Carrier-Sanyo 16NK Manual Download

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16NK

Double-Effect Steam-Fired
Absorption Chillers

Nominal cooling capacity 345-4652 kW

50 Hz

Operation and maintenance instructions

GB/T-19001-2000 to ISO9001/2000

Summary of Contents for 16NK

Page 1: ...16NK Double Effect Steam Fired Absorption Chillers Nominal cooling capacity 345 4652 kW 50 Hz Operation and maintenance instructions GB T 19001 2000 to ISO9001 2000 ...

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: ...e information on the data display 22 3 6 Changing display and setpoint 23 3 7 Maintenance message 23 3 8 Alarm messages and actions required 23 4 Maintenance 25 4 1 Daily maintenance 25 4 2 Periodic maintenance 28 4 3 Recommended maintenance and main component replacement schedule 29 4 4 Water treatment 30 5 Troubleshooting 32 6 Instructions 34 6 1 Absorbent sampling method 34 6 2 Concentration me...

Page 4: ...pecific description of the item After reading this manual it should be kept in a safe place to be available for any user at any time TURN OFF THE BREAKER BEFORE CLEANING AND CHECKING Always turn off the circuit breaker before cleaning and checking the cooling tower fan chilled water pump or other components linked to the chiller to provide protection from electric shock or or possible injury by th...

Page 5: ...use injuries Prohibited DO NOT CLIMB ON THE CHILLER Do not climb on the chiller as you may fall off Prohibited AUTHORIZED PERSONNEL ONLY A notice For Authorized Personnel Only must be affixed to the chiller to stop unauthorized personnel from touching it If necessary surround the chiller by a protective fence Misuse of the chiller may cause injury Prohibited WARNINGS CAUTIONS VENTILATE THE MACHINE...

Page 6: ... metal corrosion or skin disease Prohibited Prohibited STOP THE PURGE PUMP TO REPLACE OIL Stop the purge pump when replacing oil to avoid possible injury by fuel spillage Must be observed DO NOT TOUCH HIGH TEMPERATURE AREAS Do not touch high temperature areas as they may cause burns These areas are indicated by caution label What voltage STOP CAUTIONS OBSERVE THE SPECIFIED WATER STEAM PRESSURE The...

Page 7: ...and cooling water pump Follow the start procedure in Figure 1 below Fig 1 Auxiliary equipment start stop sequence Start sequence 1 Chilled water pump 2 Cooling water pump 3 Cooling tower 5 Air handling unit 1 Absorption chiller 2 Cooling water pump 3 Cooling tower 4 Chilled water pump 5 Air handling unit Stop sequence ONLY AUTHORIZED PERSONNEL SHOULD SERVICE THE CHILLER Only authorized personnel s...

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

Page 9: ...orbent pump 1 5 Refrigerant pump 6 Refrigerant blow valve Fig 5 High temperature generator side absorber side 1 2 3 4 5 6 7 8 Legend 1 Purge unit 2 High temperature heat reclaimer 3 Purge pump 4 Low temperature heat exchanger 5 Low temperature heat reclaimer 6 Steam drain outlet 7 High temperature heat exchanger 8 Absorbent pump 2 ...

Page 10: ...Chilled water inlet 6 Cooling water inlet 7 Condenser 8 Absorber 9 Evaporator 10 Absorber Legend 1 Low temperature generator 2 High temperature generator 3 Steam drain outlet 4 Condenser 5 Absorber 6 Evaporator 7 Absorber 1 2 3 4 5 6 7 8 Fig 8 Control panel side Legend 1 Control panel 2 Refrigerant blow valve 3 Purge tank 4 Purge unit 5 Purge pump 6 Refrigerant drain heat exchanger 7 Refrigerant p...

Page 11: ...igh temperature heat reclaimer side Legend 1 High temperature heat reclaimer 2 Absorbent pump 2 3 Low temperature heat exchanger 4 Absorbent pump 1 5 Refrigerant pump 6 High temperature heat exchanger 1 2 3 4 5 6 ...

Page 12: ...n light 8 Alarm buzzer 9 Purge pump on off switcht 10 Operating handle Fig 11 Control panel inside CE type Legend 1 Control relay 2 Circuit protector 3 Isolator 4 I O board 5 AC reactor 6 Circuit breaker 7 Inverter 8 DC reactor 9 Main circuit breaker 10 Transformer 11 Electromagnetic contactor 12 Filter 13 Transformer 14 Terminal block 1 6 7 9 8 10 2 3 4 5 1 13 2 3 4 5 6 7 8 9 10 11 12 14 ...

Page 13: ...1 12 13 14 Fig 12 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 14: ...erator is heated by the refrigerant vapour It releases refrigerant vapour and is concentrated It changes to the concentrated solution The condensed refrigerant in the heat transfer tubes of the low temperature generator flows to the condenser Condenser The refrigerant vapour from the generator is condensed on the heat transfer tubes of the condenser Cooling water from the absorber is heated by con...

Page 15: ... 13 14 15 16 17 19 20 21 22 23 24 25 26 27 Fig 13 Flow diagram Sensor Service valve Strainer Damper Check valve Orifice Valve 1 2 3 4 5 V2 V3 SV1 V1 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Fig 14 Flow diagram ...

Page 16: ...emperature generator 26 Steam inlet 27 Steam control valve D1 Diluted solution main damper D2 Diluted solution low temperature heat exchanger damper D3 Diluted solution refrigerant drain heat reclaimer damper D4 Intermediate solution damper D5 Concentrated solution damper D6 Refrigerant drain damper D7 Refrigerant recycling damper D8 Diluted solution bypass damper V1 Manual purge valve V2 Manual p...

Page 17: ...on 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 18: ... LED To 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 reset 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 di...

Page 19: ...ress t key Press s key to set the minutes Press the SET key for about 2 seconds Press the BACK key Press the BACK key Generator temperature 3 3 2 Battery backup Refer to Figure 18 SW3 Connect a backup battery which is used to maintain the time setting when a power failure occurs Turn it ON after installing the equipment CR 2025 is used as the backup battery and has an accumulative operating period...

Page 20: ...20 Fig 18 SW3 backup switch and backup battery Backup battery SW3 Backup switch UP ON DOWN OFF LABEL ...

Page 21: ... 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 3 3 3 How to change the temperature unit The temperature unit can be changed as follows even while the chiller is operating Fig 19 Display example Press the SET key for about 2 seconds Press t or s key Press the SET key for about 2 seconds Press ...

Page 22: ... 2 on off times 123 times A Combustion on off times 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 Not used 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 d...

Page 23: ...her code attention should be paid Consult Carrier service personnel at the next periodic maintenance Note These displays disappear when the problem has been corrected Fig 25 Maintenance message descriptions and actions required Maintenance message Display Action 1 Cooling water tubes Cooling water tubes must be cleaned foul Contact Carrier service agent to do the job 2 Vacuum rate The purge tank m...

Page 24: ...ter and cooling water pumps is normal Chilled water flow alarm If not the strainer may be clogged or there may Cooling water temperature is too low be an air leak in the piping etc Cooling water flow alarm option Is the chilled water setpoint too low Correct it to the specified setpoint Is the cooling water setpoint too low Correct it to specified setpoint e g 28 C Correct the above causes and res...

Page 25: ...as this is useful for troubleshooting and alarm prevention Show the record to the Carrier service personnel when they visit you for the service or the periodic inspection On the next page you will find a sample of the operation data sheet NOTE The chiller automatically stops for safety reasons when either the generator temperature or the chilled water temperature sensor has an alarm It does not st...

Page 26: ... 8 Chilled water flow rate l s gpm 9 Cooling capacity kW 10 USRT 11 Cooling water entering temperature C F 12 Cooling water leaving temperature C F 13 Cooling water entering pressure kPa psi 14 Cooling water leaving pressure kPa psi 15 Pressure drop in absorber condenser kPa psi 16 Cooling water flow rate l s gpm 17 High temperature generator pressure MPa psi 18 High temperature generator temperat...

Page 27: ...ature minus cooling water leaving temperature Notes _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ ____________________________________...

Page 28: ...gas inside the machine not only decreases cooling capacity but also potentially shortens the life of the machine Therefore purging must be done periodically This should be done by the Carrier service personnel under the maintenance contract If customers carry out the purging themselves they should take instruction from our service personnel Purging procedure When the purge indication light on the ...

Page 29: ...ion 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 imp...

Page 30: ...hould be set together with a water processing specialist and be checked periodically Typical water treatment Even if the make up water for the cooling water complies with water standards the water quality will deteriorate due to its concentration Therefore the following water treatment is necessary Depending on the degree of deterioration chilled water also requires this treatment If a concrete he...

Page 31: ...l 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 wat...

Page 32: ...o that the ratio is appropriate Charge the chiller with cooling water Operate the cooling water pump until the inhibitor is evenly mixed Close the cooling water line inlet and outlet isolation valves Dry system Before draining the cooling water from the chiller clean the inside of the tubes and provide a corrosion protection covering Drain the cooling water from its discharge port on the cooling w...

Page 33: ...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 34: ...rom these values will be 63 as shown in Figure 34 below Fig 34 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 B...

Page 35: ...35 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 36: ...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 37: ...ution level electrode Gas control valve does not move Protection relay is defective Check E1 E2 and E3 of the solution level electrodes The motor is defective Oil solenoid valve does not open Protection relay is defective The solenoid valve is defective Check if the air flow switch is ON Check setting of air flow switch Blower motor does not run 16DJ only Check breaker on the burner control panel ...

Page 38: ...terial Insufficient refrigerant amount 5 Insufficient octyl alcohol 10 Refrigerant contamination 25 Cooling water entering temperature is too low Refrigerant blow down is needed Heavy foaming condition in high temperature generator due to absorbent contamination with foreign material Crystallization Absorbent pump 1 cavitation 25 Solution flow rate is not adjusted properly Cooling water entering t...

Page 39: ...n HT generator because there is foreign material in the absorbent 16DJ NK LT generator tubes are damaged 16DJ NK 1 Crystallization Absorbent pump cavitation 25 Ambient temperature and or humidity are too high Cooling water control valve malfunctions Cooling tower water spray malfunctions Cooling tower fan malfunctions Cooling tower fan belt is broken Ambient temperature is too low 5 Cooling water ...

Page 40: ...ose Main gas shut off valves are defective Flame failure no spark Ignition transformer is defective Microprocessor is defective Position of spark rod is not properly adjusted Insulation of spark rod is defective Ignition spark wire is removed or broken Protection relay is defective Flame detector is defective Flame remains after stop of combustion Gas pressure alarm Measure gas supply pressure 80 ...

Page 41: ...ion or foreign material in the pump Pump motor is defective Open phase 10 Magnetic contactor is defective Pump motor coil is defective Primary power failure Motor Magnetic contactor with thermal relay Pump power wires Check the setting of thermal relay 10 Refrigerant pump Measure operating current 60 Overcurrent 90 Foreign material in the pump Pump motor is defective Open phase 10 Magnetic contact...

Page 42: ...interlock signal goes to the microprocessor Check if cooling water pump interlock signal goes to the microprocessor Check if cooling water pump interlock signal goes to the microprocessor Check if fan interlock signal goes to the microprocessor 16 DJ only ...

Page 43: ......

Page 44: ...8 2007 Supersedes order No New Manufactured by Sanyo Electric Co Ltd Dalian China Manufacturer reserves the right to change any product specifications without notice Printed in the Netherlands GB T 24001 to ISO14001 1996 ...

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