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user`s manual broad x generation non – electric chiller

1. Liquid 50 25 Crystallization 25 50 50 55 60 65 70 concentration Libr solution temperature density and concentration curves MISSION OF BROAD SERVICE ENGINEERS The mission of service engineers is to ensure there is no downtime occurring on chiller product even once during its life soan energy efficiency is not lower than 95 of its design level and air purification function of BROAD terminal remains its high level for lifetime To achieve this mission service engineers should love users and cherish the global environment All the engineers should understand that if a chiller shuts down it will cause users a great loss which may even exceed the cost of the chiller if the energy consumption exceeds the standard it will not only affect the users economic interest but also increase greenhouse gases as well 8 kilogram oil or 15 m3 natural gas or 19 KWH waste per year equal to cutting down a big tree which has annual 18 3kg CO2 absorption capability Besides the disabler of purification function will result in great expenses for users to buy purification device which have more value if the investment used to improve the users health All these situations will be completely against the users expectations on BROAD To achieve this mis
2. 13 Poor vacuum ja Sealing element aging a Replace b External vacuum valve is not closed tightly b Check and close tightly c Leakage caused during transportation c Conduct thorough leakage checking whereas leakage detection not and repair to the chiller performed at initial start or new d Remove the rust and eliminate the leakage occurred during operation leakage then repaint the leaking point d Leakage at welding seam caused or the whole chiller the chiller shall be by serious outside corrosion in vacuum when paint is applied e Auto purge and air vent device e Troubleshoot defective f Readjust the setting of HTG target f The chiller keeps running at high emperature to avoid HTG operating HTG temperature which generates at high temperature non condensable gases 4 Auto vent a Poor vacuum a Refer to poor vacuum eliminating method frequently b Incorrect or broken non condensable b Check and wire correctly probe wiring c Replace sealing elements c Vent valve stuck 5 Lack of anti a Anti scale agent runs out a Add anti scale agent scale agency b Level probe fault b Check or replace level probe 6 Lack of a Disinfectant runs out a Add disinfectant disinfectant b Level probe fault b Check or replace level probe 7 AC cooling ja Incorrect flow meter wiring or a Check and wire correctly hot water open short circuit b Check or replace flow meter flow meter b Flow meter damaged or fault c Eliminate s
3. NO Phenomenon Reason Solution 1 Pump head Pump is turned off or not powered Turn on the pump or connect it to the power on the unable to touch screen injection Improper output flow rate Set flow rate to 100 while injecting pump automatiedly Bottom valve doesn t stand on dosing tank bottom vertically Make bottom valve stand on dosing tank vertically straighten the suck pipe Connection seal ring distortion causes leakage Replace seal ring and tighten the connection properly Suck pipe leakage or air discharge incompletely Check if there is any split make the suck pipe vertical and vent the air completely 2 Output flow Rated pump pressure is lower than rate too small injection pipe pressure njection pipe pressure should be lower than rated pump pressure i eee Seal ring damaged Replace seal ring oesn F 7 A work under Dissepiments split l Replace of dissepiments pressure Stroke distance set improperly Check and adjust the pump to 0 position Bottom valve filter jam ake protection measures and clean the filter 4 functions valve abnormal and low pressure of injection point 3 Output flow rate too large Check 4 function valve set the injection point pressure o be gt 0 2MPa Stroke with high frequency Replace of the impulse generator or resistance 4 Can t work Pump is turned off or not powered urn on the pump or input power Pump ele
4. valve F28 condenser copper tubes necessary 26 9 Heating water drain Drains water in copper tubes of Open when while cooling valve F29 heating water heater 27 Hot water drain valve Drains water in hot water heater Open in cooling heating F30 copper tubes while hot water inlet and outlet valves are closed 28 Chilled water pressure Measures chilled water pressure Open only while valve F33 measuring pressure 29 Cooling water pressure Measures cooling water pressure Open only while valve F34 measuring pressure 30 Auto vent valve YA Vents air in system 31 Manual drain valve YC Drains water of cooling tower 32 Drain valve YD Drains dirt of cooling water filter 33 Make up valve YE Makes up water to water system 34 Make up valve manually Cooling water make up manually YF 35 Water system shut off Shut off cooling water system valve F8 36 Balance valve F17 Balance water distribution quantity of cooling tower NOTE This regulation is applicable to BZY BEY BDEY BZEY SENSOR LIST PART LIST NO Name Function Chilled water inlet temperature sensor m Detect chilled water inlet temperature for calculating cooling capacity and COP 2 Chilled water outlet temperature Detect chilled water outlet temperature to perform cooling load sensor T2 regulation to avoid froze
5. 2 90 2 50 2 30 2 02 1 80 6 39 5 65 5 02 4 50 3 95 3 50 3 12 2 65 2 45 2 19 1 92 6 75 6 00 5 35 4 75 4 35 3 73 3 35 2 85 2 63 2 32 2 05 7 23 6 40 5 70 5 18 4 50 3 96 3 55 3 15 2 82 2 50 2 20 7 65 6 75 6 05 5 45 4 75 4 25 3 80 3 35 3 00 2 65 2 35 8 23 7 35 6 47 5 75 5 15 4 50 4 05 3 57 3 22 2 85 2 55 2 22 8 65 7 65 6 82 6 15 5 39 4 80 4 35 3 82 3 45 3 05 2 72 2 38 8 94 8 15 7 26 6 50 5 80 5 20 4 65 4 15 3 70 3 25 2 85 2 53 975 8 65 7 79 6 95 6 25 5 40 4 85 4 36 3 90 3 45 3 05 2 73 0 20 9 23 8 25 7 35 6 60 5 75 5 20 4 65 4 15 3 70 3 25 2 88 1 00 9 84 8 75 7 80 6 98 6 20 5 50 4 90 4 40 3 95 3 50 3 10 12 75 1 79 0 23 9 30 8 35 7 42 6 51 5 85 5 25 4 70 4 20 3 75 3 30 12 90 2 41 1 00 9 80 8 80 7 90 6 95 6 25 5 55 5 00 4 45 3 95 3 52 3 13 3 10 1 78 10 50 9 40 8 42 7 45 6 70 5 85 5 30 4 75 4 20 3 75 3 35 3 95 2 60 11 20 0 00 8 97 7 85 7 15 6 35 5 60 9 15 4 50 4 00 12 45 3 25 4 79 3 15 11 80 0 55 9 50 8 40 7 50 6 65
6. 6 05 5 40 4 75 4 25 3 80 3 45 5 55 4 00 12 50 1 15 0 00 8 90 8 00 7 10 6 40 5 75 5 10 4 65 4 15 3 68 6 30 4 85 13 20 1 80 0 55 9 40 8 50 7 50 6 75 6 15 5 40 4 90 4 30 3 90 3 45 7 20 5 55 14 00 2 50 1 20 9 95 9 00 7 95 7 20 6 50 5 75 5 20 4 65 4 15 3 75 8 30 6 30 14 80 3 20 1 95 10 60 9 50 8 50 7 60 6 85 6 15 5 50 4 85 4 38 3 95 9 50 7 25 15 75 4 05 2 65 1125 10 00 9 00 8 20 7 30 6 50 5 85 5 25 4 70 4 25 20 72 8 28 16 50 4 85 3 45 11 95 10 70 9 50 8 70 715 6 85 6 20 5 60 5 00 4 51 21 70 9 25 17 40 5 70 4 15 12 75 11 25 10 00 9 15 8 20 7 40 6 65 5 95 5 35 4 72 22 75 20 20 18 50 6 50 4 95 13 40 11 85 10 50 9 60 8 70 7 80 7 00 6 30 5 65 9 15 24 00 21 25 19 50 7 50 5 85 14 15 12 65 11 15 10 20 9 20 8 25 7 50 6 70 5 95 5 40 4 85 25 20 22 25 20 30 8 50 6 70 14 95 13 20 11 85 10 85 9 75 8 75 7 90 17 15 6 35 5 70 5 20 LIBR SOLUTION PERFORMANCE CURVE LiBr solution crystallization curve temp Co 75
7. vent valve pa ON Start OFF Dilution 65 IFA SAFTY REGULATIONS z 1 When the chiller is started for cooling operation the chilled water pump must be started Q before the cooling water pump If the chilled water pump stops the cooling water pump 1 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 out in the above mentioned a requirements a reconfirmation is needed once every 3 months in case of any accidents like Q incorrect connection of cables or software viruses occur 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 Q BROAD s requirement of the 3 stage protection and interlock electrical diagram of the 5 chilled heating water system must be followed to avoid poor operation otherwise tubes will O be frozen The 3 stage protection should be checked every quarter 2 2 The chiller must be started by Auto Control There are some pro
8. 6 Strengthen water quality management Auto water quality stabilizer charging device should be installed auto dosing of biocide and anti sludging agent The water should be tested 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 corrosion of copper tubes or even destroy the chiller VACUUM LIFE SPAN 13 DEA SAFETY REGULATIONS 1 Anti freezing protection for the chilled water tubes must be strictly carried out Q BROAD s requirement of the 3 stage protection and interlock electrical diagram of the chilled heating water system must be followed to avoid poor operation otherwise tubes will be frozen The 3 stage protection should be checked every quarter 2 The chiller must be started in 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 can their settings 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 become frozen or serious personal injuries
9. A BROAD service engineer should help the user to check if the machine room installation drawing conforms to national codes and BROAD catalogue requirements and offer written advice in this regard Jobsite commissioning A BROAD service engineer checks the user s system against the System Check amp Accept Form and conducts the commissioning for the chillers which pass the reception check for user s systems which fail the check and accept process a BROAD engineer will issue a written rectification requirement document Commissioning cannot be done until the commissioning requirements are met After the commissioning the BROAD service engineer hands over the chiller management to the user Training Training is divided into 2 types Training in BROAD Town or training on jobsite Centralization training in BROAD town will be done by BROAD engineering institute the training has three levels operator senior operator operating engineer BROAD service engineer shall train operators at jobsite about onsite operation maintenance energy saving and management during commissioning or maintenance Operators who have already received BROAD training and obtained the qualification can operate the chiller independently Centralization training process BROAD Training Statistic Notice Feedback Training Registration Notice Training gt Training evaluation Get level qualification Credit cer
10. Cooling fan blade Replace 0 Cooling fan motor Replace 1 Butterfly valve Replace 2 Ball valve Replace 3 Motor valve body Replace 4 Control cabinet Replace cabinets PLC modules circuit breakers relays contactors 5 Water softener Replace valve control components air valve resin tank 6 Soft starter Replace 7 Gas oil flow meter Replace 8 Auto dosing devise Replace dosing pump 9 Wires of whole control panel Replace MAINTENANCE LITHIUM BROMIDE SOLUTION b Maintenance of the precision filter FILTERING 1 Cleaning The filter element should be back washed a Solution filtering to restore infiltration and filtering function The solution must be filtered under the following two conditions 1 during chiller commissioning 2 the solution is observed to be turbid from the sight glass In this case at least one week filtering is required until the color of the solution in the inlet outlet of the precision filter is the same 1 Installation of the precision filter The filter should be installed vertically hanged at the right position on the chiller and fixed reliably with a separate bracket 2 Operation of the precision filter Recycle the solution inside the chiller adequately before filtering and sample 50 ml of solution for storage Install the valve and flexible tube as per filtering sketch See next page lock with 2 level clamp collar and reinforce the connection with steel wires to prevent it
11. Gas Valve Gas HTG and drain valve W inlet drain valve Burner train inlet enclosure Rear flue HotW HotW Heating HotW Heating Steam angle Auto purge chamber heater outlet W inlet inlet W heater valve vent system Chiller control cabinet Flame sight glass Hot W relief valve Heating W relief valve Heating Inverter cabinet W drain valve Diluted Hot W HTHE Concentrated solution drain Diluted solution sampling solution angle angle valve sampling valve valve valve valve 15 PRODUCT OVERVIEW Hot W Heating W thermostatic thermostatic Heating W valve valve check valve Rupture A Chilled W 4 Ugg o AC W cooling heating switch valve Softener brine tank Hot W Softener pump control valve Softener resin tank AC W check valve header AC W pump AC W check valve header Cooling pump A C W 0 resistance filter A gt 7 7 HOW meter Cooling W 0 N P s g Ta resistance filter Hot W Drain part Distribution system control Cooling W m cabinet flow meter AC W flow meter Cooling W Auto stabilizer agent for anti scale AC W drain drain valve drain valve and anti rust valve Biocides 16 MAIN PART UST PART UST NO Name Function l H T G Use burner heat to concentrate H T G diluted s
12. and open the valve to discharge the Li2MoO4 solution users can sample solution 50ml of LiBr solution and send post it Close the valve clean the valve nozzle to BROAD for testing The testing is free with water and dry it then put back the during warranty period cork 3 Requirements for sampling solution Negative pressure sampling Applicable to Start the solution pump and let it run for 10 sampling locations with negative pressure minutes when the chiller is off or in a total or unknown pressure status diluted off state Wait until the solution is Take a sampling bottle and 2 rubber completely blended Sample according vacuum hoses Connect one end of one to the procedures described in C rubber hose to the purge nozzle of the 4 If the testing result of Li2CrO4 solution can t sampling bottle and the other end to be determined immediately on the site the sampling purge valve Use the other or the user requires a more detailed and rubber hose by connecting one end to professional testing report the user can a sampling nozzle of the bottle and the sample 50ml LiBr solution and send post other end to the nozzle of the sampling it to BROAD BROAD headquarter will valve provide a more detailed and professional esting report NOTE Make sure the connection hose is 5 Procedures for sending the solution reliable and has no leakage Start the vacuum pump open the main purge valve and the sampling purge valve in turn to purge t
13. or Chilled water a Air or dust clogged in pipes of a Vent air or drain and clean heating outlet inlet air conditioning system he filter capacity temperatures b Filter of air pipes blocked b Remove and clean filter cannot be are both low or c Some valve closed or screen c Replace or check achieved high and poor clogged d Increase the opening to air conditioning d Hydraulic equilibrium hose pipes without enough effect improperly adjusted cooling capacity decrease e Terminal volume too small o the sufficient ones e Add more terminals 3 Pump Pump outlet a Filter clogged a Remove and clean filter outlet pressure is much b There is leakage or lack of b Make up water or check the pressure higher or lower water in the system leakage abnormal than normal c Copper tubes clogged or c Open water cover quickly scaled o eliminate hidden troubles d Pump outlet inlet valve or Will cause frozen copper check valve is not completely ubes if problem is not solved open or screen clogged in time e Air locked in pipes d Open fully or check valves e Vent air 4 Severe Pressure gauge a Lack of water causes pump a Make up water vibration index wiggles cavitation b Refix or make new support to pressure with large b Pipe support is not firmly fixed after chiller is off gauge in range and high c Pump foot bolt is loose c Tighten immediately pipes frequency d Power supply phases are d Stop the chiller immed
14. 78 327 3 99 733 2 6 3 63 37 47 07 58 136 1 79 341 0 100 760 0 7 4 53 38 49 65 59 142 6 80 355 1 8 5 48 39 52 44 60 149 4 81 369 7 9 6 48 40 55 32 l 150 4 82 384 9 20 7 54 41 58 34 62 163 8 83 400 6 SATURATED STEAM PRESSURE FOR LIBR SOLUTION 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 2 37 2 09 1 84 1 62 1 42 25 09 2 60 2 25 1 99 1 73 1 62 35 18 04 2 70 2 38 2 11 1 88 1 72 AA 27 12 2 90 2 55 2 26 2 05 1 78 55 37 20 1 05 3 10 2 73 2 42 2 13 1 90 67 A8 28 1 15 3 35 2 95 2 61 2 30 2 05 81 7 38 1 24 3 60 3 15 2 81 2 45 2 20 93 69 50 1 33 15 3 87 3 35 3 02 2 65 2 33 2 05 81 61 1 42 25 4 23 3 60 3 20 2 89 2 50 2 19 94 71 1 52 34 4 35 3 85 3 42 3 05 2 65 2 35 2 09 85 1 62 AA 4 70 4 18 3 65 3 25 2 88 2 51 2 22 2 00 1 75 56 4 85 4 45 3 95 3 45 3 05 2 72 2 39 2 13 1 88 67 5 25 4 70 4 22 3 70 3 25 2 88 2 45 2 24 2 00 J 5 65 4 95 4 45 3 95 3 45 3 07 2 65 2 32 2 12 90 1 69 5 96 5 35 4 71 4 35 3 70 3 30
15. Check the brine tank when starting model Res etc ip witcien ret H type total Inlet water hardness it for the First time please add water quantity Cocoa to empty brine tank till the water level L mg Ca GT U is 30mm higher than brine y board 150 200 250 300 350 400 water input automatically after BRS 2 150 25 19 15 13 11 9 operation and add industrial brine BY75 100 200 42 31 25 21 18 16 NaCl till it reaches 2 3 of tank Make BY125 150 sure the brine remains more than 1 3 of BRS 6 hice 7A 96 49 3832 28 the tank capacity BY200 650 108181 165 54 46 41 c Discharge the air in resin tank Make BY250 sure the control valve is working RST 117 88 70 58 50 44 normally turn on power open inlet BY300 400 1050 175 131 1105 88 75 66 valve inject water to tank Close inlet BY500 600 valve after water stop running rotate BRS 20 1550 258 194 155 129 111 97 the manual regeneration tray refer to z flow rate controller drawing and adjust the control valve to reverse washing program position refer to regeneration controller drawing to release pressure then open inlet valve slowly to drain out the air in tank Repeat the process on the other tank to vent out the air NOTES BY matches package chiller machine room shipment with pipes BRS for non packaged chiller machine room shipment without pipes 3 Setting Pull out the flow rate tray rotate it and make the white point on the tray targeting
16. HOT WATER Make sure the chiller is in cooling mode the hot water drain valve is closed with the shut off valve open and the hot water system is full of water system is full of water HEATING AND HOT WATER Make sure the chiller is in heating mode the hot water drain valve is closed with the shut off valve open and the system is full of water HOT WATER ONLY a The same as Heating a b Make sure that the hot water drain valve is closed and heating water drain valve is fully open c Make sure that the hot water shut off valve is open and the system is full of water OPERATION WATER SYSTEM SELECTION BZY150XD 2007 08 22 CE1 BROAD X BZY Setting Wednesday 19 30 33 Chilled heating Hot W pump W pump Monitor 7 5 R 1 Selection 2 Selection 1 Selection 2 Selection 1 Cancel 2 Cancel 19 Cancel 2 Cancel Check up quality stabilizer pump Anti scale Disinfectant pump pump Cancel Cooling pump e it satection 26 Selection 1 Cancel 2 Cancel 16 Inverter Cancel Cancel Cooling W Cooling Fan system Valve 16 sanal 2 Selection 1 Cancel 2 Cancel 6 Cancel 3 Selectin 4 Selection Profession Drain W valve Cancel 3 Cancel l 16 Cancel Energy saving Time on ode setting Press Water System Choice on the Setting in
17. Hour Cop de Daily Cop il ON start OFF Dilution GENERAL INFORMATION 2007 08 22 Wednesday 19 30 16 Cooling l zapacity X 125 100 a 30 TB SE 17 30 25 0 TOUCH SCREEN Turn on the main interface of the chiller Directly enter monitor main interface START Press the ON start which will turn green after confirmation the A C water pump and cooling water pump will start automatically according to procedures The chiller starts operation with automatic cooling load regulation and safety protection after chilled water and cooling water flow rate are acceptable SHUT OFF Press OFF Dilution the burner steam valve will close and the chiller enters automatic dilution cycle HTG temperature will drop gradually while the chilled water temperature rises The dilution stops and chiller shuts off when shut off requirement is met the process normally lasts 30 60 minutes NOTE Nails or other sharp objects shall not touch the screen surface 2 Clean the surface with a wet cloth Alcohol or other organic solvent are not allowed 3 The professional interface is only open to BROAD service engineers GENERAL INFORMATION ALARM NOTICE BZY150XD 2007 08 22 O BROAD X BZY COOLING Wednesday 19 30 12 lt ay A x Status Setting O Refrigerant MiG solution eas level Chilled Heati 125 ue 68 DTO p E R 100 ar 14 3 E D Cooling
18. Make sure there is no gas leakage Gas fired chillers are not allowed to work if the gas leakage detection device and force fan linkage are not in reliable control 3 Make sure there is no exhaust leakage In case of exhaust leakage in machine room the operator will suffer from CO posioning 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 types and1 13 1 20 for oil fired types Otherwise even a small amount of smoke will increase fuel consumption dramatically pollute the environment and even cause fire If the Excessive Air Coefficient is too large it will cause deflagration and even stop the burner and waste fuel 6 Gas pressure and fuel heating values must be stable and fuel quality must meet the local standards Otherwise it will cause soot in the fire tubes increase energy consumption affect cooling capacity The burner might be damaged even cause deflagration if it is serious 7 The exhaust damper must be full open before chiller start and full close when the chiller stopped for long time BURNING Confirm the vacuum conditions and good condition of the auto purge and vent device 2 Prevent others from handling the va
19. all switches respond swiftly and reliably Visual Inspection Small Screw driver Canned Pump No abnormal sound when the pump is running and the rotary direction is correct The current should stay within the nominal range Insulation resistance 20 5 MQ Surface temperature rise is lt 60 C when the motor is in operation Multi meter Infrared Thermometer PLC module Check if PLC signals are consistent with touch screen display Visual Inspection FAULT AND TROUBLESHOOTING FAULT TYPE There are four different types of faults fault stop fault alarm abnormal reminding and abnormal record The touch screen will indicate when the first three types occurred a Fault stop Emergency repair is needed when fault stop occurs during chiller operation The chiller will enter dilution shut off cycle immediately and this type of fault must be dealt with in a timely manner otherwise it will lead to chiller stoppage and possibly cause a safety accident The chiller can only be started only by manual reset after all faults are cleared b Fault alarm The alarm is sent out and the chiller remains in operation but the fault should be solved and reset within 24 hours or the chiller will upgrade to ault stop When such faults appear the chiller will remain in operation and continuously alarming Some ault alarms such as burner chilled w Pump cooling w Pump and so on will reset automatically
20. conditions it can be canceled if the Chiller is stopped for a long time with power on or under other special situations OIL GAS SELECT An option for a dual fuel burner to be chosen according to fuel type OPERATION INFORMATION BZY150XD 2007 08 22 O BROAD X BZY Information Wednesday 19 30 45 Monitor Setting Check up Expense Chiller Service Check PLC H 9 English Help information infromation Press Information to enter Press Chiller Information to check user code chiller model rated chilled water temperature program version and other parameters Press Service Information to check BROAD head quarters branch offices and service engineer s hotline numbers Press Check PLC to check PLC s input signals Please see the above chart Press 0 O English to change the language OPERATION ENERGY COST BZY150XD 2007 08 22 BROAD X BZY Expense Wednesday 19 30 45 Monitor Consumption Expense Setting oil A ko G D Gas ggr BI n 2566 9 Check up Water m 145 2 lectricity 682 2 kw 476 5 Expense Total 3188 2 Information Yesterday s cost 23126 r This month cost bA 16 Profession last month cost LC 65646 oe This year cost last year cost 251685 Press Expense to check the fuel water electricity consumption and operation cost Fan coils excluded DEA SAFETY REGULATIONS When the chiller s
21. connect the wires hot w outlet open short circuit correctly cooling w Inlet b Temperature module damaged b Replace temperature module emperature c Temperature sensor damaged c Replace temperature sensor s sensor fault 2 HTG super high ja PLC control failure a Check PLC control system emperature b Excessive deviation in HTG temperature b Replace sensor c Check or replace c Temperature control abnormal d Check and recover the d Inadequate vacuum vacuum 2 HTG solution a Aging of upper and lower coating of a Replace solution probe s upper evel control solution level probe leads to short circuit and lower cover fault b Incorrect solution level control or level b Check and connect the wires probe wiring correctly 33 FAULT AND TROUBLESHOOTING cont NO Fault Cause Keys 4 Cooling water a Cooling water pumps stop a Check cooling water pumps off b Cooling water system lacks water or filter power supply and reset severely clogged b Add water vent air from c Cooling water outlet inlet closed or pipes or clear the filters damaged c Check and open valves or d Flow switch es improperly set or damaged replace them d Readjust or replace flow es 5 Burner fault a Incorrect fault feedback wiring or open a Check and connect the short circuit wires correctly b Burner fault b Refer to burner manual 6 Ignition fault ja Incorrect fault feedback wirin
22. energy efficiency Load Maintenance can be classified into three categories high load medium load and low load 1 High load users HTG temperature is always above 150 C typically district cooling process cooling luxury hotels hypermarkets etc 2 Medium load users HTG temperature is always within the range of 140 C to 150 C typically shopping malls ordinary hotels theatres clubs hospitals etc 3 Low load users HTG temperature is always below 140 C typically office buildings government buildings schools gyms etc Maintenance should be completed on the following items once every 2 months for high load 3 months for medium load and 6 months for low load NO Items Method 1 Check the a Check the running fault and energy consumption records of the chiller record and b Inquire analyze the user s energy consumption and give energy saving feel the air suggestions to the user conditioning c Check the running status of the chiller and terminals and feel the air conditioning effect effect in different areas 2 Observe the a Whether or not the burner starts and stops frequently operation b Observe for at least 30 minutes to check if the HTG solution level fluctuates and check abnormally and noisily parameter c Whether or not the refrigerant level goes up abnormally setting d Whether or not the cooling capacity of the chiller decreases and the energy consumption increases e Check wheth
23. in cooling tower the water system or water was 3 Improve the machine room anti freezing not drained out in the copper condition If the temperature is lower than tubes when the temperature in 0 C antifreeze must be added or the machine room was less than 0 C water in the copper tubes be completely drained NOTE Indicates work which can be performed by the user FAULT AND TROUBLESHOOTING cont NO Fault Cause Keys 3 Chilled a Chilled water pumps stop a Check chilled w pumps power water off b Chilled water system lacks water or filter supply and reset it severely clogged b Add water vent air from pipes c Chilled water outlet inlet valves closed or or clear the filters damaged c Check and open valves or d Flow switch s improperly adjusted or replace them damaged d Readjust or replace switch es 4 Insufficient ja Actuating value of flow switch is improperly ja Readjust chilled water adjusted b Replace flow b Flow switch damaged c Check the wiring c Open circuit or loose contact with flow d Regain the chilled water flow switch es by following methods d Insufficient water flow 1 Repair or replace Chilled water valve damaged 2 Repair 2 Chilled water pump fault 3 Clean filter 3 Chilled water system filters seriously blocked 4 Refill the water and vent air out 4 Air is not totally vented out of the chilled water system 5 Chilled w a Incorrect temperature sensor w
24. may occur 4 Power supply must be correct 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 a 6 0 mm2 wire must be used as the grounding wire and the grounding resistance should be lt 4Q otherwise it will damage the electrical components and control system or even cause personal injury 5 If the 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 or not 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 an 1 Do not place heavy objects on or near the automatic pressure escape a Otherwise there is a danger of explosion 2 Piping system vibration is forbidden and external force is not allowed onto the chiller O Otherwise it may affect the chiller s life span or even damage the chiller 3 The user should install a lightning proof device for the equipment 4 The chiller must be wel
25. piles up inside softener b Clean control valve and add cleaning c Block of control valve inlet agent into resin layer to increase regeneration frequency c Remove the piston and clean control valve 8 Resin flows a There is air inside the system a Make sure the air check valve in brine pit away through b Draining amp current limiter functions well draining pipe improper b Replace draining amp current limiter 9 Softened water Resin layer is contaminated Check backwashing brine absorption and has irony stuff water injection in brine tank to increase regeneration frequency 10 Regeneration Micro switch failure or short circuit Replace the switch or timer if they fails to functions work or replace the whole controller if the repeatedly problem remains SERVICE INFORMATION SERVICE RESPONSIBILITY Maintenance and operation of central air conditioning should be conducted by BROAD service engineer and user s operator a BROAD service engineer Givesguidance for lifting installation checking and accepting the chiller takes care ofthe operation repairing maintenance and energy saving operational guidance of the chiller Operator Assists the service engineer takes care of the operation simple maintenance and energy saving operation of the chiller and system Senior operator Assists the service engineer takes care of the operation maintenance simple trouble shooting manages and instructs operator on
26. the control valve and inlet outlet pipe Anti freeze in winter 1 When the temperature in machine room is lower than 0 C or the softener is left unused for a long time it is necessary to regenerate the resin then fill the tank with brine after washing Replace the brine when start it next time to avoid resin dehydration phycomycetes breeding and freeze 2 Drain out all the water in softener pipe when doing the anti freeze 61 WATER TREATMENT DEVICE Faults and troubleshooting NO Fault Reasons Troubleshooting phenomenon 1 Softener a Power fault a Check and troubleshoot irregeneration b Timer fault b Change the timer Regeneration 2 Softener a Bypass valve not shutdown a Close bypass valve invalidation b No brine in Brine tank b Add brine into the brine tank to keep c Insufficient of water brine level above the water level d Leakage of Central tube c Check the water injection time and clean e Valve inside leakage brine adsorption device f Actual softener working output d Check and replace the seal ring water capacity is lower than flowrate distributor and central tube set value e Replace seal ring gasket and piston g Procedure gear doesn t work f Check brine consumption calculate the while Flowrate output periodic water output and adjust it h Flowmeter doesn t work g Extract soft axis from flowmeter rotating i Control valve not in working flow tray should be rotated flexibly posit
27. time and output volume then calculate output per second ml s inserts the result to Dosing speed on operation screen 6 If there is deviation of output value adjust the flow rate switch on the adjustment panel Normally adjust stroke distance Repeat step 3 5 till the output matches the requirement T Dosing pump Graduated flask Bottom valve Demarcating drawing USE a Put the medicine Shipped together with chiller into anti fouling tank white and sterilization tank yellow b Make sure dosing pump inlet outlet pipe tightly connected to the connector Insert backflow pipe into dosing tank and fix it do not immerse pipe connector into the solution c Set manual dosing time dosing concentration dosing speed dosing internal time through water system specifications on chiller operation screen Set dosing concentration according to cooling water hardness dness gt 120mg I 60 120mg I lt 60mg I Anti fouling O0ml m 50ml m 40ml m agent Bacteriacide Normally set 100ml m UO JOUBDUOS F Manual dosing time set according to cooling water pipe and cooling tower water storage quantity and dosing speed Dosing time s cooling water storage quantity m x dosing concentration ml m dosing speed ml s WATER TREATMENT DEVICE MAINTENANCE a Dosing tank cleaning 1 Release pressure of the dosing pump and outlet pipe Confirm the injection
28. to set flowrate d Total flow rate setting softening water output from the softener between 2 regenerations unit ton value and then loose the button to original position Regeneration will start automatically when the tray point to settled value position r 5 WATER TREATMENT DEVICE e Regeneration time setting Rotate regeneration button clock wise and make the micro adjustment switch points to 0 position the regeneration will start automatically after a sound refer to regeneration controller drawing Regeneration time is set in factory but can be reset according to user s demand and local conditions 1 Backwashing time setting The first group of pins decide backwashing time and the time is changed by increasing or decreasing number of pins 2 Brine suction amp slow wash time setting The first group holes decide brine suction amp slow wash time and the time is changed by changing the hole number 3 Fast wash time setting The second group pins decide the fast wash time Change time by changing pin position Usually backwashing amp fast wash time is set to be 10 minutes decreased by 2 minutes when water inlet pressure 20 5Mpa 4 Brine tank water adding time setting The second group holes decide water input time Change the time by moving the third group pin to change the number of second group holes Model Slow wash time Water input type mi
29. to wash c Check ambient conditions air flow humidity check if the sealing of the connections is good or not and if cable joints and fasteners are loose or not d Check whether or not the grounding is good whether there is any interference or anti interference influence 13 Filter header Drain water and clean up filter and impurities in the boxes and outlet box Softener a Brine level should reach 1 3 of the brine tank otherwise add industrial brine lodized brine and powdered brine should not be used otherwise they will affect the performance and life span of the exchange resin b Check and clean the filter of the inlet Make sure that water pressure is not higher than 0 6MPa c Make sure the ambient temperature is above zero and inlet temperature is below 40 C d Check the quantity of resin and make up the resin around 5 10 every year e To avoid anti dehydration freeze and breeding germ of germen the resin you should fill up with brine when the equipment is not in use Automatic dosing device a Inspect records of adding and quantity of the chemicals add some if insufficient Note To avoid direct contact with the chemicals please take protective measures such as wearing masks gloves and safety glasses b Check the strainer of the chemicals supply valve on the bottom of tube and clean if dirty Cleaning procedure disconnect the tube connections which are connected with the anti sludging pump or bioci
30. vacuum 58 angle valve F4 if necessary valve 3 5 Diluted solution angle heating mode should be 52 valve F5 closed 100 closed 4 cZ HTG concentration Regulates HTG solution Tighten the setscrews lt s E A 2a regulating valve F6 concentration after regulation No 5 Q ub LTG concentration Regulates LTG solution random regulation gt 5 regulating valve F7 concentration Belongs to vacuum valve 6 Refrigerant sampling Take out refrigerant concentrate Commissioning use 3 valve F9 solution check pollution degree of gt refrigerant 7 2 LTHE sampling valve F10 LTG concentrated solution sampling 8 Z HTHE sampling valve F11 HTG concentrated solution D sampling 9 S Diluted solution sampling Solution 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 12 HTG purge valve F15 Purge the HTG directly through this Open only while purging valve HTG 13 Sampling purge valve Purge the sampling bottle or check Open only for sampling F16 he vacuum with the vacuum meter or checking vacuum with vacuum meter 17 PART UST cont NO Type Name Function Remark 4 Main shell pressure Checks main shell pressure Closed in operation Z detecting valve F18 open
31. whether the operation is flexible and etector i gt P whether it retrieves when the flow is above Check by opening 2 years 70 of the rated Er Bon cover When the chilled W 3 stage flow controller 13 Inverter 3 months is in protection status check whether it stops 14 Electrical system and 3 months cooling W pump after PLC or not Check componens whether water pump starts cooling W pump after starting A C W pump and whether it can only stop A C W pump after stopping cooling W pump 23 PERIODIC CHECK COMBUSTION a Burner operation check Whether the burner operation is stable or not directly determines the chiller s operational stability Therefore a weekly check up on burner operation is necessary The check up method is as follows 1 Observe the flame through flame sight glass on the rear flue chamber The flame should be stable with normal color For gas the flame color should be light blue with red in the middle For oil the color should be white red color 2 Observe the burner ignition and fire stage change The flame should be stable without deflagration b Flame Detector Check amp Cleaning The Flame detector is a component which is used to detect whether the flame is normal or not when the burner is running and it is therefore one of the most important safety protection devices of the burner Excessive resistance caused by the flue duct poor oil quality large fluctuations
32. 1 temperature emperature between 26 and 28 C C lower 4 Keep the chiller f the stop time of the chiller is less than Achieve greater reliability higher running continuously 3 hours it is recommended to keep the efficiency and more stable burner chiller running combustion by running chiller continuously at partial load 5 Scientifically f the room can be maintained at a Improve chiller efficiency with higher adjust the chilled comfortable temperature then set the chilled water outlet temperature heating water outlet chilled water outlet temperature higher or lower heating water outlet temperature in summer and heating water outlet temperature emperature lower in winter 6 Select Energy Refer to P Energy Saving Setting The same as above Saving Mode 7 Strengthen Refer to P22 AC Hot Water Quality and Ensure high heat exchanging water quality Fouling and P23 Cooling Water Quality efficiency management and Fouling SYSTEM ENERGY SAVING MANAGEMENT NO Item Method Effect 1 Use inverter control for cooling water pump and cooling fan Add inverters for cooling water pump and cooling tower fan and get them inkage controlled with the chiller This will also help to maintain cooling water emperature Save 50 to 70 electricity consumption which amounts to 12 to 20 of the total running cost of chiller and system management 2 The customer who needs Introduce a
33. 3 spray gets clogged g Check respectively the 3 heating or refrigerant inverter cooling switch valves the steam goes out of control angle valve must be fully open j Refrigerant loss h Refer to item 4 of this chapter k Comprehensive solution i Backwash or flush R pump filter concentration is too low Wash spray device when necessary Fouling in copper tubes Conduct accurate commission to m Combustion volume is R pump inverter too small j Check and fully close the refrigerant n Soot in combustion bypass valve Make sure the refrigerant chamber and fire tubes anti overflow control is reliable o Hot water is k Drain part of the refrigerant water to overloaded increase comprehensive concentration Clean the copper tube fouling Detailed plan is subject to BROAD written approval m Readjust burner and increase combustion volume n Clean the exhaust soot and readjust the burner using exhaust analyzer o Adjust according to specific condition 2 Heating Heating water a Combustion volume is a Check for clogged fuel system capacity hot water too small filters Readjust burner to increase lower than temperature b Scaling in water heater combustion rate the rated cannot be copper tubes b Clean the copper tube fouling increased c Soot in combustion Detailed plan is subject to BROAD Outlet inlet chamber or fire tube written approval temperature d Poor vacuum c Clean soot Find the root cause and difference e Level
34. 32 9 C CUP Burner High fire HIG solution level C Refrigerant level R pump A pump 1 Chilled Heating W pump 2 Chilled Heating W pump 2 Cooling W pump CA Control cabinet fan C e eA e Disinfectant pump CG Anti scale pump CG Vent pump CG Maintenance record 2007 08 22 Wednesday 19 30 43 Energy saving Ho Timing on RH Z Timing off EEH Energy cost dollar Oil Gas Rater Electricity Total Yesterday This month Network Auto vent BAS Operation time modbus Parts remain time Press Running Operation to check chiller s real time parameters status time function control mode temperature frequency solution level burner status etc Press Operation Record to check historical data select Today Yesterday and The Day Before Yesterday to check three days records Press Print to print out the records a special printer is needed Press Fault record to check fault stop fault alarm and abnormal reminders Select the corresponding fault item to further checking the fault information The fault can then be resolved by the hints Press Maintenance Record to check maintenance frequency and schedule A reminder notice will appear on the main screen 168 hrs before the deadline of the current maintenance Press Operation Time to check the accumulated
35. AD monitoring HTG solution level should be stabilized at center zone C in cooling operation The stability of 8 Solution year the HTG solution level relates directly to the 9 Package Softener check FENA stability of operation and even the life span pumps Auto water man of the chiller So during cooling operation treatment plant regular examinations for 3 hours for the check complete start up to shut down cycle of Pump check month the chiller need to be performed 3 times 10 Cooling Water level check amp 1 week per melon Momanier how theexternal auer adjust load varies the HTG solution level should be z tabilized at zone C check Fan check amp adjust year Distributor check year and adjust FLOW METER 11 AC and Check by scale 6 months Check that the value of chilled water hot water detector or soft cooling water and hot water flow rate on quality connector display is normal If it is not within the normal and scale Check by opening year range check that the flow meter is installed water box cover according to specification the battery is 12 Cooling Water quality month normal the pipes are clean there is no air water analysis inside the pipes etc quality Cooling water and year and scale circulation system CHILLED W 3 STAGE PROTECTION cleaning S Check whether 3 stage chilled water Wallet system filter yeas flow controller is in protection status when cleaning N P Check by seals zea chilled water flow is below 60 of the rated d
36. BROAD X GENERATION NON ELECTRIC CHILLER 233kW 11630kW 20 1000RT USER S MANUAL Aug 2012 EN Please read this manual carefully to ensure proper operation and maintenance of the chiller Only those who have been trained by BROAD and obtained operator qualifications can operate BROAD chillers 2 This manual should be kept for the duration of the chiller s life 3 If there are any technical improvements to this product we will inform you in a timely manner so as to facilitate your upgrading the technology of the chiller 4 It is prohibited to change the chiller s component structure and wiring diagram without BROAD s approval 5 Chiller operation environment requirements Machine room temperature 5 43 C Relative humidity lt 85 Environment The chiller should be kept away from dusts corrosive gases especially brines and strong acid or alkaline environments Vibration should also be avoided inside and around the machine room 6 Do not install the touch screen in the place where temperature or humidity varies than the recommended ratings so as to avoid condensation and freezing CONTENTS General Information pee eee eee eee eee eee reer rete etree eee eer eee 01 Operation eee 04 DFA Chiller Safety Regulations P 13 Product Overview Pee eee ee eee eee ee eee eee ee eee eee eee 15 Part List Pee eee eee eee eee eee eee eee ee eee eee eee eee eee eee ere etree eter eee errr ees 17 W
37. ER NO Fault Phenomenon Causes 1 Abnormal a Fan improperly balanced a Check balance noise and b Blade end touches the tower body b Adjust 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 too a Fan blades are not at the same angle a Adjust to the same angle 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 water Ja Insufficient air flow a Check and adjust strap adjust fan temperature b Vented hot air enters tower blade angle rising c Absorb less air b Improve ventilation condition d Dirty filling causes asymmetric c Improve ventilation condition distribution d Clean e Distribution system abnormal e Clean sundries f Strap is too loose or broken f Adjust or replace strap 4 Cooling water a Water collector level too low a Check adjust auto make up and fast amount b Filter screen clogged make up system decreasing c Insufficient water pump flow rate b Clean c Repair or replace 5 Asymmetric ja Sprayer or distribution pipe broken a Check damaged parts clear out distribution or clogged sundries and
38. No reaction Cl lt 0 05 NH4 lt 0 0001 S042 lt 0 02 Ca2 lt 0 001 Mg2 lt 0 001 Ba2 lt 0 001 Fe3 lt 0 0001 Cu2 lt 0 0001 K Na lt 0 06 Organic None Transparency Clear transparent visual Lithium molybdate type solution receiving data from PLC successfully Sm Standard ACT light Glints at a constant speed when LiBr 40 50 52 53 55 0 5 exchanging data through users LAN Li2MoO4 ppm 170 20 successfully Alkalinity N 0 05 0 2 LNK light The light is on when LAN is BrO3 No reaction connected to internet successfully Cl lt 0 05 POWER The light is on when the chiller is NH4 lt 0 0001 light powered on successfully SO42 lt 0 02 PPP light Ca2 lt 0 001 Mg2 lt 0 001 Ba2 lt 0 001 Fe3 lt 0 0001 Cu2 lt 0 0001 K Na lt 0 06 Organic None Transparency Clear transparent visual UC 7101 _ Universal Communicator Ready TX RX RB 232 422 485 PERIODIC CHECK b Annual analysis 1 Purpose of annual analysis Poor vacuum within the chiller will result in c Solution Sampling and Concentration Analysis 1 Sampling under positive pressure metal corrosion and change the solution composition The vacuum condition in the chiller can be judged by analyzing the Fe and Cu contents in the LiBr solution Sample as per the above requirements Use a 50ml ha
39. OTE This regulation is applicable to BSY BDSY BHY BDHY IFA TROUBLE SHOOTINGS outlet Exhaust outlet Generator temperature sensor fault corresponding temperature sensor faults damaged Faults Phenomenon Causes Keys Steam Heat source The chiller a Temperature module a Replace water inlet Exhaust continues to run damaged b Check temperature inlet Condensate and the touch b Break short circuit sensor wiring Heat source water screen reminds c Temperature sensor c Replace Heat source valve fault The chiller continues to run and the touch screen displays Poor connection of valve feedback contact Loose wiring of valve feedback circuit a Adjust to make reliable Repair Repair or replace fault stops Cooling operation continues and touch screen alarms protection Pump damaged Pump blocked b G corresponding c Valve actuator fault valve faults Condensate over The chiller a Condensate temperature a Increase the setting temperature continues in upper limit setting too low b Adjust normal operation b Solution circulation in c Reduce condensate heat exchanger d Replace too low c Repair c Steam temperature too high d Deviation of temperature sensor too big e Steam trap has malfunctioned Absorption pump Absorption pump ja Pump motor overload a Troubleshoot and relieve protection Replace absorption pump Find the cause and replace Gener
40. Solution outlet valve 2 6 Drain valve 3 Purge valve 5 LTHE sampling valve water a Solution recycling tank _7 several dozens of hours a bd l atter precipitation S Illustration of filter draining FUEL FILTER CLEANING AND AIR VENT a Fuel filter cleaning 1 Gas filter The gas filter is composed of a filter cylinder filter element etc It is used for filtering impurities in the gas to keep them from entering the pressure governor and the solenoid valve thus to ensure the normal operation of the burner The whole procedure is as follows Close the ball valve open the inlet clog of the main solenoid valve and diffuse the gas in the pipe section between the ball valve and the solenoid valve Remove the cover plate on the filter and take out the filter element Get rid of the impurities clinging on the filter element by swinging or cleaning with a vacuum cleaner The filter element shall be cleaned with water if there are too many impurities add non corrosive detergent into the water if necessary Reinstall the filter element after it is dried If the filter element is capillaceous after being cleaned replace it immediately otherwise it might cause leakage in the solenoid valve Leakage detection shall be processed after cleaning to avoid any gas leakage WARNING If the gas filter is not cleaned in a timely manner the impurities in the gas will enter int
41. W outlet 36 5 2 Cooling inlet ete 39 0 B we 149 3 150 0 A Exhaust 156 8 w High fire Spun 41 0 Hz R pump 37 4 Hz Energy Efficiency Vent pmp CA Instant Cop 1 43 Refri afrigerant Hour Cop 1 55 Daily Cop l 1 63 ON Start OFF Dilution If fault notice or alarm notice showed on the main interface press the blinking icon and then enter the Fault Record interface Then you can check the time of fault reset time the name of the fault the fault alarm and abnormal reminders Press the fault name and check the fault reasons and other informations Then troubleshoot the fault according to the hints W Disinfectant level low The Fault Record interface is also accessible by pressing Fault Record on the Check interface Please refer to the next page OPERATION CHECK BZY150XD BROAD X BZY Chilled Heating W outlet J49 C Chilled Heating inlet 6 9 C Cooling W inlet e Cooling W outlet 5 NYC me DAC HIG target RER La Exhaust u g Control cabinet 26 9 s punp 41 0 Hz Larghe C35 aHz L_45 aHe C4 C gs C ay ri RB Cooling W 282 257 L8 H n2 n Monitor R pump 1 cooling W pump Profession f Cooling tear Running number Cooling W drain valve Refrigerant by pass valve flowrate Gas flowrate Press Check up to enter Fault record Check capac fyi Otkeal ambient tem
42. and filters fan dust the controlof c Make sure the inverter is running normally water system d Check the reliability of the wiring terminal connections inside the control cabinet Fasten if they are loose Clean dust e Check and make sure the temperature of the surrounding area is between 5 43 C and well ventilated 2 Soot in the Open auto pressure escape to check soot in HTG fire tubes Check if the fire tubes and condensate drain pipes at front fuel chamber can drain smoothly If soot combustion exists it should be cleaned and the excess air coefficient of the burner should chamber be readjusted 4 Flue ductand Check and clean chimney stack 5 Chiller paint Check the chiller for external rust If there is rust clean the rust and paint again the repaired part or for the whole chiller note inside the chiller should be vacuum and normal temperature when paint is being applied 6 Water box and Open all the water box covers to check whether there is rust withinthe tube tube sheet sheet and inside the water box 7 Chilled heating Analyze the water Soften it if the quality standard is not met water quality 8 Oil box Completely clean dirt inside the daily oil tank and oil storage tank Check whether the oil level probe works well 9 Grounding Chiller grounding resistance should be 4Q all motor insulation resistance to earth should be 2 0 5MQ 10 Water pumps a Check if the pump temperature increase is normal The pump curr
43. at intervals then upgrade to fault stop if reset fails All ault alarms will upgrade to fault stop if aults are not solved within 24 hours c Abnormal Reminding A reminder prompt appears and the chiller remains in operation These types of faults have to be repaired within 10 days otherwise the chiller will upgrade to fault stop Although the chiller will remain in operation and continue reminding under such a fault some functions will be disenabled when something abnormal appears Some other abnormalities will upgrade the chiller to fault alarm if several attempted automatic resets fail All abnormal reminding will upgrade to fault stop if they are not solved in 10 days d Abnormal record It will not affect chiller operation The chiller will record the fault but not remind the user on the touch screen to correct the fault The PLC will store the record for the service engineer s review and reference for maintenance Any fault should be solved in a timely manner even though some faults or abnormalities will not immediately cause the chiller to stop If not solved in time a fault will cause the chiller to stop In addition if the chiller running with fault will waste energy shorten life spon and increase the complexity and difficulty of repair For these reasons every fault should be solved immediately FAULT AND TROUBLESHOOTING CHILLER a Fault stop NO Fault Cause Keys 1 Chil
44. at source outlet 85 A S pump 25 0 Hz Heat source valve opening Information 20 0 Y R pump 46 4 Hz A Purge vent pump CJ Refrigerant valve GL d Purge vent valve ply Language ON Start OFF Ditution Sunday 15 19 53 Cooling biet Te 25 0 C capacity Bumegy saving No BAT Taming on AA AA No goo Timing of AA AA No 15 ee toe wea nal m se s 50 Water distribution system 1 Chilled Wpump QM 25 24 Chilled W punp M D G ea 1 Cooling W pe D D Hz 2 Cooling W pump QM 1H Cooling tomera 15 D Hz 2H Cooling tower fn GA 3H Cooling tower Sm GY 4 Cooling tover m GD SH Cooling tover tm EY Disinfectant pmp CA Arti scale pomp CA z SINGLE STAGE STEAM CHILLER MAIN INTERFACE BROAD X COOL ING Status SettingC Refrigerant Cooling Monitor level it Energy mee Chilled W outlet 7 0 6 0 eae i iy D 1255 Timing on AA AA No Chilled W inlet 14 100 iming of Setting S ty Cooling W inlet 20 8 SH c 15 Hton Tue wea nal mi se sn Cooling W outlet 37 A 50 ie er Ci out B 25 E EEK d G ti enerator 110 0 106 8 z c 2 Chilled Woump QM Heat source inlet 114 4 Expense OG Heat source outlet 8A A G S pump 48 0 Hz Heat source valve opening i l Information 90 9 19 Cooling W re H D Hz R pump 46 A Hz se 2H Cooling W pmp QO S A pump G Profession Cootmgtomrin A D Hz Purge vent pump CA Disinfectant pap CA Z Refrigerant valve RS Language tarde pmp CA Purge
45. ator overpressure Pressure control actuates too close to the heat source valve The valve re opens after the pressure control is reset After 5 occurrences start up will automatically turn to fault alarm a Heat source temperature too high Poor internal vacuum Pressure control abnormal or setting too low Cooling water temperature too high or flow rate too low Fouling in cooling water copper tubes b G d e a Reduce b Refer to item 14 of 5 3 3 Cc d Descale Abnormal Reminder Readjust the setting or replace Reduce cooling water temperature or increase flow rate The method is subject to BROAD written approva Generator over temperature The heat source valve is closed and re opened when the generator temperature drops by 10 C a Heat source temperature too high or heat input too high Cooling water temperature too high or flow rate too low Poor vacuum condition Solution circulation too small Generator valve close temperature setting too low Generator temperature sensor abnormal b a b om d Reduce heat source temperature or heat input Reduce cooling water temperature or increase flow rate Check vacuum condition and repair leakage Adjust solution circulation rate Increase the setting Replace Heat source water outlet temperature abnormally high Normal operation a Fouling in HTG or generat
46. ature a Chiller stops no cooling inlet temperature b Fan actuation temperature islow b Readjust the setting value below the lower c Cooling tower fan linkage fails c Find the cause and recover the limit inkage control 3 HTG over a Poor vacuum a Refer to poor vacuum and eliminating Temperature b Excessive combustion method c Excessive deviation of HTG b Readjust burner temperature sensor c Replace temperature sensor 4 Vent alarm The same as Vent over temperature The same as 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 roubleshooting frequently turns on and off c Improve gas pressure and stabilize or adjust pressure switch setting value 6 lnverter a Inverter communication port a Replace inverter communication damaged b Redo the wiring abnormal b Communication cable abnormal c Replace c Communication converter d Eliminating source of electromagnetic damaged interference d Electromagnetic interference 7 Instantly power Voltage unstable Negotiate with utility company Sudden power failure a Power failure b Main switch is open c PLC control circuit fuse is burnt out d Machine room gas leakage or fire alarm is activated a Negotiate with ut
47. bes or even destroy the chiller OTHERS wo It is forbidden for the piping system to be vibrated or chiller to bear any external forces The chiller must be well kept Users should install lightning protection themselves gt The chiller should be installed at an elevation less than 1000 meter Transportation and 6 Otherwise it may affect the chiller s life span or even damage the chiller The doors and windows of the machine room must be installed with firm locks and balusters No access to unauthorized persons The shipped spare parts and documents should be well kept Humidity of machine room should be less than 85 with temperature ranging from 5 Cto43 C If the temperature in the machine room is lower than 0 C the inlets and outlets of the chilled water and cooling water system should be closed Drain valves 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 freeze If the temperature in the machine room is over 32 C the machine room ventilation and control cabinet cooling must be improved If the temperature is over 43 C electrical components will be destroyed in hours and serious damage will occur to the chiller storage temperature should be between 25 55 C Maintain operate and commission the chiller strictly following the User s Manual and Service File N
48. can be used as cooling water but industrial water underground water lake water and desalinized sea water must be analyzed by a related technical authority before being used Even if it can be used as per the following standard table regular analysis is required Drain water sea water and waste water are prohibited to be used directly If the cooling tower is affected by outside pollution such as waste gas drain water or exhaust regular analysis of the cooling water is required to maintain the water quality Based upon the water analysis result it may be required to add proper amounts of qualified water quality stabilizers for anti corrosion anti scaling amp bacteria killing all of which will prolong the chiller s life span BROAD package chillers employ auto water treatment equipment and soft water equipment please refer to Water treatment equipment part designed to scientifically manage water quality to prevent serious damage to the chiller breed bacteria and endanger personal health PERIODIC CHECK b Management of Cooling Water System Item Inspection amp Maintenance Period Water The ordinary water source is analyzed by a specialized Once 1 month Analysis technical department according to international standards to determine the water refreshing interval PH value can be self analyzed Circulation Clean fan motor fillings water pool and filter Cycle with Before each cooling System weak organic a
49. cid for 4 hours if the water is hard season Every 6 months for chillers in full time service Water System Clean the filter of cooling water and make up water must be Once a year Filter cleaned one week after operation for newly installed chillers Chiller Water Check the scale in copper tubes with a fouling detector Once half a year System Open the water box cover to check if there is fouling in the Once a year Inspection copper tubes or rust in the tube sheet and water box interior Excessively hard water will cause serious fouling in the cooling water system and result in a decrease in cooling capacity Service engineers must be informed to confirm and take steps for safe cleaning WARNING To ensure the chiller s full life span no chemical cleaning procedure can be adopted without BROAD written confirmation Cleaning of the chiller copper tubes or water system fouling by an unqualified company will seriously damage the chiller copper tubes or even cause chiller scrapped c Cooling water and make up water quality standards GB T18362 2008 Cooling water Make up water Possible hazard with non compliance standard standard Corrosion Scale PH 25 C 6 5 8 0 6 0 8 0 o too low o too high Conductivity 25 C us cm lt 800 lt 200 o Cl mg Cl I lt 200 lt 50 o S042 mg Ca S042 lt 200 lt 50 o pH4 8 mg CaCo3 lt 100 lt 50 o Har
50. clean up water filter b Water supply volume too large or screen small b Adjust water supply volume 6 Water floating a Cooling water amount too large a Adjust water rate b Air flow too great b Adjust fan blade angle reduce air rate c Asymmetric water distribution c Clean up distributing basin and nozzle d Incorrect installation direction of d Readjust installation direction filling material e Clean up filling material e Filling blocked f Reinstall as required f Incorrect installation of baffle plates OTHER PARTS Faults and troubleshooting about burner inverter heat source valve softener auto water treatment and other automation equipment please refer to manuals provided with the products accordingly MAINTENANCE MAINTENANCE OBJECTIVES Zero fault stop Minimize the occurrence of fault alarm and abnormalities Hence BROAD classifies its maintenance model as Load Maintenance and Routine Maintenance a Load maintenance Reduce energy consumption Zero repair cost excluding the expense of regularly scheduled maintenance 25 year life span MAINTENANCE METHOD The traditional maintenance model for central air conditioning system adopts only Regular maintenance without considering the relationship between the maintenance period and the operation load a chiller running at high operation load for a long period of time will experience faults and a decrease in
51. crease the cooling water increasing Specific gravity emperature too low water inlet temperature polluted gt 1 04 Cooling capacity b Too much solution properly decreases circulation causes b Readjust the solution HTG LTG solution level circulation amount o become too high c Take out some refrigerant and concentration water oo weak d Readjust the burner to c Comprehensive reduce the combustion solution concentration e Avoid sudden increase oo weak of hot water flow By pass d Excessive combustion refrigerant completely to e Hot water flow regenerate in addition to increases suddenly above measures 5 Unstable HTG solution level is not in a Improper adjustment Observe 3 times the whole HTG zone C or jumps between 2 of frequency process from start to stop for solution zones frequently to zone E or b Solution volume is 3 consecutive hours then level zone A and stays too long insufficient a Reset S pump frequency in zone D or zone B S pump__ c S pump fault and redo the chiller frequency drops over 30 in d HTG solution level commissioning if 120 seconds control fault necessary e Poor vacuum b Add solution and redo the chiller commissioning c Repair or replace d Refer to HTG solution control fault keys e Refer to Poor Vacuum and Solutions FAULT AND TROUBLESHOOTING cont NO Fault Phenomenon Causes Keys 6 Rupture Solution flows out a Incorrect operation Stop the chill
52. ctromagnetism device ailure Check electromagnetism device and check if it groundings mpulse generator failure f the driver electrical circuit works well then replace impulse generator WATER TREATMENT DEVICE by pass valve ees i soft water outlet lt tap WATER SOFTENER drain E Principle contamination control valve ow lon exchange principle DIRE meter I pressure a JY gage Softening The Ca Mg metal ions inlet valve l last valve in tap water is absorbed by resin layer in resin tank and releases Na and produces softening water 1 l salt solution 19 charging pipe distributor Regeneration After the resin becomes saturated the control valve will automatically use the brine y water in brine tank to wash the resin layer to replace the Ca Mg and drain out then the resin get recovered 1 salt box SADA OLLJUOD JOAQ UOIENJOS Start a Wash inlet and outlet pipes turn off softener inlet amp outlet valve and bypass valve open drain valve on outlet pipe wash the pipe till it s clean then close the drain valve and bypass valve 1 Formula for calculating the water output 25xresin quantity L hardness of source water mg CaCOs L 2 Reference value for water output b
53. cuum valve randomly he 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 he 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 gt 99 995 4 Use only BROAD solution it is forbidden to use solution regenerated by others t is required to sample the solution and test it once a year on the machine room site and solution should be fully circulated and diluted before sampling If result can t be confirmed or more details are needed sample the solution with special bottle and send it to BROAD ab with a 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 the BROAD filter without stopping the unit If the solution is regenerated by others BROAD will not be responsible for the unit any more 5 It is forbidden to clean the copper tubes with chemicals without BROAD written permission 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 which will reduce the life span or even destroy the chiller
54. de pump and lift the tubes with the fixer from the drum then clean the strainer of valve on the bottom of the tube with clean water or neutral solution c Check if pump head pipe connections are in working order Cooling tower a Check and clean the sprayer and strainer of cooling tower b Check the shaft of reducer if necessary add some lubricating oil which tends to use Lithium Grease 3 from the filling hole Make sure that oil does not enter the cooling water otherwise it will affect heat transfer c Check fan driving belt and make sure it is not tight or loose Too tight may lead to damage of bearings while too loose may lead to overheating or sliding Make sure that oil does not enter the cooling water otherwise it will affect heat transfer d Check fan blade damage or corrosion clean fan blade and make sure vibration and noise are acceptable Check the state of filler clean inside of the cooling tower e Check the electrical wiring terminals and reliability the grounding resistance should be 4Q and insulation resistance of 20 5MQ Check and fasten all steel structure connecting bolts of cooling tower and impellers make sure the reliability decrease the noise and vibration Check whether the make up water valve overflow tube drain valve are normal or not g Open all the drain valves and make sure there is no water in the system during cold winter Expansion tank a Check automatic make u
55. dness mg CaCO3 1 lt 200 lt 50 o Fe mg Fe 1 lt 1 0 lt 0 3 o o S2 mg 2 I No No o NH4 mg NH4 lt 1 0 lt 0 2 o SiO2 mg SiO2 lt 50 lt 30 o Notes 1 o represents possible hazard with non compliance 7 represents no hazard with non compliance 2 Water quality stabilizer can be added accordingly to prevent corrosion scaling and viscosity in cooling water system 3 Cooling water can be partly discharged or totally changed to avoid impurities concentration 4 The quality of chilled water heating water and hot water quality can referred to in the above table PERIODIC CHECK INVERTER Be checked once every 3 months Item Content Tools or method Surroundings Make sure the inverter cabinet temperature is within 10 to 40 C Visual Inspection Humidity is below 85 and no dust oil fog or water droplets in the air Thermometer Humidity Meter Voltage Main circuit and control circuit voltage should be normal Multi meter Display Displays characters clearly with full letters no omission of characters Visual Inspection or strokes Installation No loose bolts and no abnormal sound or vibration Visual Inspection Support Hearing Front Panel No deformation no color change no dust and no damage Visual Inspection Wiring There is no damage breakage color change or deformation on _ Visual Inspection Connection cable s coated wire with fi
56. e bubble detection too low while the chilled water method 3 stage protection failed or h Leaking tubes can be clogged with cone improperly adjusted which can copper blocks when less than 3 of tubes cause evaporator copper tube are leaking Replacement is required to crack when the quantity is more than 3 c Possible reasons i Check the chilled water flow switches to 1 Too much deviationof chilled see if they work Recalibrate or replace water outlet temperature them 2 Chilled water outlet j Replace the chilled water temperature Temperature set too low sensor if its deviation is 22 C c Improper cleaning within the k Solution regeneration required water system results in copper l Chiller re commissioning tube erosion m Thoroughly analyze the reasons for the d Bad water quality causes pitting fault and take steps to make sure the scaling can cause under deposit fault does not happen again corrosion and penetration of NOTES tube 1 The chemical cleaning method of the e Corrosive gas gets in to the water side copper tubes is subject to cooling water system causing BROAD approval It is forbidden to use a erosion on absorber and metal brush for cleaning condenser copper tubes 2 The cooling tower should be away from f Chiller vibration causes copper the chimney so as to avoid exhaust tubes to crack entering into cooling tower Chimney g Improper maintenance in winter should be down wind side from of the Anti freeze was not added
57. e chiller can be doubled A separate heat exchanger can provide dedicated hot water while cooling or heating operation is stopped Only BROAD has the unique technology that can realize three functions in one unit 22 PERIODIC CHECK PERIODIC CHECK ITEMS COOLING CAPACITY AND COP AND INTERVALS Every BROAD packaged chiller is equipped NO Temes ENGI with a flow meter for fuel AC water cooling water and hot water By detecting the real 1_ Capacity and COP I WES time flow rate and using control software 2_ HTG solution level 1 month the BROAD packaged chiller is able to 2 Flow meter 1 week calculate cooling capacity and COP 4 Chilled W Protection while 3 months automatically Under normal operation and 3 stage water flow rate lower maintenance chillers can maintain cooling protection than the minimum and energy efficiency and load capacity 5 Water pump chain 12 months as well However in regular operation control cooling capacity and COP might decrease 6 Com Burner operation week temporarily for various reasons such as bustion _ check scaling of the water system Therefore Flame detector month regular checks on the chiller s cooling check amp clean capacity and COP display on the touch Combustion year screen should be performed chamber and fire eee ee ee HTG SOLUTION LEVEL 7 Monitoring Normally connected 1 week E a center to BRO
58. e the softener will consume regeneration brine continually therefore in order to keep softener work at normal condition sufficient regeneration brine should be manually added in to brine tank industrial brine only Brine particles No iodate brine fine brine etc adding brine is quite simple just open the brine tank cover and add brine in till it s full Model Different hardness period Brine mgCaCO3 L addition 200 J300 400 kg times BY75 25days 17 days 12 days 140 BY100 19 days 12 days days 140 BY125 22 days 14 days 11 days 200 BY150 18 days 12 days days 200 BY200 22 days 14 days 11 days 320 BY250 17 days 11 days days 320 BY300 18 days 12 days days 400 BY400 20 days 13 days 10 days 600 BY500 16 days 11 days 8 days 600 BY600 18 days 12 days days 800 BY800 20 days 13 days 10 days 1200 BY1000 16 days 11 days 8 days 1200 NOTE Above data is calculated on condition that he cooling operation functions 10hours day Add resin About 5 10 resin will be consumed every year so resin should be added in time 1 Close inlet outlet valve of softener 2 Open softener drain valve to drain out the residual water 3 Loosen the flexible connection on control valve s outlet inlet pipe and screw off the control valve 4 Add proper resin into control valve installation hole and avoid the resin enter into central tube 5 Fix
59. eck the cooling tower s air volume and adjust the cooling fan s blade angle if necessary The smaller the fan s blades angle to the horizontal direction the smaller the air volume and vice versa The adjusting angle should be within the calibrated scope on the fan axis and every blade should be at the same angle Start the fan after adjustment and use the ampere meter to detect the running current to make sure it is within the rated current on the nameplate Otherwise adjust it again Check and Adjust Cooling Tower s Water Distribution Check whether water distribution is asymmetric The cooling tower s water distribution device is very important Insufficient water flow and unsteady valve adjustment always cause asymmetric water distribution The smaller the cooling water pump frequency and cooling water flow rate the more asymmetric the water distribution is Hence the cooling water pump frequency should not be too low A C HOT WATER QUALITY AND FOULING a Check Water Quality and Fouling Distilled water de ionized water or soft water should be used for the chilled heating water system and the primary side of the secondary heat exchanging hot water system to avoid fouling and chemical corrosion to the chiller piping system and terminals The direct hot water system can be treated by Siliphos Although water treatment is applied fouling can still form on the water side of the chilled heating and hot water copper t
60. ections drop areas For example separately design closed the low level area and reduce loops for high level areas and low level areas unnecessary water pump use 14 Reasonable air duct Choose reasonable air duct size according to Avoid unreasonable energy loss system economical air speeds avoid air leakage of during air transportation equipment or air ducts avoid air short circuit between supply and return air and clean the air ducts on time 5 Ensure all equipment Solve equipment problems on time Avoid increased energy is well maintained consumption 6 Eliminate heat nstall air return windows above the lights so Reduces the room load so that generated by room that the heat of the lights will be taken off by the air supply can be reduced lights by utilizing a he return air and power for air supply can return air system also be reduced 7 Manage doors and _ Prohibit the opening of doors and windows Avoid heat loss windows strictly when the air conditioning system is working Use an infrared ray sensing automatic door and also the door curtain 8 Use a cold light or nstall energy efficient lights Reduce indoor load natural light system 9 Improve the Reduce the area of windows Use vacuum Reduce indoor load thermodynamic heat insulated glass or film plated reflecting performance of the glass in the windows Use sealing bar and heat building insulating window curtains Use a screen on he building roof Use heat insulation materials wi
61. eezing point of the water lower Properly selected antifreeze will lower the freezing point of the water to below the lowest ambient temperature and in this way the antifreeze can prevent pipes from freeze Formula list for 100 liters antifreeze At the same time in order to maintain completely normal working conditions within the pipes in addition to antifreeze anticorrosion anti scaling and anti microbial chemical reagents mush be added to the A C water or domestic hot water Under normal operating conditions antifreeze can protect a unit against freezing forever and can extend life span of unit Formula Preparation of antifreeze must be based on the minimum ambient temperature and total volume of water in the unit s system Measure the total volumes after first drain out of the unit and then add antifreeze as following Test Density and pH values of antifreeze should be tested Use a 1 000 1 100 densimeter and test the liquid at about 20 C Use a universal pH test paper for the PH test Local minimum temperature C 5 10 15 25 30 40 99 Secure formula 12 19 27 38 43 48 Glycol Density 0 002kg L 20 C 1 021 1 029 1 038 1 051 1 056 1 062 kg Economic formula 5 8 12 16 20 22 Density 0 002kg L 20 C 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 hydrox
62. efore burner operation The sealing gaskets silicate fiber for the front flue chamber flange must be replaced to avoid exhaust leakage Recheck and adjust burner s excessive air coefficient after de scaling tubes might greatly decrease the HTG heat transfer efficiency and it will waste energy resulting in air pollution or even causing fire accident when the exhaust temperature PERIODIC CHECK MONITORING CENTER When there is downtime or downtime occurring after the chiller is connected to the monitoring center BROAD Expert system will send alarming message to service engineer and A C administrator who have been registered in BROAD monitoring center Unstable network and electromagnetic interference etc can interrupt monitoring center then will cause alarm failure So indicator light of monitoring center inside control chamber should be checked every week to assure whether monitoring center is working normally Indicator Functions light STATUS Glints at a constant speed when light the chiller is connected to BROAD monitoring center successfully TXD light Glints at a constant speed when sending data to PLC successfully RXD light Glints at a constant speed when SOLUTION a LiBr solution quality index Lithium chromate type solution Item Standard LiBr 40 50 52 53 55 0 5 LI2CrO4 0 15 0 25 PH Value 9 0 10 5 BrO3
63. energy saving work Operation engineer Instructs lifting installation checking and accepting the chiller takes care of the commissioning operating maintenance common trouble shooting manages and instructs energy saving work WARRANTY SERVICE AND PAID SERVICE a Warranty service 1 Warranty period 18 months from the shipment date or 12 months from the commissioning date whichever comes first 2 Appointment of the responsible engineer After receiving the Contract Technical Sheet BROAD Overseas Service Branch shall appoint a responsible service engineer accordingly within 15 days 3 Check amp lift amp transportation tips The BROAD service engineer together with the user should confirm the dimensions and accessibility of the machine room If anything abnormal happens BROAD will inform the user in written form and discuss with the user to find a solution When the chiller arrives at the jobsite BROAD service engineer can give guidance for checking and accepting the chiller at site or through telephone A BROAD service engineer should inform the user of any important information regarding lifting Installation guidance A BROAD service engineer shall put forward to the users the machine room installation and management requirements If necessary BROAD can organize the user installer and designer to visit the BROAD standard machine room and share the experiences of the user Ln an
64. ent must be less than the rated value Check the running noise and vibration also check if there is abnormal noise cavitation and check the foundation to see if it is flexible or not c Make sure the control system works well and flow rate is sufficient d Check the lubricant oil appearance oil temperature oil quality There should be no oil emulsion and impurities If necessary replace or add new lubricants Check the electrical wiring terminals and their reliability Make sure the grounding resistance is lt 4Q and insulation resistance is 0 5MQ f Check whether the water system is full of water and sealing is normal or not Check the pressure drop between the inlet outlet and calibrate the pressure gauge check the painting of the pump repaint if it drops The ambient temperature may be lower than 0 C If so add antifreeze or drain the water inside the pumps b Pipes valves and accessories a b Check water leakage at connection joints and the valve seals Check whether there is any damage in heat and cold insulation or paint Check whether the support is strong enough Check whether the valve switch is flexible Clean the dirt in the pipes valves and accessories MAINTENANCE cont NO Items Method 12 Flow meter a Confirm the displayed data on flow meter is the same as on the touch screen b Clean the surface of flow meter by proper tools do not use chemical method
65. er immediately cut disk broken from flow duct of during nitrogen charging off power stop water pumps the rupture disk Nitrogen overcharged close valves and notify local b Copper tubes broken BROAD service organization c HTG pressure increases abnormally due to other reasons 7 Chilled Chilled water a Overload a Add new chiller or reduce the water outlet outlet temperature b Chiller cooling capacity is load temperature is higher than the below the rated one b Refer to item 1 of this chapter higher than target setting c Deviation of the c Calibrate with accurate the target value and can not temperature sensor s thermometer If deviation 2 value be decreased d Wrong parameter setting C replace the temperature sensor deviation lt 2 C readjust the compensation value d Modify the parameter setting 8 Touch No normal display a Touch screen s power off a Power on screen out jon touch screen b PLC communication failure b Repair or replace of order c Touch screen fault c Replace d Problem with the d Repair or replace connection cable e Replace between PLC and touch f Check by programmer and screen modify e 24V DC supply failure g Re input the program f Wrong configuration on communication port g Wrong operation leads to touch screen program being lost 9 Big Touch screen a Poor grounding of a Re ground to a dedicated fluctuation chiller parameters communication cable grounding electrode w
66. er noise and vibration of the distribution system is normal or not the foundation becomes flexible or not 2 Burner a Clean off the dust and water 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 are in the right position d Clean the flame detector and confirm that the photosensitive part is transparent and not damaged e Check the excess air coefficient gas type 1 18 1 25 oil type 1 13 1 20 4 Solution and a When the solution pump is running the solution should be clear and transparent rust as 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 B Vacuum a Confirm the vacuum of the chiller by bubble comparison method detection b Check whether or not 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 a Check heating and aging status of each component in the control cabinet cabinet b Check whether or not the touch screen displays the right PLC signal c Check whether or not the control cabinet fan runs well clean rust on the fan filter 7 Canned Check the temperature rise cavitation and abnormal noise of the m
67. erature area Replace 2 Sealing materials in front rear flue chamber Replace 4 Sealing gasket for heating hot water box cover Replace 5 Replace the nozzle ion flame detector and motor bearing Following maintenance items For high load every 5 years medium load every 7 years and low load every 10 years NO Items Essentials of the method Burner Replace the oil pump ignition electrode and solenoid valve coil Inverter Replace Turbulator Replace Cold heat insulation materials Replace mos MAINTENANCE b Routine maintenance The maintenance interval of some items has nothing to do with the running load of the ler This maintenance model is called routine maintenance chi Annual maintenance NO Items Method 1 Solution analysis Fully dilute the solution inside the chiller then BROAD service engineer test the solution at site and issue a report of Site Testing of LiBr Solution If the test cannot be finished at site or the user needs a more detailed and professional report sample around 50 mI and send it to BROAD lab for testing by post or express The lithium molybdate solution cannot be tested at site sampling the solution around 50 ml and sending it to BROAD lab is required 2 Control a Check for heat radiation inside the components and aging cabinet include b Check whether or not the control cabinet fan runs normally
68. eze freezing point should be lower than the minimum ambient temperature of the system to ensure that the water system and chiller have no freezing accident This step will also help to prevent water pipes and copper tubes from corrosion b Cooling water system antifreeze Completely drain cooling water completely from the pipes cooling towels and copper tubes inside the chiller and especially make sure no water remains in the lower positions of system c Domestic hot water system antifreeze 1 Without secondary heating exchange if the ambient temperature is lower than 0 C and if domestic hot water is not in use in winter you must open the drain valve to drain all water out of the system This will help to prevent the domestic hot water system from freezing 2 With a secondary heating exchange system if domestic hot water is not in use in winter it is not necessary to drain out all water from the system This will help prevent water pipes and copper tubes from corrosion If ambient temperature is lower than 0 C antifreeze needs to be added into the first heating exchange cycle system and its freezing point should be lower than the minimum ambient temperature However water in the secondary cycle system has to be drained out d Unit antifreeze 1 If ambient temperature is lower than 0 C but antifreeze has been added water in the copper tube inside the unit does not need to be drained out If no antifreeze ha
69. f oil filter Open the inlet valve of the oil filter loosen the screw of the air vent device slowly until the oil filter is air free Tighten the screw again 2 Air vent of oil pump Use an Allen key to loosen the Allen screw on the oil inlet pipe and tighten it after the air is completely vented If it is difficult to unscrew the nut the oil pressure gauge can be loosened to vent the air REPLACEMENT OF SEALING ELEMENTS Sealing elements to be replaced Solution level probe vacuum valve regulating valve compound gauge pressure control valve and sight glass etc Note the following during replacement l Charge nitrogen with purity gt 99 995 into the chiller to make the internal pressure equal to or a little higher than the atmospheric pressure If there is solution around the sealing parts transfer part of the solution to HTG or drain out of the chiller till the solution level is below the level of the replacement 3 The replacement of the sealing parts for compound gauge and for liquid level probe under urgent cases can be done swiftly when the chiller is under vacuum condition The parts for replacement must be exactly the same as the originals Clean up the rust and oil stain on the sealing surface All valve covers must be installed and tightened after replacement Apply soap solution around the valve nozzle to detect leakage when the external vacuum valve is closed tightly Tighten
70. g or open a Check and connect the short circuit wires correctly b Burner fault b Refer to burner manual 7 Gas leakage ja Incorrect fault feedback wiring or open a Check and connect the short circuit wires correctly b Interior leakage of the solenoid valve b Repair or replace 8 Refrigerant a Inverter fault a Refer to inverter manual pump inverter b Incorrect fault feedback wiring or open b Check and connect the fault circuit wires correctly c Communication circuit fault or strong c Check communication electromagnetic interference circuit and eliminate d Refrigerant pump get stuck or electrical fault source of electromagnetic interference d Restore flexibility or replace the pump 9 Absorption a Incorrect pump wiring or short circuit loose a Check and connect the pump vent contact wires correctly pump fault b Pump overload lack of phase short circuit b Check or replace pump or damaged 10 Auto air vent a Auto purge valve is not switched to vent a Check auto purge valve abnormal b Actuating value setting too large no b Check vent valve operation venting for long time may cause valve c Reset vent interval plate s sealing elements to stick d Check solution level control c Vent interval short and vent probe wiring d Solution level control or vent probe wiring Toul e Open auto vent manual e Auto vent manual valve closed check valve normally open in operation 11 AC pump fault a Incorrect pump wiring or sh
71. ged machine room temperature c Improper temperature sensor b Repair or replace installation location c Check and reinstall in proper position 7 HTG over pressure a Poor vacuum condition a Refer to item 13 of Abnormal b Cooling water flow rate is too low or Reminding temperature is too high b Increase cooling water flow c Steam angle valve opening is too rate or reduce cooling water small temperature d Scaling with cooling water copper c Check the opening of steam tubes angle valve e Too small LTG solution circulation d De scale Plan is subject to f Pressure control actuating value is BROAD written confirmation too 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 flow ja Improper flow switch wiring a Check and connect the wires switch abnormal b Flow switch damaged or improper correctly setting b Readjust or replace flow switch c Water flow in cooling water side c Check the reason for the water before chiller started low 9 Refrigerant level a Incorrect refrigerant level probe a Check and connect the wires control fault wiring or short circuit correctly b Refrigerant level control damaged b Replace solution level control c Refrigerant box gets frozen c Refer to refrigerant freezing d Refrigerant level probe upper and keys lower covers are aging d Replace solution level probe u
72. get temperature too much will influence the effectiveness of the end air conditioning At the same time when the ambient temperature is high it is suited to decrease the target temperature properly but it will dramatically increase energy consumption if the target temperature is too low Cooling water inlet temperature Settings range is 22 34 C by default at 28 C Properly decreasing the setting helps to improve the chiller s performance HTG temperature Settings range is 120 160 C by default at150 C The HTG temperature can be set at lower value when chiller load is low and vice versa The condition where user s need is fulfilled try to set the temperature low The lower the temperature chiller is more energy efficient and safer for operation OPERATION TIMING BZY150XD 2007 08 22 O BROAD X BZY Setting Wednesday 19 30 50 Timing on HY d SA Monitor Every day once tm fa Ad Week Cancel Timing off 17 36 Profession Every day a N once mm i a setting Timing On Off functions can be selected separately or together according to need Every day Once only or Every 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 CLOCK SETTING Press Clock Setting on Setting screen to enter check and adjust the date and time Wa
73. gn and installation of the users system timely and precisely and help users to slove them They have to take the responsiblity and be initiative on supervising users to take regular maintainance of the machine and to conduct energy saving management well We should always take the user s system as our own To achieve this mission service engineers have to build close and deep relationship with users to ensure that the more BROAD products they use and longer the life soan of these products the more trust they have on BROAD Every engineer has to keep in faith that if you fulfill your mission and build good relationship with users customers will take BROAD as their first choice or even most of them will consider BROAD as their only choice Hence the BROAD ideal will be realized All the service engineers the great mission is on your shoulder BROAD Air Conditioning Service Center Issued on 2003 11 15 Revised on 2007 10 10 osi ACM O BROAD Air Conditioning has obtained international certificates from ISO CE ETL ASME and so on BROAD AIR CONDITIONING O IZA ia EYN BROAD Town Changsha China Tel 86 731 84611352 Fax 86 731 84611356 Email serviceinfo broad net www broad com To preserve forest and water resources please follow us to use thin unlaminated printing papers 2012 08 1st edition No 5 000 BY258 12 2012
74. hamber Drain water filter and clean up debris box 9 Cooling tower fan bearings Replace 0 Flange gasket Replace 1 Three way valve check valve seals Replace 2 Softener Replacement of PVC piping components 3 Cooling water conductivity sensors Replace 4 Automatic water processor Replacement of PVC tube the liquid level switch 5 Control cabinet Replacement power indicator light button 6 Inverter fan Replace Maintenance every 8 years NO Items Method Cooling water flow switch Replace 2 Cooling water temperature sensor Replace 3 HTG temperature sensor Replace 4 HTG crystallization probe Replace 5 Heating water temperature sensor Replace 6 Hot water temperature sensor Replace 7 LTG crystallization probe Replace 8 Ambient temperature sensor Replace 9 Refrigerant level probe and UDK upper lower jacket Replace 10 Non condensable probe and UDK upper lower jacket Replace 11 Solution leakage probe and UDK upper lower jacket Replace 12 Other sealing elements in low temperature area Replace 13 Sight glass and sealing elements Replace 14 Sealing gasket of chilled cooling water box cover Replace 15 Water pressure gauge Replace MAINTENANCE cont NO Items Method 16 Control cabinet fan Replace 17 Touch screen Replace 18 Actuator of motor valve Replace 19 Actuator of auto purge motor valve Replace 20 Actuator of Refrigerant W bypassing Replace va
75. he On Off function of the of burner and refrigerant pump perform load regulation and prevent refrigerant overflowing 24 Non condensable probe YK3 Detect solution level in separation canister of auto purge system and send signal to PLC If no solution level is detected the chiller will automatically vent out the non condensable gases in from the chamber 25 Auto vent sensor YK4 When the solution level in chamber is detected the auto vent process will stop 26 A C water flow rate meter V1 Detect A C water flow rate to calculate cooling heating capacity and COP 27 Cooling water flow rate meter V2 Detect cooling water flow rate to calculate exhaust heating capacity 28 Gas flow rate meter V3 Detect gas flow rate to calculate gas consumption energy cost and COP 29 Hot water flow rate meter V4 Detect hot water flow rate to calculate hot water capacity 30 Conductance rate sensors Detect cooling water quality control water draining time and add inhibitor 31 Different pressure detector AP 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 in machine room room SG2 Draft fan will be started if gas leakage is detected to avoid accidents NOTE parts with are not for heating cooling type par
76. he sampling bottle for 1 minute and use the bubble comparison method to make sure there is no air in the bottle Open the sampling valve to sample the solution Close the sampling valve sampling purge valve main purge valve and vacuum pump in turn after finishing sampling Pull off the hose connected with the sampling valve first the hose must disconnected from the valve port slowly to allow the solution inside the hose to be transferred into the bottle as well Then pull off the hose make sure the solution is transferred into the bottle Finally pour the solution from the sampling bottle to a clean glass or a plastic container e g a measuring cylinder Clean the sampling valve nozzle with water and dry it then put the cork back PERIODIC CHECK d Solution Concentration and Refrigerant PUMP SET SYSTEM Specific Gravity Check Check every part of distribution system 1 Close the hot water and heating water once a month thermostatic valve skip this step if no a Softener Checking heating and hot water function Check the softener once a week The 2 Under cooling mode the chiller should be water pressure should not exceed 0 6MPa running more than 2 hours under high fire Keep the brine tank at least 1 3 by adding 3 Run the refrigerant pump continuously industrial salt Strengthen water quality The solution level inside the refrigerant Eia c S monitoring and adjust the regeneration waer i S
77. hen the burner is in operation Soot cleaning procedures Shut off the chiller power Start cleaning when the temperatures in the combustion chamber and fire tubes are close to room temperature Disconnect the burner control wire if necessary If the marks on the wire are not clear re mark properly to avoid any false wiring the next time Close the fuel inlet valve diffuse gas or drain residual oil Take off the oil pipe or straight connecting pipe to the butterfly valve Remove the burner and keep it safe Remove HTG front flue chamber cover rear flue chamber manhole no manhole for small models cover and insulation head Take out the turbulators in the fire tubes from the front flue chamber and clean with rags non corrosive detergent can be used Clean the combustion chamber and fire tubes with steel brushes or other tube cleaning equipment Clean the soot with a vacuum cleaner Reinstall the turbulators covers of front and rear flue chamber insulation head burner and its control wire and oil pipe or straight connecting pipe in turn CAUTION Do not damage the insulation materials Remarks The setscrews of the front and rear flue chamber cover should be replaced A mixture of graphite powder and engine oil should be applied on screws before installation After the burner is reinstalled vent air oil burner or diffuse gas to the outside gas burner b
78. iately severely imbalanced or there and recover 3 phase power is even lack of phase supply e Pipes blocked by air or valve je Vent air and make up water clogged or check valve 5 Abnormal Pump runs with a Fan blade or pump blade rubs a Check sound much higher the shell b Replace when sound than b Axis damaged c Make up and vent air water common or c System lacks water and pump d Check and take out the pump is noise cavitation foreign bodies running d Something abnormal in pump e Check or replace cavity f Check static balance e Running parts such as axis carefully connector are loose f Pump axis is not in the same plane with motor axis 6 Water Pressure gauge a There is a lack of water or a Make up water pressure display changes leakage in system b Check the expansion box unstable frequently b Expansion tank loses effect and make sure auto make c Water pump inverter is running up is running normally at low frequency c Normal phenomenon 7 Flow Meter iNo display no a Installation does not meet the a Reinstall abnormal flow or abnormal requirements b Vent air and clean flow in flow b Air stacking or too many impurities c Raise flow rate or clean filter meter in pipes after installation d Replace c Water flow speed is lower than e Replace battery 0 05m s d Calculator fault e Low battery FAULT AND TROUBLESHOOTING COOLING TOW
79. id excessive cooling in equipment for indoor adjustment functions summer or excessive heating in units winter comfortable and also energy saving 7 Use variable flow air Air flow is changeable according to load Reduce electricity consumption supply for indoor units changes in the room 8 Energy computation Calculate the fuel and electricity Reduce energy consumption by consumption of indoor units separately and implement strict supervision mechanisms 10 to 20 55 ENERGY SAVING MANAGEMENT cont NO Item Method Effect 9 Ensure insulation of Check the insulation periodically Avoids energy loss and the whole system is in equipment damage from poor good condition insulation performance 10 Avoid leakage of Check the pipes periodically Save water and energy water pipes 11 Cycling mode of Closed circuit is recommended Reduce electricity water system consumption help anticorrosion and anti scaling and extend life span of pipes 12 Distribute cooling The water supplying temperature can be Avoid unreasonable energy heating load lowered and flow rate increased if the waste 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 13 Divide water pumps Arrange pumps according to different pressure Avoid excessive pressure loss in into different s
80. ide 0 15 sodium benzoate 0 5 BTAO 02 if in the preparation hard water is used add 50ml of anti corrosion inhibitors PH value 9 11 5 If not appropriate add sodium hydroxide to adjust NOTE The secure formula will not freeze at the temperature and the economic formula will form ice crystal as a result of freezing but the formula will not freeze the pipes nor will it be cycled immediately The secure formula is based on the lowest temperature records in the local history But there is always the possibility of an even lower temperature than in recent history occurring and therefore causing chiller shutdown So the economic formula is provided for reference The relationship between antifreeze density and temperature is density at X C density at 20 C 0 0003 X 20 10 lt X lt 35 ENERGY SAVING MANAGEMENT ENERGY CONSUMPTION ANALYSIS a Energy cost 1 In order to make an accurate energy analysis separate metering for heat sources electricity water and cooling heating consumption of air conditioning is necessary To make a comparative analysis of the data from different years or from different time periods under similar loads charts and graphics are helpful According to BROAD experience normally 30 60 cost savings can be achieved by introducing effective energy analysis management b Energy consumption survey BROAD completes energy consumption and energy cost surveys every year By supporting BROAD e
81. ient temperature is 22 C and restart at 24 C In high energy saving heating operation the chiller will stop when ambient temperature is 16 C and restart when it is 14 C ENERGY SAVING SELECTION GUIDANCE Please cancel this function when there is no need of air conditioning NO Mode Guidance 1 Top Energy Saving Avoids excessively heating or cooling the room when room is not in use 2 High Energy Saving Dramatically saves energy Recommended for users who do not have high demand for air conditioning Not recommended in harsh climate seasons or for users who have small capacity indoor units 3 Medium Energy Energy saving and good air conditioning effect Recommended for Saving common use except some special applications 4 Low Energy Saving Avoids energy waste due to man made imprecise temperature setting Suitable for places with high standard requirements of air conditioning OPERATION BZY150XD 2007 08 22 CE1 BROAD X BZY Setting Wednesday 19 30 34 BAS select Auto vent L Local o Select Check up BAS Cancel Expense Gas Oil select Information L DAS Profession OIL Energy saving Time on Water system E Clock Hode setting setting Choice Other choice setting Press Other Choice on the Setting screen to enter BAS Choose Local if there is no BAS AUTO VENT Should be chosen under normal operating
82. ility company b Check the main switch and restart the chiller c Find the cause and replace the fuse d Eliminate the gas leakage or fire alarm 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 water flow b Vent air out of water system and fulfill the rated both c Cooling water inlet the tank with water Check if valves value increase and temperature is higher of water system are fully opened and temperature than the rated value filters are clogged Check the pump difference d HTG fire off temperature model selection and rectify decreases setting value is too low c Cooling tower has poor heat dispersion cooling water e Chilled water flow effect Check if cooling fan belt is radiation or temperature loose or has fallen off Adjust cooling decreases measurement is fan blades angle Check distribution inaccurate angle and speed of cooling tower f Amount of added water distributor Check if the tower Octanol is insufficient selection is correct g Chiller heating cooling d Reset HTG fire off temperature switch valves are not e Calibrate the flow meter and fully opened thermometer Calculate accurately h Refrigerant water gets chilled water flow and temperature polluted difference i Refrigerant water f Increase by 0
83. in gas pressure blocked oil filter or improper djustment of the burner damper will all result in insufficient combustion in the burner Under such conditions the flame detector will be smoked black by the exhaust and thus unable to detect the flame signal which might cause burner failure Therefore the flame detector must be checked and cleaned once a month 1 Procedures for oil burner flame detector cleaning Pull out the flame detector Clean the glass cover with soft cloth or quality tissue Insert the flame detector back into the holder 2 Procedures for gas burner flame detector cleaning Power off the chiller Open the combustion head to check if there is soot on the flame detecting probe and if the distance between the probe and the diffuser or ignition electrode meets the requirements stipulated in Burner manual Clean if needed c Checking and soot cleaning of the Combustion chamber and fire tubes should be checked every year when the cooling season or heating season ends 1 The harm of soot in fire tubes and combustion chamber Soot in the combustion chamber and fire increases to a certain degree 2 Soot detection Inspect if the exhaust temperature rises abnormally Open the automatic pressure escape when the combustion stops to inspect if there is soot on fire tubes Inspect from sight glass on the rear flue chamber to see if there is soot within combustion chamber w
84. in HTG is too high readjust the burner becomes small f Too much octanol d Check and repair leakage Purge injected in HTG vacuum e Lower the solution level f Switch to cooling heat the solution for 2 hours regenerate after bypassing the refrigerant water FAULT AND TROUBLESHOOTING cont NO Fault Phenomenon Causes Keys 3 Plate heat a Rated cooling capacity Caused by frequent a Replace heat exchanger exchanger drops noticeably power failure or unstable b Redo the commissioning mixed flow b HTG temperature is solution level in HTG of the chiller Make sure obviously high and HTG the HTG solution level pressure is low S pump stays long time at zone C frequency becomes or solution level fluctuates low and refrigerant level within an allowable range increases noticeably c Contact utility company c HTG low on solution or or prepare backup solution level rises frequently generator to tackle the d HTHE crystallization is frequent power failure reported all the time problem e The concentration of HTG concentrated solution drops noticeably during operation Take the measurement after the S pump stops for 1 minute 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 C ina short time 4 Refrigerant Refrigerant water level is a Cooling water inlet a In
85. intenance and spare poris oand routine maintenance replacement Strictly follow the requirements for the load maintenance Maintenance quality Ensure that the performance and cleanliness of the chiller after maintenance is just like that of the new chiller non stop operation should also be guaranteed Response time Where there is a BROAD local service branch BROAD service engineers should reach the jobsite within 6 hours for the users inside the city and 12 hours outside the city with the agreement of the user two parts can appoint the time Service Quality 1 Routine telephone Feedback return visit from BROAD headquarter BROAD customer routine visit 24 hours hot line service 0731 84611352 4 Email yz broad net wn Contact Country District Tel Fax E mail Headquarter 0731 84086139 0731 8461 1356 F serviceinfo broad net The United States 001 2016783010 001 2016783011 F Yangdezhi broadusa com Europe 0033 134430788 0033 134430825 Broadeurope lh wanadoo fr 0033 134430657 0033 134430703 F IFA MAIN INTERFACE DOUBLE STAGE STEAM CHILLER MAIN INTERFACE BROAD X BSY COOLING Status Setting C Refrigerant HTG Monitor a level level Chilled W outlet 7 0 6 0 D E Chilled W inlet 14 7 2 Cooling W inlet 30 0 30 0 c C Cooling W outlet 37 4 Check out B B High temp generator 140 0 AA A A Heat source inlet 145 A Expense He
86. ion Regeneration procedure under operation When it comes to the halt position of regeneration coupling button will clickety clack otherwise fix or replace it h Check whether the front gear of timer works well i Check drive motor and switch 3 Over a Improper use of brine a Check the brine quality and brine consumption of b Excessive water in brine tank absorption setting brine b Refer to Q 4 4 Excessive a Block of draining amp current a Clean draining amp current limiter Water in brine limiter b Replace timer tank b Timer out of work c Clean brine valve tube and replace the c Dirt in brine tube and valve bottom of brine valve d Power failure during absorption d Check the power 5 Brine a Block of draining amp current limiter a Clean draining tube and current limiter absorption b Brine absorption pressure too low b Increase the tap water pressure to be failure c Valve inside leakage above 0 2 MPa c Replace seal ring gasket and piston 6 Draining a Control valve set improperly a Check the position of timer procedure doesn t stop b Dirt inside the valve and control valve Replace the control c Valve inside leakage valve parts if the position is incorrect b Clean the dirt and check whether the valve functions well in regeneration c Replace seal ring gasket and piston 7 Huge loss of a Block of softener inlet pipe a Clean filter and pipe water pressure b Irony stuff
87. iring open a Check and connect the wires outlet HTG short circuit correctly temperature b Temperature module s damaged b Replace temperature sensor fault c Temperature sensors damaged module s c Replace temperature sensor s 6 Temperature ja Incorrect communication lines wiring open a Check and connect the wires Detecting short circuit correctly Module fault b Temperature detecting module damaged b Replace temperature module s 7 S pump a Inverter damaged a Refer to the inverter manual Inverter fault b Incorrect fault feedback wiring open circuit b Check and connect the wires c Communication circuit fault or strong correctly electromagnetic interference c Check communication circuit and eliminate source of electromagnetic interference 8 No solution a Solution pump filter clogged wrong rotation a Clean filter repair or replace level in HTG not started or stopped by fault solution pump during b S pump s setting of maximum frequency ls b Reset s pump frequency cooling too low c Tune down concentration c Concentration regulating valve is improperly regulating valve adjusted d Check and connect the wires d Incorrect level probe wiring or open short correctly circuit e Replace solution level control e Level control damaged b Fault alarm NO Fault Cause Keys 1 Chilled heating a Incorrect temperature sensor wiring or ja Check and
88. ith touch display unstable b Temperature sensor poor b Overhaul and replace screen data wiring c Overhaul and replace display c PLC Power module fails d Shielded wires well grounded d Shielded wires are poorly e Eliminate interference and grounded ground chiller properly e Interference from inverter or high frequency from system power 10 Canned Canned pump a Pump motor overload a Find the cause and reset pump fault can not be started protection b Check the control circuit after chiller startup b Control circuit fails c Repair or replace c Pump fails d Troubleshooting d Chiller in auto protection e Try to notate solution pump e Pump is obstructed by in both directions if it still solution crystallization cannot be started then de f Power phase absence crystallization is needed f Adjust power supply to normal requirement FAULT AND TROUBLESHOOTING PUMP SET amp PIPING NO Fault Phenomenon Causes Keys 1 Water Does not start or a Control output relay of water a Replace pump or stops abnormally system damaged b Replace cooling fan after start up b PLC output module damaged c Switch to linkage position abnormal c Water system is not set in d Replace linkage control position e Find reason and recover d Motor control contactor f Reset damaged e Thermal relay protection activated f Parameters setting problem 2 Cooling
89. l stored The doors and windows of the machine room must be installed with firm lock and baluster No unauthorized persons have access the machine room Spare parts and documents should be well kept 5 Humidity of machine room should be less than 85 with temperature ranging from 5 to 43 C If the temperature in the machine room is lower than 0 C the inlets and outlets of chilled water and cooling water systems should be closed The drain valve should be open 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 C the machine room ventilation and control cabinet cooling must be increased If the temperature is over 43 C electrical components will be destroyed in hours and serious damage will occur to the chiller 6 The chiller should be installed at an elevation less than 1000 meter Transportation and storage temperature should be between 25 55 C 7 Maintain operate and commission the chiller strictly following the User s Manual and Service File NOTE This regulation is applicable to BZY BEY BDEY BZEY PRODUCT OVERVIEW Pressure Vacuum Pressure Heating Exhaust Front flue Condenser LTG escape gauge control W outlet port chamber Cooling W outlet Chilled W outlet Absorber Evaporator Cooling W inlet Cooling W Chilled Chilled W
90. led water a Wrong wiring or short circuit a Check and connect the wires correctly flow switch b Flow switch es damaged or b Readjust or replace the switch es fault improperly adjusted c Check to verify whywaterflow is taking c Before starting the chiller there place through the chilled water circuit of is water passing by the chilled the chiller and rectify situation water side 2 Copper tube a Abnormally low insufficient a Stop the pumps and cut off power supply cracks chilled water flow rate when the immediately chilled water 3 stage protection b Close water system inlet valves failed or improperly adjusted c Close the 3 angle valves for vapor diluted simultaneously which can cause solution and concentrated solution evaporator copper tube s to d Inform service engineer immediately crack e Take sample from the drain valve and Possible reasons check the specific gravity If the gravity 1 Some valves in chilled water is over 1 1 water between the inlet and system damaged outlet valves of the chiller should be 2 Chilled water pump fault collected for regeneration in the future 3 Filters on chilled water system f Drain the LiBr solution into a clean vessel are seriously chocked g Open the water box cover plug one end 4 Airis not totally vented out of of the copper tubes tightly with a cone the chilled water system rubber plug spot the leaking tubes with b Chilled water outlet temperature the positive pressur
91. loves 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 Adjust the flow to zero and then stop it Seize the edge of membrane carefully loose it anticlockwise and remove the membrane and he disc on the back of membrane if any Check if the size code of the new membrane is in line with the old membrane Fit on the new membrane and disc align its orientation line to the hollow of the EPU Note Do not scratch the surface of the TEFLON Start the pump recover the flow knob setting When the pump is running tighten the new membrane clockwise until its center locks inwards closely then stop the pump Seize the edge of membrane carefully rotate its center to align with the brim of Spacer Load the membrane put the pump head back into the original place Check that the screws are still tight after one week 2 Replace seals ball valve and injection valve spring Clean the pump head with clean water and remove it after draining out Remove the pipe joints the damaged seals and the ball valve Pay attention to the front back side and position sequence Fit on the new ring and ball valve Fit a new injection valve spring c Antifreeze in winter If temperature in machine room is possibly lower than 0 dgr then wash the dosing pump head amp pipes and drain out to prevent it from freezing and cracking
92. lve 21 Actuator of heat source valve Replace Including steam hot water electric gas valve 22 Actuator of cooling W drain valve Replace 23 HTG pressure control Replace 24 HTG temperature control Replace 25 Cooling tower Replace nozzle packing and a ball valve and vent valve 26 Fan control cabinet Replace 27 Inverter fan Replace 28 Soft Starter fan Replace 29 Cold amp Heat insulations Replace 30 Auto vent valve Replace 31 Rubber isolator Replace 32 Rubber soft connector Replace 33 Auto dosing device Replace metering pump except the diaphragm four function valve brine tank dosing valve liquid level probe 34 Softener Replace water pressure gauge brine safety valve water distributor central tube brine tank brine plate brine well cover and plane 35 Atomization tray of burner Replace Maintenance every 16 years NO Items Method 1 Components in the control Replace PLC module circuit breaker relay transformer contactor cabinet and solution level control 2 Canned pump Replace 3 Burner Replace combustion head gas upper lower pressure switch ignition cable ignition transformer air pressure switch inner oil pipe oil gas meter air damper actuator controller and motor 4 Front and rear flue chamber Replace firebricks B Vent valve Replace 6 Drain valve Replace 7 Pump impeller Replace 8 Pump motor Replace 9
93. mple change oil to gas Select the mode of High Energy Saving Mode or Medium Energy Saving Mode Adjust the temperature of all indoor units 2 to 3 C higher lower Stop some indoor units which are running unnecessarily Reduce the flow rate of fresh air If there is a fresh air system Conduct intensive training on energy saving and collect energy saving proposals including heat insulation enhancement and reducing the use of heat radiating equipment etc 3 There is a difference between the amount of fuel consumed and fuel purchased If not for the items in 1 then there is a problem with the fuel meter Require the fuel supply company to change to a calibrated meter or send the meter for re calibration ENERGY SAVING MANAGEMENT ENERGY SAVING MANAGEMENT FOR CHILLER NO Items Methods Effect 1 Scientific maintenance Do maintenance work strictly according to periodic maintenance and load maintenance requirements Ensure that the chiller is always in the highest efficiency under all conditions 2 Choose an Choose waste heat such as waste steam Recycle waste energy to save fuel appropriate energy exhaust etc costs source 3 Lower the cooling T the chiller can be guaranteed to run in a Improve COP by 5 6 when the water inlet stable fashion keep the cooling water inlet cooling water inlet temperature is
94. n time min Tap water Tap water pressure MPa _ pressure MPa 0 2 0 4 0 4 0 6 0 2 0 4 0 4 0 6 BRS 2 230 224 8 6 BY75 100 248 238 12 10 BY125 150 246 240 10 8 BRS 6 BY 200 244 238 10 8 BY250 248 240 12 10 BRS 10 BY300 400 264 250 10 8 BY500 600 272 252 8 6 BRS 20 Open the cover of control valve there is an instructor on the right side Bottom arrow instructs water supply tank top arrow instructs another tank situation Left side drawing shows NO 1 tank is supplying water and NO 2 tank is for backup white point regeneration manual wheel slow wash amp salt absorption procedure back up regeneration 2 min hole plug pin procedure tray fast wash procedure _ working procedure i between the third group pins and 0 Micro switch v brine tank NI water injection procedure backwashing procedure the first group holes group pins the first wad Wty N O Pa 3 the third re 8 amp group pins slow wash 8 backwashing into brine tank backup status Status instructions WATER TREATMENT DEVICE b Manually add brine Application a Open the cover of control valve and make sure the manual regeneration gear already turned back to work position regeneration procedure set as well b Make sure that the total flow rate has been set correctly set flowrate equals the calculated periodic water production quantity minu
95. n and recycle it after sedimentation Connect valve 3 to the city water pipe to back wash the filter ements the higher the water pressure the better blow nitrogen gas PS0 06MPa through valve 3 for 20 minutes after flushing for 1 hour If the solution is dirty repeat the process 1 or 2 times The filter can be used only after the air tightness is again confirmed U For the new chiller backwashing is unnecessary For degenerative solution the filter shall be cleaned at least once every 2 days during the filtering process Checking Check the filter element once every 2 years Clear away all broken capillaries and replace all sealing elements Anti freezing and anti cracking The filter must be placed in a wet environment otherwise its capillaries are easy to break Clean the filter completely by the backwashing method and blow the filter element dry with nitrogen gas after use If the ambient temperature is above 5 C the filter can be maintained with distilled water or clean diluted LiBr solution If the ambient temperature is below 5 C it can only be maintained with clean diluted LiBr solution DANGER It is prohibited for non solution manufacturers to treat the solution Otherwise solution deterioration cooling capacity decrease or even chiller corrosion and damage can result MAINTENANCE D lt Open Ka Closed e E one L 6 Ka Illustration of solution fil
96. n tubes in evaporator and calculate COP 23 Chilled water calibrating temperature Calibrate chilled water outlet temperature to avoid frozen tubes in sensor T2A evaporator caused by chilled water outlet temperature deviation 4 Cooling water inlet temperature Detect cooling water inlet temperature and realize cooling tower fan sensor T3 frequency control to avoid excessively higher or lower than the setting 5 Cooling water outlet temperature Detect cooling water outlet temperature to control cooling water sensor T4 frequency control 6 HTG temperature sensor T5 connect Detect HTG temperature and send signal to PLC to avoid HTG solution PLC over temperature and crystallization 7 HTG temperature control TBA Perform HTG temperature limit protection by shutting off burner directly connect burner 8 Exhaust temperature sensor T6 Detect exhaust temperature to prevent over temperature 9 Ambient temperature sensor T9 Detect ambient temperature to save energy install outside 0 HTG crystallization temperature sensor Detect HTG concentrated solution outlet temperature to judge HTHE T10 HTG crystallization 1 LTHE inlet temperature sensor T11 Detect LTHE diluted solution inlet temperature to judge LTHE crystallization 2 LTG crystallization temperature sensor Detect LTHE diluted solution outlet temperature to judge LTHE LTG T12 crystallization 3 Control cabinet temperature sensor Detect temperature inside control cabinet auto sta
97. n valves to drain out the water inside the copper tubes 2 Charge the nitrogen gas of high purity above 99 995 into the chiller to 0 01 0 02Mpa and check periodically every 1 2 months for the pressure drops 3 Check carefully whether all valves are closed tightly screws are properly mounted sight glass covers are covered and fuel supply valves are shut off 4 Cut off the power supply after informing BROAD Remote Monitoring Center 5 The doors and windows of the machine room should be steady and reliable and cannot be used for other construction purposes Unauthorized personnels are prohibited to access into the machine room The burner tools spare parts and documents should be well kept 6 Keep the humidity and temperature of the machine room normal Some dehumidification measures shall be taken for electrical parts e g the control cabinet 7 A comprehensive maintenance and inspection is necessary before restarting the chiller ANTIFREEZE IN WINTER Before winter every year users should double check the unit and system to confirm that they are in accordance with antifreeze requirements If not take the following steps to prevent a unit or system from freezing a Air conditioning water system antifreeze When the air conditioning system is disabled and if the ambient temperature may be lower than 0 C water in the system pipes needs to be drained out completely Add antifreeze to the system the antifre
98. ncentration curve vibration to see whether the base is steady 7 Sample the refrigerant water from the or not Make sure the motor s current refrigerant sampling valve with the does not exceed the rated value and its negative pressure sampling method temperature increases normally Check Get the specific weight value with a whether the frequency driver of the cooling hydrometer water pump and cooling fan are normal 8 The designed maximum concentration is LTG 61 HTG 61 diluted solution 56 and specific weight for refrigerant is lt 1 04 9 Use water to clean the sampling valve nozzle to remove the residual solution and dry the nozzle Replace the cork Rubber cork Vacuum rubber hose Purge nozzle Sampling bottle Measuring Sampling nozzle cylinder Concentration meter Hydrometer Mercury thermometer 27 PERIODIC CHECK COOLING TOWER a Check and Adjust Cooling Tower Water Level Check whether the cooling water system is full of water the level of the water collector sump should be 25mm lower than its upper edge or and 20mm lower than the overflow pipe No matter what the load is the water collector should never be empty while the cooling water pump is running no overflow should occur in water collector while the cooling water pump is powered off Otherwise the float ball valve s acting position for the water pool level should be adjusted Check and Adjust Cooling Tower Fan Ch
99. nd 5 years The agreement should be in standard format and stamped Charge policy The expense standard depends on the size function amount and age of the chiller The Annual Service Agreement should cover periodical maintenance trouble shooting and some other service work Technology upgrading In order to create more value for the customer BROAD will inform the customer of the latest technical achievements so that the customer can decide whether or not to upgrade his chiller if the user has the intention they can sign the Single Agreement with BROAD 3 Spare parts ordering The users can sign the Single Agreement to buy spare parts from BROAD Under this agreement if after the warranty period the part that was replaced causes a problem BROAD will offer free service to that part within three months of the original date of purchase of the part N e Limited declaration Excluding the responsibilities which are clearly outlined above BROAD will not take responsibilities for any direct indirect special or attached damages Service disciplines It is prohibited for a BROAD service engineer to charge the users privately or make money by selling products from other companies otherwise the service engineer will be charged with corruption and cheating and bear the corresponding legal and economic liability Service requirements and standards Requirement Standard Routine ma
100. ngineers in their energy consumption surveys users gain important information on their BROAD systems including whether their energy consumption is reasonable or not why energy consumption might be high what is the system s energy saving potential and how can better manage my energy consumption c High energy consumption troubleshooting consumption is intolerably high 1 then it may be due to the too high ambient temperature in summer or too low temperature in winter or energy prices may be excessively high Abnormality Possible reasons Solution 1 Energy A C or hot water load is Conduct a check to see whether there is too much consumption is too high waste on air conditioning and hot water consumption too high and examine the building insulation For example check whether doors windows are opened or not the air conditioning is on in rooms without people and the hot water tap has been closed etc Chilled heating water Adjust the temperature setting by 2 to 3 C higher outlet temperature is set lower or choose the Energy Saving Mode too low high Management is not strict Work out the rules accordingly and implement strictly Poor chiller performance Troubleshoot Incorrect energy Find the reason and fix it consumption metering 2 Energy If it is not for the items in If there are cheaper energy sources like natural gas or waste heat replace current energy source for exa
101. o the solenoid valve thus causing the valve not getting closed tightly and gas can leak into the combustion chamber In this case when the burner is reignited deflagration and other problems will take place which will influence the normal operation of the chiller and more seriously even cause equipment damage and personnel injury MAINTENANCE 2 Oil filter Close the inlet valve of the oil filter Dismantle the drain nozzle cover on the bottom of the oil filter Collect the dirty oil in the filter and oil pipe through the drain nozzle Take off the nuts and bolts of the filter flange remove the flange plate and dismantle the setscrew and gasket of the filter element Take out the filter element and wash it with clean water from inside to outside and dry it removing the impurities Clean the fouling collector of the oil filter with rags and reinstall the filter element Make sure its bottom edges are completely put into the slot on the base Reinstall the flange plate Open the oil inlet valve and vent air in the oil filter and pipe b Oil System Air Vent If there is air in the oil system it will enter the oil pump and prevent the pump gears from completely dipping into the oil Under these circumstances the gears will be damaged quickly due to dry friction when the oil pump is in high speed operation Therefore after each initial filling or filter cleaning the air within the oil system must be purged 1 Air vent o
102. olution generates water vapor and concentrated solution 2 EEG Use H T G steam to concentrate L T G diluted solution to generate steam and concentrated solution 3 Condensor Condensates the L T G refrigerant steam and cooling the refrigerant steam come from H T G 4 Evaporator Generates low temp chilled water 5 Absorber Absorbs evaporator refrigerant vapor and pass the absorpor heat to cooling water 6 High temp heat Heat exchange of high temp concentrate solution from H T G and low exchange temp diluted solution from absorber 7 Low temp heat Heat exchange of high temp concentrate solution from L T G and low exchange temp diluted solution from absorber 8 Heating water heater Generates heating water 9 Hot water heater Generates hot water 10 Solution pump SP Pumps diluted solution to H T G amp L T G 11 Refrigerant pump RP Enable the refrigerant water spraying in endless cycles 12 Burner BM Provide heat to H T G 13 Auto purge system Automatically collect the non condensable gases into inlet chamber and purge non condensable gases out of machine insure the operation quality and chiller lifespan 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 2 Steam angle valve F3 Separates main shell with HTG Open in cooling 9 8 g Concentrated solution during heating and maintenance belongs to
103. or copper tubes Heat source water flow rate too high a Descale The method is subject to BROAD written permission Lower the heat source water temperature or pressure or reduce the heat source valve opening Heat source water outlet temperature abnormally high Normal operation a Soot in HTG or generator fire tubes b Exhaust flow too high a b Clean soot on time and provide clean exhaust Reduce the exhaust valve opening 68 NOTE indicates the work which can be performed by the user SATURATED WATER VAPOR PRESSURE 0 100 C Temp Steam Temp Steam Temp Steam Temp Steam Temp Steam C Pressure eC Pressure C Pressure C Pressure C Pressure 0 4 579 21 18 65 42 61 50 63 171 4 84 416 8 1 4 93 22 19 83 43 64 80 64 179 3 85 433 6 2 5 29 23 21 07 44 68 26 65 187 5 86 450 9 3 5 69 24 22 38 45 71 88 66 196 1 87 468 7 4 6 10 25 23 76 46 75 65 67 205 0 88 487 1 5 6 54 26 25 21 47 79 60 68 214 2 89 500 1 6 7 01 27 26 74 48 83 71 69 223 7 90 525 8 7 751 28 28 35 49 88 02 70 233 7 91 546 1 8 8 05 29 30 04 50 92 51 7 243 9 92 567 0 9 8 61 30 31 82 51 97 20 72 254 6 93 588 6 0 9 21 31 33 70 52 102 1 73 265 7 94 610 9 1 9 84 32 35 66 53 107 2 74 G 95 633 9 2 0 52 33 37 73 54 112 5 75 289 1 96 657 0 3 1 23 34 39 90 55 118 0 76 301 4 97 682 1 4 1 99 35 42 18 56 123 8 77 314 1 98 707 3 5 2 79 36 44 56 5 7 129 8
104. orking Principles eee EEE 9 Periodic Check OPER Renne RRR nens 23 Faults and Trouble shooting Sa bdeswsbsee AEA AA AA IEEE SR S 26 rnaen 3 Maintenance Gi 43 Energy saving Management Arar eia anta rea REA Tara Ria yra rss 54 Water Treatment Devices eee eee ee eee eee eee eee eee ee eee eee rere 57 Service Information P 63 IFA Main Interface A 65 IFA Safety Regulations A 66 IFA Trouble shootings Aer 68 Saturated Steam Pressure Pee eee ee eee eee ee eee ree tree eee eee eee errr eeiersy 69 Saturated Steam Pressure for LiBr SOIUTION 111 ttre 70 LiBr Solution Specification Curve PT 71 The Mission of Service Engineers P 72 Note BROAD X Generation Non electric Chiller includes DFA and IFA The differences between DFA and IFA are listed in those sections marked with A Since the main shell technology operation check maintenance and troubleshooting are almost the same as DFA all the contents in this manual non relevant to burners are applicable to both DFA and IFA ae Operation oriented information Knowledge oriented information GENERAL INFORMATION IBZY150XD BROAD X BZY COOLING Status C 2 Refrigerant HTG solution level level wE E core Gian ashe R cl 28 1 D Cooling W outlet 34 5 g Bai Cooling W inlet 34 8 OAM B 7 mei 48 6 150 8 ALL ls Expense Exhaust da 4 Information Profession S pump CA A A Hz Krap C7 4 Hz Energy Efficiency ene pump CA Instant Cop jle Refri t e e
105. ort circuit loose a Check and connect the contact wires correctly b Pump overload lack of phase or short circuit b Check or replace pump c Soft starter fault c Check or replace soft starter 12 Cooling water a Chilled water 3 stage protection act or is a Check chilled water 3 stage pump fault wrong wired protection b Incorrect pump wiring or short circuit loose b Check and connect the contact wires correctly c Pump overload lack of phase or short circuit c Check or replace pump d Inverter or soft starter fault d Check or replace inverter soft starter 13 Cooling fan a Incorrect fan wiring or with short circuit loose d Check and connect the fault contact wires correctly b Fan overload lack of phase or short circuit b Check or replace fan c Inverter if exists fault c Check or replace inverter 14 Hot water a Incorrect wiring short circuit or loose contact a Check and connect the pump fault b Pump overload lack of phase or short circuit wires correctly b Check or replace pump FAULT AND TROUBLESHOOTING c Abnormal reminding NO Fault Cause Keys 1 Chilled w inlet a Incorrect temperature sensor wiring a Check and connect the wires cooling w outlet or open short circuit correctly HTG crystallization b Temperature module damaged b Replace temperature module LTG crystallization c Temperature sensor damaged c Replace temperature
106. otor Check pump and whether the inverter works normally inverter MAINTENANCE NO Items Method 8 Temperature Calibration To detect the temperature of chilled water HTG and crystallization sensor check with precision thermometer and compare readings with the displayed values on the touch screen Make adjustment if the difference is less than 2 C If the difference is 22 C check whether the wiring is reliable or not 9 Cooling water Check the water analysis results and ask to make improvement if the water quality quality is below the standard 10 Machine room Check the machine room ventilation is good and whether the temperature is ventilation too high or too low the range should be 5 43 C Following maintenance items For high load every 4 months medium load every 6 months and low oad every 12 months NO Items Method 1 Water side of a Take out the fouling detector for the cooling chilled water open the soft copper tubes 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 a Adjust the water pump inverter or the outlet valve after the pump starts flow switches Check whether
107. ource of electromagnetic abnormal c Electromagnetic interference interference 8 AC water a Incorrect sensor wiring or open a Check and wire correctly pressure drop short circuit b Check or replace Sensor cooling water b Sensor damaged or fault c Eliminate source of electromagnetic conductivity c Electromagnetic interference interference sensor fault 19 Internet a Incorrect wiring or internet cable a Check and wire correctly monitoring not 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 battery and the replacement screen low b Poor battery quality should be done in 2 minutes battery b Purchase battery from BROAD FAULT AND TROUBLESHOOTING d Abnormal record off NO Fault Cause Keys 1 Cooling a Poor performance of cooling tower 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 Add water and continuously add over upper limit setting is too high water d Fan blade angle improperly adjusted c Reset target temperature value causes motor strap too loosen d Adjust fan blade angle or strap 2 Cooling water a Low outdoor temper
108. p water valves signal pipes overflow pipes drain valves and insulation are good or not b Clean and repaint where necessary MAINTENANCE Maintenance every 2 years NO Items Method 1 Gas filter core Replace 2 Water pumps a Disassemble inspect and clean in particular scale on the inner and outer surface of the impeller and in the flow path b Replace mechanical seals Inspect seal wearing parts such as shaft seal shaft coupling and fillings and abrasion of the bearing 3 Cooling tower a Disassemble and check the wear of motor bearing b Replace fan belt 4 Auto chemical dosing device Replace diaphragm ball valves and spring of injection valve Note Do not use pliers or wrench PTFE tape or piping sealing glue is also prohibited B Flow meter Send to local technical supervision authority to test and calibrate Reuse after passing precision test otherwise need to be adjusted by professional Maintenance every 4 years NO Items Method 1 Vacuum pressure gauge Replace 2 Chilled water flow switch Replace 2 Batteries of PLC and touch screen Replace 4 Exhaust temperature sensor Replace B Chilled water temperature sensor Replace 6 Gas train or oil filter sealing elements Replace 7 Water pump bearing seal retainer washer Replace 8 AC water pump filter box and return c
109. plate heat exchanger Get cooling without running the cooling in winter can get between the chilled water system and chiller Economical safe and cooling from the cooling cooling water system reliable tower 3 Use simple piping Use a low resistance valve e g butterfly Reduce resistance and heat loss valve rather than a high resistance valve e g shut off valve Use zero resistance ilters Use elbows with big radius Remove all unnecessary valves and pipe fittings 4 Design a reasonable Design a linkage controlled adjustable he reasonably designed fresh air resh air system with a air damper for fresh and return air and system can effectively delay the heat recovery device control the fresh air ratio through an start and pre stop of the chiller Establish a complete enthalpy controller so that the fresh reduce the load and running resh air and exhaust air air flow can be adjusted Install a heat ime of chiller and reduce energy management system recovery device on the fresh air system consumption B Install a motorized Choose or add indoor units which are Shut off different indoor units on solenoid valve and heat equipped with motorized solenoid valves time to reduce heat loss and meter for indoor units and heat meters such as BROAD indoor Improve behavioral energy units saving consciousness 6 Install automatic speed Choose indoor units which have Control the room temperature emperature adjustment automatic speed temperature o avo
110. pper and lower cover FAULT AND TROUBLESHOOTING cont NO Fault Cause Keys 10 Refrigerant a Poor vacuum a Refer to poor vacuum eliminating method overflow b Refrigerant water polluted b Refer to polluted refrigerant eliminating c Cooling water flow too low or method temperature too high c Increase cooling water flow or improve d Comprehensive solution cooling tower performance concentration is too low d Increase solution concentration e Heating capacity is too high e Decrease heat input f Scaling in absorber copper tubes f Remove scaling in absorber copper ubes 11 Refrigerant a Cooling water temperature and a Increase cooling water temperature and freezing user s load are both low select energy saving operation mode b Chilled water outlet target b Increase chilled water outlet target temperature setting is too low emperature c Chilled water flow is too low c Check the chilled water system and increase chilled water flow 12 Crystallization Cooling water inlet temperature is a Check cooling water temperature too low Excessive combustion Poor vacuum Circulation is improperly adjusted Excessive corrosion inhibitors CQO00 setting value keep normal or add inverter to control Readjust burner and reduce combustion Refer to poor vacuum Readjust circulation amount Add corrosion inhibitors strictly according o the standard
111. r shut off and affect the user s energy management w 1 The heat source should not have corroding components Q Otherwise it will corrode the heat exchange pipes in generator even bore a hole and causes gt huge loss 9 m 2 The heat source pressure and temperature should be stable lt The pressure fluctuation range should be within 0 02MPa of the rated value and the working pressure and temperature should be less than 10 of the rated value Stable equipment should be installed offered by the users at inlet of the heat resource 3 If the chiller is shut down for over 2 hours the manual valve on the heat source pipe should be closed To prevent the solution crystallization and other accidents occurs because of high pressure leakage of heat source IFA SAFTY REGULATIONS N VACUUM AND LIFE SPAN w Confirm the vacuum conditions and good condition of auto purge and vent device Prevent others from handling the vacuum valve randomly Conduct chiller shut off management with care gt Strengthen water quality management according to the Vacuum Management Regulations The handle of the vacuum valve must be removed and well kept after operation to avoid unauthorized access If the expected shut off is over 8 months it should be charged with 0 01 mpa 0 02 mpa high purity nitrogen purity gt 99 995 Use only BROAD solution it is forbidden to use solution regenerated by othe
112. r temperature going Heating water outlet pipe emperature sensor T8 above 95 C 1 HTG crystallization sensor Prevents chiller failure caused by HTG HTG concentrated 10 crystallization solution outlet pipe 2 LTHE inlet temperature LTG Prevents chiller failure caused by LTG Low temperature heat crystallization temperature crystallization exchanger diluted sensor T11 T12 solution inlet outlet 3 Control cabinet Prevents negative impact on operation Control cabinet emperature sensor T13 reliability safety and life span of electric components caused by super high emperature of control cabinet 4 HTG solution level probes Prevents HIG damage caused by HTG solution HTG YK lacking 5 Refrigerant level probes Prevents cavitation of refrigerant pump Refrigerant chamber in YK2 evaporator 6 Main switch Powers off in case of chiller maintenance Control cabinet 7 Inverter Pump fan problem prevention Control cabinet 8 Circuit Breaker Pump fan and short circuit protection Control cabinet 9 Thermal relay Pump fan and wires over load phase lack Control cabinet protection 20 Burner safety device Prevents damage to equipment and personnel Control cabinet burner amp gas train 21 Automatic pressure escape Releases pressure in case of burner deflagration Front flue chamber No or flue duct blockade weight on it 22 Rupture disc Protects personnel and equipment in case of HTG abnormally high pressure in HTG 23 Heating water pressure Preven
113. rd plastic bottle to hold he solution with cover which can be purchased locally Fill the bottle with3mm 5mm of empty space left to he top of the bottle Wax the bottle if he sample can t be delivered within one week Users Abbr Chillers Model Sampling Dote Running Dote ae Serial NO a Operator a O Write detailed information on the label such as user abbreviation chiller model serial NO sampling date chiller operation time operator service engineer and local service office and paste the label tightly on the solution bottle Pack under the guidance of the post office or express mail service and post to BROAD Service Center BROAD Town Changsha 410138 China If it is convenient for the customer our service engineer can bring the sample to BROAD town Applicable to sampling locations with positive pressure This is suitable for a 2 stage chiller when the solution pump is running with a frequency over 40Hz but 2 In line with our customer centered not for other chillers principle BROAD service engineers will Prepare a clean glass or plastic container conduct annual solution analysis on the Remove the cork on the sampling valve site for Li2CrO4 solution users and provide Put the container under the valve nozzle an onsite test report of LiBr solution
114. reman ame 1 3 of the program period flow rate or softener SS t glass S Bar BS S settings according to inlet outlet water 4 Swiftly sample the LTG and HTG quality and variation so as to keep the concentrated solution from the LTHE c A S S E system performing best The period of and HTHE sampling valves with sampling adding salt is referred to in the chapter bottle by employing the negative pressure under Add salt and resin manually method 5 Open the diluted solution sampling valve b Auto Dosing Device Check In rated operation with inverter frequency If the cooling water system is running for above 40Hz this valve is under positive a long period of time the scale will get pressure However because of constant accumulated also mud and algae in the change of frequency it is possible for air pipes and all of these materials are thermal leakage due to temporary low frequency resistant They will reduce the heat transfer Therefore the negative pressure sampling causung energy wastage and shorten the method is suggested to discharge the chiller s life Check whether the chiller can solution directly realize auto dosing or not the stabilizer has 6 Measure the solution concentration run out and the stabilizer pump has been set and temperature with the density properly meter and thermometer then check the actual concentration against the c Pump Check LiBr Temperature Specific Gravity and Check the pump s running noise and Co
115. rm connection Cooling No abnormal sound or vibration No aging or color change owning Listening and Tower Fan to overheat on fan blades Visual Inspection Air duct No blockage Visual Inspection ELECTRIC SYSTEM AND PARTS Electrical system and parts shall be checked once every 3 months Electrical system checking general requirements parts and wiring are fixed firmly the temperature rise of parts in operation is normal labels are clear complete and pasted firmly and no dusts or objects on each part Electrical parts checklist Control Pressure Control Flow switch resets normally Cooling W flow switch shall disconnect connect when the water pump is off on No rust on bellow pipe of pressure control and flow switch Item Content Tools or method Transformer Deviation of each output voltage shall be within 5 of the Multi meter Infrared rated value Surface temperature is below 60 C Thermometer Temperature Temperature and pressure control set point activates and Visual Inspection All Temperature Sensors Calibration Measure temperature at all places with precision thermometer and compare with the value on touch screen compensate if deviation lt 2 C check the wiring and sensors if deviation 22 C Thermometer AC Contactor Circuit Breaker Touch the testing point of the AC contactor and circuit breaker with a small screw driver and check if it functions normally and
116. rs It is required to sample the solution and test it once a year and The solution should be fully circulated and diluted before sampling If the result can t come out at site or the user needs a more detailed report sample solution with special bottles and send it to the BROAD lab and fill the label on the bottle correctly BROAD will confirm the vacuum and rust condition of the copper tubes and steel material to ensure 25 year life span The solutions need not be taken out for regeneration If it is too feculent it can be filtered with the 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 Without BROAD s written permission it is forbidden to clean the copper tubes with chemicals If the chemicals are not property used and the cleaning is not strictly controlled or the chemicals are not drained completely it will seriously corrode the copper tubes affect the life span and even destroy the chiller An auto water quality stabilizer charging device should be installed auto dosing of biocide and anti sludging agent Analyze 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 tu
117. rt stop the T13 ventilation fan to avoid high temperature affecting the reliability safety and life span of electrical components 4 Heating water inlet temperature Detect heating water inlet temperature and calculate heating water sensor T14 capacity 5 Heating water outlet temperature Detect heating water outlet temperature Adjust the heating load and sensor T15 calculate heating capacity 6 Hot water inlet temperature sensor T16 Detect hot water inlet temperature and calculate hot water capacity 7 Hot water outlet temperature Detect hot water outlet temperature adjust the hot water load send an sensor T17 alarm if temperature is too high and calculate hot water capacity 8 Chilled water flow switch B1 B1A Detect chilled water flow rate to prevent frozen tubes in the evaporator Connected to PLC 9 Cooling water flow switch B2 Detect cooling water flow rate to ensure chiller capacity 20 Chilled water flow switch B3 Directly Detect chilled water flow rate to perform 3 stage protection connected to cooling water pump 21 Pressure control GY HTG overpressure protection When overpressure occurs a signal will be sent directly to PLC to the PLC to stop the burner 22 HTG solution level probe YK1 Detect HTG solution level perform solution cycling regulation and HTG low solution level protection and detect the signal of tube cracks 23 Refrigerant level probe YK2 Detect refrigerant level and send signal to PLC to control t
118. running time the auto vent frequency of the chiller and main parts Press Parts Remain Time to check the remaining life of each part OPERATION AIR CONDITIONING MODE SELECTION BZY150XD O BROAD X BZY 2007 08 22 Wednesday 19 30 30 Setting 3 Cooling Cooling and hot water 2 Heatin Information Profession Heating and hot water Hot W only Clock setting Energy saving Time on Water system 3 Hort setting Choice Other choice Press Setting to enter setting interface then press Mode to enter HEATING a Make sure that the steam angle valve concentrated solution angle valve and diluted solution angle valve are fully closed and the HTG solution level is in zone D b Make sure that the heating water drain valve is closed and hot water drain valve is fully open c Make sure that the system s cooling heating switch valve is switched to heating and the COOLING the corresponding circle turning black means the mode has been chosen and the same for other modes a Make sure the steam angle valve concentrated solution angle valve and diluted solution angle valve are fully open b Make sure the chilled water and cooling water drain valves are closed and the heating water and hot water drain valve are fully open c Make sure the system s cooling heating switch valve is switched to cooling position and the system is full of water COOLING AND
119. s been added drain the water to prevent the unit from freezing 2 When the ambient temperature is lower than 0 C because of the residual refrigerant water in the refrigerant water pump refrigerant water pressure drop pipe and condenser pressure drop pipe when the ambient temperature is lower than 0 C freeze may occur In this case pass refrigerant water into the absorber and keep the unit in a vacuum state 3 Long time disabled chillers in a nitrogen state as well as chillers that have not yet been put to use but have been previously tested on the testing platform and delivered with nitrogen in the system should be charged with some LiBr solution in refrigerant water box from refrigerant water sample valve The best concentration of solution in the refrigerant water box is 52 MAINTENANCE e Fuel system antifreeze Appropriate grade of diesel should be chosen for the ambient temperature 1 In regions where the lowest temperature is above 5 C light oil NO 10 should be used 2 In regions where the lowest temperature is above 14 5 C ight oil NO 20 should be used 3 In regions where the lowest temperature is above 29 14 C ight oil NO 25 should be used 4 In regions where the lowest temperature is above 44 29 C ight oil NO 50 should be used f Antifreeze instructions 1 Effect Antifreeze is solution of various chemical reagents in A C water or domestic hot water which make the fr
120. s breaking off due to solution pump vibration After the filter is installed and firmly connected start the vacuum pump open the purge valve solution inlet outlet valve to purge all the air inside the flexible tube and the filter check the air tightness of the filter and conduit by bubble comparison method before each purge operation Close the purge valve and stop vacuum pump Under cooling operation when the solution pump is confirmed in operation open the LTHE sampling valve and the diluted solution sampling valve to filter the solution Observe the flow rate and color during the filtering process When the solution filtering is complete close the diluted solution sampling valve then the solution inlet valve solution outlet valve and LTHE sampling valve in turn The filtering time for the new chiller is about 100 150 hours For the degenerative solution duration depends on the need of each specific situation NOTE As solution filtering needs certain pressure at the inlet of the filter filtering can only be done in cooling operation The opening of the diluted solution sampling valve cannot be too large After the filtering is complete the solution inside the chiller should be analyzed and its chemical composition adjusted as per the analysis report w Close valve 1 2 4 and Sin turn open the fouling collector clog 6 and valve 3 blow a small amount of nitrogen gas and collect the residual solutio
121. s the necessary remaining water quantity and make sure the flow meter flexible axle inserted into flow meter already c Make sure the quantity of brine in brine tank no less than 1 3 of the tank and liquid level is 1 4 1 3 of brine tank d Closing bypass valve testing valve open inlet outlet valve softener starts to work e At the beginning of operation the inspection of water quality should be strengthened According to in out water quality and variation to adjust the regeneration procedure s time and flow rate etc in order to make sure the system working at best operation state Maintainance a Regular checking and period NO Item Period 1 Check the brine tank add Imonth industrial brine if the bring quantity less than 1 3 of the tank lodate brine and fine salt is not allowed otherwise it will influence the regeneration result and resin s life span 2 Check and clean inlet filter of softener 2 Make sure the ambient temperature of softener gt 0 C inlet water temperature lower than 40 C 4 Make sure the water pressure lower than 0 6MPa 5 Check resin tank and resin and lyear add proper resin 6 Take anti dehydration and phycomycetes breeding measurements when the softener is left unused 7 Change water pressure gauge 8 years brine solution safty safety valve water distributor central tube components in brine tank and eletronic component d Becaus
122. s the LiBr solution to 140 C to generate steam which is then condensed into water by the cooling water When the condensed water enters the evaporator in high vacuum condition it evaporates immediately and its temperature goes down to 5 C It is then sprayed over the copper tubes decreasing the temperature of water in tubes from 14 C to 7 C and then producing chilled water The water absorbs heat from air conditioning system evaporates and is then absorbed by the concentrated LiBr solution from the generators The cooling water takes away the heat and releases it into the air Diluted solution is pumped into generator to be heated to repeat the process all over again NOTE LiBr is a kind of brine with strong water absorption capability with no poison and harm 21 WORKING PRINCIPLE ea Chilled water 65 55 C Hof water 80 60 C Hot water pump Heat source or fuel THE HEATING PRINCIPLE The input heat energy heats the LiBr solution The steam produced by the solution heats the heating water and hot water in the respective tubes while condensate returns to the solution to be heated and the cycle repeats As separate heating is adopted whereby the chiller does not run during the heating cycle the heating cycle becomes very simple just like the mechanism used in a vacuum boiler Therefore the life span of th
123. sensor s LTHE diluted solution inlet vent ambient control cabinet emperature sensor abnormal 2 Large deviation with a Temperature sensor resistance a Check and connect the wires chilled water outlet value drifts correctly or replace emperature sensor b Incorrect temperature sensor wiring b Replace temperature module c Temperature module drifting or c Calibrate or replace damaged temperature sensor 3 Chilled water outlet Ja Chilled water flow rate is too low a Increase chilled water flow rate emperature lower b Chilled water outlet temperature b Increase chilled water outlet han 4 C setting is too low temperature setting c Cooling water temperature is too low c Increase cooling water temperature 4 Heating hot water ja Thermostatic valve works abnormally a Check thermostatic valve wiring outlet temperature b Water flow is too low or actuation device over 95 C c Large deviation in temperature b Increase water flow rate Sensors c Replace temperature sensor d Temperature sensor installation d Move the temperature sensor to location is too close to water heater 10m away from the water heater 5 Exhaust over a Soot in fire tubes a Clear soot temperature b Excessive combustion b Adjust combustion amount c Exhaust temperature sensor deviation c Replace temperature sensor too large 6 High temperature in a Machine room overheated a Strengthen ventilation to reduce control cabinet b Control cabinet fan dama
124. sion service engineers should love BROAD deeply appreciate the service essence of Broad Every service engineer should understand that if the downtime energy waste or purification disablement occurred not only the BROAD brand which is built by all BROAD staff hardwork will be ruined but also the trust from BROAD on them To achieve this mission service engineers have to study hard to master testing maintaining energy saving running and air purifying knowledge and also consolidate and update these knowledge through annual refresher training To achieve this mission service engineers have to be able to be aware of the defects in product design and manufacturing and also can report to the production department in time Only if each engineer takes an active part in quality improvement the products can be developed constantly To achieve this mission service engineers have to work hard rigorously everyday such as making regular maintainance plan managing well tools and repair spare part monitoring the operational condition of chiller ensuring the precise maintainance and technology upgrade proceed as planned Avoid any urgent repair after breakdown of chillershave happened or any maintainance after obvious weakening of energy efficiency and purifying capability because no matter how speedy the repair and maintainance is it cannot make up for the customers loss To achieve this mission service engineers have to find out any defect in desi
125. t site Dismantle 4 function valve and take off the valve ball fill the pump head with water then assemble the valve Start anti fouling pump and sterilization pump on Commissioning interface of chiller operation screen 3 Switch the stroke distance and frequency to 100 mark when pump is working 4 Rotate blue 4 function valve by 1 4 circle clockwise to drain out the air in pipes Suck pipe starts sucking liquid medicine Rotate the blue button anticlockwise by 1 4 circle to close the pump after liquid medicine flows out from the backflow pipe of 4 function valve 7 Adjust output flow rate N nn Discharge pipe Stroke distance adjust aw J Backflow pipe Stroke frequency adjust Valve inlet Dosing pump panel b Output flow rate adjustment Stroke distance adjust switch and frequency adjust switch on anti fouling and sterilization pump panel are for flow rate adjustment Rotate clockwise to increase flow rate percentage Output flow rate max output flow rate x set value Demarcate Put dosing pump suction pipe and bottom valve into a container capacity about 1000ml as shown in the picture on the right 2 Start the pump to venting the air in pump head and suction pipe Turn off the pump and record the original solution level Ww strokes every sound Ka means 1 stroke The longer the pump operates the more accurate the result is 5 Stop the pump record the
126. tarts cooling operation the chilled heating water pump must be started before to the cooling water pump When chiller shuts down 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 out in the above mentioned requirements a reconfirmation is needed once every 3 months in case of any accidents like incorrectt connection of cables or software viruses 2 In cooling operation 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 Start the chiller and when the HTG temperature rises to 100 C check the temperature of the valve pipe on the main shell side to see if it rises A loose shut off of angle valves will result in high temperature and damage the HTG sl OPERATION Ensure good ventilation conditions in machine room Otherwise chiller will be eroded which will damage electrical insulation and affect combustion even injure people due to oxygen shortage in machine room 2
127. tection procedures under Commissioning Mode but they can be used only under the supervision of professionals otherwise serious failure will occur 3 Safety devices cannot be short circuited nor can their settings can be changed at will Before the cooling period begins all the safety devices must be calibrated especially the chilled water flow switches temperature sensors and HTG pressure controllers otherwise the copper tubes may become frozen and serious personal injuries may occur 4 Power supply must be correct and voltage must be stable Voltage fluctuation must be within 10 of the rated value A dedicated grounding wire must be available in the machine room At least a 6 0 mm2 wire must be adopted as the grounding wire and the grounding resistance should be lt 4Q otherwise it will damage the electrical components and control system or even cause personal injuries 5 The electric wire must be reliable If the electric wire is damaged the wire should be replaced by a professional to ensure 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 the BROAD monitoring center will not know if the chiller is working normally If the chiller is to be stopped for more than 3 months BROAD monitoring center must be informed before power off 7 Computing data must be set correctly If the data is wrong it will cause unexpected chille
128. ter system Choice e Energy saving Time on Hode setting setting Press Time On on the Setting screen to enter OPERATION ENERGY SAVING SETTING BZY150XD 2007 08 22 BROAD X BZY Setting Wednesday 19 30 31 Energy saving operation Top High Medium Low Cancel energy savin energy saving energy saving energy saving a accel ee arnt Meee SN Cooling Heating Unit C Ambient hich medium Ambient Top high medium Low oD Savine savine Teno Savine saving savine saving 5 41 55 E 39 1 3T Profession 5 Stop 8 7 13 i 15 a 16 i X 18 Z Restart difference 3 of ambient temp Time on Water system setting Choice Clock setting Other choice Press Energy saving setting on the Setting screen to enter the 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 energy saving mode Note After the chiller stops automatically at shutdown temperature it can automatically restart when the ambient temperature increases while cooling reduces while heating by a certain temperature difference this is called restarting the temperature difference For example in medium energy saving cooling operation the chiller will stop when the amb
129. terface Clock setting Choose the corresponding pump fan water quality stabilizer pump or valves make single or multiple choices or cancel according to system demand OPERATION TARGET TEMPERATURE SETTING BZY150XD 2007 08 22 O BROAD X BZY COOLING Wednesday 19 30 22 ante Sete Refrigerant HIG solution EE 32 9 level level capacity Chill i 125 TSTST 7 TE x Chilled Heati 28 1 MAX J 100 Setting S Y inlet 28 1 15 HI 0 Cooling Y outlet 34 5 17 30 50 Ga Cooling W inlet 34 8 0 0 i Gl a Expense e 48 0 150 0 ajile A a RBIS al E ENTER T 25 0 S pump C 0 8 Hz Reo C 0 8 Hz Enere Efficiency Vent pump CA Instant Cop 1 00 Refrigerant Hour Cop Daily Cop 1 UN Start OFF Dilution The setting target temperature of the chilled water outlet cooling water inlet and HTG can be adjusted on the main screen Input the target number and confirm in the TENKEY numerical keyboard Appear while pressing the background part The chiller will automatically adjust the load according to the target temperature setting For example if the chilled water target temperature is set at 7 C the chiller will automatically keep it around 7 C Chilled Heating W Outlet temperature Settings range is 5 25 C by default at 8 C By increasing the target temperature properly when the ambient temperature is low the user can save energy But increasing the tar
130. tering ANALYSIS OF THE EXCESS AIR COEFFICIENT 1 The amount of air required for complete combustion of the unit volume or unit weight of fuel is called the theoretical air amount In fact to assure a thorough and safe combustion the required air amount will be more than the theoretical one The ratio of the actual air amount to the theoretical one is defined as the Excess Air Coefficient A 2 To make sure that the burner works steadily the Excess Air Coefficient should be well adjusted If the air supply is too high more heat will be taken away by the exhaust gas through the chimney which will waste energy This might also cause unstable combustion or even blow out the flame If the air supply is insufficient the flame will become longer or the CO content in exhaust will go up or even secondary combustion will take place in the flue duct which is very dangerous From the environmental protection point of view reducing the Excess Air Coefficient moderately will lower NOX emissions which means the reducing pollution generated by the chiller as well as heat loss 3 The standard value of the Excess Air Coefficient A gas type 1 18 1 25 oil type 1 13 1 20 To achieve optimal combustion efficiency this coefficient shall be examined with an exhaust analyzer every 3 months If a deviation from the standard is found adjustment is necessary 1 Diluted solution sampling valve 2 Solution inlet valve SS Ie 2 4
131. th good performance on heat reflecting for outdoor envelope 20 Use 100 automatic The air conditioning system will adjust all Heavy energy waste due to and intelligent equipment according to load so that best poor operations will be avoided control for air performance is achieved at all times conditioning system 21 Lower indoor Summer When the indoor temperature temperature and No less than 26 C humidity 40 to 60 is adjusted from 26 Cto 28 C in humidity standards Winter summer the cooling load can No higher than 20 C humidity 2 35 be reduced by 20 When the indoor temperature is adjusted from 20 Cto 18 C the cooling load can be reduced by 30 22 Clean all kinds The filters of the cooling water system and fuel Avoid low heat transfer of filters in the air system should be cleaned at least every 3 efficiency conditioning system months The filters of the chilled heating water periodically system and 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 WATER TREATMENT DEVICE AUTO DOSING DEVICE Start 4 Start the pump and run it for some time and count the stroke quantity at least 50 Blue switch a Pump head injection Anti fouling pump head and bacteria kill pump head were discharged before shipment so it is needed to inject it before it starts to work a
132. the flow switch closes when the flow rate is above 70 of the rated value and whether it disconnects when the flow rate is below 60 of the rated value 40 for cooling water b Confirm the start stop sequence of the cooling and chilled water pumps 4 HTG a Make sure the pressure control actuating value is set correctly factory setting temperature b Check if protection is actuated during Nitrogen charging for repair or during and pressure maintenance control c Make sure when HTG temperature gt 170 C HTG temperature control actuates to shut off the burner 5 Gas train air ja Check valve train joints leakage by soap solution Charge Nitrogen to tightness amp maintain pressure at valve train per burner manual instructions upper lower b Check performance of gas valve leakage detecting system limit pressure c Ensure that two stages of gas solenoid valves can both open close reliably switch 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 7 Rupture disc Replace and sealing elements Following maintenance items For high load every 2 years medium load every 3 years and low load every 5 years Burner NO Items Essentials of the method 1 HTG solution level probe and UDK upper lower jacket Filter the solution with a precision filter 2 Vacuum sealing elements in high temp
133. the valve screw at the same time 8 When the sealing elements are found deformed damaged or destroyed they must be replaced immediately 9 The replaced sealing element must be labeled properly or destroyed to avoid mixing them with the new ones N BOD Oo A NOTE The replacement of vacuum sealing parts is an important job for maintenance Aging or damage to the sealing elements will lead to vacuum deterioration which will cause serious harm to chiller operation and shorten the chiller life span PUMP FILTER HEADER CLEANING Close A C or cooling water inlet and outlet valve 2 Open drain valve and drain all the water in filter header 3 Take off insulation carefully and open service door 4 Clean the filter header from inside 5 6 Close service door and if bolts are damaged replace them Put insulation back and make sure it is tight without any gap COOLING FAN MOTOR BELT REPLACEMENT 1 Loosen the fixing bolts of the motor 2 Take off motor belt and then fit with the new belt of same model 3 Regulate motor horizontal adjustment bolt to tighten loosen the new belt 4 Tighten the horizontal adjustment bolt and fixing base bolts 5 Test run cooling fan MAINTENANCE NON OPERATION MAINTENANCE If the chiller needs to be stop for more than 8 months due to some special reasons non operation maintenance should be carried out 1 Shut off all inlet outlet valves and open the water drai
134. tificate Training certificate After Centralization training finished only the people who get all credits and the performance such as discipline study attitude is excellent can get the level certificate Those who do not get all credits but have good performance can get training credit certificate and after they get the rest credits they can get the level certificate If anyone can not get any credits or the performance is bad then they can onlyget the training certificate Maintenance BROAD bears the materials labor and travel costs during the warranty period During the life span of the chiller BROAD s service engineer will offer free energy saving advice Any costs incurred due to the user damaging the chiller for example the fuel power and auxiliary devices and man made damage or force majeure for example typhoon earthquake flood and war shall be borne by the user SERVICE INFORMATION b Paid service Service after the warranty period or for users unless under some specific clauses belongs to the paid service category BROAD service engineers shall issue a Warranty Service Expiration Notice to the user 1 2 months before the warranty period expires For payment service the user has the following options 1 Signing of the annual payment service agreement After the warranty period the user is recommended to sign an annual service agreement with BROAD The period can be between 1 a
135. ts overpressure of heating water heater Heating water drain release valve YA1 or safety protection of personnel or equipment pipe 24 Domestic hot water Prevents overpressure of hot water heater for Hot water drain pipe pressure release valve YA2 safety protection of personnel or equipment 25 Grounding wire Protects personnel and equipment in case of Control cabinet Prepared electricity leakage by user 26 Gas leakage detector in Prevents accidents caused by leakage of gas Machine room Prepared machine room SG2 pipes by user 27 Fire fighting detection Protects personnel and equipment in case of Machine room Prepared device ire accident in machine room by user 28 Lightening rod Protects personnel and equipment from Above the rain cover of Prepared ightening chimney exhaust vent by user NOTE 1 Short connection or adjus 2 Special attention should be paid to reliability of all sa 20 ment of safety equipment beyond safety value is strict ety devices by regular checking ly prohibited WORKING PRINCIPLE _ Chilled water 7 14 Hot water 80 60 C E bes a Q 91 S E Rn C 5 S 5 le 5 2 f ORE a 29 5 p E 12 K X 2 z aJ O O E High temperature heat exchanger Heat source or fuel Low temperaure heat exchange THE COOLING PRINCIPLE The input heat energy heat
136. ts with and are not for cooling only type 19 SAFETY DEVICE LIST PART LIST NO Name Function Install position Remark 1 Chilled water flow switch Prevents frozen tubes in case of chilled water Chilled water inlet pipe B1 B1A stoppage or low flow lower than the lowest Connected to PLC allowable flow rate 2 Chilled water flow switch Stops the cooling W pump and prevents frozen Chilled water outlet pipe B3 ubes in case of chilled water stoppage or low Connected directly to flow lower than the lowest allowable flow rate cooling W pump 3 Pressure control GY Prevents HTG overpressure in operation HTG 4 Chilled water outlet Prevents frozen tubes in evaporator Chilled water outlet pipe emperature sensor T2 5 Chilled water calibrating Prevents frozen tubes in evaporator caused by Chilled water outlet pipe emperature sensor T2A deviation of chilled water temperature sensor 6 HTG temperature sensor Prevents HTG over temperature and HTG 5 crystallization 7 HTG temperature control Prevents HTG over temperature HTG 5A 8 Exhaust temperature sensor Prevents fire caused by extra heat in flue duct HTG exhaust outlet 6 9 Hot water outlet Prevents hot water temperature going above Hot water outlet pipe emperature sensor T7 95 C 0 Heating water outlet Prevents heating wate
137. ubes after operating for along time So it is necessary to regularly check the water side of the chilled heating and hot water pipes The checking methods are as follows 1 Every 6 months check the fouling detector to see if fouling has formed in the copper tubes or open the soft connecter to be inspected by you Take a sample using a small bottle and send it to an authoritative lab for analysis 2 Every year open the water box cover of the chilled heating and hot water system to check for fouling in the copper tubes and rust on the tube sheet or water box interior b Tube cleaning If analysis shows that fouling exists inside the copper tubes cleaning is needed Chemical cleaning is subject to BROAD written approval and BROAD service engineer s on site confirmation COOLING WATER QUALITY AND FOULING a Cooling Water Quality Requirement Since the cooling water is exposed to the atmosphere for a long time evaporation loss can be significant and water quality is subject to deterioration due to corrosion Cooling water quality must meet the requirement of the GB T18362 2008 Cooling Water Makeup Water Quality Standard as stipulated in the following C The high concentration of Chlorine ions and acidic materials in the water might corrode the metal badly too high a concentration of mineral and alkaline substances might also cause serious fouling In general city water not including sea water for flushing sewage
138. valve is installed correctly and in working condition Rotate the blue knob of the 4 function valve by 1 4 circle and vent the air in the outlet pipe until the solution flows from the return pipe to the brine tank 2 Cleaning of corrosion inhibitor amp anti sludge agent tank Open the discharge valve at the bottom of the chemical tank expel the residues and rinse with clean water until it is clean Close the discharge valve open the lid at the top of chemical tank and add the proper amount of chemicals to the box Fill chemicals to the level of the pump head then put into operation 3 Cleaning of the biocide tank Loosen the suction pipe and take out the bottom valve and clean it Loosen the fixed ring take out the chemical tank expel out the residues and clean it with clean water Reassemble the chemical tank bottom valve and suck pipe Add liquid chemical to the tank from the opening of chemical tank Inject the biocide at pump head and put it into operation b Replacement of spare parts 58 1 Membrane replacement After pressure releases of the outlet pipe drain and take out one end of the discharge pipe Put the end valve into the clean water start he pumps wash the pump head and then lift he valve off the liquid and continue to run the Fault and troubleshooting pumps until the pump head is filled with air If he membrane is broken the pump will stop working Put on latex g
139. while checking HTG 5 pressure 5 HTG pressure valve F19 Checks HTG pressure Closed in operation 9 open while checking gt main shell pressure 6 L Auto air vent valve amp Non condensable gases are vented Manual valve is open in Z manual valve F20 out of the chiller through this valve operation closed while during auto purge It can also charging nitrogenor or in prevent air into leaking in the chiller maintenance 7 Nitrogen charging valve Port used for charging nitrogen into Open only for nitrogen F21 the chiller or purging the collection charging chamber when necessary 8 Auto purging valve F22 Switches the purge venting of chiller 9 Refrigerant motor valve Bypasses refrigerant to absorber Automatic opens only F24 during refrigerant bypass 20 Hot water thermostatic Stabilizes hot water temperature Auto trace and regulate valve F25 hot water load 21 Heating water Stabilizes heating water temperature Auto trace and regulate thermostatic valve F26 heating water load 22 A C W switch valve F1 Switches between chilled W and A c W goes through B Heating W system evaporator in cooling S 2 and heater in heating 23 S A C W outlet check Prevents chilled W going into the S valve F2 heater and hot W into evaporator 24 3 Chilled water drain valve Drains water in evaporator copper Open when while 9 F27 tubes necessary 25 9 Cooling water drain Drains water in absorber and Open when while

user`s manual broad x generation non – electric chiller

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user`s manual broad x generation non &ndash; electric chiller

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user`s manual broad x generation non – electric chiller