A2
VS12
RT10 Units only VS13
VS20
VS18 VS19 Purge

Pump
* orifices may differ between various models.

** PT2 is for Steam units only.
*** May differ between various models.
Not Installed on Models 5C3, 6C4, 12F1, 13F2, & 14F3
Not Installed on Models 7D1, 7D2, 8D3, 9E2, 10E3, & 14F3
ld13806
FIGURE 5 - BASIC FLOW DIAGRAM
18 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
SYSTEM OPERATION Relatively dilute solution from the bottom of the

(Based On Standard Steam Units – Model YIA) absorber is pumped by the solution pump, through the
heat exchanger, where it is regeneratively heated by
The cycle diagram for Model YIA Steam/Hot Water hot concentrated solution draining from the generator.
operated systems is shown in FIGURE 5. The follow- The solution then travels up to the generator (see
ing discussion will describe the absorption system FIGURE 8).
operation generally, in reference to this particular 2
configuration. ABSoRBER
RT3
Liquid, usually water, for air conditioning applications

or process applications is chilled as it passes through
the evaporator tubes by giving up heat to refrigerant 3SoL
flowing over the outside of the tubes. This heat causes

(Unloader) SoL
PUMP
refrigerant to evaporate since it is at a pressure with a

VS12
RT10 VS20 VS13
corresponding boiling temperature lower than the leav- VS18 VS19
ing chilled water temperature. For example, water is

ld13806c
chilled from 54°F to 44°F (12°C to 6.6°C) with the FIGURE 8 - SOlution Pump
evaporator at 6.3 mmHg. absolute pressure which cor-
relates to a 40°F (4.4°C) boiling point (refer to FIGURE Generator tubes are submerged in lithium bromide
6). solution which enters the generator in a dilute condition
at one end and leaves concentrated at the opposite end.
A portion of the refrigerant is vaporized by steam or hot
water flowing through the generator tubes, thus con-
centrating the solution (see FIGURE 9).
RT1
CHILLED
wATER STEAM oR HoT wATER
oUTLET CoNTRoL VALVE
RT7
RT6 CHILLED HoT wATER
wATER oR
INLET STEAM
EVAPoRAToR GENERAToR **PT2
ld13806a GENERAToR
FIGURE 6 - Evaporator VS3 oUTLET
ld13806d
Refrigerant vapor in the evaporator is attracted and FIGURE 9 - Generator
absorbed by intermediate lithium bromide solution
flowing over the outside of the absorber tubes thus Concentrated solution flows by gravity and pressure dif
diluting the solution. Heat generated in the process ferential through the heat exchanger, where it is cooled
(heat of absorption) is removed by condensing water regeneratively by cooler dilute solution. The heat
from a cooling tower or other source flowing through exchanger has thus improved the efficiency of the sys-
the absorber tubes (see FIGURE 7). tem by reducing the amount of steam or hot water
required to heat the dilute solution in the generator and
the amount of concentrated solution cooling required in
the absorber.
RT5 TowER An intermediate solution, consisting of a mixture of

wATER
INLET cooled concentrated solution from the generator heat
exchanger with dilute solution from the bottom of the
ABSoRBER
absorber, is recirculated over the absorber tubes by the
solution pump, with the aid of the eductor, to complete
the solution cycle (see FIGURE 7).
ld13806a
FIGURE 7 - Absorber
JOHNSON CONTROLS 19
FORM 155.21-OM1 (510)
Refrigerant vapor released from the dilute solution in 1. Leaving Chilled Liquid Temperature Control
the generator is condensed on the condenser tubes by (LCHLT Control)
giving up its heat of condensation to condensing water
2. Strong Solution Concentration Control
passing through the tubes. This condensing water is the
same water that was used to cool the absorber (see (SSC Control)
FIGURE 9). 3. Limited load by warning conditions.
HP1
PT1 With the introduction of the RT10 sensor, the OptiView
CoNDENSER RT4
TowER wATER panel is now capable of continuous monitoring of the
VR40 oUTLET
strong solution temperature in the most critical location
HT1 where it would most likely begin to crystallize. The
RT9
logic then analize the three control mechanisms and
STEAM oR HoT wATER
CoNTRoL VALVE chooses the lowest limit to ensure trouble free opera-
RT7
HoT wATER tion. Listed below is a brief description of each control
oR
**PT2 STEAM mechanism.
GENERAToR
GENERAToR
oUTLET
Leaving Chilled Liquid Temperature (LCHLT)
ld13806E Control
FIGURE 10 - Condenser The goal of the LCHLT control is to match the leaving
Condensed refrigerant flows by gravity and pressure chilled liquid temperature with leaving chilled liquid
differential through an orifice or expansion device to temperature setpoint. It calculates an error value (current
the evaporator. This refrigerant, plus that recirculated leaving chilled liquid temp minus the leaving chilled
by the refrigerant pump, is distributed over the evapo liquid temperature setpoint) and a rate value (leaving
rator tubes to complete the refrigerant cycle. chilled liquid temperature from the current sample minus
the leaving chilled liquid temperature from the previous
Capacity of the unit is automatically controlled from sample) and returns an opening valve variation. This
the temperature of the chilled water leaving the evapo- variation is added to the current valve opening value.
rator. The steam or hot water control valve meters the
steam or hot water flow to the generator. Refer to Strong Solution Concentration (SSC) Control
FIGURE 5 for complete cycle diagram. The goal of the SSC control is to avoid solution concen-
trations that can crystallize. It calculates an error value
Capacity Control (current strong solution concentration – strong solution
concentration limit) and a rate value (Strong solution
The YIA control panel controls the capacity of the unit concentration from the current sample – strong solution
by throttling the control valve, which in turn regulates concentration from the previous sample) and returns an
heat into the generator section of the unit. opening valve variation; this variation is added to the
current valve opening value.
In prior YIA chiller controls sensors monitored incom-
ing Cooling Tower Water Temperature (CTWT). Valve Load Limited By Warning Conditions
positions were controlled based on predetermined The control valve can also be under certain limitations
reduced temperatures (see Form 155.16-OM1). This depending upon unit operating conditions. These limits
feature was kept the unit design solution concentrations will take precedence over the LCHLT and SSC controls.
in balance so the unit would not crystallize, over dilute, Unit pull down limit, soft shutdown or ramp down,
or inhibit refrigerant vaporization at reduced CTWT remote max load limit, warnings caused by refrigerant
temperatures. temp is less than 35.5°F (1.9°C), warnings caused by
generator pressure is greater than 517 mm Hg Abs.
The capacity control logic in the OptiView panel is dif-
ferent from prior YIA absorption panel logic.
There are three sub control mechanisms interacting

constantly.
20 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
Limiting Capacity by Mixing Solution and Refrigerant Overflow

Refrigerant An auxiliary refrigerant overflow pan is located near the
The YIA is capable of obtaining low load conditions with left end tube sheet and can be viewed through the two
low cooling tower water temperatures. Achievement of evaporator sight glasses. To aid in viewing this internal
low capacity at low cooling water temperatures involves component, use a focused-beam flashlight to shine
reduction of concentration in the solution circuit; thus through one of the two sight glasses (see FIGURE 4)
water removed from the refrigerant circuit is added to while looking through the other. 2
the solution circuit for dilution. This happens while the
unit is operating at low loads. Since the amount of refrigerant in the refrigerant circuit
is at a maximum at 100% capacity, overflow would
normally start to take place at this condition or slightly
above. The evaporator sight glasses allow the techni-
cian a visual means to track the refrigerant level in the
evaporator pan. A 3/16” weep hole is drilled near the
top of the evaporator pan just in front of the auxiliary
refrigerant overflow. At the correct refrigerant level dur-
ing full load conditions, refrigerant should be observed
dripping out of this hole. If refrigerant is observed to be
shooting out of this hole that means the level is above
the hole. Any tendency to over-concentrate the solution
further will cause the refrigerant to rise and overflow
from the sides of the pan. FIGURE 12 is a depiction of
what to look for.
ld04766
FIGURE 11 - Solution and refrigerant

level variation with load
By diverting lithium bromide from the solution circuit

to the refrigerant circuit under a controlled basis. The
amount of lithium bromide transferred is kept to a mini-
mum by introducing this lithium bromide only when the
refrigerant level in the refrigerant circuit is at a minimum
operational level. This is done by opening the 3SOL
(unloader solenoid valve) only when 1F level switch
opens and the chilled liquid temperature is +/- 2 °F from
setpoint. This criterion will avoid 3SOL openings at unit
start up when the refrigerant levels are inherently low.
As the unit load increases, the contaminated refrigerant
will clean up naturally as the refrigerant vaporization
ld14572
rate increases.
FIGURE 12 - EVAPORATOR AUXiliary DRAIN PAN
JOHNSON CONTROLS 21
FORM 155.21-OM1 (510)
Anti-Freeze Line DISCUSSION OF SUBSYSTEM OPERATION
For sustained operation at low loads and low condens- Automatic Decrystallization (ADC)
ing water temperature, the concentration of lithium The likelihood of solution crystallizing increases as the
bromide by weight in the refrigerant circuit may concentration increases and/or the temperature decreas-
approach 35% - 40%. With conditions such as these, es. This could happen in the shell-side of the heat
the pressures in the lower shell are reduced. The pure exchanger and could extend to the piping and the educ-
water refrigerant entering the evaporator from the con- tor, causing stoppage of flow and producing a noisy
denser would at these times be below the freezing condition. The automatic decrystallization feature is
point of water (32°F, 0°C) by as much as 12%, and available on all YORK IsoFlow Absorption Systems.
could cause ice to hang up in the refrigerant conden- All models are equipped with this basic ADC piping
sate lines (from the condenser after the orifices). circuit plus the ADC control feature.
To prevent this, a small amount of refrigerant (actually The automatic decrystallization aids for trouble-free
very dilute solution now in the refrigerant circuit) is operation of the unit. While the ADC piping circuit will
routed from the discharge of the refrigerant pump to not completely eliminate the possibility of crystalliza-
mix with the pure water refrigerant about to enter the tion requiring service assistance, it will greatly reduce
evaporator from the condenser. This line is identified the likelihood. A mild, temporary crystallization may
on the cycle diagram FIGURE 5 as the antifreeze occur in rather extreme condensing water temperature
line. variations and can be automatically managed without
loss of refrigeration or special attention from the opera-
Chilled Water Control Stability tor. Still, more positive measures attacking the major
Operation of an absorption system without the tower factors in solution crystallization are taken in models
water bypass valve control (used to maintain a given where the ADC controls are utilized. Direct dilution of
cooling water temperature to a unit) requires certain the solution with refrigerant and reducing the heat input
control measures within the unit to maintain acceptable to the generator when the tendency to crystallize is
stability of operation. The effect of rapidly changing automatically detected are both affected by ADC con-
tower water temperature, such as occurs when tower trols, arranged to continue in effect until the tendency
fans cycle off and on, would affect the unit capacity to crystallize disappears.
control. This causes steam valve opening and closing
tendencies to cut-out on refrigerant low temperature ADC Piping Circuit in Detail
thermostat if provisions are not made to offset these Referring to FIGURE 13, the normal return solution
tendencies. flow from the generator is via. the return pipe (1),
through the heat exchanger (2), and then through the
Stabilizer Refrigerant Solenoid (2SOL) eductor suction pipe (3) to the eductor (4).
YIA units are equipped with a control stabilizer
arrangement. This control operates the refrigerant valve During normal operation, the flow of solution in the
(2SOL) to permit immediate transfer of refrigerant to return pipe (1) is accomplished by a condition of
the generator drain line for immediate control of refrig- “open-sewer” flow for a portion of the return pipe from
erant temperature. This causes dilution of the solution (A) to (B). Below some point (B) a solid liquid level is
and hence, reduction of absorption and refrigeration established and solid liquid exists from (B) through the
effect. This type of action, required when cooling water heat exchanger (2) and return pipe (3).
temperature fluctuates, corrects the low temperature
condition, permits refrigeration effect to continue, and If the solution concentration from the generator is
prevents unloading of the cooling tower. excessively high, solution crystals will start to build on
the shell side of the heat exchanger. This will restrict
the flow through the normal system of return piping
described above, and the established solution level (B)
will rise in the return pipe (1). This will continue to rise
until an elevation in the pipe (C) is reached.
22 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
At this point, an emergency solution return pipe is pro- There is a simple way to tell whether the solution flow
vided. This return pipe (9), with connection entering from the generator is by normal return methods, through
the return piping at (8) is used. This return pipe (9), has the heat exchanger, or whether the automatic decrystal-
a trapped section of pipe (10), riser portion (11), and lization pipe is being used. If the trapped section of pipe
pipe sections (12 and 13) leading to the absorber. (10), or pipe (13), is hot to the touch, such as that nor-
mally experienced at pipe (1), then the solution is return-
The heat exchanger is bypassed in the operational use ing by means of the automatic decrystallization pipe. If 2
of this emergency return system of piping. Its operation it is cold to the touch, corresponding to normal tempera-
is completely automatic. ture of dilute solution or slightly above, then there is no
return flow through the automatic decrystallization
It should be noted that as crystallization proceeds, it is pipe.
not necessary for the solution to back up into the gen
erator itself to engage the use of the ADC. It is desirable Combination of Basic ADC Piping Circuit and
to bring the device into operation before an extreme ADC Control Feature (see FIGURE 13)
condition of crystallization ocurs. Connection (8) enters As hot concentrated solution backs up and overflows
the normal return piping at a level appreciably below into the emergency solution return line (9), the tempera-
the normal generator operating level (17). Since this ture of the pipe increases and the ADC sensor item (18),
enters the return piping at a point where there is open attached to the pipe, senses this temperature. At a tem-
sewer flow, there is no flow of solution down the ADC perature of approximately 160°F, the ADC sensor (18)
pipe during normal operation. starts a control panel timer, which signals the capacity
control valve (23) to close to 50% for a minimum of 10
It is necessary that this automatic decrystallization pipe minutes. During the first 2 minutes, 2SOL (16) is ener-
contain a liquid trap. Otherwise, there would be gized to permit refrigerant to be pumped into the return
unwanted flow of vapor from the top shell to the lower pipe (1) via connection (15). The cycle will be repeated
shell due to the difference in pressures between the two every 10 minutes until line (8) cools to approximately
shells. 150°F or lower. At this point crystallization has been nor
mal circulation of solution from the generator will pro-
ADC Flush Line ceed.
To provide a liquid trap, a small capacity flush line is It must be noted that the ADC operation will continue for
provided (14), to supply a small GPM flow of dilute- at least 10 minutes regardless of a shutdown or subse-
solution into the trapped portion of the decrystallization quent restart.
pipe. It is desirable that the riser portion of this trap be
sufficiently high to take care of any extreme condition 2SOL – Refrigerant Valve Blowdown
in top shell pressure, such as with unusually high con- Manual operation of the refrigerant valve (2SOL) may
densing water temperature and degree of condenser be selected by using the manual pump key on the System
fouling. Screen when in service access level. When this valve is
energized, refrigerant will flow through the line, into the
Consequently, a riser portion is extended up into the shell side of the heat exchanger and ultimately into the
exterior pipe (12). This pipe (11) inside the pipe (12) is absorber shell, thus transferring refrigerant back into the
an extension of the trapped section of the pipe (10). solution side of the system.
This flow of flush solution through the trap also serves

the purpose of sweeping out the small amount of water
condensate that tends to be absorbed into the dilute
solution at the liquid-vapor interface.
JOHNSON CONTROLS 23
FORM 155.21-OM1 (510)
legend to figURE 13
item no. description item no. description

1 solution return pipe 13 a.d.c. overflow dump line
2 solution heat exchanger 14 a.d.c. flush line
3 eductor suction 15 refrigerant valve connection
4 eductor 16 refrigerant valve (2sol)
5 solution pump suction 17 solution level in generator
6 solution pump discharge 18 a.d.c. thermostat (RT2)
7 generator SUPPLY line 19 capacity control valve
8 a.d.c. pipe overflow connection
9 a.d.c. pipe a start of open sewer flow
10 a.d.c. pipe (trapped section) b top of solid liquid level
11 a.d.c. pipe (riser section) c a.d.c. solution overflow point
12 a.d.c. overflow jacket
24 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
KEY
CONCENTRATED CoNDENSER CoNDENSER
SOLUTION (LI.BR.)
DILUTE SOLUTION
wATER
(LI.BR.)
INTERMEDIATE
SOLUTION (LI. BR.)
REFRIGERANT
(WATER)
STEAM oR HoT wATER
2
CHILLED LIQUID 17 CoNTRoL VALVE
CONDENSER GENERAToR
WATER HoT wATER oR
STEAM STEAM
C
CHILLED LIqUID
8
1
18 EVAPoRAToR
11
2F
B
12
9
CoNDENSER
13 ABSoRBER
wATER
15 16
2SoL
14REFRIGERANT VALVE 5
6 To
ADC FLUSH LINE PURGE
10 DRUM
3SoL
REFRIGERANT
LEVEL VALVE
SoLUTIoN SoLUTIoN
HEAT PUMP
2
EXCHANGER REFRIGERANT
4 3 PUMP
EDUCToR
Note: orifices may differ between various models. LD04768
FIGURE 13 - automatic decrystallization feature

(hot water units & steam units with adc control)
JOHNSON CONTROLS 25
Purging and Non-condensables
FORM 155.21-OM1 (510)
26 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 3 – Purging and NON-condensables

NON-CONDENSABLES Since it is important to correct any air leaks as soon as
possible, it is essential to develop a disciplined method
It is necessary to purge absorption chillers due to the of purging a unit so that any abnormalities can be dis-
potential for the systems to collect non-condensable covered quickly. On SmartPurge™ equipped units, the
gases. Non-condensables, if allowed to accumulate, will purge tank is automatically evacuated only when nec-
reduce the absorption unit’s performance and may cause essary and the frequency of evacuation is continuously
corrosion within the unit. monitored by the OptiView control panel.
It could be speculated that over ninety percent of all CONTINUOUS INTERNAL PURGING WHILE
capacity related complaints on IsoFlow™ units involve UNIT IS OPERATING
the presence of non-condensables.
3
The purge system is designed to automatically and con-
A non-condensable is defined as a gaseous substance tinuously remove non-condensables from the absorber
that cannot be liquefied or condensed at the pressure section of a unit and store them in an area called a purge
and temperature surrounding it. tank. Here they can be manually or automatically evacu-
ated by the unit purge pump. The transport of the non-
Non-condensables appear in two forms in absorption condensables to the purge tank is a continuous process
units. accomplished without the use of any moving parts.
1. Internally generated non-condensables are formed
The purge tank must be evacuated by the unit purge
as a by-product of corrosion.
pump. This can be done either manually or automati-
2. Air may be drawn into a unit via leaks. cally, depending if the unit is equipped with Smart-
Purge™ or not. SmartPurge™ monitors the purge tank
Non-condensables that collect in the absorber section of pressure and evacuates the purge tank when the tank
the unit blanket the heat transfer tubes and reduce the pressure reaches 80 mm Hg absolute. The automatic
absorber’s ability to capture the refrigerant vapor. purge system stops evacuating the purge tank when its
pressure is reduced to 30 mm Hg.
Non-condensables that collect in the high side of the
unit end up in the condenser where they blanket the PURGE COMPONENTS
condenser tubes, reducing the condenser’s capacity.
Full load capacity will be prevented by high condens- Several devices combine to provide the functional purge
ing pressure. system. Many of the components can be found on the
purge tree. The purge tree is a series of piping and valves
NON-CONDENSABLE QUANTITIES connected together and located on the control panel side
of the unit (see FIGURE 14). The valves are manifolded
An absorption unit’s general health can be determined together for convenience so that nearly all purge opera-
by both the quantity and quality of non-condensables it tions can be performed from one location.
produces. A properly maintained YORK IsoFlow™ unit
will produce very few non-condensables—the fewer the
better. A small amount of internally generated gases will
always be present and should be considered normal. Air
leaks, no matter how small, will almost always cause
noticeable increases in the amount of non-condensables
a unit produces.
JOHNSON CONTROLS 27
FORM 155.21-OM1 (510)
PURGE PUMP The purge pump is factory mounted on a bracket system

on the YIA units.
Each unit is equipped with a purge pump which is essen-
tially a vacuum pump specially modified to work well in The purge pump is used to:
lithium bromide service. YIA units have a 5.6 cfm, belt 1. Remove stored non-condensables from the purge
driven, two-stage, rotary vane type vacuum pump. The tank.
purge pump exhausts the unit non-condensables.
2. Manually purge the absorber.
The purge pump will go through a warm-up period when

Do not operate the purge pump with- started. This will help keep the oil free of refrigerant.
out the belt guard in place!
Although occasionally some of the non-condensable

gases produced are unpleasant in odor, the normal
quantities are very small. If venting the purge exhaust
On units with SmartPurge™, be aware is required, it can be done by running the purge piping
that the purge pump starts and stops outdoors or into a scrubbing unit of some type. Common
automatically. sense should prevail in the piping design in venting the
purge pump out doors. Total pressure drop of vent piping
must not exceed 5 psig.
VP4 PT3
EDUCTOR
8SOL
7SOL
OIL
TRAP
VP1
VP8
PURGE
PUMP
GAS
SEPARATOR
ld14573
FIGURE 14 - YIA PURGE SYSTEM
28 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
Explosion Warning: Never install an PURGE EDUCTOR

isolation valve on the discharge of the
pump or in the vent line. Closing this The purge eductor (FIGURE 16) is a liquid powered
valve while the pump is operating jet pump (ejector). Jet pumps have no moving parts
could result in an explosion. and use a high pressure stream of liquid (solution from
the solution pump discharge line) passing through a
The purge pump should be operated with the gas ballast nozzle to cause a portion of a low pressure stream
open to prevent refrigerant vapor from condensing in the (condenser refrigerant vapor and non-condensables)
oil. Close the purge pump gas ballast when performing coming into the side of the pump to combine with the
a bubble leak test procedure. nozzle stream. This causes a reduction in pressure at
the low pressure inlet and induces the rest of the low
Leave the gas ballast valve in the open position, except pressure inlet substance to flow into the body of the
when performing a leak test. See the Pumps section pump. In the diffuser section of the pump some of the 3
of this manual for further purge pump maintenance velocity of the combined liquid flow is converted back
information. to pressure. The eductor outlet will be at a pressure
between the high pressure inlet and the low pressure
inlet (see FIGURE 16).
PURGE TANK
Pressurized Solution
Flow from Solution Pump
Discharge
The purge tank is a long round tank located on the up-
per shell.
Induced Flow of Saturated
water Vapor containing Non-
The purge tank is essentially a storage container where Condensables from Condenser
Nozzle
non-condensables are kept until they can be pumped
out of the unit by the purge pump. The stored non con-
densables are pumped into the purge tank by the purge Low Pressure Area
eductor system. Created Around The Jet of
Solution That is Forced
Through the Eductor
Non-condensables stored in the purge tank do not affect Nozzle
Eductor outlet Should be
the unit performance. The purge tank is kept separate 10°F (5.6°C) warmer than
from the rest of the unit by a liquid U-trap seal. Due to Solution Inlet when working
Properly
the liquid seal height, the purge tank can safely hold at
least 100 mm Hg absolute of pressure without fear of
the non-condensables venting into the absorber.
Solution Containing
Non-Condensables
to Gas Separator ld05090d
FIGURE 16 - PURGE EDUCTOR

PT4
VP10
VP2 VP4
FIGURE 15 - YIA PURGE TANK ld1457c4
JOHNSON CONTROLS 29
FORM 155.21-OM1 (510)
GAS SEPARATOR VP1

The gas separator is where the non-condensables are This manual valve is used for initial purging of the unit
removed from the solution flowing out of the purge at unit commissioning. When open it will pull non-
eductor (FIGURE 16). condensables out of the absorber/evaporator shell from
a higher location than VP4. It is connected in series just
Solution mixed with non-condensable gases flows into before valve VP4 on the purge tree end, both valves will
the side of the separator where it enters an annulus need to be open for manual purging. Note: on larger units
between the inner chamber and the outer wall of the this valve maybe stand alone.
separator. The swirling and overflowing action induced
by the inner chamber causes the non-condensables to VP2
rise up and accumulate near the top of the separator. This manual diaphragm valve is used to remove non-
The solution outlet pipe extends down into the inner condensables from the purge tank. It must be always
chamber where solution with no non-condensables is open when in the auto-purge mode.
present. The non-condensables accumulating near the
top of the gas separator pass upward through the non- VP4
condensable outlet pipe into the purge tank. This valve is used to manually purge the absorber section
GAS SEPARAToR of the unit. It is connected to the internal absorber purge
Non-Condensables
header system located below the tube bundle. When
weak Solution
to Purge Tank Returns to open the purge pump will pull the non-condensables
Absorber
from the absorber. It is always in the closed position
Level in outlet
Pipe will Vary
Swirling Action in outer
Annulus and Spillover
for auto-purging.
with Purge into Inner Chamber
Tank Separates Non-
Pressure Condensables from 7SOL (Purge Tank Pressure Valve)
Solution
This solenoid valve is only supplied on units with the
auto-purge feature. The Optiview panel will control
the opening and closing of this valve in auto or manual
purge mode. It only opens when the pressure from PT3
is proven to be 15 mm Hg absolute or less. When this
valve is open, non-condensables from the purge tank
are allowed to be purged out.
weak Solution with
Entrained Non- 8SOL (Purge Pump Pressure Valve)
Condensables From
Purge Eductor
This motorized ball valve is only supplied on units
with the auto-purge feature. The Optiview panel will
control the opening and closing of this valve in auto
or manual purge mode. After the purge pump is started
ld05090
and completed the warm up period, 8SOL will open. A
FIGURE 17 - GAS SEPARATOR
60 second timer is started to allow this valve to open
Valves completely. If the pressure as monitored at PT3 is not
at or below 15 mmHg absolute after the 60 seconds
Some special valves have been added to the YIA auto- has expired, an additional 60 timer will commence. If
purge system. All of the valves are designed to be reli- the pressure is still above 15 mmHg absolute after the
able and leak-free. There are several special purpose second 60 seconds has expired, 8SOL will close and a
valves used, such as the check valve and the automatic purge pump failure will be displayed. 8SOL and 7SOL
purge valves. Please note all valves have been given a are connected in series in order for 8SOL to be open to
designation number for identification purposes. purge the non-condensables from the purge tank.
The following is a description of each individual valve

and its functional purpose. Not all valves may be used
on some models.
30 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
VP8 Purging Frequency

This check valve is located between the purge pump and The purge tank evacuation frequency will be dependent
oil trap. It is a flapper-type check valve which must be on several factors such as unit size, operational parame-
installed horizontally with the “hinge” marking up and ters, running time, solution chemistry, and of course, leak
the “free flow” arrow pointing towards the purge pump. tightness of the unit. Some units may only need to have
Its purpose is to provide added protection from air enter- their purge tank evacuated a few times per year. Others
ing if the purge valve were open during an unattended may require more frequent evacuation. Although very
power failure situation. It works best at high pressure frequent purge tank evacuation is a matter of concern,
differentials. Note: this valve is a maintenance item a change in the frequency is also an indicator of a unit
and may malfunction with extended or severe usage. It problem. For instance, a unit may routinely accumulate
is located so that it can be taken apart and cleaned with 80 mm Hg of pressure in the purge tank over 200 hours
kerosene or similar degreaser. The stamped “hinge” hex of operation (approximately one month). If, all of the
end will unscrew (right handed threads) from the body sudden, the purge tank accumulates 80 mm Hg pressure 3
of the valve to access the flapper assembly. in 100 hours of operation (approximately two weeks),
there is a strong indication that either a leak is develop-
Oil Separator ing, or there is a problem with the solution chemistry,
The oil separator is located in the suction line of the or both. Therefore, if a unit is manually purged, it is
purge pump. It is constructed so that oil from the vacuum important to keep track of the purging history. If the
pump cannot get drawn into the unit should a power unit is equipped with SmartPurge™, the micro processor
failure occur during purging. The separator is sized to keeps track of the purging frequency and alerts you if it
hold twice the volume of the purge pump oil charge. has become excessive.
The oil separator also serves as a trap in the unlikely When to purge the purge tank
event that solution gets drawn into the purge piping and The old philosophy of purging an absorption unit was
helps prevent contamination of the purge pump. to have the equipment room operator manually purge
the unit once per day, whether it was necessary or not.
Absolute Pressure Gauge In addition to purging from the purge tank, most opera-
This gauge is important for reading the very low pressure tors preferred to purge from the absorber with the purge
in the absorber section of the unit or the vacuum pump. pump for a given period of time. Although some users
The gauge is no longer a manometer type gauge that may still prefer this method, it should not be necessary,
contains mercury. It is a dial type, non-mercury absolute providing the unit is in good health.
gauge that will meet todays standards for prohibiting
mercury in the work environments. The gauge reads in Since the YIA unit’s internal purge system is automati-
Torr, which is the same as mmHg absolute. However, cally and continuously (while the unit is operational)
due to the extreme sensitivity of this gauge, the upper- moving non-condensables from critical areas of the unit,
most range is 40 Torr. Unlike the manometer gauge, it such as the absorber or condenser to the purge tank, it is
will not read purge tank pressure. only necessary to monitor the purge tank pressure and
evacuate it periodically. It should not be necessary to
Care should be taken to prevent lithium bromide solution purge the absorber with the purge pump on a properly
from contaminating the gauge. Contamination will cause operating unit.
inaccuracies in the pressure reading and may damage the
internal working components. The gauge will ship loose Although the purge tank can adequately maintain 100
for field installation in the purge tree. It is highly recom- mm Hg pressure, autopurge will evacuate the tank if
mended to install an isolation valve between the gauge the pressure exceeds 80 mm Hg. The purge tank will be
and the purge tree for when the gauge is not in use. evacuated until the tank pressure is reduced to 30 mm
Hg. It is recommended that units without autopurge be
purged the same way.
JOHNSON CONTROLS 31
Purge Pump Operation
FORM 155.21-OM1 (510)
PURGE TANK VP10

PT4
VP2
VP4
VACUUM
GAUGE
PT3
FRoM
SoLUTIoN
PUMP
VENT To 7SoL 8SoL DISCHARGE
ABSoRBER
To VP1 oIL
ABSoRBER TRAP
NoN-CoND. VP8
FRoM VENT To
ABSoRBER ABSoRBER
VENT
TEST
HoSE
GAS
BALLAST
PURGE
PUMP
To
SoLUTIoN
PUMP SUCTIoN
GAS
SEPARAToR
LD14575
FIGURE 18 - THE COMPLETE ISOflow PURGE SYSTEM
32 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 4 – purge pump operation

GENERAL
oil
As previously discussed, each machine is equipped Trap
with a vacuum pump (refer to FIGURE 19) which is
designed to remove non-condensables from various Bubble
Test Hose
Leak Rate
Test Valve
areas of the machine. The following issues should be (open)
kept in mind whenever operating a YORK Vacuum

Pump. Gas Ballast
Valve
(open)
Cleanliness
Take every precaution to prevent foreign particles
Purge
from entering the pump. A fine mesh screen is pro- Pump
vided for this purpose in the intake passage of all oil Drain
YORK Vacuum Pumps. ld06051
FIGURE 19 - purge pump piping and

Types of Lubricants valves - normal operation
All YORK mechanical vacuum pumps are tested with 4
DUOSEAL® oil and shipped with a full charge to pre-
vent unnecessary contamination. DUOSEAL® oil has The Presence and Removal of Condensate
been especially prepared and is ideally suited for use Condensation takes place particularly in the compres-
in mechanical vacuum pumps because of its desirable sion stroke of the second stage of a two-stage pump.
viscosity, low vapor pressure, and chemical stability. The compression stroke is that portion of the cycle
during which the gas drawn from the intake port is
The vacuum guarantee on all YORK vacuum pumps compressed to the pressure necessary to expel it past
applies only when DUOSEAL® oil is used. the exhaust valve. Condensation takes place when the
ratio between the initial pressure and the end pressure
Purge Pump Piping and Operating of the compression is high, that is, when the mixture
Valves of vapor and gas drawn from the intake port is com-
pressed from a low pressure to a high pressure. By
adding air through the gas ballast valve to the mixture
The purge pump piping and valves, illustrated in
of vapor and gas being compressed, the pressure
FIGURE 15, is installed at the factory and can be used
required for delivery past the exhaust valve is reached
for several functions. During normal operation, both
with a considerably smaller reduction of volume of
the gas ballast and the leak rate test valve must be
the mixture. Depending upon the amount of air added,
open at all times.
condensation of the vapor is either entirely avoided or
substantially reduced.
The Principle of Gas Ballast
The Effects of Unwanted Vapor - Systems which
Oil Level Determination
contain undesirable vapors cause difficulty from both
the standpoint of attaining desirable pressures, as well
The amount of oil suitable for efficient and satisfac-
as contamination of the lubricating medium. A vapor
tory performance should be determined after the pump
is defined as the gaseous form of any substance which
has reached its operating temperature. Initially the
is usually a liquid or a solid. Refrigerant (water) and
pump should be filled with fresh oil while the pump is
alcohol vapors are two of the most common vapors
idle. Fill the pump through the pump discharge port
encountered in absorption chillers. When such vapors
until the oil level falls halfway up the oil level win-
exist in a system, the vapors or mixtures of gas and
dow. If after a short period of operation, the level
vapor are subject to condensation within the pump.
should fall, it is likely the result of oil entering some
This precipitated liquid may dissolve or become emul-
of the interior pockets of the pump. If the oil level
sified with the oil. This emulsion is recirculated to the
rises, this means oil has drained into the pump cavity
chambers of the pump where it is again volatized,
while idle. To correct this shut off the pump, then
causing increased pressure within the system.
drain oil down to proper level.
JOHNSON CONTROLS 33
FORM 155.21-OM1 (510)
If a gurgling sound occurs, additional oil may need to (3) when a large leak is present in the system; and (4)
be added. Mechanical pumps will gurgle in varying when the gas ballast is open. Best performance of a
degrees under four conditions of performance: (1) mechanical pump is generally obtained after sufficient
when operating at high pressure as in the beginning time has been allowed for the pump to come to operat-
cycles of evacuation of the purge drum; (2) when the ing temperature.
oil level in the pump reservoir is lower than required;
34 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 5 – purge pump MAINTENANCE

Vacuum Problems tially closed and the intake port open. Closing the
exhaust port completely under these conditions will
Pressure Determinations create excessive pressure at the drain valve which may
A simple test for the condition of a mechanical pump cause the oil being drained to splatter.
is a determination of its ultimate pressure capability.
This can be accomplished by attaching a gauge direct- Flushing the Pump
ly to the pump. The gauge may be any suitable type This procedure should be performed whenever the
provided consideration is given to the limitations of performance of the pump is poor and changing the oil
the gauge being used. The pump must be capable of didn’t correct this shortcoming.
pulling a vacuum of at least 2 mmHg absolute. If the 1. Check the oil level.
pressure is unusually high, the pump may be badly a. If the oil level is well above the fill mark, this
contaminated, low on oil, or malfunctioning. On the can indicate the pump has ingested lithium-
other hand, if the pressure is only slightly higher than bromide solution. Go to step 2.
the guaranteed pressure of the pump, an oil change
b. If the oil level is even with the fill mark and
may be all that is required.
you do NOT suspect lithium bromide solu-
tion has been ingested accidentally by the
Oil Contamination
pump, run the pump for 15 minutes and allow
The most common cause of a loss in efficiency in a
the pump oil to warm up before going to
mechanical pump is contamination of oil. It is caused
step 2.
by condensation of water and alcohol vapors and by
foreign particles. The undesirable condensate emulsi- 2. Turn off the motor for the vacuum pump. Drain
the oil into a clear plastic container. Look for
fies with the oil which is recirculated and subjected to
water settling to the bottom of the container. In
5
re-evaporation during the normal cycle of pump activ-
ity, thus reducing the ultimate vacuum attainable. some cases, an emulsion of oil and water can be
Some foreign particles and vapors may form sludges seen between the oil and the water. If water is
with the oil, impair sealing and lubrication and cause noticed, perform steps 3 through 5 several times
eventual seizure. Although the gas ballast valve is until the oil comes out clear.
helpful in removing vapors, especially water, it is not
equally effective on all foreign substances; therefore, The oil drained from the pump is
periodic oil changes are necessary to maintain effi- from the oil case only. There may be
cient operation. The required frequency of changes water or other contaminants in the
will vary with the particular system. pumping mechanism. To be sure all
contaminants have been removed, the
The oil should be changed when it looks dirty, cloudy, pump mechanism needs to be
milky, or when the pump is not capable of pulling flushed.
below 2mmHg Abs.
3. Make sure the belt guard is installed before pro-

Oil Changes and Oil Level ceeding further. Attach a short hose to the drain
valve which runs into a clear plastic container.
Draining the Pump Secure the hose end in the container so that it does
An oil change is most easily accomplished when the not blow around during the next step.
pump is warm and the oil is less viscous. Use a clear 4. Flushing the pump is carried out by adding a cup
plastic container large enough for the oil in the par- of new DUOSEAL® oil through the exhaust
ticular pump. Stop the pump, and open the drain (OUT) port while the pump is turned on for 15-20
valve. Thoroughly drain the pump by tipping the seconds. While adding the pump oil, the exhaust
pump slightly, if this is possible. The small residue (OUT) port is blocked by the palm of your hand.
remaining in the pump may be forced out by hand- Look for water coming out of the drain hose. Turn
rotating the pump pulley with the exhaust port par- off the pump.
JOHNSON CONTROLS 35
FORM 155.21-OM1 (510)
5. Repeat step 4 until only clean oil comes out of the without loss of function. Eventually, of course, a great
drain hose. loss of oil may cause harmful damage.
6. Fill the pump (through the exhaust port) with 2.25
quarts of DUOSEAL® vacuum pump oil. Repairing Technique
An oil seam may be sealed by any of several methods.
7. Plug the intake (IN) port with a rubber stopper.
When an O-ring is employed, the surfaces of the
Turn the pump on and run the pump for 10 min-
O-ring and its groove should be wiped clean. If the
utes. Close the gas ballast valve.
O-ring is not badly deformed or scratched, it may be
reused by sealing with a slight film of vacuum oil or
Refilling the Pump vacuum grease. Thin composition gaskets are gener-
Refill the pump by pouring new DUOSEAL® oil into ally used for large irregularly shaped areas. A replace-
the exhaust port. Fill to the indicated level and start ment joint of this type should be thoroughly cleaned
the pump with the intake closed. A gurgling noise is of all previous gasket material and the mating surfaces
normal when high pressure air is drawn through the cleaned of any nicks.
pump. It should disappear quickly as the pressure
within the pump is reduced. If gurgling continues Drive Problems
(with gas ballast closed), add sufficient additional oil
through the exhaust port until gurgling ceases. When troubleshooting drive problems
or checking belt tension, always shut-
Shaft Seal Replacement
off and lock out power at the main
To replace the shaft seal of a pump, drain the oil and disconnect switch.
remove the pump pulley and key. Remove the screws
securing the old seal and pry it loose with a screw-
driver or similar wedge, being careful not to mar the If for any reason the pump will not operate, turn off
surface of the pump body against which the seal fits. and lock out the power at the main circuit breaker or
Discard the seal and its gasket, inspect all surfaces and disconnect. Check the overload assembly and electri-
repair any damages with a fine abrasive stone. Wipe cal connections. Remove the guard cover followed by
all sealing areas clean and place a film of DUOSEAL® the belt. Re-establish power to the pump. If the motor
oil on both the shaft and the inside bore of the new operates properly try hand-rotating the pump in the
shaft seal. Using a new gasket, carefully slide the new proper direction with the pump intake port open. If
seal into position and center it on the shaft. It is not both turn freely, then replace the belt and check the
necessary to apply any sealant to the gasket. Tighten belt tension. The tension should be sufficient to drive
the mounting screws uniformly and refill the pump the pump without visible slippage. Any greater ten-
with DUOSEAL® oil. Follow instructions included in sion will cause noise and possible damage to the bear-
repair kit. ings of both the motor and pump. Make certain that
both pulley grooves are clean and free from oil. The
Repairing Oil Leaks pulleys must be fastened securely on their respective
shafts, and in parallel alignment. Re-install the belt
Location, Cause and Effect guard and check for proper operation and amperage.
Oil leaks may develop wherever two mating faces are
sealed with a gasket. Such seams may fail as the result Replace or re-build any defective components.
of deterioration of the gasket material, loosening of
the screws caused by temperature variations, or
improper care as the result of previous reassembly.
Typical gasketed seams in a mechanical pump are
located at the oil level window, the shaft seal, the oil
drain and the mating faces of such mechanical sur-
faces as the intake chamber cover. The importance of
a gasketed seam is determined principally by its func-
tion. If it is a vacuum seal, the ultimate performance
of the pump is dependent upon it. If it is an oil seal,
the pump may be operated satisfactorily for some time
36 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
GAS BALLAST PoRT

1/4" NPT FEMALE CoNNECTIoN
ld05105a
1-13/16"
INTAKE NIPPLE, ACCEPTS

5/8" To 3/4" ID HoSE
3/4 - 20 THREAD
1-20 THREAD
5
STD MoToR, 1/2 HP
12-5/8"
41-0669 MTG. STRIP
2-01-0312 BoLT
2-61-3100 wASHER
9"
4"
3-1/2"
2" 1-7/8"
2-01-0316 BoLT
4-7/8" 7-3/16" 41-2363 wASHER
41-0929 BUMPER
2-35-3800 NUT
2-02-5708 SCREw ld05105B
10-1/4"
SPECIFICATIONS:
Free- Air Displacement, L/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Guaranteed Partial Pressure
Blankoff, millitorr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1
Pump Rotational Speed, RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Number of Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil Capacity, qts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1/4
Net Weight, Pump Only, lbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Net Weight, Mounted Pump, lbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Shipping Weight, Mounted Pump, lbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
FIGURE 20 - MODEL 1402 VACUUM PUMP FOR YORK
JOHNSON CONTROLS 37
Buffalo Pumps
FORM 155.21-OM1 (510)
38 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 6 – buffalo pumps

Introduction Pump Tripping on Thermal Protection
If the winding temperature thermostat is tripping the
The Buffalo pumps used on YORK IsoFlowTM chillers pump, allow the thermostat to reset. Exercise caution
are single suction, single-stage, hermetically sealed as the motor housing skin temperature may be in
centrifugal pumps designed for zero leakage, Totally excess of 300°F (148.9°C) when the winding tempera-
Closed Liquid Cooled (TCLC) applications. The ture thermostat trips. Although rare, if the thermostat
pumps employ a unique spring-loaded conical bearing will not reset in a reasonable period of time, it may be
design that allows for long life between overhauls. defective. If this is the case, temporarily bypass the
The pump bearings are cooled and lubricated by the thermostat and run the pump. Check the motor hous-
pumping fluid (refrigerant water or lithium bromide ing temperature with an infrared thermometer. The
solution). The pumping liquid also carries away heat average outside skin temperature of a solution pump
generated by the motor. motor housing is 190°F (87.8°C) at stable operating
conditions [100°F (37.8°C) suction temperature].
Do not run the pump dry. Even Refrigerant pumps run cooler than this. Check to be
momentary operation without the sure that the pump is not running dry periodically or
pump and motor casing filled with that either the suction/discharge isolation valves are
liquid will damage pump bearings. closed. Check to see that the pump is not pumping
abnormally high-temperature liquid for some reason.
If no problems related to flow through the pump are
FIGURE 21 shows a cutaway view of a single-ended found, the internal coolant passages may be blocked.
pump. The arrows indicates the cooling circuit through Pump disassembly will be required. Contact your
the pump. local YORK Factory Service office for details.
Troubleshooting Unusual Noise/Vibration

Pumps will make some noise during normal operation.
Pump Tripping on Overloads If pump is experiencing cavitation, the noise and
Check voltage supply on all three phases to be sure it vibration will be more severe. Abnormal sounds and
is correct for the pump motor in question. Check over- vibration may be due to foreign material trapped in the 6
load for proper amperage setting (Pump Motor FLA), coolant circuit and rubbing between the stator and
loose wires or poor connections that generate heat and rotor. Noise may also be a result of extreme bearing
trip the overload. If no problems are found, shut off all wear. Pump disassembly is required.
power to the unit, and lock-out / tag-out all discon-
nects. Pump Overhaul
The expected time span between Buffalo Pump over-
Check the motor connections to be sure the pump is hauls on a properly maintained IsoFlowTM unit should
wired correctly. Using a megohm meter, check the be between 50,000 and 60,000 hours. Pumps installed
pump motor windings for shorts or grounds. If motor on units running with high amounts of suspended sol-
problems are found, motor replacement will be neces- ids or high amounts of dissolved copper in the solution
sary (Contact your local York Factory Service office will suffer shorter lives. It is therefore recommended
for details). If no problems are found during this pro- to install a solution filtration kit on the unit to remove
cedure, reconnect the motor. Apply power to the unit the suspended solids and/or perform a copper removal
and run the pump while watching the operating amps. procedure as indicated on the solution chemistry
If high amps are encountered, the problem may be report. Contact your local York Factory Service
mechanical, such as bearing seizure. Pump inspection office for details.
will be necessary. If the overload continues to trip, but
the motor amperage is within the allowable range, the
overload is defective.
JOHNSON CONTROLS 39
Steam and Water Quality Control
FORM 155.21-OM1 (510)
ld05106A
FIGURE 21 - flow of refrigerant water or lithium bromide through pump
40 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 7 – STEAM and water quality control

WaterSide general Information It is equally important that the owner (operator) of the
equipment performs tube cleaning and inspection of
The absorber/condenser and evaporator water must be the absorber, condenser and evaporator waterside
free of corrosive elements or inhibited to prevent tubes at the frequencies recommended in the Tube
attack of the waterside tubing. Impurities and dis- Bundle Section of the "Preventive Maintenance
solved solids can cause scaling that reduces heat Schedule" located in this manual.
exchanger efficiency and causes corrosion of tubes.
Corrosion, in turn, can result in more serious prob- In addition to periodic cleaning with tube brushes,
lems, such as metal wastage and contamination of the tubes must be inspected for wear and corrosion. Tube
solution and refrigerant if through-wall pitting occurs. failures usually occur due to corrosion, erosion, and
For additional various water qualities see Chiller fatigue due to thermal stress. Eddy current analysis
Materials Application Guide YORK Form 160.00-AD5. and visual inspection by boroscope of all tubes are
invaluable preventative maintenance methods. These
YORK IsoFlowTM Absorption Chillers can only deliv- provide a quick method of determining waterside tube
er design output and efficiency if they are properly condition at a reasonable cost.
operated and maintained. One of the most important
elements of proper maintenance is the cleanliness of Steam/Condensate or hot water Quality
the tubes to prevent fouling, scaling and corrosion
during daily operations and shutdowns. YORK IsoFlow™ units use corrosion resistant CuNi
tubes in the generator.
It is the responsibility of the owner (operator) of this
equipment to engage the services of an experienced As with the waterside of the system, it is the responsi-
and reputable water treatment specialist for both the bility of the owner (operator) of this equipment to
initial charging of the system and its continuous engage the services of an experienced and reputable
monitoring and treatment. Improperly treated or main- steam/condensate or hot water treatment specialist for
tained water will result in decreased efficiency, high both the initial charging of the system and its continu-
operating costs and premature failure due to waterside ous monitoring and treatment. Improperly treated or
corrosion. maintained steam/condensate or hot water will result
in decreased efficiency, high operating costs and pre-
For water treatment programs to be acceptable, they mature failure due to steam/condensate or hot water
must protect all exposed metal (i.e., carbon steel, cop- side corrosion.
per and brass) from corrosive attack. The use of corro-
sion inhibitors must be effective at low concentrations,
must not cause deposits on the metal surfaces, and
Steam/Condensate or hot water samples should be 7
collected and analyzed on at least a monthly basis by
must remain effective under a broad range of pH, tem- the treatment specialist. A quarterly review with the
perature, water quality and heat flux. Furthermore, the treatment supplier should address the conditions of the
inhibitor package must prevent scale formation and steam systems and develop action plans based
disperse deposits, while having a minimal environ- on these analyses. A third party consulting company
mental impact when discharged. can help oversee the treatment programs in order to
properly protect the physical plant and avoid costly
Water samples should be collected and analyzed on at downtime.
least a monthly basis by the water treatment specialist.
A quarterly review with the treatment supplier should
address the conditions of the water systems and devel-
op action plans based on these analyses. A third party
water consulting company can help oversee the water
treatment programs in order to properly protect the
physical plant and avoid costly downtime.
JOHNSON CONTROLS 41
Unit Operating Procedures
FORM 155.21-OM1 (510)
It is equally important that the owner (operator) of the A build-up of scale on the tubes can cause a wide
equipment performs an inspection of the generator range of problems including:
tubes at the frequencies recommended in the Tube
Bundle Section of the "Preventive Maintenance • Reduced chilling capacity
Schedule" located in this manual. In addition to peri-
• High solution concentration
odic cleaning with tube brushes, tubes must be
inspected for wear and corrosion. Tube failures usu- • Crystallization
ally occur due to corrosion, erosion, and fatigue due to • Pitting and corrosion of tubes
thermal stress. Eddy current analysis and visual • Reduced efficiency
inspection by boroscope of all tubes are invaluable
preventative maintenance methods. These provide a The first step in trying to clean scales from tubes is to
quick method of determining steam generator tube brush clean them. Only soft nylon brushes should be
condition at a reasonable cost. used, as damage to the copper or CuNi tubes will
result if harder brushes (such as steel) are used.
Your local YORK Service Representative will be more
than happy to supply any or all of these services. If the brush cleaning is unsuccessful in removing all
the scale from the tubes, it will be necessary to chem-
Tube Cleaning ically clean them. An experienced and reputable con-
tractor should be consulted. If the chemical cleaning
If during an inspection, scale is identified in any of the is not performed properly, extensive tube damage may
tube bundles, it will be necessary to remove this scale result.
to prevent operational and or corrosion problems.
42 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 8 – unit operating procedures

general 2. Refer to the chart in FIGURE 22 to compare the
saturation pressure within the unit to the equiva-
For complete details on installation and how to set-up lent plant room temperature. If the measured
the companion parameters that control the YIA absorp- internal unit pressure is within the shaded area of
tion units refer to Form 155.21-N1. the chart, the start-up may continue. If not, purge
the unit until the internal unit pressure reaches the
It is recommended that Manual/Off/ shaded area of the chart.
Automatic switches be used for con-
trol of the condensing water pump, 3. Open the main shut-off valves in condensing
the chilled water pump, and the tower water, chilled water, and steam or hot water sup-
fan motor. However, the chilled water ply lines to the system.
pump and the condensing water pump
must always be operating when the 4. Close all disconnect switches to the control panel,
unit is in operation, and are thus pre- the cooling water pump, chilled water pump, and
ferred in the "Automatic" position. tower fans.
This is necessary to provide proper
dilution of the solution, thus protect- 5. Place the condensing water pump, chilled water
ing against crystallization during pump, and tower fan switches in the "Automatic"
shutdown, and to avoid freezing up position. (If manual operation is required for spe-
the evaporator tubes during unit oper- cial considerations, refer to the NOTE under
ation, including the dilution cycle General).
operation during which refrigeration
50
effect still occurs.
start-up (Normal)
This start-up covers units that have

previously been started.
PRESSURE IN mm Hg Abs.
10
See Form 155.21-O1, “Control Panel Operation

Manual” for detailed instruction on how to operate the
OptiView control panel.
1. If the chiller has been idle for a long period of

time, such as at the first start-up of the cooling
8
season, it will be necessary to check the internal
1
pressure of the unit to ensure a smooth start-up 40 60 80 100 120
and possibily perform a purge from the absorber
section. PLANT RooM TEMPERATURE °F
ld06021
FIGURE 22 - acceptable internal unit

pressures
JOHNSON CONTROLS 43
Unit Operating Procedures
FORM 155.21-OM1 (510)
operating data For greatest accuracy of the data taken on operating

units, calibrated 1/5°F increment thermometers should
General be used, particularly for measuring temperatures of
A complete set of data on operating temperatures and chilled water and cooling water. Calibrated test type
pressures should be recorded for the unit regularly. pressure gauges and manometers also contribute to the
The purpose is to permit early recognition of an abnor- attainment of accurate data. Accurate flow meters for
mal condition or trend that requires corrective mainte- water and steam condensate flow (with a subcooler)
nance, before serious damage occurs to the unit. Daily complete the instrumentation requirements for the
observation of the unit is useful to disclose any sudden attainment of an accurate heat balance. This instru-
changes. Record these changes on FORM 155.16-F2. mentation is not normally available in the field.
However, it can be obtained by special arrangements.
All measurements that are recorded should be taken as
simultaneously as possible with a steady load and a Nevertheless, a measure of the trend of system perfor-
steady cooling tower water temperature, near the mance can be obtained by the systematic measure-
design conditions. A progressive gradual deterioration ment of data taken with instrumentation normally
in unit performance is an indication that scaling is available in the field. In all cases, however, any analy-
occurring, that there is a gradual buildup of inerts or sis is only as good as the degree of accuracy of the
that there is a malfunction of controls. It is mandatory data taken. A steady state of operating conditions with
that all performance analyses be based on date, and all readings taken as simultaneously as possible,
taken on units that are free of leaks. Otherwise, the assists in obtaining valid data. All thermometers and
lithium bromide concentrations and the steam pres- pressure measuring devices should be calibrated so
sure and steam flow requirements for a given load, as that readings are corrected to the true values. Insulation
well as a complete set of operating temperatures, will placed around the pipe and the outside well will
be abnormal. improve the accuracy and validity of readings.
A thorough check of system performance, including With the assumption that all data taken are accurate
sampling of the unit fluids, requires the services of a and valid, the following method of analysis for system
Johnson Controls Field Service Representative. He performance is recommended.
will take samples of the refrigerant, the lithium bro-
mide charge, and the cooling water, as well as a com- Performance Data and Calculations
plete set of operating data. He can assist in a complete Refer to the sample operating data sheet in FIGURE
performance analysis and report on the condition of 23. This data is simulated by a computer for a YIA-
the unit. Samples can be analyzed and a complete 6C4 unit with nominal passes. The assumed operating
report obtained on the chemical content and pH levels. condition is 80% of the design load rating with
The investment by the customer in the cost of these assumed fouling factors of .0005, .001 and .0015 in
services is nominal compared to the cost of the unit the absorber and condenser, but with .0005 in the
and the ultimate cost of repairs or increased operating evaporator tubes. The effect of fouling on all readings
costs, should the unit be inadequately maintained. is readily apparent. This data also assumes that the
2-Ethyl-1-Hexanol additive is present in the unit at the
Inadvertent introduction of air into the unit by the proper concentration to promote optimum shell side
operator or the existence of leaks are to be avoided at coefficients of heat transfer. This additive is charged
all times to ensure a long life of the unit. The proper into the unit upon initial start-up, and rarely does more
method of taking samples is straight forward but Hexanol have to be added. The effect of Hexanol addi-
requires special training so that conclusions reached tive on unit performance appears later in this section.
concerning the condition of the unit, the solution
chemistry and the cooling water are valid. The design load rating for the YIA-6C4 unit used for
the data simulation is as follows:
44 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
100% Design Load 517.9 Tons Valve Inlet Steam Pressure 12PSIG =

Condenser Water Flow 1870 GPM 299°F
Entering Condenser Water Temp 85°F Normal Installation Ambient Pressure 29.5" Hg
Chilled Water Flow 1243 GPM (14.5 PSIA)
Chilled Water Range 54°F to 44°F Steam Source 15PSIG@300°F

Passes - Chiller/Condenser/Absorber 2/1/1 Assume steam condensate is flashed at atmospheric
Fouling Factor for Absorber, pressure before it is weighed for test data purposes.
Condenser and Evaporator .0005
Steam Pressure at Generator 9.2 PSIG
Steam Flow 9478 lb/hr
LD04771
FIGURE 23 - OPERATING DATA SHEET

JOHNSON CONTROLS 45
PTX Chart
FORM 155.21-OM1 (510)
46 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 9 – ptx chart

READING THE PTX CHART CRYSTALLIZATION
The PTX chart (Pressure, Temperature, and All absorption chillers that use lithium bromide and
Concentration chart) shown in FIGURE 24 is an water as the solution/refrigerant pair are subject to
invaluable tool when it comes to absorption cooling. It crystallization. This is due to the fact that some areas
can be used for almost every kind of troubleshooting of the unit operate with solution liquid concentration
situation, plotting solution cycles through each heat levels that are only possible at higher than the normal
exchanger, and determining if air is within the sys- ambient temperature surrounding the unit. For exam-
tem. ple, the solution concentration in the generator of a
single stage absorption unit is typically 64.3% lithium
However, for this exercise the PTX chart will be bromide by weight. Referring to FIGURE 24, 64.3%
explained only for determining the concentration of solution will begin to crystallize at 110°F (43.3°C).
solution samples. Since the solution temperature in the generator nor-
mally is higher than 200°F (93.3°C) at most load
Taking solution samples must only be conditions, no crystallization will occur as long as the
done by a trained and qualified higher solution temperatures are maintained. Special
Johnson Controls Field Service measures do have to be taken before the unit is shut
Representative. down so that the solution is sufficiently diluted in all
areas of the unit to prevent crystallization during the
off cycle, since the solution temperature will eventu-
Determining the Solution Concentration ally equal the surrounding ambient temperature.
The PTX chart (FIGURE 24) shows pressure in mm
Hg. absolute (horizontal lines), temperature in degrees All units employ some sort of dilution cycle, which
fahrenheit (vertical lines), and Solution Concentration fulfills this requirement. As long as the unit is allowed
in percentages (diagonal lines). The amount of water to dilute itself during an orderly shutdown sequence,
necessary to make the compound turn into a fluid is the unit should be able to sit idle at fairly low plant
represented by the area to the left of the crystallization room ambient temperatures for extended periods of
zone on the PTX Chart, at the corresponding tempera- time without any threat of crystallization. Typically,
ture. The "Crystallization Area" is the right half of the after a dilution cycle, the average solution concentra-
chart. tion within the chiller will be below 45% lithium
bromide by weight. Although the crystallization line
In reading the PTX chart, two of three pieces of infor- on FIGURE 24 does not extend that far, it can be seen
mation are required. With these two pieces of data the that the solution at 45% concentration will have no
third data point can be obtained. The temperature is tendency to crystallize at normal ambient tempera-
the easiest to obtain and the pressure can be obtained tures.
via the unit gauges. Use caution when using the unit
mounted vacuum gauge for checking the internal unit Why Does Crystallization Occur?
pressure – do NOT under any circumstances let air Probably the most common reason for crystallization
into the unit when checking the pressure. See the is due to power failures. If a chiller is running at full
Purging section of this manual for the correct method load and power is interrupted for a sufficient length of
to check the unit pressures. time, the concentrated solution in the high side of the
unit will eventually cool down. Since no dilution cycle
Looking at the PTX chart, follow the vertical tempera- was performed, the solution concentration in some
ture line and the horizontal pressure line to where the areas of the unit may still be relatively high. If the
two intersect. The closest diagonal line to this inter- temperature of this concentrated solution is allowed to 9
section would be the correct solution concentration. fall low enough, the solution will reach its crystalliza-
As the concentration of lithium bromide increases, tion point. Plant room temperature, insulation quality
reducing water content, the solution becomes more and the solution concentration all play a part in the
viscous. When all water is removed the solution determination of how long it will take before the unit
returns back to its natural state as a solid. will crystallize.
JOHNSON CONTROLS 47
48
FORM 155.17-PTX1 (609)
PTX Chart
TM TM 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350
ParaFlow and IsoFlow 995.5
Absorption Liquid Chillers
900 220 220
Useful Conversion Formulas 800
To convert °C (Centigrade) to °F (Fahrenheit) or °F to °C:
FIGURE 24 - PTX CHART

210 210
°F + 40
700
°C = – 40 °F = (°C+ 40) x 1.8 – 40
1.8
1 atm (atmosphere at sea level) = 14.696 psia = 0 psig = 760 mmHg = 29.92 in Hg 600 200 200
1 mm Hg = 1000 microns = 0.3937 inch Hg = .01934 psi
1 in Hg = 25.4 mm Hg = .491 psi % % % % % %
500 40 45 50 55 60 65 %
1 psi = 2.036 in Hg = 51.7 mm Hg = 2.31 ft H2o 190 70
190
1 ft H2o = .433 psi
1 lb = .4536 Kg = 453.6 gms

1 liter = .2641 U.S. gal = 1.057 U.S. quarts
400 180 180
1 U.S. gallon = 3.785 liters
1 inch = 25.4 mm
1 ton refrigeration (12,000 Btu/hr) = 3.52 kw 300 170 170
F
g E
h
m UR 160 160
m AT
E R
R PE
SU m
ES 200 TE 150 150
PR T
N AN
IO
AT ER
R IG 140 140
TU 150 FR
SA RE
130
130
100
90 120 120
80
70
110 110
60
50 100 100
40
90 90
% % % % % %
40 45 50 55 60 65 cRYSTALLIZATION AREA
30
80 80
20
70 70
15
60 60
10
50 50
8
6 40 40
4.2 30 30
40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350
SOLUTION TEmPERATURE F
JOHNSON CONTROLS
FORM 155.21-OM1 (510)
LD14221
FORM 155.21-OM1 (510)
FORM 155.17-PTX1 (609)
SPEcIFIc GRAVITY - cONcENTRATION TABLES

AQUEOUS LiBr SOLUTIONS
Refrigerant Table (%LiBr by Weight)
Temperature F
S.G. 40 45 50 55 60 65 70 75 80 85 90 95 100
1.00 –– –– –– –– –– –– 0.08 0.18 0.28 0.37 0.47 0.57 0.67
1.01 0.98 1.08 1.17 1.27 1.37 1.47 1.56 1.66 1.76 1.85 1.95 2.05 2.15
1.02 2.43 2.52 2.62 2.72 2.82 2.91 3.01 3.11 3.20 3.30 3.40 3.50 3.59
1.03 3.84 3.94 4.03 4.13 4.23 4.33 4.42 4.52 4.62 4.72 4.81 4.91 5.01
1.04 5.22 5.32 5.42 5.51 5.61 5.71 5.81 5.90 6.00 6.10 6.19 6.29 6.39
1.05 6.57 6.67 6.77 6.87 6.96 7.06 7.16 7.26 7.35 7.45 7.55 7.64 7.74
Solution Tables
Temperature F
S.G 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
1.350 37.27 37.5 37.75 37.98 38.21 38.44 38.67 38.90 39.13 39.35 39.58 39.80 40.02 40.24 40.46 40.68 40.90 41.11 41.33
1.360 38.03 38.26 38.50 38.73 38.96 39.19 39.42 39.64 39.87 40.09 40.31 40.53 40.75 40.97 41.19 41.41 41.62 41.83 42.05
1.370 38.78 39.01 39.24 39.47 39.70 39.93 40.15 40.38 40.60 40.82 41.04 41.26 41.48 41.69 41.91 42.12 42.34 42.55 42.76
1.380 39.52 39.75 39.98 40.20 40.43 40.66 40.88 41.10 41.32 41.54 41.76 41.98 42.20 42.41 42.62 42.83 43.04 43.25 43.46
1.390 40.25 40.48 40.70 40.93 41.16 41.38 41.60 41.82 42.04 42.26 42.48 42.69 42.90 43.12 43.33 43.54 43.75 43.95 44.16
1.400 40.97 41.20 41.42 41.65 41.87 42.09 42.31 42.53 42.75 42.97 43.18 43.39 43.61 43.82 44.03 44.23 44.44 44.64 44.85
1.410 41.69 41.91 42.14 42.36 42.58 42.80 43.02 43.24 43.45 43.67 43.88 44.09 44.30 44.51 44.72 44.92 45.12 45.33 45.53
1.420 42.39 42.62 42.84 43.06 43.28 43.50 43.72 43.93 44.15 44.36 44.57 44.78 44.99 45.19 45.40 45.60 45.80 46.00 46.20
1.430 43.10 43.32 43.54 43.76 43.98 44.19 44.41 44.62 44.83 45.04 45.25 45.46 45.67 45.87 46.07 46.27 46.47 46.67 46.87
1.440 43.79 44.01 44.23 44.45 44.66 44.88 45.09 45.30 45.51 45.72 45.93 46.13 46.34 46.54 46.74 46.94 47.14 47.33 47.53
1.450 44.47 44.69 44.91 45.13 45.34 45.55 45.76 45.97 46.18 46.39 46.59 46.80 47.00 47.20 47.40 47.60 47.79 47.99 48.18
1.460 45.15 45.37 45.58 45.80 46.01 46.22 46.43 46.6 446.85 47.05 47.25 47.46 47.66 47.85 48.05 48.25 48.44 48.63 48.82
1.470 45.82 46.03 46.25 46.46 46.67 46.88 47.09 47.30 47.50 47.70 47.91 48.11 48.30 48.50 48.70 48.89 49.08 49.27 49.46
1.480 46.48 46.69 46.91 47.12 47.33 47.54 47.74 47.95 48.15 48.35 48.55 48.75 48.94 49.14 49.33 49.52 49.71 49.90 50.09
1.490 47.13 47.35 47.56 47.77 47.97 48.18 48.38 48.59 48.79 48.99 49.19 49.38 49.58 49.77 49.96 50.15 50.34 50.53 50.71
1.500 47.78 47.99 48.20 48.41 48.61 48.82 49.02 49.22 49.42 49.62 49.82 50.01 50.20 50.39 50.58 50.77 50.96 51.14 51.33
1.510 48.42 48.63 48.84 49.04 49.25 49.45 49.65 49.85 50.05 50.24 50.44 50.63 50.82 51.01 51.20 51.38 51.57 51.75 51.93
1.520 49.05 49.26 49.46 49.67 49.87 50.07 50.27 50.47 50.66 50.86 51.05 51.24 51.43 51.62 51.80 51.99 52.17 52.35 52.53
1.530 49.67 49.88 50.08 50.28 50.49 50.68 50.88 51.08 51.27 51.46 51.66 51.84 52.03 52.22 52.40 52.59 52.77 52.95 53.12
1.540 50.29 50.49 50.69 50.89 51.09 51.29 51.49 51.68 51.87 52.06 52.25 52.44 52.63 52.81 52.99 53.18 53.36 53.53 53.71
1.550 50.89 51.10 51.30 51.50 51.69 51.89 52.08 52.28 52.47 52.66 52.84 53.03 53.21 53.40 53.58 53.76 53.94 54.11 54.29
1.560 51.49 51.69 51.89 52.09 52.29 52.48 52.67 52.86 53.05 53.24 53.43 53.61 53.79 53.97 54.15 54.33 54.51 54.68 54.86
1.570 52.09 52.28 52.48 52.68 52.87 53.06 53.25 53.44 53.6 353.82 54.00 54.18 54.37 54.55 54.72 54.90 55.07 55.25 55.42
1.580 52.67 52.87 53.06 53.26 53.45 53.64 53.83 54.02 54.20 54.39 54.57 54.75 54.93 55.11 55.28 55.46 55.63 55.80 55.97
1.590 53.25 53.44 53.64 53.83 54.02 54.21 54.39 54.58 54.77 54.95 55.13 55.31 55.49 55.66 55.84 56.01 56.18 56.35 56.52
1.600 53.81 54.01 54.20 54.39 54.58 54.77 54.95 55.14 55.32 55.50 55.68 55.86 56.04 56.21 56.38 56.55 56.72 56.89 57.06
1.610 54.37 54.57 54.76 54.95 55.13 55.32 55.50 55.69 55.87 56.05 56.23 56.40 56.58 56.75 56.92 57.09 57.26 57.43 57.59
1.620 54.93 55.12 55.31 55.49 55.68 55.86 56.05 56.23 56.41 56.59 56.76 56.94 57.11 57.28 57.45 57.62 57.79 57.95 58.12
1.630 55.47 55.66 55.85 56.03 56.22 56.40 56.58 56.76 56.94 57.12 57.29 57.46 57.64 57.81 57.97 58.14 58.31 58.47 58.63
1.640 56.01 56.20 56.38 56.57 56.75 56.93 57.11 57.29 57.46 57.64 57.81 57.98 58.15 58.32 58.49 58.66 58.82 58.98 59.14
1.650 56.54 56.72 56.91 57.09 57.27 57.45 57.63 57.81 57.98 58.15 58.33 58.50 58.67 58.83 59.00 59.16 59.32 59.49 59.65
1.660 57.06 57.25 57.43 57.61 57.79 57.97 58.14 58.32 58.49 58.66 58.83 59.00 59.17 59.33 59.50 59.66 59.82 59.98 60.14
1.670 57.58 57.76 57.94 58.12 58.29 58.47 58.65 58.82 58.99 59.16 59.33 59.50 59.66 59.83 59.99 60.15 60.31 60.47 60.63
1.680 58.08 58.26 58.44 58.62 58.79 58.97 59.14 59.31 59.48 59.65 59.82 59.99 60.15 60.31 60.48 60.64 60.79 60.95 61.11
1.690 58.58 58.76 58.94 59.11 59.29 59.46 59.63 59.80 59.97 60.14 60.30 60.47 60.63 60.79 60.95 61.11 61.27 61.43 61.58
1.700 59.07 59.25 59.42 59.60 59.77 59.94 60.11 60.28 60.45 60.61 60.78 60.94 61.10 61.26 61.42 61.58 61.74 61.89 62.05
1.710 59.55 59.73 59.90 60.08 60.25 60.42 60.59 60.75 60.92 61.08 61.25 61.41 61.57 61.73 61.89 62.04 62.20 62.35 62.50
1.720 60.20 60.38 60.55 60.72 60.88 61.05 61.22 61.38 61.54 61.71 61.87 62.03 62.18 62.34 62.50 62.65 62.80 62.95
1.730 60.67 60.84 61.01 61.18 61.34 61.51 61.67 61.84 62.00 62.16 62.32 62.48 62.63 62.79 62.94 63.09 63.25 63.40
1.740 61.13 61.30 61.46 61.63 61.80 61.96 62.12 62.28 62.44 62.60 62.76 62.92 63.07 63.23 63.38 63.53 63.68 63.83
1.750 61.74 61.91 62.08 62.24 62.40 62.56 62.72 62.88 63.04 63.20 63.35 63.51 63.66 63.81 63.96 64.11 64.26
1.760 62.35 62.51 62.68 62.84 63.00 63.16 63.31 63.47 63.62 63.78 63.93 64.08 64.23 64.38 64.53 64.68
1.770 62.78 62.94 63.10 63.26 63.42 63.58 63.74 63.89 64.04 64.20 64.35 64.50 64.65 64.80 64.95 65.09
1.780 63.37 63.52 63.68 63.84 64.00 64.15 64.30 64.46 64.61 64.76 64.91 65.06 65.21 65.35 65.50
1.790 63.78 63.94 64.09 64.25 64.40 64.56 64.71 64.86 65.01 65.16 65.31 65.46 65.60 65.75 65.89
1.800 64.34 64.50 64.65 64.81 64.96 65.11 65.26 65.41 65.56 65.70 65.85 66.00 66.14 66.28
1.810 64.89 65.05 65.20 65.35 65.50 65.65 65.80 65.94 66.09 66.24 66.38 66.52 66.67
1.820
1.830 cRYSTALLIZATION AREA
65.43 65.58
65.96
65.73
66.11
65.88
66.26
66.03
66.41
66.18
66.55
66.32
66.70
66.47
66.84
66.61
66.98
66.76
67.13
66.90
67.27
67.04
67.41 9
1.840 66.48 66.63 66.77 66.92 67.06 67.20 67.35 67.49 67.63 67.77
1.850 66.99 67.13 67.27 67.42 67.56 67.70 67.84 67.98 68.12
LD14221
FIGURE 25 - SPECIFIC GRAVITY - CONCENTRATION
JOHNSON CONTROLS 49
PTX Chart
FORM 155.21-OM1 (510)
Power failures result in the unit pumps stopping com- Non-condensables in the Absorber
pletely. Without the pumps inducing flow through the Non-condensables in the absorber result in less refriger-
various sections of the unit, concentrated solution be- ant being absorbed by the solution. The solution never
comes trapped in the generator section and the solution- gets as diluted as it should. It leaves the absorber and is
to-solution heat exchanger. If this concentrated solution heated in the generator. If the unit’s heat input is at or
is allowed to cool down to a low enough temperature, near full load, the leaving solution concentration may
it may turn to a slushy liquid and eventually to a solid exceed the level at which it can remain liquid when pass-
substance. ing through the solution-to-solution heat exchanger. For
example, the normal concentration of solution leaving
The potential for a YORK IsoFlowTM Chiller to crystal- the absorber at full load is between 58% and 59.3%.
lize during a power interruption is directly related to
the following: If there are non-condensables present in the absorber,
1. The concentration of the solution in the solution the solution concentration may exceed 61%. Since the
heat exchanger is very important. The higher the unit is attempting to operate at full load, the firing rate
concentration at the time of power failure, the will be sufficient to raise the solution concentration in
more likely the unit is to crystallize. the generator by at least the same amount as when the
a. The higher the load, the higher the concentra- absorber solution was normal, which was approximately
tion. 5%. Raising the solution concentration by 5% would
b. A unit with dirty tubes or non-condensables result in 66% solution leaving the generator.
will be more susceptible due to higher con-
centrations in the solution heat exchanger. Referring to the PTX chart in FIGURE 24, it can be seen
c. Overfiring the unit will tend to over concen- that the crystallization temperature for 66% solution is
trate the strong solution and make it more approximately 140°F (60°C). Since the generator tem-
susceptible for crystallization. perature is higher than 140°F (60°C), the solution will
be okay while it is still in the generator. The problem
2. A decrease of the solution temperature. The ambi-
occurs when this over concentrated solution passes
ent temperature of the machine room and the
through the solution-to-solution heat exchanger on its
amount of thermal insulation on the solution-to-
way back to the absorber sprays.
solution heat exchanger will also determine the
likelihood of crystallization. Improper or inade-
This solution concentration remains constant as it passes
quate thermal insulation on the hot sections of the
unit will allow heat loss to progress rapidly and through the solution-to-solution heat exchanger. If it is
therefore shorten the amount of time before the cooled below 140°F (60°C) at any point in the route,
concentrated solution cools down to its crystalli- crystallization will begin. The cool solution leaving the
zation temperature. Outside air dampers that absorber is the solution-to-solution heat exchanger’s
remain open during a power failure may allow the medium that cools the concentrated solution leaving the
plant room to cool down quickly, which will has- generator as it passes on the shell side of the solution-
ten crystallization. to-solution heat exchanger. This relatively cool solu-
tion temperature is the determining factor of whether
3. The duration of the power interruption is very
crystallization occurs. Tower water inlet temperature
important. Although it is very difficult to quantify
will greatly affect the leaving solution temperature of
the acceptable time before crystallization occurs,
it is doubtful that harmful crystallization will the absorber. If the tower water temperature is lower
occur if the power interruption is less than fifteen than design or is allowed to fluctuate in a downward
minutes. Power interruptions lasting thirty min- trend fairly rapidly, the potential exists to over cool the
utes or longer have been experienced during full concentrated solution in the solution-to-solution heat
load operation of some machines with no prob- exchanger resulting in crystallization.
lems.
To further compound this type of situation, if the ab-
Although a more rare occurrence, units can also crys- sorber is not performing well due to the presence of
tallize during operation. Two of the chief causes of non-condensables, the amount of solution flowing to
crystallization during operation are non-condensables the generator will be less than normal since there is less
in the absorber and rapidly fluctuating tower water refrigerant in it. Since the unit is attempting to make
temperatures. design capacity, the firing rate will be sufficient to raise
the solution concentration higher than the design 5%.
50 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
This will result in even higher solution concentrations 3. The third type of crystallization prevention is
leaving the generator. The temperature of the solution through the Automatic Decrystallization Cycle
leaving the absorber will also be lower than normal (ADC). Essentially, when crystallization starts to
due to the amount of subcooling that will be present as occur, a blockage usually forms in the strong solu-
a result of the lack of mass transfer taking place. This tion side of the solution-to-solution heat exchanger
will result in a greater potential for over cooling the (STS) and the solution starts to back up into the
concentrated solution in the solution-to-solution heat generator. As solution starts to fill the generator
exchanger. outlet box it will begin to exit through the ADC
line. Sensor RT2, attached to the side of the ADC
Fluctuating Tower Water Temperature line, senses the temperature rise in this line due to
Rapidly fluctuating tower water temperature can also the high temperature solution flowing through it.
cause crystallization. The reasons are essentially the At 160°F (71.1°C) the OptiView panel will ener-
same as described in the previous example. Rapidly gize the 2SOL (stabilizer) solenoid valve to allow
falling tower water temperature will cause the leaving refrigerant to flow from the discharge of the refrig-
solution temperature from the absorber to drop quickly. erant pump into the STS, thus diluting the solu-
This cool solution may over-cool the concentrated solution. Depending on the operational conditions of
tion leaving the generator as it passes on the shell side the unit, the ADC cycle may go through certain
of the solution-to-solution heat exchanger. This can steps to help reduce the solution concentration.
happen at normal generator solution concentrations, These steps are Normal, Limited, Primary and
although the problem would be compounded if there Secondary ADC cycles.
were already abnormally high solution concentrations
in the generator. Measures to Prevent Crystallization
Good practices to help prevent crystallization should
Unit Features That Help Prevent Crystallization always be employed. These include:
During operation, the chiller has some inherent fea- 1. Insulating the solution-to-solution heat exchanger,
tures that will help prevent crystallization from occur- generator solution outlet box and all interconnect-
ring. They are as follows: ing piping.
1. When the refrigerant charge is adjusted properly at 2. Tower water (absorber cooling water) must
full load conditions, the level of refrigerant in the be controlled to prevent rapid fluctuations in tem-
evaporator pan will be near the top of the pan but perature.
not spilling over. If the absorber section begins to
3. Keep the absorber, condenser and evaporator tubes
malfunction due to a loss of mass transfer (rate of
clean.
refrigerant being absorbed into the solution) either
by tube fouling or presence of non-condensables, 4. Do not allow non-condensables to accumulate in
the concentration will increase (i.e. less refrigerant the unit. Proper purging techniques and solution
present in solution). Consequently, the refrigerant chemistry control will greatly reduce the likelihood
quantity in the evaporator pan will increase and of crystallization.
begin to spill over into the absorber section. This 5. Be sure the refrigerant charge is adjusted so that
spilling will act to reduce the solution concentra- refrigerant spill will occur if solution concentrations
tion and thus lower the chances of crystallizing. exceed the norm. Refrigerant may need to be adjust-
2. The OptiView logic constantly monitors the tem- ed after several years of operation due to the amount
peratures from the refrigerant leaving the condenser of refrigerant vapor removed during purging.
section at RT9 and strong solution temperature at
RT3. From these two temperatures the logic will
calculate the solution concentration as it leaves the
generator section. When the solution concentration
reaches 65.5% the control status field will display 9
“High Concentration Control in Effect” This control
algorithm will reduce the control valve opening to
keep the solution concentration at a safe level while
maintaining the highest level of unit operation
under the present conditions.
JOHNSON CONTROLS 51
PTX Chart
FORM 155.21-OM1 (510)
PRESSURE DROP CURVES
FIGURE 26 shows the pressure drops for the chilled

water, condenser water, and the hot water in relation-
ship to the rate of flow in GPM. The absorber/con-
denser includes 1-2 PSI pressure drop through the
cross-over line. For construction of the cross-over line,
see YORK Form 155.21-N1. The data shown are for
pressure taps on the water boxes near the inlet and
outlet nozzles. If pressure gauges are used to deter-
mine pressure drop, they should be calibrated so that
maximum efficiency is obtained. Also, a correction for
static head difference must be made if the gauges are
not located at the same elevation or level. The conver-
sion from PSI to ft. of water is 2.31 ft. for 1 PSI.
52 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
pressure drop curves

MoDEL YIA – 1A1 MoDEL YIA – 1A2
70 70
PRESSURE DRoP–FT. wATER 50 50
PRESSURE DRoP–FT. wATER

S
S
30 30
AS
AS
4P
4P
S
S
AS
AS
20 20
3P
3P
S
S
AS
AS
2P
2P
10 10
S
6 6
AS
AS
1P
1P
4 4
2 2
1 1
1000
1600
1000
1600
100
200
300
400
500
700
100
200
300
400
500
700
GPM GPM
CHILLED wATER CHILLED wATER
50
40

30 30
SS
PA
20 SS 20 3/1
PA ND SS
3/1 SS PA
ND PA S/Co 2/1
o 2/1 AB D
S/C D 10 oN
10 AB oN S/C
BS/C AB
A 7
7 R
5 NSE
5 ER N DE
S
EN Co
D 3
CoN
1
200
300
400
500
600
700
1
200
300
400
500
600
700
GPM
GPM TowER wATER *
TowER wATER *
30
20
20
SS
SS
PA
PA
3
10
10
SS
SS
PA
PA
7
2
2
5
5
S
SS
AS
PA
1P
3
2
2
1
1
9
90
100
200
300
400
500
90
100
200
300
400
500
GPM
HoT wATER GPM
* See Notes on page 63 HoT wATER
LD14576
FIGURE 26 - pressure drop curves
JOHNSON CONTROLS 53
PTX Chart
FORM 155.21-OM1 (510)
MoDEL YIA – 2A3 MoDEL YIA – 2A4

80 80
60 60

40 40
SS
S
PA
AS
30 30
SS
4P
4
S
PA
20 AS 20
3
3P
SS
AS
PA
2P
2
10 10
SS
7
S
7
PA
AS
1
1P
5 5
4
3 3
2 2
1 1
1600
1000
100
200
300
400
500
700
1000
1600
100
200
300
400
500
700
GPM GPM
50 60
SS 40 SS

30 PA PA
3/1 30 3/1
20 ND ND
Co SS Co SS
S/ PA 20 S/ PA
AB 2/1 AB
2/1
ND D
10 Co oN
BS/ 10 S/C
A
8 AB
7
6
5 R R
SE 4 N SE
N
3 DE N DE
N 3
Co Co
2 2
1 1
1000
1000
200
300
400
500
600
700
800
200
300
400
500
600
800
GPM GPM
TowER wATER * TowER wATER *
30 30
20 20 SS
SS
PA
PA
3
SS
PA
10 2
10
SS
PA
8
2
7 6 SS
PA
5
SS
1
5
PA
4
1
4
3
3
2
2
1
1
90
100
200
300
400
500
90
100
200
300
400
500
GPM
GPM HoT wATER
HoT wATER
LD14577
* See Notes on page 63
FIG. 26 (CONT’D) – pressure drop curves
54 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
MoDEL YIA – 2B1 MoDEL YIA – 3B2

80 80
60 60

40 40
SS
SS
30 30
PA
SS
SS
PA
PA
PA
4
SS
20
SS
20
3
PA
PA
2
2
SS
S
10 10
AS
PA
1P
1
7 7
5 5
3 3
2 2
1 1
1000
2100
120
200
300
400
500
600
800
1000
2100
120
200
300
400
500
600
800
GPM GPM
60 60
40 40

SS SS
30 PA 30 PA
3/1 D 3/1
D SS SS oN SS
20 oN PA PA 20 S/C PA
S/C 2/1 /1 AB /1 SS
AB D 1 2 PA
oN ND o ND 1/1
Co D
10 S/C / 10 S/C oN
AB AB
S AB S/C
A B
7 7
5 5
4 ER 4
3 NS 3 ER
E NS
ND E
2 Co 2 ND
Co
1 1
1500
1000
1100
375
500
600
700
800
900
1000
200
300
400
500
600
700
800
GPM GPM
40 40
30 30
SS
20 20 PA
SS
3
PA

3
SS
10 PA
SS
10 2
PA
8 8
2
6 6
SS
SS
PA
5 5
PA
4 4
1
3 3
2 2
9
1 1
100
200
300
400
500
650
100
200
300
400
500
650
GPM GPM
* See Notes on page 63 HoT wATER HoT wATER LD14578
JOHNSON CONTROLS 55
PTX Chart
FORM 155.21-OM1 (510)
MoDEL YIA – 3B3 MoDEL YIA – 4B4
80 80
60 60

40
SS
40
SS
PA
SS
SS
PA
30 30
PA
4
PA
SS
3
3
SS
PA
20 20
PA
2
2
SS
SS
10 10
PA
PA
1
1
7 7
5 5
3 3
2 2
1 1
1000
2100
120
200
300
400
500
600
800
1000
2100
120
200
300
400
500
600
800
GPM GPM
60 65
40 SS SS
PA 40 PA
30 D3
/1
PRESSURE DRoP–FT. wATER 3/1
oN 30 D SS
/C oN PA
20 AB
S
PA
SS S/C /1
SS 20 AB 2 SS
2/1 PA ND PA
oND
D 1/1
S /Co 1/1
AB D
10 S/C oN oN
AB S/C 10 S/C
AB AB
7 7
5 R 5 R
4 SE 4 SE
E N
D EN
3 ND 3 oN
Co C
2 2
1 1
1500
375
500
600
700
800
900
1000
375
500
600
700
800
900
1000
1500
GPM GPM
40 40
30 30
S
AS
20
AS
3P
3P
20
S
AS
S
AS
2P
2P
10
10
8
8
S
S
AS
AS
6 6
1P
1P
5 5
4 4
3 3
2 2
100
200
300
400
500
650
100
200
300
400
500
650
GPM GPM
HoT wATER HoT wATER
* See Notes on page 63 LD14579
56 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
MoDEL YIA – 4C1 MoDEL YIA – 5C2

80 80
60 60

40 40
SS
SS
SS
PA
30
SS
PA
30
PA
4
PA
4
SS
SS
3
20
3
20
PA
PA
2
2
SS
SS
10 10
PA
PA
1
1
7 7
5 5
3 3
2 2
1 1
1000
2000
3000
200
300
400
500
600
800
1000
2000
3000
200
300
400
500
600
800
GPM GPM
65 65
40 40 SS

PA
30 SS 30 3/1
PA D SS
3/1 SS oN PA
20 ND PA SS 20 S/C 2/1
/Co 2/1 PA AB D SS
S ND 1/1 oN PA
AB o D S/C 1/1
S/C oN AB D
10 AB S/C 10 oN
AB S/C
AB
7 7
5 R 5
4 SE 4 R
EN SE
3 ND 3 D EN
Co oN
C
2 2
1 1
1000
1600
1000
2000
2200
400
500
600
700
800
900
500
600
700
800
900
GPM GPM
40 40
30 30
S
S
20
AS
AS
20
3P
3P
S
AS
S
AS
2P
2P
10 10
8 8
S
6 6
AS
S
AS
1P
5 5
1P
4 4
3 3
9
2 2
1000
150
200
300
400
500
600
800
1000
150
200
300
400
500
600
800
GPM GPM
HoT wATER HoT wATER
JOHNSON CONTROLS 57
PTX Chart
FORM 155.21-OM1 (510)
MoDEL YIA – 5C3 MoDEL YIA – 6C4
80 80
60 60

40 40
SS
SS
SS
PA
SS
PA
30 30
PA
PA
4
4
SS
SS
3
3
20 20
PA
PA
2
2
SS
SS
10 10
PA
PA
1
1
7 7
5 5
3 3
2 2
1 1
1000
2000
3000
200
300
400
500
600
800
1000
2000
3000
200
300
400
500
600
800
GPM GPM
65
70
40 SS
PA 50 SS
3/1 PA
30 /1
ND D 3
/Co SS 30 oN SS
S PA PA
20 AB 2/1 SS BS/C 2/1
ND PA 20 A D SS
o 1/1 oN PA
/1
S/C oN
D
S /C
D 1
AB AB oN
10 S/C
A B 10 B S/C
A
7
7
5
4 ER 5 R
NS 4 N SE
E
3 ND NDE
Co 3
Co
2 2
1 1
1000
2000
2200
500
600
700
800
900
500
600
700
800
900
1000
2200
GPM GPM
40 50
40
30
30
S
AS
S
AS
3P
20
3P
20
S
S
AS
AS
2P
2P
10 10
8
S
8
AS
1P
S
AS
6 6
1P
5 5
4 4
3 3
2
2
1000
150
200
300
400
500
600
800
1000
150
200
300
400
500
600
800
GPM
GPM HoT wATER
* See Notes on page 63 HoT wATER LD14628
58 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
MoDEL YIA – 7D1 MoDEL YIA – 7D2
80 80
60 60

40 40
SS
SS
SS
SS
PA
PA
30 30
PA
PA
4
4
SS
SS
3
3
20 20
PA
PA
2
2
SS
SS
10 10
PA
PA
1
1
7 7
5 5
3 3
2 2
1 1
1000
2000
3000
4200
1000
2000
3000
4200
250
400
500
600
800
250
400
500
600
800
GPM GPM
70 70
50 50
SS

PA SS
/1 PA
30 D 3 30 L3
oN TA
SS To SS
20 S/C PA SS 20 PA SS
AB 2/1 PA L2 PA
N D 1/1 TA L1
o D To TA
S/C oN To
10 AB S/C 10
AB
7 7
RR
5 5 SE
4 R 4 D
D EN
SE oNN
3 EN 3 CCo
ND
Co
2 2
1 1
1000
2000
3100
1000
2000
3100
800
900
800
900
GPM GPM
40 50
30 40
30
S
AS
3P
20
AS
3P
20
S
AS
2P
S
AS
10
2P
8 10
S
8
AS
6
1P
5
AS
6
1P
4 5
4
3
2
3
9
2
1000
1200
200
300
400
500
600
700
800
1000
1200
200
300
400
500
600
700
800
GPM
HoT wATER GPM
JOHNSON CONTROLS 59
PTX Chart
FORM 155.21-OM1 (510)
MoDEL YIA – 8D3 MoDEL YIA – 8E1
80 80
60 60

40 SS 40
SS
SS
PA
SS
PA
30 30
PA
PA
4
4
SS
SS
3
3
20 20
PA
PA
2
2
SS
SS
10 10
PA
PA
1
1
7 7
5 5
3 3
2 2
1 1
1000
2000
3000
4200
250
400
500
600
800
1000
2000
3000
4000
5500
300
400
500
600
800
GPM GPM
70 70
50 SS 50
PA
/1
D3
30 oN SS 30 SS
S/C
PA PA
AB SS /1
20 2/1 PA 20
2 SS
ND 1/1 ND PA
o D /Co 1/1
S/C oN AB
S D
AB S/C oN
10 AB 10 S/C
A B
7 7
5 R 5
4 N SE 4
N DE ER
3 Co 3 NS
E
2 ND
2 Co
1 1
1000
2000
3100
800
900
1000
2000
3000
4000
4500
GPM GPM
50 40
40
30
30
S
S
AS
AS
3P
20
3P
20
S
AS
S
2P
AS
2P
10
S
AS
10
1P
8
S
8
AS
6
1P
6 5
5 4
4
3
3
2
1000
1700
2
300
400
500
600
700
800
1000
1200
200
300
400
500
600
700
800
GPM
GPM HoT wATER
60 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
MoDEL YIA – 9E2 MoDEL YIA – 10E3
80 80
60 60

40 40
SS
SS
SS
PA
SS
PA
30 30
PA
PA
4
4
SS
SS
3
3
20 20
PA
PA
2
2
SS
SS
10 10
PA
PA
1
1
7 7
5 5
3 3
2 2
1 1
1000
2000
3000
4000
5500
300
400
500
600
800
1000
2000
3000
4000
5500
300
400
500
600
800
GPM GPM
70 70
50 50

SS SS
30 PA 30 PA
2/1 S 2/1 S
oN
D AS oN
D AS
20 /C 1/1P 20 /C 1/1P
S S
AB oN
D AB oN
D
S /C S /C
10 AB 10 AB
7 7
5 5
4 ER 4 ER
E NS E NS
3 ND 3 ND
Co Co
2 2
1 1
1000
2000
3000
4000
4500
1000
2000
3000
4000
4500
GPM GPM
50 50
40 40
30 S
SS
30 AS
3P
PA

20 20
SS
SS
PA
PA
SS
2
S
2
PA
AS
10 10
1
1P
8 8
6 6
5 5
4 4
3 3
2 2
9
1000
1700
300
400
500
600
700
800
1000
1700
300
400
500
600
700
800
GPM GPM
HoT wATER HoT wATER
JOHNSON CONTROLS 61
PTX Chart
FORM 155.21-OM1 (510)
MoDEL YIA – 12F1 MoDEL YIA – 13F2
80 80
60 60

40 40
SS
SS
PA
PA
30 30
3
3
SS
SS
PA
PA
20 20
2
2
SS
SS
10 10
PA
PA
1
1
7 7
5 5
3 3
2 2
1 1
1000
2000
3000
4000
5000
7000
1000
2000
3000
4000
5000
7000
500
700
500
700
GPM GPM
70
50
30 SS
PA
2/1 SS
20 D PA
oN 1/1
BS/C D
A oN
BS/C
10 A
7
5 ER
4 ENS
ND
3 Co
2
1
1500
2000
3000
4000
5000
6000
GPM
TowER wATER *
50 50
40 40
S
S
AS
30 30
AS
3P
3P
20 20
S
AS
2P
S
AS
2P
10 10
SS
PA
8 8
SS
1
PA
1
6 6
5 5
4 4
3 3
2 2
1000
2000
2500
1000
2000
2500
400
500
600
700
800
400
500
600
700
800
GPM GPM
HoT wATER HoT wATER
62 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
MoDEL YIA – 14F3
80
PRESSURE DRoP–FT. wATER 60
40
SS
PA
30
SS
PA
20
SS
10
PA
1
7
5
3
2
1
1000
2000
3000
4000
5000
7000
500
700
GPM
CHILLED wATER
70
50
SS
PA
30 2/1
D SS
oN PA
20 S/C 1/1
AB D
oN
S/C
10 AB
7
5 ER
4 E NS
ND
3 Co
2
1
1500
2000
3000
4000
5000
6000
GPM
TowER wATER *
60
50
40
SS
PA
30
3
20
SS
PA
2
SS
10
PA
8
1
6 * Pressure drop curves include 1 psi pressure drop for cross-over

5 line.
4
3 * Pressure drop curve for the condenser water circuit only is
shown as a dotted line. For total tower water pressure drop
9
2 through the chiller use the appropriate solid line. For example, a
chiller with a 2-Pass absorber and a 1-Pass condenser, use the
1000
2000
2500
400
500
600
700
800
“ABS/COND 2/1 curve.”

GPM
JOHNSON CONTROLS 63
Preventive Maintenance - Tubes
FORM 155.21-OM1 (510)
64 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
section 10 – PREVENTatIVE MAINTENANCE – tubes

cleaning and maintaining the The only positive method of identifying a scale is
tubes within the shells a chemical analysis, although an analysis of the
water used in a specific system will indicate the
Tubes type of scale which may be expected to form.
The necessity for tube cleaning will be indicated by a Although other good commercial cleaning agents
drop in capacity or other symptoms. The frequency of are available for removing a specific scale, factory
cleaning will vary as influenced by local water charac- experience shows with commercial inhibited
teristics, atmosphere contamination, operating condi- hydrochloric (muriatic) acid to be a good cleaning
tions, etc. agent for most scales.
In many major cities, reliable commercial organiza-

When it becomes necessary to clean condenser tubes,
tions are now available which offer a specialized ser-
the absorber tubes should also be cleaned. If the
vice of cleaning water sides of pressure vessels. These
chilled water system is kept clean during installation
organizations will analyze the type of dirt or scale to
and is filled with clean water, it should not be neces-
be removed and then use the proper cleaning solution
sary to clean the evaporator tubes, except if cooling
for the specific job.
water is used in an air washer. The lines to the purge
drum and its coil must be acid cleaned when the cool-
Tube fouling is commonly due to deposits of two
ing circuit is cleaned.
types of elements:
brush cleaning of tubes
1. Dirt, rust or sludge which is carried from some
other part of the system into the tubes. This mate- Tube fouling consisting of dirt and sludge can usually
rial does not usually build up to coat the entire be removed by brushing the tubes. To do this drain the
tube surface, but lies in the bottom of the tubes. water sides of the circuit to be cleaned (cooling water
When this accumulation of sludge is great enough, or chilled water), remove the heads and thoroughly
water flow through the tubes will be restricted and clean each tube with a soft bristle bronze brush. DO
the heat transfer surface will be reduced. This type NOT USE A STEEL BRISTLE BRUSH. A steel brush
of tube fouling is easily visible and can be may damage the tubes.
removed by a thorough brushing with a soft bristle
bronze brush as outlined under "Brush Cleaning Improved results can be obtained by admitting water
of Tubes". into the tube during the cleaning process. This can be
2. Scale is a hard layer of mineral deposit which done by mounting the brush on a suitable length of
precipitates out of the water and forms a hard 1/8" pipe with a few small holes at the brush end and
coating on the inside surfaces of the tubes. This connecting the other end to the water supply by means
coating is often invisible but always highly resis- of a hose.
tant to heat transfer.
The most common types of scale found within the
tubes are calcium carbonate, calcium sulphate and
silica, although other scales do form, depending
upon local water conditions. Since scale is usually
invisible when tubes are wet, it is better to blow
the water out of the tubes and allow the tubes to
thoroughly dry before checking for scale. After
the tubes have thoroughly dried, calcium scale
will usually show up as a white coating inside the
tube (silica scale may not show up at all); but the
scale can usually be flaked off of the inside of the
tube with a small knife.
10
JOHNSON CONTROLS 65
FORM 155.21-OM1 (510)
TROUBLESHOOTINg table
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
1. ABSORPTION UNIT A. Power supply and unit fuses. Replace if necessary.

WILL NOT START B. Flow switches open. Check chilled water and cooling tower pumps.
C. Starter overloads open. Push reset buttons of both starters.
D. Motor coolant float switch open. Contact local district office for service.
2. UNIT CYCLING OR A. Air in water piping causing varying Purge air from the water piping.
ERRATIC CHILLED water flow to the unit.
WATER B. Control valve not functioning Check actuator and linkage. Adjust if necessary.
TEMPERATURE properly (not closing). Check max. rate setting normal 1.0.
C. Low temperature thermostat Check cutout setting using 1/5°F thermometer
not cutting out at correct setting 39°F. (If not working properly, contact
temperature settings. local district office.)
D. Fluctuating steam pressure or Correct supply source.
hot water temperature.
E. Cooling water temp. cycling Readjust settings.
improper tower fan setting.
3. UNIT NOT MAKING A. Air in unit.

CAPACITY a. Improper purging See “Purge System Operation” section for proper
procedure for purging.
b. Purge pump malfunctioning. See “Purge Pump Maintenance” section for servicing
information.
c. Leak in unit. Contact local district office for service.
B. Cooling (Tower) water GPM Set to correct quantity using design pressure drop
below design. for your unit.
C. Insufficient steam to the Check supply. Readjust steam valve and regulating
generator flange. valves, if necessary.
D. Condensate backup into Check steam trap float and/or valves.
generator tubes.
E. Tube fouling excessive. See “Preventive Maintenance” section for proper
method of cleaning tubes.
F. Crystallization
a. Air in unit See “Purge System Operation” section for proper
procedure for purging.
b. Improper dilution cycle. Check float operation. Check dilution time operation.
See that condenser water and chilled water pumps
run until completion of dilution cycle.
G. Cooling tower water temperature Readjust setting or replace controller and/or fan
fluctuating rapidly. thermostats as necessary.
H. ADC circuit malfunction. Check sensor and 2SOL refrigerant solenoid for
proper operation.
I. Steam pressure too high. Check setting of pressure reducing valve, if used.
Adjust steam valve to reduce maximum opening..
4. PURGE PUMP INCA- A. Contaminated oil. Change oil as recommended.

PABLE OF PULLING B. Ballast valve cracked or scored. Repair with kit listed in “Renewal Parts” list.
BELOW 1MM
C. Malfunctioning pump. Repair or replace.
5. PURGE PUMP OIL A. Faulty shaft seal rubber. Repair with kit in “Renewal Parts” manual.
LEAKAGE
66 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
PREVENTATIVE MAINTENANCE SCHEDULE
Maintenance Interval (Months unless otherwise indicated)
Preventative Maintenance See
Component As
Operation Note Daily Monthly 6 12 24 36 48 60
Needed
Below
Solution Chemistry Analysis
(1), T
(Add inhibitors as needed)
Record Operational Data
O
(Data Form)
Leak Test Unit (2)
Check Electrical
T T T T T
Connections
Replace Sight Glasses or
T
Glass Gaskets
Check For Proper Solution
T T T T T T
Levels,
Unit
Check For Proper
T T T T T T
Refrigerant Levels,
Check For proper

Concentration of Octyl T
Alcohol
Check Unit Level and/or

T T T T
Pitch T
Check solenoids for bypass T T T T T T
LRT - Low Refrigerant

Temperature T T T T T
Cutout Switch
Unit Safety
Controls Chilled Water Flow Switch T T T T T
- Performance Condenser Water Flow
Test T T T T T
Switch
HT1 - High Temperature
T T T T T
Cutout Switch
Accuracy check of thermis-
tors T T T T T
and transducers
Instrumentation
Accuracy check of
Condenser Pressure Gauge T T T T T
(if applicable)
Inspection (pump bearing
and seal wear) Rebuild as (3) T
required
Inspection of pump contac-
T T T T T
tors and overloads T
Solution and
Refrigerant Check operating amperage
O T T T T T T
Pumps of pumps.
Check electrical connec-
T T T T T T
tions to pumps
Check performance of
T T T T T T
pumps (pressures, etc.)
T = YORK / Johnson Controls Qualified Service Technician
O = Operator
10
JOHNSON CONTROLS 67
FORM 155.21-OM1 (510)
PREVENTATIVE MAINTENANCE SCHEDULE (CONT’D)
Maintenance Interval (Months unless otherwise indicated)
Preventative Maintenance See
Component As
Operation Note Daily Monthly 6 12 24 36 48 60
Needed
Below
Solution and
Check average skin temper-
Refrigerant T T T T T T
atures of pumps
Pumps (cont’d)
Inspection of belt - replace
O O O O O O
or tighten as needed
Check operating amperage
O
of pump
Check electrical connec-
T T T T T T
tions to pump
Purge Pump
Inspection of pump contac-
T T T T T T
tor and overload
Change oil O
Determine ultimate vacuum
T T T T T T
of pump
Build or replace pump T
Rebuild Purge Diaphragm
T
Purge Valves
System Accuracy check of Vacuum
T T T T T T
Gauge
Clean tubes in absorber,
condenser, evaporator and
T T T T T
Tube Bundles hot water heat exchanger
(where applicable)
Eddy current (4)
Inspection for wear of steam
valve - Rebuild or replace T T T T T
as needed
Check for proper steam
Steam valve T T T T T
(Steam-fired modulation
Units Only) Inpect steam system piping
O
and components for leaks
Inspect for design steam
entering O
conditions
NOTES:
1. Units that provide year-round cooling: Once every four months, and as required due to excess purge requirements.
Units that provide only seasonal cooling: Once at the beginning of the cooling season, once in the middle, and as needed due to excess purge
requirements.
2. Units should be leak-tested when excessive purging is required. Note: The solution chemistry should always be checked (and adjusted as necessary)
prior to performing a leak test.
3. More frequent rebuilds will be required if solids and/or dissolved copper is present in the solution.
4. Perform every 2-3 years or as required.
T = YORK / Johnson Controls Qualified Service Technician

O = Operator
68 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
glossary of terms
Absorber Blowdown
The concentrated solution coming back from the gen- While running the unit, refrigerant is intentionally
erator is pumped to a solution spray header where it is dumped into the absorber shell section by opening
sprayed over the tubes in the absorber. Refrigerant 2SOL (stabilizer solenoid valve). A refrigerant blow-
vapor is absorbed into the solution and the solution is down will further dilute the solution in the absorber
thus diluted. This diluted solution is collected at the shell. A blowdown is required before taking a solution
bottom of the absorber where it is again pumped to the sample for analysis, to separate the alcohol from
generator. the refrigerant, and to hasten the refrigerant clean-up
procedure.
Auto De-crystallization (ADC) Flush Line
The ADC line runs between the solution pump dis- C.O.P.
charge and the ADCline. When the solution pump Coefficient of performance. A means of comparing the
runs, weak solution is constantly supplied to the ADC performance of a chiller as the ratio of the cooling
line. This keeps the ADC line from crystallizing, due output divided by the heat input.
to it being exposed to the low pressures generated
within the absorber while the unit is running. Concentration
The percent by weight of lithium bromide present in
ADVAGuardTM 750 solution. New solution is sent with a concentration of
YORK's newest Inhibitor. An inorganic inhibitor pro- 53% if the inhibitor is ADVAGuard 750, 55% if the
viding excellent corrosion protection to the unit's inhibitor is molybdate, 54% if Chromate, 53% if
internal steel and copper surfaces. Also see Inhibitor. Nitrate.
Alcohol (2-Ethylhexanol) Condensate

A liquid added to an absorption chiller to enhance the Condensed steam leaving the unit.
heat and mass transfer in the Absorber. It is an octyl
alcohol whose chemical name is 2-Ethyl-1-Hexanol Condenser
(C8H18O) with a molecular weight of 130.2, a boiling Vapor produced by the generator enters the condenser
point of 364.3°F (184.6°C), and a flash point of and is cooled and condensed back into a liquid by the
177.8°F (81°C) @ 760 mmHg. Having a colorless, tower water flowing through the inside of the con-
clear appearance, it has a somewhat pungent odor. By denser tubes. The condensed vapor liquid drips down
adding 2-Ethylhexanol to the absorption cycle, overall into a collection pan located at the bottom of the con-
unit performance increases by 5-15%. In addition, denser. From there it flows out of the pan, through an
cycle temperatures, pressures, and concentrations tend orifice, and into the evaporator.
to decrease with the addition of 2-Ethylhexanol.
Condenser (Tower) Water
Automatic De-crystallization (ADC) Pipe The external water loop which is used to remove heat
The ADC pipe is a U-shaped line coming off the gen- from the unit. This water first passes through the
erator solution outlet box and terminating in the Absorber and then to the Condenser. Typical tempera-
absorber shell. During normal unit operation, this line tures are entering the Absorber at 85°F, leaving the
has no flow in it. If crystallization were to occur, it Absorber (entering the Condenser, i.e., crossover) at
would normally be in the strong solution side of the 92°F (33.3°C), and leaving the Condenser at 95°F
heat exchanger. This blockage would back up solution (35°C). Some external means of removing this heat is
into the generator and into the automatic de-crystalli- necessary. Typically a cooling tower is used for this
zation pipe. Once the hot solution goes into the ADC application.
pipe, it bypasses the heat exchanger and goes directly
into the absorber shell, thus heating the solution in the Crystallization
absorber shell. The heated solution in the absorber Under certain conditions, lithium bromide solution may
then heats up the crystallized heat exchanger from the increase in viscosity and become slush-like, or even so-
opposite side of the tubes and causes the crystallized lidify. The likelihood of solution crystallizing increases
lithium bromide to dissolve back into solution. as the concentration increases and/or the temperature
decreases. For reference, here are some points where
JOHNSON CONTROLS 69
Glossary of Terms
FORM 155.21-OM1 (510)
the liquid solution of lithium bromide will crystallize, pure refrigerant generated in the generator is cooled
assuming a saturation condition: and condensed in the condenser and supplied to the
• 240°F (115°C) @ 70% evaporator. Here, it is immediately exposed to a much
lower pressure which causes some immediate flashing
• 207°F (97°C) @ 69%
(boiling). Most of the refrigerant cools to the satura-
• 182°F (83°C) @ 68% tion temperature and remains in liquid form. It is then
• 158°F (70°C) @ 67% pumped and sprayed over the Evaporator tube bundle.
• 138°F (59°C) @ 66% As the refrigerant passes over the outer surface of the
• 120°F (49°C) @ 65% tubes, it evaporates (i.e. flashes or boils) due to the
low pressure, approximately 5.5-6.5 mmHg, which is
equivalent to a saturation temperature of 36-41°F (2.2-
Typically, crystallization occurs where the heated, 5°C). The refrigerant vapor is then immediately drawn
high concentrated solution leaves the generator and through the eliminator towards the absorber. This
passes through the heat exchanger. This is where the vacuum is caused by the hygroscopic action, the affin-
solution is at its highest concentration that meets the ity lithium bromide has for the refrigerant vapor.
lowest temperature. Under normal running conditions,
crystallization is not a problem. Extreme cold ambient Evaporator Sprays
temperatures, power failures, and unit air leakage are A series of spray nozzles that evenly distribute refrig-
the typical causes for crystallization. erant from the refrigerant pump discharge to the
evaporator section tubes.
Dilution Cycle
Intentionally running the solution, refrigerant, tower Level Switch (1F), (3F)
water, and chilled water pumps after the unit has been There are two level switches that sense liquid levels
shut down to allow the concentrated solution to on the IsoFlow units. Both are located in the refriger-
become more dilute. Essentially, the cycle continues ant circuit. Switch (1F) is at the side of the evaporator
without the addition of heat, thus, slowly diluting the refrigerant outlet box, and senses the level in the box.
solution to concentration levels where it is more dif- At low levels in this box, the 1F switch will open,
ficult to crystallize. Note: The dilution cycle is causing the micropanel to initiate corrective proce-
dependent upon many factors. Please see the dures to keep the unit from running out of refriger-
micropanel instructions for details. ant.
Eductor Level switch (3F) is located just before the inlet of the
An eductor is a liquid-powered jet pump. Jet pumps Buffalo refrigerant pump. It's main purpose is to keep
have no moving parts and use a high-pressure stream the Buffalo pump from cavitation and eventual over-
of liquid to pass through a nozzle, causing a portion of heating. For more details on the operation of these
of a low-pressure stream coming into the side of the floats, see YIA Mod D Operation YORK Form 155.21-
pump to combine with the nozzle stream. This causes O1.
a reduction in pressure at the low-pressure inlet and
induces the rest of the low-pressure inlet substance to Generator
flow into the body of the pump. This component of the absorption system heats diluted
lithium bromide solution coming from the absorber
On IsoFlowTM units, an eductor is used in place of a shell. The generator can receive its heat source from
centrifugal pump to induce strong concentrated solu- either hot water (of 266°F (130°C) and 300 PSIG) or
tion exiting the generator outlet box to combine with steam (up to 337°F (169°C) and 17 PSIG). As the
weak concentrated solution exiting the solution pump solution is heated, refrigerant vapor is boiled off and
discharge, before going to the absorber spray header. rises to the condenser. The resulting concentrated
lithium bromide solution flows back to the absorber
Evaporator sprays.
The section of a chiller that is responsible for remov-
ing the heat from the chilled water circuit, thus cool- G.P.M.
ing the chilled water used to cool a building, a manu- A measure of volumetric flow rate (Gallons Per
facturing process, or whatever application it is intend- Minute).
ed. Typically, the chilled water is cooled from 54°F to
44°F (12°C to 6.6°C). In an absorption chiller, the
70 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
Heat Balance Lithium Bromide

This is also sometimes called an energy balance. It is Lithium bromide, or LiBr, is a solid salt chemical
based on the physics principle “conservation of ener- compound of lithium and bromine. When mixed with
gy” which states that the energy that is put into a cycle water it becomes a liquid solution. Its extreme hygro-
is equal to the energy coming out of the cycle, e.g., scopic character makes LiBr useful as a desiccant in
Heat in = Heat out. absorption chiller systems.
The above equation is used to mathematically prove Magnetite

within a cerain tolerance (+/- 5%) that the energy we An iron oxide layer formed on the internal unit sur-
put into the machine (or cycle) is coming out of the faces to help reduce corrosion rates.
cycle. If this is proven, then we know our measure-
Micropanel
ments used to compute unit capacity are correct.
The "brains" of the unit. The micropanel is the elec-
tronic control panel which instructs the entire unit on
Hot Water Valve
when and how to run. Integrated into the logic of the
The capacity control valve that regulates the amount
micropanel are sensors to measure key temperatures
of hot water to the generator (hot water units only).
and pressures which are then used to monitor real-
time conditions.
Inhibitor
A chemical used to help form a magnetite layer to Model Number
minimize or inhibit the corrosion on the internal steel A series of abbreviations or designations used to iden-
surface area of the unit. The Magnetite lyer, not the tify IsoFlow™ units.
inhibitor, helps reduce corrosion rates in the unit.
YORK's current inhibitor is ADVAGuardTM 750. Molybdate
Lithium Molybdate (Li2MoO4) the current corrosion
Insulation inhibitor used for YORK’s absorption units. By chem-
Units should be insulated in the field according to the ically slowing down the natural tendency of steel to
installation manual. Insulation should be installed for oxidize or corrode, the inhibitor is supplied in solution
a variety of reasons: with the Lithium Bromide (also refer to Inhibitor).
1. Decreases the heat loss through the walls of the
vessel to its surroundings, thus increasing the effi- Non-Condensables
ciency of the machine. A gaseous substance that cannot be liquified or
2. Helps reduce the potential of crystallization in the condensed at the pressure and temperature surround-
event of a power failure. ing it. The presence of non-condensables in the unit
3. Burn protection for operating personnel in high can cause severe performance problems. Non-
temperature areas. condensables appear in two forms in the unit:
4. Eliminates condensation on low temperature areas 1. Internally generated non-condensables are formed
of the machine. as a by-product of corrosion.
2. Air may be drawn into a unit via leaks.
IsoFlowTM
Our trademark name for a single-stage absorption Non-condensables that collect in the absorber section
unit. of the unit (low side) blanket the heat transfer tubes
and raise the internal pressure, thus reducing the
Isolation Valve absorber’s ability to capture the refrigerant vapor.
One isolation valve is located at each Buffalo Pump Non-condensables that collect in the condenser (high
inlet and outlet. It is a positive sealing, butterfly type side) blanket the condenser tubes, thus reducing the
valve mounted between standard ANSI flanges. Each condenser’s capacity.
valve incorporates an EPDM liner on the valve face to
act as a sealing surface. When closed, the valves will It should be noted that the only non-condensable that
isolate the unit vacuum from the pump area to offer is not self-generated by the chemistry inside the unit is
ease of serviceability when working on the pumps. nitrogen. Air is over 70% nitrogen; an air leak is the
only external source of nitrogen. All other non-con-
densables are generated by various chemical reactions
that occur internally for many different reasons.
JOHNSON CONTROLS 71
Glossary of Terms
FORM 155.21-OM1 (510)
Oil Trap Refrigerant Anti-Freeze Line

The oil trap is located between the purge pump suction This line runs between the outlet of the refrigerant
connection and the unit. It is designed so it will hold pump and the refrigerant condensate line(s) coming
one complete oil charge of the vacuum pump. In the down off the condenser. When the refrigerant pump is
event air was to get into the unit through the vacuum operating, a constant supply of refrigerant is mixed
pump, the low pressure in the absorber would induce with the refrigerant coming from the condenser to
the oil onto the system. Therefore, the oil trap is used keep it from freezing during low loads and low con-
as a safety measure to protect the absorption unit from denser water temperatures.
the oil.
Refrigerant Pump
Orifice A hermetically sealed, centrifugal pump located down-
A restriction in a liquid line for the purpose of reduc- stream of the evaporator outlet box. This pump
ing the internal diameter of the line. Usually created receives liquid refrigerant from the evaporator and
by a blank piece of metal with a small hole drilled into discharges it back up to the evaporator sprays. It con-
it, to create a pressure differential when a liquid tinues to re-circulate the refrigerant while the chiller is
passes through it. operational.
Pass Baffle Rupture Disk

A division plate or plates (baffles) inserted into a Although IsoFlowTM absorption units operate at less
water box to create chambers which force the water to than atmospheric pressure (a vacuum), if certain safe-
pass through different portions of the tube bundle, ties fail and/or incorrect valves are closed, the unit
called passes. Although the pressure drop increases could experience higher pressures in certain cham-
with each pass, the tradeoff for heat transfer optimiza- bers. Therefore, a pressure relief apparatus, a rupture
tion and nozzle locations are justified. disk, is added only to hot water units.
Power Panel Sight Glass

The power panel serves as single-point wiring loca- A leak tight port hole used to visually inspect liquid
tion for the unit’s incoming power wiring. It houses all levels within the unit. A threaded design with a quartz
the unit pump contactors and overloads, as well as glass window is presently being used.
fuses and terminal lugs for ease of serviceability. A
transformer is included to reduce the incoming unit Solution
voltage to the required control voltage to the micro- A mixture of deionized water with a certain % by
panel. weight of dissolved lithium bromide (LiBr). Corrosion
inhibitors are also added to the solution to reduce the
Pressure Drop internal corrosion rates in the unit.
The amount of pressure decrease experienced between
two locations. Often referred to when describing the Solution Heat Exchanger
drop in pressure found while passing water through A counterflow solution-to-solution heat exchanger. A
the tubes in a chiller. Typically measured in PSI or component that exchanges heat between two streams
FtH20. of lithium bromide solution. The hotter the solution
being supplied to the generator is, the less heat that
Purge Pump needs to be added, thus improving efficiency. Likewise,
An external pump connected to the purge system of the cooler the solution is going to the absorber, the less
the unit. This pump is used to evacuate non-condens- heat that needs to be removed by the cooling towers.
ables from the unit. Therefore, the heat exchanger pre-heats the solution
going to the generator and cools the solution going to
Purging the absorber.
A process by which non-condensables present in a
unit are removed through the use of a vacuum pump.
Refrigerant
Deionized water is used as the refrigerant.
72 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
Solution Pump One atmosphere is equal to 760 millimeters of mercury

A hermetically sealed, centrifugal pump located under absolute (Torr); 29.92 inches of mercury absolute; or
the absorber. It receives diluted lithium bromide solu- 14.7 pounds per square inch absolute (see FIGURE
tion from the absorber shell and circulates it through a 29).
heat exchanger, and up to the generator. The discharge
of this pump operates above atmospheric pressure. When vacuum is measured relative to atmospheric
The pump is cooled by the solution it is pumping. pressure and toward absolute zero, the negative sign
(–) is used to indicate that it is a negative gauge pres-
Specific Gravity (S.G.) sure value. When vacuum is considered in the other
The ratio of the mass of a liquid to the mass of an direction, i.e., from absolute zero, the term absolute (or
equal volume of distilled water at 39°F (3.8°C). abs.) is used (see FIGURE 29).
Steam Valve From FIGURE 28, we can see that a pressure reading
The capacity control valve which regulates the amount of 300 Torr is the same as 11.8 in Hg (abs.) and 5.8 PSI
of steam to the unit (Steam units only). (abs.).
Tube Sheet (End Sheet) Water Box

The book-ends of the mainshell. The tube sheets are A structure designed to contain the water both entering
located at each of the axial ends of the unit, where the and exiting the unit by using nozzles to restrict the
tubes are rolled and waterboxes are mounted. water into a contained area. The nozzle directs the
water into the waterbox where pressure builds up,
Tube Support forcing the water through the tubes. As the water exits
A smaller gauge steel sheet, identical in tube hole lay- the tubes on the opposite end, it is restricted by the
out to the tube sheet, but used internally to provide waterbox on the other side of the tube bundle. Again,
support and rigidity for the bundle of tubes. pressure builds up, and the water is either forced by a
pass baffle back through another section of the tube
Vacuum bundle or directly out of the outlet nozzle.
When the pressure within a vessel is less than standard
atmospheric pressure (14.7 PSIA or 0 PSIG). YIA
YORK IsoFlow™ Chiller.
The term “vacuum” usually refers to any pressure
below atmospheric pressure. The degree of vacuum
can be expressed in many ways, but most commonly
(as in this manual) it is measured in inches of mercury
or millimeters of mercury.
Atmosphere at 32°F
ToRR
(mmHg) Inches Hg (abs) PSIA
760 29.92 14.696 ABSoLUTE UNITS GAUGE UNITS
Measured From Absolute Zero Measured From Atmospheric Pressure
700 14
25
600 12 PSIA PSIG
500 20 10 ToRR in Hg
ATMoSPHERIC 147 (mm Hg) (Abs.) 0 mm Hg in Hg
PRESSURE 760 29.92 0
400 8 (0 PSIG)
15 (14.7 PSIA)
– mm Hg
300 6 INCREASING
– in Hg
VACUUM
10 – PSIG
200 4
DECREASING
VACUUM
5
100 2
0 0 0 14.7 760 29.92
Absolute Zero Pressure or Perfect Vacuum
0 0 0
ld05113 ld05114
FIGURE 28 - pressure equivalents FIGURE 29 - vacuum units of measurement
JOHNSON CONTROLS 73
FORM 155.21-OM1 (510)
NOTES
74 JOHNSON CONTROLS
FORM 155.21-OM1 (510)
NOTES
JOHNSON CONTROLS 75
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2010 www.york.com ALL RIGHTS RESERVED
Form 155.21-OM1 (510)
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SINGLE STAGE YIA

1A1 through 14F3

DANGER indicates an imminently CAUTION identifies a hazard which

WARNING indicates a potentially NOTE is used to highlight additional

External wiring, unless specified as an optional connection in the manufacturer’s product

Changeability of this document

Section 2 ABSORPTION SYSTEM OPERATION......................................................... 9

Section 3 PURGing and non-condensables................................................... 27

Section 9 PTX CHART................................................................................................. 47

CLEANING AND MAINTAINING THE TUBES WITHIN THE SHELLS....... 65

THIS PAGE INTENTIONALLY LEFT BLANK

section 2 – ABSORPTION SYSTEM OPERATION

model yia standard steam cycle diagram

GENERAToR **PT2 Typ 2 Places

ADC Flush Line VR9 1-1/2” Purge oil Trap

VS18 VS19 Purge

* orifices may differ between various models.

FIGURE 1 - COMPLETE CYCLE DIAGRAM

The absorber consists of a single or multi-pass tube Controls and Wiring

Refrigerant Pump Components in the Control Center

1M – Starter/Contactor for Solution Pump MTH1 and MTH2 – Motor Thermostats

1OL thru 3OL – Overloads

1OL 2OL 3OL

Control Components External to 3SOL – Refrigerant Level Solenoid Valve

1F – Refrigerant Level Float Switch 4SOL – Automatic Shut-Off Valve

LRT – Low Refrigerant Temperature Cutout Control Valve (not shown)

power HIGH-TEMP Hi-PressurE RUPTURE GENERATOR

FIGURE 3 - MODEL YIa ABSORPTION UNIT, FRONT VIEW

1F Refrrigerant Level Switch

FIGURE 4 - system control component locations

LEFT END of unit

Right END of unit

figURE 4 (CONT'D) – system control component locations

GENERAToR **PT2 Typ 2 Places

ADC Flush Line VR9 1-1/2” Purge oil Trap

VS18 VS19 Purge

* orifices may differ between various models.

FIGURE 5 - BASIC FLOW DIAGRAM

SYSTEM OPERATION Relatively dilute solution from the bottom of the

Liquid, usually water, for air conditioning applications

flowing over the outside of the tubes. This heat causes

refrigerant to evaporate since it is at a pressure with a

corresponding boiling temperature lower than the leav- VS18 VS19

ing chilled water temperature. For example, water is

RT5 TowER An intermediate solution, consisting of a mixture of

There are three sub control mechanisms interacting

Limiting Capacity by Mixing Solution and Refrigerant Overflow

FIGURE 11 - Solution and refrigerant

By diverting lithium bromide from the solution circuit

Anti-Freeze Line DISCUSSION OF SUBSYSTEM OP­ER­A­TION

This flow of flush solution through the trap also serves

item no. description item no. description

FIGURE 13 - automatic decrystallization feature

THIS PAGE INTENTIONALLY LEFT BLANK

section 3 – Purging and NON-condensables

PURGE PUMP The purge pump is factory mounted on a bracket system

The purge pump will go through a warm-up period when

Although occasionally some of the non-condensable

Explosion Warning: Never install an PURGE EDUCTOR

Anti-Freeze Line DISCUSSION OF SUBSYSTEM OPERATION