Documente Academic
Documente Profesional
Documente Cultură
FOR
H2 TYPE DIRECT-FIRED LITHIUM BROMIDE
ABSORPTION CHILLER/HEATER
DF99~1984
CE
INTRODUCTION
First of all, let us express heartfelt gratitude to you for the application of direct-fired lithium
bromide absorption chiller/heaters, produced by Shuangliang.
The direct-fired lithium bromide absorption chiller/heaters, produced by Shuangliang, had win a
lot of national and province level awards, had been certified for safety protection, environment
friendliness and ISO quality assurance system. The chiller/heaters are good in performance, easy
to operate and durable for life cycle.
The technical manual covers the construction, operation principle, control system and guide to
installation, operation and maintenance of direct-fired lithium bromide absorption chiller/heater.
As very sensitive to maintenance, direct-fired absorption chiller/heater should be maintained
perfectly, otherwise it will be degraded and its operation life will be reduced. Read the technical
manual carefully before You operate it. This will bring benefit to Your Company.
The technical manual did not contain the description of auxiliary equipment, such as burner,
inverter and etc. You can find appropriate reference in the individual technical manuals published
by the manufacturers of auxiliary equipment. For the Chiller/heater, gas, oil, and oil/gas can be
used as fuel, you should pay attention to your order, and can find suitable material in this manual.
Jiangsu Shuangliang Air Conditioning Equipment Co., Ltd, International Trade Department
Add: Shuangliang Industrial Park in Ligang, Jiangyin city, Jiangsu Province,
The People’s Republic of China
Post code: 214444
Tel: +86-510-86638824
Fax: +86-510-86634678
Table of Contents
CHAPTER 1 DESCRIPTION OF ABSORPTION CHILLER/HEATER......................................... 1
1
6.8 MANAGEMENT OF WATER QUALITY .............................................................................................. 51
6.9 OPERATION OF VACUUM PUMP ...................................................................................................... 52
6.10 OPERATION OF VALVES ................................................................................................................ 53
CHAPTER 7 TROUBLESHOOTING................................................................................................ 56
Appendix
Attached Table 1 Saturated Steam Table (a) and (b)
Attached Figure 1 Crystallization Temperature Curve for LiBr Solution
Attached Figure 2 Specific Gravity Curve for LiBr Solution
Attached Figure 3 Saturated Steam Curve for LiBr
Attached Figure 4 Pressure -Temperature Curve for LiBr
Attached Table 2 Running Record
Attached Table 3 Chiller Electric Parameter Table
Attached Table 4 Performance Table for Breaker Used on Chiller
2
SAFETY POINTS
Safety points must be carefully read and fully understood by the operators before operation for
safe and correct use of Shuangliang Chiller.
Safety Warning
1.1 Indication in the manual
The following indication in boldface will be marked in proper positions of the manual to remind
any possible operators.
is to indicate any possible dangers for personal injury. Normally, instruction, brief
explanation and possible results due to neglect of those instruction will be closely followed.
is to indicate useful help information. That information has no relation to safety operation
but may help chiller efficiency and prolong service life of chiller. It also should be noted that help
information will not always be the optimal and will not necessarily bring benefits to chiller.
1.2 Operation Circumstance Warning
Control system should be forbidden to start under conditions below:
z Environment temperature lower 0℃ or higher 55℃
z Places of causticity or with flammable gas
z Places with large quantities of dusts, alkaline air or metal powder
z Places where may cause vibration or impacts to control system
z Places where water, oil or chemicals may be splashed over control system
3
Chapter 1 DESCRIPTION OF ABSORPTION CHILLER/HEATER
1
to strong solution, which flows into the absorber. High temperature refrigerant vapor, which flow
through the heat transfer tubes of HP generator, is condensed by the solution outside the tubes, and
Fig. 1-1 Front view of absorption chiller/heater 11. Strong solution sampling valve
12. Refrigerant pump
13. Refrigerant sampling valve
14. Refrigerant by-pass valve
15. Cooler water inlet valve
16. Steam heating valve
17. Purging valve of absorber
18. Control panel
19. Solution heating valve
2
32-Rupture disk 33-LP generator 34-Condenser
Table 1-1 List of Valves for chiller/heaters
No Description Purpose Class Type
1 Purge valve of For purging non-condensable gases from condenser, Purge Stop
condenser opened during purge, normally closed. valve valve
2 Purge valve of For purging non-condensable gases from evaporator
evaporator during heating mode, normally closed
3 Upper purge For evacuation. Opened, while evacuate the
valve for chiller/heater by vacuum pump; Opened also, while
vacuum pump measure the pressure in the chiller/heater and leak
test the shell under positive pressure of nitrogen.
Normally closed.
4 Pressure For measuring pressure. Opened, while measure Pressure Stop
measuring pressure in the unit by Macleod gage. Normally measuring valve
valve closed. valve
5 Lower purge For evacuation. Opened, while evacuate the Purge Stop
valve for chiller/heater or non-condensable gases from gas valve valve
vacuum pump cylinder by vacuum pump. Normally closed.
6 Sampling For measuring the limiting evacuation capacity of
purge valve vacuum pump, and evacuating vessels other than
shell (such as sampler, end cover of HP generator).
Normally closed.
9 Charge valve For charge and drain solution from chiller/heater, Solution Stop
and sampling of weak solution. Normally closed. valve valve
11 Strong For sampling of strong solution. Normally closed.
solution
sampling
valve
13 Refrigerant For sampling of refrigerant, charge and drain Refrigerant Stop
sampling refrigerant from chiller/heater, and charge gas into valve valve
valve the shell during leak test and maintenance under
positive pressure. Normally closed.
14 Refrigerant For bypass refrigerant from evaporator to absorber
by-pass valve for re-generation of refrigerant or dilution of
solution. Normally closed.
15 Cooler water Valve shall be closed when purging during heating Cold water Ball
inlet valve mode. Normally open valve valve
16 Steam heating Changeover valve. Closed for cooling mode, and Refrigerant
valve opened for heating mode. valve
17 Purge valve of Valve shall be closed when purging during heating Purge valve Stop
absorber mode. Normally open valve
19 Solution Changeover valve. Closed for cooling mode, and Solution Ball
heating valve opened for heating mode. valve valve
28 Connecting For drain a part of refrigerant water from evaporator Connecting Stop
valve for water pan into absorber water box before heating valve valve
water box operation. Normally closed.
E-A
Condenser consists of heat transfer tubes and end covers. Cooling water from cooling tower
(about 32℃), enters heat transfer tuber via end covers, to condense the flashed vapor from HP
generator condensate through throttle and condense the refrigerant vapor from LP generator. Then
cooling water left the condenser at temperature about 38℃ to the cooling tower. Produced
refrigerant water flows into the flash chamber through U pipe. A part of refrigerant water is
flashed to form vapor, which flows into the re-absorption chamber at the bottom of absorber,
3
another part of refrigerant water is cooled, and enters refrigerant water pan. Condenser and LP
generator is arranged in one shell (upper shell) with identical pressure.
Evaporator consists of heat transfer tubes, end covers, refrigerant water distribution and spraying
piping, refrigerant water pan, refrigerant water chamber and refrigerant pump. Chilled water from
customer (about 12℃) enters heat transfer tubes through end cover, and evaporates refrigerant
water, which is sprayed over the tubes by the refrigerant pump from water chamber. Rest of water,
which had not been evaporated is collected in the water pan, and is sent to distribution tube again
to evaporate. Thus produced chilled water runs from the evaporator at temperature about 7℃
into the system of customer. Pressure in the evaporator is about 0.80~0.93Kpa (6-7 mmHg).
Absorber consists of heat transfer tubes, end covers, water distribution pan, solution chamber and
solution pump. Cooling water from cooling tower enters the heat transfer tubes through end cover
to cool the strong solution distributed outside tubes. At a set temperature and concentration (for
instance 50℃and 63%) lithium bromide solution possesses tremendous water vapor absorbing
capacity, and absorbs considerable refrigerant vapor, produced in the evaporator in the same shell,
and transfers the heat to the cooling water, which is dissipated to the cooling tower. After
absorbing water vapor, solution is diluted, and flows into the re-absorption chamber to absorb the
refrigerant vapor flashed in the flash chamber, then sent to HP and LP generators to be
concentrated. Absorber and evaporator locate in the same shell under the same pressure. Absorber
is divided into two parts, which are arranged in both sides of evaporator.
High temperature heat exchanger consists of two heat exchanger shells, which are composed of
heat transfer tubes, supporting rods and front and rear end covers. Weak solution flows through
internal part of tubes, and intermediate solution pass over the tubes. HT heat exchanger has the
purpose of increasing the temperature of weak solution and reducing that of intermediate solution.
Low temperature heat exchanger consists of two heat exchanger shells, which are composed of
heat transfer tubes, supporting rods and front and rear end covers. Weak solution flows through
internal part of tubes, and strong solution passes over the tubes. LT heat exchanger has the purpose
of increasing the temperature of weak solution and reducing that of strong solution.
Purge unit consists of purge piping and gas box (arranged in evaporator, absorber and condenser),
ejector, gas cylinder, solution return pipe, stop valves, and vacuum pump. It is functioned for
purge non-condensable gas from the chiller/heater to reduce the influence of .gas to the normal
operation of chiller/heater. During its operation, the non-condensable gas is extracted through
purge piping to the pressure reduced area of ejector, which is created by a part of weak solution,
supplied by the solution pump from absorber. Then gas flows with solution into the gas cylinder.
Gas is stored in the gas cylinder and gas box, and solution returns into the absorber through
solution return pipe. Stored gas can be discharged into atmosphere by vacuum pump, or
non-condensable gas can be evacuated directly by the vacuum pump.
Hermetically-sealed pumps (solution pump and refrigerant pump) are used to handling the
working media in the chiller/heater. Solution pump has the purpose to send the lithium bromide
weak solution from absorber to HP and LP generators through LT and HT heat exchangers.
Concentrated strong solution is returned to absorber. Refrigerant pump is used to spray refrigerant
over the tubes in the evaporator by extracting refrigerant from refrigerant pan of evaporator, then
refrigerant is evaporated by heat of chilled water.
Burner is the heat source for the chiller/heater, and can be oil or gas burner dependent the oil or
gas used.
4
Control panel is the control center of chiller/heater. For details of control panel, see Chapter 4.
1.4.2 Absorbent
As absorbent for the chiller/heater, lithium bromide solution is used. It can be taken as the carrier
of refrigerant water, and functions as to absorb the refrigerant vapor, produced in the evaporator
by removing heat of chilled water, and carries refrigerant into HP and LP generators. Weak
solution is divided into water and strong solution under the heat of burned fuel. Then the strong
solution returned into absorber to absorb water vapor, produced in the evaporator. Refrigerant
vapor enters condenser to be condensed by dissipating the heat into atmosphere through cooling
water. Refrigerant condensate returns into evaporator to produce cooling effect.
The new charged solution should meet the following technical requirements:
(1) Concentration: 50%±0.5%;
(2) Alkalinity: pH value in the limits of 9.5~10.5;
(3) Lithium chromate content: 0.10%±0.02%
5
1.5 Working Process
1.5.1 Working Process for Refrigeration
Refrigeration process is shown in the Fig. 1-4. During refrigeration the heating solution and vapor
valves are closed. The chiller/heater is purged from non-condensable gases, and kept under high
vacuum conditions.
Weak solution from the absorber is pumped into the HP generator through LT and HT heat
exchangers. It is heated by fired fuel and concentrated to the intermediate solution, and high
temperature refrigerant vapor is produced. Intermediate solution enters LP generator through HT
heat exchanger in exchanging heat with weak solution which is passed through the tubes, and
heated by the refrigerant vapor from HP generator, concentrated to the strong solution, releasing
refrigerant vapor at the same time. The strong solution passes through the outside tube space of LT
heat exchanger, enters absorber, transmitting heat to the weak solution from absorber. Refrigerant
vapor from HP generator is condensed in LP generator to form condensate, which enters
condenser through throttle. Refrigerant vapor formed in the LP generator enters the condenser to
form condensate also. These two parts of refrigerant condensate flows into the refrigerant pan.
Refrigerant from evaporator water pan is pumped over the evaporator tubes for the refrigeration
effect, and evaporates to form vapor by absorbing heat of chilled water flowing through tubes.
Produced refrigerant vapor enters absorber, and absorbed by strong solution in the absorber.
Produced heat during absorption in absorber is carried by cooling water inside absorber tube
bundles into atmosphere. Chilled water is cooled and return to the system of customer. Strong
solution is diluted by absorbing refrigerant vapor in absorber and absorbing flashed refrigerant
vapor in the re-absorption chamber, then is transferred by solution pump to HP and LP generator
for concentration. This process is continued, and refrigeration effect. is repeated
6
1.5.2 Working Process for Heating Mode
Working process for heating mode is shown in Fig. 1-5. During heating mode, the cooling water
pump and refrigerant pump stops to run, but solution and steam valves for heating should be
opened. Hot water is supplied from evaporator.
Weak solution is pumped from absorber into HP generator and heated by fired fuel, and
concentrated by releasing refrigerant vapor. High temperature refrigerant vapor is fed into
evaporator through vapor heating valve, releasing heat to the hot water inside the tube bundles in
the evaporator. Condensate of refrigerant vapor in the water pan of evaporator is over-flown into
the absorber, and strong solution is fed into the absorber through solution heating valve. These two
parts of solution are mixed together to form weak solution. This weak solution is pumped to the
HP generator to be heated. Hot water in the evaporator tube bundles is warmed-up due-to the heat,
released from refrigerant vapor by condensation. This process is continued, and hot water is
produced in evaporator uninterruptedly.
7
1.6 Performance of chiller/heater
The chiller/heater can be differed from nominal conditions owing to the changed requirements of
customer (such as air conditioning load, cooling water temperature and so on). Fig.1-6, 1-7,1-8 1-9
and 1-10 show the performance curves of absorption chiller/heater, which cannot be operated over
the allowed operation limits.
Conditions:
Chilled water outlet temperature 7℃
Fuel consumption (%)
Conditions:
(%)
Conditions:
(%)
8
Conditions:
Hot water outlet temperature 60℃
Fuel consumption (%)
Conditions:
Hot water flow 100%
9
Chapter 2 INSTALLATION OF CHILLER/HEATER
Air leaks in the chiller/heater, causes corrosion of internal parts, affects its operation
life, and prevents it from normal operation under severe conditions.
During shipping, handling and installation, chiller/heater should be protected from man-made
damage and unauthorized operation of valves and instruments. In order to protect the chiller/heater
from leaks, the personnel is forbidden to climb the chiller/heater by the piping and valves. Control
panel, electric instrument and wiring should be protected from damage, control panel is not
allowed be opened and wiring be removed by uncertified operator. Protection means from
dampness and rain should be adopted.
All the outlet openings of chiller/heater should be covered to protect it from ingression of dirty
and foreign matter.
With original openings covered and protections provided chiller/heater should be covered by a
tarpaulin, but not plastic sheeting (which will permeate damp and speed up its corrosion), when it
is left in the open air. Chiller/heater or its parts, stored for long time in the room or in the open air,
should be covered carefully.
Box with bulk of parts is recommended to store at dry and safe place to ensure its intact.
10
7. Machine room should be arranged in such a way, that the chiller/heater is accessible to handling,
install, maintain, repair, replace the parts and modernize chiller/heater. Space and height should
be reserved for handling and transport the chiller/heater.
8. Minimum space with the dimensions shown in the Table2-1 should be reserved. Space for
changing tubes should be provided in axial direction from any one side of chiller/heater.
Chiller/heater can be installed with the ends against window or door for pulling the leaking
tubes.
9. Machine room should be designed with due considerations of its vibration and noise to the
surrounding rooms, and provided with good sound isolation, attenuation and vibration
absorbing means.
10. Machine room should be able to carry the total weight of whole package of chiller/heater and
its auxiliary equipment such as water pumps during their operation.
11. Machine room should be equipped with locks and screens for doors and windows to protect
from the entrance of unauthorized people.
12. Machine room should be provided with tools, spare parts and materials for maintenance of
chiller/heater and systems.
Table2-1 Minimum space, reserved around the chiller/heater
Axial direction 1.0m Above chiller/heater 0.2m
From control panel 0.8m Rear side 0.8m
11
small diameter pipes, connecting wires and instrument. Chiller/heater should be handled in
horizontal position with slow movement in order to be protected from drop of unit owing to
deviation of center of gravity, when solution in chiller/heater is moved. Chiller/heater should be
lowered with all feet contacted with the surface of floor or fundament.
12
and water as follows:
1. As shown in the Figure 2-1, transparent plastic hose is hanged close to the level reference holes,
and charged with water.
2. Water lever in one end of hose is kept to the center of one reference hole. Water level in the
another end of plastic hose should be at same height with the center of another reference hole,
adjusting the height of chiller/heater at another end by crane or other means. The longitudinal
levelness of installed chiller/heater equals to the difference of water level in two ends divided
by the distance between the tube plates. Chiller/heater is kept in the limits of levelness, which
should be less than 1/1000, by insertion of long steel spacer at the lower end.
3. The transverse levelness is adjusted in the same manner by placing the plastic hose along the
tube plate.
13
circuits shall not be damaged, and sight glass, temperature-measuring tubes, valves and drainage
cocks shall not be covered.
Insulation parts are shown in Fig.2-2.
14
Chapter 3 INSTALLATION OF EXTERNAL SYSTEMS
Chiller/heater is provided with external systems, such as water system (including chilled and
cooling water), fuel system and electric system.
3.1 Water System (chilled and cooling water)
Filters must be installed at water pump inlet and at chilled water inlet to protect the
heat transfer tubes from clogging by the foreign matters, to protect the chiller/heater from
degradation of performance and rupture of tubes by freezing.
Chiller/heater and pumps (including spare pumps) should be provided with pressure gauges (or
gauge common for measuring pressure at different locations by switching from location to
location, if it desirable). At the inlets and outlets of chiller/heater thermometers shall be installed.
For water systems of unit, flow meters with scale covering the nominal water requirements should
be installed in manner accessible for reading and maintenance.
Inlets and outlets of chilled (hot) water shall be connected with chiller/heater by short pipe of
15
about 800 mm in length to remove the end cover of evaporator and clean heat transfer tubes. At
inlets of chilled (hot) water, detachable filter with element of large area of 5-8meshes should be
installed. Water piping should be provided with drain valve at its lowest point, drain piping led to
channel, and vent at its highest point.
Pressure setting device shall meet the requirements for constant pressure and water drainage when
expansion and water makeup when leakage, if closed water system is used.
Cooling tower shall conform to the requirements of chiller/heater in water flow and
thermodynamic performance. Cooling tower with water collecting tank should be selected, if no
reservoir is provided for the cooling water system. Cooling tower shall be installed at place far
from source of heat and dust, especially from chimney, with good ventilation, taking consideration
of noise and water drift. Regulating valve and instantaneous water flow meter should be installed
at the make up and drain piping to keep the quality of cooling water. Cooling tower should be
operated by thermostatic control at the outlet of cooling water from tower, or fan of tower is
connected with the control system of chiller/heater, and on/off controlled from control panel.
Bypass piping with two-way or three-way valves can be connected between the inlet and outlet of
tower to maintain constant temperature of cooling water, while part of cooling water is bypassed
tower into chiller/heater in case of too low temperature of cooling water.
Pump can be installed at the outlet of chiller/heater to reduce the water pressure working on the
chiller/heater, when water system is operated under higher pressure.
16
Water system must be flushed completely before connecting with chiller. Otherwise,
heat transfer tube will be blocked, which will lower chiller efficiency and lead to serious
problems such as rupture of heat transfer tube.
When system installation is done without any leakage, please insulate chilled water piping
3.2 Light Oil System
Fuel oil system shown In the Fig.3-3 can be used for light diesel oil (Standard GB252). The fuel
oil system should be designed to meet the safety technical requirements of National standards,
local fire-fighting authority rules, and following requirements.
Daily tank should be installed, if the fuel tank is located not higher than the burner by 0.5m. Fuel
should be transferred into daily tank, ad then supplied to the burner. Daily tank should be located
higher than the burner in the limits of 0.5-6m, but not higher than 10m. Daily tank can be canceled,
if the fuel storage tank is located higher than burner by 0.5 to 6m (but not higher than 10m from
the highest level in tank).
Daily tank, which is arranged in the machine room, should be of closed type, not more 1m3 in
volume, and strictly prohibited to be located above the water heater unit or horizontal section of
flue gas channel.
Oil tank should be provided with venting piping, which is equipped with fire trap and rain
protecting means. Emergency discharging piping with easy to access and operate valves should be
installed on the oil tank to discharge oil outside the room into a specially mounted reservoir. Oil
17
tank should be provided with oil level control means and high and low level alarm devices, and
interlocked with oil supply equipment. No glass level gauge should be installed on the tank.
Filter (80 meshes) should be installed before oil entry into chiller/heater, in order to protect oil
pump, solenoid valves and nozzles from damage due to slag. The active area of filter should not
less than 20 times of piping outlet area, and a by-pass piping with valve should be connected in
parallel with the filter in order to clean the filter, when the unit is in operation.
It is preferred to use copper piping as fuel oil piping, but steel piping also can be used. Piping is
welded, leak-proof tested with pressure of 0.2MPa. Piping should be cleaned from debris before
its installation. The fuel oil should have velocity in the piping less than 0.2m/s.
It is prohibited to use oil with flash point ≤ 40℃ (for instance the gasoline, made by
local indigenous method).
Fuel oil system shown in the Fig.3-4 is used for heavy fuel oil #20 to #60 (Standard GB 445). The
fuel oil system should meet the safety technical requirements of National standards, local rules of
fire-fighting authority, and following requirements.
18
Heavy fuel oil should be heated to 50℃ by heating coil in the tank, then to 70℃ by the piping
jacket hot water or low pressure steam, when oil passing through piping, and to 100℃-130℃ by
electric heater in the burner in order to have a good atomizing.
Before shutdown the burner, heavy fuel oil in the burner should be replaced by light oil in order to
have reliable start operation. Light oil tank should be installed higher than the heavy fuel oil tank
by 0.5m to 1m, and heavy fuel oil tank should be installed higher than burner by 1-5m, but the
highest level in tank should not higher than burner by 10m. Daily tank, which is located in the
machine room, should be of closed type, not more 5m3 in volume for heavy fuel oil, and 1m3 in
volume for light fuel oil, and strictly prohibited to be located above the water heater unit or
horizontal section of flue gas channel.
Oil tank should be provided with venting piping, which is equipped with fire trap and rain
protecting means. Emergency discharging piping with easy to access and operate valves should be
installed on the oil tank to discharge oil outside the room into a specially mounted reservoir. Oil
tank should be provided with oil level control means and high and low level alarm devices, and
interlocked with oil supply equipment. No glass level gauge should be installed on the tank.
Filter (60 meshes) should be installed before oil entry into chiller/heater, in order to protect oil
pump, solenoid valves and nozzles from damage due to slag. The active area of filter should not
less than 20 times of piping outlet area, and a by-pass piping with valve should be connected in
parallel with the filter in order to clean the filter, when the unit is in operation.
It is preferred to use copper piping as fuel oil piping, but steel piping also can be used. Oil is
flowing through piping with speed not more than 0.2m/s.
Piping should be cleaned from debris before its installation. Piping is welded, leak-proof tested
with pressure of 0.2MPa to ensure no leakage of oil to outside or between piping and jacket.
It is prohibited to use oil with flash point ≤ 40℃ (for instance the gasoline, made by
local indigenous method).
19
Gas piping in the machine room should be installed overhead. Gas piping for transporting gas with
density less than air, should be mounted in the high place with good ventilation; where as piping
for gas with density more than air, should be installed along the wall outside the machine room
with good accessibility.
Gas piping cannot be laid to machine room through bed room, stores with flammable and
explosive matters, electric distribution room, transformer room, cable trench, ventilation channel,
duct, flue gas channels and places, where piping is easy to be corroded.
Gas main should have dissipating piping, sampling and flushing ports, which are placed to purge
the gas and air from the piping. Dissipating piping should be led to outside of machine room. Its
discharge port should be rain protected, and located higher than the building roof by more than 2m
Discharged gas is not allowed to enter neighbor building, and be sucked by ventilation fans.
Dissipating piping should be designed to have purge capacity more than 10 to 20 times of section
volume to be purged, and with purge time 15 to 20 min. Gas piping should have lightning means
with grounding resistance less than 10 ohm, if it locates outside the lightning protection zone.
Gas piping should be air proof tested. As shown in Fig.3-5 the piping section, which locates
upstream pressure regulating valve, should be tested by 1.5 times working pressure and leak
checked by soap solution.
In order to ensure the gas supply to the chiller/heater, gas piping should be constructed with round
bends to decrease the pressure drop. Gas piping diameter should be at least one size bigger than
the diameter of burner.
Pressure at the gas inlet (the outlet of ball valve) should be in the limits prescribed in the catalog
of company. The pressure deduction valve should be installed, where the gas inlet pressure is
higher than high limit in the catalog.
In order to keep gas valve group, piping and fittings intact during transportation, they should be
packed in boxes, and installed on site of customer. For ensuring the tightness of connections, gas
valve fittings should be installed to meet the following requirements:
For flange connections, high quality sealing gaskets (asbestos-rubber gaskets) are used, and then
bolts tightened.
For threading connections used for gases, threading is to be sealed by following means:
For connections used for city gas, connections should be sealed by white lead compound with
linen packing
For connections used for natural gas, connections should be sealed by PTFE tape
Corrugate pipe should be installed between ball valve outlet and filter inlet.
3.5 Gas Exhaust System
Flue gas channel and chimney should be designed to keep the pressure at the outlet between
–50Pa~0Pa (-50 to 0 Pa).
The section of flue gas channel and chimney should be not less than the section of discharge port
of unit. The main flue gas piping should have section not less than the sum of sections of branches
with valves which should have opening indicating means, no matter the valve is automatic or
manual driven.
It is recommended to adopt flue gas channel with round section. The turns of piping should be
rounded, and the construction shown in Fig.3-6 should be adopted for the branches joining
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together, and converging and expanding construction for the changing sections.
Chimney height should be not less than (0.6L+ N) m, where L is the length of horizontal section of
flue gas channel in m, N is the number of turns of flue gas channel. The chimney should be higher
than the surrounding buildings by more than 3 m, if they are in the limits of 200m around the
chimney. On the outlet of chimney a rain protecting cap, lightning rod and wind protecting cover
should be mounted. Rain protecting cap should have diameter equal to two times of that of
chimney. The place of outlet of chimney should be chosen to make observations of smoke
emission easily.
The horizontal section of flue gas channel should have trap on its lowest section above the
equipment, which shall connected with the drain piping led from flue gas box of chiller/heater unit,
and through 200mm U-shaped trap discharged to the canalization.
Chimney should be constructed with bricks and concrete in order to avoid corrosion. The pipe
thickness should be not less than 4mm, if the steel construction is adopted.
For compensation the heat expansion of chimney, the expansion joint should be provided on the
straight section, and fire retarded and heat resisted soft material should be placed, when the flue
gas pipe passes through wall and when flange is installed.
Flue gas channels should be insulated, when they are checked to have good air-tightness.
Insulation material ( such as rock wool felt or cement-perlite plate ) can withstand working
temperature of 350℃
21
grounding line of chiller/heater to ensure the its safe operation.
Failure of special grounding pole or using zero line instead of grounding pole will
cause severe damage of chiller/heater or injury or death of personnel.
The standard supplied chiller/heater is provided with interlocked control of cooling water pump,
chilled water pump and fans for cooling tower. The pumps (including standby ones) and fans for
cooling tower must be connected with the control system of chiller/heater. The electric distribution
panel should have terminals for connecting control lines for pumps and fans. If more than one
chiller/heaters share one cooling water system, electric driven valves must be set at cooling water
inlets of each chiller/heater to realize interlocked function of control system. The control lines
should be laid and marked by customer. For a chiller/heater, 14 control lines of 0.75mm2 should be
provided. Power lines should be laid separately from control ones.
Chilled water and cooling water pumps (including standby pumps) and fans for
cooling tower must be interlocked with control system of chiller/heaters. At cooling water
inlets of each chiller/heater, electric driven valves must be set to interlock with control
system, if more than one chiller/heaters have to share one cooling water system. Otherwise,
Shuangliang Air-conditioning will not take any responsibility for malfunction and other bad
results such as rupture of tubes.
Signals from gas leakage and fire alarm should be interlocked with the control system of
chiller/heater.
Chiller/heater with remote control and monitoring should be installed by the customer in
accordance with the requirements of “Installation and operation manual for remote on/off and
monitoring system”.
22
Ventilation fan in machine room
Cooling tower fan
platinum resistance, flow switch, pressure sensors, level controller are implemented to ensure the
man-machine interface is used, and such measuring and control elements, as PLC controller,
For direct-fired chiller/heater advanced control system MMI with color touch screen as
23
PLC Monitoring signal of burner De-crystallization pipe temperature
Controller
Monitoring signal of hermetically sealed pumps Flue gas temperature
Evaporation temperature
Interlocking signals for external systems
Condensation temperature
Input
4.1 Configuration of System
Level signal
Signal Spray temperature of concentrated solution
Pressure signal Concentrated solution temperature from LP G
Intermediate solution temperature from HPG
Touch Flow signal
Cooling water inlet temperature
Screen
Temperature signal
Chilled water outlet temperature
Chilled water inlet temperature
4.2 Function of System
The control system is used in two modes: automatic and manual control. Automatic control mode
is preferred, manual control is used only for commissioning and to shooting the failure of
chiller/heater.
Control system is designed for efficient and automatic control of chiller/heater with the functions,
such as: setting the data, automatic staring up and shut-down the unit, limit control of cooling
water inlet temperature, limit control of solution concentration, automatic control of loads and
circulating flow of solution, measuring and displaying the operation data in real time, safety
protection, memory and storage of data and etc.
4.2.1 Normal functions
Table 4-1 Normal functions of control system
No. Name of function Description of function
1 Data setting For working the chiller/heater under expected or optimum
conditions, the data, including the chilled water outlet
temperature, are set by certified personnel in accordance with the
local conditions..
2 Automatic start and Chiller/heater is started/stopped merely by personnel pressing
stop of chiller/heater the touch screen, and will be operated steadily in nominal
conditions.
3 Limit control of Chiller/heater will be operated steadily by limiting its capacity
cooling water inlet under low inlet temperature of cooling water (18-28℃)
temperature (cooling
mode)
4 Limit control of The control system will calculate the concentration of
solution concentration concentrated solution, crystallization and safe temperatures
(cooling mode) based upon of measured actual operating data, and adjust the
operation conditions automatically, when the crystallization
trends to occur.
5 Automatic adjusting Cooling/heating capacity of chiller/heater is automatically
the load adjusted by regulating the heat source supply in accordance with
chilled (hot) water outlet temperature.
6 Automatic adjusting PLC controller will adjust the output frequency of inverter to
the circulating flow of regulate the speed of solution pump in accordance with the
solution measurement of lever and pressure in the HP generator, which
will make the solution circulation to meet the requirements of
chiller/heater operation.
7 Measurement and Control system will display the operation data, such as
display of operation temperatures, pressures, levels on the touch screen in real time
data in real time by sensors installed, to make the operation personnel to know the
chiller/heater more easily.
8 Safety protection Control system will protect the chiller/heater from the dangerous
operation, and take the appropriate measures automatically.
9 Failure diagnosis Determine the failure conditions automatically on the basis of
measured data, and take the appropriate protecting measures .
10 Data storage Control system will store the operation data of last week,
contents of last five failures, and contents and operation data of
last three failures.
11 Information storage Control system stores the information, such as working principle
of chiller/heater, guide of operation and maintenance, which can
be used by operational personnel, while operate the touch screen.
12 Other extendible The control system reserves extendible functions, such as the
functions remote and concentrated control to meet the requirements from
customer.
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4.2.2 Safety Protection
Chiller/heater will give alarm and stop operation, when it surpasses the set values. The safety
protection items and set values are indicated in Table 4-2.
Table 4-2 Safety protection data
No Item Set value No Item Set value
Evaporation Pressure in HP generator 128KPa
1 4℃ 9
temperature (960mmHg)
Chilled water outlet Chilled (hot) water flow 60% of
2 4.5℃ 10
temperature nominal value
Hot water inlet Over current of solution 100% of
3 *65℃ 11 pump (inverter)
temperature nominal value
Cooling water inlet Over current of refrigerant 100% of
4 18℃ 12 pump (thermal relay)
temperature nominal value
Middle concentrated Over current of vacuum 100% of
5 166℃ 13 pump (thermal relay)
solution temperature nominal value
De-crystallizing pipe Burner fan (Thermal relay) 100% of
6 65℃ 14
temperature nominal value
Flue gas exhaust Protection from over-voltage
7 250℃ 15 380VAC±10%
temperature or under-voltage
Safety protection for burner
Condensation
8 48℃ 16 system from accidental cut
temperature
out of flame
*It will be the sum of nominal value plus 5℃, if the chiller/heater is failed from standard series.
4.3 Control Panel
25
4.5 Operation Method
4.5.1 General
Fig. 4-5 Main menu on the touch screen
Put the switch (single pole switch, normally at position ON), which is installed in the upper
portion of control panel, into the position “ON”, lock the door of control panel, and put the switch
at the lower portion of control panel into the position “ON”. At this moment, the power supply is
connected. The signal “POWER” and ”RUN” will display. Three seconds after the display of
WELCOME, on the screen will show the main menu as shown on the Figure 4-5. Operator can
start/stop the chiller/heater as indicated by the menu. And also to adjust the operating parameters,
or to other control, and learn the working principle, basic operation procedures and methods of
maintenance.
DESCRIPTION OF TOUCH SCREEN. Press this key and on the screen will show the
descriptions of keys and give the user the instruction to operate the touch screen.
WORKING PRINCIPLE OF CHILLER/HEATER Press this key, on the screen will show the
flow chart of chiller/heater for refrigeration and heating, and working principle for refrigeration
and heating also.
OPERATION INSTRUCTION OF CHILLER/HEATER Press this key, on the screen will be show
the more than 10 methods of operation, such as sampling of refrigerant water, charge of solution,
inspection of chiller/heater for air-tightness.
OPERATION HISTORY OF CHILLER/HEATER Press this key, on the screen will show the last
three troubles and the operation data during week.
OPERATION MODE SELECTION Press this key to select the mode of operation (Auto or
Manual, the chiller/heater cannot be changed to manual operation, while the unit is operated under
AUTO control).
CHILLER/HEATER MONITORING Press this key, the screen will show the figure of monitoring,
which is dependent to the control mode. Operator can operate the chiller/heater, solution,
refrigerant and vacuum pumps, and set the data, such as outlet temperature of chilled water. The
current information on the different parts of chiller/heater can be shown also.
DATA SETTING Press this key the adjustable data, such as the outlet temperature of chilled water
27
can be set, and diminish the deviation of displayed value and actual value of operation data.
MIANTENANCE GUIDENCE Press this key the screen will show the contents and methods of
maintenance.
1) The screen protection function is provided, which will stop display (blacken), if no
operations of screen occurred during 1h. For this period the control function of
chiller/heater is maintained, and the screen will continue work, if it is touched lightly.
2) The screen can be cleaned by soft wet rag, no volatile solvent (such as benzene) can be
used.
3) Internally set values and positions of external toggle switches are fixed in the factory, and
not allowed be changed by customer.
For changing the operation mode between the refrigeration and heating modes, you should
open/close the appropriate switching valves.
28
There will be regulating data display graph by pressing the key of setting of regulating data under
the data setting graph. Pressing the key of Password for data setting, input the correct password on
numerical keyboard, and press the key “Enter” to have the graph of setting data. At this time, the
data can be changed. The graph remains unchanged, while the password is erroneous. The input
deviation will be cleaned by pressing the key CLR on the numerical keyboard.
During changing the data, touch screen will display numerical keyboard by pressing the
push-button on the left side of data to be changed. The data will be changed by input new values
and pressing the key of confirmation. The setting of data is finished by pressing the key “OFF” on
the numerical keyboard.
The lower purging valve of vacuum pump should be closed, before the vacuum
pump is to be stopped.
29
Solution and refrigerant pumps should be started or stopped by the operational personnel in the
following procedure manually, when the manual control mode is selected:
The graph of chiller/heater monitoring is displayed by pressing the key CHILLER/HEATER
MONITORING of main menu; or pressing key MENU on the upper right angle to display the
content of main menu, then pressing the key CHILLER/HEATER MONITORING to display the
graph of chiller/heater monitoring, when touch screen displays other graph; or to enter the
operation monitoring by selecting the mode of operation and control during the chiller/heater shut
down. Solution and refrigerant pumps can be started or stopped by pressing the keys SOLUTION
PUMP START, REFRIGERANT PUMP START, or SOLUTION PUMP STOP , REFRIGERANT
PUMP STOP.
1) Before startup of solution pump, it is essential to ensure that solution has been charged.
2) Prior to startup of refrigerant pump, strong solution concentration shown on touch screen
should be ensured above 56% and chilled water system is to be checked to protect heat
transfer tubes from freezing.
3) During manual control the solution pump is not allowed be operated under manual mode,
and be controlled by the control system according to the solution level and temperature.
30
B. Automatic Control (Heating mode)
Chiller/heater will be started and come to normal operation by pressing the key SYSTEM START,
and then pressing the keys CONFIRMATION, and RE-CONFIRMATION, which appears in the
graph of chiller/heater operation monitoring on the touch screen.
Chiller/heater is stopped by pressing the key SYSTEM STOP on the graph of chiller/heater
operation monitoring. Following this operation, the chiller/heater will be operated with automatic
dilution, and burner will stop firing (The fuel inlet valve is closed by operational personnel
manually). After 15min stop solution pump and 3min later stop hot water pump automatically.
C. Manual Control (cooling mode)
On the graph of chiller/heater operation monitoring the key SYSTEM START is pressed, then the
key CONFIRMATION and RE-CONFIRMATION is pressed in the following graph, then the
graph chiller/heater operation monitoring is displayed again. The solution pump is started and
solution circulation is controlled automatically by pressing the key SOLUTION PUMP START.
Burner will work at small fire by pressing the key BURNER IGNITION and BURTNER SMALL
FIRE.
During operation chiller/heater can be work on big fire or small fire by the pressing the BURNER
BIG FIRE OR BURNER SMALL FIRE.
But it is limited to work on small fire, when the cooling water inlet temperature is
less than 28℃, or chilled water outlet temperature is less than nominal value.
During refrigeration operation, when cooling water inlet temperature less than 28℃,cooling water
outlet temperature should be controlled by operational personnel in the range of 36-38℃.
Chiller/heater is stopped by pressing the key SYSTEM STOP on the graph of chiller/heater
operation monitoring. Following this operation, the chiller/heater will be operated with automatic
dilution, and burner will stop firing (The fuel inlet valve is closed by operational personnel
manually). When solution concentration detected reaches 58%, stop refrigerant pump and after 5
minutes when solution is diluted to 56%, stop solution pump and shut off cooling water pump
automatically. Afterward chilled water pump will be stopped automatically 3 min later.
But it is limited to work on small fire, when hot water outlet temperature is higher
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than nominal value.
Chiller/heater is stopped by pressing the key SYSTEM STOP on the graph of chiller/heater
operation monitoring. Following this operation, the chiller/heater will be operated with automatic
dilution, and burner will stop firing (The fuel inlet valve is closed by operational personnel
manually). After 15min stop solution pump and 3min later stop hot water pump automatically.
4.5.5 Operation Monitoring of Chiller/heater
The operation conditions of parts and chiller/heater and content of trouble, if any, can be displayed
to the operational personnel by the graph of chiller/heater operation monitoring.
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Chapter 5 COMMISSIONING OF CHILLER
33
installed properly according to the piping drawing. Piping shall be installed correctly. Sensing
and alarm means against the gas leakage shall be installed in the machine room, and
interconnected with the forced draft fan of machine room. Connected piping and elements shall
be proved tightly. Check the gas supply pressure by closing the cut-off valve at the inlet of gas
flow meter. The piping shall be purged by gas before ignition occurs, if it is worried, that the
gas in the piping is mixed with air.
3) Inspection of Burner. The burner shall be inspected according to the operation manual, wiring
drawing and piping installation as follows: (1) Check the burner for correct installation
according to the technical manual of burner. (2) Check the connections on the terminals of three
phased motor for correct direction of rotation. (3) Check, that the control wiring and power
supply cables are connected properly with the control panel according to the drawing. (4) All
the combustion control and safety protection means are connected and functioned properly.
4) Inspection of Flue Gas Piping. Check the flue gas piping against the provisions of installation
manual.
It is prohibited to use the fuel oil with flash point ≤ 40C° (such as the gasoline or fuel
oil manufactured with indigenous method)
Chiller/heater, which had been tested in the factory, shall be tested for air-tightness by the air
34
bubbles, that a rubber or plastic hose shall be connected with the discharge opening of vacuum
pump at one end, and inserted into the vacuum oil in a vessel at the another end. a) The vacuum
pump is tested for the limit of evacuation. b) If the limit of evacuation meets the requirements,
open the purge valves for condenser and absorber, then the upper and lower purge valves of
vacuum pump slowly to evacuate for 2 minutes, close the ballast valve of pump, and count the
number of bubbles per minute. The air-tightness of chiller/heater is normal, if the number of
bubbles in a minute is equal or less than 7. Repeat the test, if the number of bubbles in a minute is
more than 7. The chiller/heater shall be pressure tested for air-tightness, if the number of bubbles
not reduced in the interval of 2 hours, and kept in a rather big number.
Before filling gas the purge valve of condenser and upper purge valve of vacuum
pump shall be opened.
35
100 Pa (or to the water vapor saturation pressure, equivalent to the ambient temperature, if the
chiller is charged with solution or water). Then, as shown in Fig. 5-1, connect the vacuum or
reinforced rubber hose to the connection of solution charging valve with vacuum grease from one
end, and hose is filled with solution. Emerge the hose into a vessel with solution of 0.6m3 from
another end. Open the solution charging valve and solution will be suck into the chiller. Keep the
end of hose under the solution surface in the vessel constantly, and adjust the valve opening to a
normal flow rate of solution.
Solution is charged in three portions. First charged solution about half the required amount. Then
the solution charging valve is closed and operate the solution pump to transfer solution into the HP
generator. Stop the solution pump, when the solution level in the HP generator is up to the high
level (inverter reduces its frequency output to 10Hz). Then charge the solution additionally 1/3,
and start the burner and solution pump make the solution circulated. Stop the burner and solution
pump, and charge the rest of solution, when the solution concentration shown on touch screen is
56%.
After charging of solution, start the vacuum pump to purge the chiller.
The commissioning of burner is dependent upon the type of burner. Here only the
36
general requirements and basic procedure of commissioning of burners are described.
Reference should be made to the technical manual of applied burner. Burner should be
commissioned by trained personnel.
Burner is used to supply air and fuel, which will be burned completely under minimum coefficient
of surplus air. The burner should be started up under conditions of normal combustion of fuel,
normal operation with small fire and big fire, absence of cut off flame during transferring from big
fire to small and small fire to big, and to ensure maximum fuel and air required by the
chiller/heater.
Burner is provided with its own controller and control process for combustion, which is work
under the operation of control system of chiller/heater. Different type of burner uses different
commissioning procedure owing to the different construction and applied fuel, but provided the
same principle for commissioning: air consumption is minimized under the limits of reduced
emission (Content of CO ≤0.02%), i.e. the content of O2 in the exhaust gas is minimized (to
[3-5]% for light oil ) for maximized heat efficiency.
The CO2 and CO measuring gauge (gas analyzer) should be installed at the outlet of flue gas from
chiller/heater. For chiller/heater with 2 stage burner, the gas content is measured for the small and
big fire only. For burner with proportional regulation, there should be measured at least 3 points
evenly distributed between the small and big fire, except the small and big fire should be checked.
Commissioning of burner is carried out under the guidance of operation manual of burner. The
procedure of commissioning of burner is as follows:
1) Check the specification and type of burner in accordance with the piping system drawing of
burner;
2) Check the wiring of parts for burner;
3) Check the assembling dimensions of head parts of burner, and setting of position for
combustion head of burners of Italian Liaro company in accordance with maximum fuel oil and
gas consumption;
4) Select the manual control mode on the operation selection graph shown on the touch screen;
5) Check the fan motor for correct direction of rotation by means of its short starting (the rotation
of fan motor should be meet the direction of arrow on the fan case).
6) Set the air flow (by means of opening of register). Gas type chiller/heater should ensure that the
butterfly valve is closed when the burner is cut out.
7) The fuel manual supply valve should be opened.
For gas-fired chiller/heater, the maximum and minimum pressure switches should be adjusted to
the initial positions, and the air pressure switch at the zero position. The output pressure value
of pressure regulating valve should be set in accordance with the size of chiller/heater, heating
value of gas, gas supply pressure, and requirements of technical manual of burner (The output
pressure is increased when it turns clockwise, and only can be reduced, but not increased to
above the supply pressure).
8)Burner is set on small fire manually, and pre-purge will occur. At that time the oil pressure and
voltage applied on the solenoid valve should be checked. The voltage should absent on the
solenoid valve, otherwise the burner should be stopped, and wiring of burner should be checked.
Abnormal oil pressure should be corrected.
9)The burner should be ignited, when the pre-purge finished. The burner should be stopped, and
items 1-8 must be repeated, if the ignition cannot occur. For oil-operated chiller/heater, the
37
burner should be stopped, and the flame of first stage should be re-adjusted by register (opening
will be increased or reduced accordingly), if the smoke is discharged or flame is not stable. For
gas-fired chiller/heater, the gas to air ratio can be adjusted during combustion of gas.
For primary start up of burner, the fuel pipe may be left with some air. So the
ignition should be repeated for several times. It should be re-adjusted, if it cannot be
ignited after several trials of ignition. During primary ignition or normal operation of
chiller/heater, the ignition will fail to work, if the flame detector cannot detect the flame.
Then the safety protection cutout switch and the interlocking switch operate, and
indicator FLAME CUTOUT lights. The chiller/heater can be started again, only when the
cause of trouble is determined, and reset switch is pressed manually. The chiller/heater
shall stop work at once to prevent the heat transfer tube bundles and flue gas channel
from carbon settling, if thick smoke occurs. The commissioning of chiller/heater can be
restarted, if fuel flow is reduced or air flow is increased.
10)After the small fire is ignited, the small fire should be changed to big fire. The register for big
fire should be adjusted, if the big fire is abnormal. The maximum gas and oil flow is adjusted
during big fire.
12)The burner should be stopped, and commissioning is finished.
For gas-fired chiller/heater, the air pressure switch, maximum and minimum gas pressure
switches should be set before the burner stops operation.
Setting of air pressure switch: During the burner operation with small fire, air pressure switch is
set by turning slowly the knob clockwise to cut the flame. Make reading of the position of knob,
and turn the knob anti-clockwise to about 20% of last reading. Then the burner is re-ignited to
check the correct setting. Turn the knob anti-clockwise a little further, if the burner cannot work
normally.
Setting of maximum gas pressure switch: During the burner operation with big fire, maximum
gas pressure switch is set by turning the knob of pressure switch anti-clockwise to cut the flame.
Make reading of the position of knob, and turn the knob clockwise by about 2mbar. Then the
burner is re-ignited. Turn the knob clockwise further by 1mbar, if the burner cannot work
normally.
Setting of minimum gas pressure switch: During the burner operation with big fire, minimum
gas pressure switch is set by turning the knob clockwise to cut the flame. Make reading of the
position of knob, and turn the knob anti-clockwise by about 2 mbar. Then the burner is
re-ignited. Turn the knob anti-clockwise further by 1 mbar, if the burner cannot work normally.
For the heating mode the commissioning of chiller/heater or its primary firing shall be
done with the heat transfer tubes and water heads of absorber filled by water. That means,
close the valves on the inlet and outlet of cooling water piping, open the connecting valves on
the water heads of evaporator-absorber and venting valves for the water heads of absorber
38
and condenser to fill the heat transfer tubes of absorber and condenser. Close the venting
valves, when air discharged. Close the connecting valve of evaporator-absorber, when
pressure reaches about 0.3kg/cm2.
39
Chapter 6 OPERATION OF CHILLER/HEATER
40
12.The machine room should be kept with good ventilation without clogged intake and discharge
openings. Open the damper in the fume piping, if it is provided.
13.For oil-fired chiller/heater, the oil filter should be washed once a day successively for three
days.
14.The nominated power supply should be used. No contact with switches, wires, elements and
high-tension wires for igniter of burner to prevent from electric shock. Power supply can be
cutout only when the chiller/heater is in standstill.
15.The chiller/heater is kept from risk by dripping water on the electric elements.
16.The operation of chiller/heater is forbidden with control panel opened.
17.The operation of chiller/heater is protected from harm the operational personnel by keeping
them from touching the high temperature parts, such as the HP generator, HT heat exchanger
and its piping (with temperature of 160℃) and the LP generator, LT heat exchanger, and its
associated piping.(with temperature of 90℃)
18.No heating operation of chiller/heater is allowed, if it has not operated for cooling mode before
19.No hot water of temperature up to 60℃ is permitted to flow through the chiller/heater, which
is in standstill, if several units are in parallel operation..
20.The chiller/heater should be checked and maintained strictly with the provisions of chapter 8
“Maintenance and Service”
21.Lithium bromide solution is not poisonous, but irritant, when it is mixed with other chemicals.
The machine room should be kept with good ventilation. The place dripped with solution
should be washed.
22.The machine room should be kept with temperature in the limits of 5-40℃, and relative
humidity less than 90%.
23.Before operation of vacuum pump the oil trap should be drained to empty once a month.
24.The battery for PLC and touch screen should be changed periodically (once for 3 years).
Change of battery should be finished in 5 minutes. For PLC, the battery should be changed in
the interval of 7 days of total standstill conditions of PCL to avoid loss of program, if the
ALARM on CPU lights, but the chiller/heater can be operated further. For touch screen, the
battery should be changed in the interval of 5 days of total standstill conditions of touch screen
to avoid loss of program, if the LOW BATTERY (in Japanese) lights, but the chiller/heater can
be operated further.
25.The chiller/heater is supplied with the interlocking functions, and it is recommended, that the
customer connect the start/stop circuits of chilled and cooling water pumps and cooling tower
fans with the control system of chiller to control the start/stop of pumps and fans by the control
system of chiller. At least the chilled and cooling water pump should be interlocked to stop the
cooling water pump first and then the chilled water pump, if they do not interlocked with the
chiller.
26.The chilled and cooling water piping should be designed and installed with valves at the piping
inlets and outlet from the chiller, and a piping with a valve bypassing the chiller is provided
before the valve to the inlet of chiller and after the valve from the chiller. In order to flushing
the piping, the valves at the inlets and outlets should be closed and valve on the bypassing
piping opened. After the operation, the inlet and outlet valves should be opened, and valve on
the bypassing piping closed.
27.The chiller/heater and pumps should be installed with filters at their inlets to be prevented from
41
the entering of foreign matters to the tubes of chiller, otherwise the degrading of performance
of chiller/heater and freezing of tubes will occur.
28.The chiller/heater should be installed on the fundament after the transport rack is removed. If
the conditions required that the chiller/heater will be installed with the rack, then the welded
angle sections or plates, which fixed the heat exchangers to the transporting rack, should be
removed. For some chiller/heaters, the low temperature heat exchanger welded to the rack by
angle section only at one end, and fixed to the evaporator-absorber from the another end. In
this instance, only the angle section should be removed.
29.Solution should be charged or transferred with less loss of it. The solution traces should be
cleaned from the ground and the chiller. The chiller should be repainted at the parts, where
paint is damaged.
30.For direct fired chiller/heater, the change-over from heating to cooling mode or from cooling to
heating should be realized, in addition to open/close the vapor and solution valves, by
regulating the fuel flow with the working condition of chiller/heater (the adjusting of burner
should be done in accordance with the instruction). For the chiller/heater with generator
enlarged for more than two sizes (including two sizes), the burners are supplied with two stage
nozzles. For cooling mode the small nozzle should be installed, and for the heating operation,
the big nozzle should be used.
31.For direct fired chiller/heater, the commissioning of burner should be done by Shuangliang
engineers. The burner should be adjusted with the gas analyzer to measure the CO and O2
contents in the gas to make the appropriate ratio of air to the fuel. The sensor of analyzer
should be put into the chimney from the chiller high pressure generator, and check the CO and
O2 content, while adjusting the fuel and air ratio. The CO volume content≤0.02%, and O2
volume content ≤ 3%-5% should be maintained. The operation instruction of gas analyzer
should be followed.
42
To decrease the flowrate of cooling water in case low cooling water temperature or
running at low load conditions
1. All refrigerant water should be bypassed from evaporator to the absorber during
shutdown, when the ambient temperature is less than 20℃, and the chiller/heater will
stand longer than 8h.
2. The chiller/heater is operated normally, when the safety device is checked periodically
and its normal working is guaranteed.
3. Check the chiller/heater in accordance with the provisions of this technical manual.
43
1. All refrigerant water should be bypassed from evaporator to the absorber during shutdown,
when the ambient temperature is less than 20℃, and the chiller/heater will stand longer than
8h.
2. The chiller/heater is operated normally, when the safety device is checked periodically and its
normal working is guaranteed.
3. Check the chiller/heater in accordance with the provisions of this technical manual.
44
Check the burner for normal combustion, flue gas and percentage of fuel to air; the start and stop
of burner in accordance with the program and without abnormal noise; stop the operation and
check the fuel system and burner immediately, if abnormality occurs (smoke and flame with
abnormal noise.). Check constantly the safeguard device for its normal working, the spark
clearance for ignition electrodes, the nozzles for absence of clogging, and no shock and explosion
during ignition. Clean constantly the receiving surface of flame detector and the insulation cable
between the detector and monitoring relay. Check regularly the gas stop valve for its tightness.
6.4.1.6 Inspection of noise and amperage of running hermetically sealed pumps
Contact with Shuangliang Service company to analyze the cause, if abnormal noise and amperage
is fund.
6.4.1.7 Adjusting the deviation of displayed values
Check if there is deviation in the displayed value with the actual value, and reset, if the deviation
occurs.
6.4.1.8 Other observations
1. Checking vacuum pump for absence of emulsification and dirty.
2. Checking the water pumps for absence of vibration and motors for overheating.
3. Checking the refrigerant water density in the first two weeks of cooling operation in a year.
4. Confirmation of the normal operation of safety devices at least once a year, and repair them, if
something happened with them.
45
Check if there is deviation in the displayed value with the actual value, and reset, if the deviation
occurs.
6.4.2.6 Other Checks
1. Check vacuum pump for absence of emulsification and dirty
2. Check water pumps for absence of vibration and motors for overheating
6.5 Purge Operation
Vacuum is vital for normal operation of chiller/heater. The vacuum (the quantity of
non-condensable gas) of chiller/heater determines the operation performance and the life cycle of
chiller/heater. The purge units are provided to improve the vacuum keeping capacity of
chiller/heater. As shown in Fig.6-1, purge unit is operated automatically and manually. Purge is
carried out with the sampling purge valves and pressure measuring valve is closed, and other
valves operated in the following manner.
1- Purge valve for condenser
2- Purge valve for evaporator
3- Purge valve for absorber
4- Auto-purging unit
5- Upper purge valve of vacuum pump
6- Pressure measuring valve
7- Lower purge valve of vacuum pump
8- Sampling purge valve
9- Vacuum pump
10- Auto-purging discharge pipe
11- Gas box connection pipe
12- Pressure sensor 13- Gas box
14- Oil trap 15- Oil drain plug
16- Cooler water inlet valve
Fig. 6-1 Purging System
6.5.1 The purge of new chiller/heater or chiller/heater after service and maintenance
The new chiller/heater or chiller/heater just after maintenance, which has the internal pressure
higher than the atmospheric pressure, should be vented to the atmosphere through pressure
sampling valve until the internal pressure is equal to atmospheric. The chiller/heater can be vented
to atmosphere through other valves, if there is no LiBr solution and water in it.
The first starting-up of new or maintained chiller/heater is carried out with evacuation of
non-condensable gases by vacuum pump. (1) Confirm that the pressure measuring valve,
refrigerant sampling valve, solution charge valve and sampling valve for strong solution, which
are vented to atmosphere, are closed. (2) Measure the limiting capacity of vacuum pump. (3)
When the requirements are met, close sampling purge valve, open fully the purge valves of
condenser and upper purge valve of vacuum pump, open slowly the lower purge valve of vacuum
pump, and start vacuum pump to evacuate the chiller/heater. Open fully the lower purge valve,
when the vacuum is created in the chiller/heater. (4) Close purge valves of condenser, upper purge
valve of vacuum pump and lower purge valve of vacuum pump, and stop the operation of vacuum
pump, when the vacuum in the chiller/heater is lower than 100Pa, and no solution is left in the
chiller/heater. (5) If the chiller/heater is left with solution, a rubber or plastic hose shall be
connected with the discharge opening of vacuum pump at one end, and inserted into the vacuum
46
oil in a vessel at the another end. Then close the ballast valve of pump, and count the number of
bubbles per minute from the oil. Close purge valves of condenser and upper purge valve of
vacuum pump, lower purge valve of vacuum pump and stop the operation of vacuum pump, if the
number of bubbles in a minute is equal or less than 7. (6) During evacuation of non-condensable
gases from chiller/heater under its cooling mode, the purge valve of condenser shall be closed,
when condensation temperature is lowered to less 1°C than that of cooling water outlet
temperature from condenser. Close the upper and lower purge valves of vacuum pump, and
shutdown the vacuum pump, when weak solution inlet temperature to LT heat exchanger is 1°C
higher than that of cooling water outlet temperature from absorber.
Evacuate the chiller/heater in the same manner, when the chiller/heater is purged not for the first
time, and the vacuum is not as fair as normal.
6.5.2 The purge of chiller/heater during normal operation
During the operation of chiller/heater, usually the automatic purge unit is operating.
Non-condensable gases will be purged and stored in the gas cylinder (The purge valve for
absorber is normally closed). Open the purge valve for condenser, when condensation temperature
defers from the cooling water outlet temperature from condenser more than 1.5-2 °C, and close
that valve, if the temperature difference is 1°C only.
47
In cooling mode, cooler water inlet valve shall be always open and evaporator purge valve shall be
always closed.
In heating mode, during normal operation auto-purging system will function to purge
non-condensable gas and cooler water inlet valve and other valves in purging system except
evaporator purge valve shall keep always open. When pressure inside gas cylinder reaches set
valve (saturated pressure at hot water outlet temp. +2.666KPa (20mmHg)) of auto-purging system
in heating mode, control system will show a graph to remind operator to start vacuum pump for
gas evacuation and close cooler water inlet valve. After 15min start vacuum pump. Operation
procedure as follows: start vacuum pump and 1min later slowly open vacuum pump lower purge
valve and 5min later close vacuum pump lower purge valve and shut down vacuum pump.
Afterward, open cooler water inlet valve and continue to use auto-purging unit.
When draining water from chilled/hot and cooling water system via methods described in clause
8.2, traps equipped on inlet/outlet of solution cooler should be open to drain water from solution
cooler and its water inlet/outlet piping.
When purging operation in heating mode, cooler water inlet valve must be closed
before start of vacuum pump to prevent solution being evacuated outside.
1. During purge operation, the lower and upper purge valves of vacuum pump shall be
opened slowly to protect the vacuum pump from spraying of oil or other failure due to
high evacuation rate.
2. During purge operation the ballast valve for vacuum pump should be opened, to avoid
the emulsification of oil. Emulsified white oil for vacuum pump should be changed.
3. The oil trap shall be thoroughly drained in predetermined period
48
6.6.1 Sampling and measuring the refrigerant water
Sampling and density measuring of refrigerant is preferred to use the sampler and
cylinder, which is not used for solution. Or the sampler and cylinder had to be washed by
clean water and no drop of water is left, when the same sampler and cylinder is used for both
refrigerant and solution. Sampled refrigerant water should be placed separately.
6.6.2 Regeneration of refrigerant water
The regeneration of refrigerant is carried out, when the chiller/heater is operating.
The refrigerant is to be regenerated, while it is contaminated to density of 1.04g/ml. In this case,
the chiller/heater is operated with part opening of bypass valve, i.e. the chiller/heater is working
for refrigeration and regeneration of refrigerant water at the same time. The process is repeated to
the normal density (≤1.002g/ml) of refrigerant water.
6.7 Management of Lithium Bromide Solution
Lithium bromide solution is corrosive to the construction material of absorption chiller/heater. For
protection of chiller/heater from corrosion, the solution should be added with inhibitor, and
controlled in the limits of 9-10.5 for its pH value. Contamination of solution with products of
corrosion will cause clogging of holes in distributor of absorber, and the lubricating and cooling
piping for the pumps, which will bring influence to the operation performance and life cycle of
absorption chiller/heater. So the solution should be sampled and measured periodically during the
49
operation of chiller/heater, and measures should be taken to treat the solution in accordance with
the results of measures. The weak solution is sampled normally, and strong solution is sampled
only when its concentration is measured.
6.7.1 Sampling of LiBr solution
Sampling of solution is carried out for weak and strong ones in the similar way as for the
refrigerant water. The solution sample is taken from the charging valve at the discharge side of
solution pump and the sampling valve at the solution distribution box located at the bottom of
shell of chiller/heater.
The weak solution sample is taken with the sealing plug removed from the charging valve, and the
Rubber hose connection, which is delivered with the chiller/heater, shall be installed. The
connection shall be removed, when the solution sample had been taken. Then the sealing plug
shall be installed to ensure the secondary sealing of valve.
6.7.2 Inspection of LiBr solution
6.7.2.1 Inspection of concentration of solution
Pour the solution in the 250mL cylinder. Measure the concentration of solution by Baume
hydrometer. The concentration of solution can be determined by the graph with the measured
temperature and specific gravity, measured thermometer and hydrometer respectively. Contact
with Shuangliang Co., if solution concentration is considerably different in comparison with the
primary measured value.
6.7.2.2 Visual inspection
The solution quality i.e. the foreign matter and consumption of inhibitor, can also be determined
visually by the color of solution. The visual inspection will be carried out after sampling by
several hours. The inspection results should be compared with the Table 6-1. The final results shall
be given by Shuangliang Service Co.
Table 6-1 Visual control
Item Condition Result
Color Light yellow A lot of inhibitor is consumed.
Colorless Inhibitor consumed considerably.
Black A lot of ferric oxide is in the solution, and
inhibitor consumed.
Green The corrosion product copper oxide is in
the solution
Floating matter Very few No problem
Rust scale A lot of ferric oxide
Precipitate matter Considerable A lot of ferric oxide
6.7.3 pH value
In order to control the corrosion in the chiller/heater, the pH value should be controlled in the
limits of 9-10.5. The solution with pH value not in these limits should be adjusted. The solution is
shipped from factory with the pH value in the above limits. With the operation of chiller/heater,
the pH value will be increased. The pH value of solution should be checked periodically by
universal pH value test paper, and the results should be recorded. If the pH value is too high,
hydrobromic acid (HBr) may be added; if it is too low, lithium hydroxide (LiOH) may be added.
The hydrobromic acid and lithium hydroxide shall be suitably diluted prior to their additions to the
chiller/heater, and with appropriate rate. They can be added in such a way: take a part of solution
and pour it in a vessel, then add the lithium hydroxide or hydrobromic acid, which is diluted with
50
6 times of pure water. They should be mixed evenly.
The adjustment of pH value and addition of this matter is rather complex, and is
preferred under the instruction of qualified engineer from Shuangliang Service Co.
6.7.4 Inhibitor
In order to control the corrosion of LiBr solution to the chiller/heater, the solution is added with
inhibitor in the predetermined concentration of (0.10±0.02%) for lithium chromate and of
(0.010~0.018%) for lithium molybdate. In the process of operation, especially in the beginning
period, the inhibitor is consumed rather rapidly. The Content of inhibitor in the solution should be
checked periodically by the special laboratory. The inhibitor content should be kept in the set
limits, when its content is out the limits.
Direct addition of inhibitor in the chiller/heater is forbidden. It is added by taking a part of
solution (10 times of inhibitor) from the chiller/heater, mixed with the inhibitor slowly to even
distribution, and then the mixture is added to the chiller/heater. After the inhibitor is added, the
chiller/heater should be operated to make its even distribution in the solution.
The addition of inhibiter is rather complex, and is preferred under the instruction of
qualified engineer from Shuangliang Service Co.
6.7.5 Ethanol
Ethanol is used to improve the chiller/heater performance. The content of ethanol in the solution is
0.1-0.3%. Ethanol should be added, when the content in the solution is lower than this value. The
inadequate ethanol can be determined by two ways: the one is the chiller/heater performance is
deteriorated; the second is absence of irritant odor from the solution, or no irritant odor from the
vacuum pump discharge.
Ethanol is added in the similar way as for solution through the charging valve or sampling valve
under negative pressure.
51
Dirty in cooling water causes not only reduction the performance of chiller/heater by the scaling of
heat transfer tubes, but also shortening the life cycle of tubes by their corrosion. During operation
of chiller/heater, cooling water should be sampled and analyzed. The quality of cooling and
makeup water should meet the requirements of Table 6-2. Water should be treated, if it cannot
meet the requirements.
Table 6-2 Water quality standard
Item Unit Makeup water Cooling water Tendency
Corrosion Scaling
Basic pH value(25℃) 6.5~8.0 6.5~8.0 ○ ○
Items electric µS / cm <200 <800 ○ ○
conductivity(2
5℃)
chloric ion Cl- mg Cl-/L <50 <200 ○
sulfuric acid mg SO4 /L 2− <50 <200 ○
radical ion
SO42−
acid mg CaCO3/L <50 <100 ○
consumption
rate(pH4.8)
Total hardness mg CaCO3/L <50 <200 ○
Reference Iron Fe mg Fe/L <0.3 <1.0 ○ ○
Items sulfuric ion S2- mg S2-/L undetectable undetectable ○
ammoniac ion mg NH 4+ /L <0.2 <1.0 ○
NH 4+
silicon dioxide mg SiO2/L <30 <50 ○
SiO2
Bad cooling water quality not only causes scale formation in heat transfer tubes,
influences heat exchange efficiency and reduces the performance of chiller/heater, but also
corrodes heat transfer tubes and leads to major failure of chiller/heater.
52
the loading from direct starting, if it is under long-term shutdown.
4. To reduce the emulsification of oil, vacuum pump should be operated under opened ballast
valve.
5. For long time evacuation and avoiding the oil emulsification, the vacuum pump should be
operated idly to warming up, then open the purge valve. Before shutdown the vacuum pump, it
also needs to work idly for a while to discharge the water vapor, which mixed with the oil.
6. The vacuum pump oil should be checked constantly for oil level and preventing the oil
emulsification. The oil level should in the middle of sight glass, and drain the emulsified oil or
water drops by screwing out the plug on the bottom of oil box, if the oil is milk white. Then
appropriate amount of oil should be added. Oil should be changed and washed, if it is too dirty.
7. If lithium bromide solution comes into the vacuum pump due to accidental operation, then
contaminated oil should be drained and pump washed by running the pump repeatedly for a
short time to discharge out the rest of solution. Wash vacuum pump, if condition allows.
Remove and clean the vacuum solenoid valve from the piping, if it is installed.
8. Vacuum pump should be checked for its attainable limiting vacuum in the following. (1)
Remove the sealing plug from the purge valve, and connect Macleod gauge to the sampling
purge valve with vacuum grease by means of rubber hose. (2) Take off the sealing plate from
the oil trap and rubber hose connection from vacuum pump, connect the vacuum pump with oil
trap. (3) Run vacuum pump for 3 min, then open slowly sampling purge valve and measure the
pressure by Macleod gauge. Vacuum pump is satisfactory, if the pressure is less than 30 Pa.
Otherwise, the vacuum pump shall be checked till satisfactory results are obtained.
53
1
1- Upper hood
2
2- Press cup
3
3- O ring
4
4- Valve stem
5- Valve plug
6- Valve body
5
6
1 1- Upper hood
2
3 2- Press cup
1 4 3- O ring
2 5 4- Valve stem
3 6
5- Valve plug
4
6- Valve body
5
6
1. For the purging, charging, refrigerant probe, concentrated solution probe and
pressure measuring valves, which led to the atmosphere, block is inserted into the
valve. Operate these valves after taking out the block, and insert the block on the
Loctite after operation.
2. For probing the weak solution through the charging valve, after the block had been
taken away, the valve outlet should be connected with intermediate part supplied
with the chiller, and then operate. After the probe had been taken, remove the
intermediate part, and install the block on the Loctite.
3. Method of Changing The Sealing Ring or Valve Plug
1) Remove the upper hood.
2) Turn clockwise the press-cup to remove it. (Loosen the fitting screw, if it is provided.)
54
3) Take out the valve stem from the valve body, and change the O-ring or under part of stem (with
valve plug).
4) Install the valve stem into the valve body with the O-rings covered with vacuum grease.
5) Tighten the press-cup anti-clockwise, and turn the valve stem by torque wrench to adjust the
valve by closing and opening it.
6) Install the press-cup on place with the Loctite at the threads, and tighten the hood.
4. Troubleshooting
No Trouble Cause Measure
The valve stem Seizing of upper driving thread Remove press-cup, take out
cannot be turned. of valve stem valve stem, repair the driving
1
thread. Change the valve stem, if
the thread cannot be repaired.
Scratch at the surface of valve Change the under part of valve
plug stem (with the valve plug).
2 Leaking of sealing
Damage at the hole surface of Change the valve.
scratch at the sealing surface.
3 Leaking of O-ring Damage or aging of O-ring Change O-ring.
55
Chapter 7 TROUBLESHOOTING
2) When overflow of refrigerant water pump occurs, chiller will alarm immediately and shut down
after turning into dilution operation. When overflow of vacuum pump occurs, chiller will alarm
immediately. When cylinder gas pressure reaches set valve, a graph will appear automatically on
the graph of operation monitoring on the touch screen showing “High pressure in chiller
auto-purging unit, please start vacuum pump”. The operator may start purge according to methods
introduced in “6.5 Purge Operation”.
3) When any following severe trouble occurs, chiller will alarm instantly and shut down
emergently.
(1) Failure of chilled water
(2) Trouble in inverter;
(3) Low chilled water temperature
(4) Low refrigerant water temperature;
During automatic shutdown of chiller/heater, the operator should press key “TROUBLE
MONITORING” on the graph of operation monitoring on the touch screen to make the alarm
silent and search for the cause of trouble and its shooting. Operator should remove the cause of
trouble immediately after the trouble occurs, and then start again the chiller/heater.
56
2 Trouble of control 1. Check the normal input of control elements and apparatus.
elements and Check the normal conditions of three phase and control power
apparatus supplies for contactors. Check the power supply and electrode
circuit of level controller.
2. Check the output of control elements and apparatus, for
instance the output of three-phase power supply, the output
signals of high and low level output signals of level controller.
3. Check other control circuits, such as the control signal from
the PLC to the controllers, and etc.
4. Check the function of elements and apparatus in accordance
with their instructions.
3 Trouble of touch 1. Check the fixing of communication and power lines. Check the
screen batteries of touch panel (which should be changed every 2
years).
2. Check the touch panel according to the troubleshooting
instruction.
4 Trouble of PLC 1. Check the elements and apparatus step by step, including the
(ERROR light up) PLC controller, the power supply of controller, the input/output
modules, base plate and PLC batteries (for every two years).
2. Check the PLC according to the operation instruction.
5 Trouble of external 1. Check the fixing of connection lines and the situation of
measuring elements circuits (Connect new lines from sensors to the control panel,
and measure the output of sensors).
2. Check the installation situation of sensors (such as the
blockage of pressure sensing hole for pressure sensors, and the
damage of target plates of flow switches)..
6 Trouble of external 1. Check the correct connection of circuits and control signal.
actuating elements 2. Check the actuating elements according to the instruction.
57
No Trouble Cause Troubleshooting
9) Too much refrigerant water. 7) Sampling refrigerant water,
10) Inadequate Ethanol in and regenerate it, if density is
solution. greater than 1.04.
11) Less charge of solution. 8) Close refrigerant bypass valve,
12) Less circulating rate of reduce or increase the opening
solution. of spray valve.
13) Low chilled/hot water outlet 9) Drain refrigerant water.
temperature. 10) Add ethanol.
14) Less cooling load for user. 11) Add appropriate amount of
solution.
12) Regulate weal solution
regulating valve to meet the
requirements.
13) Cooling capacity will be
reduced with the reduction of
chilled water outlet
temperature. Set the nominal
chilled water outlet
temperature.
14) It is normal for automatic
control of cooling capacity.
4 Heating capacity is lower 1) Inadequate fuel combustion. 1) Increase fuel combustion.
than design value (Heating 2) Scale formation on tubes. 2) Clean tubes.
mode) 3) Low load from customer. 3) Normal for automatic control
of chiller/heater.
4) Low hot water flow. 4) Increase hot water flow.
5 Chilled/hot water 1) Cooling (heating) capacity is 1) See No.3 or No4.
temperature difference is less than designed value.
less than nominal value. 2) Chilled/hot water flow is 2) Reduce the flow accordingly.
greater than nominal value. Correct the display deviation.
3) Displayed temperature is not
correct.
6 High chilled water outlet 1) Cooling (heating) capacity is 1) See No.3 or No.4.
temperature or low hot less than designed value. 2) Reduce cooling load
water outlet temperature 2) Too great outside load. accordingly.
3) Set the nominal value.
3) Set value is too high (for 4) Reduce the water flow.
cooling mode),or too low (for
heating mode)
4) High chilled/hot water flow.
7 Contaminated refrigerant 1) Too big solution circulating 1) Regulate weal solution
water rate and high solution level. regulating valve to meet the
(for cooling mode) 2) Too big solution charge. requirements.
3) Low cooling water 2) Drain part of solution.
temperature. 3) Regulate cooling water
4) Too high chilled waster outlet bypass valve; check
temperature. controller of cooling water
5) Too much combustion heat inlet temperature.
supply. 4) See No. 6
6) Poor quality of solution. 5) Regulate combustion heat
supply.
6) Sampling solution, and
analyze, change solution
with more reliable quality.
8 Crystallization during 1) Air leakage or a lot amount of 1) Purge chiller/heater by
startup non-condensable gas in vacuum pump.
58
No Trouble Cause Troubleshooting
chiller/heater. 2) Regulate cooling water
2) Too low cooling water inlet bypass valve to increase
temperature. temperature. Check controller
3) Overloaded. of cooling water inlet
temperature.
3) Increase load slowly for
startup.
9 Crystallization during Inadequate dilution Check the set value for dilution
shutdown and actual situation.
10 Crystallization during 1) Non-condensable gas in 1) Purge chiller/heater by
operation chiller/heater. vacuum pump.
2) Too less solution circulation 2) Regulate weak solution
rate. regulating valve.
3) Too big heat supply. 3) Reduce heat supply.
11 Sudden shutdown during 1) Failure of power supply or 1) Check power supply to
operation loss of phase line. restore it.
2) Safety protection system 2) Remove the cause of
works. troubles, and restore the
a. Abnormal inverter. normal operation:
b. Failure of chilled water a. Check and repair inverter and
c. Other troubles solution pump. See No. 25
b. See No. 19
c. Press “TOUBLE
MONITORING” button on
operation monitoring graph on
chiller touch screen to know
trouble reasons and ways of
troubleshooting.
12 Flame cutout during small 1) Manual fuel supply valve had 1) Open the fuel supply valve.
firing or ignition not opened. 2) Check fuel supply and
2) Abnormal gas supply pressure regulating valves.
pressure. 3) Check and regulate.
3) Not correct set the flap or 4) Open more the flap.
fuel supply valve. 5) See the technical manual of
4) Inadequate air supply for burner.
fuel.
5) Troubles in burner for a lot of
causes.
13 Abnormal flame from 1) Incorrect assembling 1) Adjust in accordance with the
burner dimensions for details of burner technical manual for burner.
head. 2) Adjust the air and fuel
2) Air or fuel amount is not amount.
correct. 3) Clean the burner from ash
3) Formation of ash on the and carbonization.
burner head. 4) Clean or replace.
4) Clogged burner nozzle. 5) Clean.
5) Clogged filter.
14 High outlet temperature of 1)High pressure and temperature 1) See No. 15.
flue gas of HP generator. 2) Clean the heat transfer tubes.
2)Formation of ash in the flue 3) Adjust the air supply.
gas heat transfer tubes.
3)High air amount for burner.
15 Black smoke 1) The proportion of air to fuel is 1)Adjust the combustion
not correct. carefully by increasing the
2) The atomizing disk had not opening of air flap and see the
been adjusted correctly. technical manual of burner.
59
No Trouble Cause Troubleshooting
3) Not the correct nozzle had 2)Contact Shuangliang Service
been chosen. Company to readjust the
4) The type of fuel is not correct. combustion.
3)Chose the other ones, or
contact Shuangliang Service
company.
4)Change the sort of fuel after
5) Air supply pressure and heat examination.
value changed in big limits. . 5)It is required to stabilize the
gas supply pressure and heat
value.
16 High HP generator 1) Poor air tightness and air 1) Purge the chiller/heater by
temperature and pressure. leakage vacuum pump and remove
2) Heat input is greater than the leakage.
nominal value. 2) Regulate heat input.
3) High cooling water 3) Regulate cooling water
temperature or low cooling bypass valve, check cooling
water flow. tower and fan, or regulate
4) Severe scale on the cooling cooling water flow.
waterside of heat transfer 4) Clean heat transfer tubes.
tubes. 5) Regulate weak solution
5) Low solution circulation rate. regulating valve.
17 Cavitation of solution 1) Inadequate solution charged. 1) Charge solution.
pump 2) Crystallization. 2) De-crystallization.
3) Big solution circulation rate. 3) Regulate solution circulation
rate.
18 Cavitation of refrigerant 1) Inadequate refrigerant water. 1) Add refrigerant water.
pump 2) Low refrigerant water. 2) Regulate cooling water
temperature or add refrigerant
water.
19 Failure of chilled water 1) Damaged pump (or motor). 1) Repair or startup standby
pump.
2) Inadequate refrigerant water is 2) Add a big amount of water.
added.
20 Failure of cooling water 1) Same as failure of chilled/hot 1) Same as for failure of
water. chilled/hot water.
2) Less water is stored in the 2) Addition of water storing
cooling tower. capacity (for water collecting
type cooling tower)
21 Abnormal increase of The heat transfer tubes leak or Urgent measures should be taken:
pressure in the other parts leak abnormally. 1) Cut the power to shutdown
chiller/heater, pressure in the chiller/heater.
the auto purge unit equal 2) Close valve and stop the
or above the atmospheric chilled and cooling water
pressure pumps.
3) Drain the chiller/heater.
4) Transfer solution from
chiller/heater to tank; open the
end covers to test the air
tightness.
22 Big variations of values 1) Poor grounding. 1) Re-grounding.
displayed on the touch 2) Poor sensors for temperature 2) Repair or replace.
screen and etc. 3) Replace.
3) Troubles in touch screen.
23 Pump not operated. 1) Pump motor overload 1) Find the cause of overload
protected. and reset.
60
No Trouble Cause Troubleshooting
2) Troubles in the control 2) Check the circuit.
circuit. 3) Replace.
3) Trouble in pump itself. 4) Find the cause.
4) Automatic protection of
chiller/heater works.
24 Inverter not operated. 1) Trouble in control circuit of 1) Check the control circuit.
inverter. 2) Check and change the function
2) Erroneous setting of function codes.
code for inverter. 3) Raise the voltage of power
3) Low voltage of power supply. supply.
4) Trouble in inverter. 4) Check and repair inverter.
5) Over current protected 5) Check the solution pump for
inverter. trouble.
25 Buzzer not working. 1) Buzzer damaged. 1) Replace.
2) Fuse blown. 2) Replace.
26 Abrupt shutdown the firing 1) The automatic protecting 1) Observe touch screen to
system is working due to correct the trouble.
abnormal operation of 2) Chiller/Heater is shutdown,
systems. because chilled/hot water
2) The auto capacity regulation temperature is lower/higher
is working. than lower/higher set value,
3) Trouble in burner. and starts work, when
conditions changed.
3) Check burner.
27 Decrease the vacuum Leakage Test chiller/heater for air
during shutdown period tightness.
61
firing of burner.
2) Stop the supply of cooling water to raise the temperature of weak solution to about 60℃, but
not above 70℃.Shut the chilled/hot water, when its outlet temperature is higher than inlet
temperature.
3) Open the refrigerant bypass valve slowly to bypass part of refrigerant to absorber to dilute the
solution and not lower the solution level in the absorber considerably. The solution will
de-crystallize, if the chiller/heater is operated under such conditions continuously.
4) Heat the crystallized parts by steam or condensate, if they are difficult to be de-crystallized.
5) Put the chiller/heater into operation, when it is de-crystallized. The purge piping is also to be
de-crystallized, if it had been crystallized also.
6) Find the cause of crystallization, and appropriate measures are taken.
The chiller/heater is normal, if the de-crystallization pipe is not hot even under the full load of
chiller/heater.
7.3.3 Crystallization during Shutdown
During shutdown the solution is crystallized, if it is not adequately diluted during shutdown, or the
cooling water temperature is low. The solution pump cannot work for solution crystallization. It
can be de-crystallized by heating the pump casing and its inlet and outlet by steam to run the pump.
The caution should be taken to avoid the steam and its condensate into the motor and its control
means. No direct heating of motor is permitted.
62
then the sampling valve and lower and upper purge valves should be closed.
7.5.4.1 Treatment for Short Period (less Than 1h) Failure of Power Supply
In general the solution will not tend to be crystallized, if the power supplied is failed only for
limited time, and solution remains hot. In such case, the chiller/heater can be put into operation, as
the power supply recovered.
1) If the chilled and cooling water pumps had been shut as the power failed, then these pumps are
to be started by confirming that the valves at their discharge had been closed. Then these valves
opened and adjusted to the flow required.
2) Control the chiller/heater manually, start the solution pump and refrigerant pumps, and stop the
chiller/heater with dilution operation.
3) Control the chiller/heater automatically, start it in the normal procedure.
4) Check the refrigerant water for its density; regenerate it, if its value is above 1.04g/ml.
7.5.4.2 Treatment for Long Period (more than 1h) Failure of Power Supply
The crystallization of solution tends to occur, if the chiller/heater is shutdown for long period
under high solution concentration. Operate the chiller/heater in the following ways, when the
power recovered:
1) Start the chiller/heater manually for operation with dilution as above mentioned for short
shutdown.
2) Operate the chiller/heater under light load for 30 min in trial manner. Stop the chiller/heater for
de-crystallization, if the cavitation for solution pump occurs in 30 min. If no crystallization
occurs, then stop the chiller/heater, and re-start the chiller/heater in automatic mode.
3) Check the refrigerant water for its density after de-crystallization; regenerate it, if its value is
above 1.04g/ml.
63
No. Trouble Cause Measure
from oil pump 2) Air in oil piping. 2) Tighten the connections.
3) Oil inlet valve closed. 3) Open the oil inlet valve.
4) Filter clogged. 4) Clean the filter.
5) No oil for oil pump. 5) Charge oil.
4 Mechanical 1) Air in pump. 1) Vent the pump.
noise from 2) Filter clogged. 2) Clean filter.
pump.
5 No even 1) Atomizing disk is free to 1) Remove nozzle and tighten the
atomization of move. atomizing disk.
oil from nozzle. 2) Spray holes clogged 2) Remove and clean it.
partly.
3) Pressure reduced due to 3) Remove and clean it.
clogging of filter.
4) Nozzle is worn. 4) Replace the nozzle.
5) Nozzle is clogged. 5) Remove and clean it.
6) Trouble in the regulating 6) Replace the nozzle.
mechanism of nozzle.
7) Low oil pressure. 7) Adjusting oil pressure.
6 Abnormal noise 1) Fan blades are 1) Clean.
of fan contaminated.
2) Bearing worn. 2) Replace.
7 No feedback 1) Smoke on the surface of 1) Clean flame detector.
from flame flame detector.
detector. 2) Flame detector damaged 2) Replace.
due to high temperature.
3) Circuit board for flame 3) Replace.
detector damaged.
8 Abrupt cutout 1) Trouble in burner. 1) Check the wiring.
firing of burner. 2) Trouble in oil supply 2) Check and repair.
system.
9 Solenoid valve 1) Coil is broken. 1) Replace coil.
cannot open. 2) Valve fuse burn 2) Replace fuse.
10 Solenoid valve Foreign matter on the valve Disassemble the valve, and clean it
cannot be closed seat. from foreign matter.
tightly.
11 Burner head is 1) Head is located in wrong 1) Adjust the location of head.
contaminated by position.
oil or 2) Nozzle is too big. 2) Replace.
carbonization 3) Air is not enough. 3) Re-adjust the air flap.
4) Poor ventilation of 4) Machine room should be provided
machine room. with permanent ventilation port with
section not less than 50% of
chimney section.
5) Pressure loss of flue gas 5) Increase the section of flue gas
channel is big. channel.
12 Oil pre-heater 1) Thermostat for oil not 1) Raise the oil temperature by tighten
cannot work closed. the screw,
(for heavy fuel 2) Thermostat for oil is 2) Replace the thermostat.
oil) failed. 3) Tighten it.
3) Thermostat for oil is 4) Replace thermostat.
slackening. 5) Replace heater.
4) Oil thermostat is set with
wrong temperature
limits.
5) Trouble in heater.
64
1. Clean the fan motor, ignition electrodes, flame detector and air inlet in accordance with
the requirements.
2. Check and repair failed motor bearings to protect the burner from damage.
3. Check immediately, if the fan motor noisy.
4. Clean the oil filter timely to protect the burner oil pump and solenoid valves from
damage.
65
No. Trouble Cause Measure
2) Protection due to leakage
of solenoid valve. 3) Clean or replace filter.
3) Gas supply filter is 4) Re-adjust.
clogged.
4) Air flap is set incorrect.
7 Flame cutout after 1) Gas supply filter is 1) Clean filter.
normal ignition. clogged. 2) Check and repair gas pressure
2) Trouble in gas pressure regulator.
regulator. 3) Contact the local gas company.
3) Trouble in gas 4) Re-adjust.
instruments or water in 5) Clean the head of flame
the lowest points of gas detector.
piping. 6) Increase the gas supply
4) The ratio of gas with air pressure.
is not correct. 7) Re-grounding.
5) Flame detector is too
dirty.
6) Gas supply pressure is
low.
7) Poor grounding.
8 Flame cutout during High limit pressure switch Stabilize the gas supply pressure,
changing from big protection is working for or re-adjust the pressure switch.
fire to small, and increased pressure.
self-locked.
9 Flame cutout during Low limit pressure switch Same as above.
changing from small protection is working for
fire to big. reduced pressure.
10 Burner whistled. Gas pressure low and air Re-adjust the gas pressure and air
flow too great. flap.
11 Flap regulating Gas butterfly valve is Reduce the size of blade of valve.
mechanism cannot clogged for its blade.
rotate.
66
No Trouble Cause Solution
9) Rubber components for components are cleaned, not using
suction pipe and ballast gauze as far as possible.
valve not assembled 8) Check, repair and replace.
correctly, broken or aged. 9) Adjust and change.
10) Vacuum system, including 10) Clean.
piping, contaminated
severely.
2 Oil leakage 1) Broken oil drain plug and 1) Check and replace.
gasket. 2) Check, adjust or replace.
2) Broken or assembled not 3) Replace and lower the oil
correctly the gasket for oil temperature.
box cover. 4) Check and repair.
3) Deformed thermally the 5) Close it while shutdown the pump.
plexiglass. 6) Reassemble or replace.
4) Lost spring for oil seal.
5) Not closed the ballast valve
during shutdown of pump.
6) Oil seal is worn due to error
assembling.
3 Oil spray 1) Too high oil level. 1) Drain oil to normal level.
2) No oil or oil contaminated 2) Check, clean and repair.
in oil separator. 3) Check and re-assemble.
3) Lost or assembled not
correctly the oil trapping
plate.
4 Noise 1) Broken the springs for 1) Check and replace.
revolving plates, and 2) Check, adjust and replace, when it
increased oil supply. is necessary.
2) Worn bearings. Check and replace.
3) Broken parts.
5 Back flow of oil
1) Assembled not correct or 1) Replace.
worn the oil seal in the 2) Check and repair.
pump cover. 3) Replace.
2) Not normal the surface of
pump cover and stator.
3) Broken the discharge valve
plate
67
b. Abnormal contact in bearings. Check and replace the bearing, sleeves and thrust plate. Remove
the cause for increased friction.
c. Abnormal contact between the rotor and stator. Check the surface for abnormalities of
expansion deformation. Remove the cause for abnormal wear.
d. Poor contact between the impeller and casing of pump. Check the assembly of pump shaft and
impeller and deflection of shaft. Adjust or replace the shaft, if it is out of normal limits.
e. Foreign matter in the pump casing. Disassemble the pump casing to remove the foreign matter.
f. Reduced motor insulation resistance and unbalance of resistance of coil for three phases.
Restore, or otherwise, replace the stator. Dry the motor slowly by torch, if it is damped.
g. Motor operates under absence of any phase current. Check the fixing of wire connection of
motor. Tighten it, if it is slack.
h. The voltage and frequency of power supply is fluctuating. Check the power supply line.
4) Thermal relay protection is working frequently
a. Pump motor overloaded and overheated. Check the flow and temperature of working medium.
Check and clean filter.
b. Trouble in thermal relay. Check and replace the thermal relay.
5) Pump noisy and vibrated severely
a. Reversed rotation of pump. Change the connection of leads to pump motor to correct rotation
direction.
b. Too great or small pump flow. Check the pump operation to make the operation of pump in the
determined limits.
c. Cavitation in pump. See Table 7-2.
d. Foreign matter in pump. Check and remove foreign matter from pump.
e. Contact of casing with the impeller or inducer. Check and repair.
f. The fixing of bolts is slack. Check and repair pump.
g. Unbalanced rotor of pump. Check and balance pump dynamically.
68
Chapter 8 MAINTENANCE OF CHILLER/HEATER
The performance of chiller/heater and its life cycle is dependent not only upon the starting
commissioning, but also the maintenance of chiller/heater. The maintenance of chiller/heater is not
so complex, but it had to be done vary carefully. Chiller/heater should be maintained periodically
to operate it reliably, prevent it from accidents and to increase its life. Violation of following
maintenance precautions causes the unnecessary loss.
69
8.1.2 Yearly Inspection
Before the startup and shutdown in a yearly season, the following inspections should be checked.
Table 8-2 Items for yearly inspection
No Group Item Content Time
1 Chiller/heat 1) Clean heat transfer 1) Open the end covers of water 1) After shutdown.
er tubes. boxes for chilled and cooling
water, clean tubes and end
covers by brushes or chemical
detergent, and replace the
gaskets.
2) Inspect 2) Check the chiller/heater for 2) Before starting and
chiller/heater for air tightness by the procedure after shutdown
air tightness illustrated in paragraph 5.1.4
of chapter 5.
3) Furnace of HP 3) Clean the furnace from ash by 3) After shutdown.
generator. opening the ash door, and
repair the damaged refractory.
4) Painting 4) Painting parts or whole 4) After shutdown
chiller/heater based upon the
rust conditions
2 Solution Analyze and treat the Sampling and analyzing the Before starting
solution solution, and adjust it based upon
the results.
3 Pump 1) Hermetically 1) Check the motor insulation, Before starting
sealed pumps and measure its amperage.
Inspect the bearings for metal After shutdown.
wear, repair or replace
2) Vacuum pump 2) Inspect and clean vacuum After shutdown.
pump.
4 Burner 1) Clean burner. 1) Open the burner to clean 1) Before starting.
internal parts and fan blades.
2) Adjust. 2) Readjust the flap, oil 2) Before starting.
pressure, gas pressure,
location of ignition
electrodes and atomizing
disk to ensure that they are in
correct positions, and check
or replace, if something
wrong.
3) Check combustion 3) Check the working of safety 3) Before starting
protection for combustion,
and check the working
circuit.
5 External 1) Check gas leakage 1) Check gas piping leakage 1) Before starting.
systems and safety stop and safety stop valve
valve opening/closing.
opening/closing. 2) Clean piping from dirt, check 2) Before starting.
2) Oil or gas supply and repair it.
system. 3) Clean the flue gas channel 3) After shutdown.
3) Flue gas channel. outside of chiller/heater.
6 Electric 1) Grounding of 1) Check power supply for 1) Before starting
parts power supply grounding.
2) Isolation 2) Check motor and control 2) Before starting
resistance and panel for isolation resistance
electric strength and electric strength.
3) Check fixing of 3) Tighten screws on terminals 3) Before starting
70
No Group Item Content Time
wires on additionally.
terminals.
4) Electric control 4) Check the electric control 4) Before starting
and protections and protections for their set
points and actual working,
check for wear of contacts
and malfunction.
5) Level sounding 5) Clean the elements, if aged. 5) Before starting
Replace the corroded.
6) Electric wires 6) Check and replace, if aged 6) Before starting
and cables. and corroded.
7) Flow switch. 7) Check switch for its 7) Before starting
sensitivity, adjust it to
normal function.
8) Electric Check, repair or replace based 8) Before starting
elements, such upon the actual results (for
as sensors, inverter, see its technical
inverters. manual )
71
1) The solution in the chiller/heater should be diluted fully. Refrigerant water from evaporator
should bypass into the absorber to dilute solution and prevent crystallization, when the ambient
temperature is lower than 20℃, and chiller/heater is stopped for more than 8h. Operate the
solution pump and stop refrigerant pump, connect the solution charging valve at the discharge
of solution pump and refrigerant sampling valve together and open them, to prevent the
refrigerant pump from freezing-up by forcing the solution into refrigerant pump, when the
ambient temperature is lower than 5℃.
2) Maintain the vacuum in chiller/heater, operate vacuum pump, if absolute pressure in the
chiller/heater is increased.
3) Check the chiller/heater for air tightness, if absolute pressure in the chiller/heater is increased
too rapidly.
4) Drain the chilled/hot and cooling water systems (including chiller/heater), if the local ambient
temperature will be lower than 0℃ in the interval of shutdown.
5) It is forbidden to expose the chiller/heater to atmosphere for long time during inspection,
replacing and repairing valves or pumps. The maintenance work should be planed carefully,
and the chiller/heater is evacuated immediately after the work finished.
72
1) Inspection of scale. Open end cover of water box to check, if there is scale and sludge in the
tubes. Scale is analyzed and measures should be taken, if it occurs in the tubes.
2) Inspection of air tightness Chiller/heater is charged with nitrogen up to 0.1-0.12MPa. Tubes are
plugged from one side, and covered by a film of solution from another end. The tube is broken,
if there is bubble at the its end, or if the plug is expanded off, when tubes are plugged from both
sides. The broken tube can be observed also, if bubble comes from the tube, when water funnel
is installed instead of end cover.
8.4.2 Cleaning of Heat Transfer Tubes
Tubes are cleaned once a year based upon the scale and sludge formation inside tubes.
1) Mechanical cleaning. Mechanical cleaning is effective to remove the sludge from the tubes.
Remove the end cover, blow the tubes with nitrogen or oil-less air under pressure of
0.7-0.8MPa. Then the nylon brushes (not metal wire brushes) with rubber heads and air plugs
are inserted into the tubes, moved from one end of tube to another under high water pressure
for 2-3 times, and then dried by high pressure nitrogen or air, or cotton balls. Cleaned tubes are
protected by end covers.
2) Chemical cleaning. Chemical cleaning is used to remove scale, which contains salt with
calcium, magnesium, and other hard salts. Tubes are cleaned by chemical dosage, method and
timed in accordance with the content and thickness of scale formed.
73
Concentration
Strong Solution %
Intermediate Temp. %
Weak Solution %
Solution
Outlet Temp. ℃
HT Heat Exchanger
Weak
Inlet Temp. ℃
Weak Intermediate
Outlet Temp. ℃
Solution
Inlet Temp. ℃
Solution
Outlet Temp. ℃
LT Heat Exchanger
Time:
Inlet Temp. ℃
Outlet Temp. ℃
Solution
Strong
Direct-fired Absorption Chiller/heater Running Record
Inlet Temp. ℃
Heat Load Deviation %
Heat Load kW
Gas Exist Temp. ℃
HPG
Outlet Temp. ℃
Condensation Temp. ℃
Outlet temperature of Absorber: The front is the side near to purging unit. Another side is the rear
Total Load kw
Flow Rate m3/h
Absorber
Front ℃
Total Inlet Temp. ℃
Refrigerant water specific gravity g/ml
Refrigerant water temp. ℃
Heating Capacity
kW
Cooling Capacity
Evaporator
Inlet Temp. ℃
Customer:
Time
Model:
No.
10
11
12
Note
1
2
3
4
5
6
7
8
9