Manual - O & M For VAM PDF

THERMAX LIMITED
ABSORPTION COOLING DIVISION
VAPOUR ABSORPTION HEAT PUMP

“PROCHILL B4K (DOUBLE EFFECT)”
OPERATION & MAINTENANCE

MANUAL
C30 HP00 CVP CVP.1

CONTENTS
MANUAL PART NO: CZJB817601

Sr. No. Particulars Doc No.
Section-A C30 HP00 A00

Operation
A.1 Safety C30 HP00 A01
A.2 Part Identification C50 760 03 01
A.3 P & I Diagram C30 9PE SD01
A.4 Electrical scheme CZ JB81 760B
A.5 Product Brief C30 HP00 A05
A.6 Principle of Operation C30 HP00 A06
A.7 Control & Safeties CZ JB81 760C
A.8 Start & Stop procedures C30 HP00 A08
A.9 Operating Instructions C30 HP00 A09
A.10 Utility requirements C30 HP00 A10
A.11 Do’s & Don’t’s C30 HP00 A11
A.12 Unloading & Leveling C30 HP00 A12
SECTION-B C30 HP00 B00

TROUBLESHOOTING
B.1 Index of Troubleshooting C30 HP00 B01
B.2 Troubleshooting guide C30 HP00 B02
SECTION-C C30 HP00 C00

MAINTENANCE
C.1 Preventive maintenance schedule C30 HP00 C01
C.2 List of recommended spares C30 HP00 C02
C.3 Equipment Preservation guidelines C30 HP00 C03
C.4 Procedures for maintenance C30 HP00 C04
C.5 Calibration Schedule C30 HP00 C05
C.6 Pump Manuals C30 HP00 C06
SECTION-D C30 HP00 D00

Recommendations for consistent performance
D.1 Water treatment C30 HP00 D01
CZ JB81 760A_00 -1-

SECTION A
OPERATION
C30 HP00 A00 A00.1

A.1.Safety
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.
Safeties against hot

surfaces: The operator should avoid direct contact with the Hot Surfaces
of machine. The operator has to wear gloves while working /
touching such surfaces.
C30 HP00 A01 A01.1

A.1.Safety
3. Safeties against electric arcs:
Figure 1.1
C30 HP00 A01 A01.2

Condenser Mercury
Manometer
High Temperature
Generator
C507600301_00
Cooling Water
Control Panel Outlet
Chilled Water
Flow Switch
Chilled Water
Oulet
Cooling
Water inlet Absorber
Evaporator
A.2. PART IDENTIFICATION
Refrigerant
Level Box Chilled Water
DP Switch
Evaporator Refrigerant Auto
Sight Glass Blowdown Valve
Absorber
Refrigerant Absorbent Sight Glass
Blowdown Valve Level Box
A.2.1
Purge Unit
Purge Pump
A.2.Part Identification
Chilled
Water inlet
High Temperature
Generator
Generator Level Box Condenser
Low Temperature
Generator Generator Sight Glass
Cooling Water
C507600301_00
Outlet
Steam Inlet
Drain Heat
Exchanger
Heat Reclaimer
Evaporator
Absorber
Condensate
Outlet
Evaporator
Sight Glass
High Temperature
Heat Exchanger
Refrigerant Pump
Absorbent Pump Purge cooler
Absorber Low Temperature Heat Exchanger
A.2.2
Sight Glass Steam Trap
A.2.Part Identification
A.4. Electrical Scheme
ChapterA.4
Electrical Scheme
Objective The chapter consists of Circuit Diagram which explains the
entire electrical scheme for the Vapour Absorption Heat
Pump.
Circuit Diagram The circuit diagram of the control panel with Siemens PLC
is on the next page. The following circuit diagram is only for
customer’s reference. For actual circuit diagram please refer
the diagram supplied with the machine.
CZ JB81 760B_0 A.04 -1

A.5.Product Brief
A.5 PRODUCT BRIEF

Chapter Objectives: This chapter provides the general information about the product.
PRODUCT: Vapour Absorption Heat Pump

(PROCHILL B4K)
APPLICATION: Used for Chilling application in various Industries like

Pharmaceuticals, Hotels & Hospitality, Fertilizer & Petrochemicals,
Dairy & Confectionery, Engineering, Paper & pulp, Chemicals,
Electronics, Textiles, Edible Oils, Commercial Centers & Steel.
PRODUCT RANGE: 100 NTR – 1800 NTR.
STEAM PRESSURE: The machine can operate for steam pressure ranging from 4
kg/cm2 g to 10.5 kg/cm2 g
CONTROL PANEL: The machine is provided with state-of-the-art Internationally

accepted PLC based control panel with unique display, user
friendly interface and data-logging system.
CRYSTALLISATION The machine is uniquely designed to completely avoid

FREE: Crystallisation during normal & even abnormal operation. The
design allows use of cooling water inlet to the machine as low as
10°C which is a critical measure of Crystallisation Free design.
C30 HP00 A05 A05.1

A.06.Cycle of Operation
A.6 PRINCIPLE OF OPERATION

Chapter Objectives This chapter describes the working cycle of the vapour
absorption heat pump and the functions of its various
components
What is Refrigeration ? Refrigeration is defined as the process of extracting heat from

a low temperature medium and transferring it to a high
temperature heat sink. Refrigeration maintains the
temperature of the heat source below that of its surroundings
while transferring the extracted heat to a heat sink.
Basic Principles The boiling point of water is directly proportional to pressure.

At atmospheric pressure water boils at 100°C. At lower
pressure it boils at lower temperature. At 6mmHg absolute
pressure the boiling point of water is 3.7°C.
To change water from liquid to vapour it has to be heated.

The heat is absorbed by the water and its temperature starts
rising. However it rises until it reaches a point where the
temperature stays constant and it starts boiling, i.e. the liquid
water vapourises. This point is called the boiling point. At this
point all the heat being absorbed by the water does not
change its temperature but only its phase. This heat, required
to change the phase of a liquid to vapour, is called the Latent
of Vapoursation. Similarly the heat rejected by a vapour when
it condenses is called the Latent Heat of Condensation.
Lithium Bromide (LiBr) is a chemical similar to common salt

(NaCl). LiBr is soluble in water. The LiBr water solution has a
property to absorb water due to its chemical affinity. As the
concentration of LiBr solution increases, its affinity towards
water increases. Also as the temperature of LiBr solution
decreases, its affinity to water increases.
Further there is a large difference between vapour pressure

of LiBr and water. This means that if we heat the LiBr water
solution, the water will vapourise but the LiBr will stay in the
solution and become concentrated.
Absorption Cycle Absorption systems use heat energy to produce a

overview refrigerating effect. In these systems the refrigerant, i.e.
water, absorbs heat at a low temperature and pressure during
evaporation and releases heat at a high temperature and
pressure during condensation.
A solution known as absorbent, i.e. Lithium Bromide
(LiBr), is used to absorb the vapourised refrigerant (after its
evaporation at low pressure). This solution, containing the
absorbed vapour is heated at a higher pressure. The
refrigerant vapourises and the solution is restored to its
original concentration for recirculation.
In a double effect absorption machine, the latent heat
of condensation of the refrigerant generated in the first stage
generator, is used in a second stage generator to enhance
the efficiency of the cycle
C30 HP00 A06 A06.1

When the refrigerant undergoes a series of evaporation,

absorption, pressurisation, vapourisation, condensation,
throttling, and expansion processes, absorbing heat from a
low temperature heat source and releasing it to a high
temperature sink, so that its state is restored to its original
one, it is said to have completed a refrigerating cycle.
Modes of Operation The vapour absorption heat pump functions in two modes
namely Simultaneous Heating Cooling Mode and Cooling
Mode
Simultaneous Heating A schematic diagram of the absorption cycle in the

Cooling Mode - Simultaneous Heating Cooling Mode is shown in Figure 1.
Schematic Diagram
Individual Parts The operation of the various parts of the absorption machine
in the simultaneous heating cooling mode is described below.
Evaporator The evaporator consists of a tube bundle, an outer shell,

distribution trays, and a refrigerant pan. The heat source
water i.e. chilled water flows inside the tubes. A refrigerant
pump circulates the refrigerant from the refrigerant pan into
the distribution trays. From the trays the refrigerant falls on
the evaporator tubes. The shell pressure is very low
(≈6mmHg). At this pressure the refrigerant evaporates at a
low temperature (≈3.7°C) and extracts latent heat of
evaporation from the water being circulated through the
evaporator tubes. Thus the heat is extracted from the water
being circulated through the tubes and it becomes chilled.
Absorber The absorber consists of a tube bundle, an outer shell

(common with the evaporator), distribution trays, and an
absorbent collection sump. Concentrated absorbent solution
(≈63.4%) from the low temperature generator is fed into the
distribution trays. This solution falls on the absorber tubes.
Concentrated absorbent has an affinity to water. Hence the
vapourised refrigerant from the evaporator section is
absorbed. Due to this absorption the vacuum in the shell is
maintained at a low pressure, and ensures the heat extraction
from the heat source water. The concentrated absorbent
becomes diluted. During this dilution the 'Heat of Dilution' is
generated. This increases the temperature of the absorbent
solution. This high temperature absorbent solution heats the
hot water being circulated in the absorber tubes. As it loses
it's heat to the hot water it is able to absorb more refrigerant
vapour and gets further diluted. The diluted absorbent
(≈57.5%) collects in the bottom of the shell.
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
C30 HP00 A06 A.06.2

temperature heat exchanger where it absorbs heat from the

concentrated absorbent. It next flows through the high
intermediate absorbent solution. Then both the dilute
solutions mix at high temperature heat exchanger outlet .The
solution then enter the high temperature generator. The heat
exchangers serve to heat up the absorbent solution before it
enters the high temperature generator for regeneration. This
reduces the heat input required in the high temperature
generator. This increases the efficiency of the cycle.
High Temperature The high temperature generator (HTG) consists of a tube

Generator bundle, an outer shell and a set of eliminators. Steam is
allowed to pass inside the tubes. The diluted absorbent flows
around these tubes and is heated. The temperature of the
solution increases until it reaches the boiling point. The
refrigerant water boils out of the solution. The solution
concentration increases (to ≈61%). This increased
concentration is referred to as the intermediate concentration.
The vaporised refrigerant passes through the eliminators and
goes to the low temperature generator.
Low Temperature The low temperature generator (LTG) and condenser tube
Generator and bundles are enclosed in a shell and are separated by an
Condenser 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 to the
condenser. Refrigerant vapourised from the intermediate
absorbent passes through the eliminators to the condenser.
Here it heats the hot water being circulated inside the
condenser tubes. The refrigerant vapour condenses on the
outside of the condensor tubes, heating the hot water, 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.
C30 HP00 A06 A06.3

Fig 1. Simultaneous Heating-Cooling Mode
C30 HP00 A06 A.06.4

Cooling Mode - A schematic diagram of the absorption cycle in the Cooling

Schematic Diagram Mode is shown in Figure 2.
Individual Parts The operation of the various parts of the absorption machine
is described below.
Evaporator The evaporator consists of a tube bundle, an outer shell,

distribution trays, and a refrigerant pan. The chilled water
flows inside the tubes. A refrigerant pump circulates the
refrigerant from the refrigerant pan into the distribution trays.
From the trays the refrigerant falls on the evaporator tubes.
The shell pressure is very low (≈6mmHg). At this pressure the
refrigerant evaporates at a low temperature (≈3.7°C) and
extracts latent heat of evaporation from the water being
circulated through the evaporator tubes. Thus the water being
circulated through the tubes becomes chilled.
Absorber The absorber consists of a tube bundle, an outer shell

(common with the evaporator), distribution trays, and an
absorbent collection sump. Concentrated absorbent solution
(≈63.4%) from the low temperature generator is fed into the
distribution trays. This solution falls on the absorber tubes.
Concentrated absorbent has an affinity to water. Hence the
vapourised refrigerant from the evaporator section is
absorbed. Due to this absorption the vacuum in the shell is
maintained at a low pressure and ensures the correct chilled
water temperature. The concentrated absorbent becomes
diluted. During this dilution the 'Heat of Dilution' is generated.
This increases the temperature of the absorbent solution.
This heat is removed by the cooling water being circulated in
the absorber tubes. As the absorbent solution loses its heat to
the cooling water, it is able to absorb more refrigerant vapour,
and gets further diluted. The diluted absorbent (≈58.5%)
collects in the bottom of the shell.
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
concentrated absorbent. It next flows through the high
intermediate absorbent solution. Then both the dilute
solutions mix at high temperature heat exchanger outlet .The
solution then enter the high temperature generator. The heat
exchangers serve to heat up the absorbent solution before it
enters the high temperature generator for regeneration. This
reduces the heat input required in the high temperature
generator. This increases the efficiency of the cycle.
High Temperature The high temperature generator (HTG) consists of a tube
Generator bundle, an outer shell and a set of eliminators. Steam is
allowed to pass inside the tubes. The diluted absorbent flows
around these tubes and is heated. The temperature of the
solution increases until it reaches it's boiling point. The
C30 HP00 A06 A06.5

absorbed refrigerant boils out of the solution. The solution

concentration increases (to ≈61%). This increased
concentration is referred to as the intermediate concentration.
The vaporised refrigerant generated passes through the
eliminators and goes to the low temperature generator.
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.
C30 HP00 A06 A.06.6

Fig 2. Cooling Mode
C30 HP00 A06 A06.7

A.7. Controls and Safeties

Chapter Objective This chapter describes in detail the various controls and safeties
provided for the smooth functioning of the equipment. These
safeties and controls functions can be divided as:
A) Control Panel
B) Machine mounted safeties and controls
C) Field interlocks
A) Control Panel The chiller control panel consists of the following components to
safeguard and control the operation and reliability of the machine :
1) Programmable Logic Controller (PLC).

2) Operator interface.
3) Panel mounted safeties and controls
4) Input/Output modules
1) Programmable The chiller control panel is based on PLC of Siemens S7-200

Logic Control (PLC) series with CPU-226. It has onboard 24 digital inputs (Sink/source,
IEC Type 1) and 16 digital outputs (Solid state MOSFET). The I/O
modules can be expanded to a maximum of 7 modules, which
adds 256 digital inputs or 32 analog inputs or 32 analog outputs. It
has 2 nos of RS-485 ports for communication, one dedicated for
communication with HMI and other can be used for third party
communication via MODBUS RTU protocol (read only).
2) Operator Interface The HMI installed on the machine control panel is Siemens make
OP77B, which is alpha numeric with 4 line, 20 characters backlit
display. It has 8 functional keys used for navigation and operation.
It also has a numeric key pad and navigation buttons along with
keys for alarm acknowledge and Enter key for setting values.
3) Panel mounted The chiller control panel consists of the following safety/control
safeties and controls features.
. Main Incomer
. Control MCBs
. HTG level controller
. Refrigerant level controller
. Absorber level controllers
. Absorbent pump-1/2 contactor/overload relay
. Refrigerant pump-1/2 contactor/overload relay
. Purge pump contactor/overload relay
. Solution pump Variable Frequency Drive
4) Input/Output
modules The machine mounted control panel has been provided with the
following input/output modules.
a) EM 235 (3 nos): Each card has 4 analog inputs which are used
for temperature sensors and one analog output (4-20 mA) which
is used for controlling the SCV.
b) EM 231 (1 no): This card has 2 RTD inputs to which
temperature sensors are connected. This card and signals are
specifically used for crystallisation prevention.
CZ JB81 760C_00 A.7. 1

A.7. Controls and safeties
B) Machine mounted 1) Chilled water flow switch

safeties and controls 2) Chilled water Differential Pressure switch
3) Refrigerant level electrodes
4) HTG level electrodes
5) Absorber level electrodes
6) Auto blow down solenoid valve
7) Solenoid valve on condensate drain
8) Temperature sensors
C) Field Interlocks 1) Chilled water pump run/trip interlock.

2) Chilled water pump start/stop permissive contact.
3) Cooling water pump/ automatic shut off valve start/stop
permissive contact.
4) Cooling Tower fan start/stop permissive contact.
Machine operation The start/stop operation of the chiller can effectively carried out in
the following ways.
1) Local (From the operator panel on the machine
mounted control panel)
2) Remote (From a remote control centre)
As a default, the machine will be in Local mode. The modes can
be selected from the operator panel. In addition to this there will
be provision to “START” and “STOP” the machine from the
operator panel. Once remote operation is selected, the local
“START” and “STOP” facilities will be disabled. Now the machine
can be started or stopped by giving a digital signal to the terminals
provided in the machine control panel.
Mode of Operation The vapour absorption machine is designed to operate under the
following modes.
1) Cooling mode
2) Simultaneous cooling and heating mode (SIM Mode)
The operator panel is provided with a selector screen, from where
the required mode of operation can be conveniently selected.
COOLING MODE
Operational The operation of the Vapour Absorption Machine (VAM) is totally

Philosophy controlled by the PLC. The operational philosophy of VAM can be
classified as:
A) Start up sequence
B) Control actions
C) Safety measures
D) Shut down sequences
A) Start up sequence When the machine is powered on, the status of the machine as
displayed on the operator panel will be “MACHINE READY TO
START”, provided the machine has completed the ‘DILUTION’
cycle before it was control panel was powered off. This status
indicated that the machine can be started now. Else the machine
will first undergo ‘DILUTION’ as described in the Power failure
resumption described below.
CZ JB81 760C_00 A.7. 2

When the chiller is started, the PLC sends signal to start the
chilled water pump immediately. The steam control valve starts its
slow opening simultaneously. The absorbent pump switches on
based on HTG level. PLC then checks first Chilled Water Pump
feedback Signal after 7 sec & for the signal from the flow switch
and DP switch after the start/delta change over delay of 3 sec.
PLC then waits for signal from flow switch and DP switch for 2
seconds. After a span of 15 seconds from start, the PLC sends
signal to start the cooling water pump/to open the cooling water
automatic shut off valve. The refrigerant pump switches on based
on evaporator level. After a delay of 2 seconds, PLC sends signal
to start cooling tower fan.
B) Control actions The control actions performed by the PLC are as given below.
1) Fixed ramp rate of loading for Thermal shock prevention
2) Capacity control
3) Chilled water L-Cut control
4) Crystallisation prevention
5) Cavitation protection of refrigerant pump
6) Removal of condensate logging in HTG.
7) HTG level control
8) SCV control on HTG temperature
9) Chilled water low/no flow interlock with cooling water
flow
10) CT fan control on cooling water inlet temperature
11) Solution pump AC Drive modulation
1) Fixed ramp rate of This control is to prevent the sudden rush of steam to the high
loading for Thermal temperature generator (HTG) during cold start and to protect the
shock prevention chiller from thermal shock. For this, the steam control valve is
opened gradually over a span of 7 minutes from the machine start
up or whenever the HTG temperature is less than 120°C. After the
slow opening duration is over, the control is switched over to
chilled water temperature PID control loop automatically.
In case the chilled water outlet temperature is already below the

set point, then the slow opening is bypassed and the control is
through the PID.
2) Capacity Control The cooling capacity of the chiller is the total heat extracted from
the chilled water. If the chilled water flow rate to the chiller is kept
constant, the cooling capacity is proportional to the difference in
the temperatures of the inlet and outlet chilled water.
Load changes are reflected in the rise or fall of the temperature of

the inlet chilled water. As the inlet chilled water temperature rises
or falls, the outlet chilled water temperature tends to follow the
same pattern. A temperature sensor in the outlet chilled water
senses this change in temperature. This signal is fed to the PLC.
An inbuilt software PID control loop processes this signal with
respect to the chilled water set point. A control output signal of 4
to 20 mA is sent to control valve. This signal controls the position
of the steam control valve (SCV).
As the load increases the steam control valve opens, and as the
CZ JB81 760C_00 A.7. 3

load reduces the steam control valve closes, thus regulating the
quantity of steam entering the chiller.
Note: The above operation is in conjunction with crystallization

control.(Refer the section on crystallization control)
3) Chilled water L-Cut Sometimes the load may fall sharply due to which the chilled
control water outlet temperature will start dropping below its set point.
When the chilled water outlet temperature drops below the chilled
water outlet temperature set point minus L-Cut differential set
point, the refrigerant pump is switched off and steam control valve
shuts off fully. This safety prevents further temperature drop of
chilled water outlet temperature. The refrigerant pump and steam
control valve will return to normal operation after the Chilled water
outlet temperature rises above the Chilled water outlet
temperature set point minus L–Cut differential plus the hysterisis.
4) Crystallization If the concentrated absorbent solution returning to the absorber

prevention from the low temperature generator is excessively cooled, it
crystallizes in the low temperature heat exchanger and the
operation of the machine can be affected. Crystallization occurs
either when the concentration of the absorbent in relation to its
temperature goes too high or the temperature of LiBr drops
excessively. The following safety functions prevent the LiBr in the
machine from crystallizing.
a) SCV modulation on crystallisation prevention
b) Absorber level control
a) SCV modulation on The strong solution concentration is calculated in the PLC .The
crystallisation crystallization temperature for that concentration is also calculated
prevention by the PLC. The PLC always tries to keep the Pre set safe
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. When the
distance is less than safe distance steam control valve operates
only on crystallization control signal and capacity control signal is
overruled.
b) Absorber level In the event of LiBr getting crystallized in the spray solution line,
control the level of LiBr in the absorber sump starts reducing. To sense
the level of LiBr in absorber, four level electrodes have been
provided in the absorber level box, namely – AE1, AE2, AE3 and
AE4. The length of the electrode increases from AE1 to AE4. AE4
is the reference electrode.
When the absorber level goes below AE2 (corresponding to 25%

of sight glass level), the auto blow down solenoid valve will open
to transfer refrigerant to the absorber to build the absorber level
again. Also, the auto blow down solenoid valve will open only
when the refrigerant pump is in ‘ON’ condition. Further if the LiBr
level in absorber goes below AE3 (corresponding to 0% of sight
glass level), the steam control valve closes fully. If the level in
absorber rises above AE1 (corresponding to 50% of sight glass
CZ JB81 760C_00 A.7. 4

level), auto blow down valve will close and SCV modulation
returns back on chilled water outlet temperature PID control. A
slow opening timer of 2 minutes is provided during the reopening
of SCV. This control action will come in to action only when Chiller
is ‘ON’.
5) Cavitation If the refrigerant level in the evaporator pan falls below certain
protection of level, the pressure in the refrigerant pump suction drops below the
refrigerant pump. 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. This is done by the three level electrodes mounted in
the refrigerant level box namely – RE1, RE2 and RE3.
Of these RE1 is the shortest and RE3 is the longest. The level is
maintained between RE1 and RE2. RE3 acts as a reference
electrode. When the level reaches RE1, the pump starts and
when the level goes below RE2 the pump stops after a time delay
of 10 seconds.
6) Removal of If steam condensate is trapped in HTG then difference between

condensate logging in surface temperature of top of condensate header and pipe leaving
HTG. dish end increases. When the absolute difference of the
temperatures measured by HTG top and HTG bottom temperature
sensors is greater than the set point, the condensate drain
solenoid valve at heat reclaimer outlet will open. The condensate
drain solenoid valve will close only after the absolute value of this
temperature difference drops below set point minus its hysterisis.
This control action will come in to action only when Chiller is ‘ON’.
The condensate drain solenoid valve can be also be manually
opened / closed from control panel.
7) HTG level control If level of LiBr in HTG goes very high, it will go in to the condenser
and contaminate the refrigerant. Also the level in absorber sump
will drop. To avoid this, the level of LiBr in the HTG is sensed by
three level electrodes provided in the HTG level box namely –
GE1, GE2 and GE3.
Of these, GE1 is the shortest electrode and GE3 is the longest.

The level is to be maintained below GE1. GE3 acts as the
reference electrode. When the level reaches GE1, the pump stops
after a delay of 2 seconds. When the level goes below GE2, the
pump restarts immediately.
8) SCV control on This control is provided to prevent the chiller from tripping on high
HTG temperature temperature in the HTG. When ever the HTG temperature
exceeds the HTG high temperature set point minus a differential
set point for controlling SCV, the steam control valve closes
immediately. This prevents further increase in HTG temperature
and LiBr concentration. The valve control is returned back to the
chilled water outlet temperature control PID loop, when the HTG
temperature goes below the HTG high temperature set point
minus the differential set point for controlling SCV minus its
hysterisis. A slow opening timer of 2 minutes is provided during
the reopening of SCV.
CZ JB81 760C_00 A.7. 5

9) Chilled water low/no The freezing of chilled water inside the chiller can be prevented by
flow interlock with stopping the Cooling water circulation through the chiller. Hence,
cooling water flow in the event of chiller tripping on any of the above chilled water
safeties, the cooling water pump should be stopped. Hence it is
required that the cooling water pump should be started or stopped
through the cooling water pump start/stop permissive contact of
chiller control panel.
If the cooling water pump is not dedicated to the chiller, an

automatic shut off valve should be provided for stopping/starting
the cooling water flow to the machine. The operation of this
automatic shut off valve should be performed through the same
permissive contacts only.
10) CT fan control on When the cooling water inlet temperature to the machine goes
cooling water inlet below the CT fan OFF set point, the start permissive for CT fan is
temperature made off by the PLC. The CT fan permissive is put on only after
the cooling water inlet temperature
11) Solution pump AC The flow of LiBr into the HTG can be regulated by regulating the
Drive modulation speed of the absorbent pump which pumps the LiBr into the HTG.
The speed control is achieved by means of an AC drive which is
provided for the absorbent pump motor. The speed is controlled
based on the HTG temperature. The Minimum and maximum
frequencies of the drive are settable in the Operator interface of
the AC drive. The low and high limits of HTG temperature are
settable in the Machine PLC operator interface.
When the HTG temperature is below the low limit temperature, the
absorbent pump will run at the minimum frequency. When the
HTG temperature is in between the low limit and the high limit
temperature, the absorbent pump will be under modulation and
will run at an intermittent frequency between the low and high limit
frequencies. Once the HTG temperature goes above the high limit
value, then the absorbent pump will run at the maximum
frequency.
C) Safety measures To ensure healthy operation of the VAM certain safety measures
taken by the PLC. These are divided into two categories
1) Conditions that necessitate ‘TOTAL SHUTDOWN’

a) Anti freeze protection
b) Chilled water pump interlock trip
c) Chilled water flow switch trip
d) Chilled water differential pressure (DP) switch trip
e) AC drive trip
f) Absorbent pump-1/2 / AC Drive not responding
g) Temperature sensor errors
2) Conditions that necessitate ‘DILUTION’

a) Cooling water low inlet temperature safety
b) HTG high temperature safety
c) HTG Vapor temperature high safety
d) Refrigerant pump overload relay trip
CZ JB81 760C_00 A.7. 6

e) Refrigerant pump not responding

f) Temperature sensor errors
g) Power failure resumption
3) Warning messages
a) Vacuum pump overload relay trip
b) Temperature sensor errors
Note: All alarms shall be initiated during machine ‘ON’ condition

only.
1) Conditions that necessitate ‘TOTAL SHUTDOWN’
‘TOTAL SHUTDOWN‘ In case of a critical trip, the machine goes into ‘TOTAL
alarm sequence SHUTDOWN’ alarm sequence. The status of the machine will
read “MACHINE NOT READY TO START” and its condition will be
“TRIP”. Under the ‘TOTAL SHUTDOWN’ alarm sequence, the
PLC performs the following actions.
1. Steam control valve is closed immediately
2. Cooling water pump/Auto shut off valve start permissive
will be switched OFF immediately.
3. Cooling tower fan start permissive will be switched OFF
immediately.
4. Absorbent pump-1/2 is stopped immediately
5. Refrigerant pump-1/2 is stopped immediately.
6. Chilled water pump permissive is kept ON.
Once the fault condition has been rectified, the alarm can be
reset. On resetting the alarm, the machine goes into ‘DILUTION’.
If the time taken to reset the alarm is less than or equal to 3
minutes, the ‘DILUTION’ is not compulsory. In this case, on
resetting the alarm the status changes to “MACHINE READY TO
START” and machine condition will be ‘DILUTION’. The operator
can start the machine, if required. If the machine is restarted, a
slow opening timer of 2 minutes is given for reopening the SCV.
If the time taken to reset the alarm is more than 3 minutes, the
‘DILUTION’ is compulsory. In this case, on resetting the alarm the
status changes to “MACHINE NOT READY TO START” and
machine condition will be ‘DILUTION’. The machine can be
restarted only after completion of ‘DILUTION’.
a) Antifreeze In case the chilled water outlet temperature goes below freezing
protection point of water, the water in the chilled water header will freeze.
So, when the chilled water outlet temperature as measured by the
chilled water outlet temperature sensor drops below the Antifreeze
set point, the machine trips and the ‘TOTAL SHUTDOWN’ alarm
sequence is carried out. An alarm “ANTIFREEZE TRIP” is flashed
on the operator panel. The alarm can be reset only after the
chilled water outlet temperature rises above the antifreeze set
point plus the hysterisis set point.
b) Chilled water pump If flow rate of the chilled water is very low or is completely
interlock trip stopped, freezing of chilled water in the evaporator tubes can take
place immediately. Chilled water flow is very essential for machine
operation. Hence it is required that the chilled water pump should
CZ JB81 760C_00 A.7. 7

be started or stopped through the chilled water pump start/stop

permissive contact of machine control panel.
Also, a potential free contact is to be wired from the chilled water

pump motor starter to VAM panel to sense chilled water pump ON
/ OFF / TRIP status. The machine after giving the permissive to
start the chilled water pump waits for 7 seconds for feedback. In
case the feedback is not received, the machine immediately goes
into ‘TOTAL SHUTDOWN’ alarm sequence. An alarm “CHILLED
WATER PUMP TRIP / NOT RESPONDING” is flashed on the
operator panel. The alarm can be reset only after the chilled water
pump run feed back is received by the PLC.
c) Chilled water flow In order to ensure that the minimum required chilled water
switch trip circulation rate is maintained, a flow switch has been provided on
the chilled water outlet nozzle. The chilled water flow switch trip
value needs to be set at 50-60% of the rated value during
commissioning of the equipment. If the chilled water flow rate
drops below the chilled water flow switch set point, the ‘TOTAL
SHUTDOWN’ alarm sequence is carried out. An alarm “CHILLED
WATER FLOW SWITCH TRIP” is flashed on the operator panel.
The alarm can be reset only after the chilled water flow rate
increases above the preset value.
d) Chilled water In order to ensure that the minimum required chilled water
differential pressure circulation rate is maintained, a differential pressure (DP) switch
(DP) switch trip has been provided between the chilled water inlet and outlet
nozzles. The chilled water DP switch trip value needs to be set at
a value corresponding to 50-60% of the rated flow rate during
commissioning of the equipment. If the chilled water flow rate
drops below the chilled water DP switch set point, the ‘TOTAL
SHUTDOWN’ alarm sequence is carried out. An alarm “CHILLED
WATER DP SWITCH TRIP” is flashed on the operator panel. The
alarm can be reset only after the chilled water flow rate increases
above the preset value.
e) Absorbent pump If the absorbent pump motor draws more than its rated current,
overload relay / AC the overload relay / AC Drive trips and the ‘TOTAL SHUTDOWN’
Drive trip alarm sequence is carried out. An alarm “ABSORBENT PUMP /
AC DRIVE TRIP” is flashed on the operator panel. The alarm can
be reset only after the overload relay has been reset.
f) Absorbent pump-1/2 If the absorbent pump-1/2 contactor / AC Drive doesn’t respond to

/ AC Drive not the absorbent pump-1/2 / AC Drive ON/OFF command, the
responding machine trips and ‘TOTAL SHUTDOWN’ alarm sequence is
carried out. An alarm “ABSORBENT PUMP-1/2 / AC DRIVE NOT
RESPONDING” is flashed on the operator panel.
g) Temperature In case of temperature sensor errors (for the sensors listed

sensor errors below), the machine trips and the ‘TOTAL SHUTDOWN’ alarm
sequence is carried out. An alarm “*** TEMP. SENSOR ERROR”
is flashed on the operator panel. The alarm can be reset only after
the problem has been rectified.
Sensor list:
1) CHILLED WATER OUTLET TEMPERATURE
CZ JB81 760C_00 A.7. 8

2) HOT WATER OUTLET TEMPERATURE (Only

in SIM mode)
*** Name of the temperature sensor that has failed.
2) Conditions that necessitate ‘DILUTION’
‘DILUTION‘ alarm When the machine trips on any of the below safeties and goes
sequence into ‘DILUTION’ alarm sequence, the status of the machine will
read “MACHINE NOT READY TO START” and its condition will be
‘DILUTION’. Once the alarm has been reset the status will read as
”MACHINE READY TO START” while the machine condition
remains the same. The operator can start the machine, if required.
The duration of ‘DILUTION’ is 20 minutes and this is fixed in the

PLC. Under the ‘DILUTION’ alarm sequence, the PLC performs
the following actions.
1. Steam control valve is closed immediately.
2. Cooling tower fan start permissive will be switched OFF
immediately.
3. Cooling water pump/Auto shut off valve start permissive
will be switched OFF after 4 minutes.
4. Refrigerant pump-1/2 runs based on evaporator
refrigerant level and is stopped after 4 minutes.
5. Absorbent pump-1/2 runs based on HTG LiBr level and is
stopped at the end of 20 minutes.
6. Chilled water pump permissive is put OFF at the end of 20
minutes.
If the alarm is reset, then after completion of ‘DILUTION’, the
status of the machine will read “MACHINE READY TO START”
and its condition will be “OFF”. Else the status will be “MACHINE
NOT READY TO START” and condition will be “OFF”.
a) Cooling water low If the temperature of the cooling water entering the chiller drops,
inlet temperature the LiBr solution coming to the absorber may crystallize. To
safety prevent this, when ever the cooling water inlet temperature goes
below the cooling water low temperature set point, the ‘DILUTION’
alarm sequence is carried out. An alarm “COOLING WATER
INLET TEMP. LOW” is flashed on the operator panel. The
machine can be restarted only after the cooling water inlet
temperature rises above the cooling water low temperature set
point plus the hysterisis set value. During initial startup, till the time
HTG temperature goes above 120°C this safety is bypassed.
However, 30 minutes after machine startup this safety will be in
operation irrespective of HTG temperature.
b) HTG high If the HTG temperature goes very high, the concentration of the
temperature safety LiBr solution can go up leading to crystallisation. Hence, if the
HTG temperature exceeds the HTG high temperature set point,
the ‘DILUTION’ alarm sequence is carried out. An alarm “HTG
TEMPERATURE HIGH” is flashed on the operator panel. The
machine can be restarted only after the HTG temperature drops
below the HTG high temperature set point minus the hysterisis set
value.
CZ JB81 760C_00 A.7. 9

c) HTG Vapor The HTG vapour temperature is a clear indicator of the pressure
temperature high inside the HTG. If the HTG vapour temperature goes above the
safety HTG vapor temperature high set point, the ‘DILUTION’ alarm
sequence is carried out. An alarm “HTG VAPOUR
TEMPERATURE HIGH” is flashed on the operator panel. The
machine can be restarted only after the HTG vapor temperature
goes below the HTG vapor temperature high set point minus the
hysterisis set value.
d) Refrigerant pump- If the refrigerant pump motor draws more than its rated current,
1/2 overload relay trip the overload relay trips and the ‘DILUTION’ alarm sequence is
carried out. An alarm “REFRIGERANT PUMP TRIP” is flashed on
the operator panel. Resetting the overload relay resets the alarm.
e) Refrigerant pump If the refrigerant pump contactor doesn’t respond to the refrigerant
not responding pump ON/OFF command, the machine trips and the ‘DILUTION’
alarm sequence is carried out. An alarm “REFRIGERANT PUMP
NOT RESPONDING” is flashed on the operator panel.
f) Temperature sensor In case of temperature sensor errors (for the sensors listed
errors below), the machine trips and the ‘DILUTION’ alarm sequence is
carried out. An alarm “*** TEMP. SENSOR ERROR” is flashed on
the operator panel. The alarm can be reset only after the problem
has been rectified.
Sensor list:
1) COOLING WATER INLET TEMPERATURE
2) LTG TEMPERATURE
3) U-TUBE TEMPERATURE
4) SPRAY SOLUTION TEMPERATURE
5) HTG TEMPERTAURE
6) HTG VAPOUR TEMPERATURE
g) Power failure In case of power failure during machine operation, there is chance
resumption of LiBr crystallizing in the heat exchangers. To avoid this, when
the machine resumes after power failure, it goes into ‘DILUTION’
immediately. An alarm “POWER FAILURE” is flashed on the
operator panel. In case the duration of power failure is less than 3
minutes, the machine status will show “MACHINE READY TO
START”. In such case, ‘DILUTION’ can be bypassed and machine
can be put back to normal operation after resetting the alarm.
When the machine restarts, a slow opening timer of 2 minutes is
given for reopening the SCV. But if the duration of power failure is
more than 3 minutes, the machine status will be “MACHINE NOT
READY TO START”. In this case, ‘DILUTION’ is compulsory and
the machine can be started only after completion of ‘DILUTION’.
3) Warning Messages
a) Vacuum pump If the vacuum pump motor draws more than its rated current, the
overload relay trip overload relay trips and an alarm “VACUUM PUMP TRIP” is
flashed on the operator panel. Resetting the overload relay resets
the alarm.
CZ JB81 760C_00 A.7. 10

b) Temperature In case of temperature sensor errors (for the sensors listed

sensor errors below), an alarm “*** TEMP. SENSOR ERROR” is flashed on the
operator panel. The machine keeps running normally. The alarm
can be reset only after the problem has been rectified.
Sensor list:
1) CHILLED WATER INLET TEMPERATURE
(Only in Cooling mode)
2) HTG TOP TEMPERTAURE
3) HTG BOTTOM TEMPERATURE
D) Shut down After the completion of operation, when the machine is switched
sequence off from the operator panel it goes into ‘DILUTION’. This is done to
avoid any chances of crystallisation. While the machine is in
operation, different parts of the machine are at different
concentration and temperature. ‘DILUTION’ helps in making them
even. After completion of ‘DILUTION’ the machine status reads as
“MACHINE READY TO START” and machine condition will be
“OFF”.
Normal and Trip data The operator interface (OP77B) has a facility to log critical data
Logging periodically as per the sampling time, which can be set on the
operator interface. In addition to this, the operator interface logs
the data pertaining to trip condition and also displays the last 6
alarms.
SIMULTANEOUS COOLING AND HEATING MODE (SIM MODE)
Operational The basic operational philosophy of the machine in SIM MODE is

philosophy similar to COOLING MODE, except that the capacity control logic
is based on hot water outlet temperature (measured by the
temperature sensor mounted on the cooling water outlet nozzle**).
All the remaining safeties and controls are same as that in
COOLING MODE. An additional control is provided for limiting the
outlet hot water temperature.
** In case a temperature sensor is not provided on the cooling

water outlet nozzle, before changing to SIM MODE the
temperature sensor in the chilled water inlet nozzle should be
removed and put in the cooling water nozzle. After the SIM MODE
operation, the temperature sensor should be fitted back on the
chilled water inlet nozzle.
Hot water H-Cut This control is provided to limit the temperature of the leaving hot
control water. If the temperature of the leaving hot water goes above the
hot water outlet temperature set point plus the H-Cut differential
set point, the steam control valve closes and the refrigerant pump
stops. The normal operation is resumed once the hot water outlet
temperature goes below the hot water outlet temperature set point
plus H-Cut differential set point minus the hysterisis set value.
Set points The field instruments and the components in the control panel are
to be set as follows
CZ JB81 760C_00 A.7. 11

Sl. No. Description Set points

1. Chilled water flow switch 50-60% of rated flow
2. Chilled water D.P. switch 50-60 % of rated flow
4. Absorbent pump over current relay As per pump rating +10%
5. Refrigerant pump over current relay As per pump rating +10%
6. Purge pump over current relay As per pump rating +10%
Operator panel Set The operator terminal settings are as follows

points
Sl. No. Description Set points Remarks

1. Temperature Set point for PID control - As per specs.
2. Chilled water temperature modulation control
settings:
a) Proportional Band - 240 Adjustable
b) Integral Band + 10 Adjustable
c) Derivative Band 0 Adjustable
3. L-cut differential 1.0 °C Adjustable
4. Hysterisis 2.0 °C Adjustable
5. Antifreeze set point 3.5 °C Adjustable
7. Cooling water inlet temperature set point 10.0 °C Adjustable
9. HTG trip set point 160.0 °C Adjustable
11. HTG differential for controlling the steam control 3.0 °C Adjustable
valve
13. HTG condensate temperature difference 10.0 °C Adjustable
15. H cut differential SP (Only in SIM MODE) 1.0 °C Adjustable
16. Hysterisis (Only in SIM MODE) 2.0 °C Adjustable
17. HTG Vapour temperature trip set point 100.0 °C Adjustable
19. CT fan OFF set point 25.0 °C Adjustable
21. HTG temperature set point for AC drive minimum 130.0 °C Adjustable
frequency
22. HTG temperature set point for AC drive maximum 150.0 °C Adjustable
frequency
23. Data log sampling time 60 min Adjustable
24. Trip log sampling time 1 min Adjustable
25. Anti-chattering timer for FS, DPS & INTERLOCK of 2 sec Not accessible
chilled water.
26. Anti-chattering timer for temperature sensors and 2 sec Not accessible
dependant alarms/safeties
CZ JB81 760C_00 A.7. 12

27. Dilution cycle timer 20 min Not accessible

28. OFF delay timer for absorbent pump 2 sec Not accessible
29. OFF delay timer for refrigerant pump 10 sec Not accessible
30. Star-Delta change over time for CHW interlock 7 sec Not accessible
31. Anti chattering timer for instruments 1 sec Not accessible
PLC Input/Output List
Digital Inputs 24 VDC type Onboard PLC S7-200 CPU 226

Address Device Tag Description
I 0.0 52W Chilled water pump interlock
I 0.1 69W Chilled water flow switch
I 0.2 DPS2 Chilled water DP switch
I 0.3 SPARE
I 0.4 88A-1 DRIVE Feedback
I 0.5 51A DRIVE Overload
I 0.6 88R-1 Refrigerant Pump-1 Feedback
I 0.7 51R-1 Refrigerant Pump-1 Overload
I 1.0 51P Purge Pump Overload
I 1.1 33RL Evaporator Level
I 1.2 33GL1 HTG level Low
I 1.3 33AL4 Absorber Level Low
I 1.4 33AL5 Absorber Level Very Low
I 1.5 4Y1 Remote ON/OFF
I 1.6 88A-3 Absorbent pump-1 Feedback
I 1.7 88A-4 Absorbent pump-2 Feedback
I 2.0 88R-2 Refrigerant Pump-2 Feedback
I 2.1 51R-2 Refrigerant Pump-2 Overload
I 2.2 Chiller start/stop
I 2.3 SPARE
I 2.4 SPARE
I 2.5 SPARE
I 2.6 SPARE
I 2.7 SPARE
Digital outputs 24 VDC type onboard PLC S7-200 CPU 226
Address Description
Q 0.0 Hooter
Q 0.1 Refrigerant pump-1 on
Q 0.2 Purge pump on
Q 0.3 Remote machine on indication
Q 0.4 Remote machine trip indication
Q 0.5 Chilled Water Pump start enable
Q 0.6 Cooling Water Pump start enable
CZ JB81 760C_00 A.7. 13

Q 0.7 CT Fan start enable

Q 1.0 Drive Start
Q 1.1 Drive BYPASS
Q 1.2 Drive INLINE
Q 1.3 Absorbent pump-1 on
Q 1.4 Absorbent pump-2 on
Q 1.5 Refrigerant pump-2 on
Q 1.6 Condensate Drain Valve
Q 1.7 Auto blow down Valve
Digital Outputs 24 VDC type EM223 4 DI/DO
Address Description
Q2.0 Chiller on
Q2.1 Chiller Trip
Q2.2 Chiller Dilution
Q2.3 SPARE
Analog Input / Output

Analog I/O Module EM235 (Card-1)
Address Description
AIW0 Chilled water inlet temperature
AIW2 Chilled water outlet temperature
AIW4 Cooling water inlet temperature
AIW6 HTG Top Temperature
AQW0 Signal to SCV
AIW8 High Temperature Generator temperature
AIW10 High Temperature Generator Vapour temperature
AIW12 Spray solution temperature
AIW14 HTG Bottom Temperature
AQW4 AC DRIVE SIGNAL
RTD Module EM231 (Card-3)
Address Description
AIW16 U-Tube Temperature
AIW18 LTG Temperature
AIW20 Chilled Water Flow Transmitter
AIW22 SPARE
AIW24 SPARE
AIW28 SPARE
AQW8 SPARE
CZ JB81 760C_00 A.7. 14

OP77 Operator The entire operation of the VAM/c is controlled through the OP77
Interface:- Operator Interface.
CZ JB81 760C_00 A.7. 15

OP77 Operator The entire operation of the VAM/c is controlled through the OP77
Interface:- Operator Interface.
OP77 consists of:
1. An LCD display : High-contrast LC display with LED

back lighting. Display of up to 4 lines each having a
maximum length of 20 characters i.e. 4-Lines * 20-
characters display.
2. Function keys : 4 keys (F1 to F4) for calling freely

programmable functions, different according to the actual
menu. 4 keys (K1 to K4) for calling fixed functions from
any menu.
3. Arrow keys : Left, Right, Up, Down.
4. Numeric keys : 0 to 9 with decimal point.
5. ENTER key : To enter set points.
6. ACK key : To acknowledge Hooter/Alarm.
7. ESC key : The ESC key has the following functions:
Cancel :- Cancel field inputs provided that

they have not been terminated
by pressing ENTER.
Branch backward :- Go back to the

previous screen level by pressing
twice
7. Global Keys : K1 to K4 keys are global keys with
following functions
K1 MAIN MENU: - From any screen by pressing the “K1” key it

is possible to go directly to the Main Menu screen.
K2 MACHINE PARAMETERS: - From any screen by pressing

the “K2” key it is possible to go directly to the Machine Parameter
screen, from where it is possible to read all the relevant working
parameters of the unit.
K3 MACHINE STATUS: - From any screen by pressing the

“K3” key it is possible to go directly to the Status screen, where it
CZ JB81 760C_00 A.7. 16

is possible to read the actual status of the main components of

the unit.
K4 FAULT RESET: - By pressing the “K4” key it is possible to

reset the active alarms. By pressing the “K4” key alarms are
resetted only if the cause that has generated the alarm has been
removed.
Screen tree structure is given below
‘MAIN MENU’
‘OPERATION’
‘STATUS’
‘SETPOINTS’
'M/C PARAMETERS'
'UTILITY'
‘ALARMLOG’
'DATALOG’
'NORMAL'
'TRIP'
'SERVICES'
‘M/C OPERATIONS’
‘HTG / COW SP’
L-CUT / H-CUT SP’
‘OFFSET ADJ’
‘PID SETTINGS’
‘DRIVE SETTING’
‘M/C COMM DATE’
‘REF PUMP OPERATION’
‘MACHINE MODES’
‘SENSOR ENABLE /DISABLE’
'PLC DATE / TIME'
'PRODUCT INFO'
‘ANALYSIS LIOH'
‘ANALYSIS MOLY’
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.
CZ JB81 760C_00 A.7. 17

The second page is accessed by pressing the F4 key.

The second page displays the software version loaded in the
Programmable Logic Controller (PLC) and the Operator Interface
(OP77) also called the Man Machine Interface (MMI).
This screen can also be accessed from 'MAIN MENU'
Press K1 to go to Main Menu.
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 shows the names of the
'OPERATIONS', 'STATUS', and 'SETPONTS' screens, and shows
the keys to be pressed to activate them.
The next page of the ‘MAIN MENU’ screen can be displayed by

scrolling down using the F4 key.
The second page shows the ‘M/C PARAMETERS’, and the

‘UTILITY’ activation keys.
CZ JB81 760C_00 A.7. 18

The third page shows the ‘ALARMLOG’ and the 'DATALOG’

screen activation keys.
The fourth page shows the ‘SERVICES’ and ‘PUMP SELECTION’

the screen activation keys.
The fifth page shows the ‘PRODUCT INFO’ & ‘PLC DATE/TIME’
The fifth page shows the ‘ ‘ANALYSIS LIOH’ & ‘ANALYSIS MOLY’
CZ JB81 760C_00 A.7. 19

Operation Basic machine operations are carried out through this screen. This
screen consists of 4 pages, viz.
Machine Start / Stop screen
Purge Pump ON/OFF screen
Condensate Drain Valve Auto / Manual
Condensate Drain Valve Manual Open / Close
Machine ON / OFF Start the machine by pressing F1 and Stop the machine by
pressing F2. If the machine is ready to start the following
message will be displayed - “MACHINE READY TO START “at
top.
If there is any fault condition then the following message will be
displayed - “MACHINE NOT READY TO START “at top.
At the same time the Following Machine Status is also displayed.
OFF Machine is off.

ON Machine is on.
TRIP Machine is tripped.
Machine is on but it is
MACHINE DILUTION
performing a dilution cycle.
Machine is performing a
COMP.
compulsory dilution cycle that
DILUTION
cannot be interrupted.
The next page can be displayed by pressing F4 function key
Purge Pump ON / OFF The Purge pump can be switched on or off from this screen.
Default position is ‘STOP’. Following Pump status is displayed.
OFF Purge Pump is off.

PURGE
ON Purge Pump is on.
PUMP
TRIP Purge Pump is tripped.
Purge pump START / STOP operation can be done using F1 and

F2 keys. To start the Purge Pump, Press F1 key. To stop the
Purge Pump, Press F2 key.
CZ JB81 760C_00 A.7. 20


The previous page can be displayed by pressing F3 function key
Condensate Drain The Condensate Drain Valve Mode can be changed from this
Valve Auto / Manual screen. Default position is ‘AUTO’. Following Mode status is
displayed.
Condensate Drain Valve is in

CONDENSATE AUTO
Auto Mode.
DRAIN VALVE Condensate Drain Valve is in
MANUAL
Manual Mode.
Condensate Drain Valve AUTO / MANUAL can be done using F1

and F2 keys. To put Condensate Drain Valve in Manual Mode,
Press F1 key. To put Condensate Drain Valve again in Auto
Mode, Press F2 key.

Condensate Drain The Condensate Drain Valve Manual Open / Close Operation can
Valve Manual Open / be done from this screen. Following status is displayed.
Close
Condensate Drain Valve is
CONDENSATE CLOSE
Close
DRAIN VALVE Condensate Drain Valve is
OPEN
Open
Condensate Drain Valve OPEN / CLOSE can be done using F1

and F2 keys. To open Condensate Drain Valve in Manual Mode,
Press F1 key. To close Condensate Drain Valve again in Auto
Mode, Press F2 key.
CZ JB81 760C_00 A.7. 21

Status This screen displays the current on-line status of the Machine
Safeties, Interlocks, Pumps, Steam Control Valve, Levels,
Temperature Sensors, Switches etc.
This screen can be accessed from 'MAIN MENU' screen - page 1,

by pressing the F2 key. 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.
To return to "MAIN MENU" press K1 key.
This screen displays the current on-line status of the Machine

Mode, Machine, Refrigerant Pump-1/2 & Absorbent Pump-1/2
Following status is displayed.
Machine is operating in COOL
COOL
M/C MODE Mode
Machine is operating in SIM
SIM
Mode
OFF Machine is off.

ON Machine is on.
TRIP Machine is tripped.
Machine is on but it is
MACHINE DILUTION
performing a dilution cycle.
Machine is performing a
COMP.
compulsory dilution cycle that
DILUTION
cannot be interrupted.
OFF Refrigerant Pump-1/2 is off.

Refrigerant Pump-1/2 is on in
ON
Auto Mode.
REF PUMP-1/2 Refrigerant Pump-1/2 is
TRIP
tripped.
ON IN Refrigerant Pump-1/2 is on in
MANUAL Manual Mode.
OFF Absorbent Pump-1/2 is off.

ABSO PUMP-1/2 ON Absorbent Pump-1/2 is on.
TRIP Absorbent Pump-1/2 is tripped.
CZ JB81 760C_00 A.7. 22

This screen displays the current on-line status of the CHW Pump,
CHW Flow Switch & CHW DP Switch.
OFF Chilled Water Pump is off

CHW PUMP ON Chilled Water Pump is running
TRIP Chilled Water Pump is tripped.
Chilled Water Flow Switch is

OFF
off
FLOW S/W
Chilled Water Flow Switch is
ON
on
OFF Chilled Water D.P. Switch is off

D.P. SWITCH
ON Chilled Water D.P. Switch is on

CZ JB81 760C_00 A.7. 23

This screen displays the current on-line status of the Purge Pump
& AC Drive.
OFF Purge Pump is off.

PURGE
ON Purge Pump is on.
PUMP
TRIP Purge Pump is tripped.
AC DRIVE OFF AC Drive is off.

AC DRIVE FAULT AC Drive is tripped.
AC Drive is running at
AC DRIVE AT MIN FREQ
Minimum Frequency
AC Drive is running at
AC DRIVE AT MAX FREQ
Maximum Frequency
AC Drive is running between
AC DRIVE IN MODULN. Minimum & Maximum
Frequency
AC Drive is bypassed &
AC DRIVE IN BYPASS Absorbent Pump is fed through
Bypass Contactor

CZ JB81 760C_00 A.7. 24

This screen displays the current on-line status of the Steam

Control Valve, Cooling Water Pump & Cooling Tower Fan.
Steam Control Valve is

ON HTG CONTROL being controlled by HTG
Temp.
ON CHW CONTROL being controlled by CHW
Out Temp
Steam Control Valve is in
SLOW OPENING
slow opening
SCV CLOSED
closed
ON HW CONTROL being controlled by HW
Temp. ( For SIM Mode )
ON CONC CONTROL being controlled by
Concentration Control
Steam Control Valve control
ON ABS LEVEL
is based on Absorber Level.
Cooling Water Pump

OFF
Command is off.
COW PUMP
Cooling Water Pump
ON
Command is on.
Cooling Tower Fan Command

OFF
is off.
CT FAN
Cooling Tower Fan Command
ON
is on.
CZ JB81 760C_00 A.7. 25

This screen displays the current on-line status of the Chilled

Water Inlet (Applicable in Cool Mode) / Hot Water Outlet Sensor
(Applicable in Simultaneous Mode), Chilled Water Outlet Sensor &
Cooling Water Inlet (Applicable in Cool Mode) / Hot Water Inlet
Sensor (Applicable in Simultaneous Mode).
Chilled Water Inlet / Hot Water

CHW IN ERROR Outlet Sensor Error due to
SENSOR / Open Ckt or Short Ckt.
HW OUT Chilled Water Inlet / Hot Water
SENSOR OK Outlet Sensor in Healthy
Condition.
Chilled Water Outlet Sensor

ERROR Error due to Open Ckt or Short
CHW OUT
Ckt.
SENSOR
Chilled Water Outlet Sensor in
OK
Healthy Condition.
Cooling Water Inlet / Hot Water

COW IN ERROR Inlet Sensor Error due to Open
SENSOR / Ckt or Short Ckt.
HW IN Cooling Water Inlet / Hot Water
SENSOR OK Inlet Sensor in Healthy
Condition.

This screen displays the current on-line status of the High Temp
Generator Top Sensor, High Temp Generator Sensor & High
Temp Generator Vapour Sensor.
High Temp Generator Top
ERROR Sensor Error due to Open Ckt
HTG-T
or Short Ckt.
SENSOR
High Temp Generator Top
OK
Sensor in Healthy Condition.
High Temp Generator Sensor

HTG SENSOR Ckt.
High Temp Generator Sensor
OK
in Healthy Condition.
CZ JB81 760C_00 A.7. 26

High Temp Generator Vapour

HTG VAR SENSOR ERROR Sensor Error due to Open Ckt
or Short Ckt.
High Temp Generator Vapour
HTG VAR SENSOR OK

This screen displays the current on-line status of the Spray

Solution Sensor, High Temp Generator Bottom Sensor &
Condensate Drain Valve.
Spray Solution Sensor Error

ERROR
SPRAYSOL. due to Open Ckt or Short Ckt.
TEMP Spray Solution Sensor in
OK
Healthy Condition.
High Temp Generator Bottom

ERROR Sensor Error due to Open Ckt
HTG-B
or Short Ckt.
SENSOR
High Temp Generator Bottom
OK

CLOSE
COND VALVE Close
OPEN
Open

CZ JB81 760C_00 A.7. 27

This screen displays the current on-line status of the U-Tube

Sensor, Low Temp Generator Sensor & Autoblowdown Valve.
U-Tube Sensor Error due to
ERROR
U-TUBE Open Ckt or Short Ckt.
SENSOR U-tube Sensor in Healthy
OK
Condition.
Low Temp Generator Sensor

LTG SENSOR Ckt.
Low Temp Generator Sensor in
OK
Healthy Condition.
CLOSE Autoblowdown Valve is Close

AUTOBLOWDN
OPEN Autoblowdown Valve is Open

This screen displays the current on-line status of the Lower Cut &
Higher Cut.
In Cool Mode, Chilled Water

Outlet Temp is less than M/C
TRIP
Setpoint - L-Cut Differential
Setpoint
In Cool Mode, Chilled Water
L-CUT Outlet Temp is more than M/C
HEALTHY Setpoint - L-Cut Differential
Setpoint + L-cut Differential
Setpoint Hysterisis.
NOT Not Applicable in Simultaneous
REQRD mode of operation.
In Simultaneous Mode, Hot

Water Outlet Temp is more
H-CUT TRIP
than M/C Setpoint + H-Cut
Differential Setpoint
HEALTHY In Simultaneous Mode, Hot

Water Outlet Temp is less than
CZ JB81 760C_00 A.7. 28
M/C Setpoint + H-Cut

Differential Setpoint - H-Cut
Differential Setpoint Hysterisis.
NOT Not Applicable in Cooling mode
REQRD of operation.

This screen displays the current on-line status of the CPU ,

Ref Pump-1/2 Auto/Manual.
HEALTHY CPU is working fine.

INPUT/OUTPUT There is a fault in CPU
FAULT input/output.
NO POWER TO The EM235-1 card is not
EM235-1 powered.
EM235-1
The EM235-1 card is faulty.
FAULTY
CPU
STATUS
EM235-2 powered.
EM235-2
FAULTY
EM235-3 powered.
EM235-3
FAULTY
AUTO Ref pump-1/2 is in Auto Mode.

REF PUMP-1/2
Ref pump-1/2 is in Manual
MANUAL
Mode.

CZ JB81 760C_00 A.7. 29

This screen displays the current on-line status of the HTG level,
Ref Level and Abso level Status, Following status is displayed.
HTG LEVEL NORMAL Solution level in HTG is

normal.
HTG LEVEL HIGH Solution level in HTG is high.
Refrigerant level in evaporator

NORMAL is low and refrigerant pump is
REF LEVEL not allowed to start.
Refrigerant level in evaporator
LOW is normal and refrigerant pump
is allowed to start
Solution level in absorber is

LOW low and steam control valve
will close.
ABSO LEVEL Solution level in absorber is
MEDIUM medium and auto blowdown
valve will open.
Solution level in absorber is
NORMAL
normal.

CZ JB81 760C_00 A.7. 30

This screen displays the current on-line status of the Cool PID,
and Machine.
The steam control valve is set

AUTO in automatic mode. (Default
COOL PID set).
The steam control valve is set
MANUAL
in manual mode.
Machine control is in local

LOCAL
mode.
MACHINE
Machine control is in remote
REMOTE
mode.

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.
CHW OUT SP (Applicable in Cool Mode) / HW OUT SP

(Applicable in Simultaneous Mode) - 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.
Chilled Water Outlet Temp & Chilled Water Inlet (Applicable in

Cool Mode) / Hot Water Outlet Temp (Applicable in Simultaneous
Mode) is also displayed in this screen.
CZ JB81 760C_00 A.7. 31

TRIP D'LOG TIME – During machine trip condition, the machine

parameters are logged at the interval of specified time interval. To
change this set point scroll down cursor at set point value, cursor
blinks here, type required time interval in minutes and press
ENTER key.
NORMAL D'LOG TIME - This is the time interval at which PLC

logs all machine parameters. To change this set point scroll down
cursor at set point value, cursor blinks here, type required time
interval in minutes and press ENTER key.
SCV O/P 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 Steam Control Valve opening. 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 Centigrade, Steam Control Valve and Pump status.
This screen displays Chilled Water Inlet (Applicable in Cool Mode)

/ Hot Water Outlet Temp (Applicable in Simultaneous Mode) &
Chilled Water Outlet Temp.
CZ JB81 760C_00 A.7. 32

This screen displays Cooling Water Inlet (Applicable in Cool

Mode) / Hot Water Inlet Temp (Applicable in Simultaneous Mode),
U-Tube Temp & High Temp Generator Temp.

This screen displays High Temp Generator Vapour Temp, Spray

Solution Temp & Low Temp Generator Temp.

This screen displays High Temp Generator Top Temp, High Temp
Generator Bottom Temp & Absolute Difference between High
Temp Generator Top Temp and High Temp Generator Bottom
Temp.

CZ JB81 760C_00 A.7. 33

This screen displays LiBr Concentration, Steam Control Valve

Opening Signal & Machine Status.

This screen displays Purge Pump, Refrigerant Pump-1/2 &

Absorbent Pump-1/2 Status.

This screen displays CHW Flow and TR

Utility In the first page of this screen, Machine Run Hrs & total number of
times autoblowdown on.
Go to the next page of the screen by pressing the F4 key.
In the second page of this screen, the number of times
CZ JB81 760C_00 A.7. 34

Autoblowdown on in current month & last month counts are

displayed.

In the third page of this screen, the number of purge pump run,
Run hours & the date and time at which the purge pump was last
run is displayed are displayed.

In the fourth page of this screen, Machine Commissioned date is

displayed
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.
Data log All the data logged in PLC can be displayed here.
Where logged data of measured temperatures, percentage control
CZ JB81 760C_00 A.7. 35

valve opening, status of absorbent pump and refrigerant pump,

machine status with date and time are displayed.
Press F1 to display Normal Data Log.

Press F2 to display Trip Data Log Selection.
Use F4 Key to return to Main Menu.
Trip Log Selection Press F1 to display Trip Data Log-1. Trip Data Log-1 will show
Five Sets of Data for Machine Tripping on 1st, 7th, 13th Time and
so on.
Press F2 to display Trip Data Log-2. Trip Data Log-2 will show
nd th th
Five Sets of Data for Machine Tripping on 2 , 8 , 14 Time and
so on.
rd th th
so on.
th th th
so on.
th th th
so on.
th th th
so on.
CZ JB81 760C_00 A.7. 36

Pump selection Basic pump selections are done through this screen.
Refrigerant pump selection screen

Absorbent pump selection screen.
Refrigerant pump The Refrigerant pump1/2 can be selected from this screen.
selection
Selection of the pumps can be done using keys F1 / F21

Absorbent pump The Absorbent pump1/2 can be selected from this screen.
selection
Abso pump -1 can be selected using F1 key...
To select Abso pump-2 Press F2 key.

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’
CZ JB81 760C_00 A.7. 37

3. ‘L-CUT / H-CUT SP’

4. ‘OFFSET ADJ’
5. ‘PID SETTINGS’
6. ‘DRIVE SETTING’
7. ‘M/C COMM DATE’
8. ‘REF PUMP OPERATION’
9. ‘MACHINE MODES’
10. ‘SENSOR ENABLE /DISABLE’
Service Setting This screen displays the names of all the other function and
operation screens.
The first page of the ‘M/C OPERATIONS’ & ‘HTG / COW SP’
Screen, and shows the keys to be pressed to activate them.
The next page of the ‘SERVICE SETTING’ screen can be

displayed by scrolling down using the F4 key.
The second page shows the ‘L-CUT / H-CUT SP’and the

‘OFFSET ADJ’ activation keys.
The Third page shows ‘PID SETTINGS’ and the ‘DRIVE SETTING’
activation keys.
CZ JB81 760C_00 A.7. 38

The fourth page shows ‘M/C COMM DATE’ and the ‘REF PUMP
OPERATION’ activation keys.
The fifth page shows ‘M/C MODES’ and the ‘SENSOR

ENABLE/DISABLE ‘activation keys.
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.
Machine is in Local Operation

LOCAL
Mode
MACHINE
Machine is in Remote
REMOTE
Operation Mode
HTG / COW SP
CZ JB81 760C_00 A.7. 39

HTG Temperature Trip HTG TEMP. TRIP SP - If actual HTG temperature exceeds this set
When point value, machine trips on 'HTG TEMP. HIGH ALARM'.
Machine is ON ,
HTG HYSTERISIS - This value determines the HTG temperature,
below the HTG TEMP TRIP SET POINT, at which the HTG temp
high alarm can be reset. The HTG temp high alarm can be reset
only when the actual HTG temperature is less than ‘HTG TEMP
TRIP SETPOINT ' - 'HTG HYSTERISIS'.
Cooling Water Inlet COOLING WATER IN TRIP SETPOINT - If cooling water inlet
Trip Set Point & temperature drops below this value machine trips on "COW IN
Hysterisis TEMP LOW" alarm.
COW HYSTERISIS - This value determines the value of cooling

water inlet temp at which the alarm can be reset. The alarm is
reset at "COW IN TRIP SP" + "COW HYSTERISIS"

Cooling Tower Fan CT FAN OFF SETPOINT - This value determines the temperature
Set Point & Hysterisis of COOLING WATER at which the cooling tower fan is to be
switched off.
CZ JB81 760C_00 A.7. 40

CT HYSTERISIS - This value determines the actual cooling water

inlet temp above the CT fan off set point at which the cooling
tower fan would restart. The fan restarts at “CT FAN SP” + “CT
FAN HYSTERISIS”.

HTG Vapour Trip Set HTG VAP TRIP SP - If HTG Vapour temperature increases above
point & Hysterisis this value machine TRIP on "HTG VAPOUR HIGH” alarm.
HYSTERISIS - This value determines the HTG Vapour

temperature, below the HTG VAP TRIP Sp in cool/sim mode, at
which the HTG VAPOUR TRIP alarm can be reset. The HTG
VAPOUR TRIP in cool/Sim mode alarm can be reset only when
the actual HTG VAPOUR temperature is less than ' HTG
VAPOUR TEMP TRIP SETPOINT in cool/Heat' - ' HYSTERISIS'.

HTG TOP & BOTTOM TEMPERATURE DIFFERENCE SP: -

When actual HTG Top & Bottom Temperature difference is more
that Set point, Condensate Drain Valve will open.
HTG TOP & BOTTOM TEMPERATURE DIFFERENCE SP

HYSTERISIS: - When actual HTG Top & Bottom Temperature
difference is less than ' HTG Top & Bottom Difference Set point '
- ' HTG Top & Bottom Difference Hysterisis’, Condensate Drain
Valve will close.
The previous page is accessed by pressing the F4 key.
The next page is accessed by pressing the F3 key.
CZ JB81 760C_00 A.7. 41

HTG DIFF SP FOR SCV - If actual HTG temperature exceeds

HTG Trip SP minus this set point value, SCV will close completely
HTG DIFF HYSTERISIS FOR SCV - This value determines the

HTG temperature, below HTG TEMP TRIP SETPOINT minus HTG
DIFF SP FOR SCV value, at which the SCV will open again. SCV
will open again only when the actual HTG temperature is less than
' HTG TEMP TRIP SETPOINT ' - ' HTG DIFF SP FOR SCV’-
‘.HTG DIFF HYSTERISIS FOR SCV’.
The previous page is accessed by pressing the F4 key.
L-CUT/H-CUT SP
L-Cut Differential Set L CUT DIFFERENTIAL SP - This is one of the antifreeze safeties
Point & Hysterisis for chilled water temperature. If the chilled water outlet
temperature drops below the CHW out set point minus L cut
differential set point the refrigerant pump stops.
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 temperature rises above the CHW out set
point minus L cut differential plus the hysterisis. Unit is degree
centigrade.
CZ JB81 760C_00 A.7. 42

Antifreeze Set Point & ANTIFREEZE SP - If the Chilled water outlet temperature drops
Hysterisis below this set point the machine trips on 'INTERNAL
ANTIFREEZE ALARM'.
ANTIFREEZE HYST - The antifreeze trip alarm can be reset only

when the Chilled water outlet temperature exceeds '
ANTIFREEZE SP' + ANTIFREEZE HYST.' Unit is degree
centigrade.

H-Cut Differential Set H CUT DIFF SP - If the HOT water temperature goes above HW
Point & Hysterisis Set point plus this value the refrigerant pump stops in SIM mode.
H CUT HYST – This set point determines the value above the H
CUT SP at which the refrigerant pump restarts. The refrigerant
pump restarts when the HW outlet temperature becomes less
than or equal to HW Set point +H CUT DIFF SP - H CUT HYST.
Unit is degree centigrade.
SCV PID SETTINGS
CZ JB81 760C_00 A.7. 43

PV (PROCESS VARIABLE) - Process variable in this case is the

Chilled water temperature. This PV numeric display is the Chilled
water outlet temperature.
NUMERIC ENTRIES:
SP (SET VALUE): This is the Chilled water outlet temperature set
point. The chilled water outlet temperature set point can be
changed from here as well as from the SETPOINTS screen. In
this screen the entry for chilled water outlet temperature set point
has no function key assigned to it. To change the set point from
this screen just type in the new set point & press the ENTER key.
Unit is °C.
CV (CONTROL VALUE): This is the PID controller output or the
Control Valve opening in terms of % age. (0 to 100%).
P (PROPORTIONAL GAIN): This value is the proportional gain of

the PID control loop. It is a factor that is multiplied to the scaled
error (scaled SV - scaled PV) in the PID equation. This value
provides a continuous, linear relationship between the deviation
and the correction signal.
I (INTEGRAL GAIN): This is the integral gain value of the PID
control loop. This value adjusts the output signal based on both
the size of the deviation and its duration (reset time). It eliminates
the offset effect of the proportional action.
D (DERIVATIVE TERM): This value determines the rate of change
of the PID control loop output with respect to rate of change of
actual Chilled water temperature.
CZ JB81 760C_00 A.7. 44

SCV AUTO/MANUAL CONTROL - To control the SCV manually,

put the Chilled water temperature PID control loop into ‘MANUAL’
mode by pressing the ‘MANUAL’ (F2) key again by pressing
AUTO (F1) key SCV can be put in AUTO mode
Controlling the SCV manually is not recommended

for normal operation of the machine
OPEN (F1) – This key lets you open the SCV by increments of
1% when the chilled water PID loop is in manual mode.
CLOSE (F2) - This key closes the SCV by decrements of 1%
when the chilled water PID loop is in manual mode.
AC DRIVE SETTINGS
AC Drive Modulation AC Drive will modulate between 35 Hz to 50Hz when HTG Temp.
HTG Low Limit & HTG is between HTG low Limit & High Limit. If HTG Temp is less than
High Limit HTG Low Limit, Then AC Drive will run at 35 Hz only. If HTG
Temp is more than HTG High Limit, Then AC Drive will run at 50
Hz only. For HTG Temp
AC Drive Inline / AC Drive- will operate in INLINE / BYPASS mode. Mode Selection
Bypass can be done using F1 / F2 keys. To Put, AC Drive-1 in Bypass
mode Press F2 .To Put, AC Drive-1 in Inline mode again, Press
F1.
PLC Date & Time This screen displays the current DATE and TIME of the PLC
CZ JB81 760C_00 A.7. 45

Current DATE and TIME of PLC can be changed in this screen.

Type each field of DATE and TIME and press ENTER key on
OP77 and to write this to PLC - press ENTER (F1) key.
REFRIGERANT PUMP OPERATION
This screen is used to select the mode of operation of the

Refrigerant Pump-1/2
refrigerant pump-1/2. In order to start or stop the refrigerant pump-
Auto / Manual 1/2 irrespective of the evaporator level, (for e.g. during Blow down
cycle) the refrigerant pump has to be in ‘MANUAL’ mode. Default
position is ‘AUTO’.
Refrigerant pump-1/2 AUTO / MANUAL mode can be changed

using the F1 and F2 keys. To operate refrigerant pump-1/2 in
AUTO mode press F1 key, To operate refrigerant pump-1/2 in
manual mode press F2 key. Present mode status is also
displayed.
CZ JB81 760C_00 A.7. 46

This screen is used to switch the refrigerant pump-1/2 on or off

Refrigerant Pump-1/2
manually. It works only when the refrigerant pump-1/2 is in
manual operation ‘MANUAL’ mode. This screen action is disabled when the
screen refrigerant pump mode is in ‘AUTO’ mode. Default position is
‘STOP’.
Refrigerant pump-1/2 START / STOP operation can be done

using the F1 and F2 keys. To start the refrigerant pump-1/2 press
F1 key. To stop the refrigerant pump-1/2 press F2 key. The
current pump status is also displayed.
MACHINE MODES
Machine Modes (Cool / Sim) mode can be changed from Cool to

Sim and vice versa using F1 and F2 keys. Press F1 key to
operate machine in Cool mode, and press F2 to operate machine
in Sim mode
COOL Machine is in COOL Mode

MACHINE
SIM Machine is in SIM Mode
SENSOR ENABLE/ DISABLE
CZ JB81 760C_00 A.7. 47

Chw in sensor Enable/Disable can be done using F1 and F2

keys. Press F1 key to enable the sensor, and press F2 to Disable.
When Enable the CHW in

ENABLE
Sensor
CHW IN
When disable the CHW in
DISABLE
Sensor
HTG Top sensor Enable/Disable can be done using F1 and F2

When Enable the HTG Top

ENABLE
Sensor
HTG TOP
When disable the HTG Top
DISABLE
Sensor

HTG Bottom sensor Enable/Disable can be done using F1 and F2

When Enable the HTG Bottom

ENABLE
Sensor
HTG BOTTOM
When disable the HTG Bottom
DISABLE
Sensor
CZ JB81 760C_00 A.7. 48

ALARM
There are two alarm sequences which activate when the fault conditions occur:
• DILUTION CYCLE alarm sequence.
• TOTAL SHUTDOWN alarm sequence.
DILUTION CYCLE alarm sequence
The duration of ‘DILUTION’ is 20 minutes and this is fixed in the PLC. Under the
‘DILUTION’ alarm sequence, the PLC performs the following actions.
• Steam control valve is closed immediately.
• Cooling tower fan start permissive will be switched OFF immediately.
• Cooling water pump/Auto shut off valve start permissive will be switched
OFF after 4 minutes.
• Refrigerant pump-1/2 runs based on evaporator refrigerant level and is
stopped after 4 minutes.
• Absorbent pump-1/2 runs based on HTG LiBr level and is stopped at the
end of 20 minutes.
• Chilled water pump permissive is put OFF at the end of 20 minutes.
If the alarm is reset, then after completion of ‘DILUTION’, the status of the machine
will read “MACHINE READY TO START” and its condition will be “OFF”. Else the
status will be “MACHINE NOT READY TO START” and condition will be “OFF”.
TOTAL SHUTDOWN Cycle alarm sequence
In case of a critical trip, the machine goes into ‘TOTAL SHUTDOWN’ alarm
sequence. The status of the machine will read “MACHINE NOT READY TO
START” and its condition will be “TRIP”. Under the ‘TOTAL SHUTDOWN’ alarm
sequence, the PLC performs the following actions.
• Steam control valve is closed immediately
• Cooling water pump/Auto shut off valve start permissive will be switched
OFF immediately.
• Cooling tower fan start permissive will be switched OFF immediately.
• Absorbent pump-1/2 is stopped immediately
• Refrigerant pump-1/2 is stopped immediately.
• Chilled water pump permissive is kept ON.
Once the fault condition has been rectified, the alarm can be reset. On resetting
the alarm, the machine goes into ‘DILUTION’. If the time taken to reset the alarm is
less than or equal to 3 minutes, the ‘DILUTION’ is not compulsory. In this case, on
resetting the alarm the status changes to “MACHINE READY TO START” and
machine condition will be ‘DILUTION’. The operator can start the machine, if
required. If the machine is restarted, a slow opening timer of 2 minutes is given for
reopening the SCV.
If the time taken to reset the alarm is more than 3 minutes, the ‘DILUTION’ is
compulsory. In this case, on resetting the alarm the status changes to “MACHINE
NOT READY TO START” and machine condition will be ‘DILUTION’. The machine
can be restarted only after completion of ‘DILUTION’.
CZ JB81 760C_00 A.7. 49

ACKNOWLEDGING AND RESETING ALARM
When an Alarm sequence is initiated, alarm screen will pop up with an audio
Alarm, after pressing Ack Button hotter gets off
If the active alarms are more than one, pressing the ACK key will acknowledge
only the active alarm displayed on the screen.
After having pressed the ACK key the next active alarm will be displayed: press
the ACK key until all the active alarms have been acknowledged and remove all
the causes that have generated the alarm press K4 to reset alarm.
ALARM LIST
Alarm Description Possible Cause Remedy

Chilled water interlock Chilled water pump off/tripped Check chilled water pump for
(CHW PUMP INTERLOCK). mechanical or electrical faults.
The alarm is activated each Fix them and keep the
time the machine is not required flow rate.
sensing the feedback signal
from chilled water pump.
The feedback signal is
Contacts 20-21 in control Check electrical wiring at
checked through the potential
panel not properly wired or not contacts 20-21.
free contacts 20-21 in the
wired at all.
control panel. Contact is
closed when the chilled water
pump is on.
Chilled water Flow Switch Chilled water pump off/tripped. Check chilled water pump for
(CHW FLOW SWITCH): mechanical or electrical faults.
The alarm is activated when Fix them and keep the
chilled water flow drops below required flow rate.
50% of the nominal value. The
alarm is sensed checking the
status of the flow switch Chilled water flow too low. Check filter in chilled water
potential free contact in the line, and clean it if necessary.
control panel. The contact is Check that gate valves at inlet
closed when the flow switch is and outlet of chilled water are
not activated open.
CHW D.P SW Chilled water flow switch or Repair or replace the chilled
CHW D.P.SWITCH): D.P. switch malfunction water flow switch or the D.P.
The alarm is activated when switch
chilled water flow drops below
50% of the nominal value. The
alarm is sensed checking the
status of the D.P. switch Air storage in the chilled water Purge the air from chilled
potential free contact in the circuit water circuit.
control panel. The contact is
closed when the D.P. switch is
not activated.
CZ JB81 760C_00 A.7. 50

Internal Sudden reduction of cooling Avoid too fast reductions in

Antifreeze load cooling load.
(INTERNAL ANTIFREEZ):
The alarm is activated when
the chilled water outlet
temperature goes below the Chilled water flow rate too low. Check filter in chilled water
value set in the service line, and clean it if necessary.
screens. Check that gate valves at inlet
and outlet of chilled water are
open.
Antifreeze Chilled water set point is too Change the set value of
Thermostat low. chilled water outlet
(ANTIFREEZ THERMOSTAT): temperature and select a
The alarm is activated when higher value.
the chilled water outlet Antifreeze thermostat Repair or replace antifreeze
temperature goes below the malfunction. thermostat.
setting of the instrument. The L-cut settings are too low. Change the settings of L-cut
alarm is sensed checking the function and select a higher
status of the potential free value.
contact of the antifreeze Chilled water flow rate too low. Check filter in chilled water
thermostat in the control line, and clean it if necessary.
panel. Contact is closed when Check that gate valves at inlet
the thermostat is working fine and outlet of chilled water are
and is not activated. open.
Chw In Sensor error Temperature sensor cable is Replace sensor cable.

(CHWIN SENSOR ERR) open/short.
Chw Out Sensor error Loose connection of sensor Check the sensor cable
(CHWOUT SENSOR ERR). cable. connections.
Cow In Sensor error

(COWIN SENSOR ERR). Temperature sensor faulty. Replace the temperature
sensor.
U Tube Sensor error
(U TUBE SENSOR ERR).
LTG Sensor Error

(LTG SENSOR ERR.).
HTG Vapour Sensor Error

(HTG VAP SEN ERR.)
HTG Sensor Error

(HTG SENSOR ERR).
HTG top Sensor error

(HTG-T SENSOR ERR).
Spray Sol Sensor Error

(SPRAY SOL SENSOR ERR)
HTG-bottom Sensor Error
CZ JB81 760C_00 A.7. 51

(HTG-B SENSOR ERR).
HTG Temp high High cooling water inlet Check the setting of cooling
(HTG TEMP HIGH) temperature. water tower fan thermostat,
The alarm is activated when and reset if required.
the temperature of the HTG Check the feed water system
raises above the maximum of cooling tower.
allowed value. Check and clean the cooling
tower.
HTG Vapour Temp high
(HTG VAP TEMP) Excessive steam supply. Check and adjust the supply
The alarm is activated when steam flow.
the temperature of the HTG Check the opening of steam
vapours raises above the control valve.
maximum allowed value
Fouling in the absorber and Check for fouling in the
condenser tubes. absorber and condenser tubes
and carry out tube cleaning if
required.
Setpoint of generator Check and reset the settings.
temperature not correct.
Steam control valve select Turn the steam control valve
switch is in “MANUAL” mode select key to ‘AUTO’ mode.
and in “OPEN” position.
Air leakage into the machine. Perform nitrogen leak test and
rectify the leak point.
Insufficient cooling water flow Check the operation of the
rate. cooling water pump.
Check that the cooling water
inlet and outlet valves are
open.
Check and vent out the air in
the cooling water line.
Check and clean the strainer
in the cooling water line.
Check and maintain the
cooling water flow rate.
Cooling Water Temp Low Malfunction of cooling water Check, and replace if
Alarm tower fan cutout thermostat. necessary.
(COWI TEMP LOW)
The alarm is activated when
the cooling water inlet Setpoint of cooling water tower Reset the set point of the
temperature falls below the fan cutout switch is too low. cooling water fan cutout
minimum allowable limit set in thermostat to a higher value.
PLC. The alarm is disabled for
the first 30 minutes after the Cooling water temperature is If the outside temperature is
start up of the unit to give time not able to remain above low and the machine is
to the cooling water to warm minimum set point. working at low load, there are
up. . chances that the cooling water
temperature is not able to stay
above the minimum set point,
CZ JB81 760C_00 A.7. 52

even if cooling tower fans are

off. In such cases a three way
valve has to be present on the
cooling water circuit to
recirculate the cooling water
inside the machine.
Ref Pump trip Pump drawing over current Check and ensure proper
(REF. PUMP O/L TRIP) because of either: power supply
This alarm is activated when - Single phasing.
the current absorbed by the - Severe crystallization. De-crystallize the machine.
refrigerant pump is higher than Setpoint of overload relay is Reset the set point to a higher
the maximum limit. The alarm too low. value.
is sensed checking the status
of the potential free contact of Malfunctioning of overload Check, and replace the
the overload relay in the relay. overload relay if required.
closed when the relay is not
High TRG reading. Replace pump’s bearings.
tripped.
Abso pump/Ac Drive Trip

(ABSO PUMP O/L TRIP)
This alarm is activated when
the current absorbed by the
solution pump is higher than
the maximum limit. The alarm
is sensed checking the status
of the potential free contact of
the overload relay in the
tripped.
Purge Pump Trip Pump drawing over current Check and ensure proper
(PURGE PUMP O/L TRIP) because of: power supply.
This alarm is activated when - Single phasing. Replace the purge pump oil.
the current absorbed by the - Contamination of oil.
purge pump is higher than the
maximum limit. The alarm is Setpoint of overload relay is Reset the set point to a higher
sensed checking the status of too low. value.
the potential free contact of
the overload relay in the
Malfunctioning of overload Check, and replace the
relay. overload relay if required.
tripped.
This alarm is generating a
warning message only.
Abso pump Not Responding Loose connection on the Tighten the loose connection.
(ABSO NOT RESPONDING) contactor.
This alarm is activated when Replace the contactor coil.
one of the following conditions Contactor stuck.
occurs:
• The PLC is sending the
start signal to the pump but
this is not starting within 60 Contactor coil burnt/open.
seconds.
CZ JB81 760C_00 A.7. 53

stop signal to the pump but

this is not stopping.
The start/stop of the pump is
controlled checking the status
of the potential free contacts
of the solution pump inside the
closed when the pump is on.
Ref pump Not Responding Loose connection on the Tighten the loose connection.
(REF. PUMP NOT RESP) contactor.
This alarm is activated when Replace the contactor coil.
one of the following conditions Contactor stuck.
occurs:
start signal to the pump but
this is not starting within 60 Contactor coil burnt/open.
seconds.
stop signal to the pump but
this is not stopping.
The start/stop of the pump is
controlled checking the status
of the potential free contacts
of the refrigerant pump inside
the control panel. Contact is
closed when the pump is on.
Temp Sensor Error . Temperature sensors are not Check the temperature
This alarm is activated when working properly and are sensors.
one of the following conditions giving a wrong reading. Check the power and
occurs instrumental grounding
When there is short circuit or
open ended on sensor side or
on module
CZ JB81 760C_00 A.7. 54

A.08.Start & Stop Procedure
A.8 STARTUP & STOP PROCEDURES

Chapter Objective This chapter describes the pre-start checks, starting procedure
and the stopping procedure.
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
C30 HP00 A08 A.08.1

A.08.Start & Stop Procedure
water shut off valve in proper sequence.
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.
C30 HP00 A08 A.08.2

A.09.Operating Instructions
A.9 OPERATING INSTRUCTIONS
Chapter Objective This chapter describes the operational activities required to

keep the machine in best condition. These activities are
Ø Purging
Ø Blowdown of refrigerant
Ø Maintenance of operation log
These are to be carried out as per the Operational Activity
Schedule
Purging Purging is the activity by which non-condensable gases are

removed from the machine. This is to be carried out by
operating the vacuum pump and opening the manual purge
valves as per the table below. After purging is completed the
valves are closed, and the vacuum pump is stopped.
Purging System The purging system (see Figure 9.1) consists of

Purge unit Non condensable gases and water vapour are drawn from
The absorber into the purge unit by a venturi action using
absorbent bled off the absorbent pump discharge. The
gases are bubbled through LiBr collected at the bottom of
the storage tank to remove water vapour. The non-
condensable gases collect to a maximum pressure of
50mmHg.
Valve assembly
This consists of an arrangement of three diaphragm valves
that enable the operator to connect the vacuum manometer
to different parts of the machine by closing and opening the
valves.
Manometer A ‘mercury in glass’ vacuum manometer, capable of reading
vacuum from 0mmHg absolute to 100mmHg absolute.
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
vessel whose degree of vacuum is to be measured. Mercury

fills the glass tube from the sealed end to the bottom of the
graduated scale.
When the manometer is connected to a vessel at a vacuum
of 100mmHg or greater, the mercury drops in the sealed leg
of the glass tube. The degree of vacuum is the difference in
the level of mercury in the two legs. This is read off the
graduated scale.
The level of mercury in the sealed leg of the manometer
should always be higher than the other leg. Otherwise the
reading is wrong and the manometer has to be repaired.
When the manometer is connected to the atmosphere the
mercury should rise to the top of the sealed leg. If there is a
gap between the mercury and the top of the sealed leg of the
manometer, it is faulty and should be repaired.
Kinds of purging The two types of purging are

Ø Purging from the storage tank, and
Ø Purging from the shell.
The procedure followed for the two types of purging are the
same except for the position of the manual purge valves
(shown in the earlier table)
Purging procedure Ø Power on the machine panel if it is off.
Ø Start the purge pump.
Ø Check that the purge pump is running well.
Ø Open Manual purge valve No. 1.
Ø Check that the ultimate (no load) vacuum developed by
the vacuum pump is 4mmHg or less.
Ø Open
• Manual purge valve No. 2 - for purging storage tank.
• Manual purge valve No. 3 - for purging from shell.
Ø Continue operation of purge pump till purging is
completed.
Ø Close
• Manual purge valve No. 2 - when purging storage tank.
• Manual purge valve No. 3 - when purging from shell.
Ø Continue operation of purge pump for 30 minutes to
Remove water vapour from pump oil.
Ø Close Manual purge valve No. 1.
Ø Stop the purge pump.
Precautions Ø Check that the ultimate vacuum of the purge pump is

4mmHg or less before air purging.
Ø Carry out purging at least once a day. Purging may be
Required at more frequent intervals.
Ø Always keep the gas ballast valve open while purging to
Prevent water from contaminating the purge pump oil.
Ø Carry out purging from storage tank before the storage
Tank pressure reaches 50mmHg.
During operation, a small amount of absorbent disperses in
Blowdown of the refrigerant and accumulates over time, resulting in a
refrigerant reduction in cooling capacity. Blowdown is carried out to
purify the refrigerant. Contaminated refrigerant collected in
the refrigerant pan is transferred to the absorber sump. Pure,
fresh refrigerant collects in the refrigerant pan.
C30 HP00 A09 A09.2

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
C30 HP00 A09 A09.3

50
40
30
20
10
0
10
20
30
40
50
MANOMETER
Figure 9.2
C30 HP00 A09 A09.4

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
C30 HP00 A09 A09.5

A.10.Utility Requirements
A.10 UTILITY REQUIREMENTS

Chapter Objective: The objective of this chapter is to understand what are
the various utility requirements for the functioning of
the machine.
Utility Requirements: The various utility requirements are :
Water
Steam
Air
Electricity
The Material Safety Data Sheet for all liquids are attached
at the end of this chapter.
A) WATER:
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.
C30 HP00 A10 _03 A10.1

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.
Ensure that the hot / cooling water pump stops by

interlocking the hot / cooling water pump contactors through
start permissive signal from control panel ,so that the hot /
cooling water pump stops if the chilled water flow is stopped
in the machine.
In case the hot / cooling water pump is not dedicated to the

machine and the hot / cooling water pump cannot be
stopped when the chilled water pump stops, provide a
butterfly valve in the hot / cooling water inlet line to the
absorption machine. Hook up the hot / cooling water stop
signal from the control panel to the actuator of the butterfly
valve so as to close the valve when hot / cooling water is not
required.
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.
If the chilled or hot / cooling water becomes corrosive, it will

corrode the inside of the evaporator, absorber and
condenser tubes. Tube failure due to corrosion will occur. It
is essential to fully treat the chilled and hot / cooling water to
prevent corrosive tendency.
Water Quality The standard for water in the chilled and hot / cooling water
circuits is shown in the following tables.
C30 HP00 A10 _03 A10.2

Allowable Range For Circulating Water In Chilled water and Cooling water
Items Units Copper CuNi (95:5) CuNi (90:10)
pH (25°C) 7.0 - 8.5 7.0 - 8.5 7.0 - 8.5
TDS ppm < 1500 < 5000 < 20000
TSS (Turbidity) ppm < 10 < 10 < 10
M Alkalinity ppm < 100 < 100 < 100

-
Chloride Ion CI ppm < 400 < 3000 < 10000
-
Sulphates Ion SO4 (For scaling
ppm < 500 < 500 < 500
only)
Silica ppm < 75 < 75 < 75
Total Hardness ppm < 300 < 300 < 300
Calcium Hardness ppm < 200 < 200 < 200
Total Iron Fe ppm < 0.1 < 0.1 < 0.1

-
Sulphide Ion S ppm Not detected Not detected Not detected
+
Ammonium Ion NH4 ppm <1 <1 <1
Biological Oxygen Demand (BOD) ppm < 50 < 50 < 50
Chemical Oxygen Demand (COD) ppm < 100 < 100 < 100
Free Chorine ppm < 0.1 < 0.1 < 0.1
Oil & Grease ppm <1 <1 <1
Other contaminations like Phenol,

ppm Not detected Not detected Not detected
cyanide ,lead, manganese etc
C30 HP00 A10 _03 A10.3

Allowable Range For Circulating Water In Chilled water and Cooling water
CuNi
Items Units SS 316L Ti CS
(70:30)
pH (25°C) 7.0 - 8.5 7.0 - 8.5 7 - 8.5 7.0 - 8.5
TDS ppm < 40000 < 2500 3.00% < 1500
TSS (Turbidity) ppm < 10 < 10 < 10 < 10
M Alkalinity ppm < 100 < 100 < 100 < 100
-
Chloride Ion CI ppm < 20000 < 300 < 25000 < 300
-
Sulphates Ion SO4 (For scaling
ppm < 500 < 500 < 500 < 500
only)
Silica ppm < 75 < 75 < 75 < 75
Total Hardness ppm < 300 < 300 < 300 < 300
Calcium Hardness ppm < 200 < 200 < 200 < 200
Total Iron Fe ppm < 0.1 < 0.1 < 0.1 < 0.1
- Not Not Not Not
Sulphide Ion S ppm
detected detected detected detected
+
Ammonium Ion NH4 ppm <1 NA NA NA
Biological Oxygen Demand (BOD) ppm < 50 < 50 < 50 < 50
Chemical Oxygen Demand (COD) ppm < 100 < 100 < 100 < 100
Free Chorine ppm < 0.1 < 0.1 < 0.1 < 0.1
Oil & Grease ppm <1 <1 <1 <1

Other contaminations like Phenol, Not Not
ppm < 0.1 < 0.1
cyanide ,lead, manganese etc detected detected
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.
3 The circulating water should be clean with Turbidity < 10 to avoid any under deposit corrosion
4 Avoid stagnant water in Chiller for longer period. In case of more than 1 day of shut down,
circulate water for 30 mins in the chiller every day. For longer duration, drain
the water from chiller and keep the chiller in dry conditions"
C30 HP00 A10 _03 A10.4

5 The make-up water quality has to be derived from above considering the cycles of
concentration.
STEAM: The steam to the machine should be Dry & Saturated. The steam
pressure should be in the range of 4 kg/cm2 g to 10 kg/cm2 g.
There should not be any rapid fluctuation in steam supply.
AIR: The compressed air is required for the pneumatic operation of

Steam Control valve. The Air supplied should be Moisture free.
The supply pressure of air is required to be 7 kg/cm2 g.
ELECTRICAL: The power supply to the machine shall be strictly as per the
Voltage and frequency rating given on Machine name plate.
C30 HP00 A10 _03 A10.5

A.10.MSDS
MATERIAL SAFETY DATA SHEET

Product Name Water
Product Part Number 0413 7400 21
Issue Date 20 – Dec – 2004 Revision 0
1. Identification of the substance
Chemical name Water

Chemical formula H2O
Chemical family Inorganic
Molecular weight 18.02
Type of product and use Liquid used as refrigerant in LiBr based air conditioning and cooling
systems
2. Composition / information on ingredients
Components Weight % Annex No. EINECS No. Classification Notes

Water 100 231-792-2
7732-18-5
3. Hazards identification
Emergency Overview
Health Rating 0
Flammability Rating 0
Reactivity Rating 0
Contact Rating 0
Storage 0
Potential human health effects Nil
4. First-aid measures
Eye Contact Nil

Skin Contact Nil
Ingestion Nil
Inhalation Call a physician, seek medical attention for further treatment, observation
and support after first aid. Inhalation: Remove to fresh air at once. If
breathing has stopped give artificial respiration immediately.
5. Fire - fighting measures
Non Combustible Liquid
6. Accidental release measures
Wipe up spills with towel.
7. Handling and storage
Not applicable
C30 HP00 A10_03 A.10.6

A.10.MSDS
8. Exposure controls / personal protection

Not Applicable
9. Physical and chemical properties

Appearance Clear, colorless liquid
Odor Odorless
Specific Gravity 1
pH No information found.
Boiling Point 100°C (212°F)
Melting Point 0°C (32°F)
10. Stability and reactivity

Stability Stable under ordinary conditions of use and storage.
11. Toxicological information

Acute effects N.A.
Chronic effects N.A.
Target organs N.A.
Eye effects N.A.
Dermal LD50 N.A. (rabbit)
Oral LD50 N.A. (rat)
Inhalation LC50 N.A.
Carcinogenicity N.A.
12. Ecological information

Environmental Fate No information found.
Environmental Toxicity No information found
13. Disposal considerations
Dispose of container and unused contents in accordance with federal, state and local requirements.
14. Transportation information

Not regulated
15. Regulatory information

Not Available
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
C30 HP00 A10_03 A.10.7

A.10.MSDS

Product Name Lithium Molybdate solution
Chemical name Lithium Molybdate water solution

Chemical formula Li2MoO4
Chemical family Inorganic
Type of product and use Inorganic solution used as corrosion inhibitor in LiBr based air
conditioning and cooling systems

Lithium Molybdate 18-22 236-977-7 XI
13568-40-6 R 36/37/38
Water 78-82 231-792-2
7732-18-5
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.
Potential human health effects

- Eye Causes eye irritation.
- Skin Causes skin irritation.
- Ingestion Causes gastrointestinal irritation with nausea, vomiting and diarrhea. The
toxicological properties of this substance have not been fully investigated.
- Inhalation Causes respiratory tract irritation. The toxicological properties of this
substance have not been fully investigated.
- Chronic No information found. Risk of serious damage to eyes
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.
C30 HP00 A10_03 A.10.8

A.10.MSDS
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.
NOTE: Never give an unconscious person anything to drink.
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.
General Information No known physical hazard, non-combustible.

Flash point None
Flammable/Explosion limits Not flammable
Auto-ignition temperature Not available
Suitable extinguishing media Use agent most appropriate to extinguish fire. Use water spray, dry
chemical, carbon dioxide, or appropriate foam.
NFPA Rating Health: 1; Flammability: 0; Instability: 0

Fire Fighting Procedures Wear full protective clothing and self-contained breathing apparatus
(SCBA) approved for fire fighting. This is necessary to protect against the
hazards of heat, products of combustion and oxygen deficiency. Do not
breathe smoke, gases or vapors generated.
Unusual fire and explosion
hazards None known
General Information Use proper personal protective equipment as indicated in Section 8.

Personal precautions Wear respirator, chemical safety goggles, rubber gloves and boots.
Methods for cleaning up Contain spill with absorbent. Transfer or pump into a suitable container.
Dispose of waste according to local and Federal laws and regulations
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.
Engineering Controls Use adequate ventilation to keep airborne concentrations low.
Exposure Limits:
Components ACGIH-TLV Data OSHA (PEL) Data

Lithium bromide
Not Determined Not determined
13568-40-6
C30 HP00 A10_03 A.10.9

A.10.MSDS
OSHA Vacated PELs Lithium Molybdate (VI): No OSHA Vacated PELs are listed for this
chemical.
Personal protective equipment:

Eyes Wear appropriate protective eyeglasses or chemical safety goggles as
described by OSHA's eye and face protection regulations in 29 CFR
1910.133 or European Standard EN166.
Skin Wear appropriate protective gloves to prevent skin exposure.
Clothing Wear appropriate protective clothing to prevent skin exposure.
Respirators A respiratory protection program that meets OSHA's 29 CFR 1910.134

and ANSI Z88.2 requirements or European Standard EN 149 must be
followed whenever workplace conditions warrant a respirator's use.
Work hygiene practices Quick-drench eyewash and safety shower.
Appearance Clear, colourless liquid, odourless

pH 7 to 7.5
Percent Volatile 80 as water
Melting point/range Not available
Boiling point/range A 30% Aqueous solution boils at 102°C
Vapour pressure Not Available
Vapor density Not available
Evaporation rate (ether=1) Not available
Solubility:
- Solubility in water Not available
- Solubility in other solvents Not available
Specific gravity 1.188
Decomposition temperature Not available
Stability Stable at room temperature.

Materials to avoid Strong acids, Strong Bases
Conditions to avoid None
Hazardous decomposition None
products
Hazardous polymerization Has not been reported
Eye effects No data available.

Skin effects No data available.
Dermal LD50 No data available.
Oral LD50 No data available.
Inhalation LC50 No data available.
Acute effects No data available for the product. Exposure to large amounts of
from overexposure molybdenum may irritate the upper respiratory tract and damage the liver,
spleen and kidneys.
C30 HP00 A10_03 A.10.10

A.10.MSDS
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.
Waste disposal Avoid access to streams, lakes or ponds.

Observe all federal, state and local environmental regulations when
disposing of this material.
DOT Not regulated
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.
CERCLA (COMPREHENSIVE ENVIRONMENTAL RESPONSE COMPENSATION AND LIABILITY ACT)
CERCLA Regulatory (40 CFR 302.4): Not applicable
TSCA (TOXIC SUBSTANCE CONTROL ACT)
TSCA Regulatory (40 CFR 707.60): This product is not subject to TSCA 12 (b) Export Notification
Requirements.
C30 HP00 A10_03 A.10.11

A.10.MSDS
TSCA STATUS (40 CFR 710): Listed
STATE REGULATIONS
California Proposition 65: WARNING. This product contains a chemical known to the State of California
to cause reproductive toxicity.
CANADA
WHMIS (WORKPLACE HAZARDOUS MATERIALS INFORMATION SYSTEM):

Product Identification No.: Not applicable
Hazard Classification: Not applicable
Ingredient Disclosure List: Not listed
Thermax Disclaimer
INFORMATION REFERS.
C30 HP00 A10_03 A.10.12

A.10.MSDS

Product Name Octyl Alcohol
Chemical name 2-Ethyl 1-Hexanol

Chemical formula CH3.(CH2)3.CH.(CH2.CH3).CH2.OH
Chemical family Organic
Type of product and use Organic liquid used as additive to enhance the property of absorbent in
LiBr based air conditioning and cooling systems

2-Ethyl 1-Hexanol 100 203-234-3
104-76-7
Emergency Overview
WARNING! HARMFUL IF SWALLOWED, INHALED OR ABSORBED THROUGH SKIN. VAPORS AND

MISTS SEVERELY IRRITATE THE EYES AND RESPIRATORY TRACT, ESPECIALLY WHEN HEATED.
MAY AFFECT CENTRAL NERVOUS SYSTEM. MAY CAUSE ALLERGIC SKIN REACTION.
COMBUSTIBLE LIQUID AND VAPOR.
Health Rating 1 - Slight

Flammability Rating 2 - Moderate
Reactivity Rating 1 - Slight
Contact Rating 2 - Moderate
Lab Protective Equip GOGGLES; LAB COAT; VENT HOOD; PROPER GLOVES; CLASS B
EXTINGUISHER.
Storage Color Code Red (Flammable)
Aggravation of Pre-existing
Conditions No information found.
Potential human health effects

- Eye Causes irritation, redness, and pain.
- Skin Causes skin irritation. May be absorbed through skin. May cause
sensitization or allergic skin reaction in some individuals.
- Ingestion Harmful if swallowed. May cause headache, nausea, weakness,

dizziness, and central nervous system depression.
- Inhalation Inhalation of vapor or mist is irritating to the respiratory tract. Symptoms

include coughing and shortness of breath. High air concentrations are
unlikely due to the low vapor pressure.
C30 HP00 A10_03 A.10.13

A.10.MSDS
- Chronic Prolonged or repeated skin exposure may cause sensitization.
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.
General Information No known physical hazard, non-combustible.

Flash point 81°C (178°F)
Auto-ignition temperature 231°C (448°F)
Flammable limits in lel: 0.88; uel: 9.7
air% by Volume Combustible Liquid and Vapor!
Explosion: Above the flash point, explosive vapor-air mixtures may be formed.
NFPA Rating Health: 1; Flammability: 2; Instability: 0
Suitable extinguishing media Water spray, dry chemical, alcohol foam, or carbon dioxide. Water may be
ineffective
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!

Protect against physical damage. Outside or detached storage is preferred. Inside storage should be in a
standard flammable liquids storage room or cabinet. Separate from oxidizing materials. Storage and use
areas should be No Smoking areas. Containers of this material may be hazardous when empty since they
retain product residues (vapors, liquid); observe all warnings and precautions listed for the product.

Airborne Exposure Limits None established.
Ventilation System A system of local and/or general exhaust is recommended to keep
employee exposures as low as possible. Local exhaust ventilation is
generally preferred because it can control the emissions of the
C30 HP00 A10_03 A.10.14

A.10.MSDS
contaminant at its source, preventing dispersion of it into the general work

area. Please refer to the ACGIH document, Industrial Ventilation, A
Manual of Recommended Practices, most recent edition, for details.
Personal Respirators For conditions of use where exposure to the substance is apparent and
(NIOSH Approved) engineering controls are not feasble, consult an industrial hygienist. For
emergencies, or instances where the exposure levels are not known, use
a full-facepiece positive-pressure, air-supplied respirator. WARNING: Air
purifying respirators do not protect workers in oxygen-deficient
atmospheres.
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.
Appearance Clear, colorless liquid.

Odor Sweet floral (rose-like) odor.
Solubility Slightly soluble in water.
Specific Gravity 0.833
pH No information found.
% Volatiles by volume 100
@ 21°C (70°F)
Boiling Point 183 - 186C (361 - 367F)
Melting Point -76C (-105F)
Vapor Density (Air=1) 4.5
Vapor Pressure (mm Hg) 0.36 @ 20C (68F)
Evaporation Rate (BuAc=1) 0.01
Stability Stable under ordinary conditions of use and storage.

Materials to avoid Oxidizers, acids
Conditions to avoid Heat, ignition sources and incompatibililites
Hazardous decomposition Carbon dioxide and carbon monoxide may form when heated to
products decomposition. May produce acrid smoke and irritating fumes when
heated to decomposition.
Hazardous polymerization Has not been reported
Eye effects 20mg Severe.

Dermal LD50 1970 mg/kg (rabbit)
Oral LD50 3730 mg/kg (rat)
Inhalation LC50 No data available
Investigated as a mutagen and a reproductive effector.
C30 HP00 A10_03 A.10.15

A.10.MSDS
Carcinogenicity
- IARC Not listed
- NTP Not listed
- OSHA Not listed
- OTHER - ACGIH Not listed
Environmental Fate No information found.
Environmental Toxicity No information found

Whatever cannot be saved for recovery or recycling should be managed in an appropriate and approved
waste disposal facility. Processing, use or contamination of this product may change the waste management
options. State and local disposal regulations may differ from federal disposal regulations. Dispose of
container and unused contents in accordance with federal, state and local requirements.

DOT Not regulated

Chemical Inventory Status
- TSCA Yes
- EC Yes
- Japan Yes
- Australia Yes
- Korea Yes
- Canada
DSL Yes
NDSL No
Phil. Yes
Federal, State & International Regulations
- SARA 302
RQ No
TPQ No
- SARA 313
List No
Chemical Catg. No
- CERCLA No
- RCRA 261.33 No
- TSCA 8(d) No
Chemical Weapons
Convention No
TSCA 12(b) Yes
CDTA Yes
SARA 311/312
Acute Yes
Chronic Yes
Fire Yes
Pressure No
Reactivity No (Pure / Liquid)
Australian Hazchem Code None allocated.
Poison Schedule None allocated.
WHMIS This MSDS has been prepared according to the hazard criteria of the
Controlled Products Regulations (CPR) and the MSDS contains all of the
information required by the CPR.
C30 HP00 A10_03 A.10.16

A.10.MSDS
Label Hazard Warning: WARNING! HARMFUL IF SWALLOWED, INHALED OR ABSORBED

THROUGH SKIN. VAPORS AND MISTS SEVERELY IRRITATE THE
EYES AND RESPIRATORY TRACT, ESPECIALLY WHEN HEATED.
MAY AFFECT CENTRAL NERVOUS SYSTEM. MAY CAUSE ALLERGIC
SKIN REACTION. COMBUSTIBLE LIQUID AND VAPOR.
Label Precautions S23 Avoid breathing vapor or mist.

S24/25 Avoid contact with eyes, skin and clothing.
S7 Keep container closed.
S51 Use with adequate ventilation.
S28 Wash thoroughly after handling.
S15/16 Keep away from heat and flame.
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
INFORMATION REFERS.
C30 HP00 A10_03 A.10.17

A.10.MSDS

Product Name Lithium bromide solution
Chemical name Lithium bromide water solution

Chemical formula LiBr
Chemical family Inorganic bromide
Type of product and use Inorganic solution used as desiccant medium in air conditioning and
cooling systems

Lithium bromide 47-58 231-439-8 Xi: R41
7550-35-8
Water 42-53 231-792-2
7732-18-5
Adverse human health effects Risk of serious damage to eyes
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.
Inhalation In case of mist inhalation or breathing fumes released from heated

material, remove person to fresh air.
Keep him quiet and warm. Apply artificial respiration if necessary and get
medical attention immediately.
Ingestion If swallowed, wash mouth thoroughly with plenty of water and give water
to drink.
Get medical attention immediately.
Notes to the physician Irritant

No specific antidote. Treat symptomatically and supportively. In case of
ingestion induce vomiting in alert patient.
Flash point None
C30 HP00 A10 _03 A.10.18

A.10.MSDS
Flammable/Explosion limits Not flammable
Auto-ignition temperature Not available
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.
NFPA Rating (estimated) Health: 1; Flammability: 0; Instability: 0

Unusual fire and explosion
hazards None known
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.
Handling Avoid bodily contact.

Keep containers tightly closed.
Storage Store in a dry, cool, well-ventilated area away from incompatible materials
(see "materials to avoid").
Exposure Limits:
Components ACGIH-TLV Data OSHA (PEL) Data

Lithium bromide
Not Determined Not determined
7550-35-8
Ventilation requirements Provide adequate ventilation.

Use local exhaust as necessary, especially under misting conditions.
Personal protective equipment:

- Respiratory protection Approved respirator
- Hand protection Rubber gloves
- Eye protection Chemical safety goggles
- Skin and body protection Body covering clothes and boots
Hygiene measures Safety shower and eye bath should be provided. Do not eat, drink or
smoke until after-work showering and changing clothes.

Appearance Clear, colourless to yellow liquid, odourless
Melting point/range 10°C (58%)
Boiling point/range 146°C (55%)
C30 HP00 A10_03 A.10.19

A.10.MSDS
Vapour pressure 2.1 mm Hg at 20°C (55%)

Vapor density Not available
Evaporation rate (ether=1) Not available
Solubility:
- Solubility in water 70 g/100ml at 101°C
- Solubility in other solvents Miscible with methanol, ethanol (absolute), n-propanol
Specific gravity 1.627 (55%)
Stability Stable under normal conditions.

Materials to avoid Strong acids
Conditions to avoid None known
Hazardous decomposition None known
products
Hazardous polymerization Will not occur
Note: The following data refer to LiBr 55%

Acute toxicity:
- Rat oral LD50 >2000 mg/kg
- Rabbit dermal LD50 >2000 mg/kg
- Rat inhalation LC50 >5.1 mg/l/4 hour
- Eye irritation (rabbit) Severe irritant
- Dermal irritation (rabbit) Mild irritant
- Dermal sensitization Not a sensitizer
--(guinea pig)
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.
Chronic toxicity Repeated skin contact may cause dermatitis.

Repeated oral intake of bromides (>9 mg/kg body weight/day) may affect
the central nervous system. Warning symptoms include mental dullness,
slurred speech, weakened memory, apathy, anorexia, constipation,
drowsiness and loss of sensitivity to touch and pain.
Mutagenicity Not mutagenic by the Ames Test

Carcinogenicity Not known to be a carcinogen.
Not classified by IARC.
Not included in NTP 9th Report on Carcinogens.
C30 HP00 A10_03 A.10.20

A.10.MSDS
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
Waste disposal Avoid access to streams, lakes or ponds.

Observe all federal, state and local environmental regulations when
disposing of this material.
IMO Not regulated

ADR/RID Not regulated
ICAO/IATA Not regulated
DOT Not regulated
EEC Reported in EINECS (No. 2314398)

- Indication of danger Irritant, symbol required (Xi)
- Risk Phrases R 41 :Risk of serious damage to eyes.
- Safety Phrases S 26 :In case of contact with eyes, rinse immediately with plenty of water
and seek medical advice.
S 39 :Wear eye/face protection.
Australia Listed in AICS

USA Reported in the EPA TSCA Inventory
Canada Listed in DSL
Japan Listed in MITI (ENCS No.1-110)
China inventory Listed
South Korea Listed in ECL (KE-22549)
Philippines Listed in PICCS
Thermax Disclaimer
INFORMATION REFERS.
C30 HP00 A10_03 A.10.21

A.11.Dos and Don’ts
A.11 DO’S & DON’T S

Chapter Objective This chapter describes various activities, which are to be
carried out in the operation of the machine and others, which
should not be done.
Dos Blowdown refrigerant once a week.

Close the service valves after any operation like checking
the pressure, solutions sampling, or charging, etc.
Purge non condensable gases from the purge unit, if the
storage tank vacuum is more than 15 mm Hg.
Close the main steam isolation valve after switching off the
machine.
Maintain inlet steam pressure constant at rated value.
Check the presence of octyl alcohol and corrosion inhibitor
periodically.
Analyse chilled and hot / cooling water every three months
and maintain the quality of chilled and hot / cooling water.
Ensure that hot / cooling water flow stops one minute after
the stopping the machine.
Change the vacuum pump oil, if it is contaminated (white
misty colour) .
Charge nitrogen gas upto 0.3 kg/cm2(g) in the system for
long shutdown of the machine (i.e. more than a month). If
the shutdown is for a shorter period, purge the machine for
20 minutes, twice a week.
Ensure that the rated electric supply (3 phase) is available.
Always start the chilled water pump first and then the hot /
cooling water pump. Ensure that the rated chilled water and
hot / cooling water flows are passing through the machine.
Ensure that the steam is available at rated inlet condition.
Dry generator tubes / Headers if shutdown is more than one
month.
Drain moisture from purge pump liquid trap periodically.
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.
C30 HP00 A11 A.11.1

A.11.Dos and Don’ts
Don’t decrease the chilled water flow below the specified

value.
Don’t run the hot / cooling water pump if chilled water pump
is not running.
Do not by pass or change setting of any safety devices or
instruments
Do not open/close any angle/needle valve in the m/c
Don’t change setting of damper valves.
C30 HP00 A11 A.11.2

A.10.Unloading & Leveling
A.12 Unloading & Leveling

Unloading instructions:
• Use lifting shackles provided on the machine. Do not rig from any other point to avoid
any damage to the unit or any personal injury.
• 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 interconnecting pipes on the machine.
• Avoid any damage to the control panel and the machine mounted instruments.
PLACE THE HOOK AS SHOWN

AVOID DAMAGE TO PIPES
C30 HP00 A12 A12.1

Unloading of Machine (Single piece): As a standard feature, the machines are

shipped in single piece. The sketch shown below indicates the unloading of the single
piece machine.
C30 HP00 A12 A12.2

Unloading the Machine(Three-piece): As a non-standard feature, the machine

are shipped in three-sections for ease of rigging inside the building/ plant room. The
sketch below shows the three-piece unloading of the machine.
PART SHIPMENT
Three-section shipping
Avoid the pipes when hanging the wire on the chiller.
(1) Upper Shell (2) High temp. generator
(3) Lower Shell
Storage of the unit

If the unit is not going to be installed immediately, it is important to prevent any damage
or loss on the unit by keeping the unit covered. Indoor storage is ideal. Nitrogen should
not be removed from the machine unit. All the accessories supplied alongwith the unit
should be kept in the same place.
C30 HP00 A12 A12.3

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.
Procedure for leveling the machine:

Fill a clear vinyl hose (diameter of the hose ≥ 3/8”) with water, ensuring that there are no
air bubbles in the hose. Using the point A as the reference point, measure the difference
in the water level at the other points (B, C and D) .
A B
VAPOR ABSORPTION
MACHINE
C D
SE
HO
L
NY
VI
R
EA
CL
A B C D
0 mm mm mm mm
Leveling calculations are as shown below :
A-B , C-D , A-D , B-C , A-C , B-D

L L L L W W
C30 HP00 A12 A12.4

where L = Length of the machine

W = Width of the machine
If the tolerance is not met, provide shim at the appropriate points by inserting a metal
shim between the machine frame and the foundation. Metal shim size is approximately
2” (50 mm) width X 3” (75 mm) length. Prepare the shims of different thickness 0.024”
(0.6 mm) to 0.354” (9 mm).
After providing the shims, confirm the leveling of the machine by taking a new set of
readings.
C30 HP00 A12 A12.5

SECTION B
TROUBLESHOOTING
C30 HP00 B00 B00.1

B.01.Index for Troubleshooting
B.1 INDEX FOR TROUBLESHOOTING
Sr. No. Problem Page No.

A Problem without alarm indication B.2.1
1. Operator terminal does not light up B.2.1
2. Machine does not start. B.2.1
3. Chilled water temperature is not dropping B.2.1
4. Leaving chilled water temperature is rising day by day B.2.1
5. Fouling of hot / cooling water and / or chilled water circuit B.2.1
6. Mixing of absorbent solution in the refrigerant B.2.2
7. Insufficient octyl alcohol B.2.2
8. Very small amount of air leakage in the machine B.2.2
9. Large fluctuation in the chilled water outlet temperature B.2.2
10. Steam control valve does not close when the hot or chilled B.2.3
water outlet temperature crosses the set temperature
B. Problems with alarm indication
1. Chilled water pump put off / tripped B.2.3
2. Chilled water flow switch tripped. B.2.3
Chilled water DP switch tripped.
3. Chilled water temperature very low (Internal antifreeze). B.2.3
Antifreeze thermostat tripped
4. Chilled water inlet temperature sensor error. B.2.3
Chilled water outlet temperature sensor error.
Hot / Cooling water inlet temperature sensor error.
Hot / Cooling water outlet 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
5. HTG temperature high. B.2.4
HTG vapour temperature high.
6. Cooling water inlet temperature very low. B.2.4
7. Refrigerant pump tripped. B.2.4
Absorbent pump tripped.
MCB 1 / MCB 2 tripped
8. Purge pump tripped. B.2.5
9. Absorbent pump not responding. B.2.5
10. Refrigerant pump not responding B.2.5
11. Action in case of interrupted power supply during operation B.2.5
12. Power cut during purging operation of the machine B.2.5
13. Jamming of the purge pump B.2.5
14. PLC troubleshooting B.2.6
C30 HP00 B01 B01.1

B.02.TroubleShooting Guide
B.2 TROUBLESHOOTING GUIDE
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.
Ø Other causes for not achieving the desired chilled water

temperature are -
• 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.
C30 HP00 B02 B02.1

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.
Perform tube cleaning of the chilled water and / or hot /

cooling water tubes as required.
5. Mixing of absorbent A very small quantity of absorbent may be dispersed in the

solution in the refrigerant and accumulate during the operation of the
refrigerant machine. It causes reduction in the capacity of the machine.
Perform refrigerant blowdown to generate fresh refrigerant.
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
C30 HP00 B02 B02.2

minor leakage points, specifically at the sight glasses,

solution level electrodes, refrigerant level electrodes,
connections of manometer, diaphragm valves, absorbent
pump pressure gauge and generator pressure gauge. Rectify
the leak point and conduct nitrogen decay test for 24 hours
and confirm there is no drop in the nitrogen pressure in the
machine.Use pressure gauge of 0.01 kg/cm2
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
Description of alarm Probable cause Remedy

Chilled water pump put Chilled water pump Check the chilled water pump for
off / tripped. stopped / tripped. mechanical and electrical faults.
Rectify the same and maintain the
required flow.
Chilled water flow switch Chilled water pump Check the chilled water pump for
tripped. stopped / tripped. mechanical and electrical faults.
Chilled water DP switch Rectify the same and maintain the
tripped. required flow.
Inadequate chilled Check the strainer in the chilled
water flow rate. water circuit, and clean if
necessary.
Check that the chilled water inlet
and outlet valves are open.
Malfunction of chilled Replace / rectify the flow switch /
water flow switch / DP DP switch
C30 HP00 B02 B02.3


switch.
Accumulation of air in Perform air-venting from the
the chilled water chilled water circuit.
circuit.
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.
(*) Sudden reduction of Do not reduce the chilling load

chilling load. suddenly.
(*) Inadequate chilled Check the strainer in the chilled
water flow rate. water circuit, and clean if
necessary.
Check that the chilled water inlet
and outlet valves are open.
Main setpoint of chilled Reset the chilled water set point to
water is too low. a higher value.
Setpoint of L cut is too Reset the L cut setpoint to a
low. higher value.
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
HR in temperature sensor
error.
HTG vapour temperature
sensor error.
Sprayed solution
C30 HP00 B02 B02.4


HTG temperature high. High cooling water inlet Check the setting of cooling water
HTG vapour temperature temperature. (Cooling tower fan thermostat, and reset if
high. Mode) required.
Check the feed water system of
cooling tower.
Check and clean the cooling
tower.
Excessive steam Check and adjust the supply
supply. steam pressure.
Check the opening of steam
control valve.
Check the operation of steam
control valve.
Fouling in the absorber Check for fouling in the absorber
and condenser tubes. and condensor tubes, and carry
out tube cleaning if required.
Setpoint of HTG Check and reset the settings.
temperature / vapour
temperature is not
correct.
Steam control valve Turn the steam control valve
select switch is in select key to ‘AUTO’ mode.
‘MANUAL’ mode and
in ‘OPEN’ position.
Air leakage into the Perform nitrogen leak test and
machine. rectify the leak point.
Inadequate hot / Ø Check the operation of the hot
cooling water flow rate. / cooling water pump.
Ø Check that the hot / cooling
water inlet and outlet valves
are open.
Ø Check and vent out the air in
the hot / cooling water line.
Ø Check and clean the strainer in
the hot / cooling water line.
Ø Check and maintain the hot /
cooling water flow rate.
Wrong AC Drive Reprogram the AC Drive.
program.
Cooling water inlet Malfunction of cooling Check, and replace if necessary.
temperature very low. water tower fan cutout
(Cooling mode only) thermostat.
Setpoint of cooling Reset the set point of the cooling
water tower fan cutout water fan cutout thermostat to a
switch is too low. higher value.
Refrigerant pump tripped. Pump drawing
Absorbent pump tripped. overcurrent because of
MCB 1 / MCB 2 tripped. either - Check and ensure proper power
Single phasing. supply
Severe crystallisation. Decrystallise the machine

Setpoint of overload Reset the set point to a higher
relay is too low. value.
C30 HP00 B02 B02.5


Malfunctioning of Check, and replace the overload
overload relay. relay if required
High TRG reading. Replace the bearing.
Purge pump tripped. Pump drawing
overcurrent because of
-
Single phasing. Check and ensure proper power
supply.
Contamination of oil. Replace the purge pump oil.

Setpoint of overload Reset the set point to a higher
relay is too low. value.
Malfunctioning of Check, and replace the overload

overload relay. relay if required.
Absorbent pump not Loose connection on Tighten the loose connection.
responding. the contactor.
Contactor stuck. Replace the contactor coil.
Contactor coil burnt / Recycle the power to the AC

open. Drive.
Refrigerant pump not Loose connection on Tighten the loose connection.
responding. the contactor
Contactor stuck.
Contactor coil burnt / Replace the contactor coil.

open.
PLC fault. Refer to PLC fault troubleshooting.
• 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.
Action in case of Ø If the power supply to the machine is interrupted, switch

interrupted power off the machine immediately. Make sure that the steam
supply during operation control valve is closed.
Ø If the power supply is resumed within half an hour,

immediately start the machine and maintain the
appropriate inputs to the machine.
Ø If the power is interrupter for longer then half an hour,

carry out the following activities -
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.
C30 HP00 B02 B02.6

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.
Ø If the quality of purge pump oil is not proper and contains

too much contamination, the purge pump may become
jammed. Charge fresh oil in the purge pump as below.
• Drain out the contaminated oil from the purge pump.

• Charge kerosene oil in the purge pump and operate it
for a few seconds.
• Drain the kerosene oil from the purge pump.
• Charge purge pump oil in the purge pump and
operate the purge pump for some time.
• Drain the oil and recharge fresh purge pump oil.
• Clean Liquid Trap.
Now the pump is ready for usage.
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.
C30 HP00 B02 B02.7

SECTION C
MAINTENANCE
C30 HP00 C00 C00.1

C.01.Preventive Maintenance
C.1 PREVENTIVE 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
Weekly • Check oil in vacuum pump.

• Blowdown refrigerant.
• Check pH and hardness of chilled and hot / cooling water.
Monthly • Check the Generator sight glass bolt tightness lightly.

• Caution : Don’t overtighten as it may break the sight
glass.
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.
C30 HP00 C01 C01.1

C.01.Preventive Maintenance
• Yearly • External visual inspection of the machine for any damage.

If any safety device is missing / damaged, replace the
same.
• Conduct nitrogen leak test on the machine. If any leak is
detected, rectify the leak point.
• Replace all the diaphragms on the diaphragm valves.
• Check for any scaling / slime in the absorber, condenser
and evaporator tubes. Carry out the tube cleaning, if
required.
• Overhaul the absorbent and refrigerant pump.
• Clean the steam trap on the machine.
• Check and record the insulation resistance.
• Overhaul the purge pump and clean the moisture trap on
the purge line.
• Conduct bubble test on the machine.
• Clean the seat of the steam control valve.
• Remove of entire LiBr from the m/c and settle it.Based on
quality of LiBr decide settling / filteration.
• Replace rubber components like diaphragms,gasket,etc.,
C30 HP00 C01 C01.1

C.02.List of Recommended Spares
C.2 LIST OF RECOMMENDED SPARES

Chapter Objective: This chapter gives details of the various spares and
corresponding quantity, for one year, for the smooth functioning of the
machine.
Sr No. Item Quantity

1. Inhibitor (Moly base) 10 Ltr
2. Octyl Alcohol 5 Ltr
3. Sight Glass 04 No.
4. Package for Sight Glass 08 No.
5. Diaphragm 04 No.
6. Dia top cover 02 No.
7. ABS pump pressure guage 01 No.
8. Manometer 01 No.
9. Service valve kit 04 No.
10. Service valve 02 No.
11. Vacuum pump kit 01 No.
12. Temperature sensor 02 No.
13. ABSO level relay 01 No.
14. Refrigeration level relay 01 No.
15. Absorbent Pump Kit 01 No.
16. Refrigerant Pump Kit 01 No.
Remark: Please contact Thermax ACD spare representative and kindly quote m/c model and
serial no.
C30 HP00 C02 C02.1

C.03.Equipment Preservation Guidelines
C.3 EQUIPMENT PRESERVATION GUIDELINES

Chapter Objective This chapter gives the guidelines to be followed for
the longer life of the machine.
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.
Water circuit Water circuit preparation is done for

preparation for long • Absorber and condenser section
term shutdown • Evaporator section.
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.
Steam circuit The generator tubes should be kept dry.

preparation for long Ø Drain out all the water from the generator from the drain
term shutdown ports.
Ø Carry out tube cleaning to remove any scale if required.
Ø Clean the tubes with water.
Ø Drain the water from the tubes.
Ø Dry the inside surface of the tubes.
C30 HP00 C03 C03.1

C.04.Procedures for Maintenance
C.4 Procedures for Maintenance

Chapter Objective This chapter describes the various procedures to be carried out
during the maintenance of the machine.
Page No. List of Procedures
C.4-3 Charging solutions (absorbent and refrigerant).
C.4-5 Sampling absorbent.
C.4-6 Measuring absorbent concentration.
C.4-9 Absorbent analysis.
C.4-11 Charging inhibitor (Li2MoO4).
C.4-13 Charging alkali (LiOH).
C.4-14 Charging acid (HBr).
C.4-15 Checking and adding Octyl alcohol.
C.4-16 Charging Nitrogen gas.
C.4-17 Expelling Nitrogen gas.
C.4-18 Measuring Absorbent pump pressure.
C.4-20 Bubble test.
C.4-21 Checking insulation resistance.
C.4-21 Checking safety device operation.
C30 HP00 C04_3 C04.1

C.4
C04.2
Bending of Vacuum rubber hose
Method of Charging solution at the

bottom of the container
Figure 4.1
C30 HP00 C04_3

Charging solutions This section describes the procedure for charging absorbent
(absorbent and refrigerant) and refrigerant into the machine. (See Figure 4.1)
Equipment used 1. Solution container (absorbent and refrigerant).

2. Vacuum rubber hose with hose clamps.
3. Copper tube
Procedure 1. Place solution containers near the service valve to be used

(to be carried out when for charging. Normally refrigerant will be charged from
the machine is off) Evaporator service valve and LiBr from LTHE service
valve.
2. Operate the vacuum pump and ensure vacuum level of 35
mmHg (abs) or less inside the machine.
3. Clean the equipment.
4. Connect the equipment as shown in the figure.
5. Fill the rubber tube with distilled water to avoid air ingress
into the machine.
6. Insert the copper tube on the end of the vacuum rubber
hose into. the liquid container (keep the end of the copper
tube slightly above the bottom of the container)
7. Open the service valve using the slot in the cap.
8. When solution starts being sucked into the machine, watch
carefully to ensure that air does not leak into the machine.
9. As the container starts becomes empty, tilt it so that air
does not enter the tube as shown in the figure.
10. Before the container become fully empty, bend the rubber
vacuum hose with both hands to ensure that air does not
leak in, and quickly insert it into the next container.
11. Repeat the above steps till all the solution has been
charged into the machine.
12. Once the required amount of solution has been charged,
close the service valve.
13. Remove the rubber vacuum hose from the service valve
and put the cap back on the service valve.
14. Stop the vacuum pump.
15. Wash all the equipment with water and store carefully.
Precautions 1. When charging solution, be careful to prevent spillage.

2. Because vacuum exists inside the machine, be careful to
prevent air leaking in during the above work.
3. Carefully wash the hose used in the above work with water
so as to prevent dirt ingress.
4. Wear rubber gloves (Do not handle equipment or solution
with bare hands.) and thoroughly wash off any absorbent
which gets on hands, skin or clothes. Take care to prevent
absorbent entering the eyes or mouth.
5. If any absorbent should spill, thoroughly wash it off with
water.
C30 HP00 C04_3 C04.3

C.4
Manual purge
C04.4
valve No.2
Vacuum
Manometer Manual purge
valve No.3
Service valve
Sampling Tool
Manual purge
valve No.1
Liquid
Trap
Purge
Tank
Sampling Tool
Purge pump
Figure 4.2
C30 HP00 C04_3

Method of sampling This section describes the procedure for sampling small
absorbent amounts of absorbent.(See figure 4.2)
Equipment used 1. Sampling Tool.

2. Rubber hoses for vacuum with hose clamp.
Procedure 1. Operate purge pump.

2. Open manual air-purge valve No.1.
3. Check vacuum less than 4mmHg
4. Connect the sampling tool to the service valve on the
purge system as shown in figure.
5. Open up the service valve connected to the sampling tool.
6. Open up the service valve of the sampling tool.
7. When pressure drops below 4mmHg, close service valve
of the sampling tool.
8. Close the service valve of the purge system connected to
the sampling tool.
9. Close Manual purge valve No.1.
10. Remove the sampling tool from the purge system.
11. Connect the sampling tool to the service valve from which
sample is to be extracted as shown in figure (ensure that
the sampling bottle is held tilted downwards).
12. Open the service valve of the sampling tool.
13. Open the service valve from which sample is to be
extracted.
14. When sampling flask becomes full of the sample (find by
feeling the temperature near the mouth)
15. Close the service valve from which sample was extracted.
16. Remove the sampling tool, open the cap and transfer the
contents as required.
17. Wash all equipment with water before reuse.
18. Upon completion, refit caps and gasket on all service
valves.
19. Purge the machine for 15 minutes after sampling is over.
20. Stop purge pump.
Precautions 1. Vacuum exists inside the machine. Take care to ensure

that air does not leak into the machine.
2. Handle all valves carefully so as not to damage them.
3. Carefully wash equipment and rubber hose with water to
remove dirt before using it in the above work.
4. Do not discard the solution after measurement. Store it in
an empty bottle and when it becomes full recharge the
solution into the machine. (See procedure for charging
solution )
C30 HP00 C04_3 C04.5

C.4
Measuring absorbent This section explains the procedure to measure the

concentration. concentration of absorbent and refrigerant. (See Figure 4.4)
Equipment used 1. Sampling cylinder

2. Gravimeter (Scale of 1.4 to 1.8 for absorbent and 1.0 to
1.2 for refrigerant).
3. Thermometer
4. Concentration Diagram of Lithium Bromide Solution
(Figure 4.3)
5. Absorbent or refrigerant (solution to be checked)
Procedure 1. Take sample of solution to be checked (Refer method of

sampling).
2. Fill sampling cylinder to about 80% with solution to be
checked.
3. Maintain sampling cylinder vertical and insert the
thermometer into the cylinder and stir the solution
thoroughly.
4. When the temperature stabilizes, read the indication on the
thermometer.
5. Remove the thermometer and insert gravimeter and when
the gravimeter stops moving up and down, read the
indication on the scale.
6. Remove the gravimeter from the measuring cylinder.
7. Store the solution in an empty bottle.
8. Read the concentration of Lithium Bromide Solution, using
the Concentration Diagram (Figure 4.3).
9. Upon completion of measurement, wash the gravimeter,
thermometer, and sampling cylinder with water, and then
store them carefully.
Example In the concentration diagram the horizontal axis represents

temperature and the vertical axis specific gravity. The lines
going down from left to right represent fixed concentration. If
the specific gravity is 1.76 and the temperature is 60°C, the
concentration given by the point of intersection of lines
projected from these valves will be 63.0%.
Precautions 1. Do not damage the gravimeter and thermometer.

2. Do not spill any solution.
3. Do not fill the sampling cylinder more than about 80%.
4. Perform specific gravity and temperature measurements
quickly.
C04.6 C30 HP00 C04_3

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
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
TEMPERATURE (C)
CONCENTRATION DIAGRAM OF
LITHIUM BROMIDE SOLUTION Figure 4.3
C30 HP00 C04_3 C04.7

C.4
60
1.76
1.75
Figure 4.4
Absorbent (LiBr) Analysis of the absorbent solution is done to determine the

Analysis following
• Concentration of inhibitor (Lithium Molybdate).

• Alkalinity of the solution.
• Copper concentration.
• Iron concentration.
Standard values Inhibitor As per graph in fig. 4.5

Alkalinity 0.05 N ~ 0.105 N
Copper 200 ppm maximum
Iron 200 ppm maximum
LiBr Additives Range and Qty addition calculations
Concentration of The concentration of the Lithium Molybdate has to be checked

inhibitor by "Atomic Absorption Spectro chemical Analysis". A sample
of the absorbent solution made in following procedure is to be
sent to a laboratory for analysis.
If the concentration of Lithium Molybdate is less than the

standard refer to procedure for adding inhibitor.
C04.8 C30 HP00 C04_3

Procedure 1. This procedure decides the sequence for preparing the

sample for checking the concentration of inhibitor
2. Take solution sample (Refer solution sampling procedure).
3. Pour the solution sample into a bottle.
4. Stand the bottle for about 24 hours. After 24 hours, solids
will settle at the bottom of the bottle
5. Collect 5ml of absorbent solution from the top of the bottle
by the pipette.
6. Pour the absorbent solution by above work into the beaker.
7. Mix 4ml of Aluminum nitrate and 1ml of 50%
Hydrochloric acid solution in another bottle.
8. Add 1ml of solution made above into the beaker by another
pipette.
9. Pour 94ml of pure water into the beaker by the burette.
10. Total quantity of the solution in the beaker is 100ml.This
means that absorbent solution is diluted to 1/20.
11. Send this sample for inhibitor analysis.
12. Before sampling, it is recommended to perform De-
crystallisation cycle for 8 hours.
Lithium Molybdate Calculation prestart quantity

Addition – 20 % by wt
(Inhibitor) The prestart (for full charge) quantity of Lithium Molybdate
Solution (20% wt.) to be charged can be calculated as
I = 2.24 * B
Where, I = Amt of Inhibitor to be added (ml)

B = Total actual qty of LiBr (55 wt%)
added in the Chiller (kgs)
Example B = Total LiBr qty = 3000 kgs
Then, Prestart Qty of Inhibitor to be added will be
I = 2.24 * 3000 = 6720 ml
The Lithium Molybdate Solution Concentration Control

Diagram indicates the desired & undesired levels of Lithium
Molybdate in Absorbent solution.
NOTE If the chiller is repaired on site by opening to atmosphere or

long-term bad purging has occurred, then while restarting the
machine ½ of prestart charge of Lithium Molybdate should be
done. After 1 month, the inhibitor level in LiBr should be
analyzed.
C30 HP00 C04_3 C04.9

C.4
Region in Chart Treatment

Stable region No treatment is necessary
Unstable Region 1) When the Lithium Molybdate concentration is lower than 80

ppm, it indicates unstable region.
2) If the purge tank rise is high, i.e. Non-condensable gases are
getting generated in the Chiller, Hydrogen test needs to be done.
If hydrogen test is positive, it indicates unstable region.
3) Make -up the same qty as prestart Charge of Lithium Molybdate
solution
Cautionary region 1) Lithium Molybdate Solution Concentration to be checked after

1 month
2) After 1month, if the Lithium Molybdate concentration is same,
then charge 1/2 of prestart charge of Lithium Molybdate.
3) After 1month, if the Lithium Molybdate concentration is in
unstable region then charge qty same as prestart charge of
Lithium Molybdate.
Region which cannot be If concentration of LiBr <47% or >59% perform the LiBr Sample
judged analysis and confirm the solution conc. Refer The same to
Engineering department.
C04.10 C30 HP00 C04_3

Figure 4.5
C30 HP00 C04_3 C04.11

C.4
Alkalinity of the solution Analysis of Alkalinity is done by phenolphthalein and acid

titration method.
Procedure 1. Take solution sample (Refer solution sampling procedure).

3. A sample of absorbent is allowed to stand in a bottle for
about 24 hours to decant the solution. (After 24 hours,
solids will settle at the bottom of the bottle.)
4. Take 10 ml of absorbent solution from the top of the bottle
using a pipette.
5. Pour the sample absorbent solution into a beaker.
6. Pour 50 ml of pure water into the beaker.
7. Add Phenolphthalein (2~3 drops) into the beaker.
(Absorbent solution turns pink).
8. Add N/10 Hydrochloric acid (HCl) solution drop by drop
into the absorbent solution using a burette till the absorbent
solution becomes colourless
9. Calculate the Alkalinity using the following formula
N = A x 0.01
Where N: Alkalinity of the sample.
A : Quantity of HCl acid solution added (ml)
Maintaining alkalinity • The allowable alkalinity range is 0.05 N – 0.105 N.

(LiOH.H2O or HBr • The target alkalinity value is 0.09 N.
addition) • If the measured alkalinity is less than 0.07 N then
alkalinity has to be improved by addition of Lithium
Monohydrate.
• If the measured alkalinity is more than 0.1 N then
alkalinity has to be reduced by addition of Hydro
bromic acid (HBr – 47% by wt).
• The qty of Lithium Monohydrate or HBr to be added
can be calculated using empirical formulas mentioned
later.
Addition of Lithium A = (X1 – X2) * 26 * B

Monohydrate Where,
(LiOH.H2O). A = Amt of Lithium Monohydrate to be added (gms)
X1 = Target value of alkalinity (N)
X2 = Actual measured value of alkalinity (N)
B = Total actual qty of LiBr in the chiller (kgs).
Addition of HBr (47% by H = (X2 – X1) * 71 * B

wt). Where,
H = Amt of HBr to be added (ml)
X1 = Target value of alkalinity (N)
X2 = Actual measured value of alkalinity (N)
B = Total actual qty of LiBr in the chiller (kgs).
C04.12 C30 HP00 C04_3

Examples a) LiOH.H2O addition
X1 = Target value of alkalinity = 0.09 N

X2 = Actual value of alkalinity = 0.04 N
B = Total LiBr quantity = 3000 kgs
Then, Qty of Lithium Mono Hydrate to be added will be
A = (0.09 – 0.04) * 26 * 3000 = 3900 gms
b) HBr (47% by wt) addition
X1 = Target value of alkalinity = 0.09 N

X2 = Actual value of alkalinity = 0.12 N
B = Total LiBr quantity = 3000 kgs
Then, Qty of HBr to be added will be
H = (0.12 – 0.09) * 71 * 3000 = 6390 ml
Method of adjusting This instruction describes the procedure to add inhibitor to

inhibitor content: prevent corrosion.
Equipment used 1. Inhibitor : Li2MoO4.H2O (20wt% solution)

2. Pure water
3. Container
4. Vacuum rubber hose with copper tube
5. Hose band
6. Pliers
7. Wrench
8. Rubber gloves
Procedure 1. Pour pure water into a vacuum rubber hose in order to

remove air in the vacuum rubber hose. (Fig. 4.6 (a))
2. Connect the vacuum rubber hose to service valve (for
refrigerant) and fix it with a hose band. (Fig. 4.6 (b))
3. Pour inhibitor into a container.
4. Insert a copper tube on the end of the vacuum rubber hose
into the container after wearing rubber gloves.
5. Perform air purging from shell.
6. Open up the service valve.
carefully to ensure that air does not leak in.
8. Close up the service valve after charging all inhibitor.
9. Remove the vacuum rubber hose.
10. Place the cap of the service valve after confirming the
packing inside.
11. Wash all instruments with water.
12. Perform refrigerant blow down after these procedures are
completed and circulate solution.
C30 HP00 C04_3 C04.13

C.4
13. Continue air purging from shell for 30 minutes after

completion of this work.
Notes 1. Be sure to perform this work during operation.

2. Wear rubber gloves while this work.
3. Thoroughly wash of any inhibitor which gets on hand, skin
and clothes. Take care to prevent inhibitor entering mouth
and eyes.
4. Do not spill inhibitor on floor and do not throw it in a
drain.
5. In case the machine is operated for 18 hours or more per
day, add 650 ml of Inhibitor (Li2Mo4.H2O, 20-wt%
solution) every two months in spite of analyzing result of
inhibitor.
Figure 4.6 (a) Figure 4.6 (b)
Method of adding Alkali This instruction describes the procedure to add Alkali (LiOH)
when alkalinity is less than the targeted value.
Equipment used 1. Alkali : LiOH.H2O – Lithium Monohydrate (Powder)

2. Pure water
3. Container
4. Vacuum rubber hose with copper tube
5. Hose band
6. Pliers
7. Wrench
8. Rubber gloves
Procedure 1. Pour pure water into a vacuum rubber hose in order to

2. Connect the vacuum rubber hose to service valve for
C04.14 C30 HP00 C04_3
concentrated absorbent and fix it with a hose band. (Fig.

4.7)
3. Put LiOH into a container and melt it with pure water.
4. Insert the copper tube on the end of the vacuum rubber
hose into the container after wearing rubber gloves.
6. Open up the service valve.
8. Close up the service valve after charging all LiOH
solution.
9. Remove the vacuum rubber hose and wash inlet of service
valve with water.
10. Place the cap of the service valve after confirming the
packing inside.
A) Notes 1. Be sure to perform this work during operation.

2. Be sure to inspect again alkalinity after charging of LiOH.
3. Wear rubber gloves while this work.
4. Thoroughly wash of any LiOH, which gets on hand, skin
and clothes.
5. Take care to prevent LiOH entering mouth and eyes.
6. Do not spill LiOH on floor and do not throw it in a drain.
day, be sure to check and adjust alkalinity every two
months.
C30 HP00 C04_3 C04.15

C.4
Figure 4.7
Method of adding Acid This instruction describes the procedure to add Acid (HBr)
(HBr) when alkalinity is above the targeted value.
A. Instruments 1. Acid: HBr – Hydro bromic acid (Concentration – 47 wt.

%)
2. Pure water
3. Container
4. Vacuum rubber hose with copper tube x 2
5. Hose band x 2
6. Pliers
7. Wrench
8. Rubber gloves
9. Mask
10. pH test paper
B. Procedure 1. Pour pure water into one vacuum rubber hose in order to
2. Connect the vacuum rubber hose to service valve for
concentrated absorbent and fix it with a hose band. (Fig.
4.8 (a))
3. Connect other one of vacuum rubber hose to service valve,
which is furnished on diluted absorbent pipe between the
absorbent pump and low temperature heat exchanger, and
fix it with a hose band. (Fig. 4.8 (b))
4. Insert the two copper tubes on the end of the vacuum
rubber hoses into the container.
6. Open up the service valve for diluted absorbent.
7. Remove absorbent solution about 50 liter from service
valve into the container when absorbent pump operates.
8. Close up the service valve for diluted solution after
removing absorbent solution – 50lts.
9. Wear rubber gloves and mask.
10. Pour HBr little by little. At this time, check pH value of
this solution by pH test paper. (Allowable degree of pH
value is 6).
11. Stop pouring HBr when pH value of this solution has
become above 6.
12. Open up the service valve for concentrated absorbent.
14. Close up the service valve for concentrated absorbent after
charging all solution.
15. Repeat item 6 to item 14, and charge all required volume
of HBr solution into the machine.
16. Remove the vacuum rubber hose and wash inlet of service
valves with water.
17. Place the caps of the service valves after confirming the
packing inside.
C04.16 C30 HP00 C04_3

Notes 1. Be sure to perform this work during cooling operation.

2. Be sure to inspect again alkalinity after charging of HBr.
3. Wear rubber gloves and mask while this work.
4. Thoroughly wash of any HBr, which gets on hand, skin
and clothes.
5. Take care to prevent HBr entering mouth and eyes.
6. Do not spill HBr on floor and do not throw it in a drain.
day, be sure to check and adjust alkalinity every two
months.
Concentration of Copper The concentration of Copper and Iron can be checked by

and Iron. "Atomic Absorption Spectro chemical Analysis". A sample of
the absorbent solution is to be sent to a laboratory for analysis.
Standard of concentration of the All Copper : 20 ppm

maximum
Standard of concentration of the All Iron : 10 ppm
maximum
If concentration of the Copper and Iron are more than the

standard valves, absorbent solution in the machine is to be
filtered. Please contact service company.
Figure 4.8 (a) Figure 4.8 (b)
C30 HP00 C04_3 C04.17

C.4
Procedure This procedure decides the sequence for preparing the sample
for analysing the concentration of all Copper and all Iron
1. Take solution sample (Refer solution sampling procedure).
3. Shake the bottle before collecting the absorbent solution.
4. Collect 1ml of absorbent solution from the top of the
bottle by the pipette.
5. Pour the absorbent solution by above work into the beaker.
6. Add 1ml of N/10 Hydrochloric acid solution into the
beaker by another pipette.
7. Pour 98ml of pure water into the beaker by the burette.
8. Total quantity of the solution in the beaker is 100ml.This
means that absorbent solution is diluted to 1/100.
9. Send this sample for analysis.
Note In case that crystallization of the absorbent solution occurs,

de-crystallise the machine and carry out the above procedures.
In case that all Copper and all Iron are analyzed, wait for a
while after adding HCl solution into the absorbent solution.
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.
Equipment used 1. Solution containers

2. Octyl Alcohol
3. Rubber gloves
4. Mask
5. Pure water (DM water/Distilled water)
6. Vacuum rubber hose.
7. Copper tube
8. Hose Clips.
Procedure Charging quantity is very critical, as excess quantity

decrements the performance of the machine.
1. Take a sample of absorbent solution from the service valve

at the absorbent pump outlet. The presence of Octyl
Alcohol can be found out by its pungent smell from the
absorbent solution. If there was no smell while purging,
then topping-up is required.
2. For charging and dosage please contact the service
company.
Precautions Perform this procedure while machine is in Cooling operation.

1. Wear rubber gloves and mask while carrying out the above
procedure.
2. Thoroughly wash off any Octyl alcohol which gets onto
C04.18 C30 HP00 C04_3
hands, skin and clothes.

3. Do not spill Octyl alcohol.
4. All excess quantities of the solutions and waste fluids are
to be disposed properly as per local laws and regulations.
Charging Nitrogen Gas This section deals with the method of charging the machine
with N2 gas. (See Figure 4.9)
Equipment used 1. N2 gas cylinders required for one complete charge.

2. Pressure regulator for N2 cylinder
3. Valve key (for nitrogen cylinder)
4. Pressure resistant rubber hose
5. Hose band
6. Pliers
7. Wire
8. Compound Pressure Gauge (-1 to 7 kg/cm²g) with rubber
hose and clips.
Standard The charging pressures are as follows :

(a) For storage of machine : 0.3 Kg/cm2g
(b) For leakage test : 1.3 Kg/cm2g
(c) For parts replacement : 0.1 Kg/cm2g
Procedure 1. Connect the pressure gauge to the service valve al the

absorbent pump outlet.
2. Prepare N2 cylinder and attach N2 gas pressure regulator
3. Close the service valve connected to the manometer.
4. Connect the pressure resistant rubber hose to the outlet of
the pressure regulator, and then open the valve on the
cylinder to release a small quantity of N2 gas and purge the
air in the hose.
5. Connect the other end of the hose to No.1 service valve
and fix it by means of the hose band.
6. Check that No1. No2 and No3 manual air-purge valves
and also No1 service valve are fully closed.
7. Open No.2 manual air-purge valve.
8. Open No.1 service valve.
9. Using the pressure regulator, release a small amount of N2
at a time into the chamber.
10. Charge N2 gas while watching the pressure gauge of the
absorbent pump.
11. When the specified pressure is reached, close No.1 service
valve and No.2 manual valve and also close valve on the
outlet of the cylinder.
12. Remove the rubber hose from No.1 service valve, and
place the cap on No.1 service valve.
13. Remove the pressure regulator, and neatly arrange the N2
cylinder and rubber hose.
Precautions 1. The N2 cylinder is pressurised to 150 kg/cm2g. Take care
C30 HP00 C04_3 C04.19

C.4
when handling it.

2. Do not suddenly raise the primary or secondary pressure
of the pressure regulator on the N2 cylinder.
3. Fix the N2 cylinder so that it does not fall over.
4. On no account open No.1 and No.3 manual air-purge
valve during N2 charging.
Expelling Nitrogen Gas This section describes the procedure of expelling nitrogen
from the machine.
Equipment used None
Standard Shell pressure to equal atmospheric pressure, (0 kg/cm2g)

based on reading of absorbent pump pressure gauge.
Procedure 1. Open No.3 manual air purge valve.

2. Remove the cap from service valve and open the valve
using the slot on the valve cap so as to discharge the N2
until the internal pressure becomes equal to atmospheric
pressure.
3. When the reading on the absorbent pump pressure gauge
becomes atmospheric pressure (0 kg/cm2g), close the
service valve.
Precautions 1. Do not on any account open No.1 and No.2 manual air-
purge valve while N2 gas is being discharged from the
machine
2. When expelling N2 gas, adequately ventilate the
surrounding area.
C04.20 C30 HP00 C04_3

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 4.9
Measuring Absorbent This section explains the procedure to measure the absorbent
pump pressure pump pressure.
Equipment used 1. Pressure gauge – Range –1 to +3 kg/cm2g,

2. Least count 0.1 kg/cm2
3. Vacuum rubber hose about 15 cm long
4. Hose clips
5. Distilled water
6. Dispenser
Procedure 1. Connect the pressure gauge to the vacuum rubber hose

with the hose clip.
2. Fill the rubber hose with distilled water using the
dispenser. (This is done to avoid any air leaking into the
machine.)
3. Connect the pressure gauge to the service valve on the
absorbent pump outlet line, using the vacuum rubber hose
and the hose clips.
4. Do not let the water in the hose fall out.
5. Open the service valve slowly.
6. When pressure stabilises, note the reading.
7. Close the service valve.
8. Remove the rubber hose from the service valve slowly and
C30 HP00 C04_3 C04.21

C.4
relieve the pressure in the hose slowly so that the liquid

does not splash.
9. Wash the pressure gauge with water and dry it, before
storage.
Precautions 1. Perform this procedure while machine is in cooling

operation and the absorbent pump is running.
2. Wear rubber gloves and mask while carrying out the above
procedure.
3. Thoroughly wash off any liquid which gets onto hands,
skin and clothes.
4. Do not spill any LiBr.
5. Close service valve after measuring the pressure.
6. Do not let any air leak into the machine
Figure 4.10
Bubble test This section describes the procedure for carrying out the
bubble leak test. (see Figure 4.10)
Equipment used 1. Graduated cylinder

2. Vinyl hose (2m)
C04.22 C30 HP00 C04_3
3. Bucket
4. Putty
5. Stop watch
Standard Leak test shall be performed during shutdown of the machine.

Average of three measurements should be less than the
specified quantity for the corresponding models given below.
MODEL Leak in cc per 10 minutes

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
Procedure 1. Perform air-purging until the inside pressure of the

machine reaches the allowable degree of vacuum, and then
continue air-purging at least for one hour.
2. Make sure that the no load vacuum of the purge pump is
under 4 mmHg.
3. Connect the vinyl hose to the exhaust port of purge pump
and put its other end into the bucket filled with water as
shown in the Fig. 4.10
4. Diaphragm valves should be set as follows
5. Valve No.1 – Open, Valve No.2 & 3 – Close
6. Operate purge pump for about one minute and then
measure the bubble volume.
7. While measuring keep the vinyl hose within a depth of
10mm from the water surface.
8. If bubbles are collected, inspect and tighten downstream
connections from the diaphragm valves.
9. If bubbles are still collected in spite of the above
tightening, measure the volume of bubbles collected in 10
minutes.
10. Call this volume A
11. Then set the diaphragm valves as follows
12. Valve No.1 & 3 – Open, Valve No.2 – Close
13. Gas ballast valve and oil delivery valve should be kept
closed.
14. Continue operation of purge pump under the above
conditions.
15. Measure the volume of bubbles in 10 minutes. And call
this volume B.
16. While measuring keep the vinyl hose within a depth of
10mm from the water surface and wait until the first
bubble to come out before starting the timer.
C30 HP00 C04_3 C04.23

C.4
17. Measurement should be performed at least three times.

18. Between measurements, check that the no load vacuum of
purge pump is under 4mmHg.
19. The value of (B-A) is the result of the bubble leak test.
20. If the oil is contaminated with water, replace oil.
When is bubble leak test 1. As part of the leak test after assembly work at site.
performed? 2. As part of the periodical inspections.
3. After carrying out site procedures that break vacuum
tightness and after N2 leak test.
Precautions 1. Ensure that the no load vacuum attained by the vacuum

pump is less than 4mmHg.
2. If the no load vacuum of purge pump is above 4mmHg
carry out maintenance of the purge pump.
Measuring Insulation This section describes the procedure of inspecting the

Resistance insulation resistance of power and control circuit.
Standard Power circuit : Above 10 MΩ

Control circuit : Above 10 MΩ
Equipment used Megger DC 500 V Driver
Procedure 1. Do not supply electricity power during this measurement.

2. Disconnect green earth wire between terminal E on
terminal base and earth terminal in control panel.
3. Make sure that MCB is not put on.
4. Connect earth wire of Megger to earth terminal in control
panel.
5. Measure insulation resistance at terminals of R, S, T, U1,
U2, U3, V2, V3, W1, W2, and W3.
6. Measure insulation resistance at terminals of "No.0".
7. Record the above measured valves.
Precautions This measurement is to be performed after replacement of

Electrical components and inspection of solution pumps.
Inspection of safety This section describes the procedure to inspect the

devices Functioning of safety devices independently. These are -
• Chilled water flow switch and DP switch.
• Chilled water freeze protection thermostat.
Equipment used 1. Continuity Tester

2. Bucket (about 5 liters capacity)
3. Ice Blocks
4. Hot water (80 - 90°C)
5. Thermometer (0 - 100°C)
Chilled water Flow 1. Disconnect two wires connected to terminals strip in the
switch and Differential control panel from the flow switch and DP switch.
C04.24 C30 HP00 C04_3
Pressure switch. 2. Connect the tester between the above disconnected two
wires.
3. Set the tester to measure resistance.
4. Operate chilled water pump(s).
5. Close the valve furnished at delivery piping of chilled
water pump gradually to reduce chilled water flow rate.
6. Inspect that the indication of the tester becomes infinity at
50% of the specified chilled water flow rate.
7. If the setting was disturbed, re-adjust the flow switch and
(or) DP switch. After completion of the test, reconnect the
wires.
8. If flow switch/ DP switch is broken, replace it.
Precautions Stir the water to get the average temperature in the bucket
during measurement.
C30 HP00 C04_3 C04.25

C.05.Calibration Schedule
C.5.1 CALIBRATION SCHEDULE
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.
C30 HP00 C05 C05.1

SECTION C.6
Pump Manuals
C30 HP00 C06 C06.1

INSTALLATION,
OPERATION AND
MAINTAINANCE MANUAL
Series
WSVP
Pump Model
________----
IVP/T 100(M)
_______________
IVP/T 180(M)
IVP/T 300(M)
INDO WOOSUNG VACUUM CO. PVT. LTD
Page: 1
PDF created with FinePrint pdfFactory Pro trial version http://www.fineprint.com

Pump Introduction:
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.

Technical Data
IVP/T IVP/T IVP/T IVP/T

MODEL No.
100(M) 180(M) 300(M) 600(M)
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.

Pump Installation:
- Floor on which the pump is to be installed should be flat & stable.

- Sufficient air circulation around the vacuum pump is to be maintained.
- Ensure proximity to electric power supply & system under evacuation.
Pump Connection To System:
- Ensure the presence of intake screen in the suction port, before

connection.
- Piping length between vacuum pump & the system under evacuation
should be as short as possible. 90 0 pipe bends should be avoided for
connecting pump to the system under evacuation.
- Use wire braided hosepipe for connection between vacuum pump &
system under evacuation.
- Inlet hosepipe should be clean & leak proof.
- It is ideal to have hosepipe equal to the diameter of the suction port in
order to prevent loss of pumping capacity and pressure drop.
Electric wiring
- Connection should be made by qualified electrician.

- Rotation of the pump pulley should be clockwise when viewed from the
pump pulley side.
Check points before operating the pump
- 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.

Important Note:
− Keep the gas ballast valve closed during initial startup.
Pump Operation
- When working with non-condensable vapours the pump may be used

without gas ballast valve.
- When working with condensable vapours the suction port should be
closed until the pump reaches the temperature of the inlet vapours. If
operated under temperature lower than the inlet vapours, vapours may
condense in the vacuum oil causing oil contamination.
- If vapours are condensed in the vacuum oil, keep running the pump with
gas ballast valve fully open and intake port closed until all the moisture is
removed.
- It is better to keep pump running for 30 min. with intake port closed and
gas ballast in open position after the use of the pump.
- The pump may be used for discrete operations without switching it off, but
suction port closed.
- When pump is working in specific pressure range the consumption of
power is minimum.
Pump switch off Procedure
- 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.
Precautions before pump taking for maintenance
- Before any maintenance work electric power should be cut off

- When used for toxic gas applications necessary safety measures should
be taken

- When used for corrosive applications (the gases which can cause
corrosiveness to the pump parts) the pump must be cleaned immediately
after the use and be filled with new oil.
Parameters for changing pump oil
- Oil should be regularly changed depending upon the usage of pump.

- Normally vacuum oil is clean and transparent – if the color changes to
opaque or brownish it needs to be changed.
- Oil should be changed after FIRST 100 hours of pump run. (If the oil looks
polluted)
- Oil requires change according to viscosity, pour point and acidity check.
- When the pump is not developing ultimate pressure, the oil should be
replaced.
- If pump is used for handling hazardous / corrosive gases oil needs to be
changed frequently.

Pump Maintenance
Changing of oil seal
- 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.
Changing of vanes and springs
- 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.
Changing of exhaust valve seats and springs
• 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.

PUMP TROUBLE SHOOTING CHART
PROBLEM CAUSE REMEDIES

Pump not staring 1. Faulty wiring 1. Check the motor wiring.
2. Voltage fluctuation 2. Check supply voltages
3. Very low viscosity of oil 3. Replace with recommended vacuum oil.
4. Tension of V-belts 4. Correct the tension of belts
Pump not achieving 1. Pressure Measuring 1. Use proper gauge for the pressure / vacuum
ultimate pressure / Gauge is faulty or not measurement.
vacuum. suitable for
measurement.
2. System air leakages 2. Check the system under evacuation for leak
tightness.
3. Pump leakages 3. Check vacuum pump oil seals.
4. Pump oil 4. Replace the oil.
contamination
5. Damage of exhaust 5. Replace with new
valve seats and
springs
6. Damage of vanes and 6. Replace with new
springs
Low pump suction 1. Pump suction port 1. Clean the intake screen.
capacity blocked by particles at
intake screen.
2. Improper connection of 2. Pump suction port size connection is
pump to system required to connect between pump and
system and the length should be short.
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.
Noisy pump 1. Low oil level 1. Maintain proper oil level.

2. Faulty v belt 2. Replace V-belt
3. Breakage of bearing 3. Replace bearing
4. Miss alignment of 4. Align properly pump and motor pulley.
pump and motor
pulley.

SECTION D
Recommendations for
consistent performance
D.01.Water Treatment
D.1 Water Treatment

Objective The chapter decribes the treatment to be carried out to
maintain the desired quality of cooling and chilled water.
Problems Water is one of the important constituent in the chiller.

Hence it is essential that the water used in the system
should have the desired quality standards. If this water
quality is not as per the recommendation then following
problems may arise :
The problems which arises due to cooling water are :
i. Corrosion
ii. Scaling
iii. Fouling and
iv. Microbial problems.
The problems which occur in chilled water circuit are :
i. Corrosion and
ii. Microbial fouling.
The chemical treatment is carried out to reduce the impact

caused by corrosion, scaling and biofouling. In this chemical
treatment, various chemicals are used, hence proper
selection of chemical becomes a vital thing while suggesting
a treatment program.
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
The corrosion and scale inhibitor contains following

ingrediants
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.
Sequestrant These chemicals are special chemicals in the sense that

they prevent scale causing salts from precipitation even
when they are present in non-stiochiometric amount. They
also absorb on the crystal nucleus and prevent further
scaling.
Dispersent These are organic polymeric compounds. These compounds

are used to disperse the suspended solids which otherwise
settle down in low velocity areas forming deposits.
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.
C30 HP00 D01 D01.1

D.01.Water Treatment
Biocides Biocides are used to kill algae, bacteria and fungi which are
present in cooling water because it is expected to open
atmosphere. The biocides are of various types such as

quaternary ammonium compounds, Phenols, Cynates,
Organo tin compounds etc
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.
C30 HP00 D01 D01.2

Manual - O & M For VAM PDF

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THERMAX LIMITED

ABSORPTION COOLING DIVISION

VAPOUR ABSORPTION HEAT PUMP

OPERATION & MAINTENANCE

C30 HP00 CVP CVP.1

MANUAL PART NO: CZJB817601

Section-A C30 HP00 A00

SECTION-B C30 HP00 B00

SECTION-C C30 HP00 C00

SECTION-D C30 HP00 D00

D.1 Water treatment C30 HP00 D01

CZ JB81 760A_00 -1-

C30 HP00 A00 A00.1

Safeties against hot

C30 HP00 A01 A01.1

3. Safeties against electric arcs:

C30 HP00 A01 A01.2

CZ JB81 760B_0 A.04 -1

A.5 PRODUCT BRIEF

PRODUCT: Vapour Absorption Heat Pump

APPLICATION: Used for Chilling application in various Industries like

PRODUCT RANGE: 100 NTR – 1800 NTR.

CONTROL PANEL: The machine is provided with state-of-the-art Internationally

CRYSTALLISATION The machine is uniquely designed to completely avoid

C30 HP00 A05 A05.1

A.6 PRINCIPLE OF OPERATION

What is Refrigeration ? Refrigeration is defined as the process of extracting heat from

Basic Principles The boiling point of water is directly proportional to pressure.

To change water from liquid to vapour it has to be heated.

Lithium Bromide (LiBr) is a chemical similar to common salt

Further there is a large difference between vapour pressure

Absorption Cycle Absorption systems use heat energy to produce a

C30 HP00 A06 A06.1

When the refrigerant undergoes a series of evaporation,

Simultaneous Heating A schematic diagram of the absorption cycle in the

Evaporator The evaporator consists of a tube bundle, an outer shell,

Absorber The absorber consists of a tube bundle, an outer shell

C30 HP00 A06 A.06.2

temperature heat exchanger where it absorbs heat from the

High Temperature The high temperature generator (HTG) consists of a tube

C30 HP00 A06 A06.3

Fig 1. Simultaneous Heating-Cooling Mode

C30 HP00 A06 A.06.4

Cooling Mode - A schematic diagram of the absorption cycle in the Cooling

Evaporator The evaporator consists of a tube bundle, an outer shell,

Absorber The absorber consists of a tube bundle, an outer shell

C30 HP00 A06 A06.5

absorbed refrigerant boils out of the solution. The solution

C30 HP00 A06 A.06.6

Fig 2. Cooling Mode

C30 HP00 A06 A06.7

A.7. Controls and Safeties

1) Programmable Logic Controller (PLC).

1) Programmable The chiller control panel is based on PLC of Siemens S7-200

CZ JB81 760C_00 A.7. 1

B) Machine mounted 1) Chilled water flow switch

C) Field Interlocks 1) Chilled water pump run/trip interlock.

Operational The operation of the Vapour Absorption Machine (VAM) is totally

CZ JB81 760C_00 A.7. 2

In case the chilled water outlet temperature is already below the

Load changes are reflected in the rise or fall of the temperature of

CZ JB81 760C_00 A.7. 3