16tj_lj-Training_book-2 CARRIER ABSORB

Absorption ChillerSERVICE TRAINING BOOK

LJ TJ Model

Section 1 How the Absorption Chiller Works

1-1. Why does a heating chill ?

The cooling means keeping temperature in a room lower than outside temperature, As shown in Fig. 1-1,

operation to carry the heat from the room with a lower temperature (ex.28 deg.C : 82.4 deg.F) to the open

air with a higher temperature is required. But, in the natural world, the heat can not move from a low

temperature side to a high temperature side. So, to transmit the heat as opposed to this principle, some

method is necessary. That is, a heat pump (chiller) is used to pump up the heat from a low temperature

one as if a water pump is used to draw a water from a deep well.

Fig. 1-1 Heat flow

The typical chiller using electricity as a operation power

source as a conveyer to carry the heat shown in Fig. 1-2

is an centrifugal chiller and the typical chiller using a heat

energy is an absorption chiller. Chilled water is made by

using the latent heat released by a liquid as it evaporates.

We can experience this principle on our daily life. For

example, when having an injection, after applying alcohol

on the arm, we feel this part cool. Because, applied alcohol

took the heat from the arm when it is warmed by the body Fig. 1-2 Heat flow at cooling

heat and evaporated. Another example is that we feel cool when sweating on a hot day or by taking exercise.

Because, the body heat is cooled by the evaporation of sweat which takes the heat from the body. A chiller

also uses an latent heat of evaporation. But, reuse of evaporated vapor by returning to liquid is required.

For this purpose, the compressor is used in a centrifugal chiller, and an absorbent is chemically used in an

absorption chiller. The absorbent loses the effect. Because its concentration is diluted due to absorbing

the vapor. To recover the absorbing effect, a concentrating process of absorbent by heating is needed.

1-2. What is latent heat ?

When water is heated, the temperature rises and stops at 100 deg.C (212 deg.F). With the temperature

remaining constant at 100 deg.C (212 deg.F), the water continues to evaporates as long as it is being heated.

Once water reaches 100 deg.C (212 deg.F), all additional heat goes into changing it from liquid to vapor.

At 100 deg.C (212 deg.F), since vapor is lighter than the surrounding air, it rises. In this case, as water

changes from a liquid to a gas, the applied heat does not change the temperature but changes the state

of water. Therefore the heat is said to be hidden, or latent. Thus latent heat refers to the energy absorbed by

a liquid as it changes state, i.e., to a gas, without changing it's actual temperature. Sensible heat refers to

heat which only results in temperature change rather than change of state.

Page 1 / Sec.1 LJ/TJ Series

1-3. Principal elements of absorption chiller

There are following 3 elements on the principal of the absorption chiller.

a. The inside of chiller is vacuum condition.b. Water (H2O) is used as refrigerant ( Minimum chilled water outlet temp. is 5 deg.C=41 deg.F)

c. Lithium Bromide (LiBr) water solution that has character to absorb water vapor is used as absorbent.The following descriptions are detail explanations of each elements

1-3-1. Vacuum & water

The earth we live is pressed by the weight of the air of approximate 10 km (6 miles) which is surrounding the

earth and this pressure is called as the atmospheric pressure. The pressure lesser than this pressure is called

as the vacuum. When explaining the vacuum for the absorption chiller, it is needed to know the relation

between the pressure and the evaporation temperature of water. It is experienced in a daily life that the water

is boiled (evaporated) at 100 deg.C (212 deg.F) in the atmospheric pressure. When pressure is higher than the

atmospheric pressure, boiling temperature is higher than 100 deg.C (212 deg.F). And if the pressure is lower

(vacuum), the boiling temperature is lower than 100 deg.C (212deg.F).

The pressure higher than the atmospheric pressure can be experienced with a boiler. The pressure lower than

the atmospheric pressure can be experienced during claming a mountain. Namely, in the mountain, as the air

layer becomes weak by its height, the pressure to be applied becomes low. For this reason, the water boils

at a temperature lower than 100 deg.C (212 deg.F) at the mountain. In other words, evaporation temperature

of the water is depended on pressure. The inside of a chiller is always kept in high vacuum. In this condition,

the water evaporates at very low temperature. For example, at 0.5 kPa absolute, water evaporates at 5 deg.C

(41 deg.F).

1-3-2. Lithium Bromide (LiBr)

Lithium Bromide is medicine which is made from the lithium obtained from lithium ore and the bromide obtained

from the sea water. This medicine is not familiar to us. But we can guess easily Lithium Bromide. That is,

we usually see the salt. The another name of salt is Sodium Chloride.

They are of the same elements, that is Lithium (Li) and Sodium (Na) are alkali while Bromide (Br) and Chlorine

(Cl) are halogen. LiBr and NaCl are chemical materials in the same chemical group and have very similar

characteristics. Especially, the both materials has the characteristic to absorb moisture (water vapor). This

characteristics to absorb moisture of LiBr is stronger than NaCl. The absorption chiller uses the characteristic.

The higher its concentration and lower its temperature of LiBr water solution are, the stronger the characteristic

(absorption power) is.

1-4. Principal of single effect type

(1) Heat exchanger tubes are installed inside a closed vessel.

The vessel is then evacuated to a pressure of about 0.8 kPa

(0.12 psi) absolute. Drops of water (refrigerant) are allowed to

fall on the heat exchanger tubes.

Fig. 1-3 Evaporation process


(2) Now the vessel has a vacuum of 0.8 kPa (0.12 psi) absolute.

Drops of refrigerant water falling on the exchanger tubes

evaporate at 5 deg.C (41 deg.F) as they remove heat from

the water in the tube. Thus chilled, the water in the heat

exchanger tubes can be used for cooling. Then drops of

concentrated lithium bromide (LiBr) solution are allowed to

fall into the vessel. The LiBr solution absorbs vaporized

refrigerant.

Fig. 1-4 Absorbing process

(3) When the LiBr solution once absorbs the vaporized

refrigerant, it is diluted and loses its ability to absorb.

This means that concentrated LiBr solution must be

fed in continuously. At this stage, the diluted solution

is heated by driving heat source. The heat causes

the solution to release the absorbed refrigerant and

also re-concentrates the solution.

Fig. 1-5 Concentrating process

(4) The refrigerant vapor which is released

from the solution when heated, is cooled

in a separate chamber (condenser) to

become liquid refrigerant.

Drops of this water are again introduce

into the vacuum vessel and recycled.

(5) This is the basic operational cycle of

the single effect type absorption chiller.

Cooling water flows thru an absorber

and a condenser. The cooling water

in the condenser cools the refrigerant

vapor from the generator back into

refrigerant. The cooling water in the

absorber absorbs the heat released

by the vaporized refrigerant as it is

absorbed by the LiBr solution.

Fig. 1-7 Single effect cooling cycle

Fig. 1-6 Condensing process


1-5. Description of each section

(1) Evaporator

The refrigerant is dispersed on the heat exchanger (transfer) tubes

of an evaporator. Chilled water through the tubes is cooled by the

latent heat of vaporized refrigerant.

(2) Absorber

The concentrated LiBr solution is dispersed on the heat

exchanger (transfer) tubes of an absorber. The refrigerant

vapor from the evaporator is absorbed into the concentrated

LiBr solution on the tubes. Cooling water through the tubes

is heated by absorption heat.

Fig. 1-8

(3) Heat exchanger

The diluted LiBr solution from the absorber passes

through a heat exchanger, where it is heated

by a concentrated LiBr solution. The diluted

LiBr solution after leaving the heat exchanger

flows to the generator.

Fig. 1-9

(4) Generator

The diluted LiBr solution from the heat exchanger is heated

in a generator. It releases the refrigerant vapor and is

concentrated. The solution becomes concentrated LiBr

solution.

(5) Condenser

The refrigerant vapor from the generator is condensed

on the heat exchanger (transfer) tubes of the condenser.

Cooling water from the absorber is heated by condensation

heat.

(6) Steam drain reclaimer (Only for TJ) Fig. 1-10The diluted LiBr solution going from the heat exchanger

to the generator is heated by the driving steam drain

condensed in the generator.


1-6A. Typical cooling cycle on Duhring diagram (LJ)

Operation cycle of the single effect type is explained by using the Duhring diagram as follows.

(1) A → B shows the absorption process in the absorber.The absorbent solution with concentration of 59.5% at point A absorbs the refrigerant vapor coming from theevaporator as it is cooled until 34.2 deg.C (93.6 deg.F) by the cooling water, then the absorbent solutionbecomes diluted solution with concentration of 55.0% at point B.The pressure between point A and B is 0.84 kPa which is equal to the saturation vapor pressure of water at4.4 deg.C (39.9 deg.F), so the chilled water at 8 deg.C (46.4 deg.F) can be produced in the evaporator.

(2) B → C shows temperature rising process of the diluted LiBr solution in the heat exchanger.While the temperature of the diluted LiBr solution passes through the heat exchanger, the diluted LiBrsolution receives heat from the concentrated LiBr solution coming from the generator then it' temperaturerises up to point C.

(3) C → D → E shows heating and concentrating of the diluted LiBr solution in the generator.The diluted LiBr solution at point C is heated until point D by the driving heat source (hot water). After that,the diluted LiBr solution at point D is more heated then it releases refrigerant vapor. Consequently, itbecomes concentrated LiBr solution of 59.5% at point E.

(4) E → F shows temperature decreasing process of the concentrated LiBr solution in the heat exchanger.While the temperature of the concentrated LiBr solution passes through the heat exchanger, theconcentrated LiBr solution gives heat to the diluted LiBr solution coming from the absorber thenit' temperature decreases to point F.

(5) F → A shows that temperature decreasing process of the concentrated solution in the absorber.The concentrated LiBr solution at point F enters into the absorber and is cooled by the cooling water, thenit reaches point A which starts to absorb the refrigerant vapor. This processes are continuously repeated toachieve chilled water.

Fig. 1-11 Typical cooling cycle on Duhring diagram

0 Mpa (G)

Concentration = 0 % (Water)

Concentration = 55.0 %


AF

ED

B

C

6.7

0.84

Pre

ssur

e (k

Pa.

abso

lute

)

0 34.2 82.8 170 deg.C

32 93.6 181 338 deg.F

Page 5 / Sec.1 LJ Series

1-6B. Typical cooling cycle on Duhring diagram (TJ)

Operation cycle of the single effect type is explained by using the Duhring diagram as follows.

(1) A → B shows the absorption process in the absorber.The absorbent solution with concentration of 63.2% at point A absorbs the refrigerant vapor coming from theevaporator as it is cooled until 36.5 deg.C (97.7 deg.F) by the cooling water, then the absorbent solutionbecomes diluted solution with concentration of 56.7% at point B.The pressure between point A and B is 0.8 kPa which is equal to the saturation vapor pressure of water at3.7 deg.C (38.7 deg.F), so the chilled water at 6.7 deg.C (44 deg.F) can be produced in the evaporator.

(2) B → C shows temperature rising process of the diluted LiBr solution in the heat exchanger.While the temperature of the diluted LiBr solution passes through the heat exchanger, the diluted LiBrsolution receives heat from the concentrated LiBr solution coming from the generator then it' temperaturerises up to point C. After that time, the diluted solution is more heated by the steam drain reclaimer,then the temperature of diluted solution reaches point C'.

(3) C' → D → E shows heating and concentrating of the diluted LiBr solution in the generator.The diluted LiBr solution at point C' is heated until point D by the driving heat source (steam). After that,the diluted LiBr solution at point D is more heated then it releases refrigerant vapor. Consequently, itbecomes concentrated LiBr solution of 63.2% at point E.

(4) E → F shows temperature decreasing process of the concentrated LiBr solution in the heat exchanger.While the temperature of the concentrated LiBr solution passes through the heat exchanger, theconcentrated LiBr solution gives heat to the diluted LiBr solution coming from the absorber thenit' temperature decreases to point F.

(5) F → A shows that temperature decreasing process of the concentrated solution in the absorber.The concentrated LiBr solution at point F enters into the absorber and is cooled by the cooling water, thenit reaches point A which starts to absorb the refrigerant vapor. This processes are continuously repeated toachieve chilled water.

Fig. 1-12 Typical cooling cycle on Duhring diagram

0 Mpa (G)

Concentration = 0 % (Water)



AF

ED

B

C

8.7

0.8

Pre

ssur

e (k

Pa.

abso

lute

)

0 36.5 96.6 170 deg.C

32 97.7 205.9 338 deg.F

C'

Page 6 / Sec.1 TJ Series

1-7A. Heat Balance & COP (LJ)

(1) Heat balance

In order to check whether measured data is correct or not, heat balance is useful.Basic consideration of the heat balance : Heat amount coming into a chiller = Heat amount going out from a chiller

The above consideration shows by the formula : (Qa + Qc) / (Qe + Qg) = 1

Qe : Heat amount coming into a chiller from an evaporator

Qg : Heat amount coming into a chiller from a generator

Qa : Heat amount going out from a chiller through an absorber

Qc : Heat amount going out from a chiller through a condenser

In case of SI unit In case of US unit

Qe = (CHi - CHo) X Fe X 1000 / 860 Qe = (CHi - CHo) X Fe X 500

Qg = (Hi - Ho) X Fg X 1000 / 860 Qg = (Hi - Ho) X Fg X 500

Qa + Qc = (COo - COi) X Fc X 1000 / 860 Qa + Qc = (COo - COi) X Fc X 500

Example Example

CHi = 12.2 deg.C Qe = 352 kW CHi = 54 deg.F Qe = 1,200,000 BTU

CHo = 6.7 deg.C Qg = 503 kW CHo = 44 deg.F Qg = 1,711,814 BTU

Fe = 54.5 m3/h Qe + Qg = 855 kW Fe = 240 gpm Qe + Qg = 2,911,814 BTU

COi = 29.4 deg.C Qa + Qc = 851 kW COi = 85 deg.F Qa + Qc = 2,898,000 BTU

COo = 38.4 deg.C Heat balance = 1.00 COo = 101.1 deg.F Heat balance = 1.00

Fc = 81.8 m3/h Fc = 360 gpm

Hi = 95.0 deg.C Hi = 203 deg.F

Ho = 86.0 deg.C Ho = 186.8 deg.F

Fg = 49.8 m3/h 48.0 ton/h Fg = 219 gpm 211 gpm(at 90.5 deg.C S.G = 0.965) (at 194.9 deg.F S.G. = 0.965)

(2) COP

COP is shown by the following formula. COP of LJ series is about 0.7 under the condition of the standard

specification. This value changes depending on required specifications. When a operation

data is recorded, if its COP differs very much from the COP of specifications, it may be

wrong data recording or insufficient cooling performance of a chiller.

Remark: In case of calculating heat balance and COP, cooling water inlet temperature and cooling loadshall be stable for minimum 10 to 15 minutes. Because the response of absorption chiller is notrapid as compared with a electric type chiller.

Condense Generator

Evaporator Absorber

CHi

CHoFe

COi

FgCOo

FcHi

Ho

Cooling waterChilled water

Driving hot water

Qe Qa

QgQc

COP = QeQg


1-7B. Heat Balance & COP (LJ)

(1) Heat balance

In order to cheek whether measured data is correct or not, heat balance is useful.Basic consideration of the heat balance : Heat amount coming into a chiller = Heat amount going out from a chiller

The above consideration shows by the formula : (Qa + Qc) / (Qe + Qg) = 1

Qe : Heat amount coming into a chiller from an evaporator

Qg : Heat amount coming into a chiller from a generator

Qa : Heat amount going out from a chiller through an absorber

Qc : Heat amount going out from a chiller through a condenser

CHi,CHo,COi & COo : Temperature

Hi : Enthalpy of driving steam pressure

Ho : Enthalpy of steam drain temperature

In case of SI unit In case of US unit

Qe = (CHi - CHo) X Fe X 1000 / 860 Qe = (CHi - CHo) X Fe X 500

Qg = (Hi - Ho) X Fg / 3600 Qg = (Hi - Ho) X Fg

Qa + Qc = (COo - COi) X Fc X 1000 / 860 Qa + Qc = (COo - COi) X Fc X 500

Example Example

CHi = 12.2 deg.C Qe = 352 kW CHi = 54 deg.F Qe = 1,200,000 Btu

CHo = 6.7 deg.C Qg = 500 kW CHo = 44 deg.F Qg = 1,706,240 Btu

Fe = 54.5 m3/h Qe + Qg = 852 kW Fe = 240 gpm Qe + Qg = 2,906,240 Btu

COi = 29.4 deg.C Qa + Qc = 851 kW COi = 85 deg.F Qa + Qc = 2,898,000 Btu

COo = 38.4 deg.C Heat balance = 1.00 COo = 101.1 deg.F Heat balance = 1.00

Fc = 81.8 m3/h Fc = 360 gpm

Hi = 2706 kJ/kg (at 100 kPaG) Hi = 1163 Btu/lb (at 15 psig)

Ho = 398 kJ/kg (at 95 deg.C) Ho = 171 Btu/lb (at 203 deg.F)

Fg = 780 kg/h Fg = 1720 lb/h

(2) COP

COP is shown by the following formula. COP of TJ series is about 0.7 under the condition of the standard

specification. This value changes depending on required specifications. When a operation

data is recorded, if its COP differs very much from the COP of specifications, it may be

wrong data recording or insufficient cooling performance of a chiller.

Remark: In case of calculating heat balance and COP, cooling water inlet temperature and cooling loadshall be stable for minimum 10 to 15 minutes. Because the response of absorption chiller is notrapid as compared with a electric type chiller.

Condense Generator

Evaporator Absorber

CHi

CHoFe

COi

FgCOo

FcHo

Hi

Cooling waterChilled water

Driving steam

Qe Qa

QgQc

COP = QeQg


LJ Series

2-1A. Flow diagram of LJ series

Page 1 / Sec.2

Section 2 Flow diagram & Illustration

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TJ-Series

2-1B. Flow diagram of TJ series

Page 2 / Sec.2

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ilute

d Li

Br s

olut

ion

to p

urge

Hea

t exc

hang

er

DT7

Ste

am d

rain

hea

t exc

hang

er

Fig.

2-1

Flo

w d

iagr

am

F

A

CC'

B

DE

2-2A. Illustration of chiller (LJ)

Fig. 2-2

Fig. 2-3

Page 3 / Sec. 2 LJ Series

2-2B. Illustration of chiller (TJ)

Fig. 2-2

Fig. 2-3

Page 4 / Sec. 2 TJ Series

2-3. Control panel

2-3-1. For UL

Fig. 2-4 Front and Side view

CAUTION : Do not push the emergency stop button except an emergency. If push, the chiller stopswithout dilution operation. This may be possible to occur crystallization problem.

IP No. of control panel : 54

Function of each parts

Fan : To cool inside control panel

Terminal block : To connect wires coming from the box side and panel sideTerminal block for power supply : To connect power wires coming from power source

Ground terminal : To connect the wire for grounding

Operation board : To operate chiller and to indicate operation data, alarm code, etc

The microprocessor (CPU) is furnished at the back of the operation board.

Alarm buzzer : To give a sign by the buzzer when an alarm happened

Purge indication lamp : To indicate conducting purge

Purge pump on-off switch : To operate purge pump

Emergency stop button : To stop the chiller at an emergency

Page 5 / Sec. 2 LJ/TJ Series

Fig. 2-5 Inside view


Control relay : To output signals made in the microprocessor

Circuit protector : To cut the power off supplied to the palladium cell heater, the fan,

generator pressure switch and a hot water(LJ) / steam(TJ) control valve motor

if over-current happened in the circuits

I/O board : To transfer ON/OFF signals to the microprocessor as an interface

Main circuit breaker : To protect the control circuit of the chiller at over-current

Transformer : To change voltage from 400 volts to required voltage in the control circuit

Electricmagnetic contactor : To ON & OFF pumps and cutting power off of the pumps at over-current

Fuse : To cut the power off at over-current


2-3-2. For CE

Fig. 2-6 Front and Side view

IP No. of control panel : 54


Fan : To cool inside control panel

Terminal block : To connect wires coming from the box side and panel sideTerminal block for power supply : To connect power wires coming from power source

Earth terminal : To connect the wire for grounding

Operation board : To operate chiller and to indicate operation data, alarm code, etc

The microprocessor (CPU) is furnished at the back of the operation board.

Alarm buzzer : To give a sign by the buzzer when an alarm happened

Purge indication lamp : To indicate conducting purge

Purge pump on-off switch : To operate purge pump

Operation handle : To cut power off when the panel door is opened


Fig. 2-7 Inside view


Control relay : To output signals made in the microprocessor

Circuit protector : To cut the power off supplied to the palladium cell heater, the fan,

generator pressure switch and a hot water(LJ) / steam(TJ) control valve motor

if over-current happened in the circuits

Terminal block : To connect wires coming from the box side and panel side

I/O board : To transfer ON/OFF signals to the microprocessor as an interface

Circuit breaker : To protect high voltage circuit at over-current

Main circuit breaker : To protect the control circuit of the chiller at over-current

Transformer : To change voltage from 400 volts to required voltage in the control circuit

Electricmagnetic contactor : To ON & OFF pumps and cutting power off of the pumps at over-current

Filter : To cut noise off coming from power line


2-3-3. Operation board

Fig. 2-8 Operation board

Circle 1 thru 13 are indication lamps which show operating conditions.

CHILLER : If Circle 1 lights up, it means that the chiller is shut-down

: If Circle 5 lights up, it means that the chiller is running

ABS PUMP : If Circle 2 lights up, it means that the absorbent stops

: If Circle 6 lights up, it means that the absorbent pump is running

REF PUMP : If Circle 3 lights up, it means that the refrigerant stops

: If Circle 7 lights up, it means that the refrigerant pump is running

PURGE PUMP : If Circle 4 lights up, it means that the purge stops

: If Circle 8 lights up, it means that the purge pump is running

STAND BY : If Circle 9 lights up, it means that the chiller is waiting for the interlock signals

of a chilled water and cooling water pumps.

DILUTION : If Circle 10 lights up, it means that the chiller is in dilution operation.

SAFETY CIRCUIT : If Circle 11 lights up, it means that the power is coming to the control circuit.

CHILLER ALARM : If Circle 12 lights up, it means that some alarm occurs

POWER : If Circle 13 lights up, it means that the power is coming to the control circuit.

& keys : To change data display and every setting value

SET : To change menu displayed and set new value

BACK : To return menu displayed

BUZZER STOP : To stop the alarm buzzer

REMOTE : To select remote operation mode

LOCAL : To select local operation mode

STOP : To stop the chiller

RUN : To run the chiller


2-4A. Temperature sensor (LJ)

TSA-16LJ series uses 3 type temperature sensors. One is Resistance thermometer bulb, second one is

Thermistor, last one is Digital sensor.

2-4-1. Resistance thermometer bulb

Fig. 2-9

Model : AEK-23H520

Used for : Chilled water outlet temperature sensor (DT1)

Resistance : 2000Ω at 0 deg.C (32 deg.F)

Rating of resistance : 8.56Ω/deg.C Ex. 2256.8Ω at 30 deg.C (86 deg.F)

2-4-2. Thermistor

Fig. 2-10

Model : U1SC-D312-S2

Used for : Generator temperature sensor (DT3)

Resistance : 1kΩ±3% at 200 deg.C (392 deg.F)

Temperature & Resistance Table

Temperature Resistance

Deg. C Deg. F k ohm

0 32 806.5

30 86 184.1

40 104 118.7

50 122 78.3

60 140 52.8

70 158 36.3

80 176 25.4

90 194 18.1

100 212 13.1

200 392 1.0

50mm / 1.97 inch 2100±80mm / 82.68±3.15 inch

Dia

.5.5

mm

0.2

inch

150±3 mm5.9±0.12 inch

about 36 mm1.42 inch

2500±150mm98.4±5.9 inch

Dia

.6±0

.5 m

m0.

25±0

.02

inch


2-4-3. Digital sensor

Fig.2-11

Model : SEC-SSH-SST01SAC-L1000 & SEC-SSH-SST01SAC

Used for : Cooling water outlet temperature sensor (DT2)

: Condenser temperature sensor (DT5)

: Chilled water inlet temperature sensor (DT6)

: Cooling water inlet temperature sensor (DT7)

: Absorber temperature sensor (DT10)

: Evaporator temperature sensor (DT11)

: Middle cooling water temperature sensor (DT12)

: Hot water outlet temperature sensor (DT14)

: Hot water outlet temperature sensor (DT16)

IC tip provided in the digital sensor detects temperature and send it's data to CPU board through

the communication line as shown below. Addresses are provided in each digital sensors.

If a digital sensor is replaced, it's address must be confirmed.

Address Symbol Sensor Name

03 DT2 Cooling water outlet temperature sensor

05 DT5 Condenser temperature sensor

01 DT6 Chilled water inlet temperature sensor

02 DT7 Cooling water inlet temperature sensor

12 DT10 Absorber temperature sensor

08 DT11 Evaporator temperature sensor

04 DT12 Middle cooling water temperature sensor

10 DT14 Hot water outlet temperature sensor

09 DT15 Hot water inlet temperature sensor

11 DT16 Hot water outlet temperature sensor

Dia

.7±0

.5 m

m0.

28±0

.02 50±2mm/1.97±0.08 inch

1000±20mm / 39.4±0.79 inch: SEC-SSH-SST01SAC-L10002000±50mm / 78.7±1.97 inch : SEC-SSH-SST01SAC

Control panel

CPU Board

Digitalsensor

Digitalsensor

Digitalsensor

Communication line


2-4-4 Purge tank pressure sensor (PHI)

Model : FSK-S17

Total accuracy : +/- 3% FS (-10 --- 50 deg.C)

(12 -- 122 deg.F)

Max. working pressure : 0.15 MPa (G)3 12

Connected pin No.41.3 mm(1.63inch)

41.3

mm

(1.6

3inc

h)

3GND

2Volt

1Vc

46m

m(1

.811

inch

)

7/16-20UNF Flare

Sensor

1

2

3

Vc

DC 10.5 - 28V

Volt

GND

Connection

Fig. 2-12


2-4B. Temperature sensor (TJ)

TSA-16TJ series uses 3 type temperature sensors. One is Resistance thermometer bulb, second one is

Thermistor, last one is Digital sensor.

2-4-1. Resistance thermometer bulb

Fig. 2-9

Model : AEK-23H520

Used for : Chilled water outlet temperature sensor (DT1)

Resistance : 2000Ω at 0 deg.C (32 deg.F)

Rating of resistance : 8.56Ω/deg.C Ex. 2256.8Ω at 30 deg.C (86 deg.F)

2-4-2. Thermistor

Fig. 2-10

Model : U1SC-D312-S2

Used for : Generator temperature sensor (DT3)

Resistance : 1kΩ±3% at 200 deg.C (392 deg.F)

Temperature & Resistance Table

Temperature Resistance

Deg. C Deg. F k ohm

0 32 806.5

30 86 184.1

40 104 118.7

50 122 78.3

60 140 52.8

70 158 36.3

80 176 25.4

90 194 18.1

100 212 13.1

200 392 1.0

50mm / 1.97 inch 2100±80mm / 82.68±3.15 inch

Dia

.5.5

mm

0.2

inch

150±3 mm5.9±0.12 inch

about 36 mm1.42 inch

2500±150mm98.4±5.9 inch

Dia

.6±0

.5 m

m0.

25±0

.02

inch


2-4-3. Digital sensor

Fig.2-11

Model : SEC-SSH-SST01SAC-L1000 & SEC-SSH-SST01SAC

Used for : Cooling water outlet temperature sensor (DT2)

: Condenser temperature sensor (DT5)

: Chilled water inlet temperature sensor (DT6)

: Cooling water inlet temperature sensor (DT7)

: Absorber temperature sensor (DT10)

: Evaporator temperature sensor (DT11)

: Middle cooling water temperature sensor (DT12)

IC tip provided in the digital sensor detects temperature and send it's data to CPU board through

the communication line as shown below. Addresses are provided in each digital sensors.

If a digital sensor is replaced, it's address must be confirmed.

Address Symbol Sensor Name

03 DT2 Cooling water outlet temperature sensor

05 DT5 Condenser temperature sensor

01 DT6 Chilled water inlet temperature sensor

02 DT7 Cooling water inlet temperature sensor

12 DT10 Absorber temperature sensor

08 DT11 Evaporator temperature sensor

04 DT12 Middle cooling water temperature sensor

06 DT13 Steam drain temperature sensor

Dia

.7±0

.5 m

m0.

28±0

.02 50±2mm/1.97±0.08 inch

1000±20mm / 39.4±0.79 inch: SEC-SSH-SST01SAC-L10002000±50mm / 78.7±1.97 inch : SEC-SSH-SST01SAC

Control panel

CPU Board

Digitalsensor

Digitalsensor

Digitalsensor

Communication line


2-4-4 Purge tank pressure sensor (PCH)

Model : FSK-S17

Total accuracy : +/- 3% FS (-10 --- 50 deg.C)

(12 -- 122 deg.F)

Max. working pressure : 0.15 MPa (G)3 12

Connected pin No.41.3 mm(1.63inch)

41.3

mm

(1.6

3inc

h)

3GND

2Volt

1Vc

46m

m(1

.811

inch

)

7/16-20UNF Flare

Sensor

1

2

3

Vc

DC 10.5 - 28V

Volt

GND

Connection

Fig. 2-12


2-5. Principal of purging

Purpose of the purging

In order to achieve stable required chilled water outlet temperature for an absorption chiller, vacuum condition

of the chiller is most important factor. During operating the chiller, a little amount of Hydrogen gas generate.

If Hydrogen gas exist in the chiller, it causes to rise inside pressure of the chiller and the chilled water outlet

temperature can not go down to required temperature, as a result.

When the chiller is new, non-condensable gases such as dissolved oxygen being in absorbent solution &

refrigerant and absorbed oxygen being on the inner surface of chiller appears during operation. They cause

above condition too. They must be released from the inside of chiller to the air by the purging.

Purging system

The purge system is consists of 2 principals for purging. One is Volume moving with fluid ejector, another is

Palladium cell. They are explained as follows.

2-5-1. Volume moving with fluid ejector

When the LiBr solution gushing out from the ejector goes into

the solution level B, it involves bubbles of

non-condensable gas. The LiBr solution

and the gas together come down to

the bottom of the tank.

The LiBr solution returns to the absorber, and the gas

comes up and accumulates in the tank.

The volume of non-condensable gas

existing in the lower shell which is

equal to the gas accumulated in the

tank moves to A from the lower shell.

By means that the above is continuously

repeated during operation of the chiller,

non-condensable gas existing in the Fig.2-12

chiller is accumulated in the tank then the gas can be purged

by the purge pump to the air.

LiBr solution fromAbsorbent pump

Non-condensable gaspurged by a purge

Non-condensable gasfrom the inside of

Ejector

Fluid gushing outfrom ejector

Non-condensablebubbles

LiBr solution

Tank

A

B

Lower shell


2-5-2. Palladium cell

The palladium film has a property to permeate Hydrogen gas when it is 300 - 500 deg.C (572 deg.F - 932 deg.F).

Steps that Hydrogen permeates through the palladium are as follows.

1) Hydrogen is absorbed on the surface of the palladium by an affinity.

2) Absorbed hydrogen dissociates and loss an electron then it becomes a proton.

3) The proton invades into the grid of palladium and it diffuses in the palladium by the difference of hydrogen density.

4) The proton returns hydrogen gas state and goes out to outside.

Other gases which can not dissociate with a proton - electron state can not permeate in the palladium film.

P1 > P2

P1 : Density of hydrogen before palladium film

P2 : Density of hydrogen after palladium film

Fig.2-13

P1 P2Hydrogengas

PermeationHydrogen

Palladium film(heated to 200 - 300deg.C)


2-6. Internal structure

2-6-1. Upper shell

Shell

Purge tank

Condenser tube

Generator tube

Eliminator

Tube sheet

Shell

Baffle

Tube support

Tube sheet


2-6-2. Lower shell

Shell

Tube sheet

Tube sheet

Refrigerant tray

Absorbent tray

Tube support

Evaporator tube

Absorber tube

Eliminator

Sight glass


2-6-3. Heat exchanger

Shell Tube

Baffle

Tube sheet

Tube sheet

Header

Header


Section 3 Installation

3-1. Safety PrecautionsBefore operating the chiller, read thoroughly the following precautions. Following precautions are classified into either WARNING or CAUTION.

WARNING: Wrong operation may causes serious injury or death. CAUTION : Wrong operation may causes an injury or failure of the chiller. However

serious injury or death may occur depending on circumstances.

< Explanatory notes >symbol shows WARNING or CAUTION.symbol shows action prohibited.symbol shows action to be conducted.

(1) For safety use

WARNINGTURN OFF THE BREAKER BEFORE CLEANING AND STOP OPERATION OF THE CHILLER IN CASE OFCHECKING FIRE, EARTHQUAKE OR POSSIBLE THUNDERBOLT

Turn off the breaker before cleaning and Stop operation of the chiller in case of firechecking of a cooling tower, chilled water or earthquake or when there is likely topump, cooling water pump for the chiller be a thunderbolt to prevent an accident.to avoid electric shocks and/or injuries. Must be conducted

Must be conducted

DO NOT OPERATE SWITCHES IN THE CONTROL DO NOT TOUCH WIRINGS IN THE CONTROLPANEL WITH WET HANDS PANEL

Do not operate switches in the control Do not touch wirings in the controlpanel with wet hands to avoid electric panel to avoid electric shocks.shocks.

Do not operate Do not touch

DO NOT TOUCH ANY ROTATING PART WHILE IT VENTILATE MACHINE ROOMIS RUNNING

Keep away fingers from any rotating Ventilate the machineand/or moving parts while it is running room during dischargingto avoid an injury. Nitrogen gas to avoid

Prohibited accident of anoxia.Must be conducted VENTILATION


CAUTIONREMOVE CAUSES OF AN TROUBLE BEFORE DO NOT PUT HEAVY OBJECTS ON THE CHILLERRESTARTING THE CHILLER OR CONTROL PANEL

Remove causes of a trouble due to a Do not put heavy objects on the chiller orsafety device before restarting the chiller control panel to avoid an injury due toto avoid accident. falling.

Must be conducted Prohibited

DO NOT CLIMB UP THE CHILLER DO NOT POUR WATER TO THE CHILLER AND/ORCONTROL PANEL

Do not climb up the chiller to avoid Do not pour water to the chiller and/oraccident due to control panel to avoid electric accident.falling down.

Prohibited Prohibited

USE THE CORRECT POWER SUPPLY AUTHORIZED PERSON ONLY

Be sure to use the correct power supply A notice "For Authorized Person Only"described in the specification plate on must be provided by the chiller to avoidthe control panel. any accident caused by wrong operation

Prohibited Incorrect power causes due to unauthorizedan accident such as person.fire. Must be conducted

NEVER CHANGE THE SET VALUE DO NOT TOUCH ABSORBENT SOLUTION

Never change the set value of safety Do not touch absorbent solution. It maydevices. Wrong setting may cause failure give damage of skin. If touching, washand/or damage of the chiller and accident. thoroughly with water. If the solution

Prohibited Prohibited comes into an eye, wash with waterimmediately and takemedical examination soon.

DO NOT TOUCH HIGH TEMPERATURE PORTIONS CHECK THE PRESSURE OF CHILLED & COOLINGWATER LINE

Do not touch high temperature portions Check the operating pressure of chilledto prevent a burn & cooling water line at daily maintenance.These portion are Over-pressure may

Prohibited shown by caution cause water leakage.labels. Must be conducted

WhatVoltag


STOP A PURGE PUMP TO REPLACE OIL

Stop the purge pump at replacing oilto avoid an injury.

Must be conducted

(2) Safety precautions for overhaul, moving and scrapping

WARNINGOVERHAUL OF THE CHILLER SHALL BE DONE BY AUTHORIZED PERSON ONLY.

Overhaul and repair of the chiller shall be conducted by authorized person only.Incomplete maintenance cause failure and/or damage of the chiller and maycause an accident such as fire.

Prohibited

CAUTIONMOVING WORK OF THE CHILLER SHALL BE DONE SCRAPPING OF THE CHILLER SHALL BE DONEBY AUTHORIZED PERSON ONLY. BY AUTHORIZED COMPANY ONLY.

Moving work including installation and Scrapping of the chiller includingrelocation shall be done absorbent solution management shall beby authorized person done by authorizedhaving official company having officiallicense only to license only to avoidavoid accident. accident and environ-

mental pollution.

STOP


3-2A. Installation check list (LJ)This installation check list is covers the installation of LJ model. This check list is intend to assist the Carrier service engineer with the details required with the installation of the Carrier/SANYO chiller.

Project name :Chiller model :TSA-16LJ-Serial number :Accepted by : , dateReviewed by : , dateRecorded by : , date

Contents1. Delivery inspection2. Location and space requirements3. Leveling verification4. Piping (Chilled water, cooling water, and hot water)5. Field electric wiring6. Megger test7. Confirmation of nitrogen pressure in the unit8. Leak test (If necessary)9. Inspection of purge pump / purging10. Bubble test11. Time setting12. Battery backup13. Temperature unit change14. Remote operation signal setting15. Field insulation instruction16. Confirmation of setting menu and service mode17. Function test of modulating controls18. Aging process19. Refrigerant Blow down20. Preparation of trial run

1. Delivery inspection(1) Specifications of unit ordered vs. unit nameplate :Yes No (2) Lower shell :No-damage Damaged(3) Upper shell :No-damage Damaged(4) Heat exchangers :No-damage Damaged(5) Evaporator headers :No-damage Damaged(6) Absorber headers :No-damage Damaged(7) Condenser headers :No-damage Damaged(8) Generator headers :No-damage Damaged(9) Control panel :No-damage Damaged(10) Absorption pomp and its isolation valves :No-damage Damaged(11) Refrigerant pump and isolation valves :No-damage Damaged(12) Temperature sensors (DT1, DT2, DT3, DT5, DT6, DT'7, DT10, DT11, DT12, DT14, DT15, DT16) :No-damage Damaged(13) Generator pressure switch(63GH) and service valve (SV7) :No-damage Damaged(14) Purge unit (V1, V2, V3, B, SV1, SV2, SV9, Liquid trap) and purge pump :No-damage Damaged


(15) Chilled water flow switch (69CH) :No-damage Damaged(16) Refrigerant blow valve :No-damage Damaged(17) Purge tank pressure sensor (69PR) :No-damage Damaged(18) Palladium cells and Heater (PCH) :No-damage Damaged(19) Service valve (SV3, SV4, SV6) :No-damage Damaged

2. Location and space requirements(1) Location (Basement, Floor, Roof) :Yes No (2) Foundation :Yes No (3) Clearance for maintenance :Yes No (4) Clearance for tube cleaning/removal :Yes No

3. Leveling verification(1) Leveling

A B(Evaporator side)

W : Width of chiller leg(Absorber side)

C D L :　Length between chiller legs

Point A B C D L W0 mm mm mm mm mm mm0 inch inch inch inch inch inch

A - B C - D A - DL L L

B - C A - C B - DL W W

2 (1/4 inch)

1000 (20feet)

(2) Fix anchor bolts :Yes No

4. Piping (Chilled water, cooling water, and hot water)(1) Chilled water piping connection :Yes No (2) Cooling water piping connection :Yes No (3) Hot water piping connection :Yes No (4) Chilled water pump(s) installation :Yes No (5) Cooling water pump(s) installation :Yes No (6) Hot water pump(s) installation :Yes No (7) Cooling tower(s) installation :Yes No (8) Chilled water line flashing :Yes No (9) Cooling water line flashing :Yes No (10) Hot water line flashing :Yes No

= =

= = =

Difference

=

Tolerance　≦


5. Field electric wiring(1) Cooling water pump interlock (#121-#170) :Yes No N/A(2) Chilled water pump interlock (#120-#170) :Yes No N/A(3) Prealarm signal (#334-#335) :Yes No N/A(4) Remote check signal (#336-#337) :Yes No N/A(5) Hot water shutoff valve (#347-#348) :Yes No N/A(6) Operation indication (#350-#351) :Yes No N/A(7) Stop indication (#352-#353) :Yes No N/A(8) Alarm indication (#354-#355) :Yes No N/A(9) Chilled water pump (#356-#357) :Yes No N/A(10) Cooling water pump (#358-#359) :Yes No N/A(11) Cooling tower fan (#360-#361) :Yes No N/A(12) Answer back indication (#362-#363) :Yes No N/A(13) Dilution indication (#368-#369) :Yes No N/A(14) Hot water pump (#370-#371) :Yes No N/A(15) Alarm buzzer (#382-#383) :Yes No N/A(16) Purge indication (#384-#385) :Yes No N/A(17) Run/stop remote signal (#323-#326) :Yes No N/A(18) Grounding/Earth (#G/PE) :Yes No N/A(19) Wiring of palladium cell heater :Yes No N/AFor 460V and 400V: #232 and #0B in the control panel. :Yes No N/AFor 208V: #232 and #202 in the control panel. :Yes No N/A(20) Remote setting signal (#732-#733) :Yes No N/A

6. Megger test Standard : More than 10 M ohms(1) Absorbent pump : M ohms Good No-good---->Repaired Replaced(2) Refrigerant pump : M ohms Good No-good---->Repaired Replaced(3) Purge pump : M ohms Good No-good---->Repaired ReplacedNOTE : Do not apply this test to an inverter and an electronic controller.

7. Confirmation of nitrogen pressure in the unitUnit leakage pressure calculation (P)

t2 + 273t1 + 273

Where:P = Calculated pressure kPaP1 = Pressure from factory kPaP2 = Pressure measured kPat1 = Ambient temperature at factory oCt2 = Ambient temperature at site oC

There is no leak if P2 is nearly equal to P. :Yes No

-101.3P=(P1 + 101.3) x


8. Leak test (If necessary)Unit leakage pressure calculation (P)

t2 + 273t1 + 273

Where:P = Calculated pressure kPaP1 = Pressure at now kPaP2 = Pressure measured kPat1 = Ambient temperature at now oCt2 = Ambient temperature at least 8 hours oC


9. Inspection of purge pump / purging(1) Purge pump :Yes No (2) Purging :Yes No

10. Bubble testTable 3-12-1 Bubble test standard value

Model Standard value16LJ-

11 Less than 15 cc (0.92 cubic inch) per 10 min.12 Less than 15 cc (0.92 cubic inch) per 10 min.13 Less than 15 cc (0.92 cubic inch) per 10 min.14 Less than 15 cc (0.92 cubic inch) per 10 min.21 Less than 25 cc (1.53 cubic inch) per 10 min.22 Less than 25 cc (1.53 cubic inch) per 10 min.23 Less than 25 cc (1.53 cubic inch) per 10 min.24 Less than 30 cc (1.83 cubic inch) per 10 min.31 Less than 30 cc (1.83 cubic inch) per 10 min.32 Less than 30 cc (1.83 cubic inch) per 10 min.41 Less than 40 cc (2.44 cubic inch) per 10 min.42 Less than 40 cc (2.44 cubic inch) per 10 min.51 Less than 45 cc (2.75 cubic inch) per 10 min.52 Less than 45 cc (2.75 cubic inch) per 10 min.53 Less than 50 cc (3.05 cubic inch) per 10 min.

Pass :Yes No

11. Time settingPass :Yes No

12. Battery backupPass :Yes No

P=(P1 + 101.3) x -101.3


13. Temperature unit changePass :Yes No

14. Remote operation signal settingPass :Yes No

15. Field insulation instructionPass :Yes No

16. Confirmation of setting menu and service modePass :Yes No

17. Function test of modulating controlsPass :Yes No

18. Aging processPass :Yes No

19. Refrigerant Blow downPass :Yes No

20. Preparation of trial run(1) Unit and auxiliary equipment operating in an automatic mode. :Yes No (2) Hot water valve adjusted for design input. :Yes No (3) Refrigerant in the evaporator less than 3% LiBr. :Yes No (4) Chilled, cooling, and hot water flows at design. :Yes No (5) Chilled, cooling, and hot water temperatures at design. :Yes No (6) Confirm valves position. :Yes No


3-2B. Installation check list (TJ)This installation check list is covers the installation of LJ model. This check list is intend to assist the Carrier service engineer with the details required with the installation of the Carrier/SANYO chiller.

Project name :Chiller model :TSA-16TJ-Serial number :Accepted by : , dateReviewed by : , dateRecorded by : , date

Contents1. Delivery inspection2. Location and space requirements3. Leveling verification4. Piping (Chilled water, cooling water, and steam)5. Field electric wiring6. Megger test7. Confirmation of nitrogen pressure in the unit8. Leak test (If necessary)9. Inspection of purge pump / purging10. Bubble test11. Time setting12. Battery backup13. Temperature unit change14. Remote operation signal setting15. Field insulation instruction16. Confirmation of setting menu and service mode17. Function test of modulating controls18. Aging process19. Refrigerant Blow down20. Preparation of trial run

1. Delivery inspection(1) Specifications of unit ordered vs. unit nameplate :Yes No (2) Lower shell :No-damage Damaged(3) Upper shell :No-damage Damaged(4) Heat exchangers :No-damage Damaged(5) Evaporator headers :No-damage Damaged(6) Absorber headers :No-damage Damaged(7) Condenser headers :No-damage Damaged(8) Generator headers :No-damage Damaged(9) Control panel :No-damage Damaged(10) Absorption pomp and its isolation valves :No-damage Damaged(11) Refrigerant pump and isolation valves :No-damage Damaged(12) Temperature sensors (DT1, DT2, DT3, DT5, DT6, DT7, DT10, DT11, DT12) :No-damage Damaged(13) Generator pressure switch(63GH) and service valve (SV7) :No-damage Damaged(14) Purge unit (V1, V2, V3, B, SV1, SV2, SV9, Liquid trap) and purge pump :No-damage Damaged


(15) Chilled water flow switch (69CH) :No-damage Damaged(16) Refrigerant blow valve :No-damage Damaged(17) Purge tank pressure sensor (69PR) :No-damage Damaged(18) Palladium cells and Heater (PCH) :No-damage Damaged(19) Service valve (SV3, SV4, SV6) :No-damage Damaged

2. Location and space requirements(1) Location (Basement, Floor, Roof) :Yes No (2) Foundation :Yes No (3) Clearance for maintenance :Yes No (4) Clearance for tube cleaning/removal :Yes No

3. Leveling verification(1) Leveling



C D L :　Length between chiller legs

Point A B C D L W0 mm mm mm mm mm mm0 inch inch inch inch inch inch

A - B C - D A - DL L L

B - C A - C B - DL W W

2 (1/4 inch)

1000 (20feet)

(2) Fix anchor bolts :Yes No

4. Piping (Chilled water, cooling water, and steam)(1) Chilled water piping connection :Yes No (2) Cooling water piping connection :Yes No (3) Steam piping connection :Yes No (4) Chilled water pump(s) installation :Yes No (5) Cooling water pump(s) installation :Yes No (6) Cooling tower(s) installation :Yes No (7) Chilled water line flashing :Yes No (8) Cooling water line flashing :Yes No (9) Steam line flashing :Yes No

= =

= = =

Difference

=

Tolerance　≦


5. Field electric wiring(1) Cooling water pump interlock (#121-#170) :Yes No N/A(2) Chilled water pump interlock (#120-#170) :Yes No N/A(3) Prealarm signal (#334-#335) :Yes No N/A(4) Remote check signal (#336-#337) :Yes No N/A(5) Steam shutoff valve (#347-#348) :Yes No N/A(6) Operation indication (#350-#351) :Yes No N/A(7) Stop indication (#352-#353) :Yes No N/A(8) Alarm indication (#354-#355) :Yes No N/A(9) Chilled water pump (#356-#357) :Yes No N/A(10) Cooling water pump (#358-#359) :Yes No N/A(11) Cooling tower fan (#360-#361) :Yes No N/A(12) Answer back indication (#362-#363) :Yes No N/A(13) Dilution indication (#368-#369) :Yes No N/A(14) Hot water pump (#370-#371) :Yes No N/A(15) Alarm buzzer (#382-#383) :Yes No N/A(16) Purge indication (#384-#385) :Yes No N/A(17) Run/stop remote signal (#323-#326) :Yes No N/A(18) Grounding/Earth (#G/PE) :Yes No N/A(19) Wiring of palladium cell heater :Yes No N/AFor 460V and 400V: #232 and #0B in the control panel. :Yes No N/AFor 208V: #232 and #202 in the control panel. :Yes No N/A(20) Remote setting signal (#732-#733) :Yes No N/A

6. Megger test Standard : More than 10 M ohms(1) Absorbent pump : M ohms Good No-good---->Repaired Replaced(2) Refrigerant pump : M ohms Good No-good---->Repaired Replaced(3) Purge pump : M ohms Good No-good---->Repaired ReplacedNOTE : Do not apply this test to an inverter and an electronic controller.

7. Confirmation of nitrogen pressure in the unitUnit leakage pressure calculation (P)

t2 + 273t1 + 273



-101.3P=(P1 + 101.3) x


8. Leak test (If necessary)Unit leakage pressure calculation (P)

t2 + 273t1 + 273

Where:P = Calculated pressure kPaP1 = Pressure at now kPaP2 = Pressure measured kPat1 = Ambient temperature at now oCt2 = Ambient temperature at least 8 hours oC


9. Inspection of purge pump / purging(1) Purge pump :Yes No (2) Purging :Yes No

10. Bubble testTable 3-12-1 Bubble test standard value

Model Standard value16TJ-


Pass :Yes No

11. Time settingPass :Yes No

12. Battery backupPass :Yes No

P=(P1 + 101.3) x -101.3


13. Temperature unit changePass :Yes No

14. Remote operation signal settingPass :Yes No

15. Field insulation instructionPass :Yes No

16. Confirmation of setting menu and service modePass :Yes No

17. Function test of modulating controlsPass :Yes No

18. Aging processPass :Yes No

19. Refrigerant Blow downPass :Yes No

20. Preparation of trial run(1) Unit and auxiliary equipment operating in an automatic mode. :Yes No (2) Steam valve adjusted for design input. :Yes No (3) Refrigerant in the evaporator less than 3% LiBr. :Yes No (4) Chilled water, cooling water, and steam flows at design. :Yes No (5) Chilled water and cooling water temperatures at design. :Yes No (6) Steam pressure at design. :Yes No (7) Confirm valves position. :Yes No


3-3. Delivery inspection

Upon delivery of the Carrier/SANYO absorption chiller to the jobsite, the Carrier Service representativeshould carefully inspect the units for the following items:

1. Correct model and serial numbers. Compare all operating specifications as outlined in the "Contract Specification" with the nameplate on the unit.2. Inspect for physical damage to the unit including external sensors, control panel and wiring.3. On multiple piece assemblies insure that the proper quantity of lithium bromide and inhibitor have been received and placed next to the unit.4. Inspect all separate shipping boxes and components shipped with the unit.


3-4. Location and space requirements

The unit is designed for indoor application and must be located in a space where the ambient

temperature is between 5 oC(41oF) and 45oC(104oF), at no time more than 90% relative humidity.Clearance must be provided on either end to facilitate tube cleaning or removal and clearance on all other sides of the unit for general unit maintenance. See the dimensional data tables in the contract specification for clearance requirements.


3-5. Leveling verification

Strict leveling tolerances must be adhered to for trouble free operation. The chillers are furnished withleveling reference points at each corner of the lower shell assembly. The method to check levelingtolerance requires a clear vinyl tube with water. The water level in the tube can then be held at referencepoint "A" and the difference in level can be determined at all other points around the chiller. The tolerancethat must be maintained is <=0.002 between the measured points as shown below. When the unit doesnot meet this requirement, the unit must be shimmed at the appropriate locations to meet this require-ment.

1. Using point A as the base point, measure differences of water levels at other point (B, C, D). Fig. 3-5-1



C DL :　Length between chiller legs

Point A B C D L WDifference 0 mm mm mm mm mm mm

2. Leveling calculation

A - B C - D A - D B - C A - C B - DL L L L W W

2 mm1000

3. Note that there are four leveling check points on the chiller shown in the below figure. These check points are designated by three punch marks on the lower tube sheets.

Tolerance　≦ ( 1/4 inch par 20 feet)

Fig. 3-5-2


4. If calculated value (s) is not within the tolerance, adjust levels by inserting metal shims between the leg and the foundation. Size of the shim is approximately 50 mm (2") width and 80 mm (3") length. Different thickness shims should be prepared. (0.6 mm (0.02") - 9 mm (0.35"))

5. Fix anchor boltsa) Weld washers on the legs of the chiller.b) Tight up nuts.

Fig. 3-5-3

Fig. 3-5-4


3-6A. Piping (Chilled water, cooling water, and hot water) (LJ)

Building pump interlocksThe unit are equipped with interlock contact closures to signal the chilled and cooling water pumps to start and stop. It is important that the unit have control of the chilled and cooling water pumps to allowfor controlled shutdown of water flow during the normal shutdown/dilution cycle or in the event of a safetycondition. In addition to the start/stop signals to the chilled and cooling water pumps, the unit also requires answer-back signals from the chilled and cooling water pump starters. The answer-back signalsare necessary to report to the electric controller that the chilled and cooling water pumps are operatingin response to the electric controller start/stop signal. These answer-back signals are typicallydry-contact closure from the pump starters to the interlock contact point at the chiller panel.

Building pump interlocks on multiple unitsOn applications where there are multiple units without dedicated chilled and cooling water pumps, it willbe necessary to provide some means for an individual unit to shut off water flow during the normalshutdown/dilution cycle or in the event of a safety condition. Typically, this is accomplished by installingan in-line shutoff valve to the chilled and cooling water circuits of each individual chiller. The interlockcontact points from the chiller can then be utilized to send a start/stop signal to the common chilled andcooling water pump starters and simultaneously provide the open/close signal to the individual unit in-linewater valves. In addition to the start/stop signals to the chilled and cooling water pumps, the unit alsorequires answer-back signals from the chilled and cooling water pump starters and from an end switchsignal from the in-line water valves. The answer-back signals are necessary to report to the electriccontroller that the chilled and cooling water pumps and in-line valves are operating in response to the electric controller start/stop signal. These answer-back signals are typically dry-contact closures fromthe pump starters and in-line water valve end switches to the interlock contact/points at the chiller panel.

Water pipingWater piping should be arranged so that the circulating pumps discharge directly into the unit waterheaders. The water piping should be insulated to reduce heat gain and to prevent condensation. Airvents should be located at all high points in the water piping system, and drains should be located atallow points to facilitate complete system drainage. To reduce vibration and noise transmission, vibrationeliminators should be provided. Shutoff valves should be provided to allow unit isolation duringmaintenance. A chilled water flow switch is provided on the unit and is preset to open at approximately50% of flow rate.

Notes:1. Pipes shall be properly supported in order that water nozzles / flanges of the chiller do not receive any stress.2. Provide sockets or taps at proper positions to measure temperature and pressure in the piping line.3. Be sure to conduct flashing of chilled water line, cooling water line, and hot water line before trial operation.


3-6B. Piping (Chilled water, cooling water, and steam) (TJ)

Building pump interlocksThe unit are equipped with interlock contact closures to signal the chilled and cooling water pumps to start and stop. It is important that the unit have control of the chilled and cooling water pumps to allowfor controlled shutdown of water flow during the normal shutdown/dilution cycle or in the event of a safetycondition. In addition to the start/stop signals to the chilled and cooling water pumps, the unit also requires answer-back signals from the chilled and cooling water pump starters. The answer-back signalsare necessary to report to the electric controller that the chilled and cooling water pumps are operatingin response to the electric controller start/stop signal. These answer-back signals are typicallydry-contact closure from the pump starters to the interlock contact point at the chiller panel.

Building pump interlocks on multiple unitsOn applications where there are multiple units without dedicated chilled and cooling water pumps, it willbe necessary to provide some means for an individual unit to shut off water flow during the normalshutdown/dilution cycle or in the event of a safety condition. Typically, this is accomplished by installingan in-line shutoff valve to the chilled and cooling water circuits of each individual chiller. The interlockcontact points from the chiller can then be utilized to send a start/stop signal to the common chilled andcooling water pump starters and simultaneously provide the open/close signal to the individual unit in-linewater valves. In addition to the start/stop signals to the chilled and cooling water pumps, the unit alsorequires answer-back signals from the chilled and cooling water pump starters and from an end switchsignal from the in-line water valves. The answer-back signals are necessary to report to the electriccontroller that the chilled and cooling water pumps and in-line valves are operating in response to the electric controller start/stop signal. These answer-back signals are typically dry-contact closures fromthe pump starters and in-line water valve end switches to the interlock contact/points at the chiller panel.

Water pipingWater piping should be arranged so that the circulating pumps discharge directly into the unit waterheaders. The water piping should be insulated to reduce heat gain and to prevent condensation. Airvents should be located at all high points in the water piping system, and drains should be located atallow points to facilitate complete system drainage. To reduce vibration and noise transmission, vibrationeliminators should be provided. Shutoff valves should be provided to allow unit isolation duringmaintenance. A chilled water flow switch is provided on the unit and is preset to open at approximately50% of flow rate.

Notes:1. Pipes shall be properly supported in order that water nozzles / flanges of the chiller do not receive any stress.2. Provide sockets or taps at proper positions to measure temperature and pressure in the piping line.3. Be sure to conduct flashing of chilled water line, cooling water line, and steam line before trial operation.


3-7A. Field electric wiring (LJ)

On CE code, power supply wiring shall be in accordance with OVER VOLTAGE Category III, other wiring shall be in accordance with OVER VOLTAGE Category II. Refer to Fig. 3-7-1, 3-7-2.Field wiring work shall be conducted be a electrician who has official license for the work.

Fig. 3-7-1 Field electric wiring No.1


3-7B. Field electric wiring (TJ)

On CE code, power supply wiring shall be in accordance with OVER VOLTAGE Category III, other wiring shall be in accordance with OVER VOLTAGE Category II. Refer to Fig. 3-7-1, 3-7-2.Field wiring work shall be conducted be a electrician who has official license for the work.



3-8. Megger test

Confirming the unit controls and setpoints will also include a megger test of the unit pumps.Use a 500 VDC megger and only measure the load side of the pump being tested. The chiller pumpsshould have an insulation resistance greater than 10 meg ohms.

1. Connect an earth wire of the megger to an earth terminal in the control panel.2. Measure insulation resistances of each motor at the following terminals in the control panel.

・Absorbent pump (Terminals) : U1 / V1 / W1・Refrigerant pump (Terminals) : U3 / V3 / W3・Purge pump (Terminals) : U4 / V4 / W4

3. Record the measured values.

Fig. 3-8 Megger test


3-9. Confirmation of nitrogen pressure in the unit

Connect the pressure gauge to SV2 on the purge unit.Check and record the pressure as shown on the pressure gauge and ambient temperature in the equipment room. Compare the data obtained with the factory shipping data by using the formula inthe check list. If no leak is apparent then discharge the nitrogen holding charge. If a leak is apparentthen it will be necessary to perform a leak test. On multiple section assemblies it will be necessary to check and record pressure and temperatures for all of the separate sections. Compare the dataobtained with the factory shipping data by using the formula in the check list. If on leak is apparent theninstruct the installer to proceed with the unit assembly and welding. If a leak is apparent it will benecessary to perform a leak test on that unit section.

Fig. 3-9. Purge unit

Unit leakage pressure calculation (P)t2 + 273t1 + 273


There is no leak if P2 is nearly equal to P.

P=(P1 + 101.3) x -101.3


3-10. Leak test

Pressurizing the unit with nitrogen is only necessary after the installer assembles a multiple section unitor if a leak is apparent on a single piece unit. The nitrogen is installed through the service valve (SV1)located on the purge unit. Refer to Fig. 3-9.During this work, ventilate the unit room sufficiently.

The leak test is as follows:1. Confirm that V1, V2, V3, B valve, SV1, SV2 are fully closed.2. Confirm that each isolation valve for absorbent and refrigerant pumps are fully open.3. Connect the pressure gauge to SV2, and open SV2.4. Charge nitrogen to SV1.5. Pressurize the chiller up to 50 kPa with nitrogen. The pressure inside the chiller can be checked by the pressure gauge.6. When the pressure reaches 50 kPa, close SV1 and the valve of the nitrogen cylinder.7. Check the following positions with the soapy water.

7-1) All field welded portions (One shipping machine is not needed.)7-2) Sight glass7-3) Flare nut joints of service valves.7-4) Electrodes7-5) Flange connections ( the absorbent pumps, refrigerant pump, etc.)7-6) Diaphragm valves

8. If a leakages is observed at the points 7-2) - 7-6), tighten them. In this case, discharging nitrogen gas is not required.9. If a leakage is found out on field welding portions, repair it after discharging nitrogen.10. Repeat 3. - 8..11. If no leakage is confirmed, hold the chiller with 50 kPa at least 8 hours then recheck by soapy water.12. After completion of the test, discharge nitrogen.

Unit leakage pressure calculation (P)t2 + 273t1 + 273

Where:P = Calculated pressure kPaP1 = Pressure at now kPaP2 = Pressure measured kPat1 = Ambient temperature at now oCt2 = Ambient temperature after at least 8 hours oC

There is no leak if P2 is nearly equal to P.

Important: If the unit will be leak tested sometime after charging and start-up, it will be necessary toremove the rupture disk and install a blank off plate in its place. Because of the frangible nature of therupture disk, pressurizing the unit with the disk in the place could possibly distort the shape of the diskand cause it to leak. Removing the rupture disk for leak testing also allows for inspection of the diskitself as it may be the cause of the leak. It is recommended that the original rupture disk blank off plateshipped with the unit be stored with the unit in the case of future leak testing.

P=(P1 + 101.3) x -101.3


Table 3-10 Content volumeModel Volume Volume Model Volume VolumeLJ- (litter) (gal) LJ- (litter) (gal)

11E 1,640 433 31E 5,030 1,32812E 1,580 417 32E 4,830 1,27513E 2,510 663 41E 6,150 1,62414E 2,380 628 42E 5,910 1,56021E 3,150 832 51E 8,240 2,17522E 3,010 795 52E 9,350 2,46823E 4,210 1,111 53E 10,350 2,73224E

Model Volume Volume Model Volume VolumeTJ- (litter) (gal) TJ- (litter) (gal)

11E 1,730 457 31E 5,170 1,36512E 1,640 433 32E 5,050 1,33313E 2,590 684 41E 6,300 1,66314E 2,460 649 42E 6,150 1,62421E 3,250 858 51E 8,520 2,24922E 3,110 821 52E 9,670 2,55323E 4,340 1,146 53E 10,710 2,82724E 4,160 1,098

4,020 1,061


3-11. Inspection of purge pump/purging

The purge pump is supplied with the unit, mounted, wired and piped. The initial charge of purge pumpoil is shipped as an extra item with the unit and should be added to a level just above the bottom of thesight glass. During purge pump operation this level should rise to approximately 1/2 sight glass. If toomuch oil is added, it may cause oil to spill from the discharge port when it is first turned on. The purgepump also includes a ballast that can be opened slightly to limit the amount of condensed refrigerantfrom entering the pump and contaminating the oil. Allowing a small amount of ballast also tends to heatthe purge pump oil and exhaust the moisture out of the oil. Refer to Fig. 3-9-1.1. Always replace the oil if it becomes contaminated or milky in color.2. Confirm the pumps ability to draw a vacuum. The pump also should achieve of at least 0.5 kPa (0.07 psi). If this value cannot be obtained, perform the following:

a. Replace the purge pump oil.b. Check the liquid trap for water. If condensed water or moisture is apparent then it will be necessary to operate the purge pump for 1/2 hour to evaporate the moisture.c. Check the unit purge line piping for leakage by bubble testing.

3. If the purge pump will not rotate or trips the thermal overload it will be necessary to remove the belt and manually turn the pump by hand in an attempt to loosen the pump.4. If the pump will not rotate be hand or will not attain an adequate vacuum after performing the above tasks it may be necessary to rebuild the purge pump.

Important: When first starting the purge pump it is critical to bump start the pump and check for properrotation as shown by an arrow on the shroud. The direction of the purge pump is an indicator of thedirections of the other pumps on the unit. If the rotational direction is incorrect the phasing adjustmentshould be made at the power supply to the unit not to the purge pump wiring.

PurgingRemark : While purging work is being conducted, continuous power supply shall be required.If power interruption happens during purging, close V1 immediately in order to preventair leaking through the purge unit.During purging nitrogen work, ventilate the unit room sufficiently.1. Turn on the main breaker in the control panel.2. Turn on the purge pump switch.3. Check the rotating direction of purge pump. Correct direction is shown by arrow mark on a pulley cover of the purge pump. If the direction is wrong, stop the purge pump then correct it.4. Open V1, V3 and B valve. Purging starts.5. Open V2 after one hour.6. Continue purging until inner pressure goes down below minus 0.1 MPa. Refer to table 3-11.

Table 3-11 Approximately purging time

21-32 12h 41-53 24h

MODEL TIMETJ-11-14 5h

12h24h

21-32 41-53

5hLJ-11-14MODEL TIME


3-12. Bubble test

The term "bubble test" describes the procedure of measuring the quantity of noncondensables beingpurged from the chiller. The test consists of adapting a hose from the discharge port of the purge pumpand collecting the discharge gasses in an inverted graduated cylinder under water. The graduatedcylinder is first filled with water and inverted so that no air is contained in the cylinder. As thenoncondensable gasses are discharged into the inverted cylinder the water column in the cylinder willdrop as the water is being displaced. The quantity of noncondensable gasses can then be measuredbased on time and volume of water displacement. This test will be performed during initial evacuating ofthe chiller, during the again process, during routine maintenance, and to determine if an air leak is present. The most important maintenance item on an absorption chiller is to insure the unit vacuumcondition is within acceptable limits. Unit tightness can be checked by determining the rate at whichnoncondensable accumulate. Some noncondensables are normally generated within the unit, but an airleak will be indicated if the accumulation rate increases.

Bubble test during unit operationDuring routine maintenance the bubble test can be performed to gather the noncondensable gasses that have accumulated in the purge tank. The contents of the gasses can then checked to be air or hydrogen.Air---No odor. If the unit does not pass the bubble test it is possible that a leak has developed.Hydrogen gas---Place a match or lighter at the lip of the graduated cylinder before removing the cylinderfrom the water. If hydrogen is apparent, the gas will ignite and cause a popping sound. If hydrogen ispresent it is an indicator that hydrogen production is exceeding the capacity of the palladium cells and that the inhibitor is depleted and should be replaced. Care should be taken when performing this test.

Procedurea) Perform purging from the chiller until inner pressure reaches allowable degree of vacuum

or less. Continue purging at least one hour. Refer to Fig.3-12-1.b) Connect the vacuum gauge to SV1 and open SV1.c) Confirm that attained vacuum of the purge pump is less than 5 hPa (0.07 psi).d) Remove the discharge port cap and put the attachment to the port. Furnish the vinyl hose to

the attachment as shown in above figure.e) Open V1 and close V2 and V3.f) Continue to operate the purge pump for one minute. Then measure volume of bubbles. During

this step, keep position of the vinyl hose within 10 mm in depth. If bubbles come out, checkand tighten connections in the downstream from V2 and V3. If bubbles still come out,measure its volume collected for 10 minutes.

g) Open V1 and V3 and close V2.Note : The gas ballast valve and the oil discharge cock shall be closed.

h) Continuing operation of the purge pump under the above condition, measure volume of bubblesfor 10 minutes. This measurement shall be repeated at least three times. Duringmeasurements, attained vacuum of the purge pump shall be kept below 5 hPa (0.07 psi).

I) The measured value in item f) is as "A cc", in item h) is as "B cc".Result of bubble test value = B - C (cc)

j) After the bubble test ;Open the gas ballast valve.Replace purge pump oil.


The degree of vacuum should be mentioned withinthe allowable range. As the pressure in the chilleris variable owning to the ambient temperature, check the measured pressure by using the curve.

When ambient temperature is 30 oC (86 oF),4.4 kPa (0.64 psi) is read as an allowable vacuum.If pressure is over 4.4 kPa (0.64 psi), performair purging.

3/8" Copper tube

Flare nut

Bushing (1-1/4")

Nipple (3/8")

Fig. 3-12-2 Attachment

10m

m (1

3/32

)"

Graduated cylinder

WaterBucket

Vinyl hose

Suction port

Purge pump

Discharge port

Fig. 3-12-3 Bubble test

Fig. 3-12-1 Allowable vacuum curve


Table 3-12 Bubble test standard valueModel Standard value16LJ-


Model Standard value16TJ-



3-13. Time setting

Time setting shall be conducted before initial operation of the chiller.

3 5. 0 High temperature generator temperature (example).Push "SET" key for 2 sec..

A L A r n. Shady columns flicker.Push " " key. 0 5 - 0 5

r t. 0 7. 0 0 Push "SET" key for 2 sec..Push "SET" key for 2 sec.. d t - S E t

y r - S E t Push " " key.Push "SET" key for 2 sec.. t n. - S E t

2 0 0 1 Push "SET" key for 2 sec..Push " " or " " key. 0 7 = 0 0

2 0 0 5 Push " " key for the hour.Push "SET" key for 2 sec.. 1 6 = 0 0

y r - S E t Push " " key.Push " " key. 1 6 = 0 0

d t - S E t Push " " key for the minutePush "SET" key for 2 sec.. 1 6 = 5 0

0 1 - 0 1 Push "SET" key for 2 sec..Push " " key for the month. t n. - S E t

0 5 - 0 1 Push "BACK" key.Push " " key. r t. 1 6. 5 0

0 5 - 0 1 Push "BACK" key.Push " " key for the date. 3 5. 0


3-14. Battery backupSee to Fig. 3-3. This figure shows positions of BACKUP BATTERY and BACKUP SWITCH (SW3) providedon the CPU board in the electronic controller.

1. SW3 is set OFF at the factory to avoid consumption of battery power.2. When the power is supplied to the electronic controller, "F-21 (CPU alarm)" or "F-23 (Time set alarm)" is displayed on the data display if SW3 is turned off. In this case, turn on SW3 first and then conduct time setting.3. When the power is supplied to the electronic controller, "F-21 (CPU alarm)" or "F-23 (Time set alarm)" is displayed on the data display even if SW3 is turned on. This means that the backup battery is empty. Replace the backup battery in accordance with the following steps.Turn off SW3 - Remove the backup battery - Put new backup battery - Conduct time setting - Turn on SW3

Note : Model of the backup battery is CR-2025. The battery can do backup for approximate 4,000 hours.

Fig. 3-14. Positions of Backup switch (SW3) & Backup battery

SW

3 :B

acku

p sw

itch

UP

: O

ND

OW

N :

OFF

Bac

kup

batte

ry

LAB

EL


3-15. Temperature unit change

Unit (deg.C from/to deg.F) of temperature can be changed by the following steps. This change can beconducted even while the chiller is running.


A L A r n. Push " " or " " key.

C H G S = Push "SET" key for 2 sec..

u n I t Push " " or " " key if need.Push "SET" key for 2 sec. then push " " or " " key.

To change deg. C To change deg. F

o C o F Push "SET" key. Push "SET" key.Unit of deg. C can be fixed. Unit of deg. F can be fixed.


3-16. Remote operation signal setting

5 types can be used for operating signal of the chiller as shown below.Table 3-16 Remote operation signal

Setting

r - S I G n o F - P L S(Remote signal) (Off pulse)

S t A t I C(Contentious signal)

P u L S E P o S I t I(Pulse) (Positive)

P u L S E n E G A t I(Pulse) (Negative)

S t A t I C(Contentious signal)

P u L S E P o S I t I(Pulse) (Positive)

Note : Each signal type and their wiring shall be met. Refer to Sec. 3-7.To be continued.

Type 5DC/AC 24V

Setting is not required

Setting is not required

Type of remotesignal

Type 1Non-Voltage signal



Type 4DC/AC 24V


Type of remote operating signal can be selected by the following steps.


A L A r n. Push " " or " " key.

F I E L D Push "SET" key for 2 sec..

C o - I n PPush " " or " " key.

r - S I G n

Push "SET" key for 2 sec. then Push " " or " " key.push " " or " " key.

To change static mode To change pulse mode

S t A t I C P u L S E o F - P L SPush "SET" key. Push "SET" key.Static mode can be fixed. Pulse mode can be fixed. Push "SET" key for 2 sec. then

push " " or " " key.

To change negative mode To change positive mode

P o S I t I n E G A t IPush "SET" key. Push "SET" key.Positive mode can be fixed. Negative mode can be fixed.

In case that off pulse is required on START/STOP ofthe chiller, following steps shall be proceeded.


3-17. Field insulation instruction

Because of the many different insulating materials available in our industry and local code requirementsor regulations that must be complied with, it is impossible to specify the insulating material types to be utilized for a specific application. The selection and installation of the insulation should be addressed byexperienced personnel knowledgeable in the local requirements and regulations of this field. The follow-ing tables illustrate the square footage of materials required and the thicknesses of the materials basedon typical installations.

1. Do not insulate the unit until the leak testing procedures have been completed.2. The type of insulation utilized on the hot surface must be sufficient so that outer skin temperatures meet local safety codes for personnel protection.3. Use only noncombustible materials.4. Do not insulate motor of refrigerant pump.5. To mount insulating materials, use bonding agents, wires, and bands. Do not use screws, rivets, or impact type stick pins.6. Do not cover components such as service valves, dampers, sight glasses, or thermometer or sensor wells.7. Allow accessibility through the insulation to components such as water headers, steam headers.8. The unit is coated with a heat resistant rust inhibiting paint from the factory. Finish painting is performed in the field after insulating is complete.9. The purpose of insulation for hot surfaces are: a) protection of personnel from burns b) reduction of heat loss to equipment room c) maintain heat input in the unit for efficiency.10. The purpose of insulation for cold surfaces is to avoid condensation.

Table 3-17 Surface temperature of insulation partsCOLD SURFACES HOT SURFACESEvaporator GeneratorChilled water headers Generator headerRefrigerant piping Heat exchanger

Solution piping except from absorption pumpto heat exchanger

4 oC (40 oF) 85 oC (185 oF)


3-18. Confirmation of setting menu and service mode3-18-1. Confirmation of setting menu Confirm setting value to be necessary for normal operation. There are three steps as following to.

Symbols : To press "BACK" key : To press " " key : To press "SET" key : To press " " key

Each menu can be displayed by the following steps.

Regular indication　(Generator temperature)

3 7. 0

3rd step : Settingvalue can confirm

1st step : Setting menu mode or changeA L A r n. "ALArn." has not 2nd step. C 1.

d 1. 0 6 0 9

2nd step : Setting sub menur t. 1 4. 5 3 Y r - S E t 2 0 0 1

d t - S E t 1 0 - 2 4

The other setting sub menus.

C H G S

I I r d - S E t C o o L

H E A tThe other setting menus. The other setting sub menus.

2 sec.

2 sec.

or

2 sec.2 sec.

orIf set ischanged,

2 sec.

2 sec.2 sec.

orIf set ischanged,

2 sec.


: The setting value vary based on the specification.Table 3-18-1 Confirmation of setting menu(1/2)

Confirmation items Data display Setting Check

Specifications setting A L A r n.1) 1st alarm code (The latest) C 1.2) 1st alarm happen month and day d 1. 1 0 2 43) 1st alarm happen time t 1. 1 4. 0 24) 2nd alarm code C 2.5) 2nd alarm happen month and day d 2. 0 6 0 96) 2nd alarm happen time t 2. 0 8. 4 47) 3rd alarm code C 3.8) 3rd alarm happen month and day d 3. - - - -9) 3rd alarm happen time t 3. - - - -

10) Initialization r E - S E tTime setting r t. 1 4. 5 3

11) Year setting Y r - S E t 2 0 0 512) Month and date setting d t - S E t 1 0 - 2 413) Time setting t n. - S E t 0 8

I I 0 2Change of switch C H G S

I I

14) Cool / Heat change-over r d - S E t C o o L15) Operation data record interval change S A n. - d t 1 - H16) Select of local operation mode L o C A L o n17) Cancel of predication information S I G n C o n S E n18) Change of unit u n I t o C19) Change of low select control L o

I I S E L o F FSet of chilled water pump A P P o C H

20) Confirmation of interlock return time I n t - C H 0 0 0 S21) Set of variable flow rate V

I I V - C H o F F22) Set of parallel operation by remote control r - P A r A o F F

Inverter control for chilled water C H - I n V InvalidSet of cooling water pump A P P o C oand cooling tower

23) Confirmation of interlock return time I n t - C o 0 S24) Set of stopping cooling water pump at low load C o S t o P o F F25) Set of cooling tower fan control C t A u t o o F F26) Set of cooling water temperature control C t t E n. P 2 6. 0 o C27) Set of differential temp. of cooling tower fan C t d I F F 3. 0 o C28) Set of variable flow rate V

I I V - C o o F FInverter control for cooling water C o - I n V Invalidcont.,

1st step 2nd step 3rd step(ex.)


: The setting value vary based on the specification.Table 3-18-1 Confirmation of setting menu(2/2)


Field set F I E L d29) Set of cooling water temp. at maximum input C o - I n. P 3 2. 030) Set of slow open time I n P - t n. 0 0 0 0 S31) Set of slow open temperature I n P t n. P 0 0 0 o C32) Set of dilution time d I L u - t 0 4 n.33) Set of remote signal type r - S I G n S t A t I C34) Set of type of pulse o F - P L S P o S I t I

35) Set of low select control temperature L o S E L E o C Invalid36) Set of radiation temperature H E I I - S t o C Invalid

Set of RS-485 r S - 4 8 544) Set of address A d d 4 8 5 0 Invalid

Indication of version number V E r 0. 0 045) No-sub menu V E r 0. 9 1

Indication of version number o P V 0. 0 0of option board

46) No-sub menu o P V 0. 0 0



3-18-2A. Confirmation of service mode (LJ) Confirm setting value to be necessary for normal operation. There are three steps as following to.




3 7. 0


1st step : Service mode 2nd step : Setting sub menu or changeC H G S

I I 2 P u r G E A u t o

r E F - P o F F


n. o d E L I d 0 0 0 0 0 0

t Y P E

I

I L

I

I 0Other setting menu.


2 sec.

2 sec.

2 sec.

2 sec.

Press 2 keys for 2 sec.simultaneously

orIf set ischanged,

2 sec.

2 sec.


: The setting value vary based on the specification.Table 3-18-2 Confirmation of service mode(1/3)


Change of switch2 C H G S

I I 21) Purge P u r G E A u t o2) Run/Stop changeover of refrigerant pump r E F - P A u t o3) Pilot test setting P I L o t A u t o Invalid4) Control valve operation changeover 1 C n. - 1 A u t o5) Control valve opening 1 C n. - 1 S t 06) Control valve operation changeover 2 C n. - 2 A u t o Invalid7) Control valve opening 2 C n. - 2 S t 0 Invalid8) Control valve operation changeover 3 C n. - 3 A u t o Invalid9) Control valve opening 3 C n. - 3 S t 0 Invalid

10) Set of HBS address A d d H b S 011) High speed timer function (60 times) b A I S o K o F F12) Initializing of operation data o P - r S t 3

Model setting n. o d E L13) Set of serial number I d 0 0 0 0 0 014) Set of type t Y P E

I

I L

I

I 015) Set of control method C o n t I o C H - o u t16) Set of annual cooling operation A - C o o L o F F17) Set of automatic cooling/heating changeover C H A u t o n. A n u A L18) Set of process use P r o C o F F19) Set of purge pump installation n. P - o P o n20) Set of oil pump installation o P - o P o F F Invalid

Specification setting S P E C21) Set of chilled water outlet temperature C - t E n. P 6. 0 o C22) Set of hoe water outlet temperature H - t E n. P Invalid23) Set of chilled water temperature difference C - d t 5. 0 o C24) Set of hot water temperature difference H - d t Invalid25) No use S I n G - K Invalid26) Set of maximum operating of control valve r A n K u P 1 0 0. 027) Set of purge indication lamp on A P - S t 1 0. 0 K P A28) Set of purge indication lamp off A P - S P 7. 0 K P A29) Set of purge tank pump running time A P - t I n. Invalid30) Exhaust gas bedewing prevention temperature E I I C o n d Invalid31) Set of crystallization temperature L E C r Y S Invalid

Input setting I n P u t32) Set of control type b n t Y P E P I d33) Set of input correction I P t C o r 5 034) Set of combustion interval F - I n t 0 0 n.

Inverter setting I n V S E t Invalid





PID setting P I d S E t35) Set of proportional in cooling C o o L - P 1 0. 036) Set of integral in cooling C o o L - I 2 5 037) Set of derivative in cooling C o o L - d 038) Set of proportional in heating H E A t - P 1 0. 039) Set of integral in heating H E A t - I 2 5 040) Set of derivative in heating H E A t - d 041) Set of sampling interval S A n. P L E 1 0

Operation hours and number of C o u n ttimes setting

42) Unit operating hours u n I t - t 0 0 0 0 0 043) Absorbent pump 1 operation hours A b S 1 - t 0 0 0 0 0 044) Absorbent pump 2 operation hours A b S 2 - t Invalid45) Combustion hours F I r E - t Invalid46) Refrigerant pump operation hours r E F - t 0 0 0 0 0 047) No use P u r G - t Invalid48) Unit number of times u n I t - C 0 0 0 0 0 049) Absorbent pump 1 number of times A b S 1 - C 0 0 0 0 0 050) Absorbent pump 2 number of times A b S 2 - C Invalid51) Combustion number of times F I r E - C Invalid52) Refrigerant pump number of times r E F - C 0 0 0 0 0 053) No use P u r G - C Invalid

Prediction function setting S I G n S t54) Debasement of vacuum level P u r G E o n55) Rise of absorbent solution concentration t H I C K o F F56) Foul of cooling water C o - d I r o n57) High temperature of cooling water C o - H I o n58) Foul of combustion chamber C C - d I R o n59) Antifreeze r u L E - I o F F60) Low temperature of exhaust gas E I I G - L o o n61) Reset of predication function r E - S E t 3

Burner controller setting P r Y InvalidSensor setting S E n S o r

62) Set of chilled water outlet temperature offset C H o A d J 0. 063) Set of chilled water inlet temperature offset C H I A d J 0. 064) Set of cooling water outlet temperature offset C o o A d J 0. 065) Set of cooling water inlet temperature offset C o I A d J 0. 066) Set of hot water outlet temperature offset H o A d J 0. 0 Invalid67) Set of hot water inlet temperature offset H I A d J 0. 0 Invalid68) Set of addition sensor S E n - o P 1 1 1 0 0 0





Analog data display A n A L o G69) High temperature generator (Generator) temperature 6 0. 070) Chilled water inlet temperature 1 2. 1 1. 971) Chilled water outlet temperature 1 3. 6. 872) Cooling water inlet temperature 1 4. 3 1. 873) Condenser temperature 1 5. 3 4. 774) Steam drain/exhaust gas temperature 1 6. Invalid75) Purge tank pressure 1 6. 8. 576) Low temperature generator temperature 1 8. Invalid77) Cooling water middle temperature 1 9. 3 3. 578) Cooling water outlet temperature 2 0. 3 7. 179) Steam drain temperature 2 1. Invalid80) Refrigerant temperature 2 2. 5. 981) Diluted solution absorber outlet temperature 2 3. 2 7. 882) Inverter frequency 2 4. Invalid83) Control valve opening output 2 5. 9 6. 584) Control valve opening input 2 6. 9 6. 285) Control valve opening output for electro pneumatic type 2 7. 9 6. 586) Concentrated solution concentration 2 8. 6 3. 287) Diluted solution concentration 2 9. 5 8. 588) Remote control for chilled water outlet temp. 3 0. 4. 089) No use 3 1. Invalid90) No use 3 2. Invalid91) Diluted solution Low tem. heat exchanger outlet 3 3. Invalid92) Level of foul of cooling water 3 4. Invalid93) Level of debasement of vacuum level 3 5. Invalid94) Hot water inlet temperature 3 6. 8 5. 995) Hot water outlet temperature 3 7. 8 1. 196) Hot water outlet temperature 3 8. 8 1. 197) No use 3 9. Invalid98) No use 4 0. Invalid99) No use 4 1. Invalid

100) No use 4 2. Invalid101) No use 4 3. Invalid102) No use 4 4. Invalid103) No use 4 5. Invalid104) No use 4 6. Invalid105) No use 4 7. Invalid106) No use 4 8. Invalid107) No use 4 9. Invalid108) No use 5 0. Invalid109) No use 5 1. Invalid110) No use 5 2. Invalid111) No use 5 3. Invalid

Digital input d I G I - I InvalidDigital output d I G I - o InvalidControl state C o t n o

I I Invalid



3-18-2B. Confirmation of service mode (TJ) Confirm setting value to be necessary for normal operation. There are three steps as following to.




3 7. 0


1st step : Service mode 2nd step : Setting sub menu or changeC H G S

I I 2 P u r G E A u t o

r E F - P o F F


n. o d E L I d 0 0 0 0 0 0

t Y P E

I

I L

I

I 0Other setting menu.


2 sec.

2 sec.

2 sec.

2 sec.

Press 2 keys for 2 sec.simultaneously

orIf set ischanged,

2 sec.

2 sec.




Change of switch2 C H G S

I I 21) Purge P u r G E A u t o2) Run/Stop changeover of refrigerant pump r E F - P A u t o3) Pilot test setting P I L o t A u t o Invalid4) Control valve operation changeover 1 C n. - 1 A u t o5) Control valve opening 1 C n. - 1 S t 06) Control valve operation changeover 2 C n. - 2 A u t o Invalid7) Control valve opening 2 C n. - 2 S t 0 Invalid8) Control valve operation changeover 3 C n. - 3 A u t o Invalid9) Control valve opening 3 C n. - 3 S t 0 Invalid

10) Set of HBS address A d d H b S 011) High speed timer function (60 times) b A I S o K o F F12) Initializing of operation data o P - r S t 3

Model setting n. o d E L13) Set of serial number I d 0 0 0 0 0 014) Set of type t Y P E

I

I S

I

I 015) Set of control method C o n t I o C H - o u t16) Set of annual cooling operation A - C o o L o F F17) Set of automatic cooling/heating changeover C H A u t o n. A n u A L18) Set of process use P r o C o F F19) Set of purge pump installation n. P - o P o n20) Set of oil pump installation o P - o P o F F Invalid

Specification setting S P E C21) Set of chilled water outlet temperature C - t E n. P 6. 0 o C22) Set of hot water outlet temperature H - t E n. P Invalid23) Set of chilled water temperature difference C - d t 5. 0 o C24) Set of hot water temperature difference H - d t Invalid25) No use S I n G - K Invalid26) Set of maximum operating of control valve r A n K u P 1 0 0. 027) Set of purge indication lamp on A P - S t 1 0. 0 K P A28) Set of purge indication lamp off A P - S P 7. 0 K P A29) Set of purge tank pump running time A P - t I n. Invalid30) Exhaust gas bedewing prevention temperature E I I C o n d Invalid31) Set of crystallization temperature L E C r Y S Invalid

Input setting I n P u t32) Set of control type b n t Y P E P I d33) Set of input correction I P t C o r 5 034) Set of combustion interval F - I n t 0 0 n.

Inverter setting I n V S E t Invalid





PID setting P I d S E t35) Set of proportional in cooling C o o L - P 1 0. 036) Set of integral in cooling C o o L - I 2 5 037) Set of derivative in cooling C o o L - d 038) Set of proportional in heating H E A t - P 1 0. 039) Set of integral in heating H E A t - I 2 5 040) Set of derivative in heating H E A t - d 041) Set of sampling interval S A n. P L E 1 0

Operation hours and number of C o u n ttimes setting

42) Unit operating hours u n I t - t 0 0 0 0 0 043) Absorbent pump 1 operation hours A b S 1 - t 0 0 0 0 0 044) Absorbent pump 2 operation hours A b S 2 - t Invalid45) Combustion hours F I r E - t Invalid46) Refrigerant pump operation hours r E F - t 0 0 0 0 0 047) No use P u r G - t Invalid48) Unit number of times u n I t - C 0 0 0 0 0 049) Absorbent pump 1 number of times A b S 1 - C 0 0 0 0 0 050) Absorbent pump 2 number of times A b S 2 - C Invalid51) Combustion number of times F I r E - C Invalid52) Refrigerant pump number of times r E F - C 0 0 0 0 0 053) No use P u r G - C Invalid

Prediction function setting S I G n S t54) Debasement of vacuum level P u r G E o n55) Rise of absorbent solution concentration t H I C K o F F56) Foul of cooling water C o - d I r o n57) High temperature of cooling water C o - H I o n58) Foul of combustion chamber C C - d I R o n59) Antifreeze r u L E - I o F F60) Low temperature of exhaust gas E I I G - L o o n61) Reset of predication function r E - S E t 3

Burner controller setting P r Y InvalidSensor setting S E n S o r

62) Set of chilled water outlet temperature offset C H o A d J 0. 063) Set of chilled water inlet temperature offset C H I A d J 0. 064) Set of cooling water outlet temperature offset C o o A d J 0. 065) Set of cooling water inlet temperature offset C o I A d J 0. 066) Set of hot water outlet temperature offset H o A d J 0. 0 Invalid67) Set of hot water inlet temperature offset H I A d J 0. 0 Invalid68) Set of addition sensor S E n - o P 1 1 1 0 0 0





Analog data display A n A L o G69) High temperature generator (Generator) temperature 6 0. 070) Chilled water inlet temperature 1 2. 1 1. 971) Chilled water outlet temperature 1 3. 6. 872) Cooling water inlet temperature 1 4. 3 1. 873) Condenser temperature 1 5. 3 4. 774) Steam drain/exhaust gas temperature 1 6. 6 0. 075) Purge tank pressure 1 6. 8. 576) Low temperature generator temperature 1 8. Invalid77) Cooling water middle temperature 1 9. 3 3. 578) Cooling water outlet temperature 2 0. 3 7. 179) Steam drain temperature 2 1. 6 0. 080) Refrigerant temperature 2 2. 5. 981) Diluted solution absorber outlet temperature 2 3. 2 7. 882) Inverter frequency 2 4. Invalid83) Control valve opening output 2 5. 9 6. 584) Control valve opening input 2 6. 9 6. 285) Control valve opening output for electro pneumatic type 2 7. 9 6. 586) Concentrated solution concentration 2 8. 6 3. 287) Diluted solution concentration 2 9. 5 8. 588) Remote control for chilled water outlet temp. 3 0. 4. 089) No use 3 1. Invalid90) No use 3 2. Invalid91) Diluted solution Low tem. heat exchanger outlet 3 3. Invalid92) Level of foul of cooling water 3 4. Invalid93) Level of debasement of vacuum level 3 5. Invalid94) Hot water inlet temperature 3 6. Invalid95) Hot water outlet temperature 3 7. Invalid96) Hot water outlet temperature 3 8. Invalid97) No use 3 9. Invalid98) No use 4 0. Invalid99) No use 4 1. Invalid

100) No use 4 2. Invalid101) No use 4 3. Invalid102) No use 4 4. Invalid103) No use 4 5. Invalid104) No use 4 6. Invalid105) No use 4 7. Invalid106) No use 4 8. Invalid107) No use 4 9. Invalid108) No use 5 0. Invalid109) No use 5 1. Invalid110) No use 5 2. Invalid111) No use 5 3. Invalid

Digital input d I G I - I InvalidDigital output d I G I - o InvalidControl state C o t n o

I I Invalid



3-19A. Function test of modulating controls (LJ)

Insure that the unit is still in the "Dry run" mode with hot water control valve disabled.With the unit in the "Dry run" mode on the hot water valve should automatically drive to a full openposition(100% fire rate). The hot water valve should also respond to the 0 through 100 on the operationboard. Insure that the valve stroking is smooth and full close the valve seats properly. Because thehot water valve has not been adjusted for full load water flow, the operation board should be adjustedto prevent 100% hot water rate during the aging and hot water valve adjustment procedure. This can beaccomplished by accessing special function item "RunkuP" on the operation board. Decrease the "RunkuP" value to 50% to prevent the hot water valve from driving to full open during the aging and hotwater flow rate tests. Confirm the hot water valve responds to this adjustment via the electric controller special item "Cn.-1St".

1. How to change the hot water valve full opening set value is from 100% to 50%.

3 5. 0 High temperature generator temperature (example).Push "SET" and " " keys for 2 sec..

C H G S

I I 2Push " " or " " key.

S P E C Push "SET" key for 2 sec..

C - t E n. PPush " " or " " key.

r A n k u PPush "SET" key for 2 sec..

1 0 0. 0Push " " key.

5 0. 0Push "SET" key for 2 sec..

To be continued.


2. How to change the hot water valve opening set value by manual.This work is able to do during unit running.

3 5. 0 High temperature generator temperature (example).Push "SET" and " " keys for 2 sec..

C H G S

I I 2Push "SET" key for 2 sec..

P u r G E Push " " or " " key.

C n. - 1Push "SET" key for 2 sec..

A u t oPush " " or " " key.

n. A n u A LPush "SET" key for 2 sec..

C n. - 1Push " " key.

C n. - 1 S tPush "SET" key for 2 sec..

3 8 Data display appears valve opening by %.Push " " key, and push "SET" key, the valve is close.Push " " key, and push "SET" key, the valve is open.

Note: The set value cannot change in "Cn.-1St" more than "rAnkuP" .Important: When you will finish this procedure, you have to remove from "n.AnuaL" to " Auto".


3-19B. Function test of modulating controls (TJ)

Insure that the unit is still in the "Dry run" mode with steam control valve disabled.With the unit in the "Dry run" mode on the steam valve should automatically drive to a full openposition(100% fire rate). The steam valve should also respond to the 0 through 100 on the operationboard. Insure that the valve stroking is smooth and full close the valve seats properly. Because thesteam valve has not been adjusted for full load steam flow, the operation board should be adjustedto prevent 100% steam rate during the aging and steam valve adjustment procedure. This can beaccomplished by accessing special function item "RunkuP" on the operation board. Decrease the "RunkuP" value to 50% to prevent the steam valve from driving to full open during the aging andsteam flow rate tests. Confirm the steam valve responds to this adjustment via the electric controller special item "Cn.-1St".

1. How to change the steam valve full opening set value is from 100% to 50%.

3 5. 0 Generator temperature (example).Push "SET" and " " keys for 2 sec..

C H G S

I I 2Push " " or " " key.

S P E C Push "SET" key for 2 sec..

C - t E n. PPush " " or " " key.

r A n k u PPush "SET" key for 2 sec..

1 0 0. 0Push " " key.

5 0. 0Push "SET" key for 2 sec..

To be continued.


2. How to change the steam valve opening set value by manual.This work is able to do during unit running.

3 5. 0 Generator temperature (example).Push "SET" and " " keys for 2 sec..

C H G S

I I 2Push "SET" key for 2 sec..

P u r G E Push " " or " " key.

C n. - 1Push "SET" key for 2 sec..

A u t oPush " " or " " key.

n. A n u A LPush "SET" key for 2 sec..

C n. - 1Push " " key.

C n. - 1 S tPush "SET" key for 2 sec..

3 8 Data display appears valve opening by %.Push " " key, and push "SET" key, the valve is close.Push " " key, and push "SET" key, the valve is open.

Note: The set value cannot change in "Cn.-1St" more than "rAnkuP" .Important: When you will finish this procedure, you have to remove from "n.AnuaL" to " Auto".


3-20. Aging process

The most important reason for the aging process is to remove any air that may have entered the unitduring the solution charging process. By continuing operation at low fire, the solutions will heat upcausing any entrained air to bubble out of the solutions and be easily removed by the purge pump.During the entire aging process the purge pump should be operating and purge valves V1 and V3opened. Connect the vacuum gauge to SV2, and it can also be opened to monitor the vacuum conditionof the lower shell.

1. Run the purge pump.2. The set value of "rAnkuP" should change "0"(zero) in accordance with Section 3-19.3. Run the chiller approximately 3-4 hours.4. Monitor the condition of the purge pump oil and change as required.5. Utilizing a small amount of ballast will extend the life of each oil charge.6. Adjust the set value of "rAnkuP" between "20" and "30" in accordance with Section 3-19 in order to limit the heat input to approximately 20 percent of the rated value.7. Monitor the condition of the purge pump oil and change as required.8. Utilizing a small amount of ballast will extend the life of each oil charge.9. As the unit will be chilling the evaporator loop, closely monitor leaving chilled water temperature to prevent the possibility of over chilling.

Typically the aging process will take approximately 3-4 hours depending on unit size and the amountof air that entered during solution charging. The aging process will be complete only when the unitpasses a bubble test thus insuring that all air has been removed.

Note: If the refrigerant pump is stop and appear "J-10" on the operation board, the reset button of the refrigerant pump overload relay mounted contactor sticks out. In this case, more increase the refrigerant pump overload relay set value, push the refrigerant pump overload relay reset button, push "STOP" button on the operation board. Then run chiller again.10. Remove the refrigerant pump overload relay set value in accordance with the name plate of the refrigerant pump.


3-21. Refrigerant Blow down

During the transportation, the absorbent solution and refrigerant are mixed, the unit will manufacturenew pure refrigerant to replace it (refrigerant blow down).1. Make sure the refrigerant pump is running and also the solution level is visible through the sight glass of the evaporator.2. Open the refrigerant blow valve completely.3. When solution level becomes invisible, close the refrigerant blow valve tightly.4. Repeat steps 1, 2, and 3 until the refrigerant contains less than 3% LiBr be taking a refrigerant sample. Refer to Section 6-8.

Fig. 3-21 Refrigerant blow valve


3-22A. Preparation of trial run (LJ)

At this point of the trial run procedures the unit should be:1. Unit and auxiliary equipment operating in an automatic mode.2. Hot water valve adjusted for design input.3. Refrigerant in the evaporator less than 3% LiBr.4. Chilled, cooling, and hot water flows at design.5. Chilled, cooling, and hot water temperatures at design.6. Confirm valves position.

It will now be required to achieve a stable full load operation for a minimum of two hours to take a fullset of operation data and complete the equipment trial run data sheets. The full load test is required to(1) insure the unit is performing at its design capacity, and (2) insure that solution concentrations,and operating temperatures are within normal operating parameters. Use the following typical operatingconditions to compare actual recorded conditions. These typical conditions should be used as referenceonly, to detect gross differences in actual operation. Once full load operation has been achieved, recordthe operating data on the trial run data sheets, sign the unit over to the customer, and forward a copy ofthe trial run data sheets to the Service Department.

Table 3-22-1 Typical operating conditions LJ unit Item Location Unit1 Chilled water inlet 12.2oC (54oF)2 Chilled water outlet 6.7oC (44oF)3 Cooling water inlet 29.4oC (85oF)4 Cooling water outlet 38.4oC (101.2oF)5 Hot water inlet 95.0oC (203oF)6 Hoe water outlet 86.0oC (186.8oF)7 Dilute solution (Absorber outlet) 35.1oC (95.2oF)8 Concentrated solution (Generator outlet) 85.6oC (186.1oF)9 Diluted solution concentration (Absorber outlet) 55%

10 Concentrated solution concentration (Generator outlet) 59.5%

Table 3-22-2 Valve positionValve name Position Valve name Position Valve name Position

B Open V1 CloseSV1 Close V2 OpenSV2 Close V3 CloseSV3 CloseSV4 CloseSV6 CloseSV7 OpenSV9 Close

Open

OpenCloseRefrigerant

blow valve

Absorbent pumpisolation valves

Refrigerant pumpisolation valves


3-22B. Preparation of trial run (TJ)

At this point of the trial run procedures the unit should be:1. Unit and auxiliary equipment operating in an automatic mode.2. Hot water valve adjusted for design input.3. Refrigerant in the evaporator less than 3% LiBr.4. Chilled water, cooling water, and steam flows at design.5. Chilled water and cooling water temperatures at design.6. Steam pressure at design.7. Confirm valves position.

It will now be required to achieve a stable full load operation for a minimum of two hours to take a fullset of operation data and complete the equipment trial run data sheets. The full load test is required to(1) insure the unit is performing at its design capacity, and (2) insure that solution concentrations,and operating temperatures are within normal operating parameters. Use the following typical operatingconditions to compare actual recorded conditions. These typical conditions should be used as referenceonly, to detect gross differences in actual operation. Once full load operation has been achieved, recordthe operating data on the trial run data sheets, sign the unit over to the customer, and forward a copy ofthe trial run data sheets to the Service Department.

Table 3-22-1 Typical operating conditions TJ unit Item Location Unit1 Chilled water inlet 12.2oC (54oF)2 Chilled water outlet 6.7oC (44oF)3 Cooling water inlet 29.4oC (85oF)4 Cooling water outlet 38.4oC (101.2oF)5 Steam drain outlet 95.0oC (203oF)6 Dilute solution (Absorber outlet) 35.1oC (95.2oF)7 Concentrated solution (Generator outlet) 85.6oC (186.1oF)8 Diluted solution concentration (Absorber outlet) 56.7%9 Concentrated solution concentration (Generator outlet) 63.2%

Table 3-22-2 Valve positionValve name Position Valve name Position Valve name Position

B Open V1 CloseSV1 Close V2 OpenSV2 Close V3 CloseSV3 CloseSV4 CloseSV6 CloseSV7 OpenSV9 Close

Open

OpenCloseRefrigerant

blow valve

Absorbent pumpisolation valves

Refrigerant pumpisolation valves


3-23A. Trial run (LJ)

Trial run data sheet 1/2Project name :Chiller model :TSA-16LJ-Serial number :Accepted by : , dateReviewed by : , dateRecorded by : , date

Unit Model / Serial No. Operator : Date : / /

time: time: time:Ambient temperatureRoom temperatureChilled water inlet temperatureChilled water outlet temperatureChilled water inlet pressureChilled water outlet pressurePressure drop in evaporatorChilled water flow rateCooling water inlet temperatureCooling water outlet temperatureCooling water inlet pressureCooling water outlet pressurePressure drop in absorber & condenserCooling water flow rateHot water inlet temperatureHot water outlet temperatureHot water inlet pressureHot water outlet pressurePressure drop in generatorHot water flow rateGenerator temperatureSolution level in evaporator

Pressure in purge tank

DATA-1 DATA-2 DATA-3Spec.No. Data items Unit

kPa / psi

oC / oFoC / oFoC / oFoC / oF

kPa / psikPa / psi

m3/h / gpmoC / oFoC / oF

kPa / psikPa / psikPa / psi


kPa / psikPa / psikPa / psil/s / gpm

oC / oFn/60 mmn/2-3/8"

kPa

12345678910111213141516171819

23

202122


Trial run data sheet 2/2Project name :Chiller model :TSA-16LJ-Serial number :Accepted by : , dateReviewed by : , dateRecorded by : , date


time: time: time:%-

oC / oFConcentration of diluted solution %

25 Specific gravity of diluted solution -Temperature of diluted solution oC / oFConcentration of refrigerant %

26 Specific gravity of refrigerant -Temperature of refrigerant oC / oF

27 Condensed refrigerant temperature oC / oF28 *LTD (See below) oC / oF29 Absorbent pump current A30 Refrigerant pump current A31 Purge pump current A

*LTD = Condensed refrigerant temp. - Cooling water outlet temperature

Memo

24Concentration of concentrated solutionSpecific gravity of concentrated solution

Temperature of concentrated solution

No. Data items DATA-3Unit Spec. DATA-1 DATA-2


3-23B. Trial run (TJ)

Trial run data sheet 1/2Project name :Chiller model :TSA-16TJ-Serial number :Accepted by : , dateReviewed by : , dateRecorded by : , date


time: time: time:Ambient temperatureRoom temperatureChilled water inlet temperatureChilled water outlet temperatureChilled water inlet pressureChilled water outlet pressurePressure drop in evaporatorChilled water flow rateCooling water inlet temperatureCooling water outlet temperatureCooling water inlet pressureCooling water outlet pressurePressure drop in absorber & condenserCooling water flow rateSteam consumptionSupply steam pressureSupply steam temperatureGenerator temperatureSolution level in evaporator

Pressure in purge tank

DATA-1 DATA-2 DATA-3Spec.No. Data items Unit

kPa / psi


kPa / psikPa / psi


kPa / psikPa / psikPa / psi

oC / oF

m3/h / gpmkg/h / lb/hkPa / psi

oC / oF

n/60 mmn/2-3/8"

kPa

1234567891011

1617

12131415

20

1819


Trial run data sheet 2/2Project name :Chiller model :TSA-16TJ-Serial number :Accepted by : , dateReviewed by : , dateRecorded by : , date


time: time: time:%-

oC / oFConcentration of diluted solution %

22 Specific gravity of diluted solution -Temperature of diluted solution oC / oFConcentration of refrigerant %

23 Specific gravity of refrigerant -Temperature of refrigerant oC / oF

24 Condensed refrigerant temperature oC / oF25 *LTD (See below) oC / oF26 Absorbent pump current A27 Refrigerant pump current A28 Purge pump current A

*LTD = Condensed refrigerant temp. - Cooling water outlet temperature

Memo

21Concentration of concentrated solutionSpecific gravity of concentrated solution

Temperature of concentrated solution

No. Data items DATA-3Unit Spec. DATA-1 DATA-2


3-24A. Daily maintenance (LJ)

Proper maintenance of the unit will insure continuous, efficient, and trouble-free operation prolongequipment life and reducing service requirements. Daily maintenance should be performed by building maintenance personnel. Maintenance of auxiliary equipment is equally important and shouldbe handled according to the manufacturers specifications.

1. Check and record operating data per daily operating record sheet, temperatures, pressures, water flow rate, etc. Refer to Table 3-24.2. Make the following inspections:

a. Abnormal noise from absorbent pump.b. Abnormal noise from refrigerant pump.c. Auxiliary equipment is in proper working order.d. Cooling tower water is being treated properly.

3. Review previous and present operating data for any difference in operating conditions that develop into a problem or maintenance issue.To be continued.


Table 3-24 Daily log data sheetUnit Model / Serial No. Operator : Date : / /

time: time: time:Ambient temperatureRoom temperatureChilled water inlet temperatureChilled water outlet temperatureChilled water inlet pressureChilled water outlet pressurePressure drop in evaporatorChilled water flow rateCooling water inlet temperatureCooling water outlet temperatureCooling water inlet pressureCooling water outlet pressurePressure drop in absorber & condenserCooling water flow rateHot water inlet temperatureHot water outlet temperatureHot water inlet pressureHot water outlet pressurePressure drop in generatorHot water flow rateGenerator temperatureSolution level in evaporator

Pressure in purge tankCheck : Absorbent pump noise Refrigerant pump noise

Notes:

232425

202122

16171819

12131415

891011

n/60 mmn/2-3/8"

kPa

1234567

kPa / psikPa / psil/s / gpm

oC / oF


kPa / psi

oC / oFkPa / psikPa / psikPa / psi

kPa / psikPa / psi

m3/h / gpmoC / oF

No. Data items Unit

kPa / psi


DATA-1 DATA-2 DATA-3Spec.


3-24B. Daily maintenance (TJ)

Proper maintenance of the unit will insure continuous, efficient, and trouble-free operation prolongequipment life and reducing service requirements. Daily maintenance should be performed by building maintenance personnel. Maintenance of auxiliary equipment is equally important and shouldbe handled according to the manufacturers specifications.

1. Check and record operating data per daily operating record sheet, temperatures, pressures, water flow rate, etc. Refer to Table 3-24.2. Make the following inspections:

a. Abnormal noise from absorbent pump.b. Abnormal noise from refrigerant pump.c. Auxiliary equipment is in proper working order.d. Cooling tower water is being treated properly.

3. Review previous and present operating data for any difference in operating conditions that develop into a problem or maintenance issue.To be continued.


Table 3-24 Daily log data sheetUnit Model / Serial No. Operator : Date : / /

time: time: time:Ambient temperatureRoom temperatureChilled water inlet temperatureChilled water outlet temperatureChilled water inlet pressureChilled water outlet pressurePressure drop in evaporatorChilled water flow rateCooling water inlet temperatureCooling water outlet temperatureCooling water inlet pressureCooling water outlet pressurePressure drop in absorber & condenserCooling water flow rateSteam consumptionSupply steam pressureSupply steam temperatureGenerator temperatureSolution level in evaporator

Pressure in purge tankCheck : Absorbent pump noise Refrigerant pump noise

Notes:

2425

2122

151617

23

11121314

78910

3456

oC / oFn/60 mmn/2-3/8"

kPa

m3/h / gpmkg/h / lb/hkPa / psi

oC / oF

oC / oFkPa / psikPa / psikPa / psi

kPa / psikPa / psi

m3/h / gpmoC / oF

No. Data items Unit

kPa / psi


12

DATA-1 DATA-2 DATA-3Spec.


Section 4A Control (LJ)

The control of TSA-16LJ series consists of the following functions.

(1) Operation (Start & Stop)

(2) Safety stop (Alarm) with safety devices & safety functions

(3) Cooling capacity control with avoidance for alarms

(4) Data display

Construction of devices to achieve theses function is as follows

Fig. 4-1

Control panel

Microprocessor(CPU)

Operation board

Run key

Stop key

Display

Lamps

63GH : Generator pressure switch

69PR : Purge tank pressure switch

69CH : Chilled water flow switch

DT1 : Chilled water outlet temp. sensor

DT3 : Generator temp. sensor

DT2 : Cooling water outlet temp. sensor

DT5 : Condenser temp. sensor

DT6 : Chilled water inlet temp. sensor

DT7 : Cooling water inlet temp. sensor

DT10 : Absorber temp. sensor

DT11 : Evaporator temp. sensor

DT12 : Middle cooling water temp. sensor

DT14 : Hot water outlet temp. sensor

DT15 : Hot water inlet temp. sensor

DT16 : Hot water outlet temp. sensor


4-1. Operation

4-1-1. Run of the chiller

The sequence of starting the chiller is as follow.

Remark :The following sequence is in case of using the interlock system provided in the chiller control circuit.

Fig. 4-2

Push RUN key on the operation boardor

Remote start signal

Chilled water pump starts signal goesto chilled water pump operation circuitfrom chiller control circuit

Chilled water pumpstarts

ON signal of 69CHreturns to chiller control

Chilled water pump interlocksignal

Cooling water pump starts signal goesto cooling water pump operation circuitfrom chiller control circuit

Cooling water pumpstarts

Cooling water pump interlocksignalcooling water fan circuit

works

Chiller runs

YES

No

YES

No

Contact of chilled waterflow switch opens

YES

No J-03After 10 min., Chilledwater flow rate alarm

Chilled water temp. is above2.5 deg.C (36.5 deg.F)

YES

No J-01After 10 min., Chilledwater low temp. alarm

J-02After 10 min., Chilled

water pump alarm

YES

NoJ-03

After 10 min., Chilledwater flow rate alarm

J-06After 10 min., Cooling

water pump alarm

Hot water pump starts


4-1-2. Stop of the chiller

The sequence of stopping the chiller is as follow.

Fig. 4-3

The time chart of stop sequence is as follows.

Fig. 4-4


Remote start signal

After 1 minute, the refrigerantpump stops

Hot water control valve travels toclose

After 1minute, the cooling waterpump stops

After 1 minute, the chilled waterpump stops

After 1minute, the chiller stopsentirely

Dilu

tion

oper

atio

n

After 1 minute, hot water pump stops

Hot water control valve

Refrigerant pump

Cooling water pump

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOP

RUN

STOP

1 min.1 min.1 min.

Entiret

Stop signal

Hot water pump

RUN

STOP


4-2. Safety stop (Alarm)

Following safety stops are provide on TSA-16LJ series.Purpose Name of Alarm Stop condition

J-01 Chiller and cooling water pump stop immediately without dilution operation



J-20 Chiller stops after dilution operation

J-06 Chiller stops after dilution operation. But refrigerant pump stops immediately





J-04 Dilution operation without running absorbent & refrigerant pump is proceeding


J-12 Purge pump only stops

(1) Name of alarm : Chilled water low temp. alarm (Symbol : J-01)

Condition of work : If chilled water outlet temp. is 2.5 deg.C (36.5 deg.F) for 2 seconds at starting chiller If chilled water outlet temp. goes down to 2.5 deg.C (36.5 deg.F) for 2 seconds during operation

Time chart at alarm happened during operation

Fig.4-5

(2) Name of alarm : Chilled water pump alarm (Symbol : J-02)

Condition of work : If chilled water pump dose not start after 10 minutes of receiving the start signal

If chilled water pump stops during operation of chiller

Time chart at alarm happened during operation : Same as J-01

(3) Name of alarm : Chilled water flow rate alarm (Symbol : J-03)

Condition of work : If chilled water flow rate is below 50 % of rated flow rate at starting chiller

If chilled water flow rate goes down below 50 % of rated flow rate during operation


Purge pump alarm

Generator high pressure alarmHigh concentration alarm#1 Absorbent pump alarmRefrigerant pump alarm

Chi

lled

wat

erfre

eze

prot

ectio

n

Cry

stal

lizat

ion

prot

ectio

nM

otor

prot

ectio

nSymbol

Cooling water pump alarmCooling water flow rate alarmGenerator high temp. alarm

Chilled water low temp. alarmChilled water pump alarmChilled water flow rate alarmCooling water low temp. alarm


Refrigerant pump

Cooling water pump

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOP

RUN

STOP2 min.1 min.

Entire stopAlarm happens

Hot water pumpRUN

STOP


(4) Name of alarm : Cooling water low temp. alarm (Symbol : J-20)

Condition of work : If cooling water inlet temperature does not rise up to the temperature shown in Fig. 4-6 after 30 minutes of starting chiller or the temperature continues for 30 minutes during operation

Fig. 4-6

Time chart at alarm happened during operation : Same as Fig. 4-4.

(5) Name of alarm : Cooling water pump alarm (Symbol : J-06)

Condition of work : If cooling water pump dose not start after 10 minutes of receiving the start signal

If cooling water pump stops during operation of chiller


Fig. 4-7

(6) Name of alarm : Cooling water flow rate alarm (Symbol : J-07)OPTIONCondition of work : If cooling water flow rate is below 50 % of rated flow rate at starting chiller

If cooling water flow rate goes down below 50 % of rated flow rate during operation

Time chart at alarm happened during operation : Same as Fig. 4-7

32 deg.C(89.6 deg.F)

20 deg.C(68 deg.F)



Cooling water low temp. alarmwatched temperature

Specified cooling water inlet temperature

Refrigerant pump

Cooling water pump

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOP

RUN

STOP1 min.1 min.


Hot water pumpRUN

STOP

1 min.



(7) Name of alarm : Generator high temp. alarm (Symbol : J-13)

Condition of work : If generator temperature goes up to 95 deg.C (203 deg.F) during operation


(8) Name of alarm : Generator high pressure alarm (Symbol : J-14)

Condition of work : If generator pressure goes up to 0 MPa (0 psig) during operation


(9) Name of alarm : High concentration alarm (Symbol : J-16)

Condition of work : If concentration of concentrated LiBr solution goes up to 65 % at just 3 minutes

after starting crystallization protection control

If concentration of concentrated LiBr solution goes up to 65 % within 1 hour


If concentration of concentrated LiBr solution goes up to 65.5 %


(10) Name of alarm : #1 absorbent pump alarm (Symbol : J-04)

Condition of work : If #1 absorbent pump thermalrelay (51A1) works at starting chiller and during operation


Fig. 4-8

(11) Name of alarm : Refrigerant pump alarm (Symbol : J-10)

Condition of work : If Refrigerant pump thermalrelay (51R) works at starting chiller and during operation

Time chart at alarm happened during operation : Same as Fig. 4-4 except for the refrigerant pump

(12) Name of alarm : Purge pump alarm (Symbol : J-12)

Condition of work : If purge pump thermalrelay (51P) works

The purge pump only stops. This alarm dose not affect to operation. But, if the purge

pump stops during purging, manual purge valves shall be closed immediately.

Refrigerant pump

Cooling water pump

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOP

RUN

STOP1 min.1 min.


Hot water pumpRUN

STOP

1 min.



4-3. Capacity control

The capacity control of TSA-16LJ series is PID control. A signal of chilled water outlet temperature detected

by DT1 is sent to a microprocessor then the signal control a hot water control valve to control cooling capacity.

In addition to the PID control, there are following control functions to smooth the control.

(1) Hot water control valve slow open function

(2) Crystallization protection function during low cooling water temperature & Generator high temp. alarm

protection function during high cooling water temperature

(3) Operation continuing function at high generator temperature condition

(4) Chilled water freeze protection function by On/OFF of refrigerant pump

(5) Auto-rest function of chilled water outlet temperature setting depending on cooling water temperature

4-3-1. Hot water control valve slow open function

Purpose : This function is provided to avoid over-input at the starting of the chiller.

The hot water control valve opens gradually shown in Fig. 4-9.

4-3-2. Crystallization protection function during low cooling water temperature & Generator high temp. alarm


Purpose : This function is provided to avoid crystallization and the generator high temp. alarm during low

cooling water temperature in operation

The hot water control valve is controlled Fig. 4-10.

15 min.3 min.

100 %

0 %

70 %

TimeFig. 4-9

Hot

wat

erco

ntro

l val

ve o

peni

ng

100%

80%

60%

0%STST-4 deg.C

(ST-7.2 deg.F)ST-13 deg.C

(ST-23.4 deg.F)ST+2 deg.C

(ST+3.6 deg.F)

Crystallizationprotection

Avoidance ofGenerator high temp alarm

Cooling water inlet temp. Fig. 4-10

Hot

wat

er

contr

ol va

lve o

penin

g ST : Specified temp.


4-3-3. Operation continuing function at high generator temperature condition

Purpose : This function is to continue operation of the chiller if generator temperature abnormally rises

The hot water control valve is controlled Fig. 4-11.

If the concentration of concentrated LiBr solution reaches 65%, the hot water control valve travels to close

for 3 minutes to reduce the generator temperature. However, even if this function works, if the concentration

reaches 65.5%, J-13 happens.

4-3-4. Chilled water freeze protection function by ON/OFF of refrigerant pump

Purpose : This function is to avoid excessive low chilled water outlet temperature by means of stop of the

refrigerant pump

If the chilled water outlet temperature more goes down in the condition of close of the hot water

control valve, the refrigerant pump is stooped as shown in Fig. 4-12

4-3-5. Auto-rest function of chilled water outlet temperature setting depending on cooling water temperature

Purpose : This function is to avoid cavitation of the refrigerant pump possibly occurring under the condition

that the chilled water outlet temperature setting is comparatively high and the cooling water inlet

temperature is low

100%

0%

Hot

wat

er

contr

ol va

lve

ope

nin

g

65.5%

65%

64%

63%

Concentr

atio

nof concentr

ated

LiB

r so

lution

2 min.

3 min.

1 hour Fig. 4-11

ON (RUN)

OFF (STOP)

Refrigerantpump

ST-2 deg.C(ST-3.6 deg.F)

ST-1.5 deg.C(ST-2.7 deg.F)

ST

ST : Chilled water setting temperature

Fig. 4-12

12 deg.C (53.6 deg.F)

11 deg.C (51.8 deg.F)

10 deg.C (50.0 deg.F)

9 deg.C (48.2 deg.F)



Chi

lled

wat

er s

ettin

g te

mp.





Fig. 14-13

Cooling water inlet temp.


4-4. Operation board

By means of operating keys on the operation board, the following tasks can be done.

(1) Main menu (data display)

(2) Resetting of chilled water outlet temp. setting

(3) Confirmation & resetting of various set values

(4) Service mode for servicing : Refer to Section 3

Main menu (22 items)

Generator temp. (it is normally displayed)

1. Chiller running time

2. #1 absorbent pump running time

*

*

*

*

*

10. Chilled water outlet temp. set

*

*

*

*

*

*

Push "SET" key for 2 sec.

Resetting of chilled wateroutlet temp. setting

Remarks :An alarm indication is displayed at only occurring an alarmIf several alarms occur at the same time, a higher priorityalarm is displayed. Lower priority alarms can be displayedby & keys.


Confirmation & resetting ofvarious set values

Push "SET+ " key for 2 sec.

Service mode


4-4-1. Main menu (22 items)

22 items in the main menu can be displayed in sequence by & keys as follows.

Key Code Data item Example of display Meaning of example of displayGenerator temp. 8 5. 0 Generator temp. is 85.0 deg.C (185 deg.F)

1 Chiller running time 1. 1 2 3 5 5 Chiller running time is 12355 hours

2 #1 absorbent pump running time 2. 5 2 3 5 #1 absorbent pump running time is 5235 hours

3 #2 absorbent pump running time 3. Not used

4 Burner running time 4. Not used

5 Refrigerant pump running time 5. 5 0 3 0 Refrigerant pump running time is 5030 hours

6 Purge unit running time 6. 1 0 7 Purge unit running time is 107 hours

7 Chiller RUN/STOP times 7. 6 3 Chiller RUN/STOP times is 63 times

8 #1 absorbent pump RUN/STOP times 8. 1 0 7 1 #1 absorbent pump RUN/STOP times is 1071 times

9 #2 absorbent pump RUN/STOP times 9. Not used

A Burner RUN/STOP times A. Not used

B Refrigerant pump RUN/STOP times b. 8 7 Refrigerant pump RUN/STOP times is 87 times

C Purge unit RUN/STOP times C. 3 0 2 2 Purge unit RUN/STOP times is 3022 times

D #3 absorbent pump running time d. Not used

E #3 absorbent pump RUN/STOP times E. Not used

10 Chilled water outlet temp. set 1 0. 7. 0 Chilled water outlet temp. set is 7 deg.C (44.6 deg.F)

11 Hot water outlet temp. set 1 1. Not used

12 Chilled water inlet temp. 1 2. 1 1. 9 Chilled water inlet temp. is 11.9 deg.C (53.4 deg.F)

13 Chilled water outlet temp. 1 3. 6. 8 Chilled water outlet temp. is 6.8 deg.C (44.2 deg.F)

14 Cooling water inlet temp. 1 4. 3 1. 8 Cooling water inlet temp. is 31.8 deg.C (89.2 deg.F)

15 Condensed refrigerant temp. 1 5. 3 8. 7 Condensed refr. temp. is 34.7 deg.C (101.7 deg.F)

16 Hot water outlet temp. 1 6. 8 5. 0 Hot water outlet temp. is 85.0 deg.C (167 deg.F)

17 Pressure in purge tank 1 7. 8. 5 Pressure in purge tank is 8.5 kPa (1.23 psi) abs.

4-4-2. Resetting of chilled water outlet temp. setting

8 5. 0 85 deg.C = 185 deg.F

1 0. 7. 0 7 deg.C = 44.6 deg.F

1 0. 7. 0

1 0. 8. 0

1 0. 8. 0 8 deg.C = 46.4 deg.F

Note 1 : In case that new value is not required, push "BACK" key. The indication returns 1 0. 7. 0 .

Note 2 : If any keys are not operated for 1 minute, the indication returns to "Generator temp.".

The display "Chilled water outlet temp. set"is indicated by & keys

Push "SET" key for 2 sec.The indication blinks

The set can be changed by & keys

Blinking

Push "SET" key. New value is set


4-4-3. Confirmation & resetting of various set values (11 items)

11 items in this menu can be displayed in sequence by & keys as follows.

Indication of Generator temp. Note : Items covered with are not used

Push "SET" key for 2 sec. Push "BACK" key

Key Data item Example of display ContentsAlarm record A L A r n. Indication of a detail record of alarm

Set of Year, Month, Day, Time r t. 1 4. 5 3 Set of Year, Month, Day, Time

Change of switch C H G S Cool / Heat change-over

Operation data record interval change

Select of Local operation mode

Cancel of Predication information

Change of unit

Change of Low select controlSet of chilled water pump A P P o C H Confirmation of interlock return time

Set of variable flow rate

Set of parallel operation by remote controller

Inverter control for chilled water C H - I n V Set of specified chilled/hot water flow rate

Set of specified hot water flow rate

Controlled variable

Minimum frequency

Set of cooling water pump & cooling tower A P P o C o Confirmation of interlock return time

Set of stopping cooling water pump at low load

Set of cooling tower fan control

Set of cooling water temperature control

Set of differential temp. of cooling tower fan


Inverter control of cooling water C O - I n V Cost factor

Controlled variable

Minimum frequency

Field set F I E L d Set of cooling water temp. at maximum input

Set of slow open time

Set of slow open temp.

Set of dilution time

Set of remote signal type

Set of type of Pulse

Set of Low select control temp.

Set of radiation temp.

Set of RS-485 r S - 4 8 5 Set of address

Indication of version number V E r 0. 0 0 No-sub menu

Indication of version number of option board o P V 0. 0 0 No-sub menu

Alarm record A L A r n. Indication of a detail record of alarm

--


(1) Alarm record

Data item Example of display Contents

Alarm record A L A r n. Indication of a detail record of alarm / Clear


First alarm code C 1. First alarm code (Newest)

Date of first alarm d 1. 1 0 2 4 24, Oct.

Time of first alarm t 1. 1 4. 0 2 14:02

Second alarm code C 2. Second alarm code

Date of second alarm d 2. 0 6 0 9 09, June

Time of second alarm t 2. 0 8. 4 4 8:44

Third alarm code C 3. Third alarm code

Date of third alarm d 3. - - - - No-occurrence

Time of third alarm t 3. - - - - No-occurrence

Clear of alarm record r E - S E t

Push "SET" for 2 sec.

3

Push "SET" key

2

Push "SET" key

1 3 data records are cleared

Push "SET" key



(2) Set of Year, Month, Day, Time




Set of Year Y r - S E t


2 0 0 1 Year can be changed from 2000 to 2050

by & keys

Push "SET" key. New data is set.

Set of Month & Date d t - S E t


1 0 - 2 4 : Month Date Month

: Increasing number

Initial set : 0 1 - 0 1 Push "SET" key. Month : 1 - 12

(1st January) New data is set. Date : 1 - 31

Set of time t n. - S E t


0 8 0 2 : O'clock minute O'clock

: Increasing number

Initial set : 0 7 0 0 Push "SET" key. O'clock : 0 - 23

(7:00) New data is set. Minute : 0 - 59


Blinking

Blinking

Blinking

-

-

-

-


(3) Change of switch

Data item Example of display ContentsChange of switch C H G S Cool / Heat change-over




Change of unit

Change of Low select control


Push "SET" key for 2 sec. Push "BACK" keyCool / Heat change-over r d - S E t

Do not use this function. TSA-16LJ series is Cooling only.Push "SET" key for 2 sec. Push "BACK" key

Operation data record interval change S A n. - d t


1 - H or 5 - n. or 1 - n. or 1 0 - S ( 1 hour ) ( 5 minutes ) ( 1 minute ) ( 10 seconds )

Required interval can be selected by & keys.

Initial set : 1 - H Push "SET" key. New interval is set.

Push "SET" key for 2 sec. Push "BACK" keySelect of Local operation mode L o C A L


o n or o F F ON or OFF can be selected by & keys.

Initial set : o n Push "SET" key. New condition is set.

Push "SET" key for 2 sec. Push "BACK" keyCancel of Predication information S I G n


C o n S E n

Push "SET" key, a predication information displayed is cancelled.

Push "SET" key for 2 sec. Push "BACK" keyChange of unit u n I t Predication information


o C or o F Unit can be selected by & keys.

Initial set : o C Push "SET" key. New condition is set.

Present interval isblinking

Present condition isblinking

Blinking

NotePredication information does not goes offunless a cause of the predicationinformation is removed. If the predicationinformation is cancelled even if the causein not removed, this function is used.

Present unit is blinking

--


Push "SET" key for 2 sec. Push "BACK" keyChange of Low select control L o S E L

This function is not used for TSA-16LJ series.

Cool / Heat change-over r d - S E t

(4) Set of chilled water pumpData item Example of display Contents

Set of chilled water pump A P P o C H Confirmation of interlock return time

Set of variable flow rateSet of parallel operation by remote controller

Push "SET" key for 2 sec. Push "BACK" keyConfirmation of interlock return time I n t - C H


0 0 0 5Time can be changed by & keys. (Changeable from 0 to 250 sec.)

Initial set : 0 0 0 5Push "SET" key. New value is set.

Push "SET" key for 2 sec. Push "BACK" keySet of variable flow rate V V - C H No-function

Push "SET" key for 2 sec. Push "BACK" keySet of parallel operation by remote controller r - P A r A No-function


(5) Inverter control for chilled water pump No-function

(6) Set of cooling water pump & cooling towerData item Example of display Contents


Set of stopping cooling water pump at low loadSet of cooling tower fan controlSet of cooling water temperature controlSet of differential temp. of cooling tower fanSet of variable flow rate

Push "SET" key for 2 sec. Push "BACK" keyConfirmation of interlock return time I n t - C o




Push "SET" key for 2 sec. Push "BACK" keySet of stopping cooling water pump at low load C o S t o P No-function

Push "SET" key for 2 sec. Push "BACK" keySet of cooling tower fan control C t A u t o No-function

Push "SET" key for 2 sec. Push "BACK" keySet of cooling water temperature control C t t E n. P No-function

Push "SET" key for 2 sec. Push "BACK" keySet of differential temp. of cooling tower fan C t d I F F No-function

Push "SET" key for 2 sec. Push "BACK" keySet of variable flow rate V V - C o No-function


Present value is blinking

--


--


(7) Inverter control for cooling water pump No-function

(8) Field set

Data item Example of display ContentsField set F I E L d Set of cooling water temp. at maximum input





Set of type of Pulse



Push "SET" key for 2 sec. Push "BACK" keySet of cooling water temp. at maximum input C o - I n P


3 2. 0 o CSet can be changed by & keys. (Changeable from 20 to 33 deg.C)

Initial set : 3 2. 0 o C (68 to 91.4 deg.F)

Push "SET" key. New value is set.


Set of slow open time I n P - t n.


0 0 0 0 5Set can be changed by & keys.

Initial set : 0 0 0 0 5 (Changeable from 0 to 1800 sec., Step 10 sec.)



Set of slow open temp. I n P t n. P


0 0 0 o CSet can be changed by & keys. (Changeable from 0 to 120 deg.C)

Initial set : 0 0 0 o C (32 to 248 deg.F)








Set of dilution time d I L u - t


0 4 n.Set can be changed by & keys. (Changeable from 4 to 20 min.)

Initial set : 0 4 n.Push "SET" key. New value is set.


Set of remote signal type r - S I G n


S t A t I C or P u L S E Type can be selected by & keys.

Initial set : S t A t I CPush "SET" key. New type is set.


Set of type of puls o F - P L S


P o S I t I or P u L S E Type can be selected by & keys.

Initial set : P o S I t I

Push "SET" key. New type is set.

Push "SET" key for 2 sec. Push "BACK" keySet of Low select control temp. L o S E L E No-function

Push "SET" key for 2 sec. Push "BACK" keySet of radiation temp. H E - S t No-function

Push "SET" key for 2 sec. Push "BACK" keyConfirmation of interlock return time C o - I n P

(9) Set of RS-485 No-function


Present condition is blinking


I I


Section 4B Control (TJ)

The control of TSA-16TJ series consists of the following functions.

(1) Operation (Start & Stop)

(2) Safety stop (Alarm) with safety devices & safety functions

(3) Cooling capacity control with avoidance for alarms

(4) Data display

Construction of devices to achieve theses function is as follows

Fig. 4-1

Control panel

Microprocessor(CPU)

Operation board

Run key

Stop key

Display

Lamps

63GH : Generator pressure switch

69PR : Purge tank pressure switch

69CH : Chilled water flow switch

DT1 : Chilled water outlet temp. sensor

DT3 : Generator temp. sensor

DT2 : Cooling water outlet temp. sensor

DT5 : Condenser temp. sensor

DT6 : Chilled water inlet temp. sensor

DT7 : Cooling water inlet temp. sensor

DT10 : Absorber temp. sensor

DT11 : Evaporator temp. sensor

DT12 : Middle cooling water temp. sensor

DT13 : Steam drain temp. sensor


4-1. Operation

4-1-1. Run of the chiller

The sequence of starting the chiller is as follow.

Remark :The following sequence is in case of using the interlock system provided in the chiller control circuit.

Fig. 4-2


Remote start signal

Chilled water pump starts signal goesto chilled water pump operation circuitfrom chiller control circuit

Chilled water pumpstarts

ON signal of 69CHreturns to chiller control

Chilled water pump interlocksignal

Cooling water pump starts signal goesto cooling water pump operation circuitfrom chiller control circuit

Cooling water pumpstarts

Cooling water pump interlocksignalcooling water fan circuit

works

Chiller runs

YES

No

YES

No

Contact of chilled waterflow switch opens

YES

No J-03After 10 min., Chilledwater flow rate alarm

Chilled water temp. is above2.5 deg.C (36.5 deg.F)

YES

No J-01After 10 min., Chilledwater low temp. alarm

J-02After 10 min., Chilled

water pump alarm

YES

NoJ-03

After 10 min., Chilledwater flow rate alarm

J-06After 10 min., Cooling

water pump alarm


4-1-2. Stop of the chiller

The sequence of stopping the chiller is as follow.

Fig. 4-3

The time chart of stop sequence is as follows. (Output signals from the microprocessor)

Fig. 4-4

T1 : The time until the generator temperature T2: See the below graph.

reaches to 80 deg.C (176 deg.F) or below.

Changeable from 4 min. to 20 min.


Remote start signal

After 1 minute, the refrigerantpump stops

Steam control valve travels to close

After 1minute, the cooling waterpump stops

After 1 minute, the chilled waterpump stops

After 1minute, the chiller stopsentirely

Dilu

tion

oper

atio

nCooling water pump

Steam control valve

Refrigerant pump

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOPRUN

STOP

T1

1 min.

Entire stopStop signal

Steam shut-off valveOPEN

CLOSE

1 min.

T2

5 min.

6 min.

7 min.

8 min.

9 min.

10 min.

65 deg.C (149 deg.F) 100 deg.C (212 deg.F)Generator temp.

T2


4-2. Safety stop (Alarm)

Following safety stops are provide on TSA-16TJ series.

Purpose Name of Alarm Stop condition












J-12 Purge pump only stops

(1) Name of alarm : Chilled water low temp. alarm (Symbol : J-01)

Condition of work : If chilled water outlet temp. is 2.5 deg.C (36.5 deg.F) for 2 seconds at starting chiller If chilled water outlet temp. goes down to 2.5 deg.C (36.5 deg.F) for 2 seconds during operation


Fig.4-5

(2) Name of alarm : Chilled water pump alarm (Symbol : J-02)

Condition of work : If chilled water pump dose not start after 10 minutes of receiving the start signal

If chilled water pump stops during operation of chiller


Cooling water pump alarm

Cooling water flow rate alarm

Generator high temp. alarm

Chilled water low temp. alarm

Chilled water pump alarm

Chilled water flow rate alarm

Cooling water low temp. alarmChi

lled

wat

erfre

eze

prot

ectio

nC

ryst

alliz

atio

npr

otec

tion

Mot

orpr

otec

tion

Symbol

Purge pump alarm

Generator high pressure alarm

High concentration alarm

#1 Absorbent pump alarm

Refrigerant pump alarm

Refrigerant pump

Steam shut-off valve

Steam control valve

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOPRUN

STOP

T1

Entire stop

Alarm happens

OPEN

CLOSE

1 min.

Cooling water pump


(3) Name of alarm : Chilled water flow rate alarm (Symbol : J-03)

Condition of work : If chilled water flow rate is below 50 % of rated flow rate at starting chiller

If chilled water flow rate goes down below 50 % of rated flow rate during operation


(4) Name of alarm : Cooling water low temp. alarm (Symbol : J-20)

Condition of work : If cooling water inlet temperature does not rise up to the temperature shown in Fig. 4-6 after 30 minutes of starting chiller or the temperature continues for 30 minutes during operation

Fig. 4-6

Time chart at alarm happened during operation : Same as Fig. 4-4.

(5) Name of alarm : Cooling water pump alarm (Symbol : J-06)

Condition of work : If cooling water pump dose not start after 10 minutes of receiving the start signal

If cooling water pump stops during operation of chiller


Fig. 4-7


20 deg.C(68 deg.F)



Cooling water low temp. alarmwatched temperature

Specified cooling water inlet temperature

Cooling water pump

Steam control valve

Refrigerant pump

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOPRUN

STOP

T1

1 min.

Entire stopStop signal


CLOSE

1 min.

T2


(6) Name of alarm : Cooling water flow rate alarm (Symbol : J-07)OPTIONCondition of work : If cooling water flow rate is below 50 % of rated flow rate at starting chiller

If cooling water flow rate goes down below 50 % of rated flow rate during operation


(7) Name of alarm : Generator high temp. alarm (Symbol : J-13)

Condition of work : If generator temperature goes up to 105 deg.C (221 deg.F) during operation


Fig. 4-8

(8) Name of alarm : Generator high pressure alarm (Symbol : J-14)

Condition of work : If generator pressure goes up to 0 MPa (0 psig) during operation


(9) Name of alarm : High concentration alarm (Symbol : J-16)

Condition of work : If concentration of concentrated LiBr solution goes up to 65 % at just 3 minutes


If concentration of concentrated LiBr solution goes up to 65 % within 1 hour


If concentration of concentrated LiBr solution goes up to 65.5 %


Cooling water pump

Refrigerant pump

Chilled water pump

Steam shut-off valve

Steam control valve

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOPRUN

STOP

T1

1 min.


OPEN

CLOSE

1 min.

T2


(10) Name of alarm : #1 absorbent pump alarm (Symbol : J-04)

Condition of work : If #1 absorbent pump thermalrelay (51A1) works at starting chiller and during operation


Fig. 4-9

(11) Name of alarm : Refrigerant pump alarm (Symbol : J-10)

Condition of work : If Refrigerant pump thermalrelay (51R) works at starting chiller and during operation


Fig. 4-10

(12) Name of alarm : Purge pump alarm (Symbol : J-12)

Condition of work : If purge pump thermalrelay (51P) works

The purge pump only stops. This alarm dose not affect to operation. But, if the purge

pump stops during purging, manual purge valves shall be closed immediately.

Cooling water pump

Steam control valve

Refrigerant pump

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOPRUN

STOP

T11 min.

Alarm happens


CLOSE

1 min.

Entire stop

Cooling water pump

Steam control valve

Refrigerant pump

Chilled water pump

Absorbent pump

100%

0%

RUN

STOP

RUN

STOP

RUN

STOPRUN

STOPT1

1 min.

Alarm happens


CLOSE

1 min.T2

Entire stop


4-3. Capacity control

The capacity control of TSA-16TJ series is PID control. A signal of chilled water outlet temperature detected

by DT1 is sent to a microprocessor then the signal control a steam control valve to control cooling capacity.

In addition to the PID control, there are following control functions to smooth the control.

(1) Steam control valve slow open function

(2) Crystallization protection function during low cooling water temperature & Generator high temp. alarm


(3) Operation continuing function at high generator temperature condition

(4) Chilled water freeze protection function by On/OFF of refrigerant pump

(5) Auto-rest function of chilled water outlet temperature setting depending on cooling water temperature

4-3-1. Steam control valve slow open function

Purpose : This function is provided to avoid over-input at the starting of the chiller.

The steam control valve opens gradually shown in Fig. 4-11.

4-3-2. Crystallization protection function during low cooling water temperature & Generator high temp. alarm


Purpose : This function is provided to avoid crystallization and the generator high temp. alarm during low

cooling water temperature in operation

The steam control valve is controlled Fig. 4-12.

15 min.3 min.

100 %

0 %

70 %

TimeFig. 4-11

Stea

m c

ontro

l val

ve o

peni

ng

100%

80%

60%

0%STST-4 deg.C

(ST-7.2 deg.F)ST-13 deg.C

(ST-23.4 deg.F)ST+2 deg.C

(ST+3.6 deg.F)

Crystallizationprotection

Avoidance ofGenerator high temp alarm

Cooling water inlet temp. Fig. 4-12

Ste

am c

ontr

ol va

lve o

penin

g ST : Specified temp.


4-3-3. Operation continuing function at high generator temperature condition

Purpose : This function is to continue operation of the chiller if generator temperature abnormally rises

The steam control valve is controlled Fig. 4-13.

If the concentration of concentrated LiBr solution reaches 65%, the steam control valve travels to close

for 3 minutes to reduce the generator temperature. However, even if this function works, if the concentration

reaches 65.5%, J-13 happens.

4-3-4. Chilled water freeze protection function by ON/OFF of refrigerant pump

Purpose : This function is to avoid excessive low chilled water outlet temperature by means of stop of the

refrigerant pump

If the chilled water outlet temperature more goes down in the condition of close of the steam

control valve, the refrigerant pump is stooped as shown in Fig. 4-14.

4-3-5. Auto-rest function of chilled water outlet temperature setting depending on cooling water temperature

Purpose : This function is to avoid cavitation of the refrigerant pump possibly occurring under the condition

that the chilled water outlet temperature setting is comparatively high and the cooling water inlet

temperature is low

100%

0%Ste

am c

ontr

ol

valv

e o

penin

g

65.5%

65%

64%

63%

Concentr

atio

nof concentr

ated

LiB

r so

lution

2 min.

3 min.

1 hour Fig. 4-13

ON (RUN)

OFF (STOP)

Refrigerantpump

ST-2 deg.C(ST-3.6 deg.F)

ST-1.5 deg.C(ST-2.7 deg.F)

ST

ST : Chilled water setting temperature

Fig. 4-14

12 deg.C (53.6 deg.F)

11 deg.C (51.8 deg.F)

10 deg.C (50.0 deg.F)




Chi

lled

wat

er s

ettin

g te

mp.





Fig. 14-15

Cooling water inlet temp.


4-4. Operation board

By means of operating keys on the operation board, the following tasks can be done.

(1) Main menu (data display)

(2) Resetting of chilled water outlet temp. setting

(3) Confirmation & resetting of various set values

(4) Service mode for servicing : Refer to Section 3

Main menu (22 items)

Generator temp. (it is normally displayed)

1. Chiller running time

2. #1 absorbent pump running time

*

*

*

*

*

10. Chilled water outlet temp. set

*

*

*

*

*

*


Resetting of chilled wateroutlet temp. setting

Remarks :An alarm indication is displayed at only occurring an alarmIf several alarms occur at the same time, a higher priorityalarm is displayed. Lower priority alarms can be displayedby & keys.


Confirmation & resetting ofvarious set values

Push "SET+ " key for 2 sec.

Service mode


4-4-1. Main menu (22 items)

22 items in the main menu can be displayed in sequence by & keys as follows.

Key Code Data item Example of display Meaning of example of displayGenerator temp. 9 5. 0 Generator temp. is 95.0 deg.C (203 deg.F)

1 Chiller running time 1. 1 2 3 5 5 Chiller running time is 12355 hours

2 #1 absorbent pump running time 2. 5 2 3 5 #1 absorbent pump running time is 5235 hours

3 #2 absorbent pump running time 3. Not used

4 Burner running time 4. Not used

5 Refrigerant pump running time 5. 5 0 3 0 Refrigerant pump running time is 5030 hours

6 Purge unit running time 6. 1 0 7 Purge unit running time is 107 hours

7 Chiller RUN/STOP times 7. 6 3 Chiller RUN/STOP times is 63 times

8 #1 absorbent pump RUN/STOP times 8. 1 0 7 1 #1 absorbent pump RUN/STOP times is 1071 times

9 #2 absorbent pump RUN/STOP times 9. Not used

A Burner RUN/STOP times A. Not used

B Refrigerant pump RUN/STOP times b. 8 7 Refrigerant pump RUN/STOP times is 87 times

C Purge unit RUN/STOP times C. 3 0 2 2 Purge unit RUN/STOP times is 3022 times

D #3 absorbent pump running time d. Not used

E #3 absorbent pump RUN/STOP times E. Not used

10 Chilled water outlet temp. set 1 0. 7. 0 Chilled water outlet temp. set is 7 deg.C (44.6 deg.F)

11 Hot water outlet temp. set 1 1. Not used

12 Chilled water inlet temp. 1 2. 1 1. 9 Chilled water inlet temp. is 11.9 deg.C (53.4 deg.F)

13 Chilled water outlet temp. 1 3. 6. 8 Chilled water outlet temp. is 6.8 deg.C (44.2 deg.F)

14 Cooling water inlet temp. 1 4. 3 1. 8 Cooling water inlet temp. is 31.8 deg.C (89.2 deg.F)

15 Condensed refrigerant temp. 1 5. 3 8. 7 Condensed refr. temp. is 34.7 deg.C (101.7 deg.F)

16 Steam drain temp. 1 6. 8 5. 0 Steam drain temp. is 85.0 deg.C (167 deg.F)

17 Pressure in purge tank 1 7. 8. 5 Pressure in purge tank is 8.5 kPa (1.23 psi) abs.

4-4-2. Resetting of chilled water outlet temp. setting

9 5. 0 95 deg.C = 203 deg.F

1 0. 7. 0 7 deg.C = 44.6 deg.F

1 0. 7. 0

1 0. 8. 0

1 0. 8. 0 8 deg.C = 46.4 deg.F

Note 1 : In case that new value is not required, push "BACK" key. The indication returns 1 0. 7. 0 .

Note 2 : If any keys are not operated for 1 minute, the indication returns to "Generator temp.".

The display "Chilled water outlet temp. set"is indicated by & keys

Push "SET" key for 2 sec.The indication blinks

The set can be changed by & keys

Blinking

Push "SET" key. New value is set


4-4-3. Confirmation & resetting of various set values (11 items)

11 items in this menu can be displayed in sequence by & keys as follows.

Indication of Generator temp. Note : Items covered with are not used


Key Data item Example of display ContentsAlarm record A L A r n. Indication of a detail record of alarm


Change of switch C H G S Cool / Heat change-over




Change of unit

Change of Low select controlSet of chilled water pump A P P o C H Confirmation of interlock return time


Set of parallel operation by remote controller

Inverter control for chilled water C H - I n V Set of specified chilled/hot water flow rate

Set of specified hot water flow rate

Controlled variable

Minimum frequency


Set of stopping cooling water pump at low load

Set of cooling tower fan control

Set of cooling water temperature control

Set of differential temp. of cooling tower fan


Inverter control of cooling water C O - I n V Cost factor

Controlled variable

Minimum frequency

Field set F I E L d Set of cooling water temp. at maximum input





Set of type of pulse



Set of RS-485 r S - 4 8 5 Set of address

Indication of version number V E r 0. 0 0 No-sub menu

Indication of version number of option board o P V 0. 0 0 No-sub menu

Alarm record A L A r n. Indication of a detail record of alarm

--


(1) Alarm record


Alarm record A L A r n. Indication of a detail record of alarm / Clear



Date of first alarm d 1. 1 0 2 4 24, Oct.

Time of first alarm t 1. 1 4. 0 2 14:02

Second alarm code C 2. Second alarm code

Date of second alarm d 2. 0 6 0 9 09, June

Time of second alarm t 2. 0 8. 4 4 8:44

Third alarm code C 3. Third alarm code

Date of third alarm d 3. - - - - No-occurrence

Time of third alarm t 3. - - - - No-occurrence

Clear of alarm record r E - S E t


3

Push "SET" key

2

Push "SET" key

1 3 data records are cleared

Push "SET" key



(2) Set of Year, Month, Day, Time






2 0 0 1 Year can be changed from 2000 to 2050

by & keys

Push "SET" key. New data is set.

Set of Month & Date d t - S E t


1 0 - 2 4 : Month Date Month

: Increasing number

Initial set : 0 1 - 0 1 Push "SET" key. Month : 1 - 12

(1st January) New data is set. Date : 1 - 31

Set of time t n. - S E t


0 8 0 2 : O'clock minute O'clock

: Increasing number

Initial set : 0 7 0 0 Push "SET" key. O'clock : 0 - 23

(7:00) New data is set. Minute : 0 - 59


(3) Change of switch

Data item Example of display ContentsChange of switch C H G S Cool / Heat change-over




Change of unit

Change of Low select control

Blinking

Blinking

Blinking

-

-

-

-

--



Push "SET" key for 2 sec. Push "BACK" keyCool / Heat change-over r d - S E t

Do not use this function. TSA-16TJ series is Cooling only.Push "SET" key for 2 sec. Push "BACK" key

Operation data record interval change S A n. - d t


1 - H or 5 - n. or 1 - n. or 1 0 - S ( 1 hour ) ( 5 minutes ) ( 1 minute ) ( 10 seconds )

Required interval can be selected by & keys.

Initial set : 1 - H Push "SET" key. New interval is set.

Push "SET" key for 2 sec. Push "BACK" keySelect of Local operation mode L o C A L


o n or o F F ON or OFF can be selected by & keys.

Initial set : o n Push "SET" key. New condition is set.

Push "SET" key for 2 sec. Push "BACK" keyCancel of Predication information S I G n


C o n S E n

Push "SET" key, a predication information displayed is cancelled.

Push "SET" key for 2 sec. Push "BACK" keyChange of unit u n I t Predication information


o C or o F Unit can be selected by & keys.

Initial set : o C Push "SET" key. New condition is set.

Push "SET" key for 2 sec. Push "BACK" keyChange of Low select control L o S E L

This function is not used for TSA-16TJ series.

Cool / Heat change-over r d - S E t

Present interval isblinking

Present condition isblinking

Blinking

NotePredication information does not goes offunless a cause of the predicationinformation is removed. If the predicationinformation is cancelled even if the causein not removed, this function is used.

Present unit is blinking


(4) Set of chilled water pumpData item Example of display Contents

Set of chilled water pump A P P o C H Confirmation of interlock return time

Set of variable flow rateSet of parallel operation by remote controller





Push "SET" key for 2 sec. Push "BACK" keySet of variable flow rate V V - C H No-function

Push "SET" key for 2 sec. Push "BACK" keySet of parallel operation by remote controller r - P A r A No-function


(5) Inverter control for chilled water pump No-function

(6) Set of cooling water pump & cooling towerData item Example of display Contents


Set of stopping cooling water pump at low loadSet of cooling tower fan controlSet of cooling water temperature controlSet of differential temp. of cooling tower fanSet of variable flow rate





Push "SET" key for 2 sec. Push "BACK" keySet of stopping cooling water pump at low load C o S t o P No-function

Push "SET" key for 2 sec. Push "BACK" keySet of cooling tower fan control C t A u t o No-function

Push "SET" key for 2 sec. Push "BACK" keySet of cooling water temperature control C t t E n. P No-function

Push "SET" key for 2 sec. Push "BACK" keySet of differential temp. of cooling tower fan C t d I F F No-function

Push "SET" key for 2 sec. Push "BACK" keySet of variable flow rate V V - C o No-function



--


--


(7) Inverter control for cooling water pump No-function

(8) Field set

Data item Example of display ContentsField set F I E L d Set of cooling water temp. at maximum input





Set of type of pulse



Push "SET" key for 2 sec. Push "BACK" keySet of cooling water temp. at maximum input C o - I n P


3 2. 0 o CSet can be changed by & keys. (Changeable from 20 to 33 deg.C)

Initial set : 3 2. 0 o C (68 to 91.4 deg.F)



Set of slow open time I n P - t n.


0 0 0 0 5Set can be changed by & keys.

Initial set : 0 0 0 0 5 (Changeable from 0 to 1800 sec., Step 10 sec.)



Set of slow open temp. I n P t n. P


0 0 0 o CSet can be changed by & keys. (Changeable from 0 to 120 deg.C)

Initial set : 0 0 0 o C (32 to 248 deg.F)








Set of dilution time d I L u - t


0 4 n.Set can be changed by & keys. (Changeable from 4 to 20 min.)

Initial set : 0 4 n.Push "SET" key. New value is set.


Set of remote signal type r - S I G n


S t A t I C or P u L S E Type can be selected by & keys.

Initial set : S t A t I CPush "SET" key. New type is set.


Set of type of puls o F - P L S


P o S I t I or P u L S E Type can be selected by & keys.

Initial set : P o S I t I

Push "SET" key. New type is set.

Push "SET" key for 2 sec. Push "BACK" keySet of Low select control temp. L o S E L E No-function

Push "SET" key for 2 sec. Push "BACK" keySet of radiation temp. H E - S t No-function

Push "SET" key for 2 sec. Push "BACK" keyConfirmation of interlock return time C o - I n P

(9) Set of RS-485 No-function




I I


Section 5A Trouble Shooting (LJ)

5-1. Chilled water outlet temperature does not go down (No-chilling of chilled water)


Faci

lity

Insu

ffici

ent a

irha

ndlin

g un

itca

paci

ty

Ove

r loa

d

Coo

ling

load

incr

ease

d du

e to

expa

nsio

n of

coo

ling

Chi

lled

wat

er s

yste

m

Pas

s pa

rtitio

n ga

sket

in w

ater

box

isre

mov

ed

Chi

lled

wat

er fl

owra

te is

too

muc

h

Wat

er le

aks

due

topa

ss p

artit

ion

plat

e in

wat

er b

ox h

as c

orro

sion

Eva

pora

tor t

ubes

are

foul

ed

Inst

alla

tion

Impr

oper

leve

ling

ofch

iller

Impr

oper

foun

datio

n

Ref

riger

ant c

ycle

Ref

riger

ant b

low

valv

e is

not

clo

sed

Ref

riger

ant p

ump

rota

tes

reve

rsel

y

Eva

pora

tor t

ube

clea

ning

is in

suffi

cien

t

Ref

riger

ant l

eaks

into

abso

rben

t sid

e du

e to

aho

le a

ppea

red

onre

frige

rant

pan

with

corr

osio

n

Ref

riger

ant

cont

amin

atio

n

Too

muc

h re

frige

rant

char

ging

am

ount

Abs

orbe

nt c

ycle

Cry

stal

lizat

ion

Coo

ling

wat

er in

let

tem

p. is

too

high

Oct

yl a

lcoh

ol is

insu

ffici

ent

Impr

oper

abs

orbe

ntflo

w ra

te

No-

chill

ing

Sol

utio

n he

at e

xcha

nger

Abs

orbe

nt fl

ow ra

tede

crea

sed

due

tocl

oggi

ng o

f hea

tex

chan

ger

Abs

orbe

nt fl

ow ra

tede

crea

sed

due

tocl

oggi

ng o

f hea

tex

chan

ger

Abs

orbe

nt fl

owra

te d

ecre

ased

due

to tu

bebr

oken

Vac

uum

sid

e

Atta

ined

vac

uum

of p

urge

pum

p ca

n no

t be

obta

ined

Air

leak

age

Pal

ladi

um c

ell m

alfu

nctio

ns

Pal

ladi

um c

ell h

eate

ris

out

of o

rder

Oct

yl a

lcoh

ol is

insu

ffici

ent

Coo

ling

wat

er s

yste

m

Coo

ling

wat

er te

mp.

doe

s no

tgo

dow

n du

e to

hig

h hu

mid

ity

Pas

s pa

rtitio

n ga

sket

in w

ater

box

isre

mov

ed

Wat

er le

aks

due

topa

ss p

artit

ion

plat

e in

wat

er b

ox h

as c

orro

sion

Abs

orbe

r and

con

dens

er tu

bes

are

foul

ed

Coo

ling

wat

er fl

owra

te is

insu

ffici

ent

Con

trol s

yste

mD

rivin

g he

at s

ourc

e

Tem

p. c

ontro

ller

mal

func

tions

Hot

wat

er c

ontro

lva

lve

is o

ut o

f ord

er

Hot

wat

er in

let t

emp.

is lo

w

Hot

wat

er fl

ow ra

teis

low

5-2. AlarmError code : J-01

Error code : J-02

Error code : J-03

Chilled water pump alarmSafety device : Interlock signal(52CH)

In case that the interlock signal of thechilled water pump comes into the I/Oboard

I/O board is out of order (especially, connectors)

Imperfect contact of wires and/or connectorsconnected to I/O board happens

The chilled water pump stops

Power supply for remote control panel is OFF

Imperfect contact happens in a remote control circuit

Replace the I/O board

Start the chilled water pump

ON the power supply

Check & repair the circuit

In case that the interlock signal ofthe chilled water pump does notcome into the I/O board

Remark :The interlock signal can bechecked by the service mode

Replace wires and/or connectors

Interlock signal wires and/or a connector is out of order Replace wires and the connector

Chilled water flow rate alarmSafety device : Chilled water flow switch (69CH)

In case that chilled water flowrate is more than 50 % of therated flow rate

The flow switch malfunctions

The setting of the flow switch is wrong

The wire of flow switch is cut

I/O board is out of order

In case that chilled water flowrate is less than 50 % of therated flow rate

Capacity of the chilled water pump is insufficient

Resistance of chilled water circuit is too much

A strainer in the chilled water circuit is clogged

Replace the flow switch

Contact to a facility company

Clean the strainer

Re-adjust the flow switch

Replace the wire


A differential pressure control valve in the chilledwater circuit malfunctions

Air is exiting in the chilled water circuit Perform air vent

A valve in the chilled water circuit is closed Open the valve

Chilled water low temp. alarmSafety device : DT1

In case that the alarm occurs at2.5 deg.C (36.5 deg.F) of chilledwater outlet temp.

Hot water control valve malfunctions (Not modulate)

The microprocessor is out of order

If several or all of the following conditions mutuallyhappen and continue・Low cooling water inlet temperature・Low chilled water flow rate (More than 50%)・Low cooling load condition・Sudden change of cooling load・Holding water quantity of chilled water is a very little

In case that the alarm occursabove 2.5 deg.C (36.5 deg.F) ofchilled water outlet temp.

Breaking of wire of DT1(The Indication of chilled water outlet temp. is 30 deg.C / 86 deg.F)


Replace the control valve

Replace DT1

Replace the microprocessor


DT1 is out of order (Hot water control valve does not close) Replace DT1


Error code : J-04

Error code : J-06

Error code : J-07

#1 Absorbent pump alarmSafety device : Thermal relay(51A)

In case that the thermal relay(51A) functions

Crystallization is occurring in #1 absorbent pump

A foreign material is existing in #1 absorbent pump

Insulation failure of the pump motor coil is occurring

Short of the pump motor coli is occurring

Ground fault of the pump motor coil is occurring

The thermal relay is out of order

The setting of thermal relay is wrong

The magnet contactor of 51A is out of order

Absorbent flow rate is too much

In case that the thermal relay(51A) does not function

The contactor of thermal relay is out of order

Short is occurring on the thermal relay wires


Perform de-crystallization

Remove the foreign material

Replace #1 absorbent pump

Replace the thermal relay

Correct the setting

Replace the magnet contactor

Re-adjust the flow rate


Replace the wires


Cooling water pump alarmSafety device : Interlock signal(52CO)

In case that the interlock signal ofthe cooling water pump comesinto the I/O board



The cooling water pump stops


Imperfect contact happens in a remote control circuit


Start the cooling water pump

ON the power supply


In case that the interlock signal ofthe cooling water pump does notcome into the I/O board


Replace wires and/orconnectors

Interlock signal wires and/or a connector is out of order Replace wires and theconnector

Cooling water flow rate alarmSafety device : Cooling waterflow

In case that cooling water flowis more than 50 % of the ratedflow rate





In case that cooling water flowrate is less than 50 % of therated flow rate

Capacity of the cooling water pump is insufficient

Resistance of cooling water circuit is too much

A strainer in the cooling water circuit is clogged



Clean the strainer


Replace the wire


Air is exiting in the cooling water circuit Perform air vent

A valve in the cooling water circuit is closed Open the valve

Remark :Cooling water flowswitch(52CO) is option device


Error code : J-10

Error code : J-13

Refrigerant pump alarmSafety device : Thermal relay(51R)

In case that the thermal relay(51R) functions A foreign material is existing in Refrigerant pump






The magnet contactor of 51R is out of order

Refrigerant flow rate is too much

In case that the thermal relay(51R) does not function The contactor of thermal relay is out of order




Replace Refrigerant pump


Correct the setting




Replace the wires


Contamination of refrigerant happens Search & remove the cause

Generator high temp.alarmSafety device : DT3

In case that thealarm occurs atset value

Indication ofLOW LEVELVACUUMis displayed

Perform leak test to locate leakages.Palladium cell / Gaskets / Generatorpressure switch/ Sight glasses/ etc.

Leakage occurs

Indication ofLOW LEVELVACUUMis not displayed

Inhibitor isInsufficient Add suitable amount of the inhibitor

Suitable attainedvacuum of purgepump can not beachieved

Check a purge pump & a drain trap. Replacepurge pump oil. Drain out moisture in thedrain trap and dry up inside the drain trap.

#1 Absorbent pumpdoes not run See J04

A diluted solution damper is not set properly

Bad vacuumcondition

Insufficientabsorbentsolution flow rate

#1 Absorbentpump runs

#1 absorbent pump rotates reversely dueto wrong wiring

Crystallization occurs

Octyl alcohol is insufficient

Insufficient of charging amount ofabsorbent/refrigerant

Re-adjust thedamper

Correct thewiring

De-crystallization

Add octylalcohol

Add solution

DT3 is out of order(Short-circuit) Replace DT3

Cooling waterproblems

Cooling water inlet temp. is higher than rated temp.

Cooling water flow rate is insufficient

Absorber and condenser tubes are fouled(Foul tube of COW may be indicated)


In case that thealarm occursbelow set value

DT3 is out of order(Breaking of wire) Replace DT3


Error code : J-14

Error code : J-16

Condition of occurring alarm

1. In case that concentrated solution concentration goes up 65% after 3 minutes of starting crystallization protection function

2. In case that concentrated solution concentration goes up 65% within 1 hour after starting crystallization protection function

3. In case that concentrated solution concentration goes up 65.5%.

Error code : J-20

Generator high pressure alarmSafety device : Pressure switch(63GH)

In case that the pressureswitch functions at the setvalue

Inside pressure of the chiller increases to 0 MPa

The pressure switch is out of order

The wire of pressure switch is cut

Probable cause is mostly wrongoperation of purgingPerform purging

Replace the pressure switch

Replace the wire

In case that the pressureswitch functions below the setvalue

Cooling water low temp. alarmSafety device : DT7

In case that the alarm occurs ifcooling water inlet temp.continues below rated temp.minus 13 deg.C (23.4 deg.F)for 30 minutes

Cooling water temp. control system malfunctions Contact to a facility company

Replace the microprocessorIn case that the alarm occurseven if cooling water inlettemp. continues above ratedtemp. minus 13 deg.C (23.4deg.F)

Cooling water temp. control system malfunctionsThe microprocessor is out of order

Replace DT7DT7 is out of order

High concentrationalarmSafety device : DT3,

The alarmoccurs underthe followingconditions



Leakage occurs


Inhibitor isInsufficient Add suitable amount of the inhibitor


Check a purge pump & a drain trap. Replacepurge pump oil. Drain out moisture in thedrain trap and dry up inside the drain trap.

#1 Absorbentpump does not

See J04


Bad vacuumcondition







Re-adjust thedamper

Correct the wiring

De-crystallization

Add octyl alcohol

Add solution

Driving heat amount is too high Replace the controlvalve






The alarmoccurs withoutfollowingconditions

DT3 is out of order(Breaking of wire)DT5 is out of order(Short-circuit)

Replace

Hot water flow rate istoo high

Hot water inlet temp. istoo high

Hot water control valveis out of order

Check hot watersystem


5-3. Sensor alarmError code : F-01 Chilled water inlet temp. sensor alarmSensor : DT6 (Digital sensor)

Error code : F-02 Cooling water inlet temp. sensor alarmSensor : DT7 (Digital sensor)

Error code : F-03 Cooling water outlet temp. sensoralarm Sensor : DT2 (Digital sensor)

Error code : F-04 Cooling water mid temp. sensor alarmSensor : DT12 (Digital sensor)

Error code : F-05 Condenser temp. sensor alarmSensor : DT5 (Digital sensor)

Error code : F-08 Refrigerant temp. sensor alarmSensor : DT11 (Digital sensor)

Error code : F-09 Driving hot water inlet temp. sensoralarm Sensor : DT15 (Digital sensor)

Error code : F-10 3 way valve return temp. sensor alarmSensor : DT14 (Digital sensor)

Error code : F-11 Driving hot water outlet temp. sensor alarmSensor : DT16 (Digital sensor)

Error code : F-12 Absorbent temp. sensor alarmSensor : DT10 (Digital sensor)

Error code : F-17 Chilled water flow sensor alarmSensor : 69CH (Chilled water flow switch)

Error code : F-19 Cooling water flow sensor alarmSensor : 69CO (Cooling water flow switch) OPTION

Error code : F-21 CPU alarm

Error code : F-22 Memory alarm

Error code : F-23 Time set alarm

Error code : F-24 Constant set alarm

Error code : F-25 Chilled water outlet temp. sensor alarmSensor : DT1 (Cu resistance thermometer bulb)

Error code : F-26 High generator temp. sensor alarmSensor : DT3 (Thermistor)

Error code : F-28 Purge tank pressure sensor alarmSensor : 69PR

Sensor is out of order

Connector is removed

Wire is cut / short

Over range of temp.(Range : -20 to 120 degC)(Range : -4 to 248 deg.F)

Replace a sensor

Put a connector to the sensor

Replace a wire



Wire is cut / shortOver range of pressure(Range : 0 to 340hPa)(Range : 0 to 0.0493 psi)

Replace a sensor


Replace a wire



Wire is cut / short

Replace a sensor


Replace a wire

Replace a microprocessor

Perform time set

Clear memory then set again



Wire is cut / short

Over range of pressure(Range : 0 to 100 deg.C)(Range : 32 to 212 deg.F)

Replace a sensor


Replace a wire



Wire is cut / short


Replace a sensor


Replace a wire


5-4. Maintenance messageMessage code : H-01 OPERATE PURGE PUMP Purging shall be conducted from the purge tank.

The purge unit will be shortly filled with non-condensable gas.

Message code : H-02 HIGH CONCENTRATION There is a symptom that concentrated solution concentrationis slightly high comparing with normal operating condition.

Message code : H-03 CLEAN COOLING WATER TUBES Absorber and condenser tubes have been fouled.Tube cleaning shall be conducted.

Message code : H-04 CHECK COOLING WATER SYSTEM If cooling water inlet temp. is beyond the followingvalue, check cooling water system.PCOWT - SCOWT > 2 deg.C (3.6 deg.F) PCOWT : Present cooling water inlet temp. SCOWT : Specified cooling water inlet temp.

Message code : H-06 PURGE TANK HIGH PRESSURE Purging should be conducted from the purge unit.

Message code : H-07 COOLING WATER TUBES FOUL

Message code : H-08 COOLING WATER HIGH TEMP

Message code : H-10 POWER FAILURE When the power resumes, this message is displayed.

Absorber and condenser tubes have been slightly fouled.Tube cleaning shall be planed.

If cooling water inlet temp. is within the following value, H-08 isindicated. If H-08 is often indicated, check cooling water system.0 deg.C (0 deg.F) < PCOWT - SCOWT =/< 2 deg.C (3.6 deg.F) PCOWT : Present cooling water temp. SCOWT : Specified cooling water temp.

Graph 5-1. Fouling of heat transfer tubes in cooling water system

2

4

6

8

20 40 60 80 100

Maintenance zone

Notice zone

Normal zone

Normal Line

Maintenancejudgmentzone

Cooling load factor (%)

Foul

ing

indi

cato

r

0.6

20 80 100

Maintenance zone

Storage ratio (%)

Pre

ssur

e ris

ing

indi

cato

rof

sto

rage

tank

Graph 5-2. Vacuum condition monitoring

0

1.0

600

Noticezone

Normal zone

8

7

6

5

4

3

2

1

00 20 40 60 80 100

Abnormal stop zone

Maintenance zone atcooling water 27 deg.C (80.6 deg.F)


Normal line at cooling water 27deg.C (80.6 deg.F)


Cooling load (%)

Graph 5-3. Tendency of absorbent concentration

Concentr

atio

n indi

cat

or


Section 5B Trouble Shooting (TJ)

5-1. Chilled water outlet temperature does not go down (No-chilling of chilled water)


Faci

lity

Insu

ffici

ent a

irha

ndlin

g un

itca

paci

ty

Ove

r loa

d

Coo

ling

load

incr

ease

d du

e to

expa

nsio

n of

coo

ling

Chi

lled

wat

er s

yste

m

Pas

s pa

rtitio

n ga

sket

in w

ater

box

isre

mov

ed

Chi

lled

wat

er fl

owra

te is

too

muc

h

Wat

er le

aks

due

topa

ss p

artit

ion

plat

e in

wat

er b

ox h

as c

orro

sion

Eva

pora

tor t

ubes

are

foul

ed

Inst

alla

tion

Impr

oper

leve

ling

ofch

iller

Impr

oper

foun

datio

n

Ref

riger

ant c

ycle

Ref

riger

ant b

low

valv

e is

not

clo

sed

Ref

riger

ant p

ump

rota

tes

reve

rsel

y

Eva

pora

tor t

ube

clea

ning

is in

suffi

cien

t

Ref

riger

ant l

eaks

into

abso

rben

t sid

e du

e to

aho

le a

ppea

red

onre

frige

rant

pan

with

corr

osio

n

Ref

riger

ant

cont

amin

atio

n

Too

muc

h re

frige

rant

char

ging

am

ount

Abs

orbe

nt c

ycle

Cry

stal

lizat

ion

Coo

ling

wat

er in

let

tem

p. is

too

high

Oct

yl a

lcoh

ol is

insu

ffici

ent

Impr

oper

abs

orbe

ntflo

w ra

te

No-

chill

ing

Sol

utio

n he

at e

xcha

nger

Abs

orbe

nt fl

ow ra

tede

crea

sed

due

tocl

oggi

ng o

f hea

tex

chan

ger

Abs

orbe

nt fl

ow ra

tede

crea

sed

due

tocl

oggi

ng o

f hea

tex

chan

ger

Abs

orbe

nt fl

owra

te d

ecre

ased

due

to tu

bebr

oken

Vac

uum

sid

e

Atta

ined

vac

uum

of p

urge

pum

p ca

n no

t be

obta

ined

Air

leak

age

Pal

ladi

um c

ell m

alfu

nctio

ns

Pal

ladi

um c

ell h

eate

ris

out

of o

rder

Oct

yl a

lcoh

ol is

insu

ffici

ent

Coo

ling

wat

er s

yste

m

Coo

ling

wat

er te

mp.

doe

s no

tgo

dow

n du

e to

hig

h hu

mid

ity

Pas

s pa

rtitio

n ga

sket

in w

ater

box

isre

mov

ed

Wat

er le

aks

due

topa

ss p

artit

ion

plat

e in

wat

er b

ox h

as c

orro

sion

Abs

orbe

r and

con

dens

er tu

bes

are

foul

ed

Coo

ling

wat

er fl

owra

te is

insu

ffici

ent

Con

trol s

yste

mD

rivin

g he

at s

ourc

e

Tem

p. c

ontro

ller

mal

func

tions

Ste

am c

ontro

l val

veis

out

of o

rder

Sup

ply

stea

mpr

essu

re is

low

Ste

am fl

ow ra

te is

low

5-2. AlarmError code : J-01

Error code : J-02

Error code : J-03

Chilled water pump alarmSafety device : Interlocksignal (52CH)

In case that the interlock signalof the chilled water pump comesinto the I/O board



The chilled water pump stops


Imperfect contact happens in a remote controlcircuit


Start the chilled water pump

ON the power supply


In case that the interlock signalof the chilled water pump doesnot come into the I/O board


Replace wires and/or connectors

Interlock signal wires and/or a connector is out of order Replace wires and the connector

Chilled water flow rate alarmSafety device : Chilled water flow switch (69CH)

In case that chilled water flowrate is more than 50 % of therated flow rate





In case that chilled water flowrate is less than 50 % of therated flow rate

Capacity of the chilled water pump is insufficient

Resistance of chilled water circuit is too much

A strainer in the chilled water circuit is clogged



Clean the strainer


Replace the wire


A differential pressure control valve in the chilledwater circuit malfunctions

Air is exiting in the chilled water circuit Perform air vent

A valve in the chilled water circuit is closed Open the valve

Chilled water low temp. alarmSafety device : DT1

In case that the alarm occurs at2.5 deg.C (36.5 deg.F) of chilledwater outlet temp.

Steam control valve malfunctions (Not modulate)


If several or all of the following conditions mutuallyhappen and continue・Low cooling water inlet temperature・Low chilled water flow rate (More than 50%)・Low cooling load condition・Sudden change of cooling load・Holding water quantity of chilled water is a very little

In case that the alarm occursabove 2.5 deg.C (36.5 deg.F) ofchilled water outlet temp.

Breaking of wire of DT1(The Indication of chilled water outlet temp. is 30 deg.C / 86 deg.F)


Replace the control valve

Replace DT1



DT1 is out of order (Hot water control valve does not close) Replace DT1


Error code : J-04

Error code : J-06

Error code : J-07

#1 Absorbent pump alarmSafety device : Thermal relay(51A)

In case that the thermal relay(51A) functions

Crystallization is occurring in #1 absorbent pump

A foreign material is existing in #1 absorbent pump






The magnet contactor of 51A is out of order

Absorbent flow rate is too much

In case that the thermal relay(51A) does not function

The contactor of thermal relay is out of order



Perform de-crystallization


Replace #1 absorbent pump


Correct the setting




Replace the wires


Cooling water pump alarmSafety device : Interlock signal(52CO)

In case that the interlock signalof the cooling water pumpcomes into the I/O board



The cooling water pump stops


Imperfect contact happens in a remote controlcircuit


Start the cooling water pump

ON the power supply


In case that the interlock signalof the cooling water pump doesnot come into the I/O board


Replace wires and/orconnectors

Interlock signal wires and/or a connector is out of order Replace wires and theconnector

Cooling water flow rate alarmSafety device : Cooling waterflow

In case that cooling water flowrate is more than 50 % of therated flow rate





In case that cooling water flowrate is less than 50 % of therated flow rate

Capacity of the cooling water pump is insufficient

Resistance of cooling water circuit is too much

A strainer in the cooling water circuit is clogged



Clean the strainer


Replace the wire


Air is exiting in the cooling water circuit Perform air vent

A valve in the cooling water circuit is closed Open the valve

Remark :Cooling water flowswitch(52CO) is option device


Error code : J-10

Error code : J-13

Refrigerant pump alarmSafety device : Thermal relay(51R)

In case that the thermal relay(51R) functions A foreign material is existing in Refrigerant pump






The magnet contactor of 51R is out of order

Refrigerant flow rate is too much

In case that the thermal relay(51R) does not function The contactor of thermal relay is out of order




Replace Refrigerant pump


Correct the setting




Replace the wires


Contamination of refrigerant happens Search & remove the cause

Generator hightemp. alarmSafety device : DT3

In case that thealarm occurs atset value



Leakage occurs


Inhibitor isInsufficient

Add suitable amount of the inhibitor


Check a purge pump & a drain trap.Replace purge pump oil. Drain out moisturein the drain trap and dry up inside the drain

#1 Absorbentpump does not run See J04


Bad vacuumcondition







Re-adjust thedamper

Correct thewiring

De-crystallizationAdd octylalcohol

Add solution

DT3 is out of order(Short-circuit)

Replace DT3






In case that thealarm occursbelow set value

DT3 is out of order(Breaking of wire) Replace DT3


Error code : J-14

Error code : J-16

Condition of occurring alarm

1. In case that concentrated solution concentration goes up 65% after 3 minutes of starting crystallization protection function

2. In case that concentrated solution concentration goes up 65% within 1 hour after starting crystallization protection function

3. In case that concentrated solution concentration goes up 65.5%.

Error code : J-20

Generator high pressure alarmSafety device : Pressure switch(63GH)

In case that the pressureswitch functions at the setvalue

Inside pressure of the chiller increases to 0 MPa

The pressure switch is out of order

The wire of pressure switch is cut

Probable cause is mostly wrongoperation of purgingPerform purging

Replace the pressure switch

Replace the wire

In case that the pressureswitch functions below the setvalue

Cooling water low temp.alarmSafety device : DT7

In case that the alarm occursif cooling water inlet temp.continues below rated temp.minus 13 deg.C (23.4 deg.F)for 30 minutes

Cooling water temp. control system malfunctions Contact to a facility company

Replace the microprocessorIn case that the alarm occurseven if cooling water inlettemp. continues above ratedtemp. minus 13 deg.C (23.4deg.F)

Cooling water temp. control system malfunctionsThe microprocessor is out of order

Replace DT7DT7 is out of order

High concentrationalarmSafety device : DT3,

The alarmoccurs underthe followingconditions



Leakage occurs


Inhibitor isInsufficient

Add suitable amount of the inhibitor


Check a purge pump & a drain trap.Replace purge pump oil. Drain out moisturein the drain trap and dry up inside the drain

#1 Absorbentpump does not

See J04


Bad vacuumcondition







Re-adjust thedamper

Correct the wiring

De-crystallization

Add octyl alcohol

Add solution

Driving heat amount is too high Replace the controlvalve






The alarmoccurs withoutfollowingconditions

DT3 is out of order(Breaking of wire)DT5 is out of order(Short-circuit)

Replace

Steam flow rate is toohigh

Steam supply pressureis too high

Steam control valve isout of order

Check hot watersystem


5-3. Sensor alarmError code : F-01 Chilled water inlet temp. sensor alarmSensor : DT6 (Digital sensor)

Error code : F-02 Cooling water inlet temp. sensor alarmSensor : DT7 (Digital sensor)

Error code : F-03 Cooling water outlet temp. sensoralarm Sensor : DT2 (Digital sensor)

Error code : F-04 Cooling water mid temp. sensor alarmSensor : DT12 (Digital sensor)

Error code : F-05 Condenser temp. sensor alarmSensor : DT5 (Digital sensor)

Error code : F-06 Steam drain temp. sensor alarmSensor : DT13 (Digital sensor)

Error code : F-12 Absorbent temp. sensor alarmSensor : DT10 (Digital sensor)

Error code : F-17 Chilled water flow sensor alarmSensor : 69CH (Chilled water flow switch)

Error code : F-19 Cooling water flow sensor alarmSensor : 69CO (Cooling water flow switch) OPTION



Wire is cut / short

Over range of temp.(Range : -20 to 120 degC)(Range : -4 to 248 deg.F)

Replace a sensor


Replace a wire



Wire is cut / short

Replace a sensor


Replace a wire

Error code : F-21 CPU alarm

Error code : F-22 Memory alarm

Error code : F-23 Time set alarm

Error code : F-24 Constant set alarm

Replace a microprocessor

Perform time set

Clear memory then set again

Error code : F-25 Chilled water outlet temp. sensor alarmSensor : DT1 (Cu resistance thermometer bulb)

Error code : F-26 High generator temp. sensor alarmSensor : DT3 (Thermistor)

Error code : F-28 Purge tank pressure sensor alarmSensor : 69PR



Wire is cut / shortOver range of pressure(Range : 0 to 340hPa)(Range : 0 to 0.0493 psi)

Replace a sensor


Replace a wire



Wire is cut / short


Replace a sensor


Replace a wire



Wire is cut / short


Replace a sensor


Replace a wire

Error code : F-08 Refrigerant temp. sensor alarmSensor : DT11 (Digital sensor)


5-4. Maintenance messageMessage code : H-01 OPERATE PURGE PUMP Purging shall be conducted from the purge tank.

The purge unit will be shortly filled with non-condensable gas.

Message code : H-02 HIGH CONCENTRATION There is a symptom that concentrated solution concentrationis slightly high comparing with normal operating condition.

Message code : H-03 CLEAN COOLING WATER TUBES Absorber and condenser tubes have been fouled.Tube cleaning shall be conducted.

Message code : H-04 CHECK COOLING WATER SYSTEM If cooling water inlet temp. is beyond the followingvalue, check cooling water system.PCOWT - SCOWT > 2 deg.C (3.6 deg.F) PCOWT : Present cooling water inlet temp. SCOWT : Specified cooling water inlet temp.

Message code : H-06 PURGE TANK HIGH PRESSURE Purging should be conducted from the purge unit.

Message code : H-07 COOLING WATER TUBES FOUL

Message code : H-08 COOLING WATER HIGH TEMP

Message code : H-10 POWER FAILURE When the power resumes, this message is displayed.

Absorber and condenser tubes have been slightly fouled.Tube cleaning shall be planed.

If cooling water inlet temp. is within the following value, H-08 isindicated. If H-08 is often indicated, check cooling water system.0 deg.C (0 deg.F) < PCOWT - SCOWT =/< 2 deg.C (3.6 deg.F) PCOWT : Present cooling water temp. SCOWT : Specified cooling water temp.

Graph 5-1. Fouling of heat transfer tubes in cooling water system

2

4

6

8

20 40 60 80 100

Maintenance zone

Notice zone

Normal zone

Normal Line

Maintenancejudgmentzone

Cooling load factor (%)

Foul

ing

indi

cato

r

0.6

20 80 100

Maintenance zone

Storage ratio (%)

Pre

ssur

e ris

ing

indi

cato

rof

sto

rage

tank

Graph 5-2. Vacuum condition monitoring

0

1.0

600

Noticezone

Normal zone

8

7

6

5

4

3

2

1

00 20 40 60 80 100

Abnormal stop zone





Cooling load (%)

Graph 5-3. Tendency of absorbent concentration

Concentr

atio

n indi

cat

or


Section 6 Parts replacement & Instructions

6-1. Guidance interval of parts replacement

The following intervals are guidance for replacement of parts to get stable operation.

1 Absorbent pump 24,000 or 6 years 16,000 hours or 4 years2 Refrigerant pump 24,000 or 6 years 16,000 hours or 4 years3 Purge pump 10 years 10 years4 Generator pressure gauge 28,000 hours or 7 years 20,000 hours or 5 years5 Palladium cell & heater 12,000 hours or 3 years 12,000 hours or 3 years6 Sight glass & gaskets 6 years 6 years7 Diaphragm valve gasket 6 years 6 years8 Controller 5 years 5 years9 Circuit breaker 40,000hours or 10 years 40,000hours or 10 years

10 Magnet switch 28,000 hours or 7 years 28,000 hours or 7 years11 Temperature sensor 28,000 hours or 7 years 28,000 hours or 7 years12 Rupture disk 4,800 hours or 1 year 4,800 hours or 1 year

6-2. How to change parts

6-2-1. Absorbent pump & Refrigerant pump

This instruction describes the procedure to replace an absorbent pump and a refrigerant pump.

As procedures for the absorbent pump and the refrigerant pump are same, the procedure for the absorbent

pump is explained in this material.

(1) Instrument

a) Pan to collect spilled absorbent / refrigerant solution at disassembling them

b) wood blocks

c) Box wrenches

d) Adjustable wrenches

e) Insulation tape

f) Vinyl tape

(2) Procedure

a) Be sure to confirm that the main breaker (MCBM) is turned OFF.

b) Close the isolation valves of the pump tightly.

c) Open the cover of terminal box of the pump. Disconnect power wires (U1, V1, W1) in the terminal box

of the pump.

d) Cover each end of wires by a vinyl tape to prevent wetting with solution then cover them by a vinyl back

as shown in Fig. 6-1. At this time, record wire marks.

e) Put the pan under the pump

f) Put the wood block between the pan and the pump shown in Fig. 6-2.

Operation time is less than 4,000hours per year for air-conditioning.

Heavy load operation, process useand/or continuous annual operationReplacement parts

Power wireVinyl tape

Vinyl back

Fig. 6-1

Pump

Woodblocks

PanFig. 6-2

Terminal box


g) Remove bolts of the pump and pull out the pump carefully

h) Wash the flange and the isolation valve portion mounted under the lower shell with water.

(Pure water or distilled water should be used)

i) Check if the flange surface is clean or not. If OK, mount new pump with new gasket.

Be sure to tighten all bolt uniformly because it is very difficult to do leak test at the portion.

Non-uniform tightening causes air leakage.

j) Connect the power wires with confirming wire marks and cover each connected portions with

the insulation tape and vinyl tape. Then close the terminal box cover.

k) Open the isolation valves.

l) Run the chiller to confirm the rotating direction of the pump by a rotation direction meter.

Correct direction is clockwise viewing from back of the pump. If OK, stop the chiller.

m) Perform air purging from the chiller for 1 hour (Open purge valve V1 & V3)

n) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour.

o) If there are no- abnormality, the chiller can be run on normal operation.

6-2-2. Purge pump

This instruction describes the procedure to replace an purge pump with a motor.

(1) Instrument

a) Adjustable wrenches

b) Insulation tape

c) Vinyl tape

(2) Procedure

a) Be sure to confirm that the main breaker (MCBM) is turned OFF.

b) Be sure to confirm that the purge valves (V1, V2, V3) are closed.

c) Remove purge pump oil in the purge pump.

d) Open the cover of terminal box of the pump. Disconnect power wires (U3, V3, W3) in the terminal box

of the pump.

e) Cover each end of wires by a vinyl tape to prevent wetting with solution then cover them by a vinyl back

as shown in Fig. 6-1. At this time, record wire marks.

f) Remove the 4 bolts for the flange and 4 bolts for the base shown in Fig. 6-3. Then remove the pump.

g) Put new pump.

h) Temporally tighten 4 bolts for the base. Tighten 4 bolts for the flange tightly. Then tighten 4 bolts for

the base tightly.

i) Connect the power wires with confirming wire marks and cover each connected portions with

the insulation tape and vinyl tape. Then close the terminal box cover.

j) Run the pump to confirm the rotating direction of the pump. Correct direction is shown by the arrow mark

on the V-belt cover.

k) Charge the purge pump oil up to the center of the sight glass under running of the purge pump.

l) Check that V-belt tension is about 10 mm (0.4 inch). If not, adjust the tension by sliding

the motor position.

m) Check the attained vacuum of new pump.

Purgepump

Purgepumpmotor

4 bolts for flange

4 bolts for base

Terminal box

Fig. 6-3

Sight glass


6-2-3. Sight glass

This instruction describes the procedure to replace sight glasses with gasket.

(1) Instrument


b) Bucket for solution

c) Vacuum rubber hose with copper tube

d) Nitrogen gas

e) Hose for nitrogen gas

f) Regulator for nitrogen gas

(2) Position of the sight glass

a) Evaporator

b) Bottom of the absorber

(3) Replacement of the sight glass on the evaporator.

a) If the refrigerant solution level is beyond the bottom of the sight glass, perform the refrigerant blow down.

b) Charge Nitrogen gas into the chiller up to about 9.8 kPa.

c) Discharge Nitrogen gas. (Refer to "6-12. Method of discharging Nitrogen gas")

d) Remove 6 bolt for the sight glass and remove the sight glass and gasket.

e) Clean the surface of the sight glass flange by dry cloth.

f) Put new sight glass and gasket. Tighten bolts uniformly. (Gasket is one side only. Carefully tighten bolts.)

g) Charge Nitrogen gas into the chiller up to about 49 kPa.

h) Perform leak test by soap solution.

i) Discharge nitrogen gas.

j) Perform purging until the pressure in the chiller goes down to 1.3 kPa absolute.

k) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour.

l) If there are no- abnormality, the chiller can be run on normal operation.

(4) Replacement of the sight glass on the absorber.

a) Charge Nitrogen gas into the chiller up to about 30 kPa. (Refer to "6-11. Method of charging Nitrogen gas")

b) Discharge LiBr solution from the service valve (SV4) until the solution level in the absorber goes down

to the bottom of the sight glass.

c) Discharge Nitrogen gas. (Refer to "6-12. Method of discharging Nitrogen gas")

d) Remove 6 bolt for the sight glass and remove the sight glass and gasket.

e) Clean the surface of the sight glass flange by dry cloth.

f) Put new sight glass and gasket. Tighten bolts uniformly. (Gasket is one side only. Carefully tighten bolts.)




j) Perform purging. When the inside pressure decreases about -50kPa, charge the LiBr solution

from the service valve (SV4).

j) Continue purging until the pressure in the chiller goes down to 1.3 kPa absolute.



Sight glass flange

Sight glass

Gasket

Bolt

Bolt

Fig. 6-4


6-2-4. Rupture disk

This instruction describes the procedure to replace a rupture disk.

(1) Instrument


b) Vacuum rubber hose with copper tube

c) Nitrogen gas

d) Hose for nitrogen gas

e) Regulator for nitrogen gas

f) Torque wrench

(2) Procedure

a) Charge Nitrogen gas into the chiller up to

about 9.8 kPa.

(Refer to "6-11. Method of charging Nitrogen gas")

b) Remove 4 bolts for flanges.

c) Carefully remove the rupture disk assembly.

d) Remove the cap screws and disassembly the rupture

disk assembly. Then take out the rupture disk.

e) Put new rupture disk into base and the hold down and tighten

them uniformly by the cap screws.

Tightening torque : 2 inch 30 Nm (22 ft lbs)Tightening torque : 3 inch 35 Nm (26 ft lbs)At this time, do not make a mistake of rupture disk direction.

f) Put the rupture disk assembly and gaskets with Teflon sealant

into the flanges, and tighten them uniformly by the bolts.

Tightening torque : 2 inch 70 Nm (52 ft lbs)Tightening torque : 3 inch 75 Nm (55 ft lbs)




j) Perform purging until the pressure in the chiller goes down to 1.3 kPa absolute.



6-2-5. Palladium cell & heater

This instruction describes the procedure to replace an palladium cell and heater.

(1) Instrument

a) Screw driver

b) Torque wrench

c) Adjustable wrenches

d) Fork terminals

e) Heat resistance tube

Fig. 6-7 Palladium cell assembly with heater

Rupture diskassembly

Flanges & bolts

Fig. 6-5

Gasket (T/# 9090-OR)

Upp

er tu

be s

heet

Apply Teflon sealant (T/# 9400)

Hold down

Fig. 6-6 Rupture disk assembly

Rupture disk

Flow

Cap screw

Base

Cap screw


(2) Procedure

a) Be sure to confirm that the main

breaker (MCBM) is turned OFF.

b) Close B valve tightly.

c) Open and remove the palladium cell cover.

d) Remove the heater wire screws in the connection box and remove the heat resistance tube.

e) Remove the assembling spring and bark the adhesive tape. Then disassemble the insulations.

f) Loosen two screws fixing the heater and take out the hater.

g) Loosen the screw fixing the case to the mounting and take out the case.

h) Remove the flare nut and the palladium cell.

i) Put new palladium cell. Tighten the flare nut by the torque wrench with 59-68 Nm (522-601 lbf inch).Note : Do not touch the palladium cell by fingers directory, use clean gloves.

j) Perform leak test by the bubble test from SV9 (Purge tank service valve)

Leak rate shall be 0cc per 10 minutes.k) Insert the case to the mounting with palladium cell and fix them by the screw.

l) Insert new heater into the case and fix them by the screws.

m) Insert the heater wires into the heat resistance tube.

n) Put the fork terminals to the heater wires and the connect the wires with fork terminals to the

originals terminal positions. Then put the connection box cover.

o) Assemble the palladium cell cover.

Fig. 6-9 Palladium cell

Fig. 6-8

Fig. 6-10

Insulation

Assembling spring

Adhesive tape

CaseHeaterPalladium cell

Heater CasePalladium cell

Mounting for palladium cellwelded on purge tankHoles of screw

Flare nut


6-3. Method of absorbent solution (LiBr) analyses

This instruction described to procedure for analyses of absorbent solution.

(1) Notice for analyses

a) The time of analyses

1) In case of commercial use for air conditioning (about 4000 hours operation per year), the analyses

should be conducted twice per year.

2) In case of continuously operation such as process use, the analyses should be conducted four times

per year.

b) Sampling solution and sampling position

1) Sampling solution : Diluted absorbent solution

2) Sampling position : The service valve (SV4) at discharge pipe of the absorbent pump

c) Sampling quantity

Sample the absorbent solution of 100 cc twice. First sampling solution shall be abandoned. Second

sampling solution shall be used for analyses.

d) Sample the absorbent solution during operation of the absorbent pump.

(2) Analyses itemsa) Concentration of inhibitor (Lithium Molybdate : Li2MoO4)

b) Alkalinity (Neutralization analysis)

c) All copper content and all iron content

(3) Instruments

a) Solution sampling tool

b) Bottle for solution with a cap (100 cc)

c) Pipette with scale

d) Beaker (100 cc.)

e) Burette]

f) Syringe

g) Phenolphthalein solution

h) One-tenth normal Hydrochloric acid solution (HCl)

i) 50% Hydrochloric acid solution (HCl)

j) Aluminum nitrate (Al(NO3)3 9H2O)

Aluminum nitrate is crystal. Therefore, making aluminum nitrate solution shall be required.

The method of making it is as follows.

Put 250 g of aluminum nitrate unto a bottle and pure water into the bottle until total volume

becomes 1 liter, and then mix them.

k) Pure water

(4) Sampling of the absorbent solution

a) Remove the absorbent solution at the service valve (SV4) during operation of the absorbent pump by the

sampling tool.

b) Pour the absorbent solution to the bottle from the sampling tool.


(5) Measurement of concentration of inhibitor (Lithium Molybdate : Li2MoO4)

Standard concentration of inhibitor : 50 - 150 ppma) Stand the bottle for about 24 hours. After 24 hours, most solids in the absorbent solution accumulates at

the bottom of the bottle.

b) Collect 5 milli-litter of the absorbent solution from the top of the bottle by a pipette, and then pour it into

a beaker.

c) Add 4 milli-litter of the aluminum nitrate solution and 1 milli-litter of 50 % hydrochloric acid solution into

another beaker, and mix tem.

d) Add 1 milli-litter of the solution made in the item c) into the beaker by another pipette.

e) Pour 94 milli-litter of pure water into the beaker by the burette.

The above procedure is to make solution for analysis. And its volume is 100 milli-litter. This means that

the absorbent solution is diluted to 1/20.

f) In order to measure concentration of Lithium Molybdate, "Atomic absorption spectro chemical analysis"

must be required. There is no-way to simply measure it. Therefore, this check can not be done at an site.

It is preferred to request the analysis to an official organization or an analysis company.

g) If concentration value measured is less than its standard, add inhibitor in accordance with " Method of

adjusting inhibitor content and alkali".

(6) Measurement of alkalinity (Neutralization analysis)

Standard of the alkalinity : 0.03 N - 0.07 N (P Alkalinity)a) Stand the bottle for about 24 hours. After 24 hours, most solids in the absorbent solution accumulates

at the bottom of the bottle.

b) Collect 10 milli-litter of the absorbent solution from the top of the bottle by a pipette, and the pour it into

a beaker.

c) Pour 50 milli-litter of pure water into the beaker by the burette.

d) Add Phenolphthalein (2 -3 drops) into the beaker by the syringe. The solution is colored to pink.

The above procedure is to make solution for analysis.

e) Add one-tenth normal Hydrochloric acid solution little by little into the solution by a burette until its color

becomes colorless.

f) Calculate the alkalinity according to the following formula.

N = A X 0.01 where

N : Alkalinity

A : Quantity of Hydrochloric acid solution added (milli-litter)

g) The standard of adjustment of the alkalinity

1) Alkalinity is 0.03 N - 0.07 N No addition is required.

2) Alkalinity is less than 0.03 N Add LiOH

3) Alkalinity is beyond 0.07 N Add HBr

Remark : In case of absorbent with Li2MoO4 as inhibitor, its alkalinity reduces as compared with initial

value of the alkalinity in proportion to operation hours of the chiller.


(7) Analyses of all copper content and all iron content

Limitation of the all copper content : 250 ppm max.Limitation of the all iron content : 250 ppm max.a) Shake the bottle before collecting the absorbent solution.

b) Collect 1 milli-litter of the absorbent solution from the top of the bottle by the pipette, and then pure it

into a beaker.

c) Add 1 milli-litter of one-tenth normal Hydrochloric acid solution. Into the beaker by another pipette.

d) After a few hours, pour 98 milli-litter of pure water into the beaker by a burette.

The above procedure is to make solution for analysis. And its volume is 100 milli-litter. This means that the

absorbent solution is diluted to 1/100.

e) In order to measure concentrations of the all copper and iron, "Atomic absorption spectro chemical analysis" must be required as well as the method of the measurement of inhibitor.f) If the all copper content and all iron content are beyond their limitation, all absorbent solution charged in

the chiller shall be filtered.

(8) Notes

a) In case that the absorbent solution crystallizes, melt it first and then perform the analyses.

b) In case of the analyses of the all copper and the all iron, wait for a while after hydrochloric acid solution

is added.

Notice for all iron & all copperIf these value is beyond the limitations, it means that there is a leakage. In this case, the leak test shall be

performed and repair it as soon as possible. After that, perform filtration of all absorbent solution. Then

Analyze them again.


6-4. Method of adjusting inhibitor content and alkalinity

(1) Method of adding inhibitor

This instruction describes the procedure to add inhibitor.

a) Instruments

1) Inhibitor : Li2MoO4 H2O (20wt% solution)

2) Pure water

3) Container

4) Vacuum rubber hose

5) Hose band

6) Pliers

7) Wrench

8) Rubber gloves

b) Target value of inhibitor concentration : 150 ppm

Additional volume of the inhibitor is calculated in accordance with the following formula.

Table 6-1 Initial charge LiBr solution in the factory

where Model Absorbent solution 50wt%)

X : Measured value of inhibitor concentration (ppm) TSA-16LJ-** kg lbs

A : Initial charge amount of absorbent solution 11 430 900

D : Required volume of inhibitor (cc) 12 430 900

For example 13 560 1,200

X = 40 ppm 14 620 1,400

Model : TSA-16LJ-24 21 750 1,700

A = 1,070 kg 22 810 1,800

23 980 2,200

24 1,070 2,400

c) Procedure 31 1,230 2,700

1) In order to remove air in the rubber hose, pour pure water 32 1,340 3,000

into the hose as shown in Fig. 6-12. 41 1,560 3,400

2) Connect the vacuum rubber hose to the service valve (SV3) 42 1,680 3,700

provided on the refrigerant pump discharge and fix it by 51 1,950 4,300

a hose band as shown in Fig. 6-11. 52 2,170 4,800

53 2,420 5,300

Fig. 6-11

Fig. 6-12

150 ppm - X ppm

100 x 0.465 x A = D

150 ppm - 40 ppm

100 x 0.465 x 1,070 = 547 cc

Copper tube

Vacuumrubber hose

Filled withpure water

Refrigerantpump

Samplingservice valve(SV3)

Vacuumrubber hose

Copper tube

Solutioncontainer

Inhibitor


3) Pour inhibitor added into the container.

4) Insert a copper tube into the container.

5) perform purging from the chiller.

6) Open the service valve (SV3)

7) When inhibitor starts being sucked into the chiller, watch carefully to ensure that air does not leak in.

8) Close the service valve (SV3) after charging the inhibitor.

9) Remove the vacuum rubber hose.

10) Wash the mouth of the service valve with water and put the bonnet and flare nut. Then place the cap

of the service valve after confirming the packing inside.

11) Wash all instruments with water.

12) Perform refrigerant blow down after completion of the work, and run the chiller in order to circulate the

inhibitor in the inside of chiller.

13) Continue the purging at least 30 minutes after completion of this work.

d) Notes

1) Be sure to perform this work during operation of the chiller, and be sure to carry out purging from the

chiller during this work.

2) Wear rubber gloves while this work.

3) Thoroughly wash off any inhibitor which gets on hand, skin and clothes. Take care to prevent inhibitor

entering mouth and eyes.

4) Do not spill inhibitor on a floor and do not throe it in a drain.

(2) Method of adding alkali

This instruction describes the procedure to add Alkali (LiOH) in case that alkalinity is less than 0.03 N.

a) Instruments

1) Alkali : LiOH (powder) 6) Pliers

2) Pure water 7) Wrench

3) Container 8) Rubber gloves

4) Vacuum rubber hose 9) Mask

5) Hose band

b) Target value of alkalinity : 0.07 N

Additional volume of LiOH is calculated in accordance with the following formula.

D = 28.6 x (0.07 -X) x A

where

X : Measured value of alkalinity (N)

A : Initial charge amount of absorbent solution (see Table *-*)

D : Required volume of alkali (g)

For example

X = 0.01 N

Model : TSA-16LJ-24 A = 1,070 kg

28.6 x (0.07 - 0.01) x 1,070 = 1,836 (g)


c) Procedure

1) In order to remove air in the rubber hose, pour pure water into the hose as shown in Fig. 6-12.

2) Connect the vacuum rubber hose to the service valve (SV6) provided for concentrated absorbent and

fix it by a hose band as shown in Fig. 6-13.

3) Put the alkali added into the container and melt it with pure water.

4) Insert the copper tube into the container.

5) Perform purging from the chiller.

6) Open the service valve (SV6).

7) when the alkali solution starts being sucked into the chiller, watch carefully to ensure that air does

not leak in.

8) Close the service valve after charging the alkali solution.

9) Remove the vacuum rubber hose and wash the mouth of the service valve with water. Then put the

bonnet and flare nut. And place the cap of the service valve after confirming the packing inside.

10) wash all instrument with water.

11) Run the chiller in order to circulate the alkali in the inside of the chiller.

12) Continue the purging at least 30 minutes after completion of the work.

d) Notes

1) Be sure to perform this work during operation of the chiller,

and be sure to carry out purging from the chiller during

this work.

2) Be sure to check the alkalinity again after this work.

3) Wear rubber gloves while this work.

4) Thoroughly wash off any alkali which gets on hand,

skin and clothes. Take care to prevent alkali

entering mouth and eyes. Fig. 6-13

5) Do not spill alkali on a floor and do not throw it in a drain.

6) Pay attention not to suck in any powder of LiOH during this work.

(3) Method of adding Acid

This instruction describes the procedure to add Acid (HBr) in case that alkalinity is 0.07 N or above.

a) Instruments

1) Acid : HBr (concentration : 47 %)

2) Pure water

3) Container

4) Vacuum rubber hose x 2 pieces

5) Hose band x 2 pieces

6) Pliers

7) Wrench

8) Rubber gloves

9) Mask

10) PH test paper

Fig. 6-14

Samplingservice valve(SV6)

Vacuumrubber hose

Copper tube

Solutioncontainer

Alkali solution

Heatexchanger

SV6:Open

Vacuumrubber hose

Copper tube

Solutioncontainer

HBr + Absorbent

Heatexchanger

SV4:Close

Diluted absorbent pipe

SV6:Close

Vacuumrubber hose

Copper tube

Solutioncontainer

HBr + Absorbent

Heatexchanger

SV4:Open

Diluted absorbent pipe


b) Target value of alkalinity : 0.03 NAdditional volume of HBr is calculated in accordance with the following formula.

D = 79.2 x (X -0.03) x A

where

X : Measured value of alkalinity (N)

A : Initial charge amount of absorbent solution (see Table 6-1)

D : Required volume of acid (milli-litter)

For example

X = 0.09 N

Model : TSA-16LJ-24 A = 1,070 kg

79.2 x (0.09 - 0.03) x 1,070 = 5,085 (milli-litter)

c) Procedure

1) In order to remove air in the rubber hose, pour pure water into the hose as shown in Fig. 6-12.

2) Connect the vacuum rubber hose to the service valve (SV6) provided for concentrated absorbent and

fix it by a hose band as shown in Fig. 6-13.

3) Connect another vacuum rubber hose to the service valve (SV4) and fix it with a hose band.

4) Insert two copper tubes into the container.

5) Perform purging from the chiller.


7) Remove about 50 litters of diluted absorbent solution from the service valve (SV4) into the container

when the absorbent pump is running.

8) Close the service valve (SV4) after 50 litters of the absorbent accumulates in the container.

9) Pour HBr little by little into the absorbent removed. At this time check PH value of the absorbent by

the PH test paper.

10) Stop to pour HBr when PH value of the absorbent has become 7 to 6.


12) When the absorbent starts being sucked into the chiller, watch carefully to ensure that air does not

leak in.

13) Close the service valve(SV6) after the absorbent in the container empties.

14) Repeat item 6) thru item 13) until required amount of HBr is charged into the chiller.

15) After completion to charge required amount of HBr, confirm that SV4 and SV6 are fully closed.

16) Remove the vacuum rubber hoses and wash mouths of the service valves with water and put

bonnets and flare nuts to the service valves.

17) Place caps of the service valves after confirming the packing inside.

18) Wash all instrument with water.

19) Continue the purging at least 30 minutes after completion of the work.

d) Notes

1) Be sure to perform this work during operation of the chiller.

2) Be sure to check again the alkalinity after this work.

3) Wear rubber gloves and a mask during this work.

4) Thoroughly wash off any HBr which gets on clothes. Pay attention to handle HBr. Because HBr is very

strong acid.

5) Do not spill HBr on a floor and do not throw it in a drain.

6) There may be case that gas is generated when HBr is mixed with absorbent. Pay attention not to

inhale the gas.


6-5. Method of charging solution

This instruction describes the procedure of charging absorbent and refrigerant into a chiller.

(1) Equipment use

a) Solution container (for absorbent and refrigerant)

b) Vacuum rubber hose with copper tube

c) Hose band

d) Pliers

(2) Procedure

a) Prepare the solution containers.

b) Operate a purge pump and perform the purging from the chiller.

c) Connect the vacuum rubber hose to the service valve where

solution is charged and fix it with the hose band.

d) Insert the copper tube of the vacuum rubber hose into the container.

(Keep slightly high from the bottom of the container as shown in Fig. 6-15.) Fig. 6-15

e) Open the service valve.

f) When the solution starts being sucked in to the chiller, watch carefully to ensure that air does not leak in.

g) Before the container becomes empty, tilt it so that air does not enter into the chiller as shown in Fig.6-16.

h) When the container becomes almost empty, bend the vacuum rubber hose by your hands to ensure that

air does not leak in as shown in Fig.6-17, and quickly insert the copper tubes in the next container.

Fig. 6-16 Fig. 6-17

i) Repeat item f) to h) until required charging amount solution has been charged.

j) After completion, close the service valve at once.

k) Remove the vacuum rubber hose from the service valve and wash the mouth of the service valve with

water, then put the bonnet and flare nut. And put the cap of service valve.

l) wash the vacuum rubber hose, etc. with water

m) Continue air purging at least 30 minutes after completion of this work.

(3) Precautions

a) During this work, do not spill the solution.

b) Because of high vacuum condition inside the chiller, take case to ensure that air does not leak into the

chiller during this work.

c) Carefully wash the vacuum rubber hose used before this work with water so as to prevent dire ingress.

d) Wear rubber gloves. Do not handle tools pr solution with bare hands.

e) Thoroughly wash off any absorbent which gets on hands, skin or clothes. Take care to prevent absorbent

entering eyes or mouth.

f) If absorbent spills on metal plates, etc., thoroughly wash off with water.

Lift

up s

light

ly

Samplingservice valve

Vacuumrubber hose

Copper tube

Solutioncontainer

Solutioncontainer

Vacuumrubber hose

Bending


6-6. How to perform de-crystallization

Cause of crystallizationCrystallization is occurred under complex conditions described blow. However there is few cases that

No.3 and No.4 factors causes crystallization by suitable periodic maintenance. Usually, crystallization

is occurred by No.1 and No.2 factors.

No.1 factor : Too low cooling water inlet temperature

No.2 factor : Insufficient vacuum condition (bad vacuum condition)

No.3 factor : Over driving input

No.4 factor : Insufficient absorbent flow rate

Probable location of crystallizationCrystallization is occurred mostly at concentrated absorbent in the heat exchanger. If the crystallization occurs,

The following symptoms are observed. Therefore, de-crystallization procedure at this portion is explained.

1) Chilled water outlet temperature does not go down.

2) The temperature of concentrated solution over-flow pipe increases as the pipe can not be touched.

3) The temperature of concentrated solution outlet of heat exchanger goes down as the pipe can be touched.

4) Diluted solution temperature rises (more than 40 deg.C / 104 deg.F)

Outline of de-crystallizationCrystallization generating at the outlet of concentrated solution side in the heat exchanger is melted by means of

approximate 60 deg.C (140 deg.F) of high temperature diluted solution. This high temperature cooling water is

made by the operating condition with low driving input and without cooling water.

(1) De-crystallization procedure

a) Close compulsorily the hot water control valve by service mode.

b) Operation mode of the refrigerant pump to "ON" by service mode.

c) Open the refrigerant blow valve and perform blow down.

d) Operation mode of the refrigerant pump to "OFF" by service mode.

e) Stop the chiller by "STOP" key on the operation board.

f) Turn off the electric power supply of cooling water pump and cooling tower fan.

g) Open the control panel door and jumper two terminals of cooling water pump interlock(52CO).

h) Select the operation mode to "LOCAL". Then run the chiller.

i) Perform de-crystallization by the diluted solution delivering from the absorbent pump at 50 - 60 deg.C

(122 - 140 deg.F) with adjusting the hot water control valve opening and switching ON/OFF of the cooling

water pump.

*Be sure not to exceed atmospheric pressure in the generator during this work.

O F F

9 0. 0 SET +2 sec. C H G S = 2 SET

2 sec. P u r G E 1 time r E F - PSET2 sec.

SET2 sec. O N

O F F

Select "ON"

A u t o

PushSET

O N

Select "OFF"

PushSET

Push

9 0. 0SET +2 sec. C H G S = 2 P u r G E 3 times C n. - 1

SET2 sec. n. A n u A L

A u t o

C n. - 1 5 t 0

Select "MANUAL" by & keys

Push"SET" key

Change set value to"0" by & keys 1 0 0

(Present value)

SET2 sec.

SET2 sec.


*Working time : 2 - 3 hours (This is an common value. The working time should be extended if necessary.)

*If the crystallization is very strong, conduct followings together with above work.

i-1) Charge pure water (if possible, use hot water) from service valve (SV6).

i-2) Heat the crystallization portion by gas or oil burner.

j) Check if de-crystallization is successful or not by the followings.

*No-flow of concentrated solution in the overflow pipe is confirmed.

(Temperature of the overflow pipe goes down)

*Fluid level in absorber (bottom of the lower shell) raises and the absorbent pump pressure increases.

*The temperature of concentrated solution outlet of the heat exchanger becomes warm.

k) Stop the chiller. After dilution operation, the chiller and other equipments are shut-down completely.

l) Remove the jumper wire connected in item g)

m) Return the operation mode of the refrigerant pump to "AUTO" by service mode.

n) Return the hot water control valve opening to "AUTO" & "100".

(2) After de-crystallization

a) Locate and remove causes of the crystallization.

b) Run the chiller and perform normal operation.

c) Check operating conditions of the chiller for a while after restart, and check if crystallization occurs again

or not. *Temperature *Pressure *Fluid level

d) In case that a lot of water is added to do de-crystallization work, the water shall be removed from the chiller.

However, in case of small amount water, water removing is not necessary.

*Method of removing out water :

The water (refrigerant) can be removed from the service valve (SV3) by using a small pump because the

discharge pressure of the refrigerant pump is vacuum.

Added water amount and removed water amount shall be equal. Record both water quantity.

Check removed water specific gravity. The gravity shall be less than 1.01 (concentration :Less than 1.5%)

Crystallization occurring in the generatorIf generator temperature is higher than the temperature at last stop, hot water flows into the generator due to

leakage of a hot water shut-off valve. This causes crystallization in the generator. Accordingly, the generatortemperature should be checked even if a chiller is shut-down.If such condition is found out, run the chiller as soon as possible. Normally, the crystallization melts by the

operation. However, if the condition is not found out long time, 1 week or more, the crystallization may become

hard. In this case, it may be necessary to charge a lot of refrigerant to do de-crystallization.

In order to prevent this problem, it is most important that "the shut-off valve shall be closed during shut-down of

the chiller" shall be definitely informed to an operator.

9 0. 0 SET +2 sec. C H G S = 2 SET

2 sec. P u r G E 1 time r E F - P SET2 sec. A U T O

O F F

Select "AUTO"

O N

PushSET

9 0. 0 SET +2 sec. C H G S = 2 SET

2 sec. P u r G E 3 times C n. - 1SET2 sec.

SET2 sec.

n. A n u A LA u t o

PushC n. - 1 5 tSET2 sec. 1 0 0

Select "Auto" by & keys

Push"SET" key

Change set value to"0" by & keys 2 0

(Present value)

During de-crystallization work, this value is changed approximate0 - 30 in order that the dilution solution temperature is kept between50 deg.C (122 deg.F) and 60 deg.C (140 deg.F)


6-7A. Reference material of tube cleaning (LJ)

This instruction describes the method of tube cleaning as reference only.

(1) Cleaning procedure

Check scale condition

Check scale adhesion condition

Sample the scale

Check prior to cleaning

1) determine proper cleaning agent

*Perform dissolving test of the scale using various cleaning agents.

*determine a drainage way.

Cautions

(a) Dispose, drain, and/or treat west water properly.

(b) Do not drain a hydrogen peroxide based cleaning agent into a purifying cistern or

activate sludge treatment system.

(c) Refer cleaning using a fluoride based cleaning agent to a professional.

Preparation

2) Determine the cleaning method.

*Determine cleaning area, amount of water and chemicals.

*Prepare instruments, chemicals and protective tools.

(1) Instrument

It is recommended to use both chemical cleaning and brushing cleaning for tube cleaning.

Cooling tower

Absorption chiller

Chemicalsupplytank

Neutralizationtank

Fig. 6-18

Channel AChannel A

Channel B

Make a reversible flow direction circuit


(2) Chemical cleaning procedure

Scale / Slime

Chemical cleaning

Alkali agent Measure the amount of an alkali agent for neutralization.

Neutralization Conduct the neutralization for 30 to 60 minutes for drain out the chemical.

Drainage pH value of the solution drained shall be 6 - 8.

Cleaning with water Flow the water through the channel A and B.

Repeat 3 to 5 times

Drainage Check pH value and drained water transparency.

Visual checking Check if brush cleaning is required, Brush cleaning

Visual checking

Water cleaning Circulate water throughout entire cooling water system, then clean using

water by continuous blowing for 2 hours or more. (Channel B)

Cooling water system *Use alkaline water (pH 8 - 9) for rust prevention.

is filled with new water *If there is a possibility of freezing in winter season, use anti-freeze solution

having anti-corrosion agent.

(3) Determining a chemical agent for cleaning (Dissolving test)

Collect the scale to be cleaned. Perform the dissolving test using an available chemical agent. Determine

the most suitable chemical agent.

Put the scale into the chemical agent with the

specified concentration. Then observe the condition

of bubbles and the dissolving condition of the scale.

The more bubbles are emitted and more scale is

dissolved, the more effective the cleaning chemical

agent is.

The qualification must be necessary for handling of the fluoride based chemical agent. The chemical is

extremely hazardous to both humans and equipments. Therefore, If the chemical is required, the professional

shall be required.

Scale

A BBad

CGood

Chemical agent


(3) Notice for draining waste water

*Sewerage : Drain waste water after conducting proper treatment

*Rivers / Lakes / Swamps / Farm land / Fish farm : Do not drain

*Waste water treatment facilities : The hydrogen based waste water can not be drained into a purifying

cistern or activate sludge treatment system.

Waste water standard of public sewerage in Japan (Reference only)

Items Standard

Temperature Less than 45 deg.C (113 deg.F)

Hydrogen ion concentration 5 < pH < 9

(4) Method

a) Prepare water, chemical agent, neutralization agent and rust preventive.

b) Confirm the area and circuit to be cleaned.

c) Prepare protection tools (gloves / goggles / mask / etc.)

d) Make the cleaning circuit around the pump as shown in Fig. 6-19 for reversible water flow.

Use suitable capacity pump for circulating the chemical agent. The below table shows pumps as reference.

Table 6-2

Flow rate Total head Output

0.8 m3/h (3.5 gpm) 9.5 m (31 ft) 2.2 kW

0.2 m3/h (0.9 gpm) 6.5 m (21 ft) 0.4 kW

(5) Others

a) In case of the tube cleaning together with cooling tower, pay attention that a chemical cleaning agent does

not splash out.

b) For safety, prepare anti-chemical sheet on the working area.

c) If cleaning work continues two or more days, fill the cleaning portion with clean water (ex. City water) at the

end of daily work.

Connected with the chiller

Inlet port or Drain port

Inlet port or Drain port

Connected with the chiller

Pump

Fig. 6-19


Table 6-3 Type of scale VS Cleaning chemical agent

Type of scale : Iron rust scaleFeature of scale Color : Red brown or black / Hard scaleSuitable cleaning agent Hydrochloride acid type

Neutralizing method Take the cleaning agent out of a chiller then neutralize using caustic soda.Cautions It can not be used for water heater.

Ca.Mg.salt scaleFeature of scale Color : Gray white / The scale is soft. It can be crashed into powder by fingers.

When acid is added, bubbles are generated violentlySuitable cleaning agent Sulfamic acid typeNeutralizing method Take the cleaning agent out of a chiller then neutralize using caustic soda.Cautions As sulfamic acid solution will wither plants if it is drained as is, be sure to neutralize

it before draining.Silicate scale

Feature of scale Color : Gray white / The scale is very hard and can not be crashed into powder by fingers.The scale is not dissolved even if hydrochloric acid is added.

Suitable cleaning agent Hydrofluoric acid type / Organic salt type

Neutralizing method Take the cleaning agent out of a chiller then neutralize using slaked lime.

Cautions A professional shall be required. Do not use an agent which contains ammonia asit may react with copper (ammonia fluoride).

SlimeFeature of scale Color : Green, Gray, Black, Brown , Yellowish / Extremely soft / Viscous matterSuitable cleaning agent Hydrogen peroxide type / Organic acid type

Neutralizing method No need to neutralization, however clean with water sufficiently after cleaning.

Cautions If the cooling water is acidly, do not use hydrogen peroxide type chemical agent.The hydrogen peroxide type waste water shall not be drained into a purifying cisternor activated sludge treatment system.

Slime & Iron scale coexistFeature of scale Color : Yellowish, Brown / Soft / Viscous matterSuitable cleaning agent Hydrogen peroxide type / Hydrochloric acid type

Neutralizing method If hydrochloric acid type agent is used, neutralize it by using caustic soda.

Cautions The cautions and prohibited items for cleaning of the scale where a variety of those sameas those for the cleaning agents mentioned above.

Iron & Silicate coexistFeature of scale Color : Yellowish, Brown / Somewhat softSuitable cleaning agent Hydrochloric acid type + Hydrofluoric acid type

Neutralizing method Take it out of the system, then neutralize it by using slaked lime.

Cautions Same the aboveSilicate & Ca. Mg salt coexist

Feature of scale Color : Grayish white / Very hard scaleWhen hydrochloric acid is added, some bubbles are generated.

Suitable cleaning agent Hydrofluoric acid type + Sulfamic acid type / Hydrofluoric acid type + Hydrochloric acid type


Cautions Same the aboveScale where Iron & Ca. Mg salt coexist

Feature of scale Reddish brown / Hard scaleSuitable cleaning agent Hydrochloric acid type


Cautions Same the above


Information for tube cleaningTube quantity Tube inner dia.

Abso. Cond. Evap. Gene. Abso. Cond. Evap. Gene.

TSA-16LJ- mm inch Tubes mm inch mm inch mm inch mm inch11 2066 81.3 301 170 208 174 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

12 2066 81.3 357 204 250 192 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

13 3086 121.5 301 170 208 162 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

14 3086 121.5 357 204 250 192 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

21 3086 121.5 415 238 298 224 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

22 3086 121.5 478 272 337 256 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

23 4106 161.7 415 238 298 224 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

24 4106 161.7 478 272 337 256 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

31 4106 161.7 542 306 373 288 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

32 4106 161.7 604 340 414 324 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

41 4106 161.7 695 382 460 359 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

42 4106 161.7 791 425 560 400 14.9 0.587 15.0 0.591 14.8 0.583 16.7 0.657

51 4106 161.7 1064 400 702 458 14.9 0.587 18.0 0.709 14.8 0.583 16.7 0.657

52 4648 183.0 1064 400 702 458 14.9 0.587 18.0 0.709 14.8 0.583 16.7 0.657

53 5146 202.6 1064 400 702 458 14.9 0.587 18.0 0.709 14.8 0.583 16.7 0.657

Holding water quantity

Cooling water Chilled water Driving hot water

Abso. + Cond Evap. Gene.TSA-16LJ- Liter U.S.gal Liter U.S.gal Liter U.S.gal

11 332 87.7 114 30.1 108 28.512 365 96.4 129 34.1 116 30.613 405 107.0 151 39.9 139 36.714 450 118.9 174 46.0 159 42.021 579 153.0 224 59.2 198 52.322 632 167.0 245 64.7 220 58.123 693 183.1 276 72.9 248 65.524 763 201.6 304 80.3 277 73.231 976 257.8 354 93.5 330 87.232 1045 276.1 383 101.2 362 95.641 1305 344.7 485 128.1 439 116.042 1405 371.2 555 146.6 475 125.551 1972 520.9 703 185.7 560 147.952 2127 561.9 769 203.1 614 162.253 2270 599.7 829 219.0 664 175.4

Tube lengthModel

Model


Inner shape of tubes

Absorber tube Evaporator tube

Condenser tube

Generator tube


Information for tube cleaning

Tube quantity Tube inner diameter

Abso. Cond. Evap. Absorber Condenser Evaporator

TSA-16TJ- mm inch Tubes mm inch mm inch mm inch

11 2066 81.3 301 170 208 14.9 0.587 15.0 0.591 14.8 0.583

12 2066 81.3 357 204 250 14.9 0.587 15.0 0.591 14.8 0.583

13 3086 121.5 301 170 208 14.9 0.587 15.0 0.591 14.8 0.583

14 3086 121.5 357 204 250 14.9 0.587 15.0 0.591 14.8 0.583

21 3086 121.5 415 238 298 14.9 0.587 15.0 0.591 14.8 0.583

22 3086 121.5 478 272 337 14.9 0.587 15.0 0.591 14.8 0.583

23 4106 161.7 415 238 298 14.9 0.587 15.0 0.591 14.8 0.583

24 4106 161.7 478 272 337 14.9 0.587 15.0 0.591 14.8 0.583

31 4106 161.7 542 306 373 14.9 0.587 15.0 0.591 14.8 0.583

32 4106 161.7 604 340 414 14.9 0.587 15.0 0.591 14.8 0.583

41 4106 161.7 695 382 460 14.9 0.587 15.0 0.591 14.8 0.583

42 4106 161.7 791 425 560 14.9 0.587 15.0 0.591 14.8 0.583

51 4106 161.7 1064 400 702 14.9 0.587 18.0 0.709 14.8 0.583

52 4648 183.0 1064 400 702 14.9 0.587 18.0 0.709 14.8 0.583

53 5146 202.6 1064 400 702 14.9 0.587 18.0 0.709 14.8 0.583

Holding water quantity

Cooling water Chilled water

Absorber + Condenser Evaporator

TSA-16LJ- Liter U.S.gal Liter U.S.gal

11 332 87.7 115 30.4

12 365 96.4 130 34.3

13 405 107.0 151 39.9

14 454 119.9 174 46.0

21 579 153.0 224 59.2

22 632 167.0 245 64.7

23 693 183.1 286 75.6

24 763 201.6 314 83.0

31 976 257.8 354 93.5

32 1045 276.1 383 101.2

41 1305 344.7 485 128.1

42 1405 371.2 555 146.6

51 1978 522.5 703 185.7

52 2133 563.5 769 203.1

53 2276 601.3 829 219.0

Model

Model Tube length


Inner shape of tubes

Absorber tube Evaporator tube

Condenser tube


6-8. Solution and refrigerant sampling

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

Equipment use

1. Sampling cylinder and attachments for service valve

2. Vacuum rubber hose

3. Pliers

4. Vacuum gauge (0-1kPa (0-0.15psi))

Precautions1. Because of high vacuum condition inside the chiller, take care to ensure that air never leak

into the chiller during this work.

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

3. When solution (absorbent & refrigerant) is sampled at SV3, SV4 and SV6. Procedures at

each service valve are the same manner.

Position of service valves SV3, SV5, SV6

SV3 : Service valve mounted at the discharge pipe of the refrigerant pump

To remove refrigerant

SV4 : Service valve mounted at the discharge pipe of the absorbent pump

To remove diluted absorbent solution

SV6 : Service valve mounted at the outlet side of the heat exchanger shell

To remove concentrated absorbent solution

4. Pour solution sampled into another container. Do not spill/pour the solution to a sewage, etc..

Procedure1. Confirm manual purge valves (V1, V2 and V3) to close.

2. Remove a flare nut and a bonnet of SV1, and connect an attachment to the service valve.

3. Remove a flare nut and a bonnet of SV4 where absorbent is sampled, and connect an

attachment to the sampling service valve.

4. Connect a vacuum rubber hose and a sampling cylinder to the attachment as shown

in Fig 6-22.

5. Run a purge pump and open up V1.

6. Open SV1 and the vacuum valve.

7. When the indication of the vacuum gauge becomes about 0.5kPa(0.07psi), close the

vacuum valve.

8. Remove the vacuum rubber hose from SV1, and connect it to SV4 as shown in Fig. 6-23.

9. Open the vacuum valve.

10. Open SV4.

11. When the sampling cylinder is filled with absorbent, close SV4.

12. Close the vacuum valve and remove vacuum rubber hose from SV4 service valve.

13. Upon completion of this work, remove the attachment, and put the bonnets and flare nut.

Also put the caps of both service valves after checking their packings.

14. Stop the purge pump.

15. Finally, wash all tools with water.


Sampling cylinder

V3

V2

SV1

V1

Liquid trap

Purge pump

Attachment

Vacuum rubber hose

Vacuum valve

Fig. 6-22

Sampling service valve(SV3, SV4, SV6)

Attachment

Vacuum rubber hose

Vacuum valve

Sampling cylinder

Fig. 6-23

54(2-

54(2

-1/8

")

280(11")

Sampling cylinder(Material : Acryl rosin)

Rubber hose

Steel wire

Copper tube

Flare nut

Valve

Copper tube

Rubber cup

150(

5-15

/16"

)

150(5-15/16")

Copper tube

Attachment

Flare nutFig. 6-25

Fig. 6-24

Fig. 6-26


6-9. Measuring concentration

This instruction describes the procedure to measure concentration of absorbent solution and

refrigerant.

Equipment to use

1. Sampling cylinder

2. Gravimeter

Scale: 1.0-1.2 (for refrigerant)

Scale: 1.4-1.6 (for diluted absorbent)

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

3. Thermometer

Precautions1. Take care not to damage the gravimeter and thermometer.

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

3. Quickly perform this measurement.

Procedure1. Fill the sampling cylinder to about 80% with solution to be measured.

2. Vertically keep the sampling cylinder, and insert a gravimeter into the sampling cylinder.

3. When the gravimeter stops moving up and down, read the scale of the gravimeter which shows

gravity of the solution.

4. Remove the gravimeter and put it aside. Then insert the thermometer into the sampling

cylinder and stir the solution thoroughly.

5. When the temperature is stabilized, read the scale on the thermometer.

6. Remove the thermometer and put it aside.

7. Store the solution in another bottle.

8. Using the concentration diagram of Lithium Bromide solution, read the concentration.

9. Upon completion of measurement, wash the gravimeters, thermometer and sampling cylinder

with water. And store them so that they are not damaged.

Example:

The horizontal axis represents temperature and

the vertical axis represents specific gravity.

The lines going down from left to right represent

fixed concentrations.

For example, if the specific gravity is 1.77 and the

temperature is 45oC(113oF), the concentration given by the point of intersection of lines projected from

these values will be 63%, as shown in Fig. 6-27.

6463

62

Con

cent

ratio

n (%

)

45oC(113oF)Temperature

Spec

ific

grav

ity

1.77

Fig. 6-27


Fig. 6-28


6-10. Damper adjustment

Typically the factory damper setting is adequate for most unit start-ups, adjusting the damper should

be performed only if necessary. If the damper adjustment is necessary, make only a subtle adjustment

in 1o or 2o. Allow unit operation to stabilize for at least 1/2 - 1 hour between an adjustment before makinganother adjustment. The damper adjustment should only be performed at full load operating conditions

and never at partial load conditions. Once properly set, the damper should never require further

adjustment.

Solution line

Damper

Fig. 6-29

Note: full close 0o ; full open 90o


6-11. Method of charging Nitrogen gas

This instruction describes the procedure to charge Nitrogen gas (hereinafter N2 Gas) into a chiller.

Table 6-4 Inner Volume

(1) Equipment use TSA-16LJ- (Liter)

a) N2 gas : required volume (See the table) 11 1,635

b) Pressure regulator 12 1,578

c) Pressure proof hose 13 2,502

d) Pliers 14 2,372

e) Valve key for N2 gas cylinder 21 3,150

22 3,010

(2) Standard 23 4,207

The charged pressure can be measured by a generator pressure gauge. 24 4,020

a) For storage of a chiller : 19.6 kPa 31 5,022

b) For leak test : 49 kPa 32 4,824

d) At replacement of parts : 9.8 kPa 41 6,142

42 5,901

(3) Procedure 51 8,232

a) Prepare N2 gas cylinders and attach a pressure regulator to a N2 gas cylinder. 52 9,348

b) Connect a pressure proof hose to the outlet of the pressure regulator, then 53 10,350

slightly open a valve on the top of the cylinder in order to purge air being in the

hose. After purging, close the valve.

c) Connect the other end of the hose to SV1, and fix it with a hose band.

d) Check that V1, V2, V3 and SV1 are fully closed.

e) Open V2 and then open SV1.

f) Using the pressure regulator, charge a small amount of N2 gas into the chiller.

g) Watch the generator pressure gauge during charging N2 gas. When the pressure in the chiller reaches

to required pressure, close SV1, and then close the valve of the N2 gas cylinder.

h) Remove the hose from SV1 and put the cap to SV1.

i) Remove the pressure regulator.

(4) Precautions

a) Since the pressure in the N2 gas cylinder is very high

(Commonly 15 MPa), pay attention to handle it.

b) Do not suddenly rise the primary and/or secondary

pressure of the pressure regulator.

(Secondary pressure shall be maximum 0.5 MPa.)

c) Fix N2 Gas cylinder so that it does not fall over.

d) Be sure not to open V1 and V3 during this work.

V3

V2

SV1

V1

Liquid trap

Purge pump

Fig. 6-30


6-12. Method of discharging Nitrogen gas

This instruction describes the procedure to discharge Nitrogen gas (hereinafter N2 Gas) from a chiller.

(1) Equipment to use

a) Pliers

(2) Standard

The pressure in the chiller becomes atmospheric pressure (0MPa).

(3) Procedure

a) Check that V1, V2, V3 and SV1 are fully closed.

b) Open V3.

c) Remove a cap and flare nut of SV1 and open it.

d) When the reading of the generator pressure gauge becomes atmospheric pressure (MPa), close SV1.

(4) Precautions

a) Be sure to open V1 and V2 during this work.

b) During this work, ventilate the machine room adequately.


Section 7A Specifications (LJ)

7-1 Nomenclature

TSA- 16LJ - 11 E - L C1 2 3 4 5

1 Heat source type 16LJ : Single effect low temperature hot water type

2 Capacity code (Nominal capacity : US Refrigerant ton)

16LJ USRT

11 75

12 90

13 110

14 135

21 155

22 180

23 210

24 240

31 270

32 300

41 335

42 375

51 420

52 470

53 525

3 Operation E : Standard type

4 Fuel type

L Low temperature hot water

5 Voltage

C 400V 50Hz

E 208V 60Hz

F 460V 60Hz


7-2 Scope of supply

Fig. 7-2-1 For EC market


Fig. 7-2-1 For USA market


Section 7B Specifications (TJ)

7-1 Nomenclature

TSA- 16TJ - 11 E - S C1 2 3 4 5

1 Heat source type 16TJ : Single effect steam type

2 Capacity code (Nominal capacity : US Refrigerant ton)

16TJ USRT

11 100

12 120

13 150

14 180

21 210

22 240

23 280

24 320

31 360

32 400

41 450

42 500

51 560

52 630

53 700

3 Operation E : Standard type

4 Fuel type

S Steam

5 Voltage

C 400V 50Hz

E 208V 60Hz

F 460V 60Hz


7-2 Scope of supply

Fig. 7-2-1 For EC market

Page 5/ Sec. 7 TJ Series

Fig. 7-2-1 For USA market

Page 6/ Sec. 7 TJ Series

16tj_lj-Training_book-2 CARRIER ABSORB

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Transcript of 16tj_lj-Training_book-2 CARRIER ABSORB