Absorption Chiller

INSTALLATION MANUAL
LJ Model
 Notes to Users

Thank you for purchasing Carrire/SANYO Absorption Chiller.

Refer to read this manual and Exhibit LA before Absorption Chiller installation.

Before operating the Chiller, please read this manual thoroughly.

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 change without notice.
 Absorption Chiller Installation Manual
<Hot water fired type>

Table of Contents

1. INSTALLATION
1-1. USE ENVIRONMENT ................................................................................................................... 1
1-2. SAFETY INSTALLATION .............................................................................................................. 7
1-3. DELIVERY INSPECTION ............................................................................................................. 7
1-4. RIGGING ...................................................................................................................................... 9
1-5. SLIDING ........................................................................................................................................ 9
1-6. SETTING ON THE FOUNDATION ............................................................................................... 9
1-7. LEVELING................................................................................................................................... 10
1-8. LEAK TEST, METHODOF CHARGING/DISCHARGING NITROGEN GAS ............................... 12
1-9. PIPING ........................................................................................................................................ 18
1-10. FIELD WIRING ......................................................................................................................... 19
1-11. PURGING ................................................................................................................................. 20
1-12. INSULATION ............................................................................................................................. 24

2. TEST OPERATION
2-1. EXTERNAL VISUAL INSPECTION ............................................................................................. 25
2-2. 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 WIRING DIAG/PARTS LIST
ExhibitLG ....... Insulation
ExhibitLH ........ LiBr solution material safety data sheet
ExhibitLI ......... Operation board operating instructions for confirmation of operation board parameters
ExhibitLJ ........ DAMPER OPENING&VALVE POSTION
 SAFETY PRECAUTIONS
1. INSTALLATION

1-1. USE ENVIRONMENT

1-1-1. Machine room

Absorption Chiller is indoor use ONLY.

IP number of Absorption Chiller is IP40.

Please keep the machine room temperature between 5°C and 40°C for protection 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 contact Carrier/SANYO agent.

1
 SAFETY PRECAUTIONS
1-1-4. SAFETY PRECAUTIONS
* Before operating this chiller, you should first thoroughly read the following instructions.
*All precautions are classified into either WARNING or CAUTION.
WARNING: Failure to observe this instruction may result in serious injury or death.
CAUTION : Failure to observe this instruction may cause an injury or failure of chiller/heater.
Depending on circumstances, this may result in serious injury or death.

< Example >

symbol denotes danger, warning or caution.
The illustration in the symbol shows the specific description of such item.
(The illustration to the left indicates that a special care must be taken to avoid electric shocks.)

symbol prohibits an action.

The illustration in or near the symbol shows the specific description of such item.

symbol instructs an action to be done.

The illustration in the symbol shows 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.

(1). For safety usage

WARNING
TURN OFF THE BREAKER BEFORE CLEANING STOP THE OPERATION IN CASE OF A FIRE,
AND CHECKING EARTHQUAKE OR POSSIBLE THUNDERBOLT
Always turn off the breaker before cleaning Stop the operation in case of a fire or
and checking the cooling tower fan, earthquake or when there is likely to be a
chilled water pump, or others linking the thunderbolt, to prevent a fire or electric
chiller, to provide protection from Must be observed shocks.
electric shocks or possible injury by the
Must be observed rotating fan.

INSPECTION

DO NOT TOUCH THE CONTROL PANEL DO NOT TOUCH THE WIRINGS INSIDE THE
SWITCH WITH WET HANDS CONTROL PANEL
Do not touch the switch inside the control Do not touch the wirings inside the control
panel with wet hands to avoid electric panel to avoid electric shocks.
shocks.
Do not touch SWITCH Do not touch

2
 SAFETY PRECAUTIONS

DO NOT TOUCH HIGH VOLTAGE LEAD WIRE

Do not touch high voltage lead wire to

prevent electric shocks.

Do not touch

KEEP FLAMMABLES AWAY FROM THE

CHILLER
Do not place any flammables (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
 SAFETY PRECAUTIONS

CAUTION
SOLVE ALL THE PROBLEMS BEFORE DO NOT PLACE HEAVY OBJECTS ON THE
RESTARTING THE CHILLER CHILLER• OR CONTROL PANEL
Solve all the problems before restarting the Do not place heavy objects on the
chiller/heater when the safety device or chiller or control panel to avoid
security device operates, to prevent a fire. possible injury by falling.
Must be observed Prohibited

DO NOT CLIMB UP THE CHILLER CALL SPECIALISTS FOR SERVICE OR

MAINTENANCE
Do not climb up the chiller to avoid Call specialists for service or maintenance.
falling down. Wrong service /maintenance may cause
electric shocks, a fire or burns.
Prohibited Must be observed

AUTHORIZED PERSONNEL ONLY DO NOT POUR WATER OVER THE

CHILLER OR CONTROL PANEL
A notice, “For Authorized Personnel Only” Do not pour water over the chiller or
must be affixed to the chiller to keep away control panel to avoid electric shocks.
unauthorized personnel from
Prohibited touching it. If this is anticipated, enclose Prohibited
the chiller with
a protective fence.
Misuse of the
chiller may
cause injury.

USE 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
What
voltage?

4
 SAFETY PRECAUTIONS

NEVER CHANGE THE SET VALUE STOP THE OPERATION WHEN BLACK SMOKE
RISES
Never change the set value of the safety Stop the operation when black smoke
and/or protective devices. Wrong setting rises and call service agent, to prevent
may damage the chiller/heater or cause a a fire by poor combustion.
fire. Must be observed
Prohibited

DO NOT TOUCH THE ABSORBENT OBSERVE THE SPECIFIED PRESSURE OF

WATER
Do not touch the spare or leaked The specified pressure of chilled/hot water
absorbent which may cause corrosion of and cooling water must strictly beobserved.
metal areas or cause skin diseases. Incorrect pressure may cause spout or
Prohibited leak which may cause a short circuit or
burns.
Must be observed

DO NOT TOUCH THE HIGH TEMPERATURE STOP THE PURGE PUMP TO REPLACE OIL
AREAS
Do not touch the high temperature areas. Please stop the purge pump when
These areas are indicated by caution replacing oil to avoid possible injury by
label. Please avoid touching fuel scatter.
such areas to prevent burns. Must be observed
Prohibited STOP

5
 SAFETY PRECAUTIONS

(2). Safety precautions for repair, moving or rejection

WARNING
ONLY AUTHORIZED PERSONNEL SHOULD
OVERHAUL THE CHILLER
Only those who are authorized should
overhaul the chiller.
Incomplete service could result in electric
shocks or a fire.
Prohibited

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

6
1-2. SAFETY INSTALLATION

A proper skilled installer should carry out the equipment installation.

Take safety measures during installation works.
Take measures to prevent unauthorized people from entering installation site
during installation work.

1-3. DELIVERY INSPECTION

Upon delivery of the Carrier/Sanyo Chiller to the job site, the owner or his designated
representative should carefully inspect the Chiller for the following items:

1-3-1. The Chiller is filled with nitrogen gas of 20kPa, when it is shipped from factory.
Open SV7. Connect 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) Accessory
(6) Solution

1-3-3. Check the shipping or packing slip sent with the Chiller and note any missing items.

1-3-4. Check any separate boxes or crates shipping with the Chiller for any missing items.

NOTE 1. Isolation pads are not required for most installations.

NOTE 2. Inform Carrier/Sanyo within 24 hours of any damage or missing items.

7
 SOLUTION VOLUME

Model Name Absorbent Refrigerant Alcohol Inhibitor

kg lbs kg lbs cc gal cc gal
LJ-11E 430 900 60 130 780 0.21 250 0.07
LJ-12E 430 900 60 130 780 0.21 250 0.07
LJ-13E 560 1,200 100 220 1,020 0.27 330 0.09
LJ-14E 620 1,400 90 200 1,120 0.30 360 0.10
LJ-21E 750 1,700 110 240 1,360 0.36 440 0.12
LJ-22E 810 1,800 120 260 1,480 0.40 480 0.13
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 5,300 310 680 4,400 1.17 1,400 0.37

NOTE Absorbent : LiBr 50wt%

Inhibitor : Li2MoO4 20wt%
300ppm (Total Concentration)
Alcohol : Octyle Alcohol CH3(CH2)5CH(OH)CH3

8
1-4. RIGGING

In case that a chiller is lifted up, check first weight of the chiller by referring its contract
specifications and then choose and use suitable lifting wires and shackles. Since 4 holes are
provided on the conners of lower tube sheet, use the holes 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 LC.

Please set the Chiller on the foundation bolt position.

9
1-7. LEVELING

1-7-1. Fill a clear vinyl hose with water, checking that there are no air bubbles in the hose.

1-7-2. Using point A as the 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

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

2
Tolerance < L : Chiller length
1000
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.

10
1-7-5. If tolerance are not met, shim the appropriation points by 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
1-8. LEAK TEST, METHOD OF CHARGING/DISCHARGING NITROGEN GAS

If the chiller has some leaks, please work this items.

1-8-1. Instruction for leak test

This instruction describes the procedure of leak test for the Chiller
by means of pressurizing with nitrogen gas (hereinafter called N2 gas).

(1) Equipment use

a) Nitrogen gas cylinder

b) Pressure regulator
c) Pressure proof 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

Charge N2 gas Refer to 1-8-2

Perform recheck.

Check at 50kPa ---- Check leakages.

OK NG

Perform tightening up.

Discharge N2 gas and repair. Charge N2 gas up to

Discharge N2 gas (Note) The repair welding can be done after discharging N2 gas.
Refer to 1-8-3.
Air purging

12
(4) Procedure

a) Confirm that V1, V2, V3, B valve, SV1, SV2 are fully closed.

b) Confirm that each isolation valve for absorbent and refrigerant pumps are fully opened.

c) Connect the vacuum gauge to SV2. and open SV2.

d) Charge N2 gas (Refer to 1-8-2).

e) Pressurize the 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 absorbent pumps, refrigerant pump, etc.)
g-5) Diaphragm valves

13
h) If any leakages are observed at above g-2) - g-5), tighten them without discharge of the N2 gas.

i) If there are any leakages at the welded portions, discharge the N2 gas and then 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
1-8-2. Method of charging nitrogen gas

This instruction describes the procedure to charge nitrogen gas (hereinafter called N2 gas) to the
Chiller.

(1) Equipment use

a) N2 gas : Required volume

Content volume
Model Volume Model Volume
LJ- (litter) LJ- (litter)
11E 1,640 31E 5,030
12E 1,580 32E 4,830
13E 2,510 41E 6,150
14E 2,380 42E 5,910
21E 3,150 51E 8,240
22E 3,010 52E 9,350
23E 4,210 53E 10,350
24E 4,020

b) Pressure regulator
c) Pressure proof hose
d) Adjustable wrench
e) Valve key for N2 gas cylinder
f) Vacuum gauge (0-100kPa)

(2) Standard
The pressure in 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.

15
(4) Procedure

a) Prepare N2 gas cylinders and attach a pressure regulator to a N2 gas cylinder.

b) Connect the vacuum gauge to SV2. Open SV2.

c) Connect a pressure proof hose to the outlet of the pressure regulator, then slightly open
a valve on the top of the cylinder in order to purge air being in the hose. After purging,
close the valve.

d) Connect the other end of the hose to SV1 and fix 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 then close the valve of the
cylinder.

i) Remove the hose from SV1 and place a cap of the service valve to the service valve.

j) Remove the pressure regulator, and vacuum gauge.

k) Close SV2.

16
1-8-3. Method of discharging nitrogen gas

This instruction describes the procedure to discharge N2 gas form the Chiller.

(1) Equipment use

a) Adjustable wrench

(2) Standard

The pressure in the 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
1-9.PIPING

1-9-1. Connect each pipe according to Exhibit LE.

(1) Make all necessary connections to the building water systems: chilled and cooling water.
Ensure that all piping is adequately supported and that no strain is placed on the Chiller
nozzles and connecting flanges.

(2) Provide adequate temperature 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 cap.
(6) Fix the cap by wire with label after leak test of the Chiller.

18
1-10. FIELD WIRING

1-10-1. For CE marking; Power supply connection is overvoltage category III.

And other connections are overvoltage category 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
1-11. PURGING

1-11-1. Confirm to be possible to supply electric power continuously.

1-11-2. Discharge nitrogen gas. Refer to 1-8-3.

1-11-3. Feed oil to the center red mark of purge pump air level gauge.

1-11-4. Turn on the main breaker of the control panel. And turn on the purge pump switch. Check
the 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 5hPa at vacuum gauge. Refer to
the attached table.

MODEL TIME
LJ-11-14 5h
21-32 12h
41-53 24h

20
1-11-7. Bubble test

(1) Instruments

a) Attachment of exhaust port of purge pump

b) Graduated cylinder
c) Vinyl hose (6 mmφ)
d) Bucket
e) Putty
f) Stop watch
g) Vacuum gauge (0-10hPa)

(2) Standard

Model Standard value

TSA-LJ-11 Less than 15 cc per 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.
53 Less than 50 cc per 10 min.

21
(3) Procedure

a) Perform air purging from the Chiller until inside pressure of the Chiller reaches allowable
degree of vacuum, after that, continue air purging for at least one hour.

b) Connect vacuum gauge to SV2, and open SV2.

c) Make sure that the attained vacuum of the purge pump is under 5hPa.

d) Remove an exhaust port cap of the purge pump, and install the attachment to the
exhaust port and furnish a vinyl hose to the attachment as shown in Fig. 1-11-7.

e) Open V1, close V2 and V3.

f) Continue to operate the purge pump for one minute under the condition as mentioned
above. Then measure volume of bubbles. During this measuring, keep the position of
the vinyl hose within 10mm in depth. If 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 should be repeated at least three times.
During these measurement, attained vacuum of the purge pump shall be kept below
4 mmHg.

i) The measured volume in item f) is called as " A cc ", and that in item h) is called as
" B cc ".
( B cc - A cc ) is a result of the bubble test.

j) After bubble test, gas ballast valve should be opened. And oil delivery valve should be
opened to confirm whether any water is contained in the purge pump oil or not. If the
water is observed, drain the water and fill new oil.

22
Fig. 1-11-7

23
1-12. INSULATION

After the Chiller has been installed, it must be insulated.

1-12-1. Before installing insulation, the Chiller should be placed in its permanent position.

1-12-2. To mount insulating 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
2. TEST OPERATION

2-1. EXTERNAL VISUAL INSPECTION

2-1-1. External visual inspection

The Followings shall be inspected.

(1) Insulation for the Chiller shall be properly performed.

a) Pampers, service valves and sight glass shall be operable.
b) Temperature sensors and pressure gauges shall be replaceable.
c) Bar-thermometers shall be able to insert into holders 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 components of the Chiller.
(6) There shall be no-missing of all components of the Chiller.
(7) No-wire-cut shall be observed on electric wiring and piping

25
2-2. ELECTRICAL CHECK

2-2-1. Confirm the electrical specification compare to name plate on the control panel.
Conformation of field wiring and wiring of palladium cell heater. Refer to Exhibit LF.

2-2-2. Check of insulation resistance of motors

Standard: More than 10kΩ

Insulation resistance of the solution pumps and blower motor shall be measured by a
measure at the secondary terminals of each magnet-contactor.

2-2-3. Measuring instruction of insulation resistance

This instruction describes the procedure to 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) Connect an earth wire of the megger to an earth terminal in the control panel.
b) Measure insulation resistances of each motor at the following terminals in the control
panel.
- Absorbent pump (Terminals) : U1/V1/W1
- Refrigerant pump (Terminals) : U3/V3/W3
- Purge pump (Terminals) : U4/V4/W4
c) Record the above measured values.

26
* marks are the positions measured by the megger.

27
2-3. INITIAL SETTING FOR OPERATION BOARD

2-3-1. Time setting

Refer to Operation manual.

2-3-2. Turn on the battery Backup on the Operation Board. Refer to Operation manual.

2-3-3. Check the operation board parameters. Refer to Check list and Exhibit LI.

2-4. DAMPER SETTING AND VALVE POSITION

2-4-1. Damper set

Refer to Exhibit LJ.

2-4-2. Confirmation of valve 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 purging from the Chiller for one hour
or more.
In case of performing bubble test, the gas ballast valve shall be closed. Please refer to
Section
1-11-7.

28
2-6. FUNCTION TEST

2-6-1. How fix to close the hot water control valve.

Display example  Generator temperature

Push the "SET" and " " 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
2-6-2. Water alarm

(1) Chilled water temperature (setting point : 2.5°C)

a) Provide water 1-2 litters with ice.
b) Push “ RUN” key on the operation board.
c) Dip the chilled water temperature sensor (DT1) into the water.
d) Confirm that data display on the operation board shows J-01 “Chilled water
temperature is too low”.

(2) Chilled water flow rate (setting point : less than approximate 50% of rated flow)
a) Push “ RUN” key
b) Reduce chilled water flow rate by means that a valve provided at the outlet of
the evaporator is gradually closed.
c) Confirm that data display on the operation board shows J-03 “Few flow rate of
chilled water”.

(3) Temperature (setting point 19°C for 30 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) Absorbent pump → The data display shows J-04 “Absorbent pump has overload”.

2-6-4. System alarm

(1) Chilled water pump

a) Push “RUN” key.
b) Stop the chilled water pump.
c) Confirm data display on the operation board J-02 “Chilled water pump interlock
was failure” and the cooling water pump stops immediately.

(2) Cooling water pump

a) Push “RUN” key.
b) Stop the cooling water pump.
c) Confirm data display on the operation board J-06 “Cooling water pump interlock
was failure”.

30
 2-6-2. How to operate the hot water control valve

Display example  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
2-7. OPERATION

2-7-1. Test running

Check the opening set value of each damper of the Chiller. Refer to Exhibit LJ.
Usually the units are adjusted at factory, but when assembling them on site or operating
them for the first time on site, the following adjusting procedures should be taken.

Mark Items Criteria How to solve the situation

B1 Hummer sound Without hummer Close the diluted solution damper
(Heat exchanger) sound little by little.
o
(about 2 angle)

B1: During adjustment, service engineers have to stay by the Chiller,

because the chiller is running with the steam control valve fixed.

2-7-2. Operation and data record

During stable 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 from → SV4 (Provide on absorbent pump outlet)
(3) Quantity → 100cc
Solution shall be sampled two times.

32
33
34
CHECK LIST
Test operation shall be conducted in accordance with this check list.

1. External visual inspection

2. Confirmation of field wiring and wiring of palladium 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
Project name :
Chiller/heater model :TSA-
Serial number :
Commissioned by : , date
Accepted by : , date

1. External visual inspection

(1) Lower shell :No-damage Damaged
(2) Upper shell :No-damage Damaged
(3) Heat exchangers :No-damage Damaged
(4) Evaporator headers :No-damage Damaged
(5) Absorber headers :No-damage Damaged
(6) Condenser headers :No-damage Damaged
(7) Control panel :No-damage Damaged
(8) Absorption pomp and its isolation valves :No-damage Damaged
(9) Refrigerant pump and isolation valves :No-damage Damaged
(10) Temperature sensors (11 sensors) :No-damage Damaged
(11) Generator pressure switches :No-damage Damaged
(12) Purge unit (Diaphragm valves, Liquid trap) :No-damage Damaged
(13) Chilled water flow switch :No-damage Damaged
(14) Cooling water flow switch (option) :No-damage Damaged
(15) Refrigerant 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 Damaged
(5) Operation indication (#350-#351) :No-damage Damaged
(6) Alarm indication (#354-#355) :No-damage Damaged
(7) Chilled water pump (#356-#357) :No-damage Damaged
(8) Cooling water pump (#358-#359) :No-damage Damaged
(9) Answer back indication (#362-#363) :No-damage Damaged
(10) Grounding/Earth (#G/PE) :No-damage Damaged
(11) Wiring of palladium cell heater :No-damage Damaged
For 460V and 400V: #232 and #0B in the control panel.
For 208V: #232 and #202 in the control panel.
(12) Hot water control valve (4 to 20mA:#345-#346) :No-damage Damaged
(AC24V: #340-#344,#0)
(13) Hot water shutoff valve (#347-#348) :No-damage Damaged

36
3. Check of insulation resistance of motors
Standard : More than 10kΩ
(1) Absorbent pump : MΩ Good No-good---->RepairedReplaced
(2) Refrigerant pump : MΩ Good No-good---->RepairedReplaced
(3) Purge pump : MΩ Good No-good---->RepairedReplaced
NOTE : Do not apply this test to an electronic controller.

4. Check of settings on safeties and switches in operation 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 or
discharge oil.
(4) Rotating direction : Good (As per arrow-mark on a V-belt cover)
No-good------>Replace two power source supply wires.

37
6. Confirmation of auxiliary equipment (For confirmation purpose only)
(1) Water piping
1) Connective direction of chilled water (Inlet / Outlet) : Good No-good
2) Connective direction of cooling water (Inlet / Outlet) : Good No-good
3) Connective direction of hot water (Inlet / Outlet) : Good No-good
4) Inlet / Outlet valves of chilled water : Open Close
5) Inlet / Outlet valves of cooling water : Open Close
6) Inlet / Outlet valves of hot water : Open Close

(2) Air vent valve, drain valve, pressure gauge, thermometer

Water Circuit Air vent valve Drain valve Press. Gauge Thermometer
Chilled water Yes No Yes 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 the hot water circuit : Finished Unfinished
(9) Automatic blowing device of cooling water : Yes No
(10) Chemical feeding devise of cooling water : Yes No
(11) Check of cooling water temperature control : Good No -good
(12) Water circulating conditions
Items Chilled water Cooling water Hot water
Suction pressure (MPa)
Delivery pressure (MPa)
Amperage (A)
(13) Capacity of a main breaker : A

38
7. Bubble test

With absorbe (1) cc/10min. Refer to Section 1-11-7(2)

(2) cc/10min. Refer to Section 1-11-7(2)
(3) cc/10min. Refer to Section 1-11-7(2)

8. Confirmation of valve opening conditions and switch positions

(1) Change over valves :
1) B valve : In purge pipe (Open) : Open Close

(2) Isolation valves : Open/close condition of valves shall be as follows.

1) Absorption pump (Open) : Open Close
2) Refrigerant pump (Open) : Open 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) Concentrated solution : SV6 (Close) : Open Close
6) Generator pressure gauge : SV7 (Open) : Open Close

(5) Switch
1) Purge : (Off) On Off

(6) Rapture Disk isolation valve (Open) : Open Close

1) Confirmation work : Good No-good

39
9. Confirmation of Parameter

9-1. Confirmation of operation board parameters : They shall be as follows.

Please refer to Exhibit LH.
Data Setting
Item display point Confirm
sample
Specifications setting 
1) Chilled water setting  
2) Chilled water temperature 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) remote signal  
17) Remote off pulse signal  

40
10. Pre operation : Good No -good
(1) Start and stop : Good No -good
(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
12. Operation and date record
(1) Run the chiller. Perform refrigerant blow down. : Finished Unfinished
(2) Record operation data : Finished Unfinished

42
13. Sampling of absorbent
Sampling of absorbent : Finished Unfinished

43