Beruflich Dokumente
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USER’S MANUAL
March.2009.SI
Please read this manual carefully to ensure good
operation and maintenance to the chiller.
Touch Screen
Power on the chiller, it will enter
the “monitor” main screen
directly.
Start
Press the“ON start” key, which will
turn green after confirmation, the
chilled/heating water pump and
cooling pump will be started
automatically. After chilled water
and cooling water flowrate are
confirmed, the chiller will start
operating with automatic cooling
load regulation and safety
protection.
Shutoff
Press“OFF Dilution”key, the
burner will stop and the chiller
will enter dilution cycle. HTG
temperature drops gradually
while the chilled water
temperature rises. It will end
when the condition is met,
which needs 30-60 minutes.
Note:
1.Do not use nail or anything
sharp to touch the touch
screen surface. Use a piece
of wet cloth to clean the dust
on surface if needed. It is
prohibited to clean with
alcohol or other organic
solvents.
2.The professional interface is
only open to BROAD service
3
General information
Alarm notice
If there is fault notice on the main screen, enter the “Fault Record” screen by pressing fault
caution icon and you will be able to check the occurring time, reseting time and fault name
of fault stop, fault alarm and abnormal notice. Then do trouble shooting according to the
prompted fault information.
Fault Record screen is also accessible by pressing Fault Record on Check screen. Please refer
to page 10.
4
Operation
Temperature Setting
The temperature setting value of chilled water outlet, cooling water inlet and HTG can be
adjusted in the main screen.Just input the target number and confirm in the “TENKEY”
numerical keyboard. The chiller will automatically adjust the load according to the
temperature setting. For example, if the chilled water target temperature is set at 7℃, the
chiller will keep it around 7℃ automatically.
HTG temperature:Setting range 120~161℃,default 150℃.It’s proper to set it low with low
load.In the precondition of fulfilling users’ need, it’s better to set the temperature low. The
lower the temperature is, the safelier and more energy efficiently the chiller works.
5
Operation
Cooling (the corresponding circle turning diluted solution angle valve are fully
black means being chosen, the same to the closed, and the HTG solution level is in
following modes) zone D.
① Make sure the steam angle valve, ② Make sure the heating water drain valve
concentrated solution angle valve and is closed and hot water drain valve is fully
diluted solution angle valve are fully open. open.
② Make sure the drain valves of chilled ③Make sure the system’s cooling-heating
water and cooling water are closed, and switch valve is switched to heating and
the drain valve of heating water or hot the system is full of water.
water is fully open.
③ Make sure the system’s cooling-heating Heating and hot water
switch valve is switched to cooling state Make sure the chiller is in heating mode, the
and the system is full of water. hot water drain valve is closed while the
Cooling and hot water shut-off valve is open, and the system is full
of water.
Make sure the chiller is in cooling mode, the
hot water drain valve is closed while the Hot water only
shut-off valve is open, and the system is full ① The same with“Heating①”
of water. ② Make sure the hot water drain valve is
Heating closed and heating water drain valve is
fully open.
① Make sure the steam angle valve, ③ Make sure the hot water shut-off valve is
concentrated solution angle valve and open and the system is full of water.
6
Operation
Energy-saving setting
Press “Energy-saving setting” on the “Setting” screen to enter “Energy” screen. Select an
energy-saving mode according to the ambient temperature and cooling load: top, high,
medium or low energy-saving.The chiller will run automatically according to the ambient
temperature and chosen engery-saving mode.
Note: After the chiller stops, it can automatically restart when the ambient temperature
increases (reduces) by a certain temperature difference, this is called“restarting temperature
difference”. For example in medium energy-saving cooling operation, the chiller will stop when
the ambient temperature is 22℃ and restart when it reaches 24℃. In high energy-saving heating
operation, the chiller will stop when ambient temperature is 16℃ and restart when it reaches 14℃.
Timing
“Timing on/off” functions can be selected separately or together according to demand. One
of “Every day” , “Once ” or “week” can be selected. The chiller will realize automatic on/off
by the setting.
Timing can be reset at anytime. Press “Cancel” to cancel the timing function.
8
Operation
Other selection
Clock setting
Press “Clock setting” in “Setting” screen to enter, check and adjust to right date and time.
10
Operation
Check
Press“Check-up” to enter.
Press “Runing Operation” to check chiller’s real time parameters and status, time, function,
control mode, temperature, frequency, liquid level and burner status.
Press “Operation record” to check history data and select “Today”, “Yesterday” and “The
day before yesterday” to check three days’ record. Press “Print” to print out the records (a
special printer is needed). Press “Fault” to check fault stop, fault alarm and abnormal
reminding. Select the corresponding fault item to further check fault/abnormal occurring
time, recovery time and fault name.The fault would be resolved by following the detailed
fault information.
Press “Maintenance record” to check maintenance frequency and schedule (a reminding
notice will appear on the main screen if next maintenance is coming to the due date).
Press “Operation time” to check the accumulative running time of the chiller and main parts,
the frequency of auto-vent.
Press”Parts remain- time” to check the remaining life of each part.
11
Operation
Energy cost
Press“Expense” to enter to check the consumption and costs of fuel, water and electricity.
Operation 12
Information
Absorber
Evaporator
Rear flue
chamber
Flame
sight-glass
Hot W.
relief valve
Heating W.
relief valve
Heating W.
drain valve
Rupture
disc
Chilled W.
check valve
Cooling W.
flow meter
AC W. flow
meter
AC W. cooling/heating
switch valve
AC W. check
valve header
Cooling W. check
valve header
AC W. pump
AC W. filter
盐箱 软水器
Cooling pump
Cooling W.
filter 泵组
控制柜
Drain part 装有变频器
Auto stabilizer
drain valve
Cooling W.
drain valve
Softener resin
tank
灭菌剂
15
Working principle
The cooling principle
Combustion
might greatly decrease the HTG heat transfer
a. Burner operation check efficiency, waste energy, resulting in air
The burner operation is stable or not directly pollution, or even causing fire accident when
determines the chiller’s operation. Therefore a the exhaust temperature increases to a certain
weekly checkup on burner operation is degree.
necessary. Method is as following: ②.Soot detection:
① Observe the flame through flame sight glass ﹒Inspect if the exhaust temperature rises
on the rear flue chamber. The flame should be abnormally.
stable with normal color. For gas the flame ﹒Open the automatic pressure escape to
color should be light blue with red in the inspect if there is soot on fire tubes.
middle. For oil, the color should be white-red ﹒Inspect from sight-glass to see if there is soot
color. with combustion chamber when the burner
②Observe the burner ignition and fire stage is in operation.
change. The flame should be stable without ③.Soot cleaning procedures:
deflagration. ﹒Switch off the chiller. Start cleaning when the
b.Flame Detector Check & Cleaning temperatures in the combustion chamber and
fire tubes are close to room temperature.
Flame detector is a component which is used to
﹒Disconnect the burner control wire if
detect if the flame is normal when the burner is
necessary. If the marks on the wire are not
running, one of the most important safety
clear, re-mark properly to avoid any false
protection devices of the burner. Big resistance
wiring the next time.
caused by the flue duct, poor oil quality, big
﹒Close the fuel inlet valve, diffuse gas or drain
fluctuation of gas pressure, blocked oil filter or
residual oil.
maladjustment of the burner damper will all
﹒Take off the oil pipe or straight connecting
result in insufficient combustion in the burner. The
pipe to the butterfly valve.
flame detector will be smoked black by the
﹒Remove the burner and keep it well.
exhaust thus unable to detect the flame signal,
﹒Remove HTG front flue chamber cover, rear
which might cause burner failure. Therefore, the
flue chamber manhole (no manhole for small
flame detector must be checked and cleaned
models)cover and insulation head.
once a month.
﹒Take out the turbulators in the fire tubes from
① Procedures for oil burner flame detector
the front flue chamber and clean with rags
cleaning.
(non-corrosive detergent can be used).
﹒Pull out the flame detector.
﹒Clean the combustion chamber and fire
﹒Clean the glass cover with soft cloth or
tubes with steel brushes or other tube
quality tissue.
cleaning equipments.
﹒Insert the flame detector back into the
﹒Clean the soot with a vacuum cleaner.
holder.
﹒Reinstall the turbulators, covers of front and
②Procedures for gas burner flame detector
rear flue chamber, insulation head, burner
cleaning.
and its control wire, oil pipe or straight
﹒Power off the chiller.
connecting pipe in turn.
﹒Open the combustion head to check if
there’s soot on flame detecting probe, and if Caution: do not damage the insulation
the distance between the probe and the
④. Remarks
diffuser or ignition electrode meets the
﹒The setscrews of the front and rear flue
requirements stipulated on “Burner manual”.
chamber cover should be replaced. A mixture
Clean if needed.
of graphite powder and engine oil should be
c. De-scaling of the Combustion applied on screws before installation.
Chamber and Fire Tubes ﹒After the burner is reinstalled, vent air (oil
Combustion chamber and fire tubes should be burner) or diffuse gas to the outside (gas
checked every year (when the cooling season burner) before burner operation.
or heating season ends). Clean the fouling if ﹒The sealing gaskets (silicate fiber) for front
needed. flue chamber flange must be replaced to
①. The harm of soot in fire tubes and avoid exhaust leakage.
combustion chamber. ﹒Recheck and adjust burner’s excessive air
Soot in the combustion chamber and fire tubes coefficient after de-scaling.
19
Periodic check
Electrical System and Parts
Electrical system and parts shall be checked periodically every 3 months.Electrical system
checking general requirements: parts and wiring are fixed firmly; parts temperature rise in
operation is normal; label is clear, complete and pasted firmly; no dusts and remained
objects on each part. Electrical parts checklist:
Item Content Tools or method
Transformer Deviation of each output voltage shall be within 5% of the rated Multimeter, infrared
one. Surface temperature is below 60℃ Thermometer
Temperature Temperature and pressure control set point activates and resets Visual inspection
Control, pressure normally
Control, Flow switch shall disconnect (connect) when the water pump is off
Flow switch (on).No rust on bellow pipe of pressure control and flow switch
All temperature Calibrate. Measure temperature at all places with precision Thermometer
Sensors thermometer and compare with the value on touch screen:
compensate if deviation <2℃; check the wiring and sensors if
deviation ≥2℃
AC contactor, Touch the testing point of AC contactor and circuit breaker with Visual inspection ,
Circuit breaker A small screw driver and check if it functions normal and if all small
switches respond swiftly and reliably Screw driver
Canned pump No abnormal sound when the pump is running and the rotary Multimeter, infrared
Direction is correct. The current should stay within the nominal Thermometer
Range. Insulation resistance ≥0.5 MΩ. Surface temperature rise is
≤60℃ when the motor is in operation
PLC module Check if PLC signals are consistent with touch screen display Visual inspection
Internet gateway All indicator lights should be normal Visual inspection
STATUS light: blink upon successfully connecting with BROAD monitoring
center
PPP light: blink upon successfully log into Internet via dial-up
TXD light: blink while sending data to internal (RS233/RS485) network
RXD light: blink while receiving data from internal (RS233/RS485) network
ACT light: blink while exchanging data with user’s Ethernet
LNK light: blink upon successfully connecting with user’s Ethernet
POWER light: normal on after power-on
Inverter
Item Content Tools or method
Surroundings Make sure the inverter cabinet temperature is within -10 to 40℃, Visual inspection,
Humidity is below 85% and no dust, oil fog, water drops in air Thermometer,
humidity meter
Voltage Main circuit, control circuit voltage should be normal Multimeter
Display Display characters clearly and full letter, no omission of characters Visual inspection
and strokes
Installation support No loose bolts, no abnormal sound and vibration Visual inspection
Hearing
Front panel No deformation, no color change, no dust, no damage Visual inspection
Wiring a. There is no damage, breakage, color change and deformation Visual inspection
connection on cable’s coated wire
b. Firm connection
Cooling tower a. No abnormal sound and vibration Hearing
fan b. No aging or color change owning to overheat on fan blades Visual inspection
Air duct No blockage Visual inspection
20
Periodic check
Solution
a. Libr solution quality index
Lithium chromate type solution: Lithium molybdate type solution:
Item Standard Item Standard
Libr% 40/50/52/53/55±0.5 LiBr% 40/50/52/53/55±0.5
Li2CrO4% 0.15~0.25 Li2MoO4 ppm 170±20
PH Value 9.0~10.5 Alkalinity (N) 0.06~0.1
Bro3- No reaction BrO3- No reaction
Cl- % <0.05 Cl- % <0.05
NH4 % NH4 %
+ +
<0.0001 <0.0001
SO42- % <0.02 SO42- % <0.02
Ca2+ % <0.001 Ca2+ % <0.001
Mg2+ % <0.001 Mg2+ % <0.001
Ba2+ % <0.001 Ba2+ % <0.001
Fe3+ % <0.0001 Fe3+ % <0.0001
Cu2+ % <0.0001 Cu2+ % <0.0001
(K+Na)% <0.06 (K+Na)% <0.06
Organic None Organic None
Transparency Clear, transparent (eyeballing) Transparency Clear, transparent (eyeballing)
b. Annual analysis
①Purpose of annual analysis ﹒Use a hard plastic bottle of 50ml to
Poor vacuum of the chiller will result in metal contain the solution (with inner cover,
corrosion and cause change of solution which can be purchased in medical
composition, so the vacuum condition in the department store). Solution must be filled
chiller can be judged by analyzing Fe, Cu in full, with max. 5mm empty space to the
contents in LiBr solution. Bearing the bottle top.Wax the bottle if the sample
“customer-centered” principle, BROAD offers can not be delivered within one week.
annual solution analysis for the customer, free ﹒Write detailed information such as user
in warranty period. Customers can sample abbreviation, chiller model, serial no.,
50ml of LiBr solution after each cooling sampling date, chiller operation time,
season and send (post) it to BROAD for operator, service engineer and local
testing. BROAD will provide test report to service office on a label and paste the
address the vacuum condition of the chiller, label tightly on the solution bottle.
decide if the chiller needs to be leakage ﹒Pack under the guidance of the post
detected and if the solution needs to be office or express mail service and post to
filtered or added with some elements, e.g. BROAD Service Center in BROAD Town,
Inhibitor, hbr, etc. Changsha, 410138 China.
②Procedures of sending the solution ③If the customer is not convenient to post,
﹒Start the solution pump first to let it run for 10 our service engineer can detect the
minutes when the chiller is off or in totally Li2CrO4 concentration on site or bring the
dilution off state. Wait until the solution gets sample to BROAD Town.
totally blended, Sample according to the
procedures described in C.
21
Periodic check
c. Solution sampling and d. Solution concentration and
concentration analysis refrigerant specific gravity check
①Sample under positive pressure: applicable ①Close hot water and heating water
to sampling locations with positive pressure thermostatic valve (skip this step if no
(It’s suitable for 2 stage chiller when the heating and hot water function).
solution pump is running with a frequency ②Under cooling mode, turn on the chiller for
over 40Hz but not for other chillers). 2 hours under high fire.
﹒Prepare a clean glass or plastic container ③Run the refrigerant pump continuously,
﹒Remove the cork of the sampling valve. the solution level inside the refrigerant
﹒Put the container under the valve nozzle and water box shall maintain at the 1/3 of the
open the valve to discharge the solution. sight class and get stabilized.
﹒Close the valve, clean the valve nozzle ④Sample the LTG and HTG concentrated
with water and put back the cork. solution from LTHE and HTHE sampling
②Negative pressure sampling: applicable to valve swiftly with sampling bottle by
sampling locations with negative pressure negative pressure method.
or unknown pressure status. ⑤Open the diluted solution sampling valve (In
﹒Take a sampling bottle and 2 rubber vacuum rated operation with inverter frequency 40Hz
hoses. Connect one end of one rubber hose above, this valve is under positive pressure.
to the purge nozzle of the sampling bottle and However because of rapid change of
the other end to the sampling purge valve. As frequency it is possible for air leakage owing
for another rubber hose, one end connects to to temporary low frequency. Therefore the
sampling nozzle of the bottle and the other negative pressure sampling is suggested) to
end to the nozzle of the sampling valve. discharge the solution directly.
⑥Measure the solution concentration and
Note: make sure the connection temperature by density meter and
hose is reliable and has no leakage. thermometer, then check up the actual
concentration from “libr temperature,
﹒Start vacuum pump, open main purge specific gravity and concentration” curve.
valve and sampling purge valve in turn to ⑦Sample the refrigerant water from
purge the sampling bottle for 1 minute, refrigerant sampling valve using negative
and use bubble comparison method to pressure sampling method.Test the
make sure there is no air in the bottle. specific weight value by a hydrometer.
﹒Open the sampling valve to sample the ⑧The designed maximum concentration is:
solution. LTG: 61%; HTG: 61%; diluted solution: 56%
﹒Close the sampling valve, sampling purge and specific weight for refrigerant is
valve, main purge valve and vacuum <1.04.
pump after finishing sampling. ⑨Use water to clean sampling valve nozzle
﹒Pull off the hose connecting with the sampling to remove the residual solution. Install the
valve first (the hose must leave the valve mouth cork.
slowly to make the solution inside the hose
get into the bottle as well). Then pull off vacuum rubber cork
another hose (need also guarantee the rubber
solution flow into the bottle). Finally pour h
purge nozzle
the solution from the sampling bottle to a
clean glass or a plastic container (e.g. A
measuring
measuring cylinder). sampling
cylinder bottle
﹒Clean the sampling valve nozzle
with water and put the cork concentration
sampling
back. meter nozzle
Mercury
hydromete
thermometer
r
22
Periodic check
Pumpset
Check every part of distribution system once b. Cooling tower fan checking and
a month. adjustment
a. Softener checking Check the cooling tower’s air flow, adjust
If the city water’s hardness is too high, it the cooling fan’s blade angle if
necessary. The smaller angle the fan’s
should be softened first before filling into the blade to the horizontal direction, the
system. Check the softener once a smaller air flow, otherwise bigger. The
week.The water pressure should not exceed adjusting angle should be within the
0.6MPa. Keep the brine tank 1/3 calibrated scope on the fan axis and
otherwise add some industrial salt. every blade should be in the same angle.
Strengthen water quality monitoring and Start the fan after adjustment and use
adjust the regeneration program, period, ampere meter to detect the running
flow rate or softener settings according to current to make sure it is within the rated
current on the nameplate. Otherwise
inlet/outlet water quality and variation so adjust it again.
as to keep the system in the best
performance. The period of adding salt c. Cooling tower’s water distribution
refers to P 47,”Add salt and resin manually”. check and adjustment
The cooling tower’s water distribution
b. Auto dosing device check device is very important. The insufficient
As the cooling water system is running for water flow and unsteady valve adjustment
long period, there will be accumulated always cause asymmetric water distribution.
scale, mud and algae in the pipes which The smaller cooling water pump’s
frequency and cooling water flow rate, the
are thermal resistant. It will reduce the heat more asymmetric the water distribution is.
transfer, increase the load, causing energy Hence the cooling water pump frequency
waste and shorten the chiller’s life, or even should not be too small.
threaten the chiller safety. Check whether
the chiller can realize auto dosing, whether A.C./hot water quality and
the stabilizer is run out and whether the fouling.
stablizer pump has been set properly. a. Water quality and fouling check
c. Pump check Distilled water, de-ionized water or soft water
should be used for chilled/heating water
Check the pump’s running noise and system and primary side of secondary heat
vibration to see whether the base is exchanging hot water system to avoid fouling
steady or not. Make sure the motor’s and chemical corrosion to the chiller, piping
current does not exceed the rated value system and terminals. Direct hot water system
and the temperature rises up normally. can be treated by Siliphos. Although water
Check whether the frequency driver of treatment is applied, fouling can still be
cooling water pump and cooling fan are formed on the chilled/heating and hot water
normal. copper tubes water side after long time
operation. So regular checking on water side
Cooling tower of chilled/heating and hot water is necessary.
The methods are as follows:
a. Cooling tower water level check ①Every 6 months, check the fouling detector
and adjustment to see if fouling formed in the copper tubes,
When the cooling water system is full of or open the soft connecter to judge.
Sample a small bottle of water and send it
water, the level in the water pool should be to authoritative lab for analysis.
25mm lower than its upper edge or 20mm ②Every year, open the water box cover of
lower than the overflow pipe. In any kind chilled/heating and hot water system to
of load the water pool should never be check fouling in copper tubes and rust on
empty during the cooling water pump tube sheet or water box interior.
running and no overflow occurs in water b. Tube cleaning
pool during the cooling water pump off. If fouling is confirmed existing inside the
Otherwise the floating ball valve’s acting copper tubes, the cleaning is needed.
Chemical cleaning is subject to BROAD
position for the water pool level should be written approval and BROAD service
adjusted. engineer’s site confirmation.
23
Periodic check
Cooling Water Quality and Fouling
a. Cooling Water Quality requirement
Since the cooling water is exposed to the sea water for flushing sewage) can be used
atmosphere for a long time, evaporation as cooling water, but industrial water,
loss is important and water quality is subject underground water, lake water and
to deterioration due to corrosion.BROAD desalinized sea water must be analyzed by
package chillers adopt auto related technical authority before being
water-treatment plant to achieve scientific used. Even if it can be used as per the
management so it won’t cause serious following standard table, regular analysis is
damage to the chiller, shorten its life-span, required. Drain water, sea water and waste
breed bacteria and endanger personal water are prohibited to be used directly. If
health. Cooling water quality must meet the the cooling tower is subject to outside
requirement of GB/T18362-2008, “Cooling pollution such as waste gas, drain water or
water, makeup water quality standard” as exhaust, regular analysis of the cooling
stipulated in the following table. The high water is required to keep the water quality.
contents of Chlorine ion and acidic Based upon the water analysis result, it is
materials in water might corrode the metal required to add proper amount of qualified
badly; too much content of mineral and water quality stabilizer for anti-corrosion,
alkaline substances might cause serious anti-scale & bacteria killing, which greatly
fouling. In general, city water (not including prolongs the chiller’s life-span.
b.fault alarm
No. Fault Causes Keys
1 Chilled/heating a. Temperature sensor wrong wiring or a. Check and wire correctly
/hot w. Outlet, open/short circuit b. Replace temperature module
cooling w. Inlet b. Temperature module damaged c. Replace temperature sensor(s)
Temperature c. Temperature sensor damaged
sensor fault
2 HTG super a.PLC control failure. a. Check PLC control system
High b.Too much deviation of HTG temperature b.Replace
Temperature sensor c. Check or replace
c.Temperature control abnormal. d. Check and recover the vacuum
d.Bad vacuum
3 HTG solution a. Upper and lower coat of solution level a. Replace solution probe’s upper and
level control probe aging leads to short circuit lower cover
Fault b. Solution level control or level probe b. Check and wire correctly
wiring is wrong
4 Cooling water a.Cooling water pumps stop a.Check cooling water pumps’ power
off b.Cooling water system lacks of water or supply and reset﹡
filter serverely clogged b.Make up water(vent air from pipes) or
c.Cooling water outlet/inlet closed or clear the filters﹡
damaged c.Check and open valves or replace them﹡
d. Flow switch(es) improperly set or d.Readjust or replace flow (es)
damaged
27
Fault and troubleshooting
(cont.)
No. Fault Causes Keys
5 Chilled water low a. Actuation value of flow switch is a. Readjust
flow improperly adjusted b.Replace
b. Flow switch damaged c. Check the wiring
c. Open circuit or loose contact with flow d. Regain the chilled water flow by below
switch(es) methods﹡
d. Insufficient water flow ①Repair or replace
①Chilled water valve damaged ②Repair
②Chilled water pump fault ③Clean filter
③Chilled water system filters seriously blocked ④Refill the water full and vent air out
④Air is not totally vented out of the
chilled water system
6 Burner fault a.Fault feedback wrong wiring or a.Check and wire correctly
open/short circuit b.Refer to burner manual
b.Burner fault
7 Ignition fault a.Fault feedback wrong wiring or a.Check and wire correctly
open/short circuit b.Refer to burner manual
b.Burner fault
8 Gas leakage a. Fault feedback wrong wiring or a. Check and wire correctly
open/short circuit b. Repair or replace
b. Interior leakage of the solenoid valve.
9 Refrigerant a.Inverter fault a.Refer to inverter manual
pump inverter b.Fault feedback wrong wiring or open circuit b.Check and wire correctly
fault c. Communication circuit fault or strong c.Check communication circuit and
eclectronagnetism interferer exsiting eliminate eclectronagnetic interferer
10 Absorption a.Pump wiring is wrong or with short a. Check and wire correctly
pump, vent circuit, loose contact b. Check or replace pump
pump fault b.Pump overload, lack of phase, short
circuit or damaged
11 Auto air vent a.Auto purge valve is not switched to vent a.Check auto purge valve
abnormal b.Actuation value set too big(no venting b.Check vent valve
for long time may cause valve plate’s c.Reset vent interval
sealing elements sticked) d.Check solution level control and vent
c.Vent interval bit short probe wiring
d.Solution level control or vent probe wiring fault e.Open auto-vent manual check
e.Auto-vent manual valve closed valve(normally open in operation)
12 AC pump fault a. Pump wiring is wrong or with short a. Check and wire correctly
circuit, loose contact b. Check or replace pump
b. Pump overload, lack of phase or short c. Check or replace soft starter
circuit
c.Soft starter fault
13 Cooling water a.Chilled water 3-stage protection act or a.Check chilled water 3-stage
pump fault is wrong wired protection
b. Pump wiring is wrong or with short b.Check and wire correctly
circuit, loose contact c.Check or replace pump
c.Pump overload, lack of phase or short d.Check or replace inverter, soft starter
circuit
d.Inverter or soft starter fault
14 Cooling fan fault a.Fan wiring is wrong or with short circuit, a. Check and wire correctly
loose contact b. Check or replace fan*
b.Fan overload, lack of phase or short circuit c. Check or replace inverter
c.Inverter(if exists)fault
15 Hot water pump a.Wrong wiring, short circuit or loose contact a. Check and wire correctly
fault b. Pump overload, lack of phase or short b. Check or replace pump
circuit
28
Fault and troubleshooting
c.abnormal reminding
No. Fault Causes keys
1 Chille w. inlet a. Temperature sensor wrong wiring or a. Check and wire correctly
/cooling w. outlet open/short circuit b. Replace temperature module
/HTG crystallization b. Temperature module damaged c. Replace temperature sensor(s)
/LTG crystallization c. Temperature sensor damaged
/LTHE diluted solution
inlet/vent/ambient
/control cabinet
temp.ensor abnormal
2 Big deviation with a. Temperature sensor resistance value drifts a. Check and wire correctly or replace
chilled water outletb. Temperature sensor wiring is wrong b.Replace temperature module
temperature sensor c. Temperature module drifting or damaged c.Calibrate or replace temperature sensor
3 Chilled water a. Chilled water flow rate is too low a. Increase chilled water flow rate﹡
outlet temperature b. Chilled water outlet temperature b. Increase chilled water outlet
lower than 4℃ setting is too low temperature setting﹡
c. Cooling water temperature is too low c. Increase cooling water temperature
4 Heating/hot water a. Thermostatic valve works abnormally a. Check thermostatic valve wiring or
outlet temperature b. Water flow is too low actuation device
over 95℃ c. Large deviation with temperature sensor(s) b. Increase water flow rate﹡
d. Temperature sensor installation c. Replace temperature sensor
location is too close to water heater d. Move the temperature sensor to 10m
away from the water heater
5 Exhaust a.Soot in fire tubes a.Clear soot*
over-temp. b.Excessive combustion b.Adjust combustion amount
c. Exhaust temperature sensor deviation c.Replace temperature sensor
too big
6 High temperature a. Machine room overheated a. Enforce the ventilation to reduce
in control cabinet b. Control cabinet fan damaged machine room temperature﹡
c. Temperature sensor installation b. Repair or replace
location improper c. Check and reinstall in proper position
7 HTG over-pressure a. Poor vacuum condition a. Refer to item 14 of “Abnormal Reminding”
b. Cooling water flow rate is too low or b. Increase cooling water flowrate or
temperature is too high reduce cooling water temperature﹡
c. Steam angle valve opening is too small c. Check the opening of steam angle
d. Scaling with cooling water copper tubes. valve﹡
e. Too small LTG solution circulation d. De-scale. Plan is subject to BROAD
f. Pressure control actuation value is too written confirmation
low e. Readjust the solution circulation
g. Pressure control damaged f. Reset
h. low or no flow in heating model g. Replace
h.check the heating water loop
8 Cooling water a. Flow switch wiring is wrong a. Check and wire correctly
flow switch b. Flow switch damaged or improper b.Readjust or replace flow switch
abnormal setting c.Check the reason that flow exists
c. There is flow in cooling water side
before chiller started
9 Refrigerant level a. Refrigerant level probe wiring is wrong a.Check and wire correctly
control fault or short circuit b.Replace solution level control
b. Refrigerant level control damaged c.Refer to”refrigerant freezing keys ”
c. Refrigerant box gets frozen d.Replace solution level probe upper
d. Refrigerant level probe upper and and lower cover
lower covers are aging
10 Refrigerant a. Poor vacuum a.refer to poor vacuum eliminating method
overflow b. Refrigerant water polluted b.refer to refrigerant polluted
c. Cooling water flow too low or eliminating method
temperature too high c. Increase cooling water flow or
d. Comprehensive solution concentration improve cooling tower performance
is too low d. Increase solution concentration properly
e. Heating capacity is too much e. Decrease heat input
f. Scaling in absorber copper tubes f. Remove scale in absorber copper
tubes
29
Fault and troubleshooting
(cont.)
No. Fault Causes keys
11 Refrigerant a. Cooling water temperature and user’s a. Increase cooling water temperature
freezing load are both low and select energy saving operation
b. Chilled water outlet target temperature mode﹡
setting is too low b. Increase chilled water outlet target
c. Chilled water flow is too low temperature﹡
c. Check the chilled water system and
increase chilled water flow﹡
12 Crystallization a. Cooling water inlet temperature too low a. Check cooling water temperature
b. Excessive combustion setting value, keep it normal or add
c. Poor vacuum inverter to control
d.Circulation improperly adjusted b.Readjust burner and reduce combustion
c.Refer to “poor vacuum”
d.Readjust circulation amount
13 Poor vacuum a. Sealing element aging a. Replace
b. External vacuum valve is not closed b. Check and close tightly﹡
tightly c. Conduct thorough leakage checking
c. Leakage caused during transportation, and repair to the chiller
whereas leakage detection not d. Remove the rust and eliminate the
performed at initial start, or new leakage, then repaint the leaking point
leakage occurred during operation or the whole chiller (the chiller shall be
d. Leakage at welding seam caused by in vacuum when paint is applied)
serious outside corrosion e. Troubleshooting
e. Auto purge and air vent device out of f. Readjust the setting of HTG target
work temperature to avoid HTG operating at
f. The chiller keeps running at high HTG high temperature﹡
temperature which generates
non-condensable gases
14 Auto-vent a.Poor vacuum a.Refer to poor vacuum eliminating
frequently b.Non-condensable probe wiring wrong method
or broken b. Check and wire correctly
c.Vent valve sticked c.replace sealing elements
15 Lack of a.Anti-scale agency runs out a.add anti-scale agency﹡
anti-scale b.Level probe fault b.check or replace level probe
agency
16 Lack of a. Disinfectant runs out a.add disinfectant ﹡
disinfectant b. Level probe fault b. check or replace level probe
17 AC/cooling/hot a.Flow meter is wrongly wired or with a. Check and wire correctly
water flow open/short circuit b.check or replace flow meter
meter b.Flow meter damaged or fault c. eliminate interferer
abnormal c.Electromagnetic interfere
18 AC water pressure a.Sensor is wrongly wired or with a. Check and wire correctly
drop/cooling open/short circuit b.check or replace Sensor
water b.Sensor damaged or fault c. eliminate interferer
conductivity c.Electromagnetic interfere
sensor fault
19 Internet a.Wrong wiring or internet calbe not a. Check and wire correctly
monitoring connected b. Repair or replace
abnormal b.Communication port failed c. Repair or replace
c. Network gateway abnormal d. Fix the network problem﹡
d. Internet is abnormal e. Reset networking parameters
e. Internet parameter setting is wrong
20 PLC/touch a. Fail to replace on time a. Replace and the replacement should
screen low b. Poor battery quality be done in 2 minutes
battery b. Purchase battery from BROAD﹡
30
Fault and troubleshooting
d. Abnormal record
No. Fault Causes Keys
1 Cooling a.Cooling tower poor performance a.Refer to “cooling tower fault and
water inlet b. Lack of water leads to air in the water eliminating method”
temperature c. Cooling water target temperature b. Make up water (and continuously
over upper setting is too high. make up water)﹡
limit d. Fan blade angle improperly adjusted c. Reset target value﹡
causes motor strap too loose d. Adjust fan blade angle or strap
2 Cooling a. Low outdoor temperature a. Chiller stops, no cooling﹡
water inlet b. Fan actuation temp. is low b. Readjust the setting value﹡
temperature c. Cooling tower fan linkage fails c. Find the cause and recover the
below the linkage control
lower limit
3 HTG a.Poor vacuum a.Refer to poor vacuum and
over-temper b. Excessive combustion eliminating method
alarm c. Too much deviation of HTG b.Readjust burner
temperature sensor c.Replace temperature sensor
4 Vent alarm The same with “vent over temperature” The same with “vent over temperature”
5 Burner on-off a. Load change is dramatic and the a. Conduct load regulation function
frequently chiller’s load regulation is abnormal. commissioning accurately
b. Burner is abnormal b. Refer to 5.4 “Burner fault and
c. Gas lower limit pressure switch troubleshooting”
protects frequently c. Improve gas pressure and stabilize or
adjust pressure switch setting value
6 Inverter a. Inverter communication port a. Replace inverter
communication damaged b. Redo the wiring
abnormal b. Communication cable abnormal. c. Replace
c. Communication converter d.Eleminating interferer
damaged
d. Electromagnetic interfere
7 Instantly Voltage unstable Negotiate with utility company*
power off
8 Sudden a. Power failure a. Negotiate with utility company﹡
power failure b. Main switch is open b. Check the main switch and restart
c. PLC control circuit fuse is burnt out the chiller﹡
d. Machine room gas leakage or fire c. Find the cause and replace the fuse
alarm is activated d. Eliminate the gas leakage or fire
alarm﹡
31
Fault and troubleshooting
e. others
No. Fault Phenomenon Causes Keys
1 Cooling Chilled water a. Poor vacuum a. Refer to “poor vacuum and eliminating
capacity outlet/inlet b. Insufficient cooling method”
lower than temperature both water flow b. Vent air out of water system and make up
the rated increase and c. Cooling water inlet water in full. Check if valves of water system
temperature temperature is high are fully opened and filters are clogged.
difference (above the rated) Check the pump model selection and
decreases; cooling d. Solution circulation rectify﹡
water radiation amount is too high or c. Cooling tower has poor heat dispersion effect.
decreases too low Check if cooling fan belt is loose or fallen off.
e. HTG fire off Adjust cooling fan blades’angle. Check
temperature setting distribution angle and speed of cooling tower
value is too low water distributor. Check if the tower selection is
f. Chilled water flow or correct﹡
temperature d. Adjust solution concentration of HTG to
measurement is 63%±0.5% and LTG to 62%±0.5%. Warning: lock
inaccurate the position bolt after adjusting concentration
g. Octanol added regulation valve
amount is insufficient e. Reset HTG fire off temperature
h. Chiller heating/cooling f. Calibrate the flow meter and thermometer
switch valve are not Calculate accurately chilled water flow
fully opened and temperature difference
i. Refrigerant water gets g. Make up by 0.3%
polluted h. Check respectively the 3 heating/cooling
j. Refrigerant water switch valves. Especially the steam angle
spray gets clogged or valve must be fully open﹡
refrigerant inverter i. Refer to item 4 of this chapter
goes out of control j. Backwash or flush R-pump filter. Wash spray
k. Refrigerant loss device when necessary. Conduct accurate
l. Comprehensive commission to R-pump inverter
solution concentration k. Check and close fully the refrigerant bypass
is too low valve. Make sure the refrigerant anti-overflow
m. Fouling in copper control is reliable
tubes l. Take out part of the refrigerant water to
n. Combustion volume increase comprehensive concentration
is too small m. Clean the copper tube fouling. Detailed
o. Soot in combustion plan is subject to BROAD written approval
chamber and fire n. Readjust burner and increase combustion
tubes volume
p. Hot water is overloaded o. Clean the exhaust soot and readjust the
burner using exhaust analyzer
p. Adjust according to specific condition
2 Heating Heating water (hot a. Combustion volume a. Check if fuel system filters get clogged
capacity water) temperature is too small Readjust burner to increase combustion
lower than cannot be b. Scaling in water rate
the rated increased. heater copper tubes. b. Clean the copper tube fouling. Detailed
Outlet/inlet c. Soot in combustion plan is subject to BROAD written approval
temperature chamber or fire tube c. Clean soot. Find the root cause and
difference becomes d.Poor vacuum readjust the burner
small d. Check and repair leakage. Purge vacuum
32
Fault and troubleshooting
(cont.)
No. Fault Phenomenon Causes Keys
3 Plate heat a. Rated cooling Caused by frequent a. Replace heat exchanger
exchanger capacity drops power failure or b. Redo the commissioning of the
mixed flow obviously unstable solution level chiller. Make sure the HTG solution
b. HTG temperature is in HTG level stays long at zone C or
obviously high and HTG solution level fluctuates within an
pressure is low. S-pump allowable range
frequency becomes c. Contact utility company or
low and refrigerant prepare backup generator to
level increases tackle the frequent power failure
obviously problem﹡
c. HTG lacks of solution or
solution level rises
frequently
d. “HTHE crystallization” is
reported all the time
e. The concentration of
HTG concentrated
solution drops obviously
in operation. By
stopping the S-pump to
take the measurement
the result is 3% higher
than normal
f. When in operation
S-pump frequency
changes from
operational to maximum,
the HTG concentrated
solution outlet
temperature may drop
by 30℃ in a short time
4 Refrigerant Refrigerant water level is a. Cooling water inlet a. Increase the cooling water inlet
water increasing. Specific gravity temperature too low temperature properly﹡
polluted >1.04. Cooling capacity b. Too much solution b. Readjust the solution circulation
decreases circulation causes amount
HTG/LTG solution level too c. Take out some refrigerant water.
high and concentration d. Readjust the burner to reduce the
too weak combustion
c. Comprehensive e. Avoid sudden increase of hot water
solution concentration flow. By-pass refrigerant completely
too weak to regenerate in addition to above
d. Exccessive measures
combustion.
e. Hot water flow
increases suddenly
5 Unstable HTG solution level is not in a. Improper adjustment Observe 3 times the whole process from
HTG solution zone C, or jumps of the frequency start to stop in 3 consecutive hours, then:
level between 2 zones b. Solution volume is a. Reset S-pump frequency and redo the
frequently to zone E or insufficient chiller commissioning if necessary
zone A, and stays too c. S-pump fault. b. Make up the solution and redo the
long in zone D or zone d. HTG solution level chiller commissioning
B.S-pump frequency control fault c. Repair or replace
drops over 30% in 120 d.Refer to HTG solution control fault keys
seconds
33
Fault and troubleshooting
(cont.)
No. Fault Phenomenon Causes Keys
6 Rupture Solution flows a. Wrong operation during nitrogen Stop the chiller immediately, cut
disk out from flow charging. Nitrogen overcharged off power,stop water pumps,
broken duct of the b. Copper tubes broken close valves and notify local
rupture disk c. HTG pressure increases BROAD service organization﹡
abnormally due to other reasons
7 Chilled Chilled water a. Overload a. Add new chiller or reduce the
water outlet b. Chiller cooling capacity is load﹡
outlet temperature is below the rated one b. Refer to item 1 of this chapter.
temperat higher than c. Deviation of the temperature c. Calibrate with accurate
ure the target sensor(s) thermometer. If deviation ≥ 2℃,
higher setting and d. Wrong parameter setting replace the temperature sensor;
than can not be deviation<2℃, readjust the
the target decreased compensation value
d. Modify the parameter setting
8 Touch No normal a. Touch screen not power on a. Power on﹡
screen display on b. PLC communication failure b. Repair or replace
out of touch screen c. Touch screen fault c. Replace
work d. Problem with the connection d. Repair or replace
cable between PLC and touch e. Replace
screen f. Check by programmer and
e. 24V DC supply failure modify
f. Wrong configuration on g. Re-input the program
communication port
g. Wrong operation leads to
touch screen program lost
9 Big Touch screen a. Poor grounding of a. re-grounding (to a dedicated
fluctuation displays chiller communication cable grounding electrode)
with touch parameters b. Temperature sensor poor wiring b. overhaul and replace it
screen unstably c. PLC Power module fails c. overhaul and replace it
data d. Shielded wires are poorly d. shielded wires well grounded
display grounded e. get rid of interference and
e. Interference from inverter or make chiller well grounded
high frequency from system
power
10 Canned Canned a. Pump motor overload a. Find the cause and reset
pump pump can not protection b. Check the control circuit
fault be started b. Control circuit fails c. Repair or replace
after chiller c. Pump fails d. Troubleshooting
startup d. Chiller in auto protection e. Try to put solution pump rotate
e. Pump is obstructed by solution in both direction, if it still
crystallization cannot be started then
f. Power Phase absence decrystallization is needed
f. Make power supply normal
34
Fault and troubleshooting
Cooling tower
No. Fault Phenomenon Causes
1 Abnormal a.Poor balance in fan a.Check balance
noise and b.Blade end touches the tower body b.Ajust the space between blade and
vibration c.Loose bolts tower body
d.Motor axis abnormal c.Tighten the loose bolt﹡
e.Pipe vibration d.Add grease and replace axis﹡
f.Strap is too loose e.Install pipe support frame﹡
f.Adjust strap
2 Current a.Fan blades are not in the same angle a.Adjust to the same
too large b.Motor fault b.Repair or replace
c.Bearing fault c.Replace bearing
d.Too large air output causes overload d.Adjust blade angle
e.Power supply voltage too low e.Recover normal voltage﹡
f.Lose phase f.Check power supply phase and recover﹡
3 Cooling a.Insufficient air flow a.Check and adjust strap, adjust fan
water b.Vented hot air enters tower blade angle
temperature c.Absorb less air b.Improve ventilation condition﹡
rising d.Dirty filling causes asymmetric distribution c. Improve ventilation condition﹡
e.Distribution system abnormal d.Clean﹡
f.Strap too loose or broken e.Clean sundries﹡
f.Adjust or replace strap
4 Cooling a.Pool water level too low a.Check, adjust auto make up and
water b.Filter screen clagged fast make up system﹡
amount c.Insufficient water pump flow rate b.Clean﹡
decreasing c.Repair or replace﹡
5 Asymmetric a.Sprayer or distribution pipe broken or a.Check damaged parts, clear out
distribution clagged sundries and clean up water filter
b.Water supply volume too large or screen﹡
small b.Adjust water supply rate﹡
6 Water a.Cooling water amount too large a.Adjust water rate﹡
floating b.Air flow too big b.Adjust fan blade angle, reduce air
c. Asymmetric water distribution rate
d.Filling material with wrong installation c.Clean up distributing basin and nozzle﹡
direction d.Readjust installation direction
e.Filling blocked e.Clean up filling material﹡
f.Buffle plates wrong installation f.Reinstall as required
Other parts
Faults and keys about burner, inverter, heat source valve, softener, auto water treatment and
other automation equipment, please refer to manuals provided with the products accordingly
36
Maintenance
Maintenance objectives
a. Zero fault stop. a. Load maintenance
b. Minimize the occurrence of fault alarm “Load Maintenance” can be classified
and abnormality. into three categories: high load, medium
c. Reduce energy consumption. load and low load.
d. Zero repair cost (exclude the expense
①High load users: HTG temperature is
from scheduled maintenance).
always above 150℃, such as district
e. 25 years’ life span.
Maintenance method cooling, process cooling, high rank hotels,
Traditional maintenance mode of central air hypermarkets, etc..
conditioning system adopts only “Regular ②Medium load users: HTG temperature is
Maintenance” without considering the always within the range from 142℃ to
relationship between the maintenance period 150℃, such as shopping malls, ordinary
and the operation load, which will lead to fault hotels, theatres, clubs, hospitals, etc..
or energy efficiency decrease for those chillers ③Low load users: HTG temperature is always
running at high load all the time. Hence, below 142℃, such as office buildings,
BROAD classifies its maintenance mode into
government buildings, schools, gyms, etc.
“Load Maintenance” and “Routing Maintenance”.
Maintenance items for high load every 2 months, medium load every 3 months and low load every 6
months are as follows:
N0. Items Method
1 Check the record and a. Check the running, fault and energy consumption records of the chiller
feel the air conditioning b. Inquire/analyze the user’s energy consumption and give some energy saving
effect advice to the user’s chief
c. Check the running status of the chiller and terminals, and feel the air
conditioning effect in different areas
2 Observe the operation a. Whether the burner starts and stops frequently
and check parameter b. Observe at least 30 minutes to check if the HTG solution level fluctuates
setting abnormally and noisily
c. Whether the refrigerant level goes up abnormally
d. Whether the cooling capacity of the chiller decreases and the energy
consumption increases
3 Burner a. Clean off the dust and water stain on the steel strip to prevent rusting
b. Clean burner fan blades and oil pump filter; check the fan motor bearing
c. Wash the atomization tray, nozzle (oil type), ignition electrode and the
residual carbon on the ion flame detector; make sure they are not
damaged and at the right position
d. Clean the flame detector and confirm that the photosensitive part is
transparent without damage
e. Check the excess air coefficient: gas type 1.18~1.25, oil type 1.13~1.20
4 Solution and rust a. When the solution pump is running, the solution should be clear and
transparent observed from the sight glass
b. Observe the rust status of the copper tubes and steel plates. The vacuum
must be confirmed when something abnormal is found
5 Vacuum of the chiller a. Confirm the vacuum of the chiller by bubble comparison method
b. Check whether the vacuum valve cover, valve cork and the valve before
compound gauge is closed
c. Check the reliability of auto purge/ air vent device
6 Control cabinet a. Check heating and aging status of each components in the control cabinet
b. Check whether the touch screen displays the right PLC signal
c. Check whether the control cabinet fan runs well; clean rust on the fan filter
7 Canned pump and Check the temperature rise, cavitation and abnormal noise of the motor.
inverter Check whether the inverter works normally
37
Maintenance
(cont.)
N0. Items Method
8 Temperature sensor Calibrate: to detect the temperature of chilled water, HTG and crystallization
probe with precision thermometer, and compare them with the displayed
values on the touch screen. Make compensation if the difference is less than
2℃.If the difference is ≥2℃, check whether the wiring is reliable or not
9 Cooling water quality Check the water analysis result and push to make improvement if the water
quality is below the standard
10 Machine room ventilation Check whether the machine room ventilation is good and whether the
temperature is too high or too low (the range should be 5~32℃)
Maintenance items for high load every 4 months, medium load every 6 months and low load every 12 months
are as follow:
N0. Items Method
1 Water side of copper tubes a. Take out the fouling detector for the cooling/chilled water, open the soft
connector for heating/hot water to check the fouling with the copper
tubes. If fouling occurs, clean according to a method officially approved
by BROAD
b. Check the reliability of water quality stabilizer charging, water drain, water
makeup devices and their control
2 Fuel filter Clean
3 Action test for flow switches a. Adjust the water pump inverter or the outlet valve after the pump starts.
Check whether the flow switch closes when the flow rate is above 55% of
the rated value and whether it disconnects when the flow rate is below
45% of the rated value (40% for cooling water)
b.Confirm the start/stop sequence of the cooling and chilled water pumps
4 HTG temp. and pressure a. Make sure the pressure control actuating value at correct setting (factory
contro setting)
b. Check if protection is actuated during Nitrogen charging for repair or
during maintenance
c. Make sure when HTG temperature >172℃, HTG temperature control
actuates to dilute off the burner
5 Gas train air tightness & a. Check valve train joints leakage by soap solution. Charge Nitrogen to
upper/lower limit pressure maintain pressure at valve train per burner manual instructions
switch b. Check performance of gas valve leakage detecting system
c. Ensure that two stages of gas solenoid valves can both open/close reliably
d. Test whether the burner is stopped when gas supply pressure is beyond
upper/lower limit
6 Protection test Check the possibility of accidents which may lead to stop fault
Maintenance items for high load every 2 years, medium load every 3 years and low load every 5 years are as
follow:
N0. Items Essentials of the method
1 Solution filtering Filter the solution with a precision filter
2 HTG solution level probe and UDK Replace
upper/lower jacket
3 Rupture disc and sealing elements Replace
4 Vacuum sealing elements in high Replace
temperature area
5 Sealing materials in front/rear flue Replace
chamber
6 Sealing gasket for heating/hot water box Replace
cover
7 Burner Replace the nozzle, ion flame detector and motor bearing
Maintenance items for high load every 5 years, medium load every 7 years and low load every 10 years are as
follow:
N0. Items Essentials of the method
1 Burner Replace the oil pump, ignition electrode and solenoid valve coil
2 Inverter Replace
3 Turbulator Replace
4 Cold/heat insulation materials Replace
Maintenance 38
b. Regular maintenance
The maintenance interval of some items has nothing to do with the running load of the chiller.
Their maintenance mode is called regular maintenance.
Annual maintenance:
(cont.)
Cleaning and parts ﹒Start the pump. Adjust the flow to zero,then
replacement of the auto stop it.
﹒Seize the edge of membrane carefully,
dosing device loose it anti-clockwise, remove the
a. Pressure release of the dosing membrane and the disc on the back of
pump outlet pipe membrane (if any). Check if the size code
①Confirm the one-way valve is installed of the new membrane is in line with the old
correctly and in working condition. membrane.
②Confirm the return pipe is connected to the ﹒And then fit on the disc ,align its orientation
4-function valve with the other end dipping in line to the hollow of the EPU. Note: Do not
the chemical tank. Rotate the black knob of
scratch the surface of TEFLON.
the 4-function valve by 1/4 circle, vent the air
in the outlet pipe until the solution flows from ﹒Start the pump, adjust the flow knob
the return pipe to the brine tank. according to the "Liquifram" table set-stroke.
When the Pump is running, tighten the new
b. Cleaning of corrosion inhibiting & membrane clockwise until its center locks
antisludging agent tank
inward closely, then stop the pump .
① Release the pressure in the dosing pump
﹒Seize the edge of membrane carefully,
and outlet pipe.
② Open the discharge valve at the bottom rotate its center to align with the brim of
of the chamical tank, exhaust the Spacer.
residues, and rinse with clear water two ﹒Load the membrane, put the pump head
or three times till it is clean. into every block with 4 screws and tighten
③ Close the discharge valve, open the lid up. Check the screw loose or not in a week.
at the top of chemical tank, and add ② Replace seals, ball valve and injection
proper amount of chemicals to the box. valve spring.
④ Fill chemicals to the pump head.
﹒After pressure release of the outlet pipe,
⑤ Put into operation.
empty off and take out one end of the
c. Cleaning of the biocide tank discharge pipe. Put the end valve into the
① Replace the pressure in the dosing pump water or neutral solution box, start the pumps,
and outlet pipe. wash the pump head, and then lift the valve
②Take out the parts of the pump and clean off the liquid surface and continue to run the
them. pumps until the pump head is filled with air. If
③Take out the chemical tank, exhaust the
residues, rinse with clear water two or the membrane has been broken and is
three times till it is clean. unable to work, please put on latex gloves,
④Reassemble the chemical tank, and add remove the inlet and outlet pipes carefully,
chemicals to the tank from the opening remove the four screws on the pump head,
of pump head assembly. Reassemble the then submerge the pump head in water or
pump parts. neutral solution.
⑤ Put into operation. Note: when you open the valve, take
d. Replacement of spare parts. note of the front/back of the ball valve,
① Membrane replacement. sealing ring and their position sequence.
﹒After pressure release of the outlet pipe, ﹒Remove the pipe joints, and the damaged
empty off and take out one end of the seals, ball valve. Insert a screwdriver into the
discharge pipe. Put the end valve into the center of the sealing ring, then pry leftwards
water or neutral solution box, start the and rightwards.
pumps, wash the pump head, and then lift ﹒Fit with the new ring and ball valve. Pay
the valve off the liquid surface and
attention to the front/back side and
continue to run the pumps until the pump
head is filled with air. If the membrane has position sequence.
been broken and is unable to work, please ﹒Fit a new injection valve spring.
put on latex gloves, remove the inlet and
outlet pipes carefully, remove the four
screws on the pump head, then submerge
the pump head in water or neutral solution.
47
Maintenance
Salt manual charging and ① Close A/C (or cooling) water inlet and
outlet valve.
resin adding of water softner ② Open drain valve and drain all the water in
a. Salt manual charging filter header.
As the water softner will continue to ③ Take off insulation carefully and open
service door.
consume the reproducible salt, manual ④ Clean inside of the filter header.
charging must be done to brine tank to ⑤ Close service door and if bolts are damaged,
maintain enough reproducible salt inside. replace them.
⑥ Put insulation back and make sure it is tight
Only industrial salt (granulated) can be used.
without any gap.
Iodized salt and farinose salt are not allowed.
Adding salt is simple, just open the brine tank
Cooling fan motor belt replacemet
① Loosen fixing bolts of the motor.
cover, and add a certain amount of ② Take off motor belt, and then fit with the
reproducible salt. Amount and interval of new belt of same model.
charging reproducible salt are listed in the ③ Regulate motor horizontal adjustment bolt
table below. to tighten/loosen the new belt.
④ Tighten horizontal adjustment bolt and fixing
Model Charging interval per Weight base bolts.
different hardness kg ⑤ Test run cooling fan.
(mgCaCO3 / L)
200 300 400
Non-operation maintenance
BY75 25days 17days 12days 140 If the chiller needs to stop for more than 8
BY100 19days 12days 9days 140 months due to some special reasons,
BY125 22 days 14days 11days 200 non-operation maintenance should be
BY150 18 days 12days 9days 200
carried out.
BY200 22 days 14days 11days 320
① Shut off all inlet/outlet valves, and open
the water drain valves to drain out the
BY250 17days 11days 9days 320
water inside the copper tubes.
BY300 18days 12days 9days 400
② Charge the nitrogen gas of high purity
BY400 20days 13days 10days 600
(above 99.995%) into the chiller to
BY500 16days 11days 8days 600
0.01~0.02Mpa and check periodically
BY600 18days 12days 9days 800
(every 1~2 months) whether the
BY800 20days 13days 10days 1200
pressure drops.
BY1000 16days 11days 8days 1200 ③ Check carefully whether all valves are
Note: ① Calculated per 10 hours of cooling tightly closed, clogs are properly
a day, for reference. mounted, sight glass covers are covered
② fill up brine tank every time and fuel supply valves are shut off. Cut
off the power supply after informing
③reproducible salt in brine tank BROAD Remote Monitoring Center.
can not be less than 1/3. ④ The doors and windows of the machine
b. Add resin room should be steady and reliable, and
cannot be used for other construction
① Close inlet and outlet valve of water purpose. Unauthorized personnel are
softner. prohibited to access into the machine
② Open drain valve and drain all the room. The burner, tools, spare parts and
water in pipe. documents should be well kept.
③ Loosen the flexible joint at inlet and ⑤ Keep the humidity and temperature of
outlet pipe of the control valve, tear the machine room normal. Some
down control valve. dehumidification measures shall be
④ Add enough resin from control valve taken for electrical parts e.g. the
installation opening. control cabinet.
⑤ Re-install control valve and pipe. ⑥ A comprehensive maintenance and
inspection is necessary before restarting
the chiller.
Pump filter header cleaning
48
Maintenance
Antifreeze in winter unit does not need to be drained out,
Before winter every year, you should otherwise, drain it to prevent unit from
double-check the unit and system to be freezing.
whether they are in accordance with the ② Because of the residual refrigerant water in
antifreezing requirement. If it’s not, take the
refrigerant water pump, refrigerant water
following steps to prevent frozen unit or
system. pressure-drop pipe and condenser
a. Air-conditioning water system antifreezing pressure-drop pipe, and when ambient
When the air-conditioning system is disabled temperature is lower than 0 ℃, freeze may
and if the ambient temperature may be happen. in this case, by pass refrigerant
lower than 0 ℃, water in pipe system need water into absorber and keep unit in
to be drained out completely. The best is to vacuum state.
charge antifreeze, and its freezing
Long-time-disabled chillers in nitrogen
point should be lower than the minimum
ambient temperature to ensure that the state as well as chillers that have been
water system and chiller have no freeze tested on testing platform and delivered
accident, and it will help prevent water with nitrogen and have not been put to
pipes and copper tubes from corrosion. use, should be charged with some IiBr into
b. Cooling water system antifreeze refrigerant water box from refrigerant water
Drain cooling water completely out from sample valve. The best concentration of
pipes, cooling towers and copper tube solution in refrigerant water box is 52%.
inside chiller and especially, make sure no
e. Fuel system antifreeze
water at lower position of system
Appropriate grade of diesel should be
c. Domestic hot water system antifreeze
chosen for the ambient temperature.
① Without secondary heating exchange, if
In region where the lowest temperature
the ambient temperature is lower than 0 ℃,
is above ―5 ℃ light oil No.-10 should be
and if domastic hot water is not in use in
winter, you must open drain valve to drain used;
all water out, and it will help prevent and In region where the lowest temperature
domastic hot water system from freezing is above ―14 ~―5 ℃ light oil No.-20
② Secondary heating exchange system, if should be used;
domestic hot water is not in use in winter , It In region where the lowest temperature
isn’t necessary to drain out all water. This will
is above ―29 ~―14 ℃ light oil No.-25
help prevent water pipes and copper
should be used;
tubes from corrosion. If ambient
temperature is lower than 0 ℃, antifreeze In region where the lowest temperature
need to be charged into the first heating is above ―44 ~―29℃ light oil No.-50
exchange cycle system, and its freezing should be used.
point should be lower than the minimum
ambient temperature. However, water in !
secondary cycle system have to be
drained out.
d. Unit antifreeze
① If ambient temperature may be lower
than 0 ℃, but antifreeze has been
charged, water in copper tube inside the
49
Maintenance
F.Anti-freezing liquid instructions
① Effect ② Formula
Anti-freezing liquid is some dissoluble Preparation of Anti-freezing liquid is
associated with the minimum ambient
chemical reagents in A/C water or
temperature and total volume of
domestic hot water to make its freezing
water system. Measuring total volumes
point lower than the lowest ambient first after draining water out, and then
temperature, so it can prevent pipes from make up anti-freezing liquid as following.
freeze. Meanwhile, we need to add some ③ Test
Density and pH value of anti-freezing
other chemical reagents into anti-freezing
liquid should be tested. Use
liquid to act as anti-corrosion, anti-scaling,
“1.000~1.100 densimeter ”, and test
anti-microbe. In normal condition, liquid at about 20℃. Use “universal pH
anti-freezing liquid can protect unit forever, test paper” for PH test.
and can extend life span of unit.
Formula list for 100 liters Antifreeze
Local minimum temperature ℃ -5 -10 -15 -25 -30 -40
99% Secure formula 12 19 27 38 43 48
Glycol Density±0.002kg/L 20℃ 1.021 1.029 1.038 1.051 1.056 1.062
(kg) economical formula 5 8 12 16 20 22
Density±0.002kg/L 20℃ 1.014 1.017 1.021 1.026 1.030 1.033
water (L) The total volume increased to 100 liters of water required
Additives(kg) Borax 0.6, sodium hydroxide 0.15, sodium benzoate 0.5, BTA0.02, if
in the preparation hard water is adapted to use add anti-corrosion
inhibitors 50ml
pH value 9~11.5(If not appropriate, sodium hydroxide to adjust)
Note: The secure formula will not freeze in the temperature and the economical formula
means ice crystal will occur as a result of freezing, but it will not freeze pipes, nor could it not
be cycled immediately. The secure formula is based on the lowest temperature records in
the local history. But in fact, there is very low possibility of ccuring minimum temperature
and causing chiller shutdown. So the economical formula is provided for reference. The
relationship of antifreeze density and temperature is: density at X ℃= density at 20 ℃-0.0003
(X-20) (10 ≤ X ≤ 35).
50
Energy saving management
Energy Consumption Analysis
a. Energy cost
①In order to make an accurate energy b.Energy consumption survey
analysis, the separated metering for heat BROAD is doing energy consumption and
source, electricity, water, cooling/heating energy cost survey every year. Please
consumption of air conditioning system support and supervise BROAD engineer to
are necessary. do a real and accurate investigation, so that
②To make comparative analysis on the
we can know whether your energy
data of different years, or different time
consumption is reasonable or not, help you
with similar load with the help of chart
and graphics. According to BROAD to find the reason of high consumption, and
experience, normally 30-60% cost can be your energy saving potential, and give
saved by introducing effective energy suggestions on energy consumption
analysis management. management improvement.
4 Design a reasonable Design a linkage controlled adjustable It can effective delay the
fresh air system withair damper for fresh air and return air, start and pre-stop the chiller,
heat recovery device.control the fresh air ratio through an reduce the load and running
Establish a complete enthalpy controller, so that the fresh air time of chiller and save
fresh air and exhaust air
can be adjusted from the minimum to energy consumption
management system 100%. Install heat recovery device on air
system
5 Install Choose or add indoor units which are Cut off different indoor units
motorized/solenoid equipped with motorized/ solenoid valve on time to reduce the heat
valve and heat meter and heat meter, such as BROAD indoor loss and improve the
for indoor units units behavioral energy saving
consciousness
6 Install automatic Choose or and the indoor units which Control the room temperature to
speed/temperature have the function of automatic speed aviod too cold in summer or too
adjustment for indoor /temperature adjustment hot in winter. It’s comfortable and
units also energy saving
7 Energy computation To calculate the fuel, electricity and Saving energy consumption
management indoor units consumption separately, by 10% to 20%
and implement strice supervision
mechanism
8 Ensure insulations of the Check the insulations periodically Avoid the energy loss and
whole system are in refurnishment damage from
good condition bad performance of
unqualified insulations
9 Avoid leakage of water Check the pipes periodically Save water and energy
pipe
10 Cycling mode of Closed circuit is recommended Reduce much of the
water system electricity consumption, help
anticorrosion, anti-scale and
extend life span of pipes
53
Energy saving management
( continued from the above form)
No. Item Method Effect
11 Distribute cooling The water supplying temperature can be Avoid unreasonable
(heating) load lower and flow rate higher if the energy wasts
reasonably temperature humidity requirement is low in
the room, and vice versa. Adjust the fresh
air rate according to different requirements
and clean the air filters periodically.
12 Device water pumps Arrange pumps according to different Avoid too much pressure loss
into different sections pressure drop areas. For example, design in the low-level area, and
closed loop separately for high-level area reduce unnecessary water
and low-level area. pump running
13 Use variable flow air Air flow is changable according to load Reduce the electricity
supply for indoor units changes in the room. consumption
14 Reasonable air Choose reasonable air duct size according Avoid unreasonable
ducting system to economical air speed, avoid air leakage energy loss during
of equipment or air ducts, avoid air transportation
“short-circuit” between supply and return
air, and clean the air ducts on time
15 Ensure all equipment Solve the problems of equipment on time Avoid the energy
are well consumption rise
16 Eliminate heat Install air return windows above the lights, Reduces the load inside
generated by room so that the heat of the lights will be taken room, so that the air supply
lights by utilizing the off by the return air can be reduced, and
return air power for air supply can
also be reduced
17 Manage the doors It’s forbidden to open door or window Avoid the heat loss
and windows strictly when the air conditioning system is
working. Use an infrared ray sensing
automatic door, and also the door curtain
18 Use cold-light or Energy efficient lights. Reduce the indoor load
natural-light system
19 Improve the Reduce the area of window. Use vacuum Reduce the indoor load
thermodynamics heat-insulated glass or film plated
performance of reflecting glass. Use sealing bar and heat
building insulating window curtain. Use scree on the
building roof. Use heat insulation material
with good performance on heat reflecting
for outdoor envelope
20 Use 100% automatic The air conditioning system will adjust all A lot of energy will be saved,
and intelligent the equipment according to the load, so and heavy energy waste
control for air that a best performance is achieved all the due to wrong operation will
conditioning system time be avoided
21 Lower the standard Summero: no less than 26℃, humidity 40% When the indoor temperature
of indoor is adjusted from 26℃ to 28℃
temperature and to 60% in summer, the cooling load
humidity reasonably Winter: no higher than 20℃, humidity≥35% can be reduced by 20%
When the indoor temperature
is adjusted from 20℃ to 18℃,
the cooling load can be
reduced by 30%
22 Clean all kinds of The filters of cooling water system and fuel system Avoid low heat transfer
filters in the air should be cleanedat least every 3 months or less, efficiency
conditioning system the filters of chilled (heating) water system, or
periodically indoor units should be cleaned at least every one
year or less. The cleaning interval should be
shortened if the system is new, depending on
water quality material of ducting, etc
54
Service information
Service responsibility
The operation, maintenance and repair ﹒When the chiller arrives at the jobsite,
should be conducted by the service BROAD service engineer can give the
engineer and operator. guidance for check & accept at site or
a. Service engineer through telephone.
Gives guidance for check & accept, lifting ﹒BROAD service engineer should inform
and installation of the chiller; take care of the user of anything of importance for
the operator’s training at the jobsite. lifting.
b. Operator ④Installation guidance
Assists the service engineer to do the ﹒BROAD service engineer shall put forward
commissioning, repairing and maintenance; to the users the machine room installation
takes care of the operation and simple and management requirements. If
maintenance of the chiller. necessary, BROAD can organize the user,
c. Senior operator installer and designer to visit the BROAD
Assists the service engineer to do the standard machine room and share the
commissioning and to repair; takes care experience of the user.
of the operation, maintenance, ﹒BROAD service engineer should help the
trouble-shooting and replacement of user to check if the machine room
common-used parts. installation drawing conforms to the
d. Operation engineer national codes and BROAD catalogue
Gives guidance for check and accept, requirements, and offer written advices.
lifting and installation of the chiller; takes ⑤Jobsite commissioning
care of the commissioning, operation, BROAD service engineer checks the user’s
maintenance, ordinary trouble hooting system against ”System Check & Accept
and parts replacement. Form” and conducts the commissioning for
the chiller which passes the reception
Warranty service and paid
check; for user’s system which fails the
service
check & accept, BROAD engineer will give
a. Warranty service a written rectification requirement.
①Warranty period
Commissioning cannot be done until the
18 months from the shipment date or 12
commissioning requirements are met. After
months from the commissioning date,
the commissioning, BROAD service
whichever come first
engineer hands over the chiller
②Appointment of the responsible engineer
management to the user.
After receiving the Contract Technical
⑥Training
Sheet, BROAD International Service
BROAD engineering institute is
Department shall fax it to the corresponding
responsible for training of the user’s
oversea service branch. Overseas service
operators. BROAD service engineer shall
branch shall appoint a responsible service
train the user’s operators at the jobsite
engineer accordingly within 15 days.
during commissioning or
③Check & accept
maintenance.Operators who have
﹒BROAD service engineer, together with
the user should confirm the dimension already received the training offered by
and access of the machine room. If BROAD and obtained the qualification
anything abnormal happens, BROAD certificate can operate the chiller
will inform the user in written from and independently.
discuss with the user to find a solution.
55
Service information
⑦.Mainteanance
③. Spare parts ordering
BROAD bears the materials, labor and travel
The users can sign “single agreement” to
costs during the warranty period.During
life-span of chiller, BROAD service engineer will buy the spare parts from BROAD; out of
offer free energy-saving diagnoses. warranty period, if the same problem
Any cost caused by damage to the chiller happened in one part in three months,
because of the user’s reason (for example the BROAD offer free service.
fuel, power, auxiliary devices and man-made c.Limited declaration
damage) or force majeure (for example
Except the responsibilities which are
typhoon, earthquake, flood and war) shall be
clearly mentioned above. BROAD do not
borne by the user.
take responsibilities for any direct, indirect,
b.Paid service special or attached damages.
Service after warranty period or for users
d. Service disciplines
under some restriction clauses belongs to
It is prohibited for BROAD service engineer
paid service. BROAD service engineer
shall issue a “warranty service expiration to charge the users privately or make
notice” to the user 1~2 months before money by selling products from other brand;
the warranty period expires. For EMC user, otherwise, the service engineer will be
BROAD offer service according to the charged with corruption and cheating and
contract. No need to get other payment bear the corresponding legal and
service contract. economical liability.
For payment service, here are some manners e.Service requirement and standard
for user’s choice: Items Standards
① Signing of the annual payment service Routine Strictly follow the
maintenance requirements for the load
agreement:
and spare parts maintenance and routine
﹒After the warranty period, the user is replacement maintenance;
recommended to sign an annual service Maintenance Make sure the
agreement with BROAD. The period can quality performance and
cleaness of the chiller
be between 1 year and 5 years The after maintenance just
agreement should be in standard format like that of the new chiller
and stamped. and the non-stop
operation should be
﹒Charge policy: the expense standard depend
guaranteed;
on the size, function, amount and age of the Response time Where there is a BROAD
chiller. “Annual service agreement” should local service
cover periodical maintenance, trouble shooting branch,BROAD service
engineers should reach
and some other service work etc. the jobsite within 6 hours
②.Technology upgrading for the users inside the city
In order to create more values for the and 12 hours outside the
city (with the agreement
customers, BROAD will inform the customers
of the users, two parts
of the latest technical achievements so that can appoint the time);
the customer can decide whether to
upgrade his chiller or not; if the users has the
intention, they can sign the “single
agreement” with BROAD.
56
Service information
Operator training corresponding qualification certificates
to those trainees who got all credit hours.
a. Training mode
For those who did not get all the credit
The operator training includes jobsite
hours, they can only get the credit hours
training by BROAD service engineers and
certificate. The qualification certificate is
BROAD town training. BROAD town
issued till he got all the credit hours. The
training should be carried out by BROAD
certificate is valid for 3 years. Before its
engineering institute.
expiration, the trainees should be
b. Training classification re-trained and pass the exam to extend
The training is classified into 3 levels as of the term of validity. Otherwise, their
operator, senior operator and operation certificates will be cancelled
engineer. automatically.
Operator: Qualified to do the operation
and simple maintenance.
Senior operator: Qualified to do the
Contact
operation, maintenance, common Region BROAD International Service Department
troubleshooting and common parts Tel. 86-731-4086265
Fax 86-731-4611356
replacement.
E-mail gjb@broad.net
Operation engineers: Qualified to do the
Add. BROAD Town,Changsha,China410138
operation, maintenance, commissioning,
common troubleshooting and parts Region BROAD European Service
replacement. Be able to manage all Tel. 0033-134430788/825
BROAD absorption chiller products and Fax 0033-134430703
make energy saving upgrading plan or E-mail broad@orange.fr
Add. Bât C,2ème Etage, Boîte 1001 Centre
operation plan.
Commercial Trois Fontaines 95003
c. Training procedure Cergy-Pontoise Cedex FRANCE
30 Conductance rate sensor(S) Detect cooling water quality, control water draining time
and add inhibitor
31 Different pressure detector(△P) Detect A/C water pressure difference, control A/C water
pump energy saving operation
32 Burner gas leakage detector (SG1) Stop burner when gas leakage is detected to avoid
safety accident
33 Gas leakage detector in machine Equipped by the user, for detecting integrity of gas pipe
room (SG2) in machine room. Draft fan will be started if gas
leakage is detected to avoid accident
NOTE: parts with “**” are not for heating-cooling type; parts with “**” and “*”are not for cooling-only type.
Valve list
No. Type Name Function Remark
1 Vapor angle valve (F3)﹡Separate main shell with HTG Open in cooling,
Cooling/hea
2 Concentrated solution
if necessary valve,
angle valve (F4)﹡
heating mode should
valve
random regulation.
5 LTG concentration Regulate LTG solution Belonging to vacuum
regulating valve (F7) concentration valve
6 Refrigerant sampling Take out refrigerant; concentrate commissioning use
valve (F9) solution; check pollution degree of
refrigerant
7 LTHE sampling valve LTG concentrated solution
(F10) sampling
8 HTHE sampling valve HTG concentrated solution
(F11) sampling
9 Diluted solution samplingSolution charging/discharging or
valve (F12) diluted solution sampling
10 Main purge valve (F13) Purge the chiller or oil interceptor Purge only
11 Direct purge valve (F14) Purge the chiller directly
59
Part list
Continue
No. Type Name Function Remark
Conductivity <80 <30 <40 <40 <30 <30 <30 <30 <30 ○ ○
(25℃ μS/cm)
Cl- (mg Cl-/l) <200 <50 <50 <50 <50 <50 <50 <30 <30 ○ -
SO42- (mg <200 <50 <50 <50 <50 <50 <50 <30 <30 ○ -
Ca SO42-/l)
pH4.8 (mg <100 <50 <50 <50 <50 <50 <50 <50 <50 - ○
CaCO3/ l)
General <200 <70 <70 <70 <70 <70 <70 <70 <70 - ○
hardness
(mg CaCO3 / l)
Ca hardness <150 <50 <50 <50 <50 <50 <50 <50 <50 - ○
(mg CaCO3/l)
SiO2(mg SiO2 / l) <50 <30 <30 <30 <30 <30 <30 <30 <30 - ○
Fe (mg Fe/l) <1.0 <0.3 <1.0 <1.0 <0.3 <1.0 <0.3 <1.0 <0.3 ○ ○
Reference items
Cu (mg Cu/l) <0.3 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 ○ -
S2- (mg S2- / l) NO NO NO NO NO NO NO NO NO ○ -
NH4+(mg NH4+/ l) <1.0 <0.1 <1.0 <1.0 <0.1 <0.3 <0.1 <0.1 <0.1 ○ -
Cl (mg Cl/l) <0.3 <0.3 <0.3 <0.3 <0.3 <0.25 <0.3 <0.1 <0.3 ○ -
CO2 mg CO2/l <4.0 <4.0 <4.0 <4.0 <4.0 <4.0 <4.0 <0.4 <4.0 ○ -
Stability index 6.0~7.0 - - - - - - - - ○ ○
OPERATION
prior to the cooling water pump. If it stops, the cooling water pump must be stopped prior to
the chilled/heating water pump. Otherwise copper tubes will get frozen.
Although the on/off sequence of “Auto Control” mode is set as above mentioned requirements,
a reconfirmation is needed once every 3 months in case of any accidents like incorrect connection
of cables or software virus.
2.In cooling operation the heating water drain valve must be opened and its handle be removed.
Otherwise the piping system for heating water will be heated and expanded, wasting a great deal
of energy. The handle must be well kept for future use.
3.Random adjustment of solution concentration regulating valves is prohibited.
Otherwise it will cause crystallization, reduce cooling capacity and waste energy.
4.Angle valves must be 100% closed when the chiller is switched from cooling to heating operation.
Then start the chiller, when the HTG temp. rises to 100℃, check the temperature of the valve pipe
on main shell side to see if it rises.
The loose shut-off of angle valves will result in high temperature and damage the HTG.
Otherwise chiller will be eroded, which will damage electrical insulation, affect combustion and even injure
people due to oxygen shortage in machine room.
2.Make sure there is no gas leakage. Gas-fired chillers are not allowed to work if gas leakage detect
or and forced fan are not in reliable linkage control.
3.Make sure there is no exhaust leakage. In case of exhaust leakage in machine room, the operator
will suffer from CO asphyxia.
4.The fuel filter should be cleaned or replaced regularly. Otherwise it will stop burning, produce smoke
to damage the solenoid valve or even cause deflagration(The oil pump will also be damaged
for oil-fired type).
5.Burner operating with black smoke is prohibited.
Excessive Air Coefficient should be within a range of 1.18~1.25 for gas-fired type and1.13~1.20
for oil-fired type. Otherwise, even small amount of smoke will increase fuel consumption dramatically
to pollute environment, or even cause fire. If the Excessive Air Coefficient is too large, it will cause
deflagration, even stop the burner and waste fuel.
6.Gas pressure and fuel heating value must be stable and fuel quality must meet the local standard.
Otherwise it will cause soot in fire tubes, increase energy consumption, affect cooling capacity, or
seriously damage the burner, even cause deflagration.
7.The exhaust damper must be full open before chiller start and full close when the chiller is to be
stopped for long time.
1.Confirm the vacuum condition and good condition of auto purge & vent device according to “Vacuum
Vacuum&LIFE-SPAN
Management Regulations”.
2.Prevent others from handling the vacuum valve randomly.
The handle of the vacuum valve must be removed and well kept after operation to avoid
unauthorized access.
3.Conduct heating and chiller shut-off management with care.
The main shell should be maintained in vacuum condition during heating operation. If the expected
shut-off period is over 8 months, it should be charged with 0.01 MPa~0.02 MPa high-purity nitrogen
(purity>99.995%).
4.Use only BROAD solution. And it is forbidden to use solution regenerated by others.
Sample the solution with special bottles every year and send it to BROAD Lab. Solution should be fully
circulated and diluted before sampling, and fill the label on the bottle correctly. BROAD will confirm the
vacuum, rust condition of the copper tubes and steel to ensure 25-year life span. The solution needs not
be taken out for regeneration. If it is too feculent, it can be filtered with BROAD precise “Regenerator”
without stopping the unit and free of charge. If the solution is regenerated by others, BROAD will not be
responsible for the unit any more.
5.Without BROAD written permission, it is forbidden to clean the copper tubes with chemicals.
If the chemicals are not property used, the cleaning is not strictly controlled or the chemicals are not drained
completely, it will seriously corrode the copper tubes, affect the life-span or even destroy the chiller.
6.Strengthen water quality management.
Auto water quality stabilizer charging device should be installed(auto dosing of biocide and
anti-sludging agent). Analyse water quality at least once every 3 months and select the
appropriate anti-sludging agent according to this result. Quality of make-up cooling water should
meet the quality standard of city water. Poor water quality will cause more energy consumption,
reduce cooling capacity and result in corrosion of copper tubes, or even destroy the chiller.
63
Waste heat recovery chiller safty regulations
1.Anti-freezing protection for the chilled water tubes must be strictly carried out.
CONTROL
BROAD’s requirement of the 3-stage protection and interlock electrical diagram of the
chilled/heating water system must be followed to avoid maloperation, otherwise tubes will be frozen.
The 3-stage protection should be checked every quarter.
2.The chiller must be started by “Auto Control”.
There are some protection procedures under “commissioning mode”, but it can be used only under
the supervision of professionals, otherwise serious failure will occur.
3.The safety devices cannot be by-passed nor their settings can be changed at will.
Before the cooling period begins, all the safely devices must be calibrated, especially the chilled
water flow switch, temperature sensor and HTG pressure control. Otherwise the copper tubes may
get frozen or serious personal injuries may occur.
4.Power supply must be right and voltage must be stable.
The fluctuation of the voltage must be within 10% of the rated value. A dedicated grounding wire
must be available in the machine room.
At least 6.0 mm2 wire must be adopted as the grounding wire, and the grounding resistance should
be ≤10Ω, otherwise it will damage the electrical components and control system or even cause
personal injuries.
5. If electric wire is damaged, it should be replaced only by manufacturer, service agent or qualified
personnel.
Otherwise personnel and equipments will be in danger.
6.The chiller must be on line 24/7/365.
To ensure collecting the data and monitoring the chiller, the chiller must be on line 24/7/365.Otherwise
BROAD Monitoring Center will not know if the chiller is working normally. If the chiller is to be put into
idle for more than 3 months, BROAD Monitoring Center must be informed before power-off.
7.Computing data must be set correctly.
If the data are wrong, it will cause unexpected chiller shut-off and affect the user’s energy management.
NOTE: This regulation is applicable to BE, BDE, BZ, BZE, BZH, BZS, but for BZH, BZS “Waste heat
1. When the chiller is started for cooling operation, the chilled water pump must be started prior to the
OPERATION
cooling water pump. If it stops, the cooling water pump must be stopped prior to the chilled water
pump. Otherwise copper tubes will get frozen.
Although the on/off sequence of “auto control” mode is set as above mentioned requirements, a
reconfirmation is needed once every 3 months in case of any accidents like incorrect connection
of cables or software virus.
2. Random adjustment of solution concentration regulating valves is prohibited.
Otherwise it will cause crystallization, reduce cooling capacity and waste energy.
3.Manually drain condensed water in heating source pipe before starting the chiller. Close manual
valves on heating source pipe before chiller dilution off.
This will prevent water from leaking into the chiller when the pressure in the heating water pipe is
too high.
1.Anti-freezing protection for the chilled water tubes must be strictly carried out.
CONTROL
BROAD’s requirement of the 3-stage protection and interlock electrical diagram of the
chilled/heating water system must be followed to avoid maloperation, otherwise tubes will be
frozen. The 3-stage protection should be checked every quarter.
2.The chiller must be started by “auto control”.
There are some protection procedures under “commissioning mode”, but it can be used only
under the supervision of professionals, otherwise serious failure will occur.
3.The safety devices cannot be short-circuited nor their settings can be changed at will.
Before the cooling period begins, all the safety devices must be calibrated, especially the chilled
water flow switch, temperature sensor and HTG pressure control. Otherwise the copper tubes may
get frozen or serious personal injuries may occur.
4. Power supply must be right and voltage must be stable.
The fluctuation of the voltage must be within 10% of the rated value. A dedicated grounding wire
must be available in the machine room.
At least 6.0 mm2 wire must be adopted as the grounding wire, and the grounding resistance should
be ≤10ω, otherwise it will damage the electrical components and control system or even cause
personal injuries.
5. The electric wire must be reliable.
If electric wire damaged, the wire should be replaced by professional person for avoiding
danger.Otherwise, it will affect personalty safety.
6.The chiller must be on line 24/7/365.
To ensure collecting the data and monitoring the chiller, the chiller must be on line
24/7/365.Otherwise BROAD monitoring center will not know if the chiller is working normally. If the
chiller is to be put into idleness for more than 3 months, BROAD monitoring center must be informed
before power-off.
7.Computing data must be set correctly.
If the data are wrong, it will cause unexpected chiller shut-off and affect the user’s energy
management.
65
Waste heat recovery chiller safty regulations
1. Confirm the vacuum condition and good condition of auto purge & vent device according to
1. It is forbidden for the piping system to be vibrated or chiller to bear any external force.
OTHERS
Otherwise it may affect the chiller’s life-span, or even damage the chiller.
2. The chiller must be well kept.
The door and windows of the machine room must be installed with firm lock and baluster. No
access to unauthorized persons.
The shipped spare parts and documents should be well kept.
3. Humidity of machine room should be less than 85% with temperature ranging from 5℃to43℃.
If the temperature in the machine room is lower than 0℃, the inlets and outlets of chilled w. And
cooling w. System should be closed. Drain valve should be opened(if conditions permit, it is better
to add antifreeze instead of draining the water to avoid rust in the copper tube), otherwise the
copper tube will be frozen.
If the temperature in the machine room is over 32℃,machine room ventilation and control
cabinet cooling must be reinforced. If the temperature is over 43℃, electrical components
will be destroyed in hours and serious damage will occur to the chiller.
4. Stable equipment should be installed (offered by the users) at inlet of the heat resource;
make sure the pressure stable.
Fluctuation should be within ±0.02 mpa. Working pressure and temperature should not be 10%
higher than the rated.
5. Safety valve should be installed (offered by the users) at the heat source inlet pipe.
Make sure the pressure range between 110% and 130% of working pressure; and install the
safety valve at the outside, in order to avoid overpressure of the system.
6. The chiller should be installed at an elevation less than 1000 meter. Transportation and
storage temperature should be between -25-55℃
7. Maintain, operate and commission the chiller strictly following the “user’s manual” and
“service file”.
NOTE: This regulation is applicable to BS, BDS, BH, BDH, but for BZH, BZS “direct-fired
non-electric air con. safety ragulations” shall also be followed.
66
Waste heat recovery chiller main interface
Note: “﹡” indicates the work which can be performed by the user.
68
Saturated water vapor pressure(0~100℃)
Temp. Steam Temp. Steam Temp. Steam Temp. Steam Temp. Steam
℃ Pressure ℃ Pressure ℃ Pressure ℃ Pressure ℃ Pressure
50% 51% 52% 53% 54% 55% 56% 57% 58% 59% 60% 61% 62% 63% 64% 65%
concentration(mass%)
BROAD Town , 410138 ,
Changsha , China
BROAD central air conditioning has obtained all certification of Consultation www.BROAD.com
ISO,CE, UL, ETL, ASME, etc. Tel +86-731-4086688
+86-731-4086265 Fax 731-4611356