Carrier 16LJ-01 Operation Manual Download Page 47 | Manualshive

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4-2. PERIODIC MAINTENANCE

To use the Chiller to its optimum performance, it requires the purging, refrigerant
blow down, absorbent control, and management of combustion equipment, etc. We
recommend that you make a maintenance contract with Carrier service agent.

4-2-1. Purging

The non condensable gas of the machine inside, not only decreases cooling capacity but also
has a bad influence on the life of the machine.
Please leave it to Carrier service personnel under the
maintenance contract. The customer can carry out the purging, but should take instruction

by our service personnel.

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Summary of Contents for 16LJ-01

Page 1: ...Absorption Chiller OPERATION MANUAL 16LJ 01 02 03 Original instructions ...

Page 2: ...ce agent Product Information If you have problems of questions concerning your chiller you will need the following information Model and serial numbers are on the nameplate on the bottom of the control panel Model No Serial number DECLARATION OF CONFORMITY This product is marked CE as it satisfied EEC Directive No 2006 42 EC 2004 108 EC 97 23 EC 90 396 EEC and conforms with following standards Thi...

Page 3: ...STRUCTIONS 15 3 1 SELF DIAGNOSTIC FUNCTION 15 3 2 DESCRIPTION OF KEYS AND THEIR FUNCTIONS 16 3 3 SETTING OF OPERATION BOARD 17 3 4 COOLING OPERATION 23 3 5 HOW TO CHANGE INDICATION ON DATA DISPLAY 26 3 6 HOW TO CHANGE INDICATION AND SETTING POINT 28 3 7 MAINTENANCE MESSAGE 29 3 8 ALARM INDICATIONS AND ACTIONS 31 4 MAINTENANCE 40 4 1 DAILY MAINTENANCE 40 4 2 PERIODIC MAINTENANCE 43 4 3 WATER TREATM...

Page 4: ... global impact by greatly reducing electricity consumption and eliminating the use of greenhouse gases 7 Environment Molybdate solution inhibitor is used with no impact on environment 8 Low noise and vibration The absorption chiller doses not utilize a large motor compressor and this leads to quiet trouble free operation 9 Small footprint saves facility space 0 2 Use of product Absorption Chiller ...

Page 5: ...em The illustration to the left indicates that it should be grounded After reading this manual it should be kept in fixed place to be available for any user at any time 1 1 1 For safety usage TURN OFF THE BREAKER BEFORE CLEANING AND CHECKING STOP THE OPERATION IN CASE OF A FIRE EARTHQUAKE OR POSSIBLE THUNDERBOLT Always turn off the breaker before cleaning and checking the cooling tower fan chilled...

Page 6: ...soline thinner etc close to the chiller flue chimney and oil tank to prevent a fire DO NOT OPERATE THE CHILLER WHEN GAS SMELLS Do not operate the chiller when gas smells Do not turn on off any switch to prevent a fire DO NOT TOUCH ANY ROTATING PART OF FANS Keep away your fingers from any rotating part of fans or pumps to avoid possible injury Do not touch Prohibited Prohibited Prohibited ...

Page 7: ...l specialists for service or maintenance Wrong service maintenance may cause electric shocks a fire or burns Must be observed AUTHORIZED PERSONNEL ONLY DO NOT POUR WATER OVER THE CHILLER OR CONTROL PANEL A notice For Authorized Personnel Only must be affixed to the chiller to keep away unauthorized personnel from touching it If this is anticipated enclose Prohibited the chiller with a protective f...

Page 8: ...re or leaked absorbent which may cause corrosion of metal areas or cause skin diseases Prohibited The specified pressure of chilled hot water and cooling water must strictly be observed Incorrect pressure may cause spout or leak which may cause a short circuit or Must be observed burns DO NOT TOUCH THE HIGH TEMPERATURE AREAS STOP THE PURGE PUMP TO REPLACE OIL Do not touch the high temperature area...

Page 9: ...Y AUTHORIZED PERSONNEL SHOULD REMOVE OR REPAIR THE CHILLER ONLY AUTHORIZED PERSONNEL SHOULD DISPOSE OF THE CHILLER Any relocation or moving of the chiller should be done by authorized personnel only Incomplete work could result in water leak electric shocks or a fire Must be observed To dispose of the chiller contact the local specialists Any defective disposal may cause corrosion of metal areas o...

Page 10: ... is in the dilution cycle operation Do not stop the air handling unit before the necessary time to prevent possible subcooling Do not perform an insulation test on the control circuits of the electric controller Use Carries recommended interlock system for stop start of the auxiliary equipment The interlock system automatically stops starts chilled water pump and cooling water pump Please follow t...

Page 11: ...USE ENVIRONMENT 1 3 1 Machine room Absorption Chiller is indoor use ONLY IP number of Absorption Chiller is IP40 Please keep the machine room temperature between 5 and 40 for protection of the solution crystallization during chiller shut down Please keep the humidity in the machine room within 90 1 3 2 Field wiring For CE please connect to power source by overvoltage category Ⅲ and to other wiring...

Page 12: ...g 2 1 WATER CONNECT SIDE Fig 2 2 CONTROL PANEL SIDE Cooling water inlet Rupture disc Chilled water outlet Chilled water inlet Hot water outlet Hot water inlet Cooling water outlet Evaporator Generator Condenser Absorber Power box Control panel ...

Page 13: ...9 2 2 CONTROL PANEL Fig 2 3 CONTROL PANEL Fig 2 4 CONTROL PANEL inside ...

Page 14: ...10 Fig 2 5 POWER BOX Fig 2 6 POWER BOX inside TERMINAL BASE CIRCUIT BREAKER MAGNET SWITCH OVERCURRENT RELAY ...

Page 15: ...11 Fig 2 7 OPERATION BOARD ...

Page 16: ...on after leaving the absorber section passes through the heat exchanger where it is heated by the concentrated solution The concentrated solutions are cooled by the diluted solution This cooling process of the concentrated solution allows for greater absorbing power due to its lower temperature d GENERATOR The passes through the heat transfer tubes of generator The diluted solution in the generato...

Page 17: ... inlet temperature DT8 No use DT9 No use DT10 Diluted solution temperature at Absorber outlet DT11 Refrigerant temperature at Evaporator DT12 Cooling water mid temperature DT13 No use DT14 No use DT15 Driving hot water inlet temperature DT16 Driving hot water outlet temperature 23CH Temperature controller 69CH Chilled water flow switch PCH Palladium cell heater 69PR Purge tank pressure NAME SYMBOL...

Page 18: ...14 Fig 2 8 FLOW DIAGRAM ...

Page 19: ...er in a control panel and when it dose a self diagnostic function acts as follows 1 Data display the 7 segment LED and all LEDs light up 2 The data display shows a version number when there is no abnormality When there is a power failure H 10 is displayed after power return NOTE The version number differs according to an each Chiiler type 3 The data display shows the generator temperature 120 4 Fi...

Page 20: ... reset on an abnormality occurred 6 Data display 7 segment LED It shows temperature set value etc 7 Stand by indication lamp Push a run key and the Chiller begins operation until it light up 8 Dilution indication lamp It lights during dilution operation 9 Safety circuit indication lamp It lights a controlled circuit when a power supply is supplied 10 Power indication lamp There is a power supply t...

Page 21: ...perature generator temperature Push the SET key for about 2 seconds Push key Push the SET key for about 2 seconds Push the SET key for about 2 seconds Push or key Push the SET key for about 2 seconds Push key Push the SET key for about 2 seconds Push key to set the month Push key 17 ...

Page 22: ...ut 2 seconds Push key Push the SET key for about 2 seconds Push key to set the hour Push key Push key to set the minute Push the SET key for about 2 seconds Push the BACK key Push the BACK key Display example High temperature generator temperature 18 ...

Page 23: ...y functioning for an accumulative period of about six months Note SW3 for battery backup is set OFF at the factory to avoid burning battery power When SW3 for battery backup is set OFF in case of power failure F 21 CPU alarm or F 23 Time set alarm will is displayed Please reset time setting In case that SW3 for battery back up is set ON and F 21 or F 23 are displayed it is necessary to replace the...

Page 24: ...Fig 3 3 SW3 backup switch and backup battery SW3 Backup switch UP ON DOWN OFF Backup switch 20 ...

Page 25: ...es it Display example High temperature generator temperature Push the SET key for about 2 seconds Push or key Push the SET key for about 2 seconds Push or key if you need Push the SET key for about 2 seconds And push or key To change o C To change o F By pushing the SET key o C mode is decided By pushing the SET key o F mode is decided 21 ...

Page 26: ...ture Push the SET key for about 2 seconds Push or key Push the SET key for about 2 seconds Push or key Push the SET key for about 2 seconds Then push or key To change static mode To change pulse mode By pushing a SET key static mode is decided By pushing a SET key pulse mode is decided Push the SET key for about 2 seconds Then push or key To change static mode To change pulse mode By pushing a SET...

Page 27: ...et temperature is set as specified As for the indication of set value please refer to Section 3 8 2 Check of hot water line 1 Make daily inspection Section 4 2 Check that the valve s is open NOTE If the chilled hot water pump cooling water pump and Chiller are interlocked each pump runs automatically when starting the Chiller If otherwise the start sequence must be 1 Chilled water pump 2 Cooling w...

Page 28: ...ion mode 1 Press Remote key on the operation board of the Chiller Remote indication lamp of the key lights 2 Turn on the start switch on the remote control panel of field supply The indicator lamp of Run key on the operation board of the Chiller lights 3 Automatic operation starts Fig 3 6 Operation board NOTE In local operation mode a signal coming from the remote control panel is not effective In...

Page 29: ...e remote control panel of field supply 2 Another way to stop the chiller is to press Stop key on the operation board of the chiller during remote operation NOTE If the chilled water pump cooling water pump and Chiller are interlocked each pump stops automatically when the Chiller stops If otherwise please stop them in the following sequence 1 The Chiller 2 Cooling water pump 3 Chilled water pump T...

Page 30: ... when there is no key operation for 1 minute again 3 5 2 How to change indication If you press key the indication on data display changes in order and pressing key it changes in reverse order If you press key again when you get to the last indication it returns to the regular indication Fig 3 9 Operation board Fig 3 8 Operation board Data display Select key It changes an indication of a data displ...

Page 31: ...mes a generator temperature indication Table 3 1 Typical indication flow Data code Data name Display Means Genarator temperature 135 1 Chiller operation hours 12355hours 2 Absorbent pump operation hours 5235hours 3 2 absorbent pump operation hours No use 4 Combustion hours No use 5 Refrigerant pump operation hours 503hours 6 Purge pump operation hours 107hours 7 Chiller on off times 63times 8 Abso...

Page 32: ...ows setting point temperature blinks Push or key 7 5 Push the SET key Setting point change is decided When it pushes whether there is no key operation and the BACK key for 1 minute it becomes a generator temperature indication NOTE 1 Wrong setting may cause the failure of the Chiller If you need to change setting point please be sure to consult Carrier service agent In case you set chilled water o...

Page 33: ... cooling water system Check the cooling water pump cooling tower etc H 06 Purge tank high pressure Purge tank pressure is high H 07 Cooling water tubes foul Fouling of cooling water tubes H 08 Cooling water high temperature Cooling water temperature is high H 10 Power failure There was power failure in time that the Chiller is operating mark When this appears the Chiller needs an immediate action ...

Page 34: ...ing of cooling water tubes Cooling water tubes must be cleaned Contact Carrier service agent to do the job 2 Vacuum rate The purge tank must be purged immediately In case this indication is shown frequently contact Carrier service agent 3 High temperature of cooling water Check the cooling water pump cooling tower etc 4 Power failure See section 3 8 5 30 ...

Page 35: ... content of the alarm it stops without dilution cycle operation Display example Chilled water low temperature It shows an alarm code only when an abnormality occurrs and when an abnormality of a plural occurs high thing of a privileged grade is shown and under numeral right of the alarm code dotted is shown Display example Chilled water low temperature Further an alarm code of a plural is shown in...

Page 36: ...option Check the content of the alarm and solve it Press STOP key on the operation board after the troubleshooting is completed The indication lamp of STOP key stops blinking and remains lit The alarm code on the data display disappears NOTE 1 Data display shows alarm continually If you press the STOP key before eliminating the cause of the alarm Make sure this is done Start operation consulting S...

Page 37: ...er temperature is too low 24 or below after 30 minutes Prevention of Cooling water pump interlock has failure Crystallization Few flow rate of cooling water 50 or below Generator s 95 temperature is too high Protection of High concentration of absorbent 65 0 or above generator 2 times 65 5 or above Protection of Motor Absorbent pump has overload Rated current Refrigerant pump has overload value or...

Page 38: ...stem strainer air leak in the pipe line etc Is the chilled water setting point too low Correct them to specified setting point Cooling water temperature is too low Is the cooling water setting point too low Few flow rate of cooling water Correct them to specified setting point Option ex 28 Correct the above causes and restart the Chiller If it still gives you the CHILLER ALARM check the following ...

Page 39: ...of the Check that the chilled water pump Auxiliary Chilled water pump interlock has and cooling water pump are rotating failure Start the pumps equipment s Check the ventilation fan and or other Cooling water pump interlock has equipment s which is connected to system failure interlock Correct the above causes and restart the Chiller If it still gives you the CHILLER ALARM check the following and ...

Page 40: ...strainer air leak in the pipe line etc High concentration of absorbent Correct the above causes and restart the Chiller If it still gives you the CHILLER ALARM check the following and contact Carrier service agent 1 Temperature of chilled water inlet and outlet 2 Temperature of cooling water inlet and outlet 3 Temperature and pressure of generator 4 Is the chilled water setting point too low Corre...

Page 41: ...or or Chilled water temperature sensor has Condenser temperature alarm sensor has failure It does not stop when the other sensors have alarm but this could cause control failure Please contact Carrier service agent as soon as possible Refrigerant temperature sensor Evaporator has failure Driving hot water inlet temperature sensor has failure Driving hot water control valve outlet temperature senso...

Page 42: ... of action in case of power failure A power failure occurs The Chiller completely stops Power Power failure indication H 10 returns is shown on the data display Push RUN key Operation Power failure indication on restarts the data display disappears 38 ...

Page 43: ...failure Action Occurred during cooling operation Immediately contact Carrier service agent and took more an hour to return power Do not restart operation Occurred during cooling operation Contact Carrier service agent after and took less than an hour to return power restarting operation Occurred during purging operation Immediately close purge valve completely and turn off the purge pump switch on...

Page 44: ...onsult your system constructor for the following items 4 Cleaning of the cooling tower and the strainer of the cooling water line 5 Check of the condition of cooling tower 6 Check of the air leak in the pipe line 4 1 2 Operation data record Please record the operation data regularly It is useful for troubleshooting and alarm prevention Please show it to Carrier service personnel when they visit yo...

Page 45: ...18 HT GENE Temp 19 Exhaust Gas Temp 20 Inverter HZ HZ 21 1 ABS P Amp Amp 22 2 ABS P Amp Amp 23 Ref P Amp Amp 24 Burner Motor Amp Amp 25 HT GENE Level 26 Evap Level 27 Purge Tank Press 28 Diluted Damper 29 Intermed Damper 30 Concent Damper 31 GAS consumption m3 H GPM 32 Gas supply press 33 Oil consumption L h 34 Oil pressure kg cm2 35 Ｄｒａｆｔ mmH2O 36 Chamb Press mmH2O 37 Steam consumption Kg h 38 St...

Page 46: ...d temperature 47 Cond Temp 48 LTD This data sheets is available for Installation test running Operation test running and Service Maintenance test running Installation test 1 47 Operation test 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 25 26 27 Service Maintenance test 1 48 Others TEST OPERATION DATA SHEET TEST OPERATION DATA SHEET TEST OPERATION DATA SHEET TEST OPERATION DATA SHEET units 31 32 3...

Page 47: ...nd that you make a maintenance contract with Carrier service agent 4 2 1 Purging The non condensable gas of the machine inside not only decreases cooling capacity but also has a bad influence on the life of the machine Please leave it to Carrier service personnel under the maintenance contract The customer can carry out the purging but should take instruction by our service personnel 43 ...

Page 48: ...ated value drops If it does not drop follow the procedure e f and g and contact Carrier service agent d Perform purging for 10 minutes Even if the purge indication lamp stops lighting before 10 minutes have passed please continue purging for 10 minutes When the lamp does not stop lighting continue purging until the lamp stops lighting e Close V1 and V2 f Turn off the purge pump on off switch g Che...

Page 49: ...rigerant is transferred to absorber side and new clear refrigerant is regenerated 1 Make sure the refrigerant pump is rotating and also the solution level is visible through the sight glass of the evaporator 2 Open the blow valve completely 3 When the solution level becomes invisible close the blow valve tightly The above is the blow down procedure Repeat it a few times as necessary As for the ref...

Page 50: ...lts hardness materials chloride ion sulfate ion etc are concentrated Namely the condensation phenomena of such materials occur and water quality will be gradually degraded As the water and air always come in contact with each other in the cooling tower the sulfurous acid gas dust sand etc in the atmosphere will mix into the water further degrading the water quality In the cooling water system prob...

Page 51: ...47 ...

Page 52: ...ation chilled hot water also requires this treatment In case you use concrete heat storage tank special attention should be paid to water treatment a Periodic and continuous manual blow down by make up water b Automatic blow down by electric conductance c Addition of the anticorrosion d Slime control e Periodic water analysis Overhaul water header periodically check heat transfer tube and clean it...

Page 53: ...e is evenly mixed a 5 Close the isolation valves of inlet and outlet on the cooling water line b Dry lay up Before draining cooling water from the Chiller clean the inside of the tube and make corrosion protective covering b 1 Discharge cooling water from its discharge port on the cooling water outlet b 2 Remove the scale and or slime adhesion in the tubes by brush cleaning If scale and or slime c...

Page 54: ...4 4 RECOMMENDED SCHEDULE OF MAINTENANCE AND REPLACEMENT OF MAIN COMPONENTS Please contact Carrier service agent 50 ...

Page 55: ...initiative to keep your Chiller in its best condition and priority will be given to you for repairs of the Chiller in case of failure It is recommended to perform an overhaul of the Chiller once several years to keep it in its best condition It is included in the maintenance contract to let the customers know the timing and the parts to be overhauled There is another contract for the water quality...

Page 56: ...ep it in a safe place 5 3 2 In case the Chiller fails within the warranty period under normal operating conditions we will replace all the necessary spare parts or repair the Chiller free of charge 5 3 3 After the warranty period expires all repair costs will be charged Consult your service agent 5 3 4 As for other items please read your warranty 52 ...

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