Absorption Chiller
Matrial for Service Course
(Installation, Operation, Maintenance)
Model : TSA-16NK Series
Contents
Page
Safety precautions
Section 1
How does the absorption chiller works?
1-1
Why does a machine chill by giving heat?
1-2
What is latent heat ?
1-3
Principal of absorption chiller
1-4
Principal of single effect type
1-5
Principal of double effect type
1-6
Function of each section & Flow diagrams
1-7
Typical cooling cycle on Duhring diagram
1-8
Heat Balance & COP in cooling mode
Section 2
Illustration of Chiller
2-2
Control panel
2-3
Sensors
2-4
Principal of purging
2-5
Internal structure
2-6
Symbol list
Overview of Installation & Start-up of Chiller
3-2
Check list
3-3
Reference
(1) Typical piping diagram
(2) Field electric wiring diagram
(3) Confirmation of inside pressure of chiller
(4) Detail of interlick
(5) Aging and tube surface cleaning
36
38
56
57
60
61
62
Control
4-1
Over view of control functions
4-2
Operation sequence
4-3
Capacity control & other control functions
4-4
Predication functions (Maintenance message)
4-5
Safet shut-down time chart
Section 5
17
20
25
28
30
33
Installation & Start-up of Chiller
3-1
Section 4
3
4
4
5
7
10
15
16
Illustration of Chiller & Control panel
2-1
Section 3
1
63
66
69
74
77
Trouble Shooting
5-1
Chilled water outlet temp. does not go down in cooling mode
5-2
Trouble shooting at alarm in cooling mode
87
88
814-6-0510-005-00-0
Contents
Page
Section 6
Parts replacement & Instructions
6-1
Guidance interval of parts replacement
6-2
How to change parts
6-3
Method of absorbent solution (LiBr) analyses
6-4
Method of adjusting inhibitor content and alkalinity
6-5
Method of charging solution
6-6
How to perform de-crystallization
6-7
Reference material of tube cleaning
6-8
Solution and refrigerant sampling
6-9
Measuring concentration
6-10
Method of charging Nitrogen gas
6-11
Method of discharging Nitrogen gas
6-12
Information of signals between Chiller/Heater & Weishaupt burner
6-13
Instruction of Leak test
6-14
Instruction of inspection of purge pump
6-15
Instruction of bubble test
6-16
Instruction of refrigerant blow down
6-17
Instruction of field insulation
6-18
Instruction of function test
6-19
Instruction of set & confirmation of controls & safeties
6-20
Set of solution dampers
6-21
Scrapping
6-22
Flow switch
6-23
T.R.G. meter
6-24
How to check temperature sensors
Section 7
99
100
106
109
114
115
118
123
125
127
128
128
129
131
132
134
134
135
138
169
170
171
174
175
Seasonal inspection & operation with daily maintenance
7-1
Begining cooling season
7-2
Mid cooling season
7-3
End of cooling season
7-4
Operation of Chiller
7-5
Purging procedure
7-6
Daily maintenance
7-7
Procedure for a long term shut-down
177
179
181
182
184
185
186
814-6-0510-005-00-0
Safety Precautions
Please follow the safety precautions in this manual to ensure safe installation,
commission, operation and servicing.
WARNING
Before installation and commissioning, please confirm actual operating
condition of the driving heat source, the power supply and the maximum
working pressures of water systems, etc., as compared with the contract
specifications of Chiller to avoid unexpected problems and/or accident.
Authorized personnel only can conduct installation work and relocation work
including slinging work, sliding work to avoid any accidents and/or failure of
Chiller.
Authorized personnel only can replace any parts including electric parts in a
control panels provided on Chiller and conduct any re-adjustment of a burner
and Chiller to avoid any accidents and/or failure of Chiller.
Overhaul of Chiller shall be conducted by authorized personnel only to avoid
any accident and/or failure of Chiller due to incomplete overhaul.
Authorized personnel only can conduct scrapping Chiller to avoid any accidents
and/or to protect any influences to an environment.
A notice, "FOR AUTHORIZED PERSONNEL ONLY" must be affixed to a door or a
wall of machine room in order that any unauthorized personnel does not enter
into the machine room.
1
CAUTION
1. Always turn off breakers before cleaning and checking a cooling tower including its fan,
chilled/hot water pump, cooling water pump and others facilities linking with Chiller to
protect from electric shocks and/or possible injury due to moving parts such as cooling
tower fan.
2. Be sure to stop immediately Chiller in case of a fire, earthquake or thunderbolt to prevent
an accident.
3. Do not touch switches and keys in/on control panels mounted on Chiller with wet hands
to avoid electric shocks.
4. Do not touch wirings and any other electric devices in control panels on chiller with hands
directly to avoid electric shocks. Especially, high voltage wirings.
5. Be sure to ventilate a machine room sufficiently to an avoid oxygen deficiency accident.
6. Do not place any flammables such as gasoline, thinner, etc. near chiller, a flue, a
chimney and/or an oil tank to prevent a fire.
7. Do not touch and/or re-adjust a burner to prevent a fire and/or an oxygen deficiency
accident caused by abnormal combustion. Maintenance and re-adjustment of the burner
shall be conducted by authorized personnel.
8. To prevent a fire, do not operate chiller and turn on/off any switches if gas smell is being
in a machine room.
9. To prevent an oxygen deficiency accident and/or abnormal combustion, be sure to
inspect a flue and a chimney periodically whether there are any exhaust gas leakages
and/or accumulating carbon or not.
10. Do not touch a V-belt of purge pump directly while the purge pump is running to avoid
possible injury.
11. Do not climb up chiller to avoid falling down.
12. A control panels, electric wirings/piping and electric parts provided on chiller shall be
protected from wet to avoid a fire, electric shocks and/or failure of chiller.
13. Be sure to stop chiller if an abnormal combustion such as black smoke is observed to
prevent a fire and/or an accident. And call your service agent as soon as possible.
14. Solve all causes before restarting chiller when alarm happens. If a cause(s) is not
removed, chiller can not be restarted.
15. Do not place heavy objects on chiller or a control panel to avoid possible an injury by its
falling.
16. Do not change all set values of controls and safety devices except for the chilled or hot
water outlet temperature setting to protect abnormal operation condition, unexpected
accident, a faire and/or failure of chiller.
17. Do not touch the absorbent solution directly to prevent from skin diseases. And do not
spill the absorbent solution to prevent from corrosion of metals.
18. Do not touch high temperature portions directly to prevent from burns. Caution levels are
attached with high temperature portions.
19. Stop a purge pump at purge pump replacement to prevent from possible injury by a Vbelt rotating.
2
Section 1
How does the absorption chiller works?
1-1. Cooling : Why does a heating chill ?
The cooling means keeping temperature in a room lower than outside temperature, As shown in Fig. 1-1,
operation to carry the heat from the room with a lower temperature (ex.28 deg.C : 82.4 deg.F) to the open
air with a higher temperature is required. But, in the natural world, the heat can not move from a low
temperature side to a high temperature side. So, to transmit the heat as opposed to this principle, some
method is necessary. That is, a heat pump (chiller) is used to pump up the heat from a low temperature
one as if a water pump is used to draw a water from a deep well.
Outside 32deg.C (90 deg.F)
To the atmosphere
28deg.C
82 deg.F
Chiller
7 deg.C
(45 deg.F)
Cooling
tower
12 deg.C
(54 deg.F)
32 deg.C
(90 deg.F)
Open air
Cooling load
28 deg.C
32 deg.C
(82 deg.F) (90 deg.F)
Heat flow
Fig. 1-1 Heat flow
Air conditioner
The typical chiller using electricity as a operation power
source as a conveyer to carry the heat shown in Fig. 1-2
Lower temp. side
(Cooling)
Higher temp. side
is an centrifugal chiller and the typical chiller using a heat
Indoor
energy is an absorption chiller/heater. Chilled water is made
Grain of heat
by using the latent heat released by a liquid as it evaporates.
Outdoor
Energy
We can experience this principle on our daily life. For
example, when having an injection, after applying alcohol
on the arm, we feel this part cool. Because, applied alcohol
Fig. 1-2 Heat flow at cooling
took the heat from the arm when it is warmed by the body
heat and evaporated. Another example is that we feel cool when sweating on a hot day or by taking exercise.
Because, the body heat is cooled by the evaporation of sweat which takes the heat from the body. These
chillers also use the latent heat of evaporation. But, reuse of evaporated vapor by returning to liquid is
required. For this purpose, the compressor is used in a centrifugal chiller, and an absorbent is chemically used
in an absorption chiller. The absorbent loses the effect. Because its concentration is diluted due to absorbing
the vapor. To recover the absorbing effect, a concentrating process of absorbent by heating is needed.
3
1-2. What is latent heat ?
When water is heated, the temperature rises and stops at 100 deg.C (212 deg.F). With the temperature
remaining constant at 100 deg.C (212 deg.F), the water continues to evaporates as long as it is being heated.
Once water reaches 100 deg.C (212 deg.F), all additional heat goes into changing it from liquid to vapor.
At 100 deg.C (212 deg.F), since vapor is lighter than the surrounding air, it rises. In this case, as water
changes from a liquid to a gas, the applied heat does not change the temperature but changes the state
of water. Therefore the heat is said to be hidden, or latent. Thus latent heat refers to the energy absorbed by
a liquid as it changes state, i.e., to a gas, without changing it's actual temperature. Sensible heat refers to
heat which only results in temperature change rather than change of state.
1-3. Principal elements of absorption chiller/heater in cooling mode
There are following 3 elements on the principal of the absorption chiller/heater.
a. The inside of chiller/heater is vacuum condition.
b. Water (H2O) is used as refrigerant ( Minimum chilled water outlet temp. is 5 deg.C=41 deg.F)
c. Lithium Bromide (LiBr) water solution that has character to absorb water vapor is used as absorbent.
The following descriptions are detail explanations of each elements
(1) Vacuum & water
The earth we live is pressed by the weight of the air of approximate 10 km (6 miles) which is surrounding the
earth and this pressure is called as the atmospheric pressure. The pressure lesser than this pressure is
called as the vacuum. When explaining the vacuum for the absorption chiller/heater, it is needed to know
the relation between the pressure and the evaporation temperature of water. It is experienced in a daily life
that the water is boiled (evaporated) at 100 deg.C (212 deg.F) in the atmospheric pressure. When pressure
is higher than the atmospheric pressure, boiling temperature is higher than 100 deg.C (212 deg.F). And
if the pressure is lower(vacuum), the boiling temperature is lower than 100 deg.C (212deg.F).
The pressure higher than the atmospheric pressure can be experienced with a boiler. The pressure lower
than the atmospheric pressure can be experienced during claming a mountain. Namely, in the mountain, as
the air layer becomes weak by its height, the pressure to be applied becomes low. For this reason, the water
boils at a temperature lower than 100 deg.C (212 deg.F) at the mountain. In other words, evaporation
temperature of the water is depended on pressure. The inside of a chiller/heater is always kept in high
vacuum. In this condition, the water evaporates at very low temperature. For example, at 0.5 kPa
absolute, water evaporates at 5 deg.C (41 deg.F).
(2) Lithium Bromide (LiBr)
Lithium Bromide is medicine which is made from the lithium obtained from lithium ore and the bromide
obtained from the sea water. This medicine is not familiar to us. But we can guess easily Lithium Bromide.
That is, we usually see the salt. The another name of salt is Sodium Chloride.
They are of the same elements, that is Lithium (Li) and Sodium (Na) are alkali while Bromide (Br) and Chlorine
(Cl) are halogen. LiBr and NaCl are chemical materials in the same chemical group and have very similar
characteristics. Especially, the both materials has the characteristic to absorb moisture (water vapor). This
characteristics to absorb moisture of LiBr is stronger than NaCl. The absorption chiller uses the characteristic.
The higher its concentration and lower its temperature of LiBr water solution are, the stronger the
characteristic (absorption power) is.
4
1-4. Principal of single effect type
water
(refrigerant
Closed vessel
(1) Heat exchanger tubes are installed inside a closed vessel.
The vessel is then evacuated to a pressure of about 0.8 kPA
Vacuum
(0.12 psi) absolute. Drops of water (refrigerant) are allowed toChilled water
fall on the heat exchanger tubes.
Water circulating heat exchanger
Fig. 1-3 Evaporating process
(2) Now the vessel has a vacuum of 0.8 kPa (0.12 psi) absolute.
Concentrated LiBr solution
Drops of refrigerant water falling on the exchanger tubes
refrigerant
evaporate at 5 deg.C (41 deg.F) as they remove heat from
the water in the tube. Thus chilled, the water in the heat
exchanger tubes can be used for cooling. Then drops of
concentrated lithium bromide (LiBr) solution are allowed to
Cooling
water
Chilled
water
Absorbing
process
fall into the vessel. The LiBr solution absorbs vaporized
refrigerant.
Vaporized refrigerant
Fig. 1-4 Absorbing process
Refrigerant vapor
(3) When the LiBr solution once absorbs the vaporized
refrigerant, it is diluted and loses its ability to absorb.
Concentrated LiBr
solution
This means that concentrated LiBr solution must be
fed in continuously. At this stage, the diluted solution
Driving
heat source
refrigerant
is heated by driving heat source. The heat causes
the solution to release the absorbed refrigerant and
Cooling
water
Chilled
water
also re-concentrates the solution.
Diluted
LiBr solution
Abs.
Fig. 1-5 Concentrating process
(4) The refrigerant vapor which is released
from the solution when heated, is cooled
in a separate chamber (condenser) to
Generator
Liquid
refrigerant
Condenser
Cooling
water
Driving
heat source
Concentrated LiBr
solution
become liquid refrigerant.
Drops of this water are again introduce
Evaporator
into the vacuum vessel and recycled.
Chilled
water
Cooling
water
Absorber
Abs.
Fig. 1-6 Condensing process
5
(5) This is the basic operational cycle of
Condenser
Generator
the single effect type absorption chiller.
Cooling water flows thru an absorber
and a condenser. The cooling water
Cooling
water
Driving
heat
source
in the condenser cools the refrigerant
vapor from the generator back into
refrigerant. The cooling water in the
Chilled
water
absorber absorbs the heat released
Cooling
water
by the vaporized refrigerant as it is
Abs. pump
absorbed by the LiBr solution.
Evaporator
Absorber
Fig. 1-7 Single effect cooling cycle
6
1-5. Principal of double effect type
(1) Concept & principal of double effect type
In case of the single effect type absorption chiller, all condensation heat generated when the refrigerant
vapor coming from the generator is cooled and condensed in the condenser is released into the cooling
water. The double effect type is designed to use this released condensation heat more effectively for
improvement of energy consumption as compared with single effect type.
Before explaining the principal of double effect type in detail , its concept is simply explained by using an
example of power plant. The dam A has one power plant (Power plant A) and the dam B has two power
plant (Power plant B-1 & B-2). Water flow rate is same at the dam A and dam B. The difference of both
dams is dam height. In this conditions, generated power of Power plant B-1/B-2 is double of generated
power of Power plant A. Namely, if same power is required, the water flow rate of the dam B is enough
1/2 of the water flow rate of dam A. This water flow rate is considered as energy consumption of the
absorption chiller. The double effect type is designed by the same concept. In other words, the double
effect type has two generators and uses high level energy as compared with the single effect type.
Generally, the energy level for the single effect type is about 80 deg.C (176 deg.F)
Dam height : High
(High potential energy)
thru 110 deg.C (230 deg.F) and for the double effect type is
Water flow rate
Power
plant A
Dam A
Dam height : Low
(Low potential energy)
about 165 deg.C (329 deg.F) or more.
Water flow rate
Power
plant B-2
Power
plant B-1
Dam B
Fig. 1-8 Concept of double effect type
As a next step, difference of construction between the single effect type and the double effect type is
shown in Fig.1-9. The construction of the single effect type consists of 4 heat exchangers as section 1-4.
The double effect type consists of 5 heat exchangers. Comparison of names of solution, vapor and
Basic Double Effect Type
liquid is as follows.
Basic Single Effect Type
Refrigerant vapor
Refrigerant vapor
Condenser
Liquid
refrigerant
Generator
Liquid
refrigerant
Concentrated
LiBr solution
Low temp.
Generator
Condenser
Intermediate LiBr solution
High temp.
Generator
Refrigerant vapor
Liquid
refrigerant
Concentrated LiBr solution
Evaporator
Absorber
Refrigerant vapor
Evaporator
Absorber
Refrigerant vapor
Diluted LiBr solution
Diluted LiBr solution
Fig. 1-9 Construction difference
7
The absorption cooling cycle continues as follows.
a) The diluted LiBr solution is sent from the absorber to the high temp. generator by the absorbent pump
through the high & low heat exchangers and is heated by high level driving heat energy.
b) When the diluted LiBr solution temperature reaches at its saturated temperature, refrigerant vapor is
released from the diluted LiBr solution, then the diluted LiBr solution concentration increases
and it becomes intermediate LiBr solution.
c-1) The refrigerant vapor generated in the high
temp. generator goes to the low temp. generator
tube side.
c-2) The intermediate LiBr solution is sent to the low
temp. generator through the high temp. heat
exchanger which cools the intermediate LiBr
solution with the diluted LiBr solution by the
pressure difference between the both generators.
d-1) The refrigerant vapor releases heat to the
intermediate LiBr solution and condenses in the
low temp. generator tubes. It becomes liquid
refrigerant. The liquid refrigerant goes to the
condenser.
d-2) The intermediate LiBr solution is heated again by
the heat from the refrigerant vapor generated in the
high temp. generator and releases again refrigerant
vapor. The intermediate LiBr solution becomes
concentrated LiBr solution.
e-1) The refrigerant vapor generated in the low temp.
generator goes to the condenser and it is cooled
by the cooling water. It becomes liquid
refrigerant. The both liquid refrigerant together
goes to the evaporator.
e-2) The concentrated LiBr solution goes to the
absorber through the low temp. heat exchanger
which cools the concentrated LiBr solution
temperature with the diluted LiBr solution.
f-1) The liquid refrigerant evaporates with receiving
f-2) The concentrated LiBr solution absorbs the
heat from the chilled water. The evaporated
evaporated refrigerant coming from the evaporator,
refrigerant (refrigerant vapor) goes to the
then it becomes diluted LiBr solution.
absorber.
g) The above steps repeat then the absorption cooling cycle continues.
Condensed temp. in H.T.Generator
Temp. :98 deg.C (208 deg.F)
Refrigerant vapor
Low temperature generator
Temp. : 90 deg.C (194 deg.F)
Condenser
Condensed temp.
:38 deg.C (100 deg.F)
o
o
o
o
o
o
o
Cooling
water
o
o
o
o
o
o
o
o
o
o
High temperature generator
Temp. : 145 deg.C
(293 deg.F)
Refrigerant vapor
o
o
o
o
o o o
o o o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o o
o o
o o
o
o
Driving heat source
171 dig's
(340 dig's) or more
o
High temperature
heat exchanger
Liquid refrigerant
Chilled water
Absorber
Evaporator
Cooling
water
Intermediate
LiBr solution
Concentrated
LiBr solution
Absorbent pump
Fig. 1-10 Double effect cooling cycle
Diluted LiBr solution
Low temperature heat exchanger
8
(2) Comparison of driving energy consumption of single and double effect types
The evaporation amount of the refrigerant in the evaporator per one (1) USRT is,
Heat amount of one (1) USRT
=
Evaporation latent heat of refrigerant
3,024 kcal/h
594 kcal/kg
= 5kg/h
Namely, to achieve one (1) USRT of cooling capacity, 5 kg/h of refrigerant is required.
In case of the single effect type, the generator must generates 5 kg/h of refrigerant. Therefore, driving
energy amount to generate 5 kg/h of refrigerant is required.
However, in case of the double effect type, 5 kg/h of refrigerant is generated in the high and low temp.
generators. 3 kg/h of refrigerant is generated in the high temp. generator and 2 kg/h of refrigerant is
generated in the low temp. generator. In other words, the driving energy amount of the double effect type
is for 3 kg/h of refrigerant only. The driving heat amount to generate 2 kg/h of refrigerant can be saved as
compared with the single effect type.
Also, saving driving heat amount can save condensation heat amount in the condenser. Therefore,
cooling water flow arte or cooling water temperature difference can be reduced. It means a facility
of cooling water system can be minimized.
Condenser
Generator
Cooling
water
outlet
5 kg/h
4320 kcal/h RT
Require driving
heat amount
5 kg/h
5 kg/h
Absorbent flow
Cooling
capacity
1 USRT
5 kg/h
Evaporator
Single effect type
Cooling
water
inlet
Absorber
2 kg/h
High temp.
Generator
Low temp.
Generator
2520 kcal/h RT
(Based on LCV)
Require driving
heat amount
3 kg/h
Cooling
capacity
1 USRT
Absorbent flow
5 kg/h
5 kg/h
Condenser
Cooling
water
outlet
3 kg/h
5 kg/h
Evaporator
Double effect type
Absorber
Cooling
water
inlet
Fig. 1-11 Comparison of single effect type & double effect type
9
1-6. Function of each section & Flow diagrams
(1) Evaporator
Function :
To make chilled water
The refrigerant coming from the condenser falls on the refrigerate trays then it disperses equally on the
heat exchanger tubes (evaporator tubes). The refrigerant on the evaporator tubes evaporates with
removing heat from the chilled water which flows in the evaporator tubes. As a result, the chilled water
is chilled.
(2) Absorber
Function :
To keep the pressure for evaporation temperature of the refrigerant in the lower shell
(Remark : The lower shell consists of the evaporator and the absorber.)
The concentrated LiBr coming from the low temp. generator through the low temp heat exchanger falls on
the absorbent trays then it disperses equally on the heat exchanger tubes (absorber tubes).
The concentrated LiBr solution on the absorber tubes absorbs the evaporated refrigerant coming from the
evaporator. When LiBr solution absorbs moisture (refrigerant vapor), the heat named "absorbing heat"
generates. If the absorbing heat is not removed, the concentrated LiBr solution temperature rises. The
absorbing heat must be removed so that it causes to reduce the absorbing power of the concentrated LiBr
solution. This absorbing heat is removed by the cooling water which flows in the absorber tubes.
By means of absorbing the refrigerant vapor with the concentrated LiBr solution cooled, the pressure in
the lower shell can be kept and the chilled water can be produced continuously. After absorbing the
refrigerant vapor, the concentrated LiBr solution becomes diluted LiBr solution and accumulates in the
bottom of the lower shell, then the diluted solution is pumped up to the high temperature generator by
the #1 absorbent pump.
(3) Low temp. heat exchanger / High temp. heat exchanger / Refrigerant drain heat exchanger
Function :
To rise the diluted LiBr solution temperature for improvement of driving energy consumption
by the three heat exchangers
To lower the concentrated LiBr solution temperature for intensification of absorption power
by the low temp. heat exchanger
To lower the intermediate LiBr solution temperature for reduce heat released to cooling water
by the high temp. heat exchanger (in other words, it means saving driving energy consumption)
To lower the refrigerant drain temperature for reduce heat released to cooling water
by the refrigerant heat exchanger (in other words, it means saving driving energy consumption)
The diluted LiBr solution is pumped up to the high temp. generator by the #1 absorbent pump. During it
passes through the three heat exchangers, its temperature is risen with the concentrated LiBr solution,
the intermediate LiBr solution and the refrigerant drain. On the other hand, the concentrated LiBr solution,
the intermediate LiBr solution and the refrigerant drain are cooled with the diluted solution in the each heat
exchangers.
10
(4) High temp. generator
Function :
To heat the diluted LiBr solution for making the intermediate LiBr solution and the refrigerant
vapor for concentrating the intermediate LiBr solution in the low temp. generator.
The diluted LiBr solution coming from the high temp. heat exchanger is heated by the driving heat source.
When the diluted LiBr solution temperature reaches at its saturated temperature, refrigerant vapor is
released form the diluted LiBr solution, then the diluted LiBr solution concentration increases and it
becomes the intermediate solution.
(5) Low temp. generator
Function :
To heat the intermediate LiBr solution for making the concentrated LiBr solution and the
refrigerant vapor.
The intermediate LiBr solution coming from the high temp. generator is heated by the refrigerant vapor
coming from the high temp. generator under the low pressure condition as compared with the high temp.
generator. Then the intermediate LiBr solution releases refrigerant vapor and it becomes the concentrated
LiBr solution.
(6) Condenser
Function :
To cool and condense the refrigerant vapor coming from the low temp. generator
The refrigerant vapor coming from the low temp. generator is cooled and condensed by the cooling water
which flows in the heat exchanger tubes (condenser tubes) of the condenser.
11
Pipe for non-condensable gas going from high temp. generator
to condenser through low temp generator tube side
Pipe for non-condensable gas going from
lower shell (Abso + Evap) to purge unit
Steam inlet
63H
SV7
Pipe for diluted LiBr solution to purge
from #1 absorbent pump to purge unit
DT2
Cooling water
outlet
Low temp.
Generator
Condenser
Steam
control
valve
High temp.Generator
E1-3
Pipe for non-condensable gas going from upper shell (Cond + L Gene)
to lower shall (Abso + Evap)
69
PR
E
F
DT5
PCH
H
L
I
SV9
K
Purge tank
DT4
Rupture disk
G
DT12
D4
DT3
SV8
SV5
B valve
V2
D
69
CH
DT1
High temp.
Heat exchanger
A
Chilled water
outlet
DT6
Steam trap
B
Evaporator M
#2 Absorbent pump
Chilled water
inlet
Absorber
D7
DT11
D6
SV3
Refrigerant
blow valve
D5
Refrigerant drain
Heat reclaimer
LiBr solution
strainer
D3
SV6
DT10
D1
Low temp.Heat
reclaimer
Return pipe for diluted LiBr solution to purge
mp
Cooling water
inlet
Intermediate LiBr solution pipe
Concentrated LiBr solution pipe
Refrigerant solution pipe
Condensed refrigerant solution pipe
Refrigerant vapor pipe
Refrigerant vapor & drain pipe
Steam & steam drain pipe
Damper
Check valve
Orifice
Isolation valve for Abso. & Refr. pumps
Service valve
Diaphragm valves
DT1 :
DT2 :
DT3 :
DT4 :
DT5 :
DT6 :
DT7 :
DT10 :
DT11 :
DT12 :
DT13 :
Chilled water outlet temp. sensor
Cooling water outlet temp. sensor
High temp. generator temp. sensor
Low temp. generator temp. sensor
Condensed refrigerant temp. sensor
Chilled water inlet temp. sensor
Cooling water inlet temp. sensor
Diluted LiBr solution temp. sensor
Refrigerant in evaporator temp. sensor
Middle cooling water temp. sensor
Steam drain temp. sensor
C
DT7
#1 Absorbent pump
Purge unit
Diluted LiBr solution pipe
Low temp.
Heat
Exchanger
D2
SV4
Refrigerant pump
J
D8
DT13
High temp.
Heat reclaimer
Steam drain outlet
PCH :
63GH :
69PR :
69CH :
E1-3 :
Palladium cell heater
High temp. generator pressure switch
Purge tank pressure switch
Chilled water flow switch
High temp. generator solution level electrodes
Fig. 1-12 Flow diagram
(For 16NK-11 thru 61)
12
Pipe for non-condensable gas going from high temp. generator
to condenser through low temp generator tube side
Pipe for non-condensable gas going from
lower shell (Abso + Evap) to purge unit
Steam inlet
63H
SV7
Pipe for diluted LiBr solution to purge
from #1 absorbent pump to purge unit
DT2
Cooling water
outlet
Low temp.
Generator
Condenser
Steam
control
valve
High temp.Generator
E1-3
Pipe for non-condensable gas going from upper shell (Cond + L Gene)
to lower shall (Abso + Evap)
69
PR
E
F
DT5
PCH
H
L
I
SV9
K
Purge tank
DT4
Rupture disk
G
DT12
D4
DT3
SV8
SV5
B valve
V2
D
69
CH
DT1
High temp.
Heat exchanger
A
Chilled water
outlet
DT6
Steam trap
B
Evaporator M
#2 Absorbent pump
Chilled water
inlet
Absorber
D7
DT11
D6
SV3
Refrigerant
blow valve
LiBr solution
strainer
D5
D3
DT10
D1
Refrigerant drain
Heat reclaimer
SV6
J
C
Return pipe for diluted LiBr solution to purge
mp
D2
SV4
DT7
#1 Absorbent pump
Cooling water
inlet
Refrigerant pump
Purge unit
Diluted LiBr solution pipe
Intermediate LiBr solution pipe
Concentrated LiBr solution pipe
Refrigerant solution pipe
Condensed refrigerant solution pipe
Refrigerant vapor pipe
Refrigerant vapor & drain pipe
Steam & steam drain pipe
Damper
Check valve
Orifice
Isolation valve for Abso. & Refr. pumps
Service valve
Diaphragm valves
DT1 :
DT2 :
DT3 :
DT4 :
DT5 :
DT6 :
DT7 :
DT10 :
DT11 :
DT12 :
DT13 :
Chilled water outlet temp. sensor
Cooling water outlet temp. sensor
High temp. generator temp. sensor
Low temp. generator temp. sensor
Condensed refrigerant temp. sensor
Chilled water inlet temp. sensor
Cooling water inlet temp. sensor
Diluted LiBr solution temp. sensor
Refrigerant in evaporator temp. sensor
Middle cooling water temp. sensor
Steam drain temp. sensor
Low temp.
Heat
Exchanger
DT13
High temp.
Heat reclaimer
Steam drain outlet
PCH :
63GH :
69PR :
69CH :
E1-3 :
Palladium cell heater
High temp. generator pressure switch
Purge tank pressure switch
Chilled water flow switch
High temp. generator solution level electrodes
Fig. 1-13 Flow diagram
(For 16NK-62 thru 63)
13
Pipe for non-condensable gas going from high temp. generator
to condenser through low temp generator tube side
Pipe for non-condensable gas going from
lower shell (Abso + Evap) to purge unit
Steam inlet
63H
SV7
Pipe for diluted LiBr solution to purge
from #1 absorbent pump to purge unit
DT2
Cooling water
outlet
Low temp.
Generator
Condenser
Steam
control
valve
High temp.Generator
E1-3
Pipe for non-condensable gas going from upper shell (Cond + L Gene)
to lower shall (Abso + Evap)
69
PR
PCH
E
F
DT5
H
L
I
SV9
K
Purge tank
DT4
Rupture disk
G
DT12
D4
DT3
SV8
SV5
B valve
V2
D
69
CH
Refrigerant blow valve
DT6
Chilled water
inlet
High temp.
Heat exchanger
A
A
Steam trap
B
M
B
Evaporator
Absorber
#2 Absorbent pump
DT1
Chilled water
outlet
D7
D6
D5
DT11
LiBr
solution
strainer
SV3
Refrigerant
pump
D3
DT10
D9
D1
Refrigerant drain
Heat reclaimer
SV6
J
C
mp
D2
SV4
Return pipe for
diluted
#1 Absorbent pump
DT7
Low temp.
Heat
Exchanger
Purge unit
Diluted LiBr solution pipe
Concentrated LiBr solution pipe
Refrigerant solution pipe
Condensed refrigerant solution pipe
Refrigerant vapor pipe
Refrigerant vapor & drain pipe
Steam & steam drain pipe
Check valve
Orifice
Isolation valve for Abso. & Refr. pumps
Service valve
Diaphragm valves
PCH :
63GH :
69PR :
69CH :
E1-3 :
Palladium cell heater
High temp. generator pressure switch
Purge tank pressure switch
Chilled water flow switch
High temp. generator solution level electrodes
Cooling water
inlet
Intermediate LiBr solution pipe
Damper
DT1 :
DT2 :
DT3 :
DT4 :
DT5 :
DT6 :
DT7 :
DT10 :
DT11 :
DT12 :
DT13 :
Chilled water outlet temp. sensor
Cooling water outlet temp. sensor
High temp. generator temp. sensor
Low temp. generator temp. sensor
Condensed refrigerant temp. sensor
Chilled water inlet temp. sensor
Cooling water inlet temp. sensor
Diluted LiBr solution temp. sensor
Refrigerant in evaporator temp. sensor
Middle cooling water temp. sensor
Steam drain temp. sensor
DT13
High temp.
Heat reclaimer
Steam drain outlet
Fig. 1-14 Flow diagram
(For 16NK-71 thru 81)
14
oling cycle on Duhring diagram
of cooling operation cycle of the double effect type on the Duhring diagram is as follows.
deg.F / deg.C
(101.42kPa) 212 / 100
B
B
: Absorption process in the absorber
: Evaporation process in the evaporator
entrated LiBr solution of 62.8% at point J goes into the absorber. When the
F
D
ted LiBr solution temperature reaches point A, it begins to absorb the
vapor coming from the evaporator. The concentrated LiBr solution continues
E
Water vapor
K
(580mmHg)
588.5kPa
(47.42kPa) 176 / 80
s the refrigerant, being cooled by cooling water. Then the concentrated LiBr
ecomes the diluted LiBr solution of 55.3% and 34.6 deg.C (94.3 deg.F) at point B.
(Refrigerant) Water
LiBr : 70%
ure between point A and B is 0.83 kPa which is equal to the saturation vapor
of water at 4.3 deg.C (39.7 deg.F), so the chilled water at 6.7 deg.C (44 deg.F)
oduced in the evaporator.
Concentration of
diluted LiBr solution : 55.3%
(19.65kPa) 140 / 60
: Heat exchanging process in the refrigerant drain heat exchanger,
& the low temp. heat exchanger (and low temp. heat reclaimer)
ate 20 % of the diluted LiBr solution receives heat from the refrigerant drain in the
drain heat exchanger. Approximate 80% of the diluted LiBr solution receives heat
oncentrated LiBr solution in the low temp. heat exchanger. The both diluted LiBr
C
(7.38kPa) 104 / 40
Water vapor
L
(46.8mmHg) 4.9kPa
Concentration of
intermediate LiBr solution : 59.1%
G
I
H
of which temperatures are risen are mixed at point C.
: Heat exchanging process in high temp. heat exchanger
& high temp. heat reclaimer
(2.34kPa) 68 / 20
d LiBr solution receives heat from the intermediate LiBr solution in the high temp.
Concentration of
concentrated LiBr solution :
anger and its temperature rises more then reaches point D.
Water vapor
M
F
K
: Heating and concentrating process of the diluted LiBr solution
B
(6.2mmHg) 0.83kPa
A
in the high temp. generator
d LiBr solution at point D is heated by the driving heat source until point E. After
iluted LiBr solution at point E is more heated then it releases refrigerant vapor.
ntly, it is concentrated and becomes the intermediate LiBr solution of 59.1% and
(0.61kPa) 32 / 0
10
20
30
40
36.9 deg.C
98.4 deg.F
4.3 deg.C
39.7 deg.F
34.6 degC
94.3 deg.F
50
J
60
70
80
90
100
92.5 deg.C
198.5 deg.F
110
120
Temperature (deg.C)
130
140
150
160
144.4 deg.C
291.9 deg.F
88.6 deg.C
191.5 deg.F
.C (291.9 deg.F) at point F.
Fig. 1-15 Duhring diagram in cooling cycle
: Heat exchanging process in high temp. heat exchanger
mediate LiBr solution releases heat to the diluted LiBr solution in the high temp. heat exchanger and its temperature lowers then reaches point G.
I
L
: Heating and concentrating process of the intermediate LiBr solution
in the low temp. generator
mediate LiBr solution at point G goes into the low temp. generator and its temperature lowers by self-evaporation at point H. After that, the intermediate
on at point H is heated by the refrigerant coming from the high temp. generator then it releases refrigerant vapor. Consequently, it is concentrated and
he concentrated LiBr solution of 62.8% and 88.6 deg.C (191.5 deg.F) at point I.
: Heat exchanging process in low temp. heat exchanger
entrated LiBr solution releases heat to the diluted LiBr solution in the low temp. heat exchanger and its temperature lowers then reaches point J.
cycle can continues by means of repeating the above process.
15
1-8. Heat Balance & COP in cooling mode
(1) Heat balance
In order to cheek whether measured data is correct or not, heat balance is useful.
Basic consideration of the heat balance : Heat amount coming into a chiller = Heat amount going out from a chiller
The above consideration shows by the formula : (Qa + Qc) / (Qe + Qg) = 1
Qe : Heat amount coming into a chiller from an evaporator
Qg : Heat amount coming into a chiller from a high temp. generator
Qa : Heat amount going out from a chiller through an absorber
Qc : Heat amount going out from a chiller through a condenser
CHi,CHo,COi & COo : Temperature
Fg : Steam consumption (kg/h)
Hs : Specific enthalpy at supply steam pressure (kcal/kg)
Hd : Specific enthalpy at steam drain temperature (kcal/kg)
In case of SI unit
In case of US unit
Qe = (CHi - CHo) X Fe X 1000 / 860
Qe = (CHi - CHo) X Fe X 500
Qg = (Hs - Hd) X Fg / 860
Qg = (Hs - Hd) X Fg
Qa + Qc = (COo - COi) X Fc X 1000 / 860
Qa + Qc = (COo - COi) X Fc X 500
Example
Example
CHi =
12.2
deg.C
Qe = 352.4
kW
CHi =
54
deg.F
Qe = 1,200,000 Btu
CHo =
6.7
deg.C
Qg = 274.7
kW
CHo =
44
deg.F
Qg =
3
935,400
Btu
Fe =
54.5
m /h
Qe + Qg = 627.0
kW
Fe =
240
gpm
Qe + Qg = 2,135,400 Btu
COi =
29.4
deg.C
Qa + Qc = 628.8
kW
COi =
85
deg.F
Qa + Qc = 2,140,000 Btu
COo =
35.4
deg.C
Heat balance = 1.00
COo =
95.7
deg.F
90.8
3
m /h
Fc =
400
gpm
Fg = 400.0
kg/h
Fg =
880
lb/h
Fc =
Heat balance = 1.00
Hs = 661.93 kcal/kg at 784 kPa
Hs = 1191.5 Btu/lb at 114 psig
Hd = 71.40
Hd = 128.5
kcal/kg at 71.4 deg.C
COo
Btu/lb at 160.5 deg.F
Low temp.
Condense Generator
Fc
High temp.
Generator
Qc
Qg
Steam inlet
Fg
Steam drain outlet
CHo
Evaporator
CHi
Qe
Absorber
Fe
Chilled water
Qa
COi
Cooling water
Fig. 1-16
(2) COP
COP is shown by the following formula. COP of NK series is about 1.28 under the condition of the standard
COP =
Qe
Qg
specification. This value changes depending on required specifications. When a operation
data is recorded, if its COP differs very much from the COP of specifications, it may be
wrong data recording or insufficient cooling performance of a chiller.
Remark: In case of calculating heat balance and COP, cooling water inlet temperature and cooling load
shall be stable for minimum 10 to 15 minutes. Because the response of absorption chiller
is not rapid as compared with a electric type chiller.
16
Section 2
Illustration of chiller & control panel
2-1. Illustration of Chiller
(1) 16NK-11 thru 16NK-61
4
9
10
7
2
8
5
1
Chilled water inlet
2
Chilled water outlet
3
Cooling water inlet
4
Cooling water outlet
5
Evaporator
6
Absorber
7
Condenser
8
Control panel
9
Low temp. generator
10
High temp. generator
11
Purge pump
1
6
11
3
Fig. 2-1
12
13
14
15
16
17
18
Fig. 2-2
12 Purge unit
15 No.1 Absorbent pump
13 High temp. heat exchanger
16 Low temp. heat exchanger
14 Heat reclaimer
17 No.2 Absorbent pump
18 Steam trap
17
(2) 16NK-62 thru 16NK-63
4
9
10
7
2
8
14
5
1
1
Chilled water inlet
2
Chilled water outlet
4
Cooling water outlet
5
Evaporator
6
Absorber
7
Condenser
8
Control panel
9
Low temp. generator
10
High temp. generator
11
Purge pump
14
Heat reclaimer
6
11
Fig. 2-3
17
13
14
16
19
15
18
Fig. 2-4
13 High temp. heat exchanger 18 Steam trap
14 Heat reclaimer
19 Refrigerant pump
15 No.1 Absorbent pump
16 Low temp. heat exchanger
17 No.2 Absorbent pump
18
(3) 16NK-71 thru 16NK-81
4
9
1
Chilled water inlet
2
Chilled water outlet
3
Cooling water inlet
4
Cooling water outlet
5
Evaporator
6
Absorber
7
Condenser
8
Control panel
9
Low temp. generator
10
High temp. generator
6
11
Purge pump
1
14
Heat reclaimer
10
7
2
8
14
5
6
3
11
Fig. 2-5
13
14
15
19
16
17
18
Fig. 2-6
13 High temp. heat exchanger
14 Heat reclaimer
15 No.1 Absorbent pump
16 Low temp. heat exchanger
17 No.2 Absorbent pump
18 Steam trap
19 Refrigerant pump
19
2-2. Control panel
(1) For UL
1
2
5
6
7
8
9
2
3
4
Fig. 2-7
1
Fan
2
Terminal block
3
Terminal block for power supply
4
Ground terminal
5
Display panel
6
Alarm buzzer
7
Purge indication lamp
8
Purge pump on-off switch
9
Emergency stop button
CAUTION : Do not push the emergency stop button except an emergency.
If push, the chiller stops without dilution operation.
This may be possible to occur crystallization problem.
IP No. of control panel : 54
20
11
21
12
22
13
14
13
15
13
24
16
17
23
18
19
14
20
Fig. 2-8
11 Control relay
12 Circuit protector
13 Terminal block
14 Fuse
15 I/O board
16 AC Reactor
17 DC Reactor
18 Inverter
19 Main circuit breaker
20 Electromagnetic contactor
21 Transformer (TR-1)
22 Transformer (Class 2) (TR-2)
23 Transformer (24V) (TR-3)
24 Transformer (230V) (TR-4) for using 460V only
21
(2) For CE
1
5
2
6
7
8
2
10
3
4
Fig. 2-9
1
Fan
2
Terminal block
3
Terminal block for power supply
4
Ground terminal
5
Display panel
6
Alarm buzzer
7
Purge indication lamp
8
Purge pump on-off switch
10 Main circuit breaker
IP No. of control panel : 54
22
21
11
28
15
12
25
13
26
16
23
17
22
18
19
20
27
Fig. 2-10
11 Control relay
12 Circuit protector
13 Terminal block
15 I/O board
16 AC Reactor
17 DC Reactor
18 Inverter
19 Main circuit breaker
20 Electromagnetic contactor
21 Transformer (TR-1)
22 Transformer (24V) (TR-2)
23 Transformer (230V) (TR-3)
25 Circuit breaker for inverter
26 Circuit breaker for pumps
27 Filter
28 Isolator
23
(3) Display panel
8
1
1 2 3. 4
Super Absorption
2
STOP
RUN
13
CHILLER
#1 ABS PUMP
#2 ABS PUMP
REF PUMP
SET
BACK
PURGE PUMP
14
9
10
11
REMOTE
STAND BY
DILUTION
BUZZER STOP
LOCAL
6
SAFETY CIRCUIT
13
7
OPERATIO
CHILLER ALARM
RUN
STOP
POWER
Fig. 2-11
Symbol
3
Name
Lamp color
1
Operation indication lamp
Green
2
Stop indication lamp
Orange
3
Alarm indication lamp
Red
6
Remote/Local select key with lamp
Green
7
Operation select key with lamp
Green
8
Data display (7 segments)
LED
9
Stand by indication lamp
Green
10
Dilution indication lamp
Green
11
Safety circuit indication lamp
Green
12
Power indication lamp
Orange
13
Data select key
14
Alarm buzzer stop key
24
2-3. Sensor
(1) Pressure sensor (PCH : Purge tank pressure sensor)
41.3 mm(1.63inch)
41.3 mm(1.63inch)
Connected pin No.
Model
: FSK-S16
Total accuracy
: +/- 3% FS (-10 --- 50 deg.C)
(12 -- 122 deg.F)
Max. working pressure
: 0.15 Mpa (G)
3 2 1
Volt
2
Vc
1
Connection
Sensor
46mm(1.811inch)
GND
3
1
Vc
DC 10.5 - 28V
2
Volt
3
GND
7/16-20UNF Flare
Fig. 2-12
25
(2) Temperature sensor
TSA-16NK series uses 3 type temperature sensors. One is Resistance thermometer bulb, second one is
Thermistor, last one is Digital sensor.
Dia.5.5mm
0.2 inch
a) Resistance thermometer bulb
2100±80mm / 82.68±3.15 inch
50mm / 1.97 inch
Fig. 2-13
Model
: AEK-23H520
Used for
: Chilled water outlet temperature sensor (DT1)
Resistance : 2000Ω at 0 deg.C (32 deg.F)
Rating of resistance : 8.56Ω/deg.C
Ex. 2256.8Ω at 30 deg.C (86 deg.F)
Dia.6±0.5 mm
0.25±0.02 inch
b) Thermistor
150±3 mm
5.9±0.12 inch
about 36 mm
1.42 inch
2500±150mm
98.4±5.9 inch
Fig. 2-14
Model
: U1SC-D312-S2
Used for
: High temp. generator temperature sensor (DT3)
: Steam drain temperature sensor (DT13)
Resistance : 1kΩ±3% at 200 deg.C (392 deg.F)
Temperature & Resistance Table
Temperature
Resistance
Deg. C
Deg. F
k ohm
0
32
806.5
30
86
184.1
40
104
118.7
50
122
78.3
60
140
52.8
70
158
36.3
80
176
25.4
90
194
18.1
100
212
13.1
200
392
1.0
26
Dia.7±0.5 mm
0.28±0.02
c) Digital sensor
50±2mm/1.97±0.08 inch
1000±20mm / 39.4±0.79 inch: SEC-SSH-SST01SAC-L1000
2000±50mm / 78.7±1.97 inch : SEC-SSH-SST01SAC
Fig.2-15
Model
: SEC-SSH-SST01SAC-L1000 & SEC-SSH-SST01SAC
Used for
: Cooling water outlet temperature sensor (DT2)
: Low temp. generator temperature sensor (DT4)
: Condenser temperature sensor (DT5)
: Chilled water inlet temperature sensor (DT6)
: Cooling water inlet temperature sensor (DT7)
: Absorber temperature sensor (DT10)
: Evaporator temperature sensor (DT11)
: Middle cooling water temperature sensor (DT12)
IC tip provided in the digital sensor detects temperature and send it's data to CPU board through
the communication line as shown below. Addresses are provided in each digital sensors.
If a digital sensor is replaced, it's address must be confirmed.
Control panel
Communication line
CPU Board
Digital
sensor
Digital
sensor
Digital
sensor
Fig. 2-16
Address Symbol
Sensor Name
03
DT2
Cooling water outlet temperature sensor
07
DT4
Low temp. generator temperature sensor
05
DT5
Condenser temperature sensor
01
DT6
Chilled water inlet temperature sensor
02
DT7
Cooling water inlet temperature sensor
12
DT10 Absorber temperature sensor
08
DT11 Evaporator temperature sensor
04
DT12 Middle cooling water temperature sensor
27
2-4. Principal of purging
(1) Purpose of the purging
It is very important for the chiller to keep a vacuum.
The chiller generates a few amount of Hydrogen gas during operation, and the non-condensable gases are
contained in the solution. Those gases worse a vacuum condition of the chiller.
It means the performance fall of the chiller. Therefore, we have to discharge them from the chiller.
(2) Purge system
The chiller has two purge system. One is Palladium cell for discharge Hydrogen gas from the chiller.
Another is purge pump for purging non-condensable gases which correct into the tank by fluid ejector.
a) Palladium cell
The palladium film has a property to permeate Hydrogen gas when it is 300 - 500 deg.C (572 - 932 deg.F).
Steps that Hydrogen permeates through the palladium are as follows.
a-1) Hydrogen is absorbed on the surface of the palladium by an affinity.
a-2) Absorbed hydrogen dissociates and loss an electron then it becomes a proton.
a-3) The proton invades into the grid of palladium and it diffuses in the palladium by the difference of
hydrogen density.
a-4) The proton returns hydrogen gas state and goes out to outside.
Other gases which can not dissociate with a proton - electron state can not permeate in the
palladium film.
H2
P1
P2
Permeation
H2
Palladium film
(heated to 200 - 300 deg.C)
392 - 572 deg.F
P1 > P2
P1 : Density of hydrogen before palladium film
P2 : Density of hydrogen after palladium film
Fig. 2-17
28
b) Correct gases by fluid ejector
When the LiBr solution gushing out from the ejector goes into the solution level B,
it involves bubbles of non-condensable gas.
The LiBr solution and the gas together come down to the bottom of the tank.
The LiBr solution returns to the absorber, and the gas comes up and accumulates in the tank.
The volume of non-condensable gases existing in the lower shell which is equal to the gas
accumulated in the tank moves to A from the lower shell.
By means that the above is continuously repeated during operation of the chiller,
non-condensable gases existing in the chiller is accumulated in the tank,
then the gas can be purged by the purge pump to the air.
LiBr solution from Absorbent
pump discharge
Non-condensable gas from the
inside of Chiller
A
Ejector
Lower shell
Tank
Non-condensable gas
purged by a purge
pump
Fluid gushing out
from ejector
LiBr solution
B
Non-condensable
bubbles
Fig. 2-18
29
2-5. Internal structure
(1) Upper shell
Tube sheet
Eliminator
Shell
Tube support
Condenser tube
Purge tank
Generator tube
Baffle
Shell
Tube sheet
30
(2) Lower shell
Shell
Tube sheet
Evaporator tube
Refrigerant tray
Absorbent tray
Absorber tube
Tube support
Sight glass
Eliminator
Tube sheet
31
(3) Heat exchanger
Baffle
Shell
Tube
Header
Tube sheet
Header
Tube sheet
32
2-6. Symbol list
(1) Temperature sensor
Symbol
Name
DT1 Chilled water outlet
DT2 Cooling water outlet
DT3 High temp. generator
DT4 Low temp. generator
DT5 Condensed refrigerant
DT6 Chilled water inlet
DT7 Cooling water inlet
DT8
(Blank)
DT9
(Blank)
DT10 Diluted LiBr solution
DT11 Refrigerant
DT12
Middle cooling water
DT13
Steam drain
(2) Electric parts on the chiller
Symbol
Name
PCH Palladium cell heater
High temp. generator
63GH
pressure switch
69PR Purge tank pressure switch
69CH Chilled water flow switch
E1
High temp. generator
E2
solution level electrode
E3
(3) Damper
Symbol
Name
D1
Diluted solution #1
D2
Diluted solution #2
D3
D4
D5
D6
D7
Diluted solution #3
Intermediate solution
Concentrated solution
Refrigerant drain
Refrigerant
D8
Diluted solution bypass
D9
Refrigerant supply
Location
Chilled water outlet nozzle
Cooling water outlet nozzle
Solution outlet box on High temp. generator
Low temp. generator outlet pipe
Refrigerant pipe of condenser outlet
Chilled water inlet nozzle
Cooling water inlet nozzle
#1 Absorbent pump outlet
Refrigerant pump inlet
Cooling water pipe
between absorber and condenser
Steam drain outlet nozzle at heat reclaimer
Location
Purge tank
Refrigerant pipe on upper shell
Purge tank
Chilled water outlet nozzle
Solution outlet box on High temp. generator
Location
#1 Absorbent pump outlet
Low temp heat exchanger inlet for NK-11 thru 61
Low temp heat exchanger outlet for NK-62 thru 82
Refrigerant drain heat reclaimer inlet
High temperature heat exchanger outlet
Low temperature heat exchanger outlet
Refrigerant drain heat reclaimer outlet
Refrigerant pump outlet
Bypass pipe of Low temp. heat reclaimer
(NK-11 thru 61 only)
Refrigerant pump outlet to refregerant overflow
pipe from condenser (NK-71 - 81 only)
33
(4) Service valve
Symbol
Name
SV1 Purge
SV2 Purge
SV3 Refrigerant
SV4 Diluted solution
SV5 Intermediate solution
SV6 Concentrated solution
SV7 Generator pressure
SV8 Generator bottom
SV9 Purge tank
Location
Suction pipe of purge pump
Suction pipe of purge pump
Refrigerant pump outlet pipe
#1 Absorbent pump outlet
High temperature heat exchanger outlet
Low temperature heat exchanger outlet
Refrigerant vapor pipe on upper shell
Bottom of high temperature generator
Side of purge tank
(5) Diaphragm valve
Symbol
Name
V1
Purge pump
V2
Purge for purge unit
V3
Purge for shell
B valve Purge for purge tank
Location
Suction pipe of purge pump
Suction pipe of purge pump
Suction pipe of purge pump
Suction pipe of purge pump
34
(6) Control panel (Electric wiring diagram)
Symbol
Name
ACL AC reactor
BZ
Alarm buzzer
CP1,2, 3 Circuit protector
DCL DC reactor
F1-14 Fuse
FILTER EMI Filter
FM
Fan motor
GL
Purge indication lamp
INV
Inverter
ISO
Isolator
MA1 #1 Absorbent pump
MA2 #2 Absorbent pump
MP
Purge pump
MR
Refrigerant pump
MCBM Main circuit breaker
MCBA1 #1 Absorbent pump circuit breaker
MCB1-3 Circuit breaker
PCH Palladium cell heater
TR1 - 4 Transformer
23CH1 CPU board
23CH2 Indication board
23CH3 I/O board
23CH4 Power board
4Xn
Control relay
43ES Emergency stop switch
43P
Purge pump ON-OFF switch
51A2 #2 Absorbent pump over current relay
51P
Purge pump over current relay
51R Refrigerant pump over current relay
63GH HT generator pressure switch
69CH Chilled water flow switch
69CO Cooling water flow switch
69PR Pressure sensor for purge tank
88A2 #2 Absorbent pump magnet switch
88P
Purge pump magnet switch
88R Refrigerant pump magnet switch
4Y1,2
52CH
52CO
CMS
CVP
Remote signal
Chilled water pump inter lock
Cooling water pump interlock
Steam control valve motor
Steam control valve actuator positioner
(Field supply)
(Field supply)
(Field supply)
(Field supply)
(Field supply)
35
Section 3
Installation & Start-up of chiller
3-1. Overview of Installation & chiller Start-up
The following sequence gives an overview of the procedure for Installation and Chiller Start-up.
(1) Installation of Chiller
a Delivery inspection
To check damages and/or missing parts on Chiller
b Location
& Space requirements
To check location and service space requirements of Chiller
c Confirmation of
inside pressure
To check the inside pressure of Chiller charged at the factory
Assembly of chiller (Multiple section shipment)
Leak test after assembling multiple section shipment
d Leveling
To conduct the leveling of chiller
e Field piping connection
To conduct water, steam and steam drain piping to chiller
f Tightness confirmation
To check tightness condition of water boxes, etc. of chiller
g Field wiring connections
To conduct field wirings of power and interlock wirings, etc. to chiller
h Rupture disk discharge piping
To provide a rupture disk vent line
i Insulation
To provide insulation for hot and cold surface of chiller
(2) Confirmation before start-up of chiller
a Chilled water system
b Cooling water system
c Steam and drain system
d Electric wiring and power supply
e Cooling load
36
(3) Start-up of chiller
a Confirmation of
electric system
To confirm all field wirings for chiller
b Confirmation of
auxiliary equipments
To confirm water systems and steam systems
c Confirmation of
inside pressure
To check the inside pressure of chiller charged at the installation
d Leveling verification
To check the leveling of chiller
e Megger test
To check resistance of purge pump and solution (Abso & Refr) pumps
f Inspection of purge unit
To check purge pump running condition and its attained vacuum
g Bubble test
To check vacuum leakage of chiller by the bubble test
h Setting & confirmation of
controls & safeties
To set and confirm settings of controls and safeties by keys on the
operation board (Microprocessor)
i Function test of safeties
To confirm that safety functions work properly
j Confirmation of valve opening
conditions
To confirm valve opening condition of isolation
k Aging & refrigerant blow
down work
To clean outer surface of evaporator tubes and to conduct refrigerant
blow down
l Adjustment of steam control
valve
To adjust the valve lift
m Trial run
To run chiller and to check operating condition of systems including
chiller. (If necessary, conduct tuning the systems and chiller)
n Operating data record
37
3-2. Check list
General
This check list covers the installation and the start-up of Steam fired Chiller models TSA-16NK series.
This check list is intended to assist the personnel with the details required with the installation and the start-up
of the series. This check list should be used in conjunction with the appropriate the installation manual
provided with the unit.
Installation check list
Job Name
:
Job location
:
Chiller model
:
TSA-16NK-
The work is in process and
:
will be completed by
Serial number :
Date
:
(1) Delivery inspection : The following items shall be inspected.
Correct model and serial numbers. Compare all operating specifications as outlined in the "Contract
specification" with the nameplate on the chiller.
Inspect for physical damage to chiller including external devices, control panel and wiring.
Inspect all separate shipping boxes and components shipped with chiller.
Yes
No
N/A
1) Specifications of Chiller ordered vs. Chiller nameplate
2) Control panel
a) Display panel
b) Emergency stop button (UL only)
c) Purge pump ON/OFF switch
d) Purge indication lamp
e) Alarm buzzer
f) Fan
j) Main circuit breaker (CE only)
3) Purge unit
a) Purge pump
b) Liquid trap
c) Purge tank
d) Service valve (SV9)
e) Purge tank pressure switch (69PR)
f) Palladium cell & palladium cell heater (PCH)
g) Diaphragm valves (V1,V2,V3)
h) Service valves (SV1,SV2,SV9)
38
Yes
No
N/A
4) Main shell (upper shell, lower shell, heat exchangers)
a) Water headers (evaporator, absorber, condenser)
b) Connection flanges (chilled water, inlet/outlet)
c)
(cooling water, inlet/outlet)
d) #1 absorbent pump, #2 absorbent pump, refrigerant pump
e) Sensors (DT1, DT2, DT3, DT4, DT5, DT6, DT7, DT10, DT11, DT12, DT13)
f) Chilled water flow switch (69CH)
g) Service valves (SV3, SV4, SV5, SV6)
h) Dampers (D1, D2, D3, D4, D5, D6, D7, D8)
i) Refrigerant blow valve
j) Rupture disk
k) Absorber sight glass
l) Evaporator sight glass
5) High temperature generator and heat reclaimer
a) Headers for high temp. generator
b) Headers for heat reclaimer
c) Piping flanges
d) Steam trap
e) Steam control valve
f) Steam shutoff valve
g) Service valves (SV7, SV8)
h) High temp. generator pressure switch (63GH)
i) Generator solution level electrodes (E1, E2, E3)
j) High temp. generator sight glass for solution level
k) High temp. generator pressure gauge
6) Absorbent & Refrigerant (For multiple section shipping Chiller only)
7) Accessories (If there are shortages, record them.)
8) Spare parts (If there are shortages, record them.)
39
(2) Location & Space requirements : The following items shall be inspected.
Chiller is designed for indoor application and must be installed in a space where the ambient
temperature is between 5 deg.C (41 deg.F) and 40 deg.C (104 deg.F), at no time more than 90%
relative humidity.
Clearance must be provided at either and of to facilitate tube cleaning or removal and clearance
on all other sides of Chiller for general Chiller maintenance.
See DIMENSION drawings in the contract specification for clearance requirements.
Yes
1) Location
Basement
Floor
No
N/A
Roof
2) Foundation
3) Clearance for maintenance
4) Clearance for tube cleaning/removal
(3) Confirmation of inside pressure : The following item shall be inspected.
The inside pressure of Chiller must be more than 0 MPa on a gauge.
It can be simply checked the following way instead of using the gauge.
If nitrogen gas is powerfully and continuously released from the service valve (SV1),
it can be judged that there is no-leakage on Chiller.
Yes
No
1) In case of one section shipping
For multiple section shipping Chiller only
2) In case of multiple section shipping
3) Assembly of Chiller (Multiple section shipment Chiller only)
(See "Field assembly" of INSTALLATION MANUAL.)
b) Pipes beveled prior to welding
c) Type of welding rod utilized
d) Anti-corrosion paint applied to weld joints
4) Leak test (After assembling the multiple section shipment Chiller)
(See "Instruction of leak test" described in section 6.)
a) Pressurize Chiller with dry nitrogen gas to 30 kPa
b) No leaks checked by soap bubble test
c) Pressurize Chiller with dry nitrogen gas to 50 kPa
d) No leaks checked by soap bubble test
f) Leave 50 kPa for minimum 12 hours
g) Comparison between P and P2 (P2 is nearly equal to P)
Initial pressure
(P1)
:
kPa
Remaining pressure
(P2)
:
kPa
Calculated pressure
(P)
:
kPa
Initial ambient temp.
(T1)
:
deg.C
Ambient temp. after 12 hours
(T2)
:
deg.C
Perform tightening up flange connections and
flare connections, etc. flange
a) Dimension check of blank filler pipes received with Chiller
h) No leaks checked by soap bubble test
40
(4) Leveling
Procedure of leveling
1 Locate the leveling marks on the 4 corners of the lower shell and the high temperature generator.
The leveling marks are center punch indications on the end of the lower tube sheets and highlighted
with a white mark. The high temperature generator has similar marks at its 4 corners.
2 Fill a clear vinyl hose or tube with water, insuring there are no bubbles in the hose.
3 Using point A as the reference point, measure the PLUS or MINUS difference in the water level at
the other points B, C, D.
4 If tolerances are not met it will be necessary to shim the appropriate points by inserting metal shims
between the Chiller leg and foundation.
The size of the shims should be approximately 50mm X 75mm and of various thickness.
A:
0
B:
mm
mm
C:
D:
mm
mm
Leveling calculation
(A - B) / L =
(B - C) / L =
Tolerance
(C - D) / L =
(A - C) / W =
(A - D) / L =
(B - D) / W =
Yes
<
=
2 mm
1000
No
1) Leveling
2) Anchor bolts
L
A
B
Evaporator side
W
Anchor position
Absorber side
C
D
B
D
A
Shim positions
(both side)
Difference
C
41
(5) Field piping connection
Yes
No
N/A
1) Chilled water piping connection
2) Cooling water piping connection
3) Cooling tower(s) installation
4) Chilled water pump(s) installation
5) Cooling water pump installation
6) Steam piping connection
7) Steam drain piping connection
(6) Tightness confirmation
1) Water headers
a) Flanges of evaporator
b) Flanges of absorber
c) Flange of condenser
2) High temperature generator and heat reclaimer
a) Flanges of headers
b) Flare connection of pressure switches (63GH)
c) Flanges of steam drain piping
3) Pumps
a) Flanges of #1 absorbent pump
b) Flanges of #2 absorbent pump
c) Flanges of refrigerant pump
4) Sight glass
a) Absorber sight glass
b) Evaporator sight glass
c) High temp. generator sight glass for solution level
5) Caps of valves & dampers
a) Isolation valves for #1 absorbent pump
b) Isolation valves for #2 absorbent pump
c) Isolation valves for refrigerant pump
d) Service valve (SV1 thru SV9)
e) Dampers (D1, D2, D3, D4, D5, D6, D7, D8)
6) Purge unit
a) Connection flange of purge pump
b) Drain trap of liquid trap
c) Flare connection of purge tank pressure switch (69PR)
d) Palladium cell
7) Chilled water flow switch (69CH)
8) Sensors (DT1, DT2, DT3, DT4, DT5, DT6, DT7, DT10, DT11, DT12, D13)
9) Steam control valve
10) Flange for rupture disk
42
(7) Field wiring connections
Yes
No
N/A
1) Power supply connection
(insure Chiller main circuit breaker is "off")
a) Measurement of voltage ;
L1
V
L2
V
L3
V
2) Interlock wiring (pump starter auxiliary contacts)
a) Chilled water pump interlock : 52CH (#120 - #170)
b) Cooling water pump interlock : 52CO (#121 - #170)
3) Start/stop signal for auxiliary equipments from Chiller control panel
a) Chilled water pump (#356 - #357)
b) Cooling water pump : (#358 - #359)
c) Cooling tower fan : (#360 - #361)
4) Remote operation signal for Chiller
a) Signal type : Non-voltage continuous signal : 4Y1 (#323 - #324)
b) Signal type : Non-voltage pulse signal
4Y1 : RUN (#323 - #324)
4Y2 : STOP (#323- #325)
c) Signal type : DC/AC 24V pulse signal
RUN (#324)
STOP (#325)
COMMON (#326-#170) Jump
d) Signal type : DC/AC 24V continuous signal (#324 - #326)
5) Signal for remote indication
a) Pre-alarm indicator (#334 - #335)
(If a maintenance message arises, this signal is sent to a remote control panel.)
b) Remote check indicator (#336 - #337)
(During Chiller/Heater being in REMOTE MODE, this signal is sent to a remote control panel.)
c) Operation indicator (#350- #351)
(During Chiller/Heater being in operation, this signal is sent to a remote control panel.)
d) Stop indicator (#352 - #353)
(During Chiller/Heater being in shut-down, this signal is sent to a remote control panel.)
e) Alarm indicator (#354 - #355)
(If an alarm occurs, this signal is sent to a remote control panel.)
f) Dilution cycle operation indicator (#368 - #369)
(During Chiller/Heater being in dilution cycle operation, this signal is sent to a remote control panel.)
g) Purge indicator (#384 - #385)
(If purging is required, this signal is sent to a remote control panel.)
6) Signal for remote alarm buzzer (#382 - #383)
7) Answer back signal (#362 - #363)
(If Chiller/Heater goes into normal operation, this signal sent to a remote control panel.)
8) Grounding / Earth (#G / PE)
9) Wiring of the palladium cell heater
For 460V or 400V (#232 - #0B) / For 208V (#232 - #202)
10) Remote setting for chilled water outlet temp. (#732 - #733)
43
(8) Rupture disk discharge piping
Yes
No
N/A
1) Provide a rupture disk vent line
(9) Insulation
1) Field insulation is scheduled to be completed
after completion of related start-up functions
44
Confirmation before start-up check list
Before the start-up function of Chiller, the following conditions should be confirmed.
Job Name
:
Job location
:
Chiller/Heater model :
Date :
TSA-16NK-
(1) Chilled water
Serial number :
Yes
No
N/A
1) Piping complete
2) Water system filled, vented
3) Expansion tank piped into system
4) Pumps installed (rotation, strainers cleaned, pumps operational
5) System controls (3-way valves, bypass valves, etc.) operable
6) Water system operated and flow balance
to meet design requirements
7) Water treatment system installed
(2) Cooling water
1) Piping complete
2) Water system filled, vented
3) Expansion tank piped into system
4) Pumps installed (rotation, strainers cleaned, pumps operational
5) System controls (3-way valves, bypass valves, etc.) operable
6) Water system operated and flow balance
to meet design requirements
7) Water treatment system installed
8) Freeze protection for external water line
(3) Electrical
1) Power source completed to Chiller control panel
2) Interlock wiring completed
3) Necessary wiring between Chiller control panel
and a remote control panel
4) Pumps installed (rotation, strainers cleaned, pumps operational
5) Cooling water temperature control
6) Wiring complies with a code requested in the installation area
45
Start-up check list
Date :
Job Name
:
Job location
:
Chiller/Heater model
:
TSA-16NK-
Serial number :
The work is in process and
:
will be completed by
Date :
Yes
(1) Confirmation of electric system
No
N/A
Confirm all field wirings
Check all wire numbers for mounted parts on Chiller
Tighten terminal screws of mounted parts
Pull on wires of mounted parts to insure tightness
Insure there is no voltage provided to interlocks (52CH, 52CO)
1) Power supply connection (insure Chiller main circuit breaker is "off")
a) Measurement of voltage ;
L1
V
L2
V
L3
V
2) Interlock wiring (pump starter auxiliary contacts)
a) Chilled/hot water pump interlock : 52CH (#120 - #170)
b) Cooling water pump interlock : 52CO (#121 - #170)
3) Start/stop signal for auxiliary equipments from Chiller control panel
a) Chilled water pump (#356 - #357)
b) Cooling water pump : (#358 - #359)
c) Cooling tower fan : (#360 - #361)
4) Remote operation signal for Chiller
a) Signal type : Non-voltage continuous signal : 4Y1 (#323 - #324)
b) Signal type : Non-voltage pulse signal
4Y1 : RUN (#323 - #324)
4Y2 : STOP (#323- #325)
c) Signal type : DC/AC 24V continuous signal (#324 - #326)
d) Signal type : DC/AC 24V pulse signal
RUN (#324)
STOP (#325)
COMMON (#326)
5) Signal for remote indication
a) Pre-alarm indicator (#334 - #335)
b) Remote check indicator (#336 - #337)
c) Operation indicator (#350- #351)
d) Stop indicator (#352 - #353)
e) Alarm indicator (#354 - #355)
f) Dilution cycle operation indicator (#368 - #369)
g) Purge indicator (#384 - #385)
46
Yes
No
N/A
6) Signal for remote alarm buzzer (#382 - #383)
7) Answer back signal (#362 - #363)
8) Grounding / Earth (#G / PE)
9) Wiring of the palladium cell heater
10) Remote setting for chilled water outlet temp. (#732 - #733)
11) Wiring connections of mounted parts
a) #1 absorbent pump
b) #2 absorbent pump
c) Refrigerant pump
d) Purge pump
e) Temperature sensors (DT1, 2, 3, 4, 5, 6, 7, 10, 11, 12, 13)
f) Pressure sensors (69PR, 63GH)
g) Chilled water flow switch (69CH)
h) High temp. generator solution level electrodes (E1, 2, 3)
(2) Confirmation of auxiliary equipment
1) Chilled water piping
a) Isolation valves
Inlet (open / close)
Outlet (open / close)
b) Air vent valve
(open / close)
c) Drain valve
(open / close)
d) Thermometers
(inlet / outlet)
e) Pressure gauges (inlet / outlet)
f) Expansion tank
2) Cooling water piping
a) Isolation valves
Inlet (open / close)
Outlet (open / close)
b) Air vent valve
(open / close)
c) Drain valve
(open / close)
d) Thermometers
(inlet / outlet)
e) Pressure gauges (inlet / outlet)
3) Pump capacity
a) Chilled water pump(s)
Qty :
HP :
kW :
b) Cooling water pump(s)
Qty :
HP :
kW :
Voltage : L1 :
L2 :
L3 :
Amps : L1 :
L2 :
L3 :
c) Pump condition
Chilled water pump(s)
Suction press :
Cooling water pump(s)
Suction press :
kPa/psi
Discharge press :
Amps : L1 :
kPa/psi
Discharge press :
kPa/psi
L2 :
Lit./h /gpm
L3 :
kPa/psi
Lit./h /gpm
5) Cooling tower model :
47
Yes
No
N/A
6) 3-way tower bypass control operational
7) Chilled and cooling loops filled with water
8) Automatic blow system
9) Chilled and cooling loops chemically treated
10) Expansion door on high temp. generator able to open
11) Steam and drain piping
a) Steam control valve and the wiring connection
b) Lift adjustment of Steam control valve
c) Steam shutoff valve and the wiring connection
d) Relief valve
e) Reducing valve
f) Drain piping
12) Steam/drain flow meter
a) Location :
(3) Confirmation of inside pressure : The following item shall be inspected.
The inside pressure of Chiller must be more than 0 MPa on a gauge.
It can be simply checked the following way instead of using the gauge.
If nitrogen gas is powerfully and continuously released from the service
valve (SV1), it can be judged that there is no-leakage on Chiller.
Perform tightening up flange connections, flare connections, etc.
(4) Leveling verification
Yes
No
Yes
No
N/A
Procedure : See Page 41
Reading
Leveling calculation
mm
Lower shell
B:
mm
(A - B) / L1 =
(B - C) / L1 =
C:
mm
(C - D) / L1 =
(A - C) / W1 =
D:
mm
(A - D) / L1 =
(B - D) / W1 =
A:
0
(5) Megger test
Standard : More than 10 M/ohms
Procedure : Remove wires of the pumps connected at terminal strips in the control panel of Chiller/Heater.
Measure insulation resistances between each wires and earth (ground) with 500V megger.
a) #1 absorbent pump PE - U1:
M/ohms
PE - V1:
M/ohms
PE - W1:
M/ohms
b) #2 absorbent pump PE - U2:
M/ohms
PE - V2:
M/ohms
PE - W2:
M/ohms
c) Refrigerant pump
PE - U3:
M/ohms
PE - V3:
M/ohms
PE - W3:
M/ohms
d) Purge pump
PE - U4:
M/ohms
PE - V4:
M/ohms
PE - W4:
M/ohms
e) All reading are greater than 10 Meg ohms
NOTE : Do not apply this test to an inverter and an electronic controller.
48
(6) Inspection of purge unit (See "Instruction of inspection of purge pump" described in Section 6.)
Yes
No
N/A
1) No-existing moisture in a liquid trap (if existing, drain it)
2) Proper oil quantity (at the red mark in operation of the pump)
3) Oil quality (Colorless & no-contamination)
4) Rotating direction (as the arrow mark on V belt cover)
5) Tension of V belt (about 10 mm pressing by a finger)
6) No abnormal noise
7) Attained vacuum
kPa
(7) Bubble test (See "Instruction of bubble test" described in Section 6.)
1) Purging completed
2) Inside vacuum (below allowable vacuum curve)
kPa
3) Bubble test
Initial bubble rate
cc/10 minutes
First measurement
cc/10 minutes
Second measurement
cc/10 minutes
Third measurement
cc/10 minutes
Average (Less than below table)
Bubble test standard
The rate of gas accumulation should be an average of less 15 cc
in 10 minutes for a 700 kW unit with three separate measurement.
Perform Leak test : See "Instruction of leak test" described in Section 6.
Yes
No
49
(8) Setting & confirmation of controls & safeties without burner
(See "Instruction of Set & confirmation of control & safety functions" described in Section 6.)
Note : The settings with under-line have been factory set. Only confirm the settings.
Yes
No
N/A
1) Switching-on of back-up battery of microprocessor
2) Locally mounted devices
a) High temp. generator pressure switch (63GH : 0MPa)
3) Safety devices in the control panel
a) #1 absorbent pump over-load relay : Rated value
b) #2 absorbent pump over-load relay : Rated value
c) Refrigerant pump over-load relay : Rated value
d) Purge pump over-load relay : Rated value
4) Microprocessor (Confirmation & Setting menu)
r t. 1 3 4. 5 Present time is indicated (14:53)
a) Time setting
A.
Set of year
Y r - S E t
Input year
B.
Set of month & day
d t - S E t
Input month & day
C.
Set of time
t n. - S E t
Input time
C H G S
b) Change of switch functions
A.
Cool/Heat change-over
r d - S E t
B.
Data recode interval
S A n. - d t
C.
Select of local operation
mode
L o C A L
D.
Cancel of predication
information
S
E.
Change of unit
u n
F.
Change of low select control
G n
t
Select Cool or Heat
Select 1H, 5M, 1M
or 10S
If local mode is
required, select ON
If not required,
push "SET" twice
Select deg.C or
deg.F
L o
S E L Invalid function, must be passed.
A P P o C H
c) Set of chilled water pump
n t - C H
Select 1H, 5M, 1M
or 10S
A.
Set of interlock return time
B.
Set of variable flow rate
V
C.
Set of parallel operation by remote controller
r - P A r A Invalid function, must be passed.
V - C H Invalid function, must be passed.
d) Set of inverter control of chilled water pump C H -
n V Invalid function, must be passed.
A P P o C o
e) Set of Cooling water pump
n t - C o
Select 1H, 5M, 1M
or 10S
A.
Set of interlock return time
B.
Set of stopping cooling water pump at low load
C o S t o P Invalid function, must be passed.
C.
Set of cooling tower fan control
C t A u t o Invalid function, must be passed.
D.
Set of cooling tower fan temp. control
C t t E n. P Invalid function, must be passed.
E.
Set of differential temp. of cooling tower fan
C t d
F.
Set of variable flow rate
V
F F Invalid function, must be passed.
V - C o Invalid function, must be passed.
f) Set of inverter control of cooling water pump C o -
n V Invalid function, must be passed.
50
F
g) Field set
E L d
Yes
No
N/A
A.
Set of cooling water temp.
at maximum input
B.
Set of slow input time
n P - t n
0 0 0 0
S
C.
Set of slow input temp.
n P t n. P
0 0 0
C
D.
Set of dilution time
d
0 4
n.
E.
Set of remote signal type
r - S
S t A t
C
F.
Set of type of pulse
o F - P L S
G.
Set of low select control temperature
L o S E L E Invalid function, must be passed.
H.
Set of radiation temperature
H E
C o -
n P
L u - t
G n
Rated value
P o S
t
- S t Invalid function, must be passed.
r S - 4 8 5 Invalid function, must be passed.
h) Set of SR-485
i) Version No. of microprocessor
U E r 0. 9 1
Indication only
j) Version No. of option board
o P U 0. 0 0
Indication only
5) Microprocessor (Service mode)
a) Function of switch-2
C H G S
2
A.
Purge indication
B.
Refrigerant pump
C.
Pilot burner
D.
Control valve-1
C n. - 1
E.
Control valve-1 opening
C n. - 1 S t
F.
Control valve-2
C n. - 2
G.
Control valve-2 opening
C n. - 2 S t Invalid function, must be passed.
H.
Control valve-3
C n. - 3
I.
Control valve-3 opening
C n. - 3 S t Invalid function, must be passed.
J.
HBS address
A d d H b S Invalid function, must be passed.
K.
High speed timer function
b A
L.
Clear of operation data
o P - r S t
Fixed with "Auto", can be passed.
P u r G E
r E F - P
A u t o
P
L o t
Invalid function, must be passed.
A u t o
S o K
b) Set of model
Do not change.
1 0 0
Invalid function, must be passed.
Invalid function, must be passed.
O F F
3
Example
n. o d e L
A.
Serial number
B.
Type of chiller
t Y P E
C.
Type of control
C o n
D.
Annual cooling operation
E.
d
Do not change.
8 7 0 1 4
Do not change.
0
Do not change.
C H - o u t
Do not change.
A - C o o L
o F F
Do not change.
Automatic changeover
C H A u t o
n. A n u A L
Do not change.
F.
For process use
P r o C
o F F
Do not change.
G.
With purge pump
n. P - o P
o N
Do not change.
H.
Oil pump
o P - o P
o F F
Do not change.
G
t o
51
Yes
c) Rated specification setting
No
N/A
Example
S P E C
A.
Chilled water outlet temp.
C - t E n. P
7. 0
C
Do not change.
B.
Hot water outlet temp.
H - t E n. P
4 5. 0
C
Do not change.
C.
Chilled water temp. deff.
C - d t
6. 0
C
Do not change.
D.
Hot water temp. deff.
H - d t
4. 6
C
Do not change.
E.
No-use (extra)
F.
Max. opening of cont. valve
r A n k u P
G.
Indication of purge start
A P - S t
1 0. 0 k P A
H.
Indication of purge stop
A P - S P
7. 0 k P A
S
n G - k Invalid function, must be passed.
1 0 0. 0
I.
No-use (extra)
A P - t
J.
No-use (extra)
E
K.
Crystallization temp.
L E C r Y S Invalid function, must be passed.
d) Input setting
n. Invalid function, must be passed.
C o n d Invalid function, must be passed.
S P E C
A.
Type of control
b n t y P E
B.
Input correction
P t C o r
C.
Combustion interval
F -
n t
P
0 0
e) Inverter setting
D
Do not change.
5 0
Do not change.
n.
Do not change.
n V S E t
A.
Control estimating time
3 3 A L
B.
Estimating tuning
1 5
Do not change.
C.
Constant a1
3 3 A L - K
1. 0
Do not change.
n V - A 1
1 4 8
D.
Do not change.
Constant a2
n V - A 2
0. 0 4 2
Do not change.
E.
Constant a3
n V - A 3
0. 0 6 0
Do not change.
F.
Constant a4
n V - A 4
3. 6
Do not change.
G.
Constant a5
n V - A 5
5 0
Do not change.
H.
Constant a6
n V - A 6
2. 3
Do not change.
f) PID setting
P
A.
P for cooling
C o o L - P
B.
I for cooling
C o o L -
C.
D for cooling
D.
P for heating
E.
d S E t
2. 0
Do not change.
2 0 0
Do not change.
C o o L - d
5
Do not change.
H E A t - P
5. 0
Do not change.
I for heating
H E A t -
5 0
Do not change.
F.
D for heating
H E A t - d
3 0
Do not change.
G.
Sampling set
S A n. P L E
1 0
Do not change.
52
Yes
N/A
This can be passed at start-up.
C o u n t
g) Operation hours & On/Off times set
No
Note :Items A. - N. will be set after microprocessor replacing only.
A.
Operation hours of Chiller/Heater
u n
B.
#1 absorbent pump operation hours
A b S 1 - t
C.
#2 absorbent pump operation hours
A b S 2 - t
D.
Burner operation (firing) hours
F
E.
Refrigerant pump operation hours
r E F - t
F.
Purge pump operation hours
P u r G - t
G.
#3 absorbent pump operation hours
A b S 3 - t Invalid function, must be passed.
H.
On/Off times of Chiller/Heater
u n
I.
On/Off times of #1 absorbent pump
A b S 1 - C
J.
On/Off times of #2 absorbent pump
A b S 2 - C
K.
On/Off times of burner
F
L.
On/Off times of refrigerant pump
r E F - C
M.
On/Off times of purge pump
P u r G - C
N.
On/Off times of #3 absorbent pump
A b S 3 - C Invalid function, must be passed.
r E - t
P u r G E
t - C
r E - C
S
h) Predication function setting
t - t
G n S t
o n.
A.
Vacuum condition
B.
Absorbent concentration
C.
Cooling water tubes
fouling condition
C o - d
D.
Cooling water temp.
C o - H
E.
Combustion chamber
fouling condition
C C - d
r
o F F
Do not change.
F.
Ant freezing
r u L E - 1
o F F
Do not change.
G.
Exhaust gas temp.
E
o F F
Do not change.
H.
Clear of predication data
r E - S E t
t H
r
C K
Invalid function, must be passed.
o n.
o n.
G - L o
3
i) Japanese burner controller setting
S
j) Tuning of temp. sensors
S E n S o r
G n S t Invalid function, must be passed.
A.
Chilled/hot water outlet
temp. sensor
C H o A d J
0. 0
B.
Chilled/hot water inlet
temp. sensor
C H
A d J
0. 0
C.
Cooling water outlet temp.
sensor
C o o A d J
0. 0
D.
Cooling water inlet temp.
sensor
C o
0. 0
E.
Hot water outlet temp. sensor
H o A d J
Invalid function, must be passed.
F.
Hot water inlet temp. sensor
H
Invalid function, must be passed.
G.
Sensor option setting
A d J
S E n - o P
A d J
1 1 1 0 0 0
k) Analog data (42 data) indication
A n A L o G
l) Digital input data indication
d
G
-
m) Digital output data indication
d
G
- o
n) Control state indication
C o t n o
Do not change.
o) #3 inverter setting
n V 3
Invalid function, must be passed.
p) #2 inverter setting
n V 2
Invalid function, must be passed.
53
Yes
(9) Function test of safeties without burner side
No
N/A
1) J-01 Chilled water low temp. alarm
2) J-02 Chilled water pump alarm
3) J-03 Chilled water flow rate alarm
4) J-04 #1 Absorbent pump alarm
Not applicable
5) J-05 #2 Absorbent pump alarm
6) J-06 Cooling water pump alarm
7) J-07 Cooling water flow rate alarm
8) J-10 Refrigerant pump alarm
9) J-12 Purge pump alarm
10) J-13 Generator high temp. alarm
Not applicable
11) J-14 Generator high pressure alarm
Not applicable
12) J-15 High temp. generator solution level low alarm
13) J-16 High concentration alarm
Not applicable
14) J-20 Cooling water low temp. alarm
15) J-21 COP alarm
Not applicable
16) J-27 Cooling tower fan alarm
Not applicable
17) J-28 #3 absorbent pump alarm
Not applicable
18) Sensor alarm of temperature sensor
19) Sensor alarm of flow sensor
(10) Confirmation of valve opening conditions
1) Isolation valves of #1 absorbent pump (Open always)
2) Isolation valves of #2 absorbent pump (Open always)
3) Isolation valves of refrigerant pump
(Open always)
4) Service valve (SV7)
(Open always)
(11) Aging & refrigerant blow down
1) Aging (Evaporator tube outer surface cleaning)
2) Refrigerant blow down
hours
Concentration :
(12) Operating data record
54
Trial run data sheet
Project name
:
Chiller model
:TSA-16NK-
Serial number
:
, date
DATA-1
No.
Data items
Unit
Ambient temperature
o
C/ F
2
Room temperature
o
C / oF
3
Chilled water inlet temperature
o
C / oF
4
Chilled water outlet temperature
o
C / oF
5
Chilled water inlet pressure
kPa / psi
6
Chilled water outlet pressure
kPa / psi
7
Pressure drop in evaporator
kPa / psi
8
Chilled water flow rate
9
Cooling water inlet temperature
1
10 Cooling water outlet temperature
time:
time:
DATA-3
time:
o
m3/h / gpm
o
C / oF
o
C / oF
11 Cooling water inlet pressure
kPa / psi
12 Cooling water outlet pressure
kPa / psi
13 Pressure drop in absorber & condenser
kPa / psi
14 Cooling water flow rate
Spec.
DATA-2
m3/h / gpm
15 High temp. generator temperature
o
C / oF
16 High temp. generator pressure
o
C / oF
17 Solution level in evaporator
18 Solution level in high temp. generator
n/60 mm
n/2-3/8"
19 Solution level in bottom of absorber
20 Pressure in purge tank
kPa
Concentration of concentrated solution
%
21 Specific gravity of concentrated solution
Temperature of concentrated solution
o
Concentration of diluted solution
%
22 Specific gravity of diluted solution
Temperature of diluted solution
C / oF
-
o
Concentration of refrigerant
C / oF
%
23 Specific gravity of refrigerant
o
C / oF
24 Condensed refrigerant temperature
o
C / oF
25 *LTD (See below)
o
C / oF
Temperature of refrigerant
26 #1 absorbent pump current
A
27 #2 absorbent pump current
A
28 Refrigerant pump current
A
29 Purge pump current
A
*LTD = Condensed refrigerant temp. - Cooling water outlet temperature
Note: Concentrations of concentrated and diluted solutions should be sampled with nearly full load. If part load,
Concentrations indicated on the data display should be recorded.
55
3-3. Reference
(1) Typical piping diagram for NK series
Thermostat
Pressure gauge
Flow meter
Strainer
Valve
Thermostat
8
15
9
18
20
7
16
2
1
17
11
13
12
2
14
3
4
14 19
21
5
1
2
3
4
5
6
10
6
Cooling load
Chilled water pump (primary)
Chilled water pump (secondary)
Bypass valve
Supply header
Return header
7 Expansion tank
8
9
10
11
12
13
Main steam piping
Cooling tower
Cooling water pump
Blow down valve
Bypass valve
Make up water supply
15
16
17
18
19
20
Reducing valve
Steam shutoff valve
Steam control valve
Relief valve
To boiler
Steam trap
14 Minimum tank capacity 1 m3 21 To drain channel
(35 ft3)
General remarks on piping
12) Install drain valves at the lowest positions between
1) Equipment and parts outside the area surrounded by
the broken line are not supplied by SANYO/Carrier.
2) For pipe connections and diameter refer to the
dimensional drawings and specification tables.
13)
3) Ensure that chilled water flow rate, cooling water
flow rate are in conformity with the standard value. 14)
If the chilled water flow rate sinks to under 50% of the
standard value, the chiller will stop.
15)
4) Position the chilled water pump, cooling water
16)
pump and expansion tank correctly so that the chiller
pressure does not exceed the set value.
5) For cooling water temperature control refer to the 17)
drawing "Cooling water temperature control method".
6) Separate chilled and cooling water pumps should
be provided for each chiller.
7) Provide a cooling water blow-down valve in the cooling
tower inlet for water quality control.
18)
8) Install a filter in the chilled water and cooling water
pipes (10 mesh).
19)
9) Install stop valves on the chilled and cooling water
inlet and outlet.
20)
10) Provide a thermometer and pressure gauge at the
chilled and cooling water inlet and outlet.
21)
11) Provide an air vent valve in each of the chilled and
absorption chiller and the stop valves of the chilled
water and cooling water, and pipe them to the drain
channel.
Provide an expansion tank at highest position in the
chilled water line.
Install a cooling tower away from any exhaust gas
outlet.
Connect the pipe from rupture disk to tank.
Install stop valves between the absorption chiller
and stop valves of all inlets and outlets for chemical
cleaning of the water circuit system.
(130 psig)
The maximum allowable steam pressure is 900 kPa.
Please refer to this diagram to install a relief valve to
ensure that the maximum pressure is not exceed.
The exhaust pipe of the relief valve should be
connected to the outside.
If the steam superheat exceed 10 K (18 deg F), chiller
performance would deteriorate.
Install a filter (100 mesh), drain water pipe and
pressure gauge near the chiller steam inlet location.
The back pressure of the steam drain outlet pipe
should be controlled below 49 kPa (7 psig).
A steam trap has been installed in the chiller and
does not need to be installed by the customer.
cooling water line at point higher than the header. 22) The maximum steam drain temperature is 90oC(194oF).
56
(2) Field electric wiring diagram for NK series
Control panel of
chiller
UL
CE
Field supply panel
G
L1
L2
L3
PE
L1
L2
L3
To power sauce
UL : 3phase 60Hz 208V or 460V
CE: 3phase 50Hz 400V
Chilled water pump interlock
120
52CH
(Synchronized with the pump running 170
Cooling water pump interlock
121
52C
(Synchronized with the pump running 170
E
345
346
E
342
340
341
0A
344
343
Remote check
signal
For steam
shutoff valve
For operation
indication
For stop indication
For alarm indication
Run/stop signal for
chilled water
pump
Run/stop
signal for
cooling water
pump
Run/stop signal for
cooling tower fan
Answer back signal
For dilution
indication
For alarm buzzer
For purge indication
334
335
336
337
347
348
350
351
352
353
354
355
356
357
358
359
360
361
362
363
368
369
382
383
384
385
+
-
CVP
DC 4 - 20mA
Open
Y
T
Close
G
3
2
Open
1
Close
CMH (AC 24V)
Potisioner 135 ohm
Terminal strips in control panel
Pre-alarm signal
DC 24V 10mA
In case of steam control
valve positioner
(Field supply)
In case of steam control
valve motor
(Field supply)
Field wiring connection
1) Wiring of power supply and earthing
The chiller has MCB.
Please connect power supply wire to the terminal block.
And also connect wire between chiller control panel and
earth at field.
Earthing resistance : Local regulation
Earthing cable : Annealed copper wire
(Please use the wire as same the thickness as the wire
of the power supply)
Note)
1) Should be work the electric wiring connection by
license holder.
2) Use steel conduit for electric wiring between field
electric supply and control panel of the chiller.
3) Field wiring connections are all low voltage
without supply voltage.
57
Remote operation signal
Chiller can be operate by following signals;
1) Non-voltage Normal open contact for start & stop (DC24V 10mA)
Wiring the terminal 324 and 323, connect 170 and 326.
Jump
323
324
326
170
4Y1
Continuous signal
2) Non-voltage Normal open contact for start (DC24V 10mA)
Wiring the terminal 324 and 323, connect 170 and 326.
Non-voltage Normal open contact for stop (DC24V 10mA)
Wiring the terminal 325 and 323.
Jump
323
324
325
326
170
4Y1
Pulse signal
4Y2
3) Non-voltage Normal open contact for start (DC24V 10mA)
Wiring the terminal 324 and 323, connect 170 and 326.
Non-voltage Normal close contact for stop (DC24V 10mA)
Wiring the terminal 325 and 323.
Jump
323
324
325
326
170
4Y1
Pulse signal
4Y2
4) Continuous signal of DC/AC 24V for start & stop. (Initial setting at factory)
Wiring the terminal 324 and 326. (Those terminals are non-polarity)
324
326
DC/AC 24V
Continuous signal
5) Pulse signal of DC/AC 24V for start.
Wiring the terminal 324 and 326. (Those terminals are non-polarity)
Pulse signal of DC/AC 24V for stop.
Wiring the terminal 325 and 326. (Those terminals are non-polarity)
com
324
325
326
DC/AC 24V
Pulse signal
58
Remote setting of chilled water outlet temperature
Control panel of Chiller
E 732 733
Terminal strips in the control panel
+ DC 4 - 20 mA
(Field supply)
Input current :
Cooling mode :
DC 4-20mA
+0 to +5oC
Ste point of chilled water outlet temperature is offset by remote control panel
such as central monitoring panel.
Setting mode
Cooling mode : Set point + Offset dt (below the maximum set point)
Cooling mode
+5
+4
+3
+2
+1
0 oC
Offset dt
4mA
8mA
12mA 16mA 20mA
Input current
1) Should be work the electric wiring connection by license holder.
2) Use steel conduit for electric wiring between field electric supply and chiller control panel.
59
(3) Confirmation of inside pressure of Chiller
We have learned from experiences that the procedure for "Confirmation of nitrogen pressure in Chiller
by means of comparing the temperature and pressure between factory data and field data" is very difficult,
and also not practical. Factory charge pressure is 0.02 Mpa.
Accordingly, we have changed the procedure to check whether leakages exist or not as follows:
a) In case that the pressure gauge shows "0" : There is a possibility of leakage. Conduct the below steps.
Tighten flanges, flares → Conduct purging → Aging →Bubble test
Judge whether there is a leakage or not according to the bubble test result.
b) In case that the pressure gauge shows not "0" : It is thought of no-leakages. Conduct the below steps.
Conduct purging → Aging →Bubble test
Judge whether there is a leakage or not according to the bubble test result.
c) As simple judgment way, if nitrogen gas forcefully blow out from the service valve, it is regarded as
no leakage and start the procedure b) described above.
The reasons we changed the procedure is as follows;
Current charged N2 pressure at the factory is 20 Kpa (0.02 Mpa) and the same compound gauge as for NK
has been used for charge of N2 gas in the factory(0.25～0～-0.1 Mpa, Minimum scale unit :0.01MPa).
In this case, it is difficult to judge if there is a leakage or not. Please refer to below study.
(Condition)
Nitrogen charge pressure at the factory 0.02 Mpa
Temp. at factory when N2 was charged
25 deg. C
Temp. difference Calculated Difference
between the factory pressure with charged
pressure
(MPa)
and the site(deg. C)
5
10
15
20
25
30
0.022
0.024
0.026
0.028
0.030
0.032
0.002
0.004
0.006
0.008
0.010
0.012
Judgment Impossible
Difficult to judge
Differences are apparent
(More than one scale unit at pressure gauge)
60
(4) Detail explanation of interlock and proper interlock signal type
a) It is necessary to understand why interlock is in dispensable for operation of chillers.
If a chilled water pump and cooling water pump are reliable to run normally and stably, and they can supply
water reliably, normally and stably, interlocks of them are not required. But actually there always been
possibilities of troubles like malfunction of pumps, malfunction of electrical parts of the pumps, clogging of
strainers in chilled and cooling water lines and this kind of troubles cause abnormal supply of chilled and
cooling water. Sudden stop of chilled water will cause troubles like freezing of tubes at the evaporator, also
sudden stop of cooling water will cause generator high temperature alarm, high pressure alarm and in extreme
case, if the electrical safety device and the rupture disk does not work properly, there is a possibility to damage
the generator. Thus in order to operate a chiller, it is necessary to have interlock signal from pumps in order to
confirm proper supply of chilled water and cooling water.
b) Basically the safest interlock is to receive a signal which is sent when enough water flow is detected.
In this sense, the flow switch is the best and that's why chilled water flow switch is installed as standard
(Cooling water flow switch is an option because the damages of the chiller caused by stop of cooling water
is less when compared to chilled water cases.)
Of course there is a possibility of malfunction of the flow switch itself, so from the stand point of double
safety consideration, startup confirmation signals of pumps (Usually an auxiliary contact of magnet contactor)
are used as electrical interlock signal.
Start signals for the pumps are not appropriate for interlock signal because even the pump does not
run due to some problems, the signals will be sent to the chiller and the chiller recognizes that the
pump runs.
c) Basic Interlock Connection
Chilled water pump
start signal
During operation of a chiller or after a operation of a chiller, if you operate only the
cooling water pump, there is a possibility that the tubes in the evaporator will be
damaged by remaining cooling capacity. You can opeate the cooling water pump
only when the chilled water pump is operating. Accordingly, when the chilled water
pump stops, the cooling water pump also needs to stop.
CHW pump electric circuit
CHW pump
Auxiliary
Magnet
contact
contactor
Cooling water
pump
start signal
Chilled water flow switch
Control
panel
Chilled
water
pump
Absorption
chiller
COW pump electric circuit
COW pump
Magnet contactor
Cooling
water
pump
Auxiliary
contact
Cooling water
pump interlock
These three signal are
necessary for operation
of the chiller.
Chilled water pump interlick
61
(5) Aging & Tube surface cleaning of evaporator
a) Purpose of aging process & Cleaning outer surface of evaporator tubes
The purpose of the aging process is to remove any air that may have entered into Chiller during the
solution charging process and dissolved oxygen in the Lithium Bromide & refrigerant solution.
The purpose of the evaporator tube outer surface cleaning is to improve wetting condition of the evaporator
tubes with refrigerant for increasing evaporation efficiency.
b) By means that Chiller is continuously operated, the Lithium Bromide solution is circulated by
#1 absorbent pump in Chiller. It can bubble out any entertained air and dissolved oxygen then
the gas can be easily removed from Chiller by the purge pump. On the other hand, the
refrigerant adjusted with approximately 20 % of concentration and charged in the factory is circulated by
the refrigerant pump in the evaporator. It can clean the outer surface of the evaporator tubes.
c) Procedure
As described above, the both works can be conducted and proceeded at the same time.
c-1) Run the purge pump and check the attained vacuum. Then open V1 and V3.
c-2) The set value of "rAnkuP" should be changed to "0"(zero).
See "Instruction of Set & confirmation of control & safety functions" described in Section 6.
c-3) Run Chiller. Confirm that chilled water and cooling water is running normally.
c-4) The set value of "rAnkuP" should be changed to "50". For a while, high temp. generator temperature
rises gradually.
c-5) Adjust fuel input by "rAnkuP" to maintain the high temp. generator temperature between 100 deg.C
and 120 deg.C.
c-6) Continue this operation for approximately 6 hours.
c-7) Perform the refrigerant blow down. (See "Instruction of refrigerant blow down" described in Section 6.)
Note 1 : During the work, often check the attained vacuum whether the attained vacuum is OK or
not. If not, close V1 for approximately 30 minutes, the attained vacuum may recovers.
Note 2 : If chilled water outlet temperature may go down to the temperature of stopping the
refrigerant pump, more decrease the set value of "rAnkuP".
Note 3 : If the refrigerant pump stops with the alarm "J-10", the reset button of the refrigerant pump
overload relay mounted contactor sticks out. In this case, increase the refrigerant pump
overload relay set value and push the reset button, then re-start Chiller. After
completion of the work, return the set value at original value.
62
Section 4
Control
4-1. Overview of control functions
(1) Block diagram of control functions
The control of TSA-16NK Series consists of the following functions.
Operation
Start function
Stop function
Capacity controls
Dilution cycle operation
Main control method
Cooling capacity is controled by PID control which modulates a steam control valvge.
Maximum opening of fuel control valve changeable function
(Simple name of the function is "Ranl-up") (For DJ seres)
In case of the high heating capacity type, fuel input of heating mode is bigger than cooling
mode. Accordingly, both fuel inputs must be differently set. The fuel input of heating mode
is set at 100 % and the fuel input of cooling mode is set for the value corresponding with
cooling capacity. The both maximum fuel input settings can be automatically changed by
Cool/heat changeover function. The set value of the function has been set at the factory.
Therefore the set shall not be basically changed on normal operation.
However, this function is useful for servicing such as de-crystallization. In such case,
authorized personnel only can change the set value.
Slow open function of steam control valve
If required, the steam control valve is slowly opened at the starting Chiller in order to
achieve soft starting condition for Chiller.
Maximum steam input reduction function by cooling water inlet temp.
The maximum opening of steam control valve is reduced depending on cooling water inlet
temp. in order to protect crystallization and excessive high of temperature and/or pressure
condition in H.T.Geneator
Steam input reduction function by H.T.Generator temp.
If the H.T.Generator temperature reaches at 162 deg.C, the steam input is reduced in order
to avoid the alarm of "generator high temp." alarm (J-13)
Steam control valve close function by concentrated solution concentration
If the concentrated LiBr solution concentration rises 65 %, control valve closes in order to
avoid the alarm of "concentrated LiBr solution concentration high" alarm (J-16).
Excessive low chilled water outlet temp. control function
These conditions can be controlled by steam control valve and/or the refrigerant pump.
Absorbent solution
flow rate control
Inverter control with solution level control in H.T.Generator for #1 absorbent pump
#1 absorbent pump rotation speed is controlled by the inverter with the solution level control
in H.T.Generator in order to flow suitable absorbent flow rate corresponding with required
cooling load for saving steam consumption and achieving stable chilled water outlet
temperature in part load.
Pre-set function of
chilled water outlet
temperature
Auto-reset function of chilled water outlet temperature setting
This function is to avoid cavitations of a refrigerant pump possibly occurring under the
condition that a chilled water outlet temperature setting is comparatively high and the
cooling water inlet temperature is low.
63
Predication
functions
(Maintenance
message)
Purge tank high pressure : Message code H-06
Purging should be conducted from the purge unit. The purge unit will be shortly filled with
non-condensable gas.
Operate purge pump : Message code H-01
Purging shall be conducted from the purge tank.
Cooling water tubes fouled: Message code H-07
Absorber and condenser tubes have been slightly fouled. Tube cleaning shall be planed.
Clean cooling water tubes : Message code H-03
Absorber and condenser tubes have been fouled. Tube cleaning shall be conducted.
Cooling water high temp. : Message code H-08
If H-08 is often indicated, check cooling water system. H-08 is lights up when the cooling
water inlet temp. rises beyond the specified temp. +2 deg C.
Check cooling water system. : Message code H-04
If H-04 is indicated, check cooling water system. H-04 is lights up when the cooling water
inlet temp. rises beyond the specified temp. temp. + 2 deg.C.
Power failure : Message code H-10
When the power resumes, this message is displayed.
Safety functions
For chilled water freeze protection
See section 5. Trouble shooting
For crystallization protection
See section 5. Trouble shooting
For motor protection
See section 5. Trouble shooting
For oxygen deficiency accident protection
See section 5. Trouble shooting
For combustion accident protection on Weishaupt burner
Refer to Weishaupt burner manual
64
(2) Construction of devices for control is shown as below figure
The control of TSA-16NK Series consists of the following functions.
Control panel
Display borad
Open/Close signal
Steam control valve : DC 4-20mA
or
Microprocessor
(CPU)
Open/Close signal
Steam control valve
Feedback signal
Positioner 135 ohm
63GH : H.T.Generator pressure switch
69PR : Purge tank pressure switch
69CH : Chilled/hot water flow switch
E1, E2, E3 : High temp generator solution level electrodes
DT1 : Chilled water outlet temp. sensor
DT3 : High temp. generator temp. sensor
DT13 : Steam drain temp. sensor
DT2 : Cooling water outlet temp. sensor
DT4 : Low temp. generator temp. sensor
DT5 : Condensed refrigerant temp. sensor
DT5 : Condensed refrigerant temp. sensor
DT7 : Cooling water inlet temp. sensor
DT10 : Diluted LiBr solution temp. sensor
DT11 : Refrigerant in evaporator temp. sensor
DT12 : Middle cooling water temp. sensor
Purge pump
#1 ABS
pump
#2 ABS
pump
Ref. Pump
Fig. 4-1 Construction of devices for control
65
4-2. Operation sequence
The starting and shut-down sequences of Chiller are follow.
(These sequences are described with the interlock system of Chiller.)
(1) Starting sequence
Pressing RUN key on the operation board
or Remote start signal
Contact of chilled water
flow switch opens
No
J-03 After 10 min.,
chilled water
flow rate alarm
No
J-01 After 10 min.,
chilled water
low temp. alarm
Yes
Chilled water temp. is above
2.5 deg.C (36.5 deg.F)
Yes
Chilled water pump starts signal goes to chilled water
pump operation circuit from control circuit of Chiller
Chilled water pump starts
J-02 After 10 min.,
chilled water pump
alarm
Chilled water
pump interlock signal
goes to control circuit
of Chiller
ON signal of 69CH
returns to control circuit
of Chiller
No
Yes
No
J-03 After 10 min.,
chilled water flow
rate alarm
Yes
Cooling water pump starts signal goes to cooling water
pump operation circuit from control circuit of Chiller
Cooling water pump starts
Cooling water pump
interlock signal goes to
control
Cooling tower fan circuit works
No
J-06 After 10 min.,
cooling water pump
alarm
Yes
Chiller starts
#1 ABS pump starts
After 5 min. #2 ABS pump starts
Normal cooling operation
Fig. 4-2 Start sequence
66
(2) Shut-down sequence
Pressing STOP key on the operation
board or Remote stop signal
Steam control valve travels to close.
Steam shut-off valve closes after 1 min.
Refrigerant pump stops
according to HT generator
temp.
Cooling water pump stops
according to HT generator
temp.
Cooling tower fan stops
Chilled water pump stops
after 1 minute.
Dilution operation
#1 absorbent pump stops
within 15 minutes.
#2 absorbent pump stops
within 15 minutes.
Chiller stops entirely
Fig. 4-3 Shut-down sequence in cooling mode
67
(3) Start time chart (Fig.4-4)
Start signal
Open
Steam shut-off valve
Close
100%
Steam control valve
0%
Run
Chilled water pump
Stop
Run
Cooling water pump
Stop
Run
#1 Absorbent pump
Stop
Run
#2 Absorbent pump
Stop
Run
Refrigerant pump
Stop
10
T2 min.
5 min.
15 min.
(4) Stop time chart (Fig4-5)
Stop signal
5
Open
Steam shut-off valve
100
Gene temp. C
Fig. 4-6
155
Close
100%
Steam control valve
0%
Run
Chilled water pump
Stop
Run
Cooling water pump
Stop
Run
#1 Absorbent pump
Stop
Run
#2 Absorbent pump
Stop
Run
Refrigerant pump
Stop
1 min.
1 min.
T1
T2
T1 time is for GENE temp. goes down to below 100 deg.C (4 thru 20 min.)
68
4-3. Capacity control & other control functions
The capacity control of TSA-16NK series is PID control. A signal of chilled water outlet temperature
detected by DT1 is sent to a microprocessor then the steam control valve controls cooling capacity.
(1) Max. opening of fuel control valve changeable function (Rank-Up) : (DJ series only)
As mentioned Sec. 4-1, fuel input settings of cooling mode and heating mode must be changed in case of
the high heating capacity type. The relation between Rank-up set value and maximum fuel control valve
modulating signal is as shown in Fig. 4-7.
In case of 80% of Rank-up set, the fuel control valve modulating signal for cooling mode is varies from
0% to 80% corresponding with changing cooling load. In other words, the maximum fuel control valve
modulating signal is limited at 80%. (The fuel control valve modulating signal for heating mode is varies
from 0% to 100%.)
Do not increase Rank-up set
beyond 100 %
100
Rank-up set : 100%
80
80 Fuel consumption : Heating mode = Cooling
60
60
40
40
20
20 Fuel consumption : Heating mode is 1
Rank-Up set (%)
Fuel control valve modulating signal (%)
100
Example : Rank-up set : 80%
Cooling mode is 0.8
0
10
20
30
40
50
60
70
80
90
100
Load (%)
Fig. 4-7 Rank-Up
Reference
Using the function, the maximum fuel input is easily changed such as a case of de-crystallization work
requiring fuel input changing many times. The maximum fuel input is limited by the set of Rank-up.
The procedure of Rank-up is described in Section 6-19 "Rated specification setting".
There is the same function to limit (fix) the maximum fuel input. That is the menu items 4) and 5) of (1)
Function switch-2 in the service mode. But, in case of the method, it is not simple method to use the
menus as compared with Rank-up, because one function by 2 menus.
69
(2) Slow open function of steam control valve
The function is provided to avoid over-input at the setting of the chiller. The control valve opens gradually
show below. Factory setting, setting time(Tso) is 900 seconds. This time(Tso) is variable from 0 to 1800
seconds. How to change the control valve show refer to Section 6. But, actually valve opening depended
on control valve motor or actuator.
Control valve opening (%)
100
70
40
20
0
Tso
Tso/5
Time (sec.)
(Factory setting 900 sec.)
Fig. 4-8 Slow open
(3) Max. steaml input reduction function by cooling water inlet temp.
The maximum opening of steam control valve is reduced depending on cooling water inlet temp. in order to
protect crystallization and excessive high of temperature and/or pressure condition in H.T.Geneator
For crystallization protection :
The steam control valve modulating signal is reduced automatically depending on the cooling water
inlet temperature. The starting temperature of the reduction is the specified temperature minus 4
deg.C (7.2 deg.F) constant.
For avoidance of Generator high temp. alarm (J-13) :
The steam control valve modulating signal is reduced automatically depending on the cooling water
inlet temperature. The starting temperature of the reduction is the specified temperature plus 2
deg.C (3.6 deg.F) constant.
Fuel control valve modulating signal (%)
100%
ST : Specified temperature
ST is factory set. Do not change.
(Refer to Page 44 / Sec.6 for setting ST at
replacement of the microprocessor only)
80%
60%
Avoidance of
Generator high temp. alarm (J-13)
Crystallization protection
0%
ST-13 deg.C
(ST-23.4 deg.F)
ST-4 deg.C
(ST-7.2 deg.F)
ST
ST+2 deg.C
(ST+3.6 deg.F)
Cooling water inlet temperature
Fig. 4-9
70
(4) Steam input reduction function by H.T.Generator temp.
If the H.T.Generator temperature reaches 162 deg.C due to some cause, the steam input is reduced in
order to avoid the alarm of "Generator high temp." alarm (J-13).
In case that H.T.Generator temperature reaches 162 deg.C, the steam control valve modulation signal
reduces 80% of the present value then continues 80% for 10 minutes.
Example : The steaml control valve modulating signal reduces from 90% to 72% and continue 72% for 10 min.
After the action, there are 4 actions as follows.
(1) IF H.T.Generator temp. goes down below 162 deg.C and the condition continues, Chiller runs normally.
(2) If H.T.Generator temp. rises 162 deg.C or more within 5 minutes, Chiller stops with J-13.
But
(3) If H.T.Generator temp. rises 165 deg.C or more at any time, Chiller stops with J-13.
(4) If H.T.Generator temp. rises 162 deg.C again and the condition continues for 10 min., Chiller stops with J-13.
Fuel control valve modulating signal
90
H.T.Generator temperature
80
72
70
(3)
(4)
(2)
60
50
165
162
160
40
30
(1)
20
150
10
0
10 min.
5 min.
10 min.
H.T.Generator temp. (deg.C)
Fuel control valve modulating signal (%)
100
0
Fig. 4-10 Fuel input reduction function by H.T.Generator
(5) Steam control valve close function by concentrated solution concentration
If the concentrated Libr solution concentration rises 65 %, steam control valve closes in order to avoid the
alarm of "concentrated LiBr solution concentration high" alarm (J-16).
In case that the calculated concentrated LiBr solution concentrated rises 65%, steam control valve closes
for approximately 1 miniuite and keep to close for 2 minuites, then steam control valve opens again.
After the action, there are 4 actions as follows.
(1) IF the concentration goes down below 65% and the condition continues, Chille runs normally.
(2) If the concentration rises 65% again after just 3 minutes, Chiller stops with J-16.
But
(3) If the concentration rises 65% again within 1 hour, Chiller stops with J-16.
(4) If the concentration rises 65.5% at any time, Chiller stops with J-16.
Control
Control valve
Concentration %
0%
65.5
65.0
64.0
2 min.
3 min.
1 hour
Fig. 4-11
71
(6) Excessive low chilled water outlet temp. control function
Control for excessive low chilled water outlet temperature in cooling mode
If the chilled water outlet temperature goes down below 1.5 deg.C of the set value of specified chilled water
outlet temperature, combustion stops. But if the chilled water outlet temperature still goes down, the
refrigerant pump stops at minus 2 deg.C of the set value of specified chilled water outlet temperature.
ST : Set calue of specified chilled water outlet temp.
ON(Run)
Control valve
OFF(Stop)
ST-1.5 deg.C
(ST-2.7 deg F)
ST
ST-1.0 deg C
(ST-1.8 deg F)
Fig. 4-12
(7) Absorbent solution flow rate control
Absorbent solution flow rate is controlled by an inverter for #1 absorbent pump and H.T.Generator solution
level control in order to flow suitable absorbent flow rate corresponding with required cooling load for
saving steam consumption and achieving stable chilled water outlet temperature in part load.
a) #1 absorbent pump rotation speed controlled by the inverter
#1 absorbent pump rotation speed is controlled by the frequency signal sent from the inverter. The
frequency signal is computed by 5 parameters shown in Fig. 4-13 depending on the signal of
H.T.Generator temperature and the cooling water inlet temperature.
a
: To set maximum temperature for maximum frequency that is 60 Hz
Parameters
1
a
: To set slant of an oblique line showing change of frequency
2
a3 : To set shifting rate of the oblique line depending on cooling water inlet temperature
a4 : To set an inflection point on the oblique line
a5 : To set frequency used for heating mode only (fixed value)
a6 : To set minimum frequency
Frequency (Hz)
60
a3:0.060
50
28 deg.C
26 deg.C
a4:3.6
3.6 x 12 = 43.2
24 deg.C
40
Cooling water inlet
temp. 22 deg.C
Constant
32 deg.C
a2:0.42
30 deg.C
30
a6:2.3
2.3 x 12 = 27.6
20
80 84.0
Constant
90
100
Base temp. at
minimum frequency
110
120
130
H.T.Generator temperature (deg.C)
140
150
160
a1:148
Fig. 4-13 Example ofInverter
72
b) High temperature generator solution level control
In addition to the inverter control, the high temperature generator solution level control corrects the
frequency signal to reduce gradually if the solution level reaches the control electrode.
If the solution level rises and then it reaches E1, the
inverter frequency reduces depending on the time for
while the solution contacts with E1.
The solution level does not go down below E1 even if the
frequency is corrected by the control, #1 absorbent pump
stops.
If the solution level goes down below E1, #1 absorbent
pump re-starts.
For control of correction of inverter frequency (E1)
For solution level low alarm : J-15 (E2)
For earth (E3)
The above explanation is only on the control. #1
absorbent pump can run continuously during normal
operation condition.
If the solution level goes down below E2, the solution
level low alarm (J-15) occurs and then Chiller goes into
safety shutdown.
Solution level
of J-15
Solution level electrode box
Fig. 4-14 H.T.Generator solution level control
(8) Pre-set function of chilled water outlet temperature
Auto-reset function of chilled water outlet temperature setting
This function is to avoid cavitation of a refrigerant pump possibly occurring under the condition that a chilled
water outlet temperature setting is comparatively high and the cooling water inlet temperature is low. In
case of the operating condition, steam input may not be required to keep required chilled water outlet
temperature. No-steam causes no-generating refrigerant. Therefore, the refrigerant level in the evaporator
goes down. It may cause the cavitation.
In order to avoid the cavitation, this function chages low the setting of chilled water outlet temperature
automatically as shown in Fig. 4-15.
Chilled water setting temp.
12 deg.C (53.6 deg.F)
11 deg.C (51.8 deg.F)
10 deg.C (50.0 deg.F)
9 deg.C (48.2 deg.F)
8 deg.C (46.4 deg.F)
7 deg.C (44.6 deg.F)
22 deg.C
(71.6 deg.F)
24 deg.C
26 deg.C
27 deg.C
(75.2 deg.F)
(78.8 deg.F) (80.6 deg.F)
Cooling water inlet temp.
Fig. 4-15 Pre-set function of chilled water outlet temperature
73
4-4. Predication function (maintenance message)
(1) Poor vacuum condition predication function
There are two cases for this function as follows.
a) Judgment by the purge tank pressure
The message code "H-06 : PURGE TANK HIGH PRESSURE" will be indicated when the purge tank pressure
goes up to 10 kPa.
The message code "H-01 : OPERATE PURGE PUMP" will be indicated when the purge tank pressure goes up
to 11 kPa.
b) Judgment by increasing ratio of the purge tank pressure
If "H-06" is indicated, the purge tank will be filled with
non-condensable gas near future. Purge should be
conducted from the purge tank.
If "H-01" is indicated, the purge tank will be shortly
filled with non-condensable gas. Purge shall be
conducted from the purge tank.
Graph 4-1. Vacuum condition monitoring
1.0
Maintenance zone
Pressure rising indication
of storage tank
The message code "H-01" or "H-06" will be
indicated depending on the increasing ratio of
the purge tank pressure. For example, if the
purge tank pressure increases 1kPa per 1
minute, then H-01 will be indicated. This
function does not work in the first 60 minutes
after each startup because the purge tank
pressure goes up rapidly at startup. Also this
function does not work when Chiller is not
operating.
0.6
Notice
zone
Normal zone
0
0
20
60
100
80
Storage ratio (%)
Remark
In case of heating mode, If H.T.Generator
temperature goes up 120 deg.C, "H-01" is
indicated. In this case, the purging shall be
conducted after Chiller is cool down.
74
(2) Cooling water fouling predication function
There are two cases for this function as follows.
(1) Message code "H-07 : COOLING WATER TUBES FOUL"
If "H-07" is indicated, it shows that the heat transfer tubes in the absorber and condenser are fouled
which may affect fuel consumption. In this case, tube cleaning should be planed.
(2) Message code "H-03 : CLEAN COOLING WATER TUBES"
If "H-03" is indicated, it shows that the heat transfer tubes in the absorber and condenser are fouled
which may affect an occurrence of alarms. In this case, conduct tube cleaning as soon as possible.
Concept of the function
Graph 4-2. Fouling of heat transfer tubes
in cooling water system
This messages are made based on the
following temperatures.
Tci : Cooling water outlet temperature at condenser
Tco : Cooling water inlet temperature at condenser
Tcr : Condensed refrigerant temperature in condenser
During cooling operation, an area is
calculated by the three temperatures at
that time, and the are is compared with
LTD.
No-indication or "H-07" or "H-03" is
depending on the comparison result
between Ltd and LTD.
Maintenance
line
Maintenance zone
Fouling indicator
LTD : Standard value to judge fouling
condition
When Chiller is new (no-fouling condition),
the above temperatures are measured with
enough cooling load and an area is
calculated. This area is called as Ltd. This
Ltd is measured for several days, and then
the average is calculated from Ltd data as
shown in Fig. 4-18. This average is LTD.
8
6
4
Notice zone
2
Normal line
Normal zone
2
4
6
8
100
Cooling load factor (%)
Ltd-x
Tcr
Ltd-3
Ltd-2
Averaging
LTD
Tco
Tci
Ltd-1
Fig. 4-16 LTD
75
(3) Cooling water temperature high predication function
There are two cases for this function as follows.
(1) Message code "H-08 : COOLING WATER HIGH TEMP"
If cooling water inlet temperature is within the following value, H-08 is indicated. If H-08 is often
indicated, make a schedule to check and maintain a cooling water system.
0 deg.C < PCOIT minus SCOIT = or < 2 deg.C
PCOIT : Present cooling water inlet temp.
SCOIT : Specified cooling water inlet temp.
(2) Message code "H-04 : CHECK COOLING WATER SYSTEM"
If cooling water inlet temperature is beyond the following value, H-04 is indicated. In this case, check
and conduct necessary maintenance for a cooling water system as soon as possible.
PCOIT - SCOIT > 2 deg.C
(4) Power failure
Message code : H-10 POWER FAILURE
When the power resumes after power failure, this message is displayed.
76
4-5. Safety shutdown time chart
Following safety shutdown functions are provide on TSA-16NK series.
Chilled water
freeze
protection
Purpose Symbol
Crystallization
protection
Motor
protection
Work condition
Chilled water low temp. alarm
Below 2.5 deg.C
J-02
Chilled water pump alarm
No-chilled water pump interlock signal
J-03
Chilled water flow rate alarm
Below 50 % of specified chilled water flow rate
J-20
Cooling water low temp. alarm
Below specified cooling water inlet temp. minus 13
deg.C for 30 minutes.
J-06
Cooling water pump alarm
Cooling water flow rate alarm
(Option)
J-07
Others
Name of Alarm
J-01
No cooling water pump interlock signal
Below 50 % of specified cooling water flow rate
162 deg.C or more for 10 minutes or 165 deg.C.
(at cooling mode)
In cooling mode,0 MPa for UL & CE
J-13
Generator high temp. alarm
J-14
Generator high pressure alarm
J-15
Generator solution low level alarm Below E2
J-16
High concentration alarm
65% twice or 65.5%.
J-04
#1 Absorbent pump alarm
By working #1 absorbent pump overload relay
J-05
#2 Absorbent pump alarm
By working #2 absorbent pump overload relay
J-10
Refrigerant pump alarm
By working refrigerant pump overload relay
J-12
Purge pump alarm
By working purge pump overload relay
J-11
System interlock alarm
No-ventilation fan interlock signal
J-21
Capacity alarm
1 deg.C or less of chilled water temp. difference at
100% fuel input.
Alarm priority list
Each alarm is classified depending on their risk level viewing from Chiller protection as follows.
Each shutdown time chart is difference depending on the priorities.
Note 1 : If two or more alarms in difference priorities occur at the same time, a higher priority alarm
is indicated on the display board.
Note 2 : If two or more alarms in a same priority occur at the same time, indication on the display
board is as order.
Priority
Cooling mode
1st priority J-01, J-02, J-03
2nd priority J-04, J-05
3rd priority J-06, J-07, J-10, J-11
4th priority J-13, J-14, J-15, J-16
5th priority J-20, J-21
77
(1) Shutdown time chart of 1st priority in cooling mode
a) Alarm code & name, working condition
J-01 : Chilled water low temperature alarm
At starting
If the chilled water outlet temperature is below 2.5 deg.C and continues for 10 minutes after just
starting of Chiller, the cooling system including Chiller does not proceed and J-01 is indicated on the
During operation
If the chilled water outlet temperature goes down below 2.5 deg.C for 2 seconds during the operation
of Chiller, Chiller stops by J-01.
J-02 : Chilled water pump alarm
At staring
If the chilled water pump interlock signal does not return Chiller within 10 minutes after just starting of
Chiller, the cooling system including Chiller does not proceed and J-02 is indicated on the display
During operation
If the chilled water pump interlock signal is cut during the operation of Chiller, Chiller/Heater stops by
J-03 : Chilled water flow rate alarm
At starting
If the chilled water flow rate does not increase more then 50 % of the rated flow rate for 10 minutes
after just starting of Chiller, the cooling system including Chiller does not proceed and J-03 is
indicated on the display board.
During operation
If the chilled water flow rate decreases blow 50 % of the rated flow rate during the operation of
Chiller, Chiller stops by J-03.
b) Time chart of 1st priority alarms happened during the operation is as follows.
Alarm
Steam shut-off
valve
Steam control
valve
Chilled water
pump
Cooling water
pump
#1 Absorbent
pump
#2 Absorbent
pump
Open
Close
100%
0%
ON
OFF
1 min.
ON
OFF
ON
OFF
ON
OFF
ON
Refrigerant pump
OFF
T1 + 1 min.
Fig. 4-17 Time chart for 1st priority alarms
78
(2) Shutdown time chart of 2nd priority in cooling mode
a) Alarm code & name, working condition
J-04 : #1 absorbent pump alarm
At starting
If #1 absorbent pump overload relay is already working, J-04 is indicated immediately when the
START button is pressed or the remote start signal comes into the control circuit of Chiller, and the
cooling system including Chiller does not proceed any more.
During operation
If #1 absorbent pump overload relay works during the operation of Chiller, Chiller stops by J-04.
J-05 : #2 absorbent pump alarm
At starting
If #2 absorbent pump overload relay is already working, J-05 is indicated immediately when the
START button is pressed or the remote start signal comes into the control circuit of Chiller, and the
cooling system including Chiller does not proceed any more.
During operation
If #2 absorbent pump overload relay works during the operation of Chiller, Chiller stops by J-05.
b) Time chart of 2nd priority alarms happened during the operation is as follows.
Alarm
Steam shut-off
valve
Steam control
valve
Chilled water
pump
Cooling water
pump
#1 Absorbent
pump
#2 Absorbent
pump
Open
Close
100%
0%
ON
OFF
1 min.
ON
OFF
1 min.
ON
OFF
ON
OFF
ON
Refrigerant pump
OFF
T1
Fig. 4-18 Time chart for 2nd priority alarms
79
(3) Shutdown time chart of 3rd priority in cooling mode
a) Alarm code & name, working condition
J-06 : Cooling water pump alarm
At staring
If the cooling water pump interlock signal does not return Chiller within 10 minutes after just starting
of Chiller, the cooling system including Chiller does not proceed and J-06 is indicated on the display
During operation
If the cooling water pump interlock signal is cut during the operation of Chiller, Chiller stops by J-06.
J-07 : Cooling water flow alarm
At starting
If the cooling water flow rate does not increase more then 50 % of the rated flow rate for 10 minutes
after just starting of Chiller, the cooling system including Chiller does not proceed and J-07 is
indicated on the display board.
During operation
If the cooling water flow rate decreases blow 50 % of the rated flow rate during the operation of
Chiller, Chiller stops by J-07.
J-10 : Refrigerant pump alarm
At starting
If the refrigerant pump overload relay is already working, J-10 is indicated immediately when the
START button is pressed or the remote start signal comes into the control circuit of Chiller, and the
cooling system including Chiller does not proceed any more.
During operation
If the refrigerant pump overload relay works during the operation of Chiller, Chiller stops by J-10.
J-11 : System interlock alarm
At staring
If the ventilation fan interlock signal does not return Chiller within 10 minutes after just starting of
Chiller, the cooling system including Chiller does not proceed and J-11 is indicated on the display
During operation
If the ventilation fan interlock signal is cut during the operation of Chiller, Chiller stops by J-11.
b) Time chart of 3rd priority alarms happened during the operation is as follows.
80
Alarm
Steam shut-off
valve
Steam control
valve
Chilled water
pump
Cooling water
pump
Open
Close
100%
0%
ON
OFF
1 min.
ON
OFF
1 min.
#1 Absorbent
pump
#2 Absorbent
pump
ON
OFF
ON
OFF
ON
Refrigerant pump
OFF
T1
T2
Fig. 4-19 Time chart for 3rd priority alarms
81
(4) Shutdown time chart of 4th priority in cooling mode
a) Alarm code & name, working condition
J-13 : Generator high temperature alarm
At staring : Refer to 4-5-8 "Sensor alarm"
During operation
If H.T.Generator temperature reaches 162 deg.C again within 5 minutes after passing 10 minutes
functioning "Steam input reduction by H.T.Generator temperature" or reaches 165 deg.C, Chiller
J-14 : Generator high pressure alarm
At staring : Refer to 4-5-8 "Sensor alarm"
During operation
If H.T.Generator pressure reaches 0 MPa, Chiller stops by J-14.
J-15 : Generator solution low level alarm
During operation with combustion
If the H.T.Generator solution level goes down below E2, Chiller stops by J-15.
J-16 : High concentration alarm
During operation
If the concentrated solution concentration rises 65% again at passing just 3 minutes after starting
"Steam control valve close function by concentrated solution concentration" or rises 65% again within
1 hour after starting "Steam control valve close function by concentrated solution concentration" or
rises 65.5%, Chiller stops by J-16.
b) Time chart of 4th priority alarms happened during the operation is as follows.
Alarm
Steam shut-off
valve
Steam control
valve
Chilled water
pump
Cooling water
pump
Open
Close
100%
0%
ON
OFF
1 min.
ON
OFF
1 min.
#1 Absorbent
pump
#2 Absorbent
pump
ON
OFF
ON
OFF
ON
Refrigerant pump
OFF
T1
T2
Fig. 4-20 Time chart for 4th priority alarms
(5) Shutdown time chart of 5th priority in cooling mode
82
a) Alarm code & name, working condition
Cooling water low temp. alarm
watched temperature
J-20 : Cooling water low temperature alarm
At staring
If the cooling water inlet temperature does not reach the temperature shown in Fig. 4-23 within 30
minutes after starting Chiller with continuous steam supply condition, Chiller stops by J-20.
During operation
If the temperature shown in Fig. 4-23 is continued for 30 minutes during the operation of Chiller with
continuous steam supply, Chiller stops by J-20.
19 deg.C
(66.2 deg.F)
14 deg.C
(57.2 deg.F)
20 deg.C
(68 deg.F)
32 deg.C
(89.6 deg.F)
Fig. 4-21 Specified cooling water inlet temperature
J-21 : Capacity alarm
During operation
If the chilled water inlet/outlet temperature difference continues 1 deg.C or less for 30 minutes during
the operation of Chiller under the condition that fuel input is 100% and H.T.generator is 130 deg.C or
more, Chiller stops by J-21.
83
b) Time chart of 5th priority alarms happened during the operation is as follows.
Alarm
Steam shut-off
valve
Steam control
valve
Chilled water
pump
Cooling water
pump
Open
Close
100%
0%
ON
OFF
1 min.
ON
OFF
1 min.
#1 Absorbent
pump
#2 Absorbent
pump
ON
OFF
ON
OFF
ON
Refrigerant pump
OFF
T1
T2
Fig. 4-22 Time chart for 5th priority alarms
84
(6) Sensor alarm
If a sensor is broken (short/disconnection), Chiller shutdown manner and the alarm indication are as follows.
Sensor symbol and name
In case that sensor is already
broken at starting
In case that sensor is broken
during operation
Symbol
Name of sensor
Chiller is safety-shutdown by JJ-01 is indicated. Chiller can not
01. F25 can be indicated by
DT1 Chilled water outlet temp. sensor F25 be run. F25 can be indicated by
pressing
pressing
key.
key.
DT2 Cooling water outlet temp. sensor F3 F3 is indicated. Chiller can be run.
Alarm
code
DT3 H.T.Generator temp. sensor
J-13 is indicated. Chiller can not Chiller is safety-shutdown by JF26 be run. F26 can be indicated by 13. F26 can be indicated by
pressing
key.
pressing
key.
DT4 L.T.generator temp. sensor
J-16 is indicated. Chiller can not Chiller is safety-shutdown by JF7 be run. F7 can be indicated by 16. F7 can be indicated by
pressing
key.
pressing
key.
DT5 Condensed refrigerant temp. sensor
J-16 is indicated. Chiller can not Chiller is safety-shutdown by JF5 be run. F5 can be indicated by 16. F5 can be indicated by
pressing
key.
pressing
key.
DT6 Chilled water inlet temp. sensor
F1 F1 is indicated. Chiller can be run.
DT7 Cooling water inlet temp. sensor
J-20is indicated. Chiller can not
F2 be run. F2 can be indicated by
pressing
key.
DT10 Diluted LiBr solution temp. sensor F12 F12 is indicated. Chiller can be run.
DT11 Refrigerant temp. sensor
F8 F8 is indicated. Chiller can be run.
DT12 Middle cooling water temp. sensor
F4 F4 is indicated. Chiller can be run.
DT13 Steam drain temp. sensor
J-17 is indicated. Chiller can not Chiller is safety-shutdown by JF27 be run. F27 can be indicated by 17. F27 can be indicated by
pressing
key.
pressing
key.
Remarks : Regarding DT2, DT6, DT10, DT11 and DT12, be sure to replace a sensor broken before
operation of chiller even if Chiller can be operated. If Chiller is operated with broken sensor(s),
the control except PID control and/or predication functions do not work normally.
85
(7) Other alarm (Important information at start-up procedure & replacement of a microprocessor)
Remarks : At shipment of Chiller from the factory, the time setting in a microprocessor has been set as
follows. But if the alphabet is displayed in LED F21 and/or F23 will be displayed. In this case,
correct the time setting in accordance with Page 40 / Sec.6.
Year
:
Month & day
: 0 1 - 0 1
Time
: 0 7
2 0 0 1
Example of wrong setting
AM 7:00 1st January 2001 (Factory set value)
0 0
A
2 0 0 1
0 1 - 0 1 A
0 7 A 0 0
The alphabet "A" has been wrong inputted
The alphabet "A" has not been reased
a) F21 : CPU alarm
If F21 is displayed, causes are the wrong time setting described above or malfunction of the
microprocessor. If time setting is wrong, correct it. Even if the time setting is corrected, F21 does
not go off, it means that the microprocessor is out of order. Replace it.
b) F22 : MEMORY alarm
If F22 is displayed, it means that the reading / writing function of the microprocessor is
malfunction. In this case, the microprocessor must be replaced.
c) F23 : TIME SET alarm
If F21 is displayed, causes is the wrong time setting described above. Correct the time setting.
d) F24 : CONSTANT SET alarm
If F24 is displayed, causes is that wrong setting (s) is exist in some respects settings. It may be
possible to happen at replacement of the microprocessor. Especially , if the set of type (see page
50 / Sec.6), this alarm code happens due to allowable setting range difference depending on
models
If this alarm code is displayed, correct settings in accordance with the following steps.
d-1) Memory clear
Turn off the power for Chiller/Heater
Press
&
keys at the same time
Under the above pressing condition,
turn on the power for Chiller/Heater
C L r
is displayed.
Two keys being pressued are once free, then
press
key immediately continuously for a
while.
is displayed.
Memory clear is completed.
E n d
d-2) Perform necessary settings.
86
Section 5 Trouble Shooting
5-1. Chilled water outlet temperature does not go down in cooling mode
No chilling
Steam control valve
Related each other
Absorbent cycle
Check
Improper absorbent flow rate
Control valve signal
Malfunction of inverter & control
Octyle alcohol is insufficient
Chilled water temp controller
Microprocessor malfunction
Temp sensor (DT1) malfunction
Cooling water inlet temp. is
too high.
Crystallization
Poor vacuum condition
Too low cooling water inlet temp
Cooling water system
Cooling water temp does not go
down due to high humidity
Cooling water flow is insufficient
Fouling of tubes
Refrigerant cycle
Charging too much refrigerant
Refrigerant leaks into absorbent
side due to corrosion of
refrigerant
Fouling of tubes
Refrigerant pump reverse rotation
Water leak due to corroded pass
partition plate in water box
Refrigerant blow valve is not close
Pass partition gasket in water
box comes off
Refrigerant is contaminated with
LiBr
Vacuum side
Insulation
Air leakage
Improper foundation
Palladium cell malfunction
Improper leveling of chiller
Palladium cell heater malfunction
Inhibitor is insufficient
Purge pump can not get attained
vacuum
Chilled water system
Chilled water flow is too much
Fouling of tubes
Solution heat exchangers
Water leaks due to controlled
pass partition plate in water box
Absorbent flow rate decreased
due to tube broken
Absorbent flow rate decreased
due to clogging of heat
exchangers
Pass partition gasket in water
box comes off
Cooling load increased due to
expansion of cooling area, etc
Over load
Facility
Insufficient air handling unit
87
5-2. Trouble shooting at alarm in cooling mode
(1) Chilled water low temp. alarm / Alarm code : J-01 / Safety device : Chilled/hot water outlet temp. sensor (DT1)
J-01
In case that J-01 occurs
at 2.5 deg.C(36.5
deg.F) of the chulled
water outlet temp.
Fuel control valve does not
modulate
Check signals between
Chiller and Control valve
DT1 malfunctions
(Sensor alarm : F25)
Replace DT1
The microprocessor malfunctions
Replace the
microprocessor
If several or all of the following
conditions continue.
Check the cooling system
1)
2)
3)
4)
5)
In case that J-01 occurs
above 2.5 deg.C (36.5
deg.F) of the chilled
water outlet
Low cooling water inlet temp.
Low chilled water flow (Min. 50%)
Low cooling load condition
Sudden change of cooling load
Holding water quantity of
chilled water is a very few
DT1 malfunctions
(Sensor alarm : F25)
Replace DT1
The microprocessor malfunctions
Replace the
microprocessor
(2) Chilled water pump alarm / Alarm code : J-02 / Safety device : Chilled water pump interlock signal (52CH)
J-02
In case that 52CH
comes into the I/O
board
In case that 52CH does
not come into the I/O
board
Remark :
52CH can be checked by the
service mode.
I/O board malfunctions
(especially, connectors)
Imperfect contact of wires or
connectors connected to I/O board
happens
Replace the I/O board
Replace wires, connectors
The chilled water pump stops
Start the chilled water
pump
Power supply for remote control
panel is OFF
Tern on the power supply
Imperfect contact happens in a
remote control circuit
Check & repair the contact
Interlock signal wires or a connector
is out of order
Replace wires and the
connector
88
(3) Chilled water flow rate alarm / Alarm code : J-03 / Safety device : Chilled/hot water flow switch (69CH)
J-03
In case that chilled
water flow rate is more
than 50 % of the rated
flow rate
In case that chilled
water flow rate is less
than 50 % of the rated
flow rate
The flow switch malfunctions
Replace the flow switch
The flow switch is wrong set
Re-adjust the flow switch
The wire of flow switch is cut
Replace wire
I/O board is out of order
Replace the I/O board
Capacity of the chilled water pump
is insufficient
Resistance of chilled water circuit is
too much
Contact to a facility
company
A differential pressure control valve
in the chilled water circuit
malfunctions
Air is exiting in the chilled water
circuit
Perform air vent
A strainer in the chilled water circuit
is clogged
Clean the strainer
A valve in the chilled water circuit is
closed
Open the valve
89
(4) #1 absorbent pump alarm / Alarm code : J-04 / Safety device : Protective functions in a inverter
Note : Protective function menu & working condition of a inverter can be confirmed by a display panel on the inverter.
J-04
In case that a protec-tive
function of the inverter works
An electronic
thermal in the
inverter works
#1 absorbent
pump is fastened
(not rotating)
Crystallization
Foreign
materials
De-crystallization
Remove them
Insulation failure of pump motor coil
Replace the stator of
the pump
Short of pump motor coli
Ground fault of pump motor coil
Too much absorbent flow rate
Re-adjust absorbent flow
rate by solution dampers
The inverter malfunctions
Replace the inverter
The wrong settings of the inverter
Correct the setting
A protective function except for
the elec-tronic thermal works
In case that protective
functions of the inverter
do not work
Refer to the
manufacturer's instruction
manual of inverter
An alarm signal is not sent from the
inverter to microprocessor
The inverter malfunctions
The microprocessor malfunctions
Check the inverter,
microprocessor and
wiring of the alarm
signal, then replace
failure parts
(5) #2 absorbent pump alarm / Alarm code : J-05 / Safety device : Thermal relay (51A2)
J-05
In case that the thermal
relay (51A2) functions
#1 absorbent
pump is fastened
(not rotating)
Crystallization due
to too short dilution
operation time
De-crystallization
& changing the
time
Addition of too much
inhibitor
Insulation failure of pump motor coil
Short of pump motor coli
Replace the stator of
the pump
Ground fault of pump motor coil
The thermal relay (51A2)
malfunctions
Replace 51A2
Wrong setting of the thermal relay
Correct the setting
The magnet contactor (88A2)
malfunctions
Replace 88A2
90
(6) Cooling water pump alarm / Alarm code : J-06 / Safety device : Cooling water pump interlock (52CO)
J-06
In case that 52CO
comes into the I/O
board
In case that 52CO does
not come into the I/O
board
Remark :
52CO can be checked by the
service mode.
I/O board malfunctions
(especially, connectors)
Imperfect contact of wires or
connectors connected to I/O board
happens
Replace the I/O board
Replace wires, connectors
The cooling water pump stops
Start the cooling water
pump
Power supply for remote control
panel is OFF
Tern on the power supply
Imperfect contact happens in a
remote control circuit
Check & repair the contact
Interlock signal wires or a connector
is out of order
Replace wires and the
connector
(7) Cooling water flow rate alarm / Alarm code : J-07 / Safety device : Cooling water flow switch (69CO) OPTION
J-07
In case that cooling
water flow rate is more
than 50 % of the rated
flow rate
In case that cooling
water flow rate is less
than 50 % of the rated
flow rate
The flow switch malfunctions
Replace the flow switch
The flow switch is wrong set
Re-adjust the flow switch
The wire of flow switch is cut
Replace the wire
I/O board is out of order
Replace the I/O board
Capacity of the cooling water pump
is insufficient
Resistance of cooling water circuit
is too much
Contact to a facility
company
Air is exiting in the chilled water
circuit
Perform air vent
A strainer in the chilled water circuit
is clogged
Clean the strainer
A valve in the chilled water circuit is
closed
Open the valve
91
(8) Refrigerant pump alarm / Alarm code : J-10 / Safety device : Thermal relay (51R)
J-10
In case that the thermal
relay (51R) functions
Refrigerant pump
is fastened (Not
rotating)
Foreign
materials
Failure (insulation fault, short,
ground fault, disconnection) of
pump motor coil
In case that the thermal
relay (51R) functions
Remove foreign materials
Replace the stator of the
pump
The thermal relay (51R)
malfunctions
Replace 51R
Wrong setting of the thermal relay
Correct the setting
The magnet contactor (88R)
malfunctions
Replace 88R
Contamination of refrigerant
happens
Search & remove the
cause
Refrigerant flow rate is too much
Re-adjust the flow rate
The thermal relay (51R)
malfunctions
Replace 51R
Short of thermal relay wires
Replace the wires
The microprocessor malfunctions
Replace the
microprocessor
(9) System interlock alarm / Alarm code : J-11 / Safety device : Ventilation fan interlock (52F)
J-11
In case that 52F comes
into the I/O board
I/O board malfunctions
(especially, connectors)
Imperfect contact of wires or
connectors connected to I/O board
happens
In case that 52F does
not come into the I/O
board
Remark :
52F can be checked by the
service mode.
Replace the I/O board
Replace wires, connectors
The Ventilation fan stops
Start the ventilation fan
Power supply for remote control
panel is OFF
Tern on the power supply
Imperfect contact happens in a
remote control circuit
Check & repair the contact
Interlock signal wires or a connector
is out of order
Replace wires and the
connector
92
(10) Purge pump alarm / Alarm code : J-12 / Safety device : Thermal relay (51P)
J-12
In case that the thermal
relay (51P) functions
Purge pump is
fastened (Not
rotating)
Rotate the pulley of purge pump by
hands.
(It may occur in winter)
If absorbent solution goes into the
pump, the inside of pump is corroded
and the pump is locked. Replace the
pump motor.
Failure (insulation fault, short,
ground fault, disconnection) of
pump motor
Replace the purge pump
motor
The thermal relay (51R)
malfunctions
Replace 51R
Wrong setting of the thermal relay
Correct the setting
The magnet contactor (88P)
malfunctions
Replace 88R
93
(11) Generator high temp. alarm / Alarm code : J-13 / Safety device : H.T.Generator temp. sensor (DT3)
J-13
J-13 occurs at set value
Poor vacuum
condition
H-01 is continuously
displayed
Perform purging
immediately
If OK, the cause is only insufficient
purging
Absorbent flow
rate is Insufficient
Cooling water
problems
J-13 occurs below set
value
J-13 still occurs. Attained
vacuum of purge pump is not
suitable.
#1 abso. pump does
not run (Refer to J-04)
J-13 still occurs. Pd cell and/or
its heater malfunction.
#1 Abso. pump runs
J-13 still occurs. Leakages may
be possible. Perform leak test.
Improper set of diluted solution
dampers
Re-adjust dampers
Reverse rotation of #1 abso.pump
Correct the wiring
Crystallization
De-crystallization
Insufficient octyl alcohol
Add octyl alcohol
Insufficient solution charged
Add solution
Cooling water inlet temp. is higher
than rated temp.
Cooling water flow rate is
insufficient
Absorber and condenser tubes are
fouled
Contact to a facility
company
DT3 malfunctions
Replace DT3
F-26
94
(12) Generator high pressure alarm / Alarm code : J-14 / Safety device : H.T.Generator pressure switch (63GHH)
J-14
J-14 occurs at set value
Poor vacuum
condition
H-01 is continuously
displayed
Perform purging
immediately
If OK, the cause is only insufficient
purging
J-13 still occurs. Attained
vacuum of purge pump is not
suitable.
J-13 still occurs. Pd cell and/or
its heater malfunction.
Absorbent flow
rate is Insufficient
J-13 still occurs. Leakages may
be possible. Perform leak test.
#1 abso. pump does
not run (Refer to J-04)
#1 Abso. pump runs
Cooling water
problems
J-14 occurs below set
value
Insufficient inhibitor may be
considered. If inhibitor is
insufficient, a lot of hydrogen gas
generate.
Improper set of diluted solution
dampers
Re-adjust dampers
Reverse rotation of #1 abso.pump
Correct the wiring
Crystallization
De-crystallization
Insufficient octyl alcohol
Add octyl alcohol
Insufficient solution charged
Add solution
Cooling water inlet temp. is higher
than rated temp.
Cooling water flow rate is
insufficient
Absorber and condenser tubes are
fouled
Contact to a facility
company
63GH malfunctions DT3
malfunctions
Replace 63GH
95
(13) Generator solution level low alarm / Alarm code : J-15 / Safety device :
H.T.Generator solution level elect rods (E1& E2)
J-15
J-15 occurs even if
solution level is normal
Electrodes does
not detect the
solution level
This can be checked by the digital input indication.
E1 is ON.
Disconnection of wires of electrodes
Replace wires
Electrode surface is fouled
Replace electrodes
LiBr solution bubbling in the
electrode box
(There is a case to occur this after
long term operation)
Replace LiBr solution
The microprocessor malfunctions
J-15 occurs due to low
solution level
This can be checked by the digital input indication.
E2 is OFF.
LiBr flow rate is
insufficient
Digital input signal for
#1 abso. pump is sent
to the inverter
#1 abso. pump does
not run (Refer to J-04)
#1 Abso. pump runs
#1 abso. pump
malfunctions
Check the pump. Prepare
or replace it
Inverter
malfunctions
Replace inverter
Wrong settings of
Inverter &
microprocessor
Wrong damper settings
(D1, D2, D3)
Tube failure of solution
heat exchanger (s)
Clogging solution heat
exchanger (s)
The check valve is
locking
Insufficient LiBr in
absorber bottom due to
crystallization,
contamination,
Digital input signal for
#1 abso. pump is not
sent to the inverter
Over steam input
The microprocessor
malfunctions
Correct them
Correct them
Replace failure
heat exchanger
Replace it
Remove the cause
Replace the
microprocessor
Re-adjust the
steam input
96
(14) High concentration alarm / Alarm code : J-16 / Safety device : L.T.Generator temp. sensor (DT4)
& Condensed refrigerant temp. sensor (DT5)
J-16
J-16 occurs with
following conditions
If OK, the cause is only insufficient
purging
Poor vacuum
condition
J-13 still occurs. Attained vacuum
of purge pump is not suitable.
H-01 is continuously
displayed
Perform
purging
immediately
Absorbent flow
rate is Insufficient
#1 abso. pump does
not run (Refer to J-04)
J-13 still occurs. Pd cell and/or its
heater malfunction. Replace it
(them).
J-13 still occurs. Leakages may be
possible. Perform leak test.
Insufficient inhibitor may be
considered. If inhibitor is
insufficient, a lot of hydrogen gas
generate.
#1 Abso. pump runs
Steam input is
too much
Cooling water
problems
J-16 occurs without
following conditions
Improper set of diluted solution
dampers
Re-adjust dampers
Reverse rotation of #1 abso.pump
Correct the wiring
Crystallization
De-crystallization
Insufficient octyl alcohol
Add octyl alcohol
Insufficient solution charged
Add solution
Wrong adjustment of steam control
valve
Re-adjust steam control
valve
Wrong setting of microprocessor
Re-set microprocessor
Microprocessor malfunctions
Replace microprocessor
Cooling water inlet temp. is higher
than rated temp.
Cooling water flow rate is
insufficient
Absorber and condenser tubes are
fouled
Contact to a facility
company
DT4 malfunctions (F-7)
Replace DT4
DT5 malfunctions (F-5)
Replace DT5
Condition of occurring alarm
1. In case that concentrated solution concentration goes up 65% after 3 minutes of starting
crystallization protection function
2. In case that concentrated solution concentration goes up 65% within 1 hour after starting
crystallization protection function
3. In case that concentrated solution concentration goes up 65.5%.
97
(15) Cooling water low temp. alarm / Alarm code : J-20 / Safety device : Cooling water inlet temp. sensor (DT7)
J-20
J-20 occurs while cooling
water inlet temp. continues
below rated temp. minus 13
deg.C for 30 minutes
J-20 occurs even if cooling
water inlet temp. above rated
temp. minus 13 deg.C
I/O board malfunctions
(especially, connectors)
Contact to a facility
company
Microprocessor malfunctions
Replace the
microprocessor
DT7 malfunctions
Replace DT7
(16) Capacity alarm / Alarm code : J-21
Refer to section 5-1 "Chilled water outlet temperature does not go down in cooling mode"
98
Section 6 Parts replacement & Instructions
6-1. Guidance interval of parts replacement
The following intervals are guidance for replacement of parts to get stable operation.
Operation time is less than 4,000 Heavy load operation, process use
Replacement parts
hours per year for air-conditioning. and/or continuous annual operation
1 Absorbent pump
2 Refrigerant pump
3 Purge pump
4 Generator pressure gauge
5 Palladium cell & heater
6 Sight glass & gaskets
7 Diaphragm valve gasket
8 Controller
9 Circuit breaker
10 Magnet switch
11 Temperature sensor
# Rupture disk
24,000 or 6 years
24,000 or 6 years
10 years
28,000 hours or 7 years
12,000 hours or 3 years
6 years
6 years
5 years
40,000hours or 10 years
28,000 hours or 7 years
28,000 hours or 7 years
4,800 hours or 1 year
16,000 hours or 4 years
16,000 hours or 4 years
10 years
20,000 hours or 5 years
12,000 hours or 3 years
6 years
6 years
5 years
40,000hours or 10 years
28,000 hours or 7 years
28,000 hours or 7 years
4,800 hours or 1 year
99
6-2. How to change parts
(1) #1 & #2 Absorbent pumps & Refrigerant pump
This instruction describes the procedure to replace #1 & #2 absorbent pumps and refrigerant pump.
As procedures for the absorbent pumps and the refrigerant pump are same, the procedure for #1 absorbent
pump is explained in this material.
a) Instrument
a-1) Pan to collect spilled absorbent / refrigerant solution at disassembling them
a-2) wood blocks
a-3) Box wrenches
Pump
a-4) Adjustable wrenches
a-5) Insulation tape
a-6) Vinyl tape
Power
i
Vinyl tape
Terminal
box
Wood
blocks
Vinyl back
Fig. 6-1
Fig. 6-2
Pan
b) Procedure
b-1) Be sure to confirm that the main breaker (MCBM) is turned OFF.
b-2) Close the isolation valves of the pump tightly.
b-3) Open the cover of terminal box. Disconnect power wires (U1, V1, W1) in the terminal box.
b-4) Cover each end of wires by a vinyl tape to prevent wetting with solution then cover them
by a vinyl back as shown in Fig. 6-1. At this time, record wire marks.
b-5) Put the pan under the pump
b-6) Put the wood block between the pan and the pump shown in Fig. 6-2.
b-7) Remove bolts of the pump and pull out the pump carefully
b-8) Wash the flange and the isolation valve portion mounted under the lower shell with water.
(Pure water or distilled water should be used)
b-9) Check if the flange surface is clean or not. If OK, mount new pump with new gasket.
Be sure to tighten all bolt uniformly because it is very difficult to do leak test.
Non-uniform tightening causes air leakage.
b-10) Connect the power wires with confirming wire marks and cover each connected portions with the
insulation tape and vinyl tape. Then close the terminal box cover.
b-11) Open the isolation valves.
b-12) Run the chiller to confirm the rotating direction of the pump by a rotation direction meter.
Correct direction is clockwise viewing from back of the pump. If OK, stop the chiller.
b-13) Perform air purging from the chiller for 1 hour (Open purge valve V1 & V3)
b-14) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour.
b-15) If there are no- abnormality, the chiller can be run on normal operation.
100
(2) Purge pump
This instruction describes the procedure to replace an purge pump with a motor.
a) Instrument
a-1) Adjustable wrenches
a-2) Insulation tape
a-3) Vinyl tape
4 bolts for flange
Terminal box
Sight glass
4 bolts for base
Purge pump
Purge
pump
motor
Fig. 6-3
b) Procedure
b-1) Be sure to confirm that the main breaker (MCBM) is turned OFF.
b-2) Be sure to confirm that the purge valves (V1, V2, V3) are closed.
b-3) Remove purge pump oil in the purge pump.
b-4) Open the cover of terminal box. Disconnect power wires (U4, V4, W4) in the terminal box.
b-5) Cover each end of wires by a vinyl tape to prevent wetting with solution then cover them by a vinyl
back as shown in Fig. 6-1. At this time, record wire marks.
b-6) Remove the 4 bolts for the flange and 4 bolts for the base shown in Fig. 6-3. Then remove the pump.
b-7) Put new pump.
b-8) Temporally tighten 4 bolts for the base. Tighten 4 bolts for the flange tightly. Then tighten 4 bolts for
the base tightly.
b-9) Connect the power wires with confirming wire marks and cover each connected portions with the
insulation tape and vinyl tape. Then close the terminal box cover.
b-10) Run the pump to confirm the rotating direction of the pump.
Correct direction is shown by the arrow mark on the V-belt cover.
b-11) Charge the purge pump oil up to the center of the sight glass under running of the purge pump.
b-12) Check that V-belt tension is about 10 mm (0.4 inch). If not, adjust the tension by sliding the motor.
b-13) Check the attained vacuum of new pump.
101
(3) Sight glass
This instruction describes the procedure to replace sight glasses with gasket.
a) Instrument
a-1) Adjustable wrenches
a-2) Bucket for solution
a-3) Vacuum rubber hose with copper tube
a-4) Nitrogen gas
a-5) Hose for nitrogen gas
a-6) Regulator for nitrogen gas
b) Position of the sight glass
b-1) Evaporator
b-2) Bottom of the absorber
Bolt
Gasket
Sight glass flange
Sight glass
Bolt
Fig. 6-4
b-3) High temp. generator
c) Replacement of the sight glass on the evaporator.
c-1) If the refrigerant solution level is beyond the bottom of the sight glass,
perform the refrigerant blow down.
c-2) Charge Nitrogen gas into the chiller up to about 9.8 kPa.
c-3) Discharge Nitrogen gas. (Refer to "6-12. Method of discharging Nitrogen gas")
c-4) Remove 6 bolt for the sight glass and remove the sight glass and gasket.
c-5) Clean the surface of the sight glass flange by dry cloth.
c-6) Put new sight glass and gasket. Tighten bolts uniformly.
c-7) Charge Nitrogen gas into the chiller up to about 49 kPa.
c-8) Perform leak test by soap solution.
c-9) Discharge nitrogen gas.
Perform purging until the pressure in the chiller goes down to 1.3 kPa absolute.
c-10) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour.
c-11) If there are no- abnormality, the chiller can be run on normal operation.
d) Replacement of the sight glass on the absorber.
d-1) Charge Nitrogen gas into the chiller up to about 30 kPa.
d-2) Discharge LiBr solution from the service valve (SV4) until the solution level falls to
the sight glass bottom.
d-3) Discharge Nitrogen gas.
d-4) Remove 6 bolt for the sight glass and remove the sight glass and gasket.
d-5) Clean the surface of the sight glass flange by dry cloth.
d-6) Put new sight glass and gasket. Tighten bolts uniformly.
d-7) Charge Nitrogen gas into the chiller up to about 49 kPa.
d-8) Perform leak test by soap solution.
d-9) Discharge nitrogen gas. Perform purging. When the inside pressure decreases about -50kPa,
charge the LiBr solution from the service valve (SV4).
d-10) Continue purging until the pressure in the chiller goes down to 1.3 kPa absolute.
d-11) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour.
d-12) If there are no- abnormality, the chiller can be run on normal operation.
102
e) Replacement of the sight glass on the high temp. generator
e-1) Charge Nitrogen gas into the chiller up to about 30 kPa. (Refer to "6-11. Method of charging Nitrogen gas")
e-2) Discharge LiBr solution from the service valve (SV8) until the solution level falls to
the sight glass bottom.
e-3) Discharge Nitrogen gas. (Refer to "6-12. Method of discharging Nitrogen gas")
e-4) Remove 6 bolt for the sight glass and remove the sight glass and gasket.
e-5) Clean the surface of the sight glass flange by dry cloth.
e-6) Put new sight glass and gasket. Tighten bolts uniformly. (Gasket is one side only. Carefully tighten bolts.)
e-7) Charge Nitrogen gas into the chiller up to about 49 kPa.
e-8) Perform leak test by soap solution.
e-9) Discharge nitrogen gas. Perform purging. When the inside pressure decreases about -50kPa,
charge the LiBr solution from the service valve (SV4).
e-10) Continue purging until the pressure in the chiller goes down to 1.3 kPa absolute.
e-11) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour.
e-12) If there are no- abnormality, the chiller can be run on normal operation.
Gasket (T/# 9090-OR)
Apply Teflon sealant (T/# 9400)
a) Instrument
a-1) Adjustable wrenches
a-2) Vacuum rubber hose with copper tube
a-3) Nitrogen gas
a-4) Hose for nitrogen gas
a-5) Regulator for nitrogen gas
a-6) Torque wrench
Upper tube
(4) Rupture disk
This instruction describes the procedure to replace a rupture disk.
b) Procedure
Flanges & bolts
Rupture disk
b-1) Charge Nitrogen gas into the chiller up to
assembly
about 9.8 kPa.
Fig. 6-5
b-2) Remove 4 bolts for flanges.
Hold down
b-3) Carefully remove the rupture disk assembly.
Cap screw
b-4) Remove the cap screws and disassembly the rupture
disk assembly. Then take out the rupture disk.
b-5) Put new rupture disk into base and the hold down and tighten
Rupture disk
them uniformly by the cap screws.
Flow
Tightening torque : 2 inch 30 Nm (22 ft lbs)
Tightening torque : 3 inch 35 Nm (26 ft lbs)
At this time, do not make a mistake of rupture disk direction.
Cap screw
b-6) Put the rupture disk assembly and gaskets with Teflon sealant
Base
into the flanges, and tighten them uniformly by the bolts.
Fig. 6-6 Rupture disk assembly
Tightening torque : 2 inch 70 Nm (52 ft lbs)
Tightening torque : 3 inch 75 Nm (55 ft lbs)
b-7) Charge Nitrogen gas into the chiller up to about 49 kPa.
b-8) Perform leak test by soap solution.
b-9) Discharge nitrogen gas.
b-10) Perform purging until the pressure in the chiller goes down to 1.3 kPa absolute.
b-11) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour.
b-12) If there are no- abnormality, the chiller can be run on normal operation.
103
(5) Palladium cell & heater
This instruction describes the procedure to replace an palladium cell and heater.
a) Instrument
a-1) Screw driver
a-2) Torque wrench
a-3) Adjustable wrenches
a-4) Fork terminals
a-5) Heat resistance tube
Fig. 6-7 Palladium cell assembly with heater
b) Procedure
b-1) Be sure to confirm that the main breaker (MCBM) is turned OFF.
b-2) Close B valve tightly.
b-3) Open and remove the palladium cell cover.
b-4) Remove the heater wire screws in the connection box and remove the heat resistance tube.
b-5) Remove the assembling spring and bark the adhesive tape. Then disassemble the insulations.
b-6) Loosen two screws fixing the heater and take out the hater.
b-7) Loosen the screw fixing the case to the mounting and take out the case.
b-8) Remove the flare nut and the palladium cell.
b-9) Put new palladium cell.
Tighten the flare nut by the torque wrench with 59-68 Nm (522-601 lbf inch).
Note : Do not touch the palladium cell by fingers directory, use clean gloves.
b-10) Perform leak test by the bubble test from SV9 (Purge tank service valve)
Leak rate shall be 0cc per 10 minutes.
b-11) Insert the case to the mounting with palladium cell and fix them by the screw.
b-12) Insert new heater into the case and fix them by the screws.
b-13) Insert the heater wires into the heat resistance tube.
b-14) Put the fork terminals to the heater wires and the connect the wires with fork terminals to the
originals terminal positions. Then put the connection box cover.
b-15) Assemble the palladium cell cover.
Adhesive tape
Assembling spring
Insulation
Case
Heater
Palladium cell
Fig. 6-8
104
Fig. 6-9 Palladium cell
Case
Heater
Palladium cell
Flare nut
Mounting for palladium cell
welded on purge tank
Holes of screw
Fig. 6-10
105
6-3. Method of absorbent solution (LiBr) analyses
This instruction described to procedure for analyses of absorbent solution.
(1) Notice for analyses
a) The time of analyses
a-1) In case of commercial use for air conditioning (about 4000 hours operation per year), the analyses
should be conducted twice per year.
a-2) In case of continuously operation such as process use the analyses should be conducted four times
per year.
b) Sampling solution and sampling position
b-1) Sampling solutio : Diluted absorbent solution
b-2) Sampling positio : The service valve (SV4) at discharge pipe of the absorbent pump
c) Sampling quantity
Sample the absorbent solution of 100 cc twice. First sampling solution shall be abandoned. Second
sampling solution shall be used for analyses.
d) Sample the absorbent solution during operation of the absorbent pump.
(2) Analyses items
a) Concentration of inhibitor (Lithium Molybdate : Li2MoO4)
b) Alkalinity (Neutralization analysis)
c) All copper content and all iron content
(3) Instruments
a) Solution sampling tool
b) Bottle for solution with a cap (100 cc)
c) Pipette with scale
d) Beaker (100 cc.)
e) Burette]
f) Syringe
g) Phenolphthalein solution
h) One-tenth normal Hydrochloric acid solution (HCl)
i) 50% Hydrochloric acid solution (HCl)
j) Aluminum nitrate (Al(NO3)3 9H2O)
Aluminum nitrate is crystal. Therefore, making aluminum nitrate solution shall be required.
The method of making it is as follows.
Put 250 g of aluminum nitrate unto a bottle and pure water into the bottle until total volume
becomes 1 liter, and then mix them.
k) Pure water
(4) Sampling of the absorbent solution
a) Remove the absorbent solution at the service valve (SV4) during operation of the absorbent pump by the
sampling tool.
b) Pour the absorbent solution to the bottle from the sampling tool.
106
(5) Measurement of concentration of inhibitor (Lithium Molybdate : Li2MoO4)
Standard concentration of inhibitor : 50 - 150 ppm
a) Stand the bottle for about 24 hours. After 24 hours, most solids in the absorbent solution accumulates at
the bottom of the bottle.
b) Collect 5 milli-litter of the absorbent solution from the top of the bottle by a pipette, and then pour it into
a beaker.
c) Add 4 milli-litter of the aluminum nitrate solution and 1 milli-litter of 50 % hydrochloric acid solution into
another beaker, and mix tem.
d) Add 1 milli-litter of the solution made in the item c) into the beaker by another pipette.
e) Pour 94 milli-litter of pure water into the beaker by the burette.
The above procedure is to make solution for analysis. And its volume is 100 milli-litter. This means that
the absorbent solution is diluted to 1/20.
f) In order to measure concentration of Lithium Molybdate, "Atomic absorption spectro chemical analysis"
must be required. There is no-way to simply measure it. Therefore, this check can not be done at an site.
It is preferred to request the analysis to an official organization or an analysis company.
g) If concentration value measured is less than its standard, add inhibitor in accordance with " Method of
adjusting inhibitor content and alkali".
(6) Measurement of alkalinity (Neutralization analysis)
Standard of the alkalinity : 0.03 N - 0.07 N (P Alkalinity)
a) Stand the bottle for about 24 hours. After 24 hours, most solids in the absorbent solution accumulates
at the bottom of the bottle.
b) Collect 10 milli-litter of the absorbent solution from the top of the bottle by a pipette, and the pour it into
a beaker.
c) Pour 50 milli-litter of pure water into the beaker by the burette.
d) Add Phenolphthalein (2 -3 drops) into the beaker by the syringe. The solution is colored to pink.
The above procedure is to make solution for analysis.
e) Add one-tenth normal Hydrochloric acid solution little by little into the solution by a burette until its color
becomes colorless.
f) Calculate the alkalinity according to the following formula.
N = A X 0.01
where
N : Alkalinity
A : Quantity of Hydrochloric acid solution added (milli-litter)
g) The standard of adjustment of the alkalinity
g-1) Alkalinity is 0.03 N - 0.07 N
No addition is required.
g-2) Alkalinity is less than 0.03 N
Add LiOH
g-3) Alkalinity is beyond 0.07 N
Add HBr
Remark : In case of absorbent with Li2MoO4 as inhibitor, its alkalinity reduces as compared with initial
value of the alkalinity in proportion to operation hours of the chiller.
107
(7) Analyses of all copper content and all iron content
Limitation of the all copper content : 250 ppm max.
Limitation of the all iron content : 250 ppm max.
a) Shake the bottle before collecting the absorbent solution.
b) Collect 1 milli-litter of the absorbent solution from the top of the bottle by the pipette, and then pure it
into a beaker.
c) Add 1 milli-litter of one-tenth normal Hydrochloric acid solution. Into the beaker by another pipette.
d) After a few hours, pour 98 milli-litter of pure water into the beaker by a burette.
The above procedure is to make solution for analysis. And its volume is 100 milli-litter. This means that the
absorbent solution is diluted to 1/100.
e) In order to measure concentrations of the all copper and iron, "Atomic absorption spectro chemical
analysis" must be required as well as the method of the measurement of inhibitor.
f) If the all copper content and all iron content are beyond their limitation, all absorbent solution charged in
the chiller shall be filtered.
(8) Notes
a) In case that the absorbent solution crystallizes, melt it first and then perform the analyses.
b) In case of the analyses of the all copper and the all iron, wait for a while after hydrochloric acid solution
is added.
Notice for all iron & all copper
If these value is beyond the limitations, it means that there is a leakage. In this case, the leak test shall be
performed and repair it as soon as possible. After that, perform filtration of all absorbent solution. Then
Analyze them again.
108
6-4. Method of adjusting inhibitor content and alkalinity
(1) Method of adding inhibitor
This instruction describes the procedure to add inhibitor.
a) Instruments
a-1) Inhibitor : Li2MoO4 H2O (20wt% solution)
a-2) Pure water
a-3) Container
a-4) Vacuum rubber hose
a-5) Hose band
a-6) Pliers
a-7) Wrench
a-8) Rubber gloves
b) Target value of inhibitor concentration : 150 ppm
Additional volume of the inhibitor is calculated
in accordance with the following formula.
150 ppm - X ppm
x 0.465 x A = D
100
where
X : Measured value of inhibitor concentration (ppm)
A : Initial charge amount of absorbent solution
D : Required volume of inhibitor (cc)
For example
X = 40 ppm
Model : TSA-16LJ-24
A = 1,070 kg
150 ppm - 40 ppm
100
x 0.465 x 1,070 = 547 cc
Table 6-1 Initial charge LiBr solution in the factory
Absorbent solution(50wt%)
Model
TSA-16NK-**
kg
lbs
510
1,125
11
1,477
670
12
1,698
770
13
1,940
880
21
2,470
1,120
22
3,175
1,440
31
3,374
1,530
32
3,682
1,670
41
3,859
1,750
42
4,454
2,020
51
4,917
2,230
52
5,402
2,450
53
6,262
2,840
61
7,034
3,190
62
7,629
3,460
63
9,459
4,290
71
10,540
4,780
72
12,238
5,550
81
109
c) Procedure
c-1) In order to remove air in the rubber hose, pour pure water
into the hose as shown in Fig. 6-12.
c-2) Connect the vacuum rubber hose to the service valve (SV3)
provided on the refrigerant pump discharge and fix it by
a hose band as shown in Fig. 6-11.
Sampling
service valve(SV3)
Copper tube
Solution
container
Refrigerant
pump
Vacuum
rubber hose
Copper tube
Vacuum
rubber hose
Inhibitor
Filled with
pure water
Fig. 6-11
Fig. 6-12
c-3) Pour inhibitor added into the container.
c-4) Insert a copper tube into the container.
c-5) perform purging from the chiller.
c-6) Open the service valve (SV3)
c-7) When inhibitor starts being sucked into the chiller, watch carefully to ensure
that air does not leak in.
c-8) Close the service valve (SV3) after charging the inhibitor.
c-9) Remove the vacuum rubber hose.
c-10) Wash the mouth of the service valve with water and put the bonnet and flare nut.
Then place the cap of the service valve after confirming the packing inside.
c-11) Wash all instruments with water.
c-12) Perform refrigerant blow down after completion of the work, and run the chiller in order to
circulate the inhibitor in the inside of chiller.
c-13) Continue the purging at least 30 minutes after completion of this work.
d) Notes
d-1) Be sure to perform this work during operation of the chiller, and be sure to carry out purging
from the chiller during this work.
d-2) Wear rubber gloves while this work.
d-3) Thoroughly wash off any inhibitor which gets on hand, skin and clothes. Take care to prevent
inhibitor entering mouth and eyes.
d-4) Do not spill inhibitor on a floor and do not throe it in a drain.
110
(2) Method of adding alkali
This instruction describes the procedure to add Alkali (LiOH) in case that alkalinity is less than 0.03 N.
a) Instruments
a-1) Alkali : LiOH (powder)
a-2) Pure water
a-3) Container
a-4) Vacuum rubber hose
a-5) Hose band
6) Pliers
7) Wrench
8) Rubber gloves
9) Mask
b) Target value of alkalinity : 0.07 N
Additional volume of LiOH is calculated in accordance with the following formula.
D = 28.6 x (0.07 -X) x A
where
X : Measured value of alkalinity (N)
A : Initial charge amount of absorbent solution (see Table *-*)
D : Required volume of alkali (g)
For example
X = 0.01 N
Model : TSA-16LJ-24 A = 1,070 kg
28.6 x (0.07 - 0.01) x 1,070 = 1,836 (g)
c) Procedure
c-1) In order to remove air in the rubber hose, pour pure water into the hose as shown in Fig. 6-12.
c-2) Connect the vacuum rubber hose to the service valve (SV6) provided for concentrated absorbent
and fix it by a hose band as shown in Fig. 6-13.
c-3) Put the alkali added into the container and melt it with pure water.
c-4) Insert the copper tube into the container.
c-5) Perform purging from the chiller.
c-6) Open the service valve (SV6).
c-7) when the alkali solution starts being sucked into the chiller, watch carefully to ensure that
air does not leak in.
c-8) Close the service valve after charging the alkali solution.
c-9) Remove the vacuum rubber hose and wash the mouth of the service valve with water.
Then put the bonnet and flare nut. And place the cap of the service valve after confirming the
packing inside.
c-10) wash all instrument with water.
c-11) Run the chiller in order to circulate the alkali in the inside of the chiller.
c-12) Continue the purging at least 30 minutes after completion of the work.
d) Notes
d-1) Be sure to perform this work during operation of the chiller,
Sampling
and be sure to carry out purging from the chiller during
service valve(SV6)
this work.
Copper tube
d-2) Be sure to check the alkalinity again after this work. Solution
Vacuum
d-3) Wear rubber gloves while this work.
container
rubber hose
d-4) Thoroughly wash off any alkali which gets on hand,
Alkali solution
skin and clothes. Take care to prevent alkali
entering mouth and eyes.
Fig. 6-13
d-5) Do not spill alkali on a floor and do not throe it in a drain.
d-6) Pay attention not to suck in any powder of LiOH during this work.
Heat
exchanger
111
(3) Method of adding Acid
This instruction describes the procedure to add Acid (HBr) in case that alkalinity is 0.07 N or above.
a) Instruments
a-1) Acid : HBr (concentration : 47 %)
a-2) Pure water
a-3) Container
a-4) Vacuum rubber hose x 2 pieces
a-5) Hose band x 2 pieces
a-6) Pliers
a-7) Wrench
a-8) Rubber gloves
a-9) Mask
a-10) PH test paper
Diluted absorbent pipe
Vacuum
rubber hose
Vacuum
rubber hose
SV4:Open
SV4:Close
SV6:Close
Solution
container
Diluted absorbent pipe
SV6:Open
Heat
exchanger
Copper tube
HBr + Absorbent
Solution
container
Heat
exchanger
Copper tube
HBr + Absorbent
Fig. 6-14
b) Target value of alkalinity : 0.03 N
Additional volume of HBr is calculated in accordance with the following formula.
D = 79.2 x (X -0.03) x A
where
X : Measured value of alkalinity (N)
A : Initial charge amount of absorbent solution (see Table 6-1)
D : Required volume of acid (milli-litter)
For example
X = 0.09 N
Model : TSA-16LJ-24 A = 1,070 kg
79.2 x (0.09 - 0.03) x 1,070 = 5,085 (milli-litter)
c) Procedure
c-1) In order to remove air in the rubber hose, pour pure water into the hose as shown in Fig. 6-12.
c-2) Connect the vacuum rubber hose to the service valve (SV6) provided for concentrated absorbent
and fix it by a hose band as shown in Fig. 6-13.
c-3) Connect another vacuum rubber hose to the service valve (SV4) and fix it with a hose band.
c-4) Insert two copper tubes into the container.
c-5) Perform purging from the chiller.
c-6) Open the service valve (SV4).
c-7) Remove about 50 litters of diluted absorbent solution from the service valve (SV4) into the container
when the absorbent pump is running.
c-8) Close the service valve (SV4) after 50 litters of the absorbent accumulates in the container.
c-9) Pour HBr little by little into the absorbent removed. At this time check PH value of the
absorbent by the PH test paper.
c-10) Stop to pour HBr when PH value of the absorbent has become 7 to 6.
c-11) Open the service valve (SV6).
c-12) When the absorbent starts being sucked into the chiller, watch carefully to ensure that air
does not leak in.
c-13) Close the service valve(SV6) after the absorbent in the container empties.
c-14) Repeat item 6) thru item 13) until required amount of HBr is charged into the chiller.
c-15) After completion to charge required amount of HBr, confirm that SV4 and SV6 are fully closed.
c-16) Remove the vacuum rubber hoses and wash mouths of the service valves with water and put
bonnets and flare nuts to the service valves.
c-17) Place caps of the service valves after confirming the packing inside.
c-18) Wash all instrument with water.
c-19) Continue the purging at least 30 minutes after completion of the work.
112
d) Notes
d-1) Be sure to perform this work during operation of Chiller/Heater.
d-2) Be sure to check again the alkalinity after this work.
d-3) Wear rubber gloves and a mask during this work.
d-4) Thoroughly wash off any HBr which gets on clothes. Pay attention to handle HBr.
Because HBr is very strong acid.
d-5) Do not spill HBr on a floor and do not throw it in a drain.
d-6) There may be case that gas is generated when HBr is mixed with absorbent. Pay attention not to
inhale the gas.
113
6-5. Method of charging solution
This instruction describes the procedure of charging absorbent and refrigerant into Chiller.
(1) Equipment use
a) Solution container (for absorbent and refrigerant)
b) Vacuum rubber hose with copper tube
c) Hose band
d) Pliers
Sampling
service valve
Vacuum
rubber hose
Copper tube
Solution
Lift up slightly
container
(2) Procedure
a) Prepare the solution containers.
b) Operate a purge pump and perform the purging from the chiller.
c) Connect the vacuum rubber hose to the service valve where
solution is charged and fix it with the hose band.
d) Insert the copper tube of the vacuum rubber hose into the container.
(Keep slightly high from the bottom of the container as shown in Fig. 6-15.)
Fig. 6-15
e) Open the service valve.
f) When the solution starts being sucked in to the chiller, watch carefully to ensure that air does not leak in.
g) Before the container becomes empty, tilt it so that air does not enter into the chiller as shown in Fig.6-16.
h) When the container becomes almost empty, bend the vacuum rubber hose by your hands to ensure that
air does not leak in as shown in Fig.6-17, and quickly insert the copper tubes in the next container.
Vacuum
rubber hose
Bending
Solution
container
Fig. 6-16
Fig. 6-17
i) Repeat item f) to h) until required charging amount solution has been charged.
j) After completion, close the service valve at once.
k) Remove the vacuum rubber hose from the service valve and wash the mouth of the service valve with
water, then put the bonnet and flare nut. And put the cap of service valve.
l) wash the vacuum rubber hose, etc. with water
m) Continue air purging at least 30 minutes after completion of this work.
(3) Precautions
a) During this work, do not spill the solution.
b) Because of high vacuum condition inside the chiller, take case to ensure that air does not leak into the
chiller during this work.
c) Carefully wash the vacuum rubber hose used before this work with water so as to prevent dire ingress.
d) Wear rubber gloves. Do not handle tools pr solution with bare hands.
e) Thoroughly wash off any absorbent which gets on hands, skin or clothes. Take care to prevent
absorbent entering eyes or mouth.
f) If absorbent spills on metal plates, etc., thoroughly wash off with water.
114
6-6. How to perform de-crystallization
Cause of crystallization
Crystallization is occurred under complex conditions described blow. However there is few cases that
No.3 and No.4 factors causes crystallization by suitable periodic maintenance. Usually, crystallization
is occurred by No.1 and No.2 factors.
No.1 factor : Too low cooling water inlet temperature
No.2 factor : Insufficient vacuum condition (bad vacuum condition)
No.3 factor : Over fuel input
No.4 factor : Insufficient absorbent flow rate
Probable location of crystallization
Crystallization is occurred mostly at concentrated absorbent in the low temp. heat exchanger.
If the crystallizationoccurs, the following symptoms are observed.
Therefore, de-crystallization procedure at this portion is explained.
1) Chilled water outlet temperature does not go down.
2) The temperature of concentrated solution over-flow pipe increases as the pipe can not be touched.
3) The temperature of concentrated solution outlet of low temp. heat exchanger falls as
the pipe can be touched.
4) Diluted solution temperature rises (more than 40 deg.C / 104 deg.F)
Outline of de-crystallization
Crystallization generating at the outlet of concentrated solution side in the low temp. heat exchanger
is melted by means of approximate 60 deg.C (140 deg.F) of high temperature diluted solution.
This high temperature cooling water is made by the operating condition with low fuel input
and without cooling water.
(1) De-crystallization procedure
a) Close compulsorily the fuel control valve by service mode.
9 0. 0
SET 2 sec.
SET +
C -
2 sec.
C H G S =
t E n. P
2 times
5 times
1 0 0. 0
r A n K u P
S P E C
SET 2 sec.
0
b) Operation mode of the refrigerant pump to "ON" by service mode.
9 0. 0
1 time
SET +
2 sec.
r E F - P
C H G S =
SET 2 sec.
Select "ON"
O N
SET 2 sec.
P u r G E
A u t o
O F F
O N
Push SET
O F F
Push SET
Select "OFF"
c) Open the refrigerant blow valve and perform blow down.
d) Operation mode of the refrigerant pump to "OFF" by service mode.
e) Stop Chiller by "STOP" key on the operation board.
f) Turn off the electric power supply of cooling water pump and cooling tower fan.
115
g) Open the control panel door and jumper terminals of cooling water pump interlock(52CO), chilled water
interlock(52CH) and chilled water flow switch (69CH).
h) Select the operation mode to "LOCAL". Then run Chiller.
i) Perform de-crystallization by the diluted solution discharged from #1 absorbent pump at 50 - 60 deg.C
(122 - 140 deg.F) with adjusting fuel control valve opening by "rAnKuP" setting and switching ON/OFF
of the cooling and chilled water pumps.
*Be sure not to exceed atmospheric pressure in the generator during this work.
*Working time : 2 - 3 hours
(This is an common value. The working time should be extended if necessary.)
*If the crystallization is very strong, conduct followings together with above work.
i-1) Charge pure water (if possible, use hot water) from service valve (SV6).
i-2) Heat the crystallization portion by gas or oil burner.
j) Check if de-crystallization is successful or not by the followings.
*No-flow of concentrated solution in the overflow pipe is confirmed.
(Temperature of the overflow pipe falls)
*Fluid level in absorber (bottom of the lower shell) raises and #1 absorbent pump pressure increases.
*The temperature of concentrated solution outlet of the high temp. heat exchanger becomes warm.
k) Stop Chiller. After dilution operation, Chiller/Heater and other equipments are shut-down completely.
l) Remove the jumper wire connected in item g)
m) Return the operation mode of the refrigerant pump to "AUTO" by service mode.
9 0. 0
1 time
SET +
2 sec.
r E F - P
C H G S =
SET 2 sec.
Select "AUTO"
SET 2 sec.
A u t o
O F F
O N
P u r G E
Push SET
n) Return "rAnKuP" setting to"100".
9 0. 0
SET 2 sec.
2 0. 0
(Preset value)
SET +
C -
2 sec.
t E n. P
C H G S =
5 times
1
2 times
r A n K u P
S P E C
SET 2 sec.
0 0. 0
During de-crystallization work, this value is changed approximate 0 - 50 in order that the dilution
solution temperature is kept between 50 deg.C (122 deg.F) and 60 deg.C(140 deg.F)
(2) After de-crystallization
a) Locate and remove causes of the crystallization.
b) Run Chiller and perform normal operation.
*Fluid level
c) Check operating conditions of Chiller for a while after restart, and check if crystallization occurs again
or not.
*Temperature
*Pressure
d) In case that a lot of water is added to do de-crystallization work, the water shall be removed from Chiller.
However, in case of small amount water, water removing is not necessary.
*Method of removing out water :
The water (refrigerant) can be removed from the service valve (SV3) by using a small pump because
the discharge pressure of the refrigerant pump is vacuum.
Added water amount and removed water amount shall be equal. Record both water quantity.
Check removed water specific gravity.
The gravity shall be less than 1.01 (concentration :Less than 1.5%)
116
Reference : Chilled water flow and cooling water flow is necessary or not at de-crystallization
Chilled water
De-crystallization is to melt the crystallization occurred in the solution heat exchanger concentrated solution
side by raising the diluted solution temperature by heat from driving heat source without the chilled water and
the cooling water flow.
It is necessary to confirm chilled water temperature during de-crystallization, and once the chilled water
temperature reached 60 degree C, the chilled water pump is operated for a short time in order to prevent
influence by thermal expansion to the evaporator tubes.
The required running time of the chilled water pump is different depending on Chiller/Heater model, but in
usual case it is around for ten several seconds to thirty seconds. The judgment to stop the chilled water
pump is that the chilled water pump should be topped when chilled water box temperature becomes around
30 deg.C.
In addition, the information that warm air will often blow to air conditioning area during de-crystallization work
should be informed to a customer. Because, water around 60 degree C. goes to air handling units when the
chilled water pump is operated.
Cooling water
Same as above, it is necessary to operate the cooling water pump for a short time when cooling water
temperature becomes around 60 degree C. Operating time is the same as chilled water pump.
In the case of cooling water, heat-resistant temperature of cooling tower filler must be confirmed from a
customer beforehand. Because if the heat resistant temperature of the filler is lower than 60 deg.C, the filler
may have damages by the cooling water around 60 deg.C when the cooling water pump is operated. In this
case, the cooling water pump must be operated with lower temperature of the heat-resistant temperature of
the filler.
Even if heat-resistance temperature of the filler is low, if there is a bypass piping for the cooling tower, it is
possible to conduct de-crystallization work with the cooling water of around 60 deg.C by using the bypass
piping.
As mentioned above, discussion with a customer should be conducted at scheduling de-crystallization work
in order to avoid any trouble for auxiliary equipment.
117
6-7. Reference material of tube cleaning
This instruction describes the method of tube cleaning as reference only.
(1) Cleaning procedure
Check scale condition
Check scale adhesion condition
Sample the scale
Check prior to cleaning
a) determine proper cleaning agent
*Perform dissolving test of the scale using various cleaning agents.
*determine a drainage way.
Cautions
a-1) Dispose, drain, and/or treat west water properly.
a-2) Do not drain a hydrogen peroxide based cleaning agent into a pacifying cistern or
activate sludge treatment system.
a-3) Refer cleaning using a fluoride based cleaning agent to a professional.
Preparation
b) Determine the cleaning method.
*Determine cleaning area, amount of water and chemicals.
*Prepare instruments, chemicals and protective tools.
Instrument
It is recommended to use both chemical cleaning and brushing cleaning for tube cleaning.
Make a reversible flow direction circuit
Absorption chiller
Cooling tower
Channel A
Channel B
Chemical
supply
tank
Neutralization
tank
Fig. 6-18
118
(2) Chemical cleaning procedure
Scale / Slime
Chemical cleaning
Alkali agent
Neutralization
Drainage
Cleaning with water
Measure the amount of an alkali agent for neutralization.
Conduct the neutralization for 30 to 60 minutes for drain out the chemical.
pH value of the solution drained shall be 6 - 8.
Flow the water through the channel A and B.
Repeat 3 to 5 times
Drainage
Visual checking
Check pH value and drained water transparency.
Check if brush cleaning is required,
Brush cleaning
Visual checking
Water cleaning
Cooling water system
is filled with new water
Circulate water throughout entire cooling water system, then clean using
water by continuous blowing for 2 hours or more. (Channel B)
*Use alkaline water (pH 8 - 9) for rust prevention.
*If there is a possibility of freezing in winter season, use anti-freeze solution
having anti-corrosion agent.
(3) Determining a chemical agent for cleaning (Dissolving test)
Collect the scale to be cleaned. Perform the dissolving test using an available chemical agent. Determine
the most suitable chemical agent.
Chemical agent
A
B
Bad
Fig. 6-19
Scale
C
Good
Put the scale into the chemical agent with the
specified concentration. Then observe the condition
of bubbles and the dissolving condition of the scale.
The more bubbles are emitted and more scale is
dissolved, the more effective the cleaning chemical
agent is.
The qualification must be necessary for handling of the fluoride based chemical agent. The chemical is
extremely hazardous to both humans and equipments. Therefore, If the chemical is required, the professional
shall be required.
119
(4) Notice for draining waste water
*Sewerage : Drain waste water after conducting proper treatment
*Rivers / Lakes / Swamps / Farm land / Fish farm : Do not drain
*Waste water treatment facilities : The hydrogen based waste water can not be drained into a pacifying
cistern or activate sludge treatment system.
Waste water standard of public sewerage in Japan (Reference only)
Items
Standard
Temperature
Less than 45 deg.C (113 deg.F)
Hydrogen ion concentration
5 < pH < 9
(5) Method
a) Prepare water, chemical agent, neutralization agent and rust preventive.
b) Confirm the area and circuit to be cleaned.
c) Prepare protection tools (gloves / goggles / mask / etc.)
d) Make the cleaning circuit around the pump as shown in Fig. 6-20 for reversible water flow.
Inlet port or Drain port
Connected with the chiller
Connected with the chiller
Pump
Inlet port or Drain port
Fig. 6-20
Use suitable capacity pump for circulating the chemical agent. The below table shows pumps as reference.
Flow rate
Total head
Output
3
9.5 m (31 ft)
2.2 kW
3
6.5 m (21 ft)
0.4 kW
0.8 m /h (3.5 gpm)
0.2 m /h (0.9 gpm)
(6) Others
a) In case of the tube cleaning together with cooling tower, pay attention that a chemical cleaning agent does
not splash out.
b) For safety, prepare anti-chemical sheet on the working area.
c) If cleaning work continues two or more days, fill the cleaning portion with clean water (ex. City water) at the
end of daily work.
120
Table 6-2 Type of scale VS Cleaning chemical agent
Type of scale : Iron rust scale
Feature of scale
Color : Red brown or black / Hard scale
Suitable cleaning agent
Hydrochloride acid type
Neutralizing method
Cautions
Take the cleaning agent out of a chiller then neutralize using caustic soda.
It can not be used for water heater.
Ca.Mg.salt scale
Feature of scale
Color : Gray white / The scale is soft. It can be crashed into powder by fingers.
When acid is added, bubbles are generated violently
Suitable cleaning agent
Neutralizing method
Cautions
Sulfamic acid type
Take the cleaning agent out of a chiller then neutralize using caustic soda.
As sulfamic acid solution will wither plants if it is drained as is, be sure to neutralize
it before draining.
Silicate scale
Feature of scale
Color : Gray white / The scale is very hard and can not be crashed into powder by fingers.
Suitable cleaning agent
Hydrofluoric acid type / Organic salt type
Neutralizing method
Cautions
Take the cleaning agent out of a chiller then neutralize using slaked lime.
The scale is not dissolved even if hydrochloric acid is added.
A professional shall be required. Do not use an agent which contains ammonia as
it may react with copper (ammonia fluoride).
Slime
Feature of scale
Color : Green, Gray, Black, Brown , Yellowish / Extremely soft / Viscous matter
Suitable cleaning agent
Hydrogen peroxide type / Organic acid type
Neutralizing method
Cautions
No need to neutralization, however clean with water sufficiently after cleaning.
If the cooling water is acidly, do not use hydrogen peroxide type chemical agent.
The hydrogen peroxide type waste water shall not be drained into a pacifying cistern
or activated sludge treatment system.
Slime & Iron scale coexist
Feature of scale
Color : Yellowish, Brown / Soft / Viscous matter
Suitable cleaning agent
Hydrogen peroxide type / Hydrochloric acid type
Neutralizing method
Cautions
If hydrochloric acid type agent is used, neutralize it by using caustic soda.
The cautions and prohibited items for cleaning of the scale where a variety of those same
as those for the cleaning agents mentioned above.
Iron & Silicate coexist
Feature of scale
Color : Yellowish, Brown / Somewhat soft
Suitable cleaning agent
Hydrochloric acid type + Hydrofluoric acid type
Neutralizing method
Cautions
Take it out of the system, then neutralize it by using slaked lime.
Same the above
Silicate & Ca. Mg salt coexist
Feature of scale
Color : Grayish white / Very hard scale
When hydrochloric acid is added, some bubbles are generated.
Suitable cleaning agent
Hydrofluoric acid type + Sulfamic acid type / Hydrofluoric acid type + Hydrochloric acid type
Neutralizing method
Cautions
Take it out of the system, then neutralize it by using slaked lime.
Same the above
Scale where Iron & Ca. Mg salt coexist
Feature of scale
Reddish brown / Hard scale
Suitable cleaning agent
Hydrochloric acid type
Neutralizing method
Cautions
Take it out of the system, then neutralize it by using slaked lime.
Same the above
121
Table 6-3 Information for tube cleaning
Holding water quantity
Model
Tube quantity
Tube inner diameter
Cooling water
Chilled water
Condenser
Evaporator
Abso. + Cond.
Evaporator
Tube length
Abso. Cond. Evap.
TSA16NK
mm
inch
11
2,066
81.3
357
137
12
3,086 121.5
304
13
3,086 121.5
21
Tubes
Absorber
mm
inch
mm
inch
mm
inch
Liter
U.S.gal
Liter
U.S.gal
250
14.9
0.587
15.0
0.591
14.7
0.579
340
90
130
34
119
210
14.9
0.587
15.0
0.591
14.7
0.579
380
100
150
40
357
137
250
14.9
0.587
15.0
0.591
14.7
0.579
420
111
170
45
3,086 121.5
478
160
337
14.9
0.587
18.0
0.709
14.7
0.579
580
153
240
63
22
4,106 161.7
418
140
306
14.9
0.587
18.0
0.709
14.7
0.579
630
166
280
74
31
4,106 161.7
542
180
373
14.9
0.587
18.0
0.709
14.7
0.579
890
235
340
90
32
4,106 161.7
604
200
414
14.9
0.587
18.0
0.709
14.7
0.579
950
251
360
95
41
4,106 161.7
695
226
460
14.9
0.587
18.0
0.709
14.7
0.579
1110
293
460
122
42
4,106 161.7
791
251
560
14.9
0.587
18.0
0.709
14.7
0.579
1190
314
480
127
51
4,106 161.7 1,064
431
702
14.9
0.587
15.0
0.591
14.7
0.579
1870
494
650
172
52
4,648 183.0 1,064
431
702
14.9
0.587
15.0
0.591
14.7
0.579
2010
531
710
188
53
5,146 202.6 1,064
431
702
14.9
0.587
15.0
0.591
14.7
0.579
2140
565
770
203
61
4,648 183.0 1,381
579
911
14.9
0.587
15.0
0.591
14.7
0.579
2790
737
990
262
62
5,146 202.6 1,381
579
911
14.9
0.587
15.0
0.591
14.7
0.579
2960
782
1060
280
63
5,671 223.3 1,381
579
911
14.9
0.587
15.0
0.591
14.7
0.579
3140
830
1130
299
71
5,146 202.6 1,558
621
1,184
14.9
0.587
18.0
0.709
14.7
0.579
3670
970
1410
372
72
6,171 243.0 1,558
621
1,184
14.9
0.587
18.0
0.709
14.7
0.579
4110
1086
1610
425
81
6,171 243.0 1,846
715
1,368
14.9
0.587
18.0
0.709
14.7
0.579
4760
1257
1940
512
Inner shape of tubes
Absorber tube
Evaporator tube
Condenser tube
43deg.
Min.0.125mm
Min.0.005inch
OD :dia.16mm / dia.19mm
dia.0.63inch / dia.0.748inch
Groove
Plane
Plane
Fig. 6-21
122
6-8. Solution and refrigerant sampling
This instruction describes the procedure for sampling small amount of the absorbent solution.
(1) Equipment use
a) Sampling cylinder and attachments for service valve
b) Vacuum rubber hose
c) Pliers
d) Vacuum gauge (0-1kPa (0-0.15psi))
(2) Precautions
a) Because of high vacuum condition inside Chiller/Heater, take care to ensure that air never leak
into Chiller/Heater during this work.
b) Handle the vacuum valve carefully so as not to damage it.
c) When solution (absorbent & refrigerant) is sampled at SV3, SV4 and SV6. Procedures at
each service valve are the same manner.
Position of service valves SV3, SV5, SV6
SV3 : Service valve mounted at the discharge pipe of the refrigerant pump
To remove refrigerant
SV4 : Service valve mounted at the discharge pipe of #1 absorbent pump
To remove diluted absorbent solution
SV6 : Service valve mounted at the outlet side of the low temp. heat exchanger shell
To remove concentrated absorbent solution
d) Pour solution sampled into another container. Do not spill/pour the solution to a sewage, etc..
(3) Procedure
a) Confirm manual purge valves (V1, V2 and V3) to close.
b) Remove a flare nut and a bonnet of SV1, and connect an attachment to the service valve.
c) Remove a flare nut and a bonnet of SV4 where absorbent is sampled, and connect an
attachment to the sampling service valve.
d) Connect a vacuum rubber hose and a sampling cylinder to the attachment as shown
in Fig 6-22.
e) Run a purge pump and open up V1.
f) Open SV1 and the vacuum valve.
g) When the indication of the vacuum gauge becomes about 0.5kPa(0.07psi), close the
vacuum valve.
h) Remove the vacuum rubber hose from SV1, and connect it to SV4 as shown in Fig. 6-23.
I) Open the vacuum valve.
j) Open SV4.
k) When the sampling cylinder is filled with absorbent, close SV4.
l) Close the vacuum valve and remove vacuum rubber hose from SV4 service valve.
m) Upon completion of this work, remove the attachment, and put the bonnets and flare nut.
Also put the caps of both service valves after checking their gaskets.
n) Stop the purge pump.
o) Finally, wash all tools with water.
123
V2
Sampling service valve
(SV3, SV4, SV6)
V3
Vacuum rubber hose
Attachment
SV1
Vacuum rubber hose
Attachment
Vacuum valve
V1
Vacuum valve
Liquid trap
Sampling cylinder
Sampling cylinder
Purge pump
Fig. 6-23
Fig. 6-22
280(11")
54(2-
54(2-1/8")
Sampling cylinder
(Material : Acryl rosin)
Fig. 6-24
Steel wire
Rubber hose
Valve
Copper tube
Attachment
Rubber cup
Flare nut
Fig. 6-25
Flare nut
150(515/16")
Copper tube
Copper tube
150(5-15/16")
Fig. 6-26
124
6-9. Measuring concentration
This instruction describes the procedure to measure concentration of absorbent solution and refrigerant.
(1) Equipment use
a) Sampling cylinder
b) Gravimeter
Scale: 1.0-1.2 (for refrigerant)
Scale: 1.4-1.6 (for diluted absorbent)
Scale: 1.6-1.8 (for diluted and concentrated absorbent)
c) Thermometer
(2) Precautions
a) Take care not to damage the gravimeter and thermometer.
b) Be careful not to spill any solution. Do not fill the sampling cylinder any more than about 80%.
c) Quickly perform this measurement.
1 77
64
63
62
Concentration
Specific gravity
(3) Procedure
a) Fill the sampling cylinder to about 80% with solution to be measured.
b) Vertically keep the sampling cylinder, and insert a gravimeter into the sampling cylinder.
c) When the gravimeter stops moving up and down, read the scale of the gravimeter which shows
gravity of the solution.
d) Remove the gravimeter and put it aside. Then insert the thermometer into the sampling
cylinder and stir the solution thoroughly.
e) When the temperature is stabilized, read the scale on the thermometer.
f) Remove the thermometer and put it aside.
g) Store the solution in another bottle.
h) Using the concentration diagram of Lithium Bromide solution, read the concentration.
I) Upon completion of measurement, wash the gravimeters, thermometer and sampling cylinder
with water. And store them so that they are not damaged.
Example:
The horizontal axis represents temperature and
the vertical axis represents specific gravity.
The lines going down from left to right represent
fixed concentrations.
For example, if the specific gravity is 1.77 and the
temperature is 45oC(113oF), the concentration given
by the point of intersection of lines projected from
these values will be 63%, as shown in Fig. 6-27.
45oC(113oF)
Temperature
Fig. 6-27
125
83
82
81
1.80
79
78
77
76
75
74
73
72
71
1.70
69
68
67
66
65
64
63
62
61
1.60
59
58
57
56
55
54
53
52
51
1.50
49
48
47
46
45
44
43
42
41
1.40
1.15
14
13
12
11
1.10
9
8
7
6
5
4
3
2
1.00
99
98
97
96
95
50
10
68
20
86
30
104
40
122
50
140
60
158
70
176
80
194
90
212 oF
100 oC
66
65
64
63
62
61
60
59
58
57
56
Concentration (%)
Specific gravity
Temperature
32
0
55
54
53
52
51
50
49
48
47
46
45
22
20
18
16
14
12
10
8
6
4
0
10
20
30
40
50
Fig 6-28
60
70
80
90
100 oC
2
1
0
126
6-10. Method of charging Nitrogen gas
This instruction describes the procedure to charge Nitrogen gas (hereinafter N2 Gas) into Chiller
(1) Equipment use
Table 6-4
Inner Volume
a) N2 gas : required volume (See the table)
TSA-16NK
(Liter)
(Gal)
c) Pressure proof hose
11
1,850
7,000
d) Pliers
12
2,840
10,750
e) Valve key for N2 gas cylinder
13
2,780
10,520
21
3,470
13,130
22
4,840
18,320
The charged pressure can be measured by a generator pressure gauge.
31
5,710
21,610
a) For storage of a chiller
: 19.6 kPa
32
5,740
21,730
b) For leak test
: 49 kPa
41
7,340
27,780
d) At replacement of parts : 9.8 kPa
42
7,360
27,860
51
9,420
35,650
52
10,790
40,840
53
11,970
45,310
61
13,450
50,910
b) Connect a pressure proof hose to the outlet of the pressure regulator,
62
15,290
57,870
then slightly open a valve on the top of the cylinder in order to purge
63
16,860
63,820
air being in the hose. After purging, close the valve.
71
18,960
71,760
c) Connect the other end of the hose to SV1, and fix it with a hose band.
72
22,700
85,920
d) Check that V1, V2, V3 and SV1 are fully closed.
81
26,460 100,150
b) Pressure regulator
(2) Standard
(3) Procedure
a) Prepare N2 gas cylinders and attach a pressure regulator to
a N2 gas cylinder.
e) Open V2 and then open SV1.
f) Using the pressure regulator, charge a small amount of N2 gas into Chiller/Heater.
g) Watch the generator pressure gauge during charging N2 gas. When the pressure
in Chiller/Heater reaches to required pressure, close SV1, and then close the valve
of the N2 gas cylinder.
h) Remove the hose from SV1 and put the cap to SV1.
i) Remove the pressure regulator.
V2
V3
(4) Precautions
a) Since the pressure in the N2 gas cylinder is very high
(Commonly 15 Mpa), pay attention to handle it.
b) Do not suddenly rise the primary and/or secondary
SV1
V1
pressure of the pressure regulator.
(Secondary pressure shall be maximum 0.5 Mpa.)
Liquid trap
c) Fix N2 Gas cylinder so that it does not fall over.
d) Be sure not to open V1 and V3 during this work.
Purge pump
Fig. 6-29
127
6-10. Method of charging Nitrogen gas
This instruction describes the procedure to charge Nitrogen gas (hereinafter N2 Gas) into Chiller
(1) Equipment use
Table 6-4
Inner Volume
a) N2 gas : required volume (See the table)
TSA-16NK
(Liter)
(Gal)
c) Pressure proof hose
11
1,850
7,000
d) Pliers
12
2,840
10,750
e) Valve key for N2 gas cylinder
13
2,780
10,520
21
3,470
13,130
22
4,840
18,320
The charged pressure can be measured by a generator pressure gauge.
31
5,710
21,610
a) For storage of a chiller
: 19.6 kPa
32
5,740
21,730
b) For leak test
: 49 kPa
41
7,340
27,780
d) At replacement of parts : 9.8 kPa
42
7,360
27,860
51
9,420
35,650
52
10,790
40,840
53
11,970
45,310
61
13,450
50,910
b) Connect a pressure proof hose to the outlet of the pressure regulator,
62
15,290
57,870
then slightly open a valve on the top of the cylinder in order to purge
63
16,860
63,820
air being in the hose. After purging, close the valve.
71
18,960
71,760
c) Connect the other end of the hose to SV1, and fix it with a hose band.
72
22,700
85,920
d) Check that V1, V2, V3 and SV1 are fully closed.
81
26,460 100,150
b) Pressure regulator
(2) Standard
(3) Procedure
a) Prepare N2 gas cylinders and attach a pressure regulator to
a N2 gas cylinder.
e) Open V2 and then open SV1.
f) Using the pressure regulator, charge a small amount of N2 gas into Chiller/Heater.
g) Watch the generator pressure gauge during charging N2 gas. When the pressure
in Chiller/Heater reaches to required pressure, close SV1, and then close the valve
of the N2 gas cylinder.
h) Remove the hose from SV1 and put the cap to SV1.
i) Remove the pressure regulator.
V2
V3
(4) Precautions
a) Since the pressure in the N2 gas cylinder is very high
(Commonly 15 Mpa), pay attention to handle it.
b) Do not suddenly rise the primary and/or secondary
SV1
V1
pressure of the pressure regulator.
(Secondary pressure shall be maximum 0.5 Mpa.)
Liquid trap
c) Fix N2 Gas cylinder so that it does not fall over.
d) Be sure not to open V1 and V3 during this work.
Purge pump
Fig. 6-29
127
6-11. Method of discharging Nitrogen gas
This instruction describes the procedure to discharge Nitrogen gas (N2 Gas) from Chiller.
(1) Equipment use
a) Pliers
(2) Standard
The pressure in the chiller becomes atmospheric pressure (0MPa).
(3) Procedure
a) Check that V1, V2, V3 and SV1 are fully closed.
b) Open V3.
c) Remove a cap and flare nut of SV1 and open it.
d) When the reading of the generator pressure gauge becomes atmospheric pressure (Mpa), close SV1.
(4) Precautions
a) Be sure to open V1 and V2 during this work.
b) During this work, ventilate the machine room adequately.
6-12. Information of signals between Chiller & Steam control valve
(1) Control valve signal to valve positioner
Control panel of
Chiller
Valve positioner of
Steam valve (Field supply)
E
345
+
346
-
CVP
DC 4 - 20mA
(2) Control valve signal to valve motor
Control panel of
Chiller
Valve positioner of
Steam valve (Field supply)
E
Open/close
signal
Feed back
signal
Open
342
Y
340
T
341
G
0A
3
344
2
Open
343
1
Close
Close
128
6-13. Instruction of leak test
(1) Purpose
This instruction describes the procedure for pressurized leak test by Nitrogen gas (N 2 gas) for
an absorption Chiller at the following cases.
a) For field welding portions of multiple section shipping Chiller
b) After replacement of parts furnished with vacuum side
c) At suspicion of leakages on Chiller
(2) Judgment
In case that any bubbles can not be appeared on tested portions of Chiller, it can be judged that
the Chiller does not have leakages.
(3) Equipments & Tools
a) N2 gas cylinder
b) Pressure regulator
c) Pressure proof hose.
d) Oiler (for soapy solution)
e) Soapy solution
f) Flashlight
(4) Flow-chart
Charge N2 gas up to 30kPa
Tightening up
Check leakage
with soapy solution
NG
Discharge N2 gas
Repair leakage by welding
OK
Charge N2 gas up to 49kPa
Tightening up
Check leakage
with soapy solution
NG
Discharge N2 gas
Repair leakage by welding
OK
Discharge N2 gas
Perform purging
129
(5) Procedure
a) Confirm that V1, V2 and V3 are fully closed.
b) Confirm that isolation valves for #1& #2 absorbent pumps and refrigerant pump are fully opened.
c) Make the N2 gas charge line shown as Fig. 6-31.
d) Pressurize Chiller up to 30kPa.
(The pressure can be checked by the high temp. generator pressure gauge.)
e) Close SV1 and the N2 gas cylinder valve.
f) Check following suspicious portions of leakage by soapy solution.
f-1) Field welding portions (for multiple section shipping Chiller)
f-2) Sight glasses
f-3) Flare joints
f-4) High temp. generator solution level electrodes
f-5) Flange connections (absorbent pumps, refrigerant pump, etc.)
f-6) Caps of isolation valves, change-over valves, dampers and service valves
g) If a leakage(s) is found out, tighten it (them). If a leakage(s) is found out at field welding, discharge
N2 gas then repair the leakage portion(s) by welding.
h) If no-leakage, rise the pressure up to 49 kPa and check again.
I) If no-leakage, keep the pressure of 49 kPa for at least 12 hours then check again.
j) After completion of the leak test, discharge N2 gas.
N2 gas cylinder valve
Pressure regulator
Pressure proof hose
N2 gas cylinder
SV1
V1
Fig. 6-31
130
6-14. Instruction of inspection of purge pump
The purge pump is supplied with Chiller/Heater, mounted, wired and piped. The initial charge of purge pump
oil is shipped as an extra item with Chiller/Heater and should be added to a level just above the bottom of the
sight glass. During purge pump operation, this level should rise to approximately 1/2 sight glass. If too much
oil is added, it may cause oil to spill from the discharge port when it is first turned on. The purge pump also
includes a ballast that can be opened slightly to limit the amount of condensed refrigerant from entering the
pump and contaminating the oil. Allowing a small amount of ballast also tends to heat the purge pump oil
and exhaust the moisture out of the oil.
(1) Always replace the oil if it becomes contaminated or milky in color.
(2) Confirm the pumps ability to draw a vacuum.
The pump also should achieve of at least 0.5 kPa abs (0.07 psi abs). If this value can not be obtained,
perform the followings.
a) Replace the purge pump oil.
b) Check the liquid trap for water. If condensed water or moisture is apparent then
it will be necessary to operate the purge pump for 1/2 hour to evaporate the moisture.
c) Check the unit purge line piping for leakage by bubble testing.
(3) If the purge pump will not rotate or trips the thermal overload it will be necessary to remove the belt and
and manually turn the pump by hand in an attempt to loosen the pump.
(4) If the pump will not rotate be hand or will not attain an adequate vacuum after performing the above tasks
it may be necessary to rebuild the purge pump.
Important: When first starting the purge pump, it is critical to bump start the pump and check for proper
rotation as shown by an arrow on the cover. The direction of the purge pump is an indicator
of the directions of the other pumps on Chiller. If the rotational direction is incorrect,
the phasing adjustment should be made at the power supply to the unit not to the purge pump
wiring.
Remark 1: While purging work is being conducted, continuous power supply shall be required. If power
interruption happens during purging, close V1 immediately in order to prevent air leaking through
the purge unit.
Remark 2: During purging nitrogen work, ventilate the unit room sufficiently.
Drain plug
Liquid trap
Exhaust gas port
Oli charge port
Sight glass
Drain cock
Gas ballast valve
6-32. Purge pump
131
6-15. Instruction of bubble test
This instruction describes the procedure of measuring the quantity of non-condensables being purged from
the chiller. The test consists of adapting a hose from the discharge port of the purge pump and collecting
the discharge gasses in an inverted graduated cylinder under water. The graduated cylinder is first filled
with water and inverted so that no air is contained in the cylinder. As the non-condensable gasses are
discharged into the inverted cylinder the water column in the cylinder will drop as the water is being
displaced. The quantity of non-condensable gasses can then be measured based on time and volume
of water displacement. This test will be performed during initial evacuating of Chiller, after the
again process, during routine maintenance, and to determine if an air leak is present. The most important
maintenance item on an absorption chiller is to insure the unit vacuum condition is within acceptable limits.
Chiller tightness can be checked by determining the rate at which non-condensable accumulate.
Some non-condensables are normally generated within Chiller, but an air leak will be indicated if
the accumulation rate increases.
Bubble test during unit operation
During routine maintenance the bubble test can be performed to gather the non-condensable gasses that
have accumulated in the purge tank. The contents of the gasses can then checked to be air or hydrogen.
Air---No odor. If the unit does not pass the bubble test it is possible that a leak has developed.
Hydrogen gas---Place a match or lighter at the lip of the graduated cylinder before removing the cylinder
from the water. If hydrogen is apparent, the gas will ignite and cause a popping sound. If hydrogen is
present it is an indicator that hydrogen production is exceeding the capacity of the palladium cells and
that the inhibitor is depleted and should be replaced. Care should be taken when performing this test.
(1) Procedure
a) Perform purging from Chiller/Heater until inner pressure reaches allowable degree of vacuum or less.
Continue purging at least one hour. See Fig. 6-33.
b) Connect the vacuum gauge to SV1 and open SV1.
c) Confirm that attained vacuum of the purge pump is less than 0.5 kPa abs. (0.07 psi abs.).
d) Remove the discharge port cap and put the attachment to the port. Furnish the vinyl hose to the
attachment. See Fig. 6-34.
e) Open V1 and close V2 and V3.
f) Continue to run the purge pump for one minute. Then measure volume of bubbles. During this step,
keep position of the vinyl hose within 10 mm in depth. If bubbles come out, check and tighten
connections in the downstream from V2 and V3. If bubbles still come out, measure its volume
collected for 10 minutes.
g) Open V1 and V3 and close V2.
Note : The gas ballast valve and the oil discharge cock shall be closed.
h) Continuing operation of the purge pump under the above condition, measure volume of bubbles for
10 minutes. This measurement shall be repeated at least three times. During measurements, attained
vacuum of the purge pump shall be kept below 0.5kPa abs. (0.07 psi abs.).
i) The measured value in item 6) is as "A cc", in item 8) is as "B cc".
Result of bubble test value = B - C (cc)
j) After the bubble test, open the gas ballast valve and replace purge pump oil.
132
0.7
0.7
5
4.4
0.6
4
Inner pressure
0.5
3
0.4
0.3
2
0.2
1
0.1
0
0
0
10
32
50
20
30
70
90
40
deg.C
104
deg.F
Ambient temperature
Fig. 6-33 Allowable vacuum curve
The degree of vacuum should be mentioned within the allowable range. As the pressure in Chiller
is variable owning to the ambient temperature, check the measured pressure by using the curve. When
ambient temperature is 30 deg.C(86 deg.F), 4.4kPa abs. (0.64 psi abs.) is read as an allowable vacuum.
If pressure is over 4.4kPa abs. (0.64 psi abs.), perform purging.
3/8" Copper tube
Flare nut
Nipple (3/8")
Bushing
(1-1/4")
Suction port
Discharge port
10mm (13/32)"
Graduated cylinder
Vinyl hose
Purge pump
Bucket
Water
Fig. 6-34 Bubble test
133
6-16. Instruction of refrigerant blow down
(1) The following cases, refrigerant blow down should be conducted.
1) After aging with evaporator tube outer surface cleaning for trial-run in cooling mode
2) Before initial cooling operation at every cooling season
(2) Procedure
1) Make sure the refrigerant pump is running and also the solution level is visible through the sight glass
of the evaporator.
2) Open the refrigerant blow valve.
3) When solution level becomes invisible, close the refrigerant blow valve tightly.
4) Repeat steps 1) thru 3) until the refrigerant concentration becomes less than 3%.
Note
If the high temp. generator temperature is more than approximately 130 deg.C thru 140 deg.C, do not
fully open the refrigerant blow valve. There is a case that refrigerant contamination may occurs.
If the high temp. generator temperature is beyond the temperature, slightly open the refrigerant blow
valve to blow the refrigerant gradually.
6-17. Instruction of field insulation
The followings are requirements to insulate Chiller.
(1) Do not insulate Chiller until the leak testing procedures have been completed.
(2) The type of insulation utilized on the hot surface must be sufficient so that outer skin temperatures
meet local safety codes for personnel protection.
(3) Use only noncombustible materials.
(4) Do not insulate following portions.
a) Motor of refrigerant pump
b) Sight glasses
c) Expansion door on high temp. generator
d) Damper heads
e) Service valves
f) Change-over valve handles
g) Sensors
h) Any other portions described in Exhibit G in Installation manual
(5) Allow accessibility through the insulation to water headers and a smoke tube cleaning window.
(6) To mount insulating materials, use bonding agents, wires, and bands. Do not use screws, rivets
or impact type stick pins.
Remark :
Because of the many different insulating materials available in our industry and local code requirements
or regulations that must be complied with, it is impossible to specify the insulating material types to be
utilized for a specific application. The selection and installation of the insulation should be addressed by
experienced personnel knowledgeable in the local requirements and regulations of this field.
134
16-18. Instruction of function test
This instruction described instructions for safety functions with their sensors. This test shall be conducted
under the condition that #1 absorbent pump, #2 absorbent pump, the refrigerant pump and shall steam
control valve be off. And also a chilled/hot water pump, a cooling water pump and a ventilation fan are stop.
(1) Battery back-up
Before conducting the test, the back-up battery for the microprocessor (CPU board) shall be ON. See Fig.6-35.
This figure shows positions of BACKUP BATTERY and BACKUP SWITCH (SW3) provided on the CPU board.
SW3 has been set OFF at the factory to avoid consumption of battery power. When the power is supplied to
the electronic controller, "F-21 (CPU alarm)" or "F-23 (Time set alarm)" is displayed on the data display if SW3
is turned off. In this case, turn on SW3 first and then set time.
Note 1 : If the back-up becomes empty, "F-21" or "F-23" is displayed. Replace it.
Note 2: Model of the backup battery is CR-2025. The battery can do backup for approx. 4,000 hours.
LABEL
SW3 :Backup switch
UP
: ON
DOWN : OFF
Backup battery
Procedure : Turn off SW3 - Remove the backup battery - Put new backup battery - Conduct time setting - Turn on SW3
Fig. 6-35 Positions of Backup switch (SW3) & Backup battery
135
(2) Preparation before function test
Before performing the test, prepare the followings.
a) Jumper the following terminals
a-1) #170 - #120 52CH
Chilled/hot water pump interlock
a-2) #170 - #121 52CO Cooling water pump interlock
a-3) #170 - #124 52F
Ventilation fan interlock
a-4) #140 - #173 69CH
Chilled water flow switch
b) Remove the wires of #1 absorbent pump (U1, V1, W1), #2 absorbent pump (U2, V2, W2) and the
refrigerant pump (U3, V3, W3) at the terminals on each magnetic contactor.
c) Change "Combustion interval" from "00 n." to "-- n.". See the page 53 in section. 6.
(3) Procedure of each function test
a) J-01 Chilled water low temp. alarm
a-1) Provide 5 liter bucket filled with water and ice.
a-2) Push RUN key.
a-3) After RUN LED of #1 & #2 absorbent pump and refrigerant pump light up,
dip the sensor (DT1) into the bucket.
a-4) Confirm whether J-01 is indicated on the data display or not.
a-5) Push STOP key. Return DT1 to its sensor port. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
b) J-02 Chilled water pump alarm
b-1) Remove the jumper for Chilled water pump interlock (52CH).
b-2) Confirm whether J-02 is indicated on the data display or not.
b-3) Push STOP key. Put the jumper. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
c) J-03 Chilled water flow rate alarm
c-1) Remove the jumper for Chilled water flow switch (69CH).
c-2) Confirm whether J-03 is indicated on the data display or not.
c-3) Push STOP key. Put the jumper. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
d) J-05 #2 Absorbent pump alarm
d-1) Push the test button (white) on the magnetic contactor.
d-2) Confirm whether J-05 is indicated on the data display or not.
d-3) Push STOP key. Push rest button on the magnetic contactor. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
e) J-06 Cooling water pump alarm
e-1) Remove the jumper for Cooling water pump interlock (52CO).
e-2) Confirm whether J-06 is indicated on the data display or not.
e-3) Push STOP key. Put the jumper. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
f) J-07 Cooling water flow rate alarm (option)
f-1) Remove the jumper for a cooling water flow switch (69CO).
f-2) Confirm whether J-07 is indicated on the data display or not.
f-3) Push STOP key. Put the jumper. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
g) J-10 Refrigerant pump alarm
g-1) Push the test button (white) on the magnetic contactor.
g-2) Confirm whether J-07 is indicated on the data display or not.
g-3) Push STOP key. Push rest button on the magnetic contactor. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
136
h) J-11 Ventilation fan alarm
h-1) Remove the jumper for ventilation fan interlock (52F).
h-2) Confirm whether J-11 is indicated on the data display or not.
h-3) Push STOP key. Put the jumper. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
i) J-12 Purge pump alarm
I-1) Run the purge pump
I-2) Push the test button (white) on the magnetic contactor.
I-3) Confirm whether J-12 is indicated on the data display or not.
I-4) Stop the purge pump.
j) J-15 High temp. generator solution level low alarm
j-1) Remove wires connected to high temp.generator solution level electrodes (#30, #31, #32).
j-2) Confirm whether J-15 is indicated on the data display or not.
j-3) Push STOP key. Connect the wires. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
k) J-20 Cooling water low temp. alarm
k-1) Provide 5 liter bucket filled with water and ice.
k-2) Cheng "High speed time" setting from OFF to ON by the service mode.
k-3) Push RUN key.
After RUN LED of #1 & #2 absorbent pump and refrigerant pump light up,
dip the sensor (DT7) into the bucket.
k-4) After 30 seconds, confirm whether J-20 is indicated on the data display or not.
k-5) Push STOP key. Return DT7 to its sensor port. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
l) J-22 High hot water temp. alarm
l-1) Provide 5 liter bucket filled with hot water (more then 80 deg.C).
l-2) Push RUN key.
l-3) After RUN LED of #1 & #2 absorbent pump and refrigerant pump light up,
dip the sensor (DT1) into the bucket.
l-4) Confirm whether J-22 is indicated on the data display or not.
l-5) Push STOP key. Return DT1 to its sensor port. Push BUZZER STOP key.
Then Push RUN key, Chiller start again. Continue next test.
Note: Remove jumpers connected at the preparation stage and wires disconnected at the preparation
shall be connected.
m) Sensor alarm of temperature sensor
Remove wires of a temp. sensor or Jumper the terminal of the sensor, it's sensor alarm (F-**)
is displayed.
n) Sensor alarm of flow sensor
After running of Chiller, a chilled water pump and a cooling water pump, close gradually
a shot off valve provide at the inlet of the evaporator or the absorber, J-03 or J-07 is displayed when
water flow rate decreases less than 50% of rated flow rate.
137
Non
Note 1
1
2
3
4
5
6
7
8
9
A
B
C
D
E
10
11
12
13
14
15
or
16
17
First Stage (Main menu)
Display items
High temp. gene. Temp.
Alarm code
Chiller/Heater operation hours
#1 Abso. pump operation hours
#2 Abso. pump operation hours
Burner operation hours
Refr. pump operation hours
Purge pump operation hours
ON/OFF times of Chiller/Heater
ON/OFF times of #1 Abso. pump
ON/OFF times of #2 Abso. pump
ON/OFF times of Burner
ON/OFF times of Refr. pump
ON/OFF times of Purge pump
#3 Abso. pump operation hours
ON/OFF times of #3 Abso. pump
Chilled water setting temp.
Hot water setting. Temp.
Chilled water inlet temp.
Chilled water outlet temp.
Cooling water inlet temp.
Condensed refrigerant temp.
TJ : Steam drain temp.
LJ : Driving hot water outlet temp.
Purge tank pressure
Second Stage
(Set & Confirmation menu)
Alarm record
Time setting
Change of switch functions
Set of chilled/hot water pump
Set of inverter control of
chilled/hot water pump
SET
/
BAC
or
Set of cooling water system
Set of inverter control of
cooling water pump
or
or
Field set
Set of SR-485
Version No. of
Microprocessor (CPU)
or
Version No. of Option board
or
or
or
or
SET/BACK
Set of model
SET/BACK
Rated specification setting
SET/BACK
or
Input setting
SET/BACK
Inverter setting
SET/BACK
PID setting
SET/BACK
Operation hours &
On/Off times set
SET/BACK
Predication function setting
SET/BACK
or
Japanese burner controller
setting
SET/BACK
Tuning of temp. sensors
SET/BACK
Analog data (42 data)
indication
SET/BACK
Digital input indications
Digital output indications
or
State of control conditions
SET
/
BAC
SET/BACK
Set of inverter-2
SET/BACK
or
Third Stage
(Scroll by
&
Second Stage
or
Chilled water outlet temp.
setting
Hot water outlet temp. setting
SET/BACK
Set of inverter-3
(chilled/hot water temp. setting)
SET
BACK
SET
BACK
)
Set rage :
4 - 20 deg.C
Set rage :
40 - 95 deg.C
or
Remark : Maximum hot water outlet temp.
setting of DJ series is 60 deg.C
due to the material of evaporator.
or
or
or
Symbol
SET
BACK
oFF, abs-po, abs-un, abs-IV, sys-po, sys-un
SET/BACK
oFF, on
0 - 100 %
0 - 100 %
1.0 thru 5.0
50 thru 85
0 thru 250 seconds
oFF, on
oFF, on
22 - 30 deg.C
1.0 - 6.0 deg.C
Set of parallel operation by remote controller
Chided/hot water rated flow rate setting
SET/BACK
Hot water rated flow rate setting
Controlled variable setting
Minimum frequency setting
Set of interlock return time
SET/BACK
Set of stopping cooling water pump at low load
SET/BACK
Set of cooling tower fan control
Set of cooling tower fan temp. control
SET/BACK
Set of differential temp. of cooling tower fan
SET/BACK
Set of variable flow rate
Set of cost factor
Controlled variable setting
Minimum frequency setting
Set of temp. for maximum input
Set of slow input time
Set of slow input temp.
Set of dilution time
Set of remote signal type
Set of type of pulse
Set of low select control temp.
Set of radiation temp.
"rS-485" is indicated
SET/BACK
oFF, abs-po, abs-un, abs-IV, sys-po, sys-un
SET/BACK
0.05 thru 0.60
1.0 thru 5.0
40 thru 85
20 - 33 deg.C
5 - 1800 sec.
0 - 120 deg.C
4 - 20 minutes
StAtiC, PuLSE
PoSiti, nEGAti
60 - 95 deg.C
5 - 25 deg.C
0 thru 15
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
Fourth Stage
(scrolled by
&
)
Fixed to Auto
Auto, oFF, on
Auto, tESt
Auto, n.annual
0 - 100 %
Auto, n.annual
0 - 100 %
Auto, n.annual
0 - 100 %
0 thru 15
oFF, on
Cleared by 3 times same manner
Input a number from 0 to 9 to 6 columns
Depending on type of Chiller/Heater
Factory set for service parts : CH-out
Factory set for service parts : oFF
SET/BACK
Factory set for service parts : n.annual
SET/BACK
oFF, on
Factory set for service parts : on
Factory set for service parts : oFF
4.0 - 20.0 deg.C
40.0 - 95.0 deg.C
3.0 - 10.0 deg.C
3.0 - 10.0 deg.C
0.5 thru 1.5
0.0 - 200.0 %
8.0 - 16.0 kPa
4.0 - 7.0 kPa
5 thru 60
50 thru 80
2.0 thru 8.0
Pid, on-oFF, H-L-oF
Third Stage
Function of switch-2
or
SET/BACK
SET/BACK
Second Stage
(Service mode)
SET
+
& BACK
SET/BACK
Fourth Stage
(scrolled by
&
)
Deletion of alarm data
2001 thru 2050
Month : 1 thru 12, Day : 1 thru 31
Time : 0 thru 23, Minute : 0 thru 59
CooL, HEAt, San.E
1-H, 5-n., 1-n., 10-S
on, oFF
ConSEn
o
C, oF
oFF, on
0 thru 250 seconds
Third Stage
Record of alarms
Set of year
Set of month and day
Set of time
Cool/Heat/Simultaneous change-over
Data record interval
Select of local operation mode
Delete message sign
Change of unit
Change of low select control
Set of interlock return time
Set of variable flow rate
The functions of the key are to go to a lower stage and to fix new set value.
This key functions to be pressed for 2 seconds.
or
The function of the key is to return to an upper stage.
This key functions to be pressed for approximately 1 seconds.
The function of the key is to proceed indications.
or
Scrolling
The function of the key is to return indications.
or
or
Purge indication
Refrigerant pump
Pilot burner
Control valve-1
Control valve-1 opening
Control valve-2
Control valve-2 opening
Control valve-3
Control valve-3 opening
HBS address
High speed timer function
Clear of operating data
Serial number
Type of Chiller/Heater (Chiller)
Type of control
Annual cooling operation
Automatic changeover
For process use
With purge pump
Oil pump
Chilled water outlet temp.
Hot water outlet temp.
Chilled water temp. difference
Hot water temp. difference
No-use (extra) SinG-k
Max. opening of control valve
Indication of purge start
Indication of purge stop
No-use (extra) AP-tin.
No-use (extra) EIICond
Crystallization temp.
Type of control
Input correction
Combustion interval
Control estimating time
Estimating tuning
Constant a1
Constant a2
Constant a3
Constant a4
Constant a5
Constant a6
P for cooling
I for cooling
D for cooling
P for heating
I for heating
D for heating
Sampling set
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
#
#
#
#
#
#
#
#
#
#
#
#
$
$
$
$
$
$
$
$
$
$
$
$
#
#
#
$
$
$
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
Operation hours of Chiller/Heater #
#1 abso. pump operation hours #
#2 abso. pump operation hours #
Burner operation hours
#
Refr. pump operation hours
#
Purge pump operation hours #
#3 abso. pump operation hours
On/Off times of Chiller/Heater #
On/off times of #1 abso. pump #
On/off times of #2 abso. pump #
On/Off times of burner
#
On/Off times of refr. pump
#
On/Off times of purge pump
#
On/off times of #3 abso. pump
Vacuum condition
#
Absorbent concentration
Cooling water tubes fouling condition #
Cooling water temp.
#
Combustion chamber fouling condition #
Ant freezing
Exhaust gas temp.
#
Clear of predication data
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
$
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
Set for fundamental data collection of protect-relay
SET/BACK
Initializing of the collected data
Initializing of all data of protect-relay
Chilled/hot water outlet temp. sensor #
Chilled/hot water inlet temp. sensor #
Cooling water outlet temp. sensor #
Cooling water inlet temp. sensor #
Hot water outlet temp. sensor
Hot water inlet temp. sensor
Sensor option setting
Analog data (42 data) indication
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
(1) Key operation map of operation board
Key operation of DJ Series is consists of 4 stages shown in the map.
Data code
0 thru 100
0 - 10 minutes
2 thru 100
0.50 thru 2.00
60 thru 160
0.020 thru 0.060
0.000 thru 0.099
2.0 thru 4.0
30 thru 60
2.3 thru 3.5
1.0 thru 10.0
0 thru 2500
0 thru 100
1.0 thru 10.0
0 thru 2500
0 thru 100
5 thru 60
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
Input a number from 0 to 9 to 6 columns
oFF, on
Fixed to oFF
oFF, on
oFF, on
oFF, on
Fixed to oFF
oFF, on
See the detail
Omission
Omission
Omission
-2.0 - 2.0 deg.C
-2.0 - 2.0 deg.C
-2.0 - 2.0 deg.C
-2.0 - 2.0 deg.C
-2.0 - 2.0 deg.C
-2.0 - 2.0 deg.C
Input 0 or 1 to 6 LED figures
Digital input/output & control state indications
or
or
Constant t1
Constant t2
Constant -n
Constant -k
Constant a6
Constant t1
Constant t2
Constant a6
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
SET/BACK
100 thru 200
30 thru 100
2 thru 100
0.50 thru 2.00
2.3 thru 3.5
90 thru 160
90 thru 160
27.6 thru 42.0
137A
Note 2 : Items marked with # shall be set at replacement of the microprocessor (CPU board) and sensors.
Note 3 : Items marked with $ shall not be changed during operation of Chiller/Heater.
6-19 Instruction of Set & confirmation of controls & safeties
Remark :Red characters in green columns are items of factory set, non-use, invalid, extra, etc..
Set values of the items shall not be changed except for replacement of the microprocessor (CPU board) & sensors
and
Note 1 :An alarm code is only displayed at occurring the alarm.
The alarm code is cleared after re-starting Chiller/Heater
with eliminating its causes.
(2) First stage (Main menu)
First stage consists of 22 items and the 22 items indicate operating condition of Chiller (temperatures,
operating hours and on/off times of main devices). Each indication is displayed with 6 figures of 7 segment LED.
The indication code and its value are shown as below.
Example 1 : H.T.Generator temp. (high temperature generator temperature) (No-data code)
This shows that the H.T.Generator temp. is 145.0 deg.C.
1 4 5. 0
Example 2 : Operation hours of Chiller
This shows that the operation hors of Chiller is 12,355 hours.
1. 1 2 3 5 5
The data code is "1"that show operation hours of Chiller.
In case that the data is 150 hours, the indications is 1.
1 5 0
Example 3 : On/Off times of burner
This shows that the on/off times of burner is 0 time.
A
0
The data code is "A" that show on/off times of burner.
The data displays 0 time for TJ, LJ and NK series.
Example 4 : Steam drain temp. / Driving hot water outlet temp.
This shows that the Steam drain temp. is 70.0 deg.C.
1 6.
7 0. 0
The data code is "16" that shows Steam drain temp. for TJ and NK series,
and Driving hot water outlet temp. for LJ series.
Note)
During the dilution operation caused by an alarm, the alarm code is indicated.
If several alarms occur at the same time, most high priority alarm code is indicated.
These alarm code can be indicated by
&
keys.
However, if 4 or more alarms occur at simultaneously, three alarm codes are indicated.
138
Scroll sequence of main mane
During indicating an item in the main menu except for H.T.Generator temp.,
the indication returns immediately to H.T.Generator temp. without scrolling
by pressing the BACK key.
1 4 5. 0 :H.T. Generator temperature at present(unit : deg.C or deg.F)
:Displayed at only occurring an alarm.
J - 0 1
1. 1 2 3 5 4 :Operation hours of Chiller (unit : hours)
2. 1 1 2 3 5 :#1 absorbent pump operation hours (unit : hours)
3. 1 0 1 2 6 :#2 absorbent pump operation hours (unit : hours)
4.
5.
0 :Burner operation hours (unit : hours)
7 0 3 0 :Refrigerant pump operation hours (unit : hours)
6.
1 0 7 :Purge pump operation hours (unit : hours)
7.
8 5 4 :On/off times of Chiller (unit : times)
8.
8 7 1 :On/off times of #1 absorbent pump (unit : times)
9.
8 5 4 :On/off times of #2 absorbent pump (unit : times)
A.
0 :On/off times of burner (unit : times)
b.
1 5 2 7 :On/off times of refrigerant pump (unit : times)
C.
6 0 :On/off times of purge pump (unit : times)
d.
0 :#3 absorbent pump operation hours (unit : hours)
E.
0 :On/off times of #3 absorbent pump (unit : times)
1 0.
7. 0 :Setting temperature of chilled water outlet temperature (unit : deg.C or deg.F)
1 1.
0 :Setting temperature of hot water outlet temperature (unit : deg.C or deg.F)
1 2.
1 1. 9 :Chilled water inlet temperature at present (unit : deg.C or deg.F)
1 3.
6. 8 :Chilled water outlet temperature at present (unit : deg.C or deg.F)
1 4.
3 1. 8 :Cooling water inlet temperature at present (unit : deg.C or deg.F)
1 5.
3 4. 7 :Condensed refrigerant temperature in condenser (unit : deg.C or deg.F)
1 6.
1 7.
0
:Driving hot water outlet temp. at present for LJ Series (unit : deg.C or deg.F)
:Steam drain temp. at present for TJ and NK Series (unit : deg.C or deg.F)
8. 5 :Pressure in purge tank at present (unit : kPa)
139
(3) Second stage (Confirmation & Setting menu)
The followings show the operation steps from the second stage to fourth stage.
a) Alarm record : This function shows the three newest alarm code.
(Alarm record menu is for confirmation purpose only.)
1st stage
1 4 5. 0 :H.T.Generator temp. at present (145.0 deg.C)
SET
2nd stage BACK
:This display shows the alarm record menu.
A L A r n.
SET
BACK
:The newest alarm code (Sample : J-04 #1 absorbent pump)
3rd stage C 1. J － 0 4
d 1. 0 7 2 4
:The newest alarm date (Sample : 0724 : July 24th)
t 1. 0 4. 0 2
:The newest alarm time (Sample : 04.02 : 4:02 am)
C 2. J － 0 7
:The alarm code in front of the one [newest]
d 2. 1 0 1 6
:The alarm date in front of the one [newest]
t 2. 1 4. 1 8
:The alarm time in front of the one [newest]
C 3. J － 1 3
:The alarm code in front of the two [newest]
d 3. 1 2 2 9
:The alarm date in front of the two [newest]
t 3. 2 0. 5 3
:The alarm time in front of the two [newest]
r E - S E t
SET
:This show the alarm clear menu.
BACK
4th stage
3
SET
BACK
2
SET
BACK
BACK
1
SET (Three times alarm data are completed to clear.)
140
b) Time setting : This has the functions to confirm and set Year, Month, Day and Time.
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
BACK
Press 1 time
2nd stage
:Present time is displayed (14:53 = 02:53 pm)
r t. 1 4. 5 3
SET
3rd stage BACK
:Menu to confirm and set of year
Y r - S E t
SET
4th stage BACK
:Year set at factory is displayed.
2 0 0 1
:Blinking figures can be changed by the keys. (2001 thru 2050)
1st stage
BACK
2 0 0 5
SET
Y r - S E t
BACK
:Pressing
key 4 times, the year changes from 2001 to 2005.
:New set value is installed.
3rd stage
d t
- S E t
SET
BACK
4th stage 0 1 - 0 1
:Menu to confirm and set of date
:Date set at factory is displayed.
:Blinking figures can be changed.
1 1 - 0 5
BACK
SET
:Month and Date can sifted by
key as follows;
Month
Date
Month
Date
Figuers of month & date can be changed by key.
Changeable figure of month : 1 thru 12 (Scrolling)
Changeable figure of date : 1 thru 31 (Scrolling)
d t - S E t
BACK
:New set value is installed.
3rd stage
t n. - S E t
SET
BACK
4th stage 0 7
0 0
:Menu to confirm and set of time
:Date set at factory is displayed.
:Blinking figures can be changed.
1 0 - 1 7
SET
BACK
:Hour and Minute can sifted by key as follows;
Hour
Minute
Hour
Minute
Figuers of month & date can be changed by key.
Changeable figure of hour : 0 thru 23 (Scrolling)
Changeable figure of minute : 0 thru 59 (Scrolling)
t n. - S E t
BACK
:New set value is installed.
141
c) Change of switch functions : This has the functions to confirm and set of the followings.
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
BACK
Press 2 times.
2nd stage
:Set and confirmation of switch function menu.
C H G S
SET
BACK
:Operation mode for DJ series.
3rd stage r d - S E t
(Cool / Heat / Simultaneous change-over)
SET
BACK
4th stage
:Cooling mode
(Factory set : COOL)
C o o L
1st stage
:Heating mode
H E A t
SET
3rd stage S A n. - d t
SET
BACK
4th stage
1 - H
:Data record interval.
: Data record interval : 1hour (Factory set : 1-H)
5 - n.
: Data record interval : 5 minutes
1 - n.
: Data record interval : 1 minute
: Data record interval : 10 seconds
1 0 - S
SET
3rd stage L o C A L
SET
BACK
4th stage
o n
:Local operation mode.
:Local operation mode
(Factory set : on)
:Remote operation mode
o F F
SET
3rd stage S
I
:Delete message sign
G n
SET
BACK
C o n S E n
SET
4th stage
3rd stage u n
I
:Push "SET" key for delete message sign.
:Push "BACK" key for continue to message sign on
display.
:Change unit
t
SET
BACK
o C
4th stage
:Unit : deg.C
o F
(Factory set : deg.C)
:Unit : deg.F
SET
3rd stage L
o
S E L
:Operation mode for LJ series. (Factory set : OFF)
142
d) Set of chilled water pump : This has the functions to confirm and set of the applications for
a chilled water pump.
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
Press 3 times.
2nd stage BACK
:Set of chilled water pump menu.
A P P o C H
SET
BACK
:Set of interlock return time
3rd stage I n t - C H
SET
BACK
4th stage
:The interlock return time set at present is displayed.
0 0 0
S
(Factory set : "0")
:Changeable
from 0 to 250 sec.
2 5 0
S
SET
1st stage
3rd stage V
V - C H
SET
BACK
o F F
:Set of variable flow rate (Future use)
(Factory set : OFF)
S y S - u n
S y S - P o
A b S -
I V
A b S - u n
A b S - P o
SET
3rd stage r
4th stage
- P A r A
SET
BACK
o F F
:Set of parallel operation by the remote controller (Future use)
(Factory set : OFF)
o n
SET
143
e) Set of inverter control of chilled water pump : (Future use)
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
Press 4 times.
2nd stage BACK
:Set of inverter control of chilled water pump menu.
C H - I n V
1st stage
f) Set of cooling water system : This has the functions to confirm and set of the applications
for a cooling water pump.
f-1) Set of interlock return time
f-2) Set of stopping cooling water pump at low load
f-3) Set of cooling tower fan control
(Future use)
f-4) Set of cooling tower fan temp. control
f-5) Set of differential temp. of cooling tower fan
f-6) Set of variable flow rate
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
BACK
Press 5 times.
2nd stage A P P o C o
:Set of cooling water system menu.
SET
BACK
:Menu to set and confirm the interlock return time.
3rd stage I n t - C o
SET
BACK
:The interlock return time set at present is displayed.
4th stage
0 0 0
S
(Factory set : "0")
:Changeable from 0 to 250 sec.
2 5 0
S
SET
3rd stage C o S t o P
:Set of stopping cooling water pump at low load menu
(Future use)
3rd stage C t A u t o
:Set of cooling tower fan control menu
(Future use)
3rd stage C t
t E n. P
3rd stage C t d I F F
3rd stage V
V - C o
:Set of cooling tower fan temp. control menu
(Future use)
:Set of differential temp. of cooling tower fan menu
(Future use)
:Set of variable flow rate menu
(Future use)
144
g) Set of inverter control of cooling water pump : (Future use)
: This function is confirmation & set of an inverter signal sent from Chiller to a cooling water pump.
g-1) Set of cost factor
g-2) Controlled variable setting
g-3) Minimum frequency setting
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
BACK
Press 6 times.
2nd stage C o - I n V
:Set of inverter control of cooling water pump menu.
(Future use)
h) Field set : This has the functions to confirm and set as followings.
h-1) Set of temp. for maximum input This setting is to reduce the maximum input when cooling water inlet
temperature rises beyond the rated temp. (T deg.C).
Starting temp. of maximum input reduction at lower cooling inlet
temperature : T - 4 deg.C (fixed)
h-2) Set of slow input time :
This is time setting for a fuel control valve to open slowly in order to prevent over-input at Chiller starting.
h-3) Set of slow input temp. :
This setting is to avoid the fuel control valve slow open function in order to shorten the rise time of
chiller at starting, if H.T.Generator temperature is higher than a certain temperature.
h-4) Set of dilution time : This setting is for dilution operation time.
h-5) Set of remote signal type : This setting is select of a remote operation (start & stop) signal.
h-6) Set of type of pulse : This setting is select of the pulse signal type for operation signal.
h-7) Set of low select control temp. : (Future use)
h-8) Set of radiation temp. : (Future use)
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
BACK
Press 7 times.
2nd stage F I E L d
:Field set menu.
SET
BACK
:Set of temp. for maximum input
3rd stage C o - I n P
SET
BACK
4th stage
o C
:The temp. for maximum input set at present is displayed.
2 0. 0
(Factory set : "32")
o
:Changeable from 20 to 33 deg.C.
3 3. 0
C
SET
145
3rd stage
I
n P -
BACK
0 0 0 0
4th stage
1 8 0 0
3rd stage
:Menu to set and confirm the set of slow input time
t n
SET
I
4th stage
S
SET
n P t n. P
SET
BACK
o C
0 0 0
o C
SET
1 2 0
3rd stage d
S
I
4th stage
L u - t
SET
BACK
0 4
2 0
3rd stage r - S
4th stage
I
:Menu to set and confirm the set of slow input temp.
:The temp. for slow input set at present is displayed.
(Factory set : "000")
:Changeable from 0 to 120 deg.C.
:Menu to set and confirm the set of slow input temp.
n.
n.
SET
:The time for dilution operation set at present is displayed.
(Factory set : "04")
:Changeable from 4 to 20 deg.C.
:Menu to set and confirm the set of remote signal type
G n
SET
BACK
S t A t
:The time for slow input set at present is displayed.
(Factory set : "0000")
:Changeable from 0 to 1800 seconds
I
C
:The remote signal type set at present is displayed.
(Factory set : "StAtiC")
P u L S E
SET
3rd stage o F - P L S
SET
BACK
4th stage
P o S I t
:Menu to set and confirm the set of remote signal type
I
or
:The pulse type set at present is displayed.
(Factory set : "PoSiti")
n E G A t I
SET
3rd stage L o S E L E
3rd stage H E
- S t
:Set of low select control temperature menu
(Future use)
:Set of radiation temperature menu
(Future use)
146
i) Set of SR-485 : Invalid function, must be passed (Future use)
: This function is to install addresses to plural Chiller/Heaters in order to operate them by the remote
controller.
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
BACK
Press 8 times.
2nd stage r S - 4 8 5
:Set and confirmation of set of SR-485
j) Version No. of microprocessor (indication only)
:H.T.Generator temp. at present (145.0 deg.C)
1st stage
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
BACK
Press 9 times.
2nd stage U E r 0. 9 1
:The version No. is displayed.
k) Version No. of option board (indication only)
:H.T.Generator temp. at present (145.0 deg.C)
1st stage
1 4 5. 0
SET
BACK
:First display in 2nd stage
A L A r n.
BACK
Press 10 times.
2nd stage o P U 0. 0 0
:The version No. is displayed.
147
(4) Second stage (Service mode)
The followings show the operation steps from the second stage to fourth stage.
a) Function of switch-2 : This has the following items.
a-1) Purge indication : This is fixed with "Auto" only. It can be passed.
a-2) Refrigerant pump : Use to operate manually a refrigerant pump.
There are 3 mode "AUTO", "OFF", "ON".
(Factory set : AUTO)
a-3) Pilot burner : Select "AUTO" or "TEST" for DJ model only.
a-4) Control valve-1 : To select fuel control valve operating mode.
"AUTO" or "MANUAL"
(Factory set : AUTO)
a-5) Control valve-1 opening : Set valve opening.
a-6) Control valve-2
(Factory set : AUTO)
a-7) Control valve-2 opening
a-8) Control valve-3
(Factory set : AUTO)
a-9) Control valve-3 opening
a-10) HBS address
(Factory set : 0)
a-11) High speed timer function :
The speed of timer function in the microprocessor increases 60 times of the regular speed.
This function is useful for servicing only.
In case of select "ON", alarm light blinks on and off.
a-12) Clear of operating data : Use to clear operating data (192 times) filed in the microprocessor.
1st stage
1 4 5. 0
SET +
BACK
2nd stage C H G S
2
SET
BACK
3rd stage P U r G E
SET
BACK
4th stage
A u t o
:H.T.Generator temp. at present (145.0 deg.C)
:Service mode
:Purge indication menu.
:This is fixed with "Auto" only.
3rd stage r E F - P
SET
BACK
4th stage
A u t o
:Refrigerant pump menu.
(Factory set : Auto)
:Refrigerant pump operates automatically.
o F F
:Refrigerant pump is stopped by force.
o n
:Refrigerant pump runs continuously by force.
In this case, the refrigerant pump RUN lamp blinks.
SET
3rd stage P I L o t
:Pilot burner menu.
3rd stage C n. - 1
(Future use for DJ series)
:Control valve-1 menu.
(Factory set : Auto)
SET
4th stage
BACK
A u t o
n. A n u A L
SET
:Automatic mode.
:Manual mode.
148
3rd stage C n. - 1 S t
SET
BACK
4th stage
:Control valve-1 opening menu.
0
1 0 0
SET
(Factory set : "100")
:Control valve-1 opening set at present is displayed.
:Changeable from 0 to 100 %.
3rd stage C n. - 2
:Control valve-2 menu.
(Future use)
3rd stage C n. - 2 S t
:Control valve-2 opening menu.
(Future use)
3rd stage C n. - 3
:Control valve-3 menu.
(Future use)
3rd stage C n. - 3 S t
:Control valve-3 opening menu.
(Future use)
3rd stage H d d H b S
:HBS address menu.
(Future use)
3rd stage b A
4th stage
:High speed timer function menu.
S o k
SET
BACK
o F F
(Factory set : oFF)
:High speed timer function set at present is displayed.
:In case of ON, the alarm lamp blinks.
o n
SET
3rd stage o P - r S t
SET
BACK
4th stage
:Clear of operating data menu.
3
2
1
SET
(All operation data is cleared.)
149
b) Set of model : This has the following items.
b-1) Serial number
b-2) Type of Chiller
b-3) Type of control
b-4) Annual cooling operation
These settings have been set at the factory.
b-5) Automatic changeover
Do not change them.
b-6) For process use
(Resetting for replace the microprocessor only)
b-7) With purge pump
b-8) Oil pump
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 1 time
2nd stage n. o d E L
:Set of model menu.
SET
BACK
:Serial number menu.
:Change of figure
3rd stage
d
SET
:Movement of column
4th stage
BACK
0 0
BACK
3 0
BACK
3 0
BACK
3 2
BACK
3 2
BACK
3 2
BACK
3 2
BACK
3 2
BACK
3 2
BACK
3 2
BACK
3 2
BACK
3 2
BACK
0 0 0 0
SET
0 0 0 0
SET
0 0 0 0
SET
0 0 0 0
SET
0 0 0 0
SET
5 0 0 0
SET
5 0 0 0
SET
5 1 0 0
SET
5 1 0 0
SET
5 1 8 0
SET
5 1 8 0
SET
5 1 8 4
SET
:1st column blinks.
Example : Press
3 times
:2nd column blinks. Example : Press
2 times
:3rd column blinks.
Example : Press
5 times
:4th column blinks.
Example : Press
1 times
:5th column blinks.
Example : Press
8 times
:6th column blinks.
Example : Press
6 times
150
:Type of Chiller.
3rd stage t y p E
SET
BACK
4th stage
: Efficiency (Future use)
(Standard)
(High efficency)
(Future use)
: Type of effect
(Double effect)
(Single effect)
(Single & Double effect)
(Double & Double effect)
(Triple effect)
(Future use)
(Future use)
(Future use)
: Fuel - 1
(Gas)
(Kerosene)
(Diesel oil)
(Steam)
(High temp hot water)
(low temp hot water)
(Dual fuel : Gas-oil)
(Future use)
: Fuel - 2
(No use)
(Steam)
(High temp hot water)
(low temp hot water)
(Exhaust gas))
SET
(Future use)
(Future use)
(Future use)
(Future use)
(Future use)
(Future use)
: Option - 1
(Standard model)
(Future use)
(Simultaneous model)
(Low temp chilld water model) (Future use)
(Additional hot water heater) (Future use)
(Low temp chilld water & hot water heater)
(Future use)
: Option - 2 (Future use)
(Standard)
(Future use)
(Option)
151
3rd stage C o n t
4th stage
:Control by chilled water outlet or inlet
o
SET
BACK
C H - o u t
C H -
n
SET
3rd stage A - C o o L
SET
BACK
4th stage
o F F
(Future use)
(Standard)
(Future use)
:Option
(Future use)
(Standard)
(Future use)
o n
SET
3rd stage C H A u t o
SET
BACK
4th stage
n. A n u A L
:Option
(Future use)
(Standard)
(Future use)
A u t o
SET
3rd stage P r o C
:Increased chilled water outlet temp to max 20 degC.
SET
4th stage
BACK
o F F
(Standard)
(Possible to increase to 20 degC)
o n
SET
3rd stage n. P - o P
SET
BACK
4th stage
o n
:Option of purge pump.
(Standard)
(No option)
o F F
SET
3rd stage o P - o P
SET
BACK
4th stage
o F F
:Option
(Future use)
(Standard)
(Future use)
o n
SET
152
c) Rated specification setting : This has the following items.
c-1) Chilled water outlet temp.
c-2) Hot water outlet temp.
Factory set (Never change)
c-3) Chilled water temp. difference
c-4) Hot water temp. difference
c-5) No-use (extra) SinG-k : Future use
c-6) Max. opening of fuel control valve
c-7) Indication of purge pump starting
Factory set (Never change)
c-8) Indication of purge pump stopping
c-9) No-use (extra) AP-tin. : Future use
c-10) No-use (extra) EIICond : Future use
c-11) Crystallization temp. : Future use
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 2 times
2nd stage S P E C
:Set of rated specification setting menu.
SET
BACK
:Chilled water outlet temp.
3rd stage C - t E n. P
SET
BACK
o C
:The setting of rated chilled water outlet temp. set
4th stage
4. 0
at present is displayed.
(Factory set : "7.0")
: Up and down the spec temp. by the key .
o C
:Changeable from 4.0 to 20.0 deg.C
2 0. 0
SET
3rd stage H -
4th stage
t E n. P
SET
BACK
4 0. 0
9 5. 0
:Hot water outlet temp.
o
C
o
C
SET
3rd stage C - d t
:The setting of rated hot water outlet temp. set
at present is displayed.
(Factory set : "55.0")
: Up and down the spec temp. by the key .
:Changeable from 40.0 to 95.0 deg.C
:Chilled water temp. difference
SET
4th stage
BACK
3. 0
1 0. 0
o
C
o C
SET
:The setting of rated chilled water temp. difference set
at present is displayed.
(Factory set : "5.0")
: Up and down the spec temp. by the key .
:Changeable from 3.0 to 10.0 deg.C
153
3rd stage H - d t
:Hot water temp. difference
SET
4th stage
BACK
3. 0
o
o C
SET
1 0. 0
3rd stage S
C
n G - k
: (Future use)
3rd stage r A n K u P
SET
BACK
4th stage
0. 0
2 0 0. 0
SET
3rd stage A P - S t
SET
BACK
8. 0 k P A
1 6. 0 k P A
SET
3rd stage A P - S P
SET
BACK
4. 0
k P A
7. 0
:The setting of rated hot water temp. difference
set at present is displayed.
(Factory set : "5.0")
: Up and down the spec temp. by the key .
:Changeable from 3.0 to 10.0 deg.C
k P A
SET
:Max. opening of fuel control valve
:The setting of max. opening of fuel control valve set at
at present is displayed.
(Factory set : "100.0")
: Up and down the spec temp. by the key .
:Changeable from 0.0 to 200.0 %
:Indication of purge pump starting
:The setting of indication of purge pump starting set
at present is displayed.
(Factory set : "10.0")
: Up and down the spec temp. by the key .
:Changeable from 8.0 to 16.0 kPa
:Indication of purge pump stopping
:The setting of indication of purge pump stopping set
at present is displayed.
(Factory set : "7.0")
: Up and down the spec temp. by the key .
:Changeable from 4.0 to 7.0 kPa
n
: (Future use)
C o n d
: (Future use)
3rd stage L E C r y S
: (Future use)
3rd stage A P 3rd stage E
t
(Factory set : "1.0")
154
d) Input setting : This has the following items.
d-1) Type of control :Factory set menu.
d-2) Input correction : Factory set menu
d-3) Combustion interval : Factory set menu
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 3 times
2nd stage
:Set of rated specification setting menu.
n P u t
SET
BACK
:Set of type of control
3rd stage b n t y P E
SET
BACK
4th stage
P
d
SET
3rd stage
4th stage
3rd stage F -
4th stage
:Input correction
P t C o r
SET
BACK
5 0
SET
:Fuel interval
n t
SET
BACK
- -
n.
0 0
n.
1 0
n.
SET
(Factory set : "0")
:Changeable from 0 to 10 minutes
155
e) Inverter setting : This has the following items for #1 absorbent pump inverter.
e-1) Control estimating time
e-2) Estimating tuning
e-3) Constant a1
e-4) Constant a2
Factory set (Never change)
e-5) Constant a3
e-6) Constant a4
e-7) Constant a5
e-8) Constant a6
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 4 times
2nd stage
:Set of rated specification setting menu.
n V S E t
SET
BACK
:Control estimating time
3rd stage 3 3 A L
SET
BACK
4th stage
1 5
SET
3rd stage 3 3 A L - K
SET
BACK
4th stage
1. 0 0
SET
3rd stage
4th stage
3rd stage
4th stage
3rd stage
4th stage
3rd stage
4th stage
:Estimating tuning
n V - A 1
SET
BACK
1 4 8
SET
:Constant a1
n V - A 2
SET
BACK
0. 0 4 2
SET
:Constant a2
n V - A 3
SET
BACK
0. 0 6 0
SET
:Constant a3
n V - A 4
SET
BACK
:Constant a4
3. 6
SET
156
3rd stage
n V - A 5
SET
BACK
4th stage
3rd stage
4th stage
:Constant a5
5 0
SET
n V - A 6
SET
BACK
:Constant a6
2. 3
SET
157
f) PID setting : This is PID control setting menu for capacity control of Chiller.
All data has been set at the factory. Do not change them.
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 5 times
2nd stage P
:PID setting menu.
d S E t
SET
BACK
:P for cooling
3rd stage C o o L - P
SET
BACK
4th stage
2. 0
SET
1st stage
3rd stage C o o L - I
SET
BACK
4th stage
2 0 0
SET
:I for cooling
3rd stage C o o L - d
SET
BACK
4th stage
:D for cooling
5
SET
3rd stage H E A t - P
SET
BACK
4th stage
5. 0
SET
:P for heating
3rd stage H E A t - I
SET
BACK
4th stage
5 0
SET
:I for heating
3rd stage H E A t - d
SET
BACK
4th stage
3 0
SET
:D for heating
3rd stage S A n. P L E
SET
BACK
4th stage
1 0
SET
:Sample time
158
g) Operation hours and ON/OFF times set : (Use for CPU replacement only)
g-1) Operation hours of Chiller
g-8) On/Off times of Chiller
g-2) #1 abso. pump operation hours
g-9) On/off times of #1 abso. pump
g-3) #2 abso. pump operation hours
g-10) On/off times of #2 abso. pump
g-4) Burner operation hours
g-11) On/Off times of burner
g-5) Refr. pump operation hours
g-12) On/Off times of refr. pump
g-6) Purge pump operation hours
g-13) On/Off times of purge pump
g-7) #3 abso. pump operation hours
g-14) On/off times of #3 abso. Pump
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 6 times
2nd stage C o u n t
:Operation hours & ON/OFF times setting menu.
SET
BACK
:Operation hours of Chiller
:Change of figure
3rd stage u n
t - t
SET
:Movement of column
BACK
:1st column blinks.
4th stage
0 0 0 0 0 0
BACK
SET
0 0 0 0 0 0
BACK
SET
:2nd column blinks. Example : Press
4 times.
0 0 0 0 0 0
SET
BACK
0 4 0 0 0 0
SET
BACK
:3rd column blinks. Example : Press
1 time.
0 4 0 0 0 0
BACK
SET
0 4 1 0 0 0
SET
BACK
:4th column blinks. Example : Press
7 times.
0 4 1 0 0 0
BACK
SET
0 4 1 7 0 0
SET
BACK
:5th column blinks. Example : Press
8 times.
0 4 1 7 0 0
BACK
SET
0 4 1 7 8 0
BACK
SET
:6th column blinks. Example : Press
4 times.
0 4 1 7 8 0
SET
BACK
0 4 1 7 8 4
159
3rd stage A b S 1 -
t
:#1 absorbent pump operation hour
3rd stage A b S 2 -
t
:#2 absorbent pump operation hour
r E -
t
:Burner operation hour
3rd stage F
3rd stage r E F -
:Refrigerant pump operation hour
t
3rd stage P u r G -
t
:Purge pump operation hour
3rd stage A b S 3 -
t
:#3 absorbent pump operation hour
3rd stage u n
t - C
:On/OFF times of Chiller
3rd stage A b S 1 - C
:ON/OFF times of #1 absorbent pump
3rd stage A b S 2 - C
:ON/OFF times of #2 absorbent pump
3rd stage F
r E - C
:ON/OFF times of burner
3rd stage r E F - C
:ON/OFF times of refrigerant pump
3rd stage P u r G - C
:ON/OFF times of purge pump
3rd stage A b S 3 - C
:ON/OFF times of #3 absorbent pump
160
h) Predication function setting
h-1) Vacuum condition : Factory setting = ON
h-2) Absorbent concentration : Invalid function, must be passed.
h-3) Cooling water tubes fouling condition : Factory setting = ON
h-4) Cooling water temp. : Factory setting = ON
h-5) Combustion chamber fouling condition : For Japanese market only.
h-6) Ant freezing : For Japanese market only.
h-7) Exhaust gas temp. : For Japanese market only.
h-8) Clear of predication data
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 7 times
2nd stage S
:Predication function setting menu.
G n S t
SET
BACK
:Vacuum condition
3rd stage P u r G E
SET
BACK
:Non-display
4th stage
o F F
:Display
o n
(Factory set : "on")
SET
3rd stage t H
C K
3rd stage C o - d
4th stage
:Absorbent concentration
:Cooling water tubes fouling condition
r
SET
BACK
o n
:Display
(Factory set : "on")
:Non-display
o F F
SET
3rd stage C o - H
:Cooling water temperature
SET
4th stage
BACK
o n
:Display
(Factory set : "on")
:Non-display
o F F
SET
3rd stage C C - d
4th stage
:Combustion chamber fouling condition
r
SET
(Future use)
BACK
o F F
SET
161
3rd stage r u L E - 1
SET
BACK
4th stage
o F F
:Anti freezing
(Future use)
:Exhaust gas temperature
(Future use)
SET
3rd stage E H G - L o
SET
BACK
4th stage
o F F
SET
3rd stage r E - S E t
SET
BACK
4th stage
:Clear of predication data
3
2
1
SET
i) Burner controller setting
(Future use)
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 8 times
2nd stage P r y
:Burner controller setting (Future use)
1st stage
162
j) Tuning of temperature sensor
j-1) Chilled water outlet temp. sensor
j-2) Chilled water inlet temp. sensor
j-3) Cooling water outlet temp. sensor
j-4) Cooling water inlet temp. sensor
j-5) Hot water outlet temp. sensor
j-6) Hot water inlet temp. sensor
j-7) Sensor option setting
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 9 times
2nd stage S E n S o r
:Tuning of temp. sensor setting menu.
SET
BACK
:Chilled water outlet temp. sensor
3rd stage C H o A d J
SET
(Factory set : 0.0 deg.C)
BACK
:The tuning setting set at present is displayed.
4th stage
- 2. 0
2. 0
SET
3rd stage C H
:Chilled water inlet temp. sensor
(Factory set : 0.0 deg.C)
A d J
SET
BACK
- 2. 0
4th stage
2. 0
SET
3rd stage C o o A d J
SET
BACK
4th stage
- 2. 0
2. 0
SET
3rd stage C o
:The tuning setting set at present is displayed.
:Changeable from -2.0 thru 2.0 deg.C
:Cooling water outlet temp. sensor
(Factory set : 0.0 deg.C)
:The tuning setting set at present is displayed.
:Changeable from -2.0 thru 2.0 deg.C
:Cooling water inlet temp. sensor
(Factory set : 0.0 deg.C)
A d J
SET
BACK
- 2. 0
4th stage
:Changeable from -2.0 thru 2.0 deg.C
2. 0
SET
:The tuning setting set at present is displayed.
:Changeable from -2.0 thru 2.0 deg.C
3rd stage H o A d J
:Hot water outlet temp. sensor
3rd stage H
:Hot water inlet temp. sensor
A d J
3rd stage S E n - o P
:Sensor option
163
k) Analog data indication : 42 data can be displayed.
1st stage
2nd stage A
3rd stage
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
5
5
5
5
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 10 times
:Analog data indication menu.
n A L o G
SET
BACK
Select data
:H.T.Generator temperature (deg.C)
1 4 5. 0
:Chilled water inlet temp. (deg.C)
2.
1 1. 9
:Chilled water outlet temp. (deg.C)
3.
6. 8
:Cooling inlet temp. (deg.C)
4.
3 1. 8
:Condensed refrigerant temp. (deg.C)
5.
3 4. 7
:Steam drain temp. (deg.C)
6.
8 5. 3
:Purge tank pressure (kPa)
7.
8. 5
:L.T.Generator temperature (deg.C)
8.
9 1. 5
:Cooling water mid temp. (deg.C)
9.
3 3. 5
:Cooling water outlet temp. (deg.C)
0.
3 7. 1
:Steam drain temp. (deg.C)
1.
8 5. 3
:Refrigerant temp. (deg.C)
2.
5. 9
:Diluted solution temp. at absorber outlet (deg.C)
3.
2 7. 8
:Inverter frequency (%)
4.
5 7. 5
:Fuel control valve opening output (%)
5.
0
:Fuel control valve opening input (%)
6.
0
:CVP output (%)
7.
9 6. 0
:Concentrated solution concentration (%)
8.
6 2. 5
:Diluted solution concentration (%)
9.
9 0. 0
:Remote setting input for chilled/hot water outlet temp. setting (mA)
0.
4. 0
:Invalid item
1.
0
:Invalid item
2.
0
:Low temp. heat exchanger outlet temp. (deg.C)
3.
3 5. 9
:Abnormality ratio in absorber
4.
8 5. 1
:Abnormality ratio in condenser
5.
4 5. 3
:Driving hot water inlet temp. for LJ Series (deg.C)
6.
0
:Hot water temp. at control valve outlet for LJ Series (deg.C)
7.
0
:Driving hot water outlet temp. for LJ Series (deg.C)
8.
0
:Invalid item
9.
0
:Invalid item
0.
0
:Invalid item
1.
0
:Invalid item
2.
0
:Invalid item
3.
0
:Invalid item
4.
0
:Invalid item
5.
0
:Invalid item
6.
0
:Invalid item
7.
0
:Invalid item
8.
0
:Invalid item
9.
0
:Invalid item
0.
0
:Invalid item
1.
0
:Invalid item
2.
0
:Invalid item
3.
0. 0
164
l) Digital input indication : Present digital input state is displayed.
1st stage
2nd stage d
3rd stage
.
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 11 times
:Digital input indication menu.
G
SET
BACK
. . . . .
:Present digital input state
A
1
2
3
4
5
Column number
F
6
G
E
B
C
D
Dp
Segment number
Digital input indication table
Segment 1st column
2nd column
3rd column
4th column
A
E2：
51A2：
51AU:
H.T.Generator
#2 abso pump
(Future use)
solution level
overload relay
electrode (E2)
NH:
(Future use)
52CH：
Chilled water
pump interlock
B
E1：
AUTO:
H.T.Generator ABS2：
solution level #2 abso pump (Future use)
electrode (E1)
DI1:
(Future use)
52CO：
Cooling water
pump interlock
C
POW:
51A1：
Power
#1 abso pump
resuming
overload relay
interlock
PAS:
(Future use)
DI2:
(Future use)
52CT:
(Future use)
D
69CH:
51R：
Chilled water
Refr pump
overload relay flow switch
PGSL:
(Future use)
DI3：
23CO:
Cooling mode (Future use)
E
51B:
(Future use)
F
63GH：
generator
ABS1：
#1 abso pump pressure
switch
G
REF：
Refr pump
51O:
(Future use)
PR-11：
Fuel control
valve opened
in force
Dp
BM:
(Future use)
OIL:
(Future use)
PR-10：
Fuel control
valve closed
in force
69CO：
FIRE：
Cooling water
Combustion
flow switch
M.F：
Combustion
alarm
5th column
6th column
52F：
DI4：
Ventilation fan
Heating mode
interlock
DI5:
(Future use)
R-ST：
Remote start
signal
R-SP：
Remote stop
signal
165
m) Digital output indication : Present digital output state is displayed.
1st stage
2nd stage d
3rd stage
.
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 12 times
:Digital input indication menu.
G
- o
SET
BACK
. . . . .
:Present digital input state
A
1
2
3
4
5
Column number
F
6
G
E
B
C
D
Dp
Segment number
Digital output indication table
Segment 1st column
2nd column
EXT-ON：
Chilled water
pump is
running
3rd column
4th column
5th column
6th column
AL：
Predication
signal
DO3-ON:
(Future use)
KISYAKU：
Dilution
operation
B
CPUMP-ON：
FIRE-ON：
Cooling water EX-HEAT:
Ignition signal pump is
(Future use)
running
KIDO-R：
Local /
Remote
DO3-OFF:
(Future use)
COOL：
Cooling mode
C
CMG-BK：
ABS1-ON：
Fuel control
NH-ON:
#1Abso pump
valve opened
(Future use)
is running
in force
DO1:
(Future use)
DO4:
(Future use)
HEAT：
Heating mode
D
CMG-BJ：
Fuel control
valve closed
in force
CFAN-ON:
(Future use)
RBV:
(Future use)
DO2:
(Future use)
ABS-RES：
Abso pump
reset
E
DS-ON:
(Future use)
KIDO-I：
Answer back
AUTOV:
(Future use)
RUN：
Running
F
BM-ON:
(Future use)
AUTOP:
(Future use)
STOP：
Stop
G
ABS2-ON：
F-ON：
F-RUN:
#2 abso pump Ventilation fan
(Future use)
is running
is running
FAIL-1：
Alarm
Dp
REF-ON：
Refr pump is
running
FIRE：
Combustion
A
PR-ON:
(Future use)
PV-ON:
(Future use)
BZ：
Alarm buzzer
166
n) State of control condition : Present control condition is displayed.
The following 4 function working conditions are displayed.
1) Protection function of H.T.Generator temperature excessive high
2) Protection of concentrated solution concentration excessive high
3) Maximum input control depending on cooling water inlet temp.
4) Pre-set function of chilled water outlet temperature set value
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 13 times
2nd stage C n t n o
:State of control condition menu.
SET
BACK
:Present working conditions are displayed.
3rd stage 0 0 0 0 0 0
Function
Non-working
Extra
0
Extra
0
Function 4)
0
Function 3)
0
Function 2)
0
Function 1)
0
o) Set of inverter-3 :
1st stage
2nd stage
p) Set of inverter-2 :
1st stage
2nd stage
Working
1
1
1
1
(Future use)
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 14 times
:Set of inverter-3 menu.
n V 3
(Future use)
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
SET +
BACK
:First display in 2nd stage
C H G S
2
Press 15 times
:Set of inverter-3 menu.
n V 2
167
(5) Re-set of chilled water outlet temperature set value
Purpose : In oder to save operating energy in light cooling season, the set value of chilled.
1st stage
:H.T.Generator temp. at present (145.0 deg.C)
1 4 5. 0
Press 15 times or
Press 8 times
2nd stage 1 0.
:Chilled water outlet temperature set value is displayed.
7. 0
SET
BACK
3rd stage
: Present set value is blinking.
1 0.
7. 0
1 0.
1 0.
8. 0
BACK SET
The set value can be chaged by the keys as required.
Changeable rage in Chilled water : 4 thru 20 deg.C
Changeable rage in hot water : 40 thru 95 deg.C
8. 0
BACK
Note : The above changeable ranges are only in the microprocessor.
168
6-20. Set of solution dampers
The following table shows the factory set value of solution dampers.
Full close : 0 deg.
Full open : 90 deg.
Damper
Damper
(degree)
D9
16NK
D1
D2
D3
D4
D5
D6
D7
D8
11
25
45
22
68
18
35
52
31
12
35
45
22
68
18
35
52
31
13
62
50
15
65
15
45
40
52
21
38
57
33
90
49
32
48
63
22
17
60
30
44
50
32
35
65
31
60
60
45
45
52
45
32
60
32
60
60
45
45
52
45
32
60
41
90
90
90
90
53
90
30
88
42
90
90
90
90
53
90
30
88
51
42
75
65
90
40
65
45
60
52
80
75
65
50
40
60
45
65
53
84
79
68
45
41
61
45
75
61
90
80
70
45
40
60
45
60
62
41
65
65
35
37
37
90
63
45
65
65
35
40
40
90
71
50
65
65
35
40
40
90
72
55
65
65
35
40
40
90
15
81
60
65
65
35
40
40
90
15
D1
D2
D3
D4
D5
D6
D7
D8
D9
:
:
:
:
:
:
:
:
:
15
Diluted solution #1
Diluted solution #2
Diluted solution #3
Intermediate solution
Concentrated solution
Refrigerant drain
Refrigerant
Diluted solution bypass
Refrigerant supply
169
6-21. Scrapping
To scrap Chiller, the following remarks shall be observed.
a) The scrapping shall be conducted by a licensed party in accordance with a local regulation.
b) To move and lift Chiller, licensed personnel shall operate a machine for the works.
c) If disassembling is required for scrapping, personnel having necessary license shall conduct
the disassembling work.
d) If discharging absorbent solution and refrigerant is required, refer to the following remarks
because of vacuum condition inside the chiller.
d-1) Nitrogen gas or air is charged through the service valve SV1 up to approximate 50 kPa.
d-2) Remove absorbent solution and refrigerant from the following service valve.
SV4 : Diluted absorbent solution in the lower shell
SV5 : Intermediate absorbent solution in the high temperature heat exchanger
SV6 : Concentrated absorbent solution in the low temperature heat exchanger
SV3 : Refrigerant in the refrigerant pan
SV8 : Intermediate absorbent solution in the high temperature generator
d-3) The solution discharged shell be collected in proper containers. Do not pour the solution
to a drain, sewage, ground, etc..
d-4) If gas cutting work is required for disassembling, the work shall be conducted after the charged gas
is released.
d-5) During releasing the charged gas, air ventilation shall be provided.
d-6) Note that there are sections where the solution can not be discharged. The low temperature
generator, the heat reclaimer, the drain heat reclaimer.
And even if the solution is discharged, inside surface of Chiller/Heater is wet. Pay attention not
to touch the solution directly. If touched, wash off the solution with water.
e) The solution shall be chemically managed by a special company.
170
6-22. Flow switch
The following is the flow switch instruction manual translated from the manufacturer's manual
Model - BQS Type
Manufacturer : Saginomiya Co.,Ltd.
Safety precautions
a) Do not open the cover of flow switch to avoid an electric shock.
b) Wiring to the flow switch shall be connected with power off to avoid an electric shock.
c) Do not wet the micro-switch of flow switch to avoid an electric shock.
d) A load connected to the micro- switch shall be within electric rating specified blow to avoid any damages
on the micro-switch contactor.
e) Do not turn any screws except the set screw to avoid abnormal functioning and any other troubles.
f) The flow switch shall be mounted as the arrow mark on the cover.
Reverse mounting of the flow switch causes no-functioning and paddle damage.
g) Any fluid which gives damages to the wetted part of flow switch shall not be used.
h) Be sure to make a grounding.
The grounding wire shall not be connected to a gas piping, a city water piping, an lightning conductor and
telephone line. Imperfect grounding may cause an electric shock.
i) Fluid speed shall be less than 2 m/sec..
Model Name
Wetted part
material
Construction
BQS-C1**P
BQS-C1**PM
BQS-C1**PW
BQS-C1**PWM
Open type
Drip -proof
type
Ambient
humidity
Copper alloy
Max. 80 %RH
Bronze / Stainless
Copper alloy
Max. 95 %RH
Bronze / Stainless
Electric rating
( Unit : A )
Type
Voltage Resistance load Lamp load Motor load
AC125V
15
1.5
5
AC250V
10
1.25
3
Standard
DC 30V
2
1.4
1
DC125V
0.4
0.4
0.03
10
1.5
4
For high load DC115V
with DC
DC230V
5
0.75
1.5
Type
For
very small
load
Voltage
AC125V
DC 8V
DC 14V
DC 30V
Load
0.1
0.1
0.1
0.1
Common specification
1. Max. working pressure
0.98 Mpa
2. Allowable fluid temp.
5～80 deg.C
3. Endurance limit
100,000 times
4. Mounting screw
5. Ambient temp.
(No-icing & No-dewing)
Minus 25 - Plus 80 deg.C
6. Contact (Single pole & Double throw)
Horizontal
a
Rc1
Pipe
Screwed depth
Specifications
C
Paddle
Paddle
Flow direction
A: Normal open
Paddle
Flow
B: Normal close
A
B
C: Common
171
Mounting
a) Minimum 5 times straight length of a pipe diameter shall be required at front and
rear of the flow switch for prevention of hunting due to eddy flow.
b) The flow switch is basically mounted on horizontal piping as shown in the figure.
The flow switch can also be mounted on vertical piping.
In this case, actual working flow rate may slightly change. It about 20 %.
c) Use T-joint (JIS B3201) to mount the flow switch.
If T-joint can not be available, the dimension (a) shown above figure shall be met with T-joint
d) The screwed depth shall be 12Plus/Minus 1.2mm.
e) The wiring for flow switch shall be in accordance with the label in the flow switch.
of JIS B3201.
Setting
a) Unless otherwise specified, the flow switch is factory shipped with around minimum setting point.
b) Turn the adjusting screw with clockwise, working point increases.
Turn the adjusting screw with counter-clockwise, working point decreases.
Do not over-turn the adjusting screw to achieve stable working condition.
c) Be sure to confirm the functioning of micro-switch if a setting is changed.
d) The screw F is for factory adjustment. Do not change it.
Fluid flow direction
Adjusting screw
Screw F
(Do not change it )
172
Selection table of number of paddles
The flow switch having generally 2 paddle is furnished on the chiller in the factory.
However, in case that flow rate differs from the standard specification due to a special requirement,
the number of paddles is selected as per the following table.
Pipe size
inch
Paddle 1
Qmin. Qmax.
(l/min) (l/min)
50
2
105
65 2-1/2 195
80
3
360
100
4
615
125
5
810
150
6
1,330
200
8
2,310
250 10 3,565
300 12 5,120
350 14 6,370
400 16 8,415
450 18 10,745
500 20 13,360
250
565
850
1,435
2,230
3,140
5,470
8,435
12,120
15,070
19,915
25,430
31,620
Paddle 1 + 2
Qmin. Qmax.
(l/min) (l/min)
Paddle 1 + 2 + 3
Qmin. Qmax.
(l/min) (l/min)
50
105
170
330
510
715
1,245
1,920
2,760
3,430
4,530
5,785
7,195
200
350
530
930
1,435
2,060
2,560
3,380
4,315
5,365
150
355
480
940
1,450
2,040
3,550
5,480
7,875
9,790
12,940
16,525
20,550
600
1,120
1,700
2,960
4,565
6,560
8,160
10,780
13,770
17,120
173
6-23. T.R.G. meter
T.R.G. meter can be utilized to check abrasion condition of solution pumps easily.
The following explanation is the procedure to use and the guidance value to judge the absorbent condition
for their maintenance.
The #1 absorbent pump, #2 absorbent pump and refrigerant pump are equipped with a system of detecting
bearing wear without the need for dismantling the pump.
The T.R.G. system consists of two inspection coils embedded in the motor stator.
As the stator energized and causes the rotor to rotate, the T.R.G. coils create an AC electromotive force.
As bearings begin to wear causing the rotor to run closer to the stator the AC electro-motive force generated
by the T.R.G. coils increases.
Taking T.R.G. readings on a regular basis can be a great tool in determining rate of bearing wear and
when the pump should be overhauled.
The T.R.G. terminals are located in each pump terminal boxes and should be tested with an AC volt meter
set at the 2.5 VAC scale.
Initial Start-up
value plus
0.0 thru 0.50
0.5 thru 0.60
0.6 thru 0.75
Over 0.75
VAC
VAC
VAC
VAC
Judgment
Safe
Caution
Warning
Maintenance
Continue Operation can be done
Schedule overhaul at next inspection
Schedule immediately overhaul
Immediate overhaul required
T.R,G. (Teikoku Rotary Guardian)
Note 1
In case of an absorbent pump controlled by an inverter,
it's T.R.G. reading may change depending on inverter frequency.
Always take readings at the same frequency.
Using different meters can also result in slightly different readings.
1
TRG Inspection
coil
２
Stator
Note 2
If a reading reaches to the warning level,
an overhaul should be immediately scheduled
and conduct the overhaul as soon as possible.
Generally, warning level reading may reach to
over 0.75 VAC for about two weeks.
TRG Inspection
coil
174
6-24. How to check temperature sensors
The chiller uses 3 types temperature sensors as follows.
Resistance (copper) thermometer bulb
DT1 : Chilled water outlet temperature sensor
Thermistor
DT3 : High temp. generator temperature sensor
DT13 : Steam drain temperature sensor
Digital sensor
DT2 : Cooling water outlet temperature sensor
DT4 : Low temp. generator temperature sensor
DT5 : Condenser temperature sensor
DT6 : Chilled water inlet temperature sensor
DT7 : Cooling water inlet temperature sensor
DT10 : Absorber temperature sensor
DT11 : Evaporator temperature sensor
DT12 : Middle cooling water temperature sensor
a) How to check Resistance (copper) thermometer bulb DT1
Remove the sensor wiring from the terminal box and measure resistance between terminals of sensor itself.
And then compare measured resistance value calculated by the following formula.
For example, If the chilled water outlet temperature is 10 deg.C by a thermometer,
the resistance value is 2,085 ohms.
Charactristics of resistance : 2000Ω at 0 deg.C (32 deg.F)
: Rating of resistance : 8.56Ω/deg.C
Present resistance = 2000 + 8.56 x Present measured temperature
2000 + 8.56 x 10 = 2,086 ohms
If DT1 is disconnection, its resistance value becomes infinity. If DT1 is short, it will be 0 ohms.
In these case, J-01 next F25 are indicated in cooling mode on the display board,
J-22 next F25 are indicated in heating mode on the display board.
175
b) How to check Thermistor DT3 & DT13
DT3 and DT13 are the thermisters and the low range side is used for Chiller.
Accordingly, resistance value between the red lead wire and black lead wire need to be measured.
(The white lead wire is the high range side, do not use it.)
For example, if H.T.Ggenerator temperature measued by another thermometer (surface thermometer) is
150 degree C, resistance value is 3,161 ohms as shwon in blow table.
If DT3 / DT13 is disconnection, its resistance value becomes infinity.
If DT3 / DT13 is short, it will be 0 ohms.
IF DT3 is disconnection or short, J-13 next F26 are indicated on the display board.
If DT13 is disconnection or short, J-17 next F27 are indicated on the display board.
Temperature & Resistance Table
Accuracy : 1,000 ohms plus/minus 3% at 200 deg.C (392 deg.F)
Temperature
Resistance
Temperature
Resistance
Temperature
Resistance
Deg. C Deg. F
k ohm
Deg. C Deg. F
Ohm
Deg. C Deg. F
Ohm
0
32
806.5
110
230
9,585
210
410
815
10
50
478.8
120
248
7,131
220
428
669
20
68
292.9
130
266
5,374
230
446
554
30
86
184.1
140
284
4,098
240
464
461
40
104
118.7
150
302
3,161
250
482
387
50
122
78.3
160
320
2,464
260
500
326
60
140
52.8
170
338
194
270
518
277
70
158
36.3
180
356
1,542
280
536
236
80
176
25.4
190
374
1,237
290
554
202
90
194
18.1
200
392
1,000
300
572
174
100
212
13.1
c) How to check Digital sensors DT2, DT4, DT5, DT6, DT7, DT10, DT11 & DT12
Status of digital sensors cannot be judged by checking of sensor itself.
Therefore, the status of a digital sensor need to be judged by a sensor alarm indicated on the display board.
In case that a sensor alarm is indicated, firstly check whether there is a poor connection of connector or not.
Connect the sensor to vacant connector or remove one sensor from a connector and connect the
doubtful sensor to the connector. If there are multiple sensor errors, there is a possibility of plug
defectiveness of connector of a trunk line of wiring.
If sensor alarm is for all the sensors, connect a sensor directly and check the possibility of
damage in the first trunk line.
Other possibility is malfunction of the microcomputer.
Address setting for digital sensor
The microprocessor in Chiller control panel checks addresses of each sensor when the power supply is ON.
In case that a sensor is replaced, its address is checked by the microprocessor when the power supply is
just turned on then the address is recorded into the microprocessor.
Note : Address of each sensor has been written at the factory before shipment.
176
Section 7
Seasonal inspection & operation with daily maintenance
7-1. Beginning cooling season
Yes
a) Chilled water system
No
N/A
a-1) Check of valve open/close conditions in chilled water loop
(Including secondary loop : air handling unit side)
a-2) Cleaning of strainers in the chilled water loop
a-3) Water filling into the chilled water loop
(If necessary, new water is filled into the chilled water loop)
a-4) Performing air vent from the chilled water loop
a-5) Check of water leakages in chilled water loop
a-6) Check of control for chilled water system
a-7) Check of water circulating condition
Insulation resistance of chilled water pump
meg ohm
Amperage of chilled water pump
A
Suction pressure of chilled water pump
KPa / psi
Discharge pressure of chilled water pump
KPa / psi
a-8) Independent trial run of chilled water system
b) Cooling water system
b-1) Check of valve open/close conditions in cooling water loop
b-2) Cleaning of strainers in the cooling water loop with cooling tower
b-3) Water filling into the chilled water loop
(New water should be filled into the cooling water loop)
b-4) Performing air vent from the cooling water loop
b-5) Check of water leakages in cooling water loop
b-6) Check of control for cooling water system with temp. control
b-7) Check of water circulating condition
Insulation resistance of cooling water pump
meg ohm
Amperage of cooling water pump
A
Suction pressure of cooling water pump
KPa / psi
Discharge pressure of cooling water pump
KPa / psi
b-8) Independent trial run of cooling water system
c) Total trial run of chilled and cooling water systems
177
Yes
d) Stream and drain system
No
N/A
d-1) Check of valve open/close conditions in steam line
d-2) Cleaning of strainers in the steam line
d-3) Performing steam control valve
d-4) Check of steam leakages in steam line
d-5) Check of valve open/close conditions in steam drain line
d-6) Check of steam drain leakages in steam drain line
e) Check damages on the control panel, mounted parts, etc.
f) Check of insulation resistance of pumps (More than 10 meg ohm)
f-1) #1 absorbent pump
meg ohm
f-2) #2 absorbent pump
meg ohm
f-3) Refrigerant pump
meg ohm
f-4) Purge pump
meg ohm
g) Check of purge pump and purging
g-1) No-water in the liquid trap
g-2) Oil quality (oil color shall be clean)
g-3) Oil quantity (up to the center of purge pump sight glass)
g-4) No abnormal noise
g-5) Attained vacuum (attained vacuum shall be less than 0.5 kPa abs.)
g-6) Purging from the lower shell
Perform purging from both the purge tank (V2) and the lower shell (V3) until the inside vacuum goes
down below the allowable vacuum curve (Refer to page 133).
h) Bubble test (Refer to page 132)
:
cc
Second measuring value:
cc
Third measuring value
:
cc
Average value
:
cc
First measuring value
NG
Judgmen
Goo
d
Perform leak test and
repair the leakage
Chiller can go into the
commercial operation.
i) Inspection of steam control valve and steam trap : Contrl valve
: Steam trap
j) Operation of Chiller
k) Refrigerant blow down (Refer to page 134)
Note : Before refrigerant blow down, confirm that refrigerant level can be observed through the
sight glass. If not, continue the operation of Chiller and stop the refrigerant pump until
refrigerant the refrigerant level is observed.
l) Sampling absorbent for analyses (Refer to page 123)
m) Absorbent analyses (Refer to page 106)
j) Adjusting inhibitor content and alkalinity (if necessary) (Refer to106)
178
7-2. Mid cooling season
Even through the cooling system runs normally, viewing from preventive maintenance of the cooling system
including Chiller, the following inspections are recommended.
Yes
a) Chilled water system
No
N/A
a-1) Check of valve open/close conditions in chilled water loop
(Including secondary loop : air handling unit side)
a-2) Cleaning of strainers in the chilled water loop
a-3) Water filling into the chilled water loop
(If necessary, new water is filled into the chilled water loop)
a-4) Performing air vent from the chilled water loop
a-5) Check of water leakages in chilled water loop
a-6) Check of control for chilled water system
a-7) Check of water circulating condition
Insulation resistance of chilled water pump
meg ohm
Amperage of chilled water pump
A
Suction pressure of chilled water pump
KPa / psi
Discharge pressure of chilled water pump
KPa / psi
a-8) Independent trial run of chilled water system
b) Cooling water system
b-1) Check of valve open/close conditions in cooling water loop
b-2) Cleaning of strainers in the cooling water loop with cooling tower
b-3) Water filling into the chilled water loop
(New water should be filled into the cooling water loop)
b-4) Performing air vent from the cooling water loop
b-5) Check of water leakages in cooling water loop
b-6) Check of control for cooling water system with temp. control
b-7) Check of water circulating condition
Insulation resistance of cooling water pump
meg ohm
Amperage of cooling water pump
A
Suction pressure of cooling water pump
KPa / psi
Discharge pressure of cooling water pump
KPa / psi
b-8) Independent trial run of cooling water system
c) Total trial run of chilled and cooling water systems
179
Yes
d) Stream and drain system
No
N/A
d-1) Check of valve open/close conditions in steam line
d-2) Cleaning of strainers in the steam line
d-3) Performing steam control valve
d-4) Check of steam leakages in steam line
d-5) Check of valve open/close conditions in steam drain line
d-6) Check of steam drain leakages in steam drain line
e) Check damages on the control panel, mounted parts, etc.
f) Check of insulation resistance of pumps (More than 10 meg ohm)
f-1) #1 absorbent pump
meg ohm
f-2) #2 absorbent pump
meg ohm
f-3) Refrigerant pump
meg ohm
f-4) Purge pump
meg ohm
g) Check of purge pump and purging
g-1) No-water in the liquid trap
g-2) Oil quality (oil color shall be clean)
g-3) Oil quantity (up to the center of purge pump sight glass)
g-4) No abnormal noise
g-5) Attained vacuum (attained vacuum shall be less than 0.5 kPa abs.)
g-6) Purging from the lower shell
Perform purging from both the purge tank (V2) and the lower shell (V3) until the inside vacuum goes
down below the allowable vacuum curve (Refer to page 133).
180
7-3. End of cooling season
At the end of cooling season, the following inspections and maintenances should be conducted to avoid
troubles during shutdown of Chiller.
At the last cooling operation of the season, perform the refrigerant blow down.
Then proceed the following inspections and maintenances.
Yes
a) Chilled water system
No
N/A
a-1) Close shut-off valve provided at the inlet & outlet of Chiller
a-2) Drain out chilled water used during cooling season from Chiller
a-3) If necessary, conduct evaporator tube cleaning
a-4) Fill the evaporator with new clean water
a-5) Inspect & maintain chilled water system if necessary
b) Cooling water system
b-1) Drain out cooling water used during cooling season from Chiller
b-2) If necessary, conduct absorber & condenser tube cleaning
b-3) Close shut-off valve provided at the inlet & outlet of Chiller/heater
b-4) Fill the absorber & condenser with new clean water
b-5) Inspect & maintain cooling water system if necessary
c) Check of insulation resistance of pumps (More than 10 meg ohm)
c-1) #1 absorbent pump
meg ohm
c-2) #2 absorbent pump
meg ohm
c-3) Refrigerant pump
meg ohm
c-4) Purge pump
meg ohm
d) Check of purge pump and purging
d-1) No-water in the liquid trap
d-2) Oil quality (oil color shall be clean)
d-3) Oil quantity (up to the center of purge pump sight glass)
d-4) No abnormal noise
d-5) Attained vacuum (attained vacuum shall be less than 0.5 kPa abs.)
d-6) Purging from the lower shell
Perform purging from both the purge tank (V2) and the lower shell (V3) until the inside vacuum goes
down below the allowable vacuum curve (Refer to page 133).
e) Bubble test (Refer to page 132)
:
cc
Second measuring value:
cc
Third measuring value
:
cc
Average value
:
cc
First measuring value
NG
Judgmen
Goo
d
Perform leak test and repair
the leakage
Chiller can go into the
commercial operation.
f) Sampling absorbent for analyses (Refer to page 123)
g) Absorbent analyses (Refer to page 106)
h) Adjusting inhibitor content and alkalinity (if necessary) (Refer to106)
181
7-4. Operation of Chiller
This section describes the following operation procedures of Chiller.
a) Start & Stop procedures
b) Re-start procedure at safety shutdown
c) Re-start procedure after power failure
d) Purging procedure
a) Start & Stop procedure of Chiller
Refer to "4-2. Operation sequence"
Remark
The power shall be basically supplied continuously to the control circuit of Chiller by means of turning
on the main circuit breakers (MCBM & MCB3) and the circuit protections (CP1 & CP2) to prevent
that life of the palladium cell heater is shortened by frequent ON & OFF of the power supply.
When the power is turned on again after the power supply is turned off due to a reason,
the following indication is displayed on the operation board.
V E r 0. 9 7
2 5. 0
This indication means the version number of the microprocessor provided in Chiller
controller. And the indication is lighting up during completion of the self-diagnostic
function of the microprocessor.
(The version number differs depending on each unit type.)
: H.T.Generator temperature
b) Re-start procedure at safety shutdown
If Chiller stops by an alarm, restart Chiller by the following steps after eliminating its cause.
An alarm happens
Its alarm code is displayed on the operation board and the alarm buzzer sounds
Dilution operation
Alarm buzzer stops
Chiller stops completely
Press "BUZZER STOP key on the
operation board
Locate a cause of the alarm, then
eliminate it.
In case of following alarms, manual reset of safety devices is necessary
J-04 : #1 absorbent pump alarm --- Reset button on overcurrent relay
J-02 : #2 absorbent pump alarm --- Reset button on overcurrent relay
J-10 : Refrigerant pump alarm --- Reset button on overcurrent relay
J-14 : Generator high pressure alarm --- Gene. pressure reset button
The alarm code disappears
Press "STOP" key on the operation
board
Restart can be done
182
c) Re-start procedure after power failure
c-1) If power failure occurs during operation of Chiller,
restart Chiller by the following steps after resuming the power.
Power failure occurs
Chiller is shutdown immediately without dilution operation
The power resumes.
The alarm code "H-10" is shown in the operation board.
Local operation
Remote operation
No-voltage pulse signal
or
DC/AC 24V pulse signal
Press "RUN" key
No-voltage continuous signal
or
DC/AC 24V continuous signal
Send the start signal
H-10 goes off
Chiller restarts
d) Re-starting method depending on the period of power failure
At power failure, Chiller stops immediately without dilution operation.
Therefore, re-starting method differs depending on the period of power failure as follows.
d-1) In case that the power resumes within approximate 1 hour
Chiller can be restarted and then confirm that the chilled water outlet temperature goes down
and goes into the control mode.
If the chilled water outlet temperature does not go down, crystallization may occur at the concentrated
solution side in the low temperature heat exchanger.
Perform de-crystallization then restart Chiller.
d-2) In case that the power resumes more than 1 hour
Chiller is restarted with blow 50% fuel input and confirm that the concentrated solution outlet pipe
of the low temperature heat exchanger warms and the becomes hot.
If so, Chiller can be operated with 100% fuel input.
If not, crystallization may occur at the concentrated solution side in the low temperature heat exchanger.
Perform de-crystallization then restart Chiller.
d-3) During purging
If power failure occurs during purging, close the manual purge valve (V1) immediately and then run
Chiller with purging at least 1 hour after resuming the power.
If air may go into Chiller, stop Chiller/heater.
After resuming the power, conduct purging until the inside pressure goes down blow allowable vacuum.
Then start Chiller with purging at least 1 hour.
183
7-5. Purging procedure
When the purge indication lamp on the control panel lights up, perform purging from the purge tank by
means of the following steps.
Procedure
Turn on the purge pump ON/OFF switch.
SV9
69
PR
PCH
Purge tank
V3
Open V1 and V2 after 10 minutes.
V2
Purge
The purge pump runs.
B valve
Press
key once
Non-condensable gas coming
from
l
h ll tDiluted solution
it
coming from
The purge tank pressure is displayed.
(data code 17)
#1 absorbent pump to purge
Confirm that the indicated value goes down.
69
PR
SV9
PCH
Purge tank
Close V1 and V2.
Continue the running purge pump
more for 10 minutes to release
moisture from the purge pump oil.
Turn off the purge pump
ON/OFF switch.
The purge pump stops.
1
2
3
4
5
6
7
8
9
V2
V3
Attained
vacuum of the purge
pump is less than
0.5 kPa abs.
No
SV2
Purge unit
Yes
Continue the running purge pump
more for 10 minutes.
No
Non-condensable gas
The purge indication
lamp goes off If the indicated
value goes down below
7 kPa.
B valve
B valve shall
be opened.
SV1
V1
Liquid trap
Yes
Leakage of the
palladium cell
and/or 69PR may
be suspected.
Purge
pump
Diluted
solution
returns to
Fig. 7-1 Purge unit (cooling mode)
There are 2 choices.
1.Replacement of them
2.Leak test + Replacement
of leakage device
Replacement
Close V1 & V2, and stop the purge pump.
Close B valve.
Open SV9 (N2 charging is better).
Replace the leaked device (s).
Connect SV9 & SV1 by a vacuum hose.
Run the purge pump and open V1 & SV1.
Conduct purging for approximately 10 min..
Close SV9, SV1 and V1.
Stop the purge pump and remove the hose.
Perform maintenance of the purge pump.
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7-6. Daily maintenance
Proper maintenance of Chiller will insure continuous, efficient, and trouble-free operation prolonging
equipment life and reduce service requirements.
Daily maintenance should be performed by user's maintenance personnel.
Maintenance of auxiliary equipment is equally important and shout be handled according to the
manufacturers specifications.
Seasonal or periodical inspection work should be performed by qualified service personnel.
(1) Daily maintenance points
a) Check and recorded operating data per daily operating record sheet, temperature, pressure, etc.
b) From daily data, check if there are any sudden change on the data.
For example;
b-1) Shortening lighting interval of the purge indication lamp : Leakage and palladium cell failure
b-2) Rising diluted solution temperature : Crystallization
b-3) Rising or falling cooling water inlet temperature : Malfunction of cooling water temperature
control
b-4) etc.
c) Check for leaks in steam piping
d) Abnormal noise from #1 & #2 absorbent pumps
e) Abnormal noise form refrigerant pump
f) There are not any hammering noise from Chiller and chilled & cooling water loop
g) Auxiliary equipment is in proper working order.
h) Cooling tower water is being treated properly.
185
(2) Daily operating data sheet
Date :
Chiller model :
Serial No.:
Data points
Main menu
Non H.T.Generator temp.
Time
Chiller operation hours
hours
2
#1 Abso. pump operation hours
hours
3
#2 Abso. pump operation hours
hours
5
Refr. pump operation hours
hours
6
Purge pump operation hours
hours
7
ON/OFF times of Chiller
times
8
ON/OFF times of #1 Abso. pump
times
9
ON/OFF times of #2 Abso. pump
times
B
ON/OFF times of Refr. pump
times
C
ON/OFF times of Purge pump
times
12 Chilled water inlet temp.
deg.C
13 Chilled water outlet temp.
deg.C
14 Cooling water inlet temp.
deg.C
15 Condensed refrigerant temp.
deg.C
16 Steam drain temp.
deg.C
17 Purge tank pressure
kPa
18 L.T.Generator temp.
deg.C
19 Cooling water mid temp.
deg.C
20 Cooling water outlet temp.
deg.C
22 Refrigerant temp.
deg.C
23 Diluted sol. temp. at ABS outlet
deg.C
Inverter frequency
%
28 Concentrated solution concentrati
%
33 Low temp. heat exchanger outlet
Evaporator
Solution level Absorber
H.T.Generator
Operator :
:
:
:
:
:
:
%
25 Control valve opening output
29 Diluted solution concentration
/
deg.C
1
24
:
/
%
deg.C
n/60
n/60
n/60
Chilled water inlet pressure
kPa
Chilled water outlet pressure
kPa
Cooling water inlet pressure
kPa
Cooling water outlet pressure
kPa
Steam consumption rate
Notes:
186
7-7. Procedure for a long term shut-down
(1) Definition of a long-term shut down period: More than six months
In case of Chiller using for cooling only, usual shut down period is a half year, six months.
(2) Measure for a long-term shut down period
a) Chiller
a-1) Basically nitrogen gas (0.02MPa) shall be charged.
a-2) Instead of nitrogen charge, monthly purging from the main shell for at least 30 minutes to 1 hours
can be acceptable.
b) Chilled water loop
b-1) Basically, it is necessary to dispose all the water after the last operation and fill the evaporator
tubes with fresh water.
b-2) It is not necessary to fill the water fully to the whole chilled water loop.
Chiller only can be filled with water by means that the shutoff valves installed near the inlet
and outlet of the evaporator are closed completely.
b-3) Addition of anticorrosive is recommended. Consultation by a specialized agent is recommended.
In order to do this work, special knowledge and skill such as proper management of anticorrosive,
heat transfer tube cleaning, etc. must be required.
b-4) In case of use of brine for whole chilled water loop, contact a specialized supplier too.
c) cooling water loop
c-1) Basically, it is necessary to dispose all the water after the last operation and fill the absorber
and the condenser tubes with fresh water.
c-2) It is not necessary to fill the water fully to the whole chilled water loop.
Chiller/heater only can be filled with water by means that the shutoff valves installed near the
inlet of the absorber and outlet of the condenser are closed completely.
c-3) Addition of anticorrosive is recommended. Consultation by a specialized agent is recommended.
In order to do this work, special knowledge and skill such as proper management of anticorrosive,
heat transfer tube cleaning, etc. must be required.
c-4) In case of use of brine for whole chilled water loop, contact a specialized supplier too.
186
d) Dry lay up
If dry lay up is required for chilled water loop and/or cooling water loop,
be user to consult a specialized agent.
Because, in this case, chemical treatment to make anticorrosive film inside all transfer tubes
and the tubes must be dried completely after the treatment.
Basic procedure for the dry lay up
Discharge water used in operation
Chemical tube cleaning and/or Brush tube cleaning
Chemical treatment to make anticorrosive film inside tubes
Discharge water using for chemical treatment
Dry up tubes by dry air
e) #1 & #2 absorbents and refrigerant pump
It is not necessary to operate.
f) Palladium cell heater
During shut down period, a power supply shall be OFF continuously.
(3) In the case of less than six months
a) Chiller
Conduct monthly purging from the main shell for 30 minutes to 1 hour.
b) Chilled water loop / cooling water loop
Flow chilled water and cooling water once a week for around 1 hour for equalization of a state
of water in heat transfer tubes. Also check each water quality once a month.
If water quality is out of the standard value, it is necessary to contact a specialized agent for
management of water quality by such as injection of chemical, blow-down, to secure water quality.
c) #1 & #2 absorbents and refrigerant pump
It is not necessary to operate.
d) Palladium cell heater
During shut down period, a power supply shall be OFF continuously.
Remarks:
Frequent ON/OFF of the palladium cell heater will shorten the life of palladium call due to
repetition thermal stress.
This will cause crack on the palladium cell and infusion of the air to the chiller.
187