Manual 20381704
Mcovey SANYO
Operation and
Maintenance Data
Bulletin No. OM 111
March, 1993
Form No. 573439Y
Absorption Chiller/Heater
DC-H Model
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NOTES TO USERS
. Before operating this chiller/heater, you should first thoroughly
read this manual.
You may not understand all of the explamations for operation when
you firstly read this booklet, however, please strictly follow the
directions as shown hereinafter.
. DO NOT STORE OR USE GASOLNE, THNNER OR OTHER FLAMMABLE VAPORS,
LIQUDS AND MATERIALS N THE VICNTY OF CHLLER/HEATER AND CHMNEY.
Е ОП IS STORED OR USED, IT WLL HAPPEN TO EXPLODE OR FRE
. Be sure not to leak the air into the chiller/heater at any cases.
(Take care when you handle the manual purge valves and service
valves.)
. Perform sufficient ventilation in the machine room.
Required fresh air rate for combustion;
Approximately 1.2 m®*/h (43 ft*/h) per fuel consumption of
1,000 kcal/h (4,000 But/h).
. If you smell gas in the machine room, stop the chiller/heater
immediately and close the main gas cock, then advise the situation
to our agency as som as possible.
When you could find aut the leak point you may temporarily rectify
it.
not tun off the main supply power to the chiller/heater.
turn off the breaker, purge unit of the chiller/heater does not
rk.
ово
. Keep the operation of chilled water pump(s) and air handling unit(s)
even when chiller/heater runs into dilution cycle operation, to
avoid damage of the chiller/heater caused by over cooling or any
other unusual situation.
(Diluted cycle operation : When the chiller/heater is stopped under
normal operation or at emergency, the chiller/heater continues its
working until the density of the absorbent comes to a specified
value
. Before operating the chiller/heater on the beginning of cooling or
heating season, it shall be assured that the cooling/ heating change
over procedure in accordance with Section 3.3 has been made.
. Specifications and equipment may be changed as required by the
manufacture without any notice and obligation to the users.
814-6-0502-450-01
OPERATION MANUAL
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CONTENTS
Page No
NOTES TO USERS----------—--—————-======eee een oooeeronee eee nes
CONTENTS ------<-=-"======"=<=<"<0<cece esse eee a eo il
GENERAL DESCRIPTION -----------------------------"""--0eeeeeeeeee ee een 1
THE PRINCIPLE OF ABSORPTION -----------------------------------—"--- 9
COOLING/HEATING CYCLE DESCRIPTION ------------------------------- 20
CHILLER/HEATER ILLUSTRATION ------------ ZA ec ec ec nee 25
SAFETY DEVICES ----————- moon nen er nn 37
OPERATION o-oo mmm meme eee eee een sen nn 39
OPERATION BOARD ----------------------------------------.-0-000eeeeesese 40
TEMPERATURE SETTING ------------m-esmmmmmmmmmmmmmm cmc como anne 43
SELF -DIAGNOSTICS FUNCTION —--------——-——————————————=========eeeecee— ol
PREPARATION FOR START UP-----------------=---====-===r=croncncneoeee- 54
OPERATION o-oo mms eee 58
МАШМИЕМА№СЕ ----------------тттеотеечеоночлеееотеотетеототтттеттоотоототоотоото 71
DAILY MAINTENANCE --------------------=--=c=ceenonceneenereoneecen ee 79
SEASONAL MAINTENANCE -----------------------------------....00000000 00e 74
COOLING/HEATING CHANGE OVER --------------------=--=-==========e.— 79
WATER TREATMENT een rn nn 82
MAINTENANCE FOR INVERTER ---------------=--===========0=0e0reeeeee 86
PARTS INSPECTION ---------mmmmmmmmmsmm mmm moomoo ee 89
TROUBLE” SHOOTING --------------------=============0eeeeneeeo recono 91
ALARM INDICATION LAMP ----------------------------------------.-20000000. 92
POWER FAIRE -----------------------=-=eeeeoeeoreooroeoo eee neon en 94
ALARM IN THE COOLING OPERATION-----------------------——-———— 95
ALARM IN THE HEATING OPERATION:---------------=--=-=-=-----=-———- 98
ALARM TIME CHART------------------------""--<"<"<0000eecceec eee cesse nes 101
SECTION |
CONTENTS
Page No
SECTION 1 GENERAL DESCRIPTION === 1
1.1 THE PRINCIPLE OF ABSORPTION ---—-—---------- eae. 2
(1) WHY DOES A HEATING CHILL ? === ees 2
(2) THE PRINCIPLE OF ABSORPTION ----------------—--——-———=— 4
(3) SINGLE EFFECT TYPE (BASIC CYCLE) --------—-——————e———===———" 7
(4) DOUBLE EFFECT TYPE === sense seen. 8
(5) COOLING WATER ---------------------<---<<000ceccececee ces cesse Sense 9
(6) VACUUM --------------------="""=="0000000cecececeeceseececes SC SS nes 10
(7) LITHUM BROMIDE (LiBr : ABSORBENT) --------------------- Meno 11
(8) COOLING CYCLE -------------====-=eeecreeeeeeeeeeenreooe reee 16
(9) HEATING CYCLE --------------------===e0eeeeeeoeeaeooo enero case 19
1.2 COOLING/HEATING CYCLE DESCRIPTION -—--------------————e———=e=e===——- 20
(1) COOLING CYCLE +++ ernennen een kenn nenne Eee nn Een EEE EEE HET een 20
(2) HEATING CYCLE --------------------<---<<...<<cecececececeec cesse 24
1.3 CHILLER/HEATER ILLUSTRATION -----------------------==-eenereeooeeoo— 25
(1) ILLUSTRATION 3 -------------"""----—-—--<"====<<-<<<00ccececeeceeeeese esse 25
(2) DETAIT OF TYPICAL CHILLER/HEATER (FRONT VIEW) ------- 26
(3) DETAIT OF TYPICAL CHILLER/HEATER(REAR VIEW) ----------- 27
(4) DETAIT OF TYPICAL CHILLER/HEATER(RIGHT VIEW) ------- 28
(5) DETAIT OF TYPICAL CHILLER/HEATER(LEFT VIEW) ----------- 29
(6) TYPICAL CONTROL PANEL ------------------------------"--- 30
(7) TYPICAL BURNER, GAS TRAIN AND B. CONT PANEL ----------- 32
(8) SYMBOL --------=-=—-——=——n—or=eoeeeenos ie arancaananen nan enancana nao noeeane— 34
1.4 SAFETY DEVICES -----------------""=="=="==<00000eccceeeeee eee scans nera 37
(1) CHILLED WATER, HOT WATER AND COOLING WATER ------------ 37
(2) HIGH TEMPERATURE GENERATOR ----------------------.............. 37
(3) BURNER -----------------""-0000000cceeece ess eee seen sense es ec ess eee 38
(4) MOTOR -----------------------"2000000ee etes eee eo eeea ea aa aa no ooo 38
(5) OTHERS -------————--————e=eooroorooeooooo eo reee eea reee es een een 38
1.1 THE PRINCIPLE OF ABSORPTION
(1) WHY DOES A HEATING CHILL ?
The cooling means keeping the room temperature lower than outside temperature. AS
shown Fig.1-1. operate to carry the heat from the room with a lower temperature (28°C ,
82°F) to the open air with a higher temperature is required. But, in the nature, the
heat can not move from a low temperature side to a high temperature side. So. to
transmit the heat as opposed to this law (principle), some way (apparatus) is
Necessary. That is, a heat pump (chiller) is used to pump out the heat from a low
temperature one as if a water pump is used to draw up the water from a deep well.
OUTSIDE 32 *C (90 °F)
TO THE ATMOSPHERE
16 °C (61 °F)
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Y (64°F) 32 °C
(50 °F)
OPEN AIR COOLING TOWER
(82 °F) (90 “F)
COOLING LOAD AIR CONDITIONER m) HEAT FLOW
T =
FIG. 1-1 HEAT FLOW
The typical chiller using an electric as a operation power Source as a conveyer to
ay the heat in Fig.l-2 is an electric turbo chiller and the typical chiller using a
heat energy is an absorption chiller.
Chilled water is made by using the latent heat released by a liquid as it evaporates.
We can find this principle through our experience in a daily life. For example, when
having an injection. after applying as alcohol for disinfection on the arm, we feel
the part of arm cool. Because, the alcohol is heated by body s temperature, took the
heat from the arm when it evaporates. And another example is that we feel cool when
we sweat in a hot day or by taking exercise. Because, the body temperature is
automatically controlled by the evaporation of sweat which takes the heat from the
body. A chiller also uses an latent heat of evaporation. But in a chiller, it is
necessary to return to liquid for using vaporized liquid. For this purpose, the
compressor is used in an electric turbo chiller and an absorbent is used in an
absorption chiller.
The absorbent decreases the absorption power when it becomes diluted solution by
absorbing the vaporized solution. To recover the absorption power, the heating and
concentrating process of the absorbent is required. AS heat source, it is used by
natural gas, steam or hot water.
LOWER TEMPERATURE SIDE e . ©
(COOLING) ‚ @ =)
HIGHER TEMPERATURE SIDE
INDOOR .. OUTDOOR
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FIG.1-2 HEAT FLOW AT COOLING
(2) THE PRINCIPLE OF ABSORPTION
Install heat transfer tubes in a closed vessel and put a dry silicagel (Silicagel is
high quality absorbent material) in it as shown Fig.l-3. Take out an air in the
vessel to make a vacuum with the pressure of approx. 6.5mmHg (1/4 inchHg). Drops of
water are allowed to fall on the heat transfer tubes (Evaporator). The water in the
vacuum vessel evaporates at 5°C (41°F). The water takes an evaporation heat from the
water in the heat transfer tubes, when it become vapor. (Such liquid is called a
refrigerant and shown as a refrigerant liquid or a refrigerant vapor for the
following.) As this evaporated refrigerant vapor is absorbed immediately by a
silicagel, a vacuum is kept inside the vessel. On the other hand, the water in the
heat transfer tubes becomes chilled because the heat equivalent to the evaporation
heat is taken. But, when the silicagel reaches the limit of absorption, it is
impossible to keep a vacuum in the vessel and chilled water can not be obtained.
WATER
(REFRIGERANT) OSED
J VESSEL
VACUUM
CHILLED Ds, a
WATER ©
Y ¢
WATER >
DRY
| TRANSFER SILICAGEL
TUBE
FIG. 1-3
Therefore, replacing a silicagel as an absorbent in the vessel with new one at all
times permits to get chilled water continuously. For this purpose, instead of the
solid absorbent such as a silicagel, a liquid absorbent such as easy-to-handle lithium
bromide (LiBr) solution, etc. is used. (Such liquid is called an absorbent.) This
case is shown Fig.1-4.
REF = GERANT VAPOR
CONCENTRATED
SOLUTION
WATER ee = DRIVING
(REFRIGERANT) a HEAT
4 @ SOUCE
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CHILLED De, a
WATER © 6 8
Ss 0
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WATER =
ф
TRANSFER
UB PUMP Lo
ILUTED
SOLUTION
Drops of the LiBr solution are allowed to fall (Absorber) inside the vessel. The LiBr
solution absorbs refrigerant vapor. But, when the absorbent once absorbs the
refrigerant vapor, it is diluted and decreases ability to absorb. Resulting in the
chilled water can not be obtained. This means that concentrated solution must be fed
in continuously. At this stage, the diluted solution is heated by driving heat
source (natural gas. steam or hot water:Generator). The heat causes the solution to
release the absorbed refrigerant and also reconcentrates the solution.
The refrigerant vapor which is released from the solution when heated, is cooled in ‘a
separate vessel (Condenser) to become liquid refrigerant. Drops of this water are
again introduced into the vacuum vessel and recycled. This is shown Fig.1-5.
S =
COOLING 7 8
WATER ~~
= DRIVING
HEAT
2 SOUCE
FIG. 1-5
(3) SINGLE EFFECT TYPE (BASIC CYCLE)
As shown Fig.1-6. this is the basic operational cycle of the single effect type
absorption chiller. Part D shows a generator, part © shows a condenser, part Q
shows an evaporator and part @ shows an absorber.
Cooling water flows through an absorber and a condenser. The cooling water in the
condenser cools the refrigerant vapor from the generator back into refrigerant. The
cooling water in the absorber absorbs the heat when the refrigerant vapor is absorbed
by the absorbent. |
The generator (D heats the diluted solution by driving heat source. The diluted
solution releases the refrigerant vapor and becomes the concentrated solution.
At the condenser @ . the refrigerant vapor which came from the generator condensed by
cooling water.
The condensed refrigerant drops on the heat transfer tubes of evaporator O). Drops
of the refrigerant evaporate on the tubes. The water through the heat transfer tubes
of evaporator is cooled by the latent heat of vaporized refrigerant.
The refrigerant vapor is absorbed on the heat transfer tubes @ by absorbent from the
generator. The absorbent diluted by refrigerant vapor goes to the generator.
oe ON. \ от
COOLING | { = - , .
WATER TIA = DRIVING
ZX HEAT
«В SOUCE
CHILLED ©
WATER ©
COOLING
WATER
WATER =
«<7zZZA| > IUT TETE UI
PUMP
FIG. 1-6
(4) DOUBLE EFFECT TYPE
In case of the single effect type absorption chiller mentioned above, all condensation
heat when the refrigerant vapor coming from generator is cooled and condensed at the
condenser, is released in the cooling water.
The dable effect type absorption chiller is used the condensation heat effectively.
The generator section is divided into a high temperature generator and a low
temperature generator. The refrigerant vapor produced by the high temperature
generator is used to heat the LiBr solution in the low temperature generator in which
the pressure (hence the boiling point) is lower.
As mentioned in the single effect type, the refrigerant vapor produced by the low
temperature generator is sent to the condenser to become liquid refrigerant. On the
other hand, the refrigerant vapor produced by the high temperature generator turns to
water as it released heat to the intermediate LiBr solution. This occurs inside the
heat transfer tubes in the lôw temperature generator. The refrigerant vapor produced
by both low and high temperature generators turns to liquid refrigerant and mixes in
the condenser before returning to the evaporator.
In this step, the diluted solution is heated by driving heat source-and by the latent
heat in the refrigerant vapor which otherwise would be released into the cooling
water. This combination means a lower energy cmamption of driving heat source.
Moreover, less heat being discarded into the cooling water translates into a small
cooling tower. As shown Fig.1-7.
LOW TEMPERATURE
> GENERATOR >
REFRIGERANT VAPOR
—.
(5) COOLING WATER
a)
b)
с)
9)
Cooling water flows through an absorber and a condenser.
The cooling water takes the heat which the LiBr solution absorbs the refrigerant vapor
at absorber. This means the absorbent is cooled by cooling water.
The refrigerant vapor from the generator is cooled by cooling water.
The lower temperature of cooling water
The absorption power of LiBr solution is strong at the lower temperature of the
cooling water. When the temperature of cooling water in the condenser is low,
condensed temperature of refrigerant downs. Therefore condensed pressure becomes
low. As the boiling temperature (generator temperature) of the LiBr solution downs
when the condensed pressure is low, calolific value of driving heat source can
decrease. This means save energy.
lt is not acceptable that the temperature of cooling water is too low.
As shown Fig.1-8, a few LiBr dissolves with water at low temperature. That is, the
LiBr solution of high concentration becomes crystallization under the lower
temperature. For example, it is crystallized with concentration of 65% at the
temperature lower than 42°C (108°F), with concentration of 60% at the temperature
lower than 17°C (63°F).
Chiller has some problems when cooling water temperature becomes too high
When the temperature of the cooling water becomes high, the absorption power of the
LiBr solution decreases. The chiller can not get the normal chilled water
temperature and wastes much fuel. Therefore, to prevent this, the maintenance for
cooling water system (equipment and control) and water treatment are required.
Vater treatment of cooling water
The. water treatment of the cooling water is an important factor for the chiller. If
the water quality is no good, scale adheres to the inside of the heat transfer tubes,
resulting in the decreases transfer heat effect and waste fuel. As the heat transfer
tubes may become corroded, it is required to fully take care of the water treatment.
(6) VACUUM
On the earth, we are pressed by the air. This pressure is called atmospheric
pressure (1 kg/cm?, 14.2psi). The pressure less than atmospheric pressure is called
the vacuum. When explaining the vacnm for the absorption chiller, it is required to
know the relation between the presse and the evaroration temperature о the water.
It is experienced in a daily life that the water is boiled (evaporated) at 100°C
(212°F) in the atmospheric pressure. When the pressure is lower than the atmospheric
pressure (vacuum), the water boiled below 100°C (210°F). Table 1-1 shows the relation
between the pressure and the evaporation temperature.
The water is evaporated at lower temperature, when the pressure is lower and lower.
Therefore, the inside the chiller should be always kept in high vacuum. Since the
refrigerant is evaporated at 5°C (41°F) to get the chilled water of 7°C (45°F) by an
absorption chiller, it is required to keep a high-vacam condition with pressure of
6.54mmHg(1/4 inchHg) in the evaporator.
Table 1-1
Gauge Absolute
pressure pressure
ke/cn*G naHg
(psig) (inchHe)
10 (142)
8 (114) Driving pressure for double effect type
Atmospheric 5 (71) |
pressure 1 (14.2) Driving pressure for single effect type
1 0.5 (7.2)
1 atm. 0 (0) 760(29.9) Atmospheric pressure
$ 525.9 (20-3/4)
Vacuum 61.0 ( 2-3/8) | Pressure in the condenser |
9.2 ( 3/8)
6.54( 1/4) | Pressure in the evaporator
(7) LITHIUM BROMIDE (LiBr : ABSORBENT)
Lithium bromide (LiBr) is a medicine made from lithium obtained from lithium ore and
bromide obtained from the sea water. The lithium bromide has the same characteristic
with sodium chloride (NaCl). Because lithium (Li) and sodium (Na) are alkali while
bromide (Br) and chlorine (Cl) are halogen. The sodium chloride (NeCl) is salt. It
is well known that when salt is left in a high-humidity atmosphere, it becomes sticky.
This means it absorbs moisture in the atmosphere. The lithium bromide has the same
characteristics and its absorption power is stronger than that of salt. The higher
its concentration and the lower its temperature of liquid, the stronger the absorption
power.
Fig.1-8 shows the lithium bromide equilibrium diagram.
Fig.1-9 shows the lithium bromide concentration diagram.
Fig.1-10 shows the lithium bromide Dihring diagram. This chart is convenient to show
the condition of the cooling cycle of lithium bromide solution.
Fig.1-11 shows the lithium bromide enthalpy diagram.
Lithium bromide has corrosive action to a metal under existing oxygen. But, as the
absorption chiller is. a vacuum vessel, almost no oxygen is in a vessel, However, to
make more complete, corrosion inhibitor is added in the absorbent and further
alkalinity is adjusted. So, attention should be taken to handle the absorbent and it
is necessary to keep the amount of inhibitor by performing the chemical analysis for
the absorbent.
Chemical formula : LiBr
Molecular weight : 86.856
Component : Li= 7.89%
Br=92.01%
Specific gravity : 3.464 at 25°C (77°F)
Melting point : 549°C (1,020.2°F)
Boiling point : 1,265°C (2,309 °Е)
TEMPERATURE
(°F) (*C)
212 — 100
200 —
175} 80
150 — LIBR-H20
60
(00 |— 40
os LIBR-2K20,
20 y
50 +—
32 — O
ICE
° 20 N
-25|— \ LIBR-3H20
-40|— -40 -
-50 F—
LIBR-5H20
- 75 -60 \/
-100 }—
-112'— -80
O 10 20 30 40 50 60
CONCENTRATION (%)
FIG.1-8 LIBR EQILIBRIUM DIAGRAM
70
SPECIFIC GRAVITY
TEMPERATURE
32 50 75 100 125 150 175 200 212(°F)
I | | | | ! | ]
10 20 30 40 50 60 70 80 90 100(*C)
О
1.90
1.80 a
|
. — — | О |
1.45 — — + 48
+ 47
0 10 20 30 40 50 60 70 80 90 100(*C)
Lo | | | | | | | }
32 50 75 100 125 150 175 200 212(°F)
TEMPERATURE
FIG. 1-9 CONCENTRATION DIAGRAM
CONCENTRATION (%)
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FIG.1-11 ENTHALPY DIAGRAM
(8) COOLING CYCLE
a)
An example for the actual driving cycle of double effect type is explained using the
Dihring diagram.
A = B shows the absorption process in the absorber. The absorbent with concen-
tration of 63.6% at point A absorbs the refrigerant vapor from the evaporator as it is
cooled until 36.3°C (97.3°F) by cooling water, then becomes diluted solution with
concentration of 58.1% at point B. —. |
The pressure of this point is 6.3mmHg(torr) which is equal to the saturation vapor
pressure of water at 4.3°C (39.7°F) (cross point on the saturation liquid line), so.
the chilled water at 7°C (44.6°F) can be produced in the evaporator.
Therefore, the higher the temperature of the cooling water, the higher the absorber
internal pressure (equal to the evaporator internal pressure). As a result, the
evaporation temperature of refrigerant becomes high and chilled water can not be
obtained.
b) B= C = D' shows the temperature rise process under the fixed concentration when
the diluted solution pass through the low and high temperature heat exchangers.
с) D' => D = E shows the heating and concentrating process in the high temperature
d)
generator. The diluted solution at point D’ is heated until point D. It releases
the refrigerant vapor and is concentrated. Then it becomes the intermediate
solution of 61.1% at point E and finishes the first stage of concentrating.
The pressure at point E becomes approx. 707.1mmHg(torr). (This pressure depends on
the pressure of 55.7mmHg(torr) in the condenser determining it according to the
temperature of cooling water. — That is, the pressure inside the low temperature
generator has to be performed at the temperature higher than 91.1°C (196°F) of the
concentrated solution obtained from the cross point with the concentrated solution
of 63.6%. When setting to 97.9°C (208.2 °F) by making thisas AT 6.8°C (12.2°F). the
pressure of the high temperature generator becomes 707.1 mmHg(torr).
E => F' shows the process of the heat exchanger with the diluted solution while the
absorbent concentrated in the high temperature generator passes through the heat
exchanger. In this process, it is sent to the low temperature generator as the
temperature is lowered at the fixed concentration.
e)
f)
g)
Е’ =» F «= (С shows the concentrating process in the low temperature generator. The
absorbent with 61.1% at point Е’ is heated by the refrigerant vapor from the high
temperature generator. As a result, the refrigerant vapor is generated, the
concentration rises, and it becomes the concentrated solution of 63.6%. Thus, the
second stage of the concentration is finished.
The pressure at point G is determined by the temperature of the cooling water. With
the condensation temperature of 40.2°C (104.4°F), the pressure is the saturated vapor
pressure of this temperature, 55.7mmHg(torr). |
C = A" shows the process of the heat exchaneer with the diluted solution while the
concentrated solution goes out from low temperature generator and passes through the
low temperature heat exchanger. In this process, the temperature is lower at the
fixed concentration.
A’ = A shows that the concentrated solution enters the absorber and is cooled by the
decrease of pressre and the cooling water, then starts to absorb the refrigerant
vapar from point A: this cycle is repeated again.
As described above, it can be understood that the cycle of the absorption . cooling
system depends on the temperature condition (partially determination element from the
taking out temperature of the chilled water).
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( 9)HEATING CYCLE
The diluted solution is heated in the high temperature generator. The refrigerant
vapor is released from absorbent.
The refrigerant vapor goes to hot water heater. The refrigerant vapor condenses on
the heat transfer tubes of hot water heater. The condensed refrigerant returens to
the high temperature generator through the refrigerant dran valve.
HOT WATER
HEATER
(C-....... HOT WATER
К = = + +
+ + "MO MT +
E + + & +
LOW TEMP,
GENERATOR
* a w+ о +
a ww & + |
Фе Фо о © o | + +
CHILLED WATER
(NO FLOW)
HIGH TEMP.
GENERATOR
COOLING WATER
(NO FLOW)
FIG. 1-13
1.2 COOLING/ HEATING CYCLE DESCRIPTION
( 1)COOLING CYCLE
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a) Evaporator
The refrigerant is dispersed on the heat transfer tubes of evaporator. Chilled water
through the heat transfer tubes of evaporator is cooled by the latent heat of
vaporized refrigerant.
b) Absorber
The concentrated solution is dispersed on the heat transfer tubes of absorber. The
refrigerant vapor from evaporator is absorbed on the heat transfer tubes of absorber
by absorbent. Cooling water through the heat transfer tubes of absorber is heated by
absorption heat.
APORATOR ; “ABSORBER
FIG. 1-15
c) Heat exchanger
The diluted solution from the absorber passes through the low temperature heat
exchangers, where it is heated by concentrated solution. The diluted solution after
leaving the low temperature heat exchanger passes through the high temperature heat
exchanger, where it is heated by intermediate solution. The diluted solution after
leaving the high temperature heat exchanger flows to the high temperature generator.
HIGH TEMP.
HEAT EXCHANGER
LOY TEMP,
HEAT EXCHANGER
FIG. 1-16
d) High temperature generator
The diluted solution from the heat exchangers is heated in the high temperature
generator. It releases the refrigerant vapor and is concentrated. It becomes
intermediate solution.
HIGH TEMP.
GENERATOR
FIG. 1-17
e) Low temperature generator
f)
The refrigerant vapor from the high temperature generator passes through the heat
transfer tubes of low temperature generator. The intermediate solution in the low
temperature generator is heated by the refrigerant vapor. It releases the
refrigerant vapor and is concentrated. It becomes concentrated solution. The
condensed refrigerant in the heat transfer tube of low temperature generator flows to
the condenser.
Condenser
The refrigerant vapor from the low temperature generator is condensed on the heat
transfer tubes of condenser. Cooling water from the absorber is heated by
condensation heat.
LOW TEMP.
GENERATOR
The refrigerant vapor condenses on the heat transfer tubes of hot water heater.
The condensed refrigerant returns to high temperature generaot thourgh control valve.
The vaporized refrigerant at the high temperature generator flows to hot water heater.
( 2)HEATING CYCLE
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FIT. 1-25 CONTROL PANEL
INDICATION LAMP
OPERATION BOARD
EMERGENCY
STOP SWITCH
CONTROL PANEL
VOLTAGE
HIGH
FIELD WIRING OPENING
CONTROL CIRCUIT
FIELD WIRING OPENING
Вы Pu Въ Pe ee
Въ Be Be be Въ a Вы Вы Вы Вы
CONTROL BOARD
VAN LLL TTL AN
CONTROL RELAY
FAN MOTOR
MODE SELECT SWITCH UNIT
POTENT IOMETER
FUSES
FUSE HOLDERS
TERMINAL BLOCK
CONTROL TRANSFORMER
POWER TRANSFORMER
INVERTER
REACTOR
CIRCUIT BREAKER
WIRE CHANNELS
NO. 1 ABSORBENT PUMP
MAGNETIC CONTACTOR
NO. 2 ABSORBENT PUMP
MAGNETIC CONTACTOR
REFRIGERANT PUMP
MAGNETIC CONTACTOR
PURGE PUMP
MAGNETIC CONTACTOR
CONTROL CIRCUIT
— TERMINAL BLOCKS
—— MOTOR TERMINAL BLOCK
HIGH VOLTAGE
FIELO WIRING TERMINAL BLOCK
INTERNAL WIRING
—
SN CONTROL CIRCUIT
INSIDE OF CONTROL PANEL
FIELD WIRING TERMINAL BLOCK
( 7) TYPICAL BURNER, GAS TRAIN AND BURNER CONTROL PANEL
ANIHOLD PRESSURE GAUGE
ODULATUIN MOTOR
BUTTERFLY VALVE
BURNER BLOWER
URNER
CONTROL
PANEL |
FIG. 1-27 TYPICAL BURNER
MANUAL GAS SHUTOFF VALVE MAIN SOLENOID VALVE
REGULATOR BUTTERFLY, VALVE
2ND SOLENO!D VALVE
Р16. 1-28 TYPICAL GAS TRAIN
BURNER
ON-OFF SWITCH
CALL FOR
(EAT LIGHT FUEL TRANFER SWITCH
IGNITION LAMP ANDALZAUTO —
SELECT SWITCH
E FIRING RATE
ALARM LAMP J
SHEEN в 4 @
ojojo
IKK:
re
N\A
\ BURNER CONTROLLER
(FLAME SAFEGUARD)
“AIR FLOW
` SAFETY SWITCH
TRANSFORMER
MAGNETIC CONTACTOR
OVERCURRENT RELAY
FIG. 1-29 BURNER CONTROL PANEL
( 8)SYMBOL
a) Chiller/heater construction
Symbol Name
EVA Evaporator
ABS Absorber
COND Condenser
HW HEAT Hot water heater
HT.GENE High temperature generator
LT.GENE | Low temperature generator
HT.EX High temperature heat exchanger
LT.EX Low temperature heat exchanger
#1 ABS PUMP | No.1 Absorbent pump
#2 ABS PUMP | No.2 Absorbent pump
REF PUMP | Refrigerant pump
b) Temperature sensor
Symbol Name Location
DT1 Chilled water outlet Chilled water outlet pipe
before flange.
DT2 Cooling water outlet Cooling water outlet pipe
before flange.
DT3 High temperature generator Back side of high temperature
| generator.
DT4 Low temperature generator Intermediate solution pipe of
LT.GENE outlet.
DTS Condenser Refrigerant pipe of condenser
outlet.
DT6 Chilled water inlet Chilled water inlet pipe
before flange
DT7 Cooling water outlet Cooling water inlet pipe
before flange.
DT8 Hot water outlet Hot water outlet pipe
before flange
DT9 Hot water inlet Hot water inlet pipe
before flange.
c) Sensor
d) Valve
Symbol Name Location
23CH Electronic controller Included operation board
26E Exhaust gas thermostat Flue pipe on the HT.GENE
El E2,E3,E4 | Generator solution level Solution level box beside the
electrod high temperature generator
33AL Generator solution level In the control panel
control board switch |
63GH Generator pressure switch Near the solution level box
69CH Chilled water flow switch Chilled water outlet pipe
PCH Palladium cell heater Top on the purge tank
Symbol Name Location
A valve Cooling/ heating change over Refrigerant drain pipe from
A valve low temp. generator
B valve Cooling/ heating change over Diluted solution pipe from
B valve outlet of HT heat exchanger
C valve Cooling/ heating change over Intermediate solution pipe
C valve from HT generator
D valve Cooling/ heating change over Diluted solution pipe to
D valve - refrigerant drain pipe
E valve Purge valve for HW.heater Biside the HW Heater
G valve | Cooling/heating change Under the HW Heater
G valve |
V1 No.l purge valve Beside the purge tank
V2 No.2 purge valve Beside the purge tank
V3 No.3 purge valve Beside the purge tank
V4 Refrigerant blow valve Evaporator side
e) Service valve
f) Damper -
g) Sight
Symbol Name Location
SV1 Service valve for maintenance | Beside the purge tank
SV2 Service valve for manometer Beside the purge tank
SV3 Service valve for refrigerant | On the refrigerant pipe
Sv4 Service valve for diluted Near the No.l absorbent pump
solution (Qutlet pipe of #1 ABS PUMP)
SVS Service valve for intermediate | Beside the high temperature
solution heat exchanger
SV6 Service valve for concentrated | Beside the low temperature
| solution heat exchanger
Sv7 Service valve for generator On the solution level box
pressure gauge
Sv8 Service valve for generator Bottom of the high temperature
maintenance generator
Svg9 Service valve for heat Beside of high temperature
exchanger maintenance heat exchanger's header
SV11 Service valve for palladium Top the purge tank
cell
SV12 Service vaive for hot water Beside of hot water heater
heater maintenance
Symbol Name Location
DI Damper for diluted solution Outlet pipe of #1 ARS PUMP
after check valve
D2 Damper for intermediate Intermediate solution pipe
solution between HT.EX and LT.GENE
D3 Damper for concentrated Concentrated solution pipe
solution between LT.GENE and LT.EX
glass
Symbol Name Location
Sal Sight glass for refrigerant | Evaporator
level
Saz Sight glass for generator Generator box
SG3 Sight glass for bummer flame | Behind the gererator
1.4 SAFETY DEVICES
(1) CHLLED WATER, HOT WATER AND COOLNG WATER
No Item Setting point Alarm indication
1 | Interlock of chilled water pump — Indication lamp
2 | Interlock of hot water pump Indication lamp
3 | Interlock of cooling water pump — Indication lamp
4 | Few flow rate of chilled water 50 % Indication lamp
5 | Chilled water freeze protection 2.5°C (36.5°F)| Indication lamp
(Low-amt of chilled water outlet temp.)
6 | High-cut of hot water outlet temperature | 70°C (158 °F) Indication lamp
7 | Low-cut of cooling water inlet temperature | 19°C (66.2°F)| Indication lamp
| after 30 mi.
(2) HIGH TEMPERATURE GENERATOR
No Item Setting point Alarm indication
8 | High-aut of generator temperature (Cooling) | 165°C (329 °F) Indication lamp
9 | High-aut of generator temperature (Heating) | 130°C (266 °F) Indication lamp
10| High-cut of generator pressure 0 kg/cm*G Indication lamp
11| High-cut of generator solution level Automatic reset
12| Low-cut of generator solution level ——— Indication lamp
13 | High-at of emaust gas temperature (Gas) | 300°C (572°F) | Indication lamp
14| High-cut of edaust gas temperature (Oil) | 350°C (662°F) Indication lamp
15| Crystallization protection 65% Indication lamp
(High-aut of solution concentration) after 10 min.
(3) BURNER
No Item Setting point Alarm indication
16 | Flame failure Indication lamp
17| Abnormal combustion Indication lamp of
flame failure
(4) MOTOR
No Item Setting point Alarm indication
18 | Overcurrent relay of No.l absorbent pump | Rated amperage | Indication lamp
19 | Overcurrent relay of No.2 absorbent pump | Rated amperage Indication lamp
20 | Overcurrent relay of refrigerant pump Rated amperage Indication lamp
21 | Overcurrent relay of burner blower Rated amperage Indication lamp
(5) OTHERS
No Item Setting point Alarm indication
22 | Inverter protection Indication lamp
23|Power interruption protection 100 m sec.
24 | Chattering protection of flow switch 3 sec. Indication lamp
25
Rupture disk
SECTION 2 OPERATION
CONTENTS
Page No
SECTION 2 OPERATION -----------------------<------""000000000cecece ces ec once ce en 39
2.1 OPERATION BOARD des 40
(1) DETAIL OF OPERATION BOARD ---------------------------------<-<"- 40
(2) INSTRUCTION OF KEYS -—--———-——————-—--===eeo eee 42
2.2 TEMPERATURE SETTING --------------------------"---"--"-""==0000meceeee en ee 43
(1) DETAIL OF MONITOR ----------------------------"000000 0000 sets esse 43
(2) SEQUENCE OF THE DIGITAL DISPLAY -----------------—--—————————- 44
(3) SETTING METHOD -----------------<-<-<<<<<<<<0ecececcececceeeeees nee 46
2.3 SELF-DIAGNOSTICS FUNCTION ----------------------------------"""""000000 51
(1) SELF-DIAGNOSTKS FUNCTION ----------------------------""""0000000000. 51
(2) ERROR MESSAGE BY SELF-DIAGNOSTICS------------=-------=--=----- 52
2.4 PREPARATION FOR START UP--------------——-———————————====e 54
(1) CONFIRMATION OF OPERATION SWITCHES тесен) 54
(2) CONFIRMATION OF SETTING POINTS ----------—-—=--—=——=—————— 55
(3) CONFIRMATION OF CHANGE OVER VALVES +------------------------- 55
(4) CONFIRMATION OF EQUIPMENT------------------------------------0000 em. 56
2.5 OPERATION -----—-——-——-—=—="<=">=eeeeeeneennensennennnnn=ssnsenseaseane ess 58
(1) COOLING OPERATION ----------------------------------"-00000000 ee eee seen 58
(2) HEATING OPERATION ------------------------------------------------200000. 60
(3) OPERATION BOARD DURING OPERATION ------------------------------ 62
(4) COMBUSTION TIME CHART--------------------------.--2220000ececesss esse 64
(5) CONTROL TIME CHART ------------------- eee 66
(6) MAXIMUM INPUT CONTROL:---------------————=eeneeenneneanean 68
(7) INVERTER CONTROL OF #1 ABS PUMP----------—————————————————- 69
(8) PRESET OF CHILLED WATER TEMPERATURE ------------------------. 70
2.1 OPERATION BOARD
(1) DETAL OF OPERATION BOARD
D @ D DO DO E.
| TEMPERATURE OPERATION RECORD SET POINT |: ||: ti :
O GENERATOR О С/Н OPERATION О ви тае.!! | | 5тоР RIN "IO COOLING 11.0 BURNER
O EXHAUST GAS O C/H ON-CFF O HT Y TBe.:: ||:0 O CHLLERMEATER || | О HEATING | O ALARM ..
: O CH WOOUILET O REF. PUMP OPERATION ............--—.: ||: O O REF. PUN Enron BUZZER STOP
O 00 W INLET O COMBUSTION ete} 10 OM ABS. PUE | |... ec
: O HT W INLET O BURNER ON-OFF | A SEECT | [|iO О #2 ABS. PUP OPERATION | REMOTE
o*F 9 EJilj:o O PRE PUE x | Cr.
{| æ| =| +|o ns: io © BURNER BLOWER STOP LOCAL
OSTARTS ——] eee | | | | -
панно Low. | Is |
| WATER ALARM MOTOR ALARM GENERATOR ALARM SYSTEM ALARM (INTERLOCK) COMBUSTION ALARM :
10 CAY TOP. O REF. PUE O PRESSURE O al y Pue O AIR FLOW
; O CHWFLOWRATE O #1 ABS. PUMP O SOLUTION LEVEL O 00 Y PUE O FLAME FAILIRE :
O O Y THe. O 22 ABS. PUMP O TEMP/CONCENTRATION O HT Y PUE O GAS PRESSURE:
: O CO WFLON RATE O BURNER BLOWR | O EXHAUST GAS TBP. O AIR FAN :
O HT Y TOP. :
: © HT W FLOW RATE ;
D æœ..
FIG. 2-1 Typical Operation Board
—40—
Monitor
This area has some indication lamps (Red) which indicate temperature of several
points, operating hours, number of burner ON-OFF times and setting point of
temperature, and digital display (Red) which indicates data of lighted item.
Select key
There is "SELECT” key for selectim of display data item. The item is displayed
in seguence by push the key. The item returns to generator temperature
automatically after approx. 1 minute. There are A” and VW” keys for setting of
chilled and hot water parameter.
Equipment RUN-STOP indicator
This area has some "RUN" indication lamps (Green) and some “STOP” indication lamps
(Red) which indicate conditions of the equipment.
Operation mode indicator
The indication lamp indicates operation mode.
Combustion indicator
The indication lamp lights during combustion.
Alarm indicator
The indication lamp flickers when the chiller / heater has abnormal condition.
Alarm item indicator
The indication lamp indicates alarm item.
Operation mode select key |
There are keys for chiller/heater operation.
Alarm buzzer stop key
There is buzzer stop key when the buzzer sounds by abnormal condition of the
chiller/heater.
(2) NSTRUCTON OF KEYS
” SELECT"
” OPERATION”
n STOP "
” LOCAL”
” REMOTE”
"BUZZER STOP”
For the use of item selection far display.
The item is displayed in sequence by push the key.
Change the item automatically when you push the key
than 1 second.
continuously more
For the use of change of setting point.
Setting number is increased by push the key.
Increase the number automatically when you push the key continuausly
more than 1 second.
For the use of change of setting point.
Setting number is decreased by push the key.
Decrease the number automatically when you push the key continuously
more than 1 second.
Operate the chiller/heater by local mode.
The chiller /heater does not operate when the mode
The indication lamp on "OPERATION" key flickers when set
“Local”.
For the chiller/heater operation, You must push the more than
1 second continuously. This is protection of the chiller /heater.
Please push the key continuously until flicker the indication lamp on
the key.
Er
“Remote” .
mode is
Stop the chiller/heater by local mode.
”STOP” key is accepted on either mode of “Local” and “Remote”.
The indication lamp on "STOP" key flickers when the stop signal is
accepted by push the key.
For the chiller/heater stop, You must push the key over 1 second
continuously. This is protection of the chiller/heater.
Please push the key continuously until flicker the indication lamp an
the key.
Far the use of operation of the chiller/heater by ” OPERATION” key on
the operation board.
When the mode is set “Remote”, the chiller/heater does not operate.
For the use of operation of the chiller/heater by remote panel.
“OPERATION” key is not accepted on “Remote” mode.
For the use of stop of alarm buzzer when the buzzer sounds by
anormal condition of the chiller /beater.
2.2 TEMPERATURE SETTING
( 1)DETAIL OF MONITOR
TEMPERATURE OPERATION RECORD SET POINT
O GENERATOR O C/H OPERATION O CH W TEM.
O EXHAUST GAS O C/H ON-OFF | O HT W TEMP.
O CH W OUTLET Ш O REF. PUMP OPERATION |
O CO W INLET O COMBUSTION
О НТ W OUTLET ©О BURNER ON-OFF A SELECT
O °F
i < 3. *4 | O HOURS
OSTARTS
У
FIG. 2-2 Monitor
The data is displayed on the digital display by ” SELECT” key. The selected item is
indicated by indication lamp of item. The item is selected by push on "SELECT" key.
The data on the digital display is returned to generator temperature after approx.
1 minute automatically.
Fig. 2-2 is shown generator temperature.
The indication lamp after digital display lights. according to unit of item.
Unit of temperature is °F ( Fahrenheit ).
( 2)SEQUENCE ON THE DIGITAL DISPLAY
The item is displayed in sequence by push the key. Sequence items are as follows;
Sequence | Lighted indication lamp Sample on the digital display
(Symbol)
1 Generator temperature
(GENERATOR) 30 || 80
( 300.0) .
2 Exhaust gas temperature
(EXHAUST GAS) 3 q ||
( 390.0)
3 Chilled water -
| outlet temperature + +.
(CH W OUTLET)
( 44.0)
4 Cooling water
inlet temperature В | =. | 2
(CO W INLET)
( 85.0)
5 Hot water
inlet temperature i 3 e. | Y
(HT W INLET)
( 131.0)
6 Chiller/heater
operating hours
(C/H OPERATION)
Q
Q
Q
( 1000)
7 Number of chiller/heater
ON-OFF times i 2 | 85
(C/H ON-OFF)
( 120)
8 Refrigerant pump
operating hours g IU IZ
(REF.PUMP OPERATION)
( 900)
—
9 Combustion hours
(COMBUSTION) y < НН
{ 950)
10 Number of burner
ON-OFF times 2 с i’
(BURNER ON-OFF)
Sequence | Lighted indication lamp Sample on the digital display
11 Chilled water
temperature setting E LH. DS
for temperature
(CH W TEMP.) (t 44.0)
12 Chilled water
temperature setting P o. | =;
for proportional
(CH W TEMP.) (P 2.0)
13 Chilled water
temperature setting ; 8 | |
for integral
(CH W TEMP.) (I 800)
14 Chilled water
| temperature setting cl i | DO
for differential
(CH W TEMP.) (d 10)
15 Hot water
temperature setting E i 3 i | 2
for temperature
(HT W TEMP.) (1131.0)
16 Hot water
temperature setting P HB. | с
for proportional |
(HT W TEMP.) (P 6.0)
17 Hot water
temperature setting ; < o
for integral
(HT W TEMP.) (I 50)
18 Hot water |
temperature setting cl 3 I
for differential
(HT W TEMP.) (d 30)
Display sequence repeats No.l thru No. 18.
Note) 1 It will happen to display below number between No.11 and No.12.
This temperature which is controlied the chilled water outlet temperature by
external |
condition.
С
416
Y
(c 46.4)
2 It will happen to display below number between No.15 and No.16.
This temperature which is controlled the chilled water outlet temperature by
external
condition.
h
EQ
Ч
(5127.4)
( 3)SETTING METHOD
Chilled and hot water outlet temperatures are controlled by digital PID (Proportional,
Integral and differential). It is able to get chilled and hot water of stable
temperatures.
a) Chilled water setting point range
Setting item Range .. | Step | Remark
Chilled water outlet|41.0~ 53.6 °F; 0.1 ~ 0.2
temperature (t)
Proportional (P) | 2.0 ~ 10.0 10.1— 0.2
Integral (1) 0 ~ 2500 sec 10 sec|P or PD action at 0 sec
Differential (D) 0 ~ 100 sec 1 sec|P or PI action at 0 sec
Note) Temperature data sampling is 10 second interval.
b) Hot water setting point range
Setting item Range Step Remark
Hot water outlet 104.0- 176.0 °F | 0.1 — 0.2
temperature (t)
Proportional (P) 2.0 - 10.0 0.1 — 0.2
Integral (1) 0 ~ 2500 sec 10- sec|P or PD action at 0 sec
Differential (D) 0 ~ 100 sec 1 sec|P or PI action at 0 sec
Note) Temperature data sampling is 10 second interval.
Notice 1. Please confirm the indication lamp of setting item before setting.
2.7 A ” and” W ” keys do not accept to cross the range number.
3. If you change the setting during chiller/heater operation, chiller/heater is
controlled by new setting point soon.
4. Original setting point is set at factory.
5. Setting point of chilled water outlet temperature is for cooling mode.
And setting point of hot water outlet temperature is for heating mode.
6. Setting point is stored by non-volatile memory of semiconductor.
Therefore, setting point is kept continuously when power cut off.
c) To take an example(Chilled water setting)
Setting item Original Target
Chilled water outlet 44.0 °F 46.0 °F
temperature (t)
Proportional (P) 2.0 2.5
Integral (1) 800 sec 900 sec
Differential (D) 10 sec 40 sec
Setting procedure is as follows;
No. Key Digital display Explanation
1 ” SELECT” Select the chilled water temperature
E y 8 setting (CH W TEMP.) by push the key.
The indication lamp of "CH W TEMP.”
(t 44.0) | liehts.
2 |” А” Push the ” 4 ” key.
E y io Display data increases 0.1.
(t 44.2)
3 |" A” Push the ” A ” key until 7.5.
E 6. 5 If display data increases over 7.5,
push the ” Y ” key. The display
(t 46.0) | data decreases 0.1.
4 | SELECT” Push the “SELECT” key.
Р 25 Display data indicates proportional
of chilled water outlet temperature.
(P 2.0)
5 |” A" Push the ” À ” key.
P e. |! Display data increases 0.1.
(P 2.1)
6 1” à” Push the ” A ” key until 2.5.
p 2.5 If display data increases over 2.5,
push the ” W ” key. The display
| (P 2.5) | data decreases 0.1.
No. Key Digital display Explanation
7 | “SELECT” Push the "SELECT" key.
; UI Display data indicates integral of
chilled water outlet temperature.
(1 800)
8 A” Push the ” A ” key.
j {18 Display data increases 10.
(I 810)
9 A” Push the ” M4 ” key until 900.
j DIO If display data increases over 900,
push the ” W ” key. The display
(1 900) data decreases 10.
10 | "SELECT" Push the "SELECT" key.
d 18 Display data indicates differential
of chilled water outlet temperature.
(d 10)
11 |” À "” Push the ” 4 ” key.
d (| à Display data increases 1.
(d 11)
12 |” à Push the ” M4 ” key until 40.
d y If display data increases over 40,
push the ” W ” key. The display
(d 40)
data decreases |.
d) To take an example(Hot water setting)
Setting item Original Target
Hot water outlet 131.0 °F 134.6 °F
temperature (t)
Proportional (P) 6.0. 5.0
Integral (I) 50 sec 900 sec
Differential (D) 30 sec 20 sec
Setting procedure is as follows;
No. Key Digital display Explanation
1 "SELECT" Select the hot water temperature
EI 47131 410 setting(HT W TEMP.) by push the key.
The indication lamp of "HT W TEMP.”
(1131.0) | lights.
2 74” Push the ” 4 ” key.
E | 813} L] € Display data increases 0.1.
(t131.1)
3 ;” à" Push the ” A ” key until 57.0.
E | {1314168 If display data increases over 57.0,
- push the ” W ” key. The display
(t134.6) | data decreases 0.1.
4 | SELECT” Push the “SELECT” key.
p 6.10 Display data indicates proportional
of hot water outlet temperature.
(P 6.0)
5 Tw” Push the ” W ” key.
P S19 Display data decreases 0.1.
9 (Р 5.9)
6 |” W” Push the ” W ” key until 5.0.
p Si If display data decreases below 5.0,
push the ” A ” key. The display
(P 5.0) ¡data increases 0.1.
No. Key Digital display Explanation
7 | “SELECT” Push the “SELECT” key.
; si 5 Display data indicates integral of
hot water outlet temperature.
(I 50)
8 A Push the ” A ” key.
| BID Display data increases 10.
(1 60)
9 A” Push the ” & ” key until 900.
j 9101! 8 If display data increases over 900,
push the ” W ” key. The display
(I 900) data decreases 10.
10 : “SELECT” Push the “SELECT” key.
d 370 Display data indicates differential
of hot water outlet temperature.
(d 30)
11 wT Push the ” W ” key.
d Ci 9 Display data decreases 1.
(d 29)
12 17 w 7 Push the ” W ” key until 20.
d 2 If display data decreases below 20,
push the ” A ” key. The display
(d 20) data decreases 1.
2.3 SELF-DIAGNOSTICS FUNCTION
( 1)SELF-DIAGNOSTICS FUNCTION
Self-diagnostics function starts, when the breaker of the chiller/heater turn on.
a) Some indication lamps light as shown Fig.2-3.
Symbol O : Indication lamp does not light.
Symbol Y : Indication lamp lights.
Symbol 8 : Indication lamp of the key lights.
TEMPERATURE OPERATION RECORD SET POINT
O GENERATOR O C/H OPERATION O CH ¥ TENP. STOP RUN O COOLING @ BURNER
O EXHAUST GAS O C/H ON-OFF O HT и ТЕЖ. O © CHILLER/HEATER O HEATING E ALARN
O CH W OUTLET O REF. PUNP OPERATION @ © REF. PUP BUZZER STOP
O Cow INLET QO COMBUSTION @ © #1 ABS. PUNP E]
O HT W OUTLET O BURNER ON-OFF A SELECT @ © #2 ABS. PUNP OPERATION REMOTE
er Г mo e © PURGE PUNP 8-10 1500
В. | 8. | 8 | & | 3. | € HOURS O © BURNER BLOWER STOP LOCAL
@STARTS [____] RJ a]
- v
VATER ALARM MOTOR ALARM GENERATOR ALARM SYSTEM ALARM (INTERLOCK) COMBUSTION ALARM
@ Ci N TEIP. @ REF. PUNP @ PRESSURE O CH Y PUNP O AIR FLOW
O CH Y FLO RATE @ #1 ARS. PUXP @ SOLUTION LEVEL @ CO ¥ PUNP @ FLAME FAILURE
O © ¥ TENP. O #2 ABS. PUNP O TENP/CONCENTRATION @ HT W PUNP @ GAS PRESSURE
O CO Y FLOW RATE @ BURNER BLOWER O EXHAUST GAS TEMP. @ AIR FAN
e HT Y TEP.
OH WEY RAE
FIG. 2-3
b) Buzzer sounds 4 times after 1 second of turn on the breaker.
Some indication lamp turn off after buzzer.
c) Self-diagnostics is worked.
Version number is displayed on the digital display, if power circuit has no error by
self- diagnostics. Version number is as shown;
и “au
Note) Version number subjects to change chiller/heater's specification.
(Y 7.50)
d) Generator temperature is displayed on the digital display, if control circuit has no
error by self-diagnostics. Generator temperature is as shown;
(Blew number is for reference.)
c| 34
de dun,
( 123.4)
( 2)ERROR MESSAGE BY SELF-DIAGNOSTICS
a)
b)
Error massage is displayed on the digital display, when the error is found in the
circuit.
In case of the error, it is necessary to call Sanyo's service representative.
If necessary, please call to Sanyos servioe representative after memorized the error
message.
Power supply error
This error massage is indicated the error of power supply to electronic controller.
The key access is not accept on this message.
It is necessary to call to Sanyos service representative.
P|-|L 0
(P-LO)
Electronic controller error and setting point error
(The message on the digital display flickers)
This error message is indicated the error of electronic controller or setting point.
Please call to Sanyos service representative with below error number.
It is not accepted the chiller/heater operation during indication of this message.
ЕЁ | г | г В.
J Indicate the kind of error message
(Err ¥%)
Kind of error message
® Error number ERR-6
e | @ Error number ERR-7
| —— ree ---- (D Error number ERR-1
om] o O Error number ERR-2
Di — 0--—- ® Error number ERR-8
e @ Error number ERR-3
A ® Error number ERR-5
besessen sens nee seen @ Error number ERR-4
D Error number ERR-1 (Electronic controller error) : Call to service.
O Error number ERR-2 (Setting point error) : Check the setting point and call
to service.
@ Error number ERR-3 (Electronic controller error) : Call to service.
@ Error number ERR-4 (Number of times data error) : Call to service.
® Error number ERR-5 (Operating hours data error) : Call to service.
O Error number ERR-6 (Electronic controller error) : Call to service.
7 Error number ERR-7 (Electronic controller error) : Call to service.
O Error number ERR-8 (Electronic controller error) : Call to service.
c) Power failure error
(The message on the digital display flickers)
This error message is indicated to return the power after power failure during
operation( include dilution cycle operation).
The power failure means not only power failure( include over 100 millisecond power
interruption) but also artifical power turn off the breaker.
If will happen to indicate this message when the breaker is turned on at first after
field wiring.
Pi-lEIrir
This error massage is cleared when “OPERATION” key is pushed.
(P-Err)
d) Sensor error
(The message on the digital display flickers)
This error massage is indicated the temperature sensor trouble. Chiller/ heater stops
safety when high temperature generator temperature sensor (DT3) and chilled and hot
water outlet temperature sensors(DT1, DT8) are broken during operation.
The chiller/ heater operates continuously, when other sensors(DT2, DT4, DT5, DT6, DT7
and DT9) are broken. But it is possible to control bad condition.
Please call to Sanyo s service representative.
5 | ЕЁ | г | В. | В.
= нтк = ноет ож = = = =
ee Indicate the kind of error message
(SE rx)
Kind of error message
cree re @ Error number SER-2 (DT2 : Cooling water outlet)
pouces - © Error number SER-5 (DT5 : Condenser)
Loomis @ Error number SER-3 (DT3 : High temp. generator)
EE ee ee O Error number SER-9 (DT9 : Hot water inlet)
— : —_— eee @ Error number SER-4 (DT4 : Low temp. generator)
| ho] [ro ® Error number SER-1 (DT1 : Chilled/hot w.outlet)
— e : — @ (D Error number SER-7 (DT7 : Cooling water inlet)
; Neeen enano ® Error number SER-8 (DT8 : Hot water outlet)
o n nenne nennen nenn ®© Error number SER-6 (DT6 : Chilled/hot w.inlet)
Note) It is possible to change the display data and setting point on the digital display
using the "SELECT, ” A and VW ” keys during error massage indication of
Electronic controller error, setting point error, power failure error and sensor
error.
2.4 PREPARATION FOR START UP
Please confirm below items again before operation.
(1) CONFRMATION OF OPERATION SWITCHES
a) Operation switches in the control panel
/ — CONTROL REFRIGERANT BURNER COOL/HEAT PURGE
/ VALVE PUMP CHANGE OVER PUMP
AUTO CLOSE AUTO RUN cool STOP
STOP STOP
MANUAL OPEN MANUAL TEST HEAT START
55606606
FIG. 2-4 TYPICAL OPERATION SWITCHES
@ Gas control valve mode select switch -------------------
O) Cas control valve open-close switch --------------—---
9 Refrigerant pump mode select switch ----------- ee
@ Burner mode select switch --------------------------
® Cooling/Heating change over БМ ЙО сеет
© Purge pump operation switch ---------------------- o
7 Auxiliary switch --------------"------
b) Burner control panel
” HEAT”
position
position
position
positian
position for "COOLING mode”
position for "HEATING mode”
position
on either side
“ON” position
( 2)CONFIRMATION OF SETTING POINTS
a) Chilled water temperature setting point
(Setting sample)
DO Chilled water outlet temperature ------—-----------—-—- 44 °F
@ Proportional ===" rene 2
@ Integral =. 800
eee 131 °F
( 3) CONFIRMATION OF CHANGE OVER VALVES
No | Valve name | Cooling mode | Heating mode
1 | A valve Open Close
2 | В valve Open Close
3 | С valve Open Close
4 | D valve Close Close
5 | E valve Close Close
6! G valve Close Open
( 4)CONFIRMATION OF EQUIPMENT
a) Combustion equipment
MD Open the main and pilot gas cocks in the gas train and the gas valve of supply gas
line.
@ Never smell gas around burner and gas train.
@ Linkage between burner and gas train.
b) Water system
@ Some valves for chilled water line.
@ Some valves for hot water line.
@ Some valves for cooling water line.
@ Other system line.
c) Cooling water inlet temperature
D Cooling water inlet temperature
@ Take care that the cooling water inlet temperature is kept above 19°C (66°F)
d) Electric wiring connection
@ Interlock of chilled water pump
@ Interlock of hot water pump
@ Interlock of cooling water pump
Note) Interlock signal is detected by energized DC 24V from the chiller/heater.
Please select the contact resistance within 1009.
(Please separate other power line.)
e) Remote signal connection
No Signal name Signal Introduction Notice
1 | Answer back signal Output | Operation : ON Please select the
for operation Stop : OFF resistance within
AC250V O.1A.
2 | Stop indicatin lamp Output | ON signal when
chiller /heater stop
3 | Operation indication Output | ON signal when C/H
lamp operates.
A | Alarm mdication lamp Output | Abnormal : ON
Operation : OFF
5 | Cooling mode mdication | Output | Cooling mode : ON
lamp
6 | Heating mode indication | Output | Heating mode : ON
lamp
7 | Combustion indication Output | During combustion
lamp ON
8 | Remote ON-OFF signal Input ON-OFF signal of C/H | No—-voliage
2.5 OPERATION
(1) COOLING OPERATION
a) Local mode operation
(Operation)
@ Confirm the operation mode indicator on the operation board.
” COOLING” indication lamp is ligntine.
® Confirm the operation mode select key an the operation board.
"LOCAL" indication lamp of the key is lighting.
@ Confirm the mode of change over valves, again.
A, B, C and F valves are opened.
D and E valves are closed.
@ H you operate the system by manual, please operate chilled water pump and cooling
water pump sequentially.
® Please continue to push the ” OPERATION” key on the operation board at least 1 sec.
Confirm to light “OPERATION” indication lamp of the key.
® Chilled water pump and cooling water pump are operated by automatically, if the
systen is comected to the chiller/heater.
(D Chiller/heater is operated automatically by sequentially.
(STOP)
D Piease continue to push the “STOP” key an the operation board at least 1 second.
Confirm to light “STOP” indication lamp of the key.
@ When the system is connected to the chiller/heater, pumps are stop as follows;
Cooling water pump stops approx. 1 thru 5 minutes later.
Chilled water pump stops approx. 2 thru 6 minutes later.
Chiller/heater stops after dilution cycle operation for approx. thru 15 minutes.
@ Please stop the secondary air conditioning units after stopped chilled water pump.
b) Remote mode operation
{Operation)
© Confirm the operation mode indicator on the operation board.
"COOLING indication lamp is lighting.
@ Confirm the operation mode select key an the operation board.
“REMOTE” indication lamp of the key is lighting.
®@ Confirm the mode of change over valves, again.
A, B, C and F valves are opened.
D and E valves are closed.
O H you operate the system by manual, please operate chilled water pump and cooling
water pump sequentially.
® Please make contact with chiller/heater operation switch on the remote control
panel.
® Chilled water pump and cooling water pump are operated by automatically, if the
system is comected to the chiller/heater.
7 Chiller/heater is operated automatically by sequentially.
(STOP)
D Please cut off the chiller/heater operation switch(or stop switch) on the remote
control panel.
@ When the system is connected to the chiller/heater, pumps are stop as follows;
Cooling water pump stops approx. 1 thru 5 mmutes later.
Chilled/hot water pump stops approx. 2 thu 6 minutes later.
Chiller /heater stops after dilution cycle operation for approx.6 thru 15 minutes.
@ Please stop the secondary air conditioning units after stopped hot water pump.
(2) HEATING OPERATION
a) Local mode operation
(Operation)
D Confirm the operation mode indicator an the operation board.
“HEATING” indication lamp is lighting.
@ Confirm the operation mode select key on the operation board.
"LOCAL" indication lamp of the key is lighting.
® Confirm the mode of change over valves, again.
A, B, C, D, E and F valves are closed.
@ If you operate the system by manual, please operate hot water pump.
© Please continue to push the “OPERATION” key on the operation board at least | sec.
Confirm to light “OPERATION” indication lamp of the key.
© Hot water pump is operated by automatically, if the system is connected to the
chiller /heater.
7 (hiller/heater is operated automatically by sequentially.
(STOP)
@ Please continue to push the “STOP” key on the operation board at least 1 second.
Confirm to light "STOP" indication lamp of the key.
@ When the system is connected to the chiller/heater, hot water pump stops approx. 5
minutes later.
Chiller /beater stops after dilution cycle operation for approx. 5 minutes.
@ Please stop the secondary air conditioning units after stopped hot water pump.
b) Remote mode operation
{Operation)
@ Confirm the operation mode indicator on the operation board.
"HEATING indication lamp is lighting.
@ Confirm the operation mode select key on the operation board.
"REMOTE" indication lamp of the key is lighting.
@ Confirm the mode of change over valves, again.
A, B, C, D, E and F valves are closed.
@ KF you operate the system by manual, please operate hot water pump.
® Please make contact with chiller/heater operation switch on the remote control
panel.
© Hot water pump is operated by automatically, if the system is connected to the
chiller /heater.
7 Chiller /heater is operated automatically by sequentially.
(STOP)
D Please cut off the chiller/heater operation switch(or stop switch) on the remote
control panel.
@ When the system is connected to the chiller/heater, hot water pump stops approx. 5
minutes later.
Chiller /heater stops after dilution cycle operation for approx. 5 minutes.
@ Please stop the secondary air conditioning units after stopped hot water pump.
( 3)OPERATION BOARD DURING OPERATION
a) The operation board during normal operation
Generator temperature is indicated on the digital display during operation.
Indication lamps light during operation as follows;
Symbol O Indication lamp does not light.
Symbol @ Indication lamp lights.
Symbol § Indication lamp of the key lights.
TENPERATURE OPERATION RECORD SET POINT
@ GENERATOR O C/H OPERATION O CH ¥ TEMP. STOP RUN O COOLING @ BURNER
O EXHAUST GAS O C/H ON-OFF О HT ¥ TEMP. О e CHILLER/HEATER O HEATING CO ALARM
O CH ¥ OUTLET O REF. PUMP OPERATION О © REF. PUWP BUZZER STOP
O Co w INLET O COMBUSTION О @ #1 ABS. PUNP С
O HT W OUTLET C) BURNER ON-OFF A SELECT O e 42 ABS. PUNP OPERATION REMOTE
O °F | ] | _] @ © PURGE PUNP i J } }
: | @ | 3 | * | O HOURS O @ BURNER BLOWER STOP LOCAL
. OSTARTS HL. ] CC a
Vv
WATER LINE ALARM MOTOR ALARM GENERATOR ALARM SYSTEM ALARM (INTERLOCK) COMBUSTION ALARM
O CH Y TEIP. O REF. PUMP O PRESSURE O CH Y PUNP O AIR FLOW
О Ни FLOW КАТЕ O #1 ABS. PUNP O SOLUTION LEVEL O CO ¥ PUNP O FLAME FAILURE
O Co Y TEIP. O #2 ABS. PUNP O TEMP/CONCENTRATION O HT ¥ PUNP O GAS PRESSURE
O CO WFLOW RATE O BURNER BLOWER O EXHAUST GAS TENP. O AIR FAN
O HT Y TEMP.
O HT Y FLOW RATE
FIG. 2-5 Typical operation board
b) Maintenance massage
Massage is indicated on the digital display.
@ Combustion chamber cleaning massage (Oil fired only)
The massage on the digital display flickers, when the exhaust gas temperature is
above 300 °C (572°F). It is necessary to clean the combustion chamber.
call to Sanyos service representative.
LILIE
Note) Chiller/heater
(CLE )
1S able to operate continuously during this massage.
Operation data can indicate on the digital display by ” SELECT” key.
This massage flickers continuously after chiller/heater stop.
Please
c) Power failure error massage during operation
d)
This massage is indicated when it is happen to power failure above 100 millisecond.
The massage on the digital display flickers.
Pl-|E|lr |r
Chiller/heater stops immediately, when it is happen to power failure.
Chiller/heater has no dilution cycle operation. Please operate dilution cycle.
operation after return the power supply.
(P-Err)
Sensor error massage
The message on the digital display flickers.
This error massage is indicated the temperature sensor trouble.
Chiller/heater stops safety when high temperature generator temperature sensor ( DT3)
and chilled water outlet temperature sensor (DT1) are broken during operation.
The chiller/heater operates continuously, when other sensors(DT2, DT4, DT5, DT6, DT7,
DT8 and DT9) are broken. But it is possible to control bad condition.
Please call to Samos service representative.
S E|r|8|8
A EA
nena Indicate the kind of error message
(SE rx)
Kind of error message
ren neones @ Error number SER-2 (DT2 : Cooling water outlet)
pooooooe ne reeeoooo ee O) Error number SER-5 (DT5 : Condenser)
a @ Error number SER-3 (DT3 : High temp. generator)
Pi eeeeeseeeeeeeeeesssssesss © Error number SER-9 (DT9 : Hot water inlet)
— : —— menes @ Error number SER-4 (DT4 : Low temp. generator)
| | ene : = | A @ Error number SER-1 (DT1: Chilled/hot w.outlet)
— © : — On © Error number SER-7 (DT7 : Cooling water inlet)
; eee O Error number SER-8 (DT8 : Hot water outlet)
meee nae O Error number SER-6 (DT6 : Chilled/hot w. inlet)
Note) It is possible to change the display data and setting point on the digital display
using the "SELECT, ” A and VW ” keys during error massage indication of
Electronic controller error, setting point error, power failure error and sensor
error.
( 4)COMBUSTION TIME CHART
a) Cooling operation
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b) Heating operation
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(5) CONTROL TME CHART
a) Dilution cycle of cooling mode
Operation time of dilution cycle is decided by generator temperature.
Low combustion
Combustion ON
OFF
#1 ABS pump ON
OFF
#2 ABS pump ON
OFF
REF pump ON
OFF
Chilled ON
water pump
OFF
ON
OFF
Cooling ON
OFF
water pump
1; PO
e mn.s: eTi=> : —mn.5; *
le -T7———<
Stop signal Chiller/heater stop
FIG.2-8
44— 40|-- - — — — — — — — — — — — — — — — — — — — —
|
|
|
|
A a |
= = |
“ты? “чт |
< су |
- - |
|
I
о -- 5 | | |
100°C 125°C 150°C 155'С
212° F 267° F 302°F 311'F
GENERATOR TEMPERATURE
FIG. 2-9
b) Dilution cycle of heating mode
Low combustion
Combustion ON
OFF
#1 ABS pump ON
OFF
Chilled/hot ON
water pump
OFF
1
=mn.=—; 4mm.
Stop signal
FIG.2-10
C) Restart during dilution cycle operation
It is possible to restart during dilution cycle operation.
Chiller /heater stop
( 6 )MAXIMUM INPUT CONTROL ( COOLING OPERATION)
Gas control valve is controlled for chiller/heater protection by cooling water inlet
temperature without specification.
Maximum input is decreased, when cooling water inlet temperature is below 28°C (82.4°F)
or above 33°C (91.4°F).
a) Control data
Cooling water inlet temperature is detected 1 minute interval. Maximum input is
controlled by the data. | | |
b) Control diagram
CRYSTALIZATION HIGH TEMPERATURE
EVASION AREA EVASION AREA
FOR SOLUTION FOR HT. GENE
100 f= - — — — — 1---- == == | |
- | A
~ 80--)----d--------- I------ |- - --
| | | | | |
> | | ! |
= eof | | | |
— | | | |
= | | | |
= 401 | | |
= | | | | |
= | | | | |
= 20 | | | | |
3 1 I ¡ i
o LLL 1 1 1 tt 1
19°C 20°C 22°C 24°C 26°C 28°C 30°C 32°C 34°C
66‘ F 68° F 72°F 76°F 79°F 82°F 88° F 90°F 83°F
COOLING WATER INLET TEMPERATURE
FIG. 2-11
(7) NVERTER CONTROL OF #1 ABS PUMP
Rotation of No.1 absorbent pump is controlled by inverter.
FREQUENCY (HZ)
60
no
o
COOLING LOAD (%)
F1G. 2-12 TYPICAL CHARACTRISTIC
100
( 8)PRESET OF CHILLED WATER TEMPERATURE ( COOLING OPERATION)
Setting point of chilled water outlet is increased automatically, when cooling water
inlet temperature is lower. In this case, setting point is able to indicate on the
digital display board. Please push the “SELECT” key. Temporary setting point is
indicated after chilled water setting point.
С 416 |Y
Please check the cooling water inlet temperature, when you change the setting point of
chilled water outlet temperature. Because there is the limit for setting according
to cooling water inlet temperature. Setting range is as follows;
(c 46.4)
MAXIMUM SETTING POINT
OF CHILLED WATER OUTLET
|
|
43° F |
J
| |
|
20°C 22°C 24°C 26°C 28°C
68°F T2°F 75" F 79* F 82°F
COOLING WATER INLET
TEMPERATURE
FIG, 2-13
SECTION 3 MANTENANCE
CONTENTS
Page No
SECTION 3 MAINTENANCE --—-—---<-—-<=<=<=<ememenemenenensense=seennnenenenenn cena 71
3.1 DAILY MAINTENANCE <== eee 72
(1) INSPECTION OF CHILLER/HEATER ===) 72
(2) OPERATION DATA RECORD ------------------------....................... 72
3.2 SEASONAL MAINTENANCE -----------------------<—<<ececessss 74
(1) PURGING ------—-——-—-—————==— ommssmsn once eones 74
(2) MAINTENANCE OF PURGE PUMP--------------—--——e——o—eeoe— 76
(3) REFRIGERANT BLOW DOWN---------------------------""""< 77
(4) SOLUTION MANAGEMENT -------------------------"<-<-"<<<<cc0ceeece scene 78
(5) COMBUSTION EQUIPMENT >>" rer e een ee e Eee een 78
3.3 COOLING/HEATING CHANGE OVER --------------------------------.......000. 79
(1) ”COOLING” => ”HEATING” PROCEDURE ----------------------.... 79
(2) ”HEATING” > ” COOLING” PROCEDURE ------------------------—--—————- 81
3.4 WATER TREATMENT ---------------==-====ereeec=eceeeeeoeeoeoanoeaee nana nano 82
(1) WATER TREATMENF--------------- SE ice ec 82
(2) WATER TREATMENT FOR LONG TERM SHUT DOWN------------- 85
3.5 MAINTENANCE FOR INVERTER -----------=--------e=eeeoinene ones 86
(1) INSULATION TEST FOR INVERTER ---------------------------"""""00m- 86
(2) INSPECTION BEFORE OPERATION ----------------—-==——memnneeneenen—- 86
(3) MAINTENANCE -—----------------=--==0000000000eerenreer neon 87
(4) MEASUREMENT LOCATION ------------------------------"""-0000000000ee ses 88
3.6 PARTS INSPECTION ---------------------------------.-000000cececeneeesecnnn ne. 89
3.1 DALY MANTENANCE
(1) NSPECTON OF THE CHLLER/HEATER
H yo find the abnormal condition, please call to service representative.
@ Smell gas around chiller /heater.
@ Abnormal noise when burner starts.
@ Linkage condition between bummer and gas tram.
@ Abnormal noise of absorbent pumps.
© Анюта! noise of refrigerant pump.
® Abnormal noise of burner blower.
Please ‘ask below items to your system contructor.
© Cleaning of the cooling tower and strainer of the cooling water line.
® Check the condition of cooling tower.
O Check the air vent of the pipe line.
(2) OPERATION DATA RECORD
Please record the operation data regularly.
It is usefull to protection of trouble shooting.
The sample of operation data sheet is shown Fig.3-1(see to next page).
Operating record sheet
Items Unit Date : 7
1 | Time
2 | Ambient temp. °С 7 °F
3 | Chilled water flow rate m*/h ' gpm
4 | Chilled water inlet temp. | °C / °F
5 | Chilled water outlet temp. °C 7 °F
6 | Cooling water flow rate m°/h - gpm
7 | Cooling water inlet temp. | C / °F
8 | Cooling water outlet temp. | °C / °F
9 | Hot water flow rate m*/h - gpm
10| Hot water inlet temp. °С / °F
11| Hot water outlet temp. CT / °F
12 | Generator pressure cmHg
13 | Generator temp. °C / °F
14| Exhaust gas temp. °C / °F
15| Gas consumption ft*/h
16 | Supplied gas pressurre Inch W.C.
17| Burner inlet gas pressure | Inch W.C.
18 | Pressure in chamber Inch W.C.
19| Gas control valve %
opening rate
Remark:
3.2 SENSONAL MANTENANCE
It is necessary for the chiller/heater to maintain the purging, refrigerant blow down,
solution and combustion equipment, etc.
(1) PURGING
a) Purging frequency
D Once a cooling season, when the chiller/heater operates within 20 hours per day
and within 3 monthes of cooling. season. |
© Once 3 manthes, when the chiller/heater operates within 20 hours per day and over
3 monthes of cooling season.
@ Once a week in cooling season, when the chiller /heater has 24 hours operation.
PALLADIUM
CELL
b) Purging procedure
(During cooling operation and Stop)
the attained vaoum by the manometer.
D Check
(Vacuum is below 4 mmHg.) SV2
@ Open the No.2 purge valve (V2) far 1 minute.
® Close the No. 2 purge valve (V2). vi
© Open the No.3 puree valve (V3) for 30 minutes.
© Close the No.3 puree valve (V3).
® Keep to operate the purge pump for 30 minutes. vi
O Close the No.l purge valve (V1).
© Stop the purge pump. MANOMETER
PURGE PUMP
NPURGE
TANK
(Before heating operation)
D Operate the purge pump.
@ Open the No.1 purge valve (V1).
® Open the No.2 purge valve (V2) for 1 minute. No
@ Close the No. 2 purge valve (V2). AN
® Open the No.3 purge valve (V3) for 10 minutes. LLODIO
© Close the No.3 purge valve (V3).
7 Keep to operate the purge pump for 30 minutes. - =
® Close the No.l purge valve (V1). ' —
@ Stop the purge pump.
F1G. 3-2 PURGE UNIT
Note) 1. In heating mode, please purge before chiller/heater operation.
2. In heating mode, please close the service valves for maintenance and
manometer (SV1 and SV2).
. Never check the attamed vacum m heating mode.
. Please open gas ballast valve until sounding exhaust gas.
It is easy for purge pump oil to become dirt, when gas ballast valve close.
ww CO
C) Measurement of the vacuum
Valve position
No Measurement item Vi V2 V3
] | Attained vacuum of the purge pump | Open | Close | Close
2 | Pressure in the shell Close | Close | Open
3 | Purge tank pressure Close | Open | Close
Reading method of manometer
Please read the differential of merary surface.
Usually, the right side surface of merary is higher than left side.
H it reverse, please call to service representative.
—
a
DIFFERENTIAL
(PRESSURE MMHG)
!
{|
9)
50
25
!
[o
25
e
50
№7
9)
FIG. 3-3 MANOMETER
(2) MANTENANCE OF PURGE PUMP
Please change the purge pump oil, when the attained vacum of purge pump does not
attained to below 4 mmHg.
D Open the drain cock.
@ Discharge the oil.
@ Close the drain cock.
@ Charge the oil from oil supply port until the center of sight glass.
Note) 1. When you change the purge pump oil, please stop the purge pump.
2. Recommend the turbine oil for purge pump. (10 viscosity grade : 56,58) —
3. If purge pump does not operate, please call to Sanyo's service
representative. 4. НК attained vacam above 4 mmig when you change the oil,
please call to service representative.
LIQUID TRAP
DRAIN PLUG
BALLAST
. VALVE EXHAUST GAS PORT
/ OIL SUPPLY PORT
OTOR
SIGHT GLASS
DRAIN DISCHARGE PORT
DRAIN COCK
PURGE PUMP
FIG. 3-4 PURGE PUMP
(3) REFRIGERANT BLOW DOWN
It so happens that a few absorbent mixes m the refrigerant during cooling operation.
a) Blow down frequency
D Once a cooling season, when the chiller/heater operates within 20 hours per day
and within 3 monthes of cooling season.
© Once 3 monthes, when the chiller/heater operates within 20 hours per day and over
3 moanthes of cooling season.
Once a week in cooling season, when the chiller/heater has 24 hours operation.
Chilled water outlet temperature rises up during refrigerant blow down.
But temperature drops again after blown down.
b) Blow down procedure
OD Confirm to operate the refrigerant pump.
@ Open the V4 valve (for refrigerant blow valve) for 1 or 2 minutes.
@ Close the V4 valve.
@ Repeat D, Y and @ about 3 times.
Note) Take care that the refrigerant pump does not have cavitation.
FIG. 3-5
(4) SOLUTION MANAGEMENT
It is necessary for the solution (Absorbent) to manage the imhibitor.
The inhibitor adjustment is required technical knowledge.
Please consult with service representative.
(5) COMBUSTION EQUPMENT
It is necessary for seasonal maintenance of combustion equipment to keep safety.
The maintenance is required at least twice a year. |
Please consult with service representative, as the maintenance is required technical
knowledge. |
® Inspection of gas leak
@ Flame failure test
@ Measurement of electric insulation resistance
@ Adjustment of air-fuel ratio
® Check of the burner
© (heck of the pilot bummer, gas train and others
3.3 COOLNG/HEATNG CHANGE OVER
When you change the mode from cooling or simultaneous to heating, please work the
refrigerant blow down and operate dilutin cycle operation enough.
(1) "COOLNG"” or ” SMLTANEOUS” => ” HEATING” PROCEDURE
Cooling operation
or
Simultaneous operation
Refrigerant blow down
|
Push the “STOP” key
on the operation board
|
Dilution cycle operation
|
Chiller/heater stops
Change over work
of some valves
on the chiller/heater
Tun the operation
switches
in the control panel
|
Push the ” OPERATION” key
on the operation board
|
After stop #1 ABS pump,
close the D valve
|
Push the “STOP” key
on the operation board
|
Tun the operation
switches
in the control panel
1
(Continue to next page)
Refer to "3.2 (3) REFRIGERANT BLOW DOWN a)”
Refer to "2.5 (1) COOLING OPERATION STOP)”
A valve : Open
B valve : Open
C valve : Open
D valve : Open
E valve : Close
G valve : Close
Refrigerant pump : Stop
Burner : Test
D valve : Close
Refrigerant pump :
Burner : Run
Cool/ Heat : Heat
(Continue from previous page)
3
| о |
Drain the cooling Keep the cooling water
water from the in the chiller/heater
chiller /heater
| |
Close both isolation Close both isolation
valves of cooling valves of cooling
water inlet/outlet water inlet/outlet
| |
Switch to heating mode
by coolng/heating
change over switch
in the control panel
re Г
: HK necessary, change :
; the auxiliary equipment:
system
в р!
Heating operation Refer to "2.5 (2) HEATING OPERATION”
(2) " HEATNG” => "COOLING" PROCEDURE
Heating operation
Push the ”STOP” key Refer to "2.5 (2) HEATING OPERATION {STOP)~
an the operation board
|
Dilution cycle operation
|
Chiller/heater stops
|
Open the D valve D valve : Open
After 3 minutes, D valve : Close
close the D valve
|
A
Change over work B :
of some valves C valve : Close
D -
E
G
on the chiller/heater
Tun the operation Refrigerant pump : Auto
switches Burner : Run
in the control panel Cool/ Heat : Cool
рт... тек. | enana
LJ
М '
"
n
: HK necessary, change :
: the auxiliary equipment :
‚ system :
IT Li
Cooling operation Refer to "2.5 (1) COOLING OPERATION”
Refrigerant blow down Refer to "3.2 (3) REFRIGERANT BLOW DOWN a)”
(2 or 3 times at start)
Cooling operation
3,4 WATER TREATMENT
It is important for chilier/heater to manage the water treatment.
As the water treatment is required technical knowledge, please consult with service
representative.
(1) WATER TREATMENT
The cooling water of the open type recycling cooling tower lowers the temperature of
the cooling water using the heat of vaporized latent heat and is reused. As this
time, the water is evaporated and dissolved salts (hardness component, chloride ion,
sulfate ion, etc.) in the water will increase. Namely, the condensation phenomena
of water occur, and water quality will be gradually degraded. As the water and air
are always in contact with each other in the coolmg tower, the sulfurous acid gas,
dust, earth and sand, etc. in the atmosphere will intrude into the cooling tower,
further degradme the water quality.
In the cooling water system, the troubles arising from water are mostly caused by
these causes and typical causes include corrosion, adhesion of scales and generation
of alimes.
a) Standard values of the water quality
First of all, water quality control method is determined due to the results of
analyzing the water quality.
The standard values of water quality are shown in table 3-1 as an example. And water
quality should be controlled within the standard values. The control method includes
the blow control methed in which all water is replaced periodically or water is
continuously and forcibly replaced as suppress the concentration of water as much as
possible and a method in which water processing chemicals are put into the water
because of the poor quality of the make-up water or saving the water. |
Table 3-1 Standard values of the water quality
X 1 Cooling water Chilled/hot water Tendency
Items
One-pass or Make-up Circulatine Make-up Cor- Scale
Circulating water water rosion
pH(25°C (77°F) ) | X2 6.5~8.0| X2 6.5~8.0| X2 6.5~8.0| %X2 6.5~8.0 O O
Electrical
conductivity 800 or less | 200 or less | 500 or less | 200 or less O
(25°C u s/cm)
M alkalinity | 100 or less | 50 or less | 100 or less | 50 or less O
(ppm)
Total hardness | 200 or less 50 or less | 100 or less 50 or less
(ppm) O
Chlorine ion | 200 or less 50 or less | 100 or less 50 or less O
(ppm)
Sulfuric acid | 200 or less 50 or less | 100 or less 50 or less O
ion (ppm)
Total iron 1.0 or less 0.3 1.0 or less 0.3 O O
(ppm)
Sulfur ion Not detected | Not detected | Not detected | Not detected O
(ppm)
Ammonium ion 1.0 or less | 0.2 or less | 0.5 or less | 0.2 or less O
(ppm)
Silica (ppm) 50 or less 30 or less 50 or less 30 or less O
Free carbonic *x 3 ЖЗ 10 10 O
acid (ppm)
(Note 1) |
X 1 : The standard values of cooling water and make-up water are the standard values of the
Japan Refrigeration/Air Conditioner Industry Association(JRA 9001-1980).
X 2 :The reason why the pH value of the make-up water is 6.0 to 8.0 is that no problem
would be presented as the pH value will increase while the water 1s circulating in the
tower even if the pH value temporarily decreases when carbonic acid gas dissolves into
the underground water used.
X 3 :Japan Refrigeration/Air Conditioner Industry Association clarifies that though they
are not included in the standards because the tolerance at which failures may result
are not definite, free carbonic acid, manganese, residual chlorine, etc. do serve as
corrosive factors.
(Note 2)
Each item of the standard values has a strong bearing on the failure due to corrosion
or scale and if any value in either item deviates from the standard value, it is
assumed that corrosion or scale tends to be caused, therefore, these should be
periodically controlled.
(Note 3)
As the range of the quality of water which may become useable if the water is
processed differs depending on the chemicals to be used, it is not given here. It is
desirable to set the appropriate water quality control values under the guidance of a
water processing specialist periodically control it.
b) Typical water treatment
The blow control means the forced replacement of the cooling water in order to
suppress the excessive concentrating of the circulating water (cooling water) in the
cooling tower and to prevent the changing of pH value and the concentrating of
corrosive mutter and scale producting mutter.
In general, there are following methods;
@ Continuous manual blow by make-up water
@ Automatic blow down by electric conductance
® Addition the anticorrosion
@ Slime control
® Seasonal water amalysis
( 2)WATER TREATMENT FOR LONG TERM SHUT DOWN
a)
Perform following treatment during long term shut down with no-circulating of
chilled/hot water and cooling water in the chiller/heater.
Please consult the detail with service representative.
Cooling water
(Keep the cooling water in the chiller/heater)
@ Discharge cooling water from its discharge port on the cooling water outlet.
@ Pour anticorrosion chemicals into the water.
@ Full up the cooling water in the chiller/heater.
@ Operate the cooling water pump until mixed anticorrosion chemicals even.
® Close the isolation valves of inlet and outlet on the cooling water line.
© Open the D valve on the chiller/heater.
(Drain the cooling water in the chiller/heater (Dry condition) )
b)
с)
@ Discharge cooling water from its discharge port on the cooling water outlet.
@ Remove the scale and/or slime clung in the tubes by brush(nylon) cleaning.
(If scale and/or slime can not be removed by brush cleaning, perform chemical
cleaning.)
© Perform cleaning with water sufficiently.
@ Pour anticorrosion chemicals into the water, and circulate the water with
anticorrosion chemicals for 30 minutes or more.
® Discharge the water from the discharge port on the cooling water inlet.
® Keep to open the discharge port during shut down.
Chilled/hot water
Keep to full up the chilled/hot water in the chiller/ heater.
In winter
If you have a chance of ambient temperature below 0 °C (32°F), please protect the
freeze of chiller/heater.
Please consult with service representative.
3.5 MAINTENANCE FOR INVERTER
When you check the insulation test of control circuit, please remove all terminals to
the inverter.
( 1)INSULATION TEST FOR INVERTER
Insulation test for inverter itself checks only power circuit as shown below, never
check the control circuit of inverter. |
Check DC 500V for 1 minute by insulation resistance tester.
The resistance is above 10 MO.
POWER SUPPLY MOTOR
ln R Uhm = = = =
o! E
a a e— — —l —] “as — T \ янь GE шине не =”
INSULATION
RESISTER
RESIST INVERTER
- = EARTH
FIG. 3-6 INSULATION TEST
(2) INSPECTION BEFORE OPERATION
Please check the following items before power supply.
D Check the wiring connection to the inverter.
Q Clean in the control panel and inverter panel.
@ Tighten the screw on the terminal of inverter.
@ Do not touch between terminals.
a) Seasonal
( 3) MAINTENANCE
inspection
Check the following items when the chiller/heater shut down at end of season.
Note) 1. When you check the inverter, please confirm to light off the power lamp on
the inverter panel after a few minutes of turn off the power supply.
2. When you remove the connector of the inverter, please hoid the housing of the
connector.
Take care the connect number when you match the connector.
3. Please change the electrolytic capacitor every 5 years and the cooling fan
every 3 years.
4. Recommend to exchange the parts or board,
if it will be happen to trouble.
Item
Inspection
Disposition
1 .General
Ambient condition
5°C ( 41°F) ~
45°C (113°F)
Ambient temperature :
Return the condition
within specification
Relative humidity : 90%at45°C (113°F)
Viblation : below 0.5 С
Power supply Input voltage : Rated voltage +10% | Adjust the voltage
2.Main circuit
Transistor Discoloration, Offensive smell Exchange the module
Diode module
Looseness of screw Tightness
Electrolytic Liquid leak, Transformation Exchange the parts
capacitor Capacitance(above 85% of rated)
Resistor Discoloration, Crack Exchange the parts
Resistance(within +10% of rated)
Wire Discoloration of covered wire Exchange the wire
Tear, Short circuit
Others Dust Cleaning
looseness of screw Tightness
3.Printed wiring
board
Hybrid IC Mounting condition Viblation protection
Capacitor Transformation Exchange the board
Resistor Discoloration, Crack Exchange the board
Connector Looseness, Disconnect Fix the connector
4 Cooling fan
Cooling fan Dust Cleaning
Noise of bearing Exchange the fan
Cooling fin Dust Cleaning
( 4)MEASUREMENT LOCATION
Please use larger capacity current transformer,
if you measure the current.
Measurement item | Easy measurement Precision measurement
Input | Voltage Multiple meter Volt meter
Amperage Clamp type current meter | Ammeter
Power Wattmeter
Output | Voltage Multiple meter Volt meter of rectifier type|
Amperage Clamp type current meter | Ammeter |
Power —— Wattmeter
INVERTER
OO: DO
3 PHASE
CONEA, Ce, O то
— as) 02 s ve —(w) MOTOR
>
— a7) : fs (0) — 1623
AT e W 13 T WC CR
FIG. 3-7 MEASUREMENT
3.0 PARTS №РЕСТОМ
Please consult with service representative
Parts name Inspection item Inspection period Remark
1 Chiller / heater
Heat transfer | Corrosion, scale and/or slime Once every 3 years
tubes clung in the tube
( ABS COND EVA, | a.
HW.HEAT) (Inspected by Eddyaurrent test or
Endoscope >»
Heat transfer | Corrosion, scale and/or slime H necessary
tubes of heat | clung in the tube
exchangers
(HT.EX, LTEX) | {Inspected by Endoscope and N,
after cutting shell)
High temp. Dirty in the chamber and flue tube Once a year Cleaning
generator
(HT.GENE) (Visual inspection)
2 .Solution i
Absorbent Solution analysis 1 time per 2000 hr | Adjust the
Solution sampling) rated solution
Concentration standard
P-alkalinity
Inhibitor volume
Dissolution volume of copper
Dissolution volume of iron
3 Pump
Absorbent and | Body, Impeller, Bearing and coil H necessary Durable length
Refrigerant of time :
pump {Overhaul) Over30,000hrs
Purge pump Body (Overhaul) If necessary
V-belt (Exchange)
4 Combustion |
Burner Stocked by owner H necessary Durable length
controller {Spare parts) of time :
Flane detector Over 12 ,000hrs
Shut off valve | Stocked by owner H necessary
Solenoid valve | (Spare parts)
Regulator
Blower motor
Fan
Parts name
Inspection item
Inspection period
5 Safety device
Pressure gauge
Stocked by owner {Spare parts)
Once every 3 years
HT.GENE
Flow switch
Manometer
Stocked by owner {Spare parts)
If necessary
Air flow switch
Gas pressure
switch
Stocked by owner {Spare paris)
Once every 3 years
Temperature
sensor
Electromagnetic
contactor
Auxiliary relay
Time delay
relay
Control valve
Modutrol motor
Electronic
controller
Stocked by owner {Spare parts)
H necessary
Inverter
Stocked- by owner {Spare parts)
Once a year
Refer to 3.5
6 Others
Electrod of
solution level
Sight glass
Diaphragm valve
Gaskets
Palladium cell
Chamber cover
Gasket of water
header
Stocked by owner {Spare parts)
H necessary:
SECTON 4 TROUBLE SHOOTING
CONTENTS
Page No.
SECTION 4 TROUBLE SHOOTING tn 91
4.1 ALARM INDICATION LAMP === eee 92
(1) PROCEDURE WHEN CHILLER/HEATER HAS TROUBLE ------------- 92
(2) DETAIL OF ALARM INDICATION LAMP--------------—-- неее 92
4 2 POWER FAILURE ----------------------------------""00000000ee esse eee ce ces 94
(1) POWER FAILURE MESSAGE---------------------------=-=-000000000eseesssss 94
(2) RESET THE MESSAGE: -------sm-rsmmsssemem sees 94
(3) SERVKE CALL ————=====meoneen nen 94
4.3 ALARM IN THE COOLING OPERATION----------------=-=================="=- 95
(1) WATER LINE ALARM ------------------------"-""-"-"==" 95
A N ec ec eee Ses 95
(3) GENERATOR ALARM------------------------"---"-""000000e sense eee See S Se 96
(4) SYSTEM ALARM -------------------------<-"<<.<eceeseceese 96
ET esse 97
4.4 ALARM IN THE HEATING OPERATION--------------------------------"20000. 98
(1) WATER LINE ALARM ------------------============cerecenooeeenooeoeeo 98
(2) МОТОВ АЦАВМ cesse esse eee 98
(3) GENERATOR ALARM------------------------"""-"<--<--<.. 99
(4) SYSTEM ALARM ----------------------<-<"<<<<<cececeeeeeeee eee 99
(5) COMBUSTION ALARM ----------------------------""0000000cc eee eee eee ece sens 100
A mmm momen ener ess 101
(1) COOLING OPERATION ---------------------------"0000000e encens eee seen ee 101
(2) HEATING OPERATION -------------------==--===--0eceeeeceroeeneoeeneeoe— 106
4.1 ALARM NDICATEN LAY
Chiller/heater stops safety, when the chiller/heater has a trouble. And the same
time, alarm buzzer rings and alarm indication lamp lights.
( 1) PROCEDURE WHEN CHLLER/HEATER HAS TROUBLE
@ Stop the alarm buzzer by “BUZZER STOP” key on the operation board.
@ Confirm the trouble item by alarm item indicator on the operation board.
@ Repair the trouble item.
@ Push the “STOP” key on the operation board after repair.
Alarm indication lamp turns off, and “STOP” indication lamp flickers.
® Operate the chiller/heater.( Refer to 2.5)
(2) DETAL OF ALARM NDCATION LAMP
a) Alam item indicator
O HT W TEMP.
O HT W FLOW RATE
WATER ALARM MOTOR ALARM GENERATOR ALARM SYSTEM ALARM (INTERLOCK) COMBUSTION ALARM
O CH Y TEMP. O REF. PUW O PRESSURE О СН и РР O AIR FLOW
O CH W FLOW RATE O #1 ABS. PUM O SOLUTION LEVEL O CO W PUMP O FLAME FAILURE
O Co W TEN. O 42 ABS. PU O TEMP/CONCENTRATION O HT W PUNP O GAS PRESSURE
O CO W FLOW RATE O BURNER BLOWER O EXHAUST GAS TEMP. O AIR FAN
b) Detail
1. Water alarm
Alarm indication lamp Trouble
CH W TEMP. 1) Chilled w. outlet temperature is below 2.5°C (36.5°F)
2) Chilled water outlet temperature sensor (DT1) is
broken.
CH W FLOW RATE Chilled water flow rate decreases below 50%
CO W TEMP. Cooling water inlet temperature is below 19°C (66°F)
after 30 minuites of chiller/heater started.
CO W FLOW RATE (OPTION) Cooling water flow rate decreases below 50%.
HT W TEMP. Hot water outlet temperature is over 70°C (158°F).
HT W FLOW RATE Hot water flow rate decreases below 50%
2. Motors alarm
Alarm indication lamp
Trouble
Amperage of refrigerant pump is above rated value.
REF. PUMP
#1 ABS. PUMP Amperage of No.l absorbent pump is above rated value.
#2 ABS. PUMP Amperage of No.2 absorbent pump is above rated value.
BURNER BLOWER No- indication (DC-**S model does not use this lamp)
3. Generator alarm
Alarm mdication lamp
Trouble
PRESSURE Pressure of high temperature generator is above
atmosphere pressure.
SOLUTION LEVEL Solution level of high temperature generator is too low.
TEMP / CONCENTRATION 1) Temperature of high temperature generator is above
165°C (329°F) in cooling mode and 130°C (266°F) in
heating mode.
2) High temperature generator temperature sensor (DT3)
is broken.
3) Concentration of concentrated solution is above 65%
for 10 minutes.
EXHAUST GAS TEMP.
Exhaust gas temperature is above 300°C (572°F).
4. System alarm (Interlock)
Alarm indication lamp
Trouble
CH W PUMP Interlock of chilled water pump disconnects.
CO W PUMP Interlock of cooling water pump disconnects.
HT W PUMP Interlock of hot water pump disconnects.
AIR FAN Ш (OPTION Interlock of supply / exhaust air fan disconnects.
5. Combustion alarm
Alarm indication lamp
Trouble
AR FLOW No- indication (DC-**S model does not use this lamp)
FLAME FAHURE Burner has flame failure or other burner alarm.
GAS PRESSURE No- indication (DC-**S model does not use this lamp)
4.2 POWER FALLRE
(1) POWER FALLRE MASSAGE
This massage is indicated when it is happen to power failure above 100 millisecond.
The massage on the digital display flickers.
P|-1E|rir
Chiller/heater stops immediately, when it is happen to power failure. |
Chiller/heater has no dilution cycle operation. Please operate dilution cycle
operation after return the power supply.
(P-Err)
(2) RESET THE MESSAGE
When -you push the ” OPERATION” key, the power failure message is reset.
(3) SERVICE CAL
{Cooling or Simultaneous operation)
D Return the power within 1 hour.
Please call to service representative after chiller/heater operation.
@ Power failure continue over 1 hour.
Please call to service representative before chiller/heater operation.
(Heating operation)
Please call to servie representative after chiller/heater operation.
(During purge pump operation)
D Please close the No.l purge valve (V1) immediately, when it is happen to power
failure.
O Please tum off the purge pump operation switch in the control panel.
© Measure the pressure In the shell.
@ When the power returns, please start the purging and call to service
representative.
—g 4—
4.3 ALARM N TE COOLING OPERATION
(1) WATER LINE ALARM |
D Is Discharge pressure of chilled water or cooling water pump normal ?
> Check the strainer and air vent of the pipe line.
@ Is gas omtrol valve mode select switch in the control panel “AUTO” position ?
= Tum to “AUTO” position.
@ Is chilled water setting point too low ?
> Confirm the setting point. And if it is too low, please adjust the best
setting point.
@ Is cooling water setting point too low ?
= Confirm the setting point. And if it is too low. please adjust the best
setting point. |
Please operate the chiller/heater again after checking above items.
H the chiller/heater has an alarm the same as previous alarm, please call to service
representative with below data.
Chilled water inlet and outlet temperatures
Cooling water inlet and autlet temperatures
High temperature generator temperature
High temperature generator pressure
(2) MOTOR ALARM
Confirm to stick out the reset button of the wvercurrent relay, please call to service
representative.
ESET BUTTON
FIG. 4-1
(3) GENERATOR ALARM
D Does cooling water pump operate ?
=> Operate the coolmg water pump.
@ Does all valves of cooling water line open ?
=» Open all valves of cooling water line.
@ Is disharge pressure of cooling water pump normal ?
+ Check the strainer and air vent of the pipe line.
@ Is cooling/heating change over switch ”COOL” position ?
= Turn to "C00L” position.
O) Is gas control valve mode select switch in the control panel “AUTO” position ?
= Turn to ” AUTO” position.
© Is chilled water setting point too low ?
= Confirm the setting pont. And if it is too low, please adjust the best
setting point.-
@ Does the linkage between gas omntrol valve and damper loose ar disconect ?
= Adjust and tightness the linkage.
® Otherwise, there is dirty of heat transfer tube.
Please operate the chiller/heater again after checking above items.
If the chiller/beater has an alarm the same as previous alarm, please call to service
representative with below data.
Chilled water inlet and outlet temperatures
Cooling water inlet and outlet temperatures
High temperature generator temperature
(4) SYSTEM ALARM
@ Do chilled water and cooling water pumps operate ?
> Operate the chilled water and cooling water pumps.
O Does supply/exhaust gas fan (option) operate ?
(5) COMBUSTON ALARM
Confirm to stick out the reset button on the burner controller in the burner control
panel.
H the chiller/heater has an alarm the same as previous alarm, please call to service
representative after checking the following items.
Does the linkage between gas control valve and damper loose or disconect ?
Does the burner blower operate normally ?
Does pilot burner or main bummer fire ? |
Does the burner have a noise when the bummer ignites ?
ESET BUTTON
FIG. 4-2 BURNER CONTROLLER (FLAME SAFEGUARD)
4.4 ALARM N THE HEATNG OPERATION
(1) WATER LINE ALARM
O Is Discharge pressure of hot water pump normal ?
= Check the strainer and air vent of the pipe line.
@ Is gas control valve mode select switch in the control panel ”AUTO” positim ?
= Turn to “AUTO” position. |
@ в hot water setting point too high ?
=> Confirm the setting point. And if it is too high, please adjust the best
setting point.
Please operate the chiller/heater again after checking above items.
If the: chiller /heater has an alarm the same as previous alarm. please call to service
representative with below data.
Hot water inlet and outlet temperatures
High temperature generator temperature
High temperature generator pressure
(2) MOTOR ALARM
Confirm to stick out the reset button of the thermal relay, please call to service
representative.
ESET BUTTON
FIG. 4-3
(3) GENERATOR ALARM
® Does hot water pump operate ?
=» Operate the hot water pump.
@ Does all valves of hot water line open ?
=> Open all valves of hot water line.
© Is discharge pressure of hot water pump normal ?
=> Check the strainer and air vent of the pipe line.
@ Is oooling/heating change over switch “HEAT position ?
= Turn to “HEAT” position.
O Is gas control valve mode select switch in the control panel “AUTO” position ?
= Turm to “AUTO” position.
® Is hot water setting point too high ?
= Confirm the setting pont. And if it is too low, please adjust the best
setting point.
@ Does the linkage between gas control valve and damper loose or disconect ?
= Adjust and tightness the linkage.
® Otherwise, there is dirty of heat transfer tube.
Please operate the chiller/heater again after checking above items.
Н the chiller/heater has an alarm the same as previous alarm, please call to service
representative with below data.
Hot water inlet and outlet temperatures
High temperature generator temperature
High temperature generator pressure
Exhaust gas temperature
(4) SYSTEM ALARM
D Does hot water pump operate ?
=> Operates the hot water pump.
O) Does supply/exhaust gas fan (option) operate ?
(5) COMBUSTION ALARM
Confirm to stick out the reset button on the burner controller m the burner control
panel.
Н the chiller/heater has an alarm the same as previous alarm, please call to service
representative after checking the following items.
Does the linkage between gas control valve and damper loose or discomnect ?
Does the burner blower operate normally ?
Does -pilot burner or main bummer fire ?
Does the burner have a noise when the burner ignites ?
C )
m
ESET BUTTON
FIG. 4-4 BURNER CONTROLLER (FLAME SAFEGUARD)
—100—
4.5 ALARM TE CHART
(1) COOLNG OPERATION
а) "СО № TEMP”
Low combustion
ON +
Combustion
OFF +
ON +
#1 Abs pump
OFF +
ON +
#2 Abs pump
OFF +
ON +
Ref pump ; ;
OFF + . т
Chilled ON + :
water
pump OFF + |
Cooling ON + | :
water
pump OFF +
ое
: : 1 min.
«= => : E—— YH: e > :
1 min. : TI : T2 ;
Alarm | | Stop
signal
Fig. 4 - 7
—101—
b) " PRESSURE” , ” SOLUTION LEVEL” , ” TEMP / CONCENTRATION” , “ EXHAUST GAS TEMP.”
"AR FLOW”, "FLAME FAIRE", ” GAS PRESSURE”
ON +
Combustion
OFF +
ON +
41 Abs pump
OFF +
ON +
#2 Abs pump
OFF +
ON +
Ref pump
OFF +
Chilled ON +
water
pump OFF +
Cooling ON + :
water
pump OFF + | [
: 1 min.
= | «= =>
Tl T2
Alarm Stop
signal
Fig. 4 - 8
—102—
c) "C0 W FLOW RATEOPTION) ™ , REF. PUMP”, "BURNER BLOWER", "CO W PUMP”, "АЖ FAN”
ON +
Combustion
OFF -
ON +
#1 Abs pump
OFF +
ON +
#2 Abs pump
OFF +
t
ON +
Ref pump
OFF +
Chilled ON +
water
pump OFF +
Cooling ON +
water
pump OFF +
: 1 min.
E— —> : @ =>
Tl T2
Alarm | Stop
signal |
Fig. 4 - 9
—103—
d) "#1 ABS PUMP”, "#2 ABS PUMP”
ON +
Combustion
OFF +
ON +
#1 Abs pump
OFF +
ON +
#2 Abs pump
OFF +
ON +
Ref pump
OFF +
Chilled ON +
water
pump OFF +
Cooling ON +
water
pump OFF +
=>
Tl : 1 min.
Alarm Stop
signal
Fig. 4 - 10
—104—
e) "CHW TEMP.” , "CH W FLOW RATE”, CH W PUMP”
ON +
Combustion
OFF +
ON +
#1 Abs pump
OFF +
ON +
#2 Abs pump
OFF +
ON +
Ref pump
OFF +
Chilled ON +
water
pump OFF +
Cooling ON +
water
pump OFF +
=>
; E>— — — => ; &
: Ti : 1 min.
Alarm Stop
signal
Fig. 4 - li
—105—
(2) HEATNG OPERATION
a) "HT W TEMP.” , "HT W FLOW”, "REF PUMP”, "#2 ABS PUMP”, "BURNER BLOWER"
” PRESSURE”, ” SOLUTION LEVEL”, ” TEMP/CONCENTRATION” , "EXHAUST GAS TEMP.”
"НТ № PUMP”, "AR FAN", "AR FLOW”, "FLAME FAILURE”, "GAS PRESSURE”
Combustion ON
OFF
ON
#2 ABS pump
OFF
ON
Hot water
pump OFF
1
4 Bin. — — — :
Alarm Stop
signal
FG. 4 - 12
b) "#1 ABS PUMP”
Combustion ON
OFF
ON
#1 ABS pump
OFF
ON
Hot water :
pump OFF : —
——
1
4 min.
Alarm Stop
signal
FIG. 4 - 13
—106—
13600 Industrial Park Blvd., P.O. Box 1551, Mpls., MN 55440 (612) 553-5330
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