McQuaY” Absorption Chiller Operation and Maintenance

McQuaY” Absorption Chiller Operation and Maintenance
McQuaY”
Operation and
Maintenance Data
Bulletin No. OM 112
March, 1993
FormNo. 573440Y
Absorption Chiller
NC-U Model
/
NOTESTO USERS
1 . Before operating this chiller, YOUd-mid first thoroughly read this
manual.
You may not understand all of the explanations for operation when
you firstly read this booklet, however, P1ease strictly
follow the
directions
as shown hereinafter.
2.Be sure
not to leak
the air
into the chiller
atany cases.
(Take care when YOU handle the manual purge values and service
valves. )
3 . Do not turn off the main supply power to the chiller.
If turn off the breaker, purge unit of the chiller does not work.
4 . Operate chilled water ‘ pump(s) and air handling unit(s)
during
dilution
cycle operation of the chiller.
Chiller has a few cooling capcity
during diluted cycle operation.
5. Specifications
and eqipment
may be changed as required
manufacture without any notice and obligation to the users.
by the
814-6-0502-452-01
OfIRATIY
M4UK
CONTENTS
Page
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------ ... .... ... ... .. .. . ------- ------ .-- ..-,.----- -.---- . ..... ...”.-., -.
SKTION 1 ~
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1.3
1.4
No.
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.... ... . .. .. ....... ... .... ..... ....
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m HUtCm
OF AKORPI’IoN “---------------------------------------2
COOL14MR4TlhGCYUE DHRIPHON ------------------------------20
MU.HVHE4’IIR lLUSIRATRIN ----------------------------------------25
=
~~
.................. “-. -“--”-------------------------------”37
SKI’ION 2 CMRATION--------------------------------------------------------------------39
2.1
;::
2.4
2.5
Slxm
&iRATION 80ARD -----------------------------------------------------------40
TEMHRATURE
SE1-TINe---"-"-----------------------------------------------43
!3U-DIAGNG!XICSFUNCHON -------------------------------------------51
FRMRATIONFUU STARTUP----------------------------------------------54
OPIRATION--------------------------------------------------------------------58
3 ~~
3.1
::;
::;
3.6
DALY m~
---"----"--"--------------"
-----------------------------73
lMTNAMx-"-----------"
--"------------"
------"---"--"--------"75
=~WT~
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on
----------------------------------------80
WATIR‘lRE4TbHfI’----------------------------------------------------------82
MAMH’UNCEm
~----------------------------------------------86
PARTS INWIETION-----------------------------------------------------------89
SiCHON 4 ~
4.1
4.2
:::
4.5
----------------------------------------------------------------72
Fmm
-M
................................................
9~
INDICATION
LAMP--------------------------------------------------92
FAILURE--------------------------------------------------------------94
IN ‘IHE CIXHJhKOHRATION------------------------------------95
JN ‘lHE HE4TIIWCHRATION-----------------------------------98
TIME ~-----------------------------------------------------------lOl
I
WTKNI ENwlESUWTKN
CONTENTS
Page
mm
No.
1 G13WRAL
DB3UPTION ---"----"---""-"---------"
----"""-----"
---"----""`----"-1
1.1
‘lHE FRINCIPLEw
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
1.2
CUOLING
WA~-------------------------------------------------------------9
VAURJM
--"" ----" -"-----" "---" ---" -"----
"-"-" ""---" -----" ---" -----" "-----" ----lo
LRHJM EROMJDE(LB- : AKOREHW)--’--”---””----””----------”-ll
~~
~
...............................................................l6
~~
-
..............................................................l9
~11.UR IUKIRATION --------------------------------------------------------23
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
~.4
WHYDOIB A HEATING
(l-HI-L?--------------------------------------2
‘IHE FRINcm OF ABSCRFTIoN
"-"-----"
""---------"
------"-----"----- 4
smJI
ETEcr
TYPE
(BASIC
CYuE)
“----”””---””----””-----””--7
w
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.................................................... 8
(x)oLINGCYuE DEStxlFrIoN -----------`
"----"------"----"----"-"----------"lo
(~)
1.3
ABSORITloN“-””-----”---”-”----:
”---------”:
-----”----2
-----------------------------23
lUUSIRATION
~A~
OF TYPIC4LU-IILLH?(m
V~) ..........-....-.......24
DETAROF TYPIC4LC1-HLUR(m VIEW) -----------------------25
~A~
~ ~w
~~(R~
V~) ...........-...........26
DETAITCF mm
~~(~
Vm) .......................27
TYPBXL(DNIROLP~-------------------------------------------------28
TYPEALm
CONIROLVALVEANDm
~--..
..... 30
=
........................................................................3l
cJJqq’y ~~
(1)
(2)
(3)
(4)
............................. ....................................34
QIILI.EI WATIRANDU30UK WAIH-----------------------------34
HIGHlXMPfRAllJREG134ERATOR
---------------------------------------34
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—l–
1THE PRINCIPLE
OFABSORPTION
(1)
WHYDOES A
I-EATING CHILL ?
The cooling means keeping the room temperature lower than outside temperature.
As
shown Fig.l-l,
operate to carry the heat from the room
with alowert temperature (28C,
82 F) to the open air with a higher temperature isrequired.
But, in the nature, the
heat can not
move from
low temperature side to ahigh
temperature side.
So, to
transmit the heat as opposed to this law (principle),
some way (apmratus)
is
That is,
aheat pump
(chiller) isused
to pump out the
heat from alow
necessary.
temperature one asifawater pump isused
to draw up the water from a deep well.
RE
COOLING LOAO
(82 “F)
AIR
FIG.
(90 ‘F]
CONDITIONER
1-1 HEAT FLOW
–2–
+
HEAT FLoW
The typical chiller using an electric asa
operation power source
curry the heat in Fig.1-2
is an electric turbo chiller and the typical chiller
heat
energy isan absorption chiller.
asaconveyerto
using a
chilled water is made by using the latent heat released by a liquid as it evaporates
For example, when
We can find this principle through our experience in a daily life.
having an injection, after applying asalchol for disinfection on the arm, we feel
Because, the alchol is heated by body’s temperature, took the
the part ofarm
cool.
And another example is that we feel cool when
heat from the arm when itevaporates.
we sweat
in ahot day
orby taking exerxise. bercause, the body temperature is
automatically controlled by the evaporation ofsweat which takes the heat from the
But in a chiller, it is
A chiller also uses an latent heat ofevaporation.
body.
For this purpose, the
necessary to return to
liquid for using vaporized liquid.
compressor isused in
an electric
turbo chiller
and an absorbent isused in an
absorption
chiller.
The absorbent decreases the
absorbing the vaporized solution.
concentrating process ofthe
natural gas, steam or hot water.
absorption power when itbecomes diluted solution by
To receover the absorption power, the heating and
As heat source,
itisused by
absorbent isrequired.
k!*%
HIGHER TEWERATU?E smE
INDOOR
A GRAIN OF HEAT=
-1=.
u
FIG. 1-2 HEAT FLOW AT ~ING
–3–
(2) J-w PRINCIPLE OF ABSORPTION
t
Install heat transfer tubes in a closed vessel and put a dry silicagel (Silicagel
is
high quality absorbent material)
in it as shown Fig.1 -3.
Take out an air in the
vesselto make avacuum 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 5C (41F).
The water take an evaporation heat from
the
water in the heat
trasnfer tubes, when itbecome 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 becasese the heat eqiovalent to the evaporation
heat is taken.
But, when the silicagel reaches the limit of absorption,
it is
immpossibleto keep a vacuum in the vessel and chilled water can not be obtained.
WATER
(REFRIGERANT)
CHILLED
WATER
e
MATER *
+Y
6EA7
TRANSFER
TUBE
FIG.
—4–”
1-3
SILICAGEL
Therefore replacing
a silicagel as an absorbent in the vessel with
new one at all
For this purpose, instead of the
times permits to get chilled water continuously.
solid absorbent such as a silicagel, a liquid absorbent such aseasy-to-handle lithium
(Such liquid
is called an absorbent.) This
bromide (LiBr) solution, etc. is used
case is shown Fig.1-4.
REFRIGERANT
VAPOR
CONCENTRATE
SOLUTION
/
[
7
CHILLED
WATER
WATER
L
EAT
TRANSFER
TUBE
PUHP
bILUTED
S(MJTION
FIG.
–5–
1-4
I
drops of
LiBr solution are allowed
to fall (Absorber) inside the vessel. The
LiBr
solution absorbs
refrigerant
vapor.
But,when the absorbent once absorbes the
refrigerant
vapor, it is diluted and dereases
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 hinted 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.
refrigerant vapor which is released from the solution when heated, is cooled in a
separate vessel (Condenser)
liquid refrigerant.
Drops of this. water are.
again introduced into the vacuum vessel
and recycled This is shown Fig.1-5.
‘
The
FIG.
–6–
1-5
(3)
SINGLE EFFECT TYPE (BASIC CYCLE)
As shown Fig.1-6,
absorption chiller.
shows an evaporator
this is the basic operational cycle
Part (l)shows agenerator,
Cooling water flows
condensor cools the
cooling water in the absorber absorbs the heat when the
by the absorbent.
The generator (1) heats
the diluted solution by driving
solution releases the refrigerant vapor and becomes the
of
the single
effect type
sbows acondenser,
part (3)
The cooling water in the
back into refrigerant.
The
regrigerant vapor
is absorbed
The diluted
heat source.
concentrated solution.
transfers tubes ofevaporator (3).
The water through the heat transfer tubes
ofvaporized refrigerant.
COOLING
WATER
-----
DRIVING
HEAT
SOUCE
.-
CHILLEO
WATER
WATER
FIG.
–7–
1-6
Drops
(4) DOUBLE EFFECT TYPE
In case of the single effect type absorption chiiller mentioned above, all condensation
heat whn the
refrigerant vapors coming from generator
iscooled and condensed
atthe
condensor, is released in the cooling water.
The double effect type absorption chiller
is used
The generator section is divided into a high
The refrigerant
vapor
-generator.
generator is used to heat the LiBr solution in the
the pressure (hence the boiling point) is lower.
As mentioned
in the single
effect
the
condensation
heat
effectively.
temperature generator and alow
produced by the high temperature
low temperature generator in which
type,
the refrigerant
vapor produced by the low
to become liquid refrigerant.
On the
temperature generator issent to the condensor
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 low temperature generator.
The refiigerant 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 refrigerat
vapor which otherwise would be released into the cooling
water.
This combination means a lower energy consumption of driving heat source.
Moreover, less heat being discarded into the cooling water translates
into a snail
cooling tower.
As shown Fig.1-7.
.
I
FIG.
1-7
–8–
(5) COOLING WATER
a) The lower temperature
of cooling water
The absorption power ofLiBr solution isstrong atthe lower temperature ofthe
When the temperature ofcooling water
in the condenser islo
cooling water.
Therefore condensed pressure becomes
condensed temperature ofregrigerant downs.
As the boiling temperature (generator temperature) ofthe LiBr solution downs
low.
calolific value
of driving heat source can
when the condensed pressure islow,
decrease. This means save energy.
b) It is not acceptable
that
the
temperature
of cooling
water
is too
low.
That is, the
As shown Fig.1-8,
a few LiBr dissolves with water at low temperature.
becomes crystallization
under the lower
LiBr solution
of high concentration
65% at the
temperature
For example, it is crystallized with concentration of
temperature lower then 42C (108F),
with concentration
of 60% at the temperature
lower than 17C (63F).
c) Chiller has some problems when cooling water
temperature becomes
too
high
When the temperature of
the cooling water
becomes to high, the absorption power of
the
The chiller
can not get the normal chiller
water
LiBr solution decreases.
Therefore, to prevent this, the maintenance for
temperature and wastes much fuel.
cooling water SYStem (epuipment and control) and water treatment are required.
d) Water treatment
of cooing
water
The water treatment of the cooling water is an inportant factor for the chiller.
If
the water
quality isno good,
scale adheres to the inside ofthe heat transfer tubes,
fuel.
As the heat transfer
resulting in the decreases transfer heat effect and waste
tubes may become corroded, itisrequired
to fully take
care ofthe
water treatment.
–9–
\
(6) VACUUM
On the earth,
we are pressed by the
air.
This pressure is
called atmospheric
called
The pressure less than atmospheric is
pressure
pressure (1kg/cm, 14.2psi).
When explaining the vacuum for the absorption chiller,
it is required to
the vacuum.
know the relation between the pressure and the evaporation pressure
o the water.
lt is experienced in a daily life that the water is boiled (evaporated) at 100C
When the pressure
is lower than the atmosheric
(212F)
in the atmospheric pressure.
Table 1-1 shows the relation
pressure (vacuum), the water boiled below 100C (21OF).
between the pressure and the evaporation temperature.
.
The water
Therefore,
refrigerant
absorption
6.54mmHg
isevaporated
atlower temperature,
when the pressure
is lower and lower.
the inside the chiller should be always kept in high vacuum.
Since the
is evaporated at 5C (41F)
to get the chilled water of 7C (45F)
by an
chiller,
it is required to
keep a high-vacuum condition with pressure of
1( /4 inchHg) in the evaporator.
Table 1-1
Atmospheric
pressure
t
1 ata.
4
vacullB
Gauge
pressure
W“2G
Absolute
m=me
*
(psig)
(inch&)
10
8
5
1
0.5
{o
(142)
(114)
( 71)
(14.2)
( 7.2)
(o)
760(29.9)
525.9 (20-3/4)
61.0 ( 2-3/8)
9.2 (
3/8)
6.54(
1/4)
–lo–
Driving pressure
for double effect
type
Driving pressure
for single
type
Atmospheric pressure
Pressure
in the cmdenser
Pressure
in the evajxmtor
effect
(7)
LITHIUM
BROMIDE
(LiBf
: ABSORBENT)
Lithium bromide (LiBr)
isamedicine made
from lithium obtained from lithium ore and
The
lithium
bromide has the same characteristic
bromide obtained from
the sea water.
Because lithium (Li) and sodium (Na) are alkali while
with sodium chloride (NaCl).
The sodium chloride (NaCl)
is salt.
It
bromide (Br) and chloride (Cl) are halgen.
is well known that when salt is left in a high-humidity atmosphere, it becomes sticky.
The lithium bromide has the same
This means
itabsorbs moisture in the atmosphere.
The higher
characteristics
and its absorption power is stronger than that ofsalt.
its concentration
power.
and the lower its temperature of liquid.
the stronger the absorption
Fig.1-8 shows the lithium bromide equilibrium diagram.
Fig.1-9 shows the lithium bromide concentration diagram.
This chart
Fig.1-10 shows the lithium bromide during diagram.
the condition of the cooling cycle of lithium bromide solution.
Fig.1-l1
shows the lithium bromide enthalpy diagram.
is convenient to show
But, asthe
Lithium bromide has corrosive action to
a metal under existing
oxygen
absorption chiller
is a vacuum vessel, almost no oxygen is in a vessel.
However, to
make more complete,
corrision
inhibitor
is added in the absorbent and further
So, attention should be taken to handle the absorbent and it
alkalinity is adjusted.
is neccessary to keep the amount of inhibitor bY performing the chemical analysis for
the absorbent.
Chemical formula : LiBr
molecular weight : 86.856
: Li= 7.99%
Component
Br=92.OI%
specific
gravity : 3.464 at25C (77°F)
point : 549C. (1 ,020 .2F)
Meltingr
Boiling
point : 1.265C (2,309F)
–1
l–
“
100
21
20
80
L:
60
12!
40
10(
LX5R-21+2
20
.
.
.
c
0
.
-25
-40
-40
-50
-75
-60
I
-1oo
-80
0
10
20
30
CONCENTRATI~
EOILIBRIUM
40
50
(%)
DIAGRAM
I
60
70
TEk!.!ERATURE
32
I
50
I
10
1.9C
75
100
125
150
175
I
I
I
I
i
20
30
40
50
60
70
80
— —.-.
200
I
t
90
100[”(!
1.85
67
1.8C
1.75
63
62
1.70
61
60
1.65
59
58
57
1.60
56
55
J
1.55
54
---r--t-”
I
I
52
—
1.50’
3=1
51
I
50
I
49
48
1.45
1.40
o
10
1
32
I
50
20
30
1
75
40
w
I
100
60
I
125
TEMPERATURE
FIG.
1-9
CONCENTRATI~
–1”3–
70
I
150
80
I
175
go
I
200
100[’C)
J
212[”F)
.
x
.
760
700
600
400
300
200
160
100
80
u
60
40
30
20
10
8
5
o
I
3240
10
I
20
1,
60
30
40
1
1
80
100
60
60
I
I
I
140
160
120
70
80
100
90
I
t-10
120
1
I
I
I
180
200
220
240
TEMPERATURE
FIG.
110
DUHRING
DIAGRAM
.130
140
1.
I
260
280
I 50
1.
300
160
I
320
170(” C:
I
338(”
F
150
\
140
130
120
110
- 160
.
100
~
-l
90
%!
—
I
I
I
I
(
130
120
---
—
80
70
60
50
70
40
30
20
60
10
0
50
40
40
45
50
55
CONCENTRATION
FIG.1-11
ENTMU_PY
–15–
60
(%)
DIAGRAM
65
70
(8) COOLING CYCLE
An example for the actual driving
Duhring diagram.
cycle of double effect
type is explained
using the
The absorbent with concena)A-B shows the absorption process in
the absorber.
tration of 63.62 at point A absorbs the refrigerant vapor from the evaporator asitis
cooled until 36.3C (97.3F)
by cooing water, then becomes diluted solution with
concentration of 58.1% at point B.
The pressure of this point is 6.3mnHg(torr)
which is equal to the saturation vapor
pressure of water at 4.3C (39.7F)
(cross point on the saturation liquid line), so,
the chilled water at 7C (44.6F)
can be produced in the evaporator.
Therefore, the higher the temperature of
the cooling
internal pressure (equal to the evaporator internal
evaporation temperature ofrefrigerant becomes high
obtained.
b) BCthe diluted
water, the higher the absorber
pressure ) .
As a result,
the
and chilled water can not be
D' shows the temperature rise process under the fixed concentration
solution pass through the low and high temperature heat exchangers.
when
The diluted solution at point D’ is healed until point D.
It releases
generator
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 atpoint
Ebecomes approx. 707.1mmHg(torr).
(This pressure depends on
the pressure of 55.7mmHg(torr)
in the condenser determining
it according to the
inside the low temperature
temperature ofcooling water. That is, the pressure
generator has to be performed at the temperature higher than 91.1C (196F)
of the
concentrated solution obtained from the cross point with the concentrated solution
of 63.6%.
Whensetting to 97.9C (208.2F)
by making this as^
6.8C (12.2F),
the
pressure of the high temperature generator becomes 707.mmHg (torr).
I
—16-
e) F-F-G shows the concentrating process in
the low temper
vapor from the
absorbent with 61.1% atpoint F'isheated by the refrigerant
As a result, the refrigerant vapor isgenerated, the
temperature generator.
concentration
rises, and it
becomes the concentrated solution of63.6%. Thus, the
second stage ofthe concentration isfinished.
The pressure atpoint
Gisdetermined by the temperature
the condensation temperature of40.2C (104.4F) the pressure
pressure ofthis temperature, 55.7mmHg (torr).
ofthe
cooing water. With
isthe saturated vapor
f) G-A’shows the process ofthe heat exchanger with the diluted solution while the
concentrated solution goes
out from low temperature generator and passes through the
the absorber and iscooled by the
starts to absorb the refrigerant
g)
As described above, itcan 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).
–17–
d
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–18–
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———
—19—
———
———
a) Evaporator
The refrigerant isdispersed on the heat transfer tubes ofevaporator.
through the heat transfer
tubes of evaporator
is cooled
refrigerant.
vaporized
J
b)
Absorber
FIG.
I-14
—2 o—
Chilled water
by the
latent
heat
of
c) Heat exchanger
The diluted solution from the absor$er
passes through the low temperature
heat
exchangerss, where it is heated by concentrated solution.
The diluted solution after
leaving the
low temperature
heat exchanger passes through the high temperature heat
exchanger, where it is heated by intermdiate
solution.
The diluted solution after
leaving the high temperature heat exchanger flows to the high temperature generator.
d ) High temperature
generator
FIG. I-15
The diluted solution from the heat exchangers
generator.
It releases
the refrigerant
vapor
intermediate
solution.
FIG.
1-16
—21—
is heated in the high temperature
and is concentrated.
It becomes
e) Low temperature
generator
The refrigerant vapor from
the high temperature generator passes through the heat
The intermediate solution in
the low
transfer tubes oflow temperature generator.
It releases
the
temperature
generator
is heated by the refrigerant
vapor.
It
becomes
concentrated
solution.
The
refrigerant
vapor and is concentrated.
condensed refrigerant in the heat transfer tube oflow temperature generator flows to
the condenser.
f) Condenser
The refrigerant vapor from the low temperature
Cooling
transfer
tubes of condenser.
condensation
heat.
FIG.
1-17
—22–
water
generator iscondensed ofthe heat
from the absorber
is heated
by
103
MIERlMRATl$i
(l)
UlJSTRATI14
w
m
w
CY
12
0
n
<
>
w
9’
2.1
‘L=’
w
i-
-1
-1
m
l-!
t
w’
I
w
IL
-1
w
z
<
L
u
-1
0
CK
1-
Z
0
c-l
k
I
II
I
II
111
I
D----r&”#--”
—23–
( 2 )DETAIL
(Fret
OF TYPICAL
view
:
CHILLER
Steam inlet
side)
%%
-lx
1-
an
>
:“
u
Zm
1-
oa
U-J
\
II
\
1-
I
u
UJ
IL
m
z
w
n
0/
.
\
-1
:
<
n
a
0
wt-lW
0
-I-I
-l_l
W
-ii-lW
-t-
--l
03
00
X3
X2
00
cl-
Z*
—w
ol-
–24–
(3) IHAL OF TYPCALW-1%?
(Rmr Viw : ham Wtlet
Skk)
w
Ix
0
3
cl
C5
z
.-
-1
0
w-l
l-w
Zz
oa
c-la
\/’
//
t---
w
>
1,
1 *
w
m
1
w
N
1-
C!i
x
cl
I.L
x
\
\
-I
I--J
<u
wl-
Ww
I-3
ma
XCE
–2
5–
2
DT4
II
\
l-uul~
IL
hlhl
I-!w
.
i
//
I Phil
/
1111
L\
Ill LDl
SV9
//
/
\\
\\
\
‘ISOLATION
FOR
REF
~,~~ ~,”~
‘VALVE
PUMP
\
\’
\
\
“kSV6
\
\/
‘ISOLATION
FOR
#2
[
PURGE
ABS
PUMP
VALVE
PUMP
HEAT
\
ISOLATION
FOR
81
FIG.
ABS
I-21
EXCHANGER
VALVE
PUMP
RIGHT
STEAM
VIEW
TRAP
1“
.+
;U
mn
x
(’U+
cum
>>
/
>>+
mm>
kii$kwmm+dll
Wn
>Z
-la
\
<n
>
\
m
zm
oa
1
l-+
\
4#
-J
Otx
O-Jo
7-
IL
/
U.in
>X
-10
<n
>
m
/
Zm
0<
I-*
us
/
J
Oiz
ma
3
w
m
>
‘L--
/
Cr
u
/
>
1IL
w
A
-1
Ill
l-u
z
, ,
,
ru
1
*
cl
/
IL
‘r
u
—2 7–
(6)
TYPCI
CCNllW_ PKL
IndiCatiOn
LAMP
OPERATION
BOARD
EMERGENCY
STOP
SWITCH
CONTROL
HIGH
FIELD
PANEL
VOLTAGE
WIRING
OPENING
/
/’
CONTROL
FIELD
,,
II
FIT.
I-23
CONTROL
PANEL
—28—
CIRCUIT
WIRING
OPENING
,,,CONTROL
/ /’
/(’
/
I
EOARD
,“
/
.-
,coNTROL
,
FAN
RELAY
MOTOP
,1
,,
MODE
.
I
/’
/
1,
SELECT
SWITCH
UNIT
POTENTIOMETER
/“””
/“’’FusEs
FUSE
HOLDERS
TERMINAL
~
BLOCK
CONTROL
TRANSFORMER
I
POWER
TRANSFORL’ER
INVERTER
/---’-’
/’”
II
u“
‘EACT”R
CIRCUIT
WIRE
BREAKER
CHANNELS
PUMP
NO. 1 ABSORBENT
MAGNETIC
CONTACTOR
\
~
)
i
~
II -—H————H——+
lu-
b
i
~
)
)
i
NO.2
ABSORBENT
PUMP
MAGNETIC
CONTACTOR
REFRIGERANT
MAGNETIC
PURGE
PUMP
MAGNETIC
CONTACTOR
CONTROL
~TERMINAL
r
P
MOTOR
HIGH
FIELD
INTERNAL
FIG.
1-24
INSIDE
OF
CONTROL
PANEL
—2 9–
PUMP
CONTACTOR
CONTROL
FIELD
CIRCUIT
BLOCKS
TERMINAL
,
BLOCK
VOLTAGE
WIRING
TERMINAL
BLOCK
TERMINAL
BLOCK
WIRING
CIRCUIT
WIRING
(7)nPmlS
TEAMCwlRclv
REDUCI
ALvE/ww
EAM
TRAP
NG
POSITION
STEAM
‘-i=+’
i R
1
LET
/-
STEAM
OUTLET
Y
FIG.
DRAIN
1-25
STEAM
TRAP(PNEUMATIC
INLET
TYPE)
DRAIN
F}G.
I-26
STEAM
—3 o—
TRAP
OUTLET
(8) SYR430L
a) Chiller
construction
symbol
EVA
Name
~tor
ABS
COND
HT.GENE
HT.REC
Hmt
LT.GENE
Law tmlpe?atum
genelatm
HT.EX
High. ~tum
kit
LT.EX
w
reclaim7-
tanperatm?
bet
#l AESKJMP No.1 Akrilmt
exchanger
exchanger
llllnp
NO.2 Aknrbent Lump
——
PUMP Refr&ant
pmlp
#2 AESKJMP
REF
b) Temperatum
senmr
Location
Name
SY-mM
DT1
Chilled water
DT2
Ccoling water
DT3
High &mpe&mz
DT4
Low temrecatlm
Chilled water outlet
before flange.
outlet
cooling water cutlet me
before flange.
cutlet
%dc Si&
generator.
generator
fmet-ator
—
.——
—
DT5
pipe
—.
of high ~k
Intermediate fmlutim
LT.GENE outlet.
Refrke=mt
outlet.
pipe
—.—
pipe of ~
DT6
Chilled water
inlet
Chilled water inlet
kfm
flange
pipe
DT7
Cooling water
cutlet
Cooling water inlet
before flange.
pipe
–31–
of
symbol
Inchxkd
controller
opemtim
bc9rd
23CH
Electronic
TC1
Strom dTain tmpemtum
Skam dram outlet
beklm
[email protected]
GmeAOr
electrod
Solution level box beside the
high temperature ~ti
El ,E2 ,E3
I
Location
Name
wlutim
level
In the control
33AL
Genmitor
duticn
level
UXltrol” M
swim
63GH
Gena’atm- DFslJR
mvitrh
Near b
69CH
(Xilled wakr
Witch
Chilled water
PCH
Palladium
SYmM
I
fkw
cell heater
V2
I
V3
I
V4
solutim
“
Mel
outlet
box
pipe
tank
Location
Besick themtank
V1
I
panel
Topcnthe~
I
Name
pipe
I No.2 m
p?si(ktheml%etadc
valve
IBesdeth
elxlrgetark
Refrigerant
blow
valve
—32—
Evaporatm
Sirk?
I
I
e) Service
valve
&mhol
Location
Name
maintmane
E?eskk?themiank
Svl
Service
mlve
for
SV2
&nice
wlve
for manomk
SV3
*ice
valve
for
refr~t
(xl the
SV4
servi~
wdve
solution
for
diluted
I’karthe
(Outkt
Besi&t&lxJnge
refrigerant
No.lalKr&ltlxmlp
of xl AK FuMP)
&nice valve for
solution
rnternkxiiate
kskk
heat
SV6
Sewim mlve
solution
fw
cmcmtrated
&si&thebw*ture
kat
ex&arw-
SW
Service
~-
valve
for
gemator
On the solution
SV8
Setvice valve
maintenance
for
~tor
I?ottanofthehigh_k
-*
SV9
!krvim
ex-
valve for hczit
Imintmance
kick
bt
Svl 1
[email protected]
cell
valve
Tcx)the~tank
@lladium
pip!?
PiPe
SV5
for
tank
the
cX-
high tenzxzati
level box
of high tmpczature
mknger’s
I-Ezl&
f)
Symbol
g) Sight
Location
Name
outlet pipeof#l
A5s FuMP
afk
valve
D1
I.kunwr for
dilukl
D2
IMnPer for
solution
intermediate
MeTIIEdiate dltim
pipe
betwem HTE4 and LTGENE
D3
IkxnP=- fcr
solution
cxlncmt?akll
Gncmtrated
Solutial
pti
betwem LTJ23W and LTEX
mluticn
glass
xl
F
Location
Name
ml
sight
level
glass
fcr
reil-igerant
—33–
Ikskk
eVam&or
114
SAFETY
Elm
(l)
CHLLED WATER AN) COOLNG WATER
I
No
of chilkd
Setting
1
Ink-lock
2
Interlock of Cmling water
3
Fw
4
Gilled wakfmzz
IX-&Aim
(LAYw-cut of chilled wati cutlet
5
(2)
Item
flow rate
water
water
Alarm indication
pmnp
Indication
lamp.
m
Indication
lamp
Indication
lamp
Indication
lamp
Indication
lamp
of chilkxl wak
Low-cut of mling
point
50 %
2.5°C (36.5”F)
knp.)
inlet kmpemti
19”C (66.2”F)
after 30 min.
HGli TEWERATLRE GEMRATOR
No
Item
Setting
6
High-d
of ~tor
7
High-art
of gmmtcr
~
8
High-art
of
sohrticxI level
9
Ixnv-art
of
10 Crystallization
(High-cut of
gmmitcr
f3mm#or
tempemtum(boling)
soluticn
point
165°C (329”F)
I okg/an2G
.—
level
protection
mhrticn an(mtmticn)
—34–
Alarm indication
65%
after 10 mm.
I
Indication
lamp
Indication
lamp
Autmmtic
red
Indication
lamp
Indication
-
lamp
(3) M3TOR
Item
No
11 Ov~t
day
I
(4)
12 OvellJrrmt
mlayof
13 Overmn-ent
relay
Setting
of !40.1 aklrklt
plum
No.2aklrbentpm-lp
of mfrigemnt
m
point
Alarm indication
RaM ~
Indication
lamp
Rated ampemge
Indication
lamp
MM
Indication
lamp
~
OMRS
14 rnvder
15 Fuwer
Setting
Item
No
point
Protection
interruptim
16 Wttering
[email protected]
17 Rupture
disk
flow
Indication
lamp
Indication
lamp
100 m sec.
protectial
of
Alarm indication
witch
–35–
3
sec.
SECTION
2 OPERATION
CONTENTS
&e
~I(jN
2
-TION
2.1
-TION
No.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~~
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . ..~7
Bf)~
( 1) DETAILOF OPERATION
BOm ------.-.-------.....-... -...............37
(2) INSITWCTION
w mzYs ------.-------------------..... ..-... -.-..-........3g
2.2
2.3
TEMpERA~ ~1~
(1)
DETAIL
(2)
(3)
~
OF ~
SETTI~ -
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4o
DIGITALDIspLAy --..............................41
........ ................ ------””----”---------------”----”43
mION
-------...-................ ...................46
SEWDIAGW3TICSFUNCTION-----------------.
--.-------.............46
ERRORMESAGEBY f31F-DIAGNOSTIC .. ...... .... ... ... . ... ... .. ...47
PREPARATION
FORSTARTw ..................... ............................49
(1)
(2)
(3)
2.5
MONITOR
SEIJ?-DIAG~I~
(1)
(2)
2.4
OF
.......................................................4o
CONFIRMATION
OF OPERATION
WI... ... ... ... .. . ... ....
49
CONFIRMATION
OF SETTINGnI~
--------.-...---.................49
aFFIRMATIONw ~IPMENT .......”....................................~()
~ERATION ----------------------.............................. ..................5l
-TION
....................................................... 51
(1) ~1~
OPERATION
BOARD
WRINGOPERATION
- (2)
------”---------”””-------””-53
TIM C~T .................................... ........... ......55
(3) ~~~
~~OL ------------------............. ................56
(4) MAxI~ 1~
co~m
w #1 ~ PUMP.................................57
(5) Imm
(6) _
OF CHILUZDWA~ ~~
..........................58
–3
6–
21 OPERATION
BOARD
( 1 )DETAIL
OF OPERATION
BOARD
CD...
Q.:
G9
a.:
-,
. . ........ ... .
;
TWPI?.RATORE
OPERATION RIKORD
!0
GENERAToR
0
CHI~
OF’ZRATION
\ o
STEAM ORAIN
o
c!ilLLm
ottPFF
;OCNIWTLET
:OCO
! 0
OREF.
SET POINT
IINLET
,
::
orHmnP::
,,
::
FIJIIP OPERATION
:.
::
,. . . . . . . . . . . . . . . . ..~~
. . . . .. . . .. . . . . . . . . . .. . . . .
:
:
/STOF
RON
;0
OCNILLER ; :
:0
OREF.
;0
onl
;-0 ALAM
PUM?
\
:
ARs. Pur
:
~. . . . . . . . . . . . . . r––q
B~
.SlT3f
CONTRCLVALVE
I==sii?
'-------------------------------------------------------
T
‘::’!
. . . . . . . . . . . . . . ...1
!!..!.:E...I
[.E
E:’
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .,
..... .. .. .... . .....
! EATEXALARM
MOTORALARM
;ocHwmP.
0
~OCHI
FLOW RATE
;[email protected]
0#1
O
:OCOUUY.
RW.
PUMP
GENERATOR
ALARM
SYSTEMAURM
0
PRF-SSORE
OCHEPUIIP
o
TIWPKIM(XNTRAT
ARS. FfJIIP
#2 AK,.
PIMP
( IKI?WJXK)
,
:
OCOWFUMP
ION
FLOW RATE
:
;
:
:
:,
. .......
I
.,
~-cs
FIG. 2-1
i?5.
!
Typical Operation Board
–3
7–
.
(1) 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
data of lighted item.
temperature,
and digital display (Red ) which indicates
(2) Select key
There is “SELECT” key for selection ofdisplay data item.
The item returns
in sequence by push the key.
There are
automatically after approx. 1 minute.
chilled
and hot water
parameter.
The item is displayed
to generator
temperature
^and *
keys for setting of
(3) Equipment RUN-STOP indicator
This area has some “RUN” indication lamps (Green) and some “STOP” indication lamps
(Red) which indicate conditions ofthe equipment.
(4) Alarm indicator
The indication
lamp flickers
(6) Operation mode select key
There are keys for
(7) Alarm buzzer stop key
There is buzzer
chiller.
chiller
when the chiller
has abnormal condition.
operation.
stop key when the buzzer
—38—
sounds
by abnormal
condition
of the
(2) INSTRUCTION OF KEYS
“SELECT”
For the use of
item selection for display.
The item is
displayed in sequence
by push the key
Change the item automatically when you push the key
than 1 second.
continuously m
“^”
“*”
“OPERATION"
Operate the chiller by local mode.
The chiller does not operate when the
mode is set to "remote"
The indication lamp on "OPERATION"key flickers
when the mode isset
“Local” .
For the chiller
operation, You must push the key over 1second
This is protection
of the chiller.
continuously.
Please push the key continuously until flicker the indication lamp on
the key.
“STOP”
Stop the chiller 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 stop, You must push the key over 1 second
This is protection
of the chiller.
continuously.
Please push
the key continuously until flicker the
indication lamp on
the key.
“LOCAL"
For the use of operation of the chiller by “OPERATION”key on the
operation board.
When the mode isset
“Remote”, the chiller does not operate.
“REMOTE"
For the use of
"OPERATION"
“ BUZZERSTOP”
For the use of stop of alarm buzzer
abnormal condition of the chiller.
operation
ofthe chiller by
remote panel
key is not accepted on "Remote" mode
—39–
when the buzzer
sounds
by
-“..
2,2TEMPERATURE
SETTING
( l) DETAIL
OF “MONITOR
TEMPERATURE
“0 GENERATOR
o STEAMDRAIN
0 CHWOUTLET
o CO W INLET
0 CONTROL
VALVE
I
:
z
OPERATION
RECORD
0 CHILLEROPERATION
() CHILLERON-OFF
0 REF. PUMPOPERATION
SET POINT
0 CHWTEMP.
“
E
W
I“o’%fi
O HOURS
OSTARTS
3.
a
v
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.
I
Fig. 2-2
is drown generator
temperature.
The indication lamp after digital display lights
Unit of temperature is “F ( Fahrenheit ).
–4
o–
according to unit
of item.
(2) SEQUENCE ON THE DIGITAL
iteiu is displwed
DISPLAY
in sxqueme bypush
Sequence Lighted indication
(symbol )
—.
1
&qumce
the key.
items am as follows;
Sample on the digital
lamP
Generator temperature
(GENERATOR)
3
display
G
G.
G
( 300.0)
2
drain temperature
(STEAMDRAIN)
Steam
4-I
z
D
3-
i2
( 203.0)
3
Chi 1led water
out let tenIperature
(CHw OUT~)
-
4-
E
( 44.0)
4
Cool ing water
inlet temperature
(CoW INLET)
H
5.
( 85.0)
—
.—
5
G
Steam control valve
T
position
(CONTROL
VALVE)
zfZ
9-7
( 209.7)
6
7
Chiller
Operating hours
l“’”
;.:=;
times
(CHILLERON-OFP)
:
‘:”:”’;:”):
z=
(
8
Refrigerant pump
operating hours
(REF.PUMPOPERATION)
9
G
120)
D
( 900)
–41–
Sequence
9
10
Lighted indication lamp
——
Chilled water
temperature setting
I
for temperature
(CHWTEMP.)
—
—
\
Chilled water
temperature setting
I
for proportional
(CHWTEMP.)
Sarnpleon the digital
.—
-
-
d
display
—
w
D
(t 44. o)
F
‘
z.
G
(P 2.0)
—— .—
11
Chilled water
temperature setting
for integral
(I 800)
12
;;;*
;,
,
for differential
(CH WTEMP.)
Display
sequence
repeats
No.1
(d
thru
No.
10)
17.
Note) 1 It will happen to display below number between No.1O and No.11.
During chiller operation, below number is displayed on the digital
display
when cooling water inlet temperature is below setting point.
This number is
set
automatically
during
below setting
point
of cooling water
inlet
temperature.
Chilled water temperature is control by this number during
below setting point of cooling water inlet temperature.
EImIml(c464,
.
–4
2–
—
—
( 3) SETTING
METHOD
Chilled water outlet
and differential).
a) Chilled water
temperature is controlled by digital PID (Proportional,
It is able to get chilled water of stable temperature.
setting
Setting
Chilled water
temperature
point
Integral
range
item
Range
step
outlet
(t)
41.0-
53.6
‘F
Proportional
(P)
2.0-
Integral
(I)
o
- 2500 SEC
Differential
(D)
o
-’
10.0
0.1 -0.2
0.1-
0.2
10
m
19X
100 SEX
Por
PDactimat
OS
P or PI acticm at O w
Note) Temperature data sampling is 10 second interval.
Notice 1. Please confirm the
2. “^”and”
V
indication
keys
do not accept
3. If you change the setting
new setting point soon.
4. Original
setting
point
lamp of setting
to cross the range
during chiller
is set
at
item before setting.
operation,
number.
chiller
is controlled
factory.
5. Setting point is stored by non-volatile memory of semiconductor.
Therefore, setting point is kept continuously when power cut off.
.
–4
3–
by
c) To take an example(Chilled
Setting
water setting)
item
Chilled water
temperatlnw
outlet
(t)
44.0
(F’)
2.0
Proportional
Target
Original
‘F
46.0
‘F
2.5
:~tial
+-t=: +++=+
Setting
procedure
10.
1
is as follows;
Digital
Key
display
“SELECT”
,
ImmIIl
(t 44.0)
2
Explanation
Select the chi 1led water temperature
setting(CH M TEMP.) by push the key.
The indication lamp of “CHV TEMP.”
1ights.
.
“A”
‘;git:i;$&es
~
0-1-
(t 44.2)
3
“A”
ErIIml
~:+j!y~;:;;:
(t 46. O) data decreases
0.1. ”
4
“smT”
Display data mdlcates proportional
‘Shthe
‘w” temperature.
of chi 1led“Win:
water outlet
m
(P 2.0)
5
“A”
‘lE;t:i;:zesO1*
~
—
6
-—
(P 2.1)
—.
“A”
~
(P 2.5)
–44–
~gJ$FJ:::;::*
data decreases
0.1. ”
I
No. I
7
Key
“SELECT”
I
Digital
I
display
Enm!Ill
[email protected] ion
Push the “S3JXT” key.
Display data indicates integral
chilled water outlet t~ture.
of
(I 800)
8
“A”
10
“SEIJXT”
EInml
(d
11
“A”
12
“A”
10)
—4 5—
l%sh the “~
key.
Display data indicates different ial
of chilled witer outlet temperature.
203SELF-DIAGNOSTICS
FUNCTION
( 1 )SELF- DIAGNOSTICS
Self-diagnostics
FUNCTION
function
a) %me indication
when the lnwaker of the chiller
tum
on.
lauws light as shown Fig.2-3.
o :Indication
Symix)l
Symbolo:
symbol B
starts,
Indication
: Indication
lamP does not litit.
lamP lights.
lamP of the key lights.
SRTPOINT
ooiw TulP.
.“.
“
.,
TEMPERATURE
O -ATOR
OPERATION
RWORD
0 CXIW OFI?RATION
c)SIEAHDRAIN
o cNILLmON-m
●
● OIILLER
oawm
0
●
●
● REP.PUIIP
● tHABs. PtnlP
●
●
●
●
REP. FWP
OPERATION
ocQwlNLEr
O CCNTROL
VALVE
HZHZ13ii52
STCP RUN
WAW.
W
PURCE PUMP
“
v
WATDlALARH
KITORALARM
GENERATOR
ALARM
SYSTRU
AL4Rn(INTERJxm
● 0IWTENP.
● RW. PUMP
● ms.$m
● CNFPWP
● OIWFLOI RATE ● ttl
AES.PunP
● #2 ABs.mP
● CO WTENP.
● cormP
● TaP/~
TION
● CO WPWR ATE
FIG. 2-3
times after 1 second of turn on the breaker.
lamp turn off after buzmr.
b)
Buzzer sounds 4
Some indication
c)
Self-diagnosis
is worked.
Version number is displayed on the digital display,
Version number is as shown;
self- diagnosis.
if power circuit.
has no error
by
mzIml(v7.,
.
Note) Version number subjects
to
change chiller’s
specification.
d) Generator temperature is displayed on the digital display, if control
Generator temperature is as shown;
error by self-diagnosis.
(Blew number is for reference.)
–46–
circuit
has no
.-
( 2) ERROR MESSAGE BY SELF- DIAGNOSTICS
Error message 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 Sanyo’s service representative after
memorized the error
message.
a) Power supply error
This error massage is indicated the error of power supply to electronic
The key access is not accept on this message.
It is necessary to call to Sanyo’s service representative.
~
controller.
(,,,)
b) Electronic controller error and setting point
(The message on the digital display flickers)
error
This error message is indicated the error of electronic controller or setting
Please call to Sanyo’s service representative with below error number.
It is not accepted the chiller operation during indication of this message.
=(
Err*,
Indicate
Kind of error
point.
the kind of error
message
message
-------- @ Error number ERR-6
:-----i
}.. . . . ....
—
-----. .......... ---; ;“”1
::
● -------::
‘--------------::
:- -------------------,.‘ ---------------------------
~ Error number ERR-7
@
0
@
@
@
@
Error
Error
Error
Error
Error
Error
number
number
number
number
number
number
ERR-1
ERR-2
ERR-8
ERR-3
ERR-5
ERR-4
CDError number ERR-1 (Electronic controller
CDWor number EIU-2 (Setting point error)
error)
@ Error
error)
error)
ERR-3 (Electronic
controller
number ERR-4 (Number of times data
@ Error number ~-5
(@eratiw
buns data
controller
@ Error number ~-6
(Electronic
@ Error number ~-7
(Electronic controller
@ Error number ~-8
(Electronic
controller
number
@ Error
–4
7–
: Call
: W
to senice.
the S?tting point and call
Semite.
to
: Call to semice.
: Call to sewice.
error)
: Call
to
service.
error)
error)
error)
: Call
: Call
: Call
to
to
to
service.
=~ice.
mvice.
‘1
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.
~(~.~rr)
This error
cleared when “OPERATION”key is
message is
d) Sensor error
(Ihe message on the digital
display
This error massage is indicated
Chiller stops safety when high
chilled water outlet temperature
The chiller operates continuously,
broken.
But it is possible to
Please call to Sanyo’s service
flickers)
the temperature sensor
temperature generator
sensor(DTl ) are broken
when other sensors(DT2,
control bad condition.
representative.
... ... ......
.. .... ... ---
Kind of error
pushed.
Indicate
trouble.
temperature sensor( DT3) and
during operation.
DT4, DT5, DT6 and DT7) are
the kind of error
~
message
:[email protected] Error number SER-2 (DT2: Cool ing water outlet)
@ Error number SER-5 (DT5: Condenser)
:
:--------------------------------:[email protected] Error number SER-3 (DT3: High temp. generator)
I
I
-
,....! ‘
—
,......i :..,
—0/
,—
,
------------0 Error number SER-4 (DT4: Low temp.” generator)
1..........----- @ Error number SER-1 (DT1: Chilld w.outlet)
—
● --------- 0 Error number SER-7 (DT7: Cool ing water inlet)
‘----;[email protected] Error number SER-6 (DT6: Chilled w. inlet)
—
Note) It is posible to change the display data and ~tting point on the digital display
using the”SLWT”,
”A”
and “v
“ keys during error massage indication of
Electronic controller error, setting point error, pcwer failure error and -r
error.
–48–
2}4PREPARATION
FORSTART
UP
Please confirm below items again before operation.
( l) CONFIRMATION
OF OPERATION
a) Operation switches
~;CI~;~DL
AUTO
in the control
panel
REFRIGERANT
pu~p
>
F
SWITCHES
CLOSE
PURGE
PUMP
AUTO
STOP
STOP
MANUAL
MANUAL.
\
START
\
\
FIG.
2-4
TYPICAL
(D Steam control valve mode select
@ Steam control
@
~frigerant
@ We
switch
OF SETTING
water
“temperature
@ Chilled water
outlet
ON
SWITCHES
“AUTO”position
Witch ----------------“STOP”’position
~~---------------“’AUTO”pxition
------------------------------“STOP” position
POINTS
Wtting
point
(Setting
sample)
temperature ------------------------- 44°F
..... ......
Q Proportional
@ ]n~]
OPERAT
switcl-------------
!x?lect switch
mode
pump operation
( 2 )CONFIRMATION
a) Chilled
valve open-close
pump
\
2
................................ .......... ............... .....800”
@ Differential
10
–4
9–
( 3) CONFIRMATION
a) Steam
OF EQUIPMENT
line
(1) Open the main valve of steam line.
(2) Never leak the steam around steam line.
b) Water
system
(1) Some valves
water
line.
(2) Some valves for cooling water
line.
(3) Other
for chilled
system
c) Cooling water
line.
inlet
(1) Cooling water
.
temperature
inlet
temperature
(2) Take care that the cooling water inlet
d) Electric
wiring
temperature
is kept above 66F
connection
(l) Interlock
of chilled
water pump
(2) Interlock
of cooling water pump
Note) Interlock signal is detected by energizd DC 24V from the chiller.
Please select the contact resistance within 100Q .
(Please seperate other power line.)
e) Remote signal
No
1
2
-1
3
connection
Signal
name
.—
—
Answer back signal
for operation
Stop
indication
operation
lamp
lamP
indication
—
Signal
Operation
stop
output
ON signal when
chiller/heater
stop
output
4
Alarm indicatim
5
——
Cooling mcde indication
lamp
Output
6
Remote ON-WE signal
Input
I
_
output
..—
lamp
Introduction
——
output
ON signal
when C/H
OPemt.es.
i--Abnormal : ON
Operation
–5
: ON
:OFF
: OFF
[Cooling mode :(IN
ON-OFFsignal of C/H
o–
Pleas? select the
resistance
within
AC250V O.lA.
I
(l) COOLING OPERATION
a)Local mode operation
<Operation)
confirm the operaticn
mode selectkey
on the operation board.
“LOCAL” indication lamp of the key is lighting.
Ifyou operate
the system by manual,
water pump sequentially.
Please
Confirm to light
continue to push the
"OPERATION" key on the operation board atleast 1sec.
“OPERATION”indication lamp ofthe key.
Chilled water pump and cooling water
isconnected to the chiller.
system
Chiller
please operate chilled water pump and cooling
pump are operated by automatically, ifthe
isoperated automatically by sequentially.
<STOP)
Please continue to push "STOP" key on the operation board atleast 1second.
Confirm to light “STOP" indication lamp ofthe key.
connected to the chiller, pumps are stop asfollows;
When the system is
Cooling water pump stops approx. 1thru 5
minutes later.
Chilled water pump stops approx. 2thru 6
minutes later.
chiller stops after dilution cycle operation for approx. 6
thur 15 minutes.
1
—51–
b) Remote
mode operation
(Operation>
(1) Confirm the operation mode select key on the operation board
"REMOTE”indication lamp
(2) Ifyou
operate the system
water pump sequentially.
make contact
with
(4) Chilled water pump and Cooling Water
is connected to the chiller.
is
(1)Please
panel.
operated
automatically
cut off the chiller operation
by
squentially.
switch (or stop
switch)
to the chiller, pumps
(2)When the system isconnected
Cooling water pump stops approx. 1thru 5minutes later.
Chilled water pump stops approx. 2thru 6minutes later.
chiller stops after dilution cycle operation for approx. 6
(3)Please
stop the secondary air conditioning
on the remote control
are stop
as follows;
thru 15 minutes.
units after
stopped chiller w
( 2 ) OPERATION
a) The
BOARD
operation
DURING
OPERATION
beard during normal operation
Generator temperature is indicated on the digital display
Indication lamps light during operation as follows;
Symbol
o :
symbol
● :
symbol
H :
Indication
Indication
Indication
SET POINT
●
GENERATOR
o
fXIM
o
SIEAN DRAIN
o
CHH-LJR OROFF
o
●
oilLLFx
0
REF. FUMP OPF.RATION
o
●
REF. PIMP
o
●
I!l ABS. PUMP
0
●
#2 AM.
●
O
PURGE PWP
ooi~m
o
CO W INLET
o
CWTRCL
OFERATION
Ooirm
VALVE
A
STOF’
RUN
o
PU!iP
v
WATER LINE ALARM
MOTOR ALARM
GENERATOR ALARM
SYSTEM ALARM ( INTEIWXX)
ocslnT?lLP.
0
0
OCNW
OOi
WFLW
RATE
00JWTEW.
OOIWFLCIW
RIF.
PUMP
O#IAM.
PUHF’
o
PUMP
#2 AK.
operation.
lamp does not light.
lamp lights.
lamp of the key lights.
OPERATION RECORD
TENFSRATURR
during
PRJ?SSURE
PUMP
OCOSPUJIP
0
TEIIP/CONCENTRAT ION
RATE
FIG. 2-5
Typical operation
–53–
bar-d
ALMY
Oizzm
r—-j
k——
STOP
c) Power failure
error
masage
during
operation
This message is indicated when it is happen to power failure
Ihe message on the digital display flickers.
above 100 millisecond.
-(~.~rr)
~
Chiller stops immediately, when it is happen to power, failure.
Chiller has no dilution cycle operation.
Please” operatee dilution” cycle
after return the power supply.
d) Sensor error message
The message on the digital display flickers.
This error message is indicated the temperature sensor
Chiller stops safety when high temperature generator
chilled water outlet temperature sensor(DTl ) are broken
The chiller operates continuously, when Other sensors(DT2,
broken.
But it is possible to control bad condition.
Please call to Sanyo’s service representative.
operation
trouble.
temperature sensor( DT3) and
during operation.
DT4, DT5, DT6 and DT7) are
.. ..... ......
‘-----------Indicate
Kind of error
the kind of error
message
message
~--------------------------------------:[email protected] Error number SER-2 (DT2: Cool ing water outlet)
,[email protected] Error number SER-5 (DT5: Condenser)
:! .... [email protected] Error number SER-3 (DT3: High temp. generator)
.: :
-:
I
t--~ ~
I
I
—
[email protected] Error number SER-4 (DT4: Low temp. generator)
I
l-----~
;“”-1 }[email protected] Errornumber SER-1 (DT1: Chi 1led/hot w.outlet)
——
●
[email protected]
Error number SER-7 (DT7 : Cool ing water inlet)
—0/
w. inlet)
‘[email protected] Error nuuber SER-6 (DT6: Chilled/hot
Note) It is posible to change the display data and setting point cn h
digital display
using lhe”SELIET”, ”A”
and “ v “ keys during error masage indicaticm of
Electronic controller error, setting point error, puwer failure error and sensor
error.
—b4—
‘
(3) CUWIW Tt&
a) Dilution
Operatim
STEAM
CONTROL
VALVE
CHART
cycle
of diluticm cycle
tim
tmpemturw.
o
I
ON
81
ABS
PUMP
OFF-
–
ON
ti2
ABS
PUMP
I
I
I
I
I
I
I
I
I
I
[
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
OFF-
I
I
I
1
I
I
—
I
ON
REF
PUMP
OFF-
COOLING
WATER
PUMP
by gerEY+x
100%
I
CHILLED
WATER
PUMP
is &cidd
I
[
I
I
I
I
–
ON
OFF-
–
‘N
OFF
II
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
1
I
I
II
I
I
I
I
i
I
I
I
I
I
I
I
I
I
\
I
d
I
I
I
MIN.
~
! T2
I
L,To*
CLOSE
FIG.
2-6
TIME
TIME
—5 5–
CHART
OF
CONTROL
OF
DILUTION
-1
VALVE
CYCLE
I
I
(4) MAXIMUM INPUT CONTROL
Steam control valve is controlled
for chiller protection
by cooling water inlet
temperature without specification.
Maximum input is decreased, when cooling water inlet temperature is below 28C (82.4F)
or above 33C (91.4F).
a)
Control
data
cooling water inlet temperature
controlled
by the data.
b) Control
is detected
1 minute interval.
Maximum input is
diagram
10 ..—
z
— ———— .-——
.——
——— ___
__
P
.
~7.5
m
i-
5
.
100’ c
212° F
125.C
257” F
GENERATOR
2-7
IZATION
HIGH
TEMPERATURE
EVASION
AREA
FOR HT.GENE
EVASION
AREA
FOR
SOLUTION
.———
100
1
— l–
I
x
_______
——.
——— ——— +––––_L_
40
I
I
I
I
I
I
I
i
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
20
II
I
I
I
I
I
I
I
1
60
I
I
I
1
J.—— ——
80
155’C
311” F
TEMPERATURE
FIG.
CRYSTAL
150.C
302. F
I
I
I
o~
19.C2(I”C
22” c
24. C
66”F6B”F
?2” F
‘?5’ F
COOLING
WATER
26°C
2fl’c
30* c
79.F
82°F
86.
INLET
FIG.
—56—
TEMPERATURE
2-8
F
32°C
90” F
34°C
93. F
(5)
N’v?3?TER(xYWRuoF#l
Rotatkr-1 d
N&l
PJ3s FW?
aklrtxlt
~
is
Cr=?+alkd
b’
invel-kr.
60
N
x
>
c1
z
I.1.l
a
a
28
w
w
IL
0
100
o
COOLING
FIG.
2-9
LOAD
TYPICAL
—5 7—
(%)
CHAR
ACT
RI STIC
( 6) PRESET
OF CHILLED
WATER
TEMPERATURE
Setting point of chilled water outlet is imreased automatically, when cooling water
In this case, setting point is able to indicate on the
inlet temperature is lower.
Temporary setting point is
Please push the “SELECT”key.
digital display board.
indicated after chilled water setting point.
mIzIml(c464,
,“.
.
Please check the cooling water inlet
chilled water outlet temperature.
to cooling water inlet temperature.
12”C”
temperature, when you change the setting point of
Because there is the limit for setting according
Setting range is as follows;
._–––––––_–––––
54’F
/ 1
I
I
I
I
I
I
r
+
11”
52”
I
I
I
1
i
I
I
I
I
20” C
6B” F
““”
I
1
22”
72’
c
F
24*
75”
I
C
F
COOLING
WATER
TEMPERATURE
FIG.
–58–
2-10
26*C
79” F
INLET
I
I
I
1
I
26°
B2°
C
F
3 MAINTENANCE
SECTION
CONTENTS
Page
No.
SECTION3 MAINTENANCE
----------------------- ----------------------------------------59
3.1
DAILYwIm~
(1)
(2)
3.2
(2)
(3)
(4)
3.3
PURGING---------------------------------------------------------------------62
MAINIENAMX
OF PURGEPUMP----------------------------------------64
REFRIGERANT
BLOWDOWN
-----------------------------------------------65
SOLUTION
MANAGEMENT
--------------------------------------------------65
WATERTREATMENT
-------------------------------------------------------------66
(
1 ) wA~
(2)
TREATMENT
---------------------------------------------------------66
WATER TREATMENTFOR LONG TERM SHUT DOWN------------------
69
MAINTENANCE
FOR INVER’IER
-----------------------------------------------70
( 1)
(2)
(3)
(4)
3.5
INSF12CTION
0!? CHI~/HEA’IER ---------------------------:-----60
OPERATION
DATARECORD------------------------------------------------6O
9MSCNALMAINTENAKE
-------------------------------------------------------62
(1)
3.4
"----------------------------------------------------------6o
INSULATION
TESTFOR INVERTFR““”-”-”---”---”-”””-------”-”””””-”-70
INWECIIONBEFOREOFRRATION-------------------------------------70
MAINTENAKE
----------------- -------------------------------------------71
M&WWENT LOCATION-------------------------------------------------72
PARTSINSPECTION
------------------------------------------------------------73
–5
9–
3.1
DAILY
MAINTENANCE
(1) INSPECTION OF THE CHILLER
If you find
(1) Steam
the abnormal condition, please call
to service
representative.
leak.
(2) Abnormal noise ofabsorbent pumps
(3) Abnormal noise ofrefrigerant pump.
Please ask
(7) cleaning
contructor.
below items to your system
ofthe cooling tower and strainer ofthe
(8) Check the condition of
cooling water
line.
Fig.3- 1 (see
to
cooling tower.
(9) Check the air vent of the pipe line.
(2) OPERATION
DATARECORD
Please record the operation data regularly.
It is useful
to protection of trouble
The
sample
of
operation
data
shooting.
sheet
—6 O—
is
shown
next
page).
Operating
I terns
1
Time
2
Ambient
temp.
3
Chilled
water
flow
4
Chilled
water
inlet
5
Chilled
water
outlet
6
Cooling
water
flow
7
Cooling
water
inlet
8
Cooling
water
outlet
9
Generator
pressure
10
Generator
temp.
11
Steam drain
12
Steam
13
Steam control
position
supply
record
Uriit
“C
rate
temp.
temp.
rate
temp.
temperature
pressure
valve
temp.
/
m3/h
“F
“ gpm
“C
/
OF
“C
/
OF
mglh
“ gpm
“C
/
“F
“C
/
OF
cmHg
“C
/
OF
‘C
/
OF
psig
%
Remark:
FIG. 3-1
—61—
sheet
Date :
//
.
.
.
..
3.2 SEASONAL MAINTENANCE
It is necessay
solution,
etc.
for the chiller
to maintain
the purging,
refrigerant
blow down and
( 1 ) PURGING
a) Purging
procedure
PALLADIUM
CELL
/
(During cooling operation
and Stop)
V2
/
Operate the purge pump.
Open the No.1 purge valve (VI).
Check the attained vacuum
by the manometer.
(Vacuum is below 4 mmHg.)
Open the No.2 purge valve (V2)
for 1 minute.
Close the No. 2 purge valve (V2).
Open the No.3 purge valve ( V3)
for 30 minutes. “
Close the No.3 purge valve (V3).
Keep to operate the purge pump
for 30 minutes.
Close the No.1 purge valve (Vl ).
Stop the purge PumP.
V3
/’
SV2
/
/s”l
\vl
h
Note) 1. Please open gas ballast valve
until sounding exhaust gas.
It is easy for purge pump oil
to become dirt, when gas ballast
close.
valve
T
PURGE
2–
PUMP
\ PURGE
TANK
\
FIG.
–6
MANOMETER
3-2 PURGE
UNIT
LIQUID
TRAP
b) Mm9m!mmtofthevam
Valve
position
Mmsammwnt
No
1 Attaind
V1
vaammoflhe~rumP
2 Pressure
V2
V3
Close
Close
Close
Close
open
Close
open
Close
item
Open
in the shell
3 Pllrs2tank~
Reading method of manometer
Please read the differential ofmercury surface
Usually, the right side surface of mercury ishigher
If it reverse, please call to service representative.
than left
43
wnll-41
DIFFERENTIAL
‘PRESS”-’
t
0
30
I
FIG.
3-3 MANOMETER
—6 3–
side.
(2) MANTENPNEW- FUWEFUW
Please change the purge pump oil,
attained to below 4 mmHg.
when the attained
Open the drain cock.
Discharge the oil.
Close the drain cock.
Change the oil from oil surely
port until
vacuum ofpurge pump does
the center
not
of sight glass.
Note) l. When you change the purge pump oil, please stop the
purge pump.
2. Recommend the turbine oil for purge pump. (IS0 viscosity grade
: 56,58)
3. If purge
pump does not operate,
please
call to Sanyo’s service
representative. 4. If attained vacuum above 4 mmHg when you change the oil,
please call to service
representative.
LIQUID
“K
DRAIN
BALLAST
VALVE
T
\
TRAP
PLUG
/—EXHAU5T
GAS
SUPPLY
PORT
PORT
OTOR
L
PURGE
PUMP
.
FIG.
3-4 PURGE
—64–
PUMP
few absorbent mixes
Chilled water outlet
But temperature
in the refrigerant during cooling operation.
temperature rises
up during refrigerant blow
drops after
blown down.
down.
b) Blow down procedure
(1) Confirm to operate the refrigerant pump.
(2) Open
the V4 valve(for refrigerant
blow valve)
for 1 or 2 minutes
(3) Close the V4 valve.
(4) repeat
(1) (2) and (3) about 3times
Note) Take care that
the refrigerant
pump does not have cavitation.
(4) SOLUTIUN
MANAGEMENT
Itisnecessary
for the solution (Absorbent) to manage the inhibitor.
The inhibitor adjustment is
required technical knowledge.
Please consult with
service representative.
\v 4
FIG.
3-5
—6 5—
3.3
WATER TREATMENT
It is important for chiller to manage the water treatment.
As the water treatment is required technical knowledge, please
representative.
consult
with
service
(l)WATER TREATMENT
The cooling water ofthe 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 isevaporated and dissolved salt (hardness
componet, chloride ion,
sulfate ion, etc. ) m 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 m the cooling tower, the sulfurous acid gas,
dust, earth and sand, etc. in the atmosphere
will intrude into the cooling tower,
further degrading the water quality.
Inthe cooling
water system, the trouble arising
from water
are mostly caused by
these causes and typical causes include corrosion. adhesion of scales and generation
of slimes.
a) Standard values of the water
quality
First of all, water quality control
analyzing the water quality.
method
is determined
due to the results
of
The standard values ofwater quality are shown in table 3-1 asan example.
And water
quality should be controlled within the standard values.
The control method includes
the blow control method in which all water is replaced periodically
or water is
continuously and forcibly replaced as suppress the concentration
of water asmuch as
possible and a method in which water processing chemicals are put into the water
because ofthe poor
quality ofthe make-up water orsaving the water..
—66—
‘fable 3-1 Standard wilws
of the water quality
*1 Cooling water
Chilled
inter
Tendency
Items
(he-pass or
Circulating
!lkike-lxl
water
Circulating
Make-up
inter
COrScale
ros i on
(2SC )
*2 6.5-8.0
%2 6.5-8.0
%2 6.5-8.0
*2 6.5-8.0
0
Electrical
conduct ivi ty
(25°C Ks/~)
800 or less
200 or less
500 or less
200 or less
o
M alkalinity
100 or less
50 or less
100 or less
50 or less
Total hardness
(m)
200 or less
50 or less
100 or less
50 or less
Chlorine
ion
(m)
200 or less
50 or less
100 or less
50 or less
o
Sulfuric acid
ion
(m)
200 or less
50 or less
100 or less
50 or less
o
Total iron
(m)
l.Oor
0.3
1.0 or less
0.3
0
Sulfur
Not detected
Not detected
Not detected
Not detected
o
1.0 or less
0.2 or less
0.5
or less
0.2 or less
o
50 or less
30 or less
50 or less
30 or less
*3
*3
m
0
o
(m)
ion
(m)
Au.fmoniuuion
(m)
Silica
(mm)
—
Free carbonic
acid
(m)
(Note
o
less
10
10
0
o
0
1)
*l: TheStandadvaluesOfcmlingwatf?randmke-uPwakr arethe StarKkdValuesoftk
Jam
Refrigemtim/Air
Ccnditimcr In&[email protected] knciatim(JRA
9001-1980).
Themsm*
ttle Mvalue0f
lilenlake-uP
watfris6.oto8.ois
thatnopmblein
wculd be ~ted
as the #l value will ~
while the wati
is ciru.dating in Ihe
t.cmverevmifthe
rilvaluetemmcmrily
~
whm carixnic acid gas dismlves into
the~watiti.
* 3 :Jam
Refr&ratim/Air
Cmditicner
Ir&stry
Associatim clarifies
that thwzh they
arenotinchxklt
in the standmk beta=
the tolemncm at which failures may result
are not definite, free carbonic acid. manganese, residual chlorine, etc. do serve as
corrosive
factors.
(Note 2)
FXhitmof
thestandad
values has astrmgkmring
mthefaihmb
tocornxim
or scale and if anYvalue 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
~
cliff= _ti
m b
chemicals to be used, it is not givm here.
It is
desirable to 92t the amropriate water wlity
ccmtrol Mu=
M
*
Wof a
water processing specialist
periodically
control it.
*2:
—67—
b) Typical wat.e- treatment
I
The blow control means the forced replacement
of the cooling water in order
suppress the excessive concentrating ofthe circulating water (cooling water) in the
cooling tower and to prevent the changing of pH value and the concentrating
corrusive rotter
and scale producting mutter-.
general
these
are
following
methods;
Continuous manual blow by make-up water
Automatic blow down by electric
conductance
Addition the anticorrosion
Slime control
Seasonal water
analysis
—68—
—
to
of
(2)
WATER
TREATMENT
FOR
LONG
TERM
SHUT
DOWN
Perform following treatment
during long term shut
chilled water and cooling water in the chiller.
Please consult the Mail
with service representative.
a) Cooling
(Keep
down with no-circulating
of
water
the
cooling
water
Discharge cooling water
in
the
chiller>
from its discharge port
on
the cooling water outlet.
pour anticorrosion chemicals into the water.
Full up the cooling water
operate
the cooling water
in the chiller.
pump until
Close the isolation valve
of
mixed anticorrosion chemicals even.
inlet and outlet
on the cooling water
line.
Open the D valve on the chiller.
(1) Discharge cooling water from its discharge
port on the cooling water outlet.
(2) 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,
anticorrision chemicals for 30 minutes ormore.
Discharge the water
Keep to open
from the discharge
port on the
and circulate
cooling water
the
water
with
inlet.
the discharge port during shut down.
b Chilled water
Keep to full up. the chilled water
in the chiller.
c) In winter
Ifyou have
achange
freeze of chiller.
Please
consult
with
ofambient temperature
service
representatives.
–69–
below O ‘C (32°F) , please protect
the
3.4MAINTENANCE
FORINVERTER
When you check the insulation
the
inverter.
(1) INSULATION
TEST
FOR
test
of control
circuit,
please remove all terminals
INVERTER
Insulation test for inverter itself checks only power circuit
check the control circuit of inverter.
Check DC 500V for 1 minute by insulation
The resistance
isabove 10MQ.
resistance, tester.
.
------94
-
J----~
s
v
-----
T.
w 1-----
SUPPLY
----
INSULATION
RESISTER
TESTER
INVERTER
I
1=
FIG.3-6
( 2) INSPECTION
as Shown below, never
--------1
POWER
INSULATION
BEFORE OPERATION
Please check the following
(1) Check the wiring
items before power supply.
connection
(2) Clean in the control
to
to- the
inverter.
panel and inverter
(3) Tighten the screw on the terminal
panel.
of inverter.
(4) Do not touch between terminals.
–70–
TEST
1 ----
MOTOR
0
M
(3) ht4N1—EWWE
a) Seasonal
inspection
Check the following items When the chiller shut down atend of
season.
please confirm to light off the
power lamp on
Note) 1. when you remove the inverter,
the inverter
panel after a
few minutes ofturn off the power supply.
2. When you remove the connector
ofthe inverter,
please hold the housing ofthe
connector.
Take care the connect number when you match the connector.
3. Please change
the electrolytic capacitor every 5years and the cooling fan
every 3 years.
4. Recommend to exhange the parts orboards, ifitwill be happen to trouble
Item
1.General
Ambimt anditi(n
Inspection
Ambient t.empemti
Relative
Viblation
Pwer
slpply
2 .Main circuit
Transistor
&
Dio& rnodde
humidity
Input
voltage
Discoloration.
Disposition
: 5°C (41”F) 45T (113T)
: 90%at45°C (113T)
: below O.5 G
Return the cxniiticm
within
: R&d voltage ? 1O% AdjE3
Offensive
smell
~ificatim
&
vole
&change the
ln(xllle
Lmxn?ssofscmv
Tightness
Electrolytic
capacitor
Liq.Iid leak, Transfommtim
Camcitarm(akve
85% of ratd)
IMlangethem
Resistor
Discoloration,
Crack
RAstanm(within
tlO% of rated)
Ilxcimngethem
Wire
Dkxmloraticn of
Tear,
Short
WVered WiK!
circuit
Exchange the wire
Others
Dust
Looseness
screw
of
1.Printed wiring
board
Hybrid IC
Mculting
Capacitor
Transfomnatim
Resistor
Discoloration,
Connector
Looseness,
I.Cooling fan
Cooling fan
Cooling
fin
cmditicn
Cleaning
Tightness
Viblat h
Protacticxl
Exchange thehcxml
Crack
Exchw-lgethew
Disconnect
Fixtheamector
Dust
Noise of bearing
——
Dust
Cleaning
Excilangew
Cleaning
—71—
fan
$
( 4 )MEASUREMENT
Pl~
LOCATION
use larger
capacily
current
transformer,
if you meamre the Currmt.
%iiiiit:sim
‘—t
Power
output
Voltage
-me
1
I
I
Wattmeter
‘—
Multiple
Clmp
meter
volt
type current
meter
Power
meter
of
Ammeter
Wattmeter
INVERTER
3 PHASE
POWER
SUPPLY
YJ
YJ
FIG.
3-7
MEASUREMENT
rectifier”
iype
315
PIIRTS
N$PIECTKBI
Plea.& ccnwlt
‘arts
with
=ice
Inspection
name
, .Chiller
Heat transfer
tubes
(ABS~JIVA)
——
High temp.
EY==ti
(HT.GENE)
!.Solution
AkJr&lt
b
At#rbent
and
Refrigerant
pump
——
-fllmbstim
Burner
controller
Flame &ectnr
%ut off valve
Solenoid valve
RQgdator
Blmver nmtor
Fan
<hEPedEd
or
—
slime
bYEh3xiawand
cutting
period
Ck-lceei7w3ym
slime
IMdYalrrent test
.——
CorrQsial, WIe and/or
clung in the tube
after
Inspection
item
Cormsi(n, scale and/or
clung in the tube
(=>bY
Hmt transfer
tubes of heat
ex~
(flJZY. LTEX)
rqxzmreien+ative
Ifnemsary
N2
shell)
Dirty inthech&er
and flue tube
Orm ayear
Cleaning
<Viwalinspection)
Solution analysis
{Solution
sampling)
Concentration
P-alkalinity
volume
Inhibitor
Dkxdutim VOhIITE! of
Dkolutkn
volume of
Body, Impeller,
1 tilm? per 2000 hr
QXEr
in
Bearing and coil
lf~
<Overhaul}
—
Body <overhaul)
V-belt <12dange)
mle
kngth
of time :
over30 ,Oooti
If~
Ifnems+uy
stockedby~
(&=-e -)
.——
swby
(h
Adjust the
mtd
sdu-ticn
standard
OuneLKirts)
lfn===Y
—73–
Illrable m
of time :
over12,000hrs
——.-—
Parts
Inspection
name
5 J%fety
Pre+wre
&[email protected]
mw
Stocked lwcmner
Inspection
item
(spare
wlrts)
Flow switch
stOCked
bywmer(sE3r’7?
LElr’tS>
Air
Sta?dtmu
Manmeter
flw
switch
mr(iirerarw
R6.lmrk
period
once m6ry3
yearn
HT.GENE
Enf==im
Qlceevery3ym
Gas
Temperature
sensor
Ekctmmnetic
Cmtaclllr
.Auxiliary relay
Time dekw
relay
Control valve
Modltrol motor
Electronic
controller
Stocked bymvnei-( fipamrarts?’
if~
Inved.er
Stocked byclwner
Once ayar
b.Others
Electrod of
dutim
kwel
Sight glass
Diaphmgm valve
Gaskets
Palladium cell
Chamhz- W=
Gasket of water
header
<s?areparls)
Stocked byowner(mti>
.~n===y
—74—
Refer
to 3.4
WTIIIII
4 TIWiI
StUOTffi
CONTENTS
Page
SilxON
4 -mouBu? sJ-IooTM ...... .. ....
4.1
~~
~
~...
-......................76
PIWIZMW DETAILOF AIARM INDICATION
IJM-------------------------------76
POWERFAILLRE--------------------------------------------------------------78
( 1) ~~
4.3
FA~
(2)
REm ‘n-E ~
(3)
mvn
~
~
.............. ................................. 78
.........-------------------------------------------78
--------- ----------------------------------------------------
ALARMN THE ~lK
(1)
(2)
(3)
(4)
4.4
"-"""""""--""---"""-""--"-"-"""--'-""----------75
ALARMINDICATION
LAMP --- -----------------------------------------------76
(1)
(2)
4.2
No.
78
0HRATI0l+--------------------------------------79
WAITIl LINE ALARM
------------------------------------------------------79
MOTORw----------------------------------------------------------------79
G13’E?ATOR
m.......
-- -----------------------------------------------8O
SYSTEMAIARM--------------------------------------------------------------8O
ALARMTIME ~-------------------------------------------------------------81
( 1 ) ~~
~T~
....................................................... 81
—7 5—
401
Whi N)CATIN
LAW
Chiller stops safety, when the chiller has
rings and alarm indication lamp lights.
atrouble. And the
same time, alarm buzzer
(l) PROCEDURE
WHEN CHILLER HAS TROUBLE
(1) Stop the
alarm buzzer by "BUZZER STOP" key
on the operation board.
(2) Confirm the trouble item by alarm item indicator on the operation board.
(3) Repair
the
trouble
item.
(4) Push the "STOP" key on the operation board after repair.
Alarm indication lamp turns off, and “STOP” indication lamp flickers.
(5) Operate the chiller. (
(2) DETAILOF ALARM
Refer to 2.5)
INDICATION LAMP
a) Alarm item indicator
WATER
ALARM
O CH W TEMP.
0 CHWFLOWRATE
O COWTEMP.
0 CO W FLOWRATE
MOTORALARM
SYSTEMALARM(INTERLOCK)
GENERATORALARM
0 REF.PUMP
0 PRESSURE
0 CH/HTWPUMP
O #1 ABS.PUMP
o co w PUMP
0 #2 ABS.PUMP O TENP/CONCENTRATION
b) Detail
1. Water alarm
Alarm
indicatkn
Trouble
lamp
U-I WTEMP.
1) Cbilkxl w atlet
temperais below 2.5°C (36.5W)
2 ) Chilled water outlet temperature
sensor ( DT1) is
broken.
CI+WFWWRAIE
(hilled wati
-7
or hot water flow rate demnses
below 50%
6–
—
2. Motm
Alarm
N3?.
alarm
indication
Anwmze
HJMP
#1 AILS.FuMP
3. Generator
Alarm
Trouble
lanw
m
of reft%mmt
is *e
AmKrage CrFNO.l~t~
iS tie
indicatim
mted vati.
Trouble
lam
TIIblP/[email protected]
Alarm
value.
akmn
l%-esme ufhightenxemtm
atnx4&re
presxme.
4. &@3n
ratd
alarm
gmmdor
is-e
l)T~ti
of high temperature gmemtur
is abwe
165°C (329”F) m cooling mcde and 130”C (266”F) in
heating mode.
Z) High tempemtum gawratcr titurw
~
(IYT3)
is broken.
3 ) Cu-lcd.mticrl of ancmtrat.d
duticn
is atwe 65%
for 10 minutes.
(Intdodc)
indimtim
Trouble
lamp
(3-IWFUMP
Interlock
of
chilkd
water
~
discmnds.
mwHJMP
lnterkxk
of
cmling
water
mm
dkumneck.
–77–
412POWER
FAILURE
(1)POWER FAILURE MASSAGE
This message is indicated when it is happen to power failure
The message on the digital display flickers.
above 100 millisecond.
lIHEEId(~-~rr)
Chiller stops immediately, when it is happen to power failure.
‘Please operate
Chiller has no dilution cycle operation.
after return the power supply.
( 2) RESET
THE
(Cooling
the
"OPERATION" key.
the
power
failure
message isreset
operation)
call
(2) Power failure
Please
operation
CALL
(1) Return the power within
Please
cycle
MESSAGE
When YOU push
( 3) SERVICE
dilution
..’
call
to Service
1 hour.
representative
after
chiller
operation.
continue over 1 hour.
to service
representative
before
chiller
operation.
(During purge pump operation)
(1)Please close
failure.
the No.1 purge valve
( V1)
(2)Please turn off the purge pump operation
(3)Measure the pressure
(4)When the power
representative.
immediately,
when it
switch in the control
is happen to power
panel.
in the shell.
returns,
please
–78–
start
the
purging
and
call
to
service
4.3 ALARM IN THE COOLING OPERATION
(l)
WATER
LINE ALARM
Discharge
(1)
pressure
ofchilled water orcooling
water pump normal?
Check the strainer and air vent ofthe pipe line.
Is
(2)
gas control valve
Turn to “AUTO”
Ischilledwater
(3)
mode
select
position.
setting
point too lcw ?
Confirm the setting point.
setting
point.
And ifit
Iscooling water setting to
(4)
switch in the control panel "AUTO" position?
istoo low,
please adjust the best
low?
Confirm the setting point.
setting
point.
And ifit
istoo low.
plese adjust
operate the chiller again after checking above items.
If the chiller has an alarm the same as previous alarm,
representative with below
data.
the best
Please
please
call to service
Chilled water inlet and outlet temperatures
cooling water inlet and outlet temperatures
High ttemperature generator temperature
High temperature generator
pressure
(2)
MOTOR ALARM
Confirm to stick out the reset button ofthe
representative.
over current relay, please call service
‘f-RESET
FIG.
4-1
–79–
BUTTON
Open all valves
(3)
of cooling water
line.
Isdischage pressure ofcooling water pump normal?
Check the strainer and air vent ofthe pipe line.
(4)
steam control valve
mode select switch in the control panel "AUTO"
Confirm the setting point.
setting
point.
“
(6) Otherwise,
there dirty
And ifit
ofheat
transfer
istoo low,
please adjust
the best
tube.
Please operate the chiller again after checking above items.
If the chiller has an alarm the same as previous alarm, please
representatives with
below data.
Chilled water inlet and outlet temperature
Cooling water inlet and outlet temperature
High temperature generator temperature
High temperature generator pressure
water pumps operate ?
and cooling water pumps.
—8 O–
position ?
call to service
414
#lJRM
ThfW4RT
(l)(XX1-ffi (J%IIATCN
a) “~
W lEMP”
STEAM
CONTROL
VALVE
ON
OF
I
I
al ABS
ON
I
I
i
OF I
I
I
PUMP
I
I
I
I
I
I
I
ON
#2 ABS
PUMP
OF I
ON
REF
I
I
I
I
PUMP
I
I
OFF
I
I
I
1
I
CHILLED
WATER
I
I
I
I
I
I
I
I
I
ON
PUMP
COOLING
WATER
PUMP
OFF
ON
OFF
I
I
I
I
I
I
I
r
I
I
I
I
I
I
I
I
MI N._l -
I
I
I
I
I
I
. 1
I
I
I
I
TI
Lf
I
7-=
MIN.
I
‘ T2
m
;
I
ST’OP
[ ALARM
SIGNAL
—81–
b) “FRESURE”,
“lEMP/~TKHJ”
ON
STEAM
CONTROL
VALVE
-—
OF
I
I
I
ON
Ill
ABS
PUMP
OF
OF I
OFF
I
COOLING
WATER
I
I
I
PUMP
I
PUMP
OFF
I
I
‘1
I
I
I
I
I
I
I
I
I
I
1
I
I
1
I
I
I
1
1
I
I
I
I
I
I
1
I
‘
1
1
MIN.J
1
I
T.f
T2
&
1 ALARM
I
I
I
MIN.’
I
1
I
I
I
I
‘-l
I
1
I
I
1
I
ON
I
I
I
I
I
I
I
ON
OFF
I
I
I1
I
CHILLED
WATER
I
I
I
I
PUMP
,.
I
I
I
ON
REF
I
i
I
I
,
I
I
I
PUMP
i
I
I
I
ON
#2 ABS
I
I
SIGNAL
FIG.
—82—
4-3
I
u
STOP
STEAM
CONTROL
VALVE
ON
I
I
I
I
OF
I
ON
al
ABs
I
I
I
I
I
PUMP
OF I
i
I
:’
I
ON
#2
ABS
I
PUMP
1
I
1
i
I
I
J
I
I
I
OF I
I
●
I
I
I
ON
REF
PUMP
CHILLED
WATER
COOLING
WATER
ON
I
I
I
I
I
I
i
I
[
I
I
I
I
I
,
1’
OF I
I
I
I
I
I
I
PUMP
I
I
OFF
ON
OFF
I
I
I
I
I
I
I
;
I
I
I
I
I
I
l.l
I
!
I
I
I
I
PUMP
I
MIN.
I
I
I
1
I
I
I
;.1
TI
I
I
[
MIN.
I
I
I
I
I
d
1
_I
1
I
T2
.
S T’OP
‘ALARM
SIGtJAL
FIG.
—83—
4-4
d) “#l AIKPU?vlP”,
”##2ABSFUMP”
ON
STEAM
CONTROL
VALVE
1
OFF
I
I
I
I
I
ON
81
ABS
PUMP
I
OFF
I
1“1
ON
#2
ABS
PUMP
OFF
ON
REF
PUMP
OFF
-1’
!’”’
‘i
I
I
I
“’
I
I
I
I
ON
1
LLED
ER PUMP
I
OFF-
ON
COOL
WATER
I NG
PUMP
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9
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STOP
[ ALARM
SIGNAL
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—R !i—
4-6
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