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Carrier 16JT Series Start Up & Operation Manual

60 hz double-effect hermetic absorption liquid chillers units 810-880, 080-150, 080l-150l
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Maintenance Instructions
Absorption liquid chillers provide safe and reliable serv-
ice when operated within design specifications. When op-
erating this equipment, use good judgment and safety
precautions to avoid damage to equipment and property
or injury to personnel.
Be sure you understand and follow the procedures and
safety precautions contained in the machine instructions
as well as those listed in this guide.
DO NOT USE OXYGEN or air to purge lines, leak test, or
pressurize a machine. Use nitrogen.
NEVER EXCEED specified test pressures. For the 16JT chiller,
the maximum pressure is 12 psig (83 kPa).
WEAR goggles and suitable protective clothing when han-
dling lithium bromide, octyl alcohol, inhibitor, lithium hy-
droxide, and hydrobromic acid. IMMEDIATELY wash any
spills from the skin with soap and water. IMMEDIATELY
FLUSH EYES with water and consult a physician.
DO NOT USE eyebolts or eyebolt holes to rig machine sec-
tions or the entire assembly.
DO NOT work on high-voltage equipment unless you are a
qualified electrician.
DO NOT WORK ON electrical components, including con-
trol panels or switches, until you are sure ALL POWER IS
OFF and no residual voltage can leak from capacitors or solid-
state components.
LOCK OPEN AND TAG electrical circuits during servic-
ing. IF WORK IS INTERRUPTED, confirm that all circuits
are deenergized before resuming work.
NEVER DISCONNECT safety devices or bypass electric in-
terlocks and operate the machine. Also, never operate the
machine when any safety devices are not adjusted and func-
tioning normally.
DO NOT syphon lithium bromide or any other chemical by
mouth.
BE SURE all hydrogen has been exhausted before cutting
into purge chambers. Hydrogen mixed with air can explode
when ignited.
WHEN FLAMECUTTING OR WELDING on an absorp-
tion machine, some noxious fumes may be produced. Ven-
tilate the area thoroughly to avoid breathing concentrated fumes.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 211
Tab
5b
Double-Effect Hermetic Absorption Liquid Chillers
Start-Up, Operation, and

SAFETY CONSIDERATIONS

Catalog No. 531-607
Printed in U.S.A.
Units 810-880, 080-150, 080L-150L
DO NOT perform any welding or flamecutting to a machine
while it is under a vacuum or pressurized condition.
NEVER APPLY an open flame or live steam to a refrigerant
cylinder. Dangerous overpressure can result. When neces-
sary to heat a cylinder, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or at-
tempt to refill them. It is DANGEROUS AND ILLEGAL.
When cylinder is emptied, evacuate remaining gas pressure,
loosen the collar and unscrew and discard the valve stem.
DO NOT INCINERATE.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while
machine is under pressure or while machine is running.
DO NOT climb over a machine. Use platform, catwalk, or
staging. Follow safe practices when using ladders.
DO NOT STEP ON machine piping. It might break or bend
and cause personal injury.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to
lift or move inspection covers or other heavy components.
Even if components are light, use such equipment when there
is a risk of slipping or losing your balance.
VALVE OFF AND TAG steam, water, or brine lines before
opening them.
DO NOT LOOSEN waterbox cover bolts until the water box
has been completely drained.
DO NOT VENT OR DRAIN waterboxes containing indus-
trial brines, liquid, gases, or semisolids without permission
of your process control group.
BE AWARE that certain automatic start arrangements can
engage starters. Open the disconnects ahead of the starters
in addition to shutting off the machine or pump.
USE only repaired or replacement parts that meet the code
requirements of the original equipment.
DO NOT ALLOW UNAUTHORIZED PERSONS to tamper
with machine safeties or to make major repairs.
PERIODICALLY INSPECT all valves, fittings, piping, and
relief devices for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate or
rain water.
IMMEDIATELY wipe or flush the floor if lithium bromide
or octyl alcohol is spilled on it.
Form 16JT-2SS
16JT
60 Hz
Pg 1
4-93
Replaces: 16JT-1SS

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  Summary of Contents for Carrier 16JT Series

  • Page 1: Safety Considerations

    DO NOT USE OXYGEN or air to purge lines, leak test, or pressurize a machine. Use nitrogen. NEVER EXCEED specified test pressures. For the 16JT chiller, the maximum pressure is 12 psig (83 kPa). DO NOT climb over a machine. Use platform, catwalk, or WEAR goggles and suitable protective clothing when han- staging.
  • Page 2: Table Of Contents

    CONTENTS Page Page Final Adjustment of Capacity Controls ..25 SAFETY CONSIDERATIONS ....1 • WITH THE MANUAL PROCEDURE INTRODUCTION .
  • Page 3: Introduction

    Everyone involved in the start-up, operation, and main- concentrator. tenance of the 16JT machine should be thoroughly familiar with the following instructions and other necessary job data Machine Construction —...
  • Page 4 2 (NOT SHOWN) LEGEND 1 — High-Stage Generator 5 — Control Panel 2 — Low-Stage Generator 6 — Solution Heat Exchanger 3 — Condenser 7 — Absorber 4 — Purge Storage Chamber 8 — Evaporator Fig. 1 — Typical Machine Components, 16JT810-880 LEGEND 1 —...
  • Page 5 Fig. 3 — 16JT810-880 Machine Components, External Schematic (Typical) LEGEND 1 — Rupture Disk 2 — Refrigerant Condensate Line 3 — Auxiliary Evacuation Valve 4 — Storage Chamber for Purge 5 — Purge Separation Chamber 6 — Strong Solution Overflow Line 7 —...
  • Page 6: Flow Circuits

    Figures 5 and 6 illustrate the basic flow densed refrigerant liquid from the two generators now flows circuits of the 16JT absorption chiller. back to the evaporator to begin a new refrigerant cycle. The liquid to be chilled is passed through the evaporator The strong (reconcentrated) solution flows from the two...
  • Page 7: Solution Cycle

    The slightly sloped lines extending from the bottom of the diagram are solution-specific gravity lines. The concentra- tion of a lithium bromide solution sample can be determined by measuring its specific gravity with a hydrometer and read- ing its solution temperature. Then, plot the intersection point for these 2 values and read straight down to the percent lithium bromide scale.
  • Page 8 Point 10 represents the strong solution leaving the low-stage Point 12 represents the combined strong solution before it generator and entering the low-temperature heat exchanger. leaves the low-temperature heat exchanger after giving up It is at a weaker concentration than the solution from the heat to the weak solution.
  • Page 9: Purge System

    Some chillers also have an optional, permanently in- Purge System — The basic components and flow cir- stalled vacuum pump system (as shown in Fig. 5) cuits of the motorless purge are shown in Fig. 8 and 9. to remove noncondensables directly from the absorber for The purge system automatically removes noncondens- machine evacuation at initial start-up and after service work.
  • Page 10: Machine Controls

    88SSP — Solution Spray Pump Starter (Some Larger Chillers) NOTES FOR FIG. 10 1. The following items are not by Carrier: 3. Solution and refrigerant pump motors are hermetic, 3-phase and op- erate ±10% of rated voltage. • Chilled water pump, condensing water pump starters and discon-...
  • Page 11 Fig. 10 — Typical Wiring Diagram...
  • Page 12 Fig. 10 — Typical Wiring Diagram (cont)
  • Page 13 Fig. 11 — Typical Control Wiring...
  • Page 14: Typical Control Sequence, Normal Start

    Typical Control Sequence, Normal Start (Fig. 10 and 14) 1. When power is supplied to the chiller control panel and the chiller is not in operation, the Stop light (RL) is on. 2. To start up machine, the Cycle-Guard™ switch (43-RV) should be placed in the AUTO.
  • Page 15 LEGEND BZ — Alarm Buzzer GL — Run Light OL1 — Chilled and Cooling Water Fault Indicator Light OL2 — Refrigerant and Solution Pump Fault Indicator Light OL3 — High-Stage Generator Fault Indicator Light RL — Stop Light Fig. 14 — Typical Control Sequence, Normal Start...
  • Page 16: Typical Control Sequence, Normal Stop

    (WL1). When 4X relay deenergizes, its normally closed Typical Control Sequence, Normal Stop contacts energize the Cycle-Guard™ valve to transfer re- (Fig. 10 and 15) frigerant into the solution for dilution. The refrigerant 1. If the Local Remote switch is in the remote position, the pump and Cycle-Guard valve continue to be energized shutdown sequence begins when the remote control con- until the evaporator refrigerant drops to the dilution level...
  • Page 17: Typical Control Sequence

    4. Normally closed 4X contacts energize shutdown alarm Typical Control Sequence, Abnormal Stop relays (30X1 and 30X2), and energize the alarm buzzer. (Fig. 10 and 16) These relays remain energized through 4Y self-latching 1. Abnormal shutdown occurs automatically when any of contacts.
  • Page 18: Capacity Control

    Cycle-Guard operation, the chiller control circuit over- rides the signal to the steam valve to limit the valve opening. The 16JT is available with either electronic or pneumatic capacity control valve actuators, but both are positioned by a microprocessor-based controller.
  • Page 19: High Concentration Limit

    2. Machine assembly and field layout drawings 3. Controls and wiring drawings 4. 16JT Installation Instructions 5. Mechanic’s hand tools 6. Absolute pressure gage or water-filled wet-bulb vacuum indicator graduated with 0.1-in. (2 mm) of mercury in- crements.
  • Page 20: Inspect Field Piping

    7. Auxiliary evacuation pump, 5 cfm (2.5 l/s) or greater, with oil trap, flexible connecting hose and connection fittings Do not apply power to hermetic pumps or attempt to 8. Compound pressure gage, 30-in. vacuum to 30 psig (75 start the machine until it has been charged with lithium cm vacuum to 200 kPa) bromide solution and refrigerant.
  • Page 21: Short Interval Test

    SHORT INTERVAL TEST — Use this test procedure if: pump is off. To minimize the chance of air entering the ma- chine, the solution should not be drawn in directly from a 1. No previous absolute pressure readings have been re- small container.
  • Page 22: Initial Control Checkout

    Energize Control Circuit LiBr SOLUTION INITIAL REFRIGERANT 1. Place the main circuit breaker in the ON position to en- UNIT 16JT ergize control circuit. (Stop light turns red.) 810,812,814 2. Depress the Stop button to clear any safety fault condi- 816,818,821 1225 tions and to prepare the control circuit for starting.
  • Page 23: Check Cycle-Guard™ Valve

    The following checkout and adjustment procedure is for (if any) between actual thermometer reading and the read- standard use. The standard 16JT configuration set-up list, with ing on the thermoswitch adjustment scale. temperature measurement in degrees F, and 110 V, 60 Hz Using any temperature differential described above as a control power, is shown in Table 4.
  • Page 24: Completion

    valve actuator) in the MAN. (MANUAL) mode. Press the MAN./AUTO. button to switch between the two modes. The actual output value is not important at this time. (Pref- erably, the temperatures have been configured for dis- play [and processing] with the decimal located for tenths of a degree, but that is not critical.) The red bars on the right of the temperature display in- dicate deviation between actual and set point tempera-...
  • Page 25: Initial Start-Up

    find the corresponding weak solution con- centrations required for refrigerant charge adjustment. Table 5 — Octyl Alcohol Initial Charge Table 6 — Weak Solution Concentrations for Adjusting Refrigerant Charge OCTYL ALCOHOL 16JT PERCENT LOAD ON MACHINE REFRIGERANT 810,812,814 LEVEL 816,818,821,824...
  • Page 26 Fig. 22A — Equilibrium Diagram for Lithium Bromide in Solution (F) Fig. 22B — Equilibrium Diagram for Lithium Bromide in Solution (C)
  • Page 27: Check Machine Shutdown

    6. The refrigerant charge can be adjusted at either refriger- Check Low-Evaporator Level Operation — ant level. In Table 6, use the refrigerant level that corre- ter machine has completed a normal shutdown: sponds to the weak solution concentration in the machine 1.
  • Page 28: Start-Up After Limited Shutdown

    4. When absorber loss is reduced to 5° F (3° C) or less, place Start-Up After Limited Shutdown capacity control switch in AUTO. position, return steam 1. Place the capacity control, Cycle-Guard,™ and Local- pressure to normal and allow purge to establish the nor- Remote settings in the position indicated in Table 7.
  • Page 29: Actions After Abnormal Shutdown

    ABSX NONE PERIODIC SCHEDULED MAINTENANCE Every Year of Operation Normal preventive maintenance for 16JT absorption chill- 1. Have solution analyzed. ers requires periodic, scheduled inspection and service. Each 2. Check tubes for scale and fouling. item in the list below is detailed in the Maintenance Proce- dures section.
  • Page 30 Alcohol in Sample? Temperature Leaving Low-Temperature Heat Exchanger Temperature Leaving High-Temperature Heat Exchanger Temperature Leaving High-Stage Generator Temperature Leaving Low-Stage Generator STRONG Temperature To Sprays SOLUTION Temperature Leaving High-Stage Heat Exchanger Fig. 24 — Typical 16JT Maintenance Record Log Sheet...
  • Page 31: Purge Manual Exhaust Procedure

    Purge Manual Exhaust Procedure (Fig. 25) — See also Machine Description section, pages 3-9, for expla- nation of the purge operation, component identification, and illustrations. NOTE: The following does not apply to optional vacuum pump operation. NEVER LEAVE the machine during purging opera- tion.
  • Page 32 Fig. 26A — Equilibrium Diagram for Lithium Bromide in Refrigerant (F) Fig. 26B — Equilibrium Diagram for Lithium Bromide in Refrigerant (C)
  • Page 33: Machine Leak Test

    6. Close exhaust valve and mark liquid level on inverted bottle. Machine Evacuation — Evacuation is required for the Remove bottle from container. removal of excessive noncondensables from the machine. The machine must be evacuated after air has entered the machine 7.
  • Page 34: Solution Or Refrigerant Sampling

    Solution or Refrigerant Sampling — (See precau- tions pertaining to handling lithium bromide solution as described in Solution and Refrigerant Charging section, page 21.) Take solution or refrigerant samples from the pump serv- ice valve while the pump is operating. Before taking a sample for analysis or absorber loss de- termination, be sure machine is operating with steady load and that Cycle-Guard™...
  • Page 35: Adding Octyl Alcohol

    If machine still fails to maintain design temperature, re- Adding Octyl Alcohol — Octyl alcohol may be re- fer to the Troubleshooting section entitled Problem/Symptom quired when leaving chilled water temperature starts to rise — Leaving Chilled Water Temperature Too High or Too Low, above design temperature without alteration of the control page 41.
  • Page 36: Thermoswitch Adjustment

    If the level goes down enough to open the tion pump used on the 16JT chiller. These centrifugal pumps low refrigerant level switch 33RL, the refrigerant pump stops are hermetic and do not require seals.
  • Page 37 33 — Wear Ring Housing 34 — Radial Bearing (A) 35 — Thrust Bearing (A) 36 — Thrust Collar (A) 37 — Pin 38 — Nut 39 — O-Ring Gasket 40 — Bolt Fig. 31 — 16JT Refrigerant and Solution Pump Schematic (Typical)
  • Page 38: Inspection

    3. Open the motor wiring terminal box (Item 11) and dis- INSPECTION connect the motor power leads. Mark the leads to en- 1. Check circulation passages in motor and circulating pipe. sure proper reassembly. Clean if necessary. 4. Remove nuts (Item 21) holding motor adapter flange to 2.
  • Page 39: Reassembly

    5. Check the impeller wear surfaces. If very rough or worn REASSEMBLY to outside diameters less than listed in Table 11, replace 1. Clean all parts, gasket surfaces, and O-ring grooves. Use the impeller. new gaskets (Items 6 and 22) and new O-rings (Items 2 and 39).
  • Page 40: Solution Decrystallization

    Do not specially designed to avoid scraping or scratching the tube apply direct heat to any flange connections; high tem- walls. The brushes are available through your Carrier rep- perature can deteriorate the gasket material. resentative. Do not use wire brushes.
  • Page 41: Troubleshooting Guide

    TROUBLESHOOTING GUIDE PROBLEM/SYMPTOM PROBABLE CAUSE REMEDY Machine Will Not Start or No power to control panel Check for building power failure. Check main circuit Shuts Down breaker. (Panel RUN light out, Control panel fuse blown Examine circuits for ground or short. pumps off.) Replace fuse.
  • Page 42 TROUBLESHOOTING GUIDE (cont) PROBLEM/SYMPTOM PROBABLE CAUSE REMEDY Inadequate Purging Air leakage in vacuum side of machine Have solution analyzed for indication of air leaks. Leak test (high noncondensable accumulation rate) and repair if necessary (see Noncondensable Accumu- (Low machine capacity and lation Rate, Solution Analysis, and Machine Leak Test high absorber loss —...
  • Page 44 Copyright 1993 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 PC 211 Catalog No. 531-607 Printed in U.S.A. Form 16JT-2SS Pg 44 4-93 Replaces: 16JT-1SS...