Hermetic Absorption Liquid Chillers MACHINE COMPONENTS, 1 MACHINE DESCRIPTION 1- Flow Cycle 1 Capacity Control 3 Low Concentration Control 3 igh Concentration Control 3 Purge 3 EQUILIBRIUM DIAGRAM 4,5 Description Solution Cycle 4, START-STOP SYST ‘Semiautomatic Start-Stop Full Automatic Start-Stop START-UP PROCEDURES After Limited Shutdown After Extended Shutdown After Below-Freezing Conditions MACHINE SHUTDOWN PROCEDURES ‘Above-Freezing Conditions Below-Freezing Conditions PERIODIC SCHEDULED MAINTENANCE Every Month of Operation Every Two Months of Operation Every Six Months of Operation Every Year Every Two Years Every Seven Years GENERAL MAINTENANCE, Log Sheets: Purge Exhaust Procedure Condensing Water Tube Scale Noncondensable Accumulation Rate Solution or Refrigerant Sampling ‘Absorber Loss Determination we MACHINE COMPONENTS Identification and locations of the components of the 16JB Absorption Machine are shown in Fig. Vand 2. MACHINE DESCRIPTION ‘The Carrier two-shell hermetic absorption liquid chiller uses heat to produce refrigeration. The lower shell contains the absorber and evap- orator; the upper shell contains the generator and condenser. Lithium bromide solution is the absorb- ent, and water is the refrigerant. A solution pump and refrigerant pump circulate the system fluids. An absorption chiller operates on the simple principle that under low absolute pressure (vacuum), water will absorb heat and vaporize (boil) at’ a low temperature. Lithium bromide solution absorbs the water vapor thus formed to allow the cooling process to be continuous. Flow Cycle — Basic flow circuits are shown in Fig, Adding Octyl Alcohol on 3. Liquil to be chilled passes thru the evaporator as aaa edb ie tube bundle where it is cooled by the evaporation Auxiliary Evacuation aw) of the refrigerant sprayed over the outer surface of Refrigerant Decontamination 10 the tubes. The refrigerant vapors are drawn from Solution Decrystallization 10,11 the evaporator to the absorber section where they Solution Analysis a are absorbed by the solution as it is sprayed over Low-Temperature Cutout Adjustment 11 the absorber tubes. The heat which has been Pibtepdetiesoraanon a removed from the chilled liquid is carried to the Cycle Guard™ Operation u absorber by the refrigerant vapors and is trans- Capacity Control Adjustment D ferred to the condensing water flowing thru the Service Valve Diaphragm Replacement N absorber tubes. The solution in the absorber Hermetic Pump Inspection w becomes diluted as it absorbs water, and it is ORDERING SPARE PARTS 12 pumped to the generator to be reconcentrated. In TROUBLESHOOTING 12 the generator, the weak solution is heated by steam ©cxeree Corporation 1972 Form 1616-280LEGEND 1 = Condenser Tubes 2 = Ganerator Tubes 23 = Refrigerant Spray Header 4 = Solution Spray Header 5 — Evaporator Tubes 6 — Atzorber Tubes (Hidden! 7 = Absorber Valve 8 = Cycle Gusrd™ indicator Light 9 = LowRetrigarant Lovel Switch 40 = Shutdown Dilution Swites 11 = Refrigerant Purp Service Valve 12 — Fofrigrant Puro otrignant Condensate Line ig Low-Tomo Cutout Wall yele-Guard Valve (Hidden) Heat Exchanger Solution Purp Service Valve bk 18 — Solin Pump XO 19 ~ Steam Box Vacuum Breaker 20 ~ Strong Solution Line @ @ 21 — strong Soliton Overflow Lioe 22 ~ Sica Condensate Line 23 — Weak Solution Line 24 — Purge Storage Chamber 125 — Purge Solution Return Vale 26 = Fiotender™ Voive 27 ~ Control Comer 28 — Purgo Exhaust Valve 29 — Auxiliary Evscuation Valve 30 — Absorber Purge Device 21 = Condenser Purge Device 232 ~ Retrigrant Level Control, 33 — Thermasniteh Wells (2) 34 — Purge Level Seite - eo @ be bbs Fig. 1 — Machine Components LEGEND 4 —cyele-Guard™ Switch 12 — Rerig and Solution 2— Conteoi Circuit Fuse Pump Startors 3— Run Lignt 13 — Ambiont Componsoted 44= Exhaust Purge Light Overloads B—STARTSTOP Switch 14 —Startr Re 6 — Thermorwitchas 15 — Keyed Panet Lock (2. Hidden) 16 — Wiring Diagram 7 = Low Relrg Temp Switch 17 —Multtap Voltage Transformer tidden} 18 — Torminal Strip. 8— Capacity Contra Switch 19 — Capacity Control 9 = Solution Purnp Switen ‘Aasustr Not Shown) 10 Refrigirant Purp Switch 20-~ Elapsed Time Indicator 11 — Fused Dievonnest Switch 21 — RESET Switen NOTE: On early unis, a combined START-STOP-RESET Switch was used Fig. 2 — Control Center Components (Typical)or hot water to boil out the refrigerant. The refrigerant vapor passes into the condenser section where it contacts the cool condensing water tubes and condenses. The condensed refrigerant flows back into the evaporator section to start a new cycle. The reconcentrated solution flows from the generator back to the absorber to start a new cycle, Cycle efficiency is improved by passing the rela- tively cool weak solution from the absorber and the relatively warm strong solution from the generator thru a heat exchanger. | en ae = sour >» sure EB Fig, 3 — 1648 Flow Circuits Capacity Control — The capacity control valve modulates steam or hot water to the generator and is positioned by a controller which senses leaving chilled water temperature. At full load conditions the control valve is wide open. As the load is reduced and the chilled water temperature drops below design temperature, the control valve will be throttled. At no load conditions the control valve will be closed. The 16JB077 thru 124 machines. use two capacity control valves. On some applications, only one valve is open at low loads. When machine load increases above a predetermined point, the second capacity control valve will be energized and both valves will operate. Both sets of pumps run at all load conditions. Low Concentration Control — At part load con- ditions, operating economy is improved by the Flotender™ valve which reduces the solution flow thru the generator. When the condensing water temperature is also low, the absorber valve modulates flow to the absorber spray nozzles by bypassing some of the strong solution directly back into the absorber sump. This has the effect of limiting the dilution of the solution and main- taining enough refrigerant in the evaporator circuit to prevent refrigerant pump cavitation, ‘The absorber valve positioner senses the refrigerant level in the evaporator. High Concentration Control — When the solution approaches overconcentration, the Cycle-Guard™ transfer valve is opened to transfer refrigerant into the solution circuit to reduce the concentration. A combination of 3 refrigerant level switches and 2 solution temperature thermoswitches senses solu tion concentration to provide step control by the CycleGuard device. Purge — Basic components and flow circuitry for the 16JB motorless purge are shown in Fig. 4. During machine operation, lithium bromide solu- tion from the discharge of the solution pump flows thru two transfer devices. The absorber purge transfer device discharges directly into the second- ary heat exchanger after drawing noncondensables from the absorber. The noncondensables pass from there into the condenser. They are removed from the condenser by the second transfer device and are carried to the separation pot. From the separation pot, noncondensables flow into the storage chamber and solution passes back to the absorber. ‘As the storage chamber fills with non- condensables, the solution level is depressed and the displaced solution flows back to the absorber. 4 = fnesoneen a It ¥ 4 \ on LEGEND Ay ~ Absorber Transfer Device evel tediator ‘Ad — Condovser Tranter Device G — Aunilary Evacuation B — Secondary Heat Exchanger Vai © = Separstion Pot H Purge Exhaus Vole 5 —Storag: Chamber 3 ewtaust Botte B Solution Return Vato ic = Formate Solution Pump Fig. 4 — 16J8 Purge SystemWhen the solution reaches a predetermined level near the bottom of the storage chamber, an indicator light on the control panel signals the need. to exhaust the purge. Purge evacuation is started by closing the solution return valve. Solution from the pump discharge is thereby forced into the storage chamber, compressing the noncondensables, to a pressure higher than atmospheric. The exhaust valve is opened to pass the noncondensables thru the exhaust bottle, and is closed when the non- condensables have been exhausted. To return the purge to automatic operation, the return valve is opened to allow the flow of solution back to the absorber, The purge operation is continuous, automatic and motorless. The noncondensables are stored outside the machine, thus avoiding any flow back into the machine. Operator should log the time between purges. EQUILIBRIUM DIAGRAM A basic equilibrium diagram for lithium bro- mide in solution with water is shown in Fig. 5. Description — The left scale (horizontal lines) indicates solution vapor pressure at equilibrium conditions. The right scale is the corresponding saturation temperatures of the refrigerant (water). The bottom scale (vertical lines) represent solution concentration, For example, a lithium bromide concentration of 60% means 60% lithium bromide and 40% water by weight. ‘The curved lines running left to right are solution temperature lines. Do nor confuse these with saturation temperature lines. The curved line at the lower right cornet represents the crystalliza- tion line. At any combination of temperature and concentration to the right of this line, the solution will begin to erystallize and restrict flow. The curved lines extending upward from the bottom of the diagram are specific gravity lines. Percent lithium bromide concentration can be determined by measuring the specific gravity with a hydrometer and checking the solution tempera- ture. Then plot the intersecting point for these values on the diagram. Read down to determine the percent lithium bromide. Solution Cycle — A typical absorption solution cycle is plotted in Fig. 5. Points | thru 7 represent a complete cycle. Typical values for each point are given in Table 1. These values will vary with different loads and operating conditions. An explanation of each point and lines drawn between is as follows: Point 1 represents the strong solution as it begins to absorb water vapor. VAPOR PRESSURE ININGHES oF MERCURY ABSOLUTE SATURATION TEMPERATURE (FY PERCENT LITHION BROMIDE S¥ WE'GYT IN SOLUTION Fig. 5 — Equilibrium Diagram 4Point 2 represents the weak solution leaving the absorber and entering the heat exchanger after having absorbed water vapor. Point 3 represents the weak solution leaving the heat exchanger with the sme concentration as at point 2 but at a higher temperature. Point 4 represents the weak solution in the generator after being pre-heated to the boiling temperature. Point $ represents the maximum solution con- centration in the generator after the refrigerant has been boiled out. Point 6 represents the strong solution leaving the heat exchanger after losing heat to the weak solution. Point 7 represents strong solution leaving the spray nozzles. Table 1 — Cycle Data SATURATED soLution| varor| PERCENT TEMP |PRESS.| LITHIUM | TEMP fF) fOMIDE SOL| _(F) _ ns Sea 2] wr Jo 55 4 3 1 | 595 % 4 12 | 300 595 Ms s | 25 | 300 ea 1 6 | isa | 04 640 7 1m | 0 6 START-STOP SYSTEMS The type of start-stop system for a given machine is established by the customer. The most commonly used systems are covered herein. R view these and determine which system applicable. If machine has been shut down for more than two days, follow start-up procedures under Start- Up After Limited Shutdown or Start-Up After Extended Shutdown. Semiautomatic Start-Stop system is basic, with auxiliary equipment wired into the machine con- trol circuit. The machine is started and stopped manually with the machine START-STOP switch, The following variations of this system can be used WITH PILOT RELAYS — The chilled water pump and condensing water pump starters (or other auxiliary equipment) are wired into the machine control circuit and will operate when the machine operates. The flow switches will remain in the machine control circuit, and the pump starters and overloads will be in an extemal circuit. On shu down, the machine and all auxiliary equipment will continue to run until automatic dilution has been completed. WITH MANUAL AUXILIARIES — This system applies where the auxiliaries must be manually started entirely independent of the machine start and before the machine can start. The flow switches for the auxiliary pumps are in the machine control circuit and must be closed for the machine to operate. Auxiliaries can be stopped manually after the machine has diluted and stopped. Full Automatic Start-Stop is basically the same as semiautomatic except that the unit START-STOP switch is bypassed by a fiell-supplied thermostat or timer, On initial start, restart after low- temperature cutout, restart after interruption of supply power, or restart after cutout caused by low refrigerant level, RESET switch must be manually pressed. The START-STOP switch remains in the “Stop” position, START-UP PROCEDURES To initially energize the control circuit, press the momentary RESET switch, Then place the START-STOP switch in “Start” position to start the machine. The RESET switch must be pressed again only for restart after power failure, for restart after low-temperature cutout or for restart after cutout caused by low refrigerant level The start-up procedure will be determined by the lengta of time the machine has been shut down. If the down period was from 3 days to 3 weeks, use Start-Up After Limited Shutdown procedure. If shutdown exceeded 3 weeks, follow procedure for Start-Up After Extended Shutdown, Start-Up After Limited Shutdown — Place various ‘machine switches in positions shown below: REFRIGERANT PUNP(S) SOLUTION PUMP(S) CAPACITY CONTROL, CYCLE-GUARD START-STOP Machine should start in normal manner. If, however, the leaving chilled water does not pull down to cesign temperature, noncondensables may be present in the machine. To determine if noncondensables are present, an absorber loss reading should be taken (refer to General Mal tenance section for procedure). Machine sizes 077 thru 124 require absorber loss readings from both ends. If absorber loss is greater than 5 F, follow procedure for Start-Up After Extended Shutdown. If absorber loss is $F or less, the chilled water temperature should drop to design within a short period as the automatic purge evacuates the machine. A completely evacuated machine nor- mally has an absorber loss of 2 F or less.Start-Up After Extended Shutdown — Start the machine in the normal manner by placing the various machine switches in positions shown below: SWITCH POSITION REFRIGERANT PUMP(S) ‘Qn SOLUTION PUMP(S) Om CAPACITY CONTROL, CYCLE-GUARDT START-STOP. Bates Start When refrigerant pump starts and the solution has become warm, place capacity control switch in “Off” position. Determine machine absorber loss (refer to General Maintenance section for procedure). If absorber loss is 5 F or less, open capacity control valve and allow machine to operate. If absorber loss is greater than SF, auxiliary evacuation is, necessary because noncondensables may prevent normal operation (refer to General Maintenance section for procedure). When the absorber loss reads 5F or less, the machine can be put on automatic operation, with the capacity control switch in “Auto.” position. The purge will evacuate the machine to the normal absorber loss of 2 F or less. After evacuation, check machine tightness with a noncondensable accumulation rate check (refer to General Maintenance section). Also, if octyl alcohol has been removed by evacuation, it should be replaced (see General Maintenance section), Start-Up After Below-Freezing Conditions — Refill all water circuits if previously drained, then follow procedure for Start-Up After Extended Shutdown. Remove lithium bromide from refrigerant circuit using procedure described under Reftigerant De- contamination in General Maintenance section, MACHINE SHUTDOWN PROCEDURES Above-Freezing Conditions — Place START-STOP switch in “Stop” position. The machine will go thru automatic dilution and shut down. The machine may be left in this condition until the next start-up, Below-Freezing Conditions — Place START-STOP switch in “Stop” position, Wait until automatic, dilution has been completed and all pumps in the machine have stopped. Completely drain all tube bundles and flush all tubes with an antifreeze chemical such as glycol. In addition, the refrigerant circuit requires special treatment. Contact your local Carrier representative for this information, These precautions must be taken for total anti- freeze protes PERIODIC SCHEDULED MAINTENANCE Normal preventive maintenance for 16JB Ab- sorption Machines requires periodic, scheduled inspections and service. Refer to General Main- tenance section for procedures. Every Month of Operation 1, Determine absorber loss. 2. Check refrigerant contamination. 3. Determine noncondensable accumulation rate. 4, Check capacity control adjustment. Every Two Months of Operation 1. Check low-temperature cutout. 2. Check Flotender™ operation 3. Check Cycle-Guard™ operation. Every Six Months of Operation 1, Have solution analyzed, 2. Check refrigerant charge. Every Year — Check tube scale. Every Two Years — service valve diaphragms. Replace Every Seven Years — Inspect hermetic pumps, GENERAL MAINTENANCE Log Sheets — Periodic readings of machine and system pressare-temperature conditions should be recorded to aid the operator in recognizing normal machine conditions. Also, the record will aid in planning a maintenance schedule and in diagnosing machine troubles. Log sheets are available in pads from your Carrier representative. Purge Exhaust Procedure 1, Close the purge solution return valve (Fig. 4). 2. Wait approximately 5 minutes for storage chamber pressure to rise above atmospheric pressure, 3. Open purge exhaust valve slowly. If level in exhaust bottle drops, close valve and wait approximately 2 minutes. 4, Reopen valve slowly. If bubbles appear in the exhaust bottle, leave exhaust valve open until bubbles stop and solution level in bottle begins to rise, then close valve. Purge is now exhausted. 5. Open purge return valve. 6. Open purge exhaust valve slowly and allow solution in bottle to be drawn into purge tube. Lower solution level until the bottle is 1/3 to 1/2 full. Close exhaust valve before the solution level in bottle nears the end of the tube. Do not allow air to be drawn into the purge tube.Condensing Water Tube Scale — Scale in the condensing water tubes is indicated if the tempera- ture difference between the condensing water leaving the condenser and the refrigerant con- densate from the condenser is greater than normal (8—12F) at full load (capacity control valve(s) fully open). Scale will reduce heat transfer, in- crease steam consumption and limit machine capacity. Soft scale in tubes may be removed with brushes, If scale is hard, it may be necessary to clean the tubes with chemicals before brushing. It is recommended that an adequate water treatment program be followed. Refer to a local water treatment service representative. Noncondensable Accumulation Rate ~ The most important maintenance item on the absorption machine is maintaining vacuum tightness within acceptable limits. Check machine tightness by determining the noncondensable accumulation rate. Some noncondensables are normally gen erated within the machine, but an air leak or the need for additional inhibitor is indicated if the accumulation rate exceeds the maximum allowable rate shown in Table 2. After evacuation or other service, operate the machine at least 200 hours: before determining noncondensable accumulation rate. Then proceed as follows: 1. Fill a flexible length of tubing with water and connect to the purge exhaust connection. Insert the free end into a container of water. Close purge retum valve. Wait 5 minutes then open purge exhaust valve slightly. If the liquid level in container recedes, close exhaust valve. Wait several minutes, then repeat this step. Purge is exhausting when bubbles rise thru liquid to surface. Leave valve open until bubbles stop and liquid level rises, then close valve, Purge is now exhausted. 2. Open purge return valve and allow machine to operate for 24 hours. 3. Fill a 1,000 cubic centimeter (or equivalent) bottle with water and invert it in a clean container filled with water (Fig. 6). 4. Insert the free end of the water-filled hose into bottle. 5. Exhaust the purge, following step 1. Non- condensables will displace water in the inverted bottle. Continue until bubbling in bottle ceases and only solution flows from exhaust tubing. 6. Close exhaust valve and mark liquid level on inverted bottle. Remove bottle from container, Open purge return valve. 8, Measure amount of noncondensables removed. If a graduated bottle was used, the amount (volume) of noncondensables removed is in- dicated by mark on bottle. If a nongraduated bottle is used, empty the bottle, then fill bottle with liquid to exhaust mark. Pour liquid into a graduated container to measure volume displaced. 9. Refer to Table 2 for your machine’s maximum, allowable noncondensable accumulation rate during operation. If operating accumulation rate exceeds allowable rate for your machine, then machine either has an air leak or addi- tional inhibitor is required. Submit a solution sample to your Carrier representative for analy- sis to determine what corrective action is required (see Solution Analysis for procedur ‘Table 2 — Maximum Allowable Noncondensable ‘Accumulation Rate* tnt | wax acon owt | wat Aton, deaths Gotta] HB [aalte Os thin aioraoe pao fash oar Seon | cae leetase| 024,028 040 (07,084 | 140 see | oe iterate] 308 wees | 03 iitenae] 3% "During operation Fig. 6 — Collecting Noncondensables Solution or Refrigerant Sampling — The following procedure should be used when taking a solution or refrigerant sample from the machine. The sample is taken from the pump service valve when the pump is operating (see Fig. 7). 1. Install a hose adapter to pump service valve. Do ‘not use copper or brass fittings, as copper oxide will form and contaminate the samples. 2. Filla length of flexible tubing with water and connect one end to the adapter on the valve. Place free end in container of water (be sure end is submerged), 3. Open service valve slightly. When water level in container rises, wait several seconds to purge the water from the tube and then remove tube end from water and fill sample container. Before taking sample, be sure machine is operating without load variations and Cycle- Guard™ valve had not been energized within 10 minutes prior to sampling.ee = Fig. 7 — Adding or Removing Liquids Absorber Loss Determination — Absorber loss readings should be taken when the machine is operating with stable temperatures and the Cycle Guard™ valve closed (the Cycle-Guard indicator light is “Out”). Fill wells with heat conductive compound and insert thermometers, Remove a solution sample (see Solution ot Refrigerant Sampling) and determine its. specific gravity and temperature. The sample can be re~ turned to the machine thru the purge exhaust bottle. Use an equilibrium diagram to plot an intersecting point between specific gravity and temperature (see Fig. 8). Extend this point to saturation temperature scale (right side of diagram) to determine solution saturation temperature. Re- cord refrigerant temperature at refrigerant pump discharge line. Subtract solution saturation. tem- perature from refrigerant temperature. The di ference is the absorber loss. Repeat readings with a second sample to verify steady state conditions, Absorber loss must be checked at both ends of the unit on sizes 077 thru 124. If the absorber loss is greater than 5 F, auxiliary evacuation is necessary because noncondensables may prevent normal op- eration (see Auxiliary Evacuation). Refer to Troubleshooting for probable cause of high ab- sorber loss and suggested remedies. Adding Octyl Alcohol — Octyl alcohol may be required when the leaving chilled water tempera ture starts to rise above design temperature (pro- viding the control set point has not been altered). Since a rise in leaving chilled water temperature is also an indication of fouled condensing water tubes, or other problems, use the following procedure to determine if alcohol is required. Remove a sample of solution from solution pump service valve (see Solution or Refrigerant Sampling). If solution has no odor of alcohol (very pungent), then octyl alcohol should be added. Octyl alcohol addition may be required after the unit has been evacuated; Fig, 8 — Equilibrium Diagram for Lithium 3romide 8it also may be required after extended period of operation. The amount of octyl alcohol required ferent size units is as follows: ‘10-027 7 024.028 2 032.068 3 07; 4 Fill a length of flexible tubing with water and connect one end of the tubing to solution pump service valve (see Fig. 7). Insert other end in container of octyl alcohol. Place the solution pump switch in the “OfT” position to de-energize solu- tion pump, and open the service valve to allow alcohol to’ be drawn into machine. Close valve before air can be drawn into hose. Return the solution pump switch to the “On” position. Refrigerant Charge Adjustment — The correct evaporator refrigerant (water) charge should be maintained for normal operation. An increase in the amount of water indicates a tube leak. The refrigerant charge may be checked when: + a The machine is operating with stable tempera- tures at 80% to 100% of full load. b. Absorber temperature loss is 3 F or less (see ‘Absorber Loss Determination). c. Refrigerant specific gravity is not greater than 1,02 (see Refrigerant Decontamination). Use the following procedure 1. Place Cycle-Guard™ switch in “Off” position, 2. Remove a sample of solution (see Solution or Refrigerant Sampling) and determine the specific gravity and temperature. Locate inter- secting point of specific gravity and tempera- ture values plotted on Equilibrium Diagram (see Fig. 8). Extend this point down to Percent Concentration scale on bottom of diagram to determine concentration of weak solution. » 3, Adjust operating conditions until machine op- erates with stable temperatures at any one of the following weak solution concentrations (40.1%): a. 60%, b. 58%, ¢. 57%. Concentrations can be increased by any of the following: a, Increase the load. b. Lower the chilled water temperature (adjust the control point setting in the control panel) c. Raise the condensing water temperature. +4, Depending on the solution concentration, pro- ceed as follows: 60% (high level) — Mark position of dial settings on TSW-I and TSW-2. Turn both adjustment knobs fully counterclockwise (55 F) to open switches. 58% (middle level) — Mark position of dial settings on TSW-1 and TSW-2, Turn TSW-1 adjustment knob fully counterclockwise (55 F) to open switch. Turn TSW-2 adjustment knob fully clockwise (175 F) to close switch. ark position of dial setting on TSW-1, Turn TSW-I adjustment knob fully clockwise (175 F) to close switch, 5, Place the Cycle-Guard switch in “Auto.” position. 6. If Cycle-Guard valve and indicator light are energized (valve open), remove water from refrigerant pump service valve gradually until Cycl-Guard valve closes (see Solution or Refrigerant Sampling). If Cycle-Guard_ valve does not energize, add small quantities of water to machine until Cycle-Guard device starts to energize, Water can be added to the machine thru the refrigerant pump service valve. Connect a hose to the service valve with vacuum-tight connec- tions (see Fig. 7). Fill the hose with water and insert the other end in a container of water. Place the refrigerant pump switch in “Off” position. Open the service valve slowly and draw a small amount of water into the machine. Close the valve, Do not allow any air to be drawn into the ‘machine. Place the refrigerant pump switch in “On” position. The Cycle-Guard valve cannot ener- size when the refrigerant pump is off. When adding or removing water, allow approx- imately 10 minutes for temperatures and con: centrations to stabilize, Periodically check weak solution concentration while adjusting refrig- erant charge, and readjust machine conditions, if necessary, to maintain controlled conditions. 7. Reset TSW-1 and TSW-2 adjustment knobs to original settings (110 F for TSW-1 and 122 F for TSW-2), Auxiliary Evacuation — Evacuation is required to remove excessive noncondensables from the ma- chine, When machine absolute pressure is one in. of mercury or greater during shutdown or the ab- sorber loss is greater than 5 F during operation, the machine must be evacuated. The following is a procedure for evacuation of the machine. 1. Connect auxiliary evacuation device (three common types are illustrated in Fig, 9) to auxiliary evacuation valve. Be certain that as short a line as possible is used, and that line size is no smaller than the connection to the auxiliary device. A check valve must be used on the suction lines for all devices. Ensure that all connections are vacuum tight.If a vacuum pump is used, the oil trap can also setve as a cold trap if it has a center well to hold dry ice or a mixture of salt and ice, Any water vapor, which could contaminate the oil in the vacuum pump, will be condensed and removed by the cold trap. This will reduce the time required for evacuation and will eliminate the need to frequently replace the oil charge in the pump. Start auxiliary evacuation device and open auxiliary evacuation valve, Reduce machine absolute pressure to the pressure equivalent to the saturation temperature of the refrigerant (sce Fig. 5) if the machine is not running, or until absorber loss is 5 F or less if machine is running 3. Close auxiliary evacuation valve and shut off auxiliary evacuation device. Fig. 9 — Auxiliary Evacuation Devices Refrigerant Decontamination — During normal operation, some lithium bromide solution may be carried over into the refrigerant. To check for contamination, remove a refrigerant sample (see Solution or Refrigerant Sampling) and measure the specific gravity. Check refrigerant samples from both ends on 077 thru 124 units. If specific gravity exceeds 1,02, refrigerant must be pumped into the solution circuit to recover the lithium bromide. To transfer refrigerant to the solution circuit, place Cycle-Guard™ switch at “Manual.” Reftig- crant will flow thru the Cycle-Guard valve into the solution circuit, where the lithium bromide will be separated from the water. After 15 minutes, take additional refrigerant sample and check the specific gravity. If below 1.02, decontamination is com- plete. If not, continue the separation process until a sample is satisfactory. Return Cycle-Guard switch to “Auto,” to de-energize (close) the Cycle-Guard valve. Solution Decrystallization — Crystallization may occur, under some conditions, during a tong, unscheduled shutdown period (such as power failure) without proper dilution. If it occurs in the shell side of the heat exchanger and blocks the flow of strong solution from the generator, the solution will overflow into a pipe which returns it directly to the absorber sump. The solution pump then returns the hot solution thru the tubes in the heat exchanger, automatically heating and de- crystallizing the shell side. If crystallization results from a long, un scheduled shutdown period without proper dilu- tion, the solution pump may become bound and fail to rotate. This will cause the motor overloads to trip out. In such a case, use the following procedure to decrystallize: 1, Heat the solution pump casing and adjacent lines with steam, Special precautions must be taken with her- metic pumps. The pump casing may be warmed with steam, but under no conditions should direct heat be applied directly to the motor and controls. Also, the heat must not be directly applied to any flange connections, as the high temperature will deteriorate the gasket material 2. Check solution pump for rotation. Rotation of a hermetic pump is determined by discharge pressure at the pump service valve, Rotation cannot be viewed directly. Install a compound pressure gage on the pump service valve. Reset the pump overloads in the control panel if they have tripped out. If the pump is rotating normally, the gage will show a reading above atmospheric pressure. If the pump casing and discharge line are completely blocked, the gage will show zero atmospheric pressure. If the pump interior is only partially blocked, with some opening thru it, a deep vacuum will indicate the pump is not rotating. If this occurs, continue to heat the casing until the gage pressure shows above atmospheric with the pump overloads reset. If the heat exchanger is also blocked, the decrystallization process described at the beginning of this section will start as soon as the solution pump starts rotating. If the strong solution line from the heat exchanger to the absorber spray nozzles is blocked, tum off the condensing water pump and operate the machine with the capacity control valve open. =Turn the Cycle-Guard™ switch to “Manual” to dilute the solution. The entire unit will pick up heat and the crystallization will dissolve, When heating the machine in this manner, the Low- ‘Temperature Cutout (LTCO) and thermoswitch sensing bulbs should be removed from their wells and insulated to avoid overheating. When the machine temperatures return to normal, the LTCO and thermoswitches should be recalibrated. (See Low-Temperature Cutout Adjustment and Cycle- Guard Operation.) Refer to Troubleshooting for probable causes of crystallization and suggested remedies. Solution Analysis — Analysis of a solution sample will give an indication of machine tightness and will also indicate any inhibitor depletion. The inhibitor is gradually used during normal machine operation and it may be necessary to occasionally partially replenish the inhibitor charge. The sample should be taken from the solution pump service valve while the machine is running. (See Solution or Refrigerant Sampling.) The sample concentra- tion should be between 58% and 62%, If necessary, the solution concentration can be increased by increasing the load or condensing water tempera~ ture. Another method would be to tum off the machine and allow the chilled water temperature to rise; then take the solution sample after re- starting the machine. Solution analysis service is provided by Carrier. Contact your local Carrier representative for details. Low-Temperature Cutout Adjustment — Controls should be recalibrated any time the sensor is exposed to temperatures above 120. Remove control sensing element(s) from the well(s) on the evaporator shell. Immerse bulb in container of cool tap water, Slowly stir crushed ice into the water so that the temperature goes down at a rate not exceeding | F per minute. Observe the temperature at cutout, which should be 5F below design leaving chilled water temperature, or a minimum of 34 F. When control cuts out, the machine will shut down immediately without going thru a dilution cycle. When sensing bulb has warmed 3, the control will cut in, Restart machine by pressing the RESET switch and then placing the START-STOP switch in “Start” position. Replace elements in wells on evaporator shell. Flotender™ Operation ELECTRONIC CAPACITY CONTROL ~The Flo- tender valve should energize and open when the electronic motor has rotated 75 or more angular degrees from the closed position. When energized, there will be a magnetic field near the top of the solenoid which can be sensed with a screwdriver or any piece of thin steel. The valve is controlled by an adjustable switch mounted on the capacity control valve motor. u PNEUMATIC CAPACITY CONTROL ~ The Flo- tender valve should energize and open when the branch ait pressure to the valve operator exceeds 8.5 psig. When energized, there will be a magnetic ficld near the top of the solenoid which can be sensed wich a screwdriver or any piece of thin steel. The valve is controlled by an adjustable pressure~ electric switch in the control panel. Cycle-Guard Operation — To check operation, place Cycle-Guard switch in “Manual” position. The transfer valve and adjacent white indicator light will energize. The flow of refrigerant will cause the transfer line between valve and solution pump sump to feel cold to the touch. This line should not feel cold when transfer valve is closed (not energized). Return Cycle-Guard switch to “Auto.” During normal operation, the Cycle-Guard valve is controlled by two thermoswitches (TSW-1 and ‘TSW-2), which sense the temperature of the strong, solution flowing to the absorber spray header, and three refrigerant level switches (SW8, SW9 and SW10), which are located in the upper part of the refrigerant level control chamber. TSW-1 and TSW-2 switches should close on temperature dropat 110 F and 122 F (+1 F) respectively. Level switches SW8, ‘SW9 and SW1O should close with rising refrigerant levels corresponding to solution concentrations of 51%, 58%, and 60% (20.1%) respectively (see Refrigerant Charge Adjustment), Capacity Control Adjustment — Check leaving chilled water temperature. If design temperature is not being maintained, reset electronic or pneu- matic control set point in control panel. For electronic control, turn control point adjuster slightly to warmer or to colder as required. For pneumatic control, turn set point adjustment shaft on side of controller slightly to warmer or to colder as required. Service Valve Diaphragm Replacement — To re- place valve diaphragms, break machine vacuum with nitrogen. Solution and refrigerant can be transferred to opposite sumps within the machine or removed from the machine. If solution is removed from the machine, store it in clean containers for recharging. Remove old valve dia- phragms and replace. Torque valve bolts to 3 ft-lb. Test all affected connections for leakage. Replace solution and refrigerant in machine. The same quantity of solution and refrigerant removed must be replaced. Re-evacuate machine after servicing (see Auxiliary Evacuation). Hermetic Pump Inspection — The hermetic pumps used on Carrier Absorption Machines do not require seals. The motors are cooled by the fluid being pumped, and are thermally protected by 3-phase ambient-compensated overloads. These pumps and motors should be inspected every seven years or after 30,000 hours of operation, which- ever cones firstORDERING SPARE PARTS Order spare_parts from your nearest Carrier representati ive. To assure prompt action on spare parts orders, the following information must be 1, Delivery address 2, Machine size and serial number 3, Part name, part number and quantity needed 4, Orders for pump parts must include the motor furnished: serial number shown on the motor nameplate. 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Vacuum loss at | Leakage in vacuurn Leak-test the machine Tanaris ere | co va wesc | aslsrnesiecm | easier estes . terres = Fat wisp | Ronnaensip scr] Ose rnin ratio | crsans eo |e ore rabsrcome, | Mantcereitec”| session own on fe eon | pump or chilled water pump overloads ar Flow switches tripped Frigerant or sol tion pump overloads pes aut ‘Shutdown oa reaton for fallure ‘Raset eterine reason for fale Tk eaten: canerar Settiog Adjust contro! Polne setting oF child ‘water comtratier 12 ‘maintain design leaving Chilled water ternge ture, Chock capacity antrol valve act ‘ment end closure pumping rate ot the ‘ate Hove soliton ample analyzed for indieation of leak or Inhibitor depletion {Conk tos ane repair foraddintibtor it ‘Check valve positions | Purge waiver not positioned correctly Purge avsalized | Dowytalize ‘ack of soliton fsw | Contact your Gari fram solution pump | representative wo pune replacement items use Carrier Specified Parts. Manufacturer rears the right to change any product specifications without notie, CARRIER AIR CONDITIONING COMPANY + Tab 15 Form 1618-250 Supersedes 1618-150 Printed in USA, 1072 SYRACUSE, NEW YORK Codes MA and ML Catalog No. 531-603