Carrier Sanyo 16TJ Operation And Maintenance Instructions Download Page 2

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NOTES TO USERS

Thank you for purchasing a Carrier/Sanyo absorption chiller.

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

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

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

Summary of Contents for Sanyo 16TJ

Page 1: ...16TJ Single Effect Steam Fired Absorption Chillers Nominal cooling capacity 352 2461 kW 50 Hz Operation and maintenance instructions GB T 19001 2000 to ISO9001 2000 ...

Page 2: ...tructions for the operation and maintenance of the chiller Please utilize the chiller to its optimum performance by carrying out the recommended daily maintenance and handling instructions as well as the periodic service If you need any information about maintenance contracts or have any other enquiries please contact your Carrier service agent ...

Page 3: ... keys and their functions 13 3 3 Control board settings 14 3 4 Operation 16 3 5 Changing the information on the data display 17 3 6 Changing display and setpoint 18 3 7 Maintenance message 18 3 8 Alarm messages and actions required 18 4 MAINTENANCE 20 4 1 Daily maintenance 20 4 2 Periodic maintenance 23 4 3 Recommended maintenance and main component replacement schedule 24 4 4 Water treatment 25 5...

Page 4: ...s manual it should be kept in a safe place to be available for any user at any time TURN OFF THE BREAKER BEFORE CLEANING AND CHECKING Always turn off the circuit breaker before cleaning and checking the cooling tower fan chilled water pump or other components linked to the chiller to provide protection from electric shock or possible injury from the rotating fan DO NOT TOUCH THE CONTROL PANEL SWIT...

Page 5: ...ler or control panel as these may fall off and cause injuries PROHIBITED DO NOT CLIMB ON THE CHILLER Do not climb on the chiller as you may fall off PROHIBITED CALL SPECIALISTS FOR SERVICE OR MAINTENANCE Call specialists for service or maintenance Incorrect service maintenance may cause electric shocks ﬁre or burns MUST BE OBSERVED AUTHORIZED PERSONNEL ONLY A notice For Authorized Personnel Only m...

Page 6: ...d call a service engineer MUST BE OBSERVED DO NOT TOUCH THE ABSORBENT Do not touch the spare or leaked absorbent as this can cause metal corrosion or skin disease PROHIBITED OBSERVE THE SPECIFIED WATER AND STEAM PRESSURE The speciﬁed chilled water steam and cooling water pressure must be strictly observed Incorrect pressure may cause the water to leak spray which can lead to short circuits or burn...

Page 7: ...y cause the failure of the chiller 2 Keep the power supply to the control panel turned on unless carrying out maintenance or service 3 During the chiller dilution cycle the chilled water pump both the primary side and the secondary side and air handling unit must be operated for the required time The chiller has some cooling capacity even in the dilution cycle Do not stop the air handling unit bef...

Page 8: ...since it contains high voltage wiring Do not touch the terminal box during operation since it contains high voltage wiring 1 3 Environmental requirements 1 3 1 Installation considerations The 16TJ absorption chiller is designed for indoor installation in a machine room The protection rating of the chiller is IP40 Room temperature should be maintained between 5 C and 40 C to protect against solutio...

Page 9: ...r supply 5 Earth terminal 6 Control board 7 Purge indication light 8 Purge pump on off switch 9 Operating handle Fig 5 Control panel inside CE type 1 9 2 3 10 4 5 6 7 8 Legend 1 Control relay 2 Circuit protector 3 I O board 4 Circuit breaker 5 Main circuit breaker 6 Transformer 7 Electromagnetic contactor 8 Filter 9 Transformer 10 Terminal block ...

Page 10: ...3 14 Fig 6 Control board Legend 1 Stop indication light 2 Operation indication light 3 Data display 4 Select key 5 Function set key 6 Back select key 7 Remote local select key with LED 8 Alarm buzzer stop key 9 Operation select key with LED 10 Alarm indication light 11 Stand by indication light 12 Dilution indication light 13 Safety circuit indication light 14 Power indication light ...

Page 11: ... B valve manual purge valve 13 Condenser SV1 Charge removal service valve N2 gas 3 Chilled water outlet 14 Generator SV2 Purge unit service valve 4 Chilled water inlet 15 Evaporator SV3 Refrigerant service valve 5 Purge unit 16 Absorber SV4 Diluted solution service valve 6 Cooling water outlet 17 Cooling water inlet SV6 Concentrated solution service valve 7 Purge tank 18 Heat exchanger SV7 Generat...

Page 12: ...ion Data display 7 segment LED and all LEDs light up If there is no abnormality the data display shows the version number If there is a power failure H 10 is displayed after the power is restored NOTE The version number differs with each chiller type The data display shows the generator temperature 120 4 If the self diagnosis function detects an error this will be shown on the data display For the...

Page 13: ... select remote operation or local operation 5 Operation select key with LED Key used to run stop the chiller The stop key is also used for alarm rset 6 Data display 7 segment LED Shows the temperature setpoint etc 7 Standby indication light On when the chiller is waiting for the interlock signals form the chilled water and the cooling water pump 8 Dilution indication light On during the dilution c...

Page 14: ...s key Press key to set the minutes Press the SET key for about 2 seconds Press the BACK key Press the BACK key High temperature generator temperature 3 3 2 Battery backup Refer to Figure 12 SW3 Connect a backup battery which is used to maintain the time setting when a power failure occurs Turn it ON after installing the equipment CR 2025 is used as the backup battery and has an accumulative operat...

Page 15: ...15 Fig 11 SW3 backup switch and backup battery Backup battery SW3 Backup switch UP ON DOWN OFF LABEL ...

Page 16: ...on Keep pressing the RUN key for more than a second and make sure that the RUN indicator lightp of the key is on Automatic operation starts Remote operation mode Press the REMOTE key on the chiller control board The REMOTE indicaton light of the key is on Turn on the start switch on the remote control panel for the ﬁeld supply The indicator light of the RUN key on the chiller control board is on A...

Page 17: ...Not used B Refrigerant pump on off times 138 times C Purge pump on off times 51 times 10 Chilled water temperature setpoint 7 0 C 11 Hot water temperature setpoint 55 0 C 12 Chilled water entering temperature 11 9 C 13 Chilled water leaving temperature 6 8 C 14 Cooling water entering temperature 31 8 C 15 Condenser temperature 34 7 C 16 Steam drain exhaust gas temperature 211 7 C 17 Purge tank pre...

Page 18: ...d water low temperature An alarm code is only shown when one or several abnormalities occur If several errors have occurred the most important one is shown with a dot Chilled water low temperature The other alarm codes are shown by pressing the key option The high temperature generator solution level is too low Maintenance Message Display Action 1 Fouling of cooling water tubes Cooling water tubes...

Page 19: ... in the piping etc High concentration of absorbent Correct the above causes and restart the chiller If the CHILLER ALARM continues check the following and contact your Carrier service agent Entering and leaving chilled water temperature Entering and leaving cooling water temperature Generator temperature and pressure Is the chilled water setpoint too low Correct it to the speciﬁed setpoint Water i...

Page 20: ...n hour Do not restart operation Occurred during cooling operation and Contact Carrier service agent after restarting power returned in less than an hour operation Occurred during purging operation Immediately close the purge valve completely and turn the purge pump switch on the control panel off After the power is restored restart purging and consult your Carrier service agent 4 MAINTENANCE 4 1 D...

Page 21: ...me 1 Ambient temperature C F 2 Room temperature C F 3 Chilled water entering temperature C F 4 Chilled water leaving temperature C F 5 Chilled water entering pressure kPa psi 6 Chilled water leaving pressure kPa psi 7 Evaporator pressure drop kPa psi 8 Chilled water ﬂow rate l s gpm 9 Cooling water entering temperature C F 10 Cooling water leaving temperature C F 11 Cooling water entering pressure...

Page 22: ...sed refrigerant temperature minus cooling water leaving temperature Notes _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ ______________...

Page 23: ...hine not only decreases cooling capacity but also potentially shortens the life of the machine Therefore purging must be done periodically This should be done by the Carrier service personnel under the maintenance contract If customers carry out the purging themselves they should take instruction from our service personnel Purge procedure When the purge indication light on the control panel comes ...

Page 24: ...ction etc Once a year Cleaning Solution Absorbent X Solution analysis Concentration Alkalinity Inhibitor ratio Copper dissolution ratio Iron dissolution ratio Solution random inspection Two to four times per year To be adjusted to the standard controls Pump Absorbent pump X Pump body impeller bearing motor Overhaul As necessary Inspection interval 20000 hours or more Refrigerant pump X Pump body i...

Page 25: ...scale and slime Water quality standard The water quality standard is shown in the example in Figure 27 This is an extract from JRA GL 02 1994 NOTES 1 If any item deviates from the standard values it may cause failure due to corrosion or scale Therefore the water quality should be checked periodically 2 As the water quality range differs depending on the chemicals used it is not given here The appr...

Page 26: ... factors of corrosion and scale problems Cooling water systems Chilled water systems Mid range temperature 20 90 C water systems Tendency Lower mid range temperature water system Higher mid range teperature water system Recirculating water Make up water Once through water Recirculating water T 20 C Make up water Recirculating water 20 T 60 C Make up water Recirculating water 60 T 90 C Make up wate...

Page 27: ...y so that the ratio is appropriate Charge the chiller with cooling water Operate the cooling water pump until the inhibitor is evenly mixed Close the cooling water line inlet and outlet isolation valves Dry system Before draining the cooling water from the chiller clean the inside of the tubes and provide a corrosion protection covering Drain the cooling water from its discharge port on the coolin...

Page 28: ...hment Legend 1 Attachment 2 Liquid trap 3 Vacuum gauge 4 Vacuum rubber hose 5 Vacuum valve 6 Sampling cylinder 7 Purge pump 8 Sampling service valve 9 Attachment 10 Vacuum rubber hose 11 Vacuum valve 12 Sampling cylinder 13 Rubber plug 14 Copper tube 15 Flare nut brass 16 Rubber hose 17 Steel wire 18 Copper tube 19 Flare nut brass 20 Copper tube ...

Page 29: ... from these values will be 63 as shown in Figure 28 below Fig 28 Relative density Concentration Temperature C 0 4 5 1 77 64 63 62 6 INSTRUCTIONS 6 1 Absorbent sampling method This instruction describes the procedure for sampling a small amount of the absorbent 6 1 1 Equipment to use Sampling cylinder and attachments for service valve Vacuum rubber hose Pliers Vacuum gauge 0 1 kPa 6 1 2 Precautions...

Page 30: ...29 Concentration vs temperature vs relative density Relative density kg m 3 x 10 3 Concentration Temperature C 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 0 10 20 30 40 50 60 70 80 90 100 65 60 55 50 45 ...

Page 31: ...maintenance contract we advise our customers of the timing and the parts to be overhauled There is an additional contract for water quality control and cleaning of the heat transfer tubes in the water system We recommend that you also take out this contract 7 2 Inspection report We issue an inspection report for the annual maintenance under the contract The report contains a thorough description o...

Page 32: ...32 APPENDIX 1 TROUBLESHOOTING FLOWCHART 1 chiller does not run 2 Chilled water temperature is high 3 Generator alarm 4 Combustion alarm 16DJ 5 Water alarm 6 Motor alarm 7 System alarm Problem ...

Page 33: ...Gas control valve does not move Oil solenoid valve does not open Protection relay is defective Check E1 E2 and E3 of the solution level electrodes The motor is defective Protection relay is defective The solenoid valve is defective Check if the air ﬂow switch is ON Check setting of air ﬂow switch Blower motor does not run 16DJ Interlock Fuse has blown Check if chilled water pump interlock signal g...

Page 34: ...mperature generator and condenser is clogged Heat transfer tubes in high low temperature heat exchangers leak Heat exchanger is clogged with foreign material Insufﬁcient refrigerant amount 5 Insufﬁcient octyl alcohol 10 Cooling water entering temperature is too low Refrigerant blow down is needed Heavy foaming condition in high temperature generator due to absorbent contamination with foreign mate...

Page 35: ...absorbent solution Insufﬁcient octyl alcohol Ambient temperature is too low 5 Cooling water entering temperature is too low with insufﬁcient air purging 70 Rank up set too low Air gas oil linkage has shifted to low combustion Gas supply pressure ﬂuctuates Chilled water set too high Temperature sensor is defective Microprocessor is defective Electric parts and sensors are defective Wrong setting on...

Page 36: ...r water spray malfunctions Cooling tower fan malfunctions Cooling tower fan belt is broken Cooling water temperature control thermostat malfunctions Partition plate in water box is removed Absorber and condenser tubes are fouled Wrong inverter setting Check valve malfunctions Wrong damper adjustment Heat exchanger s tubes are damaged Heat exchanger s is are clogged Oriﬁce in pipe betw LT generator...

Page 37: ...NG FLOWCHART CONT Generator alarm Microprocessor malfunctions Cam switches malfunction Pressure switch malfunctions Microprocessor solution level incorrect Temperature sensor malfunctions Electrode surface is contaminated Electrode is defective Teﬂon tube on electrode has been removed Incorrect combustion adjustment Blower suction is clogged air gas oil ratio is incorrect Flue is clogged air gas o...

Page 38: ...ﬂuctuates Flue is clogged Protection relay is defective Gas air linkage is not properly adjusted Main gas regulator is defective Gas oil ﬂow meter is locked Flue is clogged Voltage drops Protection relay is defective Check if test cock opens or not Check if gas oil air linkage is loose Main gas shut off valves are defective Ignition transformer is defective Microprocessor is defective Position of ...

Page 39: ...ENDIX 1 TROUBLESHOOTING FLOWCHART CONT Microprocessor Flow switch Temperature sensor Auxiliary relay in chiller control panel Temperature control function does not work properly Wrong operating order Holding water quantity in the chiller is too low Ambient temperature is too low Cooling water temp control malfunctions Temperature control function does not work properly Wrong operating order Holdin...

Page 40: ...hermal relay 10 Blower motor is defective APPENDIX 1 TROUBLESHOOTING FLOWCHART CONT Crystallization or foreign material in the pump Pump motor is defective Magnetic contactor is defective Pump motor coil is defective Primary power failure Motor Magnetic contactor with thermal relay Pump power wires Foreign material in the pump Pump motor is defective Magnetic contactor is defective Pump motor coil...

Page 41: ...nterlock signal goes to the microprocessor Check if cooling water pump interlock signal goes to the microprocessor Check if fan interlock signal goes to the microprocessor 16 DJ 7 System alarm APPENDIX 1 TROUBLESHOOTING FLOWCHART CONT ...

Page 42: ...rsedes order No New Manufactured by Sanyo Carrier Dalian China Manufacturer reserves the right to change any product speciﬁcations without notice Printed in the Netherlands on totally chlorine free paper GB T 24001 to ISO14001 1996 ...

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