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Vam Manual
Vam Manual
COOLING GROUP
OPERATION
A.1 SAFETY
Chapter Objective: This chapter describes the general precautions the operator
should take care while operating the machine.
Safeties in Handling LiBr: LiBr has to be stored in a cool and well-ventilated location and
possible contact with water is to be avoided. Special measures
are not required for handling. However, while handling the
chemical, exposure is to be avoided with minimum contact with
skin and eye. It is not recommended to inhale LiBr smell too
much. The emptied containers should be disposed of properly
(as per applicable regulations).
The work area should be provided with adequate local exhaust
ventilation, where dust or mist may be generated. Local
exhaust ventilation, confinement of the mist generation
equipment and/or room ventilation system, as well as
adequate engineering controls are needed, to ensure worker
exposure below TLV (Threshold Limit Value for Chemical
Substances in the Work Environment).
a] Number of persons exposed should be minimum.
b] Chemical goggles, rubber gloves and respiratory
protection are recommended for use.
c] Clothing should be close fitting and clean.
d] Eating, smoking and drinking are not permitted, while
handling LiBr.
e] Breathing LiBr mist is prohibited.
f] A hot shower is recommended for the worker, handling
the chemical, after the work shift.
g] The leaking and spilled liquid is to be collected in
sealable containers as far as possible.
h] The remaining liquid has to be absorbed in dry sand or
inert absorbent.
i] Washing away the chemical to sewer is not
recommended.
Figure 1.1
STEAM PRESSURE: The machine can operate for steam pressure ranging from 4
kg/cm2 g to 10.5 kg/cm2 g
Individual Parts The operation of the various parts of the absorption machine
is described below.
Heat exchangers The absorbent pump pumps the diluted absorbent to the high
temperature generator. A part of it first passes through drain
heat exchangers where it absorbs heat from the condensed
refrigerant from the low temperature generator. It next flows
through heat reclaimer where it absorbs heat from steam
condensate. The other part of liquid passes the low
temperature heat exchanger where it absorbs heat from the
concentrated absorbent. It next flows through the high
temperature heat exchanger where it absorbs heat from the
intermediate absorbent solution. Then both the dilute
solutions mix at high temperature heat exchanger outlet .The
Low Temperature The low temperature generator (LTG) and condensor tube
Generator and bundles are enclosed in a shell and are separated by an
Condensor insulation plate. The vaporised refrigerant flows into the LTG
tubes. It heats the intermediate absorbent, flowing outside the
tubes, and condenses. The condensed refrigerant flows into
the condenser. Refrigerant vapourised from the intermediate
absorbent passes through the eliminators to the condenser.
Here cooling water being circulated inside the condenser
tubes cools it. The refrigerant vapour condenses on the
outside of the condensor tubes and collects in the bottom of
the condensor. The condensed refrigerant from the LTG and
the condensor mix and flows to the evaporator. The
absorbent, which has become concentrated in the LTG drains
to the absorber to begin a new absorbent cycle.
Fig.1.Cooling mode
Capacity Control The cooling capacity of the machine is the total heat extracted
from the chilled water. The chilled water flow rate to the machine is
kept constant. Hence the capacity is proportional to the difference
in the temperatures of the inlet and outlet chilled water.
BLOCK DIAGRAM:
Safeties Safety devices are provided to protect the machine from abnormal
conditions and safeguard it from damage and ensure continued
availability.
Safety devices are -
• Machine mounted safeties located on the machine,
• Panel mounted safeties in the control panel
• Field Interlocks passing signals from the field to the machine.
Antifreeze protection. To prevent the chilled water from freezing in the evaporator tubes,
(i) L-cut : If the chilled water outlet temperature drops below the L-cut
setpoint, the refrigerant pump is switched off. The L-cut is set from
the cool mode control loop screen. This safety prevents further
temperature drop of the chilled water. The refrigerant pump will
restart after the Chilled water outlet temperature rises above the L-
cut setpoint plus the hysterisis set point.
(ii)Antifreeze : If the chilled water outlet temperature drops below the antifreeze
set point, the machine trips and the ‘TOTAL SHUTDOWN’ alarm
sequence is carried out. The alarm will be reset only after the
chilled water outlet temperature rises above the antifreeze set
point plus the hysterisis set point.
Chilled water pump Chilled water flow is essential for machine operation. A potential
interlock : free contact is to be wired from the chilled water pump motor
starter to VAM/c panel to sense chilled water pump ON / OFF /
TRIP status. The machine starts only when the chilled water pump
is ON. If the chilled water pump stops / trips during operation, the
‘TOTAL SHUTDOWN’ alarm sequence is carried out.
Chilled water flow If the chilled water flow drops below 50% of the rated value, the
switch : ‘TOTAL SHUTDOWN’ alarm sequence is carried out.
Chilled water DP If the chilled water flow drops below 50-60% of the rated value, the
switch: ‘TOTAL SHUTDOWN’ alarm sequence is carried out.
Electrical wiring should be done such that if flow switch or DP
switch operates either all the cooling water pumps should stop OR
the pneumatic butterfly valve in cooling water circuit should close
instantly.
Cooling water flow Cooling water flow should be stopped immediately when the chilled
cutoff: water flow stops in the m/c. So the cooling water pump should be
started through the start permissive of cooling water pump. If the
cooling water pump is not dedicated to the chiller then the
pneumatically controlled auto shut off valve should be used for
stopping the cooling water flow.
Steam control valve The strong solution concentration is calculated in the PLC .The
modulation on crystallization temperature for that concentration is also calculated
crystallization by the PLC. The PLC always tries to keep the Pre set safe
prevention safety distance between the crystallization temperature and strong
solution temperature of low temperature heat exchanger outlet. If
the distance is less than the pre set safe distance then the PLC
modulates the steam control valve so that the strong solution
temperature will never reach crystallization temperature.
.
Absorber level safety: If the absorber level goes below first safety limit (25% of sight glass) AE2
then the auto blow down solenoid valve will open to transfer refrigerant to
absorber to build the absorber level again. If the absorber level goes
further below (0% of sight glass) AE3, the steam control valve closes
fully.(0 amps). When the level in absorber rises back to 50% of sight glass
AE1, auto blow down valve will shut, SCV valve will open and machine will
come back in to operation automatically. AE4 is reference electrode.
Cooling water low If the cooling water inlet temperature drops below the cooling
temperature safety water low temperature set point, the ‘DILUTION CYCLE’ alarm
sequence is carried out and the machine goes into dilution cycle
immediately. The alarm can be reset only when the cooling water
inlet temperature rises above the cooling water low temperature
set point plus hysterisis set value. During initial startup till
generator temperature reaches to 120°C this safety is bypassed.
However 30min after startup this safety will be in operation
irrespective of generator temperature.
Valve control on HTG When the HTG temperature exceeds the value (set point minus
temperature 3.6°F), the steam control valve closes immediately. This prevents
further increase in LiBr concentration. The valve control is returned
to the chilled water temperature control loop when the HTG
temperature drops below (set point minus 7.2°F).
HTG Vapor If the HTG vapor temperature exceeds above the HTG vapor
temperature high temperature set point, the DILUTION alarm sequence is carried
out and the machine goes into dilution cycle. The alarm can only
be reset only when the HTG vapor temperature goes below the
HTG vapor temp trip set point minus the set hysterisis value.
HTG high If the HTG temperature exceeds the HTG high temperature set
temperature safety point, the ‘DILUTION CYCLE’ alarm sequence is carried out and
the machine goes into dilution cycle immediately. HTG high
temperature alarm can be reset only when the HTG temperature
drops below the set point minus the hysterisis set value (9°F).
This setpoint may vary slightly for nonstandard machines.
Note The set points mentioned in above descriptions are nominal set
points and may vary to some extent if machine parameters are
different from literature parameters.
Cavitation protection If the refrigerant level in the evaporator pan falls below set level,
of refrigerant pump. the pressure in the refrigerant pump suction drops below the
saturation pressure of the refrigerant and the refrigerant pump
starts to cavitate. To ensure minimum acceptable suction pressure
the level of refrigerant is not allowed to fall below a certain level.
Motor protection
safeties
Absorbent pump If the absorbent pump motor draws more than its rated current,
overload relay / AC this overload relay trips and the ‘TOTAL SHUTDOWN’ alarm
Drive sequence is carried out. The alarm is reset by resetting the
overload relay / AC Drive .(if applicable)
Refrigerant pump If the refrigerant pump motor draws more than its rated current,
overload relay this overload relay trips and the ‘DILUTION CYCLE’ alarm
sequence is carried out. Resetting the overload relay resets the
alarm.
Purge pump overload If the purge pump motor draws more than its rated current, this
relay overload relay trips. Resetting the overload relay resets the alarm.
Alarm sequences : There are three alarm sequences which activate when the fault
conditions occur
Ø Dilution cycle alarm sequence.
Ø Total shutdown alarm sequence.
Ø Purge pump trip alarm.
Dilution cycle alarm This alarm sequence protects the machine from crystallisation.
sequence.
Fault conditions which activate this alarm sequence are -
Total Shutdown Alarm This alarm sequence protects the machine from freezing of the
Sequence evaporator or any other damage.
Power failure alarm This alarm is displayed when the machine is powered up after a
sequence power failure during operation. After acknowledging and resetting
the alarm the machine will go in dilution cycle.
NOTE During vacuum pump trip, HTG top and bottom condensate line
sensor error, Chilled inlet temp sensor error only alarm will come.
Alarm When an alarm sequence is initiated, the alarm screen will pop up,
acknowledgment and with an audio alarm.
reset sequence
Unless and until the activated alarm is acknowledged the user will
Example If the chilled water pump trips, three alarms will be triggered :
Chilled water pump ‘OFF / TRIP’
Chilled water flow switch ‘TRIP’
Chilled water DP switch ‘TRIP’
Ø The ‘ALARM’ screen will pop-up and the hooter will start.
‘CHILLED WATER PUMP OFF / TRIP’ will be displayed on the
‘ALARM’ screen.
Ø Pressing ACK key will stop the hooter, and ‘CHILLED WATER
FLOW SWITCH TRIPPED’ will be displayed on the ‘ALARM’
screen.
Ø Pressing ACK again will display the next active alarm i.e.
‘CHILLED WATER DP SWITCH TRIPPED’.
Ø Once all the alarms have been acknowledged, go to the
‘STATUS’ screen and monitor the current status of the
concerned devices, i.e.
Chilled water pump ‘CHW’ ‘PUMP OFF’
Chilled water flow switch ‘FLSw’ ‘TRIP’
Chilled water DP switch ‘DPSw’ ‘TRIP’
Ø After the chilled water pump has been started and the required
flow is resumed, the ‘STATUS’ screen display will be -
Chilled water pump ‘CHW’ ‘PUMP ON’
Chilled water flow switch ‘FLSw’ ‘HEALTHY’
Chilled water DP switch ‘DPSw’ ‘HEALTHY’
Ø Once this condition is achieved, press alarm reset K4 key to
reset the alarms. The red LED will go off to indicate that the
alarm has been reset.
Start the machine by pressing the 'M/C START' key on the
operation screen.
Set points
The field instruments and the components in the control panel are
to be set as follows
PLC Input/Output
assignments
OP7 Operator The entire operation of the VAM/c is controlled through the OP7
Interface:- operator interface.
K1 MAIN MENU
K2 MACHINE PARAMETERS
K3 MACHINE STATUS
K4 FAULT RESET
Ø 'DATALOG’
• 'NORMAL'
• 'TRIP'
Ø 'SERVICES'
• 'M/C OPERATION'
• 'HTG / COW SP'
• 'LCUT / HCUT SP'
• 'OFFSET ADJ'
• 'PID SETTINGS'
• 'A/C DRIVE SETTINGS'
• M/C/ COMM DATE'
Ø 'PLC DATE / TIME'
Ø 'PRODUCT INFO'
Ø 'M/C MODES'
Ø 'ALARM LOG’
Product Info Screen This screen is the startup screen and is displayed on power up.
The first page of this screen displays the Product and Model
number.
Main Menu : This screen displays the names of all the other function and
operation screens.
Access - K1 Key The first page of the 'MAIN MENU' screen shown the names of the
The third page shows the ‘ALARMS’ and the 'DATALOG’ screen
activation keys.
The fourth page shows the ‘SERVICES’ and the 'PLC DATE/TIME’
screen activation keys.
The fifth page shows the ‘PRODUCT INFO’, 'M/C MODES' and the
'ALARM LOG’ screen activation keys.
Operation Basic machine operations are carried out through this screen. This
screen consists of 6 pages, viz.
Status This screen displays the current on-line status of the machine
Access - K3 Key safeties, Interlocks, pumps, control valve, levels, temperature
sensors, switches etc.
To invoke this screen, press K3 key. (It can also be accessed from
the 'MAIN MENU' screen.) This will display the first page of
'STATUS' screen. Other pages can be scrolled up by pressing F3
key and down by pressing F4 key.
Set points This screen can be accessed from 'MAIN MENU' screen - page 1,
by pressing the F3 key. Access the different set points by scrolling
down.
Here following set points can be changed.
CHW OUT SP OUT SP - On access of the 'SET POINTS' screen,
the cursor blinks at this set point entry field. Type the required set
point here and press ENTER key. To discard wrongly keyed
entries press ESC (escape) key.
CHW OUT TEMP and COW OUT TEMP are also displayed.
VALVE LIMIT - As the steam control valves are selected for the
range of machine models, the value of steam control valve
opening at which the rated capacity is achieved has to be the limit
for valve openings. This value determines the maximum limit on
the steam control valve opening. To change this set point scroll
down cursor to this set point value. When the cursor blinks here,
type the required %, and press ENTER key.
M/C Parameters This screen displays all measured temperatures in degree
Access - K2 Key Fahrenheit Control valve status and pump status.
Utility In the first page of this screen, the number of hours the machine
has run and the number of times the machine has tripped are
displayed
In the second page of this screen, the number of purge pump run
hours is displayed. The date and time at which the purge pump
was last run is also displayed
The activated alarm text will be displayed, with date and time of
occurrence, in the alarm window.
Service Settings The critical machine parameter settings can be edited through the
SERVICE screen. To avoid access from unauthorized persons,
these screens are password protected
There are 10 pages of Service Settings
1. M/c OPERATIONS
2. HTG / COW SP
3. L-CUT / H-CUT SP
4. OFFSET ADJ
5. PID SETTINGS
6. DRIVE SETTINGS
7. M/C COMM DATE
8. REFRIGERANT PUMP OPERATION
9. MACHINE MODE.
M/C OPERATIONS
Machine operation (start / stop) mode can be changed from local
to remote and vice versa using F1 and F2 keys. Press F1 key to
operate machine locally, and press F2 to operate machine
remotely.
HTG / COW SP
CT FAN SP
L-CUT/H-CUT SP
L CUT HYST – This set point determines the value above the L
CUT SP at which the refrigerant pump restarts. The refrigerant
pump restarts when the chilled water outlet temperature becomes
greater than or equal to L CUT SP + L CUT HYST. Unit is degree
F.
PID SETTINGS
screen just type in the new set point & press the ENTER key. Unit
is °F.
OPEN (F1) – This key lets you open the STEAM CONTROL
VALVE by increments of 1% when the chilled water PID loop is in
manual mode.
CLOSE (F2) - This key closes the STEAM CONTROL VALVE by
decrements of 1% when the chilled water PID loop is in manual
mode.
HTG TEMP LOW LIMIT - This set point is used to start the AC
drive modulation at minimum frequency (35 Hz).
HTG TEMP LOW LIMIT - This set point is used to stop the AC
drive modulation at maximum frequency (50 Hz).
PLC date / time This screen displays the current DATE and TIME of the PLC
To synchronize the time setting of the PLC and the OP7, switch off
power to PLC panel, and then switch it on again.
Machine Mode Machine "COOL" mode (F1) / "HEAT" mode (F2) can be changed
from this screen.
Alarm Log In this screen, the last six alarms logged in PLC are displayed. By
pressing F3 and F4 keys all six alarms can be scrolled.
Pre - start checks Ø Switch on the input power supply to the control panel.
Ø Check and maintain the vacuum in the machine.
Ø Check all the set points on the operator panel.
( Refer list of set points )
Ø Set the position of all the function keys on the operator panel,
as follows :
• ‘MACHINE ’ status. - OFF
• ‘PURGE’ key. - STOP
• ‘REF. PUMP’ key. - AUTO
• ‘AUTO/MAN’ key - AUTO
Note : - These settings are default and should appear when
the machine is powered up.
Starting Procedure Ø Start the chilled water pump and maintain the required ∆P
across the machine. If the flow rate is less than minimum rated
flow, CHILLED WATER FLOW LOW status will be displayed
on the ‘STATUS’ screen of the operator panel. After setting
right the flow, the DP switch and the flow switch will indicate
HEALTHY indication.
Ø Start the hot / cooling water pump / flow and maintain the
required ∆P across the machine.
Ø Start the air-compressor and / or maintain the required air
pressure (oil and moisture free air) supply to the air filter
regulators.
Ø Open the isolating valve before the steam control valve and
maintain the required dry and saturated steam pressure before
the steam control valve.
Ø Give machine ‘START’ command on the operator panel.
Machine ON indication is displayed on the ‘STATUS’ screen.
Ø Absorbent pump contactor 88A is energized. Absorbent pump
‘ON/OFF’ is controlled by the level controller 33AL. Absorbent
pump ‘ON/RUN’ indication is displayed on the ‘STATUS’
screen.
Ø Refrigerant pump contactor 88R is energized. Refrigerant
pump ‘ON/OFF’ is controlled by the level controller 33RL. The
refrigerant pump ‘ON/RUN’ indication is available on the
‘STATUS’ screen.
Ø Slow opening of steam control valve starts and opens from 0-
100% in 10 minutes, when the high temperature generator
temperature is below 70°C. The steam control valve slow
opening indication is available on the ‘STATUS’ screen.
Ø After 10 minutes the control valve is put into modulation
control. The valve opening is controlled according to the chilled
water PID temperature control and the valve status will be
displayed accordingly.
When the potential free contacts of the PLC are used to start or
stop chilled water pump and hot / cooling water pump or shut off
valve, the machine start command automatically starts the chilled
water pump and the hot / cooling water pump or opens the cooling
Stopping Procedure Ø Press the ‘M/C STOP’ switch into the ‘OFF’ position on the
operator panel.
Ø Steam control valve closes immediately.
Ø Machine goes into dilution cycle and the indication ‘DILUTION
CYCLE ON’ on the ‘STATUS’ screen.
Ø The contactor 88R is de-energized and the refrigerant pump is
stopped after 4 minutes.
Ø Hot / Cooling water pump stops or shut off valve closes after 4
minutes.
Ø The status screen will indicate hot / cooling water pump / shut
off valve ‘DISABLED’.
Ø After 20 minutes, dilution cycle completes and the absorbent
pump stops.
Ø ‘STATUS’ screen indicates ‘MACHINE : OFF’.
Ø Stop the chilled water pump / flow.
Ø The machine stops completely.
When the potential free contacts of the PLC are used to start and
stop the chilled water pump and hot / cooling water pump / shut off
valve, the machine stop command automatically stops the chilled
water pump and the hot / cooling water pump or closes the cooling
water shut off valve in proper sequence.
Service valves One service valve provides access for the manometer to the
machine, and the other provides access for maintenance
procedures like N2 charging and sampling.
Purge pump
A two stage oil sealed vacuum pump for evacuating the
machine and carrying out maintenance procedures.
Measuring vacuum Three different vacuum measurements are carried out. The
positions of the manual purge valves for these measurements
are described in the table below.
Position of Manual Purge Valves
Vacuum reading Valve no. 1 Valve no. 2 Valve No. 3
Ultimate (No Load) Vacuum Open Closed Closed
Pressure in the storage Closed Open Closed
tank
Pressure in the shell Closed Closed Open
Reading the The manometer (see Figure 9.2) consists of a glass tube
manometer fitted into a casing with a graduated scale. One end of the
glass tube is sealed and the other end is connected to the
C30 HP00 A09 A09.1
A.09.Operating Instructions
Procedure Ø Put the refrigerant pump switch into “auto” mode if it is not
so already.
Ø Confirm that the refrigerant pump is running and
refrigerant is visible in the sight glass.
Ø Open the refrigerant blowdown valve completely.
Refrigerant starts being pumped to the absorber sump.
Ø Wait till the refrigerant pump stops due to low level signal
from the refrigerant level relay (about 15min), and close
the refrigerant blowdown valve completely.
Ø Refrigerant will start building up and the refrigerant pump
will start when the refrigerant level reaches the center of
the evaporator sight glass. (About 20 min)
Ø Repeat the procedure two or three times for complete
purification of refrigerant.
Precautions Ø Outlet chilled water temperature goes up during the
blowdown procedure, and will go down when the
refrigerant restarts. Blowdown operation is carried out
when chilling requirement is not critical.
Ø Carry out refrigerant blowdown once a week.
P u rge System
Manual purge
valve No. 2
Vacuum
Manual purge
M a n o m e ter
v a l v e N o .3
S e rvice valve
M a n u a l purge
v a l v e N o .1
L i q u id
Trap
Purge
tank
Purge pump
Figure 9.1
50
40
30
20
10
0
10
20
30
40
50
MANOMETER
Figure 9.2
Operating Log
Record readings in accordance with the operating log at frequent intervals. These aid the
operator to recognize both normal and abnormal machine conditions and also aids in
planning the preventive maintenance schedule and in diagnosing machine problems. A
typical operating log sheet is shown below.
Re Items Unit Date : / /
.
1. Time : : : :
2. Chilled water flow rate m3/hr
3. Chilled water inlet & outlet temp. °C ( / / / /
)
4. Chilled water inlet & outlet kg/cm2g / / /
pressure
5. Hot / Cooling water flow rate m3/hr
6. Hot / Cooling water inlet & outlet °C ( / / / /
temp. )
7. Hot / Cooling water inlet & outlet kg/cm2g / / /
pressure
8. Generator temp. °C
9. Generator vapour temp. °C
10. Generator fluid level O
11. Absorber fluid level O
12. Evaporator fluid level O
2
13. Steam pressure before SCV kg/cm g
14. Steam pressure in HTG header kg/cm2g
15. Steam control valve opening %
16. Pressure in storage tank mmHg
17. Pressure in shell mmHg
18. Attained vacuum of purge pump mmHg
19. Steam Consumption Kg/hr
The lower the The temperature at which the refrigerant vapour in the
temperature of hot / condenser condenses, goes down in proportion to the
cooling water, the reduction in the temperature of hot / cooling water. Hence
better. the temperature differences available in the absorber and
condenser increase enabling the machine to deliver a higher
than rated capacity. As the capacity increases for the same
solution flow rate, the various inefficiencies of the heat
exchange reduce, thereby increasing the efficiency of
operation.
Extremely low hot / LiBr solution crystallizes when it is cooled. As the LiBr
cooling water solution concentration decreases, the crystallization
temperature is not temperature decreases. At a concentration of 65% the
acceptable. crystallization temperature is 42°C, at a concentration of
60% the crystallization temperature is 17°C and at a
concentration of 55% the crystallization temperature is 5°C.
The cooling water cools the diluted LiBr in the absorber,
which cools the concentrated LiBr in the low temperature
heat exchanger (LTHE). If the concentrated LiBr is cooled so
that it crystallizes in the LTHE, the LiBr stops flowing through
the LTHE, and the machine cannot operate. Hence the
temperature of cooling water is to be controlled to ensure
that the LiBr does not crystallize.
Capacity of the machine LiBr becomes hot when it absorbs vapourised refrigerant. As
reduces when hot / the temperature of LiBr solution increases its the absorption
cooling water power decreases. Hot / cooling water removes heat from the
temperature increases LiBr and ensures maximum absorption of the refrigerant. If
the hot / cooling water temperature increases, so does the
LiBr temperature. Hence the absorption of refrigerant vapour
is reduced and the pressure in the evaporator increases. The
rated chilled water temperature cannot be maintained and
steam is wasted. To prevent this, the maintenance of the hot
/ cooling water temperature is essential and hot / cooling
water temperature should not be allowed to rise.
Interlock between If the chilled water flow to the machine stops for any reason,
chilled and hot / cooling the hot / cooling water flow to the machine should also stop
water flows immediately. If the hot / cooling water flow to the machine
continues when the chilled water flow is stopped, the
absorbent solution in the absorber continues to get cooled
and creates a high vacuum in the lower shell. The refrigerant
temperature drops sharply and ice formation may start in the
stagnant chilled water in evaporator tubes.
Water treatment of The water treatment of chilled and hot / cooling water is
chilled and hot / cooling important for the machine performance and long life.
water
If the water quality is bad and shows a scaling tendency,
scale adheres to the inside of the heat transfer tubes of the
evaporator, absorber and condenser. The heat transfer
between the chilled water and the refrigerant, and the hot /
cooling water and the LiBr solution and the condensing
refrigerant reduces. This causes an increase in the LiBr and
condensed refrigerant temperatures and increases the
steam consumption. The chilled and hot / cooling water
should be treated to prevent scaling inside the tubes.
Water Quality The standard for water in the chilled and hot / cooling water
circuits is shown in the following tables.
NOTE :
1. Each item of the standard values has a strong bearing on the failure due to corrosion
or scale formation, and if any value item deviates from the standard value, it will
cause corrosion or scaling. Therefore, these should be controlled.
2. The range of the quality of water which may be used differs depending on the
chemicals used to treat the water, and is not given here. It is desirable to set the
appropriate water quality control values under the guidance of a water processing
specialist who will periodically control it.
STEAM: The steam to the machine should be Dry & Saturated. The steam
pressure should be in the range of 4 kg/cm 2 g to 10 kg/cm2 g.
There should not be any rapid fluctuation in steam supply.
ELECTRICAL: The power supply to the machine shall be strictly as per the
Voltage and frequency rating given on Machine name plate.
3. Hazards identification
Emergency Overview
Health Rating 0
Flammability Rating 0
Reactivity Rating 0
Contact Rating 0
Storage 0
4. First-aid measures
Not applicable
Dispose of container and unused contents in accordance with federal, state and local requirements.
Thermax Disclaimer
Although the information and recommendations set forth herein (herinafter "information") are presented in
good faith and believed to be correct as of the date hereof, Thermax Ltd. makes no representations as to the
completeness or accuracy thereof.
Information is supplied upon the condition that the persons receiving same will make their own determination
as to its safety and suitability for their purposes prior to use.
In no event will Thermax Ltd. be responsible for damages of any nature whatsoever resulting from the use of
or reliance upon information.
NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESSED OR IMPLIED, OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE, ARE
MADE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH THE
INFORMATION REFERS.
Prepared by Absorption Cooling Division, Thermax Limited in INDIA
3. Hazards identification
EMERGENCY OVERVIEW
- Appearance: Odorless, clear liquid
Warning! Causes eye and skin irritation. Causes digestive and respiratory
tract irritation. The toxicological properties of this material have not been
fully investigated.
-Target Organs None known.
4. First-aid measures
Eye contact Flush eyes with plenty of water for at least 15 minutes, occasionally lifting
the upper and lower eyelids. Get medical aid.
Skin contact Get medical aid. Flush skin with plenty of water for at least 15 minutes
while removing contaminated clothing and shoes. Wash clothing before
reuse.
Inhalation Remove from exposure and move to fresh air immediately. If not
breathing, give artificial respiration. If breathing is difficult, give oxygen.
Get medical aid.
Ingestion Never give anything by mouth to an unconscious person. Get medical aid.
Do NOT induce vomiting. If conscious and alert, rinse mouth and drink 2-4
cupfuls of milk or water.
Notes to the physician This product is anticipated to have low oral toxicity and may be irritating to
eyes, skin and mucous membranes. Treat symptomatically and
supportively.
Handling Wash thoroughly after handling. Use with adequate ventilation. Avoid
contact with eyes, skin, and clothing. Keep container tightly closed. Avoid
ingestion and inhalation. Wash clothing before reuse. Keep from contact
with moist air and steam. Wear safety glasses or goggles and rubber
gloves.
Storage Store in a tightly closed container. Keep away from strong acids.
Exposure Limits:
OSHA Vacated PELs Lithium Molybdate (VI): No OSHA Vacated PELs are listed for this
chemical.
Chronic effects No data available for the product. Prolonged exposure to high
from overexposure concentrations of molybdenum may cause damage to the liver, kidneys
and spleen, and cause gout symptoms in humans. Molybdenum is
reported to affect female reproductive capacity. Subchronic exposure in
diet studies (sodium molybdate) with laboratory animals caused growth
retardation, anemia, bone and joint deformities, and bony growths of the
jawbone.
Carcinogenicity
- IARC Not listed
- NTP Not listed
- OSHA Not listed
- OTHER - ACGIH Not listed
Environmental toxicity testing of the product has not been carried out. For
molybdenum, reported 96 hour LC50 values for marine fish and
invertebrate range from 1045 ppm to 2587 ppm molybdenum.
Molybdenum is considered to be non-toxic to marine fish and invertebrate.
Lithium carbonate is expected to be moderately toxic to aquatic
invertebrates (Daphnia magna: 48 hr. EC50 = 33.2 mg/L), and freshwater
fish (Rainbow trout: 96 hr. LC50 = 30.0 mg/L).
Chemical fate Information Lithium molybdate exists as the inorganic ions of lithium and molybdenum
in aqueous solutions. Lithium molybdate is not biodegraded,
bioaccumulated or photodegraded.
UNITED STATES
SARA TITLE III (SUPERFUND AMENDMENTS AND REAUTHORIZATION ACT)
Section 302 Extremely hazardous substances (40 CFR 355): Not listed
Section 311 Hazard Category (40 CFR 370): Immediate (Acute) Health Hazard
Section 313 Reportable Ingredients (40 CFR 372): This product does not contain a toxic chemical
subject to the reporting requirements of Section 313 of Emergency Planning and Community Right-To-
Know Act of 1986.
TSCA Regulatory (40 CFR 707.60): This product is not subject to TSCA 12 (b) Export Notification
Requirements.
STATE REGULATIONS
California Proposition 65: WARNING. This product contains a chemical known to the State of California
to cause reproductive toxicity.
CANADA
Thermax Disclaimer
Although the information and recommendations set forth herein (herinafter "information") are presented in
good faith and believed to be correct as of the date hereof, Thermax Ltd. makes no representations as to the
completeness or accuracy thereof.
Information is supplied upon the condition that the persons receiving same will make their own determination
as to its safety and suitability for their purposes prior to use.
In no event will Thermax Ltd. be responsible for damages of any nature whatsoever resulting from the use of
or reliance upon information.
NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESSED OR IMPLIED, OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE, ARE
MADE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH THE
INFORMATION REFERS.
3. Hazards identification
Emergency Overview
Aggravation of Pre-existing
Conditions No information found.
4. First-aid measures
Eye Contact Immediately flush eyes with plenty of water for at least 15 minutes, lifting
lower and upper eyelids occasionally. Get medical attention immediately.
Skin Contact Remove any contaminated clothing. Wash skin with soap or mild
detergent and water for at least 15 minutes. Wash clothes before reuse.
Get medical attention if irritation develops or persists.
Inhalation Remove to fresh air. If not breathing, give artificial respiration. If breathing
is difficult, give oxygen. Call a physician.
Ingestion Give large amounts of water to drink. Never give anything by mouth to an
unconscious person. Get medical attention.
Special Information In the event of a fire, wear full protective clothing and NIOSH-approved
self-contained breathing apparatus with full facepiece operated in the
pressure demand or other positive pressure mode.
Ventilate area of leak or spill. Remove all sources of ignition. Wear appropriate personal protective
equipment as specified in Section 8. Isolate hazard area. Keep unnecessary and unprotected personnel from
entering. Contain and recover liquid when possible. Use non-sparking tools and equipment. Collect liquid in
an appropriate container or absorb with an inert material (e. g., vermiculite, dry sand, earth), and place in a
chemical waste container. Do not use combustible materials, such as saw dust. Do not flush to sewer!
Skin Protection Wear impervious protective clothing, including boots, gloves, lab coat,
apron or coveralls, as appropriate, to prevent skin contact.
Eye Protection Use chemical safety goggles and/or a full face shield where splashing is
possible. Maintain eye wash fountain and quick-drench facilities in work
area.
Carcinogenicity
- IARC Not listed
- NTP Not listed
- OSHA Not listed
- OTHER - ACGIH Not listed
12. Ecological information
Environmental Fate No information found.
Environmental Toxicity No information found
Label First Aid In case of contact, immediately flush eyes with plenty of water for at least
15 minutes while removing contaminated clothing and shoes. Flush skin
with soap or mild detergent and water for at least 15 minutes. Wash
contaminated clothing before reuse. If inhaled, remove to fresh air. If not
breathing, give artificial respiration. If breathing is difficult, give oxygen. If
swallowed, give large amounts of water to drink. Never give anything by
mouth to an unconscious person. In all cases call a physician.
Thermax Disclaimer
Although the information and recommendations set forth herein (herinafter "information") are presented in
good faith and believed to be correct as of the date hereof, Thermax Ltd. makes no representations as to the
completeness or accuracy thereof.
Information is supplied upon the condition that the persons receiving same will make their own determination
as to its safety and suitability for their purposes prior to use.
In no event will Thermax Ltd. be responsible for damages of any nature whatsoever resulting from the use of
or reliance upon information.
NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESSED OR IMPLIED, OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE, ARE
MADE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH THE
INFORMATION REFERS.
3. Hazards identification
4. First-aid measures
Eye contact Holding the eyelids apart, flush eyes promptly with copious flowing water
for at least 20 minutes. Get medical attention immediately.
Skin contact Remove contaminated clothing. Wash skin thoroughly with mild soap and
plenty of water for at least 15 minutes. Wash clothing before re-use.
Get medical attention if irritation persists.
Ingestion If swallowed, wash mouth thoroughly with plenty of water and give water
to drink.
Get medical attention immediately.
Suitable extinguishing media Material is not combustible. Use extinguishing media appropriate to
surrounding fire conditions.
Fire fighting procedure Cool containers with water spray. In closed stores, provide fire-fighters
with self-contained breathing apparatus in positive pressure mode.
Personal precautions Wear respirator, chemical safety goggles, rubber gloves and boots.
Methods for cleaning up Absorb on sand or vermiculite and place in closed container for disposal.
Avoid access to streams, lakes or ponds.
Ventilate area and wash spill site after material pickup is complete.
Storage Store in a dry, cool, well-ventilated area away from incompatible materials
(see "materials to avoid").
Exposure Limits:
Hygiene measures Safety shower and eye bath should be provided. Do not eat, drink or
smoke until after-work showering and changing clothes.
Effects of overexposure :
- Ocular Severe irritant
- Dermal Mild irritant to intact skin.
- Inhalation May irritate the upper respiratory tract
- Ingestion May cause vomiting, nausea, diarrhea and ataxia.
Slurred speech, blurred vision, dizziness, sensory loss, convulsions and
stupor may occur in cases of large intake.
Aquatic toxicity :
- 96 Hour-LC50, Fish >1000 mg/l
- 72 hour - EC50, Marine alga 751.9 mg/l
- 48 Hour-EC50,Marine Invertebrate 1527.7 mg/l
13. Disposal considerations
Thermax Disclaimer
Although the information and recommendations set forth herein (herinafter "information") are presented in
good faith and believed to be correct as of the date hereof, Thermax Ltd. makes no representations as to the
completeness or accuracy thereof.
Information is supplied upon the condition that the persons receiving same will make their own determination
as to its safety and suitability for their purposes prior to use.
In no event will Thermax Ltd. be responsible for damages of any nature whatsoever resulting from the use of
or reliance upon information.
NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESSED OR IMPLIED, OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE, ARE
MADE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH THE
INFORMATION REFERS.
Don’ts Don’t open any of the valves of the purge unit without
running the vacuum pump.
Don’t connect the pressure gauge to any service valve
continuously.
Don’t disturb the setting of any instrument or safety provided
on the machine.
Don’t put the refrigerant pump switch, or the steam control
valve operational switch in ‘MANUAL’, during normal
operation of the machine.
Don’t increase the overload setting of any motor, even if the
overload alarm trips.
Do not run the vacuum pump continuously.
Do not let the temperature of hot / cooling water fall below
10 deg.C. Maintain it by stopping the cooling tower fan or by
bypassing the cooling water into the cooling tower basin by
installing a 3 way valve.
• Use proper sized hooks/slings and approved methods for lifting the machine.
• Lift the machine from all the four corners while keeping the unit leveled with respect
to the ground.
• Take care while hooking up the shackles, provided near the pipes. (Refer figure )
• Avoid any damage to the control panel and the machine mounted instruments.
PART SHIPMENT
Three-section shipping
Avoid the pipes when hanging the wire on the chiller.
Leveling of machine :
It is very important to level the machine prior to hooking up the machine with the external
piping. Proper leveling of the machine ensures that the rated capacity of the unit is
achieved. Allowable tolerance is less than or equal to 1/16 inch per 5 ft. (1mm per 1000
mm) both lengthwise and sidewise.
There are four leveling check points provided on the machine. (labeled as A, B, C and D
in the figure below) These check points are designated by the three punch marks on the
tube sheet or shell of the lower shell of the machine.
A B
VAPOR ABSORPTION
MACHINE
C D
SE
HO
L
NY
VI
R
EA
CL
A B C D
0 mm mm mm mm
After providing the shims, confirm the leveling of the machine by taking a new set of
readings.
TROUBLESHOOTING
A.Problems without These problems may occur either when the machine starts or
alarm indication. during operation of the machine.
1. Operator terminal Ø Check if the main circuit breaker is turned on. If not,
does not light up. switch it on.
Ø Check if all the MCB's are on. If not, switch them on.
2. Machine does not In case the machine does not start up, check the following :
start. Ø Are the chilled water and hot / cooling water pumps
running? If not, operate the pump(s).
Ø Are the inlet and outlet valves of the chilled water and hot
/ cooling water on the machine open? If not, open the
valve(s).
Ø Check if the chilled water flow rate sufficient. If not, check
the following :
a)If the strainer in the chilled water circuit is clogged,
clean the strainer in the chilled water circuit.
b)Is air accumulated in the chilled water circuit? If yes,
vent out the air from the chilled water circuit.
Ø Maintain the proper chilled water flow across the machine.
3. Chilled water In case the leaving chilled water temperature is not dropping,
temperature is not check the following -
dropping.
Ø Are the auxillary equipments ON ?
Ø Is the steam control valve select key in ‘AUTO’ position? If
not, put the steam control valve in ‘AUTO’ mode.
Ø Is the refrigerant pump in ‘AUTO’ mode? If not, put the
refrigerant pump in ‘AUTO’ mode.
• Insufficient vacuum.
• Insufficient steam supply.
• Insufficient hot / cooling water supply.
• Hot / Cooling water inlet temperature is higher than
the design temperature.
• Refrigerant pump not operating.
• Chilled water flow rate higher than rated.
• Load on machine is higher than rated.
4. Fouling of hot / Fouling in the hot / cooling water and / or chilled water circuit
cooling water and / or accumulates in proportion to the operating hours of the
chilled water circuit machine, and the capacity decreases in proportion to the
fouling.
Occurrence of fouling can be observed by noticing the
pressure difference across the evaporator for chilled water
circuit and across the absorber and condenser for hot /
cooling water circuit of the machine. If the pressure difference
across the respective heat exchanger has increased
compared to the original value with the chilled water and hot /
cooling water flows remaining constant, it indicates scaling in
the respective circuit. Fouling in the hot / cooling water tubes
can also be confirmed by comparing the temperature
difference between the hot / cooling water outlet and
condensed refrigerant . If the difference is more than 3°C, it
indicates scaling in the hot / cooling water tubes. Fouling in
the chilled water tube can be confirmed by observing the
temperature difference between the chilled water outlet
temperature and the refrigerant temperature on the outlet of
the refrigerant pump line. In case the temperature difference
exceeds 3°C, it indicates fouling in the chilled water tubes.
6. Insufficient octyl Insufficient quantity of octyl alcohol in the machine will cause
alcohol a reduction in the capacity of the machine. If there is no smell
of octyl alcohol in the exhaust from the purge pump, octyl
alcohol is insufficient.
Charge the required quantity of octyl alcohol into the
machine.
The charge volume of octyl alcohol is 1.1 litres / 1,000 kgs of
LiBr ( 55 % by weight ). Excessive addition of octyl alcohol
will affect the absorbent circulation. Hence charge octyl
alcohol in small quantities and observe the change in capacity
of the machine. Do not charge excess quantity of octyl
alcohol into the machine. Charge it from refrigerant service
valve.
7. Very small amount If the machine is operating with a very small amount of air
of air leakage in the leakage, the capacity of the machine will reduce slowly over a
machine period of time .
Check the corrosion inhibitor level in the machine and
maintain it as per the standard requirements.
Perform the nitrogen leak test on the machine. Check for any
8. Large fluctuation in The reasons for large fluctuation in the chilled water outlet
the chilled water temperature are -
outlet temperature
Ø Variation in chilled water flow
Check and maintain the required flow.
Ø Variation in load
Check and maintain a constant load on the machine.
Ø Incorrect setting of PID values
Check and correct the required PID values as per the
setpoint datasheet.
Ø Frequent ON/OFF operation of refrigerant pump due to
less refrigerant quantity at low load.
9. Steam control If the steam control valve does not close when the desired
valve does not close temperature of hot or chilled water is achieved, check and
when the hot or correct the hot or chilled water set points.
chilled water outlet
temperature crosses
the set temperature
B.Problems with alarm If the machine is in operation and any of the following
indication problems occur, the machine stops with an audio alarm and a
suitable visual alarm on the panelview operator terminal
screen.
The probable cause and remedy for the warning stop are as
follows
Chilled water temperature Steam passing through Ensure no steam passing when
very low ( Machine machine due to valve control valve position in panel is
tripped by antifreeze not closing fully,valve zero.
thermostat) leakage or bypass
valve leakage.
Sensor not reading Calibrate the sensor.
correct temperature.
Difference between L- Increase the difference.
cut and antifreeze set
point is too low.
Chilled water inlet Sensor cable is open / Replace the sensor cable.
temperature sensor error. short.
Chilled water outlet Loose connection of Check the tightness of the cable
temperature sensor error. sensor cable. connections.
Faulty temperature Replace the temperature sensor.
Hot / Cooling water inlet sensor.
temperature sensor error. Sensor terminal box is Clean the sensor terminal box.
Hot / Cooling water outlet moist.
temperature sensor error.
HTG temperature sensor
error.
LTG temperature sensor
error.
REF U tube temperature
sensor error.
HTG condensate
temperature sensor error.
HR in temperature sensor
error.
HTG vapour temperature
sensor error.
Sprayed solution
temperature sensor error.
• Restart the machine only after the fault has been rectified.
• Whenever any safety device is replaced, make sure that the electrical connections are
done correctly.
• Check and tighten any loose connection in the control panel and on the safety device.
Ø Start the machine and stop it, to put the machine into
dilution cycle.
Ø Start the machine and check for crystallisation. If there is
no indication of crystallisation, operate the machine.
Ø If there is any indication of crystallisation, perform
decrystallisation, and then operate the machine.
Power cut during If the power is interrupted when the air-purging of the
purging operation of machine is in progress, immediately close manual purge
the machine valve no.1, and then close the other manual purge valves. As
soon as the power is resumed, operate the purge pump and
continue air-purging.
Jamming of the purge Ø If the absorbent solution is forced into the purge pump by
pump the incorrect operation of charging or discharging nitrogen
gas, the absorbent solution causes jamming of the purge
pump.
Precautions for Always charge fresh purge pump oil in the purge pump for
operation of purge long term shut down.
pump. After a long term shut down or in the cold season, rotate the
pulley of the purge pump manually several times before
starting the purge pump.
Precautions to be Ø Never ever remove / insert any of the PLC cards under
observed while powered conditions.
troubleshooting the Ø Prior to power up always confirm that all the PLC cards
PLC are in their respective slots as per the machines’ electrical
drawing.
Ø Always keep the slelector switch on the CPU in ‘RUN’
position.
Ø Ensure perfect earthing for the machine panel.
Ø Before interchanging / replacing any of the cards ensure
that they are exactly as per the card specifications
mentioned in the machine manual (I/O list).
Ø Do not change the jumper settings on any of the cards.
Ensure that they are as per the notes in the machines’
electrical drawing
Correction Procedure- This fault deals with the temperature control software loop.
External signal error Confirm that the P, I and D values and chilled water outlet
(S*) temperature setpoint, are not negative, zero, or out of range.
If found so, correct the values.
MAINTENANCE
Chapter Objective This chapter details the schedule of the various preventive
maintenance procedure to be carried out. Preventive maintenance
ensures best performance and long life of the machine.
Daily • Check chilled water and hot / cooling water flow rates.
• Check steam inlet temperature and pressure.
• While the machine is in operation the following may be
observed -
No abnormality in the steam control valve.
No abnormal sound in the absorbent, refrigerant and
purge pumps.
No other abnormality.
Purging.
• Purging
Quarterly • Check and record working of all the safeties and their
settings. Reset or replace the safety devices, as required.
• Check all the set point values on the control panel
• Measure and record current drawn by absorbent,
refrigerant and purge pumps.
• Measure the absorbent pump pressure and record the
generator vapour temperature at the same time.
• Analyze and control chilled and hot / cooling water quality.
• Analyze the Lithium bromide solution, and maintain the
corrosion inhibitor level and alkalinity. Charge corrosion
inhibitor, if required. Charge alkali or acid, if required to
maintain the desired parameters of lithium bromide
• Check for the presence of octyl alcohol. Charge octyl
alcohol, if required.
• Check the actual position of Steam Control valve matches
with the control valve opening indicator.
Remark: Please contact Thermax ACD spare representative and kindly quote m/c model and
serial no.
Maintenance for long This section describes the activities to be carried out during
term shut down the long-term shut down of the machine.
Ø Make sure that the steam control valve is closed and
there is no circulation of cooling and chilled water through
the machine.
Ø In case the shutdown is for one week or more, perform
either :
A. Perform air-purging once a week, to maintain the
required vacuum in the machine.
B. If the shutdown is for a period more than three weeks
charge nitrogen gas into the machine upto a positive
pressure of 0.2 kg/cm2g. No purging is required in this
case
Ø Dry generator headers / tubes.
Absorber and The absorber and condenser tubes should be kept dry.
condenser section Ø Drain out all the water from the absorber and condenser
from the drain port of the absorber header.
Ø Carry out tube cleaning to remove any scale or slime in
the absorber and condenser tubes.
Ø Clean the tubes with water.
Ø Add anti-corrosion chemicals to water and circulate it in
the absorber and condenser circuit.
Ø Drain the water from the tubes.
Ø Dry the inside surface of the tubes.
Evaporator section The evaporator tubes should be kept full with water. *
* If the machine is located at a site where the ambient
temperature will be below freezing point of water, drain out all
the chilled water and dry the evaporator tubes.
Page No.
C04.2
Figure 4.1
C.04.Procedures for Maintenance
C.04.Procedures for Maintenance
Charging solutions This section describes the procedure for charging absorbent
(absorbent and and refrigerant into the machine. (See Figure 4.1)
refrigerant)
Service valve
Sampling Tool
Manual purge
valve No.1
Liquid
Trap
Purge
Tank
Sampling Tool
Purge pump
C04.4
Figure 4.2
C.04.Procedures for Maintenance
C.04.Procedures for Maintenance
Method of sampling This section describes the procedure for sampling small
absorbent amounts of absorbent.(See figure 4.2)
60
1.76
1.75
Figure 4.3
1.95
94
93
92
91
1.90
89
88
87
86 70
85
84
83 69
82
81
68
1.80
79
78 67
77
76
66
SPECIFIC GRAVITY
75
74
73
65
72
71
CONCENTRATION (\)
64
1.70
69
68 63
67
66 62
65
64 61
63
62 60
61
1.60 59
59
58 58
57
56 57
55
54 56
53
55
52
51 54
1.50
.49 53
0 10 20 30 40 50
.48
52
1.20 1.47
19 .46
60 70 80 90 100 110 51
18 .45
17 .44 50
16 1.43
15
120 130 140 150 160 170 180
14 22
13
12 20
TEMPERATURE (C)
11
110 18
09
16
08
LITHIUM
07 14
06
CONCENTRATION (\)
05 12
04
03 10
02 8
01
100 6
99 4
98
97 2
1
96 0
095
0 10 20 30 40 50 60 70 80 90 100
Adding Inhibitor This section describes the procedure to add inhibitor into the
machine to prevent corrosion.
Target concentration of inhibitor : 300 ppm
Adding Alkali (LiOH) This section describes the method of adding Lithium
Hydroxide (LiOH) into the machine when the measured
alkalinity is less than 0.03N.
Adding Acid (HBr) This section describes the method of adding Hydrogen
Bromide (HBr) into the machine when the measured alkalinity
is more than 0.07N.
Adding Octyl Alcohol Octyl alcohol is charged in small quantities to enhance the
performance of the machine. As there are chances of losing
Octyl alcohol, it is necessary to top up the quantity of Octyl
alcohol. This section describes the procedure for checking
and the method of adding Octyl Alcohol (2-Ethyl 1-Hexanol)
into the machine.
Charging Nitrogen Gas This section deals with the method of charging the machine
with N2 gas. (See Figure 4.5)
Expelling Nitrogen Gas This section describes the procedure of expelling nitrogen
from the machine.
Equipment used . None
Precautions Ø Do not on any account open No.1 and No.2 manual air-
purge valve while N2 gas is being discharged from the
machine
Ø When expelling N2 gas, adequately ventilate the
surrounding area.
Manual purge
valve No.2
Vacuum
Manometer Manual purge
valve No.3
Service valve
N2
Cylinder
Manual purge
valve No.1
Liquid
Trap
Purge
tank
Purge pump
Figure 4.5
Measuring Absorbent This section explains the procedure to measure the absorbent
pump pressure pump pressure.
Figure 4.6
Bubble test This section describes the procedure for carrying out the
bubble leak test. (see Figure 4.6)
20 Series 15
30 Series 25
40 Series 30
50 Series 40
60A & 60B 45
60C & 60D 60
70 Series 70
80A & 80B 85
80C & 80D 105
When is bubble leak Ø As part of the leak test after assembly work at site.
test performed? Ø As part of the periodical inspections.
Ø After carrying out site procedures that break vacuum
tightness and after N2 leak test.
Chilled water Flow Ø Disconnect two wires connected to terminals strip in the
switch and Differential control panel from the flow switch and DP switch.
Pressure switch. Ø Connect the tester between the above disconnected two
wires.
Ø Set the tester to measure resistance.
Ø Operate chilled water pump(s).
Ø Close the valve furnished at delivery piping of chilled
water pump gradually to reduce chilled water flow rate.
Ø Inspect that the indication of the tester becomes infinity at
50% of the specified chilled water flow rate.
Ø If the setting was disturbed, re-adjust the flow switch and
(or) DP switch. After completion of the test, reconnect the
wires.
Ø If flow switch/ DP switch is broken, replace it.
Precautions Stir the water to get the average temperature in the bucket
during measurement.
Calibration of all the Instruments should be done once a year. Based on the
dependence of some instruments the calibration frequency can be increased
(may be 2 to 4 times a year) based on customer’s operating conditions.
OPERATION AND
MAINTAINANCE MANUAL
Series
WSVP
Pump Model
________----
IVP/T 100(M)
_______________
IVP/T 180(M)
IVP/T 300(M)
Page: 1
INDO WOOSUNG pumps are Oil Sealed Rotary Vane Positive Displacement
Vacuum Pump. The pump is double stage consisting of first and second cylinder
(body), shaft with rotor having slots for first and second stage vanes placed at
right angle. The first and second stage vanes are fitted in the rotor and rotor is
placed eccentrically in the first and second stage cylinder. The exhaust valve
consisting of valve seat and springs has been fitted on first and second stage
cylinder. On the shaft two lip type oil seals have been fitted, one from inside to
prevent oil leakages and the other externally for preventing atmospheric air
leakages. The bearing has been fitted in-between the two oil seals and oil
lubrication for the same is provided through the slot provided on the front cover
internally. The gas ballast has been fitted on the front cover through which
atmospheric air is being admitted at the exhaust end of second cylinder for
preventing condensation of vapours inside the pump internals. All these parts
assembled on front cover forms complete cartridge assembly of the pump which
is fitted inside the oil reservoir tank. The oil reservoir tank has been provided
with suction, exhaust and oil inlet ports. Oil reservoir tank has been fitted with
sight glass with marking for maintaining the oil level inside the tank. The suction
port is press fitted on the first stage cylinder having o-rings at the bottom end.
Intake lock nut with o-ring has been fitted on the suction port for holding the
suction port. Cap type exhaust port has been fitted on the oil reservoir tank for
trapping oil droplets.
Displacement
50Hz 100 180 300 600
LPM
-2 -2 -2 -2
Ultimate With gasballast 1 x 10 1x10 1x10 1x10
Pressure Torr Without gasballast -4 -4 -4 -4
5 x 10 5x10 5x10 5x10
suction port (mm) Ø25 Ø32 Ø32 Ø46
1/2
Outlet port PF 3/4" PF 1" PF 1" PF 1 "
Power requirements (Kw) 0.4 0.4 0.75 0.75
Rotational speed (R.P.M) 600 600 600 600
Oil capacity ( ) 1.3 1.8 2.2 4
Weight (including motor) kg 45 50 60 80
Note: Under specified test conditions & with standard suction port. KF type suction port will be supplied on
request.
Outside Dimension
MODEL A B C D E F G H I J K L
IVP/T 100(M) 463 25 285 425 175 Ø 25 30 20 122 73 Ø 171 Ø 13
IVP/T 180(M) 488 285 342 450 200 Ø32 35 25 135 88 Ø171 Ø13
IVP/T 300(M) 545 310 365 515 272 Ø 32 40 30 145 100 Ø171 Ø13
IVP/T 600(M) 610 350 424 580 310 Ø 46 50 35 171 110 Ø210 Ø13
Note: All dimensions are in millimeters. Design & Specifications are subject to alterations without prior notice.
Electric wiring
- Quantity of the vacuum oil to be checked for desired level through oil level
indicator.
- Check for any leakage of oil from the pump. (Pump shaft sealing)
- Check the belt tension, belt should not be too tight or too loose, ideal
fitting (belt tension) is, when pressed by finger it sinks about 10 to 15 mm.
- If the pump has been unused for a long time and/or after the oil change,
the ultimate pressure cannot be obtained until moisture is removed from
the oil. In order to obtain the ultimate pressure, the moisture should be
removed by running the pump for 30 minutes by blanking the suction port
and gas ballast in fully open position.
- Ensure intake screen in the suction port, this is provided to prevent any
foreign material entering into the vacuum pump. It should be kept clean in
order to prevent drop in the pumping capacity.
Pump Operation
- Before switching off the pump admit air into the pump to bring the pump
at atmospheric pressure and then switch off.
- If the pump is to be kept for long time without operation cover the intake
port and other connecting ports such as hose pipe etc.
- Pump doesn’t require any special storage.
Caution
- Do not switch off the pump under vacuum. It may result in oil getting
inside the system under evacuation through pump internals if anti-
suckback device is not provided at suction port of the pump.
- INDO WOOSUNG vacuum pumps have 2 oil seals, one fitted externally to
avoid air in leakages and the other internally to prevent oil leakage. To
change the oil seals and bearings the following steps are to be followed.
I. Remove the safety cover, V-belt and pump pulley.
II. External oil seal can be replaced by making use of puller.
III. For replacement of bearing and internal oil seal, front cover is to be
separated out from the first stage body by removing hex socket head
cap screws provided on the front cover.
IV. Remove bearing and internal oil seals by use of special jig.
V. Reassemble the front cover and first cylinder by fixing the dowel pin
and then screw the bolt.
- Remove the rear end cover fitted on second stage of the pump body.
- Remove the II nd Stage body by unscrewing the bolts and slightly hammer
the pump shaft vertically on the flat surface.
- Replace second stage vanes.
- For replacement of I st stage vanes remove the rotor from the I st Stage
body.
• The Ist and IInd Stage exhaust valve seats and springs can be replaced by
unscrewing the Ist and IInd Stage exhaust valve plates.
Use only
INDO WOOSUNG IVC 200
HIGH PERFORMANCE VACUUM OIL
Specially formulated to increase service life of INDO WOOSUNG Oil Sealed Rotary
Vane Vacuum Pumps and for achieving high vacuum performance. A high level of
thermal and chemical stability offer extended oil drain interval and trouble free
operation of these pumps.
High pump 1. Less oil in the pump 1. Maintain required oil quantity.
temperature 2. Wrong use of vacuum 2. Use proper vacuum oil compactable to
oil processes
3. Oil circulation problem 3. Dismantle and clean the pump internal oil
lubrication passages
4. Damage of exhaust 4. Replace exhaust valve seats and springs.
valve
Motor drawing high 1. Pump oil contaminated 1. Replace pump oil
current / tripping 2. Due to contaminants, 2. Maintain proper oil level
oil level increased.
Open Loop Treatment : Open Loop treatment is carried out to maintain the desired
quality of cooling water.
The chemicals which are recommended for cooling water
open loop treatment are :
i.) Corrosion and Scale Inhibitor and Biocide
ii.) Corrosion and Scale Inhibitor
Corrosion Inhibitor These are water soluble corrosion inhibitors which absorb on
the metal surface and a thin film of corrosion inhibitors is
formed on the metal surface. This film however does not
interfere in the heat transfer.
Copper Corrosion These are special compounds which are used to protect
Inhibitor: copper metallurgy. These chemicals form a protective layer
on the copper metallurgy and prevent galvanic corrosion.
Biocides Biocides are used to kill algae, bacteria and fungi which are
present in cooling water because it is expected to open
Chilled Water Treatment : The main problems which arises are corrosion and microbial
fouling because the problem of scaling is eliminated by using
soft / DM water. Therefore following products are used for
chilled water treatment.
Corrosion Inhibitors These are special compounds specially designed for close
loop like chilled water circuit and in a way are different from
corrosion inhibitors which are used for open loop or cooling
water treatment. The main difference is that corrosion
inhibitors used in close loop work in absence of oxygen. This
corrosion inhibitor formulation has a pH buffer system which
take care of pH upset in the system.
Biocide The biocide used for chilled water ciruit is different from the
biocides which are used for open loop systems. This
problem of biofouling is not as frequent as in open loop
circuit. The trade name of this product is Maxtreat 651. This
product is not the recommendation, but it is an advised to
consult head office whenever biofouling problem is
encountered in chilled water circuit.
DEALER
( Service Franchisee)
Area Manager
Regional Manager