Carrier-Sanyo LJ, Installation Manual

Page 1: ...Absorption Chiller INSTALLATION MANUAL LJ Model ...

Page 2: ...y It contains instruction for the operation and maintenance of the Chiller Please utilize the Chiller to its optimum performance by following recommended daily maintenance and handling and periodic service If you need any information about maintenance contract or any other inquiries please contact Carrier SANYO service agent 814 6 0502 958 00 0 Note The contents of this manual are subject to chang...

Page 3: ... ELECTRICAL CHECK 26 2 3 INITIAL SETTING FOR OPERATION BOARD 28 2 4 DAMPER SETTING AND VALVE POSITION 28 2 5 PURGING 28 2 6 FUNCTION TEST 29 2 7 OPERATION 32 CHECK LIST 35 ExhibitLA Precautions for use Precautions for installation FLOW DIAGRAM ExhibitLB Shipping dimensions ExhibitLC Foundation ExhibitLE Typical piping diagram DIMENSIONS RUPTURE DISK ExhibitLF Field electric wiring Wire size ELEC W...

Page 4: ...of the solution crystallization during chiller shut down Please keep the humidity in the machine room within 90 1 1 2 Field wiring For CE please connect to power source by overvoltage category III and to other wiring by overvoltage category II 1 1 3 Altitude Please install Absorption Chiller at a height of less than 1000m above sea level If the location is higher than 1000m above sea level please ...

Page 5: ...ows the specific description of such item 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 TURN OFF THE BREAKER BEFORE CLEANING AND CHECKING Always turn off the breaker before cleaning and checking the cooling tower fan chilled water pump or others linking the chiller to provide pro...

Page 6: ...ammables gasoline thinner etc close to the chiller flue chimney and oil tank to prevent a fire Prohibited 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 Prohibited DO NOT TOUCH ANY ROTATING PART OF FANS Keep away your fingers from any rotating part of fans or pumps to avoid possible injury Prohibited 3 ...

Page 7: ... THE CORRECT POWER SUPPLY This is indicated on the name plate of the chiller Use of the power other than specified here may cause a fire or electric shocks Prohibited SOLVE ALL THE PROBLEMS BEFORE RESTARTING THE CHILLER Solve all the problems before restarting the chiller heater when the safety device or security device operates to prevent a fire Must be observed DO NOT CLIMB UP THE CHILLER Do not...

Page 8: ...PUMP TO REPLACE OIL Please stop the purge pump when replacing oil to avoid possible injury by fuel scatter Must be observed NEVER CHANGE THE SET VALUE Never change the set value of the safety and or protective devices Wrong setting may damage the chiller heater or cause a fire Prohibited DO NOT TOUCH THE ABSORBENT Do not touch the spare or leaked absorbent which may cause corrosion of metal areas ...

Page 9: ...THE CHILLER To dispose of the chiller contact the local specialists Any defecitive disposal may cause corrosion of metal areas or skin diseases by absorbent leak Must be observed 2 Safety precautions for repair moving or rejection ONLY AUTHORIZED PERSONNEL SHOULD REMOVE OR REPAIR THE CHILLER Any relocation or moving of the chiller should be done by authorized personnel only Incomplete work could r...

Page 10: ...onnect the vacuum gauge to SV2 Open SV2 and SV3 Check the pressure of the vacuum gauge If the pressure becomes to 0kPa the Chiller has leak In this case please check the leak point by pressurized nitrogen gas at 50kPa Close the cap of SV7 with sealant Refer to Exibit LA and 1 8 1 1 3 2 Check for physical damage to the Chiller 1 Main shell 2 Valves 3 Control panel 4 Wiring and connection 5 Accessor...

Page 11: ... 13 LJ 23E 980 2 200 150 330 1 780 0 48 570 0 16 LJ 24E 1 070 2 400 140 310 1 940 0 52 620 0 17 LJ 31E 1 230 2 700 190 420 2 240 0 60 720 0 20 LJ 32E 1 340 3 000 170 370 2 440 0 65 780 0 21 LJ 41E 1 560 3 400 250 550 2 840 0 76 910 0 25 LJ 42E 1 680 3 700 230 510 3 060 0 81 980 0 26 LJ 51E 1 950 4 300 260 570 3 540 0 94 1 130 0 30 LJ 52E 2 170 4 800 290 640 3 940 1 05 1 260 0 34 LJ 53E 2 420 5 300...

Page 12: ... to lift the chiller Note that the angle of wires shall be within 60 deg as shown in the figure below Please refer to Exhibit LB 1 5 SLIDING In case that sliding of the chiller is required using tiltdozers trail builders is recommended If a wire to slide the chiller is used the wire shall be connected as shown in the figure below 1 6 SETTING ON THE FOUNDATION Please refer the foundation to Exhibit...

Page 13: ...ts B C and D A B Evaporator side Absorber side C D A B C D 0 mm mm mm mm 1 7 3 Leveling calculation as shown A B C D A D B C A C B D L L L L W W Tolerance L Chiller length W Chiller width 1 7 4 Note that there are four leveling check points on the chiller labeled A B C and D in the sketch below These check points are designated by three punch markers on the tube sheet or shell of the lower shell 2...

Page 14: ...inserting a metal shim between the frame and foundation Metal shim size is approximately 50mm width and 80mm length Prepare the shim of some different thickness 0 6mm to 9mm 1 7 6 Fix the anchor bolts a Weld the washers on the chiller s frame b Tight up the nuts 11 ...

Page 15: ... hose d Flashlight e Soapy water f Adjustable wrench g Hose band h Vacuum gauge 0 100kPa 2 Standard Pressurize the Chiller up to 50 kPa with the nitrogen gas then confirm that any bubble shall not be observed by the soapy water and any oozy liquid shall not be visually observed 3 Sequence of this test Refer to 1 8 2 Check leakages OK NG Note The repair welding can be done after discharging N2 gas ...

Page 16: ...Chiller up to 50 kPa with N2 gas The pressure inside the Chiller can be checked by the vacuum gauge f When the pressure reaches 50 kPa close the service valve and the valve of the N2 gas cylinder g Check the following positions with the soapy water g 1 All field welded portions One shipping machine is not needed g 2 Sight glass g 3 Flare nut joints of service valves g 4 Flange connections the abso...

Page 17: ...hen repair them j Repeat c g k If no leakage is confirmed at 50kPa of the pressure keep the Chiller under the pressurizing condition with 50kPa for 24 hours and then check the pressure again l After completion of the test discharge the N2 gas and remove the vacuum gauge Refer to 1 8 3 m Close SV2 Note In case of discharging the N2 gas perform ventilation sufficiently 14 ...

Page 18: ...the Chiller is charged until 50kPa at generator pressure gauge 3 Precautions a Since the N2 gas cylinders are pressurized up to 15MPa pay attention to handle them b Do not suddenly raise the primary or secondary pressure of the pressure regulator c Fix the N2 gas cylinder so that it does not fall over d Be sure not to open V1 V2 during this work Model Volume Model Volume LJ litter LJ litter 11E 1 ...

Page 19: ... it with a hose band e Check that V1 V2 V3 B SV1 are fully closed f Open the V3 B valve and then open SV1 Note B valve shall be closed after solution charge in the Chiller g Using the pressure regulator charge a small amount of N2 gas into the Chiller h Watch the vacuum gauge during charging of N2 gas When the pressure inside the Chiller reaches to required pressure close SV1 V3 and B valve and th...

Page 20: ...e Chiller is discharged until atmospheric pressure 3 Precautions 1 Be sure not to open V1 V2 during this work 2 During this work adequately ventilate a machine room 4 Procedure a Check that the V1 V2 V3 SV1 SV2 are fully closed b Open V3 c Remove a cap and a flare nut of SV1 and open it d When the reading of the generator pressure gauge becomes atmospheric pressure close SV1and V3 17 ...

Page 21: ...mperature and pressure sockets or taps on all supply and return piping 1 9 2 Flashing It is necessary to flash in the pipe of all water system before through the water in the Chiller 1 9 3 Furnishing of rupture disk 1 Confirm to close the isolation valve 2 Take off the end plate 3 Install rupture disk according to Exhibit LE Furnishing of Rupture Disk 4 Open isolation valve 5 Close isolation valve...

Page 22: ...ategory II Please connect to each wire according to CE marking required 1 10 2 Refer wiring connection to Exhibit LF Please prepare to supply power of the steam control valve and steam shut off valve at field 1 10 3 Refer to 2 3 ELECTRICAL CHECK 1 10 4 A properly qualified electrician should carry out the electrical wiring works 19 ...

Page 23: ... pump direction If the direction is wrong turn off the power supply to the Chiller Then please change the wire of main power source supply The Chiller was connected all wire to meet same phase Run the purge pump continuously 1 11 5 Connect the vacuum gauge 0 10hPa to SV2 Open SV2 Open V1 V3 and B valve evacuate the Chiller Then open V2 after one hour 1 11 6 Continuously running purge pump until 5h...

Page 24: ...r 10 min 12 Less than 15 cc per 10 min 13 Less than 15 cc per 10 min 14 Less than 15 cc per 10 min 21 Less than 25 cc per 10 min 22 Less than 25 cc per 10 min 23 Less than 25 cc per 10 min 24 Less than 30 cc per 10 min 31 Less than 30 cc per 10 min 32 Less than 30 cc per 10 min 41 Less than 40 cc per 10 min 42 Less than 40 cc per 10 min 51 Less than 45 cc per 10 min 52 Less than 45 cc per 10 min 5...

Page 25: ... bubbles are collected inspect and tighten the downstream connections from V2 and V3 If bubbles are still generated in spite of the tightening measure its volume collected for 10 minutes g Open V1 and V3 Close V2 A gas ballast valve and an oil delivery valve should be closed h Continuing operation of the purge pump under the above condition measure volume of bubbles for 10 minutes The measurement ...

Page 26: ...Fig 1 11 7 23 ...

Page 27: ... materials use bonding agents iron wires and bands 1 12 3 Insulation on outer equipment and flange sections should be mounted so that it can be removed easily 1 12 4 The drawings show the areas to be insulated and the recommended insulating materials and procedures Please refer to Exhibit LG 1 12 5 Material of insulation Fiber glass Coeffcient of thermal conductivity about 0 04kcal mhºC 24 ...

Page 28: ...ders provided on water headers and solution pipes d Evaporator headers shall be removable e The following position shall not be insulated The motor portion of the refrigerant pump Rupture dick 2 No rust shall be observed on the Chiller 3 No looseness shall be observed at each flange and bolted connections 4 There shall be no liquid leakage from the Chiller 5 No damage shall be observed on all comp...

Page 29: ...measure insulation resistances of absorbent pumps a refrigerant pump and a purge pump 1 Instrument a DC 500V Megger b Screw driver 2 Standard a Insulation resistance More than 10 MΩ 3 Precautions a Be sure to perform this measurement at seasonal maintenance and after replacement of pumps b Do not supply electric power during the work Make sure to put off the circuit breaker MCBM 4 Procedure a Conn...

Page 30: ... marks are the positions measured by the megger 27 ...

Page 31: ...lve opening conditions and switch positions The position of each valve and switch are different by mode Refer to Operation manual 2 5 PURGING 2 5 1 During operation of the purge pump the gas ballast valve shall be opened However if the gas ballast valve is excessively opened there is a case that purge oil spouts from oil charge port 2 5 2 Bubble Test Before conducting the bubble test perform purgi...

Page 32: ...nd keys simultaneously for about 2 seconds Push SET keys for about 2 seconds Push SET key 3 times Push SET keys for about 2 seconds Push or key Push SET key Push key 1time Push SET keys for about 2 seconds Push key to 0 Push SET key Push BACK keys 2 times Generator temperature Contirm the hot water control valve closes 29 ...

Page 33: ...minutes during operation a Dip the cooling water inlet temperature sensor into the water b Push RUN key c After about 30 minutes confirm that data display on the operation board shows J 20 Cooling water temperature is too low 2 6 3 Motor alarm After starting the Chiller push the test levers of each thermal relay 1 Refrigerant pump The data display shows J 10 Refrigerant pump has overload 2 Absorbe...

Page 34: ...ple Generator temperature Push the SET and keys simultaneously for about 2 seconds Push SET keys for about 2 seconds Push key 3 times Push SET keys for about 2 seconds Pushor or key Push SET keys for about 2 seconds Push BACK keys 2 times Generator temperature 31 ...

Page 35: ...e operating condition data shall be recorded each 10 15 minutes for 3 times Data shall be recorded Required tool for taking operation data 1 Thermometer 2 Pressure gauge 3 Stop watch 4 Solution sampling tool 5 Gravimeter 6 Concentration table as attached 2 7 3 Sampling of absorbent The sampling shall be conducted in accordance with the followings 1 Sampling absorbent Diluted solution 2 Sampling fr...

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Page 38: ...ium cell heater 3 Check of insulation resistance of motors 4 Check of settings on safeties and switches in operation board 5 Check of purge pump 6 Confirmation of auxiliary equipment 7 Bubble test 8 Confirmation of valve opening conditions and switch positions 9 Confirmation of parameter 10 Pre operation 11 Operation and data record 12 Sampling of absorbent 35 ...

Page 39: ...t blow valve No damage Damaged 16 Purge tank pressure sensors No damage Damaged 17 Palladium cells and Heater No damage Damaged 2 Confirmation of field wiring and wiring of palladium cell heater 1 Cooling water pump interlock 121 170 No damage Damaged 2 Chilled water pump interlock 120 170 No damage Damaged 3 Run stop remote signal 323 326 No damage Damaged 4 Stop indication 352 353 No damage Dama...

Page 40: ...on board 1 Generator pressure gauge 63GH MPa PSI 2 Purge tank pressure sensor 69PR kPa 3 Absorption pump thermal relay 51A A 4 Refrigerant pump thermal relay 51R A 5 Purge pump thermal relay 51P A 5 Check of purge pump 1 No water in liquid trap Finished Unfinished 2 Oil quality Clean Not clean or water is contained Replace oil 3 Oil quantity Good No good Add new oil up to the center of sight glass...

Page 41: ...es No Yes No Yes No Cooling water Yes No Yes No Yes No Yes No 3 Water pump capacity 1 Chilled water pump kW 2 Cooling water pump kW 3 Hot water pump kW 4 Cooling tower RT 5 Cooling water temperature control On Off of fan 2 way valve 3 way valve 6 Water filling into the chilled water circuit Finished Unfinished 7 Water filling into the cooling water circuit Finished Unfinished 8 Water filling into ...

Page 42: ...en Close 3 Diaphragm valves Open close condition of valves shall be as follows 1 Manual purge Valve V1 V2 V3 Close Open Close 2 Refrigerant blow valve Close Open Close 4 Service valves Open close condition of valves shall be as follows 1 Charge discharge N2 gas SV1 Close Open Close 2 Purge unit SV2 Close Open Close 3 Refrigerant SV3 Close Open Close 4 Diluted solution SV4 Close Open Close 5 Concen...

Page 43: ...erature difference setting 3 Rank up down 4 Purge pump lamp on 5 Purge pump lamp off Input setting 6 Burner control type 7 Input correction PID setting 8 Proportional setting in cooling 9 Integral setting in cooling 10 Derivative setting in cooling 11 Sampling setting Field setting 12 Cooling water temperature at maximum input 13 Slow input time 14 Slow input temperature 15 Dilution cycle time 16 ...

Page 44: ...od 2 Interlock alarm Chilled water Good No good Cooling water Good No good 3 Motor alarm Good No good 4 System alarm Good No good 5 Check for rotation direction of pump 1 Absorbent pump Good No good 2 Refrigerant pump Good No good 3 Purge pump Good No good 41 ...

Page 45: ...12 Operation and date record 1 Run the chiller Perform refrigerant blow down Finished Unfinished 2 Record operation data Finished Unfinished 42 ...

Page 46: ...13 Sampling of absorbent Sampling of absorbent Finished Unfinished 43 ...