lt manual de instalación agua caliente 2009

7/28/2019 LT Manual de instalacin agua caliente 2009

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LT-CLow temperature hot water redAbsorption chillers

Single effect

INSTALLATION MANUAL


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Contents

11 Introduction 1-31.1 Explanation of manual conventions 1-3

22 Safety precautions 2-3

2.1 Warnings 2-3

2.2 Cautions 2-4

2.3 Support request 2-5

2.4 Installation 2-5

2.5 Place of installation 2-5

33 Unloading and Installation 3-3

3.1 Reception 3-3

3.2 Unloading 3-3

3.2.1 One piece shipment 3-3

3.2.2 Two pieces shipment 3-4

3.3 Storage of the unit 3-5

3.4 Inspections 3-6

3.4.1 Checking nitrogen pressure 3-7

3.4.2 Visual inspections 3-8

3.5 Rigging and shifting to the foundation 3-9

3.6 Positioning the machine on foundation 3-11

3.7 Levelling of the machine 3-12

3.7.1 Procedure for levelling the machine 3-13


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3.8 Water connections 3-14

3.8.1 Flow rate 3-14

3.8.2 Water quality 3-15

3.8.3 Water connection of the evaporator 3-16

3.8.4 Water connection to condenser/absorber 3-17

3.8.5 Water connection of generator 3-19

3.8.6 Connection of hot water control valve 3-19

3.8.7 Connection of rupture disk 3-20

3.9 Electrical wirings 3-22

3.9.1 Check of the feed voltage 3-23

3.9.2 Field electrical wirings required 3-23

3.10 Insulation 3-25

44 Pre-Commissioning Quick Guide 4-3


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1 Introduction


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1 Introduction

1-3Thermax LT-C

Introduction1

Thank you for purchasing a THERMAX LTD. absorption chiller.

This manual contains details on the various operations invloved in the installation of the machine,

from the moment it reaches site to when it is ready to be operated.

Even if information inside this manual dont correspond exactly with the machine, this is notcompromising their function.

Thermax Ltd. reserves itself the right for changes and/or modications without notice.

For any trouble or bad working not considered in this manual, contact at the right time the authorizedservice personnel.

After reading carefully the manual, it should be kept in xed place to be available for any user at any

time.

Explanation of manual conventions1.1

This Installation Manual uses the following symbols to indicate important information. Alwaysobserve the instructions indicated by these symbols.

Safety advices

I WARNING

Instructions that, if ignored, could result in death or serious personal injury caused by incorrectoperation of the equipment. These must be observed for safe operation.

I CAUTION

Instructions that, if ignored, could result in personal injury or material damage caused by incorrectoperation of the equipment. These must be observed for safe operation.


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1Introduction

1-4 Thermax LT-C

Tips

NOTE

Text highlighted in this manner contains useful information and tips to ensure safe use of themachine.

Text formatted in this style describes the action that will ensure the desired results are achieved.


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2 Safety Precautions


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2-3Thermax LT-C

Safety precautions2

Read carefully the instructions reported in this manual before installing the machine. Do not installthe unit in a way different from what described in this guide.

Do not tamper with, elude, eliminate or bypass any safety device installed on the machine. Any faultin respecting this principle can cause severe risks to the safety and health of people. Such an action

it also causes the immediate decay of the warranty.

Personnel who will performe any kind of action on the machine during its entire working life musthave precise technical competence, skill and experience acquired and recognized in this specic

eld. Lack of these qualications can cause damages to the safety and health of people.

The appliance must only be used for the purposes for which it has been designed. Any other use isconsidered inappropriate and therefore dangerous for the safety and health of people. It can alsocause great economic damages.

Keep the appliance in maximum efciency conditions by following scheduled maintenance operations

required by the manufacturer. A proper maintenance will grant a better performance, a longer lifeand a safe operation of the unit.

Warnings2.1

The following indicator is used in this manual to categorize the level of safety warnings.

I WARNING

Ignoring these warnings could cause serious injury or even death.

Do not ignore these safety advises.

H Follow below instructions to avoid dangerous electric shocks.

Do not touch electrical devices inside the control panel with wet hands.

Do not touch electrical wirings inside the control panel when this one is powered.

Do not touch high voltage lead wire on the machine.

Always turn off the main circuit breaker before doing any check on the machine.


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2Safety Precautions

2-4 Thermax LT-C

` Always turn off the breaker before touching or inspecting moving parts, in order toavoid electric shocks or personal injuries.

Do not touch moving parts of the appliance.

Do not touch moving parts of the auxiliary equipment (pumps, cooling tower fans, ...).

Stop the operation in case of a re or when is likely to be a thunderbolt.

Do not place any ammables close to the chiller.

Cautions2.2

The following indicator is used in this manual to categorize the level of safety cautions.

I CAUTION

Ignoring these cautions could cause injury or damage to property.

Do not ignore these safety advises.

r Ignoring below caution indications can result in serious personal injury and alsoserious damage of the appliance.

Do not climb up or walk on the chiller.

Do not place heavy objects on the chiller or on the control panel of the chiller.

I Ignoring below caution indications can result in a bad working or even in the seriousdamage of the appliance, and can result in serious personal injury.

For any service operation on the machine or for the ordinary scheduled maintenance always call

authorized and specialized personnel.

Operation of the machine has to be carried out only by authorized personnel.


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2-5Thermax LT-C

Use the correct power supply to the control panel: refer to the data indicated in the nameplate ofthe machine.

Do not modify the settings of the safety devices.

Do not store the Lithium Bromide solution in metallic tanks: always use plastic recipients.

Use the necessary protections while handling the Lithium Bromide solution.

Do not exceed the maximum working pressures of the water circuits, to avoid breakages in the sealsand consequently water leakage.

\ Do not touch hot surfaces on the machine to avoid danger of burnings.

Support request2.3

For any request contact one of the authorized service centers. For any request of technical assistanceregarding the machine, indicate all the relevant data reported on the machines name plate, inparticular the serial number.

Installation2.4

Ensure that the installation of the unit is carried on by a qualied installer only.

Respect all safety rules required by national and local authorities.

Access to machine should be allowed to skilled and authorized personnel only.

Place of installation2.5

The machine has been designed for indoor installation (control panel protection IP 42).

Temperature in the plant room has to be maintained between 5C and 45C, with a maximumrelative humidity of 90%.


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3 Unloading &Installation


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3 Unloading & Installation

3-3Thermax LT-C

Unloading and Installation3

The machines are delivered CIF port indicated in the order, if not agreed in a different way at themoment of the order.

Always refer to ofcial packing list of the shipment to have information on number of items,dimensions and weights to be given to the forwarder for the inland transport.

Reception3.1

Upon reception, make sure that the machines have not been damaged during transport and checkthat they are complete of all requested accessories against their order. Check that all items describedin packing list are delivered.

NOTE

Any damage or contestation shall be written down on the delivery note upon reception and shall bereceived by registered letter within 8 days after material reception.

Unloading3.2

Machines are usually shipped in one single piece. In case of special requirements units can be

shipped in two sections: lower shell and upper shell.

One piece shipment3.2.1

Lift the unit using lifting holes provided on the chiller. Do not rig from any other point toavoid any damage to the unit or any personal injury.

Use proper sized hooks/slings and approved methods for lifting the chiller.

Lift the chiller from all the four corners while keeping the unit level with respect to the

ground.

Ensure the included angle between sling is equal to or less than 90 degree.

Take care while hooking up the shackles, when these are used to lift the unit.

Avoid any damage to the interconnecting pipes on the chiller.

During unloading, be careful not to incline the machine.

I WARNING


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3Unloading & Installation

3-4 Thermax LT-C

Before lifting please ensure the crane & sling capacity. (conrm the chiller weight as per packing

slip).

Two pieces shipment3.2.2

On special request units can be delivered in two sections: lower shell and upper shell. Lift lowerand upper shells using lifting holes provided in the tube plate sheets, as indicated in the following

90


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3-5Thermax LT-C

A

A = Lifting points

picture.

Refer to the instructions provided with the unit to reassemble the two pieces on site. Upon requesta Thermax technician can be available at extra cost for the supervision of the reassembling

operations.

NOTE

After having reassembled the two pieces, a nitrogen leak test has to be carried out for the following24 hours, to ensure that there are no leakages in the unit..

Storage of the unit3.3

If the unit is not going to be installed immediately, it is important to prevent any damage or loss onthe unit by keeping the unit covered and protected from atmospheric agents. Indoor storage is ideal,


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3-6 Thermax LT-C

90

90

A B

A = Upper shell lifting pointsB = Lower shell lifting points

in a room with ambient temperature above 5C. If machines are stored outside, ensure that they areproperly protected against atmospheric agents, specially rain.

Machines are delivered with a nitrogen charge at a pressure slightly more than the atmospheric one.

Nitrogen should not be removed from the chiller unit. All the accessories supplied along with theunit should be kept in the same place.

I CAUTION

Since refrigerant used in the machine is water, do not leave cans containing water in environmentwhere temperature can go below zero.

Inspections3.4

After receiving the unit, it is recommended to carry on some basic checks, in order to ensure thatno major damages have occurred during transport.


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3-7Thermax LT-C

1 = purge pump2 = liquid trap

3 = diaphragm valve DV14 = service valve SV34a = closing bolt

4b = service valve cap4c = rabbet

5 = service valve SV46 = diaphragm valve DV3

7 = diaphragm valve DV28 = storage tank9 = vacuum manometer

10 = isolating valve11 = palladium cell

Checking nitrogen pressure3.4.1

The units are shipped with a charge of nitrogen, at approximately 20-30 kPa.

Remove the closing bolt (4a) from the connection of service valve SV3.

Unscrew the service valve cap (4b) and use the rabbet on its top (4c) to open the service valvespindle. Open diaphragm valve DV3, and check if nitrogen is being released into atmosphere.

I WARNING

1

3

4

4a

4c

4b

5

2

8

10

11

9

6

7


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3-8 Thermax LT-C

Item to be checked Damages Remarks

A. Chiller body

B. Components & devices

1. Temperature sensors (7)

2. Vacuum manometer

3. Solution pump

4. Refrigerant pump

5. Purge pump

6. Refrigerant level electrodes box

7. Antifreeze thermostat

8. Chilled water D.P. switch

9. Chilled water ow switch

10.Sight glasses in evaporator, absorber

and generator.

11. Isolation valves on solution pump

12. Isolation valves on refrigerant pump

13. Diaphragm valves on purge system (3) Valves must be closed.

14. Refrigerant blowdown valve

15. Palladium cell box

16. Control panel

17. Electrical wirings

18. Service valves Check that valve caps and arednuts are not missed.

If no nitrogen is coming out from machine, there is a leakage. Charge nitrogen at a maximumpressure of 50 kPa to nd out the leakage.

Do not start the commissioning procedures before having found and repaired the leakage.

Visual inspections3.4.2

Perform a visual inspection of the machine, to check the presence of possible damages. For an easyreference it is possible to follow the below table:

Check that all components supplied loose are present and that they are not damaged:


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3-9Thermax LT-C

Item to be checked Remarks1. Check the number of lithium bromide cans

2. Check the conditions of lithium bromide cans

3. Check the number of refrigerant cans

4. Check the conditions of refrigerant cans

5. Check the number of foundation bolts

6. External visual inspection of the following:

a. Hot water control valve (if supplied)b. Box with working tools

Rigging and shifting to the foundation3.5

Rig the chiller to its proper location with care to avoid any damage to the unit. Provide a plate (seegure) below both the saddles of the chiller. Roll the chiller with the help of castors or rollers,

placed below the plates. The chiller can be pulled gradually from one end by means of winch. Thewire rope used for pulling is to be tied to the saddle.

200 Max.

200 Max.


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3-10 Thermax LT-C

I WARNING

200 200

Do not pull the unit from one end unless castors or rollers are placed below the chiller: this can leadto serious damages to the machine.

Set rollers at 200 mm from main body at front and rear ends.

DIRECTLY LIFT BY CRANE

TO THE LOCATION

10 MAX.

DO NOT PULL

ON DANGERIOUS

INCLINATIONS


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3-11Thermax LT-C

I WARNING

Do not pull the unit on dangerous inclinations.

Positioning the machine on foundation3.6

Position the machine on the foundation.

I WARNING

Machine has to be installed indoor, in a place with ambient temperature always above 5C.

L

100 100120

= =

100

100

150

1200

1000 =

=

1

2

1

T

2

T

1 Machines foot base

2 FoundationT Machines weight on each foundation

Model LT 10-C LT 12-C LT 14-C LT 16-C LT 18-C LT 21-CL (mm) 2.966 2.966 3.574 3.574 4.574 4.574

T (kg) 3.000 3.150 3.550 3.650 4.100 4.300


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3-12 Thermax LT-C

Previous drawing indicates the dimensions of the equipment base frame and suggested size offootings. The foundation shall be designed to suit the soil conditions and other design considerationsat site.

NOTE

Refer to the foundation drawing provided along with the machine for more details on foundation.

I CAUTION

Check that sufcient clearance space is provided on either side of the unit for service and maintenance.

Installation clearance required by the machines are illustrated in the following tables.

B

A

C

D

Model LT 10-C LT 12-C LT 14-C LT 16-C LT 18-C LT 21-C

A (**) 3.200 3.200 3.800 3.800 4.800 4.800

B 500 500 500 500 500 500

C 500 500 500 500 500 500

D 1.200 1.200 1.200 1.200 1.200 1.200

TOP 200 200 200 200 200 200

(**): A is the clearance space for tubes maintenance and removal. It can be left on either side of the chiller,depending on the convenience of site.

Levelling of the machine3.7

The machines use a gravity feed system for distributing water and solution in evaporator, absorber andgenerator. Therefore, it is very important to level the chiller prior to hooking it up with the externalpiping. Proper levelling of the chiller ensures that the rated capacity of the unit is achieved.


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3-13Thermax LT-C

NOTE

Allowable tolerance is less than or equal to 1mm per 1000 mm both lengthwise and sidewise.

There are four levelling checkpoints provided on the chiller (labelled as A, B, C and D in the gure

below). These check points are designated by the three punch marks on the tube sheet or shell of

the lower shell of the chiller.

DC

A B

Procedure for levelling the machine3.7.1

Fill a clear vinyl hose (diameter of the hose 10mm) with water, ensuring that there are no air

bubbles in the hose. Using the point A as the reference point, measure the difference in the waterlevel at the other points (B, C and D).

D

A-B

C

A

B


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3-14 Thermax LT-C

Levelling calculations are shown below:

A B

L;C D

L;A D

L;B C

L;A C

W;B D

W

where L = Length of the machine

W = Width of the machine

A-B, C-D= Difference of level at the two points indicated

If the tolerance is not met, provide shim at the appropriate points by inserting a metal shim betweenthe chiller frame and the foundation. Metal shim size is approximately 2 (50 mm) width x 3 (75mm) length. Prepare the shims of different thickness 0,024 (0,6 mm) to 0,354 (9 mm).

After providing the shims, conrm the levelling of the chiller by taking a new set of readings.

Water connections3.8

Refer to the typical P&I drawing provided with the manual to have a typical installation drawing.

In the following page it is described a basic P&I diagram just for bid purpose.

NOTERefer to the GA drawing provided after the order for knowing the correct orientation of waternozzles. Nozzle orientation can vary from machine to machine, depending on the number of passesselected for each heat exchanger of the machine.

Flow rate3.8.1

Chilled and cooling water circuits are designed for constant ow systems. Number of passes and

friction losses are optimized at the moment of the nal selection. Keep chilled and cooling water

ows within 10% of the rated values. Outside this range performance of the machine may beseverely affected due to not proper velocity of water in tubes.

NOTE

In case of systems designed for variable ow, contact nearest Thermax ofce to discuss the proper

solution to be chosen. Anyway it is not recommended to use a ow below 55% of the rated value.


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3-15Thermax LT-C

T

T

TT

T

T

4...20mA

2...10V

4...20mA

T

T

E/PFM

FM

E/P

Device closed

Device open

Butterfly valve

Globe valve

Non return valve

"Y" strainer

Cock

Manometer

Water pump

Thermostat

Thermometer

Flowmeter

Control valve

50mm insulation

Drive signal

Pneumatic line

Air filter regulator

E/P convertor

CHILLED WATER

HOT WATER

COOLING

TOWER

COOLING WATER

BLOWDOWN

MAKE-UP

WATER

A A A

ELECTRIC ACTUATOR

(*)

Water quality3.8.2

The water treatment of chilled and cooling water is important for the machine performance andlong life. If the water quality is bad and shows a scaling tendency, scale adheres to the inside wall ofthe tubes of the evaporator, absorber and condenser. The heat transfer between the chilled water

and the refrigerant, and the cooling water and the LiBr solution and the condensing refrigerantreduces. This causes an increase in the LiBr and condensed refrigerant temperatures and increasesthe hot water consumption. The chilled and cooling water should be treated to prevent scaling insidethe tubes.

Also standard tubes in machines are copper made. If the chilled or cooling water becomes corrosive,it will corrode the inside of the evaporator, absorber and condenser tubes. Tube failure due to


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3-16 Thermax LT-C

ITEMS Cooling water Chilled water Tendency

Circulating Make up Circulating Corrosion Scaling

pH (25C) 6,5~8,5 6.5~8.0 6.5~8.0

Electrical

conductivity at 25C

(mS/m)< 80 < 20 < 50

M alkalinity (ppm)< 100 < 50 < 100

Total hardness (mg

CaCO3/l) < 200 < 50 < 100

Chloride ion (mg

Cl/l)< 200 < 50 < 100

Sulphuric acid ion

(mg SO4/l) < 200 < 50 < 100

Total iron (mg

Fe/l)< 1,0 < 0,3 < 1,0

Sulphur ion (mg

S/l)Not detected Not detected Not detected

Ammonium ion (mg

NH4/l) < 1,0 < 0,2 < 0,5

Silica (SiO/l) < 50 < 30 < 50

Free carbonic acid

(mg H2CO

3/l) - - < 10

NOTE

In case water quality cannot be correct with proper treatment, it may be necessary specify specialmaterials for tubes.

Water connection of the evaporator3.8.3

Provide a chilled water piping of proper diameter up to the equipment. Chilled water pump shouldbe located to discharge through the unit to assure positive pressure and ow through the unit. On

the input and output pipes mount two water shut-off valves. Piping should be arranged to prevent

drainage of water when the pumps are shut down. Piping should be adequately supported to avoidmechanical stress on nozzles. Complete connection to the unit with exible pipes. On the highest

corrosion will occur. It is essential to fully treat the chilled and cooling water to prevent corrosivetendency.

The standard for water in the chilled and cooling water circuits is shown in the table below:


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3-17Thermax LT-C

point of the hydraulic circuit mount an automatic air-relief valve and close to the water entry to theevaporator provide a discharge for circuit bleeding. We recommend installing a lter on the water

feed pipe close to the machine. Before nal connection, wash the pipes to remove any machining

residuals and/or dirt inside the pipes. Fill the circuit in and provide for air vent from the suitable

automatic air-relief valves on the system. Check the hydraulic connections to locate any water leaks.Check that the system has no water leaks and then isolate the refrigerated water piping (to avoidthermal losses and surface condensations).

Evaporator headers are provided with plugged drain connections. Install drain valves and make aprovision to connect them to an open drain with a pipe.

NOTE

Unless specially ordered, standard water headers of evaporator are designed for a maximum workingpressure of 785 kPa: do not exceed this value during the operation of the machine.

I CAUTION

During decrystallisation or hot degreasing cycles, temperature in chilled water piping closed to inlet

and outlet can raise up to 50-60C. In case plastic piping is used for chilled water line, choose aplastic type that can withstand with temperatures of at least 70-80C.

Water connection to condenser/absorber3.8.4

Provide a water piping up to the equipment. Cooling water pump should be located to dischargethrough the unit to assure positive pressure and ow through the unit. On the input and output pipes

mount two water shut-off valves. Piping should be arranged to prevent drainage of water when the

pumps are shut down. Piping should be adequately supported to avoid mechanical stress on nozzles.Complete connection to the unit with exible pipes. On the highest point of the hydraulic circuit

mount an automatic air-relief valve close to the water entry to the machine and provide a dischargefor circuit bleeding. We recommend installing a lter on the water feed pipe close to the machine.

Before nal connection, wash the pipes to remove any machining residuals and/or dirt inside the

pipes. Fill the circuit in and provide for air vent from the suitable automatic air-relief valves on thesystem. Check the hydraulic connections to locate any water leaks. Provide an automatic shut off

valve on the cooling water inlet if cooling water pump or cooling water circuit are used by otherequipments.

Absorber and condenser headers are provided with plugged drain connections. Install drain valvesand make a provision to connect them to an open drain with a pipe.

Minimum cooling water inlet temperature allowable is 20C. If there is a chance that in middle


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3-18 Thermax LT-C

season or at partial load the cooling water inlet temperature goes below 20C even after havingstopped all cooling towers fans, two options are available.

- an anticrystallisation system provided as optional feature. With this system the chiller canoperate with cooling water inlet temperatures as low as 10C.

- a three way valve, to be installed at the inlet of the cooling water circuit. So part of the coolingwater ow is kept on circulating inside the machine avoiding the cooling water inlet temperature

drop below 20C.

NOTE

Anticrystallisation system will maintain the machine in a safe working area even with low coolingwater temperatures, but in doing there are chances that it will limit the hot water ow inside the

machine. In normal air conditioning applications this is not signicant because cooling load generallyreduces when outside temperature reduces. For process applications the option of the three way

valve is recommended.

NOTE

Unless specially ordered, standard water headers of absorber and condenser are designed for amaximum working pressure of 785 kPa: do not exceed this value during the operation of the

machine.

COOLING

TOWER

BLOWDOWN

MAKE-UP

WATER


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3-19Thermax LT-C

NOTE

The low cooling water inlet temperature alarm is bypassed for the rst 30 minutes after the start upof the unit, in order to give time to the cooling water to warm up.

I CAUTION

During decrystallisation or hot degreasing cycles, temperature in chilled water piping closed to inletand outlet can raise up to 50-60C. In case plastic piping is used for chilled water line, choose aplastic type that can withstand with those temperatures.

Water connection of generator3.8.5

On the input and output pipes mount two water shut-off valves. Hot water pump should be locatedto discharge through the unit to assure positive pressure and ow through the unit. Piping should

be adequately supported to avoid mechanical stress on nozzles. Complete connection to the unitwith exible pipes. On the highest point of the hydraulic circuit mount an automatic air-relief valve

close to the water entry to the machine and provide a discharge for circuit bleeding. We recommend

installing a lter on the water feed pipe close to the machine. Before nal connection, wash the pipesto remove any machining residuals and/or dirt inside the pipes. Fill the circuit in and provide for airvent from the suitable automatic air-relief valves on the system. Check the hydraulic connections tolocate any water leaks. Check that the system has no water leaks and then isolate the hot water piping(to avoid thermal losses and risks of burnings for people).

NOTE

Unless specially ordered, standard water headers of generator are designed for a maximum working

pressure of 785 kPa: do not exceed this value during the operation of the machine.

Connection of hot water control valve3.8.6

Install the hot water control valve according to the valve specications: hot water control valve can

be a 2-way valve, or a 3 -way valve, diverting or mixing type.

The valve has to be installed at a distance between 1,2 and 3 meters from the machine.

In case the valve is not provided along with the machine, ensure it has a safety return (closed in case

of power failure, when the valve is electric type), and that the actuator can receive a 4-20 mA controlsignal. A 2-10V control signal can also be used, provided that the necessary changes are made in thesettings of EM-235 card.


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3-20 Thermax LT-C

A

B

C

T

T T

T

T

T

T

T T

A = 3-way valve diverting type. In case of diverting type 3-way control valve, it has to be installedat the inlet of hot water to the machine. In case of water above 95C a diverting type valve is always

recommended.

B = 3-way valve mixing type. In case of 3-way mixing valve it has to be installed on the outlet of hotwater from chiller. For hot water temperatures above 95C a mixing valve is not recommended.

C = 2-way valve. In case of 2-way valve a variable ow hot water pump can be used.

Connection of rupture disk3.8.7

At the moment of commissioning, a rupture disk is mounted on the machine: it is a safety againstaccidental pressure increase inside the machine. Rupture disk is shipped loose, in the wooden cratecontaining accessories. Rupture disk connection on machine is closed by a blank ange.

The mounting of the rupture disk will be done by the authorized technical personnel that will

perform the commissioning of the unit.


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3-21Thermax LT-C

NOTE

If the blank ange on the rupture disk connection is removed, nitrogen inside the machine will be

released and it wont be possible anymore to read nitrogen pressure to check for possible leakages.

I CAUTION

Never remove the blank ange at rupture disk connection when machine is pressurized with

nitrogen. Before remove the ange, release the nitrogen in atmosphere using appropriate servicevalve SV3 in the purge system.

I WARNING

Never charge nitrogen at a pressure higher than maximum pressure of rupture disk, otherwise thiswill get burnt and machine will loose its vacuum tightness.

After mounting of rupture disk, its discharge has to be connected to a small storage tank, to avoid


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3-22 Thermax LT-C

A

B

C

D

that in case of rupture disk opening hot solution is sprayed around the machine.

Ensure that storage tank has a discharge at its bottom and an air relief valve at its top.

I CAUTION

Lithium bromide solution is corrosive for metals in presence of air. Both storage tank and connecting

pipe from rupture disk to storage tank must be in plastic material to protect them from corrosion.

Electrical wirings3.9

All electrical connections shall be in compliance with CEI standards or with national standards. Allfeed cables shall pass through the appropriate holes and shall have suitable section and material to

withstand the electric loading of the machine (see the rating plate on the machine). Carefully followthe wiring diagrams provided with the machines and this manual. Do not operate the machine inconditions other than design conditions, even for short periods of time. Do not mount on the unit

components that cannot ensure sufcient safety.

Any modication made to the wiring diagram not authorized by Thermax shall make the warranty

and the CE mark void.

I CAUTION

Always refer to the wiring diagram provided along with the machine for precise details on the

electrical wirings.

A Flexible jointB SupportC TankD Drain valve


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3-23Thermax LT-C

Check of the feed voltage3.9.1

The feed voltage of the unit is specied on the rating plate close to the switchboard. Before the unit

is powered check that the main voltage corresponds to the rating of the machine. Check that themain voltage is ranging between +/-10% of the rated voltage of the machine.

Field electrical wirings required3.9.2

Before starting the machine, it is necessary to make some wiring connections with some externalequipment, such as valves and pumps. With reference to the below scheme, following connectionshave to be done:

L1 L2 L3 N E 74 75 20 21 30 31

51 52 53 54 55 56 57 58 59 60

F G B C D

EAL H

A CONTACTS 20-21: CHILLED WATER PUMP SAFETY INTERLOCK

To start machine cycle, chilled water pump must be working. So it is necessary an input signal to thecontrol panel which conrms that the chilled water pump is working. This signal can come from thepump motor starter of from a ow switch mounted on chilled water line circuit (in customer scope).

This signal has to be wired to contacts 20-21 in the control panel, unless working cycle is not started.This wiring is compulsory.

B & C CONTACTS 55-56 & 57-58: START SIGNAL FOR CHILLED WATER PUMP (55-56)

AND COOLING WATER PUMP (57-58)

Chilled water pump and cooling water pump are not starting and stopping together with the startingor the stopping of the machine, but they are following a precise start and stop logic. For this reason

it is necessary that the pumps are directly controlled by the machine control panel. For this purposefour potential free contacts are provided in the control panel: contacts 55-56 control the chilled


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3-24 Thermax LT-C

water pump while contacts 57-58 control the cooling water pump. If the required wiring with thesecontacts is realized, chilled and cooling water pumps are automatically started and stopped by themachine. In case chilled or cooling water pumps are not used only by the absorption chiller, thesecontacts are used to open or close the motorized shut-off valves that must be provided on these

circuits.These wirings are compulsory.

D CONTACTS 59-60: START SIGNAL FOR COOLING TOWER/DRY COOLING FAN

It is possible to start and stop cooling tower fans to control the cooling water inlet temperatureand to avoid it becomes too low. For this purpose it is necessary to wire the fans motor with the

contacts 59-60 of the control panel. In this way cooling tower fans will stop when cooling waterinlet temperature will drop below the value set in the PLC. These contacts allow only starting orstopping one motor or one group of motors. In case of more than one fan, it is not possible torealize a step regulation, stopping one fan after the other. In this case, it is recommended the cooling

water temperature control to be made by the cooling tower itself or by the supervision system. In

order to avoid large uctuations of chilled water outlet temperature, it is important to avoid largeuctuations in cooling water inlet temperature. For this reason step by step starting and stopping of

cooling tower fans is always recommended in order to have a precise control of the cooling waterinlet temperature.

E CONTACTS 30-31: REMOTE CHILLER ON/OFF

Use these contacts for the remote start and stop of the machine.

F CONTACTS 51-52: CHILLER ON/OFF SIGNAL

Use these contacts for the remote indication of machine status (on/off).

G CONTACTS 53-54: CHILLER TRIP SIGNAL

Use these contacts for the remote indication of machine trips.

H CONTACTS 74-75: 4-20 mA SIGNAL TO HOT WATER CONTROL VALVE

Use these contacts to connect machine control panel to hot water control valve. Through these

contacts a 4-20 mA signal is sent to the valve in order to realize the capacity control of the machine.Screened cable is required. A 2-10V control signal can also be used, provided that the necessary

changes are made in the settings of EM-235 card.

EARTHING

Inside control panel there are two different earth bus bar: one for power (indicated with E) andone for electronic (indicated with EE). In case the earthing on site is only one, connect the twoearthing bar inside control panel before connecting one of the two to site earthing.

NOTE

The hot water control valve is not powered by machine control panel. Hot water control valve poweris in customer scope. Power requirement of the valve depends on the type of valve supplied.


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3-25Thermax LT-C

Insulation3.10

After commissioning, machine has to be insulated (if insulation has not been included in the scopeof supply).

Insulation will not cause an appreciable operation economy, but it is required to prevent sweatingof cold surfaces or to prevent overheating of the installation room due to heat gains from the hightemperature surfaces of the unit. Also insulation will protect from possible skin burnings whenaccidentally touching hot surfaces.

Refer to insulation drawing supplied along with the machine for precise details on insulation of theunit. Below is a small sketch to illustrate the surfaces to be insulated. Table illustrates the approximateinsulation areas.

Model LT 10-C LT 12-C LT 14-C LT 16-C LT 18-C LT 21-C

12 12 13 13 17 17

7 7 8 8 12 12

19 mm thick insulation for hot surfaces (120C max).

25 mm thick insulation for cold surfaces (5C min).


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3-26 Thermax LT-C

Respect indication illustrated in drawing while making the insulation.

Do not cover

sight glasses

with insulation

Do not cover the

cap of dampers

with insulation

Do not cover the

refrigerant pump

motor with insulation

Do not cover the handle of

the refrigerant blowdown

valve with insulation.

Do not cover the refrigerant

level electrode box with

insulation.

Also respect these other indications:

Use adhesive agents, iron wires and bounds to mount the insulation material. Do not usetapping screws or rivets.Use non-combustible insulation material.Do not cover the sight glass with insulation.Do not cover the service valves with insulation.Insulation of the evaporator header should be removable for tube cleaning.Insulation for generator headers should be removable for tube inspection.Insulation for the following components should be removable:

Chilled water ow switch

Chilled water antifreeze thermostat

Chilled water temperature sensor

Rupture disk

The chiller is coated with rust preventive paint before delivery, but is not provided with nish

paint.


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4 PreCommissioningQuick Guide


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4 PreCommissioning Quick Guide

4-3Thermax LT-C

Pre-Commissioning Quick Guide4

Before applying for a commissioning request, check that all installations work are over. Refer tofollowing checklist table for a quick help.

1

2

* Has machine been positioned on foundation?

Refer to paragraph 3.6.

* Has machine been levelled?

i Allowable tolerance is less than or equal to 1mm

per 1000 mm both lengthwise and sidewise.


A - B

3

* Has machine been installed with proper clearance

spaces?


STEP A: POSITIONING

D

D

1 2

3


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4PreCommissioning Quick Guide

4-4 Thermax LT-C

T

T

TT

T

T T

FM

CHILLED WATER

HOT WATER

COOLING

TOWER

COOLING WATER

BLOWDOWN

MAKE-UP

WATER

CHILLED

WATER4A

* Has chilled water piping been completed?

* Has chilled water piping been flushed before

having connected to the machine?

* Has water been charged into the circuit?

* Does the chilled water circuit has been

checked for leakages?

Refer to paragraph 3.8.3.

4B

* Have chilled water pumps been checked for

direction?

* Have chilled water filters been cleaned?

* Has air been removed from chilled water

circuit?

* Has chilled water flow been checked?


5B

5C

5D

5E

6A

6B

6D

6C

4A

4B

5A

4C

STEP B: PIPING


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4-5Thermax LT-C

T

T4C

* Have manometers and thermometers been

installed on chilled water circuit?

* Have isolation valves been installed on chilled

water circuit?


COOLING

WATER

T

T

5A

* Has cooling water piping been completed?

* Has cooling water piping been flushed before



* Does the cooling wayer circuit has beenchecked for leakages?


5B

* Have cooling water pumps been checked for

direction?

* Have cooling water filters been cleaned?

* Has air been removed from cooling water

circuit?

* Has cooling water flow been checked?


5C


installed on cooling water circuit?

* Have isolation valves been installed on

cooling water circuit?



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4-6 Thermax LT-C

5E

* Has 3-way valve been installed in cooling

water circuit (if required)?

* Has automatic shut off valve been installed(if required)?

Refer to notes at paragraph 3.8.4.

5D

* Has make up water connected to the cooling

tower?

* Has blowdown been provided on cooling

tower?* Has water treatment been installed to grant

the required water quality?


COOLING

TOWER

BLOW

DOWN

MAKE-UP

WATER

HOTWATER6A

* Has hot water piping been completed?

* Has hot water piping been flushed before



* Does the hot water circuit has beenchecked for leakages?


6B

* Have hot water pumps been checked for

direction?

* Have hot water filters been cleaned?

* Has air been removed from hot watercircuit?

* Has hot water flow been checked?



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4-7Thermax LT-C

T

T

6C


installed on hot water circuit?

* Have isolation valves been installed on

hot water circuit?


6D

* Has hot water control valve been installed?

i Mixing or diverting type valves require

different installations. Check carefuly the

type of valve used.

Refer to paragraph 3.8.6.HOT WATER

7

* Has electrical power been connected?

* Have electrical field wiring been connected?

* Has hot water control valve been powered?* Have chilled, cooling and hot water pumps

been powered?

Refer to paragraph 3.9. Refer to Quick Wiring Guide at the end of

this chapter.

STEP C: ELECTRICAL WIRING

7


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4-8 Thermax LT-C

8

* Are machines liquids available close to the machine?

i Liquids drum must be within a distance of max

3 meters from the machine, at the same level of

the machine.

i Liquids may come in drums of different sizes.

Always remember to check that all the drums

specified in the packing lishave been placed near

the machine.

Refer to packing list shipped along with the machine to

check the exact quantities of liquid drums.

STEP D: GENERAL ISSUES

< 3 m < 3 m

89

9

* Is cooling load available to commission the machine?

i An adequate cooling load is required to properly

commission the machine. An insufficient load

will lead to an incomplete commissioning.


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lt manual de instalación agua caliente 2009

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