Manual de Instalação - Chiller YORK® Absorção ... - Johnson Controls

FORM 155.16-N3 (904)TABLE OF CONTENTSSECTION 1 - INSTALLATIONRESPONSIBILITIES ...........................8MECHANICAL CONTRACTOR:....................................... 8ELECTRICAL CONTRACTOR: ........................................ 8YORK DISTRICT SERVICE OFFICE: .............................. 8INSULATION CONTRACTOR: ......................................... 8SECTION 2 - INTRODUCTION................................10INTRODUCTION ............................................................ 10ADVANCED PREPARATION SITE SELECTION ........... 10UNIT CLEARANCES ..................................................... 10FOUNDATION .................................................................11UNIT SHIPMENTS ..........................................................11SOLUTION AND REFRIGERANT SHIPMENT................11INITIAL INSPECTION OF UNIT ..................................... 12SECTION 3 - UNIT RIGGING ..................................14ONE-PIECE UNIT LIFTS................................................ 14TWO-PIECE UNITS........................................................ 14UNIT LEVLING AND MOUNTING .................................. 15Steam Units .................................................................. 15Hot Water Units ............................................................ 15Neoprene Pads............................................................. 15Spring Isolators............................................................. 16Unit Mounting ............................................................... 16SECTION 4 - UNIT RE-ASSEMBLY ........................22TWO-PIECE SHIPMENTS ............................................. 22BREAKING THE UNIT PRESSURE............................... 22UNIT RE-ASSEMBLY ..................................................... 22INSTALLING THE ABSOLUTE PRESSUREGAUGE........................................................................... 23COMPLETING THE PURGE PUMPCONNECTIONS ............................................................. 24SECTION 5 - UNIT WATER PIPING ........................26UNIT WATER PIPING..................................................... 26GENERATOR NOZZLE CONNECTIONS ...................... 26PIPING COMPONENTS................................................. 27Wells For Sensors ........................................................ 27Chilled Water Flow Switch ............................................ 27Tower Water (Condenser) Flow Switch ........................ 27Differential Pressure Control......................................... 28Strainers ...................................................................... 28Unit Crossover Line ...................................................... 28Tower Water (Condenser) Bypass Valve ...................... 28COMPLETING THE PIPING........................................... 29SYSTEM PUMP CONTROL ........................................... 29SECTION 6 - RUPTURE DISK AND RELIEFPIPING ...............................................32RUPTURE DISK AND RELIEF PIPING.......................... 32Rupture Disk Discharge Piping Material....................... 32Rupture Disk Discharge Piping Construction ............... 32Rupture Disk Discharge Piping Sizing.......................... 33Rupture Disk Discharge Piping Lengths....................... 33Rupture Disk Discharge Piping Arrangement andLocation ........................................................................ 34SECTION 7 - INLET STEAM PIPING ......................36INLET STEAM PIPING ................................................... 36INLET STEAM CONDITIONS......................................... 36Pressure ....................................................................... 36Flow .............................................................................. 36Steam Purity ................................................................. 36STEAM PIPING ARRANGEMENT ................................. 37INLET PIPING COMPONENTS...................................... 37Manual Block Valve ...................................................... 37Pressure Reducing Valve (PRV) (If Applicable)............ 37Steam Strainer.............................................................. 38Steam Desuperheater (If Applicable)............................ 38Steam Separator .......................................................... 38Automatic Shut-Off Valve (4SOL) ................................ 39(If Applicable)................................................................ 39Steam Control Valve ..................................................... 39Steam Control Valve Installation................................... 39Steam Control Valve Wiring.......................................... 39Steam Control Valve Orientation & Placement............. 40Safety Relief Valve........................................................ 40(Supplied by Others)..................................................... 40SECTION 8 - STEAM CONDENSATE RETURNSYSTEM.............................................42STEAM CONDENSATE RETURN SYSTEM.................. 42Types of Condensate Systems..................................... 42CONDENSATE RETURN SYSTEMCOMPONENTS.............................................................. 43Steam Condensate Drain Solenoid Valve..................... 43Valve Installation and Wiring......................................... 43Vacuum Breaker ........................................................... 46CHILLER OPERATION AND THE FUNCTION OF ........ 46THE VACUUM BREAKER .............................................. 46Strainer(s)..................................................................... 47Steam Traps ................................................................. 47Float and Thermostatic Steam Trap ............................. 47Thermostatic Trap......................................................... 47Check Valve.................................................................. 47Condensate Cooler....................................................... 47Auxiliary Condensate Receiver .................................... 474 YORK INTERNATIONAL

FORM 155.16-N3 (904)TABLE OF CONTENTSSECTION 9 - HOT WATER PIPING.........................48HOT WATER PIPING ..................................................... 48HOT WATER FLOW & CONTROL ................................. 48DIVERGING FLOW ........................................................ 483-Way Diverging valves ................................................ 482-Way Hot Water Valves............................................... 493-Way Converging valves............................................. 49HOT WATER PIPING COMPONENTS........................... 50Manual Isolation Valves ................................................ 50Hot Water Control Valve ............................................... 50Valve Installation........................................................... 51Valve Wiring.................................................................. 52Check Valve.................................................................. 52Pressure and Temperature Indicators........................... 52SECTION 10 - ELECTRICAL CONNECTIONS .......54Flow switches .............................................................. 55MISCELLANEOUS WIRING........................................... 55Automatic Steam Shut-off Valve (4SOL) ...................... 55Steam Condensate Drain Valve (6SOL) ...................... 55Control Valve Connections ........................................... 58System Pump Control Wiring ....................................... 58Remote Steam/Hot Water Control Valve Limit Setpoint WithPwm Signal................................................................... 58Remote Ready To Start Contacts ................................. 58Remote Leaving Chilled Water Temperature Setpoint WithPWM Signal.................................................................. 58Cycling Shutdown Contacts.......................................... 59Run Contacts................................................................ 59Auxiliary Safety Shutdown Contacts............................. 59Safety Shutdown Contacts ........................................... 59Remote/local Cycling Devices ...................................... 59Remote Start/Stop contacts from Energy ManagementSystem.......................................................................... 59Multi-Unit Sequence ..................................................... 59Warning Contacts ......................................................... 59SECTION 12 - INSULATION....................................61INSULATION .................................................................. 61Hot Surface Insulation .................................................. 61Cold Surface Insulation ................................................ 61Insulation Tips............................................................... 61Factory Applied Chiller Insulation ................................. 61MAJOR COMPONENT LOCATION.........................64APPENDIX A............................................................64UNIT WEIGHTS.............................................................. 65SHELL AND TUBE VOLUMES....................................... 66SHELL AND TUBE VOLUMES....................................... 66ELECTRICAL DATA........................................................ 67UNIT CHARGE QUANTITIES ........................................ 70INSULATION .................................................................. 71REFRIGERANT SIDE INSULATION ............................. 74COLD SIDE INSULATION ............................................. 75REFRIGERANT SIDE AND COLD SIDEINSULATION .................................................................. 76HOT SURFACES INSULATION .................................... 77APPENDIX B............................................................85Receiving Inspection Checklist .................................... 85Installation Checklist..................................................... 87SECTION 11 - PROTECTION FROMCRYSTALLIZATION DURINGPOWER FAILURES .........................60POWER FAILURES........................................................ 60Eliminating Heat Input .................................................. 60Unit Insulation............................................................... 60YORK INTERNATIONAL 5

FORM 155.16-N3 (904)LIST OF FIGURESFIG. 1 – UNIT NEOPRENE PADS ...........................14FIG. 2 – MOUNTING ANGLES.................................15FIG. 3 – ISOLATION PADS ......................................15FIG. 4 – CORRECT ONE-PIECE UNIT LIFTINGMETHOD ...................................................16FIG. 5 – INCORRECT ONE-PIECE UNIT LIFTINGMETHODS..................................................18FIG. 6 – EVAPORATOR/ABSORBER CORRECTLIFTING METHODS...................................19FIG. 7 – CONDENSER/GENERATOR CORRECTLIFTING METHODS...................................20FIG. 8 - BREAKING UNIT PRESSURE....................22FIG. 9 - MANOMETER CONNECTIONS .................23FIG. 10 - PURGE PUMP CONNECTIONS...............24FIG. 11 - PURGE PUMP ..........................................24FIG. 12 – INSTALLATION OF FLOW SWITCH........27FIG. 13 – INSTALLATION OF FLOW SWITCH........29FIG. 14 – PLASTIC PIPE STUB...............................32FIG. 15 – RUPTURE DISK FROM FACTORY .........33FIG. 16 – RUPTURE DISK DISCHARGE PIPINGARRANGEMENT......................................34FIG. 17 – STEAM PIPING ARRANGEMENT ...........37FIG. 19 – 3274 ACTUATOR INSTALLATIONCLEARANCES .........................................40FIG. 18 – 3274 ACTUATOR ORIENTATION ............40FIG. 20 – PSQ ACTUATOR ORIENTATION.............40FIG. 21 – PSQ ACTUATOR INSTALLATIONCLEARANCES .........................................40FIG. 22 – SYSTEM 1 - ATMOSPHERICCONDENSATE RETURN SYSTEM ..........44FIG. 23 – SYSTEM 2 - VACUUM CONDENSATERETURN SYSTEM...................................45FIG. 24 – SYSTEM 3 - VACUUM CONDENSATERETURN SYSTEM WHEN INLET STEAMAND OUTLET CONDENSATE ARE UNDERVACUUM ..................................................46FIG. 25 – TYPICAL 2-WAY CONTROL VALVEARRANGEMENT......................................49FIG. 26 – TYPICAL 3-WAY DIVERGING CONTROLVALVE ARRANGEMENT..........................50FIG. 27 – TYPICAL 3-WAY CONTROL VALVEARRANGEMENT .....................................51FIG. 28 – ACTUATOR CLEARANCES.....................52FIG. 29 – 3274 ACTUATOR ORIENTATION ............52FIG. 30 – INCOMING 3 PHASE POWER WIRING..54FIG. 31 – SYSTEM WATER PUMP AND FLOWSWITCH INTERFACE DETAILS ..............56FIG. 32 – ISOFLOW MICRO PANEL CONTROLCENTER COMPONENT LOCATIONS.....57FIG. 33 – MAJOR COMPONENT LOCATIONSFOR ISOFLOW TM CHILLERS...................64FIG. 34 – REFRIGERANT SIDE INSULATION(FACTORY SUPPLIED OPTION)............74FIG. 35 – COLD SIDE INSULATION(FIELD SUPPLIED AND INSTALLED) ....75FIG. 36 – REFRIGERANT SIDE AND COLD SIDEINSULATION ...........................................76FIG. 37 – HOT SURFACES INSULATION(FIELD SUPPLIED) .................................77FIG. 38 – UNIT ASSEMBLY FOR MODELS1A1 AND 1A2 .........................................78FIG. 39 – UNIT ASSEMBLY FOR MODELS2A3 AND 2A4 .........................................79FIG. 40 – UNIT ASSEMBLY FOR MODELS2B1 THRU 4B4.........................................80FIG. 41 – UNIT ASSEMBLY FOR MODELS4C1 THRU 6C4 .......................................81FIG. 42 – UNIT ASSEMBLY FOR MODELS7D1 THRU 8D3 ........................................82FIG. 43 – UNIT ASSEMBLY FOR MODELS8E1 THRU 10E3.......................................83FIG. 44 – UNIT ASSEMBLY FOR MODELS12F1 THRU 14F3 .....................................846 YORK INTERNATIONAL

FORM 155.16-N3 (904)RELATED PUBLICATIONSFORM NUMBER155.16-PA1155.16-PA1.1155.16-PA1.2155.16-PA2155.16-W1155.16-W3155.16-W4DESCRIPTIONField Control Modifi cations Diagram for Millennium Control CenterDimensions and Physical Data for Steam Heat Source UnitsDimensions and Physical Data for Hot Water Heat Source UnitsField Connections for Micro Panel Control CenterWiring Diagram for Units with Franklin PumpsWiring Diagram for CE Coded Units with Franklin PumpsWiring Diagram for All Units with Buffalo PumpsYORK INTERNATIONAL 7

Installation ResponsibilitiesFORM 155.16-N3 (904)SECTION 1INSTALLATION RESPONSIBILITIESThe following steps must be completed for the properinstallation of a YORK absorption chiller. These listsare not intended to be the final steps for each installerto complete, but only used as a guideline. Becausesome of the work may be completed by others, theremay be duplicated steps. The most important part ofa successful installation is that each installer knowsahead of time what to do and when to do it.The overall responsibility for theproper installation of the absorptionchiller remains with YORK Service.MECHANICAL CONTRACTOR:1. Construct a housekeeping pad and floor drains.2. Rig and level the unit into place, set the unit onneoprene pads if applicable.3. Move the solution, refrigerant drums and unit shiploose parts into the building.4. If the unit is a two-piece shipment, install theCondenser/Generator section on the Absorber/Evaporator section and weld the interconnectingpiping between the two shells.5. Install the absorber, evaporator and condenser lines.Construct and install Crossover Piping on applicableunits. Provide flanges and taps in the piping formonitoring, control, and safety devices.6. Install the steam/hot water lines and all applicablecomponents, including; control valve, failsafe &condensate drain valves (if applicable). Provideflanges and taps in the piping for monitoring,control, and safety devices.7. Install the rupture disk piping.8. Installing/mechanical contractor is responsible forcompletely filling out and signing the “InstallationCheck List and Request for Authorized StartupEngineer” form, located in the back of thisdocument.ELECTRICAL CONTRACTOR:1. Supply, mount, and wire a fused unit disconnectswitch prior to the power panel of the absorptionchiller.2. Wire the main power supply lines into unit mountedpower panel.YORK DISTRICT SERVICE OFFICE:1. Charge the unit with solution and refrigerant. Fillthe Vacuum Pump with oil. Refer to Appendix Afor proper oil volumes in the Vacuum Pump.2. Re-check the levelness of the unit.3. Run shielded wiring to the flow switches, controlvalve, and fail closed valve on steam/hot waterpiping (if applicable). Run shielded wiring to thecondensate drain solenoid on steam units.4. If the unit was a two-piece shipment, leak check allfield assembled chiller piping connections.5. Check all unit-mounted pumps for correct rotationdirection.6. Mount and connect the manometer pressure gauge.Refer to SECTION 4 in this manual.7. Install all sensors, switches, and indicating devicespertaining to the unit in their appropriate wells oncustomers piping.8. Perform all normal and customary unit pre-startupand start-up procedures (TCA). Refer to the Fill-Out Forms section of the Absorption Chillers areaof the YORK International Intranet.INSULATION CONTRACTOR:1. Insulate the chilled water lines and water boxes.Refer to the Insulation section in this manual.2. Insulate the steam/hot water lines and boxes. Referto the Insulation section in this manual.3. Insulate the unit refrigerant piping, if applicable.4. Insulate the evaporator shell if necessary. Refer tothe Insulation section in this manual.8 YORK INTERNATIONAL

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IntroductionFORM 155.16-N3 (904)SECTION 2INTRODUCTIONINTRODUCTIONThis manual describes the installation of an IsoFlowabsorption chiller with the new style (internallycooled) circulation pumps. The unit is a completeself-contained, forced circulation refrigeration systemusing steam or hot water as the activation medium.De-ionized water is used as the refrigerant and lithiumbromide solution is used as an absorbent. The systemconsists of a generator-condenser shell mounted ontop of an absorber-evaporator shell. The system alsoutilizes a solution pump, refrigerant pump; purgepump, and interconnecting piping. See the Appendix Afor the location of the above listed components.For more detailed information about design, specificationsor operation on the particular unit being installed,please contact your local YORK office.When using this manual, the installer should pay particularattention to the Safety Symbols: DANGER,WARNING, CAUTION and NOTE. These symbolsalert the installer of areas of potential hazard. For furtherexplanation, Refer to the Safety Symbols sectionat the beginning of this manual.The contractor is advised to become thoroughlyfamiliar with the installation requirements of theYORK IsoFlow Chiller. Careful study of the factorysubmittal drawing package and this manual is highlyrecommended. YORK representatives are available toanswer any questions and to coordinate delivery of theunit and the accessories.YORK must be advised by the contractor of thescheduled Start-Up time so that qualified personnel canbe made available on the Start-Up date. Complete the“INSTALLATION CHECK LIST AND REQUESTFOR AUTHORIZED START-UP ENGINEER” formfound in Appendix B and submit the form to YORK.A minimum of four weeks advance notice must beallowed to schedule a unit Start-Up and to have theLithium Bromide Solution delivered to the jobsite.ADVANCED PREPARATION SITE SELECTIONIt is recommended the installer make a first-hand onsite, job site inspection to ensure a smooth installationprocess. Check all factory submittals and drawingsto verify unit clearances, overall dimensions andweight. Electrical requirements, steam or hot waterpressure and temperature, foundation dimensions, andfloor drains should also be verified before the chillerarrives.When selecting an installation site, consider structuralsupport, access of service and service equipment,overhead space, floor drains, and tube pulling space.Tube pull area is approximately equalto the length of the main shell.Follow standard engineering practices in designing thepiping system and other services. See the Appendix fora listing of the unit rigging and operational weights.YORK does not recommend theIsoFlow unit to be installed outof doors. During unit operationthe ambient temperatures in theimmediate surrounds of the unit mustnot become lower than 35°F (1.67°C)or above 104°F (40°C).The equipment room must be enclosed, well lighted,and properly ventilated. Relative humidity in theequipment room must never reach the saturationpoint.UNIT CLEARANCESCondensation of moisture may causecorrosion and damage to electricalcomponents.The minimum recommended UNIT clearances arelisted in the following Table. If the site selection failsto meet these minimums, contact the local YORKoffice for special considerations.10 YORK INTERNATIONAL

FORM 155.16-N3 (904)UNIT CLEARANCESUnit Side Opposite Panel 40” (1.0 m)Panel Side of UnitPer CodeTube Pull End of UnitOne Unit LengthOpposite Tube Pull End of Unit 60" (1.5 m)Top of UnitSee BelowBottom of UnitLevel with FloorTABLE 1 – UNIT CLEARANCESFor clearance on top of the unit YORK recommendsallowing enough room for removal of unit skids,ventilation, and accessibility for maintenance or unitcleaning. For unit overall dimensions refer to YORKInternational forms 155.16-PA1.1 and 155.16-PA1.2.FOUNDATIONIn many situations IsoFlow units are set on concretehousekeeping pads to help with machine roomcleanliness. These foundations are usually made ofconcrete with a compressive strength rating of not lessthan 4000 psi and are able to support the full operatingweight of the unit. (See the Appendix “A” for tableswithin this document for specifi c unit weights). Wheninstalling a concrete foundation, use steel to reinforcethe concrete and finish the surface smoothly. Theconcrete foundation pad must be level within .25 inches(6.35mm) at all contact surface locations of the unit tothe pad. Where equipment headroom allows, it maybedesirable to elevate the portions of the housekeepingpad just where the chiller’s mounting feet are. Thiswill provide additional clearance under the unit formaintenance and cleaning purposes. For foundationsizes, footprints and unit dimensions, See YORKInternational forms 155.16-PA1.1 and 155.16-PA1.2.UNIT SHIPMENTSThere are two types of shipments for the YORK Iso-Flow units, One-piece or two-piece. Model sizes 1A1through 10E3 are shipped standard in one piece (completelyassembled). Model sizes 12F1 through 14F3are shipped in two separate sections, which requirefield assembly at the jobsite.Unit Models 12F1 through 14F3 are assembled at thefactory for fit-up then separated for shipment. TheCondenser/Generator top shell is one piece and theAbsorber/Evaporator bottom shell is the other.An option is available to have any size unit ship asa two-piece, if specified at the time of factory ordersubmittal. However, if the unit model is smaller thana 12F1, the unit will ship as one-piece but will beseparable at the jobsite, for a two-piece rig into thebuilding.Shipments outside of North America will normally beshipped without a solution and refrigerant charge. Theshells will have a nitrogen holding charge. All otherunit shipments will normally be uncharged and in avacuum.All split ship (two-piece) units will be shipped witha nitrogen holding charge.Depending on the unit shipping instructions, therewill usually be two wooden crates of ship looseitems included with the unit shipment. One cratewill contain miscellaneous unit materials necessary tocomplete the unit re-assembly and or start-up. For anitemized listing of what is included in the ship looseitems, see the “Ship Loose Items List” found in YORKform 155.16-RP3. The other crate will contain a unitcontrol valve, if ordered with the unit.SOLUTION AND REFRIGERANT SHIPMENTNorth America and Canada orders. YORK FactoryCustomer Service will place an order with the solutionsupplier and send a release form to the local YORKservice office responsible for the chiller start-up.The local YORK Service office is then responsiblefor completing and forwarding the release form tothe solution/refrigerant supplier 2 weeks before theyrequire shipment.2YORK INTERNATIONAL 11

IntroductionFORM 155.16-N3 (904)International orders. If the solution and refrigerantis purchased with the unit, YORK Factory CustomerService will place an order with the solution/refrigerantsupplier. The solution and refrigerant will ship inbarrels with the chiller to the port for packaging andconsolidation. If the solution and refrigerant were notordered with the unit, the local YORK Service officewould be responsible for obtaining this.INITIAL INSPECTION OF UNITSee Appendix B of this document for a “ReceivingInspection Checklist”. This document must be fi lledout during the initial inspection and given to the localYORK Service offi ce upon completion. It is advisableto have a YORK Service Technician on site during theinitial unit inspection process.The unit should be checked on the trailer or rail carwhen received and before unloading, for any visiblesigns of damage. Any signs of damage or possibledamage must be reported to the transportationcompany immediately! Negating this step if unitis damaged during transit could result in the unitwarranty being void!YORK will not be responsible forany unit damage during shipmentor at the jobsite during installationor rigging.Make sure all pieces of the shipment, such as boxesand crates are received with the unit. The solution andrefrigerant charge is usually not part of the initial unitshipment; normally these materials must be ordered byrequisition, contact the local YORK office when thesematerials are required.If the unit is a one-piece shipment, a pressure gaugewill be mounted directly off the unit’s Purge Systemline on the lower shell. If a two-piece shipment isreceived, an additional pressure gauge will be installedat one of the pipe closure plates on the upper shell.The gauge(s) must either read a vacuum or a pressuredepending on the type of shipment. If any gauge(s)indicates “0”, notify the local YORK Service officeimmediately. Bring the unit into the building as soonas possible after it has been off loaded.A “Field Material Catalog” can be found in with theunit’s ship loose parts. This catalog is a pictorial listingof all parts that were shipped with the unit before itleft the YORK factory. Use this catalog along withthe unit’s package list to identify and determine if allship loose items arrived with the unit. Any missing ordamaged ship loose items must be reported to thelocal YORK Service immediately!12 YORK INTERNATIONAL

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Unit RiggingFORM 155.16-N3 (904)SECTION 3UNIT RIGGINGUnder no circumstances shouldthe unit internals be opened to theatmosphere during the riggingoperation.If the unit has skids, remove them before setting theunit into its final position. If the unit is to receiveneoprene pads, set the unit squarely on the pads asshown below.ONE-PIECE UNIT LIFTSSee Appendix A in this document for complete andpartial unit weights.When lifting the complete unit, use a spreader barequal to or greater in length as the unit. Keep thechains vertical! Attach the chains at the Absorber/Evaporator endsheets lifting holes as shown in Fig.4.DO NOT lift a one-piece unit from asingle point as shown in Fig. 5. Damageto the external unit componentsmay occur.Care should be used at all times during the rigging andhandling of the unit to avoid damage to any projectingbrackets, pipes, fittings, or any apparatus. Thesecomponents may be damaged under the weight of theunit when lifted. Keep the unit Horizontal and levelat all times.Do not rig the unit in a vertical position,the unit must be kept horizontalduring the entire rigging operation!The unit is not designed to be in avertical position. Internal unit damageand/or personal injury may result.Do not attempt to lift the complete unitvia the holes located in the top shell!These holes are plugged at the factory– Do not unplug these holes for anyreason! Lifting from these holes willnot support the entire weight of theunit and personal injury and/or unitdamage will result!*Compressed Thickness of Isolation Pad AssemblyFIG. 1 – UNIT NEOPRENE PADSLD00936TWO-PIECE UNITSSee Appendix A in this document for complete andpartial unit weights.All units have the option of being a two-piece unit. Thismeans the unit will ship in one piece but will allow forseparation at the jobsite for a two-piece rigging into thebuilding. Some of the larger model units, due to theirphysical size, always ship in two pieces, these units aremodel sizes 12F1 through 14F3.When lifting the bottom shell of the unit, attach thechains at the Evaporator/Absorber endsheets liftingholes as shown in Fig. 6.When lifting the top shell of the unit, attach thechains at the Condenser/Generator endsheets liftingholes as shown in Fig. 7.Care should be used at all times during the rigging andhandling of the unit to avoid damage to any projectingbrackets, pipes, fittings, or any apparatus. These componentsmay be damaged under the weight of the unitwhen lifted. Keep the unit Horizontal and level atall times.14 YORK INTERNATIONAL

FORM 155.16-N3 (904)Do not rig the unit in a vertical position,the unit must be kept horizontal duringthe entire rigging operation! Theunit is not designed to be in a verticalposition. Internal unit damage and/orpersonal injury may result.Place the lower shell on the foundation pad. Disconnectany skidding from the upper shell and rig usingspreader bar and hooks into the end sheets holes. Hoistthe top shell assembly into position above the bottomshell assembly. Refer to Figure 2.Make sure the ends of the top shell assembly are in thecorrect orientation. See note below.Match identification numbers arestamped on each shell end sheet. Donot mismatch the upper and lowershell assemblies!The inside end sheets of the top and lowershells have a mounting angle bracket with mountingholes installed at the factory. Using two tapered pins(supplied by others) at opposite corners, align thebrackets and carefully set the top shell on the lowershell. Install the four factory supplied bolts and nuts tohold the shell assemblies in place. Refer to Figure 2.(6.35mm) at all four unit contact locations with thepad. If the concrete foundation pad is not level withinYORK’s requirements, metal shims may be placedbetween the bottom of the unit feet and the concretepad to compensate. Do not place any shims betweenthe top shell and the lower shell.Steam UnitsWhether the unit is shipped as a one-piece or two-piece,the mounding feet on the lower shell at the steam inletend are 1/2" (12.7 mm) thicker than the mounting feetat the steam outlet end. The steam inlet end is alwayson the right when looking at the unit control panel.This design allows for generator tube drainage duringunit operation in the event of wet steam.Hot Water UnitsThere is no inclination on hot water units. Unitlevelness can be checked by placing a level on the topshell for longitudinal alignment and on the top surfaceof the end sheets for transverse alignment.Neoprene PadsYORK IsoFlow units are quiet and operate free ofvibration. Normally the unit will not require fastenersinto the concrete to hold the unit in place. YORK doesoffer neoprene isolator pads to set the unit on if theunit is going to be installed in an area where even mildnoise would be objectionable. If the unit is to set onneoprene pads, the unit mounting feet must make directcontact with the neoprene. If shims must be used, theymust be placed between the concrete and the neoprenepad. Please keep in mind that total pad compressionwill not take place until the unit is fully charged withsolution and refrigerant and each tube bundle section iscompletely filled with fluid.3Mounting AnglesFIG. 2 – MOUNTING ANGLESLD09452UNIT LEVLING AND MOUNTINGYORK IsoFlow units do not have any leveling markson the unit. Do not attempt leveling the unit bycorresponding locations on the unit.Leveling is accomplished by setting the unit on aflat, level surface of the foundation pad as describedin SECTION 2, “Foundation” in this document.The foundation pad must be level within .25 inchesFloor to be level within 1/4" (6.35 mm). Place optional isolation padssquarely under all four unit feet. No bolting to fl oor required. Approximateheight after defl ection is 3/4" (19 mm).FIG. 3 – ISOLATION PADSLD00936YORK INTERNATIONAL 15

Unit RiggingFORM 155.16-N3 (904)Spring IsolatorsSpring-type vibration eliminating mountings are notnecessary the therefore not recommended. If the unitis being installed in a seismic restraint area, YORKrecommends seeking the advise of a professionalvibration consultant for mounting requirements.Unit MountingDue to the nature of operation, YORK IsoFlow units donot normally require bolting down. Simply set the uniton a level surface according to the recommendations inSECTION 2, “Foundation”, in this document.Spreader BarLifting HoleLifting HoleLifting HoleEvaporator/AbsorberEndsheetLD09453FIG. 4 – CORRECT ONE-PIECE UNIT LIFTING METHOD16 YORK INTERNATIONAL

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Unit RiggingFORM 155.16-N3 (904)ONE-PIECE SHIPMENTSLD09455LD09456FIG. 5 – INCORRECT ONE-PIECE UNIT LIFTING METHODS18 YORK INTERNATIONAL

FORM 155.16-N3 (904)TWO-PIECE SHIPMENTS(BOTTOM SHELL)3Chain angle must be 60°or less.≤ 60ºLD09457FIG. 6 – EVAPORATOR/ABSORBER CORRECT LIFTING METHODSYORK INTERNATIONAL 19

Unit RiggingFORM 155.16-N3 (904)TWO-PIECE SHIPMENTS(TOP SHELL)Chain angle must be 60°or less.≤ 60ºLD09458FIG. 7 – CONDENSER/GENERATOR CORRECT LIFTING METHODS20 YORK INTERNATIONAL

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Unit Re-AssemblyFORM 155.16-N3 (904)SECTION 4UNIT RE-ASSEMBLYTWO-PIECE SHIPMENTSUnits shipped in two pieces require field welding toreconnect the piping between the upper and lowershells.Notify the local YORK ServiceOffice before proceeding with theunit re-assembly. Do not open theunit to expose the interior surfacesto atmospheric conditions unless aYORK Service Technician is present.YORK must provide guidance andsupervision during the welding, reassembly,and leak check process.All YORK units are shipped in eithera vacuum or a nitrogen holdingpressure. The YORK ServiceTechnician can instruct how to bringthe unit to atmospheric pressure.Do not open the unit to atmosphericpressure without YORK’s guidance.YORK factory installs pressure gauges on each shellsection (total 2 for each unit). These gauges will indicatewhether the unit is in a vacuum or pressure. Two-pieceunit shipments will always be pressurized.PURGEDRUMFIG. 8 - BREAKING UNIT PRESSUREPROCEDURES:U-TUBEMANOMETERLD100741. Open the service valves and read the pressure.2. Close the service valves and remove the factorysuppliedpressure gauge.3. After the gauge has been removed, slowly open theservice valves again to discharge the pressure fromthe shells.For safety reasons, do not openthe valves to a complete full openposition.BREAKING THE UNIT PRESSUREThere are two standard forms of shipment for YIAunits: one piece or two-piece (sometimes called,Split Shipment). Units shipped as one piece withdestinations in North America are shipped unchargedand in a vacuum. Units with overseas destinations andtwo-piece shipments will be shipped uncharged with anitrogen holding pressure. A service valve with pressureindicator will be attached to the purge piping of the lowershell and off a closure plate on the upper shell. (Referto Figure 8) The following are procedures for breakingthe unit pressure.4. Close the service valves when the unit pressureapproaches atmospheric pressure (~ 0.5 psig, 3.4KPa).UNIT RE-ASSEMBLYFor a detail of what pipes and unit connections arerequired for each unit model, please refer to AppendixA of this document. Read the notes carefully on theappropriate figures to determine how many lines requirewelding and what is included in the unit’s ship looseparts.All factory pipe connections will have factory weldedclosure caps or flat plates that will require removal inthe field. When removing the closure caps or flatplates, always grind these enclosures from the pipes.DO NOT CUT INTO THE PIPE. Each pipe is at the22 YORK INTERNATIONAL

FORM 155.16-N3 (904)correct length to accept the factory supplied filler piece.Cutting into these pipes will shorten the length and animproper connection will result.Carefully remove all debris from the filler pieces, fittings,and sections of pipe before installing on the unit.Care must be taken to keep dirt andother foreign matter out of the unitduring the grinding and welding processes.If there is any delay in thework and the pipes will be open for along period of time, tape the ends ofthe pipes shut and apply a nitrogenblanket to the unit.When welding in the filler pieces, all welds must be fullpenetration welds. To achieve full penetration welds,grind both sides of each joint to a 75° angle prior towelding . Leave a small gap (~3/32 – 5/32”) (2.5 – 4mm)between the two mating parts.NEVER USE BACKUP RINGS FORANY JOINTS. For field weldingdetails ask for YORK form 155.17-M3.The leak check method used must, at minimum, becompleted with an Electronic Halide leak detectiondevice. This leak check must be completed or supervisedby a qualified YORK Service Technician.Testing by soap or vacuum decay isnot a recommended method for leakchecking.INSTALLING THE ABSOLUTE PRESSURE GAUGEThe Absolute Pressure gauge and a 1/4" copperconnecting line can be found within the unit’s shiploose parts container. The following are proceduresfor installing the Absolute Pressure Gauge.PROCEDURES:1. Locate the Absolute Pressure Gauge and inspect itfor any damage.2. Place the Absolute Pressure Gauge on the bracketlocated on the lower shell near the Purge Pump OilTrap. (Refer to Figure 9)4All weld root passes and second (hot) passes must bemade using Gas Tungsten-Arc Welding commonlycalled TIG. The purpose of using TIG for the first twopasses is primarily to provide a smooth gap free surfaceon the inside of the pipe. Historically it is impossible toachieve the gap free surface using Shielded Metal Arc(commonly called stick) welding.PURGEDRUMU-TUBEMANOMETERNever use any type of oil on any materials, tools orsurfaces that may come in contact with the internals ofthe absorption unit. Oil in the system could seriouslyhinder the units performance.Do not do any welding on the shellvessels of the unit. Doing so may voidthe unit’s factory warranty!Every field weld MUST be leak checked before unitcommissioning can begin.FIG. 9 - MANOMETER CONNECTIONSLD098163. Install the Absolute Pressure Gauge on the bracketusing two #10-24 UNC x 1 inch flat head machinescrews and hex nuts. The mounting hardware isincluded with the ship loose parts.4. Make sure the Absolute Pressure Gauge is absolutelyvertical by placing a level on the side edge of thegauge.5. Tighten the mounting screws and nuts securely.6. Close the Isolation Ball Valve.YORK INTERNATIONAL 23

Unit Re-AssemblyFORM 155.16-N3 (904)7. Remove the factory-supplied pressure gauge fromthe valve outlet, if not already completed.8. Install the two factory supplied flare connectors, oneinto the Absolute Pressure Gauge connection and thesecond into the valve outlet. (Refer to Figure 9)9. Connect the 1/4" copper line between the two flareconnectors.10. Tighten the connectors securely.PURGE PUMPSUCTION INLETOILTRAPCHECKVALVECOMPLETING THE PURGE PUMP CONNECTIONSThe purge pump is factory mounted and wired on allYIA units. The following are procedures for the PurgePump connections.FIG. 10 - PURGE PUMP CONNECTIONSLD09815PROCEDURES:1. Carefully remove the shrink-wrap from the PurgePump.The only required connection is to connect the PurgePump suction inlet to the unit. The line is a 3/4" IDclear, wire-enforced hose that is included with theship loose parts.2. Connect the Suction line onto the suction portconnector located at the top of the Purge Pump withthe factory supplied hose clamp. (Refer to Figure10)DISCHARGEPORTSUCTIONPORTOILTRAPCHECKVALVEGAS BALLESTIt is NOT recommended to use any oil,or vacuum grease on the line to makethe assembly easier.LD098173. Install the other end of the Suction line over a factoryinstalled pipe nipple. The pipe nipple is threaded,into a check valve, just below the oil trap. (Referto Figure 10)FIG. 11 - PURGE PUMP4. Remove the pipe cap on the nipple and discard.5. Tighten the Suction line over the nipple with a factorysupplied hose clamp. (Refer to Figure 10)24 YORK INTERNATIONAL

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Unit Water PipingFORM 155.16-N3 (904)SECTION 5UNIT WATER PIPINGUNIT WATER PIPINGOnce the unit is placed on the foundation pad and leveledaccording to YORK’s recommendations, the customer’spiping connections may be fitted to the unit.YORK International does not mandate that any specificpiping codes be followed for the unit’s water pipingfabrication. However good piping practices shouldbe followed for best results. YORK recommends theresponsible parties for the piping fabrication check tomake sure all, if any, local codes be followed during thesystem piping fabrication.The absorber, evaporator and condenser tube bundlescome from the factory rated for 150 PSIG (10 Bar)designed working pressure (DWP) on the tubeside ofthe bundle. The water connections (nozzles) will be apipe stub suitable for Victaulic couplings or welding.Tube bundles can also be specially ordered for 300 PSIG(21 Bar) DWP. Also, raised faced, ANSI flanges for thewater connections can be supplied if ordered with theunit. When flanges are specified, they are selected inaccordance with the design pressure of the vessel.The nozzle diameter is based on the customer’srequirements. The local YORK Sales office can provideinformation on the sizes of the nozzles, the DWP of thevessel and whether or not the unit will have flanges, ifnot known.GENERATOR NOZZLE CONNECTIONSRefer to the following tables for the unit’s generatorDWP and nozzle connections. The standard is alwayssupplied unless a special option is ordered from thefactory.Hot Water units shipped to USA, Europe andthe rest of the world:GENERATOR SECTION DWPStandard 150 psig (10 Bar)Option 300 psig (21 Bar)GENERATOR CONNECTIONSStandard Pipe stub w/Victaulic grooveOption ANSI, RF FlangesHot Water units shipped to Germany:GENERATOR SECTION DWPStandard 150 psig (10 Bar)Option 300 psig (21 Bar)GENERATOR CONNECTIONSStandard Pipe stub w/Victaulic grooveOption N/ASteam units shipped to USA, Europe and therest of the world:GENERATOR SECTION DWPStandard 150 psig (10 Bar)OptionN/AGENERATOR CONNECTIONSStandard 150 psi ANSI, RF FlangesOption N/ASteam units shipped to Germany:GENERATOR SECTION DWPStandard 150 psig (10 Bar)OptionN/AGENERATOR CONNECTIONSStandard Pipe stub w/Victaulic grooveOption N/AFor Hot water units shipped to USA, Europe andthe rest of the world. The supplied flange ratingwill be in accordance with the vessel DWP. Othersmust obtain all gaskets required for completingflange connections.When connecting the piping to the unit nozzlestake note to which nozzle is the inlet and whichis the outlet. Factory supplied labels will identifyall unit nozzles. First the tower water return linemust be piped into the absorber nozzle. The towerwater supply line will come off the condenseroutlet nozzle.All water piping MUST be adequatelysupported and braced independentof the unit. NO STRAIN IS TOBE PLACED ON THE UNITNOZZLES AND/OR CONNECTIONFLANGES.26 YORK INTERNATIONAL

FORM 155.16-N3 (904)All unit system piping must be arranged with offsetsfor flexibility and movement. All piping must befabricated so that water box removal can be facilitatedeasily. Installing a set of flanges close to the water boxnozzles may do this. All piping must be adequatelysupported and braced independently of the unit toavoid strain on the unit and vibration transmission.Hangers must allow for alignment of pipe. Isolators(supplied by others, if required) in the piping are notnecessary but may be desirable in some cases.PIPING COMPONENTSWells For SensorsVarious temperature and pressure sensors are requiredfor building and tower water circuits. Please make sureboth the supply and return lines to the unit have theseconnections installed. Seek the advice of the systemspiping engineer if uncertain about the proper locationor sizing of these wells.Chilled Water Flow SwitchA chilled water flow switch is supplied as a ship looseitem from the factory. This devise can be found amongthe unit’s shipped loose parts. It is recommended thatthe flow switch be installed in the leaving chilled waterline (as depicted in the following figure). YORK highlyrecommends the mounting of this switch in a horizontallength of pipe with the switch in a vertical position. Itis NOT recommended to mount the flow switch in avertical pipe with an upward flow due to the fact thatminimum flow may not be substantial enough to liftthe switches paddle. Please see the following figure foradditional assembly and installation guidelines of thisdevice.Tower Water (Condenser) Flow SwitchThis switch may or may not be supplied by the factorybut it is required for proper unit operation. If the YORKfactory supplies it, it will be found within the unit’sshipped loose parts container. Please follow the sameassembly and installation guidelines for this device asyou did the chilled water flow switch.5ITEMDESCRIPTION1 Switch, Flow Control2 Coupling, Pipe, 1” x 1” Lg.3 Compound, Heat ConductiveNOTES:1. Adjust the Flow Switch Paddle to the sizeof the pipe in which it is to be used. Trimex tend ed paddle to the “L” di men sion asfol lows:DIAMETER OF PIPE “L” DIMENSION(INCHES) (INCHES)5 4-5/86 5-5/88 AND LARGER FULL PADDLE2. The Flow Switch is to be installed and upright,as shown.3. Screw the Flow Switch in position so thatthe paddle is at a right angle to the liquidfl ow. (Arrow mark on side of cast ing mustpoint in same direction as liq uid fl ow.)4. The Flow Switch must be installed in outletfl ow con nec tion of the bundle.5. Before installing Item 2 , make sure it is 1inch long maximum.FIG. 12 – INSTALLATION OF FLOW SWITCHYORK INTERNATIONAL 27LD09813

Unit Water PipingFORM 155.16-N3 (904)Differential Pressure ControlDifferential pressure control may be substituted in theplace of a flow switch. YORK has options for this type ofcontrol if the device is not purchased locally. Differentialcontrol serves the same function as a flow switch – toensure that flow is established for chiller operation. Thisis accomplished by determining a difference betweentwo sample points in the chiller’s water piping, usuallynear the inlet and outlet of a heat exchanger bundle. Itis very important that the pressure differential switchbe installed as close to the heat exchanger bundle aspossible so that only the pressure difference across thebundle is sensed. Do not put the pressure differentialswitch across the suction and discharge of a heatexchanger pump. Doing so may not absolutely ensureflow across the chiller bundle due to other piping valvesthat could be closed.Another important aspect to remember when using apressure differential switch is to ensure both the samplepoints are on the same elevation with each other. If oneconnection to the control is higher than the other, staticpressure becomes a factor in reading total differentialacross the switch. In this condition, the control couldpossibly read a difference in pressure even when noflow is present.StrainersPermanent strainers (supplied by others) are required inboth the tower water and chilled water circuits to protectthe chiller water bundles and controls. The strainershould be a #10 mesh and be installed in the enteringwater piping line, directly upstream of the chiller. Waterpiping circuits should be arranged so that the pumpsdischarge to maintain essentially constant chilled andtower water flows through the unit at all load conditions.If pumps discharge through the chiller, the strainer maybe located upstream from the pumps to protect bothpump and chiller. If pumps are remotely installed fromchiller, strainers should be located directly upstream ofthe chiller.Unit Crossover LineThe crossover line is a unit-mounted line that is the samediameter as the tower water (condenser) water lines.It serves the purpose of transferring the tower waterfrom the outlet of the absorber bundle to the inlet ofthe condenser bundle. THIS LINE IS ALWAYS FIELDFABRICATED. Others must obtain all fabricationmaterials. In some rare cases, the factory can supplythis line but it must be ordered as a special at the timewhen the chiller is ordered.YORK recommends the following for fabrication of theUnit Crossover line:1. The arrangement of this line must be made so thateasy access to the bundle tubes can be accomplished.For every time the Absorber/Condenser tube bundlegets cleaned, this line must be removed.2. The crossover line should be positioned so that theevaporator water boxes can be removed withoutremoval of this line. This may not be possible insome cases.3. The crossover line must be fabricated so that thepressure drop across the line is kept to an absoluteminimum! The average pressure drop shouldbe 1 psi or less. The following tips are suggestedto accomplish this:a. Use butt-welded connections. Do not useVictaulic connections other than at the unitnozzles.b. If the absorber and condenser nozzles are notthe same size, use a gradual reducer. Do not gofrom one diameter size to another abruptly!c. Use long radius elbows if possible.d. Make the line as short as possible.e. Do not use back-up welding rings.f. Use the couplings on the absorber outlet boxand condenser inlet box to check the pressuredrop across the line.The design working pressure rating on the crossoverline must be the same pressure rating as the remainderof the tower water system piping.Tower Water (Condenser) Bypass ValveThis valve is sometimes referred to as a three-waymixing valve. This valve is not a requirement, due tothe fact that IsoFlow units are capable of operating withentering tower water temperatures down to 45°F (7.2°C).However, YORK recommends installing this valve ifefficient chiller operation is desired. See Detail “A” onFig 13 for piping.The valve functions to keep a constant tower watertemperature to the absorption unit. It does this bymonitoring the tower water temperature just beforeentering the unit via an attached temperature sensor.28 YORK INTERNATIONAL

FORM 155.16-N3 (904)5FIG. 13 – INSTALLATION OF FLOW SWITCHLD09814The valve, located upstream, will open or close toallow warmer leaving tower water to mix with thecolder entering tower water to maintain a constanttemperature.COMPLETING THE PIPINGUpon completion of the piping, a connection in eachline as close to the unit as possible should be opened,by removing the flange bolts or coupling and check forpiping alignment. If any of the bolts are bound in theirholes, or if the connection springs out of alignment, themisalignment must be corrected by properly supportingthe piping or by applying heat to the anneal the pipe.If piping is annealed to relieve stress,the inside of the pipe must be cleanedof scale before it is finally bolted inplace.Foreign objects that could lodge in, or block flowthrough the chiller’s tubes must be cleaned or flushedbefore being connected to the chiller pumps, or otherequipment. Furthermore, when flushing the water piping,DO NOT flush through the chiller tubes. Make surethe chiller is out of the circuit when doing this operation.Otherwise, dirt, small particles and fabrication debrismay become lodged in the chiller bundles.All chiller water piping must beproperly cleaned and flushed beforeputting the unit into service!YORK will not be held responsiblefor failures or damages of any kindto the chiller or the piping due toconstruction debris in the chiller tubesand unit piping.SYSTEM PUMP CONTROLSince absorption chillers require a dilution cycle of anunpredictable amount of time, it is important that theunit’s control panel control the operation of the chilledwater and Absorber/Condenser water pumps.YORK INTERNATIONAL 29

Unit Water PipingFORM 155.16-N3 (904)YORK’s prescribed method to employ pump control isto hardwire the pump starter control circuit through theappropriate contacts on the relay board.Should a customer insist on using another device suchas an Energy Management System (EMS) to control thepumps, that device must turn on and off as a result of thisdirect interface with the contacts on the relay board.If there is a desire to interface the pumps with somedevice other than the unit control panel, that device mustreceive its instructions from the control panel and notfrom the EMS.YORK will not be responsible for anycosts associated with equipment problems,failures or damage due to YORKnot controlling the system pumps.Failure to adhere to the instructionsgiven in this section could result inevaporator tube freeze-up and unitcrystallization.As a minimum, the customer must monitor the drycontacts in the unit’s control panel and control his pumpsin response to these contacts opening and closing.30 YORK INTERNATIONAL

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Rupture Disk and Relief PipingFORM 155.16-N3 (904)SECTION 6RUPTURE DISK AND RELIEF PIPINGRUPTURE DISK AND RELIEF PIPINGThe ANSI/ASHRAE 15-2001 safetystandard code was recently revisedto include absorption chiller reliefdevices. Please read and followthese instructions closely to ensurethe chiller installation is compliantto the revised code.Both the steam and hot water IsoFlow units are fittedwith an ANSI/ASHRAE 15-2001 safety standard codecompliant pressure relief device. For IsoFlow units, thisdevice is a metallic, one time use, rupture disk burst ratedat 7.0 PSIG, +/- 2.0 PSI (48.2 kPa, +/- 13.8 kPa).Plastic stub to be removed30°The rupture disk will protect the chiller’s integrity shouldthere ever be a tube rupture or in the very unlikely eventthat the unit’s refrigerant vapor pressure gets too high.Unlike vapor compression cooling machines that relieverefrigerant vapor, if the rupture disk bursts, absorptionmachines could expel a vapor and a liquid.Liquid coming out of the rupturedisk could be in excess of 200°F(93.3°C)!The metallic disk is mounted at the factory betweentwo special flanges. The flanges have a knife-edgethat perforates a special flange on the disk to createan airtight seal. Do not loosen the bolts around theflange or remove the disk from the holder. If thedisk is removed for any reason, it must be replacedwith a new one! The outer flange of the disk holderhas a plastic pipe stub supplied by the factory forshipping purposes. THE PLASTIC STUB MUST BEREMOVED! Refer to Figure 14.FIG. 14 – PLASTIC PIPE STUBRupture Disk Discharge Piping MaterialLD09818ANSI/ASHRAE 15-2001 calls for the relief pipingmaterial to be compatible with the refrigerant in thesystem. The refrigerant is De-ionized water thatcould exceed 200°F (93.3°C) in some cases. YORKrecommends using schedule 40 steel pipe for the rupturedisk discharge line material.Rupture Disk Discharge Piping ConstructionFor the piping material, YORK recommends carbonsteel. The relief piping must be fabricated andconstructed in accordance with piping best practices.Follow any local codes (if applicable) governing therupture disk discharge relief piping. Due to the hightemperatures of an absorption unit during operation, andthe expansion and contraction associated with this, therupture disk vent piping must have a flexible connectionbetween the rupture disk outlet and the relief piping. Theinstalling contractor must supply the flexible connectionand the relief piping.32 YORK INTERNATIONAL

FORM 155.16-N3 (904)Piping supports must be spaced according to the pipematerial, size and temperature. At no time should therebe any weight or moment arm forces imposed on theflanges of the rupture disk!Rupture Disk Discharge Piping SizingThe sizing of the rupture disk discharge piping mustnot be less than the rupture disk diameter. Where two ormore relief devices are connected to a common line orheader the effect of backpressure that will be developedwhen more than one relief device operates shall beconsidered. The sizing of the discharge line for abovecondition must be based on the sum of each rupture diskoutlet area in addition to the pressure drop allowancethrough the outlet piping. Please see the appropriate tablein this section for the rupture disk outlet areas.Rupture Disk Discharge Piping LengthsThe maximum length of the discharge piping installedon the outlet side of the rupture disk discharging to theatmosphere must not exceed the equivalent length valvecolumn in the following table.LD09819FIG. 15 – RUPTURE DISK FROM FACTORY6DiskSizeMAXIMUM DISCHARGE PIPING LENGTH FOR SCHEDULE 40 STEEL PIPECapacityLbs air/minPPsi.Unit Models 1A1 Through 4B4NPSInIDInfDisk areasq. in.1-1/2 24.55 7.0 1-1/2 1.610 0.0202 1.623 19.121-1/2 24.55 7.0 2 2.067 0.019 1.623 77.551-1/2 24.55 7.0 2-1/2 2.469 0.0182 1.623 201.861-1/2 24.55 7.0 3 3.068 0.0173 1.623 637.89Unit Models 4C1 Through 10E32 47.50 7.0 2 2.067 0.019 3.140 17.882 47.50 7.0 2-1/2 2.469 0.0182 3.140 50.382 47.50 7.0 3 3.068 0.0173 3.140 165.772 47.50 7.0 4 4.026 0.0163 3.140 701.91Unit Models 12F1 Through 14F33 106.95 7.0 3 3.068 0.0173 7.070 27.633 106.95 7.0 4 4.026 0.0163 7.070 131.403 106.95 7.0 5 5.047 0.0155 7.070 444.833 106.95 7.0 6 6.065 0.0149 7.070 1175.38Notes:1) Length calculation per ANSI/ASHRAE 15-2001, Appendix HL *Ft.YORK INTERNATIONAL 33

Rupture Disk and Relief PipingFORM 155.16-N3 (904)Rupture Disk Discharge Piping Arrangementand LocationANSI/ASHRAE 15-2001 specifies the discharge pipingshall discharge to the atmosphere at a location not lessthan 15 ft above the adjoining ground level and not lessthan 20 ft from any window, ventilation opening, or exitin any building.The section of discharge piping that will see a liquidshould never be at an elevation higher than the unit.Doing so will impose an undesirable static headbackpressure, which the unit must first overcome beforerelieving the internal pressure within the unit.DESCRIPTION OF FIG 16:Depending on the situation of a rupture disk bursting,a vapor, liquid or both may be expelled out of the unit.If a vapor is expelled, it will travel up and out of thedischarge line. If a liquid expels out of the unit, it willflow into a holding tank that is sized to hold the completeunit’s refrigerant charge. If more liquid comes out ofunit than what the tank can hold, an overflow pipelocated near the top of the tank will expel liquid to afloor drain.There may be restrictions for discharging certaintypes of liquids into floor drains. Check with yourlocal water treatment company or sewer authorityfor possible restrictions in your area.Approximate Storage/Holding Tank Sizes.APPROX TANK SIZEUNIT FAMILYGALLONS (LITERS)A 50 (190)B 70 (265)C 90 (341)D 125 (473)E 200 (757)F 230 (871)RooflineMinimum 15' from Ground Level and20' from Nearest Building Opening.Flexible ConnectionPipingSupportThis Portion of theInstallation is Optional forChiller Liquid Retention.Tank Overflow PipeMinimum Diameter of PipeNot to Be Less than ReliefPipingSurge/Holding TankTotal Volume to HoldComplete RefrigerantCharge of UnitSee Appendix Tables forUnit Refrigerant Charge10 – 12 inchesFloor DrainFIG. 16 – RUPTURE DISK DISCHARGE PIPING ARRANGEMENTLD0982034 YORK INTERNATIONAL

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Inlet Steam PipingFORM 155.16-N3 (904)SECTION 7INLET STEAM PIPINGINLET STEAM PIPINGYORK Steam fired IsoFlow TM absorption unitsare designed for a maximum generator inlet steampressure of 150 PSIG DWP, (1.5 bar G if PED codeis specified), and a maximum steam temperature of337°F (169°C). The generator tubeside will be ASMEcoded unless otherwise indicated on the factory ordersubmittal.Since generator nozzle connections can vary, referto the Unit Water Piping section of this document todetermine which type of connection is supplied onyour unit.Steam piping should be designed inaccordance with good engineeringpractice. All field installed steampiping must be in accordance withall local, state, or federal codes thatmay apply.The steam inlet piping support system must becapable to adequately support the full weight of allpiping and components independent of the unit. Thesupport system must account for the expansion andcontraction of the steam piping. No imposing forcesor strains are to be on the generator inlet nozzle.All piping must be fabricated so that water boxremoval can be facilitated easily. If your unit’sgenerator nozzles are not supplied with flanges fromthe factory, a set of flanges installed in the steampiping close to the generator inlet will satisfy thisrequirement.INLET STEAM CONDITIONSPressureThe main steam supply may be either low-pressuresteam or high-pressure steam that is reduced to a lowpressure via a pressure reducing station or other process.The preferred steam quality is dry and saturated(D&S) with minimal superheat. The generator is designedfor latent heat transfer, increasing the sensibleheat by allowing higher steam temperatures will providelittle, if any, performance improvement. Sincesteam saturation pressure corresponds to a specifictemperature, an IsoFlow chiller’s available capacitywill vary greatly with the steam pressure at the inlet tothe generator. Steam pressure into the inlet nozzle of thegenerator should not exceed 14.0 PSIG (1.0 bar). Steamsupply pressure upstream of the unit control valve mustnot exceed 16.0 PSIG (2.1 bar). This will allow for atypical pressure drop through the control valve of 2.0psi (13.8 kPa). All pipe design and fabrication must bedone so the pressure drop is kept to a minimum.Generator operating pressure may notexceed the specified unit operatingpressure. Under no circumstances maythe chiller operate with steam pressureexceeding 14.0 psig (1.0 barG)! Doingso will over fire the unit and cause operationalproblems as well as shortenthe unit’s longevity!FlowSteam flow is equally important as steam pressure. Flowis usually measured in pounds per hour (lb/hr) or (liters/min). Each YORK IsoFlow chiller is rated at a specificsteam flow and pressure at time of unit selection. Itis very important that these values are maintainedthroughout the operational lifetime of the unit. Notadhering to this specification will drastically affectthe performance and longevity of the chiller.Consideration should be given to the steam flowvelocity, especially in applications where noise will be afactor. Generally speaking, steam velocities up to 6,000fpm (30 m/s) will not produce an objectionable noiselevel.Steam PurityIt is the responsibility of the customer to engage theservices of an experienced and reputable steam /condensate treatment specialist to constantly maintainthe purity. Improperly treated or maintained steam /condensate will result in decreased efficiency, highoperation costs and premature tube failure due to steam/ condensate side corrosion.Steam/condensate samples should be collected andanalyzed on at least a monthly basis by the treatmentspecialist. A quarterly review with the treatment suppliershould address the conditions of the steam systemsand develop action plans based on these analysis. Athird party consulting company can help oversee the36 YORK INTERNATIONAL

FORM 155.16-N3 (904)Generator inlet box1) Manual Block Valve2) Pressure Reducing Valve (PRV)3) Steam Strainer4) Steam Desuperheater5) Steam Separator6) Automatic Shut Off Valve (If Applicable)7) Steam Control Valve8) Safety Relief ValveP = Pressure gauge 435678PMinimum 5 pipe diameters straight lengthP2P1PPSupply line to pitch upward into thegenerator nozzle.Main steam supply lineFIG. 17 – STEAM PIPING ARRANGEMENTLD09821treatment programs in order to properly protect thephysical plant and avoid costly downtime.It is equally important that the customer of theequipment perform an inspection of the generator tubesat the frequencies recommended in the preventivemaintenance schedule located in manual 155.16-OM1.In addition to periodic cleaning with tube brushes,tubes must be inspected for wear and corrosion. Tubefailures usually occur due to corrosion, erosion, andfatigue due to thermal stress. Eddy current analysisand visual inspection by boroscope of all tubes areinvaluable preventative maintenance methods. Theseprovide a quick method of determining waterside /steam generator tube condition at a reasonable cost.STEAM PIPING ARRANGEMENTRefer to Figure 17 for the proceeding discussion andcorrect placement of the steam inlet components.Steam piping mains, condensate pipes and the steamline to the unit must be properly sized in accordancewith the required unit full load steam flow rate andacceptable pressure drops. The steam inlet pipingshould avoid sharp curves and abrupt piping sizechanges. Whenever possible, the steam supply lineto the unit should be taken off the main steam supplyline from the topside to minimize the possibilityof condensate carry-over into the unit. Both steamsupply and condensate pipes must be properly sizedand pitched to prevent liquid hammering. YORKrecommends a straight length of pipe approximately 5to 10 pipe diameters long just before the steam entersthe generator.INLET PIPING COMPONENTSManual Block ValveThe Manual Block Valve is required to manuallyshut off steam supply to all devices downstream forserviceability (refer to Figure 17). This valve is oftenclosed during prolonged chiller shutdown periods toprevent steam flow into the generator bundle. A tapmay be installed just downstream of this valve to allowfor draining the condensate from the steam line. TheManual Block Valve must be bubble tight to ensure noleakage of steam.Pressure Reducing Valve (PRV) (If Applicable)The pressure-reducing valve reduces high-pressuresteam to a lower pressure. A pressure reducingstation will also act to help steady fluctuating steam7YORK INTERNATIONAL 37

Inlet Steam PipingFORM 155.16-N3 (904)pressures. As a general rule of thumb, if the steampressure fluctuates more than 5 lbs (1.3 bar A) it isrecommended to incorporate a pressure reducingstation. When selecting a pressure-reducing valve, itshould be sized on the basis of the pressure drop at theunit’s full load design steam conditions. Do not sizethis valve based solely on the pipe size. The valvemust be suitable for dead-end service.The pressure-reducing valve should be provided withstop valves and pressure gauges on both the inlet andoutlet sides of the valve. A full size bypass with a globevalve will permit manual operation during maintenanceperiods.Two pressure reducing valves; one large and one small,piped in parallel may be desirable for those applicationswith continued operation at low loads or where highlyvariable upstream pressures exist. The smaller valvewould be set at a slightly higher pressure than thelarge valve so it will stay open at low flow rates whilethe larger valve closes, thus protecting the seat of thelarger valve. The use of a two-step steam pressurereduction method may be desirable on applicationswith pressure differentials in excess of 100 psig (8.0bar A). Furthermore, the noise generation in a singlestep pressure reduction system may be objectionable.Steam StrainerA fine mesh steam strainer (#50 mesh) is used tocapture any impurities in the steam supply line. Theseimpurities may manifest themselves in the form ofdirt, rust, or precipitates. This strainer will preventthe chiller system components form getting plugged.Plugged components will reduce system capacity andincrease maintenance costs. A pressure gauge must beinstalled just before and after the steam strainer. If thepressure drop as read from these two gauges increasesto an unacceptable level, the steam strainer should beremoved and cleaned.Steam Desuperheater (If Applicable)Latent heat at saturation temperature is much larger thanthe sensible heat that is extracted when superheatedsteam cools down. Therefore, superheated steam haslittle benefit to the absorption process. For this reasonsuperheated steam should be kept to a minimum.In some applications, high-pressure steam expandingthrough a pressure-reducing valve can be at an undesirablehigh temperature, which is not recommendedfor use in the absorption process. In these cases a desuperheatermust be incorporated to reduce the steamtemperature before entering the unit.Damage to the unit and/or chillerwarranty will be VOID if the steamtemperature exceeds YORK’s specifiedrecommendations.The desuperheater must be located downstream of thepressure reducing valve, if one is utilized. The flow ofcoolant to the desuperheater should be automaticallycontrolled to maintain a constant steam supplytemperature to the absorption unit within the designlimits specified. Suitable automatic means shouldbe provided to remove any condensate that mayaccumulate within the desuperheater. This task couldalso be accomplished by a steam separator locateddownstream of the desuperheater. Care should be takento ensure that the desuperheater is installed accordingto the manufacturer’s recommendations.Steam SeparatorAll IsoFlow absorption chillers must operate with onlydry steam entering the generator section. Wet steamwill lessen the heating content of the steam, whichin turn will affect unit performance. Wet steam mayalso cause excess tube erosion or water hammer. Bothof these conditions could be detrimental to generatortubes or steam piping components. If dry stream can besupplied to the chiller with minimal superheat, it maynot be necessary to install a steam separator. In caseswhere a desuperheater is utilized and the desuperheaterdoes not automatically remove liquid condensate, asteam separator must be installed.The steam separator is installed in the steam supply linedownstream of the desuperheater. It is used to separateany liquid present in the steam after leaving thedesuperheater and before entering the unit. All trappedcondensate liquid should normally be piped through asteam trap before going back to the condensate tank.The steam trap will prevent any steam from blowingthrough the separator into the condensate returnsystem. The use of a steam separator and trap willensure only dry steam to enter the unit at all times38 YORK INTERNATIONAL

FORM 155.16-N3 (904)Automatic Shut-Off Valve (4SOL)(If Applicable)This valve may not be necessary for all IsoFlow units.It is only recommended if the unit is steam-fired andDOES NOT have a spring-return, fail-closed controlvalve .If a power failure occurs, a non-spring return unitcontrol valve will remain in whatever position ithappened to be in at the time of the power failure.However, at the same time the automatic shut-offvalve will close due to the power loss. Since the steamboiler will emit steam for an undetermined period oftime. This valve will prevent the steam from enteringthe unit, protecting it from crystallization during thisperiod. Please see the note in this section for moreinfo.As stated above, this valve is recommended by YORKto help protect the unit from crystallization. It is underthe discretion of the customer or his representative tosupply and install this valve. The valve type is notcritical as long as it meets the following.The Valve’s size is usually the same size as the steaminlet line; however, sizing determination must bebased upon the steam system design, application andcondition. Valve wiring will originate in unit-mountedjunction box 3, (JB3) terminals 2 & 5. The coil shouldbe 120 volts, 60 Hz, a transient suppressor must bewired in parallel with the coil. Maximum allowablecurrent draw is 1 amp holding, 10 amps inrush. Pleasesee YORK wiring form 155.16-W4 for more detailson the wiring and voltage. The valve must be a NC,bubble-tight (100% tight shut off), designed to keepthe pressure drop through the valve to a minimum.The valve’s closing time should not exceed 2 minutes.The Automatic Shut-off valve offersthe lowest form of protection fromcrystallization in the event of a shortinterval of power loss. It will notprotect the unit from crystallizationduring long extended periods of powerloss.Steam Control ValveThis valve is selected and supplied by the YORKfactory unless otherwise specified on the chillerorder. If not supplied by YORK factory others mustsupply the control valve. If this is the case, the YORKfactory will not be responsible for the valve orconsequential equipment damage if not supplied bythe YORK factory. If supplied by the factory, it willbe found among the unit’s ship loose parts. The controlvalve assembly consists of a valve, positioner andactuator. A separate set of installation and operationinstructions will be packaged along with each valvefrom the valve’s original manufacturer. Please makesure these instructions are kept safe for future use.All personnel involved in the installation of thecontrol valve must read and understand the safety andinstallation instructions.The valve controls the steam flow into the unit andis wired to unit-mounted junction box 3, (JB3). Themicropanel will throttle the valve open or closedbased upon the customers cooling load demands and/or built-in unit safety controls. All YORK suppliedsteam valves are two-way valves of either the cage orbutterfly design. Cage valves have a fail-safe, springreturnfeature included within the actuator. If loss ofpower is experienced the valve will fail-closed. TheYORK supplied butterfly type control valves do nothave the fail-safe, spring-return closed feature. Pleasesee the previous discussion under “Automatic shut-offvalve” for these installations.DO NOT under any circumstancesremove the factory-sealed screws onthe type 3274 actuator case cover.Opening this cover will render thevalve assembly inoperative!Steam Control Valve InstallationThe valve will mount between flanges that are to besupplied by others. Please note the valve body size andpressure rating before selecting the mounting flanges.Also note the flow direction arrow as indicated on thevalve body before inserting between the flanges. Thevalve assembly must be installed in a location whereambient temperatures are between 0 to +140 deg F (-20to +60 deg C). If high temperature fluctuations or highhumidity will be a factor, it is suggested that a heatingresistor be fitted to prevent the buildup of condensationwithin the actuator enclosure.Steam Control Valve WiringYORK supplies the control signal wiring to the valve,however YORK DOES NOT supply the power wiringto the control valve. For the power wiring, YORK7YORK INTERNATIONAL 39

Inlet Steam PipingFORM 155.16-N3 (904)recommends the following: #18 AWG, AWG dia0.049, UL or CSA (nom) 1620 with 16 strands, 600volt rating, AWM/UL style 1015. Insulation withminimum temp rating 105 deg C, nominal thickness2/64, color white for the wire #2 because it will bethe neutral and black for the other wires. These wiresshould be routed using 1/2" (12.7 mm) metallic flexibleconduit and appropriate fittings at each end. The lengthis determined by how far the control valve is mountedfrom the JB3 terminal box, which is mounted on theright side of the unit.Steam Control Valve Orientation & PlacementThe normal arrangement for all actuated controlvalves is to install the valve in a horizontal line withthe actuator vertical above the valve. Other positionsmay result in uneven valve plug and cage wear andimproper operation. If the actuator is not completelyvertical, it may require additional support to keep theweight off the valve body. Never install the controlvalve actuator where condensate could drip or flowinto it. It is NOT RECOMMENDED to mount theNo installation is permitted where actuator isbeneath the centerline of the steam line or wherecondensate could drip or flow down into actuator.Do not mount actuator so that it’s cover pointsdownwards.FIG. 20 – PSQ ACTUATOR ORIENTATION9-1/2” (243 mm)LD09824No installation is permitted where actuator isbeneath the centerline of the steam line or wherecondensate could drip or flow into actuator.FIG. 18 – 3274 ACTUATOR ORIENTATION> 6” (150 mm)LD09822FIG. 21 – PSQ ACTUATOR INSTALLATIONCLEARANCESLD09825control valve in a vertical line.YORK recommends that the Steam Control Valve notbe installed more than 10 feet (3 meters) away fromthe generator inlet nozzle. Pressure drops may resultfrom greater installation distances. Refer to Figure22, 23, 24, 25 and 26 for the 3274 or PSQ Actuatororientation to the steam line.> 12”(300 mm)FIG. 19 – 3274 ACTUATOR INSTALLATIONCLEARANCESLD09823Safety Relief Valve(Supplied by Others)A safety relief valve must be mounted between theunit’s control valve and the generator inlet steamconnection. The purpose of the relief valve is to ensurehigh-pressure steam does not enter the generatortubes.40 YORK INTERNATIONAL

FORM 155.16-N3 (904)The valve must be a rapid opening, self-closingvalve, sized and designed for the specified pressure,temperature and flow of steam into the unit. This valvemust not be used to control steam pressure into theunit.The relief valve MUST NOT; UNDER ANYCIRCUMSTANCES be set for pressures higherthan 15.0 psig (2.047 bar A). Although the setpressure should be high enough to allow the valve toremain closed during normal chiller operation. Followthe valve’s manufacture’s recommendations and allapplicable codes for installing and venting the safetyrelief valve.Even though the generator tubes are designed for ahigher pressure, the saturation temperature of steamat 15.0 psig (205 kPa) is appropriate for proper chilleroperation. Exceeding this pressure, large amounts ofsuperheat or greater flow than design could cause theunit to overfire. This in turn could result in inefficientoperation, unit failure or damage to the unit.Damage to the unit and/or chillerwarranty will be VOID if the steamdesign conditions are not adhered toduring chiller operation.7A relief valve is not required if thereis a properly sized relief valve onthe boiler of a low-pressure steamsystem.YORK INTERNATIONAL 41

Steam Condensate Return SystemFORM 155.16-N3 (904)SECTION 8STEAM CONDENSATE RETURN SYSTEMSTEAM CONDENSATE RETURN SYSTEMThe following descriptions of the basic types andapproaches used in condensate return systems.This section does not describe the fine details of theproper condensate system design. Because of thelarge number of variables, an experienced individualknowledge in steam piping systems, fluid flow and allcode requirements must address this on an applicationspecific basis.The chiller’s steam condensate return system isdesigned for the purpose of removing condensate fromthe absorption unit’s generator and returning it to theboiler. An Inefficient or poorly designed condensatereturn system could interfere with steam flow throughthe unit causing poor chiller capacity and damage tothe unit.Before a discussion of condensate return systems, itwould be beneficial to the reader to have a generalunderstanding of the YORK single-stage absorptionunit operating requirements and characteristics.The absorption chiller will operate at full load steampressure in the 9 to 12 PSIG (62 to 88 kPa) range, downto pressures well into the vacuum region at part loads. Asthe cooling load decreases, the micropanel will throttlethe steam control valve closed, hence reducing the steamflow and pressure into the generator section of the unit.At some part load point, say 50% for illustration, thesteam pressure will be at or near 0 PSIG, in other words,atmospheric pressure. With further reduction in load, thesteam valve will continue to close, resulting in generatorsteam pressures traveling below atmospheric pressure.If the condensate return system were not designed forsub-atmospheric pressures, the steam flow through theunit would not flow smoothly thus resulting in inefficientand/or unstable unit operation.Types of Condensate SystemsThere three basic types of condensate return systemspossible:1. A complete atmospheric system.2. An atmospheric/vacuum type system.3. A system that operates in a total vacuum.System (1) (Refer to Figure 22)For an entirely atmospheric system, a vacuum breakermay be installed at the outlet of the generator. (See“Condensate Return System Components” in this sectionfor a description of this device). A float & thermostatictype steam trap is used to minimize steam loss. Two trapspiped in parallel will allow continuous unit operationduring maintenance of the trap. A check valve installeddownstream in the line will keep the condensate fromback flowing during chiller shutdowns. In this systemboth the auxiliary condensate receiver (if needed) and themain condensate receiver, must be vented to atmosphericpressure. The auxiliary condensate receiver should beused on completely atmospheric systems when themain condensate receiver is located a far distance fromthe condensate outlet or above the condensate outlet.This type of system requires a float controlled pump tomove condensate from the auxiliary receiver to the maincondensate receiver in addition to the main condensatepump/boiler feed pump.System (2) (Refer to Figure 23)This system allows the chiller and steam traps tooperate at atmospheric pressure, but the remainder ofthe condensate system, after the auxiliary condensatereceiver, is under a vacuum. Since the condensate willbe at atmospheric pressure when it leaves the chiller, avacuum breaker can be installed on the generator outletbox. Two float & thermostatic type steam traps are pipedin parallel, followed by a check valve. Up to this point,system 2 is exactly the same as System 1.The auxiliary condensate receiver must be used insystem number 2. The main condensate tank will nolonger be vented to the atmosphere. A float control isstill used in the auxiliary condensate receiver however; itcontrols a valve instead of a pump. The low pressure inthe main tank will draw the condensate through anothercheck valve installed between the two tanks when thevalve is opened.System (3) (Refer to Figure 24)This system is designed for operating the chillergenerator tube bundle while under a vacuum; even atthe inlet to the generator bundle. This system workswell when the incoming steam to the generator comesfrom the exhaust of a non-condensing type steam turbine(Turbo-Absorption).42 YORK INTERNATIONAL

FORM 155.16-N3 (904)By using a vacuum pump on the condensate returnsystem, the entire system can run at a higher efficiency.This is because more latent energy can be extracted fromthe steam because it can be used well into the vacuumregion. This becomes particularly true when the unit isoperating at low loads with the steam valve throttled.Since the condensate will be at sub-atmospheric pressurewhen it leaves the generator bundle, a vacuum breakercannot be used. The float & thermostatic type steamtraps and check valve are piped the same as in Systems1 and 2.After the condensate leaves the check valve thecondensate liquid flows into a condensate cooler.The condensate cooler will ensure a 5 to 10°F (3.3 to5.5°C) of subcooling to the condensate. A thermostaticvalve sensing the condensate cooler outlet temperaturewhile controlling the cooling medium flow does this.This is necessary to make sure that no flashing takesplace with further pressure drop in the downstreamcondensate system. See the “Condensate Return SystemComponents” in this section for sizing the condensatecooler.Any air trapped in the condensate system after leavingthe check valve will slowly flow upward into thebellows-type, thermostatic steam trap. When the airreaches the trap it will be nearly the same temperatureas the steam. However, as the air cools down the steamtrap will open to expel the air.Both the subcooled liquid coming out of the condensatecooler and the air coming out of the steam trap willconverge into a common line downstream of thesedevices. The condensate/air will then continue to acondensate return tank/vacuum system where it will becollected so it can be returned back to the boiler.CONDENSATE RETURN SYSTEM COMPONENTSRefer to the Appendix “A” in this document forshell and tube volumes for the various YORKmodel units. The following table will aid inthe selection and sizing of various condensatecomponents.Steam Condensate Drain Solenoid ValveIf the unit has a factory supplied, butterfly-typesteam control valve. A condensate drain solenoidvalve will be supplied by YORK and shippedloose for field installation. If the unit has a failsafe,cage-type steam control valve or a UPS(Uninterrupted Power Supply) the unit does NOTrequire this valve.The steam condensate drain solenoid valve is a NCsolenoid valve that will close at unit shutdown or powerloss to the unit. Its function is to stop heat input to thegenerator tube section via stopping condensate flowwhen the unit is shutdown. It is particularly beneficialin the event of a power outage to the unit.The condensate drain solenoid valve offers thelowest form of protection from crystallizationin the event of a power loss. It will not protectthe unit from crystallization during extendedperiods of power loss.Valve Installation and WiringThis should be within 24 inches (0.6 m) of thegenerator condensate outlet box. The preferredvalve orientation is horizontal however otherpositions are acceptable. Wiring for this valve issupplied by the factory and comes already prewiredin the control panel. The remainder of the wiringwill be coiled and ty-wrapped in the vicinity of thegenerator condensate outlet box. Locate electricaljunction box (JB8) among the units ship looseparts. This box is directly connected to the valve’scoil housing via a ridged conduit connection andlock nut, also supplied by YORK. Remove oneMOV out of the cloth bag located in the unit’spanel. Connect the MOV between wire #17 andwhite natural wire #2. JB8 houses the MOV andthe remainder of the valves connections (refer toYORK Form 155.16-W4). This valve will work inconjunction with the Automatic shut-off valve.8UNIT MODEL FAMILY VALVE SIZEA & B2 inchC, D, E & F 3 inchYORK INTERNATIONAL 43

Steam Condensate Return SystemFORM 155.16-N3 (904)CHECKVALVECHECK VALVELD00684 (R)FIG. 22 – SYSTEM 1 - ATMOSPHERIC CONDENSATE RETURN SYSTEM44 YORK INTERNATIONAL

FORM 155.16-N3 (904)CHECKVALVEDRAIN VALVECHECK VALVE8LD00685 (R)FIG. 23 – SYSTEM 2 - VACUUM CONDENSATE RETURN SYSTEMYORK INTERNATIONAL 45

Steam Condensate Return SystemFORM 155.16-N3 (904)FLOAT AND THERMOSTATICTYPE STEAM TRAP(S)CONDENSATEDRAINSOLENOIDSTOP VALVETHERMOSTATIC TRAPAIRCOOLANT12" MIN.GENERATORCONDENSATE OUTLETCONDENSATE,FLASH STEAMAND AIRCHECKVALVECONDENSATECOOLERCONDENSATEAND AIRTO CONDENSATETO VACUUMRETURN CONDENSATE TANK/ PUMPVACUUM SYSTEMLD04748 (R)FIG. 24 – SYSTEM 3 - VACUUM CONDENSATE RETURN SYSTEM WHEN INLET STEAM AND OUTLETCONDENSATE ARE UNDER VACUUMVacuum BreakerA vacuum breaker may not always be necessary ordesired. Its main function is to prevent condensatebuild-up and/or water hammer in the generatortube section of the chiller. This is especially so oncondensate return system’s that operate in atmosphericconditions. Basically, the vacuum breaker will providea non-fluctuating flow rate of condensate leaving thegenerator hence; the steam flow into the generatorwill also be steady. The vacuum breaker does this bykeeping the generator tubes from going into a subatmosphericcondition by allowing air into the system.CHILLER OPERATION AND THE FUNCTION OFTHE VACUUM BREAKERIf the Condensate Return System 1 or 2 is employed,the generator tube bundle should always be aboveatmospheric pressure for proper operation. This maynot always be the case especially at a part load condition.At part load, the steam valve will throttle the steam inputto the chiller unit. This may cause the steam to collapse(or condensate) thus creating a vacuum condition dueto the reduced volume in the generator tubes. At thiscondition, the condensate will start to backup into thegenerator tubes and impede steam flow. Consequently,the vacuum breaker will open to allow air into the steamsystem. By doing this, it will prevent a vacuum conditionthus allowing proper flow. If no vacuum breaker wereinstalled, the flow would temporary stop or slowdown until the heat and pressure were able to buildupand overcome the vacuum. This condition shouldnot hurt unit performance at part loads. However, theaccumulation of condensate in the generator tubes andsubsequent drainage could overload the main systemcondensate receiver if not over-sized accordingly tohandle the fluctuation of condensate quantities.The capacity of the condensate system receiver(s) isassumed to be equal to the absorption unit generatortube volume as a maximum. See Appendix “A” for unitgenerator tube volumes.A vacuum breaker device should be selected andapplied with discretion. If the condensate is to be usedfor other processes downstream of the chiller introducedair through the vacuum breaker maybe objectionable.Any air that enters the condensate return system, mustbe purged from the system.46 YORK INTERNATIONAL

FORM 155.16-N3 (904)Strainer(s)A fine mesh strainer with a blow-off valve should beprovided ahead of the steam traps(s). A stop valve shouldbe installed upstream of the strainer for isolation.Steam TrapsThe latent heat in steam is a very effective and efficientmeans of providing heat to a building or process. The byproductof steam as it cools is condensate. If condensatewere not drained from the devices and components thatprovide the process, they would soon fill with condensateand quit operating. A steam trap’s main function is toremove condensate away from the steam vapor. Itssecond function is to move air and/or non-condensablegasses to the condensate system.There are many types of steam traps available on themarket today. However, no one type is “best” for allapplications; each type of trap has its unique features andabilities. There are basically three groups of steam trapsbased on how the trap makes the distinction betweencondensate and steam; thermostatic, mechanical, andthermodynamic. The following descriptions cover two ofthe three groups this is recommended for the condensatesystem.Float and Thermostatic Steam TrapThis type of steam trap incorporates two groups of steamtraps in one: mechanical and thermostatic. A float locatedat the bottom of the trap rises with increased condensatelevel to open a valve. When steam enters the trap, thefloat drops, closing the valve. At the top of the trap isa thermostatic vent. This type of trap is essential if thecondensate is to be used for other in plant operationswhere air in the condensate would be objectionable.The float and thermostatic steam trap should be installedin accordance with the manufactures recommendations.A by-pass line with isolation valves before and afterthe steam trap will allow for maintenance of the trapwithout taking the chiller off line. The trap should belocated below and as close to the generator’s outlet aspossible in a horizontal plane. A full size trap outletline size connection and valve should be provided forblow-down and testing purposes.Thermostatic TrapThis type of trap senses the temperature differencebetween steam and condensate by means of a bellows,flexible disk or bi-metal sensing element. For this tohappen, the condensate must be slightly subcooled.As steam enters the trap a sensing element heats upand expands, forcing the stem against the valve seatto keep the steam within the trap. As the steam cools,condensate is formed; which collects behind the seat.As the temperature lowers, the sensing element willcontract and lift the stem off the valve seat to allow thecondensate to exit.Check ValveA check valve installed in the condensate drain line willprevent any condensate or air from back flowing in thecondensate system during reduced load conditions.THIS IS A MUST FOR ALL CONDENSATE DRAINSYSTEMS. Please see the system diagrams for thelocation of the check valve.Condensate CoolerThe condensate cooler is installed in drain systembetween the steam trap and condensate receiver. Thepurpose is to sub cool the condensate below its flashpoint. The usage of this device is especially importantin vacuum drain systems (system #3) where flashing ofthe condensate liquid would be more likely to occur.Variations in condensate flow must be recognized and thecooler selected to cool the maximum flow of condensate5-10 deg F (3 – 6 deg C) below the saturation temperatureof the lowest pressure in the system. Sufficient coolantmust be provided to cool the maximum condensateflow to the desired temperature. Coolers may be airor evaporatively cooled, providing they can producethe desired leaving condensate temperature. Coolantflow could be manually set for maximum load andallowed to operate continuously at that level with nooperation difficulties, but the poor economics of such anarrangement make automatic control preferable.Auxiliary Condensate ReceiverAn auxiliary condensate receiver must be used if themain condensate receiver is located above the chiller ora long distance from the chiller. An auxiliary condensatepump is used to send condensate from the auxiliaryreceiver to the main condensate receiver.The auxiliary condensate receiver should be located atfloor level as close to the absorption unit as possible. Acheck valve in the auxiliary condensate pump dischargeline is recommended where condensate backflow mayoccur.8YORK INTERNATIONAL 47

Hot Water PipingFORM 155.16-N3 (904)SECTION 9HOT WATER PIPINGHOT WATER PIPINGYORK Hot Water single-stage (IsoFlow) absorptionunits are designed for a maximum generator inlet hotwater temperature of 266°F (130°C) and a generatorworking hot water pressure of 150 PSIG (10 bar). Aspecial option can be purchased to enable the hot waterworking pressure up to 300PSIG (21 bar).Do not exceed the unit’s design hot watertemperature or pressure ratings. Possible damageto the unit, components or serious personal injurycould result!Generator Hot Water Connections Table:GENERATOR TUBE BUNDLE DWPStandardOptionStandardOptionUnits shippedto Germany150 psig (10 bar)300 psig (21 bar)GENERATOR CONNECTIONSPipe stub w/Victaulic grooveANSI, RF fl angesPipe stub w/Victaulic groove,no other options available.All field hot water supply and return piping should beinstalled in accordance with all local, state, or federalcodes that may apply. All piping must be adequatelysupported and braced independent of the chiller. Thechiller water boxes and nozzles are not designed tohandle any load bearing stress or strain. The supportsystem must account for the expansion and contractionof the hot water being supplied to and from the unit. Allhot water piping should be designed in accordance withgood engineering practice.The hot water piping must be fabricated so that waterbox removal can be facilitated easily for maintenancepurposes. Installing a set of flanges close to the waterbox nozzles may do this.Hot water piping must be properly sized in accordancewith the required unit full load flow rates and pressuredrops. Piping must be designed to avoid abrupt pipe sizechanges and sharp curves to keep system pressure dropsto a minimum. For the inlet to the generator, YORKrecommends a straight length of pipe down stream ofthe control valve approximately 5 to 10 pipe diameterslong.HOT WATER FLOW & CONTROLThere are basically two types of hot water valves thatare utilized on YORK absorption chillers: two-way andthree-way. The three-way valve is the more commontype of control method. Three-way valves can befurther broke down into two categories.1. Diverging (flow-splitting)2. Converging (flow-mixing)Normally a tag fixed on the valve will indicate whichtype it is and how it operates; see the below example.DIVERGING FLOWThe three-way, diverging type valve will have its inleton the bottom (sometimes called the branch or commonport) and flow will go either to the left port or right portor both ports depending on the position of the valve’splug. Whether the hot water goes to the generator orby-pass depends on how it’s piped.3-Way Diverging valvesThe valves will vary the water flow rate through thegenerator while keeping the temperature constant. Thisis the recommended valve for hot water temperaturesequal to or below 266 ºF (130º C).A three-way, diverting valve will have one inlet andtwo outlets. The valve will vary the flow rate throughthe generator section of the chiller as load increasesor decreases. At a full load condition, the by-pass portwill be completely shut off allowing all the flow of thehot water to go directly to the generator section of thechiller. As the load decreases, the by-pass port will beginto open, allowing some of the hot water to bypass thegenerator section of the chiller. When there is no demandfor cooling, the by-pass port on the control valve willbe completely open while the port to the chiller will becompletely closed. Refer to Figure 26.48 YORK INTERNATIONAL

FORM 155.16-N3 (904)2-Way Hot Water ValvesThe valves are a straightforward open/shut type of valve.One important thing to keep in mind is that the hot watercirculator pump must be kept from deadheading whenthe hot water control valve completely closes. If the hotwater pump does not have other hot water appliancesin the same loop, the piping must be arranged so thatan upstream “by-pass” valve will automatically openupon hot water control valve closing. This will allowthe hot water flow to travel back to the pump suction.Refer to Figure 25.Contact YORK factory if the hot water temperatureis above YORK’s recommendations.3-Way Converging valvesThese valves have two inlets and one outlet; they willvary the water temperature while the flow remains thesame. This type of flow is recommended for hot watertemperatures above 266º F (130º C). The outlet of thisvalve is normally piped to the generator section of thechiller and usually incorporates an inner loop circulationpump. Hot water is continually circulated around thispiping loop while a temperature sensor throttles thevalve open or closed to keep the water temperature ata preset temperature less than 266 ºF (130ºC). Referto Figure 27.1 Manual isolation valves2 Hot water control valve3 Check valve4 By-pass valve (if required)PI = Pressure indicatorTI = Temperature indicatorHot water supply224” (630 mm) minimum vertical rise41Hot water return3PITIPI9Check valve w/3/4” by-pass lineFIG. 25 – TYPICAL 2-WAY CONTROL VALVE ARRANGEMENTLD09827YORK INTERNATIONAL 49

FORM 155.16-N3 (904)HOT WATER PIPING COMPONENTSManual Isolation ValvesThese valves are furnished and installed by othersfor serviceability of the inlet hot water pipingsystem. For convenience purposes, they shouldonly isolate the unit and it’s required components.Hot Water Control ValveAs a standard, one hot water control valve is furnishedwith each absorption unit. This valve may be separatelypackaged in it’s own create or it may be among theremainder of the unit’s shipped loose parts. The controlvalve may also be omitted from the unit’s factory orderif preferred by the customer. In these cases, others mustsupply the valve. YORK will not be responsible forthe control valve or it’s operation if NOT suppliedby the YORK factory. A separate set of installationand operation instructions will be packaged along witheach valve from the valve’s original manufacturer. Allpersonnel involved in the installation of the control valvemust read and understand the safety and installationprocedure. These instructions may have more detailsin valve installation than what this document covers;in these cases follow the valve’s manufacturersinstructions. Always keep the valve’s instructions in asafe place for future use.1) Manual isolation valves2) Hot water (diverging) control valve3) Check valvePI = pressure indicatorTI = Temperature indicatorsupplyValve Operation input By-passvalve section view hereTo chillerHot water supply224” (620 mm) minimum vertical rise1Hot water returnPITIPI3Check Valve with ¾” By-passLD09826FIG. 26 – TYPICAL 3-WAY DIVERGING CONTROL VALVE ARRANGEMENT50 YORK INTERNATIONAL

FORM 155.16-N3 (904)Valve InstallationThe mechanical contractor is usually the responsibleparty for installation of the control valve. Please referto the appropriate piping diagram in this section for aguideline on how this valve is arranged in the pipingsystem. The valve will mount between mating flangessupplied by others, these flanges must comply withthe same size and body pressure design as the valves.A label on the valve will indicate flow directions,please study this to make sure the valve gets installedcorrectly. The valve assembly must be installed in alocation where ambient temperatures are between0 to +140º F (-20 to +60º C). If high temperaturefluctuations or high humidity will be a factor, it issuggested that a heating resistor be fitted to prevent thebuildup of condensation within the actuator enclosure.No installation is permitted where the actuator isbeneath the centerline of the hot water line or whereliquid could drip or enter the actuator.Always support the actuator if it is not completelyvertical above the valve. It is not recommended toinstall the control valve in a vertical line. See thefollowing figure for actuator clearances.1 Manual Block Valves2 Hot Water Control Valve3 Check Valve4 Manual Isolation Valves5 Strainer6 PumpPI = Pressure IndicatorTI = Temperature Indicator5624Hot water supply124” (630 mm) minimumvertical riseHot water return3PITIPICheck Valve w/3/4” By-pass lineNOTE: For Hot Water Temperatures > 266ºF (130ºC)FIG. 27 – TYPICAL 3-WAY CONTROL VALVE ARRANGEMENTYORK INTERNATIONAL 51

Hot Water PipingFORM 155.16-N3 (904)> 6” (150 mm)> 12”(300 mm)FIG. 28 – ACTUATOR CLEARANCESLD098232/64, color white for the wire #2 neutral wire, black forthe other wires. These wires should be routed using1/2" (12.7 mm) metallic flexible conduit and appropriatefittings at each end. The length is determined by howfar the control valve will be located fro from the unitmounted JB3 junction box.Check ValveUpon unit shutdown, the hot water left remaining inthe generator section will start to contract as it coolsdown. This may form a vacuum inside the generatortube bundle. A check valve installed on the leavingwaterside of the generator will break this vacuum. Thecheck valve may not be necessary if the control valve islocated 24" (610 mm) above the generator connection.A 3/4" (19 mm) bypass line should be installed aroundthe check valve.Pressure and Temperature IndicatorsAppropriate indicators should be installed before andafter the generator bundle. This will allow the operatorand service technician to determine and verify operatingconditions of the unit.No installation is permitted where actuator isbeneath the centerline of the steam line or wherecondensate could drip or flow into actuator.FIG. 29 – 3274 ACTUATOR ORIENTATIONLD09822Valve WiringThe valve control harness is supplied by the factory andwill be coiled up on the generator inlet end of the unit.This harness will connect to unit-mounted junctionbox 3 (JB3) and terminate in the valve actuator. It isrecommended that a trained YORK Service Techniciancomplete the valve control wiring.The YORK factory does not supply the power wiring tothe control valve. The following is recommended, #18AWG, AWG dia 0.049, UL or CSA (nom) 1620 with 16strands, 600 volt rating, AWM/UL style 1015. Insulationwith minimum temp rating 105 deg C, nominal thickness52 YORK INTERNATIONAL

FORM 155.16-N3 (904)This page intentionally left blank9YORK INTERNATIONAL 53

Electrical ConnectionsFORM 155.16-N3 (904)SECTION 10ELECTRICAL CONNECTIONSELECTRICAL CONNECTIONSAll field wiring must be in accordancewith the National ElectricalCode (NEC) as well as all other applicablestate and local laws, codes andspecifications. The wiring installer(s)must be a fully qualified and licensedindividual(s) that is familiar with andoperates within these codes.L1L2L3CustomersuppliedFusedDisconnectSwitchDisconnect and lockout all electricalpower to the unit before proceedingwith any work. Failure to adhere tothis could result in damage to theequipment, personal injury or evenloss of life.A packet of unit literature is located with every uniton the inside door of the micropanel. Among the itemsin this package you will find a unit wiring and sensorlocation diagram. If for any reason this literature is notavailable, notify the local YORK Service office. TheWiring diagram manual is YORK form 155.16-W4.Do not attempt to wire the unit without properinstruction.Incoming three-phase power supply to the unitMUST be routed through a CUSTOMER SUP-PLIED remote, FUSED disconnect switch. See theappendix in the back of this document for determiningthe size of fuses, unit amp requirements and all electricalratings for the unit.Unit Grounding, the unit must be grounded in accordancewith NEC, table 250-95 and any other applicablecodes. Use only copper conductors for allunit wiring, do not use aluminum! The power panelis furnished with ground lugs suitable for wire sizesbetween #14 to 1/0 AWG.Incoming power wiring, located in the unit mounted,power panel is a 100 amp, non-fused, servicedisconnect switch. The incoming power lines from thecustomer supplied, remote mounted, fused disconnectswitch must be connected to terminals L1, L2 andL3 of this non-fused disconnect switch. Refer to thefollowing Figure for incoming 3-phase power wiring.GL L2 L3Unit mounted powerpanelCustomer suppliedFactoryinstalled,non-fusedservicedisconnectswitchwithin powerpanelFIG. 30 – INCOMING 3 PHASE POWER WIRINGLD09860The micro panel control center power (115V, 50/60Hz, 10 amps, 1.0 KVA) is supplied through a factorymounted control power transformer (CPT) located inthe power panel. If multiple conduits are used for theincoming three-phase power, they should contain anequal number of wires from each phase in each conduitto prevent overheating. Use copper conductors only forall unit wiring.Power factor correction capacitors, Are rarely usedon absorption equipment due to their low power usage.However, when used they must be sized to meet NECand all applicable codes. Improperly sized or installedcapacitors may result in equipment malfunctionor damage and will not be covered under YORKInternational warranty.Refer to Figure 31, in this section, “System waterpump and flow switch interface details” for the properinstalling location of the power factor correctioncapacitors.54 YORK INTERNATIONAL

FORM 155.16-N3 (904)Flow switchesRefer to “System pump control” inthe “Water Piping” section of thismanual for important informationon pump control.The IsoFlow absorption chiller must monitor theflow of water through the various heat exchangerbundles in order to operate correctly. Therefore, flowswitches or differential pressure control switches arerequired on the chilled water and tower (condenser)water flow circuits to determine if flow is established.The chilled water flow switch is a safety control. Itmust be connected to prevent operation of the unitwhenever chilled water flow is stopped. One chilledwater flow switch for each unit is always suppliedby YORK and included with the unit’s shipped looseparts. A differential pressure switch and a condenserflow switch are available on an optional basis. YORKhighly recommends installing one of these devices.For installation of these devices, refer to the “UnitWater Piping” section of this manual. For wiringthe chilled water flow switch, connect the commonterminal on the switch to terminal 24 on TB5 in thepanel. Connect the NO terminal of the switch toterminal 25 on TB5. Connect the NC terminal on theswitch to terminal 12 located on the digital input boardTB2.For wiring the tower (condenser) water flow switch,connect the common terminal of the switch to terminal1, and the NO to terminal 20. Both the 1 and 20terminals can be found on TB2, digital input board.The contact rating for these devices must be able tomeet 5 milliamperes at 115 volts A.C.Unit mounted control panelMISCELLANEOUS WIRINGThis section covers wiring devices that may or may notbe applicable to all units. To find out what applies toyour unit, contact your local YORK office.The below items are listed for reference purposes only.A qualified YORK service technician must accomplishall wiring to unit control and junction boxes. Pleaserefer to YORK form 155.16-W4 for more details.Each 115VAC field-connected inductive load i.e., relaycoil, motor starter, etc. must have a transient suppressorwired in parallel with its coil, physically located at thecoil. A bag of transient suppressors can be found insidethe unit panel.All wiring must be of copper and wiredin accordance with all National, stateand local codes.Customer supplied wiringFactory supplied wiringAutomatic Steam Shut-off Valve (4SOL)This device must not exceed 1 amp holding and 10amps inrush for 115 volts AC.SUPR5 2LD09863Terminals 5 & 2 are located on terminal board 7 (TB7) in remoteunit mounted junction box 3.Steam Condensate Drain Valve (6SOL)If applicable, this valve is shipped loose for fieldinstallation. Wiring will be supplied by factory andconnected to unit. Connection at valve to be completedby qualified technician.10DigitalInput BoardRelayBoardTB5SUPR17 2Condenser waterflow switchChilled water flow switchLD09861Terminals 17 & 2 are located on the digital input board, TB3.LD09862YORK INTERNATIONAL 55

Electrical ConnectionsFORM 155.16-N3 (904)Diagram depicts the unit.Ready to run with power applied & cond water pump on.FIG. 31 – SYSTEM WATER PUMP AND FLOW SWITCH INTERFACE DETAILSLD0989656 YORK INTERNATIONAL

FORM 155.16-N3 (904)I/O EXPANSION BOARD MICRO BOARD OPTIONAL CARDSLOCATION OFOPTIONAL CARD FILESTB6POWER SUPPLYBOARDTRANSFORMERTB1FUSETB2TB4DIGITAL INPUT BOARDRELAY OUTPUTBOARDTB3SUPPRESSORTB5START RELAY10* TB7 is located in JB3 (remote unit mounted Junction box)FIG. 32 – ISOFLOW MICRO PANEL CONTROL CENTER COMPONENT LOCATIONSYORK INTERNATIONAL 5726762A

Electrical ConnectionsFORM 155.16-N3 (904)Control Valve ConnectionsActuator 3274 (2 & 3 - way cage valves)N LBLKWhiteMOVActuator PSQ 201/501 (B-fly valves)GroundScrew4 to 20 mAInput controlsignal12 11- +BLK REDActuator power 120 volt, 1 ph,60 Hz From unit mounted JB3junction box,terminals 91 (L)& 2 (N) Power Harnesscustomer suppliedG ndI in LNFrom micropanelI/O board J3-1 (-)& J3-2 (+)4 to 20 mA input controlsignalFrom- BLK micropanelI/O board+ RED J3 -1 (-) &J3- 2 (+)91(L) BlkMOVLD09864Actuator power 120volt, 1 ph, 60 HzFrom unit mountedJB3 junction box,terminals 91 (L) & 2(N) Power Harnesscustomer suppliedThe wiring requirements for the control panel tocontrol the pumps are below.Unit mounted control panelDigitalInput BoardRelayBoardChilled water pumpcontacts, 44 & 45 onRelay board, TB4Condenser water pumpcontacts, 55 & 56 on Relayboard, TB4For further details on the following wiring connections,refer to YORK manual 155.16-PA1.Remote Steam/Hot Water Control Valve LimitSetpoint With Pwm SignalDigital input boardTB5LD098662 (N)WhiteThe above control valve connections are illustrated forpower wiring purposes only. A qualified YORK servicetechnician must complete control signal wiring.For the power wiring, YORK recommends thefollowing: #18 AWG, AWG dia 0.049, UL or CSA(nom) 1620 with 16 strands, 600 volt rating, AWM/ULstyle 1015. Insulation with minimum temp rating 105deg C, nominal thickness 2/64, color white for the wire#2 because it will be the neutral and black for the otherwires. These wires should be routed using ½” metallicflexible conduit and appropriate fittings at each end.The length of this wire can be measured from the unitmounted JB3 junction box to the valve.System Pump Control WiringFor YORK’s recommendation on pump control, referto the “Unit Water Piping” section in this document.The customer must supply all wiring. Contact rating is5 amps resistive at 250 volts A.C. & 30 volts D.C., 2amps inductive (0.4 PF) at 250 volts A.C. & 30 voltsD.C.1 82LD09865TB2To Energy management system (relay closure) 1 to 11second Pulse-Width Modulated (PWM) signal withcontacts rated 5 mA @ 115 VAC.Remote Ready To Start ContactsRelay Output BoardTB426 27LD09867LD09868To Energy management system. NO contacts (incontrol center) rated 2 amps inductive @ 250 VAC, 5amps resistive @ 250 VAC.Remote Leaving Chilled Water TemperatureSetpoint With PWM SignalDigital Input BoardEach 115VAC field-connected inductive load i.e., relaycoil, motor starter, etc. must have a transient suppressorwired in parallel with its coil, physically located at thecoil. A bag of transient suppressors can be found insidethe unit panel.TB219 1LD0986658 YORK INTERNATIONAL

FORM 155.16-N3 (904)To energy management system (relay closure) 1 to 11second pulse width modulated signal with contactsrated 5mA @ 115 VACCycling Shutdown ContactsRemote/local Cycling DevicesDigital Input BoardStopRunRelay Output BoardTB2 13 1LD09874NO contacts (in control center) rated 2 amps inductive@ 250 VAC, 5 amps resistive @ 250 VAC.Run ContactsTB440 41Relay Output BoardLD09866Remove jumper between 1 & 13 to employ cyclingdevice. If a remote start/stop switch is employed itmust be a maintained switch. Device contact rating tobe 5 mA @ 115 VAC.Remote Start/Stop contacts from Energy ManagementSystemDigital Input BoardTB435 36LD09866TB27 1 8LD09875NO contacts (in control panel) rated 5 amps resistive@ 120 or 240 VACAuxiliary Safety Shutdown ContactsTerminal Board 5Contact rating to be 5 mA @ 115 VAC.Multi-Unit SequenceDigital Input Board3135 36 1 4 53All device contact ratings to be 5 mA @ 115 VAC.Remove jumpers between 1, 4 & 53 to employ safetydevices.Safety Shutdown ContactsRelay Output boardLD09866TB21Contact rating to be 5 mA @ 115 VAC.Remove jumper to activate multi-unit sequence.Warning Contacts9Relay Output BoardLD09876TB442 43SUPRA10LD09873NO contacts (in control panel) rated 2 amps inductive@ 250 VAC, 5 amps resistive @ 250 VAC.TB489 90LD09877Warning contacts in the control panel are rated 2 ampsinductive @ 250 VAC, 5 amps resistive @ 250 VAC.YORK INTERNATIONAL 59

Protection from CrystallizationFORM 155.16-N3 (904)SECTION 11PROTECTION FROM CRYSTALLIZATION DURING POWER FAILURESPROTECTION FROM CRYSTALLIZATION DURINGPOWER FAILURESIn the event of a power failure, an absorption chiller issusceptible to crystallization as it cools down.Because of this, there are certain techniques that canbe applied to the chiller to help avoid crystallization.Listed below are some of these techniques.Eliminating Heat InputThis is especially important on steam-fired units.During a power failure, steam from the boiler willcontinue to flow to the chiller for an undeterminedamount of time. If not stopped, the steam will continueto boil the water out of the solution in the generator,pushing the solution’s concentration closer to thecrystallization area on the PTX chart.YORK factory can provide one of two methods toreduce Heat Input, depending on the type of steamvalve selected for the chillers application.1) YORK will provide a fail-closed steam valve. Thefail-closed steam valve has an internal spring, whichwill close the valve upon power failure. Fail-closedsteam valves are only available in the cage-typedesign from the factory.2) If the chiller has been selected for a butterfly-typecontrol valve, YORK will supply a steam condensatedrain solenoid valve. This NC valve will close uponpower failure to keep the steam condensate fromexiting the generator section.The above options are not available for hot water firedunits. Normally, during a power failure the hot waterpump will lose power as well, stopping the flow of hotwater to the unit.Basically, the customer supplied shut-off valve willremain open when current is applied to terminals 2 and5 on terminal board 7, which is located in unit-mountedjunction box 3. Upon loss of current, this NC valve willshut to assure zero steam flow into the chiller. Thisvalve works in conjunction with the condensate drainsolenoid valve, if the unit is so equipped.Uninterruptible Power Supply (UPS): This deviceis a special factory option available at time of ordersubmittal. A relay in the control panel will commandthe control valve to close using the UPS for power inthe event that AC power is lost to the chiller.If the unit has a factory supplied UPS, certain startup,operation and maintenance procedures will be ineffect. Please contact your local YORK service officefor more details.Unit InsulationThere are many reasons why insulation is used on units.Please see the Insulation section in this documentfor more information and details on the benefi ts ofinsulation.Insulation on an absorption unit plays an additionalrole by helping to retain heat within the solution of theunit. Some areas of the chiller, such as small diametersolution piping will cool quicker than larger thermalmass areas such as the generator. By insulating thesecritical areas, the heat in the solution may be retainedlong enough for the power to be restored to the chillerbefore crystallization happens.See the Appendix in the back of this document forrecommended unit insulation areas and amounts.Automatic shut-off valve: Another method of stoppingthe heat into a steam machine is to install an automaticshut-off valve in the steam inlet line to the chiller’sgenerator bundle. The automatic shut-off valve isnot supplied by the factory and must be purchasedand installed by the customer or the installingcontractor. Please see the Inlet Steam Piping sectionof this document for details for piping and selection ofthis valve.60 YORK INTERNATIONAL

FORM 155.16-N3 (904)SECTION 12INSULATIONINSULATIONInsulation on a single-stage absorption chiller can offermany benefits, such as: Elimination of condensationon cold surfaces (this is especially true in warm, humidenvironments); protects personnel working on or aroundthe absorption equipment from the high temperaturesurfaces; prevents or prolongs the unit from crystallizingduring a power failure.Hot Surface InsulationYORK recommends using 2" (51 mm) thick, 3-pounddensity fiberglass insulation. The insulation may becovered with metallic jacketing or sealed with thermalmastique compound if desired. The main surfaces toreceive this type of insulation are: solution-to-solutionheat exchanger, piping between the solution-to-solutionheat exchanger and generator, generator heads, and thesteam/hot water piping. See Appendix A, Figures 34,35 and 36 at the end of this document for detailedillustrations on which surfaces get cold insulation.As an option, the upper shell may be insulated tolimit the amount of heat gain to the equipmentroom.Glued insulation pins may be used for installing thefiberglass insulation to the hot areas of the unit. A hightemperatureepoxy adhesive is available from varioussupply houses for this purpose. DO NOT USE WELDPINS!Never weld to the unit shell or use weldpins for applying insulation. This actioncould penetrate the shell exteriorand may jeopardize the integrity of thechiller. If in question contact the localYORK service office.Cold Surface InsulationYORK recommends using 3/4" (19 mm), closed-cellfoam insulation. Cold surfaces to be insulated areevaporator shell and heads, refrigerant pump, evaporatorrefrigerant outlet box, miscellaneous piping betweenand around the refrigerant pump, and piping to theevaporator sprays.The surface of the cold insulation must be sealed vaportight to keep the glue intact and prevent sweating andmildew from forming underneath the insulation. Allseams must also be sealed or covered with tape.See Appendix A, Figures 34, 35 and 36 at theend of this document for detailed schematics onwhich surfaces get cold side insulation.Insulation TipsBefore applying any insulation to the unit, pleaseread the following for important information.Not adhering to any of the following statements mayeither void unit warranty, or cause damage the chiller.Never insulate the unit’s pump motors.The motor housings have air holes,for ventilation and cooling purposes.Blocking these holes will cause prematuremotor failure.Do not apply any insulation to theunit until the unit has been completelystarted up and confirmed tobe leak free.When insulating the unit, do not cover any sight glasses,hand valves, or water head bolts or nuts. These areasmust be accessible for service and operation personnel.If insulation is desired in these areas, do not glue theinsulation to the surface, in that way it can be easilyremoved for servicing the unit.Factory Applied Chiller InsulationAs a special option, chiller refrigerant- side (anti-sweat)insulation can be furnished and installed at the factoryif so desired. This option must be taken advantage of atthe time of the original chiller order.12YORK INTERNATIONAL 61

InsulationFORM 155.16-N3 (904)Note: The factory supplied, refrigerant-sideinsulation option must begiven consideration before ordering.This is due to the fact that additionalfield supplied and installed chillerinsulation is a must after the unit iscommissioned. Furthermore, factoryinstalled insulation, due to it’s vulnerablenature, is prone to damage duringshipping, rigging and installationprocess.YORK will not be responsible fordamaged insulation due to negligencein shipping, rigging or installation ofthe chiller.Specific applications and economic concerns maycontrol the decision to have insulation applied at thefactory. Evaporator water boxes and the customer’schilled water lines must be insulated in the field tokeep condensation from dripping onto machine roomequipment and floors. Usually, when this insulation isapplied, the insulation contractor will also insulate thenecessary components and piping on the chiller.If the factory applied anti-sweat insulation option isordered, the following chiller components will beinsulation with closed-cell foam insulation from thefactory.• Evaporator spill box.• Refrigerant pump suction line.• Refrigerant pump housing.• Refrigerant pump discharge line.• Refrigerant spray header.• Unloading solenoid (3SOL) line.• Anti-freeze line.• Intersection of Evaporator/Absorber shell (bothsides). NOT THE COMPLETE SHELL.Refer to Appendix A, Figures 34 thru 37 for insulationillustrations.Refrigerant-side (anti-sweat) insulationis not offered as a field retrofit oran aftermarket product.62 YORK INTERNATIONAL

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Appendix AAPPENDIX AFORM 155.16-N3 (904)REFRIGERANT CON DEN SATELINE TO EVAP O RA TOR(TYP 2)PURGECHAMBEROIL TRAPMAJOR COMPONENT LOCATIONPURGEPUMPSOLUTIONSUPPLYLINE TOGENERATORSO LU TIONDUMPVALVERUPTURE DISKHP1 CUTOUT SWITCHREFRIGERANT PT1 TRANSDUCERANTI-FREEZELINEHIGH TEM PER A TURECUTOUT SWITCHHT1GENERATOROUTLET BOXCONDENSERGENERATORPOWERPANELSOLUTIONSIGHTGLASSEVAPORATORSPRAYHEADEREVAPORATORSOLUTIONLINE TOABSORBERSPRAYSABSORBERREFRIGERANT LINETO EVAPORATORSPRAYSSERVICEVALVEEDUC TORSERVICEVALVESOLUTIONPUMPREFRIGERANTOUTLET BOXREFRIGERANTLEVEL FLOATCHAMBER(1F)SERVICEVALVEREFRIGERANTPUMPCUTOUT FLOAT(3F)PUMPISOLATIONVALVESREFRIGERANTPUMPISN MICROCONTROL PAN ELADCFLUSHLINEAUTOMATICDECRYSTALLIZATIONPIPE (ADC)SOLUTION RETURNLINE FROMGENERATORFIG. 33 – MAJOR COMPONENT LOCATIONS FOR ISOFLOW TM CHILLERSLD0945164 YORK INTERNATIONAL

UNIT WEIGHTS (ENGLISH)YIAModelOperatingWeight(lbs)²ShippingWeight(lbs)RiggingWeight(lbs)SolutionWeight(lbs)RefrigerantWeight(lbs)Water Weight inAbs/Cond/Evap/GenTop ShellRigging Weight(lbs)FORM 155.16-N3 (904)Bottom ShellRigging Weight(lbs)1A1 11,424 8,900 8,700 1,501 167 856 2,225 6,6751A2 12,808 9,800 9,700 1,782 250 976 2,450 7,3502A3 14,120 10,800 10,600 1,916 284 1,120 2,700 8,1002A4 15,583 11,700 11,500 2,318 317 1,248 2,925 8,7752B1 17,896 13,400 13,300 2,600 400 1,496 3,350 10,0503B2 19,963 14,800 14,600 3,002 434 1,728 3,700 11,1003B3 21,857 16,200 16,000 3,270 484 1,904 4,050 12,1504B4 23,891 17,600 17,400 3,685 534 2,072 4,400 13,2004C1 25,185 18,500 18,200 3,819 434 2,432 4,625 13,8755C2 27,962 20,200 19,900 4,502 475 2,784 5,050 15,1505C3 30,300 21,800 21,500 4,918 542 3,040 5,450 16,3506C4 33,080 23,500 23,200 5,601 642 3,336 5,875 17,6257D1 38,827 28,700 28,400 5,601 734 3,792 7,175 21,5257D2 43,446 32,200 31,900 6,285 826 4,136 8,050 24,1508D3 48,138 35,700 35,400 6,968 926 4,544 8,925 26,7758E1 54,223 39,000 38,600 8,603 1,076 5,544 9,750 29,2509E2 60,976 43,400 43,000 10,238 1,235 6,104 10,850 32,55010E3 67,210 48,500 48,100 16,653 1,401 6,656 12,125 36,37512F1 80,775 59,700 44,400¹ 12,288 1,351 7,936 14,800 44,40013F2 88,081 64,634 48,100¹ 13,789 1,502 8,656 16,034 48,10014F3 93,797 67,967 50,600¹ 15,276 1,702 9,352 16,867 50,600UNIT WEIGHTS (METRIC)UNIT WEIGHTSYIAModelOperatingWeight(kg)²ShippingWeight(kg)RiggingWeight(kg)SolutionWeight(kg)RefrigerantWeight(kg)Water Weight inAbs/Cond/Evap/GenTop ShellRigging Weight(kg)Bottom ShellRigging Weight(kg)1A1 5,182 4,037 3,946 681 76 388 1,009 3,0281A2 5,810 4,445 4,400 808 114 443 1,111 3,3342A3 6,405 4,899 4,808 869 129 508 1,225 3,6742A4 7,069 5,307 5,216 1,052 144 566 1,327 3,9802B1 8,118 6,078 6,033 1,179 182 679 1,520 4,5593B2 9,055 6,713 6,623 1,362 197 784 1,678 5,0353B3 9,915 7,348 7,258 1,483 219 864 1,837 5,5114B4 10,837 7,983 7,893 1,672 242 940 1,996 5,9874C1 11,424 8,392 8,256 1,732 197 1,103 2,098 6,2945C2 12,684 9,163 9,027 2,042 216 1,263 2,291 6,8725C3 13,744 9,888 9,752 2,231 246 1,379 2,472 7,4166C4 15,005 10,660 10,524 2,541 291 1,513 2,665 7,9957D1 17,612 13,018 12,882 2,541 333 1,720 3,255 9,7647D2 19,707 14,606 14,470 2,851 375 1,876 3,652 10,9558D3 21,835 16,194 16,057 3,161 420 2,061 4,049 12,1468E1 24,596 17,690 17,509 3,902 488 2,515 4,423 13,2689E2 27,659 19,686 19,505 4,644 560 2,769 4,922 14,76510E3 30,487 22,000 21,818 4,832 636 3,019 5,500 16,50012F1 36,641 27,354 20,140¹ 5,574 613 3,600 6,714 20,14013F2 39,953 29,591 21,818¹ 6,255 681 3,926 7,273 21,81814F3 42,546 31,103 22,952¹ 6,929 772 4,242 7,651 22,952NOTES:¹ Bottom shell only.² Operating weight = shipping weight + weight of refrigerant and solution + weight of chilled, tower and hot water in the tubes.AYORK INTERNATIONAL 65

Appendix AFORM 155.16-N3 (904)SHELL AND TUBE VOLUMESSHELL AND TUBE VOLUMESCHILLER SHELL AND TUBE VOLUMESSHELL SIDETUBE SIDEUnitGen / Cond Abs / Evap Absorber Evaporator Generator CondenserModelGallons Liters Gallons Liters Gallons Liters Gallons Liters Gallons Liters Gallons Liters1A1 175 662 543 2055 45 170 32 121 14 53 16 611A2 211 799 653 2472 52 197 36 136 16 61 18 682A3 249 943 764 2892 58 220 40 151 17 64 25 952A4 277 1049 875 3312 64 242 45 170 19 72 28 1062B1 361 1366 1006 3808 81 307 55 208 23 87 28 1063B2 405 1533 1152 4361 90 341 61 231 25 95 40 1513B3 456 1726 1298 4913 99 375 67 254 28 106 44 1674B4 508 1923 1444 5466 108 409 73 276 30 114 48 1824C1 587 2222 1516 5739 130 492 88 333 37 140 49 1855C2 646 2445 1701 6439 143 541 96 363 41 155 68 2575C3 719 2722 1899 7188 156 591 105 397 44 167 75 2846C4 810 3066 2136 8085 171 647 115 435 49 185 82 3107D1 904 3422 2690 10182 193 731 134 507 56 212 91 3447D2 1004 3800 2992 11326 210 795 146 553 61 231 100 3798D3 1130 4277 3371 12760 232 878 160 606 66 250 110 4168E1 1264 4785 3756 14218 278 1052 192 727 82 310 141 5349E2 1423 5386 4230 16012 306 1158 211 799 90 341 156 59110E3 1582 5988 4705 17810 334 1264 230 871 97 367 171 64712F1 1911 7234 5137 19445 395 1495 269 1018 124 469 204 77213F2 2125 8044 5730 21690 431 1631 293 1109 135 511 223 84414F3 2340 8858 6311 23889 467 1768 315 1192 145 549 242 91666 YORK INTERNATIONAL

FORM 155.16-N3 (904)TABLE 3 – ELECTRICAL RATINGSELECTRICAL DATAModelVoltageCodeVoltage(V-Ph-Hz)WireAmpacity(amps)Non-FusedDisconnectSwitch (amps)Max Dual Element Fuseamperage (customersupplied)SolutionPumpRefrigerantPumpPurgePumpTotalunit KWUnit totalAmps1A11A22A32A42B13B23B3-17 200/208-3-60 35.2 100 45 12.5 12.5 2.1 5.9 32.10-28 230-3-60 33.5 100 45 12.0 12.0 2.2 5.9 30.50-50 380-3-50 18.3 100 20 6.5 6.5 1.1 5.9 16.70-50 400-3-50 17.7 100 20 6.3 6.3 1.1 5.9 16.15-46 460-3-60 16.8 100 20 6.0 6.0 1.1 5.9 15.30-57 575-3-60 13.7 100 15 4.9 4.9 1.0 5.9 12.50-17 200/208-3-60 35.2 100 45 12.5 12.5 2.1 5.9 32.10-28 230-3-60 33.5 100 45 12.0 12.0 2.2 5.9 30.50-50 380-3-50 18.3 100 20 6.5 6.5 1.1 5.9 16.70-50 400-3-50 17.7 100 20 6.3 6.3 1.1 5.9 16.15-46 460-3-60 16.8 100 20 6.0 6.0 1.1 5.9 15.30-57 575-3-60 13.7 100 15 4.9 4.9 1.0 5.9 12.50-17 200/208-3-60 35.2 100 45 12.5 12.5 2.1 5.9 32.10-28 230-3-60 33.5 100 45 12.0 12.0 2.2 5.9 30.50-50 380-3-50 18.3 100 20 6.5 6.5 1.1 5.9 16.70-50 400-3-50 17.7 100 20 6.3 6.3 1.1 5.9 16.15-46 460-3-60 16.8 100 20 6.0 6.0 1.1 5.9 15.30-57 575-3-60 13.7 100 15 4.9 4.9 1.0 5.9 12.50-17 200/208-3-60 35.2 100 45 12.5 12.5 2.1 5.9 32.10-28 230-3-60 33.5 100 45 12.0 12.0 2.2 5.9 30.50-50 380-3-50 18.3 100 20 6.5 6.5 1.1 5.9 16.70-50 400-3-50 17.7 100 20 6.3 6.3 1.1 5.9 16.15-46 460-3-60 16.8 100 20 6.0 6.0 1.1 5.9 15.30-57 575-3-60 13.7 100 15 4.9 4.9 1.0 5.9 12.50-17 200/208-3-60 35.2 100 45 12.5 12.5 2.1 5.9 32.10-28 230-3-60 33.5 100 45 12.0 12.0 2.2 5.9 30.50-50 380-3-50 18.3 100 20 6.5 6.5 1.1 5.9 16.70-50 400-3-50 17.7 100 20 6.3 6.3 1.1 5.9 16.15-46 460-3-60 16.8 100 20 6.0 6.0 1.1 5.9 15.30-57 575-3-60 13.7 100 15 4.9 4.9 1.0 5.9 12.50-17 200/208-3-60 44.6 100 60 20.0 12.5 2.1 7.3 39.60-28 230-3-60 42.3 100 60 19.0 12.0 2.2 7.3 37.50-50 380-3-50 18.3 100 20 6.5 6.5 1.1 7.3 16.70-50 400-3-50 17.7 100 20 6.3 6.3 1.1 7.3 16.15-46 460-3-60 21.2 100 30 9.5 6.0 1.1 7.3 18.80-57 575-3-60 17.4 100 25 7.8 4.9 1.0 7.3 15.40-17 200/208-3-60 44.6 100 60 20.0 12.5 2.1 7.3 39.60-28 230-3-60 42.3 100 60 19.0 12.0 2.2 7.3 37.50-50 380-3-50 22.1 100 30 9.5 6.5 1.1 7.3 19.70-50 400-3-50 22.9 100 30 10.4 6.3 1.1 7.3 20.25-46 460-3-60 21.2 100 30 9.5 6.0 1.1 7.3 18.80-57 575-3-60 17.4 100 25 7.8 4.9 1.0 7.3 15.40AYORK INTERNATIONAL 67

Appendix AFORM 155.16-N3 (904)ELECTRICAL DATA (CONT'D)TABLE 3 – ELECTRICAL RATINGS (Cont’d)-17 200/208-3-60 44.6 100 60 20.0 12.5 2.1 7.3 39.60-28 230-3-60 42.3 100 60 19.0 12.0 2.2 7.3 37.504B44C15C25C36C47D17D2-50 380-3-50 22.1 100 30 9.5 6.5 1.1 7.3 19.70-50 400-3-50 22.9 100 30 10.4 6.3 1.1 7.3 20.25-46 460-3-60 21.2 100 30 9.5 6.0 1.1 7.3 18.80-57 575-3-60 17.4 100 25 7.8 4.9 1.0 7.3 15.40-17 200/208-3-60 44.6 100 60 20.0 12.5 2.1 7.3 39.60-28 230-3-60 42.3 100 60 19.0 12.0 2.2 7.3 37.50-50 380-3-50 22.1 100 30 9.5 6.5 1.1 7.3 19.70-50 400-3-50 22.9 100 30 10.4 6.3 1.1 7.3 20.25-46 460-3-60 21.2 100 30 9.5 6.0 1.1 7.3 18.80-57 575-3-60 17.4 100 25 7.8 4.9 1.0 7.3 15.40-17 200/208-3-60 44.6 100 60 20.0 12.5 2.1 7.3 39.60-28 230-3-60 42.3 100 60 19.0 12.0 2.2 7.3 37.50-50 380-3-50 24.0 100 30 11.0 6.5 1.1 7.3 21.20-50 400-3-50 23.2 100 30 10.7 6.3 1.1 7.3 20.55-46 460-3-60 21.2 100 30 9.5 6.0 1.1 7.3 18.80-57 575-3-60 17.4 100 25 7.8 4.9 1.0 7.3 15.40-17 200/208-3-60 44.6 100 60 20.0 12.5 2.1 7.3 39.60-28 230-3-60 42.3 100 60 19.0 12.0 2.2 7.3 37.50-50 380-3-50 24.0 100 30 11.0 6.5 1.1 7.3 21.20-50 400-3-50 23.2 100 30 10.7 6.3 1.1 7.3 20.55-46 460-3-60 21.2 100 30 9.5 6.0 1.1 7.3 18.80-57 575-3-60 17.4 100 25 7.8 4.9 1.0 7.3 15.40-17 200/208-3-60 44.6 100 60 20.0 12.5 2.1 7.3 39.60-28 230-3-60 42.3 100 60 19.0 12.0 2.2 7.3 37.50-50 380-3-50 27.7 100 40 14.0 6.5 1.1 7.3 24.20-50 400-3-50 27.7 100 40 14.3 6.3 1.1 7.3 24.15-46 460-3-60 21.2 100 30 9.5 6.0 1.1 9.2 18.80-57 575-3-60 17.4 100 25 7.8 4.9 1.0 9.2 15.40-17 200/208-3-60 44.6 100 60 20.0 12.5 2.1 7.3 39.60-28 230-3-60 42.3 100 60 19.0 12.0 2.2 7.3 37.50-50 380-3-50 27.7 100 40 14.0 6.5 1.1 7.3 24.20-50 400-3-50 27.7 100 40 14.3 6.3 1.1 7.3 24.15-46 460-3-60 21.2 100 30 9.5 6.0 1.1 9.2 18.80-57 575-3-60 17.4 100 25 7.8 4.9 1.0 9.2 15.40-17 200/208-3-60 60.9 100 90 33.0 12.5 2.1 9.2 52.60-28 230-3-60 56.0 100 80 30.0 12.0 2.2 9.2 48.50-50 380-3-50 27.7 100 40 14.0 6.5 1.1 9.2 24.20-50 400-3-50 27.7 100 40 14.3 6.3 1.1 9.2 24.15-46 460-3-60 28.1 100 40 15.0 6.0 1.1 9.2 24.30-57 575-3-60 22.6 100 30 12.0 4.9 1.0 9.2 19.60NOTES:1. Table is appropriate for both Hot Water and Steam Units.2. All purge pump electrical ratings are for the Welch model 1402.3. A YORK supplied 100 amp, non-fused, unit disconnect switch is located in the power panel of all chiller models.68 YORK INTERNATIONAL

FORM 155.16-N3 (904)ELECTRICAL DATA (CONT'D)TABLE 3 – ELECTRICAL RATINGS (Cont’d)-17 200/208-3-60 60.9 100 90 33.0 12.5 2.1 9.2 52.60-28 230-3-60 56.0 100 80 30.0 12.0 2.2 9.2 48.508D38E19E210E312F113F214F3-50 380-3-50 27.7 100 40 14.0 6.5 1.1 9.2 24.20-50 400-3-50 27.7 100 40 14.3 6.3 1.1 9.2 24.15-46 460-3-60 28.1 100 40 15.0 6.0 1.1 9.2 24.30-57 575-3-60 22.6 100 30 12.0 4.9 1.0 9.2 19.60-17 200/208-3-60 60.9 100 90 33.0 12.5 2.1 9.2 52.60-28 230-3-60 56.0 100 80 30.0 12.0 2.2 9.2 48.50-50 380-3-50 30.7 100 40 14.0 9.5 1.1 9.2 27.20-50 400-3-50 31.8 100 45 14.3 10.4 1.1 9.2 28.25-46 460-3-60 28.1 100 40 15.0 6.0 1.1 10.7 24.30-57 575-3-60 22.6 100 30 12.0 4.9 1.0 10.7 19.60-17 200/208-3-60 79.0 100 110 40.7 21.0 2.1 10.7 68.80-28 230-3-60 71.5 100 100 36.8 19.0 2.2 10.7 62.30-50 380-3-50 35.2 100 45 14.0 14.0 1.1 10.7 31.70-50 400-3-50 35.7 100 50 14.3 14.3 1.1 12.6 32.15-46 460-3-60 35.8 100 50 18.4 9.5 1.1 12.6 31.20-57 575-3-60 29.3 100 40 15.0 7.8 1.0 12.6 25.50-17 200/208-3-60 91.0 100 125 40.7 33.0 2.1 12.6 80.80-28 230-3-60 82.5 100 110 36.8 30.0 2.2 12.6 73.30-50 380-3-50 35.2 100 45 14.0 14.0 1.1 12.6 31.70-50 400-3-50 35.7 100 50 14.3 14.3 1.1 14.4 32.15-46 460-3-60 41.3 100 50 18.4 15.0 1.1 12.6 36.70-57 575-3-60 33.5 100 45 15.0 12.0 1.0 12.6 29.70-17 200/208-3-60 81.4 100 110 33.0 33.0 2.1 12.6 73.10-28 230-3-60 74.0 100 100 30.0 30.0 2.2 12.6 66.50-50 380-3-50 35.2 100 45 14.0 14.0 1.1 12.6 31.70-50 400-3-50 35.7 100 50 14.3 14.3 1.1 12.6 32.15-46 460-3-60 37.1 100 50 15.0 15.0 1.1 12.6 33.30-57 575-3-60 29.7 100 40 12.0 12.0 1.0 12.6 26.70-17 200/208-3-60 91.0 100 125 40.7 33.0 2.1 12.6 80.80-28 230-3-60 82.5 100 110 36.8 30.0 2.2 12.6 73.30-50 380-3-50 35.2 100 45 14.0 14.0 1.1 12.6 31.70-50 400-3-50 35.7 100 50 14.3 14.3 1.1 14.4 32.15-46 460-3-60 41.3 100 50 18.4 15.0 1.1 12.6 36.70-57 575-3-60 33.5 100 45 15.0 12.0 1.0 12.6 29.70-17 200/208-3-60 91.0 100 125 40.7 33.0 2.1 12.6 80.80-28 230-3-60 83.2 100 110 36.8 30.0 2.2 12.6 74.00-50 380-3-50 35.2 100 45 14.0 14.0 1.1 12.6 31.70-50 400-3-50 35.7 100 50 14.3 14.3 1.1 14.4 32.15-46 460-3-60 41.3 100 50 18.4 15.0 1.1 12.6 36.70-57 575-3-60 33.5 100 45 15.0 12.0 1.0 12.6 29.70NOTES:1. Table is appropriate for both Hot Water and Steam Units.2. All purge pump electrical ratings are for the Welch model 1402.3. A YORK supplied 100 amp, non-fused, unit disconnect switch is located in the power panel of all chiller models.AYORK INTERNATIONAL 69

Appendix AFORM 155.16-N3 (904)TABLE 4 – UNIT CHARGE QUANTITIESUNIT CHARGE QUANTITIESSolution Charge 4Refrigerant ChargeUnitModel Nominal Charge Unit 3 AlcoholUnit Tonnage Charge Shipped Unit Charge3 Shipped Charge ChargeDrums 1 Pounds Gallons Pounds Gallons Drums 2 Gallons Gallons Quarts1A1 120 4 1,608 120 1,474 112 1 55 20 1-1/21A2 155 5 2,010 150 1,742 133 1 55 30 1-1/22A3 172 5 2,010 150 1,876 143 1 55 34 1-1/22A4 205 6 2,412 180 2,278 173 1 55 38 1-1/22B1 235 7 2,814 210 2,546 194 1 55 48 23B2 273 8 3,216 240 2,948 224 2 110 52 23B3 311 9 3,216 240 3,216 244 2 110 58 24B4 334 10 3,618 270 3,618 275 2 110 64 24C1 363 10 4,020 300 3,752 285 2 110 52 35C2 410 12 4,422 330 4,422 336 2 110 57 35C3 446 13 4,824 360 4,824 367 2 110 65 36C4 518 14 5,628 420 5,494 418 2 110 77 37D1 565 14 5,628 420 5,494 418 2 110 88 47D2 617 16 6,432 480 6,164 469 2 110 99 48D3 704 18 6,834 510 6,834 520 3 165 111 48E1 794 22 8,442 630 8,442 642 3 165 129 59E2 908 26 9,648 780 9,514 764 3 165 148 510E3 960 27 10,452 780 10,452 795 3 165 168 512F1 1148 31 12,060 900 12,060 917 3 165 162 613F2 1235 35 13,668 1020 13,534 1029 4 220 180 614F3 1377 38 15,276 1140 15,008 1140 4 220 204 6NOTES:1. Solution drums are 30 gallon capacity.2. Refrigerant drums are 55 gallon capacity.3. The unit charge given in the table is typical only at unit start-up. Final trimming of solution and refrigerant may require more or less from thestart-up amount.4. Solution quantities are based on ADVAGuard 750 @ 53% base concentration weight.5. 1 gal. water = 8.334 lbs.70 YORK INTERNATIONAL

FORM 155.16-N3 (904)INSULATIONTABLE 5 – APPROXIMATE INSULATION FOR HOT AND COLD SURFACES – ENGLISH MEASURECOLD SURFACES HOT SURFACES COLD SURFACES HOT SURFACESREFRIGREFRIG.EVAP. REFRIG SUCTION EVAP REFRIG SUCTIONMODEL HEADS & OUTLET & DISCHARGE UPPER GEN. MODEL HEADS & OUTLET & DISCHARGE UPPER GEN.YIA END BOX & LINES – SHELL HEADS YIA END BOX & LINES – SHELL HEADSSHEETS PUMP TUBULAR INSUL SQ. FT. SQ. FT. SHEETS PUMP TUBULAR SQ. FT SQ. FT.SQ. FT. SQ. FT. DIA. INCH/LIN FT. SQ. FT. SQ. FT. DIA. INCH/LIN FT1A1 16 16 2/11, 4/4 70 2 6C4 26 18 2- 1 / 2/ 14, 3/4, 4/6 185 41A2 16 16 2/12, 4/3 70 2 7D1 39 31 3/17, 4/6 180 72A3 16 16 2/12, 4/3 81 2 7D2 39 31 3/18, 4/6 200 72A4 16 16 2/13, 4/3 93 2 8D3 39 31 3/19, 4/6 225 72B1 19 17 2/9, 2- 1 / 2/ 4, 4/4 95 3 8E1 55 43 3/22, 4/8 225 83B2 19 17 2/10, 2- 1 / 2/ 4, 4/4 110 3 9E2 55 43 3/24, 4/8 255 83B3 19 17 2/11, 2- 1 / 2/ 4, 4/4 125 3 10E3 55 43 3/24 285 84B4 19 18 2/12, 2- 1 / 2/ 4, 4/4 136 3 12F1 67 44 3/21 290 104C1 26 18 2- 1 / 2/ 11, 3/4, 4/6 132 4 13F2 67 44 3/23 320 105C2 26 18 2/12, 3/4, 4/6 148 4 14F3 67 44 3/24 355 105C3 26 18 2- 1 / 2/ 13, 3/4, 4/6 165 4TABLE 6 – APPROXIMATE INSULATION FOR HOT AND COLD SURFACES – METRIC MEASURECOLD SURFACES HOT SURFACES COLD SURFACES HOT SURFACESREFRIGREFRIG.EVAP. REFRIG SUCTION EVAP REFRIG SUCTIONMODEL HEADS & OUTLET & DISCHARGE UPPER GEN. MODEL HEADS & OUTLET & DISCHARGE UPPER GEN.YIA END BOX & LINES – SHELL HEADS YIA END BOX & LINES – SHELL HEADSSHEETS PUMP TUBULAR INSUL m 2 m 2 SHEETS PUMP TUBULAR m 2 m 2m 2 m 2 DIA. CM/LIN. m m 2 m 2 DIA. CM/LIN. m1A1 1.5 1.5 5/3.4, 10/1.2 6.5 0.2 6C4 2.4 1.7 6.5/4.3, 7.5/1.2, 10/1.8 17.1 0.41A2 1.5 1.5 5/3.7, 10/0.9 6.5 0.2 7D1 3.6 2.9 7.5/5.2, 10/1.8 16.7 0.72A3 1.5 1.5 5/3.7, 10/0.9 7.5 0.2 7D2 3.6 2.9 7.5/5.5, 10/1.8 18.6 0.72A4 1.5 1.5 5/4.0, 10/0.9 8.6 0.2 8D3 3.6 2.9 7.5/5.8, 10/1.8 21.0 0.72B1 1.8 1.6 5/2.7, 6.5/1.2, 10/1.2 8.8 0.3 8E1 5.1 4.0 7.5/6.7, 10/2.4 21.0 0.73B2 1.8 1.6 5/3.0, 6.5/1.2, 10/1.2 10.2 0.3 9E2 5.1 4.0 7.5/7.3, 10/2.4 21.0 0.73B3 1.8 1.6 5/3.4, 6.5/1.2, 10/1.2 11.6 0.3 10E3 5.1 4.0 7.5/7.3 26.5 0.74B4 1.8 1.7 5/3.7, 6.5/1.2, 10/1.2 12.6 0.3 12F1 6.2 4.1 7.5/6.4 27.0 0.94C1 2.4 1.7 6.5/3.4, 7.5/1.2, 10/1.8 12.2 0.4 13F2 6.2 4.1 7.5/7.0 29.8 0.95C2 2.4 1.7 5/3.7, 7.5/1.2, 10/1.8 13.7 0.4 14F3 6.2 4.1 7.5/7.3 33.0 0.95C3 2.4 1.7 6.5/4.0, 7.5/1.2, 10/1.8 15.3 0.4NOTES:1. Evaporator shell insulation is only required if evaporator shell surface sweats.2. Some of the cold surface insulation may be purchased as an extra option from the factory. Refer to Figure 34 for the proper locations.AYORK INTERNATIONAL 71

Appendix AFORM 155.16-N3 (904)INSULATION (CONT'D)TABLE 7 – EVAPORATOR SHELL APPROXIMATE INSULATION SIZES (ENGLISH)ModelUnitInsulationWidthSq. Ft.1A1 10" 171A2 10" 202A3 10" 242A4 10" 272B1 12" 283B2 12" 323B3 12" 364B4 12" 404C1 14" 385C2 14" 425C3 14" 476C4 14" 537D1 16" 487D2 16" 548D3 16" 608E1 18" 609E2 18" 6810E3 18" 7512F1 20" 7513F2 20" 8414F3 20" 9272 YORK INTERNATIONAL

FORM 155.16-N3 (904)INSULATION (CONT'D)TABLE 8 – EVAPORATOR SHELL APPROXIMATE INSULATION SIZES (METRIC)ModelUnitInsulationWidth (cm)Sq. Meters1A1 26 1.581A2 26 1.852A3 26 2.232A4 26 2.502B1 31 2.603B2 31 3.003B3 31 3.344B4 31 3.724C1 36 3.535C2 36 3.905C3 36 4.376C4 36 4.927D1 41 4.467D2 41 5.028D3 41 5.578E1 46 5.579E2 46 6.3210E3 46 7.0012F1 51 7.0013F2 51 7.8014F3 51 8.55AYORK INTERNATIONAL 73

Appendix AFORM 155.16-N3 (904)REFRIGERANT SIDE INSULATION(FACTORY SUPPLIED OPTION)NOTE: Partial insulationshown for location. The entirelength of the shell must becovered with the insulation.8Insulation Locations:1. - Evaporator Split Box2. - Refrigerant Pump Suction Line3. - Refrigerant Pump Housing4. - Refrigerant Pump Discharge Line5. - Refrigerant Spray Header6. - Unloading Solenoid Line7. - Anti-Freeze Line8. - Evaporator Shell Insulation8771Shaded areas are the locations of theinsulation.23645FIG. 34 – REFRIGERANT SIDE INSULATION (FACTORY SUPPLIED OPTION)74 YORK INTERNATIONALLD10077

FORM 155.16-N3 (904)COLD SIDE INSULATION(FIELD SUPPLIED AND INSTALLED)Cold Side Insulation must be appliedin addition to the Refrigerant SideInsulation as shown on Figure 36.Shaded areas are the locations of theinsulation.FIG. 35 – COLD SIDE INSULATION (FIELD SUPPLIED AND INSTALLED)YORK INTERNATIONAL 75LD10078A

Appendix AFORM 155.16-N3 (904)REFRIGERANT SIDE AND COLD SIDE INSULATIONCold Side Insulation must be appliedin addition to the Refrigerant SideInsulation as shown below. Figure36 shows all the unit cold surfacesthat must be insulated . Some ofthis insulation can be purchased asa factory option. Refer to Figure 34for locations of the Refrigerant SideInsulationShaded areas are the locations of theinsulation.LD10078FIG. 36 – REFRIGERANT SIDE AND COLD SIDE INSULATION76 YORK INTERNATIONAL

FORM 155.16-N3 (904)HOT SURFACES INSULATION(FIELD SUPPLIED AND INSTALLED)Solution-to-Solution Heat Exchanger (STS)Shaded areas are the locations of theinsulation.FIG. 37 – HOT SURFACES INSULATION (FIELD SUPPLIED)YORK INTERNATIONAL 77LD10079A

Appendix AFORM 155.16-N3 (904)FIG. 38 – UNIT ASSEMBLY FOR MODELS 1A1 AND 1A2LD1007578 YORK INTERNATIONAL

FORM 155.16-N3 (904)FIG. 39 – UNIT ASSEMBLY FOR MODELS 2A3 AND 2A4LD04712AYORK INTERNATIONAL 79

Appendix AFORM 155.16-N3 (904)FIG. 40 – UNIT ASSEMBLY FOR MODELS 2B1 THRU 4B4 LD0471380 YORK INTERNATIONAL

FORM 155.16-N3 (904)FIG. 41 – UNIT ASSEMBLY FOR MODELS 4C1 THRU 6C4LD04714AYORK INTERNATIONAL 81

Appendix AFORM 155.16-N3 (904)FIG. 42 – UNIT ASSEMBLY FOR MODELS 7D1 THRU 8D3LD0471582 YORK INTERNATIONAL

FORM 155.16-N3 (904)LD04716FIG. 43 – UNIT ASSEMBLY FOR MODELS 8E1 THRU 10E3AYORK INTERNATIONAL 83

Appendix AFORM 155.16-N3 (904)FIG. 44 – UNIT ASSEMBLY FOR MODELS 12F1 THRU 14F3 LD0471784 YORK INTERNATIONAL

Appendix BFORM 155.16-N3 (904)RECEIVING INSPECTION CHECKLISTQuality Control Receiving Inspection ChecklistLarge Tonnage Liquid ChillersName of Inspector: _______________________ York District: ___________________________ Date: ______________Job Name : _______________________________________________________________________________________York Order # ______________________ Unit Serial # ____________________ Unit Model # ____________________Ambient Temperature _______ °F (°C)A. Unit Specification CheckVerify that the unit delivered matches the order specifications.B. Holding Charge Verification (Read directly from pressure gauge)Internal pressure in unit checked and recorded.Internal Pressure in components verified (Split Shipped Units).Vapor Compression:______ PSIG (Factory Charged Units) R-_____.______ PSIG (Uncharged Units) N 2Absorption:______ PSIG (Uncharged Units) N 2______ mm Hg Abs (vacuum)Vapor Compression:Compressor ________ PSIG N 2Condenser Shell ________ PSIG N 2Evaporator Shell ________ PSIG N 2Single-Stage Absorption:Generator/Cond. Shell ________ PSIG N 2Evap./Abs. Shell ________ PSIG N 2Two-Stage Absorption:Generator/Cond. Shell ________ PSIG N 2Main Shell ________ PSIG N 2Hot Water Hxer. ________ PSIG N 2If the pressure in the unit or component has dropped to atmosphere (0 PSIG), a leak test must be performed immediately.Once the leak is found and repaired, the unit or component should be evacuated followed by the addition of a 4 PSIGholding charge.Leak Test Necessary? Yes NoIf yes, indicate location and probable cause of leak(s) below:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________BYORK INTERNATIONAL 85

Appendix BFORM 155.16-N3 (904)RECEIVING INSPECTION CHECKLIST (CONT'D)C. Visual Inspection of unitRecord damage or deficiencies below:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________D. Inspection of ship loose items❒ All items listed on packing slip present in ship loose Record damaged or missing ship loose items below.crate(s).❒ Visually check for damage to ship loose components. Part Number Missing Damaged_______________ ❒ ❒_______________ ❒ ❒_______________ ❒ ❒_______________ ❒ ❒Note: Shipping damage or missing ship loose items.Any shipping damage or missing items must be noted at the time of this inspection so that appropriate repairs made andor claims can be processed.York will not be liable for the loss or damage of any part(s) or material(s) whether the part(s) of the original equipment orpart of the ship loose items on the order after the date of this receiving inspection.E. Customer Training❒ Customer provided with appropriate installation literature and name of local York contact.❒ Customer instructed on proper storage and handling procedures.Customer Signature ______________________________________________________ Date ________________Company Name: _______________________________________________________________________________Address: ______________________________________________________________________________________City: ___________________________________ State: ___________ Zip Code ____________________________Inspector’s Signature _____________________________________________________ Date _________________Comments:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________86 YORK INTERNATIONAL

FORM 155.16-N3 (904)INSTALLA TION CHECK LIST AND REQUEST FOR AUTHORIZED ST ART-UP ENGINEERTo:YORK Telephone No:Unit Model No:District Service and Maintenance ManagerJob Name:Location:Customer Order No:YORK Order No:Unit Serial No:This work (as checked below) is in process and will be completed by: ___________________________________________________Month Day YearThe following work must be completed in accordance with YORK Installation Instructions of the above Model and Absorption Unit.A. UNIT SHIPMENT, INITIAL INSPECTION:Local YORK Service has been notified of unit arrival.All major pieces, boxes and crates are received.No visible signs of damage.With a local YORK Service Representative present, openall containers and check for contents against the packing list.Unit holding charge or vacuum has been verified.All damage or signs of possible damage have been reportedto the transportation company.B. FOUNDATION:Unit is mounted on a foundation level to 1/4".Unit located in accordance with the minimum clearancedimensions as recommended.Unit installed in an area protected from weather and maintainedat a temperature above freezing.If the unit is a knockdown shipment, unit assembled underYORK supervision.Unit is level per YORK’s allowable tolerance.C. PIPING:All tower water piping installed between chiller and tower,including cross-over line.Chilled water piping installed between evaporator, pumpsand cooling coils.Steam piping (if applicable) installed between unit andsource of supply.If steam unit, all condensate and removal systems installed.Make-up and fill lines installed to cooling tower and chilledwater system.All thermometer wells, flow switches and gauge connectionsinstalled in chilled and condenser water lines.All water piping checked for strain (piping should not springwhen connections are broken at unit).System water piping leak tested and flushed, and waterstrainers cleaned after flushing. Piping system filled withwater, and trapped air vented.Chilled and condenser water, hot water, or steam flow availableto meet unit design requirements.All pressure relief devices (including unit rupture disk) arevented to a safe area.D. BURNER:Free of damage; all fasteners, fittings, and plugs are tightAll mechanisms, control arms and ball-swivels are tight andare in working order.Burner support has been installed.All gas train components supplied, properly installed andleak-checked.Breeching connections have been installed to the chimneyand are open and unobstructed.Draft control equipment installed properly.High stack temperature probe installed properly and wired.Have properly sized vent lines been installed on all gas traincomponents which require venting? This includes pressureregulators, normally open vent valves, diaphragm valves,low and high gas pressure switches, etc.Have gas train piping and components been tested andproven gas tight?Purge both main and pilot gas lines.Is the proper gas pressure available at the inlet to the controls?(Pressure must meet the requirements shown on theburner “as built specification sheet” as provided by the burnermanufacturer.)OIL FIRED BURNERS:Is the oil tank installed and filled with #2 fuel oil?Have oil supply and return lines been sized to meet the maximumpumping capacity of the pump?Has the oil piping system been leak tested and purged ofair?Is the proper oil pressure available at the inlet to the controls?E. ELECTRIC WIRING:Wiring completed from customers’ main power supply fuseddisconnect switch to power panel on unit.External control wiring completed from control panel to flowswitches, vacuum pump motor, etc., in accordance withYORK Wiring Diagram.Power available and wiring completed to the followingstarters and motors:a. Chilled water pump contacts.b. Tower water pump contacts.c. Hot Water pump contacts (if applicable).Vacuum pump motor and blower fan motor (direct-fired unitsonly) rotating in correct directionAll electrical terminal connections are tight.F. UNIT CHARGING AND COMMISSIONING:Lithium bromide, refrigerant and alcohol is available at jobsitefor YORK Service to charge into the unit?Is vacuum pump oil available for charging into the vacuumpump?Is there a full capacity cooling load available for unit start-up?With reference to the terms of the above contract, we are requesting the presence of a YORK Authorized Representative at the job site on__________________________ to start the system and instruct operating personnel. Please contact ______________________________.Month Day Year NamesYORK INTERNATIONAL 87B

P.O. Box 1592, YORK, Pennsylvania USA 17405-1592Copyright © by YORK International Corporation 2004Form 155.16-N3 (904)Supersedes: 155.16-N3 (899)Tele. 800-861-1001www.YORK.comSubject to change without notice. Printed in USAALL RIGHTS RESERVED