Sanyo Carrier 16LJ Series, Installation Instructions Manual

Page 1: ...16LJ Single Effect Hot Water Fired Absorption Chillers Nominal cooling capacity 264 1846 kW 50 Hz GB T 19001 2000 to ISO9001 2000 Installation instructions ...

Page 2: ...ing the absorption chiller and read this manual carefully before operating the unit It contains instructions for the installation 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 co...

Page 3: ...ing 9 1 8 Leak test and method of charging removing nitrogen gas 10 1 9 Piping 12 1 10 Field wiring 12 1 11 Purging 12 1 12 Insulation 13 2 TEST OPERATION 13 2 1 External visual inspection 13 2 2 Solution charge 13 2 3 Electrical check 13 2 4 Initial control board setting 14 2 5 Damper setting and valve position 14 2 6 Purging 14 2 7 Function test 15 2 8 Operation 16 3 CHECK LIST 19 3 1 External v...

Page 4: ...jury or death This symbol denotes danger a warning or a caution The illustration in this symbol shows the specific description of the item This symbol prohibits an action The illustration next to this symbol shows the specific description of the item This symbol instructs an action to be done The illustration in this symbol shows the specific description of the item After reading this manual it sh...

Page 5: ...fter a safety or security device is activated to prevent fire Must be observed DO NOT PLACE HEAVY OBJECTS ON THE CHILLER OR CONTROL PANEL Do not place heavy objects on the chiller 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...

Page 6: ... smoke is black and call a service engineer Must be observed DO NOT TOUCH THE ABSORBENT Do not touch spare or leaked absorbent as this can cause metal corrosion or skin disease Prohibited OBSERVE THE SPECIFIED WATER PRESSURE The specified chilled hot water and cooling water pressure must be strictly observed Incorrect pressure may cause the water to leak spray which can lead to short circuits or b...

Page 7: ...SHOULD REMOVE OR REPAIR THE CHILLER Any relocation or moving of the chiller should only be done by authorized personnel Incorrect work could result in water leaks electric shock or fire Must be observed ONLY AUTHORIZED PERSONNEL SHOULD DISPOSE OF THE CHILLER To dispose of the chiller contact local specialists Incorrect disposal may result in absorbent leaks and cause metal corrosion or skin diseas...

Page 8: ...2 Fig 5 exhibit LA and the specification drawings Solution volume 16LJ Absorbent Refrigerant Alcohol Inhibitor kg kg l l 11 430 60 0 78 0 25 12 430 60 0 78 0 25 13 560 100 1 02 0 33 14 620 90 1 12 0 36 21 750 110 1 36 0 44 22 810 120 1 48 0 48 23 980 150 1 78 0 57 24 1070 140 1 94 0 62 31 1230 190 2 24 0 72 32 1340 170 2 44 0 78 41 1560 250 2 84 0 91 42 1680 230 3 06 0 98 51 1950 260 3 54 1 13 52 ...

Page 9: ...er and check there are no air bubbles in the hose Using point A as reference point measure the difference in the water level at the other points B C and D A B Evaporator side Absorber side C D A B C D 0 mm ___ mm ___ mm ___ mm The levelling calculation is as shown below A B C D A D B C A C B D L L L L W W L Chiller length W Chiller width 2 1000 Fig 1 Evaporator side Absorber side Fig 2 1 5 Moving ...

Page 10: ... kPa pressure keep the chiller pressurized to 50 kPa for 24 hours and then check the pressure again 8 After completion of the test remove the N2 gas and the vacuum gauge refer to chapter 1 8 3 9 Close SV2 NOTE If N2 gas is removed ensure that the room is sufficiently ventilated Spacer position Spacer position If tolerances are not met shim the appropriate points by inserting a metal spacer between...

Page 11: ...hose After purging close the valve Connect the other end of the hose to SV1 and fix it with a hose band Check that V1 V2 V3 B SV1 are fully closed Open the V3 and B valve and then open SV1 Note B valve should be closed after the solution is charged to the chiller Using the pressure regulator charge a small amount of N2 gas into the chiller Watch the vacuum gauge while N2 gas is charged When the pr...

Page 12: ...Pa Refer to the following table 16LJ Time 11 14 5 hours 21 32 12 hours 41 53 24 hours 1 11 1 Carry out a bubble test refer to Fig 6 Equipment to use Purge pump exhaust attachment Graduated cylinder Vinyl hose ø 6 mm Bucket Putty Stop watch Vacuum gauge 0 to 1 kPa Required purge rate 16LJ Standard value ml per 10 min 11 15 12 15 13 15 14 15 21 25 22 25 23 25 24 30 31 30 32 30 41 40 42 40 51 45 52 4...

Page 13: ...pecifications must comply with the control panel nameplate data Check the field wiring and the palladium cell heater wiring Refer to exhibit LF and the specification drawings 2 3 1 Check the motor insulation resistance Always ensure that the motors are disconnected from the wiring before carrying out this check The standard value is 10 MΩ minimum The insulation resistance of the absorbent pump sol...

Page 14: ...and maintenance manual 2 6 Purging 2 6 1 Ensure the gas ballast valve is closed before starting the purge pump During operation of the purge pump the gas ballast valve should be opened However if the valve is opened too far purge pump oil may spill from the oil charge port 2 6 2 Bubble test Before conducting the bubble test purge the chiller for at least one hour The gas ballast valve should be cl...

Page 15: ...isplay on the control board shows J 02 Chilled water pump interlock alarm and the cooling water pump stops immediately Cooling water pump a Press the RUN key b Stop the cooling water pump c Confirm that the data display on the control board shows J 06 Cooling water pump interlock alarm 2 7 5 Hot water control valve operation 2 7 2 Water alarm Chilled water temperature setpoint 2 5 C a Provide 1 2 ...

Page 16: ...d operation data Thermometer Pressure gauge Stop watch Solution sampling tool Gravimeter Concentration table as attached 2 8 3 Absorbent sampling Sampling should be carried out as follows Sampling of diluted solution Sampling from SV4 located on the absorbent pump outlet Solution should be sampled twice The sample quantity is 100 ml The second sample should be used for analysis Mark Item Criteria ...

Page 17: ... 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 Relative density kg m 3 x 10 3 Concentration Fig 10 Concentration versus temperature and relative density Temperature C Crystallization ...

Page 18: ...0 1 15 1 20 1 25 1 30 1 35 1 40 1 45 1 50 0 10 20 30 40 50 60 70 80 90 100 45 40 35 30 25 20 15 10 5 0 Relative density kg m 3 x 10 3 Concentration Fig 11 Concentration versus temperature and relative density Temperature C ...

Page 19: ...mp 358 359 Not damaged Damaged Feedback indication 362 363 Not damaged Damaged Earth connection G PE Not damaged Damaged Wiring of palladium cell heater Not damaged Damaged For 460 V and 400 V 232 and 0B on the control panel For 208 V 232 and 202 on the control panel Hot water control valve 4 to 20 mA 345 346 Not damaged Damaged 24 V a c 340 344 0 Hot water shut off valve 347 348 Not damaged Damag...

Page 20: ...e pressure gauge thermometer Water circuit Air vent Drain valve Pressure Thermo valve gauge meter Chilled water Yes No Yes No Yes No Yes No Cooling water Yes No Yes No Yes No Yes No Water pump duty Chilled water pump ____________kW Cooling water pump ____________kW Hot water pump ____________kW Cooling tower ____________kW For information only Cooling water temperature control Fan on off 2 way val...

Page 21: ...ng Field setting 12 Cooling water temperature at maximum input 13 Slow input time 14 Slow input temperature 15 Dilution cycle time 16 Remote signal 17 Remote off pulse signal 21 3 10 Pre operation checks Start and stop Good Not good Interlock alarm Chilled water Good Not good Cooling water Good Not good Motor alarm Good Not good System alarm Good Not good Check direction of pump rotation Absorbent...

Page 22: ... 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 kPa psi 12 Cooling water leaving pressure kPa psi 13 Pressure drop in absorber condenser kPa psi 14 Cooling water ...

Page 23: ...urge pump current A LTD Condensed refrigerant temperature minus cooling water leaving temperature Notes _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ ________________________________________________________________________________________...

Page 24: ...ntact the service agent 4 1 2 Precautions for installation Always make sure that the installation complies with local regulations The chiller is designed for indoor installation Install the chiller on a floor that is suitable to carry the weight Leave the service and maintenance clearances shown in the dimensional drawing Do not install the unit in a dusty environment If necessary install anti vib...

Page 25: ...amage caused may be irreparable 16LJ Shipping dimensions Suspension hole location L W H Weight A B C mm mm mm kg mm mm mm 11 2720 1295 2215 3500 400 1440 2066 12 2720 1295 2215 3600 400 1440 2066 13 3740 1295 2215 4500 400 1440 3086 14 3740 1295 2215 4700 400 1440 3086 21 3830 1455 2350 5700 470 1530 3086 22 3830 1455 2350 6000 470 1530 3086 23 4860 1455 2350 7000 470 1530 4106 24 4860 1455 2350 7...

Page 26: ...390 800 13 1270 390 800 14 1270 390 800 21 1380 490 1000 22 1380 490 1000 23 1380 490 1000 24 1380 490 1000 31 1530 530 1100 32 1530 530 1100 41 1610 560 1150 42 1610 560 1150 51 1710 780 1600 52 1710 780 1600 53 1710 780 1600 Fig 14 4 2 Exhibit LB cont 4 2 3 Centre of gravity location L Lx Ly ...

Page 27: ...00 400 1000 150 1300 200 1100 31 10600 5300 5300 3836 225 450 1100 150 1400 250 1200 32 11100 5550 5550 3836 225 450 1100 150 1400 250 1200 41 12900 6450 6450 3836 225 450 1150 150 1450 250 1250 42 13400 6700 6700 3836 225 450 1150 150 1450 250 1250 51 18200 9100 9100 3706 130 190 510 1600 180 1960 250 1700 52 19700 9850 9850 4248 130 190 510 1600 180 1960 250 1700 53 21100 10550 10550 4746 130 19...

Page 28: ...ressure gauge at the chilled cooling and hot water inlet and outlet 4 4 Exhibit LE 4 4 1 Typical piping diagram Fig 18 NOTE In order to prevent freezing of the chilled water during the chiller dilution cycle ensure continued operation of the chilled water pumps and cooling load until the dilution symbol on the control panel goes off For the same reason the chilled water volume must be higher than ...

Page 29: ...ow 50 X Sulphuric acid ion mgSO4 2 l below 200 below 50 below 50 below 50 below 50 X Acid consumption pH 4 8 mgCaCO3 l below 100 below 50 below 50 below 50 below 50 X Total hardness mgCaCO3 l below 200 below 70 below 70 below 70 below 70 X Calcium hardness mgCaCO3 l below 150 below 50 below 50 below 50 below 50 X Ion silica mgSiO2 l below 50 below 30 below 30 below 30 below 30 X Reference Iron mgF...

Page 30: ...r to control the cooling water entering temperature properly Legend 1 From chiller heater 2 To chiller heater 3 Cooling water pump 4 Constant flow blow down valve 5 Cooling tower 6 Bypass valve 7 Water supply 8 Cooling water thermostat Case B If the chiller operates during an intermediate season or in winter provide an automatic three way control valve shown as above 4 4 Exhibit LE cont 4 4 4 Cool...

Page 31: ...own volume as follows N Concentration factor N 3 is normal condition M Volume of make up water E Evaporation loss 860 x 2 43 exhaust heat factor divided by 575 latent heat of water at 40 C 3 63 l h kW W Splash loss 0 2 of circulation water volume B Blow down volume P P P P Chiller Manual valve Make up water Overflow Make up water Blow down adjustment valve Chiller Chiller Chiller Higher than cooli...

Page 32: ...onsumption pH 4 8 M alkalinity mgCaCO3 l Acid consumption pH 8 3 P alkalinity mgCaCO3 l Hydrazine mgN2 H4 l Chloride ion mgCl l Phosphoric acid ion mgPO4 3 l Boiler water Processing Alkali treatment Alkali treatment Alkali treatment pH at 25 C 11 0 11 8 11 0 11 8 11 0 11 8 Acid consumption pH 4 8 M alkalinity mgCaCO3 l 100 800 100 800 100 800 Acid consumption pH 8 3 P alkalinity mgCaCO3 l 80 600 8...

Page 33: ...iver tank for the solution The tank volume is approx 1 m3 3 Install piping support near the rupture disc connection 4 4 8 Rupture disk replacement 1 Apply a small amount of Teflon paste part No 814 2 3701 002 00 to both sides of the gasket as shown in Fig 21 to avoid leakage Do not apply too much Teflon paste 2 The gasket part No 814 2 2101 675 00 0 or 677 00 0 should be used as indicated in Fig 2...

Page 34: ... of anchor bolts 3 Clearance space must be available at the front and rear of the chiller 4 All external water piping are to be provided with welded ANSI 150 LB flanges by the customer 5 indicates the position of the power supply connection on the control panel diameter 35 mm 6 Installation clearance Ends 1000 mm Top 200 mm Others 500 mm Space for tube removall Hot water inlet 4 inch Hot water inl...

Page 35: ...power supply connection on the control panel diameter 35 mm 6 Installation clearance Ends 1000 mm Top 200 mm Others 500 mm Space for tube removal 16LJ 23 through 16LJ 24 mm NOTE Dimensions are for guidance only Refer to the certified drawings supplied upon request when designing an installation Wire connection Ø 35 hole Wire connection Ø 35 hole 4 4 Exhibit LE cont 16LJ 21 through 16LJ 22 mm Cooli...

Page 36: ...trol panel diameter 35 mm 6 Installation clearance Ends 1000 mm Top 200 mm Others 500 mm Space for tube removal 16LJ 41 through 16LJ 42 mm NOTE Dimensions are for guidance only Refer to the certified drawings supplied upon request when designing an installation Wire connection Ø 35 hole Cooling water inlet Chilled water outlet Cooling water outlet Wire connection Ø 35 hole Chilled water inlet Cool...

Page 37: ...tion on the control panel diameter 35 mm 6 Installation clearance Ends 1000 mm Top 200 mm Others 500 mm Space for tube removal NOTE Dimensions are for guidance only Refer to the certified drawings supplied upon request when designing an installation Wire connection Ø 35 hole 16LJ A B C D E F K L 51 3706 3836 4031 4229 851 4081 4600 5200 52 4248 4378 4573 4771 845 4623 5200 5740 53 4746 4876 5071 5...

Page 38: ... 2 2 2 8 9 0 2 5 M5 2 2 2 8 9 2 2 5 M5 2 2 2 8 22 18 8 4 M5 2 2 2 8 9 0 2 5 M5 2 2 2 8 9 2 2 5 M5 2 2 2 8 23 19 0 4 M5 2 2 2 8 9 1 2 5 M5 2 2 2 8 9 3 2 5 M5 2 2 2 8 24 19 0 4 M5 2 2 2 8 9 1 2 5 M5 2 2 2 8 9 3 2 5 M5 2 2 2 8 31 23 5 4 M5 2 2 2 8 11 1 2 5 M5 2 2 2 8 11 5 2 5 M5 2 2 2 8 32 23 5 4 M5 2 2 2 8 11 1 2 5 M5 2 2 2 8 11 5 2 5 M5 2 2 2 8 41 23 5 4 M5 2 2 2 8 11 1 2 5 M5 2 2 2 8 11 5 2 5 M5 2...

Page 39: ...e determined from local regulations Earthing cable annealed copper wire please use a cable of the same cross section as the power supply cable REMOTE SIGNAL Chiller can be operated by the following five signal types 1 Volt free normally open contact a for start stop 24 V d c 10 mA Wire terminal 324 and 323 connect 170 and 326 2 Volt free normally open contact a for start 24 V d c 10 mA Wire termin...

Page 40: ...0 4 X 1 14 4X 5 21 0 B 16 A 0V 206 205 0 V 0A 203 400 V 0 V 202 CP2 1A 400V 209 TR 3 207 230V 0V 208 4X 6 PCH 22 MCB1 3 A R TR2 r 24 V 204 25 20 4 X 3 88 P 1 3 39 2 38 4X 3 69CH FM 1 20 R S 232 24 A 147 4X 37 R0 S0 T0 X R1 R FILTER 4X 4X 345 346 CVP 42 41 CP4 1 A FFO NO 43P GL 51 4X 7 48 41 0A 4X 9 24 A 50 348 347 4X 4 42 383 382 4X 7 52 24 30 31 42 88 A d c 4 20 mA E 337 336 4X 9 41 31 33 37 32 2...

Page 41: ...Filter 8 Purge pump 9 Refrigerant pump 10 Absorbent pump 11 Located on hot water control valve positioner field suppiied 12 Chilled water pump interlock 13 Cooling water pump interlock 14 Located on hot water control valve motor field supplied 15 Remote setting signal d c 4 20 mA chilled water set point 0 to 5 C 16 For pre alarm indicator 17 For remote check 18 For hot water shutoff valve 19 For o...

Page 42: ...ulation m2 Cold surface insulation m2 75 mm 30 mm 50 mm 30 mm 11 2 8 1 6 4 0 0 3 12 2 8 1 8 4 0 0 3 13 3 8 1 9 5 5 0 3 14 3 8 2 2 5 5 0 3 21 4 0 2 5 6 1 0 4 22 4 0 2 5 6 1 0 4 23 5 2 3 1 7 6 0 5 24 5 2 3 3 7 6 0 5 31 6 0 3 5 8 5 0 5 32 6 0 3 6 8 5 0 5 41 6 6 3 7 9 9 0 5 42 6 6 3 9 9 9 0 5 51 7 6 4 8 13 8 0 7 52 8 4 5 1 15 0 0 7 53 9 2 5 3 16 1 0 7 75 mm heat insulation generator generator cover 30...

Page 43: ...ssification Notes Lithium bromide 7550 35 8 47 58 Listed Xi R41 4 7 Exhibit LH Material safety data sheet The following chapters are a material safety data sheet issued by DSBG Dead Sea Bromine Group on April 30 2002 For more information refer to the supplier Product name Lithium bromide solution Product identification 1910S Revision date 30 05 2002 Supersedes 15 09 1998 Revision 3 4 7 1 Identific...

Page 44: ...orexia constipation drowsiness and loss of sensitivity to touch and pain Mutagenicity Not mutagenic by the Ames Test Carcinogenicity Not known to be a carcinogen Not classified by IARC Not included in NTP 9th Report on Carcinogens 4 7 12 Ecological information Aquatic toxicity 96 hour LC50 Fish 1000 mg l 72 hour EC50 Marine alga 751 9 mg l 48 hour EC50 Marine invertebrate 1527 7 mg l 4 7 13 Dispos...

Page 45: ...the DSBG Internet Site 9 Develop business relationships with responsible suppliers transporters and distributors and provide them with HSE support information and training 10 Support Product Stewardship programs in cooperation with customers distributors and transporters 11 Allocate the necessary resources for implementation of this policy DSBG Disclaimer Although the information and recommendatio...

Page 46: ...d parameters Fig 27 Refer to chapter 4 8 3 Specification setting Push the set and q keys simultaneously for about 2 seconds Generator temperature 35 C Refer to chapter 4 8 4 Input setting Refer to chapter 4 8 5 PID setting Push BACK key 4 8 Exhibit LI 4 8 1 Character recognition table for digital display Fig 26 Push p key Push q key Push the SET key for about 2 seconds Push the BACK key Legend ...

Page 47: ... change push the p or q key and the push SET key Legend Push BACK key Push the set key for about 2 seconds Value given as example Chilled water setting Chilled water temperature difference setting Hot water temperature difference setting Purge pump lamp on Value given as example Hot water setting Purge pump lamp off Rank up down Note Note Note Note Note No change No change No change Fig 28 cont 4 ...

Page 48: ... there is a change push the p or q key and the push SET key Proportional setting in heating Integral setting in heating Derivative setting in heating Sampling setting Proportional setting in cooling For example Note No change No change No change Push BACK key Proportional setting in cooling Integral setting in cooling Derivative setting in cooling Given as example Given as example Given as example...

Page 49: ...he p or q key and the push SET key Push the set keys for about 2 seconds Push q key 7 times Push the set keys for about 2 seconds Cooling water temperature at maximum input Slow input time Slow input temperature Dilution cycle time Remote signal Remote off pulse signal Fig 31 cont Push BACK key Note Note Note Note Note Note Generator temperature 35 C Legend 4 8 Exhibit LI cont 4 8 6 Field setting ...

Page 50: ... 13 45 90 14 45 90 21 45 90 22 45 90 23 45 90 24 45 90 31 45 90 32 45 90 41 45 90 42 45 90 51 45 90 52 45 90 53 45 90 Damper opening 0 closed 90 fully open Valve name Position B Open SV1 Closed SV2 Closed SV3 Closed SV4 Closed SV6 Closed SV7 Open SV9 Closed V1 Closed V2 Closed V3 Closed Valve position Legend 1 Hot water control valve 2 Hot water inlet 3 Hot water outlet 4 Heat exchanger 5 Cooling ...

Page 51: ...51 ...

Page 52: ... order No New Manufactured by Sanyo Electric Co Ltd Dalian PR 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 ...