Vam Manual

THERMAX LIMITED
ABSORPTION COOLING DIVISION
VAPOUR ABSORPTION HEAT PUMP

“PROCHILL B4K (DOUBLE EFFECT)”
OPERATION & MAINTENANCE

MANUAL
C30 HP00 CVP CVP.1

CONTENTS
Sr. No. Particulars Page No.
Section-A C30 HP00 A00.1

Operation
A.1 Safety C30 HP00 A01.1
A.2 Machine Ilustration C30 HP00 A02.1
A.3 P & I Diagram C30 9PE SD01.1
A.4 Electrical scheme & Control Valve Tubing C30 HP00 A04.1
A.5 Product Brief C30 HP00 A05.1
A.6 Principle of Operation C30 HP00 A06.1
A.7 Control & Safeties C30 HP00 A07.1
A.8 Start & Stop procedures C30 HP00 A08.1
A.9 Operating Instructions C30 HP00 A09.1
A.10 Utility requirements C30 HP00 A10.1
-Water C30 HP00 A10.1
-Steam C30 HP00 A10.5
-Air C30 HP00 A10.5
-Electrical C30 HP00 A10.5
-MSDS C30 HP00 A10.6
A.11 Do’s & Don’t’s C30 HP00 A11.1
A.12 Unloading & Leveling C30 HP00 A12.1
SECTION B C30 HP00 B00.1

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

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

Recommendations for consistent performance
D.1 Water treatment C30 HP00 D01.1
C30 HP00 TOC TOC.1

SECTION A
OPERATION
C30 HP00 A00 A00.1

A.1.Safety
A.1 SAFETY
Chapter Objective: This chapter describes the general precautions the operator
should take care while operating the machine.
Safeties in Handling LiBr: LiBr has to be stored in a cool and well-ventilated location and
possible contact with water is to be avoided. Special measures
are not required for handling. However, while handling the
chemical, exposure is to be avoided with minimum contact with
skin and eye. It is not recommended to inhale LiBr smell too
much. The emptied containers should be disposed of properly
(as per applicable regulations).
The work area should be provided with adequate local exhaust
ventilation, where dust or mist may be generated. Local
exhaust ventilation, confinement of the mist generation
equipment and/or room ventilation system, as well as
adequate engineering controls are needed, to ensure worker
exposure below TLV (Threshold Limit Value for Chemical
Substances in the Work Environment).
a] Number of persons exposed should be minimum.
b] Chemical goggles, rubber gloves and respiratory
protection are recommended for use.
c] Clothing should be close fitting and clean.
d] Eating, smoking and drinking are not permitted, while
handling LiBr.
e] Breathing LiBr mist is prohibited.
f] A hot shower is recommended for the worker, handling
the chemical, after the work shift.
g] The leaking and spilled liquid is to be collected in
sealable containers as far as possible.
h] The remaining liquid has to be absorbed in dry sand or
inert absorbent.
i] Washing away the chemical to sewer is not
recommended.
Safeties against hot

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

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

A.2.Exploded View
A.2 EXPLODED VIEW OF VAHP
STEAM FIRED VAPOUR ABSORPTION HEAT PUMP
C30 HP00 A02 A.2.1

A.3.1.
A.3.1
Please refer Drawing file A.3.1.DWG
A.3.1
A.4.1. Electrical scheme
A.4.1
Please refer Drawing file - A.4.1-Electrical scheme.DWG
A.4.1
A.5.Product Brief
A.5 PRODUCT BRIEF

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

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

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

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

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

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

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

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

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

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

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

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

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

When the refrigerant undergoes a series of evaporation,

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

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

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

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

temperature heat exchanger where it absorbs heat from the

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

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

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

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

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

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

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

absorbed refrigerant boils out of the solution. The solution

concentration increases (to ≈61%). This increased
concentration is referred to as the intermediate concentration.
The vaporised refrigerant generated passes through the
eliminators and goes to the low temperature generator.
Low Temperature The low temperature generator (LTG) and condensor tube
Generator and bundles are enclosed in a shell and are separated by an
Condensor insulation plate. The vaporised refrigerant flows into the LTG
tubes. It heats the intermediate absorbent, flowing outside the
tubes, and condenses. The condensed refrigerant flows into
the condenser. Refrigerant vapourised from the intermediate
absorbent passes through the eliminators to the condenser.
Here cooling water being circulated inside the condenser
tubes cools it. The refrigerant vapour condenses on the
outside of the condensor tubes and collects in the bottom of
the condensor. The condensed refrigerant from the LTG and
the condensor mix and flows to the evaporator. The
absorbent, which has become concentrated in the LTG drains
to the absorber to begin a new absorbent cycle.
C30 HP00 A06 A.06.6

Fig 2. Cooling Mode
C30 HP00 A06 A06.7

A.07.Control & Safeties
A.7 CONTROL & SAFETIES

Chapter Objective This chapter describes the operational controls of the machine and
the safeties provided.
Control Panel The control panel consists of the following components :

¾ Programmable Logic Controller (PLC).
¾ Operator interface.
¾ Power circuit for pumps.
¾ Panel mounted instruments.
Capacity Control The cooling capacity of the machine is the total heat extracted from
the chilled water. The chilled water flow rate to the machine is kept
constant. Hence the capacity is proportional to the difference in the
temperatures of the inlet and outlet chilled water.
Load changes are reflected in the rise or fall of the temperature of

the inlet chilled water. As the inlet chilled water temperature rises
or falls the outlet chilled water temperature tends to follow the
same pattern. A RTD sensor in the outlet chilled water senses this
change in temperature. This signal is fed to the PLC.
An inbuilt software PID control loop processes this signal with

respect to the chilled water set point. A control output signal of 4 to
20 mA is sent to the I/P converter.
The I/P converter converts the 4 to 20 mA electrical signal to a 0.2

to 1 kg/cm2g pneumatic signal. This pneumatic signal controls the
position of the steam control valve. As the load increases the
steam control valve opens, as the load reduces the steam control
valve closes, and thus regulates the quantity of steam entering the
machine.
The above operation is in conjunction with crystallization

control.(refer crystallization prevention )
BLOCK DIAGRAM:
PT100 TEMP. SENSOR PLC I to P STEAM CONTROL

CONVERTER VALVE
Safeties Safety devices are provided to protect the machine from abnormal
conditions and safeguard it from damage and ensure continued
availability.
Safety devices are –
C30HP00A07 A07.1.
• Machine mounted safeties located on the machine,

• Panel mounted safeties in the control panel
• Field Interlocks passing signals from the field to the machine.
Machine mounted ¾ Chilled water flow switch :

safeties Paddle type device mounted on the chilled water outlet
nozzle.
¾ Chilled water Differential Pressure (DP) switch :
Connected to the inlet and outlet chilled water nozzles.
¾ Chilled water Antifreeze thermostat :
Capillary thermostat mounted on the chilled water
outlet nozzle.
¾ Refrigerant level electrodes :
Mounted in the refrigerant level box.
¾ Generator level electrodes :
Mounted in the high temperature generator level box.
¾ Absorber level electrodes :
Mounted in absorber level box.
¾ Auto blowdown solenoid valve :
Mounted on refrigerant pump outlet tapping to
absorber.
¾ Solenoid valve on condensate drain.
Mounted on drain line from heat reclaimer outlet.
¾ Temperature sensors mounted at various locations to display
temperatures.
Panel mounted . Generator level controller.

safeties . Refrigerant level controller.
. Absorber level controller – 2 nos
. Absorbent pump overload relay
. Refrigerant pump overload relay.
. Purge pump overload relay.
Field Interlocks ¾ Chilled water pump interlock.
¾ Cooling water butterfly valve interlock.
Safety Functions The safety functions of the machine protect it against abnormal
conditions. The various safety functions are
¾ Thermal shock protection.
¾ Antifreeze protection.
¾ Crystallization protection.
¾ Cavitation protection of refrigerant pump.
¾ Cavitation protection of absorbent pump.
¾ Motor protection.
Thermal shock To protect the machine from thermal shock, the steam control
protection. valve is opened gradually for first 10 minutes after machine start
up, when the HTG temperature is less than 100°C. After the slow
opening duration is over, the control is switched over to chilled
water temperature modulation automatically.
Antifreeze protection. To prevent the chilled water from freezing in the evaporator tubes,
the safety functions below stops the machine if abnormal
conditions leading to ice formation appear.
(i) L-cut : If the chilled water outlet temperature drops below the L-cut
setpoint, the refrigerant pump is switched off. The L-cut is set from
C30HP00A07 A07.2.
the cool mode control loop screen. This safety prevents further
temperature drop of the chilled water. The refrigerant pump will
restart after the Chilled water outlet temperature rises above the L-
cut setpoint plus the hysterisis set point.
(ii) Antifreeze :
If the chilled water outlet temperature drops below the antifreeze
set point, the machine trips and the ‘TOTAL SHUTDOWN’ alarm
sequence is carried out. The alarm will be reset only after the
chilled water outlet temperature rises above the antifreeze set point
plus the hysterisis set point.
Chilled water pump Chilled water flow is essential for machine operation. A potential
interlock : free contact is to be wired from the chilled water pump motor
starter to VAM/c panel to sense chilled water pump ON / OFF /
TRIP status. The machine starts only when the chilled water pump
is ON. If the chilled water pump stops / trips during operation, the
‘TOTAL SHUTDOWN’ alarm sequence is carried out.
Chilled water flow If the chilled water flow drops below 50% of the rated value, the
switch : ‘TOTAL SHUTDOWN’ alarm sequence is carried out.
Chilled water DP If the chilled water flow drops below 50-60% of the rated value, the
switch: ‘TOTAL SHUTDOWN’ alarm sequence is carried out.
Electrical wiring should be done such that if flow switch or DP
switch operates either all the cooling water pumps should stop OR
the pneumatic butterfly valve in cooling water circuit should close
instantly.
DURING ANY OF THE ABOVE SAFETIES COOLING WATER

FLOW TO M/C MUST STOP IMMEDIATELY OTHERWISE
FREEZING MAY OCCUR INSPITE OF M/C TRIPPING.DURING
THESE SAFETIES STEAM CONTROL VALVE CLOSES FULLY(0
AMPS)
Cooling water flow Cooling water flow should be stopped immediately when the chilled
cutoff: water flow stops in the m/c. So the pneumatically controlled auto
shut off valve should is used for stopping the cooling water flow.
Crystallization If the concentrated absorbent solution returning to the absorber

prevention from the low temperature generator is excessively cooled, it
crystallizes in the low temperature heat exchanger and the
operation of the machine is affected. Crystallization occurs either
when the concentration of the absorbent (related to its
temperature) goes too high or its temperature drops excessively.
The following safety functions prevent the machine from
crystallizing.
Steam control valve The strong solution concentration is calculated in the PLC .The
modulation on crystallization temperature for that concentration is also calculated
crystallization by the PLC. The PLC always tries to keep the Pre set safe
prevention safety distance between the crystallization temperature and strong
solution temperature of low temperature heat exchanger outlet. If
the distance is less than the pre set safe distance then the PLC
C30HP00A07 A07.3.
modulates the steam control valve so that the strong solution

temperature will never reach crystallization temperature.
.
Absorber level safety: If the absorber level goes below first safety limit (25% of sight glass) AE2
then the auto blow down solenoid valve will open to transfer refrigerant to
absorber to build the absorber level again. If the absorber level goes
further below (0% of sight glass) AE3, the steam control valve closes
fully.(0 amps). When the level in absorber rises back to 50% of sight glass
AE1, auto blow down valve will shut, SCV valve will open and machine
will come back in to operation automatically. AE4 is reference electrode.
Cooling water low If the cooling water inlet temperature drops below the cooling water
temperature safety low temperature set point, the ‘DILUTION CYCLE’ alarm sequence
is carried out and the machine goes into dilution cycle immediately.
The alarm can be reset only when the cooling water inlet
temperature rises above the cooling water low temperature set
point plus hysterisis set value. During initial startup till generator
temperature reaches to 120°C this safety is bypassed. However
30min after startup this safety will be in operation irrespective of
generator temperature.
Valve control on HTG When the HTG temperature exceeds the value(set point minus
temperature 1°C), the steam control valve closes immediately. This prevents
further increase in LiBr concentration. The valve control is returned
to the chilled water temperature control loop when the HTG
temperature drops below (set point minus 4°C).
HTG Vapor If the HTG vapor temperature exceeds above the HTG vapor
temperature high temperature set point, the DILUTION alarm sequence is carried out
and the machine goes into dilution cycle. The alarm can only be
reset only when the HTG vapor temperature goes below the HTG
vapor temp trip set point minus the set hysterisis value.
HTG high If the HTG temperature exceeds the HTG high temperature set
temperature safety point, the ‘DILUTION CYCLE’ alarm sequence is carried out and
the machine goes into dilution cycle immediately. HTG high
temperature alarm can be reset only when the HTG temperature
drops below the set point minus the hysterisis set value (5°C).
This setpoint may vary slightly for nonstandard machines.
Note The set points mentioned in above descriptions are nominal set
points and may vary to some extent if machine parameters are
different from literature parameters.
Cavitation protection If the refrigerant level in the evaporator pan falls below set level,
of refrigerant pump. the pressure in the refrigerant pump suction drops below the
saturation pressure of the refrigerant and the refrigerant pump
starts to cavitate. To ensure minimum acceptable suction pressure
the level of refrigerant is not allowed to fall below a certain level.
This is done by means of three level electrodes, RE1, RE2, RE3,
and a level relay, 33RL.
The three electrodes are mounted in the refrigerant level
box assembly on the lower shell (Evaporator side). RE1 electrode
is the smallest in length and RE3 is the longest. The level is
maintained between RE1 and RE2. RE3 acts as a reference
electrode. When the level reaches RE1, the pump starts and when
C30HP00A07 A07.4.
the level goes below RE2, the pump stops and restarts only when
the level reaches RE1 again. When the level goes below RE2, a
delay of 20 seconds is provided before the pump is switched off.
Pump will not stop if level goes upto/above RE2 in this 20sec.
Cavitation protection If the absorbent level in the absorber sump falls excessively, the
of absorbent pump. pressure in the absorbent pump suction drops below the saturation
pressure of the absorbent solution and the absorbent pump starts
to cavitate. To ensure minimum acceptable suction pressure, the
level of absorbent is controlled. Absorbent level in the HTG is not
allowed to rise above a certain level. This prevents excess
absorbent from being pumped out of the absorber sump. This is
done by means of three level electrodes, AE1, AE2, AE3, and a
level relay, 33AL.
The three electrodes are mounted on the high temperature
generator level box. AE1 is the smallest electrode and AE3 is the
longest. The level is to be maintained below AE1. AE3 acts as the
reference electrode. When the level reaches AE1, the pump stops
after a delay of 5 seconds. When the level goes below AE2, the
pump restarts.
Motor protection
safeties
Absorbent pump If the absorbent pump motor draws more than its rated current, this
overload relay overload relay trips and the ‘TOTAL SHUTDOWN’ alarm sequence
is carried out. The alarm is reset by resetting the overload relay.
Refrigerant pump If the refrigerant pump motor draws more than its rated current, this
overload relay overload relay trips and the ‘DILUTION CYCLE’ alarm sequence is
carried out. Resetting the overload relay resets the alarm.
Purge pump overload If the purge pump motor draws more than its rated current, this
relay overload relay trips. Resetting the overload relay resets the alarm.
Alarm sequences : There are three alarm sequences which activate when the fault
conditions occur
¾ Dilution cycle alarm sequence.
¾ Total shutdown alarm sequence.
¾ Purge pump trip alarm.
Dilution cycle alarm This alarm sequence protects the machine from crystallisation.
sequence.
Fault conditions which activate this alarm sequence are -
. High temperature generator temperature high.

. Vapor temperature high.
. For following sensor errors:
1) HTG SENSOR.
2) VAPOR SENSOR
3) COOLING INLET SENSOR.
4) LTG SENSOR.
5) SPRAY SOLUTION.
6) REFRIGERANT ‘U’ TUBE
. Cooling water inlet temperature low.
. Refrigerant pump trips not responding.
C30HP00A07 A07.5.
The alarm action is as follows

• Steam control valve closes immediately.
• Refrigerant pump stops after one minute.
• Machine goes into dilution cycle for 20 minutes.
• Cooling water Auto shutoff valve closes along with refrigerant
pump.
If the operator does not acknowledge the fault within 20 minutes,

the machine stops completely.
Total Shutdown Alarm This alarm sequence protects the machine from freezing of the
Sequence evaporator or any other damage.
Fault conditions which activate this alarm sequence are -
¾ Chilled water flow switch trip.

¾ Chilled water D.P. switch trip.
¾ Chilled water pump interlock trip.
¾ Chilled water outlet temperature sensor fault.
¾ Antifreeze trip .
¾ Absorbent pump over current trip .
¾ Absorbent pump contactor not responding.
The alarm action is as follows

• Steam control valve closes immediately.
• Refrigerant and absorbent pump stop.
• Cooling water shutoff valve closes.
• Machine shuts down.
After the fault(s) is reset the machine goes into dilution cycle. If the
machine is not restarted during the dilution cycle, the machine
stops completely after the dilution cycle is over.
Power failure alarm This alarm is displayed when the machine is powered up after a
sequence power failure during operation. After acknowledging and resetting
the alarm the machine will go in dilution cycle.
NOTE During vacuum pump trip, HTG top and bottom condensate line
sensor error, Chilled inlet temp sensor error only alarm will come.
Alarm When an alarm sequence is initiated, the alarm screen will pop up,
acknowledgment and with an audio alarm.
reset sequence
Unless and until the activated alarm is acknowledged the user will
not be allowed access to any other screen.
¾ Currently activated alarm(s) will be displayed, with the date and

time.
¾ Press ACK to stop the hooter (audio signal).
¾ If there is more than one alarm, pressing the ACK key will
display the next active alarm. Use ACK key to scroll through all
active alarms.
¾ After rectifying the fault condition, each alarm will have to be
individually displayed on the ALARM screen, and then reset all
the alarm conditions by pressing the alarm reset key i.e. K4
C30HP00A07 A07.6.
key.
Start the machine by pressing the key on the ‘OPERATION’

screen.
Example If the chilled water pump trips, three alarms will be triggered :
Chilled water pump ‘OFF / TRIP’
Chilled water flow switch ‘TRIP’
Chilled water DP switch ‘TRIP’
¾ The ‘ALARM’ screen will pop-up and the hooter will start.
‘CHILLED WATER PUMP OFF / TRIP’ will be displayed on the
‘ALARM’ screen.
¾ Pressing ACK key will stop the hooter, and ‘CHILLED WATER
FLOW SWITCH TRIPPED’ will be displayed on the ‘ALARM’
screen.
¾ Pressing ACK again will display the next active alarm i.e.
‘CHILLED WATER DP SWITCH TRIPPED’.
¾ Once all the alarms have been acknowledged, go to the
‘STATUS’ screen and monitor the current status of the
concerned devices, i.e.
Chilled water pump ‘CHW’ ‘PUMP OFF’
Chilled water flow switch ‘FLSw’ ‘TRIP’
Chilled water DP switch ‘DPSw’ ‘TRIP’
¾ After the chilled water pump has been started and the required
flow is resumed, the ‘STATUS’ screen display will be -
Chilled water pump ‘CHW’ ‘PUMP ON’
Chilled water flow switch ‘FLSw’ ‘HEALTHY’
Chilled water DP switch ‘DPSw’ ‘HEALTHY’
¾ Once this condition is achieved, press alarm reset K4 key to
reset the alarms. The red LED will go off to indicate that the
alarm has been reset.
Start the machine by pressing the 'M/C START' key on the
operation screen.
Set points
The field instruments and the components in the control panel are
to be set as follows
S.NO. Description Set points

1. Chilled water flow switch 50 % of rated flow
2. Chilled water D.P. switch 50 % of rated flow
3. Absorbent pump over current relay As per pump rating
4. Refrigerant pump over current relay As per pump rating
5. Purge pump over current relay As per pump rating
OP 7 Set points The operator terminal settings are as follows
S.NO Description Set points Remarks
C30HP00A07 A07.7.
.
1. Chilled water temperature control set - Refer machine specs.
point (CHWSP)
2. Chilled water temperature modulation
control settings:
a) Proportional Band - 240
b) Integral Band + 10
c) Derivative Band 0
3. L-cut set point 1°C
4. L-cut hysterisis 2°C
5. Antifreeze 4°C
6. Hysterisis 2°C
7. Cooling water inlet temperature set 10oC
point
8. Cooling water inlet temperature 5°C
hysterisis
9. HTG trip set point 160°C
10. HTG hysterisis 5°C
11. HTG temperature set point for AC drive 150° C Optional
for absorbent pump speed control
12. HTG condensate temperature 10° C
difference
13. Data log sampling time 60 min
14. Trip log sampling time 1 min
15. Anti-chattering timer for FS, DPS & 3 sec Not accessible
INTERLOCK of chilled water.
16. Dilution cycle timer 20 min Not accessible
17. OFF delay timer for absorbent pump 3 sec Not accessible
18. OFF delay timer for refrigerant pump 20 sec Not accessible
19. Star-Delta change over time for CHW 7 sec Not accessible
interlock
20. H cut differential (Applicable for heat 1° C Adjustable
pump only)
21. H cut hysterisis (Applicable for heat 5° C Adjustable
pump only)
22. HTG Vapour temperature trip set point 100° C Adjustable
23. HTG Vapour temperature hysterisis 10° C Adjustable
24. CT fan ON/OFF set point 25° C Adjustable
25. CT fan hysterisis 3° C Adjustable
PLC Input/Output
assignments
Digital Inputs 24 VDC type Onboard PLC S7-200 CPU 226

Address Device Tag Description
I 0.0 52W Chilled water pump interlock
I 0.1 69W Chilled water flow switch
C30HP00A07 A07.8.
I 0.2 DPS2 Chilled water DP switch

I 0.3 spare Spare
I 0.4 88A Abso pump contactor/AC Drive ON
I 0.5 51A Abso pump overload
I 0.6 88R Refrigerant pump contactor on
I 0.7 51R Refrigerant pump overload
I 1.1 51P Purge pump overload
I 1.2 33RL Evaporator level low
I 1.3 33AL1 HTG level low
I 1.4 33AL2 Absorber level
I 1.5 33AL3 Absorber level
I 1.6 4Y1 Remote start/stop
I 1.7 SPARE SPARE
I 2.0 SPARE SPARE
I 2.1 SPARE SPARE
I 2.2 SPARE SPARE
I 2.3 SPARE SPARE
I 2.4 SPARE SPARE
I 2.5 SPARE SPARE
I 2.6 SPARE SPARE
I 2.7 SPARE SPARE
Digital outputs 24 VDC type onboard PLC S7-200 CPU 226
Address Description
Q 0.0 Hooter
Q 0.1 Refrigerant pump on
Q 0.2 Purge pump on
Q 0.3 Remote machine on indication
Q 0.4 Remote machine trip indication
Q 0.5 Chilled water pump start enable
Q 0.6 Cooling water butterfly valve start enable
Q 0.7 CT Fan start enable
Q 1.0 Absorbent pump / AC drive start
Q 1.1 SPARE
Q 1.2 SPARE
Q 1.3 SPARE
Q 1.4 SPARE
Q 1.5 SPARE
Q 1.6 Condensate Drain Solenoid Valve
Q 1.7 Auto Blowdown Solenoid Valve
Analog Input / Output

Analog Inputs RTD PT100 and Outputs 4 ma to 20 ma
Module type EM235 2 Nos.
C30HP00A07 A07.9.
Address Description
AIW0 Chilled water inlet temperature
AIW2 Chilled water outlet temperature
AIW4 Cooling water inlet temperature
AIW6 HTG Top temperature
QW0 Signal to I/P converter
AIW8 HTG temperature
AIW10 HTG vapour temperature
AIW12 Spray solution temperature
AIW14 HTG Bottom Temperature
QW4 Spare
Analog Inputs RTD PT100
Module type EM231 1 No.
Address Description
AIW16 ‘U’ Tube Temperature
AIW18 LTG Temperature
OP7 Operator The entire operation of the VAM/c is controlled through the OP7
Interface:- operator interface.
OP7 consists of:
1. An LCD display 4-Lines * 20-characters.

2. Function keys F1 to F4 and
K1 to K4
3. Arrow keys Left, Right, Up, Down.
4. Numeric keys 0 to 9 with decimal point.
5. ENTER key to enter set points.
6. ACK key to acknowledge Hooter/Alarm.
K1 to K4 keys are global keys with functions
K1 MAIN MENU
K2 MACHINE PARAMETERS
K3 MACHINE STATUS
K4 FAULT RESET
The LCD display is programmed to show the interface screens. A

screen consists of a combination of indications, and keys. Through
these, the machine status is observed, and its operation can be
controlled.
Screen tree structure is given below

‘MAIN MENU’
¾ ‘OPERATION’
¾ ‘STATUS’
¾ ‘SETPOINTS’
¾ 'M/C PARAMETERS'
¾ 'UTILITY'
¾ ‘ALARMS’
¾ 'DATALOG’
C30HP00A07 A07.10.
• 'NORMAL'
• 'TRIP'
¾ 'SERVICES'
• 'M/C OPERATION'
• 'HTG / COW SP'
• 'LCUT / HCUT SP'
• 'OFFSET ADJ'
• 'PID SETTINGS'
• 'A/C DRIVE SETTINGS'
• M/C/ COMM DATE'
¾ 'PLC DATE / TIME'
¾ 'PRODUCT INFO'
¾ 'M/C MODES'
¾ 'ALARM LOG’
Product Info Screen This screen is the startup screen and is displayed on power up.
The first page of this screen displays the Product and Model
number.
The second page is accessed by pressing the F4 key.
The second page displays the software version loaded in the

Programmable Logic Controller (PLC) and the Operator Interface
(OP7) also called the Man Machine Interface (MMI).
This screen can also be accessed from 'MAIN MENU'
Press K1 to go to Main Menu.
Main Menu : This screen displays the names of all the other function and
operation screens.
Access - K1 Key The first page of the 'MAIN MENU' screen shown the names of the
'OPERATIONS', 'STATUS', and 'SETPONTS' screens, and shows
the keys to be pressed to activate them.
The other pages of the ‘MAIN MENU’ screen can be displayed by
C30HP00A07 A07.11.
scrolling down using the F4 key.
The second page shows the ‘M/C PARAMETERS’, and the

‘UTILITY’ activation keys.
The third page shows the ‘ALARMS’ and the 'DATALOG’ screen
activation keys.
The fourth page shows the ‘SERVICES’ and the 'PLC DATE/TIME’
screen activation keys.
The fifth page shows the ‘PRODUCT INFO’, 'M/C MODES' and the
'ALARM LOG’ screen activation keys.
Other screens can be displayed by pressing the function keys

indicated by the name of each screen.
Use F3 (<<) and F4 (>>) Function keys for scrolling pages up

and down respectively.
Operation Basic machine operations are carried out through this screen. This
screen consists of 6 pages, viz.
• Machine start screen

• Refrigerant pump auto / manual selection screen
• Refrigerant pump manual operation screen
• Purge pump operation screen
• Concentration limit control activation screen
• Chilled water inlet temperature control override screen
Machine start screen
C30HP00A07 A07.12.
Start the machine by pressing F1 and stop the machine by

pressing F2. If the machine is ready to start the following
message will be displayed - " MACHINE READY TO
START".
If there is any fault condition then the following message will

be displayed - " MACHINE NOT READY TO START ".
At the same time the machine status is also displayed.
The next page can be displayed by pressing F4 function key
Purge pump operation screen
The Purge pump can be switched on or off from this screen.

Default position is ‘STOP’. Current pump status is also displayed.
Purge pump START / STOP operation can be done using F1 and

F2 keys. To start the purge pump press F1 key. To stop the purge
pump press F2 key.
Condensate Drain Valve auto / manual selection screen
This screen is used to select the mode of operation of the

Condensate Drain Valve. In order to open or close the condensate
drain valve.
Condensate Drain Valve AUTO / MANUAL mode can be changed
using the F1 and F2 keys. To operate condensate drain valve in
AUTO mode press F1 key, To operate condensate drain valve in
manual mode press F2 key. Present mode status is also displayed
Condensate Drain Valve manual operation screen
C30HP00A07 A07.13.
This screen is used to switch the condensate drain valve open or

close manually. It works only when the condensate drain valve is in
‘MANUAL’ mode. This screen action is disabled when the
condensate drain valve mode is in ‘AUTO’ mode. Default position
is ‘CLOSE’.
Condensate Drain Valve OPEN / CLOSE operation can be done

using the F1 and F2 keys. To open the condensate drain valve
press F1 key. To close the condensate drain valve press F2 key.
The current valve status is also displayed.
Status This screen displays the current on-line status of the machine
Access - K3 Key safeties, Interlocks, pumps, control valve, levels, temperature
sensors, switches etc.
To invoke this screen, press K3 key. (It can also be accessed from
the 'MAIN MENU' screen.) This will display the first page of
'STATUS' screen. Other pages can be scrolled up by pressing F3
key and down by pressing F4 key.
To return to "MAIN MENU" press K1 key.
Set points This screen can be accessed from 'MAIN MENU' screen - page 1,
by pressing the F3 key. Access the different set points by scrolling
down.
Here following set points can be changed.
CHW OUT SP OUT SP - On access of the 'SET POINTS' screen,
the cursor blinks at this set point entry field. Type the required set
point here and press ENTER key. To discard wrongly keyed
entries press ESC (escape) key.
CHW OUT TEMP and COW OUT TEMP are also displayed.
TRIP D'LOG TIME - During machine trip condition, the machine

parameters are logged at the interval of specified time interval. To
change this set point scroll down cursor at set point value, cursor
blinks here, type required time interval in minutes and press
ENTER key.
NORMAL D'LOG TIME - This is the time interval at which PLC logs
all machine parameters. To change this set point scroll down
cursor at set point value, cursor blinks here, type required time
interval in minutes and press ENTER key.
C30HP00A07 A07.14.
VALVE LIMIT - As the steam control valves are selected for the
range of machine models, the value of steam control valve opening
at which the rated capacity is achieved has to be the limit for valve
openings. This value determines the maximum limit on the steam
control valve opening. To change this set point scroll down cursor
to this set point value. When the cursor blinks here, type the
required %, and press ENTER key.
M/C Parameters This screen displays all measured temperatures in degree
Access - K2 Key Centigrade, steam control valve status, and pump status.
Utility In the first page of this screen, the number of hours the machine
has run and the number of times the machine has tripped are
displayed
Go to the next page of the screen by pressing the F4 key
In the second page of this screen, the number of purge pump run
hours is displayed. The date and time at which the purge pump
was last run is also displayed
Go to the next page of the screen by pressing the F4 key
On the page the machine commissioned date is displayed.
Alarms : The 'ALARMS' screen is an auto popup screen that is triggered

whenever an alarm condition is detected.
The activated alarm text will be displayed, with date and time of
occurrence, in the alarm window.
Press the ACK; i.e. acknowledge Key, to acknowledge the alarm,

and to stop the hooter. The operator can scroll through all the
C30HP00A07 A07.15.
activated alarms by pressing the UP/DOWN arrow keys on the

OP7. As soon as the alarm is acknowledged, the alarm screen
disappears and screen displayed prior to alarm activation is
displayed.
Datalogs All the data logged in PLC can be displayed here.
Where logged data of measured temperatures, percentage steam

control valve opening, status of absorbent pump and refrigerant
pump, machine status with date and time are displayed.
Press F1 to display normal data log.

Press F2 to display trip data log.
Using F3 and F4 Keys scroll pages UP/DOWN.
Service Settings The critical machine parameter settings can be edited through the
SERVICE screen. To avoid access from unauthorized persons,
these screens are password protected
There are 10 pages of Service Settings
1. M/c OPERATIONS
2. HTG / COW SP
3. L-CUT / H-CUT SP
4. OFFSET ADJ
5. PID SETTINGS
6. DRIVE SETTINGS
7. M/C COMM DATE
8. REFRIGERANT PUMP OPERATION
9. MACHINE MODE.
C30HP00A07 A07.16.
M/C OPERATIONS
Machine operation (start / stop) mode can be changed from local to
remote and vice versa using F1 and F2 keys. Press F1 key to
operate machine locally, and press F2 to operate machine
remotely.
HTG / COW SP
HTG TEMP. TRIP SP - If actual HTG temperature exceeds this set

point value, machine trips on 'HTG TEMP. HIGH ALARM'.
HTG HYSTERISIS - This value determines the HTG temperature,
below the HTG TEMP TRIP SET POINT, at which the HTG temp
high alarm can be reset. The HTG temp high alarm can be reset
only when the actual HTG temperature is less than 'HTG TEMP
TRIP SETPOINT ' - 'HTG HYSTERISIS'.
COOLING WATER IN TRIP SETPOINT - If cooling water inlet

temperature drops below this value machine trips on "COW IN
TEMP LOW" alarm.
COW HYSTERISIS - This value determines the value of cooling

water inlet temp at which the alarm can be reset. The alarm is
reset at "COW IN TRIP SP" + "COW HYSTERISIS"
C30HP00A07 A07.17.
CT FAN SP
CT FAN OFF SETPOINT - This value determines the temperature

of COOLING WATER at which the cooling tower fan is to be
switched off.
CT HYSTERISIS - This value determines the actual cooling water

inlet temp above the CT fan off setpoint at which the cooling tower
fan would restart.
L-CUT/H-CUT SP
L CUT SP - This is one of the antifreeze safeties for chilled water

temperature. If the chilled water temperature drops below this
value the refrigerant pump stops. Set this value at 'CHILLED
WATER OUTLET TEMPERATURE SP' - '1.O' (degree C).
L CUT HYST – This set point determines the value above the L
CUT SP at which the refrigerant pump restarts. The refrigerant
pump restarts when the chilled water outlet temperature becomes
greater than or equal to L CUT SP + L CUT HYST. Unit is degree
centigrade.
ANTIFREEZE SP - If the Chilled water outlet temperature drops

below this set point the machine trips on 'INTERNAL ANTIFREEZE
ALARM'.
ANTIFREEZE HYST - The antifreeze trip alarm can be reset only
when the Chilled water outlet temperature exceeds ' ANTIFREEZE
SP' + ANTIFREEZE HYST.' Unit is degree centigrade.
H CUT SP - If the Chilled water outlet temperature goes above this

value an alarm is activated. Value set is in O c.
H CUT HYST - This value determines the actual temperature of

chilled water outlet below the 'H CUT TRIP SP’ at which the chilled
water outlet temp. High alarm can be reset. The alarm will only
reset when the outlet temp value is less than ' H CUT TRIP SP' -
C30HP00A07 A07.18.
'H CUT TRIP HYST'
PID SETTINGS
PV (PROCESS VARIABLE) - Process variable in this case is the

Chilled water temperature. This PV numeric display is the Chilled
water outlet temperature.
NUMERIC ENTRIES:
SV (SET VALUE): This is the Chilled water outlet temperature set
point. The chilled water outlet temperature set point can be
changed from here as well as from the SETPOINTS screen. In this
screen the entry for chilled water outlet temperature set point has
no function key assigned to it. To change the set point from this
screen just type in the new set point & press the ENTER key. Unit
is °C.
CV (CONTROL VALUE): This is the PID controller output or the

Steam control valve opening in terms of % age. (0 to 100%).
P (PROPORTIONAL GAIN): This value is the proportional gain of
the PID control loop. It is a factor that is multiplied to the scaled
error (scaled SV - scaled PV) in the PID equation. This value
provides a continuous, linear relationship between the deviation
and the correction signal.
I (INTEGRAL GAIN): This is the integral gain value of the PID
control loop. This value adjusts the output signal based on both the
size of the deviation and its duration (reset time). It eliminates the
offset effect of the proportional action.
C30HP00A07 A07.19.
D (DERIVATIVE TERM): This value determines the rate of change

of the PID control loop output with respect to rate of change of
actual Chilled water temperature.
SCV AUTO/MANUAL CONTROL - To control the valve manually,

put the Chilled water temperature PID control loop into ‘MANUAL’
mode by pressing the ‘MANUAL’ (F2) key again by pressing AUTO
(F1) key SCV can be put in AUTO mode.
Controlling the steam control valve manually is not
recommended for normal operation of the machine
OPEN (F1) – This key lets you open the STEAM CONTROL
VALVE by increments of 1% when the chilled water PID loop is in
manual mode.
CLOSE (F2) - This key closes the STEAM CONTROL VALVE by
decrements of 1% when the chilled water PID loop is in manual
mode.
HTG TEMP LOW LIMIT - This set point is used to start the AC
drive modulation at minimum frequency (35 Hz).
HTG TEMP LOW LIMIT - This set point is used to stop the AC
drive modulation at maximum frequency (50 Hz).
M/C COMM DATE: -
Machine commissioned date is over written by pressing this key.
PLC date / time This screen displays the current DATE and TIME of the PLC
Current DATE and TIME of PLC can be changed in this screen.

Type each field of DATE and TIME and press ENTER key on OP7
and to write this to PLC - press ENTER (F1) key.
C30HP00A07 A07.20.
To synchronize the time setting of the PLC and the OP7, switch off
power to PLC panel, and then switch it on again.
Machine Mode Machine "COOL" mode (F1) / "HEAT" mode (F2) can be changed
from this screen.
Refrigerant pump auto / manual selection screen
This screen is used to select the mode of operation of the

refrigerant pump. In order to start or stop the refrigerant pump
irrespective of the evaporator level, (for e.g. during Blowdown
cycle) the refrigerant pump has to be in ‘MANUAL’ mode. Default
position is ‘AUTO’.
Refrigerant pump AUTO / MANUAL mode can be changed using

the F1 and F2 keys. To operate refrigerant pump in AUTO mode
press F1 key, To operate refrigerant pump in manual mode press
F2 key. Present mode status is also displayed.
Refrigerant pump manual operation screen
This screen is used to switch the refrigerant pump on or off

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

F1 and F2 keys. To start the refrigerant pump press F1 key. To
stop the refrigerant pump press F2 key. The current pump status is
also displayed
Alarm Log In this screen, the last six alarms logged in PLC are displayed. By
pressing F3 and F4 keys all six alarms can be scrolled.
C30HP00A07 A07.21.
C30HP00A07 A07.22.
A.08.Start & Stop Procedure
A.8 STARTUP & STOP PROCEDURES

Chapter Objective This chapter describes the pre-start checks, starting procedure and
the stopping procedure.
Pre - start checks ¾ Switch on the input power supply to the control panel.
¾ Check and maintain the vacuum in the machine.
¾ Check all the set points on the operator panel.
( Refer list of set points )
¾ Set the position of all the function keys on the operator panel,
as follows :
• ‘MACHINE ’ status. - OFF
• ‘PURGE’ key. - STOP
• ‘REF. PUMP’ key. - AUTO
• ‘AUTO/MAN’ key - AUTO
Note : - These settings are default and should appear when
the machine is powered up.
Starting Procedure ¾ Start the chilled water pump and maintain the required ∆P
across the machine. If the flow rate is less than minimum rated
flow, CHILLED WATER FLOW LOW status will be displayed on
the ‘STATUS’ screen of the operator panel. After setting right
the flow, the DP switch and the flow switch will indicate
HEALTHY indication.
¾ Start the cooling water flow and maintain the required ∆P
across the machine.
¾ Maintain the required air pressure (oil and moisture free air)
supply to the air filter regulators.
¾ Open the isolating valve before the steam control valve and
maintain the required dry and saturated steam pressure before
the steam control valve.
¾ Give machine ‘START’ command on the operator panel.
Machine ON indication is displayed on the ‘STATUS’ screen.
¾ Absorbent pump contactor 88A is energized. Absorbent pump
‘ON/OFF’ is controlled by the level controller 33AL. Absorbent
pump ‘ON/RUN’ indication is displayed on the ‘STATUS’
screen.
¾ Refrigerant pump contactor 88R is energized. Refrigerant
pump ‘ON/OFF’ is controlled by the level controller 33RL. The
refrigerant pump ‘ON/RUN’ indication is available on the
‘STATUS’ screen.
¾ Slow opening of steam control valve starts and opens from 0-
100% in 10 minutes, when the high temperature generator
temperature is below 70°C. The steam control valve slow
opening indication is available on the ‘STATUS’ screen.
¾ After 10 minutes the control valve is put into modulation control.
The valve opening is controlled according to the chilled water
PID temperature control and the valve status will be displayed
accordingly.
When the potential free contacts of the PLC are used to start or
stop chilled water pump and hot / cooling water pump or shut off
valve, the machine start command automatically starts the chilled
water pump and the hot / cooling water pump or opens the cooling
water shut off valve in proper sequence.
C30 HP00 A08 A.08.1

A.08.Start & Stop Procedure
Stopping Procedure ¾ Press the ‘M/C STOP’ switch into the ‘OFF’ position on the
operator panel.
¾ Steam control valve closes immediately.
¾ Machine goes into dilution cycle and the indication ‘DILUTION
CYCLE ON’ on the ‘STATUS’ screen.
¾ The contactor 88R is de-energized and the refrigerant pump is
stopped after 4 minutes.
¾ Cooling water shut off valve closes after 4 minutes.
¾ The status screen will indicate hot / cooling water pump / shut
off valve ‘DISABLED’.
¾ After 20 minutes, dilution cycle completes and the absorbent
pump stops.
¾ ‘STATUS’ screen indicates ‘MACHINE : OFF’.
¾ Stop the chilled water pump / flow.
¾ The machine stops completely.
When the potential free contacts of the PLC are used to start and
stop the chilled water pump and hot / cooling water pump / shut off
valve, the machine stop command automatically stops the chilled
water pump and the hot / cooling water pump or closes the cooling
water shut off valve in proper sequence.
C30 HP00 A08 A.08.2

A.09.Operating Instructions
A.9 OPERATING INSTRUCTIONS

Chapter Objective This chapter describes the operational activities required to
keep the machine in best condition. These activities are
¾ Purging
¾ Blowdown of refrigerant
¾ Maintenance of operation log
These are to be carried out as per the Operational Activity
Schedule
Purging Purging is the activity by which non-condensable gases are

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

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

vacuum from 0mmHg absolute to 100mmHg absolute.
Service valves One service valve provides access for the manometer to the
machine, and the other provides access for maintenance
procedures like N2 charging and sampling.
Purge pump A two stage oil sealed vacuum pump for evacuating the
machine and carrying out maintenance procedures.
Measuring vacuum Three different vacuum measurements are carried out. The
positions of the manual purge valves for these measurements
are described in the table below.
Position of Manual Purge Valves
Vacuum reading Valve no. 1 Valve no. 2 Valve No. 3
Ultimate (No Load) Vacuum Open Closed Closed
Pressure in the storage Closed Open Closed
tank
Pressure in the shell Closed Closed Open
Reading the The manometer (see Figure 9.2) consists of a glass tube
manometer fitted into a casing with a graduated scale. One end of the
glass tube is sealed and the other end is connected to the
vessel whose degree of vacuum is to be measured. Mercury
C30 HP00 A09 A09.1
fills the glass tube from the sealed end to the bottom of the
graduated scale.
When the manometer is connected to a vessel at a vacuum of
100mmHg or greater, the mercury drops in the sealed leg of
the glass tube. The degree of vacuum is the difference in the
level of mercury in the two legs. This is read off the graduated
scale.
The level of mercury in the sealed leg of the manometer
should always be higher than the other leg. Otherwise the
reading is wrong and the manometer has to be repaired.
When the manometer is connected to the atmosphere the
mercury should rise to the top of the sealed leg. If there is a
gap between the mercury and the top of the sealed leg of the
manometer, it is faulty and should be repaired.
Kinds of purging The two types of purging are

¾ Purging from the storage tank, and
¾ Purging from the shell.
The procedure followed for the two types of purging are the
same except for the position of the manual purge valves
(shown in the earlier table)
Purging procedure ¾ Power on the machine panel if it is off.
¾ Start the purge pump.
¾ Check that the purge pump is running well.
¾ Open Manual purge valve No. 1.
¾ Check that the ultimate (no load) vacuum developed by
the vacuum pump is 4mmHg or less.
¾ Open
• Manual purge valve No. 2 - for purging storage tank.
• Manual purge valve No. 3 - for purging from shell.
¾ Continue operation of purge pump till purging is
completed.
¾ Close
• Manual purge valve No. 2 - when purging storage tank.
• Manual purge valve No. 3 - when purging from shell.
¾ Continue operation of purge pump for 30 minutes to
Remove water vapour from pump oil.
¾ Close Manual purge valve No. 1.
¾ Stop the purge pump.
Precautions ¾ Check that the ultimate vacuum of the purge pump is

4mmHg or less before air purging.
¾ Carry out purging at least once a day. Purging may be
Required at more frequent intervals.
¾ Always keep the gas ballast valve open while purging to
Prevent water from contaminating the purge pump oil.
¾ Carry out purging from storage tank before the storage
Tank pressure reaches 50mmHg.
During operation, a small amount of absorbent disperses in
Blowdown of the refrigerant and accumulates over time, resulting in a
refrigerant reduction in cooling capacity. Blowdown is carried out to
purify the refrigerant. Contaminated refrigerant collected in
the refrigerant pan is transferred to the absorber sump. Pure,
fresh refrigerant collects in the refrigerant pan.
Procedure ¾ Put the refrigerant pump switch into “auto” mode if it is not
C30 HP00 A09 A09.2
so already.
¾ Confirm that the refrigerant pump is running and
refrigerant is visible in the sight glass.
¾ Open the refrigerant blowdown valve completely.
Refrigerant starts being pumped to the absorber sump.
¾ Wait till the refrigerant pump stops due to low level signal
from the refrigerant level relay (about 15min), and close
the refrigerant blowdown valve completely.
¾ Refrigerant will start building up and the refrigerant pump
will start when the refrigerant level reaches the center of
the evaporator sight glass. (About 20 min)
¾ Repeat the procedure two or three times for complete
purification of refrigerant.
Precautions ¾ Outlet chilled water temperature goes up during the
blowdown procedure, and will go down when the
refrigerant restarts. Blowdown operation is carried out
when chilling requirement is not critical.
¾ Carry out refrigerant blowdown once a week.
P u r g e S y s te m
M a n u a l p u rg e
v a lv e N o . 2
Vacuum
M a n o m e te r
v a lv e N o .3
S e r v ic e v a lv e
v a lv e N o .1
L iq u id
T ra p
P u rg e
ta n k
P u rg e p u m p
Figure 9.1
C30 HP00 A09 A09.3

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

Operating Log
Record readings in accordance with the operating log at frequent intervals. These aid the
operator to recognize both normal and abnormal machine conditions and also aids in
planning the preventive maintenance schedule and in diagnosing machine problems. A
typical operating log sheet is shown below.
Re Items Unit Date : / /
.
1. Time : : : :
3
2. Chilled water flow rate m /hr
3. Chilled water inlet & outlet temp. °C ( / ) / / /
4. Chilled water inlet & outlet kg/cm2g / / /
pressure
5. Cooling water flow rate m3/hr
6. Cooling water inlet & outlet temp. °C ( / ) / / /
7. Cooling water inlet & outlet kg/cm2g / / /
pressure
8. Generator temp. °C
9. Generator vapour temp. °C
10. Generator fluid level O
11. Absorber fluid level O
12. Evaporator fluid level O
13. Steam pressure before SCV kg/cm2g
14. Steam pressure in HTG header kg/cm2g
15. Steam control valve opening %
16. Pressure in storage tank mmHg
17. Pressure in shell mmHg
18. Attained vacuum of purge pump mmHg
19. Steam Consumption Kg/hr
C30 HP00 A09 A09.5

A.10.Utility Requirements
A.10 UTILITY REQUIREMENTS

Chapter Objective: The objective of this chapter is to understand what are
the various utility requirements for the functioning of
the machine.
Utility Requirements: The various utility requirements are :
¾ Water
¾ Steam
¾ Air
¾ Electricity
The Material Safety Data Sheet for all liquids are attached
at the end of this chapter.
A) WATER:
The lower the The temperature at which the refrigerant vapour in the
temperature of hot / condenser condenses, goes down in proportion to the
cooling water, the reduction in the temperature of hot / cooling water. Hence
better. the temperature differences available in the absorber and
condenser increase enabling the machine to deliver a higher
than rated capacity. As the capacity increases for the same
solution flow rate, the various inefficiencies of the heat
exchange reduce, thereby increasing the efficiency of
operation.
Extremely low cooling LiBr solution crystallizes when it is cooled. As the LiBr
water temperature is not solution concentration decreases, the crystallization
acceptable. temperature decreases. At a concentration of 65% the
crystallization temperature is 42°C, at a concentration of
60% the crystallization temperature is 17°C and at a
concentration of 55% the crystallization temperature is 5°C.
The cooling water cools the diluted LiBr in the absorber,
which cools the concentrated LiBr in the low temperature
heat exchanger (LTHE). If the concentrated LiBr is cooled so
that it crystallizes in the LTHE, the LiBr stops flowing through
the LTHE, and the machine cannot operate. Hence the
temperature of cooling water is to be controlled to ensure
that the LiBr does not crystallize.
Capacity of the machine LiBr becomes hot when it absorbs vapourised refrigerant. As
reduces when cooling the temperature of LiBr solution increases its the absorption
water temperature power decreases. Cooling water removes heat from the LiBr
increases and ensures maximum absorption of the refrigerant. If the
cooling water temperature increases, so does the LiBr
temperature. Hence the absorption of refrigerant vapour is
reduced and the pressure in the evaporator increases. The
rated chilled water temperature cannot be maintained and
steam is wasted. To prevent this, the maintenance of the
cooling water temperature is essential and cooling water
temperature should not be allowed to rise.
C30 HP00 A10.1 A10.1

Interlock between If the chilled water flow to the machine stops for any reason,
chilled and cooling the cooling water flow to the machine should also stop
water flows immediately. If the cooling water flow to the machine
continues when the chilled water flow is stopped, the
absorbent solution in the absorber continues to get cooled
and creates a high vacuum in the lower shell. The refrigerant
temperature drops sharply and ice formation may start in the
stagnant chilled water in evaporator tubes.
Ensure that the cooling water shut off valve stops by

interlocking the cooling water shut off valve through start
permissive signal from control panel ,so that the cooling
water flow stops if the chilled water flow is stopped in the
machine.
Water treatment of The water treatment of chilled and cooling water is important
chilled and cooling for the machine performance and long life.
water
If the water quality is bad and shows a scaling tendency,
scale adheres to the inside of the heat transfer tubes of the
evaporator, absorber and condenser. The heat transfer
between the chilled water and the refrigerant, and the
cooling water and the LiBr solution and the condensing
refrigerant reduces. This causes an increase in the LiBr and
condensed refrigerant temperatures and increases the
steam consumption. The chilled and hot / cooling water
should be treated to prevent scaling inside the tubes.
If the chilled or cooling water becomes corrosive, it will

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

STANDARD WATER QUALITY For Cupro Nickel 90:10 tubes of Evaporator,

Absorber & Condenser.
Items Hot / Cooling water Heat source / Tendency

Chilled water
One-pass or Make-up water Circulating Corrosion Scaling
circulating
pH 25°C 6.5~8.5 6.5~8.5 6.5~8.5 9 9
Total hardness 200 max 50 max 100 max 9
(ppm)
Chlorine Ion (ppm) 4000 max 1000 max 2000 max 9
Sulphuric acid ion 800 max 200 max 400 max 9
(ppm)
Total Iron (ppm) 1.0 max 0.3 max 1.0 max 9 9
Sulphur ion (ppm) Not detected Not detected Not detected 9
Ammonium Ion 1.0 max 0.2 max 0.5 max 9
Silica (ppm) 50 max 30 max 50 max 9
Turbidity (NTU) 20 max 5 max 10 max
Suspended solids 20 max 5 max 10 max
(mg/l)
Biological Oxygen - Below 160 -
Demand (BOD) ppm
Chemical Oxygen - Below 160 -
Demand (COD) ppm
STEAM: The steam to the machine should be Dry & Saturated. The steam
pressure should be in the range of 4 kg/cm2 g to 10 kg/cm2 g.
There should not be any rapid fluctuation in steam supply.
AIR: The compressed air is required for the pneumatic operation of

Steam Control valve.The Air supplied should be Moisture free.
The supply pressure of air is required to be 7 kg/cm2 g.
ELECTRICAL: The power supply to the machine shall be strictly as per the
Voltage and frequency rating given on Machine name plate.
C30 HP00 A10.3 A10.3

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

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

Close the service valves after any operation like checking
the pressure, solutions sampling, or charging, etc.
Purge non condensable gases from the purge unit, if the
storage tank vacuum is more than 15 mm Hg.
Close the main steam isolation valve after switching off the
machine.
Maintain inlet steam pressure constant at rated value.
Check the presence of octyl alcohol and corrosion inhibitor
periodically.
Analyse chilled and cooling water every three months and
maintain the quality of chilled and hot / cooling water.
Ensure that cooling water flow stops one minute after the
stopping the machine.
Change the vacuum pump oil, if it is contaminated (white
misty colour) .
Charge nitrogen gas upto 0.3 kg/cm2(g) in the system for
long shutdown of the machine (i.e. more than a month). If the
shutdown is for a shorter period, purge the machine for 20
minutes, twice a week.
Ensure that the rated electric supply (3 phase) is available.
Always start the chilled water pump first and then the hot /
cooling water pump. Ensure that the rated chilled water and
cooling water flows are passing through the machine. Ensure
that the steam is available at rated inlet condition.
Dry generator tubes / Headers if shutdown is more than one
month.
Drain moisture from purge pump liquid trap periodically.
Don’ts Don’t open any of the valves of the purge unit without
running the vacuum pump.
Don’t connect the pressure gauge to any service valve
continuously.
Don’t disturb the setting of any instrument or safety provided
on the machine.
Don’t put the refrigerant pump switch, or the steam control
valve operational switch in ‘MANUAL’, during normal
operation of the machine.
Don’t increase the overload setting of any motor, even if the
overload alarm trips.
Do not run the vacuum pump continuously.
Do not let the temperature of cooling water fall below 10
deg.C. Maintain it by stopping the cooling tower fan or by
bypassing the cooling water into the cooling tower basin by
installing a 3 way valve.
C30 HP00 A11 A.11.1

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

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

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

Unloading instructions:
• Use lifting shackles provided on the machine. Do not rig from any other point to avoid
any damage to the unit or any personal injury.
• Use proper sized hooks/slings and approved methods for lifting the machine.
• Lift the machine from all the four corners while keeping the unit leveled with respect
to the ground.
• Take care while hooking up the shackles, provided near the pipes. (Refer figure )
• Avoid any damage to the interconnecting pipes on the machine.
• Avoid any damage to the control panel and the machine mounted instruments.
PLACE THE HOOK AS SHOWN

AVOID DAMAGE TO PIPES
C30 HP00 A12 A12.1

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

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

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

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

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

Leveling of machine :
It is very important to level the machine prior to hooking up the machine with the external
piping. Proper leveling of the machine ensures that the rated capacity of the unit is
achieved. Allowable tolerance is less than or equal to 1/16 inch per 5 ft. (1mm per 1000
mm) both lengthwise and sidewise.
There are four leveling check points provided on the machine. (labeled as A, B, C and D
in the figure below) These check points are designated by the three punch marks on the
tube sheet or shell of the lower shell of the machine.
Procedure for leveling the machine:

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

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

where L = Length of the machine

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

SECTION B
TROUBLESHOOTING
C30 HP00 B00 B00.1

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

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

B.02.TroubleShooting Guide
B.2 TROUBLESHOOTING GUIDE
A.Problems without These problems may occur either when the machine starts or
alarm indication. during operation of the machine.
1. Operator terminal ¾ Check if the main circuit breaker is turned on. If not,
does not light up. switch it on.
¾ Check if all the MCB's are on. If not, switch them on.
2. Machine does not In case the machine does not start up, check the following :
start. ¾ Are the chilled water and hot / cooling water pumps
running? If not, operate the pump(s).
¾ Are the inlet and outlet valves of the chilled water and hot
/ cooling water on the machine open? If not, open the
valve(s).
¾ Check if the chilled water flow rate sufficient. If not, check
the following :
a)If the strainer in the chilled water circuit is clogged,
clean the strainer in the chilled water circuit.
b)Is air accumulated in the chilled water circuit? If yes,
vent out the air from the chilled water circuit.
¾ Maintain the proper chilled water flow across the machine.
3. Chilled water In case the leaving chilled water temperature is not dropping,
temperature is not check the following -
dropping.
¾ Are the auxillary equipments ON ?
¾ Is the steam control valve select key in ‘AUTO’ position? If
not, put the steam control valve in ‘AUTO’ mode.
¾ Is the refrigerant pump in ‘AUTO’ mode? If not, put the
refrigerant pump in ‘AUTO’ mode.
¾ Other causes for not achieving the desired chilled water

temperature are -
• Insufficient vacuum.
• Insufficient steam supply.
• Insufficient hot / cooling water supply.
• Hot / Cooling water inlet temperature is higher than
the design temperature.
• Refrigerant pump not operating.
• Chilled water flow rate higher than rated.
• Load on machine is higher than rated.
C30 HP00 B02 B02.1

4. Fouling of Fouling in the hot / cooling water and / or chilled water circuit
cooling water and / or accumulates in proportion to the operating hours of the
chilled water circuit machine, and the capacity decreases in proportion to the
fouling.
Occurrence of fouling can be observed by noticing the
pressure difference across the evaporator for chilled water
circuit and across the absorber and condenser for hot /
cooling water circuit of the machine. If the pressure difference
across the respective heat exchanger has increased
compared to the original value with the chilled water and hot /
cooling water flows remaining constant, it indicates scaling in
the respective circuit. Fouling in the hot / cooling water tubes
can also be confirmed by comparing the temperature
difference between the hot / cooling water outlet and
condensed refrigerant . If the difference is more than 3°C, it
indicates scaling in the hot / cooling water tubes. Fouling in
the chilled water tube can be confirmed by observing the
temperature difference between the chilled water outlet
temperature and the refrigerant temperature on the outlet of
the refrigerant pump line. In case the temperature difference
exceeds 3°C, it indicates fouling in the chilled water tubes.
Perform tube cleaning of the chilled water and / or hot /

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

solution in the refrigerant and accumulate during the operation of the
refrigerant machine. It causes reduction in the capacity of the machine.
Perform refrigerant blowdown to generate fresh refrigerant.
6. Insufficient octyl Insufficient quantity of octyl alcohol in the machine will cause
alcohol a reduction in the capacity of the machine. If there is no smell
of octyl alcohol in the exhaust from the purge pump, octyl
alcohol is insufficient.
Charge the required quantity of octyl alcohol into the
machine.
The charge volume of octyl alcohol is 1.1 litres / 1,000 kgs of
LiBr ( 55 % by weight ). Excessive addition of octyl alcohol
will affect the absorbent circulation. Hence charge octyl
alcohol in small quantities and observe the change in capacity
of the machine. Do not charge excess quantity of octyl
alcohol into the machine. Charge it from refrigerant service
valve.
7. Very small amount If the machine is operating with a very small amount of air
of air leakage in the leakage, the capacity of the machine will reduce slowly over a
machine period of time .
Check the corrosion inhibitor level in the machine and
maintain it as per the standard requirements.
Perform the nitrogen leak test on the machine. Check for any
C30 HP00 B02 B02.2

minor leakage points, specifically at the sight glasses,

solution level electrodes, refrigerant level electrodes,
connections of manometer, diaphragm valves, absorbent
pump pressure gauge and generator pressure gauge. Rectify
the leak point and conduct nitrogen decay test for 24 hours
and confirm there is no drop in the nitrogen pressure in the
machine.Use pressure gauge of 0.01 kg/cm2
8. Large fluctuation in The reasons for large fluctuation in the chilled water outlet
the chilled water temperature are -
outlet temperature
¾ Variation in chilled water flow
Check and maintain the required flow.
¾ Variation in load
Check and maintain a constant load on the machine.
¾ Incorrect setting of PID values
Check and correct the required PID values as per the
setpoint datasheet.
¾ Frequent ON/OFF operation of refrigerant pump due to
less refrigerant quantity at low load.
9. Steam control If the steam control valve does not close when the desired
valve does not close temperature of hot or chilled water is achieved, check and
when the hot or correct the hot or chilled water set points.
chilled water outlet
temperature crosses
the set temperature
B.Problems with alarm If the machine is in operation and any of the following
indication problems occur, the machine stops with an audio alarm and a
suitable visual alarm on the panelview operator terminal
screen.
The probable cause and remedy for the warning stop are as
follows
Description of alarm Probable cause Remedy

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


switch.
Accumulation of air in Perform air-venting from the
the chilled water chilled water circuit.
circuit.
Chilled water temperature Steam passing through Ensure no steam passing when
very low ( Machine machine due to valve control valve position in panel is
tripped by antifreeze not closing fully,valve zero.
thermostat) leakage or bypass
valve leakage.
Sensor not reading Calibrate the sensor.
correct temperature.
Difference between L- Increase the difference.
cut and antifreeze set
point is too low.
(*) Sudden reduction of Do not reduce the chilling load

chilling load. suddenly.
(*) Inadequate chilled Check the strainer in the chilled
water flow rate. water circuit, and clean if
necessary.
Check that the chilled water inlet
and outlet valves are open.
Main setpoint of chilled Reset the chilled water set point to
water is too low. a higher value.
Setpoint of L cut is too Reset the L cut setpoint to a
low. higher value.
Chilled water inlet Sensor cable is open / Replace the sensor cable.
temperature sensor error. short.
Chilled water outlet Loose connection of Check the tightness of the cable
temperature sensor error. sensor cable. connections.
Faulty temperature Replace the temperature sensor.
Hot / Cooling water inlet sensor.
temperature sensor error. Sensor terminal box is Clean the sensor terminal box.
Hot / Cooling water outlet moist.
temperature sensor error.
HTG temperature sensor
error.
LTG temperature sensor
error.
REF U tube temperature
sensor error.
HTG condensate
HR in temperature sensor
error.
HTG vapour temperature
sensor error.
Sprayed solution
C30 HP00 B02 B02.4


HTG temperature high. High cooling water inlet Check the setting of cooling water
HTG vapour temperature temperature. (Cooling tower fan thermostat, and reset if
high. Mode) required.
Check the feed water system of
cooling tower.
Check and clean the cooling
tower.
Excessive steam Check and adjust the supply
supply. steam pressure.
Check the opening of steam
control valve.
Check the operation of steam
control valve.
Fouling in the absorber Check for fouling in the absorber
and condenser tubes. and condensor tubes, and carry
out tube cleaning if required.
Setpoint of HTG Check and reset the settings.
temperature / vapour
temperature is not
correct.
Steam control valve Turn the steam control valve
select switch is in select key to ‘AUTO’ mode.
‘MANUAL’ mode and
in ‘OPEN’ position.
Air leakage into the Perform nitrogen leak test and
machine. rectify the leak point.
Inadequate hot / ¾ Check the operation of the hot
cooling water flow rate. / cooling water pump.
¾ Check that the hot / cooling
water inlet and outlet valves
are open.
¾ Check and vent out the air in
the hot / cooling water line.
¾ Check and clean the strainer in
the hot / cooling water line.
¾ Check and maintain the hot /
cooling water flow rate.
Wrong AC Drive Reprogram the AC Drive.
program.
Cooling water inlet Malfunction of cooling Check, and replace if necessary.
temperature very low. water tower fan cutout
(Cooling mode only) thermostat.
Setpoint of cooling Reset the set point of the cooling
water tower fan cutout water fan cutout thermostat to a
switch is too low. higher value.
Refrigerant pump tripped. Pump drawing
Absorbent pump tripped. overcurrent because of
MCB 1 / MCB 2 tripped. either - Check and ensure proper power
Single phasing. supply
Severe crystallisation. Decrystallise the machine

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


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

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

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

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

open.
PLC fault. Refer to PLC fault troubleshooting.
• Restart the machine only after the fault has been rectified.
• Whenever any safety device is replaced, make sure that the electrical connections are
done correctly.
• Check and tighten any loose connection in the control panel and on the safety device.
Action in case of ¾ If the power supply to the machine is interrupted, switch

interrupted power off the machine immediately. Make sure that the steam
supply during operation control valve is closed.
¾ If the power supply is resumed within half an hour,

immediately start the machine and maintain the
appropriate inputs to the machine.
¾ If the power is interrupter for longer then half an hour,

carry out the following activities -
¾ Start the machine and stop it, to put the machine into
dilution cycle.
¾ Start the machine and check for crystallisation. If there is
no indication of crystallisation, operate the machine.
¾ If there is any indication of crystallisation, perform
decrystallisation, and then operate the machine.
C30 HP00 B02 B02.6

Power cut during If the power is interrupted when the air-purging of the
purging operation of machine is in progress, immediately close manual purge
the machine valve no.1, and then close the other manual purge valves. As
soon as the power is resumed, operate the purge pump and
continue air-purging.
Jamming of the purge ¾ If the absorbent solution is forced into the purge pump by
pump the incorrect operation of charging or discharging nitrogen
gas, the absorbent solution causes jamming of the purge
pump.
¾ If the quality of purge pump oil is not proper and contains

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

• Charge kerosene oil in the purge pump and operate it
for a few seconds.
• Drain the kerosene oil from the purge pump.
• Charge purge pump oil in the purge pump and
operate the purge pump for some time.
• Drain the oil and recharge fresh purge pump oil.
• Clean Liquid Trap.
Now the pump is ready for usage.
Precautions for Always charge fresh purge pump oil in the purge pump for
operation of purge long term shut down.
pump. After a long term shut down or in the cold season, rotate the
pulley of the purge pump manually several times before
starting the purge pump.
Precautions to be ¾ Never ever remove / insert any of the PLC cards under
observed while powered conditions.
troubleshooting the ¾ Prior to power up always confirm that all the PLC cards
PLC are in their respective slots as per the machines’ electrical
drawing.
¾ Always keep the slelector switch on the CPU in ‘RUN’
position.
¾ Ensure perfect earthing for the machine panel.
¾ Before interchanging / replacing any of the cards ensure
that they are exactly as per the card specifications
mentioned in the machine manual (I/O list).
¾ Do not change the jumper settings on any of the cards.
Ensure that they are as per the notes in the machines’
electrical drawing
Correction Procedure- This fault deals with the temperature control software loop.
External signal error Confirm that the P, I and D values and chilled water outlet
(S*) temperature setpoint, are not negative, zero, or out of range.
If found so, correct the values.
C30 HP00 B02 B02.7

SECTION C
MAINTENANCE
C30 HP00 C00 C00.1

C.01.Preventive Maintenance
C.1 PREVENTIVE MAINTENANCE
Chapter Objective This chapter details the schedule of the various preventive
maintenance procedure to be carried out. Preventive maintenance
ensures best performance and long life of the machine.
Daily • Check chilled water and hot / cooling water flow rates.
• Check steam inlet temperature and pressure.
• While the machine is in operation the following may be
observed -
No abnormality in the steam control valve.
No abnormal sound in the absorbent, refrigerant and
purge pumps.
No other abnormality.
Purging.
• Purging
Weekly • Check oil in vacuum pump.

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

• Caution : Don’t overtighten as it may break the sight
glass.
Quarterly • Check and record working of all the safeties and their
settings. Reset or replace the safety devices, as required.
• Check all the set point values on the control panel
• Measure and record current drawn by absorbent,
refrigerant and purge pumps.
• Measure the absorbent pump pressure and record the
generator vapour temperature at the same time.
• Analyze and control chilled and hot / cooling water quality.
• Analyze the Lithium bromide solution, and maintain the
corrosion inhibitor level and alkalinity. Charge corrosion
inhibitor, if required. Charge alkali or acid, if required to
maintain the desired parameters of lithium bromide
• Check for the presence of octyl alcohol. Charge octyl
alcohol, if required.
• Check the actual position of Steam Control valve matches
with the control valve opening indicator.
C30 HP00 C01 C01.1

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

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

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

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

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

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

Chapter Objective This chapter gives the guidelines to be followed for
the longer life of the machine.
Maintenance for long This section describes the activities to be carried out during
term shut down the long-term shut down of the machine.
¾ Make sure that the steam control valve is closed and
there is no circulation of cooling and chilled water through
the machine.
¾ In case the shutdown is for one week or more, perform
either :
A. Perform air-purging once a week, to maintain the
required vacuum in the machine.
B. If the shutdown is for a period more than three weeks
charge nitrogen gas into the machine upto a positive
pressure of 0.2 kg/cm2g. No purging is required in this
case
¾ Dry generator headers / tubes.
Water circuit Water circuit preparation is done for

preparation for long • Absorber and condenser section
term shutdown • Evaporator section.
Absorber and The absorber and condenser tubes should be kept dry.
condenser section ¾ Drain out all the water from the absorber and condenser
from the drain port of the absorber header.
¾ Carry out tube cleaning to remove any scale or slime in
the absorber and condenser tubes.
¾ Clean the tubes with water.
¾ Add anti-corrosion chemicals to water and circulate it in
the absorber and condenser circuit.
¾ Drain the water from the tubes.
¾ Dry the inside surface of the tubes.
Evaporator section The evaporator tubes should be kept full with water. *
* If the machine is located at a site where the ambient
temperature will be below freezing point of water, drain out all
the chilled water and dry the evaporator tubes.
Steam circuit The generator tubes should be kept dry.

preparation for long ¾ Drain out all the water from the generator from the drain
term shutdown ports.
¾ Carry out tube cleaning to remove any scale if required.
¾ Clean the tubes with water.
¾ Drain the water from the tubes.
¾ Dry the inside surface of the tubes.
C30 HP00 C03 C03.1

C.04.Procedures for Maintenance
C.4 Procedures for Maintenance
Chapter Objective This chapter describes the various procedures to be carried

out during the maintenance of the machine.
Page No.
Charging solutions (absorbent and refrigerant). C.4-3

List of Procedures
Sampling absorbent. C.4-5
Measuring absorbent concentration. C.4-6
Absorbent analysis. C.4-9
Charging inhibitor (Li2MoO4). C.4-11
Charging alkali (LiOH). C.4-13
Charging acid (HBr). C.4-14
Checking and adding Octyl alcohol. C.4-15
Charging Nitrogen gas. C.4-16
Expelling Nitrogen gas. C.4-17
Measuring Absorbent pump pressure. C.4-18
Bubble test. C.4-20
Electrical and Checking insulation resistance. C.4-21

Instrumentation
Checking safety device operation. C.4-21
C30 HP00 C04 C04.1

C30 HP00 C04
Bending of Vacuum rubber hose
Method of Charging solution at the

bottom of the container
C04.2
Figure 4.1
Charging solutions This section describes the procedure for charging absorbent
(absorbent and and refrigerant into the machine. (See Figure 4.1)
refrigerant)
Equipment used ¾ Solution container (absorbent and refrigerant).

¾ Vacuum rubber hose with hose clamps.
¾ Copper tube
Procedure ¾ Place solution containers near the service valve to be

(to be carried out when used for charging.Normally refrigerant will be charged
the machine is off) from Evaporator service valve and LiBr from LTHE service
valve.
¾ Operate the vacuum pump and ensure vacuum level of
35mmHg(abs) or less inside the machine.
¾ Clean the equipment.
¾ Connect the equipment as shown in the figure.
¾ Fill the rubber tube with distilled water to avoid air ingress
into the machine.
¾ Insert the copper tube on the end of the vacuum rubber
hose into. the liquid container (keep the end of the copper
tube slightly above the bottom of the container)
¾ Open the service valve using the slot in the cap.
¾ When solution starts being sucked into the machine,
watch carefully to ensure that air does not leak into the
machine.
¾ As the container starts becomes empty, tilt it so that air
does not enter the tube as shown in the figure.
¾ Before the container become fully empty, bend the rubber
vacuum hose with both hands to ensure that air does not
leak in, and quickly insert it into the next container.
¾ Repeat the above steps till all the solution has been
charged into the machine.
¾ Once the required amount of solution has been charged,
close the service valve.
¾ Remove the rubber vacuum hose from the service valve
and put the cap back on the service valve.
¾ Stop the vacuum pump.
¾ Wash all the equipment with water and store carefully.
Precautions ¾ When charging solution, be careful to prevent spillage.

¾ Because vacuum exists inside the machine, be careful to
prevent air leaking in during the above work.
¾ Carefully wash the hose used in the above work with
water so as to prevent dirt ingress.
¾ Wear rubber gloves (Do not handle equipment or solution
with bare hands.) and thoroughly wash off any absorbent
which gets on hands, skin or clothes. Take care to prevent
absorbent entering the eyes or mouth.
¾ If any absorbent should spill, thoroughly wash it off with
water.
C30 HP00 C04 C04.3

Manual purge
valve No.2
Vacuum
Manometer Manual purge
C30 HP00 C04

valve No.3
Service valve
Sampling Tool
Manual purge
valve No.1
Liquid
Trap
Purge
Tank
Sampling Tool
Purge pump
C04.4
Figure 4.2
Method of sampling This section describes the procedure for sampling small
absorbent amounts of absorbent.(See figure 4.2)
Equipment used ¾ Sampling Tool.

¾ Rubber hoses for vacuum with hose clamp.
Procedure ¾ Operate purge pump.

¾ Open manual air-purge valve No.1.
¾ Check vacuum less than 4mmHg
¾ Connect the sampling tool to the service valve on the
purge system as shown in figure.
¾ Open up the service valve connected to the sampling tool.
¾ Open up the service valve of the sampling tool.
¾ When pressure drops below 4mmHg, close service valve
of the sampling tool.
¾ Close the service valve of the purge system connected to
the sampling tool.
¾ Close Manual purge valve No.1.
¾ Remove the sampling tool from the purge system.
¾ Connect the sampling tool to the service valve from which
sample is to be extracted as shown in figure (ensure that
the sampling bottle is held tilted downwards).
¾ Open the service valve of the sampling tool.
¾ Open the service valve from which sample is to be
extracted.
¾ When sampling flask becomes full of the sample (find by
feeling the temperature near the mouth)
¾ Close the service valve from which sample was extracted.
¾ Remove the sampling tool, open the cap and transfer the
contents as required.
¾ Wash all equipment with water before reuse.
¾ Upon completion, refit caps and gasket on all service
valves.
¾ Purge the machine for 15 minutes after sampling is over.
¾ Stop purge pump.
Precautions ¾ Vacuum exists inside the machine. Take care to ensure

that air does not leak into the machine.
¾ Handle all valves carefully so as not to damage them.
¾ Carefully wash equipment and rubber hose with water to
remove dirt before using it in the above work.
¾ Do not discard the solution after measurement. Store it in
an empty bottle and when it becomes full recharge the
solution into the machine. (See procedure for charging
solution )
C30 HP00 C04 C04.5

Measuring absorbent This section explains the procedure to measure the

concentration. concentration of absorbent and refrigerant. (See Figure 4.3)
Equipment used ¾ Sampling cylinder

¾ Gravimeter (Scale of 1.4 to 1.8 for absorbent and 1.0 to
1.2 for refrigerant).
¾ Thermometer
¾ Concentration Diagram of Lithium Bromide Solution
(Figure 4.4)
¾ Absorbent or refrigerant (solution to be checked)
Procedure ¾ Take sample of solution to be checked (Refer method of

sampling).
¾ Fill sampling cylinder to about 80% with solution to be
checked.
¾ Maintain sampling cylinder vertical and insert the
thermometer into the cylinder and stir the solution
thoroughly.
¾ When the temperature stabilizes, read the indication on
the thermometer.
¾ Remove the thermometer and insert gravimeter and when
the gravimeter stops moving up and down, read the
indication on the scale.
¾ Remove the gravimeter from the measuring cylinder.
¾ Store the solution in an empty bottle.
¾ Read the concentration of Lithium Bromide Solution, using
the Concentration Diagram (Figure 4.4).
¾ Upon completion of measurement, wash the gravimeter,
thermometer, and sampling cylinder with water, and then
store them carefully.
Example In the concentration diagram the horizontal axis represents

temperature and the vertical axis specific gravity. The lines
going down from left to right represent fixed concentration. If
the specific gravity is 1.76 and the temperature is 60°C, the
concentration given by the point of intersection of lines
projected from these valves will be 63.0%.
Precautions ¾ Do not damage the gravimeter and thermometer.

¾ Do not spill any solution.
¾ Do not fill the sampling cylinder more than about 80%.
¾ Perform specific gravity and temperature measurements
quickly.
C30 HP00 C04 C04.6

60
1.76
1.75
Figure 4.3
C30 HP00 C04 C04.7

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
1.95
94
93
92
91
1.90
89
88
87
86 70
85
84
83 69
82
81
68
1.80
79
78 67
77
76
66
SPECIFIC GRAVITY
75
74
73
65
72
71
64
CONCENTRATION (\)
1.70
69
68 63
67
66 62
65
64 61
63
62 60
61
1.60 59
59
58 58
57
56 57
55
54 56
53
55
52
51 54
1.50
.49 53
0 10 20 30 40 50
.48
52
1.20 1.47
19 .46
60 70 80 90 100 110 51
18 .45
17 .44 50
16 1.43
15
120 130 140 150 160 170 180
14 22
13
12 20
TEMPERATURE (C)
11
110 18
09
16
08
LITHIUM
07 14
06
CONCENTRATION (\)
05 12
04
03 10
02 8
01
100 6
99 4
98
97 2
1
96 0
095
0 10 20 30 40 50 60 70 80 90 100
TEMPERATURE (C) Figure 4.4

CONCENTRATION DIAGRAM OF
LITHIUM BROMIDE SOLUTION
C30 HP00 C04 C04.8
Absorbent (LiBr) Analysis of the absorbent solution is done to determine the

Analysis following
¾ Concentration of inhibitor (Lithium Molybdate).

¾ Alkalinity of the solution.
¾ Copper concentration.
¾ Iron concentration.
Standard values Inhibitor 50 ~ 300ppm

Alkalinity 0.03N ~ 0.07N
Copper 20 ppm maximum
Iron 10 ppm maximum
Concentration of The concentration of the Lithium Molybdate has to be

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

standard refer to procedure for adding inhibitor.
Procedure ¾ This procedure decides the sequence for preparing the

sample for checking the concentration of inhibitor
¾ Take solution sample (Refer solution sampling
procedure).
¾ Pour the solution sample into a bottle.
¾ Stand the bottle for about 24 hours. After 24 hours, solids
will settle at the bottom of the bottle
¾ Collect 5ml of absorbent solution from the top of the bottle
by the pipette.
¾ Pour the absorbent solution by above work into the
beaker.
¾ Mix 4ml of Aluminum nitrate and 1ml of 50% Hydrochloric
acid solution in another bottle.
¾ Add 1ml of solution made above into the beaker by
another pipette.
¾ Pour 94ml of pure water into the beaker by the burette.
¾ Total quantity of the solution in the beaker is 100ml.This
means that absorbent solution is diluted to 1/20.
¾ Send this sample for inhibitor analysis.
¾ Before sampling, It is recommended to perform De-
crystallisation cycle for 8 hours.
Alkalinity of the Analysis of Alkalinity is done by phenolphthalein and acid

solution titration method.
Standard Concentration of the alkalinity : 0.03 N ~ 0.07 N
Procedure ¾ . Take solution sample (Refer solution sampling
procedure).
¾ . Pour the solution sample into a bottle.
¾ . A sample of absorbent is allowed to stand in a bottle for
about 24 hours to decant the solution. (After 24 hours,
solids will settle at the bottom of the bottle.)
¾ . Take 10 ml of absorbent solution from the top of the
bottle using a pipette.
C30 HP00 C04 C04.9

¾ . Pour the sample absorbent solution into a beaker.

¾ . Pour 50 ml of pure water into the beaker.
¾ . Add Phenolphthalein (2~3 drops) into the beaker.
(Absorbent solution turns pink).
¾ .Add N/10 Hydrochloric acid (HCl) solution drop by drop
into the absorbent solution using a burette till the
absorbent solution becomes colourless
¾ Calculate the Alkalinity using the following formula
N = A x 0.01
Where N: Alkalinity of the sample.
A : Quantity of HCl acid solution added (ml)
¾ Action to be taken based on the alkalinity result (adding

chemicals)
a. Alkalinity is 0.03 N~0.07 N: No addition.

b. Alkalinity is less than 0.03 N : Add LiOH.
c. Alkalinity is more than 0.07 N : Add HBr
Refer to the procedure for adding LiOH or HBr. As applicable.
Concentration of The concentration of Copper and Iron can be checked by

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

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

standard valves, absorbent solution in the machine is to be
filtered. Please contact service company.
C30 HP00 C04 C04.10

Procedure This procedure decides the sequence for preparing the

sample for analysing the concentration of all Copper and all
Iron
¾ Take solution sample (Refer solution sampling
procedure).
¾ Pour the solution sample into a bottle.
¾ Shake the bottle before collecting the absorbent solution.
¾ Collect 1ml of absorbent solution from the top of the bottle
by the pipette.
¾ Pour the absorbent solution by above work into the
beaker.
¾ Add 1ml of N/10 Hydrochloric acid solution into the beaker
by another pipette.
¾ Pour 98ml of pure water into the beaker by the burette.
¾ Total quantity of the solution in the beaker is 100ml.This
means that absorbent solution is diluted to 1/100.
Send this sample for analysis.
Note In case that crystallization of the absorbent solution occurs,

de-crystallise the machine and carry out the above
procedures.
In case that all Copper and all Iron are analyzed, wait for a
while after adding HCl solution into the absorbent solution.
Adding Inhibitor This section describes the procedure to add inhibitor into the
machine to prevent corrosion.
Target concentration of inhibitor : 300 ppm
Equipment used ¾ Inhibitor : Li2MoO4 H2O (20 w% solution)

¾ Container
¾ Rubber gloves
¾ Pure water (DM water/Distilled water)
¾ Vacuum rubber hose.
¾ Copper tube
¾ Hose clips.
Procedure ¾ Contact the service company for dosage of Inhibitor.

¾ Put pure water into the rubber hose and replace the air it
with the pure water.
¾ Connect the rubber hose to the refrigerant service valve
using the hose clip and push the copper tube into the
other end of the rubber hose and secure it with a hose
clip.
¾ Pour inhibitor into a container.
¾ Put on rubber gloves.
¾ Insert the copper tube on the end of the vacuum rubber
hose into the inhibitor container.
¾ Perform air purging from the shell side of VAM.
¾ Open up the refrigerant service valve.
¾ When solution starts being sucked into the machine,
watch carefully to ensure that air does not leak into the
machine.
¾ Close the service valve after completely charging the
calculated amount of inhibitor.
C30 HP00 C04 C04.11

¾ Remove the rubber hose.

¾ Place the cap on service valve after checking the packing
inside.
¾ Wash the equipment with water.
¾ Perform refrigerant blow-down twice or thrice after these
procedures are completed to circulate the inhibitor in the
machine.
¾ Perform air purging from the shell side of VAM for 30
minutes after completion of the above steps.
Precautions ¾ Carry out this procedure while the machine operates.

¾ Wear rubber gloves while working.
¾ Thoroughly wash off any inhibitor which gets on hands,
skin and clothes. Take care to prevent inhibitor entering
the mouth.
¾ Don't spill inhibitor on the floor.
¾ All excess quantities of the solutions and waste fluids are
to be disposed properly as per local laws and regulations.
¾ Check the inhibitor level every three months and adjust
accordingly.
¾ Addition is required when the Li2MoO4 goes below 50
ppm.
C30 HP00 C04 C04.12

Adding Alkali (LiOH) This section describes the method of adding Lithium
Hydroxide (LiOH) into the machine when the measured
alkalinity is less than 0.03N.
Equipment used ¾ Solution container – 25 litre capacity

¾ LiOH powder.
¾ Rubber gloves
¾ Copper tube
¾ Hose clips
Procedure ¾ Contact service company for dosage and method of

adding alkali - LiOH.
¾ Perform air purging from the shell side of VAM
continuously throughout the process.
¾ After completing the process, Remove the rubber hose
and wash the inlet port of service valves with water.
¾ Replace the cap on the service valve after checking the
packing inside.
¾ Wash all equipment used with water.
Precautions Perform this procedure while machine is in operation.

Wear rubber gloves while carrying out the above procedure.
Thoroughly wash off any LiOH which gets onto hands, skin
and clothes.
Don't spill LiOH.
All excess quantities of the solutions and waste fluids are to
be disposed properly as per local laws and regulations.
C30 HP00 C04 C04.13

Adding Acid (HBr) This section describes the method of adding Hydrogen
Bromide (HBr) into the machine when the measured alkalinity
is more than 0.07N.
Equipment used ¾ Solution containers

¾ HBr solution (Concentration: 47 w%).
¾ pH test paper
¾ Rubber gloves
¾ Mask
¾ Copper tube
¾ Hose Clips.
Procedure ¾ Contact service company for dosage and method of

adding acid – HBr.
¾ Perform air purging from the shell side of VAM
continuously throughout the process.
¾ After completing the process, Remove the rubber hose
and wash the inlet port of service valves with water.
¾ Replace the cap on the service valve after checking the
packing inside.
¾ Wash all equipment used with water.
Precautions ¾ Perform this procedure while machine is in Cooling

operation.
¾ Wear rubber gloves and mask while carrying out the
above procedure.
¾ Thoroughly wash off any HBr which gets onto hands, skin
and clothes.
¾ Do not spill HBr.
¾ In case that machine is operated for 18 hours or more per
day, be sure to check and adjust alkalinity every two
months.
C30 HP00 C04 C04.14

Adding Octyl Alcohol Octyl alcohol is charged in small quantities to enhance the
performance of the machine. As there are chances of losing
Octyl alcohol, it is necessary to top up the quantity of Octyl
alcohol. This section describes the procedure for checking
and the method of adding Octyl Alcohol (2-Ethyl 1-Hexanol)
into the machine.
Equipment used ¾ Solution containers

¾ Octyl Alcohol
¾ Rubber gloves
¾ Mask
¾ Copper tube
¾ Hose Clips.
Procedure Charging quantity is very critical, as excess quantity

decrements the performance of the machine.
¾ Take a sample of absorbent solution from the service

valve at the absorbent pump outlet. The presence of Octyl
Alcohol can be found out by it’s pungent smell from the
absorbent solution. If there was no smell while purging,
then topping-up is required.
¾ For charging and dosage please contact the service
company.
Precautions Perform this procedure while machine is in Cooling operation.

above procedure.
¾ Thoroughly wash off any Octyl alcohol which gets onto
hands, skin and clothes.
¾ Do not spill Octyl alcohol.
C30 HP00 C04 C04.15

Charging Nitrogen Gas This section deals with the method of charging the machine
with N2 gas. (See Figure 4.5)
Equipment used ¾ N2 gas cylinders required for one complete charge.

¾ Pressure regulator for N2 cylinder
¾ Valve key (for nitrogen cylinder)
¾ Pressure resistant rubber hose
¾ Hose band
¾ Pliers
¾ Wire
¾ Compound Pressure Gauge( -1 to 7 kg/cm²g) with rubber
hose and clips.
Standard The charging pressures are as follows :

(a) For storage of machine : 0.3 Kg/cm2g
(b) For leakage test : 1.3 Kg/cm2g
(c) For parts replacement : 0.1 Kg/cm2g
Procedure ¾ Connect the pressure gauge to the service valve al the

absorbent pump outlet.
¾ Prepare N2 cylinder and attach N2 gas pressure regulator
¾ Close the service valve connected to the manometer.
¾ Connect the pressure resistant rubber hose to the outlet
of the pressure regulator, then open the valve on the
cylinder to release a small quantity of N2 gas and purge
the air in the hose.
¾ Connect the other end of the hose to No.1 service valve
and fix it by means of the hose band.
¾ Check that No1. No2 and No3 manual air-purge valves
and also No1 service valve are fully closed.
¾ Open No.2 manual air-purge valve.
¾ Open No.1 service valve.
¾ Using the pressure regulator, release a small amount of
N2 at a time into the chamber.
¾ Charge N2 gas while watching the pressure gauge of the
absorbent pump.
¾ When the specified pressure is reached, close No.1
service valve and No.2 manual valve and also close valve
on the outlet of the cylinder.
¾ Remove the rubber hose from No.1 service valve, and
place the cap on No.1 service valve.
¾ Remove the pressure regulator, and neatly arrange the N2
cylinder and rubber hose.
Precautions ¾ The N2 cylinder is pressurised to 150 kg/cm2g. Take care

when handling it.
¾ Do not suddenly raise the primary or secondary pressure
of the pressure regulator on the N2 cylinder.
¾ Fix the N2 cylinder so that it does not fall over.
¾ On no account open No.1 and No.3 manual air-purge
valve during N2 charging.
C30 HP00 C04 C04.16

Expelling Nitrogen Gas This section describes the procedure of expelling nitrogen
from the machine.
Equipment used . None
Standard Shell pressure to equal atmospheric pressure, (0 kg/cm2g)

based on reading of absorbent pump pressure gauge.
Procedure ¾ Open No.3 manual air purge valve.

¾ Remove the cap from service valve and open the valve
using the slot on the valve cap so as to discharge the N2
until the internal pressure becomes equal to atmospheric
pressure.
¾ When the reading on the absorbent pump pressure gauge
becomes atmospheric pressure (0 kg/cm2g), close the
service valve.
Precautions ¾ Do not on any account open No.1 and No.2 manual air-
purge valve while N2 gas is being discharged from the
machine
¾ When expelling N2 gas, adequately ventilate the
surrounding area.
Manual purge
valve No.2
Vacuum
Manometer Manual purge
valve No.3
Service valve
N2
Cylinder
Manual purge
valve No.1
Liquid
Trap
Purge
tank
Purge pump
Figure 4.5
C30 HP00 C04 C04.17

Measuring Absorbent This section explains the procedure to measure the absorbent
pump pressure pump pressure.
Equipment used ¾ Pressure gauge – Range –1 to +3 kg/cm2g,

¾ Least count 0.1 kg/cm2
¾ Vacuum rubber hose about 15 cm long
¾ Hose clips
¾ Distilled water
¾ Dispenser
Procedure ¾ Connect the pressure gauge to the vacuum rubber hose

with the hose clip.
¾ Fill the rubber hose with distilled water using the
dispenser. (This is done to avoid any air leaking into the
machine.)
¾ Connect the pressure gauge to the service valve on the
absorbent pump outlet line, using the vacuum rubber hose
and the hose clips.
¾ Do not let the water in the hose fall out.
¾ Open the service valve slowly.
¾ When pressure stabilises, note the reading.
¾ Close the service valve.
¾ Remove the rubber hose from the service valve slowly
and relieve the pressure in the hose slowly so that the
liquid does not splash.
¾ Wash the pressure gauge with water and dry it, before
storage.
Precautions ¾ Perform this procedure while machine is in Cooling

operation and the absorbent pump is running.
above procedure.
¾ Thoroughly wash off any liquids which gets onto hands,
skin and clothes.
¾ Do not spill any LiBr.
¾ Close service valve after measuring the pressure.
¾ Do not let any air leak into the machine
C30 HP00 C04 C04.18

Figure 4.6
C30 HP00 C04 C04.19

Bubble test This section describes the procedure for carrying out the
bubble leak test. (see Figure 4.6)
Equipment used ¾ Graduated cylinder

¾ Vinyl hose (2m)
¾ Bucket
¾ Putty
¾ Stop watch
Standard Leak test shall be performed during shutdown of the machine.

Average of three measurements should be less than the
specified quantity for the corresponding models given below.
MODEL Leak in cc per 10 minutes
20 Series 15
30 Series 25
40 Series 30
50 Series 40
60A & 60B 45
60C & 60D 60
70 Series 70
80A & 80B 85
80C & 80D 105
Procedure ¾ Perform air-purging until the inside pressure of the

machine reaches the allowable degree of vacuum, and
then continue air-purging at least for one hour.
¾ Make sure that the no load vacuum of the purge pump is
under 4 mmHg.
¾ Connect the vinyl hose to the exhaust port of purge pump
and put its other end into the bucket filled with water as
shown in the figure
¾ Diaphragm valves should be set as follows
¾ Valve No.1 – Open, Valve No.2 & 3 – Close
¾ Operate purge pump for about one minute and then
measure the bubble volume.
¾ While measuring keep the vinyl hose within a depth of
10mm from the water surface.
¾ If bubbles are collected, inspect and tighten downstream
connections from the diaphragm valves.
¾ If bubbles are still collected in spite of the above
tightening, measure the volume of bubbles collected in 10
minutes.
¾ Call this volume A
¾ Then set the diaphragm valves as follows
¾ Valve No.1 & 3 – Open, Valve No.2 – Close
¾ Gas ballast valve and oil delivery valve should be kept
closed.
¾ Continue operation of purge pump under the above
conditions.
¾ Measure the volume of bubbles in 10 minutes. And call
this volume B.
C30 HP00 C04 C04.20

¾ While measuring keep the vinyl hose within a depth of

10mm from the water surface and wait until the first
bubble to come out before starting the timer.
¾ Measurement should be performed at least three times.
¾ Between measurements, check that the no load vacuum
of purge pump is under 4mmHg.
¾ The value of (B-A) is the result of the bubble leak test.
¾ If the oil is contaminated with water, replace oil.
When is bubble leak ¾ As part of the leak test after assembly work at site.
test performed? ¾ As part of the periodical inspections.
¾ After carrying out site procedures that break vacuum
tightness and after N2 leak test.
Precautions ¾ Ensure that the no load vacuum attained by the vacuum

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

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

b. Control circuit : Above 10 M
Equipment used . Megger DC 500 V Driver
Procedure ¾ Do not supply electricity power during this measurement.

¾ Disconnect green earth wire between terminal E on
terminal base and earth terminal in control panel.
¾ Make sure that MCB is not put on.
¾ Connect earth wire of Megger to earth terminal in control
panel.
¾ Measure insulation resistance at terminals of R, S, T, U1,
U2, U3, V2, V3, W1, W2, and W3.
¾ Measure insulation resistance at terminals of "No.0".
¾ Record the above measured valves.
Precautions This measurement is to be performed after replacement of
electrical components and inspection of solution pumps.
Inspection of safety This section describes the procedure to inspect the

devices functioning of safety devices independently. These are -
• Chilled water flow switch and DP switch.
• Chilled water freeze protection thermostat.
Equipment used ¾ Continuity Tester

¾ Bucket (about 5 liters capacity)
¾ Ice Blocks
¾ Hot water (80 - 90°C)
¾ Thermometer (0 - 100°C)
C30 HP00 C04 C04.21

Chilled water Flow ¾ Disconnect two wires connected to terminals strip in the
switch and Differential control panel from the flow switch and DP switch.
Pressure switch. ¾ Connect the tester between the above disconnected two
wires.
¾ Set the tester to measure resistance.
¾ Operate chilled water pump(s).
¾ Close the valve furnished at delivery piping of chilled
water pump gradually to reduce chilled water flow rate.
¾ Inspect that the indication of the tester becomes infinity at
50% of the specified chilled water flow rate.
¾ If the setting was disturbed, re-adjust the flow switch and
(or) DP switch. After completion of the test, reconnect the
wires.
¾ If flow switch/ DP switch is broken, replace it.
Precautions Stir the water to get the average temperature in the bucket
during measurement.
C30 HP00 C04 C04.22

C.05.Calibration Schedule
C.5.1 CALIBRATION SCHEDULE
Calibration of all the Instruments should be done once a year. Based on the
dependence of some instruments the calibration frequency can be increased
(may be 2 to 4 times a year) based on customer’s operating conditions.
C30 HP00 C05 C05.1

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

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

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

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

caused by corrosion, scaling and biofouling. In this chemical
treatment, various chemicals are used, hence proper
selection of chemical becomes a vital thing while suggesting
a treatment program.
Open Loop Treatment : Open Loop treatment is carried out to maintain the desired
quality of cooling water.
The chemicals which are recommended for cooling water
open loop treatment are :
i.) Corrosion and Scale Inhibitor and Biocide
ii.) Corrosion and Scale Inhibitor
The corrosion and scale inhibitor contains following

ingrediants
Corrosion Inhibitor These are water soluble corrosion inhibitors which absorb on
the metal surface and a thin film of corrosion inhibitors is
formed on the metal surface. This film however does not
interfere in the heat transfer.
Sequestrant These chemicals are special chemicals in the sense that

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

are used to disperse the suspended solids which otherwise
settle down in low velocity areas forming deposits.
Copper Corrosion These are special compounds which are used to protect
Inhibitor: copper metallurgy. These chemicals form a protective layer
on the copper metallurgy and prevent galvanic corrosion.
C30 HP00 D01 D01.1

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

quaternary ammonium compounds, Phenols, Cynates,
Organo tin compounds etc
Chilled Water Treatment : The main problems which arises are corrosion and microbial
fouling because the problem of scaling is eliminated by using
soft / DM water. Therefore following products are used for
chilled water treatment.
Corrosion Inhibitors These are special compounds specially designed for close
loop like chilled water circuit and in a way are different from
corrosion inhibitors which are used for open loop or cooling
water treatment. The main difference is that corrosion
inhibitors used in close loop work in absence of oxygen. This
corrosion inhibitor formulation has a pH buffer system which
take care of pH upset in the system.
Biocide The biocide used for chilled water ciruit is different from the
biocides which are used for open loop systems. This
problem of biofouling is not as frequent as in open loop
circuit. The trade name of this product is Maxtreat 651. This
product is not the recommendation, but it is an advised to
consult head office whenever biofouling problem is
encountered in chilled water circuit.
C30 HP00 D01 D01.2

WHOM TO CONTACT
CONTACT Details ( Address,Tel No., Fax No.,

E mail Id,Mobile No.)
DEALER
( Service Franchisee)
Area Manager
Regional Manager
Divisional Service Chief
C30 HP00 WTC WTC.1

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THERMAX LIMITED

ABSORPTION COOLING DIVISION

VAPOUR ABSORPTION HEAT PUMP

OPERATION & MAINTENANCE

C30 HP00 CVP CVP.1

Section-A C30 HP00 A00.1

SECTION B C30 HP00 B00.1

SECTION C C30 HP00 C00.1

SECTION D C30 HP00 D00.1

D.1 Water treatment C30 HP00 D01.1

C30 HP00 TOC TOC.1

C30 HP00 A00 A00.1

Safeties against hot

C30 HP00 A01 A01.1

3. Safeties against electric arcs:

C30 HP00 A01 A01.2

A.2 EXPLODED VIEW OF VAHP

STEAM FIRED VAPOUR ABSORPTION HEAT PUMP

C30 HP00 A02 A.2.1

Please refer Drawing file A.3.1.DWG

Please refer Drawing file - A.4.1-Electrical scheme.DWG

A.5 PRODUCT BRIEF

PRODUCT: Vapour Absorption Heat Pump

APPLICATION: Used for Chilling application in various Industries like

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

CRYSTALLISATION The machine is uniquely designed to completely avoid

C30 HP00 A05 A05.1

A.6 PRINCIPLE OF OPERATION

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

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

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

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

Further there is a large difference between vapour pressure

Absorption Cycle Absorption systems use heat energy to produce a

C30 HP00 A06 A06.1

When the refrigerant undergoes a series of evaporation,

Simultaneous Heating A schematic diagram of the absorption cycle in the

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

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

C30 HP00 A06 A.06.2

temperature heat exchanger where it absorbs heat from the

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

C30 HP00 A06 A06.3

Fig 1. Simultaneous Heating-Cooling Mode

C30 HP00 A06 A.06.4

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

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

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

C30 HP00 A06 A06.5

absorbed refrigerant boils out of the solution. The solution

C30 HP00 A06 A.06.6

Fig 2. Cooling Mode

C30 HP00 A06 A06.7

A.7 CONTROL & SAFETIES

Control Panel The control panel consists of the following components :

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

An inbuilt software PID control loop processes this signal with

The I/P converter converts the 4 to 20 mA electrical signal to a 0.2

The above operation is in conjunction with crystallization