Absorption Chiller

OPERATION MANUAL

TJ Model
 Notes to Users

Thank you for purchasing Carrier/SANYO Absorption Chiller.

Before operating the Chiller, please read this manual thoroughly.

It contains instruction for the operation and maintenance of the Chiller.

Please utilize the Chiller to its optimum performance by following

recommended daily maintenance and handling, and periodic service.

If you need any information about maintenance contract or any other inquiries,
please contact Carrier/SANYO service agent.

814-6-0502-953-00-1
May 2005
Note: The contents of this manual are subject to change without notice.
 Absorption Chiller Operation Manual
<Single effect steam fired type>

Table of Contents

1. SAFETY PRECAUTIONS …………………………………………1

1-1. SAFETY PRECAUTIONS …………………………………………1
1-2. HIGH TEMPERATURE HIGH VOLTAGE CAUTION …………………………………………7
1-3. USE ENVIRONMENT …………………………………………7
1-4. WATER TREATMENT …………………………………………7

2. ILLUSTRATION …………………………………………8
2-1. DETAIL OF TYPICAL CHILLER …………………………………………8
2-2. TYPICAL CONTROL PANEL …………………………………………9
2-3. FLOWCHART OF CHILLER/HEATER
AND FUNCTION OF EACH SECTION …………………………………………14

3. OPERATING INSTRUCTIONS …………………………………………17

3-1. SELF-DIAGNOSTIC FUNCTION …………………………………………17
3-2. DESCRIPTION OF KEYS AND THEIR FUNCTIONS …………………………………………18
3-3. SETTING OF OPERATION BOARD …………………………………………19
3-4. COOLING OPERATION …………………………………………25
3-5. HOW TO CHANGE INDICATION ON DATA DISPLAY …………………………………………28
3-6. HOW TO CHANGE INDICATION AND SETTING POINT …………………………………………30
3-7. MAINTENANCE MESSAGE …………………………………………31
3-8. ALARM INDICATIONS AND ACTIONS …………………………………………33

4. MAINTENANCE …………………………………………42
4-1. DAILY MAINTENANCE …………………………………………42
4-2. PERIODIC MAINTENANCE …………………………………………45
4-3. WATER TREATMENT …………………………………………48
4-4. RECOMMENDED SCHEDULE OF MAINTENANCE
AND REPLACEMENT OF MAIN COMPONENTS …………………………………………52

5. MAINTENANCE CONTRACT …………………………………………53

5-1. ANNUAL MAINTENANCE CONTRACT …………………………………………53
5-2. INSPECTION REPORT …………………………………………53
5-3. WARRANTY …………………………………………54

6. PED REQUIREMENT (FOR EC MARKET)

6-1. DEPEND ON DIRECTIVE 97/23/EC ANNEX I Section 3.4 …………………………………………55
1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS

1-1. SAFETY PRECAUTIONS

* Before operating this chiller, you should first thoroughly read the following instructions.
* All precautions are classified into either WARNING or CAUTION.
WARNING: Failure to observe this instruction may result in serious injury or death.
CAUTION : Failure to observe this instruction may cause an injury or failure of chiller.
Depending on circumstances, this may result in serious injury or death.
< Example >
symbol denotes danger, warning or caution.
The illustration in the symbol shows the specific description of such item.
(The illustration to the left indicates that a special care must be taken to avoid electric shocks.)

symbol prohibits an action.

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

symbol instructs an action to be done.

The illustration in the symbol shows the specific description of such item.
(The illustration to the left indicates that it should be grounded.)

* After reading this manual, it should be kept in fixed place to be available for any user at any time.

1-1-1. For safety usage

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

INSPECTION

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

ON

1
 SAFETY PRECAUTIONS

DO NOT TOUCH HIGH VOLTAGE LEAD WIRE

Do not touch high voltage lead wire to
prevent electric shocks.

Do not touch

KEEP FLAMMABLES AWAY FROM THE

CHILLER
Do not place any flammables (gasoline, .
thinner, etc.) close to the chiller,
flue, chimney and oil tank to prevent a fire.
Prohibited

DO NOT OPERATE THE CHILLER

WHEN GAS SMELLS
Do not operate the chiller when gas
smells. Do not turn on/off any switch to
prevent a fire.

Prohibited

DO NOT TOUCH ANY ROTATING PART OF

FANS
Keep away your fingers from any rotating
part of fans or pumps to avoid possible
injury.

Prohibited

2
 SAFETY PRECAUTIONS

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

DO NOT CLIMB UP THE CHILLER CALL SPECIALISTS FOR SERVICE OR

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

AUTHORIZED PERSONNEL ONLY DO NOT POUR WATER OVER THE CHILLER

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

USE THE CORRECT POWER SUPPLY

This is indicated on the name plate of the
chiller. Use of the power other
than specified here may cause a fire or
electric shocks.
Prohibited

What
voltage?

3
 SAFETY PRECAUTIONS

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

DO NOT TOUCH THE ABSORBENT OBSERVE THE SPECIFIED PRESSURE OF WATER

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

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

4
 SAFETY PRECAUTIONS

1-1-2. Safety precautions for repair, moving or rejection

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

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

5
 SAFETY PRECAUTIONS

1-1-3.Operating precautions

1 Keep the purge valve shut tightly to prevent air from leaking into the Chiller/heater, which may
cause the failure of the Chiller.

2 Keep to turn on the power supply to the control panel without maintenance service.

3 During the dilution cycle operation of the Chiller as well, the chilled water pump (both the
primary side and the secondary side) and air handling unit must be operated for the necessary
time. The Chiller has a little cooling capacity even if it is in the dilution cycle operation.
Do not stop the air handling unit before the necessary time to prevent possible subcooling.

4 Do not perform an insulation test on the control circuits of the electric controller.

5 Use Carrier/SANYO recommended interlock system for stop/start of the auxiliary equipment.
The interlock system automatically stops/starts chilled water pump and cooling water pump.
Please follow the start procedure in Figure 1-1 below.

Start Procedure

1 2 3 4
Chilled Cooling Cooling Absorption
water pump water pump tower Chiller

5
Air handling unit

Stop Procedure

1 2 3 4
Absorption Cooling Cooling Chilled water
Chiller water pump tower pump

5
Air handling unit

Fig.1-1 Auxiliary Equipment Start/Stop Sequence

6
1-2. HIGH TEMPERATURE•HIGH VOLTAGE CAUTION

1-2-1.Do not touch the Chiller during operation since the surface of it reaches a high
temperature.

1-2-2. Do not touch the absorbent pump, the refrigerant pump, the purge pump during
operation, since they reach a high temperature.

1-2-3. Do not touch the junction box during operation, since it contains high voltage wiring.

1-2-4. Do not touch the terminal box during operation, since it contains high voltage wiring.

1-3. USE ENVIRONMENT

1-3-1. Machine room

Absorption Chiller is indoor use ONLY.

IP number of Absorption Chiller is IP40.

o o
Please keep the machine room temperature between 5 C and 40 C for protection of the
solution crystallization during chiller shut down. Please keep the humidity in the
machine room within 90%.

1-3-2. Field wiring

For CE, please connect to power source by overvoltage category III, and to other wiring
by overvoltage category II.

1-3-3. Altitude

Please install Absorption Chiller at a height of less than 1000m above sea level.
If the location is higher than 1000m above sea level, please contact Carrier/SANYO agent.

1-4. WATER TREATMENT

Refer to "4. Maintenance" section.

7
2. ILLUSTRATION
2-1. DETAIL OF TYPICAL CHILLER

Fig.2-1 WATER HEADER SIDE

Fig.2-2 CONTROL PANEL SIDE

8
2-2. TYPICAL CONTROL PANEL

Fig.2-3 CONTROL PANEL (UL type)

CAUTION
Please do not push the emergency stop button except for emergency time.
The Chiller may be broken.

9
Fig.2-9 CONTROL PANEL inside (UL type)

10
Fig.2-5 CONTROL PANEL (CE type)

11
Fig.2-6 CONTROL PANEL inside (CE type)

12
Fig.2-7 TYPICAL OPERATION BOARD

13
 2-3. FLOWCHART OF CHILLER AND FUNCTION OF EACH SECTION

a) EVAPORATOR
The refrigerant is dispersed on the heat transfer tubes of evaporator. Chilled water through the heat
transfer tubes of evaporator is cooled by the latent heat of vaporized refrigerant.
b) ABSORBER
The concentrated solution is dispersed on the heat transfer tubes of absorber. The refrigerant vapor
from evaporator is absorbed on the heat transfer tubes of absorber by the concentrated solution.
Cooling water through the heat transfer tubes of absorber is heated by absorption heat.
c) HEAT EXCHANGER
The diluted solution, after leaving the absorber section, passes through the heat exchanger, where
it is heated by the concentrated solution.
The concentrated solutions are cooled by the diluted solution. This cooling process of the
concentrated solution allows for greater absorbing power due to its lower temperature.
d) LOW TEMPERATURE GENERATOR
The passes through the heat transfer tubes of generator.
The diluted solution in the generator is heated by the steam.
It releases the refrigerant vapor and is concentrated. It becomes concentrated solution.
e) CONDENSER
The refrigerant vapor from the generator is condensed on the heat transfer tubes of condenser. Cooling
water from the absorber is heated by condensation heat.
f) PURGE UNIT
Gather the non-condensable gas within the Chiller and store it in the purge tank.

14
 Table 2-1 Sensor

SYMBOL NAME
DT1 Chilled water outlet temperature

DT2 Cooling water outlet temperature

DT3 Generator temperature

DT5 Condenser temperature

DT6 Chilled water inlet temperature

DT7 Cooling water inlet temperature

DT8 No use

DT9 No use

DT10 Diluted solution temperature at Absorber outlet

DT11 Refrigerant temperature at Evaporator

DT12 Cooling water mid temperature

DT13 No use

23CH Temperature controller

63GH High temperature generator pressure switch for cooling.

69CH Chilled water flow switch

PCH Palladium cell heater

69PR Purge tank pressure

15
Fig.2-8 FLOW DIAGRAM

16
3. OPERATING INSTRUCTIONS

3-1. SELF-DIAGNOSTIC FUNCTION

Self-diagnostic function starts when the breaker inside the control panel of the
Chiller is turned on.
After self-diagnosis is completed, the data display on the operation board shows the
following indication.

3-1-1. Action after power supply throwing in and an indication

Throw a power supply into and (turn on a breaker in a control panel and)
when it dose, a self-diagnostic function acts as follows.

(1)Data display (the 7 segment LED) and all LEDs light up.
(2)The data display shows a version number when there is no abnormality.
When there is a power failure, H-10 is displayed after power return.


NOTE : The version number differs according to
an each Chiiler type.

(3)The data display shows the generator temperature.

 (120.4)

If self-diagnosis function detects any failure, it will be shown on the Fig. 3-1 Typical
data display. As for the alarm indication, please refer to Section 3-8. control panel

17
3-2. DESCRIPTION OF KEYS AND THEIR FUNCTIONS

Fig.3-2 Typical Operation Board

1. Operation indication lamp :Operation indication lamps light while the Chiller,
pumps, etc. operate them.
2. Stop indication lamp :Stop indication lamps light while the Chiller,
pumps, etc. stop them.
3. Alarm indication lamp :Alarm indication lamps light that an abnormality occurred.

4. Remote/local select key :Used to select remote operation or local operation.

with lamp
5. Operation select key with lamp :It is a key that a Chiller uses in the operation/stop.
It uses a stop key also in reset on an abnormality occurred.
6. Data display(7 segment LED) :It shows temperature, set value, etc..

7. Stand by indication lamp :Push a run key and the Chiller begins operation
until it light up.
8. Dilution indication lamp :It lights during dilution operation.

9. Safety circuit indication lamp :It lights a controlled circuit when a power supply is supplied.

10 Power indication lamp :There is a power supply than equipment side and,
a breaker in an operational board lights time of ON.
11 Data select key :When changing an indication of a data display, when
changing establishment value each, it is a key that uses
establishment when being decided.
12 Alarm buzzer stop key :It uses an alarm buzzer when stopping by a case of alarm
buzzer attachment(option).

18
3-3.SETTING OF OPERATION BOARD

3-3-1.HOW TO TIME SETTING

Display example  High temperature generator temperature

Push the "SET"key
for about 2 seconds.


Push " " key.


Push the "SET"key
for about 2 seconds.


Push the "SET"key
for about 2 seconds.
! ! ! !

Push " "or" " key.
! ! ! !


Push the "SET"key
for about 2 seconds.


Push " " key.


Push the "SET"key
for about 2 seconds.
! ! ! !

Push " " key to set the month.
! ! ! !


Push " " key.

19
 ! ! ! !


Push " " key to set the day.
! ! ! !

Push the "SET"key
for about 2 seconds.


Push " " key.


Push the "SET"key
for about 2 seconds.
! ! ! !


Push " " key to set the hour.
! ! ! !


Push " " key.
! ! ! !

Push " " key to set the minute.
! ! ! !

Push the "SET"key
for about 2 seconds.


Push the "BACK" key.


Push the "BACK" key.

Display example  High temperature generator temperature

20
3-3-2. Battery backup

Refer to Fig.3-3.

SW3
Connect a backup battery which is used to maintain time setting
at the time of power failure. Turn it ON after installing
equipment. CR-2025 is used as the backup battery, functioning
for an accumulative period of about six months.

Note
•SW3 for battery backup is set OFF at the factory to avoid burning battery power.
•When SW3 for battery backup is set OFF in case of power failure, "F-21 (CPU alarm)"
or "F-23( Time set alarm)" will is displayed. Please reset time setting.
•In case that SW3 for battery back up is set ON and "F-21" or "F-23" are displayed, it is necessary
to replace the battery.

21
 Backup battery

SW3 : Backup switch

UP : ON
DOWN : OFF

22
LABEL
3-3-3. HOW TO CHANGE TEMPERATURE UNIT

It can changes a temperature unit by a following way, and can changes it even while the
Chiller operates it.

Display example  High temperature generator temperature

Push the"SET"key
for about 2 seconds.


Push" "or" " key.


Push the"SET"key
for about 2 seconds.

 Push" "or" " key if you need.

Push the"SET"key for about 2 seconds.
And push" "or" " key.

To change oC To change oF
 
o
By pushing the"SET" key, C mode is decided. By pushing the"SET" key, oF mode is decided.

23
3-3-4. How to change remote continuous, pulse ,etc. setting

After wiring of remote signal, setting of operation board shown below should be conducted.
Refer to Field Electric Wiring.

Operation board setting

REMOTE
SIGNAL
type
 
(1)  free
(2)  
(3)  
(4)  free
(5)  
Display example  High temperature generator temperature
Push the "SET" key
for about 2 seconds.


Push " " or " " key.


Push the "SET" key
for about 2 seconds.



Push " " or " " key.

Push " " or " " key.


Push the "SET" key for about 2 seconds.
Then push " " or " " key.
To change
static mode To change pulse mode
 
By pushing a "SET" key, static mode is decided. By pushing a "SET" key, pulse mode
is decided.


Push the "SET" key for about 2 seconds.
Then push " " or " " key.
To change
static mode To change pulse mode
 
By pushing a "SET" key, positive mode is decided. By pushing a "SET" key, negative mode is decided.
24
3-4. COOLING OPERATION

3-4-1. Pre-operation check

Please check the following items before starting operation.

Fig. 3-4 Typical operation board

(1) Check of the setting point of the chilled water outlet temperature
Make sure that the chilled water outlet temperature is set as specified.
As for the indication of set value, please refer to Section 3-8.

(2) Check of steam and steam drain equipments

a) Make daily inspection.(Refer to Section 4.)
b) Check that the steam valve(s) is open.

NOTE : If the chilled water pump, cooling water pump, and Chiller are
interlocked, each pump runs automatically when starting the Chiller.
If otherwise, the start sequence must be: 1) Chilled water pump,
2) Cooling water pump, and 3) The Chiller.

25
3-4-2. Start cooling operation

(1) Local operation mode

a) Press "LOCAL" key on the operation
board of the Chiller.
"LOCAL" indication lamp of the key lights.

b) Keep pressing “RUN” key for more

than a second and make sure that “RUN”
indicator lamp of the key lights.

c)Automatic operation starts.

Fig. 3-5 Typical operation board

(2) Remote operation mode

a) Press “REMOTE” key on the operation
board of the Chiller .
“REMOTE” indication lamp of the key
lights.

b) Turn on the start switch on the remote

control panel of field supply.
The indicator lamp of “RUN” key on the
operation board of the Chiller lights.

c) Automatic operation starts.

Fig. 3-6 Typical operation board

NOTE : In local operation mode, a signal coming from the remote control panel is
not effective. In remote operation mode, “RUN” key on the operation board
of the Chiller does not work.

26
 3-4-3. Stop operation

(1) Local operation mode

a) Keep pressing "STOP" key on the
operation board of the chiller for
more than a second.

b) Make sure that “RUN” indication lamp

goes off and "STOP" indication lamp lights.

Fig.3-7 Typical operation board

(2) Remote operation mode

a) Turn on the stop switch on the remote control panel of field supply.

b) Another way to stop the Chiller is to press "STOP" key on the operation board of the
chiller during remote operation.

NOTE : If the chilled water pump, cooling water pump, and Chiller are interlocked,
each pump stops automatically when the Chiller stops.
If otherwise, please stop them in the following sequence:
1) The Chiller 2) Cooling water pump 3) Chilled water pump
The air handling unit must be stopped after the chilled water pump is stopped.

27
3-5. HOW TO CHANGE INDICATION ON DATA DISPLAY

3-5-1. Regular indication

Data display on the operation board usually shows high temperaure genarator temperature
as follows.
(Display Example)

Fig.3-8 Typical operation board

It returns to a genarator temperature indication when there is no key operation for 1 minute
again.

3-5-2. How to change indication

If you press key, the indication on data display changes in order, and pressing
key, it changes in reverse order.
If you press key again when you get to the last indication, it returns to the regular
indication.

Fig.3-9 Typical operation board

28
3-5-3. Typical indication flow

It shows present data timely in data indication copy (7 segment LED and 6 figures). Indicative
contents shows a data code (contents distinction by a code number) by various operational
time, on/off time,every part temperature, chilled/hot water temterature setting point and alarm
code.
It sends a data code in turn by a key and shows it. It shows an alarm code only when an
abnormality occurrs and, when an abnormality of a plural occurrs, high thing of a privileged
grade is shown and, under numeral right of the alam code dotted "." is shown. Further, an
alame code of a plural is shown in oeder by means of a key when existing.
When it pushes whether threr is no key operation and a "BACK" key for 1 minute, it becomes a
generator temperature indication.

Table 3-1 Typical indication flow

Data code Data name Display Means
- Genarator temperature  135.0oC
1. Chiller operation hours  1234hours

2. Absorbent pump operation hours  1111hours

3. #2 absorbent pump operation hours  No use

4. Combustion hours  No use

5. Refrigerant pump operation hours  1201hours

6. Purge pump operation hours  107hours

7. Chiller on/off times  123times

8. Absorbent pump on/off times  169times

9. #2 absorbent pump on/off times  No use

A. Combustion on/off times  No use

B. Refrigerant pump on/off times  138times

C. Purge pump on/off times  51times

10. Chilled water temperature setting point  7.0oC

11. Hot water temperature setting point  55.0oC
12. Chilled water inlet temperature  11.9oC
13. Chilled water outlet temperature  6.8oC
14. Cooling water inlet temperature  31.8oC
15. Condenser temperature  34.7oC
16. Steam drain/exhaust gas temperature  211.7oC
17. Purge tank pressure  8.5kPa

- Generator temperature  135.0oC

29
3-6. HOW TO CHANGE INDICATION AND SETTING POINT

3-6-1. Indication of setting point

Section 3-5-2. How to change indication by, it makes shows present "chilled water temperature
setting point", or "Hot water temperature setting point".

3-6-2. How to change setting point

After making showing present setting point temperature, it changes setting point
temperature by a following process.

To change the temperature

of chilled water
 7.0oC
Push the"SET"key
for about 2 seconds.



A numeral that shows setting

point temperature blinks.

Push" "or" " key.

 7.5oC

Push the"SET"key


Setting point change is decided.

When it pushes whether there is no key operation and the"BACK" key for 1 minute, it becomes a
generator temperature indication.

NOTE 1: Wrong setting may cause the failure of the Chiller.

If you need to change setting point, please be sure to consult Carrier/SANYO service
agent. In case you set chilled water outlet temperature below rated value,
maximum input(gas or oil) needs to be decreased. Please be sure to
consult Carrier/SANYO service agent.

NOTE 2: Setting point become effective upon changing them.

Please be careful in changing set values during operation.

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3-7. MAINTENANCE MESSAGE

3-7-1. Maintenance message

When a trouble which could disturb an efficient operation of the Chiller is predicted,
it provides you with the forewarning.

3-7-2. How it is shown

It provides you with a comment on the data display as follows when a trouble is predicted.

Table 3-2 Maintenance message

Data code Data name Display Means
H-01 Operate purge pump  Operate purge pump.
H-03 Clean cooling water tubes  Fouling of cooling water tubes.
H-04 Check cooling water system  Check the cooling water pump,
cooling tower, etc.
H-06 Purge tank high pressure  Purge tank pressure is high.
H-07 Cooling water tubes foul  Fouling of cooling water tubes.
H-08 Cooling water high temperature Cooling water temperature is high.
H-10 Power failure  There was power failure in time
that the Chiller is operating.

mark : When this appears, the Chiller needs an immediate action.

mark : When this appears, the Chiller does not need an immediate action.
However, as this might lead to mark code, attention should be paid.
Consult Carrier/SANYO service personnel at the next periodic maintenance.

NOTE : These indications disappear when the failure is corrected.

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3-7-3. Descriptions of Maintenance Message and Actions

Table 3-3 Descriptions of Maintenance Messages and Actions

Maintenance Message Display Action
1 Fouling of cooling 
water tubes  Cooling water tubes must be cleaned.
Contact Carrier/SANYO service agent to do the job.
2 Vacuum rate 
 The purge tank must be purged immediately.
In case this indication is shown frequently,
contact Carrier/SANYO service agent.
3 High temperature 
of cooling water  Check the cooling water pump, cooling tower, etc.
4 Power failure  See section 3-8-5.

32
3-8. ALARM INDICATIONS AND ACTIONS

3-8-1. How they are shown

When an alarm is detected, alarm buzzer sounds(option) and the content of the alarm is shown
on the data display. At the same time, the indication lamp of “STOP” key blinks.
The Chiller stops for safety reasons after dilution cycle operation.
Depending on the content of the alarm, it stops without dilution cycle operation.

Display example  Chilled water low temperature

It shows an alarm code only when an abnormality occurrs,and when an abnormality of a

plural occurs, high thing of a privileged grade is shown, and under numeral right of the
alarm code dotted "." is shown.

Display example  Chilled water low temperature

Further, an alarm code of a
plural is shown in order by
means of a key when existing.
Display example  High temperature generator's
solution level is too low.

33
3-8-2. Troubleshooting flowchart

THE CHILLER ACTION

An alarm occurs.

Alarm buzzer sounds(option), and the indication

lamp of “STOP” key blinks.
Content of alarm is shown on the data display.

Press the “BUZZER STOP” key on the

operation board.

The alarm buzzer stops(option).

Check the content of the alarm and

solve it.

Press “STOP” key on the operation board

after the troubleshooting is completed.

The indication lamp of “STOP” key stops

blinking and remains lit. The alarm code on the
data display disappears.

NOTE 1: Data display shows alarm

continually If you press the
“STOP” key before eliminating
the cause of the alarm.
Make sure this is done.

NOTE 2: In case of combustion alarm,

operation does not restart
without pressing the reset
button on the burner controller.

Start operation consulting

Section 3-4

Operation restarts.

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 3-8-3. Content of alarm and setting point

Table 3-4 List of alarm and setting point in cooling operation

Purpose Display Contents of alarm Setting point
Protection of  Chilled water temperature is too low. o
2.5 C or below
Chilled water  Chilled water pump interlock has failure. -
system  Few flow rate of chilled water 50% or below
 Cooling water temperature is too low. o
24 C or below
after 30 minutes
Prevention of  Cooling water pump interlock has failure. -
Crystallization  Few flow rate of cooling water 50% or below
 Generator’s 105oC
temperature is too high.

Protection of  Generator’s 1,013hPa or above

high temperature pressure is too high.
generator  High concentration of absorbent 65.0% or above
2 times
65.5% or above
Protection of Motor  Absorbent pump has overload. Rated current
 Refrigerant pump has overload. value or above
 Purge pump has overload.
Others  Ventilation fan interlock etc. have failure.
 Capacity is too low. -
 Cooling tower fan has overload.

35
 3-8-4. Locating Alarm and Disposal

Table 3-5 List of Alarm Indications and their Causes and Remedies
Display and contents of alarm
Alarm of the  Check that the discharge pressure of both
Chilled water Chilled water temperature is too low. chilled water and cooling water pumps
and/or  are normal.
cooling water Few flow rate of chilled water If not, there may be the clogging of
system strainer, air leak in the pipe line, etc.

Is the chilled water setting point too low?

 Correct them to specified setting point.

Cooling water temperature is too low.
 Is the cooling water setting point too low?
Few flow rate of cooling water Correct them to specified setting point.
o
(Option) (ex. 28 C )

Correct the above causes and restart the

Chiller. If it still gives you the
“CHILLER ALARM”, check the following and
contact Carrier/SANYO service agent.

1) Temperature of chilled/hot water inlet

and outlet
2) Temperature of cooling water inlet
and outlet
3) Temperature and pressure of generator

36
Alarm of the  First, check that the reset button(s) of the
Motor(s) Absorbent pump has overload. overload relay connected to electromagnetic
electromagnetic contactor sticks out, and
then contact Carrier/SANYO service agent.

Refrigerant pump has overload.

reset buttons

Alarm of the  Check that the chilled/hot water pump

Auxiliary Chilled water pump interlock has and cooling water pump are rotating.
failure. Start the pumps.
equipment(s)  Check the ventilation fan and/or other
Cooling water pump interlock has equipment(s) which is connected to system
failure. interlock.
Correct the above causes and restart the
Chiller. If it still gives you the
“CHILLER ALARM”, check the following and
 contact Carrier/SANYO service agent.
Cooling tower fan has overload.

37
Alarm of the 
generator Generator’s Check that the cooling water pump is rotating.
temperature is too high. Start the pump.
 Check that the valve of the cooling water
Generator’s line is open.
pressure is too high. Open the valve.
Check that the discharge pressure of cooling
water pump is normal.
If not, there may be the clogging of
 strainer, air leak in the pipe line, etc.
High concentration of absorbent

Correct the above causes and restart the

Chiller. If it still gives you the
“CHILLER ALARM”, check the following and
contact Carrier/SANYO service agent.

1) Temperature of chilled water inlet

and outlet
2) Temperature of cooling water inlet
and outlet
3) Temperature and pressure of generator.

4) Is the chilled water setting point too low?

Correct it to specified setting point.

5) There may be the fouling of heat

transfer tube in the water (especially,
cooling water) line.

38
Alarm of sensor  Do the sensors measuring each area of the
Chilled water inlet Chiller have short circuits or open
temperature sensor has failure. circuits?
 Check all the sensors of the
Cooling water inlet Chiller and contact Carrier/SANYO
temperature sensor has failure. service agent.

Cooling water outlet NOTE :
temperature sensor has failure. The Chiller automatically
 stops for safety reasons when either
Cooling water intermediate the generator’s
temperature sensor has failure. temperature sensor or Chilled
 water temperature sensor has
Condenser temperature alarm.
sensor has failure. It does not stop when the other
sensors have alarm, but this could
cause control failure. Please
contact Carrier/SANYO service agent as
 soon as possible.
Refrigerant temperature
sensor(Evaporator)has failure.

Diluted solution temperature
sensor (Absorber outlet ) has
failure.


Chilled water outlet
temperature sensor has failure.

High temperature generator’s
temperature sensor has failure.


Purge tank pressure
sensor has failure.

39
3-8-5. Action in case of power failure

(1) Flowchart of action in case of power failure

A power failure
occurs.

The Chiller/Heater
completely stops.

Power Power failure indication "H-10"

returns is shown on the data display.

Push “RUN”
key.

Operation Power failure indication on

restarts. the data display disappears.

40
(2) Matters to be attended to when a power failure occurs

When a power failure occurs, the Chiller stops completely without

dilution cycle operation. Special attention should be paid to the following.

Table 3-6 Matters to be attended to when a power failure occurs

Condition of Operation at power failure Action
Occurred during cooling operation, Immediately contact Carrier/SANYO service agent.
and took more an hour to return power Do not restart operation.
Occurred during cooling operation, Contact Carrier/SANYO service agent after
and took less than an hour to return power restarting operation.

Occurred during purging operation Immediately close purge valve completely

and turn off the purge pump switch on
the control panel. After power returns,
restart the purging, and consult Carrier/SANYO
service agent.

41
4. MAINTENANCE
4-1. DAILY MAINTENANCE

4-1-1. Inspection of each part of the Chiller

If you find the abnormal condition, please contact Carrier/SANYO service agent.

(1) Smell of gas or oil leak around the Chiller

(2) Abnormal noise at the start of burner
(3) Abnormal noise of absorbent pump and refrigerant pump

Please consult your system constructor for the following items.

(4) Cleaning of the cooling tower and the strainer of the cooling water line
(5) Check of the condition of cooling tower
(6) Check of the air leak in the pipe line

4-1-2. Operation data record

Please record the operation data regularly.

It is useful for troubleshooting and alarm prevention. Please show it to Carrier/SANYO
service personnel when they visit you for the service or the periodic inspection.

The sample of operation data sheet is shown in Table 4-1.

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43
44
4-2. PERIODIC MAINTENANCE

To use the Chiller to its optimum performance, it requires the purging, refrigerant
blow down, absorbent control, and management of combustion equipment, etc. We
recommend that you make a maintenance contract with Carrier/SANYO service agent.

4-2-1. Purging

The non condensable gas of the machine inside, not only decreases cooling/heating capacity but also
has a bad influence on the life of the machine. Therefore the purging must be done at cooling/
heating changeover. Please leave it to Carrier/SANYO service personnel under the
maintenance contract. The customer can carry out the purging, but should take instruction
by our service personnel.

45
(1) Purge procedure

When the purge indication lamp on the control panel lights, start purging by
following the instructions below.

a) Turn on the purge pump on/off switch on the control panel, and operate the purge
pump for 10 minutes.

b) Open V1 and V2.

c) Press "t" key on the operation board once to indicate 17. purge tank pressure
(refer to section 3-5-3) and confirm whether the indicated value drops.
If it does not drop, follow the procedure e), f), and g), and contact Carrier/SANYO
service agent.

d) Perform purging for 10 minutes. Even if the purge indication lamp stops lighting before 10
minutes have passed, please continue purging for 10 minutes. When the lamp does
not stop lighting, continue purging until the lamp stops lighting.

e) Close V1 and V2.

f) Turn off the purge pump on/off switch.

g) Check whether the valves are open/closed.

Fig.4-1-1

46
4-2-2. Refrigerant blow down

During cooling operation, a little quantity of absorbent could mix into the refrigerant.
This absorbent could increase by a long-term operation and result in a lowering of the
cooling capacity, so refrigerant blow down must be performed once in a cooling season.
By this work, the dirty refrigerant is transferred to absorber side, and new, clear refrigerant
is regenerated.

(1) Make sure the refrigerant pump is

rotating, and also the solution level is
visible through the sight glass of the
evaporator.
(2) Open the blow valve completely.
(3) When the solution level becomes
invisible, close the blow valve tightly.

The above is the blow down procedure.

Repeat it a few times as necessary.
As for the refrigerant blow down, please
Fig.4-2 make a maintenance contract with Carrier/SANYO
service agent.

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4-3. WATER TREATMENT

The water treatment is very important to the Chiller.

As the water treatment requires technical knowledge, please consult Carrier/ Sanyo service ag

4-3-1. Water Treatment for Chilled water and Cooling water

The cooling water of an open-type recycling cooling tower lowers the temperature of the
cooling water using vaporized latent heat, and is reused. At this time, the water is evaporated
and the following salts (hardness materials, chloride ion, sulfate ion, etc.) are concentrated.
Namely, the condensation phenomena of such materials occur, and water quality will be
gradually degraded.
As the water and air always come in contact with each other in the cooling tower, the sulfurous
acid gas, dust, sand, etc. in the atmosphere will mix into the water, further degrading the
water quality.
In the cooling water system, problems with water are caused by these factors.
Typical problems are corrosion, scales and slimes.

(1) Water quality standard

Water quality standard is shown in table 4-2 as an example.
Table4-2 is an extract from JRA-GL 02-1994.

48
49
[Note 1] Each item of the standard values may cause the failure due to corrosion
or scale and if any item deviates from the standard value, it is assumed
that corrosion or scale tends to be caused, therefore, these should be periodically managed.

[Note 2] As the range of the water quality which may become usable if the water is processed
differs depending on the chemicals to be used, it is not given here. It is desirable to set
the appropriate water quality management values under the guidance of a water processing
specialist and periodically manage the water quality.

(2) Typical water treatment

Even if make-up water for cooling water agrees with water standards, the water quality gets
worse by its concentration, therefore the following water treatment is necessary. To varying
extent of deterioration, chilled/hot water also requires this treatment.
In case you use concrete heat storage tank, special attention should be paid to water
treatment.

a) Periodic and continuous manual blow down by make-up water

b) Automatic blow down by electric conductance
c) Addition of the anticorrosion
d) Slime control
e) Periodic water analysis
Overhaul water header periodically, check heat transfer tube and clean it as
necessary.
For example, if 0.6mm of scale clings
to tube, cooling capacity drops to
76%, and chilled water temperature
rises by 2°C and fuel consumption
rises by 23%.

A In case of constant cooling capacity

(Ratio at rated fuel consumption)

B Rise in fuel consumption

C Lowering of cooling capacity

(In case of constant chilled water
temperature)

1 2 3 4 5 6 7 8 9 10 D Rise in chilled water temperature

Fouling factor (m 2ihri°C/kcal)×10 -4 (In case of constant cooling
1 2 3 4 5 6 7 8 9
Fouling factor (m 2i°C/kw)×10-4
capacity)
0.2 0.4 0.6 0.8 1.0 1.2
Scale/Slime(mm)

Fig.4-3 Example of effect by fouling of tube

50
4-3-2. Water treatment for long term shut down

Perform the following treatment during long term shut down with no-circulation of chilled/hot
water, cooling water in the Chiller. Please consult Carrier/SANYO service agent for the
the details.
(1) Cooling water

Wet lay up usually. (Keep the cooling water full in the Chiller.)
In case the freezing of cooling water is likely to happen, drain it from the Chiller.
(Dry lay up)
Operation of valve is different between wet lay up and dry lay up.

a)Wet lay up
a-1)Discharge cooling water from its discharge port on the cooling water outlet.
a-2)Pour anticorrosive into the water.
Check holding water quantity and decide the anticorrosive quantity so that the
propotion of both quantity is appropriate.
a-3)Full up the cooling water in the Chiller.
a-4)Operate the cooling water pump until anticorrosive is evenly mixed.
a-5)Close the isolation valves of inlet and outlet on the cooling water line.

b)Dry lay up
Before draining cooling water from the Chiller, clean the inside of the tube and
make corrosion protective covering.
b-1)Discharge cooling water from its discharge port on the cooling water outlet.
b-2)Remove the scale and/or slime adhesion in the tubes by brush cleaning.
(If scale and/or slime cannot be removed by brush cleaning, perform chemical
cleaning.)
b-3)After sufficient washing, pour anticorrosive into the water, and circulate the
water with anticorrosive for 30 minutes or more.
(The concentration of anticorrosive should be even.)
b-4)Discharge the water from the discharge port on the cooling water inlet.
b-5)Keep the discharge port open during shut down.

(2) Chilled water

Wet lay up usually. (Keep the chilled water full in the Chiller.)

4-3-3. Winter season

In case the ambient temperature of the Chiller in winter is likely to be below 0°C,
freeze prevention is necessary.

Consult Carrier/SANYO service agent for the details.

51
4-4. RECOMMENDED SCHEDULE OF MAINTENANCE
AND REPLACEMENT OF MAIN COMPONENTS

Please contact Carrier/SANYO service agent.

52
5. MAINTENANCE CONTRACT

To enjoy safe and efficient operation of the Chiller for a long time, daily maintenance
and periodic inspection are essential. The main items are as follows.

(1) Confirmation of the function of Safety devices and their Adjustment

(2) Check of the condition of the operation and Recording of the data

These works need special tools and a special skill.

We offer an annual maintenance contract to users of the Chiller.

In the contract, we provide trained service personnel, who perform the periodic diagnosis and
adjustment of the Chiller with the latest technology.

Consult Carrier/SANYO service agent for the details.

5-1. ANNUAL MAINTENANCE CONTRACT

We established an annual maintenance contract to offer our customers periodic inspection

and maintenance for Carrier/SANYO Absorption Chiller. If you make this contract,
Carrier/SANYO service agent will perform maintenance/inspection and adjustment works
on their own initiative to keep your Chiller in its best condition, and priority will be
given to you for repairs of the Chiller in case of failure.

It is recommended to perform an overhaul of the Chiller once several years to keep it in

its best condition. It is included in the maintenance contract to let the customers know the
timing and the parts to be overhauled. There is another contract for the water quality control
and the cleaning of heat transfer tubes in the water system. We also recommend that
you make this contract as well.

5-2. INSPECTION REPORT

We issue an inspection report when you make an annual maintenance contract.

In the report, a thorough description of the inspection/adjustment items are written so that
Carrier/SANYO service personnel will not overlook any of the inspection items. At inspection,
Carrier/SANYO service personnel fill in the report, leave one copy with the customer, and take
one copy back to the office so that they can use it for future maintenance works.

We will not re-issue this report, so please be sure to keep it in the fixed place and show it to
Carrier/SANYO service personnel when they visit you.

53
5-3. WARRANTY

5-3-1. Carrier/SANYO service agent will hand it to you after filling in the warranty.
Please confirm the warranty period, read it carefully and keep it in a safe place.

5-3-2. In case the Chiller fails within the warranty period under normal operating
conditions, we will replace all the necessary spare parts or repair the Chiller
free of charge.

5-3-3. After the warranty period expires, all repair costs will be charged.
Consult your service agent.

5-3-4. As for other items, please read your warranty.

54
6. PED REQUIREMENT (FOR EC MARKET)

6-1. DEPEND ON DIRECTIVE 97/23/EC ANNEX I Section 3.4

Refer to "CM-021-142-00"

55