16NK Double-Effect Steam-Fired Absorption Chillers

16NK Double-Effect Steam-Fired Absorption Chillers

16NK

Double-Effect Steam-Fired

Absorption Chillers

Nominal cooling capacity 345-4652 kW

50 Hz

Operation and maintenance instructions

GB/T-19001-2000 to ISO9001/2000

Notes to Users

Thank you for purchasing a Carrier/Sanyo absorption chiller.

Read this manual carefully before operating the unit. It contains instructions for the operation and maintenance of the chiller.

Please utilize the chiller to its optimum performance by carrying out the recommended daily maintenance and handling instructions as well as the periodic service.

If you need any information about maintenance contracts or have any other enquiries, please contact your Carrier service agent.

2

Contents

NOTes TO Users ........................................................................................................................................................................... 2

1 - PrecaUTiONs .......................................................................................................................................................................... 4

1.1 - Safety precautions ....................................................................................................................................................................... 4

1.2 - High-temperature - high-voltage caution.................................................................................................................................... 8

1.3 - Environmental requirements ....................................................................................................................................................... 8

1.4 - Water treatment ........................................................................................................................................................................... 8

2 - MacHiNe illUsTraTiONs .................................................................................................................................................. 8

2.1 - Typical chiller views - all sides ................................................................................................................................................... 8

2.2 - Typical control panel ................................................................................................................................................................ 12

2.3 - Chiller flowchart and component function description ............................................................................................................ 14

3 - OPeraTiNg iNsTrUcTiONs .............................................................................................................................................. 17

3.1 - Self-diagnostic function ............................................................................................................................................................ 17

3.2 - Description of keys and their functions .................................................................................................................................... 18

3.3 - Control board settings ............................................................................................................................................................... 19

3.4 - Cooling operation ..................................................................................................................................................................... 21

3.5 - Changing the information on the data display .......................................................................................................................... 22

3.6 - Changing display and setpoint .................................................................................................................................................. 23

3.7 - Maintenance message ............................................................................................................................................................... 23

3.8 - Alarm messages and actions required ....................................................................................................................................... 23

4 - MaiNTeNaNce ....................................................................................................................................................................... 25

4.1 - Daily maintenance .................................................................................................................................................................... 25

4.2 - Periodic maintenance ................................................................................................................................................................ 28

4.3 - Recommended maintenance and main component replacement schedule ............................................................................... 29

4.4 - Water treatment ......................................................................................................................................................................... 30

5 - TrOUblesHOOTiNg ............................................................................................................................................................ 32

6 - iNsTrUcTiONs ....................................................................................................................................................................... 34

6.1 - Absorbent sampling method ..................................................................................................................................................... 34

6.2 - Concentration measurement method ........................................................................................................................................ 34

7 - MaiNTeNaNce cONTracT ............................................................................................................................................... 36

7.1 - Annual maintenance contract .................................................................................................................................................... 36

7.2 - Inspection report ....................................................................................................................................................................... 36

7.3 - Warranty .................................................................................................................................................................................... 36

aPPeNdix 1 - TrOUblesHOOTiNg FlOWcHarT ........................................................................................................... 37

Problem 1 - Chiller does not run ....................................................................................................................................................... 37

Problem 2 - Chilled-water temperature is high. ................................................................................................................................ 38

Problem 3 - Generator alarm. ............................................................................................................................................................ 39

Problem 4 - Combustion alarm (16DJ only) ..................................................................................................................................... 40

Problem 5 - Water alarm ................................................................................................................................................................... 41

Problem 6 - Motor alarm ................................................................................................................................................................... 41

Problem 7 - System alarm ................................................................................................................................................................. 42

The cover photograph is for illustrative purposes only, and are not contractually binding.

3

1 - PreCaUtioNs

1.1 - safety precautions

• Before operating this chiller, first carefully read the following instructions.

• All precautions are classified as either WARNING or

CAUTION.

WARNING: Failure to observe this instruction may result in serious injury or death.

CAUTION : Failure to observe this instruction may cause an injury or failure of chiller. Depending on circumstances, this may result in serious injury or death.

1.1.4.1 safety considerations

WARNINGS

TURN OFF THE BREAKER BEFORE CLEANING AND

CHECKING

Always turn off the circuit breaker before cleaning and checking the cooling tower fan, chilled water pump, or other components linked to the chiller, to provide protection from electric shock or or possible injury by the rotating fan.

INSPECTION

This symbol denotes danger, a warning or a caution.

The illustration in this symbol shows the specific description of the item.

This symbol prohibits an action.

The illustration next to this symbol shows the specific description of the item.

This symbol instructs an action to be done.

The illustration in this symbol shows the specific description of the item.

• After reading this manual, it should be kept in a safe place to be available for any user at any time.

STOP OPERATION IN CASE OF FIRE, EARTHQUAKE OR

ELECTRICAL STORMS

Stop operation in case of fire, earthquake or an electrical storm, to prevent fire or electric shock.

MUST BE OBSERvED

DO NOT TOUCH THE CONTROL PANEL SWITCH WITH

WET HANDS

Do not touch the switch inside the control panel with wet hands to avoid electric shock.

SWITCH

DO NOT TOUCH

DO NOT TOUCH THE WIRING INSIDE THE CONTROL

PANEL

Do not touch the wiring inside the control panel to avoid electric shock.

DO NOT TOUCH

4

WARNINGS

DO NOT TOUCH ROTATING MOTOR PARTS

Keep away from rotating parts of motors or pumps to avoid possible injury.

CAUTIONS

SOLvE ALL PROBLEMS BEFORE RESTARTING THE

CHILLER

Solve all the problems before restarting the chiller after a safety or security device is activated.

MUSt bE obSErvED

PROHIBITED vENTILATE THE MACHINE ROOM ventilate the machine room while nitrogen gas is discharged to avoid anoxia.

PROHIBITED

DO NOT PLACE HEAvY OBJECTS ON THE CHILLER

OR CONTROL PANEL

Do not place heavy objects on the chiller or control panel as these may fall off and cause injuries.

MUST BE OPERATED

PROHIBITED

DO NOT CLIMB ON THE CHILLER

Do not climb on the chiller as you may fall off.

AUTHORIZED PERSONNEL ONLY

A notice, "For Authorized Personnel Only" must be affixed to the chiller to stop unauthorized personnel from touching it. If necessary surround the chiller by a protective fence. Misuse of the chiller may cause injury.

PROHIBITED

DO NOT POUR WATER ON THE CHILLER OR CONTROL

PANEL

Do not pour water on the chiller or control panel to avoid electric shock.

PROHIBITED

5

CAUTIONS

USE THE CORRECT POWER SUPPLY

This is indicated on the chiller name plate. Use of an incorrect power supply may cause fire or electric shock.

DO NOT TOUCH HIGH-TEMPERATURE AREAS

Do not touch high-temperature areas, as they may cause burns.

These areas are indicated by caution label.

PROHIBITED

PROHIBITED

What voltage?

NEvER CHANGE THE SET vALUES

Never change the set values of the safety and/or protective devices. Wrong settings may damage the chiller or cause fire.

STOP THE PURGE PUMP TO REPLACE OIL

Stop the purge pump when replacing oil to avoid possible injury by fuel spillage.

STOP

MUST BE OBSERvED

PROHIBITED

DO NOT TOUCH THE ABSORBENT

Do not touch spare or leaked absorbent, as this can cause metal corrosion or skin disease.

PROHIBITED

OBSERvE THE SPECIFIED WATER/STEAM PRESSURE

The specified chilled water, cooling water and steam pressure must be strictly observed.

Incorrect pressure may cause the water to leak/spray which can lead to short circuits or burns.

MUST BE OBSERvED

6

1.1.2 - safety precautions for repair, moving or disposal

WARNINGS

ONLY AUTHORIZED PERSONNEL SHOULD SERvICE

THE CHILLER

Only authorized personnel should service the chiller. Incorrect service could result in electric shock or fire.

PROHIBITED

1.1.3 - Operating precautions

1. Keep the purge valve tightly shut to prevent air from leaking into the chiller, which may cause the failure of the chiller.

2. Keep the power supply to the control panel turned on, unless carrying out maintenance or service.

3. During the chiller dilution cycle the chilled-water pump

(both the primary side and the secondary side) and air handling unit must be operated for the required time. The chiller has some cooling capacity, even in the dilution cycle. Do not stop the air handling unit before the required time to prevent possible subcooling.

4. Do not perform an insulation test on the control circuits of the electric controller.

5 . Use a Carrier recommended interlock system to stop/start the auxiliary equipment. The interlock system automatically stops/starts the chilled-water pump and cooling water pump. Follow the start procedure in Figure 1 below.

CAUTIONS

ONLY AUTHORIZED PERSONNEL SHOULD REMOvE OR

REPAIR THE CHILLER

Any relocation or moving of the chiller should only be done by authorized personnel. Incorrect work could result in water leaks, electric shock or fire.

Fig. 1 - auxiliary equipment start/stop sequence start sequence

1: Chilled water pump

2: Cooling water pump

3: Cooling tower

4: Absorption chiller

MUST BE OBSERvED

5: Air handling unit

stop sequence

1 Absorption chiller

2: Cooling water pump

3: Cooling tower

4: Chilled water pump

ONLY AUTHORIZED PERSONNEL SHOULD DISPOSE OF

THE CHILLER

To dispose of the chiller, contact local specialists. Incorrect disposal may result in absorbent leaks and cause metal corrosion or skin disease, electric shock or fire.

5: Air handling unit

MUST BE OBSERvED

7

1.2 - High-temperature - high-voltage caution

• Do not touch the chiller during operation since its surface becomes hot.

• Do not touch the absorbent pump, the refrigerant pump, and the purge pump during operation, since their surface becomes hot.

• Do not touch the junction box during operation, since it contains high-voltage wiring.

• Do not touch the terminal box during operation, since it contains high-voltage wiring.

1.3 - environmental requirements

1.3.1 - installation considerations

The 16NK absorption chiller is designed for indoor installation in a machine room. The protection rating of the chiller is IP40.

Room temperature should be maintained between 5°C and

40°C to protect against solution crystallization during chiller shutdown. The humidity in the machine room must be kept below 90%.

1.3.2 - Field wiring

The machines should be connected to a power source that complies with overvoltage category III (IEC 60664). All other wiring should comply with overvoltage category II.

1.3.3 - altitude

Please install the absorption chiller at a maximum height of

1000 m above sea level. If the location is higher than 1000 m above sea level, please contact your local Carrier office.

1.4 - Water treatment

Refer to chapter 4 "Maintenance”.

2 - MaCHiNe illUstratioNs

2.1 - typical chiller views - all sides

2.1.1 - 16NK 11 to 63

Fig. 2 - Water header side

2

3

4

5

1

9

6

7

8

legend

1 Condenser

2 Chilled water outlet

3 Chilled water inlet

4 Evaporator

5 Cooling water inlet

6 Low-temperature generator

7 High temperature generator

8 Steam inlet

9 Absorber

Fig. 3 - Water header side (rear)

1

2

6

3

7

4

legend

1 High-temperature generator

2 Low-temperature generator

3 Cooling water outlet

4 Evaporator

5 Steam trap

6 Condenser

7 Absorber

5

8

Fig. 4 - Control panel side (evaporator side)

1 2

6

5 4 3

legend

1 Control panel

2 Purge tank

3 refrigerant drain heat reclaimer

4 Absorbent pump 1

5 refrigerant pump

6 refrigerant blow valve

Fig. 5 - High-temperature generator side (absorber side)

1

2

legend

1 Purge unit

2 High-temperature heat reclaimer

3 Purge pump

4 Low-temperature heat exchanger

5 Low-temperature heat reclaimer

6 Steam drain outlet

7 High-temperature heat exchanger

8 Absorbent pump 2

3 4

5

6 7 8

9

4

5

6

2.1.2 - 16NK 71 to 81

Fig. 6 - Water header side

2 1

3

7

8

9

10

legend

1 Steam inlet/high-temperature generator

2 Low-temperature generator

3 Cooling water outlet

4 Chilled water outlet

5 Chilled water inlet

6 Cooling water inlet

7 Condenser

8 Absorber

9 Evaporator

10 Absorber

3

Fig. 7 - Water header side (rear) legend

1 Low-temperature generator

2 High-temperature generator

3 Steam drain outlet

4 Condenser

5 Absorber

6 Evaporator

7 Absorber

Fig. 8 - Control panel side

1 2

3

5

2 1

4

6

4

7

legend

1 Control panel

2 refrigerant blow valve

3 Purge tank

4 Purge unit

5 Purge pump

6 refrigerant drain heat exchanger

7 refrigerant pump

8 Low-temperature heat exchanger

10

8 7 6 5

Fig. 9 - High-temperature heat reclaimer side legend

1 High-temperature heat reclaimer

2 Absorbent pump 2

3 Low-temperature heat exchanger

4 Absorbent pump 1

5 refrigerant pump

6 High-temperature heat exchanger

1

6 5 4 3 2

11

2.2 - typical control panel

Fig. 10 - Control panel (Ce type)

1

6

2

7

8

3

4

5

legend

1 Fan

2 terminal block

3 terminal block

4 terminal block for power supply

5 Earth terminal

6 Control board

7 Purge indication light

8 Alarm buzzer

9 Purge pump on/off switcht

10 operating handle

9

10

Fig. 11 - Control panel inside (Ce type)

1

13

2

3

4

5

6

7

8

9

10

11

12

14

legend

1 Control relay

2 Circuit protector

3 Isolator

4 I/o board

5 AC reactor

6 Circuit breaker

7 Inverter

8 DC reactor

9 Main circuit breaker

10 transformer

11 Electromagnetic contactor

12 Filter

13 transformer

14 terminal block

12

Fig. 12 - Control board

StoP

CHILLEr

#1 AbS PUMP

#2 AbS PUMP rEF PUMP

PUrGE PUMP rUN

StAND bY

DILUtIoN

SAFEtY CIrCUIt

CHILLEr ALArM

PoWEr

SEt bACK rEMotE bUZZEr StoP LoCAL

StoP oPErAtIoN rUN

11

12

13

14

legend

1 Stop indication light

2 operation indication light

3 Data display

4 Select key

5 Function set key

6 back select key

7 remote/local select key with LED

8 Alarm buzzer stop key

9 operation select key with LED

10 Alarm indication light

11 Stand-by indication light

12 Dilution indication light

13 Safety circuit indication light

14 Power indication light

4

5

6

7

8

9

10

1

2

3

13

2.3 - Chiller flowchart and component function description evaporator

The refrigerant is dispersed on the heat transfer tubes of the evaporator. Chilled water running through the heat transfer tubes of evaporator is cooled by the latent heat of vaporized refrigerant.

absorber

The concentrated solution is dispersed on the heat transfer tubes of absorber. The refrigerant vapour from the evaporator is absorbed on the heat transfer tubes of the absorber by the concentrated solution. Cooling water running through the heat transfer tubes of the absorber is heated by the absorption heat.

solution heat exchangers

In order to increase the efficiency of the chiller, two solution heat exchangers are provided. One is a low-temperature heat exchanger and the other is a high-temperature heat exchanger.

In the low-temperature heat exchanger, heat exchange takes place between the concentrated solution and the diluted solution.

In the high-temperature heat exchanger, heat exchange takes place between the intermediate solution and the diluted solution.

High-temperature generator

The diluted solution from the high-temperature heat exchanger is heated and releases refrigerant vapour. It then changes to the intermediate solution.

sensors symbol

DT1

DT3

DT4

DT5

DT6

DT7

DT8

DT9

DT11

DT12

DT13

E1-3

63CH

69CH

69PR

low-temperature generator

The refrigerant vapour from the high-temperature generator passes through the heat transfer tubes of the low-temperature generator. The intermediate solution in the low-temperature generator is heated by the refrigerant vapour. It releases refrigerant vapour and is concentrated. It changes to the concentrated solution. The condensed refrigerant in the heat transfer tubes of the low-temperature generator flows to the condenser.

condenser

The refrigerant vapour from the generator is condensed on the heat transfer tubes of the condenser. Cooling water from the absorber is heated by condensation heat.

Purge unit

The purge unit collects the non-condensable gas in the chiller and stores it in the purge tank.

refrigerant drain heat reclaimer

This heat exchanger is provided in order to increase the efficiency of the chiller. In this heat reclaimer heat exchange takes place between the diluted solution and the condensed refrigerant from the low-temperature generator.

High and low-temperature heat reclaimers

These heat reclaimers are provided in order to recover heat from the steam drain, In these heat reclaimers heat exchange takes place between the diluted solution and the steam drain.

Name

Chilled-water leaving temperature

High-temperature generator temperature

Low-temperature generator temperature

Condenser temperature

Chilled-water entering temperature

Cooling water entering temperature

Cooling water intermediate temperature

Cooling water leaving temperature

Evaporator refrigerant temperature

Diluted solution temperature sensor at absorber outlet

Steam drain temperature

High-temperature generator solution level electrode

High-temperature generator pressure switch

Chilled water flow switch

Purge tank pressure switch

14

V2

V3

SV1

V1

1

5

6

3

4

2

7

12

Fig. 13 - Flow diagram

13

11

14

15

20

8

9

10

16

19

18

21

22

17

25

26

27

23

24

1

5

6

3

4

2

7

12

Fig. 14 - Flow diagram

13

11

14

15

20

8

9

10

16

Sensor

Service valve

Strainer

Damper

Check valve orifice

Valve

17

21

22

25

19

23

24

26

27

15

legend for Figs. 13 and 14

1 Purge pump

2 b-valve

3 Chilled water outlet

4 Chilled water inlet

5 Purge unit

6 Cooling water outlet

7 Purge tank

8 refrigerant pump

9 refrigerant blow valve

10 Absorbent pump 1

11 rupture disk

12 Condenser

13 Low-temperature generator

14 Evaporator

15 Absorber

16 Cooling water inlet

17 Low-temperature heat exchanger

18 Low-temperature heat reclaimer

19 Steam drain outlet

20 refrigerant drain heat reclaimer

21 Absorbent pump 2

22 High-temperature heat exchanger

23 Steam trap

24 High-temperature heat reclaimer

25 High-temperature generator

26 Steam inlet

27 Steam control valve

D1

D2

D3

D4

D5

D6

D7

Diluted solution main damper

Diluted solution low temperature heat exchanger damper

Diluted solution refrigerant drain heat reclaimer damper

Intermediate solution damper

Concentrated solution damper refrigerant drain damper refrigerant recycling damper

D8

V1

V2

V3

SV1

SV3

SV4

SV5

SV6

SV7

Diluted solution bypass damper

Manual purge valve

Manual purge valve

Manual purge valve

Charge/discharge N

2

gas and pressure gauge installation service valve refrigerant service valve

Diluted solution service valve

Intermediate solution service valve

Concentrated solution service valve

Generator maintenance service valve

SV8 Generator maintenance service valve b valve Manual purge valve

16

3 - oPeratiNg iNstrUCtioNs

3.1 - self-diagnostic function

The self-diagnostic function starts when the breaker inside the control panel of the chiller is turned on. After self-diagnosis is completed, the data display on the control board shows the following information.

• Data display (7-segment LED) and all LEDs light up.

• If there is no abnormality the data display shows the version number. If there is a power failure, H-10 is displayed after the power is restored.

Fig. 15 - Control panel

NOTe: The version number differs with each chiller type.

• The data display shows the generator temperature.

(120.4)

If the self-diagnosis function detects an error, this will be shown on the data display. For the alarm indication, please refer to chapter 3.8.

17

3.2 - Description of keys and their functions

Fig. 16 - typical control board

6

1

2

7

8

9

10

StoP

CHILLEr

#1 AbS PUMP

#2 AbS PUMP rEF PUMP

PUrGE PUMP rUN

StAND bY

DILUtIoN

SAFEtY CIrCUIt

CHILLEr ALArM

PoWEr

SEt bACK rEMotE bUZZEr StoP LoCAL

StoP oPErAtIoN rUN

11

12

4

5

3

legend

1 operation indication light:

2 Stop indication light:

3 Alarm indication light:

4 remote/local select key with LED:

5 operation select key with LED:

6 Data display (7-segment LED):

7 Standby indication light:

8 Dilution indication light:

9 Safety circuit indication light:

10 Power indication light:

11 Data select key:

12 Alarm buzzer stop key: the operation indication light is on when the chiller is running.

the stop indication light is on when the chiller is shut down.

the alarm indication light is on when an alarm occurs.

to select remote operation or local operation.

Key used to run/stop the chiller.

the stop key is also used for alarm reset.

Shows the temperature, setpoint, etc.

on when the chiller is waiting for the interlock signals form the chilled water and the cooling water pump.

on during the dilution cycle.

on when power is supplied to the control circuit.

on when power is supplied to the control circuit.

to change the menu and set a new value.

to stop the alarm buzzer.

18

3.3 - Control board settings

3.3.1 -Time setting

Refer to Figure 17.

Fig. 17 - Display example

Generator temperature

Press the " SEt " key for about 2 seconds.

Press t key.

Press the " SEt " key for about 2 seconds.

Press the " SEt " key for about 2 seconds.

Press t or s key.

Press the " SEt " key for about 2 seconds.

Press t key.

Press the SEt key for about 2 seconds.

Press s key to set the month.

Press t key.

Fig. 17 - Display example (cont.)

Press s key to set the day.

Press the SEt key for about 2 seconds.

Press t key.

Press the SEt key for about 2 seconds.

Press s key to set the hour.

Press t key.

Press s key to set the minutes.

Press the SEt key for about 2 seconds.

Press the bACK key.

Press the bACK key.

Generator temperature

3.3.2 - battery backup

Refer to Figure 18.

sW3

Connect a backup battery which is used to maintain the time setting when a power failure occurs. Turn it ON after installing the equipment. CR-2025 is used as the backup battery and has an accumulative operating period of about six months.

NOTeS:

1. SW3 (battery backup) is set to OFF at the factory to avoid using battery power.

2. If SW3 (battery backup) is set to OFF when a power failure occurs, F-21 (CPU alarm) or F-23 (Time set alarm) is displayed. Please reset the time setting.

3. If SW3 (battery backup) is set to ON and F-21 or F-23 is displayed, it is necessary to replace the battery.

19

20

3.3.3 - How to change the temperature unit

The temperature unit can be changed as follows, even while the chiller is operating.

Generator temperature

Fig. 19 - Display example

Press the " SEt " key for about 2 seconds.

to select °C

Press t or s key.

Press the SEt key for about 2 seconds.

Press t or s key if you need.

Press the SEt key for about 2 seconds.

And push t or s key.

to select °F

3.4 - Cooling operation

3.4.1 - Pre-operation checks

Please check the following items before starting operation:

• Check the setpoint of the chilled-water leaving temperature. Make sure that the chilled-water leaving temperature is set as specified. For the indication of the set value, please refer to chapter 3.8.

• Check the steam and steam drain equipment

- Make a daily inspection (refer to chapter 4).

- Check that the steam valve(s) is (are) open.

NOTe: To start and stop the chilled water pump and cooling water pump, always use the start and stop signal from the chiller control panel. Strictly ensure that the interlock signals from the chilled water pump and the cooling water pump are connected to the chiller control panel.

3.4.2 - start of operation

Refer to Figure 21.

Fig. 21 - Control board

Press the "SEt" key to select °C mode and again to select the °F mode

3.3.4 - changing remote signal setting (continuous, pulse etc.)

After wiring of the remote signal, the control board shown below should be set. Refer to field wiring diagram.

Fig. 20 - Display example

Control board setting

remote signal type

(1)

(2)

(3)

(4)

(5) free free

Generator temperature Press the SEt key for about 2 seconds.

StoP

CHILLEr

#1 AbS PUMP

#2 AbS PUMP rEF PUMP

PUrGE PUMP rUN

SEt bACK

1 rEMotE

Press the t or s key.

StAND bY

DILUtIoN

SAFEtY CIrCUIt bUZZEr StoP LoCAL

2

Press the SEt key for about 2 seconds.

CHILLEr ALArM

StoP oPErAtIoN rUN

PoWEr

3 4

Press the t or s key.

to select the static mode by pressing the SEt key, the static mode is selected.

to select the positive mode

Press the t or s key.

Press the SEt key for about 2 seconds.

then press the t or s key.

to select the pulse mode

legend

1 remote key

2 Local key

3 Stop key

4 run key

by pressing the SEt key, the pulse mode is selected.

Press the SEt key for about 2 seconds.

then press the t or s key.

local operation mode

• Press the "LOCAL" key on the chiller control board. The

"LOCAL" indication light of the key is on.

• Keep pressing the "RUN" key for more than a second and make sure that the "RUN" indicator lightp of the key is on.

• Automatic operation starts.

to select the negative mode

remote operation mode

• Press the "REMOTE" key on the chiller control board.

The "REMOTE" indicaton light of the key is on.

Press SEt key to select positive mode.

Press SEt" key to select negative mode.

21

• Turn on the start switch on the remote control panel for the field supply. The indicator light of the "RUN" key on the chiller control board is on.

• Automatic operation starts.

3.5.1 - Normal display information

The data display on the control board usually shows the generator temperature as follows.

NOTe: In local operation mode the signal from the remote control panel does not work. In remote operation mode the

"RUN" key of the chiller control board does not work.

It returns to the generator temperature display when no key is pressed for 1 minute.

3.5.2 - changing the display

Refer to Figure 22.

3.4.3 - stop of operation

Refer to Figure 21.

local operation mode

• Keep pressing the "STOP" key on the chiller control board for more than a second.

• Make sure that the "RUN" indication light goes off and the

"STOP" indication light comes on.

If you press the s

key, the information on data display changes in the correct order, and pressing the t

key, it changes in reverse order.

If you press the s

key again when the last information is shown, the display returns to the normal display information.

remote operation mode

Turn on the stop switch on the field supply remote control panel.

Another way to stop the chiller is to press the "STOP" key on the chiller control board during remote operation.

NOTe: Since the chilled-water pump, cooling water pump, and chiller are interlocked, each pump stops automatically when the chiller stops.

The air handling unit must be stopped after the chilled-water pump is stopped

3.5.3 - Typical display order

Real-time data is shown in the data display (7-segment

LED and 6 figures). The display shows a data code (content distinction by code number) and various operating times, on/off time, component temperatures, chilled-water temperature setpoints and alarm codes. A data code is sent in turn from the s t keys and displayed. An alarm code is only shown when one or several abnormalities occur. The alarm code is shown in order of importance, and a dotted "." is shown under the number to the right of the alarm code. When several faults occur, use the s t

keys to display the additional alarm codes.

If no key including the "BACK" key is pressed for 1 minute, the display returns to the generator temperature display.

3.5 - Changing the information on the data display

StoP

Fig. 22 - Control board

CHILLEr

#1 AbS PUMP

#2 AbS PUMP rEF PUMP

PUrGE PUMP rUN

1

SEt bACK

2

3

Fig. 23 - typical display order

13.

14.

15.

16.

17.

- b.

C.

10.

11.

12.

6.

7.

8.

9.

A.

Data code Data name

- Generator temperature

1.

2.

3.

4.

5.

Chiller operating hours

Absorbent pump 1 operating hours

Absorbent pump 2 operating hours

Combustion hours refrigerant pump operating hours

Purge pump operating hours

Chiller on/off times

Absorbent pump 1 on/off times

Absorbent pump 2 on/off times

Combustion on/off times refrigerant pump on/off times

Purge pump on/off times

Chilled-water temperature setpoint

Hot-water temperature setpoint*

Chilled-water entering temperature

Chilled-water leaving temperature

Cooling water entering temperature

Condenser temperature

Steam drain/exhaust gas temperature

Purge tank pressure

Generator temperature

Display

* Hot-water reference is not applicable to 16NK units

Means

135.0°C

1234 hours

1111 hours

1230 hours

Not used

1201 hours

107 hours

123 times

169 times

123 times

Not used

138 times

51 times

7.0°C

Not used

11.9°C

6.8°C

31.8°C

34.7°C

211.7°C

8.5 kPa

135.0°C rEMotE

StAND bY

DILUtIoN

SAFEtY CIrCUIt

CHILLEr ALArM

PoWEr bUZZEr StoP LoCAL

StoP oPErAtIoN rUN

legend

1 Data display

2 Select key: changes the data display information

3 back select key

22

3.6 - Changing display and setpoint setpoint display change

Select the current setpoint temperature and change it as follows.

To change the chilled-water temperature:

7.0°C

Press the SET key for about 2 seconds.

A number showing the setpoint temperature blinks.

Press the

7.5°C s

or t

key.

Press the SET key

Fig. 24 - Maintenance message

Data code Data name

H-01*

H-03* operate purge pump

Clean cooling water tubes

H-04* Check cooling water system

H-06**

H-07**

H-08**

H-10

Purge tank high pressure

Cooling water tubes foul

Cooling water high temperature

Power failure

Display Means

operate purge pump.

Fouling of cooling water tubes.

Check cooling water pump, cooling tower, etc.

Purge tank pressure is high.

Fouling of cooling water tubes.

Cooling water temperature is high.

there was a power failure while the chiller was operating

legend

* When this appears, immediate action is required.

** When this appears, no immediate action is required, but as this might lead to a higher code, attention should be paid. Consult Carrier service personnel at the next periodic maintenance.

NOTe: These displays disappear when the problem has been corrected.

Fig. 25 - Maintenance message descriptions and actions required

Maintenance message Display action

Action

1 Cooling water tubes

foul water tubes

3 Cooling water

high temperature of cooling water

Cooling water tubes must be cleaned.

Contact Carrier service agent to do the job

Contact Carrier/SANYo service agent to do the job.

the purge tank must be purged immediately.

If this message is shown frequently, contact your Carrier service agent. contact Carrier/SANYo service agent.

Check the cooling water pump, cooling tower, etc.

Check the cooling water pump, cooling tower, etc.

3.8 - alarm messages and actions required

The setpoint change has been made.

If no key including the "BACK" key is pressed for 1 minute, the display returns to the generator temperature.

NOTeS:

1. Incorrect setting may cause chiller failure. If you need to change the setpoint, always consult your Carrier service agent.

2. Setpoints become effective as soon as they have been changed. Be careful when changing setpoints during operation.

3.8.1 - How they are shown

When an alarm is detected, the alarm buzzer sounds, and the alarm message is shown on the data display. At the same time, the indication light of the "STOP" key blinks. The chiller stops for safety reasons after the dilution cycle. Depending on the alarm message it may also stop without carrying out the dilution cycle.

Fig. 26 - Display example

Chilled-water low temperature

3.7 - Maintenance message

An alarm code is only shown when one or several abnormalities occur. If several errors have occurred, the most important one is shown with a dot ".".

If a problem that could affect the efficient operation of the chiller is predicted, a warning message is given. This includes a comment on the data display as shown in Figure 18.

Chilled-water low temperature

The other alarm codes are shown by pressing the s

key.

The high-temperature generator solution level is too low.

23

3.8.2 - Troubleshooting flowchart symptoms action

3.8.4 - locating and clearing alarm

An alarm occurs.

Alarm buzzer sounds, and the

indication light of the "StoP" key blinks.

the alarm message is shown in the data

display.

the alarm buzzer stops.

Press the "bUZZEr StoP" key on the control board.

Check alarm message and solve the problem.

Press the "StoP" key on the control board after the troubleshooting is completed.

Fig. 28 - list of alarm messages and their causes and remedies

Display and content of alarm alarm of the chilled water and/or cooling water system

Check that the discharge pressure of both chillled-

Chilled water temperature is too low. water and cooling water pumps is normal.

Chilled water flow alarm

Cooling water temperature is too low

Cooling water flow alarm (option)

→ If not, the strainer may be clogged, or there may be an air leak in the piping, etc.

Is the chilled-water setpoint too low?

→ Correct it to the specified setpoint.

Is the cooling water setpoint too low?

→ Correct it to specified setpoint (e.g. 28°C).

Correct the above causes and restart the chiller.

If the "CHILLEr ALArM" continues, check the following and contact your Carrier service agent:

• Entering and leaving chilled-water temperature

• Entering and leaving cooling water temperature

• Generator temperature and pressure

the indication light of the "StoP" key

stops blinking and remains lit. the alarm

code on the data display disappears.

NOTe: If the data display still shows an alarm, after the "STOP" key has been pressed, ensure that the alarm cause has definitely been removed.

alarm of the motor(s)

Absorbent pump 1 overload alarm.

Absorbent pump 2 overload alarm. refrigerant pump overload alarm

First check that the reset button(s) of the overload relay connected to the electromagnetic contactor is not pushed in, and then contact your

Carrier service agent.

reset buttons

operation restarts.

3.8.3 - alarm message and setpoint

Fig. 27 - list of alarms and setpoints in cooling operation

Purpose

Protection of chilled water system from freezing

Display

Prevention of

Crystallisation and Generator protection

Start operation

alarm message setpoint

Chilled water temperature is too low 2.5°C or below

Chilled water pump interlocl alarm -

Chilled water flow alarm 50% or below

Cooling water temperature is too low

Cooling water pump interlock alarm below monitoring temperature for 30 minutes

alarm of the auxiliary equipment

Chilled water pump interlock alarm.

Cooling water pump interlock alarm.

generator alarm

Generator temperature is too high.

Generator pressure is too high.

High concentration of absorbent

Check that the chilled-water pump and cooling water pump are rotating.

→ Start the pumps

Check the fan and/or other equipment connected to the system interlock.

Correct the above causes and restart the chiller.

If the "CHILLEr ALArM" continues, contact your

Carrier service agent.

Check that the cooling water pump is rotating.

Start the pump.

Check that the cooling water line valve is open.

→ open the valve.

Check that the cooling water pump discharge pressure is normal.

→ If not, the strainer may be clogged, or there may be an air leak in the piping, etc.

Correct the above causes and restart the chiller

If the "CHILLEr ALArM" continues, check the following and contact your Carrier service agent:

• Entering and leaving chilled-water temperature

• Entering and leaving cooling water temperature

• Generator temperature and pressure.

• Is the chilled water setpoint too low?

→ Correct it to the specified setpoint.

• Water in the heat transfer tubes may be fouled

(especially cooling water).

Motor protection

Cooling water flow alarm (option) 50 % or below

Generator temperature is too high 162°C or higher for 10 minutes

165°C or higher immediately

Generator pressure is too high 0 MPa or above

High concentration of absorbent 65% twice

65.5% Immediately

Absorbent pump 1 overload alarm rated current value or above

Absorbent pump 2 overload alarm rated current value or above refrigerant pump overload alarm

Purge pump overload alarm rated current value or above rated current value or above

24

sensor alarm

Entering chilled-water temperature sensor alarm.

Entering cooling water temperature sensor alarm.

Leaving cooling water temperature sensor alarm.

Cooling water intermediate temperature sensor alarm.

Condenser temperature sensor alarm.

Low-temperature generator temperature sensor alarm. refrigerant temperature sensor alarm

(evaporator).

Diluted solution temperature sensor alarm (absorber outlet).

Leaving chilled-water temperature sensor alarm.

Generator temperature sensor alarm.

Steam drain temperature sensor failure

Purge tank pressure sensor alarm.

Is the sensor short-circuited?

→ Check all chiller sensors and contact your

Carrier service agent.

NOTe: The chiller automatically stops for safety reasons when either the generator temperature or the chilled-water temperature sensor has an alarm. It does not stop when other sensors have an alarm, but this could cause control failure. Please contact your Carrier service agent as soon as possible.

3.8.5 - action in case of a power failure

Flowchart of actions in case of a power failure

Power failure occurs.

The chiller stops completely.

actions to be taken if a power failure occurs

If a power failure occurs, the chiller stops completely without carrying out a dilution cycle. Special attention should be paid to the following.

actions required when a power failure occurs operation condition at power failure

occurred during cooling operation, and power did not return for over an hour

action

Immediately contact your Carrier service agent.

Do not restart operation.

occurred during cooling operation, and power returned in less than an hour

Contact Carrier service agent after restarting operation.

occurred during purging operation Immediately close the purge valve completely and turn the purge pump switch on the control panel off. After the power is restored, restart purging, and consult your Carrier service agent.

4 - MaiNteNaNCe

4.1 - Daily maintenance

4.1.1 - inspection of each chiller component

If you find an abnormal condition, contact your Carrier service agent:

• Oil leak around the chiller

• Abnormal noise of absorbent pump and refrigerant pump

For the following items please consult the system manufacturer:

• Cleaning of cooling tower and cooling water line strainer

• Check the condition of the cooling tower

• Check for air leaks in the piping

4.1.2 - Operation data record

Please record the operation data regularly, as this is useful for troubleshooting and alarm prevention. Show the record to the

Carrier service personnel when they visit you for the service or the periodic inspection.

On the next page you will find a sample of the operation data sheet.

Press the "RUN"

key.

Power returns.

Operation restarts.

Power failure alarm H-10 is shown on the data display.

Power failure alarm on the data display disappears.

25

test oPeratioN Data sHeet

Trial run data sheet

Project name chiller model

Serial number

Accepted by

Reviewed by

Recorded by

Unit model/serial No.

No. Data items

: ________________________________________

: 16NK- ___________________________________

: ________________________________________

: ___________________________ Date __________________________

: ___________________________

: ___________________________

Date __________________________

Date __________________________

Operator:

Unit

1 Ambient temperature

2 Room temperature

3 Chilled-water entering temperature

4 Chilled-water leaving temperature

5 Chilled-water entering pressure

6 Chilled-water leaving pressure

7 Evaporator pressure drop

8 Chilled water flow rate

9 Cooling capacity

10

11 Cooling water entering temperature

12 Cooling water leaving temperature

13 Cooling water entering pressure

14 Cooling water leaving pressure

15 Pressure drop in absorber & condenser

16 Cooling water flow rate

17 High-temperature generator pressure

18 High-temperature generator temperature

19 Solution level in high-temperature generator

20 Inverter frequency

21 Operating current of absorbent pump 1

22 Operating current of absorbent pump 2

23 Operating current of refrigerant pump

24 Operating current of purge pump

25 Evaporator solution level l/s/gpm

MPa/psi

°C/°F n/60 mm

Hz

A

A

A

26 Purge tank pressure

27 Opening degree of dilution solution damper

A n/60 mm n/2-3/8" kPa n/90

28 Opening degree of intermediate solution damper n/90

29 Opening degree of concentrated solution damper n/90

30 Steam consumption

31 Supply steam pressure kg/h / lb/h kPa/psi

32 Supply steam temperature °C/°F l/s/gpm kW

USRT

°C/°F

°C/°F kPa/psi kPa/psi kPa/psi

°C/°F

°C/°F

°C/°F

°C/°F kPa/psi kPa/psi kPa/psi

Spec.

DATA-1

Time:

1/2

Date: / /

DATA-2

Time:

DATA-3

Time:

26

test oPeratioN Data sHeet - cont.

Trial run data sheet

Project name chiller model

Serial number

Accepted by

Reviewed by

Recorded by

: ________________________________________

: 16NK- ___________________________________

: ________________________________________

: ___________________________ Date __________________________

: ___________________________

: ___________________________

Date __________________________

Date __________________________

2/2

Unit model/serial No.

No. Data items

Operator:

Unit Spec.

DATA-1

Time:

Date: / /

DATA-2

Time:

DATA-3

Time:

33

34

Concentration of concentrated solution %

Relative density of concentrated solution

-

Temperature of concentrated solution °C/°F

Concentration of diluted solution

Relative density of diluted solution

Temperature of diluted solution

Concentration of refrigerant

-

%

°C/°F

%

35 Relative density of refrigerant

Temperature of refrigerant

36 Condensed refrigerant temperature

37 *LTD (See below)

-

°C/°F

°C/°F

K

* LTD (Leaving Temperature Difference) = Condensed refrigerant temperature minus cooling water leaving temperature

Notes:

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

27

4.2 - Periodic maintenance

To optimize performance, the chiller requires purging, refrigerant blow down, absorbent control, and management of combustion equipment (16DJ), etc. We recommend that you arrange a maintenance contract with your Carrier service agent.

4.2.1 - Purging (Fig. 30)

Non-condensable gas inside the machine not only decreases cooling capacity, but also potentially shortens the life of the machine. Therefore purging must be done periodically. This should be done by the Carrier service personnel under the maintenance contract. If customers carry out the purging themselves, they should take instruction from our service personnel.

4.2.2 - refrigerant blow down

During cooling operation a small quantity of absorbent can mix with the refrigerant. This amount can increase over time and result in a reduced cooling capacity. Therefore refrigerant blow-down must be performed once during the cooling season.

By doing this the dirty refrigerant is transferred to the absorber side and new, clean refrigerant is regenerated.

Fig. 29

Purging procedure

When the purge indication light on the control panel comes on, start purging, following the instructions below.

1. Turn on the purge pump on/off switch on the control panel and operate the purge pump for 10 minutes.

2. Open v1 and v2.

3. Press the s

key on the control board once to show data code 17 "Purge tank pressure" (refer to chapter 3.5.3) and check if the indicated value drops. If it does not drop, follow the procedure described in steps 5, 6 and 7 below, and contact your Carrier service agent.

4. Purge for 10 minutes. Even if the purge indication light goes off before 10 minutes have elapsed, continue purging for the full 10 minutes. If the light does not go off, continue purging until it does.

5. Close v1 and v2.

6. Turn off the purge pump on/off switch.

7. Check whether the valves are open/closed. v1 Closed v2 v3

Closed

Closed

B-valve Open

Fig. 30

refrigerant blow-down valve

• Make sure the refrigerant pump is rotating and that the solution level is visible through the evaporator sight glass.

• Open the transfer valve completely.

• When the solution level is no longer visible, close the transfer valve tightly.

The above blow-down procedure should be repeated a few times, as necessary. We recommend that you arrange a maintenance contract with your Carrier service agent which will include refrigerant blow-down.

Purge tank b-valve

V2

Maintenance pressure gauge

V3

SV2

SV1

Liquid trap

V1

Purge indication light (green)

Purge pump on/off switch

Purge pump

28

4.3 - recommended maintenance and main component replacement schedule

Standard controls

29

4.4 - Water treatment

Fig. 31 - example of the effect of tube fouling

Water treatment is very important for the chiller. As this requires specialised technical knowledge, please consult your

Carrier service agent.

4.4.1 - Water treatment for chilled water and cooling water

The cooling water temperature in an open-type recycling cooling tower is decreased using vaporized latent heat, and the cooling water is reused. At this time, the water is evaporated, and the concentration of the remaining dissolved salts increases. This means that the water quality will gradually deteriorate.

As the water and air are always in contact with each other in the cooling tower, the sulfurous acid gas, dust, sand, etc. in the atmosphere will mix with the water, further degrading the water quality.

These factors cause problems in the cooling water system, such as corrosion, scale and slime.

Water quality standard

The water quality standard is shown in the example in Figure

25. This is an extract from JRA-GL 02-1994.

NOTeS:

1. If any item deviates from the standard values it may cause failure due to corrosion or scale. Therefore the water quality should be checked periodically.

2. The water quality range that can be used after chemical treatment is not given here, as the range depends on the chemicals used. The appropriate water quality values should be set together with a water processing specialist and be checked periodically.

Typical water treatment

Even if the make-up water for the cooling water complies with water standards, the water quality will deteriorate due to its concentration. Therefore the following water treatment is necessary. Depending on the degree of deterioration, chilledwater also requires this treatment.

If a concrete heat storage tank is used, special attention should be paid to water treatment.

• Regular manual blow-down of the tower sump water

• Automatic blow-down by measuring electric conductance

• Addition of the anti-corrosion inhibitor

• Slime control

• Periodic water analysis

Service the water header periodically, check the heat transfer tube and clean it as necessary.

105

100

5

4

125

120

115

110

3

2

1

A

B

C

1 2 3 4 5 6 7 8 9 10

Fouling factor (m

2

h °C/kcal) x 10

-4

1 2 3 4 5 6 7

Fouling factor (m

2

K/kW) x 10

-4

8 9

0.2 0.4 0.6 0.8 1.0 1.2

Scale/slime (mm)

100

90

80

70

60

For example, if 0.6 mm of scale clings to the tubes, the cooling capacity drops to 76%, the chilled-water temperature rises by

2°C and fuel consumption rises by 23%.

A Increase in fuel consumption (for constant cooling capacity, ratio at rated fuel consumption)

B Decrease in cooling capacity

(for constant chilled water temperature)

C Increase in chilled water temperature

(for constant cooling capacity)

30

31

4.4.2. Water treatment for long-term shut-down

Perform the following procedure during long-term shut-down when no chilled-water or cooling water circulates in the chiller.

Please consult your Carrier service agent for the details.

cooling water

The usual system is a wet system with the cooling water kept in the chiller. If the cooling water is likely to freeze, drain it from the chiller (dry system). The valve operation is different between wet and dry systems.

long-term shut-down (wet system)

• Drain the cooling water from its discharge port on the cooling water outlet.

• Add anti-corrosion inhibitor to the water.

Check the holding water quantity and decide the inhibitor quantity so that the ratio is appropriate.

• Charge the chiller with cooling water.

• Operate the cooling water pump until the inhibitor is evenly mixed.

• Close the cooling water line inlet and outlet isolation valves.

dry system

Before draining the cooling water from the chiller, clean the inside of the tubes and provide a corrosion protection covering.

• Drain the cooling water from its discharge port on the cooling water inlet.

• Remove the scale and/or slime from the tubes with a brush. If scale and/or slime cannot be removed with a brush use chemical cleaning.

• After sufficient cleaning, add anti-corrosion inhibitor to the water, and circulate the water with the inhibitor for 30 minutes or more. The inhibitor concentration should be even.

• Drain the water from the discharge port on the cooling water inlet.

• Keep the discharge port open during shut-down.

chilled water

The usual system is a wet system with the chilled water kept in the chiller.

4.4.3 - Winter season

If the ambient temperature of the chiller is likely to be below

0°C in winter, freeze protection is necessary. Consult your

Carrier service agent for the details.

5 - troUblesHootiNg

For identifying and eliminating the causes of machine failure, please refer to the following chapters:

3.7 - Maintenance message

3.8 - Alarm indication and actions

Appendix 1 - Flowchart (at the end of this document)

32

13

14

15

V2

SV2

1

SV1

V1

2

280

Sampling cylinder

(MAtErIAL : ACrYL rESIN)

3

4

5

6

7

V3

Fig. 33

54

10

11

8

9

12

Valve

Attachment

16

17

18

legend

1 Attachment

2 Liquid trap

3 Vacuum gauge

4 Vacuum rubber hose

5 Vacuum valve

6 Sampling cylinder

7 Purge pump

8 Sampling service valve

9 Attachment

10 Vacuum rubber hose

11 Vacuum valve

12 Sampling cylinder

13 rubber plug

14 Copper tube

15 Flare nut (brass)

16 rubber hose

17 Steel wire

18 Copper tube

19 Flare nut (brass)

20 Copper tube

19

20

150

100

33

6 - iNstrUCtioNs

6.1 - absorbent sampling method

This instruction describes the procedure for sampling a small amount of the absorbent.

6.1.1. equipment to use

• Sampling cylinder and attachments for service valve

• vacuum rubber hose

• Pliers

• vacuum gauge (0-1 kPa)

6.1.2 - Precautions

• Because of the high vacuum condition inside the chiller, ensure that air never leaks into the chiller during this work.

• Handle the vacuum valve carefully so as not to damage it.

• Solution (absorbent and refrigerant) is sampled at Sv5,

Sv6 and Sv3 in the same manner.

• Pour the sampled solution into a container.

Refer to figure 8.

6.1.3 - Procedure

• Confirm that manual purge valves (v1, v2 and v3) are closed.

• Remove the flare nut and the bonnet of Sv1, and connect the attachment to the service valve.

• Connect the vacuum gauge to Sv2 and open Sv2.

• Remove the flare nut and the bonnet of Sv4 when absorbent is sampled, and connect the attachment to the sampling service valve.

• Connect the vacuum rubber hose and the sampling cylinder to the attachment as shown in Figure 33.

• Run the purge pump and open up v1.

• Open Sv1 and the vacuum valve.

• Once the vacuum gauge shows about 0.5 kPa, close the vacuum valve.

• Close Sv1 and v1.

• Remove the vacuum rubber hose from Sv1, and connect it to the attachment connected to Sv4, as shown in

Figure 33.

• Open the vacuum valve.

• Open Sv4.

• When the sampling cylinder is filled with absorbent, close

Sv4.

• Close the vacuum valve and remove the vacuum rubber hose from the attachment on Sv4 .

• Upon completion of this work, remove the attachment, and replace the bonnets and flare nut. Also replace the caps of both service valves after checking their packing.

• Stop the purge pump.

• Finally, wash all tools with water.

6.2 - Concentration measurement method

This is the procedure used to measure the absorbent and refrigerant concentration.

6.2.1 - equipment to use

• Sampling cylinder

• Gravimeter

Scale: 1.0-1.2 (for refrigerant)

Scale: 1.4-1.6 (for diluted absorbent)

Scale: 1.6-1.8 (for diluted, intermediate and concentrated absorbent)

• Thermometer

6.2.2 - Precautions

• Take care not to damage the gravimeter and thermometer.

• Be careful not to spill any solution. Do not fill the sampling cylinder more than about 80%.

• Perform this measurement quickly.

6.2.3 - Procedure

• Fill the sampling cylinder to about 80% with the solution to be measured.

• Keep the sampling cylinder vertical, and insert the gravimeter into it.

• When the gravimeter stops moving up and down, read its scale which shows the gravity of the solution.

• Remove the gravimeter and put it aside. Then insert the thermometer into the sampling cylinder and stir the solution thoroughly.

• When the temperature stabilizes, read the scale on the thermometer.

• Remove the thermometer and put it aside.

• Store the solution in another bottle.

• Using the concentration diagram of the lithium bromide solution, read the concentration.

• Upon completion of the measurement, wash the gravimeters, thermometer and sampling cylinder with water, and store them so that they are not damaged.

example:

The horizontal axis represents temperature and the vertical axis represents relative density. The lines going down from left to right represent the fixed concentrations.

For example, if the relative density is 1.77 and the temperature is 45°C, the concentration given by the point of intersection of the lines projected from these values will be 63%, as shown in

Figure 34 below.

Fig. 34

1.77

64

63

62

0 4 5 temperature (°C)

34

Fig. 35 - Concentration vs temperature vs relative density

1,75

1,70

1,65

1,85

1,80

65%

60%

1,60

55%

1,55

1,50

50%

1,45

1,40

0 10 20 30 40 50 temperature (°C)

60 70 80 90 100

45%

35

7 - MaiNteNaNCe CoNtraCt

To enjoy safe and efficient operation of the chiller for a long time, daily maintenance and periodic inspection are essential.

The main items are as follows:

• verification of the function of safety devices and their adjustment

• Checking the operating conditions and recording the data

These procedures require special tools and a special skills.

We offer an annual maintenance contract to users of the chiller.

Under the contract we provide trained service personnel that will perform the periodic diagnosis and adjustment of the chiller, using the latest technology. Consult your Carrier service agent for details.

7.1 - annual maintenance contract

7.3 - Warranty

• Your Carrier service agent will fill in the warranty and leave it with you. Please check the warranty period, read the document carefully and keep it in a safe place.

• If the chiller fails within the warranty period under normal operating conditions, we will replace all necessary spare parts or repair the chiller free-of-charge.

• After the warranty period expires, all repair costs will be charged. Consult your service agent.

• For all other items please read your warranty document.

We offer an annual maintenance contract to our customers with periodic inspection and maintenance of the Carrier absorption chiller. Under this contract your Carrier service agent will perform maintenance/inspection and adjustment works to keep your chiller in its optimal condition, and you will be given priority for chiller repairs, in case there is a problem.

It is recommended to perform a complete chiller overhaul every few years to keep it in its optimal condition. Under the maintenance contract we advise our customers of the timing and the parts to be overhauled. There is an additional contract for water quality control and cleaning of the heat transfer tubes in the water system. We recommend that you also take out this contract.

7.2 - inspection report

We issue an inspection report for the annual maintenance under the contract. The report contains a thorough description of the inspection/adjustment items and ensures that Carrier service personnel will not overlook any of the inspection items. At the time of inspection the Carrier service personnel will fill in the report, leave one copy with the customer, and take one copy back to the office to be available for future maintenance works.

We will not re-issue this report, so please be sure to keep it in a safe place. Show it to the Carrier service technicians when they visit you.

36

aPPeNDix 1 - troUblesHootiNg FloWCHart

Problem list

Problem 1.

Problem 2.

Problem 3.

Problem 4.

Problem 5.

Problem 6.

Problem 7. chiller does not run chilled-water temperature is high generator alarm combustion alarm (16dJ only)

Water alarm

Motor alarm system alarm

Problem 1 - Chiller does not run

blower motor runs (16DJ only).

blower motor does not run (16DJ only).

Interlock

Gas control valve moves.

Gas control valve does not move.

Motor moves to fully open, but then does not move any more.

Protection relay is defective.

Check E1 of the solution level electrode.

the motor is defective.

Check if the air flow switch is oN

Check setting of air flow switch.

Check E2 of the solution level electrode.

Motor moves to fully closed, but then does not move any more.

Protection relay is defective.

Check E1 of the solution level electrode the motor is defective.

Check if the air flow switch is oN.

Check setting of air flow switch.

Check E3 of the solution level electrode.

.

Protection relay is defective

Check E1, E2 and E3 of the solution level electrodes.

the motor is defective.

oil solenoid valve does not open.

Protection relay is defective.

the solenoid valve is defective.

Check if the air flow switch is oN.

Check setting of air flow switch.

Check breaker on the burner control panel.

If solution level alarm exists at start-up, the blower does not run.

Air flow contact is welded.

Check if the motor is in fully closed position. the motor may stop in the half-way position after a power failure.

Protection relay is defective.

Check if chilled-water pump interlock signal goes to the microprocessor.

Check if cooling water pump interlock signal goes to the microprocessor.

Check if fan interlock signal goes to the microprocessor (16DJ only).

Fuse has blown.

NOTe: The troubleshooting charts apply to all 16 series absorption chillers, and the service engineer should determine if the failure mode is relevant to the specific machine.

37

Problem 2 - Chilled-water temperature is high.

Vacuum problem

Chilled water problem

Cooling water problem

Solution problem

Crystallization

Combustion problem (16DJ only)

Electrical problem

Generating hydrogen gas: 60% Insufficient inhibitor

Pd cell is defective

Pd cell heater is defective

Air leakage: 30%

Insufficient air purging: 30%

Chilled-water flow rate is too high

Flow rate is inadequate: 30%

.

Cooling water temp. is too high: 50%

Cooling water pump control malfunctions.

Strainer is clogged.

Insufficient feed water.

Air in the cooling water line.

Ambient temperature and/or humidity are too high.

Cooling water control valve malfunctions.

Cooling tower water spray malfunctions.

Cooling tower fan malfunctions.

Cooling tower fan belt is broken.

Cooling water temperature control thermostat malfunctions.

20%

Partition plate in water box is removed.

Absorber and condenser tubes are fouled.

Insufficient absorbent flow rate: 30% Solution flow rate is not adjusted properly.

Wrong inverter setting.

Check valve malfunctions.

Wrong damper adjustment.

Condensed refrigerant pipe connected between the low temperature generator and condenser is clogged.

Heat transfer tubes in high/low temperature heat exchangers leak.

Heat exchanger is clogged with foreign material.

Insufficient refrigerant amount: 5%

Insufficient octyl alcohol: 10% refrigerant contamination : 25% Cooling water entering temperature is too low.

refrigerant blow-down is needed.

Heavy foaming condition in high temperature generator due to absorbent contamination with foreign material.

Absorbent pump 1 cavitation: 25%

Ambient temperature is too low: 5%

Cooling water entering temperature is too low with insufficient air purging: 70%

Gas/oil flow rate is insufficient.

rank up set too low.

Air/gas/oil linkage has shifted to low combustion.

Gas supply pressure fluctuates.

Chilled water set too high.

temperature sensor is defective.

Microprocessor is defective

Parts, setting position: 20%

Solution flow rate is not adjusted properly.

Cooling water entering temperature fluctuates strongly

Vacuum condition in the chiller is poor.

Insufficient absorbent solution.

Insufficient octyl alcohol.

Solution level electrode malfunctions: 80%

Electric parts and sensors are defective.

Wrong setting on microprocessor and inverter.

Wrong position of select switches.

Electrode surface is contaminated.

Electrode is defective.

teflon tube on electrode has been removed.

NOTe: The troubleshooting charts apply to all 16 series absorption chillers, and the service engineer should determine if the failure mode is relevant to the specific machine.

38

Problem 3 - generator alarm.

Vacuum problem

Cooling water problem

Absorbent flow problem

Crystallization

Electrical parts problem

High-temp. generator problem (16DJ only)

Hydrogen gas is generated: 60% Insufficient inhibitor

Pd cell is defective

Pd cell heater is defective

Air leakage: 30%

Purging is inadequate: 10%

Flow rate is inadequate: 30%

.

Cooling water pump is too high: 50%

Cooling water pump control malfunctions.

Strainer is clogged.

Insufficient feed water.

Air in cooling water line.

Ambient temperature and/or humidity are too high.

Cooling water control valve malfunctions.

Cooling tower water spray malfunctions.

Cooling tower fan malfunctions.

Cooling tower fan belt is broken.

Cooling water temperature control thermostat malfunctions.

20%

Partition plate in water box is removed.

Absorber and condenser tubes are fouled.

Absorbent flow rate is inadequate: 75% refrigerant is contaminated by absorbent: 24% Cooling water temperature is too low.

refrigerant blow-down is inadequate.

Heavy absorbent foaming condition in Ht generator because there is foreign material in the absorbent (16DJ/NK)

Lt generator tubes are damaged (16DJ/NK): 1%

Absorbent pump cavitation: 25%

Ambient temperature is too low: 5%

Cooling water entering temperature is too low with insufficient air purging: 70%

Electrical parts/sensors malfunction: 20% Microprocessor malfunctions.

Cam switches malfunction.

Pressure switch malfunctions.

Microprocessor solution level incorrect.

temperature sensor malfunctions.

Solution level electrode malfunctions: 80%

Ambient temperature and/or humidity are too high.

Cooling water control valve malfunctions.

Cooling tower water spray malfunctions.

Cooling tower fan malfunctions.

Cooling tower fan belt is broken

Combustion chamber and smoke tube are sooted: 90% too much gas/oil: 8%

Electrode surface is contaminated.

Electrode is defective.

teflon tube on electrode has been removed.

Incorrect combustion adjustment.

blower suction is clogged ‡ air/gas/oil ratio is incorrect.

Flue is clogged ‡ air/gas/oil ratio is incorrect.

Gas pressure increases.

Incorrect gas/oil linkage adjustment.

baffles provided in smoke tube are defective: 2%

Wrong adjustment Wrong inverter setting.

Check valve malfunctions.

Wrong damper adjustment.

Heat exchanger(s) tubes are damaged.

Heat exchanger(s) is (are) clogged.

orifice in pipe betw. Lt generator + condenser is clogged (16DJ/NK)

NOTe: The troubleshooting charts apply to all 16 series absorption chillers, and the service engineer should determine if the failure mode is relevant to the specific machine.

39

Problem 4 - Combustion alarm (16DJ only)

Flame failure (spark oK) Flame failure occurs at the end of ignition spark.

Flame failure (pilot burner ignites) Flame failure occurs during main flame trial: 50%

Pilot burner is oK: 50%

Main burner does not ignite: 70%

Protection relay is defective.

Pilot burner is not properly adjusted.

Pilot solenoid valve is defective.

Pilot gas regulator is defective.

Flame detector (UV tubes) is defective.

Protection relay is defective.

Pilot burner is not properly adjusted.

Main gas regulator is defective.

Flame detector cannot detect a flame.

Main gas shut-off valve is defective.

Gas supply pressure fluctuates.

Flue is clogged

Flame failure occurs after main flame was ignited for a while: 30%

Protection relay is defective.

Gas/air linkage is not properly adjusted.

Main gas regulator is defective.

Gas/oil flow meter is locked.

Flue is clogged.

Voltage drops.

Protection relay is defective.

Check if test cock opens or not.

Check if gas/oil/air linkage is loose.

Main gas shut-off valves are defective.

Flame failure (no spark)

Gas pressure alarm

Ignition transformer is defective.

Microprocessor is defective.

Position of spark rod is not properly adjusted.

Insulation of spark rod is defective.

Ignition spark wire is removed or broken.

Protection relay is defective.

Flame detector is defective.

Flame remains after stop of combustion.

Measure gas supply pressure: 80%

Air flow alarm

Check gas pressure switch: 20%

Confirm air flow switch: 80%

Measure pressure inside the wind box: 20%

Check gas regulator in main gas pipe line.

Check gas strainer.

Check other equipment installed in main gas pipe line.

Check gas regulator installed in gas train.

Confirm movement of the switch.

Check the setting.

Check the setting.

Check the contact of the air flow switch.

Check if the air flow switch is installed correctly.

Check the suction side of the wind box for obstruction by foreign material.

Check the tube between the box and the air flow switch for obstruction by foreign material.

NOTe: The troubleshooting charts apply to all 16 series absorption chillers, and the service engineer should determine if the failure mode is relevant to the specific machine.

40

Problem 5 - Water alarm

Electric system Electrical parts defective: 60% Microprocessor

Flow switch temperature sensor

Auxiliary relay in chiller control panel

Water system

Interlock: 40% temperature: 40%

Check wiring and electric parts of interlock wiring

Leaving chilled water temperature too low: 70%

Entering cooling water temperature too low: 20% temperature control function does not work properly.

Wrong operating order.

Holding water quantity in the chiller is too low.

Ambient temperature is too low.

Cooling water temp. control malfunctions.

Flow rate: 60%

Leaving hot water temperature too low: 10%

Check chilled-water flow switch temperature control function does not work properly.

Wrong operating order.

Holding water quantity in the chiller is too low.

Air in water system?

Strainer in water system is clogged?.

Valves in water system opened properly?

Problem 6 - Motor alarm

Absorbent pump refrigerant pump blower motor (16DJ only)

Measure operating current: 60% open phase: 10%

Crystallization or foreign material in the pump.

Pump motor is defective.

Magnetic contactor is defective.

Pump motor coil is defective.

Primary power failure.

Motor

Magnetic contactor with thermal relay.

Pump power wires

Check the setting of thermal relay: 10%

Measure operating current: 60% overcurrent: 90% open phase: 10%

Foreign material in the pump/Pump motor is defective.

Magnetic contactor is defective.

Pump motor coil is defective.

Primary power failure.

Measure insulation resistance: 30% Motor

Magnetic contactor with thermal relay.

Pump power wires

Check the setting of thermal relay 10%

Measure operating current: 60% overcurrent: 90% open phase: 10%

Foreign material in the pump/pump motor is defective.

Magnetic contactor is defective.

Pump motor coil is defective.

Primary power failure.

Measure insulation resistance: 30% Motor

Magnetic contactor with thermal relay.

Pump power wires

Check the setting of thermal relay 10%

NOTe: The troubleshooting charts apply to all 16 series absorption chillers, and the service engineer should determine if the failure mode is relevant to the specific machine.

41

Problem 7 - system alarm

Check if chilled water pump interlock signal goes to the microprocessor.

Check if cooling water pump interlock signal goes to the microprocessor.

Check if cooling water pump interlock signal goes to the microprocessor.

Check if fan interlock signal goes to the microprocessor (16 DJ only).

42

order No.: 11634-76, 08.2007

.

Supersedes order No.: New

Manufacturer reserves the right to change any product specifications without notice.

GB/T-24001 to ISO14001:1996

Manufactured by: Sanyo Electric Co. Ltd., Dalian, China

Printed in the Netherlands.

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