Carrier-Sanyo 16NK User manual

16NK
Double-Effect Steam-Fired
Absorption Chillers
Nominal cooling capacity 345-4652 kW
50 Hz
Operation and maintenance instructions
GB/T-19001-2000 to ISO9001/2000

2
NOTES TO USERS
Thank you for purchasing a Carrier/Sanyo absorption chiller.
Read this manual carefully before operating the unit. It contains instructions for the operation and maintenance of the chiller.
Please utilize the chiller to its optimum performance by carrying out the recommended daily maintenance and handling
instructions as well as the periodic service.
If you need any information about maintenance contracts or have any other enquiries, please contact your Carrier service agent.

3
The cover photograph is for illustrative purposes only, and are not contractually binding.
Contents
NOTES TO USERS........................................................................................................................................................................... 2
1 - PRECAUTIONS .......................................................................................................................................................................... 4
1.1 - Safety precautions....................................................................................................................................................................... 4
1.2 - High-temperature - high-voltage caution....................................................................................................................................8
1.3 - Environmental requirements.......................................................................................................................................................8
1.4 - Water treatment........................................................................................................................................................................... 8
2 - MACHINE ILLUSTRATIONS .................................................................................................................................................. 8
2.1 - Typical chiller views - all sides...................................................................................................................................................8
2.2 - Typical control panel ................................................................................................................................................................ 12
2.3 - Chiller owchart and component function description ............................................................................................................14
3 - OPERATING INSTRUCTIONS .............................................................................................................................................. 17
3.1 - Self-diagnostic function............................................................................................................................................................17
3.2 - Description of keys and their functions.................................................................................................................................... 18
3.3 - Control board settings...............................................................................................................................................................19
3.4 - Cooling operation ..................................................................................................................................................................... 21
3.5 - Changing the information on the data display.......................................................................................................................... 22
3.6 - Changing display and setpoint..................................................................................................................................................23
3.7 - Maintenance message............................................................................................................................................................... 23
3.8 - Alarm messages and actions required....................................................................................................................................... 23
4 - MAINTENANCE....................................................................................................................................................................... 25
4.1 - Daily maintenance .................................................................................................................................................................... 25
4.2 - Periodic maintenance................................................................................................................................................................28
4.3 - Recommended maintenance and main component replacement schedule............................................................................... 29
4.4 - Water treatment......................................................................................................................................................................... 30
5 - TROUBLESHOOTING ............................................................................................................................................................ 32
6 - INSTRUCTIONS....................................................................................................................................................................... 34
6.1 - Absorbent sampling method ..................................................................................................................................................... 34
6.2 - Concentration measurement method ........................................................................................................................................34
7 - MAINTENANCE CONTRACT ............................................................................................................................................... 36
7.1 - Annual maintenance contract.................................................................................................................................................... 36
7.2 - Inspection report....................................................................................................................................................................... 36
7.3 - Warranty.................................................................................................................................................................................... 36
APPENDIX 1 - TROUBLESHOOTING FLOWCHART ...........................................................................................................37
Problem 1 - Chiller does not run....................................................................................................................................................... 37
Problem 2 - Chilled-water temperature is high................................................................................................................................. 38
Problem 3 - Generator alarm............................................................................................................................................................. 39
Problem 4 - Combustion alarm (16DJ only)..................................................................................................................................... 40
Problem 5 - Water alarm ................................................................................................................................................................... 41
Problem 6 - Motor alarm................................................................................................................................................................... 41
Problem 7 - System alarm................................................................................................................................................................. 42

4
1 - PRECAUTIONS
1.1 - Safety precautions
• Before operating this chiller, first carefully read the
following instructions.
• All precautions are classified as either WARNING or
CAUTION.
WARNING: Failure to observe this instruction may result in
serious injury or death.
CAUTION : Failure to observe this instruction may cause an
injury or failure of chiller. Depending on circumstances, this
may result in serious injury or death.
This symbol denotes danger, a warning or a caution.
The illustration in this symbol shows the specic
description of the item.
This symbol prohibits an action.
The illustration next to this symbol shows the specific
description of the item.
This symbol instructs an action to be done.
The illustration in this symbol shows the specific
description of the item.
• After reading this manual, it should be kept in a safe place
to be available for any user at any time.
TURN OFF THE BREAKER BEFORE CLEANING AND
CHECKING
Always turn off the circuit breaker before cleaning and checking
the cooling tower fan, chilled water pump, or other components
linked to the chiller, to provide protection from electric shock or
or possible injury by the rotating fan.
INSPECTION
DO NOT TOUCH THE CONTROL PANEL SWITCH WITH
WET HANDS
Do not touch the switch inside the control panel with wet hands
to avoid electric shock.
STOP OPERATION IN CASE OF FIRE, EARTHQUAKE OR
ELECTRICAL STORMS
Stop operation in case of re, earthquake or an electrical storm, to
prevent re or electric shock.
DO NOT TOUCH THE WIRING INSIDE THE CONTROL
PANEL
Do not touch the wiring inside the control panel to avoid electric
shock.
SWITCH
DO NOT TOUCH
DO NOT TOUCH
MUST BE OBSERVED
1.1.4.1 Safety considerations
WARNINGS

5
DO NOT TOUCH ROTATING MOTOR PARTS
Keep away from rotating parts of motors or pumps to avoid
possible injury.
PROHIBITED
SOLVE ALL PROBLEMS BEFORE RESTARTING THE
CHILLER
Solve all the problems before restarting the chiller after a safety
or security device is activated.
MUST BE OBSERVED
DO NOT PLACE HEAVY OBJECTS ON THE CHILLER
OR CONTROL PANEL
Do not place heavy objects on the chiller or control panel as
these may fall off and cause injuries.
PROHIBITED
DO NOT CLIMB ON THE CHILLER
Do not climb on the chiller as you may fall off.
PROHIBITED
AUTHORIZED PERSONNEL ONLY
A notice, "For Authorized Personnel Only" must be afxed to
the chiller to stop unauthorized personnel from touching it. If
necessary surround the chiller by a protective fence. Misuse of
the chiller may cause injury.
PROHIBITED
WARNINGS CAUTIONS
VENTILATE THE MACHINE ROOM
Ventilate the machine room while nitrogen gas is discharged to
avoid anoxia.
MUST BE OPERATED
DO NOT POUR WATER ON THE CHILLER OR CONTROL
PANEL
Do not pour water on the chiller or control panel to avoid electric
shock.
PROHIBITED

6
USE THE CORRECT POWER SUPPLY
This is indicated on the chiller name plate. Use of an incorrect
power supply may cause re or electric shock.
PROHIBITED
NEVER CHANGE THE SET VALUES
Never change the set values of the safety and/or protective
devices. Wrong settings may damage the chiller or cause re.
PROHIBITED
DO NOT TOUCH THE ABSORBENT
Do not touch spare or leaked absorbent, as this can cause metal
corrosion or skin disease.
PROHIBITED
PROHIBITED
STOP THE PURGE PUMP TO REPLACE OIL
Stop the purge pump when replacing oil to avoid possible injury
by fuel spillage.
MUST BE OBSERVED
DO NOT TOUCH HIGH-TEMPERATURE AREAS
Do not touch high-temperature areas, as they may cause burns.
These areas are indicated by caution label.
What
voltage?
STOP
CAUTIONS
OBSERVE THE SPECIFIED WATER/STEAM PRESSURE
The specied chilled water, cooling water and steam pressure
must be strictly observed.
Incorrect pressure may cause the water to leak/spray which can
lead to short circuits or burns.
MUST BE OBSERVED

7
4: Absorption
chiller
1.1.3 - Operating precautions
1. Keep the purge valve tightly shut to prevent air from
leaking into the chiller, which may cause the failure of the
chiller.
2. Keep the power supply to the control panel turned on,
unless carrying out maintenance or service.
3. During the chiller dilution cycle the chilled-water pump
(both the primary side and the secondary side) and air
handling unit must be operated for the required time. The
chiller has some cooling capacity, even in the dilution
cycle. Do not stop the air handling unit before the required
time to prevent possible subcooling.
4. Do not perform an insulation test on the control circuits of
the electric controller.
5 . Use a Carrier recommended interlock system to stop/start
the auxiliary equipment. The interlock system automatically
stops/starts the chilled-water pump and cooling water
pump. Follow the start procedure in Figure 1 below.
Fig. 1 - Auxiliary equipment start/stop sequence
Start sequence
1: Chilled
water pump
2: Cooling
water pump
3: Cooling
tower
5: Air
handling
unit
1 Absorption
chiller
2: Cooling
water pump
3: Cooling
tower
4: Chilled
water pump
5: Air handling
unit
Stop sequence
ONLY AUTHORIZED PERSONNEL SHOULD SERVICE
THE CHILLER
Only authorized personnel should service the chiller. Incorrect
service could result in electric shock or re.
PROHIBITED
1.1.2 - Safety precautions for repair, moving or disposal
ONLY AUTHORIZED PERSONNEL SHOULD REMOVE OR
REPAIR THE CHILLER
Any relocation or moving of the chiller should only be done by
authorized personnel. Incorrect work could result in water leaks,
electric shock or re.
MUST BE OBSERVED
ONLY AUTHORIZED PERSONNEL SHOULD DISPOSE OF
THE CHILLER
To dispose of the chiller, contact local specialists. Incorrect
disposal may result in absorbent leaks and cause metal corrosion
or skin disease, electric shock or re.
MUST BE OBSERVED
WARNINGS
CAUTIONS

8
2 - MACHINE ILLUSTRATIONS
2.1 - Typical chiller views - all sides
2.1.1 - 16NK 11 to 63
Fig. 2 - Water header side
6
7
8
2
9
1
3
4
5
Legend
1 Condenser
2 Chilled water outlet
3 Chilled water inlet
4 Evaporator
5 Cooling water inlet
6 Low-temperature generator
7 High temperature generator
8 Steam inlet
9 Absorber
Fig. 3 - Water header side (rear)
12
3
4
5
7
6
Legend
1 High-temperature generator
2 Low-temperature generator
3 Cooling water outlet
4 Evaporator
5 Steam trap
6 Condenser
7 Absorber
1.2 - High-temperature - high-voltage caution
• Do not touch the chiller during operation since its surface
becomes hot.
• Do not touch the absorbent pump, the refrigerant pump,
and the purge pump during operation, since their surface
becomes hot.
• Do not touch the junction box during operation, since it
contains high-voltage wiring.
• Do not touch the terminal box during operation, since it
contains high-voltage wiring.
1.3 - Environmental requirements
1.3.1 - Installation considerations
The 16NK absorption chiller is designed for indoor installation
in a machine room. The protection rating of the chiller is IP40.
Room temperature should be maintained between 5°C and
40°C to protect against solution crystallization during chiller
shutdown. The humidity in the machine room must be kept
below 90%.
1.3.2 - Field wiring
The machines should be connected to a power source that
complies with overvoltage category III (IEC 60664). All other
wiring should comply with overvoltage category II.
1.3.3 - Altitude
Please install the absorption chiller at a maximum height of
1000 m above sea level. If the location is higher than 1000 m
above sea level, please contact your local Carrier office.
1.4 - Water treatment
Refer to chapter 4 "Maintenance”.

9
Fig. 4 - Control panel side (evaporator side)
1 2
345
6
Legend
1 Control panel
2 Purge tank
3 Refrigerant drain heat reclaimer
4 Absorbent pump 1
5 Refrigerant pump
6 Refrigerant blow valve
Fig. 5 - High-temperature generator side (absorber side)
12
3 4
56 7 8
Legend
1 Purge unit
2 High-temperature heat reclaimer
3 Purge pump
4 Low-temperature heat exchanger
5 Low-temperature heat reclaimer
6 Steam drain outlet
7 High-temperature heat exchanger
8 Absorbent pump 2

10
2.1.2 - 16NK 71 to 81
Fig. 6 - Water header side
12
3
4
5
6
8
7
10
9
2
3
1
4
5 6 7
Fig. 7 - Water header side (rear)
Legend
1 Steam inlet/high-temperature generator
2 Low-temperature generator
3 Cooling water outlet
4 Chilled water outlet
5 Chilled water inlet
6 Cooling water inlet
7 Condenser
8 Absorber
9 Evaporator
10 Absorber
Legend
1 Low-temperature generator
2 High-temperature generator
3 Steam drain outlet
4 Condenser
5 Absorber
6 Evaporator
7 Absorber
1 2 3 4
5678
Fig. 8 - Control panel side
Legend
1 Control panel
2 Refrigerant blow valve
3 Purge tank
4 Purge unit
5 Purge pump
6 Refrigerant drain heat exchanger
7 Refrigerant pump
8 Low-temperature heat exchanger

11
Fig. 9 - High-temperature heat reclaimer side
Legend
1 High-temperature heat reclaimer
2 Absorbent pump 2
3 Low-temperature heat exchanger
4 Absorbent pump 1
5 Refrigerant pump
6 High-temperature heat exchanger
1
23456

12
2.2 - Typical control panel
Fig. 10 - Control panel (CE type)
Legend
1 Fan
2 Terminal block
3 Terminal block
4 Terminal block for power supply
5 Earth terminal
6 Control board
7 Purge indication light
8 Alarm buzzer
9 Purge pump on/off switcht
10 Operating handle
Fig. 11 - Control panel inside (CE type)
Legend
1 Control relay
2 Circuit protector
3 Isolator
4 I/O board
5 AC reactor
6 Circuit breaker
7 Inverter
8 DC reactor
9 Main circuit breaker
10 Transformer
11 Electromagnetic contactor
12 Filter
13 Transformer
14 Terminal block
1
6
7
9
8
10
2
3
4
5
1
13
2
3
4
5
6
7
8
9
10
11
12
14

13
STOP RUN
CHILLER
REF PUMP
PURGE PUMP
#1 ABS PUMP
STAND BY
DILUTION
SAFETY CIRCUIT
CHILLER ALARM
POWER
STOP RUN
OPERATION
BUZZER STOP LOCAL
REMOTE
SET BACK
#2 ABS PUMP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Fig. 12 - Control board
Legend
1 Stop indication light
2 Operation indication light
3 Data display
4 Select key
5 Function set key
6 Back select key
7 Remote/local select key with LED
8 Alarm buzzer stop key
9 Operation select key with LED
10 Alarm indication light
11 Stand-by indication light
12 Dilution indication light
13 Safety circuit indication light
14 Power indication light

14
2.3 - Chiller flowchart and component function
description
Evaporator
The refrigerant is dispersed on the heat transfer tubes of the
evaporator. Chilled water running through the heat transfer
tubes of evaporator is cooled by the latent heat of vaporized
refrigerant.
Absorber
The concentrated solution is dispersed on the heat transfer
tubes of absorber. The refrigerant vapour from the evaporator is
absorbed on the heat transfer tubes of the absorber by the
concentrated solution. Cooling water running through the heat
transfer tubes of the absorber is heated by the absorption heat.
Solution heat exchangers
In order to increase the efciency of the chiller, two solution
heat exchangers are provided. One is a low-temperature heat
exchanger and the other is a high-temperature heat exchanger.
In the low-temperature heat exchanger, heat exchange takes
place between the concentrated solution and the diluted solution.
In the high-temperature heat exchanger, heat exchange takes
place between the intermediate solution and the diluted solution.
High-temperature generator
The diluted solution from the high-temperature heat exchanger
is heated and releases refrigerant vapour. It then changes to the
intermediate solution.
Low-temperature generator
The refrigerant vapour from the high-temperature generator
passes through the heat transfer tubes of the low-temperature
generator. The intermediate solution in the low-temperature
generator is heated by the refrigerant vapour. It releases refrigerant
vapour and is concentrated. It changes to the concentrated
solution. The condensed refrigerant in the heat transfer tubes of
the low-temperature generator ows to the condenser.
Condenser
The refrigerant vapour from the generator is condensed on the
heat transfer tubes of the condenser. Cooling water from the
absorber is heated by condensation heat.
Purge unit
The purge unit collects the non-condensable gas in the chiller
and stores it in the purge tank.
Refrigerant drain heat reclaimer
This heat exchanger is provided in order to increase the
efciency of the chiller. In this heat reclaimer heat exchange
takes place between the diluted solution and the condensed
refrigerant from the low-temperature generator.
High and low-temperature heat reclaimers
These heat reclaimers are provided in order to recover heat
from the steam drain, In these heat reclaimers heat exchange
takes place between the diluted solution and the steam drain.
Sensors
Symbol Name
DT1 Chilled-water leaving temperature
DT3 High-temperature generator temperature
DT4 Low-temperature generator temperature
DT5 Condenser temperature
DT6 Chilled-water entering temperature
DT7 Cooling water entering temperature
DT8 Cooling water intermediate temperature
DT9 Cooling water leaving temperature
DT11 Evaporator refrigerant temperature
DT12 Diluted solution temperature sensor at absorber outlet
DT13 Steam drain temperature
E1-3 High-temperature generator solution level electrode
63CH High-temperature generator pressure switch
69CH Chilled water ow switch
69PR Purge tank pressure switch

15
1
2
3
4
5
6
7
8
9
10
11
12 13
14
15
16
17
19
20
21
22 23
24
25
26
27
Fig. 13 - Flow diagram
Sensor
Service valve
Strainer
Damper
Check valve
Orice
Valve
1
2
3
4
5
V2
V3
SV1
V1
6
7
8
9
10
11
12 13
14
15
16
17
18
19
20
21
22 23
24
25 26
27
Fig. 14 - Flow diagram

16
Legend for Figs. 13 and 14
1 Purge pump
2 B-valve
3 Chilled water outlet
4 Chilled water inlet
5 Purge unit
6 Cooling water outlet
7 Purge tank
8 Refrigerant pump
9 Refrigerant blow valve
10 Absorbent pump 1
11 Rupture disk
12 Condenser
13 Low-temperature generator
14 Evaporator
15 Absorber
16 Cooling water inlet
17 Low-temperature heat exchanger
18 Low-temperature heat reclaimer
19 Steam drain outlet
20 Refrigerant drain heat reclaimer
21 Absorbent pump 2
22 High-temperature heat exchanger
23 Steam trap
24 High-temperature heat reclaimer
25 High-temperature generator
26 Steam inlet
27 Steam control valve
D1 Diluted solution main damper
D2 Diluted solution low temperature heat exchanger damper
D3 Diluted solution refrigerant drain heat reclaimer damper
D4 Intermediate solution damper
D5 Concentrated solution damper
D6 Refrigerant drain damper
D7 Refrigerant recycling damper
D8 Diluted solution bypass damper
V1 Manual purge valve
V2 Manual purge valve
V3 Manual purge valve
SV1 Charge/discharge N2gas and pressure gauge installation service valve
SV3 Refrigerant service valve
SV4 Diluted solution service valve
SV5 Intermediate solution service valve
SV6 Concentrated solution service valve
SV7 Generator maintenance service valve
SV8 Generator maintenance service valve
B valve Manual purge valve

17
3 - OPERATING INSTRUCTIONS
3.1 - Self-diagnostic function
The self-diagnostic function starts when the breaker inside the
control panel of the chiller is turned on. After self-diagnosis
is completed, the data display on the control board shows the
following information.
• Data display (7-segment LED) and all LEDs light up.
• If there is no abnormality the data display shows the
version number. If there is a power failure, H-10 is
displayed after the power is restored.
NOTE: The version number differs with each chiller type.
• The data display shows the generator temperature.
(120.4)
If the self-diagnosis function detects an error, this will be
shown on the data display. For the alarm indication, please
refer to chapter 3.8.
Fig. 15 - Control panel

18
STOP RUN
CHILLER
REF PUMP
PURGE PUMP
#1 ABS PUMP
STAND BY
DILUTION
SAFETY CIRCUIT
CHILLER ALARM
POWER
STOP RUN
OPERATION
BUZZER STOP LOCAL
REMOTE
SET BACK
#2 ABS PUMP
1
2
4
6
7
8
9
10
12
5
11
3
Fig. 16 - Typical control board
Legend
1 Operation indication light: The operation indication light is on when the chiller is running.
2 Stop indication light: The stop indication light is on when the chiller is shut down.
3 Alarm indication light: The alarm indication light is on when an alarm occurs.
4 Remote/local select key with LED: To select remote operation or local operation.
5 Operation select key with LED: Key used to run/stop the chiller.
The stop key is also used for alarm reset.
6 Data display (7-segment LED): Shows the temperature, setpoint, etc.
7 Standby indication light: On when the chiller is waiting for the interlock signals form the chilled water and the cooling water pump.
8 Dilution indication light: On during the dilution cycle.
9 Safety circuit indication light: On when power is supplied to the control circuit.
10 Power indication light: On when power is supplied to the control circuit.
11 Data select key: To change the menu and set a new value.
12 Alarm buzzer stop key: To stop the alarm buzzer.
3.2 - Description of keys and their functions

19
3.3 - Control board settings
3.3.1 -Time setting
Refer to Figure 17.
Fig. 17 - Display example
Generator temperature
Press the " SET " key for about 2 seconds.
Press tkey.
Press the " SET " key for about 2 seconds.
Press the " SET " key for about 2 seconds.
Press tor skey.
Press the " SET " key for about 2 seconds.
Press tkey.
Press the SET key for about 2 seconds.
Press skey to set the month.
Press tkey.
Fig. 17 - Display example (cont.)
Press skey to set the day.
Press the SET key for about 2 seconds.
Press tkey.
Press the SET key for about 2 seconds.
Press skey to set the hour.
Press tkey.
Press skey to set the minutes.
Press the SET key for about 2 seconds.
Press the BACK key.
Press the BACK key.
Generator temperature
3.3.2 - Battery backup
Refer to Figure 18.
SW3
Connect a backup battery which is used to maintain the time
setting when a power failure occurs. Turn it ON after installing
the equipment. CR-2025 is used as the backup battery and has
an accumulative operating period of about six months.
NOTES:
1. SW3 (battery backup) is set to OFF at the factory to
avoid using battery power.
2. If SW3 (battery backup) is set to OFF when a power
failure occurs, F-21 (CPU alarm) or F-23 (Time set
alarm) is displayed. Please reset the time setting.
3. If SW3 (battery backup) is set to ON and F-21 or F-23 is
displayed, it is necessary to replace the battery.

20
Fig. 18- SW3 backup switch and backup battery
Backup battery
SW3: Backup switch UP: ON DOWN: OFF
LABEL