Absorption Chiller

SERVICE TRAINING BOOK

LJ TJ Model

Section 1 How the Absorption Chiller Works

1-1. Why does a heating chill ? The cooling means keeping temperature in a room lower than outside temperature, As shown in Fig. 1-1, operation to carry the heat from the room with a lower temperature (ex.28 deg.C : 82.4 deg.F) to the open air with a higher temperature is required. But, in the natural world, the heat can not move from a low temperature side to a high temperature side. So, to transmit the heat as opposed to this principle, some method is necessary. That is, a heat pump (chiller) is used to pump up the heat from a low temperature one as if a water pump is used to draw a water from a deep well.

Fig. 1-1 Heat flow The typical chiller using electricity as a operation power source as a conveyer to carry the heat shown in Fig. 1-2 is an centrifugal chiller and the typical chiller using a heat energy is an absorption chiller. Chilled water is made by using the latent heat released by a liquid as it evaporates. We can experience this principle on our daily life. For example, when having an injection, after applying alcohol on the arm, we feel this part cool. Because, applied alcohol took the heat from the arm when it is warmed by the body Fig. 1-2 Heat flow at cooling heat and evaporated. Another example is that we feel cool when sweating on a hot day or by taking exercise. Because, the body heat is cooled by the evaporation of sweat which takes the heat from the body. A chiller also uses an latent heat of evaporation. But, reuse of evaporated vapor by returning to liquid is required. For this purpose, the compressor is used in a centrifugal chiller, and an absorbent is chemically used in an absorption chiller. The absorbent loses the effect. Because its concentration is diluted due to absorbing the vapor. To recover the absorbing effect, a concentrating process of absorbent by heating is needed. 1-2. What is latent heat ? When water is heated, the temperature rises and stops at 100 deg.C (212 deg.F). With the temperature remaining constant at 100 deg.C (212 deg.F), the water continues to evaporates as long as it is being heated. Once water reaches 100 deg.C (212 deg.F), all additional heat goes into changing it from liquid to vapor. At 100 deg.C (212 deg.F), since vapor is lighter than the surrounding air, it rises. In this case, as water changes from a liquid to a gas, the applied heat does not change the temperature but changes the state of water. Therefore the heat is said to be hidden, or latent. Thus latent heat refers to the energy absorbed by a liquid as it changes state, i.e., to a gas, without changing it's actual temperature. Sensible heat refers to heat which only results in temperature change rather than change of state. Page 1 / Sec.1 LJ/TJ Series

1-3. Principal elements of absorption chiller There are following 3 elements on the principal of the absorption chiller. a. The inside of chiller is vacuum condition. b. Water (H2O) is used as refrigerant ( Minimum chilled water outlet temp. is 5 deg.C=41 deg.F) c. Lithium Bromide (LiBr) water solution that has character to absorb water vapor is used as absorbent. The following descriptions are detail explanations of each elements 1-3-1. Vacuum & water The earth we live is pressed by the weight of the air of approximate 10 km (6 miles) which is surrounding the earth and this pressure is called as the atmospheric pressure. The pressure lesser than this pressure is called as the vacuum. When explaining the vacuum for the absorption chiller, it is needed to know the relation between the pressure and the evaporation temperature of water. It is experienced in a daily life that the water is boiled (evaporated) at 100 deg.C (212 deg.F) in the atmospheric pressure. When pressure is higher than the atmospheric pressure, boiling temperature is higher than 100 deg.C (212 deg.F). And if the pressure is lower (vacuum), the boiling temperature is lower than 100 deg.C (212deg.F). The pressure higher than the atmospheric pressure can be experienced with a boiler. The pressure lower than the atmospheric pressure can be experienced during claming a mountain. Namely, in the mountain, as the air layer becomes weak by its height, the pressure to be applied becomes low. For this reason, the water boils at a temperature lower than 100 deg.C (212 deg.F) at the mountain. In other words, evaporation temperature of the water is depended on pressure. The inside of a chiller is always kept in high vacuum. In this condition, the water evaporates at very low temperature. For example, at 0.5 kPa absolute, water evaporates at 5 deg.C (41 deg.F). 1-3-2. Lithium Bromide (LiBr) Lithium Bromide is medicine which is made from the lithium obtained from lithium ore and the bromide obtained from the sea water. This medicine is not familiar to us. But we can guess easily Lithium Bromide. That is, we usually see the salt. The another name of salt is Sodium Chloride. They are of the same elements, that is Lithium (Li) and Sodium (Na) are alkali while Bromide (Br) and Chlorine (Cl) are halogen. LiBr and NaCl are chemical materials in the same chemical group and have very similar characteristics. Especially, the both materials has the characteristic to absorb moisture (water vapor). This characteristics to absorb moisture of LiBr is stronger than NaCl. The absorption chiller uses the characteristic. The higher its concentration and lower its temperature of LiBr water solution are, the stronger the characteristic (absorption power) is.

1-4. Principal of single effect type (1) Heat exchanger tubes are installed inside a closed vessel. The vessel is then evacuated to a pressure of about 0.8 kPa (0.12 psi) absolute. Drops of water (refrigerant) are allowed to fall on the heat exchanger tubes.

Fig. 1-3 Evaporation process Page 2 / Sec.1 LJ/TJ Series

(2) Now the vessel has a vacuum of 0.8 kPa (0.12 psi) absolute. Drops of refrigerant water falling on the exchanger tubes evaporate at 5 deg.C (41 deg.F) as they remove heat from the water in the tube. Thus chilled, the water in the heat exchanger tubes can be used for cooling. Then drops of concentrated lithium bromide (LiBr) solution are allowed to fall into the vessel. The LiBr solution absorbs vaporized refrigerant. Fig. 1-4 Absorbing process (3) When the LiBr solution once absorbs the vaporized refrigerant, it is diluted and loses its ability to absorb. This means that concentrated LiBr solution must be fed in continuously. At this stage, the diluted solution is heated by driving heat source. The heat causes the solution to release the absorbed refrigerant and also re-concentrates the solution.

Fig. 1-5 Concentrating process (4) The refrigerant vapor which is released from the solution when heated, is cooled in a separate chamber (condenser) to become liquid refrigerant. Drops of this water are again introduce into the vacuum vessel and recycled.

Fig. 1-6 Condensing process

(5) This is the basic operational cycle of the single effect type absorption chiller. Cooling water flows thru an absorber and a condenser. The cooling water in the condenser cools the refrigerant vapor from the generator back into refrigerant. The cooling water in the absorber absorbs the heat released by the vaporized refrigerant as it is absorbed by the LiBr solution. Fig. 1-7 Single effect cooling cycle Page 3 / Sec.1 LJ/TJ Series

1-5. Description of each section (1) Evaporator The refrigerant is dispersed on the heat exchanger (transfer) tubes of an evaporator. Chilled water through the tubes is cooled by the latent heat of vaporized refrigerant.

(2) Absorber The concentrated LiBr solution is dispersed on the heat exchanger (transfer) tubes of an absorber. The refrigerant vapor from the evaporator is absorbed into the concentrated LiBr solution on the tubes. Cooling water through the tubes is heated by absorption heat.

Fig. 1-8

(3) Heat exchanger The diluted LiBr solution from the absorber passes through a heat exchanger, where it is heated by a concentrated LiBr solution. The diluted LiBr solution after leaving the heat exchanger flows to the generator.

Fig. 1-9 (4) Generator The diluted LiBr solution from the heat exchanger is heated in a generator. It releases the refrigerant vapor and is concentrated. The solution becomes concentrated LiBr solution.

(5) Condenser The refrigerant vapor from the generator is condensed on the heat exchanger (transfer) tubes of the condenser. Cooling water from the absorber is heated by condensation heat.

(6) Steam drain reclaimer (Only for TJ) The diluted LiBr solution going from the heat exchanger to the generator is heated by the driving steam drain condensed in the generator. Page 4 / Sec.1

Fig. 1-10

LJ/TJ Series

1-6A. Typical cooling cycle on Duhring diagram (LJ) Operation cycle of the single effect type is explained by using the Duhring diagram as follows. (1) A B shows the absorption process in the absorber. The absorbent solution with concentration of 59.5% at point A absorbs the refrigerant vapor coming from the evaporator as it is cooled until 34.2 deg.C (93.6 deg.F) by the cooling water, then the absorbent solution becomes diluted solution with concentration of 55.0% at point B. The pressure between point A and B is 0.84 kPa which is equal to the saturation vapor pressure of water at 4.4 deg.C (39.9 deg.F), so the chilled water at 8 deg.C (46.4 deg.F) can be produced in the evaporator. (2) B C shows temperature rising process of the diluted LiBr solution in the heat exchanger. While the temperature of the diluted LiBr solution passes through the heat exchanger, the diluted LiBr solution receives heat from the concentrated LiBr solution coming from the generator then it' temperature rises up to point C. (3) C D E shows heating and concentrating of the diluted LiBr solution in the generator. The diluted LiBr solution at point C is heated until point D by the driving heat source (hot water). After that, the diluted LiBr solution at point D is more heated then it releases refrigerant vapor. Consequently, it becomes concentrated LiBr solution of 59.5% at point E. (4) E F shows temperature decreasing process of the concentrated LiBr solution in the heat exchanger. While the temperature of the concentrated LiBr solution passes through the heat exchanger, the concentrated LiBr solution gives heat to the diluted LiBr solution coming from the absorber then it' temperature decreases to point F. (5) F A shows that temperature decreasing process of the concentrated solution in the absorber. The concentrated LiBr solution at point F enters into the absorber and is cooled by the cooling water, then it reaches point A which starts to absorb the refrigerant vapor. This processes are continuously repeated to achieve chilled water.
0 Mpa (G)

Pressure (kPa.absolute)

Concentration = 0 % (Water)

Concentration = 55.0 %

6.7

D C

Concentration = 59.5 %

0.84 0 32

B
34.2 93.6

F A
82.8 181 170 deg.C 338 deg.F

Fig. 1-11 Typical cooling cycle on Duhring diagram

Page 5 / Sec.1

LJ Series

1-6B. Typical cooling cycle on Duhring diagram (TJ) Operation cycle of the single effect type is explained by using the Duhring diagram as follows. (1) A B shows the absorption process in the absorber. The absorbent solution with concentration of 63.2% at point A absorbs the refrigerant vapor coming from the evaporator as it is cooled until 36.5 deg.C (97.7 deg.F) by the cooling water, then the absorbent solution becomes diluted solution with concentration of 56.7% at point B. The pressure between point A and B is 0.8 kPa which is equal to the saturation vapor pressure of water at 3.7 deg.C (38.7 deg.F), so the chilled water at 6.7 deg.C (44 deg.F) can be produced in the evaporator. (2) B C shows temperature rising process of the diluted LiBr solution in the heat exchanger. While the temperature of the diluted LiBr solution passes through the heat exchanger, the diluted LiBr solution receives heat from the concentrated LiBr solution coming from the generator then it' temperature rises up to point C. After that time, the diluted solution is more heated by the steam drain reclaimer, then the temperature of diluted solution reaches point C'. (3) C' D E shows heating and concentrating of the diluted LiBr solution in the generator. The diluted LiBr solution at point C' is heated until point D by the driving heat source (steam). After that, the diluted LiBr solution at point D is more heated then it releases refrigerant vapor. Consequently, it becomes concentrated LiBr solution of 63.2% at point E. (4) E F shows temperature decreasing process of the concentrated LiBr solution in the heat exchanger. While the temperature of the concentrated LiBr solution passes through the heat exchanger, the concentrated LiBr solution gives heat to the diluted LiBr solution coming from the absorber then it' temperature decreases to point F. (5) F A shows that temperature decreasing process of the concentrated solution in the absorber. The concentrated LiBr solution at point F enters into the absorber and is cooled by the cooling water, then it reaches point A which starts to absorb the refrigerant vapor. This processes are continuously repeated to achieve chilled water.
0 Mpa (G)

Pressure (kPa.absolute)

Concentration = 0 % (Water)

Concentration = 56.7 %

8.7

D C C'

Concentration = 63.2 %

0.8 0 32

B
36.5 97.7

F A
96.6 205.9 170 deg.C 338 deg.F

Fig. 1-12 Typical cooling cycle on Duhring diagram Page 6 / Sec.1 TJ Series

1-7A. Heat Balance & COP (LJ) (1) Heat balance In order to check whether measured data is correct or not, heat balance is useful.
Basic consideration of the heat balance : Heat amount coming into a chiller = Heat amount going out from a chiller

The above consideration shows by the formula : (Qa + Qc) / (Qe + Qg) = 1 Qe : Heat amount coming into a chiller from an evaporator Qg : Heat amount coming into a chiller from a generator Qa : Heat amount going out from a chiller through an absorber Qc : Heat amount going out from a chiller through a condenser In case of SI unit Qe = (CHi - CHo) X Fe X 1000 / 860 Qg = (Hi - Ho) X Fg X 1000 / 860 Qa + Qc = (COo - COi) X Fc X 1000 / 860 Example CHi = 12.2 deg.C CHo = 6.7 deg.C Fe = 54.5 m /h COi = 29.4 deg.C COo = 38.4 deg.C Fc = 81.8 m3/h Hi = 95.0 deg.C Ho = 86.0 deg.C Fg = 49.8 m /h
3 3

In case of US unit Qe = (CHi - CHo) X Fe X 500 Qg = (Hi - Ho) X Fg X 500 Qa + Qc = (COo - COi) X Fc X 500 Example Qe = 352 kW Qg = 503 kW Qe + Qg = 855 kW Qa + Qc = 851 kW Heat balance = 1.00 CHi = 54 CHo = 44 COi = 85 deg.F deg.F deg.F Qe = 1,200,000 BTU Qg = 1,711,814 BTU Qe + Qg = 2,911,814 BTU Qa + Qc = 2,898,000 BTU Heat balance = 1.00

Fe = 240 gpm COo = 101.1 deg.F Fc = 360 gpm Hi = 203 deg.F Ho = 186.8 deg.F

48.0 ton/h
(at 90.5 deg.C S.G = 0.965) COo Fc

Fg = 219 gpm

211 gpm
(at 194.9 deg.F S.G. = 0.965)

Condense

Generator

Ho Fg Hi Driving hot water

Qc

Qg

CHo Fe CHi Chilled water

Evaporator

Absorber

Qe

Qa

COi Cooling water

(2) COP COP is shown by the following formula. COP of LJ series is about 0.7 under the condition of the standard COP = Qe Qg specification. This value changes depending on required specifications. When a operation data is recorded, if its COP differs very much from the COP of specifications, it may be wrong data recording or insufficient cooling performance of a chiller. Remark: In case of calculating heat balance and COP, cooling water inlet temperature and cooling load shall be stable for minimum 10 to 15 minutes. Because the response of absorption chiller is not rapid as compared with a electric type chiller.

Page 7 / Sec.1

LJ Series

1-7B. Heat Balance & COP (LJ) (1) Heat balance In order to cheek whether measured data is correct or not, heat balance is useful.
Basic consideration of the heat balance : Heat amount coming into a chiller = Heat amount going out from a chiller

The above consideration shows by the formula : (Qa + Qc) / (Qe + Qg) = 1 Qe : Heat amount coming into a chiller from an evaporator Qg : Heat amount coming into a chiller from a generator Qa : Heat amount going out from a chiller through an absorber Qc : Heat amount going out from a chiller through a condenser CHi,CHo,COi & COo : Temperature Hi : Enthalpy of driving steam pressure Ho : Enthalpy of steam drain temperature In case of SI unit Qe = (CHi - CHo) X Fe X 1000 / 860 Qg = (Hi - Ho) X Fg / 3600 Qa + Qc = (COo - COi) X Fc X 1000 / 860 Example CHi = 12.2 deg.C CHo = 6.7 deg.C Fe = 54.5 m /h COi = 29.4 deg.C COo = 38.4 deg.C Fc = 81.8 m /h Hi = 2706 kJ/kg Ho = 398 kJ/kg Fg = 780 kg/h
COo Fc
3 3

In case of US unit Qe = (CHi - CHo) X Fe X 500 Qg = (Hi - Ho) X Fg Qa + Qc = (COo - COi) X Fc X 500 Example Qe = 352 kW Qg = 500 kW Qe + Qg = 852 kW Qa + Qc = 851 kW Heat balance = 1.00 (at 100 kPaG) (at 95 deg.C) CHi = 54 CHo = 44 COi = 85 deg.F deg.F deg.F Qe = 1,200,000 Btu Qg = 1,706,240 Btu Qe + Qg = 2,906,240 Btu Qa + Qc = 2,898,000 Btu Heat balance = 1.00 (at 15 psig) (at 203 deg.F)

Fe = 240 gpm COo = 101.1 deg.F Fc = 360 gpm Hi = 1163 Btu/lb Ho = 171 Btu/lb Fg = 1720 lb/h
Condense Generator Hi

Driving steam Fg

Qc

Qg

Ho

CHo Fe CHi

Evaporator

Absorber

Qe

Qa

COi Cooling water

(2) COP Qe Qg

Chilled water

COP is shown by the following formula. COP of TJ series is about 0.7 under the condition of the standard COP = specification. This value changes depending on required specifications. When a operation data is recorded, if its COP differs very much from the COP of specifications, it may be wrong data recording or insufficient cooling performance of a chiller. Remark: In case of calculating heat balance and COP, cooling water inlet temperature and cooling load shall be stable for minimum 10 to 15 minutes. Because the response of absorption chiller is not rapid as compared with a electric type chiller.

Page 8 / Sec.1

TJ Series

Pipe for non-condensable gas going from lower shell (Abso + Evap) to purge unit

Pipe for diluted LiBr solution to purge from absorbent pump to purge unit

DT 16

DT 14

Scope of customer

Rupture disk

Cooling water outlet SV7

63 GH

DT2

Driving hot water outlet

Pipe for non-condensable gas going from upper shell (Cond + Gene) to lower shell (Abso + Evap)

Condenser Generator D
DT 15

2-1A. Flow diagram of LJ series

69 PR

PCH

DT5

Driving hot water inlet

SV9
DT12 DT3

Purge tank

Diluted LiBr solution pipe Concentrated LiBr solution pipe Refrigerant solution pipe Condensed refrigerant solution pipe DT1 : Chilled water outlet temp. sensor

Section 2 Flow diagram & Illustration

V3

V2

B valve

DT1

Chilled water outlet

69 CH

DT2 : Cooling water outlet temp. sensor DT3 : Generator temp. sensor DT5 : Condenser temp. sensor

Non-condensable gas

Cooling water inlet

Page 1 / Sec.2

SV2

DT6

SV1

Chilled water inlet

Evaporator Absorber

DT6 : Chilled water inlet temp. sensor DT7 : Cooling water inlet temp. sensor DT10 : Absorbent temp. sensor DT11 : Evaporator temp. sensor DT12 : Middle cooling water temp. sensor

V1

DT11

DT14 : Hot water outlet temp. sensor DT15 : Hot water inlet temp. sensor DT16 : Hot water outlet temp. sensor PCH : Palladium cell heater

Purge unit

SV3 Refrigerant blow valve

63GH : Generator pressure switch 69PR : Purge tank pressure switch

DT7 DT10

F
SV6

69CH : Chilled water flow switch

Diluted LiBr solution damper SV4 Absorbent pump

U-seal pipe

Purge pump Refrigerant pump

C
Heat exchanger

Check valve Orifice

Isolation valve for Abso. & Refr. pumps Pipe for concentrated LiBr solution over-flow from generator to absorber at part load or occurring crystallization

Fig. 2-1 Flow diagram

Return pipe for diluted LiBr solution to purge

Service valve Diaphragm valve for purge

LJ Series

Pipe for non-condensable gas going from lower shell (Abso + Evap) to purge unit

Pipe for diluted LiBr solution to purge from absorbent pump to purge unit

Scope of customer
Rupture disk

Steam inlet

Cooling water outlet SV7

63 GH

DT2

Pipe for non-condensable gas going from upper shell (Cond + Gene) to lower shell (Abso + Evap)

Condenser Generator D E C'

2-1B. Flow diagram of TJ series

Steam drain heat exchanger

69 PR

PCH

DT5

DT 13

Steam drain outlet

SV9
DT12 DT3

Purge tank

Section 2 Flow diagram & Illustration

Diluted LiBr solution pipe Concentrated LiBr solution pipe Refrigerant solution pipe Condensed refrigerant solution pipe DT1 : Chilled water outlet temp. sensor DT2 : Cooling water outlet temp. sensor DT3 : Generator temp. sensor DT5 : Condenser temp. sensor

V3

V2

B valve

DT1

Chilled water outlet

69 CH

Non-condensable gas

Cooling water inlet

Page 2 / Sec.2

SV2

DT6

SV1

Chilled water inlet

Evaporator Absorber

DT6 : Chilled water inlet temp. sensor DT7 : Cooling water inlet temp. sensor DT10 : Absorbent temp. sensor DT11 : Evaporator temp. sensor DT12 : Middle cooling water temp. sensor

V1

DT11

DT13 : Steam drain temp. sensor PCH : Palladium cell heater 63GH : Generator pressure switch 69PR : Purge tank pressure switch

Purge unit

SV3 Refrigerant blow valve

69CH : Chilled water flow switch

DT7 DT10

F
SV6

Damper Check valve Orifice SV4 Absorbent pump

U-seal pipe Pipe for concentrated LiBr solution over-flow from generator to absorber at part load or occurring crystallization

Purge pump Refrigerant pump

C
Heat exchanger

Isolation valve for Abso. & Refr. pumps

Service valve Diaphragm valve for purge

Fig. 2-1 Flow diagram

Return pipe for diluted LiBr solution to purge

TJ-Series

2-2A. Illustration of chiller (LJ)

Fig. 2-2

Fig. 2-3 Page 3 / Sec. 2 LJ Series

2-2B. Illustration of chiller (TJ)

Fig. 2-2

Fig. 2-3 Page 4 / Sec. 2 TJ Series

2-3. Control panel 2-3-1. For UL

Fig. 2-4 Front and Side view CAUTION : Do not push the emergency stop button except an emergency. If push, the chiller stops without dilution operation. This may be possible to occur crystallization problem. IP No. of control panel : 54 Function of each parts Fan Terminal block
Terminal block for power supply

: To cool inside control panel : To connect wires coming from the box side and panel side : To connect power wires coming from power source : To connect the wire for grounding : To operate chiller and to indicate operation data, alarm code, etc The microprocessor (CPU) is furnished at the back of the operation board. : To give a sign by the buzzer when an alarm happened : To indicate conducting purge : To operate purge pump : To stop the chiller at an emergency

Ground terminal Operation board Alarm buzzer Purge indication lamp Purge pump on-off switch Emergency stop button

Page 5 / Sec. 2

LJ/TJ Series

Fig. 2-5 Inside view Function of each parts Control relay Circuit protector : To output signals made in the microprocessor : To cut the power off supplied to the palladium cell heater, the fan, generator pressure switch and a hot water(LJ) / steam(TJ) control valve motor if over-current happened in the circuits I/O board Main circuit breaker Transformer Electricmagnetic contactor Fuse : To transfer ON/OFF signals to the microprocessor as an interface : To protect the control circuit of the chiller at over-current : To change voltage from 400 volts to required voltage in the control circuit : To ON & OFF pumps and cutting power off of the pumps at over-current : To cut the power off at over-current

Page 6 / Sec. 2

LJ/TJ Series

2-3-2. For CE

Fig. 2-6 Front and Side view IP No. of control panel : 54 Function of each parts Fan Terminal block
Terminal block for power supply

: To cool inside control panel : To connect wires coming from the box side and panel side : To connect power wires coming from power source : To connect the wire for grounding : To operate chiller and to indicate operation data, alarm code, etc The microprocessor (CPU) is furnished at the back of the operation board. : To give a sign by the buzzer when an alarm happened : To indicate conducting purge : To operate purge pump : To cut power off when the panel door is opened

Earth terminal Operation board Alarm buzzer Purge indication lamp Purge pump on-off switch Operation handle

Page 7 / Sec. 2

LJ/TJ Series

Fig. 2-7 Inside view Function of each parts Control relay Circuit protector : To output signals made in the microprocessor : To cut the power off supplied to the palladium cell heater, the fan, generator pressure switch and a hot water(LJ) / steam(TJ) control valve motor if over-current happened in the circuits Terminal block I/O board Circuit breaker Main circuit breaker Transformer Electricmagnetic contactor Filter : To connect wires coming from the box side and panel side : To transfer ON/OFF signals to the microprocessor as an interface : To protect high voltage circuit at over-current : To protect the control circuit of the chiller at over-current : To change voltage from 400 volts to required voltage in the control circuit : To ON & OFF pumps and cutting power off of the pumps at over-current : To cut noise off coming from power line

Page 8 / Sec. 2

LJ/TJ Series

2-3-3. Operation board

Fig. 2-8 Operation board Circle 1 thru 13 are indication lamps which show operating conditions. CHILLER ABS PUMP REF PUMP PURGE PUMP STAND BY DILUTION SAFETY CIRCUIT CHILLER ALARM POWER & SET BACK BUZZER STOP REMOTE LOCAL STOP RUN keys : If Circle 1 lights up, it means that the chiller is shut-down : If Circle 5 lights up, it means that the chiller is running : If Circle 2 lights up, it means that the absorbent stops : If Circle 6 lights up, it means that the absorbent pump is running : If Circle 3 lights up, it means that the refrigerant stops : If Circle 7 lights up, it means that the refrigerant pump is running : If Circle 4 lights up, it means that the purge stops : If Circle 8 lights up, it means that the purge pump is running : If Circle 9 lights up, it means that the chiller is waiting for the interlock signals of a chilled water and cooling water pumps. : If Circle 10 lights up, it means that the chiller is in dilution operation. : If Circle 11 lights up, it means that the power is coming to the control circuit. : If Circle 12 lights up, it means that some alarm occurs : If Circle 13 lights up, it means that the power is coming to the control circuit. : To change data display and every setting value : To change menu displayed and set new value : To return menu displayed : To stop the alarm buzzer : To select remote operation mode : To select local operation mode : To stop the chiller : To run the chiller Page 9 / Sec. 2 LJ/TJ Series

2-4A. Temperature sensor (LJ) TSA-16LJ series uses 3 type temperature sensors. One is Resistance thermometer bulb, second one is Thermistor, last one is Digital sensor. 2-4-1. Resistance thermometer bulb

Dia.5.5mm 0.2 inch

50mm / 1.97 inch Fig. 2-9 : AEK-23H520

2100

80

mm / 82.68

3.15

inch

Model Used for

: Chilled water outlet temperature sensor (DT1) Rating of resistance : 8.56/deg.C Ex. 2256.8 at 30 deg.C (86 deg.F)

Resistance : 2000 at 0 deg.C (32 deg.F)

2-4-2. Thermistor

Dia.60.5 mm 0.250.02 inch

1503 mm 5.90.12 inch

about 36 mm 1.42 inch Fig. 2-10

2500150mm 98.45.9 inch

Model Used for

: U1SC-D312-S2 : Generator temperature sensor (DT3)

Resistance : 1k3% at 200 deg.C (392 deg.F) Temperature & Resistance Table Temperature Deg. C Deg. F 0 30 40 50 60 70 80 90 100 200 32 86 104 122 140 158 176 194 212 392 Resistance k ohm 806.5 184.1 118.7 78.3 52.8 36.3 25.4 18.1 13.1 1.0

Page 10 / Sec. 2

LJ Series

2-4-3. Digital sensor

Dia.70.5 mm 0.280.02

502mm/1.970.08 inch

100020mm / 39.40.79 inch: SEC-SSH-SST01SAC-L1000 200050mm / 78.71.97 inch : SEC-SSH-SST01SAC

Fig.2-11 : SEC-SSH-SST01SAC-L1000 & SEC-SSH-SST01SAC : Cooling water outlet temperature sensor (DT2) : Condenser temperature sensor (DT5) : Chilled water inlet temperature sensor (DT6) : Cooling water inlet temperature sensor (DT7) : Absorber temperature sensor (DT10) : Evaporator temperature sensor (DT11) : Middle cooling water temperature sensor (DT12) : Hot water outlet temperature sensor (DT14) : Hot water outlet temperature sensor (DT16)

Model Used for

IC tip provided in the digital sensor detects temperature and send it's data to CPU board through the communication line as shown below. Addresses are provided in each digital sensors. If a digital sensor is replaced, it's address must be confirmed. Control panel CPU Board Communication line Digital sensor Digital sensor Digital sensor

Address Symbol 03 05 01 02 12 08 04 10 09 11 DT2 DT5 DT6 DT7

Sensor Name Cooling water outlet temperature sensor Condenser temperature sensor Chilled water inlet temperature sensor Cooling water inlet temperature sensor

DT10 Absorber temperature sensor DT11 Evaporator temperature sensor DT12 Middle cooling water temperature sensor DT14 Hot water outlet temperature sensor DT15 Hot water inlet temperature sensor DT16 Hot water outlet temperature sensor

Page 11 / Sec. 2

LJ Series

2-4-4 Purge tank pressure sensor (PHI) 41.3 mm(1.63inch) Connected pin No. 41.3 mm(1.63inch) Model Total accuracy Max. working pressure : FSK-S17 : +/- 3% FS (-10 --- 50 deg.C) (12 -- 122 deg.F)
3 2 1

: 0.15 MPa (G)

GND 3

Volt 2

Vc 1

Connection Sensor 46mm(1.811inch) 1 Vc DC 10.5 - 28V 2

Volt

7/16-20UNF Flare 3 Fig. 2-12 GND

Page 12 / Sec. 2

LJ Series

2-4B. Temperature sensor (TJ) TSA-16TJ series uses 3 type temperature sensors. One is Resistance thermometer bulb, second one is Thermistor, last one is Digital sensor. 2-4-1. Resistance thermometer bulb

Dia.5.5mm 0.2 inch

50mm / 1.97 inch Fig. 2-9 : AEK-23H520

2100

80

mm / 82.68

3.15

inch

Model Used for

: Chilled water outlet temperature sensor (DT1) Rating of resistance : 8.56/deg.C Ex. 2256.8 at 30 deg.C (86 deg.F)

Resistance : 2000 at 0 deg.C (32 deg.F)

2-4-2. Thermistor

Dia.60.5 mm 0.250.02 inch

1503 mm 5.90.12 inch

about 36 mm 1.42 inch Fig. 2-10

2500150mm 98.45.9 inch

Model Used for

: U1SC-D312-S2 : Generator temperature sensor (DT3)

Resistance : 1k3% at 200 deg.C (392 deg.F) Temperature & Resistance Table Temperature Deg. C Deg. F 0 30 40 50 60 70 80 90 100 200 32 86 104 122 140 158 176 194 212 392 Resistance k ohm 806.5 184.1 118.7 78.3 52.8 36.3 25.4 18.1 13.1 1.0

Page 13 / Sec. 2

LJ Series

2-4-3. Digital sensor

Dia.70.5 mm 0.280.02

502mm/1.970.08 inch

100020mm / 39.40.79 inch: SEC-SSH-SST01SAC-L1000 200050mm / 78.71.97 inch : SEC-SSH-SST01SAC

Fig.2-11

Model Used for

: SEC-SSH-SST01SAC-L1000 & SEC-SSH-SST01SAC : Cooling water outlet temperature sensor (DT2) : Condenser temperature sensor (DT5) : Chilled water inlet temperature sensor (DT6) : Cooling water inlet temperature sensor (DT7) : Absorber temperature sensor (DT10) : Evaporator temperature sensor (DT11) : Middle cooling water temperature sensor (DT12)

IC tip provided in the digital sensor detects temperature and send it's data to CPU board through the communication line as shown below. Addresses are provided in each digital sensors. If a digital sensor is replaced, it's address must be confirmed. Control panel CPU Board Communication line Digital sensor Digital sensor Digital sensor

Address Symbol 03 05 01 02 12 08 04 06 DT2 DT5 DT6 DT7

Sensor Name Cooling water outlet temperature sensor Condenser temperature sensor Chilled water inlet temperature sensor Cooling water inlet temperature sensor

DT10 Absorber temperature sensor DT11 Evaporator temperature sensor DT12 Middle cooling water temperature sensor DT13 Steam drain temperature sensor

Page 14 / Sec. 2

LJ Series

2-4-4 Purge tank pressure sensor (PCH) 41.3 mm(1.63inch) Connected pin No. 41.3 mm(1.63inch) Model Total accuracy Max. working pressure : FSK-S17 : +/- 3% FS (-10 --- 50 deg.C) (12 -- 122 deg.F)
3 2 1

: 0.15 MPa (G)

GND 3

Volt 2

Vc 1

Connection Sensor 46mm(1.811inch) 1 Vc DC 10.5 - 28V 2

Volt

7/16-20UNF Flare 3 Fig. 2-12 GND

Page 15 / Sec. 2

LJ Series

2-5. Principal of purging

Purpose of the purging In order to achieve stable required chilled water outlet temperature for an absorption chiller, vacuum condition of the chiller is most important factor. During operating the chiller, a little amount of Hydrogen gas generate. If Hydrogen gas exist in the chiller, it causes to rise inside pressure of the chiller and the chilled water outlet temperature can not go down to required temperature, as a result. When the chiller is new, non-condensable gases such as dissolved oxygen being in absorbent solution & refrigerant and absorbed oxygen being on the inner surface of chiller appears during operation. They cause above condition too. They must be released from the inside of chiller to the air by the purging.

Purging system The purge system is consists of 2 principals for purging. One is Volume moving with fluid ejector, another is Palladium cell. They are explained as follows.

2-5-1. Volume moving with fluid ejector

When the LiBr solution gushing out from the ejector goes into the solution level B, it involves bubbles of non-condensable gas. The LiBr solution Lower shell A
Ejector LiBr solution from Absorbent pump

and the gas together come down to Non-condensable gas

from the inside of

the bottom of the tank.

Non-condensable gas purged by a purge Fluid gushing out from ejector

comes up and accumulates in the tank. The volume of non-condensable gas existing in the lower shell which is equal to the gas accumulated in the tank moves to A from the lower shell.
LiBr solution

Tank

The LiBr solution returns to the absorber, and the gas

By means that the above is continuously repeated during operation of the chiller, non-condensable gas existing in the chiller is accumulated in the tank then the gas can be purged by the purge pump to the air. Page 16 / Sec. 2 Fig.2-12

Non-condensable bubbles

LJ/TJ Series

2-5-2. Palladium cell

The palladium film has a property to permeate Hydrogen gas when it is 300 - 500 deg.C (572 deg.F - 932 deg.F).

Steps that Hydrogen permeates through the palladium are as follows. 1) Hydrogen is absorbed on the surface of the palladium by an affinity. 2) Absorbed hydrogen dissociates and loss an electron then it becomes a proton.
3) The proton invades into the grid of palladium and it diffuses in the palladium by the difference of hydrogen density.

4) The proton returns hydrogen gas state and goes out to outside. Other gases which can not dissociate with a proton - electron state can not permeate in the palladium film.

Hydrogen gas

P1

P2

Permeation Hydrogen

Palladium film (heated to 200 - 300 deg.C) P1 > P2 P1 : Density of hydrogen before palladium film P2 : Density of hydrogen after palladium film Fig.2-13

Page 17 / Sec. 2

LJ/TJ Series

2-6. Internal structure 2-6-1. Upper shell

Tube sheet Shell Eliminator

Tube support Condenser tube Purge tank Generator tube Baffle

Shell

Tube sheet

Page 18 / Sec. 2

LJ/TJ Series

2-6-2. Lower shell

Shell

Tube sheet Evaporator tube

Refrigerant tray Absorbent tray Tube support Absorber tube

Sight glass

Eliminator

Tube sheet

Page 19 / Sec. 2

LJ/TJ Series

2-6-3. Heat exchanger

Baffle Shell Header Tube

Tube sheet Header

Tube sheet

Page 20 / Sec. 2

LJ/TJ Series

Section 3 Installation
3-1. Safety Precautions Before operating the chiller, read thoroughly the following precautions. Following precautions are classified into either WARNING or CAUTION. WARNING: Wrong operation may causes serious injury or death. CAUTION : Wrong operation may causes an injury or failure of the chiller. However serious injury or death may occur depending on circumstances. < Explanatory notes > symbol shows WARNING or CAUTION. symbol shows action prohibited. symbol shows action to be conducted. (1) For safety use

WARNING
TURN OFF THE BREAKER BEFORE CLEANING AND STOP OPERATION OF THE CHILLER IN CASE OF CHECKING Turn off the breaker before cleaning and checking of a cooling tower, chilled water pump, cooling water pump for the chiller to avoid electric shocks and/or injuries. Must be conducted FIRE, EARTHQUAKE OR POSSIBLE THUNDERBOLT Stop operation of the chiller in case of fire or earthquake or when there is likely to be a thunderbolt to prevent an accident. Must be conducted

DO NOT OPERATE SWITCHES IN THE CONTROL PANEL WITH WET HANDS Do not operate switches in the control panel with wet hands to avoid electric shocks. Do not operate

DO NOT TOUCH WIRINGS IN THE CONTROL PANEL Do not touch wirings in the control panel to avoid electric shocks. Do not touch

DO NOT TOUCH ANY ROTATING PART WHILE IT IS RUNNING Keep away fingers from any rotating and/or moving parts while it is running to avoid an injury. Prohibited

VENTILATE MACHINE ROOM Ventilate the machine room during discharging Nitrogen gas to avoid accident of anoxia. Must be conducted
VENTILATION

Page 1 / Sec.3

LJ/TJ Series

CAUTION
REMOVE CAUSES OF AN TROUBLE BEFORE RESTARTING THE CHILLER Remove causes of a trouble due to a safety device before restarting the chiller to avoid accident. Must be conducted Prohibited DO NOT PUT HEAVY OBJECTS ON THE CHILLER OR CONTROL PANEL Do not put heavy objects on the chiller or control panel to avoid an injury due to falling.

DO NOT CLIMB UP THE CHILLER Do not climb up the chiller to avoid accident due to falling down. Prohibited

DO NOT POUR WATER TO THE CHILLER AND/OR CONTROL PANEL Do not pour water to the chiller and/or control panel to avoid electric accident. Prohibited

USE THE CORRECT POWER SUPPLY Be sure to use the correct power supply described in the specification plate on the control panel. Prohibited Incorrect power causes an accident such as fire.
What Voltag

AUTHORIZED PERSON ONLY A notice "For Authorized Person Only" must be provided by the chiller to avoid any accident caused by wrong operation due to unauthorized person. Must be conducted DO NOT TOUCH ABSORBENT SOLUTION Do not touch absorbent solution. It may give damage of skin. If touching, wash thoroughly with water. If the solution Prohibited comes into an eye, wash with water immediately and take

NEVER CHANGE THE SET VALUE Never change the set value of safety devices. Wrong setting may cause failure and/or damage of the chiller and accident. Prohibited

medical examination soon. DO NOT TOUCH HIGH TEMPERATURE PORTIONS CHECK THE PRESSURE OF CHILLED & COOLING WATER LINE Do not touch high temperature portions to prevent a burn These portion are Prohibited shown by caution labels. Check the operating pressure of chilled & cooling water line at daily maintenance. Over-pressure may cause water leakage. Must be conducted

Page 2 / Sec.3

LJ/TJ Series

STOP A PURGE PUMP TO REPLACE OIL Stop the purge pump at replacing oil to avoid an injury. Must be conducted

STOP

(2) Safety precautions for overhaul, moving and scrapping

WARNING
OVERHAUL OF THE CHILLER SHALL BE DONE BY AUTHORIZED PERSON ONLY. Overhaul and repair of the chiller shall be conducted by authorized person only. Incomplete maintenance cause failure and/or damage of the chiller and may cause an accident such as fire. Prohibited

CAUTION
MOVING WORK OF THE CHILLER SHALL BE DONE SCRAPPING OF THE CHILLER SHALL BE DONE BY AUTHORIZED PERSON ONLY. Moving work including installation and relocation shall be done by authorized person having official license only to avoid accident. BY AUTHORIZED COMPANY ONLY. Scrapping of the chiller including absorbent solution management shall be done by authorized company having official license only to avoid accident and environmental pollution.

Page 3 / Sec.3

LJ/TJ Series

3-2A. Installation check list (LJ) This installation check list is covers the installation of LJ model. This check list is intend to assist the Carrier service engineer with the details required with the installation of the Carrier/SANYO chiller. Project name Chiller model Serial number Accepted by Reviewed by Recorded by Contents 1. Delivery inspection 2. Location and space requirements 3. Leveling verification 4. Piping (Chilled water, cooling water, and hot water) 5. Field electric wiring 6. Megger test 7. Confirmation of nitrogen pressure in the unit 8. Leak test (If necessary) 9. Inspection of purge pump / purging 10. Bubble test 11. Time setting 12. Battery backup 13. Temperature unit change 14. Remote operation signal setting 15. Field insulation instruction 16. Confirmation of setting menu and service mode 17. Function test of modulating controls 18. Aging process 19. Refrigerant Blow down 20. Preparation of trial run 1. Delivery inspection (1) Specifications of unit ordered vs. unit nameplate (2) Lower shell (3) Upper shell (4) Heat exchangers (5) Evaporator headers (6) Absorber headers (7) Condenser headers (8) Generator headers (9) Control panel (10) Absorption pomp and its isolation valves (11) Refrigerant pump and isolation valves (12) Temperature sensors (DT1, DT2, DT3, DT5, DT6, DT'7, DT10, DT11, DT12, DT14, DT15, DT16) (13) Generator pressure switch(63GH) and service valve (SV7)
(14) Purge unit (V1, V2, V3, B, SV1, SV2, SV9, Liquid trap) and purge pump

: :TSA-16LJ: : : : , date , date , date

:Yes :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage

No Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged

Page 4 / Sec.3

LJ Series

(15) Chilled water flow switch (69CH) (16) Refrigerant blow valve (17) Purge tank pressure sensor (69PR) (18) Palladium cells and Heater (PCH) (19) Service valve (SV3, SV4, SV6) 2. Location and space requirements (1) Location (Basement, Floor, Roof) (2) Foundation (3) Clearance for maintenance (4) Clearance for tube cleaning/removal

:No-damage :No-damage :No-damage :No-damage :No-damage

Damaged Damaged Damaged Damaged Damaged

:Yes :Yes :Yes :Yes

No No No No

3. Leveling verification (1) Leveling A (Evaporator side) W : Width of chiller leg (Absorber side) C L :Length between chiller legs Point Difference A-B L B-C L = A 0 mm 0 inch B mm inch L A-C W 2 1000 C mm inch C-D = D mm inch L mm inch L B-D W W mm inch A-D = D B

Tolerance

(1/4 inch) (20feet)

:Yes No

(2) Fix anchor bolts

4. Piping (Chilled water, cooling water, and hot water) (1) Chilled water piping connection (2) Cooling water piping connection (3) Hot water piping connection (4) Chilled water pump(s) installation (5) Cooling water pump(s) installation (6) Hot water pump(s) installation (7) Cooling tower(s) installation (8) Chilled water line flashing (9) Cooling water line flashing (10) Hot water line flashing Page 5 / Sec.3 :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes No No No No No No No No No No LJ Series

5. Field electric wiring (1) (2) (3) (4) (5) (6) (7) (8) (9) Cooling water pump interlock (#121-#170) Chilled water pump interlock (#120-#170) Prealarm signal (#334-#335) Remote check signal (#336-#337) Hot water shutoff valve (#347-#348) Operation indication (#350-#351) Stop indication (#352-#353) Alarm indication (#354-#355) Chilled water pump (#356-#357) :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes No No No No No No No No No No No No No No No No No No No No No No N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

(10) Cooling water pump (#358-#359) (11) Cooling tower fan (#360-#361) (12) Answer back indication (#362-#363) (13) Dilution indication (#368-#369) (14) Hot water pump (#370-#371) (15) Alarm buzzer (#382-#383) (16) Purge indication (#384-#385) (17) Run/stop remote signal (#323-#326) (18) Grounding/Earth (#G/PE) (19) Wiring of palladium cell heater For 460V and 400V: #232 and #0B in the control panel. For 208V: #232 and #202 in the control panel. (20) Remote setting signal (#732-#733)

6. Megger test Standard : More than 10 M ohms (1) Absorbent pump (2) Refrigerant pump (3) Purge pump : : : M ohms Good M ohms Good M ohms Good No-good---->Repaired No-good---->Repaired No-good---->Repaired Replaced Replaced Replaced

NOTE : Do not apply this test to an inverter and an electronic controller.

7. Confirmation of nitrogen pressure in the unit Unit leakage pressure calculation (P) P=(P1 + 101.3) x Where: P = Calculated pressure P1 = Pressure from factory P2 = Pressure measured t1 = Ambient temperature at factory t2 = Ambient temperature at site There is no leak if P2 is nearly equal to P. kPa kPa kPa
o o

t2 + 273 t1 + 273

-101.3

C C :Yes No

Page 6 / Sec.3

LJ Series

8. Leak test (If necessary) Unit leakage pressure calculation (P) P=(P1 + 101.3) x Where: P = Calculated pressure P1 = Pressure at now P2 = Pressure measured t1 = Ambient temperature at now t2 = Ambient temperature at least 8 hours There is no leak if P2 is nearly equal to P. kPa kPa kPa
o o

t2 + 273 t1 + 273

-101.3

C C :Yes No

9. Inspection of purge pump / purging (1) Purge pump (2) Purging :Yes :Yes No No

10. Bubble test Table 3-12-1 Bubble test standard value

Model 16LJ11 12 13 14 21 22 23 24 31 32 41 42 51 52 53 Pass

Standard value Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than 15 15 15 15 25 25 25 30 30 30 40 40 45 45 50 cc (0.92 cubic inch) cc (0.92 cubic inch) cc (0.92 cubic inch) cc (0.92 cubic inch) cc (1.53 cubic inch) cc (1.53 cubic inch) cc (1.53 cubic inch) cc (1.83 cubic inch) cc (1.83 cubic inch) cc (1.83 cubic inch) cc (2.44 cubic inch) cc (2.44 cubic inch) cc (2.75 cubic inch) cc (2.75 cubic inch) cc (3.05 cubic inch) per per per per per per per per per per per per per per per 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 min. min. min. min. min. min. min. min. min. min. min. min. min. min. min.
:Yes No

11. Time setting Pass 12. Battery backup Pass :Yes No :Yes No

Page 7 / Sec.3

LJ Series

13. Temperature unit change Pass 14. Remote operation signal setting Pass 15. Field insulation instruction Pass 16. Confirmation of setting menu and service mode Pass 17. Function test of modulating controls Pass 18. Aging process Pass 19. Refrigerant Blow down Pass 20. Preparation of trial run (1) Unit and auxiliary equipment operating in an automatic mode. (2) Hot water valve adjusted for design input. (3) Refrigerant in the evaporator less than 3% LiBr. (4) Chilled, cooling, and hot water flows at design. (5) Chilled, cooling, and hot water temperatures at design. (6) Confirm valves position. :Yes :Yes :Yes :Yes :Yes :Yes No No No No No No :Yes No :Yes No :Yes No :Yes No :Yes No :Yes No :Yes No

Page 8 / Sec.3

LJ Series

3-2B. Installation check list (TJ) This installation check list is covers the installation of LJ model. This check list is intend to assist the Carrier service engineer with the details required with the installation of the Carrier/SANYO chiller. Project name Chiller model Serial number Accepted by Reviewed by Recorded by Contents 1. Delivery inspection 2. Location and space requirements 3. Leveling verification 4. Piping (Chilled water, cooling water, and steam) 5. Field electric wiring 6. Megger test 7. Confirmation of nitrogen pressure in the unit 8. Leak test (If necessary) 9. Inspection of purge pump / purging 10. Bubble test 11. Time setting 12. Battery backup 13. Temperature unit change 14. Remote operation signal setting 15. Field insulation instruction 16. Confirmation of setting menu and service mode 17. Function test of modulating controls 18. Aging process 19. Refrigerant Blow down 20. Preparation of trial run 1. Delivery inspection (1) Specifications of unit ordered vs. unit nameplate (2) Lower shell (3) Upper shell (4) Heat exchangers (5) Evaporator headers (6) Absorber headers (7) Condenser headers (8) Generator headers (9) Control panel (10) Absorption pomp and its isolation valves (11) Refrigerant pump and isolation valves (12) Temperature sensors (DT1, DT2, DT3, DT5, DT6, DT7, DT10, DT11, DT12) (13) Generator pressure switch(63GH) and service valve (SV7)
(14) Purge unit (V1, V2, V3, B, SV1, SV2, SV9, Liquid trap) and purge pump

: :TSA-16TJ: : : : , date , date , date

:Yes :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage :No-damage

No Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged Damaged

Page 9 / Sec.3

TJ Series

(15) Chilled water flow switch (69CH) (16) Refrigerant blow valve (17) Purge tank pressure sensor (69PR) (18) Palladium cells and Heater (PCH) (19) Service valve (SV3, SV4, SV6) 2. Location and space requirements (1) Location (Basement, Floor, Roof) (2) Foundation (3) Clearance for maintenance (4) Clearance for tube cleaning/removal

:No-damage :No-damage :No-damage :No-damage :No-damage

Damaged Damaged Damaged Damaged Damaged

:Yes :Yes :Yes :Yes

No No No No

3. Leveling verification (1) Leveling A (Evaporator side) W : Width of chiller leg (Absorber side) C L :Length between chiller legs Point Difference A-B L B-C L = A 0 mm 0 inch B mm inch L A-C W 2 1000 C mm inch C-D = D mm inch L mm inch L B-D W W mm inch A-D = D B

Tolerance

(1/4 inch) (20feet)

:Yes No

(2) Fix anchor bolts

4. Piping (Chilled water, cooling water, and steam) (1) Chilled water piping connection (2) Cooling water piping connection (3) Steam piping connection (4) Chilled water pump(s) installation (5) Cooling water pump(s) installation (6) Cooling tower(s) installation (7) Chilled water line flashing (8) Cooling water line flashing (9) Steam line flashing :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes No No No No No No No No No

Page 10 / Sec.3

TJ Series

5. Field electric wiring (1) (2) (3) (4) (5) (6) (7) (8) (9) Cooling water pump interlock (#121-#170) Chilled water pump interlock (#120-#170) Prealarm signal (#334-#335) Remote check signal (#336-#337) Steam shutoff valve (#347-#348) Operation indication (#350-#351) Stop indication (#352-#353) Alarm indication (#354-#355) Chilled water pump (#356-#357) :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes :Yes No No No No No No No No No No No No No No No No No No No No No No N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

(10) Cooling water pump (#358-#359) (11) Cooling tower fan (#360-#361) (12) Answer back indication (#362-#363) (13) Dilution indication (#368-#369) (14) Hot water pump (#370-#371) (15) Alarm buzzer (#382-#383) (16) Purge indication (#384-#385) (17) Run/stop remote signal (#323-#326) (18) Grounding/Earth (#G/PE) (19) Wiring of palladium cell heater For 460V and 400V: #232 and #0B in the control panel. For 208V: #232 and #202 in the control panel. (20) Remote setting signal (#732-#733)

6. Megger test Standard : More than 10 M ohms (1) Absorbent pump (2) Refrigerant pump (3) Purge pump : : : M ohms Good M ohms Good M ohms Good No-good---->Repaired No-good---->Repaired No-good---->Repaired Replaced Replaced Replaced

NOTE : Do not apply this test to an inverter and an electronic controller.

7. Confirmation of nitrogen pressure in the unit Unit leakage pressure calculation (P) P=(P1 + 101.3) x Where: P = Calculated pressure P1 = Pressure from factory P2 = Pressure measured t1 = Ambient temperature at factory t2 = Ambient temperature at site There is no leak if P2 is nearly equal to P. kPa kPa kPa
o o

t2 + 273 t1 + 273

-101.3

C C :Yes No

Page 11 / Sec.3

TJ Series

8. Leak test (If necessary) Unit leakage pressure calculation (P) P=(P1 + 101.3) x Where: P = Calculated pressure P1 = Pressure at now P2 = Pressure measured t1 = Ambient temperature at now t2 = Ambient temperature at least 8 hours There is no leak if P2 is nearly equal to P. kPa kPa kPa
o o

t2 + 273 t1 + 273

-101.3

C C :Yes No

9. Inspection of purge pump / purging (1) Purge pump (2) Purging :Yes :Yes No No

10. Bubble test Table 3-12-1 Bubble test standard value

Model 16TJ11 12 13 14 21 22 23 24 31 32 41 42 51 52 53 Pass

Standard value Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than Less than 15 15 15 15 25 25 25 30 30 30 40 40 45 45 50 cc (0.92 cubic inch) cc (0.92 cubic inch) cc (0.92 cubic inch) cc (0.92 cubic inch) cc (1.53 cubic inch) cc (1.53 cubic inch) cc (1.53 cubic inch) cc (1.83 cubic inch) cc (1.83 cubic inch) cc (1.83 cubic inch) cc (2.44 cubic inch) cc (2.44 cubic inch) cc (2.75 cubic inch) cc (2.75 cubic inch) cc (3.05 cubic inch) per per per per per per per per per per per per per per per 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 min. min. min. min. min. min. min. min. min. min. min. min. min. min. min.
:Yes No

11. Time setting Pass 12. Battery backup Pass :Yes No :Yes No

Page 12 / Sec.3

TJ Series

13. Temperature unit change Pass 14. Remote operation signal setting Pass 15. Field insulation instruction Pass 16. Confirmation of setting menu and service mode Pass 17. Function test of modulating controls Pass 18. Aging process Pass 19. Refrigerant Blow down Pass 20. Preparation of trial run (1) Unit and auxiliary equipment operating in an automatic mode. (2) Steam valve adjusted for design input. (3) Refrigerant in the evaporator less than 3% LiBr. (4) Chilled water, cooling water, and steam flows at design. (5) Chilled water and cooling water temperatures at design. (6) Steam pressure at design. (7) Confirm valves position. :Yes :Yes :Yes :Yes :Yes :Yes :Yes No No No No No No No :Yes No :Yes No :Yes No :Yes No :Yes No :Yes No :Yes No

Page 13 / Sec.3

TJ Series

3-3. Delivery inspection Upon delivery of the Carrier/SANYO absorption chiller to the jobsite, the Carrier Service representative should carefully inspect the units for the following items: 1. Correct model and serial numbers. Compare all operating specifications as outlined in the "Contract Specification" with the nameplate on the unit. 2. Inspect for physical damage to the unit including external sensors, control panel and wiring. 3. On multiple piece assemblies insure that the proper quantity of lithium bromide and inhibitor have been received and placed next to the unit. 4. Inspect all separate shipping boxes and components shipped with the unit.

Page 14 / Sec.3

LJ/TJ Series

3-4. Location and space requirements The unit is designed for indoor application and must be located in a space where the ambient temperature is between 5 oC(41oF) and 45oC(104oF), at no time more than 90% relative humidity. Clearance must be provided on either end to facilitate tube cleaning or removal and clearance on all other sides of the unit for general unit maintenance. See the dimensional data tables in the contract specification for clearance requirements.

Page 15 / Sec.3

LJ/TJ Series

3-5. Leveling verification Strict leveling tolerances must be adhered to for trouble free operation. The chillers are furnished with leveling reference points at each corner of the lower shell assembly. The method to check leveling tolerance requires a clear vinyl tube with water. The water level in the tube can then be held at reference point "A" and the difference in level can be determined at all other points around the chiller. The tolerance that must be maintained is <=0.002 between the measured points as shown below. When the unit does not meet this requirement, the unit must be shimmed at the appropriate locations to meet this requirement. 1. Using point A as the base point, measure differences of water levels at other point (B, C, D). Fig. 3-5-1 A (Evaporator side) W : Width of chiller leg (Absorber side) C L :Length between chiller legs Point Difference A 0 mm B mm C mm D mm L mm W mm D B

2. Leveling calculation A-B L Tolerance C-D L 2 mm 1000 A-D L B-C L A-C W B-D W

( 1/4 inch par 20 feet)

3. Note that there are four leveling check points on the chiller shown in the below figure. These check points are designated by three punch marks on the lower tube sheets.

Fig. 3-5-2

Page 16 / Sec.3

LJ/TJ Series

4. If calculated value (s) is not within the tolerance, adjust levels by inserting metal shims between the leg and the foundation. Size of the shim is approximately 50 mm (2") width and 80 mm (3") length. Different thickness shims should be prepared. (0.6 mm (0.02") - 9 mm (0.35"))

Fig. 3-5-3

5. Fix anchor bolts a) Weld washers on the legs of the chiller. b) Tight up nuts.

Fig. 3-5-4

Page 17 / Sec.3

LJ/TJ Series

3-6A. Piping (Chilled water, cooling water, and hot water) (LJ) Building pump interlocks The unit are equipped with interlock contact closures to signal the chilled and cooling water pumps to start and stop. It is important that the unit have control of the chilled and cooling water pumps to allow for controlled shutdown of water flow during the normal shutdown/dilution cycle or in the event of a safety condition. In addition to the start/stop signals to the chilled and cooling water pumps, the unit also requires answer-back signals from the chilled and cooling water pump starters. The answer-back signals are necessary to report to the electric controller that the chilled and cooling water pumps are operating in response to the electric controller start/stop signal. These answer-back signals are typically dry-contact closure from the pump starters to the interlock contact point at the chiller panel. Building pump interlocks on multiple units On applications where there are multiple units without dedicated chilled and cooling water pumps, it will be necessary to provide some means for an individual unit to shut off water flow during the normal shutdown/dilution cycle or in the event of a safety condition. Typically, this is accomplished by installing an in-line shutoff valve to the chilled and cooling water circuits of each individual chiller. The interlock contact points from the chiller can then be utilized to send a start/stop signal to the common chilled and cooling water pump starters and simultaneously provide the open/close signal to the individual unit in-line water valves. In addition to the start/stop signals to the chilled and cooling water pumps, the unit also requires answer-back signals from the chilled and cooling water pump starters and from an end switch signal from the in-line water valves. The answer-back signals are necessary to report to the electric controller that the chilled and cooling water pumps and in-line valves are operating in response to the electric controller start/stop signal. These answer-back signals are typically dry-contact closures from the pump starters and in-line water valve end switches to the interlock contact/points at the chiller panel. Water piping Water piping should be arranged so that the circulating pumps discharge directly into the unit water headers. The water piping should be insulated to reduce heat gain and to prevent condensation. Air vents should be located at all high points in the water piping system, and drains should be located at allow points to facilitate complete system drainage. To reduce vibration and noise transmission, vibration eliminators should be provided. Shutoff valves should be provided to allow unit isolation during maintenance. A chilled water flow switch is provided on the unit and is preset to open at approximately 50% of flow rate. Notes: 1. Pipes shall be properly supported in order that water nozzles / flanges of the chiller do not receive any stress. 2. Provide sockets or taps at proper positions to measure temperature and pressure in the piping line. 3. Be sure to conduct flashing of chilled water line, cooling water line, and hot water line before trial operation.

Page 18 / Sec.3

LJ Series

3-6B. Piping (Chilled water, cooling water, and steam) (TJ) Building pump interlocks The unit are equipped with interlock contact closures to signal the chilled and cooling water pumps to start and stop. It is important that the unit have control of the chilled and cooling water pumps to allow for controlled shutdown of water flow during the normal shutdown/dilution cycle or in the event of a safety condition. In addition to the start/stop signals to the chilled and cooling water pumps, the unit also requires answer-back signals from the chilled and cooling water pump starters. The answer-back signals are necessary to report to the electric controller that the chilled and cooling water pumps are operating in response to the electric controller start/stop signal. These answer-back signals are typically dry-contact closure from the pump starters to the interlock contact point at the chiller panel. Building pump interlocks on multiple units On applications where there are multiple units without dedicated chilled and cooling water pumps, it will be necessary to provide some means for an individual unit to shut off water flow during the normal shutdown/dilution cycle or in the event of a safety condition. Typically, this is accomplished by installing an in-line shutoff valve to the chilled and cooling water circuits of each individual chiller. The interlock contact points from the chiller can then be utilized to send a start/stop signal to the common chilled and cooling water pump starters and simultaneously provide the open/close signal to the individual unit in-line water valves. In addition to the start/stop signals to the chilled and cooling water pumps, the unit also requires answer-back signals from the chilled and cooling water pump starters and from an end switch signal from the in-line water valves. The answer-back signals are necessary to report to the electric controller that the chilled and cooling water pumps and in-line valves are operating in response to the electric controller start/stop signal. These answer-back signals are typically dry-contact closures from the pump starters and in-line water valve end switches to the interlock contact/points at the chiller panel. Water piping Water piping should be arranged so that the circulating pumps discharge directly into the unit water headers. The water piping should be insulated to reduce heat gain and to prevent condensation. Air vents should be located at all high points in the water piping system, and drains should be located at allow points to facilitate complete system drainage. To reduce vibration and noise transmission, vibration eliminators should be provided. Shutoff valves should be provided to allow unit isolation during maintenance. A chilled water flow switch is provided on the unit and is preset to open at approximately 50% of flow rate. Notes: 1. Pipes shall be properly supported in order that water nozzles / flanges of the chiller do not receive any stress. 2. Provide sockets or taps at proper positions to measure temperature and pressure in the piping line. 3. Be sure to conduct flashing of chilled water line, cooling water line, and steam line before trial operation.

Page 19 / Sec.3

TJ Series

3-7A. Field electric wiring (LJ) On CE code, power supply wiring shall be in accordance with OVER VOLTAGE Category III, other wiring shall be in accordance with OVER VOLTAGE Category II. Refer to Fig. 3-7-1, 3-7-2. Field wiring work shall be conducted be a electrician who has official license for the work. Fig. 3-7-1 Field electric wiring No.1

Page 20 / Sec.3

LJ Series

Fig. 3-7-2 Field electric wiring No.2

Page 21 / Sec.3

LJ Series

3-7B. Field electric wiring (TJ) On CE code, power supply wiring shall be in accordance with OVER VOLTAGE Category III, other wiring shall be in accordance with OVER VOLTAGE Category II. Refer to Fig. 3-7-1, 3-7-2. Field wiring work shall be conducted be a electrician who has official license for the work. Fig. 3-7-1 Field electric wiring No.1

Page 22 / Sec.3

TJ Series

Fig. 3-7-2 Field electric wiring No.2

Page 23 / Sec.3

TJ Series

3-8.

Megger test Confirming the unit controls and setpoints will also include a megger test of the unit pumps. Use a 500 VDC megger and only measure the load side of the pump being tested. The chiller pumps should have an insulation resistance greater than 10 meg ohms. 1. Connect an earth wire of the megger to an earth terminal in the control panel. 2. Measure insulation resistances of each motor at the following terminals in the control panel. Absorbent pump Refrigerant pump Purge pump 3. Record the measured values. (Terminals) (Terminals) (Terminals) : U1 / V1 / W1 : U3 / V3 / W3 : U4 / V4 / W4

Fig. 3-8 Megger test

Page 24 / Sec.3

LJ/TJ Series

3-9. Confirmation of nitrogen pressure in the unit Connect the pressure gauge to SV2 on the purge unit. Check and record the pressure as shown on the pressure gauge and ambient temperature in the equipment room. Compare the data obtained with the factory shipping data by using the formula in the check list. If no leak is apparent then discharge the nitrogen holding charge. If a leak is apparent then it will be necessary to perform a leak test. On multiple section assemblies it will be necessary to check and record pressure and temperatures for all of the separate sections. Compare the data obtained with the factory shipping data by using the formula in the check list. If on leak is apparent then instruct the installer to proceed with the unit assembly and welding. If a leak is apparent it will be necessary to perform a leak test on that unit section. Fig. 3-9. Purge unit

Unit leakage pressure calculation (P) P=(P1 + 101.3) x Where: P = Calculated pressure P1 = Pressure from factory P2 = Pressure measured t1 = Ambient temperature at factory t2 = Ambient temperature at site There is no leak if P2 is nearly equal to P. kPa kPa kPa
o o

t2 + 273 t1 + 273

-101.3

C C

Page 25 / Sec.3

LJ/TJ Series

3-10. Leak test Pressurizing the unit with nitrogen is only necessary after the installer assembles a multiple section unit or if a leak is apparent on a single piece unit. The nitrogen is installed through the service valve (SV1) located on the purge unit. Refer to Fig. 3-9. During this work, ventilate the unit room sufficiently. The leak test is as follows: 1. Confirm that V1, V2, V3, B valve, SV1, SV2 are fully closed. 2. Confirm that each isolation valve for absorbent and refrigerant pumps are fully open. 3. Connect the pressure gauge to SV2, and open SV2. 4. Charge nitrogen to SV1. 5. Pressurize the chiller up to 50 kPa with nitrogen. The pressure inside the chiller can be checked by the pressure gauge. 6. When the pressure reaches 50 kPa, close SV1 and the valve of the nitrogen cylinder. 7. Check the following positions with the soapy water. 7-1) All field welded portions (One shipping machine is not needed.) 7-2) Sight glass 7-3) Flare nut joints of service valves. 7-4) Electrodes 7-5) Flange connections ( the absorbent pumps, refrigerant pump, etc.) 7-6) Diaphragm valves 8. If a leakages is observed at the points 7-2) - 7-6), tighten them. In this case, discharging nitrogen gas is not required. 9. If a leakage is found out on field welding portions, repair it after discharging nitrogen. 10. Repeat 3. - 8.. 11. If no leakage is confirmed, hold the chiller with 50 kPa at least 8 hours then recheck by soapy water. 12. After completion of the test, discharge nitrogen. Unit leakage pressure calculation (P) P=(P1 + 101.3) x Where: P = Calculated pressure P1 = Pressure at now P2 = Pressure measured t1 = Ambient temperature at now t2 = Ambient temperature after at least 8 hours There is no leak if P2 is nearly equal to P. Important: If the unit will be leak tested sometime after charging and start-up, it will be necessary to remove the rupture disk and install a blank off plate in its place. Because of the frangible nature of the rupture disk, pressurizing the unit with the disk in the place could possibly distort the shape of the disk and cause it to leak. Removing the rupture disk for leak testing also allows for inspection of the disk itself as it may be the cause of the leak. It is recommended that the original rupture disk blank off plate shipped with the unit be stored with the unit in the case of future leak testing. Page 26 / Sec.3 LJ/TJ Series kPa kPa kPa
o o

t2 + 273 t1 + 273

-101.3

C C

Table 3-10 Content volume Model LJ11E 12E 13E 14E 21E 22E 23E 24E Model TJ11E 12E 13E 14E 21E 22E 23E 24E Volume Volume (litter) 1,640 1,580 2,510 2,380 3,150 3,010 4,210 4,020 (gal) 433 417 663 628 832 795 1,111 1,061 Model TJ31E 32E 41E 42E 51E 52E 53E Volume Volume (litter) 5,170 5,050 6,300 6,150 8,520 9,670 10,710 (gal) 1,365 1,333 1,663 1,624 2,249 2,553 2,827 Model LJ31E 32E 41E 42E 51E 52E 53E Volume Volume (litter) 5,030 4,830 6,150 5,910 8,240 9,350 10,350 (gal) 1,328 1,275 1,624 1,560 2,175 2,468 2,732

Volume Volume (litter) 1,730 1,640 2,590 2,460 3,250 3,110 4,340 4,160 (gal) 457 433 684 649 858 821 1,146 1,098

Page 27 / Sec.3

LJ/TJ Series

3-11. Inspection of purge pump/purging The purge pump is supplied with the unit, mounted, wired and piped. The initial charge of purge pump oil is shipped as an extra item with the unit and should be added to a level just above the bottom of the sight glass. During purge pump operation this level should rise to approximately 1/2 sight glass. If too much oil is added, it may cause oil to spill from the discharge port when it is first turned on. The purge pump also includes a ballast that can be opened slightly to limit the amount of condensed refrigerant from entering the pump and contaminating the oil. Allowing a small amount of ballast also tends to heat the purge pump oil and exhaust the moisture out of the oil. Refer to Fig. 3-9-1. 1. Always replace the oil if it becomes contaminated or milky in color. 2. Confirm the pumps ability to draw a vacuum. The pump also should achieve of at least 0.5 kPa (0.07 psi). If this value cannot be obtained, perform the following: a. Replace the purge pump oil. b. Check the liquid trap for water. If condensed water or moisture is apparent then it will be necessary to operate the purge pump for 1/2 hour to evaporate the moisture. c. Check the unit purge line piping for leakage by bubble testing. 3. If the purge pump will not rotate or trips the thermal overload it will be necessary to remove the belt and manually turn the pump by hand in an attempt to loosen the pump. 4. If the pump will not rotate be hand or will not attain an adequate vacuum after performing the above tasks it may be necessary to rebuild the purge pump. Important: When first starting the purge pump it is critical to bump start the pump and check for proper rotation as shown by an arrow on the shroud. The direction of the purge pump is an indicator of the directions of the other pumps on the unit. If the rotational direction is incorrect the phasing adjustment should be made at the power supply to the unit not to the purge pump wiring. Purging Remark : While purging work is being conducted, continuous power supply shall be required. If power interruption happens during purging, close V1 immediately in order to prevent air leaking through the purge unit. During purging nitrogen work, ventilate the unit room sufficiently. 1. Turn on the main breaker in the control panel. 2. Turn on the purge pump switch. 3. Check the rotating direction of purge pump. Correct direction is shown by arrow mark on a pulley cover of the purge pump. If the direction is wrong, stop the purge pump then correct it. 4. Open V1, V3 and B valve. Purging starts. 5. Open V2 after one hour. 6. Continue purging until inner pressure goes down below minus 0.1 MPa. Refer to table 3-11. Table 3-11 Approximately purging time

MODEL LJ-11-14 21-32 41-53

TIME 5h 12h 24h

MODEL TJ-11-14 21-32 41-53

TIME 5h 12h 24h

Page 28 / Sec.3

LJ/TJ Series

3-12. Bubble test The term "bubble test" describes the procedure of measuring the quantity of noncondensables being purged from the chiller. The test consists of adapting a hose from the discharge port of the purge pump and collecting the discharge gasses in an inverted graduated cylinder under water. The graduated cylinder is first filled with water and inverted so that no air is contained in the cylinder. As the noncondensable gasses are discharged into the inverted cylinder the water column in the cylinder will drop as the water is being displaced. The quantity of noncondensable gasses can then be measured based on time and volume of water displacement. This test will be performed during initial evacuating of the chiller, during the again process, during routine maintenance, and to determine if an air leak is present. The most important maintenance item on an absorption chiller is to insure the unit vacuum condition is within acceptable limits. Unit tightness can be checked by determining the rate at which noncondensable accumulate. Some noncondensables are normally generated within the unit, but an air leak will be indicated if the accumulation rate increases. Bubble test during unit operation During routine maintenance the bubble test can be performed to gather the noncondensable gasses that have accumulated in the purge tank. The contents of the gasses can then checked to be air or hydrogen. Air---No odor. If the unit does not pass the bubble test it is possible that a leak has developed. Hydrogen gas---Place a match or lighter at the lip of the graduated cylinder before removing the cylinder from the water. If hydrogen is apparent, the gas will ignite and cause a popping sound. If hydrogen is present it is an indicator that hydrogen production is exceeding the capacity of the palladium cells and that the inhibitor is depleted and should be replaced. Care should be taken when performing this test. Procedure a) Perform purging from the chiller until inner pressure reaches allowable degree of vacuum or less. Continue purging at least one hour. Refer to Fig.3-12-1. b) Connect the vacuum gauge to SV1 and open SV1. c) Confirm that attained vacuum of the purge pump is less than 5 hPa (0.07 psi). d) Remove the discharge port cap and put the attachment to the port. Furnish the vinyl hose to the attachment as shown in above figure. e) Open V1 and close V2 and V3. f) Continue to operate the purge pump for one minute. Then measure volume of bubbles. During this step, keep position of the vinyl hose within 10 mm in depth. If bubbles come out, check and tighten connections in the downstream from V2 and V3. If bubbles still come out, measure its volume collected for 10 minutes. g) Open V1 and V3 and close V2. Note : The gas ballast valve and the oil discharge cock shall be closed. h) Continuing operation of the purge pump under the above condition, measure volume of bubbles for 10 minutes. This measurement shall be repeated at least three times. During measurements, attained vacuum of the purge pump shall be kept below 5 hPa (0.07 psi). I) The measured value in item f) is as "A cc", in item h) is as "B cc". Result of bubble test value = B - C (cc) j) After the bubble test ; Open the gas ballast valve. Replace purge pump oil.

Page 29 / Sec.3

LJ/TJ Series

Fig. 3-12-1 Allowable vacuum curve

The degree of vacuum should be mentioned within the allowable range. As the pressure in the chiller is variable owning to the ambient temperature, check the measured pressure by using the curve. When ambient temperature is 30 oC (86 oF), 4.4 kPa (0.64 psi) is read as an allowable vacuum. If pressure is over 4.4 kPa (0.64 psi), perform air purging.

Fig. 3-12-2 Attachment 3/8" Copper tube Flare nut

Nipple (3/8") Bushing (1-1/4")

Fig. 3-12-3 Bubble test Suction port Discharge port Graduated cylinder

Purge pump

Bucket

Water

Page 30 / Sec.3

LJ/TJ Series

10mm (13/32)"

Vinyl hose

Table 3-12 Bubble test standard value Model 16LJ11 12 13 14 21 22 23 24 31 32 41 42 51 52 53 Less than 15 cc (0.92 cubic inch) per 10 min. Less than 15 cc (0.92 cubic inch) per 10 min. Less than 15 cc (0.92 cubic inch) per 10 min. Less than 15 cc (0.92 cubic inch) per 10 min. Less than 25 cc (1.53 cubic inch) per 10 min. Less than 25 cc (1.53 cubic inch) per 10 min. Less than 25 cc (1.53 cubic inch) per 10 min. Less than 30 cc (1.83 cubic inch) per 10 min. Less than 30 cc (1.83 cubic inch) per 10 min. Less than 30 cc (1.83 cubic inch) per 10 min. Less than 40 cc (2.44 cubic inch) per 10 min. Less than 40 cc (2.44 cubic inch) per 10 min. Less than 45 cc (2.75 cubic inch) per 10 min. Less than 45 cc (2.75 cubic inch) per 10 min. Less than 50 cc (3.05 cubic inch) per 10 min. Standard value

Model 16TJ11 12 13 14 21 22 23 24 31 32 41 42 51 52 53

Standard value

Less than 15 cc (0.92 cubic inch) per 10 min. Less than 15 cc (0.92 cubic inch) per 10 min. Less than 15 cc (0.92 cubic inch) per 10 min. Less than 15 cc (0.92 cubic inch) per 10 min. Less than 25 cc (1.53 cubic inch) per 10 min. Less than 25 cc (1.53 cubic inch) per 10 min. Less than 25 cc (1.53 cubic inch) per 10 min. Less than 30 cc (1.83 cubic inch) per 10 min. Less than 30 cc (1.83 cubic inch) per 10 min. Less than 30 cc (1.83 cubic inch) per 10 min. Less than 40 cc (2.44 cubic inch) per 10 min. Less than 40 cc (2.44 cubic inch) per 10 min. Less than 45 cc (2.75 cubic inch) per 10 min. Less than 45 cc (2.75 cubic inch) per 10 min. Less than 50 cc (3.05 cubic inch) per 10 min.

Page 31 / Sec.3

LJ/TJ Series

3-13. Time setting Time setting shall be conducted before initial operation of the chiller.

3 5. 0 High temperature generator temperature (example).

Push "SET" key for 2 sec..

A L A r n.
Push " " key.

Shady columns flicker.

r t. 0 7. 0 0
Push "SET" key for 2 sec..

0 5 - 0 5
Push "SET" key for 2 sec..

y r - S E t
Push "SET" key for 2 sec..

d t - S E t
Push " " key.

2 0 0 1
Push " " or " " key.

t n. - S E t
Push "SET" key for 2 sec..

2 0 0 5
Push "SET" key for 2 sec..

0 7 = 0 0
Push " " key for the hour. " key. " key for the minute

y r - S E t
Push " " key.

1 6 = 0 0
Push "

d t - S E t
Push "SET" key for 2 sec..

1 6 = 0 0
Push "

0 1 - 0 1
Push " " key for the month. " key. " key for the date.

1 6 = 5 0
Push "SET" key for 2 sec..

0 5 - 0 1
Push "

t n. - S E t
Push "BACK" key.

0 5 - 0 1
Push "

r t. 1 6. 5 0
Push "BACK" key.

3 5. 0

Page 32 / Sec.3

LJ/TJ Series

3-14. Battery backup See to Fig. 3-3. This figure shows positions of BACKUP BATTERY and BACKUP SWITCH (SW3) provided on the CPU board in the electronic controller. 1. SW3 is set OFF at the factory to avoid consumption of battery power. 2. When the power is supplied to the electronic controller, "F-21 (CPU alarm)" or "F-23 (Time set alarm)" is displayed on the data display if SW3 is turned off. In this case, turn on SW3 first and then conduct time setting. 3. When the power is supplied to the electronic controller, "F-21 (CPU alarm)" or "F-23 (Time set alarm)" is displayed on the data display even if SW3 is turned on. This means that the backup battery is empty. Replace the backup battery in accordance with the following steps.
Turn off SW3 - Remove the backup battery - Put new backup battery - Conduct time setting - Turn on SW3

Note : Model of the backup battery is CR-2025. The battery can do backup for approximate 4,000 hours.

SW3 :Backup switch UP : ON DOWN : OFF

Backup battery

Fig. 3-14. Positions of Backup switch (SW3) & Backup battery Page 33 / Sec.3

LABEL

LJ/TJ Series

3-15. Temperature unit change Unit (deg.C from/to deg.F) of temperature can be changed by the following steps. This change can be conducted even while the chiller is running.

3 5. 0 High temperature generator temperature (example).

Push "SET" key for 2 sec..

A L A r n.
Push " " or " " key.

C HG S =
Push "SET" key for 2 sec..

u n I t
Push " " or " " key if need. " or " " key. Push "SET" key for 2 sec. then push " To change deg. C o To change deg. F o Push "SET" key. Unit of deg. C can be fixed.

F
Push "SET" key. Unit of deg. F can be fixed.

Page 34 / Sec.3

LJ/TJ Series

3-16. Remote operation signal setting 5 types can be used for operating signal of the chiller as shown below. Table 3-16 Remote operation signal Setting Type of remote r - S I G n o F signal
(Remote signal)

- P L S
(Off pulse)

Type 1
Non-Voltage signal

S t A t I C
(Contentious signal)

Setting is not required

Type 2
Non-Voltage signal

P u L S E
(Pulse)

P o S I t I
(Positive)

Type 3
Non-Voltage signal

P u L S E
(Pulse)

n E G A t I
(Negative)

Type 4
DC/AC 24V

S t A t I C
(Contentious signal)

Setting is not required

Type 5
DC/AC 24V

P u L S E
(Pulse)

P o S I t I
(Positive)

Note : Each signal type and their wiring shall be met. Refer to Sec. 3-7. To be continued.

Page 35 / Sec. 3

LJ/TJ Series

Type of remote operating signal can be selected by the following steps.

3 5. 0 High temperature generator temperature (example).

Push "SET" key for 2 sec..

A L A r n.
Push " " or " " key.

F I E L D
Push "SET" key for 2 sec..

C o - I n P
Push " " or " " key.
In case that off pulse is required on START/STOP of the chiller, following steps shall be proceeded.

r - S I G n

Push "SET" key for 2 sec. then push " " or " " key.

Push "

" or "

" key.

To change static mode

To change pulse mode

S t A t I C
Push "SET" key. Static mode can be fixed.

P u L S E
Push "SET" key. Pulse mode can be fixed.

o F - P L S
Push "SET" key for 2 sec. then push " " or " " key.

To change negative mode

To change positive mode

P o S I t I
Push "SET" key. Positive mode can be fixed.

n E G A t I
Push "SET" key. Negative mode can be fixed.

Page 36 / Sec. 3

LJ/TJ Series

3-17. Field insulation instruction Because of the many different insulating materials available in our industry and local code requirements or regulations that must be complied with, it is impossible to specify the insulating material types to be utilized for a specific application. The selection and installation of the insulation should be addressed by experienced personnel knowledgeable in the local requirements and regulations of this field. The following tables illustrate the square footage of materials required and the thicknesses of the materials based on typical installations. 1. Do not insulate the unit until the leak testing procedures have been completed. 2. The type of insulation utilized on the hot surface must be sufficient so that outer skin temperatures meet local safety codes for personnel protection. 3. Use only noncombustible materials. 4. Do not insulate motor of refrigerant pump. 5. To mount insulating materials, use bonding agents, wires, and bands. Do not use screws, rivets, or impact type stick pins. 6. Do not cover components such as service valves, dampers, sight glasses, or thermometer or sensor wells. 7. Allow accessibility through the insulation to components such as water headers, steam headers. 8. The unit is coated with a heat resistant rust inhibiting paint from the factory. Finish painting is performed in the field after insulating is complete. 9. The purpose of insulation for hot surfaces are: a) protection of personnel from burns b) reduction of heat loss to equipment room c) maintain heat input in the unit for efficiency. 10. The purpose of insulation for cold surfaces is to avoid condensation. Table 3-17 Surface temperature of insulation parts COLD SURFACES Evaporator Chilled water headers Refrigerant piping HOT SURFACES Generator Generator header Heat exchanger Solution piping except from absorption pump to heat exchanger 4 C (40 F)
o o

85 oC (185 oF)

Page 37 / Sec. 3

LJ/TJ Series

3-18. Confirmation of setting menu and service mode 3-18-1. Confirmation of setting menu Confirm setting value to be necessary for normal operation. There are three steps as following to. Symbols : To press "BACK" key : To press "SET" key : To press " : To press " " key " key

Each menu can be displayed by the following steps. Regular indication(Generator temperature) 3 7. 0
2 sec. 2 sec.

3rd step : Setting value can confirm or change C 1. or d 1. 0 6 0 9

2 sec.

1st step : Setting menu mode A L A r n. "ALArn." has not 2nd step.

2nd step : Setting sub menu Y r - S E t

2 sec.

r t. 1 4. 5 3

2 0 0 1
2 sec.

or

If set is changed,

d t

- S E t

1 0 - 2 4

The other setting sub menus.

2 sec. 2 sec.

C H G S

r d - S E t
2 sec.

C o o L or If set is changed,

The other setting menus.

II

H E A t The other setting sub menus.

Page 38 / Sec. 3

LJ/TJ Series

: The setting value vary based on the specification. Table 3-18-1 Confirmation of setting menu(1/2) Confirmation items 1st step Specifications setting A L A r n. C 1. d 1. 1 0 2 4 t 1. 1 4. 0 2 C 2. d 2. 0 6 0 9 t 2. 0 8. 4 4 C 3. d 3. t 3. r t. 1 4. 5 3 Y r d t C H G S
II

Data display 2nd step

Setting 3rd step(ex.)

Check

1) 1st alarm code (The latest) 2) 1st alarm happen month and day 3) 1st alarm happen time 4) 2nd alarm code 5) 2nd alarm happen month and day 6) 2nd alarm happen time 7) 3rd alarm code 8) 3rd alarm happen month and day 9) 3rd alarm happen time 10) Initialization Time setting 11) Year setting 12) Month and date setting 13) Time setting Change of switch 14) Cool / Heat change-over 15) Operation data record interval change 16) Select of local operation mode 17) Cancel of predication information 18) Change of unit 19) Change of low select control Set of chilled water pump 21) Set of variable flow rate 22) Set of parallel operation by remote control Inverter control for chilled water C H Set of cooling water pump and cooling tower 23) Confirmation of interlock return time 24) Set of stopping cooling water pump at low load 25) Set of cooling tower fan control 26) Set of cooling water temperature control 27) Set of differential temp. of cooling tower fan 28) Set of variable flow rate Inverter control for cooling water C o cont.,
I I I

r E - S E t - S E t - S E t 1 0 2 0 0 5 - 2 4 0 2
II

t n. - S E t 0 8 r d - S E t C o S A n. - d t L o C A L S I G n u n I L o
I II

o L - H n S E n F 0 F F Invalid S

1 o n C o
o

S E L o F - C H 0 0

A P P o C H n t
II

20) Confirmation of interlock return time

V r n V

V - C H o F

- P A r A o F

A P P o C o n t - C o 0 F F S

C o S t o P o F C t A u t o o F C t V
II

t E n. P 2 6. 0 V - C o o F F

C t d I F F 3. 0

o C o C
Invalid

n V

Page 39 / Sec. 3

LJ/TJ Series

: The setting value vary based on the specification. Table 3-18-1 Confirmation of setting menu(2/2) Confirmation items 1st step Field set 30) Set of slow open time 31) Set of slow open temperature 32) Set of dilution time 33) Set of remote signal type 34) Set of type of pulse 35) Set of low select control temperature 36) Set of radiation temperature Set of RS-485 44) Set of address Indication of version number 45) No-sub menu Indication of version number of option board 46) No-sub menu o P V 0. 0 0 o P V 0. 0 0 V E r 0. 0 0 V E r 0. 9 1 r S - 4 8 5 A d d 4 8 5 0 Invalid F I E L d C o I I I

Data display 2nd step

Setting 3rd step(ex.)

Check

29) Set of cooling water temp. at maximum input

n. P 3 2. 0 t n. 0 0 0 0 0 A t t 0 4 t

n P I

n P t n. P 0 0 L u - S I G n S t

o C
n. I C
I

d r

o F - P L S P o S I L o S E L E H E II - S t

o C Invalid o C Invalid

Page 40 / Sec. 3

LJ/TJ Series

3-18-2A. Confirmation of service mode (LJ) Confirm setting value to be necessary for normal operation. There are three steps as following to. Symbols : To press "BACK" key : To press "SET" key : To press " : To press " " key " key

Each menu can be displayed by the following steps. Regular indication(Generator temperature) 3 7. 0
Press 2 keys for 2 sec. simultaneously

3rd step : Setting 2nd step : Setting sub menu P u r G E

2 sec. 2 sec.

1st step : Service mode C H G S 2

II

2 sec.

value can confirm or change A u t o or o F F If set is changed,

r E F - P

The other setting sub menus.

2 sec.

2 sec. I

n. o d E L

0 0 0 0 0 0

2 sec.

t Y P E Other setting menu.

The other setting sub menus.

Page 41 / Sec. 3

LJ Series

: The setting value vary based on the specification. Table 3-18-2 Confirmation of service mode(1/3) Confirmation items 1st step Change of switch2 1) Purge 2) Run/Stop changeover of refrigerant pump 3) Pilot test setting 4) Control valve operation changeover 1 5) Control valve opening 1 6) Control valve operation changeover 2 7) Control valve opening 2 8) Control valve operation changeover 3 9) Control valve opening 3 10) Set of HBS address 11) High speed timer function (60 times) 12) Initializing of operation data Model setting 13) Set of serial number 14) Set of type 15) Set of control method 16) Set of annual cooling operation 17) Set of automatic cooling/heating changeover 18) Set of process use 19) Set of purge pump installation 20) Set of oil pump installation Specification setting S P E C C H t E n. P 6. 0 t E n. P 5. 0 21) Set of chilled water outlet temperature 22) Set of hoe water outlet temperature 23) Set of chilled water temperature difference 24) Set of hot water temperature difference 25) No use 26) Set of maximum operating of control valve 27) Set of purge indication lamp on 28) Set of purge indication lamp off 29) Set of purge tank pump running time 30) Exhaust gas bedewing prevention temperature 31) Set of crystallization temperature Input setting 32) Set of control type 33) Set of input correction 34) Set of combustion interval Inverter setting
I I

Data display 2nd step 2 P u r G E r E F - P P I L o t C n. - 1 C n. - 1 S t C n. - 2 C n. - 2 S t C n. - 3 C n. - 3 S t A d d H b S b A I S o K o F o P I II

Setting 3rd step(ex.) A u t o A u t o A u t o A u t o 0 A u t o A u t o 0 F 3 0 0

I I

Check

C H G S

Invalid

Invalid 0 Invalid Invalid 0 Invalid

r S t

n. o d E L d
I

0 0 0 0 L 0
I I

t Y P E C o n t

o C H - o u t

A - C o o L o F F C H A u t o n. A n u A L P r o C n. P - o P o P - o P o F F o n o F F Invalid

o C o C
Invalid Invalid Invalid 1 0 0. 0

C - d t H - d t S I n G - K r A n K u P A P - S t A P - S P A P t
I

1 0. 0 K P A 7. 0 K P A n. Invalid Invalid Invalid P I d 5 0 0 0 n. Invalid

E II C o n d L E C r Y S b n t Y P E
I

n P u t P t C o r I n t

F n V S E t

Page 42 / Sec. 3

LJ Series

: The setting value vary based on the specification. Table 3-18-2 Confirmation of service mode(2/3) Confirmation items 1st step PID setting 36) Set of integral in cooling 37) Set of derivative in cooling 38) Set of proportional in heating 39) Set of integral in heating 40) Set of derivative in heating 41) Set of sampling interval Operation hours and number of C o u n t times setting 42) Unit operating hours 43) Absorbent pump 1 operation hours 44) Absorbent pump 2 operation hours 45) Combustion hours 46) Refrigerant pump operation hours 47) No use 48) Unit number of times 49) Absorbent pump 1 number of times 50) Absorbent pump 2 number of times 51) Combustion number of times 52) Refrigerant pump number of times 53) No use Prediction function setting S I G n S t P u r G E t H I C K C o - d I C o - H I r u L E I

Data display 2nd step

Setting 3rd step(ex.) 1 0. 0 2 5 0 0 1 0. 0 2 5 0 0 1 0

Check

P I d S E t C o o L - P C o o L H E A t H E A t H E A t
I

35) Set of proportional in cooling

C o o L - d - P I

- d

S A n. P L E

u n I

t 0 0 0 0 0 0 t 0 0 0 0 0 0 t t 0 0 0 0 0 0 t Invalid Invalid Invalid

A b S 1 A b S 2 F I r E t r E F u n
I

P u r G t

- C 0 0 0 0 0 0 Invalid Invalid 0 0 0 0 0 0 Invalid o n o F F r o n o n o F F 3 Invalid

A b S 1 - C 0 0 0 0 0 0 A b S 2 - C F I r E - C r E F - C P u r G - C

54) Debasement of vacuum level 55) Rise of absorbent solution concentration 56) Foul of cooling water 57) High temperature of cooling water 58) Foul of combustion chamber 59) Antifreeze 60) Low temperature of exhaust gas 61) Reset of predication function Burner controller setting Sensor setting P r Y S E n S o r

C C - d I R o n E II G - L o o n r E - S E t

62) Set of chilled water outlet temperature offset 63) Set of chilled water inlet temperature offset 64) Set of cooling water outlet temperature offset 65) Set of cooling water inlet temperature offset 66) Set of hot water outlet temperature offset 67) Set of hot water inlet temperature offset 68) Set of addition sensor

C H o A d J C H I A d J C o o A d J C o I A d J H o A d J H I A d J

0. 0 0. 0 0. 0 0. 0 0. 0 Invalid 0. 0 Invalid

S E n - o P 1 1 1 0 0 0

Page 43 / Sec. 3

LJ Series

: The setting value vary based on the specification. Table 3-18-2 Confirmation of service mode(3/3) Confirmation items 1st step Analog data display A n A L o G 6 0. 0 1 2. 1 3. 1 4. 1 5. 1 6. 1 6. 1 8. 1 9. 2 0. 2 1. 2 2. 2 3. 2 4. 2 5. 2 6. 2 7. 2 8. 2 9. 3 0. 3 1. 3 2. 3 3. 3 4. 3 5. 3 6. 3 7. 3 8. 3 9. 4 0. 4 1. 4 2. 4 3. 4 4. 4 5. 4 6. 4 7. 4 8. 4 9. 5 0. 5 1. 5 2. 5 3. d I G I d
I

Data display 2nd step

Setting 3rd step(ex.)

Check

69) High temperature generator (Generator) temperature 70) Chilled water inlet temperature 71) Chilled water outlet temperature 72) Cooling water inlet temperature 73) Condenser temperature 74) Steam drain/exhaust gas temperature 75) Purge tank pressure 76) Low temperature generator temperature 77) Cooling water middle temperature 78) Cooling water outlet temperature 79) Steam drain temperature 80) Refrigerant temperature 81) Diluted solution absorber outlet temperature 82) Inverter frequency 83) Control valve opening output 84) Control valve opening input 85) Control valve opening output for electro pneumatic type 86) Concentrated solution concentration 87) Diluted solution concentration 88) Remote control for chilled water outlet temp. 89) No use 90) No use 91) Diluted solution Low tem. heat exchanger outlet 92) Level of foul of cooling water 93) Level of debasement of vacuum level 94) Hot water inlet temperature 95) Hot water outlet temperature 96) Hot water outlet temperature 97) No use 98) No use 99) No use 100) No use 101) No use 102) No use 103) No use 104) No use 105) No use 106) No use 107) No use 108) No use 109) No use 110) No use 111) No use Digital input Digital output Control state I

1 1. 9 6. 8 3 1. 8 3 4. 7 Invalid 8. 5 Invalid 3 3. 5 3 7. 1 Invalid 5. 9 2 7. 8 Invalid 9 6. 5 9 6. 2 9 6. 5 6 3. 2 5 8. 5 4. 0 Invalid Invalid Invalid Invalid Invalid 8 5. 9 8 1. 1 8 1. 1 Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid LJ Series

- o
II

C o t n o

Page 44 / Sec. 3

3-18-2B. Confirmation of service mode (TJ) Confirm setting value to be necessary for normal operation. There are three steps as following to. Symbols : To press "BACK" key : To press "SET" key : To press " : To press " " key " key

Each menu can be displayed by the following steps. Regular indication(Generator temperature) 3 7. 0
Press 2 keys for 2 sec. simultaneously

3rd step : Setting 2nd step : Setting sub menu P u r G E

2 sec. 2 sec.

1st step : Service mode C H G S 2

II

2 sec.

value can confirm or change A u t o or o F F If set is changed,

r E F - P

The other setting sub menus.

2 sec.

2 sec. I

n. o d E L

0 0 0 0 0 0

2 sec.

t Y P E Other setting menu.

The other setting sub menus.

Page 45 / Sec. 3

TJ Series

: The setting value vary based on the specification. Table 3-18-2 Confirmation of service mode(1/3) Confirmation items 1st step Change of switch2 1) Purge 2) Run/Stop changeover of refrigerant pump 3) Pilot test setting 4) Control valve operation changeover 1 5) Control valve opening 1 6) Control valve operation changeover 2 7) Control valve opening 2 8) Control valve operation changeover 3 9) Control valve opening 3 10) Set of HBS address 11) High speed timer function (60 times) 12) Initializing of operation data Model setting 13) Set of serial number 14) Set of type 15) Set of control method 16) Set of annual cooling operation 17) Set of automatic cooling/heating changeover 18) Set of process use 19) Set of purge pump installation 20) Set of oil pump installation Specification setting S P E C C H t E n. P 6. 0 t E n. P 5. 0 21) Set of chilled water outlet temperature 22) Set of hot water outlet temperature 23) Set of chilled water temperature difference 24) Set of hot water temperature difference 25) No use 26) Set of maximum operating of control valve 27) Set of purge indication lamp on 28) Set of purge indication lamp off 29) Set of purge tank pump running time 30) Exhaust gas bedewing prevention temperature 31) Set of crystallization temperature Input setting 32) Set of control type 33) Set of input correction 34) Set of combustion interval Inverter setting
I I

Data display 2nd step 2 P u r G E r E F - P P I L o t C n. - 1 C n. - 1 S t C n. - 2 C n. - 2 S t C n. - 3 C n. - 3 S t A d d H b S b A I S o K o F o P I II

Setting 3rd step(ex.) A u t o A u t o A u t o A u t o 0 A u t o A u t o 0 F 3 0 0

I I

Check

C H G S

Invalid

Invalid 0 Invalid Invalid 0 Invalid

r S t

n. o d E L d
I

0 0 0 0 S 0
I I

t Y P E C o n t

o C H - o u t

A - C o o L o F F C H A u t o n. A n u A L P r o C n. P - o P o P - o P o F F o n o F F Invalid

o C o C
Invalid Invalid Invalid 1 0 0. 0

C - d t H - d t S I n G - K r A n K u P A P - S t A P - S P A P t
I

1 0. 0 K P A 7. 0 K P A n. Invalid Invalid Invalid P I d 5 0 0 0 n. Invalid

E II C o n d L E C r Y S b n t Y P E
I

n P u t P t C o r I n t

F n V S E t

Page 46 / Sec. 3

TJ Series

: The setting value vary based on the specification. Table 3-18-2 Confirmation of service mode(2/3) Confirmation items 1st step PID setting 36) Set of integral in cooling 37) Set of derivative in cooling 38) Set of proportional in heating 39) Set of integral in heating 40) Set of derivative in heating 41) Set of sampling interval Operation hours and number of C o u n t times setting 42) Unit operating hours 43) Absorbent pump 1 operation hours 44) Absorbent pump 2 operation hours 45) Combustion hours 46) Refrigerant pump operation hours 47) No use 48) Unit number of times 49) Absorbent pump 1 number of times 50) Absorbent pump 2 number of times 51) Combustion number of times 52) Refrigerant pump number of times 53) No use Prediction function setting S I G n S t P u r G E t H I C K C o - d I C o - H I r u L E I

Data display 2nd step

Setting 3rd step(ex.) 1 0. 0 2 5 0 0 1 0. 0 2 5 0 0 1 0

Check

P I d S E t C o o L - P C o o L H E A t H E A t H E A t
I

35) Set of proportional in cooling

C o o L - d - P I

- d

S A n. P L E

u n I

t 0 0 0 0 0 0 t 0 0 0 0 0 0 t t 0 0 0 0 0 0 t Invalid Invalid Invalid

A b S 1 A b S 2 F I r E t r E F u n
I

P u r G t

- C 0 0 0 0 0 0 Invalid Invalid 0 0 0 0 0 0 Invalid o n o F F r o n o n o F F 3 Invalid

A b S 1 - C 0 0 0 0 0 0 A b S 2 - C F I r E - C r E F - C P u r G - C

54) Debasement of vacuum level 55) Rise of absorbent solution concentration 56) Foul of cooling water 57) High temperature of cooling water 58) Foul of combustion chamber 59) Antifreeze 60) Low temperature of exhaust gas 61) Reset of predication function Burner controller setting Sensor setting P r Y S E n S o r

C C - d I R o n E II G - L o o n r E - S E t

62) Set of chilled water outlet temperature offset 63) Set of chilled water inlet temperature offset 64) Set of cooling water outlet temperature offset 65) Set of cooling water inlet temperature offset 66) Set of hot water outlet temperature offset 67) Set of hot water inlet temperature offset 68) Set of addition sensor

C H o A d J C H I A d J C o o A d J C o I A d J H o A d J H I A d J

0. 0 0. 0 0. 0 0. 0 0. 0 Invalid 0. 0 Invalid

S E n - o P 1 1 1 0 0 0

Page 47 / Sec. 3

TJ Series

: The setting value vary based on the specification. Table 3-18-2 Confirmation of service mode(3/3) Confirmation items 1st step Analog data display A n A L o G 6 0. 0 1 2. 1 3. 1 4. 1 5. 1 6. 1 6. 1 8. 1 9. 2 0. 2 1. 2 2. 2 3. 2 4. 2 5. 2 6. 2 7. 2 8. 2 9. 3 0. 3 1. 3 2. 3 3. 3 4. 3 5. 3 6. 3 7. 3 8. 3 9. 4 0. 4 1. 4 2. 4 3. 4 4. 4 5. 4 6. 4 7. 4 8. 4 9. 5 0. 5 1. 5 2. 5 3. d I G I d
I

Data display 2nd step

Setting 3rd step(ex.)

Check

69) High temperature generator (Generator) temperature 70) Chilled water inlet temperature 71) Chilled water outlet temperature 72) Cooling water inlet temperature 73) Condenser temperature 74) Steam drain/exhaust gas temperature 75) Purge tank pressure 76) Low temperature generator temperature 77) Cooling water middle temperature 78) Cooling water outlet temperature 79) Steam drain temperature 80) Refrigerant temperature 81) Diluted solution absorber outlet temperature 82) Inverter frequency 83) Control valve opening output 84) Control valve opening input 85) Control valve opening output for electro pneumatic type 86) Concentrated solution concentration 87) Diluted solution concentration 88) Remote control for chilled water outlet temp. 89) No use 90) No use 91) Diluted solution Low tem. heat exchanger outlet 92) Level of foul of cooling water 93) Level of debasement of vacuum level 94) Hot water inlet temperature 95) Hot water outlet temperature 96) Hot water outlet temperature 97) No use 98) No use 99) No use 100) No use 101) No use 102) No use 103) No use 104) No use 105) No use 106) No use 107) No use 108) No use 109) No use 110) No use 111) No use Digital input Digital output Control state I

1 1. 9 6. 8 3 1. 8 3 4. 7 6 0. 0 8. 5 Invalid 3 3. 5 3 7. 1 6 0. 0 5. 9 2 7. 8 Invalid 9 6. 5 9 6. 2 9 6. 5 6 3. 2 5 8. 5 4. 0 Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid Invalid TJ Series

- o
II

C o t n o

Page 48 / Sec. 3

3-19A. Function test of modulating controls (LJ) Insure that the unit is still in the "Dry run" mode with hot water control valve disabled. With the unit in the "Dry run" mode on the hot water valve should automatically drive to a full open position(100% fire rate). The hot water valve should also respond to the 0 through 100 on the operation board. Insure that the valve stroking is smooth and full close the valve seats properly. Because the hot water valve has not been adjusted for full load water flow, the operation board should be adjusted to prevent 100% hot water rate during the aging and hot water valve adjustment procedure. This can be accomplished by accessing special function item "RunkuP" on the operation board. Decrease the "RunkuP" value to 50% to prevent the hot water valve from driving to full open during the aging and hot water flow rate tests. Confirm the hot water valve responds to this adjustment via the electric controller special item "Cn.-1St". 1. How to change the hot water valve full opening set value is from 100% to 50%.

3 5. 0 High temperature generator temperature (example).

Push "SET" and " " keys for 2 sec..

C HG S

2
Push " " or " " key.

II

S P E C
Push "SET" key for 2 sec..

C - t E n. P
Push " " or " " key.

r A n k u P
Push "SET" key for 2 sec..

1 0 0. 0
Push " " key.

5 0. 0
Push "SET" key for 2 sec.. To be continued.

Page 49 / Sec. 3

LJ Series

2. How to change the hot water valve opening set value by manual. This work is able to do during unit running.

3 5. 0 High temperature generator temperature (example).

Push "SET" and " " keys for 2 sec..

C HG S

2
Push "SET" key for 2 sec..

P u r G E
Push " " or " " key.

II

C n. - 1
Push "SET" key for 2 sec..

A u t o
Push " " or " " key.

n. A n u A L
Push "SET" key for 2 sec..

C n. - 1
Push " " key.

C n. - 1 S t
Push "SET" key for 2 sec..

3 8

Data display appears valve opening by %. Push " Push " " key, and push "SET" key, the valve is close. " key, and push "SET" key, the valve is open.

Note: The set value cannot change in "Cn.-1St" more than "rAnkuP" . Important: When you will finish this procedure, you have to remove from "n.AnuaL" to " Auto".

Page 50 / Sec. 3

LJ Series

3-19B. Function test of modulating controls (TJ) Insure that the unit is still in the "Dry run" mode with steam control valve disabled. With the unit in the "Dry run" mode on the steam valve should automatically drive to a full open position(100% fire rate). The steam valve should also respond to the 0 through 100 on the operation board. Insure that the valve stroking is smooth and full close the valve seats properly. Because the steam valve has not been adjusted for full load steam flow, the operation board should be adjusted to prevent 100% steam rate during the aging and steam valve adjustment procedure. This can be accomplished by accessing special function item "RunkuP" on the operation board. Decrease the "RunkuP" value to 50% to prevent the steam valve from driving to full open during the aging and steam flow rate tests. Confirm the steam valve responds to this adjustment via the electric controller special item "Cn.-1St". 1. How to change the steam valve full opening set value is from 100% to 50%.

3 5. 0 Generator temperature (example).

Push "SET" and " " keys for 2 sec..

C HG S

2
Push " " or " " key.

II

S P E C
Push "SET" key for 2 sec..

C - t E n. P
Push " " or " " key.

r A n k u P
Push "SET" key for 2 sec..

1 0 0. 0
Push " " key.

5 0. 0
Push "SET" key for 2 sec.. To be continued.

Page 51 / Sec. 3

TJ Series

2. How to change the steam valve opening set value by manual. This work is able to do during unit running.

3 5. 0 Generator temperature (example).

Push "SET" and " " keys for 2 sec..

C HG S

2
Push "SET" key for 2 sec..

P u r G E
Push " " or " " key.

II

C n. - 1
Push "SET" key for 2 sec..

A u t o
Push " " or " " key.

n. A n u A L
Push "SET" key for 2 sec..

C n. - 1
Push " " key.

C n. - 1 S t
Push "SET" key for 2 sec..

3 8

Data display appears valve opening by %. Push " Push " " key, and push "SET" key, the valve is close. " key, and push "SET" key, the valve is open.

Note: The set value cannot change in "Cn.-1St" more than "rAnkuP" . Important: When you will finish this procedure, you have to remove from "n.AnuaL" to " Auto".

Page 52 / Sec. 3

TJ Series

3-20. Aging process The most important reason for the aging process is to remove any air that may have entered the unit during the solution charging process. By continuing operation at low fire, the solutions will heat up causing any entrained air to bubble out of the solutions and be easily removed by the purge pump. During the entire aging process the purge pump should be operating and purge valves V1 and V3 opened. Connect the vacuum gauge to SV2, and it can also be opened to monitor the vacuum condition of the lower shell. 1. Run the purge pump. 2. The set value of "rAnkuP" should change "0"(zero) in accordance with Section 3-19. 3. Run the chiller approximately 3-4 hours. 4. Monitor the condition of the purge pump oil and change as required. 5. Utilizing a small amount of ballast will extend the life of each oil charge. 6. Adjust the set value of "rAnkuP" between "20" and "30" in accordance with Section 3-19 in order to limit the heat input to approximately 20 percent of the rated value. 7. Monitor the condition of the purge pump oil and change as required. 8. Utilizing a small amount of ballast will extend the life of each oil charge. 9. As the unit will be chilling the evaporator loop, closely monitor leaving chilled water temperature to prevent the possibility of over chilling. Typically the aging process will take approximately 3-4 hours depending on unit size and the amount of air that entered during solution charging. The aging process will be complete only when the unit passes a bubble test thus insuring that all air has been removed. Note: If the refrigerant pump is stop and appear "J-10" on the operation board, the reset button of the refrigerant pump overload relay mounted contactor sticks out. In this case, more increase the refrigerant pump overload relay set value, push the refrigerant pump overload relay reset button, push "STOP" button on the operation board. Then run chiller again. 10. Remove the refrigerant pump overload relay set value in accordance with the name plate of the refrigerant pump.

Page 53 / Sec. 3

LJ/TJ Series

3-21. Refrigerant Blow down During the transportation, the absorbent solution and refrigerant are mixed, the unit will manufacture new pure refrigerant to replace it (refrigerant blow down). 1. Make sure the refrigerant pump is running and also the solution level is visible through the sight glass of the evaporator. 2. Open the refrigerant blow valve completely. 3. When solution level becomes invisible, close the refrigerant blow valve tightly. 4. Repeat steps 1, 2, and 3 until the refrigerant contains less than 3% LiBr be taking a refrigerant sample. Refer to Section 6-8. Fig. 3-21 Refrigerant blow valve

Page 54 / Sec. 3

LJ/TJ Series

3-22A. Preparation of trial run (LJ) At this point of the trial run procedures the unit should be: 1. Unit and auxiliary equipment operating in an automatic mode. 2. Hot water valve adjusted for design input. 3. Refrigerant in the evaporator less than 3% LiBr. 4. Chilled, cooling, and hot water flows at design. 5. Chilled, cooling, and hot water temperatures at design. 6. Confirm valves position. It will now be required to achieve a stable full load operation for a minimum of two hours to take a full set of operation data and complete the equipment trial run data sheets. The full load test is required to (1) insure the unit is performing at its design capacity, and (2) insure that solution concentrations, and operating temperatures are within normal operating parameters. Use the following typical operating conditions to compare actual recorded conditions. These typical conditions should be used as reference only, to detect gross differences in actual operation. Once full load operation has been achieved, record the operating data on the trial run data sheets, sign the unit over to the customer, and forward a copy of the trial run data sheets to the Service Department. Table 3-22-1 Typical operating conditions LJ unit Item 1 2 3 4 5 6 7 8 9 10 Chilled water inlet Chilled water outlet Cooling water inlet Cooling water outlet Hot water inlet Hoe water outlet Dilute solution (Absorber outlet) Concentrated solution (Generator outlet) Diluted solution concentration (Absorber outlet) Concentrated solution concentration (Generator outlet) Location Unit 12.2oC (54oF) 6.7oC (44oF) 29.4oC (85oF) 38.4oC (101.2oF) 95.0oC (203oF) 86.0oC (186.8oF) 35.1oC (95.2oF) 85.6oC (186.1oF) 55% 59.5%

Table 3-22-2 Valve position Valve name Position Valve name Position B SV1 SV2 SV3 SV4 SV6 SV7 SV9 Open Close Close Close Close Close Open Close V1 V2 V3 Refrigerant blow valve Close Open Close Close Valve name Absorbent pump isolation valves Refrigerant pump isolation valves Position Open Open

Page 55 / Sec. 3

LJ Series

3-22B. Preparation of trial run (TJ) At this point of the trial run procedures the unit should be: 1. Unit and auxiliary equipment operating in an automatic mode. 2. Hot water valve adjusted for design input. 3. Refrigerant in the evaporator less than 3% LiBr. 4. Chilled water, cooling water, and steam flows at design. 5. Chilled water and cooling water temperatures at design. 6. Steam pressure at design. 7. Confirm valves position. It will now be required to achieve a stable full load operation for a minimum of two hours to take a full set of operation data and complete the equipment trial run data sheets. The full load test is required to (1) insure the unit is performing at its design capacity, and (2) insure that solution concentrations, and operating temperatures are within normal operating parameters. Use the following typical operating conditions to compare actual recorded conditions. These typical conditions should be used as reference only, to detect gross differences in actual operation. Once full load operation has been achieved, record the operating data on the trial run data sheets, sign the unit over to the customer, and forward a copy of the trial run data sheets to the Service Department. Table 3-22-1 Typical operating conditions TJ unit Item 1 2 3 4 5 6 7 8 9 Chilled water inlet Chilled water outlet Cooling water inlet Cooling water outlet Steam drain outlet Dilute solution (Absorber outlet) Concentrated solution (Generator outlet) Diluted solution concentration (Absorber outlet) Concentrated solution concentration (Generator outlet) Location Unit 12.2oC (54oF) 6.7oC (44oF) 29.4oC (85oF) 38.4oC (101.2oF) 95.0oC (203oF) 35.1oC (95.2oF) 85.6oC (186.1oF) 56.7% 63.2%

Table 3-22-2 Valve position Valve name Position Valve name Position B SV1 SV2 SV3 SV4 SV6 SV7 SV9 Open Close Close Close Close Close Open Close V1 V2 V3 Refrigerant blow valve Close Open Close Close Valve name Absorbent pump isolation valves Refrigerant pump isolation valves Position Open Open

Page 56 / Sec. 3

TJ Series

3-23A. Trial run (LJ) Trial run data sheet Project name Chiller model Serial number Accepted by Reviewed by Recorded by Unit Model / Serial No. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Data items Ambient temperature Room temperature Chilled water inlet temperature Chilled water outlet temperature Chilled water inlet pressure Chilled water outlet pressure Pressure drop in evaporator Chilled water flow rate Cooling water inlet temperature Cooling water outlet temperature Cooling water inlet pressure Cooling water outlet pressure Pressure drop in absorber & condenser Cooling water flow rate Hot water inlet temperature Hot water outlet temperature Hot water inlet pressure Hot water outlet pressure Pressure drop in generator Hot water flow rate Generator temperature Solution level in evaporator Pressure in purge tank
o o o o

1/2

: :TSA-16LJ: : : : Operator : Unit C/ F C / oF C / oF C / oF

o

, date , date , date Date : Spec. DATA-1 time: / DATA-2 time: / DATA-3 time:

kPa / psi kPa / psi kPa / psi m3/h / gpm

o o

C / oF C / oF

kPa / psi kPa / psi kPa / psi m3/h / gpm

o o

C / oF C / oF

kPa / psi kPa / psi kPa / psi l/s / gpm

o

C / oF

n/60 mm n/2-3/8" kPa

Page 57 / Sec. 3

LJ Series

Trial run data sheet Project name Chiller model Serial number Accepted by Reviewed by Recorded by Unit Model / Serial No. No. Data items Concentration of concentrated solution 24
Specific gravity of concentrated solution

2/2

: :TSA-16LJ: : : : Operator : Unit % o

, date , date , date Date : Spec. DATA-1 time: / DATA-2 time: / DATA-3 time:

Temperature of concentrated solution Concentration of diluted solution 25 Specific gravity of diluted solution Temperature of diluted solution Concentration of refrigerant 26 27 28 29 30 31 Specific gravity of refrigerant Temperature of refrigerant Condensed refrigerant temperature *LTD (See below) Absorbent pump current Refrigerant pump current Purge pump current

C / oF % -

C / oF % -

o o o

C / oF C / oF C / oF A A A

*LTD = Condensed refrigerant temp. - Cooling water outlet temperature Memo

Page 58 / Sec. 3

LJ Series

3-23B. Trial run (TJ) Trial run data sheet Project name Chiller model Serial number Accepted by Reviewed by Recorded by Unit Model / Serial No. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Data items Ambient temperature Room temperature Chilled water inlet temperature Chilled water outlet temperature Chilled water inlet pressure Chilled water outlet pressure Pressure drop in evaporator Chilled water flow rate Cooling water inlet temperature Cooling water outlet temperature Cooling water inlet pressure Cooling water outlet pressure Pressure drop in absorber & condenser Cooling water flow rate Steam consumption Supply steam pressure Supply steam temperature Generator temperature Solution level in evaporator Pressure in purge tank
o o o o

1/2

: :TSA-16TJ: : : : Operator : Unit C/ F C / oF C / oF C / oF

o

, date , date , date Date : Spec. DATA-1 time: / DATA-2 time: / DATA-3 time:

kPa / psi kPa / psi kPa / psi m3/h / gpm

o o

C / oF C / oF

kPa / psi kPa / psi kPa / psi m3/h / gpm kg/h / lb/h kPa / psi
o o

C / oF C / oF

n/60 mm n/2-3/8" kPa

Page 59 / Sec. 3

TJ Series

Trial run data sheet Project name Chiller model Serial number Accepted by Reviewed by Recorded by Unit Model / Serial No. No. Data items Concentration of concentrated solution 21
Specific gravity of concentrated solution

2/2

: :TSA-16TJ: : : : Operator : Unit % o

, date , date , date Date : Spec. DATA-1 time: / DATA-2 time: / DATA-3 time:

Temperature of concentrated solution Concentration of diluted solution 22 Specific gravity of diluted solution Temperature of diluted solution Concentration of refrigerant 23 24 25 26 27 28 Specific gravity of refrigerant Temperature of refrigerant Condensed refrigerant temperature *LTD (See below) Absorbent pump current Refrigerant pump current Purge pump current

C / oF % -

C / oF % -

o o o

C / oF C / oF C / oF A A A

*LTD = Condensed refrigerant temp. - Cooling water outlet temperature Memo

Page 60 / Sec. 3

TJ Series

3-24A. Daily maintenance (LJ) Proper maintenance of the unit will insure continuous, efficient, and trouble-free operation prolong equipment life and reducing service requirements. Daily maintenance should be performed by building maintenance personnel. Maintenance of auxiliary equipment is equally important and should be handled according to the manufacturers specifications. 1. Check and record operating data per daily operating record sheet, temperatures, pressures, water flow rate, etc. Refer to Table 3-24. 2. Make the following inspections: a. Abnormal noise from absorbent pump. b. Abnormal noise from refrigerant pump. c. Auxiliary equipment is in proper working order. d. Cooling tower water is being treated properly. 3. Review previous and present operating data for any difference in operating conditions that develop into a problem or maintenance issue. To be continued.

Page 61 / Sec. 3

LJ Series

Table 3-24 Daily log data sheet Unit Model / Serial No. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Notes: Data items Ambient temperature Room temperature Chilled water inlet temperature Chilled water outlet temperature Chilled water inlet pressure Chilled water outlet pressure Pressure drop in evaporator Chilled water flow rate Cooling water inlet temperature Cooling water outlet temperature Cooling water inlet pressure Cooling water outlet pressure Pressure drop in absorber & condenser Cooling water flow rate Hot water inlet temperature Hot water outlet temperature Hot water inlet pressure Hot water outlet pressure Pressure drop in generator Hot water flow rate Generator temperature Solution level in evaporator Pressure in purge tank Check : Absorbent pump noise Refrigerant pump noise
o o o o

Operator : Unit C/ F C / oF C / oF C / oF
o

Date : Spec. DATA-1 time:

/ DATA-2 time:

/ DATA-3 time:

kPa / psi kPa / psi kPa / psi m3/h / gpm

o o

C / oF C / oF

kPa / psi kPa / psi kPa / psi m3/h / gpm

o o

C / oF C / oF

kPa / psi kPa / psi kPa / psi l/s / gpm

o

C / oF

n/60 mm n/2-3/8" kPa

Page 62 / Sec. 3

LJ Series

3-24B. Daily maintenance (TJ) Proper maintenance of the unit will insure continuous, efficient, and trouble-free operation prolong equipment life and reducing service requirements. Daily maintenance should be performed by building maintenance personnel. Maintenance of auxiliary equipment is equally important and should be handled according to the manufacturers specifications. 1. Check and record operating data per daily operating record sheet, temperatures, pressures, water flow rate, etc. Refer to Table 3-24. 2. Make the following inspections: a. Abnormal noise from absorbent pump. b. Abnormal noise from refrigerant pump. c. Auxiliary equipment is in proper working order. d. Cooling tower water is being treated properly. 3. Review previous and present operating data for any difference in operating conditions that develop into a problem or maintenance issue. To be continued.

Page 63 / Sec. 3

TJ Series

Table 3-24 Daily log data sheet Unit Model / Serial No. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 21 22 23 24 25 Notes: Data items Ambient temperature Room temperature Chilled water inlet temperature Chilled water outlet temperature Chilled water inlet pressure Chilled water outlet pressure Pressure drop in evaporator Chilled water flow rate Cooling water inlet temperature Cooling water outlet temperature Cooling water inlet pressure Cooling water outlet pressure Pressure drop in absorber & condenser Cooling water flow rate Steam consumption Supply steam pressure Supply steam temperature Generator temperature Solution level in evaporator Pressure in purge tank Check : Absorbent pump noise Refrigerant pump noise
o o o o

Operator : Unit C/ F C / oF C / oF C / oF
o

Date : Spec. DATA-1 time:

/ DATA-2 time:

/ DATA-3 time:

kPa / psi kPa / psi kPa / psi m3/h / gpm

o o

C / oF C / oF

kPa / psi kPa / psi kPa / psi m3/h / gpm kg/h / lb/h kPa / psi
o o

C / oF C / oF

n/60 mm n/2-3/8" kPa

Page 64 / Sec. 3

TJ Series

Section 4A Control (LJ)

Control panel Operation board

Display Lamps Stop key Run key

The control of TSA-16LJ series consists of the following functions. (1) Operation (Start & Stop) (2) Safety stop (Alarm) with safety devices & safety functions (3) Cooling capacity control with avoidance for alarms (4) Data display Construction of devices to achieve theses function is as follows

Microprocessor (CPU)

63GH : Generator pressure switch 69PR : Purge tank pressure switch 69CH : Chilled water flow switch DT1 : Chilled water outlet temp. sensor DT3 : Generator temp. sensor DT2 : Cooling water outlet temp. sensor DT5 : Condenser temp. sensor DT6 : Chilled water inlet temp. sensor DT7 : Cooling water inlet temp. sensor DT10 : Absorber temp. sensor DT11 : Evaporator temp. sensor DT12 : Middle cooling water temp. sensor DT14 : Hot water outlet temp. sensor DT15 : Hot water inlet temp. sensor DT16 : Hot water outlet temp. sensor Fig. 4-1

Page 1 / Sec. 4

LJ Series

4-1. Operation 4-1-1. Run of the chiller The sequence of starting the chiller is as follow. Remark :The following sequence is in case of using the interlock system provided in the chiller control circuit.
Push RUN key on the operation board or Remote start signal

Hot water pump starts

Chilled water pump starts signal goes to chilled water pump operation circuit from chiller control circuit

Contact of chilled water flow switch opens

YES

No

J-03 After 10 min., Chilled water flow rate alarm

Chilled water temp. is above 2.5 deg.C (36.5 deg.F)

YES

No

J-01 After 10 min., Chilled water low temp. alarm

Chilled water pump starts

YES

No

J-02 After 10 min., Chilled water pump alarm

Chilled water pump interlock signal

ON signal of 69CH returns to chiller control

YES

No

J-03 After 10 min., Chilled water flow rate alarm

Cooling water pump starts signal goes to cooling water pump operation circuit from chiller control circuit

Cooling water pump starts

YES

No

J-06 After 10 min., Cooling water pump alarm

cooling water fan circuit works

Cooling water pump interlock signal

Chiller runs

Fig. 4-2 Page 2 / Sec. 4 LJ Series

4-1-2. Stop of the chiller The sequence of stopping the chiller is as follow.
Push RUN key on the operation board or Remote start signal

Hot water control valve travels to close

After 1 minute, the refrigerant pump stops

After 1minute, the cooling water pump stops

After 1 minute, the chilled water pump stops

After 1 minute, hot water pump stops

After 1minute, the chiller stops entirely

Fig. 4-3 The time chart of stop sequence is as follows.

RUN

Hot water pump

STOP 100%

Hot water control valve

0% RUN

Refrigerant pump
STOP RUN

Cooling water pump

STOP RUN

Chilled water pump

STOP RUN

Absorbent pump
STOP 1 min. Stop signal 1 min. 1 min. Entire t

Fig. 4-4 Page 3 / Sec. 4

LJ Series

Dilution operation

4-2. Safety stop (Alarm) Following safety stops are provide on TSA-16LJ series. Purpose Symbol Name of Alarm Stop condition J-01 Chilled water low temp. alarm Chiller and cooling water pump stop immediately without dilution operation Chiller and cooling water pump stop immediately without dilution operation J-02 Chilled water pump alarm J-03 Chilled water flow rate alarm Chiller and cooling water pump stop immediately without dilution operation J-20 Cooling water low temp. alarm Chiller stops after dilution operation Chiller stops after dilution operation. But refrigerant pump stops immediately J-06 Cooling water pump alarm J-07 Cooling water flow rate alarm Chiller stops after dilution operation. But refrigerant pump stops immediately J-13 Generator high temp. alarm Chiller stops after dilution operation J-14 Generator high pressure alarm Chiller stops after dilution operation Chiller stops after dilution operation J-16 High concentration alarm Dilution operation without running absorbent & refrigerant pump is proceeding J-04 #1 Absorbent pump alarm Dilution operation without running absorbent & refrigerant pump is proceeding J-10 Refrigerant pump alarm Purge pump only stops J-12 Purge pump alarm (1) Name of alarm
Motor protection Crystallization protection Chilled water freeze protection

: Chilled water low temp. alarm (Symbol : J-01)

If chilled water outlet temp. goes down to 2.5 deg.C (36.5 deg.F) for 2 seconds during operation

Condition of work : If chilled water outlet temp. is 2.5 deg.C (36.5 deg.F) for 2 seconds at starting chiller Time chart at alarm happened during operation
RUN

Hot water pump

STOP 100%

Hot water control valve

0% RUN STOP

Refrigerant pump

Cooling water pump

RUN STOP RUN STOP RUN

Chilled water pump

Absorbent pump
STOP 1 min. Alarm happens 2 min.

Fig.4-5

Entire stop

(2) Name of alarm

: Chilled water pump alarm (Symbol : J-02) If chilled water pump stops during operation of chiller

Condition of work : If chilled water pump dose not start after 10 minutes of receiving the start signal Time chart at alarm happened during operation : Same as J-01 (3) Name of alarm : Chilled water flow rate alarm (Symbol : J-03) If chilled water flow rate goes down below 50 % of rated flow rate during operation Time chart at alarm happened during operation : Same as J-01

Condition of work : If chilled water flow rate is below 50 % of rated flow rate at starting chiller

Page 4 / Sec. 4

LJ Series

(4) Name of alarm

: Cooling water low temp. alarm (Symbol : J-20)

after 30 minutes of starting chiller or the temperature continues for 30 minutes during operation

Condition of work : If cooling water inlet temperature does not rise up to the temperature shown in Fig. 4-6

19 deg.C (66.2 deg.F) Cooling water low temp. alarm watched temperature 14 deg.C (57.2 deg.F) 20 deg.C (68 deg.F) Specified cooling water inlet temperature 32 deg.C (89.6 deg.F)

Fig. 4-6 Time chart at alarm happened during operation : Same as Fig. 4-4. (5) Name of alarm : Cooling water pump alarm (Symbol : J-06) If cooling water pump stops during operation of chiller Time chart at alarm happened during operation
RUN

Condition of work : If cooling water pump dose not start after 10 minutes of receiving the start signal

Hot water pump

STOP 100%

Hot water control valve

0% RUN STOP

Refrigerant pump

Cooling water pump

RUN STOP RUN STOP RUN

Chilled water pump

Absorbent pump
STOP 1 min. Alarm happens 1 min. 1 min. Entire stop

Fig. 4-7

(6) Name of alarm

: Cooling water flow rate alarm (Symbol : J-07) OPTION If cooling water flow rate goes down below 50 % of rated flow rate during operation

Condition of work : If cooling water flow rate is below 50 % of rated flow rate at starting chiller Time chart at alarm happened during operation : Same as Fig. 4-7

Page 5 / Sec. 4

LJ Series

(7) Name of alarm

: Generator high temp. alarm (Symbol : J-13)

Condition of work : If generator temperature goes up to 95 deg.C (203 deg.F) during operation Time chart at alarm happened during operation : Same as Fig. 4-4 (8) Name of alarm : Generator high pressure alarm (Symbol : J-14)

Condition of work : If generator pressure goes up to 0 MPa (0 psig) during operation Time chart at alarm happened during operation : Same as Fig. 4-4 (9) Name of alarm : High concentration alarm (Symbol : J-16) after starting crystallization protection control If concentration of concentrated LiBr solution goes up to 65 % within 1 hour after starting crystallization protection control If concentration of concentrated LiBr solution goes up to 65.5 % Time chart at alarm happened during operation : Same as Fig. 4-4 (10) Name of alarm : #1 absorbent pump alarm (Symbol : J-04)

Condition of work : If concentration of concentrated LiBr solution goes up to 65 % at just 3 minutes

Condition of work : If #1 absorbent pump thermalrelay (51A1) works at starting chiller and during operation Time chart at alarm happened during operation
RUN

Hot water pump

STOP 100%

Hot water control valve

0% RUN STOP

Refrigerant pump

Cooling water pump

RUN STOP RUN STOP RUN

Chilled water pump

Absorbent pump
STOP 1 min. Alarm happens 1 min. 1 min. Entire stop

Fig. 4-8

(11) Name of alarm

: Refrigerant pump alarm (Symbol : J-10)

Condition of work : If Refrigerant pump thermalrelay (51R) works at starting chiller and during operation Time chart at alarm happened during operation : Same as Fig. 4-4 except for the refrigerant pump (12) Name of alarm : Purge pump alarm (Symbol : J-12) The purge pump only stops. This alarm dose not affect to operation. But, if the purge pump stops during purging, manual purge valves shall be closed immediately.

Condition of work : If purge pump thermalrelay (51P) works

Page 6 / Sec. 4

LJ Series

4-3. Capacity control The capacity control of TSA-16LJ series is PID control. A signal of chilled water outlet temperature detected by DT1 is sent to a microprocessor then the signal control a hot water control valve to control cooling capacity. In addition to the PID control, there are following control functions to smooth the control. (1) Hot water control valve slow open function (2) Crystallization protection function during low cooling water temperature & Generator high temp. alarm protection function during high cooling water temperature (3) Operation continuing function at high generator temperature condition (4) Chilled water freeze protection function by On/OFF of refrigerant pump (5) Auto-rest function of chilled water outlet temperature setting depending on cooling water temperature 4-3-1. Hot water control valve slow open function Purpose : This function is provided to avoid over-input at the starting of the chiller. The hot water control valve opens gradually shown in Fig. 4-9.
100 %

Hot water control valve opening

70 %

0%

3 min.

Time Fig. 4-9

15 min.

4-3-2. Crystallization protection function during low cooling water temperature & Generator high temp. alarm protection function during high cooling water temperature Purpose : This function is provided to avoid crystallization and the generator high temp. alarm during low cooling water temperature in operation The hot water control valve is controlled Fig. 4-10.
100%

Hot water control valve opening

80%

ST : Specified temp.

60%

Crystallization protection

Avoidance of Generator high temp alarm

0% ST-13 deg.C (ST-23.4 deg.F) ST-4 deg.C (ST-7.2 deg.F)

ST

ST+2 deg.C (ST+3.6 deg.F)

Cooling water inlet temp. Page 7 / Sec. 4

Fig. 4-10 LJ Series

4-3-3. Operation continuing function at high generator temperature condition Purpose : This function is to continue operation of the chiller if generator temperature abnormally rises The hot water control valve is controlled Fig. 4-11. If the concentration of concentrated LiBr solution reaches 65%, the hot water control valve travels to close for 3 minutes to reduce the generator temperature. However, even if this function works, if the concentration reaches 65.5%, J-13 happens. Hot water control valve opening
100%

0%

2 min.

65.5%

Concentration of concentrated LiBr solution

65%

64% 3 min. 63% 1 hour

Fig. 4-11

4-3-4. Chilled water freeze protection function by ON/OFF of refrigerant pump Purpose : This function is to avoid excessive low chilled water outlet temperature by means of stop of the refrigerant pump If the chilled water outlet temperature more goes down in the condition of close of the hot water control valve, the refrigerant pump is stooped as shown in Fig. 4-12
ON (RUN)

Refrigerant pump
OFF (STOP) ST-2 deg.C (ST-3.6 deg.F) ST-1.5 deg.C (ST-2.7 deg.F) ST Fig. 4-12

ST : Chilled water setting temperature

4-3-5. Auto-rest function of chilled water outlet temperature setting depending on cooling water temperature Purpose : This function is to avoid cavitation of the refrigerant pump possibly occurring under the condition that the chilled water outlet temperature setting is comparatively high and the cooling water inlet temperature is low
12 deg.C (53.6 deg.F) Chilled water setting temp. 11 deg.C (51.8 deg.F) 10 deg.C (50.0 deg.F) 9 deg.C (48.2 deg.F) 8 deg.C (46.4 deg.F) 7 deg.C (44.6 deg.F)

22 deg.C (71.6 deg.F)

24 deg.C 26 deg.C 27 deg.C (75.2 deg.F) (78.8 deg.F) (80.6 deg.F) Cooling water inlet temp.

Fig. 14-13

Page 8 / Sec. 4

LJ Series

4-4. Operation board By means of operating keys on the operation board, the following tasks can be done. (1) Main menu (data display) (2) Resetting of chilled water outlet temp. setting (3) Confirmation & resetting of various set values (4) Service mode for servicing : Refer to Section 3 Main menu (22 items) Generator temp. (it is normally displayed) 1. Chiller running time 2. #1 absorbent pump running time * * * * * 10. Chilled water outlet temp. set * * * * * * Remarks : An alarm indication is displayed at only occurring an alarm If several alarms occur at the same time, a higher priority alarm is displayed. Lower priority alarms can be displayed by & keys. Resetting of chilled water outlet temp. setting Push "SET" key for 2 sec. Confirmation & resetting of various set values Service mode Push "SET" key for 2 sec.
Push "SET+ " key for 2 sec.

Page 9 / Sec. 4

LJ Series

4-4-1. Main menu (22 items) 22 items in the main menu can be displayed in sequence by Key
Code

&

keys as follows. Meaning of example of display

Data item
Generator temp. Chiller running time #1 absorbent pump running time #2 absorbent pump running time Burner running time Refrigerant pump running time Purge unit running time Chiller RUN/STOP times #1 absorbent pump RUN/STOP times #2 absorbent pump RUN/STOP times Burner RUN/STOP times Refrigerant pump RUN/STOP times Purge unit RUN/STOP times #3 absorbent pump running time #3 absorbent pump RUN/STOP times

Example of display

8 5. 0 Generator temp. is 85.0 deg.C (185 deg.F) 1. 1 2 3 5 5 Chiller running time is 12355 hours 2. 3. 4. 5. 6. 7. 8. 9. A. b. C. d. E. 1 0. 1 1. 1 2. 1 3. 1 4. 1 5. 1 6. 1 7. 1 1. 9 6. 8 3 1. 8 3 8. 7 8 5. 0 8. 5 7. 0 5 2 3 5 #1 absorbent pump running time is 5235 hours
Not used Not used

1 2 3 4 5 6 7 8 9 A B C D E

5 0 3 0 Refrigerant pump running time is 5030 hours 1 0 7 Purge unit running time is 107 hours 6 3 Chiller RUN/STOP times is 63 times 1 0 7 1
#1 absorbent pump RUN/STOP times is 1071 times

Not used Not used

8 7 Refrigerant pump RUN/STOP times is 87 times 3 0 2 2 Purge unit RUN/STOP times is 3022 times
Not used Not used
Chilled water outlet temp. set is 7 deg.C (44.6 deg.F)

10 Chilled water outlet temp. set 11 Hot water outlet temp. set 12 Chilled water inlet temp. 13 Chilled water outlet temp. 14 Cooling water inlet temp. 15 Condensed refrigerant temp. 16 Hot water outlet temp. 17 Pressure in purge tank 4-4-2. Resetting of chilled water outlet temp. setting The display "Chilled water outlet temp. set" is indicated by & keys

Not used
Chilled water inlet temp. is 11.9 deg.C (53.4 deg.F) Chilled water outlet temp. is 6.8 deg.C (44.2 deg.F) Cooling water inlet temp. is 31.8 deg.C (89.2 deg.F) Condensed refr. temp. is 34.7 deg.C (101.7 deg.F) Hot water outlet temp. is 85.0 deg.C (167 deg.F) Pressure in purge tank is 8.5 kPa (1.23 psi) abs.

8 5. 0 1 0. 7. 0

85 deg.C = 185 deg.F 7 deg.C = 44.6 deg.F Blinking

Push "SET" key for 2 sec. The indication blinks The set can be changed by & keys

1 0. 1 0. 1 0.

7. 0 8. 0 8. 0 8 deg.C = 46.4 deg.F

Push "SET" key. New value is set

Note 1 : In case that new value is not required, push "BACK" key. The indication returns 1 0. Note 2 : If any keys are not operated for 1 minute, the indication returns to "Generator temp.".

7. 0 .

Page 10 / Sec. 4

LJ Series

4-4-3. Confirmation & resetting of various set values (11 items) 11 items in this menu can be displayed in sequence by
Indication of Generator temp.

&

keys as follows. are not used

Note : Items covered with

Push "SET" key for 2 sec.

Push "BACK" key

Key
Alarm record

Data item
Set of Year, Month, Day, Time Change of switch

Example of display

Contents
Indication of a detail record of alarm

A L A r n.

r t. 1 4. 5 3 Set of Year, Month, Day, Time Cool / Heat change-over C H G S Operation data record interval change Select of Local operation mode Cancel of Predication information Change of unit

Change of Low select control

Set of chilled water pump

A P P o C H

Confirmation of interlock return time

Set of variable flow rate Set of parallel operation by remote controller Inverter control for chilled water

C H -

n V Set of specified chilled/hot water flow rate

Set of specified hot water flow rate Controlled variable Minimum frequency

Set of cooling water pump & cooling tower

A P P

C o

Confirmation of interlock return time

Set of stopping cooling water pump at low load Set of cooling tower fan control Set of cooling water temperature control Set of differential temp. of cooling tower fan Set of variable flow rate Inverter control of cooling water

C O -

n V Cost factor
Controlled variable Minimum frequency

Field set

E L d

Set of cooling water temp. at maximum input Set of slow open time Set of slow open temp. Set of dilution time Set of remote signal type Set of type of Pulse Set of Low select control temp. Set of radiation temp.

Set of RS-485 Indication of version number

Indication of version number of option board

r S - 4 8 5 Set of address V E r 0. 0 0 No-sub menu o P V 0. 0 0 No-sub menu A L A r n.

Indication of a detail record of alarm

Alarm record

Page 11 / Sec. 4

LJ Series

(1) Alarm record Data item

Alarm record Example of display

Contents
Indication of a detail record of alarm / Clear

A L A r n. Push "BACK" key C 1.

Push "SET" key for 2 sec.

First alarm code

First alarm code (Newest)

Date of first alarm

d 1. 1 0 2 4 24, Oct. t 1. 1 4. 0 2 14:02 C 2.

Second alarm code

Time of first alarm

Second alarm code

Date of second alarm

d 2. 0 6 0 9 09, June t 2. 0 8. 4 4 8:44 C 3. d 3. t 3. Third alarm code

Time of second alarm

Third alarm code

Date of third alarm

- No-occurrence - No-occurrence

Time of third alarm

Clear of alarm record

r E - S E t Push "SET" for 2 sec. 3 Push "SET" key 2 Push "SET" key 1 Push "SET" key 3 data records are cleared

First alarm code

C 1.

First alarm code (Newest)

Page 12 / Sec. 4

LJ Series

(2) Set of Year, Month, Day, Time Data item

Set of Year, Month, Day, Time Example of display

Contents

r t. 1 4. 5 3 Set of Year, Month, Day, Time Push "BACK" key Y r - S E t Blinking

Push "SET" key for 2 sec.

Set of Year

Push "SET" for 2 sec.

2 0 0 1

Year can be changed from 2000 to 2050 by & keys

Push "SET" key. New data is set.

Set of Month & Date

d t

- S E t

Blinking

Push "SET" for 2 sec.

1 0 - 2 4

: Month

Date

Month

: Increasing number Initial set : 0 1 - 0 1 (1st January) Push "SET" key. New data is set. Month : 1 - 12 Date : 1 - 31

Set of time

t n. - S E t

Blinking

Push "SET" for 2 sec. 0 2 -

0 8 Initial set : 0 7 - 0 0 (7:00)

: O'clock

minute

O'clock

: Increasing number Push "SET" key. New data is set. O'clock : 0 - 23 Minute : 0 - 59

Set of Year

Y r

- S E t

Page 13 / Sec. 4

LJ Series

(3) Change of switch Data item

Change of switch Example of display

Contents
Cool / Heat change-over Operation data record interval change Select of Local operation mode Cancel of Predication information Change of unit

C H G S -

Change of Low select control Push "SET" key for 2 sec. Push "SET" key for 2 sec.
Cool / Heat change-over

Push "BACK" key Push "BACK" key r d - S E t Push "BACK" key S A n. - d t Push "SET" for 2 sec.

Do not use this function. TSA-16LJ series is Cooling only. Push "SET" key for 2 sec.
Operation data record interval change

Present interval is blinking 1 - H ( 1 hour ) Initial set : 1 - H or

5 - n. ( 5 minutes )

or &

1 - n. ( 1 minute ) keys.

or 1 0 - S ( 10 seconds )

Required interval can be selected by

Push "SET" key. New interval is set. Push "SET" key for 2 sec.
Select of Local operation mode

Push "BACK" key L o C A L Push "SET" for 2 sec.

Present condition is blinking

o n Initial set : o n

or o F F & keys.

ON or OFF can be selected by

Push "SET" key. New condition is set. Push "SET" key for 2 sec.
Cancel of Predication information

Push "BACK" key

Note Predication information does not goes off Push "SET" for 2 sec. unless a cause of the predication information is removed. If the predication information is cancelled even if the cause in not removed, this function is used. C o n S E n

G n

Blinking

Push "SET" key, a predication information displayed is cancelled.

Push "SET" key for 2 sec.

Change of unit

Push "BACK" key u

n I

Predication information Present unit is blinking o C Initial set : o C Push "SET" key. New condition is set. Push "SET" for 2 sec. or o F & keys.

Unit can be selected by

Page 14 / Sec. 4

LJ Series

Push "SET" key for 2 sec.

Change of Low select control

Push "BACK" key L

o

S E L

This function is not used for TSA-16LJ series.

Cool / Heat change-over

r d - S E t

(4) Set of chilled water pump Data item

Set of chilled water pump

Example of display

Contents
Confirmation of interlock return time

A P P o C H

Set of variable flow rate Set of parallel operation by remote controller

Push "SET" key for 2 sec.

Confirmation of interlock return time

Push "BACK" key I n t - C H Push "SET" for 2 sec.

Present value is blinking

0 0 0 5 Time can be changed by & keys. (Changeable from 0 to 250 sec.) Initial set : 0 0 0 5 Push "SET" key. New value is set. Push "SET" key for 2 sec. Push "BACK" key Set of variable flow rate V - V - C H No-function Push "SET" key for 2 sec. Push "BACK" key Set of parallel operation by remote controller r - P A r A No-function Push "SET" key for 2 sec. Push "BACK" key I n t - C H Confirmation of interlock return time (5) Inverter control for chilled water pump No-function (6) Set of cooling water pump & cooling tower Data item
Set of cooling water pump & cooling tower

Example of display

Contents
Confirmation of interlock return time

A P P

C o

Set of stopping cooling water pump at low load Set of cooling tower fan control Set of cooling water temperature control Set of differential temp. of cooling tower fan Set of variable flow rate

Push "SET" key for 2 sec.

Confirmation of interlock return time

Push "BACK" key I n t - C o Push "SET" for 2 sec.

Present value is blinking

0 0 0 5 Time can be changed by & keys. (Changeable from 0 to 250 sec.) Initial set : 0 0 0 5 Push "SET" key. New value is set. Push "SET" key for 2 sec. Push "BACK" key Set of stopping cooling water pump at low load C o S t o P No-function Push "SET" key for 2 sec. Push "BACK" key Set of cooling tower fan control C t A u t o No-function Push "SET" key for 2 sec. Push "BACK" key Set of cooling water temperature control C t t E n. P No-function Push "SET" key for 2 sec. Push "BACK" key Set of differential temp. of cooling tower fan C t d No-function I F F Push "SET" key for 2 sec. Push "BACK" key Set of variable flow rate V No-function - V - C o Push "SET" key for 2 sec. Push "BACK" key I n t - C o Confirmation of interlock return time

Page 15 / Sec. 4

LJ Series

(7) Inverter control for cooling water pump No-function (8) Field set Data item
Field set Example of display

Contents
Set of cooling water temp. at maximum input Set of slow open time Set of slow open temp. Set of dilution time Set of remote signal type Set of type of Pulse Set of Low select control temp. Set of radiation temp.

E L d

Push "SET" key for 2 sec.

Set of cooling water temp. at maximum input

Push "BACK" key

C

o -

n P

Present value is blinking

Push "SET" for 2 sec. 3 2. 0 o C & keys. (Changeable from 20 to 33 deg.C) (68 to 91.4 deg.F)

Initial set : 3 2. 0

Set can be changed by o C Push "BACK" key

I

Push "SET" key. New value is set. Push "SET" key for 2 sec. Set of slow open time Present value is blinking n P
-

t n.

Push "SET" for 2 sec. 0 0 0 0 5 & keys.

Set can be changed by Initial set : 0 0 0 0 5

(Changeable from 0 to 1800 sec., Step 10 sec.) Push "SET" key. New value is set. Push "BACK" key
I

Push "SET" key for 2 sec. Set of slow open temp. Present value is blinking

n P

n. P

Push "SET" for 2 sec. 0 0 0 o C & keys. (Changeable from 0 to 120 deg.C) (32 to 248 deg.F)

Initial set : 0 0 0

Set can be changed by o C Push "BACK" key

Push "SET" key. New value is set. Push "SET" key for 2 sec.

Page 16 / Sec. 4

LJ Series

Push "SET" key for 2 sec. Set of dilution time Present value is blinking

Push "BACK" key d

I

Push "SET" for 2 sec. 0 4 n. & keys. (Changeable from 4 to 20 min.)

Set can be changed by Initial set : 0 4 n.

Push "SET" key. New value is set. Push "SET" key for 2 sec. Set of remote signal type Present condition is blinking Push "BACK" key r
-

G n

Push "SET" for 2 sec. S t A t C or P u L S E & keys.

Type can be selected by Initial set : S t A t

I

C Push "SET" key. New type is set. Push "BACK" key o F - P L S Push "SET" for 2 sec. P o S t or P u L S E & keys.

Push "SET" key for 2 sec. Set of type of puls Present condition is blinking

Type can be selected by Initial set : P o S

I

Push "SET" key. New type is set. Push "SET" key for 2 sec.
Set of Low select control temp.

Push "BACK" key L o S E L E Push "BACK" key H E II - S t Push "BACK" key C o I

No-function No-function

Push "SET" key for 2 sec.

Set of radiation temp.

Push "SET" key for 2 sec.

Confirmation of interlock return time

n P

(9) Set of RS-485 No-function

Page 17 / Sec. 4

LJ Series

Section 4B Control (TJ)

The control of TSA-16TJ series consists of the following functions. (1) Operation (Start & Stop) Control panel Operation board
Display Lamps Stop key Run key

(2) Safety stop (Alarm) with safety devices & safety functions (3) Cooling capacity control with avoidance for alarms (4) Data display Construction of devices to achieve theses function is as follows

Microprocessor (CPU)

63GH : Generator pressure switch 69PR : Purge tank pressure switch 69CH : Chilled water flow switch DT1 : Chilled water outlet temp. sensor DT3 : Generator temp. sensor DT2 : Cooling water outlet temp. sensor DT5 : Condenser temp. sensor DT6 : Chilled water inlet temp. sensor DT7 : Cooling water inlet temp. sensor DT10 : Absorber temp. sensor DT11 : Evaporator temp. sensor DT12 : Middle cooling water temp. sensor DT13 : Steam drain temp. sensor Fig. 4-1

Page 18 / Sec. 4

TJ Series

4-1. Operation 4-1-1. Run of the chiller The sequence of starting the chiller is as follow. Remark :The following sequence is in case of using the interlock system provided in the chiller control circuit.
Push RUN key on the operation board or Remote start signal

Chilled water pump starts signal goes to chilled water pump operation circuit from chiller control circuit

Contact of chilled water flow switch opens

YES

No

J-03 After 10 min., Chilled water flow rate alarm

Chilled water temp. is above 2.5 deg.C (36.5 deg.F)

YES

No

J-01 After 10 min., Chilled water low temp. alarm

Chilled water pump starts

YES

No

J-02 After 10 min., Chilled water pump alarm

Chilled water pump interlock signal

ON signal of 69CH returns to chiller control

YES

No

J-03 After 10 min., Chilled water flow rate alarm

Cooling water pump starts signal goes to cooling water pump operation circuit from chiller control circuit

Cooling water pump starts

YES

No

J-06 After 10 min., Cooling water pump alarm

cooling water fan circuit works

Cooling water pump interlock signal

Chiller runs

Fig. 4-2 Page 19 / Sec. 4 TJ Series

4-1-2. Stop of the chiller The sequence of stopping the chiller is as follow.
Push RUN key on the operation board or Remote start signal

Steam control valve travels to close

After 1 minute, the refrigerant pump stops

After 1minute, the cooling water pump stops

After 1 minute, the chilled water pump stops

After 1minute, the chiller stops entirely

Fig. 4-3 The time chart of stop sequence is as follows. (Output signals from the microprocessor)
OPEN

Steam shut-off valve

CLOSE 100%

Steam control valve

0% RUN

Refrigerant pump
STOP RUN

Cooling water pump

STOP RUN

Chilled water pump

STOP RUN

Absorbent pump
STOP 1 min. T1 1 min. T2

Stop signal

Fig. 4-4 T1 : The time until the generator temperature reaches to 80 deg.C (176 deg.F) or below. Changeable from 4 min. to 20 min. T2
10 min. 9 min. 8 min. 7 min. 6 min. 5 min. 65 deg.C (149 deg.F) Generator temp.

Entire stop

T2: See the below graph.

100 deg.C (212 deg.F)

Page 20 / Sec. 4

TJ Series

Dilution operation

4-2. Safety stop (Alarm) Following safety stops are provide on TSA-16TJ series. Purpose
Chilled water freeze protection
Symbol

Name of Alarm

Stop condition
Chiller and cooling water pump stop immediately without dilution operation

J-01 Chilled water low temp. alarm Chiller and cooling water pump stop immediately without dilution operation J-02 Chilled water pump alarm J-03 Chilled water flow rate alarm Chiller and cooling water pump stop immediately without dilution operation J-20 Cooling water low temp. alarm Chiller stops after dilution operation J-06 Cooling water pump alarm
Chiller stops after dilution operation. But refrigerant pump stops immediately

Crystallization protection

J-07 Cooling water flow rate alarm Chiller stops after dilution operation. But refrigerant pump stops immediately J-13 Generator high temp. alarm J-16 High concentration alarm
Chiller stops after dilution operation

J-14 Generator high pressure alarm Chiller stops after dilution operation
Chiller stops after dilution operation Dilution operation without running absorbent & refrigerant pump is proceeding Dilution operation without running absorbent & refrigerant pump is proceeding Purge pump only stops

Motor protection

J-04 #1 Absorbent pump alarm J-10 Refrigerant pump alarm J-12 Purge pump alarm

(1) Name of alarm

: Chilled water low temp. alarm (Symbol : J-01)

If chilled water outlet temp. goes down to 2.5 deg.C (36.5 deg.F) for 2 seconds during operation

Condition of work : If chilled water outlet temp. is 2.5 deg.C (36.5 deg.F) for 2 seconds at starting chiller Time chart at alarm happened during operation
OPEN

Steam shut-off valve

CLOSE 100%

Steam control valve

0% RUN

Refrigerant pump
STOP RUN

Cooling water pump

STOP RUN

Chilled water pump

STOP RUN

Absorbent pump
STOP 1 min. T1 Entire stop

Alarm happens

Fig.4-5

(2) Name of alarm

: Chilled water pump alarm (Symbol : J-02) If chilled water pump stops during operation of chiller

Condition of work : If chilled water pump dose not start after 10 minutes of receiving the start signal Time chart at alarm happened during operation : Same as J-01

Page 21 / Sec. 4

TJ Series

(3) Name of alarm

: Chilled water flow rate alarm (Symbol : J-03) If chilled water flow rate goes down below 50 % of rated flow rate during operation

Condition of work : If chilled water flow rate is below 50 % of rated flow rate at starting chiller Time chart at alarm happened during operation : Same as J-01 (4) Name of alarm : Cooling water low temp. alarm (Symbol : J-20)
after 30 minutes of starting chiller or the temperature continues for 30 minutes during operation

Condition of work : If cooling water inlet temperature does not rise up to the temperature shown in Fig. 4-6

19 deg.C (66.2 deg.F) Cooling water low temp. alarm watched temperature 14 deg.C (57.2 deg.F) 20 deg.C (68 deg.F) Specified cooling water inlet temperature 32 deg.C (89.6 deg.F)

Fig. 4-6 Time chart at alarm happened during operation : Same as Fig. 4-4. (5) Name of alarm : Cooling water pump alarm (Symbol : J-06) If cooling water pump stops during operation of chiller Time chart at alarm happened during operation
OPEN

Condition of work : If cooling water pump dose not start after 10 minutes of receiving the start signal

Steam shut-off valve

CLOSE 100%

Steam control valve

0% RUN

Refrigerant pump
STOP RUN

Cooling water pump

STOP RUN

Chilled water pump

STOP RUN

Absorbent pump
STOP 1 min. T1 Stop signal 1 min. T2 Entire stop

Fig. 4-7

Page 22 / Sec. 4

TJ Series

(6) Name of alarm

: Cooling water flow rate alarm (Symbol : J-07)OPTION If cooling water flow rate goes down below 50 % of rated flow rate during operation

Condition of work : If cooling water flow rate is below 50 % of rated flow rate at starting chiller Time chart at alarm happened during operation : Same as Fig. 4-7

(7) Name of alarm

: Generator high temp. alarm (Symbol : J-13)

Condition of work : If generator temperature goes up to 105 deg.C (221 deg.F) during operation Time chart at alarm happened during operation

OPEN

Steam shut-off valve

CLOSE 100%

Steam control valve

0% RUN

Refrigerant pump
STOP RUN

Cooling water pump

STOP RUN

Chilled water pump

STOP RUN

Absorbent pump
STOP 1 min. T1 Alarm happens 1 min. T2 Entire stop

Fig. 4-8

(8) Name of alarm

: Generator high pressure alarm (Symbol : J-14)

Condition of work : If generator pressure goes up to 0 MPa (0 psig) during operation Time chart at alarm happened during operation : Same as Fig. 4-8

(9) Name of alarm

: High concentration alarm (Symbol : J-16) after starting crystallization protection control If concentration of concentrated LiBr solution goes up to 65 % within 1 hour after starting crystallization protection control If concentration of concentrated LiBr solution goes up to 65.5 %

Condition of work : If concentration of concentrated LiBr solution goes up to 65 % at just 3 minutes

Time chart at alarm happened during operation : Same as Fig. 4-8

Page 23 / Sec. 4

TJ Series

(10) Name of alarm

: #1 absorbent pump alarm (Symbol : J-04)

Condition of work : If #1 absorbent pump thermalrelay (51A1) works at starting chiller and during operation Time chart at alarm happened during operation
OPEN

Steam shut-off valve

CLOSE 100%

Steam control valve

0% RUN

Refrigerant pump
STOP RUN

Cooling water pump

STOP RUN

Chilled water pump

STOP RUN

Absorbent pump
STOP 1 min. T1 1 min. Entire stop

Fig. 4-9

Alarm happens

(11) Name of alarm

: Refrigerant pump alarm (Symbol : J-10)

Condition of work : If Refrigerant pump thermalrelay (51R) works at starting chiller and during operation Time chart at alarm happened during operation
OPEN

Steam shut-off valve

CLOSE 100%

Steam control valve

0% RUN

Refrigerant pump
STOP RUN

Cooling water pump

STOP RUN

Chilled water pump

STOP RUN

Absorbent pump
STOP 1 min. T1 1 min. T2 Entire stop

Alarm happens

Fig. 4-10

(12) Name of alarm

: Purge pump alarm (Symbol : J-12) The purge pump only stops. This alarm dose not affect to operation. But, if the purge pump stops during purging, manual purge valves shall be closed immediately. Page 24 / Sec. 4 TJ Series

Condition of work : If purge pump thermalrelay (51P) works

4-3. Capacity control The capacity control of TSA-16TJ series is PID control. A signal of chilled water outlet temperature detected by DT1 is sent to a microprocessor then the signal control a steam control valve to control cooling capacity. In addition to the PID control, there are following control functions to smooth the control. (1) Steam control valve slow open function (2) Crystallization protection function during low cooling water temperature & Generator high temp. alarm protection function during high cooling water temperature (3) Operation continuing function at high generator temperature condition (4) Chilled water freeze protection function by On/OFF of refrigerant pump (5) Auto-rest function of chilled water outlet temperature setting depending on cooling water temperature 4-3-1. Steam control valve slow open function Purpose : This function is provided to avoid over-input at the starting of the chiller. The steam control valve opens gradually shown in Fig. 4-11. Steam control valve opening
100 %

70 %

0%

3 min.

Time Fig. 4-11

15 min.

4-3-2. Crystallization protection function during low cooling water temperature & Generator high temp. alarm protection function during high cooling water temperature Purpose : This function is provided to avoid crystallization and the generator high temp. alarm during low cooling water temperature in operation The steam control valve is controlled Fig. 4-12.
100%

Steam control valve opening

80%

ST : Specified temp.

60%

Crystallization protection

Avoidance of Generator high temp alarm

0% ST-13 deg.C (ST-23.4 deg.F) ST-4 deg.C (ST-7.2 deg.F)

ST

ST+2 deg.C (ST+3.6 deg.F)

Cooling water inlet temp.

Fig. 4-12 TJ Series

Page 25 / Sec. 4

4-3-3. Operation continuing function at high generator temperature condition Purpose : This function is to continue operation of the chiller if generator temperature abnormally rises The steam control valve is controlled Fig. 4-13. If the concentration of concentrated LiBr solution reaches 65%, the steam control valve travels to close for 3 minutes to reduce the generator temperature. However, even if this function works, if the concentration reaches 65.5%, J-13 happens. Steam control valve opening
100%

0%

2 min.

65.5%

Concentration of concentrated LiBr solution

65%

64% 3 min. 63% 1 hour

Fig. 4-13

4-3-4. Chilled water freeze protection function by ON/OFF of refrigerant pump Purpose : This function is to avoid excessive low chilled water outlet temperature by means of stop of the refrigerant pump If the chilled water outlet temperature more goes down in the condition of close of the steam control valve, the refrigerant pump is stooped as shown in Fig. 4-14.
ON (RUN)

Refrigerant pump
OFF (STOP) ST-2 deg.C (ST-3.6 deg.F) ST-1.5 deg.C (ST-2.7 deg.F) ST Fig. 4-14

ST : Chilled water setting temperature

4-3-5. Auto-rest function of chilled water outlet temperature setting depending on cooling water temperature Purpose : This function is to avoid cavitation of the refrigerant pump possibly occurring under the condition that the chilled water outlet temperature setting is comparatively high and the cooling water inlet temperature is low
12 deg.C (53.6 deg.F) Chilled water setting temp. 11 deg.C (51.8 deg.F) 10 deg.C (50.0 deg.F) 9 deg.C (48.2 deg.F) 8 deg.C (46.4 deg.F) 7 deg.C (44.6 deg.F)

22 deg.C (71.6 deg.F)

24 deg.C 26 deg.C 27 deg.C (75.2 deg.F) (78.8 deg.F) (80.6 deg.F) Cooling water inlet temp.

Fig. 14-15

Page 26 / Sec. 4

TJ Series

4-4. Operation board By means of operating keys on the operation board, the following tasks can be done. (1) Main menu (data display) (2) Resetting of chilled water outlet temp. setting (3) Confirmation & resetting of various set values (4) Service mode for servicing : Refer to Section 3 Main menu (22 items) Generator temp. (it is normally displayed) 1. Chiller running time 2. #1 absorbent pump running time * * * * * 10. Chilled water outlet temp. set * * * * * * Remarks : An alarm indication is displayed at only occurring an alarm If several alarms occur at the same time, a higher priority alarm is displayed. Lower priority alarms can be displayed by & keys. Resetting of chilled water outlet temp. setting Push "SET" key for 2 sec. Confirmation & resetting of various set values Service mode Push "SET" key for 2 sec.
Push "SET+ " key for 2 sec.

Page 27 / Sec. 4

TJ Series

4-4-1. Main menu (22 items) 22 items in the main menu can be displayed in sequence by Key
Code

&

keys as follows. Meaning of example of display

Data item
Generator temp. Chiller running time #1 absorbent pump running time #2 absorbent pump running time Burner running time Refrigerant pump running time Purge unit running time Chiller RUN/STOP times #1 absorbent pump RUN/STOP times #2 absorbent pump RUN/STOP times Burner RUN/STOP times Refrigerant pump RUN/STOP times Purge unit RUN/STOP times #3 absorbent pump running time #3 absorbent pump RUN/STOP times

Example of display

9 5. 0 Generator temp. is 95.0 deg.C (203 deg.F) 1. 1 2 3 5 5 Chiller running time is 12355 hours 2. 3. 4. 5. 6. 7. 8. 9. A. b. C. d. E. 1 0. 1 1. 1 2. 1 3. 1 4. 1 5. 1 6. 1 7. 1 1. 9 6. 8 3 1. 8 3 8. 7 8 5. 0 8. 5 7. 0 5 2 3 5 #1 absorbent pump running time is 5235 hours
Not used Not used

1 2 3 4 5 6 7 8 9 A B C D E

5 0 3 0 Refrigerant pump running time is 5030 hours 1 0 7 Purge unit running time is 107 hours 6 3 Chiller RUN/STOP times is 63 times 1 0 7 1
#1 absorbent pump RUN/STOP times is 1071 times

Not used Not used

8 7 Refrigerant pump RUN/STOP times is 87 times 3 0 2 2 Purge unit RUN/STOP times is 3022 times
Not used Not used
Chilled water outlet temp. set is 7 deg.C (44.6 deg.F)

10 Chilled water outlet temp. set 11 Hot water outlet temp. set 12 Chilled water inlet temp. 13 Chilled water outlet temp. 14 Cooling water inlet temp. 15 Condensed refrigerant temp. 16 Steam drain temp. 17 Pressure in purge tank 4-4-2. Resetting of chilled water outlet temp. setting The display "Chilled water outlet temp. set" is indicated by & keys

Not used
Chilled water inlet temp. is 11.9 deg.C (53.4 deg.F) Chilled water outlet temp. is 6.8 deg.C (44.2 deg.F) Cooling water inlet temp. is 31.8 deg.C (89.2 deg.F) Condensed refr. temp. is 34.7 deg.C (101.7 deg.F) Steam drain temp. is 85.0 deg.C (167 deg.F) Pressure in purge tank is 8.5 kPa (1.23 psi) abs.

9 5. 0 1 0. 7. 0

95 deg.C = 203 deg.F 7 deg.C = 44.6 deg.F Blinking

Push "SET" key for 2 sec. The indication blinks The set can be changed by & keys

1 0. 1 0. 1 0.

7. 0 8. 0 8. 0 8 deg.C = 46.4 deg.F

Push "SET" key. New value is set

Note 1 : In case that new value is not required, push "BACK" key. The indication returns 1 0. Note 2 : If any keys are not operated for 1 minute, the indication returns to "Generator temp.".

7. 0 .

Page 28 / Sec. 4

TJ Series

4-4-3. Confirmation & resetting of various set values (11 items) 11 items in this menu can be displayed in sequence by
Indication of Generator temp.

&

keys as follows. are not used

Note : Items covered with

Push "SET" key for 2 sec.

Push "BACK" key

Key
Alarm record

Data item
Set of Year, Month, Day, Time Change of switch

Example of display

Contents
Indication of a detail record of alarm

A L A r n.

r t. 1 4. 5 3 Set of Year, Month, Day, Time Cool / Heat change-over C H G S Operation data record interval change Select of Local operation mode Cancel of Predication information Change of unit

Change of Low select control

Set of chilled water pump

A P P o C H

Confirmation of interlock return time

Set of variable flow rate Set of parallel operation by remote controller Inverter control for chilled water

C H -

n V Set of specified chilled/hot water flow rate

Set of specified hot water flow rate Controlled variable Minimum frequency

Set of cooling water pump & cooling tower

A P P

C o

Confirmation of interlock return time

Set of stopping cooling water pump at low load Set of cooling tower fan control Set of cooling water temperature control Set of differential temp. of cooling tower fan Set of variable flow rate Inverter control of cooling water

C O -

n V Cost factor
Controlled variable Minimum frequency

Field set

E L d

Set of cooling water temp. at maximum input Set of slow open time Set of slow open temp. Set of dilution time Set of remote signal type Set of type of pulse Set of Low select control temp. Set of radiation temp.

Set of RS-485 Indication of version number

Indication of version number of option board

r S - 4 8 5 Set of address V E r 0. 0 0 No-sub menu o P V 0. 0 0 No-sub menu A L A r n.

Indication of a detail record of alarm

Alarm record

Page 29 / Sec. 4

TJ Series

(1) Alarm record Data item

Alarm record Example of display

Contents
Indication of a detail record of alarm / Clear

A L A r n. Push "BACK" key C 1.

Push "SET" key for 2 sec.

First alarm code

First alarm code (Newest)

Date of first alarm

d 1. 1 0 2 4 24, Oct. t 1. 1 4. 0 2 14:02 C 2.

Second alarm code

Time of first alarm

Second alarm code

Date of second alarm

d 2. 0 6 0 9 09, June t 2. 0 8. 4 4 8:44 C 3. d 3. t 3. Third alarm code

Time of second alarm

Third alarm code

Date of third alarm

- No-occurrence - No-occurrence

Time of third alarm

Clear of alarm record

r E - S E t Push "SET" for 2 sec. 3 Push "SET" key 2 Push "SET" key 1 Push "SET" key 3 data records are cleared

First alarm code

C 1.

First alarm code (Newest)

Page 30 / Sec. 4

TJ Series

(2) Set of Year, Month, Day, Time Data item

Set of Year, Month, Day, Time Example of display

Contents

r t. 1 4. 5 3 Set of Year, Month, Day, Time Push "BACK" key Y r - S E t Blinking

Push "SET" key for 2 sec.

Set of Year

Push "SET" for 2 sec.

2 0 0 1

Year can be changed from 2000 to 2050 by & keys

Push "SET" key. New data is set.

Set of Month & Date

d t

- S E t

Blinking

Push "SET" for 2 sec.

1 0 - 2 4

: Month

Date

Month

: Increasing number Initial set : 0 1 - 0 1 (1st January) Push "SET" key. New data is set. Month : 1 - 12 Date : 1 - 31

Set of time

t n. - S E t

Blinking

Push "SET" for 2 sec. 0 2 -

0 8 Initial set : 0 7 - 0 0 (7:00)

: O'clock

minute

O'clock

: Increasing number Push "SET" key. New data is set. O'clock : 0 - 23 Minute : 0 - 59

Set of Year

Y r - S E t

(3) Change of switch Data item

Change of switch Example of display

Contents
Cool / Heat change-over Operation data record interval change Select of Local operation mode Cancel of Predication information Change of unit

C H G S -

Change of Low select control

Page 31 / Sec. 4

TJ Series

Push "SET" key for 2 sec. Push "SET" key for 2 sec.
Cool / Heat change-over

Push "BACK" key Push "BACK" key r d - S E t Push "BACK" key S A n. - d t Push "SET" for 2 sec. 5 - n. ( 5 minutes ) & or 1 - n. ( 1 minute ) keys. or 1 0 - S ( 10 seconds )

Do not use this function. TSA-16TJ series is Cooling only. Push "SET" key for 2 sec.
Operation data record interval change

Present interval is blinking

1 - H ( 1 hour ) Initial set : 1 - H

or

Required interval can be selected by

Push "SET" key. New interval is set. Push "SET" key for 2 sec.
Select of Local operation mode

Push "BACK" key L o C A L Push "SET" for 2 sec.

Present condition is blinking

o n Initial set : o n

or o F F & keys.

ON or OFF can be selected by

Push "SET" key. New condition is set. Push "SET" key for 2 sec.
Cancel of Predication information

Push "BACK" key

Note Predication information does not goes off Push "SET" for 2 sec. unless a cause of the predication information is removed. If the predication information is cancelled even if the cause in not removed, this function is used. C o n S E n

G n

Blinking

Push "SET" key, a predication information displayed is cancelled.

Push "SET" key for 2 sec.

Change of unit

Push "BACK" key u

n I

Predication information Present unit is blinking o C Initial set : o C Push "SET" key. New condition is set. Push "SET" key for 2 sec.
Change of Low select control

Push "SET" for 2 sec. or o F & keys.

Unit can be selected by

Push "BACK" key L

o

S E L

This function is not used for TSA-16TJ series.

Cool / Heat change-over

r d - S E t

Page 32 / Sec. 4

TJ Series

(4) Set of chilled water pump Data item

Set of chilled water pump

Example of display

Contents
Confirmation of interlock return time

A P P o C H

Set of variable flow rate Set of parallel operation by remote controller

Push "SET" key for 2 sec.

Confirmation of interlock return time

Push "BACK" key I n t - C H Push "SET" for 2 sec.

Present value is blinking

0 0 0 5 Time can be changed by & keys. (Changeable from 0 to 250 sec.) Initial set : 0 0 0 5 Push "SET" key. New value is set. Push "SET" key for 2 sec. Push "BACK" key Set of variable flow rate V - V - C H No-function Push "SET" key for 2 sec. Push "BACK" key Set of parallel operation by remote controller r - P A r A No-function Push "SET" key for 2 sec. Push "BACK" key
Confirmation of interlock return time
I

n t

- C H

(5) Inverter control for chilled water pump No-function (6) Set of cooling water pump & cooling tower Data item
Set of cooling water pump & cooling tower

Example of display

Contents
Confirmation of interlock return time

A P P

C o

Set of stopping cooling water pump at low load Set of cooling tower fan control Set of cooling water temperature control Set of differential temp. of cooling tower fan Set of variable flow rate

Push "SET" key for 2 sec.

Confirmation of interlock return time

Push "BACK" key I n t - C o Push "SET" for 2 sec.

Present value is blinking

0 0 0 5 Time can be changed by & keys. (Changeable from 0 to 250 sec.) Initial set : 0 0 0 5 Push "SET" key. New value is set. Push "SET" key for 2 sec. Push "BACK" key
Set of stopping cooling water pump at low load

C o S t o P Push "SET" key for 2 sec. Push "BACK" key Set of cooling tower fan control C t A u t o Push "SET" key for 2 sec. Push "BACK" key Set of cooling water temperature control C t t E n. P Push "SET" key for 2 sec. Push "BACK" key
Set of differential temp. of cooling tower fan C t d

No-function No-function No-function No-function No-function

Push "SET" key for 2 sec.

Set of variable flow rate

Push "SET" key for 2 sec.

Confirmation of interlock return time

I F F Push "BACK" key V - V - C o Push "BACK" key I n t - C o

Page 33 / Sec. 4

TJ Series

(7) Inverter control for cooling water pump No-function (8) Field set Data item
Field set Example of display

Contents
Set of cooling water temp. at maximum input Set of slow open time Set of slow open temp. Set of dilution time Set of remote signal type Set of type of pulse Set of Low select control temp. Set of radiation temp.

E L d

Push "SET" key for 2 sec.

Set of cooling water temp. at maximum input

Push "BACK" key

C

o -

n P

Present value is blinking

Push "SET" for 2 sec. 3 2. 0 o C & keys. (Changeable from 20 to 33 deg.C) (68 to 91.4 deg.F) Push "SET" key. New value is set. Push "BACK" key
I

Set can be changed by Initial set : 3 2. 0 o C

Push "SET" key for 2 sec. Set of slow open time Present value is blinking

n P

t n.

Push "SET" for 2 sec. 0 0 0 0 5 & keys.

Set can be changed by Initial set : 0 0 0 0 5

(Changeable from 0 to 1800 sec., Step 10 sec.) Push "SET" key. New value is set. Push "BACK" key
I

Push "SET" key for 2 sec. Set of slow open temp. Present value is blinking

n P

n. P

Push "SET" for 2 sec. 0 0 0 o C & keys. (Changeable from 0 to 120 deg.C) (32 to 248 deg.F) Push "SET" key. New value is set. Push "BACK" key

Set can be changed by Initial set : 0 0 0 o C

Push "SET" key for 2 sec.

Page 34 / Sec. 4

TJ Series

Push "SET" key for 2 sec. Set of dilution time Present value is blinking

Push "BACK" key d

I

Push "SET" for 2 sec. 0 4 n. & keys. (Changeable from 4 to 20 min.)

Set can be changed by Initial set : 0 4 n.

Push "SET" key. New value is set. Push "SET" key for 2 sec. Set of remote signal type Present condition is blinking Push "BACK" key r
-

G n

Push "SET" for 2 sec. S t A t C or P u L S E & keys.

Type can be selected by Initial set : S t A t

I

C Push "SET" key. New type is set. Push "BACK" key o F - P L S Push "SET" for 2 sec. P o S t or P u L S E & keys.

Push "SET" key for 2 sec. Set of type of puls Present condition is blinking

Type can be selected by Initial set : P o S

I

Push "SET" key. New type is set. Push "SET" key for 2 sec.
Set of Low select control temp.

Push "BACK" key L o S E L E Push "BACK" key H E II - S t Push "BACK" key C o I

No-function No-function

Push "SET" key for 2 sec.

Set of radiation temp.

Push "SET" key for 2 sec.

Confirmation of interlock return time

n P

(9) Set of RS-485 No-function

Page 35 / Sec. 4

TJ Series

Solution heat exchanger Cooling water temp. does not go down due to high humidity Temp. controller malfunctions Hot water control valve is out of order Cooling water flow rate is insufficient Absorber and condenser tubes are fouled

Vacuum side

Cooling water system

Control system Driving heat source

Air leakage

Palladium cell malfunctions

Section 5A Trouble Shooting (LJ)

Absorbent flow rate decreased due to tube broken Water leaks due to pass partition plate in water box has corrosion Hot water inlet temp. is low Hot water flow rate is low

Palladium cell heater is out of order

Octyl alcohol is insufficient

Absorbent flow rate decreased due to clogging of heat exchanger Pass partition gasket in water box is removed

Attained vacuum of purge pump can not be obtained

No-chilling Too much refrigerant charging amount Improper absorbent flow rate

5-1. Chilled water outlet temperature does not go down (No-chilling of chilled water)

Page 1 / Sec. 5
Improper leveling of chiller Refrigerant leaks into absorbent side due to a hole appeared on refrigerant pan with corrosion Evaporator tube cleaning is insufficient Refrigerant pump rotates reversely Refrigerant blow valve is not closed Refrigerant contamination Installation Refrigerant cycle

Over load

Cooling load increased due to expansion of cooling

Chilled water flow rate is too much

Evaporator tubes are fouled

Octyl alcohol is insufficient

Water leaks due to pass partition plate in water box has corrosion

Cooling water inlet temp. is too high

Insufficient air handling unit capacity

Pass partition gasket in water box is removed

Crystallization

Improper foundation

LJ Series

Facility

Chilled water system

Absorbent cycle

5-2. Alarm
Error code : J-01
Chilled water low temp. alarm Safety device : DT1 In case that the alarm occurs at 2.5 deg.C (36.5 deg.F) of chilled water outlet temp. Hot water control valve malfunctions (Not modulate)

Replace the control valve

DT1 is out of order (Hot water control valve does not close)

Replace DT1

The microprocessor is out of order

Replace the microprocessor

If several or all of the following conditions mutually happen and continue Low cooling water inlet temperature Low chilled water flow rate (More than 50%) Low cooling load condition Sudden change of cooling load Holding water quantity of chilled water is a very little
In case that the alarm occurs above 2.5 deg.C (36.5 deg.F) of chilled water outlet temp.

Breaking of wire of DT1 (The Indication of chilled water outlet temp. is 30 deg.C / 86 deg.F) The microprocessor is out of order

Replace DT1

Replace the microprocessor

Error code : J-02 Chilled water pump alarm Safety device : Interlock signal (52CH) Remark : The interlock signal can be checked by the service mode
In case that the interlock signal of the chilled water pump does not come into the I/O board
In case that the interlock signal of the chilled water pump comes into the I/O board

I/O board is out of order (especially, connectors) Imperfect contact of wires and/or connectors connected to I/O board happens

Replace the I/O board

Replace wires and/or connectors

The chilled water pump stops

Start the chilled water pump

Power supply for remote control panel is OFF

ON the power supply

Imperfect contact happens in a remote control circuit

Check & repair the circuit

Interlock signal wires and/or a connector is out of order

Replace wires and the connector

Error code : J-03 Chilled water flow rate alarm

Safety device : Chilled water flow switch (69CH)

In case that chilled water flow rate is more than 50 % of the rated flow rate

The flow switch malfunctions

Replace the flow switch

The setting of the flow switch is wrong

Re-adjust the flow switch

The wire of flow switch is cut

Replace the wire

I/O board is out of order

Replace the I/O board

In case that chilled water flow rate is less than 50 % of the rated flow rate

Capacity of the chilled water pump is insufficient

Resistance of chilled water circuit is too much A differential pressure control valve in the chilled water circuit malfunctions Air is exiting in the chilled water circuit

Contact to a facility company

Perform air vent

A strainer in the chilled water circuit is clogged

Clean the strainer

A valve in the chilled water circuit is closed

Open the valve

Page 2 / Sec. 5

LJ Series

Error code : J-04 #1 Absorbent pump alarm

Safety device : Thermal relay (51A)

In case that the thermal relay (51A) functions

Crystallization is occurring in #1 absorbent pump A foreign material is existing in #1 absorbent pump Insulation failure of the pump motor coil is occurring Short of the pump motor coli is occurring Ground fault of the pump motor coil is occurring The thermal relay is out of order The setting of thermal relay is wrong The magnet contactor of 51A is out of order Absorbent flow rate is too much

Perform de-crystallization Remove the foreign material

Replace #1 absorbent pump

Replace the thermal relay Correct the setting Replace the magnet contactor Re-adjust the flow rate

In case that the thermal relay (51A) does not function

The contactor of thermal relay is out of order Short is occurring on the thermal relay wires The microprocessor is out of order

Replace the thermal relay Replace the wires Replace the microprocessor

Error code : J-06 Cooling water pump alarm

Safety device : Interlock signal (52CO)

In case that the interlock signal of the cooling water pump comes into the I/O board

I/O board is out of order (especially, connectors) Imperfect contact of wires and/or connectors connected to I/O board happens

Replace the I/O board Replace wires and/or connectors

Remark : The interlock signal can be checked by the service mode

In case that the interlock signal of the cooling water pump does not come into the I/O board

The cooling water pump stops Power supply for remote control panel is OFF Imperfect contact happens in a remote control circuit

Start the cooling water pump ON the power supply Check & repair the circuit Replace wires and the connector

Interlock signal wires and/or a connector is out of order

Error code : J-07 Cooling water flow rate alarm

Safety device : Cooling water flow

In case that cooling water flow is more than 50 % of the rated flow rate

The flow switch malfunctions The setting of the flow switch is wrong The wire of flow switch is cut I/O board is out of order

Replace the flow switch Re-adjust the flow switch Replace the wire Replace the I/O board

Remark : Cooling water flow switch(52CO) is option device

In case that cooling water flow rate is less than 50 % of the rated flow rate

Capacity of the cooling water pump is insufficient Contact to a facility company Resistance of cooling water circuit is too much Air is exiting in the cooling water circuit A strainer in the cooling water circuit is clogged A valve in the cooling water circuit is closed Perform air vent Clean the strainer Open the valve

Page 3 / Sec. 5

LJ Series

Error code : J-10 Refrigerant pump alarm

Safety device : Thermal relay (51R)

In case that the thermal relay (51R) functions

A foreign material is existing in Refrigerant pump

Remove the foreign material

Insulation failure of the pump motor coil is occurring

Short of the pump motor coli is occurring

Replace Refrigerant pump

Ground fault of the pump motor coil is occurring

The thermal relay is out of order

Replace the thermal relay

The setting of thermal relay is wrong

Correct the setting

The magnet contactor of 51R is out of order

Replace the magnet contactor

Contamination of refrigerant happens

Search & remove the cause

Refrigerant flow rate is too much

Re-adjust the flow rate

In case that the thermal relay (51R) does not function

The contactor of thermal relay is out of order

Replace the thermal relay

Short is occurring on the thermal relay wires

Replace the wires

The microprocessor is out of order

Replace the microprocessor

Error code : J-13 Generator high temp. alarm Safety device : DT3
In case that the alarm occurs at set value

Indication of Bad vacuum condition

LOW LEVEL VACUUM

Leakage occurs Inhibitor is Insufficient

is displayed

Perform leak test to locate leakages. Palladium cell / Gaskets / Generator pressure switch/ Sight glasses/ etc. Add suitable amount of the inhibitor
Check a purge pump & a drain trap. Replace purge pump oil. Drain out moisture in the drain trap and dry up inside the drain trap.

Indication of
LOW LEVEL VACUUM

is not displayed Insufficient absorbent solution flow rate

#1 Absorbent pump does not run

Suitable attained vacuum of purge pump can not be achieved

See J04
Re-adjust the damper

#1 Absorbent pump runs

A diluted solution damper is not set properly

#1 absorbent pump rotates reversely due to wrong wiring Crystallization occurs Octyl alcohol is insufficient Insufficient of charging amount of absorbent/refrigerant
DT3 is out of order (Short-circuit)

Correct the wiring Decrystallization Add octyl alcohol Add solution

Replace DT3

Cooling water problems

Cooling water inlet temp. is higher than rated temp. Cooling water flow rate is insufficient Absorber and condenser tubes are fouled (Foul tube of COW may be indicated) Contact to a facility company

In case that the alarm occurs below set value

DT3 is out of order (Breaking of wire)

Replace DT3

Page 4 / Sec. 5

LJ Series

Error code : J-14

Generator high pressure alarm Safety device : Pressure switch (63GH)

In case that the pressure switch functions at the set value In case that the pressure switch functions below the set value

Inside pressure of the chiller increases to 0 MPa

Probable cause is mostly wrong operation of purging Perform purging

The pressure switch is out of order

Replace the pressure switch

The wire of pressure switch is cut

Replace the wire

Error code : J-16 High concentration alarm Safety device : DT3, The alarm occurs under the following conditions Bad vacuum condition

Indication of
LOW LEVEL VACUUM

Leakage occurs Inhibitor is Insufficient

is displayed

Perform leak test to locate leakages. Palladium cell / Gaskets / Generator pressure switch/ Sight glasses/ etc. Add suitable amount of the inhibitor
Check a purge pump & a drain trap. Replace purge pump oil. Drain out moisture in the drain trap and dry up inside the drain trap.

Indication of
LOW LEVEL VACUUM

is not displayed Insufficient absorbent solution flow rate #1 Absorbent pump does not #1 Absorbent pump runs

Suitable attained vacuum of purge pump can not be achieved

See J04
Re-adjust the damper Correct the wiring

A diluted solution damper is not set properly

#1 absorbent pump rotates reversely due to wrong wiring Crystallization occurs Octyl alcohol is insufficient Insufficient of charging amount of absorbent/refrigerant
Driving heat amount is too high

De-crystallization Add octyl alcohol Add solution

Hot water flow rate is too high Hot water inlet temp. is too high

Hot water control valve is out of order

Replace the control valve Check hot water system

Cooling water problems

Cooling water inlet temp. is higher than rated temp. Cooling water flow rate is insufficient Absorber and condenser tubes are fouled (Foul tube of COW may be indicated) Contact to a facility company

The alarm occurs without following conditions Condition of occurring alarm

DT3 is out of order (Breaking of wire) DT5 is out of order (Short-circuit)

Replace

1. In case that concentrated solution concentration goes up 65% after 3 minutes of starting crystallization protection function 2. In case that concentrated solution concentration goes up 65% within 1 hour after starting crystallization protection function 3. In case that concentrated solution concentration goes up 65.5%.

Error code : J-20 Cooling water low temp. alarm Safety device : DT7

In case that the alarm occurs if cooling water inlet temp. continues below rated temp. minus 13 deg.C (23.4 deg.F) for 30 minutes

Cooling water temp. control system malfunctions

Contact to a facility company

In case that the alarm occurs even if cooling water inlet temp. continues above rated temp. minus 13 deg.C (23.4 deg.F)

Cooling The microprocessor water temp. is control out ofsystem order malfunctions

Replace the microprocessor

DT7 is out of order

Replace DT7

Page 5 / Sec. 5

LJ Series

5-3. Sensor alarm

Error code : F-01 Chilled water inlet temp. sensor alarm Sensor : DT6 (Digital sensor) Error code : F-02 Cooling water inlet temp. sensor alarm Sensor : DT7 (Digital sensor) Error code : F-03 Cooling water outlet temp. sensor alarm Sensor : DT2 (Digital sensor) Error code : F-04 Cooling water mid temp. sensor alarm Sensor : DT12 (Digital sensor) Error code : F-05 Condenser temp. sensor alarm Sensor : DT5 (Digital sensor) Error code : F-08 Refrigerant temp. sensor alarm Sensor : DT11 (Digital sensor) Error code : F-09 Driving hot water inlet temp. sensor alarm Sensor : DT15 (Digital sensor) Error code : F-10 3 way valve return temp. sensor alarm Sensor : DT14 (Digital sensor) Error code : F-11 Driving hot water outlet temp. sensor alarm Sensor : DT16 (Digital sensor) Error code : F-12 Absorbent temp. sensor alarm Sensor : DT10 (Digital sensor) Error code : F-17 Chilled water flow sensor alarm Sensor : 69CH (Chilled water flow switch) Error code : F-19 Cooling water flow sensor alarm Sensor : 69CO (Cooling water flow switch) OPTION Error code : F-21 CPU alarm Error code : F-22 Memory alarm Error code : F-23 Time set alarm Error code : F-24 Constant set alarm Error code : F-25 Chilled water outlet temp. sensor alarm Sensor : DT1 (Cu resistance thermometer bulb) Sensor is out of order Connector is removed Wire is cut / short Over range of pressure Error code : F-26 High generator temp. sensor alarm Sensor : DT3 (Thermistor)
(Range : 0 to 100 deg.C) (Range : 32 to 212 deg.F)

Sensor is out of order Connector is removed Wire is cut / short Over range of temp.
(Range : -20 to 120 degC) (Range : -4 to 248 deg.F)

Replace a sensor Put a connector to the sensor Replace a wire

Sensor is out of order Connector is removed Wire is cut / short

Replace a sensor Put a connector to the sensor Replace a wire Replace a microprocessor

Perform time set

Clear memory then set again Replace a sensor Put a connector to the sensor Replace a wire

Sensor is out of order Connector is removed Wire is cut / short Over range of pressure
(Range : 0 to 200 deg.C) (Range : 32 to 392 deg.F)

Replace a sensor Put a connector to the sensor Replace a wire

Error code : F-28 Purge tank pressure sensor alarm Sensor : 69PR

Sensor is out of order Connector is removed Wire is cut / short

Over range of pressure (Range : 0 to 340hPa) (Range : 0 to 0.0493 psi)

Replace a sensor Put a connector to the sensor Replace a wire

Page 6 / Sec. 5

LJ Series

5-4. Maintenance message

Message code : H-01 OPERATE PURGE PUMP Message code : H-02 HIGH CONCENTRATION Message code : H-03 CLEAN COOLING WATER TUBES Message code : H-04 CHECK COOLING WATER SYSTEM

Purging shall be conducted from the purge tank. The purge unit will be shortly filled with non-condensable gas. There is a symptom that concentrated solution concentration is slightly high comparing with normal operating condition.

Absorber and condenser tubes have been fouled. Tube cleaning shall be conducted. If cooling water inlet temp. is beyond the following value, check cooling water system. PCOWT - SCOWT > 2 deg.C (3.6 deg.F)
PCOWT : Present cooling water inlet temp. SCOWT : Specified cooling water inlet temp.

Message code : H-06 PURGE TANK HIGH PRESSURE Message code : H-07 COOLING WATER TUBES FOUL Message code : H-08 COOLING WATER HIGH TEMP

Purging should be conducted from the purge unit.

Absorber and condenser tubes have been slightly fouled. Tube cleaning shall be planed. If cooling water inlet temp. is within the following value, H-08 is indicated. If H-08 is often indicated, check cooling water system. 0 deg.C (0 deg.F) < PCOWT - SCOWT =/< 2 deg.C (3.6 deg.F)
PCOWT : Present cooling water temp. SCOWT : Specified cooling water temp.

Message code : H-10 POWER FAILURE Graph 5-1. Fouling of heat transfer tubes in cooling water system 8 Fouling indicator Maintenance zone 6 4 Notice zone 2 Normal zone 20
Normal Line

When the power resumes, this message is displayed. Graph 5-2. Vacuum condition monitoring 1.0 Pressure rising indicator of storage tank
Maintenance judgment zone

Maintenance zone 0.6

Notice zone

Normal zone 80 100

0 0 60 20 40 60 80 100 Storage ratio (%) Cooling load factor (%) Graph 5-3. Tendency of absorbent concentration

8 7 Concentration indicator 6 5 4 3 2 1 0 0 20 40 Cooling load (%) Normal line at cooling water 31 deg.C (87.8 deg.F) Normal line at cooling water 27 deg.C (80.6 deg.F) 60 80 100

Abnormal stop zone

Maintenance zone at cooling water 27 deg.C (80.6 deg.F) Maintenance zone at cooling water 31 deg.C (87.8 deg.F)

Page 7 / Sec. 5

LJ Series

Solution heat exchanger Cooling water temp. does not go down due to high humidity Temp. controller malfunctions Steam control valve is out of order Cooling water flow rate is insufficient Absorber and condenser tubes are fouled

Vacuum side

Cooling water system

Control system Driving heat source

Air leakage

Palladium cell malfunctions

Section 5B Trouble Shooting (TJ)

Absorbent flow rate decreased due to tube broken Water leaks due to pass partition plate in water box has corrosion Supply steam pressure is low Steam flow rate is low

Palladium cell heater is out of order

Octyl alcohol is insufficient

Absorbent flow rate decreased due to clogging of heat exchanger Pass partition gasket in water box is removed

Attained vacuum of purge pump can not be obtained

No-chilling Too much refrigerant charging amount Improper absorbent flow rate

5-1. Chilled water outlet temperature does not go down (No-chilling of chilled water)

Page 8 / Sec. 5
Improper leveling of chiller Refrigerant leaks into absorbent side due to a hole appeared on refrigerant pan with corrosion Evaporator tube cleaning is insufficient Refrigerant pump rotates reversely Refrigerant blow valve is not closed Refrigerant contamination Installation Refrigerant cycle

Over load

Cooling load increased due to expansion of cooling

Chilled water flow rate is too much

Evaporator tubes are fouled

Octyl alcohol is insufficient

Water leaks due to pass partition plate in water box has corrosion

Cooling water inlet temp. is too high

Insufficient air handling unit capacity

Pass partition gasket in water box is removed

Crystallization

TJ Series

Improper foundation

Facility

Chilled water system

Absorbent cycle

5-2. Alarm
Error code : J-01
Chilled water low temp. alarm Safety device : DT1 In case that the alarm occurs at 2.5 deg.C (36.5 deg.F) of chilled water outlet temp. Steam control valve malfunctions (Not modulate)

Replace the control valve

DT1 is out of order (Hot water control valve does not close)

Replace DT1

The microprocessor is out of order

Replace the microprocessor

If several or all of the following conditions mutually happen and continue Low cooling water inlet temperature Low chilled water flow rate (More than 50%) Low cooling load condition Sudden change of cooling load Holding water quantity of chilled water is a very little
In case that the alarm occurs above 2.5 deg.C (36.5 deg.F) of chilled water outlet temp.

Breaking of wire of DT1 (The Indication of chilled water outlet temp. is 30 deg.C / 86 deg.F) The microprocessor is out of order

Replace DT1

Replace the microprocessor

Error code : J-02 Chilled water pump alarm Safety device : Interlock signal (52CH) Remark : The interlock signal can be checked by the service mode
In case that the interlock signal of the chilled water pump does not come into the I/O board In case that the interlock signal of the chilled water pump comes into the I/O board

I/O board is out of order (especially, connectors) Imperfect contact of wires and/or connectors connected to I/O board happens

Replace the I/O board

Replace wires and/or connectors

The chilled water pump stops

Start the chilled water pump

Power supply for remote control panel is OFF Imperfect contact happens in a remote control circuit
Interlock signal wires and/or a connector is out of order

ON the power supply

Check & repair the circuit

Replace wires and the connector

Error code : J-03 Chilled water flow rate alarm

Safety device : Chilled water flow switch (69CH)

In case that chilled water flow rate is more than 50 % of the rated flow rate

The flow switch malfunctions

Replace the flow switch

The setting of the flow switch is wrong

Re-adjust the flow switch

The wire of flow switch is cut

Replace the wire

I/O board is out of order

Replace the I/O board

In case that chilled water flow rate is less than 50 % of the rated flow rate

Capacity of the chilled water pump is insufficient Contact to a facility company

Resistance of chilled water circuit is too much A differential pressure control valve in the chilled water circuit malfunctions Air is exiting in the chilled water circuit

Perform air vent

A strainer in the chilled water circuit is clogged

Clean the strainer

A valve in the chilled water circuit is closed

Open the valve

Page 9 / Sec. 5

TJ Series

Error code : J-04 #1 Absorbent pump alarm

Safety device : Thermal relay (51A)

In case that the thermal relay (51A) functions

Crystallization is occurring in #1 absorbent pump A foreign material is existing in #1 absorbent pump Insulation failure of the pump motor coil is occurring Short of the pump motor coli is occurring Ground fault of the pump motor coil is occurring The thermal relay is out of order The setting of thermal relay is wrong The magnet contactor of 51A is out of order Absorbent flow rate is too much

Perform de-crystallization Remove the foreign material

Replace #1 absorbent pump

Replace the thermal relay Correct the setting Replace the magnet contactor Re-adjust the flow rate

In case that the thermal relay (51A) does not function

The contactor of thermal relay is out of order Short is occurring on the thermal relay wires The microprocessor is out of order

Replace the thermal relay Replace the wires Replace the microprocessor

Error code : J-06 Cooling water pump alarm

Safety device : Interlock signal (52CO)

In case that the interlock signal of the cooling water pump comes into the I/O board

I/O board is out of order (especially, connectors) Imperfect contact of wires and/or connectors connected to I/O board happens

Replace the I/O board Replace wires and/or connectors

Remark : The interlock signal can be checked by the service mode

In case that the interlock signal of the cooling water pump does not come into the I/O board

The cooling water pump stops Power supply for remote control panel is OFF Imperfect contact happens in a remote control circuit
Interlock signal wires and/or a connector is out of order

Start the cooling water pump ON the power supply Check & repair the circuit Replace wires and the connector

Error code : J-07 Cooling water flow rate alarm

Safety device : Cooling water flow

In case that cooling water flow rate is more than 50 % of the rated flow rate

The flow switch malfunctions The setting of the flow switch is wrong The wire of flow switch is cut I/O board is out of order

Replace the flow switch Re-adjust the flow switch Replace the wire Replace the I/O board

Remark : Cooling water flow switch(52CO) is option device

In case that cooling water flow rate is less than 50 % of the rated flow rate

Capacity of the cooling water pump is insufficient Contact to a facility company Resistance of cooling water circuit is too much Air is exiting in the cooling water circuit A strainer in the cooling water circuit is clogged A valve in the cooling water circuit is closed Perform air vent Clean the strainer Open the valve

Page 10 / Sec. 5

TJ Series

Error code : J-10 Refrigerant pump alarm

Safety device : Thermal relay (51R)

In case that the thermal relay (51R) functions

A foreign material is existing in Refrigerant pump

Remove the foreign material

Insulation failure of the pump motor coil is occurring

Short of the pump motor coli is occurring

Replace Refrigerant pump

Ground fault of the pump motor coil is occurring

The thermal relay is out of order

Replace the thermal relay

The setting of thermal relay is wrong

Correct the setting

The magnet contactor of 51R is out of order

Replace the magnet contactor

Contamination of refrigerant happens

Search & remove the cause

Refrigerant flow rate is too much

Re-adjust the flow rate

In case that the thermal relay (51R) does not function

The contactor of thermal relay is out of order

Replace the thermal relay

Short is occurring on the thermal relay wires

Replace the wires

The microprocessor is out of order

Replace the microprocessor

Error code : J-13 Generator high temp. alarm Safety device : DT3

In case that the alarm occurs at set value

Bad vacuum condition

Indication of LOW LEVEL VACUUM is displayed

Leakage occurs Inhibitor is Insufficient

Perform leak test to locate leakages. Palladium cell / Gaskets / Generator pressure switch/ Sight glasses/ etc. Add suitable amount of the inhibitor
Check a purge pump & a drain trap. Replace purge pump oil. Drain out moisture in the drain trap and dry up inside the drain

Indication of LOW LEVEL VACUUM is not displayed

Suitable attained vacuum of purge pump can not be achieved

Insufficient absorbent solution flow rate

#1 Absorbent pump does not run

See J04
Re-adjust the damper

#1 Absorbent pump runs

A diluted solution damper is not set properly

#1 absorbent pump rotates reversely due to wrong wiring Crystallization occurs Octyl alcohol is insufficient Insufficient of charging amount of absorbent/refrigerant
DT3 is out of order (Short-circuit)

Correct the wiring Decrystallization Add octyl alcohol Add solution

Replace DT3

Cooling water problems

Cooling water inlet temp. is higher than rated temp. Cooling water flow rate is insufficient Absorber and condenser tubes are fouled (Foul tube of COW may be indicated) Contact to a facility company

In case that the alarm occurs below set value

DT3 is out of order (Breaking of wire)

Replace DT3

Page 11 / Sec. 5

TJ Series

Error code : J-14

Generator high pressure alarm Safety device : Pressure switch (63GH)

In case that the pressure switch functions at the set value In case that the pressure switch functions below the set value

Inside pressure of the chiller increases to 0 MPa

Probable cause is mostly wrong operation of purging Perform purging

The pressure switch is out of order

Replace the pressure switch

The wire of pressure switch is cut

Replace the wire

Error code : J-16 High concentration alarm Safety device : DT3,

The alarm occurs under the following conditions

Bad vacuum condition

Indication of
LOW LEVEL VACUUM

Leakage occurs Inhibitor is Insufficient

is displayed

Perform leak test to locate leakages. Palladium cell / Gaskets / Generator pressure switch/ Sight glasses/ etc. Add suitable amount of the inhibitor
Check a purge pump & a drain trap. Replace purge pump oil. Drain out moisture in the drain trap and dry up inside the drain

Indication of
LOW LEVEL VACUUM

is not displayed Insufficient absorbent solution flow rate #1 Absorbent pump does not #1 Absorbent pump runs

Suitable attained vacuum of purge pump can not be achieved

See J04
Re-adjust the damper Correct the wiring

A diluted solution damper is not set properly

#1 absorbent pump rotates reversely due to wrong wiring Crystallization occurs Octyl alcohol is insufficient Insufficient of charging amount of absorbent/refrigerant
Driving heat amount is too high

De-crystallization Add octyl alcohol Add solution

Steam flow rate is too high Steam supply pressure is too high

Steam control valve is out of order

Replace the control valve Check hot water system

Cooling water problems

Cooling water inlet temp. is higher than rated temp. Cooling water flow rate is insufficient Absorber and condenser tubes are fouled (Foul tube of COW may be indicated) Contact to a facility company

The alarm occurs without following conditions Condition of occurring alarm

DT3 is out of order (Breaking of wire) DT5 is out of order (Short-circuit)

Replace

1. In case that concentrated solution concentration goes up 65% after 3 minutes of starting crystallization protection function 2. In case that concentrated solution concentration goes up 65% within 1 hour after starting crystallization protection function 3. In case that concentrated solution concentration goes up 65.5%.

Error code : J-20 Cooling water low temp. alarm Safety device : DT7

In case that the alarm occurs if cooling water inlet temp. continues below rated temp. minus 13 deg.C (23.4 deg.F) for 30 minutes

Cooling water temp. control system malfunctions

Contact to a facility company

In case that the alarm occurs even if cooling water inlet temp. continues above rated temp. minus 13 deg.C (23.4 deg.F)

Cooling The microprocessor water temp. is control out ofsystem order malfunctions

Replace the microprocessor

DT7 is out of order

Replace DT7

Page 12 / Sec. 5

TJ Series

5-3. Sensor alarm

Error code : F-01 Chilled water inlet temp. sensor alarm Sensor : DT6 (Digital sensor) Error code : F-02 Cooling water inlet temp. sensor alarm Sensor : DT7 (Digital sensor) Error code : F-03 Cooling water outlet temp. sensor alarm Sensor : DT2 (Digital sensor) Error code : F-04 Cooling water mid temp. sensor alarm Sensor : DT12 (Digital sensor) Error code : F-05 Condenser temp. sensor alarm Sensor : DT5 (Digital sensor) Error code : F-06 Steam drain temp. sensor alarm Sensor : DT13 (Digital sensor) Error code : F-08 Refrigerant temp. sensor alarm Sensor : DT11 (Digital sensor) Error code : F-12 Absorbent temp. sensor alarm Sensor : DT10 (Digital sensor) Sensor is out of order Connector is removed Wire is cut / short Over range of temp.
(Range : -20 to 120 degC) (Range : -4 to 248 deg.F)

Replace a sensor Put a connector to the sensor Replace a wire

Error code : F-17 Chilled water flow sensor alarm Sensor : 69CH (Chilled water flow switch) Error code : F-19 Cooling water flow sensor alarm Sensor : 69CO (Cooling water flow switch) OPTION

Sensor is out of order Connector is removed Wire is cut / short

Replace a sensor Put a connector to the sensor Replace a wire

Error code : F-21 CPU alarm Error code : F-22 Memory alarm Error code : F-23 Time set alarm Error code : F-24 Constant set alarm

Replace a microprocessor

Perform time set

Clear memory then set again

Error code : F-25 Chilled water outlet temp. sensor alarm Sensor : DT1 (Cu resistance thermometer bulb)

Sensor is out of order Connector is removed Wire is cut / short Over range of pressure
(Range : 0 to 100 deg.C) (Range : 32 to 212 deg.F)

Replace a sensor Put a connector to the sensor Replace a wire

Error code : F-26 High generator temp. sensor alarm Sensor : DT3 (Thermistor)

Sensor is out of order Connector is removed Wire is cut / short Over range of pressure
(Range : 0 to 200 deg.C) (Range : 32 to 392 deg.F)

Replace a sensor Put a connector to the sensor Replace a wire

Error code : F-28 Purge tank pressure sensor alarm Sensor : 69PR

Sensor is out of order Connector is removed Wire is cut / short

Over range of pressure (Range : 0 to 340hPa) (Range : 0 to 0.0493 psi)

Replace a sensor Put a connector to the sensor Replace a wire

Page 13 / Sec. 5

TJ Series

5-4. Maintenance message

Message code : H-01 OPERATE PURGE PUMP Message code : H-02 HIGH CONCENTRATION Message code : H-03 CLEAN COOLING WATER TUBES Message code : H-04 CHECK COOLING WATER SYSTEM

Purging shall be conducted from the purge tank. The purge unit will be shortly filled with non-condensable gas. There is a symptom that concentrated solution concentration is slightly high comparing with normal operating condition.

Absorber and condenser tubes have been fouled. Tube cleaning shall be conducted. If cooling water inlet temp. is beyond the following value, check cooling water system. PCOWT - SCOWT > 2 deg.C (3.6 deg.F)
PCOWT : Present cooling water inlet temp. SCOWT : Specified cooling water inlet temp.

Message code : H-06 PURGE TANK HIGH PRESSURE Message code : H-07 COOLING WATER TUBES FOUL Message code : H-08 COOLING WATER HIGH TEMP

Purging should be conducted from the purge unit.

Absorber and condenser tubes have been slightly fouled. Tube cleaning shall be planed. If cooling water inlet temp. is within the following value, H-08 is indicated. If H-08 is often indicated, check cooling water system. 0 deg.C (0 deg.F) < PCOWT - SCOWT =/< 2 deg.C (3.6 deg.F)
PCOWT : Present cooling water temp. SCOWT : Specified cooling water temp.

Message code : H-10 POWER FAILURE Graph 5-1. Fouling of heat transfer tubes in cooling water system 8 Fouling indicator Maintenance zone 6 4 Notice zone 2 Normal zone 20
Normal Line

When the power resumes, this message is displayed. Graph 5-2. Vacuum condition monitoring 1.0 Pressure rising indicator of storage tank
Maintenance judgment zone

Maintenance zone 0.6

Notice zone

Normal zone 80 100

0 0 60 20 40 60 80 100 Storage ratio (%) Cooling load factor (%) Graph 5-3. Tendency of absorbent concentration

8 7 Concentration indicator 6 5 4 3 2 1 0 0 20 40 Cooling load (%) Normal line at cooling water 31 deg.C (87.8 deg.F) Normal line at cooling water 27 deg.C (80.6 deg.F) 60 80 100

Abnormal stop zone

Maintenance zone at cooling water 27 deg.C (80.6 deg.F) Maintenance zone at cooling water 31 deg.C (87.8 deg.F)

Page 14 / Sec. 5

TJ Series

Section 6 Parts replacement & Instructions

6-1. Guidance interval of parts replacement The following intervals are guidance for replacement of parts to get stable operation. Replacement parts
1 Absorbent pump 2 Refrigerant pump 3 Purge pump 4 Generator pressure gauge 5 Palladium cell & heater 6 Sight glass & gaskets 7 Diaphragm valve gasket 8 Controller 9 Circuit breaker 10 Magnet switch 11 Temperature sensor 12 Rupture disk

Operation time is less than 4,000 hours per year for air-conditioning. 24,000 or 6 years 24,000 or 6 years 10 years 28,000 hours or 7 years 12,000 hours or 3 years 6 years 6 years 5 years 40,000hours or 10 years 28,000 hours or 7 years 28,000 hours or 7 years 4,800 hours or 1 year

Heavy load operation, process use and/or continuous annual operation 16,000 hours or 4 years 16,000 hours or 4 years 10 years 20,000 hours or 5 years 12,000 hours or 3 years 6 years 6 years 5 years 40,000hours or 10 years 28,000 hours or 7 years 28,000 hours or 7 years 4,800 hours or 1 year

6-2. How to change parts 6-2-1. Absorbent pump & Refrigerant pump This instruction describes the procedure to replace an absorbent pump and a refrigerant pump. As procedures for the absorbent pump and the refrigerant pump are same, the procedure for the absorbent pump is explained in this material. (1) Instrument a) Pan to collect spilled absorbent / refrigerant solution at disassembling them b) wood blocks c) Box wrenches d) Adjustable wrenches e) Insulation tape f) Vinyl tape (2) Procedure a) Be sure to confirm that the main breaker (MCBM) is turned OFF. b) Close the isolation valves of the pump tightly. c) Open the cover of terminal box of the pump. Disconnect power wires (U1, V1, W1) in the terminal box of the pump. d) Cover each end of wires by a vinyl tape to prevent wetting with solution then cover them by a vinyl back as shown in Fig. 6-1. At this time, record wire marks. e) Put the pan under the pump f) Put the wood block between the pan and the pump shown in Fig. 6-2. Page 1 / Sec. 6 LJ/TJ Series Power wire Vinyl tape Vinyl back Fig. 6-1 Fig. 6-2 Pan Pump Terminal box Wood blocks

g) Remove bolts of the pump and pull out the pump carefully h) Wash the flange and the isolation valve portion mounted under the lower shell with water. (Pure water or distilled water should be used) i) Check if the flange surface is clean or not. If OK, mount new pump with new gasket. Be sure to tighten all bolt uniformly because it is very difficult to do leak test at the portion. Non-uniform tightening causes air leakage. j) Connect the power wires with confirming wire marks and cover each connected portions with the insulation tape and vinyl tape. Then close the terminal box cover. k) Open the isolation valves. l) Run the chiller to confirm the rotating direction of the pump by a rotation direction meter. Correct direction is clockwise viewing from back of the pump. If OK, stop the chiller. m) Perform air purging from the chiller for 1 hour (Open purge valve V1 & V3) n) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour. o) If there are no- abnormality, the chiller can be run on normal operation. 6-2-2. Purge pump This instruction describes the procedure to replace an purge pump with a motor. (1) Instrument a) Adjustable wrenches b) Insulation tape c) Vinyl tape (2) Procedure a) Be sure to confirm that the main breaker (MCBM) is turned OFF. b) Be sure to confirm that the purge valves (V1, V2, V3) are closed. c) Remove purge pump oil in the purge pump. d) Open the cover of terminal box of the pump. Disconnect power wires (U3, V3, W3) in the terminal box of the pump. e) Cover each end of wires by a vinyl tape to prevent wetting with solution then cover them by a vinyl back as shown in Fig. 6-1. At this time, record wire marks. f) Remove the 4 bolts for the flange and 4 bolts for the base shown in Fig. 6-3. Then remove the pump. g) Put new pump. h) Temporally tighten 4 bolts for the base. Tighten 4 bolts for the flange tightly. Then tighten 4 bolts for the base tightly. i) Connect the power wires with confirming wire marks and cover each connected portions with the insulation tape and vinyl tape. Then close the terminal box cover. j) Run the pump to confirm the rotating direction of the pump. Correct direction is shown by the arrow mark on the V-belt cover. k) Charge the purge pump oil up to the center of the sight glass under running of the purge pump. l) Check that V-belt tension is about 10 mm (0.4 inch). If not, adjust the tension by sliding the motor position. m) Check the attained vacuum of new pump. Fig. 6-3
Sight glass 4 bolts for base Purge pump Purge pump motor 4 bolts for flange Terminal box

Page 2 / Sec. 6

LJ/TJ Series

6-2-3. Sight glass This instruction describes the procedure to replace sight glasses with gasket. (1) Instrument a) Adjustable wrenches b) Bucket for solution c) Vacuum rubber hose with copper tube d) Nitrogen gas e) Hose for nitrogen gas f) Regulator for nitrogen gas (2) Position of the sight glass a) Evaporator b) Bottom of the absorber (3) Replacement of the sight glass on the evaporator. a) If the refrigerant solution level is beyond the bottom of the sight glass, perform the refrigerant blow down. b) Charge Nitrogen gas into the chiller up to about 9.8 kPa. c) Discharge Nitrogen gas. (Refer to "6-12. Method of discharging Nitrogen gas") d) Remove 6 bolt for the sight glass and remove the sight glass and gasket. e) Clean the surface of the sight glass flange by dry cloth. f) Put new sight glass and gasket. Tighten bolts uniformly. (Gasket is one side only. Carefully tighten bolts.) g) Charge Nitrogen gas into the chiller up to about 49 kPa. h) Perform leak test by soap solution. i) Discharge nitrogen gas. j) Perform purging until the pressure in the chiller goes down to 1.3 kPa absolute. k) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour. l) If there are no- abnormality, the chiller can be run on normal operation. (4) Replacement of the sight glass on the absorber. a) Charge Nitrogen gas into the chiller up to about 30 kPa. (Refer to "6-11. Method of charging Nitrogen gas") b) Discharge LiBr solution from the service valve (SV4) until the solution level in the absorber goes down to the bottom of the sight glass. c) Discharge Nitrogen gas. (Refer to "6-12. Method of discharging Nitrogen gas") d) Remove 6 bolt for the sight glass and remove the sight glass and gasket. e) Clean the surface of the sight glass flange by dry cloth. f) Put new sight glass and gasket. Tighten bolts uniformly. (Gasket is one side only. Carefully tighten bolts.) g) Charge Nitrogen gas into the chiller up to about 49 kPa. h) Perform leak test by soap solution. i) Discharge nitrogen gas. j) Perform purging. When the inside pressure decreases about -50kPa, charge the LiBr solution from the service valve (SV4). j) Continue purging until the pressure in the chiller goes down to 1.3 kPa absolute. k) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour. l) If there are no- abnormality, the chiller can be run on normal operation. Page 3 / Sec. 6 LJ/TJ Series
Sight glass flange Gasket Sight glass Bolt Bolt

Fig. 6-4

6-2-4. Rupture disk This instruction describes the procedure to replace a rupture disk. (1) Instrument b) Vacuum rubber hose with copper tube c) Nitrogen gas d) Hose for nitrogen gas e) Regulator for nitrogen gas f) Torque wrench (2) Procedure a) Charge Nitrogen gas into the chiller up to about 9.8 kPa. (Refer to "6-11. Method of charging Nitrogen gas") b) Remove 4 bolts for flanges. c) Carefully remove the rupture disk assembly. d) Remove the cap screws and disassembly the rupture disk assembly. Then take out the rupture disk. e) Put new rupture disk into base and the hold down and tighten them uniformly by the cap screws. Tightening torque : 2 inch 30 Nm (22 ft lbs) Tightening torque : 3 inch 35 Nm (26 ft lbs) At this time, do not make a mistake of rupture disk direction. f) Put the rupture disk assembly and gaskets with Teflon sealant into the flanges, and tighten them uniformly by the bolts. Tightening torque : 2 inch 70 Nm (52 ft lbs) Tightening torque : 3 inch 75 Nm (55 ft lbs) g) Charge Nitrogen gas into the chiller up to about 49 kPa. h) Perform leak test by soap solution. i) Discharge nitrogen gas. j) Perform purging until the pressure in the chiller goes down to 1.3 kPa absolute. k) Run the chiller with about 50% input and perform air purging from the chiller for 1 hour. l) If there are no- abnormality, the chiller can be run on normal operation. 6-2-5. Palladium cell & heater This instruction describes the procedure to replace an palladium cell and heater. (1) Instrument a) Screw driver b) Torque wrench c) Adjustable wrenches d) Fork terminals e) Heat resistance tube Fig. 6-7 Palladium cell assembly with heater Page 4 / Sec. 6 LJ/TJ Series Base Fig. 6-6 Rupture disk assembly Cap screw Rupture disk Flow Hold down Cap screw Flanges & bolts Fig. 6-5 Rupture disk assembly Upper tube sheet a) Adjustable wrenches Gasket (T/# 9090-OR)
Apply Teflon sealant (T/# 9400)

(2) Procedure a) Be sure to confirm that the main breaker (MCBM) is turned OFF. b) Close B valve tightly. c) Open and remove the palladium cell cover. d) Remove the heater wire screws in the connection box and remove the heat resistance tube. e) Remove the assembling spring and bark the adhesive tape. Then disassemble the insulations. f) Loosen two screws fixing the heater and take out the hater. g) Loosen the screw fixing the case to the mounting and take out the case. h) Remove the flare nut and the palladium cell. i) Put new palladium cell. Tighten the flare nut by the torque wrench with 59-68 Nm (522-601 lbf inch). Note : Do not touch the palladium cell by fingers directory, use clean gloves. j) Perform leak test by the bubble test from SV9 (Purge tank service valve) Leak rate shall be 0cc per 10 minutes. k) Insert the case to the mounting with palladium cell and fix them by the screw. l) Insert new heater into the case and fix them by the screws. m) Insert the heater wires into the heat resistance tube. n) Put the fork terminals to the heater wires and the connect the wires with fork terminals to the originals terminal positions. Then put the connection box cover. Adhesive tape o) Assemble the palladium cell cover. Assembling spring Insulation

Case Heater Palladium cell

Fig. 6-9 Palladium cell Fig. 6-8 Heater Case Palladium cell Flare nut

Holes of screw

Fig. 6-10 Page 5 / Sec. 6

Mounting for palladium cell welded on purge tank

LJ/TJ Series

6-3. Method of absorbent solution (LiBr) analyses This instruction described to procedure for analyses of absorbent solution. (1) Notice for analyses a) The time of analyses 1) In case of commercial use for air conditioning (about 4000 hours operation per year), the analyses should be conducted twice per year. 2) In case of continuously operation such as process use, the analyses should be conducted four times per year. b) Sampling solution and sampling position 1) Sampling solution : Diluted absorbent solution 2) Sampling position : The service valve (SV4) at discharge pipe of the absorbent pump c) Sampling quantity Sample the absorbent solution of 100 cc twice. First sampling solution shall be abandoned. Second sampling solution shall be used for analyses. d) Sample the absorbent solution during operation of the absorbent pump. (2) Analyses items a) Concentration of inhibitor (Lithium Molybdate : Li2MoO4) b) Alkalinity (Neutralization analysis) c) All copper content and all iron content (3) Instruments a) Solution sampling tool b) Bottle for solution with a cap (100 cc) c) Pipette with scale d) Beaker (100 cc.) e) Burette] f) Syringe g) Phenolphthalein solution h) One-tenth normal Hydrochloric acid solution (HCl) i) 50% Hydrochloric acid solution (HCl) j) Aluminum nitrate (Al(NO3)3 9H2O) Aluminum nitrate is crystal. Therefore, making aluminum nitrate solution shall be required. The method of making it is as follows. Put 250 g of aluminum nitrate unto a bottle and pure water into the bottle until total volume becomes 1 liter, and then mix them. k) Pure water (4) Sampling of the absorbent solution a) Remove the absorbent solution at the service valve (SV4) during operation of the absorbent pump by the sampling tool. b) Pour the absorbent solution to the bottle from the sampling tool.

Page 6 / Sec.6

LJ/TJ Series

(5) Measurement of concentration of inhibitor (Lithium Molybdate : Li2MoO4) Standard concentration of inhibitor : 50 - 150 ppm a) Stand the bottle for about 24 hours. After 24 hours, most solids in the absorbent solution accumulates at the bottom of the bottle. b) Collect 5 milli-litter of the absorbent solution from the top of the bottle by a pipette, and then pour it into a beaker. c) Add 4 milli-litter of the aluminum nitrate solution and 1 milli-litter of 50 % hydrochloric acid solution into another beaker, and mix tem. d) Add 1 milli-litter of the solution made in the item c) into the beaker by another pipette. e) Pour 94 milli-litter of pure water into the beaker by the burette. The above procedure is to make solution for analysis. And its volume is 100 milli-litter. This means that the absorbent solution is diluted to 1/20. f) In order to measure concentration of Lithium Molybdate, "Atomic absorption spectro chemical analysis" must be required. There is no-way to simply measure it. Therefore, this check can not be done at an site. It is preferred to request the analysis to an official organization or an analysis company. g) If concentration value measured is less than its standard, add inhibitor in accordance with " Method of adjusting inhibitor content and alkali". (6) Measurement of alkalinity (Neutralization analysis) Standard of the alkalinity : 0.03 N - 0.07 N (P Alkalinity) a) Stand the bottle for about 24 hours. After 24 hours, most solids in the absorbent solution accumulates at the bottom of the bottle. b) Collect 10 milli-litter of the absorbent solution from the top of the bottle by a pipette, and the pour it into a beaker. c) Pour 50 milli-litter of pure water into the beaker by the burette. d) Add Phenolphthalein (2 -3 drops) into the beaker by the syringe. The solution is colored to pink. The above procedure is to make solution for analysis. e) Add one-tenth normal Hydrochloric acid solution little by little into the solution by a burette until its color becomes colorless. f) Calculate the alkalinity according to the following formula. N = A X 0.01 where N : Alkalinity A : Quantity of Hydrochloric acid solution added (milli-litter) g) The standard of adjustment of the alkalinity 1) Alkalinity is 0.03 N - 0.07 N 2) Alkalinity is less than 0.03 N 3) Alkalinity is beyond 0.07 N No addition is required. Add LiOH Add HBr

Remark : In case of absorbent with Li2MoO4 as inhibitor, its alkalinity reduces as compared with initial value of the alkalinity in proportion to operation hours of the chiller. Page 7 / Sec.6 LJ/TJ Series

(7) Analyses of all copper content and all iron content Limitation of the all copper content : 250 ppm max. Limitation of the all iron content : 250 ppm max. a) Shake the bottle before collecting the absorbent solution. b) Collect 1 milli-litter of the absorbent solution from the top of the bottle by the pipette, and then pure it into a beaker. c) Add 1 milli-litter of one-tenth normal Hydrochloric acid solution. Into the beaker by another pipette. d) After a few hours, pour 98 milli-litter of pure water into the beaker by a burette. The above procedure is to make solution for analysis. And its volume is 100 milli-litter. This means that the absorbent solution is diluted to 1/100. e) In order to measure concentrations of the all copper and iron, "Atomic absorption spectro chemical analysis" must be required as well as the method of the measurement of inhibitor. f) If the all copper content and all iron content are beyond their limitation, all absorbent solution charged in the chiller shall be filtered. (8) Notes a) In case that the absorbent solution crystallizes, melt it first and then perform the analyses. b) In case of the analyses of the all copper and the all iron, wait for a while after hydrochloric acid solution is added.

Notice for all iron & all copper

If these value is beyond the limitations, it means that there is a leakage. In this case, the leak test shall be performed and repair it as soon as possible. After that, perform filtration of all absorbent solution. Then Analyze them again.

Page 8 / Sec.6

LJ/TJ Series

6-4. Method of adjusting inhibitor content and alkalinity (1) Method of adding inhibitor This instruction describes the procedure to add inhibitor. a) Instruments 1) Inhibitor : Li2MoO4 H2O (20wt% solution) 2) Pure water 3) Container 4) Vacuum rubber hose 5) Hose band 6) Pliers 7) Wrench 8) Rubber gloves b) Target value of inhibitor concentration : 150 ppm Additional volume of the inhibitor is calculated in accordance with the following formula. 150 ppm - X ppm 100 where X : Measured value of inhibitor concentration (ppm) A : Initial charge amount of absorbent solution D : Required volume of inhibitor (cc) For example X = 40 ppm Model : TSA-16LJ-24 A = 1,070 kg 150 ppm - 40 ppm 100 c) Procedure 1) In order to remove air in the rubber hose, pour pure water into the hose as shown in Fig. 6-12. 2) Connect the vacuum rubber hose to the service valve (SV3) provided on the refrigerant pump discharge and fix it by a hose band as shown in Fig. 6-11.
Sampling service valve(SV3) Copper tube Solution container Vacuum rubber hose Refrigerant pump

x 0.465 x A = D

Table 6-1 Initial charge LiBr solution in the factory

Model TSA-16LJ-** 11 12 13 14 21 22 x 0.465 x 1,070 = 547 cc 23 24 31 32 41 42 51 52 53

Absorbent solution 50wt%)

kg 430 430 560 620 750 810 980 1,070 1,230 1,340 1,560 1,680 1,950 2,170 2,420

lbs 900 900 1,200 1,400 1,700 1,800 2,200 2,400 2,700 3,000 3,400 3,700 4,300 4,800 5,300
Copper tube Vacuum rubber hose Filled with pure water

Inhibitor

Fig. 6-11 Fig. 6-12 Page 9 / Sec.6 LJ/TJ Series

3) Pour inhibitor added into the container. 4) Insert a copper tube into the container. 5) perform purging from the chiller. 6) Open the service valve (SV3) 7) When inhibitor starts being sucked into the chiller, watch carefully to ensure that air does not leak in. 8) Close the service valve (SV3) after charging the inhibitor. 9) Remove the vacuum rubber hose. 10) Wash the mouth of the service valve with water and put the bonnet and flare nut. Then place the cap of the service valve after confirming the packing inside. 11) Wash all instruments with water. 12) Perform refrigerant blow down after completion of the work, and run the chiller in order to circulate the inhibitor in the inside of chiller. 13) Continue the purging at least 30 minutes after completion of this work. d) Notes 1) Be sure to perform this work during operation of the chiller, and be sure to carry out purging from the chiller during this work. 2) Wear rubber gloves while this work. 3) Thoroughly wash off any inhibitor which gets on hand, skin and clothes. Take care to prevent inhibitor entering mouth and eyes. 4) Do not spill inhibitor on a floor and do not throe it in a drain. (2) Method of adding alkali This instruction describes the procedure to add Alkali (LiOH) in case that alkalinity is less than 0.03 N. a) Instruments 1) Alkali : LiOH (powder) 2) Pure water 3) Container 4) Vacuum rubber hose 5) Hose band b) Target value of alkalinity : 0.07 N Additional volume of LiOH is calculated in accordance with the following formula. D = 28.6 x (0.07 -X) x A where X : Measured value of alkalinity (N) A : Initial charge amount of absorbent solution (see Table *-*) D : Required volume of alkali (g) For example X = 0.01 N Model : TSA-16LJ-24 A = 1,070 kg 28.6 x (0.07 - 0.01) x 1,070 = 1,836 (g) Page 10 / Sec.6 LJ/TJ Series 6) Pliers 7) Wrench 8) Rubber gloves 9) Mask

c) Procedure 1) In order to remove air in the rubber hose, pour pure water into the hose as shown in Fig. 6-12. 2) Connect the vacuum rubber hose to the service valve (SV6) provided for concentrated absorbent and fix it by a hose band as shown in Fig. 6-13. 3) Put the alkali added into the container and melt it with pure water. 4) Insert the copper tube into the container. 5) Perform purging from the chiller. 6) Open the service valve (SV6). 7) when the alkali solution starts being sucked into the chiller, watch carefully to ensure that air does not leak in. 8) Close the service valve after charging the alkali solution. 9) Remove the vacuum rubber hose and wash the mouth of the service valve with water. Then put the bonnet and flare nut. And place the cap of the service valve after confirming the packing inside. 10) wash all instrument with water. 11) Run the chiller in order to circulate the alkali in the inside of the chiller. 12) Continue the purging at least 30 minutes after completion of the work. d) Notes 1) Be sure to perform this work during operation of the chiller, and be sure to carry out purging from the chiller during this work. 2) Be sure to check the alkalinity again after this work. 3) Wear rubber gloves while this work. 4) Thoroughly wash off any alkali which gets on hand, skin and clothes. Take care to prevent alkali entering mouth and eyes. 5) Do not spill alkali on a floor and do not throw it in a drain. 6) Pay attention not to suck in any powder of LiOH during this work. (3) Method of adding Acid This instruction describes the procedure to add Acid (HBr) in case that alkalinity is 0.07 N or above. a) Instruments 1) Acid : HBr (concentration : 47 %) 2) Pure water 3) Container 4) Vacuum rubber hose x 2 pieces 5) Hose band x 2 pieces 6) Pliers 7) Wrench 8) Rubber gloves 9) Mask 10) PH test paper
HBr + Absorbent HBr + Absorbent Copper tube Copper tube Solution container Heat exchanger Solution container Heat exchanger SV4:Open SV6:Close SV4:Close SV6:Open Diluted absorbent pipe Vacuum rubber hose Diluted absorbent pipe Vacuum rubber hose Alkali solution Sampling service valve(SV6) Heat exchanger Vacuum rubber hose

Copper tube Solution container

Fig. 6-13

Fig. 6-14 Page 11 / Sec.6 LJ/TJ Series

b) Target value of alkalinity : 0.03 N Additional volume of HBr is calculated in accordance with the following formula. D = 79.2 x (X -0.03) x A where X : Measured value of alkalinity (N) A : Initial charge amount of absorbent solution (see Table 6-1) D : Required volume of acid (milli-litter) For example X = 0.09 N Model : TSA-16LJ-24 c) Procedure 1) In order to remove air in the rubber hose, pour pure water into the hose as shown in Fig. 6-12. 2) Connect the vacuum rubber hose to the service valve (SV6) provided for concentrated absorbent and fix it by a hose band as shown in Fig. 6-13. 3) Connect another vacuum rubber hose to the service valve (SV4) and fix it with a hose band. 4) Insert two copper tubes into the container. 5) Perform purging from the chiller. 6) Open the service valve (SV4). 7) Remove about 50 litters of diluted absorbent solution from the service valve (SV4) into the container when the absorbent pump is running. 8) Close the service valve (SV4) after 50 litters of the absorbent accumulates in the container. 9) Pour HBr little by little into the absorbent removed. At this time check PH value of the absorbent by the PH test paper. 10) Stop to pour HBr when PH value of the absorbent has become 7 to 6. 11) Open the service valve (SV6). 12) When the absorbent starts being sucked into the chiller, watch carefully to ensure that air does not leak in. 13) Close the service valve(SV6) after the absorbent in the container empties. 14) Repeat item 6) thru item 13) until required amount of HBr is charged into the chiller. 15) After completion to charge required amount of HBr, confirm that SV4 and SV6 are fully closed. 16) Remove the vacuum rubber hoses and wash mouths of the service valves with water and put bonnets and flare nuts to the service valves. 17) Place caps of the service valves after confirming the packing inside. 18) Wash all instrument with water. 19) Continue the purging at least 30 minutes after completion of the work. d) Notes 1) Be sure to perform this work during operation of the chiller. 2) Be sure to check again the alkalinity after this work. 3) Wear rubber gloves and a mask during this work. 4) Thoroughly wash off any HBr which gets on clothes. Pay attention to handle HBr. Because HBr is very strong acid. 5) Do not spill HBr on a floor and do not throw it in a drain. 6) There may be case that gas is generated when HBr is mixed with absorbent. Pay attention not to inhale the gas. Page 12 / Sec.6 LJ/TJ Series A = 1,070 kg 79.2 x (0.09 - 0.03) x 1,070 = 5,085 (milli-litter)

6-5. Method of charging solution This instruction describes the procedure of charging absorbent and refrigerant into a chiller. (1) Equipment use a) Solution container (for absorbent and refrigerant) b) Vacuum rubber hose with copper tube c) Hose band d) Pliers (2) Procedure a) Prepare the solution containers. b) Operate a purge pump and perform the purging from the chiller. c) Connect the vacuum rubber hose to the service valve where solution is charged and fix it with the hose band. d) Insert the copper tube of the vacuum rubber hose into the container. (Keep slightly high from the bottom of the container as shown in Fig. 6-15.) e) Open the service valve. f) When the solution starts being sucked in to the chiller, watch carefully to ensure that air does not leak in. g) Before the container becomes empty, tilt it so that air does not enter into the chiller as shown in Fig.6-16. h) When the container becomes almost empty, bend the vacuum rubber hose by your hands to ensure that air does not leak in as shown in Fig.6-17, and quickly insert the copper tubes in the next container.
Vacuum rubber hose Solution container Bending Sampling service valve Vacuum rubber hose Copper tube Solution container

Fig. 6-15

Fig. 6-16 i) Repeat item f) to h) until required charging amount solution has been charged. j) After completion, close the service valve at once.

Fig. 6-17

k) Remove the vacuum rubber hose from the service valve and wash the mouth of the service valve with water, then put the bonnet and flare nut. And put the cap of service valve. l) wash the vacuum rubber hose, etc. with water m) Continue air purging at least 30 minutes after completion of this work. (3) Precautions a) During this work, do not spill the solution. b) Because of high vacuum condition inside the chiller, take case to ensure that air does not leak into the chiller during this work. c) Carefully wash the vacuum rubber hose used before this work with water so as to prevent dire ingress. d) Wear rubber gloves. Do not handle tools pr solution with bare hands. e) Thoroughly wash off any absorbent which gets on hands, skin or clothes. Take care to prevent absorbent entering eyes or mouth. f) If absorbent spills on metal plates, etc., thoroughly wash off with water. Page 13 / Sec. 6 LJ/TJ Series

Lift up slightly

6-6. How to perform de-crystallization Cause of crystallization Crystallization is occurred under complex conditions described blow. However there is few cases that No.3 and No.4 factors causes crystallization by suitable periodic maintenance. Usually, crystallization is occurred by No.1 and No.2 factors. No.1 factor : Too low cooling water inlet temperature No.2 factor : Insufficient vacuum condition (bad vacuum condition) No.3 factor : Over driving input No.4 factor : Insufficient absorbent flow rate Probable location of crystallization Crystallization is occurred mostly at concentrated absorbent in the heat exchanger. If the crystallization occurs, The following symptoms are observed. Therefore, de-crystallization procedure at this portion is explained. 1) Chilled water outlet temperature does not go down. 2) The temperature of concentrated solution over-flow pipe increases as the pipe can not be touched. 3) The temperature of concentrated solution outlet of heat exchanger goes down as the pipe can be touched. 4) Diluted solution temperature rises (more than 40 deg.C / 104 deg.F) Outline of de-crystallization Crystallization generating at the outlet of concentrated solution side in the heat exchanger is melted by means of approximate 60 deg.C (140 deg.F) of high temperature diluted solution. This high temperature cooling water is made by the operating condition with low driving input and without cooling water.
Select "MANUAL" by & keys

(1) De-crystallization procedure a) Close compulsorily the hot water control valve by service mode.
9 0. 0 SET + 2 sec. C H G S = 2 SET 2 sec. P u r G E
3 times

A u t o C n. - 1 SET 2 sec. Push n. A n u A L

Change set value to "0" by & keys

1 0 0 (Present value)

SET 2 sec.

C n. - 1 5 t

Push "SET" key

b) Operation mode of the refrigerant pump to "ON" by service mode.

9 0. 0 SET + 2 sec. C H G S = 2 SET 2 sec. P u r G E r E F - P SET 2 sec. Select "ON" Push SET O F F

A u t o O F F O N Push SET O N Select "OFF"

1 time

c) Open the refrigerant blow valve and perform blow down. d) Operation mode of the refrigerant pump to "OFF" by service mode. e) Stop the chiller by "STOP" key on the operation board.

f) Turn off the electric power supply of cooling water pump and cooling tower fan. g) Open the control panel door and jumper two terminals of cooling water pump interlock(52CO). h) Select the operation mode to "LOCAL". Then run the chiller. i) Perform de-crystallization by the diluted solution delivering from the absorbent pump at 50 - 60 deg.C (122 - 140 deg.F) with adjusting the hot water control valve opening and switching ON/OFF of the cooling water pump. *Be sure not to exceed atmospheric pressure in the generator during this work. Page 14 / Sec.6 LJ/TJ Series

*Working time : 2 - 3 hours (This is an common value. The working time should be extended if necessary.) *If the crystallization is very strong, conduct followings together with above work. i-1) Charge pure water (if possible, use hot water) from service valve (SV6). i-2) Heat the crystallization portion by gas or oil burner. j) Check if de-crystallization is successful or not by the followings. *No-flow of concentrated solution in the overflow pipe is confirmed. (Temperature of the overflow pipe goes down) *Fluid level in absorber (bottom of the lower shell) raises and the absorbent pump pressure increases. *The temperature of concentrated solution outlet of the heat exchanger becomes warm. k) Stop the chiller. After dilution operation, the chiller and other equipments are shut-down completely. l) Remove the jumper wire connected in item g) m) Return the operation mode of the refrigerant pump to "AUTO" by service mode.
9 0. 0 SET + 2 sec. C H G S = 2 SET 2 sec. P u r G E 1 time r E F - P SET 2 sec. Select "AUTO" O N O F F A U T O Push SET

n) Return the hot water control valve opening to "AUTO" & "100".
SET + 2 sec. SET 2 sec.

Select "Auto" by

&

keys n. A n u A L A u t o Push "SET" key

9 0. 0

C H G S = 2 1 0 0

P u r G E

3 times

C n. - 1

SET 2 sec. Push

Change set value to "0" by & keys

2 0 (Present value)

SET 2 sec.

C n. - 1 5 t

(2) After de-crystallization b) Run the chiller and perform normal operation.

During de-crystallization work, this value is changed approximate 0 - 30 in order that the dilution solution temperature is kept between 50 deg.C (122 deg.F) and 60 deg.C (140 deg.F)

a) Locate and remove causes of the crystallization. c) Check operating conditions of the chiller for a while after restart, and check if crystallization occurs again or not. *Temperature *Pressure *Fluid level d) In case that a lot of water is added to do de-crystallization work, the water shall be removed from the chiller. However, in case of small amount water, water removing is not necessary. *Method of removing out water : The water (refrigerant) can be removed from the service valve (SV3) by using a small pump because the discharge pressure of the refrigerant pump is vacuum. Added water amount and removed water amount shall be equal. Record both water quantity. Check removed water specific gravity. The gravity shall be less than 1.01 (concentration :Less than 1.5%) Crystallization occurring in the generator If generator temperature is higher than the temperature at last stop, hot water flows into the generator due to leakage of a hot water shut-off valve. This causes crystallization in the generator. Accordingly, the generator temperature should be checked even if a chiller is shut-down. If such condition is found out, run the chiller as soon as possible. Normally, the crystallization melts by the operation. However, if the condition is not found out long time, 1 week or more, the crystallization may become hard. In this case, it may be necessary to charge a lot of refrigerant to do de-crystallization. In order to prevent this problem, it is most important that "the shut-off valve shall be closed during shut-down of the chiller" shall be definitely informed to an operator. Page 15 / Sec.6 LJ/TJ Series

6-7A. Reference material of tube cleaning (LJ) This instruction describes the method of tube cleaning as reference only. (1) Cleaning procedure Check scale condition Check scale adhesion condition Sample the scale Check prior to cleaning 1) determine proper cleaning agent *Perform dissolving test of the scale using various cleaning agents. *determine a drainage way. Cautions (a) Dispose, drain, and/or treat west water properly. (b) Do not drain a hydrogen peroxide based cleaning agent into a purifying cistern or activate sludge treatment system. (c) Refer cleaning using a fluoride based cleaning agent to a professional. Preparation 2) Determine the cleaning method. *Determine cleaning area, amount of water and chemicals. *Prepare instruments, chemicals and protective tools. (1) Instrument It is recommended to use both chemical cleaning and brushing cleaning for tube cleaning. Make a reversible flow direction circuit

Absorption chiller
Cooling tower

Channel A Channel B
Chemical supply tank Neutralization tank

Fig. 6-18 LJ/TJ Series

Page 16 / Sec.6

(2) Chemical cleaning procedure Scale / Slime Chemical cleaning Alkali agent Neutralization Drainage Cleaning with water Repeat 3 to 5 times Drainage Visual checking Check pH value and drained water transparency. Check if brush cleaning is required, Brush cleaning Visual checking Water cleaning Circulate water throughout entire cooling water system, then clean using water by continuous blowing for 2 hours or more. (Channel B) Cooling water system is filled with new water *Use alkaline water (pH 8 - 9) for rust prevention. *If there is a possibility of freezing in winter season, use anti-freeze solution having anti-corrosion agent. Measure the amount of an alkali agent for neutralization. Conduct the neutralization for 30 to 60 minutes for drain out the chemical. pH value of the solution drained shall be 6 - 8. Flow the water through the channel A and B.

(3) Determining a chemical agent for cleaning (Dissolving test) Collect the scale to be cleaned. Perform the dissolving test using an available chemical agent. Determine the most suitable chemical agent. Chemical agent Scale Put the scale into the chemical agent with the specified concentration. Then observe the condition of bubbles and the dissolving condition of the scale. A B Bad C Good The more bubbles are emitted and more scale is dissolved, the more effective the cleaning chemical agent is. The qualification must be necessary for handling of the fluoride based chemical agent. The chemical is extremely hazardous to both humans and equipments. Therefore, If the chemical is required, the professional shall be required.

Page 17 / Sec.6

LJ/TJ Series

(3) Notice for draining waste water *Sewerage : Drain waste water after conducting proper treatment *Rivers / Lakes / Swamps / Farm land / Fish farm : Do not drain *Waste water treatment facilities : The hydrogen based waste water can not be drained into a purifying cistern or activate sludge treatment system. Waste water standard of public sewerage in Japan (Reference only) Items Temperature Hydrogen ion concentration (4) Method a) Prepare water, chemical agent, neutralization agent and rust preventive. b) Confirm the area and circuit to be cleaned. c) Prepare protection tools (gloves / goggles / mask / etc.) d) Make the cleaning circuit around the pump as shown in Fig. 6-19 for reversible water flow. Inlet port or Drain port Connected with the chiller Pump Inlet port or Drain port Fig. 6-19 Use suitable capacity pump for circulating the chemical agent. The below table shows pumps as reference. Table 6-2 Flow rate 0.8 m /h (3.5 gpm) 0.2 m /h (0.9 gpm) (5) Others a) In case of the tube cleaning together with cooling tower, pay attention that a chemical cleaning agent does not splash out. b) For safety, prepare anti-chemical sheet on the working area. c) If cleaning work continues two or more days, fill the cleaning portion with clean water (ex. City water) at the end of daily work.
3 3

Standard Less than 45 deg.C (113 deg.F) 5 < pH < 9

Connected with the chiller

Total head 9.5 m (31 ft) 6.5 m (21 ft)

Output 2.2 kW 0.4 kW

Page 18 / Sec.6

LJ/TJ Series

Table 6-3 Type of scale VS Cleaning chemical agent

Type of scale : Iron rust scale Feature of scale Suitable cleaning agent Color : Red brown or black / Hard scale Hydrochloride acid type

Neutralizing method Cautions

Ca.Mg.salt scale Feature of scale Suitable cleaning agent

Take the cleaning agent out of a chiller then neutralize using caustic soda. It can not be used for water heater.
Color : Gray white / The scale is soft. It can be crashed into powder by fingers. When acid is added, bubbles are generated violently

Neutralizing method Cautions

Silicate scale Feature of scale Suitable cleaning agent

Sulfamic acid type Take the cleaning agent out of a chiller then neutralize using caustic soda.
As sulfamic acid solution will wither plants if it is drained as is, be sure to neutralize it before draining. Color : Gray white / The scale is very hard and can not be crashed into powder by fingers. The scale is not dissolved even if hydrochloric acid is added. Hydrofluoric acid type / Organic salt type Take the cleaning agent out of a chiller then neutralize using slaked lime. A professional shall be required. Do not use an agent which contains ammonia as it may react with copper (ammonia fluoride).

Neutralizing method Cautions

Slime Feature of scale Suitable cleaning agent

Color : Green, Gray, Black, Brown , Yellowish / Extremely soft / Viscous matter Hydrogen peroxide type / Organic acid type No need to neutralization, however clean with water sufficiently after cleaning. If the cooling water is acidly, do not use hydrogen peroxide type chemical agent. The hydrogen peroxide type waste water shall not be drained into a purifying cistern or activated sludge treatment system.

Neutralizing method Cautions

Slime & Iron scale coexist Feature of scale Suitable cleaning agent Color : Yellowish, Brown / Soft / Viscous matter Hydrogen peroxide type / Hydrochloric acid type If hydrochloric acid type agent is used, neutralize it by using caustic soda. The cautions and prohibited items for cleaning of the scale where a variety of those same as those for the cleaning agents mentioned above. Iron & Silicate coexist Feature of scale Suitable cleaning agent Color : Yellowish, Brown / Somewhat soft Hydrochloric acid type + Hydrofluoric acid type Take it out of the system, then neutralize it by using slaked lime. Same the above Color : Grayish white / Very hard scale When hydrochloric acid is added, some bubbles are generated. Suitable cleaning agent Hydrofluoric acid type + Sulfamic acid type / Hydrofluoric acid type + Hydrochloric acid type Take it out of the system, then neutralize it by using slaked lime. Same the above Reddish brown / Hard scale Hydrochloric acid type Take it out of the system, then neutralize it by using slaked lime. Same the above

Neutralizing method Cautions

Neutralizing method Cautions

Feature of scale

Silicate & Ca. Mg salt coexist

Neutralizing method Cautions

Feature of scale Suitable cleaning agent

Scale where Iron & Ca. Mg salt coexist

Neutralizing method Cautions

Page 19 / Sec.6

LJ/TJ Series

Information for tube cleaning

Model TSA-16LJ11 12 13 14 21 22 23 24 31 32 41 42 51 52 53 Tube length mm 2066 2066 3086 3086 3086 3086 4106 4106 4106 4106 4106 4106 4106 4648 5146 inch 81.3 81.3 121.5 121.5 121.5 121.5 161.7 161.7 161.7 161.7 161.7 161.7 161.7 183.0 202.6 301 357 301 357 415 478 415 478 542 604 695 791 1064 1064 1064 Tube quantity Abso. Cond. Evap. Gene. Tubes 170 204 170 204 238 272 238 272 306 340 382 425 400 400 400 208 250 208 250 298 337 298 337 373 414 460 560 702 702 702 174 192 162 192 224 256 224 256 288 324 359 400 458 458 458 mm 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 Abso.

Tube inner dia.

Cond. mm 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 18.0 18.0 18.0 Evap. mm 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 Gene. mm 16.7 16.7 16.7 16.7 16.7 16.7 16.7 16.7 16.7 16.7 16.7 16.7 16.7 16.7 16.7

inch
0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587

inch
0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.709 0.709 0.709

inch
0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583

inch
0.657 0.657 0.657 0.657 0.657 0.657 0.657 0.657 0.657 0.657 0.657 0.657 0.657 0.657 0.657

Holding water quantity Model TSA-16LJ11 12 13 14 21 22 23 24 31 32 41 42 51 52 53

Cooling water Abso. + Cond Liter 332 365 405 450 579 632 693 763 976 1045 1305 1405 1972 2127 2270 U.S.gal 87.7 96.4 107.0 118.9 153.0 167.0 183.1 201.6 257.8 276.1 344.7 371.2 520.9 561.9 599.7

Chilled water Evap. Liter 114 129 151 174 224 245 276 304 354 383 485 555 703 769 829 U.S.gal 30.1 34.1 39.9 46.0 59.2 64.7 72.9 80.3 93.5 101.2 128.1 146.6 185.7 203.1 219.0

Driving hot water Gene. Liter 108 116 139 159 198 220 248 277 330 362 439 475 560 614 664 U.S.gal 28.5 30.6 36.7 42.0 52.3 58.1 65.5 73.2 87.2 95.6 116.0 125.5 147.9 162.2 175.4

Page 20 / Sec.6

LJ/TJ Series

Inner shape of tubes Absorber tube Evaporator tube

Condenser tube

Generator tube

Page 21 / Sec.6

LJ/TJ Series

Information for tube cleaning Model TSA-16TJ11 12 13 14 21 22 23 24 31 32 41 42 51 52 53 Tube length mm 2066 2066 3086 3086 3086 3086 4106 4106 4106 4106 4106 4106 4106 4648 5146 inch 81.3 81.3 121.5 121.5 121.5 121.5 161.7 161.7 161.7 161.7 161.7 161.7 161.7 183.0 202.6 301 357 301 357 415 478 415 478 542 604 695 791 1064 1064 1064 Tube quantity Abso. Cond. Tubes 170 204 170 204 238 272 238 272 306 340 382 425 400 400 400 208 250 208 250 298 337 298 337 373 414 460 560 702 702 702 Evap. Absorber mm 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 14.9 inch 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 0.587 Tube inner diameter Condenser mm 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 15.0 18.0 18.0 18.0 inch 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.591 0.709 0.709 0.709 Evaporator mm 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 inch 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583 0.583

Holding water quantity Model TSA-16LJ11 12 13 14 21 22 23 24 31 32 41 42 51 52 53 Cooling water Absorber + Condenser Liter 332 365 405 454 579 632 693 763 976 1045 1305 1405 1978 2133 2276 U.S.gal 87.7 96.4 107.0 119.9 153.0 167.0 183.1 201.6 257.8 276.1 344.7 371.2 522.5 563.5 601.3 Chilled water Evaporator Liter 115 130 151 174 224 245 286 314 354 383 485 555 703 769 829 U.S.gal 30.4 34.3 39.9 46.0 59.2 64.7 75.6 83.0 93.5 101.2 128.1 146.6 185.7 203.1 219.0

Page 22 / Sec.6

LJ/TJ Series

Inner shape of tubes Absorber tube Evaporator tube

Condenser tube

Page 23 / Sec.6

LJ/TJ Series

6-8. Solution and refrigerant sampling This instruction describes the procedure for sampling small amount of the absorbent solution. Equipment use 1. Sampling cylinder and attachments for service valve 2. Vacuum rubber hose 3. Pliers 4. Vacuum gauge (0-1kPa (0-0.15psi)) Precautions 1. Because of high vacuum condition inside the chiller, take care to ensure that air never leak into the chiller during this work. 2. Handle the vacuum valve carefully so as not to damage it. 3. When solution (absorbent & refrigerant) is sampled at SV3, SV4 and SV6. Procedures at each service valve are the same manner. Position of service valves SV3, SV5, SV6 SV3 : Service valve mounted at the discharge pipe of the refrigerant pump To remove refrigerant SV4 : Service valve mounted at the discharge pipe of the absorbent pump To remove diluted absorbent solution SV6 : Service valve mounted at the outlet side of the heat exchanger shell To remove concentrated absorbent solution 4. Pour solution sampled into another container. Do not spill/pour the solution to a sewage, etc.. Procedure 1. Confirm manual purge valves (V1, V2 and V3) to close. 2. Remove a flare nut and a bonnet of SV1, and connect an attachment to the service valve. 3. Remove a flare nut and a bonnet of SV4 where absorbent is sampled, and connect an attachment to the sampling service valve. 4. Connect a vacuum rubber hose and a sampling cylinder to the attachment as shown in Fig 6-22. 5. Run a purge pump and open up V1. 6. Open SV1 and the vacuum valve. 7. When the indication of the vacuum gauge becomes about 0.5kPa(0.07psi), close the vacuum valve. 8. Remove the vacuum rubber hose from SV1, and connect it to SV4 as shown in Fig. 6-23. 9. Open the vacuum valve. 10. Open SV4. 11. When the sampling cylinder is filled with absorbent, close SV4. 12. Close the vacuum valve and remove vacuum rubber hose from SV4 service valve. 13. Upon completion of this work, remove the attachment, and put the bonnets and flare nut. Also put the caps of both service valves after checking their packings. 14. Stop the purge pump. 15. Finally, wash all tools with water.

Page 24 / Sec.6

LJ/TJ Series

V2 V3 Vacuum rubber hose SV1 Vacuum rubber hose Sampling service valve (SV3, SV4, SV6) Attachment

Attachment V1 Liquid trap Sampling cylinder Sampling cylinder Purge pump Vacuum valve Vacuum valve

Fig. 6-23

Fig. 6-22 280(11") Sampling cylinder (Material : Acryl rosin) 54(2-1/8") Fig. 6-24 Valve Steel wire Rubber hose Copper tube Attachment Copper tube Rubber cup Flare nut Fig. 6-25 Flare nut 150(5-15/16") Fig. 6-26 LJ/TJ Series Copper tube 150(5-15/16") Page 25 / Sec.6 54(2-

6-9. Measuring concentration This instruction describes the procedure to measure concentration of absorbent solution and refrigerant. Equipment to use 1. Sampling cylinder 2. Gravimeter Scale: 1.0-1.2 (for refrigerant) Scale: 1.4-1.6 (for diluted absorbent) Scale: 1.6-1.8 (for diluted and concentrated absorbent) 3. Thermometer Precautions 1. Take care not to damage the gravimeter and thermometer. 2. Be careful not to spill any solution. Do not fill the sampling cylinder any more than about 80%. 3. Quickly perform this measurement. Procedure 1. Fill the sampling cylinder to about 80% with solution to be measured. 2. Vertically keep the sampling cylinder, and insert a gravimeter into the sampling cylinder. 3. When the gravimeter stops moving up and down, read the scale of the gravimeter which shows gravity of the solution. 4. Remove the gravimeter and put it aside. Then insert the thermometer into the sampling cylinder and stir the solution thoroughly. 5. When the temperature is stabilized, read the scale on the thermometer. 6. Remove the thermometer and put it aside. 7. Store the solution in another bottle. 8. Using the concentration diagram of Lithium Bromide solution, read the concentration. 9. Upon completion of measurement, wash the gravimeters, thermometer and sampling cylinder with water. And store them so that they are not damaged. Example: The horizontal axis represents temperature and the vertical axis represents specific gravity. Specific gravity 64 63 62 Concentration (%) 1.77 The lines going down from left to right represent fixed concentrations. For example, if the specific gravity is 1.77 and the temperature is 45oC(113oF), the concentration given by the point of intersection of lines projected from these values will be 63%, as shown in Fig. 6-27. 45oC(113oF) Temperature Fig. 6-27

Page 26 / Sec.6

LJ/TJ Series

Fig. 6-28 Page 27 / Sec.6 LJ/TJ Series

6-10. Damper adjustment Typically the factory damper setting is adequate for most unit start-ups, adjusting the damper should be performed only if necessary. If the damper adjustment is necessary, make only a subtle adjustment in 1o or 2o. Allow unit operation to stabilize for at least 1/2 - 1 hour between an adjustment before making another adjustment. The damper adjustment should only be performed at full load operating conditions and never at partial load conditions. Once properly set, the damper should never require further adjustment.

Damper Solution line

Note: full close 0o ; full open 90o

Fig. 6-29

Page 28 / Sec.6

LJ/TJ Series

6-11. Method of charging Nitrogen gas This instruction describes the procedure to charge Nitrogen gas (hereinafter N2 Gas) into a chiller. Table 6-4 Inner Volume (1) Equipment use a) N2 gas : required volume (See the table) b) Pressure regulator c) Pressure proof hose d) Pliers e) Valve key for N2 gas cylinder (2) Standard The charged pressure can be measured by a generator pressure gauge. a) For storage of a chiller b) For leak test : 19.6 kPa : 49 kPa TSA-16LJ11 12 13 14 21 22 23 24 31 32 41 42 (3) Procedure a) Prepare N2 gas cylinders and attach a pressure regulator to a N2 gas cylinder. b) Connect a pressure proof hose to the outlet of the pressure regulator, then slightly open a valve on the top of the cylinder in order to purge air being in the hose. After purging, close the valve. c) Connect the other end of the hose to SV1, and fix it with a hose band. d) Check that V1, V2, V3 and SV1 are fully closed. e) Open V2 and then open SV1. f) Using the pressure regulator, charge a small amount of N2 gas into the chiller. g) Watch the generator pressure gauge during charging N2 gas. When the pressure in the chiller reaches to required pressure, close SV1, and then close the valve of the N2 gas cylinder. h) Remove the hose from SV1 and put the cap to SV1. i) Remove the pressure regulator. (4) Precautions a) Since the pressure in the N2 gas cylinder is very high (Commonly 15 MPa), pay attention to handle it. b) Do not suddenly rise the primary and/or secondary pressure of the pressure regulator. (Secondary pressure shall be maximum 0.5 MPa.) c) Fix N2 Gas cylinder so that it does not fall over. d) Be sure not to open V1 and V3 during this work. Liquid trap V1 SV1 V2 V3 51 52 53 (Liter) 1,635 1,578 2,502 2,372 3,150 3,010 4,207 4,020 5,022 4,824 6,142 5,901 8,232 9,348 10,350

d) At replacement of parts : 9.8 kPa

Purge pump Fig. 6-30

Page 29 / Sec.6

LJ/TJ Series

6-12. Method of discharging Nitrogen gas This instruction describes the procedure to discharge Nitrogen gas (hereinafter N2 Gas) from a chiller. (1) Equipment to use a) Pliers (2) Standard The pressure in the chiller becomes atmospheric pressure (0MPa). (3) Procedure a) Check that V1, V2, V3 and SV1 are fully closed. b) Open V3. c) Remove a cap and flare nut of SV1 and open it. d) When the reading of the generator pressure gauge becomes atmospheric pressure (MPa), close SV1. (4) Precautions a) Be sure to open V1 and V2 during this work. b) During this work, ventilate the machine room adequately.

Page 30 / Sec.6

LJ/TJ Series

Section 7A Specifications (LJ)

7-1 Nomenclature TSA16LJ 1 1 Heat source type - 11 2 E 3 L 4 C 5

16LJ : Single effect low temperature hot water type

2 Capacity code (Nominal capacity : US Refrigerant ton) 16LJ 11 12 13 14 21 22 23 24 31 32 41 42 51 52 53 USRT 75 90 110 135 155 180 210 240 270 300 335 375 420 470 525

3 Operation E : Standard type 4 Fuel type L Low temperature hot water 5 Voltage C 400V 50Hz E 208V 60Hz F 460V 60Hz

Page 1 / Sec. 7

LJ Series

7-2

Scope of supply

Fig. 7-2-1 For EC market

Page 2 / Sec. 7

LJ Series

Fig. 7-2-1 For USA market

Page 3 / Sec. 7

LJ Series

Section 7B Specifications (TJ)

7-1 Nomenclature TSA16TJ 1 1 Heat source type - 11 2 E 3 S 4 C 5

16TJ : Single effect steam type

2 Capacity code (Nominal capacity : US Refrigerant ton) 16TJ 11 12 13 14 21 22 23 24 31 32 41 42 51 52 53 USRT 100 120 150 180 210 240 280 320 360 400 450 500 560 630 700

3 Operation E : Standard type 4 Fuel type S Steam 5 Voltage C 400V 50Hz E 208V 60Hz F 460V 60Hz

Page 4 / Sec. 7

TJ Series

7-2

Scope of supply

Fig. 7-2-1 For EC market

Page 5/ Sec. 7

TJ Series

Fig. 7-2-1 For USA market

Page 6/ Sec. 7

TJ Series