Yazaki AROACE CH-MG200 Operating Instructions Manual

Brand: Yazaki

Model: AROACE CH-MG200

Category: Water heaters & boilers

Type: Operating Instructions Manual

This manual is also suitable for

AROACE CH-MG150

Yazaki AROACE CH-MG200 is a gas-fired, double-effect absorption chiller-heater that provides both cooling and heating functions. It uses a lithium bromide and water solution as the working fluid and operates on the absorption principle. With a nominal refrigeration capacity of 200 tons, it's suitable for central plant-type air conditioning systems.

GAS-FIRED DOUBLE-EFFECT

ABSORPTION CHILLER-HEATER

FOR YOUR SAFETY

If you smell gas:

1. Open windows (only if installed

indoors)

2. Don’t touch electrical switches

3. Extinguish any open flame

4. DO NOT SMOKE!

5. Immediately call your gas supplier

FOR YOUR SAFETY

Do not store or use gasoline or

other flammable vapors and

liquids in the vicinity of this or any

other equipment.

CONTENTS

GENERAL Page

 ABSORPTION PRINCIPLE 2

 COOLING OPERATION 3

 HEATING OPERATION 4

CONTROLS

 GENERAL INFORMATION 5

 CONTROL ADJUSTMENTS 8

 CONTROL SEQUENCE 12

OPERATION

 COOLING 13

 PRECAUTIONS 13

 HEATING 13

 REMOTE CONTROL 13

Page

 SAFETY CONTROLS 13

 WINTER SHUTDOWN 14

MAINTENANCE

 GENERAL INFORMATION 14

 MAINTENCE SCHEDULE 14

 ROUTINE MAINTENANCE 15

 EVACUATION OVERVIEW 15

 CHEMICAL MAINTENANCE 17

 WINTERIZING 17

 TROUBLESHOOTING 17

 WATER QUALITY 18

 ERROR CODES 19

OPERATING INSTRUCTIONS

CH-MG150

CH-MG200

This product is a gas-fired absorption unit which provides

chilled water for cooling or hot water for heating in central

plant-type air conditioning systems. Units with nominal

refrigeration capacities of 150 and 200 tons are complete

with operating and safety controls. The chiller-heater is fitted

with a low NOx burner, automatic spark ignition systems,

power combustion blower and proportional firing control.

When this equipment has been applied correctly,

installed in accordance with Yazaki INSTALLATION

INSTRUCTIONS (supplied with the chiller-heater), and with

proper maintenance on the chiller-heater itself and

accompanying support items such as pumps, cooling tower,

etc., it can provide many years of trouble free operation.

GENERAL

These instructions are intended to

acquaint the Owner/End User with the

operation and general maintenance

requirements of Yazaki Gas-Fired

Double-Effect Absorption Chiller-Heater

units.

Please read ALL instructions carefully

and observe precautions. Failure to

operate and properly maintain this

equipment in accordance with the

OPERATING INSTRUCTIONS may

affect the equipment performance and

product Warranty.

If the equipment does not operate as

expected, check the Troubleshooting

Guide in these instructions BEFORE

calling your Yazaki Authorized Service

Provider (ASP). This approach will not

only save cost but also helps to avoid

any unnecessary down time.

THE ABSORPTION PRINCIPLE

Yazaki absorption chiller-heaters use

a solution of lithium bromide and water,

under vacuum, as the working fluid.

Water is the refrigerant and lithium

bromide is the absorbent. During cooling

operation, refrigerant liquid boils under

the influence of a deep vacuum in the

evaporator and creates a refrigerating

effect which removes heat from the

chilled water circuit.

The double-effect absorption cycle

has two generators – one heated by a

gas burner and another heated by

superheated refrigerant vapor. The

resulting refrigerant is passed through to

the condenser, and is then metered into

the evaporator. Lithium bromide solution

leaving the generators flows into the

absorber.

Heat from the cycle is removed by

cooling water flowing inside the

condenser and absorber tubing bundles.

Heat from the cooling water is rejected

most typically to a cooling tower, but may

also be rejected by alternative methods,

including ground loops.

COOLING OPERATION

High-Temperature Generator (HGE)

The gas burner heats a dilute lithium

bromide solution in the High-

Temperature Generator resulting in a

release of superheated refrigerant vapor.

The dilute solution becomes more

concentrated due to this release.

Gravity, temperature, and pressure

differences push the more concentrated

solution through Heat Exchangers to

recycle heat before the concentrated

solution is sent to the Absorber (ABS).

After release, the superheated

refrigerant vapor flows through the Low-

Temperature Generator (LGE) tubing

bundle and is used as the heat source for

the dilute solution that the LGE contains.

Most, if not all, of the refrigerant vapor

will condense into liquid refrigerant

during this process. Ultimately, this

tubing dumps the liquid refrigerant into

the Condenser (COND).

Low-Temperature Generator (LGE)

After release, the superheated

refrigerant vapor heats dilute lithium

bromide solution in the Low-Temperature

Generator. The refrigerant vapor

liberated from this solution flows into the

Condenser while the lithium bromide

solution becomes more concentrated.

Gravity, temperature, and pressure

differences push this more concentrated

solution through Heat Exchangers to

recycle heat before the concentrated

solution is sent to the Absorber.

Condenser (COND)

In the Condenser, refrigerant vapor is

condensed on the outer surface of the

condenser tubing bundle. Latent heat is

removed by the cooling water that flows

inside this tubing bundle. The heat

absorbed by the cooling water is rejected

to a cooling tower or alternative system.

The liquid refrigerant that drips off the

tubing bundle joins the liquid refrigerant

that resulted from the operation of the

LGE and accumulates in the condenser

sump. Liquid refrigerant is routed from

the condenser sump through an

electronic expansion valve which meters

the liquid refrigerant as required into the

Evaporator (EVA).

Evaporator (EVA)

In the Evaporator, liquid refrigerant is

exposed to a substantially deeper

vacuum than in the Condenser due to the

influence of the Absorber. As the liquid

refrigerant flows over the surface of the

Evaporator tubing bundle, it boils and

removes heat from the chilled water

flowing inside the Evaporator tubing

bundle. The heat removed from the

chilled water circuit is equal to the latent

heat of the refrigerant, roughly 1000 BTU

per pound of liquid refrigerant boiling into

refrigerant vapor.

Absorber (ABS)

The Evaporator and the Absorber

share the same space. A deep vacuum

in the ABS is maintained by the affinity of

the concentrated solution for refrigerant

vapor. The concentrated solution flows

over the outside of the Absorber tubing

bundle where it is cooled by the cooling

water flowing inside the Absorber tubing

bundle. When the concentrated solution

is cooled, it develops an even greater

affinity for the refrigerant vapor. The

heat absorbed by the cooling water is

rejected to a cooling tower or alternative

system.

The deep level of vacuum in the ABS

section is maintained by the action of the

concentrated solution absorbing the

refrigerant vapor that is being generated

by the EVA during its normal operation.

This action dilutes the concentrated

solution back to the same concentration

level as it was when the cycle began.

The dilute solution gathers in the

Absorber sump before being pumped

back into the Generators to start the

cycle anew.

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

HEATING OPERATION

High-Temperature Generator (HGE)

Dilute lithium bromide solution is heated

in the HGE by the gas burner in the

same manner as in the cooling cycle.

The solution boils vigorously, releasing

superheated refrigerant vapor and

leaving a more concentrated solution.

The refrigerant vapor flows through a

changeover valve into the Evaporator

section. The concentrated solution flows

through another changeover valve into

the Absorber sump.

Low-Temperature Generator (LGE)

Although solution does flow through the

LGE, since the superheated refrigerant

vapor is not flowing in any meaningful

amount through the LGE, the solution

does not release any refrigerant vapor

and the solution simply flows back into

the Absorber sump in essentially a still-

diluted state. The lack of this generator

operation in heating mode is why the

heating capacity is lower than the cooling

capacity in these chiller-heaters.

HEATING OPERATION

Evaporator (EVA)

Superheated refrigerant vapor

condenses on the outer surface of the

Evaporator tubing bundle. Heat equal to

the latent heat of the refrigerant is

transferred into the hot water circuit. The

liquid refrigerant that condensed on the

outer surface simply drips off into the

Absorber sump, diluting the solution back

to the same concentration level as when

it started the cycle.

Absorber (ABS)

Liquid refrigerant that condensed on the

outer surface of the Evaporator tubing

bundle drips into the Absorber sump.

Concentrated solution from the HGE and

dilute solution cycled through the LGE

also ends up in the Absorber sump. The

joining of all the liquids results in diluting

the solution back to the state at which it

began the cycle. This diluted solution is

then pumped to the Generators to begin

the cycle anew.

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

CONTROLS

GENERAL INFORMATION

A control panel, shown in Fig. 3, is

built into each absorption chiller-heater

and is located on the front of the control

box. The control box is located behind

the right-hand service door, as shown in

Fig. 4. After inspecting the control panel

or changing the mode of operation, make

sure that the front panel is latched and

locked in order to prevent rain from

entering the cabinet and damaging the

controls. This will also help to prevent

unauthorized tampering with controls and

settings.

The chiller-heater may also be

supervised and controlled in a limited

manner by Building Automation Systems

(BAS, BMS) when Remote Operation is

engaged. Additional controls and

interlocks may be required in some

instances. These controls and their

functions can be explained by your

Yazaki Authorized Service Provider.

Once COOLING or HEATING

operation is selected and the unit has

started, the chiller-heater will function

automatically and remain in operation for

as long as there is a demand for chilled

or hot water. The burner modulates the

Generator heat input in response to the

leaving chilled/hot water temperature.

When the chilled water temperature

demand is satisfied, the solution pump

automatically changes to Dilution Mode

and the cooling water pump demand

stops after a minimum of 4 minutes

additional time.

Fig. 3 – Chiller-Heater Control Panel

GENERAL INFORMATION

Fig. 4

SOLUTION PUMP CONTROL

The VFD Solution Pump is controlled

by a Hitachi VFD Controller. This

controller has been set up at the factory

and SHOULD NOT BE ADJUSTED!

Universal replacements are NOT

recommended. Only use OEM parts for

the solution pump and controller.

Fig. 5 – Hitachi VFD Controller

Control Panel

located behind

this panel in this

location.

Evacuation Service

Valves A and B are

located behind this

panel in this location.

CONTROL ADJUSTMENTS

The chiller-heater is normally operated

from the control panel behind the right

access door. If it is necessary to open

the control box for troubleshooting,

observe all safety warnings on the chiller-

heater and in these instructions. Only

qualified and trained personnel should

have access to the live electrical parts

inside the chiller-heater. Failure to

observe the safety warnings can

result in personal injury, death, and/or

damage to property.

Fig. 6 – Control Box (Opened)

CONTROL ADJUSTMENTS

The ACT5 Maintenance Checker

plugs into the Main CPU Board, shown in

Fig. 8, and is used in many functions,

including choosing the leaving chilled/hot

water temperature set points.

This board also has the Mode Setting

Switch. This switch must be positioned

to the left whenever the unit is to be in

normal operating condition. Position this

switch to the right when adjusting the

burner. Position this switch to the middle

when the unit is to sit dormant and

unresponsive, but with power applied to

it. The Unit Number Setting Dip Switch is

only used in conjunction with the optional

AroTrend Remote Monitoring or an

optional LON Adapter. If not being

monitored, this dial switch must be set to

“0” or “F”.

Fig. 8 – Main CPU Board

CONTROL ADJUSTMENTS

The leaving chilled water and hot

water temperature controls are set at the

factory to the Standard Specifications Set

Points, which are a cooling set point of

44.6°F (7°C) and a heating set point of

140.0°F (60°C). A Yazaki Authorized

Service Provider can adjust these set

points using the ACT5 Maintenance

Checker. The cooling set point is

adjustable from 41°F (5°C) to 53.6°F

(12°C). The heating set point is

adjustable from 104.0°F (40°C) to 145.4°F

(63°C).

The CH-MG Series has an Economy

Mode feature as well that can be

controlled by the Building Management

System. Economy Mode functions in

much the same way as night set-back.

When engaged, the cooling set point will

rise by 5.4°F (3°C) and the heating set

point will fall by 9°F (5°C). Dis-engaging

the Economy Mode will immediately

restore the cooling and heating set points

back to their original values.

Fig. 7 – ACT5 Maintenance Checker

Adjusting the chilled and hot water set

points can only be done using the ACT5.

Using a standard CAT5 cable (one was

provided from the factory), connect the

ACT5 to the Main CPU Board located in

the upper right of the control box. There

is a jack in the upper middle of the CPU

Board (See Figure 8) that is for use with the

ACT5.

There is also an identical jack on the

Sub-Control Board located in the top left

corner of the control box. This board’s

jack is not functional and should not be

used.

To adjust the chilled and hot water set

points:

1. On the ACT5, use the “Λ” and “V”

buttons to move the cursor to the line

“2. Unit data set” and press “ENTER”.

2. Then use the “Λ” and “V” buttons to

move the cursor to the line “B2 CB

Set” and press “ENTER”.

3. Use the “◄” and “►” buttons to reach

the menu displaying data points 13-16.

4. Use the “Λ”, “V”, “<”, and “>” buttons to

move the cursor to temperature

numbers of data point 14 to change

the cooling set point, or data point 15

to change the heating set point.

5. Once highlighting the block to be

changed, use the “+” and “-“ buttons to

scroll through the available values until

the desired value is displayed.

6. Press “ENTER” to save the new

setting.

7. Press and hold the “◄” for longer than

one full second to back out of the

menu, or simply unplug the ACT5 if it

is no longer needed for other

functions.

CONTROL ADJUSTMENTS

To enable the Economy Mode, locate

terminals TB1-75 and TB1-76 (See Fig. 9)

on the I/O Board, located at the middle

left in the control box. The board sends

voltage out on TB1-75, so no external or

field-supplied power should be applied to

the circuit or else damage to the board

could result.

To engage Economy Mode, close a

circuit between TB1-75 and TB1-76.

When that circuit is closed, the Main

CPU Board logic will automatically apply

a modifier to the temperature set point

data in memory. When the circuit is

open, no modifier will be applied.

Most often, a relay with dry contacts

that is controlled by the BMS is used to

control Economy Mode. However, a

timer, light sensor, or a simple toggle

switch could also be used to make or

break this circuit.

Fig. 9 – I/O Board

CONTROL SEQUENCE

A built-in microprocessor in the chiller-

heater controls the external pump

demand signals in response to the

cooling and heating load. The operating

sequence of each pump and the cooling

tower fan after start-up, during normal

operation, and after a normal stop or

abnormal shut down is shown in Fig. 10.

It is important that the chiller-heater have

control over the pumps to allow for

controlled shut down under normal and

abnormal conditions.

Running the chilled water pump at all

times is discouraged as the chiller-heater

logic will expect to see the flow switch

open when the “P” dry contacts are

opened. If it does not open, the chiller

assumes the flow switch has failed and

will generate error code E016.

Fig. 10 – General Control Sequence

CP = Cooling Water Pump Demand Relay

CTF = Cooling Tower Fan Demand Relay

P = Chilled/Hot Water Pump Demand Relay

OPERATION

COOLING

1. Select “ON” on the DIRECT

OPERATION section of the control

panel.

2. Select “COOLING” on the MODE

SELECT section of the control panel.

Cooling operation will commence after

all self-check functions have completed.

This can take as long as 5 minutes so do

not be alarmed if the unit does not seem

to respond immediately. If the unit is

being switched over from HEATING

mode, there is an enforced 30-minute

delay period before COOLING mode will

engage.

PRECAUTIONS

1. Ensure that all AUTO-OFF-MANUAL

switches for external pumps and the

cooling tower fan are set in the AUTO

position during normal operation. The

chiller-heater is designed to

automatically control the chilled/hot

water pump, cooling water pump, and

cooling tower fan signals as it

requires.

2. At the beginning of the cooling

season, clean and refill the cooling

tower with fresh water. Check

strainers for debris and spray nozzles

for proper operation.

3. During the heating season, the cooling

tower and cooling water circuit should

be drained in order to help prevent

freezing and scaling in the Absorber

and Condenser tubing bundles.

4. When two or more absorption chiller-

heaters are installed in parallel, set all

units to the same operating mode.

HEATING

1. Select “ON” on the DIRECT

OPERATION section of the control

panel.

2. Select “HEATING” on the MODE

SELECT section of the control panel.

Heating operation will commence after

all self-check functions have completed.

This can take as long as 5 minutes so do

not be alarmed if the unit does not seem

to respond immediately. If the unit is

being switched over from COOLING

mode, there is an enforced 30-minute

delay period before HEATING mode will

engage.

REMOTE CONTROL

In order to respond to BMS signals,

the chiller-heater must be set to remote

operation. Simply press the “REMOTE”

button on the REMOTE OPERATION

section of the control panel. The LED

will illuminate on the “REMOTE” button

to indicate remote operation has been

engaged.

SAFETY CONTROLS

Safety and limit controls monitor

critical operating conditions in the chiller-

heater and may shut down the unit when

abnormal conditions occur. Not all

abnormal conditions are harmful to the

chiller-heater, therefore, the chiller-

heater may not always shut down when

an error code is displayed.

An Error Code will be displayed when

an abnormal condition arises. This error

code will be displayed by LEDS located

at the top left of the control panel. A list

of error codes and their meanings is

shown in Table 2 at the back of this

manual.

Some Error Codes will automatically

reset themselves once the abnormal

condition clears. Others may require a

manual reset by pressing the “RESET”

button on the control panel. Some

manual reset codes will not clear until

certain conditions are met, so if the Error

Code does not clear or the chiller-heater

does not restart, contact your Yazaki

Authorized Service Provider (ASP).

WINTER SHUT DOWN

If a chiller-heater is only used in the

cooling mode and is to be shut down for

the winter, it is necessary to run the

chiller-heater in Heat mode for a

minimum of 30 minutes in order to

properly return all fluids to the bottom of

the unit and to prepare the unit for long

term shutdown. Without running in Heat

mode, some water will be trapped in

upper portions of the chiller-heater and

could potentially damage the unit should

it freeze in the winter conditions.

See the Service Manual for detailed

information on proper Winter Shut Down.

MAINTENANCE

GENERAL INFORMATION

ALL MAINTENANCE SHOULD BE

PERFORMED BY SKILLED,

EXPERIENCED PERSONNEL. Your

Yazaki Authorized Service Provider

(ASP) can help you establish a standard

maintenance procedure.

For your safety, keep the area around

the equipment clear and free of

combustible materials, gasoline, and

other flammable substances. DO NOT

obstruct service access to the

equipment.

MAINTENANCE SCHEDULE

Every 6 months:

Evacuation

Inhibitor Check (if required)

Combustion Analysis

Gas Pressure Check

Flow Rate Check

Palladium Cell Heater Check

Verify Flow Switch Operation

Every 12 months:

Flame Rod Replacement

Igniter Rod Replacement

Every 3 years:

Generator Internal Inspection

Average Cycle for Inhibitor

Replenishment

ROUTINE MAINTENANCE

Routine maintenance should be

provided throughout the life of the

equipment in order to ensure satisfactory

operation and performance.

During the warranty period, an ASP

must be engaged to provide routine

maintenance at the beginning of each

cooling season (spring changeover) and

heating season (fall changeover). When

the chiller-heater is used for process

cooling or heavy load operation, it may

be necessary to schedule additional

service visits to evacuate non-

condensable gasses from the vacuum

section.

Be aware that during the first few

months of operation, non-condensable

gases may accumulate at a greater rate

than expected as the inhibitor coating in

the unit finishes forming. However, after

approximately 3 months, the formation of

non-condensable gases should decrease

to the normal expected rates.

Each routine maintenance item is

covered in detail, many in step-by-step

detail, in Section 5 of the Service

Manual. What is provided here is a brief

summary of what the Service Manual

covers.

EVACUATION OVERVIEW

Arguably the most important aspect of

maintenance for the chiller-heater is

maintaining a proper level of vacuum.

Evacuation is performed at the front of

the machine. The evacuation service

valves are referred to as Service Valve A

(upper) and Service Valve B (lower).

Refer to Fig. 4 for detail on where these

valves are located at the front of the unit.

The evacuation service valves are

back-seating access valves similar to

those used throughout the refrigeration

industry. The stem has a 10mm square

head. The stem secures a copper seal

to a steel seat inside the valve. Do not

over-torque this valve or else the seal

can become damaged and compromise

vacuum integrity.

Yazaki offers a torque wrench (P/N

N7510) specifically for use with this service

valve.

A number of precautions should be

observed at all times during evacuation.

Key points are:

*** Great care must be taken to

ensure that no oil enters the Yazaki

chiller-heater! Permanent damage

could result from even a small amount

of oil being introduced into the

vacuum section! ***

 Never leave a vacuum pump running

unattended. Power loss could allow

the chiller-heater vacuum section to

suck oil out of the pump in a matter of

minutes.

 Never have the Service Valve open

unless the vacuum pump is running

and the integrity of the vacuum lines

between the valve and the pump has

been verified as tight.

 Never have the vacuum pump

discharge tube in the water bucket

unless the vacuum pump is running.

The vacuum pump could suck water

from the bucket and contaminate the

oil charge.

 Never pull a vacuum when the unit is

running in Heat mode. Only pull a

vacuum in “Off” or “Cool” modes.

 Always start with a fresh oil charge in

the vacuum pump.

 Always use a liquid trap or collection

flask.

 Always use a vacuum gauge to verify

the level of vacuum achieved. Run

time has almost nothing to do with the

level of vacuum achieved.

 Never pull a vacuum if the ACT5

Maintenance Checker indicates an LT

temperature exceeding 90°F (32°C).

 Never pull an extended vacuum

(exceeding a few hours). If such seems

to be necessary, there is likely to be

something wrong with the vacuum

pump or the oil has been

contaminated with moisture inherently

found inside the chiller-heater vacuum

section.

Use only dual-stage, deep vacuum

pumps. Typical refrigeration vacuum

pumps may not perform well on a vessel

as large as the chiller-heater vacuum

section. Just because the vacuum pump

has stopped producing bubbles in the

water bucket does NOT mean the

vacuum level is adequate. A digital

vacuum gauge MUST be used in order to

determine the true level of vacuum

achieved.

The desired level of vacuum on a

machine that is not running would be

less than 2000 microns (<2mmHg), with

less than 1000 microns (<1mmHg)

preferred. On a machine actively

running in Cool mode (burner engaged),

the desired level of vacuum is 5000

microns (5mmHg), no less. Any lower

than 5000 microns (5mmHg) on a running

machine will cause the vacuum pump to

remove an extraordinary amount of

refrigerant vapor (water).

A step-by-step, detailed evacuation

method is provided in Section 5 of the

Service Manual. The general evacuation

assembly setup is displayed in Fig. 11.

Fig. 11 – General Evacuation Assembly Setup

CHEMICAL MAINTENANCE

It is not necessary to perform regular

chemical maintenance on the Yazaki

chiller-heater itself. The chemical

balance has been established in the

factory during run testing. Normally, the

only chemical that must be maintained is

the inhibitor charge. By capturing non-

condensable gases, as shown in Fig. 12,

comparison can be made to determine if

the normal hydrogen byproduct is being

produced at anticipated rates. If more

hydrogen is being produced than

anticipated, a maintenance inhibitor

charge may need to be introduced into

the machine by the ASP. An inhibitor

charge is typically needed every three

years in Yazaki gas-fired chiller-heaters.

Fig. 12 – Capturing Gases

WINTERIZING

When equipment is located outdoors

in climates subject to freezing, cooling

water must be drained from the chiller-

heater, piping, and cooling tower at the

end of the cooling season. Use of glycol

may also be permissible. Consult the

Service Manual for details concerning

Anti-Freeze Strategies.

When draining a fluid loop, make sure

to blow through the emptied loop with

compressed air (or similar). Blow in both

directions through the loop so as to blow

out as much of the residual fluid as

possible. This is to help prevent

potential tube damage during freezing

conditions.

TROUBLESHOOTING

SYMPTOM: Chiller-Heater does not operate.

Possible Cause

REMEDY

No High Voltage

Check the LED for the Power indication on the Control Panel. If it is not illuminated, check the

main power disconnect, fuses, and breakers.

Solution Pump Not Running

Check for illumination of the "FAILURE" LED in the row of indicator LEDs for the Solution

Pump. If lit, check the VFD Controller.

Manual Reset Device Tripped

Check the error codes using the display on the front panel or the ACT5 Maintenance Checker

to identify which device is tripped.

Unit Overheated

Check combustion, gas pressure, and vent assembly for conditions that cause over-firing or

prevent proper venting. Check the VFD controller for the Solution Pump. Improper mass flow

through the machine can cause overheating symptoms.

SYMPTOM: Poor cooling capacity.

Possible Cause

REMEDY

Poor Vacuum

Evacuate the machine per normal maintenance procedure.

High Inlet Cooling Water

Temperature

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

Low Cooling Water Flow Rate

Check the cooling tower sump and cooling water circuit strainers.

Condenser/Absorber Fouling,

Scale Buildup

Check the cooling water circuit strainers. It may be necessary to drain the cooling water circuit

and open the inspection doors on the chiller-heater condenser and absorber for a visual

confirmation.

WATER QUALITY

It is the responsibility of the Owner or

End User to have the cooling water

analyzed and chemically treated as often

as is necessary so that it conforms to the

limits shown in Table 1. The water

quality in the chilled/hot water and the

cooling water circuits should not exceed

the following limits:

Note:

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

out of acceptable range.

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

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

inhibitors.

3. For closed-loop cooling towers, use the Hot Water column data in the Circulating Water chart instead

of the Cooling Water column data. For make-up water, use the Chilled Water column data instead of

the Cooling Water column data.

Table 1 – Water Quality Charts

ERROR CODES

Error

Code

Error Description

Notes

DCP power error

Remote monitoring package has lost power.

DCP communication line short

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

DCP communication line noise

Remote monitoring package cannot communicate with the chiller-heater.

Accessory error

Optional fire safety shutdown has been enacted.

Chilled/hot water pump interlock

error

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

junction box.

Cooling water pump interlock

error

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

junction box.

Cooling tower fan interlock error

Voltage signal from terminal CM2 in the junction box is not returning to terminal 5 in the

junction box.

Solution pump error

Solution pump VFD is reporting alarm status.

Generator (HGE) over heat error

GP sensor indicates 325°F (163°C) or greater. Reset allowed when GP sensor reads below

302°F (150°C).

Generator (HGE) temp error

GPSC or GPSH manual limit switch open when it should be closed.

Generator (HGE) solution level

error

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

of burner operation.

WTO sensor error

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

Flow switch error (FS1)

FS1 did not open after "P" dry contacts opened. FS1 assumed stuck closed.

Seismic switch error

Seismic switch is open when it should be closed.

Generator (HGE) over heat alarm

The Generator temperature or HPS pressure reading has been unusually elevated for 30

consecutive minutes, but has not reached 325°F (163°C).

Cooling water scale alarm

The temperature rise through the cooling water circuit is less than expected.

Cooling water scale error

The temperature rise through the cooling water circuit is less than expected to the point

of potentially damaging the chiller-heater.

Freeze protection error

Freeze protection logic steps have been ineffective.

High cooling water temperature

Cooling water above acceptable temperatures: CTI above 95°F (35°C) and/or CTO above

108°F (42°C) for 3 consecutive minutes.

Generator (HGE) over heat in

heating mode

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

Chilled water flow switch error

Flow Switch FS1 is open when it should be closed.

Cooling water flow switch error

Optional cooling water Flow Switch (FS2) is open when it should be closed.

CTO sensor error

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

of P2 operation.

Exhaust gas temperature error

EXH sensor reads above 446°F (230°C)

Generator (HGE) pressure error

HPS indicates a pressure above 750 mmHg for 10 consecutive seconds. Reset allowed

when pressure falls below 550 mmHg.

GP sensor error

GP sensor reads above 446°F (230°C)

CTI sensor error

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

of P2 operation.

Aspirator and exhaust fan error

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

CND sensor error

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

Loss of cooling capacity

LT temperature reading has not fallen below 59°F (15°C) within 30 minutes.

Low cooling water temperature

CTI sensor reads below 46.4°F (8°C) at start of operation, or has dropped below this limit

for 2 consecutive minutes during operation.

Changeover valve error

Changeover valve end switch has not closed within 22 seconds.

Combustion system error

Burner control indicates alarm status. This incorporates all burner limits including air

pressure switch, gas pressure switches, and flame safeties.

LT sensor error

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

Generator (HGE) pressure sensor

error

HPS output below 0.5vdc for 30 consecutive seconds, OR correlation of HPS pressure

reading disagrees with GP senor reading after 10 minutes while GP sensor reads above

212°F (100°C).

Corpus pressure error

HPS pressure reads above typical atmospheric pressure. Chiller-heater requires tubing

inspection to check for tubing breech.

Model setting error

Configuration and options do not match the model selected in ACT5 Unit Data Set.

Check mode neglect

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

Data initial clear

CPU board requires reboot or replacement.

Extended Error Code Alert

An error code number beyond 99 exists.

101

WTI sensor error

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

105

Low chilled/hot water temp alert

WTO sensor reads below 35.6°F (2°C).

Table 2 – Error Codes

YAZAKI AUTHORIZED SERVICE PROVIDER

For information concerning service, operation

or technical assistance, please contact your

Yazaki Authorized Service Provider or the following:

YAZAKI ENERGY SYSTEMS, INC.

701 E PLANO PKWY, SUITE 305

PLANO, TEXAS

75074-6700

Phone: 469-229-5443

Fax: 469-229-5448

Email: yazaki@yazakienergy.com

Web: www.yazakienergy.com

This symbol on the product’s nameplate means it is listed by

UNDERWRITERS LABORATORIES, INC.

Yazaki reserves the right to discontinue, or change at any time,

specifications or designs without notice and without incurring obligations.

MGUL-OI-1C2-0813

Yazaki AROACE CH-MG200 Operating Instructions Manual

Brand: Yazaki

Model: AROACE CH-MG200

Category: Water heaters & boilers

Type: Operating Instructions Manual

This manual is also suitable for

AROACE CH-MG150

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Yazaki AROACE CH-MG200 Operating Instructions Manual

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Yazaki AROACE CH-MG200 Operating Instructions Manual

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