H2 Type Direct Fire Chiller Operation Manual

SAFETY, INSTALLATION & OPERATION MANUAL
FOR
H2 TYPE DIRECT-FIRED LITHIUM BROMIDE
ABSORPTION CHILLER/HEATER
DF99~1984
JIANGSU SHUNGLIANG AIR CONDITIONING

EQUIPMENT CO., LTD.
January 2009
CE
INTRODUCTION
First of all, let us express heartfelt gratitude to you for the application of direct-fired lithium
bromide absorption chiller/heaters, produced by Shuangliang.
The direct-fired lithium bromide absorption chiller/heaters, produced by Shuangliang, had win a
lot of national and province level awards, had been certified for safety protection, environment
friendliness and ISO quality assurance system. The chiller/heaters are good in performance, easy
to operate and durable for life cycle.
The technical manual covers the construction, operation principle, control system and guide to
installation, operation and maintenance of direct-fired lithium bromide absorption chiller/heater.
As very sensitive to maintenance, direct-fired absorption chiller/heater should be maintained
perfectly, otherwise it will be degraded and its operation life will be reduced. Read the technical
manual carefully before You operate it. This will bring benefit to Your Company.
The technical manual did not contain the description of auxiliary equipment, such as burner,
inverter and etc. You can find appropriate reference in the individual technical manuals published
by the manufacturers of auxiliary equipment. For the Chiller/heater, gas, oil, and oil/gas can be
used as fuel, you should pay attention to your order, and can find suitable material in this manual.
Warning: The chiller/heater You purchased from Shuangliang, should be commissioned by

Shuangliang engineering staff, and operated and maintained in accordance with the
provisions of this manual, otherwise the occurred trouble and damage of chiller/heater
should not included in the scope of guarantee offered by Shuangliang Co., Ltd.
Jiangsu Shuangliang Air Conditioning Equipment Co., Ltd, International Trade Department
Add: Shuangliang Industrial Park in Ligang, Jiangyin city, Jiangsu Province,
The People’s Republic of China
Post code: 214444
Tel: +86-510-86638824
Fax: +86-510-86634678
Table of Contents
CHAPTER 1 DESCRIPTION OF ABSORPTION CHILLER/HEATER......................................... 1
1.1 DESCRIPTION OF FORMATION OF TYPE NUMBER ............................................................................. 1

1.2 THE NOMINAL OPERATION CONDITIONS AND WORKING LIMITS ..................................................... 1
1.3 CONFIGURATION OF CHILLER/HEATER ............................................................................................. 1
1.4 WORKING FLUID ............................................................................................................................. 5
1.5 WORKING PROCESS ......................................................................................................................... 6
1.6 PERFORMANCE OF CHILLER/HEATER ................................................................................................ 8
CHAPTER 2 INSTALLATION OF CHILLER/HEATER ............................................................... 10
2.1 REQUIREMENTS TO MAINTENANCE DURING INSTALLATION........................................................... 10

2.2 REQUIREMENTS TO MACHINE ROOM ............................................................................................. 10
2.3 INSTALLATION OF CHILLER/HEATER .............................................................................................. 11
2.4 ADJUSTMENT OF LEVELNESS OF CHILLER/HEATER ........................................................................ 12
2.5 INSULATION OF CHILLER/HEATER .................................................................................................. 13
CHAPTER 3 INSTALLATION OF EXTERNAL SYSTEMS ....................................................... 15
3.1 WATER SYSTEM (CHILLED AND COOLING WATER) .......................................................................... 15

3.2 LIGHT OIL SYSTEM ........................................................................................................................ 17
3.3 HEAVY OIL SYSTEM ...................................................................................................................... 18
3.4 FUEL GAS SYSTEM ........................................................................................................................ 19
3.5 GAS EXHAUST SYSTEM ................................................................................................................. 20
3.6 ELECTRIC SYSTEM......................................................................................................................... 21
CHAPTER 4 CHILLER CONTROL SYSTEM ................................................................................ 23
4.1 CONFIGURATION OF SYSTEM ......................................................................................................... 23

4.2 FUNCTION OF SYSTEM ................................................................................................................... 24
4.3 CONTROL PANEL ........................................................................................................................... 25
4.4 CONTROL FLOW CHART ................................................................................................................ 25
4.5 OPERATION METHOD ..................................................................................................................... 27
CHAPTER 5 COMMISSIONING OF CHILLER............................................................................. 33
5.1 PREPARING TO COMMISSIONING .................................................................................................... 33

5.2 COMMISSIONING OF BURNER ........................................................................................................ 36
5.3 COMMISSIONING OF CHILLER/HEATER ........................................................................................... 38
CHAPTER 6 OPERATION OF CHILLER/HEATER...................................................................... 40
6.1 SAFETY PROTECTION RULES ......................................................................................................... 40

6.2 PROCEDURE FOR COOLING OPERATION......................................................................................... 42
6.3 PROCEDURE FOR HEATING............................................................................................................. 43
6.4 OPERATION OBSERVATION AND INSPECTION .................................................................................. 44
6.5 PURGE OPERATION ........................................................................................................................ 46
6.6 MANAGEMENT OF REFRIGERANT WATER ...................................................................................... 48
6.7 MANAGEMENT OF LITHIUM BROMIDE SOLUTION .......................................................................... 49
1
6.8 MANAGEMENT OF WATER QUALITY .............................................................................................. 51
6.9 OPERATION OF VACUUM PUMP ...................................................................................................... 52
6.10 OPERATION OF VALVES ................................................................................................................ 53
CHAPTER 7 TROUBLESHOOTING................................................................................................ 56
7.1 SHUTDOWN OF CHILLER/HEATER DUE TO TROUBLES ..................................................................... 56

7.2 COMMON TROUBLES AND THEIR SHOOTING .................................................................................. 56
7.3 SOLUTION CRYSTALLIZATION AND ITS TREATMENT ...................................................................... 61
7.4 FREEZING OF REFRIGERANT WATER .............................................................................................. 62
7.5 TREATMENT OF EMERGENCY ......................................................................................................... 62
7.6 TROUBLES OF BURNERS .............................................................................................................. 63
7.7 TROUBLE OF VACUUM PUMP .......................................................................................................... 66
7.8 TROUBLES OF HERMETICALLY SEALED PUMP ............................................................................... 67
CHAPTER 8 MAINTENANCE OF CHILLER/HEATER............................................................... 69
8.1 PERIODICAL INSPECTION ............................................................................................................... 69

8.2 MAINTENANCE DURING SHUTDOWN PERIOD ................................................................................. 71
8.3 INSPECTION OF AIR TIGHTNESS ..................................................................................................... 72
8.4 INSPECTION, CLEANING AND CHANGE OF HEAT TRANSFER TUBES................................................ 72
8.5 CLEANING OF CHILLER/HEATER .................................................................................................... 73
Appendix
Attached Table 1 Saturated Steam Table (a) and (b)
Attached Figure 1 Crystallization Temperature Curve for LiBr Solution
Attached Figure 2 Specific Gravity Curve for LiBr Solution
Attached Figure 3 Saturated Steam Curve for LiBr
Attached Figure 4 Pressure -Temperature Curve for LiBr
Attached Table 2 Running Record
Attached Table 3 Chiller Electric Parameter Table
Attached Table 4 Performance Table for Breaker Used on Chiller
2
SAFETY POINTS
Safety points must be carefully read and fully understood by the operators before operation for
safe and correct use of Shuangliang Chiller.
Safety Warning
1.1 Indication in the manual
The following indication in boldface will be marked in proper positions of the manual to remind
any possible operators.
is to indicate any possible dangers for personal injury. Normally, instruction, brief
explanation and possible results due to neglect of those instruction will be closely followed.
is to indicate possible damages of chiller or other equipments or environment pollution.

Normally corresponding instruction, brief explanation and possible results due to neglect of those
instruction will be closely followed.
is to indicate useful help information. That information has no relation to safety operation
but may help chiller efficiency and prolong service life of chiller. It also should be noted that help
information will not always be the optimal and will not necessarily bring benefits to chiller.
1.2 Operation Circumstance Warning
Control system should be forbidden to start under conditions below:
z Environment temperature lower 0℃ or higher 55℃
z Places of causticity or with flammable gas
z Places with large quantities of dusts, alkaline air or metal powder
z Places where may cause vibration or impacts to control system
z Places where water, oil or chemicals may be splashed over control system
3
Chapter 1 DESCRIPTION OF ABSORPTION CHILLER/HEATER
1.1 Description of Formation of Type Number

□ ----□ □ □
Fuel type: L-light oil; H-Heavy oil; N-LNG/LPG

Design number: H2 (H2-type Unit)
Nominal cooling capacity: (USRT)
Chiller type: DF-direct fired lithium bromide absorption

chiller/heater
Type Example:
DF-496 H2Lwill be the H2 type light oil-fired lithium bromide absorption chiller/heater with
cooling capacity 496USRT, chilled water inlet/outlet temperature 12/7°C and MMI2 control and
without enlarged HPG.
1.2 The Nominal Operation Conditions and Working Limits

The nominal operation conditions of chiller/heater, see data on the nameplate.
Allowed working limits:
Chilled water outlet temperature (t): Nominal value minus 2°C≤ t ≤ Nominal value plus 3°C
Cooling water inlet temperature (t): 18°C≤ t ≤ 34°C
Power supply voltage: 380~415 VAC
1.3 Configuration of Chiller/heater

Direct-fired lithium bromide absorption chiller/heater (shortened as chiller/heater hereinafter) is a
equipment, which uses oil or gas as fuel, water as refrigerant, lithium bromide as absorbent
solution, produces the chilled and hot water for the purpose of air-conditioning and technology
process. The absorption chiller/heater contains such main parts, as high pressure generator (HP
generator), low pressure generator (LP generator), condenser, evaporator, absorber, high
temperature heat exchanger (HT heat exchanger), low temperature heat exchanger (LT heat
exchanger); and such auxiliary parts, as purge unit, de-crystallization piping and
hermetically-sealed pumps (solution pump and refrigerant pump). The external view of absorption
chiller/heater is shown in the Fig. 1-1, 1-2 and 1-3. The valves for chiller/heater are listed in the
Tables 1-1 .
High Pressure generator consists of external shell, furnace, heat transfer tubes, flue gas box and
so on. The flue gas from burned fuel is passing through furnace and heat transfer tubes to heat and
boil the lithium bromide weak solution in the HP generator. The weak solution is concentrated to
intermediate solution, which flows into the low pressure generator through HT heat exchanger,
and produces high temperature refrigerant vapor, which enters LP generator also. Pressure in the
HP generator is about 93.1KPa.
Low Pressure generator consists of steam chamber, heat transfer tubes, condensate chamber and
so on. The high temperature refrigerant vapor, produced in the high pressure generator, is passing
into the heat transfer tubes of LP generator to heat and boil the lithium bromide intermediate
solution from the HP generator via HT heat exchanger. The intermediate solution is concentrated
1
to strong solution, which flows into the absorber. High temperature refrigerant vapor, which flow
through the heat transfer tubes of HP generator, is condensed by the solution outside the tubes, and
1. Purge valve of condenser

2. Purge valve of evaporator
3. Upper purge valve for vacuum
pump
4. Pressure measuring valve
5. Lower purge valve for vacuum
pump
6. Sampling purge valve
7. Vacuum pump
8. Gas cylinder
9. (55
enters condenser through throttle. Pressure in the LP generator is about 7.33KP Charge valve
mmHg).
10. Solution pump
Fig. 1-1 Front view of absorption chiller/heater 11. Strong solution sampling valve
12. Refrigerant pump
13. Refrigerant sampling valve
14. Refrigerant by-pass valve
15. Cooler water inlet valve
16. Steam heating valve
17. Purging valve of absorber
18. Control panel
19. Solution heating valve
Fig. 1-2 Rear view of chiller/heater
(1) Left view of chiller/heater (2) Right view of chiller/heater

Fig.1-3 Left and right views of chiller/heater
20-HP generator 21-De-crystallization pipe 22-HT heat exchanger 23-LT heat exchanger
24-absorber 25-Evaporator 26-Burner 27-Cooling water inlet 28-Connecting valve for
water box E-A 29-Chillled water inlet 30-Chilled water outlet 31-Cooling water outlet
2
32-Rupture disk 33-LP generator 34-Condenser
Table 1-1 List of Valves for chiller/heaters
No Description Purpose Class Type
1 Purge valve of For purging non-condensable gases from condenser, Purge Stop
condenser opened during purge, normally closed. valve valve
2 Purge valve of For purging non-condensable gases from evaporator
evaporator during heating mode, normally closed
3 Upper purge For evacuation. Opened, while evacuate the
valve for chiller/heater by vacuum pump; Opened also, while
vacuum pump measure the pressure in the chiller/heater and leak
test the shell under positive pressure of nitrogen.
Normally closed.
4 Pressure For measuring pressure. Opened, while measure Pressure Stop
measuring pressure in the unit by Macleod gage. Normally measuring valve
valve closed. valve
5 Lower purge For evacuation. Opened, while evacuate the Purge Stop
valve for chiller/heater or non-condensable gases from gas valve valve
vacuum pump cylinder by vacuum pump. Normally closed.
6 Sampling For measuring the limiting evacuation capacity of
purge valve vacuum pump, and evacuating vessels other than
shell (such as sampler, end cover of HP generator).
Normally closed.
9 Charge valve For charge and drain solution from chiller/heater, Solution Stop
and sampling of weak solution. Normally closed. valve valve
11 Strong For sampling of strong solution. Normally closed.
solution
sampling
valve
13 Refrigerant For sampling of refrigerant, charge and drain Refrigerant Stop
sampling refrigerant from chiller/heater, and charge gas into valve valve
valve the shell during leak test and maintenance under
positive pressure. Normally closed.
14 Refrigerant For bypass refrigerant from evaporator to absorber
by-pass valve for re-generation of refrigerant or dilution of
solution. Normally closed.
15 Cooler water Valve shall be closed when purging during heating Cold water Ball
inlet valve mode. Normally open valve valve
16 Steam heating Changeover valve. Closed for cooling mode, and Refrigerant
valve opened for heating mode. valve
17 Purge valve of Valve shall be closed when purging during heating Purge valve Stop
absorber mode. Normally open valve
19 Solution Changeover valve. Closed for cooling mode, and Solution Ball
heating valve opened for heating mode. valve valve
28 Connecting For drain a part of refrigerant water from evaporator Connecting Stop
valve for water pan into absorber water box before heating valve valve
water box operation. Normally closed.
E-A
Condenser consists of heat transfer tubes and end covers. Cooling water from cooling tower
(about 32℃), enters heat transfer tuber via end covers, to condense the flashed vapor from HP
generator condensate through throttle and condense the refrigerant vapor from LP generator. Then
cooling water left the condenser at temperature about 38℃ to the cooling tower. Produced
refrigerant water flows into the flash chamber through U pipe. A part of refrigerant water is
flashed to form vapor, which flows into the re-absorption chamber at the bottom of absorber,
3
another part of refrigerant water is cooled, and enters refrigerant water pan. Condenser and LP
generator is arranged in one shell (upper shell) with identical pressure.
Evaporator consists of heat transfer tubes, end covers, refrigerant water distribution and spraying
piping, refrigerant water pan, refrigerant water chamber and refrigerant pump. Chilled water from
customer (about 12℃) enters heat transfer tubes through end cover, and evaporates refrigerant
water, which is sprayed over the tubes by the refrigerant pump from water chamber. Rest of water,
which had not been evaporated is collected in the water pan, and is sent to distribution tube again
to evaporate. Thus produced chilled water runs from the evaporator at temperature about 7℃
into the system of customer. Pressure in the evaporator is about 0.80~0.93Kpa (6-7 mmHg).
Absorber consists of heat transfer tubes, end covers, water distribution pan, solution chamber and
solution pump. Cooling water from cooling tower enters the heat transfer tubes through end cover
to cool the strong solution distributed outside tubes. At a set temperature and concentration (for
instance 50℃and 63%) lithium bromide solution possesses tremendous water vapor absorbing
capacity, and absorbs considerable refrigerant vapor, produced in the evaporator in the same shell,
and transfers the heat to the cooling water, which is dissipated to the cooling tower. After
absorbing water vapor, solution is diluted, and flows into the re-absorption chamber to absorb the
refrigerant vapor flashed in the flash chamber, then sent to HP and LP generators to be
concentrated. Absorber and evaporator locate in the same shell under the same pressure. Absorber
is divided into two parts, which are arranged in both sides of evaporator.
High temperature heat exchanger consists of two heat exchanger shells, which are composed of
heat transfer tubes, supporting rods and front and rear end covers. Weak solution flows through
internal part of tubes, and intermediate solution pass over the tubes. HT heat exchanger has the
purpose of increasing the temperature of weak solution and reducing that of intermediate solution.
Low temperature heat exchanger consists of two heat exchanger shells, which are composed of
heat transfer tubes, supporting rods and front and rear end covers. Weak solution flows through
internal part of tubes, and strong solution passes over the tubes. LT heat exchanger has the purpose
of increasing the temperature of weak solution and reducing that of strong solution.
Purge unit consists of purge piping and gas box (arranged in evaporator, absorber and condenser),
ejector, gas cylinder, solution return pipe, stop valves, and vacuum pump. It is functioned for
purge non-condensable gas from the chiller/heater to reduce the influence of .gas to the normal
operation of chiller/heater. During its operation, the non-condensable gas is extracted through
purge piping to the pressure reduced area of ejector, which is created by a part of weak solution,
supplied by the solution pump from absorber. Then gas flows with solution into the gas cylinder.
Gas is stored in the gas cylinder and gas box, and solution returns into the absorber through
solution return pipe. Stored gas can be discharged into atmosphere by vacuum pump, or
non-condensable gas can be evacuated directly by the vacuum pump.
Hermetically-sealed pumps (solution pump and refrigerant pump) are used to handling the
working media in the chiller/heater. Solution pump has the purpose to send the lithium bromide
weak solution from absorber to HP and LP generators through LT and HT heat exchangers.
Concentrated strong solution is returned to absorber. Refrigerant pump is used to spray refrigerant
over the tubes in the evaporator by extracting refrigerant from refrigerant pan of evaporator, then
refrigerant is evaporated by heat of chilled water.
Burner is the heat source for the chiller/heater, and can be oil or gas burner dependent the oil or
gas used.
4
Control panel is the control center of chiller/heater. For details of control panel, see Chapter 4.
1.4 Working Fluid

1.4.1 Refrigerant
As the refrigerant of absorption chiller/heater, water is used. For producing chilled water with 7
℃ , pressure in the evaporator is only 0.9kPa (6.75 mmHg), and saturation temperature under
such pressure is 5.5℃(for relation of saturated steam and temperature of water, see attached table
1 ), which is the boiling point of water under such conditions. Refrigerant water is handled from
the refrigerant pan of evaporator, and sprayed over the tubes in the evaporator. System water to be
chilled in the evaporator has temperature of 12℃, which gives heat to refrigerant, and decreases
temperature. In the mean time, the refrigerant water gains heat, and evaporates.
1.4.2 Absorbent
As absorbent for the chiller/heater, lithium bromide solution is used. It can be taken as the carrier
of refrigerant water, and functions as to absorb the refrigerant vapor, produced in the evaporator
by removing heat of chilled water, and carries refrigerant into HP and LP generators. Weak
solution is divided into water and strong solution under the heat of burned fuel. Then the strong
solution returned into absorber to absorb water vapor, produced in the evaporator. Refrigerant
vapor enters condenser to be condensed by dissipating the heat into atmosphere through cooling
water. Refrigerant condensate returns into evaporator to produce cooling effect.
The new charged solution should meet the following technical requirements:
(1) Concentration: 50%±0.5%;
(2) Alkalinity: pH value in the limits of 9.5~10.5;
(3) Lithium chromate content: 0.10%±0.02%
: Quality of lithium bromide solution influences the performance of chiller/heater

Note directly, so the solution, produced by the Company, must be used.
Solution in the chiller/heater held in predetermined limits of concentration. Too high concentration
and too low temperature can lead to separation of crystals from solution, known as crystallization.
Severe crystallization will prevent chiller/heater from normal operation.
LiBr solution corrodes metal material, especially in the presence of oxygen. Corrosion takes place
very quickly, and shortens the operation life of chiller/heater. So the chiller/heater should be kept
under high vacuum conditions. In addition, proper content of lithium chromate in solution and
maintaining pH within 9.5~10.5 are also essential to corrosion prevention. Measures should be
taken in accordance with the recommendations, contained in the following text, when the content
of lithium chromate and pH values are not in the specified limits.
LiBr solution without addition of corrosion-inhibitor (lithium chromate Li2CrO4) is a colorless,
transparent and nonpoisonous liquid. With the addition of Li2CrO4, it is changed to light yellow,
and slightly poisonous. Skin spattered with LiBr solution is itching. Make sure that LiBr solution
does not directly contact with skin. Wash spattered skin with clean water.
5
1.5 Working Process
1.5.1 Working Process for Refrigeration
Refrigeration process is shown in the Fig. 1-4. During refrigeration the heating solution and vapor
valves are closed. The chiller/heater is purged from non-condensable gases, and kept under high
vacuum conditions.
Weak solution from the absorber is pumped into the HP generator through LT and HT heat
exchangers. It is heated by fired fuel and concentrated to the intermediate solution, and high
temperature refrigerant vapor is produced. Intermediate solution enters LP generator through HT
heat exchanger in exchanging heat with weak solution which is passed through the tubes, and
heated by the refrigerant vapor from HP generator, concentrated to the strong solution, releasing
refrigerant vapor at the same time. The strong solution passes through the outside tube space of LT
heat exchanger, enters absorber, transmitting heat to the weak solution from absorber. Refrigerant
vapor from HP generator is condensed in LP generator to form condensate, which enters
condenser through throttle. Refrigerant vapor formed in the LP generator enters the condenser to
form condensate also. These two parts of refrigerant condensate flows into the refrigerant pan.
Refrigerant from evaporator water pan is pumped over the evaporator tubes for the refrigeration
effect, and evaporates to form vapor by absorbing heat of chilled water flowing through tubes.
Produced refrigerant vapor enters absorber, and absorbed by strong solution in the absorber.
Produced heat during absorption in absorber is carried by cooling water inside absorber tube
bundles into atmosphere. Chilled water is cooled and return to the system of customer. Strong
solution is diluted by absorbing refrigerant vapor in absorber and absorbing flashed refrigerant
vapor in the re-absorption chamber, then is transferred by solution pump to HP and LP generator
for concentration. This process is continued, and refrigeration effect. is repeated
6
1.5.2 Working Process for Heating Mode
Working process for heating mode is shown in Fig. 1-5. During heating mode, the cooling water
pump and refrigerant pump stops to run, but solution and steam valves for heating should be
opened. Hot water is supplied from evaporator.
Weak solution is pumped from absorber into HP generator and heated by fired fuel, and
concentrated by releasing refrigerant vapor. High temperature refrigerant vapor is fed into
evaporator through vapor heating valve, releasing heat to the hot water inside the tube bundles in
the evaporator. Condensate of refrigerant vapor in the water pan of evaporator is over-flown into
the absorber, and strong solution is fed into the absorber through solution heating valve. These two
parts of solution are mixed together to form weak solution. This weak solution is pumped to the
HP generator to be heated. Hot water in the evaporator tube bundles is warmed-up due-to the heat,
released from refrigerant vapor by condensation. This process is continued, and hot water is
produced in evaporator uninterruptedly.
7
1.6 Performance of chiller/heater
The chiller/heater can be differed from nominal conditions owing to the changed requirements of
customer (such as air conditioning load, cooling water temperature and so on). Fig.1-6, 1-7,1-8 1-9
and 1-10 show the performance curves of absorption chiller/heater, which cannot be operated over
the allowed operation limits.
Conditions:
Chilled water outlet temperature 7℃
Fuel consumption (%)
Chilled water flow 100%

Cooling water flow 100%
Scale coefficient 0.086 m2.K/kW
Cooling water inlet temperature is changed
(lineally in relation to load)
100%load 32℃ 60%load 28℃
20%load 24℃
Cooling capacity
Fig. 1-6 Curve of cooling capacity in relation to fuel consumption
Conditions:
(%)

Cooling capacity
Chilled water outlet temperature (℃)

Fig.1-7 Curve of cooling capacity in relation to chilled water outlet temperature and cooling
water inlet temperature
Conditions:
(%)
Chilled water outlet temperature 7℃

Cooling capacity
Cooling water inlet temperature 32℃

Cooling water flow (%)

Fig. 1-8 Curve of cooling capacity in relation to cooling water flow
8
Conditions:
Hot water outlet temperature 60℃
Fuel consumption (%)
Hot water flow 100%
Heating capacity (%)

Fig.1-9 Curve of heating capacity in relation to fuel consumption
Heating capacity (%)
Conditions:
Hot water flow 100%
Hot water outlet temperature (%)

Fig. 1-10 Curve of heating capacity in relation to hot water outlet temperature
9
Chapter 2 INSTALLATION OF CHILLER/HEATER
2.1 Requirements to Maintenance during Installation

For chiller/heater tested in the Company, customer should pay attention to check the chiller/heater
for its air tightness, observe the vacuum of internal space of chiller/heater by Macleod gauge.
During storage and installation of chiller/heater, customer is required to observe the vacuum
conditions of chiller/heater in accordance with the provisions of paragraph 5.1.4and 8.3. Observe
the vacuum conditions daily. Information about the change of reading of pressure gauge should be
given to the service engineer of Company. Abnormality of chiller/heater, observed by the service
engineer of Company, should be corrected by the customer under his guidance and technical
manual.
Air leaks in the chiller/heater, causes corrosion of internal parts, affects its operation
life, and prevents it from normal operation under severe conditions.
During shipping, handling and installation, chiller/heater should be protected from man-made
damage and unauthorized operation of valves and instruments. In order to protect the chiller/heater
from leaks, the personnel is forbidden to climb the chiller/heater by the piping and valves. Control
panel, electric instrument and wiring should be protected from damage, control panel is not
allowed be opened and wiring be removed by uncertified operator. Protection means from
dampness and rain should be adopted.
All the outlet openings of chiller/heater should be covered to protect it from ingression of dirty
and foreign matter.
With original openings covered and protections provided chiller/heater should be covered by a
tarpaulin, but not plastic sheeting (which will permeate damp and speed up its corrosion), when it
is left in the open air. Chiller/heater or its parts, stored for long time in the room or in the open air,
should be covered carefully.
Box with bulk of parts is recommended to store at dry and safe place to ensure its intact.
2.2 Requirements to Machine Room

1. Machine room should be designed in accordance with the provisions of fire-fighting rules for
buildings, design rules for gas and oil fuel supply system, and other standards and
specifications.
2. Machine room should be provided with good ventilation and lighting facility. Discharge fans
should be installed with air change rate of 6-10 times in hour to meet the needs of combustion,
heat dissipation and safety.
3. Temperature in the room should be kept in the limits of 5-40℃, and humidity less than 90%.
4. Machine room should be supplied with power voltage of 380VAC±10%, and without
accidental failure of power.
5. Machine room is provided with perfect drain system. Machine room should be constructed
against fire and water flood.
6. Machine room with gas-fired chiller/heater should be provided with gas leakage detection and
warning device, which should be designed with perfect functioning in the installed positions,
and interlocked with air discharging fans and gas quick shut-down valves.
10
7. Machine room should be arranged in such a way, that the chiller/heater is accessible to handling,
install, maintain, repair, replace the parts and modernize chiller/heater. Space and height should
be reserved for handling and transport the chiller/heater.
8. Minimum space with the dimensions shown in the Table2-1 should be reserved. Space for
changing tubes should be provided in axial direction from any one side of chiller/heater.
Chiller/heater can be installed with the ends against window or door for pulling the leaking
tubes.
9. Machine room should be designed with due considerations of its vibration and noise to the
surrounding rooms, and provided with good sound isolation, attenuation and vibration
absorbing means.
10. Machine room should be able to carry the total weight of whole package of chiller/heater and
its auxiliary equipment such as water pumps during their operation.
11. Machine room should be equipped with locks and screens for doors and windows to protect
from the entrance of unauthorized people.
12. Machine room should be provided with tools, spare parts and materials for maintenance of
chiller/heater and systems.
Table2-1 Minimum space, reserved around the chiller/heater
Axial direction 1.0m Above chiller/heater 0.2m
From control panel 0.8m Rear side 0.8m
2.3 Installation of Chiller/heater

The foundation for chiller/heater should be designed to carry the chiller/heater with operation
weight. as static load, because of its stable operation and minor vibration. The foundation should
be raised from the floor with dimensions in accordance with installation drawings provided by our
Company. During installation the transportation rack should be removed. The installation work of
chiller/heater is essential to its successful operation, especially the levelness should be ensured,
though the installation of chiller/heater is not so complicated.
In general, the chiller/heater is installed in the machine room, but it can be installed outside it, if
the conditions not allowed. But, the unit cannot be installed in the open air, when the lowest
circumstance temperature in the year is less than 5℃.When installed outside the room, means
should be taken to protect the chiller/heater body, control panel, measuring and control instrument,
burner and piping valves from rain, wind, corrosion and heat dissipation. Chiller/heater should be
installed with consideration of daily operation, and provision of space for withdraw of heat
transfer tubes from any end of chiller/heater. In the mean time, it can be installed with one end
oriented to the window. Drainage should be provided around the chiller/heater and covered with
perforated plate made from cast iron.
Before positioning the chiller/heater on the fundament, which should be cleaned from dirty, be
kept level and with dimensions in accordance with the design requirements. On the support area of
fundament, hard rubber plates with area bigger than supporting foot and thickness of about 10mm
should be covered.
1. Installation Of Assembled Chiller/heater
During installation of chiller/heater, it should be handled carefully with steel ropes placed on the
marked area. Every steel rope should have capacity to carry whole weight of chiller/heater.
Chiller/heater should be handled with care to be protected from damage of any parts. The position
of contact of ropes with the chiller/heater should be adjusted to avoid the damage of parts, such as
11
small diameter pipes, connecting wires and instrument. Chiller/heater should be handled in
horizontal position with slow movement in order to be protected from drop of unit owing to
deviation of center of gravity, when solution in chiller/heater is moved. Chiller/heater should be
lowered with all feet contacted with the surface of floor or fundament.
To avoid damage of chiller/heater, handling equipment and steel wire should

have capacity to carry weight more than that of chiller/heater. During operation
personnel is not allowed stay under the handling equipment for avoiding injuries and
deaths.
After positioning of chiller/heater on the fundament, the longitudinal and transversal levelness
should be checked. Two holes on the both sides of tube plates of evaporator-absorber are provided,
and should be on the same level with deviation less than 1/1000. Chiller/heater can be raised at
one end by crane or two jacks at each side of unit, and long steel spacer can be inserted between
the foot and fundament, if the levelness of unit is not in the prescribed limits.
Deviation from prescribed levelness of installed chiller/heater causes

re-distribution of working fluid flow in the unit, and affects its normal operation under
severe conditions.
2. Installation of unit of chiller/heater from split parts

Separation of chiller/heater into split units impairs vacuum of chiller/heater, and causes its
corrosion. Chiller/heater tested in the works, should be separated close to the machine room, and
handled into the machine room to be tested for refrigeration operation as quickly as possible.
For split chiller/heater, its installation is basically the same as for assembled unit of chiller/heater.
The main difference is: the separated parts should be put at their own fundament, lined up for
connections, checked for longitudinal and transversal levelness, and welded together, if it is
separated into two parts. Or the lower shell should be put on the fundament, checked with
longitudinal and transversal levelness; then the upper shell should be put on the lower shell, lined
up for connection, checked for longitudinal and transversal levelness, and welded together with
lower shell. Afterwards, the high pressure generator should be put on the fundament, lined up for
connections, checked for longitudinal and transversal levelness, and welded together with the
other parts, if the chiller/heater is separated into three parts. Cautions should be taken to prevent
the welding from ingression of slag and scales into the unit. Welded chiller/heater should be
checked again for levelness. Installed unit should be evacuated, and checked for air tightness.
At the outlet end cover of LP generator installed a rupture device, which is

forbidden to be connected with any piping, and to bear any load. During installation
this part should be protected from damage.
2.4 Adjustment of Levelness of Chiller/heater

Method of checking the levelness of unit usually is done by level or with transparent plastic hose
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and water as follows:
1. As shown in the Figure 2-1, transparent plastic hose is hanged close to the level reference holes,
and charged with water.
2. Water lever in one end of hose is kept to the center of one reference hole. Water level in the
another end of plastic hose should be at same height with the center of another reference hole,
adjusting the height of chiller/heater at another end by crane or other means. The longitudinal
levelness of installed chiller/heater equals to the difference of water level in two ends divided
by the distance between the tube plates. Chiller/heater is kept in the limits of levelness, which
should be less than 1/1000, by insertion of long steel spacer at the lower end.
3. The transverse levelness is adjusted in the same manner by placing the plastic hose along the
tube plate.
2.5 Insulation of Chiller/heater

When the chiller/heater is installed and checked for air tightness, the following parts should be
insulated:
Thermal insulation locations: high pressure generator (~160 ℃ ), high temperature heat
exchanger(~160℃), low pressure generator (~90℃), low temperature heat exchanger (~90℃), and
relevant pipes between them. Pipes connected with high pressure generator are at 160℃, others at
90℃.
Cold insulation locations(~7℃): evaporator water pan, evaporator water chamber end covers,
piping before and after refrigerant pump.
Thickness of thermal insulation layer: 70mm for locations of surface temperature 160℃ and
40mm for locations of surface temperature 90℃
Thermal insulating material: super-fine glass fiber felt, rock wool felt, or material with similar
property.
Thickness of cold insulation layer: 30mm.
Cold insulating material: polyethylene foam plastics, or material with similar property. Cold
insulating material shall not absorb water, and no gas can be pass through. Joints shall be sealed
by adhesive tapes.
Thermal/cold insulation construction: welding shall not be conducted on the chiller/heater, electric
13
circuits shall not be damaged, and sight glass, temperature-measuring tubes, valves and drainage
cocks shall not be covered.
Insulation parts are shown in Fig.2-2.
Fig.2-2 The parts of chiller/heater to be insulated
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Chapter 3 INSTALLATION OF EXTERNAL SYSTEMS
Chiller/heater is provided with external systems, such as water system (including chilled and
cooling water), fuel system and electric system.
3.1 Water System (chilled and cooling water)
Fig 3-1 Diagram for water system

External water system for chiller/heater is shown in Fig.3-1.
Water piping is designed to ensure the water speed in the limits of 1.5-2.5m/s (for nominal water
flow, see nameplate). Piping should be constructed with fewer turns or round turns. Piping is
supported or hanged carefully to prevent the chiller/heater from the load by piping. Chiller/heater
is influenced in operation life by external load or vibration, or damaged during severe conditions.
At the inlets and outlets chiller/heater and pumps (including spare pumps) should be provided with
compensators (including rubber compensators, rubber hoses, metal bellows, and metal hoses).
At the inlets of chiller/heater and pumps the detachable filter with element of large area of
5-8meshes should be installed. Piping should be designed to clean filter and maintain the pumps
without interrupting the operation of chiller/heater.
Filters must be installed at water pump inlet and at chilled water inlet to protect the
heat transfer tubes from clogging by the foreign matters, to protect the chiller/heater from
degradation of performance and rupture of tubes by freezing.
Chiller/heater and pumps (including spare pumps) should be provided with pressure gauges (or
gauge common for measuring pressure at different locations by switching from location to
location, if it desirable). At the inlets and outlets of chiller/heater thermometers shall be installed.
For water systems of unit, flow meters with scale covering the nominal water requirements should
be installed in manner accessible for reading and maintenance.
Inlets and outlets of chilled (hot) water shall be connected with chiller/heater by short pipe of
15
about 800 mm in length to remove the end cover of evaporator and clean heat transfer tubes. At
inlets of chilled (hot) water, detachable filter with element of large area of 5-8meshes should be
installed. Water piping should be provided with drain valve at its lowest point, drain piping led to
channel, and vent at its highest point.
Pressure setting device shall meet the requirements for constant pressure and water drainage when
expansion and water makeup when leakage, if closed water system is used.
Cooling tower shall conform to the requirements of chiller/heater in water flow and
thermodynamic performance. Cooling tower with water collecting tank should be selected, if no
reservoir is provided for the cooling water system. Cooling tower shall be installed at place far
from source of heat and dust, especially from chimney, with good ventilation, taking consideration
of noise and water drift. Regulating valve and instantaneous water flow meter should be installed
at the make up and drain piping to keep the quality of cooling water. Cooling tower should be
operated by thermostatic control at the outlet of cooling water from tower, or fan of tower is
connected with the control system of chiller/heater, and on/off controlled from control panel.
Bypass piping with two-way or three-way valves can be connected between the inlet and outlet of
tower to maintain constant temperature of cooling water, while part of cooling water is bypassed
tower into chiller/heater in case of too low temperature of cooling water.
Pump can be installed at the outlet of chiller/heater to reduce the water pressure working on the
chiller/heater, when water system is operated under higher pressure.
Pressure working on the water head of chiller/heater cannot be above its

maximum load carrying capability, otherwise, the chiller/heater cannot be working
normally owing to the deformation of water head.
Water treatment means should be provided to protect heat transfer tubes from corrosion or scale
formation, if water cannot meet the requirements in quality.
Chiller/heater is supplied with a flow switch, which is installed in a straight section with length not
less than 10 times of pipe diameter (horizontal or vertical) of chilled (hot) water piping from the
chiller/heater. For installation of flow switch a round hole shall be done at the straight pipe (or at
up side for horizontal section). Then the support of flow switch shall be welded to the hole, and
switch is installed with deflector perpendicular to the flow direction. The direction marked on the
meter shall be the same for the direction of water flow. Switch shall be connected with the control
system of chiller/heater. The length of straight section of pipe shall be at least 5 times of pipe
diameter, as shown in Fig.3-2.
16
Water system must be flushed completely before connecting with chiller. Otherwise,
heat transfer tube will be blocked, which will lower chiller efficiency and lead to serious
problems such as rupture of heat transfer tube.
When system installation is done without any leakage, please insulate chilled water piping
3.2 Light Oil System
Fig.3-3 schema of light oil system
Fuel oil system shown In the Fig.3-3 can be used for light diesel oil (Standard GB252). The fuel
oil system should be designed to meet the safety technical requirements of National standards,
local fire-fighting authority rules, and following requirements.
Daily tank should be installed, if the fuel tank is located not higher than the burner by 0.5m. Fuel
should be transferred into daily tank, ad then supplied to the burner. Daily tank should be located
higher than the burner in the limits of 0.5-6m, but not higher than 10m. Daily tank can be canceled,
if the fuel storage tank is located higher than burner by 0.5 to 6m (but not higher than 10m from
the highest level in tank).
Daily tank, which is arranged in the machine room, should be of closed type, not more 1m3 in
volume, and strictly prohibited to be located above the water heater unit or horizontal section of
flue gas channel.
Oil tank should be provided with venting piping, which is equipped with fire trap and rain
protecting means. Emergency discharging piping with easy to access and operate valves should be
installed on the oil tank to discharge oil outside the room into a specially mounted reservoir. Oil
17
tank should be provided with oil level control means and high and low level alarm devices, and
interlocked with oil supply equipment. No glass level gauge should be installed on the tank.
Filter (80 meshes) should be installed before oil entry into chiller/heater, in order to protect oil
pump, solenoid valves and nozzles from damage due to slag. The active area of filter should not
less than 20 times of piping outlet area, and a by-pass piping with valve should be connected in
parallel with the filter in order to clean the filter, when the unit is in operation.
It is preferred to use copper piping as fuel oil piping, but steel piping also can be used. Piping is
welded, leak-proof tested with pressure of 0.2MPa. Piping should be cleaned from debris before
its installation. The fuel oil should have velocity in the piping less than 0.2m/s.
It is prohibited to use oil with flash point ≤ 40℃ (for instance the gasoline, made by
local indigenous method).
3.3 Heavy Oil System
Fig. 3-4 schema of heavy fuel system
Fuel oil system shown in the Fig.3-4 is used for heavy fuel oil #20 to #60 (Standard GB 445). The
fuel oil system should meet the safety technical requirements of National standards, local rules of
fire-fighting authority, and following requirements.
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Heavy fuel oil should be heated to 50℃ by heating coil in the tank, then to 70℃ by the piping
jacket hot water or low pressure steam, when oil passing through piping, and to 100℃-130℃ by
electric heater in the burner in order to have a good atomizing.
Before shutdown the burner, heavy fuel oil in the burner should be replaced by light oil in order to
have reliable start operation. Light oil tank should be installed higher than the heavy fuel oil tank
by 0.5m to 1m, and heavy fuel oil tank should be installed higher than burner by 1-5m, but the
highest level in tank should not higher than burner by 10m. Daily tank, which is located in the
machine room, should be of closed type, not more 5m3 in volume for heavy fuel oil, and 1m3 in
volume for light fuel oil, and strictly prohibited to be located above the water heater unit or
horizontal section of flue gas channel.
Oil tank should be provided with venting piping, which is equipped with fire trap and rain
protecting means. Emergency discharging piping with easy to access and operate valves should be
installed on the oil tank to discharge oil outside the room into a specially mounted reservoir. Oil
tank should be provided with oil level control means and high and low level alarm devices, and
interlocked with oil supply equipment. No glass level gauge should be installed on the tank.
Filter (60 meshes) should be installed before oil entry into chiller/heater, in order to protect oil
pump, solenoid valves and nozzles from damage due to slag. The active area of filter should not
less than 20 times of piping outlet area, and a by-pass piping with valve should be connected in
parallel with the filter in order to clean the filter, when the unit is in operation.
It is preferred to use copper piping as fuel oil piping, but steel piping also can be used. Oil is
flowing through piping with speed not more than 0.2m/s.
Piping should be cleaned from debris before its installation. Piping is welded, leak-proof tested
with pressure of 0.2MPa to ensure no leakage of oil to outside or between piping and jacket.
It is prohibited to use oil with flash point ≤ 40℃ (for instance the gasoline, made by
local indigenous method).
3.4 Fuel Gas System
Fig.3-5 Schema of gas system

Fuel gas system should be designed to ensure safety and gas pressure (or flow). Gas quality,
system design and construction should meet the requirements of National standards“Design rules
for boiler house”(GB50041-92),“Design rules for urban gas installation”(GB50028-93) and
“Safety rules for gas in the industrial enterprises”.
On the main gas piping to the machine room a main stop valve should be installed to ensure its
safe operation and easy access.
19
Gas piping in the machine room should be installed overhead. Gas piping for transporting gas with
density less than air, should be mounted in the high place with good ventilation; where as piping
for gas with density more than air, should be installed along the wall outside the machine room
with good accessibility.
Gas piping cannot be laid to machine room through bed room, stores with flammable and
explosive matters, electric distribution room, transformer room, cable trench, ventilation channel,
duct, flue gas channels and places, where piping is easy to be corroded.
Gas main should have dissipating piping, sampling and flushing ports, which are placed to purge
the gas and air from the piping. Dissipating piping should be led to outside of machine room. Its
discharge port should be rain protected, and located higher than the building roof by more than 2m
Discharged gas is not allowed to enter neighbor building, and be sucked by ventilation fans.
Dissipating piping should be designed to have purge capacity more than 10 to 20 times of section
volume to be purged, and with purge time 15 to 20 min. Gas piping should have lightning means
with grounding resistance less than 10 ohm, if it locates outside the lightning protection zone.
Gas piping should be air proof tested. As shown in Fig.3-5 the piping section, which locates
upstream pressure regulating valve, should be tested by 1.5 times working pressure and leak
checked by soap solution.
In order to ensure the gas supply to the chiller/heater, gas piping should be constructed with round
bends to decrease the pressure drop. Gas piping diameter should be at least one size bigger than
the diameter of burner.
Pressure at the gas inlet (the outlet of ball valve) should be in the limits prescribed in the catalog
of company. The pressure deduction valve should be installed, where the gas inlet pressure is
higher than high limit in the catalog.
In order to keep gas valve group, piping and fittings intact during transportation, they should be
packed in boxes, and installed on site of customer. For ensuring the tightness of connections, gas
valve fittings should be installed to meet the following requirements:
For flange connections, high quality sealing gaskets (asbestos-rubber gaskets) are used, and then
bolts tightened.
For threading connections used for gases, threading is to be sealed by following means:
For connections used for city gas, connections should be sealed by white lead compound with
linen packing
For connections used for natural gas, connections should be sealed by PTFE tape
Corrugate pipe should be installed between ball valve outlet and filter inlet.
3.5 Gas Exhaust System
Flue gas channel and chimney should be designed to keep the pressure at the outlet between
–50Pa~0Pa (-50 to 0 Pa).
The section of flue gas channel and chimney should be not less than the section of discharge port
of unit. The main flue gas piping should have section not less than the sum of sections of branches
with valves which should have opening indicating means, no matter the valve is automatic or
manual driven.
It is recommended to adopt flue gas channel with round section. The turns of piping should be
rounded, and the construction shown in Fig.3-6 should be adopted for the branches joining
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together, and converging and expanding construction for the changing sections.
Chimney height should be not less than (0.6L+ N) m, where L is the length of horizontal section of
flue gas channel in m, N is the number of turns of flue gas channel. The chimney should be higher
than the surrounding buildings by more than 3 m, if they are in the limits of 200m around the
chimney. On the outlet of chimney a rain protecting cap, lightning rod and wind protecting cover
should be mounted. Rain protecting cap should have diameter equal to two times of that of
chimney. The place of outlet of chimney should be chosen to make observations of smoke
emission easily.
The horizontal section of flue gas channel should have trap on its lowest section above the
equipment, which shall connected with the drain piping led from flue gas box of chiller/heater unit,
and through 200mm U-shaped trap discharged to the canalization.
Chimney should be constructed with bricks and concrete in order to avoid corrosion. The pipe
thickness should be not less than 4mm, if the steel construction is adopted.
For compensation the heat expansion of chimney, the expansion joint should be provided on the
straight section, and fire retarded and heat resisted soft material should be placed, when the flue
gas pipe passes through wall and when flange is installed.
Flue gas channels should be insulated, when they are checked to have good air-tightness.
Insulation material ( such as rock wool felt or cement-perlite plate ) can withstand working
temperature of 350℃
Fig. 3-6 Gas exhaust system
3.6 Electric System

As power source the three phases and five lines electric system of AC 380~415V is used. Power
lines are laid to the control panel of chiller/heater by customer, and connected by Shuangliang
engineer during commissioning (Phase and zero lines are connected to internal terminals in the
control panel, and ground line is connected to the ground screw in the panel). Power lines should
meet the power specifications, indicated on the nameplate of chiller/heater.
Special grounding pole with resistance less than 10Ωshould be provided, and connected with the
21
grounding line of chiller/heater to ensure the its safe operation.
Failure of special grounding pole or using zero line instead of grounding pole will
cause severe damage of chiller/heater or injury or death of personnel.
The standard supplied chiller/heater is provided with interlocked control of cooling water pump,
chilled water pump and fans for cooling tower. The pumps (including standby ones) and fans for
cooling tower must be connected with the control system of chiller/heater. The electric distribution
panel should have terminals for connecting control lines for pumps and fans. If more than one
chiller/heaters share one cooling water system, electric driven valves must be set at cooling water
inlets of each chiller/heater to realize interlocked function of control system. The control lines
should be laid and marked by customer. For a chiller/heater, 14 control lines of 0.75mm2 should be
provided. Power lines should be laid separately from control ones.
Chilled water and cooling water pumps (including standby pumps) and fans for
cooling tower must be interlocked with control system of chiller/heaters. At cooling water
inlets of each chiller/heater, electric driven valves must be set to interlock with control
system, if more than one chiller/heaters have to share one cooling water system. Otherwise,
Shuangliang Air-conditioning will not take any responsibility for malfunction and other bad
results such as rupture of tubes.
Signals from gas leakage and fire alarm should be interlocked with the control system of
chiller/heater.
Chiller/heater with remote control and monitoring should be installed by the customer in
accordance with the requirements of “Installation and operation manual for remote on/off and
monitoring system”.
Proper screening measures should be taken when chiller is to be installed in places

below.
z Places where chiller is subject to be interfered by static electricity or other noise
source
z Places with strong magnetic field.
z Places where chiller is subject to be exposed to radiation
22
Ventilation fan in machine room
Cooling tower fan
platinum resistance, flow switch, pressure sensors, level controller are implemented to ensure the
man-machine interface is used, and such measuring and control elements, as PLC controller,
For direct-fired chiller/heater advanced control system MMI with color touch screen as
Interlocked control signal for external systems Cooling water pump

Remote, Chilled water pump
Burner
Concentrated
optimized control of chiller/heater. The configuration of control system is shown below
Output Cooling water pump

Control Signal Vacuum pump
Chilled water pump
Refrigerant pump
Chapter 4 CHILLER CONTROL SYSTEM
Ventilation fan in machine room

Solution pump/Inverter Level of HP generator
Extendible
Functions
Pressure in auto purging unit

Pressure of HP generator
Chilled water flow
23
PLC Monitoring signal of burner De-crystallization pipe temperature
Controller
Monitoring signal of hermetically sealed pumps Flue gas temperature
Evaporation temperature
Interlocking signals for external systems
Condensation temperature
Input
4.1 Configuration of System
Level signal
Signal Spray temperature of concentrated solution
Pressure signal Concentrated solution temperature from LP G
Intermediate solution temperature from HPG
Touch Flow signal
Cooling water inlet temperature
Screen
Temperature signal
Chilled water outlet temperature
Chilled water inlet temperature
4.2 Function of System
The control system is used in two modes: automatic and manual control. Automatic control mode
is preferred, manual control is used only for commissioning and to shooting the failure of
chiller/heater.
Control system is designed for efficient and automatic control of chiller/heater with the functions,
such as: setting the data, automatic staring up and shut-down the unit, limit control of cooling
water inlet temperature, limit control of solution concentration, automatic control of loads and
circulating flow of solution, measuring and displaying the operation data in real time, safety
protection, memory and storage of data and etc.
4.2.1 Normal functions
Table 4-1 Normal functions of control system
No. Name of function Description of function
1 Data setting For working the chiller/heater under expected or optimum
conditions, the data, including the chilled water outlet
temperature, are set by certified personnel in accordance with the
local conditions..
2 Automatic start and Chiller/heater is started/stopped merely by personnel pressing
stop of chiller/heater the touch screen, and will be operated steadily in nominal
conditions.
3 Limit control of Chiller/heater will be operated steadily by limiting its capacity
cooling water inlet under low inlet temperature of cooling water (18-28℃)
temperature (cooling
mode)
4 Limit control of The control system will calculate the concentration of
solution concentration concentrated solution, crystallization and safe temperatures
(cooling mode) based upon of measured actual operating data, and adjust the
operation conditions automatically, when the crystallization
trends to occur.
5 Automatic adjusting Cooling/heating capacity of chiller/heater is automatically
the load adjusted by regulating the heat source supply in accordance with
chilled (hot) water outlet temperature.
6 Automatic adjusting PLC controller will adjust the output frequency of inverter to
the circulating flow of regulate the speed of solution pump in accordance with the
solution measurement of lever and pressure in the HP generator, which
will make the solution circulation to meet the requirements of
chiller/heater operation.
7 Measurement and Control system will display the operation data, such as
display of operation temperatures, pressures, levels on the touch screen in real time
data in real time by sensors installed, to make the operation personnel to know the
chiller/heater more easily.
8 Safety protection Control system will protect the chiller/heater from the dangerous
operation, and take the appropriate measures automatically.
9 Failure diagnosis Determine the failure conditions automatically on the basis of
measured data, and take the appropriate protecting measures .
10 Data storage Control system will store the operation data of last week,
contents of last five failures, and contents and operation data of
last three failures.
11 Information storage Control system stores the information, such as working principle
of chiller/heater, guide of operation and maintenance, which can
be used by operational personnel, while operate the touch screen.
12 Other extendible The control system reserves extendible functions, such as the
functions remote and concentrated control to meet the requirements from
customer.
24
4.2.2 Safety Protection
Chiller/heater will give alarm and stop operation, when it surpasses the set values. The safety
protection items and set values are indicated in Table 4-2.
Table 4-2 Safety protection data
No Item Set value No Item Set value
Evaporation Pressure in HP generator 128KPa
1 4℃ 9
temperature (960mmHg)
Chilled water outlet Chilled (hot) water flow 60% of
2 4.5℃ 10
temperature nominal value
Hot water inlet Over current of solution 100% of
3 *65℃ 11 pump (inverter)
Cooling water inlet Over current of refrigerant 100% of
4 18℃ 12 pump (thermal relay)
Middle concentrated Over current of vacuum 100% of
5 166℃ 13 pump (thermal relay)
solution temperature nominal value
De-crystallizing pipe Burner fan (Thermal relay) 100% of
6 65℃ 14
Flue gas exhaust Protection from over-voltage
7 250℃ 15 380VAC±10%
temperature or under-voltage
Safety protection for burner
Condensation
8 48℃ 16 system from accidental cut
temperature
out of flame
*It will be the sum of nominal value plus 5℃, if the chiller/heater is failed from standard series.
4.3 Control Panel
4.4 Control Flow Chart

Control flow chart describes the procedure of start and stop of elements of chiller/heater during its
start/stop. Control process is shown in Fig.4-4 “Control Flow Chart”.
25
4.5 Operation Method
4.5.1 General
Fig. 4-5 Main menu on the touch screen
Put the switch (single pole switch, normally at position ON), which is installed in the upper
portion of control panel, into the position “ON”, lock the door of control panel, and put the switch
at the lower portion of control panel into the position “ON”. At this moment, the power supply is
connected. The signal “POWER” and ”RUN” will display. Three seconds after the display of
WELCOME, on the screen will show the main menu as shown on the Figure 4-5. Operator can
start/stop the chiller/heater as indicated by the menu. And also to adjust the operating parameters,
or to other control, and learn the working principle, basic operation procedures and methods of
maintenance.
DESCRIPTION OF TOUCH SCREEN. Press this key and on the screen will show the
descriptions of keys and give the user the instruction to operate the touch screen.
WORKING PRINCIPLE OF CHILLER/HEATER Press this key, on the screen will show the
flow chart of chiller/heater for refrigeration and heating, and working principle for refrigeration
and heating also.
OPERATION INSTRUCTION OF CHILLER/HEATER Press this key, on the screen will be show
the more than 10 methods of operation, such as sampling of refrigerant water, charge of solution,
inspection of chiller/heater for air-tightness.
OPERATION HISTORY OF CHILLER/HEATER Press this key, on the screen will show the last
three troubles and the operation data during week.
OPERATION MODE SELECTION Press this key to select the mode of operation (Auto or
Manual, the chiller/heater cannot be changed to manual operation, while the unit is operated under
AUTO control).
CHILLER/HEATER MONITORING Press this key, the screen will show the figure of monitoring,
which is dependent to the control mode. Operator can operate the chiller/heater, solution,
refrigerant and vacuum pumps, and set the data, such as outlet temperature of chilled water. The
current information on the different parts of chiller/heater can be shown also.
DATA SETTING Press this key the adjustable data, such as the outlet temperature of chilled water
27
can be set, and diminish the deviation of displayed value and actual value of operation data.
MIANTENANCE GUIDENCE Press this key the screen will show the contents and methods of
maintenance.
1) The screen protection function is provided, which will stop display (blacken), if no
operations of screen occurred during 1h. For this period the control function of
chiller/heater is maintained, and the screen will continue work, if it is touched lightly.
2) The screen can be cleaned by soft wet rag, no volatile solvent (such as benzene) can be
used.
3) Internally set values and positions of external toggle switches are fixed in the factory, and
not allowed be changed by customer.
4.5.2 Operation Mode and Control Selection

The Graph of Operation Mode selection can be selected by pressing the Key OPERATION MODE
SELECTION of main menu, or pressing the Key MENU to have display the menu graph, then to
select operation mode by pressing the appropriate key. On the Graph of OPERATION MODE
there are two operation modes (refrigeration and heating), and two types of control (Auto and
Manual). You can select the operation mode and control type, and then to press the key
“CONFIRMATION” to get the appropriate chiller/heater operation monitoring graph.
For changing the operation mode between the refrigeration and heating modes, you should
open/close the appropriate switching valves.
4.5.3 Data Setting

The Data setting graph can be selected by pressing the Key DATA SETTING of main menu on the
touch screen, or by pressing the Key MENU on the right upper angle of screen. In later case, touch
screen will display menu graph, then to select Data setting graph by pressing the appropriate key,
when the screen is displaying other graph. There are two kinds of data can be set, namely the
regulating data setting and setting of deviation for displayed data.
4.5.3.1Regulating Data Setting

The regulating data should be changed, while the chiller/heater will be operated on the new
conditions. Regulating data include set values for chilled (hot) water outlet temperature, cooling
water inlet temperature, pressure in HP generator, and appropriate P,I D values. P,I,D values
should be set by certified personnel.
Set values of data should be approved by certified personnel from Shuangliang

Service Company. The set values of regulating data cannot be over its limiting value, and not
too far from the nominal operation conditions to prevent the chiller/heater from abnormal
operation.
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There will be regulating data display graph by pressing the key of setting of regulating data under
the data setting graph. Pressing the key of Password for data setting, input the correct password on
numerical keyboard, and press the key “Enter” to have the graph of setting data. At this time, the
data can be changed. The graph remains unchanged, while the password is erroneous. The input
deviation will be cleaned by pressing the key CLR on the numerical keyboard.
During changing the data, touch screen will display numerical keyboard by pressing the
push-button on the left side of data to be changed. The data will be changed by input new values
and pressing the key of confirmation. The setting of data is finished by pressing the key “OFF” on
the numerical keyboard.
4.5.3.2 Setting of Deviation for Displayed Data

The deviation between the value measured by calibrated standard instruments and displayed value
on the touch screen can be removed by changing the set deviation of displayed data. For example,
the value of chilled water outlet temperature measured by calibrated thermometer is 7℃, and
displayed value of this temperature is 6.5℃, then the deviation of displayed data should be
increased by 0.5℃ on the basis of set deviation. Changing of set deviation is similar to that of
changing of set value of operation data.
During changing the data, touch screen will display numerical keyboard by pressing the
push-button on the left side of data to be changed. The data will be changed by input new values
and pressing the key CONFIRMATION. The data are set by pressing the key “OFF” on the
numerical keyboard.
4.5.4 Operation of Chiller/heater

4.5.4.1 Start/stop of Vacuum Pump
Vacuum pump can be started or stopped at any time. But before attempting to start vacuum pump,
it should be checked for oil level, and operated in accordance of paragraph 6.9 of Chapter 6
Management of vacuum pump.
The graph of chiller/heater monitoring is displayed by pressing the key CHILLER/HEATER
MONITORING of main menu; or pressing key MENU on the upper right angle to display the
content of main menu, then pressing the key CHILLER/HEATER MONITORING to display the
graph of chiller/heater monitoring, when touch screen displays other graph; or to display the graph
of chiller/heater monitoring after selecting the operation conditions.
Purge is realized by pressing key VACUUM PUMP START to start the vacuum pump, then open
the lower purging valve and related purge valves. Before shutdown of vacuum pump, close lower
and upper purging valves then press the key VACUUM PUMP STOP.
The lower purging valve of vacuum pump should be closed, before the vacuum
pump is to be stopped.
4.5.4.2 Start/Stop of Solution and Refrigerant Pump

Solution and refrigerant pumps are started and stopped automatically, when the automatic
operation mode is selected. The only work to be done by the operational personnel is to start and
stop chiller/heater in accordance with the following procedure.
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Solution and refrigerant pumps should be started or stopped by the operational personnel in the
following procedure manually, when the manual control mode is selected:
The graph of chiller/heater monitoring is displayed by pressing the key CHILLER/HEATER
MONITORING of main menu; or pressing key MENU on the upper right angle to display the
content of main menu, then pressing the key CHILLER/HEATER MONITORING to display the
graph of chiller/heater monitoring, when touch screen displays other graph; or to enter the
operation monitoring by selecting the mode of operation and control during the chiller/heater shut
down. Solution and refrigerant pumps can be started or stopped by pressing the keys SOLUTION
PUMP START, REFRIGERANT PUMP START, or SOLUTION PUMP STOP , REFRIGERANT
PUMP STOP.
1) Before startup of solution pump, it is essential to ensure that solution has been charged.
2) Prior to startup of refrigerant pump, strong solution concentration shown on touch screen
should be ensured above 56% and chilled water system is to be checked to protect heat
transfer tubes from freezing.
3) During manual control the solution pump is not allowed be operated under manual mode,
and be controlled by the control system according to the solution level and temperature.
4.5.4.3 Start/Stop of Chiller/heater

The chiller/heater monitoring graph is displayed by the operation mode selection and data setting.
Graph of trouble monitoring will be displayed by pressing key TROUBLE MONITORING. The
following ope4ations can be done, when the chiller/heater trouble-free indicating red LED lights
(except failure of chilled/hot water)
The positions of heating solution and vapor valves should be confirmed. They will be closed for
cooling mode, and opened for heating mode.
The chilled/hot water pump is to be started with its outlet valve closed. Then the outlet valve is
opened step by step to get the nominal flow rate. Cooling water pump is started in the same way as
for chilled/hot water pump. After the ventilation fan for machine room and fuel input valve is
opened, and chiller/heater will be started and stopped in the following way according selected
operation mode.
A. Automatic Control (Cooling Mode)

Chiller/heater will be started and come to normal operation by pressing the key SYSTEM START,
and then pressing the keys CONFIRMATION, and RE-CONFIRMATION, which appears in the
graph of chiller/heater operation monitoring on the touch screen. During cooling operation cooling
water inlet temperature should be controlled by operational personnel in the limits of 36-38℃.
Chiller/heater is stopped by pressing the key SYSTEM STOP on the graph of chiller/heater
operation monitoring. Following this operation, the chiller/heater will be operated with automatic
dilution, and burner will stop firing (The fuel inlet valve is closed by operational personnel
manually). When solution concentration detected reaches 58%, stop refrigerant pump and after 5
minutes when solution is diluted to 56%, stop solution pump and shut off cooling water pump
automatically. Afterward chilled water pump will be stopped automatically 3 min later.
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B. Automatic Control (Heating mode)
Chiller/heater will be started and come to normal operation by pressing the key SYSTEM START,
and then pressing the keys CONFIRMATION, and RE-CONFIRMATION, which appears in the
graph of chiller/heater operation monitoring on the touch screen.
manually). After 15min stop solution pump and 3min later stop hot water pump automatically.
C. Manual Control (cooling mode)
On the graph of chiller/heater operation monitoring the key SYSTEM START is pressed, then the
key CONFIRMATION and RE-CONFIRMATION is pressed in the following graph, then the
graph chiller/heater operation monitoring is displayed again. The solution pump is started and
solution circulation is controlled automatically by pressing the key SOLUTION PUMP START.
Burner will work at small fire by pressing the key BURNER IGNITION and BURTNER SMALL
FIRE.
During operation chiller/heater can be work on big fire or small fire by the pressing the BURNER
BIG FIRE OR BURNER SMALL FIRE.
But it is limited to work on small fire, when the cooling water inlet temperature is
less than 28℃, or chilled water outlet temperature is less than nominal value.
During refrigeration operation, when cooling water inlet temperature less than 28℃,cooling water
outlet temperature should be controlled by operational personnel in the range of 36-38℃.
manually). When solution concentration detected reaches 58%, stop refrigerant pump and after 5
minutes when solution is diluted to 56%, stop solution pump and shut off cooling water pump
automatically. Afterward chilled water pump will be stopped automatically 3 min later.
D. Manual Control (Heating Mode)

On the graph of chiller/heater operation monitoring the key SYSTEM START is pressed, then the
key CONFIRMATION and RE-CONFIRMATION is pressed in the following graph, then the
graph chiller/heater operation monitoring is displayed again. The solution pump is started and
solution circulation is controlled automatically by pressing the key SOLUTION PUMP START.
Burner will work at small fire by pressing the key BURNER IGNITION and BURTNER SMALL
FIRE.
During operation chiller/heater can be work on big fire or small fire by the pressing the BURNER
BIG FIRE OR BURNER SMALL FIRE.
But it is limited to work on small fire, when hot water outlet temperature is higher
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than nominal value.
manually). After 15min stop solution pump and 3min later stop hot water pump automatically.
4.5.5 Operation Monitoring of Chiller/heater
The operation conditions of parts and chiller/heater and content of trouble, if any, can be displayed
to the operational personnel by the graph of chiller/heater operation monitoring.
4.5.6 Trouble Shooting

The chiller/heater will give alarm and stop operation automatically, when trouble occurs. The
alarm bell will be silent, and trouble content graph will be displayed upon pressing the key
TROUBLE MONITORING by the operational personnel. The content of trouble will be shown
(by the red light before the trouble). The cause of this trouble and method of shooting will be
given by pressing the key TROUBLE FUNCTION. The TROUBLE MONITORING will be
returned, when the return key is pressed.
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Chapter 5 COMMISSIONING OF CHILLER
5.1 Preparing to Commissioning

Chiller/heater shall be commissioned by Shuangliang Service Co with the assistance of customer
5.1.1 Inspection of Exteriors and Installation Engineering

1. Check chiller for absence of severe vibration and shock, painting, cracking of hermetically
sealed pump, damage and deformation of control panel, inverter, instrument valves and cables,
check chiller raining damage or exposition to the open air for long time. Recover chiller, if there
are damages or deviations.
2. Check the installation, which should meet the requirements.
5.1.2 Inspection of External Conditions

5.1.2.1 Inspection of Chilled and Cooling Water Piping
1) Check piping system for cleanness, cooling tower, pond and outlet connections for foreign
matters.
2) Check piping system for drain and vent at the lowest and highest points of piping respectively.
3) Check the system for filter.
4) Check the piping system again the drawing. Check the piping for the correct direction and
position, piping system for its hanging, supporting to avoid the transmission of load to the end
covers of water boxes.
5) Check water systems for leakage, pumps and piping for vibration, flow rate to meet the
requirements. Install water treatment means, if poor water quality.
6) Check the piping system for thermometers, thermostats, flow switches, temperature sensors,
and pressure gages for their correct installation positions.
7) Check pumps for: a. Absence slackness of bolt connections; b. adequate amount of lubricating
oil and grease; c. leakage of water through sealing. It should be not form continuous line of
water; d. Check the correct operation electric current; E. Check the pump for normal pressure,
noise and motor temperature.
8) Check cooling tower for its correct type, water flow and reasonable temperature difference;
Check fan for its correct operation and electric current.
5.1.2.2 Inspection of Fuel Piping

1) Inspection of Fuel Oil piping. Check the piping for the safety requirements. Check the supply
and return piping for correct size and installation to ensure the maximum oil supply. (1) The
elements of piping shall be selected, sized and installed correctly. (2) Oil tank shall be installed
correctly with the specified fuel filled, no water contaminated, with good ventilation and
fire-fighting means provided. (3) Piping shall be checked against the leakage and washed. (4)
Piping shall be checked for the drain valve at the lowest point and bleed at the highest point of
piping. (5) Piping shall be checked for filter. (6) For the heavy fuel oil system, the heating
means and auxiliary light oil piping shall be provided.
2) Inspection of Gas Piping. The gas piping shall be checked for adjusting valve, ball valve, high
and low gas pressure switches, filter, gages, cut-off valves, which shall be selected, sized and
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installed properly according to the piping drawing. Piping shall be installed correctly. Sensing
and alarm means against the gas leakage shall be installed in the machine room, and
interconnected with the forced draft fan of machine room. Connected piping and elements shall
be proved tightly. Check the gas supply pressure by closing the cut-off valve at the inlet of gas
flow meter. The piping shall be purged by gas before ignition occurs, if it is worried, that the
gas in the piping is mixed with air.
3) Inspection of Burner. The burner shall be inspected according to the operation manual, wiring
drawing and piping installation as follows: (1) Check the burner for correct installation
according to the technical manual of burner. (2) Check the connections on the terminals of three
phased motor for correct direction of rotation. (3) Check, that the control wiring and power
supply cables are connected properly with the control panel according to the drawing. (4) All
the combustion control and safety protection means are connected and functioned properly.
4) Inspection of Flue Gas Piping. Check the flue gas piping against the provisions of installation
manual.
It is prohibited to use the fuel oil with flash point ≤ 40C° (such as the gasoline or fuel
oil manufactured with indigenous method)
5.1.3 Inspection of Vacuum Pump

1) Check vacuum pump oil for its correct type; check vacuum pump oil for its appearance, oil will
be emulsified, if it contains water.
2) Check vacuum pump for its correct rotation. Ensure the low purge valve of vacuum pump is
closed. Remove the plug from the sampling and purge valve, and cover the valve opening by
finger. Put the vacuum pump into operation. The pump is operated in the correct direction, if air
is socked through the valve opening. Change the motor cable connections, if it is rotated in the
wrong direction.
5.1.4 Inspection of Chiller for Air Tightness

The chiller has been tested for air tightness strictly before shipping. However, leakage is likely to
occur at some locations due to vibration and impact during transportation handling, and
installation. Chiller should be rechecked for air tightness prior to starting the commissioning first
under vacuum, and then under pressure, if the former is not satisfactory. The inspection of air
tightness is repeated to get the satisfactory results.
5.1.4.1 Leakage Detection under Vacuum
Close all valves, which are exposed to atmosphere. The chiller is evacuated by vacuum pump to a
pressure below 30Pa, if it is not tested in factory. Stop the vacuum pump, record local ambient
temperature t1 and read the absolute pressure P1 by McLeod gage. Record ambient temperature t2
and absolute pressure P2 in chiller after 24h. Calculate the pressure increase ( ∆P ) in the chiller
by the following formula, and shall not exceed 5Pa:
273 + t 2
∆P = P 2 − P1 ×
273 + t1
Chiller/heater, which had been tested in the factory, shall be tested for air-tightness by the air
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bubbles, that a rubber or plastic hose shall be connected with the discharge opening of vacuum
pump at one end, and inserted into the vacuum oil in a vessel at the another end. a) The vacuum
pump is tested for the limit of evacuation. b) If the limit of evacuation meets the requirements,
open the purge valves for condenser and absorber, then the upper and lower purge valves of
vacuum pump slowly to evacuate for 2 minutes, close the ballast valve of pump, and count the
number of bubbles per minute. The air-tightness of chiller/heater is normal, if the number of
bubbles in a minute is equal or less than 7. Repeat the test, if the number of bubbles in a minute is
more than 7. The chiller/heater shall be pressure tested for air-tightness, if the number of bubbles
not reduced in the interval of 2 hours, and kept in a rather big number.
5.1.4.2 Leakage Detection under Pressure

The chiller/heater is charged with nitrogen (for LiBr solution charged chiller only nitrogen is used)
to the pressure of 0.1~0.12Mpa (760-910mmHg)or oil free compressed air, and possible locations
of leakage for welds, valves, flange seals, sight glasses etc is covered by soap solution. Leakage
takes place while bubbling. Then vent nitrogen from chiller and repair by welding. After that, the
chiller/heater is rechecked under vacuum as mentioned earlier.
Gas is charged and vented normally by refrigerant sampling valve (refrigerant is bypassed, then
gas charged), or other valves, which communicate with atmosphere, if chiller/heater is not filled
with solution and refrigerant.
Before filling gas the purge valve of condenser and upper purge valve of vacuum
pump shall be opened.
5.1.5 Inspection of Control Elements and Electric Equipment

During transportation and installation of chiller the control elements and electric equipment is easy
to be damaged. So after installation, the chiller is checked for its completeness by the personnel of
Shuangliang Service Co.
1) Inspection of Field Wiring
Check the power and interlocking wiring of power source and its equipment (such as cooling
tower, pumps, and etc.)
2) Inspection of Chiller Control
Inspect the control panel for its intact, and correct wiring, data setting and installation of sensors
and flow switch.
5.1.6 Charging of Solution

LiBr solution is supplied with (0.10±0.02)% of lithium chromate or (0.010~0.0018)% of lithium
molybdate as corrosion inhibitor. pH value for LiBr solution mixed with lithium chromate has
been adjusted to 9-10.5, and concentration of (50±0.5)%. Alkalinity for LiBr solution mixed with
lithium molybdenum has been adjusted to 0.01~0.02, and concentration of (50±0.5)%. These data
should be reconfirmed before their charging into the chiller.
Solution is charged under negative pressure through solution charging valve at the discharge side
of solution pump. Before solution is charged, the weak solution regulating valve and intermediate
solution valve is opened. Evacuate the chiller down to absolute pressure in the chiller is lower than
35
100 Pa (or to the water vapor saturation pressure, equivalent to the ambient temperature, if the
chiller is charged with solution or water). Then, as shown in Fig. 5-1, connect the vacuum or
reinforced rubber hose to the connection of solution charging valve with vacuum grease from one
end, and hose is filled with solution. Emerge the hose into a vessel with solution of 0.6m3 from
another end. Open the solution charging valve and solution will be suck into the chiller. Keep the
end of hose under the solution surface in the vessel constantly, and adjust the valve opening to a
normal flow rate of solution.
Solution is charged in three portions. First charged solution about half the required amount. Then
the solution charging valve is closed and operate the solution pump to transfer solution into the HP
generator. Stop the solution pump, when the solution level in the HP generator is up to the high
level (inverter reduces its frequency output to 10Hz). Then charge the solution additionally 1/3,
and start the burner and solution pump make the solution circulated. Stop the burner and solution
pump, and charge the rest of solution, when the solution concentration shown on touch screen is
56%.
After charging of solution, start the vacuum pump to purge the chiller.
Solution is charged manually. Solution pump cannot be controlled by the inverter

under the PU conditions, but controlled by the control system. Before starting the solution
pump, the vacuum pump shall be checked for correct rotation.
5.1.7 Charging of Ethanol

Ethanol with content of about 0.3%(weight) of solution is charged in the similar manner as
solution.
5.2 Commissioning of Burner
The commissioning of burner is dependent upon the type of burner. Here only the
36
general requirements and basic procedure of commissioning of burners are described.
Reference should be made to the technical manual of applied burner. Burner should be
commissioned by trained personnel.
Burner is used to supply air and fuel, which will be burned completely under minimum coefficient
of surplus air. The burner should be started up under conditions of normal combustion of fuel,
normal operation with small fire and big fire, absence of cut off flame during transferring from big
fire to small and small fire to big, and to ensure maximum fuel and air required by the
chiller/heater.
Burner is provided with its own controller and control process for combustion, which is work
under the operation of control system of chiller/heater. Different type of burner uses different
commissioning procedure owing to the different construction and applied fuel, but provided the
same principle for commissioning: air consumption is minimized under the limits of reduced
emission (Content of CO ≤0.02%), i.e. the content of O2 in the exhaust gas is minimized (to
[3-5]% for light oil ) for maximized heat efficiency.
The CO2 and CO measuring gauge (gas analyzer) should be installed at the outlet of flue gas from
chiller/heater. For chiller/heater with 2 stage burner, the gas content is measured for the small and
big fire only. For burner with proportional regulation, there should be measured at least 3 points
evenly distributed between the small and big fire, except the small and big fire should be checked.
Commissioning of burner is carried out under the guidance of operation manual of burner. The
procedure of commissioning of burner is as follows:
1) Check the specification and type of burner in accordance with the piping system drawing of
burner;
2) Check the wiring of parts for burner;
3) Check the assembling dimensions of head parts of burner, and setting of position for
combustion head of burners of Italian Liaro company in accordance with maximum fuel oil and
gas consumption;
4) Select the manual control mode on the operation selection graph shown on the touch screen;
5) Check the fan motor for correct direction of rotation by means of its short starting (the rotation
of fan motor should be meet the direction of arrow on the fan case).
6) Set the air flow (by means of opening of register). Gas type chiller/heater should ensure that the
butterfly valve is closed when the burner is cut out.
7) The fuel manual supply valve should be opened.
For gas-fired chiller/heater, the maximum and minimum pressure switches should be adjusted to
the initial positions, and the air pressure switch at the zero position. The output pressure value
of pressure regulating valve should be set in accordance with the size of chiller/heater, heating
value of gas, gas supply pressure, and requirements of technical manual of burner (The output
pressure is increased when it turns clockwise, and only can be reduced, but not increased to
above the supply pressure).
8)Burner is set on small fire manually, and pre-purge will occur. At that time the oil pressure and
voltage applied on the solenoid valve should be checked. The voltage should absent on the
solenoid valve, otherwise the burner should be stopped, and wiring of burner should be checked.
Abnormal oil pressure should be corrected.
9)The burner should be ignited, when the pre-purge finished. The burner should be stopped, and
items 1-8 must be repeated, if the ignition cannot occur. For oil-operated chiller/heater, the
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burner should be stopped, and the flame of first stage should be re-adjusted by register (opening
will be increased or reduced accordingly), if the smoke is discharged or flame is not stable. For
gas-fired chiller/heater, the gas to air ratio can be adjusted during combustion of gas.
For primary start up of burner, the fuel pipe may be left with some air. So the
ignition should be repeated for several times. It should be re-adjusted, if it cannot be
ignited after several trials of ignition. During primary ignition or normal operation of
chiller/heater, the ignition will fail to work, if the flame detector cannot detect the flame.
Then the safety protection cutout switch and the interlocking switch operate, and
indicator FLAME CUTOUT lights. The chiller/heater can be started again, only when the
cause of trouble is determined, and reset switch is pressed manually. The chiller/heater
shall stop work at once to prevent the heat transfer tube bundles and flue gas channel
from carbon settling, if thick smoke occurs. The commissioning of chiller/heater can be
restarted, if fuel flow is reduced or air flow is increased.
10)After the small fire is ignited, the small fire should be changed to big fire. The register for big
fire should be adjusted, if the big fire is abnormal. The maximum gas and oil flow is adjusted
during big fire.
12)The burner should be stopped, and commissioning is finished.
For gas-fired chiller/heater, the air pressure switch, maximum and minimum gas pressure
switches should be set before the burner stops operation.
Setting of air pressure switch: During the burner operation with small fire, air pressure switch is
set by turning slowly the knob clockwise to cut the flame. Make reading of the position of knob,
and turn the knob anti-clockwise to about 20% of last reading. Then the burner is re-ignited to
check the correct setting. Turn the knob anti-clockwise a little further, if the burner cannot work
normally.
Setting of maximum gas pressure switch: During the burner operation with big fire, maximum
gas pressure switch is set by turning the knob of pressure switch anti-clockwise to cut the flame.
Make reading of the position of knob, and turn the knob clockwise by about 2mbar. Then the
burner is re-ignited. Turn the knob clockwise further by 1mbar, if the burner cannot work
normally.
Setting of minimum gas pressure switch: During the burner operation with big fire, minimum
gas pressure switch is set by turning the knob clockwise to cut the flame. Make reading of the
position of knob, and turn the knob anti-clockwise by about 2 mbar. Then the burner is
re-ignited. Turn the knob anti-clockwise further by 1 mbar, if the burner cannot work normally.
5.3 Commissioning of Chiller/heater

Chiller/heater shall be commissioned by trained personnel from Shuangliang Service Co. Ltd.
For the heating mode the commissioning of chiller/heater or its primary firing shall be
done with the heat transfer tubes and water heads of absorber filled by water. That means,
close the valves on the inlet and outlet of cooling water piping, open the connecting valves on
the water heads of evaporator-absorber and venting valves for the water heads of absorber
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and condenser to fill the heat transfer tubes of absorber and condenser. Close the venting
valves, when air discharged. Close the connecting valve of evaporator-absorber, when
pressure reaches about 0.3kg/cm2.
39
Chapter 6 OPERATION OF CHILLER/HEATER
6.1 Safety Protection Rules

1. In the machine room, the “Operation Procedure of Direct-Fired Lithium Bromide Absorption
chiller ”, instructed by Shuangliang Co., should be hung.
2. For machine room the strict rules of management and shift relief had to be formulated.
Unauthorized person is not permitted enter the room, and touch the safety devices. The chiller
cannot be operated independently by the personnel not trained by the Shuangliang Co.
3. The chiller should be confirmed to be without any leakage, which would influence the life
cycle of chiller. The chiller/heater is considered with leakage, if its working under cooling
mode is dependent on the running of vacuum pump or its working under heating mode features
abnormal increase of pressure over the normal value in the chiller/heater. Then the
chiller/heater should be checked for air tightness with nitrogen charged. The chiller/heater
should stop operation at once, if the air leakage is more than 60 Pa/48h. The chiller should be
maintained with periodically change of sealing elements by the ones of same type or same
material and with correct method.
4. The rust spots, especially welding connections, should be cleaned and painted, if the rust
occurs, otherwise the rust will cause the leakage. The machine room should be protected from
explosion by keeping the electric elements far from the paint, and the chiller is not working,
when it is painted. No corrosive, explosive and poisonous gas is permitted in the machine
room.
5. The safety devices are not allowed to be set over the permitted limits. The chiller/heater cannot
be started in case of potential trouble with the safety devices. The chiller should be operated
without any trouble.
6. The chiller/heater is shipped from manufacturer with the chilled water flow for the flow switch
set to the minimum allowed value. It is strictly forbidden to decrease the set value of flow
switch. It is strictly forbidden to start the chiller with the chilled water flow switch in trouble.
The chiller/heater is forbidden to operate with the vibrating piping.
7. It is not allowed to first shutdown the chilled/hot water pump, and then the cooling water
pump.
8. The chilled/hot water pump and air conditioning units should be stop only when the chiller is in
standstill.
9. Only nominated fuel can be used. It is prohibited to use the fuel oil with flash point ≤ 40C°
(such as the gasoline or fuel oil manufactured with indigenous method). The gas shall be
maintained with constant heat value (±3%) and constant supply pressure (±10%), otherwise the
black smoke will cause scale formation on the heat transfer tubes, even explosion casualties
will occur.
10.Before starting the chiller/heater, it should be checked for its normal situation and without any
leak of fuel. In the machine room with gas-fired chiller/heater, it is forbidden to open the main
gas valve, when the gas leak detector-alarm and interlocking mean are under question. Stop
chiller/heater, close the main gas supply valve, and find the area of leakage, if the gas or fuel is
smelled in the machine room.
11. The gas piping should be flushed by gas before ignition for starting the chiller/heater, if it is
suspected that the gas piping is mixed with air for any reason.
40
12.The machine room should be kept with good ventilation without clogged intake and discharge
openings. Open the damper in the fume piping, if it is provided.
13.For oil-fired chiller/heater, the oil filter should be washed once a day successively for three
days.
14.The nominated power supply should be used. No contact with switches, wires, elements and
high-tension wires for igniter of burner to prevent from electric shock. Power supply can be
cutout only when the chiller/heater is in standstill.
15.The chiller/heater is kept from risk by dripping water on the electric elements.
16.The operation of chiller/heater is forbidden with control panel opened.
17.The operation of chiller/heater is protected from harm the operational personnel by keeping
them from touching the high temperature parts, such as the HP generator, HT heat exchanger
and its piping (with temperature of 160℃) and the LP generator, LT heat exchanger, and its
associated piping.(with temperature of 90℃)
18.No heating operation of chiller/heater is allowed, if it has not operated for cooling mode before
19.No hot water of temperature up to 60℃ is permitted to flow through the chiller/heater, which
is in standstill, if several units are in parallel operation..
20.The chiller/heater should be checked and maintained strictly with the provisions of chapter 8
“Maintenance and Service”
21.Lithium bromide solution is not poisonous, but irritant, when it is mixed with other chemicals.
The machine room should be kept with good ventilation. The place dripped with solution
should be washed.
22.The machine room should be kept with temperature in the limits of 5-40℃, and relative
humidity less than 90%.
23.Before operation of vacuum pump the oil trap should be drained to empty once a month.
24.The battery for PLC and touch screen should be changed periodically (once for 3 years).
Change of battery should be finished in 5 minutes. For PLC, the battery should be changed in
the interval of 7 days of total standstill conditions of PCL to avoid loss of program, if the
ALARM on CPU lights, but the chiller/heater can be operated further. For touch screen, the
battery should be changed in the interval of 5 days of total standstill conditions of touch screen
to avoid loss of program, if the LOW BATTERY (in Japanese) lights, but the chiller/heater can
be operated further.
25.The chiller/heater is supplied with the interlocking functions, and it is recommended, that the
customer connect the start/stop circuits of chilled and cooling water pumps and cooling tower
fans with the control system of chiller to control the start/stop of pumps and fans by the control
system of chiller. At least the chilled and cooling water pump should be interlocked to stop the
cooling water pump first and then the chilled water pump, if they do not interlocked with the
chiller.
26.The chilled and cooling water piping should be designed and installed with valves at the piping
inlets and outlet from the chiller, and a piping with a valve bypassing the chiller is provided
before the valve to the inlet of chiller and after the valve from the chiller. In order to flushing
the piping, the valves at the inlets and outlets should be closed and valve on the bypassing
piping opened. After the operation, the inlet and outlet valves should be opened, and valve on
the bypassing piping closed.
27.The chiller/heater and pumps should be installed with filters at their inlets to be prevented from
41
the entering of foreign matters to the tubes of chiller, otherwise the degrading of performance
of chiller/heater and freezing of tubes will occur.
28.The chiller/heater should be installed on the fundament after the transport rack is removed. If
the conditions required that the chiller/heater will be installed with the rack, then the welded
angle sections or plates, which fixed the heat exchangers to the transporting rack, should be
removed. For some chiller/heaters, the low temperature heat exchanger welded to the rack by
angle section only at one end, and fixed to the evaporator-absorber from the another end. In
this instance, only the angle section should be removed.
29.Solution should be charged or transferred with less loss of it. The solution traces should be
cleaned from the ground and the chiller. The chiller should be repainted at the parts, where
paint is damaged.
30.For direct fired chiller/heater, the change-over from heating to cooling mode or from cooling to
heating should be realized, in addition to open/close the vapor and solution valves, by
regulating the fuel flow with the working condition of chiller/heater (the adjusting of burner
should be done in accordance with the instruction). For the chiller/heater with generator
enlarged for more than two sizes (including two sizes), the burners are supplied with two stage
nozzles. For cooling mode the small nozzle should be installed, and for the heating operation,
the big nozzle should be used.
31.For direct fired chiller/heater, the commissioning of burner should be done by Shuangliang
engineers. The burner should be adjusted with the gas analyzer to measure the CO and O2
contents in the gas to make the appropriate ratio of air to the fuel. The sensor of analyzer
should be put into the chimney from the chiller high pressure generator, and check the CO and
O2 content, while adjusting the fuel and air ratio. The CO volume content≤0.02%, and O2
volume content ≤ 3%-5% should be maintained. The operation instruction of gas analyzer
should be followed.
6.2 Procedure For Cooling Operation

6.2.1 Procedure of starting
1. The air breaker in the control panel is closed, and on the graph of “TROUBLE
MONITORING” the NO TROUBLE indicator lights (except the trouble of failure of chilled
water), and the graph can be switched to the “CHILLER/HEATER MONITORING”.
2. The chilled/hot water pump is started when the valve on the chilled/hot water pump outlet is
closed, and then to open the valve slowly to adjust the flow or pressure drop to the nominal
value.
3. The cooling water pump is started when the valve on the cooling water pump outlet is closed,
and then to open the valve slowly to adjust the flow or pressure drop to the nominal value.
4. Open the fuel inlet valve.
5. Press the key “SYSTEM START”, then the key “CONFIRMATION”, and finally the key
“RECONFIRMATION” on the “CHILLER/HEATER MONITORING”, to put the chiller/heater
into the operation condition.
6. Start the fan of cooling tower, and adjust the cooling water flow to control the cooling water
outlet temperature in the limits of 36-38℃.
7. Check the chiller/heater operation periodically, and take records every 2h.
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To decrease the flowrate of cooling water in case low cooling water temperature or
running at low load conditions
6.2.2 Procedure of shutdown

1. Press the key “SYSTEM STOP”, and chiller/heater will be put into operation of dilution.
2. Automatically shut down burner and manually close the fuel inlet valve for chiller/heater.
3. Automatically stop refrigerant pump when solution concentration detected is 58%.
4. When solution is diluted to 5%, delay 5min to automatically stop solution pump and cooling
water pump and afterward delay 3min to automatically stop chilled water pump
5. Cut the power supply from the control panel.
1. All refrigerant water should be bypassed from evaporator to the absorber during
shutdown, when the ambient temperature is less than 20℃, and the chiller/heater will
stand longer than 8h.
2. The chiller/heater is operated normally, when the safety device is checked periodically
and its normal working is guaranteed.
3. Check the chiller/heater in accordance with the provisions of this technical manual.
6.3 Procedure for Heating

6.3.1 Procedure of Starting
1. The air breaker in the control panel is closed, and on the graph of “TROUBLE
MONITORING” the NO TROUBLE indicator lights (except the trouble of failure of
chilled/hot water), and the graph can be switched to the “CHILLER/HEATER
MONITORING”.
2. The chilled/hot water pump is started when the valve on the chilled/hot water pump outlet is
closed, and then to open the valve slowly to adjust the flow or pressure drop to the nominal
value.
3. Open the fuel inlet valve.
4. Press the key “SYSTEM START”, then the key “CONFIRMATION”, and finally the key
“RECONFIRMATION” on the “CHILLER/HEATER MONITORING”, to put the chiller/heater
into the operation condition.
5. Check the chiller/heater operation periodically, and take records every 2h.
6.3.2 Procedure of shutdown
1. Press the key “SYSTEM STOP”, and chiller/heater will be put into operation of dilution.
2. Automatically shut down burner and manually close the fuel inlet valve for chiller/heater.
3. Delay 15min to automatically stop solution pump and afterward delay 3min to automatically
stop hot water pump
4. Cut the power supply from the control panel.
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1. All refrigerant water should be bypassed from evaporator to the absorber during shutdown,
when the ambient temperature is less than 20℃, and the chiller/heater will stand longer than
8h.
2. The chiller/heater is operated normally, when the safety device is checked periodically and its
normal working is guaranteed.
3. Check the chiller/heater in accordance with the provisions of this technical manual.
6.4 Operation Observation and Inspection

In order to ensure the normal operation of chiller/heater constantly, observation of chiller/heater is
required during its operation. All abnormalities should be removed, when their potential risk
occurs.
6.4.1 Cooling Mode

6.4.1.1 Observation of chilled/hot water outlet temperature
The chilled/hot water outlet temperature should be checked constantly. The cause should be fund,
if the chilled/hot water outlet temperature rises, and it is not the influence of ambient conditions.
The causes for poor performance of chiller/heater, such as the poor air tightness, the presence of
non-condensable gases, contaminated refrigerant water, crystallization of solution, less surfactant
additive (ethanol), scale formation on tubes, crack on the separator plates in the water boxes and
so on, should be closely analyzed.
6.4.1.2 Observation of cooling water
The cooling water outlet temperature from the chiller/heater should be measured, and controlled in
the limits of 36-38℃ by means of starting or stop the fan for cooing tower, adjusting the bypass
water valve or water flow.
Cooling water should be carefully be controlled for its pressure and temperature difference in the
inlet and outlet during operation. Analyze the cause, if they changed greatly. It may be the scale
formed on tubes or clogged tubes, if the other parameters are not changed significantly.
6.4.1.3 Observation of de-crystallization pipe
The de-crystallization pipe should be touched by the operational personnel to test is it hot. In
normal conditions, the piping end, which close to the absorber, can be touched by hand for a long
time period. The cause would be checked, if this end can be touched, but not for long time. This
cause should be removed, if this is the mark of potential crystallization. De-crystallizing measures
should be taken, if it is very hot, and there is potential crystallization on the strong solution side.
6.4.1.4 Inspection of vacuum condition of chiller/heater
The conditions should be analyzed, if the vacuum pump evacuates non-condensable gas constantly.
If the cause cannot be determined, then the air tightness of chiller/heater should be checked. The
heat transfer tube may be burst, or abnormal leakage occurs, if the pressure inside chiller/heater is
increased considerably. In this case the chiller/heater should be stopped immediately, and
chilled/hot water and cooling water system should be checked, and the chilled/hot and cooling
water system to be isolated from the chiller/heater, and the air tightness should be checked.
6.4.1.5 Inspection of firing
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Check the burner for normal combustion, flue gas and percentage of fuel to air; the start and stop
of burner in accordance with the program and without abnormal noise; stop the operation and
check the fuel system and burner immediately, if abnormality occurs (smoke and flame with
abnormal noise.). Check constantly the safeguard device for its normal working, the spark
clearance for ignition electrodes, the nozzles for absence of clogging, and no shock and explosion
during ignition. Clean constantly the receiving surface of flame detector and the insulation cable
between the detector and monitoring relay. Check regularly the gas stop valve for its tightness.
6.4.1.6 Inspection of noise and amperage of running hermetically sealed pumps
Contact with Shuangliang Service company to analyze the cause, if abnormal noise and amperage
is fund.
6.4.1.7 Adjusting the deviation of displayed values
Check if there is deviation in the displayed value with the actual value, and reset, if the deviation
occurs.
6.4.1.8 Other observations
1. Checking vacuum pump for absence of emulsification and dirty.
2. Checking the water pumps for absence of vibration and motors for overheating.
3. Checking the refrigerant water density in the first two weeks of cooling operation in a year.
4. Confirmation of the normal operation of safety devices at least once a year, and repair them, if
something happened with them.
6.4.2 Heating Mode

6.4.2.1 Observation of hot water outlet temperature
The hot water outlet temperature should be checked constantly. The cause should be fund, if the
hot water outlet temperature rises, and it is not the influence of ambient conditions. The causes for
poor performance of chiller/heater, such as scale formation on tubes, crack on the separator plates
in the water boxes and so on, should be closely analyzed.
6.4.2.2 Inspection of vacuum condition of chiller/heater
The chiller/heater should be purged before its put into operation, and the vacuum is checked
before operation of chiller/heater. The conditions should be analyzed, if the vacuum pump
evacuates non-condensable gas constantly. The heat transfer tube may be burst, or abnormal
leakage occurs, if the pressure inside chiller/heater is increased considerably. In this case the
chiller/heater should be stopped immediately, and the air tightness should be checked.
6.4.2.3 Inspection of firing
Check the burner for normal combustion, flue gas and percentage of fuel to air; the start and stop
of burner in accordance with the program and without abnormal noise; stop the operation and
check the fuel system and burner immediately, if abnormality occurs (smoke and flame with
abnormal noise.). Check constantly the safeguard device for its normal working, the spark
clearance for ignition electrodes, the nozzles for absence of clogging, and no shock and explosion
during ignition. Clean constantly the receiving surface of flame detector and the insulation cable
between the detector and monitoring relay. Check regularly the gas stop valve for its tightness.
6.4.2.4 Inspection of noise and amperage of running hermetically sealed pumps
Contact with Shuangliang Service company to analyze the cause, if abnormal noise and amperage
is fund.
6.4.2.5Adjusting the deviation of displayed values
45
Check if there is deviation in the displayed value with the actual value, and reset, if the deviation
occurs.
6.4.2.6 Other Checks
1. Check vacuum pump for absence of emulsification and dirty
2. Check water pumps for absence of vibration and motors for overheating
6.5 Purge Operation
Vacuum is vital for normal operation of chiller/heater. The vacuum (the quantity of
non-condensable gas) of chiller/heater determines the operation performance and the life cycle of
chiller/heater. The purge units are provided to improve the vacuum keeping capacity of
chiller/heater. As shown in Fig.6-1, purge unit is operated automatically and manually. Purge is
carried out with the sampling purge valves and pressure measuring valve is closed, and other
valves operated in the following manner.
1- Purge valve for condenser
2- Purge valve for evaporator
3- Purge valve for absorber
4- Auto-purging unit
5- Upper purge valve of vacuum pump
6- Pressure measuring valve
7- Lower purge valve of vacuum pump
8- Sampling purge valve
9- Vacuum pump
10- Auto-purging discharge pipe
11- Gas box connection pipe
12- Pressure sensor 13- Gas box
14- Oil trap 15- Oil drain plug
16- Cooler water inlet valve
Fig. 6-1 Purging System
6.5.1 The purge of new chiller/heater or chiller/heater after service and maintenance
The new chiller/heater or chiller/heater just after maintenance, which has the internal pressure
higher than the atmospheric pressure, should be vented to the atmosphere through pressure
sampling valve until the internal pressure is equal to atmospheric. The chiller/heater can be vented
to atmosphere through other valves, if there is no LiBr solution and water in it.
The first starting-up of new or maintained chiller/heater is carried out with evacuation of
non-condensable gases by vacuum pump. (1) Confirm that the pressure measuring valve,
refrigerant sampling valve, solution charge valve and sampling valve for strong solution, which
are vented to atmosphere, are closed. (2) Measure the limiting capacity of vacuum pump. (3)
When the requirements are met, close sampling purge valve, open fully the purge valves of
condenser and upper purge valve of vacuum pump, open slowly the lower purge valve of vacuum
pump, and start vacuum pump to evacuate the chiller/heater. Open fully the lower purge valve,
when the vacuum is created in the chiller/heater. (4) Close purge valves of condenser, upper purge
valve of vacuum pump and lower purge valve of vacuum pump, and stop the operation of vacuum
pump, when the vacuum in the chiller/heater is lower than 100Pa, and no solution is left in the
chiller/heater. (5) If the chiller/heater is left with solution, a rubber or plastic hose shall be
connected with the discharge opening of vacuum pump at one end, and inserted into the vacuum
46
oil in a vessel at the another end. Then close the ballast valve of pump, and count the number of
bubbles per minute from the oil. Close purge valves of condenser and upper purge valve of
vacuum pump, lower purge valve of vacuum pump and stop the operation of vacuum pump, if the
number of bubbles in a minute is equal or less than 7. (6) During evacuation of non-condensable
gases from chiller/heater under its cooling mode, the purge valve of condenser shall be closed,
when condensation temperature is lowered to less 1°C than that of cooling water outlet
temperature from condenser. Close the upper and lower purge valves of vacuum pump, and
shutdown the vacuum pump, when weak solution inlet temperature to LT heat exchanger is 1°C
higher than that of cooling water outlet temperature from absorber.
Evacuate the chiller/heater in the same manner, when the chiller/heater is purged not for the first
time, and the vacuum is not as fair as normal.
6.5.2 The purge of chiller/heater during normal operation
During the operation of chiller/heater, usually the automatic purge unit is operating.
Non-condensable gases will be purged and stored in the gas cylinder (The purge valve for
absorber is normally closed). Open the purge valve for condenser, when condensation temperature
defers from the cooling water outlet temperature from condenser more than 1.5-2 °C, and close
that valve, if the temperature difference is 1°C only.
The purge valve of condenser is normally closed.

When high pressure alarm of automatic purge unit occurs , the operator shall inform about this
situation to the service engineer from Shuangliang Service Co. In this case non-condensable gases
from gas cylinder are evacuated by vacuum pump only with permission of Shuangliang service
engineer in the following manner. Measure the limiting capacity of vacuum pump to meet the
requirements, close sampling purge valve, open slowly lower purge valves of vacuum pump to
evacuate the unit After 5 min close the lower purge valve of vacuum pump, and stop the vacuum
pump.
When the cooling capacity of chiller/heater is decreasing owing to poor vacuum in it, the operator
shall also inform about this situation to the service engineer from Shuangliang Service Co. In this
case non-condensable gases are evacuated by vacuum pump only with permission of Shuangliang
service engineer in the following manner. Measure the limiting capacity of vacuum pump to meet
the requirements, close sampling purge valve, open slowly lower and upper purge valves of
vacuum pump to evacuate the unit (Open the purge valve for condenser, when condensation
temperature defers from the cooling water outlet temperature from condenser more than 1.5-2 °C,
and close that valve, if the temperature difference is 1°C only). Close the upper and lower purge
valves, and stop the vacuum pump operation.
When the chiller/heater is shutdown for maintenance, it is evacuated in the following manner.
Measure the limiting capacity of vacuum pump to meet the requirements, close sampling purge
valve, open slowly lower and upper purge valves of vacuum pump and purge valve for condenser
to evacuate the unit. A rubber or plastic hose shall be connected with the discharge opening of
vacuum pump at one end, and inserted into the vacuum oil in a vessel at the another end. Then
close the ballast valve of pump, and count the number of bubbles per minute from the oil. Close
all the valves, which were opened during evacuation, if the number of bubbles in a minute is equal
or less than 7.
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In cooling mode, cooler water inlet valve shall be always open and evaporator purge valve shall be
always closed.
In heating mode, during normal operation auto-purging system will function to purge
non-condensable gas and cooler water inlet valve and other valves in purging system except
evaporator purge valve shall keep always open. When pressure inside gas cylinder reaches set
valve (saturated pressure at hot water outlet temp. +2.666KPa (20mmHg)) of auto-purging system
in heating mode, control system will show a graph to remind operator to start vacuum pump for
gas evacuation and close cooler water inlet valve. After 15min start vacuum pump. Operation
procedure as follows: start vacuum pump and 1min later slowly open vacuum pump lower purge
valve and 5min later close vacuum pump lower purge valve and shut down vacuum pump.
Afterward, open cooler water inlet valve and continue to use auto-purging unit.
When draining water from chilled/hot and cooling water system via methods described in clause
8.2, traps equipped on inlet/outlet of solution cooler should be open to drain water from solution
cooler and its water inlet/outlet piping.
When purging operation in heating mode, cooler water inlet valve must be closed
before start of vacuum pump to prevent solution being evacuated outside.
1. During purge operation, the lower and upper purge valves of vacuum pump shall be
opened slowly to protect the vacuum pump from spraying of oil or other failure due to
high evacuation rate.
2. During purge operation the ballast valve for vacuum pump should be opened, to avoid
the emulsification of oil. Emulsified white oil for vacuum pump should be changed.
3. The oil trap shall be thoroughly drained in predetermined period
6.6 Management of Refrigerant Water

During operation of chiller/heater the LiBr solution droplets from HP generator or LP generator
may be carried into the refrigerant water into the condenser or evaporator by the refrigerant vapor.
The refrigerant is contaminated, if it contains LiBr. The chiller/heater performance will be
degraded with the contamination of refrigerant water, and even had to be shutdown, when a lot of
LiBr is carried into the refrigerant. So the refrigerant density should be measured periodically
during operation of chiller/heater. Refrigerant needs to be regenerated, when it contaminated.
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6.6.1 Sampling and measuring the refrigerant water
Fig.6-2 Refrigerant sampling

1) As shown in Fig. 6-2, the sampler is connected to the sampling purge valve of purge system by
vacuum rubber hose with the connections covered by vacuum grease.
2) Start vacuum pump and open the sampling purge valve to evacuate the sampler for 1-3 min.
3) Open the sampling valve for refrigerant water, it will flow into the sampler.
4) When appropriate quantity of refrigerant water is taken, close the refrigerant sampling valve,
then close the sampling purge valve, and last stop the vacuum pump.
5) Pour refrigerant water out of sampler into a 250mL cylinder, and measure the relative density of
refrigerant water by hydrometer with scale of 1.0-1.1.
Sampling and density measuring of refrigerant is preferred to use the sampler and
cylinder, which is not used for solution. Or the sampler and cylinder had to be washed by
clean water and no drop of water is left, when the same sampler and cylinder is used for both
refrigerant and solution. Sampled refrigerant water should be placed separately.
6.6.2 Regeneration of refrigerant water
The regeneration of refrigerant is carried out, when the chiller/heater is operating.
The refrigerant is to be regenerated, while it is contaminated to density of 1.04g/ml. In this case,
the chiller/heater is operated with part opening of bypass valve, i.e. the chiller/heater is working
for refrigeration and regeneration of refrigerant water at the same time. The process is repeated to
the normal density (≤1.002g/ml) of refrigerant water.
6.7 Management of Lithium Bromide Solution
Lithium bromide solution is corrosive to the construction material of absorption chiller/heater. For
protection of chiller/heater from corrosion, the solution should be added with inhibitor, and
controlled in the limits of 9-10.5 for its pH value. Contamination of solution with products of
corrosion will cause clogging of holes in distributor of absorber, and the lubricating and cooling
piping for the pumps, which will bring influence to the operation performance and life cycle of
absorption chiller/heater. So the solution should be sampled and measured periodically during the
49
operation of chiller/heater, and measures should be taken to treat the solution in accordance with
the results of measures. The weak solution is sampled normally, and strong solution is sampled
only when its concentration is measured.
6.7.1 Sampling of LiBr solution
Sampling of solution is carried out for weak and strong ones in the similar way as for the
refrigerant water. The solution sample is taken from the charging valve at the discharge side of
solution pump and the sampling valve at the solution distribution box located at the bottom of
shell of chiller/heater.
The weak solution sample is taken with the sealing plug removed from the charging valve, and the
Rubber hose connection, which is delivered with the chiller/heater, shall be installed. The
connection shall be removed, when the solution sample had been taken. Then the sealing plug
shall be installed to ensure the secondary sealing of valve.
6.7.2 Inspection of LiBr solution
6.7.2.1 Inspection of concentration of solution
Pour the solution in the 250mL cylinder. Measure the concentration of solution by Baume
hydrometer. The concentration of solution can be determined by the graph with the measured
temperature and specific gravity, measured thermometer and hydrometer respectively. Contact
with Shuangliang Co., if solution concentration is considerably different in comparison with the
primary measured value.
6.7.2.2 Visual inspection
The solution quality i.e. the foreign matter and consumption of inhibitor, can also be determined
visually by the color of solution. The visual inspection will be carried out after sampling by
several hours. The inspection results should be compared with the Table 6-1. The final results shall
be given by Shuangliang Service Co.
Table 6-1 Visual control
Item Condition Result
Color Light yellow A lot of inhibitor is consumed.
Colorless Inhibitor consumed considerably.
Black A lot of ferric oxide is in the solution, and
inhibitor consumed.
Green The corrosion product copper oxide is in
the solution
Floating matter Very few No problem
Rust scale A lot of ferric oxide
Precipitate matter Considerable A lot of ferric oxide
6.7.3 pH value
In order to control the corrosion in the chiller/heater, the pH value should be controlled in the
limits of 9-10.5. The solution with pH value not in these limits should be adjusted. The solution is
shipped from factory with the pH value in the above limits. With the operation of chiller/heater,
the pH value will be increased. The pH value of solution should be checked periodically by
universal pH value test paper, and the results should be recorded. If the pH value is too high,
hydrobromic acid (HBr) may be added; if it is too low, lithium hydroxide (LiOH) may be added.
The hydrobromic acid and lithium hydroxide shall be suitably diluted prior to their additions to the
chiller/heater, and with appropriate rate. They can be added in such a way: take a part of solution
and pour it in a vessel, then add the lithium hydroxide or hydrobromic acid, which is diluted with
50
6 times of pure water. They should be mixed evenly.
The adjustment of pH value and addition of this matter is rather complex, and is
preferred under the instruction of qualified engineer from Shuangliang Service Co.
6.7.4 Inhibitor
In order to control the corrosion of LiBr solution to the chiller/heater, the solution is added with
inhibitor in the predetermined concentration of (0.10±0.02%) for lithium chromate and of
(0.010~0.018%) for lithium molybdate. In the process of operation, especially in the beginning
period, the inhibitor is consumed rather rapidly. The Content of inhibitor in the solution should be
checked periodically by the special laboratory. The inhibitor content should be kept in the set
limits, when its content is out the limits.
Direct addition of inhibitor in the chiller/heater is forbidden. It is added by taking a part of
solution (10 times of inhibitor) from the chiller/heater, mixed with the inhibitor slowly to even
distribution, and then the mixture is added to the chiller/heater. After the inhibitor is added, the
chiller/heater should be operated to make its even distribution in the solution.
The addition of inhibiter is rather complex, and is preferred under the instruction of
qualified engineer from Shuangliang Service Co.
6.7.5 Ethanol
Ethanol is used to improve the chiller/heater performance. The content of ethanol in the solution is
0.1-0.3%. Ethanol should be added, when the content in the solution is lower than this value. The
inadequate ethanol can be determined by two ways: the one is the chiller/heater performance is
deteriorated; the second is absence of irritant odor from the solution, or no irritant odor from the
vacuum pump discharge.
Ethanol is added in the similar way as for solution through the charging valve or sampling valve
under negative pressure.
6.7.6 Regeneration of LiBr solution

The LiBr solution should be regenerated, when the content of solution is changed from the normal
value. The regeneration of solution should be done with the assistance of Shuangliang Co. During
regeneration of solution the chiller/heater is charged by nitrogen to positive pressure to discharge
the solution from the chiller/heater. The solution is treated by sediment or filtering outside the
chiller/heater, or filtered in the chiller/heater, while it is in operation.
6.8 Management of Water Quality

6.8.1 Management of cooling water
During operation of chiller/heater, cooling water outlet temperature is preferred be kept in the
limits of 36-38℃. Cooling water temperature can be regulated by variation of speed of pump
motor, or by changing the opening of valve on the bypass pipe between the water inlet and outlet
of cooling tower.
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Dirty in cooling water causes not only reduction the performance of chiller/heater by the scaling of
heat transfer tubes, but also shortening the life cycle of tubes by their corrosion. During operation
of chiller/heater, cooling water should be sampled and analyzed. The quality of cooling and
makeup water should meet the requirements of Table 6-2. Water should be treated, if it cannot
meet the requirements.
Table 6-2 Water quality standard
Item Unit Makeup water Cooling water Tendency
Corrosion Scaling
Basic pH value(25℃) 6.5~8.0 6.5~8.0 ○ ○
Items electric µS / cm <200 <800 ○ ○
conductivity(2
5℃)
chloric ion Cl- mg Cl-/L <50 <200 ○
sulfuric acid mg SO4 /L 2− <50 <200 ○
radical ion
SO42−
acid mg CaCO3/L <50 <100 ○
consumption
rate(pH4.8)
Total hardness mg CaCO3/L <50 <200 ○
Reference Iron Fe mg Fe/L <0.3 <1.0 ○ ○
Items sulfuric ion S2- mg S2-/L undetectable undetectable ○
ammoniac ion mg NH 4+ /L <0.2 <1.0 ○
NH 4+
silicon dioxide mg SiO2/L <30 <50 ○
SiO2
Bad cooling water quality not only causes scale formation in heat transfer tubes,
influences heat exchange efficiency and reduces the performance of chiller/heater, but also
corrodes heat transfer tubes and leads to major failure of chiller/heater.
6.8.2 Management of Chilled/Hot Water

Chilled/hot water system can be opened or closed. Soft water is preferred, if closed system is
adopted. For opened chilled/hot water system, it is managed as for the cooling water system.
6.9 Operation of Vacuum Pump

Vacuum pump is vital equipment to keep the chiller/heater under vacuum condition. It is important
to ensure the reliability of vacuum pump. The vacuum pump should be maintained in the
following manner. For more information, see Operation manual of vacuum pump.
1. Before the primary startup of vacuum pump, it should be started for very short period to
determine whether the direction of rotation of pump meets the indicated direction. This can be
determined also by the gas, discharged from the pump outlet. The checking of pump rotation
can be done after the vacuum pump oil is charged.
2. Vacuum pump oil is charged or changed while the pump is shutdown to avoid the damage of
pump and splashing of oil.
3. The vacuum pump should be start/stop repeatedly for short time to avoid damage the pump by
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the loading from direct starting, if it is under long-term shutdown.
4. To reduce the emulsification of oil, vacuum pump should be operated under opened ballast
valve.
5. For long time evacuation and avoiding the oil emulsification, the vacuum pump should be
operated idly to warming up, then open the purge valve. Before shutdown the vacuum pump, it
also needs to work idly for a while to discharge the water vapor, which mixed with the oil.
6. The vacuum pump oil should be checked constantly for oil level and preventing the oil
emulsification. The oil level should in the middle of sight glass, and drain the emulsified oil or
water drops by screwing out the plug on the bottom of oil box, if the oil is milk white. Then
appropriate amount of oil should be added. Oil should be changed and washed, if it is too dirty.
7. If lithium bromide solution comes into the vacuum pump due to accidental operation, then
contaminated oil should be drained and pump washed by running the pump repeatedly for a
short time to discharge out the rest of solution. Wash vacuum pump, if condition allows.
Remove and clean the vacuum solenoid valve from the piping, if it is installed.
8. Vacuum pump should be checked for its attainable limiting vacuum in the following. (1)
Remove the sealing plug from the purge valve, and connect Macleod gauge to the sampling
purge valve with vacuum grease by means of rubber hose. (2) Take off the sealing plate from
the oil trap and rubber hose connection from vacuum pump, connect the vacuum pump with oil
trap. (3) Run vacuum pump for 3 min, then open slowly sampling purge valve and measure the
pressure by Macleod gauge. Vacuum pump is satisfactory, if the pressure is less than 30 Pa.
Otherwise, the vacuum pump shall be checked till satisfactory results are obtained.
6.10 Operation of Valves

6.10.1 Ball Valves (Steam and Solution Heating Valves)
The two ball valves are used to change the operation mode of chiller/heater from cooling to
heating and vice versa. When this occurs, remove the secondary sealing cover from valve, turn the
valve by spanner to open or close it, then install the secondary sealing cover applying sealing
adhesive.
6.10.2 Stop Valve

6.10.2.1 Description of Operation of Stop Valve
The valve construction is shown in the Fig.6-3-1 and 6-3-2. Here followed the methods of opening
and closing the valve, and changing the sealing ring, valve plug and others. The working principle
and description of construction of valve are included in the “Operation Instruction of Welded
Special Valves”. For the allowable torque of valve stem, see torque wrench operation.
1. Method of Opening The Valve
1)Remove the upper hood, check and tighten the press-cup (turn the press-cup in anti-clockwise
for tightening).
2)Turn the valve stem in anti-clockwise by wrench to open the valve.
3)Install the press-cup on place with the Loctite at the threads, and tighten the hood.
53
1
1- Upper hood
2
2- Press cup
3
3- O ring
4
4- Valve stem
5- Valve plug
6- Valve body
5
6
Fig. 6-3-1 DN10/1 and DN25/1 type stop valve
1 1- Upper hood
2
3 2- Press cup
1 4 3- O ring
2 5 4- Valve stem
3 6
5- Valve plug
4
6- Valve body
5
6
Fig. 6-3-2 DN25/II type stop valve

2. Method of Closing The Valve
1) Remove the upper hood.
2) Adjust the setting value of torque wrench to the permitted torque for the valve.
3) Turn the valve stem in clockwise by wrench to close the valve.
4) Check and tighten the press-cup (turn the press-cup in anti-clockwise for tightening).
5) Install the press-cup on place with the Loctite at the threads, and tighten the hood.
1. For the purging, charging, refrigerant probe, concentrated solution probe and
pressure measuring valves, which led to the atmosphere, block is inserted into the
valve. Operate these valves after taking out the block, and insert the block on the
Loctite after operation.
2. For probing the weak solution through the charging valve, after the block had been
taken away, the valve outlet should be connected with intermediate part supplied
with the chiller, and then operate. After the probe had been taken, remove the
intermediate part, and install the block on the Loctite.
3. Method of Changing The Sealing Ring or Valve Plug
1) Remove the upper hood.
2) Turn clockwise the press-cup to remove it. (Loosen the fitting screw, if it is provided.)
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3) Take out the valve stem from the valve body, and change the O-ring or under part of stem (with
valve plug).
4) Install the valve stem into the valve body with the O-rings covered with vacuum grease.
5) Tighten the press-cup anti-clockwise, and turn the valve stem by torque wrench to adjust the
valve by closing and opening it.
6) Install the press-cup on place with the Loctite at the threads, and tighten the hood.
4. Troubleshooting
No Trouble Cause Measure
The valve stem Seizing of upper driving thread Remove press-cup, take out
cannot be turned. of valve stem valve stem, repair the driving
1
thread. Change the valve stem, if
the thread cannot be repaired.
Scratch at the surface of valve Change the under part of valve
plug stem (with the valve plug).
2 Leaking of sealing
Damage at the hole surface of Change the valve.
scratch at the sealing surface.
3 Leaking of O-ring Damage or aging of O-ring Change O-ring.
6.10.2.2 The Operation of Torque Wrench

The FDN 100 type torque wrench is used with overall length of 380mm, torque limits of
20-100Nm, torque tolerance of ±4%. The overall view of torque wrench is shown on the Fig.6-4.
Fig. 6-4 Torque wrench

1) Allowable torque limits for the valve stem
Allowable torque limits for the valve stem is 60Nm for type DN10/I; 35Nm for type DN10/II; and
70Nm for type DN25.
2) Preset torque
Turn the handle, the dial disk will be revolved accordingly, stop at the place, where the required
torque is at the red division on the dial disk. Then fix the torque by turning the rear cover in the
direction of arrow to stop.
3) Force applying
Apply the wrench with preset torque to the valve stem, turn it in the direction “↓” smoothly. The
valve is closed, when “click” sound is taken place, or the hand feeling became different than
before. The operation is finished at this moment. Stop applying force, and keep the original
position of wrench.
4) Storing
After the operation, the torque setting should be restored to the minimum value for store the
wrench.
5) Note:
1. The wrench can be applied only in the direction of “↓”.
2. Never use the wrench over the allowable torque.
3. Never disassemble the wrench by yourself.
55
Chapter 7 TROUBLESHOOTING
7.1 Shutdown of Chiller/heater due to Troubles

During operation of chiller/heater, control system will check the running conditions of different
parts of chiller to judge if chiller is running in normal conditions. The control system will
automatically solve the 3 type troubles shown below. For troubleshooting process, see Fig.4-4.
1) If any abnormal phenomena below occurs, chiller will be unloaded firstly. If chiller system still
does not turn well after 10-minute unloading, control system will alarm immediately and
automatic shut down chiller after turning into dilution operation.
(1) Failure of cooling water;
(2) High HP generator pressure;
(3) Low cooling water temperature;
(4) High de-crystallization pipe temperature;
(5) High flue gas temperature;
(6) High HP generator solution temperature
2) When overflow of refrigerant water pump occurs, chiller will alarm immediately and shut down
after turning into dilution operation. When overflow of vacuum pump occurs, chiller will alarm
immediately. When cylinder gas pressure reaches set valve, a graph will appear automatically on
the graph of operation monitoring on the touch screen showing “High pressure in chiller
auto-purging unit, please start vacuum pump”. The operator may start purge according to methods
introduced in “6.5 Purge Operation”.
3) When any following severe trouble occurs, chiller will alarm instantly and shut down
emergently.
(1) Failure of chilled water
(2) Trouble in inverter;
(3) Low chilled water temperature
(4) Low refrigerant water temperature;
During automatic shutdown of chiller/heater, the operator should press key “TROUBLE
MONITORING” on the graph of operation monitoring on the touch screen to make the alarm
silent and search for the cause of trouble and its shooting. Operator should remove the cause of
trouble immediately after the trouble occurs, and then start again the chiller/heater.
7.2 Common Troubles and Their Shooting
7.2.1 Troubleshooting for Electrical System

Table 7-1 Troubleshooting for Electrical System
No Trouble Measure
1 No power supply for 1. Check the availability of power to the chiller.
control system 2. Check the air breaker of the control panel to the power at its
input and output sides.
3. Check the single-pole switch of control loop for the control
panel to the power at its input and output sides.
4. Check the power supply of control elements and apparatus in
accordance with the electrical principal circuit.
56
2 Trouble of control 1. Check the normal input of control elements and apparatus.
elements and Check the normal conditions of three phase and control power
apparatus supplies for contactors. Check the power supply and electrode
circuit of level controller.
2. Check the output of control elements and apparatus, for
instance the output of three-phase power supply, the output
signals of high and low level output signals of level controller.
3. Check other control circuits, such as the control signal from
the PLC to the controllers, and etc.
4. Check the function of elements and apparatus in accordance
with their instructions.
3 Trouble of touch 1. Check the fixing of communication and power lines. Check the
screen batteries of touch panel (which should be changed every 2
years).
2. Check the touch panel according to the troubleshooting
instruction.
4 Trouble of PLC 1. Check the elements and apparatus step by step, including the
(ERROR light up) PLC controller, the power supply of controller, the input/output
modules, base plate and PLC batteries (for every two years).
2. Check the PLC according to the operation instruction.
5 Trouble of external 1. Check the fixing of connection lines and the situation of
measuring elements circuits (Connect new lines from sensors to the control panel,
and measure the output of sensors).
2. Check the installation situation of sensors (such as the
blockage of pressure sensing hole for pressure sensors, and the
damage of target plates of flow switches)..
6 Trouble of external 1. Check the correct connection of circuits and control signal.
actuating elements 2. Check the actuating elements according to the instruction.
7.2.2 Troubleshooting for chiller/heater

Table 7-2 Common Troubles and Their Shooting
No Trouble Cause Troubleshooting
1 Chiller/heater cannot be 1) No power to control panel. 1) Check main power supply
started. 2) Switch for control power and air breaker
supply is OFF 2) Put the control switch and
main air breaker ON.
2 Poor vacuum 1) Leakage in chiller/heater. 1) Leak test and remove the
2) Poor performance of vacuum leakage.
pump and trouble in purge 2) Check the vacuum pump for
system performance, and remove the
trouble in the purge system.
3 Cooling capacity is lower 1) Poor vacuum 1) See No.2
than design value.(cooling 2) High cooling water inlet 2) Regulate cooling water bypass
mode) temperature. valve, check the controller for
3) Less cooling water flow. cooling water inlet
4) Scale or clogging of heat temperature, check cooling
transfer tubes by foreign tower and its fan.
matter 3) Check the valve opening and
5) Inadequate fuel combustion. filter cleanness in the cooling
6) Heating solution valve and water system, check the
heating vapor valve closed not cooling water pump.
completely. 4) Clean heat transfer tubes.
7) Refrigerant water 5) Check fuel combustion
contaminated. system, and increase heat
8) Too much or too less sprayed supply.
refrigerant water. 6) Check these valves.
57
9) Too much refrigerant water. 7) Sampling refrigerant water,
10) Inadequate Ethanol in and regenerate it, if density is
solution. greater than 1.04.
11) Less charge of solution. 8) Close refrigerant bypass valve,
12) Less circulating rate of reduce or increase the opening
solution. of spray valve.
13) Low chilled/hot water outlet 9) Drain refrigerant water.
temperature. 10) Add ethanol.
14) Less cooling load for user. 11) Add appropriate amount of
solution.
12) Regulate weal solution
regulating valve to meet the
requirements.
13) Cooling capacity will be
reduced with the reduction of
chilled water outlet
temperature. Set the nominal
chilled water outlet
temperature.
14) It is normal for automatic
control of cooling capacity.
4 Heating capacity is lower 1) Inadequate fuel combustion. 1) Increase fuel combustion.
than design value (Heating 2) Scale formation on tubes. 2) Clean tubes.
mode) 3) Low load from customer. 3) Normal for automatic control
of chiller/heater.
4) Low hot water flow. 4) Increase hot water flow.
5 Chilled/hot water 1) Cooling (heating) capacity is 1) See No.3 or No4.
temperature difference is less than designed value.
less than nominal value. 2) Chilled/hot water flow is 2) Reduce the flow accordingly.
greater than nominal value. Correct the display deviation.
3) Displayed temperature is not
correct.
6 High chilled water outlet 1) Cooling (heating) capacity is 1) See No.3 or No.4.
temperature or low hot less than designed value. 2) Reduce cooling load
water outlet temperature 2) Too great outside load. accordingly.
3) Set the nominal value.
3) Set value is too high (for 4) Reduce the water flow.
cooling mode),or too low (for
heating mode)
4) High chilled/hot water flow.
7 Contaminated refrigerant 1) Too big solution circulating 1) Regulate weal solution
water rate and high solution level. regulating valve to meet the
(for cooling mode) 2) Too big solution charge. requirements.
3) Low cooling water 2) Drain part of solution.
temperature. 3) Regulate cooling water
4) Too high chilled waster outlet bypass valve; check
temperature. controller of cooling water
5) Too much combustion heat inlet temperature.
supply. 4) See No. 6
6) Poor quality of solution. 5) Regulate combustion heat
supply.
6) Sampling solution, and
analyze, change solution
with more reliable quality.
8 Crystallization during 1) Air leakage or a lot amount of 1) Purge chiller/heater by
startup non-condensable gas in vacuum pump.
58
chiller/heater. 2) Regulate cooling water
2) Too low cooling water inlet bypass valve to increase
temperature. temperature. Check controller
3) Overloaded. of cooling water inlet
temperature.
3) Increase load slowly for
startup.
9 Crystallization during Inadequate dilution Check the set value for dilution
shutdown and actual situation.
10 Crystallization during 1) Non-condensable gas in 1) Purge chiller/heater by
operation chiller/heater. vacuum pump.
2) Too less solution circulation 2) Regulate weak solution
rate. regulating valve.
3) Too big heat supply. 3) Reduce heat supply.
11 Sudden shutdown during 1) Failure of power supply or 1) Check power supply to
operation loss of phase line. restore it.
2) Safety protection system 2) Remove the cause of
works. troubles, and restore the
a. Abnormal inverter. normal operation:
b. Failure of chilled water a. Check and repair inverter and
c. Other troubles solution pump. See No. 25
b. See No. 19
c. Press “TOUBLE
MONITORING” button on
operation monitoring graph on
chiller touch screen to know
trouble reasons and ways of
troubleshooting.
12 Flame cutout during small 1) Manual fuel supply valve had 1) Open the fuel supply valve.
firing or ignition not opened. 2) Check fuel supply and
2) Abnormal gas supply pressure regulating valves.
pressure. 3) Check and regulate.
3) Not correct set the flap or 4) Open more the flap.
fuel supply valve. 5) See the technical manual of
4) Inadequate air supply for burner.
fuel.
5) Troubles in burner for a lot of
causes.
13 Abnormal flame from 1) Incorrect assembling 1) Adjust in accordance with the
burner dimensions for details of burner technical manual for burner.
head. 2) Adjust the air and fuel
2) Air or fuel amount is not amount.
correct. 3) Clean the burner from ash
3) Formation of ash on the and carbonization.
burner head. 4) Clean or replace.
4) Clogged burner nozzle. 5) Clean.
5) Clogged filter.
14 High outlet temperature of 1)High pressure and temperature 1) See No. 15.
flue gas of HP generator. 2) Clean the heat transfer tubes.
2)Formation of ash in the flue 3) Adjust the air supply.
gas heat transfer tubes.
3)High air amount for burner.
15 Black smoke 1) The proportion of air to fuel is 1)Adjust the combustion
not correct. carefully by increasing the
2) The atomizing disk had not opening of air flap and see the
been adjusted correctly. technical manual of burner.
59
3) Not the correct nozzle had 2)Contact Shuangliang Service
been chosen. Company to readjust the
4) The type of fuel is not correct. combustion.
3)Chose the other ones, or
contact Shuangliang Service
company.
4)Change the sort of fuel after
5) Air supply pressure and heat examination.
value changed in big limits. . 5)It is required to stabilize the
gas supply pressure and heat
value.
16 High HP generator 1) Poor air tightness and air 1) Purge the chiller/heater by
temperature and pressure. leakage vacuum pump and remove
2) Heat input is greater than the leakage.
nominal value. 2) Regulate heat input.
3) High cooling water 3) Regulate cooling water
temperature or low cooling bypass valve, check cooling
water flow. tower and fan, or regulate
4) Severe scale on the cooling cooling water flow.
waterside of heat transfer 4) Clean heat transfer tubes.
tubes. 5) Regulate weak solution
5) Low solution circulation rate. regulating valve.
17 Cavitation of solution 1) Inadequate solution charged. 1) Charge solution.
pump 2) Crystallization. 2) De-crystallization.
3) Big solution circulation rate. 3) Regulate solution circulation
rate.
18 Cavitation of refrigerant 1) Inadequate refrigerant water. 1) Add refrigerant water.
pump 2) Low refrigerant water. 2) Regulate cooling water
temperature or add refrigerant
water.
19 Failure of chilled water 1) Damaged pump (or motor). 1) Repair or startup standby
pump.
2) Inadequate refrigerant water is 2) Add a big amount of water.
added.
20 Failure of cooling water 1) Same as failure of chilled/hot 1) Same as for failure of
water. chilled/hot water.
2) Less water is stored in the 2) Addition of water storing
cooling tower. capacity (for water collecting
type cooling tower)
21 Abnormal increase of The heat transfer tubes leak or Urgent measures should be taken:
pressure in the other parts leak abnormally. 1) Cut the power to shutdown
chiller/heater, pressure in the chiller/heater.
the auto purge unit equal 2) Close valve and stop the
or above the atmospheric chilled and cooling water
pressure pumps.
3) Drain the chiller/heater.
4) Transfer solution from
chiller/heater to tank; open the
end covers to test the air
tightness.
22 Big variations of values 1) Poor grounding. 1) Re-grounding.
displayed on the touch 2) Poor sensors for temperature 2) Repair or replace.
screen and etc. 3) Replace.
3) Troubles in touch screen.
23 Pump not operated. 1) Pump motor overload 1) Find the cause of overload
protected. and reset.
60
2) Troubles in the control 2) Check the circuit.
circuit. 3) Replace.
3) Trouble in pump itself. 4) Find the cause.
4) Automatic protection of
chiller/heater works.
24 Inverter not operated. 1) Trouble in control circuit of 1) Check the control circuit.
inverter. 2) Check and change the function
2) Erroneous setting of function codes.
code for inverter. 3) Raise the voltage of power
3) Low voltage of power supply. supply.
4) Trouble in inverter. 4) Check and repair inverter.
5) Over current protected 5) Check the solution pump for
inverter. trouble.
25 Buzzer not working. 1) Buzzer damaged. 1) Replace.
2) Fuse blown. 2) Replace.
26 Abrupt shutdown the firing 1) The automatic protecting 1) Observe touch screen to
system is working due to correct the trouble.
abnormal operation of 2) Chiller/Heater is shutdown,
systems. because chilled/hot water
2) The auto capacity regulation temperature is lower/higher
is working. than lower/higher set value,
3) Trouble in burner. and starts work, when
conditions changed.
3) Check burner.
27 Decrease the vacuum Leakage Test chiller/heater for air
during shutdown period tightness.
7.3 Solution Crystallization and Its Treatment

7.3.1 Crystallization during startup of chiller/heater
Solution in the heat exchanger from the strong solution side and in the generator may be
crystallized as the low cooling temperature and non-condensable gas exists in the chiller/heater
during its startup period. The measures for de-crystallization are as follows:
1) The de-crystallization measures are similar as for operation period, if the crystallization of
solution occurs in the LT heat exchanger.
2) When solution in generator is crystallized, then the generator is supplied with minor heat from
burner to raise the temperature of solution. For speeding up the de-crystallization, shell of
generator can be heated by steam from outside. The solution pump is started, when the solution
is de-crystallized, and the chiller/heater can be put into operation, when all solution in the
chiller/heater is even mixed.
3) De-crystallize the generator at first, and then the heat exchanger, if the generator and LT heat
exchanger is crystallized in the same time.
7.3.2 Crystallization during Operation
The place prone to crystallize during chiller/heater operation is the strong solution side of LT heat
exchanger and the strong solution outlet. Hot de-crystallization pipe is the outstanding mark of
solution crystallization. But hot de-crystallization pipe also can be caused by the poor circulation
rate of solution. In general, if the hot de-crystallization pipe is caused by crystallization, then the
weak solution temperature at the outlet of heat exchanger and the surface temperature of heat
exchanger will go down. The measures for de-crystallization are as follows:
1) Change the control of chiller/heater to manual mode, and re-start the chiller/heater by small
61
firing of burner.
2) Stop the supply of cooling water to raise the temperature of weak solution to about 60℃, but
not above 70℃.Shut the chilled/hot water, when its outlet temperature is higher than inlet
temperature.
3) Open the refrigerant bypass valve slowly to bypass part of refrigerant to absorber to dilute the
solution and not lower the solution level in the absorber considerably. The solution will
de-crystallize, if the chiller/heater is operated under such conditions continuously.
4) Heat the crystallized parts by steam or condensate, if they are difficult to be de-crystallized.
5) Put the chiller/heater into operation, when it is de-crystallized. The purge piping is also to be
de-crystallized, if it had been crystallized also.
6) Find the cause of crystallization, and appropriate measures are taken.
The chiller/heater is normal, if the de-crystallization pipe is not hot even under the full load of
chiller/heater.
7.3.3 Crystallization during Shutdown
During shutdown the solution is crystallized, if it is not adequately diluted during shutdown, or the
cooling water temperature is low. The solution pump cannot work for solution crystallization. It
can be de-crystallized by heating the pump casing and its inlet and outlet by steam to run the pump.
The caution should be taken to avoid the steam and its condensate into the motor and its control
means. No direct heating of motor is permitted.
7.4 Freezing of Refrigerant Water

Refrigerant water is frozen by low chilled/hot water outlet temperature or small flow, or failures in
the safety protection means. So, the safety protection should be inspected and calibrated
periodically, or the chilled/hot water system should be checked and cleaned.
For de-freezing the refrigerant water, the cooling tower fan should be stopped, the cooling water
flow should be reduced, and the chiller/heater is put into operation in the normal manner. If the
refrigerant water still is frozen, then close the burner, solution pump.
7.5 Treatment of Emergency

7.5.1 Fire and earthquake
Cut the power supply, close all the valves, and fire protection measures should be taken.
7.5.2 Water flooding
Remove the control panel and vacuum pump, and handle them to safe place. All the hermetically
sealed pumps, sensors and electric wires should be covered by plastic films to be protected from
water leakage.
7.5.3 Freezing or cracking of heat transfer tubes (abnormal rising of pressure and liquid
level in the chiller/heater)
Stop chiller/heater operation (stop immediately the burner, refrigerant and solution pumps), stop
the chilled/hot water and cooling water pumps after shutoff their valves, and transfer the solution
from chiller/heater to the tank. Drain water from the chiller/heater, check the chiller/heater for air
tightness and change the broken tubes by opening the end covers.
7.5.4 Failure of Power Supply
When the power supply is failed, close the valves at the discharge of cooling and chilled/hot water
pumps and stop the pumps. If before the power failed, the sampling or purge process is taken place,
62
then the sampling valve and lower and upper purge valves should be closed.
7.5.4.1 Treatment for Short Period (less Than 1h) Failure of Power Supply
In general the solution will not tend to be crystallized, if the power supplied is failed only for
limited time, and solution remains hot. In such case, the chiller/heater can be put into operation, as
the power supply recovered.
1) If the chilled and cooling water pumps had been shut as the power failed, then these pumps are
to be started by confirming that the valves at their discharge had been closed. Then these valves
opened and adjusted to the flow required.
2) Control the chiller/heater manually, start the solution pump and refrigerant pumps, and stop the
chiller/heater with dilution operation.
3) Control the chiller/heater automatically, start it in the normal procedure.
4) Check the refrigerant water for its density; regenerate it, if its value is above 1.04g/ml.
7.5.4.2 Treatment for Long Period (more than 1h) Failure of Power Supply
The crystallization of solution tends to occur, if the chiller/heater is shutdown for long period
under high solution concentration. Operate the chiller/heater in the following ways, when the
power recovered:
1) Start the chiller/heater manually for operation with dilution as above mentioned for short
shutdown.
2) Operate the chiller/heater under light load for 30 min in trial manner. Stop the chiller/heater for
de-crystallization, if the cavitation for solution pump occurs in 30 min. If no crystallization
occurs, then stop the chiller/heater, and re-start the chiller/heater in automatic mode.
3) Check the refrigerant water for its density after de-crystallization; regenerate it, if its value is
above 1.04g/ml.
7.6 Troubles of Burners

7.6.1 Common Troubles of Oil Burners and Their Shooting
The common troubles of oil burner and their shooting measures are listed in the Table 7-3, For
adjusting, see technical manual of burner.
Table 7-3 Common Troubles of Oil Burner and Their Shooting Measures
No. Trouble Cause Measure
1 No spark from 1) Gap between the 1) Adjust the gap between the
ignition electrodes is not correct. electrodes.
electrodes 2) Electrodes contaminated 2) Clean and adjust the electrodes.
or wet. 3) Replace.
3) Insulation cracked. 4) Find the cause, repair or replace.
4) Ignition cables are 5) Replace.
carbonated.
5) Ignition transformer
damaged.
2 Burner motor 1) Overload protection. 1) Check the set value, and find the
cannot be 2) Trouble in contactor. cause for overload, if no problem
started. 3) Trouble in thermal relay. for set value.
4) Trouble in burner motor. 2) Replace.
5) No output from 3) Replace.
programmable controller. 4) Replace.
6) Motor bearings failed. 5) Check the cause for absence of
output from controller.
6) Replace bearing or motor.
3 No oil supply 1) Gear damaged. 1) Replace.
63
from oil pump 2) Air in oil piping. 2) Tighten the connections.
3) Oil inlet valve closed. 3) Open the oil inlet valve.
4) Filter clogged. 4) Clean the filter.
5) No oil for oil pump. 5) Charge oil.
4 Mechanical 1) Air in pump. 1) Vent the pump.
noise from 2) Filter clogged. 2) Clean filter.
pump.
5 No even 1) Atomizing disk is free to 1) Remove nozzle and tighten the
atomization of move. atomizing disk.
oil from nozzle. 2) Spray holes clogged 2) Remove and clean it.
partly.
3) Pressure reduced due to 3) Remove and clean it.
clogging of filter.
4) Nozzle is worn. 4) Replace the nozzle.
5) Nozzle is clogged. 5) Remove and clean it.
6) Trouble in the regulating 6) Replace the nozzle.
mechanism of nozzle.
7) Low oil pressure. 7) Adjusting oil pressure.
6 Abnormal noise 1) Fan blades are 1) Clean.
of fan contaminated.
2) Bearing worn. 2) Replace.
7 No feedback 1) Smoke on the surface of 1) Clean flame detector.
from flame flame detector.
detector. 2) Flame detector damaged 2) Replace.
due to high temperature.
3) Circuit board for flame 3) Replace.
detector damaged.
8 Abrupt cutout 1) Trouble in burner. 1) Check the wiring.
firing of burner. 2) Trouble in oil supply 2) Check and repair.
system.
9 Solenoid valve 1) Coil is broken. 1) Replace coil.
cannot open. 2) Valve fuse burn 2) Replace fuse.
10 Solenoid valve Foreign matter on the valve Disassemble the valve, and clean it
cannot be closed seat. from foreign matter.
tightly.
11 Burner head is 1) Head is located in wrong 1) Adjust the location of head.
contaminated by position.
oil or 2) Nozzle is too big. 2) Replace.
carbonization 3) Air is not enough. 3) Re-adjust the air flap.
4) Poor ventilation of 4) Machine room should be provided
machine room. with permanent ventilation port with
section not less than 50% of
chimney section.
5) Pressure loss of flue gas 5) Increase the section of flue gas
channel is big. channel.
12 Oil pre-heater 1) Thermostat for oil not 1) Raise the oil temperature by tighten
cannot work closed. the screw,
(for heavy fuel 2) Thermostat for oil is 2) Replace the thermostat.
oil) failed. 3) Tighten it.
3) Thermostat for oil is 4) Replace thermostat.
slackening. 5) Replace heater.
4) Oil thermostat is set with
wrong temperature
limits.
5) Trouble in heater.
64
1. Clean the fan motor, ignition electrodes, flame detector and air inlet in accordance with
the requirements.
2. Check and repair failed motor bearings to protect the burner from damage.
3. Check immediately, if the fan motor noisy.
4. Clean the oil filter timely to protect the burner oil pump and solenoid valves from
damage.
7.6.2 Common Troubles of Gas Burners and Their Shooting

Common troubles of gas burner and their shooting are listed in table 7-4.
Table 7-4 Common Troubles of Oil Burner and Their Shooting Measures
1 Burner fan not work. 1) Power supply not 1) Connect power supply.
connected.
2) Fan overload protected. 2) Find the cause of overload, and
correct.
3) Trouble in fan. 3) Replace.
4) Trouble in control 4) Check and repair circuit.
circuit.
5) Gas supply shut or with 5) Restore gas supply.
less pressure.
6) Trouble in burner 6) Replace burner controller.
controller.
2 Burner fan started, 1) Air breaker is failed or set 1) Adjust or replace.
but burner is locked wrong value.
after pre-purge. 2) Foreign matters in the 2) Clean the piping.
pressure piping to the
pressure switch.
3 Burner fan is locked Air supply solenoid valve Correct the leakage.
in about 20 sec after leaks.
starting
4 Burner is started, but 1) Air pressure switch is not 1) Set the correct value for the
locked in 10sec after working at the working pressure switch, and replace it,
full load pre-purge. position. if damaged.
2) Fan blades were dirty. 2) Clean from dirt.
3) Fan rotation reversed. Correct rotation.
5 No spark between 1) Gap between the 1) Adjust in accordance with the
electrodes. electrodes is too big. burner technical manual.
2) Ignition electrode or its 2) Replace damaged electrodes
insulation damaged, or and wires, correct the short
short circuit against circuit against the ground and
ground, or poor improve the contact.
contact. 3) Replace.
3) Trouble in ignition 4) Re-adjust.
transformer.
4) Flame detector not
installed correctly.
6 Fan started, spark 1) Gas supply solenoid valve 1) Replace solenoid valve, and
takes place, but no cannot be opened due to connect the control circuit.
ignition. failed coil or broken
control circuit. 2) Seal the solenoid valve.
65
2) Protection due to leakage
of solenoid valve. 3) Clean or replace filter.
3) Gas supply filter is 4) Re-adjust.
clogged.
4) Air flap is set incorrect.
7 Flame cutout after 1) Gas supply filter is 1) Clean filter.
normal ignition. clogged. 2) Check and repair gas pressure
2) Trouble in gas pressure regulator.
regulator. 3) Contact the local gas company.
3) Trouble in gas 4) Re-adjust.
instruments or water in 5) Clean the head of flame
the lowest points of gas detector.
piping. 6) Increase the gas supply
4) The ratio of gas with air pressure.
is not correct. 7) Re-grounding.
5) Flame detector is too
dirty.
6) Gas supply pressure is
low.
7) Poor grounding.
8 Flame cutout during High limit pressure switch Stabilize the gas supply pressure,
changing from big protection is working for or re-adjust the pressure switch.
fire to small, and increased pressure.
self-locked.
9 Flame cutout during Low limit pressure switch Same as above.
changing from small protection is working for
fire to big. reduced pressure.
10 Burner whistled. Gas pressure low and air Re-adjust the gas pressure and air
flow too great. flap.
11 Flap regulating Gas butterfly valve is Reduce the size of blade of valve.
mechanism cannot clogged for its blade.
rotate.
7.7 Trouble of Vacuum pump

Troubles, causes and their solutions are listed in Table 7-5.
Table 7-5 Normal troubles and their solutions for vacuum pump
No Trouble Cause Solution
1 Low limit vacuum 1) Oil cannot seals the 1) Add oil to the level in the limits of
discharge valve, noisy 5mm under middle line.
discharge, as the oil level 2) Change to correct type vacuum
is low. pump oil.
2) Not correct type of oil is 3) Drain the emulsified oil or water
used. droplets from the drain plug on the
3) Oil emulsified. bottom of oil box, and add oil;
4) Leakage in the oil trap change oil, if it is too dirty.
and its piping. 4) Check for tightness, and remove
5) Not working vacuum leakage.
solenoid valve. 5) Check and repair vacuum solenoid
6) Broken spring for valve.
revolving plate. 6) Change to new spring.
7) Clogged oil holes lower
the vacuum. 7) Drain the oil, remove the oil box,
8) Worn and torn the lose the press plate of oil nozzle,
revolving plates and and withdraw the oil nozzle and
stator. clean the oil holes. The
66
No Trouble Cause Solution
9) Rubber components for components are cleaned, not using
suction pipe and ballast gauze as far as possible.
valve not assembled 8) Check, repair and replace.
correctly, broken or aged. 9) Adjust and change.
10) Vacuum system, including 10) Clean.
piping, contaminated
severely.
2 Oil leakage 1) Broken oil drain plug and 1) Check and replace.
gasket. 2) Check, adjust or replace.
2) Broken or assembled not 3) Replace and lower the oil
correctly the gasket for oil temperature.
box cover. 4) Check and repair.
3) Deformed thermally the 5) Close it while shutdown the pump.
plexiglass. 6) Reassemble or replace.
4) Lost spring for oil seal.
5) Not closed the ballast valve
during shutdown of pump.
6) Oil seal is worn due to error
assembling.
3 Oil spray 1) Too high oil level. 1) Drain oil to normal level.
2) No oil or oil contaminated 2) Check, clean and repair.
in oil separator. 3) Check and re-assemble.
3) Lost or assembled not
correctly the oil trapping
plate.
4 Noise 1) Broken the springs for 1) Check and replace.
revolving plates, and 2) Check, adjust and replace, when it
increased oil supply. is necessary.
2) Worn bearings. Check and replace.
3) Broken parts.
5 Back flow of oil
1) Assembled not correct or 1) Replace.
worn the oil seal in the 2) Check and repair.
pump cover. 3) Replace.
2) Not normal the surface of
pump cover and stator.
3) Broken the discharge valve
plate
7.8 Troubles of Hermetically Sealed Pump

Troubles, causes and their solutions are listed as follows:
1) Cavitation of pump
Cause and solution see Table 7-1.
2) Bearings worn.
a. The rotating parts of pump are not balanced dynamically. Check and repair rotating parts.
b. Cavitation in pump. Check and solve the problem.
c. Foreign matters in solution. Re-generate solution, check and clean filter.
d. Pump flow is not in the appropriate limits, and axial load is increased. Adjust the pump flow in
the designed limits.
3) Amperage of pump motor is increased.
a. The internal resistance of pump is increased. Open and check the pump casing, impeller and
inducer. Remove the roughness of surface by sandpaper or other mechanical means.
67
b. Abnormal contact in bearings. Check and replace the bearing, sleeves and thrust plate. Remove
the cause for increased friction.
c. Abnormal contact between the rotor and stator. Check the surface for abnormalities of
expansion deformation. Remove the cause for abnormal wear.
d. Poor contact between the impeller and casing of pump. Check the assembly of pump shaft and
impeller and deflection of shaft. Adjust or replace the shaft, if it is out of normal limits.
e. Foreign matter in the pump casing. Disassemble the pump casing to remove the foreign matter.
f. Reduced motor insulation resistance and unbalance of resistance of coil for three phases.
Restore, or otherwise, replace the stator. Dry the motor slowly by torch, if it is damped.
g. Motor operates under absence of any phase current. Check the fixing of wire connection of
motor. Tighten it, if it is slack.
h. The voltage and frequency of power supply is fluctuating. Check the power supply line.
4) Thermal relay protection is working frequently
a. Pump motor overloaded and overheated. Check the flow and temperature of working medium.
Check and clean filter.
b. Trouble in thermal relay. Check and replace the thermal relay.
5) Pump noisy and vibrated severely
a. Reversed rotation of pump. Change the connection of leads to pump motor to correct rotation
direction.
b. Too great or small pump flow. Check the pump operation to make the operation of pump in the
determined limits.
c. Cavitation in pump. See Table 7-2.
d. Foreign matter in pump. Check and remove foreign matter from pump.
e. Contact of casing with the impeller or inducer. Check and repair.
f. The fixing of bolts is slack. Check and repair pump.
g. Unbalanced rotor of pump. Check and balance pump dynamically.
68
Chapter 8 MAINTENANCE OF CHILLER/HEATER
The performance of chiller/heater and its life cycle is dependent not only upon the starting
commissioning, but also the maintenance of chiller/heater. The maintenance of chiller/heater is not
so complex, but it had to be done vary carefully. Chiller/heater should be maintained periodically
to operate it reliably, prevent it from accidents and to increase its life. Violation of following
maintenance precautions causes the unnecessary loss.
Chiller/heater should be maintained by qualified maintenance personnel from

Shuangliang Service Co. Before the service is carried out, the power should be cut from the
control panel. It is forbidden to do the maintenance and repair under the power is supplied
to prevent the injuries and deaths of people from the electric shock. During the handling and
moving the chiller/heater, the specialized instrument should be used.
8.1 Periodical Inspection

8.1.1 Monthly inspection
During operation of chiller/heater, it is inspected monthly following the Table 8-1.
Table 8-1 Items for monthly inspection
No Group Item Content
1 Solution 1) pH value and 1) Sampling and analyzing the solution, and
concentration of additives adjust it based upon the results.
in solution 2) Measuring the concentration after dilution
2) Concentration of solution operation, find cause and inform the
Shuangliang Service Co., if the
abnormality is found.
2 Refrigerant Refrigerant density Sampling and measuring the density of
water refrigerant, and regenerate it, when it is larger
than 1.04.
3 Chilled/hot pH value and inhibitor in Sampling and measuring chilled/hot water,
water chilled/hot water adjust it, if it is out the limits.
4 Cooling water Cooling water quality Analyzing the water quality, and treat it based
upon the results.
5 External 1) Clean filter. 1) Remove filters from external systems,
systems and clean them.
2) Chilled and cooling water 2) Inspect, repair and change oil, tighten the
pumps screw connections, especially the
fundament bolts.
3) Cooling tower. 3) Clean the tower from dirty, check fans
for slackness and drop of driving belts,
correct them, if abnormality is found.
4) Check gas leakage and 4) Check piping for leakage and safety stop
safety stop valve valve opening/closing
opening/closing.
6 Vacuum pump The limit vacuum Measuring the limit vacuum by vacuum
pump, check and restore the capability of
pump.
7 Control Reliability of working Check the control elements for their reliability
elements of working. Check the insulation between
level sounding electrodes, and between the
shell and electrodes for short circuit.
69
8.1.2 Yearly Inspection
Before the startup and shutdown in a yearly season, the following inspections should be checked.
Table 8-2 Items for yearly inspection
No Group Item Content Time
1 Chiller/heat 1) Clean heat transfer 1) Open the end covers of water 1) After shutdown.
er tubes. boxes for chilled and cooling
water, clean tubes and end
covers by brushes or chemical
detergent, and replace the
gaskets.
2) Inspect 2) Check the chiller/heater for 2) Before starting and
chiller/heater for air tightness by the procedure after shutdown
air tightness illustrated in paragraph 5.1.4
of chapter 5.
3) Furnace of HP 3) Clean the furnace from ash by 3) After shutdown.
generator. opening the ash door, and
repair the damaged refractory.
4) Painting 4) Painting parts or whole 4) After shutdown
chiller/heater based upon the
rust conditions
2 Solution Analyze and treat the Sampling and analyzing the Before starting
solution solution, and adjust it based upon
the results.
3 Pump 1) Hermetically 1) Check the motor insulation, Before starting
sealed pumps and measure its amperage.
Inspect the bearings for metal After shutdown.
wear, repair or replace
2) Vacuum pump 2) Inspect and clean vacuum After shutdown.
pump.
4 Burner 1) Clean burner. 1) Open the burner to clean 1) Before starting.
internal parts and fan blades.
2) Adjust. 2) Readjust the flap, oil 2) Before starting.
pressure, gas pressure,
location of ignition
electrodes and atomizing
disk to ensure that they are in
correct positions, and check
or replace, if something
wrong.
3) Check combustion 3) Check the working of safety 3) Before starting
protection for combustion,
and check the working
circuit.
5 External 1) Check gas leakage 1) Check gas piping leakage 1) Before starting.
systems and safety stop and safety stop valve
valve opening/closing.
opening/closing. 2) Clean piping from dirt, check 2) Before starting.
2) Oil or gas supply and repair it.
system. 3) Clean the flue gas channel 3) After shutdown.
3) Flue gas channel. outside of chiller/heater.
6 Electric 1) Grounding of 1) Check power supply for 1) Before starting
parts power supply grounding.
2) Isolation 2) Check motor and control 2) Before starting
resistance and panel for isolation resistance
electric strength and electric strength.
3) Check fixing of 3) Tighten screws on terminals 3) Before starting
70
No Group Item Content Time
wires on additionally.
terminals.
4) Electric control 4) Check the electric control 4) Before starting
and protections and protections for their set
points and actual working,
check for wear of contacts
and malfunction.
5) Level sounding 5) Clean the elements, if aged. 5) Before starting
Replace the corroded.
6) Electric wires 6) Check and replace, if aged 6) Before starting
and cables. and corroded.
7) Flow switch. 7) Check switch for its 7) Before starting
sensitivity, adjust it to
normal function.
8) Electric Check, repair or replace based 8) Before starting
elements, such upon the actual results (for
as sensors, inverter, see its technical
inverters. manual )
8.1.3 Other periodical inspection

The following inspections and maintenance should be done for the items listed in Table 8-3
according to the years of operation.
Table 8-3 Items for other periodical inspection
No Item Content Time
1 Burner 1) Check solenoid valves, oil pumps, filters, 1) Per 4 years.
ignition electrodes, flame detectors, and
replace nozzles.
2) Replace solenoid valves and flame 2) Per 8 years.
detectors.
3) Replace oil pumps and all electric cables. 3) 16th year.
4) Replace whole burner. 4) Per 20 years.
2 Hermetically 1) Replace bearing 1) Per 15,000h.
sealed pump 2) Capital repair and replace. 2) Per 8-10 years.
3 Vacuum pump Capital repair and replace. Per 5-7 years.
4 External systems Clean the piping from foreign matter Per 2 years
thoroughly, and inspect and repair the
pumps, cooling towers, piping valves,
electric distribution lines, fuel and gas
discharging system in the machine room.
5 Pressure gauge Replace. Per 3-4 years
6 Buzzer Replace Per 4 years
7 PLC battery Replace (in less than 3 min) Per 3 years
8 Relay and AC Replace Per 8 years
contactor
9 Bolts Replace Per 8 years
10 Electric control Replace Per 20th year
panel
11 Cutoff valve Replace sealing ring. Per 2-3 years
8.2 Maintenance during Shutdown Period

8.2.1 Maintenance during Short Shutdown
Short shutdown means the chiller/heater is stopped for an interval not longer than 1-2 weeks.
Maintenance in this period is listed as follows:
71
1) The solution in the chiller/heater should be diluted fully. Refrigerant water from evaporator
should bypass into the absorber to dilute solution and prevent crystallization, when the ambient
temperature is lower than 20℃, and chiller/heater is stopped for more than 8h. Operate the
solution pump and stop refrigerant pump, connect the solution charging valve at the discharge
of solution pump and refrigerant sampling valve together and open them, to prevent the
refrigerant pump from freezing-up by forcing the solution into refrigerant pump, when the
ambient temperature is lower than 5℃.
2) Maintain the vacuum in chiller/heater, operate vacuum pump, if absolute pressure in the
chiller/heater is increased.
3) Check the chiller/heater for air tightness, if absolute pressure in the chiller/heater is increased
too rapidly.
4) Drain the chilled/hot and cooling water systems (including chiller/heater), if the local ambient
temperature will be lower than 0℃ in the interval of shutdown.
5) It is forbidden to expose the chiller/heater to atmosphere for long time during inspection,
replacing and repairing valves or pumps. The maintenance work should be planed carefully,
and the chiller/heater is evacuated immediately after the work finished.
8.2.2 Maintenance during Long Shutdown

During long time shutdown, all refrigerant should bypass into the absorber, and mixed with
solution fully to prevent chiller/heater from crystallization and heat transfer tubes from freezing up.
In order to protect the refrigerant pump from freezing up during shutdown period, part of solution
should be bypassed into the refrigerant pump in the procedure shown in the above first paragraph
for “Maintenance during short shutdown”
During the long time shutdown the chiller/heater should be under supervision by special appointed
personnel. The chiller/heater should be checked for air tightness, which is kept for good operation
of chiller/heater.
The solution can be left in the chiller/heater, if it has good air tightness and solution is clear.
Solution is preferred be kept in special tank to be settled, if it is turbid, and the chiller/heater is
rather severe corroded. Solution may be treated outside the chiller/heater, and then recharged into
it.
Clean the chilled/hot and cooling water systems (including the chiller/heater), and dry them during
the long time shutdown in the following manner:
1) From water systems drain water, which flows during the operation of chiller/heater.
2) Clean and blow the internal surface of tubes and pipes from rust and settlings (or by aid
cleaning, if they cannot be removed by usual cleaning).
3) Drain the cleaned tubes and keep them dry (the drainage piping is left opened)
8.3 Inspection of Air Tightness

Attention should be paid to the air tightness during operation and shutdown. Inspect the
chiller/heater for air tightness, if abnormality occurs. Inspection for air tightness is carried out for
chiller/heater under pressure or under vacuum in the procedure shown in the paragraph 5.1.4
“ Inspection of chiller/heater for air tightness” of chapter 5.
8.4 Inspection, Cleaning and Change of Heat Transfer Tubes
8.4.1 Inspection of Heat Transfer Tubes
72
1) Inspection of scale. Open end cover of water box to check, if there is scale and sludge in the
tubes. Scale is analyzed and measures should be taken, if it occurs in the tubes.
2) Inspection of air tightness Chiller/heater is charged with nitrogen up to 0.1-0.12MPa. Tubes are
plugged from one side, and covered by a film of solution from another end. The tube is broken,
if there is bubble at the its end, or if the plug is expanded off, when tubes are plugged from both
sides. The broken tube can be observed also, if bubble comes from the tube, when water funnel
is installed instead of end cover.
8.4.2 Cleaning of Heat Transfer Tubes
Tubes are cleaned once a year based upon the scale and sludge formation inside tubes.
1) Mechanical cleaning. Mechanical cleaning is effective to remove the sludge from the tubes.
Remove the end cover, blow the tubes with nitrogen or oil-less air under pressure of
0.7-0.8MPa. Then the nylon brushes (not metal wire brushes) with rubber heads and air plugs
are inserted into the tubes, moved from one end of tube to another under high water pressure
for 2-3 times, and then dried by high pressure nitrogen or air, or cotton balls. Cleaned tubes are
protected by end covers.
2) Chemical cleaning. Chemical cleaning is used to remove scale, which contains salt with
calcium, magnesium, and other hard salts. Tubes are cleaned by chemical dosage, method and
timed in accordance with the content and thickness of scale formed.
Chemical cleaning should be followed by qualified person of Shuangliang Service Co.

8.4.3 Replacement of tubes
Leakage of chilled and cooling water through tubes will dilute solution, deteriorate vacuum,
increase corrosion and influence the chiller/heater performance. Leaky tubes should be withdrawn,
changed by new ones, and then expanded. It should be prevented to make longitudinal lines in the
tube plate, which will cause leakage in the connections.
8.5 Cleaning of Chiller/heater

In addition to the LiBr solution regeneration, chiller/heater is cleaned when it is poor maintained,
has corrosion products and foreign matter in the solution, which will influence the chiller/heater
performance. Chiller/heater is cleaned by LiBr solution, distilled water or chemical solutions. But
for Shuangliang Co., chiller/heater is cleaned solely by solution, and no distilled (or softened)
water or chemical solutions can be used. .
Cleaning of chiller/heater by solution is similar to the operation of chiller/heater, but with minor
heat supply by burner. Solution of suitable temperature will wash off the dirt in the following
manner:
1) Start the chill, and operate it for a period of time, then drain solution to tank. Drained solution
can be settled in solution tank, or filtered by two tanks, if the settlement takes too long time.
2) Start vacuum pump to evacuate the chiller/heater up to high vacuum, charge it with cleaned
solution, and operate it. This process is repeated to have clear solution drainage.
3) After cleaning, the chiller/heater is tested under pressure, especially the parts disassembled.
4) Solution should be regenerated after the chiller/heater is washed by this solution, and adjusted
to the standard limits for inhibitor and content of foreign matter. Chiller/heater is purged
continuously.
73
Concentration
Strong Solution %
Intermediate Temp. %
Weak Solution %
Solution
Outlet Temp. ℃
HT Heat Exchanger
Weak
Inlet Temp. ℃
Weak Intermediate
Outlet Temp. ℃
Solution
Inlet Temp. ℃
Solution
Outlet Temp. ℃
LT Heat Exchanger
Time:
Inlet Temp. ℃
Outlet Temp. ℃
Solution
Strong
Direct-fired Absorption Chiller/heater Running Record
Inlet Temp. ℃
Heat Load Deviation %
Heat Load kW
Gas Exist Temp. ℃
HPG
Low Heat Valu kJ/kg kJ/Nm3

Fuel
Consumption kg/h Nm3/h

Refrigerant Water Outlet Temp. ℃
LPG
Refrigerant Vapor Inlet Temp. ℃

Product Numner:
Outlet Pressure Mpa

Condensor
Inlet Pressure Mpa

Operator:
Outlet Temp. ℃
Condensation Temp. ℃
Outlet temperature of Absorber: The front is the side near to purging unit. Another side is the rear
Total Load kw
Flow Rate m3/h
Absorber
Total Outlet Temp. ℃

Rear ℃
Temp.
Outlet
Front ℃
Total Inlet Temp. ℃
Refrigerant water specific gravity g/ml
Refrigerant water temp. ℃
Heating Capacity
kW
Cooling Capacity
Evaporator
Flow rate m3/h

Outlet pressure Mpa
Inlet pressure Mpa
Outlet Temp. ℃
Attached Table 1
Inlet Temp. ℃
Customer:
Time
Model:
No.
10
11
12
Note
1
2
3
4
5
6
7
8
9

H2 Type Direct Fire Chiller Operation Manual

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SAFETY, INSTALLATION & OPERATION MANUAL

JIANGSU SHUNGLIANG AIR CONDITIONING

Warning: The chiller/heater You purchased from Shuangliang, should be commissioned by

1.1 DESCRIPTION OF FORMATION OF TYPE NUMBER ............................................................................. 1

CHAPTER 2 INSTALLATION OF CHILLER/HEATER ............................................................... 10

2.1 REQUIREMENTS TO MAINTENANCE DURING INSTALLATION........................................................... 10

CHAPTER 3 INSTALLATION OF EXTERNAL SYSTEMS ....................................................... 15

3.1 WATER SYSTEM (CHILLED AND COOLING WATER) .......................................................................... 15

CHAPTER 4 CHILLER CONTROL SYSTEM ................................................................................ 23

4.1 CONFIGURATION OF SYSTEM ......................................................................................................... 23

CHAPTER 5 COMMISSIONING OF CHILLER............................................................................. 33

5.1 PREPARING TO COMMISSIONING .................................................................................................... 33

CHAPTER 6 OPERATION OF CHILLER/HEATER...................................................................... 40

6.1 SAFETY PROTECTION RULES ......................................................................................................... 40

7.1 SHUTDOWN OF CHILLER/HEATER DUE TO TROUBLES ..................................................................... 56

CHAPTER 8 MAINTENANCE OF CHILLER/HEATER............................................................... 69

8.1 PERIODICAL INSPECTION ............................................................................................................... 69

is to indicate possible damages of chiller or other equipments or environment pollution.

1.1 Description of Formation of Type Number

Fuel type: L-light oil; H-Heavy oil; N-LNG/LPG

Chiller type: DF-direct fired lithium bromide absorption

1.2 The Nominal Operation Conditions and Working Limits

1.3 Configuration of Chiller/heater

1. Purge valve of condenser

Fig. 1-2 Rear view of chiller/heater

(1) Left view of chiller/heater (2) Right view of chiller/heater

1.4 Working Fluid

: Quality of lithium bromide solution influences the performance of chiller/heater

Chilled water flow 100%

Chilled water flow 100%

Scale coefficient 0.086 m2.K/kW

Chilled water outlet temperature (℃)

Chilled water outlet temperature 7℃

Cooling water inlet temperature 32℃

Cooling water flow (%)

Hot water flow 100%

Heating capacity (%)

Hot water outlet temperature (%)

2.1 Requirements to Maintenance during Installation

2.2 Requirements to Machine Room

2.3 Installation of Chiller/heater

To avoid damage of chiller/heater, handling equipment and steel wire should

Deviation from prescribed levelness of installed chiller/heater causes

2. Installation of unit of chiller/heater from split parts

At the outlet end cover of LP generator installed a rupture device, which is

2.4 Adjustment of Levelness of Chiller/heater

2.5 Insulation of Chiller/heater

Fig.2-2 The parts of chiller/heater to be insulated

Fig 3-1 Diagram for water system

Pressure working on the water head of chiller/heater cannot be above its

Fig.3-3 schema of light oil system

3.3 Heavy Oil System

Fig. 3-4 schema of heavy fuel system

3.4 Fuel Gas System

Fig.3-5 Schema of gas system

Fig. 3-6 Gas exhaust system

3.6 Electric System

Proper screening measures should be taken when chiller is to be installed in places

Interlocked control signal for external systems Cooling water pump

Output Cooling water pump

Ventilation fan in machine room

Pressure in auto purging unit

4.4 Control Flow Chart