Operation and maintenance manual

Operation and maintenance manual
16DJ
Double-Effect Direct-Fired
Absorption Chillers/Heaters
Nominal cooling capacity 352-5274 kW
50 Hz
Operation and maintenance manual
GB/T-19001-2000 to ISO9001/2000
Notes to Users
Thank you for purchasing a Carrier/Sanyo absorption chiller/heater.
Read this manual carefully before operating the unit. It contains instructions for the operation and maintenance of the chiller/
heater.
Please utilize the chiller/heater 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.
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/heater detail......................................................................................................................................................... 8
2.2 - Typical control panel.....................................................................................................................................................................
2.2 - Typical burner and gas train....................................................................................................................................................... 11
2.3 - Typical control panel................................................................................................................................................................. 12
2.4 - Chiller/heater 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 - How to change cooling/heating mode....................................................................................................................................... 21
3.5 - Cooling operation...................................................................................................................................................................... 22
3.6 - Heating operation...................................................................................................................................................................... 23
3.7 - Changing the information on the data display........................................................................................................................... 24
3.8 - Changing display and setpoint................................................................................................................................................... 24
3.9 - Maintenance message................................................................................................................................................................ 25
3.10 - Alarm indications and actions.................................................................................................................................................. 26
4 - MAINTENANCE........................................................................................................................................................................ 28
4.1 - Daily maintenance..................................................................................................................................................................... 28
4.2 - Periodic maintenance................................................................................................................................................................. 31
4.3 - Recommended schedule of maintenance and replacement of main components...................................................................... 33
4.4 - Water treatment.......................................................................................................................................................................... 34
5 - TROUBLESHOOTING............................................................................................................................................................. 36
6 - INSTRUCTIONS........................................................................................................................................................................ 38
6.1 - Absorbent sampling method...................................................................................................................................................... 38
6.2 - Concentration measurement method......................................................................................................................................... 38
7 - MAINTENANCE CONTRACT................................................................................................................................................ 41
7.1 - Annual maintenance contract..................................................................................................................................................... 41
7.2 - Inspection report........................................................................................................................................................................ 41
7.3 - Warranty..................................................................................................................................................................................... 41
8. - CHILLER/HEATER DISPOSAL/REPLACEMENT............................................................................................................ 41
8.1 - Precaution.................................................................................................................................................................................. 41
8.2 - Procedure................................................................................................................................................................................... 41
Appendix 1 - Troubleshooting flowchart........................................................................................................................................ 42
The cover photograph is for illustrative purposes only, and are not contractually binding.
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/heater. Depending on
circumstances, this may result in serious injury or death.
1.1.1 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/heater, to provide protection from electric
shock or possible injury from 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
DO NOT TOUCH HIGH-VOLTAGE CABLES
Do not touch high-voltage cables to avoid electric shock.
Do not touch
1 - Precautions - cont.
WARNINGS
CAUTIONS
KEEP FLAMMABLE substanceS AWAY FROM THE
Chiller/heater
SOLVE ALL PROBLEMS BEFORE RESTARTING THE
Chiller/heater
Do not place any flammable substances (e.g. gasoline, thinner)
close to chiller/heater, flue, chimney and oil tank to prevent
fire.
Solve all problems before restarting the chiller/heater after a
safety or security device is activated, to prevent fire.
Must be observed
Prohibited
DO NOT PLACE HEAVY OBJECTS ON THE Chiller/
heater OR CONTROL PANEL
DO NOT OPERATE THE Chiller/heater IF THERE IS A
SMELL OF GAS
Do not place heavy objects on the chiller/heater or control panel
as these may fall off and cause injuries.
Do not operate the chiller/heater if there is a smell of gas. Do not
turn on/off any switch, as this could cause a fire.
Prohibited
Prohibited
DO NOT CLIMB ON THE Chiller/heater
DO NOT TOUCH ROTATING PARTS OF FANS
Do not climb on the chiller/heater as you may fall off.
Keep away from rotating part of fans or pumps to avoid
possible injury.
Prohibited
Prohibited
CALL SPECIALISTS FOR SERVICE OR MAINTENANCE
Call specialists for service or maintenance. Incorrect service/
maintenance may cause electric shocks, fire or burns.
Must be observed
AUTHORIZED PERSONNEL ONLY
A notice, "For Authorized Personnel Only" must be affixed to
the chiller/heater to stop unauthorized personnel from touching
it. If necessary surround the chiller/heater by a protective fence.
Misuse of the chiller/heater may cause injury.
Prohibited
1 - Precautions - cont.
CAUTIONS
DO NOT POUR WATER ON THE Chiller/heater OR
CONTROL PANEL
Do not pour water on the chiller/heater or control panel to avoid
electric shock.
OBSERVE THE SPECIFIED WAter and PRESSURE
The specified chilled/hot water, and cooling water pressure must
be strictly observed.
Incorrect pressure may cause the water to leak/spray which can
lead to short circuits or burns.
Prohibited
Must be observed
USE THE CORRECT POWER SUPPLY
This is indicated on the chiller/heater name plate. Use of an
incorrect power supply may cause fire or electric shock.
Prohibited
DO NOT TOUCH HIGH-TEMPERATURE AREAS
Do not touch high-temperature areas, as they may cause burns.
These areas are indicated by caution label.
What
voltage?
Prohibited
NEVER CHANGE THE SET VALUES
Never change the set values of the safety and/or protective
devices. Wrong settings may damage the chiller/heater or cause
fire.
STOP THE PURGE PUMP TO REPLACE OIL
Stop the purge pump when replacing oil to avoid possible injury
by fuel spillage.
Prohibited
STOP
Must be observed
STOP THE OPERATION WHEN COmbustion smoke is
BLACK
Stop the operation when combustion smoke is black and call a
service engineer..
Must be observed
DO NOT TOUCH THE ABSORBENT
Do not touch the spare or leaked absorbent, as this can cause
metal corrosion or skin disease.
Prohibited
1 - Precautions - cont.
1.1.2 - Safety precautions for repair, moving or disposal
WARNINGS
ONLY AUTHORIZED PERSONNEL SHOULD service
THE Chiller/heater
Only authorized personnel should service the chiller/heater.
Incorrect service could result in electric shock or fire.
Prohibited
CAUTION
ONLY AUTHORIZED PERSONNEL SHOULD REMOVE OR
REPAIR THE Chiller/heater
Any relocation or moving of the chiller/heater should only be
done by authorized personnel. Incorrect work could result in
water leaks, electric shock or fire.
1.1.3 - Operating precautions
1. Keep the purge valve tightly shut to prevent air from
leaking into the chiller/heater, which may cause the failure
of the chiller/heater.
2. Keep the power supply to the control panel turned on,
unless carrying out maintenance or service.
3. During the chiller/heater 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/heater 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. Before operating the chiller/heater at the beginning of the
cooling or heating season, make sure that necessary cooling/
heating changeover is done. Failure in the changeover may
cause damage to the chiller/heater. We recommend that
you take out a maintenance contract with a Carrier service
agent and leave the changeover to them.
5. Do not perform an insulation test on the control circuits of
the electric controller.
6 . 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. Please follow the start procedure in Figure 1 below.
Fig. 1 - Auxiliary equipment start/stop sequence
Start sequence
Must be observed
1: Chilled/hot
water pump
2: Cooling
water pump
3: Cooling
tower
4: Absorption
chiller/heater
5: Air
handling
unit
Stop sequence
ONLY AUTHORIZED PERSONNEL SHOULD DISPOSE OF
THE Chiller/heater
To dispose of the chiller/heater, contact local specialists.
Incorrect disposal may result in absorbent leaks and cause metal
corrosion or skin disease, electric shock or fire.
1 Absorption
chiller/heater
2: Cooling
water pump
3: Cooling
tower
4: Chilled/hot
water pump
5: Air handling
unit
Must be observed
1 - Precautions - cont.
2 - MACHINE ILLUSTRATIONS
1.2 - High-temperature - high-voltage caution
2.1 - Typical chiller/heater detail
•
2.1.1 - DJ-11 to DJ-42
•
•
•
Do not touch the chiller/heater 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.
Fig. 2 - Water header side
1
2
3
1.3 - Environmental requirements
4
1.3.1 - Installation considerations
The 16DJ absorption chiller/heater is designed for indoor
installation in a machine room. The protection rating of the
chiller/heater is IP40. Room temperature should be maintained
between 5°C and 40°C to protect against solution crystallization during chiller/heater shutdown. The humidity in the
machine room must be kept below 90%.
5
Ensure that the machine room is sufficiently ventilated. The
required fresh air rate for combustion is a minimum of 0.28 l/s
per kW fuel consumed.
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/heater 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.
11
6
7
12
8
13
9
10
Legend
1 Low-temperature generator
2 Condenser
3 Cooling water outlet
4 Chilled water flow switch
5 Chilled water outlet
6 Evaporator
7 Chilled water inlet
8 Cooling water inlet
9 Absorbent pump 2
10 Purge pump
11 Generator pressure switch
12 Absorber
13 Control panel
1.4 - Water treatment
Refer to chapter 4 "Maintenance”.
Fig. 3 - High-temperature generator side
1
2
3
4
Legend
1 A valve
2 Rupture disk
3 High-temperature generator
3 Burner
2.1.2 - DJ-51 to DJ-63
Fig. 4 - Water header side
10
1
2
3
4
5
6
7
8
11
9
Legend
1 Cooling water outlet
2 Purge tank
3 Low-temperature generator
4 Chilled water outlet
5 Evaporator
6 Absorber
7 Chilled water inlet
8 Low-temperature heat exchanger
9 High temperatrure heat exchanger
10 Condenser
11 C valve
Fig. 5 - High-temperature generator side
3
6
7
1
2
8
9
10
4
Legend
1 Generator pressure gauge
2 Control panel
3 A valve
4 Absorbent pump 1
5 Refrigerent pump
6
7
8
9
10
5
Exhaust gas outlet
Rupture disk
High-temperature generator
Burner
Cooling water inlet
2.1.3 - DJ-71 to DJ-82
Fig. 6 - Water header side
9
10
1
2
3
4
5
6
7
8
11
12
Legend
1 Low-temperature generator
2 D valve
3 Chilled water outlet
4 Evaporator
5 Absorber
6 Chilled water inlet
7 Cooling water inlet
8 Purge pump
9 Condenser
10 Rupture disk
11 Absorber
12 C valve
Fig. 7 - High-temperature generator side
1
2
3
4
5
6
Legend
1 A valve
2 Exhaust gas outlet
3 Cooling water outlet
4 Generator pressure gauge
5 High-temperature generator
6 Burner
7 Absorbent pump 2
10
7
2.2 - Typical burner and gas train
Fig. 8 - Typical burner
5
2
1
3
4
6
Legend
1 Ball valve
2 Filter
3 Pressure regulator
4 Shut-off valve
5 Blower
6 Gas control valve
11
2.3 - Typical control panel
Fig. 9 - Control panel (CE type)
Fig. 10 - Control panel inside (CE type)
1
1
14
6
2
3
2
4
5
6
7
7
8
8
9
3
10
9
11
10
12
4
13
5
Legend
1 Fan
2 Terminal block
3 Terminal block
4 Terminal block for power supply
5 Earth terminal
6 Control board
7 Purge pump on/off switch
8 Purge/indication light
9 Cooling/heating changeover switch
10 Operating handle
12
Legend
1 Control relay
2 Circuit protector
3 Isolator
4 I/O board
5 Terminal block
6 AC reactor
7 Circuit breaker
8 Inverter
9 DC reactor
10 Main circuit breaker
11 Transformer
12 Electromagnetic contactor
13 Filter
14 Transformer
15 Terminal block
15
Fig. 11 - Interface board
1
2
3
4
STOP
RUN
5
CHILLER/HEATER
6
#1ABS PUMP
#2ABS PUMP
REF PUMP
PURGE PUMP
7
SET
BACK
8
BURNER
REMOTE
9
STAND BY
COOLING
DILUTION
HEATING
SAFETY CIRCUIT
BUZZER STOP
LOCAL
COMBUSTION
CHILLER/HEATER ALARM
BURNER ALARM
11
OPERATION
STOP
10
RUN
POWER
12
13
14
15
16
Legend
1 Stop indication light
2 Operation indication light
3 Data display
4 Select key
5 Function set key
6 Back select key
7 Cooling/heating light
8 Remote/local select key with light
9 Alarm buzzer stop key
10 Combustion indication light
11 Operation select key with light
12 Alarm indication light
13 Stand by indication light
14 Dilution indication light
15 Safety circuit indication light
16 Power indication light
13
2.4 - Chiller/heater 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 the vaporized
refrigerant. In the heating mode, the evaporator functions as a
hot water heater. Hot water in the heat transfer tubes of the
evaporator is heated by the refrigerant and used for heating.
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.
Heat exchangers
After leaving the absorber section the diluted solution passes
through the low-temperature heat exchanger, where it is heated
by the concentrated solution. The diluted solution then passes
through the high-temperature heat exchanger, where it is
further heated by the intermediate solution. The intermediate
and concentrated solutions are cooled by the diluted solution.
This cooling process of the concentrated solution allows for
greater absorbing power due to its lower temperature.
High-temperature generator
The diluted solution from the heat exchangers is heated in the
high-temperature generator. It releases the refrigerant vapour
and is concentrated. It becomes intermediate solution.
14
Low-temperature generator
The refrigerant vapour from the high-temperature generator
passes through the heat transfer tubes of low-temperature
generator. The intermediate solution in the low-temperature
generator is heated by the refrigerant vapour. It releases the
refrigerant vapour and is concentrated. It becomes concentrated
solution. The condensed refrigerant in the heat transfer tubes of
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/
heater and stores it in the purge tank.
Refrigerant heat recovery exchanger
Heat the low-temperature absorbent using the heat of the
refrigerant drain condensed in the low-temperature generator.
Sensors
SymbolName
DT1
Chilled/hot water outlet temperature
DT2
Cooling water outlet temperature
DT3
High-temperature generator temperature
DT4
Low-temperature generator temperature
DT5
Condenser temperature
DT6
Chilled/hot water inlet temperature
DT7
Cooling water inlet temperature
DT8
Not used
DT9
Not used
DT10 Diluted solution temperature at absorber outlet
DT11 Refrigerant temperature at evaporator
DT12 Cooling water mid temperature
DT13 Exhaust gas temperature
E1-3
High-temperature generator solution level electrode
63GHH High-temperature generator pressure switch for cooling.
63GHL High-temperature generator pressure switch for heating
(CE only)
69CH Chilled/hot water flow switch
69PR
Purge tank pressure
15
Legend
Valve
Orifice
Check valve
Damper
Strainer
Service valve
Sensor
V1
SV2
SV1
V3
V2
D1:
D2:
D3:
D4:
D5:
D6:
SV1:
SV2:
SV3:
SV4:
SV5:
SV6:
SV7:
SV8:
5
4
69CH
DT6
DT1
8
69PR PCH
9
SV3
DT11
DT12
DT5
11
10
16
23CH
SV4
DT10
17
18
14
13
DT7
15
D1
Diluted solution damper
V1: Manual purge valve
Diluted solution low-temperature heat exchanger damper V2: Manual purge valve
Diluted solution refrigerant heat recovery exch. damper
V3: Manual purge valve
Intermediate solution damper
Consentrated solution damper 1: Purge pump
Refrigerant solution damper
2: Purge unit
Charge/discharge N2 gas service valve
3: Cooling water outlet
Purge unit service valve
4: D valve (cooling/heating changeover valve)
Refrigerant service valve
5: B valve (cooling/heating changeover valve)
Diluted solution service valve
6: Chilled/hot water outlet
Intermediate solution service valve
7: Chilled/hot water inlet
Concentrated solution service valve
8: Purge tank
Generator pressure gauge service valve
9: Refrigerant pump
Generator maintenance service valve
10: Refrigerant blow-down valve
1
2
7
6
3
DT2
12
19
22
D2
SV6
21
23
20
D5
DT4
SV5
24
D4
27
25
DT3
DT13
27: Burner
26: High-temperature generator
25: Exhaust gas
SV7
63GHH 63GHL
SV8
E1-3
11: Absorbent pump 1
12: Condenser
13: Low-temperature generator
14: Z valve (rupture disk isolation valve)
15: Rupture disk
16: Evaporator
17: Absorber
18: Cooling water inlet
19: Refrigerant heat recovery exchanger
20: A valve (cooling/heating changeover valve)
21: C valve (cooling/heating changeover valve)
22: Absorbent pump 2
23: Low-temperature heat exchanger
24: High-temperature heat exchanger
D3
D6
Fig. 12- Flow diagram (DJ-11-42)
26
16
Legend
Valve
Orifice
Check valve
Damper
Strainer
Service valve
Sensor
V1
D1:
D2:
D3:
D4:
D5:
D6:
SV1:
SV2:
SV3:
SV4:
SV5:
SV6:
SV7:
SV8:
SV2
SV1
V3
V2
7
5
4
8
DT6
DT1 69CH
V4
69PR
PCH
9
SV3
DT11
DT12
DT5
Diluted solution damper
Diluted solution low-temperature heat exchanger damper
Diluted solution refrigerant heat recovery exch. damper
Intermediate solution damper
Consentrated solution damper Refrigerant solution damper
Charge/discharge N2 gas service valve
Purge unit service valve
Refrigerant service valve
Diluted solution service valve
Intermediate solution service valve
Concentrated solution service valve
Generator pressure gauge service valve
Generator maintenance service valve
1
2
6
3
DT2
10
11
16
23CH
SV4
DT10
17
14
13
DT7
15
D1
V1: Manual purge valve
V2: Manual purge valve
V3: Manual purge valve
V4: Manual purge valve
1: Purge pump
2: Purge unit
3: Cooling water outlet
4: D valve (cooling/heating changeover valve)
5: B valve (cooling/heating changeover valve)
6: Chilled/hot water outlet
7: Chilled/hot water inlet
8: Purge tank
9: Refrigerant pump
10: Refrigerant blow-down valve
12
19
22
D2
SV6
21
D5
23
20
DT4
SV5
24
D4
27
25
DT3
DT13
26
27: Burner
26: High-temperature generator
25: Exhaust gas
SV7
63GHH 63GHL
SV8
E1-3
11: Absorbent pump 1
12: Condenser
13: Low-temperature generator
14: Z valve (rupture disk isolation valve)
15: Rupture disk
16: Evaporator
17: Absorber
18: Cooling water inlet
19: Refrigerant heat recovery exchanger
20: A valve (cooling/heating changeover valve)
21: C valve (cooling/heating changeover valve)
22: Absorbent pump 2
23: Low-temperature heat exchanger
24: High-temperature heat exchanger
D3
D6
Fig. 13- Flow diagram (DJ-51-82)
3 - OPERATING INSTRUCTIONS
3.1 - Self-diagnostic function
The self-diagnostic function starts when the breaker inside
the control panel of the chiller/heater is turned on. After selfdiagnosis 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. 14 - Control panel
Note: The version number differs with each chiller/heater
type.
•
The data display shows the high-temperature 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. 15 - Typical control board
8
1
2
STOP
13
RUN
CHILLER/HEATER
#1ABS PUMP
5
#2ABS PUMP
REF PUMP
PURGE PUMP
SET
BACK
14
9
BURNER
10
11
STAND BY
COOLING
DILUTION
HEATING
SAFETY CIRCUIT
REMOTE
BUZZER STOP
6
LOCAL
COMBUSTION
12
CHILLER/HEATER ALARM
BURNER ALARM
POWER
4
OPERATION
STOP
RUN
7
3
Legend
1 Operation indication light:
2 Stop indication light:
3 Alarm indication light:
4 Combustion indication light:
5 Cooling/heating light:
6 Remote/local select key with LED:
7 Operation select key with LED:
8 Data display (7-segment LED):
9 Standby indication light:
10 Dilution indication light:
11 Safety circuit indication light:
12 Power indication light:
13 Data select key:
14 Alarm buzzer stop key:
18
The operation indication light is on when the chiller/heater is running.
The stop indication light is on when the chiller/heater is shut down.
The alarm indication light is on when an alarm occurs.
Combustion indication lamps light through out burner burning.
The indication light indicates cooling or heating mode.
To select remote operation or local operation.
Key used to run/stop the chiller/heater.
The stop key is also used for alarm reset.
Shows the temperature, setpoint, etc.
On when the chiller/heater 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.
3.3 - Control board settings
Fig. 16 - Display example (cont.)
3.3.1 -Time setting
Refer to Figure 16.
!!!!
Press the p key to set the day.
Fig. 16 - Display example
Generator temperature
Press the " SET " key for about 2 seconds.
!!!!
Press the q key.
Press the q key.
Press the " SET " key for about 2 seconds.
!!!!
!!!!
!!!!
Press the SET key for about 2 seconds.
Press the " SET " key for about 2 seconds.
!!!!
Press the p key to set the hour.
Press the p or qkey.
!!!!
Press the q key.
Press the " SET " key for about 2 seconds.
!!!!
Press the q key.
!!!!
Press the SET key for about 2 seconds.
!!!!
Press the SET key for about 2 seconds.
Press the p key to set the month.
Press the q key.
Press the p 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 17.
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
LABEL
SW3: Backup switch
UP:
ON
DOWN: OFF
Backup battery
Fig. 17- SW3 backup switch and backup battery
3.3.3 - How to change the temperature unit
The temperature unit can be changed as follows, even while the
chiller/heater is operating.
Fig. 18 - Display example
Generator
temperature
3.4 - How to change cooling/heating mode
Purging is necessary at each changeover process. Please contact
your Carrier service agent.
Press the " SET " key
for about 2 seconds.
3.4.1 - Cooling/heating changeover
Before you change the operation mode from cooling to heating,
please perform refrigerant blow down and dilution cycle.
Press the q or p key.
1. Cooling ‡ heating procedure
Press the SET key for about 2
seconds.
Cooling operation
Press the q or p key if you need.
Press the SET key for about 2
seconds.
Refrigerant blow down
And press the q or p key.
To select °C
Refer to section 4.2.2 “Refrigerant blow down”
To select °F
Press the "SET" key to select °C mode and again to select the °F mode
Press the «Stop» key on
the operation board.
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.
Chiller/heater stops.
Fig. 19 - Display example
Control board setting
Dilution cycle operation
Remote
signal type
(1)
(2)
(3)
(4)
(5)
free
Changeover position of
the chiller/heater valves
free
Generator temperature
Press the SET key for about 2 seconds.
Press the q or p key.
Press the SET key for about 2 seconds.
Press the q or p key.
Press the q or p key.
Press the SET key for about 2 seconds.
Dry system
Drain the cooling
water from the
chiller/heater.
Close the cooling
water inlet/outlet
valve.
A valve : Open
B valve : Closed
C valve : Open
D valve : Open
(refer to figure 12)
Wet system
Changeover of valve in
the cooling water line
If necessary, change
the auxiliary equipment
system.
Change to heating mode
by control board key
- refer to section 3.4.2.
Keep the cooling
water full in the
chiller/heater.
Close cooling
water inlet/outlet
isolation valves
and open D valve.
If the cooling
water is likely to
freeze, drain the
cooling water
from the chiller/
heater.
Then press the q or p key.
Purging
To select the static mode
To select the pulse mode
By pressing the SET key, the pulse mode
is selected.
By pressing the SET key, the static
mode is selected.
Press the SET key for about 2 seconds.
Heating operation
Then press the q or p key.
To select the negative mode
To select the positive mode
Press SET key to select positive mode. Press SET" key to select negative mode.
21
Fig. 21 - Typical control board
2. Heating ‡ cooling procedure
Changeover must be done with chiller/heater switched off..
A valve : Closed
B valve : Open
C valve : Closed
D valve : Closed
(refer to figure 12)
Changeover chiller/
heater valves
STOP
RUN
Change to heating mode
using control board key
- refer to section 3.4.2.
CHILLER/HEATER
#1ABS PUMP
#2ABS PUMP
REF PUMP
SET
PURGE PUMP
If necessary, change
the auxiliary equipment
system.
BURNER
STAND BY
COOLING
DILUTION
HEATING
BACK
REMOTE
1
2
BUZZER STOP
SAFETY CIRCUIT
LOCAL
5
6
COMBUSTION
Refrigerant blow down (2
or 3 times at start-up)
OPERATION
CHILLER/HEATER ALARM
RUN
STOP
BURNER ALARM
POWER
3
4
Purging
Cooling operation
3.4.2 - Change the cooling/heating mode using the key while
checking the data display.
Legend
1 Cooling light
2 Heating light
3 Stop key
4 Run key
5 Remote key
6 Local key
Fig. 20 - Display example
High-temperature
generator
temperature
Push the " SET " key
for about 2 seconds.
Press the q or p key.
Press the q or p key..
for about 2 seconds.
Press the q or p key, if necessary.
Push the " SET " key
for about 2 seconds.
To select heating mode
By pushing the "SET" key, the heating
mode is selected and the heating light
comes on. The cooling light turns it off.
Continue with section 3.6.
And press the q or p key.
To select cooling mode
By pushing the "SET" key, the cooling
mode is selected and the cooling light
lcomeson. The heating light turns it off.
Continue with section 3.5.
3.4.3 - Cooling/heating changeover switch (for CE)
There are two high-temperature generator pressure switches for
cooling and heating. It is possible to select the pressure switch
using the cooling/heating changeover switch. The operation
mode on the control board and the operation mode of the
pressure switch must be the same.
Otherwise the high-temperature generator high-temperature
alarm (J-14) is activated, preventing the operation. Ensure
that the mode on the control board is the same as that of the
pressure switch. Refer to Fig. 9.
22
3.5 - Cooling operation
3.5.1 - Pre-operation check
Refer to Fig. 21.
Check the following items before starting operation.
• Verify the operation mode. Confirm that the cooling light
on the control board is on.
• Check the chilled water leaving temperature setpoint.
Make sure that the chilled water leaving temperature is set
as specified. For the display of the set value, please refer
to section 3.8.
• Check the combustion equipment
- Make a daily inspection. (refer to section 4.)
- Check that the valve(s) is (are) open.
• Check the valves on the chiller/heater.
A valve
B valve
Closed
Open
D valve
Closed
C valve
Closed
Refer to Fig. 12
NOTE: If the chilled/hot water pump, cooling water pump,
and chiller/heater are interlocked, each pump runs automatically when starting the chiller/heater.
If not, the start sequence must be: chilled/hot water pump,
cooling water pump, chiller/heater.
3.5.2 - Start cooling operation
Refer to Fig. 22.
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.
Remote operation mode
• Press the "REMOTE" key on the chiller control board.
The "REMOTE" indicaton light of the key is on.
• 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.
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.
3.5.3 - Stop operation
Refer to Fig. 22.
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.
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: If the chilled-water pump, cooling water pump, and
chiller are interlocked, each pump stops automatically when
the chiller stops.
If not, the stop sequence must be: chiller, cooling water pump,
chilled-water pump.
The air handling unit must be stopped after the chilled-water
pump is stopped.
3.6 - Heating operation
3.6.1 - Pre-operation check
Refer to Fig. 22.
Check the following items before starting operation.
• Verify the operation mode. Confirm that the heating light
on the control board is on.
• Check the hot water temperature setpoint. Make sure that
the hot water leaving temperature is set as specified. For
the display of the set value, please refer to section 3.8.
• Check the combustion equipment
- Make a daily inspection (refer to section 4.)
- Check that the fuel valve(s) is (are) open.
4. Check the chiller/heater valves.
A valve
Open
D valve
Open
B valve
Closed
C valve
Open
Refer to Fig. 12
NOTE: If the chilled/hot water pump and chiller/heater are
interlocked, the pump runs automatically when starting the
chiller/heater.
If not, the start sequence must be: chilled/hot water pump,
chiller/heater.
3.6.2 - Start heating operation
Refer to Fig. 22.
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.
Remote operation mode
• Press the "REMOTE" key on the chiller control board.
The "REMOTE" indicaton light of the key is on.
• 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.
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.
23
3.7 - Changing the information on the data display
3.6.3 - Stop heating operation
Refer to Fig. 22.
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.
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: If the chilled-water pump, cooling water pump, and
chiller are interlocked, each pump stops automatically when
the chiller stops. If not, the stop sequence must be:
Chiller, cooling water pump, chilled-water pump
The air handling unit must be stopped after the chilled-water
pump is stopped.
Fig. 22 - Typical control board
1
STOP
2
RUN
CHILLER/HEATER
#1ABS PUMP
3
#2ABS PUMP
REF PUMP
PURGE PUMP
SET
BACK
BURNER
STAND BY
COOLING
DILUTION
HEATING
SAFETY CIRCUIT
REMOTE
BUZZER STOP
LOCAL
COMBUSTION
CHILLER/HEATER ALARM
BURNER ALARM
OPERATION
STOP
POWER
Legend
1 Data display
2 Select key: changes an indication of a data display
3 Back select key
RUN
3.7.1 - Normal display information
The data display on the control board usually shows the
generator temperature as follows (refer to Fig. 22).
It returns to the generator temperature display when no key is
pressed for 1 minute.
3.7.2 - Changing the display
Refer to Fig. 22.
If you press the p key, the information on the data display
changes in the correct order, and pressing the q key, it changes
in reverse order. If you press the p key again when the last
information is shown, the display returns to the normal display
information.
3.7.3 - 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 p q 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
p q 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.
Fig. 23 - Typical indication flow
Data code
-
1.
2.
3.
4.
5.
6.
7.
8.
9.
A.
B.
C.
10.
11.
12.
13.
14.
15.
16.
17.
-
Data name
Display
Generator temperature
Chiller/heater operating hours
Absorbent pump 1 operating hours
Absorbent pump 2 operating hours
Combustion hours
Refrigerant pump operating hours
Purge pump operating hours
Chiller/heater 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/hot water entering temperature
Chilled/hot water leaving temperature
Cooling water entering temperature
Condenser temperature
Steam drain/exhaust gas temperature
Purge tank pressure
Generator temperature
Means
135.0°C
1234 hours
1111 hours
1230 hours
1100 hours
1201 hours
107 hours
123 times
169 times
123 times
189 times
138 times
51 times
7.0°C
55.0°C
11.9°C
6.8°C
31.8°C
34.7°C
211.7°C
8.5 kPa
135.0°C
3.8 - Changing display and setpoint
Setpoint display change
Select the current setpoint temperature and change it as follows.
24
To change the chilled-water temperature:
7.0°C
Press the "SET" key
for about 2 seconds.
3.9 - Maintenance message
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 Fig. 24
Fig. 24 - Maintenance message
A number showing the setpoint
temperature blinks.
Press the p or qkey.
7.5°C
Press the "SET" key
Data code Data name
Display
H-01*
Operate purge pump
H-03*
Clean cooling water tubes
H-04*
Check cooling water system
H-05*
Clean chamber
H-06**
Purge tank high pressure
H-07**
Cooling water tube fouling
H-08**
Cooling water high temperature
H-10
Power failure
Means
Operate purge pump.
Fouling of cooling water tubes.
Check the cooling water pump,
cooling tower, etc.
Fouling of combustion chamber.
Purge tank pressure is high.
Fouling of cooling water tubes.
Cooling water temperature is high.
There was power failure when
the chiller/heater 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
The setpoint change has been made.
To change the hot water temperature
55.0°C
Press the "SET" key
for about 2 seconds.
A number showing the setpoint
temperature blinks.
Press the p or qkey.
57.0°C
Press the "SET" key
Maintenance message Display
Action
1 Cooling water tube
fouling
2 Vacuum rate
3 High cooling water
temperature
4 Combustion chamber
fouling (for oil-fired type)
5 Power failure
Clean cooling water tubes.
Contact Carrier service agent to do the job
The purge tank must be purged immediately.
If this display is shown frequently, contact a
Carrier service agent.
Check the cooling water pump, cooling tower, etc.
Clen the combustion chamber.
Contact Carrier service agent to do the job
See section 3.10.5.
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.
25
3.10 - Alarm indications and actions
3.10.1 - 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
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 ".".
Chilled-water low temperature
The other alarm codes are shown by
pressing the p key.
The high-temperature generator
solution level is too low.
3.10.2 - Troubleshouting flowchart
3.10.3 - Alarm message and setpoint
Fig. 27 - List of alarms and setpoints in cooling
operation
Purpose
Action
An alarm occurs.
Alarm buzzer sounds (option), and the
indication light of the "STOP" key blinks.
The alarm message is shown in the data
display.
Press the "BUZZER STOP" key on the control
board.
The alarm buzzer stops (option).
Check the alarm message and solve the
problem.
Press the "STOP" key on the control board
after the troubleshouting is completed.
The indication light of the "STOP" key
stops blinking and remains lit. The alarm
code on the data display disappears.
NoteS:
1. If the data display still shows an alarm
after the "STOP" key has been pressed,
ensure that the alarm cause has
definitely been removed.
2 In case of a combustion alarm, operation
does not restart without pressing the reset
button on the burner controller.
Start operation referring section 3.5 or 3.6
Operation restarts.
26
Alarm messageSetpoint
2.5°C or below
50% or below
24°C or below
for 30 minutes
50% or below
162°C or above
for 10 minutes
165°C or above
101.3 kPa or above
65.0 % or above
twice
65.0 % or above
300°C or above
350°C or above
Rated current
value or above
"
"
"
-
Fig. 28 - List of alarms and setpoints in heating
operation
Purpose
Symptoms
Display
Protection of
Chilled water temperature is too low.
chilled water
Chilled water pump interlock alarm.
system
Chilled water flow alarm
Cooling water temperature is too low.
Prevention of
Cooling water pump interlock alarm.
crystallisation
Cooling water flow alarm
High-temperature generator temperature
is too high.
High-
High-temperature generator pressure temperature
is too high.
generator
High-temperature generator solution
protection
level is too low
High concentration of absorbent
Exhaust gas temperature is too high (gas)
Exhaust gas temperature is too high (oil)
Combustion
Flame failure and burner failure
alarm
Motor
Absorbent pump 1 overload alarm.
protection
Absorbent pump 2 overload alarm.
Refrigerant pump overload alarm.
Purge pump overload alarm.
Absorbent pump 3 overload alarm.
Others
Ventilation fan interlock etc. alarm
Capacity is too low.
Changeover during operation:
heating ‡ cooling
Cooling tower fan overload alarm.
Display
Protection of
hot water
system
Combustion
alarm
Motor
protection
Others
Alarm messageSetpoin
Hot water temperature is too high.
Hot water pump interlock alarm.
Hot water flow alarm
High-temperature generator temperature
is too high.
High-temperature generator pressure
is too high.
High-temperature generator solution
level is too low.
Exhaust gas temperature is too high (gas)
Exhaust gas temperature is too high (oil)
Flame failure or burner failure.
Absorbent pump 1 overload alarm.
Absorbent pump 2 overload alarm.
Refrigerant pump overload alarm.
Purge pump overload alarm.
Absorbent pump 3 overload alarm.
Ventilation fan interlock etc. alarm.
Capacity is too low.
Changeover during operation:
Cooling ‡ heating
70°C or above
50% or below
130°C or above
101.3 kPa or above
300°C or above
350°C or above
Rated current
value or above
"
"
"
-
3.10.4 - Locating and clearing an alarm
Fig. 29 - List of alarm indications and their causes and remedies
Display and content of alarm
Display and content of alarm
Alarm of the chilled/hot water and/or cooling water system
Check that the discharge pressure of both
Chilled/hot water temperature is too low. chilled/hot water and cooling water pumps is
normal.
Chilled water flow alarm
‡If not, the strainer may be the clogged or there
may be an air leak in the piping, etc.
Hot water temperature is too high.
Is the chilled water setpoint too low?
Hot water flow alarm
Is the hot water setpoint too high?
‡Correct them to the specified setpoint.
Cooling water temperature is too low
Is the cooling water setpoint too low?
Cooling water flow alarm (option)
‡Correct it to specified setpoint.
(e.g. 28°C)
Correct the above causes and restart the chiller/
heater. If the "ALARM STOP" continues, check the
following and contact your Carrier service agent.
• Entering and leaving chilled/hot water
temperature
• Entering and leaving cooling water temperature
• High-temperature generator temperature and
pressure
Alarm of the high-temperature generator
HEATING OPERATION
High-temperature generator
temperature is too high.
If the chiller/heater shows "ALARM STOP" right
after it starts, try to re-start it. If it occurs again,
High-temperature generator
contact your Carrier service agent.
pressure is too high.
High-temperature generator
If the chiller/heater shows "ALARM STOP" during
solution level is too low.
operation, check the following.
High absorbent concentration
Exhaust gas temperature is too high.
Check that the reset button(s) of the overload relay
connected to electromagnetic contactor is (are) not
pushed in, then contact your Carrier service agent.
Check that the hot water line valve is open.
‡
Open the valve.
Check that the delivery pressure of the hot water
pump is normal.
‡
If not, the strainer may be clogged, or there may
be an air leak in the piping etc.
Alarm of the motor(s)
Absorbent pump 1 overload alarm.
Absorbent pump 2 overload alarm.
Refrigerant pump overload alarm
Absorbent pump 3 overload alarm.
Alarm of the auxiliary equipment
Chilled water pump interlock alarm.
Cooling water pump interlock alarm.
Ventilation fan interlock etc. alarm.
Check that the hot water pump is rotating.
‡
Start the pump.
Check that the "Heating" light is on.
‡To change heating operation refer to section 3.4.
Correct the above causes and restart the chiller/
heater. If the "ALARM STOP"continues, check the
following and contact your Carrier service agent.
• Entering and leaving hot water temperature
• High-temperature generator temperature and
pressure, and exhaust gas temperature.
• Is the hot water setpoint too low?
‡Correct it to specified setpoint.
• Linkage between gas control valve and damper
(disconnected and/or loose).
• There may be the fouling of heat transfer tube
in the hot water line.
reset buttons
Check that the chilled/hot water pump and cooling
water pump are rotating.
‡Start the pumps
Check the ventilation fan and/or other equipment
connected to the system interlock.
Correct the above causes and restart the chiller/
heater. If the "ALARM STOP" continues, contact
your Carrier service agent.
Cooling tower fan overload alarm.
Alarm of the high-temperature generator
COOLING OPERATION
High-temperature generator
Check that the cooling water pump is rotating.
temperature is too high.
‡Start the pump.
Check that the cooling water line valve is open.
High-temperature generator
pressure is too high.
‡Open the valve.
Check that the discharge pressure of cooling
High-temperature generator
water pump is normal.
solution level is too low.
‡If not, the strainer, may be clogged, there may be
an air leak in the piping, etc.
High concentration of absorbent
Check that the "Cooling" light is on.
‡To change cooling operation refer to section 3.4.
Exhaust gas temperature is too high.
Correct the above causes and restart the chiller/
heater. If the "ALARM STOP" continues, check the
following and contact your Carrier service agent.
• Entering and leaving chilled water temperature
• Entering and leaving cooling water temperature
• High-temperature generator temperature and
pressure, and exhaust gas temperature.
• Is the chilled water setpoint too low?
‡Correct it to specified setpoint.
• There may be the fouling of heat transfer tube
in the water (especially cooling water) piping.
Alarm of sensor
Chilled/hot water inlet
temperature sensor alarm.
Cooling water inlet
temperature sensor alarm.
Cooling water outlet
temperature sensor alarm.
Cooling water intermediate
temperature sensor alarm.
Condenser temperature
sensor alarm.
Low-temperature generator's
temperature sensor alarm.
Refrigerant temperature
sensor (Evaporator) alarm.
Diluted solution temperature
sensor (absorber outlet) has
failure.
Do the sensors measuring each area of the chiller/
heater have short-circuits or open circuits?
‡Check all the sensors of the chiller/heater and
contact your Carrier service agent.
NOTE: The chiller/heater automatically stops for safety reasons
when either the high-temperature
generator temperature sensor or
the chilled/hot water temperature
sensor has an alarm. It does not
stop when other sensors have an
alarm, but this could cause a
control failure. Please contact
your Carrier service agent as
soon as possible.
Concentrated solution temperature
sensor (low-temperature heat
exchanger) alarm.
Chilled/hot water outlet
temperture sensor alarm.
High-temperature generator's
temperature sensor alarm.
Exhaust gas temperature
sensor alarm.
Purge tank pressure
sensor alarm.
27
3.10.5 - Action in case of power failure
4 - MAINTENANCE
1. Flowchart of action in case of power failure
4.1 - Daily maintenance
4.1.1 - Inspection of each chiller/heater component
If you find an abnormal condition, contact your Carrier service
agent:
• Smell of gas or oil leak around the chiller/heater
• Abnormal noise at the start of the burner
• Abnormal noise of absorbent pump and refrigerant pump
A power failure
occurs.
The chiller/heater
stops completely.
Power returns.
Power failure
indication "H-10"
is shown on the
data display.
Operation restarts
Power failure
indication on
the data display
disappears.
Press the "RUN"
key.
2. Actions to be taken if a power failure occurs
If a power failure occurs, the chiller/heater stops completely
without carrying out a dilution cycle. Special attention should
be paid to the following.
Operating condition at power failure
Action
Occurred during cooling operation, and
Immediately contact Carrier service agent.
power did not return for more than an hour 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 heating operation
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
and consult your Carrier service agent.
28
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.
TEST OPERATION DATA SHEET
Unit model/serial No.
No. Data items
Operator:
Unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
°C/°F
°C/°F
°C/°F
°C/°F
kPa/psi
kPa/psi
kPa/psi
l/s/gpm
°C/°F
°C/°F
kPa/psi
kPa/psi
kPa/psi
l/s/gpm
°C/°F
kPa/psi
n/60 mm n/2-3/8”
n/60 mm n/2-3/8”
n/60 mm n/2-3/8”
kPa
%
°C/°F
%
°C/°F
%
°C/°F
°C/°F
°C/°F
A
A
A
A
22
23
24
25
26
27
28
29
Ambient temperature
Room temperature
Chilled/hot-water entering temperature
Chilled/hot-water leaving temperature
Chilled/hot-water entering pressure
Chilled/hot-water leaving pressure
Evaporator pressure drop
Chilled/hot-water flow rate
Cooling water entering temperature
Cooling water leaving temperature
Cooling water entering pressure
Cooling water leaving pressure
Pressure drop in absorber & condenser
Cooling water flow rate
High-temperature generator temperature
High-tempersture generator pressure
Evaporator solution level
High-temperature generator solution level
Solution level in bottom of absorber
Purge tank pressure
Concentration of concentrated solution
Relative density of concentrated solution
Temperature of concentrated solution
Concentration of diluted solution
Relative density of diluted solution
Temperature of diluted solution
Concentration of refrigerant
Relative density of refrigerant
Temperature of refrigerant
Condensed refrigerant temperature
LTD *
Absorbent pump 1 current
Absorbent pump 2 current
Refrigerant pump current
Purge pump current
Spec.
Date:
DATA-1
Time:
/
/
DATA-2
Time:
DATA-3
Time:
* LTD = Condensed refrigerant temperature minus cooling water leaving temperature
Notes
29
4.2 - Periodic maintenance
2. Purge procedure (DJ-51-82)
Refer to Figs. 30 and 32. When the purge indication light on
the control panel comes on, start purging, following the
instructions below.
• Turn on the purge pump on/off switch on the control panel
and operate the purge pump for 10 minutes.
• Close B valve and V4, and open V1 and V2.
• Press the p key on the control panel once to show data
code 17 "Purge tank pressure" (refer to chapter 3.7.3) and
check if the indicated value drops. If it does not drop,
follow the procedure described in steps 1, 2 and 3 below
and contact your Carrier service agent.
• Open B valve and V4, and 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.
1. Close V1 and V2.
2. Turn the purge pump on/off switch off.
3. Check if the valves are open/closed.
To optimize performance, the chiller/heater requires purging,
refrigerant blow down, absorbent control and management of
the combustion equipment etc. We recommend that you arrange
a maintenance contract with your Carrier service agent.
4.2.1 - Purging
Non-condensable gas inside the machine not only decreases
cooling/heating capacity, but also potentially shortens the life of
the machine. Therefore purging must be done at cooling/heating
changeover. This should be done by the Carrier service personnel
under a maintenance contract. If customers carry out the purging
themselves, they should take instruction from our service
personnel.
Purge procedure (DJ-11-42)
Refer to Figs. 30 and 31. When the purge indication light on the
control panel comes on, start purging, following the instructions below. Do not purge during the heating mode.
• Turn on the purge pump on/off switch on the control
panel, and operate the purge pump for 10 minutes.
• Open V1 and V2.
• Press the p key on the control panel once to show data
code 17 "Purge tank pressure" (refer to chapter 3.7.3) and
check if the indicated value drops. If it does not drop,
follow the procedure described in steps 1, 2 and 3 below
and contact your Carrier service agent.
• 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.
1. Close V1 and V2.
2. Turn the purge pump on/off switch off.
3. Check whether the valves are open/closed.
V1
V2
V3
V4
B valve
Closed
Closed
Closed
Open
Open
V1
V2
V3
B valve
Closed
Closed
Closed
Open
Fig. 31
Fig. 32
Purge tank
Purge tank
B valve
V4
V2
Fig. 30
V2
B valve
V3
V3
Maintenance
pressure
gauge
Purge indication
light
SV2
SV1
V1
Liquid trap
SV2
SV1
V1
Liquid trap
Purge pump
on/off switch
Purge pump
30
Maintenance
pressure
gauge
Purge pump
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. 33
Refrigerant
blow 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.
31
32
X
High/Low temp. heat exchanger tube
X
X
Palladium cell
X
Water line packing
X
Other packing
X
X
Diaphragm valve packing
Smoke chamber cover
X
X
Inverter
Sight glass
X
Relay
X
X
Electro-magnetic contactor
Solution level relay electrode
X
Temperature sensor
Others
X
Flow switch
Control device
(X)
X
Pressure gauge
Purge pump
Safety device
(X)
Refrigerant pump
Flame detector
X
Absorbent pump
Pump
X
X
X
Fuel
X
Absorbent
Solution
(X)
X
Cooling water line pipes
High temp. generator
X
Chilled/hot water line pipes
Main shell
Periodic replacement
V-belt
Periodic inspection with a maintenance contract (service agent will keep spare
parts)
Periodic replacement ((maintaining the vacuum)
Periodic inspection with a maintence contract (service agent will keep spare
parts)
Periodic inspection with a maintenance contract
Periodic replacement (because of safety device)
Customer will keep spare parts for one unit
Overhaul
Overhaul
Overhaul
Solution random inspection
Visual inspection etc.
Overhaul
Eddy-current test/endoscope/visual
inspection
Eddy-current test/endoscope/visual
inspection
Method
Pump body
Pump body, impeller, bearing, coil
Pump body, impeller, bearing, coil
Concentration
Alkalinity
Inhibitor ratio
Dissolved copper ratio
Dissolved iron ratio
Solution analysis
Check fouling inside
Corrosion of the surface of the heat
transfer tube. Reduced metal by
abrasion scale and/or slime adhesion
Corrosion of the internal surface of the
heat transfer tube
Scale and/or slime adhesion
Corrosion of the surface of the heat
transfer tube
Corrosion of the internal surface of the
heat transfer tube
Scale and/or slime adhesion
Corrosion of the surface of the heat
transfer tube
Item
Vacuum
area
Nonvacuum
area
Inspection
Inspection area
Name
Component
All inspection
As necessary
Every 3 years
Every 3 years
Every 3 years
Every 3 years
Every 3 years
Once a year
As necessary
As necessary
Every 3 years
Once a year
As necessary
As necessary
As necessary
As necessary
6 times per year
Once a year
Every 3 years
Once a year
Every 3 years
Once a year
Every 3 years
Interval
Generator pressure gauge
Inspection interval 20000 hours or more
Inspection interval 20000 hours or more
To be adjusted to the control standards
Cleaning
Random inspection from the bundle (no vacuum destruction)
Random inspection from the bundle (no vacuum destruction)
Remarks
4.3 - Recommended schedule of maintenance and replacement of main components
Control Standards
4.4 - Water treatment
Fig. 34 - Example of the effect of tube fouling
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 35. 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.
120
115
Decrease in cooling capacity (%)
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.
125
A
110
105
100
5
Rise in chilled water temperature (°C)
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.
Fuel composition (%)
Water treatment is very important for the chiller/heater. As this
requires specialised technical knowledge, please consult your
Carrier service agent.
4
C
B
100
3
90
2
80
1
70
60
1
2
3
4
5
6
7
8
9
10
Fouling factor (m2 h °C/kcal) x 10-4
1
0,2
2
0,4
3
4
5
6
7
Fouling factor (m2 K/kW) x 10-4
0,6
0,8
1,0
8
9
1,2
Scale/slime (mm)
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)
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.
33
34
mg SO42-/l
mg CaCO3/l
mg CaCO3/l
mg CaCO3/l
mg SiO2/l
Acid consumption (pH 4.8)
Total hardness
Calcium hardness
Ionic silica
-
-
<= 4.0
-
<= 0.4
<= 0.1
-
<= 4.0
<= 0.3
<= 0.1
X
X
X
X
X
X
X
X
X
X
X
X
The 15 items listed above show typical factors of corrosion and scale problems.
-
<= 0.4
<= 0.3
<= 0.1
<= 0.1
X
X
+++
-
<= 4.0
<= 0.25
<= 0.1
<= 1.0
<= 0.3
<= 30
<= 50
<= 70
<= 50
X
X
X
City water, industrial water and ground water shall be used as source water, and demineralized water, reclaimed water, softened water, etc. shall be excluded.
-
<= 4.0
<= 0.3
<= 0.3
<= 0.1
<= 1.0
<= 30
<= 50
<= 70
<= 50
<= 30
<= 30
X
X
++
-
<= 4.0
<= 0.3
<= 0.1
Not detected
<= 1.0
<= 0.3
<= 30
<= 50
<= 70
<= 50
<= 30
<= 30
<= 300
<= 30
7.0 - 8.0
For the cooling water system using a closed-type cooling tower, the water quality standard for the mid-range temperature water sysem shall be applied to the closed-circuit recirculating/spray water and its make-up water, while the water quality standard for the recirculating
cooling water system shall be applied to the spray water and its make-up water, respectively.
6.0 - 7.0
<= 4.0
<= 0.3
<= 1.0
<= 0.1
<= 1.0
<= 30
<= 50
<= 70
<= 50
<= 50
<= 50
<= 300
<= 30
7.0 - 8.0
****
-
Ryzner stability index
<= 4.0
<= 0.3
<= 1.0
Not detected
<= 1.0
<= 0.3
<= 30
<= 50
<= 70
<= 50
<= 50
<= 50
<= 300
<= 30
7.0 - 8.0
Scale-forming
When temperature is high (above 40°C), corrosiveness generally increases. Especially, when iron/steel surface has no protective film and is in direct contact with water, it is desirable to take adequate countermeasures against corrosion, such as addition of corrosion inhibitor and
deaeration treatment
mg CO2/l
Free carbone dioxide
<= 0.3
<= 1.0
<= 1.0
<= 1.0
<= 30
<= 50
<= 70
<= 50
<= 50
<= 50
<= 300
<= 30
7.0 - 8.0
Corrosive
***
mg Cl/l
Residual chlorine
<= 1.0
<= 0.1
50
<= 50
<= 300
<= 30
6.8 - 8.0
Make-up
water
The mark X indicates factors affecting the corrosive or scale-forming tendency.
mg NH4+/l
Ammonium ion
Not detected
<= 0.3
<= 1.0
<= 30
<= 50
<= 70
<= 50
<= 50
<= 50
<= 400
<= 40
6.8 - 8.0
Recirculating
water
(60<T<=90°C)
**
mg S2-/l
Sulfide ion
<= 0.3
<= 30
<= 50
<= 70
<= 50
<= 50
<= 50
<= 400
<= 40
6.8 - 8.0
Make-up
water
Higher mid-range teperature
water system***
Tendency**
The nomenclature of items, definition of terms and units shall comply with the JIS K 0101. The units and values in ( ) are conventional ones put here for reference.
mg Cu/l
Copper
<= 1.0
<= 50
<= 150
<= 200
<= 100
<= 200
<= 200
<= 300
<= 30
6.0 - 8.0
Recirculating
water
(20<T<=60°C)
Lower mid-range temperature
water system
Mid-range temperature (20-90°C) water systems***
*
NOTES
mg Fe/l
Iron
Reference items (see footnotes)
mg Cl-/l
<= 800
µS/cm
Sulfate ion
<= 80
Electrical conductivity (25°C)
Chroride ion
6.5 - 8.2
mS/m
pH (25°C)
Standard items (see footnotes)
Make-up water
Recirculating
water (T 20°C)
Once
through
water
Recirculating
water
Make-up
water
Chilled water systems
Cooling water systems****
Fig. 35 - Water quality standard values for cooling water, chilled water, mid-range temperature water and make-up water++
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/
heater. Please consult your Carrier service agent for the details.
5 - TROUBLESHOOTING
Cooling water
The usual system is a wet system with the cooling water kept
in the chiller/heater. If the cooling water is likely to freeze,
drain it from the chiller/heater (dry system). The valve
operation is different between wet and dry systems.
3.7 - Maintenance message
3.8 - Alarm indication and actions
Appendix 1 - Flowchart (at the end of that document)
For identifying and eliminating the causes of machine failure,
please refer to the following chapters:
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/heater 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/heater,
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/heater.
4.4.3 - Winter season
If the ambient temperature of the chiller/heater is likely to be
below 0°C in winter, freeze protection is necessary. Consult
your Carrier service agent for the details.
35
Fig. 36
V2
SV2
V3
1
8
SV1
9
3
V1
10
11
4
5
6
2
7
12
54
280
54
Sampling cylinder
(MATERIAL : ACRYL RESIN)
Attachment
Valve
19
100
20
13
16
14
17
15
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
36
18
150
6 - INSTRUCTIONS
6.2 - Concentration measurement method
6.1 - Absorbent sampling method
This is the procedure used to measure the absorbent and
refrigerant concentration.
6.1.2 - Precautions
• Because of the high vacuum condition inside the chiller/
heater, ensure that air never leaks into the chiller/heater
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 12.
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 37.
• 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 36.
• 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.
6.2.2 - 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 37 below.
Fig. 37
1.77
64
63
62
0
Concentration (%)
6.1.1. Equipment to use
• Sampling cylinder and attachments for service valve
• Vacuum rubber hose
• Pliers
• Vacuum gauge (0-1 kPa)
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
Relative density
This instruction describes the procedure for sampling a small
amount of the absorbent.
45
Temperature (°C)
37
Fig. 38a - Concentration vs temperature vs relative density
1,85
1,80
65%
1,75
1,70
60%
Concentration (%)
Relative density (kg/m3) x 10-3
1,65
1,60
55%
1,55
1,50
50%
1,45
45%
1,40
0
10
20
30
40
50
Temperature (°C)
38
60
70
80
90
100
Fig. 38b - Concentration versus temperature and relative density
1,50
1,45
45%
1,40
1,35
40%
1,30
1,25
30%
1,20
Concentration (%)
Relative density (kg/m3) x 10-3
35%
25%
1,15
20%
1,10
15%
1,05
10%
5%
1,00
0%
0,95
0
10
20
30
40
50
60
70
80
90
100
Temperature (°C)
39
7 - MAINTENANCE CONTRACT
8. - chiller/heater DISPOSAL/Replacement
To enjoy safe and efficient operation of the chiller/heater 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
8.1 - Precaution
These procedures require special tools and a special skills.
1
We offer an annual maintenance contract to users of the chiller/
heater. Under the contract we provide trained service personnel
that will perform the periodic diagnosis and adjustment of the
chiller/heater, using the latest technology. Consult your Carrier
service agent for details.
2
Only qualified personnel should perform welding and cutting
operations.
8.2 - Procedure
3
7.1 - Annual maintenance contract
We offer an annual maintenance contract to our customers with
periodic inspection and maintenance of the Carrier absorption
chiller/heater. Under this contract your Carrier service agent
will perform maintenance/inspection and adjustment works to
keep your chiller/heater in its optimal condition, and you will
be given priority for chiller/heater repairs, in case there is a
problem.
It is recommended to perform a complete chiller/heater
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
4
5
6
7
8
Power supply circuit, gas piping, and oil piping of the
absorption chillers/heaters are separated from each other.
Chilled/hot water and cooling water remaining in heat
transfer tubes should be drained by opening the water
header provided for this purpose and draining it from one
side of the header. Safety measures should be taken to
prevent drained water from spattering.
By closing the valve at the point where a purge pump of
a purge circuit is connected to a service valve, the path of
the purge circuit is separated from that of the purge pump.
Nitrogen gas of 50 kPa should be charged through the
service valve shown in Fig. 39.
A hose should be attached to SV3, SV4, SV5, SV6 and
SV8. Use a bottle to collect the drained absorbent.
Open SV3, SV4, SV5, SV6 and SV8, and remove the
absorbent.
After the absorbent has been drained through each valve,
the absorbent pump and the refrigerant pump should be
removed to drain the absorbent remaining at the bottom of
the heat exchanger.
If it is difficult to remove the replaced absorption chiller/
heater due to limited space, the chiller/heater can be cut
into individual components. If gas is used to separate the
machine, alwways wear a protective mask and protective
goggles to prevent injuries which may be caused by the
gas.
Dispose of the chiller/heater according to the local
regulations.
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.
Fig. 39
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.
3
7.3 - Warranty
•
•
•
•
40
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/heater fails within the warranty period under
normal operating conditions, we will replace all necessary
spare parts or repair the chiller/heater 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.
1
4
2
5
Legend
1 Refrigerant pump
2 Absorbent pump
3 Service valve
4 Plate to separate the purge pump
5 Purge pump
Appendix 1 - Troubleshooting flowchart
Problem
1. Chiller does not run.
2. Chilled water temperature is high.
3. Generator alarm.
4. Combustion alarm (16DJ).
5. Water alarm.
6. Motor alarm.
7. System alarm.
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
Appendix 1 - Troubleshooting FLOWCHART - Cont.
1 - Chiller does not run.
Blower motor
runs (16DJ).
Gas control valve
moves.
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.
Protection relay is defective.
Motor moves to fully
closed, but then does
not move any more.
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.
Gas control valve
does not move.
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.
Blower motor
does not run
(16DJ).
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.
Interlock
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).
Fuse has blown.
42
Appendix 1 - Troubleshooting FLOWCHART - Cont.
2 - Chilled-water temperature is high.
Vacuum
problem
Insufficient inhibitor.
Generating
hydrogen gas
Pd cell is defective.
60%
Pd cell heater is defective.
Air leakage
30%
Insufficient
air purging.
30%
Chilled water
problem
Chilled-water flow rate is too high.
Cooling water
problem
Flow rate is
inadequate. 30%
Cooling water pump control malfunctions.
Strainer is clogged.
Insufficient feed water.
Air in the cooling water line.
Cooling water
temp. is too high.
50%
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.
Solution
problem
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.
43
Appendix 1 - Troubleshooting FLOWCHART - Cont.
(Chilled-water temp is high.)
Crystallization
No.1 absorbent
pump cavitation.
25%
Solution flow rate is not adjusted properly.
Cooling water entering temperture fluctuates strongly
Vacuum condition in the chiller is poor.
Insufficient absorbent solution.
Insufficient octyl alcohol.
Ambient temperature is too low. 5%
Cooling water entering temperature is too low with insufficient air purging. 70%
Combustion
problem (16DJ)
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.
Electrical
problem
Parts, setting
position
Electric parts and sensors are defective.
20%
Wrong setting on microprocessor and inverter.
Wrong position of select switches.
Electrode surface is contaminated.
Solution level
electrode
malfunctions.
Electrode is defective.
80%
44
Teflon tube on electrode has been removed.
Appendix 1 - Troubleshooting FLOWCHART - Cont.
3 - Generator alarm
Vacuum
problem
Hydrogen gas is
generated.
60%
Insufficient inhibitor.
Pd cell heater is defective.
Pd cell is defective.
Air leakage 30%
Purging is inadequate. 10%
Cooling water
problem
Flow rate is
inadequate.
Cooling water pump control malfunctions.
30%
Strainer is clogged.
Insufficient feed water.
Air in cooling water line.
Cooling water
pump is too high.
50%
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 problem
Absorbent flow
rate is
inadequate
75%
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).
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%
Crystallization
Absorbent
pump cavitation
25%
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.
Ambient temperature is too low. 5%
Cooling water entering temperature is too low with insufficient air purging. 70%
45
Appendix 1 - Troubleshooting FLOWCHART - Cont.
(Generator alarm)
Electrical
parts problem
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%
High-temp.
generator
problem (16DJ)
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%
46
Appendix 1 - Troubleshooting FLOWCHART - Cont.
4 - Combustion alarm (16DJ)
Flame failure
(spark OK)
Flame failure
occurs at the end
of ignition spark.
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.
Flame failure
(pilot burner
ignites)
Flame failure
occurs during
main flame trial
50%
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.
Pilot burner is
OK.
50%
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.
Main burner does not
ignite
70%
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)
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.
Gas pressure
alarm
Measure gas
supply pressure
80%
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.
Air flow
alarm
Check gas pressure
switch
20%
Confirm movement of the switch.
Confirm air flow
switch
80%
Check the setting.
Check the setting.
Check the contact of the air flow switch.
Check if the air flow switch is installed correctly.
Measure pressure
inside the wind
box
20%
Check the wind box suction side for obstruction by foreign material.
Check the tube between the box and the air flow switch for
obstruction by foreign material.
47
Appendix 1 - Troubleshooting FLOWCHART - Cont.
5 - Water alarm
Electric
system
Electrical parts
defective
60%
Microprocessor
Flow switch
Temperature sensor
Auxiliary relay in chiller control panel
Interlock
40%
Water system
Temperature
40%
Check wiring and electric parts of interlock wiring
Leaving chilled water
temperature too
low
70%
Temperature control function
does not work properly.
Wrong operating order.
Holding water quantity in the chiller
is too low.
Entering cooling
water temperature
too low
20%
Ambient temperature is too low.
Leaving hot water
temperature too low
10%
Temperature control function
does not work properly.
Cooling water temp. control malfunctions.
Wrong operating order.
Holding water quantity in the chiller
is too low.
Flow rate
60%
Check chilled-water
flow switch
Air in water system?
Strainer in water system is clogged?.
Valves in water system opened properly?
48
Appendix 1 - Troubleshooting FLOWCHART - Cont.
6 - Motor alarm
Absorbent
pump
Measure
operating
current
Overcurrent
90%
60%
Crystallization or foreign material
in the pump.
Pump motor is defective.
Magnetic contactor is defective.
Open phase
10%
Pump motor coil is defective.
Primary power failure.
Measure
insulation
resistance
Motor
Magnetic contactor with thermal relay.
30%
Pump power wires
Check the setting of thermal relay 10%
Refrigerant
pump
Measure
operating
current
Overcurrent
90%
Foreign material in the pump
Pump motor is defective.
60%
Magnetic contactor is defective.
Open phase
10%
Pump motor coil is defective.
Primary power failure.
Measure
insulation
resistance
Motor
Magnetic contactor with thermal relay.
30%
Pump power wires
Check the setting of thermal relay 10%
Blower motor
(16DJ)
Measure
operating
current
Overcurrent
90%
Blower motor is defective.
60%
Magnetic contactor is defective.
Open phase
10%
Pump motor coil is defective.
Primary power failure.
Measure
insulation
resistance
Motor
Magnetic contactor with thermal relay.
30%
Pump power wires
Check the setting of thermal relay 10%
49
Appendix 1 - Troubleshooting FLOWCHART - Cont.
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 fan interlock signal goes to the microprocessor (16 DJ).
50
GB/T-24001 to ISO14001:1996
Order No.: 11618-76, 07.2006. Supersedes order No.: New
Manufacturer reserves the right to change any product specifications without notice.
Manufactured by: Sanyo Electric Co. Ltd., Dalian, China
Printed in the Netherlands on totally chlorine-free paper.
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